MA-20 Manual 6-09.vp
Contents
1. DIP SWITCH NAME SWITCH POSITION 1 CLOSED INHIBIT 2 OPEN 1 OPEN TAPER 2 CLOSED SELECT ONE 1 2 ss 55 5 FIGURE 24 TAPER DIP SWITCH SETTINGS When Taper Signal is used Remote Start put in a Normally Closed N C configuration the control unit will oscillate the arc whenever there is a closure between Pins J and When closure be tween Pins J and A is removed the Taper Feature will OSC Sure eje OPEN STAB FIGURE 23 DEFAULT OSC STAB DIP SWITCH SETTINGS S1 20 0600 0312 OPERATION be enabled and the magnetic field strength generated by the controller will begin to decrease The Taper adjustment will set the time to reach zero or no mag netic field strength At the end of the Taper Time the magnetic oscillation will stop Arc oscillation will not begin again until the N C Taper closure is made Once the Taper input has been made the arc will be gin to oscillate again at the Amplitude adjustment set ting INSTALLATION Once the MA 20 system has been properly installed and the operator has familiarized himself with the unit functions we recommend that the operator set up a test block strike an arc and then experiment with the MA 20 controls to get a good feel for the equipment With2. P5 Taper N O Contact Open to Enable Taper DN Wht D N C Bik Taper Contact J i T MN Grn Power Ground A Bik N C N N C Earth Ground PE FIGURE 26 REMOTE N C TAPER INTERFACE P5 Inhibit N C Contact Open to Enable Arc Oscillation 2 DN Red B 57 Inhibit Contact l __ RS Grn Power Ground Bik N C N N C PL Earth Ground PE FIGURE 27 REMOTE N C INHIBIT INTERFACE 22 0600 0312 P5 Inhibit N O Contact Close to Enable Arc Oscillation Red Inhibit N O Contact t Bik N C PJ Grn Power Ground A Bik N C N Earth Ground PE FIGURE 28 REMOTE INHIBIT INTERFACE POSITION CHANNEL 1 CHANNEL 2 REMOTE O O 0 ol 0 ol gt SELECT ONE PANEL 2 0 3 52 5 FIGURE 29 DEFAULT POSITION DIP SWITCH SETTINGS 23 0600 0312 24 0600 0312 MAINTENANCE MAINTENANCE MAINTENANCE REQUIREMENTS NOTE This section contains preventative main tenance suggestions only Should repair of the MA 20 system become necessary please call Arc Products Customer Ser vice at 1 800 770 0063 for troubleshooting infor mation an
3. DIP SWITCH NAME SWITCH POSITION 1 CLOSED INHIBIT 2 OPEN 1 CLOSED TAPER 2 OPEN Normally Open Start To use the Remote Start feature not the Taper feature with a Normally Open Start Signal that will close when the arc is to oscillate there are two sets of DIP Switches that need to be configured in addition to the remote interface wiring The Inhibit and Taper DIP Switches must be set for Normally Open positions See Table 7 Remote Start N O Inhibit Settings on page 18 The Remote Start Input also known as Inhibit must also be wired correctly on the remote interface cable Figure 28 Remote N O Inhibit Interface shows the proper wiring for N O Configuration Also Figure 20 Default Inhibit DIP Switch Settings illustrate the proper DIP settings 18 0600 0312 OPERATION When the Remote Start Inhibit Signal is used Normally Open N O configuration the control unit will oscillate the arc whenever there is closure be tween Pins and When closure between Pins and A is made the Remote Start will be enabled and arc oscillation will begin When the closure between Pins B and A is removed arc oscillation will stop and will not begin again until the closure is made again Once the Remote Start input has been closed the arc will begin to oscillate again at the Amplitude adjust ment setting SELECT ONE gt NO NC 1 2 O ej 54 cj o OPEN INHIBIT FIG
4. For Your Safety Read this manual before installing or using this equipment 1 IMPORTANT 20 OPERATIONS AND SERVICE MANUAL 1245 30th Street San Diego CA 92154 3477 619 628 1022 619 628 1028 FAX sales Qarc products com service Qarc products com www ap automation com www arc products com THANK YOU for purchasing Arc Products Equipment Our commitment to you is to pro vide an ever expanding family of quality arc positioning equipment controller and accessories Please take the time to read the following pages as they contain important information regarding proper use of this product and of welding cutting safety and procedures WHO DO CONTACT For help Contact your distributor For additional information such as Technical Manuals Service and Parts Circuit and Wire Diagrams User s Guides Distributor Direc tories Contact your distributor To file a claim for loss or damage during shipment Contact your delivering carrier For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Trans portation Department How to contact Arc Products Call 619 628 1022 Fax 619 628 1028 E mail sales arc products com service Qarc products com Arc Products Attn Customer Service 1245 30th Street San Diego CA 92154 Write ALWAYS PROVIDE MODEL NAME AN
5. e TAPER INHIBIT RP1 20k Col 10 0 po d 08 05 06 A06 ieli om e MITTIT R40 RP2 33 Ril R43 24k LC7226 SUE es RP4 100k 00000001 c 13 14 15 6126 3016626 625018 POSITION POWER SUITCH VOLTAGE SELECTOR eee o o o e 2006 Arc Products San Diego CA Y MA 20 40 Magnetic Arc Control 10600 0384 MA 20 Main Bd Assy 10600 0385 MA 40 Main Bd Assy 2 7 9 0600 0386 MA 20 40 Main Bd Rev FIGURE 30 MA 20 MAIN BOARD LAYOUT 27 DRAWING AND PARTS LIST 0600 0312 REV D FIGURE 31 MA 20 MAGNETIC ARC CONTROL EXPLODED VIEW 28 0600 0312 DRAWING AND PARTS LIST TABLE 11 MA 20 MAGNETIC ARC CONTROL PARTS LIST ITEM QPA UM PART DESCRIPTION 1 1 000 EA 0600 0436 MA 20 40 CHASSIS W PEMS 2 1 000 EA 0600 0437 MA 20 40 DOOR 3 1 000 EA 0600 0438 MA 20 FACE PLATE 4 1 000 EA 0600 0384 MA 20 MAIN BOARD ASSY 5 1 000 EA 0600 0463 MA 20 40 TRANSFORMER ASSEMBLY 6 1 000 EA 0600 0464 MA 20 40 RMT ITFC CONN HARNESS 7 1 000 0600 0465 20 CONN HARNESS 8 1 000 0600 0371 POWER SWITCH ASSEMBLY 9 1 000 EA 2120 0123 FILTER RFI PWR LINE 3 AMP 10 1 000 EA 920035 001 SLIDE SW 2 POS LINE VOLT SEL 11 1 000 EA 212
6. FIGURE 26 REMOTE N C TAPER INTERFACE FIGURE 27 REMOTE N C INHIBIT INTERFACE FIGURE 28 REMOTE INHIBIT INTERFACE FIGURE 29 DEFAULT POSITION DIP SWITCH SETTINGS MAINTENANCE NNNNRNNNN SS N O Q M DRAWING AND PARTS LIST N N FIGURE 30 MA 20 MAIN BOARD LAYOUT FIGURE 31 MA 20 MAGNETIC ARC CONTROL EXPLODED VIEW FIGURE 32 POWER SWITCH ASSEMBLY EXPLODED VIEW FIGURE 33 TRANSFORMER ASSEMBLY EXPLODED VIEW FIGURE 34 PROBE CABLE HARNESS EXPLODED VIEW FIGURE 35 REMOTE INTERFACE CABLE HARNESS EXPLODED VIEW FIGURE 36 MP 1 MAGNETIC ARC PROBE EXPLODED VIEW FIGURE 37 MP 2 ARC PROBE EXPLODED VIEW FIGURE 38 MP 22 MAGNETIC ARC PROBE EXPLODED VIEW FIGURE 39 MP 100 MAGNETIC ARC PROBE EXPLODED VIEW FIGURE 40 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW TROUBLESHOOTING WH Co Co Co N G N O CIRCUIT DESCRIPTIONS FIGURE 41 20 MAGNETIC ARC CONTROL SIGNAL FLOW SCHEMATICS AND BLOCK DIAGRAMS RA FIGURE 42 1 PROBE BLOCK DIAGRAM viii 0600 0312 TABLE OF FIGURES FIGURE 43 MP 2 ARC PROBE BLOCK DIAGRAM 47 FIGURE 44 MA 20 MAGNETIC ARC CONTROL BLOCK DIAGRAM Rod 248 FIGURE 45 MA 20 MAGNETIC ARC CONTROL BLOCK DIAGRAM CONT Rods A FIGU
7. MP 100 Magnetic Arc DESCRIPTION OF EQUIPMENT 0600 0312 REV D Porbe Assembly for detailed dimensions and specifi cations MP 2 PROBE The dual tip MP 2 slips over conventional torch and can be used either for cross seam arc weaving or in line arc weaving In line weave is primarily used in tube mills to preheat the tube pishing the arc into the direction of travel giving increased weld travel speeds See page 12 is Table 5 MP 2 Magnetic Arc Probe Assembly Specifications and Figure 11 MP 2 Magnetic Arc Probe Assembly for detailed dimensions and specifications MP 22 PROBE This twin tip side mount unit is capable of delivering the full 600 gauss magnetic field to the welding arc area Though normally used in an air cooled mode if necessary the MP 22 can also be water cooled For detailed specifications on the MP 22 probe see Table 6 MP 22 Magnetic Arc Probe Assembly Specifications and Figure 12 MP 22 Magnetic Arc Probe Assembly on page 13 FIGURE 1 MP 1 AND MP 100 MOUNTING METHOD CROSS SEAM FIGURE 2 MP 1 AND MP 100 MOUNTING METHOD ALONG SEAM 0600 0312 REV D DESCRIPTION OF EQUIPMENT FIGURE 3 MP 2 MOUNTING METHOD ALONG SEAM FIGURE 5 MP 22 MOUNTING METHOD ALONG SEAM FIGURE 4 MP 2 MOUNTING METHOD CROSS SEAM FIGURE 6 MP 22 MOUNTING METHOD CROSS SEAM INSTALLATION 0600 0312
8. INSTALLATION GENERAL SETUP OPTIONS AND SPECIALS CONTROL UNIT LOCATION MAGNETIC ARC PROBE MOUNTING MP 1 amp MP 100 MP 2 MP 22 OPERATION 0000000 OPERATION SE GENERAL OPERATIONAL DESCRIPTION CONTROL FEATURES amp FUNCTIONS REMOTE PANEL POSITION CONTROL STABILIZE OSCILLATE SWEEP TABLE OF CONTENTS 0600 0312 REV D LEFT amp RIGHT DWELL AMPLITUDE POSITION FINAL TAPER REMOTE START NORMALLY OPEN START NORMALLY CLOSED START NORMALLY OPEN START USING TAPER NORMALLY CLOSED START USING TAPER INSTALLATION MAINTENANCE MAINTENANCE MAINTENANCE REQUIREMENTS CONTROL UNIT PROBES ASSEMBLIES CABLE ASSEMBLY PREVENTIVE MAINTENANCE SCHEDULE MONTHLY MAINTENANCE PROBE ASSEMBLIES PROPER FUNCTION TEST QUARTERLY MAINTENANCE SEMI ANNUAL MAINTENANCE CONTROL UNIT ASSEMBLY DRAWING AND PARTS LIST DRAWING AND PARTS LIST TROUBLESHOOTING 27 TROUBLESHOOTING RECOMMENDED SPARES FOR TROUBLESHOOTING PROBLEM 1 PROBLEM 2 PROBLEM 3 CIRCUIT DESCRIPTIONS 43 43 43 43 CIRCUIT DESCRIPTIONS SYSTEM WIRING DIAGRAM MAIN BOARD ASSEMBLY SCHEMATICS AND BLOCK DIAGRAMS 45 45 45 SCHEMATICS AND BLOCK DIAGRAMS INDEX 47 INDEX 53 vi 0600 0312 TABLE OF TABLES Table of Tables MA 20 MAGNETIC ARC CON
9. Board FIGURE 41 MA 20 MAGNETIC ARC CONTROL SIGNAL FLOW 46 0600 0312 SCHEMATICS AND BLOCK DIAGRAMS SCHEMATICS AND BLOCK DIAGRAMS FI FIGURE 42 MP 1 MAGNETIC ARC PROBE BLOCK DIAGRAM FI FIGURE 43 2 ARC BLOCK DIAGRAM 47 SCHEMATICS AND BLOCK DIAGRAMS 0600 0312 REV D Mounted to Front Panel Right Dwell 2 o 1 R6 10K 1 R5 10K Right Dwell 1 Left Dwell i 3 Q O NO Left Dwell 053 y Yel N 082 Front Panel 2 psi o Speed Taper iwht Gm tab l R11 32 10K Stk amplitude 2 Position Front Panel 1 Power Switch 81 L1 2 oso og gt os 0030 Ao 3 1 H v E ASSEMBLY 2N 0400 POWER SWITCH Secondary 110 110 Primary TRANSFORMER ASSEMBLY Voltage Selector S2 am oO 8 INPUT POWER ASSEMBLY F1 EMI RFI Bik White L Filter a Black N Green 110 230VAC FB 60 50Hz PE Chassis Ground Stud FIGURE 44 M
10. CLOSED TAPER 2 MC 1 2 55 O OPEN INHIBIT FIGURE 21 INHIBIT NC DIP SWITCH SETTINGS Normally Open Start Using Taper To Remote Start the magnetic arc control using the Taper feature with a Normally Open Signal that will close when the arc is to oscillate there are two sets of DIP Switches that need to be configured in addition to the remote interface wiring The Inhibit and Taper DIP switches must be set for the Normally Open positions See Table 10 Remote Taper N O Settings on page 20 The Taper input must be maintained to keep the mag netic arc control from oscillating the arc To begin os cillating again simply remove the input to the magnetic arc control unit See Figure 22 Default Taper DIP Switch Settings for proper configuration Refer also to Figure 25 Remote N O Taper Interface on page 21 for proper remote interface cable wiring When the Taper Signal is used as a Remote Start in put in a Normally Open N O configuration the con trol unit will oscillate the arc whenever there is not a closure between Pins D and A When a closure be 19 0600 0312 tween Pins D and is made the Taper Feature will be enabled and the magnetic field strength generated by the controller will begin to decrease The Taper adjustment will set the time to reach zero or no mag netic field strength At the end of t
11. Cooling Hose Length 12 3 6M Optional Accessories Tip Extensions Consult Factory 11 INSTALLATION 0600 0312 REV D 1 455 36 96 MM Cable to unit 220in __ 658 1 500 in 38 10 MM PIN 24 1 380 35 05 MM L E 15 5MM 460901 1 and 3 FIGURE 11 MP 2 MAGNETIC ARC PROBE ASSEMBLY TABLE 5 MP 2 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS ITEM DESCRIPTION SPECIFICATION Arc Welding Amperage is limited due to heat and Weld Current Rating strength of arc 400 amps 100 duty cycle 1 quart or water per minute at 68 degrees F 20 C Cooling quid cooling or he probe with a miximum water pressure of 40 PSI Ship Weight 4 pounds 2 3Kg Cable Length Control Cable Length 8 feet 2 4M Hose Length Liquid Cooling Hose Length 12 3 6 Accessories Probe Adaptors 1 380 35 05 mm Torch Adaptor 1 455 39 96 mm Torch Adaptor 1 500 38 10 mm Torch Adaptor Tip Extensions 1 88 Replacement Extended Length Tips 2 req 2 38 Replacement Extended Length Tips 2 req 2 88 Replacement Extended Length Tips 2 req 3 88 Replacement Extended Length Tips 2 req 12 0600 0312 INSTALLATION Torch Mounting Alternate 1 75 Dia Max Torch Mounting Control Cable Water Cooling Connectors Opt
12. Extensions Available 1 3 33mm Dia MIN FIGURE 9 MP 1 MAGNETIC ARC PROBE ASSEMBLY TABLE 3 MP 1 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS ITEM DESCRIPTION SPECIFICATION Arc Welding Amperage is limited due to heat and Weld Current Rating strength of arc 600 amps 100 duty cycle 1 quart or water per minute at 68 degrees F 20 C Cooling liquid co ling or the probe with a miximum water pressure of 40 PSI Ship Weight 5 pounds 2 3Kg Cable Length Control Cable Length 8 feet 2 4M Hose Length Liquid Cooling Hose Length 12 3 6M Accessories Tip Extensions 1 Tip Extension 1 required 2 Tip Extension 1 required 3 Tip Extension 1 required 4 Tip Extension 1 required 10 0600 0312 INSTALLATION Connector for control cable alli FIGURE 10 MP 100 ARC ASSEMBLY TABLE 4 100 MAGNETIC PROBE ASSEMBLY SPECIFICATIONS ITEM DESCRIPTION SPECIFICATION Weld Current Rating Arc Welding Amperage is limited due to heat and strength of arc 600 amps 100 duty cycle Cooling Liquid cooling of the probe 1 quart or water per minute at 68 degrees F 20 C with miximum water pressure of 40 PSI Ship Weight 5 pounds 2 Cable Length Control Cable Length 8 feet 2 4M Hose Length Liquid
13. Logic Controllers xii Qualified 45 R Radio Frequency Interference 45 rectified Sonn 45 Remote 17 Requirements 25 RFI 45 rod gt xi 5 Safety Information x Schedule 25 schematics 43 45 selector 45 Service 45 shield xi xii Source xi45 Stabilize he we ur Romy static electricity discharge 43 Sweep s gt 17 T Taper 17 Technicians 45 test points 45 torch X Xii travel sse xd Troubleshooting 43 44 V Voltage 43 45 W wiring 25 53 INDEX 0600 0312 REV D 54 WZ Arc Products AR 4 A Lincoln Electric Companv ARC PRODUCTS INC 1245 30TH STREET SAN DIEGO CA 92154 3477 619 628 1022 619 628 1028 FAX sales Qarc products com service arc products com www ap automation com www arc products com 0600 0312 Rev D September 2011
14. REV D INSTALLATION and Figure 31 MA 20 Magnetic Arc Control Exploded View The operator may select the proper GENERAL SETUP input voltage using small slotted screwdriver The A standard MA 20 Magnetic Arc Control system is shown in Figure 13 Interconnection Diagram with the necessary interconnects shown schematically The major parts required for installing this system are listed below Check all items for damage when un packing System should consist of the following Control Unit Probe Assembly Remote Interface Cable Power Cord Operators Manual OPTIONS AND SPECIALS Options for the MA 20 System may be purchased from Arc Products Specials include probe tips probe tip extensions and extension length cables designed to fit a particular mechanical configuration when the standard tips or cables will not The installation of the MA 20 System is very easy and can be accomplished on most automatic or semiauto matic setups within minutes CONTROL UNIT LOCATION The MA 20 Control Unit should be placed in a location which provides easy access to the controls and proper air ventilation for cooling To allow adequate ventilation maintain a minimum of 5 inches of unre stricted space between the control unit sides and the nearest obstruction The location should be selected to minimize the amount of dust dirt moisture and cor rosive vapors the Control Unit will be subjected to Please see Figure 14 MA
15. the operator can widen or narrow the weld bead as required to pro vide control of the heat affected zone undercutting and irregular joint edges The controlled magnetic field also reduces arc blow and arc wander while the motion of the arc stirs the molten weld puddle reduc ing porosity and providing a more uniform bead sur face pattern The MA 20 is a simple reliable control with an oscil lating frequency range up to 50 Hz The Pulse Width Modulation PWM design provides a constant mag netic field for a given amplitude setting over the entire frequency range Control functions allow independent control of each of the key waveform parameters and left and right dwell intervals are also independently adjustable The control unit is convection cooled al lowing for less power dissipation and lower operating temperatures The top panel or door of the control unit contains all the controls needed for operation There are three Light Emitting Diode LED indicators in a pattern to the left of the control knobs Each lamp will illuminate alternately during arc oscillation When power is ap plied to the Control Unit the Power On LED will also illuminate The MA 20 Control unit has additional features se lected from inside the control enclosure These fea tures Stabilize Oscillate mode STAB OSC and Remote Panel Position Control are selected via DIP Switches on the main board Stabilize Oscillate mode allows the opera
16. to the probe creating a constant magnetic field which displaces the arc The arc Position dial controls this displacement see Figure 16 Position Settings on page 16 In the Stabilize mode Position can be used to stabi lize the arc and control it without oscillation and in the Oscillate mode Position can be used to offset the os cillating pattern The distance the arc can be dis placed is dependent on the same factors as the Amplitude settings If high amplitude and large offsets are used distortion of the magnetic field is likely and instability will result Final Taper The Taper function is a new feature in Magnetic Arc Control Systems This feature sets the amount of time to decrease the Amplitude setting from its current value to zero in order to perform a better downslope function in coordination with the welding power source or controller Referring to Figure 19 Taper Function the Taper feature is only used with a remote input to feather out the weld pool at the end of the weld 17 0600 0312 The Taper setting should be slightly less than tual downslope time of the welding amperage to be sure the oscillation has stopped completely prior the arc extinguishing This Taper Feature is primarily useful in applications when downslope is used As the welding amperage decreases during downslope the arc becomes weaker and easier to move or oscil late by the magnetic ar
17. 0 0107 HOLDER FUSE 3 AG SOLDER 12 4 000 EA 903009 001 POT 10 TURN PANEL MOUNT 10K 13 2 000 EA 903009 002 POT 10 TURN PANEL MOUNT 1K 14 6 000 EA 940010 001 PRECISION MULTIDIAL 15 2 000 EA 941006 008 LED INDICATOR RED 12VDC 16 1 000 EA 941006 009 LED INDICATOR YELLOW 17 1 000 EA 0600 0440 MA 20 6 PIN COVER 18 1 000 EA 970039 614 SCR 1 4 20X1 00 H SBZ G8 19 2 000 EA 974004 006 WSR F 1 4 734X 312X 065 SBZ 20 2 000 EA 974010 006 WSR SL 1 4 489X 263X 062 SBZ 21 1 000 EA 974011 018 WSR ITA 1 4 478X 267X 028 SBZ 22 2 000 EA 972000 006 NUT 1 4 20 H SBZ 29 DRAWING AND PARTS LIST 0600 0312 REV D ik PowerSwith J wk ye TABLE 12 POWER SWITCH ASSEMBLY PARTS LIST P3 18 gauge wire 4 FIGURE 32 POWER SWITCH ASSEMBLY EXPLODED VIEW ITEM UM PART DESCRIPTION 1 1 000 EA 2066 0171 SWITCH SELECT 1 3 16 RED 4 1 000 EA 2208 0181 CONN RECT PLUG 8CKT 5 6 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 6 5 000 EA 979001 001 CABLE 75 BUNDLE DIA 30 0600 0312 DRAWING AND PARTS LIST D P P2 T N PARS 4 pl T1 G 4 18 gauge I HAr wire MAA AN 2 2 5 3714 p
18. 0014 001 CONN CIRC BOX 20 275 2 1 000 EA 2208 0202 CONN RECT PLUG 12CKT 3 12 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 4 1 000 EA 2340 0588 TERM RING INSUL 6 X 92 LG 5 3 000 EA 979001 001 CABLE TIE 75 BUNDLE DIA 33 DRAWING AND PARTS LIST 0600 0312 REV D FIGURE 36 MP 1 MAGNETIC ARC PROBE EXPLODED VIEW 34 0600 0312 DRAWING AND PARTS LIST TABLE 16 MP 1 MAGNETIC ARC PROBE PARTS LIST UM PART DESCRIPTION 1 1 000 EA 1030 0096 TIP 4604 PROBE 2 2 000 EA 1030 0100 LINK MOUNTING CLAMP 3 2 000 EA 2380 0161 ASSY WATER HOSE 12FT 4 4 000 EA 970015 608 SCR 1 4 20X 62 HSC SBZ 6 1 000 EA 970015 504 SCR 10 32 38 HSC SBZ 7 4 000 974010 006 WSR SL 1 4 489 263 062 587 8 4 000 974004 006 WSR 1 4 734 312 065 SBZ 10 4 000 EA 963018 008 CLAMP HOSE 2 EAR 5 16 11 1 000 EA 1030 0118 CLAMP MACHINED LEFT 12 2 000 EA 974005 006 WSR F 1 4 468X 255X 032 SBZ 13 1 000 EA 1030 0878 CLAMP MACHINED RIGHT 14 2 000 EA 2380 0136 FTG STR MALE 3 16 TB X 1 8 NPT 15 2 000 EA 963020 001 FTG 1 8 FEM NPT 1 8 TUBE ID 16 1 000 EA 1034 0012 CABLE ASSY PROBE 35 DRAWING AND PARTS LIST 0600 0312 REV D DO NOT EXCEED FIGURE 37 MP 2 MAGNETIC ARC PROBE EXPLODED VIEW 36 0600 0312 DRAWING AND PARTS LIST TABLE 17 MP 2 MA
19. 20 Magnetic Arc Control Mounting Dimensions for mounting hole patterns and other dimensions NOTE Although the control unit requires no other electrical interfacing with any of the users s other equipment be sure to se lect the proper input voltage before plug ging the unit into the ac power outlet This unit operates on either 110 220 VAC 50 60 hz power Be sure the Voltage Selector switch is in the proper position for the power you are using The Voltage Selector switch is located on the outside of the control unit near the AC power cord receptacle Refer to Figure 7 MA 20 Magnetic Arc Control Unit mounting dimensions of the control unit are shown in Figure 14 MA 20 Magnetic Arc Control Mounting Di mensions should the user choose to install the MA 20 on a fixture or control panel MAGNETIC ARC PROBE MOUNTING The MP 1 MP 22 and MP 100 Probes will mount on any machine torch with a body diameter from 1 31 inches to 2 inches The MP 2 Probe will mount on any machine torch with a body diameter of 1 625 inches or less See review the figures and tables on the following pages beginning on page 10 for dimen sional references MP 1 amp MP 100 Back off the two socket screws which secure the probe mounting bracket to the torch body Slip the probe over the torch and align the tips approx imately even with the gas cup or bottom of torch Tighten the 2 screws then loosen the screws holding the bracket to the prob
20. 312X 065 SBZ 11 2 000 EA 970015 616 SCR 1 4 20 1 25 HSC SBZ 12 2 000 EA 974005 006 WSR F 1 4 468X 255X 032 SBZ 13 1 000 EA 0600 0322 BOLT 10 32 1 00 SOCHD 14 2 000 EA 974010 005 WSR SL 10 334X 202X 047 587 15 1 000 EA 0600 0321 BOLT 10 32X 5 SOCHD 16 1 000 EA 972005 005 NUT 10 32 HB 17 1 000 EA 0600 0329 WATERHOSE MP 100 w FITTINGS NOT SHOWN 41 DRAWING AND PARTS LIST 0600 0312 REV D F1 52 Dopo C PP Ay HV YAN 4 5 pl EMI RFI B L Hd 1 ji z Uu FIGURE 40 VOLTAGE SWITCH ASSEMBLY EXPLODED VIEW TABLE 20 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST ITEM QPA UM PART NUMBER DESCRIPTION 1 1 000 EA 920035 001 SLIDE SW 2 POS LINE VOLT SEL 2 1 000 EA 2120 0123 FILTER RFI PWR LINE 3 AMP 3 1 000 EA 2208 0551 CONN RECT PLUG 6 PIN 200 P 4 5 000 EA 2212 0152 TERMINAL CRIMP PIN 18 24 GA 5 1 000 EA 2120 0000 FUSE CARRIER 1 4 X 1 1 4 FEK 6 1 000 EA 2360 6087 FUSE 2 5A 250 7 1 000 EA 2340 0618 TERM RING 1 4 22 16 RED 42 0600 0312 TROUBLESHOOTING TROUBLESHOOTING The following list describes typical problems and sug gested corre
21. A 20 MAGNETIC ARC CONTROL BLOCK DIAGRAM Main Board Assembly 0600 0312 SCHEMATICS AND BLOCK DIAGRAMS J12 P12 Blu Bik Brn 12 12 11 11 Wht Blu Gm Wht Grn Wht See Remote Interface 5114110 SLNaNI 310 38 TO REMOTE EQUIPMENT Wnt Yel Wht Org 2N 0420030003 Wht See Probe Schematic 380Hd FIGURE 45 20 MAGNETIC CONTROL BLOCK DIAGRAM CONT 49 SCHEMATICS AND BLOCK DIAGRAMS 0600 0312 REV D P1 FIGURE 46 MP 22 MAGNETIC BLOCK DIAGRAM FIGURE 47 100 BLOCK DIAGRAM 50 0600 0312 SCHEMATICS AND BLOCK DIAGRAMS N C N C Start N O Contact Start N C Contact Taper Contact Taper N C Contact Power Ground N C SVDC Output MA 20 40 Position I MA 40 Position II 5VDC Output Earth Ground PE 5 K L Brn NIC Bik M NIC Uae any ane method B Red o Start N O Contact Close to Start Bik Contact Open to Start Wht gt gt D Taper Contact Close to Start Bik J Taper Contact Open t
22. AL CAN BE MORE SEVERE THAN SUNBURN Usea proper face shield fitted with the cor rect filter 410 or greater and cover plates to protect your eyes face neck and ears from the sparks and rays of the cutting welding arc when cutting welding or observing cut ting welding Warn bystanders not to watch the arc and not to expose themselves to the cutting welding arc rays or to hot metal B wear flameproof gauntlet type gloves a heavy long sleeve shirt cuff less trousers high topped shoes and a welding helmet or cap for hair protection to protect the skin from arc rays and hot sparks or hot metal C Protect other nearby personnel from arc rays and hot sparks with a suitable non flam mable partition D Always wear safety glasses or goggles when in a cutting or welding area Use safety glasses with side shields or goggles when chipping slag or grinding Chipped slag is hot and may travel a considerable distance By standers should also wear safety glasses or goggles E Compressed gas oylinders are potentially dangerous refer to the suppliers for proper handling procedures F wear ear plugs or other ear protection de vices when operating cutting or welding equip ment FIRE SAFETY HOT SLAG OR SPARKS CAN CAUSE A SERIOUS FIRE WHEN IN CONTACT WITH COMBUSTIBLE SOLIDS LIQUIDS OR GASES Move all combustible materials well away from the cutting area or completely cover ma terials with a non flammable covering
23. Com bustible materials include but are not limited to wood clothing sawdust gasoline kerosene paints solvents natural gases acetylene pro pane and similar articles B Do not weld cut or perform other hot work on used barrels drums tanks or other con tainers until they have been completely cleaned There must be no substances in the container which might produce flammable or toxic vapors C For fire protection have suitable extin guishing equipment handy for instant use WELDING AND CUTTING FUMES AND GASES PARTICULARLY IN CONFINED SPACES CAN CAUSE DISCOMFORT AND PHYSICAL HARM IF INHALED OVER AN EXTENDED PERIOD OF TIME At al times provide adequate ventilation in the welding and cutting area by either natural or mechanical means Do not weld or cut on galvanized zinc lead beryllium or cadmium materials unless positive mechanical ventila tion is provided to prevent inhaling fumes and gases from these materials B Do not weld or cut in locations close to chlorinated hydrocarbon vapors coming from degreasing or spraying operations The heat of arc rays can react with solvent vapors to form phosgene a highly toxic gas and other irritant gases you develop momentary eye nose throat irritation during welding or cutting it is an indication that the ventilation is not ade quate Stop work and take the necessary steps to improve ventilation in the welding or cutting area Do not continue to we
24. D PART NUMBER OVERVIEW 0600 0312 REV D Overview OVERVIEW IV TABLE OF CONTENTS TABLE OF TABLES VII TABLE OF FIGURES VIII SAFETY SAFETY PRECAUTIONS ADDITIONAL SAFETY HAZARDS XII MA 20 MAGNETIC ARC CONTROL SYSTEM DESCRIPTION OF EQUIPMENT INSTALLATION OPERATION 17 MAINTENANCE 25 DRAWING AND PARTS LIST 27 TROUBLESHOOTING 43 CIRCUIT DESCRIPTIONS 45 SCHEMATICS AND BLOCK DIAGRAMS 47 INDEX INDEX 53 0600 0312 TABLE OF CONTENTS Table of Contents OVERVIEW Rod TABLE OF CONTENTS TABLE OF TABLES TABLE OF FIGURES SAFETY SAFETY PRECAUTIONS IV vil VIII DEFINITIONS NOTE CAUTION WARNING DANGER SAFETY INFORMATION ELECTRIC SHOCK FIRE SAFETY ADDITIONAL SAFETY HAZARDS gt x x gt x X x gt x gt x FIRE AND EXPLOSION FALLING EQUIPMENT HOT PARTS MOVING PARTS MAGNETIC FIELDS CAN AFFECT PACEMAKERS WELDING WIRE FLYING PIECES OF METAL OR DIRT OVERHEATED EQUIPMENT HIGH FREQUENCY SAFETY REFERENCES MA 20 MAGNETIC ARC CONTROL SYSTEM DESCRIPTION OF EQUIPMENT XII XII XII XII XII XII XII XII XII DESCRIPTION OF EQUIPMENT MA 20 CONTROL UNIT MAGNETIC ARC CONTROL PROBES MP 1 PROBE MP 100 PROBE MP 2 PROBE MP 22 PROBE INSTALLATION Co Co W Co
25. GNETIC ARC PROBE PART LIST UM PART DESCRIPTION 1 1 000 EA 1026 0370 PROBE SUB ASSY MAG 2 2 000 EA 1033 0203 TIP STD PROBE 4608 3 2 000 EA 970015 302 SCREW 6 32 25 HSC SBZ 4 2 000 EA 2380 0161 ASSY WATER HOSE 12FT 5 2 000 EA 2380 0136 FTG STR MALE 3 16 TB X 1 8 NPT 6 2 000 EA 963020 001 FTG 1 8 FEM NPT 1 8 TUBE ID 7 4 000 963018 008 2 5 16 9 1 000 2200 0616 CIRC STR PLUG 8 4P 37 0600 0312 DRAWING AND PARTS LIST 000009 000000 4 t Lo 140 NT gt lt pr Me DETAL A FIGURE 38 MP 22 MAGNETIC ARC PROBE EXPLODED VIEW 38 0600 0312 DRAWING AND PARTS LIST TABLE 18 MP 22 MAGNETIC ARC PROBE PARTS LIST ITEM UM PART DESCRIPTION 1 1 000 EA 1026 0141 MAGNET ASSY 2 1 000 EA 1030 0703 HOUSING BACK 3 1 000 EA 1030 0711 HOUSING FRONT 4 1 000 EA 1032 0143 COVER END 5 1 000 EA 1036 0064 COVER HEAT SHIELD 7 1 000 1037 0116 INSULATOR COVER 8 1 000 EA 1030 0207 CLAMP TORCH 9 1 000 EA 1030 0215 CLAMP TORCH 10 2 000 EA 1030 0223 LINK TORCH CLAMP 11 1 000 EA 1037 0108 PAD THERMOSTAT 12 1 000 EA 979001 001 CABLE TIE 75 BUNDLE DIA 13 2 000 EA 2380 0004 PLUG 1 8IN NPT BRAS
26. LOCK DIAGRAMS 47 vii TABLE OF FIGURES 0600 0312 REV D Table of Figures MA 20 MAGNETIC ARC CONTROL SYSTEM DESCRIPTION OF EQUIPMENT FIGURE 1 MP 1 AND MP 100 MOUNTING METHOD CROSS SEAM FIGURE 2 MP 1 AND MP 100 MOUNTING METHOD ALONG SEAM FIGURE 3 MP 2 MOUNTING METHOD ALONG SEAM FIGURE 4 MP 2 MOUNTING METHOD CROSS SEAM FIGURE 5 MP 22 MOUNTING METHOD ALONG SEAM FIGURE 6 MP 22 MOUNTING METHOD CROSS SEAM INSTALLATION FIGURE 7 MA 20 MAGNETIC ARC CONTROL UNIT FIGURE 8 MA 20 MAGNETIC ARC CONTROL SYSTEM COMPONENTS FIGURE 9 MP 1 MAGNETIC ARC PROBE ASSEMBLY FIGURE 10 MP 100 MAGNETIC ARC PORBE ASSEMBLY FIGURE 11 MP 2 MAGNETIC ARC PROBE ASSEMBLY FIGURE 12 MP 22 MAGNETIC ARC PROBE ASSEMBLY FIGURE 13 INTERCONNECTION DIAGRAM FIGURE 14 MA 20 MAGNETIC ARC CONTROL MOUNTING DIMENSIONS FIGURE 15 AMPLITUDE SETTINGS FIGURE 16 POSITION SETTINGS FIGURE 17 SWEEP SETTINGS FIGURE 18 DWELL SETTINGS OPERATION Q Q Q Q uan O Co N N FIGURE 19 TAPER FUNCTION FIGURE 20 DEFAULT INHIBIT DIP SWITCH SETTINGS FIGURE 21 INHIBIT NC SWITCH SETTINGS FIGURE 22 DEFAULT TAPER SWITCH SETTINGS FIGURE 23 DEFAULT OSC STAB DIP SWITCH SETTINGS FIGURE 24 TAPER SWITCH SETTINGS FIGURE 25 REMOTE TAPER INTERFACE
27. P 100 MP 2 and MP 22 Probes or the Cyclomatic 4604 4608 and 4615 Probes MA 20 CONTROL UNIT The control unit is a heavy gauge steel enclosure con taining the electronic circuitry used in the system A microprocessor and other solid state circuits are used to provide long trouble free operation The control unit operates on 115 230VAC 50 60 Hz commercial power capable of supplying approximately 2 amps peak current The unit has a lighted power switch and fuse holder mounted on the exterior of the unit See Table 1 MA 20 Magnetic Arc Control Specifications Table 2 MA 20 Magnetic Arc Control System Components Specifications Figure 7 MA 20 Mag netic Arc Control Unit and Figure 8 MA 20 Magnetic Arc Control System components for additional specifications The system is operated using the controls potentiom eters pushbuttons located on the front panel Addi tional switches are located on the inside of the control unit on the main board via DIP switches A heatsink mounted on the inside of the control unit allows ade quate cooling for the heat dissipating devices Two connectors located on the bottom of the unit pro vide for connection of the probe cable and a remote interface cable The MA 20 system is primarily intended for use with the TIG GTAW process but can also be used with the PLASMA PAW welding process Additionally the MA 20 System can be used with spray MIG and Sub Arc processes With this system
28. RE 46 MP 22 MAGNETIC ARC PROBE BLOCK DIAGRAM hye 190 FIGURE 47 MP 100 MAGNETIC ARC PROBE BLOCK DIAGRAM 50 FIGURE 48 MA 20 MAGNETIC ARC CONTROL INTERFACE CABLE SCHEMATIC De Of SAFETY 0600 0312 REV D SAFETY SAFETY PRECAUTIONS THIS MANUAL HAS BEEN DESIGNED FOR EXPE RIENCED WELDING AND CUTTING EQUIPMENT OPERATORS AND MUST BE READ COMPLETELY BEFORE USING THIS EQUIPMENT IF YOU LACK EXPERIENCE OR ARE UNFAMILIAR WITH THE PRACTICES AND SAFE OPERATION OF WELDING AND CUTTING EQUIPMENT PLEASE CONSULT YOUR FOREMAN DO NOT ATTEMPT TO INSTALL PERFORM MAINTENANCE ON THIS EQUIPMENT UNLESS YOU ARE QUALIFIED AND HAVE READ AND UNDERSTOOD THIS MANUAL IF IN DOUBT ABOUT INSTALLING OR OPERATING THIS EQUIPMENT CONTACT YOUR DISTRIBUTOR OR THE CUSTOMER SERVICE DEPARTMENT OF ARC PRODUCTS DEFINITIONS Throughout this manual NOTE CAUTION WARNING and DANGER are inserted to call attention to particular information The methods used to identify these highlights and the purpose for which each is used are as follows Operational procedural and background in formation which aids the operator in the use of the machine helps the service personnel in the performance of maintenance and prevents damage to the equipment z gt m CAUTION An operational procedure which if not fol lowed may cause minor injury to the opera tor service personnel and or bystanders
29. S 14 1 000 EA 1034 0047 ASSY CABLE 10FT 6IN 15 1 000 EA 976000 008 GROMMET RUBBER 5 16IDX3 4 OD 17 1 000 EA 2120 0026 THERMOSTAT 375F 18 1 000 EA 1030 0231 TIP RIGHT PROBE 4615 19 1 000 EA 1030 0240 TIP LEFT PROBE 4615 20 4 000 EA 2408 1001 SCR TRUSS HD PH 6 32 X3 8 21 2 000 EA 970015 518 SCR 10 32X1 50 HSC SBZ 22 2 000 EA 970015 418 SCREW 8 32X1 50 HSC SBZ 23 4 000 EA 970015 610 SCREW 1 4 20X 75 HSC SBZ 24 2 000 EA 970015 622 SCREW 1 4 20 X 2 00 HSC SBZ 25 2 000 EA 970015 416 SCR 8 32 1 25 HSC SBZ 26 5 000 EA 974010 004 WSR SL 8 293 175 040 SBZ 28 4 000 EA 974010 006 WSR SL 1 4 489 263 062 SBZ 29 1 000 EA 932009 007 LUG SOLDER 8 39 DRAWING AND PARTS LIST 0600 0312 REV D FIGURE 39 MP 100 MAGNETIC ARC PROBE EXPLODED VIEW 40 0600 0312 DRAWING AND PARTS LIST TABLE 19 MP 100 MAGNETIC ARC PROBE PARTS LIST ITEM NUMBER DESCRIPTION 1 1 000 EA 0600 0470 MP 100 POTTED PROBE COIL ASSY 2 1 000 EA 0600 0320 MP 100 PROBE TIP STANDARD 3 1 000 EA 0600 0318 MP 100 RETURN RING 4 2 000 EA 1030 0100 LINK MOUNTING CLAMP 5 1 000 EA 1030 0878 CLAMP MACHINED RIGHT 6 1 000 EA 1030 0118 CLAMP MACHINED LEFT 7 2 000 2200 0527 CONN CIRC BOX 8 45 8 4 000 EA 970015 608 SCR 1 4 20X 62 HSC SBZ 9 4 000 EA 974010 006 WSR SL 1 4 489X 263X 062 SBZ 10 4 000 EA 974004 006 WSR F 1 4 734X
30. TROL SYSTEM DESCRIPTION OF EQUIPMENT INSTALLATION OPERATION TABLE 1 MA 20 MAGNETIC ARC CONTROL SPECIFICATIONS TABLE 2 MA 20 MAGNETIC ARC CONTROL SYSTEM COMPONENTS Si SPECIFICATIONS TABLE 3 MP 1 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS TABLE 4 MP 100 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS TABLE 5 MP 2 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS TABLE 6 MP 22 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS 10 12 13 17 TABLE 7 REMOTE START INHIBIT SETTINGS TABLE 8 REMOTE START INHIBIT SETTINGS TABLE 9 REMOTE TAPER SETTINGS TABLE 10 REMOTE TAPER SETTINGS MAINTENANCE 18 19 20 25 DRAWING AND PARTS LIST 27 TABLE 11 MA 20 MAGNETIC ARC CONTROL PARTS LIST TABLE 12 POWER SWITCH ASSEMBLY PARTS LIST TABLE 13 TRANSFORMER ASSEMBLY PARTS LIST TABLE 14 PROBE CABLE HARNESS PARTS LIST TABLE 15 REMOTE INTERFACE CABLE HARNESS PARTS LIST TABLE 16 MP 1 MAGNETIC ARC PROBE PARTS LIST TABLE 17 MP 2 MAGNETIC ARC PROBE PART LIST TABLE 18 MP 22 MAGNETIC ARC PROBE PARTS LIST TABLE 19 MP 100 MAGNETIC ARC PROBE PARTS LIST TABLE 20 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS TROUBLESHOOTING 29 30 31 33 35 39 41 42 43 TABLE 21 TROUBLESHOOTING TABLE 22 RECOMMENDED SPARE PARTS TABLE 23 VOLTAGE POINTS MAIN BOARD CIRCUIT DESCRIPTIONS 43 43 45 SCHEMATICS AND B
31. URE 20 DEFAULT INHIBIT DIP SWITCH SETTINGS Normally Closed Start To use the Remote Start feature not the Taper fea ture with a Normally Closed Start Signal that will open when the arc is to oscillate there are two sets of DIP Switches that need to be configured in addition to the remote interface wiring The Inhibit DIP switch must be set for Normally Closed position and the Taper DIP switch must be set for the Normally Open positon See Table 8 Remote Start N C Inhibit Settings on page 19 The Remote Start Input also known as Inhibit must also be wired correctly on the remote interface cable Figure 27 Remote N C Inhibit Interface shows the proper wiring for N C configuration Also Figure 21 Inhibit NC DIP Switch Settings illustrate the proper DIP settings When the Remote Start Signal is used in a Normally Closed N C configuration the control unit will oscil late the arc whenever there is a not a closure be tween Pins I and A When a closure between Pins I and A is made arc oscillation will stop Arc oscillation will not begin again until the Remote Start input is re moved Once the Remote Start input has been re moved the arc will begin to oscillate again at the Am plitude adjustment setting TABLE 8 REMOTE START N C INHIBIT SETTINGS DIP SWITCH NAME SWITCH POSITION 1 INHIBIT 2 CLOSED 1
32. WARNING An operational procedure which if not fol lowed may cause severe injury to the oper ator service personnel and or bystanders DANGER An operational procedure which if not fol lowed will cause severe injury or even death to the operator service personnel or bystanders gt gt gt SAFETY INFORMATION Safety is a combination of good judgment and proper training Operation and maintenance of any arc weld ing and cutting equipment involves potential hazards Individuals who are unfamiliar with cutting and weld ing equipment use faulty judgment or lack proper training may cause injury to themselves and others Personnel should be alerted to the following potential hazards and the safeguards necessary to avoid possi ble injury In addition before operating this equipment you should be aware of your employer s safety regula tions 2 BE SURE READ THIS MANUAL FORE INSTALLING OR USING THIS g EQUIPMENT BE SURE TO READ AND FOLLOW ALL AVAILABLE SAFETY REGULATIONS BE FORE USING THIS EQUIPMENT ELECTRIC SHOCK e i THE VOLTAGES PRESENT IN THE WELDING AND CUTTING ENVIRONMENT CAN CAUSE SEVERE BURNS TO THE BODY OR FATAL SHOCK THE SEVERITY OF ELECTRICAL SHOCK IS DETER MINED BY THE PATH AND THE AMOUNT OF CURRENT THROUGH THE BODY Install and continue to maintain equipment according to USA Standard C1 National Elec tric Code Never allow live metal parts to touch bare
33. ain board and is then routed through the power On Off Switch located on the door of the enclosure Once the Switch is in the On position voltage is passed through the transformer to step down the primary input voltage to an acceptable voltage for use by the control cir cuitry on the main board The voltage is rectified on the board and filtered through electrolytic capacitors The resultant 4 and 18VDC is used as the source voltage for the probe driver circuit All voltages are referenced to power ground The Main board is as the name implies the primary controller of the MA 20 System Additionally DIP Switches are also incorporated to se lect other processes and or features for use in the magnetic arc control process The waveform generation for the magnetic arc control is embedded in a microcontroller With power applied to the unit and power turned On the microcontroller creates the necessary waveform based upon the six potentiometer control settings on the front panel Once the waveforms have been generated by the microcontroller the signals are passed to the porbe power driver circuit creating the magnetic field neces sary to control the arc NOTE Troubleshooting of this board because of this embedded circuitry is difficult and should be limited to the board replacement 45 0600 0312 CIRCUIT DESCRIPTIONS 115 230VAC 50 60 Hz Magnetic Control Enclosure Main
34. been removed the arc will begin to oscillate again at the Amplitude adjustment setting For wiring instructions on the Remote Taper signal please review the schematic in Figure 48 MA 20 Magnetic Arc Control Interface Cable Schematic on page 51 for more details Weld Seam Amplitude FIGURE 19 TAPER FUNCTION Remote Start The magnetic arc control is equipped with a Remote Start and Stop input to control the arc oscillation For proper operation of this feature the Inhibit DIP Switches must be configured for your start signal There are two Start Signal Modes of operation i e Signal Normally Open N O and Signal Normally Closed N C The Inhibit DIP Switches must be con figured correctly if a signal is not being used and op eration is simply by powering up the control or to match the signal input being used If no input is being used and or the unit is initially be ing setup the DIP switches must be configured as in Figure 20 Default Inhibit DIP Switch Settings Only one switch of the DIP switch should be depressed to the closed position away from the word OPEN The other switch of the DIP switch should be de pressed in the opposite position WARNING Ifthe Taper and Inhibit DIP switches are not cofigured correctly to match your application the system will not create a magnetic field to oscillate the arc TABLE 7 REMOTE START N O INHIBIT SETTINGS
35. c control system If the mag netic field strength does not decrease along with the amperage the arc could be blown out by the mag netic arc control system especially on lower amper age arcs and or when higher amplitude settings on the magnetic arc control unit are used The Taper input can also be used to start and stop the oscillation when needed If only one output is avail able from a controller and remote start stop is de sired use the Taper input to Start and Stop arc oscillation The Taper input must be maintained to keep the magnetic arc control from oscillating the arc To begin oscillating again simply remove the input to the magnetic arc control unit See Figure 22 Default Taper DIP Switch Settings for proper configuration Refer also to Figure 25 Remote N O Taper Interface on page 21 for proper remote interface cable wiring When the Taper Signal is used as a Remote Start in put in a Normally Open N O configuration the con trol unit will oscillate the arc whenever there is not a closure between Pins D and A When a closure be tween Pins D and A is made the Taper Feature will be enabled and the magnetic field strength generated by the controller will begin to decrease The Taper adjustment will set the time to reach zero or no mag netic field strength At the end of the Taper Time the magnetic oscillation will stop Arc oscillation will not begin again until the Taper input is removed Once the Taper input has
36. ctive procedures The Circuit Descriptions section which includes block diagrams and schematics will also be helpful refer ence for troubleshooting WARNING Full line voltage is exposed inside the con 4 trol unit Do not turn the power when the Main board 15 removed partially removed or disconnected TABLE 21 TROUBLESHOOTING RECOMMENDED SPARES FOR TROUBLE SHOOTING This manual was written in a manner to provide enough detail to identify individual components parts and subassemblies for maintenance purposes ommended spare parts lists is given in Table 22 Recommended Spare Parts on page 43 For trouble shooting the following items are recommended to iso late most problems PROBLEM DESCRIPTION CAUSE SOLUTION Unit unplugged Plug unit into an appropriate AC Blown Fuse Source Problem 1 Lamp is not lit Replace Fuse Lampis bad Replace Lamp Cables disconnected from the control Check cables from the control to other to other components of the system components of the system Problem 2 Power Switch and Indicator Lamp Connectors are disconnected inside Check connectors inside the control ON but nothing works the control unit Power Driver Board voltages are not Check Power Driver Board voltage present 12VDC Probe Coil is open Check Probe Coil for 5 to 15 ohms M tic Probe will not deflect th No Output from Main Board qep
37. d assistance CAUTION All repairs should be performed by quali FIN fied service personnel only CONTROL UNIT The MA 20 control unit is factory calibrated and re quires no periodic adjustments by the operator or maintenance technician The unit is cooled by heat convection to the case which keeps the inside of the unit free from dust and dirt buildup on the circuitry We recommend periodic visual inspection of the unit checking for loose connections etc The best preventative measure that can be taken is to keep the enclosure closed tightly CAUTION Do not operate the unit with the cover open and always remove power to the unit before opening to check inside PROBES ASSEMBLIES The MP 1 and MP 2 probes are water cooled and should never be operated without the coolant being circulated by cooling source water cooler The wa ter hoses are rated for 40 psi maximum These rat ings should not be exceeded as leakage or bursting of the water hoses will result Remove any slag buildup from the probe tips frequently as loss in the probe s effectiveness to control the arc may result if slag is allowed to accumulate CABLE ASSEMBLY Maintenance of the cable assemblies is to periodically remove dust soot metal particles slag etc from the cable s insulation and checking for cracking in the in sulation sharp bends in the cable at the connectors Also check to be sure the connectors are tightened and seated corr
38. e in order to position the probe on the torch body See Figure 2 MP 1 and MP 100 Mounting Method Along Seam and Figure 1 MP 1 and MP 100 Mounting Method Cross Seam begin ning on page 4 for illustrations of probe to seam orien tation MP 2 The MP 2 probe is a torroidial design probe where the torch mounts through the center of the probe To make mounting this probe to a torch easier torch adapters are available but are not required to mount the probe to the torch A Select a suitable adapter for your torch if neces sary Without adaptor 1 625 in Adapter P N 1030 0517 1 500 in Adapter P N 1026 0582 1 455 in Adapter P N 1026 0574 1 380 in Back off the three socket head cap screws which se cure the probe to the torch body Slip the probe over the torch and align the tips approx imately even with the gas cup or bottom of torch Tighten the three screws while insuring that the probe remains centered on the torch body For probe to seam orientation please refer to Figure 3 MP 2 Mounting Method Along Seam and Figure 4 MP 2 Mounting Method Cross Seam beginning on page 4 for illustrations of this probes probe to seam orientation 0600 0312 INSTALLATION MP 22 The MP 22 probe has the strongest magnetic field strength of all of the Magnetic Arc Probes Under nor mal conditions the MP 22 doesn t need water cool ing but water cooling hoses and coolant can be added to th
39. e probe during high amperage welding ap plications or when high amplitude settings are de sired See Figure 5 MP 22 Mounting Method Along Seam and Figure 6 MP 22 Mounting Method Cross Seam beginning on page 5 for mounting information and Figure 12 MP 22 Magnetic Arc Probe Assembly on page 13 for additional probe specifications The MP 1 and MP 2 probes are water cooled units and require cooling water 40 psi max Be sure to connect the probe to a circulating cooling system be fore starting operation as severe damage to the probe may result if the probe is not properly cooled Once mounting is complete connect the probe to the MA 20 Control Unit then connect the control unit to an AC power outlet NOTE Be sure of select the correct input voltage at the Voltage Selector switch matching that which you intend to use before con nect the control unit to an AC power out let INSTALLATION 0600 0312 REV D FIGURE 7 MA 20 MAGNETIC ARC CONTROL UNIT TABLE 1 MA 20 MAGNETIC ARC CONTROL SPECIFICATIONS ITEM DESCRIPTION SPECIFICATIONS Frequency Oscillating Frequency 1 0 to 50 Hz maximum with Sweep at Zero Amplitude Oscillating Width on each side of the weld line approxi Position Arc Position nS on each side of the weld line approxi Dw
40. ectly in their mating receptacles Repair of the cable assemblies is limited to replace ment of defective parts A wiring diagram of the cable assemblies is included for troubleshooting purposes see the Schematics and Block Diagrams Section be ginning on page 48 PREVENTIVE MAINTENANCE SCHEDULE The following schedule is provided to assist in pre forming timely maintenance to the system to maintain optimum performance Monthly Maintenance Probe Assemblies Proper Function Cable connectors and strain reliefs should be tight and they should be properly seated in their mating re ceptacles Test Clean slag dirt and spatter from probe and tip assem bly Verify that the probe creates a magnetic field at the tip Quarterly Maintenance Semi Annual Maintenance Control Unit Assembly Be sure the control unit is turned off and unplugged Using clean dry air blow out dust from the inside of the control unit if any exists Remember the best pre ventive maintenance to take is to keep the control en closure tightly closed Be sure all other connections in the control unit are seated firmly in their receptacles and reconnect the power cord to an electrical outlet Turn power on and check for proper operation 25 MAINTENANCE 0600 0312 REV D 26 0600 0312 DRAWING AND PARTS LIST DRAWING AND PARTS LIST ee 011 aro erte R23 330 o 45 100
41. ell Left and Right Arc Dwell Time 2 Sweep Transition Adjustment between either side nee transition Trail off of Amplitude the end of the weld cycle Aiea downslope Hearne Controls Frequency Amplitude Left Right Dwell Sweep Taper Stabilize Oscillate Mode DIP Switches Input Power Requirements 90 132 VAC 180 264 VAC 50 60 Hz Control Unit Enclosure Standard NEMA Style Sealed enclosure Probes MA 20 can be used with these probes MP 1 MP 2 MP 22 MP 100 Power Cable Standard Length 8 1 8 M Remote Interface Cable Standard Length 10 3 M Weight Standard Weight 10 Ibs 4 1 Kg 0600 0312 INSTALLATION FIGURE 8 MA 20 MAGNETIC ARC CONTROL SYSTEM COMPONENTS TABLE 2 MA 20 MAGNETIC ARC CONTROL SYSTEM COMPONENTS SPECIFICATIONS ITEM SPECIFICATION Control Unit MA 20 Magnetic Arc Control Probe Assembly MP 1 MP 2 MP 22 MP 100 Probes Cables Power Cord Assembly Remote Interface Cable Assembly Probe Cable Assembly MP 100 only Manual MA 20 Operators and Service Manual INSTALLATION 0600 0312 REV D 3 75 95 mm Cable to Control Unit Note Special Tips and
42. he Taper Time the magnetic oscillation will stop Arc oscillation will not begin again until the Taper input is removed Once the Taper input has been removed the arc will begin to oscillate again at the Amplitude adjustment setting TABLE 10 REMOTE TAPER SETTINGS DIP SWITCH NAME SWITCH POSITION 1 CLOSED INHIBIT 2 OPEN 1 CLOSED TAPER 2 OPEN SELECT ONE AN NO NC 1 2 ss lt FIGURE 22 DEFAULT TAPER DIP SWITCH SETTINGS Normally Closed Start Using Taper To Remote Start the magnetic arc control using the Taper feature with a Normally Closed Signal that will remain closed when the arc is to oscillate there are two sets of DIP Switches that need to be configured in addition to the remote interface wiring The Inhibit DIP switch must be set for Normally Open position and the Taper switch must be set for the Normally Closed positon See Table 9 Remote Taper N C Settings on page 20 The Taper input must be maintained to keep the mag netic arc control oscillating the arc To enable the Taper Feature simply remove the input to the mag netic arc control unit See Figure 24 Taper NC DIP Switch Settings for proper DIP Switch Seetings Re fer also to Figure 26 Remote N C Taper Interface on page 22 for proper remote interface cable wiring TABLE 9 REMOTE TAPER SETTINGS
43. ional FIGURE 12 MP 22 MAGNETIC ARC PROBE ASSEMBLY TABLE 6 MP 22 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS ITEM DESCRIPTION SPECIFICATION Arc Welding Amperage is limited due to heat and Weld Current Rating strength of arc 600 amps 100 duty cycle 1 quart or water per minute at 68 degrees F 20 C Cooling with miximum water pressure of 40 PSI Ship Weight 6 pounds 2 3Kg Cable Length Control Cable Length 8 feet 2 4M Hose Length Liquid Cooling Hose Length 12 3 6 Optional Accessories Tip Extensions 1 Tip Extensions 2 req 3 Tip Extensions 2 req 5 Tip Extensions 2 req 13 0600 0312 INSTALLATION 3d punog lquiessy 8001 UJOL yao 7 aur seo seur JUBJOOQ vr 481009 01400 18JEM Je o puoo UONEIS JSUJOLIE s qeO 8 6119IVII jeuond 95 9 856119IVI EUONdO seo 03002 3d punolg uye3 oL 1ndu FIGURE 13 INTERCONNECTION DIAGRAM 14 0600 0312 INSTALLATION Height of power switch 10 844 10 000 Mounting holes center to center 4 holes 3 8 dia cente
44. l 6 2 pl FIGURE 33 TRANSFORMER ASSEMBLY EXPLODED VIEW TABLE 13 TRANSFORMER ASSEMBLY PARTS LIST UM PART DESCRIPTION 1 1 000 EA 1037 0063 TRANSFORMER DUAL PRI DUAL SEC 2 1 000 EA 2208 0199 CONN RECT PLUG 10CKT 3 10 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 4 2 000 EA 970000 426 SCR 8 32 2 50 CR1P SBZ 5 2 000 EA 972001 004 NUT 8 32 FH SBZ SL GB 6 2 000 EA 974010 004 WSR SL 8 293 175 040 SBZ 31 DRAWING AND PARTS LIST 0600 0312 REV D 4 18 gauge wire M ex FIGURE 34 PROBE CABLE HARNESS EXPLODED VIEW TABLE 14 PROBE CABLE HARNESS PARTS LIST UM JPART DESCRIPTION 1 1 000 EA 2200 0527 CONN CIRC BOX RCPT 8 48 2 1 000 EA 2208 0091 CONN RECT PLUG 6CKT 3 3 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 32 0600 0312 DRAWING AND PARTS LIST FF A ET d 2 3 FIGURE 35 REMOTE INTERFACE CABLE HARNESS EXPLODED VIEW TABLE 15 REMOTE INTERFACE CABLE HARNESS PARTS LIST ITEM UM PART DESCRIPTION 1 1 000 EA 93
45. ld or cut if physical discomfort persists D Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases Beware of gas leaks Welding or cutting gases containing argon are denser than air and will replace air when used in confined spaces Do not locate gas cylinders in con fined spaces When not in use shut OFF the gas supply at its Source Refer to AWS Standard Z49 1 for specific ventilation recommendations 0600 0312 REV D ADDITIONAL SAFETY HAZARDS Do not press gun trigger until instructed to do so FIRE AND EXPLOSION Do not point the gun toward any part of the Fire and Explosion can result from placing units on over or near combustible surfaces Do not install units on over or near com bustible surfaces Do not install unit near flammables FALLING EQUIPMENT Falling Equipment can cause serious per sonal injury and equipment damage Use lifting eyes to lift unit only not running gear gas cylinders or any other accesso ries Use equipment of adequate capacity to lift units If using fork lifts to move units be sure forks are long enough to extend beyond opposite side of the unit HOT PARTS Hot parts can cause severe burns TIKAN IL Do not touch hot parts bare handed Allow cooling period before working on gun or torch MOVING PARTS We Moving Parts can cause injury Keep away fro
46. lustrations of the 20 controls with explana tions of their functions are included to aid the opera tor in achieving optimum results while operating this system However the best way to become familiar with the capabilities of the MA 20 is to strike an arc on a piece of heavy steel and experiment with the arc length the relationship of the probe tip to the arc and the effects of the individual control functions Remote Panel Position Control The operator may control the arc position from re mote potentiometer or PLC with an analog output or from the front panel controls default Remote or Panel Position Control is selected with an internal DIP switch see Figure 29 Default Position DIP Switch Settings Stabilize Oscillate There are two modes for the operation of the Control Unit the Stabilize mode and the Oscillate mode The STAB OSC DIP switch is located on the PC board in side the chassis see Figure 30 MA 20 Main Board Layout When these switches are in the Oscillate OSC posi tion as illustrated in Figure 23 Default Osc Stab DIP Switch Settings the control will deflect the arc left and right This will be indicated by the three lamps on the front panel Each lamp will illuminate alternately completing one cycle When the STAB OSC switch is in the Stabilized STAB position the arc is stabilized In Stabilize mode the operator can use the Position control to preheat post heat or concentrate
47. m moving parts such as fans Keep all doors panels covers and guards closed and securely in place Keep away from pinch points such as me chanical slides drive rolls carriage assem blies etc MAGNETIC FIELDS CAN AFFECT Y PACEMAKERS _ Magnetic Fields from High Currents can fect pacemaker operation Pacemaker wearers should keep away Wearers of pacemakers should consult their doctors before going near arc welding gouging plasma cutting or spot welding operations WELDING WIRE Welding wire can cause puncture wounds body other people or any metal when threading welding wire through the gun FLYING PIECES OF METAL OR DIRT 4h Flying pieces of metal or dirt can injure 2 7 eyes Wear safety glasses with side shields or face shields OVERHEATED EQUIPMENT High output power for long durations can cause equipment to overheat Allow cooling periods Reduce current or reduce duty cycle before starting to weld again Follow rated duty cycle HIGH FREQUENCY High Frequency can cause electrical inter ference NM Take appropriate precautions to shield sen sitive electronic equipment such as com puters Programmable Logic Controllers etc Be sure to ground each component of the system to one ground point i e Earth Ground Earth or Protective Earth PE SAFETY REFERENCES The following publications provide additional informa tion o
48. n important welding safeguards ANSI ASC 249 1 1988 American National Standard Safety in Welding and Cutting B Bulletin No F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting Containers and Piping that hav held Hazardous Substances C OSHA Safety and Health Standards 29CFR 1910 available from the United States Department of Labor Washington DC 20210 D NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes avail able from the National Fire Protection Associ ation 470 Atlantic Avenue Boston MA 00210 NEMA Standards Publication No EW1 1989 Electric Arc Welding Apparatus approved as ANSI C87 1 1989 Available from National Electrical Manufacturers Association 155 E 44th Street New York NY 10017 xii 0600 0312 Arc Products Automation MA 20 Magnetic Arc Control 9 Final Taper Postion Dm MA 20 Magnetic Arc Control System 0600 0312 0600 0312 DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT The AP AUTOMATION MA 20 Magnetic Arc Control System is precise controllable means for oscillat ing stabilizing or positioning welding arc This al lows the operator to control heat distribution minimize undercutting reduce porosity improve penetration provide uniform sidewall fusion and improve the over all integrity of the weld Used with the Model 1 M
49. o Start Grn A Use only one method Maintain to prevent magnetic arc oscillation N Bik NIC 6 IK Bik E 5 L Position l IK 2 Yel a es Fi 8 Position II gt H Bik MA 40 Only F 0600 0352 MA 20 40 Automation Interface Cable assy FIGURE 48 20 MAGNETIC ARC CONTROL INTERFACE CABLE SCHEMATIC 51 SCHEMATICS AND BLOCK DIAGRAMS 0600 0312 REV D 52 INDEX 0600 0312 REV B INDEX A adequate xii Amplitude 17 B barrel xi Cable 8 25 43 carriage xii CMOS 43 Control xii 3 8 current xii 3 D diagram 25 43 45 diagrams 43 duration XII dust xi 25 Dwell 17 E electrolytic 65 45 Electro Magnetic Interference 45 EMI E DE 45 enclosure 3 8 45 Equipment X 3 5 Exploded 28 34 40 F faulty x Field xii fuse holder 3 G ground x xii 45 H held xii I IC xii 43 Integrated Circuits 43 Inhibit 19 input 45 insulated PX Integrated Circuits 43 interface 45 L Lamp 43 lug xi 25 43 M Main board 43 45 maintained lt Maintenance 25 26 manual x 43 momentary oxi 0 ON X xii 3 5 21 43 45 46 Oscillate er VES nee dee output xii P Panel 17 panels xii parts list 43 periodic 25 Position 17 power switch yo Precautions xX primary 45 Problem 43 Programmable
50. o provided and begin on page 47 The Figures 44 and 45 show all wires and connector pins in the interfaces between the various assemblies in the control unit Figure 31 MA 20 Magnetic Arc Control Exploded View on page 28 identifies the major assemblies Parts lists for each assembly are also included in the Drawing and Parts Lists section beginning on page 27 MAIN BOARD ASSEMBLY This section will describe generally the circuitry signal flows and test points on the Main board to assist in a better understanding and more effective and accurate troubleshooting of the system The Figure 30 MA 20 Main Board Layout on page 27 is a drawing of the board to assist in placement of the DIP switch settings and other components for better understanding and troubleshooting In addition to the board layout draw ing Figure 41 MA 20 Magnetic Arc Control Signal Flow on page 46 illustrates very simply the flow of sig nals in the MA 20 control system The Main board contains control circuitry for the sys tem and also performs primary input voltage and con trol voltage regulation Input voltage to the control unit is supplied to the Main board through a fuse and Radio Frequency Interference and Electro Magnetic Interference RFI EMI filter and voltage selector Switch mounted on the bottom of the enclosure The system will operate from 110 220 VAC 50 60 Hz at less than 1 amps input power The voltage into the control unit is brought to the M
51. ondlng on te probe Problem 3 AQNEUG Probe wtrinoE detect ME Check for output voltage at probe arc Main Board Faulty connector on control unit Replace Main Board Many of the Integrated Circuits IC s on the Main board are CMOS logic and require standard CMOS precautions against damage by static electricity dis charge TABLE 22 RECOMMENDED SPARE PARTS ITEM QTY PART DESCRIPTION 1 2 1373 3041 Fuse 1 Amps 2 1 2100 0086 Power Lamp 3 1 0600 0384 Main Board Assembly 5 1 2068 0161 Power Switch TABLE 23 VOLTAGE POINTS MAIN BOARD POSITION DESCRIPTION VALUES U15 1 24VDC 24VDC 1 00VDC U1 1 15VDC 15VDC 1 00VDC U15 3 12VDC 12VDC 0 500VDC J2 8 5VDC 5VDC 0 500VDC J2 9 5VDC 5VDC 0 500VDC U1 2 Ground Reference Ground 43 TROUBLESHOOTING 0600 0312 REV D 44 0600 0312 CIRCUIT DESCRIPTIONS CIRCUIT DESCRIPTIONS WARNING 4 For use by Qualified Service Technicians SYSTEM WIRING DIAGRAM The Figure 44 MA 20 Magnetic Arc Control Block Diagram and Figure 45 MA 20 Magnetic Arc Control Block Diagram Cont beginning on page 48 is a circuit diagram of the entire MA 20 Magnetic Arc Control System These diagrams include detailed schematics of all portions of the system except the Main Board assembly Schematics of each of the probes are als
52. r to center Mounting holes 10 450 FIGURE 14 MA 20 MAGNETIC ARC CONTROL MOUNTING DIMENSIONS INSTALLATION 0600 0312 REV D Heat Distribution Higher Amplitude Setting Lower Amplitude Setting Centered Position FIGURE 15 AMPLITUDE SETTINGS Heat Distribution Slow Sweep Setting Faster Sweep Setting Dwell s are set equally FIGURE 17 SWEEP SETTINGS Heat Distribution Postision Shifted Right Position Shifted Left Lower Amplitude Setting FIGURE 16 POSITION SETTINGS Seam Heat Distribution More time set for Right Dwell More time set for Left Dwell Dwell s are not set equally FIGURE 18 DWELL SETTINGS 16 0600 0312 OPERATION OPERATION GENERAL OPERATIONAL DESCRIPTION CONTROL FEATURES amp FUNCTIONS To give the operator better understanding of the MA 20 Magnetic Arc Control System this section con tains information regarding the various features of the Control Unit and illustrations of the various basic weld patterns that can be achieved in operation In order to oscillate the arc the control unit generates alternating currents These alternating currents can be controlled by 3 functions of the control unit i e Sweep Left Dwell and Right Dwell The magnetic field strength is controlled by the Amplitude adjust ment The Position adjustment controls the arc s cen ter line The il
53. skin or any wet clothing Use only dry gloves C when welding or cutting in a damp area or when standing on metal make sure you are well insulated by wearing dry gloves rubber Soled shoes and by standing on a dry board or platform je Pt under d D Do not use worn or damaged welding or torch cables Do not overload the cables Use well maintained equipment E When not welding cutting turn equipment OFF Accidental grounding can cause over heating and create a fire hazard Do not coil or loop the cable around parts of the body F The ground cable should be connected to the work piece as close to the work area as possible Grounds connected to building framework or other locations remote to the gt 0600 0312 SAFETY d 7 work area reduce efficiency and increase the potential hazard of electric shock Avoid the possibility of the welding or cutting current passing through lifting chains crane cables or other electrical paths G Keep everything dry you might touch in cluding clothing the work area welding gun torch and welding or cutting machines Fix wa ter leaks immediately Do not operate equip ment standing in water H Never use a cutting torch or welding gun which is damaged or contains cracked hous ing Refer to AWS Z49 1 for grounding recom mendations SKIN AND EYE BURNS RESULTING FROM BODY EXPOSURE TO ELEC TRIC ARC WELDING AND CUTTING RAYS OR HOT MET
54. the arc heat in the center in relation to torch or workpiece movement Sweep The Sweep function controls the speed in which the magnetic field changes from the left dwell position to the right dwell position See Figure 17 Sweep Settings on page 16 Generally a fast welding travel speed requires higher frequency oscillation or a lower Sweep Dial Setting Left amp Right Dwell The Left and Right Dwell functions of the control unit control the amount of time the arc will remain on ei ther side during oscillation See Figure 18 Dwell Settings on page 16 The settings ar independently adjustable Amplitude The Amplitude dial adjusts the gauss strength of the magnetic field see Figure 15 Amplitude Settings on page 16 The effect of the magnetic field on the de flection of the arc is related to the length of the arc the type of material being welded the joint configura tion and the welding process being used The prox imity of the probe tip to the arc also greatly influences the degree to which the magnetic field will deflect the arc The optimum amplitude control setting in a given application can span a relatively broad range It is best to utilize the lowest amplitude setting possible as high gauss strength can result in arc instability Position Arc positioning provides a means of offsetting the arc path relative to the center line of the torch This is ac complished by a controllable current which is applied
55. the power Off set the Sweep and Amplitude controls to their fully counter clockwise positions 000 on the dial and set the Position control at its center position 500 on the dial Set both the Left and Right Dwell controls to about 1 second 300 on the dial Open the controller door and find the STAB OSC DIP switch on the main board see Figure 30 MA 20 Main Board Layout Set the STAB OSC Switch in the Oscillate position Strike an arc allow it to stabilize then turn On the MA 20 Control Unit At this point the operator will not see any significant change in the arc action but if you look at the 3 red LED indicator lamps on the front panel of the control unit you will notice they are sequencing completing one cycle in roughly two sec onds With the arc established adjust the Position control to position the arc directly below the Torch tungsten This adjustments offsets the position of the arc and makes up for the probe mechanical mounting errors P5 See Figure 16 Position Settings on page 16 to re view the controls function Now turn the Amplitude control clockwise to approxi mately mid range of its settings 500 on the dial The arc will now deflect left to right The Figure 15 Amplitude Settings on page 16 illustrate the function of the Amplitude control As you turn the Sweep control clockwise you will also notice the arc oscillation cycle decreasing in speed because we have added
56. time to the left to right dwell transistions and vice versa See Figure 17 Sweep Settings and Figure 18 Dwell Settings on pages 16 and 16 respectively for visual explanations of these functions When the STAB OSC switch is placed in the STAB position the arc is stabilized This feature allows for preheating post heating or center heating optimizing Use the Position control to determine the placement of the arc in relation to the torch and seam positions NOTE The preceding control descriptions are written with respect to the probe being in stalled as described in the installation section of this manual with the Cross Seam mounting method Additional adjustments may be necessary to achieve the desired weld bead penetration and profile Dwell and Sweep controls are the primary adjustments to change the weld bead profile Position and Amplitude are primarily the adjustments to control penetration However all control functions of the Magnetic Arc Control System interact slightly with each other and on the weld bead profile penetration etc Working on a test block is the best way to gain experience and understanding of the interaction between the controls and the weld bead Taper N O Contact Close to Enable Taper Wht Taper Contact D Blk J N C Grn Power Ground A Bik N C N N C pi Earth Ground PE FIGURE 25 REMOTE N O TAPER INTERFACE 21 0600 0312
57. tor the abil ity to oscillate the arc either across the seam or along the seam depending on how the probe is mounted on the torch Oscillate Mode or to stabilize the arc posi tioning the arc in the desired location Stabilize Mode Remote Panel Position Control allow the operator to control the arc position of the each axis from a remote potentiometer or PLC with an analog output or from the front panel controls default MAGNETIC ARC CONTROL PROBES MP 1 PROBE The MP 1 is a single tip water cooled probe that adapts to conventional torches The MP 1 works well in tight clearances and is primarily used to weave the arc across the seam or to stabilize the arc On page 10 is Table 3 MP 1 Magnetic Arc Probe Assembly Specifications and Figure 9 MP 1 Magnetic Arc Probe Assembly for detailed dimensions and specifi cations MP 100 PROBE The MP 100 probe incorporates the latest magnetic technologies Though similar to the MP 1 probe the new MP 100 probe has a much higher gauss strength and three times the efficiency of the MP 1 The MP 100 does not require water cooling however it does allow for optional water cooling For added con venience and flexibility it also features a detachable control cable This single axis probe adapts to con ventional torches A variety of return rings and tips are available for different configurations See page 11 is Table 4 MP 100 Magnetic Arc Probe Assembly Specifications and Figure 10
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