INSTRUCTIONS for
DIGIPULSE WIRE FEEDERS
DIGIPULSE 2 Roll Drive Wire Feeder, P/N 30680* (ESAB); 35640 (L-TEC)
DIGIPULSE 4 Roll Drive Wire Feeder, P/N 31821* (ESAB); 35658 (L-TEC)
Optional DIGIPULSE Teach Kit, P/N 35638**
* These Digipulse Wire Feeders provide preprogrammed Wire Type Material Codes 1
thru 6 (see Specifications), plus codes 7 thru 10 which are reserved for custom
applications where you can add programs for alloys such as inconel, titanium, metal
cored wire, flux cored wire, etc.
** This field-installed Teach Kit (see II-B-1) allows you to quickly develop pulse parameters
for any weldable alloy and storing up to 5 teach conditions in Material Codes 11 thru
15. The teach portion of the Digipulse is covered in booklet F-15-013.
F-15-012-B
November, 1996
SPECIFICATIONS
Input Power Required ........................................ 7 Amp., 115 vac, 1 ph, 50/60 Hz
Wire Feed Speed Range ................................... 20-999 in/min (.5-25.2 m/min)
Wire Sizes Preprogrammed .............................. .023-in. (.7 mm), .030-in. (.76 mm), .035-in. (.9 mm), .045-in. (1.2 mm), and .063-
in. ( 1.6 mm)
Wire Type (Mat.) Preprogrammed ..................... 1. Carbon Steel, 2. Alternate Steel, 3. 4043 Alum., 4. 5356 Alum., 5. Stainless
Steel, 6. Silicon Bronze, and 7. thru 10 reserved for custom application
Dimensions ........................................................ 18.5-in. (470 mm) l.,13.0-in. (330 mm) w, 16.5-in. (419 mm) h
Weight (less wire) .............................................. 46 Ibs (21 kg)
Note: This manual provides complete coverage on the Digipulse Wire Feeders starting with Serial No. WF-I512043
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 3 before
installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CONTENTS
Specifications .................................................................................... 1
Safety Precautions ......................................................................... 3/4
I. INTRODUCTION ............................................................... 5
II. SYSTEM REQUIREMENTS .............................................. 6
A. Required Equipment ............................................................... 6
B. Optional Accessories .............................................................. 6
III. INSTALLATION ........................................................ 7
A. Unpacking and Placement ...................................................... 7
B. Power Source/Wire Feeder Control Interconnection .............. 8
C. Wire Feeder Installation Requirements .................................. 8
IV. OPERATING INSTRUCTIONS ....................................... 10
A. Power Source Welding Controls ................... Refer to F-15-014
B. Wire Feeder Control Functions ............................................. 10
C. Gas/Wire Adjustments .......................................................... 14
V. SETTING UP PROGRAM PARAMETERS ...................... 14
A. Typical Welding Conditions ................................................... 15
B. Preliminary Power Source Checks ........................................ 15
C. Program Control Parameters
(includes Hot Start Setting information) ................................ 15
Vl. WELDING OPERATION ................................................. 18
A. Pulse/Spray/Short Arc Wire Speed Recommendations ........ 18
B. Welding in Pulse or Spray or Short Arc Mode ...................... 19
C. Spot Welding ......................................................................... 18
Vll. MAINTENANCE ............................................................. 19
Vlll. TROUBLESHOOTING.................................................. 20
A. Digipulse 450 Power Source ......................... Refer to F-15-014
B. Digipulse Wire Feeder .......................................................... 20
IX. REPLACEMENT PARTS DATA ....................................22
Figure 1- Operational Sequence .................................................. 5
Figure 2 - Digipulse Interconnection Diagram ............................. 9
Figure 3 - Rear Panel Controls .................................................. 10
Figure 4 - Front Panel Controls .................................................. 11
Figure 5 - MPU PC Board - Dip Switch location ........................ 18
Figure 5A - Input/Output (I/O) P.C. Board .................................. 20
Figure 6 - Typical Digipulse Wire Feeder .................................. 22
Figure 7 - EH-10A Digital Motor-Gear Unit Assembly ................ 22
Figure 7A - EH-10A Motor-Gear Unit Parts Breakdown ............ 23
Figure 8 - Accessory Support Assembly .................................... 23
Figure 9 - Digipulse Control Assembly. ..................................... 24
Figure 10 - Spindle Assembly/Optional Wire reel ...................... 24
Figure 11 - Water Kit with/without Solenoid Valve ..................... 24
Figure 12 - Schematic Diagram - Digipulse XR and XRT .......... 25
Figure 13 - Wiring Diagram, Digipulse
TABLES
Table 1. - Feed rolls, feed roll kit and outlet guides ..................... 6
Table 11. - Recommended Shielding Gases ............................. 15
Table III. - Typical "Short Arc" Wire Speed Ranges .................. 17
Table IV. - Typical "Spray Arc Wire Speed Ranges ................. 17
Table V - Typical "Pulse Arc" Wire Speed Ranges ................... 17
2
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precautionary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if movement is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). Welding and cutting current creates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
3
from your body as possible.
11/95
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.
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.
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."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.
4
I. INTRODUCTION
Through the use of advanced electronics and state-ofthe-art technology, ESAB has created in the Digipulse a
high performance welding system that is extremely simple
to operate, yet much more versatile than anything previously available. The Digipulse system automatically determines all critical welding parameters in pulsed and
conventional mig short and spray arc welding applications-simply select wire type, diameter, wire feed speed,
and the Digipulse control does the rest. Note that the
power source used in this system is also suitable for
stick, scratch-start tig and air carbon arc applications
(see F-15-014).
These features are provided by advanced Digipulse
systems which combine a special Digipulse 450 ampere
inverter-type power source, and a microprocessor-based
Digipulse wire feeder/control. These system components work together to provide a pulsed or nonpulsed mig
set-up using synergic/adaptive logic that self-adjusts
while welding for optimum arc performance.
In the synergic mode, the control selects an appropriate
arc length, based on weld mode (short, pulse or spray),
for a given wire type, size and feed rate. The pulse
frequency in pulse mode remains constant regardless of
torch manipulation. This pulse logic offers many advantages to the welder, particularly where joint geometry
caused rapid changes in torch stickout resulting in unstable puddle conditions.
In the adaptive mode, the control varies the frequency
during pulse welding to maintain a constant arc voltage
regardless of changes in torch stickout or angle. This
logic is very useful where joint geometry is clean.
Heres how it works for Pulse arc operation (Fig. 1). The
Digipulse wire feeder control is preprogrammed to accommodate a wide variety of welding combinations.
These combinations are derived by selecting one of the
wire diameter sizes and wire material type that are
preprogrammed in the controls memory (available selections depend on the specific model purchased). The
operator programs one of these combinations (electing
a particular wire size and type), and a wire feed speed
(ipm) for the desired welding condition. The microcomputer then, automatically calculates the required pulse
characteristic and arc voltage, and commands the inverter power source to produce the proper output. While
welding, the microcomputer constantly monitors arc
parameters and wire feed speed, and automatically
adjusts the pulse rate to changing arc conditions. Although arc length/voltage is automatically computed for
each welding condition, this parameter can be fine-tuned
from its computed value to accommodate unique applications or operator preferences.
For conventional (non-pulsed) mig spray or short arc
applications (Fig. 1), the welding setup procedure is
exactly the same as that described for the pulse welding
mode. That is, the operator still presets a wire type
(material), wire size (diameter) and wire feed speed
(ipm) parameter from one of the available preprogrammed
welding conditions. Once these parameters are programmed, the microprocessor automatically provides
the correct arc length (for synergic operation) or arc
voltage (for adaptive operation) for a stable welding
condition. For further information regarding synergic and
adaptive mode operation, see sections IV-B-4-b., IV- B7-b., Vl-B and VI-D.
Two digital readout windows (1/2-in. high) on the control
continuously display the preset welding parameters
(speed and arc length for synergic mode; or arc voltage
for adaptive mode) as determined by the Pulse/Spray/
Short Arc mode switch. After the arc is struck, they
automatically display the actual wire feed speed and arc
WELD SET-UP PROCEDURE
As Easy As 1-2-3!
1. Select your welding processShort, Spray or Pulse.
2. Depress this key to access wire type MATERIAL
in IPM window and wire size DIAMETER in
VOLTS window select by simultaneously using
INC/DEC keys.
3. Use this key to set your wire feed speed in the
IPM window and your ready to weld!
Other parameterspre/postflow gas, spotweld,
burnback, cold inch, etc. are just as easy to add
read on!
Fig. 1- Operational Sequence
5
voltage conditions for the selected mode. The readouts
can also provide selectable displays of other applicable
welding parameters (depending on the specific model)
such as wire inch speed, spot time in cycles, manual
burnback time in cycles, gas pre- and postflow times in
tenth of a second increments. In addition, average current is displayed on the power source digital ammeter
window.
The wire feeder uses a heavy duty EH-10A wire drive
motor designed to feed hard or soft wires. Rate of wire
feed (20-999 ipm) is precisely controlled by using a
closed-loop digital feed back circuit that employs an
optical tachometer to monitor the motor speed. Arc
Voltage regulation is also controlled by a closed-loop
digital feedback circuit that monitors the arc voltage and
automatically adjusts the power source output to maintain the preset condition.
All interconnecting cable, hose and auxiliary equipment
connections are easy to install to provide quick setup as
shown in the Installation section. A water kit with or
without solenoid valve may be purchased, as an optional
accessory, for use with water cooled torches.
thickness on all materials, a water cooled torch is
recommended.
When using a water-cooled torch it will be necessary
to connect the torch water hose to either a continuous
water supply or to the wire feeder base by using an
optional water kit.
5. Gas Regulation. Shielding gas regulator/flowmeter
and fitted hose to bring gas from flowmeter to wire
feeder. Such as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 CO2, P/N 998125.
Standard Duty, P/N 40V77 (12-1/2-ft.) or P/N 34V38
(25-ft.)
Heavy Duty*, P/N 19416 (12-1/2-ft.) or P/N 19415 (25ft.)
* Must be used for CO2.
6. Feed Roll. The Digipulse 2-Roll Drive comes equipped
with a pressure roll but NOT a feed roll. Select the
proper feed roll from Table 1 for the wire size and type
to be used. To convert the 2-Roll to 4-Roll Drive; order
Table 1
II. SYSTEM REQUIREMENTS
A. REQUIRED EQUIPMENT
A typical Digipulse Pulsed-Mig Welding Package
requires:
1. One of the following Digipulse Wire Feeders;
a. Digipulse, 2 Roll Drive, P/N 30680.
b. Digipulse, 4 Roll Drive, P/N 31821.
2. One of the following three-phase Digipulse Power
Sources;
a. Digipulse 450i cvcc for 230/460-volt, 60 Hz service
P/N 31120, covered in booklet F-15-014.
b. Digipulse 450i cvcc for 575-volt, 60 Hz service P/N
31238, covered in booklets F-15-014 and Supplement F-15-015.
c. Digipulse 450i cvcc for 50 Hz. service P/N 31690,
covered in booklets F-15-014 and Supplement F15-039.
3. Control cable assembly as follows:
a. A 6-ft. control cable (19/c) with 19-pin amphenol
connectors each end, P/N 30686 is supplied as
part of the package. For longer length assemblies,
order one of the following:
b. 30-ft. long, control cable P/N 30780.
c. 60-ft. long, control cable P/N 30781.
4. Welding Torch. A mig welding torch, with contact tip,
wire conduit and outlet guide for wire size/type to be
employed, will be required. A suitable air (MT-400) or
water- cooled (ST-16) torch may be used with the
Digipulse. When using Digipulse systems to weld
aluminum, we strongly recommend using a MIG-41
Push-Pull Torch. For applications above 1/8-inch metal
Wire/Size Two Roll Drive Four Roll Drive Outlet
in. (mm) Feed Roll Feed Roll Kit* Guide
Soft
.030 (.8) 2075304 (U) 999320 (U) 29N13**
.035 (.9) 2075304 (U) 999321 (U) 29N13**
3/64 (1.2) 2075301 (U) 999322 (U) 29N13**
1/16 (1.6) 2075298 (U) 999323 (U) 29N13**
Hard
.023 (.6) 17998 (V) 999745 (c)
.030 (.8) 2075300 (V) 999325 (V) 993860 (a)
.035 (.9) 2075303 (V) 999326 (V) 993860 (a)
.045 (1.2) 2075302 (V) 999327 (V) 39N15 (b)
.052 (1.4) 2075330 (V) 999328 (V) 39N15 (b)
.063,1/16 (1.6) 2075299 (V) 999329 (V) 39N15 (b)
Cored Hard
.035 (.9) 19761 (Serr.) 993860 (a)
.045 (1.2) 19761 (Serr.) 999330 (Serr.) 39N15 (b)
.052 (1.4) 2075261 (Serr.) 999331 (Serr.) 39N15 (b)
.063,1/16 (1.6) 2075261 (Serr.) 999332 (Serr.) 39N15 (b)
optional 4- Roll Drive Accessory Support, P/N 600216,
and the appropriate kit listed in Table 1.
U= U-groove, V = V-groove, Serr. = serrated
(a) Includes replaceable sleeve (995651).
(b) Includes replaceable sleeve (995692).
(c) Requires guide bushing 17997.
* Includes a center wire guide and 2 upper and 2 lower feed rolls.
** Requires outlet guide as follows: For .030/.035 wire use
993902, For 3/64 wire use 05N57, For 1/16 wire use 12N57.
Recommended U-Groove Pressure Roll 2075346 be used.
B. OPTIONAL ACCESSORIES
1. Digipulse Teach Kit (P/N 35638). This field-in-
stalled kit adds pulse teach functions which allow the
operator to set unique pulse conditions by setting
pulse height (PH), pulse with (PW), pulse frequency
(PF) and background current (PB). Up to five sets of
unique pulse conditions can be stored in memory.
6
The kit includes software (EPROM), hardware (switch
and simple wire harness assembly) and installation
instructions (F-15-233).
2. Water Kit (P/N 994466). Permits the convenient
connection of a water-cooled torch and continuous
water supply or water cooler to the wire feeder.
The kit consists of a coupling, two adaptors and a
fitting. A dependable cooling water supply, delivery
and return water hoses (P/N 40V76, 2 required) will
also be required. Note that Fig. 2 illustrated the use
of power cable adaptor P/N 634693, in addition to the
kit. If adaptor (634693) is not used, adaptor (45V11
supplied with kit) can be connected to the output
terminal of the power source. Install the kit in accordance with Fig. 11 and Sec. Ill-C-7. Connect the
water-cooled torch as shown in Fig. 2.
3. Lifting Bracket (P/N 634287). Mounts on the wire
feeder spool support between the support and the
spindle assembly. Enables you to mount the wire
feeder over head on a boom.
4. Spool Enclosure Kit (P/N 600240). Provides protection of spool of wire against dust and dirt. For
installation instructions refer to Form 12-824.
5. Standard Wire Reel Assembly (P/N 995570). R e e l
slips over spindle to allow use of coiled wire, see Fig.
10.
6. 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.
7. 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.
8. Four Roll Drive Accessory Support Assembly
(P/N 600216). This assembly (illustrated in booklet
F-12-821) utilizes four feed rolls to provide the backup force necessary for positive nonslip wire feed. It
is designed for feeding .030 through 1/8-in. diameter
wire(s). Feed rates using the four roll drive assembly
are virtually the same as with the two roll assembly.
For feed roll/outlet guide accessories refer to F-12821 or Table 1.
9. Cart, P/N 31700. Provides complete mobility for
Digipulse power source and wire feeder. The cart
also includes a support for gas cylinder(s) and WC8C water cooler.
10. Wire Feeder Mobile Undercarriage Kit, P/N
680005. This kit includes a mounting plate and
caster type wheels to provide complete mobility for
the wire feeder (see F-14-322).
11. Wire Feeder Turntable, P/N 678940, allows rotation of wire feeder as operator changes work positions. This reduces strain and bending of torch
cables (see F-12-984).
III. INSTALLATION
Proper installation contributes materially to the satisfactory and troublefree operation of the welding system. It is
suggested that each step in this section be studied
carefully and followed as closely as possible.
A. UNPACKING AND PLACEMENT
1. Immediately upon receipt of the equipment, inspect for
damage which may have occurred in transit. Notify the
carrier of any defects or damage at once.
2. After removing the components from the shipping
container(s), check the container for any loose parts.
Remove all packing materials.
3. Check air passages of power source for any packing
materials that may obstruct air flow through the power
source.
4. If the equipment is not to be installed immediately,
store it in a clean, dry, well-ventilated area.
5. The location of the welding equipment should be care
fully selected to insure satisfactory and dependable
service. The maximum separation between the power
source and the wire feeder should be less than 60-feet
for best performance. Choose a location relatively
close to a properly fused source of electrical power.
6. The machine components are maintained at proper
operating temperatures by forced air which is drawn
through the cabinet by the fan unit on the rear panel.
For this reason, it is important that the machine be
located in an open area where air can circulate freely
at front and rear openings. If space is at a premium,
leave at least (1) foot of clearance between the rear of
the power source and wall or other obstruction. The
area around the unit should be relatively free of dust,
fumes and excessive heat. It is also desirable to locate
the unit so the cover can be removed easily for
cleaning and maintenance.
B. POWER SOURCE/WIRE FEEDER CONTROL IN-
TERCONNECTION (See Fig. 2).
1. Remote Digital Control Connections. Voltage regu-
lation, 115- volt power, remote contactor control, and
monitoring is provided by a 19-pin receptacle, located
on the power source rear panel, which receives a
mating plug-cable assembly from the remote wire
feeder control receptacle J1.
7
These functions are provided by one of the following
19/c, amphenol to amphenol cable assemblies following:
6-ft. (supplied w/Pkg.) P/N 30686
30-ft. (optional) 30780
60-ft. (optional) 30781
2. Connect positive (+) power cable from power source
to wire feeder power terminal block, and work (-) cable
from power source to workpiece. Both cables should
be #4/0 size and should not exceed 50-ft. in length.
Cables should be the minimum length practical, and
tywrapped together to optimize output.
C. WIRE FEEDER INSTALLATION REQUIREMENTS
1. Hose and Electrical Connections. Having connected
the control cable assembly (section II-A) between the
power source and wire feeder, connect the shielding
gas and water (if used) supply hoses as shown in Fig.
2.
2. Torch Connections. Attach torch gas hose to gas
connection. Plug in torch switch cable and lock by
twisting. After inserting conduit liner (if used) and
attaching wire outlet guide of correct size, connect
wire feed conduit to welding head accessory support
clamp and lock in place. Connect torch power cable to
power source, or to power cable adaptor block (with a
second cable from that block to the power source).
3. Important Water-Cooled Torch Connections. Due
to the inherently higher power cable resistance of
water-cooled torches, the potential drop that is fed
back to the power source as arc-voltage can be in
error. To eliminate this cable drop in most watercooled torches, it is necessary to monitor the arcvoltage potential at or near the torch body itself.
In order to accommodate this desirable feature, two
water-cooled torches (MT-450W and MIG-41) were
designed to include the necessary voltage pickup
lead. The voltage pickup lead is attached to the torch
body and extends the length of the torch cables to a
single-pin Molex connector. This voltage pickup
lead connector must be connected to the wire feeder
controls pickup lead connector (J4) in place of the
accessory supports J4 connector as shown in Fig. 2
and on the Schematic diagram at the rear of this
booklet.
IMPORTANT: If competitive water-cooled torches (other
than ESAB) are used, they must be modified to add this voltage pickup lead; otherwise, they may not provide the performance desired.
4. Installing Feed Roll.
a. Release the clapper on the accessory support
assembly (Fig. 8) by disengaging the retainer from
the clapper fork.
b. Remove thumbscrew and washer from the feed roll
shaft.
c. Slip the feed roll on the shaft, engaging the key. Be
sure to observe the THIS SIDE OUT marking on
the feed roll.
d. Replace washer and thumbscrew, tightening screw
sufficiently to eliminate all end play from the feed
roll.
5. Installing Spool of Wire.
CAUTION: Make sure safety glasses with side shields
are worn when handling or changing wire, or
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.
a. Remove hairpin clip from spindle.
b. 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.
c. Slide the spool onto the spindle until it engages the
lug. Lock in place with the hairpin clip.
d. 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
overrun, causing the wire to kink and tangle.
e. Thread the wire on to the accessory support assem-
bly as described in Section C-6.
f. When wire coils are to be used instead of spools,
mount wire reel on spindle as though it were a spool
(see a. and c. above). Remove thumbnuts and
cover plate from reel. Remove coil from its package, but do not remove its binding wires. Slide coil
onto reel so that wire will be drawn from bottom of
coil (starting end for a coil is always the outer end).
Replace reel cover plate and thumbnuts. Cut off
coil tie wires and any kinked wire. Then adjust
brake screw and thread wire to torch as covered in
d. and e. above.
6. Adjusting the Accessory Support Assembly. When
a new wire size or type is to be used, set the pressure
roll adjustment as follows (see Fig. 8):
a. Round off the free end of the welding wire with a file.
b. Release the clapper and unscrew the pressure
adjusting knob until the pressure spring is free.
c. Thread the wire through the inlet and outlet guides
of the accessory support, and 3 or 4 inches into the
torch conduit.
d. Engage the clapper making sure the wire is held in
the feed roll groove.
e. Tighten the pressure adjusting knob until the wire is
8
Customers Fused Line Disconnect Switch
CAUTION: Make sure all input power is disconnected
before performing any operation inside the power source.
(See F-15-014)
Customers 3Ø Input
and Ground or use:
Factory-supplied 10ft. lg. Input power
cable (No. 6 AWG.
4/c. type SO)
connected to ONOFF switch (LS).
See F-15-014
Line Switch (LS) Rear
View - See F-15-014.
J1
Control Cable
See III-B-1
J2 See Note 2.
Input Voltage
Connections
(See F-15-014)
TO WORK
NEG. (-)
OUTPUT
For Wire Feeder
Torch & Service
Connections
See Below
Approved
Earth Ground
Work
To Wire Feeder
See III-B-2
4/0 WELDING
CABLES
(Cust. Supplied) are
set-up for DCRP
(Neg. to work)
Operation, see
NOTE 1. below
MALE
CONNECTOR - 950693
(Supplied w/Power
Source)
ACCESSORY SUPPORT
VOLTAGE PICK UP LEAD
See Sec. III-C-3, and
Schematic Diagram
TORCH CONDUIT
TORCH SWITCH
TORCH WATER HOSE
TORCH GAS HOSE
MIG-41 VOLTAGE
PICKUP LEAD - See III-C-3
FRONT VIEW
WATER KIT 994466*
ADAPTOR 45VII*
Power Cable
Adaptor Assy. 634693
TORCH POWER CABLE
WATER DRAIN HOSE - 40V76 (12-1/2 FT.)*
WATER IN HOSE - 40V76 (12-1/2 FT.)*
REAR VIEW
REGULATOR/
FLOWMETER
(See II-A-5)
GAS HOSE
(See II-A-5)
* PARTS REQUIRED WHEN
USING A WATER KIT &
WATER COOLED TORCH
IMPORTANT NOTE:
1. Both output welding cable leads (torch and work) must be a minimum size of No. 4/0 welding cable (nothing smaller), and
both leads should be kept as close to the same length as possible - with neither lead exceeding 50-ft. in length. Also, both
cables must be run next to each other and tywrapped every couple of feet to minimize cable reactance.
2. Make sure that all Tig/Stick Controls are physically unplugged from the power source receptacle J2 when a Mig setup is to
be used.
Fig. 2 - Digipulse Interconnection Diagram
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