ESAB Digipulse Wire Feeders Troubleshooting instruction

Brand: ESAB

Model: Digipulse Wire Feeders

Category: Welding System

Type: Troubleshooting instruction

F-15-012-B

November, 1996

INSTRUCTIONS for

DIGIPULSE WIRE FEEDERS

DIGIPULSE 2 Roll Drive Wire Feeder, P/N 30680* (ESAB); 35640 (L-TEC)

DIGIPULSE 4 Roll Drive Wire Feeder, P/N 31821* (ESAB); 35658 (L-TEC)

Optional DIGIPULSE Teach Kit, P/N 35638**

* These Digipulse Wire Feeders provide preprogrammed Wire Type Material Codes 1

thru 6 (see Specifications), plus codes 7 thru 10 which are reserved for custom

applications where you can add programs for alloys such as inconel, titanium, metal

cored wire, flux cored wire, etc.

** This field-installed Teach Kit (see II-B-1) allows you to quickly develop pulse parameters

for any weldable alloy and storing up to 5 teach conditions in Material Codes 11 thru

15. The teach portion of the Digipulse is covered in booklet F-15-013.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe

practices for arc 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. If you do not fully understand

these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on page 3 before

installing or operating this equipment.

Note: This manual provides complete coverage on the Digipulse Wire Feeders starting with Serial No. WF-I512043

SPECIFICATIONS

Input Power Required ........................................ 7 Amp., 115 vac, 1 ph, 50/60 Hz

Wire Feed Speed Range ................................... 20-999 in/min (.5-25.2 m/min)

Wire Sizes Preprogrammed .............................. .023-in. (.7 mm), .030-in. (.76 mm), .035-in. (.9 mm), .045-in. (1.2 mm), and .063-

in. ( 1.6 mm)

Wire Type (Mat.) Preprogrammed ..................... 1. Carbon Steel, 2. Alternate Steel, 3. 4043 Alum., 4. 5356 Alum., 5. Stainless

Steel, 6. Silicon Bronze, and 7. thru 10 reserved for custom application

Dimensions ........................................................ 18.5-in. (470 mm) l.,13.0-in. (330 mm) w, 16.5-in. (419 mm) h

Weight (less wire) .............................................. 46 Ibs (21 kg)

CONTENTS

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

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

I. INTRODUCTION ............................................................... 5

II. SYSTEM REQUIREMENTS .............................................. 6

A. Required Equipment ............................................................... 6

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

III. INSTALLATION ........................................................ 7

A. Unpacking and Placement ...................................................... 7

B. Power Source/Wire Feeder Control Interconnection .............. 8

C. Wire Feeder Installation Requirements .................................. 8

IV. OPERATING INSTRUCTIONS ....................................... 10

A. Power Source Welding Controls ................... Refer to F-15-014

B. Wire Feeder Control Functions ............................................. 10

C. Gas/Wire Adjustments .......................................................... 14

V. SETTING UP PROGRAM PARAMETERS ...................... 14

A. Typical Welding Conditions ................................................... 15

B. Preliminary Power Source Checks ........................................ 15

C. Program Control Parameters

(includes Hot Start Setting information) ................................ 15

Vl. WELDING OPERATION ................................................. 18

A. Pulse/Spray/Short Arc Wire Speed Recommendations ........ 18

B. Welding in Pulse or Spray or Short Arc Mode ...................... 19

C. Spot Welding ......................................................................... 18

Vll. MAINTENANCE ............................................................. 19

Vlll. TROUBLESHOOTING.................................................. 20

A. Digipulse 450 Power Source ......................... Refer to F-15-014

B. Digipulse Wire Feeder .......................................................... 20

IX. REPLACEMENT PARTS DATA ....................................22

Figure 1- Operational Sequence .................................................. 5

Figure 2 - Digipulse Interconnection Diagram ............................. 9

Figure 3 - Rear Panel Controls .................................................. 10

Figure 4 - Front Panel Controls .................................................. 11

Figure 5 - MPU PC Board - Dip Switch location ........................ 18

Figure 5A - Input/Output (I/O) P.C. Board .................................. 20

Figure 6 - Typical Digipulse Wire Feeder .................................. 22

Figure 7 - EH-10A Digital Motor-Gear Unit Assembly ................ 22

Figure 7A - EH-10A Motor-Gear Unit Parts Breakdown ............ 23

Figure 8 - Accessory Support Assembly .................................... 23

Figure 9 - Digipulse Control Assembly. ..................................... 24

Figure 10 - Spindle Assembly/Optional Wire reel ...................... 24

Figure 11 - Water Kit with/without Solenoid Valve ..................... 24

Figure 12 - Schematic Diagram - Digipulse XR and XRT .......... 25

Figure 13 - Wiring Diagram, Digipulse

TABLES

Table 1. - Feed rolls, feed roll kit and outlet guides ..................... 6

Table 11. - Recommended Shielding Gases ............................. 15

Table III. - Typical "Short Arc" Wire Speed Ranges .................. 17

Table IV. - Typical "Spray Arc Wire Speed Ranges ................. 17

Table V - Typical "Pulse Arc" Wire Speed Ranges ................... 17

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

11/95

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.

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.

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 im-

properly 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."

This symbol appearing throughout this manual

means Attention! Be Alert! Your safety is

involved.

The following definitions apply to DANGER, WARNING,

CAUTION found throughout this manual:

Used to call attention to immediate haz-

ards which, if not avoided, will result in

immediate, serious personal injury or loss

of life.

Used to call attention to potential haz-

ards which could result in personal injury

or loss of life.

Used to call attention to hazards which

could result in minor personal injury.

I. INTRODUCTION

Through the use of advanced electronics and state-of-

the-art technology, ESAB has created in the Digipulse a

high performance welding system that is extremely simple

to operate, yet much more versatile than anything previ-

ously available. The Digipulse system automatically de-

termines all critical welding parameters in pulsed and

conventional mig short and spray arc welding applica-

tions-simply select wire type, diameter, wire feed speed,

and the Digipulse control does the rest. Note that the

power source used in this system is also suitable for

stick, scratch-start tig and air carbon arc applications

(see F-15-014).

These features are provided by advanced Digipulse

systems which combine a special Digipulse 450 ampere

inverter-type power source, and a microprocessor-based

Digipulse wire feeder/control. These system compo-

nents work together to provide a pulsed or nonpulsed mig

set-up using synergic/adaptive logic that self-adjusts

while welding for optimum arc performance.

In the synergic mode, the control selects an appropriate

arc length, based on weld mode (short, pulse or spray),

for a given wire type, size and feed rate. The pulse

frequency in pulse mode remains constant regardless of

torch manipulation. This pulse logic offers many advan-

tages to the welder, particularly where joint geometry

caused rapid changes in torch stickout resulting in un-

stable puddle conditions.

In the adaptive mode, the control varies the frequency

during pulse welding to maintain a constant arc voltage

regardless of changes in torch stickout or angle. This

logic is very useful where joint geometry is clean.

Heres how it works for Pulse arc operation (Fig. 1). The

Digipulse wire feeder control is preprogrammed to ac-

commodate a wide variety of welding combinations.

These combinations are derived by selecting one of the

wire diameter sizes and wire material type that are

preprogrammed in the controls memory (available se-

lections depend on the specific model purchased). The

operator programs one of these combinations (electing

a particular wire size and type), and a wire feed speed

(ipm) for the desired welding condition. The microcom-

puter then, automatically calculates the required pulse

characteristic and arc voltage, and commands the in-

verter power source to produce the proper output. While

welding, the microcomputer constantly monitors arc

parameters and wire feed speed, and automatically

adjusts the pulse rate to changing arc conditions. Al-

though arc length/voltage is automatically computed for

each welding condition, this parameter can be fine-tuned

from its computed value to accommodate unique appli-

cations or operator preferences.

For conventional (non-pulsed) mig spray or short arc

applications (Fig. 1), the welding setup procedure is

exactly the same as that described for the pulse welding

mode. That is, the operator still presets a wire type

(material), wire size (diameter) and wire feed speed

(ipm) parameter from one of the available preprogrammed

welding conditions. Once these parameters are pro-

grammed, the microprocessor automatically provides

the correct arc length (for synergic operation) or arc

voltage (for adaptive operation) for a stable welding

condition. For further information regarding synergic and

adaptive mode operation, see sections IV-B-4-b., IV- B-

7-b., Vl-B and VI-D.

Two digital readout windows (1/2-in. high) on the control

continuously display the preset welding parameters

(speed and arc length for synergic mode; or arc voltage

for adaptive mode) as determined by the Pulse/Spray/

Short Arc mode switch. After the arc is struck, they

automatically display the actual wire feed speed and arc

WELD SET-UP PROCEDURE

As Easy As 1-2-3!

1. Select your welding process-

Short, Spray or Pulse.

2. Depress this key to access wire type MATERIAL

in IPM window and wire size DIAMETER in

VOLTS window select by simultaneously using

INC/DEC keys.

3. Use this key to set your wire feed speed in the

IPM window and your ready to weld!

Other parameterspre/postflow gas, spotweld,

burnback, cold inch, etc. are just as easy to add

read on!

Fig. 1- Operational Sequence

Table 1

Wire/Size Two Roll Drive Four Roll Drive Outlet

in. (mm) Feed Roll Feed Roll Kit* Guide

Soft

.030 (.8) 2075304 (U) 999320 (U) 29N13**

.035 (.9) 2075304 (U) 999321 (U) 29N13**

3/64 (1.2) 2075301 (U) 999322 (U) 29N13**

1/16 (1.6) 2075298 (U) 999323 (U) 29N13**

Hard

.023 (.6) 17998 (V)  999745 (c)

.030 (.8) 2075300 (V) 999325 (V) 993860 (a)

.035 (.9) 2075303 (V) 999326 (V) 993860 (a)

.045 (1.2) 2075302 (V) 999327 (V) 39N15 (b)

.052 (1.4) 2075330 (V) 999328 (V) 39N15 (b)

.063,1/16 (1.6) 2075299 (V) 999329 (V) 39N15 (b)

Cored Hard

.035 (.9) 19761 (Serr.)  993860 (a)

.045 (1.2) 19761 (Serr.) 999330 (Serr.) 39N15 (b)

.052 (1.4) 2075261 (Serr.) 999331 (Serr.) 39N15 (b)

.063,1/16 (1.6) 2075261 (Serr.) 999332 (Serr.) 39N15 (b)

voltage conditions for the selected mode. The readouts

can also provide selectable displays of other applicable

welding parameters (depending on the specific model)

such as wire inch speed, spot time in cycles, manual

burnback time in cycles, gas pre- and postflow times in

tenth of a second increments. In addition, average cur-

rent is displayed on the power source digital ammeter

window.

The wire feeder uses a heavy duty EH-10A wire drive

motor designed to feed hard or soft wires. Rate of wire

feed (20-999 ipm) is precisely controlled by using a

closed-loop digital feed back circuit that employs an

optical tachometer to monitor the motor speed. Arc

Voltage regulation is also controlled by a closed-loop

digital feedback circuit that monitors the arc voltage and

automatically adjusts the power source output to main-

tain the preset condition.

All interconnecting cable, hose and auxiliary equipment

connections are easy to install to provide quick setup as

shown in the Installation section. A water kit with or

without solenoid valve may be purchased, as an optional

accessory, for use with water cooled torches.

II. SYSTEM REQUIREMENTS

A. REQUIRED EQUIPMENT

A typical Digipulse Pulsed-Mig Welding Package

requires:

1. One of the following Digipulse Wire Feeders;

a. Digipulse, 2 Roll Drive, P/N 30680.

b. Digipulse, 4 Roll Drive, P/N 31821.

2. One of the following three-phase Digipulse Power

Sources;

a. Digipulse 450i cvcc for 230/460-volt, 60 Hz service

P/N 31120, covered in booklet F-15-014.

b. Digipulse 450i cvcc for 575-volt, 60 Hz service P/N

31238, covered in booklets F-15-014 and Supple-

ment F-15-015.

c. Digipulse 450i cvcc for 50 Hz. service P/N 31690,

covered in booklets F-15-014 and Supplement F-

15-039.

3. Control cable assembly as follows:

a. A 6-ft. control cable (19/c) with 19-pin amphenol

connectors each end, P/N 30686 is supplied as

part of the package. For longer length assemblies,

order one of the following:

b. 30-ft. long, control cable P/N 30780.

c. 60-ft. long, control cable P/N 30781.

4. Welding Torch. A mig welding torch, with contact tip,

wire conduit and outlet guide for wire size/type to be

employed, will be required. A suitable air (MT-400) or

water- cooled (ST-16) torch may be used with the

Digipulse. When using Digipulse systems to weld

aluminum, we strongly recommend using a MIG-41

Push-Pull Torch. For applications above 1/8-inch metal

thickness on all materials, a water cooled torch is

recommended.

When using a water-cooled torch it will be necessary

to connect the torch water hose to either a continuous

water supply or to the wire feeder base by using an

optional water kit.

5. Gas Regulation. Shielding gas regulator/flowmeter

and fitted hose to bring gas from flowmeter to wire

feeder. Such as:

Regulator/Flowmeters:

R-5007 Argon/Helium/Nitrogen, P/N 998124.

R-5008 CO

, P/N 998125.

Standard Duty, P/N 40V77 (12-1/2-ft.) or P/N 34V38

(25-ft.)

Heavy Duty*, P/N 19416 (12-1/2-ft.) or P/N 19415 (25-

ft.)

* Must be used for CO

6. Feed Roll. The Digipulse 2-Roll Drive comes equipped

with a pressure roll but NOT a feed roll. Select the

proper feed roll from Table 1 for the wire size and type

to be used. To convert the 2-Roll to 4-Roll Drive; order

optional 4- Roll Drive Accessory Support, P/N 600216,

and the appropriate kit listed in Table 1.

U= U-groove, V = V-groove, Serr. = serrated

(a) Includes replaceable sleeve (995651).

(b) Includes replaceable sleeve (995692).

* Includes a center wire guide and 2 upper and 2 lower feed rolls.

** Requires outlet guide as follows: For .030/.035 wire use

993902, For 3/64 wire use 05N57, For 1/16 wire use 12N57.

 Recommended U-Groove Pressure Roll 2075346 be used.

B. OPTIONAL ACCESSORIES

1. Digipulse Teach Kit (P/N 35638). This field-in-

stalled kit adds pulse teach functions which allow the

operator to set unique pulse conditions by setting

pulse height (PH), pulse with (PW), pulse frequency

(PF) and background current (PB). Up to five sets of

unique pulse conditions can be stored in memory.

The kit includes software (EPROM), hardware (switch

and simple wire harness assembly) and installation

instructions (F-15-233).

2. Water Kit (P/N 994466). Permits the convenient

connection of a water-cooled torch and continuous

water supply or water cooler to the wire feeder.

The kit consists of a coupling, two adaptors and a

fitting. A dependable cooling water supply, delivery

and return water hoses (P/N 40V76, 2 required) will

also be required. Note that Fig. 2 illustrated the use

of power cable adaptor P/N 634693, in addition to the

kit. If adaptor (634693) is not used, adaptor (45V11

supplied with kit) can be connected to the output

terminal of the power source. Install the kit in accor-

dance with Fig. 11 and Sec. Ill-C-7. Connect the

water-cooled torch as shown in Fig. 2.

3. Lifting Bracket (P/N 634287). Mounts on the wire

feeder spool support between the support and the

spindle assembly. Enables you to mount the wire

feeder over head on a boom.

4. Spool Enclosure Kit (P/N 600240). Provides pro-

tection of spool of wire against dust and dirt. For

installation instructions refer to Form 12-824.

5. Standard Wire Reel Assembly (P/N 995570). R e e l

slips over spindle to allow use of coiled wire, see Fig.

10.

6. Heavy Duty Wire Reel Assembly (P/N 19V89).

Spoke-type wire reel includes a four spoke alumi-

num alloy casting mounted on a lightweight support

shaft of steel tubing. The reel will handle all wire coils

from 2 to 4-5/8-in. wide The finger design permits

quick and easy accommodation of different coil

widths by simply rotating from one finger position to

the other.

7. Wire Straightener, (P/N 34V74). Reduces wire cast

to improve feedability and increase service life of

torch liners and contact tips. Mounts to the acces-

sory support inlet guide.

Wire Inlet Guide, P/N 11N53 is required to complete

the installation on the wire inlet side of the straight-

ener.

8. Four Roll Drive Accessory Support Assembly

(P/N 600216). This assembly (illustrated in booklet

F-12-821) utilizes four feed rolls to provide the back-

up force necessary for positive nonslip wire feed. It

is designed for feeding .030 through 1/8-in. diameter

wire(s). Feed rates using the four roll drive assembly

are virtually the same as with the two roll assembly.

For feed roll/outlet guide accessories refer to F-12-

821 or Table 1.

9. Cart, P/N 31700. Provides complete mobility for

Digipulse power source and wire feeder. The cart

also includes a support for gas cylinder(s) and WC-

8C water cooler.

10. Wire Feeder Mobile Undercarriage Kit, P/N

680005. This kit includes a mounting plate and

caster type wheels to provide complete mobility for

the wire feeder (see F-14-322).

11. Wire Feeder Turntable, P/N 678940, allows rota-

tion of wire feeder as operator changes work posi-

tions. This reduces strain and bending of torch

cables (see F-12-984).

III. INSTALLATION

Proper installation contributes materially to the satisfac-

tory and troublefree operation of the welding system. It is

suggested that each step in this section be studied

carefully and followed as closely as possible.

A. UNPACKING AND PLACEMENT

1. Immediately upon receipt of the equipment, inspect for

damage which may have occurred in transit. Notify the

carrier of any defects or damage at once.

2. After removing the components from the shipping

container(s), check the container for any loose parts.

Remove all packing materials.

3. Check air passages of power source for any packing

materials that may obstruct air flow through the power

source.

4. If the equipment is not to be installed immediately,

store it in a clean, dry, well-ventilated area.

5. The location of the welding equipment should be care

fully selected to insure satisfactory and dependable

service. The maximum separation between the power

source and the wire feeder should be less than 60-feet

for best performance. Choose a location relatively

close to a properly fused source of electrical power.

6. The machine components are maintained at proper

operating temperatures by forced air which is drawn

through the cabinet by the fan unit on the rear panel.

For this reason, it is important that the machine be

located in an open area where air can circulate freely

at front and rear openings. If space is at a premium,

leave at least (1) foot of clearance between the rear of

the power source and wall or other obstruction. The

area around the unit should be relatively free of dust,

fumes and excessive heat. It is also desirable to locate

the unit so the cover can be removed easily for

cleaning and maintenance.

B. POWER SOURCE/WIRE FEEDER CONTROL IN-

TERCONNECTION (See Fig. 2).

1. Remote Digital Control Connections. Voltage regu-

lation, 115- volt power, remote contactor control, and

monitoring is provided by a 19-pin receptacle, located

on the power source rear panel, which receives a

mating plug-cable assembly from the remote wire

feeder control receptacle J1.

b. Remove thumbscrew and washer from the feed roll

shaft.

c. Slip the feed roll on the shaft, engaging the key. Be

sure to observe the THIS SIDE OUT marking on

the feed roll.

d. Replace washer and thumbscrew, tightening screw

sufficiently to eliminate all end play from the feed

roll.

5. Installing Spool of Wire.

CAUTION: Make sure safety glasses with side shields

are worn when handling or changing wire, or

clipping wire off at the spool or at the end of

the torch-serious eye injury can result due to

the springiness of the wire which quickly

unravels, or a cut wire end which may shoot

across the room.

a. Remove hairpin clip from spindle.

b. Position the spool of wire so that when it is placed

on the spindle, wire will be drawn to the feed roll

from the bottom of the spool. The spool should be

held so that the index hole on the back will engage

the lug on the spindle.

c. Slide the spool onto the spindle until it engages the

lug. Lock in place with the hairpin clip.

d. Loosen the brake screw in the center of the spindle

hub, then tighten it just enough to prevent coasting

of the spool when wire is drawn from it. Too much

pressure will load the wire feed motor unnecessar-

ily. Too little pressure will permit the spool to

overrun, causing the wire to kink and tangle.

e. Thread the wire on to the accessory support assem-

bly as described in Section C-6.

f. When wire coils are to be used instead of spools,

mount wire reel on spindle as though it were a spool

(see a. and c. above). Remove thumbnuts and

cover plate from reel. Remove coil from its pack-

age, but do not remove its binding wires. Slide coil

onto reel so that wire will be drawn from bottom of

coil (starting end for a coil is always the outer end).

Replace reel cover plate and thumbnuts. Cut off

coil tie wires and any kinked wire. Then adjust

brake screw and thread wire to torch as covered in

d. and e. above.

6. Adjusting the Accessory Support Assembly. When

a new wire size or type is to be used, set the pressure

roll adjustment as follows (see Fig. 8):

a. Round off the free end of the welding wire with a file.

b. Release the clapper and unscrew the pressure

adjusting knob until the pressure spring is free.

c. Thread the wire through the inlet and outlet guides

of the accessory support, and 3 or 4 inches into the

torch conduit.

d. Engage the clapper making sure the wire is held in

the feed roll groove.

e. Tighten the pressure adjusting knob until the wire is

These functions are provided by one of the following

19/c, amphenol to amphenol cable assemblies follow-

ing:

6-ft. (supplied w/Pkg.) P/N 30686

30-ft. (optional) 30780

60-ft. (optional) 30781

2. Connect positive (+) power cable from power source

to wire feeder power terminal block, and work (-) cable

from power source to workpiece. Both cables should

be #4/0 size and should not exceed 50-ft. in length.

Cables should be the minimum length practical, and

tywrapped together to optimize output.

C. WIRE FEEDER INSTALLATION REQUIREMENTS

1. Hose and Electrical Connections. Having connected

the control cable assembly (section II-A) between the

power source and wire feeder, connect the shielding

gas and water (if used) supply hoses as shown in Fig.

2. Torch Connections. Attach torch gas hose to gas

connection. Plug in torch switch cable and lock by

twisting. After inserting conduit liner (if used) and

attaching wire outlet guide of correct size, connect

wire feed conduit to welding head accessory support

clamp and lock in place. Connect torch power cable to

power source, or to power cable adaptor block (with a

second cable from that block to the power source).

3. Important Water-Cooled Torch Connections. Due

to the inherently higher power cable resistance of

water-cooled torches, the potential drop that is fed

back to the power source as arc-voltage can be in

error. To eliminate this cable drop in most water-

cooled torches, it is necessary to monitor the arc-

voltage potential at or near the torch body itself.

In order to accommodate this desirable feature, two

water-cooled torches (MT-450W and MIG-41) were

designed to include the necessary voltage pickup

lead. The voltage pickup lead is attached to the torch

body and extends the length of the torch cables to a

single-pin Molex connector. This voltage pickup

lead connector must be connected to the wire feeder

controls pickup lead connector (J4) in place of the

accessory supports J4 connector as shown in Fig. 2

and on the Schematic diagram at the rear of this

booklet.

IMPORTANT: If competitive water-cooled torches (other

than ESAB) are used, they must be modi-

fied to add this voltage pickup lead; oth-

erwise, they may not provide the perfor-

mance desired.

4. Installing Feed Roll.

a. Release the clapper on the accessory support

assembly (Fig. 8) by disengaging the retainer from

the clapper fork.

Customers Fused Line Disconnect Switch

CAUTION: Make sure all input power is disconnected

before performing any operation inside the power source.

(See F-15-014)

Customers 3Ø Input

and Ground or use:

Factory-supplied 10-

ft. lg. Input power

cable (No. 6 AWG.

4/c. type SO)

connected to ON-

OFF switch (LS).

See F-15-014

Line Switch (LS) Rear

View - See F-15-014.

NEG. (-)

OUTPUT

J2 See Note 2.

Input Voltage

Connections

(See F-15-014)

To Wire Feeder

See III-B-2

Approved

Earth Ground

4/0 WELDING

CABLES

(Cust. Supplied) are

set-up for DCRP

(Neg. to work)

Operation, see

NOTE 1. below

MALE

CONNECTOR - 950693

(Supplied w/Power

Source)

Control Cable

See III-B-1

TO WORK

Work

For Wire Feeder

Torch & Service

Connections

See Below

ACCESSORY SUPPORT

VOLTAGE PICK UP LEAD

See Sec. III-C-3, and

Schematic Diagram

TORCH CONDUIT

TORCH SWITCH

TORCH WATER HOSE

TORCH GAS HOSE

TORCH POWER CABLE

FRONT VIEW

ADAPTOR -

45VII*

Power Cable

Adaptor Assy. -

634693

GAS HOSE

(See II-A-5)

* PARTS REQUIRED WHEN

USING A WATER KIT &

WATER COOLED TORCH

WATER DRAIN HOSE - 40V76 (12-1/2 FT.)*

WATER IN HOSE - 40V76 (12-1/2 FT.)*

REAR VIEW

REGULATOR/

FLOWMETER

(See II-A-5)

IMPORTANT NOTE:

1. Both output welding cable leads (torch and work) must be a minimum size of No. 4/0 welding cable (nothing smaller), and

both leads should be kept as close to the same length as possible - with neither lead exceeding 50-ft. in length. Also, both

cables must be run next to each other and tywrapped every couple of feet to minimize cable reactance.

2. Make sure that all Tig/Stick Controls are physically unplugged from the power source receptacle J2 when a Mig setup is to

be used.

Fig. 2 - Digipulse Interconnection Diagram

MIG-41 VOLTAGE

PICKUP LEAD - See III-C-3

WATER KIT -

994466*

firmly against the feed roll - do not overtighten. The

spring pressure applied should be the minimum

required to provide positive, nonslip wire feed. Too

little pressure will result in wire slippage while

excessive pressure will scar and deform the wire.

Further adjustment can be made after the wire feed

is put into operation. Note that a light spring

(182W55) is installed on the accessory support for

use with soft and small diameter hard wire. For

large diameter hard wire, replace this spring with a

heavy spring (182W54) supplied with the unit.

7. Water Kit (Optional see Fig. 11). Mount bulkhead

adaptor (58V75) behind opening provided in vertical

base plate, above gas connection, and secure with

screws (No. 8-32 x 3/8-in.) and lockwashers provided.

Attach coupling and adaptor ( 11N16) behind bulk-

head adaptor. Mount torch cable adaptor (45V11) on

welding power stud. Connect water drain hose to this

adaptor and water inlet hose to adaptor 11N16.

IV. OPERATING INSTRUCTIONS

CAUTION: Never, under any circumstances, operate

the power source with the cover removed. In

addition to the safety hazard, improper

cooling may cause damage to internal com-

ponents. Keep side panels closed when unit

is energized. Also make sure you are ad-

equately protected before you start welding

- welding helmet, gloves, eye and ear pro-

tection should always he worn.

Do not allow metal-to-metal contact between the

wire feeder chassis and a metal surface connected

in any way welding round. With such contact a poor

welding ground connection may create a difference

in potential that sends part of the welding current

through the safety ground wiring in the control cable

and wire feeder resulting in burnout of that wiring

and/or damage to wire feeder circuitry. If the safety

ground burns out, the operator may be exposed to

115V. shock hazard.

A. POWER SOURCE WELDING CONTROLS

For detailed information regarding the power source

welding controls, refer to F-15-014.

B. WIRE FEEDER CONTROL FUNCTIONS

For location of rear panel control features, refer to

Figure 3 following:

1. Power Switch. This two-position toggle switch turns

power on or off to the wire feeder control.

2. Lock-ln Key. This key-operated switch must be in

the SET position to preset, vary and weld-test the

welding parameters programmed into the control.

After the desired results are achieved, the program(s)

can be locked-in by turning the key to the RUN

position. The only parameter which can be altered by

the operator in the RUN position is the cold wire INCH

speed.

3. 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, depress the breaker button to reset

the circuit.

3A. Trigger Lock/Crater (Fill) Switch. the toggle-

configuration position of this switch follow:

 toggle-center is the normal maintained

OFF position for the Trigger-Lock func-

tion, and/or normal spring-return rest

position for the toggle-configuration posi-

tions as follows:

 toggle-up is the maintained ON position

to provide the Trigger-Lock function.

 Toggle-down is the momentary ON posi-

tion to program Crater Fill (or alternate

schedule) parameters to a primary

preprogrammed conditions.

Please note that either of these features

can be set or programmed individually, or

combined to provide both functions with a

preprogrammed condition (codes 1-10).

Neither of these features, however, are

available in the teach codes 11-15. Also,

when programmed, these functions are

automatically locked into all

preprogrammed codes (until they are

removed or programmed-out), and this

will be indicated by the energized Trig-

ger Lock indicating light on the front

panel. To set and/or program thee func-

tions, see the following:

IMPORTANT: If a SPOT weld function has been

added to the existing programmed

codes 1-10, it must be removed (ze-

roed-out) before either of these func-

tions (trigger lock/crater fill) can be

set or programmed.

a. Trigger Lock function. To set this function in a

condition, simply place the switch toggle to its (ON

(p) position. This feature allows the operator to

release the torch switch (trigger-lock on) after

starting the welding cycle. To stop the welding

cycle, you simply repress the torch switch again

and all welding action ceases. Remember that the

front panel Trigger Lock indicating light will be on

when this feature is engaged. In the OFF position,

this function is inactive.

TRIGGER

LOCK

CRATER

TORCH

SW.

RECPT.

Fig. 4 - Front Panel Controls

that establishes the approximate background

current in pulse applications (in Teach option

only).

b. Volts Digital Readout. This window is primarily

used to display an arbitrary number (100) that

represents a programmed arc length in the syner-

gic mode*, or a computed arc voltage in the

adaptive mode**-with power on, but not weld-

b. Crater Fill function. This function actually serves

a dual purpose: first, it allows you to alter your

primary welding condition (speed/voltage) by se-

lecting a slightly different condition to achieve cra-

ter-fill at the end of your weld;' or second, the

sequenced-in crater condition can actually be used

as an alternate schedule controlled by the torch

switch. For example; set up a hot condition in the

standard weld mode, and a cold condition in the

crater-fill mode for bridging gaps. To program this

feature, refer to Section V-C-10A.

c. Combined Trigger Lock/Crater. If you wish to

add the crater-fill feature to the trigger-lock func-

tion, do the following:

(1) Program the Crater-Fill parameters (wire speed

and voltage) as described in section V-C-10a.

(2) Place the Trigger-Lock in its on (up) position

as described in 3A-a. above.

(3) Depress the torch trigger to start the arc, re-

lease the trigger (lock-in mode) and weld using

the primary weld condition. Depress the trigger

again and the crater (or alternate schedule)

conditions will take over. When the trigger is

released the arc will terminate.

(4) To remove these functions, place the trigger

lock toggle to its center off position, and then

hold-down the toggle to its crater position and

zero-out the setting in the IPM window.

For location of the following front panel control

features, refer to Figure 4 following:

4. Digital Readout Window. Two individual three-digit

windows are provided to display preset or actual

welding parameters as follows:

a. IPM Digital Readout. This window is primarily

used to display actual and/or preset wire feed

speed* in a range from 20 to 999 inches per minute

in one inch increments. However with the appropri-

Fig. 3 - Rear Panel Controls

STRAIN RELIEF

ate function selector actuated, this window can

also display the following:

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

window will continuously read the Preset wire

speed setting. When the arc is struck, the IPM

window will then continuously read the actual weld-

ing wire speed as the weld conditions cycle thru the

welding sequence.

 shielding gas PREFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments

 a code number indicates a type of MATERIAL

which is programmed for various welding wire

applications, as follows: code #1 indicates Car-

bon Steel, #2 is Alternate Steel, #3 is 4043

Aluminum, #4 is 5356 Aluminum, #5 is 308

Stainless, #6 is Silicon Bronze. (Additional Ma-

terial code numbers 7 thru 10 are reserved

for custom applications.)

 SPOT welding time from 1 to 999 cycles in one

cycle increments.

 cold wire INCH speed in IPM from 40 to 999

inches per minute in one-inch increments

 if provided, Ph indicates PULSE HEIGHT which

is displayed as a reference voltage setting,

from 0.1 to 10 (in 0.1 volt increments), that

controls or establishes the amplitude of the

pulse peak (in Teach option only).

 if provided, Pb indicates PULSE BACKGROUND

which is displayed as a reference current set-

ting, from 15 to 100 (in one ampere increments),

 if provided, Pf indicates PULSE FREQUENCY

which is displayed as a frequency (Hertz) refer-

ence setting, from 25 to 909* pulse cycles per

second, that establishes the approximate pulse

frequency required for the wire feed speed set

on the control (in Teach option only).

* Please note that the number of pulse/sec is

dependent on the pulse width  the narrower

the width, the fewer the cycles; and the wider the

width, the more the cycles.

5. Pulse-Short (Arc)-Spray (Arc) Selector. This three-

position rotary switch allows you to select the welding

process mode you wish to use Pulsed mig spray arc,

or non-pulsed mig Short Arc, or non-pulsed mig

Spray Arc.

In all process modes, the operator simply codes the

control (wire diameter and material) for any one of the

preprogrammed welding conditions, sets the desired

wire feed speed (ipm) and the control automatically

provides the proper welding parameters to produce

the necessary output for the process selected.

6. L.E.D. Indicator Lights. Either or both of these LEDs

will light to indicate the following:

The NO PROGRAM l.e.d. will only light if you select

a wire type (Material) and size (Diameter) that is not

programmed in the control. In addition, if you close the

torch switch, the power source will not energize and

the Digipulse will not feed wire in this condition.

The TRIGGER LOCK l.e.d. will only light to indicate

that either one, or a combination, of three special

features (Trigger Lock, or Crater Fill, or Alternate

Schedule) has been programmed on to a selected

welding condition. Further, having been programmed,

this feature will always be included in all process

modes and programmed welding conditions until it is

zeroed-out and removed. (Additional details regard-

ing programming and operation of these features are

covered in sections IV-B-3a and V-C-10a.

NOTE: All of the following controls are springloaded,

center-return toggle switches which must

be operated to actuate their indicated

function(s). Item No. 7, Inc/Dec toggle

switches, describes the adjustment setting

toggle used to preset the program-function

selectors. Except as noted above and follow-

ing, regulation for selected function(s) can

only be made if the Lock- In key, described in

Item No. 2 is in the SET position.

7. Inc/Dec Toggle Switches. Two control toggles are

provided to preset the individual welding parameters

required for the selected welding mode, PULSE,

ing. When the arc is struck, the VOLTS Window will

continuously display actual welding voltage in a

range from 12 to 50 vdc in one-tenth (0.1) volt

increments. However, with the appropriate func-

tion selector actuated, the VOLTS Window will

also display the following:

* In the synergic mode, the control will automati-

cally select and display an appropriate arc length

integer for a given wire type, size, feed rate and gas

shielding. An arbitrary number, represented by the

integer If 100, is the normalized value for all appli-

cations programmed in the control, and this figure

will be displayed in the VOLTS window during

setup (not welding). This value (set at 100) can be

readjusted within a range from 0 to 200, to fine-

tune the operating arc length of the selected weld-

ing condition. By reducing the number below 100

(minimum 0) you will reduce the arc length. Con-

versely, by increasing this value above 100 (maxi-

mum 200) you can increase the arc length. After

the arc is struck, the number will be replaced by

the actual welding arc voltage.

** The Digipulse can also operate in the adaptive

mode, where the arc is continuously monitored by

a closed loop feedback circuit and the machine

modulates its output to maintain a given voltage for

preprogrammed data. In the adaptive mode, a

computed arc voltage (unique to your

preprogrammed welding selection) will be displayed

in the VOLTS window before welding. Once the

arc is struck, the control will measure the actual

welding voltage and change the output of the power

source to maintain the precalculated voltage set-

ting. In this manner, the power source automati-

cally compensates for variations in stickout or weld

joint geometry Further, all of the precalculated arc

voltages programmed in the control can be read-

justed +/-10 volts to fine-tune the welding arc.

 shielding gas POSTFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

 a pair of numbers represent WIRE DIA. sizes

which are programmed for selection as follows-

#23 represents .023" dia., and #30 is .030" dia.;

#35 is .035" dia., #45 is .045" dia. hard (3/64" dia.

soft) and #63 is .063" (1/16") dia.

 manual BURNBACK time. Manually adjustable

burnback time period which when preset over-

rides the automatic adaptive anti-stick feature.

This time period will be set in one-cycle incre-

ments (60 cycles = 1 sec.). When set to zero,

the auto-adaptive-anti-stick feature is opera-

tional.

 if provided, Pw indicates PULSE WIDTH which

is displayed as a reference time setting, from

1.0 to 10 (in one-tenth millisecond increments),

that measures or establishes the width of pulse

duration (in Teach option only).

SPRAY or SHORT arc, as follows:

a. IPM Increase/Decrease Control. This toggle

switch is primarily used to set and/or vary the wire

feed speed (IPM), along with its other functions

(when provided); Preflow, Material, Inch, Spot, PH

and PB. With the appropriate function selector

actuated, each parameter setting will be displayed

in the digital window directly above this toggle.

b. VOLTS Increase/Decrease Control. This toggle

switch is primarily used to set and/or vary VOLT-

AGE*, along with all its other functions; Postflow,

Wire Dia., Burnback, PW and PF. With the appro-

priate function selector actuated, each parameter

setting will be displayed in the digital window di-

rectly above this toggle.

* Please note that the term VOLTAGE denotes

arc voltage (in the adaptive mode) and/or arc

length (in the synergic mode) and is the com-

puted value that has been precalculated for

each of the combinations programmed into the

control. And further, any of these computed

voltages can be altered (+/-10 volts in the adap-

tive mode; and +/-100 numerals from its midrange

value of 100 in the synergic mode) to fine tune

the welding arc; however, having done so, the

computed voltage value(s) is altered for all of the

other preprogrammed wire size/type combina-

tions.

Therefore, if the computed voltage for your

selected welding combination had been altered

and you plan to use a new combination (a

different wire size and/or type), it is suggested

that the control be reset to provide the

correct voltage computed for the

preprogrammed combination as follows:

Adaptive Mode. To reset the computed arc

voltage value for a given wire size and type,

place the Run-Set key switch in its SET position

and then decrease the arc voltage key until the

number in the VOLTS window stops This num-

ber is 10 volts below the computed or midrange

value. To establish the computed value, add 10

(volts) to the displayed number using the in-

crease (INC) portion of the Volts Inc/Dec key.

Synergic Mode. Resetting the computed value

in this mode is much simpler-remember that the

computed or midrange value is the arbitrary

numeral 100 (this number represents a

precalculated arc length based on the wire

feed speed of the programmed wire size and

type). Therefore, if the number appearing in the

VOLTS display window is any numeral between

0 and 200 (other than 100) simply use the

appropriate Inc/Dec key to reset the condition to

the numeral 100.

8. Spot/Burnback - Wire Dia./Material Selector.

Operating this toggle allows you to select the follow-

ing:

a. Access the SPOT/BURNBACK time mode (up

position) to preset either or both of these welding

features into a preprogrammed weld condition;

however, once preset, these features automati-

cally become part of all preprogrammed weld con-

ditions in all these process modes.

The SPOT mode allows you to preset timed arc

periods from 1 to 999 cycles in one cycle incre-

ments (60 cycles/sec) in the IPM window using its

Inc/Dec toggle switch. When a spotweld time is

preset into the control, all continuous- type weld-

ing programs are temporarily disabled. To re-

sume normal (continuous) operation, you must

deactivate the spotweld program by keying its

time parameter back to zero (000).

At the same time (or independently), you can also

preset a manual BURNBACK time into the VOLTS

window using its Inc/Dec toggle switch. The Burn-

back time is adjustable in one cycle increments (60

cycles/sec); and when preset, it will override the

automatic adaptive anti-stick feature. If automatic

anti-stick operation is desired, the preset Burnback

time must be set back to zero.

NOTE: Actuating the Spot/BBack position when the

control is set-up to operate in the PULSE mode

and the torch switch is energized, allows you

to read the actual pulse frequency (for a

preprogrammed pulse condition) in the VOLTS

display window. (If this position is actuated dur-

ing a standard mig short or spray arc welding

operation, the numbers appearing in the Volts

display window are not related to the actual

condition.)

b. Access the WIRE DIA/MATERIAL, mode (down

position) to select one of the welding conditions

preprogrammed into the control, as follows:

To select the type of wire MATERIAL, actuate

the INC position of the Inc/Dec switch below the

IPM window (while holding the Wire Dia/Matl key

down) until the desired code number for your

material selection appears in the IPM window,

and these material codes follow: #1 is carbon steel,

#2 is alternate steel #3 is 4043 aluminum, #4 is

5356 aluminum, #5 is 308 stainless, #6 is silicon

bronze. (Additional Material codes 7 thru 10 are

reserved for custom applications.)

Now select the Wire DIA. size to be used, by

actuating the INC position of the Inc/Dec switch

below the VOLTS window (while holding the Wire

Dia/Matl key down) until the desired pair of num-

bers for your wire size selection appears in the

VOLTS window, and these wire diameter numbers

follow: #23 is 023" dia, and #30 is 030" dia.; #35 is

035" dia., #45 is 045" dia. hard (3/64" dia soft), and

#63 is 063" ( 1/16") dia.

NOTE: Accessing the WIRE DIA/MAT'L and the

PURGE/RESET selector keys (simulta-

neously) during an actual weld, allows you

to check the factory-preset numbers that

determine the quality of starts (hot, cold,

etc.) for your preset welding condition. These

numbers are preset to provide optimum starting

characteristics required for most welding appli-

cations. This is a diagnostic tool available to the

experienced operator or serviceman and need

not be activated during a normal operation un-

less you are experiencing weld starting prob-

lems, or weld condition (speed and /or voltage)

aborting problems. It must also be noted that

only the speed (IPM) condition can be

checked when a unit is operating in the

synergic mode (the VOLTS Window will

always display the number 100) and cannot

be adjusted; however, in the adaptive mode

both speed and voltage conditions can be

checked and adjusted. The factory-set start-

ing condition is represented by numbers that are

displayed, on command, in the digital IPM and

VOLTS windows. For good welds and starts,

these numbers should be in a range from 105 to

115 (with 110 being the norm) in the IPM window

(synergic and adaptive mode), and from 90 to

100 (with 95 being the norm) in the VOLTS

window (adaptive mode only) If your weld starts

are not acceptable, please refer to Section V-

B-Il for a simple adjustment procedure that

will enhance good starting. If you are experi-

encing frequent speed and/or voltage aborts,

please refer to Section Vlll-B-7 (Troubleshoot-

ing) for checking and resetting condition func-

tions.

9. Inch-Purge/Reset Selector.

Operating this toggle allows the following functions:

a. The INCH selection permits cold-wire inching

without energizing the welding circuit through the

torch switch. The wire inching speed can be inde-

pendently controlled by operating its Inc/Dec toggle

switch.

b. The PURGE/RESET position provides the fol-

lowing when actuated:

(1) During initial programming, it permits pre-

setting of gas PREFLOW and POSTFLOW

time requirements which are simultaneously

displayed in the IPM and VOLTS windows

respectively.

(2) Prior to actual torch triggering, it permits

you to actuate the gas solenoid and PURGE

the shielding gas line of the torch. At the same

time, it also lets you adjust the gas regulator

without energizing the welding circuit.

(3) After starting the welding sequence, if an

abort-shutdown condition occurs (indicated

by a flashing digital display), the RESET posi-

tion can be actuated and the control automati-

cally resets for a new start.

(4) When this key is actuated during a weld,

and simultaneously with the Wire Dia/Matl

key, a diagnostic operation allows you to check

the preset numbers (displayed in the IPM and

VOLTS windows) that determine the quality of

starts (hot, cold, etc.) for your preset welding

condition (see NOTE following IV-B-8- b).

10. SYN.-ADAPT. Switch. This switch allows front-

panel selection of synergic or adaptive logic modes.

The operating characteristics of synergic vs. adap-

tive logic in the welding operation are covered in

sections I, IV-B-4-b, IV-B-7-b, Vl-B and -D. Please

note that either type of logic can be used in the a

preprogrammed material codes #1-#10; however,

only the synergic logic can be used in the teach mode

material codes #11-#15.

11. Teach Pulse Parameter Switch (Teach option

only). This switch allows you to program Pulse

Height (PH), Pulse Width (PW), Pulse Background

(PB), and Pulse Frequency (PF) teach parameters

into material codes 11 thru 15. These features and

operating functions are fully covered in the Teach

supplemental booklet F-15-013.

C. GAS/WIRE ADJUSTMENTS

The following wire feed control functions must be made

to feed wire through the torch conduit and to adjust the

shielding gas flow rate.

1. Place Power switch (on rear panel) to on position to

energize the control

2. Place key-operated Run-Set switch in Set position

3. With torch connection made as shown in Fig 2, and

wire engaged in accessory support (Sect III-C-6), feed

wire through torch conduit and into torch as follows:

a. Remove nozzle and contact tip from torch.

b. Hold Inch-Purge toggle in INCH position (Sect IV-

B-9) until cold wire protrudes from the torch front

end.

c. Slide the contact tip over the end of the wire and

secure it to the torch. Replace the torch nozzle.

d. Reoperate the Inch-Purge toggle in INCH position

and check for wire feed slippage on the accessory

support assembly. Tighten (or loosen) the pres-

sure adjusting knob until the wire feeds smoothly.

4. With shielding gas cylinder and torch gas hose con-

nection assembled as shown in Fig. 2, set gas flow

rate as follows:

a. Hold Inch-Purge toggle in PURGE position and

open the gas regulator-flowmeter control valve and

set the shielding gas flow rate.

b. Continue to hold the Purge position for approx. 15

seconds to insure adequate purging of gas hose

and torch.

5. Place controls Power switch to off position.

\/. SETTING UP PROGRAM PARAMETERS

A. TYPICAL WELDING CONDITIONS

Three sets of welding (process) mode parameters can

be preset in your Digipulse control; one for the PULSE

mode, one for standard SPRAY arc mode, and another

for standard SHORT arc mode.

The setup procedure for each welding arc mode is

exactly the same, except for wire feed speed input and

gas shielding requirements which may be peculiar to

each process. The following parameters are provided as

an example of a Typical Welding Condition which can

be used to set-up all welding modes, with exceptions as

noted.

Typical Welding Condition (Parameter):

Cold Wire Inch Speed .............................................. 75 IPM*

Type Material ...................................................... 1 (Steel)

Wire Dia. ......................................................... 45 (.045-in.)

Wire Feed Speed ..................................................... 185 IPM

Arc Voltage/Arc Length ........ Preprogrammed for MAT./DIA.

Spot Weld Time ................................................... 45 Cycles*

Preflow Time .................................................... 1.2 Seconds*

Postflow Time .................................................. 3.1 Seconds*

Burnback Time ....................................................... 7 Cycles*

Trigger Lock/Crater Fill ...................... Program Parameters*

* If programmed, these parameters are automatically incorporated

in all other preprogrammed welding conditions until they are

programmed (zeroed) out.

 For recommended shielding gases used for preprogrammed

welding wire material, see Table II.

B. PRELIMINARY POWER SOURCE CHECKS

Before programming the wire feeder control, make sure

that the power source is properly set-up as follows:

 Check the rear panel of the power source to make

sure that only the Digipulse control cable is con-

nected. The remaining stick control receptacle/cable

must be disconnected.

 Depending on the welding process mode programmed

on the wire feeder control, set the power source

INDUCTOR control pot as follows:

For SHORT ARC mode, set Inductance @ 12 Oclock

position and adjust for best performance when weld-

ing.

For PULSE and SPRAY ARC modes set Inductance

@ MINIMUM .

C. PROGRAM CONTROL PARAMETERS

Remember, the following procedures represent a typical

example of how to set-up one of the many preprogrammed

welding conditions available in this control and that these

procedures are the same for all weld arc modes  Pulse

Spray, or Short Arc. The only difference(s) between weld

arc modes (for the same Wire Diameter and Material)

will, or may, be your wire feeder speed (IPM) and gas

shielding selection  the control automatically provides

the required welding voltage for every condition, and

even this parameter (voltage) can be fine-tuned as

described following.

1. Set the Power switch (on rear panel) to the on

position to energize Digipulse Control.

2. Place the rear panel key switch in its SET position to

preset all welding parameters. In this position the

operator or supervisor is free to weld and make any

changes before locking-them-in, in the RUN position.

3. Set the PULSE, SPRAY, SHORT arc mode switch to

the process you wish to preset. And set the Synergic

- Adaptive switch to the logic mode you wish to use.

4. To set the type of Wire Material (carbon steel) and

Wire Diameter (.045 in.) to be used, depress and

hold WIRE DIA/MATERIAL toggle switch in its down

position and simultaneously preset each of the follow-

ing:

a. Operate (increase or decrease) the left INC/DEC

toggle switch lever until a 1 (indicating carbon

steel wire) appears in the IPM display window.

b. Now operate (increase or decrease) the right

INC/DEC toggle switch lever until 45 (indicating

.045-in. dia. wire) appears in the VOLTS display

window.

NOTE: If no program exists for a given material or

diameter, a No Program l.e.d. on the front of

the control will light.

5. To set a Wire Feed Speed parameter of 185 ipm,

raise and hold the toggle of the left Inc/Dec switch in

its INCREASE position until 185 appears in the IPM

window. Notice that this parameter setting will start at

zero and immediately jump to 20 and then rapidly

increases (1 ipm at a time) until the 185 ipm setting is

reached. If you overshoot the planned setting, simply

bump the DECREASE position of the left Inc/Dec

toggle to obtain the exact IPM setting.

Table II

Recommended Shielding Gas

Wire Material Welding Arc Mode

Code # Type Short Arc Spray Arc Pulse Arc

1 Carbon Steel CO

/C25 C-5/C- 8 C- 5

2 Alternate Stl. C-25 Stargon/C-8 Stargon/C-5

3 4043 Aluminum  Argon Argon

4 5356 Aluminum  Argon Argon

5 308 Stainless A1025 1%/2%O

Pulse SS

6 Silicon Bronze  Argon Argon

10*

* These codes are reserved for custom applications.

6. After items 4 and 5 have been preset, the micro-

computer automatically sets a preprogrammed arc

voltage in the adaptive mode or arc length integer in

the synergic mode that will be displayed in the VOLTS

window. If this precalculated value* does not provide

a stable condition, it can be fine-tuned by using the

right-side Inc/Dec toggle switch-as described in IV-B-

7-b.

* If the existing welding condition is altered (fine tuned),

it is suggested that each time a new wire size/type is

used that you reset the control to set up the original

computed (mid-range) arc voltage values as described

in Section IV -B-7-b.

NOTE: The remaining parameters can also be pro-

grammed into the selected mode of opera-

tion; however, when preset, these param-

eters will automatically be operational in all

process conditions.

7. To set a Cold Wire Inch parameter of 75 ipm, raise

and hold the toggle of the Inch-Purge/Reset switch

in its INCH position. Simultaneously, raise and hold

the toggle of the left Inc/Dec switch in its INCREASE

position until 75 appears in the IPM window. Note

that the cold inch setting starts at 40 ipm and rapidly

increases (1 ipm at a time) until the 75 ipm setting is

reached. If you overshoot the planned setting, simply

bump the DECREASE position of the left Inc/Dec

toggle to obtain the exact IPM setting.

8. To set shielding gas Preflow and Postflow times

of 1.2 seconds and 3.1 seconds respectively,

depress and hold the toggle of the Inch-Purge/

Reset switch in its PURGE/RESET position. Simul-

taneously, raise and hold the toggle of the left Inc/

Dec switch in its INCREASE position until 1.2 sec-

onds of Preflow time appears in the IPM window and

then; repeat this procedure using the right Inc/Dec

switch until 3.1 seconds of Postflow time appears in

the VOLTS window. Both of these parameter set-

tings will start at zero and rapidly increase ( 1/10

second at a time) until the desired time is achieved.

If you overshoot the planned settings, simply bump

the DECREASE position of the respective Inc/Dec

toggles to obtain the desired Preflow and Postflow

time settings.

9. To set a Spotweld time of 45 cycles, raise and hold

the toggle of the Spot/Burnback - Wire Dia/Material

switch in its SPOT/Burnback position. Simulta-

neously, raise and hold the toggle of the left Inc/

Dec switch in its INCREASE position until 45 cycles

appears in the IPM window ( note: 60 cycles = 1

sec.). This parameter setting will still start at zero and

rapidly increase (1 cycle at a time) until the 45 cycle

time is achieved. If you overshoot the planned set-

ting, simply bump the DECREASE position of the

left Inc/Dec toggle to obtain the desired Spot cycle

setting.

10. To set a manual Burnback time of 7 cycles, raise

and hold the toggle of the Spot/Burnback - Wire Dia/

Material switch in its Spot/BURNBACK position.

Simultaneously, raise and hold the toggle of the

right Inc/Dec switch in its INCREASE position until

7 cycles appears in the VOLTS window (note: 60

cycles = 1 sec.) This parameter setting will start at

zero and rapidly increase (1 cycle at a time) until the

7 cycle time is achieved. If you overshoot the planned

setting, simply bump the DECREASE position of

the right Inc/Dec toggle to obtain the desired Burn-

back cycle setting.

Remember  if a manual Burnback function is

programmed, it will override the standard automatic

adaptive anti-stick feature in all welding modes.

10-A. To program a Crater Fill Function do the fol-

lowing:

a. Set a process, material type and wire diameter

combination, for example; pulse welding, mate-

rial code 1 and diameter 045. This will be your

primary welding condition. Note the Trigger Lock/

Crater Switch functions are described in section

IV-B-3A.

b. Hold the Crater Fill/Trigger Lock switch down.

Set the desired wire feed speed and voltage

required to achieve the crater fill results. These

crater parameters will be displayed in the appro-

priate will be displayed in the appropriate IPM

and VOLTS window. Release the CRATER

switch.

c. Depress the torch trigger and weld using the

primary welding condition. Release the trigger

and the crater (or alternate schedule) conditions

will take over. Depress the trigger again and the

arc will terminate.

d. To remove the crater fill parameters, hold down

the CRATER key and zero out the setting in the

IPM window (it is not necessary to zero the

VOLTS window).

e. If you wish to combine the Crater-Fill feature to

the Trigger Lock function, refer to section IV-B-

3A.

11. Using the torch switch, the selected process mode

parameters can be weld-tested and if necessary

readjusted. If your weld starts are not acceptable,

refer to the following Hot Start adjustment proce-

dures that will enhance starting.

Hot Start Adjustment Procedures

As mentioned earlier in the italicized Note following

Section IV-B-8-b, the control is preset at the factory to

provide the optimum starting characteristic for most

welding conditions. However, due to factors such as

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

welding technique, shielding gas, or wire feed speed,

you may have to readjust the factory-set starting

characteristics to provide the best arc starts possible.

To do this, it is necessary to readjust the factory-set

calibrations to provide a hot start characteristic in

which the initial starting voltage (open-circuit voltage)

will be slightly higher than 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 following:

a. Program the welding condition you need in the IPM

(wire feed speed) and VOLTS (arc voltage) win-

dows, 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, proceed as

follows:

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

Wire Dia/Matl. and Purge/Reset key positions

(simultaneously) and observe the numbers

displayed in the IPM and VOLTS windows.

Remember that only the speed (IPM) condition

can be checked when a unit is operating in the

synergic mode( the VOLTS window will al-

ways display the number "100" and cannot be

adjusted); however, in the adaptive mode

both speed and voltage conditions can be

checked and adjusted.

(2) For proper starts, the number in the IPM win-

dow should be in the range from 105 to 115. If

it is not, adjust the Inc/Dec toggle (below the

IPM window) until the displayed number reads

110.

(3) Similarly, the number in the VOLTS window

should be in the range of 90 to 100. Again, if it

is not, adjust the Inc/Dec toggle (below the

VOLTS window) until the displayed number

(4) These adjustments to the control should now

provide good arc starts to a legitimate welding

condition.

(5) A good rule-of-thumb to follow whenever you

set up a new welding condition and you expe-

rience unstable starts, is to simply check the

start characteristic numbers (while welding) to

make sure they are within the ranges de-

scribed in the preceding steps.

c. If you continue experiencing problems, refer to

Section VIII-B-7 for Troubleshooting procedures.

Table III for Typical Short Arc Wire Speed Ranges

Wire Material Wire Diameter & Wire Speed Ranges

Code# Type .023 .030 035 .045 .063

1 Carbon Steel 175- 180- 130- 130- NP

500 600 600 450

2 Alternate Stl. 125 175- 100- 100- NP

350 350 300 250

3 4043 Alum. NP NP NP NP NP

4 5356 Alum. NP NP NP NP NP

5 308 Stainless 250- 100- 75- 50- NP

450 400 300 250

6 Sil. Bronze NP NP NP NP NP

7**

8**

9**

10**

** These codes are reserved for custom applications.

NP Not programmed.

Table IV for Typical Spray Arc Wire Speed Ranges

Wire Material Wire Diameter & Wire Speed Ranges

Code # Type .023 .030 .035 .045 .063

1 Carbon Steel 800- 525- 425- 275- 170-

999 900 800 550 275

2 Alternate Stl. 800- 525- 425- 275- 170-

999 900 800 550 275

3 4043 Alum. NP 400- 400- 200- 200-

800 600 500 300

4 5356 Alum. NP 450- 450- 300- 250-

750 750 500 450

5 308 Stainless 750- 450- 350- 250- 150-

950 650 650 550 300

6 Sil. Bronze NP 400- 400- 300- NP

550 550 500

7**

8**

9**

10**

** These codes are reserved for custom applications.

NP Not programmed.

Table V for Typical Pulse Arc Wire Speed Ranges

Wire Material Wire Diameter Wire & Speed Ranges

Code # Type .023 .030 .035 .045 .063

1 Carbon Steel 150- 115- 85- 55- 75-

700 500 700 450 250

2 Alternate Stl. 140- 150- 140- 70- 70-

700 500 700 400 220

3 4043 Alum. NP 225- 225- 130- 100-

500 500 300 250

4 5356 Alum. NP 225- 250- 170- 150-

500 500 500 300

5 308 Stainless 150- 100- 100- 60- 55-

700 500 450 450 260

6 Sil. Bronze 225- 250- 175- 125- NP

500 500 500 500

7**

8**

9**

10**

* These codes are reserved for custom applications.

NP Not Programmed.

VI. WELDING OPERATION

After the desired welding arc modes (Pulse, Spray or

Short arc) have been weld-tested in the SET position and

satisfactory results achieved, the program parameters

can be locked-in by placing the key switch into its RUN

position. The only parameter that can be readjusted in

the Run position is the cold wire INCH speed setting.

Other functions (if provided) which can be read or checked,

but are not adjustable in the Run position are the Preflow/

Postflow times, Spot/Burnback times, and the Wire dia/

Material.

CAUTION: Power source contactor becomes energized

the moment the torch trigger is depressed.

Arcing can occur if the wire touches an object

grounded to the workpiece.

A. PULSE/SPRAY/SHORT ARC WIRE SPEED REC-

OMMENDATIONS

I. General

The listings in the following tables give approximate

wire feed speed ranges (IPM) for the various types of

wire diameters and materials which have been

preprogrammed in these controls.

2. Material Code Operating Tips (Where Applicable)

a. Carbon Steel (Code #1) and Alternate Steel (Code

#2). The Code #2 parameters are very similar to the

Code #1 parameters; however, Code #2 has wider

Pulse Widths and higher Pulse Background set-

tings. The arc characteristics will appear to be

softer than Code #1. Arc penetration could also

be slightly less do to the lower pulse peak used.

This type arc characteristic might be used on

applications requiring improved bead wetting.

Operation Note: Excessive resistances in the weld-

ing system, caused by water cooled torches or

excessively long welding cables, can produce pulse

peak currents below that which is required for

stable droplet detachment. This condition can be

recognized by occasional large droplets propelled

across the arc. Some short circuiting and spatter

could also result. Long arc lengths can also cause

less than optimum performance. The arc length

should be kept short for best arc stability and

puddle control. Too short an arc length will produce

spatter and less than optimum arc stability. If a

globular type transfer occurs check for high resis-

tance in the welding current.

b. Aluminum 4043 (code #3) and 5356 (code #4).

Each alloy and diameter has been set for best are

performance and puddle control. The wire feed

speed of 4043 3/64-inch diameter (.045) is limited

to 300 ipm at which point the pulses begin to

overlap and spray arc results. If higher wire feed

speeds are required on this alloy, switch to Code #4

(5356 .045) and adjust the arc voltage for stable arc

performance. This action will extend the wire feed

speed to approximately 600 ipm.

c. 308 Stainless Steel (Code #5). The stainless steel

pulse parameters are based on gases listed below.

These gases improve the bead wetting of stainless

steel as compared to the 1% and 2% oxygen

mixtures. The program can still be used with the

oxygen mixtures but a small adjustment in arc

voltage will be necessary.

1. Pulse Blend SS

2. 2-1/2%-C0

, 1%--H

, Bal. Argon

Operation Note: Arc Starting with stainless steel

can be inconsistent at times due to the higher

resistivity of the alloy and other variables. Some-

times increasing the voltage will improve starting. A

weld technique adjustment might also help. When

striking the arc, immediately move out of the puddle

and begin traveling. A hesitation in travel at the start

causes the puddle to build under the arc while the

control is trying to adjust for arc voltage. Eliminating

the puddle build-up helps the voltage control circuit

establish the proper arc length more quickly.

d. Silicon Bronze (Code #6). The welding perfor-

mance of silicone bronze alloys currently sold can

vary widely. Small differences in chemistry, clean-

liness, and feedability can affect the pulse welding

characteristics. To overcome instability problems,

be sure wire feeding is steady and slack in the liner

is minimized. Use tip-to-work distances slightly

longer than normal if arc instability occurs.

B. WELDING IN PULSE OR SPRAY OR SHORT ARC

MODE

The Digipulse Wire Feeder youre using is designed to

operate using synergic/adaptive logic in all three mig

metal transfer modes (pulse, spray or short arc).

The adaptive/synergic capability is selectable from a

front panel switch and does not require entering the

control to provide this feature.

It is very easy to identify which logic mode (synergic or

adaptive) is selected for. All you have to do is check the

numbers displayed in title VOLT window. In the syner-

gic mode, the numbers which appear have no decimals

and will range from 0 to 200, with the number 100 being

the preprogrammed midpoint for any selected condi-

tioned. In the adaptive mode, the numbers will reflect an

arc voltage somewhere within a range from 12 to 50 vdc,

and will contain a decimal point because the arc voltage

can be adjusted in 1/10 volt increments.

To start the welding in either logic mode, set the

process control switch to the desired welding operation

that has been preset for use-Pulse, Spray or Short arc.

Close the torch switch lever to energize and sequence-

in all of the selected process welding parameters. The

torch switch must be held closed throughout the opera-

tion unless you have activated the trigger-lock/crater-fill

function (see section IV-B-3A). The arc is established

when the welding wire touches the workpiece.

To stop welding (with no trigger-lock or crater-fill pro-

grammed), simply release the torch switch lever (do not

reactivate) and all functions will shutdown except auto

antistick and postflow. If trigger-lock or crater-fill is pro-

grammed, refer to section IV-B-3A for this function.

The system will also shutdown if preset wire speed or

arc voltage parameters cannot be maintained due to

abnormal (abort) conditions. If this occurs, the param-

eters causing the system shutdown will be signaled by a

flashing digital display and the welding sequence must

be restarted by actuating the RESET toggle switch.

After welding has been stopped, the control will always

recycle to the initial preset parameters of the selected

mode.

C. SPOT WELDING

If spot time is set, it is automatically programmed into all

welding conditions, i.e. short arc, spray and pulse. If this

feature is not desired, spot time must be set to zero. If

both spot time and trigger-lock are set, the trigger-lock

will be disregarded.

Close the torch switch to energize gas flow, weld contactor,

wire feed motor and start spot timing cycle. The torch

switch must be depressed during the entire weld period.

After the spotweld timing cycle is completed, all welding

action except auto-antistick or burnback and postflow

gas will stop automatically. Release the torch lever to

enable the next spot weld cycle.

D. SETTING/DISABLING SLOW RUN-IN FEATURE:

This feature allows the operator to have the wire feed

motor start at either full welding speed or half-speed, if

desired. Half speed starts may give better starts in some

cases. This feature works in all three processes. If half

speed is selected, the motor starts at half of the final

welding speed and jumps up to full speed once the arc is

established. To change this, remove the feeder cover

and locate the 4-position red rocker dip-switch on the

MPU pc board (see Figure 5). SW2-1 should be open for

half-speed run-in selection, and closed for fully speed

starts.

Do not allow metal-to-metal contact between the

wire feeder chassis and a metal surface connected

in any way to a welding ground. With such contact,

a poor welding ground connection may create a

difference in potential that sends part of the welding

current through the safety ground wiring in the

control cable and wire feeder, resulting in burnout of

that wiring and/or damage to wire feeder circuitry. If

the safety ground burns out, the operator may be

exposed to 115V shock hazard.

Vll. MAINTENANCE

If this equipment does not operate properly stop work

immediately and investigate the cause of the malfunc-

tion. Maintenance work must be performed by an expe-

rienced person, and electrical work by a trained electri-

cian. Do not permit untrained persons to inspect, clean,

or repair this equipment. Use only recommended re-

placement parts.

Be sure that the wall disconnect switch or circuit

breaker is open before attempting any inspection or

work on the inside of the power source or wire

feeder.

Location For Dip Sw. SW1

Location For Teach Option E-PROM

Fig. 5 - MPU P.C. board

1. General Maintenance

Little maintenance is required to keep the wire feeder

in top operating condition. It is important, however,

that moving parts such as feed and pressure rolls,

wire feed motor, etc. be kept clean and free of dust or

dirt. Cleaning is best accomplished by regularly blow-

ing off these parts with dry compressed air. This

should be done once for every eight hours of operating

time, more often if necessary.

2. Lubrication of Digital Motor-Gear Unit

The EH- 10A motor-gear digital unit is lubricated with

a heavy duty grease when assembled at the factory

and should not require further lubrication unless dis-

assembled. If disassembled relubricate with Texaco

Multifak grease.

3. Check or Replacement of Motor Brushes.

Motor brushes should be checked periodically. If a

brush is broken, or worn down to less than 3/8-in.

Location For "Dip" Sw. SW2

length, it must be replaced. Brushes can be inspected

by unscrewing the brush-holder plug and withdrawing

the brush assembly. Never remove a brush without

matchmarking it and its holder, so that it can be

replaced in the same holder in its original position.

4. Removal of EH-10A Digital Welding Head

a. Unplug the control cables from the rear panel of the

wire feeder control.

b. Remove the accessory support assembly from the

motor-gear unit by loosening the capscrew at the

bottom of the assembly.

c. Disconnect the motor and tachometer cables from

terminal board (T1) inside the control assembly as

shown on the wiring diagram.

d. Remove the four screws which secure the digital

motor-gear unit to the base and remove the digital

unit.

Vlll. 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 WIRE FEEDER

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 num-

ber of the PC board (and preprogram number, as de-

scribed 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

number (e.g.:3) will appear in the IPM readout

window and will only be displayed for 1-second.

This number identifies the current program (E-

PROMS) used in your control. When a Program is

changed, the new E-PROMS will automatically

identify the new program number being used. If a

revision is made to an existing program a number

.1, .2, .3, etc. indicating the numerical revision will

also appear in the VOLTS readout window simulta-

neously.

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 units 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 T1-11

and T1-12; 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. 11 volts between

terminals T1-12 and VR-1. If voltage is not

present, replace I/O board.

(2) The output should be 5 volts between termi-

nals T1-12 and T1-11. If voltage is not present,

replace, voltage regulator

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.

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ESAB Digipulse Wire Feeders Troubleshooting instruction

Brand: ESAB

Model: Digipulse Wire Feeders

Category: Welding System

Type: Troubleshooting instruction

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ESAB Digipulse Wire Feeders Troubleshooting instruction

ESAB Digipulse Wire Feeders Troubleshooting instruction

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