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WARNING:

 T

hese Safety Precautions are for

your protection. They summarize precautionary
information from the references listed in Addi-
tional Safety Information section. Before per-

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

PROTECT YOURSELF AND OTHERS

 -

-

 Some welding, cutting, and gouging

processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and

can injure skin and eyes.  Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:

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

area, even if welding helmets, face shields, and goggles
are also required.

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

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and not
to expose themselves to the rays of the electric-arc or hot
metal.

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

shirt, cuffless trousers, high-topped shoes, and a welding
helmet or cap for hair protection, to protect against arc rays
and hot sparks or hot metal. A flameproof apron may also
be desirable as protection against radiated heat and sparks.

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

cuffs, or pockets. Sleeves and collars should be kept
buttoned, and open pockets eliminated from the front of
clothing

5. Protect other personnel from arc rays and hot sparks with

a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far. Bystand-
ers should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS --

 

Heat from

flames and arcs  can start fires. Hot slag
or sparks can also cause fires and explo-
sions. Therefore:

1.

Remove all combustible materi-

als well away from the work area or cover the materials
with a protective non-flammable covering. Combustible
materials include wood, cloth, sawdust, liquid and gas
fuels, solvents, paints and coatings, paper, etc.

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

in floors or wall openings and cause a hidden smoldering
fire or fires on the floor below. Make certain that such
openings are protected from hot sparks and metal.“

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

workpiece has been completely cleaned so that there are
no substances on the workpiece which might produce
flammable or toxic vapors. Do not do hot work on closed
containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

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

overloaded welding cable can overheat and create a fire
hazard.

6. After completing operations, inspect the work area to make

certain there are no hot sparks or hot metal which could
cause a later fire. Use fire watchers when 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 parts
and ground can cause severe injury or death. DO NOT use

AC welding current in damp areas, if
movement is confined, or if there is
danger of falling.

1.

Be sure the power

source frame (chassis) is connected to
the ground system of the input power.

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

missing connection can expose you or others to a fatal
shock.

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

aged cables.

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

torch/electrode holder, and power source.

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

work and from ground.

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

tight quarters or a damp area; stand on dry boards or an
insulating platform and wear rubber-soled shoes.

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

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

for specific grounding recommendations. Do not mistake
the 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 current
creates EMF around welding cables
and welding machines. Therefore:

1.

Welders having pacemakers

should consult  their physician before
welding. 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

Содержание Digimig Dual

Страница 1: ...lly understand these instructions If you do not fully understand these instructions contact your supplier for further information Be sure to read the Safety Precautions on page 2 before installing or operating this equipment 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 ...

Страница 2: ... of the manufacturer The user of this equipment shall have the sole responsibility for any malfunction which results from improper use faulty maintenance damage improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer TABLE OF CONTENTS SECTION TITLE PAGE PARAGRAPH SECTION 1 DESCRIPTION 5 1 1 General 5 1 2 Scope 5 1 3 Specifications 5 ...

Страница 3: ...ubstances on the workpiece which might produce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire extinguishing equipment handy for instant use such as a garden hose water pail sand bucket or portable fire extinguisher Be sure you are trained in its use 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create...

Страница 4: ...mes Never strike an arc on a cylinder 5 For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 EQUIPMENT MAINTENANCE Faulty or improperly maintained equipment can cause injury or death Therefore 1 Always have qualified personnel perform the...

Страница 5: ...orsoftwiresfrom 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 ispreciselycontrolledbyusingaclosed loop J governor digitalfeedbackcircuitthatemploysanopticaltachometer tomonitorthemotorspeed Arcvoltageregulationisalso controlled by a closed loop digital feedback circuit that monitors the arc voltage and automatically adjusts the p...

Страница 6: ...LEFT INC DEC SW 6 POS ROTARY SELECTOR SW TORCH ACCY LEFT SUPPORT ASSY EH 10 MOTOR GEAR TACH UNIT TORCH ACCY RIGHT SUPPORT 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 SECTION 1 DESCRIPTION RIGHT TORCH RECPT LEFT TORCH RECPT LEFT TORCH GAS SOL CONNECTION RIGHT TORCH GAS SOL CONNEC TION ...

Страница 7: ...onnect the torches water hose to either a continuous water supply or to the wire feeder base by using an optional water kit see Section 1 5 D Gas Regulation Shieldinggasregulator flowmeterandfittedhosetobring gas from flowmeter to wire feeder Such as Table 1 Digimig Feed Rolls Wire Type Two Roll Drive Four Roll Drive Outlet Size In mm Feed Roll Feed Roll Kit Guide Soft 030 8 2075304 U 999320 29N13...

Страница 8: ... b Wire Wiper Holder P N 598763 F Wire Spool Spacer P N 948378 Enables the use of a 8 in diameter spool of welding wire with spindle assembly on the Digimig wire feeder G WC 9 Coolant Circulator P N 33540 is used for water cooled torch operation and is designed to be freestanding inaconvenientlocationnearthetorch A four gallon capacity tank provides 1 0 gal min 50 psi using 115 volts 50 60 Hertz 1...

Страница 9: ...ON 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 carefully studied and followed as closely as possible After checking to be sure you have all required compo nents and accessories see Section 1 proceed as follows with reference to Figs 2 1 2 2 Interconnec tion Diagrams To...

Страница 10: ...e 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 cover plate from reel Remove coil from its package but do not remove its binding wires Slide coil on...

Страница 11: ...ontrol NOTE Immediately after the control has been turned on various numerical code data e g Pro gram I D Power Source and Slope will appear in 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 in the SET p...

Страница 12: ...d designated by the numeral 1 3 or 6 see Rotary Switch Item 6 a pair of numbers represent WIRE DIAMETER sizes which are programmed for selection as follows 30 35 45 52 or 63 see Rotary Switch Item 6 shielding gas POSTFLOW from 1 to 99 9 sec onds in one tenth of a second increments manual BURNBACK time Manually adjustable burnback time period which when preset will override the automatic adaptive a...

Страница 13: ...3 is for the 5000 aluminum series of wires 2 Wire Diameter This parameter is displayed in the right VOLTS window and offers a choice of five 5 wire diameter sizes which can be used for each torch and is set by operating 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 Position3 SpotTime BurnbackTime ...

Страница 14: ...without energizing the welding circuit It also allows you to look at a pair of numbers that will SECTION 3 OPERATION have a bearing on the quality of starts as explained in Section 3 4 B 5 2 After starting the welding sequence if an abort shutdown condition occurs indicated by a flashing digital display the RESET posi tion can be actuated and the control automati cally resets for a new start 3 Act...

Страница 15: ...cteristic set on your power source One of three slope designations will ap pear in the VOLTS window 1 for Flat 3 for Medium or 6 for Steep Slope Make sure the feeder 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 when added on both torches are locked in B PROGRAM FIRST e g RIGHT TOR...

Страница 16: ... such as cable length type of torch used water ver sus gas cooled shielding gas condition of weldment type of welding wire etc To mini mize the effect of these variables a simple adjustment will allow you to increase or de SECTION 3 OPERATION crease the initial arc striking voltage to optimize starting The following procedure 5 A allows you to make this correction 5A Setting Controller For Optimum...

Страница 17: ... metal to metal contact between the wire feeder chassis and a metal surface connected in any way to a welding ground With such contact a poor welding ground connection may create a difference In potential that sends part of the welding current through the safety ground wiring resulting inburnoutofthatwiringand ordamagetothefeeder circuitry Ifthesafetygroundburnsout theoperator may be exposed to 11...

Страница 18: ...s decimals etc or are completely incorrect in relation to your settings the memory must be cleared This condition might occur after a bad lightning storm extremely bad power line surge etc To clear the memory do the following a Place the Run Set key switch in its SET position b Turn off the unit s 115 volt Power switch c Using one hand hold both of the Inc Dec toggle switches in their INC position...

Страница 19: ...l Shut Down either preset VOLTS or IPM displays will flash The control will flash the param eter VOLTS or IPM that cannot be maintained If this condition occurs the respective speed and voltage conditions servos need to be checked for each 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 all of the following the factory s...

Страница 20: ...o this setting will override the servo b Place the Panel Remote switch on the power source in PANEL position c Make a weld by controlling the arc voltage directly from the power source potentiometer d If a weld can be made with good control over power source voltage a problem exists either in the inter connecting voltage control cable or in the Digimig control e Check the control wires in the inte...

Страница 21: ...21 SECTION 4 TROUBLESHOOTING Fig 4 1 Schematic Diagram Dual Digimig 30914 L ...

Страница 22: ......

Страница 23: ...t or dirt Cleaning is best accomplished by regularly blowing off these parts with dry compressed air This should be done once for every eight hours of operating time more often if necessary B LUBRICATION OF DIGITAL MOTOR GEAR UNIT The EH 10A motor gear digital unit is lubricated with a heavy duty grease when assembled at the factory and should not require further lubrication unless disas sembled I...

Страница 24: ...H 10A DIGITAL MOTOR GEAR UNIT ASSY 679777 See Fig 6 BASE 678806 LEFT TORCH J4 RECEPTACLE 182W64 C16 CAPACITOR 672348 2 ACCESSARY SUPPORT ASSY 2 ROLL DRIVE See Fig 8 49V51 FRONT CONTROL SUPPORT 30917 SW1 3 5 SWITCH 950087 LIFTING BRACKET 30916 CONTROL ASSY 30913 see Fig 7 6 POS ROTARY SW 679914 Fig 6 1 DigiMig Dual Wire Feeder P N 30912 Front View ...

Страница 25: ...LEVILLE WASHER 950783 Replace decal if it becomes excessively worn or lost when replacing panel s Recommended Spare Parts Replacement key for Run Set SW 32778 J1 RECEPTACLE 950762 19 pin C20 CAPACITOR 1uf 500 V CB CIRCUIT BREAKER 950874 MSL POWER ON OFF SW 634517 STRAIN RELIEF 96W76 RUN SET SW 950956 2 GAS INLET CONNECTION 74S76 2 GAS SOLENOID VALVE 2062305 2 GAS BULKHEAD ADAPTOR 58V58 VR VOLTAGE ...

Страница 26: ...19731 BRUSH HOLDERzz zGASKET SEAL KIT 20542 Includes those items market with Fig 6 3 EH 10A Motor Gear Unit Parts Breakdown TACH P C B D 675429 2 Screw 61324746 Gear Case Lubricated with Texac Multifak Grease 11 6 2 370 93 6251 MOTOR END HOUSING Ref 54 LG 10 2 875 50 DP MIN VENTPLUG 3 25 2 000 5 16 18 UNC 2B 2 86 25 4 010 SQ 2 25 1 375 1 375 25 END VIEW w COVER REMOVED 63 MIN DEPTH MTR LEAD TACH D...

Страница 27: ...P4 To MPU P2 CABLE ASSY 677938 For Replacement Battery on I O Board order P N 951733 I 0 P C BOARD ASSY 674956 CTR1 BOT CONT TRANSFORMER 950088 Replace decal if it becomes excessively worn or lost Recommended Spare Parts CTR2 TOP CONT TRANSFORMER 994303 T1 20 PT Terminal Strip 950182 NOTE The heat sinks of the J gov board are electrically hot Do NOT touch or ground while unit is energized DISPLAY ...

Страница 28: ...INER 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 TYPE WASHER 948254 SCREW 5 16 18 x 2 HAIR PIN CLIP 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 995570 Includes REEL 995568 COVER 9955...

Страница 29: ...29 NOTES ...

Страница 30: ...30 NOTES ...

Страница 31: ...e upper corners of the control panel on the power source and open the control panel 4 Install the 14 pin receptacle into the front panel from the inside and secure with the four screws provided with the kit 5 Locate the control leads access grommet to the control panel Insert the connector from the 14 pin receptacle through this grommet Route the leads along with the other control leads and se cur...

Страница 32: ... Warranty 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 EST Part 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 5...

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