ESAB Digipulse Dual Wire Feeder Bombardier Troubleshooting instruction

Brand: ESAB

Model: Digipulse Dual Wire Feeder Bombardier

Category: Welding System

Type: Troubleshooting instruction

INSTRUCTIONS for

F-15-496-A

May, 1999

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 2 before installing or operating this equipment.

DIGIPULSE DUAL

WIRE FEEDER

Bombardier

P/N 33299

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels

and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This

equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts

that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or

replacement become necessary, the manufacturer recommends that a telephone or written request for service advice

be made to the Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user

of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty

maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility

designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SAFETY PRECAUTIONS .......................................................................................................................... 3

SECTION 1 DESCRIPTION ................................................................................................. 7

SECTION 2 INSTALLATION ................................................................................................ 12

SECTION 3 OPERATION ..................................................................................................... 16

SECTION 4 MAINTENANCE ................................................................................................ 19

SECTION 5 REPLACEMENT PARTS .................................................................................. 22

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary information from the references listed in

Additional Safety Information section. Before

performing any installation or operating procedures, be

sure to read and follow the safety precautions listed below

as well as all other manuals, material safety data sheets,

labels, etc. Failure to observe Safety Precautions can result

in injury or death.

PROTECT YOURSELF AND OTHERS --

Some welding, cutting, and gouging

processes are noisy and require ear

protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and

can injure skin and eyes. Hot metal can cause burns.

Training in the proper use of the processes and equip-

ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles

are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from

sparks and rays of the arc when operating or observing

operations. Warn bystanders not to watch the arc and

not to expose themselves to the rays of the electric-arc

or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld-

ing helmet or cap for hair protection, to protect against

arc rays and hot sparks or hot metal. A flameproof apron

may also be desirable as protection against radiated

heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be

kept buttoned, and open pockets eliminated from the

front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from

flames and arcs can start fires. Hot slag

or sparks can also cause fires and ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable covering. Combustible materials include wood,

cloth, sawdust, liquid and gas fuels, solvents, paints and

coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden

smoldering fire or fires on the floor below. Make certain

that such openings are protected from hot sparks and

metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there

are no substances on the workpiece which might pro-

duce flammable or toxic vapors. Do not do hot work on

closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or

portable fire extinguisher. Be sure you are trained in its

use.

SAFETY PRECAUTIONS

10/98

5. Do not use equipment beyond its ratings. For example,

overloaded welding cable can overheat and create a fire

hazard.

6. After completing operations, inspect the work area to

make certain there are no hot sparks or hot metal which

could cause a later fire. Use fire watchers when neces-

sary.

7. For additional information, refer to NFPA Standard 51B,

"Fire Prevention in Use of Cutting and Welding Pro-

cesses", available from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live

electrical parts and ground can cause

severe injury or death. DO NOT use AC

welding current in damp areas, if move-

ment is confined, or if there is danger of

falling.

1. Be sure the power source frame (chassis) is connected

to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a fatal

shock.

4. Use well-maintained equipment. Replace worn or dam-

aged cables.

5. Keep everything dry, including clothing, work area,

cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from

work and from ground.

7. Do not stand directly on metal or the earth while working

in tight quarters or a damp area; stand on dry boards or

an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)

for specific grounding recommendations. Do not mis-

take 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 posi-

tive mechanical ventilation is provided. Do not breathe

fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly toxic

gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation

while operating, this is an indication that ventilation is not

adequate. Stop work and take necessary steps to im-

prove ventilation in the work area. Do not continue to

operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)

for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which

contain chemicals known to the State of

California to cause birth defects and, in

some cases, cancer. (California Health &

Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, valve, or relief device can injure or

kill. Therefore:

1. Use the proper gas for the process and use the proper

pressure reducing regulator designed to operate from

the compressed gas cylinder. Do not use adaptors.

Maintain hoses and fittings in good condition. Follow

manufacturer's operating instructions for mounting regu-

lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain

or strap to suitable hand trucks, undercarriages, benches,

walls, post, or racks. Never secure cylinders to work

tables or fixtures where they may become part of an

electrical circuit.

3. When not in use, keep cylinder valves closed. Have

valve protection cap in place if regulator is not con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, troubleshooting, and maintenance work. Do not

perform any electrical work unless you are qualified to

perform such work.

2. Before performing any maintenance work inside a power

source, disconnect the power source from the incoming

electrical power.

3. Maintain cables, grounding wire, connections, power

cord, and power supply in safe working order. Do not

operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep

equipment away from heat sources such as furnaces,

wet conditions such as water puddles, oil or grease,

corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position

and in good repair.

6. Use equipment only for its intended purpose. Do not

modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For

more information on safe practices for elec-

tric arc welding and cutting equipment, ask

your supplier for a copy of "Precautions and

Safe Practices for Arc Welding, Cutting and

Gouging", Form 52-529.

The following publications, which are available from the

American Welding Society, 550 N.W. LeJuene Road, Mi-

ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc

Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc

Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon

Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tungsten

Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used through-

out this manual: Means Attention! Be Alert!

Your safety is involved.

Means immediate hazards which, if

not avoided, will result in immediate,

serious personal injury or loss of life.

Means potential hazards which could

result in personal injury or loss of life.

Means hazards which could result in

minor personal injury.

SP98-10

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LOCATION FOR OPT.

WATER CONNECTIONS

POWER CABLE

ADAPTOR BLOCK

POWER ON-OFF SW.

J1 CONTROL RECPT.

RESET CIRCUIT BREAKER

RUN-SET KEY SW.

LEFT TORCH GAS SOL

CONNECTION

RIGHT TORCH GAS

SOL CONNECTION

Fig. 1 - Digipulse Dual Feeder

INTRODUCTION

This Digipulse Dual wire feeder is designed as a dual

torch welder with each torch capable of furnishing eight

completely different sets of welding parametersin

other words, sixteen (16) completely different welding

schedules can be preset to meet the requirements of

high production shops. The standard Dual control fea-

tures include presettable wire feed speed (ipm), volt-

age, pre and postflow gas shielding, cold wire inching,

gas purging, adaptive or manual burnback, spot weld-

ing timer and crater fill functions.

SECTION I DESCRIPTION

SPINDLE ASSY.

RIGHT DIGITAL READOUT (VOLT)

RIGHT INC-DEC TOGGLE

SPOT/BACK-SELECT SWITCH

TORCH ACCY. RIGHT

SUPPORT ASSY.

& EH-10 MOTOR-GEAR-TACH UNIT

RIGHT TORCH RECPT.

LEFT TORCH ACCY.

SUPPORT ASSY.

& EH-10 MOTOR

GEAR TACH UNIT

LEFT TORCH RECEPT.

INCH/GAS PURGE

RESET SELECTOR

LEFT INC-DEC TOGGLE

LEFT DIGITAL READOUT (IPM)

CRATER SELECTOR SW.

SPECIFICATIONS

Input Power Required ....................... 115 volts 50/60 Hz single phase Wire

Feed Speed Range ................................... 20-999 in./min. (.5-26.4 m/min.)

Wire Sizes Accommodated:

Hard/Soft  ............................................. .023 thru 1/8-in. (.6 thru 3.2 mm)

Flux Cored  ......................................... .035 thru 1/8-in. (0.9 thru 3.2 mm)

Length ................................................................................ 24-in. (610 mm)

Width ............................................................................ 22-1/2-in. (572 mm)

Height ................................................................................. 15-in. (381 mm)

Weight (less wire) .................................................................. 80-lbs. (36 kg)

A. STANDARD FEATURES/BENEFITS

n microprocessor accuracy  the microprocessor, the

controlling "brain" of the Digipulse Dual, operates

exclusively on drift free digital logic. The digital logic

delivers extraordinarily precise computer-accurate

weld parameter control and weld consistency.

n microprocessor flexibility  the Digipulse incorpo-

rates electronically reprogrammable modules; by sim-

ply reprogramming this small plug-in module many

existing functions may be extended or new features

maybe added.

n microprocessor reliability  ESABs Digipulse Dual

Wire Feeders have proven to be rugged and reliable

in test after test for absolute minimum downtime.

n presettable wire feed speed (Ipm) and voltage (volts)

 provides ability to easily and accurately preset the

exact welding parameters desired before the welding

sequence begins.

n patented microprocessor controlled closed loop sys-

tems  provides most accurate means of maintaining

wire feed speed (amperage) and welding voltage; the

microprocessor compensates for deviations in ambi-

ent temperature primary voltage fluctuation and

changes in arc dynamics or wire feed force conditions,

to assure that preset parameters are maintained.

n sure start interlock  to assure trouble free starts the

Digipulse Dual has an interlock circuit which will not

allow wire feed to initiate when the torch trigger Is

pulled unless the power supply contactor is closed

and voltage is present; the cold wire INCH, however,

will be operative at all times.

n individual digital LED meters provide large 1/2-in.

readout of voltage and wire feed speed  continuous

display of preset and then actual welding voltage and

wire feed speed for accurate observation.

n automatic "shut down"  assures welding is done at

the preset parameters; unit automatically shuts down,

if for any reason either the volts or ipm cannot be

maintained for a preprogrammed time period; simul-

taneously, cause is indicated by flashing digital dis-

play.

n toggle switch adjustment of weld parameters by fine

increments or rapid coarse adjustment  allows

quick, easy, and accurate adjustments of welding

parameters.

n gas pre and postflow and cold wire inch capability

gas pre and postflow provides independent adjust-

ment in tenths of a second for highest weld quality and

economy; cold wire inch speed can be independently

adjusted from welding wire feed speed to reduce

downtime.

n eight schedule capability per torchenables operator

to have two different sets of weld parameters (for each

torch) at his fingertips. The microprocessor allows the

operator to change schedules with a simple click-

click squeeze of the torch trigger switch to be used.

n automatic adaptive anti-stick or manual burnback

time featurea patented adaptive anti-stick circuit

automatically adjusts the same amount of wire

burnback regardless of wire size, speed or voltage; or,

you can manually preset a BurnbackTime to specifi-

cally suit a specialized application; the manual burnback

function (programmed up to 30 cycles in the VOLTS

window) allows you to override the automatic adaptive

anti-stick by setting a specific burnback time.

n spot weld timerbecause the spot weld timer is

adjustable up to 999 cycles (16.5 sec.) in the IPM

window, it is more than a conventional spot feature;

it is also a weld timer extending its use for Increment

or Stitch welding.

n the Crater Fill feature allows the operator to preset a

special welding wire feed speed (IPM), arc length

(VOLTS) and time (TIMES) to control the shape and

size of the weld crater upon termination of the weld-

ing process.

n circuit protectionresettable circuit breaker for input

power minimizes downtime and maintenance.

n EH-10A permanent magnet motorsprovide the high-

est torque, fastest response, and best efficiency of

any mig p.m. motor on the market.

n patented closed loop J governor/optical tachom-

eterprovides most accurate means of maintaining

wire feed speed and voltage, regardless of any volt-

age drop or drift.

SECTION I DESCRIPTION

I. DESCRIPTION

The Digipulse Dual torch welder is a microprocessor

controlled digital wire feeder designed for mig short arc/

spray and pulse arc welding applications. Its electronic

brain  the microprocessor  not only controls, it also

remembers and automatically coordinates the program

sequencing (that you preset) which results in the most

accurate wire feed speed and voltage control possible.

By virtue of its microprocessor controlled wire speed and

arc voltage design, the Digipulse Dual allows the cus-

tomer to preset 8 welding parameters (for each torch),

and be assured that each setting will be precisely held

regardless of changes in line voltage, arc or load condi-

tions.

Two digital readout windows continuously display (1/2-

in. high) the preset welding parameters (speed and

voltage). After the arc is struck, they automatically dis-

play the actual wire speed and arc voltage conditions for

the selected schedule. The read-outs can also provide

selectable displays of other welding parameters such as

inching speed, gas pre- and postflow times, spot time in

cycles, manual burnback time in cycles, schedule selec-

tion, crater times and conditions.

The Dual Digipulse uses a pair of heavy duty EH-10A

wire drive motors designed to feed hard or soft wires from

.023-in. to 1/8-in. in diameter and flux-cored wires from

.035-in to 1/8-in. in diameter. Rate of wire feed (20-999

ipm) is precisely controlled by using a closed-loop J

governor digital feedback 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 auto-

matically adjusts the power source output voltage to

maintain the preset voltage.

For identification and location of all functional controls

and connections refer to Figure 1. The front panel

contains the torch switch receptacles which use low

voltage (5 v.d.c.) for operator safety. The rear panel

contains the on-off power switch, the run/set switch, a 7-

ampere reset circuit breaker for overload protection, a

19-pin receptacle (J1) provides 115vac, contactor con-

trol, arc monitoring and control signals from the power

source.

All interconnecting cable, hose and auxiliary equipment

connections are quickly detachable to provide easy

setup and maximum portability of the wire feeder as

shown in Figs. 2 & 3. A water kit with or without solenoid

may be purchased, as an optional accessory, for use with

water-cooled torch operation.

II. REQUIRED EQUIPMENT

A. CONSTANT VOLTAGE POWER SOURCE

The Digipulse Dual is specifically designed for use with

constant voltage (C.V.) power sources utilizing elec-

tronically controlled voltage regulation such as:*

SVI-450i, P/N 34055

* The power sources provides three (3) Slope outputs

 Flat, Medium and Steep.

B. CABLE ASSEMBLIES

A multi-conductor control cable assembly is required to

connect the Digipulse to a power source with electronic

voltage control (see Fig. 3).

115 Volt/Contactor/Remote Control J1 Cable, 19-con-

ductor with Amphenol to Amphenol plugs; order one of

the following:

6-foot. 19-cond., P/N 30686.

30-foot, 19-cond., P/N 30780.

60-foot, 19-cond., P/N 30781.

C. WELDING TORCH

Mig welding torches, with contact tip, wire conduit and

outlet guide for wire size/type to be employed, will be

required. Suitable air (MT-400) or water-cooled (MT-

450W, ST-16) torches may be used with the Digipulse.

When using a water-cooled torch it will be necessary to

connect the torches water hose to either a continuous

water supply or to the wire feeder base by using an

optional water kit (with or without a solenoid valve, see

Section III-A and B).

D. 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 C0

, P/N 998125.

Gas Hoses:

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

(25-ft.)

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

(25-ft.).u

u Must be used for C0

SECTION I DESCRIPTION

Table 1 - Digipulse Feed Rolls

Wire Type/ Outlet Four Roll Drive

Size In. (mm) Feed Roll Guide Feed Roll Kit

Soft

.030 (.8) 2075304 (U) 29N13u 999320

.035 (.9) 2075304 (U) 29N13u 999321 (U)

3/64 (1.2) 2075301 (U) 29N13u 999322 (U)

1/16 (1.6) 2075298 (U) 29N13u 999322 (U)

3/32 (2.4) 2075297 (U) 29N13u

Hard

.023 (.6) 17998 (V) 999745n

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

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

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

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

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

Cored

.035 (.9) 19761 (Serr.) 993860 (a)

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

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

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

5/64 (2.0) 2075261 (Serr.) 62N17 (c) 999333 (Serr.)

3/32 (2.4) 2075257 (Serr.) 62N17 (c)

7/64 (2.8) 2075257 (Serr.) 39N16

1/8 (3.2) 2075255 (Serr.) 39N17

n Requires guide bushing P/N 17997.

u Requires outlet guide insert as follows: For .030, .035 wire use

993902, For 3/64 wire use 05N57, For 1/16 wire use 12N75,

For 3/32 wire use 05N58.

 Recommended U-Groove Pressure Roll 2075346 be used.

 Recommended U-Groove Pressure Roll 2075348 be used

(a) Includes replaceable sleeve (995651).

(b) Includes replaceable sleeve (995692).

E. FEED ROLLS

The Digipulse comes equipped with a pressure roll but

NOT a feed roll. Select the proper feed roll and outlet

guide from Table 1 for the wire size and type to be used.

F. WATER COOLING

Water supply with fitted hose assemblies are required to

bring cooling water from supply to wire feeder, order

Water Hose 12-1/2-ft. P/N 40V76 as shown in Fig. 2.

III. OPTIONAL ACCESSORIES

A. Water Kit without Solenoid Valve (P/N 994466).

Permits the convenient connection of water-cooled

torches and continuous water supply to the wire

feeder.

A kit is required for each torch and 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 illustrates the use of power cable adaptor P/N

674156, in addition to the kit. If adaptor (674156) is not

used, adaptor (45V11 supplied with kit) can be con-

nected to the output terminal of the power source.

Install the kit in accordance with Fig. 10 and Sec. IV-

F. Connect the water-cooled torch as shown in Fig. 2.

B. Water Kit with Solenoid Valve (P/N 2075760). Same

as kit P/N 994466 listed above except a solenoid valve

is required for each torch and is supplied in place of the

coupling. The solenoid valve can be used in areas

where you wish to conserve water or the water tem-

perature is below the dew point causing sweating of

torch parts, resulting in poor welds. Install kit in accor-

dance with Fig. 10 and Section IV-F. Do NOT use with

coolant circulators.

C. Spool Enclosure Kit (P/N 600240). Provides protec-

tion for spool of wire against dust and dirt.

D. Standard Wire Reel Assembly (P/N 34323). Reel

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

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

Spoke-type wire reel includes a four spoke aluminum

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.

F. Wire Straightener P/N 34V74). Reduces wire cast to

improve feedability and increase service life of torch

liners and contact tips. Mounts to the accessory

support inlet guide.

Wire inlet Guide P/N 11N53 is required to complete

the installation on the wire inlet side of the straight-

ener.

G. WC-9 Coolant Circulator, P/N 33540, is used for

water cooled torch operation and is designed to be

"free standing" in a convenient location near the torch.

A four-gallon capacity tank provides 1.0 gal/min @ 50

psi, using 115 volts, 50/60 Hertz, 1 phase input. Since

the cooler is designed to run continuously during a

welding operation, never connect it to a power source

or wire feeder that uses a solenoid controlled water

supply that opens and closes with each operation of

the welding contactor - the cooling efficiency of the

unit will be hampered and the starting winding in the

pump motor may burn out.

H. WC-8C Coolant Circulator, P/N 33739, is used for

water cooled torch operation and is designed to fit in

a cylinder rack of a power supply truck. A 1.5 gallon

capacity tank provides 1.0 gal/min @ 50 psi, 115 volts,

50/60 Hertz, 1 phase input. Since the cooler is de-

signed to run continuously during a welding operation,

never connect it to a power source or wire feeder that

uses a solenoid controlled water supply that opens or

SECTION I DESCRIPTION

Fig. 2 - Torch and Service Interconnection diagram

SECTION I DESCRIPTION

RIGHT TORCH

MOTOR/ACC. SUPPORT

PLAN VIEW DUAL FDR.

GAS HOSE

40V77 (12-1/2 FT.)

34V38 (25 FT.)

LEFT TORCH

(WATER COOLED)

TORCH SWITCH

TORCH GAS HOSE

n TORCH WATER HOSE

TORCH POWER CABLE

TORCH CONDUIT

n ADAPTOR - 45V11

n WATER "DRAIN" HOSE - 40V76 (12-1/2 FT.)

n WATER KIT (BELOW)

2075760

n WATER KIT

994466

GAS HOSE

40V77 (12-1/2 FT.)

34V38 (25 FT.)

REGULATOR/

FLOWMETER

n WATER "IN" HOSE - 40V76

(12 1/2 FT.)

REGULATOR/

FLOWMETER

REF. CONTROL'S REAR

SUPPORT FRAME

GAS SOLENOIDS ABOVE

OPT. WATER SOL. BELOW

TORCH CONDUIT

TORCH SWITCH

TORCH GAS HOSE

TORCH POWER CABLE

RIGHT TORCH

(AIR COOLED)

FRONT

VIEW

CONTROL

n Parts required when

using a Water Kit & Water

LEFT TORCH

MOTOR/ACC. SUPPORT

closes with each operation of the welding contactor -

the cooling efficiency of the unit will be hampered and

the starting winding in the pump motor may burn out.

I. Wire Feeder Turntable P/N 678940, allows rotation

of wire feeder as operator changes work positions.

This reduces strain and bending of torch cables.

J. Four Roll Drive Accessory Support Assembly, P/

N 600216. This assembly (shown in booklet F-12-

821) utilizes 4 feed rolls to provide positive nonslip

wire feed. It is designed for feeding .030 thru 1/8-in.

diameter wire. Feed rates for the 4-roll drive are

virtually the same as with the 2-roll drive. For feed roll/

outlet guide accessories refer to Table 1.

IV. INSTALLATION

To avoid possible lethal shock make sure that all

power to the Digipulse is OFF before making any

welding/control cable and or accessory connec-

tions on this unit. Do this by "locking-open" the

input line disconnect switch to the power source.

After checking to be sure you have all required compo-

nents and accessories (see Section II), proceed as

follows (with reference to Figs. 2 & 3, Interconnection

Diagrams):

A. HOSE AND ELECTRICAL CONNECTIONS

Connect shielding gas and water (if used) supply hoses

as shown in Fig. 2. Connect the control cable assembly

(J1) from the Digipulses rear panel to the power source

as shown in Fig. 3.

B. TORCH CONNECTIONS

Attach torch gas hose to gas connections. Plug in torch

switch cables 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 clamp

and lock in place. Attach water hose (if used) to wire

feeder. Connect torch power cables to power source, or

to power cable adaptor block (with a second cable from

that stud to the power source).

C. INSTALLING FEED ROLL

1. Release the clapper on the accessory support assem-

bly (Figure 8) by disengaging the retainer from the

clapper fork.

2. Remove thumbscrew, belleville washer, and flat

washer from the feed roll shaft.

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

sure to observe this THIS SIDE OUT marking on the

feedroll.

4. Reassemble flatwasher, belleville washer, and thumb

screw, tightening screw sufficiently to eliminate all end

play from the feed roll.

D. INSTALLING SPOOL OF WIRE

CAUTION: Make sure safety glasses are worn when

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.

1. Remove hairpin clip from spindle.

2. 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.

3. Slide the spool onto the spindle until it engages the lug.

Lock in place with the hairpin clip.

4. 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 unnecessarily.

Too little pressure will permit the spool to over-run,

causing the wire to kink and tangle.

5. Thread the wire on to the accessory support assembly

as described in Section E.

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

mount wire reel on spindle as through it were a spool

(see 1 and 3 above). Remove thumbnuts and cover

plate from reel. Remove coil from its package, 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 brakescrew and thread wire

to torch as covered in 4 and 5 above.

E. ADJUSTING THE ACCESSORY SUPPORT ASSEM-

BLY (See Fig. 8).

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

pressure roll adjustment as follows:

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

2. Release the clapper and unscrew the pressure ad-

justing knob until the pressure spring is free.

3. Thread the wire through the inlet and outlet guides of

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

conduit.

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

feed roll groove.

5. Tighten the pressure adjusting knob until the wire is

firmly against the feed roll - do not overtighten. The

spring pressure applied should be the minimum re-

quired to provide positive, nonslip wire feed. Too little

pressure will result in wire slippage while excessive

pressure will scar and deform the wire. Further adjust-

ment can be made after the wire feed is put into

operation. Note that a light silver-colored 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

blue- colored spring (182W54) supplied with the unit.

SECTION 2 INSTALLATION

A. CONTROL FUNCTIONS

For location of rear panel control features, refer to Fig. 4.

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

power on or off to the wire feeder control.

2. Run Set Key. This "key-operated switch must be in

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

welding parameters programmed into the control (e.g.:

F. WATER KITS (Optional see Fig. 10)

Mount bulkhead adaptor (58V75) behind opening pro-

vided in rear vertical support plate, below gas connec-

tions, and secure with screws (No. 8 - 32 x 3/8-in.) and

lockwashers provided. Attach coupling or solenoid valve

(depending on the type of water kit) and adaptor (11N16)

to the bulkhead adaptor. Mount torch cable adaptor

(45V11) on welding power stud. Connect water drain

hose to this adaptor, and water inlet hose to adaptor

11N16. Wire the solenoid valve (if used) in parallel with

the gas solenoid valve (see wiring diagram).

V. ADJUSTMENTS

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 weld

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.

 ESAB will not honor the warranty on Digipulse that are used with non-ESAB manufactured

interconnect cables and sustain damage that in ESABs opinion is caused by these cables.

For a listing of the proper cables available refer to Section II-B.

* 4/0 welding cables (customer supplied) are set-up for DCRP (NEG. TO WORK) operation.

Fig. 3 - Welding and Control Interconnection Diagram

SECTION 2 INSTALLATION

Fig. 4 - Rear Panel Control

TYPICAL POWER

SUPPLY HOOKUP

TO WORK*

RECPT.

4/0 WELDING CABLE*

POWER CABLE

ADAPTOR

J1 CABLE

Sched. I, Sched. II for each torch, Spot). 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.

4. Digital Readout Windows. 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 wire feed speed in IPM from 20 to

999 inch per minute in one inch increments. How-

ever, with the appropriate function selector actu-

ated, this window can also display the following:

 shielding gas PREFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

 SPOT welding time for each Torch, from 1 to 999

cycles in 1 cycle increments.

 cold wire INCH speed in IPM from 50 to 999

inches per minute in one inch increments.

 Schedule select-Left Torch

 Crater time - Left Torch

NOTE: With the power turned on, but not welding, the

IPM window will continuously read Preset wire

speed. When the arc is struck, the IPM window

will then continuously read Actual welding wire

speed.

b. Volts Digital Readout. This window is primarily

used to display arc voltage in VOLTS from 12 to 50

vdc in one tenth volt increments. However, with the

appropriate toggle selector actuated, this window

can also display the following:

 shielding gas POSTFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.

 accumulative welding ARC HOUR usage record

in one tenth of an hour increments.

 manual BURNBACK time. Manually adjustable

burnback time period which when preset will

override the automatic adaptive anti-stick fea-

ture. This time period will be set In one-cycle (60

cycle = 1 sec.) Increments. When set to zero,

the Automatic Anti-stick feature will be opera-

tional.

 Schedule select - Right Torch

 Crater time - Right Torch

NOTE: With the power turned on, but not welding, the

VOLTS window will continuously read Preset

voltage. When the arc is struck, the VOLTS

window will then continuously read Actual weld-

ing voltage.

5. LED Light. This LED lights to indicate that the torch on

the left side is in use.

NOTE: All of the following controls are spring-loaded,

center-return toggle switches which must be

operated to actuate their indicated function(s).

Item No. 6 describes the adjustment setting

toggle used to preset the program- function

selectors. Except as noted above and following,

regulation for selected function(s) can only be

made if Item No. 2 is in the SET position.

SECTION 2 INSTALLATION

Fig. 4A - Front Panel Controls

6. Inc.-Dec. Toggle Switches. Two control toggles are

provided to preset the individual welding parameters

required for the selected welding mode 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;

Preflow, Spot for both torches, Inch, Crater time

and Left Side schedule. With 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 the arc

Volts, along with all its other functions: Postflow,

Burnback, Right Side schedule and Crater time.

With the appropriate function selector actuated,

each parameter setting will be displayed in the

digital window directly above this toggle.

7. Inch-Gas Purge/Abort Reset Selector. This two

position (momentary on contact) switch allows the

following operation.

a. Inch Function. The INCH selection permits cold-

wire inching without energizing the welding circuit

through the torch switch. The preset cold wiring

inching speed (set in Item 9) can also be indepen-

programming is chosen by simply squeezing

and releasing the torch switch lever for the

particular torch desired. The manual Burnback

time(s) is adjustable in one cycle increments

(60 cycles/sec.) and is programmed in the

VOLTS window using its Inc/Dec toggle switch.

When preset, the Burnback time will override

the automatic adaptive anti-stick feature in ei-

ther schedule for that particular torch. If auto-

matic anti-stick operation is desired, the

Burnback time must be keyed back to zero.

Schedule Select. When the switch is in the

schedule select position, any schedule from 1

through 8 can be selected for the torch in use.

Schedules 1 - 4 are provided for pulse welding

and schedules 5 - 8 for short arc welding.

9. "Crater" Times/Conditions. This toggle switch al-

lows the operator to preset a special welding wire

feed speed (IPM), arc length (VOLTS) and time

(TIMES) to control the shape and size of the weld

crater .

Each weld schedule can be preset with a unique

crater fill IPM, VOLTAGE and crater time.

B. GAS/WIRE ADJUSTMENTS

The following Digipulse control functions must be set to

feed wire through the torch conduit and to adjust the

shielding gas flow rate.

1. Place Power switch (rear panel) to on position to

energize the control.

2. Place key-operated Lock-In Set switch (rear panel) in

Set position.

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

wire engaged in accessory support (Sect. IV-E), feed

wire through torch conduit and into torch as follows:

a. Actuate and immediately release the torch switch

lever for the Left Torch/Motor. This action (thru the

controls switching relay circuitry) sets-up the con-

trol to receive the parameter programming for the

Left Torch.

b. Remove nozzle and contact tip from torch.

c. Hold Inch-Purge toggle in INCH position (Sect. V-

A-8) until cold wire protrudes from the torch front

end.

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

secure it to the torch. Replace the torch nozzle.

e. Reoperate 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.

f. Now, actuate and immediately release the torch

switch lever for the Right Torch/Motor. This action

(thru the controls switching relay circuitry) sets-up

the control to receive the parameter programming

for the Right Torch, and you can repeat steps b-e.

dently changed by operating its associated Inc./

Dec. toggle switch, and this setting (which is inde-

pendent of hot wire feed) will appear in the IPM

window.

b. The Gas PURGE (Abort Reset) position provides

the following when actuated:

(1) During initial programming, it permits preset-

ting of gas PREFLOW and POSTFLOW time

requirements which are simultaneously dis-

played in the IPM and VOLTS windows respec-

tively.

(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.

8. Spot/Burnback. This two- position (momentary con-

tacts) switch allows the following operations:

Spot Weld/Manual Burnback times. Actuat-

ing this position allows you to preset either or

both of these features for either or both torches.

The SPOT time mode can be programmed into

either schedule (I or II) for each torch  and the

torch selected for operation is chosen by simply

squeezing and releasing the torch switch lever

for the particular torch desired. These preset

timed-arc periods (up to 999 cycles, in one

cycle increments) are programmed in the IPM

window using its Inc/Dec toggle switch. When

the Spotwelding feature has been preset into

one of the schedules for a particular torch,

all continuous" welding applications for

that torch are temporarily disabled. To re-

sume normal program operation in Schedules I

and II for either or both torches, you must deac-

tivate the Spotweld mode by keying its timing

parameter back to zero.

When a spotweld time is programmed for a

torch, the "click-click" torch switch feature for

changing schedules cannot be used as it was for

continuous-type welding operations. To change

schedules for spotwelding, you must manually

reposition the Schedule toggle switch selector to

the desired schedule for that torchthe torch

switch is only used to start the arc, and the spot

time cuts it off (unless the torch switch is prema-

turely released).

At the same time, you can also preset a

manual BURNBACK time mode into any sched-

ule for each torchand the torch selected for

SECTION 2 INSTALLATION

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 each gas

hose and torch.

5. Place controls Power switch to off position.

VI GENERAL

This dual pulse Mig welding system has been

designed and manufactured to specifications provided

by Bombardier, Inc.. The software is modified to

provide eight separate schedules for each torch. The

first four schedules (1-4) on each torch are dedicated

to pulse welding of stainless steel in the synergic

mode. The second four schedules (5-8) are dedicated

to short or spray arc welding and have no synergic

relationships. This means that IPM and VOLTS are

entered separately depending if a short arc or spray

arc weld condition is required. The following will detail

the set-up and operation of this unique welding

system.

Start Up

Assembly of the power source, feeder and

interconnect cable is the same as specified in the

general operating instruction manuals provided with

the SVI-450i Power Source and Digipulse Dual wire

feeder. After power up of the SVI-450i (460 Vac) and

the feeder, the windows on the feeder will display

IPM=51 and VOLTS=45 for a brief period. This

indicates that the stainless steel program (same as a

standard Digipulse) is running and the synergic curve

is for .045-inch (1.2 mm) diameter wire. These

parameters CANNOT be changed. The windows will

then display the last welding parameters set by the

operator. Place the Remote/Panel switch on the

SVI-450i power source in the Remote position and

follow the instructions below.

Selecting System Presets

System parameters are those that affect BOTH

torches and ALL schedules. These parameters are

always active and should be set first. They are:

Gas preflow preset

Gas postflow preset

Cold inch preset

Trigger selection (dual schedule operation)

Half speed run-in

Set the shield gas preflow parameters by holding

down the Purge key and using the Inc/Dec key

under the IPM window to set a preflow time in 1/10

seconds. Repeat the above for postflow using the key

below the VOLTS window.

The cold inching feature is a two speed design. When

placing the Inch key in the up position, the feed

motor will operate at 50 ipm for a period of 2-1/2

seconds. This is for bumping the wire to adjust the

wire stick-out from the contact tip. After 2-1/2

seconds the wire feed speed will transfer to the cold

inching speed shown in the IPM window. The wire

feed speed can be further adjusted using the Inc/Dec

key under the IPM window. This function is designed

for wire threading.

The Trigger Selection option allows dual schedule

operation. This means that two welding schedules are

available to the operator on each torch. This option is

disabled when Rocker Switch #4 on Dip Switch #2 is

in the closed position. Dip switch #2 is located on

the MPU board inside the feeder control box. Place

this switch in the open position for Trigger selection

(dual schedule operation). Welding will always begin

using the current weld schedule selected. Double

clicking the torch trigger switch changes the welding

parameters to the next highest schedule number. See

diagram below.

Example:

If pulse arc welding is being used in schedule #4,

double click the torch trigger to switch to the short/

spray arc parameters resident in schedule #5.

Double click the torch trigger a second time causes

the weld parameters to switch back to the pulse weld

parameters in schedule #4. Releasing the torch

trigger stops welding.

SECTION 3 OPERATING INSTRUCTIONS

The Trigger Selection function (dual schedule

operation) is automatically disabled when a spot weld

time is preset or its crater conditions are set for the

schedules in use on that torch. See Torch Parameter

Presets below.

Half speed run-in is always on when using the pulse

arc schedules (1 to 4). Half speed run-in will also be

on in the short/spray arc schedules (5 to 8) when the

arc voltage is 26 volts or higher. Below 26 volts will

result in full speed run-in of the welding wire. This

option is enabled when Rocker Switch #1 on Dip

Switch #2 is in the open position. Dip switch #2 is

located on the MPU board inside the feeder control

box . Place this switch in the closed position for full

speed run-in for all welding schedules 1 to 8. This

function is triggered off the high open circuit voltage

(OCV) of the SVI-450i power source. Half speed run-

in cannot be enabled using power sources having a

low OCV.

Torch Parameter Presets

Each torch can have the following parameters or

variables preset:

Schedule number preset

Wire burnback preset

Spot weld time

Crater time

Crater conditions

The software will automatically switch to the torch

being used when the torch trigger is depressed. Each

torch may have two welding schedules assigned at a

time when using the Trigger Selection mode

(described above). The right side torch (viewed from

the front of the feeder) is the default torch setting.

This means that when the feeder is first powered up

this torch and its parameters will be displayed. If a red

light between the IPM and VOLTS display windows is

illuminated, the left side torch parameters are being

displayed.

Choose the schedule number (1- 8) for each torch by

depressing the Schedule Selection key and setting

the desired schedule number in IPM window for the

left torch and the VOLTS window for the right torch.

Preset the desired burnback by depressing the torch

trigger switch to be preset. This action displays the

current welding parameters for that torch. Hold

Burnback/Spot key in the up position and set a

burnback number in VOLTS window. Repeat this

procedure for the other torch.

Attach the desired gas mixture to the appropriate torch

for the type of welding to be completed.

Some shielding gases will not pulse arc and short arc

equally well. Therefore, the optimization of both pulse

arc and short/spray arc parameters will be dependent

on the shielding gas and its ability to support both

processes.

If spot welding is desired, depress the torch trigger

switch to be preset. This action displays the current

welding parameters for that torch. Hold the

Burnback/Spot key in the up position and set a

spot time in seconds in the IPM window. Repeat this

procedure for the other torch if desired. Entering a

spot weld time automatically disables the Trigger

Selection mode and dual schedule operation is not

possible.

Weld Schedule Parameter Presets

Pulse Arc Welding

Schedules 1 through 4 are dedicated pulse arc

welding schedules for stainless steel using .045" (1.2

mm) diameter wire. The synergic relationship is the

same on each torch and for each schedule. When

entering a schedule number 1 to 4, the feeder control

and power source is automatically set for pulse

welding with .045" stainless steel wire.

Note: The SVI-450i power source slope switch should

be set to the STEEP slope position. The

INDUCTANCE & VOLTAGE knob on the SVI-

450i is deactivated.

The IPM window will display the wire feed speed in

inches per minute and the VOLTS window will show a

number between 0 and 200 with 100 being the default

value. These numbers relate to the synergic

relationship programmed into the software and

correspond to a pulse frequency. The number 100 is

the nominal pulse frequency required for the wire feed

speed selected in the IPM window. This number will

also affect the arc length. If the welding arc length is

too long the number can be decreased which shortens

the arc length. If the welding arc is too short, increase

the number in the VOLTS window. Each count in the

window changes the pulse frequency by one pulse per

second.

SECTION 3 OPERATING INSTRUCTIONS

Short/Spray Arc Welding

When setting a schedule number 5 to 8, the feeder

control and power source is automatically set for

short/spray welding. The operator has full control over

the slope and inductance of the power source. The

IPM window will display the preset wire feed speed in

inches per minute. The VOLTS window will display

arc voltage and can be adjusted to any arc voltage

needed for a good welding condition by using the Inc/

Dec key under the VOLTS window. The feeder

control will automatically adjust the power source to

maintain the arc voltage set in the VOLTS window.

There is no synergic relationship present in the short/

spray arc schedules.

Crater Fill

The Crater Fill feature allows the operator to preset a

special welding wire feed speed (IPM), arc length

(VOLTS) and time (TIMES) to control the shape and size

of the weld crater upon termination of the welding pro-

cess.

Each weld schedule can be preset with a unique crater

fill IPM, VOLTAGE and crater time. The feeder thus of-

fers 16 sets of crater conditions.

Note

When a crater TIME is programmed, the double click

method of changing torch schedules by using the weld-

ing torch trigger is automatically disabled for that torch.

Programming a Crater Condition

1. Momentarily depress the trigger of the torch to be

programmed. Be sure the desired schedule num-

ber is assigned to that torch. Schedules 1 - 4 are

Pulse arc welding schedules and schedules 5 - 8

are Short Circuiting/Spray arc welding schedules.

2. Hold the Crater toggle switch in the TIMES position.

The window corresponding to the torch being used

will illuminate. Enter the desired crater time (in sec-

onds) using the INC/DEC switch under the illumi-

nated window. A zero (0) will disable the crater fill

feature.

3. Hold the Crater toggle switch in the CONDITIONS

position and enter the crater IPM and VOLTS set-

tings desired using the INC/DEC toggle switches

beneath their respective window.

4. During welding the crater fill schedule will be en-

abled when the operator releases the torch trigger.

The crater timer will start and the arc will extinguish

automatically when the preset crater time has timed

out.

5. The preset crater time can be terminated also by

reoperating the torch switch during the crater condi-

tion.

6. For a legitimate crater condition, both crater speed

and crater time needs to be set.

Arc Start (Servo) Settings - For short or spray arc

welding only, not applicable to pulse welding.

Each schedule on each torch can have its own starting

characteristic for any given weld parameter. The arc

start level must be set during welding. Choose

desired schedule number and set a good welding

condition. If the arc starting is less than desirable it

can be adjusted as follows:

Depress the Purge and Schedule Select key

simultaneously while making a weld (two man

operation). The VOLTS window will display a number

between 0 and 200 (95 is the typical setting). Using

the Inc/Dec key below the VOLTS window, reduce

the number shown to give a hotter arc start or

increase the number for a colder arc start. Your

setting will be saved to that schedule and will be

recalled when you select that schedule again.

Changes in wire feed speed and/or voltage might

necessitate readjusting the voltage servo to optimize

starting characteristics. Repeat this procedure for

other welding schedules being used.

Note: The set number 80 - 95 will only effect the

starts, it will not change the preset arc voltage.

Motor Servo Setting

You can adjust the feed motor response by presetting

the motor speed servo. Release the pressure roll and

pull the torch switch while depressing the Purge and

Schedule Select key simultaneously. Change the

number (110 is standard) in the IPM window using the

Inc/Dec key to a lower value if a faster motor

acceleration is needed or a higher number for a

slower motor acceleration.

The motor response adjustment will be in effect

for ALL schedules and BOTH torches. The servo

number set in the IPM window can be set exactly

for the schedule being used and wire feed speed

preset but switching to a different schedule

having a different wire feed speed setting will

cause the servo number in the IPM window to vary

slightly. This is normal and should have little

affect on welding performance.

SECTION 3 OPERATING INSTRUCTIONS

Vll. TROUBLESHOOTING

Listed below are a number of trouble symptoms

each followed by the checks or action suggested to

determine the cause. Listing of checks and/or ac-

tions is in most probable order but is not neces-

sarily 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 ESAB supplier for a trade-

in on a new PC board. Supply the distributor with the

part number of the PC board as well as the serial

number of the wire feeder. Do not attempt to repair

the PC board or any other component yourself.

Warranty on a PC board or control will be null and

void if repaired by customer or an unauthorized

repair shop.

A. General

1. Check interconnection between digipulse control and

power source. Make sure that the contactor and

voltage control switches are placed in the Remote

position.

2. Energize the power source and the control.

3. Immediately after the control is turned on, a number

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

only be displayed for 1-second. This number identifies

the current program (E-Prom) used in your control.

When a Program is changed, the new E-Prom 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 simul-

taneously.

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

parameters for the Right-Side Torch will be dis-

played in the IPM and VOLTS windows.

5. If the control is not functioning properly (or as de-

scribed above); for example, the numbers that appear

in one or both of the display windows are meaningless

(all zeroes, 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 surge,

etc. To clear the memory, do the following:

a. Place the Run-Set key switch in its SET position.

b. Turn off the units 115-volt Power switch.

c. Using one hand, hold both of the Inc/Dec toggle

switches in their INC position while reapplying 115-

volt power with the other hand.

d. 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 taken place.

6. You can now enter the desired information as de-

scribed in this booklet.

B. No preset displays appear in windows.

1. Make sure the LED Display board harness/plug is

plugged into the P5 receptacle on the MPU board.

2. Check that 110 vac is available across terminals T1-

18 and T1-19, if present;

3. Check for plus (+) 5 volts between terminals T1-8 and

T1-9; if voltage is present, replace the MPU board. If

voltage is not present, check the voltage regulator

(VR). The voltage regulator is located on the rear

panel of the control box.

4. Check the input and output voltage of the regulator

VR.

a. The input should be approx. 11 volts between VR-

1 and T1-9. If voltage is not present, replace I/O

board.

b. The output should be + 5 volts between terminals

T1-8 and T1-9. If voltage is not present, replace VR,

voltage regulator.

C. Preset display is provided, but cannot be varied.

1. Check normal setup procedures described in Section

VI, then;

2. Make sure the Inc/Dec key harness plug is properly

connected to receptacle P6 on the MPU board and the

lock-in key switch is placed in its SET position.

3. If neither of the above resolve the problem, replace the

MPU board.

D. Motor does not run.

1. Check to make sure all required accessories are

correctly assembled as described in Section IV.

2. Make sure that power source is connected, plug P2 is

securely connected to receptacle P2 on the Digipulses

I/0 Board, and then release the clapper arm (pressure

roll) on the Accessory Support Assembly.

a.Operate the Digipulse INCH switch. If motor does

not run; replace the J governor board, and if it still

does not run, replace I/O and MPU boards respec-

tively.

b.If the motor inches, but does not run when the torch

switch is operated (energized), check the torch

switch circuit componentsswitch, plug, recep-

tacle, etc. If motor still does not run, check if power

source is providing open-circuit voltage to the

SECTION 4 MAINTENANCE

If this condition occurs, the respective servos need to

be checked and, if necessary, readjusted.

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

of the following; the Speed and Voltage servo) adjust-

ments are incorrect and the conditions set may not

be maintainable. To check and, if necessary, readjust

the servos  proceed as follows:

NOTE: Prior to checking the servos, make sure the

Digipulse is connected to SVI-450i power source

in order to obtain the necessary o.c.v. (open

circuit voltage); otherwise, the motor will not run.

2. The Speed and Voltage servos in this control are

simultaneously checked and displayed by depressing

and holding the front-panel Schedule Select switch in

its "down" position during an actual weld with the

wirefeed motor running. The speed servo number is

displayed in left (IPM) window and should be about

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

voltage servo number. This number will be between

90 and 100* for the actual welding condition.

* Voltage servo setting below 95 will normally provide hot arc

starts; whereas, setting over 100 will not.

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

check and/or adjust the speed (servo) as follows:

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

toggle-down the Schedule Select switch position, and

either close the torch switch lever or toggle-up the

INCH position of the Inch-Purge switch. Check the

number in the IPM window  it may appear unsteady

but readable and should be about 110.

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

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

holding the A.H./INCH Preset and Purge/Reset toggle

as mentioned above and while the wire feed motor

is running.

If the speed servo cannot be adjusted at all, the

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

MPU p.c. boards which needs to be as required.

4. If a Voltage abort had occurred (VOLTS window

flashing), check and/or adjust the voltage (servo) as

follows:

This is a two man operation. Set a welding condition

which closely corresponds to your welding application

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

then  close the torch switch and strike a welding arc.

While welding, toggle-down the Schedule Select switch

Digipulse  if o.c.v. is not being supplied, motor will

not run. Check the power source for trouble.

c.Also check that +/- 12 volts d.c. are provided from

the power source on T1-7 and T1-5 respectively.

d.If power source is O.K., replace the I/0 and MPU

boards respectively.

E. Motor runs, but not at right speed.

1. Check tachometer assembly mounted on the end of

EH-10A wire feed motor.

2. Make sure the tach disc is securely fastened to the

motorshaft and that the strobe markings are not

scratched. Check that the disc is properly centered

in the optical switch on the p.c. board.

3. If all items in step 2 are in order, and motor speed

is still incorrect, replace MPU board.

F. Arc VOLTS display reads zero after TS Is operated.

1. Check that the 5-pin plug is securely connected to the

P3 receptacle on the MPU board

2. If no reading is displayed, check for arc voltage

feedback between terminals TP1 and TP2 test points

on the I/0 board (see Fig. 4B). This voltage signal

should correspond to that shown on the power source

voltmeter.

3. If voltage still reads zero, trace the voltage pickup

wiring from the power source to digipulse.

4. Remove the J-Gov. p.c. board to gain access to the P3

plug (harness) on the MPU p.c. board. Disconnect the

P3 plug from its MPU board socket and, using a meter

check for +/-12 volt power supply output between plug

pins P3-1 and P3-2 (for +12 v.) and between plug pins

P3-4 and P3-2 (for -12 v.) respectively. If voltage is

present, replace the MPU board.

SECTION 4 MAINTENANCE

Fig. 4B - Input/Output (110) P.C. Board

G. Control Shut Down  either preset VOLTS or IPM

displays will flash. The control will flash the parameter,

VOLTS or IPM, that cannot be maintained.

TP2

TP1

position and read the number displayed in the VOLTS

window, it may appear unsteady but readable and

should be 95.

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

Dec toggle (below the VOLTS window) to adjust the

number to 95  while holding the toggle positions

mentioned above and while welding.

5. If the voltage servo cannot be adjusted, check for

proper operation of the power source as follows:

a. Set the Digipulse voltage display to zero (this

setting will override the servo).

b. Place the Panel/Remote switch on the power source

in PANEL position.

c. Make a weld by controlling the arc voltage directly

from the power source potentiometer.

d. If a weld can be made with good control over power

source voltage; a problem exists either in the inter-

connecting voltage control cable, or in the Digipulse

control.

e. Check the control wires in the interconnecting

voltage control cable for continuity between the

appropriate terminals in the power source and

digipulse using the schematic diagrams.

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

the MPU board.

H. Control Shut-Down Due to Ground Fault Detec-

tion  both IPM and VOLTS displays will flash.

The purpose of this circuit is to make sure that welding

current is not present in the wire feeder frame/base,

control box, or the equipment safety ground. If this

should occur, the ground fault detector will temporarily

energize and immediately terminate the weld. This abort

is indicated by both visual displays flashing simulta-

neously.  Before attempting to make a new weld, make

sure that the Work Ground cable and its connections are

properly and securely made to the workpiece.

VIII. MAINTENANCE

If this equipment does not operate properly, stop

work immediately and investigate the cause of the

malfunction. Maintenance work must be performed

by an experienced person, and electrical work by a

trained electrician. Do not permit untrained persons

to inspect, clean, or repair this equipment. Use only

recommended replacement parts.

A. 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 blowing off

these parts with dry compressed air. This should be done

once for every eight hours of operating time, more often

if necessary.

B. 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 disassembled.

If disassembled relubricate with Texaco Multifak grease.

C. 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. length, it must

be replaced. Brushes can be inspected by unscrewing

the brush-holder plug and withdrawing the brush assem-

bly. Never remove a brush without matchmarking it and

its holder, so that it can be replaced in the same holder

in its original position.

D. REMOVAL OF EH-10A DIGITAL WELDING HEAD

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

wirefeeder control.

2. Remove the accessory support assembly from the

motor-gear unit by loosening the cap screw at the

bottom of the assembly.

3. Disconnect the motor and tachometer cables from

terminal board (T1) inside the control assembly as

shown on the wiring diagram.

4. Remove the four screws which secure the digital

motor-gear unit to the base and remove the digital

unit.

E. ADDITIONAL DIGIMIG PROGRAM FEATURES

The Digipulses MPU board contains an integral 4-rocker

dip switch (SW1) that is factory-set to the following

positions: Rocker #1 is CLOSED, and Rockers #2, 3, 4

are OPEN. The microprocessor technology utilized by

the Digipulse control is extremely versatile and can be

modified for specific purpose by ESABs engineering

services group. To add specific features or programs to

your unit, consult your ESAB representative. If additional

optional features are provided, the SW1 rocker positions

may need to be repositioned  and this information will

be conveyed in the appropriate instruction booklets

provided with the option kits.

SECTION 4 MAINTENANCE

1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and

part name, shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE.

2. Always state the series or serial number of the machine on which the parts are to be used. The serial number is

stamped on the unit nameplate.

COVER - 30170YL

WARNING DECAL - 2091514*

(SW1, 3, 5, 7) SWITCH - 950087 n

(2) ACCESSARY SUPPORT ASSY.

2 ROLL DRIVE (See Fig. 8) - 49V51

LEFT TORCH (J4) RECEPTACLE -

182W64

C16 CAPACITOR

672348

FRONT CONTROL SUPPORT - 35742

(2) EH-10A DIGITAL MOTOR-GEAR

UNIT ASSY. 679777 (See Fig. 6)

RIGHT TORCH (J3) RECEPTACLE

- 182W64

(C10, 11) CAPACITOR

- 672348

WARNING DECAL - 995204*

Fig. 5 - DIGIPULSE Dual Wire Feeder, P/N 33299

n Recommended Spare Parts

CONTROL ASSY.

33387 (see Fig. 7)

SECTION 5 REPLACEMENT PARTS

(MSL) POWER ON-OFF SW

634517 n

STRAIN RELIEF - 96W76

uRUN-SET SW - 950956

(2) GAS INLET CONNECTION - 74S76

(2) GAS SOLENOID VALVE - 2062305 n

(2) GAS BULKHEAD ADAPTOR - 58V58

KNOCKOUT OPTIONAL

WATER CONNECTIONS (See Fig. 10)

REAR CONTROL SUPPORT

36278

(J1) RECEPTACLE - 950762 (19-pin)

C20 CAPACITOR - .1uf, 500 V

(2) SPINDLE ASSY.

948259 (See Fig. 9)

POWER CABLE ADAPTOR BLOCK - 674156

1/2-IN.-13 STL. NUT

1/2-IN. LOCKWASHER

(2) 1/2-IN. FLATWASHER

(VR) VOLTAGE REGULATOR includes:

VOLTAGE REGULATOR - 950159

TRANSISTOR SOCKET - 950158

(C4) CAPACITOR - 995544

BASE w/SUPPOFT - 36279

Not Illustrated  Accy. Support

INSULATOR RING

60N90

Key - 28N33

THUMBSCREW

61351087

FLATWASHER - 64309431

BELLEVILLE WASHER - 950783

(CB) CIRCUIT BREAKER - 950874 n

* Replace decal if it becomes

excessively worn or lost when

replacing panel(s)

n Recommended Spare Parts

u Replacement key for Run-

Set SW - 32778

REAR VIEW

FRONT VIEW

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ESAB Digipulse Dual Wire Feeder Bombardier Troubleshooting instruction

Brand: ESAB

Model: Digipulse Dual Wire Feeder Bombardier

Category: Welding System

Type: Troubleshooting instruction

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ESAB Digipulse Dual Wire Feeder Bombardier Troubleshooting instruction

ESAB Digipulse Dual Wire Feeder Bombardier Troubleshooting instruction

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