ESAB Welding System Part No. 677190 User's Manual
Contents
1. gd i i i toea l LITAOOY SIHL NI WVHOVIO NOILOJNNOJYJLNI 3HL NI Ad on 33 dS YAMOd JISIDAdS V OL Y34384 NOLLO3NNOO HYINDILH Y HOJ NOILLO3N He i i EE amabi i dg NOJ AlddNS 83A MOd 1VOladAL Y MOHS Gd ONY 9d WOH3 SINN GSLLO 0 3S3HL l L E o TONINMAL LdLAO ISVIYYYI te aa SN 39wWl lOA t ALON 335 4dO LSACOV 39v110A 3iO0W3M Q032lHOlON goe ugg m KA 01 181 eul e 1e 9 TGL 0 pej euuoo eq ueo esou zo euo AjuO pesn eq iouuePD 2 8d nay Bufwod pes dn 491d YAOM y Jj pesn aq Ajuo IM M SIUL SsouJeu oj eanoes pue jeu uo3seJ ojeinsu peal sjas So3e2 Iput pe3eubisep speay ISL r TVLAG E Di eio i E d kie e E P B NET S l Gei I Ie ig is ld H 71v130 e niarsqujaj oim o 2 o x 9 x r c x ie c jm i m jc jm oye 1S eo x o z r jc ic 2 La Im DR Jo t 4 X ja a ee le ici Wiel TH I fe le Is le 7 llls Iw j v m o lg ini th ae E E 8 1 45 LE dS nl Li nme TivL 30 235 2 m z l 2 21 18 3 130 33 KK l i D c II D D rir x SS S ds 43 1140 338 n d 03uU l 181 2 71 130 33 AT TINY 30178 AVA CRIA 3 A3lA bd Am Z ld LA 2 Wi 101 u09 8g 93f weibeig BuulM 8 Du KE z a ANONS AJIA SNIMIM it l Y Y MAFIA E i9 5552. Bi Ar 96 SI bI CELLO LLL Emad DLE a mad EL L Hob f 11 130 335 H 1 Y130 335 UTY3H M3I 5NI NIA 8 8 MJA 9 110130 335 TUI VES N 6 24 Aum Wr1i I81 iH pm Con e LL EP 4718 ER DR B 2d EI ICH wid DC AJIA SNIIA 9 2r Mia w iiid 334 ed 1 dnjis 9 1 IYL 20 O0NhnONS NIR EIDE oj 2 sis EA E 2 Le zl cpm Silo AA sis Aa G CL v EI als must je LI In o jus T ie u x iv AINO dfi 400H H313WWY 20 n 45v fons gunown 9d q 14130 Ipi ES a E diy Z 3498 WC 6d 29 1v130 Bans anno koi NewS 21 15 7 11v13Q 898466 5 NOILdO MYOM HINOL ARM p ti xW Z iu F 12 747 F 3 95 ESAB Welding amp Cutting Products Florence SC Welding Equipment COMMUNICATION GUIDE CUSTOMER SERVICES CUSTOMER SERVICE QUESTIONS Telephone 800 362 7080 Fax 800 634 7548 Order Entry Product Availability Pricing ENGINEERING SERVICE Telephone 843 664 4416 Fax 800 446 5693 Warranty Returns TECHNICAL SERVICE Telephone 800 ESAB 123 Fax 843 664 4452 Part Numbers Technical Applications LITERATURE REQUESTS Telephone 843 664 5562 Fax 843 664 5548 WELDING EQUIPMENT REPAIRS Telephone 843 664 4487 Fax 843 664 5557 Repair Estimates Repair Status Specifications Hours 8 00 AM to 7 00 PM EST Order Information Returns Hours 7 30 AM to
3. 2 Check fuse power supply 3 Replace logic PC board H SYMPTOM Erratic or pulsing wire feed rate 1 Replace logic PC board Vil REPLACEMENT PART 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 ONLY 2 Many of the parts on the illustrations particularly electronic parts are vendor items This means that they are standard commercial parts made by and purchased from other manufacturers If you order from these outside sources use the manufacturer s part number or designated as shown in the Electrical Parts List 3 Always state the series or serial number of the machine on which the parts are used The serial number is stamped on the unit nameplate VOLTMETER AMMETER INCHES PER MINUTE METER Accy Refer to Sec III A Accy Refer to Sec III A Ge COVER 677867 OLD COVER 2075227 SIDE PANEL 6787866 OLD PANEL 2075186 Z gt WSSS SWITCH 634518 ISP l POTENTIOMETER POWER PILOT LIGHT A 995301 598227 e CABINET 30782 IS SWITCH MLS SWITCH 97W64 y Down 599692 Lues VCP POTENTIOMETER 639541 KNOB 996501 NOTE Two cap screws 5 16 18 X 1 2 Ig provided in cloth bag for WSP 10 TURN POTENTIOMETER 181W8 attaching control to OM 48 Side KNOW 181W87 Beam Carriage Fig 2 UEC 8 Control P N 677190 WARNING LABEL 9
4. SINGLE COND CABLES 6 FT ASSY 996806 also see III A 2 WIRE FEED MOTOR BUSBAR 4 0 CABLES TO TERMINAL ON POWER SUPPLY NOZZLE WORK PIECE med SE E 4 0 CABLES TO TERMINAL ON POWER SUPPLY NOTES 1 If shunt wound motor does NOT have mating plug for UEC 8 motor receptacle P7 use connector plug 996513 amp cable clamp 525564 and wire per chart 1 2 f permanent magnet motor does NOT have mating plug for UEC 8 motor receptacle P7 use above plug and cable clamp and wire per chart 2 3 The work voltage pick up lead must be corrected as shown from the workpiece This function is also provided from the power supply thru P6 1 to TB1 6 in the UEC 8 via a faston connection This connection must be disconnected and taped Fig 1 Interconnection Diagram CABLE 10 IN 948226 OM 48 CARRIAGE receptacle P8 on the side of the control Connect the lead tagged No 1 to busbar and lead No 2 to the workpiece or fixture see Note 3 on Fig 1 4 Connect the plug end of the carriage governor cable to receptacle P9 on the control NOTE When using J Gov P N 953534 cable 997965 is required see Section III B 5 In sert the lugged end through the strain relief on the back of the J Governor and connect to TB1 in governor as follows Hed to TB1 8 White to TB1 9 Black to TB1 10 Green to ground stud F CONNECTIONS FOR DUAL WIRE OPERATION 1 DC AC Connection see Fig 1
5. With the numerous power supplies available for use with the UEC 8 it is suggested in dual wire applications that the operator use a DC unit as the lead power supply source to provide weld penetration An AC unit should be used as the trail power supply to give the weld a cosmetic finish G IMPORTANT WIRING OPERATING MODIFICA TION USING EH 10A MOTOR As noted in this booklet one of the welding heads the UEC 8 is recommended for use with is the new EH 10A motor that can accommodate wire speeds from 0 1000 ipm As a result the Wire Feed Speed potentiometer may not have the fine adjustment or resolution range settings that you may prefer and would normally be af forded the other motors with lower wire speed ipm ranges If finer resolution in the speed potentiometer is desired and you do not plan to operate the control at wire feed speeds above 500 ipm you can modify the circuitry to spread the operating range of this speed control To do this add a resistor 100K ohm 1 4 watt to the Wire Speed potentiometer as shown in the schematic dia gram Remember if this modification is made that the effective operating range of the potentiometer Will be changed from 0 1000 ipm to 0 500 ipm 7 IV IMPORTANT CHECKLIST To confirm that the various components control head carriage and power supply have been properly inter connected it is imperative that the following tests be performed BEFORE operation starts Note Fail
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7. 5 00 PM EST Authorized Repair Stations Welding Equipment Troubleshooting Hours 8 00 AM to 5 00 PM EST Equipment Recommendations Hours 7 30 AM to 4 00 PM EST Hours 7 30 AM to 3 30 PM EST WELDING EQUIPMENT TRAINING Telephone 843 664 4428 Fax 843 679 5864 Training School Information and Registrations 1M WELDING PROCESS ASSISTANCE Telephone 800 ESAB 123 TECHNICAL ASST CONSUMABLES Telephone 800 933 7070 IF YOU DONOT KNOW WHOMTOCALL Telephone 800 ESAB 123 Fax 843 664 4462 Hours 7 30 AM to 5 00 PM EST or visit us on the web at http www esabna com The ESAB web site offers Comprehensive Product Information Material Safety Data Sheets Warranty Registration Instruction Literature Download Library Distributor Locator Global Company Information Press Releases Customer Feedback amp Support Printed in U S A E ESAB E Hours 7 30 AM to 4 00 PM EST Hours 7 30 AM to 4 00 PM EST Hours 7 30 AM to 5 00 PM EST ESAB Welding amp Cutting Products PO Box 100545 Florence SC 29501 0545
8. Reversible Governor PC Board P N 675332 For Mig Welding Solder Jumper Wire Across C and ih Solder Jts 8 Daso A 3 Colactor C E oe Equitas E HJ Top View of Transistor Q2 Mig Welding Plug Position Sub Arc Waking 77 Plug Position J1 lfeador J1 Plug J Plug A H C Top View of Process Plug Ji Jumper modification required for enzlier pie boards without Jumper Dun JL Factory positioned Phag Jumper fur later p c boards FUSE 1 2 AMP CURRENT DETECTOR LED Ww E Io ca 0 3 pi III SR i u i o KS bu ias las T Ee EE DEE EH GC Fig 6 Logic P C Board P N 997115 Earlier Units obso lete Logic P C Board P N 675330 Later Units after March 1984 043u02 8 93n urejbeiq 2neuieuos Z Du eui 1 e 3 9 TE L 0 pejoeuuo2 eq ue asaui 40 euo fA uoO MEE ERE TS dcc EE RE dap ee pesn eq 1ouue2 2 8d ubno4uj 5ujuo2 pea ewe ee ee en ee ee 4 m ne dn 421d 10 eui 4 pesn eq JJM AM siut Z i i CENENE EE l open te 4455 4839Uu10 1u91od 013U09 a6e 0A y jo opd i j ne _ _ E 7 ier l S gt ul payeisuy aq Pinoys u2 s J49 0 asie1 d T i ee l 1 leuofydo ue oe 008 IA TOST OOZT oW2 l l 2S SS S d l l y SE YONS pesn s 824nos J MOd peziJ010UJ 1 dfi9id 39V 10A po l AYOM HONOL e j SONOS 19 Od OOZT IA 410 LOB HDA E JYNLVNWYY YOLOW E e 2 of l i o o l d
9. 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 Puton dry hole free gloves before turning on the power 9 Turn off the power before removing your gloves 10 Referto 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 flow 2N ing through any conductor causes lo calized Electric and Magnetic Fields S9 EMF Welding and cutting current cre ates EMF around welding cables and welding machines Therefore 1 Welders having pacemakers should consult their physi cian before welding EMF may interfere with some pace makers Exposure to EMF may have other health effects which are unknown 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 11 95 FUMES AND GASES Fumes and s gases cancausediscomfortor harm particular
10. to call attention to immediate haz ards which if not avoided will result in immediate serious personal injury orloss of life Used to call attention to potential haz A UAE ards which could result in personal injury or loss of life A CAUTION Used to call attention to hazards which could result in minor personal injury I INTRODUCTION 1 The UEC 8 electronic welding control P N 677190 is designed for a wide range of SubarcT welding appli cations and can be used with either a constant volt age or a constant current power supply as follows 650 CUVGC BO ME P N36006 553 OVOD 00 eg P N36234 If higher welding currents are desired a kit is avail able from ESAB that allows you to parallel two 650 cvcc units to provide up to 1300 amperes output If the UEC 8 is to be used with power sources no longer manufactured or recommended please con tact your ESAB Welding Supplier or the Factory and request a copy of edition F 12 747 E The E edi tion contains historical information and requirements previously provided for low range Subarc and Mig welding applications The UEC 8 is recommended for use with the following welding heads EH 11 for either constant voltage or constant current operation or the EH 10 or 10A for con stant voltage operation only The control utilizes two solid state printed circuit boards described in Sec IC to obtain excellent wire feed speed regulation The con trol is designed
11. whenever main line switch is turned ON 1 Check wiring for shorts 2 If no short replace governor PC board B SYMPTOM F1 fuses blows when Inch Switch is operated 1 Check for jammed or defective wire feed motor drive unit 2 Replace governor PC board C SYMPTOM Motor inoperative 1 Check setting of Inch Speed pot 2 Check main line fuse F1 3 Check motor plug 4 Check motor brushes 5 Replace logic PC board 6 Replace Governor PC board D SYMPTOM Wire feed motor operates by inching but does not operate for welding 1 Check setting of WFSP 2 Check touch work indicator light for operation when wire torches work 3 Observe that both LED lights on logic PC board are lit after arc initiating 4 Replace logic PC board E SYMPTOM If wire feed motor continues to run when wire touches plate and work light not on 1 Check fuse 1 2 amp located on logic board 2 Check for fused flux at tip of welding wire 3 Check power supply ground cable for connec tion to workpiece 4 Replace logic PC board F SYMPTOM No control over motor speed at wire feed potentiometer 1 Check wire speed potentiometer with ohmmeter Resistance should range from O through 100 K ohms Resistance should range from O through 100 K ohms Replace if defective 2 Replace governor PC board 3 Replace logic PC board G SYMPTOM Contactor in power supply does not energize Motor operates 1 Check power supply control cable
12. 1 3 and the red wire on WSSS switch Reading should be approx 40 ohms If flux gate is used check for continuity be tween TB 1 3 and the center terminal of the Flux switch Readings should be approx 40 ohms D TEST FOR VOLTMETER AND AMMETER CON NECTIONS 1 If hookup is made to a DC power supply a Place the positive meter lead on TB1 5 and nega tive meter lead on TB1 6 Reading should be approx 500 ohms but this reading will vary con siderably from power supply to power supply b Reverse meter leads and reading should be 50 ohms or less To test for ammeter harnessing place meter across terminals TB1 7 and TB1 8 reading should be approx 1 ohm E TEST FOR MOTOR CONNECTION 1 For permanent magnet motors such as EH 10 EH 11 check for continuity between TB1 13 and TB1 14 Reading should be approx 5 ohms 2 For shunt wound motors such as EH 2 EH 3 check for continuity between P7 A and P7 B Reading should be approx 500 ohms 3 Check for shorts between TB1 13 and ground stud check for continuity between P7 B and ground stud Both readings should be infinity F RESULTS If any of the readings do NOT correspond with the read ings above DO NOT APPLY POWER Instead check all connections between components until the problem is found and corrected If all readings correspond with the readings above place MLS switch in the OFF position and re install the printed circuit boards inside the control UEC 8 is no
13. 330 provides basic se quencing of wire feed motor weld contactor and anti stick A 1 2 amp standard fuse to protect the current detector circuit is located on the right side of the board Also the PC board contains two LED indicator lights These lights help in troubleshooting the unit by indi cating the state of the voltage and current detector at all times 2 Reversible Governor Board P N 675332 solid state motor speed control Automatic reversing fea ture for retract starts During welding if wire stubs to the plate or the arc is lost the wire will retract at inch speed and inch down automatically until the arc is reestablished A weld power selector switch see Il B 2 above is located on the right side of the PC board Also the board contains an LED indicator light to check proper electrical installation of the wire feed motor Light emitting diode Ill INSTALLATION A EQUIPMENT REQUIRED 1 A 25 ft 12 conductor cable with 14 pin UEC 8 extension cables with 19 pin power source amphenols at each end to connect the UEC 8 to the 650 cvcc power source P N 34135 Also available are extension cables with 19 pin amphenols at each as follows 30 ft 19 conductor cable P N 34378 60 ft 19 conductor cable P N 34377 2 Iwo single conductor voltage pickup cables Gm long P N 996806 or 25 ft long P N 996805 3 D C Analog meters as follows Voltmet
14. 95204 WARNING ELECTRICAL SHOCK HAZARD SENSITIVITY POTENTIOMETER 92W64 DO NOT OPERATE WITH COVER REMOVED KNOB 994305 LOGIC BOARD 675330 INCLUDES FN FILTER NETWORK 996918 FUSE 996523 1 2 A STD PER C fe eee IJ REVERSIBLE GOV RI RESISTOR dika Rm ma Be BOARD 675332 17240005 VA i S zw dana BW s TB1 TERMINAL BLOCK we 635568 TOUCH WORK KIT 997868 OPTIONAL INCLUDES FUSE 82W43 IA SLO BLO TI CONTROL TRANSFORMER 995284 Replace label if it becomes excessively worn or lost Fig 3 UEC 8 Control Inside View WARNING LABEL 995164 WARNING Disconnect power cord before performing any maintenance P POWER SUPPLY n E RECEPTACLE 6271128 ASP POTENTIOMETER 995301 ANTI STICK ba T MIN MAX 5A SB VOLTAGE PICK UP RECEPTACLE 636694 RECEPTACLE 996514 Replace label if it becomes excessively worn or lost Be sure to order decal if replac ing sheet metal F 1 FUSE 97W06 FUSE HOLDER 182W15 CARRIAGE 2 RECEPTACLE 523543 Fig 4 UEC 8 Control Left Side View REV LED See WELD POWER Sect IV G MOV 2 The new Rev Gov Bd P N 675332 which replaced old P N 997250 is designed for use with permanent magnet motors only such as EH 10 or EH 11 and can not be used with field wound motors such as EH 2 or EH 5 If your set up uses a field wound motor consult with the factory Fig 5
15. CH STRIKE Wire Feed Speed Smooth starts can be obtained even under the most demand ing conditions with the UEC 8 s front panel variable INCH STRIKE wire feed speed adjustment Positive Starts Result from the UEC 8 voltage current detection circuit This circuit will only allow transfers from INCH STRIKE to Welding Wire Feed speed after an ARC has been established Most competitive controls do not offer this feature Adjustable Anti Stick This feature allows adjust Be sure this information reaches the operator You can get extra copies through your supplier Before applying electrical power refer to Section IV for an important checklist on the proper interconnection of the UEC 8 Con r SPECIFICATIONS Dimensions and weight of the UEC 8 are as follows 152 mm 6 in 305 mm 12 in 209 mm 8 1 3 Input requirements 120 Volt 50 60 Hz 1 phase power 5 amps A C ment of the wire retract time to prevent the electrode from sticking in the puddle after completion of a weld OM 48 Compatibility The UEC 8 has a plug in connection for direct interface with the J Governor OM 48 Carriage UEC 8 and EH 10 or EH 11 Motor With large 2 in diameter feed rolls offers the reserve power needed to assure consistent wire feeding under the most demanding conditions Optional Digital Meters Provide excellent means of observing and controlling welding voltage wire feed speed I P M and amperage ESAB W
16. INSTRUCTIONS for F 12 747 F March 1995 UEC 8 UNIONMELT ELECTRONIC WELDING CONTROL Part No 677190 A These INSTRUCTIONS are for experienced operators If you are not fully familiar with the principles of operation and safe practices for electrical welding equipment we urge you to read our booklet Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 Do NOT permit untrained persons to install operate or maintain this equipment Do NOT attempt to install or operate this equipment 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 trol FEATURES BENEFITS Solid State Control To assure economical weld ing precise control of welding conditions and arc sta bility is maintained with UEC 8 solid state accuracy Compact Size For easy installation and capability to fit into simple fixtures OM 48 carriages or the most complex automated production lines Low Maintenance Two basic solid state plug in printed circuit boards simplify troubleshooting and minimize maintenance time Operating Versatility The UEC 8 is adapted to a wide range of Sub Arc operations Rugged Construction Minimize downtime and maintenance costs and provides for worry free op eration Variable IN
17. e power supply ammeter reading E CONNECTIONS FOR SINGLE WIRE OPERATION Make the required cable connections in accordance with the interconnection diagram Fig 1 and the following 1 Connect the 14 pin Amphenol of the 12 conductor cable to the receptacle P6 on the side of the con trol Connect the 19 pin Amphenol to the power sup ply as shown in Fig 1 NOTE When using DC power and making ammeter connections from power supply to two leads of 12 cond cable connected to control via the 14 pin receptacle the polarity MUST be proper or the weld current detector will not operate and the control will not properly sequence 2 Connect the motor cable to receptacle P7 on the side of the control See Note 1 on Fig 1 3 Connect the plug end of the voltage pick up cable to 19 PIN 650 cvcc POWER SOURCE CHART 1 WIRE COLOR PIN FIELD BLK FIELD RED B ARM GRN ARM WHT WR CHART 2 WIRE COLOR ARM GRN ARM WHT OPTONAL EXT CABLE see IIl A 1 4 0 CABLES TO WORKPIECE 4 0 CABLE TO NOZZLE BUSBAR UEC 8 CONTROL TB1 7 TB1 8 TB1 6 TB1 5 RED BLU P6 VIO YEL P10 P11 P7 VIO BLU Pe P9 12 COND CABLE 25 FT 34135 3 COND CABLE SUPPLIED WITH WIRE FEED MOTOR see Note 1 or 2 Q 8 DC VOLTMETER DC AMMETER W TRMPOT STRAIN LEFT 4 COND GOV CABLE 2FI 997965 J GOV 2 COND CARRIAGE EH 9 MOTOR 2
18. elding amp Cutting Products P at ESAB EP WARNING These Safety Precautions are for your protection They summarize precaution ary 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 p processes are noisy and require ear AZ protection The arc like the sun emits ultraviolet UV and other radiation and can injure skin and eyes Hot metal can cause burns Training in the proper use of the processes and equip ment is essential to prevent accidents Therefore 1 Always wear safety glasses with side shields in any work area even if welding helmets face shields and goggles are also required 2 Use a face shield fitted with the correct filter and cover plates to protect your eyes face neck and ears from sparks and rays of the arc when operating or observing operations Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric arc or hot metal 3 Wearflameproof gauntlettype gloves heavy long sleeve shirt cuffless trousers high topped shoes and a weld ing helmet or cap for hair protection to protect against arc rays and h
19. er 0 80 volts P N 2062416 Ammeter 0 800 amps P N 2062422 and Trimpot assembly P N 997507 The trimpot ad justs the ammeter to match the power source amme ter for precise current readings 4 Flux Manual Auto Switch Kit P N 996369 This switch can be used to operate an optional automatic flux gate P N 01E62 ordered separately To install the switch refer to the schematic and wiring diagrams in this booklet and to instructions packed with the kit B OPTIONAL ACCESSORIES Motor Extension Cable P N 996808 Provides an ex tra 25 ft of cable between the welding head and the UEC 8 2 Touch Work Kit P N 997868 Recommended for sub arc welding for use only in D C applications The touch work kit senses contact between the weld ing wire and workpiece automatically stopping the wire when contact is established and lighting the touch work light For installation refer to Figs 7 and 8 and the instruction literature packed with the kit 3 Voltage Raise Lower Switch Kit P N 953559 For use only with power supplies with motorized control The remote voltage control consists of a switch and silkscreened mounting plate The switch is installed in the UEC 8 to control the voltage when the power supply is not located near the control For installa tion refer to instructions packed with kit sch C MOUNTING THE CONTROL Since the operating controls are in the control front panel the box should be mounted so that the met
20. ers and con trols are within easy reach and view of the operator The control can be mounted on a sidebeam carriage or other vertical surface by means of the two holes provided on back of the control D INSTALLATION OF METERS Amma Before performing any installation inside the con trol disconnect the electrical power cable at the re ceptacle P6 on the control With the UEC 8 cover removed install the two analog meters using screws supplied with the meters Volt meter on left ammeter at right as viewed from the front Connect meter leads in UEC 8 control as fol lows Ammeter leads Violet to in line connector P10 Blue to in line connector P11 Voltmeter leads Positive terminal to Yellow lead from TB1 5 Negative terminal to Violet lead from TB1 6 ARGS Be careful when making the following adjustment so as not to touch other components Touching other components could result in damage to the unit or personal injury 2 The trimpot calibrates the ammeter for applications where the control is more than 25 ft from the power supply On the rear of the ammeter mount trimpot assembly so that the adjusting screw is at the top of the meter as you are looking at the chassis Connect trimpot leads to terminal points for ammeter as shown in D 1 above Under actual welding conditions re move the UEC 8 cover and adjust the trimpot adjust ing screw to bring the control ammeter reading in line with th
21. essed gas cylinder Always secure cylinders in an upright position by chain or strap to suitable hand trucks undercarriages benches walls post or racks Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit When not in use keep cylinder valves closed Have valve protection cap in place if regulator is not con nected Secure and move cylinders by using suitable hand trucks Avoid rough handling of cylinders Locate cylinders away from heat sparks and flames Never strike an arc on a cylinder For additional information refer to CGA Standard P 1 Precautions for Safe Handling of Compressed Gases in Cylinders which is available from Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 A 1 Always have qualified personnel perform the installa tion troubleshooting and maintenance work Do not EQUIPMENT MAINTENANCE Faulty or im properly maintained equipment can cause injury or death Therefore Do not abuse any equipment or accessories perform any electrical work unless you are qualified to perform such work Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical power Maintain cables grounding wire connections power cord and power supply in safe working order Do not operate any equipment in faulty condition Keep equipment away from heat source
22. hunt taps Since this can only occur if you are welding in a low load welding current range e g 70 to 120 amperes a minimum shunt pickup signal 12 mv must be main tained in order to transfer speed control from the UEC 8 s Inch Potentiometer to the Weld Potentiometer Please note that if the existing shunt in your power supply is 50 mv it must either be replaced by a 100 mv shunt or the existing shunt pickup leads must be separated sufficiently to provide the minimum 12 mv signal to the control If this transfer does not take place check the following l Polarity of shunt pickup leads see schematic diagram are properly connected 2 Make sure shunt pickup leads are connected to the 100 mv output taps 3 If 1 and 2 are correct and transfer still does not take place increase wire feed speed amperage and see ifthe unit works properly transfers a If it does the problem was that of insufficient signal strength or your original welding range was too low If you still need to stay with your original lower current the existing 100 mv distance between the shunt lead connections will have to be widened or separated in order to increase the signal strength b When the unit is setup for mig operation the voltage pickup leads are only required if a voltmeter is used on the UEC 8 Control otherwise the unit will oper ate properly withoutthe arc voltage input c As shipped from the factory all Logic p c boards are
23. ire speed is transferred to the main control potentiometer and the weld is in progress 4 Place Carriage Auto Manual switch in Auto posi tion if automatic stoppage of the carriage is required 5 To stop weld place Weld Start Stop switch into the Stop position s B POSITIONED STARTING SEQUENCE without touch work kit installed 1 Wedge a tightly rolled ball of steel wool about 3 8 in in diameter between the welding wire and the workpiece and cover the weld zone with flux Place the Carriage Auto Manual switch in Auto position 2 Place Weld Start Stop switch in Start position The power supply contactor comes in immediately initiat ing the welding action and carriage travel 3 To stop the welding action place Weld Start Stop switch in Stop position C TOUCH WORK STARTING SEQUENCE optional accessory 1 Place Carriage Auto Manual in Auto Carriage will start and stop with welding action 2 Place Inch Up Down in Down position Wire will inch toward work and automatically stop when con tact is made at which time the touch work light will be energized 3 Place flux over weld zone leaving Weld Start Stop switch in Stop position 4 Place Weld Start Stop switch in Start position Power supply contactor is automatically energized and weld commences 5 With start of welding current carriage starts and wire retracts at inch speed creating an arc 6 After arc is established the wire is fed in
24. ly in confined spaces Do not breathe fumes and gases Shield ing gases can cause asphyxiation Therefore Always provide adequate ventilation in the work area by natural or mechanical means Do not weld cut or gouge on materials such as galvanized steel stainless steel copper zinc lead beryllium or cadmium unless positive mechanical ventilation is provided Do not breathe fumes from these materials Do not operate near degreasing and spraying opera tions The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene a highly toxic gas and other irritant gases If you develop momentary eye nose or throat irritation while operating this is an indication that ventilation is not adequate Stop work and take necessary steps to im prove ventilation in the work area Do not continue to operate if physical discomfort persists Refer to ANSI ASC Standard Z49 1 see listing below for specific ventilation recommendations CYLINDER HANDLING Cylinders if al Zee mishandled can rupture and violently 1 release gas Sudden rupture of cylin V A der valve or relief device can injure or Vs kill Therefore Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder Do not use adaptors Maintain hoses and fittings in good condition Follow manufacturer s operating instructions for mounting regu lator to a compr
25. nguishing 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 A SAFETY PRECAUTIONS A 5 Do not use equipment beyond its ratings For example overloaded welding cable can overheat and create a fire hazard 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 neces sary For additional information refer to NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Pro cesses available from the National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 ELECTRICAL SHOCK Contact with live 9 electrical parts and ground can cause severe injury or death DO NOT use AC welding current in damp areas if move ment is confined or if there is danger of falling 1 Be sure the power source frame chassis is connected to the ground system of the input power 2 Connect the workpiece to a good electrical ground 3 Connect the work cable to the workpiece A poor or missing connection can expose you or others to a fatal shock 4 Use well maintained equipment Replace worn or dam aged cables 5 Keepeverything 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
26. ot 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 3 flames and arcs can start fires Hot slag p or sparks can also cause fires and ex plosions Therefore 1 Remove all combustible materials well away from the work area or cover the materials with a protective non flammable covering Combustible materials include wood cloth sawdust liquid and gas fuels solvents paints and coatings paper etc 2 Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below Make certain that such openings are protected from hot sparks and metal 3 Do not weld cut or perform other hot work until the workpiece has been completely cleaned so that there are no substances on the workpiece which might pro duce flammable or toxic vapors Do not do hot work on closed containers They may explode 4 Have fire exti
27. s such as furnaces wet conditions such as water puddles oil or grease corrosive atmospheres and inclement weather Keepall safety devices and cabinet covers in position and in good repair Use equipment only for its intended purpose Do not modify it in any manner A ADDITIONAL SAFETY INFORMATION For more information on safe practices for elec tric arc welding and cutting equipment ask your supplier for a copy of Precautions and Safe Practices for Arc Welding Cutting and Gouging Form 52 529 The following publications which are available from the American Welding Society 550 N W LeJuene Road Miami FL 33126 are recommended to you 1 2 3 ANSI ASC Z49 1 Safety in Welding and Cutting AWS C5 1 Recommended Practices for Plasma Arc Welding AWS C5 2 Recommended Practices for Plasma Arc Cutting AWS C5 3 Recommended Practices for Air Carbon Arc Gouging and Cutting AWS C5 5 Hecommended Practices for Gas Tungsten Arc Welding AWS C5 6 Hecommended Practices for Gas Metal Arc Welding AWS SP Safe Practices Reprint Welding Handbook ANSI AWS F4 1 Recommended Safe Practices for Weld ing and Cutting of Containers That Have Held Hazardous Substances This symbol appearing throughout this manual A means Attention Be Alert Your safety is involved The following definitions apply to DANGER WARNING CAUTION found throughout this manual A DE Used
28. setup for Sub Arc welding operations To adapt the UEC 8 for mig welding operation the Logic p c boards must be modified as shown in Figure 8 Please note that the earlier board P N 997115 only con tained a transistor Q2 which had to be jumpered as shown to provide mig capability conversely this jumper must be removed to do Sub Arc again The present boards P N 675330 now contain a jumper plug J1 which provides the mig capability as shown V OPERATION In each of the starting methods to be considered it will be assumed that the unit has been properly installed wire placed on reel and fed through sub arc nozzle and checked to insure proper operation and that fuses are of the proper values In no case should fuses of larger capacity be substituted If sub arc welding fill the hop per with welding composition The following is a description of the procedures to be followed in making starts IMPORTANT NOTE When using any of the procedures make sure that the Weld Start Stop Switch is in the Stop position be fore the Main Line Switch is moved to ON position to energize the control A SUB ARC SCRATCH STARTING SEQUENCE Provide flux cover of weld zone 2 Place Carriage Auto Manual switch in Manual Car riage will move in direction of weld 3 Place Weld Start Stop switch in Start position Welding wire will begin slow inch down through flux burden when the wire touches the plate and an arc is established w
29. the forward direction at weld speed required to properly maintain the selected arc voltage 7 To end the weld the Weld Start Stop switch is placed in the Stop position Wire feed will cease and the contractor and carriage travel will continue for the de sired anti stick time To adjust the length of time for the anti stick refer to Section II A 9 D SUB ARC RETRACT START C C MODE In this mode the wire is in contact with the workpiece before the Start key is operational After the wire is en ergized and the current detector detects short circuit current the motor will reserve and the wire will retract at inch speed As soon as the wire separates from the workpiece and arc voltage and current and detected the motor will change direction to forward and feed wire at preset weld speed VI TROUBLESHOOTING INFORMATION If this equipment does not operate properly stop work immediately and investigate the cause of the malfunction Troubleshooting and 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 replace ment parts ATTEN Precautionary measures should be taken to provide maximum protection against electrical shock Be sure that all power is off by operating the line wall disconnect switch before attempting any work in side the control A SYMPTOM F1 fuse blows
30. to be used for Touch Work with op tional D C touch work kit and scratch starts for AC or DC In scratch starting the carriage is moving before the wire has contacted the work in touch work starting the wire inches down to the work and the carriage does not move until the welding arc has been initiated Il DESCRIPTION A FRONT PANEL CONTROLS 1 Main Line Switch double pole single throw breaks both sides of 120 VAC power to control Pilot light built in 5 ampere Slo Blo fuse in hot side of AC lines 2 Voltage Control Potentiometer allows remote ad justment of output voltage 3 Wire Feed Speed Potentiometer controls rate of wire feed speed during welding This potentiometer dial contains a 10 turn vernier calibrated from O to 100 and a computer which indicates the number of turns 0 to 9 giving a total of 1000 increment settings for accurate repeatable wire speed conditions 4 Inch Speed Potentiometer screwdriver adjustment controls rate of wire feed speed during inching 5 Inch Up Down Switch spring loaded to center off position provides signal to allow motor to inch wire up or down 6 Carriage Auto Manual Off Switch when a compat ible carriage governor is connected to the UEC 8 allows automatic starting and stopping of carriage in Auto position In Manual position carriage drive is energized continuously In center Off position there is no carriage operation 7 Weld Start Stop Switch do
31. uble pole double throw no center off position in Start position is initiates welding action In Stop position weld sequence is terminated 8 Touch Work Light included in optional Touch Work Kit lights when wire touches work prior to arc initia tion 9 Anti Stick Potentiometer located on the left side panel of the UEC 8 control The potentiometer con trols the length of time the wire is retracted at the end of the weld cycle thus allowing the welding wire to retract a controlled amount With a clockwise adjust ment the anti stick time will increase with a counter clockwise adjustment the anti stick time will increase with a counter clock wise adjustment the anti stick time will decrease B INTERNAL CONTROLS Sensitivity Potentiometer See Figure 3 an arc voltage sensitivity potentiometer is located on the in side back panel of the UEC 8 control The adjust ment of this pot controls the amount of arc voltage signal with respect to motor back e m f electro mo tive force used thus controlling motor response to arc voltage changes 2 Weld Power Selector Switch See Figure 5 lo cated on the Reversible Governor PC Board allows the control to be used with either a constant current or a constant potential power supply Switch must be placed in the proper position with respect to the type of power supply selected ech C PRINTED CIRCUIT BOARDS See Figures 5 and 6 1 Logical Board P N 675
32. ure to perform these tests may result in dam age to the printed circuit boards in the control A PREPARATORY INSTRUCTIONS AAR Precautionary measures should be taken to provide maximum protection against electrical shock Be sure that all power is off by opening the line wall disconnect switch To be doubly safe check your input leads with a voltmeter to make sure that all power is OFF 1 Remove the cover 5 screws from the UEC 8 Con trol 2 Remove the two printed circuit boards P N s 677330 amp 675332 from inside the UEC 8 3 Thefollowing readings should be taken after all equip ment has been installed and interconnected BEFORE POWER IS APPLIED to the system and WITH PRINTED CIRCUIT BOARDS REMOVED TEST FOR INPUT POWER CONNECTION Place MLS switch in the ON position Place ohmmeter to the highest resistance scale Check for continuity between TB1 3 and ground stud then check for continuity between TB1 1 and ground stud There should be a small deflection when the meter leads are first connected to these points then both readings should be infinity wW N D C TEST FOR CONTACTOR CARRIAGE AND FLUX GATE CONNECTION 1 Place carriage travel and flux gate switches in the OFF position MLS switch ON 2 Place ohmmeter on Rx 1 scale Check for continuity between TB1 3 and the center terminal of CTS switch Reading should be approx 1000 ohms for J Gov 3 Check for continuity between TB
33. w ready for operation G LED INDICATOR LIGHTS There are three LED indicator lights mounted on the PC boards that will help in setting up the equipment and in troubleshooting Two of the lights are located on the Logic Board 675330 and one on the Reversible Gov ernor Board 675332 In setting up the equipment the indicating light REV LED on the Reversible Gov Board 675332 is of main concern Refer to Fig 5 1 The control and wire feeder should be set up such that when the inch switch is depressed in the down position the motor should be feeding forward If the motor feeds in the reverse direction reverse the yel low and gray armature leads at TB1 13 and TB1 14 2 To double check motor setup perform this final test Depress inch up switch and see if indicating light on the Reversible Gov Board is dimly lit The unit should not be operated if the indicating light is not on The other two lights are located on the logic board Fig 6 and marked C DET and V DET These lights will be illuminated only when welding currents and welding volt ages are detected H IMPORTANT INFORMATION AND REQUIREMENTS FORLOW RANGE SUBARC AND OR MIG WELDING In order of magnitude the welding current required for mig is much lower than that used for Sub Arc therefore it is vitally important that the shunt signal needed to operate the Logic board s current detector circuit never drops below 12 mv min from the power supply s 100 mv s
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