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WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

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 andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a 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.Bystanders 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 ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. 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.

SAFETY PRECAUTIONS

10/98

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 tomake certain there are no hot sparks or hot metal whichcould cause a later fire. Use fire watchers when neces-sary.

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

ELECTRICAL SHOCK -- Contact with liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto the ground system of the input power.

2. Connect the workpiece to a good electrical ground.3. Connect the work cable to the workpiece. A poor or

missing connection can expose you or others to a 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 workingin tight quarters or a damp area; stand on dry boards oran insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)for specific grounding recommendations. Do not mis-take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —May be dangerous. Electric current flow-ing through any conductor causes lo-calized Electric and Magnetic Fields(EMF). Welding and cutting current cre-ates EMF around welding cables andwelding machines. Therefore:

1. Welders having pacemakers should consult their physi-cian before welding. EMF may interfere with some pace-makers.

2. Exposure to EMF may have other health effects which areunknown.

3. Welders should use the following procedures to minimizeexposure 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.

3

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 posi-tive mechanical ventilation is provided. Do not breathefumes from these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant 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 im-prove ventilation in the work area. Do not continue tooperate if physical discomfort persists.

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

5. WARNING: This product, when used for welding 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 injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap 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. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand 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 installa-tion, troubleshooting, and maintenance work. Do notperform any electrical work unless you are qualified toperform such work.

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

3. Maintain cables, grounding wire, connections, powercord, and power supply in safe working order. Do notoperate any equipment in faulty condition.

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

5. Keep all safety devices and cabinet covers in positionand in 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 elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

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

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

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

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

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

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

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

Welding and Cutting of Containers That Have HeldHazardous Substances."

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

Means immediate hazards which, ifnot avoided, will result in immediate,serious 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.

SP98-10

4

a. Éloigner suffisamment tous les matériaux combus-tibles du secteur où l’on exécute des soudures ou descoupes à l’arc, à moins de les recouvrir complètementd’une bâche non-inflammable. Ce type de matériauxcomprend notamment le bois, les vêtements, la sciure,l’essence, le kérosène, les peintures, les solvants, legaz naturel, l’acétylène, le propane et autres sub-stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-cent peuvent tomber dans des fissures du plancher oudans des ouvertures des murs et y déclencher uneignition lente cachée. Veiller à protéger ces ouverturesdes étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérationsde gougeage ou autres travaux à chaud à la surfacede barils, bidons, réservoirs ou autres contenantsusagés, avant de les avoir nettoyés de toute trace desubstance susceptible de produire des vapeursinflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, ilconvient de disposer d’un matériel d’extinction prêt àservir immédiatement, tel qu’un tuyau d’arrosage, unseau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteurde façon à vous assurer qu’aucune étincelle ou projec-tion de métal incandescent ne risque de provoquerultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arcau plasma exige l’emploi de tensions à viderelativement importantes; or, celles-ci risquent decauser des dommages corporels graves et mêmemortels en cas d’utilisation inadéquate. La gravité duchoc électrique reçu dépend du chemin suivi par lecourant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-sion venir au contact direct de la peau ou devêtements humides. Veillez à porter des gants biensecs.

b. Si vous devez effectuer un travail sur une surfacemétallique ou dans un secteur humide, veillez à assu-rer votre isolation corporelle en portant des gants secset des chaussures à semelles de caoutchouc et envous tenant sur une planche ou une plate-formesèche.

c. Mettez toujours à la terre le poste de soudage/coupageen le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Nesurchargez jamais le câble. Utilisez toujours unéquipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas enservice. une mise à la masse accidentelle peut en effetprovoquer une surchauffe de l’équipement et un dan-ger d’incendie. Ne pas enrouler ou passer le câbleautour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce enun point aussi proche que possible de la zone detravail. Le branchement des câbles de masse àl’ossature du bâtiment ou en un point éloigné de lazone de travail augmente en effet le risque depassage d’un courant de sortie par des chaînes de

PRÉCAUTIONS DE SÉCURITÉAVERTISSEMENT: Ces règles de sécurité ont pour objetd’ assurer votre protection. Veillez à lire et à observer lesprécautions énoncées ci-dessous avant de monter l’équipement ou de commercer à l’utiliser. Tout défautd’observation de ces précautions risque d’entraîner desblessures graves ou mortelles.1. PROTECTION INDIVIDUELLE-- Les brûlures de la

peau et des yeux dues au rayonnement de l’arcélectrique ou du métal incandescent, lors du soudageau plasma ou à l’électrode ou lors du gougeage àl’arc, peuvent s’avérer plus graves que cellesrésultant d’une exposition prolongée au soleil. Aussiconvient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaquesprotectrices et des verres filtrants appropriés afin devous protéger les yeux, le visage, le cou et les oreillesdes étincelles et du rayonnement de l’arc électriquelorsque vous effectuez des soudures ou des coupesou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximitéde façon à ce qu’elles ne regardent pas l’arc et à cequ’elles ne s’exposent pas à son rayonnement, ni àcelui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tuniqueépaisse à manches longues, des pantalons sansrebord, des chaussures à embout d’acier et uncasque de soudage ou une calotte de protection, afind’éviter d’exposer la peau au rayonnement de l’arcélectrique ou du métal incandescent. L est égalementsouhaitable d’utiliser un tablier ininflammable defaçon à se protéger des étincelles et du rayonnementthermique.

c. Les étincelles ou les projections de métal incandes-cent risquent de se loger dans des manchesretroussées, des bords relevés de pantalons ou dansdes poches. Aussi convient-il de garder boutonnés lecol et les manches et de porter des vêtements sanspoches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arcélectrique les autres personnes travaillant à proximitéà l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécuritélorsque vous vous trouvez dans un secteur où l’oneffectue des opérations de soudage ou de coupage àl’arc. Utilisez des lunettes de sécurité à écrans ouverres latéraux pour piquer ou meûler le laitier. Lespiquetures incandescentes de laitier peuvent êtreprojetées à des distances considérables. Lespersonnes se trouvant à proximité doivent égalementporter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasmaproduisent un niveau de bruit extrêmement élevé (de100 à 114 dB) et exigent par conséquent l’emploi dedispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections delaitier incandescent ou d’étincelles peuventprovoquer de graves incendies au contact dematériaux combustibles solides, liquides ou gazeux.Aussi faut-il observer les précautions suivantes:

9/97

5

levage, des câbles de grue ou divers cheminsélectriques.

g. Empêchez l’apparition de toute humidité, notammentsur vos vêtements, à la surface de l’emplacement detravail, des câbles, du porte-électrode et du poste desoudage/coupage. Réparez immédiatement toutefuite d’eau.

4. VENTILATION-- La respiration prolongée des fuméesrésultant des opérations de soudage/coupage, àl’intérieur, d’un local clos, peut provoquer des mal-aises et des dommages corporels. Aussi convient-ild’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate del’emplacement de travail en maintenant une ventila-tion naturelle ou à l’aide de moyens mécaniques.N’effectuez jamais de travaux de soudage ou decoupage sur des matériaux de zinc, de plomb, deberyllium ou de cadmium en l’absence de moyensmécaniques de ventilation capables d’empêcherl’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou decoupage à proximité de vapeurs d’hydrocarburechloré résultant d’opérations voisines de dégraissageou de pulvérisation. La chaleur dégagée ou lerayonnement de l’arc peut déclencher la formation dephosgène -- gaz particulièrement toxique -- et d’autresgaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de lagorge constatée au cours de l’utilisation del’équipement dénote un défaut de ventilation. Arrêtez-vous de travailler afin de prendre les mesures néces-saires à l’amélioration de la ventilation. Ne poursuivezpas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisationsoù circule de l’hydrogène. L’armoire de commande estmunie d’un ventilateur destiné à empêcher la forma-tion de poches d’hydrogène, lesquelles présentent undanger d’explosion; ce ventilateur ne fonctionne quesi l’interrupteur correspondant du panneau avant setrouve placé en position ON (Marche). Veillez àmanœuvrer cette commande en vérifiant si lecouvercle est bien en place, de façon à assurerl’efficacité de la ventilation ainsi réalisée. Ne jamaisdébrancher le ventilateur.

e. Les fumées produites par l’opération de soudage oude coupage peuvent s’avérer toxiques. Aussi est-ilnécessaire de disposer en permanence d’un dispositifadéquat de ventilation de type aspirant, afin d’élimi-ner du voisinage de l’opérateur tout dégagement defumée visible.

f. Consultez les recommandations particulières enmatière de ventilation indiquées à l’alinéa 6 de lanorme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipemententretenu de façon défectueuse ou inadéquate risquenon seulement de réaliser un travail de mauvaise

qualité mais, chose plus grave encore, d’entraîner desdommages corporels graves, voire mortels endéclenchant des incendies ou des chocs électriques.Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-lifié l’installation, le dépannage et l’entretien du postede soudage et de coupage. N’effectuez aucuneréparation électrique sur l’équipement à moins d’êtrequa-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretienquelconque à l’intérieur du poste de soudage/coupage, avant d’avoir débranché l’alimentationélectrique.

c. Maintenez en bon état de fonctionnement les câbles,le câble de masse, les branchements, le cordond’alimentation et le poste de soudage/coupage.N’utilisez jamais le poste ou l’équipement s’il présenteune défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et deséquipements accessoires. Gardez-les à l’écart dessources de charleur, notamment des fours, del’humidité, des flaques d’eau maintenez-les à l’abri destraces d’huile ou de graisse, des atmosphères corro-sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tousles panneaux de l’armoire de commande en veillant àles garder en bon état.

f. Utilisez le poste de soudage/coupage conformément àson usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVESÀ LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur lesrègles de sécurité à observer pour le montage etl’utilisation d’équipements de soudage et de coupageélectriques et sur les méthodes de travailrecommandées, demandez un exemplaire du livret N°52529 “Precautions and Safe Practices for Arc Weld-ing, Cutting and Gouging” publié par ESAB. Nousconseillons également de consulter les publicationssui-vantes, tenues à votre disposition par l’AmericanWelding Society, 550 N.W. LeJuene Road, Miami, FL32126:

a. “Safety in Welding and Cutting” AWS Z49.1b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

9/97

6

SPECIFICATIONS

Input Power Required115 volts 50/60 Hz single phase WireFeed Speed Range ............ 20-999 in./min. (.5-26.4 m/min.)Wire Sizes Accommodated:Hard/Soft — ...................... .023 thru 1/8-in. (.6 thru 3.2 mm)Flux Cored — ................. .035 thru 1/8-in. (0.9 thru 3.2 mm)Length .......................................................... 24-in. (610 mm)Width ..................................................... 22-1/2-in. (572 mm)Height ........................................................... 15-in. (381 mm)Weight (less wire) .......................................... 80-lbs. (36 kg)

I. DESCRIPTION

This manual has been prepared for use by an experi-enced operator. It provides information to familiarize theoperator with the design, installation and operation of theDigipulse Dual XR wire feeder designed to Dana Corpo-ration specifications. DO NOT attempt to install oroperate this equipment until you have read and fullyunderstood these instructions. The information presentedhere should be given careful consideration to ensureoptimum performance of this equipment.

II. RECEIVING-HANDLING

Upon receipt, remove all packing material and carefullyinspect for any damage that may have occurred duringshipment. Any claims for loss or damage that may haveoccurred in transit must be filed by the purchaser with thecarrier. A copy of the bill of lading and freight bill will befurnished by the carrier on request.

When requesting information concerning this equip-ment, it is essential that Item number, Serial number andModel number of the equipment be supplied.

SECTION I INTRODUCTION

Means immediate hazards which, ifnot avoided, will result in immediate,serious 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.

MEANING OF SYMBOLS - As used throughoutthis manual: Means Attention! Be Alert! Yoursafety is involved.

Fig. 1 - DANA DIGIPULSE Dual Wire Feeder

7

III. FEATURES

Microprocessor accuracy — the microprocessor, thecontrolling "brain" of the Digipulse Dual, operates exclu-sively on drift free digital logic unlike competitive sys-tems. The digital logic delivers extraordinarily precisecomputer-accurate weld parameter control and weldconsistency.Microprocessor flexibility — in contrast with competi-tive digital systems that require additional printed circuitboards and hard wiring whenever a feature or function isto be added, the Digipulse incorporates electronicallyreprogrammable modules; by simply reprogrammingthis small plug-in module many existing functions may beextended or new features maybe added.Microprocessor reliability — ESAB’s Digipulse Familyof Wire Feeders have proven to be rugged and reliablein test after test for absolute minimum downtime.Presettable wire feed speed (Ipm) and voltage (volts)— provides ability to easily and accurately preset theexact welding parameters desired before the weldingsequence begins.Patented microprocessor controlled closed loop sys-tems — provides most accurate means of maintainingwire feed speed (amperage) and welding voltage; themicroprocessor compensates for deviations in ambienttemperature, primary voltage fluctuation and changes inarc dynamics or wire feed force conditions, to assure thatpreset parameters are maintained.Sure start interlock — to assure trouble free starts theDigipulse Dual has an interlock circuit which will not allowwire feed to initiate when the torch trigger Is pulled unlessthe power supply contactor is closed and voltage ispresent; the cold wire INCH, however, will be operativeat all times.Individual digital LED meters provide large 1/2-in.readout of voltage and wire feed speed — continuousdisplay of preset and then actual welding voltage andwire feed speed for accurate observation.

Automatic "shut down" — assures welding is done atthe preset parameters; unit automatically shuts down, iffor any reason either the volts or ipm cannot be main-tained for a preprogrammed time period; simultaneously,cause is indicated by flashing digital display.Toggle switch adjustment of weld parameters byfine increments or rapid coarse adjustment — allowsquick, easy, and accurate adjustments of welding pa-rameters.Gas pre and postflow and cold wire inch capability—gas pre and postflow provides independent adjustmentin tenths of a second for highest weld quality and economy;cold wire inch speed can be independently adjusted fromwelding wire feed speed to reduce downtime.Automatic adaptive anti-stick or manual burnbacktime feature—a patented adaptive anti-stick circuit au-tomatically adjusts the same amount of wire burnbackregardless of wire size, speed or voltage; or, you canmanually preset a “BurnbackTime” to specifically suit aspecialized application; the manual burnback function(programmed up to 999 cycles in the VOLTS window)allows you to override the automatic adaptive anti-stickby setting a specific burnback time.Spot weld timer—because the spot weld timer is adjust-able up to 999 cycles (16.5 sec.) in the IPM window, it ismore than a conventional “spot” feature; it is also a weldtimer extending its use for “Increment’’ or “Stitch” weld-ing.Circuit protection—resettable circuit breaker for inputpower minimizes downtime and maintenance.EH-10A permanent magnet motors—provide the high-est torque, fastest response, and best efficiency of anymig p.m. motor on the market.Patented closed loop “J” governor/optical tachom-eter—provides most accurate means of maintainingwire feed speed and voltage, regardless of any voltagedrop or drift.DANA interlock feature insures that all automatic clampsare engaged before welding can begin.DANA arc detect circuit reports all welding activity to anexternal programmable controller.

SECTION I INTRODUCTION

8

SECTION 2 INSTALLATION

I. INSTALLATION

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

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 weldcurrent 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.

After checking to be sure you have all required compo-nents and accessories (see Section II), proceed asfollows (with reference to Figs. 2 & 3, InterconnectionDiagrams):

LOCATION INSTRUCTIONSThe wire feeder should be placed close enough to beeasily accessible from the workstation but not so closethat weld spatter could affect the unit. It is criticallyimportant to insure that the base of the wire feeder isnot placed in contact with a grounded metal surface.

A. ELECTRICAL CONNECTIONSConnect the control cable assembly to the J1receptacle on the rear panel of the DANA Digipulsewire feeder. Next, connect the opposite end of thecable to the J1 receptacle on the rear panel of thepower source as shown in Fig. 3.

Connect the welding cable from the positive outputterminal of the power supply to the power cableadapter block located on the base of the wire feeder.A second welding cable should then lead to thewelding torch.

B. HOSESGAS REGULATIONInstall shielding gas supply hoses as shown in Fig. 2.

Regulator/Flowmeters for Argon/C25/Helium/Nitrogen:R-33-FM-580 P/N 21557R-36-FM-580 P/N 21505R-5007, P/N 998124.

Shielding Gas Hoses:Std Duty, P/N 40V77 (12.5-ft.) or P/N 34V38 (25-ft.)Hvy Duty, P/N 19416 (12.5-ft.) or P/N 19415 (25-ft.)

TORCH COOLANTIf you are using a water-cooled torch, install coolantsupply and drain hoses as shown in Fig. 2.

Coolant Supply and Drain hoses:Std Duty, P/N 40V76 (12.5-ft.) or P/N 406196 (25-ft.).

All interconnecting cable, hose and auxiliaryequipment connections are quickly detachable toprovide easy setup and maximum portability of thewire feeder as shown in Figs. 2 & 3. A water kit with orwithout solenoid may be purchased, as an optionalaccessory, for use with water-cooled torch operation.

C. WATER KITS (Optional see Fig. 13)Mount bulkhead adapter (58V75) behind openingprovided in rear vertical support plate, below gasconnections, and secure with screws (No. 8 - 32 x 3/8-in.) and lockwashers provided. Attach coupling orsolenoid valve (depending on the type of water kit) andadapter (11N16) to the bulkhead adapter. Mount torchcable adapter (45V11) on welding power stud.Connect water drain hose to this adapter, and waterinlet hose to adapter 11N16. Wire the solenoid valve(if used) in parallel with the gas solenoid valve (seewiring diagram).

D. TORCH CONNECTIONSAttach torch gas hose to outlet of gas solenoid. Plug intorch switch cables and lock by twisting. Attach waterhose (if used) to wire feeder. Connect torch powercables to power source, or to power cable adapterblock (with a second cable from that stud to the powersource).

E. INSTALLING FEED ROLLTo install the desired feed roll kit (optional selection)proceed as shown in Fig. 11:1. Position the feed rolls over the four gear assembly

hubs aligning the feed roll holes with the gearassembly holes.

2. Secure the feed rolls to the gear assemblies usingthe No. 8-32 x 5/8-in. screws and lockwasherssupplied.

CENTER WIRE GUIDETo install the proper center wire guide (optionalselection) proceed as follows:1. Remove the two No. 8-32 x 5/8-in. panhead

screws which attach the Center Guide Clamping

9

SECTION 2 INSTALLATION

Plate (P/N 2075495) to the Center Guide Block(P/N 2075496). Remove the plate.

2. Insert the center wire guide (optional selection) inthe groove of the guide block.

3. Replace the clamping plate, using the screwsremoved in step 1 above.

F. INSTALLING SPOOL OF WIRE

CAUTION: Make sure safety glasses are worn whenclipping wire off at the spool or at the endof the torch - serious eye injury can resultdue to the springiness of the wire whichquickly unravels, or a cut wire end whichmay shoot across the room.

1. Remove “hairpin” clip from spindle.2. Position the spool of wire so that when it is placed on

the spindle, wire will be drawn to the feed roll from 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 the lug.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 assemblyas described in Section E.

6. When wire coils are to be used instead of spools,mount wire reel on spindle as through it were a spool(see 1 and 3 above). Remove thumbnuts and coverplate from reel. Remove coil from its package, but donot remove its binding wires. Slide coil onto reel so thatwire will be drawn from bottom of coil (starting end fora coil is always the outer end). Replace reel coverplate and thumbnuts. Cut off coil tie wires and anykinked wire. Then adjust brakescrew and thread wireto torch as covered in 4 and 5 above.

G. ADJUSTING THE ACCESSORY SUPPORT ASSEM-BLY (See Fig. 8).

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

1. Round off the free end of the welding wire with a file.2. Release the clapper and unscrew the pressure ad-

justing knob until the pressure spring is free.3. Thread the wire through the inlet and outlet guides of

the accessory support, and 3 or 4 inches into the torchconduit.

4. Engage the clapper making sure the wire is held in thefeed 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 minimum re-quired to provide positive, nonslip wire feed. Too littlepressure will result in wire slippage while excessivepressure will scar and deform the wire. Further adjust-ment 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 the op-tional heavy blue- colored spring (182W54).

II. REQUIRED EQUIPMENT

A. CONSTANT VOLTAGE POWER SOURCEThe DANA Digipulse Dual is specifically designed for usewith the Digipulse power supply.B. CABLE ASSEMBLIESA multi-conductor control cable assembly is required toconnect the DANA Digipulse to the power source. (SeeFig. 3).

115 Volt/Contactor/Remote Control J1 Cable, 19-con-ductor with Amphenol to Amphenol plugs; order one ofthe following:

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 (Gunmaster 400) or water-cooled( ST-16) torches may be used with the DANA Digipulse.

When using a water-cooled torch it will be necessary toconnect the torches water hose to either a continuouswater supply or to the wire feeder base by using anoptional water kit (with or without a solenoid valve, seeSection III-A and B).

D. DRIVE ROLLS, See Table 1 and F-12-821.

III. OPTIONAL ACCESSORIES

A. Water Kit without Solenoid Valve (P/N 994466).Permits the convenient connection of water-cooledtorches and continuous water supply to the wirefeeder.

A kit is required for each torch and consists of acoupling, two adaptors and a fitting. A dependable

10

cooling water supply, delivery and return water hoses(P/N 40V76, 2 required) will also be required. Notethat Fig. 2 illustrates the use of power cable adaptorP/N 674156, in addition to the kit. If adaptor (674156)is not used, adaptor (45V11 supplied with kit) can beconnected to the output terminal of the power source.Install the kit in accordance with Fig. 13 . Connect thewater-cooled torch as shown in Fig. 2.

B. Water Kit with Solenoid Valve (P/N 2075760).Same as kit P/N 994466 listed above except a sole-noid valve is required for each torch and is supplied inplace of the coupling. The solenoid valve can be usedin areas where you wish to conserve water or thewater temperature is below the dew point causingsweating of torch parts, resulting in poor welds. Installkit in accordance with Fig. 13. Do NOT use withcoolant circulators.

C. Spool Enclosure Kit (P/N 600240). Provides protec-tion for spool of wire against dust and dirt.

D. Standard Wire Reel Assembly (P/N 34323). Reelslips over spindle to allow use of coiled wire, see Fig.12.

E. Heavy Duty Wire Reel Assembly (P/N 19V89).Spoke-type wire reel includes a four spoke aluminumalloy casting mounted on a lightweight support shaftof steel tubing. The reel will handle all wire coils from2 to 4-5/8-in. wide. The finger design permits quickand easy accommodation of different coil widths bysimply rotating from one finger position to the other.

F. Wire Straightener P/N 34V74). Reduces wire cast toimprove feedability and increase service life of torchliners and contact tips. Mounts to the accessorysupport inlet guide.

Wire inlet Guide P/N 11N53 is required to completethe installation on the wire inlet side of the straight-ener.

SECTION 2 INSTALLATION

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 ofthe welding contactor - the cooling efficiency of theunit will be hampered and the starting winding in thepump motor 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, 115 volts,50/60 Hertz, 1 phase input. Since the cooler is de-signed to run continuously during a welding operation,never connect it to a power source or wire feeder thatuses a solenoid controlled water supply that opensand 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 rotationof wire feeder as operator changes work positions.This reduces strain and bending of torch cables.

J. Four Roll Drive Accessory Support Assembly,P/N 600216. This assembly (shown in booklet F-12-821) utilizes 4 feed rolls to provide positive nonslipwire feed. It is designed for feeding .030 thru 1/8--in.diameter wire. For feed roll/outlet guide accessoriesrefer to Table 1.

K. PLC Interface Retrofit Kit, P/N 0558001518. This kit(shown in booklet F-15-608) inhibits the unit fromwelding until an external 'enable' signal is received. Italso puts out a signal to DANA's PLC indicating whenthe unit is welding. This is a standard part of0558001536, but an optional component for 34849.

Feed Roll Center Upper Lower Wire Size Kit * Wire Guide Feed Roll + Feed Roll +

.045 999327 2075561 2075545 2075537

.052 999328 2075562 2075546 2075538

.062 999329 2075563 2075547 2075539

+ (2) Upper and (2) Lower feed Rolls are required as a complete set.* Feed Roll Kit includes Center Wire Guide, (2) Upper and (2) Lower Feed RollsFor a complete listing of available feed rolls, see F-12-821.

Table 1

11

Fig. 2 - Interconnection diagram

SECTION 2 INSTALLATION

PLAN VIEW DUAL FEEDER

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

LEFT TORCH(WATER COOLED)

TORCH SWITCHTORCH GAS HOSE

� TORCH WATER HOSE

TORCH POWER CABLE

TORCH CONDUIT

� ADAPTOR - 45V11

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

� WATER KIT (BELOW)2075760OR

� WATER KIT994466

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

GAS SOLENOIDS ABOVEOPT. WATER SOL. BELOW

TORCH CONDUIT

TORCH SWITCH

TORCH GAS HOSE

TORCH POWER CABLE

RIGHT TORCH(AIR COOLED)

FRONTVIEWCONTROL

� Parts required whenusing a Water Kit & Water

LEFT MOTOR/ACCY. SUPPORTTORCH CONNECTION

RIGHT MOTOR/ACCY. SUPPORTTORCH CONNECTION

12

SECTION 2 INSTALLATION

P4, PLC CONNECTOR

† ESAB will not honor the warranty on Digipulse that are used with non-ESAB manufacturedinterconnect cables and sustain damage that in ESAB’s opinion is caused by these cables.For a listing of the proper cables available refer to Section II-B.

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

Fig. 3 - Welding and Control Interconnection Diagram

13

I. CONTROL FUNCTIONS

BACK PANEL CONTROL

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

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, Sched. II for each torch, Spot). After thedesired results are achieved, the program(s) can be“locked-in” by turning the key to the RUN position. Theonly parameter which can be altered by the operatorin the RUN position is the cold wire INCH speed.

3. Reset Circuit Breaker. A seven (7) ampere circuit

— cold wire INCH speed in IPM from 50 to 999inches per minute in one inch increments.

— wire type

NOTE: With the power turned “on”, but not welding, theIPM window will continuously read Preset wirespeed. 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 toggle selector actuated, this windowcan also display the following:— shielding gas POSTFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.— manual BURNBACK time. Manually adjustable

burnback time period which when preset willoverride the automatic adaptive anti-stick fea-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.

— wire diameter

NOTE: With the power turned “on”, but not welding, theVOLTS window will continuously read Presetvoltage. When the arc is struck, the VOLTSwindow will then continuously read Actual weld-ing voltage.

SECTION 3 OPERATION

Fig. 4 - Rear Panel Control

breaker 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.

FRONT PANEL CONTROL

4. Digital Readout Windows. Two individual three-digitwindows 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 function selector actu-ated, this window can also display the following:— shielding gas PREFLOW from .1 to 99.9 sec-

onds in one tenth of a second increments.— SPOT welding time for each Torch, from 1 to 999

cycles in 1 cycle increments.

P4, PLC Connector

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SECTION 3 OPERATION

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SECTION 3 OPERATION

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5. LED Light. This LED only lights to indicate that thetorch on the left side is in use.

NOTE: All of the following controls are spring-loaded,center-return toggle switches which must beoperated to actuate their indicated function(s).

6. Inc.-Dec. Toggle Switches. Two control togglesare provided to preset the individual welding param-eters required for the selected welding mode asfollows:

a. “IPM” Increase/Decrease Control. This toggleswitch is primarily used to set and/or vary the wirefeed speed (IPM), along with its other functions;Preflow, Spot for both torches, Inch, and wire typeselection. With appropriate function selector actu-ated, each parameter setting will be displayed inthe digital window directly above this toggle.

b. “VOLTS” Increase/Decrease Control. This toggleswitch is primarily used to set and/or vary the arcVolts, along with all its other functions: Postflow,Burnback, and wire diameter selection. With theappropriate function selector actuated, each pa-rameter setting will be displayed in the digital win-dow directly above this toggle.

7. Inch/Purge/Reset Switch. This two position (mo-mentary) switch allows the following operation.a. Inch Function. The INCH selection permits cold-

wire inching without energizing the welding circuit.To preset cold inching speed, operate the inchswitch and while the motor is running using the INC/DEC toggle below the IPM window; set the desiredspeed. This setting (is independent of the “hot” wirefeed) will be displayed in the IPM window.

b. The Gas PURGE (Abort Reset) position providesthe following when actuated:(1) During initial programming, it permits preset-

ting of gas PREFLOW and POSTFLOW “timerequirements” which are simultaneously dis-played in the IPM and VOLTS windows respec-tively.

(2) Prior to actual torch triggering, it permits youto actuate the gas solenoid and PURGE theshielding gas line of the torch. At the same time,it also lets you adjust the gas regulator withoutenergizing the welding circuit.

(3) 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.

8. Spot/Burnback. This two- position (momentary con-tacts) switch allows the following operations:a. Spot Time Setting: operate the Spot/Burnback

switch and observe that both the IPM and voltsdisplays will change. The Spot time can be pro-

grammed into the IPM window by holding the Spot/Burnback switch in the "up" position and the timecan be incremented or decremented by the INC//DEC switch under the IPM window.

Note:To get out of Spot welding mode, the Spot timehas to be decremented to 0.

b. Burnback Time Setting:The Burnback time can be set into the voltagewindow in a similar fashion, to increment or decre-ment the burnback time, the INC/DEC switch underthe volts window is used. Both the Spot and Burnbacktimes are set in cycles (1 cycle - 1/60th of a second).

9. Mode Selector Toggle Switch. This three-posi-tion switch allows you to select the welding processmode you wish to use - non-pulsed mig "Short Arc",mig "Spray Arc" or "Pulsed" mig spray arc.

In all process modes, the operator simply codes thecontrol (wire diameter and material) for any one ofthe preprogrammed welding conditions, sets thedesired wire feed speed (ipm) and the controlautomatically provides the proper welding param-eters to produce the necessary output for the pro-cess selected.

II. GENERAL

This dual torch pulsed mig welding system has beendesigned and manufactured to specifications providedby DANA. The software is modified to provide 3 pre-settable process schedules. These are short arc,spray arc and pulsed spray arc. When one set ofthese parameters is entered into the feeder on oneside, the other side will automatically be set to thesame parameters.

III. GETTING STARTED

Start UpWhen primary power is applied, the windows on thefeeder will display the Product Code (in the IPMwindow) and Software Version # (VOLTS window) forone second. This information indicates the type ofsoftware installed in the control and the latest versionnumber. To insure all your units have the samesoftware, the Product Code and Software Versionnumbers shown on start up should all be identical.After one second, the windows will then revert todisplay the last welding parameters (IPM and Voltage)set by the operator and the unit is ready to weld.

The following DANA Digipulse control functions mustbe set to feed wire through the torch conduit and toadjust the shielding gas flow rate.

SECTION 3 OPERATION

17

SECTION 3 OPERATION

1. Place the Power switch on the rear panel to the“on” position to energize the control.

2. Place key-operated Run / Set switch (also on therear panel) in the Set position.

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

trigger switch of the left torch. This action(through the control’s switching relay circuitry)sets-up the control to receive the parameterprogramming for the left torch.

b. Remove the gas nozzle and contact tip fromtorch.

c. Hold Inch-Purge toggle (front panel) in theINCH position until “cold” wire feeds throughthe torch front end.

d. Slide the contact tip over the end of the wireand secure it to the torch. Replace the torchnozzle.

e. Operate the Inch-Purge toggle in INCHposition and check for wire feed slippage onthe accessory support assembly. Tighten (orloosen) the pressure adjusting knob until thewire feeds smoothly with minimum pressure.

f. The parameters for the right side torch willautomatically duplicate the setting of the lefttorch. No separate programming is requiredfor this torch since it is used as a backup inthe DANA system.

4. With shielding gas supply and torch gas hoseconnections assembled as shown in Fig. 2, setgas flow rate as follows:a. Hold Inch-Purge toggle in PURGE position.

Open the gas regulator-flowmeter controlvalve and set the required shielding gas flowrate.

b. Continue to hold the Purge position forapproximately 15 seconds to insure adequatepurging of each gas hose and torch.

A. PROGRAMMING THE WIRE FEEDER

1. Gas Preflow and Postflowa. Preset the shield gas preflow time by holding

down the purge key and using the Inc/Dec keyunder the IPM window to set a time in 1/10seconds.

b. Repeat the above for postflow using the keybelow the VOLTS window.

2. Cold Incha. The cold inching feature has a two step speed

control. When the Inch key is operated, thewire will feed at a non-adjustable rate of 100inches per minute for a period of 2.5 seconds.This speed is displayed in the IPM window

and is designed to “bump” the wire slowly forfine adjustment of wire stick out.

b. Set the cold inching speed by holding the Inchkey adjust IPM using the Inc/Dec key to anyspeed desired between 50 and 999 inches perminute. This function is designed for wirethreading.

3. Burnback PresetAdjust the wire burnback by holding the Spot/B’backkey in the “up” position and setting a burnbacknumber in VOLTS window using the Inc./Dec. key.The number entered relates to line cycles (60=1sec.). A number between 2 and 6 is the typical range.

4. Spot Weld Preseta. For normal continuous welding, set this number

to zero (0).b. If a timed spot weld is required, set the length of

weld time by holding the Spot/B’back key in the“up” position and setting a spot weld time incycles per second (60 = 1 sec.) in the IPMwindow.

5. Material/Diameter PresetChoose the Material/Diameter code (1 through 6) bydepressing the Mat’l/Dia key and setting the desiredmaterial number (see Material Code Table) in IPMwindow and wire diameter to be used in the VOLTSwindow. Most DANA plants run steel on Code #1.

6. Slow Wire “Run In”a. The slow wire “run in” is set to provide one half

the preset wire feed speed (IPM) until the wiretouches the work piece. At that point, the wirefeed rate will accelerate to the speed preset inthe IPM window. This option, in most cases,improves arc starting characteristics.

b. If full speed “run in” is preferred, the halfspeed can be disabled by locating dip switch#2 on the MPU board (see MPU boarddrawing) and placing rocker switch #1 in the“closed” position.

7. TORCH DEFAULTThe right side torch (Torch #1 - viewed from thefront of the feeder) is the default torch. Thismeans that when the feeder is first powered upthis torch is ready for use. The software willautomatically switch to the torch being used whenthe torch trigger is depressed. The weldparameter settings, material/dia. code, burnback,spot weld time and cold inching speed, setpreviously, are ready for use.

8. WELD PROCESS SELECTIONThe DANA Digipulse Dual feeder is a synergicwelding system in all weld process modes. Thismeans that a specific wire feed speed and arcvoltage relationship has been pre-programmed intothe control based on the weld process selected the

18

SECTION 3 OPERATION

Fig. 6 - DANA MPU Board

type of weld wire and the diameter of the wire beingused. This information is supplied to the control byselecting the welding process using the “ProcessSelection” switch on the front panel (short circuit,spray of pulsed spray) and then entering the mate-rial/diameter information as described above.

B. ARC STARTING (SERVO) SETTINGSMost of DANA’s manual welding applications areperformed in the “Adaptive” mode. Poor arc starts inthe “Adaptive” weld mode are usually caused by animproperly adjusted arc voltage servo. If your arcstumbles upon starting, you should first adjust thevoltage servo. The IPM servo should then be ad-justed only if setting the voltage servo does not solvethe problem. The arc voltage servo is disabled whenthe control is set up for “Synergic” welding.

1. Arc Voltage Servo Adjustments (AdaptiveMode Only.)The voltage servo setting can be observed onlyduring welding. While welding, depress the“Purge” key and “Mat’l/Dia.” selection key simul-taneously. The VOLTS window will display anumber between 0 and 200 with 90 being typical.These numbers will fluctuate and change duringwelding. Only look for an average of 80 - 100when the arc voltage is in a steady stable state.Using the “Inc/Dec” key below the VOLTS win-dow, reduce the number shown to give a “hotter”arc start or increase the number for a “colder”arc start. DO NOT make large changes at anyone time. Wire burnbacks and other problemscan result. Make small adjustments and retest

the arc starting several times in order to optimizestarting characteristics. Changes in wire feedspeed and/or voltage might necessitate read-justing the voltage servo. This setting will applyto ALL weld process modes.

2. Wire Feed Motor Servo SettingsYou can adjust the feed motor response bypresetting the motor speed servo. In order to seeand adjust the actual speed servo settings,release the pressure roll and pull the torchswitch while depressing the “Purge” key and“Mat’l/Dia.” key simultaneously. The IPM win-dow will display a number between 0 and 200with 110 being typical. Using the “Inc/Dec” keybelow the IPM window, reduce the number shownby 3 or 4 digits at a time to give a faster accelera-tion to the wire feed speed or increase thenumber for a slower acceleration. DO NOTmake large changes at any one time.

WELDING PROCESS SELECTION

A. Adaptive Arc WeldingThe IPM window will display the wire feed speedin inches per minute and the VOLTS window willdisplay a voltage corresponding the material typeand wire diameter you have preset. The arcvoltage (arc length) will be automaticallymaintained by the control at the pre-set valuesindependent of torch manipulation. You can trimthe preset values to optimize arc performance andwelding characteristic by adjusting the IPM or arcvolts using the Inc/Dec keys under each window. Ifthe welding arc length is too long, decrease the

19

SECTION 3 OPERATION

RECOMMENDED MATERIAL AND SHIELD GAS TABLE

WIRE MATERIAL WELD PROCESSESCode # Material Type Short Arc Spray Arc Pulse Arc

1 CO2 Argon-5% CO2 Argon-5%CO2Carbon Steel Argon-25% CO2 Argon 2-5% O2 Argon 2-5% O2

Argon-8% CO2

2 Alternate Steel C-25 Argon-8%CO2-2%O2 Argon-8%CO2-2% O2

Ar-8% CO2-2% O2 Argon-8% CO2 Argon-8% CO2

3 4043 Aluminum Argon Argon4 5356 Aluminum Argon Argon5 308 Stainless Steel A-1025 Argon 1%-2% O2 Argon-2% CO2-1% H2

6 Silicon Bronze Argon Argon7*8*9*10*

*These codes are reserved for custom synergic weld parameters.

voltage using the Inc./Dec. key under the VOLTSwindow which shortens the arc length. If thewelding arc is too short, increase the voltage inthe VOLTS window. The “adaptive” characteristicis noticeable when pulse spray welding by audiblechanges in the pulse frequency caused byvariations in the wire electrical stick out or torchmanipulation. The pulse frequency willautomatically be adjusted to maintain the arcvoltage you have set in the VOLTS window whenwelding in the pulse spray process mode.

B. Synergic (Non-Adaptive) Arc WeldingIf the “Adaptive” mode is not desired, the feedercan be switched to “non-adaptive” operation. Thisis still a synergic relationship but the arc voltage isnot automatically maintained by the control. Thismeans the arc length will vary with torchmanipulation. When pulse spray welding, thepulse frequency will not automatically change withvariations in wire electrical stick out. The pulsefrequency will remain constant at any givenvoltage setting. To enter “non-adaptive” pulseoperation proceed as follows:1. Disconnect all input power to power supply.2. Remove the sheet metal cover on the wire

feeder control box by removing the five sheetmetal screws.

3. Remove the “J” governor P/C board (small P/C board in front). Locate the MPU boardwhich is the large P/C board facing you whenyou remove the “J” governor board. Find dipswitch #1 and open rocker switch #1 (asshown in Fig. 6).

4. Replace the “J” governor P/C board.5. Replace the sheet metal control cover and five

screws.

6. Reconnect input power to power supply.

The IPM window will now display the wire feed speedin inches per minute and the VOLTS window will showa number between 0 and 200 with 100 being thedefault value. This is NOT an arc voltage value!The number is a reference integer used by the digitalcircuitry and corresponds to the synergic relationshipprogrammed into the control. The number 100 relatesto the nominal arc voltage required for the wire feedspeed selected in the IPM window. This number willaffect the arc length. You can trim the preset values tooptimize arc performance and welding characteristicby adjusting the IPM or arc volts using the Inc/Deckeys under each window.

If the welding arc length is too long the number can bedecreased which shortens the arc length. If thewelding arc is too short, increase the number in theVOLTS window. The ACTUAL arc voltage will bedisplayed during welding.

The following will detail the installation and operationof this unique welding system. The feeder controlcircuitry stores weld parameters for the shortcircuiting, spray and pulse spray welding processesbut only one set of welding parameters is used at anyone time. Independent control of weld parameters oneach torch is NOT supported in this specialized DANAmodel. It should also be noted that this is a oneoperator welding system and both torches CANNOTbe used at the same time. The operator can chooseeither Torch #1 or Torch #2, depending onrequirements.

20

SECTION 3 OPERATION

DANA DIGIPULSE XR DUAL PROGRAM CHARTPULSE PARAMETERS

Not in Use

WIRE DIAMETER.030" .035" .045" .052" 1/16"5.8 6.5 6.8 7.0 8.025 30 30 40 501.8 2.0 2.2 2.3 2.45.4 5.8 6.0 6.560 60 60 602.2 2.5 2.6 3.8

New Data

Vp

Ib

Tp

Carbon SteelC-5O-5Gas

1

Vp

Ib

Tp

AlternateCarbon SteelC-5/Stargonor O-5 Gas

2

PROGRA

M #

MATER

IAL

TYPE

&SH

IELD

GAS

VARI

ABLE

S

DANA Digipulse Dual Feeder 34849 0558001536EPROM P/N 18095 18168Product Code 261 261Software Code 17.2 17.3

With Arc Standard Detect

21

SECTION 4 MAINTENANCE

V . TROUBLESHOOTING

Be sure that all primary power to the machine hasbeen externally disconnected. Open wall disconnectswitch or circuit breaker before attempting inspec-tion or work inside of the power source.

A. DANA DIGIPULSE 450 POWER SOURCEIf power source is operating improperly, refer to thetroubleshooting information located in F-15-014.B. DIGIPULSE DUAL WIRE FEEDER for DANA CORP.

(Refer to Schematic Diagram D-0558001734)Listed below are a number of trouble symptoms, eachfollowed by the checks or action suggested to determinethe cause. Listing of checks and/or actions is in “mostprobable” order, but is not necessarily 100 exhaustive.Always follow this general rule: Do not replace a printedcircuit (PC) board until you have made all the precedingchecks. Always put the power switch in “off” positionbefore removing or installing a PC board. Take greatcare not to grasp or pull on components when removinga PC board. Always place p.c. boards on a “static free”surface. If a printed circuit (PC) board is determined to bethe problem, check with your supplier for a trade-in on anew PC board. Supply the distributor with the part num-ber of the PC board (and program number, as describedin step 1-c. following) as well as the serial number of thewire feeder. Do not attempt to repair the PC boardyourself. Warranty on a PC board will be null and void ifrepaired by customer or an unauthorized repair shop.

1. Generala. Check interconnection between control and power

source.b. Energize the power source and the control.c. Immediately after the control is turned “on”, a

number (e.g.:3) will appear in the IPM readoutwindow and an additional number of numbers in thevolts window. They will only be displayed for 1-second. These numbers identify the current pro-gram (E-PROM) used in your control. When aProgram is changed, the new E-PROMS will auto-matically identify the new program number beingused. If a revision is made to an existing programa number .1, .2, .3, etc. indicating the numericalrevision will also appear in the VOLTS readoutwindow simultaneously.

d. After the one (l) second delay; the preset “Weld”parameters will be displayed in the IPM and VOLTSwindows.

e. If the control is not functioning properly (as de-scribed above); for example, the numbers thatappear in one or both of the display windows aremeaningless (all zeros, eights, decimals, etc.), orare completely incorrect in relation to your settings,

— the memory must be cleared. This conditionmight occur after lightning storm, extremely badpower line surges, etc. To clear the memory, do thefollowing:(1) Place the Run-Set key switch in its SET posi-

tion.(2) Turn “off” the unit’s 110-volt Power switch.(3) Using one hand, hold both of the Inc/Dec

toggle switches in their INC position whilereapplying 110-volt power with the other hand.

(4) Almost immediately after the Power has beenturned “On”, release the Inc/Dec toggle switchesto the neutral (spring-return center) positionand the IPM window should display 0 or de-pending on how quickly the INC/DEC switchwere released if might be a number higher than20, but in any case it will have changed from theoriginal displayed info, indicating that a suc-cessful reset or clearing has take place.

f. You can now enter the desired information asdescribed in this booklet.

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

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

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

and T1-9; if voltage is present, replace the MPUboard. If voltage is not present, check the voltageregulator (VR) The voltage regulator is located onthe rear panel of the control box.

d. Check the input and output voltage of the regulator “VR”.

(1) The input should be approximately 10 voltsbetween terminals T1-9 and VR-1. If voltage isnot present, replace I/O board.

3. Preset display is provided, but cannot be varied.a. Check normal setup procedures described in Sec-

tion V, then;b. Make sure the key wiring harness plug is properly

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

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

4. Motor does not run.a. Check to make sure all required (and/or optional)

accessories are correctly assembled as describedin SECTION II.

b. Make sure that power source is connected, plug P2is securely connected to receptacle P2 on theDANA Digipulse I/0 Board, and then release theclapper arm (pressure roll) on the Accessory Sup-port Assembly.

22

SECTION 4 MAINTENANCE

(1) Operate the control INCH switch. If motor doesnot run; replace the “J” governor board, and ifit still does not run, replace I/O and MPUboards respectively.

(2) If the motor inches, but does not run when thetorch switch is operated (energized), check thetorch switch circuit components-switch, plug,receptacle, etc. If motor still does not run,check if power source is providing open-circuitvoltage to the control. If o.c.v. is not beingsupplied, motor will not run. Check the powersource for trouble.

(3) Also check that the +/- 12 vdc are providedfrom the power source on T1-7 and T1-5respectively.

(4) If power source if O.K., replace the I/O andMPU boards respectively.

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

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

motor shaft. Check that the disc is properly cen-tered in the strobe pickup on the p.c. board.

c. If all items in step b. are in order, and motor speedis still incorrect, check the bios supply to the tach-board. If the bios supply +5 volt DC and the com-mon are present at the Tach board on the Red andGreen wires respectively, test the tach board asfollows:(1) Remove power.(2) Remove (unplug the "J" governor, and resup-

ply 115 power. Connect a DC voltmeter be-tween T1-3 and the chassis of the controlcabinet on the feeder. Positive input on T1-3,negative - chassis. Read the potential. It shouldbe either 0 volts or 4.5 - 4.8 volts. Slowly turnthe motor armature using the exposed mount-ing screw at the end of the motor armature.The voltmeter should fluctuate between 0 andthen 4.8 volts. If no change occurs, replace theTach board. If the Tach board is OK., but themotor still runs at the wrong sped, replace theMPU board.

6. Arc VOLTS display reads zero after TS is operated.a. Check that the 5-pin plug is securely connected to

the P3 receptacle on the MPU board.b. If no reading is displayed, check for arc voltage

feedback between terminals TP1 and TP2 testpoints on the l/O p.c. board (see Fig. 7). Thisvoltage signal should correspond to that shown onthe power source voltmeter.

c. If voltage still reads zero, trace the voltage pickupwiring from the power source to digipulse and verifythat the power source indeed provides O.C.V. Ifnot, ascertain that the power source is energized.

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

If power source (P.S.) is not energized, work oncontactor - check troubleshooting F-15-014. If P.S.is energized, correct wiring until O.C.V. is obtainedbetween TP1 and TP2 on I/O board. Only after that,go to part "d" if necessary.

d. If its known that the p.c. is energized, proceed asfollows: remove the J-Gov power source board togain access to the P3 plug (harness) on the MPUp.c. board. Disconnect the P3 plug from its MPUboard socket and, using a meter check for +/- 12volt power supply output between plug pins P3-1and P3-2 (for +12 v), and between plug pins P3-4and P3-2 (for - 12 v) respectively. If voltage ispresent, replace MPU board.

7. Control Shut-Down — either preset VOLTS or IPMdisplays will flash. The control will flash the pa-rameter VOLTS or IPM that cannot be maintained.These symptoms can occur if the preset conditions,IPM or VOLTS, cannot be maintained by the control.The speed (IPM) and voltage (VOLTS) conditions areused to enhance arc starting in the “adaptive mode” ofoperation. In the “synergic mode”, the voltage condi-tion window will always display the number 100 andcannot be adjusted; the speed condition, however,can be checked and adjusted as described following.To help determine which logic mode (adaptive orsynergic) the control is set to operate in, or how tochange it, please review Section 3.

a. IPM (speed) abort and possible causes:(1) Initial “hot start” parameters incorrectly set. For

proper adjustment, refer to Section 3-B-1 and2.

(2) Defective J-governor board.(3) Defective Motor tachometer board.(4) Defective l/O board.(5) Defective MPU board.

Contact ESAB Engineering Services forfurther assistance. (803- 664-4416).

TP2TP1

23

SECTION 4 MAINTENANCE

b. VOLTS (voltage) abort and possible causes:This problem may be located in the wire feeder orthe power source. To determine this, check thewire feeder as follows.(1) Set the wire feeder for synergic operation in the

Pulse welding mode.(2) Strike an arc and while welding, measure the

potential between T1-4 and T1-6 Note that asthe arc voltage setting is increased, the poten-tial between T1-4 and T1-6 also increases, andwill range from 0 to 8 vdc. If it does not, replacethe l/O and/or MPU board. If the potential ispresent and responding to the voltagechange setting, continue with step (3) follow-ing.

(3) Now measure the control voltage, for the back-ground current, between T1-6 and pin J1-J ofthe amphenol connector. This measurementcan be taken without striking an arc. The po-tential will the be in a range from 1 to 2.5 volts.If it is not, replace the I/O and/or MPU board.If the background potential is present, con-tinue with step (4) following.

(4) If both of the preceding conditions (steps 2 and3) are okay, but the arc is still unsatisfactory,the problem is either in the interconnectingcable, the welding setup, or in the power source.If possible, substitute a cable or power source(known to be good) to check out the possibleproblem; if these are not available, continuewith the wire feeder “calibration test” in step 8following.

8. Erratic arc especially evident in the Pulse mode.This could be caused by insufficient pulse height.To check this, make the following “calibrationtest” of the I/O board and power source.To set up the control in the diagnostic mode, simulta-neously depress the Wire Dia/Mat’l. key and hold theIPM Inc/Dec key in its down position for 2.5 secondsuntil a zero (0) appears in the IPM window. (The 2.5seconds will prevent accidental zeroing of the Materialcode.)

Now release both keys. The display windows willchange to show a BACKGROUND current value(from 0 to 100) in the IPM window, and a PULSEHEIGHT value (from 0.1 to 10) in the VOLTS window.These numbers can be changed by their respectiveINC/DEC switches.

To check the calibration of the l/O board, connect avoltmeter from T1-6 (negative) to T1-4 (positive).Energize the torch switch, and check the measuredvoltage against the number displayed in the VOLTS

window — they should both be the same (for example:for a setting of 8.0, the measured potential should be8 vdc.). If the measured potential is different, the l/Oboard should either be recalibrated (by a qualifiedtechnician) or the board should be replaced.

Next, check the potential from T1-6 (-) to pin J1- J ofthe amphenol connector for a display of 40 in the IPMwindow. The measured reading should be 2 vdc. If itis not, replace the I/O board. If all of the readings arecorrect, check the power source by using the “calibra-tion procedure” described in Inverter Control Board(lCB) Troubleshooting in the Power Source manualF-15-014.

9. Torch Switch does not activate the machine.A. Check function and continuity of trigger switch.B. Check for 'enable' signal from PLC through P4

connector. For diagnostic purposes, this signalcan be supplied by setting Dip Switch SW2-3 tothe closed position (See Fig. 6).

VI. MAINTENANCE

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.

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 be doneonce for every eight hours of operating time, more oftenif necessary.B. LUBRICATION OF MOTOR-GEAR UNITThe EH-10A motor-gear unit is lubricated with a heavyduty grease when assembled at the factory and shouldnot require further lubrication unless disassembled. Ifdisassembled relubricate with Texaco Multifak grease.C. CHECK OR REPLACEMENT OF MOTOR BRUSHESMotor brushes should be checked periodically. If a brushis broken, or worn down to less than 3/8-in. length, it mustbe replaced. Brushes can be inspected by unscrewingthe brush-holder plug and withdrawing the brush assem-bly. Never remove a brush without matchmarking it andits holder, so that it can be replaced in the same holderin its original position.

24

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

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

motor-gear unit by loosening the cap screw at 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 DIGIPULSE PROGRAM FEATURES(See DANA MPU Board - Fig. 6)The MPU Board (Fig. 6) contains two integral 4-rocker'DIP' switches. For DANA Digipulse Dual Feeders Part

Number 0558001536 with the PLC interface, these shouldbe positioned as:

SW-1 SW-21 CLOSED 1 OPEN2 OPEN 2 OPEN3 OPEN 3 OPEN4 OPEN 4 OPEN

For the DANA Digipulse Dual P/N 37879, SW2-3 shouldbe in the closed position.

F. DANA Interface BoardThe DANA interface board 0558001143 sends a signalto the external Programmable Logic Control through theP4 connector whenever the unit is actively welding. Theboard also looks for input from the PLC indicating that allclamps are energized. It can be disabled by settingdipswitch SW2-3 to the closed position.

SECTION 4 MAINTENANCE

25

SECTION 5 REPLACEMENT PARTS

5.0 PARTS

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

5.2 ORDERINGTo 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. For a list of Authorized Distributors in yourarea, contact ESAB at 1-800-ESAB-123.

For your convenience an ESAB Communication Guidelisting important contact phone numbers has been printedon the rear cover of this book.

26

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INLET GUIDE(See torch instruction booklet)

FORK - 49V43

ROLLPIN - 62350066(3/16 X 1-3/4")

(2) LOCKING HANDLE(49V44)

(4) FLATWASHER -2075524

SCREW - 1/4 X 20 X 1/2"(61307087)BELL WASHER - 1/4"(950783)FLATWASHER - 1/4"(64309431)

GEAR & INSULATOR ASSY. - 999179

CAPSCREW - 5/15" - 18 X 1 3/4"(61340166)NUT - 5/16" - 18 (63350121)

OUTLET GUIDE(See torch instruction booklet)

CLAMPING PLATE - 2075495

CLAPPER ASSY. -2075500

ROLLPIN - 2075523

KNOB - 60N68

SPRING - 182W54

RETAINER - 58N24

(4) FEED ROLL( Optional Selections - see Table 1)Feed Roll Mounting Hardware:(17) SCREW - No. 8-32 x 5/8"(61307881)(17) LOCKWASHER - No. 8(63402887)

Fig. 11 Four Roll Drive “Uniform Pressure” Accessory Support Assembly - P/N 600216

(4) GEAR ASSY.(2075492)

SECTION 5 REPLACEMENT PARTS

30

5/8 -18 Lh

WATERCONNECTION58V75(OUTLET)

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

5/8 -18 Lh

COUPLING - 68121075

ADAPTOR - 11N16(INLET)

WATERCONNECTION58V75(OUTLET)

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

ADAPTOR - 11N16(INLET)

WATER SOLENOIDVALVE - 2062355

Fig. 12 - Spindle Assembly, P/N 948259,Optional Wire Reel, P/N 995570

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

(Ref. Hair Pin Clip)REEL

(4) .359" DIA. HOLE ON 3" DIA. D.C.SPINDLE - 948258

"D" TYPEWASHER - 948254

SCREW -5/16" -18 x 2"

HAIR PINCLIP - 634347

WASHER -948256

SUPPORT -948257

SPRING - 948253

(2) BRAKE PAD - 948255

SPINDLEWITHOUT SOLENOID VALVE

WITH SOLENOID VALVE

Fig. 13 - Water Kit with Solenoid Valve, P/N 2075760*Water Kit without Solenoid Valve, P/N 994466

*Do not use with Coolant Recirculator

SECTION 5 REPLACEMENT PARTS

31

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33

NOTES

34

NOTES

35

NOTES

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

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

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