HMC-410
AUTOMATIC &
SEMI-AUTOMATIC
CONTROL PANEL
Instruction Manual
V
ersion No: AA.02 Issue Date: July 27, 2005 Manual #: 430429-445
Operating Features:
120
VAC
50
60
888
Hz
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
Copyright 2005 by
Thermal Dynamics Corporation
All rights reserved.
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 #: ___________________________________
i
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.
July 27, 2005
9. Do not wrap cables around your body.
10.Ground the workpiece to a good electrical (earth)
ground.
1-1
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
1-2
July 27, 2005
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.
July 27, 2005
1-3
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.
July 27, 2005
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.
July 27, 2005
1-5
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.
July 27, 2005
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
toutes conditions 12
toutes conditions 12
épais plus de 400 amperès 14
Nuance de
filtre oculaire
July 27, 2005
1-7
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.
July 27, 2005
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.
July 27, 2005
1-9
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.
1-10
July 27, 2005
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
July 27, 2005
1-11
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
July 27, 2005
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.
July 27, 2005
2-1
HMC-410
2.04 Symbol Chart
Note that only some of these symbols will appear on your model.
On
Off
Dangerous Voltage
Increase/Decrease
Circuit Breaker
AC Auxiliary Power
Fuse
Amperage
Voltage
X
%
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
t1
Output Voltage Off.
Welding Gun
Purging Of Gas
Continuous Weld
Mode
Spot Weld Mode
Spot Time
t
Preflow Time
Postflow Time
t2
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
t
Disturbance In
Ground System
IPM
MPM
Inches Per Minute
Meters Per Minute
115V 15A
2-2
Receptacle RatingAuxiliary Power
Voltage Input
V
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.
4
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
July 27, 2005
2-3
HMC-410
p
y
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
July 27, 2005
HMC-410
July 27, 2005
Art # A-04356
Figure 2-1A: Semiautomatic Configuration
2-5
HMC-410
2-6
Art # A-04357
Figure 2-1B: Automatic Configuration
July 27, 2005
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.
July 27, 2005
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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2-9
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
.
2-10
Art # A-04358
Figure 2-2: Front Panel Controls
July 27, 2005
HMC-410
2.08 Rear Panel Connections
Refer to Figure 2-3 for details.
Remote Pendant
(See HMC-410 Accessories
And Option Descriptions)
37
38
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:
Pin
Assignment Function
39
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:
Pin
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 (-)
July 27, 2005
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).
2-11
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.
2-12
July 27, 2005
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