ESAB UEC-8 User Manual

INSTRUCTIONS for
F-12-747-F
March, 1995
UEC-8
UNIONMELT® ELECTRONIC
WELDING CONTROL
Part No. 677190
Before applying electrical power, refer to Section IV for an important checklist on the proper interconnection of the UEC-8 Con­trol.
FEA TURES/BENEFITS
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Solid State Control ... To assure economical weld-
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ing, precise control of welding conditions and arc sta­bility is maintained with UEC-8 solid state accuracy.
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Compact Size ... For easy installation and capability
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to fit into simple fixtures, OM-48 carriages, or the most complex automated production lines.
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Low Maintenance ... Two basic solid state plug-in
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printed circuit boards simplify troubleshooting and minimize maintenance time.
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Operating Versatility ... The UEC-8 is adapted to a
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wide range of Sub Arc operations.
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Rugged Construction ... Minimize downtime and
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maintenance costs, and provides for worry-free op­eration.
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Variable INCH/STRIKE Wire Feed S peed ... Smooth
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starts can be obtained even under the most demand­ing conditions with the UEC-8's front panel variable INCH/STRIKE wire feed speed adjustment.
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Positive Starts ... Result from the UEC-8 voltage/
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current detection circuit. This circuit will only allow transfers from INCH/STRIKE to Welding Wire Feed speed after an "ARC" has been established. Most competitive controls do not offer this feature.
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Adjustable Anti-Stick ... This feature allows adjust-
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Dimensions and weight of the UEC-8 are as follows:
Height ...................................................... (152 mm) 6-in.
Width ..................................................... (305 mm) 12-in.
Depth ...................................................... (209 mm) 8-1/3
Input requirements: 120 Volt 50/60 Hz. 1 phase power @ 5 amps A.C.
ment of the wire retract time to prevent the electrode from sticking in the puddle after completion of a weld.
OM-48 Compatibility.... The UEC-8 has a plug-in
connection for direct interface with the J Governor/ OM-48 Carriage.
UEC-8 and EH-10 or EH-11 Motor .... With large 2-
in. diameter feed rolls offers the reserve power needed to assure consistent wire feeding under the most demanding conditions.
Optional Digital Meters .... Provide excellent means
of observing and controlling welding voltage, wire feed speed - I.P.M., and amperage.
SPECIFICATIONS
Be sure this information reaches the operator. You can get extra copies through your supplier.
SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precaution­ary information from the references listed in
Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld­ing helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far. Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and ex­plosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non­flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when neces­sary.
7. For additional information, refer to NFPA Standard 51B, "Fire Prevention in Use of Cutting and Welding Pro-
--
2
cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if move­ment is confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or missing connection can expose you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or dam­aged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flow­ing through any conductor causes lo­calized Electric and Magnetic Fields (EMF). Welding and cutting current cre­ates EMF around welding cables and welding machines. Therefore:
1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF: A. Route the electrode and work cables together. Secure
them with tape when possible. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work
cables. Route cables on the same side of your body. D. Connect the work cable to the workpiece as close as
possible to the area being welded. E. Keep welding power source and cables as far away
from your body as possible.
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:
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.
1. Always have qualified personnel perform the installa­tion, troubleshooting, and maintenance work. Do not
Used to call attention to hazards which could result in minor personal injury.
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I. INTRODUCTION
1. The UEC-8 electronic welding control P/N 677190 is designed for a wide range of Subarc† welding appli­cations, and can be used with either a constant-volt­age or a constant-current power supply as follows:
650 cvcc, 60 hz.*....................................P/N36006
653 cvcc, 60 hz.*....................................P/N36234
* If higher welding currents are desired, a kit is avail-
able from ESAB that allows you to parallel two 650 cvcc units to provide up to 1300 amperes output.
† If the UEC-8 is to be used with power sources no
longer manufactured (or recommended), please con­tact your ESAB Welding Supplier or the Factory and request a copy of edition F-12-747-"E". The "E" edi­tion contains historical information and requirements previously provided for low-range Subarc and Mig welding applications.
The UEC-8 is recommended for use with the following welding heads: EH-11 (for either constant-voltage or constant-current operation) or the EH-10 or 10A (for con­stant-voltage operation only). The control utilizes two solid-state printed circuit boards (described in Sec. II-C) to obtain excellent wire feed speed regulation. The con­trol is designed to be used for "Touch Work" (with op­tional D.C. touch work kit) and "scratch" starts (for AC or DC). In scratch starting the carriage is moving before the wire has contacted the work; in touch-work starting, the wire inches down to the work and the carriage does not move until the welding arc has been initiated.
II. DESCRIPTION
A. FRONT PANEL CONTROLS
1. Main Line Switch -- double pole single throw; breaks
both sides of 120 VAC power to control. Pilot light built in 5 ampere Slo-Blo fuse in hot side of AC lines.
2. Voltage Control Potentiometer--allows remote ad-
justment of output voltage.
3. Wire Feed Speed Potentiometer -- controls rate of
wire feed speed during welding. This potentiometer dial contains a 10 turn vernier calibrated from 0 to 100, and a computer which indicates the number of turns (0 to 9) giving a total of 1000 increment settings for accurate repeatable wire speed conditions.
4. Inch Speed Potentiometer -- screwdriver adjustment
controls rate of wire feed speed during inching.
5. Inch Up-Down Switch--spring loaded to center off
position - provides signal to allow motor to inch wire up or down.
6. Carriage Auto-Manual-Off Switch---when a compat-
ible carriage governor is connected to the UEC-8,
allows automatic starting and stopping of carriage in "Auto" position. In "Manual" position, carriage drive is energized continuously. In center "Off" position, there is no carriage operation.
7. Weld Start-Stop Switch--double pole double throw,
no center off position - in. "Start" position is initiates welding action. In "Stop" position, weld sequence is terminated.
8. T ouch Work Light -- included in optional Touch Work
Kit-lights when wire touches work prior to arc initia­tion.
9. Anti-Stick Potentiometer -- located on the left side
panel of the UEC-8. control. The potentiometer con­trols the length of time the wire is retracted at the end of the weld cycle, thus allowing the welding wire to retract a controlled amount. With a clockwise adjust­ment, the anti-stick time will increase, with a counter­clockwise adjustment, the anti- stick time will increase, with a counter-clock wise adjustment, the anti-stick time will decrease.
B. INTERNAL CONTROLS
1. Sensitivity Potentiometer (See Figure 3) -- an arc
voltage sensitivity potentiometer is located on the in­side back panel of the UEC-8 control. The adjust­ment of this "pot" controls the amount of arc voltage signal with respect to motor back e.m.f. (electro-mo­tive force) used; thus controlling motor response to arc voltage changes.
2. Weld Power Selector Switch (See Figure 5) -- lo-
cated on the Reversible Governor PC Board - allows the control to be used with either a constant-current
or a constant-potential power supply. Switch must
be placed in the proper position with respect to the type of power supply selected.
C. PRINTED CIRCUIT BOARDS (See Figures 5 and
6)
1. Logical Board (P/N 675330) -- provides basic se-
quencing of wire feed motor, weld contactor and anti­stick. A 1/2- amp standard fuse to protect the current detector circuit is located on the right side of the board. Also the PC board contains two LED* indicator lights. These lights help in troubleshooting the unit by indi­cating the state of the voltage and current detector at all times.
2. Reversible Governor Board (P/N 675332) -- solid
state motor speed control. Automatic reversing fea­ture for retract starts. During welding, if wire stubs to the plate or the arc is lost the wire will retract (at inch speed ) and inch down automatically until the arc is reestablished. A weld power selector switch (see II­B-2 above) is located on the right side of the PC board. Also the board contains an LED indicator light to check proper electrical installation of the wire feed motor.
* Light emitting diode
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III. INSTALLATION
A. EQUIPMENT REQUIRED
1. A 25-ft., 12-conductor cable with 14-pin (@ UEC-8) extension cables with 19-pin (@ power source) amphenols at each end to connect the UEC-8 to the 650 cvcc power source, P/N 34135.
D. INST ALLA TION OF METERS
Before performing any installation inside the con­trol, disconnect the electrical power cable at the re­ceptacle (P6) on the control.
Also available are extension cables with 19-pin amphenols at each as follows:
30-ft., 19-conductor cable ...................... P/N 34378
60-ft., 19-conductor cable ...................... P/N 34377
2. Two-single conductor voltage pickup cables; 6-ft. long, P/N 996806; or 25-ft. long, P/N 996805.
3. D. C. Analog meters as follows: Voltmeter, 0-80 volts, P/N 2062416; Ammeter, 0-800 amps, P/N 2062422, and Trimpot assembly P/N 997507. The trimpot ad­justs the ammeter to match the power source amme­ter for precise current readings.
4. Flux Manual/Auto Switch Kit, P/N 996369. This
switch can be used to operate an (optional) automatic flux gate P/N 01E62 (ordered separately).
To install the switch, refer to the schematic and wiring
diagrams in this booklet, and to instructions packed with the kit.
B. OPTIONAL ACCESSORIES
1. Motor Extension Cable P/N 996808. Provides an ex­tra 25-ft. of cable between the welding head and the UEC-8.
2. Touch Work Kit, P/N 997868: (Recommended for
sub-arc welding; for use only in D.C. applications.) The touch work kit senses contact between the weld­ing wire and workpiece, automatically stopping the wire when contact is established and lighting the touch work light. For installation, refer to Figs. 7 and 8 and the instruction literature packed with the kit.
3. Voltage Raise/Lower Switch Kit, P/N 953559: (For use only with power supplies with motorized control. The remote voltage control consists of a switch and silkscreened mounting plate. The switch is installed in the UEC-8 to control the voltage when the power supply is not located near the control. For installa­tion, refer to instructions packed with kit.
C. MOUNTING THE CONTROL
Since the operating controls are in the control front panel the box should be mounted so that the meters and con­trols are within easy reach and view of the operator. The control can be mounted on a sidebeam carriage or other vertical surface by means of the two holes provided on back of the control.
1. With the UEC-8 cover removed, install the two analog meters using screws supplied with the meters. (Volt­meter on left, ammeter at right, as viewed from the front.) Connect meter leads in UEC-8 control as fol­lows:
Ammeter leads: Violet (-) to in-line connector P10
Blue (+) to in-line connector P11
Voltmeter leads: Positive (+) terminal to Yellow lead
from TB1-5, Negative (-) terminal to Violet lead from TB1-6
Be careful when making the following adjustment so as not to touch other components. T ouching other components could result in damage to the unit or personal injury .
2. The trimpot calibrates the ammeter for applications where the control is more than 25-ft. from the power supply. On the rear of the ammeter, mount trimpot assembly so that the adjusting screw is at the top of the meter, as you are looking at the chassis. Connect trimpot leads to terminal points for ammeter as shown in D-1 above. Under actual welding conditions, re­move the UEC-8 cover and adjust the trimpot adjust­ing screw to bring the control ammeter reading in line with the power supply ammeter reading.
E. CONNECTIONS FOR SINGLE WIRE OPERATION
Make the required cable connections in accordance with the interconnection diagram, Fig. 1, and the following:
1. Connect the 14-pin Amphenol of the 12-conductor cable to the receptacle (P6) on the side of the con­trol. Connect the 19-pin Amphenol to the power sup­ply as shown in Fig. 1.
NOTE: When using DC power and making ammeter
connections from power supply to two leads of 12-cond. cable connected to control via the 14-pin receptacle, the polarity MUST be proper or the weld current detector will not operate and the control will not properly sequence.
2. Connect the motor cable to receptacle (P7) on the side of the control. See Note 1 on Fig. 1.
3. Connect the plug end of the voltage pick-up cable to
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19-PIN
650 cvcc POWER SOURCE
4/0 CABLES TO WORKPIECE
4/0 CABLE TO NOZZLE BUSBAR
12 COND. CABLE
(OPTONAL EXT. CABLE, see III-A-1
25-FT. 34135
3 COND. CABLE SUPPLIED WITH WIRE FEED MOTOR, see Note 1 or 2.
STRAIN LEFT
UEC-8 CONTROL
DC AMMETER
W/TRMPOT
TB1-8
BLU
P11
BLU
TB1-7
RED
P6
P10
VIO
P7
P8
P9
4 COND. GOV CABLE
2 FT. - 997965
2 - SINGLE COND. CABLES
6-FT. ASSY. - 996806
(also see III-A-2)
TB1-6
VIO
DC VOLTMETER
'J' GOV.
TB1-5
YEL
2 COND. CARRIAGE CABLE, 10-IN. - 948226
OM-48 CARRIAGE
EH-9 MOTOR
CHART 1 WIRE COLOR PIN FIELD (-), BLK A FIELD (+), RED B ARM (-), GRN C ARM (+), WHT D
CHART 2 WIRE COLOR PIN ARM (-), GRN C ARM (+), WHT D GND, GRN E
WIRE FEED MOTOR
BUSBAR
4/0 CABLES TO TERMINAL ON POWER SUPPLY
NOZZLE
See Note 3
4/0 CABLES TO TERMINAL ON POWER SUPPLY
NOTES
1. If shunt wound motor does NOT have mating plug for UEC-8 motor receptacle (P7) use connector plug 996513 & cable clamp 525564 and wire per chart-1.
2. If permanent magnet motor does NOT have mating plug for UEC-8 motor receptacle (P7) use above plug and cable clamp and wire per chart-2.
3. The work voltage pick-up lead must be corrected as shown from the workpiece. This function is also provided from the power supply thru P6-1 to TB1-6 in the UEC-8 (via a faston connection). This connection must be disconnected and taped.
Fig. 1 - Interconnection Diagram
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receptacle (P8) on the side of the control. Connect the lead tagged No. 1 to busbar and lead No. 2 to the workpiece or fixture (see Note 3 on Fig. 1).
4. Connect the plug end of the carriage governor cable to receptacle (P9) on the control.
NOTE: When using "J" Gov. P/N 953534 cable
997965 is required (see Section III-B-5). In­sert the lugged end through the strain relief on the back of the "J" Governor and connect to TB1 in governor as follows: Red to TB1-8; White to TB1-9; Black to TB1-10; Green to ground stud.
F. CONNECTIONS FOR DUAL WIRE OPERATION
1. DC/AC Connection (see Fig. 1). With the numerous power supplies available for use with the UEC-8, it is suggested in dual-wire applications that the operator use a DC unit as the lead power supply source to provide weld penetration. An AC unit should be used as the trail power supply to give the weld a cosmetic finish.
G.IMPORTANT WIRING/OPERATING MODIFICA-
TION USING EH-10A MOTOR
As noted in this booklet, one of the welding heads the UEC-8 is recommended for use with is the new EH-10A motor that can accommodate wire speeds from 0-1000 ipm. As a result, the Wire Feed Speed potentiometer may not have the fine adjustment (or resolution) range settings that you may prefer, and would normally be af­forded the other motors with lower wire speed (ipm) ranges.
If finer resolution in the "speed" potentiometer is desired, and you do not plan to operate the control at wire feed speeds above 500 ipm, you can modify the circuitry to spread the operating range of this "speed control". To do this, add a resistor (100K ohm, 1/4 watt) to the Wire Speed potentiometer as shown in the schematic dia-
gram. Remember, if this modification is made, that
the effective operating range of the potentiometer will be changed from 0-1000 ipm to 0-500 ipm.
IV. IMPORTANT CHECKLIST
To confirm that the various components (control, head, carriage, and power supply) have been properly inter­connected, it is imperative that the following tests be performed BEFORE operation starts.
Note: Failure to perform these tests may result in dam-
age to the printed circuit boards in the control.
A. PREP ARA TORY INSTRUCTIONS
Precautionary measures should be taken to provide maximum protection against electrical shock. Be sure that all power is off by opening the line (wall) disconnect switch. To be doubly safe, check your input leads with a voltmeter to make sure that all power is OFF.
1. Remove the cover (5 screws) from the UEC-8 Con­trol.
2. Remove the two printed circuit boards (P/N's 677330 & 675332) from inside the UEC-8.
3. The following readings should be taken after all equip­ment has been installed and interconnected, BEFORE POWER IS APPLIED to the system, and WITH PRINTED CIRCUIT BOARDS REMOVED.
B. TEST FOR INPUT POWER CONNECTION
1. Place "MLS" switch in the ON position.
2. Place ohmmeter to the highest resistance scale.
3. Check for continuity between TB1-3 and ground stud; then check for continuity between TB1-1 and ground stud. There should be a small deflection when the meter leads are first connected to these points; then both readings should be infinity.
C. TEST FOR CONTACTOR, CARRIAGE AND FLUX
GATE CONNECTION
1. Place carriage travel and flux gate switches in the "OFF" position, ("MLS" switch ON).
2. Place ohmmeter on Rx-1 scale. Check for continuity between TB1-3 and the center terminal of CTS switch. Reading should be approx. 1000 ohms (for "J" Gov.).
3. Check for continuity between TB1-3 and the red wire on WSSS switch. Reading should be approx. 40 ohms. If flux gate is used, check for continuity be­tween TB 1-3 and the center terminal of the Flux switch. Readings should be approx. 40 ohms.
D. TEST FOR VOLTMETER AND AMMETER CON-
NECTIONS
1. If hookup is made to a DC power supply: a. Place the positive meter lead on TB1-5 and nega-
tive meter lead on TB1-6. Reading should be approx. 500 ohms, but this reading will vary con-
7
siderably from power supply to power supply.
b. Reverse meter leads and reading should be 50 ohms
or less. To test for ammeter harnessing, place meter across terminals TB1-7 and TB1-8, reading should be approx. 1 ohm.
E. TEST FOR MOTOR CONNECTION
1. For permanent-magnet motors such as EH-10, EH­11, check for continuity between TB1-13 and TB1-14. Reading should be approx. 5 ohms.
2. For shunt-wound motors such as EH-2, EH-3, check for continuity between P7-A and P7-B. Reading should be approx. 500 ohms.
3. Check for shorts between TB1-13 and ground stud; check for continuity between P7-B and ground stud. Both readings should be infinity.
F. RESULTS
If any of the readings do NOT correspond with the read­ings above, DO NOT APPLY POWER. Instead, check all connections between components until the problem is found and corrected.
If all readings correspond with the readings above, place "MLS" switch in the OFF position and re-install the printed circuit boards inside the control. UEC-8 is now ready for operation.
G. LED INDICATOR LIGHTS
There are three LED indicator lights mounted on the PC boards that will help in setting up the equipment and in troubleshooting. Two of the lights are located on the Logic Board (675330) and one on the Reversible Gov­ernor Board (675332).
In setting up the equipment, the indicating light (REV­LED) on the Reversible Gov. Board (675332) is of main concern. (Refer to Fig. 5)
1. The control and wire feeder should be set up such that when the inch switch is depressed in the down position the motor should be feeding forward. If the motor feeds in the reverse direction, reverse the yel­low and gray armature leads at TB1-13 and TB1-14.
2. To double check motor setup, perform this final test: Depress inch up switch and see if indicating light on
the Reversible Gov. Board is dimly lit. The unit should not be operated if the indicating light is not on.
The other two lights are located on the logic board (Fig.
6) and marked C-DET and V-DET. These lights will be
illuminated only when welding currents and welding volt­ages are detected.
V. OPERATION
In each of the starting methods to be considered, it will be assumed that the unit has been properly installed, wire placed on reel and fed through sub-arc nozzle, and checked to insure proper operation and that fuses are of the proper values. In no case should fuses of larger capacity be substituted. If sub-arc welding, fill the hop­per with welding composition.
The following is a description of the procedures to be followed in making starts.
IMPORTANT NOTE: When using any of the procedures,
make sure that the Weld Start-Stop Switch is in the "Stop" position be­fore the Main Line Switch is moved to "ON" position to energize the control.
A. SUB-ARC SCRATCH STARTING SEQUENCE
1. Provide flux cover of weld zone.
2. Place Carriage Auto-Manual switch in "Manual", Car­riage will move in direction of weld.
3. Place Weld Start-Stop switch in "Start" position. Welding wire will begin slow inch down through flux burden; when the wire touches the plate and an arc is established, wire speed is transferred to the main control potentiometer and the weld is in progress.
4. Place Carriage Auto-Manual switch in "Auto" posi­tion if automatic stoppage of the carriage is required.
5. To stop weld, place Weld Start-Stop switch into the "Stop" position.
4. Place Weld Start-Stop switch in "Start" position. Power supply contactor is automatically energized and weld commences.
5. With start of welding current, carriage starts, and wire retracts at inch speed creating an arc.
6. After arc is established, the wire is fed in the forward direction at weld speed required to properly maintain the selected arc voltage.
7. To end the weld, the Weld Start-Stop switch is placed in the "Stop" position. Wire feed will cease, and the contractor and carriage travel will continue for the de­sired anti-stick time. (To adjust the length of time for the anti-stick, refer to Section II-A-9).
D. SUB-ARC RETRACT ST ART - C. C. MODE
In this mode the wire is in contact with the workpiece before the Start key is operational. After the wire is en­ergized, and the current detector detects short circuit current, the motor will reserve and the wire will retract at inch speed. As soon as the wire separates from the workpiece, and arc voltage and current and detected, the motor will change direction to forward and feed wire at preset weld speed.
B. POSITIONED STARTING SEQUENCE
(without touch-work kit installed)
1. Wedge a tightly rolled ball of steel wool about 3/8-in. in diameter between the welding wire and the workpiece, and cover the weld zone with flux. Place the Carriage Auto-Manual switch in "Auto" position.
2. Place Weld Start-Stop switch in "Start" position. The power supply contactor comes in immediately, initiat­ing the welding action and carriage travel.
3. To stop the welding action, place Weld Start-Stop switch in "Stop" position.
C. TOUCH WORK STARTING SEQUENCE (optional
accessory)
1. Place Carriage Auto-Manual in "Auto" Carriage will start and stop with welding action.
2. Place Inch Up-Down in "Down" position. Wire will inch toward work and automatically stop when con­tact is made, at which time the touch work light will be energized.
3. Place flux over weld zone, leaving Weld Start-Stop switch in "Stop" position.
VI. TROUBLESHOOTING INFORMATION
If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Troubleshooting and 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.
Precautionary measures should be taken to provide maximum protection against electrical shock. Be sure that all power is off by operating the line (wall) disconnect switch, before attempting any work in­side the control.
A. SYMPTOM: F1 fuse blows whenever main line
switch is turned "ON".
1. Check wiring for shorts.
2. If no short, replace governor PC board.
B. SYMPTOM: F1 fuses blows when Inch Switch is
operated.
1. Check for jammed or defective wire feed motor/ drive unit.
2. Replace governor PC board.
F. SYMPTOM: No control over motor speed at wire
feed potentiometer.
1. Check wire speed potentiometer with ohmmeter. Resistance should range from 0 through 100 K ohms. Resistance should range from 0 through 100 K ohms. Replace if defective.
2. Replace governor PC board.
3. Replace logic PC board.
G. SYMPTOM: Contactor in power supply does not
energize. Motor operates.
1. Check power supply control cable.
2. Check fuse (power supply).
3. Replace logic PC board.
H. SYMPTOM: Erratic or pulsing wire feed rate.
1. Replace logic PC board.
C. SYMPTOM: Motor inoperative.
1. Check setting of Inch Speed pot.
2. Check main line fuse F1.
3. Check motor plug.
4. Check motor brushes.
5. Replace logic PC board.
6. Replace Governor PC board.
D. SYMPTOM: Wire feed motor operates by inching
but does not operate for welding.
1. Check setting of WFSP.
2. Check touch work indicator light for operation when wire torches work.
3. Observe that both LED lights on logic PC board are lit after arc initiating.
4. Replace logic PC board.
E. SYMPTOM: If wire feed motor continues to run
when wire touches plate and work light not on.
1. Check fuse (1/2 amp) located on logic board.
2. Check for fused flux at tip of welding wire.
3. Check power supply ground cable for connec­tion to workpiece.
4. Replace logic PC board.
VII. REPLACEMENT P ART 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 ONLY.
2. Many of the parts on the illustrations, particularly electronic parts, are 'vendor items.' This means that they are standard commercial parts made by and purchased from other manufacturers. If you order from these outside sources, use the manufacturer's part number or designated as shown in the Electrical Parts List.
3. Always state the series or serial number of the machine on which the parts are used. The serial number is stamped on the unit nameplate.
.
VOLTMETER (Accy, Refer to Sec. III-A)
CTS, SWITCH ­672831
SIDE PANEL - 6787866 (OLD PANEL - 2075186)
CABINET - 30782
POWER PILOT LIGHT ­598227
MLS, SWITCH - 97W64
VCP, POTENTIOMETER - 639541 KNOB - 996501
WSP, 10-TURN POTENTIOMETER - 181W85 KNOW - 181W87
* WARNING LABEL - 995204
WARNING
ELECTRICAL SHOCK HAZARD
DO NOT OPERATE WITH COVER REMOVED
NETWORK - 996918
FN, FILTER
RI, RESISTOR 17240005
Fig. 2 - UEC-8 Control, P/N 677190
SENSITIVITY POTENTIOMETER - 92W64 KNOB - 994305
AMMETER/INCHES-PER MINUTE METER (Accy, Refer to Sec. III-A)
COVER - 677867 (OLD COVER - 2075227)
WSSS, SWITCH ­634518
ISP, POTENTIOMETER ­995301
IS, SWITCH ­599692
NOTE: Two cap screws 5/16" — 18 X 1/2" lg. (provided in cloth bag) for attaching control to OM-48 Side Beam Carriage.
LOGIC BOARD - 675330 INCLUDES: FUSE - 996523 (1/2 A. STD)
REVERSIBLE GOV. BOARD - 675332
TB1, TERMINAL BLOCK ­635568
TI, CONTROL
TRANSFORMER
995284
* Replace label if it becomes excessively worn or lost.
TOUCH WORK KIT 997868 (OPTIONAL) INCLUDES: FUSE - 82W43 (IA. SLO-BLO)
Fig. 3 - UEC-8 Control (Inside View)
WARNING LABEL - 995164
WARNING
Disconnect power cord before performing any maintenance
RECEPTACLE - 6271128
ASP, POTENTIOMETER
­995301
RECEPTACLE - 636694
RECEPTACLE - 996514
Replace label if it becomes
excessively worn or lost. Be sure to order decal if replac­ing sheet metal.
REV. LED, See Sect. IV-G
MOV-2
WELD POWER SEL. SW.
F-1, FUSE - 97W06 FUSE HOLDER ­182W15
RECEPTACLE - 523543
Fig. 4 - UEC-8 Control (Left Side View)
The new Rev. Gov. Bd. P/N 675332 (which replaced old P/N 997250) is designed for use with permanent magnet motors only (such as EH-10 or EH-11) and can- not be used with field-wound motors (such as EH-2 or EH-5). If your set-up uses a field-wound motor, consult with the factory.
Fig. 5 - Reversible Governor PC Board, P/N 675332
FUSE 1/2 AMP.
VOLTAGE DETECTOR LED
CURRENT DETECTOR LED
Fig. 6 - Logic P .C. Board, P/N 9971 15 (Earlier Unit s - obso-
lete) Logic P.C. Board, P/N 675330 (Later Units - after March 1984)
Fig. 7 - Schematic Diagram, UEC-8 Control
Fig. 8 - Wiring Diagram, UEC-8 Control
ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES
A. CUSTOMER SERVICE QUESTIONS:
Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM EST
Order Entry Product Availability Pricing Order Information Returns
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Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations Welding Equipment Troubleshooting
C. TECHNICAL SERVICE:
Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM EST
Part Numbers Technical Applications Specifications Equipment Recommendations
D. LITERATURE REQUESTS:
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E. WELDING EQUIPMENT REPAIRS:
Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM EST
Repair Estimates Repair Status
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Telephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM EST
Training School Information and Registrations
G. WELDING PROCESS ASSISTANCE:
Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST
H. TECHNICAL ASST. CONSUMABLES:
Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST
IF YOU DO NOT KNOW WHOM TO CALL
Telephone: (800) ESAB-123
Fax: (843) 664-4462
Hours: 7:30 AM to 5:00 PM EST
or
visit us on the web at http://www.esabna.com
The ESAB web site offers
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