MA-40 Manual C.vp
Contents
1. P5 Inhibit N C Contact Open to Enable Arc Oscillation 2 DN Red B N C A BIk Inhibit N C Contact l ge RS Grn Power Ground BIk N C N N C PL Earth Ground PE FIGURE 22 REMOTE N C INHIBIT INTERFACE 18 0600 0311 REV D INSTALLATION 5 Inhibit Contact Close to Enable Arc Oscillation o Red Inhibit Contact t BIk N C PJ Grn Power Ground A BIk 7 Earth Ground FIGURE 23 REMOTE N O INHIBIT INTERFACE POSITION CHANNEL 1 CHANNEL 2 REMOTE O O O gt GOl ol 0 ol gt SELECT ONE PANEL 2 0 3 S2 S FIGURE 24 DEFAULT POSITION DIP SWITCH SETTINGS INSTALLATION 0600 0311 REV D 20 0600 0311 REV D MAINTENANCE MAINTENANCE MAINTENANCE REQUIREMENTS NOTE This section contains preventative main tenance suggestions oniv Should repair of the MA 40 svstem become necessarv please call Arc Products Customer Ser vice at 1 800 770 0063 for troubleshooting infor mation and assistance CAUTION All repairs should be performed by quali FIN fied service personnel only CONTROL UNIT The MA 40 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 t2. 31 DRAWINGS AND PARTS LIST 0600 0311 REV D F1 52 Dopo 7 f y PP As ot d gt N S 4 5 pl EMI RFI B L Hd Lf ji JJ z Uu FIGURE 32 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW TABLE 14 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST ITEM UM PARTNUMBER 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 250V 7 1 000 EA 2340 0618 TERM RING 1 4 22 16 RED 32 0600 0311 REV D TROUBLESHOOTING TROUBLESHOOTING The following list describes tvpical problems and sug gested corrective procedures The Circuit Descriptions section which includes block diagrams and schematics will also be a helpful refer ence for troubleshooting WARNING Full line voltage is exposed inside the con 4 trol unit Do not turn the power On when the Main board is removed partially removed or disconnected TABLE 15 TROUBLESHOOTING RECOMMENDED SPARES FOR TROUBLE
3. 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 17 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 33 TROUBLESHOOTING 0600 0311 REV D 34 0600 0311 REV D CIRCUIT DESCRIPTIONS CIRCUIT DESCRIPTIONS WARNING 4 For by Qualified Service Technicians SYSTEM WIRING DIAGRAM The Figure 35 MA 40 Magnetic Arc Control Block Diagram and Figure 36 MA 40 Magnetic Arc Control Block Diagram Cont beginning on page 38 is a circuit diagram of the entire MA 40 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 also provided and begin on page 37 The Figures 35 and 36 show all wires and connector pins in the interfaces between the various assemblies in the control unit Figure 26 MA 40 Magnetic Arc Control Exploded View on page 24 identifies the major assemblies Parts lists for each assembly are also included in the Drawing and Parts Lists section beginning on page 23 MAIN BOARD ASSEMBLY This s
4. RP2 3364 RP4 100k spp 00000008 a IN s POHER SHI 13 14 15 12 19 16 26 25 18 a 1 25 or e ee he Pur Magnetic Arc Control Rat 4 1 10 10600 0384 MA 20 Main Bd Assy D 0600 0385 MA 40 Main Bd Assy 07 0 17 6048 0600 0386 MA 20 40 Main Bd Rev A VOLTAGE SELECTOR eee o o o c55 0 001 2006 Arc Products San Diego CA FIGURE 25 MA 40 MAIN BOARD LAYOUT 23 DRAWINGS AND PARTS LIST 0600 0311 REV D FIGURE 26 MA 40 MAGNETIC ARC CONTROL EXPLODED VIEW 24 0600 0311 REV D DRAWINGS AND PARTS LIST TABLE 8 MA 40 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 0436 MA 40 FACE PLATE 4 1 000 EA 0600 0385 MA 40 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 EA 0600 0466 MA 40 PROBE CONN HARNESS 8 1 000 EA 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 2120 0107 HOLDER FUSE 3 AG SOLDER 12 2 000 EA 903009 001 POT 10 TURN PANEL MOUNT 10K 13 4 000 EA 903009 002 POT 10 TURN PANEL MOUNT 1K 14 6 000 EA 9400
5. For Your Safety Read this manual before installing or using this equipme IMPORTANT MA 40 MAGNETIC CONTROL OPERATIONS AND SERVICE MANUAL 1245 30th Street San Diego CA 92154 3477 619 628 1022 619 628 1028 FAX sales arc products com service arc products com www ap automation com www arc products com VOU for purchasing Arc Products Equipment Our commitment to you is to pro vide an ever expanding family of quality arc positioning equipment controllers and accessories Please take the time to read the following pages as they con tain important information regarding proper use of this product and of weld ing 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 Visit our website at ap automation com 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 arc products com Arc Products Attn Customer Service 1245 30th Street San Diego CA 92154 Write
6. probe driver circuit All voltages are referenced to power ground The Main board is as the name implies the primary controller of the MA 40 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 35 0600 0311 REV D CIRCUIT DESCRIPTIONS pieog eJnsojou3 JOJJUOD ZH 09 06 OVNOEZIS L L FIGURE 33 MA 40 MAGNETIC ARC CONTROL SIGNAL FLOW 36 0600 0311 REV D SCHEMATICS AND BLOCK DIAGRAMS SCHEMATICS AND BLOCK DIAGRAMS L SIXV lt lt 8 m m 3 D L rr m gt m F FIGURE 34 MP 4 MAGNETIC ARC PROBE BLOCK DIAGRAM 37 SCHEMATICS AND BLOCK DIAGRAMS 0600 0311
7. 3 10 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 4 2 000 EA 970000 426 SCR 8 32X2 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 293X 175X 040 SBZ DRAWINGS AND PARTS LIST 0600 0311 REV D 4 18 gauge wire ex FIGURE 29 PROBE CABLE HARNESS EXPLODED VIEW TABLE 11 PROBE CABLE HARNESS PARTS LIST ITEM UM JPART DESCRIPTION 1 1 000 EA 930014 010 CONN CIRC BOX RCPT 145 65 2 1 000 EA 2208 0091 CONN RECT PLUG 6CKT 3 3 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 28 0600 0311 REV DRAWINGS AND PARTS LIST 4 FF Av d 2 3 FIGURE 30 INTERFACE CABLE HARNESS EXPLODED VIEW TABLE 12 REMOTE INTERFACE CABLE HARNESS PARTS LIST UM PART DESCRIPTION 1 1 000 EA 930014 001 CONN CIRC BOX RCPT 20 27S 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 29 DRAWINGS AND PARTS LIST 0600 0
8. 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 5 Standard Tip 4 required 3 Extended Tip 4 required INSTALLATION 0600 0311 REV D Magnetic Arc Control Input Power Optional Remote Interface Cable s J2 to another weld station controller Control Cable J4 Coolant Lines To Earth Ground PE Sheilding Gas Line d 5 B Torch Clamp Probe Bolts Assembly J Electrode Earth Ground PE Sheilding Gas TIG Welding Power Source FIGURE 5 INTERCONNECTION DIAGRAM INSTALLATION 0600 0311 REV D 4 315 918 Height of power switch 10 844 10 000 Mounting holes center to center 4 holes 3 8 dia 2 250 Mountina holes center to center FIGURE 6 MA 40 MAGNETIC ARC CONTROL MOUNTING DIMENSIONS 10 0600 0311 REV D Seam Control Setting Amplitude 1 500 Amplitude 2 500 Postion 1 500 Position 2 500 FIGURE 7 ALL CONTROLS EQUAL Seam Control Setting Amplitude 1 500 Amplitude 2 250 Postion 1 500 Position 2 500 FIGURE 9 ANPLITUDE 2 EFFECT INSTALLATION Seam Control Setting Amplitude 1 250 Amplitude 2 500 Postion 1 500 Position 2 500 FIGURE 8 AMPLITUDE 1
9. 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 21 MAINTENANCE 0600 0311 REV D 22 0600 0311 REV D DRAWINGS AND PARTS LIST DRAWINGS AND PARTS LIST 0000 011 R23 330 0 C45 100 31 CPL 23 000 0 O e TAPER e INHIBIT e RPL 200 50v HOG00000 BE ur R38 rd e eft e 76 e Ril R43 1 2 5k 24k TO PROBE 06 08 06 06 Be x TRANSPORER 1 eg o o AP MEGA 8 eRe 2 MCT6 R40
10. 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 Amplitude adjustment setting 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 7 Remote Taper N O Settings on page 16 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 15 OPERATION 0600 0311 REV D magnetic arc control unit See Figure 17 Default Taper DIP Switch Settings for proper configuration Refer also to Figure 20 Remote N O Taper Interface on page 17 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 TABLE 7 REMOTE TAPER N O SETTINGS DIP SWITCH SWITCH POSITION 1 CLOSED INHIBIT 2 OPEN 1 CLOS
11. Available from National Electrical Manufacturers Association 155 E 44th Street New York NY 10017 xi SAFETV 0600 0311 REV D xii 0600 0311 REV ab Arc Products Automation MA 40 Magnetic Arc Control i Frequency Final Taper e Position 1 Amplitude 1 Position 2 2 MA 40 Magnetic Arc Control Svstem 0600 0311 REV D 0600 0311 REV D DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT The AP AUTOMATION MA 40 Magnetic Arc Control Svstem is a precise controllable means for oscillat ing stabilizing or positioning a welding arc This al lows the operator to control heat distribution minimize undercutting reduce porositv improve penetration provide uniform sidewall fusion and improve the over all integrity of the weld Used with the Model MP 4 or the Cyclomatic 4613 Probes MA 40 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 40 Magnetic Arc Control Specifications Table 2 MA 40 Magnetic Arc Control System Components Specifica
12. SHOOTING This manual was written in a manner to provide enough detail to identify individual components parts and subassemblies for maintenance purposes A rec ommended spare parts lists is given in Table 16 Recommended Spare Parts on page 33 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 Lamp is 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 are 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 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 16 RECOMMENDED SPARE PARTS
13. are included to aid the opera tor in achieving optimum results while operating this svstem However the best wav to become familiar with the capabilities of the MA 40 is to strike an arc on a piece of heavv 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 mav control the arc position for both axes from a remote potentiometer or PLC with an an alog output or from the front panel controls default Remote or Panel Position Controls is selected with an internal DIP switch see Figure 24 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 25 MA 40 Main Board Lavout When these switches are in the Oscillate OSC posi tion as illustrated in Figure 18 Default Osc Stab DIP Switch Settings the control will deflect the arc in a circular pattern This will be indicated by the four lamps on the front panel Each lamp will illuminate al ternately completing one cycle When the STAB OSC switch is in the Stabilized STAB position the arc is aloowed only to oscillate in a left right pat tern across the seam see Figure 13 Amplitude 1 and 2 Adjustments on page 12 In Stabilize mode the operator can
14. 40 MAGNETIC ARC CONTROL SYSTEM DESCRIPTION OF EQUIPMENT INSTALLATION TABLE 1 MA 40 MAGNETIC ARC CONTROL SPECIFICATIONS TABLE 2 MA 40 MAGNETIC ARC CONTROL SYSTEM COMPONENTS 8 SPECIFICATIONS TABLE 3 MP 4 MAGNETIC ARC PROBE ASSEMBLY SPECIFICATIONS OPERATION TABLE 4 REMOTE START N O INHIBIT SETTINGS TABLE 5 REMOTE START N C INHIBIT SETTINGS TABLE 6 REMOTE TAPER N C SETTINGS TABLE 7 REMOTE TAPER SETTINGS INSTALLATION MAINTENANCE DRAWINGS AND PARTS LIST TABLE 8 MA 40 MAGNETIC ARC CONTROL PARTS LIST TABLE 9 POWER SWITCH ASSEMBLY PARTS LIST TABLE 10 TRANSFORMER ASSEMBLY PARTS LIST TABLE 11 PROBE CABLE HARNESS PARTS LIST TABLE 12 REMOTE INTERFACE CABLE HARNESS PARTS LIST TABLE 13 MP 4 MAGNETIC ARC PROBE PARTS TABLE 14 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST TROUBLESHOOTING TABLE 15 TROUBLESHOOTING TABLE 16 RECOMMENDED SPARE PARTS TABLE 17 VOLTAGE POINTS MAIN BOARD CIRCUIT DESCRIPTIONS SCHEMATICS AND BLOCK DIAGRAMS vii TABLE OF FIGURES 0600 0311 REV D Table of Figures MA 40 MAGNETIC ARC CONTROL SVSTEM DESCRIPTION OF EQUIPMENT 3 FIGURE 1 MP 4 MOUNTING METHOD 4 INSTALLATION 5 FIGURE 2 MA 40 MAGNETIC ARC CONTROL UNIT Lu 2 2 oe oe 46 FIGURE 3 MA 40 MAGNETIC ARC CONTROL SVSTEM COMPONENTS 7 FIGURE 4 MP 4 MAGNETIC ARC PROBE ASSEMBLY 8 FIGURE 5 INTERCON
15. 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 Frequencv 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 on 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 E NEMA Standards Publication No EW1 1989 Electric Arc Welding Apparatus approved as ANSI C87 1 1989
16. 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 gt m CAUTION An operational procedure which if not fol lowed may cause minor injury to the opera tor service personnel and or bystanders 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 SAFETV INFORMATION Safetv is a combination of good judgment and proper training Operation and maintenance of anv arc weld ing and cutting equipment involves potential hazards Individuals who are unfamiliar with cutting and weld ing equipment use faultv judgment or lack proper training mav cause injurv to themselves and others Personnel should be
17. REV D Mounted to Front Panel J2 P2 Amplitude 2 Wht 42142 Wht Grn 10110 R6 1K GM Position 2 Red aran s RS 1K I Org Jala Dwell DS4 Dwell 5 2 2 Dwell jose AQ josz em 166 pst Yel 93 i Blu 313 o 1 4 J3 P3 Frequenc Taper 4 y pi Red 10 10 Gm 77 R1 R2 Brn 10K T M ds 10K H Amplitude 1 Mb P 6 4 4 Y 66 i i is 165 osition BIk 2 2 Org 3 3 R4 1K Yel_ 4 4 Power Switch 81 L1 N 5 J5 v E wnt Ye Wht Grn Grn Wht gt 0400 1 Secondarv 71 110 110 P6 J6 Voltage Selector S2 Red F1 EMI RFI Bik Org L Filter Grn 110 230VAC 60 50Hz PE Chassis Ground Stud FIGURE 35 MA 40 MAGNETIC ARC CONTROL BLOCK DIAGRAM Front Panel 2 Front Panel 1 POWER SWITCH ASSEMBLY TRANSFORMER ASSEMBLY VOLTAGE SELECTOR amp INPUT POWER ASSEMBLY Main Board Assembly 38 0600 0311 REV SCHEMATICS AND BLOCK DIAGRAMS J12 P12 Blu Yel BIK Brn 12 12 11 11 Wht Blu Grn Wht Grn Wht See Remote Interface 5114110 SLNaNI 310 38 TO REMOTE
18. Taper Time the magnetic oscillation will stop Arc oscillation will not FIGURE 14 TAPER FUNCTION 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 For wiring instructions on the Remote Taper signal please review the schematic in Figure 37 MA 40 Magnetic Arc Control Interface Cable Schematic on page 40 for more details 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 15 Default Inhibit DIP Switch Settings Only one switch of the DIP switch should be depressed to TABLE 4 REMOTE START N O INHIBIT SETTINGS DIP SWITCH NAME SWITCH POSITION 1 CLOSED INHIBIT 2 OPEN 1 CLOSED TAPER 2 OPEN the closed position away from the word OPEN The other switch of the DIP switch should
19. alerted to the following potential hazards and the safeguards necessarv to avoid possi ble injurv In addition before operating this equipment you should be aware of your employer s safety regula tions Z BE SURE TO READ THIS MANUAL BE FORE INSTALLING OR USING THIS g EQUIPMENT BE SURE TO READ AND FOLLOW ALL AVAILABLE SAFETY REGULATIONS BE FORE USING THIS EQUIPMENT ELECTRIC SHOCK han 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 B never allow live metal parts to touch bare skin or any wet clothing Use only dry gloves C When welding or cutting in damp area or when standing on metal make sure you are well insulated by wearing dry gloves rubber soled shoes and by standing on dry board or platform je Pt 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 b
20. or less MP 4 Position the probe so that the Axis 1 Deflect sten ciled into the probe body is facing the direction of travel of the weld Back off the four socket screws which secure 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 4 screws See Figure 1 MP 4 Mounting Method on page 4 for illustrations of probe to seam orientation 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 0311 REV D FIGURE 2 MA 40 MAGNETIC ARC CONTROL UNIT TABLE 1 MA 40 MAGNETIC ARC CONTROL SPECIFICATIONS ITEM DESCRIPTION SPECIFICATIONS Frequency Oscillating Frequency 1 0 to 50 Hz maximum with Sweep at Zero Amplitude Oscillating Width oa on each side of the weld line approxi Position Arc Position a on each side of the weld line approxi Final Taper Trail off of Amplitude at the end of the weld cycle downslope Controls Frequency Amplitude 1 amp 2 Position 1 8 2 Final Taper Stabilize Oscillate Mode DIP Switches Input Power Requirements 90 132 VAC 180 2
21. use the Position control to preheat post heat or concentrate the arc heat in the center in relation to torch or workpiece movement Frequency The Frequency function controls the speed in which the magnetic field changes oscillating the arc Gen erally a fast welding travel speed requires a higher frequency of oscillation or a higher Frequency Dial Setting Amplitude Control The Amplitude dials adjusts the gauss strength of the magnetic field see Figure 8 Amplitude 1 Effect and Figure 9 Amplitude 2 Effect beginning on page 11 The effect of the magnetic field on the deflection of the arc is related to the length of the arc the type of material being welded the joint configuration and the welding process being used The proximity 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 applica tion 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 Amplitude 1 Amplitude 1 relates to the axis in line with the seam Amplitude 2 Amplitude 2 relates to the axis at a perpendicular to the seam Position Control 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 to the probe creating a constant magneti
22. x21 electrolytic gt RO 35 Electro Magnetic Interference 35 EMI 35 enclosure 3 6 35 Equipment ix 3 4 Exploded 24 30 F faulty ix Field xi fuse holder 3 G ground ix xi 35 H held xi fo ix 33 Integrated Circuits 33 Inhibit 15 input 35 insulated ES ix Integrated Circuits 33 interface 5 95 L Lamp 33 lug 21 33 Main board 33 35 maintained ix Maintenance 21 22 manual ix 33 momentary OX O ON ix 3 4 17 20 33 35 36 Oscillate E 13 output gt xi P Panel 13 panels gt xi parts list 33 periodic gt 21 Position gt 13 power switch 3 Precautions ix primary 35 Problem 33 Programmable Logic Controllers xi Qualified 35 R Radio Frequency Interference 35 rectified 35 Remote 13 Requirements 21 RFI 35 rod x 5 Safetv Information ix Schedule 21 schematics 33 35 selector 35 Service ix 35 shield xi source X 35 Stabilize fa se 13 static electricitv discharge 33 Sweep gt s gt 13 T Taper 13 Technicians 35 test points 35 torch ix xi travel x Troubleshooting 33 34 V Voltage 33 35 W wiring 21 41 0600 0311 REV D INDEX 42 WZ Arc Products AR A Lincoln Electric Companv ARC PRODUCTS INC 1245 30TH STREET SAN DIEGO CA 92154
23. 10 001 PRECISION MULTIDIAL 15 4 000 EA 941006 008 LED INDICATOR RED 12VDC 17 1 000 EA 0600 0441 MA 40 4 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 25 DRAWINGS AND PARTS LIST 0600 0311 REV D Power Switch J wk FIGURE 27 POWER SWITCH ASSEMBLY EXPLODED VIEW TABLE 9 POWER SWITCH ASSEMBLY PARTS LIST P3 ITEM QPA 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 TIE 75 BUNDLE DIA 26 0600 0311 REV D DRAWINGS AND PARTS LIST J 4 pl T1 gt _ 18 gauge 5 6 2 pl FIGURE 28 TRANSFORMER ASSEMBLV EXPLODED VIEW TABLE 10 TRANSFORMER ASSEMBLY PARTS LIST ITEM UM PART DESCRIPTION 1 1 000 EA 1037 0063 TRANSFORMER DUAL PRI DUAL SEC 2 1 000 EA 2208 0199 CONN RECT PLUG 10CKT
24. 311 REV D FIGURE 31 MP 4 MAGNETIC ARC PROBE EXPLODED VIEW 30 0600 0311 REV D DRAWINGS AND PARTS LIST TABLE 13 MP 4 MAGNETIC ARC PROBE PARTS LIST ITEM PART NUMBER gt DESCRIPTION 1 1 000 EA 1036 0021 HOUSING 4613 PROBE 2 1 000 EA 1026 0388 INSULATING SLEEVE ASSY 3 1 000 EA 1030 0355 COLLAR MAGNETIC 4 4 000 EA 1026 0396 MAGNET ASSY MDL 4613 6 1 000 EA 1026 0540 HEAT EXCHANGER ASSY 7 4 000 1030 0657 4613 8 1 000 1034 0021 ASSV CABLE 4613A 9 1 000 EA 1030 0665 COVER END 11 EA 3070 0066 COATING PROTECTIVE 12 2 000 EA 2380 0063 CLIP TUBE 3 16 OD 13 1 000 EA 930014 401 CONN CIRC BUSHING 220 ID 14 1 000 EA 976000 005 GROMMET RUBBER 5 16ID X 5 8 OD 15 1 000 EA 979001 001 CABLE TIE 75 BUNDLE DIA NOT SHOWN 16 1 000 EA 970015 306 SCREW 6 32X 50 HSC SBZ NOT SHOWN 17 4 000 EA 970000 302 SCREW 6 32 x 25 CR1P SBZ 18 2 000 EA 970000 402 SCREW 8 32X 25 CR1P SBZ 19 4 000 EA 970015 410 SCREW 8 32X 75 HSC SBZ 20 4 000 EA 970015 406 SCR 8 32X 50 HSC SBZ NOT SHOWN 21 4 000 EA 974010 004 WSR SL 8 293X 175X 040 SBZ 22 4 000 EA 970015 418 SCREW 8 32X1 50 HSC SBZ 23 2 000 EA 2380 0161 ASSY WATER HOSE 12FT 24 8 000 EA 963018 008 CLAMP HOSE 2 EAR 5 16 25 2 000 EA 963020 001 FTG 1 8 FEM NPT 1 8 TUBE ID 26 2 000 EA 2380 0136 FTG STR MALE 3 16 TB X 1 8 NPT
25. 3477 619 628 1022 619 628 1028 FAX sales arc products com service arc products com www ap automation com www arc products com 0600 0311 Rev D September 2011
26. 6 The Taper input must be maintained to keep the mag netic arc control oscillating the arc To enable the Taper Feature simplv remove the input to the mag netic arc control unit See Figure 19 Taper NC DIP OSC ija eje OPEN STAB FIGURE 18 DEFAULT OSC STAB DIP SWITCH SETTINGS S1 16 0600 0311 REV INSTALLATION Switch Settings for proper DIP Switch Seetings Re fer also to Figure 21 Remote N C Taper Interface on page 18 for proper remote interface cable wiring When the Taper Signal is used as a Remote Start in put in a Normally Closed N C configuration the control unit will oscillate the arc whenever there is a closure between Pins J and A When a closure be tween Pins J and Ais removed 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 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 40 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 exp
27. 64 VAC 50 60 Hz Control Unit Enclosure Standard NEMA Style Sealed enclosure Probes MA 40 can be used with this probe MP 4 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 0311 REV INSTALLATION FIGURE 3 MA 40 MAGNETIC CONTROL SVSTEM COMPONENTS TABLE 2 MA 40 MAGNETIC ARC CONTROL SYSTEM COMPONENTS SPECIFICATIONS ITEM SPECIFICATION Control Unit MA 40 Magnetic Arc Control Probe Assembly MP 4 Probes Cables Power Cord Assembly Remote Interface Cable Assembly Probe Cable Assembly MP 100 only Manual MA 40 Operators and Service Manual INSTALLATION 0600 0311 REV D Water Cooling Tube 8 32 Screw for Mounting Torch 4 PLC s Control Cable 1 56 Dia 3 5 Dia 3 00 FIGURE 4 MP 4 MAGNETIC ARC PROBE ASSEMBLY TABLE 3 MP 4 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
28. ALWAYS PROVIDE MODEL NAME AND PART NUMBER OVERVIEW 0600 0311 REV D Overview OVERVIEW IV TABLE OF CONTENTS TABLE OF TABLES VII TABLE OF FIGURES VIII SAFETY SAFETY PRECAUTIONS IX ADDITIONAL SAFETY HAZARDS XI MA 40 MAGNETIC ARC CONTROL SYSTEM DESCRIPTION OF EQUIPMENT INSTALLATION OPERATION 13 INSTALLATION 17 MAINTENANCE 21 DRAWINGS AND PARTS LIST 23 TROUBLESHOOTING 33 CIRCUIT DESCRIPTIONS 35 SCHEMATICS AND BLOCK DIAGRAMS 37 INDEX INDEX 41 0600 0311 REV D TABLE OF CONTENTS Table of Contents OVERVIEW b 3 IV TABLE OF CONTENTS e Y TABLE OF TABLES VII TABLE OF FIGURES VIII SAFETY SAFETY PRECAUTIONS DEFINITIONS IX NOTE IX CAUTION IX WARNING IX DANGER IX SAFETY INFORMATION IX ELECTRIC SHOCK IX FIRE SAFETY x ADDITIONAL SAFETY HAZARDS FIRE AND EXPLOSION XI FALLING EQUIPMENT XI HOT PARTS XI MOVING PARTS ee XI MAGNETIC FIELDS CAN AFFECT PACEMAKERS XI WELDING WIRE XI FLYING PIECES OF METAL OR DIRT XI OVERHEATED EQUIPMENT XI HIGH FREQUENCY XI SAFETY REFERENCES XI MA 40 MAGNETIC ARC CONTROL SYSTEM DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT 3 MA 40 CONTROL UNIT 2 3 MAGNETIC ARC CONTROL PROBES 3 MP 4 PROBE 3 INSTALLATION INSTALLATION 5 GENERAL SETUP 5 OPT
29. ED TAPER 2 OPEN SELECT ONE AN NO NC 1 2 ss 2 9 FIGURE 17 DEFAULT DIP SWITCH SETTINGS tween Pins D and A is made the Taper Feature will be enabled and the magnetic field strength generated bv 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 been removed the arc will begin to oscillate again at the Amplitude adjustment setting 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 DIP switch must be set for the Normally Closed positon See Table 6 Remote TABLE 6 REMOTE TAPER N C SETTINGS DIP SWITCH NAME SWITCH POSITION 1 CLOSED INHIBIT 2 OPEN 1 OPEN TAPER 2 CLOSED SELECT ONE 1 2 ss 212 5 FIGURE 19 DIP SWITCH SETTINGS Taper Settings on page 1
30. EFFECT Seam Control Setting Amplitude 1 250 Amplitude 2 500 Postion 1 250 or 750 Position 2 500 FIGURE 10 POSITION 1 ADJUSTMENTS 11 INSTALLATION 0600 0311 REV D Seam Seam Q Control Setting Control Setting Amplitude 1 500 Amplitude 1 500 Amplitude 2 250 Amplitude 2 500 Postion 1 250 or 750 Postion 1 250 or 750 Position 2 500 Position 2 500 FIGURE 11 POSITION 1 ADJUSTMENTS Seam Amplitude 2 000 or STAB OSC set to STAB Amplitude 1 000 Control Setting Postion 1 500 Position 2 500 FIGURE 13 AMPLITUDE 1 AND 2 ADJUSTMENTS FIGURE 12 POSITION 1 ADJUSTMENTS 12 0600 0311 REV D OPERATION OPERATION GENERAL OPERATIONAL DESCRIPTION CONTROL FEATURES amp FUNCTIONS To give the operator a better understanding of the MA 40 Magnetic Arc Control Svstem 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 5 functions of the control unit i e Frequencv Amplitude 1 Amplitude 2 Position 1 and Position 2 The magnetic field strength is controlled bv the Amplitude adjustments The Position adjust ments controls the arc s center line The illustrations of the MA 40 controls with explana tions of their functions
31. EQUIPMENT Wht Yel Wht Org SN wR ADNAN 2N 0420030003 Org Org Grn Grn Grn See Probe Schematic 3804d FIGURE 36 40 MAGNETIC CONTROL BLOCK DIAGRAM 39 SCHEMATICS AND BLOCK DIAGRAMS 0600 0311 REV D Start Contact Start N C Contact Taper N O Contact Taper N C Contact Power Ground N C 5VDC Output MA 20 40 Position MA 40 Position II 5VDC Output Earth Ground PE 5 L Brn NIC Blk M NIC Uae ane method B Red Start N O Contact Close to Start Blk N C Contact Open to Start Wht D o Taper N O Contact Close to Start Blk J Taper N C Contact Open to Start Grn A Use only one method Maintain to prevent magnetic arc oscillation N Blk NIC c Blu IK J Blk E 5 L Position l IK 2 en Yel a es G Fi 8 Position II gt Blk MA 40 Only F 0600 0352 MA 20 40 Automation Interface Cable assy ae FIGURE 37 MA 40 MAGNETIC ARC CONTROL INTERFACE CABLE SCHEMATIC 40 0600 0311 REV INDEX INDEX A adequate xi Amplitude 13 B barrel x C Cable 6 21 33 carriage xi CMOS 33 Control xi 3 6 current x xi 3 D diagram 21 33 35 diagrams 192 duration xi dust
32. IONS AND SPECIALS 5 CONTROL UNIT LOCATION 5 MAGNETIC ARC PROBE MOUNTING 5 MP 4 5 OPERATION OPERATION 13 GENERAL OPERATIONAL DESCRIPTION CONTROL FEATURES amp FUNCTIONS REMOTE PANEL POSITION CONTROL STABILIZE OSCILLATE FREQUENCY A AMPLITUDE CONTROL AMPLITUDE 1 AMPLITUDE 2 POSITION CONTROL POSITION 1 POSITION 2 TABLE OF CONTENTS 0600 0311 REV D FINAL TAPER REMOTE START NORMALLY OPEN START NORMALLY CLOSED START NORMALLY OPEN START USING TAPER NORMALLY CLOSED START USING TAPER INSTALLATION INSTALLATION MAINTENANCE MAINTENANCE oF ueni te 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 DRAWINGS AND PARTS LIST 21 21 21 21 21 21 21 21 21 21 DRAWINGS AND PARTS LIST TROUBLESHOOTING 23 TROUBLESHOOTING RC ue A ui 8 RECOMMENDED SPARES FOR TROUBLESHOOTING PROBLEM 1 PROBLEM 2 PROBLEM 3 CIRCUIT DESCRIPTIONS 33 33 33 33 CIRCUIT DESCRIPTIONS SYSTEM WIRING DIAGRAM MAIN BOARD ASSEMBLY SCHEMATICS AND BLOCK DIAGRAMS 35 35 SCHEMATICS AND BLOCK DIAGRAMS INDEX 37 INDEX 41 vi 0600 0311 REV D TABLE OF TABLES Table of Tables MA
33. NECTION DIAGRAM 020 FIGURE 6 40 ARC CONTROL MOUNTING DIMENSIONS fe sas O FIGURE 7 ALL CONTROLS EQUAL 11 FIGURE 8 AMPLITUDE 1 EFFECT 2 u 2 amp a O Q s dog s MM FIGURE 9 AMPLITUDE 2EFFECT s s MM FIGURE 10 POSITION 1ADJUSTMENTS A FIGURE 11 POSITION 1 ADJUSTMENTS 12 FIGURE 12 POSITION 1 ADJUSTMENTS he ok Aw di de Die mie mek cep FIGURE 13 AMPLITUDE 1 AND 2 ADJUSTMENTS Han o mx 25 50 Q singer OPERATION 13 FIGURE 14 TAPER FUNCTION A Woods quo g u 5 Ms FIGURE 15 DEFAULT INHIBIT DIP SWITCH SETTINGS 800 u u FIGURE 16 INHIBIT DIP SWITCH SETTINGS 2 15 FIGURE 17 DEFAULT TAPER DIP SWITCH SETTINGS 16 FIGURE 18 DEFAULT OSC STAB DIP SWITCH SETTINGS 16 FIGURE 19 TAPER DIP SWITCH SETTINGS 16 INSTALLATION 17 FIGURE 20 REMOTE N O TAPER INTERFACE 17 FIGURE 21 REMOTE N C TAPER INTERFACE 18 FIGURE 22 REMOTE N C INHIBIT INTERFACE 18 FIGURE 23 REMOTE N O INHIBIT INTERFACE kf liom m 5 9 25 19 FIGURE 24 DEFAULT POSITION DIP SWITCH SETTINGS V modus sb Su MAINTENANCE 21 DRAWINGS AND PA
34. RTS LIST 23 FIGURE 25 MA 40 MAIN BOARDLAYOUT HL FIGURE 26 MA 40 MAGNETIC ARC CONTROL EXPLODED VIEW ue FIGURE 27 POWER SWITCH ASSEMBLY EXPLODED VIEW 2 26 FIGURE 28 TRANSFORMER ASSEMBLY EXPLODED VIEW 27 FIGURE 29 PROBE CABLE HARNESS EXPLODED VIEW Bee ee 120 FIGURE 30 REMOTE INTERFACE CABLE HARNESS EXPLODED VIEW soco 209 FIGURE 31 MP 4 MAGNETIC ARC PROBE EXPLODED VIEW soe ow 290 FIGURE 32 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW sd 32 TROUBLESHOOTING 33 CIRCUIT DESCRIPTIONS 35 FIGURE 33 MA 40 MAGNETIC ARC CONTROL SIGNAL FLOW 36 SCHEMATICS AND BLOCK DIAGRAMS 37 FIGURE 34 MP 4 MAGNETIC ARC PROBE BLOCK DIAGRAM 37 FIGURE 35 MA 40 MAGNETIC ARC CONTROL BLOCK DIAGRAM za 98 FIGURE 36 40 MAGNETIC CONTROL BLOCK DIAGRAM CONT boa 299 FIGURE 37 MA 40 MAGNETIC ARC CONTROL INTERFACE CABLE SCHEMATIC 40 vili 0600 0311 REV D SAFETV SAFETV 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 OPERATE OR PERFORM MAINTENANCE ON THIS EQUIPMENT UNLESS YOU ARE
35. aveform 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 40 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 operator 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 4 PROBE The MP 4 is a four tipped water cooled probe that adapts to conventional torches The MP 4 works well in tight clearances and is primarily used to weave the ar
36. be de pressed in the opposite position WARNING If the 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 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 14 0600 0311 REV D OPERATION See Table 4 Remote Start Inhibit Settings on page 14 The Remote Start Input also known as Inhibit must also be wired correctiv on the remote interface cable Figure 23 Remote Inhibit Interface shows the proper wiring for N O Configuration Also Figure 15 Default Inhibit DIP Switch Settings illustrate the proper DIP settings When the Remote Start Inhibit Signal is used in Normally Open N O configuration the control unit SELECT ONE NO NC 1 2 O ej 54 cj o OPEN INHIBIT FIGURE 15 DEFAULT INHIBIT DIP SWITCH SETTINGS will oscillate the arc whenever there is a closure be tween Pins B and A When a closure between Pins B 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 w
37. c across the seam and along the seam in tube mill applications The MP 4 has four tipped allowing the magneitc field to oscillate the arc in a stabilized mode across the seam or in the oscillate mode circular or eliptical patterns On page 8 is Table 3 MP 4 Magnetic Arc Probe Assembly Specifications and Figure 4 MP 4 Magnetic Arc Probe Assembly for detailed dimensions and specifi cations 0600 0311 REV D DESCRIPTION OF EQUIPMENT FIGURE 1 MP 4 MOUNTING METHOD 0600 0311 REV D INSTALLATION INSTALLATION GENERAL SETUP A standard MA 40 Magnetic Arc Control svstem is shown in Figure 5 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 40 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 40 System is very easy and can be accomplished on most automatic or semiauto matic setups within minutes CONTROL UNIT LOCATION The MA 40 Control Unit should be placed in a location whic
38. c field which displaces the arc The Position Control dials controls this displacement see Figure 12 Position 1 Adjustments on page 12 In the Stabilize mode both Position controls can be used to offset the arc across the seam Position 2 but Position 1 can be used to provide an offset to pre heat or postheat the arc The distance the arc can be displaced 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 Position 1 Position 1 adjusts the offset for the cross seam adjustments Position 2 Position 2 adjusts the offset for in line seam adjust ments for Preheat or Postheat deflection Final Taper The Taper function is a new feature in Magnetic Arc Control Systems This feature sets the amount of 13 OPERATION 0600 0311 REV D time to decrease the Amplitude settings from its cur rent value to zero in order to perform a better downslope function in coordination with the welding power source or controller Referring to Figure 14 Taper Function the Taper feature is only used with a remote input to feather out the weld pool at the end of the weld The Taper setting should be slightly less than the ac 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 do
39. ection 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 25 MA 40 Main Board Layout on page 23 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 on page illustrates very simply the flow of sig nals in the MA 40 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 Main 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 40VDC and 18VDC is used as the source voltage for the
40. eriment with the MA 40 controls to get a good feel for the equipment With the power Off set the Frequency and Amplitude controls to their fully counter clockwise positions 000 on the dial and set the Position controls at its center position 500 on the dial Open the controller door and find the STAB OSC DIP switch on the main board see Figure 25 MA 40 Main Board Layout Set the STAB OSC switch in the Oscillate OSC posi tion Strike an arc allow it to stabilize then turn On the MA 40 Control Unit At this point the operator will not see any significant change in the arc action but if you P5 look at the 4 LED indicator lamps on the front panel of the control unit vou will notice thev are sequencing completing one cvcle in roughiv one to two seconds 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 See Figure 7 All Controls Equal on page 11 to review the controls function and the other figures that follow beginning at page 11 Please note this figure has the Amplitude dials set at 500 Now turn the Amplitudes control clockwise to approxi mately mid range of its settings 500 on the dial The arc will now be deflected in a circular pattern as is illustrated in Figure 7 All Controls Equal As you turn the Frequency contr
41. h 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 6 MA 40 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 2 MA 40 Magnetic Arc Control Unit and Figure 26 MA 40 Magnetic Arc Control Exploded View The operator may select the proper input voltage using a small slotted screwdriver The mounting dimensions of the control unit are shown in Figure 6 MA 40 Magnetic Arc Control Mounting Di mensions should the user choose to install the MA 40 on a fixture or control panel MAGNETIC ARC PROBE MOUNTING The MP 4 Probe will mount on any machine torch with a body diameter from 1 56 inches
42. he 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 4 probe is water cooled and should never be operated without the coolant being circulated by a cooling source water cooler The water hoses are rated for 40 psi maximum These ratings should not be exceeded as leakage or bursting of the water hoses will result Remove any slag buildup from the probe tips frequently as a loss in the probe s effec tiveness 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 correctly 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 38 PREVENTIVE MAINTENANCE SCHEDULE
43. ill 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 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 5 Remote Start N C Inhibit Settings on page 15 The Remote Start Input also known as Inhibit must also be wired correctly on the remote interface cable Figure 22 Remote N C Inhibit Interface shows the proper wiring for N C configuration Also Figure 16 Inhibit NC DIP Switch Settings illustrate the proper DIP settings TABLE 5 REMOTE START N C INHIBIT SETTINGS DIP SWITCH NAME SWITCH POSITION 1 OPEN INHIBIT 2 CLOSED 1 CLOSED TAPER 2 SELECT ONE S NO NC 1 2 Pal o S5 c E OPEN INHIBIT FIGURE 16 INHIBIT NC DIP SWITCH 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 and A When a closure between Pins
44. itable 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 cylinders 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 A Move all combustible materials well away from the cutting area or completely cover ma terials with a non flammable covering Com bustible materials include but are not limited to wood clothing sawdust gasoline kerosene paints solvents natural gases acetylene pro pane and similar articles 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 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 ade
45. ol clockwise you will also notice the arc oscillation cycle increasing in speed When the STAB OSC switch is placed in the STAB position the arc is stabilized on only one axis Axis 1 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 and to provide preheat or postheat of the seam Additional adjustments may be necessary to achieve the desired weld bead penetration and profile Ampli tude 1 and 2 Position 1 and 2 and Frequency con trols are the primary adjustments to change the weld bead profile and 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 N O Contact D Blk J N C Grn Power Ground A BIk pi Earth Ground PE FIGURE 20 REMOTE N O TAPER INTERFACE 17 INSTALLATION 0600 0311 REV D PS Taper N O Contact Open to Enable Taper DN Wht D N C BIk Taper N C Contact J i T MN Grn Power Ground A BIk N C N N C Earth Ground PE FIGURE 21 REMOTE N C TAPER INTERFACE
46. om bustible surfaces Do not install unit near flammables FALLING EQUIPMENT Falling Equipment can cause serious per sonal injurv and equipment damage Use lifting eyes to lift unit only not running gear gas cvlinders or anv 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 R 16 gt i 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 from 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 Af MAGNETIC FIELDS CAN AFFECT PACEMAKERS _ Magnetic Fields from High Currents af 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 Do not press gun trigger until instructed to do so Do not point the gun toward any part of the body other people or any metal when threading welding wire through the gun FLYING PIECES OF METAL
47. quate 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 vou develop momentarv eve nose throat irritation during welding or cutting it is an indication that the ventilation is not ade quate Stop work and take the necessarv steps to improve ventilation in the welding or cutting area Do not continue to weld or cut if physical discomfort persists D Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases E 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 249 1 for specific ventilation recommendations 0600 0311 REV D SAFETV ADDITIONAL SAFETV HAZARDS FIRE AND EXPLOSION Fire and Explosion can result from placing units on over or near combustible surfaces Do not install units on over or near c
48. tions Figure 2 MA 40 Mag netic Arc Control Unit and Figure 3 MA 40 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 40 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 40 System can be used with spray MIG and Sub Arc processes With this system 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 40 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 w
49. uilding framework or other locations remote to the SAFETV 0600 0311 REV D 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 METAL CAN BE MORE SEVERE THAN SUNBURN A Usea proper face shield fitted with the cor rect filter 10 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 su
50. wnslope is used As the welding amperage decreases during downslope the arc becomes weaker and easier to move or oscil late by the magnetic arc 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 17 Default Taper DIP Switch Settings for proper configuration Refer also to Figure 20 Remote N O Taper Interface on page 17 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 Ais 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
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