ESAB Digipulse Dual XR Custom Welding System for Dana Corporation User manual
- Category
- Welding System
- Type
- User manual
F-15-267
August, 1995
FEATURES AND FUNCTIONS
DIGIPULSE DUAL XR
CUSTOM WELDING SYSTEM
For Dana Corporation
This welding system was modified using a standard Digimig Dual Feeder and
Digipulse XR control and software. All material codes and wire diameters are
identical to the Digipulse XR except where noted. This system has been modified
to have the functions and features requested by Dana Corporation to meet their
specific weld application requirements.
Custom Part Numbers
Control Only..................................................... 34850
SCO EPROM Ref. ......................................... 000269
MPU Board w/EPROM .................................... 18160
Electrical Schematic ........................................ 34851
Wiring Diagram ............................................... 34852
Custom Features
1. Same Weld Parameters on Torch #1 & 2.
2. Synergic or Adaptive Operation..
3. .052" Wire Diameter Added to Carbon Steel #1.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
Complete System P/N ..............Not Issued
DigiMig/Pulse Dual Feeder P/N .............. 34849
EPROM Part Number ..............18095 Labeled on EPROM
Software Code .............. 17.0 Shown in VOLTS window of control
2
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS
--
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex-
plosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro-
duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
SAFETY PRECAUTIONS
10/98
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move-
ment is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or dam-
aged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
3
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless positive
mechanical ventilation is provided. Do not breathe fumes
from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im-
prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
5. WARNING: This product, when used for welding or
cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &
Safety Code §25249.5 et seq.)
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin-
der, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu-
lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position
and in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi-
ami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Hand-
book.
8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."
MEANING OF SYMBOLS - As used through-
out this manual: Means Attention! Be Alert!
Your safety is involved.
Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.
Means potential hazards which could
result in personal injury or loss of life.
Means hazards which could result in
minor personal injury.
SP98-10
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6
Dana Corporation Welding System
Supplemental Operating Instructions
Digipulse Dual XR Wire Feeder with Digipulse 450 Power Supply
Features
Two torch system
1 weld schedule controls both torches
Three independent weld process schedules
1-Pulse arc schedule
1-Short arc schedule
1-Spray arc schedule
Pulse Arc - Carbon Steel, Stainless Steel,
Aluminum & Silicon Bronze
Pulse Arc - 030, .035, .045, .052 & 1/16"
diameter wires
Pulse Arc - Adaptive or Synergic operation
Key lock all weld parameters
System Parameters
Gas Preflow Set
Gas Postflow Set
Cold Inch Set
Material/Dia. Code
Spot/Burnback Set
IPM & Volts Servo Set
Short Circuit
GMAW Process
Spray
GMAW Process
Pulse
GMAW Process
IPM VOLTS
Torch #1
Torch #2
IPM VOLTS
IPM VOLTS
7
OPERATING INSTRUCTIONS
A. GENERAL
Your Digipulse Dual XR wire feeder has been designed to
Dana Corporation specifications and incorporates fea-
tures from both the Digipulse XR and the Digimig Dual
wire feeds. General operating instructions for these
feeders have been supplied with your Digipulse Dual weld
system. The Digipulse Dual wire feeder is a combination
of a Digipulse XR control (with software modifications)
and a Digimig Dual wire feeder frame and switching
circuitry.
The intent of the following information and instruction is to
supplement ESABs standard literature supplied with the
wire feeder and power supply. Be aware of all safety
warnings and equipment installation procedures
before continuing with the following additional infor-
mation.
The Digipulse Dual wire feeder has two wire feed motors
and can accommodate two welding torches. The feeder
control circuitry stores weld parameters for the short
circuiting, spray and pulse spray welding processes but
only one set of welding parameters is used at any one
time. Independent control of weld parameters on each
torch is
NOT supported. It should be noted, this is a one
operator welding system and both torches CANNOT be
used at the same time. The operator can choose either
Torch #1 or Torch #2, depending on requirements.
The following will detail the installation and operation of
this unique welding system.
B. START-UP
Digipulse 450 power supply, feeder and interconnect
cable assembly is the same as specified in the Digipulse
Wire Feeders ( F-15-012) and Digipulse 450 Power
Supply (F-15-014) general operating instruction manu-
als. The Digimig Dual instructions (F-14-489) have also
been supplied for further reference to general information
covering feeder operation.
After power has been applied, the windows on the feeder
will display IPM=261 and VOLTS=17.0 for one second.
This indicates Product Code (IPM window) and Software
Version # (VOLTS window). This information indicates
the type of software installed in the control and the latest
version number. To insure all your units have the same
software, these numbers shown on start up should be
identical.
After one second, the windows will then display the last
welding parameters (IPM and Voltage) set by the opera-
tor.
C. SYSTEM VARIABLES
System variables are those parameters that are set once
and will affect both torches. These parameters are
always active for both torches and should be set first.
Gas Preflow
Gas Postflow
Cold Inch
Spot/B'back
Mat'l/Diameter
Servo Settings (when applicable)
1. Gas Preflow and Postflow
a. Preset the shield gas preflow time by holding down the
purge key and using the Inc/Dec key under the IPM
window to set a time in 1/10 seconds.
b. Repeat the above for postflow using the key below the
VOLTS window.
2. Cold Inch
a. The cold inching feature has a two step speed control.
When the Inch key is held in the "Up" position, the wire
will feed at a non adjustable rate of 100 inches per
minute for a period of 2 seconds. This speed is
displayed in the IPM window and is designed to
"bump" the wire slowly for fine adjustment of wire stick
out.
8
b. Set the cold inching speed by holding the Inch key in
the "Up" position for more than 2 seconds and adjust
IPM using the Inc/Dec key to any speed desired
between 50 and 999 inches per minute. This function
is designed for wire threading.
3. Burnback Preset
a. Adjust the wire burnback by holding the Spot/Bback
key in the up position and setting a burnback number
in VOLTS window using the Inc./Dec. key. The number
entered relates to line cycles (60=1 sec.). A number
between 2 and 6 is the typical range.
b If you prefer the feeder to automatically set the wire
burnback, set the burnback number to zero (0).
4. Spot Weld Preset
a. If a spot weld is required, choose the spot weld time by
holding the Spot/Bback key in the up position and
setting a spot weld time in cycles per second (60=1
sec.) in the IPM window .
b. If continuous welding is desired, set this number to zero
(0).
5. Material/Diameter Preset
a. Choose the Material/Diameter code (1 through 6) by
depressing the Mat'l/Dia key and setting the desired
material number (see Material Code Table) in IPM
window and wire diameter to be used in the VOLTS
window.
5. Slow Wire "Run In"
a. The slow wire "run in" is set to provide one half the
preset wire feed speed (IPM) until the wire touches the
work piece, at which time, the wire feed rate will switch
to the speed preset in the IPM window. This option, in
most cases, improves arc starting characteristics.
b. If full speed "run in" is preferred, the half speed can be
disabled by locating dip switch #2 on the MPU board
(see MPU board drawing) and placing rocker switch
#1 in the "close" position.
C. TORCH DEFAULT
The right side torch (Torch #1 - viewed from the front of
the feeder) is the default torch. This means that when the
feeder is first powered up this torch is ready for use. The
software will automatically switch to the torch being used
RECOMMENDED MATERIAL AND SHIELD GAS TABLE
WIRE MATERIAL WELD PROCESSES
Code # Material Type Short Arc Spray Arc Pulse Arc
1CO
2
Argon-5% CO
2
Argon-5%CO
2
Carbon Steel Argon-25% CO
2
Argon 2-5% O
2
Argon 2-5% O
2
Argon-8% CO
2
2 Alternate Steel C-25 Argon-8%CO
2
-2%O
2
Argon-8%CO
2
-2% O
2
Ar-8% CO
2
-2% O
2
Argon-8% CO
2
Argon-8% CO
2
3 4043 Aluminum Argon Argon
4 5356 Aluminum Argon Argon
5 308 Stainless Steel A-1025 Argon 1%-2% O
2
Argon-2% CO
2
-1% H
2
6 Silicon Bronze Argon Argon
7*
8*
9*
10*
*These codes are reserved for custom synergic weld parameters.
9
when the torch trigger is depressed. The weld parameter
settings, material/dia. code, burnback, spot weld time
and cold inching speed, set previously, are ready for use
D. WELD PROCESS SELECTION
The Digipulse Dual feeder is a synergic welding system in
all weld process modes. This means that a specific wire
feed speed and arc voltage relationship has been pre-
programmed into the control based on the weld process
selected and the type of weld wire and diameter weld wire
being used. This information is supplied to the control by
selecting the welding process using the "Process Selec-
tion" switch on the front panel (short circuit, spray of pulse
spray) and then entering the material/diameter informa-
tion as described above.
1. Adaptive Arc Welding
The IPM window will display the wire feed speed in inches
per minute and the VOLTS window will display a voltage
corresponding the material type and wire diameter you
have preset. The arc voltage (arc length) will be automati-
cally maintained by the control at the pre-set values
independent of torch manipulation. You can trim the
preset values to optimize arc performance and welding
characteristic by adjusting the IPM or arc volts using the
Inc/Dec keys under each window.
If the welding arc length is too long, decrease the voltage
using the Inc./Dec. key under the VOLTS window which
shortens the arc length. If the welding arc is too short,
increase the voltage in the VOLTS window. The adap-
tive characteristic is noticeable when pulse spray weld-
ing by audible changes in the pulse frequency caused by
variations in the wire electrical stick out or torch manipu-
lation. The pulse frequency will automatically be adjusted
to maintain the arc voltage you have set in the VOLTS
window when welding in the pulse spray process mode.
2. Synergic (Non-Adaptive) Arc Welding
If the Adaptive mode is less than desirable, the
feeder can be switched to non-adaptive operation.
This is still a synergic relationship but the arc voltage
is not automatically maintained by the control. This
means the arc length will vary with torch manipulation.
When pulse spray welding, the pulse frequency will
not automatically change with variations in wire elec-
trical stick out. The pulse frequency will remain con-
stant at any given voltage setting. To enter non-
adaptive pulse operation proceed as follows:
a. Disconnect all input power to power supply.
b. Remove the sheet metal cover on the wire feeder
control box by removing the five sheet metal screws.
c. Remove the J governor P/C board ( small P/C board
in front). Locate the MPU board which is the large P/
C board facing you when you remove the J governor
board. Find dip switch #1 and open rocker switch #1
(as shown above).
d. Replace the J governor P/C board.
Program
EPROM
Dip Switch #2
Closed
Open
Dip Switch #1
Closed
Open
Open Position
1
2
3
4
1
2
3
4
MPU Board w/EPROM (P/N - 18160)
Closed Position
10
e. Replace the sheet metal control cover and five screws.
Reconnect input power to power supply .
The IPM window will now display the wire feed speed in
inches per minute and the VOLTS window will show a
number between 0 and 200 with 100 being the default
value. This is NOT an arc voltage value!!! The number
is a reference integer used by the digital circuitry and
corresponds to the synergic relationship programmed
into the control. The number 100 relates to the nominal
arc voltage required for the wire feed speed selected in
the IPM window. This number will also effect the arc
length. You can trim the preset values to optimize arc
performance and welding characteristic by adjusting the
IPM or arc volts using the Inc/Dec keys under each
window.
If the welding arc length is too long the number can be
decreased which shortens the arc length. If the welding
arc is too short, increase the number in the VOLTS
window. The ACTUAL arc voltage will be displayed
during welding.
E. ARC STARTING (SERVO) SETTINGS
In most cases, when using the "Adaptive" weld mode, the
arc voltage servo is the most frequent culprit when arc
starting is poor. I suggest that this adjustment be done
first if arc starting seems to be a problem. The IPM servo
can be adjusted second if the voltage servo does not
solve the problem. The arc voltage servo is disabled
when the control is set up for "Synergic" welding.
Arc Voltage Servo Adjustments
The voltage servo setting can be observed only during
welding. While welding, depress the "Purge" key and
"Mat'l/Dia." selection key simultaneously. The VOLTS
window will display a number between 0 and 200 with 90
being typical.
Using the "Inc/Dec" key below the VOLTS window, re-
duce the number shown to give a "hotter" arc start or
increase the number for a "colder" arc start. DO NOT
make large changes at any one time. Wire burnbacks
and other problems can result. Make small adjustments
and retest the arc starting several times in order to
optimize starting characteristics. Changes in wire feed
speed and/or voltage might necessitate readjusting the
voltage servo. This setting will apply to ALL weld process
modes.
Feed Motor Servo Settings
You can adjust the feed motor response by presetting the
motor speed servo. In order to see and adjust the actual
speed servo settings, release the pressure roll and pull
the torch switch while depressing the "Purge" key and
"Mat'l/Dia." key simultaneously. The IPM window will
display a number between 0 and 200 with 110 being
typical. Using the "Inc/Dec" key below the IPM window,
reduce the number shown by 3 or 4 digits at a time to give
a faster acceleration to the wire feed speed or increase
the number for a slower acceleration. DO NOT make
large changes at any one time.
11
DIGIPULSE XR DUAL PROGRAM CHART
PULSE PARAMETERS
Not in Use
WIRE DIAMETER
.030"
.035" .045" .052" 1/16"
5.8 6.5 6.8 7.0 8.0
25 30 30 40 50
1.8 2.0 2.2 2.3 2.4
5.4 5.8 6.0 6.5
60 60 60 60
2.2 2.5 2.6 3.8
4.5 4.3 4.3 5.0
25 40 40 40
1.3 2.0 2.5 2.2
5.3 5.0 5.5 5.9
25 40 40 50
1.1 1.5 2.0 2.6
5.3 7.0 7.4 7.1
20 25 25 45
2.4 2.0 2.0 2.7
5.7 5.5 8.0
45 30 40
2.2 2.5 2.0
New Data
V
p
I
b
T
p
Carbon Steel
C-5
O-5
Gas
1
V
p
I
b
T
p
Alternate
Carbon Steel
C-5/Stargon
or O-5 Gas
2
V
p
I
b
T
p
3
4043
Aluminum
Argon Gas
V
p
I
b
T
p
4
V
p
I
b
T
p
308L
Stainless
Steel
Pulse Blend
5
V
p
I
b
T
p
6
Silicon
Bronze
Argon Gas
5356
Aluminum
Argon Gas
7
8
9
10
PROGRAM #
MATERIAL
TYPE &
SHIELD GAS
VARIABLES
V
p
I
b
T
p
V
p
I
b
T
p
V
p
I
b
T
p
V
p
I
b
T
p
DigiPulse Dual Feeder 34849
EPROM P/N 18095
Product Code 261
Software Code 17.0
12
F. TROUBLESHOOTING
Be sure that all primary power to the machine has
been externally disconnected. Open wall disconnect
switch or circuit breaker before attempting inspec-
tion or work inside of the power source.
A. DIGIPULSE 450 POWER SOURCE
If power source is operating improperly, refer to the
troubleshooting information located in F-15-014.
B. DIGIPULSE DUAL WIRE FEEDER for DANA CORP.
(Refer to Schematic Diagram D-34851)
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. Always place p.c. boards on a static free surface.
If a printed circuit (PC) board is determined to be the
problem, check with your supplier for a trade-in on a new
PC board. Supply the distributor with the part number of
the PC board (and preprogram number, as described in
step 1-c. following) 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.
1. General
a. Check interconnection between control and power
source.
b. Energize the power source and the control.
c. Immediately after the control is turned on, a num-
ber (e.g.:3) will appear in the IPM readout window
and will only be displayed for 1-second. This num-
ber 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 number .1, .2, .3, etc. indicat-
ing the numerical revision will also appear in the
VOLTS readout window simultaneously.
d. After the one (l) second delay; the preset Weld
parameters will be displayed in the IPM and VOLTS
windows.
e. 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:
(1) Place the Run-Set key switch in its SET posi-
tion.
(2) Turn off the units 110-volt Power switch.
(3) Using one hand, hold both of the Inc/Dec
toggle switches in their INC position while
reapplying 110-volt power with the other hand.
(4) 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 take place.
f. You can now enter the desired information as
described in this booklet.
2. No preset displays appear in windows.
a. Make sure the LED Display board harness/plug is
plugged into the P5 receptacle on the MPU board.
b. Check that 110 vac is available across terminals
T1-18 and T1- 19, if present;
c. Check for plus (+) 5 volts between terminals T1-8
and T1-9; 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 rear panel of the control box.
d. Check the input and output voltage of the regulator
VR.
(1) The input should be approx. 10 volts between
terminals T1-9 and VR-1. If voltage is not
present, replace I/O board.
3. Preset display is provided, but cannot be varied.
a. Check normal setup procedures described in Sec-
tion V, then;
b. Make sure the key wiring harness plug is properly
connected to receptacle P6 on the MPU board, and
the lock-in key switch is placed in its SET position.
c. If neither of the above resolve the problem, replace
the MPU board.
4. Motor does not run.
a. Check to make sure all required (and/or optional)
accessories are correctly assembled as described
in Sect. III.
b. Make sure that power source is connected, plug P2
is securely connected to receptacle P2 on the
Digipulse I/0 Board, and then release the clapper
arm (pressure roll) on the Accessory Support As-
sembly.
(1) Operate the control INCH switch. If motor does
not run; replace the J governor board, and if
it still does not run, replace I/O and MPU
boards respectively.
(2) If the motor inches, but does not run when the
torch switch is operated (energized), check the
torch switch circuit components-switch, plug,
receptacle, etc. If motor still does not run,
check if power source is providing open-circuit
voltage to the control-if o.c.v. is not being
supplied, motor will not run. Check the power
13
source for trouble.
(3) Also check that the +/- 12 vdc are provided from
the power source on T1-7 and T1-5 respec-
tively.
(4) If power source if O.K., replace the I/O and MPU
boards respectively.
5. Motor runs, but not at right speed.
a. Check tachometer assembly mounted on the end of
the EH-10 wire feed motor.
b. 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.
c. If all items in step b. are in order, and motor speed
is still incorrect, replace MPU board.
6. Arc VOLTS display reads zero after TS is operated.
a. Check that the 5-pin plug is securely connected to
the P3 receptacle on the MPU board.
b. If no reading is displayed, check for arc voltage
feedback between terminals TP1 and TP2 test
points on the l/O p.c. board (see Fig. 5A). This
voltage signal should correspond to that shown on
the power source voltmeter.
c. If voltage still reads zero, trace the voltage pickup
wiring from the power source to digipulse.
d. Remove the J-Gov p.c. board to gain access to the
P3 plug (harness) on the MPU p.c. board. Discon-
nect 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 MPU
board.
7. Control Shut-Down either preset VOLTS or IPM
displays will flash. The control will flash the pa-
rameter 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, the voltage condi-
tion 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 syner-
gic) the control is set to operate in, or how to change it,
please review Section VI-B.
a. IPM (speed) abort and possible causes:
(1) Initial hot start parameters incorrectly set. For
proper adjustment, refer to Set-up Procedures
following V-C-11.
(2) Defective J-governor board.
(3) Defective Motor tachometer board.
(4) Defective l/O board.
(5) Defective MPU board.
TP2
TP1
Fig. 5A - Input/Output (I/O) P. C. Board, P/N 674994
Contact ESAB Engineering Services for
further assistance. (803- 664-4416).
b. 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.
(1) Set the wire feeder for synergic operation in the
Pulse welding mode.
(2) Strike an arc and while welding, measure the
potential between T1-4 and T1-6 Note that as
the arc voltage setting is increased, the poten-
tial between T1-4 and T1-6 also increases, and
will range from 0 to 10 vdc. If it does not,
replace the l/O and/or MPU board. If the poten-
tial is present and responding to the voltage
change setting, continue with step (3) follow-
ing.
(3) Now measure the control voltage, for the back-
ground current, between T1-6 and pin J1-J of
the amphenol connector. This measurement
can be taken without striking an arc. The poten-
tial will the 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 (4) following.
(4) If both of the preceding conditions (steps 2 and
3) 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 source
(known to be good) to check out the possible
problem; if these are not available, continue
with the wire feeder calibration test in step 8
following.
8. 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.
14
To set up the control in the diagnostic mode, simulta-
neously depress the Wire Dia/Matl. 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 l/O board, connect a
voltmeter from T1-6 (negative) to T1-4 (positive).
Energize the torch 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 l/O
board should either be recalibrated (by a qualified
technician) or the board should be replaced.
Next, check the potential from T1-6 (-) 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 the readings are
correct, check the power source by using the calibra-
tion procedure described in Inverter Control Board
(lCB) Troubleshooting in the Power Source manual F-
15-014.
F-15-267 8/95
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ESAB Digipulse Dual XR Custom Welding System for Dana Corporation User manual
- Category
- Welding System
- Type
- User manual
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