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OPERATION MANUAL for Cyclomatic Series AVC

1. Red Sense 9 l AVC 5 Drive i M Torch Clamps h ii H I Electrode Workpiece Workpiece Earth Ground PE 177 FIGURE 6 INTERCONNECTION DIAGRAM 24 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM 3 375 Direction Tos of Travel Y FIGURE 7 AVC 501 STANDARD DRIVE ASSEMBLY MOUNTING DIMENSIONS 25 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM 3QISUYJN 5 27 6 3046893 6514 6330 Z9 x 82 INN PZ 91 9 310H DNILNNOM UNN 19310Hd A9Nanoaud 17VNINU3L 393ld NHOM Qv31 3SN3S 1 FIGURE 8 AVC 501 COMPACT DRIVE ASSEMBLY MOUNTING DIMENSIONS 26 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM EA E REJA SV en p E Red Sense Lead From AVC FIGURE 9 AVC 501 SENSE LEAD TIG TORCH CONNECTION 27 AVC 501 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF EQUIPMENT Red Sense Lead From AVC FIGURE 10 AVC 501 SENSE LEAD PLASMA TORCH CONNECTIONS 28 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM Red Torch Sense Lead Work Piece Binding Post AVC Drive A Junction Box Assembly AVC 5 Drive Top View FIGURE 11 AVC 501 DRIVE WORK PIECE CONNECTIONS 29 AVC 501 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF
2. DESCRIPTION SPECIFICATIONS RATING Load Capacity Mounted in Torch Clamp Brackets 45 Ibs 20 Kg at Center Line of Torch Non Standard Stroke Length Optionally available 4 101 mm to 12 304 mm Stroke Lengths Tracking Controls Manual Up Down Acme Screw with brass nut running on Dual Vee Drive System Wheels Drive Cable Standard Length 10 3 M Sense Lead Standard Length 3 1 M Weights 6 152 mm Drive Assembly 15 Ibs 6 8 Kg 22 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM FIGURE 5 AVC 501 COMPACT DRIVE ASSEMBLY TABLE 4 AVC 501 COMPACT DRIVE ASSEMBLY SPECIFICATIONS DESCRIPTION SPECIFICATIONS RATING Load Capacity Mounted in Torch Clamp Bracket 10 Ibs 4 5 Kg at Center Line of Torch Tracking Controls Manual Up Down t Precision Ball Screw and Nut running on mi Drive System cro slides Drive Cable Standard Length 10 3 M Sense Lead Standard Length 3 1 M Weights 1 25 4 mm Drive Assembly 12 Ibs 5 4 Kg 23 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM AVC 5 Control i Sheilding Gas Input Power Optional Remote Interface Cable s J5 and J6 Earth Ground PE Drive Cable J4 TIG or Plasma Welding Power Ground Stud Oraina Senes Lead Source
3. dody de 220 Table 3 501 Standard Drive Assembly Spe ifi i ogr sk En g u w 222 Table 4 AVC 501 Compact Drive Assembly Specifications 23 Operation i dad S MAE LE SG Ler Et wd OKA qq et ded xA E 31 Installation 44 445 ASRS EA redd TT ME AE A STN 35 45 Drawings and Parts 1 45 sake AEM VR ed a A a ad A 47 Table 5 Voltage Selector Switch Assembly Parts List 49 Table 6 AVC 501 Control Parts List s SL Table 7 Power Switch Assembly Parts List 52 Table 8 Transformer Assembly Parts 53 Table 9 AVC Drive Cable Assembly Parts 1481 2 4 84 Table 10 AVC Remote Interface Cable Parts 1 4 4 o S Table 11 AVC 501 Standard Drive Assembly Parts List 4 ST Table 12 AVC 501 Compact Drive Assembly Parts List 59 Table 13 AVC Aux Remote Interface Cable Parts List 60 Troubleshooting R D ee A uoa x Mdr BALE Ara 61 Table 14 Troubleshooting Board 1 BA eb BL gl OG Table 15 Voltage Points Micro controller Board 5 X ek m ode l4 BR mech 102 Table 16 Voltage Points Power Driver Board 1 4
4. 0 5VDC to 10VDC 5V to 50V Welding Voltage FIGURE 27 AVC 501 REMOTE VOLTAGE SET POINT ANALOG Drive Up Logic Ground Drive Down P5 Remote Mushroom Switch FIGURE 28 AVC 501 REMOTE UP DOWN DRIVE WITH E STOP 42 INSTALLATION AVC 501 ARC VOLTAGE CONTROL SYSTEM ANC 5 Control 5 Output 2040 500 Ohms 5K Ohms 10 Pot Zener _ Diode Remote Set Y Remote Set M Output Return FIGURE 29 501 REMOTE VOLTAGE SET POINT INTERNAL VOLTAGE 10VDC 10K Pot 5 Blk 500 Ohm Remote Voltage Pre Set Wiper V 57 sh R gt Remote Voltage Pre Set reference M Optional V 0 5VDC to 10VDC 5V to 50V Welding Voltage FIGURE 30 AVC 501 REMOTE VOLTAGE SET POINT EXTERNAL VOLTAGE 43 AVC 501 ARC VOLTAGE CONTROL SYSTEM INSTALLATION 44 MAINTENANCE MAINTENANCE MAINTENANCE REQUIREMENTS Jetline Arc Voltage Control Systems are designed for trouble free operation and normally require only min imal preventive care and cleaning This section of the users manual provides instructions for maintaining user serviceable items The suggested repair proce dure for all user serviceable items is to remove and re place defective assemblies or parts Service personnel employed by the user should be familiar with electri cal and electronic equipment or else service proble
5. 62 Table 17 Recommended Spare Parts 63 Table 18 Voltage Preset Selection SI 63 Circuit Descriptions io soe EE gx RETO 65 Example System 67 Table 19 AVC 501 Setup Parameters ee 67 Table 20 DWF 3 Setup Parameters D NUS OS uh Pe pte ge uu Be i uu s OZ Table 21 Carriage Control Setup Parmbteni hcm cse iE ac SSS os et tal 16 Table 22 Magnetic Arc Control Setup Parameters 68 Table 23 Miller MaxStar 300LX Setup Parameters 68 Schematics and Block Diagrams 2222s 71 Optional Equipment sci ser se state sa Gad M IUOS E DU er CA 81 TABLE OF FIGURES AVC 501 ARC VOLTAGE CONTROL SYSTEM Table of Figures AVC 501 Arc Voltage Control System Description of Equipment 17 Figure 1 Arc Voltage Control Theory s 17 Figure 2 AVC 501 Control Unit 20 Figure 3 AVC 501 System components AI Figure 4 AVC 501 Standard Drive Assembly 22 Figure 5 AVC 501 Compact Drive Assembly 23 Figure Interconn
6. Chassis Ground Stud POWER SWITCH ASSEMBLY TRANSFORMER ASSEMBLY VOLTAGE SELECTOR amp INPUT POWER ASSEMBLY 5 Power Board Assembly FIGURE 44 AVC 501 CONTROL BLOCK DIAGRAM 72 SCHEMATICS AND BLOCK DIAGRAMS AVC 501 ARC VOLTAGE CONTROL SYSTEM 6 E nu E x E 2 1010 cy D m H E 4 lels 7 Gl 3 m 0 21717 L 5 Blu w 66 315 a 515 2 5 E e 4l Reg 3 3 3 el e 212 ha A 7222 Jtalp13 18 18 s 17 17 R 16 16 B See Remote Interface 15 15 D y 114114 G 13 13 PIE 9 oto n im Wht 1111 5 5 Gry Ho 10 a lalo 2 Vio 5 8 8 V E 717 3 Blu G 6 6 oF e 91515 Org L Rea T J E H Grn TT a TU e 25 15 15 5 Drive Assembly Std Stroke Mot 16116 mim 1 Motor o 14 14 B B FF Red 2 Bik B 1313 DID Wht Blk Blu 0 1242 a Wht Red ec Yel E 11 11 PIPE Gm Red am foto Rad E E 818 R R gm 717 F F zu N
7. o oo XV do C8 Ih RR eO AG CMOS 61 Compact 18 21 23 26 36 58 59 65 7 1 contamination gt R w og 45 Continuously gt 62 Control xv 18 20 22 45 coupling 5 7058 ons 4 Gras eR 720 current 5 xiv xv 18 D Deadband 20 32 33 61 62 65 67 Delay 20 31 32 36 38 62 65 67 69 diagram 45 61 65 diagrams 61 18 31 32 37 65 Downslope 32 68 Drive 2265 Driver 61 62 65 66 duration s XV dust 6 45 46 E electrolytic 65 Electro Magnetic M Interference 65 EMI 65 enclosure 18 20 45 65 Equipment 17 30 Example 79 Exploded 46 50 56 58 F factory o o 45 faulty gt gt tr rn xi Field fuse holder gt gt 18 45 G ground ilii ge Xiii xv 65 17 H held xv 45 46 AVC 501 ARC VOLTAGE CONTROL SYSTEM HF gt gt 20 31 34 38 61 67 Q Qualified 65 IC xij xiv 20 22 23 61 R Integrated Circuits 61 Indication 20 Radio Frequency Interference 65 input 65 Rating gt 20 22 23 insulated o xii rectified
8. 708 804 90 LT or rue Inhibit AP Automation maire Tm Model MA 20 Inhibit Retum MA 40 TB Main Junction to house wiring and switches etc Opt FIGURE 51 AVC 501 SYSTEM INTERFACE EXAMPLE CONT 79 AVC 501 ARC VOLTAGE CONTROL SYSTEM SCHEMATICS AND BLOCK DIAGRAMS 80 OPTIONAL EQUIPMENT OPTIONAL EQUIPMENT CROSS SEAM ADJUSTMENT ASSEMBLY 1046 0271 The Cross Seam Adjustment assembly provides for a two inch cross seam fine adjustment of the AVC 501 and 501 drive units and torch assembly Two versions available are knob or crank style handle TILTING BRACKET ASSEMBLY 1043 0046 The Tilting Bracket assembly provides for approxi mately 45 degrees tilting of the standard AVC 501 and 501 drive unit and torch assembly DRIVE CABLE EXTENSION The Drive Cable Extension extends the cable between the drive unit and the control unit The maximum ca ble length is 80 feet NOTE MAGNETIC ARC CONTROL SYSTEMS There are several cable extension lengths available Please consult the factory for more information regarding the cable length needed for your specific application 81 AVC 501 ARC VOLTAGE CONTROL SYSTEM Magnetic Arc Control Systems can enhance and fur ther control the arc in a TIG or Plasma application by oscillating the arc across the seam or in a direction along the seam Using a magnetic arc control system can prevent undercutting arc blow arc drag and c
9. Each component of the system will have its own ter minal strip to make the enclosure less cluttered and to make it easier to troubleshoot it needed TABLE 21 CARRIAGE CONTROL SETUP PARAMETERS Parameter Setting Closure to Start Input Selection start carriage The lid or cover of the enclosure where the switches and potentiometers are mounted can be used as a op erator console This saves time in that the wiring and control switches etc are housed in one enclosure and minimizes the possibility of grounding problems and possible HF damage often associated with these types of problems OPERATION OF THE SYSTEM The operation of the system can be started and stopped by the switches and other components mounted to the lid or cover of the enclosure In order for this to function properly certain setup pa rameters in the AVC 5 DWF 3 4 and Miller MaxStar 300LX power source must be performed Below is a list of such parameters Table 19 AVC 501 Setup Parameters Table 20 DWF 3 Setup Parameters Table 21 Carriage Control Setup Parameters Table 22 Magnetic Arc Control Setup Parameters Table 23 Miller MaxStar 300LX Setup Parameters AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE 22 MAGNETIC ARC CONTROL SETUP PARAMETERS Parameter Setting Model 80A amp MAG 8020 Position 50 Amplitude 20 Left Dwell 10 Speed 10 Right Dwell 10
10. OPERATION MANUAL for Cyclomatic Series AVC 501 System Revised December 2006 IMPORTANT Read this manual carefully before installing commissioning or operating this product Jetline Engineering 15 Goodyear Street Irvine CA 92618 Telephone 949 951 1515 Fax 949 951 9237 Web site www jetline com www cyclomatic com E mail sales jetline com LIMITED WARRANTY Jetline Engineering of Irvine California U S A warrants all new equipment to be free from defects in material and workmanship for the period of one 1 year provided that the equipment is installed and oper ated according to instructions Jetline Engineering s obligation under this warranty is expressly limited to replacing or repairing and de fective part or correcting any manufacturing defect without charge during the warranty period if Jetline s in spection confirms the existence of such defects Jetline s option of repair or replacement will be F O B Factory at Irvine California and therefore no compensation for transportation costs of any kind will be al lowed The warranty period begins on the date of sale to the original purchase user of the equipment Jetline Engineering will not be liable for any loss or consequential damage or expense accruing directly or indirectly from the use of equipment covered by this warranty This warranty supersedes all previous Jetline Warranties and is exclusive with no other guarantees or warranties expre
11. 65 Integrated Circuits 61 Relay 32 36 38 interface 65 Remote 20 21 37 38 40 42 Interface 78 43 55 60 63 65 68 76 77 Retract 20 32 33 65 67 69 J BEL S ge Sr dress tt 5559565 2222 AN XIV 2005 bom W oe x 520 5 Safety BRE E EE 3 25 35 2 Ba 69 Information gt xiii K2 tot tt c t 7 9268 69 Sehedule 46 schematics gt lt 61 65 L secondary gt 1 65 Lamp s s s 61 63 selector gt Rowi 65 Lift Start 18 Sensitivity 20 32 33 61 65 67 liquid 45 service gt xili 45 Load Capacity 22 Service gt gt gt 45 65 Lockout 20 31 32 36 38 40 61 69 See Also Troubleshooting lug 20 45 46 61 serviceable gt gt 45 shield XIV XV M Slide 22 source 65 Main 45 61 65 Specifications 20 22 23 a Standard 18 20 23 25 36 56 57 74 75 MANS CE 26 we 227282 seen A 30 static electricity discharge 61 manual z xiii 45 61 Stroke Length 22 Manual gt 2245 T Mode 21 31 32 34 36 38 61 63 67 69 momentary se xiv Technicians gt gt gt 65 fotor s x sm GOL RO Uo 365 test points 1 1 65 Theory gt A TIG gt 17 18 27 31 32 67 81 torch xiij 46 Non S
12. AVC 501 ARC VOLTAGE CONTROL SYSTEM Emergency Stop using a mushroom style switch Process Stop using a pushbutton switch The Emergency Stop switch stops the output amper age of the Miller MaxStar 300LX and commands an up drive signal to the AVC 501 Arc Voltage Control ler The Up drive signal to the AVC 501 during a welding cycle immediately de energizes both K1 and K2 relays and thereby stopping the remaining equip ment interfaced in this example NOTE Itis up to the operator and or installer to make sure this Emergency Stop switch is adequate for your application and to be within your building and safety codes Power Source Section The power source section provides to simple controls primarily because all of the other parameters are ac cessed through the front panel of the Miller MaxStar 300LX and are not available externally Welding Amperage Adjustment using a potentiometer Gas Purge using a pushbutton switch OPTIONAL FEATURES Optional features can be installed as needed to allow greater benefit but have been omitted for clarity and to fit the majority of the applications Examples of these features are as follows with expla nations and are organized by the console section Cold Wire Feed Section An additional Inhibit switch could be added to pre vent wire from feeding during the entire welding cy cle if desired This can also be accomplished by turning off the DWF 3 or by selecting the Off p
13. Wearers of pacemakers should consult their doctors before going near arc weld XV AVC 501 ARC VOLTAGE CONTROL SYSTEM ing 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 OR DIRT amp Flying pieces of metal or dirt can injure Z 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 be fore starting to weld again Follow rated duty cycle HIGH FREQUENCY High Frequency can cause electrical inter ference Take appropriate precautions to shield sensitive electronic equipment such as computers 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 infor mation on important welding safeguards A ANSI ASC 249 1 1988 American National Standard Safety Welding and Cutting Bulletin No F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting Con tainers and Piping that have held Hazardous Substa
14. Assemblies 2 2 2 AS Mounting Brackets RER SE Ge TT Mr ar ue FO Preventive Maintenance Schedule e wa w M w ES SE ee Monthly Maintenance 2 0220 2 2 2 2 2 2 22 2 2 2 0 6 AVC Drive Assemblies a 46 Proper Function a 100 26442 26 lnc lu lh 80040275 46 8 de mo JE do X et c P rer b oe a 240 Test GENET EE dy i A oka ka dk BB an let mood uon HO Torch Bracket Assembly 4 46 Proper Function w s 4 o o s 46 LOSE x 5 We ON Te A anm ET BE QAAE Sot ge 40 Cables A TEM Semi Annual Verne Mn ee Qua IJIET NA sete Control Unit Assembly 46 Drawings and Parts Lists Drawings and Parts Lists 47 Troubleshooting Troubleshooting Recommended Spares uir oublesosting 2 20 BE ous A MAD ex SSE 0 Problem in il a cM Mone 5 xh ae le w r Lo ch A Ue ow do dil Ee wz du Wa s ta Problema doc ww CAR e eo We DE GA Ge mal Or up Ge GOL Problems a amp mo dl la 40020528 hc Wap bea M epo ho datio un SOL Problem do 4 Ge dak de cB al eM E d
15. Ce Mo da ke EIUS un cie SOL Problema il 50 X vm ta DUR GE ch We fe d Mk Nis no o OL Problem 4 mS st r uw Tet ue Ja e umo ure BUM A GE fuga dE 160 Problem 2 d a m GS on Mob W Wow Bos Row O02 viii TABLE OF CONTENTS AVC 501 ARC VOLTAGE CONTROL SYSTEM Problem Dad se Regu De RNA Bet A Be ee heck 3 cx us 102 Problem 973 a x as 28 oe Gr day xeu wm det xs 2602 Problem d0 Xo e 2 eat Wow Ge ae ir uw OG Circuit Descriptions Circuit Descriptions a 65 System Wiring Diagram s 65 Power Driver Board Assembly arr s 65 Micro Controller Board Assembly aar 6 Motor Driver Circuit 2 66 Remote Voltage Preset Circuit 2 66 Example System Interface Example System Interface 2 2755 E Tso GLE OT AVC 501 System ARE Ex mple A a ous oa 102 Design Intent OO Interface Intenta G modre o buo oue RE oum op cn 707 Operation of the System ar 67 Start Sequence 4 5 TE 6 6 os Wok ee E wod Wow W Sex u wo az wo gr 68 IOP SEGUENCE OG Ae soos p oda GE Pa Rowe om held 008 Console Features ta AL de Bo Mr p che Cold Wire Feeder Section Arc Voltage Co
16. EQUIPMENT co 2 o M Height of on off switch Y 11 844 11 000 Mounting holes center to center 10 500 Mounting holes center to center 11 700 FIGURE 12 AVC 501 CONTROL UNIT MOUNTING DIMENSIONS 30 OPERATION OPERATION GENERAL OPERATIONAL DESCRIPTION The 501 microprocessor controlled system auto matically controls the arc voltage and arc gap during a welding operation by digitizing and processing the arc voltage The operational parameters required for this function Setpoint Voltage Start Delay etc are pre set pre selected by the operator using the controls on the front panel of the control unit These operational parameters are read by the micro processor prior to an arc start and during the welding process When the control unit is first turned on and no arc voltage is present manual mode of operation is in effect When an arc is struck the system goes into automatic The first phase of automatic is Start Delay During Start Delay the drive will not adjust to control the arc voltage When Start Delay times out the drive will begin to adjust to control the arc voltage and con tinue to do so unless Lockout is activated or the arc is extinguished The following sections describe in de tail the various modes of operation NOTE In all modes of operation the Up pushbuttons on the drive unit on the front panel or via remote input will perform the same fun
17. FIGURES Figure 39 AVC 501 Standard Drive Assembly Exploded View 56 Figure 40 AVC 501 Compact Drive Assembly Exploded View 58 Figure 41 AVC Aux Remote Interface Cable Exploded View 60 Troubleshooting is 61 Figure 42 AVC 501 Signal Flow 63 Circuit Descriptions LE baade RE eese dea da 65 Example System 67 Schematics and Block 5 71 Figure 43 AVC 501 Compact Drive Block Diagram 71 Figure 44 AVC 501 Control Block Diagram D E 272 Figure 45 AVC 501 Control Block Diagram 5 Lib BIE had Ch EL A med 3 Figure 46 AVC 501 Standard Drive Block Diagram 74 Figure 47 AVC 4 Standard Drive Block Diagram we 75 Figure 48 AVC 501 Remote Interface Cable Schematic da de 15 Su abs Figure 49 AVC 501 Auxiliary Remote Interface Cable Schematic ck nit ta 8 222 Figure 50 AVC 501 System Interface Example 76 Figure 51 AVC 501 System Interface Example 79 Optional Equipment ses da W blk EE A 81 SAFETY SAFETY PRECAUTIONS
18. MAG 8020 Final Taper Time 3 seconds Inhibit Final Taper Input Signal set Normally Open Keep in mind each application is different and this list may need to be expanded upon to meet your needs Start Sequence To start the system be sure the above parameters are set properly To start the welding process press the AVC 501 Drive Down pushbutton on the console un til the AVC 501 drives the torch down to the work piece and the tungsten makes contact The Protect Arm LED on the AVC 501 front panel will light At this time the AVC S s K1 relay is energized turn ing on the Miller MaxStar 300LX power source and giving the start signal to the DWF 3 wire feeder be cause of start delay on the DWF 3 wire feeding does n t start until the time expires The power source starts pre purge and then Lift Arc output current The AVC 501 has also began the Tungten Preheat timer Once the Tungsten Preheat timer has expired the AVC 501 control drives the torch up momentarily un til an arc is established After the arc is established the AVC 501 immediately starts the Start Delay Timer The Miller MaxStar 300LX also begins producing welding output current at 20 amps as selected by the initial current setting and begins ramping the current through upslope time to reach the welding current selected 60 amps Once the Start Delay timer of the AVC 501 and the Miller MaxStar 300LX s Upslope timer have com pleted the MaxS
19. THIS MANUAL HAS BEEN DESIGNED FOR EXPERIENCED WELDING AND CUTTING EQUIPMENT OPERATORS AND MUST BE READ COMPLETELY BEFORE USING THIS EQUIP MENT IF YOU LACK EXPERIENCE OR ARE UN FAMILIAR 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 QUAL IFIED AND HAVE READ AND UNDERSTOOD THIS MANUAL IF IN DOUBT ABOUT IN STALLING OR OPERATING THIS EQUIPMENT CONTACT YOUR DISTRIBUTOR OR THE CUS TOMER SERVICE DEPARTMENT OF ITW JETLINE DEFINITIONS Throughout this manual NOTE CAUTION WARNING and DANGER are inserted to call atten tion to particular information The methods used to identify these highlights and the purpose for which each is used are as follows NOTE 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 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 b
20. compared to scratch starting the arc using the tungsten electrode S8 AC WELDING m DC WELDING LIFT START FIGURE 16 LIFT START START MODE AND DC WELDING HIGH FREQ START AUTOMATIC MANUAL MODES Manual mode The manual mode of operation is in effect whenever the torch voltage is outside the voltage range of opera tion of 5 to SOVDC and the system is not in Retract In manual the Up Down pushbuttons will move the drive in the selected direction When the drive is operated from the Up Down pushbuttons the drive will move at the manual motor speed in the direction selected While in manual all of the operational parameters can be changed Automatic and Start Delay Modes The Automatic Mode of operation is in effect when ever the torch voltage is within the Automatic Volt age Sense Range of 5 50VDC which indicates that an arc is present Prior to the arc voltage coming into range the AVC 501 simply waits During this time down drive is not operable but the up drive pushbutton is If the Up drive pushbutton on the front panel either remote interface cables or at the drive as sembly is pressed the AVC 501 will reset back to the manual mode of operation NOTE This is important to note for the AVC 501 to re set and the arc to extinguished the AVC 501 must control the contactor of the power source This Up drive signal can be used to act as a stop signal again on the front panel the remote in ter
21. only with a power supply that provides contact closures rather than voltage outputs REMOTE SET POINT VOLTAGE INPUT The 501 is capable of having the set point volt age set by an external voltage supplied from other equipment rather than from the front panel potentiom eter To use the Remote Set Point mode it must first be selected using the DIP Switch S1 inside the unit on the Micro controller board see Figure 31 AVC 501 Micro Controller Board Layout on page 47 for DIP switch locations and Figure 21 Panel Volt age Preset DIP Switch Selection and Figure 20 Remote Voltage Preset DIP Switch Selection begin ning on page This DIP Switch has two positions and they must be positioned so that only one is in the On position NOTE Both DIP Switches must not be set in the same position 1 e both in the On position or both in the Off position The system will not function properly if the DIP switch is positioned in such a Way 51 PANEL VOLTAGE PRESET REMOTE VOLTAGE PRESET SELECT ONE Shown in Remote Voltage Preset Mode FIGURE 20 REMOTE VOLTAGE PRESET DIP SWITCH SELECTION The set point shown on the display will be the value measured at the remote set point input From the fac tory this input voltage is scaled and calibrated cor rectly for an input voltage of 0 to 10VDC The 37 AVC 501 ARC VOLTAGE CONTROL SYSTEM resultant set point voltage will be 0 to 50VDC of ac tual welding arc voltage If t
22. selecting the maximum Deadband setting makes the AVC 501 the least accu rate see Figure 18 Maximum Deadband Setting For example the user selects 10 volts as the welding voltage The user adjusts the Deadband fully clock wise This selects the maximum Deadband setting or the largest possible window of voltage The AVC 501 will not correct for any voltage error greater than 8 5 volts and less than 11 5 volts a 3 volt window 1 5 volts If the voltage goes below the 8 5 volts or above 11 5 volts the 501 control will correct the arc length to return the voltage back into the 3 volt window Burn Through Protection Feature Initiated 13 5V 1 5 Volt Deadband Window 11 5V 10V 4 8 5V FIGURE 18 MAXIMUM DEADBAND SETTING Likewise if the Deadband was adjusted fully counter clockwise minimum Deadband or smallest possible window of voltage the 501 will correct for er rors in the voltage when the voltage exceeds the 2 volt window below 9 9 volts and above 10 1 volts see Figure 17 Minumum Deadband Setting Burn Through Protection Feature Initiated 12 1V 2 Volt Deadband Window 10 1V 10V 9 9V FIGURE 17 MINUMUM DEADBAND SETTING Sensitivity The Sensitivity feature is an adjustment to allow the user to select how fast to correct for voltage errors once the voltage exceeds the Deadband setting Ad justing the Sensitivity fully C
23. shuts sa the arc Starting Arc Gap is set to high caus Feature as soon as the arc is starte ing the arc to start at a higher voltage than the Voltage Preset Decrease the Starting Arc Gap to a smaller gap preventing the arc from starting at a higher voltage above Preset preventing the Burn Through Protection Feature from being initi ated TABLE 15 VOLTAGE POINTS MICRO TABLE 16 VOLTAGE POINTS POWER DRIVER CONTROLLER BOARD BOARD TP A Description Values TP Description Values U18 11 12 VDC 12 VDC 0 50 VDC R13 Bottom 40VDC 40VDC 1 00VDC U18 4 12 VDC 12 VDC 0 50 VDC R13 Top 25VDC 25VDC 1 00VDC U11 10 5 VDC 5 VDC 0 50 VDC D5 Cathode 20VDC 20VDC 1 00VDC C1 Ground Reference Ground D15 Cathode 20VDC 20VDC 1 00VDC U3 8 12VDC 12VDC 0 50VDC C41 Ground Reference Ground 62 TROUBLESHOOTING AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE 17 RECOMMENDED SPARE PARTS TABLE 18 VOLTAGE PRESET SELECTION S1 Item Qty Part Description Pos Panel Mode Remote Mode 1 2 1373 3041 Fuse 2 Amps 1 OFF ON 2 1 2100 0086 Power Lamp 2 ON OFF 3 1 0600 0304 4 1 0600 0102 Power Board Assembly 5 1 2068 0161 Power Switch 6 1 2068 0078 Contact Blocks AVC 5 Enclosure Front Microcontroller Board
24. source will maintain a constant current output But because the arc voltage wasn t kept constant the heat or power into the work piece being welded was not kept constant With the advent of an arc voltage control system arc voltage was also kept constant thereby providing a constant heat or power into the work piece being welded see Figure 1 Arc Voltage Control Theory on page 17 Welding Torch TIG Shown Are Voltage amp VWorlePiac WeldPuddle i FIGURE 1 ARC VOLTAGE CONTROL THEORY ARC VOLTAGE CONTROL SYSTEM The 501 system includes many new features not found on any other arc voltage control systems or arc length control systems currently available The most innovative feature in the 501 system is our pat ented Lift Start process 501 will start an arc without any High Frequency using a welding power source with a touch start or Lift Arc an ITW trademark starting process The feature enables reliable automated non High Frequency HF arc starting on all metals The 501 commands the torch to touch the AVC 501 ARC VOLTAGE CONTROL SYSTEM work piece then tungsten is preheated for an adjust able time unique to the diameter of the electrode and the type of material being welded This provides a smooth consistent arc start without tungsten inclu sion The Lift Start feature is enabled by a DIP switch set ting on the micro controller boar
25. taining argon are denser than air and will re place air when used in confined spaces Do not locate gas cylinders in confined spaces When not in use shut OFF the gas supply at its source Refer to AWS Standard Z49 1 for specific ventilation recommendations ADDITIONAL SAFETY 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 com bustible surfaces Do not install unit near flammables FALLING EQUIPMENT Falling Equipment can cause serious per sonal injury and equipment damage Use lifting eyes to lift unit only not running gear gas cylinders or any other accesso ries Use equipment of adequate capacity to lift units If using fork lifts to move units be sure forks are long enough to extend beyond opposite side of the unit LE HOT PARTS Hot parts can cause severe burns erme aa Do not touch hot parts bare handed Allow cooling period before working on gun or torch MOVING PARTS Moving Parts can cause injury gt a 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 mechanical slides drive rolls carriage as semblies etc MAGNETIC FIELDS CAN AFFECT PACEMAKERS Magnetic Fields from High Currents can af fect pacemaker operation Pacemaker wearers should keep away
26. the conducting body of the torch A binding screw is normally provided on the torch for this purpose Please refer to torch manufacturers operators manual for details Be sure to allow adequate lead length for full stroke travel see Figure 9 AVC 501 Sense Lead TIG Torch Connection and Figure 10 AVC 501 Sense Lead Plasma Torch Connections for refer ence 35 AVC 501 ARC VOLTAGE CONTROL SYSTEM CAUTION For safe operation any insulating or protective covers removed for installation of the sense lead must be replaced prior to welding Securely clamp the welding torch to the drive unit us ing the torch clamp and hardware provided Workpiece Ground Stud A wire from the drive unit to the workpiece must be connected to allow the arc voltage to be sense and tracked The secure connection to the workpiece ground to the ground stud located on the top of the drive must be connected IMPORTANT Proper operation of the AVC 501 system requires that both sense lead and ground lead are properly connected and that ground lead makes a secure electrical connection with the workpiece CONTROL UNIT MOUNTING The control unit should be located or mounted in such a manner 50 as not to interfere with the movement of the drive unit or the remainder of the system compo nents Use the mounting holes provided making sure to mount the control unit for easy access to the power switch cable connectors faceplate controls and inte rior s
27. the cycle can begin again the operator has to release the Process Stop switch This completes the system reset and is ready to start again CONSOLE FEATURES As mentioned previously the cover or lid can be used as an operator console to provide easy parameter changes prior to and during the welding cycle The following describes key benefits of the console as it pertains to each of the components that is interfaced Cold Wire Feeder Section The Cold Wire Feeder section on the console pro vides access to common parameters used on the DWF 3 Cold Wire Feeder e Wire Feed Speed Control using a potentiometer Forward and Reverse Wire Jog using a toggle switch Pulse Inhibit Lockout to synchronize the feeding of wire during a High Pulse of welding current if pulse welding is used and synchronization is desired Arc Voltage Control Section The Arc Voltage Control section on the console pro vides access to common parameters used on the AVC 501 Arc Voltage Controller including items not needed for this example Arc Voltage Preset using a potentiometer Protect Arm using a pushbutton for applications such as Plasma Arc Welding when the Tungsten doesn t protrude past the tip and therefore can t be touched to the work piece Up and Down Drive using a toggle switch Process Control Section The Process Control Section is made up of only two switches and are to be a maintained contact type for proper operation 69
28. 1 and 12 are provided to aid in parts ordering and replacement beginning on page 57 MOUNTING BRACKETS Each drive assembly is provided with a torch bracket for mounting the torch and other equipment to the drive assembly PREVENTIVE MAINTENANCE SCHEDULE The following schedule is provided to assist in pre forming timely maintenance to the system to maintain optimum performance Monthly Maintenance AVC Drive Assemblies Proper Function There should be no play in the drive assembly throughout the entire travel of the drive Cable con nectors and strain reliefs should be tight and they should be properly seated in their mating receptacles Test Clean slag dirt and spatter from drive assembly Verify that the drive assembly travels the full length of its stroke Test Check for axial play on each axis Position the drive assembly in the center of its stroke Grasp the drive assembly or torch with one hand Try to move the torch in and out and up and down to check for play in the drive as sembly or torch mounting brackets There should be little to no play in the drive assembly or torch bracketry If play is felt troubleshoot the assembly further to determine the cause of the play and to adjust the drive or replace worn parts to remove the cause Quarterly Maintenance Torch Bracket Assembly Proper Function Holds the torch firmly to the drive assembly Test Clean dirt from bracket and torch Check the torch
29. 10 32X1 75 HSC SBZ 39 12 000 EA 0600 0039 SCREW M3 X 12MM SCH BLK 40 3 000 EA 974010 003 WSR SL 6 250X 148X 031 SBZ NOT SHOWN 41 1 000 2410 0472 NUT LOCK CONDUIT 1 2INCH SHOWN 57 AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS FIGURE 40 AVC 501 COMPACT DRIVE ASSEMBLY EXPLODED VIEW 58 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE 12 AVC 501 COMPACT DRIVE ASSEMBLY PARTS LIST Item UM Part Description 1 1 000 EA 1046 0069 HOUSING ASSY 1 IN STROKE 2 1 000 EA 1046 0077 MOTOR ASSY 1IN STROKE 3 1 000 EA 1050 0222 CLAMP TORCH 1 IN STROKE 4 4 000 EA 970015 508 SCR 10 32X 62 HSC SBZ 5 1 000 EA 2208 0725 CONN RECT PLUG 8CKT NOT SHOWN 5 4 000 EA 970015 314 SCREW 6 32 x 1 00 HSC SBZ 6 2 000 EA 970015 612 SCR 1 4 20X 88 HSC SBZ 7 4 000 EA 974010 005 WSR SL 10 334X 202X 047 SBZ 8 1 000 EA 930014 401 CONN CIRC BUSHING 220 ID 8 2 000 EA 974010 006 WSR SL 1 4 489X 263X 062 SBZ 9 1 000 EA 1050 0150 HOUSING 1IN STROKE 10 1 000 EA 1050 0184 COVER HOUSING 1IN STROKE 11 1 000 EA 1050 0168 SUPPORT BALLNUT 1IN STR 12 1 000 EA 1050 0176 SPACER BALLNUT 1IN STR 13 1 000 EA 1050 0192 SLIDE HOUSING 1IN STROKE 14 1 000 EA 1050 0214 PLATE SLIDE END 1IN STR 15 1 000 EA 1056 0225 LOCK NUT BALL SCREW 1IN 15 2 000 EA 970043 300 SCR SET 6 32X 1
30. 2 0041 FIGURE 47 AVC 4 STANDARD DRIVE BLOCK DIAGRAM 75 AVC 501 ARC VOLTAGE CONTROL SYSTEM SCHEMATICS AND BLOCK DIAGRAMS Pe DN Red Output Voltage Blk Output voltage E gt Wht Lockout Signal B 5 Lockout Signal D gt G 3 Not Used 9 Remote Voltage Pre Set Wiper V BIK K1 A Contact 1 Common J NJ Yel NotUsed L Blk Remote Voltage Pre Set Reference M Bm Drive Down N Drive Up 5 K2 A Contact R Bik K2 A Common 5 Wht Arc Established Signal from 5 Red Arc Established Signal from P S Common U Protect Arm C Red Logic Ground G Earth Ground PE F FIGURE 48 AVC 501 REMOTE INTERFACE CABLE SCHEMATIC 76 SCHEMATICS AND BLOCK DIAGRAMS AVC 501 ARC VOLTAGE CONTROL SYSTEM P6 R K1 B Contact A I Drive Up Wht K1 B Common B I Drive Down D K2 B Common Protect Arm H Du Blu K2 B N O Contact J e ells NI Yel K2 B Contact L Blk d 5 Brn J Grn K1 B Contact Red Logic Ground Earth Ground PE F FIGURE 49 AVC 501 AUXILIARY REMOTE INTERFACE CABLE SCHEMATIC 77 AVC 501 ARC VOLTAGE CONTROL SYSTEM SCHEMAT
31. 2 HHC SBZ 16 1 000 EA 1046 0085 BALL SCREW ASSY 1IN STR 17 1 000 EA 2320 0104 BALLNUT SBN 18 1 000 EA 2320 0384 SLIDE CROSSED BRG 19 2 000 EA 2320 0325 BEARING BALL RADIAL 20 2 000 EA 974031 201 WSR F 735X 627X 032 B 20 1 000 EA 1055 0645 DECAL UP ARROW C AVC NOT SHOWN 21 3 000 EA 970010 304 SCR 6 32X 38 CR1F SBZ 22 2 000 EA 970000 102 SCREW 4 40 x 3 16 S Steel 23 1 000 EA 979002 005 PIN SPR 093X 375 S 24 2 000 EA 970015 308 SCR 6 32X 62 HSC SBZ 25 8 000 EA 970015 005 SCR 5 40X 31 HSC SBZ 26 1 000 EA 1057 0158 MOTOR STEPPER 27 1 000 EA 2360 0625 PIN ROLL 093 DIA X 500 LG 28 2 000 EA 2320 0228 GEAR BEVEL SET 1 3 48P MATCHED SET 59 AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS A 18 gauge wire FIGURE 41 AVC AUX REMOTE INTERFACE CABLE EXPLODED VIEW TABLE 13 AVC AUX REMOTE INTERFACE CABLE PARTS LIST Item UM Part Description 1 1 000 EA 930014 001 CONN CIRC BOX RCPT 20 275 2 1 000 EA 2208 0114 TERMINL HOUSING 12PIN 156 P 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 6 0 400 EA ZZLABOR SHOP LABOR 60 TROUBLESHOOTING TROUBLESHOOTING The following list describes typical problems and
32. 222 622 GG UN 013 213 029999 123 40123735 39917100 283 683 OSD 6 2 T 70179 ek o ASSY 3NIYO vr 071 310438 N 10 0 212 Tr 8 w gt CI Tiu T L l 2 3 301 3 6e d W 0 1 310438 XNU 1 Sc 1998 UINYOASNYUL 1 5 87 2 seu Eu 301 0701 v e os 5 AZT HOLIMS UBMOd 16 2 2 g Ca zn 8 iini 2 50 43 913 AF al CI 8 8 401 019 9 401 2 D o qee 5 Gad 2 8 8 2 2 8 zeu ea sssm 070001 922 La oogen 0700 ZOO NI 810 ZOO NI SQ 2 3272 CT ey ved W AL T id 5 vid Ha g 3 F ca S di 04 Fed 9 0 0Zy ZED IR 0000 201 18 53 mr e i i 8 E Bm x 121847 818 88 614 q 909 3 3 A 60 2 0 7283 3001 224 5 8 CI 01 ix rh E 1070 E 3 622 AE OOPNI 3 59 20 29 3 Dra 2002 11 Y AS 010 0090 N d p4eog Ta Tau A8 2010 0090 hIquessy 2 0 zi 10703 J9ATAQ 041003 DAY FIGURE 32 501 POWER BOARD LAYOUT 48 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL SYSTEM F1 AW m II NI EMI RFI l f TT 9 Z v AS T 2 al
33. 23 AVC 501 Process Timeline Example One 39 Figure 24 AVC 501 Remote Lockout Two Supplies 40 Figure 25 AVC 501 Remote Up Down Drive 40 Figure 26 AVC 501 Process Timeline Example Two 41 Figure 27 AVC 501 Remote Voltage Set Point Analog 42 Figure 28 AVC 501 Remote Up Down Drive With E Stop 42 Figure 29 AVC 501 Remote Voltage Set Point Internal Voltage 43 Figure 30 AVC 501 Remote Voltage Set Point External Voltage 43 Maintenance it oS Peres e AS a a 45 Drawings and Parts Lists 2220 2502 LES Se EL NE a 47 Figure 31 AVC 501 Micro Controller Board Layout 47 Figure 32 AVC 501 Power Board Layout yo sb m ue gt Figure 33 Voltage Selector Switch assembly 12505277 May gh fen de W sr ep 449 Figure 34 AVC 501 Control Exploded View 1 4 50 Figure 35 Power Switch Assembly Exploded View 1 122 Figure 36 Transformer Assembly Exploded View 1 41 53 Figure 37 AVC Drive Cable Assembly Exploded View 1 4 Figure 38 AVC Remote Interface cable Exploded View 55 xi AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE OF
34. 2X 065 SBZ 5 2 000 EA 974010 006 WSR SL 1 4 489X 263X 062 SBZ 5 2 000 EA 972000 006 NUT 1 4 20 H SBZ 6 1 000 EA 2120 0123 FILTER RFI PWR LINE 3 AMP 7 1 000 EA 920035 001 SLIDE SW 2 POS LINE VOLT SEL 8 1 000 EA 2120 0000 FUSE CARRIER 1 4 1 1 4 FEK 9 1 000 EA 0600 0091 AVC OVERLAY PLATE 10 1 000 EA 0600 0224 DOOR 8 HINGE AVC 501 CONTROL 12 1 000 EA 0600 0459 AVC 501 REMOTE INTRFC CABLE ASSY 13 1 000 EA 0600 0458 AVC 501 DRIVE CABLE ASSY 14 1 000 EA 0600 0104 AVC 501 MICROPROCESSOR BOARD ASY 15 5 000 EA 0600 0277 KNOB SMALL 1 8 15 1 000 EA 0600 0278 KNOB MODIFIED TO 1 4 AP AUTO 16 1 000 EA 0600 0371 POWER SWITCH ASSEMBLY 17 1 000 EA 0600 0238 SPACER ALUM 140X 25X 25 51 AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS P3 Power Switch gt 2 2 pl L zz i 18 gauge wire 6 pl FIGURE 35 POWER SWITCH ASSEMBLY EXPLODED VIEW TABLE 7 POWER SWITCH ASSEMBLY PARTS LIST Item UM Part Number Description 1 1 000 EA 2066 0171 SWITCH SELECT 1 3 16 RED 2 1 000 EA 2100 0086 INCANDESCENT LAMP 7 28V 4 1 000 EA 2208 0181 CONN RECT PLUG 8CKT 5 6 000 2212 0018 TERMINAL CRIMP PIN 18 24 GA 52 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL
35. AVC 501 1s a modified digital voltmeter While welding the AVC 5 s microcontroller board is monitoring the actual arc voltage and making discisions to move the torch up or down in order to keep the actual arc voltage at the de sired voltage preset by the operator If the actual arc voltage drops below the preset voltage the Mi cro controller drive the torch upward until the actual arc voltage 1s at the desired voltage level Likewise if the actual arc voltage goes up the AVC 501 will drive downward to keep the actual arc voltage at the desired level The actual arc voltage is brought to the mi cro controller through the Power board through sev eral filters to reject noise and to steady the typically erractic arc voltage The voltage is also scaled down to an acceptable level for the micro controller IC Once to the micro controller the voltage is received on an analog to digital converter input on the IC The voltage is monitored and compared to arc voltage pre set selected by the operator and decisions are made maintain the desired arc voltage AVC 501 ARC VOLTAGE CONTROL SYSTEM Throughout the process relays are energized and or de energized depending upon the start method AC or DC welding and other setup parameters selected by the operator Motor Driver Circuit The motor driver circuit is made up primarily of a sin gle IC used to drive the motor The motor is a stepper type not a DC motor The driver circuit then pulse
36. BE 6 6 9 515 Do ae 11 Blu Wht M Grn Wht Bik a 22 ay B 1313 ane aa em 5 5 5 Red ve Bik lt 414 Protect Assembly 1042 0041 FIGURE 45 AVC 501 CONTROL BLOCK DIAGRAM CONT 73 AVC 501 ARC VOLTAGE CONTROL SYSTEM Stepper Motor x 9 CD gt 5 o lt 2 2 gt lt Torch SCHEMATICS AND BLOCK DIAGRAMS sx E aono mer oosH 7 7 e je e gt LOT ste L1 Protect PCB Assembly 1042 0041 C1 O1uF FIGURE 46 AVC 501 STANDARD DRIVE BLOCK DIAGRAM 74 AVC 501 ARC VOLTAGE CONTROL SYSTEM SCHEMATICS AND BLOCK DIAGRAMS P4 K AVC 4 Drive Assembly Std Stroke Stepper Motor M 1 Dx Yel D BIK Red Wht Blu Red 4 ve Yel Wht Red Blk lt G Red Orn Wht Wht Orn R BIk Wht Orn S H Wht J S2 Down A Grn U t Bik STI can NAAA L1 i OtuF Protect PCB Assembly 104
37. Button Up Controller Servo Down True Tungsten Touches the Work Arc Voltage Arc Amperage Welding Power Source with Lift Arc TM Circuit AVC 501 ARC VOLTAGE CONTROL SYSTEM Lift Start Process Flow Adjusts Up and Down to track Voltage Tungsten is in Contact with the work Gas Preflow FIGURE 23 AVC 501 PROCESS TIMELINE EXAMPLE ONE 39 AVC 501 ARC VOLTAGE CONTROL SYSTEM INSTALLATION ES Lockout Signal D wht I 4 Lockout Signal Lockout Signal B ie Downslope 4 Lockout Signal i e Low Pulse Voltage is present when Lockout to be Enabled FIGURE 24 AVC 501 REMOTE LOCKOUT TWO SUPPLIES ES Bik Drive Up t Red 1 Up Logic Ground Drive Down 5 n TENERE FIGURE 25 AVC 501 REMOTE UP DOWN DRIVE 40 INSTALLATION AVC 501 ARC VOLTAGE CONTROL SYSTEM HF Start Process Flow Pressed Start Button Lip f Adats and Down Deven rue Tungsten Touches the Work Arc Vokage Welding Power Source Arc Amperage Gas FIGURE 26 AVC 501 PROCESS TIMELINE EXAMPLE TWO 41 AVC 501 ARC VOLTAGE CONTROL SYSTEM Remote Voltage Pre Set Wiper Remote Voltage Pre Set reference INSTALLATION Analog Output Device ES Bik V
38. EA 1050 0613 BODY DRIVE AVC 4 8 1 000 EA 0600 0017 AVC TOP PLATE 9 1 000 EA 0600 0018 AVC BOTTOM PLATE 10 1 000 EA 1046 0492 NUT ASSY DRIVE 11 1 000 EA 0600 0019 AVC 501 DRIVE SCREW 12 2 000 EA 2320 0333 BEARING BALL RADIAL 13 1 000 EA 1052 0142 JUNCTION BOX DRIVE AVC 14 4 000 EA 2040 1192 SPACER 375X 194X1 1 8 LG A 15 1 000 EA 0600 0226 HELICAL COUPLING 25 312 625 16 2 000 EA 2062 0072 SWITCH PUSH BUTTON BLACK 17 1 000 EA 0600 0368 AVC JUNCTION BOX COVER 18 1 000 EA 1042 0041 BD ASSY AVC PROTECT CKT PC 19 1 000 EA 2340 1126 POST BINDING 8 32 30A 1KV BLK 20 1 000 EA 1054 0178 CABLE ASSY AVC DRV 8 5FT 21 1 000 EA 976000 007 GROMMET RUBBER 1 410 9 16 OD 22 3 000 EA 970000 304 SCR 6 32X 38 CR1P SBZ 23 2 000 EA 1110 1445 CLAMP GTA TORCH 24 1 000 EA 1050 0801 END PLATE AVC 4 DRIVE 25 2 000 EA 1110 1453 CLAMP BASE GTA TORCH 26 3 000 FT 2140 0301 CABLE VOLT 18 AWG SHOWN 27 8 000 EA 970010 204 SCR 4 40X 38 CR1F SBZ 28 1 000 EA 1035 0450 PLATE LEGEND UP DOWN 29 2 000 EA 1057 0212 CURTAIN BELLOWS 30 1 000 EA 2300 0406 MOTOR ASSY STEPPER AVC 501 DRV 31 1 000 EA 1050 0806 SCREW SHOULDER AVC 4 DRIVE 32 4 000 EA 0600 0040 SCREW M4 X 16MM SCH BLK 33 4 000 EA 0600 0457 VINYL BUMPER ADHESIVE BACKED 34 12 000 EA 970000 404 SCREW 8 32X 38 CR1P SBZ 35 4 000 EA 970015 622 SCREW 1 4 20 X 2 00 HSC SBZ 36 8 000 EA 970015 614 SCR 1 4 20X1 00 HSC SBZ 37 8 000 EA 970015 608 SCR 1 4 20X 62 HSC SBZ 38 4 000 EA 970015 520 SCR
39. ICS AND BLOCK DIAGRAMS Upper Section can be mounted away from Main Junction Boxto accommodate a remote console using Sheilded Cable Cold Wire Feeder Arc Voltage Control Jog Wire 1 For Rev Feed i Arc Voltage Protect Dn Up ra Set Point Arm Speed pa I X I Pulse Inhibit ii dae J 2 I Disable Sa 10K 11 pote Shown Pot i i 1 E TB8 2345678 9 10 11 12 13 14 15 16 zu DYYF 4 Control ES P3 B 20VDC Output B 1 Remote Stat C 2 Remote Start F 3 Inhibit JE 4 Inhibit G 5 Forward Jog L 6 Digital Ground D Di Reverse Jog 8 Pot Reference 9 Wire Feed Ref Viper 10 Analog Ground 11 5 Control P5 TB2 Remote Set PY 1 Remote Set 2 Protect Arm C 5 Down Drive 4 Logic Ground 5 Up Drive P 6 Output 20VDC E 7 Lockout Signal 0 8 Qutpu 9 B 10 R 11 12 H 13 J 14 1 1 2 K1 B Con 3 K2 B Con J 4 K2 B Common K2 B Contact L 6 Drive Up JE Y Logic Ground 3 Down Driwe D El Protect Arm JH 10 otes AN This resistor an
40. LDING AND CUTTING RAYS OR HOT METAL CAN BE MORE SEVERE THAN SUNBURN 2 La Vi Cor v x B Wear flameproof gauntlet type gloves a heavy ca long sleeve shirt cuff less trousers high topped shoes and welding helmet i 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 hh hotsparks with a suitable non flammable par gt tition 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 sel grinding Chipped slag is hot and may travel a D considerable distance Bystanders should also wear safety glasses or goggles E Compressed gas cylinders are potentially dangerous refer to the suppliers for proper handling pro cedures Wear ear plugs or other ear protection devices when operating cutting or welding equipment FIRE SAFETY HOT SLAG OR SPARKS CAN CAUSE A SERIOUS FIRE WHEN IN CONTACT WITH COMBUSTIBLE SOLIDS LIQUIDS OR GASES Move all combustible materials well away from the cutting area or completely cover materials with a non flammable covering Combustible materials include but are not limited to wood clothing sawdust gasoline kerosene paints A solvents natural gases acetylene propane gt similar articles B Do not weld cut or perform other hot work on used barr
41. Max in DC Welding Min to 1 5 Max in AC Welding Sensitivity Adjustment Adjustment for Speed of correction 0 to 100 Retract Time 0 to 10 sec Starting Arc Gap 01 to 09 Start Delay 0 0 to 12 5 sec Burn Through Detection 2 0 Voltage above Pre Set Voltage initiates S HF Start Arc Starting Capability AC or DC Welding Lift Start Indication Auto Tracking Start Delay Lockout Digital Display of Actual and Pre Set Voltage Start Delay Start Gap Tungsten Preheat Touch sense Voltage Threshold Manual Inputs Up Down Jog Remote and Front panel and Drive unit Protect Arm Lockout Power Cable Standard Length 8 1 8 M 20 DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM FIGURE 3 AVC 501 SYSTEM COMPONENTS DESCRIPTION Part Models Control Unit 0600 0101 AVC 501 Arc Voltage Control 0600 0009 Standard AVC 501 6 Drive Assembly Drive Assembly Or Or 1040 0031 Compact AVC 501 1 Drive Assembly Cables 929000 001 Power Cable Assembly 1054 0046 Remote Interface cable assembly 1054 0047 Auxiliary Remote Interface Cable assembly Manual 201327 001 AVC 501 Operators and Service Manual 21 AVC 501 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF EQUIPMENT FIGURE 4 AVC 501 STANDARD DRIVE ASSEMBLY TABLE 3 AVC 501 STANDARD DRIVE ASSEMBLY SPECIFICATIONS
42. Power Board Panel Circuit t Fiter p Filter Power Circuit I O Circuit Motor Driver Circuit 115 230VAC 50 60 Hz FIGURE 42 AVC 501 SIGNAL FLOW 63 AVC 501 ARC VOLTAGE CONTROL SYSTEM TROUBLESHOOTING 64 CIRCUIT DESCRIPTIONS CIRCUIT DESCRIPTIONS WARNING For use by Qualified Service Technicians SYSTEM WIRING DIAGRAM The Figure 44 501 Control Block Di agram and Figure 45 AVC 501 Control Block Dia gram Cont beginning on page 72 is a circuit diagram of the entire AVC 501 Arc Voltage Control system These diagrams include detailed schematics of all portions of the system except the Power Board and Micro Controller Board assemblies Schematics of the AVC 501 drive and Compact Drive assemblies are shown as well The Figures 44 and 45 show all wires and connector pins in the interfaces between the various assemblies in the control unit Figure 34 AVC 501 Control Ex ploded View on page 50 and Table 6 AVC 501 Control Parts List on page 51 identifies the major as semblies Parts lists for each assembly are also in cluded in the DRAWINGS AND PARTS LISTS section beginning on page 47 POWER DRIVER BOARD ASSEMBLY This section will describe generally the circuitry sig nal flows and test points on the Main board to assist in a better unde
43. SYSTEM 2 7 4 7 4 18 gauge wire Pa 2 je 3 14 pl FIGURE 36 TRANSFORMER ASSEMBLY EXPLODED VIEW TABLE 8 TRANSFORMER ASSEMBLY PARTS LIST Item QPA UM Part Number Description 1 1 000 EA 1037 0061 XFRMR 115 230VAC DUAL PRIMARY QUAD SECONDARY 2 1 000 EA 2208 0211 CONN RECT PLUG 14CKT 3 9 000 EA 2212 0158 TERMINAL CRIMP PIN 18 24 GA 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 53 AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS 18 gauge wire 3 FIGURE 37 AVC DRIVE CABLE ASSEMBLY EXPLODED VIEW TABLE 9 AVC DRIVE CABLE ASSEMBLY PARTS LIST Item UM Part Description 1 1000 930014 014 CONN CIRC BOX RCPT 20 295 2 1000 2208 0116 TERMINL HOUSING 16PIN 156 P 3 16 000 EA 2212 0018 TERMINAL CRMP MOLEX 18 20 156 4 1000 2340 0588 TERM RING INSUL 6 X 92 LG 5 3 000 979001 001 CABLE TIE 75 BUNDLE DIA 6 0 400 EA ZZLABOR SHOP LABOR 54 DRAWINGS AND PARTS LISTS A
44. TT l l 27 Y 4 5 pl FIGURE 33 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW TABLE 5 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST Item QPA UM Part Number Description 1 1 000 EA 920035 001 SLIDE SW 2 POS LINE VOLT SEL 2 1 000 EA 2120 0123 FILTER RFI PWR LINE 3 AMP 3 1 000 EA 2208 0551 CONN RECT PLUG 6 PIN 200 P 4 5 000 EA 2212 0158 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 2120 0263 FUSE 7 1 2A 250V 7 1 000 EA 2340 0618 TERM RING 1 4 22 16 RED 49 AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS 14 FIGURE 34 501 CONTROL EXPLODED VIEW 50 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE 6 AVC 501 CONTROL PARTS LIST Item QPA UM Part Description 1 1 000 EA 0600 0225 CHASSIS AVC 501 CONTROL 2 1 000 EA 0600 0354 AVC 501 TRANSFORMER ASSEMBLY 3 1 000 EA 0600 0102 AVC POWER DRIVER BOARD ASSY 4 1 000 EA 0600 0460 AVC 501 AUX REMOTE INTRFC CABLE 5 1 000 EA 970039 614 SCR 1 4 20X1 00 H SBZ G8 5 2 000 EA 974004 006 WSR F 1 4 734X 31
45. VC 501 ARC VOLTAGE CONTROL SYSTEM pu 18 gauge wire 3 FIGURE 38 AVC REMOTE INTERFACE CABLE EXPLODED VIEW TABLE 10 AVC REMOTE INTERFACE CABLE PARTS LIST Item UM Part Description 1 1 000 EA 930014 015 CIRC BOX RCPT 22 145 2 1 000 2208 0117 TERMINL HOUSING 18PIN 156 P 3 18 000 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 6 0 400 EA ZZLABOR SHOP LABOR 99 AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS FIGURE 39 AVC 501 STANDARD DRIVE ASSEMBLY EXPLODED VIEW 56 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE 11 AVC 501 STANDARD DRIVE ASSEMBLY PARTS LIST Item QPA UM Part Description 1 1 000 EA 0600 0010 AVC RAIL BASE 2 2 000 EA 0600 0011 AVC 501 RAIL 6 STROKE 3 1 000 EA 0600 0012 AVC DRIVE SLIDER 4 2 000 EA 0600 0014 SUPPORT BUSHING ADJUSTABLE 5 2 000 EA 0600 0015 SUPPORT BUSHING FIXED 6 4 000 EA 0600 0016 W 1 DUALVEE WHEEL 7 1 000
46. VOLTAGE CONTROL SYSTEM SCHEMATICS AND BLOCK DIAGRAMS Stepper Motor 23 36 231257 EO de gt dz m SAT OK To Torch Protect Assembly 1042 0041 L1 AVC 5 Drive Assembly Compact HF Protect Junction Box Assembly m 0tuF Rui 5522232355554 Ex dmm 6 o 8m om at 8 1 4 AA 2 ZMOOCOLUOCU0I gt lt IH P4 FIGURE 43 AVC 501 COMPACT DRIVE BLOCK DIAGRAM 71 AVC 501 ARC VOLTAGE CONTROL SYSTEM Power Switch Si uN SCHEMATICS AND BLOCK DIAGRAMS AVC 5 Micro Controller Board Assembly Org R 3 Wht Yel 7 7 o 6 6 woe 5 8 d ala rm 3 3 Grn 2 Wht 1 1 P2 2 15 5 6 6 os 10110 R 1111 Er 12 12 13 13 PurAWht 14 Red Redrvel 9 7 7 10 16 20 18 14 14 Secondary Ti 110 119 Primary ala 2233 Brn 212 111 P4 J4 Voltage Selector 52 Red 6 6 EN 26 Wot 220 2 1 110 Org 2a 1 Asja Wht 111 EMI RFI M White L Filter BEN E Black N Wht Green Gm 110 230VAC 60 50Hz PE
47. an increase grain refinement of the base and filler mate rial Contact Jetline Sales or Technical Service de partments for additional information and assistance in the proper selection of components COLD WIRE FEED SYSTEMS Cold Wire Feed Systems offered by Jetline provide reliable accurate delivery of filler wire to the weld puddle Offered in two styles a standard and a com pact version the systems are capable of delivering up to 300 ipm of filler wire from sizes of 020 to 062 Contact Jetline Sales or Technical Service depart ments for additional information and assistance in the proper selection of components ORDERING INFORMATION Jetline manufactures a variety of equipment for use in automatic welding processes and manufactures turn key automated welding systems for a broad range of applications Detailed information and literature be obtained by consulting Jetline Sales and or Technical Service departments Part numbers for the AVC 501 system are given in the Drawing and Parts Lists Section and should be used for ordering pur poses Please consult this manual or contact Jetline for further information AVC 501 ARC VOLTAGE CONTROL SYSTEM OPTIONAL EQUIPMENT 82 15 VDC 52 2 62 adequate gt lt lt xiv xv adjustment 45 Arc 17 20 21 31 33 34 45 62 65 67 69 81 B barrel sr c c C Cable 20 22 45 46 61 carriage
48. ay would typically be used to turn on a wire feeder a carriage assembly magnetic arc con trols etc Two sets of Form contacts are provided These are capable of switching 10 amps 110VAC and are protected by 130V 10 Joule varistors A sche matic of the relay outputs is shown in Figure 48 AVC 501 Remote Interface Cable Schematic and Fig 49 501 Auxiliary Remote Interface Cable Schematic beginning on page 76 LOCKOUT INPUTS The Lockout Modes are described in the previous sec tion see Figure 22 501 Remote Lockout Relay Figure 19 501 Remote Lockout Sup ply and Figure 24 501 Remote Lockout Two Supplies beginning on page 38 One input is pro vided for Lockout The inputs are optically isolated INSTALLATION and require an input of 5 to 12 5 to be activated Special consideration needs to be given to input voltages greater than 35V If your inputs are greater than 35V consult the factory for assistance It is also possible to operate the inputs with contact clo sures This is accomplished by using the DC voltage pro vided at the E arid E outputs of the interface cable A schematic of the interface cable inputs and their typical use with voltage outputs from the power sup ply is shown in Figure 19 501 Remote Lockout Supply and Figure 24 501 Remote Lockout Two Supplies Figure 22 AVC 501 Remote Lockout Relay shows the same setup
49. ble before voltage tracking begins S8 ii DC WELDING HIGH FREQ START FIGURE 14 HF START MODE AND DC WELDING AC WELDING LIFT START Lift Start Lift Start is a process patent pending in which TIG welding process is started without the use of HF The Lift Start process uses a feature in certain TIG power sources that preheat the tungsten with a small amperage while in contact with the work once the se lected preheat time has completed the AVC 501 will drive the torch up away from the work At the mo ment the torch is driven up and contact between the work piece and tungsten no longer exists a small spark jumps the gap and the power source immedi ately goes into standard welding amperages to main tain the arc and begin the welding process See Figure 15 Lift Start Start Mode and AC Welding on page 31 and Figure 16 Lift Start Start Mode and DC Welding on page 32 for DIP Switch Settings required for Lift Start Arc Starting in and DC Welding Modes The advantage of using the Lift StartTM method com pared to the HF method of starting a TIG welding arc 1s that HF noise is not emitted from the area that could harm sensitive electronic equipment In addition the tungsten inclusion into the weld is reduced and even S8 AC WELDING LIFT START FIGURE 15 LIFT START START MODE AND AC WELDING DC WELDING HIGH FREQ START AVC 501 ARC VOLTAGE CONTROL SYSTEM eliminated using this method
50. ction START MODES There are two methods of starting an arc using the 501 system 1 High Frequency Start and Lift Start Modes Each method is described below but the Start Mode must be selected using DIP Switches on the back of the Micro Controller board see Figure 31 501 Micro Controller Board Layout on page 47 for the DIP switch location High Frequency Start High Frequency HF arc starts is the typical method of starting welding process 501 drive moves the torch and tungsten down to the work piece until it touches The AVC 501 Control senses that the tungsten has touched the work piece and immediately drives up to the preselected Starting Arc Gap Once the desired gap has been reached the 58 WELDING DC WELDING HIGH FREQ START KE LIFT START FIGURE 13 HF START MODE AND AC WELDING 31 AVC 501 ARC VOLTAGE CONTROL SYSTEM AVC 501 turns on the relay The relay is used to turn the contactor on the power source to start the arc See Figure 13 HF Start Mode and AC Welding and Figure 14 HF Start Mode and DC Welding for DIP Switch Settings required for HF Arc Starting in AC and DC Welding Modes At this time the AVC 501 control is monitoring the arc voltage and waits until a voltage is within the range of 5 to 50VDC Once a voltage within range is sensed the AVC 501 goes immediately into Start Delay Mode to allow the arc to become established and sta
51. d Zener Diode is used to scale the voltage to the potentiometer so that the voltage supply does not exceed 100 FIGURE 50 AVC 501 SYSTEM INTERFACE EXAMPLE 78 SCHEMATICS AND BLOCK DIAGRAMS AVC 501 ARC VOLTAGE CONTROL SYSTEM Process Control Power Source EM Stop Stop Switch Weld Gas Switch Opt Maintained Amperage Purge i i i i al 1 NO N C pog 1 o amp Pot 1 i I i 2 1 I AA Z ee Miller MaxStar 300LX 1718 19 20 21 22 23 24 25 26 ZBI 20 81 Power Source w AIC a Remote Inputs 4 14 Pin 1 cf Output to Remote to 10 2 Oto 10 Amperage Reference 3 D Remote Common 10 Pin 4 A Output Start 5 8 Gas Purge Output Disable T D Chassis Ground 8 E Final Slope Call 9 F Final Slope 10 G Pulse Lockout Call e 11 HI Pulse Lockout Em 12 Valid Arc Coll 13 J Valid Arc Em TB5 1 2 To Carriage Control Start 3 LIZ 2 1 115 220 2 3 TZ 277 Magnetic Arc Control TB 4 115 220VAC Cyclomatic 2 115 220V AC Rtn Models 60 70A 8
52. d on the inside of the 501 Control unit allowing easy selection The AVC 501 controls welding as well as DC welding applications without any additional compo nents cables etc This feature is also enabled via a DIP switch on the micro controller board CONTROL UNIT The control unit is a heavy gauge steel enclosure con taining the electronic circuitry used in the system Solid state circuits are used to provide long trou ble 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 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 back side of the micro controller board via DIP switches A heatsink mounted on the inside of the control unit allows adequate cooling for the heat dissipating devices 1 e motor stepper drivers The three connectors located on the bottom of the unit provide for connection of the drive cable and two re mote interface cables DRIVE ASSEMBLY The AVC System can be purchased with one of two different drive assemblies 1 Standard 501 Drive assembly or the Compact AVC Drive assembly The controller can also be used with older drive as semblies built by Cyclomatic which include the S
53. ds usually involving the removal of mounting hardware unplugging the old part subas sembly mounting the replacement part and reconnect ing the connectors 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 ca ble assemblies is included for troubleshooting purposes see the Schematics and Block Diagrams Section AVC DRIVE ASSEMBLIES The AVC Drive assemblies maintenance should in clude periodic inspections for worn moving parts e g drive screws and nuts couplings Further main tenance includes removing excess dust weld slag soot etc from the assemblies If any connectors or parts are damaged during operation the defective parts should be replaced as soon as practical Repair of the drive assemblies is limited to the re placement of defective parts and adjustment of the drive assemblies to remove play between wheels and rails or axial play between the drive screw and the bearings AVC 501 ARC VOLTAGE CONTROL SYSTEM Exploded views of the drive assemblies beginning on page 56 in Figures 39 and 40and their parts lists in Tables 1
54. e as Problem 5 starting arc gap i e Touchsense The ground sense lead or the red necessary Feature voltage sense lead is not connected to the drive assembly Verify the leads are connected to the The Touchsense calibration needs clive as emo adjustment Adjust the Touchsense Calibration as necessary page 38 61 AVC 501 ARC VOLTAGE CONTROL SYSTEM TROUBLESHOOTING Problem description Cause Solution System is set for the wrong Mode Verify the AVC 501 System is set up i e Welding with DC and AVC 501 for the correct welding mode AVC 501 System doesn t track or SO AR Mode of ite valen Check the sense leads are securely Problem 6 show voltage on the front panel while Sense leads are not connected or are connected wedling loose Verfiv the Voltage Preset is set be Voltage Preset is improperly set tween 5 to 50VDC while pressing the Preset button Power Source is not set for Lift Start Verify the power source is set for mode Lift Start arc starting Notenough Tungsten Pre Heat Time Increase the Tungsten Pre Heat Time on the AVC 501 to account for to include the gas pre purge and to prepurge and tungsten preheat caus allow approximately 2 seconds of ing the AVC 501 to drive up before Tungsten Pre Heat as a starting Problem 7 The arc doesn t start using Lift Start the power source starts producing point Mode on the AVC 501 System Lift Start amperage Decrea
55. e control unit see Figure 12 AVC 501 Control Unit Mounting Dimen sions on page 30 AVC 501 ARC VOLTAGE CONTROL SYSTEM The AC power cord from the control unit should be plugged into a properly grounded outlet Both the Red Sense lead and the Work Piece Ground lead should be properly attached See Figure 6 Intercon nection Diagram on page 24 for a typical system in terconnection TOUCHSENSE CALIBRATION The Touchsense feature gives the 501 system the to sense the work piece and set a starting arc gap to assist in reliable consist arc starting in HF Start Modes This feature uses a small voltage generated in the 501 Control unit and is provided on the torch and work piece sense leads This voltage typically around 3 4VDC displayed on the AVC 501 Control unit front panel when the system is at idle shorted or brought down to nearly zero volts when the 501 Control unit drives the tungsten into contact with the work piece When the 501 Control unit senses the voltage is shorted indicating the tungsten is touching the work piece the AVC 501 drive drives up for a pre selected distance set by the operator on the front panel creating the starting arc gap The Touchsense circuit is factory calibrated for oper ate with welding power sources having an open cir cuit impedance of 10 or greater In some cases the power source impedance may be greater which re quire no adjustment to the 501 Cont
56. e panel cover on the high frequency protect unit by removing the two screws holding the cover in place Switch the green wire on terminal 1 to terminal 3 Change the black wire on terminal 3 to terminal 1 nstructions are also printed on the board for reference Replace the cover using the hardware used when re moving the cover CAUTION Remember to wire the high frequency protect assembly for the correct polarity whenever welding polarities change INTERFACING THE AVC 501 WITH OTHER EQUIPMENT When a remote interface cable is used between the customer s interface and the AVC 501 control unit signals can be triggered remotely to achieve various functions that would normally be done manually These remote signals interface with the AVC 501 con trol through the J5 connector on the bottom of the control unit A schematic of the cable connections and pin definitions is shown in Figure 44 AVC 501 Con trol Block Diagram on page 72 The following sec tions describe in detail how each of the inputs are used CAUTION The foil shield in the interface cable is connected to the chassis of the 501 control unit Make certain that all unused wires and shielding are insulated to pre vent any accidental contact with voltages present inside the power supply END OF START DELAY RELAY EOSD The end of start delay relay energizes upon Start Delay timeout and de energizes when the arc extin guishes The rel
57. ection Diagram Figure 7 501 Standard Drive 27707 Voie Danes 25017129 Figure 8 AVC 501 Compact Drive Assembly Mounting Dimensions 26 Figure 9 AVC 501 Sense Lead TIG Torch Connection 27 Figure 10 AVC 501 Sense Lead Plasma Torch Connections 28 Figure 11 AVC 501 Drive Work Piece Connections 29 Figure 12 AVC 501 Control Unit Mounting Dimensions 30 Operations sai aks ZOP OE Ead NUR Np ee pa 31 Figure 13 HF Start Mode and AC Welding 31 Figure 14 HF Start Mode and DC Welding o 1 Bl Figure 15 Lift Start Start Mode AC Welding 31 Figure 16 Lift Start Start Mode and DC Welding 32 Figure 17 Minumum Deadband Setting aar 33 Figure 18 Maximum Deadband Setting 2 33 Installation at bedt 5 ka ac en LS A toss 35 Figure 19 AVC 501 Remote Lockout Supply 36 Figure 20 Remote Voltage Preset DIP Switch Selection 37 Figure 21 Panel Voltage Preset DIP Switch Selection 37 Figure 22 AVC 501 Remote Lockout Relay 38 Figure
58. ed welding or torch cables Do not overload the cables Use well maintained equipment E When not welding cutting turn equipment OFF Ac cidental grounding can cause overheating and create a fire hazard Do not coil or loop the ca ble around parts of the body F The ground cable should be connected to the work piece as close to the work area as possible Grounds connected to building framework or other locations remote to the work area reduce efficiency and increase the potential hazard of electric shock Avoid the possibility of the weld AVC 501 ARC VOLTAGE CONTROL SYSTEM ing or cutting current passing through lifting chains crane cables or other electrical paths G Keep everything dry you might touch including clothing the work area welding gun torch and welding or cutting machines Fix water leaks immediately Do not operate equipment stand ing in water H Never use a cutting torch or welding gun which is damaged or contains cracked housing I Refer to AWS Z49 1 for grounding recommendations E A Use a proper face shield fitted with the correct filter m 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 cutting welding Warn bystanders not to watch the arc and not to expose themselves to the cutting welding arc rays or to hot metal SKIN AND EYE BURNS RESULTING FROM BODY EXPOSURE TO ELECTRIC ARC WE
59. ee Figure 12 AVC 501 Control Unit Mounting Dimensions on page 30 for reference Also be certain that the unit has unrestricted air flow Connect the drive interface cable from the AVC 501 drive to the AVC 501 control unit NOTE A chassis ground lug is located near the power cord Care must be taken that this be connected to a solid earth ground in a high noise environment system com ponents are connected to chassis ground thru the shields of the drive and interface cables Plug the control unit power cord into a properly grounded 50 60 Hz power 230 50 60hz is to be used first switch the power selector switch on the bottom of the control unit to the 230VAC position The 501 drive is wired for straight polarity If the operator is using reverse polarity in the weld pro cess then the AVC drive must be rewired to accom modate the reverse polarity This procedure is easily accomplished by following these steps AVC 501 ARC VOLTAGE CONTROL SYSTEM INSTALLATION Wht Lockout Signal Power Supply P5 Lockout Signal D Lockout Signal B 7 Voltage is present when Lockout to be Enabled FIGURE 19 AVC 501 REMOTE LOCKOUT SUPPLY Remove power to the drive unit Standard drive remove the panel cover to the junction box assembly This can be done by removing the six 6 pan head screws holding the cover in place Compact drive remove th
60. els drums tanks or other containers until W they have been completely cleaned There must be no substances in the container which might produce flammable or toxic vapors C For fire protection have suitable extinguishing 3 equipment handy for instant use M WELDING AND CUTTING FUMES AND GASES PARTICULARLY IN CONFINED SPACES CAN CAUSE DISCOMFORT AND PHYSICAL HARM IF INHALED OVER AN EXTENDED PERIOD OF TIME A Atall times provide adequate ventilation in the weld 3 ing and cutting area by either natural or me chanical 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 9 hydrocarbon vapors coming from degreasing p or spraying operations The heat of arc rays Su can react with solvent vapors to form phos gene a highly toxic gas and other irritant gases C If you develop momentary eye nose or throat irrita Y tion during welding or cutting it is an indica gt a tion that the ventilation is not adequate Stop S work and take the necessary steps to improve ventilation in the welding or cutting area Do not continue to weld or cut if physical discom fort persists D Use an air supplied respirator if ventilation is not Y adequate to remove all fumes and gases vare of gas leaks Welding cutting gases con
61. eplacement should be per formed after the user has determined that the part or assembly to be replaced is the cause of a system prob lem see Troubleshooting on page 61 Replacement of the fuse does not require opening the control unit however blowing a fuse may indicate other system problems The fuse is replaced by un screwing the fuse holder lid removing and replacing 45 AVC 501 ARC VOLTAGE CONTROL SYSTEM the blown fuse with a new fuse Then restore power and turn ON system to perform a test run Replacement of the printed circuit board the Power Board involves disconnecting the connectors to the board removing the mounting screws and replacing the Power Board with another The service person should exercise care in removing the Power Board to ensure that excessive force is not placed on the connectors or components on the board and that the mounting screws are not over tightened The Main Board is held by six screws to stand offs mounted in the enclosure and 3 screws to standoffs mounting through the heatsink mounted to the power board Disconnect all necessary cabling at the connec tion plugs provided Remove the mounting screws and the Power Board Install another Power board and tighten the mounting screws until snug do not over tighten as damage to the board and enclosure standoffs may result Replacement of other user serviceable items is to be performed according to normal maintenance and re pair standar
62. face cables or on the drive assembly As soon as the arc is present the system goes immedi ately into Start Delay indicated by flashing the arc voltage on the digital display During Start Delay the drive unit will not move to control arc voltage and the Up Down pushbuttons are inoperative When Start Delay times out the digi tal display stops flashing the End of Start Delay EOSD Relay K2 energizes and the drive unit will now move to maintain the arc voltage at the preset value The Automatic Mode will continue until the 32 OPERATION arc voltage falls outside the Automatic Voltage Sense Range after which Retract will occur Con trol of the arc voltage will continue unless Lockout is activated While in Automatic Mode the Voltage Pre set Deadband and Sensitivity parameters may or can be changed from the control panel Lockout Mode While the Automatic Mode is in effect AVC 501 con trol can be halted momentarily or continuously by ac tivating Lockout Lockout can be activated either through the Lockout Pushbutton on the front panel or via either of the customer interface cables When Lockout is activated the Lockout LED above the Lockout pushbutton will turn On To de activate Lockout simply press the Lockout pushbutton or re move the Lockout input from either of the remote in terface cables Two typical uses for the Lockout function are for am perage Downslope and for a Pulsed TIG welding In Pul
63. ges are not Check Power Driver Board voltage present 12VDC Drive may be at its stroke limits Jog the drive the opposite direction Drive may be binding due to too much Remove weight from the drive as Drive assembly doesn t drive up or weight on the drive assembly sembly Problem 3 d in M Mod Mounting hardware or other obstruc Verify drive is free and clear to move tion is interfering with the drive move up and down ment Deaband and Sensitivity Adjustments Adjust Deadband and Sensitivity set are not set properly tings to a more accurate setting i e A Deadband more CounterClockwise rm is Enabled Lockout LED is and Sensitivity more Clockwise A Press the Lockout Button to Disable AVG 501 System doesn t track and Burn Through Detection has been ini the Lockout Feature and or check the Problem 4 compensate for voltage changes in tiated Protect LED is not lit remote interface cables to remove re Automatic Mode mote Lockout Input Adjust Deadband and Sensitivity set tings to a less accurate setting i e Deadband more Clockwise and Sensitivity more CounterClockwise The System is set up for Lift Start Change the system to HF Start Mode Welding Mode see Figure 13 HF Start Mode and Welding and Figure 14 HF Start The tungsten is contaminated or the Mode and DC Welding on page 31 work is dirty AVC 501 System doesn t preforma Clean the tungsten and workpiec
64. he input voltage is not from 0 to 10VDC you may need to adjust the scaling of the voltage measured by the controller to achieve a reading of 0 to SOVDC on the front panel This is accomplished by adjusting the potentiometer R26 labeled REM while the remote input voltage signal is present NOTE No other calibrations inside the control is re quired by the operator except the R22 Trim pot labeled Touchsense Calibration This scaling feature of the Remote Set Point input is included to allow the full range of the set point to be commanded from a wide range of applied voltages S1 REMOTE VOLTAGE PRESET Shown in Panel Voltage Preset Mode SELECT ONE PANEL VOLTAGE PRESET FIGURE 21 PANEL VOLTAGE PRESET DIP SWITCH SELECTION NOTE The set point range is limited to 5 to 50V Ifa remote set point voltage and scale factor are chosen that would try to program a set point to be less than 5 volts the control will set the set point to a voltage out of the AVC 5 s operating range Likewise if a set point of greater than 50 volts is attempted the control will set the set point to a voltage greater than the operating range of the AVC 501 The AVC 501 System will not function operated in this manner SYSTEM VISUAL CHECK Before operation begins verify that all system inter connections have been made The interface cable from the drive unit should be installed in the J4 con nector on the bottom panel of th
65. ical interfacing with the welding power source is required or to other controlling equipment e g PLC s etc The maintenance section of this manual contains the necessary information for the interfacing of the Burn Through Protection feature When in operation the Burn Through Protection cir cuit detects a rapid increase in the arc voltage that ex ceeds the preset voltage on the control unit by 2 volts When this occurs the welding power source is shut off via the contactor the torch is extinguished and the AVC 501 drive retracts away from the work piece This eliminates the AVC 501 Control from diving into the work piece which would normally happen when a burn though occurs The AVC 501 must then be reset to continue operation NOTE The Burn Through Protection feature will fol low the limits of the Deadband control The Burn Through Protection circuit will not trigger until the rapid increase in arc voltage exceeds the Deadband window by the 2 volt threshold of the protect circuit Starting Arc Gap Starting Arc Gap feature sets the starting arc gap of the arc voltage over a range of 0 to 09 inches To set AVC 501 ARC VOLTAGE CONTROL SYSTEM the arc gap pre positioning the operator must select the desired gap length and manually drive the AVC 501 Drive head down until it touches the work piece at which time the AVC 501 Drive auto matically backs off to the pre selected Start Arc Gap setting NOTE Dur
66. ing Pre positioning the operator must hold down the Down pushbutton or the Down drive Input signal on either of the remote interface ca bles must be maintained until the K1 A relay s Contact closes also indicated by the Protect LED illuminating Also be sure the work piece is secure As it may spring up when the AVC 501 drive backs off causing an incorrect arc gap setting Tungsten Preheat The potentiometer that presets the Starting Arc Gap in HF Start Mode also presets the Tungsten Preheat time in Lift Start Mode Tungsten Preheat adjustment presets the time the tungsten is held in contact with the work piece with the power source contactor on before driving up to start the arc Typically the larger the tungsten the longer preheat time is required Likewise with smaller diameter tungsten and or thinner material the shorter the pre heat time required There isn t a set time for a given material and tung sten size Therefore tests must be conducted to deter mine a balance between reliable arc starting and unnecessary preheat time that may hinder production Tungsten Preheat time is selectable from 0 to 12 5 seconds NOTE The Tungsten Preheat time entered by the opera tor must include enough time to accommodate pre purge time for the shielding gas 34 OPERATION INSTALLATION INSTALLATION NOTE Figure 6 Interconnection Diagram on page 24 Illustrates a typical AVC 501 system interconnecti
67. ms should be corrected by factory authorized representa tives CONTROL UNIT ASSEMBLY The control unit assembly see Figure 34 501 Control Exploded View and Table 6 AVC 501 Control Parts List beginning on page 50 consists of an enclosure housing the major electronic assemblies of the arc voltage control system Maintenance is generally limited to periodic dusting of the enclosure The user should ensure that the unit is not operated with the access door open and or cable connector mounting holes open The user should exercise cau tion in operating the unit if it has been inadvertently exposed to excessive dust or liquid contamination since such conditions may cause electrical shorting and or malfunctioning of the electrical electronics as semblies The user should consult with the factory if such conditions have occurred Repair of the control unit assembly is generally limited to a remove and re place operation NOTE If the user should decide to repair unau thorized items then the user should exer cise caution when repairing the control unit subassemblies and printed circuit boards since these repairs can void the warranty WARNING When repairing the control unit assembly disconnect A C power from the unit be fore opening the access door and turn the power switch OFF Assemblies and parts which are authorized for user replacement are listed in Table 6 AVC 501 Control Parts List on page 51 R
68. nal Safety Hazards Fire and Explosion gt a deco om W Falling Equipment XV m uou w Ala ow de Mowa Wo ER owe ue Moo cu WM Moving Parts od g Ana Rob as amos fan Z ide al eX Magnetic Fields Can Affect Pacemakers 3 UE GR 00 Welding Wire ge 4 ike Flying Pieces Of Metal Or Dirt pet nit deut 0a zde ue Ub dia 4 anas eu XE Overheated Equipment 0202 XV High Frequency VI Safety References tu s nose w Bow go 4 e OG ae or Re 405 a AW AVC 501 Arc Voltage Control System kr Description of Equipment Description of Equipment we 4 4 4 7 Arc Voltage Control Theory aa 47 Arc Voltage Control System 17 Control Unit s a hod Gb ao de dee ee Norge In ofe ge doe Bue tua 4 716 Drive Assembly gt a ce Ro docu ORO 8 aj bed AE Gr SOSNE us woo ox 216 Operation Operation General detentan be o a Oho ET ur S Start Modes y 1 257 ro 022741 unte 205 2 02042208 Ge de ia Aa High Frequency Start ST Lift Start de Se Seven Sh x Automatic Manual Modes Manual mode 29 22 213 a 423 130 Au
69. nces C OSHA Safety and Health Standards 29CFR 1910 avallable from the United States Department of Labor Washington DC 20210 AVC 501 ARC VOLTAGE CONTROL SYSTEM D NFPA Standard 51B Fire Prevention in Use of Cut Standards Publication No EW1 1989 Elec ting and Welding Processes available from the tric Arc Welding Apparatus approved as ANSI National Fire Protection Association 470 Atlan C87 1 1989 Available from National Electrical tic Avenue Boston MA 00210 Manufacturers Association 155 E 44th Street New York NY 10017 xvi DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM 501 Arc Voltage Control System DESCRIPTION OF EQUIPMENT The Jetline 501 Arc Voltage Control system is a precision microprocessor controlled arc voltage con trol unit for use with the Gas Tungsten Arc Welding process GTAW also known as and Plasma Arc Welding PAW This equipment by means of a closed loop servo moves the welding torch in order to maintain a constant arc voltage Automatic correc tions are made by the drive head to match the actual arc voltage with that set on the front panel controls thus keeping the arc length constant Other features designed into the 501 Arc Voltage Control sys tem makes it a truly innovative product suited to the customer s needs ARC VOLTAGE CONTROL THEORY The Jetline 501 Arc Voltage Control System or other arc voltage length c
70. nt 40VDC and 25VDC is used as the source voltage for the motor driver circuit All voltages are refer enced to power ground at C41 minus side MICRO CONTROLLER BOARD ASSEMBLY The following will describe in basic terms how the AVC 501 Control system functions beginning from the sensing of the arc voltage Comparative circuit and to the stepper motor drivers The Micro controller board is as the name implies the primary controller of the AVC 501 System The Arc Voltage Preset circuit uses an analog to digital converter built in to the mircro controller IC and a potentiometer to determine the desired arc voltage Likewise the Deadband Sensitivity Retract Start Delay and the Starting Arc Gap Tungsten Pre heat Features all incorporate this same method of commu nication with the micro controller Additionally DIP Switches are also incorporated to set other process selections to the micro controller 1 e AC verses DC Welding Lift Start verses High Frequency Start methods and Local or Remote Voltage Preset selections The micro controller running at 4MHz clock fre quency is programmed with the logic required to con trol the welding process for the AVC 501 The micro coontroller board communicates to the outside world via LED s seven segment LED digital display and relays to control other related welding equipment e g welding power source contactor carriage start wire feed start etc In simplistic terms the
71. ntrol Section s 69 Process Control Section 2 2 69 Power Source Section 69 Optional Features ow os woa 22 8008 SVG FG W de ko z dm 09 Cold Wire Feed Section ee rare s 69 Arc Voltage Control Section 69 Process Control Section 69 Power Source Section s eee 70 Schematics and Block Diagrams Schematics and Block Diagrams wwe s aar IIL Optional Equipment Optional Equipment e pi lus Bo oh oe 4h TO Cross seam adjustment 1 04 6 02 7 1 Tilting bracket assembly 1043 ki KR m Ea ue XU 23 56 Moce TA R W Drive cable extension Be AM Go X pU SOE g ar ck tan 087 Magnetic Arc Control wie A Set a cy 28 Awe PAP Me ofe ge Wes hue m Cold Wire Feed Systems ee s s s BI Ordering information s s BI Index Index e e dle ode Wa g mo OR UR nous 008 AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE OF TABLES Table of Tables AVC 501 Arc Voltage Control System Description of Equipment 17 Table I AVC 501 Control Specifications Oo Seah
72. on and should be used for reference in the following instal lation instructions DRIVE ASSEMBLY MOUNTING Mount the 501 drive unit to allow positioning of the weld torch above the weld joint Refer to Figure 7 501 Standard Drive Assembly Mounting Di mensions on page 25 for the mounting hole pattern for the standard drive If a compact drive is to be used it comes in two pieces the drive motor assem bly and the high frequency protect unit For the com pact drive assembly see Figure 8 AVC 501 Compact Drive Assembly Mounting Dimensions on page 26 for placement Mount the drive motor assembly from either side us ing the 5 16 24 UNF 2b x 62 deep mounting holes provided Position the high frequency protect unit to allow the operator access to the up down switches and mount it using the four holes provided Connect the two units together using the cables provided The AVC 501 drive should be mounted so that ade quate space around the drive is provided to accommo date the various parameters of operation 1 e workpiece retract movement automatic correction etc The requirements for mounting will to a large extent depend on the user s application Some mounting ex perimentation may be required Red Voltage Sense Lead Connect the red sense lead from the drive unit to the torch NOTE High voltage insulation test lead wire is pro vided for this purpose The red sense lead must be connected to
73. ontrols are simply stated primarily a modified Digital Voltage Meter A Digital Volt Meter measures a voltage drop across a resistor or other component at two points 1 e the and sense leads As current increases or decreases through the resistor or component the voltage drop across also increases or decreases proportionately Likewise in a welding arc if the arc length increases 1 the torch moving away from the work piece the arc voltage also in creases Arc Voltage is directly proportional to arc length As one increases the other increases or as one decreases the other decreases Like the Digital Volt Meter our 501 system also measures the voltage across a resistor at two points In the AVC 501 system s case the resistor is a weld ing arc In a TIG arc the positive lead connects to the work piece and the Negative lead connects to the TIG welding torch While welding the AVC 501 system measures the voltage across the arc and compares this voltage to the voltage pre set on the front panel or from the remote input and adjusts the torch up or down to maintain the pre set welding arc voltage selected The importance of an arc voltage control system was first realized in an automated welding system where heat input is critical TIG welding power sources are known as Consant Current or CC power sources which means that no matter what arc voltage reason ably obtained from the power source the power
74. osition on the start switch on the front panel of the DWF 3 Arc Voltage Control Section An additional Lockout Switch could be installed to provide a means of preventing the AVC 501 from tracking the arc during a welding cycle This is useful as a troubleshooting tool particularly during initial setup This can also be accomplished by pressing the Lockout pushbutton on the front panel of the AVC 501 Controller Process Control Section Another Process Start switch could be added to make the Process control section a bit more complete i e Start Stop and Emergency Stop This switch s con tacts would simply parallel the Down Drive Switch in the Arc Voltage Control section and would be a mo mentary type switch AVC 501 ARC VOLTAGE CONTROL SYSTEM Power Source Section The Miller MaxStar 300LX power source has addi tional outputs such as Voltage Feedback and Amper age Feedback These outputs can be used to display the actual welding amperage and welding voltage dur ing a welding cycle Adding digital displays will re quire additional power supplies in the interface console to provide regulated voltages to these dis plays Keep in mind both the 501 and the Miller MaxStar 300LX have digital readouts on them to indi cate actual welding voltage and the MaxStar has two digital displays to indicate both actual welding amper age and voltage 70 EXAMPLE SYSTEM INTERFACE SCHEMATICS AND BLOCK DIAGRAMS AVC 501 ARC
75. ounterclockwise sets the Sensitivity to minimum Likewise adjusting the Sensitivity clockwise sets it to maximum 33 AVC 501 ARC VOLTAGE CONTROL SYSTEM A compromise should be made when using the Sensitivity setting Setting the Sensitivity to maxi mum will cause the AVC 501 system to overcompen sate for arc voltage errors causing erratic type drive movement which can be detrimental to the weld Set ting this feature to minimum can also effects on the weld by causing the AVC 501 system to be sluggish in response to arc voltage errors In setting up the AVC 501 system for the first time it 1s recommended to set the Deadband and Sensitivity settings as follows Deadband set to approximately an 11 O clock position Sensitivity set to approximately a 2 O clock position This allows the system enough tolerance to track and control the arc length without being so accurate that the system overcompensates and initiates the Burn Through Protection feature Once the arc has been established and the AVC 501 system controls the arc voltage adjustments can be made to obtain the level of accuracy desired for each application Burn Through Protection Protect Use of the Burn Through Protection feature is op tional However if the Burn Through Protection fea ture is initiated the AVC 501 system will stop tracking the arc voltage go into Retract mode and then into Manual mode To utilize this feature proper electr
76. per ator to press the Process Stop pushbutton to begin the sequence Once the pushbutton has been pressed the Miller MaxStar 300LX no longer has a output start signal and begins downsloping the amperage for the preset time of 3 5 seconds As the MaxStar 300LX downslopes a lockout signal is provided to the AVC 501 to prevent the torch from moving during the amperage downslope and for the remainder of the weld cycle until the arc extinguished In addition the Remote Start signal to the DWF 3 has been removed and stops feeding wire If you d like wire to feed during a portion of this time set the Stop EXAMPLE SYSTEM INTERFACE Delay Timer to a time less than the Miller MaxStar 300LX s downslope timer The Model 80A Magnetic Arc Control system is also stopped from oscillating the arc If the MAG 8020 is used the Magnetic Arc Controller will start the Final Taper feature After this feature has timed out the magnetic oscillation will stop As the amperage reaches the final amperage 20 amps the power source stops producing output and the arc extinguishes Once the arc is not present the AVC 501 goes immediately into Retract time driving the torch away from the work piece for the duration of the retract time Also at the time the arc extin guishes the AVC 501 de energizes both the K1 amp K2 relays The carriage stops and upon the AVC 501 re tract feature completing the system resets and is ready to begin again Before
77. r oe a SUN ee dos 61 Circuit Des riptions 022102 eds lo dati PAT EAE RI CAPIT NC S Pere Te Def iP 65 Example System Interface e zou 20 En Ke NX a AE A 67 Schematics and Block Diagrams 71 Optional Equipment 81 Index Ne beta s em ed IndeX z x2 ata etan a mus daten AS SD ebur tus is eut WE A 83 vi TABLE OF CONTENTS AVC 501 ARC VOLTAGE CONTROL SYSTEM Table of Contents Overview Weed SAD XAR cz GONE ID fe sibi eb wu BR Uber y WI Table of Conni LD M m m fs oos 2 5 rg Se fuscum OR eo VIE Jabl Of Tables 5 4 22 50206 546 SE Aa Wo a wq GAGE A obo og po dod 28 30 Safety Precautions Definitions 4 4 619 6 wo gy de Me Dei URS od oe ee lt gt RM Caution lucir boue td oue A SLR ER ELS SK Warning 22 oie s I ute W w Boire Fate Fo dzo pee omis SAT Danger SEG ER Wee dr X Bow wr GL Ax e UAR ege Safety For EE EE EN ElectricShock as a KG od OE m ROE AE uje on XE Fire Safety co ul th Aug Home MUR ete ta XLV Additio
78. rol unit Other power sources having an impedance of less than 10 do require adjustments to the Touchsense circuit indicated by the 501 Drive standard or compact driving Up continuously once the sense lead is connected to the tungsten and the work piece To calibrate Touchsense a potentiometer is provided on the Micro Controller Board and is labeled INSTALLATION Touchsense Calibration R22 10K With all of the equipment installed and the 501 connected to the welding power source adjust this potentiometer until the 5 Drive just stops driving then turn the potentiometer one half turn counter clockwise While calibrating the Touchsense circuit or anytime the 501 system is at idle pressing and holding the Start Delay and Voltage Preset buttons the 501 front panel will display the Touchsense cali bration setting in DC volts This displayed voltage in dicates the voltage a short circuit between the tungsten and the work piece must go below to accu rately sense a short or a Touch This is useful in troubleshooting the 501 in the initial setup or when a different welding power source is used P gt Red Output Voltage 1 Wht Lockout Si N C poROHEsIghase p BIk Contacts of a Output Voltage E Relay Switch Lockout Signal D 4 N O FIGURE 22 AVC 501 REMOTE LOCKOUT RELAY 38 INSTALLATION Pressed Start
79. rstanding and more effective and accu rate troubleshooting of the system The Figure 32 AVC 501 Power Board Layout on page 48 is a draw ing of the board to assist in placement of the Test Points for better understanding and troubleshooting In addition to the board layout drawing on page il lustrates very simply the flow of signals in the AVC 501 control system The Power board contains control circuitry for the system and also performs primary input voltage and control voltage regulation Input voltage to the con trol unit is supplied to the Power board through a fuse and Radio Frequency Interference and Elec tro 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 3 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 approximately 28VAC with a Center Tap two secondaries at 14VAC a 16VAC secondary winding a 18VAC 31VAC tapped secondary and a 10VAC secondary winding used for the Microcontroller board discussed later beginning on page 65 65 AVC 501 ARC VOLTAGE CONTROL SYSTEM The voltage is rectified on the board and filtered through electrolytic capacitors The resulta
80. s the motor in a certain pattern to drive the rotate the motor clockwise or counter clockwise depending upon the direction of travel needed The drive motor pulses are generated by the micro controller IC and passed to the driver circuit Remote Voltage Preset Circuit The remote voltage preset circuit uses an exact dupli cate of the circuit used to measure the actual arc volt age There is a scalar potentiometer used to adjust the input voltage from the operator s output circuit to an acceptable level for the micro controller For exam ple the operator s output voltage may be 0 to 15 VDC The system can be scaled to adjust this remote preset voltage to be equal to 5 to SOVDC 66 CIRCUIT DESCRIPTIONS EXAMPLE SYSTEM INTERFACE EXAMPLE SYSTEM INTERFACE AVC 501 SYSTEM INTERFACE EXAMPLE The following describes the design and interface in tent and the operation of the system of Figure 50 501 System Interface Example beginning on page 78 DESIGN INTENT The design intent of the example interface wiring of the 501 and other equipment in the diagram is to provide a sample interface for typical TIG applica tions using an 501 Arc Voltage Control System The basic components of the complete welding sys tem is illustrated in the diagram and include the fol lowing e Miller MaxStar 300LX Welding Power Source with an Automation Interface Connector AIC Cyclomatic DWF 3 Cold Wire Feed System Cycloma
81. se the Tungsten Pre Heat Too much Tungsten Preheat Time set Time so that the power source begins on the AVC 501 causing the power producing Lift Start amperage while source to time out in Lift Start while the tungsten is in contact with the the tungsten is in contact with the workpiece workpiece AVC 501 System doesn t preform a The Tungsten is contaminated orthe Clean the tungsten and workpiece as starting arc gap once the tungsten work is dirty necessary Problem 8 touches the workpiece i e The Touchsense calibration needs Adjust the Touchsense calibration as Touchsense Feature but does drive adjustment necessary page 38 up after the down drive signal is re moved i i Touchsense is out of calibration i e Adjust the Touchsense calibration un ID drives up the power source have low til the AVC 501 System stops driving Problem 9 E Weld Power leads are connecte output impedance causing the up page 38 to the voltage sense leads on the AVC 501 System to sense a short be AVC Drive tween the tungsten and the workpiece Not enough Start Delay Time seton Increase the Start Delay Time to allow the AVC 501 to allow for the arc to es arc to become stable and to allow tablish and become stable Upslope of the welding amperage to complete Deadband is set to narrow causing the Burn Through Protection Feature Increase the Deadband setting to be initiated Clockwise to prevent the Problem 10 AVC 501
82. sed welding the 501 would be disabled or locked out during the low pulse so that the 501 will only track the voltage of the high pulse In Downsloping of the welding amperage at the end of the welding cycle the 501 should be locked out to prevent the 501 system from correcting for the voltage decreasing during the Downslope pro cess It may also be desirable to be able to manually Lockout the AVC 501 during setup and initial instal lation Retract Mode The Retract Mode is used to retract the torch away from the workpiece at the end of a weld cycle When the torch voltage goes outside the Automatic Voltage Sense Range of 5 to 50VDC indicating the arc has extinguished the torch will retract for the selected time NOTE Retract will only occur if Start Delay has timed out so that false arc starts will not cause the torch position to change There are a number of operational parameters that control the AVC 501 operation The user can select the desired parameters depending on the welding pro cess requirements These parameters are selected us ing the potentiometers on the front panel and DIP Switches on the inside of the control unit Deadband Deadband is a window of voltage centered around the set point voltage selected by the user This window is adjustable from voltto 1 5 volts This window is considered an acceptable error of voltage by the OPERATION AVC 501 Control system and
83. ssed or implied The installation operation and maintenance guidelines set out in this manual will enable you to maintain the equipment in peak condition and achieve maximum effi ciency with your welding operation Please read these instructions carefully to become aware of every advantage Only experienced personnel familiar with the operation and safe practice of welding equipment should install and or use this equipment AVC 501 ARC VOLTAGE CONTROL SYSTEM OVERVIEW Overview OVERVIEW a Se Ra ew AAA SP Se BEETS vi Table of Contents aer BERR BA DUREE AAA BE SNE koka vil 48 11 10 Tables 23 ER bee ainda a ete ane ea Ban Mie x Table of Figures be www KA UE b RO de R Arb W xi a ved AG Safety Precautions 22522222 Bre La SE xiii Additional Safety Hazards 43 id bt Mate ROG no EBA B XV AVC 501 Arc Voltage Control System Description of Equipment ss ss ngo 5 DR Yves NOE SSE LUE de p 17 Operationy 24 23 tot Eo ee sh LM hr A p ga dd 31 Installation sa 2052559 bi A DAA SES TG 35 Maintenance sos Gs ba ati tan sel e A a nud reu sd 45 Drawim s and Parts 88 55 10 1 A a secedere RIDES 47 Troubleshooting 4 d bo de La GER ARES Ge de
84. sug gested corrective procedures The Circuit Descriptions section which includes block diagrams and schematics will also be helpful reference for troubleshooting Full line voltage is exposed inside the control unit Do not turn power when the Power board is re AVC 501 ARC VOLTAGE CONTROL SYSTEM Many of the Integrated Circuits 1C s on the Main board are CMOS logic and require standard CMOS precautions against damage by static electricity discharge RECOMMENDED SPARES FOR TROUBLE SHOOTING This manual was written in a manner to provide enough detail to identify individual components parts and subassemblies for maintenance purposes A recommended spare parts lists is given in Table 17 moved partially removed or disconnected TABLE 14 TROUBLESHOOTING Recommended Spare Parts on page 63 For trouble shooting the following items are recommended to isolate most problems Problem description Cause Solution Unit unplugged Plug unit into an appropriate 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 volta
85. tandard AVC 3 and Standard AVC 4 Drive assem blies and the Compact AVC Drive assembly provid ing these drive assemblies are in good working order The Standard AVC 501 Drive assembly and Cyclomatic s AVC 3 and AVC 4 drives has a 6 stroke length This is an adequate stroke length for many applications The Compact AVC drive assemblies have a 1 stroke length for use in tight welding areas where physical constraints prevent the use of the Standard 6 stroke drive assembly Each drive is equipped with a Red Voltage Sense lead which connects to the TIG or Plasma welding torch and a Work piece Stud for connecting to the DESCRIPTION OF EQUIPMENT work piece making up the two leads of a digital volt meter as discribed earlier DESCRIPTION OF EQUIPMENT AVC 501 ARC VOLTAGE CONTROL SYSTEM AVC 501 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF EQUIPMENT FIGURE 2 AVC 501 CONTROL UNIT TABLE 1 AVC 501 CONTROL SPECIFICATIONS DESCRIPTION SPECIFICATIONS RATING Voltage Sensing Accuracy 1 of setting or 1V whichever is greater Voltage Sense Range Lower Limits are possible 5 to 50V DC or AC Maximum Open Circuit Voltage 80VDC 80VAC Input Power Requirements 90 132 VAC 180 264 VAC 50 60 Hz Control Unit Enclosure Standard NEMA Style Sealed enclosure with provi sions for plug in options Deadband Adjustment Voltage Error Range Min to 1 5
86. tandards TA SETE TE ENG o Touchsense gt gt E se 596 Tracking 20 22 23 ON 5 2 45 61 travel c c 46 Output 5 wow Tungsten 17 20 34 62 65 67 69 P U panels c XV Upslope 62 68 parts listi 1 61 PE xilil xv 20 22 23 periodic 45 AS TA AS Plasma 17 18 28 69 81 ee Power20 21 45 48 52 61 63 65 67 69 70 power switch 1845 Precautions gt Ww gt U 65 Weights 1 22 Preset gt 37 38 62 63 65 67 69 Wheel 5 8 X lt w 422 preventive gt gt vac AD wiring 45 primary s 5 o 65 Problem gt 61 62 Z Programmable Logic Controllers xv u UE Protect 20 33 34 61 62 68 69 Pulse gt gt gt 32 68 69 83 AVC 501 ARC VOLTAGE CONTROL SYSTEM 84 m Jetline engineering An illinois Tool Works Company Jetline Engineering 15 Goodyear Street Irvine California 92618 Telephone 949 951 1515 Fax 949 951 9237 Fax AVC 501 Manual Rev A December 2006 Web site www jetline com www cyclomatic com E Mail sales jetline com service jetline com
87. tar has reached peak welding amper age The AVC 501 begins tracking the arc voltage keeping the voltage at the desired level In addition the AVC 501 energizes the K2 relay This relay is 68 EXAMPLE SYSTEM INTERFACE TABLE 23 MILLER MAXSTAR 300LX SETUP PARAMETERS Parameter Setting Welding Mode DC Welding Starting Method Lift Arc Tungten Preheat Time 1 second Upslope Time 2 5 seconds Pre Purge Time 5 seconds Welding Amperage 60 amps Downslope Time 3 5 seconds Initial Amperage 20 amps Final Amperage 20 amps Post Purge Time 5 seconds Pulse Amperage Off used to turn on the magnetic arc control system and the carriage control The DWF 3 has been given the start signal via the relay but since the DWF 3 has a start delay set at 4 5 seconds wire feeding has been delayed The intent of this delay is to match the start delay of the AVC 501 and the Upslope time of the MaxStar 300L X so that the wire begins at the time the MaxStar reaches peak current and the AVC 501 begins tracking the arc volt age At this time the system is fully active welding is be ing performed the AVC 501 is tracking the arc volt age wire is being added to the weld pupple the part is being rotated or the torch 1s being moved depending upon your welding fixture and the magnetic arc con trol 1s oscillating the arc Stop Sequence The stop sequence is automated but requires the o
88. tic Model 80A MAG 8020 Magnetic Arc Control System output connection for a carraige controller Anda front panel for control switches and potentiom eters that can be used as a console for the operator With this interface and the components described the customer can control the welding system from start to finish without the need for additional and sometimes costly system controllers INTERFACE INTENT The interfce intent of this example is to have the re mote interface cables brought into the interface enclo sure and immediately terminate to a terminal strip From there additional wiring installed by the cus TABLE 19 AVC 501 SETUP PARAMETERS Parameter Setting Welding Mode DC Welding Starting Mode Lift Start Tungsten Preheat Time 1 5 seconds Start Delay Time 3 seconds Deadband Adjustment 4096 Sensitivity Adjustment 60 Retract Time 25 Arc Voltage Preset 12 VDC Local or Remote Voltage Preset Internal Remote 67 AVC 501 ARC VOLTAGE CONTROL SYSTEM tomer would be used to interconnect the descrete components of the system 1 e welding power source magnetic arc controller etc TABLE 20 DWF 3 SETUP PARAMETERS Parameter Setting Start Delay Time 4 5 seconds Stop Delay Time 0 seconds Start Switch Local or Remote Remote Wire Feed Speed Selector Switch Local or Remote Remote Wire Feed Speed As Desired
89. to be sure it is held tight If not tighten bolts that hold the torch to the bracket 46 MAINTENANCE Cables Check for proper installation All cables should be connected tightly to the respec tive receptacles Be sure that the cables do not have sharp bends in them and that the insulation of the ca ble is not frayed or cracked 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 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 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL SYSTEM DRAWINGS AND PARTS LISTS BONO DL 5 send saw 1 pen sa c FLASHA CUTTING OC MELDING LIFT START m e 2002 Arc Products Diego UGA B D UEL DING MELDING HIGH FRED START bE tuy 3g 52 EL 10 2002 Li CLICK OC sECBRSDRLU rin ut ne Osage i E Callbr ation P N 0600 0105 Rev Microcontroller Board Assembly P N 0600 0104 Rev Arc Voltage Control Board FIGURE 31 AVC 501 MICRO CONTROLLER BOARD LAYOUT 47 DRAWINGS AND PARTS LISTS AVC 501 ARC VOLTAGE CONTROL SYSTEM 613
90. tomatic and Start Delay Modes 0532 Lockout Mode 0040 ut a so Wi dew wipe Te de GN bas menant 082 Retra t Mode as 4 m Mi w ve 82 al na R a SA vii AVC 501 ARC VOLTAGE CONTROL SYSTEM TABLE OF CONTENTS Deadband wos 6 uk oom him BR 5 ne ow ow 292 Sensitivity Som M e 5 Lo du osz M 038 Burn Through Protectan Protect Starting Ar Gap iu so ul up 5 cg op OB dog GE Regem 33 Tungsten Preheat wo b 50 oom Le dd bog eg ES Wos s ee A Installation Installation ga ee ah Set LAS WPiA W ARR Lie hoe W fo OA 39 Drive Assembly oia O Red Voltage Sense Lead s 2 2 BS Workpiece Ground Stud 2 2 35 Control Unit Mounting s dub uk PP mop Xe doge Bride pogo BD Interfacing the AVC 501 with other wo e a tee RT 13 we cet 30 End of Start Delay Relay EOSD 86 Lockout Inputs 17 OE GR STORA a lUe p na DO Remote Set point 27299 System Visual Check 2 2 2 27 Touchsense Calibration 38 Maintenance Maintenance ar N Maintenance Requirements 12 22 me dle esM de ENE 229 Control Unit Assembly AS Cable Assembly 2 s AS AVC Drive
91. ystanders xiii AVC 501 ARC VOLTAGE CONTROL SYSTEM SAFETY INFORMATION Safety is a combination of good judgment and proper training Operation and maintenance of any arc weld ing and cutting equipment involves potential hazards Individuals who are unfamiliar with cutting and weld ing equipment use faulty judgment or lack proper training may cause injury to themselves and others Personnel should be alerted to the following potential hazards and the safeguards necessary to avoid possi ble injury In addition before operating this equip ment you should be aware of your employer s safety regulations BE SURE TO READ THIS MANUAL BE FORE INSTALLING OR USING THIS EQUIPMENT BE SURE TO READ AND FOLLOW ALL AVAILABLE SAFETY REGULATIONS BE FORE USING THIS EQUIPMENT ELECTRIC SHOCK TN THE VOLTAGES PRESENT IN THE 27 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 A Install and continue to maintain equipment according to USA Standard C1 National Electric Code B Never allow live metal parts to touch bare skin or any wet clothing Use only dry gloves b n en welding or cutting in a damp area or when standing on metal make sure you are well in sulated by wearing dry gloves rubber soled shoes and by standing on a dry board or plat form wi D Do not use worn or damag

OPERATION MANUAL for Cyclomatic Series AVC

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