ESAB Digipulse Wire Feeders Troubleshooting instruction

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

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precautionary information from the references listed in

Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there are no substances on the workpiece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Processes", available from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling.

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF: A. Route the electrode and work cables together. Secure

them with tape when possible. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.

D. Connect the work cable to the workpiece as close as

possible to the area being welded. E. Keep welding power source and cables as far away

from your body as possible.

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.

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.

Heres 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 controls 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 parameterspre/postflow gas, spotweld, burnback, cold inch, etc. are just as easy to add

read on!

Fig. 1- Operational Sequence

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.

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.

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. 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 controls pickup lead connector (J4) in place of the accessory supports 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

Customers Fused Line Disconnect Switch CAUTION: Make sure all input power is disconnected before performing any operation inside the power source. (See F-15-014)

Customers 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.

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

firmly against the feed roll - do not overtighten. The spring pressure applied should be the minimum required to provide positive, nonslip wire feed. Too little pressure will result in wire slippage while excessive pressure will scar and deform the wire. Further adjustment can be made after the wire feed is put into operation. Note that a light spring (182W55) is installed on the accessory support for use with soft and small diameter hard wire. For large diameter hard wire, replace this spring with a heavy spring (182W54) supplied with the unit.

7. Water Kit (Optional see Fig. 11). Mount bulkhead adaptor (58V75) behind opening provided in vertical base plate, above gas connection, and secure with screws (No. 8-32 x 3/8-in.) and lockwashers provided. Attach coupling and adaptor ( 11N16) behind bulkhead adaptor. Mount torch cable adaptor (45V11) on welding power stud. Connect water drain hose to this adaptor and water inlet hose to adaptor 11N16.

IV. OPERATING INSTRUCTIONS

CAUTION: Never, under any circumstances, operate

the power source with the cover removed. In addition to the safety hazard, improper cooling may cause damage to internal components. Keep side panels closed when unit is energized. Also make sure you are adequately protected before you start welding

- welding helmet, gloves, eye and ear protection should always he worn.

Do not allow metal-to-metal contact between the wire feeder chassis and a metal surface connected in any way welding round. With such contact a poor welding ground connection may create a difference in potential that sends part of the welding current through the safety ground wiring in the control cable and wire feeder resulting in burnout of that wiring and/or damage to wire feeder circuitry. If the safety ground burns out, the operator may be exposed to 115V. shock hazard.

A. POWER SOURCE WELDING CONTROLS

For detailed information regarding the power source welding controls, refer to F-15-014.

B. WIRE FEEDER CONTROL FUNCTIONS For location of rear panel control features, refer to Figure 3 following:

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

power on or off to the wire feeder control.

2. Lock-ln Key. This key-operated switch must be in the SET position to preset, vary and weld-test the welding parameters programmed into the control.

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 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. 3A. Trigger Lock/Crater (Fill) Switch. the toggle-

configuration position of this switch follow:

 toggle-center is the normal maintained

OFF position for the Trigger-Lock function, and/or normal spring-return rest position for the toggle-configuration positions as follows:

 toggle-up is the maintained ON position

to provide the Trigger-Lock function.

 Toggle-down is the momentary ON posi-

tion to program Crater Fill (or alternate schedule) parameters to a primary preprogrammed conditions.

Please note that either of these features can be set or programmed individually, or combined to provide both functions with a preprogrammed condition (codes 1-10). Neither of these features, however, are available in the teach codes 11-15. Also,

when programmed, these functions are automatically locked into all preprogrammed codes (until they are removed or programmed-out), and this will be indicated by the energized Trigger Lock indicating light on the front panel. To set and/or program thee func-

tions, see the following:

IMPORTANT: If a SPOT weld function has been

added to the existing programmed codes 1-10, it must be removed (zeroed-out) before either of these functions (trigger lock/crater fill) can be set or programmed.

a. Trigger Lock function. To set this function in a

condition, simply place the switch toggle to its (ON (p) position. This feature allows the operator to release the torch switch (trigger-lock on) after starting the welding cycle. To stop the welding cycle, you simply repress the torch switch again and all welding action ceases. Remember that the front panel Trigger Lock indicating light will be on when this feature is engaged. In the OFF position, this function is inactive.

b. Crater Fill function. This function actually serves

a dual purpose: first, it allows you to alter your primary welding condition (speed/voltage) by selecting a slightly different condition to achieve crater-fill at the end of your weld;' or second, the sequenced-in crater condition can actually be used as an alternate schedule controlled by the torch switch. For example; set up a hot condition in the standard weld mode, and a cold condition in the crater-fill mode for bridging gaps. To program this feature, refer to Section V-C-10A.

c. Combined Trigger Lock/Crater. If you wish to

add the crater-fill feature to the trigger-lock function, do the following: (1) Program the Crater-Fill parameters (wire speed

and voltage) as described in section V-C-10a.

(2) Place the Trigger-Lock in its on (up) position

as described in 3A-a. above.

(3) Depress the torch trigger to start the arc, re-

lease the trigger (lock-in mode) and weld using the primary weld condition. Depress the trigger again and the crater (or alternate schedule) conditions will take over. When the trigger is released the arc will terminate.

(4) To remove these functions, place the trigger

lock toggle to its center off position, and then hold-down the toggle to its crater position and zero-out the setting in the IPM window.

For location of the following front panel control features, refer to Figure 4 following:

4. Digital Readout Window. 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 actual and/or preset wire feed speed* in a range from 20 to 999 inches per minute in one inch increments. However with the appropri-

ate function selector actuated, this window can also display the following:

* With power turned ON, but not welding, the IPM

window will continuously read the Preset wire speed setting. When the arc is struck, the IPM window will then continuously read the actual welding wire speed as the weld conditions cycle thru the welding sequence.

 shielding gas PREFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments

 a code number indicates a type of MATERIAL

which is programmed for various welding wire applications, as follows: code #1 indicates Carbon Steel, #2 is Alternate Steel, #3 is 4043 Aluminum, #4 is 5356 Aluminum, #5 is 308 Stainless, #6 is Silicon Bronze. (Additional Ma-

terial code numbers 7 thru 10 are reserved for custom applications.)

 SPOT welding time from 1 to 999 cycles in one

cycle increments.

 cold wire INCH speed in IPM from 40 to 999

inches per minute in one-inch increments

 if provided, Ph indicates PULSE HEIGHT which

is displayed as a reference voltage setting, from 0.1 to 10 (in 0.1 volt increments), that controls or establishes the amplitude of the pulse peak (in Teach option only).

 if provided, Pb indicates PULSE BACKGROUND

which is displayed as a reference current setting, from 15 to 100 (in one ampere increments),

STRAIN RELIEF

Fig. 3 - Rear Panel Controls

TRIGGER

LOCK

CRATER

Fig. 4 - Front Panel Controls

that establishes the approximate background current in pulse applications (in Teach option

only).

b. Volts Digital Readout. This window is primarily

used to display an arbitrary number (100) that represents a programmed arc length in the synergic mode*, or a computed arc voltage in the adaptive mode**-with power on, but not weld-

TORCH SW. RECPT.

ing. When the arc is struck, the VOLTS Window will continuously display actual welding voltage in a range from 12 to 50 vdc in one-tenth (0.1) volt increments. However, with the appropriate function selector actuated, the VOLTS Window will also display the following:

* In the synergic mode, the control will automati-

cally select and display an appropriate arc length integer for a given wire type, size, feed rate and gas shielding. An arbitrary number, represented by the integer If 100, is the normalized value for all applications programmed in the control, and this figure will be displayed in the VOLTS window during setup (not welding). This value (set at 100) can be readjusted within a range from 0 to 200, to finetune the operating arc length of the selected welding condition. By reducing the number below 100 (minimum 0) you will reduce the arc length. Conversely, by increasing this value above 100 (maximum 200) you can increase the arc length. After the arc is struck, the number will be replaced by the actual welding arc voltage.

** The Digipulse can also operate in the adaptive

mode, where the arc is continuously monitored by a closed loop feedback circuit and the machine modulates its output to maintain a given voltage for preprogrammed data. In the adaptive mode, a computed arc voltage (unique to your preprogrammed welding selection) will be displayed in the VOLTS window before welding. Once the arc is struck, the control will measure the actual welding voltage and change the output of the power source to maintain the precalculated voltage setting. In this manner, the power source automatically compensates for variations in stickout or weld joint geometry Further, all of the precalculated arc voltages programmed in the control can be readjusted +/-10 volts to fine-tune the welding arc.

 shielding gas POSTFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

 a pair of numbers represent WIRE DIA. sizes

which are programmed for selection as follows#23 represents .023" dia., and #30 is .030" dia.; #35 is .035" dia., #45 is .045" dia. hard (3/64" dia. soft) and #63 is .063" (1/16") dia.

 manual BURNBACK time. Manually adjustable

burnback time period which when preset overrides the automatic adaptive anti-stick feature. This time period will be set in one-cycle increments (60 cycles = 1 sec.). When set to zero, the auto-adaptive-anti-stick feature is operational.

 if provided, Pw indicates PULSE WIDTH which

is displayed as a reference time setting, from

1.0 to 10 (in one-tenth millisecond increments), that measures or establishes the width of pulse duration (in Teach option only).

 if provided, Pf indicates PULSE FREQUENCY

which is displayed as a frequency (Hertz) reference setting, from 25 to 909* pulse cycles per second, that establishes the approximate pulse frequency required for the wire feed speed set on the control (in Teach option only).

* Please note that the number of pulse/sec is

dependent on the pulse width  the narrower the width, the fewer the cycles; and the wider the width, the more the cycles.

5. Pulse-Short (Arc)-Spray (Arc) Selector. This threeposition rotary switch allows you to select the welding process mode you wish to use Pulsed mig spray arc, or non-pulsed mig Short Arc, or non-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.

6. L.E.D. Indicator Lights. Either or both of these LEDs will light to indicate the following:

The NO PROGRAM l.e.d. will only light if you select a wire type (Material) and size (Diameter) that is not programmed in the control. In addition, if you close the torch switch, the power source will not energize and the Digipulse will not feed wire in this condition.

The TRIGGER LOCK l.e.d. will only light to indicate that either one, or a combination, of three special features (Trigger Lock, or Crater Fill, or Alternate Schedule) has been programmed on to a selected welding condition. Further, having been programmed, this feature will always be included in all process modes and programmed welding conditions until it is zeroed-out and removed. (Additional details regarding programming and operation of these features are covered in sections IV-B-3a and V-C-10a.

NOTE: All of the following controls are springloaded,

center-return toggle switches which must be operated to actuate their indicated function(s). Item No. 7, Inc/Dec toggle switches, describes the adjustment setting toggle used to preset the program-function selectors. Except as noted above and following, regulation for selected function(s) can only be made if the Lock- In key, described in Item No. 2 is in the SET position.

7. Inc/Dec Toggle Switches. Two control toggles are provided to preset the individual welding parameters required for the selected welding mode, PULSE,

SPRAY or SHORT arc, 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 (when provided); Preflow, Material, Inch, Spot, PH and PB. With the appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

b. VOLTS Increase/Decrease Control. This toggle

switch is primarily used to set and/or vary VOLTAGE*, along with all its other functions; Postflow, Wire Dia., Burnback, PW and PF. With the appropriate function selector actuated, each parameter setting will be displayed in the digital window directly above this toggle.

* Please note that the term VOLTAGE denotes

arc voltage (in the adaptive mode) and/or arc length (in the synergic mode) and is the computed value that has been precalculated for each of the combinations programmed into the control. And further, any of these computed voltages can be altered (+/-10 volts in the adaptive mode; and +/-100 numerals from its midrange value of 100 in the synergic mode) to fine tune the welding arc; however, having done so, th e computed voltage value(s) is altered for all of the other preprogrammed wire size/type combinations.

Therefore, if the computed voltage for your selected welding combination had been altered and you plan to use a new combination (a different wire size and/or type), it is suggested

that the control be reset to provide the correct voltage computed for the preprogrammed combination as follows:

Adaptive Mode. To reset the computed arc

voltage value for a given wire size and type, place the Run-Set key switch in its SET position and then decrease the arc voltage key until the number in the VOLTS window stops This number is 10 volts below the computed or midrange value. To establish the computed value, add 10 (volts) to the displayed number using the increase (INC) portion of the Volts Inc/Dec key.

Synergic Mode. Resetting the computed value in this mode is much simpler-remember that the computed or midrange value is the arbitrary numeral 100 (this number represents a precalculated arc length based on the wire feed speed of the programmed wire size and type). Therefore, if the number appearing in the VOLTS display window is any numeral between 0 and 200 (other than 100) simply use the appropriate Inc/Dec key to reset the condition to the numeral 100.

8. Spot/Burnback - Wire Dia./Material Selector.

Operating this toggle allows you to select the following: a. Access the SPOT/BURNBACK time mode (up

position) to preset either or both of these welding features into a preprogrammed weld condition; however, once preset, these features automatically become part of all preprogrammed weld conditions in all these process modes.

The SPOT mode allows you to preset timed arc periods from 1 to 999 cycles in one cycle increments (60 cycles/sec) in the IPM window using its Inc/Dec toggle switch. When a spotweld time is preset into the control, all continuous- type welding programs are temporarily disabled. To resume normal (continuous) operation, you must deactivate the spotweld program by keying its time parameter back to zero (000).

At the same time (or independently), you can also preset a manual BURNBACK time into the VOLTS window using its Inc/Dec toggle switch. The Burnback time is adjustable in one cycle increments (60 cycles/sec); and when preset, it will override the automatic adaptive anti-stick feature. If automatic anti-stick operation is desired, the preset Burnback time must be set back to zero.

NOTE: Actuating the Spot/BBack position when the

control is set-up to operate in the PULSE mode and the torch switch is energized, allows you to read the actual pulse frequency (for a preprogrammed pulse condition) in the VOLTS display window. (If this position is actuated during a standard mig short or spray arc welding operation, the numbers appearing in the Volts display window are not related to the actual condition.)

b. Access the WIRE DIA/MATERIAL, mode (down

position) to select one of the welding conditions preprogrammed into the control, as follows:

To select the type of wire MATERIAL, actuate the INC position of the Inc/Dec switch below the IPM window (while holding the Wire Dia/Matl key down) until the desired code number for your material selection appears in the IPM window, and these material codes follow: #1 is carbon steel, #2 is alternate steel #3 is 4043 aluminum, #4 is 5356 aluminum, #5 is 308 stainless, #6 is silicon bronze. (Additional Material codes 7 thru 10 are reserved for custom applications.)

Now select the Wire DIA. size to be used, by actuating the INC position of the Inc/Dec switch below the VOLTS window (while holding the Wire Dia/Matl key down) until the desired pair of num-

bers for your wire size selection appears in the VOLTS window, and these wire diameter numbers follow: #23 is 023" dia, and #30 is 030" dia.; #35 is 035" dia., #45 is 045" dia. hard (3/64" dia soft), and #63 is 063" ( 1/16") dia.

NOTE: Accessing the WIRE DIA/MAT'L and the

PURGE/RESET selector keys (simultaneously) during an actual weld, allows you to check the factory-preset numbers that determine the quality of starts (hot, cold, etc.) for your preset welding condition. These

numbers are preset to provide optimum starting characteristics required for most welding applications. This is a diagnostic tool available to the experienced operator or serviceman and need not be activated during a normal operation unless you are experiencing weld starting problems, or weld condition (speed and /or voltage) aborting problems. It must also be noted that

only the speed (IPM) condition can be checked when a unit is operating in the synergic mode (the VOLTS Window will always display the number 100) and cannot be adjusted; however, in the adaptive mode both speed and voltage conditions can be checked and adjusted. The factory-set start-

ing condition is represented by numbers that are displayed, on command, in the digital IPM and VOLTS windows. For good welds and starts, these numbers should be in a range from 105 to 115 (with 110 being the norm) in the IPM window (synergic and adaptive mode), and from 90 to 100 (with 95 being the norm) in the VOLTS window (adaptive mode only) If your weld starts

are not acceptable, please refer to Section VB-Il for a simple adjustment procedure that will enhance good starting. If you are experi-

encing frequent speed and/or voltage aborts, please refer to Section Vlll-B-7 (Troubleshooting) for checking and resetting condition functions.

9. Inch-Purge/Reset Selector.

Operating this toggle allows the following functions: a. The INCH selection permits cold-wire inching

without energizing the welding circuit through the torch switch. The wire inching speed can be independently controlled by operating its Inc/Dec toggle switch.

b. The PURGE/RESET position provides the fol-

lowing when actuated: (1) During initial programming, it permits pre-

setting 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.

(4) When this key is actuated during a weld,

and simultaneously with the Wire Dia/Matl key, a diagnostic operation allows you to check

the preset numbers (displayed in the IPM and VOLTS windows) that determine the quality of starts (hot, cold, etc.) for your preset welding condition (see NOTE following IV-B-8- b).

10. SYN.-ADAPT. Switch. This switch allows front-

panel selection of synergic or adaptive logic modes. The operating characteristics of synergic vs. adaptive logic in the welding operation are covered in sections I, IV-B-4-b, IV-B-7-b, Vl-B and -D. Please note that either type of logic can be used in the a preprogrammed material codes #1-#10; however, only the synergic logic can be used in the teach mode material codes #11-#15.

11. Teach Pulse Parameter Switch (Teach option

only). This switch allows you to program Pulse

Height (PH), Pulse Width (PW), Pulse Background (PB), and Pulse Frequency (PF) teach parameters into material codes 11 thru 15. These features and operating functions are fully covered in the Teach supplemental booklet F-15-013.

C. GAS/WIRE ADJUSTMENTS

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

1. Place Power switch (on rear panel) to on position to energize the control

2. Place key-operated Run-Set switch in Set position

3. With torch connection made as shown in Fig 2, and

wire engaged in accessory support (Sect III-C-6), feed wire through torch conduit and into torch as follows: a. Remove nozzle and contact tip from torch. b. Hold Inch-Purge toggle in INCH position (Sect IV-

B-9) until cold wire protrudes from the torch front end.

c. Slide the contact tip over the end of the wire and

secure it to the torch. Replace the torch nozzle.

d. Reoperate 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.

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

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

b. Continue to hold the Purge position for approx. 15

seconds to insure adequate purging of gas hose and torch.

5. Place controls Power switch to off position.

\/. SETTING UP PROGRAM PARAMETERS

A. TYPICAL WELDING CONDITIONS

Three sets of welding (process) mode parameters can be preset in your Digipulse control; one for the PULSE mode, one for standard SPRAY arc mode, and another for standard SHORT arc mode.

The setup procedure for each welding arc mode is exactly the same, except for wire feed speed input and gas shielding requirements which may be peculiar to each process. The following parameters are provided as an example of a Typical Welding Condition which can be used to set-up all welding modes, with exceptions as noted.

Typical Welding Condition (Parameter):

Cold Wire Inch Speed .............................................. 75 IPM*

Type Material ...................................................... 1 (Steel)

Wire Dia. ......................................................... 45 (.045-in.)

Wire Feed Speed ..................................................... 185 IPM

Arc Voltage/Arc Length ........ Preprogrammed for MAT./DIA.

Spot Weld Time ................................................... 45 Cycles*

Preflow Time .................................................... 1.2 Seconds*

Postflow Time .................................................. 3.1 Seconds*

Burnback Time ....................................................... 7 Cycles*

Trigger Lock/Crater Fill ...................... Program Parameters*

* If programmed, these parameters are automatically incorporated

in all other preprogrammed welding conditions until they are programmed (zeroed) out.

 For recommended shielding gases used for preprogrammed

welding wire material, see Table II.

B. PRELIMINARY POWER SOURCE CHECKS

Before programming the wire feeder control, make sure that the power source is properly set-up as follows:

 Check the rear panel of the power source to make

sure that only the Digipulse control cable is connected. The remaining stick control receptacle/cable must be disconnected.

 Depending on the welding process mode programmed

on the wire feeder control, set the power source INDUCTOR control pot as follows:

For SHORT ARC mode, set Inductance @ 12 Oclock position and adjust for best performance when welding.

For PULSE and SPRAY ARC modes set Inductance @ MINIMUM .

C. PROGRAM CONTROL PARAMETERS

Remember, the following procedures represent a typical example of how to set-up one of the many preprogrammed welding conditions available in this control and that these

Table II

Recommended Shielding Gas

Wire Material Welding Arc Mode Code # Type Short Arc Spray Arc Pulse Arc

1 Carbon Steel CO 2 Alternate Stl. C-25 Stargon/C-8 Stargon/C-5 3 4043 Aluminum  Argon Argon 4 5356 Aluminum  Argon Argon 5 308 Stainless A1025 1%/2%O 6 Silicon Bronze  Argon Argon 7* 8* 9* 10*

* These codes are reserved for custom applications.

/C25 C-5/C- 8 C- 5

Pulse SS

procedures are the same for all weld arc modes  Pulse Spray, or Short Arc. The only difference(s) between weld arc modes (for the same Wire Diameter and Material) will, or may, be your wire feeder speed (IPM) and gas shielding selection  the control automatically provides the required welding voltage for every condition, and even this parameter (voltage) can be fine-tuned as described following.

1. Set the Power switch (on rear panel) to the on position to energize Digipulse Control.

2. Place the rear panel key switch in its SET position to preset all welding parameters. In this position the operator or supervisor is free to weld and make any changes before locking-them-in, in the RUN position.

3. Set the PULSE, SPRAY, SHORT arc mode switch to the process you wish to preset. And set the Synergic

- Adaptive switch to the logic mode you wish to use.

4. To set the type of Wire Material (carbon steel) and Wire Diameter (.045 in.) to be used, depress and

hold WIRE DIA/MATERIAL toggle switch in its down position and simultaneously preset each of the following: a. Operate (increase or decrease) the left INC/DEC

toggle switch lever until a 1 (indicating carbon steel wire) appears in the IPM display window.

b. Now operate (increase or decrease) the right

INC/DEC toggle switch lever until 45 (indicating .045-in. dia. wire) appears in the VOLTS display window.

NOTE: If no program exists for a given material or

diameter, a No Program l.e.d. on the front of the control will light.

5. To set a Wire Feed Speed parameter of 185 ipm,

raise and hold the toggle of the left Inc/Dec switch in its INCREASE position until 185 appears in the IPM window. Notice that this parameter setting will start at zero and immediately jump to 20 and then rapidly increases (1 ipm at a time) until the 185 ipm setting is reached. If you overshoot the planned setting, simply bump the DECREASE position of the left Inc/Dec toggle to obtain the exact IPM setting.

6. After items 4 and 5 have been preset, the microcomputer automatically sets a preprogrammed arc voltage in the adaptive mode or arc length integer in the synergic mode that will be displayed in the VOLTS window. If this precalculated value* does not provide a stable condition, it can be fine-tuned by using the right-side Inc/Dec toggle switch-as described in IV-B7-b.

* If the existing welding condition is altered (fine tuned),

it is suggested that each time a new wire size/type is used that you reset the control to set up the original computed (mid-range) arc voltage values as described in Section IV -B-7-b.

NOTE: The remaining parameters can also be pro-

grammed into the selected mode of operation; however, when preset, these parameters will automatically be operational in all process conditions.

7. To set a Cold Wire Inch parameter of 75 ipm, raise

and hold the toggle of the Inch-Purge/Reset switch in its INCH position. Simultaneously, raise and hold the toggle of the left Inc/Dec switch in its INCREASE position until 75 appears in the IPM window. Note that the cold inch setting starts at 40 ipm and rapidly increases (1 ipm at a time) until the 75 ipm setting is reached. If you overshoot the planned setting, simply bump the DECREASE position of the left Inc/Dec toggle to obtain the exact IPM setting.

8. To set shielding gas Preflow and Postflow times

of 1.2 seconds and 3.1 seconds respectively, depress and hold the toggle of the Inch-Purge/

Reset switch in its PURGE/RESET position. Simultaneously, raise and hold the toggle of the left Inc/ Dec switch in its INCREASE position until 1.2 seconds of Preflow time appears in the IPM window and then; repeat this procedure using the right Inc/Dec switch until 3.1 seconds of Postflow time appears in the VOLTS window. Both of these parameter settings will start at zero and rapidly increase ( 1/10 second at a time) until the desired time is achieved. If you overshoot the planned settings, simply bump the DECREASE position of the respective Inc/Dec toggles to obtain the desired Preflow and Postflow time settings.

9. To set a Spotweld time of 45 cycles, raise and hold

the toggle of the Spot/Burnback - Wire Dia/Material switch in its SPOT/Burnback position. Simultaneously, raise and hold the toggle of the left Inc/ Dec switch in its INCREASE position until 45 cycles appears in the IPM window ( note: 60 cycles = 1 sec.). This parameter setting will still start at zero and rapidly increase (1 cycle at a time) until the 45 cycle time is achieved. If you overshoot the planned setting, simply bump the DECREASE position of the left Inc/Dec toggle to obtain the desired Spot cycle setting.

10. To set a manual Burnback time of 7 cycles, raise and hold the toggle of the Spot/Burnback - Wire Dia/ Material switch in its Spot/BURNBACK position. Simultaneously, raise and hold the toggle of the right Inc/Dec switch in its INCREASE position until 7 cycles appears in the VOLTS window (note: 60 cycles = 1 sec.) This parameter setting will start at zero and rapidly increase (1 cycle at a time) until the 7 cycle time is achieved. If you overshoot the planned setting, simply bump the DECREASE position of the right Inc/Dec toggle to obtain the desired Burnback cycle setting.

Remember  if a manual Burnback function is programmed, it will override the standard automatic adaptive anti-stick feature in all welding modes.

10-A. To program a Crater Fill Function do the fol-

lowing:

a. Set a process, material type and wire diameter

combination, for example; pulse welding, material code 1 and diameter 045. This will be your primary welding condition. Note the Trigger Lock/ Crater Switch functions are described in section IV-B-3A.

b. Hold the Crater Fill/Trigger Lock switch down.

Set the desired wire feed speed and voltage required to achieve the crater fill results. These crater parameters will be displayed in the appropriate will be displayed in the appropriate IPM and VOLTS window. Release the CRATER switch.

c. Depress the torch trigger and weld using the

primary welding condition. Release the trigger and the crater (or alternate schedule) conditions will take over. Depress the trigger again and the arc will terminate.

d. To remove the crater fill parameters, hold down

the CRATER key and zero out the setting in the IPM window (it is not necessary to zero the VOLTS window).

e. If you wish to combine the Crater-Fill feature to

the Trigger Lock function, refer to section IV-B3A.

11. Using the torch switch, the selected process mode parameters can be weld-tested and if necessary readjusted. If your weld starts are not acceptable, refer to the following Hot Start adjustment procedures that will enhance starting.

Hot Start Adjustment Procedures

As mentioned earlier in the italicized Note following Section IV-B-8-b, the control is preset at the factory to provide the optimum starting characteristic for most welding conditions. However, due to factors such as inaccurate parameters (for a given wire type and size), welding technique, shielding gas, or wire feed speed, you may have to readjust the factory-set starting

characteristics to provide the best arc starts possible. To do this, it is necessary to readjust the factory-set calibrations to provide a hot start characteristic in which the initial starting voltage (open-circuit voltage) will be slightly higher than actual welding voltage ( arc voltage) and speed which initially is somewhat lower than the selected wire feed speed desired.

To set-up the control to provide this, do the following: a. Program the welding condition you need in the IPM

(wire feed speed) and VOLTS (arc voltage) windows, and fine-tune these parameters until you have the welding arc desired. Do not at this point concern yourself with the arc starts, this follows.

b. If after the welding condition is fine-tuned you find

that the arc starts are unsatisfactory, proceed as follows: (1) During an actual weld, actuate and hold the

Wire Dia/Matl. and Purge/Reset key positions (simultaneously) and observe the numbers displayed in the IPM and VOLTS windows.

Table III for Typical Short Arc Wire Speed Ranges

Wire Material Wire Diameter & Wire Speed Ranges Code# Type .023 .030 035 .045 .063

1 Carbon Steel 175- 180- 130- 130- NP

500 600 600 450

2 Alternate Stl. 125 175- 100- 100- NP

350 350 300 250

3 4043 Alum. NP NP NP NP NP

4 5356 Alum. NP NP NP NP NP

5 308 Stainless 250- 100- 75- 50- NP

450 400 300 250

6 Sil. Bronze NP NP NP NP NP

7** 8** 9** 10**

** These codes are reserved for custom applications. NP Not programmed.

Table IV for Typical Spray Arc Wire Speed Ranges

Remember that only the speed (IPM) condition can be checked when a unit is operating in the synergic mode( the VOLTS window will always display the number "100" and cannot be adjusted); however, in the adaptive mode both speed and voltage conditions can be checked and adjusted.

(2) For proper starts, the number in the IPM win-

dow should be in the range from 105 to 115. If it is not, adjust the Inc/Dec toggle (below the IPM window) until the displayed number reads

110.

(3) Similarly, the number in the VOLTS window

should be in the range of 90 to 100. Again, if it is not, adjust the Inc/Dec toggle (below the VOLTS window) until the displayed number reads 95.

(4) These adjustments to the control should now

provide good arc starts to a legitimate welding condition.

(5) A good rule-of-thumb to follow whenever you

set up a new welding condition and you experience unstable starts, is to simply check the start characteristic numbers (while welding) to make sure they are within the ranges described in the preceding steps.

c. If you continue experiencing problems, refer to

Section VIII-B-7 for Troubleshooting procedures.

Wire Material Wire Diameter & Wire Speed Ranges

Code # Type .023 .030 .035 .045 .063

1 Carbon Steel 800- 525- 425- 275- 170-

999 900 800 550 275

2 Alternate Stl. 800- 525- 425- 275- 170-

999 900 800 550 275

3 4043 Alum. NP 400- 400- 200- 200-

800 600 500 300

4 5356 Alum. NP 450- 450- 300- 250-

750 750 500 450

5 308 Stainless 750- 450- 350- 250- 150-

950 650 650 550 300

6 Sil. Bronze NP 400- 400- 300- NP

550 550 500

7** 8** 9** 10**

** These codes are reserved for custom applications. NP Not programmed.

Table V for Typical Pulse Arc Wire Speed Ranges

Wire Material Wire Diameter Wire & Speed Ranges

Code # Type .023 .030 .035 .045 .063

1 Carbon Steel 150- 115- 85- 55- 75-

700 500 700 450 250

2 Alternate Stl. 140- 150- 140- 70- 70-

700 500 700 400 220

3 4043 Alum. NP 225- 225- 130- 100-

500 500 300 250

4 5356 Alum. NP 225- 250- 170- 150-

500 500 500 300

5 308 Stainless 150- 100- 100- 60- 55-

700 500 450 450 260

6 Sil. Bronze 225- 250- 175- 125- NP

500 500 500 500

7** 8** 9** 10**

* These codes are reserved for custom applications. NP Not Programmed.

VI. WELDING OPERATION

After the desired welding arc modes (Pulse, Spray or Short arc) have been weld-tested in the SET position and satisfactory results achieved, the program parameters can be locked-in by placing the key switch into its RUN position. The only parameter that can be readjusted in the Run position is the cold wire INCH speed setting. Other functions (if provided) which can be read or checked, but are not adjustable in the Run position are the Preflow/ Postflow times, Spot/Burnback times, and the Wire dia/ Material.

CAUTION: Power source contactor becomes energized

the moment the torch trigger is depressed. Arcing can occur if the wire touches an object grounded to the workpiece.

A. PULSE/SPRAY/SHORT ARC WIRE SPEED REC-

OMMENDATIONS

I. General

The listings in the following tables give approximate wire feed speed ranges (IPM) for the various types of wire diameters and materials which have been preprogrammed in these controls.

2. Material Code Operating Tips (Where Applicable)

a. Carbon Steel (Code #1) and Alternate Steel (Code

#2). The Code #2 parameters are very similar to the Code #1 parameters; however, Code #2 has wider Pulse Widths and higher Pulse Background settings. The arc characteristics will appear to be softer than Code #1. Arc penetration could also be slightly less do to the lower pulse peak used. This type arc characteristic might be used on applications requiring improved bead wetting.

Operation Note: Excessive resistances in the welding system, caused by water cooled torches or excessively long welding cables, can produce pulse peak currents below that which is required for stable droplet detachment. This condition can be recognized by occasional large droplets propelled across the arc. Some short circuiting and spatter could also result. Long arc lengths can also cause less than optimum performance. The arc length should be kept short for best arc stability and puddle control. Too short an arc length will produce spatter and less than optimum arc stability. If a globular type transfer occurs check for high resistance in the welding current.

b. Aluminum 4043 (code #3) and 5356 (code #4).

Each alloy and diameter has been set for best are performance and puddle control. The wire feed speed of 4043 3/64-inch diameter (.045) is limited to 300 ipm at which point the pulses begin to overlap and spray arc results. If higher wire feed speeds are required on this alloy, switch to Code #4

(5356 .045) and adjust the arc voltage for stable arc performance. This action will extend the wire feed speed to approximately 600 ipm.

c. 308 Stainless Steel (Code #5). The stainless steel

pulse parameters are based on gases listed below. These gases improve the bead wetting of stainless steel as compared to the 1% and 2% oxygen mixtures. The program can still be used with the oxygen mixtures but a small adjustment in arc voltage will be necessary.

1. Pulse Blend SS

2. 2-1/2%-C02, 1%--H2, Bal. Argon

Operation Note: Arc Starting with stainless steel can be inconsistent at times due to the higher resistivity of the alloy and other variables. Sometimes increasing the voltage will improve starting. A weld technique adjustment might also help. When striking the arc, immediately move out of the puddle and begin traveling. A hesitation in travel at the start causes the puddle to build under the arc while the control is trying to adjust for arc voltage. Eliminating the puddle build-up helps the voltage control circuit establish the proper arc length more quickly.

d. Silicon Bronze (Code #6). The welding perfor-

mance of silicone bronze alloys currently sold can vary widely. Small differences in chemistry, cleanliness, and feedability can affect the pulse welding characteristics. To overcome instability problems, be sure wire feeding is steady and slack in the liner is minimized. Use tip-to-work distances slightly longer than normal if arc instability occurs.

B. WELDING IN PULSE OR SPRAY OR SHORT ARC

MODE

The Digipulse Wire Feeder youre using is designed to operate using synergic/adaptive logic in all three mig metal transfer modes (pulse, spray or short arc).

The adaptive/synergic capability is selectable from a front panel switch and does not require entering the control to provide this feature.

It is very easy to identify which logic mode (synergic or adaptive) is selected for. All you have to do is check the numbers displayed in title VOLT window. In the syner- gic mode, the numbers which appear have no decimals and will range from 0 to 200, with the number 100 being the preprogrammed midpoint for any selected conditioned. In the adaptive mode, the numbers will reflect an arc voltage somewhere within a range from 12 to 50 vdc, and will contain a decimal point because the arc voltage can be adjusted in 1/10 volt increments.

To start the welding in either logic mode, set the process control switch to the desired welding operation

that has been preset for use-Pulse, Spray or Short arc. Close the torch switch lever to energize and sequencein all of the selected process welding parameters. The torch switch must be held closed throughout the operation unless you have activated the trigger-lock/crater-fill function (see section IV-B-3A). The arc is established when the welding wire touches the workpiece.

To stop welding (with no trigger-lock or crater-fill programmed), simply release the torch switch lever (do not reactivate) and all functions will shutdown except auto antistick and postflow. If trigger-lock or crater-fill is programmed, refer to section IV-B-3A for this function.

The system will also shutdown if preset wire speed or arc voltage parameters cannot be maintained due to abnormal (abort) conditions. If this occurs, the parameters causing the system shutdown will be signaled by a flashing digital display and the welding sequence must be restarted by actuating the RESET toggle switch.

After welding has been stopped, the control will always recycle to the initial preset parameters of the selected mode.

C. SPOT WELDING

If spot time is set, it is automatically programmed into all welding conditions, i.e. short arc, spray and pulse. If this feature is not desired, spot time must be set to zero. If both spot time and trigger-lock are set, the trigger-lock will be disregarded.

difference in potential that sends part of the welding current through the safety ground wiring in the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder circuitry. If the safety ground burns out, the operator may be exposed to 115V shock hazard.

Vll. 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.

Be sure that the wall disconnect switch or circuit breaker is open before attempting any inspection or work on the inside of the power source or wire feeder.

Location For "Dip" Sw. SW2

Location For Teach Option E-PROM

Close the torch switch to energize gas flow, weld contactor, wire feed motor and start spot timing cycle. The torch switch must be depressed during the entire weld period. After the spotweld timing cycle is completed, all welding action except auto-antistick or burnback and postflow gas will stop automatically. Release the torch lever to enable the next spot weld cycle.

D. SETTING/DISABLING SLOW RUN-IN FEATURE:

This feature allows the operator to have the wire feed motor start at either full welding speed or half-speed, if desired. Half speed starts may give better starts in some cases. This feature works in all three processes. If half speed is selected, the motor starts at half of the final welding speed and jumps up to full speed once the arc is established. To change this, remove the feeder cover and locate the 4-position red rocker dip-switch on the MPU pc board (see Figure 5). SW2-1 should be open for half-speed run-in selection, and closed for fully speed starts.

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

Location For Dip Sw. SW1

Fig. 5 - MPU P.C. board

1. 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.

2. Lubrication of Digital Motor-Gear Unit

The EH- 10A motor-gear digital unit is lubricated with a heavy duty grease when assembled at the factory and should not require further lubrication unless disassembled. If disassembled relubricate with Texaco Multifak grease.

3. 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.

4. Removal of EH-10A Digital Welding Head

a. Unplug the control cables from the rear panel of the

wire feeder control.

b. Remove the accessory support assembly from the

motor-gear unit by loosening the capscrew at the bottom of the assembly.

c. Disconnect the motor and tachometer cables from

terminal board (T1) inside the control assembly as shown on the wiring diagram.

d. Remove the four screws which secure the digital

motor-gear unit to the base and remove the digital unit.

Vlll. 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. DIGIPULSE 450 POWER SOURCE

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

B. DIGIPULSE WIRE FEEDER

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 preprogram 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 will only be displayed for 1-second.

This number identifies the current program (EPROMS) used in your control. When a Program is changed, the new E-PROMS will automatically identify the new program number being used. If a revision is made to an existing program a number .1, .2, .3, etc. indicating the numerical revision will also appear in the VOLTS readout window simultaneously.

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 (or as

described 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 a bad 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 each of the windows should display one

zero, indicating a successful 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 T1-11

and T1-12; if voltage is present, replace the MPU board. If voltage is not present, check the voltage regulator (VR) The voltage regulator is located on the rear panel of the control box.

d. Check the input and output voltage of the regulator

VR.

(1) The input should be approx. 11 volts between

terminals T1-12 and VR-1. If voltage is not

present, replace I/O board. (2) The output should be 5 volts between termi-

nals T1-12 and T1-11. If voltage is not present,

replace, voltage regulator

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 Sect. III.

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

is securely connected to receptacle P2 on the Digipulse I/0 Board, and then release the clapper arm (pressure roll) on the Accessory Support Assembly. (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 T1-10 and T1-8 respectively with respect to T1-9 (Com.).

(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 and that the strobe markings are not scratched. 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, replace MPU board.

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. 5A). 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.

d. Remove the J-Gov p.c. board to gain access to the

P3 plug (harness) on the MPU p.c. board. Disconnect the P3 plug from its MPU board socket and, using a meter check for +/- 12 volt power supply output between plug pins P3-1 and P3-2 (for +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 VI-B.

a. IPM (speed) abort and possible causes:

(1) Initial hot start parameters incorrectly set. For

proper adjustment, refer to Set-up Procedures

following V-C-11. (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).

b. VOLTS (voltage) abort and possible causes:

This problem may be located in the wire feeder or

TP2

TP1

Fig. 5A - Input/Output (I/O) P. C. Board, P/N 674994

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 T1-7 and T1-9 Note that as

the arc voltage setting is increased, the poten-

tial between T1-7 and T1-9 also increases, and

will range from 0 to 10 vdc. If it does not,

replace the l/O and/or MPU board. If the po-

tential is present and responding to the

voltage change setting, continue with step (3)

following.

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

ground current, between T1-9 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 T1-9 (negative) to T1-7 (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 T1-9 (-) 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 F15-014.

NOTE: Training and Troubleshooting Courses are avail-

able for maintenance and repair of this and other equipment. For details, contact ESAB Welding & Cutting Products, P.O. Box 100545, Florence, SC 29501-0545; Telephone (803) 669-4411. Attention: Technical Training Coordinator.

X. REPLACEMENT PARTS DATA

1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part name, as shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE.

2. Always state the series or serial number of the machine on which the parts are to be used. The serial number is stamped on the unit nameplate.

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

(SW 9) SWITCH 950492

TEACH SWITCH 950087 PART OF OPT. TEACH KIT P/N 35638

Not illustrated** INSULATOR RING 60N90 KEY - 28N33 THUMBSCREW 61351087 FLATWASHER - 64309431 BELLWASHER - 950783

** FOR ACCESSORY

SUPPORT ASSY.

SPINDLE ASSY. 948259 (See Fig. 10)

BASE FRAME - 2075554

(SW 2) SWITCH -680359 KNOB - 951050

WARNING DECAL

- 2091514*

COVER - 30170*

EH-10A DIGITAL MOTOR-GEAR UNIT ASSY. - 679777 (See Fig. 7)

ACCESSORY SUPPORT ASSYS: 2 ROLL DRIVE (Shown, See Fig. 8) - 49V51 4 ROLL DRIVE (Not Shown, See Suppl. L-12-821) - 600216

(J3) RECEPTACLE 182W64

WARNING DECAL

- 995204*

STRAIN RELIEF 96W76

KEYLOCK - 950956, REPLACEMENT KEY - 32778

(MLS) SWITCH 634517

(Ref.) OPENING FOR POWER SUPPLY LIFTING RING

POWER CABLE ADAPTOR BLOCK - 674156 1/2-IN. - 13 STL. NUT 1/2-IN. LOCKWASHER (2) 1/2-IN. FLATWASHER

CONTROL ASSY. (See Fig. 9)

TRIGGER LOCK CRATER FILL SW 951059

(CB) CIRCUIT BREAKER 950874

VOLTAGE REGULATOR - 950159n TRANSISTOR SOCKET - 950158 (C4) CAPACITOR - 995544

J1 RECEPTACLE - 950762 C20 CAPACITOR - 950265

GAS INLET CONN. 74S76 GAS OUTLET CONN. 58V58 (Front of Mtg. Plate)

n Recommended Spare

Parts

* Replace decal if it

becomes excessively worn or lost or when replacing panel(s) we recommend that they be inspected and if necessary, replaced (free of charge from 6 to 12 months.

(GSV) GAS SOLENOID VALVE -2062305

TACH, P.C. BD. 675429 (2) SCREW61324746

TACH DISK 950313

TACH COVER - 18787 (2) SCREWS #61324974

Fig. 7 - EH-10A Digital Motor-Gear Unit Assembly, W/54" Lug Cables (40:1), P/N 679777

Fig. 6 - Typical Digipulse Wire Feeder (All Models, Except As Noted)

TACH HOUSING - 18786 (2) #8  32 x 3/8" SCREW

.6251Ø

View AA

END VIEW

W/COVER REMOVED

Gear Case Lubricated with Texaco Multifak Grease

(ref) 54" lg

11.6

VENT PLUG

3.25 Ø

2.875

.020 REF.

1.0

2.370

.93

50 D.P. MIN.

LOCATING COLLAR (REF)

FOR MOTOR REPLACEMENT PARTS - See Fig. 7A

MTR LEAD

4.010 SQ.

2.25Ø

2.000

1.375 1.375

.25

5/16 - 18UNC 2B

63 MIN DEPTH (11 full threads)

2.86

.25

OUTPUT SHAFT ASSY. (Part of 19734 - OUTPUT GEAR CASE)

OUTPUT GEAR CASE 19734 (Includes Output Shaft Assy. Shown above)

GEAR ASSY. B - 20293

OUTPUT SHAFT SEAL

GEAR ASSY. A - 20292

MAGNET ASSY. - 19730

ARMATURE SHAFT SEAL

OUTPUT GEAR CASE GASKET

GASKET/SEAL KIT - 20542 (Includes those items marked with )

BRUSH END BELL - 19732 (Includes TWO-BRUSH HOLDER ASSYS.)

BRUSH

ARMATURE & BEARINGS 19726 Includes: ARMATURE BEARING - 20288

Alternate gear sets* are available for the EH-10A motor. 50 1 Gear Set P/N 19211 17 1 Output Gear P/N 19210

NOTE: If an alternate gear set is used with a digital wire feed control an E-Prom

change is required in the control. Contact ESAB Welding & Cutting Products Engineering Services in Florence, S.C.

Fig. 7A, EH-10A Motor-Gear Unit Parts Breakdown - 40:1 Gear Ratio

MOTOR CORD LEAD - 19731

BRUSH HOLDER

CAP

(2) CARBON BRUSH REPLACEMENT KIT - 679784 Includes: (2) BRUSH CAP (2) CARBON BRUSH

ROLL PIN 1/4" x 1-3/4" LG

INLET

INLET WIRE GUIDE

29N13

INLET GUIDE INSERT

05N58

WIPER HOLDER*

598764

SET SCREW #6-32 x 1/4" LG

(61330849)

(2) LOCKING HANDLE

ASSEM - 49V44

(INCLUDES)

BOLT 1/4" x 1-5/8" LG

SPACER - 60N79

CLAPPER - 60N98

SHAFT - 60N65

KNOB - 60N68

LIGHT SPRING - 182W55 (FOR SOFT 8 SMALL DIA. HARD WIRE)

RETAINER - 58N24

FORK - 49V43

ROLLPIN - 3/16" x 1-3/4" LG.

SCREW - 5/16" - 18 x 2" LG.

WIRE OUTLET GUIDE INSERT*

CONDUIT

OUTLET

WIRE OUTLET*

GUIDE

CLAMP -- 61N02

PRESSURE ROLL

28V52

SUPPLIED

HEAVY SPRING - 182W54 (FOR LARGE DIA. HARD WIRE)

Fig. 8 - Accessory Support Assembly, P/N 49V51

NUT - 5/16" - 18

* Outlet Guide And Wiper Holder Not Included In

Assembly Part No. 49V51

WARNING DECAL - 995164*

I/O-P4 To MPU-P2 CABLE ASSY. - 677938

DISPLAY P/C BOARD ASSY. 675269

MPU P.C. BD. ASSY. - 18131

For 4.5 volt. Type 531 Replacement Battery (on I/O Bd.). Order P/N 951733

(I/O) P.C. BOARD ASSY. - 674994n

(R1) RESISTOR 17240005 (25W, 5 Ohm)

(CTR2) CONTROL TRANSFORMER Assy. - 994303

(FN1) FILTER NETWORK

(CTR1) CONTROL TRANSFORMER ASSY. - 950088

(T1) 20 PT. TERMINAL STRIP - 950182

NOTE: The heat sinks on the J gov. board are electrically hot. Do NOT touch or ground while unit is energized

Fig. 9 - DIGIPULSE Control Assembly, P/N 30681 (ESAB); 35653 (L-TEC)

REEL

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

SPINDLE - 948258

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

(Ref. Hair Pin Clip)

D TYPE WASHER 948254

SCREW 5/16"  18 X 2"

HAIR PIN CLIP 634347

J GOV. P.C. BOARDn ASSY. - 994236 (See Note) MTG. BRACKET - 995297 P.C. BOARD RECEPTACLE (P1) 636608

WATER

CONNECTION

58V75

(OUTLET)

COUPLING - 68121075

ADAPTOR - 11N16 (INLET)

n Recommended Spare Parts * Replace decal if it becomes

excessively worn or lost.

SPRING - 948253

SUPPORT 948257

(2) BRAKE PAD - 948255

SPINDLE

Fig. 10 - Spindle Assembly, P/N 948259

Optional Wire Reel, P/N 995570

WASHER 948256

5/8-18 Lh

1/4 N.P.T.

WITHOUT SOLENOID VALVE

Fig. 11 - Water Kit without Solenoid Valve, P/N 994466

5/8-18 Lh

E C R U O S

R E W O P

D-30682 (H)

Fig. 12 - Schematic Diagram - Digipulse XR and XRT (Except As Noted)

D-30683 (F)

Fig. 13A - Wiring Diagram - Digipulse

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATIONS GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS: Telephone (803) 664-5540/Fax: (800) 634-7548

Order Entry Product Availability Pricing Hours: 8:30 AM to 5:00 PM EST Order Changes Saleable Goods Returns Delivery Shipping Information

B. ENGINEERING SERVICE: Telephone: (803) 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: (803) 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: (803) 664-5501 / Fax: (803) 664-5548

E. WELDING EQUIPMENT REPAIRS: Telephone: (803) 664-4469 / Fax: (803) 664-5557

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

F. WELDING EQUIPMENT TRAINING:

Telephone: (803)664-4428 / Fax: (803) 664-4476 Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (803) 664-4248 / Fax: (803) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone: (800) 934-9353 Hours: 7:30 AM to 5:00 PM EST

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

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (803) 664-4452/Web: http://www.esab.com

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

F-15-012-B 11/96 Printed in U.S.A.

ESAB Digipulse Wire Feeders Troubleshooting instruction

Specifications and Main Features

Frequently Asked Questions

User Manual