Miller JETLINE CYCLOMATIC 8040 MAGNETIC ARC CONTROL Owner's manual

OPERATION MANUAL

for Cyclomatic Series

8040 Control

JetlineEngineering,15GoodyearStreet,IrvineCA 92618

Telephone:949-951-1515·Fax:949-951-9237

Website: www.jetline.com · www.cyclomatic.com

E-mail: [email protected]

IMPORTANT

RevisedAugust2010

Readthismanualcarefullybeforeinstalling,

commissioningoroperatingthisproduct.

LIMITEDWARRANTY

JetlineEngineering,ofIrvine,California,U.S.A.,warrantsallnewequipmenttobefreefromdefectsin

materialandworkmanshipfortheperiodofone(1)year,providedthattheequipmentisinstalledandoper-

atedaccordingtoinstructions.

JetlineEngineering’sobligationunderthiswarrantyisexpresslylimitedtoreplacingorrepairingandde-

fectivepartorcorrectinganymanufacturingdefectwithoutchargeduringthewarrantyperiod,ifJetline’sin-

spectionconfirmstheexistenceofsuchdefects.Jetline’soptionofrepairorreplacementwillbeF.O.B.

FactoryatIrvine,California,andthereforenocompensationfortransportationcostsofanykindwillbeal

-

lowed.

Thewarrantyperiodbeginsonthedateofsaletotheoriginal-purchaseuseroftheequipment.

JetlineEngineeringwillnotbeliableforanylossorconsequentialdamageorexpenseaccruingdirectly

orindirectlyfromtheuseofequipmentcoveredbythiswarranty.

ThiswarrantysupersedesallpreviousJetlineWarrantiesandisexclusivewithnootherguaranteesor

warrantiesexpressedorimplied.

NOTICE

Theinstallation,operationandmaintenanceguidelinessetoutinthismanualwill

enableyoutomaintaintheequipmentinpeakconditionandachievemaximumeffi

-

ciencywithyourweldingoperation.Pleasereadtheseinstructionscarefullytobecome

awareofeveryadvantage.

CAUTION

Onlyexperiencedpersonnelfamiliarwiththe

operationandsafepracticeofweldingequipment

shouldinstalland/orusethisequipment.

Overview

Overview .................................................... vi

TableofContents ............................................... vii

TableofTables ................................................. ix

TableofFigures ................................................. x

Safety .......................................................

SafetyPrecautions ............................................... xii

AdditionalsafetyHazards ........................................... xiv

8040MagneticArcControlSystem .......................................

DescriptionOfEquipment ........................................... 1

Installation.................................................... 3

Operation .................................................... 11

Maintenance .................................................. 18

DrawingsandPartsList ............................................ 19

Troubleshooting ................................................ 29

CircuitDescriptions .............................................. 31

SchematicsandBlockDiagrams........................................ 33

Index .......................................................

Index ...................................................... 37

vi

OVERVIEW 8040MAGNETICARCCONTROLLER

TableofContents

Overview .............................. vi

TableofContents ........................... vii

TableofTables ............................ ix

TableofFigures ............................ x

Safety .......................................................

SafetyPrecautions

Definitions ............................. xii

Note ............................... xii

CAution .............................. xii

Warning .............................. xii

Danger .............................. xii

SafetyInformation........................... xii

ElectricShock ............................ xii

FireSafety ............................. xiii

AdditionalsafetyHazards

FireandExplosion .......................... xiv

FallingEquipment .......................... xiv

HotParts ............................. xiv

MovingParts ............................ xiv

MagneticFieldsCanAffectPacemakers ................... xiv

WeldingWire ............................ xiv

FlyingPiecesOfMetalOrDirt ...................... xiv

OverheatedEquipment ......................... xiv

HighFrequency ........................... xiv

SafetyReferences ........................... xiv

8040MagneticArcControlSystem .......................................

DescriptionOfEquipment

DescriptionOfEquipment ........................ 1

8040ControlUnit ........................... 1

MagneticArcControlProbe ........................ 1

4613Probe ............................. 1

Installation

Installation ............................. 3

GeneralSetup ............................ 3

OptionsandSpecials .......................... 3

ControlUnitLocation .......................... 3

MagneticArcProbeMounting ....................... 3

4613Probe ............................. 3

Operation

Operation ............................. 11

GeneralOperationalDescription ...................... 11

ControlFeatures&Functions ....................... 11

8040MAGNETICARCCONTROLLER TABLEOFCONTENTS

vii

Remote/PanelPositionControl ...................... 11

Stabilize/Oscillate .......................... 11

Frequency ............................. 11

AmplitudeControl ........................... 11

Amplitude1 ........................... 11

Amplitude2 ........................... 11

PositionControl ........................... 11

Position1 ............................ 11

Position2 ............................ 11

FinalTaper ............................. 11

RemoteStart ............................ 12

NormallyOpenStart ........................ 12

NormallyClosedStart ........................ 13

NormallyOpenStartUsingTaper .................... 13

NormallyClosedStartUsingTaper .................... 14

Maintenance

Maintenance ............................ 18

MaintenanceRequirements ........................ 18

ControlUnit ............................ 18

ProbesAssemblies........................... 18

CableAssembly ........................... 18

PreventiveMaintenanceSchedule ...................... 18

MonthlyMaintenance ......................... 18

ProbeAssemblies ........................... 18

ProperFunction .......................... 18

Test .............................. 18

QuarterlyMaintenance ......................... 18

SemiAnnualMaintenance ........................ 18

ControlUnitAssembly ......................... 18

DrawingsandPartsList

DrawingsandPartsList ......................... 19

Troubleshooting

Troubleshooting ........................... 29

RecommendedSparesforTroubleshooting ................... 29

Problem1 ............................. 29

Problem2 ............................. 29

Problem3 ............................. 29

CircuitDescriptions

CircuitDescriptions .......................... 31

SystemWiringDiagram ......................... 31

MainBoardAssembly ......................... 31

SchematicsandBlockDiagrams

SchematicsandBlockDiagrams ...................... 33

Index

Index ............................... 37

viii

TABLEOFCONTENTS 8040MAGNETICARCCONTROLLER

TableofTables

8040MagneticArcControlSystem

DescriptionOfEquipment ........................................... 1

Installation.................................................... 3

Table1-8040MagneticArcControlSpecifications ................ 4

Table2-8040MagneticArcControlSystemComponentsSpecifications .......... 5

Table3-4613MagneticArcProbeAssemblySpecifications .............. 6

Operation .................................................... 11

Table4-RemoteStartN.O.InhibitSettings ................... 12

Table5-RemoteStartN.C.InhibitSettings ................... 13

Table6-RemoteTaperN.C.Settings ..................... 14

Table7-RemoteTaperN.O.Settings ..................... 14

Maintenance .................................................. 18

DrawingsandPartsList ............................................ 19

Table8-8040MagneticArcControlPartsList ................. 21

Table9-PowerSwitchAssemblyPartsList................... 22

Table10-TransformerAssemblyPartsList................... 23

Table11-ProbeCableHarnessPartsList ................... 24

Table12-RemoteInterfaceCableHarnessPartsList ............... 25

Table13-4613MagneticArcProbePartsList.................. 27

Table14-VoltageSelectorSwitchAssemblyPartsList ............... 28

Troubleshooting ................................................ 29

Table15-Troubleshooting ........................ 29

Table16-RecommendedSpareParts .................... 29

Table17-VoltagePointsMainBoard .................... 29

CircuitDescriptions .............................................. 31

SchematicsandBlockDiagrams........................................ 33

8040MAGNETICARCCONTROLLER TABLEOFTABLES

ix

TableofFigures

8040MagneticArcControlSystem

DescriptionOfEquipment ........................................... 1

Figure1-4613MountingMethod ...................... 2

Installation.................................................... 3

Figure2-8040MagneticArcControlUnit ................... 4

Figure3-8040MagneticArcControlSystemcomponents .............. 5

Figure4-4613MagneticArcProbeAssembly .................. 6

Figure5-InterconnectionDiagram ..................... 7

Figure6-8040MagneticArcControlMountingDimensions ............. 8

Figure7-AllControlsEqual........................ 9

Figure8-Amplitude1Effect........................ 9

Figure9-Amplitude2Effect........................ 9

Figure10-Position1Adjustments ...................... 9

Figure11-Position1Adjustments ..................... 10

Figure12-Position1Adjustments ..................... 10

Figure13-Amplitude1and2Adjustments ................... 10

Operation .................................................... 11

Figure14-TaperFunction ........................ 12

Figure15-DefaultInhibitDIP SwitchSettings ................. 13

Figure16-InhibitNCDIP SwitchSettings ................... 13

Figure17-DefaultTaperDIP SwitchSettings .................. 14

Figure18-DefaultOsc/StabDIP SwitchSettings ................ 14

Figure19-TaperNCDIP SwitchSettings ................... 14

Figure20-RemoteN.O.TaperInterface ................... 15

Figure21-RemoteN.C.TaperInterface.................... 16

Figure22-RemoteN.C.InhibitInterface ................... 16

Figure23-RemoteN.O.InhibitInterface ................... 17

Figure24-DefaultPositionDIP SwitchSettings ................. 17

Maintenance .................................................. 18

DrawingsandPartsList ............................................ 19

Figure25-8040MainBoardLayout ..................... 19

Figure26-8040MagneticArcControlExplodedView ............... 20

Figure27-PowerSwitchAssemblyExplodedView ................ 22

Figure28-TransformerAssemblyExplodedView................. 23

Figure29-ProbeCableHarnessExplodedView ................. 24

Figure30-RemoteInterfaceCableHarnessExplodedView ............. 25

Figure31-4613MagneticArcProbeExplodedView ............... 26

Figure32-VoltageSelectorSwitchAssemblyExplodedView ............. 28

Troubleshooting ................................................ 29

CircuitDescriptions .............................................. 31

Figure33-8040MagneticArcControlSignalFlow ................ 32

SchematicsandBlockDiagrams........................................ 33

x

TABLEOFFIGURES 8040MAGNETICARCCONTROLLER

Figure34-4613MagneticArcProbeBlockDiagram ............... 33

Figure35-8040MagneticArcControlBlockDiagram ............... 34

Figure36-8040MagneticArcControlBlockDiagram(Cont.) ............ 35

Figure37-8040MagneticArcControlInterfaceCableSchematic ........... 36

8040MAGNETICARCCONTROLLER TABLEOFFIGURES

xi

SAFETY

SAFETY PRECAUTIONS

THISMANUAL HASBEENDESIGNEDFOREX

-

PERIENCEDWELDINGANDCUTTINGEQUIP

-

MENT OPERATORSANDMUST BEREAD

COMPLETELY BEFOREUSINGTHISEQUIP

-

MENT.IFYOULACKEXPERIENCEORAREUN

-

FAMILIARWITHTHEPRACTICESANDSAFE

OPERATIONOFWELDINGANDCUTTING

EQUIPMENT,PLEASECONSULT YOURFORE

-

MAN.DONOT ATTEMPT TOINSTALL,OPER

-

ATE,ORPERFORMMAINTENANCEONTHIS

EQUIPMENT UNLESSYOUAREQUALIFIED

ANDHAVEREADANDUNDERSTOODTHIS

MANUAL.IFINDOUBT ABOUT INSTALLING

OROPERATINGTHISEQUIPMENT,CONTACT

YOURDISTRIBUTORORTHECUSTOMER

SERVICEDEPARTMENT OFARCPRODUCTS.

DEFINITIONS

Throughoutthismanual,NOTE,CAUTION,

WARNINGandDANGERareinsertedtocallatten-

tiontoparticularinformation.Themethodsusedto

identifythesehighlightsandthepurposeforwhich

eachisused,areasfollows:

NOTE

Operational,procedural,andbackgroundinfor

-

mationwhichaidstheoperatorintheuseofthe

machine,helpstheservicepersonnelintheper

-

formanceofmaintenance,andpreventsdamage

totheequipment.

CAUTION

Anoperationalprocedurewhich,ifnotfollowed,

maycauseminorinjurytotheoperator,service

personneland/orbystanders.

WARNING

Anoperationalprocedurewhich,ifnotfollowed,

maycausesevereinjurytotheoperator,service

personneland/orbystanders.

DANGER

Anoperationalprocedurewhich,ifnotfollowed,

willcausesevereinjuryorevendeathtotheop

-

erator,servicepersonnelorbystanders.

SAFETY INFORMATION

Safetyisacombinationofgoodjudgmentandproper

training.Operationandmaintenanceofanyarcweld

-

ingandcuttingequipmentinvolvespotentialhazards.

Individualswhoareunfamiliarwithcuttingandweld

-

ingequipment,usefaultyjudgmentorlackproper

training,maycauseinjurytothemselvesandothers.

Personnelshouldbealertedtothefollowingpotential

hazardsandthesafeguardsnecessarytoavoidpossi

-

bleinjury.Inaddition,beforeoperatingthisequip

-

ment,youshouldbeawareofyouremployer'ssafety

regulations.

BESURETOREADTHISMANUAL BE

-

FOREINSTALLINGORUSINGTHISEQUIP

-

MENT.

BESURETOREADANDFOLLOW ALL

AVAILABLESAFETY REGULATIONSBE

-

FOREUSINGTHISEQUIPMENT.

ELECTRIC SHOCK

THEVOLTAGESPRESENT INTHE

WELDINGANDCUTTINGENVIRONMENT

CANCAUSESEVEREBURNSTOTHE

BODY ORFATAL SHOCK.THESEVERITY

OFELECTRICAL SHOCKISDETERMINED

BY THEPATHANDTHEAMOUNT OFCUR

-

RENT THROUGHTHEBODY.

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.

8040MAGNETICARCCONTROLLER

xii

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

-

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.

SKINANDEYEBURNSRESULTING

FROMBODY EXPOSURETO

ELECTRIC-ARCWELDING AND

CUTTING RAYSORHOT METAL CANBE

MORESEVERETHANSUNBURN.

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.

8040MAGNETICARCCONTROLLER

xiii

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.

Referto AWS StandardZ49.1forspecificventilation

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 combusti

-

ble surfaces.

Do not install unit near flammables.

FALLING EQUIPMENT

FallingEquipmentcancauseseriouspersonalin-

juryandequipmentdamage.

Use lifting eyes to lift unit only, not running

gear, gas cylinders, or any other accessories.

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 me

-

chanical slides, drive rolls, carriage assem

-

blies, etc.

MAGNETIC FIELDS CAN AFFECT

PACEMAKERS

MagneticFieldsfromHighCurrentscanaffect

pacemakeroperation.

Pacemaker wearers should keep away.

Wearers of pacemakers should consult their

doctors before going near arc welding, goug

-

ing, plasma cutting, or spot welding opera

-

tions.

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 thread

-

ing 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 before

starting to weld again.

Follow rated duty cycle.

HIGH FREQUENCY

HighFrequencycancauseelectricalinterfer

-

ence.

Take appropriate precautions to shield sensi

-

tive electronic equipment, such as computers,

Programmable Logic Controllers, etc.

Be sure to ground each component of the sys

-

tem 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

-

8040MAGNETICARCCONTROLLER

xiv

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.

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.

8040MAGNETICARCCONTROLLER

xv

8040MAGNETICARCCONTROLLER

xvi

8040 Magnetic Arc Control System

DESCRIPTION OF EQUIPMENT

The8040MagneticArcControlSystemisaprecise,

controllablemeansforoscillating,stabilizing,orposi

-

tioningaweldingarc.Thisallowstheoperatortocon

-

trolheatdistribution,minimizeundercutting,reduce

porosity,improvepenetration,provideuniformside

-

wallfusionandimprovetheoverallintegrityofthe

weld.UsedwiththeCyclomatic™4613Probes.

8040 CONTROL UNIT

Thecontrolunitisaheavygaugesteelenclosurecon

-

tainingtheelectroniccircuitryusedinthesystem.A

microprocessorandothersolidstatecircuitsareused

toprovidelong,trouble-freeoperation.Thecontrol

unitoperateson115/230VAC,50/60Hzcommercial

power,capableofsupplyingapproximately2amps

peakcurrent.Theunithasalightedpowerswitchand

fuseholdermountedontheexterioroftheunit.See

Table1-8040MagneticArcControlSpecifications,

Table2-8040MagneticArcControlSystem

ComponentsSpecifications, Figure2-8040Magnetic

ArcControlUnit,and Figure3-8040MagneticArc

ControlSystemcomponents foradditionalspecifica-

tions.

Thesystemisoperatedusingthecontrols,potentiom

-

eters,pushbuttonslocatedonthefrontpanel.Addi

-

tionalswitchesarelocatedontheinsideofthecontrol

unitonthemainboardviaDIP switches.A heatsink

mountedontheinsideofthecontrolunitallowsade

-

quatecoolingfortheheatdissipatingdevices.

Twoconnectorslocatedonthebottomoftheunitpro

-

videforconnectionoftheprobecableandaremote

interfacecable.

The8040systemisprimarilyintendedforusewith

theTIG(GTAW)process,butcanalsobeusedwith

thePLASMA (PAW)weldingprocess.Additionally,

the8040SystemcanbeusedwithsprayMIGandSub

Arcprocesses.Withthissystem,theoperatorcan

widenornarrowtheweldbeadasrequiredtoprovide

controloftheheataffectedzone,undercutting,andir

-

regularjointedges.Thecontrolledmagneticfieldalso

reducesarcblowandarcwander,whilethemotionof

thearcstirsthemoltenweldpuddle,reducingporosity

andprovidingamoreuniformbeadsurfacepattern.

The8040isasimple,reliablecontrolwithanoscillat

-

ingfrequencyrangeupto50Hz.ThePulseWidth

Modulation(PWM)designprovidesaconstantmag

-

neticfieldforagivenamplitudesettingovertheentire

frequencyrange.Controlfunctionsallowindependent

controlofeachofthekeywaveformparameters,and

leftandrightdwellintervalsarealsoindependently

adjustable.Thecontrolunitisconvectioncooled,al

-

lowingforlesspowerdissipationandloweroperating

temperatures.

Thetoppanelordoorofthecontrolunitcontainsall

thecontrolsneededforoperation.Therearethree

LightEmittingDiode(LED)indicatorsinapatternto

theleftofthecontrolknobs.Eachlampwillillumi

-

natealternatelyduringarcoscillation.Whenpoweris

appliedtotheControlUnit,thePowerOnLEDwill

alsoilluminate.

The8040Controlunithasadditionalfeaturesselected

frominsidethecontrolenclosure.Thesefeatures,

Stabilize/Oscillatemode(STAB/OSC)andRemote/

PanelPositionControl,areselectedviaDIP Switches

onthemainboard.

Stabilize/Oscillatemodeallowstheoperatortheabil-

itytooscillatethearceitheracrosstheseamoralong

theseamdependingonhowtheprobeismountedon

thetorch(OscillateMode),ortostabilizethearc,po-

sitioningthearcinthedesiredlocation(Stabilize

Mode).

Remote/PanelPositionControlallowtheoperatorto

controlthearcpositionoftheeachaxisfromaremote

potentiometerorPLCwithananalogoutput,orfrom

thefrontpanelcontrols(default).

MAGNETIC ARC CONTROL PROBE

4613 Probe

The4613isafour-tipped,water-cooledprobethat

adaptstoconventionaltorches.The4613workswell

intightclearancesandisprimarilyusedtoweavethe

arcacrosstheseamandalongtheseamintubemill

applications.The4613hasfourtippedallowingthe

magneitcfieldtooscillatethearcinastabilized

mode--acrosstheseam,orintheoscillate

mode--circularorelipticalpatterns.Onpage 6 is

Table3-4613MagneticArcProbeAssembly

Specifications and Figure4-4613MagneticArc

ProbeAssembly fordetaileddimensionsandspecifi

-

cations.

8040MAGNETICARCCONTROLLER DESCRIPTION OFEQUIPMENT

1

DESCRIPTION OFEQUIPMENT 8040MAGNETICARCCONTROLLER

2

FIGURE 1 - 4613 MOUNTING METHOD

INSTALLATION

GENERAL SETUP

A standard8040MagneticArcControlsystemis

shownin Figure5-InterconnectionDiagram,with

thenecessaryinterconnectsshownschematically.

Themajorpartsrequiredforinstallingthissystemare

listedbelow.Checkallitemsfordamagewhenun

-

packing.

Systemshouldconsistofthefollowing:

•

Control Unit

•

Probe Assembly

•

Remote Interface Cable

•

Power Cord

•

Operators Manual

OPTIONS AND SPECIALS

Optionsforthe8040Systemmaybepurchased.Spe

-

cialsincludeprobetips,probetipextensionsand

extensionandextendedlengthcablesdesignedtofita

particularmechanicalconfigurationwhenthestandard

tipsorcableswillnot.

Theinstallationofthe8040Systemisveryeasyand

canbeaccomplishedonmostautomaticorsemiauto-

maticsetupswithinminutes.

CONTROL UNIT LOCATION

The8040ControlUnitshouldbeplacedinalocation

whichprovideseasyaccesstothecontrolsandproper

airventilationforcooling.Toallowadequateventila

-

tion,maintainaminimumof5inchesofunrestricted

spacebetweenthecontrolunit(sides)andthenearest

obstruction.Thelocationshouldbeselectedtomini

-

mizetheamountofdust,dirt,moistureandcorrosive

vaporstheControlUnitwillbesubjectedto.Please

see Figure6-8040MagneticArcControlMounting

Dimensions formountingholepatternsandotherdi

-

mensions.

NOTE

Althoughthecontrolunitrequiresno

otherelectricalinterfacingwithanyof

theusers'sotherequipment,besuretose

-

lecttheproperinputvoltagebeforeplug

-

gingtheunitintotheacpoweroutlet!Thisunit

operatesoneither110/220VAC50/60hzpower.

BesuretheVoltageSelectorswitchisinthe

properpositionforthepoweryouareusing!

TheVoltageSelectorswitchislocatedontheoutside

ofthecontrolunitneartheACpowercordreceptacle

(Referto Figure2-8040MagneticArcControlUnit

and Figure26-8040MagneticArcControlExploded

View).Theoperatormayselecttheproperinputvolt

-

ageusingasmallslottedscrewdriver.Themounting

dimensionsofthecontrolunitareshownin Figure6-

8040MagneticArcControlMountingDimensions,

shouldtheuserchoosetoinstallthe8040onafixture

orcontrolpanel.

MAGNETIC ARC PROBE MOUNTING

The4613Probewillmountonanymachinetorch

withabodydiameterfrom1.56inchesorless.

4613 Probe

•

Position the probe so that the “Axis 1 Deflect” sten

-

ciled into the probe body is facing the direction of

travel of the weld.

•

Back off the four socket screws which secure the

probe to the torch body.

•

Slip the probe over the torch and align the tips approx

-

imately even with the gas cup, or bottom of torch.

Tighten the 4 screws. (See Figure 1 - 4613 Mounting

Method on page 2 for illustrations of probe-to-seam

orientation.)

NOTE

Besureofselectthecorrectinputvoltage

attheVoltageSelectorswitchmatching

thatwhichyouintendtousebeforecon-

nectthecontrolunittoanACpowerout-

let.

8040MAGNETICARCCONTROLLER INSTALLATION

3

INSTALLATION 8040MAGNETICARCCONTROLLER

4

Item Description Specifications

Frequency OscillatingFrequency 1.0to50HzmaximumwithSweepatZero

Amplitude OscillatingWidth

.25inchesoneachsideoftheweldline(approxi-

mate)

Position ArcPosition

.25inchesoneachsideoftheweldline(approxi-

mate)

FinalTaper TrailoffofAmplitudeattheendoftheweldcycle

0to15secondstomatchdownslopetimeofthe

weldingpowersource

Controls Frequency

Amplitude1&2

Position1&2

Taper

Stabilize/OscillateModeDIP Switches

Input PowerRequirements 90-132VAC/180-264VAC50/60Hz

ControlUnit Enclosure Standard NEMA StyleSealedenclosure

Probes 8040canbeusedwiththisprobe 4613

PowerCable StandardLength 8’ (1.8M)

RemoteInterfaceCable StandardLength 10’ (3M)

Weight StandardWeight 10lbs.(4.1Kg)

TABLE 1 - 8040 MAGNETIC ARC CONTROL SPECIFICATIONS

FIGURE 2 - 8040 MAGNETIC ARC CONTROL UNIT

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Miller JETLINE CYCLOMATIC 8040 MAGNETIC ARC CONTROL Owner's manual

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