DIGIMIG DUAL WIRE FEEDER - esabna.com - f14-999/digimig...3 WARNING: These Safety Precautions are...

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arcwelding 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 untilyou have read and fully understand these instructions. If you do not fully understand these instructions contact your supplier for furtherinformation. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment.

INSTRUCTION MANUAL

DIGIMIG DUAL WIRE FEEDER

This manual provides installation and operating instructions for the following wire feeder(s):

ESAB Part No. 30912 — 115V, 1-Phase, 50/60 Hertz. (Starting with Serial No. #####)L-TEC Part No. ????? — 115V, 1-Phase, 50/60 Hertz. (Starting with Serial No. #####)

F-14-489-CSept., 2003

Be sure this information reaches the operator.You can get extra copies through your supplier.

2

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompany-ing labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructionsprovided. This equipment must be checked periodically. Defective equipment should not be used. Parts that arebroken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replace-ment become necessary, the manufacturer recommends that a telephone or written request for service advice bemade to the Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.The user of this equipment shall have the sole responsibility for any malfunction which results from improper use,faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a servicefacility designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGEPARAGRAPH

SECTION 1 DESCRIPTION ...................................................................................................................... 51.1 General ................................................................................................................................. 51.2 Scope .................................................................................................................................... 51.3 Specifications ........................................................................................................................ 51.4 Required Equipment ............................................................................................................. 51.5 Optional Accessories ............................................................................................................ 8

SECTION 2 INSTALLATION ..................................................................................................................... 92.1 General ................................................................................................................................. 92.2 Connections .......................................................................................................................... 9

SECTION 3 OPERATION ......................................................................................................................... 113.1 General ................................................................................................................................. 113.2 Description/Function of Control Features ............................................................................. 113.3 Gas/Wire Adjustments .......................................................................................................... 143.4 Setting Up Torch Program Parameters ................................................................................. 153.5 Welding Operation ................................................................................................................ 16

SECTION 4 TROUBLESHOOTING .......................................................................................................... 184.1 Troubleshooting General ...................................................................................................... 184.2 Troubleshooting Guide .......................................................................................................... 18

SECTION 5 MAINTENANCE .................................................................................................................... 235.1 General ................................................................................................................................. 235.2 Inspection and Cleaning ....................................................................................................... 23

SECTION 6 REPLACEMENT PARTS....................................................................................................... 236.1 General ................................................................................................................................. 236.2 Ordering ................................................................................................................................ 23

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WARNING: These Safety Precautions are foryour protection. They summarize precautionaryinformation from the references listed in Addi-tional Safety Information section. Before per-

forming any installation or operating procedures, be sure toread and follow the safety precautions listed below as well asall other manuals, material safety data sheets, labels, etc.Failure to observe Safety Precautions can result in injury ordeath.

PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (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 workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc and notto expose themselves to the rays of the electric-arc or hotmetal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weldinghelmet or cap for hair protection, to protect against arc raysand hot sparks or hot metal. A flameproof apron may alsobe desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trousercuffs, or pockets. Sleeves and collars should be keptbuttoned, and open pockets eliminated from the front ofclothing

5. Protect other personnel from arc rays and hot sparks witha suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far. Bystand-ers should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and explo-sions. Therefore:

1. Remove all combustible materi-als well away from the work area or cover the materialswith a protective non-flammable covering. Combustiblematerials include wood, cloth, sawdust, liquid and gasfuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevicesin floors or wall openings and cause a hidden smolderingfire or fires on the floor below. Make certain that suchopenings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that there areno substances on the workpiece which might produceflammable or toxic vapors. Do not do hot work on closedcontainers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area to makecertain there are no hot sparks or hot metal which couldcause a later fire. Use fire watchers when necessary.

7. For additional information, refer to NFPA Standard 51B,"Fire Prevention in Use of Cutting and Welding Processes",available from the National Fire Protection Association,Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live electrical partsand ground can cause severe injury or death. DO NOT use

AC welding current in damp areas, ifmovement is confined, or if there isdanger of falling.

1. Be sure the powersource frame (chassis) is connected tothe 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 fatalshock.

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 fromwork and from ground.

7. Do not stand directly on metal or the earth while working intight quarters or a damp area; stand on dry boards or aninsulating 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 mistakethe work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous.Electric current flowing through any conductor causes

localized Electric and Magnetic Fields(EMF). Welding and cutting currentcreates EMF around welding cablesand welding machines. Therefore:

1. Welders having pacemakersshould consult their physician beforewelding. EMF may interfere with some

pacemakers.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.

SAFETY PRECAUTIONS

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FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless positivemechanical ventilation is provided. Do not breathe fumesfrom these materials.

2. Do not operate near degreasing and spraying operations.The heat or arc rays can react with chlorinated hydrocar-bon vapors to form phosgene, a highly toxic gas, and otherirritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to improveventilation in the work area. Do not continue to operate ifphysical discomfort persists.

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

5. WARNING: This product, when used for welding orcutting, produces fumes or gases whichcontain chemicals known to the State ofCalifornia to cause birth defects and, insome cases, cancer. (California Health &Safety Code §25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injureor kill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate from thecompressed gas cylinder. Do not use adaptors. Maintainhoses and fittings in good condition. Follow manufacturer'soperating instructions for mounting regulator to a com-pressed gas cylinder.

2. Always secure cylinders in an upright position by chain orstrap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Have valveprotection cap in place if regulator is not connected.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 inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty orimproperly maintained equipment cancause injury or death. Therefore:

1. Always have qualified personnel perform the installation,troubleshooting, and maintenance work. Do not performany electrical work unless you are qualified to performsuch work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, power cord,and power supply in safe working order. Do not operateany equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment away from heat sources such as furnaces, wetconditions such as water puddles, oil or grease, corrosiveatmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position andin good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for electricarc welding and cutting equipment, ask yoursupplier for a copy of "Precautions and SafePractices for Arc Welding, Cutting and Goug-ing", Form 52-529.

The following publications, which are available from theAmerican Welding Society, 550 N.W. LeJuene Road, Miami,FL 33126, are recommended to you:1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"2. AWS C5.1 - "Recommended Practices for Plasma Arc

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

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

Gouging and Cutting"5. AWS C5.5 - "Recommended Practices for Gas Tungsten

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

Welding"“7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-

ing and Cutting of Containers That Have Held HazardousSubstances."

MEANING OF SYMBOLS - As used through-out this manual: Means Attention! Be Alert!Your safety is involved.

Means immediate hazards which, if notavoided, will result in immediate, seri-ous personal injury or loss of life.

Means potential hazards which couldresult in personal injury or loss of life.

Means hazards which could result inminor personal injury.

5

SECTION 1 DESCRIPTION

1.1 GENERAL

This Digimig wire feeder is designed as a “dual” torchwelder with each torch capable of furnishing two com-pletely different sets of welding parameters—in otherwords, four (4) completely different welding schedulescan be preset to meet the requirements of high productionshops. The standard Dual control features include powersource, slope, wire type, wire diameter selections, andpresettable wire feed speed (ipm), voltage, pre andpostflow gas shielding, cold wire inching, gas purging,adaptive or manual burnback and spot welding timefunctions.

The Digimig Dual torch welder is a microprocessorcontrolled digital wire feeder designed for mig short arcand spray arc, and flux core welding applications. Itselectronic brain (the microprocessor) not only controls, italso remembers and automatically coordinates the pro-gram sequencing (that “you” preset) which results in themost accurate wire feed speed and voltage controlpossible.

By virtue of its microprocessor controlled wire speed andarc voltage design, the Digimig Dual allows the customerto preset both welding parameters (for each torch), lock-them-in, and be assured that each setting will be preciselyheld regardless of changes in line voltage, arc or loadconditions.

Two digital readout windows continuously display (1/2-in.high) the preset welding parameters (speed and voltage).After the arc is struck, they automatically display theactual wire speed and arc voltage conditions for theselected schedule. The read-outs can also provide select-able displays of power source and slope, and wire typeand diameter used, and other welding parameters such asinching speed, gas pre- and postflow times, spot time inseconds and manual burnback time in cycles.

The Dual Digimig uses a pair of heavy duty EH-10A wiredrive motors designed to feed hard or soft wires from .030-in. to 1/16-in. in diameter and flux-cored wires from .035-in to 5/64-in. in diameter. Rate of wire feed (20-999 ipm)is precisely controlled by using a closed-loop “J” governordigital feedback circuit that employs an optical tachometerto monitor the motor speed. Arc voltage regulation is alsocontrolled by a closed-loop digital feedback circuit thatmonitors the arc voltage and automatically adjusts the

power source output voltage to maintain the preset voltage.

For identification and location of all functional controls andconnections refer to Figure 1-1. The front panel containsthe torch switch receptacles which use low voltage, d.c.,for operator safety. The rear panel contains the on-offpower switch, the run/set switch, trigger lock switch, a 7-ampere reset circuit breaker for overload protection, a 19-pin receptacle (J1) provides 115vac and contactor con-trol, arc monitoring and control signals from the powersource.

All interconnecting cable, hose and auxiliary equipmentconnections are quickly detachable to provide easy setupand maximum portability of the wire feeder as shown inFigs. 2-1 & 2-2. A water kit may be purchased, as anoptional accessory, for use with water-cooled torchoperation.

1.2 SCOPE

The purpose of this manual is to provide the operator withall information required to install and operate the DualDigimig wire feeder. Technical information and referencematerial is also provided to assist in troubleshooting.

1.3 SPECIFICATIONS

Input Power Required ......................... 115 volts 50/60 Hz single phaseFeed Speed Range .............................. 20-999 in./min. (.5-26.4 m/min.)Wire Sizes Accommodated:Hard/Soft — ......................................... .030 thru 1/16-in. (.8 thru 1.6 mm)Flux Cored — .................................. .035 thru 5/64-in. (0.9 thru 2.0 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)

1.4 REQUIRED EQUIPMENT

A. CONSTANT VOLTAGE POWER SOURCE

One of the following power sources must be used:SVI-300i cv/cc, P/N 34835.VI-450, P/N 33322.SVI-450i, P/N 31950V-650 cv/cc, P/N 33324.

B. Cable Assemblies115 Volt/Contactor/Remote Control J1 Cable, 19-con-

6

POWER ON-OFF SW.

RESET CIRCUITBREAKER

TRIGGER LOCK

J1 CONTROL RECPT.

LOCATION FOR OPT.WATER CONNECTIONS

POWER CABLEADAPTOR BLOCK

RUN-SET KEYSW.

LEFT DIGITAL READOUT IPM

LEFT INC./DEC. SW.

6-POS. ROTARYSELECTOR SW.

TORCH ACCY. LEFTSUPPORT ASSY.

& EH-10 MOTOR-GEAR-TACH UNIT

TORCH ACCY. RIGHTSUPPORT ASSY.& EH-10 MOTOR-GEAR-TACH UNIT

RIGHT INC./DEC. SW.

RIGHT DIGITAL READOUT VOLTS

INCH-PURGE (RESET) SW.

SPINDLE

Fig. 1-1 - Digimig Dual Feeder


RIGHT TORCH RECPT.LEFT TORCHRECPT.

LEFTTORCH GAS SOLCONNECTION

RIGHTTORCH

GAS SOLCONNEC-

TION

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Regulator/Flowmeters:R-5007 Argon/Helium/Nitrogen, P/N 998124.R-5008 C02, P/N 998125.

Gas Hoses:Standard Duty, 40V77 (12-1/2-ft.) or P/N 34V38 (25-ft.)Heavy Duty, P/N 19416 (12-1/2-ft.) or P/N 19415 (25-ft.).

Must be used for C02.

E. Feed RollsThe Digimig comes equipped with a pressure roll but NOTa feed roll. Select the proper feed roll and outlet guide fromTable 1 for the wire size and type to be used. To convertthe 2-Roll to 4-Roll Drive, order optional 4-roll DriveAccessory Support, P/N 600216 and the appropriate kitlisted in Table 1.

F. Water CoolingWater supply with fitted hose assemblies are required tobring cooling water from supply to wire feeder, orderWater Hose 12-1/2-ft. P/N 40V76 as shown in Fig. 2-1.

ductor with Amphenol to Amphenol plugs; order one of thefollowing:

6-foot. 19-cond., P/N 30686.30-foot, 19-cond., P/N 30780.60-foot, 19-cond., P/N 30781.

C. Welding TorchMig welding torches, with contact tip, wire conduit andoutlet guide for wire size/type to be employed, will berequired. Suitable air (MT-400) or water-cooled (MT-450W, ST-16) torches may be used with the Digimig.When using a water-cooled torch it will be necessary toconnect the torches water hose to either a continuouswater supply or to the wire feeder base by using anoptional water kit (see Section 1.5).

D. Gas RegulationShielding gas regulator/flowmeter and fitted hose to bringgas from flowmeter to wire feeder. Such as:

Table 1 - Digimig Feed Rolls

Wire Type/ Two Roll Drive Four Roll Drive OutletSize In. (mm) Feed Roll Feed Roll Kit* Guide

Soft.030 (.8) 2075304 (U) 999320 29N13**.035 (.9) 2075304 (U) 999321 (U) 29N13**3/64 (1.2) 2075301 (U)† 999322 (U) 29N13**1/16 (1.6) 2075298 (U)†† 999322 (U) 29N13**

Hard.023 (.6) 17998 (V) — 999745 (c).030 (.8) 2075300 (V) 999325 (V) 993860 (a).035 (.9) 2075303 (V) 999326 (V) 993860 (a).045 (1.2) 2075302 (V) 999327 (V) 39N15 (b).052 (1.4) 2075330 (V) 999328 (V) 39N15 (b)1/16 (1.6) 2075299 (V) 999329 (V) 39N15 (b)

Cored.035 (.9) 19761 (Serr.) — 993860 (a).045 (1.2) 19761 (Serr.) 999330 (Serr.) 39N15 (b).052 (1.4) 2075261 (Serr.) 999331 (Serr.) 39N15 (b).063, 1/16 (1.6) 2075261 (Serr.) 999332 (Serr.) 39N15 (b)5/64 (2.0) 2075261 (Serr.) 999333 (Serr.) 62N17 (d)

U=U-groove, V=V-groove, Serr. = serrated** Requires outlet guide insert as follows: For .030, .035 wire use 993902, For 3/64 wire use 05N57, For 1/16 wire use 12N75, For 3/32 wire

use 05N58.† Recommended U-Groove Pressure Roll 2075346 be used.†† Recommended U-Groove Pressure Roll 2075348 be used(a) Includes replaceable sleeve (995651).(b) Includes replaceable sleeve (995692).(c) Requires guide bushing (17997).(d) Requires replaceable sleeve (995693)

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1.5 OPTIONAL ACCESSORIES

A. Water Kit (P/N 994466). Permits the convenientconnection of water-cooled torches and continuouswater supply to the wire feeder.

A kit is required for each torch and consists of acoupling, two adaptors and a fitting. A dependablecooling water supply, delivery and return water hoses(P/N 40V76, 2 required) will also be required. Note thatFig. 2-1 illustrates the use of power cable adaptor P/N 634693, in addition to the kit. If adaptor (634693) isnot used, adaptor (45V11 supplied with kit) can beconnected to the output terminal of the power source.Install the kit in accordance with Fig. 6-7 and Sec. 2.2-F. Connect the water-cooled torch as shown in Fig. 2-1.

B. Spool Enclosure Kit (P/N 600240). Provides protec-tion for spool of wire against dust and dirt. Forinstallation instructions refer to Form 12-824.

C. Standard Wire Reel Assembly (P/N 995570). Reelslips over spindle to allow use of coiled wire, see Fig.6-6.

D. Heavy Duty Wire Reel Assembly (P/N 19V89).Spoke-type wire reel includes a four spoke aluminumalloy casting mounted on a lightweight support shaft ofsteel tubing. The reel will handle all wire coils from 2 to4-5/8-in. wide. The finger design permits quick andeasy accommodation of different coil widths by simplyrotating from one finger position to the other.

E. Wire Straightener (P/N 34V74). Reduces wire castto improve feedability and increase service life of torchliners and contact tips. Mounts to the accessorysupport inlet guide.

Either of two additional accessories are required tocomplete the installation on the wire inlet side of thestraightener:a. Wire Inlet Guide, P/N 11N53, or -b. Wire Wiper Holder, P/N 598763.

F. Wire Spool Spacer (P/N 948378). Enables the use ofa 8-in. diameter spool of welding wire with spindleassembly on the Digimig wire feeder.

G.WC-9 Coolant Circulator (P/N 33540) is used forwater 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 @ 50psi, using 115 volts, 50/60 Hertz, 1 phase input. Sincethe cooler is designed to run continuously during awelding operation, never connect it to a power sourceor wire feeder that uses a solenoid controlled watersupply that opens and closes with each operation of thewelding contactor - the cooling efficiency of the unit willbe hampered and the starting winding in the pumpmotor may burn out.

H. WC-8C Coolant Circulator (P/N 33739) is used forwater cooled torch operation and is designed to fit ina cylinder rack of a power supply truck. A 1.5 galloncapacity tank provides 1.0 gal/min @ 50 psi, using 115volts, 50/60 Hertz, 1 phase input. Since the cooler isdesigned to run continuously during a welding opera-tion, never connect it to a power source or wire feederthat uses a solenoid controlled water supply that opensor closes with each operation of the welding contactor- the cooling efficiency of the unit will be hampered andthe starting winding in the pump motor may burn out

I. Wire Feeder Turntable P/N 678940, allows rotation ofwire feeder as operator changes work positions. Thisreduces strain and bending of torch cables (see F-12-984).

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 wirefeed. It is designed for feeding .030 thru 1/8-in.diameter wire. Feed rates for the 4-roll drive are virtuallythe same as with the 2-roll drive. For feed roll/outletguide accessories refer to F-12-821 or Table 1.

9

Fig. 2-1 - Torch and Service Interconnection diagram

RIGHT TORCHMOTOR/ACC. SUPPORT

PLAN VIEW DUAL FDR.

GAS HOSE40V77 (12-1/2 FT.)34V38 (25 FT.)

LEFT TORCH(WATER COOLED)

TORCH SWITCH

TORCH GAS HOSE

TORCH WATER HOSE

TORCH POWER CABLE

TORCH CONDUIT

LEFT TORCHMOTOR/ACC. SUPPORT

ADAPTOR - 45V11

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

GAS HOSE40V77 (12-1/2 FT.)34V38 (25 FT.)

REGULATOR/FLOWMETER

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

REGULATOR/FLOWMETER

REF. CONTROL'S REARSUPPORT FRAME

TORCH CONDUIT

TORCH SWITCH

TORCH GAS HOSE

TORCH POWER CABLE

RIGHT TORCH(AIR COOLED)

FRONT VIEWCONTROLParts required when

using a Water Kit & WaterCooled Torch.

WATER KIT - 994466

GAS SOLENOIDS

SECTION 2 INSTALLATION

2.1 GENERAL

Proper installation can contribute materially to the sat-isfactory and trouble-free operation of the wire feeder.It is suggested that each step in this section be carefullystudied and followed as closely as possible.

After checking to be sure you have all required compo-nents and accessories (see Section 1), proceed asfollows (with reference to Figs. 2-1 & 2-2, Interconnec-tion Diagrams):

To avoid possible lethal shock make sure that allpower to the Digimig is OFF before making anywelding/control cable and or accessory connec-tions on this unit. Do this by "locking-open" theinput line disconnect switch to the power source.

2.2 CONNECTIONS

A. Hose And Electrical ConnectionsConnect shielding gas and water (if used) supply hosesas shown in Fig. 2-1. Connect the control cable assem-bly (J1) from the Digimig’s rear panel to the powersource as shown in Fig. 2-2.

10

B. Torch ConnectionsAttach torch gas hose to gas connections. Plug in torchswitch cables and lock by twisting. After inserting con-duit liner (if used) and attaching wire outlet guide ofcorrect size, connect wire feed conduit to welding headclamp and lock in place. Attach water hose (if used) towire feeder. Connect torch power cables to powersource, or to power cable adaptor block (with a secondcable from that stud to the power source).

C. Installing Feed Roll1. Release the clapper on the accessory support as-

sembly (Figure 6-5) by disengaging the retainer fromthe clapper fork.

2. Remove thumbscrew, belleville washer, and flatwasher from the feed roll shaft.

3. Slip the feed roll on the shaft, engaging the key. Besure to observe this “THIS SIDE OUT” marking on thefeedroll.

4. Reassemble flatwasher, belleville washer, and thumbscrew, tightening screw sufficiently to eliminate allend play from the feed roll.

D. Installing Spool Of WireCAUTION: Make sure safety glasses are worn when

clipping wire off at the spool or at the end ofthe torch - serious eye injury can result dueto the springiness of the wire which quicklyunravels, or a cut wire end which may shootacross 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 thebottom of the spool. The spool should be held so thatthe index hole on the back will engage the lug on thespindle.

3. Slide the spool onto the spindle until it engages thelug. Lock in place with the hairpin clip.

4. Loosen the brake screw in the center of the spindlehub, then tighten it just enough to prevent coasting ofthe spool when wire is drawn from it. Too muchpressure 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 assem-bly as described in E, following.

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 coverplate from reel. Remove coil from its package, but donot remove its binding wires. Slide coil onto reel sothat wire will be drawn from bottom of coil (starting

J2

J1

TYPICAL POWERSOURCE HOOKUP

† ESAB will not honor the warranty on Digimigs that are used with non-ESAB manufactured interconnect cables and sustain damage thatin ESAB’s opinion is caused by these cables. For a listing of theproper J1 cables available refer to Section 1.4.

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

Fig. 2-2. Welding and Control Interconnection Diagram

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 thetorch conduit.

4. Engage the clapper making sure the wire is held inthe feed roll groove.

5. Tighten the pressure adjusting knob until the wire isfirmly against the feed roll - do not overtighten. Thespring pressure applied should be the minimumrequired to provide positive, nonslip wire feed. Toolittle pressure will result in wire slippage while exces-sive pressure will scar and deform the wire. Further

end for a coil is always the outer end). Replace reelcover plate and thumbnuts. Cut off coil tie wires andany kinked wire. Then adjust brakescrew and threadwire to torch as covered in 4 and 5 above.

E. Adjusting The Accessory Support Assembly (SeeFig. 6-5).

When a new wire size or type is to be used, set thepressure roll adjustment as follows:


TO WORK*

RECPT.

4/0 WELDING CABLE*

OPT. WATERADAPTOR

POWER CABLEADAPTOR

J1 CABLE †GSV'S

11

adjustment can be made after the wire feed is put intooperation. Note that a light silver-colored spring(182W55) is installed on the accessory support foruse with soft and small diameter hard wire. For largediameter hard wire, replace this spring with a heavyblue- colored spring (182W54) supplied with the unit.


F. WATER KIT (Optional see Fig. 6-7)Mount bulkhead adaptor (58V75) behind opening pro-vided in rear vertical support plate, below gas connec-tions, and secure with screws (No. 8 - 32 x 3/8-in.) andlockwashers provided. Attach coupling and adaptor(11N16) to the bulkhead adaptor. Mount torch cableadaptor (45V11) on welding power stud. Connect waterdrain hose to this adaptor, and water inlet hose toadaptor 11N16.

SECTION 3 OPERATION

3.1 GENERAL

Do not allow metal-to-metal contact between thewire feeder chassis and a metal surface connectedin any way to a welding ground. With such contact,a poor welding ground connection may create adifference In potential that sends part of the weldingcurrent through the safety ground wiring in thecontrol cable and wire feeder, resulting in burnout ofthat wiring and/or damage to wire feeder circuitry. Ifthe safety ground burns out, the operator may beexposed to 115V. shock hazard.

3.2 DESCRIPTION/FUNCTION OF CONTROL FEA-TURES

1. Power Switch. This two-position toggle switch turnspower “on” or “off’ to the wire feeder control.

NOTE: Immediately after the control has been turned“on” various numerical code data (e.g.; Pro-gram I.D., Power Source and Slope) will appearin the IPM and VOLTS display windows for 4-seconds. After this delay, the preset weld pa-rameters for the last torch used will be shown.This is further described in the General Trouble-shooting Section.

2. Run-Set Key. This "key-operated” switch must be inthe SET position to preset, vary and weld-test thewelding parameters programmed into the control(e.g.: Sched. I (RUN), 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 RUNposition. No parameter can be altered by the opera-tor in the RUN position. Fig. 3-1. Rear Panel Control

3. Reset Circuit Breaker. A seven (7) ampere circuitbreaker provides protection to the 115-volt controlcircuit and the wire feed motor. If an overload occurs,the breaker will trip and suspend all operation. Torestore service, depress the breaker button to resetthe circuit.

3a.Trigger -Lock-In Switch. This feature allows theoperator to release the torch switch (trigger lock“on”), of the torch being used, after starting the weldcycle. To stop the welding cycle, you simply de-press the torch switch again, and all welding actionceases. When this function is selected (on), it“locks-in” both torches and their selected schedule.It will also automatically override a Spotweld opera-tion (if programmed). An indicator light (LED) on thefront panel lights when this feature is engaged. Inthe “off” position this feature in not functional, andthe LED is off.

3A

1

3

2

12

4. Digital Readout Windows. Two individual three-digit windows are provided to display preset or actualwelding parameters as follows:a. IPM Digital Readout. This window is primarily

used to display wire feed speed in IPM from 20 to999 inch per minute in one inch increments. How-ever, with the appropriate Rotary function actu-ated, this window can also display the following:— Power Source selection designated by the nu-

merals “300”, “450” or “650” (see Rotary SwitchItem 6)

— a code number that indicates the MATERIALselection programmed for various welding wireapplications; #1, #2, or #3 (see Rotary SwitchItem 6)

— 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 to99.9 seconds in one tenth of a second incre-ments.

— cold wire INCH speed in IPM from 40 to 999inches per minute in one inch increments. Pleasenote the initial starting speed jumps to 100 ipmfor 2-seconds and then goes to preset value.

NOTE: When power is first turned “on” (but not welding)the display windows will initially show the Pro-gram I.D. numbers for 1 second and then flashthe Power Source and Slope selections for 3-seconds (to make sure that the correct powersource and slope are being used). Then, theIPM window will “continuously” read Preset wirespeed if the Rotary switch is in the RUN or SCH.II mode. When the arc is struck, the IPM windowwill then continuously read Actual welding wirespeed.

b. Volts Digital Readout. This window is primarilyused to display arc voltage in VOLTS from 12 to 50vdc in one tenth volt increments. However, with theappropriate Rotary function actuated, this windowcan also display the following:— indicates power source SLOPE selected and

designated by the numeral 1, 3 or 6 (see RotarySwitch Item 6)

— a pair of numbers represent WIRE DIAMETERsizes which are programmed for selection asfollows: #30, #35, #45, #52 or #63 (see RotarySwitch Item 6).

— shielding gas POSTFLOW from .1 to 99.9 sec-onds in one tenth of a second increments.

— manual BURNBACK time. Manually adjustableburnback time period which when preset willoverride the automatic adaptive anti-stick fea-

SECTION 3 OPERATION

ture. This time period will be set In one-cycle (60cycle = 1 sec.) Increments. When set to “zero”,the Automatic Anti-stick feature will be opera-tional.

NOTE: When power is first turned “on” (but not welding)the display windows will initially show the Pro-gram I.D. numbers for 1 second and then flashthe Power Source and Slope selections for 3-seconds (to make sure that the correct powersource and slope are being used). Then, theVOLTS window will “continuously” read Presetvoltage if the Rotary Switch is in the RUN orSCH. II mode. When the arc is struck, theVOLTS window will then continuously read Ac-tual welding voltage.

5. LED Light. This LED lights to indicate that Trigger-Lock-In is engaged.

IMPORTANT

To setup the torches for programming, simply oper-ate and release the torch switch lever for one torchand preset the desired parameters. Then, repeatthis procedure with the remaining torch to preset itswelding parameters. Under normal operation, thecontrol’s memory will always “default” to the torch/parameters last used during the preceding weldingoperation. When the unit is initially turned “on” or“reset”, the “right” torch is the dominant or “de-fault” torch.

6. Rotary Switch. This six (6) position switch allowsyou to select a “pair” of welding parameters perposition as follows:

a. Position 1, Power Source/Slope (Must be set).This position must match the Power Source used,and its Slope setting. These selections will be

Fig. 3-2. Front Panel Controls

Pos. #6

4BPositions

#1#2#3#4#5

13

SECTION 3 OPERATION

displayed in the IPM and VOLTS windows respec-tively and are set as follows:(1) Power source. Four power sources are avail-

able for use with this feeder. The choices are,the SVI-300i cv/cc and this designated by thenumeral “300”; and the VI-450, or the SVI-450I, and these are designated by the nu-meral “450”; and/or the V-650 cv/cc and this isdesignated by the numeral “650”. The PowerSource “numeral” designation selection is dis-played in the left (IPM) window, and set usingthe IPM Inc./Dec. toggle switch.

(2) Slope. In order to provide optimum starts withthe many Power Source and Slope combina-tions, the same slope setting used on thepower source must also be preset on the wirefeeder control, and are designated as follows:by the numeral “1” for Flat; by numeral “3” forMedium; or by numeral “6” for Steep slope.The slope “numeral” designation selected isdisplayed in the right (VOLTS) window, andset using the VOLTS Inc./Dec. toggle switch.Remember, that the feeder slope selectionmust always match the slope output se-lected at the power source.

In order to help you select the correct Slope settingfor the Power Source used, refer to the chart follow-ing:

Power Control Slope CodesSource #1 #3 #6

SVI-300i X X XSVI-450i X X XVI-450 X X —V-650 cv/cc X — —

Note, Slope codes indicate the following:#1 = Flat = 1 volt/100 amps.#3 = Medium = 3 volt/100 amps.#6 = Steep = 6 volt/100 amps.

b. Position 2, Material/Wire Diameter (Must beSet). In this position you set the wire Material typeand Wire Diameter. These selections will be dis-played in the IPM and VOLTS windows respec-tively, and are set as follows:(1) Material. This parameter is set in the left (IPM)

window and displays one of the three avail-able wire material type code numbers that canbe used (for each torch), and is set by operat-ing the IPM Inc./Dec. toggle switch. Materialcode “1” is for Carbon or Stainless Steels,code “2” is for the 4000 aluminum series, and

code “3” is for the 5000 aluminum series ofwires.

(2) Wire Diameter. This parameter is displayedin the right (VOLTS) window and offers achoice of five (5) wire diameter sizes whichcan be used (for each torch), and is set byoperating the VOLTS Inc./Dec. toggle switch.The wire sizes available are: “30” for .030" dia.“35” for .035" dia., “45” for .045" dia., “52” for.052" dia. and “63” for .063" dia wires.

c. Position 3, Spot Time/Burnback Time (OptionalSetup). This position allows you to preset either orboth of these welding features for either or bothtorches. These parameter times will be displayedin the IPM and VOLTS windows respectively, andare set as follows:(1) Spot time. If a timed weld is desired, a time

from 0.1 to 99.9 seconds can be set in Spotweldtimer (IPM window) using its Inc/Dec key.Once set, both Schedules I and II will become“timed” or spot welds. To return to “continu-ous” welds, the time has to be set to zero (0.0).

When a spot time is programmed for a torch,the “click-click” the torch switch feature forchanging schedules cannot be used.

(2) Burnback Time. At the same time, you canalso preset a manual Burnback time. TheBurnback time is adjustable in one cycle incre-ments (60 cycles/sec.) and is programmed inthe VOLTS window using its Inc./Dec. toggleswitch. When preset, the Burnback time willoverride the automatic adaptive anti-stick fea-ture. To resume automatic anti-stick opera-tion, the Burnback time must be set back to“zero” (0).

d. Position 4, Schedule II/Schedule II (OptionalSetup). This position allows you to preset a sec-ond welding schedule. The wire speed rate is setusing the left Inc./Dec. toggle switch and thesetting will appear in the IPM window. The arcvoltage is set using the right Inc./Dec. toggleswitch and the setting will appear in the VOLTSwindow.

e. Position 5, Preflow/Postflow (Optional Setup).In this position (5), Gas Preflow (.1 to 99.9 sec.)can be set by the left Inc./Dec. toggle and dis-played in the IPM window. Gas Postflow (.1 to 99.9sec.) is set by the operating the right Inc./Dec.toggle and is displayed in the VOLTS window.These features are adjustable in 0.1 second incre-ments and are shared by both welding schedules.

14

f. Position 6, RUN Schedule I (Must be Set). Thisposition allows you to preset the welding param-eters (IPM/VOLTS) for Schedule I (RUN position).The wire speed rate is set using the left Inc./Dec.toggle switch and the setting will appear in the IPMwindow. The arc voltage requirement is set usingthe right Inc./Dec. toggle and the setting will ap-pear in the VOLTS window. After all preset param-eters have been programmed, the unit is ready toweld.

7. Inc.-Dec. Toggle Switches. Two control toggles areprovided to preset the individual welding param-eters required for the selected welding Schedules(per torch) as follows:

a. “IPM “ Increase/Decrease Control. This toggleswitch is used to set and/or vary the wire feedspeed (IPM), and all of the parameters that appearin the box above the switch, such as; PowerSource selection, Material selection, Preflow, Spotfor both torches, and Inch. With appropriate func-tion selector actuated, each parameter setting willbe displayed in the digital window directly abovethis toggle.

b. “VOLTS” Increase/Decrease Control. This toggleswitch is used to set and/or vary the arc Volts, andall of the parameters that appear in the box abovethe switch, such as; Slope selection, Wire Diam-eter selection, Postflow, Burnback. With the ap-propriate function selector actuated, each param-eter setting will be displayed in the digital windowdirectly above this toggle.

8. Inch-Purge (Reset) Switch (Optional Setup). Thistwo position (momentary “on” contact) switch allowsthe following operation.a. Inch Function. The INCH selection permits cold-

wire inching without energizing the welding circuit.A preset cold wiring inching speed (40 to 999 ipm)can be set and/or changed by operating its Inc./Dec. toggle switch, and this setting (which isindependent of welding wire speed) will appear inthe IPM window. Note that the initial starting speedwill jump to 100 ipm for 2-seconds and then will goto its preset value. This setting is shared by bothtorches.

b. the Gas PURGE (Abort Reset) position providesthe following when actuated:(1) Prior to actual torch triggering, it permits you

to actuate the gas solenoid and PURGE theshielding gas line of the torch. At the sametime, it also lets you adjust the gas regulatorwithout energizing the welding circuit. It alsoallows you to look at a pair of numbers that will

SECTION 3 OPERATION

have a bearing on the quality of starts asexplained in Section 3.4-B-5.

(2) After starting the welding sequence, if an“abort-shutdown” condition occurs (indicatedby a flashing digital display). the RESET posi-tion can be actuated and the control automati-cally “resets” for a new start.

(3) Actuating the Purge (Reset) key during aweld, allows you to check the factory-presetnumbers that determine the quality of the “arcstarts” for each of the four (4) possible welding-conditions. These numbers are displayed inthe IPM and VOLTS windows and representthe optimum arc starting (servo) characteris-tics required for most welding applications.This diagnostic feature is fully explained in thetroubleshooting Section 4.2-G.

3.3 GAS/WIRE ADJUSTMENTSThe following Digimig control functions must be set tofeed wire through the torch conduit and to adjust theshielding gas flow rate.

1. Place Power switch (rear panel) to “on” position toenergize the control.

2. Place key-operated Run-Set switch (rear panel) inSet position.

3. With torch connections made as shown in Fig. 2-1,and wire engaged in accessory support, feed wirethrough torch conduit and into torch as follows:a. Actuate and immediately release the torch switch

lever for the Right Torch/Motor. This action (thruthe control’s switching relay circuitry) sets-up thecontrol to receive the parameter programming forthe Right Torch.

b. Remove nozzle and contact tip from torch.c. Hold Inch-Purge toggle in INCH position until

“cold” wire protrudes from the torch front end.d. Slide the contact tip over the end of the wire and

secure it to the torch. Replace the torch nozzle.e. Reoperate Inch-Purge toggle in INCH position

and check for wire feed slippage on the accessorysupport assembly. Tighten (or loosen) the pres-sure adjusting knob until the wire feeds smoothly.

f. Now, actuate and immediately release the torchswitch lever for the Left Torch/Motor. This action(thru the control’s switching relay circuitry) sets-upthe control to receive the parameter programmingfor the Left Torch, and you can repeat steps b-e.

4. With shielding gas cylinder and torch gas hoseconnection assembled as shown in Fig. 2-1, set gasflow rate as follows:a. Hold Inch-Purge toggle in PURGE position and

open the gas regulator-flowmeter control valveand set the shielding gas flow rate.

15

b. Continue to hold the Purge position for approx. 15seconds to insure adequate purging of each gashose and torch.

5. Place control’s Power switch to “off’ position.

3.4 SETTING UP WELDING PARAMETERS

A. INITIAL SETUP PARAMETERS

1. Set POWER switch (on rear panel) to ON position toenergize Digimig control.

2. Place RUN-SET keylock switch (on rear panel) toSET position to program welding parameters for thetorch. After the desired program (following) has beenpreset, the operator or supervisor is free to weld andmake any changes is in the SET position. The RUNposition locks-in all parameters.

NOTE

The following parameters (#3, #4, and #5) are sharedbetween the two torches and cannot be setup inde-pendently.

SECTION 3 OPERATION

is reached. To feed the cold wire preset, you mustactuate the INCH position of the Inch-Purge (Reset)switch, with the accessory support closed.

4. Set the Rotary switch to Position #1 (Must be set)to select the Power Source and Slope used for yourwelding application as follows:

Remember that this must be correctly set tomatch the Power Source being used and its slopeselection.

a. Power Source: operate the left Inc./Dec. switchuntil the numeral “300”, “450” or “650” appears inthe IPM window. One of these numbers shouldmatch the power source being used: “300” desig-nates an SVI-300i cv/cc; “450” would designate aVI-450 or SVI-450i and “650” would designate a V-650 cv/cc. (see section 3.2-6-a.)

b. Slope: operate the right Inc./Dec. switch to set theappropriate slope characteristic set on your powersource. One of three slope designations will ap-pear in the VOLTS window; #1 for Flat, #3 forMedium, or #6 for Steep Slope. Make sure thefeeder slope number matches the slope se-lected at the power source. (see section 3.2-6-a)

5. You can also select (optional) Trigger Lock-In(see Section 3.2-3A); however, remember whenadded (“on”), both torches are locked in.

B. PROGRAM FIRST (e.g. RIGHT) TORCH

After the initial setup has been completed, you canprogram the welding parameters for the Right torch asfollows:

1. To set-up the “Right” torch program circuitry,actuate and immediately release its trigger switchlever.

2. Set the Rotary Switch to Position #2 (Must be set)to select the wire Material and Wire Diameter usedfor your welding application as follows:

Remember, this must be set correctly to matchthe wire material and diameter being used.

a. Material: operate the left Inc./Dec. switch to setthe wire Material you intend to use. One of threeMaterial designations will appear in the IPM win-dow; #1 for carbon or stainless steel, #2 for 4000series, aluminum, or #3 for 5000 series aluminum.

Pos. #6

3. To set a “cold wire inch speed” parameter (op-tional), open the accessory support (so as not to feedwire) and then raise and hold the toggle of the INCH-PURGE switch. (The IPM display window will imme-diately show a speed setting of 100 ipm for 2-sec-onds, and then the preset rate following). Now, alsoraise and hold the toggle of the "left" Inc/Dec switchin its INC position until the desired inch speed setting(e.g.: 75 ipm) appears in the IPM window. Note thatthe cold inch setting starts at 40 ipm and rapidlyincrements (1 ipm at a time) until the desired setting

Positions#1#2#3#4#5

16

Match the Material number to the wire type beingused. (see 3.2-6-b)

b. Wire Diameter: operate the right Inc./Dec. switchto select the Wire Diameter you intend to use. Oneof five diameter designations will appear in theVOLTS window; #30 for .030" dia., #35 for .035"dia., #45" for .045" dia., #52 for .052" dia., or #63for .063" dia. Match the Diameter number to thewire diameter being used. (see 3.2-6-b)

3. Set the Rotary switch to the RUN (Sch. I) Position#6 (Must be set), and then program the following:a. To set the Wire Feed Speed parameter, raise

and hold the toggle of the "left" Inc/Dec switch in itsINC position until the desired hot wire speed (e.g.:185 ipm) appears in the IPM window. Notice thatthis parameter will start at zero and immediatelyjump to 20 and then will rapidly increment (ipm ata time) until the planned wire speed setting isreached.

b. To set the Arc Voltage parameter, raise and holdthe toggle of the “right” Inc/Dec switch in its INCposition until the desired arc voltage (e.g.: 17.9volts) appears in the VOLTS window. Notice thatthis parameter will start at zero and immediatelyjump to 12 and then will rapidly increment (1/10volt at a time) until the desired arc voltage settingis reached.

4. The following parameters are “optional” func-tions which can also be added to the torch setup:a. A Second Schedule (II). Set the rotary switch to

Position #4, and program another set of conditionsas described in B-3 above and in Section 3.2-6d.

b. Preflow/Postflow function. Set the rotary switchto Position #5, and program as described in Sec-tion 3.2-6e.

c. Spotweld/Burnback function. Set the rotaryswitch to Position #3, and program as described inSection 3.2-6c.

5. Using the torch switch, the parameters for Sched-ules I and II (of the selected torch) can be weld-tested and if necessary readjusted to provide stablestart and welding conditions.

NOTE: The control is designed to provide excellentstarting characteristics with the latest ESABinverter power sources. However, arc startingcan be affected by many external factors suchas cable length, type of torch used (water ver-sus gas cooled), shielding gas, condition ofweldment, type of welding wire, etc. To mini-mize the effect of these variables, a simpleadjustment will allow you to increase or de-

SECTION 3 OPERATION

crease the initial arc striking voltage to optimizestarting. The following procedure (5-A) allowsyou to make this correction.

5A. Setting Controller For Optimum Starts.

1. Increase Starting Voltage;a. Prior to striking the arc, depress the Purge key on

the right side of the feeder. This can be done ineither the RUN (Sch. I) or Sch. II mode of theRotary switch.

b. Initially, the display in both windows will show thenumber 100. This number has an adjustmentrange of 0 to 200, so that 100 is right in the middleof the range.

c. To increase the starting voltage by 1-volt, thenumber in the right (VOLTS) window must beincreased to 105 using its Inc./Dec. key.

d. To see if this adjustment is adequate, start a newweld and observe the start. If it is still not “hot”enough, increase the adjusted number until thestarts are optimized.

e. The number in the left (IPM) window controls initialmotor speed and, in most cases, the number 100will work well for the whole speed range.

2. Decrease Starting Voltage.a. Follow the same procedures outlined above (in 1),

but instead of increasing the numbers decreasethem until the starts are optimized.

Please note that if either schedule for either torchrequired a voltage adjustment to the present con-dition, you will more than likely require additionaladjustments when a different condition is used.

C. PROGRAM REMAINING (e.g. LEFT) TORCH

If you wish to program a different set of conditions for theremainng (or left) torch, simply “click” its trigger switchlever and then repeat the procedures outlined in thepreceding section B-2 through B-5.

3.5. WELDING OPERATION

After the desired welding modes have been weld-tested(with control to SET position) and satisfactory resultsachieved, the program parameters can be "lock-in" byplacing the key switch in the RUN (Lock-In) position. Inthe Lock-In position, and the key removed, none of thepreset parameters can be changed.

CAUTION: Power source contactor becomes ener-gized the moment the torch trigger is de-

17

SECTION 3 OPERATION

shutdown if preset wire speed or arc voltage parameterscannot be maintained due to an abnormal condition. Ifthis occurs, the parameter causing the system shut-down will be signaled by a flashing digital displaywindow. To clear the shutdown/abort, activate the RE-SET position of the Inch-Purge (Reset) switch on thefront panel.

To stop welding if the Trigger-Lock-In feature isactuated (on), simply repress the torch switch leveragain and all welding action will cease.

Whenever you wish to change torches for a different setof welding conditions, simply stop welding with onetorch and energize the torch switch lever of the othertorch to actuate its programmed circuitry.

B. SPOTWELDINGRemember, if a spotwelding operation is desired, theSpot-weld-time can be programmed into either Sched-ule (I or II) for either or both torches; and that whenprogrammed, the ”click-click” feature for changing sched-ules cannot be used as it was for “continuous-type”welding operations. To change schedules forspotwelding, you must manually reposition the Rotaryswitch selector to the desired Schedule (I or II) for thattorch.

To start a spotweld operation; close the torch switchto energize gas flow, weld contactor, wire feed motorand start spot timing cycle. The torch switch must bedepressed during the entire weld period. After the spottiming cycle is completed; all welding action, exceptauto-antistick or burnback and postflow will stop whenthe torch lever is released.

To resume normal (continuous) welding operation inSchedule I and II for either or both torches, you mustdeactivate the Spot mode by resetting each “timed-arc”parameter back to zero (000).

Do not allow metal-to-metal contact between thewire feeder chassis and a metal surface connectedin any way to a welding ground. With such contact,a poor welding ground connection may create adifference In potential that sends part of the weldingcurrent through the safety ground wiring, resultingin burnout of that wiring and/or damage to the feedercircuitry. If the safety ground burns out, the operatormay be exposed to 115-volt shock hazard.

Positions

Pos. #6

#1#2#3#4#5

pressed. Arcing can occur if the wire touchesa ground. Keep torch away from metalground until welding is to begin.

A. WELDINGAssuming that both Schedules (I and II) for each torchhave been preset per section 3.4, the operator simplyplaces the ROTARY switch to the schedule (I or II) hechooses to use first.

To start welding, select either of the two torches andclose its torch switch lever to utilize the previouslyselected welding Schedule (I or II)—please rememberthat if gas preflow time is programmed, the arc will notestablish until the preflow has timed-out. If during the“selected” schedule welding, the torch switch lever isreleased and reactivated within 2/10 of a second, themicroprocessor will automatically switch the control tothe "remaining" schedule parameters for the selectedtorch. Using this simple “click-click” (off-on) cyclingaction, the operator can easily shift back and forthbetween Schedules I and II by sequencing the torchlever within the 2/10 second time frame.

Remember, if Trigger-Lock-In is actuated, it automati-cally overrides the alternate Schedule and/or Spotweldfunction if programmed (see 3.2-3a).

To stop welding, (w/o Trigger-Lock-In), simply re-lease the torch switch lever and do not reactivate (allservices will shutdown except auto-antistick or manualburnback and postflow). After welding has been stopped,the control will always recycle back to the “selected”schedule welding parameters. The system will also

18

SECTION 4 TROUBLESHOOTING

4.1 TROUBLESHOOTING

Listed below are a number of trouble symptomseach followed by the checks or action suggested todetermine the cause. Listing of checks and/or ac-tions is in “most probable” order but is not neces-sarily 100% exhaustive. Always follow this generalrule: Do not replace a printed circuit (PC) board untilyou have made all the preceding checks. Alwaysput the Power switch in off position before remov-ing or installing a PC board. Take great care not tograsp or pull on components when removing a PCboard. Always place p. c. boards on a “static-free”surface. If a printed circuit (PC) board is determinedto be the problem check with your ESAB supplier fora trade-in on a new PC board. Supply the distributorwith the part number of the PC board as well as theserial number of the wire feeder. Do not attempt torepair the PC board or any other component your-self. Warranty on a PC board or control will be nulland void if repaired by customer or an unauthorizedrepair shop.

4.2 TROUBLESHOOTING GUIDE

A. General1. Check interconnection between digimig control and

power source. Make sure that the contactor andvoltage control switches are placed in the Remoteposition.

2. Energize the power source and the control.3. Immediately after the control is turned “on”, a number

will appear in the IPM and VOLTS readout windowand will only be displayed for 1-second. This numberidentifies the current program (E-Prom) used in yourcontrol. When a Program is changed, the new E-Prom will automatically identify the new programnumber being used. If a revision is made to anexisting program a number .1, .2, .3, etc. indicatingthe numerical revision will also appear in the VOLTSreadout window simultaneously. Then, the PowerSource and Slope settings will flash for 3 seconds.

4. After the four (4) second delay; the preset “Weld”parameters for the “Right-Side” Torch will be dis-played in the IPM and VOLTS windows.

5. If the control is not functioning properly (or as de-scribed above); for example, the numbers that ap-pear in one or both of the display windows aremeaningless (all zeroes, eights, decimals, etc.), orare completely incorrect in relation to your settings,—the memory must be cleared. This condition mightoccur after a bad lightning storm, extremely badpower line surge, etc. To clear the memory, do thefollowing:

a. Place the Run-Set key switch in its SET position.b. Turn “off” the unit’s 115-volt Power switch.c. Using one hand, hold both of the Inc/Dec toggle

switches in their INC position while reapplying110-volt power with the other hand.

d. Almost immediately after the Power has beenturned “On”, release the Inc/Dec toggle switchesto the neutral (spring-return center) position andeach of the windows should display one zero,indicating a successful reset or clearing has takenplace.

6. You can now enter the desired information as de-scribed in this booklet.

B. No preset displays appear in windows.1. Make sure the LED Display board harness/plug is

plugged into the P5 receptacle on the MPU board.2. Check that 110 vac is available across terminals T1-

18 and T1-19, if present;3. Check for plus (+) 5 volts between terminals T1-8 and

T1-9; if voltage is present, replace the MPU board. Ifvoltage is not present, check the voltage regulator(VR). The voltage regulator is located on the rearpanel of the control box.

4. Check the input and output voltage of the regulator“VR”.a. The input should be approx. 11 volts between VR-

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

b. The output should be + 5 volts between terminalsT1-8 and T1-9. If voltage is not present, replaceVR, voltage regulator.

C. Preset display is provided, but cannot be varied.1. Check normal setup procedures described in Section

VI, then;2. Make sure the Inc/Dec key harness plug is properly

connected to receptacle P6 on the MPU board andthe lock-in key switch is placed in its SET position.

3. If neither of the above resolve the problem, replacethe MPU board.

D. Motor does not run.1. Check to make sure all required accessories are

correctly assembled as described in Section IV.2. Make sure that power source is connected, plug P2

is securely connected to receptacle P2 on theDigimig’s I/0 Board, and then release the clapper arm(pressure roll) on the Accessory Support Assembly.a.Operate the Digimig INCH switch. If motor does

not run; replace the “J” governor board, and if it stilldoes not run, replace I/O and MPU boards respec-tively.

19

b.If the motor inches, but does not run when the torchswitch is operated (energized), check the torchswitch circuit components—switch, plug, recep-tacle, etc. If motor still does not run, check if powersource is providing open-circuit voltage to theDigimig — if o.c.v. is not being supplied, motor willnot run. Check the power source for trouble.

c.Also check that +/- 12 volts d.c. are providedfrom the power source on T1-7 and T1-5respectively.

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

E. Motor runs, but not at right speed.1. Check tachometer assembly mounted on the end

of EH-10A wire feed motor.2. Make sure the tach disc is securely fastened to the

motorshaft and that the strobe markings are notscratched. Check that the disc is properly centeredin the strobe pickup on the p.c. board.

3. If all items in step 2 are in order, and motor speedis still incorrect, replace MPU board.

F. Arc VOLTS display reads zero after TS Is oper-ated.

1. Check that the 5-pin plug is securely connected to theP3 receptacle on the MPU board

2. If no reading is displayed, check for arc voltagefeedback between terminals TP1 and TP2 test pointson the I/0 board (see Fig. 4-1). This voltage signalshould correspond to that shown on the power sourcevoltmeter.

3. If voltage still reads zero, trace the voltage pickupwiring from the power source to digimig.

4. Remove the J-Gov. p.c. board to gain access to theP3 plug (harness) on the MPU p.c. board. Disconnectthe P3 plug from its MPU board socket and, using ameter check for +/-12 volt power supply output be-tween plug pins P3-1 and P3-2 (for +12 v.) andbetween plug pins P3-4 and P3-2 (for -12 v.) respec-tively. If voltage is present, replace the MPU board.

G. Control Shut Down — either preset VOLTS or IPMdisplays will flash. The control will flash the param-eter, VOLTS or IPM, that cannot be maintained.

If this condition occurs, the respective speed andvoltage conditions (servos) need to be checked foreach of the four (4) possible schedules and, if neces-sary, readjusted as follows:

1. This symptom can of occur as a result of either or allof the following; the factory-set Speed and Voltage(servo) adjustments are incorrect and the conditions

TP2TP1

Fig. 4-1 - Input/Output (110) P.C. Board

“set” may not be maintainable. To check and, ifnecessary, readjust the servos — proceed as fol-lows:

NOTE: Prior to checking the servos, make sure theDigimig is connected to suitable ESAB powersource in order to obtain the necessary o.c.v.(open circuit voltage); otherwise, the motor willnot run.

2. The factory-set Speed and Voltage (servos) adjust-ments in this control are simultaneously checked anddisplayed by actuating and holding the front-panelPurge (Reset) key position during an actual weldwith the wirefeed motor running. The speed servonumber is displayed in left (IPM) window and shouldbe about 110, and the right (VOLTS) window willdisplay the voltage servo number. This number willbe between 90 and 100* for the actual weldingcondition.

* Voltage servo setting below 95 will normally pro-vide hot arc starts; whereas, setting over 100 willnot.

3. If a Speed abort had occurred (IPM window flashing),check and/or adjust the speed (servo) as follows:

Open the pressure roll clapper (so as not to feedwire), actuate the Purge (Reset) switch position andclose the torch switch lever. Check the number in theIPM window — it may appear unsteady but readableand should be about 110.

If it is higher or lower, use the Inc/Dec toggle (belowthe IPM window) to adjust the number to 110 - while“holding” the Purge (Reset) toggle as mentionedabove and while the wire feed motor is running.


20


If the speed servo cannot be adjusted at all, theproblem may be in the J-Governor, and/or I/O, and/orMPU p.c. boards which need to be replaced asrequired.

4. If a Voltage abort had occurred (VOLTS windowflashing), check and/or adjust the voltage (servo) asfollows:

This is a two man operation. Set a welding conditionwhich closely corresponds to your welding applica-tion and the proper speed (ipm) for a given wire sizeand then — close the torch switch and strike awelding arc. While welding, actuate the Purge (Re-set) switch position, and read the number displayedin the VOLTS window, it may appear unsteady butreadable and should be 95.

If the number is not in the 90-100 range, use the Inc/Dec toggle (below the VOLTS window) to adjust thenumber to 95 — while “holding” the toggle positionsmentioned above and while welding.

5. If the voltage servo cannot be adjusted, check forproper operation of the power source as follows:

a. Set the Digimig voltage display to zero (this settingwill override the servo).

b. Place the Panel/Remote switch on the powersource in PANEL position.

c. Make a weld by controlling the arc voltage directlyfrom the power source potentiometer.

d. If a weld can be made with good control over powersource voltage; a problem exists either in the inter-connecting voltage control cable, or in the Digimigcontrol.

e. Check the control wires in the interconnectingvoltage control cable for continuity between theappropriate terminals in the power source anddigimig using the schematic diagrams.

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

H. Control Shut-Down Due to Ground Fault Detec-tion — both IPM and VOLTS displays will flash.

The purpose of this circuit is to make sure that weldingcurrent is not present in the wire feeder frame/base,control box, or the equipment safety ground. If thisshould occur, the ground fault detector will temporarilyenergize and immediately terminate the weld. Thisabort is indicated by both visual displays flashing simul-taneously. — Before attempting to make a new weld,make sure that the Work Ground cable and its connec-tions are properly and securely made to the workpiece.

21


Fig.

4-1

. Sch

emat

ic D

iagr

am -

Dua

l Dig

imig

3091

4-L

22

SECTION 4 TROUBLESHOOTING30

915-

N

Fig

. 4-2

. Wiri

ng

Dia

gram

- D

ual D

igim

ig

23

SECTION 5 MAINTENANCE

SECTION 6 REPLACEMENT PARTS

6.1 GENERAL

Replacement Parts are illustrated on the following fig-ures. When ordering replacements parts, order by partnumber and part name, as illustrated on the figure. DONOT ORDER BY PART NUMBER ALONE.

Always provide the series or serial number of the unit onwhich the parts will be used. The serial number isstamped on the unit nameplate.

6.2 ORDERING

To assure proper operation, it is recommended that onlygenuine ESAB parts and products be used with thisequipment. The use of non-ESAB parts may void yourwarranty.

Replacement parts may be ordered from your ESABdistributor or from:

ESAB Welding & Cutting ProductsAttn: Customer Service Dept.PO Box 100545, Ebenezer RoadFlorence, SC, 29501-0545

Be sure to indicate any special shipping instructionswhen ordering replacement parts.

To order parts by phone, contact ESAB at 1-803-664-5540 or 4460. Orders may also be faxed to 1-800-634-6548. Be sure to indicate any special shipping instruc-tions when ordering replacement parts.

Refer to the Communication Guide located on the lastpage of this manual for a list of customer service phonenumbers.

5.1 GENERAL

If this equipment does not operate properly, stopwork immediately and investigate the cause of themalfunction. Maintenance work must be performedby an experienced person, and electrical work by atrained electrician. Do not permit untrained personsto inspect, clean, or repair this equipment. Use onlyrecommended replacement parts.

5.2 INSPECTION AND CLEANING

A. GENERAL MAINTENANCELittle maintenance is required to keep the wire feeder intop operating condition. It is important, however, thatmoving parts such as feed and pressure rolls, wire feedmotor, etc., be kept clean and free of dust or dirt.Cleaning is best accomplished by regularly blowing offthese parts with dry compressed air. This should bedone once for every eight hours of operating time, moreoften if necessary.

B. LUBRICATION OF DIGITAL MOTOR-GEAR UNITThe EH-10A motor-gear digital unit is lubricated with aheavy duty grease when assembled at the factory andshould not require further lubrication unless disas-sembled. If disassembled relubricate with TexacoMultifak grease.

C. CHECK OR REPLACEMENT OF MOTOR BRUSHESMotor brushes should be checked periodically. If abrush is broken, or worn down to less than 3/8-in. length,

it must be replaced. Brushes can be inspected byunscrewing the brush-holder plug and withdrawing thebrush assembly. Never remove a brush withoutmatchmarking it and its holder, so that it can be replacedin the same holder in its original position.

D. REMOVAL OF EH-10A DIGITAL WELDING HEAD1. Unplug the control cable from the rear panel of the

wirefeeder control.2. Remove the accessory support assembly from the

motor-gear unit by loosening the cap screw at thebottom of the assembly.

3. Disconnect the motor and tachometer cables fromterminal board (T1) inside the control assembly asshown on the wiring diagram.

4. Remove the four screws which secure the digitalmotor-gear unit to the base and remove the digitalunit.

E. ADDITIONAL DIGIMIG PROGRAM FEATURESThe Digimig’s MPU board contains an integral 4-rocker“dip” switch (SW1) that is factory-set to the followingpositions: Rocker #1, #2, 3, 4 are all OPEN. Themicroprocessor technology utilized by the Digimig con-trol is extremely versatile and can be modified forspecific purpose by ESAB’s engineering services group.To add specific features or programs to your unit,consult your ESAB representative. If additional optionalfeatures are provided, the SW1 rocker positions mayneed to be repositioned — and this information will beconveyed in the appropriate instruction booklets pro-vided with the option kits.

24


RIG

HT TO

RC

H (J3) R

ECEPTAC

LE-182W

64(C

10, 11) CAPAC

ITOR

672348

CO

VER - 30170*

WAR

NIN

G D

ECAL - 2091514*

WAR

NIN

G D

ECAL - 995204*

(2) EH-10A D

IGITAL M

OTO

R-G

EARU

NIT ASSY. 679777 (See Fig. 6)

BASE - 678806

LEFT TOR

CH

(J4) REC

EPTACLE -

182W64

C16 C

APACITO

R672348

(2) ACC

ESSARY SU

PPOR

T ASSY.2 R

OLL D

RIVE (See Fig. 8) - 49V51

FRO

NT C

ON

TRO

L SUPPO

RT - 30917

(SW1, 3, 5) SW

ITCH

- 950087

LIFTING

BRAC

KET - 30916

CO

NTR

OL ASSY.

30913 (see Fig. 7)

6-POS. R

OTAR

Y SW. - 679914

Fig. 6-1. DigiMig Dual Wire Feeder, P/N 30912 (Front View)

25


KNO

CKO

UT

OPT

ION

ALW

ATER

CO

NN

ECTI

ON

S (S

ee F

ig.

10)

REA

R C

ON

TRO

L SU

PPO

RT

6788

02

(2)

SPIN

DLE

ASS

Y.94

8259

(Se

e Fi

g. 9

)

POW

ER C

ABLE

AD

APTO

R B

LOC

K -

6741

561/

2-IN

.-13

STL.

NU

T1/

2-IN

. LO

CKW

ASH

ER(2

) 1/

2-IN

. FL

ATW

ASH

ER

(2)

REE

L SU

PPO

RT

- 63

4288

Not

Illu

stra

ted

— A

ccy.

Sup

port

INSU

LATO

R R

ING

- 6

0N90

Key

- 28

N33

THU

MBS

CR

EW -

613

5108

7FL

ATW

ASH

ER -

643

0943

1BE

LLEV

ILLE

WAS

HER

- 9

5078

3

*R

epla

ce d

ecal

if

it be

com

es e

xces

sive

lyw

orn

or lo

st w

hen

repl

acin

g pa

nel(s

)

Rec

omm

ende

d Sp

are

Parts

Rep

lace

men

t ke

y fo

r R

un-S

et S

W -

327

78

(J1)

REC

EPTA

CLE

- 9

5076

2 (1

9-pi

n)C

20 C

APAC

ITO

R -

.1u

f, 50

0 V

(CB)

CIR

CU

IT B

REA

KER

-95

0874

(MSL

) PO

WER

ON

-OFF

SW

6345

17

STR

AIN

REL

IEF

- 96

W76

RU

N-S

ET S

W -

950

956

(2)

GAS

INLE

T C

ON

NEC

TIO

N -

74S

76

(2)

GAS

SO

LEN

OID

VAL

VE -

206

2305

(2)

GAS

BU

LKH

EAD

AD

APTO

R -

58V

58

(VR

) VO

LTAG

E R

EGU

LATO

R i

nclu

des:

VOLT

AGE

REG

ULA

TOR

- 9

5015

9TR

ANSI

STO

R S

OC

KET

- 95

0158

(C4)

CAP

ACIT

OR

- 9

9554

4

(SW

) TR

IGG

ER-L

OC

K -

9504

92

Fig. 6-1. DigiMig Dual Wire Feeder, P/N 30912

26

(2) CARBON BRUSHREPLACEMENT KIT - 679784Includes:(2) BRUSH CAP(2) CARBON BRUSH

BRUSH

CAP

GEAR ASSY. "A" 20292

ARMATURE & BEARINGS19726

Includes:ARMATURE BEARINGS 20288

ARMATURESHAFT SEAL

OUTPUT GEAR CASEGASKET

OUTPUT SHAFT SEAL

OUTPUT GEAR CASE19734 (Includes OutputShaft Assy. Shown Above)

OUTPUT SHAFT ASSY. (Part of 19734- OUTPUT GEAR CASE

GEAR ASSY. "B" - 20293

MAGNET ASSY. 19730

11 BRUSH END BELL - 19732(Includes TWO BRUSHHOLDER ASSYS.)

MOTOR CORD LEAD - 19731BRUSH HOLDER

GASKET/SEAL KIT - 20542(Includes those itemsmarket with)

Fig. 6-3. EH-10A Motor-Gear Unit Parts Breakdown

TACH. P.C.B.D.675429(2) Screw-61324746

Gear Case Lubricated withTexac Multifak Grease

11.6

2.370

.93

.6251

MOTOR ENDHOUSING

(Ref.) 54"LG

10

2.875

50DP

MIN.

VENT PLUG

3.25

2.000

5.16 18 UNC 2B

2.86

.25

4.010 SQ.2.25

1.375 1.375

.25

END VIEWw/COVER REMOVED 63 MIN. DEPTH

MTR.LEAD

TACH DISK950313

.020REF

TACH HOUSING - 18786(2) 8-32 X 3/8" Screw

33 LOCATING COLLAR(REF.)

TACH COVER - 18787(2) Screws 61324974

FOR MOTOR REPLACEMENTPARTS (See Fig. 6-3)

Fig. 6-2. EH-10A Digital Motor-Gear Unit Assembly (40:1) P/N 679777


27


Fig. 6-4 DigiMig Dual Control Assembly, P/N 30913

(GR

F) SENSO

R - 950448

(Mtd. on C

abinet Base)

(MPU

) P/C BD

. ASSY. - 18163

"J" GO

V P/C BO

ARD

ASSY. - 994236 (See Note)

MTG

Bracket 995297(P1) R

eceptacle 636608

(RLY) R

ELAY - 951089 C

21, C22 - C

APACITO

R - .1uf, 500 V

BR-R

ECTIFIER

- 2 Amp., 400 V - 635152

(I/0 P4 To MPU

P2 CABLE ASSY. 677938

For Replacem

ent Battery (on I/O Board), order P/N

951733(I/0) P/C

BOAR

D ASSY. - 674956

(CTR

1) BOT. C

ON

T. TRAN

SFOR

MER

- 950088

*R

eplace decal if it becomes

excessively worn or lost.

Recomm

ended Spare Parts

(CTR

2) TOP C

ON

T. TRAN

SFOR

MER

- 994303

(T1) 20 PT. Terminal

Strip - 950182

NOTE:The heat sinks of the "J" gov. board are electrically hot. D

oN

OT touch or ground w

hile unit is energized.

DISPLAY P/C

BOAR

D

ASSY. - 675269

(FN1) FILTER

NETW

OR

K - 996918

(R1) R

ESISTOR

- 17240003 (25W

, 3 Ohm

)

WAR

NIN

G D

ECAL -

995164*

28

CONDUIT

OUTLET

CLAMP - 61N02

SCREW 5/16" -18 X 2" LG

NUT 5/16"-18

ROLL PIN 3/16" X 1-3/4" LG

INLET

Fig. 6-5. Accessory Support Assembly, P/N 49V51

HEAVY SPRING - 182W54 (FOR LARGE DIA. HARD WIRE)

PRESSURE ROLL28V52

BOLT 1/4" x 1-5/8"LGSPACER - 60N79

(2) LOCKING HANDLE ASSEM - 49V44

SET SCREW # 6-32 X 1/4" LG61330849

WIPER HOLDER*598764

INLET GUIDE INSERT05N58

INLET WIRE GUIDE29N13

ROLL PIN 1/4" X 1-3/4" LG

CLAPPER - 60N98 SHAFT - 60N65

KNOB - 60N68

LIGHT SPRING 182W55 (FORSOFT & SMALL DIA. HARD WIRE)

RETAINER 58N24

FORK - 49V43

*Outlet guide And Wiper Holder Not Included in Assembly Part No. 49V51.

INCLUDES:

SUPPLIED

WIRE OUTLET GUIDE*(See Table 1)

WIRE OUTLET GUIDE INSERT*

SPINDLE - 948258

"D" TYPEWASHER - 948254

SCREW -5/16" -18 x 2"

HAIR PINCLIP - 634347

WASHER -948256

SUPPORT -948257

SPRING - 948253

(2) BRAKE PAD - 948255

(4) .359" DIA. HOLE ON 3" DIA. D.C.

REEL

(Ref. Hair Pin Clip)

WIRE REEL - 995570Includes:REEL - 995568COVER - 995569(4) WING NUT, 1/2" - 1363398183

COUPLING - 68121075

ADAPTOR - 11N16(INLET)

5/8 -18 Lh

WITHOUT SOLENOID VALVE

1/4 N.P.T.5/8 -18 Lh

Fig. 6-7. Water Kit, P/N 994466

SPINDLE

Fig. 6-6. Spindle Assembly, P/N 948259,Optional Wire Reel, P/N 995570


WATERCONNECTION58V75(OUTLET)

29

NOTES

30

NOTES

31

INSTRUCTIONS for F-15-286 December,

1995

REMOTE CONTROL KITItem No. 36010

For V 452, V 582, V 652cvcc and V 782cvcc Power Sources

This kit, when installed, permits the use of the HC-3BRemote Pendant Control (I/N 33838) with the powersource.

To Install, proceed as follows:

Before installing this kit, make sure all primary in-put power to the power source is disconnectedand/or lock out procedures are in place.

1. Remove the left side panel of the power source.2. Remove the plastic cover from the REMOTE CON-

TROL location on the front panel of the powersource.

3. Remove the two screws from the upper corners ofthe control panel on the power source and openthe control panel.

4. Install the 14-pin receptacle into the front panelfrom the inside and secure with the four screwsprovided with the kit.

5. Locate the control leads access grommet to thecontrol panel. Insert the connector from the 14-pin receptacle through this grommet. Route theleads along with the other control leads and se-cure with tie-wraps provided with the kit.

6. Connect the connector from the 14-pin receptacleto the J4 header on the control PC board (seeFig. 1). Make sure the connector is firmly con-nected.

7. Reinstall left side panel and the upper control panel.The power source is now ready to operate withthe HC-3B Remote Pendant Control.

Fig. 1. Control Board Assembly (located behind Control Panel)

J4 Header

F-14-489-C 09/2003 Printed in U.S.A.

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123 Fax: (843) 664-4452

Hours: 7:30 AM to 5:00 PM EST

orvisit us on the web at http://www.esabna.com

The ESAB web site offersComprehensive Product Information

Material Safety Data SheetsWarranty Registration

Instruction Literature Download LibraryDistributor Locator

Global Company InformationPress Releases

Customer Feedback & Support

A. CUSTOMER SERVICE QUESTIONS:Telephone: (800)362-7080 / Fax: (800) 634-7548 Hours: 8:00 AM to 7:00 PM ESTOrder Entry Product Availability Pricing Order Information Returns

B. ENGINEERING SERVICE:Telephone: (843) 664-4416 / Fax : (800) 446-5693 Hours: 7:30 AM to 5:00 PM ESTWarranty Returns Authorized Repair Stations Welding Equipment Troubleshooting

C. TECHNICAL SERVICE:Telephone: (800) ESAB-123/ Fax: (843) 664-4452 Hours: 8:00 AM to 5:00 PM ESTPart Numbers Technical Applications Specifications Equipment Recommendations

D. LITERATURE REQUESTS:Telephone: (843) 664-5562 / Fax: (843) 664-5548 Hours: 7:30 AM to 4:00 PM EST

E. WELDING EQUIPMENT REPAIRS:Telephone: (843) 664-4487 / Fax: (843) 664-5557 Hours: 7:30 AM to 3:30 PM ESTRepair Estimates Repair Status

F. WELDING EQUIPMENT TRAININGTelephone: (843)664-4428 / Fax: (843) 679-5864 Hours: 7:30 AM to 4:00 PM ESTTraining School Information and Registrations

G. WELDING PROCESS ASSISTANCE:Telephone: (800) ESAB-123 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products, Florence, SC Welding EquipmentCOMMUNICATION GUIDE - CUSTOMER SERVICES

DIGIMIG DUAL WIRE FEEDER - esabna.com - f14-999/digimig...3 WARNING: These Safety Precautions are...

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