ESAB Digimatic II Four Schedule Microprocessor Control Troubleshooting instruction

Brand: ESAB

Model: Digimatic II Four Schedule Microprocessor Control

Category: Welding System

Type: Troubleshooting instruction

INSTRUCTIONS for

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 Arc Welding, Cutting and Gouging," Form 52-529. Do NOT permit untrained persons to install,

operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and

fully understand these instructions, contact your supplier for further information. Be sure to read the SAFETY

PRECAUTIONS on page 3 and 4 before installing or operating this equipment.

Input Power Required 1A., 115 volts, 50/60 Hz, 1 ph

Height 15.5-in. (394mm)

Depth 8-in. (200mm)

Width 13-in. (330mm)

Weight (approx.) 20-lbs. (9.1kg)

In the same way that Digimig changed the face of semiautomatic mig welding, the Digimatic II's

microprocessor accuracy and flexibility revolutionized Automatic Mechanized MIG Welding. The

Four-Schedule Digimatic II is truly "the first Intelligent Mechanized Mig System".

Presettable Wire Feed Speed (IPM) and Volt-

age (VOLTS) ...Provides ability to easily and

accurately preset the exact welding param-

eters desired, before the welding sequence

begins!

Patented Microprocessor Controlled Closed

Loop System ...Provides most accurate means

of maintaining wire feed sped (amperage) and

welding voltage. The microprocessor com-

pensates for deviations in ambient tempera-

ture, primary voltage fluctuation and changes

in arc dynamics or wire feed force conditions,

to assure that preset parameters are main-

tained.

FEATURES/BENEFITS

Four Presettable Welding Schedules...Unlike the origi-

nal single- schedule Digimatic II, this unit allows you

to preset up to four (4) completely different welding

schedules that can save control setup time and im-

prove productivity. By presetting four of your most

common welding requirements, all you have to do is

switch weldments and select the appropriate sched-

ule for that particular job.

Eight Presettable Conditions Per Schedule...In se-

quence, including, PREFLOW, STRIKE, START,

WELD, CRATER, ANTI-STICK (Burnback),POSTFLOW

and WIRE RETRACT. Total weld condition

presettability means improved weld quality and pro-

ductivity.

DIGIMATIC II

FOUR SCHEDULE

MICROPROCESSOR

CONTROL

P/N 31551

FOR AUTOMATED MECHANIZED

MIG WELDING

SPECIFICATIONS

F-15-070-A

April, 1994

CONTENTS

Specifications ...................................................................................................................... 1

Features/Benefits ............................................................................................................. 1/5

Safety Precautions ........................................................................................................... 3/4

I. INSTALLATION .................................................................................................................. 5

A. Required Equipment ....................................................................................................... 5

B. Optional Accessories ...................................................................................................... 6

C. Mount/Connect Equipment.............................................................................................. 8

II. CONTROL FUNCTIONS .................................................................................................... 9

A. Front Panel Controls ....................................................................................................... 9

B. Inside Panel Controls .................................................................................................... 10

C. Additional Program Controls ........................................................................................ 12

III.PRESETTING WELDING SCHEDULES .......................................................................... 12

IV.WELDING SEQUENCE ................................................................................................... 14

V. TROUBLESHOOTING ...................................................................................................... 15

VI.REPLACEMENT PARTS DATA ....................................................................................... 21

Figure 1 - Interconnection Diagram .................................................................................... 8

Figure 1-A. - OM-48 J-Governor Hookup ............................................................................ 9

Figure 1-B - Plumbing Box Hook-up .................................................................................... 9

Figure 2 - Front Panel Controls ........................................................................................ 10

Figure 3 - Inside Panel Controls ........................................................................................ 12

Figure 4 - MPU Dip Switch Location .................................................................................. 13

Figure 4-A - Typical Time Parameter Setup ...................................................................... 14

Figure 5 - Typical Weld Condition Sequence Per Schedule .............................................. 16

Figure 6 - Sequential Troubleshooting Flow Diagram ........................................................ 20

Figure 7 - Control Assy. Replacement Parts/External ....................................................... 21

Figure 8, 9 - Control Assy. Replacement Partts/Internal .................................................... 22

Figure 10 - Plumbing Box Replacement Parts ................................................................... 23

Figure 11 - Control Schematic Diagram ............................................................................ 24

Figure 12, 13 - Control Wiring Diagrams ...................................................................... 25\26

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 pre-

set 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 Digimatic II cold wire Inch

sped can be independently adjusted (up

to 999 ipm) without affecting any of the

other preset welding conditions.

Circuit Protection...Resettable cir-

cuit 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 to-

tally test the Digimatic II electronics

as well as run it through a complete

timed sequence of preset weld conditions

without actually welding.

Sure Start Interlock...To assure troublefree starts,

the Digimatic II 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 consis-

tent starts. If for any reason the Strike Time is

exceeded (wire does not feed or misses the work)

the Digimatic II will automatically shut down and

flash the preset STRIKE TIME in the VOLTS dis-

play window.

Arc Detector Circuit...Senses that both Welding

Voltage and Amperage are present to facilitate

transfer from Strike to Start condition param-

eters, 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 param-

eters, Digimatic II will automatically shutdown in

the rare event that either voltage or wire feed

speed cannot be maintained during the welding

sequence.

The Digimatic II 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.

Remote Control Capabilities...To provide easy

interfacing with fixtures, the Digimatic II incorpo-

rates remote Start/Stop and Wire Inch Capabili-

ties which can be controlled by switches or relays

at a central control panel.

Single or Repeat Timed Weld Capabilities ...Be-

cause the Digimatic II incorporates a Repeat weld

timer, adjustable up to 999 cycles (16.5 seconds),

the Digimatic II offers more than conventional con-

tinuous seam, or Single Times welding capabili-

ties. 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 trans-

fer from preset to display of actual VOLTS and

IPM for each welding condition as the Digimatic II

sequences through the preset welding sequence.

Arc Hours Readout...This unique feature pro-

vides a direct measure of productivity by accu-

mulating and displaying, upon command, actual

welding Arc Hours.

I. INSTALLATION

A. EQUIPMENT REQUIRED

1. Digimatic II Four-Schedule Control Assy. P/N

31551.

2. EH-10A Digital Welding Head (20-999IPM). The

welding head is composed of three basic units; a wire

feed motor- tachometer unit, a gear reduction unit, and

the accessory support assembly. This control (4-sched-

ule) is only usable with a EH-10A Digital Welding Head,

and either of two welding head (following) are available

for use. The wire sizes accommodated are:

Hard ................................ .030 -1/8-in. (.8 - 3.2mm)

Soft ............................... .030 - 3/32-in. (.8 - 2.4mm)

Flux Core ...................... .045 - 1/8-in. (1.2 - 3.2mm)

a. Two Roll Drive EH-10A Head - P/N 600416. This

head provides wire feed speeds from 20 - 999 IPM

using a 40:1 gear reduction ratio, and a two-roll acces-

sory 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 L12-873.

b. Four Roll Drive E-10A Head - P/N 600417. This head

is the same as P/N 600416, except that it incorporates

a four- roll accessory support wire drive assembly.

For further information, refer to booklets F12-873

and F12-821.

NOTE: If the motor direction is to be changed, inter-

change the blue and grey wires on the reversing

relay terminals R-9 and R-7 respectively.

3. Feed Rolls. Select the proper feed roll, for the wire

size to be used, from the data provided in booklets

F12- 873 and F12-821.

4. Constant Voltage Power Supply. In order to use the

Digimatic II Control, it must be operated with

C.V. power supplies designed with “electroni-

cally controlled arc voltage regulation” , such as: *

VI-450A Mig Power Supply, P/N 680180; or, ESAB

450 Power Supply, P/N 678530; ESAB 450 Pulse, P/

N 679981; or, ESAB 650CV/CC Power Supply, P/N

677910; or ESAB 650CV Power Supply, P/N 679321;

or ESAB 400i, P/N 31920, or SVI-450i, P/N 31950.

*Some of these power supplies provide two (2) Posi-

tive output Slope terminals—Flat and Steep. The

micro- processor control is factory set to operate

from the power supply Flat slope output terminal.

If the power supply Steep slope output terminal is to

be used, you must check and readjust the Hot Start

as described in Section III-I-1, in order to provide

the best arc starts possible.

5. Welding Torch. A mechanized mig welding torch

having a rated capacity suitable for the welding appli

cation, such as:

a. ST-12 Water-Cooled Torch (for currents up to 700

amps) P/N 46V59, or—

b. ST-21M Water-Cooled Mechanized Torch (for cur-

rents up to 600 amps.) P/N 690509, or—

c. MT-500M Air-Cooled Torch (for currents up to 500

amps) P/N 17705.

6. Power Supply Control Cable (J1) Assembly.

Depending on the type of power supply used (trans-

former- rectifier/SCR, or inverter), one of the following

control cables is required.

a. 12-conductor control cable with 14-pin amphenol

plug each end for transformer-rectifier/SCR power

supplies such as VI-450*,ESAB-450*-650’s*, -450

Pulse*, etc.—order one of the following cables:

P/N 30780, 30-ft. long assembly.

P/N 30781, 60-ft. long assembly.

7. Shielding Gas Regulation. A gas regulator/flowme-

ter and fitted hose are required to bring gas to the

torch, such as:

a. R-5007 Argon Regulator/Flowmeter, P/N 998124.

b. Heavy Duty Gas Hose, P/N 19416 (12-1/2-ft.), or P/

N 19415 (25-ft.).

c. Gas Hose Coupling, P/N 11N17.

8. 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:

a. Water Hose, 12-1/2-foot, P/N 40V76—or,

b. Water Hose, 25-foot, P/N 406196.

c. Water (In/Out) Adaptor (Connects hose to 1/4

NPT), P/N 11N16.

d. Water Hose Coupling, P/N 11N18.

B.OPTIONAL ACCESSORIES

1. Digital D.C. Ammeter Kit, P/N 679111. 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 snap-

on/plug-in installation and consists of an LED Display

P/C Board (P/N 675284), an Ammeter Control P/C

Board (P/N 675334), and assorted mounting hard-

ware—for installation refer to booklet L14-220.

2. Control Cable Kit, P/N 600412. This kit consists of

three (3) separate cable assemblies which can

beused to signal various external control functions

provided from or to the Digimatic II, as shown in Fig.

1 and as follows:

a. Gas Cable Assy. P/N 678036. This cable ener-

gizes an external solenoid to provide gas shielding

during the preflow, welding, and postflow cycles.

The assembly is a 25-foot, 2-conductor cable with

a 3-pin amphenol plug to self-lead wire connec-

tions.

b. Remote Start Output Cable Assembly, P/N

678037. This cable provides connection for Weld-

Start operation from a remote maintain

contact switch. The assembly is a 25-foot, 6-

conductor cable with a 6-pin amphenol plug to

self-lead wire connections.

c. Remote Inch/Arc Detector (Carriage) Cable As

sembly, P/N 678038. This cable provides connec-

tion for Cold- Wire Inch operation from a remote

momentary contact switch, power (115 VAC) to

energize a remote solenoid for continuous water

cooling, and also provides an Arc Detector signal to

initiate a carriage or fixture drive mechanism. The

assembly is a 25-foot, 8-conductor cable with a 8-

pin amphenol to self-lead wire connections.

3. Motor-Tachometer Extension Cable Assem-

bly, P/N 996808. This assembly allows you to ex-

tend the welding head location using a 25-foot, 6

conductor cable (1-conductor not used) with a 5-pin

amphenol plug (which connects to the control’s J2

receptacle) and an 5-pin amphenol receptacle (which

connects to the EH-10’s plug).

4. Gas and Water Solenoid Valves, P/N 636386. Used

to control flow of shielding gas and cooling water.

5. Reel/Spindle Support, P/N 634288. 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 996498 is used.

6. Spindle Assy., P/N 948259. Mounts to Item 5 above

and is used for 12-in. diam. spools.

7. H.D. Spoke-Type Wire Reel, P/N 19V89. Mounts to

Item 5 above and is used for 65 lb coils.

8. Spool Enclosure Kit, P/N 600240, covers and pro-

tects 12-in. spools from dust and moisture.

9. WC-5B Coolant Recirculator, P/N 19947 (F- 14-

422)

For use with water cooled torches such as the ST-12.

A three-gallon tank provides 1.8 gal/min. at 60

psi pump capacity , using 5.4 amps, 115 volts, 60 Hz

input.

10. OM-48 Carriage/J-Governor Packages.

NOTE: The Digimatic II is primarily designed to interface

with fixture builder controls as shown in Fig. 1.

However, it can be connected to a J-Governor/

OM-48 Carriage package. The OM-48 is avail-

able in two different speed ranges, P/N 01E52

with a 4 - 112 IPM travel speed range and P/N

01E54 with a 2 - 56 IPM speed range. Both pack-

ages include a solid state J-Governor for speed

control. The Digimatic II inch/arc detector cable

P/N 67803 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

14292 is available as a special customer or-

der.

Refer to Section I-C and Figure 1A for OM-48/J-

Gov. wiring hook-up.

11.Plumbing Box, P/N 677261.

NOTE: The Digimatic II is primarily designed to interface

with individual gas and water solenoid opera-

tions commonly used in most fixture builder

welding applications as shown in Figure 1.How-

ever, with some field-modification (to obtain

the desired type of control), the Plumbing Box

can be adapted to provide a convenient work-

ing companion with the Digimatic II control.

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 inade-

equate. Depending on how the cooling water is

to be controlled. Automatic or Continuous,

one of the following interconnecting setups are

required:

a. For Automatic - Gas and Water operation,

order cable assy. P/N 678036.

b. For Automatic-Gas and Continuous - Water

with Pressure Switch operation, order cable

assemblysP/N 678036 and P/N 678037.

Refer to Section I-C for installation instructions, and

Figure 1-B for Plumbing Box/Digimatic II wiring modi-

fications and hook-up.

C. MOUNTING/CONNECTING THE EQUIPMENT

Since the operating controls are mounted on and

inside the Digimatic front panel, the box should be

located so that the meters and controls are within

easy reach of the operator. The control can be

mounted on a side-beam carriage or other vertical

surface by using the mounting holes provided.

WELDING OUTPUT CABLES ARE SHOWN HOOKED UP FOR

D.C. REV POLARITY - IF D.C. STRAIGHT IS DES-SIRED,

INTERCHANGE THE WELDING CABLES AT THE POWER

SUPPLY OUTPUT TERMINALS.

DEPENDING UPON THE TYPE OF WELDING HEAD USED,

& ITS LOCATION - ORIENTATION IN YOUR PARTICULAR

INSTALLATION, YOU MAY NEED TO REVERSE THE MOTOR

LEADS IN THE CONTROL TO ESTABLISH PROPER WIRE

FEED DIRECTION TO DO THIS, INTERCHANGE THE BLUE

AND GREY WIRES ON THE REVERSING RELAY TERMINALS

R-9 AND R-7 RESPECTIVELY.

Figure 1 - Interconnection Diagram

Figure 1-B - Plumbing Box Hook-Up

Figure 1-A, OM-48/J-Governor Hook-Up

For complete Interconnection Diagram of the

Digimatic II Control with all required and/or optional

related accessories, see Figure 1. For additional

interconnection and wiring of specific optional ac-

cessories see the following:

1. For specific hook-up of the Digimatic II with OM-48

Carriage/J-Governor packages see Figure 1-A.

2. For specific hook-up of the digimatic II with Plumbing

Box for torch shielding gas and cooling water control

interconnection and wiring modifications, see Figure

1-B and the following instructions.

a. For Automatic Gas and Water operation, connect

2/c cable (P/N 678036) from J5 receptacle to

Box terminals T1-1 and T1-2. Customer must

supply and add jumper wire between Box termi-

nals T1-1 and T1-3 (refer to Fig. 1B).

b. For Automatic - Gas and Continuous - Water

operation, connect 2/c cable (P/N 678036) from J5

receptacle to Box terminal T1-1 and T1-2, Do not

add jumper wire. Disconnect water solenoid

(WSV) wires from terminal T1-2 & T1-3, and re-

reconnect WSV wires to an external (customer

supplied) source of 120 VAC power, as shown in

Fig. 1-B.

c. If Automatic - Gas and Continuous - water with

Pressure Switch Control is desired, repeat all

steps in 2-b above, and add the following: 1.)

Disconnect wire from N/C contact of Pressure Sw.

and recon nect it to the N/O contact, as shown

in Fig. 1-B; 2.)Connect 6/c cable (P/N 678037)

from receptacle J4 asfollows: Blu. wire to T1-4 and

Orn. wire to T1-5; 3.) Disconnect insulated jumper

plug between J4-E and -F inside of control cabi-

net, see Fig. 1-B.

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 flash-

ing digital display), the Purge/Reset rocker can

beactuated and the control will automatically reset

for a new start.

3. Schedule Select Switch. This four-position rotary

switch allows you to program and select Schedule No.

1 and program (using the Condition Selector, section

II-B-1) a complete welding sequence for a particu-

lar application. All of the remaining schedules (No. 2,

No. 3 or No. 4) can be programmed in the same

manner for each different welding application.

4. Inch Up-Down Rocker. This switch is used to cold

inch the wire, up or down, as a preset speed which

you have programmed on the inside panel (II-B-2-b).

IMPORTANT: Cold inching is only possible when the

weld Start-Stop rocker switch is in its stop (or off)

position.

5. 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 (for

typical setup procedures, refer to Section IV-F):

a. Continuous Seam welding applications. The stop

signal does not immediately terminate the weld-

ing 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 termi-

nate 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).

6. 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 nomally

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 0 - 999 amperes in one amp incre-

ments.

II. CONTROL FUNCTIONS

A. FRONT PANEL CONTROLS

For location of control features refer to Fig. 2.

1. Power Switch. Pulling-out the mushroom-style red

button of this switch turns power on in the control as

indicated by the illuminated display windows. To turn

power off , simply push-in the red button and the dis-

play windows and control will deenergize.

Figure 2 - Front PanelControls

NOTE: Immediately after the control is turned on,

a number (e.g.:3) will appear in the IPM read-

out window and will only be displayed for 1-

second. This information identifies the cur-

rent program (E-PROMS) used in your con-

trol. When a Program is changed,the new E-

PROMS will automatically indicate a 2,3,etc.

to identify the 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.

2. Gas Purge/Reset Rocker. A momentary on switch,

this rocker provides a dual function when actuated.

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

b. IPM Digital Readout. This window is primarily

used to display wire feed speed (IPM) for each of

the four welding conditions(Strike, Start, Weld, and

Crater) during a typical welding sequence. De-

pending on the position of the inside condition

selector switch (functionally defined in II-B); the

IPM window displays actual and/or preset wire

feed speed in a range from 20 to 999 inches-

per-minute, in one-inch increments for each weld

condition in the program sequence.

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

dow will continuously read the Preset STRIKE Condi-

tion 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 weld-

ing sequence.

In addition to the above, and using the Condition and

Time selector controls on the inner panel (functionally

defined in II-B), this window can also display the follow-

ing 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.

- WELDTIME. Weld condition duration for

timed-welding (must be set to zero for Continu-

ous-Seam Welding), from 1 to 999 cycles, in

one cycle increments.

- CRATER TIME.Crater fill duration, from 1 to

999cycles, in one cycle increments.

- MISSWELD TIME. Presets the number of cycles

of arc time that can reasonably be missed (from 1

up 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 re-

quired setting for a given application

obviously involves 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 a r c

time. Be careful not to make the missweld time too

short, otherwise nuisance aborts will occur. If

this feature is not desired, preset

the time for zero cycles.

- INCH PRESET. Cold wire inch speed from 50 to

999 inches-per- minute, in one inch increments.

c. VOLTS Digital Readout. This window is primarily

used to display arc voltage (VOLTS) for each of the

four welding conditions (Strike, Start, Weld, and Cra-

ter) during a typical welding sequence. Depending on

the position of the inside Condition Selector switch

(functionally defined II-B); the VOLTS window dis-

plays actual and/or preset arc voltage range from

12 to 50 vdc, in one-tenth (0.1) volt increments, for

each weld condition in the program sequence.

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

window will continuously read the Preset STRIKE

condition voltage setting. When the arc is struck, the

VOLTS window will then continuously read the Actual

welding voltage as the weld conditions cycle thru the

welding sequence.

In addition to the above, and using the inside "Condition"

and "Time" selector controls (functionally defined in II-

B), this window can also display the following pro-

grammed times:

- POSTFLOW. Controls time for gas postflow after

the arc extinguishes from 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 Digimatic will automati-

cally shutdown, and flash the strike time in the

VOLTS display window. Simultaneously, it also pro-

vides 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 pe-

riod 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. At the end of the anti-stick se-

quence and during 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.

Figure 3 - Inside Panel Controls

- ARC HOURS. Selectable display (record) of accumu-

lative welding time in one tenth of an hour increments.

After 99.9 hours it will automatically return to zero.

7. Welding Condition (LED) Lights. These lights

are labeled START, WELD, and CRATER, and they

energize individually as the welding program se-

quences through each of these weld conditions.

Prior to the Start, and after the Crater Conditions,

none of these lights will be on .

8. 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.

B. INSIDE PANEL CONTROLS

For location of internal control features, refer to

Fig.3

1. Condition Selector. This six-position rotary switch is

used to select two sets of parameters, Welding and

Timing, for each of the four available schedules:

a. Weld Parameters. The selector’s primary func-

tion, when used with the appropriate Inc./Dec.

toggle, allows you to preset and display (see II-A-

6-b & c) the wire feed speed (IPM) and voltage

(VOLTS) weld parameters for its first-four posi-

tions labeled—STRIKE, START,WELD, and CRA-

TER. The fifth position of this selector has no

label, but is the required position used for pre-

setting 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

using the INC./DEC. toggle located directly

- STRIKE. This condition sets the desired ap-

proach speed of the wire before striking the

workpiece, and the open-circuit voltage needed

to control the short-circuit current for arc initia-

tion.

- START. This condition can be used to set an

appropriate wire speed and voltage parameter

to create a hotstart to help stabilize the arc (for

its preset time) prior to the weld cycle.

- WELD. This condition sets the desired wire

speed and voltage used during the actual weld

cycle.

- CRATER. This condition allows you to set a

higher or lower weld speed and/or 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.

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/A.H.-Inch Selector (following).

2. Times/Arc Hours-Inch Preset Selector. This two

position, momentary on , toggle must be actuated in

order to preset or change the following parameters:

a. Time Functions. This position actuates the

times-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-param-

eters to be programmed from its Strike, Start,

Weld, and Crater settings. To check or observe the

time settings, actuate the TIMES 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 times-

parameters which can be programmed in each

display window are shown in Figure 3, and were

previously described in Section II-A-6-b (IPM

window) and Section II-A-6-c (VOLTS window).

b. Arc Hours-Inch Preset Function. This switch

position operates in the same manner as the Times

function position; except that it only actuates the

programs to preset the Cold-Inch speed parameter

and to monitor or reset the accumulative Arc-

Hours (welding) time.These functions are

preselected by positioning the Condition Selec-

tor to its Run setting. To checkor monitor these

parameters actuate the A.H.- INCH position;

and to set or zero the data, simultaneously operate

the INC/DEC toggle switch directly below the func-

tion being set. The cold-inch parameter will appear

in the IPM window, and the arc-hours time will

be shown in the VOLTS window.

NOTE: Actuating this position (Arc Hours/Inch Preset)

during an actual weld allows you to check the

factory-preset numbers that will determine

the quality of starts (hot, cold, etc.) for your

preset welding condition. These numbers are

preset to provide optimum starting characteris-

tics required for most welding applications. This

is a diagnostic tool available to the experience

operator or serviceman and need not be acti-

vated during a normal operation unless you

are experiencing weld starting problems, or

weld condition (speed and/or voltage) aborting

problems. 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,

and from 90 to 100 (with 95 being the norm) in

the VOLTS window. If your weld starts are not

acceptable, please refer Section III-I-1 for a

simple adjustment procedure that will enhance

good starting. If you are experiencing inordinate

speed and/or voltage aborts, please refer to

Section V-G (Troubleshooting) for checking and

resetting servo functions.

3. Inc./Dec. Toggle Switches. A control toggle (two

position, momentary on ) is provided below the IPM

and VOLTS digital display windows. These two toggles

are used to preset the individual welding condition

and time-sequence parameters desired for the

welding operation, as follows:

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 , and also

the following; Preflow (time), Start Time, Weld

Time, Crater Time, Missweld Time and Inch Pre-

set (ipm). By setting and/or operating the appro-

priate Control Selectors (see B-1 and -2, 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 conditions,

and also the following; Postflow (time), Strike Time,

Burnback Time, Repeat Time, Retract Time and to

zero (dec.) the Arc Hour accumulation. By setting

and/or operating the appropriate Control Selector

(see B-1 and -2 above), each parameter setting will

be displayed in the digital window directly above

this toggle.

4. TEST Toggle Switch—AMPS and VOLTS. As the

title implies, these two toggles simply provide a conven-

ient way of test-sequencing all of the program para-

meters to either diagnose a problem or to

demonstratethe control assembly without actually

striking a welding arc. A complete set of actual

weld parameters must be preset for this test except

for the following: all voltage conditions and missweld

time parametersmust be set to zero—otherwise an

abort will occur.

To do this, place the two-position "Volts" toggle into

its TEST position—the WELD position being the loca-

tion for normal operation. The Volts-Test position

does two things: first, it safely disconnects the actual

contactorcircuit in the power supply; and second, it

provides a 12-volt signal to simulate the arc voltage

required to sequence the welding cycle.

With this accomplished; open up the accessory sup-

port to release wire feed pressure, and place the

Start- Stop rocker on the front panel into its START

position, and the control will sequence thru the

programmedPreflow time and enter the Strike condi-

tion.

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 Strike

time.

Figure 4 - MPU "Dip Switch" Location

During the Strike condition; you must actuate the

momentary "Amps" toggle to its TEST position, to

simulate closure of the arc/current detection circuitry

that verifies the arc has initiated. This action automati-

cally allows you to enter the timed Start condition, and

the subsequent Weld, Crater, etc., conditions to evalu-

ate and/or demonstrate the welding sequence.

NOTE: The momentary WELD position of the Amps

toggle has no significance in the Test proce-

dures. The normal spring-return center posi-

tion, and/or its toggled Weld position essen-

tially perform the same function.

C. ADDITIONAL PROGRAM CONTROLS

The MPU (microprocessor) board incorporates an

integral 4-rocker/position dip switch (see Fig. 4)

that is primarily used for internal program func-

tions. Switch positions No. 1, No. 2, No. 3 and No. 4

are factory-set in the open (or off) position and must

never be changed.

III. PRESETTING THE WELD SCHEDULE(S)

Remember, the front panel SCHEDULE SELECT

switch allows you to preset a complete and different

welding program for each of the four (4) available

schedules. To preset a typical schedule, do the

following.

A. Pull the Power button out to energize the control, and

then place the Schedule Select switch to position No.

1. The control is now operationally ready to preset a

Schedule No. 1 welding sequence program as des-

cribed in steps B thru I following:

NOTE: Upon completion of Schedule No. 1, place the

SCHEDULE SELECT switch to each of the re-

maining positions (No. 2, No. 3 and No. 4) and

preset a different welding sequence program in

the same manner as Schedule No. 1.

B. Unlock the front panel door of the control cabinet to

gain access to the inside panel controls.

C. Make sure the Test-Volts toggle switch is in the

WELD position.

D. Place the rotary Condition selector to the Strike posi-

tion, and program each of the following (see Sect. II-

A-6-b, -c and II-B-1,-2):

1. Set the STRIKE wire feed speed (IPM) by oper-

ating the INC./DEC. toggle directly below the

IPM digitaldisplay, and the desired setting will

appear in its window.

Figure 4-A - Typical Time Parameter Set Up

2. Set the STRIKE open-circuit voltage require-

ment (VOLTS) by operating the INC./DEC. toggle

directly below the VOLTS digital display, and

the desired setting will appear in its window.

3. Leave the rotary selector in the STRIKE position

to set the PREFLOW and POSTFLOW Time

parameters (as shown in Fig. 4A). Actuate the

Times/A.H.-INCH 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. 4A); actuate and hold the TIMES toggle posi-

tion, while simultaneously operating the appro-

priate INC./DEC. toggle switch below each of the

time parameters being set. The preset time inter-

vals will be displayed in their respective IPM and

VOLTS digital windows.

E. Reposition the rotary Condition Selector to the Start

position, and program the following:

1. Set the START wire feed speed (IPM) and arc

voltage (VOLTS) parameters using the procedures

outlined in III-D-1 and -2.

2. Leave the rotary selector in the START position to

set the START TIME and STRIKE TIME param-

eters and use the procedure outline in III-D-3.

F. Reposition the rotary Condition to the Weld position,

and program the following:

1. Set the WELD wire feed speed (IPM) and arc

voltage (VOLTS) parameters using the procedures

outlines in III-D-1, and -2.

2. Leave the rotary selector in the WELD position to

set the WELD TIME and BURNBACK TIME

paramet-ers and use the procedures outlined in III-

D-3, and also the following:

a. WELD TIME setting requirements for:

(1) Continuous Seam Welding—set time to

zero .

(2) Single Time Weld without carriage

travel (customer must deenergize the

arc detection output signal)—set time

from 1 up to 999 cycles.

(3) 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.

(4) Repeat Timed Weld (same as 3) except

that the elapsed time between welds is

preset in the REPEAT TIME parameters.

b. BURNBACK TIME setting requirements:

(1) If automatic adaptive anti-stick is de-

sired—set time to zero.

(2 )If manual burnback (anti-stick) is

needed—set time required from 1 cycle

on up.

G. Reposition the rotary Condition Selector to the Crater

position, and program the following:

1. Set the CRATER wire feed speed (IPM) and arc

voltage (VOLTS) parameters using procedures

outlined in III-D-1 and -2.

2. Leave the rotary selector in the CRATER position

to set the CRATER TIME and REPEAT TIME

parameters and use the procedure outlined in III-

D-3.

* If the Weld Crater conditions are both Timed ; simply

preset the appropriate time desired for each condition

- .1 up to 99.9 seconds for Weld, and .1 up to 99.6

seconds 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 welds 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.

H. Reposition the rotary Condition Selector to the blank

position, and program the following:

1. Set the MISSWELD TIME* and RETRACT TIME

parameters using the procedures outlined in III-D-

3. *The Missweld cycle only monitors the WELD

Condition. If not desired, set Missweld Time to

zero .

I. Reposition the rotary Condition Selector to the RUN

position for the following operations:

1. This is the normal operating setting used when the

control is fully programmed and ready-for-use.

As mentioned earlier in the Note following Section

II-B-2-b, the control is preset at the factory toprovide

the optimum starting characteristic for most weling

conditions. However, due to factors such as inaccu-

rate parameters (for a given wire type and size),

welding technique, shielding gas, power supply

slope and/or response, you may have to readjust

the factory-set starting characteristics to prvide

the best arc starts possible. To do this, it is neces

sary to readjust the factory-set condition to provide

a hot start characteristic in which the initial starting

voltage (open-circuit voltage) will be slightly higher

than actual welding voltage (arc voltage) and speed

which initially is somewhat lower than the selected

wire feed speed desired.

To set-up the control to provide this, do the follow

ing:

a. Program the welding condition you need in the

IPM (wire feed speed) and VOLTS (arc voltage)

windows, and fine-tune these parameters until

you have the welding arc desired - Do not at this

point concern yourself with the arc starts , this

follows.

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

find that the arc starts are unsatisfactory, pro-

ceed as follows:

(1) During an actual weld, depress and hold the

Arc Hours/Inch Preset toggle position

andobserve the numbers displayed in the

IPM and VOLTS windows.

(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 win-

dow 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 dis-

played number reads 95.

Figure 5 - Typical Welding Conditions Sequence Per Schedule

(4) These adjustments to the control should

now provide good arc starts to a viable

welding condition.

(5) A good rule-of-thumb to follow when-

ever you set up a new welding condition

and you experience unstable starts, is to

simplycheck the start characteristic num-

bers (while welding) to make sure they are

within the ranges described in the preced-

ing steps.

2. Set the cold wire INCH wire feed speedandmontor

or reset (zero) the ARC HOURS by actuating Arc

Hours-Inch Preset toggle switch position, while op-

erating the appropriate INC./DEC. toggle below

their respective charts. The preset cold-inch wire

feed speed, and accumulated arc hour usage will be

displayed in the appropriate IPM/VOLTS digital

windows.

IV. WELDING SEQUENCE

After the desired parameters have been weld-tested

and satisfactory results achieved, the preset condi-

tion can be lock-in by securing the front panel door

to the cabinet with a lock. None of the welding

parameters can be altered once the cover is closed.

To operate the preset welding schedule do the fol-

lowing (a typical welding sequence is shown in Fig.

5):

A. Pull the Power switch button out to energize the con-

trol. (For one second, the IPM and VOLTS will display

an identification program number for the MPU printed

circuit board in your control.)

B. Operate the GAS PURGE switch to purge the shield-

ing gas line of the torch.

C. Place the SCHEDULE SELECT switch to the desired

schedule No. 1, No. 2, No, 3, or No. 4.

D.Operate the cold wire UP/DOWN INCH switch to posi-

tion the wire above the workpiece.

E. You are now ready to weld in the selected schedule.

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.

F. To stop welding, proceed as follows:

1. For continuous seamwelds, simply operate the

STOP switch (or a remotely actuated stop

button or micro switch), and all welding will

cease except Crater-Fill, Burnback, Postflow and

Retract.

2. For single "Timed" weld setup, the control will

automatically provide an orderly sequenced shut

down; 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.

3. For repeat "Timed" weld setups, the control will

automatically continue to cycle through its preset

weld on and weld off sequence, until theDigimatic’s

Stop (or remote stop device) is operated.

4. The control can, or will, also shutdown as a result

of the following:

a. If preset Strike Time or Missweld Time is ex-

ceeded, and /or preset wire feed speed or arc

voltage parameters cannot be maintained,

the Digimatic will shutdown and simulta-

neously indicate the cause by flashing a digital

display in the IPM or VOLTS window.

(1) 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.

(2) 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.

(3) If the wire feed speed (IPM) and/or arc

voltage (VOLTS) parameters cannot be

maintained in any of the welding condi-

tions (Strike, Start, Weld, or Crater), the

flashing display will only signal the original

preset Strike parameter(s).

b. 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

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 ac-

tions is in most probable order, but is not necessar-

ily 100% exhaustive. In addition to the following

troubleshooting symptoms/checks, we have also

provided a Sequential Troubleshooting Flow Dia-

gram (Fig. 6) which can be very useful in your

diagnosis.

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 com-

ponents 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 digimatic control and

power supply. Make sure that the contactor and volt-

age control switches are placed in the Remote

position.

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 identi-

fies 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 win-

dow simultaneously.

4. After the one (1) second delay; the preset Weld

parameters, corresponding to the position of the Con-

dition selector switch, will be displayed in the IPM/

VOLTS windows. With the switch in its normal Run

position the STRIKE parameters will initially be dis-

played.

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 de-

scribed above); for example, the numbers that ap-

pear in one or both of the display windows are mean-

ingless (all zeros, eights, decimals,etc.), or are com-

pletely 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 beenturned

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 des-

cribed in this booklet.

start switch circuit components—switch, plug,

receptacle, etc.

c. If motor will not turn using either of the above

switches, replace the J governor board. If motor

still refuses to run, replace 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.

E. Arc VOLTS display reads zero after TS is oper-

ated.

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 feed-

back between terminals T1-18 and T1-19 (test points

TP1 and TP2, respectively, on I/O board). This volt-

age 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 digimatic. If wiring is correct

and problem persist, proceed to step 4.

4. 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 thparam-

eter, VOLTS or IPM, that cannot be maintained.

If this condition occurs, the respective servos need

to be checked and, if necessary, readjusted as follows:

Please note that the servo checking/setting procedure

for the Digimatic II control contained herein is different

from all previous Digimatic controls. Therefore, you

need not adjust the voltage servo trimpot or speed

servo trimpot on the I/O p.c. board - these trimpots are

factory-set and sealed, and should never be adjusted

(as was required of older Digimatics).

B. No preset numbers, or meaningless numbers, ap

pear in display windows.

1. Make sure the LED Display board harness/plugis

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;

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 win-

dows—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 Digimatic 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 of 10 volts

ormore 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

1. This symptom can occur as a result of the either or all

of the following; the Speed and Voltage servo adjust-

ments are incorrect and the conditions "set " may not

be maintainable. To check and, if necessary, readjust

the servos - proceed as follows.

NOTE: Prior to checking the servos, make sure the

control is connected to a suitable ESAB power

supply in order to obtain the necessary

o.c.v.(open circuit voltage); otherwise, the mo-

tor will not run.

2. The Speed and Voltage servos in this control are

simultaneously checked and displayed by depressing

and holding the Arc Hrs./Inch Preset switch (on inside

panel) in its "down" position during an actual weld and

the wire feed motor running. The speed servo number

is displayed in the left (IPM) window and should be

about 110, and the right (VOLTS) window will display

the voltage servo number. This number will between

90 and 100* for the actual welding condition.

* Voltage servo setting below 95 will normally provide

hot arc starts; whereas, setting over 100 will not.

3. If a Speed abort had occurred (IPM window flashing),

check and/or adjust the speed servo as follows:

Open the pressure roll clapper (so as not to feed wire),

toggle-down the Arc Hrs/Inch Preset switch position,

and either place the weld Start/Stop switch in START

position or toggle down the INCH switch. Check the

number in the IPM window - it may appear unsteady

but readable and should be about 110.

If it is higher or lower, use the Inc/Dec toggle (below

the IPM window) to adjust the number to 110 - while

"holding" the A.H.\Inch Preset as mentioned above

and while the wire feed motor is running.

If the speed servo cannot be adjusted at all, the

problem may be in the J-Governor, and/or I/O, and/or

MPU p.c. boards which must be replaced as required.

4. If a Voltage abort had occurred (VOLTS window flash-

ing), check and/or adjust the voltage servo as follows:

This is a two-man operation. Set a welding condition

which closely corresponds to your welding application

and the proper speed (ipm) for a given wire size, and

then place the Weld switch in Start position and strike

a welding arc. While welding, toggle-down the Arc

Hrs./Inch Preset switch position and read the

number displayed in the VOLTS window, it may

appear unsteady but readable and should be 95.

If the number is not in the 90-100 range, use the Inc./

Dec toggle (below the VOLTS window) to adjust the

number to 95 - while holding the toggle position

mentioned above and while welding.

5. If the voltage servo cannot be adjusted, check

for proper operation of the power supply as follows:

a. Set the Digimatic voltage display to zero (thissetting

will override the servo).

b. Place the Panel/Remote switch on the power sup-

ply in PANEL position.

c. Make a weld by controlling the arc voltage directly

from the power supply potentiometer. If a weld can

be made with good control over powers connecting

voltage control cable, or in the Digimatic control.

e. Check the control wires in the interconnecting volt-

age control cable for continuity between the appro-

priate terminals in the power supply and Digimatic

using the schematic diagrams.

f. If continuity is correct, replace the I/O board and/or

the MPU board.

IMPORTANT: In addition to the Welding Condition Sequence Diagram (Figure 5) and the Trouble Symptom/checks described

in Section V, the Sequential Troubleshooting Flow Diagram (Figure 6) can be very useful in diagnosing your problem.

Before using the Flow Diagram, make sure the Digimatic Control is connected to a suitable ESAB power supply designed for

electronically controlled arc voltage regulation (see Section 1-A-4). The power supply muct be setup for "remote" operation, and

the control preset and energized to provide the desired welding condition parameters.

If you wish to troubleshoot the Digimatic Control without using a power supply, two TEST toggle switches labeled "Amps" and

"Volts", on the inside control panel provide a convenient way to "test-sequence" all of the welding condition parameters without

actually striking an arc. To do this, the control must be connected to an external 120 VAC power source (by customer),

preset all "arc voltage" condition parameters to zero (0) cycles, and preset the "Strike-Time" parameter to at least 150

cycles. The extended strike-time period is necessary to allow enough time to manually simulate an arc detection signal by

momentarily actuating the "Amp" toggle TEST position. Now, place the "Volts" toggle to its TEST position, and release the clapper

on the accessory support to remove wire feed pressure. With this accomplished, follow the Flow Diagram instruction sequence

until the weld condition is into the Strike-Time sequence. During this time period you must actuate the "Amps-Test" toggle (to

simulate arc detection), otherwise the strike-time will time out and the control will abort as shown in the diagram. If done correctly,

the unit will automatically continue through the remaining welding sequences.

Figure 6 - Sequential Troubleshooting Flow

Diagram

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ESAB Digimatic II Four Schedule Microprocessor Control Troubleshooting instruction

Brand: ESAB

Model: Digimatic II Four Schedule Microprocessor Control

Category: Welding System

Type: Troubleshooting instruction

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ESAB Digimatic II Four Schedule Microprocessor Control Troubleshooting instruction

ESAB Digimatic II Four Schedule Microprocessor Control Troubleshooting instruction

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