EH-10A. DIGITAL WELDING HEADS P/N s &

Transcription

1 INSTRUCTION MANUAL EH-10A DIGITAL WELDING HEADS P/N s & F C September, 2000 SPECIFICATIONS Motor volts, DC Permanent Magnet Continuous 2.2 Amps DC. Gear Unit - 40:1 Reduction, Grease Lubricated Max. Output Full Load RPM Max. Wire Feed Speed IPM Dimensions - See Figure 3 Weight (approx) lbs. I. INTRODUCTION The EH-10A Digital Welding Head is designed for automatic mechanized mig installations which use a microprocessor controlled, digital logic operated wire feeding system. The Welding Head is composed of three basic assemblies; a wire feed motor - tachometer assembly, a gear reduction box, and the accessory support system. Either of two welding heads (section II following) are available for use, and wire sizes accommodated are: Hard /8 inch ( mm) Soft /32 inch ( mm) Flux Core /8 inch ( mm) These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding, Cutting, and Gouging", Form Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on page 2 before installing or operating this equipment. Be sure this information reaches the operator. You can get extra copies through your supplier.

2 SAFETY PRECAUTIONS WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death. PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment 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. Bystanders should also wear goggles over safety glasses. FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore: 1. Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable 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 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 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 damaged 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. 10/98

3 II. REQUIRED EQUIPMENT A. Two Roll Drive Digital Welding Head Package This head provides wire speeds from ipm using a 40:1 gear reduction ratio, and accessory support wire drive assembly. The motor-tachometer power and control signals are provided through a 5-pin amphenol plug. The complete Two Roll EH-10A Digital Welding Head Package, will consist of the following with custom variations as listed below. D. Optional Accessories 1. Wire Straightener, P/N 34V74 (See Figure 2). By manipulating the adjusting screw, various pressures can be placed on the welding wire as it passes through the wire straightener, straightening the wire and removing any kinks or residual curvature. To install the wire straightener, remove the inlet wire guide (29N13) and insert (05N58) from the accessory support, and screw it into the straightener. If wires larger than 3/32- in. are used, the insert (05N58) should be omitted. This assembly (straightener/inlet wire guide) is then inserted into the clamp of the accessory support and secured by tightening the locking handle. EH-10A Digital Motor Roll Accessory Support 49V51 Insulator Ring 60N90 Motor Control Cables 25 ft ft EH-10A Digital Motor Roll Accessory Support 49V51 Insulator Ring 60N90 Motor Control Cables 25 ft ft Either of two additional accessories are required to complete the installation on the wire inlet side of the straightener: a. Wire Inlet Guide, P/N 11N53, or -- b. Wire Wiper Holder, P/N Wire Wiper. The wire wiper effectively cleans and lubricates the welding wiper as it is being fed, thus providing smoother wire feeding and longer conduit life. A complete wiping assembly consists of a Felt Wiper (P/N , Pkg. of 10) and one of the Wiper Holders following: a. Wiper Holder, P/N , screws into the optional wire straightener (see D-1 and Figure 2). b. Wiper Holder, P/N , screws on to the accessory support s inlet wire guide as shown in Figure 4. III. DESCRIPTION A. The Welding Head B. Four Roll Drive Digital Welding Head Package The complete Four Roll EH-10A Digital Welding Head Package, will consist of the following with custom variations as listed below. The EH-10A Digital Welding Head illustrated in Figure 1 is the wire drive mechanism which, when used in combination with appropriate accessory and control equipment, feeds welding wire to the weld zone at controlled rates. Wire speed is precisely controlled by a microprocessor/j-governor closed loop digital feedback circuit which constantly monitors the welding head s wire speed through its optical tachometer. EH-10A Digital Motor Roll Accessory Support Insulator Ring 60N90 Motor Control Cables 25 ft ft EH-10A Digital Motor Roll Accessory Support Insulator Ring 60N90 Motor Control Cables 25 ft ft C. Feed Roll and Outlet Guides Feed rolls and outlet guides are not supplied as part of the accessory support and must be ordered seperately. See Table 1 on page 5. 3 The force for feeding welding wire is provided by a rapid response, permanent magnet, open-ventilated motor. The motortachometer is mounted to a gear reduction unit which has a feed roll or insulated drive gear assembly (depending on the accessory support provided) mounted on its output shaft. The gear reduction is composed of two sections of gearing which reduce the output speed of the motor to that required for feeding wire. The accessory support assembly provides the back-up force necessary for positive non-slip wire feed. The Four Roll Drive Accessory Support Assembly (P/N ,Figure 6) is fully covered in booklet F The Two Roll Drive Accessory Support Assembly (P/N 49V51, Figure 5) is fully covered in booklet F Both of these assemblies utilize a quick release clapper/pressure roll assembly which allow you to reduce wire change and pressure resetting time without disturbing the pressure spring setting. The assembly also includes quick release turn-locking handles for mounting a torch and/or wire conduits. This assembly comes equipped with a pressure roll but does not include a feed roll. Refer to Table 1 page 5 to select proper feed roll for wire size and type to be used.

4 IV. INSTALLATION AND OPERATION A. MOUNTING THE WELDING HEAD (2 Roll Drive) All EH-10A Digital Motor-Gear Units are lubricated with grease and must be mounted in a horizontal position (at no more than 45 from level) with the vent plug on top of the gear reduction assembly to avoid lubricant leakage thru the vent plug. B. INSTALLING THE FEED ROLL To install the feed roll, proceed as follows: 1. Release the clapper on the accessory support assembly (Figure 4) by disengaging the retainer from the clapper fork. 2. Remove thumbscrew, bell washer and flat washer from the feed roll shaft. 3. Slip the feed roll on the shaft, engaging the key. Be sure to observe the THIS SIDE OUT marking on the feed roll. 4. Replace flat washer, bellwasher and thumbscrew, tightening screw sufficiently to eliminate all end play from the feed roll. C. INSTALLING INLET AND OUTLET WIRE GUIDES 1. Inlet guide 29N13 and insert 05N58 are supplied with the accessory support assembly 49V51 (see Figure 4). They are held in place by rotating the locking handle on the accessory support. Note that insert 05N58 should be removed if 7/64-in. or 1/8-in. cored wire is to be used. 2. An outlet guide is supplied as part of the wire feed accessories kits for the torch used. The guide is first attached to the wire feed conduit, then locked in place in the clamp at the outlet side of the accessory support assembly. D. INSTALLING SPOOL/COIL OF WIRE 1. Remove the hairpin clip from spindle. 2. Position the spool of wire so that when it is placed on the spindle, wire will be drawn to the feed roll from the bottom of the spool. The spool should be held so that the index hole on the back will engage the lug on the spindle. 3. Slide the spool onto the spindle until it engages the lug. Lock in place with the hairpin clip. 4. Loosen the brake screw in the center of the spindle hub, then tighten it just enough to prevent coasting of the spool when wire is drawn from it. Too much pressure will load the wire feed motor unnecessarily. Too little pressure will permit the spool to over-run, causing the wire to kink and tangle. 5. Thread the wire on to the accessory support assembly as described in Section E. 6. When wire coils are to be used instead of spools, mount wire reel on spindle as though 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 it binding wires. Slide coil onto reel so that wire will be drawn from bottom of coil (starting end for a coil is always the outer end). Replace reel cover plate and thumbnuts. Cut off coil tie wires and thread wire to torch as covered in 4 and 5 above. E. ADJUSTING THE ACCESSORY SUPPORT ASSEMBLY When a new wire size or type is to be used, set the pressure roll adjusting as follows: 1. Round off the free end of the welding wire with a file to remove sharp edges and burrs which might damage the conduit liner. 2. Release the clapper and unscrew the pressure adjusting knob until the pressure spring is free. 3. Thread the wire through the inlet and outlet guides of the accessory support, and 3 or 4 inches into the torch conduit Engage the clapper making sure the wire is held in the feel roll groove. 5. Tighten the pressure adjusting knob until the wire is firmly against the feed roll -- do not overtighten. The spring pressure applied should be the minimum required to provide positive, nonslip wire feed. Too little pressure will result in wire slippage while excessive pressure will scar and deform the wire. Further adjustment can be made after the wire feed is put into operation. Note that a light spring (182W55) is installed on the accessory support for use with soft and small diameter hard wire. For larger diameter hard wire, replace this spring with a heavy spring (182W54) supplied with the unit. F. FEEDING WIRE AND ADJUSTMENTS With wire engaged in the accessory support per section IV-E, feed wire through torch conduit and torch as follows: 1. Remove nozzle and contact tip from torch. 2. Operate remote INCH switch until cold wire protrudes from torch front end. Release the INCH switch. 3. Slide the contact tip over the end of the wire and secure to torch. Replace the torch nozzle. 4. Reoperate the remote INCH switch and check for wire feed slippage on the accessory support assembly. Tighten (or loosen) the pressure adjusting knob until the wire feeds smoothly. 5. Refer to the appropriate welding control instruction booklet for remaining operating procedures. V. INSTALLATION OF THE FOUR ROLL DRIVE A. FOUR ROLL DRIVE ASSEMBLY To install the four roll drive assembly on an EH-10 Motor-Gear Unit proceed as follows: 1. Remove the jam nut (EH-3) or thumbscrew (EH - 10) and washer from the output shaft of the motor-gear unit. 2. Fit the Gear and Insulator Assembly (P/N ) onto the motor-gear unit shaft and engage the Key (P/N 28N33). 3. Insert the 1/4-in.-20 x 1/2-in. panhead screw (P/N ), 1/4-in. bell washer (P/N ), and 1/4-in. flatwasher (P/ N ) in the motor-gear unit shaft to secure the gear and insulator assembly. 4. Position the four roll drive assembly on the motor-gear unit insulator ring and secure by tightening the 5/16-18 capscrew at the bottom of the assembly. Be sure the gear and insulator assembly meshes correctly with the lower feed roll gears in the four roll drive assembly. B. FEED ROLLS To install the desired feed roll kit (see Table l) proceed as follows: 1. Position the feed rolls over the four gear assembly hubs aligning the feed roll holes with the gear assembly holes. 2. Secure the feed rolls to the gear assemblies using the No x 5/8-in. screws and lockwashers supplied. C. CENTER WIRE GUIDE To install the proper center wire guide (see Table l) proceed as follows:

5 1. Remove the two No x 5/8-in. panhead screws which attach the Center Guide Clamping Plate (P/N ) to the Center Guide Block (P/N ). Remove the plate. 2. Insert the center wire guide in the groove of the guide block. 3. Replace the clamping plate, using the screws removed in step 1 above. B. LUBRICATION OF DIGITAL MOTOR-GEAR UNIT The EH-10A digital motor-gear unit is lubricated with a heavy duty grease when assembled at the factory and should not require further lubrication unless disassembled. If disassembled relubricate with Texaco Multifak grease. C. CHECK OR REPLACEMENT OF MOTOR BRUSHES VI. MAINTENANCE If this equipment does not operate properly, stop work immediately and investigate the cause of the malfunction. Maintenance work must be performed by an experienced person, and electrical work by a trained electrician. Do not permit untrained persons to inspect, clean, or repair this equipment. Use only recommended replacement parts. Motor brushes should be checked periodically. If a brush is broken, or worn down to less than 3/8-in. length, it must be replaced. Brushes can be inspected by unscrewing the brushholder plug and withdrawing the brush assembly. Never remove a brush without matchmarking it and its holder, so that it can be replaced in the same holder in its original position. REMOVAL OF EH-10A DIGITAL WELDING HEAD A. GENERAL MAINTENANCE Little maintenance is required to keep the welding head in top operating condition. It is important, however, that moving parts such as feed and pressure rolls, wire feed motor, etc., be kept clean and free of dust 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. Table 1. Feed Roll & Outlet Guide Selection 1. Unplug the control cable(s) from the control assembly. 2. Remove the accessory support assembly from the motorgear unit be loosening the capscrew at the bottom of the assembly. 3. Unplug the motor/tachometer cable from the control assembly. 4. Remove the four screws which secure the digital motor-gear unit to the base and remove the digital unit. 4 Roll Notes 1 4-roll kit includes center wire guide and 2 upper and 2 lower feed rolls. 2 Roll Notes 2 Flat pressure roll 28V52 recommended for all applications except 3/64 and 1/16 aluminum. * U groove pressure roll, P/N , is recommended. ** U groove pressure roll, P/N , is recommended. 3 2" feed rolls only - 2 roll drive a Includes replaceable sleeve P/N b Includes replaceable sleeve P/N c Includes replaceable sleeve P/N d Requires outlet guide insert:.030/.035 yellow P/N /64 red P/N 05N57 1/16 white P/N 12N75 3/32 blue P/N 05N58 5

6 VI. REPLACEMENT PARTS DATA 1. All replacement parts are keyed on the illustrations which follow. Order replacement parts by part number and part name, as shown on illustrations. DO NOT ORDER BY PART NUMBER ALONE. 2. Always state the series or serial number of the machine on which the parts are to be used. The serial number is stamped on the unit nameplate. 3. Indicate any special shipping instructions. 4. Order replacement parts from the ESAB office or distributor nearest you. Accessory Support: Four Roll Assy (see Fig. 6 or Booklet F ) EH-10A Motor/Gear/Tachometer Assembly (40:1) w/plug , See Figure 3 5-Pin Amphenol Plug (on end of motor/tach leads) Insulating Ring - 60N90 (Between Acc. Support & Motor) Accessory Support: Two Roll Assy. - 49V51 Illustrated (see Fig. 5 or Booklet F ). Thumbscrew, 1/4-20 ( ) Bellwasher, 1/4 - (950783) Flatwasher, 1/4 - ( ) Key - 28N33 For Tachometer & Related Part Numbers (See Figure 3.) EH-10A Digital MotorP/N (With 5-pin amphenol plug on power and control wiring harness) Figure 1A - Two Roll Drive Digital Welding Head Pkg Four Roll Drive Digital Welding Head Pkg

7 5-pin Amphenol Plug 5-Pin Amphenol Plug (on end of motor/tach leads) EH-10A P/N EH-10A P/N Figure 1B. EH-10A Digital Motor Variations NOTE: Motor control cables for both & are identical. These cables are available in two lengths: 25 ft. P/N ft. P/N Fig.2 - Optional Wire Straightener, P/N 34V74 7

8 8 Fig.3 - EH-10A Digital Motor-Gear Assembly (40:1, IPM) P/N Installed in units manufactured after October, 1984.

9 OUTPUT SHAFT ASSY. (Part of OUTPUT GEAR CASE) GEAR ASSY. "B" GEAR ASSY. "A" ** BRUSH END BELL (Includes TWO BRUSH HOLDER ASSY) MAGNET ASSY MOTOR CORD LEAD BRUSH HOLDER ** BRUSH CAP 9 OUTPUT GEAR CASE (Includes Output Shaft Assy. Shown Above) (2) CARBON BRUSH REPLACEMENT KIT Includes: (2) BRUSH CAP (2) CARBON BRUSH ARMATURE SHAFT SEAL * OUTPUT GEAR CASE GASKET * ARMATURE & BEARINGS Includes: ARMATURE BEARING OUTPUT SHAFT SEAL * * GASKET SEAL KIT (Includes Those Items Marked With *) Fig.4 - EH-10A Motor-Gear Unit Parts Breakdown (40:1)

10 KNOB - 60N68 SHAFT - 60N65 SPRING - 182W54 RETAINER - 58N24 OUTLET GUIDE (See Table 1 Page 5) FORK - 49V43 CAPSCREW - 5/16" - 18 X 1 3/4" NUT - 5/16" - 18 INLET GUIDE (See your Torch Instruction Booklet) SETSCREW X 1/4 LG PRESSURE ROLL - 28V52 CLAPPER ASSY. - 60N98 ROLLPIN (1/4 X 1-3/4" LG) CLAMP - 61N02 SUPPLIED: KEY - 29N33 THUMB SCREW WASHER (2) LOCKING HANDLE ASSY. (49V44) Includes: Bolt - 1/4 x 1 5/8 LG Spacer - 60N79 Fig.5 - Two Roll Drive Accessory Support Assembly - P/N 49V51 10

11 INLET GUIDE (See Table 1 Page 5) (2) LOCKING HANDLE (49V44) OUTLET GUIDE (See your Torch Instruction Booklet) CAPSCREW - 5/16" - 18 X 1 3/4" ( ) NUT - 5/16" - 18 ( ) (4) FEED ROLL ( Optional Selections) Feed Roll Mounting Hardware: (17) SCREW - No x 5/8" ( ) (17) LOCKWASHER - No. 8 ( ) (4) FLATWASHER CLAPPER ASSY KNOB - 60N68 SPRING - 182W54 (4) GEAR ASSY. ( ) RETAINER - 58N24 ROLLPIN FORK - 49V43 CLAMPING PLATE GEAR & INSULATOR ASSY SCREW - 1/4 X 20 X 1/2" ( ) BELL WASHER - 1/4" ( FLATWASHER - 1/4" ( ) ROLLPIN (3/16 X 1-3/4") Fig.6 - Four Roll Drive Uniform Pressure Accessory Support Assembly - P/N

12 Literature Changes The C Edition of this Instruction Book Covers: 1. The addition of the Digital Motor information. 2. The addition of the ( ft.) and the ( ft.) motor control cable assemblies. 3. The modification of parts and assembly drawings for clarification. 4. The removal of Pre-1984 Motor Gear Unit Parts Assembly Drawing. Related Literature 2-Roll Drive Accessory Support Assembly, F Roll Drive Accessory Support Assembly, F F C 9/2000