ESAB Digipulse Dual Wire Feeder Dana Corporation Troubleshooting instruction

Brand: ESAB

Model: Digipulse Dual Wire Feeder Dana Corporation

Category: Welding System

Type: Troubleshooting instruction

INSTRUCTIONS for

F-15-626-E

September, 2000

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

DANA Corporation

P/N 558001536 with PLC Interface

P/N 34849 - Standard Unit

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 Tung-

sten 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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SPECIFICATIONS

Input Power Required115 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)

I. DESCRIPTION

This manual has been prepared for use by an experi-

enced operator. It provides information to familiarize the

operator with the design, installation and operation of the

Digipulse Dual XR wire feeder designed to Dana Corpo-

ration specifications. DO NOT attempt to install or

operate this equipment until you have read and fully

understood these instructions. The information presented

here should be given careful consideration to ensure

optimum performance of this equipment.

II. RECEIVING-HANDLING

Upon receipt, remove all packing material and carefully

inspect for any damage that may have occurred during

shipment. Any claims for loss or damage that may have

occurred in transit must be filed by the purchaser with the

carrier. A copy of the bill of lading and freight bill will be

furnished by the carrier on request.

When requesting information concerning this equip-

ment, it is essential that Item number, Serial number and

Model number of the equipment be supplied.

SECTION I INTRODUCTION

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.

MEANING OF SYMBOLS - As used throughout

this manual: Means Attention! Be Alert! Your

safety is involved.

Fig. 1 - DANA DIGIPULSE Dual Wire Feeder

III. FEATURES

Microprocessor accuracy — the microprocessor, the

controlling "brain" of the Digipulse Dual, operates exclu-

sively on drift free digital logic unlike competitive sys-

tems. The digital logic delivers extraordinarily precise

computer-accurate weld parameter control and weld

consistency.

Microprocessor flexibility — in contrast with competi-

tive digital systems that require additional printed circuit

boards and hard wiring whenever a feature or function is

to be added, the Digipulse incorporates electronically

reprogrammable modules; by simply reprogramming

this small plug-in module many existing functions may be

extended or new features maybe added.

Microprocessor reliability — ESAB’s Digipulse Family

of Wire Feeders have proven to be rugged and reliable

in test after test for absolute minimum downtime.

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.

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 ambient

temperature, primary voltage fluctuation and changes in

arc dynamics or wire feed force conditions, to assure that

preset parameters are maintained.

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.

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.

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 main-

tained for a preprogrammed time period; simultaneously,

cause is indicated by flashing digital display.

Toggle switch adjustment of weld parameters by

fine increments or rapid coarse adjustment — allows

quick, easy, and accurate adjustments of welding pa-

rameters.

Gas pre and postflow and cold wire inch capability—

gas pre and postflow provides independent adjustment

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.

Automatic adaptive anti-stick or manual burnback

time feature—a patented adaptive anti-stick circuit au-

tomatically adjusts the same amount of wire burnback

regardless of wire size, speed or voltage; or, you can

manually preset a “BurnbackTime” to specifically suit a

specialized application; the manual burnback function

(programmed up to 999 cycles in the VOLTS window)

allows you to override the automatic adaptive anti-stick

by setting a specific burnback time.

Spot weld timer—because the spot weld timer is adjust-

able 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” weld-

ing.

Circuit protection—resettable circuit breaker for input

power minimizes downtime and maintenance.

EH-10A permanent magnet motors—provide the high-

est torque, fastest response, and best efficiency of any

mig p.m. motor on the market.

Patented closed loop “J” governor/optical tachom-

eter—provides most accurate means of maintaining

wire feed speed and voltage, regardless of any voltage

drop or drift.

DANA interlock feature insures that all automatic clamps

are engaged before welding can begin.

DANA arc detect circuit reports all welding activity to an

external programmable controller.

SECTION I INTRODUCTION

SECTION 2 INSTALLATION

I. INSTALLATION

To avoid possible lethal shock make sure that all

power to the DANA 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.

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.

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):

LOCATION INSTRUCTIONS

The wire feeder should be placed close enough to be

easily accessible from the workstation but not so close

that weld spatter could affect the unit. It is critically

important to insure that the base of the wire feeder is

not placed in contact with a grounded metal surface.

A. ELECTRICAL CONNECTIONS

Connect the control cable assembly to the J1

receptacle on the rear panel of the DANA Digipulse

wire feeder. Next, connect the opposite end of the

cable to the J1 receptacle on the rear panel of the

power source as shown in Fig. 3.

Connect the welding cable from the positive output

terminal of the power supply to the power cable

adapter block located on the base of the wire feeder.

A second welding cable should then lead to the

welding torch.

B. HOSES

GAS REGULATION

Install shielding gas supply hoses as shown in Fig. 2.

Regulator/Flowmeters for Argon/C25/Helium/Nitrogen:

R-33-FM-580 P/N 21557

R-36-FM-580 P/N 21505

R-5007, P/N 998124.

Shielding Gas Hoses:

Std Duty, P/N 40V77 (12.5-ft.) or P/N 34V38 (25-ft.)

Hvy Duty, P/N 19416 (12.5-ft.) or P/N 19415 (25-ft.)

TORCH COOLANT

If you are using a water-cooled torch, install coolant

supply and drain hoses as shown in Fig. 2.

Coolant Supply and Drain hoses:

Std Duty, P/N 40V76 (12.5-ft.) or P/N 406196 (25-ft.).

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.

C. WATER KITS (Optional see Fig. 13)

Mount bulkhead adapter (58V75) behind opening

provided in rear vertical support plate, below gas

connections, 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

adapter (11N16) to the bulkhead adapter. Mount torch

cable adapter (45V11) on welding power stud.

Connect water drain hose to this adapter, and water

inlet hose to adapter 11N16. Wire the solenoid valve

(if used) in parallel with the gas solenoid valve (see

wiring diagram).

D. TORCH CONNECTIONS

Attach torch gas hose to outlet of gas solenoid. Plug in

torch switch cables and lock by twisting. Attach water

hose (if used) to wire feeder. Connect torch power

cables to power source, or to power cable adapter

block (with a second cable from that stud to the power

source).

E. INSTALLING FEED ROLL

To install the desired feed roll kit (optional selection)

proceed as shown in Fig. 11:

1. Position the feed rolls over the four gear assembly

hubs aligning the feed roll holes with the gear

assembly holes.

2. Secure the feed rolls to the gear assemblies using

the No. 8-32 x 5/8-in. screws and lockwashers

supplied.

CENTER WIRE GUIDE

To install the proper center wire guide (optional

selection) proceed as follows:

1. Remove the two No. 8-32 x 5/8-in. panhead

screws which attach the Center Guide Clamping

SECTION 2 INSTALLATION

Plate (P/N 2075495) to the Center Guide Block

(P/N 2075496). Remove the plate.

2. Insert the center wire guide (optional selection) in

the groove of the guide block.

3. Replace the clamping plate, using the screws

removed in step 1 above.

F. 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.

G. 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 the op-

tional heavy blue- colored spring (182W54).

II. REQUIRED EQUIPMENT

A. CONSTANT VOLTAGE POWER SOURCE

The DANA Digipulse Dual is specifically designed for use

with the Digipulse power supply.

B. CABLE ASSEMBLIES

A multi-conductor control cable assembly is required to

connect the DANA Digipulse to the power source. (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 (Gunmaster 400) or water-cooled

( ST-16) torches may be used with the DANA 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. DRIVE ROLLS, See Table 1 and F-12-821.

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

connected to the output terminal of the power source.

Install the kit in accordance with Fig. 13 . 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 sole-

noid 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 temperature is below the dew point causing

sweating of torch parts, resulting in poor welds. Install

kit in accordance with Fig. 13. 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.

12.

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.

SECTION 2 INSTALLATION

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

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.

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. For feed roll/outlet guide accessories

refer to Table 1.

K. PLC Interface Retrofit Kit, P/N 0558001518. This kit

(shown in booklet F-15-608) inhibits the unit from

welding until an external 'enable' signal is received. It

also puts out a signal to DANA's PLC indicating when

the unit is welding. This is a standard part of

0558001536, but an optional component for 34849.

Feed Roll Center Upper Lower

Wire Size Kit * Wire Guide Feed Roll + Feed Roll +

.045 999327 2075561 2075545 2075537

.052 999328 2075562 2075546 2075538

.062 999329 2075563 2075547 2075539

+ (2) Upper and (2) Lower feed Rolls are required as a complete set.

* Feed Roll Kit includes Center Wire Guide, (2) Upper and (2) Lower Feed Rolls

For a complete listing of available feed rolls, see F-12-821.

Table 1

Fig. 2 - Interconnection diagram

SECTION 2 INSTALLATION

PLAN VIEW DUAL FEEDER

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 MOTOR/ACCY. SUPPORT

TORCH CONNECTION

RIGHT MOTOR/ACCY. SUPPORT

TORCH CONNECTION

SECTION 2 INSTALLATION

P4, PLC CONNECTOR

† 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

I. CONTROL FUNCTIONS

BACK PANEL CONTROL

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.:

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

— cold wire INCH speed in IPM from 50 to 999

inches per minute in one inch increments.

— wire type

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.

— 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.

— wire diameter

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.

SECTION 3 OPERATION

Fig. 4 - Rear Panel Control

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.

FRONT PANEL CONTROL

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.

P4, PLC Connector

Fig. 4A - Front Panel Controls

SPINDLE ASSY.

RIGHT DIGITAL READOUT (VOLT)

RIGHT INC-DEC TOGGLE

SPOT/BACK-SELECT SWITCH

RIGHT TORCH ACCY.

SUPPORT ASSY.

& EH-10 MOTOR-GEAR-TACH UNIT

RIGHT TORCH TRIGGER

SWITCH RECPT.

LEFT TORCH ACCY.

SUPPORT ASSY.

& EH-10 MOTOR

GEAR TACH UNIT

LEFT TORCH TRIGGER

SWITCH RECEPT.

INCH-/GAS PURGE

RESET SELECTOR

LEFT INC-DEC TOGGLE

LEFT DIGITAL READOUT (IPM)

MODE SELECTOR SW.

Fig. 5 - DANA Digipulse Dual Feeder (Front View)

SECTION 3 OPERATION

LOCATION FOR OPT.

WATER CONNECTIONS

POWER ON-OFF SW.

J1 CONTROL RECPT.

RESET CIRCUIT BREAKER

RUN-SET KEY SW.

LEFT SHIELDING GAS SOLENOID

CONNECTION

RIGHT SHIELDING GAS

SOLENOID CONNECTION

VOLTAGE REGULATOR

POWER CABLE ADAPTOR

BLOCK - 674156

1/2-IN.-13 STL. NUT

1/2-IN. LOCKWASHER

(2) 1/2-IN. FLATWASHER

POWER CABLE

ADAPTOR BLOCK

Fig. 5A - DANA Digipulse Dual Feeder (Rear View)

SECTION 3 OPERATION

PLC CONNECTOR

5. LED Light. This LED only 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).

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

are provided to preset the individual welding param-

eters 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, and wire type

selection. With appropriate function selector actu-

ated, 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, and wire diameter selection. With the

appropriate function selector actuated, each pa-

rameter setting will be displayed in the digital win-

dow directly above this toggle.

7. Inch/Purge/Reset Switch. This two position (mo-

mentary) switch allows the following operation.

a. Inch Function. The INCH selection permits cold-

wire inching without energizing the welding circuit.

To preset cold inching speed, operate the inch

switch and while the motor is running using the INC/

DEC toggle below the IPM window; set the desired

speed. This setting (is independent of the “hot” wire

feed) will be displayed 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:

a. Spot Time Setting: operate the Spot/Burnback

switch and observe that both the IPM and volts

displays will change. The Spot time can be pro-

grammed into the IPM window by holding the Spot/

Burnback switch in the "up" position and the time

can be incremented or decremented by the INC//

DEC switch under the IPM window.

Note:To get out of Spot welding mode, the Spot time

has to be decremented to 0.

b. Burnback Time Setting:

The Burnback time can be set into the voltage

window in a similar fashion, to increment or decre-

ment the burnback time, the INC/DEC switch under

the volts window is used. Both the Spot and Burnback

times are set in cycles (1 cycle - 1/60th of a second).

9. Mode Selector Toggle Switch. This three-posi-

tion switch allows you to select the welding process

mode you wish to use - non-pulsed mig "Short Arc",

mig "Spray Arc" or "Pulsed" mig spray arc.

In all process modes, the operator simply codes the

control (wire diameter and material) for any one of

the preprogrammed welding conditions, sets the

desired wire feed speed (ipm) and the control

automatically provides the proper welding param-

eters to produce the necessary output for the pro-

cess selected.

II. GENERAL

This dual torch pulsed mig welding system has been

designed and manufactured to specifications provided

by DANA. The software is modified to provide 3 pre-

settable process schedules. These are short arc,

spray arc and pulsed spray arc. When one set of

these parameters is entered into the feeder on one

side, the other side will automatically be set to the

same parameters.

III. GETTING STARTED

Start Up

When primary power is applied, the windows on the

feeder will display the Product Code (in the IPM

window) and Software Version # (VOLTS window) for

one second. This information indicates the type of

software installed in the control and the latest version

number. To insure all your units have the same

software, the Product Code and Software Version

numbers shown on start up should all be identical.

After one second, the windows will then revert to

display the last welding parameters (IPM and Voltage)

set by the operator and the unit is ready to weld.

The following DANA Digipulse control functions must

be set to feed wire through the torch conduit and to

adjust the shielding gas flow rate.

SECTION 3 OPERATION

1. Place the Power switch on the rear panel to the

“on” position to energize the control.

2. Place key-operated Run / Set switch (also on the

rear panel) in the Set position.

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

and wire engaged in accessory support, feed wire

through torch conduit and into torch as follows:

a. Actuate and immediately release the torch

trigger switch of the left torch. This action

(through the control’s switching relay circuitry)

sets-up the control to receive the parameter

programming for the left torch.

b. Remove the gas nozzle and contact tip from

torch.

c. Hold Inch-Purge toggle (front panel) in the

INCH position until “cold” wire feeds through

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. Operate the Inch-Purge toggle in INCH

position and check for wire feed slippage on

the accessory support assembly. Tighten (or

loosen) the pressure adjusting knob until the

wire feeds smoothly with minimum pressure.

f. The parameters for the right side torch will

automatically duplicate the setting of the left

torch. No separate programming is required

for this torch since it is used as a backup in

the DANA system.

4. With shielding gas supply and torch gas hose

connections assembled as shown in Fig. 2, set

gas flow rate as follows:

a. Hold Inch-Purge toggle in PURGE position.

Open the gas regulator-flowmeter control

valve and set the required shielding gas flow

rate.

b. Continue to hold the Purge position for

approximately 15 seconds to insure adequate

purging of each gas hose and torch.

A. PROGRAMMING THE WIRE FEEDER

1. Gas Preflow and Postflow

a. Preset the shield gas preflow time by holding

down the purge key and using the Inc/Dec key

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

seconds.

b. Repeat the above for postflow using the key

below the VOLTS window.

2. Cold Inch

a. The cold inching feature has a two step speed

control. When the Inch key is operated, the

wire will feed at a non-adjustable rate of 100

inches per minute for a period of 2.5 seconds.

This speed is displayed in the IPM window

and is designed to “bump” the wire slowly for

fine adjustment of wire stick out.

b. Set the cold inching speed by holding the Inch

key adjust IPM using the Inc/Dec key to any

speed desired between 50 and 999 inches per

minute. This function is designed for wire

threading.

3. Burnback Preset

Adjust the wire burnback by holding the Spot/B’back

key in the “up” position and setting a burnback

number in VOLTS window using the Inc./Dec. key.

The number entered relates to line cycles (60=1

sec.). A number between 2 and 6 is the typical range.

4. Spot Weld Preset

a. For normal continuous welding, set this number

to zero (0).

b. If a timed spot weld is required, set the length of

weld time by holding the Spot/B’back key in the

“up” position and setting a spot weld time in

cycles per second (60 = 1 sec.) in the IPM

window.

5. Material/Diameter Preset

Choose the Material/Diameter code (1 through 6) by

depressing the Mat’l/Dia key and setting the desired

material number (see Material Code Table) in IPM

window and wire diameter to be used in the VOLTS

window. Most DANA plants run steel on Code #1.

6. Slow Wire “Run In”

a. The slow wire “run in” is set to provide one half

the preset wire feed speed (IPM) until the wire

touches the work piece. At that point, the wire

feed rate will accelerate to the speed preset in

the IPM window. This option, in most cases,

improves arc starting characteristics.

b. If full speed “run in” is preferred, the half

speed can be disabled by locating dip switch

#2 on the MPU board (see MPU board

drawing) and placing rocker switch #1 in the

“closed” position.

7. TORCH DEFAULT

The right side torch (Torch #1 - viewed from the

front of the feeder) is the default torch. This

means that when the feeder is first powered up

this torch is ready for use. The software will

automatically switch to the torch being used when

the torch trigger is depressed. The weld

parameter settings, material/dia. code, burnback,

spot weld time and cold inching speed, set

previously, are ready for use.

8. WELD PROCESS SELECTION

The DANA Digipulse Dual feeder is a synergic

welding system in all weld process modes. This

means that a specific wire feed speed and arc

voltage relationship has been pre-programmed into

the control based on the weld process selected the

SECTION 3 OPERATION

Fig. 6 - DANA MPU Board

type of weld wire and the diameter of the wire being

used. This information is supplied to the control by

selecting the welding process using the “Process

Selection” switch on the front panel (short circuit,

spray of pulsed spray) and then entering the mate-

rial/diameter information as described above.

B. ARC STARTING (SERVO) SETTINGS

Most of DANA’s manual welding applications are

performed in the “Adaptive” mode. Poor arc starts in

the “Adaptive” weld mode are usually caused by an

improperly adjusted arc voltage servo. If your arc

stumbles upon starting, you should first adjust the

voltage servo. The IPM servo should then be ad-

justed only if setting the voltage servo does not solve

the problem. The arc voltage servo is disabled when

the control is set up for “Synergic” welding.

1. Arc Voltage Servo Adjustments (Adaptive

Mode Only.)

The voltage servo setting can be observed only

during welding. While welding, depress the

“Purge” key and “Mat’l/Dia.” selection key simul-

taneously. The VOLTS window will display a

number between 0 and 200 with 90 being typical.

These numbers will fluctuate and change during

welding. Only look for an average of 80 - 100

when the arc voltage is in a steady stable state.

Using the “Inc/Dec” key below the VOLTS win-

dow, reduce the number shown to give a “hotter”

arc start or increase the number for a “colder”

arc start. DO NOT make large changes at any

one time. Wire burnbacks and other problems

can result. Make small adjustments and retest

the arc starting several times in order to optimize

starting characteristics. Changes in wire feed

speed and/or voltage might necessitate read-

justing the voltage servo. This setting will apply

to ALL weld process modes.

2. Wire Feed Motor Servo Settings

You can adjust the feed motor response by

presetting the motor speed servo. In order to see

and adjust the actual speed servo settings,

release the pressure roll and pull the torch

switch while depressing the “Purge” key and

“Mat’l/Dia.” key simultaneously. The IPM win-

dow will display a number between 0 and 200

with 110 being typical. Using the “Inc/Dec” key

below the IPM window, reduce the number shown

by 3 or 4 digits at a time to give a faster accelera-

tion to the wire feed speed or increase the

number for a slower acceleration. DO NOT

make large changes at any one time.

WELDING PROCESS SELECTION

A. Adaptive Arc Welding

The IPM window will display the wire feed speed

in inches per minute and the VOLTS window will

display a voltage corresponding the material type

and wire diameter you have preset. The arc

voltage (arc length) will be automatically

maintained by the control at the pre-set values

independent of torch manipulation. You can trim

the preset values to optimize arc performance and

welding characteristic by adjusting the IPM or arc

volts using the Inc/Dec keys under each window. If

the welding arc length is too long, decrease the

SECTION 3 OPERATION

RECOMMENDED MATERIAL AND SHIELD GAS TABLE

WIRE MATERIAL WELD PROCESSES

Code # Material Type Short Arc Spray Arc Pulse Arc

1CO

Argon-5% CO

Argon-5%CO

Carbon Steel Argon-25% CO

Argon 2-5% O

Argon-8% CO

2 Alternate Steel C-25 Argon-8%CO

-2%O

Argon-8%CO

-2% O

Ar-8% CO

-2% O

Argon-8% CO

3 4043 Aluminum Argon Argon

4 5356 Aluminum Argon Argon

5 308 Stainless Steel A-1025 Argon 1%-2% O

Argon-2% CO

-1% H

6 Silicon Bronze Argon Argon

10*

*These codes are reserved for custom synergic weld parameters.

voltage using the Inc./Dec. key under the VOLTS

window which shortens the arc length. If the

welding arc is too short, increase the voltage in

the VOLTS window. The “adaptive” characteristic

is noticeable when pulse spray welding by audible

changes in the pulse frequency caused by

variations in the wire electrical stick out or torch

manipulation. The pulse frequency will

automatically be adjusted to maintain the arc

voltage you have set in the VOLTS window when

welding in the pulse spray process mode.

B. Synergic (Non-Adaptive) Arc Welding

If the “Adaptive” mode is not desired, the feeder

can be switched to “non-adaptive” operation. This

is still a synergic relationship but the arc voltage is

not automatically maintained by the control. This

means the arc length will vary with torch

manipulation. When pulse spray welding, the

pulse frequency will not automatically change with

variations in wire electrical stick out. The pulse

frequency will remain constant at any given

voltage setting. To enter “non-adaptive” pulse

operation proceed as follows:

1. Disconnect all input power to power supply.

2. Remove the sheet metal cover on the wire

feeder control box by removing the five sheet

metal screws.

3. Remove the “J” governor P/C board (small P/

C board in front). Locate the MPU board

which is the large P/C board facing you when

you remove the “J” governor board. Find dip

switch #1 and open rocker switch #1 (as

shown in Fig. 6).

4. Replace the “J” governor P/C board.

5. Replace the sheet metal control cover and five

screws.

6. Reconnect input power to power supply.

The IPM window will now display the wire feed speed

in inches per minute and the VOLTS window will show

a number between 0 and 200 with 100 being the

default value. This is NOT an arc voltage value!

The number is a reference integer used by the digital

circuitry and corresponds to the synergic relationship

programmed into the control. The number 100 relates

to the nominal arc voltage required for the wire feed

speed selected in the IPM window. This number will

affect the arc length. You can trim the preset values to

optimize arc performance and welding characteristic

by adjusting the IPM or arc volts using the Inc/Dec

keys under each window.

If the welding arc length is too long the number can be

decreased which shortens the arc length. If the

welding arc is too short, increase the number in the

VOLTS window. The ACTUAL arc voltage will be

displayed during welding.

The following will detail the installation and operation

of this unique welding system. The feeder control

circuitry stores weld parameters for the short

circuiting, spray and pulse spray welding processes

but only one set of welding parameters is used at any

one time. Independent control of weld parameters on

each torch is NOT supported in this specialized DANA

model. It should also be noted that this is a one

operator welding system and both torches CANNOT

be used at the same time. The operator can choose

either Torch #1 or Torch #2, depending on

requirements.

SECTION 3 OPERATION

DANA DIGIPULSE XR DUAL PROGRAM CHART

PULSE PARAMETERS

Not in Use

WIRE DIAMETER

.030"

.035" .045" .052" 1/16"

5.8 6.5 6.8 7.0 8.0

25 30 30 40 50

1.8 2.0 2.2 2.3 2.4

5.4 5.8 6.0 6.5

60 60 60 60

2.2 2.5 2.6 3.8

New Data

Carbon Steel

C-5

O-5

Gas

Alternate

Carbon Steel

C-5/Stargon

or O-5 Gas

PROGRAM #

MATERIAL

TYPE &

SHIELD GAS

VARIABLES

DANA Digipulse Dual Feeder 34849 0558001536

EPROM P/N 18095 18168

Product Code 261 261

Software Code 17.2 17.3

With Arc

Standard Detect

SECTION 4 MAINTENANCE

V . TROUBLESHOOTING

Be sure that all primary power to the machine has

been externally disconnected. Open wall disconnect

switch or circuit breaker before attempting inspec-

tion or work inside of the power source.

A. DANA DIGIPULSE 450 POWER SOURCE

If power source is operating improperly, refer to the

troubleshooting information located in F-15-014.

B. DIGIPULSE DUAL WIRE FEEDER for DANA CORP.

(Refer to Schematic Diagram D-0558001734)

Listed below are a number of trouble symptoms, each

followed by the checks or action suggested to determine

the cause. Listing of checks and/or actions is in “most

probable” order, but is not necessarily 100 exhaustive.

Always follow this general rule: Do not replace a printed

circuit (PC) board until you have made all the preceding

checks. Always put the power switch in “off” position

before removing or installing a PC board. Take great

care not to grasp or pull on components when removing

a PC board. Always place p.c. boards on a “static free”

surface. If a printed circuit (PC) board is determined to be

the problem, check with your supplier for a trade-in on a

new PC board. Supply the distributor with the part num-

ber of the PC board (and program number, as described

in step 1-c. following) as well as the serial number of the

wire feeder. Do not attempt to repair the PC board

yourself. Warranty on a PC board will be null and void if

repaired by customer or an unauthorized repair shop.

1. General

a. Check interconnection between control and power

source.

b. Energize the power source and the control.

c. Immediately after the control is turned “on”, a

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

window and an additional number of numbers in the

volts window. They will only be displayed for 1-

second. These numbers identify the current pro-

gram (E-PROM) used in your control. When a

Program is changed, the new E-PROMS will auto-

matically 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 simultaneously.

d. After the one (l) second delay; the preset “Weld”

parameters will be displayed in the IPM and VOLTS

windows.

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

scribed above); for example, the numbers that

appear in one or both of the display windows are

meaningless (all zeros, eights, decimals, etc.), or

are completely incorrect in relation to your settings,

— the memory must be cleared. This condition

might occur after lightning storm, extremely bad

power line surges, etc. To clear the memory, do the

following:

(1) Place the Run-Set key switch in its SET posi-

tion.

(2) Turn “off” the unit’s 110-volt Power switch.

(3) Using one hand, hold both of the Inc/Dec

toggle switches in their INC position while

reapplying 110-volt power with the other hand.

(4) Almost immediately after the Power has been

turned “On”, release the Inc/Dec toggle switches

to the neutral (spring-return center) position

and the IPM window should display 0 or de-

pending on how quickly the INC/DEC switch

were released if might be a number higher than

20, but in any case it will have changed from the

original displayed info, indicating that a suc-

cessful reset or clearing has take place.

f. You can now enter the desired information as

described in this booklet.

2. No preset displays appear in windows.

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

plugged into the P5 receptacle on the MPU board.

b. Check that 110 vac is available across terminals

T1-18 and T1- 19, if present;

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

and T1-9; if voltage is present, replace the MPU

board. If voltage is not present, check the voltage

regulator (VR) The voltage regulator is located on

the rear panel of the control box.

d. Check the input and output voltage of the regulator

“VR”.

(1) The input should be approximately 10 volts

between terminals T1-9 and VR-1. If voltage is

not present, replace I/O board.

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

a. Check normal setup procedures described in Sec-

tion V, then;

b. Make sure the key wiring harness plug is properly

connected to receptacle P6 on the MPU board, and

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

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

the MPU board.

4. Motor does not run.

a. Check to make sure all required (and/or optional)

accessories are correctly assembled as described

in SECTION II.

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

is securely connected to receptacle P2 on the

DANA Digipulse I/0 Board, and then release the

clapper arm (pressure roll) on the Accessory Sup-

port Assembly.

SECTION 4 MAINTENANCE

(1) Operate the control INCH switch. If motor does

not run; replace the “J” governor board, and if

it still does not run, replace I/O and MPU

boards respectively.

(2) If the motor inches, but does not run when the

torch switch is operated (energized), check the

torch switch circuit components-switch, plug,

receptacle, etc. If motor still does not run,

check if power source is providing open-circuit

voltage to the control. If o.c.v. is not being

supplied, motor will not run. Check the power

source for trouble.

(3) Also check that the +/- 12 vdc are provided

from the power source on T1-7 and T1-5

respectively.

(4) If power source if O.K., replace the I/O and

MPU boards respectively.

5. Motor runs, but not at right speed.

a. Check tachometer assembly mounted on the end

of the EH-10 wire feed motor.

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

motor shaft. Check that the disc is properly cen-

tered in the strobe pickup on the p.c. board.

c. If all items in step b. are in order, and motor speed

is still incorrect, check the bios supply to the tach-

board. If the bios supply +5 volt DC and the com-

mon are present at the Tach board on the Red and

Green wires respectively, test the tach board as

follows:

(1) Remove power.

(2) Remove (unplug the "J" governor, and resup-

ply 115 power. Connect a DC voltmeter be-

tween T1-3 and the chassis of the control

cabinet on the feeder. Positive input on T1-3,

negative - chassis. Read the potential. It should

be either 0 volts or 4.5 - 4.8 volts. Slowly turn

the motor armature using the exposed mount-

ing screw at the end of the motor armature.

The voltmeter should fluctuate between 0 and

then 4.8 volts. If no change occurs, replace the

Tach board. If the Tach board is OK., but the

motor still runs at the wrong sped, replace the

MPU board.

6. Arc VOLTS display reads zero after TS is operated.

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

the P3 receptacle on the MPU board.

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

feedback between terminals TP1 and TP2 test

points on the l/O p.c. board (see Fig. 7). This

voltage signal should correspond to that shown on

the power source voltmeter.

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

wiring from the power source to digipulse and verify

that the power source indeed provides O.C.V. If

not, ascertain that the power source is energized.

Fig. 7 - Input/Output (I/O) P. C. Board, P/N 674994

If power source (P.S.) is not energized, work on

contactor - check troubleshooting F-15-014. If P.S.

is energized, correct wiring until O.C.V. is obtained

between TP1 and TP2 on I/O board. Only after that,

go to part "d" if necessary.

d. If its known that the p.c. is energized, proceed as

follows: remove the J-Gov power source 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 MPU board.

7. Control Shut-Down — either preset VOLTS or IPM

displays will flash. The control will flash the pa-

rameter VOLTS or IPM that cannot be maintained.

These symptoms can occur if the preset conditions,

IPM or VOLTS, cannot be maintained by the control.

The speed (IPM) and voltage (VOLTS) conditions are

used to enhance arc starting in the “adaptive mode” of

operation. In the “synergic mode”, the voltage condi-

tion window will always display the number 100 and

cannot be adjusted; the speed condition, however,

can be checked and adjusted as described following.

To help determine which logic mode (adaptive or

synergic) the control is set to operate in, or how to

change it, please review Section 3.

a. IPM (speed) abort and possible causes:

(1) Initial “hot start” parameters incorrectly set. For

proper adjustment, refer to Section 3-B-1 and

(2) Defective J-governor board.

(3) Defective Motor tachometer board.

(4) Defective l/O board.

(5) Defective MPU board.

Contact ESAB Engineering Services for

further assistance. (803- 664-4416).

TP2

TP1

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ESAB Digipulse Dual Wire Feeder Dana Corporation Troubleshooting instruction

Brand: ESAB

Model: Digipulse Dual Wire Feeder Dana Corporation

Category: Welding System

Type: Troubleshooting instruction

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ESAB Digipulse Dual Wire Feeder Dana Corporation Troubleshooting instruction

ESAB Digipulse Dual Wire Feeder Dana Corporation Troubleshooting instruction

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