Tweco HMC-410 User Manual

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HMC-410

AUTOMATIC & SEMI-AUTOMATIC CONTROL PANEL

Instruction Manual

ersion No: AA.02 Issue Date: July 27, 2005 Manual #: 430429-445

Operating Features:

120

VAC

50 60

888

IPM

Art # A-04355

WE APPRECIA TE YOUR BUSINESS!

Congratulations on your new Thermal Arc product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7621, or visit us on the web at www.Thermalarc.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Arc product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Arc is a Global Brand of Arc Welding Products for Thermadyne Industries Inc. We manufacture and supply to major welding industry sectors worldwide including; Manufacturing, Construction, Mining, Automotive, Aerospace, Engineering, Rural and DIY/Hobbyist.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to develop technologically advanced products to achieve a safer working environment within the welding industry.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

HMC-410 Automatic/Semi-Automatic Control Panel Instruction Manual Number 430429-445 for: Spec Number 100050-1 Spec Number 100050-2

Published by: Thermadyne Industries 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermalarc.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Publication Date: Juky 27, 2005

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date: ___________________________________

Equipment Serial #: ___________________________________

TABLE OF CONTENTS

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS ....................................................... 1-1

1.01 Arc Welding Hazards ...................................................................................... 1-1

1.02 PRINCIPAL SAFETY STANDARDS .................................................................. 1-5

1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC .................................... 1-6

1.04 Dangers relatifs au soudage à l’arc ................................................................. 1-6

1.05 PRINCIPALES NORMES DE SECURITE ........................................................ 1-10

1.06 DECLARATION OF CONFORMITY ................................................................. 1-11

1.07 LIMITED WARRANTY ................................................................................... 1-12

SECTION 2:

INTRODUCTION ...................................................................................... 2-1

2.01 How To Use This Manual ................................................................................ 2-1

2.02 Equipment Identification................................................................................. 2-1

2.03 Receipt Of Equipment ..................................................................................... 2-1

2.04 Symbol Chart ................................................................................................. 2-2

2.05 General Information ....................................................................................... 2-3

2.06 Product Specifications ................................................................................... 2-3

2.07 Front Panel Controls ....................................................................................... 2-7

2.08 Rear Panel Connections ............................................................................... 2-11

2.09 Power Source Interface Description ............................................................. 2-13

2.10 Hardware Description ................................................................................... 2-14

SECTION 3:

INSTALLATION ....................................................................................... 3-1

3.01 Location ......................................................................................................... 3-1

3.02 Assembly ........................................................................................................ 3-1

3.03 Electrical Connections .................................................................................... 3-1

3.04 Load Suppression .......................................................................................... 3-1

3.05 Grounding ...................................................................................................... 3-2

SECTION 4:

OPERATION........................................................................................... 4-1

4.01 System Configuration ..................................................................................... 4-1

4.02 Softswitch Description (Table 4-1) ................................................................. 4-2

4.03 System Setup ............................................................................................... 4-10

4.04 HMC-410 Setup Checklist ............................................................................ 4-12

4.05 Programming ............................................................................................... 4-13

4.06 Setup ............................................................................................................ 4-16

4.07 Operation ...................................................................................................... 4-17

TABLE OF CONTENTS (continued)TABLE OF CONTENTS

SECTION 5:

SERVICE .............................................................................................. 5-1

5.01 Maintenance ................................................................................................... 5-1

5.02 Controller Maintenance .................................................................................. 5-1

5.03 Troubleshooting ............................................................................................. 5-1

5.04 Troubleshooting Guide ................................................................................... 5-2

5.05 Diagnostics..................................................................................................... 5-6

5.06 Built In Test (BIT) Definition ........................................................................... 5-7

5.06 Built In Test (BIT) Definition (continued as Table 5-1b).................................. 5-8

5.06 Built In Test (BIT) Definition (continued as Table 5-1c) .................................. 5-9

SECTION 6:

ACCESSORIES AND OPTION DESCRIPTIONS.................................................... 6-1

6.01 Remote Pendant Description .......................................................................... 6-1

6.02 Feedhead ........................................................................................................ 6-1

6.03 Feed Roll Kits ................................................................................................. 6-1

6.04 Control Cables: ............................................................................................... 6-2

6.05 171238-17 Software Kits ................................................................................ 6-2

6.06 171238-19 Software Kits ................................................................................ 6-3

6.07 171238 Software Kits ..................................................................................... 6-3

6.08 870236 Robotic Interface Kits ........................................................................ 6-4

6.09 870236-002 Fanuc Robotic Interface Kit ........................................................ 6-5

6.10 870236-003 Comau Robotic Interface Kit ...................................................... 6-6

6.11 Other Available Options .................................................................................. 6-7

SECTION 7:

GLOSSARY ........................................................................................... 7-1

SECTION 8:

PARTS LIST .......................................................................................... 6-1

8.01 Equipment Identification................................................................................. 6-1

8.02 How To Use This Parts List ............................................................................ 6-1

8.03 Parts List for the Control Box Assembly (1 of 2) ............................................ 6-2

8.03 Parts List for the Control Box Assembly (2 of 2) ............................................ 6-4

8.04 Parts List for the Remote Pendant ................................................................. 6-6

APPENDIX 1: GENERAL INFORMATION ................................................................. A-1

APPENDIX 2: SCHEMATIC DIAGRAM 1 OF 4 ........................................................... A-2

APPENDIX 3: SCHEMATIC DIAGRAM 2 OF 4 ........................................................... A-4

APPENDIX 4: SCHEMATIC DIAGRAM 3 OF 4 ........................................................... A-6

APPENDIX 5: SCHEMATIC DIAGRAM 4 OF 4 ........................................................... A-8

TABLE OF CONTENTS

APPENDIX 6: SYSTEM OUTLINE 1 OF 2 ............................................................... A-10

APPENDIX 7: SYSTEM OUTLINE 2 OF 2 ............................................................... A-11

HMC-410

SECTION 1:

SAFETY INSTRUCTIONS AND WARNINGS

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.

Welding products and welding processes can cause serious injury or death, or damage to other equipment or property, if the operator does not strictly observe all safety rules and take precautionary actions.

Safe practices have developed from past experience in the use of welding and cutting. These practices must be learned through study and training before using this equipment. Some of these practices apply to equipment

connected to power lines; other practices apply to engine driven equipment. Anyone not having extensive training in welding and cutting practices should not attempt to weld.

Safe practices are outlined in the American National Standard Z49.1 entitled: This publication and other guides to what you should learn before operating this equipment are listed at the end of these safety precautions. HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED

ONLY BY QUALIFIED PEOPLE.

SAFETY IN WELDING AND CUTTING.

1.01 Arc Welding Hazards

WARNING

ELECTRIC SHOCK can kill.

Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly installed or improperly grounded equipment is a hazard.

3. Insulate yourself from work and ground using dry insulating mats or covers.

4. Disconnect input power or stop engine before installing or servicing this equipment. Lock input power disconnect switch open, or remove line fuses so power cannot be turned on accidentally.

5. Properly install and ground this equipment according to its Owner’s Manual and national, state, and local codes.

6. Turn off all equipment when not in use. Disconnect power to equipment if it will be left unattended or out of service.

7. Use fully insulated electrode holders. Never dip holder in water to cool it or lay it down on the ground or the work surface. Do not touch holders connected to two welding machines at the same time or touch other people with the holder or electrode.

8. Do not use worn, damaged, undersized, or poorly spliced cables.

1. Do not touch live electrical parts.

2. Wear dry, hole-free insulating gloves and body protection.

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9. Do not wrap cables around your body.

10.Ground the workpiece to a good electrical (earth) ground.

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HMC-410

11.Do not touch electrode while in contact with the work (ground) circuit.

12. Use only well-maintained equipment. Repair or replace damaged parts at once.

13.In confined spaces or damp locations, do not use a welder with AC output unless it is equipped with a voltage reducer. Use equipment with DC output.

14.Wear a safety harness to prevent falling if working above floor level.

15.Keep all panels and covers securely in place.

WARNING

ARC RAYS can burn eyes and skin; NOISE can damage hearing.

Arc rays from the welding process produce intense heat and strong ultraviolet rays that can burn eyes and skin. Noise from some processes can damage hearing.

4. Wear protective clothing made from durable, flameresistant material (wool and leather) and foot protection.

5. Use approved ear plugs or ear muffs if noise level is high.

WARNING

FUMES AND GASES can be hazardous to your health.

Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.

1. Keep your head out of the fumes. Do not breath the fumes.

2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases.

3. If ventilation is poor, use an approved air-supplied respirator.

1. Wear a welding helmet fitted with a proper shade of filter (see ANSI Z49.1 listed in Safety Standards) to protect your face and eyes when welding or watching.

2. Wear approved safety glasses. Side shields recommended.

3. Use protective screens or barriers to protect others from flash and glare; warn others not to watch the arc.

Eye protection filter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or cutting Electrode Size Filter Welding or cutting Electrode Size Filter

Torch soldering 2

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Ga s w eld ing

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded me tal-arc

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in., 12

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

4. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instruction for metals, consumables, coatings, and cleaners.

5. Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Shielding gases used for welding can displace air causing injury or death. Be sure the breathing air is safe.

Gas metal-arc

Ferrous bas e metal All 12

Carbon arc welding All 12

Carbon arc air gouging

Plasma arc cutting

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

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6. Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form highly toxic and irritating gases.

7. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, and if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded.

WARNING

WELDING can cause fire or explosion.

HMC-410

WARNING

FLYING SPARKS AND HOT METAL can cause injury.

Chipping and grinding cause flying metal. As welds cool, they can throw off slag.

1. Wear approved face shield or safety goggles. Side shields recommended.

2. Wear proper body protection to protect skin.

WARNING

Sparks and spatter fly off from the welding arc. The flying sparks and hot metal, weld spatter, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode or welding wire to metal objects can cause sparks, overheating, or fire.

1. Protect yourself and others from flying sparks and hot metal.

2. Do not weld where flying sparks can strike flammable material.

3. Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved covers.

4. Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.

5. Watch for fire, and keep a fire extinguisher nearby.

6. Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.

7. Do not weld on closed containers such as tanks or drums.

8. Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long, possibly unknown paths and causing electric shock and fire hazards.

9. Do not use welder to thaw frozen pipes.

CYLINDERS can explode if damaged. Shielding gas cylinders contain gas under high

pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully.

1. Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs.

2. Install and secure cylinders in an upright position by chaining them to a stationary support or equipment cylinder rack to prevent falling or tipping.

3. Keep cylinders away from any welding or other electrical circuits.

4. Never allow a welding electrode to touch any cylinder.

5. Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and associated parts in good condition.

6. Turn face away from valve outlet when opening cylinder valve.

7. Keep protective cap in place over valve except when cylinder is in use or connected for use.

8. Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

10.Remove stick electrode from holder or cut off welding wire at contact tip when not in use.

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HMC-410

WARNING

Engines can be dangerous.

WARNING

ENGINE EXHAUST GASES can kill.

4. To prevent accidental starting during servicing, disconnect negative (-) battery cable from battery.

5. Keep hands, hair, loose clothing, and tools away from moving parts.

6. Reinstall panels or guards and close doors when servicing is finished and before starting engine.

WARNING

Engines produce harmful exhaust gases.

1. Use equipment outside in open, well-ventilated areas.

2. If used in a closed area, vent engine exhaust outside and away from any building air intakes.

WARNING

ENGINE FUEL can cause fire or explosion. Engine fuel is highly flammable.

1. Stop engine before checking or adding fuel.

2. Do not add fuel while smoking or if unit is near any sparks or open flames.

3. Allow engine to cool before fueling. If possible, check and add fuel to cold engine before beginning job.

4. Do not overfill tank — allow room for fuel to expand.

5. Do not spill fuel. If fuel is spilled, clean up before starting engine.

SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin.

Batteries contain acid and generate explosive gases.

1. Always wear a face shield when working on a battery.

2. Stop engine before disconnecting or connecting battery cables.

3. Do not allow tools to cause sparks when working on a battery.

4. Do not use welder to charge batteries or jump start vehicles.

5. Observe correct polarity (+ and –) on batteries.

WARNING

STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.

WARNING

MOVING PARTS can cause injury.

Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing.

1. Keep all doors, panels, covers, and guards closed and securely in place.

2. Stop engine before installing or connecting unit.

3. Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.

1-4

The coolant in the radiator can be very hot and under pressure.

1. Do not remove radiator cap when engine is hot. Allow engine to cool.

2. Wear gloves and put a rag over cap area when removing cap.

3. Allow pressure to escape before completely removing cap.

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HMC-410

WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals know to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety code Sec. 25249.5 et seq.)

NOTE

Considerations About Welding And The Effects of Low Frequency Electric and Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Frequency Electric & Magnetic Fields - Background Paper, OTA-BP-E-63 (Washington, DC: U.S. Government Printing Office, May 1989): “...there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields and interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following procedures.

1. Keep cables close together by twisting or taping them.

Biological Effects of Power

1.02 PRINCIPAL SAFETY STANDARDS

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cable around the body.

4. Keep welding power source and cables as far away from body as practical.

ABOUT PACEMAKERS:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

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HMC-410

1.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC

MISE EN GARDE

LE SOUDAGE A L’ARC EST DANGEREUX

PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.

Les produits et procédés de soudage peuvent sauser des blessures graves ou la mort, de même que des dommages au reste du matériel et à la propriété, si l’utilisateur n’adhère pas strictement à toutes les règles de sécurité et ne prend pas les précautions nécessaires.

En soudage et coupage, des pratiques sécuritaires se sont développées suite à l’expérience passée. Ces pratiques doivent être apprises par étude ou entraînement avant d’utiliser l’equipement. Toute personne n’ayant pas suivi un entraînement intensif en soudage et coupage ne devrait pas tenter de souder. Certaines pratiques concernent les équipements raccordés aux lignes d’alimentation alors que d’autres s’adressent aux groupes électrogènes.

La norme Z49.1 de l’American National Standard, intitulée “SAFETY IN WELDING AND CUTTING” présente les pratiques sécuritaires à suivre. Ce document ainsi que d’autres guides que vous devriez connaître avant d’utiliser cet équipement sont présentés à la fin de ces instructions de sécurité.

SEULES DES PERSONNES QUALIFIEES DOIVENT FAIRE DES TRAVAUX D’INSTALLATION, DE REPARATION, D’ENTRETIEN ET D’ESSAI.

1. Ne touchez pas à des pièces sous tension.

2. Portez des gants et des vêtements isolants, secs et non troués.

1.04 Dangers relatifs au soudage à l’arc

AVERTISSEMENT

L’ELECTROCUTION PEUT ETRE MORTELLE.

Une décharge électrique peut tuer ou brûler gravement. L’électrode et le circuit de soudage sont sous tension dès la mise en circuit. Le circuit d’alimentation et les circuits internes de l’équipement sont aussi sous tension dès la mise en marche. En soudage automatique ou semi-automatique avec fil, ce dernier, le rouleau ou la bobine de fil, le logement des galets d’entrainement et toutes les pièces métalliques en contact avec le fil de soudage sont sous tension. Un équipement inadéquatement installé ou inadéquatement mis à la terre est dangereux.

1-6

3 Isolez-vous de la pièce à souder et de la mise à la

terre au moyen de tapis isolants ou autres.

4. Déconnectez la prise d’alimentation de l’équipement ou arrêtez le moteur avant de l’installer ou d’en faire l’entretien. Bloquez le commutateur en circuit ouvert ou enlevez les fusibles de l’alimentation afin d’éviter une mise en marche accidentelle.

5. Veuillez à installer cet équipement et à le mettre à la terre selon le manuel d’utilisation et les codes nationaux, provinciaux et locaux applicables.

6. Arrêtez tout équipement après usage. Coupez l’alimentation de l’équipement s’il est hors d’usage ou inutilisé.

7. N’utilisez que des porte-électrodes bien isolés. Ne jamais plonger les porte-électrodes dans l’eau pour les refroidir. Ne jamais les laisser traîner par terre ou sur les pièces à souder. Ne touchez pas aux porteélectrodes raccordés à deux sources de courant en même temps. Ne jamais toucher quelqu’un d’autre avec l’électrode ou le porte-électrode.

8. N’utilisez pas de câbles électriques usés, endommagés, mal épissés ou de section trop petite.

9. N’enroulez pas de câbles électriques autour de votre corps.

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HMC-410

10.N’utilisez qu’une bonne prise de masse pour la mise à la terre de la pièce à souder.

11.Ne touchez pas à l’électrode lorsqu’en contact avec le circuit de soudage (terre).

12.N’utilisez que des équipements en bon état. Réparez ou remplacez aussitôt les pièces endommagées.

13.Dans des espaces confinés ou mouillés, n’utilisez pas de source de courant alternatif, à moins qu’il soit muni d’un réducteur de tension. Utilisez plutôt une source de courant continu.

14. Portez un harnais de sécurité si vous travaillez en hauteur.

15.Fermez solidement tous les panneaux et les capots.

AVERTISSEMENT

LE RAYONNEMENT DE L’ARC PEUT BRÛLER LES YEUX ET LA PEAU; LE BRUIT PEUT ENDOMMAGER L’OUIE.

L’arc de soudage produit une chaleur et des rayons ultraviolets intenses, susceptibles de brûler les yeux et la peau. Le bruit causé par certains procédés peut endommager l’ouïe.

1. Portez une casque de soudeur avec filtre oculaire de nuance appropriée (consultez la norme ANSI Z49 indiquée ci-après) pour vous protéger le visage et les yeux lorsque vous soudez ou que vous observez l’exécution d’une soudure.

2. Portez des lunettes de sécurité approuvées. Des écrans latéraux sont recommandés.

3. Entourez l’aire de soudage de rideaux ou de cloisons pour protéger les autres des coups d’arc ou de l’éblouissement; avertissez les observateurs de ne pas regarder l’arc.

4. Portez des vêtements en matériaux ignifuges et durables (laine et cuir) et des chaussures de sécurité.

5. Portez un casque antibruit ou des bouchons d’oreille approuvés lorsque le niveau de bruit est élevé.

AVERTISSEMENT

LES VAPEURS ET LES FUMEES SONT DANGEREUSES POUR LA SANTE.

Le soudage dégage des vapeurs et des fumées dangereuses à respirer.

SELECTION DES NUANCES DE FILTRES OCULAIRS POUR LA PROTECTION

DES YEUX EN COUPAGE ET SOUDAGE (selon AWS á 8.2-73)

Opération de coupage

ou soudage

Brassage tendre au chalumeau Brassage fort au chalumeau

Oxycoupage métaux ferreux toutes conditions 12

moyen de 1 á 6 po. (25 á 150 mm) 4 ou 5

Soudage aux gaz Soudage á l'arc Plasm a (PAW) toutes dimens ions 12

moyen de 1/8 á 1/2 po. (3 á 12 mm ) 5 ou 6 mince 12

Soudage á l'arc avec électrode enrobees (SMAW)

Dimens ion d'électrode ou

Epiasseur de métal ou

Intens ité de courant

toutes conditions 2

toutes conditions 3 ou 4 m étaux non-ferreux toutes conditions 11

mince m oins de 1 po. (25 mm) 2 ou 3

épais plus de 6 po. (150 mm) 5 ou 6

mince m oins de 1/8 po. (3 m m) 4 ou 5

épais plus de 1/2 po. (12 mm) 6 ou 8 épais 14

moins de 5/32 po. (4 mm) 10 Coupage á l'arc Plasma (PAC)

5/32 á 1/4 po. (4 á 6.4 mm) 12 mince moins de 300 amperès 9

plus de 1/4 po. (6.4 mm ) 14 moyen de 300 á 400 amperès 12

Nuance de

filtre oculaire

Opération de coupage

ou soudage

Soudage á l'arc s ous gaz avec fil plein (GMAW)

Soudage á l'arc s ous gaz avec électrode de tungstène (GTAW)

Soudage á l'hydrogène atom ique (AHW) Soudage á l'arc avec électrode de carbone (CAW)

Gougeage Air-Arc avec électrode de carbone

Dimens ion d'électrode ou

Epiasseur de métal ou

Intens ité de courant

toutes conditions 12

épais plus de 400 amperès 14

Nuance de

filtre oculaire

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HMC-410

1. Eloignez la tête des fumées pour éviter de les respirer.

2. A l’intérieur, assurez-vous que l’aire de soudage est bien ventilée ou que les fumées et les vapeurs sont aspirées à l’arc.

3. Si la ventilation est inadequate, portez un respirateur à adduction d’air approuvé.

4. Lisez les fiches signalétiques et les consignes du fabricant relatives aux métaux, aux produits consummables, aux revêtements et aux produits nettoyants.

5. Ne travaillez dans un espace confiné que s’il est bien ventilé; sinon, portez un respirateur à adduction d’air. Les gaz protecteurs de soudage peuvent déplacer l’oxygène de l’air et ainsi causer des malaises ou la mort. Assurez-vous que l’air est propre à la respiration.

6. Ne soudez pas à proximité d’opérations de dégraissage, de nettoyage ou de pulvérisation. La chaleur et les rayons de l’arc peuvent réagir avec des vapeurs et former des gaz hautement toxiques et irritants.

7. Ne soudez des tôles galvanisées ou plaquées au plomb ou au cadmium que si les zones à souder ont été grattées à fond, que si l’espace est bien ventilé; si nécessaire portez un respirateur à adduction d’air. Car ces revêtements et tout métal qui contient ces éléments peuvent dégager des fumées toxiques au moment du soudage.

1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.

2. Ne soudez pas dans un endroit où des particules volantes ou des projections peuvent atteindre des matériaux inflammables.

3. Enlevez toutes matières inflammables dans un rayon de 10, 7 mètres autour de l’arc, ou couvrez-les soigneusement avec des bâches approuvées.

4. Méfiez-vous des projections brulantes de soudage susceptibles de pénétrer dans des aires adjacentes par de petites ouvertures ou fissures.

5. Méfiez-vous des incendies et gardez un extincteur à portée de la main.

6. N’oubliez pas qu’une soudure réalisée sur un plafond, un plancher, une cloison ou une paroi peut enflammer l’autre côté.

7. Ne soudez pas un récipient fermé, tel un réservoir ou un baril.

8. Connectez le câble de soudage le plus près possible de la zone de soudage pour empêcher le courant de suivre un long parcours inconnu, et prévenir ainsi les risques d’électrocution et d’incendie.

9. Ne dégelez pas les tuyaux avec un source de courant.

10.Otez l’électrode du porte-électrode ou coupez le fil au tube-contact lorsqu’inutilisé après le soudage.

11.Portez des vêtements protecteurs non huileux, tels des gants en cuir, une chemise épaisse, un pantalon revers, des bottines de sécurité et un casque.

AVERTISSEMENT

LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION

L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie.

1-8

AVERTISSEMENT

LES ETINCELLES ET LES PROJECTIONS BRULANTES PEUVENT CAUSER DES BLESSURES.

Le piquage et le meulage produisent des particules métalliques volantes. En refroidissant, la soudure peut projeter du éclats de laitier.

1. Portez un écran facial ou des lunettes protectrices approuvées. Des écrans latéraux sont recommandés.

2. Portez des vêtements appropriés pour protéger la peau.

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HMC-410

1. Utilisez l’équipement à l’extérieur dans des aires ouvertes et bien ventilées.

AVERTISSEMENT

LES BOUTEILLES ENDOMMAGEES PEUVENT EXPLOSER

Les bouteilles contiennent des gaz protecteurs sous haute pression. Des bouteilles endommagées peuvent exploser. Comme les bouteilles font normalement partie du procédé de soudage, traitez-les avec soin.

1. Protégez les bouteilles de gaz comprimé contre les sources de chaleur intense, les chocs et les arcs de soudage.

2. Enchainez verticalement les bouteilles à un support ou à un cadre fixe pour les empêcher de tomber ou d’être renversées.

3. Eloignez les bouteilles de tout circuit électrique ou de tout soudage.

4. Empêchez tout contact entre une bouteille et une électrode de soudage.

2. Si vous utilisez ces équipements dans un endroit confiné, les fumées d’échappement doivent être envoyées à l’extérieur, loin des prises d’air du bâtiment.

AVERTISSEMENT

LE CARBURANT PEUR CAUSER UN INCENDIE OU UNE EXPLOSION.

Le carburant est hautement inflammable.

1. Arrêtez le moteur avant de vérifier le niveau e carburant ou de faire le plein.

2. Ne faites pas le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.

3. Si c’est possible, laissez le moteur refroidir avant de faire le plein de carburant ou d’en vérifier le niveau au début du soudage.

4. Ne faites pas le plein de carburant à ras bord: prévoyez de l’espace pour son expansion.

5. N’utilisez que des bouteilles de gaz protecteur, des détendeurs, des boyauxs et des raccords conçus pour chaque application spécifique; ces équipements et les pièces connexes doivent être maintenus en bon état.

6. Ne placez pas le visage face à l’ouverture du robinet de la bouteille lors de son ouverture.

7. Laissez en place le chapeau de bouteille sauf si en utilisation ou lorsque raccordé pour utilisation.

8. Lisez et respectez les consignes relatives aux bouteilles de gaz comprimé et aux équipements connexes, ainsi que la publication P-1 de la CGA, identifiée dans la liste de documents ci-dessous.

AVERTISSEMENT

LES MOTEURS PEUVENT ETRE DANGEREUX LES GAZ D’ECHAPPEMENT DES MOTEURS

PEUVENT ETRE MORTELS.

5. Faites attention de ne pas renverser de carburant. Nettoyez tout carburant renversé avant de faire démarrer le moteur.

AVERTISSEMENT

DES PIECES EN MOUVEMENT PEUVENT CAUSER DES BLESSURES.

Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples.

1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés.

2. Avant d’installer ou de connecter un système, arrêtez le moteur.

3. Seules des personnes qualifiées doivent démonter des protecteurs ou des capots pour faire l’entretien ou le dépannage nécessaire.

Les moteurs produisent des gaz d’échappement nocifs.

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HMC-410

4. Pour empêcher un démarrage accidentel pendant l’entretien, débranchez le câble d’accumulateur à la borne négative.

5. N’approchez pas les mains ou les cheveux de pièces en mouvement; elles peuvent aussi accrocher des vêtements amples et des outils.

6. Réinstallez les capots ou les protecteurs et fermez les portes après des travaux d’entretien et avant de faire démarrer le moteur.

AVERTISSEMENT

DES ETINCELLES PEUVENT FAIRE EXPLOSER UN ACCUMULATEUR; L’ELECTROLYTE D’UN ACCUMU-LATEUR PEUT BRULER LA PEAU ET LES YEUX.

Les accumulateurs contiennent de l’électrolyte acide et dégagent des vapeurs explosives.

1. Portez toujours un écran facial en travaillant sur un accumu-lateur.

AVERTISSEMENT

LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT BRULANT SOUS PRESSION PEUVENT BRULER LA PEAU ET LES YEUX.

Le liquide de refroidissement d’un radiateur peut être brûlant et sous pression.

1. N’ôtez pas le bouchon de radiateur tant que le moteur n’est pas refroidi.

2. Mettez des gants et posez un torchon sur le bouchon pour l’ôter.

3. Laissez la pression s’échapper avant d’ôter complètement le bouchon.

1.05 PRINCIPALES NORMES DE

SECURITE

2. Arrêtez le moteur avant de connecter ou de déconnecter des câbles d’accumulateur.

3. N’utilisez que des outils anti-étincelles pour travailler sur un accumulateur.

4. N’utilisez pas une source de courant de soudage pour charger un accumulateur ou survolter momentanément un véhicule.

5. Utilisez la polarité correcte (+ et –) de l’accumulateur.

Safety in Welding and Cutting, norme ANSI Z49.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

Safety and Health Standards, OSHA 29 CFR 1910, Superintendent of Documents, U.S. Government Printing Office, Washington, D.C.

20402.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have Held Hazardous Substances, norme AWS F4.1, American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33128.

National Electrical Code, norme 70 NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

Safe Handling of Compressed Gases in Cylinders, document P-1, Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202.

Code for Safety in Welding and Cutting, norme CSA W117.2 Association canadienne de normalisation, Standards Sales, 276 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3.

Safe Practices for Occupation and Educational Eye and Face Protection, norme ANSI Z87.1, American National Standards Institute, 1430 Broadway, New York, NY 10018.

Cutting and Welding Processes, norme 51B NFPA, National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

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HMC-410

1.06 DECLARATION OF CONFORMITY

Manufacturer: Thermadyne Corporation Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the “EMC Directive” (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements. Among them are:

• CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

• UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

• ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.

• For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

• Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative:

Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

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HMC-410

1.07 LIMITED WARRANTY

LIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customers of itsauthorized distributors hereafter “Purchaser” that its products will be free of defects in workmanship or material. Should anyfailure to conform to this warranty appear within the time period applicable to the Thermal Arc products as stated below, Thermal Arc shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal Arc’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal Arc’s sole option, of any components or parts of the product determined by Thermal Arc to be defective.

THERMAL ARC MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED. THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHERS, INCLUDING, BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR ANY PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: THERMAL ARC SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INDIRECT OR CONSEQUENTIAL DAMAGES, SUCH AS, BUT NOT LIMITED TO, LOST PROFITS AND BUSINESS INTERRUPTION. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal Arc with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal Arc whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. No employee, agent, or representative of Thermal Arc is authorized to change this warranty in any way or grant any other warranty.

PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN THERMAL ARC’S SOLE JUDGEMENT MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL ARC PRODUCT. PURCHASER’S RIGHTS UNDER THIS WARRANTY ARE VOID IF THE PRODUCT IS SOLD TO PURCHASER BY NON-AUTHORIZED PERSONS.

The warranty is effective for the time stated below beginning on the date that the authorized distributor delivers the products to the Purchaser. Notwithstanding the foregoing, in no event shall the warranty period extend more than the time stated plus one year from the date Thermal Arc delivered the product to the authorized distributor.

POWER SUPPLIES

MAIN POWER MAGNETICS (STATIC & ROTATING) 3 YEARS 3 YEAR ORIGINAL MAIN POWER RECTIFIER 3 YEARS 3 YEAR CONTROL PC BOARD 3 YEARS 3 YEAR ALL OTHER CIRCUITS AND COMPONENTS INCLUDING BUT NOT LIMITED TO: CONTACTORS, RELAYS, SOLENOIDS, PUMPS, POWER SWITCHING SEMI-CONDUCTORS. ENGINES: ENGINES ARE NOT WARRANTED BY THERMAL ARC,

ALTHOUGH MOST ARE WARRANTED BY THE ENGINE MANUFACTURER. SEE THE ENGINE MANUFACTURE'S 1 YEAR 1 YEAR

WAR RANTY FOR D ETAILS. CONSOLES, CONTROL EQUIPMENT, HEAT EXCHANGES ACCESSORY EQUIPMENT

NOTE: Dragster 85® excluded from this policy. Refer to Dragster 85 warranty in Dragster 85 Owner’s Manual.

Warranty repairs or replacement claims under this limited warranty must be submitted to Thermal Arc by an authorized Thermal Arc repair facility within thirty (30) days of purchaser’s notice of any Warranty Claim. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the Purchaser. All returned goods shall be at the Purchaser’s risk and expense. This warranty supersedes all previous Thermal Arc warranties. Thermal Arc® is a Registered Trademark of Thermadyne Industries Inc.

September 27, 2004

ALL OTHER

POWER SUPPLIES

1 YEAR 1 YEAR

LABOR

1-12

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HMC-410

SECTION 2:

INTRODUCTION

2.01 How To Use This Manual

This Owner’s Manual applies to just specification or part numbers listed on page i.

To ensure safe operation, read the entire manual, including the chapter on safety instructions and warnings.

Throughout this manual, the words WARNING, CAUTION, and NOTE may appear. Pay particular attention to the information provided under these headings. These special annotations are easily recognized as follows:

WARNING

A WARNING gives information regarding possible personal injury.

2.02 Equipment Identification

The unit’s identification number (specification or part number), model, and serial number usually appear on a nameplate attached to the control panel. In some cases, the nameplate may be attached to the rear panel. Equipment which does not have a control panel such as gun and cable assemblies is identified only by the specification or part number printed on the shipping container. Record these numbers on the bottom of page 1 for future reference.

2.03 Receipt Of Equipment

When you receive the equipment, check it against the invoice to make sure it is complete and inspect the equipment for possible damage due to shipping. If there is any damage, notify the carrier immediately to file a claim. Furnish complete information concerning damage claims or shipping errors to the location in your area listed in the inside back cover of this manual.

Include all equipment identification numbers as described above along with a full description of the parts in error.

CAUTION

A CAUTION refers to possible equipment damage.

NOTE

A NOTE offers helpful information concerning certain operating procedures.

Additional copies of this manual may be purchased by contacting Thermal Arc at the address and phone number given in the next section. Include the Owner’s Manual number and equipment identification numbers.

Electronic copies of this manual can also be downloaded at no charge in Acrobat PDF format by going to the Thermal Arc web site listed below and clicking on the Literature Library link:

http://www.thermalarc.com

Move the equipment to the installation site before uncrating the unit. Use care to avoid damaging the equipment when using bars, hammers, etc., to un-crate the unit.

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HMC-410

2.04 Symbol Chart

Note that only some of these symbols will appear on your model.

Off

Dangerous Voltage

Increase/Decrease

Circuit Breaker

AC Auxiliary Power

Fuse

Amperage

Voltage

Single Phase

Three Phase

Three Phase Static Frequency ConverterTransformer-Rectifier

Remote

Duty Cycle

Percentage

Panel/Local

Shielded Metal Arc Welding (SMAW)

Gas Metal Arc Welding (GMAW)

Wire Feed Function

Wire Feed Towards Workpiece With

Output Voltage Off.

Welding Gun

Purging Of Gas

Continuous Weld Mode

Spot Weld Mode

Spot Time

Preflow Time

Postflow Time

Hertz (cycles/sec)

Frequency

Negative

Positive

Direct Current (DC)

Protective Earth (Ground)

Line

Line Connection

Auxiliary Power

Gas Tungsten Arc Welding (GTAW)

Air Carbon Arc Cutting (CAC-A)

Constant Current

Constant Voltage Or Constant Potential

High Temperature

Fault Indication

Arc Force

Touch Start (GTAW)

Variable Inductance

2 Step Trigger Operation

Press to initiate wirefeed and welding, release to stop.

4 Step Trigger Operation

Press and hold for preflow, release to start arc. Press to stop arc, and hold for preflow.

Burnback Time

Disturbance In Ground System

IPM

MPM

Inches Per Minute

Meters Per Minute

115V 15A

2-2

Receptacle RatingAuxiliary Power

Voltage Input

Art # A-04130

July 27, 2005

HMC-410

2.05 General Information

The HMC-410 is an automatic/semiautomatic control panel capable of precisely controlling a power source (welding machine), wire feed motor, gas valve solenoid, and if present an automatic fixture. The HMC-410 can be controlled from the front panel or remotely through an optional remote pendant assembly, optional auxiliary interface cable, or optional robotic interface (see HMC410 Accessories And Option Descriptions chapter for more details). The functional capability of the HMC-410 can be changed to meet more specific customer applications by changing the system’s software. The HMC410 divides the weld process (schedule) into ready, preflow, run in, weld, crater fill, burnback, post-flow, and recycle segments. The user can program the appropriate parameters (time, voltage, and wire feed speed) into each segment. The HMC- 410 can store up to 10 weld schedules in nonvolatile memory (schedules are saved even with input power removed)

The HMC-410 comes with an abundance of standard features which include:

• an on/off rocker switch with built-in circuit breaker for total system protection

• a weld/program key switch for operator lockout

• an inch switch

• a solid state circuit providing current limit to the wire feed motor

• a solid state dynamic brake.

The HMC-410 has been designed to comply with CSA NRTL/C, NEMA EW 3, and CE (IEC974-5) standards.

2.06 Product Specifications

HMC-410 Specifications

Input Voltage: 120 VAC Input Frequency: 50/60 Hz Input Voltage Tolerance ±10% Maximum Input Current 4.0 Amps Number of Weld Schedules 10 Number of Weld Sub Segments (per Schedule) Maximum Auxilliary Relay Rating 4

Approvals

Table 2-1: Specification Chart

Refer to sheet 2 of the System Outline Drawing (number

170921) in the Appendix section of this manual for dimensional information.

CSA NRTL/C NEMA EW 3 CE (IEC974-5)

• a purge switch

• a test mode switch allowing a run through of a programmed weld sequence setup without welding

• continuous-turn encoders for precise parameter input

• numerous LED displays for visual indication of parameters and modes

• a special soft switch screen allowing custom programming of system capabilities

• software upgrades to tailor the performance and capability of the system

• a self-diagnostics routine to aid in servicing

• a remote pendant amphenol input

• an auxiliary amphenol input for connection to PLC controllers or other fixturing

• a tachometer feedback control loop for precise wire feed speed control

• onboard fuses for system protection

• a ground fault circuit to protect the operator and equipment from welding current flowing through the ground system of the control panel

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HMC-410

Features Benefits

1. Solid State Circuitry

2. Tachometer Feedback

3. Continuous-Turn Encoders A. Allows precise input of welding parameters

4. Multiple LED Displays A. Provides visual indication of parameter input

5. Inch Switch A. Allows “cold” inching of wire at set wire feed speed

6. Purge Switch A. Allows purging of gas without running wire

7. Test Switch

8. Keyswitch A. Provides operator lockout to preset welding parameters

HMC-410 Features & Benefits

A. Provides input voltage compensation B. Provides current limit to the motor C. Provides overcurrent shutdown A. Provides

recise wire feed speed accurac

B. Provides motor load compensation

A. Permits a practice run through of a programmed weld sequence without welding

A. Operator can store up to 10 weld schedules into non-

9. 10 Weld Schedules

volatile memory for easy job changeover B. Eliminates the need for continuous resetting of weld parameters

10. Soft Switch Screen A. Allows custom programming of system capabilities

11. Self-Diagnostics Routine A. Aids in troubleshooting and servicing

12. Multiple Software Upgrades

13. Remote Pendant Amphenol

A. Permits a reconfiguration of system capabilities with a simple change in software A. Provides a connection point for the use of a remote pendant control A. Allows an easy interface to PLC’s or similar controllers

14. Auxiliary Interface Amphenol

B. Provides 3 system relays that can be used to provide timing signals to PLC controllers

15. Dynamic Brake

A. Solid state control of a motor brake offers precise stopping of the wire

16. Input Circuit Breaker A. Provides total system protection

17. On-Board Fuses A. Provides I/O protection A. Protects the operator and equipment from welding

18. Ground Fault Circuit

current flowing through the ground system of the control panel

2-4

19. 100% Duty Cycle A. Eliminates nuisance shutdowns due to overtemperature

20. Small Size/Light Weight A. Takes up small amount of space

Table 2-2: Features and Benefits

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HMC-410

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Art # A-04356

Figure 2-1A: Semiautomatic Configuration

2-5

HMC-410

2-6

Art # A-04357

Figure 2-1B: Automatic Configuration

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HMC-410

2.07 Front Panel Controls

Refer to Figure 2-2 for details.

1. UPPER DISPLAY — This display shows numerical information for arc hours and time during normal operation. It can also contain diagnostic test information when diagnostics are performed.

2. ARC HOURS X100 LED—When lit, the upper display will display the number of “hundreds of hours” the control panel has controlled an arc. This number must be added to the number of hours in the center display for a total count of arc hours.

3. IME LED — When lit, the upper display will contain the time, in seconds, of the selected segment.

4. ARC HOURS X1 LED — When lit, the center display will show the number of hours the control panel has controlled an arc. This number must be added to the number of “hundreds of hours” in the upper display for a total count of arc hours.

5. VOLTS LED —When lit, the center display will show arc voltage. If the unit is being programmed, this number represents the programmed arc voltage. If the system is welding, this number is the actual arc voltage.

NOTE

If the PSC softswitch is off, this LED will not light. Refer to the Operation - Softswitch Description chapter of this manual.

6. COUNT LED—When lit, the center display will represent the number of weld sequence recycles. The number displayed is the number of times the weld sequence will repeat itself automatically. This number can be 1 to 255.

7. PROG DELAY LED — When lit, the center display will display the user selected programmable fault delay in seconds.

NOTE

Refer to the Operation - Softswitch Description chapter of this manual.

8. CENTER DISPLAY — This display shows numerical information for arc hours, volts, count, and prog delay during normal operation. It can also contain diagnostic test information when diagnostics are performed.

9. SCHEDULE NUMBER LED — When lit, the lower display will contain the schedule number currently active.

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Art # A-04358

Figure 2-2: Front Panel Controls

2-7

HMC-410

10.AMPS LED — When lit, the lower display will show actual weld current in amps.

NOTE

To have the lower display show amps instead of wire feed speed, the mode select encoder will have to be turned.

11.WFS LED — When lit, the lower display shows the wire feed speed. If the unit is being programmed, this number represents the programmed wire feed speed. If the system is welding, the value displayed is actual wire feed speed.

NOTE

The unit comes from the factory with the WFS displayed in inches per minute (IPM). The WFS can be displayed in meters per minute (MPM). Refer to the Operation - Softswitch Description chapter of this manual.

12.WELD SUB SEGMENT LED — When lit, the lower display contains the current weld sub segment number. The weld sub segment number may be from 1 to 4. The system must be configured for weld sub segment operation for this to be selectable.

NOTE

Refer to the Operation - Softswitch Description chapter of this manual.

13.LOWER DISPLAY — This display shows numerical information for schedule number, amps, WFS, and weld sub segment during normal operation. It can also contain diagnostic test information when diagnostic are performed.

14.TEST LED — When lit, the control panel is in a test mode. The test mode allows the weld operator to perform the weld schedule with all of its control signals, timing, and displayed voltages and wire feed speeds. However the wire feeder and power source will not operate.

15.TEST BUTTON — This button will toggle the control panel in and out of test mode. This button has no effect during a weld.

16.PURGE BUTTON — Depressing the purge button will allow shielding gas to flow out of the welding gun without feeding wire. This button has no effect during a weld.

2-8

Art # A-04358

Figure 2-2: Front Panel Controls

July 27, 2005

HMC-410

17. POWER ON/OFF SWITCH — This switch controls only the control panel and not the power source (welding machine). It is used as an on/off switch and also serves as a circuit breaker. NOTE: If the circuit breaker trips, it turns the power switch to the OFF position. A short cooling period must be allowed before an attempt is made to reset the unit by placing the switch in the ON position.

18.INCH BUTTON—Depressing the inch button will feed wire (without the flow of gas) at a speed programmed into the Run In section of the weld schedule; the welding wire WILL NOT be electrically “hot”. This button has no effect during a weld.

19. TRIGGER HOLD SWITCH (OPTIONAL) — This optional switch selects either 2 Step or 4 Step gun switch mode of operation for semiautomatic applications (to change the operation of this switch, refer to the Operation Softswitch Description chapter of this manual). A detailed theory of operation for both modes of operation is given in the Operation chapter of this manual.

20. SUB SEGMENT ENABLE SWITCH (OPTIONAL) — This optional switch disables or enables the sub segment mode of operation for semiautomatic applications (to change the operation of this switch, refer to the Operation - Softswitch Description chapter of this manual). A detailed theory of operation for the sub segment mode of operation is given in the Operation chapter of this manual.

21.CYCLE START BUTTON — This button is used to start the weld cycle. When pressed, the control panel advances to the preflow section of the weld cycle. Depressing this button while in a weld cycle has no effect.

22.PROGRAM/WELD SWITCH — When this switch is in the program mode, weld parameters can be changed. When this switch is in the weld mode, weld parameters cannot be changed.

NOTE

The functionality of this switch can be changed in the softswitch screen and/or with different software upgrades. Refer to the Operation and Option chapters of this manual for further detail.

23.CYCLE STOP BUTTON—This button is used to stop a front panel initiated weld cycle. When pressed, the control panel leaves the weld section and enters the crater fill section of the weld cycle. When a weld is stopped with the cycle stop button, the control panel skips over the recycle section of the weld cycle.

NOTE

Depressing this button ONLY stops the weld cycle if the weld cycle was started with the cycle start button. This button WILL NOT stop a weld cycle that was started with a gun switch closure, remote pendant, or auxiliary fixture.

24.LOWER ENCODER—This encoder changes parameters displayed in the lower display. Turning this encoder clockwise increases the value of the parameter and counterclockwise decreases the value of the parameter.

25.MODE SELECT ENCODER — This encoder serves two functions. While not welding, the encoder selects the desired section of the weld cycle for parameter input and viewing. While welding, the encoder selects whether actual wire feed speed (WFS) or actual welding current (AMPS) is shown in the lower display.

26.RECYCLE LED — When lit, the control panel is in the recycle section of the weld cycle.

27.POST-FLOW LED—When lit, the control panel is in the post-flow section of the weld cycle.

28.BURNBACK LED—When lit, the control panel is in the burnback section of the weld cycle.

29.CRATER FILL LED — When lit, the control panel is in the crater fill section of the weld cycle.

30.WELD LED — When lit, the control panel is in the weld section of the weld cycle.

31.RUN IN LED — When lit, the control panel is in the run in section of the weld cycle.

32.Preflow LED — When lit, the control panel is in the preflow section of the weld cycle.

33.READY LED — When lit, the control panel is in the ready section of the weld cycle.

34.CENTER ENCODER — This encoder changes parameters displayed in the center display. Turning this encoder clockwise increases the value of the parameter and counterclockwise decreases the value of the parameter.

NOTE

The (Arc Hours X1) information cannot be changed with the center encoder. To reset the count to 0, refer to the Operation - Softswitch Description chapter of this manual.

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HMC-410

35. ERROR LED—When lit, the control panel has detected an error. Refer to the Operation - Operational Faults section of this manual.

36.UPPER ENCODER — This encoder changes parameters displayed in the upper display. Turning this encoder clockwise increases the value of the parameter and counterclockwise decreases the value of the parameter.

NOTE

The (Arc Hours X100) information cannot be changed with the upper encoder. To reset the count to 0, refer to the Operation - Softswitch Description chapter of this manual

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Art # A-04358

Figure 2-2: Front Panel Controls

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HMC-410

2.08 Rear Panel Connections

Refer to Figure 2-3 for details.

Remote Pendant

(See HMC-410 Accessories

And Option Descriptions)

Art # A-04359

Figure 2-3: Rear Panel Connections

37.POWER SOURCE AMPHENOL—This 19 pin male amphenol serves as the interface between the HMC410 and power source. A control cable will have to be connected between this amphenol and the 19 pin amphenol on the power source (Refer to the HMC410 Accessories And Option Descriptions chapter of this manual for control cable part numbers). The HMC410 utilizes the following pins of the 19 pin amphenol:

Assignment Function

NOTE

These pin assignments are for the HMC-410 only. Power source amphenol pin assignments will differ slightly (Refer to the power source owner’s manual for details).

38.FEEDHEAD AMPHENOL — This 19 pin female amphenol serves as the interface between the HMC410 and feedhead assembly. A control cable will have to be connected between this amphenol and the 19 pin amphenol on the feedhead assembly (refer to the HMC-410 Accessories And Option Descriptions chapter of this manual for control cable part numbers). The HMC-410 utilizes the following pins of the 19 pin amphenol:

Assignment Function

A (-) Motor Voltage B (+) Motor Voltage C Inch Enable Out D Gun Switch Enable In F Inch Enable In G Chassis Ground J Gas Valve Lo M Tachometer Common N Tachometer (+15 VDC) P Tachometer Feedback Signal T Gas Valve High V Gun Switch Enable Out

39. AUXILIARY AMPHENOL—If used, this 19 pin male amphenol would serve as the interface between the HMC-410 and appropriate external fixture. An auxiliary cable would have to be connected between this amphenol and the fixture (Refer to the HMC-410 Accessories And Option Descriptions chapter of this manual for auxiliary cable part numbers).

A Power Source Contactor Input B Power Source Contactor Output C Arc Volts (+) D Arc Amps (+) E 120 VAC High F 120 VAC Neutral G Chassis Ground J Remote Voltage Control Reference L Power Source Control Circuit Common M Arc Established Signal Input U Arc Amps (+) V Arc Volts (-)

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This amphenol would only be used in an automatic application where the HMC-410 was to be controlled from some type of external fixture. Through this interface, the control panel accepts start, stop, inch, purge, and sub segment advance commands from the fixture and provides relay outputs to the fixture for timing and error conditions. The HMC-410 utilizes the following pins of the 19 pin amphenol (refer to Figure 3-4 for graphical assistance).

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HMC-410

Art # A-04360

Figure 2-4: Fixture Electrical Interface

Pin A (Purge Input) —If connected to Pin H, the control panel will allow the flow of gas without running wire.

Pin B (Inch Input) — If connected to Pin H, the control panel will feed wire (without the flow of gas) at a speed programmed into the Run In section of the weld cycle; the welding wire WILL NOT be electrically “hot.”

Pin E (Sub Segment Advance Input) — Connecting (momentarily or permanently) to Pin H will advance the control panel to the next programmed weld sub segment (i.e. 1 to 2, 2 to 3, 3 to 4, and 4 to 1). However, if permanently connecting Pin E to Pin H, the connection will have to be momentarily opened and then closed again for another sub segment advance. Refer to the Operation

- Auxiliary Interface Operation or Semiautomatic Operation section of this manual for specific details on setup and operation of the sub segment feature.

Pin F (Start/Stop Input)— To start the weld cycle, connect to Pin H. The control panel will then cycle from preflow to weld. To stop the weld cycle, disconnect from Pin H. The control panel will then leave weld and cycle from crater fill to ready.

Pins M and N (Relay 2) — This relay is normally open. When the control is in the recycle segment in between spot welds or at end of continuous weld, the relay will close (between pins M and N).

Pins P and R (Error Relay)—This relay is normally open. When the control detects a tolerance or ground fault, the relay will close (between pins P and R). The relay will remain closed for the duration of the weld in which the fault occurred, and .1 second into Ready. This relay can be used to drive another relay to latch the occurrence of an error. A tolerance fault can be one of: arc voltage out of tolerance, wire feed speed out of tolerance, or loss of arc established. The tolerance fault is reset when a new weld is initiated.

Pins T and S (Relay 1) — This relay is normally open. When the control is in the weld segment, the relay will close (shorting pins T and S). This relay is used for an arc on condition.

Pin H (Common) — This pin serves as the common for pins A, B, E, and F.

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HMC-410

2.09 Power Source Interface Description

The power source interface is used to supply operating power to the control panel and for the panel to control the power source output. The interface also provides arc voltage and current information to the panel.

The interface is shown in Figure 2-5.

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Art # A-04361

Figure 2-5: Power Source Interface

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HMC-410

2.10 Hardware Description

The HMC-410 is comprised of five major subassemblies. Each subassembly provides a distinct function, and understanding these functions can be helpful in understanding the operation of the HMC- 410. The subassemblies are:

1. Enclosure/Cabling

2. Control/Display Printed Circuit Board PCB Assembly.

3. Power Supply/Motor Control PCB Assembly

4. Controller PCB Assembly

5. Interface/Suppression PCB Assembly These assemblies will be described in the following text.

Enclosure/Cabling

The enclosure and cabling will be the assembly that the equipment operator will be in most constant contact with. The enclosure provides the safe isolation between the internal circuitry and the outside world. The cabling allows the internal circuitry to communicate with itself, as well as to the equipment outside of the enclosure.

The cabling is shielded internally to limit susceptibility to electrical noise. Keeping the cabling at a maximum distance from electrical noisy devices (such as TIG welders and high power lines) will also limit susceptibility of the cabling (and the control) to noise.

The internal cabling interconnects the internal components for proper operation of the control panel. Care has been taken to choose interconnection systems that will provide years of trouble-free operation. However, in cases of jarring during shipping or use, it may be necessary to occasionally re-seat these connectors.

Control/Display PCB Assembly

(Refer to Figure 2-6) The Control/Display PCB (C/D Board) Assembly provides

the front panel controls and displays. It mounts directly behind the front panel. Included on the C/D Board are the numeric displays, light emitting diodes (LEDs), encoders and pushbuttons. The C/D Board connects to the controller board via a 26-position ribbon cable. The C/D Board provides the controller board with encoder and button status, and receives display data for the numeric and LED displays.

The reason for the enclosure to isolate the circuitry is twofold. First is to protect the operators from dangerous signals which are present at various points inside the panel. Second, the enclosure protects the internal circuitry from damage and malfunction due to foreign objects and external electrical emissions (noise). Both of these functions are provided by having the whole chassis electrically tied to earth ground. Because of this fact, it is extremely critical that all chassis hardware is installed when the panel is operating. The earth ground is provided via the power source cable, pin G.

The enclosure also provides the operator with front panel control of the panel. The power switch, toggle switches (optional), control buttons, encoders, and displays are all presented through the front panel. Care should be taken to protect the front panel since many of these controls are susceptible to damage.

The external cabling will interface the control with the power source, wire feeder, a remote pendant (if present) and user defined fixturing (as described in Rear Panel Connections). The cabling is made of high durability neoprene covering for long life. Care should be taken to avoid damage to the cabling as that may cause safety problems and possible damage to the equipment.

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HMC-410

Pushbuttons

LEDs

Numeric Displays

Art # A-04362

Encoders

Figure 2-6: Control/Display PCB Assembly

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HMC-410

Power Supply/Motor Control PCB Assembly

(Refer to Figure 2-7) The Power Supply/Motor Control PCB Assembly (PS/MC

Board) has two functions. It provides the various low voltage control voltages used by the solid state circuitry throughout the HMC-410. It also translates control signals from the controller board into power for the motor.

The power supply section of the board utilizes the off board transformer to divide the line voltage down to the voltage levels used by the circuitry in the system. The rough functionality of this circuitry can be performed by visually inspecting the LEDs on the board. If the LED is lit, then the voltage is at least approximately what it should be. In order to verify the exact voltages, a meter can be used on the following test points:

HI LO Expected Reading Status LED TP1 TP2 –15 VDC (± .05 VDC) CR3 TP3 TP2 +5 VDC (± .5 VDC) CR7 TP4 TP2 +15 VDC 1 (± .05 VDC) CR2

NOTE

These measurements and repairs should be performed only by a qualified electrical technician.

The motor control circuitry drives the DC motor which feeds the filler metal used in the MIG process. There are various protection circuits which will disable the motor control circuitry should it detect an excessive load on the motor or control circuitry. Some of these protections require that the panel’s power be cycled to reset them. Also, the fuse F5 could blow should the motor current exceed its limits. Should these shutdowns continuously set, check that the filler metal can freely feed. If it is not impeded, verify that the cabling is not damaged. The PS/ MC board interconnects to the transformer, the controller board, and the interface/suppressor board.

TP5 TP7 +15 VDC 2 (± .5 VDC) CR9 TP6 TP7 +15 VDC UNREG CR8

(+25 to +35 VDC)

TP7 TP9 +12 VDC (±.5 VDC) CR17

CR9

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Art # A-04363

Figure 2-7: Power Supply/Motor Control PCB Assembly

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THIS PAGE INTENTIONALLY LEFT BLANK

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HMC-410

Controller PCB Assembly

(Refer to Figure 2-8) The Controller PCB Assembly (controller) is the main

control for the panel. It collects all of the data from the various controls and interfaces and provides control stimuli to all of the equipment under its control. This board has five receptacles on it to interface with the other systems. It also has two connectors which allow expandability for future enhancements.

At the heart of the controller board is a Signetics 80C552 Microcontroller designed specifically for harsh environments such as automotive and industrial applications. This microcontroller, and its associated software, drive the HMC-410 to perform its activities like timing, conversion of voltages and currents to digital data to be displayed by the C/D board, and the conversion of programmed data into voltages used by the power source and PS/MC board.

The controller interfaces with the C/D board presenting data for display and collecting control switch states. The controller interfaces with the PS/MC board by receiving power from that board, and supplying control stimuli to the motor control circuitry.

The controller also interfaces with the interface/ suppressor board. It sends relay closures to the interface/ suppressor board for use on the auxiliary interface, power source, and gas valve. This interface supplies external control switch states, arc voltage, arc current, and tach information to the controller.

onto it. When replacing (or maintenance stocking), please verify that this board also has the appropriate software kit installed onto it.

Controller Board Test Points

(Refer to Figure 2-8) This board was designed to survive in an industrial,

electrically noise heavy environment. There are several test points on the board, but are typically only used for initial test and calibrations of the board. The test points are included here only as a reference.

TP1 Signal Common TP2 Wire Feed Speed Control Voltage TP3 +5 VDC TP4 +10 VDC TP5 WFS Tach Input TP6 Power Source Control Voltage TP7 Arc Current 5 VDC TP8 Power Source Signature TP9 Arc Voltage TP10 +4.4 VDC TP11 Arc Current

Controller Board Jumpers

(Refer to Figure 2-8)

Refer to Figure 2-8 for the following descriptions of the controller board’s test points, jumpers, and DIP switch.

Controller Board Software

The controller may have optional software installed onto it. This software can be installed in the field. The software may be ordered as a 171238- dash number) kit. Refer to the Options chapter for more information on these software options.

Care must be exercised when ordering replacement controller boards for systems that have had optional software installed. New controller boards ordered from the factory will ship with the standard software installed

There are three jumpers on the controller board. The jumpers are used to configure the board for various products that this panel may be used with. Jumper JP2 is used to select power source control voltage polarity. Refer to System Configuration located in the Operation chapter for power source compatibility. Jumper JP3 and JP4 are used for voltage feedback. Refer to System Configuration located in the Operation chapter for power source compatibility.

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HMC-410

Art # A-04364

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Figure 2-8: Controller Board Test Points and Jumpers

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HMC-410

Controller Board DIP Switch

These switches will normally be set to the open position. All of these functions are controllable from the front panel by the soft switches, described in the Operation chapter of this manual.

The controller board also has a DIP switch (reference designator number S1) which is used to configure the board to operate in an application specific mode. The DIP switch can be used to run the diagnostic routines. The diagnostic selections are described in the Troubleshooting chapter of this manual.

Art: A-05054

Figure 2-9: Dip Switch

Trigger Hold Enable — This DIP switch is enabled only when the PdE soft switch is set to HAr. When this switch is in the OPEN position, the Trigger Hold feature for semiautomatic welding is enabled. When this switch is CLOSED, the triggering mechanism is called deadman, meaning that for the panel to continue welding, the switch must continue to be pulled. The trigger hold feature allows the welder to initiate the weld with a momentary pull of the switch, and terminate the weld with another momentary pull of the switch. The full description of this process is described in the Semiautomatic section of the Operation chapter of this manual. This feature can also be selected from an optional switch on the front panel.

Interface/Suppressor PCB Assembly

(Refer to Figure 2-10) The Interface/Suppressor PCB Assembly (I/S Board) is

the link between the external, Amphenol type connectors, and the internal ribbon and discrete wire connectors. Several signals are filtered in order to reduce electrical noise coming into the control panel.

NOTE

OPEN is sometimes called ON or 1 and should be considered the same state. Conversely, not OPEN will be referred to as CLOSED, OFF, or

Diagnostics Select — When this switch is in the CLOSED position, the diagnostics routines are executed. These routines are described in detail in the Troubleshooting chapter of the manual. In order to use the control panel operationally, this switch should be OPEN.

Weld Sub Segment Enable—This DIP switch is enabled only when the SSE soft switch is set to HAr. When this switch is in the OPEN position, the multiple Weld Sub Segment feature of the control panel is enabled. This feature is used to change the weld parameters because of a discontinuity in the work. This feature is described in the Semiautomatic Operation section and Auxiliary Interface Operation section located in the Operation chapter of this manual. When this switch is CLOSED, the control panel will ignore instructions to use the next sequential Weld Sub Segment parameters.

There are four jumpers on the I/S board. The jumpers are used to configure the board for various products that this panel may be used with. Refer to Figure 2-10 for jumper locations.

100050-2 Specification HMC-410

The 100050-2 HMC-410 is a special configuration of the HMC-410 that has an RS-232C interface installed into it and the 171238-19 software kit installed into it. This configuration has a 870200-2 board installed that provides the RS-232C circuitry and a 9 pin D-Sub connector.

Contact the factory for additional information in using the RS-232 interface.

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Front View

HMC-410

Art # A-04365

Back View

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Figure 2-10: Interface/Suppressor PCB Assembly

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HMC-410

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SECTION 3:

INSTALLATION

3.01 Location

When selecting an installation site, take care to avoid locations exposed to high ambient temperature, high humidity, dust, or corrosive liquids or fumes. Moisture condenses on electrical parts, causing corrosion or short circuits. Dirt on parts retains moisture and increases wear on moving parts.

3.02 Assembly

Components of this system are completely assembled at the factory. When received at the job site, it will be necessary to refer to instruction manuals and/or instruction sheets for details on setup of the system in which the controller is to be used. See TIPs supplied with the manual for information on the feedhead, wire supply, and cabling.

8. Connect the welding gun control leads to the wire feeder gun switch terminals located on the front of the feeder.

3.04 Load Suppression

The HMC-410 provides three relays on the auxiliary amphenol connector for customer use, the ratings of these relays are listed in the Description of Equipment chapter of this manual. Proper load suppression will extend relay life as well as minimize electromagnetic interference. Due to the unique nature and requirements of each load, it is required that the customer provide load suppression. The following guidelines and Figure 3-1 are provided to help with the selection of components.

Device Selection for AC Operation Resistor — 0.5 to 1 Ohm per contact volts Capacitor—0.5 to 1 Microfarad per contact amps Use AC type capacitors (non-polarized) with a breakdown

voltage of 200 to 300 V. Always test your selection in actual use.

3.03 Electrical Connections

See the System Outline drawing (170921) in the Appendix chapter of this manual for details.

CAUTION:

Make sure all connections are tight; otherwise, arcing or overheating could result.

1. Make the proper welding cable connections between the power source and wire feeder and between the power source and work connection.

2. Connect the power source control cable to the control panel “PS” amphenol connector.

3. Connect a control cable between the wire feeder and the control panel “FDR” amphenol connector.

4. Connect the remote pendant (if used) to the control panel “REM” amphenol connector.

5. Connect a control cable (if used) between the PLC or similar controller and the control panel “AUX” amphenol connector.

Example:

An inductive load requiring 120 V AC, 1 Amp; the resistor should be between 60 and 120 ohms, and the capacitor between 0.5 and 1 microfarad with a 200 to 300 volt rating.

Art # A-04367

Figure 3-1: Load Suppression Schematic

6. Make the proper gas line connection from the gas supply to the wire feeder gas valve (if gas will be used).

7. Attach the welding gun to the wire feeder.

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HMC-410

3.05 Grounding

The case of the HMC-410 control should be grounded for personnel safety. Where grounding is mandatory under state or local codes, it is the responsibility of the user to comply with all applicable rules and regulations. Where no state or local codes exist, it is recommended that the National Electrical Code be followed.

The HMC-410 control like all solid-state equipment is susceptible to EMI (electromagnetic interference). All welding power sources and, in particular, TIG power sources using high frequency arc stabilization are major sources of EMI radiation. Care must be taken to minimize interference through proper equipment grounding. The chassis of the controller must be connected to a driven ground(Figure 3-2) or a water pipe that enters the ground not more than 10 feet from the equipment.

The ground lead should be as short as possible and a minimum of #8 wire. This is normally accomplished by grounding the power source chassis which is connected to the controller chassis through the power source interface cable.

CAUTION

Electromagnetic interference can cause the HMC-410 to malfunction in unexpected ways. Care should be taken when the HMC-410 is used in motion control applications to provide emergency shutdown in case of equipment malfunction. Proper grounding techniques will minimize the problem, however, an emergency shutdown facility is still recommended.

3-2

Outside Ground

Art # A-04366

Inside Ground

Figure 3-2: Grounding Rod Installation

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HMC-410

SECTION 4:

OPERATION

This chapter is organized to guide the user from setup, to power up, and to start up. The first section will direct the user how to configure the HMC-410 control panel. The second section will describe how to program the HMC410 for use. The third section will guide the integrator on how to configure the system to be mated with the control panel, i.e., feeder/torch, power source, and fixturing. The fourth section will detail the operation of the HMC-410 in its different modes of operation.

This entire chapter (and manual) should be read and understood before any actual setup is performed. This list is given in a general order of performance, but actual order may vary.

4.01 System Configuration

This section is divided into two areas. The first is a description of the software configurable parameters for the proper operation of the HMC-410. The second section provides an overview for the setup of the HMC-410, including jumpers, switch settings and board placement.

The following chart shows softswitches for all available software as of the date of this manual. If your unit has only the standard software, then the softswitches available are shown for software dash number 3. Otherwise, the software number is the same as the dash number of the kit installed (ie 171238-17 has a software dash number

17). The following parameters are set by the soft switches:

Soft Switch Description

The HMC-410 has several programmable setup parameters. These parameters are typically only set once during the initial system setup.

Programming the soft switches is achieved with a fourstep sequence.

1. The HMC-410 is powered on while the front panel TEST button is being pressed. The panel should display PAr in the upper display.

2. The Mode Select Encoder is rotated until the parameter(s) to be changed (shown in the center display) is selected.

3. The Lower Encoder is rotated until the desired parameter displayed in the lower display is selected.

4. Wait at least 2 seconds and cycle power on the control panel. The parameters will then be set.

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HMC-410

4.02 Softswitch Description (Table 4-1)

Display Feature Description Settings

UPS, User Password The user’s password is programmed into UPS. The 0 TO 999 17+ SPS Setting/ supervisor’s password is programmed into SPS. If the UPS

Supervisor matches the SPS, then the system’s authority level will be set Password by the keyswitch. If the keyswitch is absent, then the system’s Setting authority level will be the PROG (supervisor authority) level. If

the UPS does not match the SPS, then the authority level is only WELD (user authority) level. Also, if the UPS number does not match the SPS number when entering the softswitch screens, the user is only allowed to program the UPS value. Thus, the user may not edit any other softswitch screens unless he powers up with the UPS and SPS set the same.

PSC Power Source This parameter checks the welding voltage against the voltage OFF, 0 to 10.0 3+

Tolerance set by the 410. If it is outside of a certain preset window for an Check amount of time specified in the Programmable Delay (PDE)

softswitch, then an error occurs. This switch may now be programmed to OFF to disable constant voltage checking (normal setting for Pulsed MIG welding). When OFF, the Volts LED next to the center window will not turn ON. This switch is turned on by programming the desired voltage range for the on line checking. For the 17 and newer software, this parameter may be set for up to +/- 10 volts.

LOE Minimum This parameter sets the minimum programmable weld 0 to 44.0 3+

Voltage Select voltage. This number is a function of the type of power source

used with the HMC-410. This number is typically 0.0 for Pulse MIG power sources, and 10.0 for CV only type power sources.

HIE Maximum This parameter sets the maximum programmable weld 0 to 44.0 3+

Voltage Select voltage. This number is a function of the type of power source

used with the HMC-410. This number is typically 36.0 to 44.0.

ICS Current This parameter sets the current input channel type, 50mV or .05, 10 3 to 17

Channel Select 10V input range. For 50mV systems (Fabstar and RC/RCC

Families), the parameter .05 is programmed. For 10V systems (ArcMaster, PowerMaster, ExcelArc, and Ultraflex), the parameter 10 is programmed.

SYS English/ When this switch is in the ENG position, the WFS is displayed ENG, MET 3+

Metric Select in inches per minute (IPM). When this switch is in the SI

(International System) position, WFS is displayed in meters per minute (MPM).

FAE Fault Abort When this switch is in the ON position, the Fault Abort is activ- ON, OFF 3+

Enable ated. When a tolerance fault is recognized by the control

panel (see Programmable Delay) and the Fault Abort is enabled, the control panel will terminate the weld by proceeding to the crater fill segment. When this switch is in the OFF position, the Fault Abort is disabled. The ERROR LED and ERROR relay will always signify the occurrence of a fault regardless of the state of this softswitch.

PDE Programmable The programmable fault delay sets the amount of time that a OFF, .1 to 2.55 3+

Delay fault condition (like loss of arc, wire speed out of range, voltage

out of range) must be present before the error is considered to be an error. A lower value may create nuisance errors.

Software Dash Number

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HMC-410

Software Dash

Display Feature Description Settings Number

ADJ Trim Enable This setting controls the ability of a user to change his weld

parameters. This capability can be turned OFF, so that the user may not change any programmed data without the ON, OFF -3 keyswitch in the PROGRAM position. If a number is entered into the screen, that number is the +/-%from the programmed data (for wire feed speed and voltage only). Any changes OFF, 5 – 6+ made will stay until the power is turned off. The data will then 100, return to the data last entered when the keyswitch was last in FUL the PROGRAM position. Also, this setting may be set to full scale (FUL), which allows the users to change programmed data (for wire feed speed and voltage only) to any allowable value. This data will also stay until the unit is turned off.

AS Adjustment This setting may be ALL or PAR. If ALL, then user may trim ALL, 19+

Select adjust any voltage or wire feed speed parameter. If PAR (for PAR

partial), then a user may only trim adjust voltage or wire feed speed for the weld segments.

SEA Synergic Error

Accumulator

NOTE: Use the synergic settings only with the CC mode pulse welding. Contact the factory for more information.

ON, OFF 22+

This softswitch allows the error conditions to be saved between arcs when ON. This means that if a condition changes over time, the regulator will compensate based on the accumulation of error from past welds as well as the current weld. OFF may be more appropriate if the issues causing the error are more part to part variation; then the compensation will start from the same point with each new weld.

SIG Synergic This softswitch is a gain term which controls how responsive OFF, 1 to 22+

Integral Gain the synergic compensation is to accumulated error 255

(accumulated from the start of the weld if SEA is OFF, or from all of the welds since the machine was turned on if SEA is ON). This term is what will make the long term error approach zero, i.e. eventually the system will get to the specified point (arc voltage in this case). If this number is high, the compensated wire feed speed will tend to hunt (or oscillate), but will get to the target value most quickly. The lower the number, the longer it will take to zero in on the target, but will be more steady.

SPG Synergic

Proportional Gain This softswitch is a gain term which controls how responsive

NOTE: Use the synergic settings only with the CC mode pulse welding. Contact the factory for more information.

the synergic compensation is to instantaneous error (how far the actual voltage is from the target voltage). This type of control needs some error in order to compensate, so if this were the only gain term used, the feed-system would never be able to completely eliminate error. This term does have less tendency to hunt (oscillate) then the Integral control, but still can for very high settings.

OFF, 1 to 22+ 255

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4-3

HMC-410

Display Feature Description Settings Number

AHR Arc Hour When this switch is in the ON position, the Arc Hour Timer will ON, OFF 3+

Timer Reset be reset to 0. After resetting the timer, this parameter will

automatically reset itself to OFF.

SSE Weld When this switch is in the ON position, the multiple Weld ON, 3+

Sub Segment Sub segment feature of the control panel is enabled. This OFF, Enable feature is used to change the weld parameters because of a HAR

discontinuity in the work or for start and end weld tweaking of the arc. This feature is described in the sections on Semiautomatic Operation and Auxiliary Interface Operation. When this switch is OFF, the control panel will ignore instructions to use the next sequential Weld Sub Segment parameters. When this switch is HAR, the mode is set by the optional front panel switch.

HDE Trigger Hold ON: Trigger Hold ON. Pull and release gun switch to start an ON, 3+

Enable arc. Weld will continue without holding gun switch. Pull and OFF,

release gun switch to stop an arc. HAR OFF: Trigger Hold OFF. Pull gun switch to start and maintain welding arc. Release gun switch to end the welding arc. HAR: Trigger Hold mode is set by the optional trigger hold switch on the front panel. When HAR is selected and the trigger hold switch is up, trigger hold is OFF. When HAR is selected and the trigger hold switch is down, trigger hold is ON.

DF Display Filter This feature sets the responsiveness (jitter) of the welding 0.00 to 17+

displays. This number sets the amount of time between each 1.00 new screen update (in seconds). The arc voltage, arc current, and actual wire feed speed displays are all affected. The data is averaged over that time frame. A number of 1.00 seconds is the slowest that the displays will change, giving a very stable but deadened response. A number below .05 will give a very lively, but sometimes unreadable response.

SP Switch Period This number sets gun switch responsiveness. This number 0.00 to 17+

sets the amount of time that the gun trigger must stay in its 1.00 current position before it is recognized. A change faster than this number is used when ‘flickering’ the gun trigger to advance to the next weld sub segment. For example, if this number is set to .30 (seconds), any changes on the gun trigger faster than .30 seconds will advance the sub segment (if that feature is on), and any gun trigger action slower than .30 seconds will stop the weld.

NOS Number of This number allows the customer to set the number of 1 to 8 8+

Schedules schedules in use. This number may be set from 1 to 8.

CFE Crater fill This setting may be ON or OFF. If ON, the system will operate ON, 17+

Enable as the ‘standard’ system did for crater fill. If crater fill is OFF, the OFF

system will not allow the crater fill settings to be programmed. Also, crater fill will not execute in the weld sequence.

Software

Dash

4-4

July 27, 2005

HMC-410

Software Dash

Display Feature Description Settings Number

BBE Burnback This setting may be ON or OFF. If ON, the system will operate ON, 17+

Enable as the ‘standard’ system did for burnback. If burnback if OFF, OFF

the system will not allow the burnback settings to be programmed. Also, burnback will not execute in the weld sequence.

RCE Recycle This setting may be ON or OFF. If ON, the system will operate ON, 17+

Enable as the ‘standard’ system did for recycle. If recycle is OFF, the OFF

system will not allow the recycle settings to be programmed (including the sub segment features!). Also, recycle will not execute in the weld sequence.

RSE Random This feature allows the HMC-410 to execute with multiple, ON, 8+

Schedule remotely selectable schedules (up to 8). The remote pendant OFF Enable start, stop, and auxiliary segment advance pins are

reconfigured to binary coded decimal (BCD) to select the schedule number, as shown in Table 2. The schedule may be changed while in standby, or while welding (without stopping the arc). If the user has selected less schedules (in the Number of Schedules above), then the random schedule operation is limited to those schedules enabled. For example, if the Number of Schedules is 4, then random schedule operation is limited to schedules 1 to 4, and any schedule selected above 4 will be use schedule 4 instead. The schedule is selected by opening or shorting these pins to Auxiliary Pin H (+30 VDC). See following Random Schedule Select Table for details on schedule selection.

FPE Front Panel This feature allows the user to disable the front panel Cycle ON, 17+

Enable Start button. The Cycle Start button is disabled when this is OFF

set to OFF. The button will still allow a cycle test to be run from the Cycle Start button when in the test mode.

BID Built In Delay This setting configures the 410’s built in delay time between 0 to .50 17+

burnback and postflow. This time allows the ExcelArc, ArcMaster, Ultraflex, and PowerMaster power sources to perform their wire sharpening and/or built in burnback features before the 410 signals an end of cycle. This number defaults to .50 seconds, and may be set to 0 to .50 seconds.

ESE Electrode This setting allows the 410 to sense a wire stuck to the work ON, 19+

Stick condition by checking the voltage at the output terminals of the OFF Enable power source. Should the welding output of the power source

short out (have less than 2.0 volts across the output terminals) when not welding, then an electrode short has occurred. When ESE is set to ON, then this will trigger an error. When ESE is set to OFF, the check is ignored and no error is generated. This mode is meant to be used with the PowerMaster or ArcMaster power sources with an 870210 board installed. This board is typically part of the 870236 robotic interface kit.

July 27, 2005

4-5

HMC-410

Display Feature Description Settings Number

ROB Robotic This mode selects a robotic interface configuration as follows: 1 to 4 20+

DBG Debug This feature will display weld error diagnostics information on ON, 17+

IL Current Level This setting sets the minimum number of amps that a weld 0 to 510 17+

IP Current This setting sets the minimum time that a weld must remain at 0 to 25.5 17+

SOF Software This number is set to the current software dash number. Software 17+

DCS Diagnostics When this switch selects a test number, that diagnostics 1 to 64 3+

Software Dash

Interface 1 - 24 Pin Direct Control (ABB) Mode 2 - 24 Pin Master Weld On/Off Control (ABB) Selection 3 - 37 Pin Direct Control (Fanuc)

Please see the following text for additional information on this configuration. A 870236 kit is required for these modes to work.

the 410 when it is turned ON. The following error codes can OFF be displayed:

RNG: Voltage or Wire Feed Speed tolerance error ARC: Loss of Arc Established E C: Current error. See IL/IP softswitch description for a more complete discussion of this mode. When this error is displayed, the actual current readings for the first

3.5seconds of the weld are displayed in the bottom 2

displays. Scroll through the data with the middle encoder. To return to the ready mode, the user should press the Cycle Stop button. The error relay will stay until the unit returns to the ready mode.

must achieve to be considered a ‘good’ weld. The number of amps may be set anywhere from 0 to 510 amps. The weld must also have this number of amps for the time set in Current Period to be considered a ‘good’ weld. If a ‘good’ weld is not achieved, the Error Relay will close and the Error LED on the front of the panel is lit. If debug is turned ON, the first 3.5 seconds of the weld may be reviewed to see how the actual weld progressed.

Period its set Current Level to be considered a ‘good’ weld. The time

may be set from 0 to 25.5 seconds. This feature works in conjunction with Current Level above.

Version Dash

Number

Select routine is executed on power up. These routines are described

in detail in the Troubleshooting chapter of the manual. In order to use the control panel operationally, this switch should be OFF.

4-6

July 27, 2005

HMC-410

Software

Dash

Display Feature Description Settings Number

NAR Arc Counter This softswitch enables a mode for the 410 where the 410 ON, OFF 23+

counts the number of 'good' arcs (as defined by the arc current monitor softswitches IL and IP) while a part is loaded. If the correct number (or more) of arcs have occurred while the part is loaded, then when the part is unloaded no errors are shown. Otherwise, the ERROR relay is closed and the ERROR light is lit. The correct number of arcs is set in the COUNT window of the RECYCLE segment.

Here is what's required to setup for this mode: (1) Integrate the ERROR relay (AUX pins P and R) and the

PART LOADED (REMOTE pins C and E) signal with the station's logic.

Note that the REMOTE PENDANT START signal will no longer function as a start signal, and RANDOM SCHEDULE MODE is no longer possible since this signal has been redefined as this PART LOADED signal.

(2) Setup desired welding parameters. (3) Determine the minimum requirements for a good weld and

set those in the arc current monitor softswitches IL and IP. (4) Set the NAR soft-switch to ON. (5) The desired number of arcs per part is set into the COUNT

window of the RECYCLE segment. Note that each SCHEDULE may have a different COUNT, so

that 8 discrete parts with different weld counts are possible. Here's an operational sequence of events: (1) The part is loaded by using the REMOTE START signal

as a PART LOADED signal (i.e. shorting the REMOTE PENDANT amphenol pins C and E is now a PART LOADED signal).

(2) Each arc that meets the parameters set in the arc current monitor (IL and IP, if both are 0 then any arc will meet that criteria) will increment the arc counter. The current number of good arcs is displayed in the COUNT window of the RECYCLE segment when the part is loaded.

(3) If the part is UNLOADED (by opening REMOTE pins C and E) before the desired number of arcs are accumulated, then the ERROR relay and the ERROR LED is lit. The station can use the ERROR relay for a variety of purposes (light a light, turn on an alarm, signal a PLC). The part can be re-loaded and the weld count continue where it was at when the part was UNLOADED.

(4) If the part is UNLOADED (by opening remote pins C and E) with the desired number of arcs accumulated, then the ERROR relay and ERROR LED do not light, and the weld counter is reset to 0, ready for the next part to be loaded.

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4-7

HMC-410

For the Random Schedule Enable feature, use the following table for selecting the correct schedule:

Random Select 2

(Auxiliary E to H; Random Select 1 (Remote Random Select 0 (Remote

Schedule Number (Segment Advance) D to E; Stop) C to E; Start)

1 Closed Closed Closed 2 Closed Closed Open 3 Closed Open Closed 4 Closed Open Open 5 Open Closed Closed 6 Open Closed Open 7 Open Open Closed 8 Open Open Open

Table 4-2: Random Schedule Select Table

4-8

July 27, 2005

Other Features (Non Softswitch) of software options (Table 4-3):

Software

Dash Number Feature Description

-17 Wire Jogging The wire jog setting has been eliminated from the softswitches, but is still available in the lower display of the Preflow screen.

NOTE: Quickly cycling the inch button with a high wire feed speed may cause the current protection circuit to trip. To reset the protection circuit, cycle power on the HMC-410. To avoid tripping, program in a lower wire feed speed or don’t re-hit the inch button so quickly

17+ Fixture 2 Relay 2 will close at the end of any weld, not just between spots of a stitch weld

Relay and after a continuous weld. Operation

17+ Error Relay The Error Relay and Error Light will both operate whenever there is an error

Operation condition (loss of arc, out of tolerance, ground fault, or current error). The Error

light will stay lit until another weld is started, or power is cycled. The Error Relay will stay closed from the time the error is found until .5 seconds into Ready mode. At that time the relay will open, so if it is desired to have this condition latched on for a longer period an externally latched relay should be used. The ground fault relay is an exception to this, it will remain latched until power is cycled. Note that this will result in the condition that the Error light can be lit while the Error relay is open.

When using the Debug feature, these same features apply except for the Error Relay opening up. The Error Relay will remain closed while the Debug screen is displayed. The Error Light will remain on until the next weld is initiated. When the error is cleared (by pressing Cycle Stop), the system will leave the Debug screen and turn off the Error Relay. In any case, the Error Relay will stay closed for at least .5 seconds.

17+ Password The user’s password is programmed into UPS. The supervisor’s password is

Operation programmed into SPS. If the UPS matches the SPS, then the authority level is

only WELD, regardless of the setting of the keyswitch. Also, if the UPS number does not match the SPS number when entering the softswitch screens, the user is only allowed to program the UPS value. Thus, the user may not edit any other softswitch screens unless he powers up with the UPS and SPS set the same.

17+ Enhanced Added END function to sub segments. Now, subsegments will automatically

Sub Segment sequence from 1 to 2 to 3 to 4 based on times (ie, the whole sequence is Operation continuous). By programming END into subsegment times (subsegments 2 to

4), the sequence will exit to craterfill. Thus, now we can have 3 start phases, and perform a continuous weld in the 4th subsegment. Recycle may be used if the sequence exits based on ‘END’ programmed into the subsegment timer.

The subsegment advance pin found on the auxiliary interface may be utilized for front panel or remote pendant initiated welds.

20 External The 171238-20 software allows the 410 to utilize externally generated voltages

Control to control the wire feed speed and arc voltage (pulse frequency) functions of

the power source. These features are normally used in conjunction with the 870236 Robotic Interface Kits. In order to utilize the external voltages for any phase of the weld, simply program in EEE (for external) where the wire feed speed or arc voltage setting is normally entered. For that part of the weld, the external voltages will then set the wire feed speed and / or arc voltages as programmed.

HMC-410

July 27, 2005

4-9

HMC-410

4.03 System Setup

In order to properly utilize the HMC-410 control panel, it must be configured correctly for the application and the equipment it is to be used with. There are several items which need to be considered before the control panel can be used. They include:

Fixturing... how the control panel should interact? Power Source... what type of power source is used? Control Panel Setup... desired configuration? Process... Semiautomatic or Automatic?

Follow the HMC-410 Setup Checklist found at the end of this section when initially configuring the panel. Standard software softswitches are shown on this configuration table.

Table 4-4 contains the various settings used for the various power source configurations. Also included is special setup for semiautomatic operation.

NOTES:

P. The weld sub segment enable can depend upon many

factors. If in an automatic application, and there is a need for various weld segments in a continuous weld, then it should be ON. Otherwise, it should be OFF. For semiautomatic applications, and the optional front panel switches are available, then this function should also be OPEN, to be disabled by the front panel switch. If the front panel options are not available, then this switch will be set to the discretion of the welder.

Q. For automatic applications, this switch should be set

OFF to disable it. This function should be enabled (set to HAr) for semiautomatic applications used with the optional front panel switches, to be disabled by the front panel switch. If the front panel options are not available, then this switch would be set to the discretion of the welder.

By following this checklist, the control panel can be set up for use. Care should be taken to follow static safe procedures when handling PCBs. Also, when buttoning up the panel, all hardware should be used since it is critical for the integrity of the panel.

K. The English/Metric Select should be set to user

standards or discretion.

L. The fault abort enable can be a function of many

factors. In many instances, when the panel is configured to a fixture, that fixture requires that the weld proceed through completion even if there is an error in the weld. Alternatively, some situations dictate that once there is an error, the process should stop and the error should be rectified. This switch should be ON to enable the fault abort and will be set to the discretion of the user for their procedure.

M. The program delay enable can be used if required by

the procedure.

N. Trim Enable is up to the welder. Typically, to get a weld

fine tuned, this would initially be ON to enable the trim function. Then, depending on the consistency of the process, this function could be left on or disabled.

O. Since the arc hours should be set to 0 out of the box,

this switch should be OFF as it is not necessary to clear the arc hours.

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July 27, 2005

HMC-410

Arc-Master Arc-Master Power Power Semi-auto

Selection 350/500 351/501 Ultra Flex Fabstar 4030 Excel-Arc Master 500 Master 500P Selections

A. Controller Board: Polarity Jumper JP2 B. Controller Board: Voltage Jumper JP3 C. Controller Board: Voltage Jumper JP4

D.Interface/Suppressor

JUMPER 1-2 JUMPER 1-2 JUMPER 1-2

JUMPER 1-2

JUMPER 1-2 JUMPER 2-3

JUMPER 1-2

JUMPER 2-3JUMPER 1-2

JUMPER 2-3

JUMPER 1-2 JUMPER 1-2 JUMPER 1-2

JUMPER 1-2JUMPER 1-2

JUMPER 2-3 JUMPER 2-3

JUMPER 2-3JUMPER 2-3

Board: Amps (–) Jumper J9 E.Interface/ Suppressor

Board: Amps (+) Jumper J10 F.Interface/Suppressor

Board: Volts (–) Jumper J12

G. Soft Switch: PSC Pulsed MIG: OFF

H. Soft Switch: LOE Pulsed MIG: 0.0

I. Soft Switch: HIE Pulsed MIG: 44.0

J. Soft Switch: ICS 10 10 10 0.05 10 10 10 K. Soft Switch: SyS User’s User’s User’s User’s User’s User’s User’s

L. Soft Switch: FAE User’s User’s User’s User’s User’s User’s User’s

M. Soft Switch: PdE User’s User’s User’s User’s User’s User’s User’s

N. Soft Switch: Adj User’s User’s User’s User’s User’s User’s User’s

O. Soft Switch: AHr OFF OFF OFF OFF OFF OFF OFF P. Soft Switch: SSE User’s User’s User’s User’s User’s User’s User’s User’s

Q. Soft Switch: HdE User’s User’s User’s User’s User’s User’s User’s User’s

R. Soft Switch: dCS OFF OFF OFF OFF OFF OFF OFF

JUMPER 1-2 JUMPER 1-2 JUMPER 1-2 JUMPER 1-2 JUMPER 1-2 JUMPER 1-2 JUMPER 1-2

JUMPER 1-2 JUMPER 2-3 JUMPER 2-3 JUMPER 1-2 JUMPER 2-3 JUMPER 2-3 JUMPER 2-3

JUMPER 2-3 JUMPER 2-3 JUMPER 1-2 JUMPER 2-3 JUMPER 2-3 JUMPER 1-2

Pulsed MIG: OFF Pulsed MIG: OFF OFF (no voltage

tolerance

CV: ON CV: ON CV: ON

Pulsed MIG:

0.0 Pulsed MIG: 0.0 10.0

CV: 10.0 CV: 10.0 CV: 10.0

Pulsed MIG:

44.0 CV (500 A):

CV (500 A): 42.0

CV (350 A): 38.0

Standard Standard Standard Standard Standard Standard Standard

Preference Preference Preference Preference Preference Preference Preference

Preference Preference Preference Preference Preference Preference Preference Secs)

Preference Preference Preference Preference Preference Preference Preference

Preference Preference Preference Preference Preference Preference Preference Preference

42.0 CV (350 A): 38.0 CV (350 A):

38.0

Pulsed MIG:

44.0 10.0

check)

(350 A):

11.0 10.0 0.0 (500 A):

12.0 Pulsed MIG (650 A):

14.0 (350 A):

36.0 42.0 44.0 (500 A):

42.0 Pulsed MIG (650 A):

44.0

JUMPER 2-3

Pulsed MIGON ON OFF

ON (typ >

2.0

July 27, 2005

Table 4-2: HMC-410/Power Cource Configuration Table

4-11

HMC-410

4.04 HMC-410 Setup Checklist

Refer to Table 4-4

Controller Board

Jumpers A JP2 — Power Source Control Voltage Polarity ___ B JP3 — Volts Gain ___ C JP4 — Volts Gain ___

DIP Switch S1

I/S Board

Jumpers D JP9 Amps (–) Position ___ E JP10 Amps (+) Position ___

JP11 1-2

F J12 Volts (-) Position ___

Soft Switch Configuration

G Power Source Select ___ H Minimum Programmable Voltage ___ I Maximum Programmable Voltage ___ J Current Channel Select ___

OPEN

K English/Metric Select ___ L Arc Loss Abort Select

___ M Programmable Delay Enable ___ N Trim Adjust Enable ___ O Arc Hour Reset ___ P Weld Sub Segment Enable ___ Q Trigger Hold Enable ___ R Diagnostic Select

4-12

OFF

July 27, 2005

4.05 Programming

Programming for the HMC-410 is the process of setting weld parameters into long term memory for each weld schedule. Programming the HMC-410 is a simple task, but as with everything new, may take some getting used to.

SCHEDULE

HMC-410

ONE CYCLE = ONE TIME THROUGH THE SEQUENCE

SUB SEGMENT

In understanding the programming of the HMC- 410, it may be helpful to visualize the memory as a book with 10 pages. Each page contains the information for a complete weld (see Figure 4-1). Each page contains the following information:

Preflow Data — Time Run In Data — Time, Voltage, Current Weld Data — Time, Voltage, Current Crater Fill Data — Time, Voltage, Current Burnback Data — Time, Voltage Postflow Data — Time Recycle Data — Count, Sub Segment On each page is taped four smaller pieces of paper, one

on top of another over the Weld Data. This is the weld segment data. If the weld sub segment enable is enabled, the bottom three pieces of paper can be viewed (one at a time). Otherwise, just the top piece of paper can be viewed.

In order to view each page (schedule), the page to be viewed is entered in the lower display when the SCHEDULE light is illuminated. That entire page can then be viewed by moving the MODE SELECT encoder. As that encoder is rotated, each segment’s data becomes visible. In order to change, instead of just viewing what is displayed, rotate the encoder next to the value to be changed (remember that to do this, the PROG/WELD key switch must be in the PROG position).

Art # A-04368

SEGMENT

Cycle — one execution of a weld schedule Schedule — collection of weld parameters describing a weld procedure

Figure 4-1: Programming the HMC-410

In order to view any of the other smaller pieces of paper in the weld data position, the smaller paper’s number is entered into the RECYCLE segment’s WELD SUB SEGMENT entry (1 to 4).

By performing this procedure on the full page (schedule), the schedule is programmed with data pertinent to a particular weld procedure. Once the data is entered, the panel is ready to weld. In order to test the sequencing, put the panel into test mode and initiate the weld as if it were an actual weld. The timing should mimic the programmed parameters, only without the power source and feeder operating.

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4-13

HMC-410

Segment Programming

The details of programming each of the HMC- 410’s segments are discussed in this section. Additionally, the function of each segment is defined. The segments are discussed in the order in which they would occur during a weld cycle. The segments are selected by rotating the MODE SELECT encoder. The segment selected is shown by the light lit next to the segment.

Ready

The ready segment is not actually part of the weld sequence. The top two displays of the ready segment display the accumulated arc hours on the control panel. The bottom display allows the operator to select the schedule to be viewed, programmed, or executed.

Preflow

The preflow segment is programmed in time and is the delay time before the start of run in and initiation of the arc. The gas valve is turned on at the beginning of preflow and remains on through the completion of postflow. The time is programmed in the upper display. The range is 0 to 25.5 seconds, in .1 second increments.

Weld

The weld segment is responsible for the major portion of the weld cycle. This segment has three programmable parameters: time, voltage, and WFS. If the time is selected to be continuous (CON in the upper display), the panel requires the operator or master control to issue the stop command to enter the crater fill segment. If the programmed time is not continuous, the weld cycle is a timed spot weld and will automatically proceed to the crater fill segment after the weld time has expired.

The weld time is programmed in the upper display. The time can be programmed from .1 to 25.5 seconds, in .1 second increments. When CON is displayed, the continuous weld is selected. When OFF is displayed, that weld sub segment is disabled. The various weld sub segments are selected in the recycle segment.

The voltage is programmed in the center display. The voltage can be programmed from the minimum programmable voltage (0 to 10.0) to the maximum programmable voltage (between 36.0 and 44.0), in .2 volt increments.

SCHEDULE

ONE CYCLE = ONE TIME THROUGH THE SEQUENCE

Run In

The run in segment has three programmable parameters; the strike time or time allotted to strike the arc, voltage, and WFS. Each of these signals is output at the beginning of run in and remains constant until the next segment is executed. If the arc is detected within the programmed time, execution passes to the weld segment. If the arc is not detected within the programmed time, the cycle will be terminated and the control will return to the ready segment and the ready mode.

The run in time is programmed in the upper display. The time can be programmed from 0.2 to 25.5 seconds, in .1 second increments.

The WFS is programmed in the bottom display. The WFS can be programmed from 0 to 8881 IPM (0 to 22.5 MPM), in 4 IPM (.1 MPM) increments (888 is displayed, but the actual limit is 887 IPM).

SUB SEGMENT

Art # A-04368

SEGMENT

Cycle — one execution of a weld schedule Schedule — collection of weld parameters describing a weld procedure

4-14

Figure 4-1: Programming the HMC-410

July 27, 2005

HMC-410

Crater fill

Crater fill is normally used to reduce heat input to the work and to fill the crater which is typically left at the termination of the weld. Crater fill has three programmable parameters: time, voltage, and WFS.

The crater fill time is programmed in the upper display. The time can be programmed from 0 to 25.5 seconds, in .1 second increments.

The voltage is programmed in the center display. The voltage can be programmed from the minimum programmable voltage (10.0) to the maximum programmable voltage (between 36.0 and 44.0), in .2 volt increments.

The WFS is programmed in the bottom display. The WFS can be programmed from 0 to 888 IPM (0 to 22.5 MPM), in 4 IPM (.1 MPM) increments.

Burnback

The burnback function is used to burn back the welding wire from the work at the termination of the weld. This is done by turning off the feed motor and leaving the power source contactor on for a short period of time (typically .2 second). The burnback segment is programmed in time and voltage.

Recycle can also be used in a continuous weld as an ‘end of weld’ segment. During the programmed Recycle time, Auxiliary Relay 2 will close. At the conclusion of Recycle,the panel will return to the Ready Mode, regardless of the programmed recycle count.

The recycle time is programmed in the upper display. The time can be programmed from 0 to 25.5 seconds, in .1 second increments.

The count is programmed in the center display. The count can be programmed from 1 to 255.

Also included in the recycle segment is the weld sub segment number (if enabled). This number is programmed in the lower display. The number can be programmed from 1 to 4.

The burnback time is programmed in the upper display. The time can be programmed from 0 to 2.55 seconds, in .01 second increments.

Postflow

Programmed in time only, this is the duration of gas flow at the completion of the weld. The postflow time is programmed in the upper display. The time can be programmed from 0 to 25.5 seconds, in .1 second increments.

Recycle

Recycle is used with the spot weld mode for multiple executions of a programmed weld cycle. Recycle is programmed in the number of total cycles (i.e., 5 recycles results in 5 spot welds), and the delay time between spot welds. The delay time is the time between the end of the postflow segment of the previous spot weld and the beginning of the preflow segment of the next spot weld. During this time the feed motor, gas valve, and power source contactor are turned off.

July 27, 2005

4-15

HMC-410

4.06 Setup

Before attempting to operate this system, read and carefully follow instructions in the manuals for the HMC410, welding power source, and feedhead. Observe all Safety Warning chapters included in all of these manuals.

Power Source Setup

The HMC-410 is designed to operate with the Arc-Master, the Power Master, the Ultra Flex, the Fabstar 4030, the Excel-Arc, and the RC/RCC Family of power sources. The power source configuration will vary from machine to machine so consult the manual for details. The following sections will describe generally the power source setup for the two families.

Arc-Master Inverter Family Configuration

Set “Remote/Local” toggle switch to REMOTE. If CV welding, set process selection switch to GMAW/

FCAW. If Pulsed MIG welding, set process selection switch to

PULSED GMAW. Also set “Pulsed MIG Schedule Select” switch to the appropriate material and gas.

Fabstar 4030 Configuration

Set “Remote/Local” toggle switch to REMOTE.

Excel-Arc Family Configuration

Set the “Arc Voltage Control” toggle switch to REMOTE. Set the CC/CV Selector Switch to CV (if available).

Power Master

The amphenol connections/color codes are given here: PinWire Color Function A WHT-GRN Auxiliary Gas Purge B WHT-RED Auxiliary Feeder Inch C VIOLET D GRAY E GREEN Auxiliary Weld Sub

Segment Advance F RED-BLK Auxiliary Start/Stop G WHT-YEL H RED Auxiliary Control (+30 VDC) J WHT K BLK L WHT-BLK M ORG Auxiliary Relay 2 Lo N YEL Auxiliary Relay 2 Hi P BLU Auxiliary Error Relay Lo R BRN Auxiliary Error Relay Hi S WHT-BLU Auxiliary Relay 1 Lo T TAN Auxiliary Relay 1 Hi

HMC-410 Setup

The HMC-410 must be configured before it is powered up for the first time. Refer to the System Configuration section of this chapter for details.

Set Local/Remote to remote operation. Select GMAW process.

Ultra Flex Configuration

Set Local/Remote to remote operation. Select process (GMAW or Pulse GMAW).

Fixturing Setup

Any customer specific fixturing should be setup before power is applied to the system. This fixturing should be interfaced to the HMC-410 through the auxiliary interface port. The functional description of this port is in the Auxiliary description in the Description of Equipment chapter of this manual.

4-16

After the HMC-410 is configured and installed following the procedures set forth in this manual, attach all pertinent cables to the HMC-410. Make sure that power is OFF on the power source and HMC-410.

Power ON the power source and HMC-410. Program the control panel. Instructions for this are given in the Programming section of this chapter.

After the HMC-410 is configured, installed, programmed, and properly connected with its associated equipment, it is ready to use. The different modes of operation are discussed in the following section of this manual.

July 27, 2005

HMC-410

4.07 Operation

The HMC-410 may be used in an automatic or semiautomatic welding configuration. Because of the different requirements of these two types of welding processes, the HMC-410 operates differently depending on how it is used. The following sections will describe how the control panel operates for automatic and semiautomatic applications.

The operation discussion will pertain to starting and stopping the weld, and if configured, executing weld sub segments. The gas purge and wire feeder inch functions can be operated on any interface regardless of the control interface. For example, the front panel INCH button is always active (if the control is in the ready mode) even if the auxiliary interface or semiautomatic gun trigger interface is used.

Automatic Operation

When in the automatic configuration, the HMC- 410 has various methods of operation. If the unit is to be operated from the front panel, the control panel would be considered the master control (slave only to the operator), and the rest of the equipment (particularly the fixturing) would be slaved to control inputs from the panel. The remote pendant operation is very similar to front panel control, only certain controls of the front panel are provided on a cable. Conversely, if the unit is to be operated via the auxiliary interface, then the HMC- 410 becomes a slave to that interface, controlling only the feeder, power source, and possibly timing. The following sections will describe these different types of automatic operation.

Front Panel Operation

When used in a front panel operation, the control panel will require a weld operator to start and possibly stop the weld. The proper weld schedule for the work should be selected or programmed. Front panel controls GAS PURGE and INCH can be used to test the gas and ready the filler metal at the torch. Once the welding system and the work is ready, the weld operator can start the weld by pressing CYCLESTART on the front panel.

During welding, the front panel will display the segment it is in and the amount of time in that segment. Also, during run in, weld, and crater fill, actual arc voltage and arc current/wire feed speed will be displayed (selectable on the lower display with the MODE SELECT encoder). If trim is enabled, the center encoder can be rotated to increase/decrease arc voltage and the encoder cander can be rotated to increase/decrease wire feed speed (and thus current in a CV process).

Termination of the weld cycle will occur when either the weld time expires (if the weld time is not CONtinuous, a spot weld) or the weld operator presses CYCLE STOP. If it is a spot weld, the control may automatically recycle to another weld cycle if it were so programmed until the last recycle is done or the CYCLE STOP is pressed. If the front panel CYCLE START initiated the weld, only the front panel CYCLE STOP will terminate the weld. This fact is consistent for the remote pendant and the fixture.

After the weld terminates, the control panel returns to the ready mode and is ready to start the sequence over again.

Remote Pendant Operation

As already mentioned, remote pendant operation is similar to front panel operation. The main point of difference is that the operator has a pendant to allow him more mobility. The front panel still provides the display information and also the capability to trim.

Auxiliary Interface Operation

When the HMC-410 is controlled by the auxiliary interface, it acts as a slave to that interface. In this capacity, the HMC-410 takes on the role of a power source control, feeder control, and possibly timing control in the weld system. Because of this role change, the panel not only needs to accept commands but send information back to the auxiliary/ master.

The interfacing to the control panel acts similar to the front panel type of control. The gas purge control will cause the panel to close the gas valve, and the feeder inch control will cause the panel to feed filler metal at the rate programmed in the run in segment. The auxiliary start/stop is different from the front panel start and stop in that both functions are merged into one control. Start/ stop is run in the deadman mode; the control will continue to weld as long as the control is in start. Once the control line is not active, the control panel terminates the weld. Also, the control panel must be in the stopped state before it can start (for safety).

Also included in the auxiliary control interface is a weld sub segment advance control, which when enabled (see Soft Switch description) will cause the weld to change parameters while in mid-weld. The segments to be executed may be timed or continuous. If they are timed, the sub segments will continue with the next sub segment after time expires. If the sub segments are CONtinuous timed, the sub segment can change by reissuing the weld sub segment advance control. Once the sub segment

July 27, 2005

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HMC-410

executing tries to advance to a segment that is OFF or is in the fourth sub segment, execution passes to the first sub segment.

The auxiliary interface also provides three relay closure signals to the fixturing. These relays provide information on which phase of the weld cycle is active, as well as an error output relay for fault notification. Relay 1 will close during the weld segment of the weld. Relay 2 will close during the recycle segment of the weld cycle. The error relay will close during a tolerance or ground fault condition.

During weld cycle execution, the front panel will display arc voltage, arc current and wire feed speed. Also, if enabled, trim is active on the front panel.

For more information on the auxiliary interface, refer to sections Fixturing Setup (located in this chapter) and Auxiliary description located in the Description of Equipment chapter.

Semiautomatic Operation

The HMC-410 has a wide variety of modes in which it can operate when in a semiautomatic configuration. There are four items which greatly impact how the control will react to the gun trigger. They are:

Weld segment time — continuous/non-continuous Weld sub segment enable — see soft switch

description

Manual Trigger Modes

Manual modes are selected with CONtinuous weld times.

Manual Single Segment Deadman Operation

Trigger pull and hold through weld, release advances to crater fill.

Manual Multi Segment Deadman Operation

Pull and hold trigger through weld. Flicker the gun trigger to advance to the next weld segment. Release for more than one second to advance to crater fill.

Manual Single Segment Hold Operation

Pull and release the gun trigger before one second of the weld segment has executed. If the gun trigger is still held one second into the weld segment, the mode is considered Manual Single Segment Deadman Operation. The next time the gun trigger is pulled, the weld cycle continues with crater fill.

Manual Multi Segment Hold Operation

Pull and release the gun trigger before one second of the weld segment has executed. If the gun trigger is still held one second into the weld segment, the mode is considered Manual Multi Segment Deadman Operation. Flicker the gun trigger to advance to the next weld segment. The next time the gun trigger is pulled, the weld cycle continues with crater fill.

Trigger hold enable — see soft switch description Recycle count — if non-continuous weld segment time

When in the ready mode, the front panel INCH will feed wire through the gun. The front panel GAS PURGE will purge gas. Also, the INCH on the feeder package will feed wire through the gun (if applicable).

When welding, the front panel displays arc voltage and arc current/wire feed speed. Trim is active if enabled. Also, at the completion of the weld the panel will continue to display the last displayed values for arc voltage, arc current, and wire feed speed. These will be displayed on the lower and center displays in 1 second intervals for the amount of time programmed in the recycle time. This way the welder may view his welding parameters.

The following sections will describe how the control will react to the gun trigger based on the control setup. The ‘hold’ modes are enabled by turning trigger hold on. The ‘multi segment’ operation is enabled by turning weld sub segment on and programming the sub segments.

Spot/Stitch Trigger Modes

Spot modes are selected with Non Continuous weld times. Stitch is selected with recycle count more than one.

Spot Deadman Operation —Recycle count is

programmed to one

Trigger pull and hold through the end of the weld segment, release resets for the next spot weld. Releasing the trigger before the end of the weld segment advances to crater fill.

Stitch Deadman Operation

programmed to more than one

Trigger pull and hold through the end of the stitch, release resets for the next stitch weld. Releasing the trigger before the end of the stitch cycle advances to crater fill and ends the current stitch cycle.

— Recycle count is

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July 27, 2005

HMC-410

Spot Hold Operation — Recycle count is

programmed to one

Trigger pull and release through the first second of the weld segment (otherwise the mode defaults to the Spot Deadman mode of operation). Pulling the trigger before the end of the weld segment advances to crater fill.

Stitch Hold Operation — Recycle count is

programmed to more than one

Trigger pull and release through the first second of the weld segment (otherwise the mode defaults to the Stitch Deadman mode of operation). Pulling the trigger before the end of the weld advances to crater fill and stops the current stitch.

Operational Faults

During operation of the control panel, several factors can create an operational fault. Faults for the HMC-410 are grouped into three classifications:

Ground fault Feeder fault, and

The tolerance fault will occur during welding. It will show via a light on the front panel, the activation of the error relay, and may terminate the weld cycle if the fault abort function is enabled (See Soft Switch Description located in the Operation chapter). This error is caused because of arc voltage out of tolerance (± .5 Volt variance from programmed value), wire feed speed out of tolerance (± 10 IPM variance from programmed value), or a loss of arc established from the power source. The error will be recognized if any of these conditions continuously persist for more time than the fault delay time. This type of error will clear itself once a new weld cycle is initiated.

NOTE

The error relay will close from the occurrence of the error through .1 second after the weld is done. It is envisioned that this relay will drive a customer’s latching relay which can be reset by the customer.

Tolerance fault

The ground fault is activated whenever a large current is sensed through the earth ground from the power source to the HMC-410 chassis. Since this is a significant safety hazard, the control will immediately shut down all systems under its control, excite the error light and relay, and display “gnd Err” on the front panel. This will stay on until the power is cycled on the control panel. This situation should be researched and fixed before welding is continued.

The feeder fault will be noticed by the fact that wire will not feed during welding or during the INCH execution. If there are no obvious impediments to the wire feeding (e.g., blocked tip), then the feeder fault may have activated. This occurs if the current through the motor exceeds specifications. This could be from a bind on the feed, bad cabling or

various other causes. In order to clear the error, power should be cycled on the control panel. If the problem persists, the feeder control cable, feeder, gun/torch, and wire feed should be thoroughly checked for blockage and short circuits.

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HMC-410

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HMC-410

SECTION 5:

SERVICE

5.01 Maintenance

The HMC-410 requires periodic maintenance to maximize its life. The frequency of repairs given should be used as a guideline, and in some situations may need to be accelerated.

WARNING

Before attempting any maintenance, turn off the controller and remove fuses of disconnect switch supplying the power source with AC line power.

5.02 Controller Maintenance

Every Day: check all cables, leads, and hoses for cuts or

other damage. Repair any damage immediately to prevent shorts and further damage.

Once a Week: check the tightness of all electrical connections. If arcing has occurred at any connection, recondition the connection and securely refasten.

Every Six Months (more often if located in an excessively dirty environment): use clean, dry, compressed air of not over 25 PSI (172 kPa) to clean the control box internal components.

WARNING

Interconnecting cables must be disconnected before the execution of any diagnostic; the controller interfaces will be active during the diagnostic execution which could result in uncontrolled activation of the power source, fixture, and feedhead.

WARNING

Disconnecting the controller interconnecting cables will expose the connector pins which may contain lethal voltage levels (115 VAC). The diagnostic procedures should be attempted only by qualified service personnel.

CAUTION

Extreme care must be used when handling the PC boards. Static discharge will damage PC board components. A grounded wrist strap should be used at all times when handling the PC boards. Storage and shipment of PC boards should be done in antistatic packaging.

WARNING

5.03 Troubleshooting

These troubleshooting instructions are given as an aid to the user. In case of trouble, it is helpful to have a set of instructions suggesting where to look. This may save everyone involved time and resources if the problem can be resolved on site. Certain problems may not be resolvable on site, and it is also helpful to know this.

This section is divided into two areas: a troubleshooting guide and the controller diagnostics. The troubleshooting guide will state the problem and provide a list of items to be checked. In isolating the problem, the controller diagnostics may be of help. These diagnostics will give the troubleshooter absolute control over the HMC-410 control panel’s interfaces.

May 5, 2005

Opening the HMC-410 control panel will expose lethal voltage levels (115 VAC). Disconnect all cables from the control panel before servicing. Troubleshooting and service should be done only by a qualified service technician.

5-1

HMC-410

5.04 Troubleshooting Guide

A. Controller will not power up

1. Power source is not turned on.

a. Turn on the power source.

2. Interconnecting cable between the power source and controller is not plugged in or may have a bad connection or short circuit.

a. Repair or replace the interconnecting cable.

3. Loose connections or faulty wiring in the controller or power source.

a. Check power source and controller wiring for

loose or faulty connections.

4. Blown fuse in the controller or power source.

a. Check power source fuses. Check controller

fuses (refer to Power Source/Motor Control PCB Assembly description located in the Description of Equipment chapter).

5. Controller’s power switch is bad.

a. Replace power switch.

B. No voltage control on the power source, but

programming appears to be correct.

1. Power source front panel settings may be incorrect.

a. Check power source front settings with respect

to the desired setup.

2. Interconnecting cable between the power source and controller may have a bad connection or short circuit.

a. Repair or replace the interconnecting cable.

3. Power source fault.

C. No power source output.

1. Cycle test mode is active.

a. Turn off cycle test.

2. Interconnecting cable between the panel and power source may have a bad connection or short circuit.

a. Repair or replace interconnecting cable.

3. Controller problem.

a. Check power source contactor relay (diagnostic

test #49).

b. Replace controller board or relay if bad.

4. Power source problem.

a. Check power source manual for service

information.

5. Blown fuse in the controller or power source.

a. Check PS/MC board’s fuses (easily done by

checking power LEDs). Also check in power source. Replace if bad fuse is found.

D. Power source is always energized.

1. Interconnecting cable between the controller and the power source has a short circuit (pins A, B).

a. Repair or replace cable.

2. Controller problem.

a. Check PS contactor drive circuit and relay in

the controller using the controller diagnostic test #49. Replace relay or controller board if bad.

3. Power source problem.

a. Check power source manual for service

information.

a. Check power source manual for service

information.

4. Blown fuse/power regulator in the controller.

a.Verify ±15 VDC on PS/MC board. Replace fuses

if blown. Replace board if fuses are good.

5. Controller fault.

a. Check for loose or faulty connections. Check

Power Source Control Output diagnostic output (diagnostic test #1).

b. Replace controller board if a bad channel is

detected.

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HMC-410

E. No wire feed speed control, but programming

appears to be correct.

1. Tachometer failure. The normal symptom of tach failure is that the feed motor runs at full speed whenever the motor is activated.

a. Adjust or replace PC board in motor housing.

2. Interconnecting cable between the controller and feedhead is not plugged in or may have a bad connection or short circuit.

a. Repair or replace interconnecting cable.

3. PS/MC PC board failure.

a. Replace motor control PC board or bad drive

component.

4. Controller board failure.

a. Check wire feed speed control signal on con-

troller board using diagnostic test #2. Replace controller board if defective.

F. Wire feed motor does not run, but programming

appears to be correct.

1. Cycle test mode is active.

a. Turn off cycle test mode.

2. Interconnecting cable between the controller and feedhead is not plugged in or may have a bad connection or short circuit.

a. Repair or replace interconnecting cable.

3. PS/MC board failure.

a. Replace motor control board or bad drive

component.

4. Controller board failure.

a. Check wire feed speed control signal on

controller board using diagnostic test #2. Replace controller board if defective.

5. Blown fuse on the PS/MC board.

a. Replace fuse.

5. Blown fuse on the PS/MC board.

a. Replace fuse.

6. Over current shutdown on PS/MC board.

a. Replace fuse.

6. Over current shutdown on PS/MC board.

a. This could be from a bind on the feed, bad

cabling or various other causes. In order to clear the error, power should be cycled on the control panel. If the problem persists, the feeder control cable, feeder, gun/torch, and wire feed should be thoroughly checked for blockage and short circuits in the feeder control cable. EMI can also create this problem, so check for electrical interference in the area (like TIG machines).

7. Motor failure.

a. Verify motor/feeder is not frozen or stuck.

Replace motor.

G. Wire feed motor will not inch, but motor will run

during the weld cycle.

1. C/D board failure.

a. Replace C/D board.

2. Controller board failure.

May 5, 2005

a. Replace Controller Board.

3. C/D board/Controller board ribbon cable interface failure.

a. Repair or replace ribbon cable.

5-3

HMC-410

H. Gas valve is stuck on or off.

1. Interconnecting cable between control panel and feedhead may have a bad connection or short circuit.

a. Repair or replace interconnecting cable.

2. Gas valve control relay failure on controller board.

a. Check relay control signal using diagnostic test

#50. Replace relay or controller board if bad.

3. Gas valve failure.

a. Replace valve.

4. 24 VAC failure.

a. Check 24 VAC out of transformer by checking

+15 VDC UNREG LED on PS/MC board. Replace transformer if bad.

I. Front panel does not function.

1. Unit does not power up

a. Verify unit powers up. Verify PS/MC board

voltages are OK by checking the power LEDs.

3. Incorrectly installed cable, switches.

a. Verify cables installed on controller board

correctly. Verify option switches are in the correct position.

K. Schedule program data lost or corrupted after

controller power down. Also, if OFF is displayed for Schedule Number.

1. Bad memory chip.

a. Replace controller board.

L. Control panel fails to respond to control input or

responds unusually.

1. Line voltage drop or spikes on the AC power line.

a. Isolate controller AC power lines.

2. EMI radiation from equipment in the vicinity of the controller.

a. Remove suspect equipment from the vicinity.

Reduce interconnecting cable lengths to a minimum. Be sure all weld system equipment is properly grounded to earth ground.

2. Interconnect between C/D board and controller board. Interconnect between controller board and PS/MC board.

a. Verify cables are good. Repair or replace if de-

fective.

3. Defective controller board.

a. Replace controller board if bad. One easy way

to check if the controller board is working without seeing the front panel is to select diagnostics test #49 and #48 alternatively. If the relay can be heard turning on and off (it is very quiet but audible), the board can be presumed to be functioning. Replace if not functioning.

4. Defective C/D board.

a. Replace C/D board.

J. DIP switch functions do not work.

1. Bad DIP switch.

a. Replace controller board.

2. Controller board failure.

3. Controller board failure.

a. Replace controller board.

4. Unusual weld starts or transients from the power source.

a. Check power source for malfunctions.

M. The controller allows the weld cycle to progress

through the run in segment and terminates the cycle.

1. Power source is not providing an arc established signal.

a. Check power source manual for service

information.

2. Controller does not recognize the arc established signal provided by the power source, may be a bad controller board channel or interconnect to I/ S board.

a. Replace controller board, I/S board, or

controller to I/S ribbon cable.

3. Difficulty starting arc due to dirty work or improper programming.

a. Replace controller board.

5-4

a. Reprogram run in parameters, lengthen time,

increase arc voltage and/or wire feed speed.

July 27, 2005

N. Auxiliary relays do not function.

1. Interconnecting cable between control panel and fixture may have a bad connection or short circuit.

a. Repair or replace interconnecting cable.

2. Fixture control relays failure on controller board. Interconnect between I/S board and controller board. Interface/Suppressor board failure.

a. Check relay control signal using diagnostic test

#51 and #52. Replace bad component. If these go bad, also verify that fixture load is not more than 115 VAC, 2 A, and that proper load suppression techniques were employed.

HMC-410

May 5, 2005

5-5

HMC-410

5.05 Diagnostics

Each test described in this section is selected in one of two ways: (1) with the DIP switch on the controller board or (2) with the Diagnostics Select soft switch (described in the System Configuration section located in Operation chapter). Selecting with the Diagnostics Select soft switch is the preferred method because it does not require access to the inside of the panel.

In order to select the Diagnostic Test with the DIP switches, consult the Built in Test Definition table (on following page). The position of the DIP switch for the selected test is shown to the right of the test, with a 1 being OPEN (switch pressed on the OPEN side), and a 0 is closed. The toggle switches on the front panel are tied into this DIP switch, so they will need to be set to the UP position. Note that DIP switch 9 is not required and can be kept in the OPEN position.

IMPORTANT: Note that by selecting a diagnostic with the DIP switches, the configuration of the control unit is changed. It is important to record the position of the DIP switches before a test is selected so that the unit can be reconfigured to its pre-test setup (typically all OPEN).

DISP B is the center display. All tests will display the test number in the upper display. If diagnostics are enabled, but the combination of switches is not one of the shown tests, the controller board will perform test number 60, EEPROM Test, which will reset the panel’s configuration to its default settings.

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July 27, 2005

5.06 Built In Test (BIT) Definition

Switch Position

1=OPEN, 0=CLOSED

Test No. Name Description SSSSSSSS

12345678

1 POWER SOURCE The Power Source Control Voltage will output a 01000000

VOLTAGE 5 VDC 5 VDC signal onto J3-6.

2 WIRE FEEDER The wire feed speed control voltage output 00100000

VOLTAGE 8 VDC will output a 8.0 VDC voltage on pin J1-13.

3 DISPLAY CH0 The conversion of the Arc Voltage input 01100000

(ARC VOLTAGE) voltage is output to the display board’s DISP B.

4 DISPLAY CH1 The conversion of the Arc Current input 00010000

(ARC CURRENT) voltage is output to the display board’s DISP B.

5 DISPLAY CH2 The conversion of the WFS Tach Reference 01010000

(WFS TACH REF) input voltage is output to the display board’s

DISP B.

6 DISPLAY CH3 The conversion of the inverter arc current 00110000

(INVERTER ARC input voltage is output to the display board’s

CURRENT) DISP B. 7 DISPLAY CH4 01110000 8 DISPLAY CH5 The conversion of the Power Source 00001000

(PS SIGNATURE) Signature’s input voltage is output to the

display board’s DISP B.

9 DISPLAY ALL LEDS The display board is directed to display all 8’s 01001000

(AND 8’S) on the seven segment displays.

10 DISPLAY LED1 The display board turns on LED1 (craterfill). 00101000 11 DISPLAY LED2 LED2 (burnback) is turned ON. 01101000 12 DISPLAY LED3 LED3 (postflow) is turned ON. 00011000 13 DISPLAY LED4 LED4 (recycle) is turned ON. 01011000 14 DISPLAY LED5 LED5 (ready) is turned ON. 00111000 15 DISPLAY LED6 LED6 (preflow) is turned ON. 01111000 16 DISPLAY LED7 LED7 (run in) is turned ON. 00000100 17 DISPLAY LED8 LED8 (weld) is turned ON. 01000100 18 DISPLAY LED9 LED9 (wfs) is turned ON. 00100100 19 DISPLAY LED10 LED10 (schedule) is turned ON. 01100100 20 DISPLAY LED11 LED11 (test) is turned ON. 00010100 21 DISPLAY LED12 LED12 (error) is turned ON. 01010100 22 DISPLAY LED13 LED13 (time) is turned ON. 00110100 23 DISPLAY LED14 LED14 (arc hours) is turned ON. 01110100 24 DISPLAY LED15 LED15 (volts) is turned ON. 00001100 25 DISPLAY LED16 LED16 (count) is turned ON. 01001100

HMC-410

May 5, 2005

Table 5-1a: Built In Test Definitions

5-7

HMC-410

5.06 Built In Test (BIT) Definition (continued as Table 5-1b)

Switch Position

1=OPEN, 0=CLOSED

Test No. Name Description SSSSSSSS

12345678

26 DISPLAY LED17 LED17 (amps) is turned ON. 00101100 27 DISPLAY LED18 LED18 (arc hours x100) is turned ON. 01101100 28 DISPLAY LED19 LED19 (prog delay) is turned ON. 00011100 29 DISPLAY LED20 LED20 (weld segment) is turned ON. 01011100 30 DISPLAY LED21 LED21 (c4a) is turned ON. 00111100 31 DISPLAY SE1 Current shaft position (0 to 255) is output to 01111100

DISP B. Turning SE1 CW will increase this number, and CCW will decrease this number.

32 DISPLAY SE2 Current shaft position (0 to 255) of SE2 is 00000010

output to DISP B. Turning SE2 CW will increase this number, and CCW will decrease this number.

33 DISPLAY SE3 Current shaft position (0 to 255) of SE3 is 01000010

output to DISP B. Turning SE3 CW will increase this number, and CCW will decrease this number.

34 DISPLAY CH5 The conversion of the Power Source 00001000

(PS SIGNATURE) Signature’s input voltage is output to the

display board’s DISP B.

35 Display Start Display B will display the state of the Front 01100010

Panel Start Switch. 0 = Pressed, 1 = Not Pressed

36 Display Cycle Test Display B will display the state of the Cycle 00010010

Test Switch. 0 = Pressed, 1 = Not Pressed

37 Display Inch Display B will display the state of the lnch 01010010

Switch. 0 = Pressed, 1 = Not Pressed

38 Display Purge Display B will display the state of the Purge 00110010

Switches. 0 = Pressed, 1 = Not Pressed

39 Display Program/Weld Display B will display the state of the 01110010

Program/Weld Switch. 0 = Pressed, 1 = Not Pressed

40 Display Stop Display B will display the state of the Front 00001010

Panel Stop Switch. 0 = Pressed, 1 = Not Pressed

41 Display Gun Trigger Display B will display the state of the Gun 01001010

Trigger. 0 = Pulled, 1 = Not Pulled

42 Display Aux Seg Display B will display the state of the Auxillary 00101010

Advance Segement Advance. 0 = Pressed,

1 = Not Pressed

43 Display Remote Start Display B will display the state of the Remote 01101010

Start Switch. 0 = Pressed, 1 = Not Pressed

5-8

July 27, 2005

HMC-410

5.06 Built In Test (BIT) Definition (continued as Table 5-1c)

Switch Position

1=OPEN, 0=CLOSED

Test No. Name Description SSSSSSSS

12345678

44 Display Remote Stop Display B will display the state of the Remote 00011010

Stop Switch. 0 = Pressed, 1 = Not Pressed

45 Display Aux Start/Stop Display B will display the state of the 01011010

Auxiliary Start/Stop Switch. 0 = Pressed, 1 = Not Pressed

46 Display Arc Established Display B will display the state of Arc 00111010

Established. 1 = Arc Established, 0 = Arc Not Established

47 Display Ground Fault Display B will display the state of the Ground 01111010

Fault. 0 = Ground Fault, 1 = No Ground Fault

48 Display Ground Fault Display B will display the state of the Ground 00000110

(Latched) Fault Latch. 0 = Ground Fault has occurred,

1 = No Ground Fault has occurred. 49 RELAY 0 TEST Contactor Relay Closed. 01000110 50 RELAY 1 TEST Gas Valve Relay Closed. P1-7 will have 24 00100110

VAC Hi on it. 51 RELAY 2 TEST Fixture Relay #1 Closed. 01100110 52 RELAY 3 TEST Fixture Relay #2 Closed. 00010110 53 RELAY 4 TEST Error Relay Closed. 01010110 54 RELAY 5 TEST 00110110 55 RELAY 6 TEST 01110110 56 IL2 TEST 00001110 57 RAM TEST The RAM test will perform a diagnostic test 01001110

on internal RAM. The top display will display a

memory location (selected by the top encoder)

and the middle display will display a value

written to RAM (selected by the middle

encoder). The bottom display will show the

data at that memory location; if the RAM is

working correctly, that value will be the same

as the number in the middle display. 58 No Test 59 EEPROM This selection will configure the schedules 01101110 60 Initialization and softswitches to factory defaults. This 00011110

selection will show the test number in the top

display, and count numbers in the middle

display (normally 1 to 255, with some jumping

around towards the end). When the middle

display clears, the initialization is complete.

May 5, 2005

5-9

HMC-410

5-10

July 27, 2005

SECTION 6:

ACCESSORIES AND OPTION

DESCRIPTIONS

6.01 Remote Pendant Description

The remote pendant is an option for remote control operation of the control panel. Features under remote control include Cycle Start, Cycle Stop, Wire Feed (Inch), and Gas Purge. If the remote pendant is not to be used, this section can be skipped. The Remote Pendant is shown in Figure 6-1.

CYCLE START BUTTON - This button is used for remote pendant initiation of the weld cycle. When pressed, the control will initiate the selected weld schedule. Pressing this button while in a weld has no effect.

CYCLE STOP BUTTON - This button is used for termination of the remote pendant initiated weld cycle. When pressed, the control will proceed to the crater fill segment of the weld cycle. Also, recycle will be disabled so that the weld will stop after the postflow segment. Pressing this button during a gun switch, front panel, or fixture initiated weld, or during standby, will have no effect.

HMC-410

Art # A-04369

Gas PURGE BUTTON - This button will turn on the gas valve when pressed. This button has no effect during a weld.

INCH BUTTON - This button will feed wire (at the rate programmed in the Run In WFS setting) when pressed. This button has no effect during a weld.

6.02 Feedhead

170896A-002 60 - 888 IPM

6.03 Feed Roll Kits

375980-XXX (one kit is supplied standard, but part number must be specified at time of order).

Figure 6-1: Remote Pendant

July 27, 2005

6-1

HMC-410

6.04 Control Cables:

These control cables are used from the HMC-410 to the power source, and for the HMC-410 to the feedhead, thus 2 are required per system.

Description Part Number

2’ Control Cable 170552-005 10’ Control Cable 170552-001 15’ Control Cable 170552-006 25’ Control Cable 170552-002 50’ Control Cable 170552-003 75’ Control Cable 170552-007 100’ Control Cable 170552-004

6.05 171238-17 Software Kits

The 171238-17 Software Kit has the following additional features:

Feature Benefit

1. Programmable Gun Switch A. Allows user to customize gun switch speed for changing weld levels Sensitivity (SP) at gun with a flick of the switch.

2. Password Protection (UPS, A. Allows the supervisor to protect weld settings. SPS) B. Eliminate uncontrolled access to importanct weld parameters.

3. Arc Monitoring (IL, IP) A. Allows customer to perform some basic weld monitoring. B. Verify that basic weld currents occur for some set amount of time.

4. Trim Adjustment Range A. Allows customer to limit amount of change by operators from some

(ADJ) preset level

B. Allows operator ability to tweak in operating point while reducing the possibility of operating out of the process range

5. Remote Schedule Selection A. Ability to select 1 of 8 schedules remotely while welding or in standby

(RSE)

6. Display Filter (DF) A. Ability to make display read update at an optimum rate for each application

Table 6-1: Software Kits 171238-17

See the descriptions of the softswitches for details on these and other additions to the HMC-410 capability.

6-2

July 27, 2005

HMC-410

6.06 171238-19 Software Kits

The 171238-19 Software Kit has the following additional features (beyond all of the features described in the 17123817 described above):

Feature Benefit

1. Gun Switch Selectable Schedule A. Ability to change welding schedule by flickering gun switch in standby. (RSE: Gun) B. Useful for situations where welder may be away from welder, but still

wishes to change to an alternate welding schedule

2. Limited Segment Adjustment A. Limit ability to change parameters to just ‘weld’ segment (AS) B. Avoid confusion to operators by allowing them to change only main

weld parameters.

Table 6-2 Software Kits 171238-19

See Softswitch Descriptions for details on these and other additions to the HMC-410 capability.

6.07 171238 Software Kits

A variety of software kits have been released for the HMC-

410. As new customer requests / requirements are generated, these additional features are normally implemented as a new dash number of kit. The following table shows the softswitch screens, and which softswitch screen is implemented with which kit number. The softswitch description details the additional features available with each kit. The standard HMC-410 is delivered with the ‘-3’ software, and upgrades are available through your normal channels.

July 27, 2005

6-3

HMC-410

6.08 870236 Robotic Interface Kits

870236-001 ABB Robotic Interface Kit This kit includes the components required to allow the HMC-410 to plug into the 24 position amphenol connector

provided on the ABB robots.

Feature Benefit

1. 24 Position Amphenol A. Easy to install welding interface for Thermal Arc welder to ABB Robot

2. Analog Voltage Control A. Control welding voltage (or pulse frequency) remotely from robot controller. B. Integrate robot control of welding voltage for none, some, or all of the welding segments for maximum flexibility.

3. Analog Wire Feed Speed Control A. Control wire feed speed remotely from robot controller. B. Integrate robot control of wire feed speed for cold inching or welding for none, some, or all of the welding segments for maximum flexibility.

4. Robot Controlled Gas A. Allows robot control of shielding gas

5. Robot Controlled Wire Forward A. Allows robot control of wire in the forward direction

6. Robot Controlled Wire Reverse A. Allows robot control of wire in the reverse direction

7. Robot Controlled Contactor A. Allows robot control of the welder output terminals

8. Welder Ready Signal A. Communicates status of welder to robot

9. Welder Inhibit Signal A. Communicates selection of a test (cold run) mode to the robot

10. Weave Inhibit Signal A. Communicates selection of a weave inhibit mode to the robot

11. Inch Speed Signal A. Communicates selection of a local inch command to the robot

12 Arc Established Signal A. Communicates selection of an Arc Established condition to the robot

13. Wire Stuck Signal A. Communicates the occurrence of a wire stuck to the work condition to the robot

14. Water/Gas Sensor Signal A. Communicates the occurrence of a lack of water or shielding gas condition to the robot

Table 6-3: Robotic Interface Kits

Included in this kit are:

(1) One 870200 Robotic Interface Board (2) One 870213 24 Position Amphenol Board (3) One 870210 12 VDC Wire Stick Sensing Board (4) One 6 Position Terminal Strip for Water/Gas/Wire Sensors (5) Cables and Other Installation Hardware for this Kit (6) Installation and Operating Instructions

6-4

July 27, 2005

HMC-410

6.09 870236-002 Fanuc Robotic Interface Kit

This kit includes the components required to allow the HMC-410 to plug into the 37 position amphenol connector provided on the Fanuc robots.

Feature Benefit

1. 37 Position Amphenol A. Easy to install welding interface for Thermal Arc welder to Fanuc Robot

3. Analog Wire Feed Speed

Control

4. Analog Arc Current Signal A. Communicates actual arc current to the robot

5. Analog Arc Voltage Signal A. Communicates actual arc voltage to the robot

6. Robot Controlled Gas A. Allows robot control of shielding gas

7. Robot Controlled Wire Forward A. Allows robot control of wire in the forward direction

8. Robot Controlled Wire Reverse A. Allows robot control of wire in the reverse direction

9. Robot Controlled Master Weld A. Allows robot control of the welding sequence by commanding a start

Control or end of the weld

10. Welder Fail Signal A. Communicates status of welder to robot

11. Arc Established Signal A. Communicates selection of an Arc Established condition to the robot

12. Wire Stuck Signal A. Communicates the occurrence of a wire stuck to the work condition

13. Water Sensor Signal A Communicates the occurrence of a lack of water condition to the robot

14. Gas Sensor Signal A. Communicates the occurrence of a lack of shielding gas condition to

15. Wire Sensor Signal A. Communicates the occurrence of a lack of welding wire condition to

A. Control wire feed speed remotely from robot controller. B. Integrate robot control of wire feed speed for cold inching or welding for none, some, or all of the welding segments for maximum flexibility.

to the robot

the robot

Table 6-4: Fanuc Robot Kits

Included in this kit are:

(1) One 870200 Robotic Interface Board (2) One 870244 37 Position Amphenol Board (3) One 870210 12 VDC Wire Stick Sensing Board (4) One 6 Position Terminal Strip for Water/Gas/Wire Sensors (5) Cables and Other Installation Hardware for this Kit (6) Installation and Operating Instructions

July 27, 2005

6-5

HMC-410

6.10 870236-003 Comau Robotic Interface Kit

This kit includes the components required to allow the HMC-410 to plug into the 64 position amphenol connector provided on the Comau robots.

Feature Benefit

1. Analog Voltage Control A. Control welding voltage (or pulse frequency) remotely from robot controller. B. Integrate robot control of welding voltage for none, some, or all of the welding segments for maximum flexibility.

2. Analog Wire Feed Speed

Control

3. Robot Controlled Gas A. Allows robot control of shielding gas

4. Robot Controlled Wire Forward A. Allows robot control of wire in the forward direction

5. Robot Controlled Contactor A. Allows robot control of the welder output terminals

6. Arc Established Signal A. Communicates selection of an Arc Established condition to the robot

7. Wire Stuck Signal A. Communicates the occurrence of a wire stuck to the work condition

to the robot

Table 6-5: Comau Robot Kits

Included in this kit are:

6-6

July 27, 2005

6.11 Other Available Options

1. Wire Spool Kit 870058

2. Wire Reel Kit 870059

3. Wire Reel / Spool Support Assembly 870060-001

4. Base Plate (For Mounting Feedhead, Wire Reel / Spool Support) 375769-004

5. Base Plate (For Mounting 410 Onto Power Supply) 170962

6. * 60 Lb. Coil Adapter 407142A

7. * 30 Lb. Spool Cover 375582A-004

8. * 60 Lb Spool Cover / Lifting Eye 375733A-001

9. ** Lifting Eye Kit 375104A

10. Semiautomatic Trigger Hold / Subsegment Controls 170925-001

11. Remote Pendant With 15’ Cable (Start, Stop, Inch, Purge) 170470A-002

12. 10’ Remote Pendant Extension Cable 170486-001

13. 35’ Remote Pendant Extension Cable 170486-002

14. 10’ Auxiliary Control Cable 170487-001

15. 25’ Auxiliary Control Cable 170487-002

16. Random Schedule Select Cable 171239-001

17. Dual Feeder Interlock Box 870008-001

18. Inch/Purge Switch For Dual Feeder Interlock Box Only 870023

19. Software Upgrades (Consult Factory) 171238-XXX

20. ¾" Gun Adapter 375999

HMC-410

Table 6-6: Additional Options

* Must Be Used With Both 870058 & 870060-001 ** Must Be Used With 870060-001 Only

July 27, 2005

6-7

HMC-410

6-8

July 27, 2005

HMC-410

SECTION 7: GLOSSARY

Arc Established — A signal generated by the power

source indicating that an arc is struck from the wire to the work.

Arc Hours — Amount of time that the control panel has been in control of an arc, i.e., the accumulated amount of weld time on the panel.

Automatic Configuration — This is the configuration where the weld is controlled entirely by the welding equipment.

CV — constant voltage power source. Deadman Operation — This mode of operation requires

that the control signal to start an event is required throughout the whole event or that event will be terminated.

Fault — A condition where an operation normally under control of the panel is not operating correctly. Faults can be Ground, Feeder, or Tolerance Faults. See Operational Faults section located in the Operation chapter.

Fault Abort — The control panel will terminate the weld by proceeding to the crater fill segment when a tolerance fault is recognized by the control panel (see Fault Delay Time) and the fault abort is enabled. See Soft Switch section located in the Operation chapter.

Fault Delay Time — The amount of time that a tolerance fault condition must continuously exist before the control panel recognizes the error. This time is default set to 1 second, or programmable. See Soft Switch section located in the Operation chapter.

Maximum Programmable Voltage — This voltage is the maximum number that can be programmed in the center display for the run-in, weld, crater fill, and burnback segments. This number changes depending on the type of power source that is used.

The following table shows the various maximums:

RC/RCC 300 36 V RC/RCC 450 42 V RC/RCC 650 44 V Arc-Master 501 40 V (44 V Pulsed MIG) Arc-Master 351 38 V (44 V Pulsed MIG) Fabstar 4030 36 V Excel-Arc 4030 36 V Excel-Arc 6045 42 V Excel-Arc 8065 44 V Ultra Flex CC/CV 38 V (44 V Pulsed MIG) Ultra Flex Pulse 38 V (44 V Pulsed MIG)

Minimum Programmable Voltage — This voltage is the minimum number that can be programmed in the center display for the run-in, weld, crater fill, and burnback segments. This number changes depending on the type of power source that is used. The following table shows the various minimums:

RC/RCC 300 10 V RC/RCC 450 10 V RC/RCC 650 10 V Arc-Master 500 10 V (0 V Pulsed MIG)

Feeder Fault — This occurs if the current through the motor exceeds specifications. This could be from a bind on the feed, bad cabling or various other causes. This fault will disable the motor control circuitry. In order to clear the error, power should be cycled on the control panel.

Ground Fault — The ground fault occurs when a large current is sensed through the earth ground from the power source to the HMC-410 chassis. This fault will cause the control panel to shut down all systems under its control since it is a significant safety hazard.

July 27, 2005

Arc-Master 350 10 V (0 V Pulsed MIG) Fabstar 4030 10 V Excel-Arc 4030 11 V Excel-Arc 6045 12 V Excel-Arc 8065 14 V Ultra Flex CC/CV 10 V (0 V Pulsed MIG) Ultra Flex Pulse 10 V (0 V Pulsed MIG)

7-1

HMC-410

Multi Sub Segment Operation — This type of operation allows the weld parameters to automatically change during a weld without stopping and restarting the weld. Refer to the Operation chapter for more details.

Nonvolatile Memory — This memory will store the various, long term programmable parameters. Nonvolatile means that it is not disrupted by power loss.

Ready Mode — The mode in which the control panel segments can be viewed, and if so privileged, programmed. The control panel is in ready mode if the unit is not in a weld cycle, and is not performing diagnostics.

Schedule — The collection of various segments which together describe a complete weld.

Semiautomatic Configuration — This configuration is where the control panel controls the power source and the feeder, but the welder moves, guides, and directs the arc on the work. In this configuration, the HMC-410 may typically be physically placed on a feeder.

Sequence/Weld Sequence — Weld cycle.

Trim — This capability allows the weld operator to change

the weld parameters arc voltage and WFS during the weld. See Soft Switch section located in the Operation chapter.

Weld Cycle — A weld cycle is the completion of the segments preflow through postflow once. Thus, if a schedule dictates a recycle, this would be considered multiple weld cycles.

Weld Segment — The weld segment is the segment which describes the static part of the weld. This segment will dictate if the weld is a spot weld (time noncontinuous), or a continuous weld.

WFS — wire feed speed.

Soft Switch — Soft switches allow for setup of

configuration parameters. Refer to the Operation chapter for more details.

Sub Segment — The weld sub segment(s) are segments which can be executed while the weld is in the weld segment. This may be required because of discontinuity in the work where different weld parameters are required. See Operation chapter for a description of the weld sub segment operation.

Tolerance Fault — This error is caused because of arc voltage out of tolerance (± .5 Volt variance from programmed value), wire feed speed out of tolerance (± 10 IPM variance from programmed value), or a loss of arc established from the power source. If any of these conditions continuously persist for more time than the fault delay time the error will be recognized. If the fault was caused by the loss of arc established, the panel will shut off the power source and feeder automatically. This type of error will clear itself once a new weld cycle is initiated.

Trigger Hold — For semiautomatic applications. The trigger hold feature allows the welder to initiate the weld with a momentary pull of the switch, and terminate the weld with another momentary pull of the switch. The full description of this process is described in the Semiautomatic section located in the Operation chapter of this manual.

7-2

July 27, 2005

SECTION 8:

PARTS LIST

8.01 Equipment Identification

All identification numbers as described in the Introduction chapter must be furnished when ordering parts or making inquiries. This information is usually found on the nameplate attached to the equipment. Be sure to include any dash numbers following the Specification or Assembly numbers.

8.02 How To Use This Parts List

The Parts List is a combination of an illustration (Figure Number) and a corresponding list of parts which contains a breakdown of the equipment into assemblies, subassemblies, and detail parts. All parts of the equipment are listed except for commercially available hardware, bulk items such as wire, cable, sleeving, tubing, etc., and permanently attached items which are soldered, riveted, or welded to another part. The part descriptions may be indented to show part relationships.

HMC-410

To determine the part number, description, quantity, or application of an item, simply locate the item in question from the illustration and refer to that item number in the corresponding Parts List.

An “Application Code” is used to distinguish parts that are applicable only to certain Specifications and/or Assemblies. This code is found in the right most column of the Parts List. If an item in the Parts List applies to all Specifications or Assemblies, the word “ALL” will be in the Application Code column. Refer to the following list to determine the appropriate Application Codes for the Specifications or Assemblies covered by this manual. If only the assembly or specification number is listed, the use of an Application Code does not apply to this manual.

SPEC NUMBER APPLICATION CODE 100050-1 A

100050-2 B

July 27, 2005

8-1

HMC-410

8.03 Parts List for the Control Box Assembly (1 of 2)

ItemItem

Item

ItemItem NumberNumber

Number

NumberNumber

1 170913A-1 Bracket - Mounting 2 All 2 870071 Cover - Control Box 1 A

3 204036 Label - Warning 1 All 4 870239 Wrapper - Control Box 1 All 5 870087-1 Label - Company 2 All 6 170860B-1 Board - P.C. Microprocessor - See Note 2 1 A

7 375426-4 Spacer - P.C. Board 6 All 8 870284 Board - PC, Control & Display 1 A

9 375426-1 Spacer - P.C. Board 6 All 10 170916B Overlay - Control Panel 1 All 11 406807-6 Knob - Control 4 All

PartPart

Part

PartPart

NumberNumber

Number

NumberNumber

100050-1 Box - Control, HMC-410 Assembly 1 A 100050-2 Box - Control, HMC-410 Assembly 1 B

870268 Cover - Control Box 1 B

170860B-2 Board - P.C. Microprocessor - See Note 2 1 B

170858 Board - PC, Control & Display 1 B

DescriptionDescription

Description

DescriptionDescription

Qty/Qty/

Qty/

Qty/Qty/

AssyAssy

Assy

AssyAssy

ApplicationApplication

Application

ApplicationApplication

CodeCode

Code

CodeCode

12 408971-1 Switch - Program/Weld 1 All 13 403091-12 Plug - Hole 2 All 14 870032-3 Switch - Rocker Arm, Circuit Breaker 1 All 15 171138-1 Transformer - Control 1 All 16 409838 Grommet - Mounting 4 All 17 409837 Spacer - Mounting 4 All 18 170869C-1 Board - P.C., Interface/Suppressor 1 All 19 830116 Label - Ground 1 All 20 See Note 1 Screw - 1/4-20 x 7/8 Hex Head Med Hard Steel 1 All 21 See Note 1 Washer - 1/4, Lock 1 All 22 See Note 1 Nut - 1/4-20, Keps 2 All 23 See Note 1 Washer - 1/4, Flat 1 All 24 170862A Board - P.C., Motor Control 1 All 25 870294 Label - Amphenol 1 All 26 W-11166-10 Fuse - AGC3, 3 Amp 2 All 27 375426-11 Spacer - P.C. Board 5 All 28 No Number Label - CSA NRTL/C 1 All 29 204038-2 Cable - Ribbon Assembly 2 All NOTES:

1. This part may be purchased locally.

2. When ordering this board, please verify that any installed software options are also ordered. Refer to the Controller Board Software on page 2-16 for more information.

8-2

July 27, 2005

HMC-410

July 27, 2005

Art # A-04370

Figure 8-1: Control Box Assembly

8-3

HMC-410

8.03 Parts List for the Control Box Assembly (2 of 2)

ItemItem

Item

ItemItem NumberNumber

Number

NumberNumber

30 870190 .Cover - HMC Face 1 B 32 870234 Standoff - P.C. Board 6 B 33 870267 Connector - D-Sub 1 B 34 870269 Screwlock - Jackscrew 1 B 35 870255 Panel - Blank Term. Strip 1 A

36 870227 Panel - Blank Amphenol 1 All 37 870200-2 Board - Robotic Interface 1 B

PartPart

Part

PartPart

NumberNumber

Number

NumberNumber

870263 Panel - Blank Term. Strip 1 B

DescriptionDescription

Description

DescriptionDescription

Qty/Qty/

Qty/

Qty/Qty/

AssyAssy

Assy

AssyAssy

ApplicationApplication

Application

ApplicationApplication

CodeCode

Code

CodeCode

8-4

July 27, 2005

HMC-410

July 27, 2005

Art # A-04370

Figure 8-1 Control Box Assembly

8-5

HMC-410

8.04 Parts List for the Remote Pendant

ItemItem

Item

ItemItem NumberNumber

Number

NumberNumber

1 170471 Handle 1 All 2 170478 Box - Pendant 1 All 3 405535-5 .Support - PC Board 4 All 4 170468-1 .Strain - Relief 1 All 5 170479 Cable - Assembly 1 All 6 170922 Board - Remote Pendant 1 All 7 408092-9 Receptacle - 8 Pos. 1 All 8 170928 Cover 1 A

PartPart

Part

PartPart

NumberNumber

Number

NumberNumber

170470-2 Pendant - Remote, Assembly 1 A

170470A-2 Pendant - Remote, Assembly 1 B

170928-1 NOTE

DescriptionDescription

Description

DescriptionDescription

Qty/Qty/

Qty/

Qty/Qty/

AssyAssy

Assy

AssyAssy

ApplicationApplication

Application

ApplicationApplication

CodeCode

Code

CodeCode

8-6

July 27, 2005

HMC-410

July 27, 2005

Art # A-04470

Figure 8-2: Remote Pendant

8-7

HMC-410

8-8

July 27, 2005

APPENDIX 1: GENERAL INFORMATION

• Note the model and specification number shown on the equipment nameplate.

• Locate these numbers in the model and specification number columns below.

• Use only those diagrams and instructions that are applicable.

HMC-410

Model

HMC-410

Specification

Number

100050-1 870241 170921 100050-2 870241 170921

Connection &

Schematic Diagram

System

Outline

July 27, 2005

A-1

HMC-410

POWER

SOURCE

AMPHENOL

FEEDHEAD ASSEMBLY AMPHENOL

REMOTE

PENDANT

AMPHENOL

AUXILIARY

FIXTURE

AMPHENOL

APPENDIX 2: SCHEMATIC DIAGRAM 1 OF 4

PS CONTACTOR HI

PS CONTACTOR LO

ARC VOLTS (+)

ARC AMPS (+)

120 VAC HI

120 VAC LO

CHASSIS GND

REMOTE CONTROL MAX.

REMOTE CONTROL INPUT

REMOTE CONTROL MIN.

PS COM.

ARC ESTABLISHED

NOT USED

ARC AMPS (+)

ARC VOLTS (-)

MOTOR (+)

MOTOR (-)

+15 VDC UNREG.

GUN SWITCH INPUT

NOT USED

INCH INPUT

CHASSIS GND

NOT USED

24 VAC LO

NOT USED

TACH. COM.

TACH. +15 VDC

TACH. SIGNAL

NOT USED

GAS VALVE INPUT

NOT USED

24 VAC HI

REMOTE PURGE

REMOTE INCH

REMOTE START

REMOTE STOP

+15 VDC UNREG.

NOT USED

AUX. PURGE

AUX. INCH

NOT USED

AUX. SUBSEGMENT ADVANCE

AUX. START/STOP

NOT USED

+15 VDC UNREG.

NOT USED

RELAY #2 CONTACT

ERROR RELAY CONTACT

RELAY #1 CONTACT

NOT USED

INTERFACE/SUPPRESSOR

P.C. BOARD

24 VAC LO

120 VAC LO

120 VAC HI

17 VAC HI (3)

17 VAC LO (3)

MOTOR CONTROL/

POWER SUPPLY

P.C. BOARD

MOTOR (-)

MOTOR (+)

PS. COM.

24 VAC HI

17 VAC HI (2)

17 VAC LO (2)

8 VAC LO

17 VAC LO (1)

17 VAC HI (1)

34567

120 VAC HI

120 VAC LO

2345678

8 VAC HI

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

DIGITAL +5 VDC

DIGITAL COM.

DIGITAL -15 VDC

DIGITAL +15 VDC

FOWARD/REVERSE

NOT USED

24 VAC HI

24 VAC LO

WFS TACH. REF.

FEEDER RUN ENABLE

WFS CONTROL INPUT

GROUND FAULT DETECT

EXT. +15 VDC

EXT. COM.

+15 VDC UNREG.

TACH. SIGNAL

PS CONTACTOR HI PS CONTACTOR LO ARC VOLTS (+) ARC AMPS (+) REMOTE CONTROL MAX. REMOTE CONTROL INPUT ARC ESTABLISHED ARC AMPS (-) ARC VOLTS (-) NOT USED NOT USED REMOTE START REMOTE STOP GUN SWITCH INPUT AUX. PURGE AUX. INCH AUX. SUBSEGMENT ADVANCE AUX. START/STOP +15 VDC +15 VDC UNREG. TACH. SIGNAL TACH. COM. GAS VALVE INPUT 24 VAC HI 24 VAC LO NOT USED

RELAY #2 CONTACT

ERROR RELAY CONTACT

RELAY #1 CONTACT RELAY #1 CONTACT

789101112

DIGITAL +5 VDC DIGITAL +5 VDC DIGITAL COM. DIGITAL COM. DIGITAL -15 VDC DIGITAL +15 VDC FOWARD/REVERSE NOT USED 24 VAC HI 24 VAC LO WFS TACH. REF. FEEDER RUN ENABLE WFS CONTROL INPUT GROUND FAULT DETECT EXT. +15 VDC EXT. COM. +15 VDC UNREG. TACH. SIGNAL

A-2

Art # A-05055

120 VAC HI (IN)

120 VAC HI (OUT)

12 11 10 9 8 7

July 27, 2005

SEE SHEET 3 FOR OPTIONAL KIT SCHEMATIC

456 123

LEGEND

J11 SERIAL PORT (OPTIONAL)

S1 ON/OFF SWITCH WITH 4 AMP CIRCUIT BREAKER

S2 TRIGGER HOLD ENABLE SWITCH (OPTIONAL)

S3 SUBSEGMENT ENABLE SWITCH (OPTIONAL)

S4 PROGRAM/WELD SELECT SWITCH

T1 CONTROL TRANSFORMER

TB-1 TERMINAL BLOCK (OPTIONAL)

HMC-410

A213A3

NOT USED

ARC VOLTS (-)

12A411

987

9A78A87A96

ARC AMPS (+)

REMOTE CONTROL MAX.

REMOTE CONTROL INPUT

ARC AMPS (-)

ARC ESTABLISHED

16A015A114

TRIM EN.

HOLD EN.

NOT USED

ABORT EN.

DIG +5VDC DIG +5VDC DIG +5VDC DIG +15VDC DIG -15VDC NOT USED EXT. AD7 EXT. AD6 EXT. AD5 EXT. AD4 EXT. AD3 EXT. AD2 EXT. AD1 EXT. AD0 EXT. INT IF0 IF1 **WR **RD *ALE

*PSEN DIG COM DIG COM DIG COM

NOT USED

ENGLISH

ARC HR RESET

SEGMENT SELECT

PROGRAM DELAY EN.

DIAGNOSTICS EN.

MICROPROCESSOR

P.C. BOARD

2 3 4

5 6 7 8 9

10 11 12 13 14 15 16 17 18 19 20 21

XTAL1

XTAL2 23 24 25 26

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18

242322

212019

TACH. SIGNAL

24 VAC LO

+15 VDC

GAS VALVE INPUT

+15 VDC UNREG.

TACH. COM.

24 VAC HI

NOT USED

6 5 4 3 2 1

131211

171615

REMOTE START

REMOTE STOP

GUN SWITCH INPUT

AUX. PURGE

AUX. INCH

AUX. SUBSEGMENT ADV.

AUX. START/STOP

A12

A11

A10

321

ARC VOLTS (+)

PS CONTACTOR LO

PS CONTACTOR HI

A14

A13

A15

123

DIGITAL COM.

PROG.\WELD ENABLE

J10

OPTIONAL

321

DIGITAL COM.

SUBSEGMENT ENABLE

TRIGGER HOLD ENABLE

DIGITAL +5 VDC

DISPLAY A SELECT

DISPLAY B SELECT

DISPLAY C SELECT

DISPLAY DATA

DISPLAY CLOCK

ENCODER 1-A

ENCODER 1-B

ENCODER 2-A

ENCODER 2-B

ENCODER 3-A

ENCODER 3-B

ENCODER 4-A

ENCODER 4-B

CYCLE START

CYCLE STOP

TEST

INCH

PURGE

NOT USED

DIGITAL COM.

SEE SHEET 3 FOR OPTIONAL KIT SCHEMATIC

RELAY #2 CONTACT

2 3

ERROR RELAY CONTACT

5 6

RELAY #1 CONTACT

CHANGE RECORD

E.C. No. DATE

CONFIDENTIAL: This drawing, including all information contained thereon, is the exclusive and confidential property of Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is not to be copied, reproduced, delivered or disclosed to others, in whole or in part, except with express written permission.

1 2 3 4 5 6 7

DISPLAY/INPUT

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24

25 26

PROG./WELD ENABLE

SUBSEGMENT ENABLE

TRIGGER HOLD ENABLE

PLOT DATE

FILE NAME

870241S1 11-3-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS TOLERANCES BELOW APPLY EXCEPT FOR VENDOR DESIGNED PARTS AND ITEMS. PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

ANGLES

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

P.C. BOARD

TROY, OHIO 45373 , U.S.A.

DIGITAL COM.

OPTIONAL

120 VAC HI (OUT)

11 LINE

120 VAC HI (IN)

FINISH CODE PER

ACTIVITY

REPLACED BY REPLACES

QUANTITY-U.M.

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

HMC-410

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

ATC ATC 11-3-99

TECH. PUB.

OUTSIDE DISTR.

DWG. NO.SIZE

130

DISTRIBUTION TABLE

NONE

SHEET

870241

12 (K)

COMM. CLS.

FULLATC DBB 11-3-99

1 OF 4

Art #A-05055

July 27, 2005

A-3

HMC-410

POWER

SOURCE

AMPHENOL

FEEDHEAD ASSEMBLY

AMPHENOL

REMOTE

PENDANT

AMPHENOL

AUXILIARY

FIXTURE

AMPHENOL

APPENDIX 3: SCHEMATIC DIAGRAM 2 OF 4

PS CONTACTOR HI

PS CONTACTOR LO

ARC VOLTS (+)

ARC AMPS (+)

120 VAC HI

120 VAC LO

CHASSIS GND

REMOTE CONTROL MAX.

REMOTE CONTROL INPUT

REMOTE CONTROL MIN.

PS COM.

ARC ESTABLISHED

NOT USED

ARC AMPS (+)

ARC VOLTS (-)

MOTOR (+)

MOTOR (-)

+15 VDC UNREG.

GUN SWITCH INPUT

NOT USED

INCH INPUT

CHASSIS GND

NOT USED

24 VAC LO

NOT USED

TACH. COM.

TACH. +15 VDC

TACH. SIGNAL

NOT USED

GAS VALVE INPUT

NOT USED

24 VAC HI

REMOTE PURGE

REMOTE INCH

REMOTE START

REMOTE STOP

+15 VDC UNREG.

NOT USED

AUX. PURGE

AUX. INCH

NOT USED

AUX. SUBSEGMENT ADVANCE

AUX. START/STOP

NOT USED

+15 VDC UNREG.

NOT USED

RELAY #2 CONTACT

ERROR RELAY CONTACT

RELAY #1 CONTACT

NOT USED

INTERFACE/SUPPRESSOR

P.C. BOARD

24 VAC HI

24 VAC LO

120 VAC LO

120 VAC HI

17 VAC HI (3)

17 VAC LO (3)

MOTOR CONTROL/

POWER SUPPLY

P.C. BOARD

MOTOR (-)

MOTOR (+)

PS. COM.

17 VAC HI (2)

17 VAC LO (1)

17 VAC LO (2)

34567

120 VAC LO

8 VAC HI

8 VAC LO

17 VAC HI (1)

120 VAC HI

2345678

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

RELAY #2 CONTACT RELAY #2 CONTACT

ERROR RELAY CONTACT ERROR RELAY CONTACT

RELAY #1 CONTACT RELAY #1 CONTACT

DIGITAL +5 VDC

DIGITAL COM.

DIGITAL -15 VDC

DIGITAL +15 VDC

FOWARD/REVERSE

NOT USED

24 VAC HI

24 VAC LO

WFS TACH. REF.

FEEDER RUN ENABLE

WFS CONTROL INPUT

GROUND FAULT DETECT

EXT. +15 VDC

EXT. COM.

+15 VDC UNREG.

TACH. SIGNAL

PS CONTACTOR HI PS CONTACTOR LO ARC VOLTS (+) ARC AMPS (+) REMOTE CONTROL MAX. REMOTE CONTROL INPUT ARC ESTABLISHED ARC AMPS (-)

ARC VOLTS (-)

NOT USED NOT USED REMOTE START REMOTE STOP GUN SWITCH INPUT AUX. PURGE AUX. INCH

AUX. SUBSEGMENT ADVANCE

AUX. START/STOP +15 VDC +15 VDC UNREG. TACH. SIGNAL TACH. COM. GAS VALVE INPUT 24 VAC HI

24 VAC LO

NOT USED

789101112

A-4

Art # A-05056

120 VAC HI (IN)

120 VAC HI (OUT)

12 11 10 9 8 7

July 27, 2005

SEE SHEET 3 FOR OPTIONAL KIT SCHEMATIC

456 123

LEGEND

J11 SERIAL PORT (OPTIONAL)

S1 ON/OFF SWITCH WITH 4 AMP CIRCUIT BREAKER

S2 TRIGGER HOLD ENABLE SWITCH (OPTIONAL)

S3 SUBSEGMENT ENABLE SWITCH (OPTIONAL)

S4 PROGRAM/WELD SELECT SWITCH

T1 CONTROL TRANSFORMER

TB-1 TERMINAL BLOCK (OPTIONAL)

HMC-410

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

10 11 12 13 14 15 16 17 18

1 2 3 4 5 6 7 8 9

DIG +5VDC DIG +5VDC DIG +5VDC DIG +15VDC DIG -15VDC NOT USED EXT. AD7 EXT. AD6 EXT. AD5 EXT. AD4 EXT. AD3 EXT. AD2 EXT. AD1 EXT. AD0 EXT. INT IF0

IF1 **WR **RD *ALE XTAL1 XTAL2 *PSEN

DIG COM

NOT USED

ABORT EN.

NOT USED

HOLD EN.

ENGLISH

ARC HR RESET

SEGMENT SELECT

PROGRAM DELAY EN.

16A015A114

A213A3

12A411

9A78A87A96

TRIM EN.

DIAGNOSTICS EN.

MICROPROCESSOR

A14

A15

A12

A11

A13

A10

J10

DIGITAL +5 VDC

DISPLAY A SELECT

DISPLAY B SELECT

DISPLAY C SELECT

DISPLAY DATA

DISPLAY CLOCK

ENCODER 1-A

ENCODER 1-B

ENCODER 2-A

ENCODER 2-B

ENCODER 3-A

ENCODER 3-B

ENCODER 4-A

ENCODER 4-B

CYCLE START

CYCLE STOP

TEST

INCH

PURGE

NOT USED

DIGITAL COM.

SEE SHEET 3 FOR OPTIONAL KIT SCHEMATIC

1 2 3 4 5 6 7

DISPLAY/INPUT

8 9

P.C. BOARD

10 11 12 13

14 15 16 17 18 19 20 21 22 23

24 25 26

P.C. BOARD

RELAY #2 CONTACT

2 3

ERROR RELAY CONTACT

5 6

RELAY #1 CONTACT

OPTIONAL

987

321

242322

212019

171615

131211

123

321

PROG./WELD ENABLE

DIGITAL COM.

SUBSEGMENT ENABLE

DIGITAL COM.

TRIGGER HOLD ENABLE

OPTIONAL

120 VAC HI (OUT)

11 LINE

NOT USED

July 27, 2005

120 VAC HI (IN)

DIGITAL COM.

NOT USED

TACH. SIGNAL

24 VAC LO

6 5 4 3 2 1

GAS VALVE INPUT

TACH. COM.

24 VAC HI

+15 VDC

+15 VDC UNREG.

AUX. SUBSEGMENT ADV.

AUX. START/STOP

REMOTE STOP

GUN SWITCH INPUT

AUX. PURGE

AUX. INCH

NOT USED

ARC VOLTS (-)

REMOTE START

ARC VOLTS (+)

ARC AMPS (+)

REMOTE CONTROL MAX.

REMOTE CONTROL INPUT

ARC AMPS (-)

ARC ESTABLISHED

PS CONTACTOR LO

PS CONTACTOR HI

PROG.\WELD ENABLE

SUBSEGMENT ENABLE

TRIGGER HOLD ENABLE

CHANGE RECORD

E.C. No. DATE

FILE NAME

870241S1 11-3-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS TOLERANCES BELOW APPLY EXCEPT FOR VENDOR DESIGNED PARTS AND ITEMS. PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

TECH. PUB.

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

HMC-410

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

ATC ATC 11-3-99

REPLACED BY REPLACES

QUANTITY-U.M.

DWG. NO.SIZE

130

OUTSIDE DISTR.

NONE

12 (K)

DISTRIBUTION TABLE

SHEET

870241

Art #A-05056

COMM. CLS.

1 OF 4

FULLATC DBB 11-3-99

A-5

HMC-410

APPENDIX 4: SCHEMATIC DIAGRAM 3 OF 4

OPTIONAL (ROBOTIC INTERFACE OPTIONS SHOWN ONLY)

SEE SHEETS 1 AND 2 FOR STANDARD UNIT.

RXD

TXD

SERIAL COMMON

RTS

CTS

DO8 a DO8 b DO9 a DO9 b DO0 a DO0 b DO1 a DO1 b DO2 a DO2 b DO3 a DO3 b DO4 a DO4 b DO5 a DO5 b DO6 a DO6 b DO7 a DO7 b DI0 a DI0 b DI1 a DI1 b DI2 a DI2 b DI3 a DI3 b DI4 a DI4 b DI5 a DI5 b DI6 a DI6 b DI7 a DI7 b

EXT. +15 VDC EXT. COMMON

TB-1

TB-2

TB-3

TB-4

TB-5

TB-6

EXT. COMMON EXT. +15 VDC

DI7 b DI7 a

DI6 b DI6 a DI5 b DI5 a DI4 b

DI4 a DI3 b DI3 a DI2 b

DI2 a

DI1 b

DI1 a

DI0 b

DI0 a

DO7 b DO7 a DO6 b DO6 a

DO5 b

DO5 a

DO4 b

DO4 a

DO3 b

DO3 a DO2 b DO2 a DO1 b

DO1 a

DO0 b

DO0 a

DO9 b

DO9 a

DO8 b

DO8 a

TERMINAL

BLOCK

GAS SHORTAGE a

GAS SHORTAGE b

WIRE SHORTAGE a

WIRE SHORTAGE b

WATER SHORTAGE a

WATER SHORTAGE b

40 39 38 37 36 35 34 33 32

31 30 29 28 27 26 25 24 23 22 21 20

19 18 17 16 15 14 13 12 11 10

9 8 7 6 5 4 3 2 1

AMPHENOL

P.C. BOARD

GAS SHORTAGE a

WIRE SHORTAGE b

WIRE SHORTAGE a

WATER SHORTAGE a

GAS SHORTAGE b

483

J11

SERIAL PORT

WATER SHORTAGE b

634

6789101112

TXD

CTS

RXD

RTS

EXT. +15 VDC

EXT. COMMON

5 VDC

-15 VDC

SERIAL COMMON

546

1 2 3

5 6 7 8 9 10 11 12 13

17 18 19

22 23 24 25 26 27 28 29 30 31

38 39 40

ROBOTIC INTERFACE

5 VDC

967

131011

P.C. BOARD

97856

EXT. VOLT -

EXT. WFS +

EXT. WFS -

EXT. VOLT +

+15 VDC

EXT. VFB -

I2C SDA

COMMON

342

EXT. IFB -

EXT. VFB+

EXT. IFB +

I2C SCL

COMMON

341

COMMON

Art # A-05057

A-6

EXT. WFS +

EXT. VFB -

EXT. WFS -

EXT. IFB +

EXT. VFB +

EXT. IFB -

EXT. VOLT +

EXT. VOLT -

12 11 10 9 8 76

July 27, 2005

45 123

COMMON

163

I2C SDA

I2C SCL

COMMON

587

+15 VDC

-15 VDC

5 VDC

111013

EXT. +15 VDC

EXT. COMMON

HMC-410

MICROPROCESSOR

P.C. BOARD

LOCAL IFB +

LOCAL IFB -

LOCAL VFB +

LOCAL VFB -

LOCAL WFS +

6 7 8 9

LOCAL WFS LOCAL VOLT +

LOCAL VOLT -

LOCAL IFB +

LOCAL IFB -

LOCAL VFB +

LOCAL VFB -

LOCAL WFS +

6 7 8 9

LOCAL WFS LOCAL VOLT + LOCAL VOLT -

J10

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

± 3˚

DESCRIPTIVE DATA

HMC-410 (W/ ROBOTIC INTERFACE OPTIONS)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

ATC ATC 11-3-99

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

REPLACED BY REPLACES

QUANTITY-U.M.

TECH. PUB.

OUTSIDE DISTR.

DWG. NO.SIZE

130

DISTRIBUTION TABLE

NONE

SHEET

870241

COMM. CLS.

FULLATC DBB 11-3-99

Art # A-05057

.0 ± .1

FILE NAME

ANGLES

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

PLOT DATE

METRIC

CHANGE RECORD

E.C. No. DATE

5 4 3 2 1

in whole or in part, except with express written permission.

870241S3 11-3-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS TOLERANCES BELOW APPLY EXCEPT FOR VENDOR DESIGNED PARTS AND ITEMS. PRODUCED TO RECOGNIZED STANDARDS.

FRACT. INCH

DECIMAL-INCH

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

July 27, 2005

A-7

HMC-410

APPENDIX 5: SCHEMATIC DIAGRAM 4 OF 4

789101112

OPTIONAL (ROBOTIC INTERFACE OPTIONS SHOWN ONLY)

SEE SHEETS 1 AND 2 FOR STANDARD UNIT.

J11 USED ON SPEC.

100050-2 ONLY

J11

47 RD

49 OR

6978

12345

48 BK

50 VT

51 GY

71 YL

3131313131

75 OR

76 VT

72 BR

74 BL

73 GY

243

71 YL

72 BR

73 GY

TB-1

74 BL

75 OR

53412

76 VT

AMPHENOL

P.C. BOARD

REAR

70 BR

68 RD

69 YL

222222

67 BL

66 OR

324

65 BK

64 WT

63 GY

BOTTOM

A-8

Art # A-05058

12 11 10 9 8 7

July 27, 2005

J4 USED ON SPEC.

100050-2 ONLY

HMC-410

456 123

49 OR

50 VT

48 BK

47 RD

453

ROBOTIC INTERFACE

3030303030

51 GY

P.C. BOARD

46 BL

45 PK

121311

43 TN

42 GY

323232

32323232323232

40 YL

38 WT

39 BK

41 VT

587

37 BL

36 OR

35 RD

34 BR

252525252525252525

35 RD

36 OR

37 BL

34 BR

40 YL

38 WT

39 BK

798

243

MICROPROCESSOR

P.C. BOARD

JP2

53 BL

1 2 3 4 5 6 7 8 9

54 WT

55 BK

56 YL 57 RD 58 GY 59 OR

60 BR

33 33 33 33 33 33 33 33

JP3

JP4

41 VT

42 GY

43 TN

J10

45 PK

121311

46 BL

53 BL

1 2 3 4 5 6 7 8 9

54 WT 55 BK 56 YL 57 RD 58 GY 59 OR

60 BR

26 26 26 26 26 26 26 26

879

324

July 27, 2005

69 YL

67 BL

68 RD

70 BR

FRONT

6 5 4 3 2 1

64 WT

66 OR

65 BK

63 GY

282828

TECH. PUB.

OUTSIDE DISTR.

CHANGE RECORD

E.C. No. DATE

FILE NAME

870241S4 11-3-99

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS TOLERANCES BELOW APPLY EXCEPT FOR VENDOR DESIGNED PARTS AND ITEMS. PRODUCED TO RECOGNIZED STANDARDS.

FRACT.

INCH

DECIMAL-INCH

.0 ± .1

.00 ± .02

.000 ± .003

DO NOT SCALE DRAWING

PLOT DATE

ANGLES

± 3˚

METRIC

0. ± 1.0mm

0.0 ± 0.4mm

0.00 ± 0.1mm

A THERMADYNE Company

TROY, OHIO 45373 , U.S.A.

FINISH CODE PER

ACTIVITY

MATERIAL NO.

MATERIAL SPEC.

TITLE

DIAGRAM, CONNECTION & SCHEMATIC

DESCRIPTIVE DATA

HMC-410 (W/ ROBOTIC INTERFACE OPTIONS)

DESIGNED DRAWN DATE SCALE

CHECKED APPROVED RECORDS ITEM TYPE

ATC ATC 11-3-99

REPLACED BY REPLACES

QUANTITY-U.M.

DWG. NO.SIZE

130

DISTRIBUTION TABLE

NONE

SHEET

870241

COMM. CLS.

FULLATC DBB 11-3-99

Art # A-05058

A-9

HMC-410

APPENDIX 6: SYSTEM OUTLINE 1 OF 2

(OPTIONAL)

WITH 15' CABLE

REMOTE PENDANT

(OPTIONAL)

EXTENSION CABLE

170486-X REMOTE PENDANT

WORK TABLE

WELDING GUN

SHEETS AFFECTED

REVISION CHART

1570

ECN NO.REV DATE

A 8-14-97 1, 2

1/92

150

8/97

TECH. PUB.

COMM. CLS.

DWG DTD

1-16-92

DISTRIBUTION TABLE

NONE

OUTSIDE DISTR.

REPLACED BY REPLACES

QUANTITY-U.M.

ACTIVITY

MATERIAL NO.

FINISH CODE PER

PLOT DATE

FILE NAME

170921S1 8-14-97

UNLESS OTHERWISE SPECIFIED

DIMENSIONS ARE IN INCHES/MILLIMETERS

CHANGE RECORD

E.C. No. DATE

1) AA6822 5-3-95

FULLTLT DBB 8-14-97

TLT TLT 1-16-92

CHECKED APPROVED RECORDS ITEM TYPE

DESIGNED DRAWN DATE SCALE

OUTLINE, SYSTEM

HMC-410

DESCRIPTIVE DATA

TITLE

MATERIAL SPEC.

± 3˚

0.00 ± 0.1mm

0.0 ± 0.4mm

0. ± 1.0mm

ANGLES

.0 ± .1

.00 ± .02

DO NOT SCALE DRAWING

.000 ± .003

DECIMAL-INCH

FRACT.

INCH

TOLERANCES BELOW APPLY EXCEPT FOR

VENDOR DESIGNED PARTS AND ITEMS.

PRODUCED TO RECOGNIZED STANDARDS.

1 OF 2

Art # A-04475

SHEET

170921

123654

DWG. NO.SIZE

TROY, OHIO 45373, U.S.A.

A THERMADYNE Company

CONFIDENTIAL: This drawing, including all information

contained thereon, is the exclusive and confidential property of

Thermal Arc Corporation of Troy, Ohio 45373 . This drawing is

not to be copied, reproduced, delivered or disclosed to others,

in whole or in part, except with express written permission.

CONTROL PANEL

AUTOMATIC/SEMIAUTOMATIC

78 56 4 3 2 1

HMC-410

FRONT REAR

MTG.

BRACKETS

AUX

REM

FDR

170552-X POWER SOURCE

CONTROL CABLE (1 REQUIRED)

GAS SUPPLY

TO GAS VALVE

170487-X AUXILIARY

INTERFACE CABLE (OPTIONAL)

(1 REQUIRED)

170552-X FEEDHEAD

ASSEMBLY CONTROL CABLE

4 ROLL FEEDHEAD

ASSEMBLY (1 REQUIRED)

CABLES

WELDING

GUN SWITCH LEADS

POWER SOURCE

A-10

July 27, 2005

Tweco HMC-410 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

DCS Diagnostics When this switch selects a test number, that diagnostics 1 to 64 3+