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Miller JETLINE CYCLOMATIC 8020 MAGNETIC ARC CONTROL, MH000000 Owner's manual

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OPERATION MANUAL
for Cyclomatic Series
8020 Control
JetlineEngineering,15GoodyearStreet,IrvineCA 92618
Telephone:949-951-1515·Fax:949-951-9237
Website: www.jetline.com · www.cyclomatic.com
E-mail: [email protected]
IMPORTANT
RevisedAugust2010
Readthismanualcarefullybeforeinstalling,
commissioningoroperatingthisproduct.
LIMITEDWARRANTY
JetlineEngineering,ofIrvine,California,U.S.A.,warrantsallnewequipmenttobefreefromdefectsin
materialandworkmanshipfortheperiodofone(1)year,providedthattheequipmentisinstalledandoper-
atedaccordingtoinstructions.
JetlineEngineering’sobligationunderthiswarrantyisexpresslylimitedtoreplacingorrepairingandde-
fectivepartorcorrectinganymanufacturingdefectwithoutchargeduringthewarrantyperiod,ifJetline’sin-
spectionconfirmstheexistenceofsuchdefects.Jetline’soptionofrepairorreplacementwillbeF.O.B.
FactoryatIrvine,California,andthereforenocompensationfortransportationcostsofanykindwillbeal
-
lowed.
Thewarrantyperiodbeginsonthedateofsaletotheoriginal-purchaseuseroftheequipment.
JetlineEngineeringwillnotbeliableforanylossorconsequentialdamageorexpenseaccruingdirectly
orindirectlyfromtheuseofequipmentcoveredbythiswarranty.
ThiswarrantysupersedesallpreviousJetlineWarrantiesandisexclusivewithnootherguaranteesor
warrantiesexpressedorimplied.
NOTICE
Theinstallation,operationandmaintenanceguidelinessetoutinthismanualwill
enableyoutomaintaintheequipmentinpeakconditionandachievemaximumeffi
-
ciencywithyourweldingoperation.Pleasereadtheseinstructionscarefullytobecome
awareofeveryadvantage.
CAUTION
Onlyexperiencedpersonnelfamiliarwiththe
operationandsafepracticeofweldingequipment
shouldinstalland/orusethisequipment.
Overview
Overview .................................................... vi
TableofContents ............................................... vii
TableofTables ................................................. ix
TableofFigures ................................................. x
Safety .......................................................
SafetyPrecautions ............................................... xii
AdditionalSafetyHazards .......................................... xiv
8020MagneticArcControlSystem .......................................
DescriptionofEquipment ........................................... 17
Installation ................................................... 20
Operation.................................................... 31
Maintenance .................................................. 39
DrawingandPartsList............................................. 41
Troubleshooting ................................................ 57
CircuitDescriptions .............................................. 59
SchematicsandBlockDiagrams........................................ 61
Index .......................................................
Index ...................................................... 67
vi
OVERVIEW 8020MAGNETICARCCONTROLLER
TableofContents
Overview .............................. vi
TableofContents ........................... vii
TableofTables ............................ ix
TableofFigures ............................ x
Safety .......................................................
SafetyPrecautions
Definitions ............................. xii
Note ............................... xii
Caution .............................. xii
Warning .............................. xii
Danger .............................. xii
SafetyInformation........................... xii
ElectricShock ............................ xii
FireSafety ............................. xiii
AdditionalSafetyHazards
FireandExplosion .......................... xiv
FallingEquipment .......................... xiv
HotParts ............................. xiv
MovingParts ............................ xiv
MagneticFieldscanaffectPacemakers .................... xiv
WeldingWire ............................ xiv
FlyingPiecesofMetalorDirt ....................... xiv
OverheatedEquipment ......................... xiv
HighFrequency ........................... xiv
SafetyReferences ........................... xiv
8020MagneticArcControlSystem .......................................
DescriptionofEquipment
DescriptionofEquipment ........................ 17
8020ControlUnit ........................... 17
MagneticArcControlProbes ....................... 17
4604Probe ............................. 17
4600Probe ............................. 17
4608CProbe ............................ 18
4615Probe ............................. 18
Installation
Installation ............................. 20
GeneralSetup ............................ 20
OptionsandSpecials .......................... 20
ControlUnitLocation ......................... 20
MagneticArcProbeMounting ....................... 20
4604&4600 ............................ 20
4608C .............................. 20
4615 ............................... 20
8020MAGNETICARCCONTROLLER TABLEOFCONTENTS
vii
Operation
Operation ............................. 31
GeneralOperationalDescription ...................... 31
ControlFeatures&Functions ....................... 31
Remote/PanelPositionControl ...................... 31
Stabilize/Oscillate .......................... 31
Sweep .............................. 31
Left&RightDwell .......................... 31
Amplitude ............................. 31
Position .............................. 31
FinalTaper ............................. 31
RemoteStart ............................ 32
NormallyOpenStart ........................ 32
NormallyClosedStart ........................ 33
NormallyOpenStartUsingTaper .................... 33
NormallyClosedStartUsingTaper .................... 33
Maintenance
Maintenance ............................ 39
MaintenanceRequirements ........................ 39
ControlUnit ............................ 39
ProbesAssemblies........................... 39
CableAssembly ........................... 39
PreventiveMaintenanceSchedule ...................... 39
MonthlyMaintenance ......................... 39
ProbeAssemblies ........................... 39
ProperFunction .......................... 39
Test .............................. 39
QuarterlyMaintenance ......................... 39
SemiAnnualMaintenance ........................ 39
ControlUnitAssembly ......................... 39
DrawingandPartsList
DrawingandPartsList ......................... 41
Troubleshooting
Troubleshooting ........................... 57
RecommendedSparesforTroubleshooting ................... 57
Problem1 ............................. 57
Problem2 ............................. 57
Problem3 ............................. 57
CircuitDescriptions
CircuitDescriptions .......................... 59
SystemWiringDiagram ......................... 59
MainBoardAssembly ......................... 59
SchematicsandBlockDiagrams
SchematicsandBlockDiagrams ...................... 61
Index
Index ............................... 67
viii
TABLEOFCONTENTS 8020MAGNETICARCCONTROLLER
TableofTables
8020MagneticArcControlSystem
DescriptionofEquipment ........................................... 17
Installation ................................................... 20
Table1-8020MagneticArcControlSpecifications ................ 22
Table2-8020MagneticArcControlSystemComponentsSpecifications ......... 23
Table3-4604MagneticArcProbeAssemblySpecifications ............. 24
Table4-4600MagneticArcProbeAssemblySpecifications ............. 25
Table5-4608CMagneticArcProbeAssemblySpecifications ............. 26
Table6-4615MagneticArcProbeAssemblySpecifications ............. 27
Operation.................................................... 31
Table7-RemoteStartN.O.InhibitSettings ................... 32
Table8-RemoteStartN.C.InhibitSettings ................... 33
Table9-RemoteTaperN.C.Settings ..................... 34
Table10-RemoteTaperN.O.Settings .................... 34
Maintenance .................................................. 39
DrawingandPartsList............................................. 41
Table11-8020MagneticArcControlPartsList ................. 43
Table12-PowerSwitchAssemblyPartsList .................. 44
Table13-TransformerAssemblyPartsList................... 45
Table14-ProbeCableHarnessPartsList ................... 46
Table15-RemoteInterfaceCableHarnessPartsList ............... 47
Table16-4604MagneticArcProbePartsList.................. 49
Table17-4608CMagneticArcProbePartList ................. 51
Table18-4615MagneticArcProbePartsList.................. 53
Table19-4600MagneticArcProbePartsList.................. 55
Table20-VoltageSelectorSwitchAssemblyPartsList ............... 56
Troubleshooting ................................................ 57
Table21-Troubleshooting ........................ 57
Table22-RecommendedSpareParts .................... 57
Table23-VoltagePointsMainBoard .................... 57
CircuitDescriptions .............................................. 59
SchematicsandBlockDiagrams........................................ 61
8020MAGNETICARCCONTROLLER TABLEOFTABLES
ix
TableofFigures
8020MagneticArcControlSystem
DescriptionofEquipment ........................................... 17
Figure1-4604and4600MountingMethod,CrossSeam .............. 18
Figure2-4604and4600MountingMethod,AlongSeam .............. 18
Figure3-MP-2MountingMethod,AlongSeam ................. 19
Figure4-4608CMountingMethod,CrossSeam ................. 19
Figure5-4615MountingMethod,AlongSeam ................. 19
Figure6-4615MountingMethod,CrossSeam ................. 19
Installation ................................................... 20
Figure7-8020MagneticArcControlUnit ................... 22
Figure8-8020MagneticArcControlSystemcomponents .............. 23
Figure9-4604MagneticArcProbeAssembly .................. 24
Figure10-4600MagneticArcPorbeAssembly ................. 25
Figure11-4608CMagneticArcProbeAssembly ................. 26
Figure12-4615MagneticArcProbeAssembly ................. 27
Figure13-InterconnectionDiagram..................... 28
Figure14-8020MagneticArcControlMountingDimensions ............. 29
Figure15-AmplitudeSettings ....................... 30
Figure16-PositionSettings ....................... 30
Figure17-SweepSettings ........................ 30
Figure18-DwellSettings ........................ 30
Operation.................................................... 31
Figure19-TaperFunction ........................ 32
Figure20-DefaultInhibitDIP SwitchSettings ................. 33
Figure21-InhibitNCDIP SwitchSettings ................... 33
Figure22-DefaultTaperDIP SwitchSettings .................. 34
Figure23-DefaultOsc/StabDIP SwitchSettings ................ 34
Figure24-TaperNCDIP SwitchSettings ................... 34
Figure25-RemoteN.O.TaperInterface ................... 35
Figure26-RemoteN.C.TaperInterface.................... 36
Figure27-RemoteN.C.InhibitInterface ................... 36
Figure28-RemoteN.O.InhibitInterface ................... 37
Figure29-DefaultPositionDIP SwitchSettings ................. 37
Maintenance .................................................. 39
DrawingandPartsList............................................. 41
Figure30-8020MainBoardLayout ..................... 41
Figure31-8020MagneticArcControlExplodedView ............... 42
Figure32-PowerSwitchAssemblyExplodedView ................ 44
Figure33-TransformerAssemblyExplodedView................. 45
Figure34-ProbeCableHarnessExplodedView ................. 46
Figure35-RemoteInterfaceCableHarnessExplodedView ............. 47
Figure36-4604MagneticArcProbeExplodedView ............... 48
Figure37-4608CMagneticArcProbeExplodedView ............... 50
Figure38-4615MagneticArcProbeExplodedView ............... 52
x
TABLEOFFIGURES 8020MAGNETICARCCONTROLLER
Figure39-4600MagneticArcProbeExplodedView ............... 54
Figure40-VoltageSelectorSwitchAssemblyExplodedView ............. 56
Troubleshooting ................................................ 57
CircuitDescriptions .............................................. 59
Figure41-8020MagneticArcControlSignalFlow ................ 60
SchematicsandBlockDiagrams........................................ 61
Figure42-MP-1MagneticArcProbeBlockDiagram ............... 61
Figure43-4608CMagneitcArcProbeBlockDiagram ............... 61
Figure44-8020MagneticArcControlBlockDiagram ............... 62
Figure45-8020MagneticArcControlBlockDiagram(Cont.) ............ 63
Figure46-4615MagneticArcProbeBlockDiagram ............... 64
Figure47-4600MagneticArcProbeBlockDiagram ............... 64
Figure48-8020MagneticArcControlInterfaceCableSchematic ........... 65
8020MAGNETICARCCONTROLLER TABLEOFFIGURES
xi
SAFETY
SAFETY PRECAUTIONS
THISMANUAL HASBEENDESIGNEDFOREX
-
PERIENCEDWELDINGANDCUTTINGEQUIP
-
MENT OPERATORSANDMUST BEREAD
COMPLETELY BEFOREUSINGTHISEQUIP
-
MENT.IFYOULACKEXPERIENCEORAREUN
-
FAMILIARWITHTHEPRACTICESANDSAFE
OPERATIONOFWELDINGANDCUTTING
EQUIPMENT,PLEASECONSULT YOURFORE
-
MAN.DONOT ATTEMPT TOINSTALL,OPER
-
ATE,ORPERFORMMAINTENANCEONTHIS
EQUIPMENT UNLESSYOUAREQUALIFIED
ANDHAVEREADANDUNDERSTOODTHIS
MANUAL.IFINDOUBT ABOUT INSTALLING
OROPERATINGTHISEQUIPMENT,CONTACT
YOURDISTRIBUTORORTHECUSTOMER
SERVICEDEPARTMENT OFJetline.
DEFINITIONS
Throughoutthismanual,NOTE,CAUTION,
WARNINGandDANGERareinsertedtocallatten-
tiontoparticularinformation.Themethodsusedto
identifythesehighlightsandthepurposeforwhich
eachisused,areasfollows:
NOTE
Operational,procedural,andbackgroundinfor
-
mationwhichaidstheoperatorintheuseofthe
machine,helpstheservicepersonnelintheper
-
formanceofmaintenance,andpreventsdamage
totheequipment.
CAUTION
Anoperationalprocedurewhich,ifnotfollowed,
maycauseminorinjurytotheoperator,service
personneland/orbystanders.
WARNING
Anoperationalprocedurewhich,ifnotfollowed,
maycausesevereinjurytotheoperator,service
personneland/orbystanders.
DANGER
Anoperationalprocedurewhich,ifnotfollowed,
willcausesevereinjuryorevendeathtotheop
-
erator,servicepersonnelorbystanders.
SAFETY INFORMATION
Safetyisacombinationofgoodjudgmentandproper
training.Operationandmaintenanceofanyarcweld
-
ingandcuttingequipmentinvolvespotentialhazards.
Individualswhoareunfamiliarwithcuttingandweld
-
ingequipment,usefaultyjudgmentorlackproper
training,maycauseinjurytothemselvesandothers.
Personnelshouldbealertedtothefollowingpotential
hazardsandthesafeguardsnecessarytoavoidpossi
-
bleinjury.Inaddition,beforeoperatingthisequip
-
ment,youshouldbeawareofyouremployer'ssafety
regulations.
BESURETOREADTHISMANUAL BE
-
FOREINSTALLINGORUSINGTHISEQUIP
-
MENT.
BESURETOREADANDFOLLOW ALL
AVAILABLESAFETY REGULATIONSBE
-
FOREUSINGTHISEQUIPMENT.
ELECTRIC SHOCK
THEVOLTAGESPRESENT INTHE
WELDINGANDCUTTINGENVIRONMENT
CANCAUSESEVEREBURNSTOTHE
BODY ORFATAL SHOCK.THESEVERITY
OFELECTRICAL SHOCKISDETERMINED
BY THEPATHANDTHEAMOUNT OFCUR
-
RENT THROUGHTHEBODY.
A Install and continue to maintain equipment according
to USA Standard C1, National Electric Code.
B Never allow live metal parts to touch bare skin or any
wet clothing. Use only dry gloves.
C When welding or cutting in a damp area, or when
standing on metal, make sure you are well in
-
sulated by wearing dry gloves, rubber soled
shoes, and by standing on a dry board or plat
-
form.
D Do not use worn or damaged welding or torch cables.
Do not overload the cables. Use well maintained
equipment.
E When not welding/cutting, turn equipment OFF. Ac
-
cidental grounding can cause overheating and
create a fire hazard. Do not coil or loop the ca
-
ble around parts of the body.
8020MAGNETICARCCONTROLLER
xii
F The ground cable should be connected to the work
piece as close to the work area as possible.
Grounds connected to building framework or
other locations remote to the work area reduce
efficiency and increase the potential hazard of
electric shock. Avoid the possibility of the weld
-
ing or cutting current passing through lifting
chains, crane cables or other electrical paths.
G Keep everything dry you might touch, including
clothing, the work area, welding gun, torch and
welding or cutting machines. Fix water leaks
immediately. Do not operate equipment stand
-
ing in water.
H Never use a cutting torch or welding gun which is
damaged or contains cracked housing.
I Refer to AWS-Z49.1 for grounding recommendations.
SKINANDEYEBURNSRESULTING
FROMBODY EXPOSURETO
ELECTRIC-ARCWELDING AND
CUTTING RAYSORHOT METAL CANBE
MORESEVERETHANSUNBURN.
A Use a proper face shield fitted with the correct filter
(#10 or greater) and cover plates to protect
your eyes, face, neck and ears from the sparks
and rays of the cutting/welding arc when
cutting/welding or observing cutting/welding.
Warn bystanders not to watch the arc and not
to expose themselves to the cutting/welding
arc rays or to hot metal.
B Wear flameproof gauntlet-type gloves, a heavy
long-sleeve shirt, cuff-less trousers,
high-topped shoes, and a welding helmet or
cap (for hair protection) to protect the skin
from arc rays and hot sparks or hot metal.
C Protect other nearby personnel from arc rays and
hot sparks with a suitable non-flammable par
-
tition.
D Always wear safety glasses or goggles when in a
cutting or welding area. Use safety glasses with
side shields or goggles when chipping slag or
grinding. Chipped slag is hot and may travel a
considerable distance. Bystanders should also
wear safety glasses or goggles.
E Compressed gas cylinders are potentially dangerous,
refer to the suppliers for proper handling pro
-
cedures.
F Wear ear plugs or other ear protection devices when
operating cutting or welding equipment.
FIRE SAFETY
HOT SLAG ORSPARKSCANCAUSEA
SERIOUSFIREWHENINCONTACT
WITHCOMBUSTIBLESOLIDS,LIQUIDS
ORGASES.
A Move all combustible materials well away from the
cutting area or completely cover materials
with a non-flammable covering. Combustible
materials include but are not limited to wood,
clothing, sawdust, gasoline, kerosene, paints,
solvents, natural gases, acetylene, propane,
and similar articles.
B Do not weld, cut or perform other hot work on used
barrels, drums, tanks or other containers until
they have been completely cleaned. There
must be no substances in the container which
might produce flammable or toxic vapors.
C For fire protection, have suitable extinguishing
equipment handy for instant use.
WELDING ANDCUTTING FUMESAND
GASES,PARTICULARLY INCONFINED
SPACES,CANCAUSEDISCOMFORT AND
PHYSICAL HARMIF INHALEDOVERAN
EXTENDEDPERIODOF TIME.
A At all times, provide adequate ventilation in the weld
-
ing and cutting area by either natural or me
-
chanical means. Do not weld or cut on
galvanized, zinc, lead, beryllium or cadmium
materials unless positive mechanical ventila
-
tion is provided to prevent inhaling fumes and
gases from these materials.
B Do not weld or cut in locations close to chlorinated
hydrocarbon vapors coming from degreasing
or spraying operations. The heat of arc rays
can react with solvent vapors to form phos
-
gene, a highly toxic gas, and other irritant
gases.
C If you develop momentary eye, nose or throat irrita
-
tion during welding or cutting, it is an indica
-
tion that the ventilation is not adequate. Stop
work and take the necessary steps to improve
ventilation in the welding or cutting area. Do
not continue to weld or cut if physical discom
-
fort persists.
8020MAGNETICARCCONTROLLER
xiii
D Use an air supplied respirator if ventilation is not
adequate to remove all fumes and gases.
E Beware of gas leaks. Welding or cutting gases con
-
taining argon are denser than air and will replace
air when used in confined spaces. Do not locate
gas cylinders in confined spaces. When not in
use, shut OFF the gas supply at its source.
Referto AWS StandardZ49.1forspecificventilation
recommendations.
ADDITIONAL SAFETY HAZARDS
FIRE AND EXPLOSION
FireandExplosioncanresultfromplacingunits
on,over,ornearcombustiblesurfaces.
Do not install units on, over, or near combusti
-
ble surfaces.
Do not install unit near flammables.
FALLING EQUIPMENT
FallingEquipmentcancauseseriouspersonalin-
juryandequipmentdamage.
Use lifting eyes to lift unit only, not running
gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift
units.
If using fork lifts to move units, be sure forks
are long enough to extend beyond opposite
side of the unit.
HOT PARTS
Hotpartscancausesevereburns.
Do not touch hot parts bare handed.
Allow cooling period before working on gun
or torch.
MOVING PARTS
MovingPartscancauseinjury.
Keep away from moving parts, such as fans.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep away from pinch points, such as me
-
chanical slides, drive rolls, carriage assem
-
blies, etc.
MAGNETIC FIELDS CAN AFFECT PACE
-
MAKERS
MagneticFieldsfromHighCurrentscanaffect
pacemakeroperation.
Pacemaker wearers should keep away.
Wearers of pacemakers should consult their
doctors before going near arc welding, goug
-
ing, plasma cutting, or spot welding opera
-
tions.
WELDING WIRE
Weldingwirecancausepuncturewounds.
Do not press gun trigger until instructed to do
so.
Do not point the gun toward any part of the
body, other people, or any metal when thread
-
ing welding wire through the gun.
FLYING PIECES OF METAL OR DIRT
Flyingpiecesofmetalordirtcaninjureeyes.
Wear safety glasses with side shields or face
shields.
OVERHEATED EQUIPMENT
Highoutputpowerforlongdurationscancause
equipmenttooverheat.
Allow cooling periods.
Reduce current or reduce duty cycle before
starting to weld again.
Follow rated duty cycle.
HIGH FREQUENCY
HighFrequencycancauseelectricalinterfer
-
ence.
Take appropriate precautions to shield sensi
-
tive electronic equipment, such as computers,
Programmable Logic Controllers, etc.
Be sure to ground each component of the sys
-
tem to one ground point, i.e., Earth Ground
(Earth) or Protective Earth (PE).
SAFETY REFERENCES
Thefollowingpublicationsprovideaddi
-
tionalinformationonimportantwelding
safeguards.
A ANSI/ASC 249.1-1988, American National Stan
-
dard "Safety in Welding and Cutting".
8020MAGNETICARCCONTROLLER
xiv
B
Bulletin No. F4-1, "Recommended Safe Practices for
the Preparation for Welding and Cutting Con
-
tainers and Piping that have held Hazardous
Substances".
C OSHA Safety and Health Standards, 29CFR 1910,
available from the United States Department of
Labor, Washington, DC 20210.
D NFPA Standard 51B, "Fire Prevention in Use of Cut
-
ting and Welding Processes", available from the
National Fire Protection Association, 470 Atlan
-
tic Avenue, Boston, MA 00210.
E NEMA Standards Publication/No. EW1-1989, Elec
-
tric Arc-Welding Apparatus, approved as ANSI
C87.1-1989. Available from National Electrical
Manufacturers Association, 155 E. 44th Street,
New York, NY 10017.
8020MAGNETICARCCONTROLLER
xv
8020MAGNETICARCCONTROLLER
xvi
8020 Magnetic Arc Control System
DESCRIPTION OF EQUIPMENT
The8020MagneticArcControlSystemisaprecise,
controllablemeansforoscillating,stabilizing,orposi
-
tioningaweldingarc.Thisallowstheoperatortocon
-
trolheatdistribution,minimizeundercutting,reduce
porosity,improvepenetration,provideuniformside
-
wallfusionandimprovetheoverallintegrityofthe
weld.UsedwiththeCyclomatic™Models4604,
4608C,and4615Probes.
8020 CONTROL UNIT
Thecontrolunitisaheavygaugesteelenclosurecon
-
tainingtheelectroniccircuitryusedinthesystem.A
microprocessorandothersolidstatecircuitsareused
toprovidelong,trouble-freeoperation.Thecontrol
unitoperateson115/230VAC,50/60Hzcommercial
power,capableofsupplyingapproximately2amps
peakcurrent.Theunithasalightedpowerswitchand
fuseholdermountedontheexterioroftheunit.See
Table1-8020MagneticArcControlSpecifications,
Table2-8020MagneticArcControlSystem
ComponentsSpecifications, Figure7-8020Magnetic
ArcControlUnit,and Figure8-8020MagneticArc
ControlSystemcomponents foradditionalspecifica-
tions.
Thesystemisoperatedusingthecontrols,potentiom
-
eters,pushbuttonslocatedonthefrontpanel.Addi
-
tionalswitchesarelocatedontheinsideofthecontrol
unitonthemainboardviaDIP switches.A heatsink
mountedontheinsideofthecontrolunitallowsade
-
quatecoolingfortheheatdissipatingdevices.
Twoconnectorslocatedonthebottomoftheunitpro
-
videforconnectionoftheprobecableandaremote
interfacecable.
The8020systemisprimarilyintendedforusewith
theTIG(GTAW)process,butcanalsobeusedwith
thePLASMA (PAW)weldingprocess.Additionally,
the8020SystemcanbeusedwithsprayMIGandSub
Arcprocesses.Withthissystem,theoperatorcan
widenornarrowtheweldbeadasrequiredtoprovide
controloftheheataffectedzone,undercutting,andir
-
regularjointedges.Thecontrolledmagneticfieldalso
reducesarcblowandarcwander,whilethemotionof
thearcstirsthemoltenweldpuddle,reducingporosity
andprovidingamoreuniformbeadsurfacepattern.
The8020isasimple,reliablecontrolwithanoscillat
-
ingfrequencyrangeupto50Hz.ThePulseWidth
Modulation(PWM)designprovidesaconstantmag
-
neticfieldforagivenamplitudesettingovertheentire
frequencyrange.Controlfunctionsallowindependent
controlofeachofthekeywaveformparameters,and
leftandrightdwellintervalsarealsoindependently
adjustable.Thecontrolunitisconvectioncooled,al
-
lowingforlesspowerdissipationandloweroperating
temperatures.
Thetoppanelordoorofthecontrolunitcontainsall
thecontrolsneededforoperation.Therearethree
LightEmittingDiode(LED)indicatorsinapatternto
theleftofthecontrolknobs.Eachlampwillillumi
-
natealternatelyduringarcoscillation.Whenpoweris
appliedtotheControlUnit,thePowerOnLEDwill
alsoilluminate.
The8020Controlunithasadditionalfeaturesselected
frominsidethecontrolenclosure.Thesefeatures,
Stabilize/Oscillatemode(STAB/OSC)andRemote/
PanelPositionControl,areselectedviaDIP Switches
onthemainboard.
Stabilize/Oscillatemodeallowstheoperatortheabil-
itytooscillatethearceitheracrosstheseamoralong
theseamdependingonhowtheprobeismountedon
thetorch(OscillateMode),ortostabilizethearc,po
-
sitioningthearcinthedesiredlocation(Stabilize
Mode).
Remote/PanelPositionControlallowtheoperatorto
controlthearcpositionoftheeachaxisfromaremote
potentiometerorPLCwithananalogoutput,orfrom
thefrontpanelcontrols(default).
MAGNETIC ARC CONTROL PROBES
4604 Probe
The4604isasingle-tip,water-cooledprobethat
adaptstoconventionaltorches.The4604workswell
intightclearancesandisprimarilyusedtoweavethe
arcacrosstheseamortostabilizethearc.Onpage 24
is Table3-4604MagneticArcProbeAssembly
Specifications and Figure9-4604MagneticArc
ProbeAssembly fordetaileddimensionsandspecifi
-
cations.
4600 Probe
The4600probeincorporatesthelatestmagnetictech
-
nologies.Thoughsimilartothe4604probe,thenew
4600probehasamuchhighergaussstrengthand
threetimestheefficiencyofthe4604.The4600does
notrequirewatercooling;however,itdoesallowfor
optionalwatercooling.Foraddedconvenienceand
8020MAGNETICARCCONTROLLER DESCRIPTIONOFEQUIPMENT
17
flexibility,italsofeaturesadetachablecontrolcable.
Thissingle-axisprobeadaptstoconventionaltorches.
Avarietyofreturnringsandtipsareavailablefordif
-
ferentconfigurations.Seepage 25 is Table4-4600
MagneticArcProbeAssemblySpecifications and
Figure10-4600MagneticArcPorbeAssembly for
detaileddimensionsandspecifications.
4608C Probe
Thedual-tip4608CslipsoveraconventionalTIG
torchandcanbeusedeitherforcross-seamarcweav
-
ingorin-linearcweaving.In-lineweaveisprimarily
usedintubemillstopreheatthetube,pishingthearc
intothedirectionoftravel,givingincreasedweld
travelspeeds.Seepage 26 is Table5-4608C
MagneticArcProbeAssemblySpecifications and
Figure11-4608CMagneticArcProbeAssembly for
detaileddimensionsandspecifications.
4615 Probe
Thistwin-tipside-mountunitiscapableofdelivering
thefull600gaussmagneticfieldtotheweldingarc
area.Thoughnormallyusedinanair-cooledmode,if
necessary,the4615canalsobewater-cooled.Forde
-
tailedspecificationsonthe4615probe,see Table6-
4615MagneticArcProbeAssemblySpecifications
and Figure12-4615MagneticArcProbeAssembly
onpage 27.
DESCRIPTIONOFEQUIPMENT 8020MAGNETICARCCONTROLLER
18
FIGURE 1 - 4604 AND 4600 MOUNTING
METHOD, CROSS SEAM
FIGURE 2 - 4604 AND 4600 MOUNTING
METHOD, ALONG SEAM
8020MAGNETICARCCONTROLLER DESCRIPTIONOFEQUIPMENT
19
FIGURE 3 - MP-2 MOUNTING METHOD, ALONG
SEAM
FIGURE 4 - 4608C MOUNTING METHOD, CROSS
SEAM
FIGURE 5 - 4615 MOUNTING METHOD, ALONG
SEAM
FIGURE 6 - 4615 MOUNTING METHOD, CROSS
SEAM
INSTALLATION
GENERAL SETUP
A standard8020MagneticArcControlsystemis
shownin Figure13-InterconnectionDiagram,with
thenecessaryinterconnectsshownschematically.
Themajorpartsrequiredforinstallingthissystemare
listedbelow.Checkallitemsfordamagewhenun
-
packing.
Systemshouldconsistofthefollowing:
•
Control Unit
•
Probe Assembly
•
Remote Interface Cable
•
Power Cord
•
Operators Manual
OPTIONS AND SPECIALS
Optionsforthe8020Systemmaybepurchased.Spe
-
cialsincludeprobetips,probetipextensionsandex
-
tensionlengthcablesdesignedtofitaparticular
mechanicalconfigurationwhenthestandardtipsor
cableswillnot.
Theinstallationofthe8020Systemisveryeasyand
canbeaccomplishedonmostautomaticorsemiauto-
maticsetupswithinminutes.
CONTROL UNIT LOCATION
The8020ControlUnitshouldbeplacedinalocation
whichprovideseasyaccesstothecontrolsandproper
airventilationforcooling.Toallowadequateventila
-
tion,maintainaminimumof5inchesofunrestricted
spacebetweenthecontrolunit(sides)andthenearest
obstruction.Thelocationshouldbeselectedtomini
-
mizetheamountofdust,dirt,moistureandcorrosive
vaporstheControlUnitwillbesubjectedto.Please
see Figure14-8020MagneticArcControlMounting
Dimensions formountingholepatternsandotherdi
-
mensions.
NOTE
Althoughthecontrolunitrequiresno
otherelectricalinterfacingwithanyof
theusers'sotherequipment,besuretose
-
lecttheproperinputvoltagebeforeplug
-
gingtheunitintotheacpoweroutlet!Thisunit
operatesoneither110/220VAC50/60hzpower.
BesuretheVoltageSelectorswitchisinthe
properpositionforthepoweryouareusing!
TheVoltageSelectorswitchislocatedontheoutside
ofthecontrolunitneartheACpowercordreceptacle
(Referto Figure7-8020MagneticArcControlUnit
and Figure31-8020MagneticArcControlExploded
View).Theoperatormayselecttheproperinputvolt
-
ageusingasmallslottedscrewdriver.Themounting
dimensionsofthecontrolunitareshownin Figure14
-8020MagneticArcControlMountingDimensions,
shouldtheuserchoosetoinstallthe8020onafixture
orcontrolpanel.
MAGNETIC ARC PROBE MOUNTING
The4604,4615,and4600Probeswillmountonany
machinetorchwithabodydiameterfrom1.31inches
to2inches.The4608CProbewillmountonanyma
-
chinetorchwithabodydiameterof1.625inchesor
less.(Seereviewthefiguresandtablesonthefollow
-
ingpagesbeginningonpage 24 fordimensionalrefer
-
ences.)
4604 & 4600
•
Back off the two socket screws which secure the probe
mounting bracket to the torch body.
•
Slip the probe over the torch and align the tips approx
-
imately even with the gas cup, or bottom of torch.
Tighten the 2 screws, then loosen the screws holding
the bracket to the probe in order to position the probe
on the torch body. (See Figure 2 - 4604 and 4600
Mounting Method, Along Seam and Figure 1 - 4604
and 4600 Mounting Method, Cross Seam beginning
on page 18 for illustrations of probe-to-seam orienta-
tion.)
4608C
The4608Cprobeisatorroidialdesignprobe,where
thetorchmountsthroughthecenteroftheprobe.To
makemountingthisprobetoatorcheasier,torch
adaptersareavailable,butarenotrequiredtomount
theprobetothetorch.
•
A) Select a suitable adapter for your torch (if neces
-
sary).
Withoutadaptor:1.625in.
AdapterP/N1030-0517:1.500in.
AdapterP/N1026-0582:1.455in.
AdapterP/N1026-0574:1.380in.
•
Back off the three socket head cap screws which se
-
cure the probe to the torch body.
•
Slip the probe over the torch and align the tips approx
-
imately even with the gas cup, or bottom of torch.
Tighten the three screws while insuring that the probe
remains centered on the torch body.
Forprobe-to-seamorientation,pleasereferto Figure3
-MP-2MountingMethod,AlongSeam and Figure4-
4608CMountingMethod,CrossSeam beginningon
page 18 forillustrationsofthisprobesprobe-to-seam
orientation.
4615
The4615probehasthestrongestmagneticfield
strengthofalloftheMagneticArcProbes.Under
INSTALLATION 8020MAGNETICARCCONTROLLER
20
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