Miller JETLINE CYCLOMATIC AVC-501 ARC VOLTAGE CONTROL Owner's manual
- Category
- Welding System
- Type
- Owner's manual
This manual is also suitable for
OPERATION MANUAL
for Cyclomatic Series
AVC-501 System
JetlineEngineering,15GoodyearStreet,IrvineCA 92618
Telephone:949-951-1515·Fax:949-951-9237
Website: www.jetline.com · www.cyclomatic.com
E-mail: [email protected]
IMPORTANT
RevisedSeptember 2011
Readthismanualcarefullybeforeinstalling,
commissioningoroperatingthisproduct.
LIMITEDWARRANTY
JetlineEngineering,ofIrvine,California,U.S.A.,warrantsallnewequipmenttobefreefromdefectsin
materialandworkmanshipfortheperiodofone(1)year,providedthattheequipmentisinstalledandoper-
atedaccordingtoinstructions.
JetlineEngineering’sobligationunderthiswarrantyisexpresslylimitedtoreplacingorrepairingandde-
fectivepartorcorrectinganymanufacturingdefectwithoutchargeduringthewarrantyperiod,ifJetline’sin-
spectionconfirmstheexistenceofsuchdefects.Jetline’soptionofrepairorreplacementwillbeF.O.B.
FactoryatIrvine,California,andthereforenocompensationfortransportationcostsofanykindwillbeal
-
lowed.
Thewarrantyperiodbeginsonthedateofsaletotheoriginal-purchaseuseroftheequipment.
JetlineEngineeringwillnotbeliableforanylossorconsequentialdamageorexpenseaccruingdirectly
orindirectlyfromtheuseofequipmentcoveredbythiswarranty.
ThiswarrantysupersedesallpreviousJetlineWarrantiesandisexclusivewithnootherguaranteesor
warrantiesexpressedorimplied.
NOTICE
Theinstallation,operationandmaintenanceguidelinessetoutinthismanualwill
enableyoutomaintaintheequipmentinpeakconditionandachievemaximumeffi
-
ciencywithyourweldingoperation.Pleasereadtheseinstructionscarefullytobecome
awareofeveryadvantage.
CAUTION
Onlyexperiencedpersonnelfamiliarwiththe
operationandsafepracticeofweldingequipment
shouldinstalland/orusethisequipment.
Overview
Overview .................................................... vi
TableofContents ............................................... vii
TableofTables ................................................. x
TableofFigures................................................. xi
Safety .......................................................
SafetyPrecautions............................................... xiii
AdditionalSafetyHazards ........................................... xv
AVC-501ArcVoltageControlSystem ......................................
DescriptionofEquipment ........................................... 17
Operation.................................................... 31
Installation ................................................... 35
Maintenance .................................................. 45
DrawingsandPartsLists............................................ 47
Troubleshooting ................................................ 61
CircuitDescriptions .............................................. 65
ExampleSystemInterface ........................................... 67
SchematicsandBlockDiagrams........................................ 71
OptionalEquipment .............................................. 81
Index .......................................................
Index ...................................................... 83
vi
AVC-501ARCVOLTAGECONTROL SYSTEM OVERVIEW
TableofContents
Overview .............................. vi
TableofContents ........................... vii
TableofTables ............................ x
TableofFigures............................ xi
Safety .......................................................
SafetyPrecautions
Definitions ............................. xiii
Note ............................... xiii
Caution .............................. xiii
Warning ............................. xiii
Danger .............................. xiii
SafetyInformation .......................... xiii
ElectricShock ............................ xiii
FireSafety ............................. xiv
AdditionalSafetyHazards
FireandExplosion .......................... xv
FallingEquipment ........................... xv
HotParts ............................. xv
MovingParts ............................ xv
MagneticFieldsCanAffectPacemakers .................... xv
WeldingWire ............................ xv
FlyingPiecesOfMetalOrDirt....................... xv
OverheatedEquipment ......................... xv
HighFrequency ........................... xv
SafetyReferences ........................... xv
AVC-501ArcVoltageControlSystem ......................................
DescriptionofEquipment
DescriptionofEquipment ........................ 17
ArcVoltageControlTheory ........................ 17
ArcVoltageControlSystem ........................ 17
ControlUnit ............................ 18
DriveAssembly ........................... 18
Operation
Operation ............................. 31
Generaloperationaldescription ...................... 31
StartModes ............................. 31
High-FrequencyStart.......................... 31
Lift-StartÔ ............................. 31
Automatic/ManualModes ........................ 32
Manualmode ............................ 32
AutomaticandStartDelayModes ...................... 32
LockoutMode ............................ 32
RetractMode ............................ 32
TABLEOFCONTENTS AVC-501ARCVOLTAGECONTROL SYSTEM
vii
Deadband ............................. 32
Sensitivity ............................. 33
Burn-ThroughProtection(Protect) ..................... 33
StartingArcGap ........................... 33
TungstenPreheat ........................... 34
Installation
Installation ............................. 35
DriveAssemblyMounting ........................ 35
RedVoltageSenseLead ......................... 35
WorkpieceGroundStud ......................... 35
ControlUnitMounting ......................... 35
InterfacingtheAVC-501withotherequipment .................. 36
EndofStartDelayRelay(EOSD) ...................... 36
LockoutInputs ............................ 36
RemoteSetpointVoltageInput ....................... 37
SystemVisualCheck .......................... 38
Touchsense Calibration ......................... 38
Maintenance
Maintenance ............................ 45
MaintenanceRequirements ........................ 45
ControlUnitAssembly ......................... 45
CableAssembly ........................... 45
AVCDriveAssemblies ......................... 45
MountingBrackets .......................... 46
PreventiveMaintenanceSchedule ...................... 46
MonthlyMaintenance ......................... 46
AVCDriveAssemblies ......................... 46
ProperFunction .......................... 46
Test .............................. 46
Test .............................. 46
QuarterlyMaintenance ......................... 46
TorchBracketAssembly ......................... 46
ProperFunction .......................... 46
Test .............................. 46
Cables .............................. 46
SemiAnnualMaintenance ........................ 46
ControlUnitAssembly ......................... 46
DrawingsandPartsLists
DrawingsandPartsLists ........................ 47
Troubleshooting
Troubleshooting ........................... 61
RecommendedSparesforTroubleshooting ................... 61
Problem1 ............................. 61
Problem2 ............................. 61
Problem3 ............................. 61
Problem4 ............................. 61
Problem5 ............................. 61
Problem6 ............................. 62
Problem7 ............................. 62
viii
AVC-501ARCVOLTAGECONTROL SYSTEM TABLEOFCONTENTS
Problem8 ............................. 62
Problem9 ............................. 62
Problem10 ............................. 62
CircuitDescriptions
CircuitDescriptions .......................... 65
SystemWiringDiagram ......................... 65
PowerDriverBoardAssembly ....................... 65
Micro-ControllerBoardAssembly ...................... 65
MotorDriverCircuit .......................... 66
RemoteVoltagePresetCircuit ....................... 66
ExampleSystemInterface
ExampleSystemInterface ........................ 67
AVC-501SystemInterfaceExample ..................... 67
DesignIntent ............................ 67
InterfaceIntent............................ 67
OperationoftheSystem ......................... 67
StartSequence ............................ 68
StopSequence ............................ 68
ConsoleFeatures ........................... 69
ColdWireFeederSection ........................ 69
ArcVoltageControlSection ........................ 69
ProcessControlSection ......................... 69
PowerSourceSection.......................... 69
OptionalFeatures ........................... 69
ColdWireFeedSection ......................... 69
ArcVoltageControlSection ........................ 69
ProcessControlSection ......................... 69
PowerSourceSection.......................... 70
SchematicsandBlockDiagrams
SchematicsandBlockDiagrams ...................... 71
OptionalEquipment
OptionalEquipment .......................... 81
Crossseamadjustmentassembly(1046-0271) .................. 81
Tiltingbracketassembly(1043-0046)..................... 81
Drivecableextension.......................... 81
MagneticArcControlSystems ....................... 81
ColdWireFeedSystems ......................... 81
Orderinginformation .......................... 81
Index
Index ............................... 83
TABLEOFCONTENTS AVC-501ARCVOLTAGECONTROL SYSTEM
ix
TableofTables
AVC-501ArcVoltageControlSystem
DescriptionofEquipment ........................................... 17
Table1-AVC-501ControlSpecifications ................... 20
Table3-AVC-501StandardDriveAssemblySpecifications.............. 22
Table4-AVC-501CompactDriveAssemblySpecifications.............. 23
Operation.................................................... 31
Installation ................................................... 35
Maintenance .................................................. 45
DrawingsandPartsLists............................................ 47
Table5-VoltageSelectorSwitchAssemblyPartsList ............... 49
Table6-AVC-501ControlPartsList..................... 51
Table7-PowerSwitchAssemblyPartsList................... 52
Table8-TransformerAssemblyPartsList ................... 53
Table9-AVCDriveCableAssemblyPartsList ................. 54
Table10-AVCRemoteInterfaceCablePartsList................. 55
Table11-AVC-501StandardDriveAssemblyPartsList............... 57
Table12-AVC-501CompactDriveAssemblyPartsList............... 59
Table13-AVCAuxRemoteInterfaceCablePartsList ............... 60
Troubleshooting ................................................ 61
Table14-Troubleshooting ........................ 61
Table15-VoltagePointsMicro-controllerBoard................. 62
Table16-VoltagePointsPowerDriverBoard .................. 62
Table17-RecommendedSpareParts .................... 63
Table18-VoltagePresetSelection(S1) .................... 63
CircuitDescriptions .............................................. 65
ExampleSystemInterface ........................................... 67
Table19-AVC-501SetupParameters .................... 67
Table20- DWF-3 SetupParameters ..................... 67
Table21-CarriageControlSetupParameters .................. 67
Table22-MagneticArcControlSetupParameters ................ 68
Table23-Miller MaxStar 300LXSetupParameters ................ 68
SchematicsandBlockDiagrams........................................ 71
OptionalEquipment .............................................. 81
x
AVC-501ARCVOLTAGECONTROL SYSTEM TABLEOFTABLES
TableofFigures
AVC-501ArcVoltageControlSystem
DescriptionofEquipment ........................................... 17
Figure1-ArcVoltageControlTheory .................... 17
Figure2-AVC-501ControlUnit ...................... 20
Figure3-AVC-501Systemcomponents .................... 21
Figure4-AVC-501StandardDriveAssembly .................. 22
Figure5-AVC-501CompactDriveAssembly .................. 23
Figure6-InterconnectionDiagram ..................... 24
Figure7-AVC-501StandardDriveAssemblyMountingDimensions ........... 25
Figure8-AVC-501CompactDriveAssemblyMountingDimensions........... 26
Figure9-AVC-501SenseLead TIG TorchConnection ............... 27
Figure10-AVC-501SenseLeadPlasmaTorchConnections ............. 28
Figure11-AVC-501DriveWork-PieceConnections ................ 29
Figure12-AVC-501ControlUnitMountingDimensions .............. 30
Operation.................................................... 31
Figure13-HFStartModeandACWelding .................. 31
Figure14-HFStartModeandDCWelding .................. 31
Figure15-Lift-StartStartModeandACWelding ................. 31
Figure16-Lift-StartStartModeandDCWelding................. 32
Figure17- Minumum Deadband Setting.................... 33
Figure18-Maximum Deadband Setting.................... 33
Installation ................................................... 35
Figure19-AVC-501RemoteLockout(Supply) ................. 36
Figure20-RemoteVoltagePresetDIP SwitchSelection............... 37
Figure21-PanelVoltagePresetDIP SwitchSelection ............... 37
Figure22-AVC-501RemoteLockout(Relay) .................. 38
Figure23-AVC-501Process Timeline,ExampleOne ............... 39
Figure24-AVC-501RemoteLockout(TwoSupplies) ............... 40
Figure25-AVC-501RemoteUp/DownDrive ................. 40
Figure26-AVC-501Process Timeline,ExampleTwo ............... 41
Figure27-AVC-501RemoteVoltageSetPoint(Analog) .............. 42
Figure28-AVC-501RemoteUp/DownDriveWithE-Stop ............. 42
Figure29-AVC-501RemoteVoltageSetPoint(InternalVoltage)............ 43
Figure30-AVC-501RemoteVoltageSetPoint(ExternalVoltage) ........... 43
Maintenance .................................................. 45
DrawingsandPartsLists............................................ 47
Figure31-AVC-501Micro-ControllerBoardLayout ............... 47
Figure32-AVC-501PowerBoardLayout ................... 48
Figure33-VoltageSelectorSwitchassemblyExplodedView ............. 49
Figure34-AVC-501ControlExplodedView .................. 50
Figure35-PowerSwitchAssemblyExplodedView ................ 52
Figure36-TransformerAssemblyExplodedView................. 53
Figure37-AVCDriveCableAssemblyExplodedView ............... 54
Figure38-AVCRemoteInterfacecableExplodedView ............... 55
TABLEOFFIGURES AVC-501ARCVOLTAGECONTROL SYSTEM
xi
Figure39-AVC-501StandardDriveAssemblyExplodedView ............ 56
Figure40-AVC-501CompactDriveAssemblyExplodedView ............ 58
Figure41-AVCAuxRemoteInterfaceCableExplodedView ............. 60
Troubleshooting ................................................ 61
Figure42-AVC-501SignalFlow ...................... 63
CircuitDescriptions .............................................. 65
ExampleSystemInterface ........................................... 67
SchematicsandBlockDiagrams........................................ 71
Figure43-AVC-501CompactDriveBlockDiagram................ 71
Figure44-AVC-501ControlBlockDiagram .................. 72
Figure45-AVC-501ControlBlockDiagram(Cont.)................ 73
Figure46-AVC-501StandardDriveBlockDiagram ................ 74
Figure47-AVC-4StandardDriveBlockDiagram ................ 75
Figure48-AVC-501RemoteInterfaceCableSchematic .............. 76
Figure49-AVC-501AuxiliaryRemoteInterfaceCableSchematic ........... 77
Figure50-AVC-501SystemInterfaceExample ................. 78
Figure51-AVC-501SystemInterfaceExample(Cont.) ............... 79
OptionalEquipment .............................................. 81
xii
AVC-501ARCVOLTAGECONTROL SYSTEM TABLEOFFIGURES
SAFETY
SAFETY PRECAUTIONS
THISMANUAL HASBEENDESIGNEDFOR
EXPERIENCEDWELDINGANDCUTTING
EQUIPMENT OPERATORSANDMUST BEREAD
COMPLETELY BEFOREUSINGTHISEQUIP
-
MENT.IFYOULACKEXPERIENCEORAREUN
-
FAMILIARWITHTHEPRACTICESANDSAFE
OPERATIONOFWELDINGANDCUTTING
EQUIPMENT,PLEASECONSULT YOUR
FOREMAN.DONOT ATTEMPT TOINSTALL,
OPERATE,ORPERFORMMAINTENANCEON
THISEQUIPMENT UNLESSYOUAREQUAL
-
IFIEDANDHAVEREADANDUNDERSTOOD
THISMANUAL.IFINDOUBT ABOUT IN
-
STALLINGOROPERATINGTHISEQUIPMENT,
CONTACT YOURDISTRIBUTORORTHECUS
-
TOMERSERVICEDEPARTMENT OFITW
JETLINE
DEFINITIONS
Throughoutthismanual,NOTE,CAUTION,
WARNINGandDANGERareinsertedtocallatten-
tiontoparticularinformation.Themethodsusedto
identifythesehighlightsandthepurposeforwhich
eachisused,areasfollows:
NOTE
Operational,procedural,andbackgroundin-
formationwhichaidstheoperatorintheuse
ofthemachine,helpstheservicepersonnel
intheperformanceofmaintenance,and
preventsdamagetotheequipment.
CAUTION
Anoperationalprocedurewhich,ifnotfol
-
lowed,maycauseminorinjurytotheopera
-
tor,servicepersonneland/orbystanders.
WARNING
Anoperationalprocedurewhich,ifnotfol
-
lowed,maycausesevereinjurytotheoper
-
ator,servicepersonneland/orbystanders.
DANGER
Anoperationalprocedurewhich,ifnotfol
-
lowed,willcausesevereinjuryoreven
deathtotheoperator,servicepersonnelor
bystanders.
SAFETY INFORMATION
Safetyisacombinationofgoodjudgmentandproper
training.Operationandmaintenanceofanyarcweld
-
ingandcuttingequipmentinvolvespotentialhazards.
Individualswhoareunfamiliarwithcuttingandweld
-
ingequipment,usefaultyjudgmentorlackproper
training,maycauseinjurytothemselvesandothers.
Personnelshouldbealertedtothefollowingpotential
hazardsandthesafeguardsnecessarytoavoidpossi
-
bleinjury.Inaddition,beforeoperatingthisequip
-
ment,youshouldbeawareofyouremployer'ssafety
regulations.
BESURETOREADTHISMANUAL BE
-
FOREINSTALLINGORUSINGTHIS
EQUIPMENT.
BESURETOREADANDFOLLOWALL
AVAILABLESAFETY REGULATIONSBE
-
FOREUSINGTHISEQUIPMENT.
ELECTRIC SHOCK
THEVOLTAGESPRESENT INTHE
WELDINGANDCUTTINGENVIRONMENT
CANCAUSESEVEREBURNSTOTHE
BODY ORFATAL SHOCK.THESEVERITY
OFELECTRICAL SHOCKISDETER-
MINEDBY THEPATHANDTHEAMOUNT
OFCURRENT THROUGHTHEBODY.
A Install and continue to maintain equipment according
to USA Standard C1, National Electric Code.
B Never allow live metal parts to touch bare skin or any
wet clothing. Use only dry gloves.
C When welding or cutting in a damp area, or when
standing on metal, make sure you are well in
-
sulated by wearing dry gloves, rubber soled
shoes, and by standing on a dry board or plat
-
form.
D Do not use worn or damaged welding or torch cables.
Do not overload the cables. Use well maintained
equipment.
E When not welding/cutting, turn equipment OFF. Ac
-
cidental grounding can cause overheating and
create a fire hazard. Do not coil or loop the ca
-
ble around parts of the body.
F The ground cable should be connected to the work
piece as close to the work area as possible.
Grounds connected to building framework or
other locations remote to the work area reduce
efficiency and increase the potential hazard of
electric shock. Avoid the possibility of the weld
-
AVC-501ARCVOLTAGECONTROL SYSTEM
xiii
ing or cutting current passing through lifting
chains, crane cables or other electrical paths.
G Keep everything dry you might touch, including
clothing, the work area, welding gun, torch and
welding or cutting machines. Fix water leaks
immediately. Do not operate equipment stand
-
ing in water.
H Never use a cutting torch or welding gun which is
damaged or contains cracked housing.
I Refer to AWS-Z49.1 for grounding recommendations.
SKINANDEYEBURNSRESULTING
FROMBODY EXPOSURETO
ELECTRIC-ARCWELDINGANDCUTTING
RAYSORHOTMETAL CANBEMORE
SEVERETHANSUNBURN.
A Use a proper face shield fitted with the correct filter
(#10 or greater) and cover plates to protect
your eyes, face, neck and ears from the sparks
and rays of the cutting/welding arc when
cutting/welding or observing cutting/welding.
Warn bystanders not to watch the arc and not
to expose themselves to the cutting/welding
arc rays or to hot metal.
B Wear flameproof gauntlet-type gloves, a heavy
long-sleeve shirt, cuff-less trousers,
high-topped shoes, and a welding helmet or
cap (for hair protection) to protect the skin
from arc rays and hot sparks or hot metal.
C Protect other nearby personnel from arc rays and
hot sparks with a suitable non-flammable par
-
tition.
D Always wear safety glasses or goggles when in a
cutting or welding area. Use safety glasses with
side shields or goggles when chipping slag or
grinding. Chipped slag is hot and may travel a
considerable distance. Bystanders should also
wear safety glasses or goggles.
E Compressed gas cylinders are potentially dangerous,
refer to the suppliers for proper handling pro
-
cedures.
F Wear ear plugs or other ear protection devices when
operating cutting or welding equipment.
FIRE SAFETY
HOT SLAG OR SPARKS CAN CAUSE A
SERIOUS FIRE WHEN IN CONTACT WITH
COMBUSTIBLE SOLIDS, LIQUIDS OR
GASES.
A Move all combustible materials well away from the
cutting area or completely cover materials
with a non-flammable covering. Combustible
materials include but are not limited to wood,
clothing, sawdust, gasoline, kerosene, paints,
solvents, natural gases, acetylene, propane,
and similar articles.
B Do not weld, cut or perform other hot work on used
barrels, drums, tanks or other containers until
they have been completely cleaned. There
must be no substances in the container which
might produce flammable or toxic vapors.
C For fire protection, have suitable extinguishing
equipment handy for instant use.
WELDING AND CUTTING FUMES AND
GASES, PARTICULARLY IN CONFINED
SPACES, CAN CAUSE DISCOMFORT
AND PHYSICAL HARM IF INHALED
OVER AN EXTENDED PERIOD OF TIME.
A At all times, provide adequate ventilation in the weld-
ing and cutting area by either natural or me-
chanical means. Do not weld or cut on
galvanized, zinc, lead, beryllium or cadmium
materials unless positive mechanical ventila-
tion is provided to prevent inhaling fumes and
gases from these materials.
B Do not weld or cut in locations close to chlorinated
hydrocarbon vapors coming from degreasing
or spraying operations. The heat of arc rays
can react with solvent vapors to form phos
-
gene, a highly toxic gas, and other irritant
gases.
C If you develop momentary eye, nose or throat irrita
-
tion during welding or cutting, it is an indica
-
tion that the ventilation is not adequate. Stop
work and take the necessary steps to improve
ventilation in the welding or cutting area. Do
not continue to weld or cut if physical discom
-
fort persists.
D Use an air supplied respirator if ventilation is not
adequate to remove all fumes and gases.
E Beware of gas leaks. Welding or cutting gases con
-
taining argon are denser than air and will re
-
place air when used in confined spaces. Do not
locate gas cylinders in confined spaces. When
not in use, shut OFF the gas supply at its source.
AVC-501 ARC VOLTAGE CONTROL SYSTEM
xiv
Referto AWS StandardZ49.1forspecificventilation
recommendations.
ADDITIONAL SAFETY HAZARDS
FIRE AND EXPLOSION
Fire and Explosion can result from placing
units on, over, or near combustible surfaces.
Do not install units on, over, or near com
-
bustible surfaces.
Do not install unit near flammables.
FALLING EQUIPMENT
Falling Equipment can cause serious per
-
sonal injury and equipment damage.
Use lifting eyes to lift unit only, not running
gear, gas cylinders, or any other accesso
-
ries.
Use equipment of adequate capacity to lift
units.
If using fork lifts to move units, be sure
forks are long enough to extend beyond
opposite side of the unit.
HOT PARTS
Hot parts can cause severe burns.
Do not touch hot parts bare handed.
Allow cooling period before working on
gun or torch.
MOVING PARTS
Moving Parts can cause injury.
Keep away from moving parts, such as
fans.
Keep all doors, panels, covers, and
guards closed and securely in place.
Keep away from pinch points, such as
mechanical slides, drive rolls, carriage as
-
semblies, etc.
MAGNETIC FIELDS CAN AFFECT
PACEMAKERS
Magnetic Fields from High Currents can af
-
fect pacemaker operation.
Pacemaker wearers should keep away.
Wearers of pacemakers should consult
their doctors before going near arc weld
-
ing, gouging, plasma cutting, or spot
welding operations.
WELDING WIRE
Welding wire can cause puncture wounds.
Do not press gun trigger until instructed to
do so.
Do not point the gun toward any part of
the body, other people, or any metal when
threading welding wire through the gun.
FLYING PIECES OF METAL OR DIRT
Flying pieces of metal or dirt can injure
eyes.
Wear safety glasses with side shields or
face shields.
OVERHEATED EQUIPMENT
High output power for long durations can
cause equipment to overheat.
Allow cooling periods.
Reduce current or reduce duty cycle be
-
fore starting to weld again.
Follow rated duty cycle.
HIGH FREQUENCY
High Frequency can cause electrical inter-
ference.
Take appropriate precautions to shield
sensitive electronic equipment, such as
computers, Programmable Logic
Controllers, etc.
Be sure to ground each component of the
system to one ground point, i.e., Earth
Ground (Earth) or Protective Earth (PE).
SAFETY REFERENCES
The following publications provide additional infor
-
mation on important welding safeguards.
A ANSI/ASC 249.1-1988, American National Standard
"Safety in Welding and Cutting".
B Bulletin No. F4-1, "Recommended Safe Practices for
the Preparation for Welding and Cutting Con
-
tainers and Piping that have held Hazardous
Substances".
C OSHA Safety and Health Standards, 29CFR 1910,
available from the United States Department of
Labor, Washington, DC 20210.
AVC-501 ARC VOLTAGE CONTROL SYSTEM
xv
D NFPA Standard 51B, "Fire Prevention in Use of Cut
-
ting and Welding Processes", available from the
National Fire Protection Association, 470 Atlan
-
tic Avenue, Boston, MA 00210.
E NEMA Standards Publication/No. EW1-1989, Elec
-
tric Arc-Welding Apparatus, approved as ANSI
C87.1-1989. Available from National Electrical
Manufacturers Association, 155 E. 44th Street,
New York, NY 10017.
AVC-501ARCVOLTAGECONTROL SYSTEM
xvi
AVC-501 Arc Voltage Control System
DESCRIPTION OF EQUIPMENT
TheJetlineAVC-501ArcVoltageControlsystemisa
precisionmicroprocessor-controlledarcvoltagecon
-
trolunitforusewiththeGasTungstenArcWelding
process(GTAW,alsoknownas TIG)andPlasmaArc
Welding(PAW).Thisequipment,bymeansofa
closed-loopservo,movestheweldingtorchinorder
tomaintainaconstantarcvoltage.Automaticcorrec
-
tionsaremadebythedriveheadtomatchtheactual
arcvoltagewiththatsetonthefrontpanelcontrols,
thuskeepingthearclengthconstant.Otherfeatures
designedintotheAVC-501ArcVoltageControlsys
-
temmakesitatrulyinnovativeproductsuitedtothe
customer’sneeds.
ARC VOLTAGE CONTROL THEORY
TheJetlineAVC-501ArcVoltageControlSystemor
otherarcvoltage/lengthcontrolsare,simplystated,
primarilyamodifiedDigitalVoltageMeter.A Digital
VoltMetermeasuresavoltagedropacrossaresistor
orothercomponentattwopoints, i.e.,the+and-
senseleads.
Ascurrentincreasesordecreasesthroughtheresistor
orcomponent,thevoltagedropacrossalsoincreases
ordecreasesproportionately.Likewise,inawelding
arcifthearclengthincreases, i.e.,thetorchmoving
awayfromthework-piece,thearcvoltagealsoin
-
creases.ArcVoltageisdirectlyproportionaltoarc
length.Asoneincreasestheotherincreasesorasone
decreasestheotherdecreases.
LiketheDigitalVoltMeter,ourAVC-501systemalso
measuresthevoltageacrossaresistorattwopoints.
IntheAVC-501system’scase,theresistorisaweld
-
ingarc.Ina TIG arc,thepositive(+)leadconnectsto
thework-pieceandtheNegative(-)leadconnectsto
the TIG weldingtorch.
Whilewelding,theAVC-501systemmeasuresthe
voltageacrossthearcandcomparesthisvoltagetothe
voltagepre-setonthefrontpanel(orfromtheremote
input)andadjuststhetorchupordowntomaintain
thepre-setweldingarcvoltageselected.
Theimportanceofanarcvoltagecontrolsystemwas
firstrealizedinanautomatedweldingsystemwhere
heatinputiscritical. TIG weldingpowersourcesare
knownas Consant Current(orCC)powersources,
whichmeansthatnomatterwhatarcvoltage(reason
-
ablyobtainedfromthepowersource)thepower
sourcewillmaintainaconstantcurrentoutput.
Butbecausethearcvoltagewasn’tkeptconstant,the
heat(orpower)intothework-piecebeingweldedwas
notkeptconstant.
Withtheadventofanarcvoltagecontrolsystem,arc
voltagewasalsokeptconstant,therebyprovidinga
constantheat(orpower)intothework-piecebeing
welded(see Figure1-ArcVoltageControlTheory on
page 17).
ARC VOLTAGE CONTROL SYSTEM
TheAVC-501systemincludesmanynewfeaturesnot
foundonanyotherarcvoltagecontrolsystems(orarc
lengthcontrolsystems)currentlyavailable.Themost
innovativefeatureintheAVC-501systemisourpat
-
entedLift-Startprocess.TheAVC-501willstartan
arcwithoutanyHigh-Frequency,usingawelding
powersourcewithatouchstartorLift-Arc(an ITW
trademark)startingprocess.
Thefeatureenablesreliable,automatednon-
High-Frequency(HF)arcstartingonallmetals.The
AVC-501commandsthetorchtotouchthe
DESCRIPTIONOFEQUIPMENT AVC-501ARCVOLTAGECONTROL SYSTEM
17
FIGURE 1 - ARC VOLTAGE CONTROL THEORY
work-piece,thentungstenispreheatedforanadjust
-
abletimeuniquetothediameteroftheelectrodeand
thetypeofmaterialbeingwelded.Thisprovidesa
smooth,consistentarcstart,withouttungsteninclu
-
sion.
The Lift-StartfeatureisenabledbyaDIP switchset
-
tingonthemicro-controllerboardontheinsideofthe
AVC-501Controlunit,allowingeasyselection.
TheAVC-501controlsACweldingaswellasDC
weldingapplications,withoutanyadditionalcompo
-
nents,cables,etc.Thisfeatureisalsoenabledviaa
DIP switchonthemicro-controllerboard.
CONTROL UNIT
Thecontrolunitisaheavygaugesteelenclosurecon
-
tainingtheelectroniccircuitryusedinthesystem.
Solidstatecircuitsareusedtoprovidelong,trou
-
ble-freeoperation.Thecontrolunitoperateson
115/230VAC,50/60Hzcommercialpower,capableof
supplyingapproximately2ampspeakcurrent.The
unithasalightedpowerswitchandfuseholder
mountedontheexterioroftheunit.
Thesystemisoperatedusingthecontrols,potentiom
-
eters,pushbuttonslocatedonthefrontpanel.Addi-
tionalswitchesarelocatedontheinsideofthecontrol
unit,onthebacksideofthemicro-controllerboard
viaDIP switches.A heatsinkmountedontheinside
ofthecontrolunitallowsadequatecoolingforthe
heatdissipatingdevices, i.e.,motorstepperdrivers.
Thethreeconnectorslocatedonthebottomoftheunit
provideforconnectionofthedrivecableandtwore
-
moteinterfacecables.
DRIVE ASSEMBLY
TheAVCSystemcanbepurchasedwithoneoftwo
differentdriveassemblies, i.e.,StandardAVC-501
DriveassemblyortheCompactAVCDriveassembly.
Thecontrollercanalsobeusedwitholderdriveas
-
sembliesbuiltby Cyclomaticä,whichincludethe
StandardAVC-3andStandardAVC-4Driveassem
-
bliesandtheCompactAVCDriveassembly,provid
-
ingthesedriveassembliesareingoodworkingorder.
TheStandardAVC-501Driveassembly(and
Cyclomatic’sä AVC-3andAVC-4drives)hasa6”
strokelength.Thisisanadequatestrokelengthfor
manyapplications.
TheCompactAVCdriveassemblieshavea1”stroke
lengthforuseintightweldingareaswherephysical
constraintspreventtheuseoftheStandard6”stroke
driveassembly.
EachdriveisequippedwithaRedVoltageSenselead,
whichconnectstothe TIG orPlasmaweldingtorch,
andaWork-pieceStudforconnectingtothe
work-piece,makingupthetwoleadsofadigitalvolt
meter,as discribed earlier.
AVC-501ARCVOLTAGECONTROL SYSTEM DESCRIPTIONOFEQUIPMENT
18
DESCRIPTIONOFEQUIPMENT AVC-501ARCVOLTAGECONTROL SYSTEM
19
20
AVC-501ARCVOLTAGECONTROL SYSTEM DESCRIPTIONOFEQUIPMENT
DESCRIPTION SPECIFICATIONS RATING
VoltageSensing Accuracy
± 1%ofsettingor.1Vwhicheverisgreater
VoltageSenseRange (LowerLimitsarepossible) 5to50VDCorAC
MaximumOpenCircuitVoltage 80VDC,80VAC
InputPowerRequirements 90-132VAC/180-264VAC50/60Hz
ControlUnit Enclosure
Standard NEMA StyleSealedenclosurewithprovi-
sionsforplug-inoptions
Deadband Adjustment VoltageErrorRange
.1(Min.)to1.5V(Max.)inDCWelding
.1(Min.)to1.5V(Max.)inACWelding
SensitivityAdjustment AdjustmentforSpeedofcorrection 0to100%
RetractTime 0to10sec.
StartingArcGap .01to.09in.
StartDelay 0.0to12.5sec.
Burn-ThroughDetection 2.0VoltageabovePre-SetVoltageinitiates
ArcStartingCapability ACorDCWelding
HF Start
Lift-Start
Indication AutoTracking
StartDelay
Lockout
DigitalDisplayofActualandPre-SetVoltage,Start
Delay,StartGap,TungstenPreheat,Touch-sense
VoltageThreshold
ManualInputs
Up/Down Jog(RemoteandFrontpanelandDrive
unit)
ProtectArm
Lockout
PowerCable StandardLength 8’ (1.8M)
TABLE 1 - AVC-501 CONTROL SPECIFICATIONS
FIGURE 2 - AVC-501 CONTROL UNIT
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Miller JETLINE CYCLOMATIC AVC-501 ARC VOLTAGE CONTROL Owner's manual
- Category
- Welding System
- Type
- Owner's manual
- This manual is also suitable for
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