INSTRUCTIONS for DIGIPULSE AUTOMATIC MICROPROCESSOR CONTROL P/N FOR AUTOMATED MECHANIZED MIG WELDING. F A April, 1995 DIGIPULSE AUTOMATIC

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1 INSTRUCTIONS for F A April, 1995 DIGIPULSE AUTOMATIC MICROPROCESSOR CONTROL DIGIPULSE AUTOMATIC MICROPROCESSOR CONTROL P/N FOR AUTOMATED MECHANIZED MIG WELDING SPECIFICATIONS Input Power Required... 7 Amp., 115 vac, 1ph, 50/60 Hz Wire Feed Speed Range in/min ( m/min) Wire Sizes Preprogrammed in. (.7 mm),.030-in. (.76 mm),.035-in. (.9 mm),.045-in (1.2 mm) and.063 (1.6 mm) Wire type (mat.) Preprogrammed Carbon Steel, 2. Alternate Steel, Alum., Alum. 5. Stainless Steel, 6. Silicon Bronze, and 7. thru 10. reserved for custom applications Dimensions in. (394 mm) h, 13.0-in. (330 mm) w, 8-in. (200 mm) d Weight lbs (9.1 kg) These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for electric welding equipment, we urge you to read our booklet, Precautions and Safe Practices for Electric Welding and Cutting, Form Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on page 3 and 4 before installing or operating this equipment. Be sure this information reaches the operator. You can get extra copies through your supplier.

2 CONTACTS Specifications... 1 Safety Precautions... 3/4 Features/Benefits... 5 I. INSTALLATION... 5 A. Equipment Supplied... 5 B. Required Accessories... 5 C. Optional Accessories... 6 II. OPERATING INSTRUCTIONS... 7 A. Power Supply Welding Controls... Refer to F B. Digipulse Front Panel Control Functions... 9 C. Inside Panel Controls III. SETTING UP PROGRAM PARAMETERS A. General Welding Program Data B. Preliminary Power Supply Checks C. Program Control Parameters for Short/Spray Pulse Welding Process Modes (Includes Hot Start Adjustment Procedures) D. Programming Your Own Pulse Parameters in optional Teach Mode. Graphs 19) E. Custom Program Development Procedures (Includes Customer Development Chart IV. WELDING OPERATION A. Pulse/Spray/Short Arc Wire Speed Recommendations B. Welding Sequence for Teach Pulse or Spray or Short Arc Mode V. TROUBLESHOOTING VI. REPLACEMENT PARTS DATA Figure 1 - Digipulse Interconnection Diagram... 8 Figure 1A, OM-48 J-Governor Carriage Hookup... 9 Figure 2 - Front Panel Controls... 9 Figure 3 - Inside Panel Controls Figure 4 - Typical Time Parameter Set-up Figure 5 - Pulse Wave Description Figure 6 - Teach Set-up On Inside Panel Figure 7 - Typical Welding Conditions Sequence Per Schedule Figure 8 - Control Assy Figure 9 - Inside Control Panel Figure 10 - Inner Cabinet Components Figure 11 - Optional Plumbing Box Figure 12 - Schematic Diagram - Digipulse Automatic Figure 13 - Wiring Diagram - Sheet 1 of Figure 13A - Wiring Diagram - Sheet 2 of TABLES Table I. - Feed rolls, feed roll kit and outlet guides... 6 Table II. - Recommended Shielding Gases Table III. - Typical Short Arc Wire Speed Ranges Table IV. - Typical Spray Arc Wire Speed Ranges Table V. - Typical Pulse Arc Wire Speed Ranges

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5 FEATURES/BENEFITS The Digipulse Automatic is a unique, state-of-the-art pulse welding control that combines a microcomputer with inverter power technology to provide a welder friendly system for automatic mechanized mig welding operations. Matched with an EH-10A digital welding head, it can be directly interfaced with the J- Governor/OM-48 carriage and the mig plumbing box for use in fixture builder applications. The control stores four selectable mig welding schedules -- Short Arc, Spray Arc, Pulse Arc and optional Teach Pulse Arc that can save control setup time and improve productivity. By presetting three of your most common welding requirements --wire type, diameter and wire feed speed, the microcomputer automatically provides the correct arc length (for synergic operation) or arc voltage (for adaptive operation) for a stable welding condition. All you have to do is switch weldments and select the appropriate schedule for that particular job. Eight presettable welding condition parameters per schedule in sequence, including, Preflow, Strike, Start, Weld, Crater, Anti-Stick (Burnback), Postflow and Wire Retract. Total weld condition presettability means improved weld quality and production. The control is preprogrammed for six standard materials and five standard wire sizes and the computer calculates all other welding parameters to produce ultra-high quality performance and results. An optional field installed Teach mode is available and is used to develop a complete set of synergic pulsedmig parameters for any weldable alloy quickly and easily. Operate in the logic mode of your choice, Synergic or Adaptive. In the Synergic logic mode, the arc length changes with tip to work distance while frequency remains constant. Conversely, in the Adaptive logic mode, the arc length does not change with tip to work distance while frequency constantly varies. Other standard features include: - Sure Start Interlock...To assure troublefree starts, the control has an interlock circuit which will not allow wire feed to initiate unless the power supply contactor is closed and STRIKE voltage is present. - Presettable STRIKE Time...Assures safe consistent starts. If for any reason the Strike Time is exceeded (wire does not feed or misses the work) the control will automatically shut down and flash the preset STRIKE TIME in the VOLTS display window. - Arc Detector Circuit...Senses that both Welding Voltage and Amperage are present to facilitate transfer from Strike to Start condition parameters, and also provide a signal to initiate travel of a carriage or fixture. - Automatic Controlled Shutdown. To assure that all welding is performed only at the preset parameters, control will automatically shutdown in the rare event that either voltage or wire feed speed cannot be maintained during the welding sequence. The control will always sequence through a controlled shutdown including dynamic motor brake, anti-stick and postflow. Simultaneously, the cause is indicated by a flashing VOLTS or IPM display. 5 - Remote Control Capabilities...To provide easy interfacing with fixtures, the control incorporates remote Start/ Stop and Wire Inch Capabilities which can be controlled by switches or relays at a central control panel. - Single or Repeat Timed Weld Capabilities...Because the control incorporates a Repeat weld timer, adjustable up to 999 cycles (16.5 seconds), the Digipulse offers more than conventional continuous seam, or Single Times welding capabilities. It can also be preset for Repeat Timed skip or stitch welding applications. - Individual Digital Meters Provide Large 1/2-in. Display of Voltage And Wire Feed Speed IPM...After the arc is struck, the meters automatically transfer from preset to display of actual VOLTS and IPM for each welding condition as the control sequences through the preset welding sequence. - Arc Hours Readout...This unique feature provides a direct measure of productivity by accumulating and displaying, upon command, actual welding Arc Hours. - Automatic Adaptive Anti-Stick or Manual Burnback Time Feature...A patented adaptive anti-stick circuit automatically adjusts the same amount of wire burnback, regardless of wire size, speed or voltage. Or, you can manually preset a Burnback Time to specifically suit a specialized application. - Missweld Time...depending on the criticality of the weld, this feature allows you to preset the number of cycles of arc time that can reasonably be missed during a welding condition and still produce an acceptable weld. If more than the allowable number of arc cycles are missed, the unit will shutdown/abort and flash the preset Missweld Time cycles in the IPM display window. - Wire Retract Feature...Provides the ability to preset a Wire Retract time which will assure that the wire is well removed from the work area and not subject to possible postweld bending due to contact with the workpiece or fixture. - Independent Presettable Cold Wire Inch...To reduce down time for reloading welding wire, the cold wire Inch speed can be independently adjusted (up to 999 ipm) without affecting any of the other preset welding conditions. - Circuit Protection...Resettable circuit breaker for 115 VAC, 50 or 60 HZ input power minimizes down time and maintenance. - Unique Diagnostic Set-up/Test Circuit...Provides the ability to totally test the control electronics as well as run it through a complete timed sequence of preset weld conditions without actually welding. I. INSTALLATION A. EQUIPMENT SUPPLIED The following Digipulse Automatic control; 1. Digipulse Automatic Control P/N B. EQUIPMENT REQUIRED 1. One of the following three-phase Digipulse Inverter- Type Power Sources: a. Digipulse 450i cvcc for 230/460-volt, 60 Hz service P/N 31120, covered in booklet F b. Digipulse 450i cvcc for 575-volt, 60 Hz service P/N 31238, covered in booklets F and Supplement F

6 c. Digipulse 450i cvcc for 50 Hz. service P/N 31690, covered in booklets F and Supplement F EH-10A Digital Welding Head ( IPM). The welding head is composed of three basic units; a wire feed motortachometer unit, a gear reduction unit, and the accessory support assembly. This control is only usable with an EH- 10A Digital Welding Head, and either of two versions (following) are available for use. a. Two Roll Drive EH-10A Head - P/N This head provides wire feed speeds from IPM using a 40:1 gear reduction ratio, and a two-roll accessory support wire drive. The motor-tachometer power and control leads are provided by a pair of 52 inch long cables connected to a 5-pin amphenol. For further information refer to booklet L b. Four Roll Drive EH-10A Head - P/N This head is the same as P/N , except that it incorporates a four-roll accessory support wire drive assembly. For further information, refer to booklets F and F NOTE: If the motor direction is to be changed, interchange the blue and grey wires on the reversing relay terminals R-9 and R-7 respectively. 3. Feed Rolls. The 2-Roll Drive comes equipped with a pressure roll but NOT a feed roll. Select the proper feed roll from Table 1 for the wire size and type to be used. To convert the 2-Roll to 4-Roll Drive; order optional 4-Roll Drive Accessory Support, P/N , and the appropriate kit listed in Table 1. Table 1 Wire/Size Two Roll Drive Four Roll Drive Outlet in. (mm) Feed Roll Feed Roll Kit* Guide Soft.030 (.8) (U) (U) 29N13**.035 (.9) (U) (U) 29N13** 3/64 (1.2) (U) (U) 29N13** 1/16 (1.6) (U) (U) 29N13** Hard.023 (.6) (V) (c).030 (.8) (V) (V) (a).035 (.9) (V) (V) (a).045 (1.2) (V) (V) 39N15 (b).052 (1.4) (V) (V) 39N15 (b).063,1/16(1.6) (V) (V) 39N15 (b) Cored Hard.035 (.9) (Serr.) (a).045 (1.2) (Serr.) (Serr.) 39N15 (b).052 (1.4) (Serr.) (Serr.) 39N15 (b).063,1/16(1.6) (Serr.) (Serr.) 39N15 (b) U = U-groove, V = V-groove, Serr. = serrated (a) Includes replaceable sleeve (995651). (b) Includes replaceable sleeve (995692). (c) Requires guide bushing * Includes a center wire guide and 2 upper and 2 lower feed rolls. ** Requires outlet guide as follows: For.030/.035 wire use , For 3/64 wire use 05N57, For 1/16 wire use 12N57. Recommended U-Groove Pressure Roll be used. 4. Welding Torch. A mechanized mig welding torch having a rated capacity suitable for the welding application, such as ESAB: a. St-12 Water-Cooled Torch (for currents up to 700 amps) P/N 46V59, or-- b. ST-21M Water-Cooled Mechanized Torch (for currents up to 600 amps.) P/N , or-- c. MT-500M Air-Cooled Torch (for currents up to 500 amps) P/N Power Supply Control Cable (J1) Assembly. One of the following control cables is required to connect the Digipulse Control to the power supply as shown on Interconnection Diagram Fig. 1. Each assembly consists of a 19- conductor cable with a 19-pin amphenol plug on each end: 30-ft. long assembly, P/N 30780, 60-ft. long assembly, P/N Torch Voltage Pickup Lead (J6) Assy. (3-pin, 1/c), P/N Required to connect the control to the power lug on the torch (or the accessory support) to provide a positive arc voltage feedback to the control for reliable arc starting and arc stability. 7. Gas Regulation. Shielding gas regulator/flowmeter and fitted hose to bring gas from flowmeter to a plumbing box or connection block. R-5007 Regulator/Flowmeter, P/N Heavy-Duty Gas Hose, P/N (12-1/2-ft.), or P/N (25- ft.). Gas Hose Coupling, for connecting additional 5/8-18 (R.H.) hoses together, P/N 11N Water Cooling Requirements. When using a water cooled torch (ST-12 and ST-21M), the following are required to supply and drain the cooling water: Water Hose, 12-1/2 ft. P/N 40V76--or, Water Hose, 25-ft., P/N Water (In/Out) Adaptor (Connects 5/8-18 (L.H.) hose to 1/4 NPT), P/N 11N16. Water Hose Coupling (Connect 5/8-18 hose together), P/ N 11N18. C. OPTIONAL ACCESSORIES 1. Digipulse Automatic Teach Kit, P/N This fieldinstalled kit adds pulse-teach functions that allow the operator to set pulse height (PH), - width (PW), - frequency (PF) and - background current (PB) to a unique pulse-weld condition. One complete set of teach pulse functions can be developed and stored (in Material Codes 11 thru 15) for each of the following weld conditions; Strike, Start, Weld and Crater of any weldable alloy. The kit s installation instructions are covered in booklet F , and the operating instructions are covered in this booklet. 2. Digital D.C. Ammeter Kit, P/N This kit permits direct visual indication of welding current up to 999 amps d.c., and is available as a field installed option. The kit is designed for easy bolt-on/plug-in installation and consists of an LED Display P/C Board (P/N ), and Ammeter Control P/C Board (P/N ), and assorted mounting hardware--for installation refer to booklet F Plumbing Box Control Cable (J5) Assembly; 4-1/2-ft. long, P/N , or 25-ft P/N This cable provides connections to energize solenoid valves for gas shielding and water cooling (if connected) during the preflow, welding, and postflow cycles. It also provides an interlock to a pressure switch in the water line which will shutdown the control if the supply to a water-cooled torch is inadequate. The assembly is a 6-conductor cable with a 6-pin amphenol to self-lead wire connections. 6

7 4. Motor-Tachometer Extension Cable (J2) Assembly, P/ N This assembly allows you to extend the welding head location using a 25-ft., 6-conductor cable (1-conductor not used) with a 5-pin amphenol plug (which connects to the control's J2 receptacle) and a 5-pin amphenol receptacle (which connects to the EH-10's plug). 5. Remote Control Cable (J3) Assembly; 25-ft. long, P/N This assembly allows you to connect remote control functions (as shown on Fig. 1) such as Up/Down coldwire Inching, Welding Start-Stop, Weld Abort Output signal (to shutdown a carriage or fixture drive mechanism), Weld Current Detector signal (to initiate a carriage or fixture drive mechanism), and a Purge/Reset (to purge the shielding gas line of the torch, or to reset the welding sequence after an abort shutdown occurs). The cable assembly consists of a 25-ft., 12 conductor cable with a 14- pin male amphenol plug on one end and self-lead wire connections at the other end. 6. Reel/Spindle Support, P/N This support arm is utilized to mount either wire spools or coils. Will mount to any fixture or to the OM-48 carriage when the required support adaptor P/N is used. 7. Spindle Assy., P/N Mounts to Item 6 above and is used for 12-in. diam. spools. 8. H.D. Spoke-Type Wire Reel, P/N 19V89. Mounts to item 6 above and is used for 65 lb. coils. 9. Spool Enclosure Kit, P/N , covers and protects 12-in. spools from dust and moisture. 10.Wire Wiper. The wire wiper effectively cleans and lubricates the welding wire as it is being fed, thus providing smoother wire feeding and longer conduit life. A complete wiping assembly consists of a Felt Wiper (P/N , Pkg. of 10) and one of the Wiper Holders following: a. Wiper Holder, P/N , screws into the optional wire straightener. b. Wiper Holder, P/N , screws on to the accessory support's inlet wire guide. As shipped from the factory, the digipulse control is wired for air-cooled torch operation and this is provided by an insulated jumper splice connection between pins J5-E & - F of the control's plumbing Box receptacle J5. When water-cooled torch operation is to be used with the plumbing box, the jumper splice (between J5-E and -F) must be disconnected because these pin locations will be connected across the water pressure switch in the plumbing box. Also note that pressure switch is factory connected for normally- closed (N/C) operation, and must be reconnected for normally- open (N/O) operation as shown in Fig OM-48 Carriage/J-Governor Packages. The OM-48 is available in two different speed ranges, P/N 01E52 with a IPM travel speed range and P/N 01E54 with a 2-56 IPM speed range. Both packages include a solid state J-Governor for speed control. The Remote Control Cable, Item I-C-5 is required to connect the control to the J-Governor. Carriage track is not provided with the OM-48 packages but, is available in ten foot (10') lengths under P/N 38V16. An optional J-Governor digital travel speed meter P/N is available as a special customer order. Refer to Figure 1-A for OM-48/J-Gov. wiring hook-up. II. OPERATING INSTRUCTIONS Never, under any circumstances, operate the power supply with the cover removed. In addition to the safety hazard, improper cooling may cause damage to internal components. Keep side panels closed when unit is energized. Also make sure you are adequately protected before you start welding - welding helmet, gloves, eye and ear protection should always be worn. 11.WC-9 Coolant Recirculator, P/N (F ), is used for water cooled torch operation and is designed to be free standing in a convenient location near the torch. A four-gallon capacity tank provides psi, 115/230 volts, 50/60 Hertz, 1 phase input. Since the cooler is designed to run continuously during a welding operation, never connect it to a power supply or wire feeder that uses a solenoid controlled water supply that opens and closes with each operation of the welding contactor -- the cooling efficiency of the unit will be hampered and the starting winding in the pump motor may burn out. 12.Plumbing Box, P/N The plumbing box assembly contains the solenoid valves which provide shielding gas and cooling water control. It is also equipped with a pressure switch in the water line which (if connected) will shut down the welding operation when the water supply is inadequate. K The Plumbing Box Control Cable, Item I-C-3 is required to connect the control to the Plumbing Box. Refer to Figure 1 for Plumbing Box wiring hook-up. K Fig. 1A, OM-48/J-Gov. Carriage Hookup 7

8 NOTES: 1. Both output welding cable leads (torch and work) must be a minimum size of No. 4/0 welding cable (nothing smaller), and both leads should be kept as close to the same length as possible with neither lead exceeding 50-ft. in length. Also, both cables must be run next to each other and tywrapped every couple of feet to minimize cable reactance. 2. If wire feed runs backwards, reverse motor direction as follows: In the control, disconnect the blue wire (RLY-7) from T1-5 and connect it to T1-6; disconnect orange wire (RLY-9) from T1-6 and connect it to T As shipped from the factory, the Digipulse control is wired for air-cooled torch operation and this is provided by an insulated jumper splice connection between pins J5-E and -F of the control s plumbing box receptacle J5. When water-cooled torch operation is to be used with the plumbing box, the jumper splice (between J5-E and -F) must be disconnected because these pins will be connected across the water pressure switch in the plumbing box. Also note that the pressure switch is factory-connected for normally-closed (NC) operation, and must be reconnected for normally-open (NO) operation as shown above and in the schematic and detail wiring diagrams. Figure 1 - Interconnection Diagram 8

9 Do not allow metal-to-metal contact between the wire feeder chassis and a metal surface connected in any way to a welding ground. With such contact, a poor welding ground connection may create a difference in potential that sends part of the welding current through the safety ground wiring in the control cable and wire feeder, resulting in burnout of that wiring and/or damage to wire feeder circuitry. If the safety ground burns out, the operator may be exposed to 115V. shock hazard. A. POWER SUPPLY WELDING CONTROLS For detailed information regarding the power supply welding controls, refer to F B. DIGIPULSE FRONT PANEL CONTROL FUNCTIONS For location of front panel control features, refer to Figure 2 following: 1. Power Switch. Pulling-out the mushroom-style red button of this switch turns power on into the control as indicated 5a 5b 1 DIGIPULSE AUTOMATIC MICROPROCESSOR CONTROL Fig. 2 Front Panel Controls 6 5c (Ref) Key Lock by the illuminated display windows. To turn power off, simply push-in red button and the display windows and control will deenergize. NOTE: Immediately after the control is turned on a number will appear in the IPM window (e.g. 3) and another number will appear in the VOLTS window, and these numbers will only be displayed for 1-second. This information identifies the E- Prom program used in your control. The number shown in the VOLTS window will be in decimal form (e.g.,.1,.2,.3 etc.). 2. Gas Purge/Reset Rocker. A momentary on switch, this rocker provides a dual function when actuated. 9 a. Prior to starting the welding sequence, it actuates the gas solenoid and lets you purge the shielding gas line of the torch. At the same time, the IPM and VOLTS windows will also display the preset times (in cycles) for gas preflow and gas postflow respectively. b. After starting the welding sequence -- if an abort shutdown condition occurs (indicated by flashing digital display), the Purge/Reset rocker can be actuated and the control will automatically reset. 3. Inch-Up-Down Rocker. This switch is used to cold inch the wire, up or down, at a preset speed which is programmed from the inside control panel (see II-C-4). IMPORTANT: Cold inching is only possible when the weld Start-Stop rocker switch is in its stop (or off) position. 4. Start-Stop Rocker. This two position (no neutral) switch initiates the welding sequence when placed in its START position; and, depending on the type of welding -- Continuous Seam or Timed, terminates the welding sequence in its STOP position as follows. a. Continuous Seam welding applications. The stop signal does not immediately terminate the welding sequence, it only terminates the weld condition parameter. The sequence then transfers to the remaining condition parameters (crater fill, burnback, postflow/retract). b. Single or Repeat Timed welding applications. Although the stop signal is not normally used for timed-welds, you may wish to prematurely terminate a burn thru or unstable weld condition. When the stop is used; all welding action (including crater-fill) will terminate, except burnback and postflow/retract. 5. Digital Readout Windows. Three individual 3- digit windows labeled AMPS (optional ammeter), IPM and VOLTS are provided to display actual welding current, preset or actual welding parameters (wire feed speed and welding voltage) and time parameters as follows: a. AMP Digital Readout. This window is normally blank unless the optional Ammeter Kit is provided to monitor actual welding current. When installed, the window displays d.c. current (AMPS) in a range from amperes in one amp increments. b. IPM Digital Readout. This window is primarily used to display wire feed sped (IPM) for each of the four welding conditions (Strike, Start, Weld, and Crater) during a typical welding sequence. Depending on the position of the inside condition selector switch functionally defined in II-C, the IPM window displays actual and/or preset wire feed speed in a range from 20 to 999 inchesper-minute, in one-inch increments, for each weld condition in the program sequence. With power turned ON, but not welding, the IPM window will continuously read the Preset wire speed setting. When the arc is struck, the IPM window will then continuously read the Actual welding wire speed as the weld conditions cycle thru the welding sequence. In addition to the above, and using the Condition and Time/ Wire Dia.-Material selector controls on the inner panel func-

10 a 5b Figure 3 - Inside Panel Controls tionally defined in II-C, this window can also display the following programmed times: - PREFLOW. Shielding gas time from 0 to 999 cycles (16.5 sec.) in one cycle increments (60 cycles per second). - START TIME. Start time duration is factory preset at 6 cycles, and can be increased up to 999 cycles, in one cycle increments. - WELD TIME. Weld condition duration for timed-welding (must be set to zero for Continuous-Seam Welding), from 1 to 999 cycles, in one cycle increments. - CRATER TIME. Crater fill duration, from 1 to 999 cycles, in one cycle increments. - MISSWELD TIME. Presets the number of cycles of arc time that can reasonably be missed (from 1 to 999 cycles) during the WELD condition and still produce an acceptable weld. If the number of missed cycles match the preset cycles, the unit will abort. Since the number of missed cycles to be preset is based upon many variables, the required setting for a given application obviously involved good judgment and technique. As an example, to set up a critical 45 cycle spot weld, you might want to preset no more than 5 cycles of missweld arc time. Be careful not to make the missweld time to short, otherwise nuisance aborts will occur. If this feature is not desired, preset the time for zero cycles. - INCH. Cold wire inch sped from 50 to 999 inches-perminute, in one inch increments. - a code number indicates a type of MATERIAL which is programmed for various welding wire applications, as follows: code #1 indicates Carbon Steel, #2 is Alternate Steel, #3 is 4043 Aluminum, #4 is 5356 Aluminum, #5 is 308 Stainless, #6 is Silicon Bronze. (Additional Material code numbers 7 thru 10, are reserved for custom applications.) - if provided, Ph indicates PULSE HEIGHT which is displayed as a reference voltage setting, from 0.1 to 10 (in 0.1 volt increments), that controls or establishes the amplitude of the pulse peak (in teach option only). - if provided, Pb indicates PULSE BACKGROUND which is displayed as a reference current setting, from 15 to 100 (in one ampere increments), that establishes the approximate background current in pulse applications (in teach option only). c. Volts Digital Readout. In a typical weld sequence, with power on but not welding, this window will selectively display an arbitrary number (100) that represents a programmed arc length in the synergic mode*, or a computed arc voltage in the adaptive mode* for each of the four welding conditions (Strike, Start, Weld, and Crater). When the arc is struck, the VOLTS window will continuously display actual welding voltage in a range from 12 to 50 vdc in one-tenth (0.1) volt increments. * In the synergic mode, the control will automatically select and display an appropriate arc length integer for a given wire type, size, feed rate and gas shielding. An arbitrary number, represented by the integer 100, is the normalized value for all applications programmed in the control, and this figure will be displayed in the VOLTS window during setup (not welding). This value 100) can be readjusted, within a range from 0 to 200, to fine-tune the operating arc length of the selected welding condition. By reducing the number below 100 (minimum 0), you will reduce the arc length. Conversely, by increasing this value above 100 (maximum 200) you can increase the arc length. After the arc is struck, the number will be replaced by the actual welding arc voltage. The Digipulse can also operate in the adaptive mode, where the arc is continuously monitored by a closed loop feedback circuit and the machine modulates 10

11 its output to maintain a given voltage for preprogrammed data. In the adaptive mode, a computed arc voltage (unique to your preprogrammed welding selection) will be displayed in the VOLTS window before welding. Once the arc is struck, the control will measure the actual welding voltage and change the output of the power supply to maintain the precalculated voltage setting. In this manner, the power supply automatically compensates for variations in stickout or weld joint geometry. Further, all of the precalculated arc voltages programmed in the control can be readjusted +/- 10 volts to fine-tune the welding arc. In addition to the above, and using the inside Condition and Time/Wire Dia.-Material selector controls (functionally defined in II-C), this window can also display the following programmed times. - POSTFLOW. Controls time for gas postflow after the arc extinguishes form 0 to 999 cycles. - STRIKE TIME. Preset time period allowed, for the wire to come down and hit the plate during the Strike Condition. If the wire does not strike the plate within the allowed time period, the control will automatically shutdown, and flash the strike time in the VOLTS display window. Simultaneously, it also provides an abort output signal to stop carriage or fixture travel. Time range is factory preset for a minimum of 20 cycles and can be increased in one cycle increments. The strike time setting is dependent upon the strike IPM setting. The lower the speed, the longer the strike time needs to be, otherwise nuisance shutdowns will occur. - BURNBACK TIME. Manually adjustable burnback time period which when preset will over-ride the automatic adaptive anti-stick feature. This time period can be set in one cycle increments. When set to zero, the Automatic Adaptive Anti-Stick feature will be operational. - REPEAT TIME (or Pause Time). Time period preset between timed- welds from 1 to 999 cycles, in one cycle increments. - RETRACT TIME. After the postflow cycle, the wire feed motor will reverse for automatic wire retract for a preset time period. A setting of 10 to 30 cycles is recommended to prevent excessive withdrawal of the wire into the contact tip. If a normal stop is desired, preset this time for zero cycles. - ARC HOURS. Selectable display (record) of accumulative welding time in one tenth of an hour increments. After 99.9 hours it will automatically return to zero. - a pair of numbers represent WIRE DIA. sizes which are programmed for selection as follows: #23 represents.023'' dia., and #30 is.030'' dia.; #35 is.035'' dia., #45 is.045'' dia. hard (3/64'' dia. soft) and #63 is.063'' (1/16'') dia. - if provided, Pw indicates PULSE WIDTH which is displayed as a reference time setting, from 1.0 to 10 (in one-tenth millisecond increments), that measures or establishes the width of pulse duration (in teach option only). - if provided, Pf indicates PULSE FREQUENCY which is displayed as a frequency (Hertz) reference setting, from 25 to 909* pulse cycles per second, that establishes the approximate pulse frequency required for the wire feed speed set on the control (in teach option only). * Please note that the maximum Pulse Frequency is dependent on the pulse width - the narrower the width, the higher the maximum frequency; and the wider the width, the lower the maximum frequency. 6. Welding Condition (LED) Lights. These lights are labeled START, WELD, and CRATER, and they energize individually as the welding program sequences through each of these weld conditions. Prior to the Start, and after the Crater Conditions, none of these lights will be on. 7. Reset Circuit Breaker. A seven (7) ampere circuit breaker provides protection to the 115 volt control circuit and the wire feed motor. If an overload occurs, the breaker will trip and suspend all operation. To restore service, simply depress the breaker button on the front panel. C. INSIDE PANEL CONTROLS For location of inside panel controls, see. Fig Short (arc), Spray (arc), Pulse, optional Teach Mode Schedule Selector. This four-position rotary switch allows you to select the welding process mode you wish to use-- non-pulsed mig Short or Spray Arc, or Pulsed mig spray arc, and/or Teach mode (with teach option only) for selfdeveloped Synergic Pulsed mig spray arc applications. In the Short, Spray, or Pulse schedule modes, the operator must code the control to select any one of the preprogrammed welding wire Materials and wire Diameters, and then set the desired wire feed speed (IPM) for each of the four weld conditions (Strike, Start, Weld, and Crater) required for the weldment--the control automatically provides the computed arc voltage parameters to produce the necessary output for the process/conditions selected. The optional Teach schedule mode is used in conjunction with the Teach Pulse Parameter switch (item C-7), and it allows the operator to develop and store one complete set of customized pulsed-mig parameters. These parameters include a wire feed speed (ipm) and a Pulse Frequency (PF) setting for each of the four weld conditions (Strike, Start, Weld, and Crater) needed. The remaining teach parameters that must be programmed include a Pulse Background (PB) a Pulse Height (PH) and a Pulse Width (PW), and these parameters are common to all four conditions. The set-up procedure for using the teach mode is more fully described in Section III-D of this booklet. 2. Condition Selector. This six-position rotary switch is used to select two sets of parameters, Welding and Timing for each of the available welding schedules (Short Arc, Spray Arc, Pulse, or Teach). a. Welding Parameters. The selector's primary function, when used with the appropriate Inc./Dec. toggle, allows you to preset and display (see II-B-5-b & c) the wire feed speed (IPM) and computed arc voltage (VOLTS) weld parameters for its first-four positions labeled -- 11

12 STRIKE, START, WELD, and CRATER. The fifth position of this selector has no label, but is the required position used for presetting the Missweld and Retract Time features. The sixth position of this selector, labeled RUN, is the normal operating setting used after the control is fully programmed and ready for use. The IPM and VOLTS parameters, for each of the following welding conditions, are preset or adjusted using the INC./ DEC. toggle located directly below their respective digital window displays. - STRIKE. This condition sets the desired approach speed of the wire before striking the workpiece, and displays the computed voltage needed to control the short-circuit current for arc initiation. - START. This condition can be used to set an appropriate wire speed and display the computed voltage parameter to create a hot-start to help stabilize the arc (for its preset time) prior to the weld cycle. - WELD. This condition sets the desired wire speed and displays the computed arc voltage used during the actual weld cycle. - CRATER. This condition allows you to set a higher or lower weld speed and/or displayed computed arc voltage (for a preset time period), depending on the welding condition needed, to regulate the weld termination size or crater-fill appearance at the end of the weld. In all Process modes (Short, Spray, or Pulse) except Teach, the microprocessor automatically provides the correct arc voltage (in the adaptive mode) or arc length/frequency (in synergic mode) for each welding combination -- for additional information regarding the Adaptive versus Synergic modes of operation, refer to Section II-C-4. b. Time Parameters. The secondary function of this selector is to setup the Time parameters, located within the charts adjacent to each of the weld conditions. These times are preset by using the Times/Wire Dia.-Material selector (following). 3. Times-Wire Dia./Material Selector. This two-position, momentary on, toggle must be actuated in order to preset or change the following parameters, or welding setups: a. Access the Time Functions. This position actuates the timed-parameters for the sequences shown in the chart beneath each digital display window. These sequences are preselected by positioning the Condition Selector to the pair of time-parameters to be programmed from its Strike, Start, Weld, and Crater settings. To check or observe the time settings, actuate the TIMES (up) position; and to set or change the settings, simultaneously operate the INC./DEC. toggle switch directly below the parameter (chart) being set -- the time setting in cycles will appear in its digital display. The timed- parameters which can be programmed in each display window are shown in Fig. 3, and were previously described in Section II-B-5- b (IPM window) and Section II-B-5-c (VOLTS window). b. Access the WIRE DIA/MATERIAL mode (down position) to select one of the welding conditions preprogrammed into the control, as follows: NOTE: To select the type of wire MATERIAL, actuate the INC position of the Inc/Dec switch below the IPM window (while holding the Wire Dia/Mat'l key down) until the desired code number for your material selection appears in the IPM window, and these material codes follow: #1 is carbon steel, #2 is alternate steel, #3 is 4043 aluminum, #4 is 5356 aluminum, #5 is 308 stainless, #6 is silicon bronze. (Additional Material codes 7 thru 10, are reserved for custom applications.) Now select the Wire DIA. size to be used, by actuating the INC position of the Inc/Dec switch below the VOLTS window (while holding the Wire Dia/Mat'l key down) until the desired pair of numbers for your wire size selection appears in the VOLTS window, and these wire diameter numbers follow: #23 is.023" dia., #30 is.030" dia., #35 is.035" dia., #45 is.045" dia. hard (3/64" dia. soft), and #63 is.063" (1/16" dia.). Accessing the WIRE DIA/MAT'L selector key during an actual weld, allows you to check the factory- preset numbers that determine the quality of starts (hot, cold, etc.) for your preset welding condition. These numbers are preset to provide optimum starting characteristics required for most welding applications. This is a diagnostic tool available to the experienced operator or serviceman and need not be activated during a normal operation unless you are experiencing weld starting problems, or weld condition (speed and/ or voltage) aborting problems. It must also be noted that only the speed (IPM) condition can be checked when a unit is operating in the synergic mode (the VOLTS window will always displayed the number 100 and cannot be adjusted; however, in the adaptive mode both speed and voltage conditions can be checked and adjusted. The factory-set starting condition is represented by numbers that are displayed, on command, in the digital IPM and VOLTS windows. For good welds and starts, these numbers should be in a range from 105 to 115 (with 110 being the norm) in the IPM window (synergic and adaptive mode), and from 90 to 100 (with 95 being the norm) in the VOLTS window (adaptive mode only). If your weld starts are not acceptable, please refer Section III-C-10-b for a simple adjustment procedure that will enhance good starting. 4. Synergic-Adaptive-Inch Preset/Arc Hours Selector. This switch provides three essential functions; depending on the toggle-positions selected as follows: a. The toggle-down location is a momentary on position for checking or presetting a cold-wire INCH parameter ( ipm), or to monitor and reset the accumulated ARC HOURS (welding) time. These features are only functional when the control is in its non-welding mode. To check or monitor this data, you must place the Con- 12

13 dition selector switch in its RUN setting and toggle-down the Inch Preset/A.H. function--the data will be displayed in the IPM and VOLTS windows respectively. To set or zero the data, place the Condition selector in its RUN setting & actuate the Inch Preset/A.H. position while simultaneously operating the Inc./Dec. switch below the function being adjusted--this data will be displayed in the appropriate IPM and/or VOLTS window. b. The toggle-center location is a maintained ON position for operating the control in the ADAPTIVE* logic mode. The Adaptive logic utilizes a closed loop feedback system that continuously modifies the output to maintain a constant arc voltage. The adaptive operation works as follows: Pulse Arc Welding: Adaptive welding is a synergic relationship programmed into the weld control which will calculate and display the proper arc voltage for a given wire feed speed and material setting (see graph). As the wire feed speed increases the control will automatically increase the pulse frequency to maintain the arc voltage set in the control VOLTS window. Changes in tip to work will not affect arc length. Spray Arc and Short Arc: In this mode the machine will control the power supply to maintain the arc voltage set-up in the volts window of the control. Changes in tip to work will not change arc length. The voltage can be preset before welding and changed during welding to obtain a stable welding condition based on the wire feed speed used. If the wire feed speed is changed then the program will calculate the new voltage necessary to maintain a stable arc. c. The toggle-up location is a maintained ON position for operating the control in the SYNERGIC* logic mode. The Synergic program logic provides the weld process modes with fixed operating parameters that follow preprogrammed relationships. The synergic operation works as follows: Arc Length Will Not Change with Tip to Work Distance Frequency Changes with Tip to Work Distance Pulse Arc Welding: Synergic welding is a relationship of pulse frequency and wire feed speed (see graph) programmed into the weld control. As the wire feed speed increases the control will automatically increase the pulse frequency to maintain stable weld performance. Changes in welding current (heat) can be completed by increasing or decreasing the IPM switch without readjusting voltage. Changes in tip to work will affect arc length. Spray Arc and Short Arc: In this mode the machine will operate like a conventional welder where an arc Arc Volts Wire Feed (ipm) voltage is set-up by the weld control program and changes in tip to work will effect arc length. The voltage can be read during welding and increased accordingly to obtain a stable welding condition based on the wire feed speed used. If the wire feed speed is changed, the program will calculate the new voltage necessary to maintain a stable arc. * Please note that either type of logic (adaptive or synergic) can be used in the preprogrammed material codes; however, only the synergic logic can be used in the optional Teach process mode. 5. Inc/Dec Toggle Switches. These two control toggles are used to preset or change the individual welding Condition parameters required for the selected Process mode (Short, Spray, Pulse, and Teach). The switches are spring loaded, center-return toggles which must be operated (Inc or Dec) to actuate their indicated functions as follows: Arc Length Will Change with Tip to Work Distance Frequency Does Not Change with Tip to Work Distance Pulse Frequency or Arc Volts (Spray/Short) Wire Feed (ipm) a. IPM-TIME Increase/Decrease Control. This toggle switch is used to set and/or vary wire feed speed (IPM) for the required weld conditions (Strike, Start, Weld & Crater), and also the following: Material-type, Preflow (time), Start Time, Weld Time, Crater Time, Missweld Time and Inch Preset (ipm), and Pulse Height (PH) and Pulse Background (PB) in the optional teach mode. By setting and/or operating the appropriate Control Selectors (see C-2 and -3 above), each parameter setting will be displayed in the digital window directly above this toggle. b. VOLTS-TIME Increase/Decrease Control. This toggle switch is used to set and/or vary the arc voltage* (VOLTS), for the required weld condition (Strike, Start, Weld & Crater), and also the following: Wire Diameter, Postflow (time), Strike Time, Burnback Time, Repeat Time, Retract Time and to zero (dec.) the Arc Hour accumulation, and Pulse Width (PW) and Pulse Frequency (PF) in the teach mode. By setting and/or operating the appropriate Control Selector (see C- 2 and -3, above), each parameter setting will be displayed in the digital window directly above this toggle. * Please note that the term VOLTAGE denotes arc voltage (in the adaptive mode) and/or arc length (in the synergic mode) and is the computed value that has been precalculated for each of the combinations programmed into the control. And further, any of these computed voltages can be altered (+/- 5 volts in the adaptive mode; and +/- 50 numerals from its midrange value of 100 in the synergic mode) to fine tune each welding condition (Strike, Start, Weld, & Crater). 13

14 However, when a condition (e.g.: the Strike Condition) is altered, the computed value is altered for all other precalculated wire size/type combinations available in that condition--the computed values for the remaining conditions (Start, Weld, Crater) are not affected unless they also are altered. Therefore, when you plan to use a new combination (a different wire size and/or type), it is suggested that the control be reset to provide the correct computed value for the new program combination as follows: Adaptive Mode. To reset the computed arc voltage value for a given wire size and type, make sure the control's Power switch is on and the unit is not in a welding mode, then decrease the arc voltage key until the number in the VOLTS window stops. This number is 5 volts below the computed or midrange value. To establish the computed value, add 5 (volts) to the displayed number using the increase (INC) portion of the Volts Inc./Dec. key. Synergic Mode. Resetting the computed value in this mode is much simpler--remember that the computed or midrange value is the arbitrary numeral 100 (this number represents a precalculated arc length/frequency based on the wire feed speed of the programmed wire size and type). Therefore, if the number appearing in the VOLTS display window is any numeral between 50 and 150 (other than 100) simply use the appropriate Inc./Dec. key to reset the condition to the numeral Amp Test-Weld Switch. This two-position toggle switch provides the following functions: a. The WELD position is the normal and required setting for all schedule welding operations. b. The AMP TEST position is only used to provide a convenient way of test-sequencing all of the program parameters to either diagnose a problem, or to demonstrate the control without actually striking a welding arc. The test can be set up with the control operated in any of its preprogrammed schedule modes (Short, Spray or Pulse) that have a complete set of actual welding parameters preset, except for the Missweld time which must be set to zero --otherwise an abort will occur. With this accomplished, make sure that the welding wire is clear of the workpiece/weldment and then open up the accessory support (on the welding head) to release pressure on the wire feed roll. Now place the Start-Stop rocker switch (on the front panel) to its START position, and the control will sequence thru the programmed Preflow-time and enter the Strike condition--remember that open-circuit or welding voltage is present on the welding wire during the test sequence. Make sure that the Strike Time is set long enough to give you ample time to operate the Amp test toggle (a setting of 200 cycles is recommended for the Strike time). During the Strike condition; you must actuate the Amps toggle to its TEST position, to simulate closure of the arc/current detection circuitry that verifies the arc has initiated. This action automatically allows you to enter the timed Start condition, and the subsequent Weld, Crater, etc., conditions to evaluate and/or demonstrate the welding sequence. 7. Teach Pulse Parameter Selector PH, PW, PB, PF (in teach kit only). This momentary two-position switch is only operative when the process (Short/Spray/Pulse/Teach) control selector is placed in the Teach mode position (see Item II-C-1). When the Teach Parameter switch is actuated, it allows you to program one complete set of customized (self-developed) pulsed- spray arc mig parameters. The subsequent teach parameter settings for Pulse Height (PH) and Pulse Background (PB) are displayed in the IPM window (and described in Section II-B-5-b); and Pulse width (PW) and Pulse Frequency (PF) are displayed in the VOLTS window (previously described in Section II- B-5-C). Please note that a Pulse Frequency (PF) parameter must be programmed for each wire feed speed (ipm) setting selected for use in each of the four welding conditions (Strike, Start, Weld, and Crater). The remaining teach parameters PH, PB, and PW are common to all four weld conditions, and therefore only need to be programmed once (for example, in the Strike mode). The set-up procedure for the teach mode is fully covered in Section III-D. III. SETTING UP PROGRAM PARAMETERS A. GENERAL WELDING PROGRAM DATA Four sets of welding (schedule) mode parameters can be preset in the Digipulse control: one each for the standard SHORT arc, standard SPRAY arc and one for the PULSE (spray) arc schedule modes using any one of the preprogrammed wire material/diameters parameters; and one for the optional Teach (pulse) schedule mode, which incorporates the customer's self- developed pulsed welding parameters. Because of the distinct differences between the preprogrammed welding parameters (for the Short/Spray/ Pulse schedule modes) and the self- developed welding parameters (for the pulsed Teach schedule mode), the specific set-up procedures for Short/Spray/Pulse control parameters are covered in Section C, and the optional Teach control parameters in Section D following. Since proper gas shielding is extremely important in conventional and pulsed welding applications, we have also provided a list of recommended shielding gases (Table II-following) suggested for use with the wire material preprogrammed in this control--however, you may find other combinations that are equally successful. B. PRELIMINARY POWER SUPPLY CHECKS Before programming the control, make sure that the power supply is properly set-up as follows: - Check the rear panel of the power supply to make sure that only the Digipulse control cable is connected. The remaining stick control receptacle/cable must be disconnected. - Depending on the welding process mode programmed on the control, set the power supply INDUCTOR control pot as follows: 14

15 Table II Recommended Shielding Gas Wire Material Welding Arc Mode Code # Type Short Arc Spray Arc Pulse Arc 1 Carbon Steel CO 2 /C25 C-5/C- 8 C- 5 2 Alternate Stl. C-25 Stargon/C-8 Stargon/C Aluminum - Argon Argon Aluminum - Argon Argon Stainless A1025 1%/2%O 2 Pulse SS 6 Silicon Bronze - Argon Argon 7* 8* 9* 10* * These codes are reserved for custom applications. For SHORT ARC mode, set 12 O'clock position and adjust for best performance when welding. For PULSE and SPRAY ARC and TEACH modes set MINIMUM. C. PROGRAM CONTROL PARAMETERS FOR SHORT/ SPRAY/PULSE WELDING PROCESS MODES The following procedures represent a typical example of how to set up one of the many preprogrammed welding material conditions available in this control, and that these procedures can be used in each schedule mode--short, Spray, and Pulse. The only difference(s) between each schedule mode will, or may, be the Wire Material and/or Wire Diameter used, the IPM wire feed speed setting for each weld condition (Strike, Start, Weld and Crater), the pair of Time parameters for each weld condition, and the shielding gas used--the control automatically provides the required arc voltage for each weld condition, and even this parameter (voltage) can be fine-tuned as described following. 1. Pull the POWER switch button to its out position to energize the control for programming. 2. On the inside panel, set the SHORT-SPRAY-PULSE mode selector switch to the process you wish to preset. 3. Make sure the inside Amp Test toggled switch is in its WELD position. 4. Select the type of Wire Material and Wire Diameter to be used as follows. Depress and hold the WIRE DIA./MATE- RIAL toggle switch in its down position and simultaneously preset each of the following: a. Set the STRIKE wire feed speed (IPM) by operating the left Inc./Dec. toggle until the desired setting appears in the IPM display window. Notice that this parameter setting will start at zero and immediately jump to 20 and then rapidly increase (1 ipm at a time) until the desired setting is reached. If you overshoot the planned setting, simply bump the DEC position of the left toggle to obtain the exact IPM setting. b. As mentioned previously, after the welding condition in items 4 and 5-a (above) have been preset, the microcomputer automatically sets a preprogrammed arc voltage (in the adaptive mode) or arc length/frequency (in the synergic mode) for the STRIKE condition will be displayed in the VOLTS window. If this precalculated value (voltage or frequency) does not provide a stable condition it can be fine-tuned by using the right Inc./ Dec. toggle switch--as described in Section II-C-5-b. If the existing welding condition is altered (fine tuned), it is suggested that each time a new wire size/type is used that you reset the control to set up the original computed (mid-range) arc voltage/frequency values as described in Section II-C-5-b. c. Leave the rotary selector in the STRIKE position to set the PREFLOW and POSTFLOW time parameters (as shown in Fig. 4). Actuate the Times-Wire Dia./Mat. toggle switch to its TIMES (cycle) position, and observe that the existing numbers shown in the IPM and VOLTS windows will change--the new parameters being the pair of time functions in the chart(s) adjacent to the selected condition (in this case, the pre- and postflow data). To reset or change these Time parameters (see Fig. 4); actuate and hold the TIMES toggle position, while simultaneously operating the appropriate INC./DEC. toggle switch below each of the time parameters being set. The preset time intervals will be displayed in their respective IPM and VOLTS digital windows. 6. Reposition the rotary Condition selector to the START position and program the following: a. Set the START wire feed speed (IPM) using the same procedure outlined in III-C-5-a. b. The subsequent arc voltage or arc length/frequency for the START condition will be set as outlined in III-C- 5-b. a. Operate (increase or decrease) the left Inc./Dec. toggle switch (beneath the IPM window) until the desired MA- TERIAL numeral (1-carbon steel, 2-alternate steel, aluminum, aluminum, 5-stainless steel, 6-silicon bronze) appears in the IPM display window. b. Now, operate (increase or decrease) the right Inc./ Dec. toggle switch until the desired WIRE DIA. numeral (#23 for.023", #30 for.030" dia., #35 for.035" dia., #45 for.045" dia., or #63 for.063" dia.) appears in the VOLTS display window. 5. Place the rotary Condition selector to the STRIKE position and program the following: Figure 4, Typical Time Parameter Set Up 15

16 c. Leave the rotary selector in the START position and set the START TIME and STRIKE TIME parameters using the procedures outlined in III-C-5-c. 7. Reposition the rotary Condition selector to the WELD position and program the following: a. Set the WELD wire feed speed (IPM) using the same procedure outlined in III-C-5-a. b. The subsequent arc voltage or arc length/frequency for the WELD condition will be set as outlined in III-C-5- b. c. Leave the rotary selector in the WELD position and set the WELD TIME and BURNBACK TIME parameters using the procedures outlined in III-C-5-c, and also the following: (1) WELD TIME setting requirements for: (a) Continuous Seam Welding--set time to zero. (b) Single Time Weld without carriage travel (customer must deenergize the arc detection output signal)--set time from 1 up to 999 cycles. (c) Single Time Weld with carriage travel (the Arc Detector Circuit provides a signal to initiate travel of a carriage, or fixture)--set time from 1 up to 999 cycles. (d) Repeat Timed Weld (same as c) except that the elapsed time between welds is preset in the RE- PEAT TIME PARAMETERS. (2) BURNBACK TIME setting requirements: (a) If automatic adaptive anti-stick is desired--set time to zero. (b) If manual burnback (anti-stick) is needed--set time required from 1 cycle on up. 8. Reposition the rotary Condition selector to the CRATER position and program the following: a. Set the CRATER wire feed speed (IPM) using the same procedures outlined in III-C-5-a. b. The subsequent arc voltage or arc length/frequency for the CRATER condition will be set as outlined in III- C-5-b. c. Leave the rotary selector in the CRATER position and set the CRATER TIME and REPEAT TIME parameters using the procedures outlined in III-C-5-c. If the Weld and Crater conditions are both Timed ; simply preset the appropriate time desired for each condition - 1 up to 999 cycles for Weld, and 1 up to 999 cycles for Crater. If the Weld condition is a Continuous Seam weld, the CRATER condition can either be Timed or skipped completely. If Crater Fill is desired; enter from 1 to 999 cycle in the Crater Time parameter. If Crater fill is not desired; simply enter zero in the Crater Time parameter, and this sequence will be skipped after the STOP switch terminates the Weld condition sequence. Repeat Time--if repeat timed weld are not used, set this time to zero. If repeat welds are desired, the cycles set will control the elapsed time between the Timed weld parameters. 9. Reposition the rotary Condition selector to the blank position, and program the following: a. Set the MISSWELD TIME and RETRACT TIME parameters using the procedures outlined in III-C-5-c. The Missweld time cycle only monitors the WELD Condition. If not desired, set Missweld Time to zero. 10.Reposition the rotary Condition selector to the RUN position to perform the following operations: a. To check or preset a cold-wire INCH parameter (50-999ipm), or to monitor or zero the accumulated ARC HOURS (welding) time. (These features are only functional in a non-welding mode.) To check or monitor this data, you must place the Condition Selector switch in its RUN setting and actuating the Inch Preset/Arc Hrs. switch position*--the data will be displayed in the IPM and VOLTS windows respectively. To set or zero the data, place the Condition Selector in its RUN setting and actuate the Inch Preset/Arc Hrs. switch position* while simultaneously operating the Inc/Dec switch below the function being adjusted--this data will be displayed in the appropriate IPM and/or VOLTS window. * This momentary switch position (Arc Hrs/Inch Preset) is part of the SYNERGIC-ADAPTIVE-ARC HRS/INCH PRESET switch (covered in Section II-C-4). After the control is fully programmed, the operator must set either the SYNERGIC or ADAPTIVE position to determine the program logic that the control will utilize for the programmed schedule sequence. In the synergic mode, the control selects an appropriate arc length, based on weld mode (short, pulse or spray), for a given wire type, size and feed rate. The pulse frequency in pulse mode remains constant regardless of torch manipulation. This pulse logic offers many advantages to the welder particularly where joint geometry cause rapid changes in torch stickout resulting in unstable puddle conditions. In the adaptive mode, the control varies the frequency during pulse welding to maintain a constant arc voltage regardless of changes in torch stickout or angle. This logic is very useful where joint geometry is clean. b. The RUN position is the normal operating setting used when the control is fully programmed and ready to be weld- tested, and if necessary readjusted. If your weld starts are not acceptable, refer to the following Hot Start adjustment procedures that will enhance starting. Hot Start Adjustment Procedures As mentioned earlier in the italicized Note following Section II-C-3-b, the control is preset at the factory to provide the optimum starting characteristic for most welding conditions. However, due to factors such as inaccurate parameters (for a given wire type and size), welding technique, shielding gas, or wire feed speed, you may have to readjust the factory-set starting characteristics to provide the best arc starts possible. To do this, it is necessary to readjust the factory-set calibrations to provide a hot start characteristic in which the initial starting voltage (open- circuit voltage) will be slightly higher than ac- 16

17 tual welding voltage (arc voltage) and speed which initially is somewhat lower than the selected wire feed speed desired. To set-up the control to provide this, do the following: Program the welding condition you need in the IPM (wire feed speed) and VOLTS( arc voltage) windows, and fine-tune these parameters until you have the welding arc desired. Do not at this point concern yourself with the arc starts, this follows. If after the welding condition is fine-tuned you find that the arc starts are unsatisfactory, proceed as follows: (1) During an actual weld, actuate and hold the Wire Dia/ Mat'l. key position and observe the numbers displayed in the IPM and VOLTS windows. Remember that only the speed (IPM) condition can be checked when a unit is operating in the synergic mode (the VOLTS window will always display the number 100 and cannot be adjusted); however, in the adaptive mode both speed and voltage conditions can be checked and adjusted. (2) For proper starts, the number in the IPM window should be in the range from 105 to 115. If it is not, adjust the Inc/Dec toggle (below the IPM window) until the displayed number reads 110. (3) Similarly, the number in the VOLTS window should be in the range of 90 to 100. Again, if it is not, adjust the Inc/Dec toggle (below the VOLTS window) until the displayed number reads 95. (4) These adjustments to the control should now provide good arc starts to a legitimate welding condition. (5) A good rule-of-thumb to follow whenever you set up a new welding condition and you experience unstable starts, is to simply check the start characteristic numbers (while welding) to make sure they are within the ranges described in the preceding steps. If you continue experiencing problems, refer to Troubleshooting procedures. The following instructions assume that the operator is familiar with pulse-mig welding and the effects of pulse variables with respect to arc performance. The Pulse Height, Width, and Background parameter settings (derived from the appropriate pulse parameter graphs) need only be set once, in the STRIKE condition, because they are common to all other weld conditions (START, WELD and CRA- TER). The Pulse Frequency parameter setting (also derived from the appropriate graph examples) must be programmed for each wire feed speed set in the IPM window for each weld condition (Strike, Start, Weld & Crater). The metal transfer and arc characteristics are defined by pulse height (PH), width (PW) and background current (PB). These parameters, shown in Figure 5, must be developed for each wire type, diameter, shielding gas, and stickout. To maintain the proper arc characteristics once an appropriate pulse height, width and background have been established, the pulse frequency should be the only parameter requiring readjustment with changes in wire feed speed to maintain a stable arc condition. The teach mode operates in the synergic logic only (not adaptive), and only one wire feed speed and its respective pulse frequency setting can be programmed in each weld condition (Strike, Start, Weld, and Crater). Changes in wire feed speed will require a manual adjustment to the pulse frequency to maintain stable metal transfer. Since the operator selects pulse parameters at a given point, the control will not assume values at other wire feed speeds. For the inexperienced operator, use the following graphs to assist in pulse parameter set-up. These graphs will provide you with pulse parameters used in the preprogrammed codes (1-6). To obtain specific arc characteristics these parameters can be set- up and changed in the teach mode. The following procedure will achieve a reasonable starting point for pulse welding in each weld condition (Strike, Start, Weld, and Crater). 1. Pull the POWER switch button, on the front panel, out to energize the control. 2. Make sure the Amp-Test toggle switch (Item 2, Fig. 6) is in WELD position. D. PROGRAMMING YOUR OWN PULSE PARAMETERS IN TEACH MODE (with Teach option kit). The teach mode program is designed to allow the operator to develop and store one set of customized Pulsed mig parameters* for wire types which have not been preprogrammed in this control (for example; titanium, inconel, monel, etc.). In some instances the preprogrammed carbon steel or stainless steel parameters may be inadequate, and the teach mode can then be used to further refine those particular arc characteristics. * You may wish to permanently incorporate your selfdeveloped conditions in codes 7 thru 10 which are reserved for custom applications. If so, you can specialorder a custom E-PROM, from ESAB, that will include your teach conditions along with the other preprogrammed applications. In order to do this, you will have to provide the necessary welding condition development parameters outlined in Section E following. Figure 5 - Pulse Wave Description 3. Set the Process control selector (Item 1, Fig. 6) in its TEACH position. 17

18 1 The selected Teach position automatically sets-up the control for Synergic pulse operation (and disables voluntary selection of synergic/adaptive logic using toggle switch Item 3, Fig 6). At the same time, it enables the optional Pulse Parameter program switch (Item 5, Fig. 6) to be operative for programming the teach-pulse functions described following. b. Using the pulse parameter graph(s), shown following Step D-11, approximate the pulse Height*, Width* (for step c), and pulse Background* and Frequency (for step d) settings for the material type and diameter you plan to use. Select the appropriate pulse parameter graph which corresponds to the material type being used. For wire types other than those shown, choose the graph that comes closest to your wire type. For example, for coppers use the silicon bronze graph parameters as a starting point Figure 6 - Teach Set-Up On Inside Panel 4. When programming in the teach mode, you do not need to enter a code number for Wire Diameter or Material (as is required for pre-programmed data)--therefore it is not necessary to actuate the Wire Dia./Mat'l toggle for this data. IMPORTANT: Please note that all other parameters (one complete set) that are programmed (following) will be retained in memory (except for wire size and type of material)--therefore, it is suggested that you document all wire data and developed parameters relating to a particular teach application for future reference. 5. Place the rotary Weld Condition selector (Item 4, Fig. 6) to the STRIKE position and program the following: a. Set the STRIKE wire feed speed (IPM) by operating the left Inc./Dec. toggle (Item 7, Fig. 6) until the desired setting appears in the IPM display window. Notice that this parameter setting will start at zero and immediately jump to 20 and then rapidly increase (1 ipm at a time) until the desired setting is reached * Please remember that these pulse parameter settings (Height, Background & Width) are only set once, in the STRIKE condition, and are then common for all remaining Weld conditions. Only the pulse Frequency and wire feed speed parameter settings need be programmed for each Weld condition. c. Program the Pulse Height (PH) and Pulse Width (PW) parameters, from the material graph legend for the diameter wire installed, by holding the Pulse Parameter switch (Item 5, Fig. 6) in its up position and the following: (1) Set the selected Pulse Height (PH) parameter in the IPM window using its Inc/Dec switch (Item 7). The number in this window represents pulse height from.1 to 10 volts (in 1/10 volt increments). (2) Now, set the selected Pulse Width (PW) parameter in the VOLTS window using its Inc/Dec switch (Item 8). The number in this window represents pulse width from 1 to 10 milliseconds (in 1/10 millisecond increments). d. Program the Pulse Background (PB) and Pulse Frequency (PF) parameters, from the material graph legend for the diameter wire installed, by holding the Pulse Parameter switch (Item 5, Fig. 6) in its down position and the following: (1) Set the selected Pulse Background (PB) parameter in the IPM window using its Inc/Dec switch (Item 7). The number in this window represents pulse background current from 15 to 100 amperes (in 1 amp increments). (2) Now, set the selected Pulse Frequency (PF) parameter in the VOLTS window using its Inc/Dec switch (Item 8). The number in this window represents the approximated pulse frequency derived from the graph for wire feed speed selected (step 5a) and is display in Hertz from 25 to 909 pulse cycles/second. e. Once an acceptable arc condition has been obtained by further modifying pulse height, pulse width, and pulse background, changes in wire feed speed will necessitate a manual adjustment to the pulse frequency to maintain a stable metal transfer. f. Leave the rotary Condition selector in the STRIKE position to set the PREFLOW and POSTFLOW time parameters. Actuate the Times-Wire Dia./Mat. toggle switch (Item 6, Fig. 6) to its TIMES (cycle) position, and observe that the existing numbers shown in the IPM and VOLTS windows will change--the new parameters being the pair of time functions in the chart(s) adjacent to the selected condition (in this case, the pre- and postflow date). To reset or change these Time parameters, actuate and hold the TIMES toggle position, while simultaneously operating the appropriate INC./DEC. toggle 18

19 switch below each of the time parameters being set. The preset time intervals will be displayed in their respective IPM and VOLTS digital windows. 6. Reposition the rotary Condition selector (Item 4, Fig. 6) to the START position and program the following: a. Set the START wire feed speed (IPM) using the same procedure outlined in III-D-5-a. b. Now set the selected Pulse Frequency (PF) for the START wire feed speed using the same procedure outlined in III-D-5-d-(2) & D-5-e.--Remember that the remaining pulse parameters (Height, Background & Width) are only set once, in the Strike mode. c. Leave the rotary selector in the START position and set the START TIME and STRIKE TIME parameters using the procedures outlined in III-D-5-f. 7. Reposition the rotary Condition selector to the WELD position and program the following: a. Set the WELD wire feed speed (IPM) using the same procedure outlined in III-D-5-a. b. Now set the selected Pulse Frequency (PF) for the Weld wire feed speed using the same procedure outlined in III-D-5-d-(2) & D-5-e. -- Remember that the remaining pulse parameters (Height, Background & Width) are only set once, in the Strike mode. c. Leave the rotary selector in the WELD position and set the WELD TIME and BURNBACK TIME parameters using the procedures outlined in III-D-5-f, and also the following: (1) WELD TIME setting requirements for: (a) (b) (c) (d) Continuous Seam Welding -- set time to zero. Single Time Weld with carriage travel (customer must deenergize the arc detection output signal) - set time from 1 up to 999 cycles. Single Time Weld with carriage travel (the Arc Detector Circuit provides a signal to initiate travel of a carriage, or fixture) - set time from 1 up to 999 cycles. Repeat Timed Weld (same as c) except that the elasped time between welds is preset in the REPEAT TIME parameters. (2) BURNBACK TIME setting requirements: (a) If automatic adaptive anti-stick is desired - set time to zero. (b) If manual burnback (anti-stick) is needed - set time required from 1 cycle on up. 8. Reposition the rotary Condition selector to the CRATER position and program the following: a. Set the CRATER wire feed speed (IPM) using the same procedures outlined in III-D-5-a. b. Now set the selected Pulse Frequency (PF) for the Crater wire feed speed using the same procedure outlined in III-D-5-d-(2) & D-5-e.-- Remember that the remaining pulse parameters (Height, Background & Width) are only set once, in the Strike mode. c. Leave the rotary selector in the CRATER position and set the CRATER TIME and REPEAT TIME parameters using the procedures outlined in III-D-5-f. If the Weld and Crater conditions are both Timed ; simply preset the appropriate time desired for each condition 1 up to 999 cycles for Weld, and 1 up to 999 cycles for Crater. If the Weld condition is a Continuous Seam weld, the CRATER condition can either be Timed or skipped completely. If Crater Fill is desired; enter from 1 to 999 cycled in the Crater Time parameter. If Crater fill is not desired; simply enter zero in the Crater Time parameter, and this sequence will be skipped after the STOP switch terminates the Weld condition sequence. Repeat Time -- if repeat timed weld are not used, set this time to zero. If repeat welds are desired, the cycles set will control the elapsed time between the Timed weld parameters. 9. Reposition the rotary Condition selector to the blank position, and program the following: a. Set the MISSWELD TIME and RETRACT TIME parameters using the procedures outlined III-D-5-f. The missweld time cycle only monitors the WELD Condition. If not desired, set Missweld Time to zero. 10.Reposition the rotary Condition selector to the RUN position to perform the following operations: a. To check or preset a cold-wire INCH parameter (50-999ipm), or to monitor or zero the accumulated ARC HOURS (welding) time. (These features are only functional in a non-welding mode.) To check or monitor this data, you must place the Condition Selector switch in its RUN setting and actuating the Inch Preset/Arc Hrs. switch position--the data will be displayed in the IPM and VOLTS windows respectively. To set or zero the data, place the Condition Selector in its RUN setting and actuate the Inch Preset/Arc Hrs. switch position while simultaneously operating the Inc/Dec switch below the function being adjusted--this data will be displayed in the appropriate IPM and/or VOLTS window. b. The run position is the normal operating setting used when the control is fully programmed and ready to be weld- tested, and if necessary readjusted. 11.The following pulse parameter graphs (previously referred to in Step D-5-b) can be used to approximate the pulse parameters required for Height, Background, Width, and Frequency (in respect to a selected wire feed speed) settings for a material type and diameter you plan to use. Select the graph that most closely corresponds to your weld material requirements 19

20 Carbon Steel Pulse Paramaters Stainless Steel Pulse Paramaters 4043 Aluminum Pulse Paramaters 5356 Aluminum Pulse Paramaters Pulse Frequency Pulse Frequency Pulse Frequency Wire Feed Speed (ipm) Wire Feed Speed (ipm) Silicon Bronze Pulse Paramaters Pulse Frequency Pulse Frequency Wire Feed Speed (ipm) Wire Feed Speed (ipm) Wire Feed Speed (ipm) 20

21 E. CUSTOM PROGRAM DEVELOPMENT PROCEDURES ESAB can supply custom Synergic and Adaptive programs to be placed in Material Codes 7 thru 10 if the proper data is supplied (see Chart below). Once acceptable arc stability and weld performance has been established using the pulse parameter keys on the teach option, record the pulse height, width and background settings you have programmed. Then take 5 samples at different wire feed speeds and record the data in the chart below at each wire feed speed tested. You will have to increase the pulse frequency as the wire feed speed increases in order to establish a GOOD welding condition which will also change the arc voltage. From this information we can program the synergic and adaptive relationships for your custom program. Contact your ESAB Sales Representative for further details and pricing information on this custom service. Custom Program Development DO NOT Change Once Established Wire Average Average Pulse Pulse Pulse Pulse Additional Information Feed Current Arc Freqency Height Width Bkgrd (ipm) (Amps) Volts (Hz.) (Ref. Volts) (m sec) (Amps) Wire Type Base Metal Type 1 Wire Diameter Weld Joint Type 2 Shielding Gas Mig Gun Type 3 Tip to Work Weld Position 4 Travel Speed 5 IV. WELDING OPERATION After the desired parameters have been weld-tested and satisfactory results achieved, the preset welding conditions for the selected process mode can be locked-in by securing the front panel door to the cabinet with the key-lock. None of the welding parameters can be altered once the cover is locked. A. PULSE/SPRAY/SHORT ARC WIRE SPEED RECOM- MENDATIONS 1. General The listings in the following tables give approximate wire feed speed ranges (IPM) for the various types of wire diameters and materials which have been preprogrammed in these controls. Table III for Typical Short Arc Wire Speed Ranges Wire Material Wire Diameter & Wire Speed Range Code # Type Carbon Steel NP Alternate Stl NP Alum. NP NP NP NP NP Alum. NP NP NP NP NP Stainless NP Sil. Bronze NP NP NP NP NP 7** 8** 9** 10** NP Not programmed. ** These codes are reserved for custom applications. Table IV for Typical Spray Arc Wire Speed Ranges Wire Material Wire Diameter & Wire Speed Ranges Code # Type Carbon Steel Alternate Stl Alum. NP Alum. NP Stainless Sil. Bronze NP NP ** 8** 9** 10** NP Not programmed. ** These codes are reserved for custom applications. Table V for Typical Pulse Arc Wire Speed Ranges Wire Material Wire Diameter & Wire Speed Ranges Code # Type Carbon Steel Alternate Stl Alum. NP Alum. NP Stainless Sil. Bronze NP ** 8** 9** 10** NP Not Programmed. ** These codes are reserved for custom applications. 21

22 2. Material Code Operating Tips (Where Applicable) a. Carbon Steel (Code #1) and Alternate Steel (Code #2). The Code #2 parameters are very similar to the Code #1 parameters; however, Code #2 has wider Pulse Widths and higher Pulse Background settings. The arc characteristics will appear to be softer than Code #1. Arc penetration could also be slightly less do to the lower pulse peak used. This type arc characteristic might be used on applications requiring improved bead wetting. Operation Note: Excessive resistances in the welding system, caused by water cooled torches or excessively long welding cables, can produce pulse peak currents below that which is required for stable droplet detachment. This condition can be recognized by occasional large droplets propelled across the arc. Some short circuiting and spatter could also result. Long arc lengths can also cause less than optimum performance. The arc length should be kept short for best arc stability and puddle control. Too short an arc length will produce spatter and less than optimum arc stability. If a globular type transfer occurs, check for high resistance in the welding current. b. Aluminum 4043 (code #3) and 5356 (code #4). Each alloy and diameter has been set for best arc performance and puddle control. The wire feed speed of /64-inch diameter (.045) is limited to 300 ipm at which point the pulses begin to overlap and spray arc results. If higher wire feed speeds are required on this alloy, switch to Code #4 ( ) and adjust the arc voltage for stable arc performance. This action will extend the wire feed speed to approximately 600 ipm. c. 308 Stainless Steel (Code #5). The stainless steel pulse parameters are based on gases (listed below). These gases improve the bead wetting of stainless steel as compared to the 1% and 2% oxygen mixtures. The program can still be used with the oxygen mixtures but a small adjustment in arc voltage will be necessary. 1. Linde Pulse Blend SS /2%-CO 2, 1%-H 2, Bal. Argon Operation Note: Arc starting with stainless steel can be inconsistent at times due to the higher resistivity of the alloy and other variables. Sometimes increasing the voltage will improve starting. A weld technique adjustment might also help. When striking the arc, immediately move out of the puddle and begin traveling. A hesitation in travel at the start causes the puddle to build under the arc while the control is trying to adjust for arc voltage. Eliminating the puddle buildup helps the voltage control circuit establish the proper arc length more quickly. d. Silicon Bronze (Code #6). The welding performance of silicone bronze alloys currently sold can vary widely. Small differences in chemistry, cleanliness, and feedability can affect the pulse welding characteristics. To overcome instability problems, be sure wire feeding is steady and slack in the liner is minimized. Use tip-to-work distances slightly longer than normal if arc instability occurs. B. WELDING SEQUENCE FOR TEACH (option), PULSE, SHORT OR SPRAY ARC PROCESS MODES. To operate the control do the following--a typical welding sequence is shown in Fig Pull the Power switch button to its out position to energize the control. (For one second, the IPM and VOLTS will display an identification program number for the MPU printed circuit board in your control.) 2. Set the inside Process mode selector for the programmed sequence you plan to use Teach, Pulse, Short or Spray. 3. Set the logic you wish to use Synergic or Adaptive. Remember that the Teach mode automatically uses Synergic logic, the remaining modes use either. 4. The Amp-Test toggle should be in its WELD position. 5. Assuming the welding parameters are all programmed, the Weld condition selector should be its RUN position. 6. Operate the front-panel GAS PURGE switch to purge the shielding gas line of the torch. 7. Operate the front-panel cold wire UP/DOWN INCH switch to position the wire above the workpiece. 8. You are now ready to weld in the selected schedule mode. Place the Start-Stop switch in its START position, and the control will automatically sequence thru Preflow, Strike, Start (also initiates arc detector carriage drive signal), and into the Weld condition programmed. 9. To stop welding, proceed as follows: a. For continuous seamwelds, simply operate the STOP switch (or a remotely actuated stop button or microswitch), and all welding will cease except Crater- Fill, Burnback, Postflow and Retract. b. For single Timed weld setup, the control will automatically provide an orderly sequenced shutdown; however, in order to start another weld, you must press the Stop switch (panel or remote) and then reoperate the Start position to reinitiate the preset sequence. c. For repeat Timed weld setups, the control will automatically continue to cycle through its preset weld on and weld off sequence, until the control's Stop (or remote stop device) is operated. d. The control can, or will also shutdown as a result of the following: (1) Pushing-in the mushroom-head Power button immediately ceases all welding. (2) If preset Strike time or Missweld Time is exceeded, and/or preset wire feed speed or arc voltage parameters cannot be maintained, the control will shutdown and simultaneously indicate the cause by flashing a digital display in the IPM and VOLTS window. The control will also provide an abort output signal to a carriage or fixture to stop travel. (a) If the Strike Time parameter was exceeded, its preset time- interval will flash in the VOLTS WINDOW--and you may have to preset a little more time. (b) If the Missweld time cycles was exceeded, its preset time will flash in the IPM window and the unit will abort/shutdown--make sure that all parameters accurately reflect the welding application. (c) If the wire feed speed (IPM) and/or arc voltage (VOLTS) parameters cannot be maintained in any of the welding conditions (Strike, Start, Weld, or Crater), the flashing display will only signal the original preset Strike parameter(s). 22

23 MOTOR STOPS REVERSING WIRE RETRACT ENDS WELD MODE STARTS WELD TIMER STARTS IF PROGRAMMED WELD PARAMETERS ARE MAINTAINED POSTFLOW TIMER STARTS MISSWELD TIME STARTS MONITORING ARC DETECTOR START TIMER BEGINS START MODE INITIATED CRATER TIME STARTS CRATER PARAMETERS MAINTAINED AUTOMATIC OR MANUAL ANTI-STICK TIMER STARTS REPEAT TIMER STARTS IF SET. IF NOT WELD CYCLE IS OVER PREFLOW TIMES OUT CONTACTOR ON MOTOR STARTS AT STRIKE IPM SETTING STRIKE TIMER STARTS TIMIMG START SW OPERATED PREFLOW STARTS WIRE HITS WORKPIECE START TIMER TIMES OUT STOP SW OPERATED WELD TIMER TIMES OUT IF SCHEDULED MISSWELD TIME ENDS DYNAMIC BRAKE MOTOR APPLIED REVERSES FOR WIRE CRATER TIMER RETRACT TIMES OUT ANTI-STICK TIMER TIMES OUT CONTACTOR DROPS OUT POSTFLOW TIMES OUT REPEAT TIMER STOPS & NEW WELD BEGINS PREFLOW STRIKE START WELD MISSWELD CRATER ANTI-STICK POSTFLOW REPEAT RETRACT TIME PURGE COLD INCH PRESET Figure 7 - Typical Welding Conditions Sequence Per Schedule (3)In order to restart an abort shutdown, simply depress the Gas Purge/Reset rocker switch to clear the abort, and then repress the Start rocker switch to start a new weld. V. TROUBLESHOOTING NOTE: If the dedicated Digipulse 450 Power Supply is operating improperly, refer to troubleshooting information located in booklet F Listed below are a number of trouble symptoms, each followed by the checks or action suggested to determine the cause. Listing of checks and/or actions is in most probable order, but is not necessarily 100% exhaustive. Always follow this general rule: Do not replace a printed circuit (PC) board until you have made all the preceding checks. Always put the Power switch in off position before removing or installing a PC board. Take great care not to grasp or pull on components when removing a PC board. If a printed circuit (PC) board is determined to be the problem, check with your ESAB supplier for a trade-in on a new PC board. Supply the distributor with the part number of the PC board as well as the serial number of the wire feeder. Do not attempt to repair the PC board yourself. Warranty on a PC board will be null and void if repaired by customer or an unauthorized repair shop. A. General 1. Check interconnection between control and power supply. 2. Energize the power supply and the control. 3. Immediately after the control is turned on, a number (e.g.:3) will appear in the IPM readout window and will only be displayed for 1-second. This number identifies the current program (E-Proms) used in your control. When a Program is changed, the new E-Proms will automatically identify the new program number being used. If a revision is made to an existing program a decimal number.1,.2,.3,etc. indicating the numerical revision will also appear in the VOLTS readout window simultaneously. 4. After the one (1) second delay; the preset Weld parameters, corresponding to the position of the Condition selector switch, will be displayed in the IPM/VOLTS windows. With the switch in its normal Run position the STRIKE parameters will initially be displayed. 5. It is also important to set the STRIKE time long enough to provide adequate time for the current detector to energize before the Strike timer times out. If the Strike timer times out the unit will abort and the preset Strike time parameters will flash in the VOLTS window. 6. If the control is not functioning properly (or as described above); for example, the numbers that appear in one or both of the display windows are meaningless (all zeros, eights, decimals, etc.), or are completely incorrect in relation to your settings, - the memory must be cleared. This condition might occur after a bad lightning storm, extremely bad power line surges, etc. To clear the memory, do the following: a. Turn off the unit's 110-volt Power switch. b. Using one hand, hold both of the Inc./Dec. toggle switches in their INC position while reapplying 110-volt power with the other hand. c. Almost immediately after the Power has been turned On, release the Inc./Dec. toggle switches to the neutral (spring-return center) position and each of the windows should display one zero, indicating a successful reset or clearing has taken place. 7. You can now enter the desired information as described in this booklet. B. No preset numbers, or meaningless numbers, appear in display windows. 1. Make sure the LED Display board harness/plug is plugged into the P5 receptacle on the MPU board. 2. Check that 110 vac is available across terminals T1-1 and T1-3, if present; 23

24 3. Check for (+) 5 volts between terminals T1-12 and T1-10; if voltage is present, replace the MPU board. If voltage is not present, check the voltage regulator (VR). The voltage regulator is located on the bottom of the control box. 4. Check the input and output voltage of the regulator VR as follows: The input should be approx. 11 volts, as measured across capacitor C4 (between T1-10 and VR-1) located on the VR socket. If voltage is not present check the output of transformer CTR-1. It should read 10 volts AC from the center tap (Grn/Yel) to both of the green windings taps. If CTR-1 good, but the input to VR is still not present, check plug P3 per the schematic diagram. If no opens or shorts are found and input is still missing (to VR)--replace I/O board. If input to VR is present, but output is missing-- replace VR. If numbers still do not appear in windows-- replace I/O and/or MPU boards. 5. If all microprocessor memory is lost, it may be due to low (sagging) line voltage or excessive line voltage drops. This may occur if auxiliary equipment (such as carriage drives(s), drill motor, hot plates, etc.) also derive their 115- volt power from the same power supply as the control. Do NOT connect auxiliary equipment to the 115-volt duplex receptacle on the power supply. If problem still exists, call for factory assistance. C. Motor does not run. 1. Check to make sure all required (and/or optional) accessories are correctly assembled as described in Section I. 2. Make sure that plug P2 is securely connected to receptacle P2 on the I/O Board, and then release the clapper arm (pressure roll) on the Accessory Support Assembly. a. Operate the Start Switch (arc voltage must be present) and the motor shaft/feed roll should turn. If motor doesn't run, release start switch and; b. Operate the INCH switch. If the motor inches, but will not operate from the start switch, check the start switch circuit components--switch, plug, receptacle, etc. Also check that arc voltage pickup lead is sensing. c. If motor will not turn using either of the above switches, replace the J governor board. If motor still does not run, check if power supply is providing open-circuit voltage to the control - if o.c.v. is not being supplied, motor will not run. Check the power supply for trouble. d. Also check that the +/- 12 vdc are provided from the power supply on T1-10 and T1-8 respectively. e. If power supply is O.K., replaced the I/O and MPU boards respectively. D. Motor runs, but not at right speed. 1. Check tachometer assembly mounted on the end of EH- 10 wire feed motor. 2. Make sure the tach disc is securely fastened to the motor shaft and that the strobe markings are not scratched. Check that the disc is properly centered in the strobe pickup on the p.c. board. 3. If all items in step 2 are in order, and motor speed is still incorrect, replaced MPU board. 4. If motor speed is excessive, but display reads zero or low speed, replace tach p.c. board. E. Arc VOLTS display reads zero after Start switch is operated. 1. Check that the 5-pin plug is securely connected to the P3 receptacle on the MPU board. 2. If no reading is displayed, check for arc voltage feedback between terminals T1-18 and T1-19 (test points TP1 and TP2, respectively, on I/O board). This voltage signal should correspond to that shown on the power supply voltmeter. 3. If voltage still reads zero, but power supply indicates a potential, trace the voltage pickup wiring from the power supply to control. If wiring is correct and problem persist, proceed to step Disconnect the P3 plug from its MPU board socket and, using a meter check for +/-12 volt power supply output between plug pins P3-1 and P3-2 (for +12 v.), and between plug pins P3-4 and P3-2 (for -12 v.) respectively. If voltage is present, replace the MPU board. F. Control Shut Down - either present VOLTS or IPM displays will flash. The control will flash the parameter, VOLTS or IPM, that cannot be maintained. These symptoms can occur if the preset conditions, IPM or VOLTS, cannot be maintained by the control. The speed (IPM) and voltage (VOLTS) conditions are used to enhance arc starting in the adaptive mode of operation. In the synergic mode (all units), the voltage condition window will always display the number 100 and cannot be adjusted; the speed condition, however, can be checked and adjusted as described following. To help determine which logic mode (adaptive or synergic) the control is set to operate in, or how to change it, please review Sections II-C-5-b. 1. IPM (speed) abort and possible causes: (a)initial hot start parameters incorrectly set. For proper adjustment, refer to Set-up Procedures following III-C- 10-b. (b) Defective J-governor board. (c) Defective Motor tachometer board. (d) Defective I/O board. (e) Defective MPU board. Contact ESAB Engineering Services for further assistance. 2. VOLTS (voltage) abort and possible causes: This problem may be located in the wire feeder or the power source. To determine this, check the wire feeder as follows. (a)set the wire feeder for synergic operation in the Pulse welding mode. (b) Strike an arc and while welding, measure the potential between T1-23 and T1-24. Note that as the arc voltage setting is increased, the potential between T1-23 and T1-24 also increases, and will range from 0 to 10 vdc. If it does not, replace the I/O and/or MPU board. If the potential is present and responding to the voltage change setting, continue with step (c) following. (c) Now measure the control voltage, for the background current, between T1-24 and pin J1-J of the amphenol connector. This measurement can be taken without striking an arc. The potential will be in a range from 1 to 2.5 volts. If it is not, replace the I/O and/or MPU board. If the background potential is present, continue with step (d) following. 24

25 (d)if both of the preceding conditions (steps a and b) are okay, but the arc is still unsatisfactory, the problem is either in the interconnecting cable, the welding setup, or in the power source. If possible, substitute a cable or power supply (known to be good) to check out the possible problem; if these are not available, continue with the wire feeder calibration test in step G following. G. Erratic arc especially evident in the Pulse mode. This could be caused by insufficient pulse height. To check this, make the following calibration test of the I/O board and power source. Set the control in the diagnostic mode and the process selector switch to the spray mode. Simultaneously depress the Wire Dia/Mat'l. key and hold the IPM Inc/Dec key in its down position for 2.5 seconds until a zero (0) appears in the IPM window. (The 2.5 seconds will prevent accidental zeroing of the Material code.) Now release both keys. The display windows will change to show a BACKGROUND current value (from 0 to 100) in the IPM window, and a PULSE HEIGHT value (from 0.1 to 10) in the VOLTS window. These numbers can be changed by their respective INC/DEC switches. To check the calibration of the I/O board, connect a voltmeter from T1-24 (negative) to T1-23 (positive). Energize the START switch, and check the measured voltage against the number displayed in the VOLTS window -- they should both be the same (for example: for a setting of 8.0, the measured potential should be 8 vdc.). If the measured potential is different, the I/O board should either be recalibrated (by a qualified technician) or the board should be replaced. Next, check the potential from T1-24 (-) to pin J1- J of the amphenol connector for a display of 40 in the IPM window. The measured reading should be 2 vdc. If it is not, replace the I/O board. If all of these readings are correct, check the power supply by using the calibration procedure described in Inverter Control Board (ICB) Troubleshooting in the Power Supply manual F NOTE: Training and Troubleshooting Courses are available for maintenance and repair of this and other ESAB equipment. For details, contact ESAB Welding & Cutting Products, PO Box Florence, SC ; Telephone (803) Attention: Technical Training Coordinator. 25

26 VI. REPLACEMENT PARTS DATA 1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by number and part name, as shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE. 2. Always state the series or serial number of the machine on which the parts are to be used. The serial number is stamped on the unit nameplate. 3. Indicate any special shipping instructions. 4. Replacement parts may be ordered from your ESAB distributor or from ESAB Welding & Cutting Products, Customer Service Department, Florence, SC. (SW2) PURGE/RESET ROCKER SW (SW9) START-STOP ROCKER SW CABINET LOCK DIGIPULSE AUTOMATIC MICROPROCESSOR CONTROL (J1) 19 - PIN RECPT (C20) Capacitor (J3) 14-SOCKET RECPT (J5) 6-SOCKET RECPT (SW7) UP-DN INCH ROCKER SW (CB) CIRCUIT BKR (MLS) OPERATOR CONTACT BUTTON (J2) 5-SOCKET RECPT (VR) VOLTAGE REGULATOR TRANSISTOR SOCKET (C4) CAPACITOR (J6) 3-PIN RECPT Figure 8 - Digipulse Automatic Control Assy., P/N

27 LENS (PSS) 4 - POS. PROCESS SCHED. SEL KNOB WASHER OPT. DIGITAL D.C. AMMETER KIT (See F ) (MSS) 6 - POS. ROTARTY SW ; KNOB ; WASHER DISPLAY P. C. BD. ASSY (SW6) SYN. - ADP.I.P./AH. TOGGLE SW (SW8) AMP TEST TOGGLE SW (SW5) INC/DEC (SW4) INC/DEC (SW3) TIMES-WIRE TOGGLE SWS (SW1) PULSE PARAMETER TEACH SW (Part of optional Teach Kit ) Figure 9 - Digipulse Automatic - Inside Control Panel (R1) RESISTOR (REVRLY) REVERSE RELAY (MPU) MICROPROCESSOR P.C.BD. ASSY (BR) BRIDGE (T1) TERMINAL BOARD (CTR3) CONTROL TRANSFORMER (I/O) INPUT/OUTPUT P.C. BD. ASSY J-GOV. P.C. BD ASSY (FN1) FILTER NETWORK CURR. DETECT P.C. BD. ASSY (2) P.C. BD. RECEPTACLES OPTIONAL (A/O) ABORT OUTPUT P.C. BD OPTIONAL (I/F) INTERFACE P. C. BD (FB) FILTER BOARD ASSY (CTR1) CONTROL TRANSFORMER (Bottom). (CTR2) CONTROL TRANSFORMER (Top). Figure 10 - Digipulse Automatic Inner Cabinet Components 27

28 Fig Optional Plumbing Box - P/N