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AVC-5 Manual rB 9-8-11.vp

1. die x E 2 1010 rn 99 H Vio E 18 8 Gi m 7 7 Blu 66 J 5 151579 a 2 4l Rea 33 3 B E z 212 IZ J13 P13 1818 5 1747 R 16116 B See Remote Interface 1515 D y 1414 E B 13113 PIE Yel 1212 NT m Wht MMS S 1010 2 e amp 99 m 5 1818 3 77 Al a 155 Org L 414 K T 22 J H Gm J5 P5 1515 AVC 5 Drive Assembly Std Stroke Grn I 1616 e 1 Stepper Motor 1414 B B Bik Red 8 D p pp Wht Blk Blu 1242 a Wht Red E Yel gt 1040 Gm Ele Red 35 alo Org ale 7 Red 28 Jala Yel alate Wht Gm N 166 55 oF Blu Wht 22 Grn AWht sy 2 ala 2 Gm B 55 Rod Le Blk lt 44 T T an Protect Assembly 1042 0041 FIGURE 45 AVC 5 CONTROL BLOCK DIAGRAM CONT 59 201327 001 REV B SCHEMATICS AND BLOCK DIAGRAMS E 1700 2701 Be lquiessy anyo LO OL
2. 2 EN L E Le sumi E N 4 pl T1 y 2 G 4 18 gauge VEO 1 A Ya wire 2 5 3 14 pl 6 2 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 39 DRAWINGS AND PARTS LISTS 201327 001 REV B PE i T MET us gt 4 FIGURE 37 AVC DRIVE CABLE ASSEMBLY EXPLODED VIEW TABLE 9 AVC DRIVE CABLE ASSEMBLY PARTS LIST ITEM PART DESCRIPTION 1 1 000 EA 930014 014 CONN CIRC BOX RCPT 20 29S 2 1 000 EA 2208 0116 TERMINL HOUSING 16PIN 156 P 3 16 000 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
3. DESCRIPTION OF EQUIPMENT 3 TABLE 1 AVC 5 CONTROL SPECIFICATIONS 6 TABLE 3 AVC 5 STANDARD DRIVE ASSEMBLY SPECIFICATIONS 8 TABLE 4 AVC 5 COMPACT DRIVE ASSEMBLY SPECIFICATIONS 9 OPERATION 17 INSTALLATION 21 MAINTENANCE 31 DRAWINGS AND PARTS LISTS 33 TABLE 5 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST 35 TABLE 6 AVC 5 CONTROL PARTS LIST 37 TABLE 7 POWER SWITCH ASSEMBLY PARTS LIST 38 TABLE 8 TRANSFORMER ASSEMBLY PARTS LIST 39 TABLE 9 AVC DRIVE CABLE ASSEMBLY PARTS LIST 40 TABLE 10 AVC REMOTE INTERFACE CABLE PARTS LIST 41 TABLE 11 AVC 5 STANDARD DRIVE ASSEMBLY PARTS LIST 43 TABLE 12 AVC 5 COMPACT DRIVE ASSEMBLY PARTS LIST 45 TABLE 13 AVC AUX REMOTE INTERFACE CABLE PARTS LIST 46 TROUBLESHOOTING 47 TABLE 14 TROUBLESHOOTING 47 TABLE 15 VOLTAGE POINTS MICRO CONTROLLER BOARD 48 TABLE 16 VOLTAGE POINTS POWER DRIVER BOARD 48 TABLE 17 RECOMMENDED SPARE PARTS 49 TABLE 18 VOLTAGE PRESET SELECTION S1 49 CIRCUIT DESCRIPTIONS 51 EXAMPLE SYSTEM INTERFACE 53 TABLE 19 AVC 5 SETUP PARAMETERS 53 TABLE 20 DWF 3 4 SETUP PARAMETERS 53 TABLE 21 CARRIAGE CONTROL SETUP PARAMETERS 53 TABLE 22 MAGNETIC ARC CONTROL SETUP PARAMETERS 54 TABLE 23 WELDING POWER SOURCE SETUP PARAMETERS 54 SCHEMATICS AND BLOCK DIAGRAMS 57 OPTIONAL EQUIPMENT 67 viii 201327 001 REV B TABLE OF FIGURES Table of Figures
4. Ala UM Ala ul 9 pay ISA Ala xig SONS PIS S OAV lt m OQ u Q o r 5 arc a FIGURE 46 AVC 5 STANDARD DRIVE BLOCK DIAGRAM 60 SCHEMATICS AND BLOCK DIAGRAMS 201327 001 REV B 4 K AVC 4 Drive Assembly Std Stroke M J1 P1 Yel D Is Bik 21015 Red Wht Blu Red Yel 2 Yel Wht Red Bik G OrnAWht Wht Orn R P F BIkK VWht Orn H Du Wht j Bik 5 G rn o B Bik Tre C1 01uF Protect PCB Assembly 1042 0041 FIGURE 47 AVC 4 STANDARD DRIVE BLOCK DIAGRAM 61 SCHEMATICS AND BLOCK DIAGRAMS 201327 001 REV B P5 Output Voltage A C 196 Output Voltage E pei Sos u Lockout Signal D BK Not Used K Zu Remote Voltage Pre Set Wiper V EN K1 A Contact H p K1 A Common Not Used L Ms Remote Voltage Pre Set Reference M Drive Down N Drive Up P i Orn K2 A N O Contact R BK K2 A Common S Wht Arc Established Signal
5. Logic Ground Drive Down N 4 Red Up Brn Down FIGURE 28 AVC 5 REMOTE UP DOWN DRIVE WITH E STOP Remote Voltage Pre Set Wiper Remote Voltage Pre Set reference BIk Analog Output Device 0 5VDC to 10VDC 5V to 50V Welding Voltage FIGURE 27 AVC 5 REMOTE VOLTAGE SET POINT ANALOG 28 201327 001 REV B INSTALLATION PS Remote Voltage Pre Set Wiper Remote Voltage Pre Set reference M AYC 5 Control Output 20D Remote Set Remote Set Output Return 10VDC gt 10K Pot 500 Ohm Resistor Blk hog N 0 5VDC to 10VDC 5V to 50V Welding Voltage FIGURE 30 AVC 5 REMOTE VOLTAGE SET POINT EXTERNAL VOLTAGE P5 E 500 Ohms 5K Ohms 10 Pot Zener V Diode M A FIGURE 29 AVC 5 REMOTE VOLTAGE SET POINT INTERNAL VOLTAGE 29 INSTALLATION 201327 001 REV B 30 201327 001 REV B MAINTENANCE MAINTENANCE MAINTENANCE REQUIREMENTS AP Automation Arc Voltage Control Systems are de signed for trouble free operation and normally require only minimal preventive care and cleaning This sec tion of the users manual provides instructions for maintaining user serviceable items The suggested re pair procedure for all user serviceable items is to re move and re
6. Filter Power Circuit Circuit __ Motor Driver Circuit 115 230VAC 50 60 Hz FIGURE 42 AVC 5 SIGNAL FLOW 49 TROUBLESHOOTING 201327 001 REV B 50 201327 001 REV B CIRCUIT DESCRIPTIONS CIRCUIT DESCRIPTIONS WARNING For use by Qualified Service Technicians SYSTEM WIRING DIAGRAM The Figure 44 AVC 5 Control Block Dia gram and Figure 45 AVC 5 Control Block Diagram Cont beginning on page 58 is a circuit diagram of the entire AVC 5 Arc Voltage Control system These diagrams include detailed schematics of all portions of the system except the Power Board and Micro Con troller Board assemblies Schematics of the AVC 5 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 5 Control Ex ploded View on page 36 and Table 6 AVC 5 Control Parts List on page 37 identifies the major assemblies Parts lists for each assembly are also included in the DRAWINGS AND PARTS LISTS section beginning on page 33 POWER DRIVER BOARD ASSEMBLY This section will describe generally the circuitry signal flows and test points on the Main board to assist in a better understanding and more effective and accurate troubleshooting of the system The Figure 32 AVC 5 Powe
7. For Your Safety Read this manual before installing or using this equipme IMPORTANT 5 ARC VOLTAGE CONTROL OPERATIONS AND SERVICE MANUAL 1245 30th Street San Diego CA 92154 3477 619 628 1022 619 628 1028 FAX sales arc products com service arc products com www ap automation com www arc products com THANK YOU for purchasing Arc Products Equipment Our commitment to you is to pro vide an ever expanding family of quality arc positioning equipment controller and accessories Please take the time to read the following pages as they contain important information regarding proper use of this product and of welding cutting safety and procedures WHO DO CONTACT For help Contact your distributor For additional information such as Technical Manuals Service and Parts Circuit and Wire Diagrams User s Guides Distributor Direc tories Contact your distributor To file a claim for loss or damage during shipment Contact your delivering carrier For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Trans portation Department How to contact Arc Products Call 619 628 1022 Fax 619 628 1028 E mail sales arc products com service arc products com Arc Products Attn Customer Service 1245 30th Street San Diego CA 92154 Write ALWAYS PROVIDE MODEL NAME AND PART
8. 40 201327 001 REV B DRAWINGS AND PARTS LISTS 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 CONN CIRC BOX RCPT 22 145 2 1 000 EA 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 41 DRAWINGS AND PARTS LISTS 201327 001 REV B Y e E A OS MIES OS ls 4 5 2 89 O 83 A FIGURE 39 AVC 5 STANDARD DRIVE ASSEMBLY EXPLODED VIEW 42 201327 001 REV B DRAWINGS AND PARTS LISTS TABLE 11 AVC 5 STANDARD DRIVE ASSEMBLY PARTS LIST ITEM UM PART DESCRIPTION 1 1 000 EA 0600 0010 AVC RAIL BASE 2 2 000 EA 0600 0011 AVC 5 RAIL 6 STROKE 3 1 000 EA 0600 0012 AVC DRIVE SLIDER 4 2 000 EA 0600 0014 SUPPORT BUSHING ADJUSTABLE
9. DRIVE ASSEMBLY The AVC System can be purchased with one of two different drive assemblies i e Standard AVC 5 Drive assembly or the Compact AVC Drive assembly The controller can also be used with older drive assem blies built by Cyclomatic which include the Standard AVC 3 and Standard AVC 4 Drive assemblies and the Compact AVC Drive assembly providing these drive assemblies are in good working order The Standard AVC 5 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 work piece making up the two leads of a digital volt meter as discribed earlier 201327 001 REV B DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT 201327 001 REV B FIGURE 2 AVC 5 CONTROL UNIT TABLE 1 AVC 5 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 Requi
10. MICRO CONTROLLER BOARD ASSEMBLY The following will describe in basic terms how the AV C 5 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 5 System The Arc Voltage Preset circuit uses an analog to digital con verter built in to the mircro controller and a potentiometer to determine the desired arc voltage Likewise the Deadband Sensitivity Retract Start De lay and the Starting Arc Gap Tungsten Pre heat Fea tures all incorporate this same method of communication with the micro controller Additionally DIP Switches are also incorporated to set other process selections to the micro controller i e AC verses DC Welding Lift Start verses High Fre quency Start methods and Local or Remote Voltage Preset selections The micro controller running at a 4MHz clock fre quency is programmed with the logic required to con trol the welding process for the AVC 5 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 AVC 5 is a modified digital volt meter While welding the AVC 5 s microcontroller board is monitoring the actual arc voltage and making discis
11. PROBLEM 3 PROBLEM 4 PROBLEM 5 PROBLEM 6 PROBLEM 7 PROBLEM 8 PROBLEM 9 PROBLEM 10 CIRCUIT DESCRIPTIONS 47 47 47 47 47 48 48 48 48 CIRCUIT DESCRIPTIONS SYSTEM WIRING DIAGRAM POWER DRIVER BOARD ASSEMBLY MICRO CONTROLLER BOARD ASSEMBLY MOTOR DRIVER CIRCUIT REMOTE VOLTAGE PRESET CIRCUIT EXAMPLE SYSTEM INTERFACE 51 51 51 52 EXAMPLE SYSTEM INTERFACE AVC 5 SYSTEM INTERFACE EXAMPLE DESIGN INTENT INTERFACE INTENT OPERATION OF THE SYSTEM START SEQUENCE 53 53 53 53 54 vi 201327 001 REV B TABLE OF CONTENTS STOP SEQUENCE CONSOLE FEATURES COLD WIRE FEEDER SECTION ARC VOLTAGE CONTROL SECTION PROCESS CONTROL SECTION POWER SOURCE SECTION OPTIONAL FEATURES COLD WIRE FEED SECTION ARC VOLTAGE CONTROL SECTION PROCESS CONTROL SECTION POWER SOURCE SECTION SCHEMATICS AND BLOCK DIAGRAMS 54 55 55 55 55 55 56 56 SCHEMATICS AND BLOCK DIAGRAMS OPTIONAL EQUIPMENT 57 INDEX OPTIONAL EQUIPMENT CROSS SEAM ADJUSTMENT ASSEMBLY 1046 0271 TILTING BRACKET ASSEMBLY 1043 0046 DRIVE CABLE EXTENSION MAGNETIC ARC CONTROL SYSTEMS COLD WIRE FEED SYSTEMS ORDERING INFORMATION 67 67 67 67 67 INDEX 69 vii TABLE OF TABLES 201327 001 REV B Table of Tables AVC 5 ARC VOLTAGE CONTROL SYSTEM
12. 5 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF EQUIPMENT OPERATION FIGURE 1 ARC VOLTAGE CONTROL THEORY FIGURE 2 AVC 5 CONTROL UNIT FIGURE 3 AVC 5 SYSTEM COMPONENTS FIGURE 4 AVC 5 STANDARD DRIVE ASSEMBLY FIGURE 5 AVC 5 COMPACT DRIVE ASSEMBLY FIGURE 6 INTERCONNECTION DIAGRAM FIGURE 7 AVC 5 STANDARD DRIVE ASSEMBLY MOUNTING DIMENSIONS FIGURE 8 AVC 5 COMPACT DRIVE ASSEMBLY MOUNTING DIMENSIONS FIGURE 9 AVC 5 SENSE LEAD TIG TORCH CONNECTION FIGURE 10 AVC 5 SENSE LEAD PLASMA TORCH CONNECTIONS FIGURE 11 AVC 5 DRIVE WORK PIECE CONNECTIONS FIGURE 12 AVC 5 CONTROL UNIT MOUNTING DIMENSIONS FIGURE 13 HF START MODE AND AC WELDING FIGURE 14 HF START MODE AND DC WELDING FIGURE 15 LIFT START START MODE AND WELDING FIGURE 16 LIFT START START MODE AND DC WELDING FIGURE 17 MINUMUM DEADBAND SETTING FIGURE 18 MAXIMUM DEADBAND SETTING INSTALLATION FIGURE 19 AVC 5 REMOTE LOCKOUT SUPPLY FIGURE 20 REMOTE VOLTAGE PRESET DIP SWITCH SELECTION FIGURE 21 PANEL VOLTAGE PRESET DIP SWITCH SELECTION FIGURE 22 AVC 5 REMOTE LOCKOUT RELAY FIGURE 23 AVC 5 PROCESS TIMELINE EXAMPLE ONE FIGURE 24 AVC 5 REMOTE LOCKOUT TWO SUPPLIES FIGURE 25 AVC 5 REMOTE UP DOWN DRIVE x FIGURE 26 AVC 5 PROCESS TIMELINE EXAMPLE TWO FIGURE 27 AVC 5 REMOTE VOLTAGE SET POINT ANALOG FIGURE 28 AVC 5 REMOTE UP DOWN DRIVE WITH E STOP FIGURE 29 AVC 5 RE
13. or when standing on metal make sure you are well insulated by wearing dry gloves rubber soled shoes and by standing on a dry board or platform CROSS D Do not use worn or damaged welding or torch cables Do not overload the cables Use well maintained equipment E When not welding cutting turn equipment OFF Accidental grounding can cause over heating and create a fire hazard Do not coil or loop the cable around parts of the body F The ground cable should be connected to the work piece as close to the work area as possible Grounds connected to building framework or other locations remote to the SAFETY 201327 001 REV B H X NX N y AN work area reduce efficiency and increase the potential hazard of electric shock Avoid the possibility of the welding or cutting current passing through lifting chains crane cables or other electrical paths G Keep everything dry you might touch in cluding clothing the work area welding gun torch and welding or cutting machines Fix wa ter leaks immediately Do not operate equip ment standing in water H Never use a cutting torch or welding gun which is damaged or contains cracked hous ing Refer to AWS Z49 1 for grounding recom mendations SKIN AND EYE BURNS RESULTING FROM BODY EXPOSURE TO ELEC TRIC ARC WELDING AND CUTTING RAYS OR HOT METAL CAN BE MORE SEVERE THAN SUNBURN Use a proper face shield fitted with the cor r
14. CONTROL UNIT DRIVE ASSEMBLY OPERATION OPERATION GENERAL OPERATIONAL DESCRIPTION START MODES HIGH FREQUENCY START LIFT STARTM AUTOMATIC MANUAL MODES MANUAL MODE AUTOMATIC AND START DELAY MODES LOCKOUT MODE RETRACT MODE DEADBAND SENSITIVITY BURN THROUGH PROTECTION PROTECT STARTING TUNGSTEN PREHEAT INSTALLATION INSTALLATION TABLE OF CONTENTS 201327 001 REV B DRIVE ASSEMBLY MOUNTING RED VOLTAGE SENSE LEAD WORKPIECE GROUND STUD CONTROL UNIT MOUNTING INTERFACING THE AVC 5 WITH OTHER EQUIPMENT END OF START DELAY RELAY EOSD LOCKOUT INPUTS REMOTE SET POINT VOLTAGE INPUT SYSTEM VISUAL CHECK TOUCHSENSE CALIBRATION MAINTENANCE 21 21 21 22 22 24 24 MAINTENANCE 5 MAINTENANCE REQUIREMENTS CONTROL UNIT ASSEMBLY CABLE ASSEMBLY AVC DRIVE ASSEMBLIES MOUNTING BRACKETS PREVENTIVE MAINTENANCE SCHEDULE MONTHLY MAINTENANCE AVC DRIVE ASSEMBLIES PROPER FUNCTION TEST TEST QUARTERLY MAINTENANCE TORCH BRACKET ASSEMBLY PROPER FUNCTION TEST CABLES SEMI ANNUAL MAINTENANCE CONTROL UNIT ASSEMBLY DRAWINGS AND PARTS LISTS 31 31 31 32 32 32 32 32 32 32 32 32 32 32 32 32 32 DRAWINGS AND PARTS LISTS TROUBLESHOOTING 33 TROUBLESHOOTING SPARES FOR TROUBLESHOOTING PROBLEM 1 PROBLEM 2
15. TROUBLESHOOTING TROUBLESHOOTING The following list describes typical problems and sug gested corrective procedures The CIRCUIT DESCRIPTIONS section which in cludes block diagrams and schematics will also be a helpful reference for troubleshooting Full line voltage is exposed inside the control unit Do not turn power ON when the Power board is re moved partially removed or disconnected Many of the Integrated Circuits IC s on the Main board are CMOS logic and require standard CMOS precautions against damage by static electricity dis charge 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 rec ommended spare parts lists is given in Table 17 Recommended Spare Parts on page 49 For trouble shooting the following items are recommended to iso TABLE 14 TROUBLESHOOTING late most problems PROBLEM DESCRIPTION CAUSE SOLUTION Unit unplugged Plug unit into an appropriate AC Blown Fuse Source Problem 1 Lamp is not lit Replace Fuse Lampis bad Replace Lamp Cables disconnected from the control Check cables from the control to other to other components of the system components of the system Problem 2 Power Switch and Indicator Lamp are Connectors are disconnected inside Check connectors inside the co
16. 1056 0225 LOCK NUT BALL SCREW 11 15 2 000 EA 970043 300 SCR SET 6 32X 12 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 45 DRAWINGS AND PARTS LISTS 201327 001 REV B 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 46 201327 001 REV B
17. 5 2 000 EA 0600 0015 SUPPORT BUSHING FIXED 6 4 000 EA 0600 0016 W 1 DUALVEE WHEEL 7 1 000 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 5 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 25X 312X 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 HI VOLT 18 AWG NOT 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 5 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
18. AVC 5 POWER BOARD LAYOUT 34 201327 001 REV B DRAWINGS AND PARTS LISTS 4 5 pl FIGURE 33 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW TABLE 5 VOLTAGE SELECTOR SWITCH ASSEMBLY PARTS LIST EMI RFI 2 ITEM QPA UM PART NUMBER DESCRIPTION 1 1 000 EA 920035 001 SLIDE SW 2 POS LINE VOLT SEL 2 1 000 EA 2120 0123 FILTER RFI PWR LINE 3 AMP 3 1 000 EA 2208 0551 CONN RECT PLUG 6 PIN 200 P 4 5 000 EA 2212 0152 TERMINAL CRIMP PIN 18 24 GA 5 1 000 EA 2120 0000 FUSE CARRIER 1 4 X 1 1 4 FEK 6 1 000 EA 2360 6087 FUSE 2 5A 250V 7 1 000 EA 2340 0618 TERM RING 1 4 22 16 RED 35 DRAWINGS AND PARTS LISTS 201327 001 REV B 14 FIGURE 34 AVC 5 CONTROL EXPLODED VIEW 36 201327 001 REV B DRAWINGS AND PARTS LISTS TABLE 6 AVC 5 CONTROL PARTS LIST ITEM UM PART DESCRIPTION 1 1 000 EA 0600 0225 CHASSIS AVC 5 CONTROL 2 1 000 EA 0600 0354 AVC 5 TRANSFORMER ASSEMBLY 3 1 000 EA 0600 0102 AVC POWER DRIVER BOARD ASSY 4 1 000 EA 0600 0460 AVC 5 AUX REMOTE INTRFC CABLE
19. NUMBER OVERVIEW 201327 001 REV B Overview OVERVIEW IV TABLE OF CONTENTS TABLE OF TABLES VIII TABLE OF FIGURES IX SAFETY SAFETY PRECAUTIONS XI ADDITIONAL SAFETY HAZARDS XIII AVC 5 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF EQUIPMENT OPERATION 17 INSTALLATION 21 MAINTENANCE 31 DRAWINGS AND PARTS LISTS 33 TROUBLESHOOTING 47 CIRCUIT DESCRIPTIONS 51 EXAMPLE SYSTEM INTERFACE 53 SCHEMATICS AND BLOCK DIAGRAMS 57 OPTIONAL EQUIPMENT 67 INDEX INDEX 69 201327 001 REV B TABLE OF CONTENTS Table of Contents OVERVIEW TABLE OF CONTENTS 5 TABLE OF TABLES TABLE OF FIGURES SAFETY SAFETY PRECAUTIONS IV DEFINITIONS NOTE CAUTION WARNING DANGER SAFETY INFORMA TI ON ELECTRIC SHOCK FIRE SAFETY ADDITIONAL SAFETY HAZARDS XI XI XI XI XI XI XI XII FIRE AND EXPLOSION FALLING EQUIPMENT HOT PARTS MOVING PARTS MAGNETIC FIELDS CAN AFFECT PACEMAKERS WELDING WIRE FLYING PIECES OF METAL OR DIRT OVERHEATED EQUIPMENT HIGH FREQUENCY SAFETYREFERENCES AVC 5 ARC VOLTAGE CONTROL SYSTEM DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT ARC VOLTAGE CONTROL THEORY ARC VOLTAGE CONTROL SYSTEM
20. assem blies etc Af MAGNETIC FIELDS CAN AFFECT Y PACEMAKERS LR Magnetic Fields from High Currents can af fect pacemaker operation Pacemaker wearers should keep away Wearers of pacemakers should consult their doctors before going near arc welding gouging plasma cutting or spot welding operations WELDING WIRE Welding wire can cause puncture wounds Do not press gun trigger until instructed to do so Do not point the gun toward any part of the body other people or any metal when threading welding wire through the gun FLYING PIECES OF METAL OR DIRT 4h Flying pieces of metal or dirt can injure 2 2 eyes Wear safety glasses with side shields or face shields OVERHEATED EQUIPMENT High output power for long durations can cause equipment to overheat Allow cooling periods Reduce current or reduce duty cycle before starting to weld again Follow rated duty cycle HIGH FREQUENCY High Frequency can cause electrical inter ference W Take appropriate precautions to shield sen sitive electronic equipment such as com puters Programmable Logic Controllers etc Be sure to ground each component of the system to one ground point i e Earth Ground Earth or Protective Earth PE SAFETY REFERENCES The following publications provide additional informa tion on important welding safeguards A ANSI ASC 249 1 1988 American National Standard Safety
21. connections have been made The interface cable from the drive unit should be installed in the J4 con nector on the bottom panel of the control unit see Figure 12 AVC 5 Control Unit Mounting Dimensions on page 16 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 10 for a typical system inter connection TOUCHSENSE CALIBRATION The Touchsense feature gives the AVC 5 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 AVC 5 Control unit and is provided on the torch and work piece sense leads This voltage typically around 3 4VDC displayed on the AVC 5 Control unit front panel when the system is at idle shorted or brought down to nearly zero volts when the AVC 5 Control unit drives the tungsten into contact with the work piece When the AVC 5 Control unit senses the voltage is shorted indicating the tungsten is touching the work piece the AVC 5 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 circuit impedance of 10Q or greater In some cases the power source
22. cover CAUTION Remember to wire the high frequency protect assembly for the correct polarity whenever weld ing polarities change INTERFACING THE AVC 5 WITH OTHER EQUIPMENT When a remote interface cable is used between the customer s interface and the AVC 5 control unit sig nals can be triggered remotely to achieve various functions that would normally be done manually These remote signals interface with the AVC 5 control 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 5 Control Block Diagram on page 58 The following sections 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 AVC 5 control unit Make certain that all unused wires and shielding are insulated to pre vent any accidental contact with voltages pres ent 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 relay would typically be used to turn on a wire feeder a carriage assembly magnetic arc con trols etc Two sets of Form C contacts are provided These are capable of switching 10 amps 110VAC and are protected by 130V 10 Joule varistors A schematic of the relay outputs is shown in Figure 48 AVC 5 Remote Interface Cable Schematic and Figure 4
23. cycle This is useful as a troubleshooting tool particularly during initial setup This can also be accomplished by pressing the Lock out pushbutton on the front panel of the AVC 5 Con troller 55 EXAMPLE SYSTEM INTERFACE 201327 001 REV B 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 Power Source Section The welding power source should have additional out puts such as Voltage Feedback and Amperage Feed back These outputs can be used to display the actual welding amperage and welding voltage during a welding cycle Adding digital displays will require additional power supplies in the interface console to provide regulated voltages to these displays Keep in mind the AVC 5 and quite possibly the weld ing power source have digital readouts on them to in dicate actual welding voltage 56 201327 001 REV B SCHEMATICS AND BLOCK DIAGRAMS SCHEMATICS AND BLOCK DIAGRAMS Stepper Motor J1 P1 4 Protect PCB Assembly 1042 0041 AVC 5 Drive Assembly Compact HF Protect Junction Box Assembly gt gt EE x Ex asaf
24. inter face cables or on the drive assembly As soon as the arc is present the system goes imme diately into Start Delay indicated by flashing the arc voltage on the digital display During Start Delay the drive unit will not move to con trol arc voltage and the Up Down pushbuttons are in operative When Start Delay times out the digital 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 arc voltage falls outside the Automatic Voltage Sense Range after which Retract will occur Control 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 5 control can be halted momentarily or continuously by activat ing Lockout Lockout can be activated either through the Lockout Pushbutton on the front panel or via ei ther of the customer interface cables When Lockout is activated the Lockout LED above the Lockout pushbutton will turn On To de activate Lockout sim ply press the Lockout pushbutton or remove the Lock out input from either of the remote interface cables Two typical uses for the Lockout function are for am perage Downslope and for a Pulsed TIG welding In Pulsed TIG weldi
25. it needed The lid or cover of the enclosure where the switches and potentiometers are mounted can be used as a operator console This saves time in that the wiring and control switches etc are housed in one enclo sure and minimizes the possibility of grounding prob lems 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 TABLE 21 CARRIAGE CONTROL SETUP PARAMETERS PARAMETER SETTING Closure to Start Input Selection start carriage In order for this to function properly certain setup pa rameters in the AVC 5 DWF 3 4 and the welding power source must be performed Below is a list of such parameters Table 19 AVC 5 Setup Parameters Table 20 DWF 3 4 Setup Parameters Table 21 Carriage Control Setup Parameters 53 EXAMPLE SYSTEM INTERFACE 201327 001 REV B Table 22 Magnetic Arc Control Setup Parameters Table 23 Welding Power Source Setup Parameters Keep in mind each application is different and this list may need to be expanded upon to meet your needs TABLE 22 MAGNETIC ARC CONTROL SETUP PARAMETERS PARAMETER SETTING Model 80A or MA 20 Position 50 Amplitude 20 Left Dwell 10 Speed 10 Right Dwell 10 MA 20 Final Taper Time 3 seco
26. 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 5 Sense Lead TIG Torch Connection and Figure 10 AVC 5 Sense Lead Plasma Torch Connections for reference 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 5 system re quires 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 so 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 see Figure 12 AVC 5 Control Unit Mounting Di mensions on page 16 for reference Also be certain
27. 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 Pro tect LED illuminating Also be sure the work piece is secure As it may spring up when the AVC 5 drive backs off caus ing 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 de termine 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 oper ator must include enough time to accommodate pre purge time for the shielding gas 20 201327 001 REV B INSTALLATION INSTALLATION NOTE Figure 6 Interconnection Diagram on page 10 Illustrates a typical AVC 5 sys tem interconnection and should be used for r
28. that the unit has unrestricted air flow Connect the drive interface cable from the AVC 5 drive to the AVC 5 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 All 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 If 230VAC 50 60hz is to be used first switch the power selector switch on the bottom of the control unit to the 230VAC position The AVC 5 drive is wired for straight polarity If the op erator is using reverse polarity in the weld process then the AVC drive must be rewired to accommodate the reverse polarity This procedure is easily accomplished by following these steps Remove power to the drive unit 21 INSTALLATION 201327 001 REV B 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 the 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 Instructions are also printed on the board for refer ence Replace the cover using the hardware used when re moving the
29. the drive unit on the front panel or via remote in put will perform the same function START MODES There are two methods of starting an arc using the AVC 5 system i e 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 AVC 5 Micro Controller Board Layout on page 33 for the DIP switch location High Frequency Start High Frequency HF arc starts is the typical method of starting a TIG welding process The AVC 5 drive moves the torch and tungsten down to the work piece until it touches The AVC 5 Control senses that the S8 AC WELDING DC WELDING HIGH FREQ START LIFT START FIGURE 13 HF START MODE AND AC WELDING tungsten has touched the work piece and immediately drives up to the preselected Starting Arc Gap Once the desired gap has been reached the AVC 5 turns on the K1 relay The K1 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 Fig ure 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 5 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 5 goes immediately into Start Delay Mode to allow the arc to become establish
30. to the oper ator service personnel and or bystanders DANGER An operational procedure which if not fol lowed will cause severe injury or even death to the operator service personnel or bystanders gt gt gt SAFETY INFORMATION Safety is a combination of good judgment and proper training Operation and maintenance of any arc weld ing and cutting equipment involves potential hazards Individuals who are unfamiliar with cutting and weld ing equipment use faulty judgment or lack proper training may cause injury to themselves and others Personnel should be alerted to the following potential hazards and the safeguards necessary to avoid possi ble injury In addition before operating this equipment you should be aware of your employer s safety regula tions 2 SURE READ THIS MANUAL FORE INSTALLING OR USING THIS g EQUIPMENT BE SURE TO READ AND FOLLOW ALL AVAILABLE SAFETY REGULATIONS BE FORE USING THIS EQUIPMENT ELECTRIC SHOCK 2 THE VOLTAGES PRESENT IN THE D 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 Elec tric Code B Never allow live metal parts to touch bare skin or any wet clothing Use only dry gloves C When welding or cutting in a damp area
31. 18 19 47 51 53 coupling 3a RUNE service X31 Ca wem m Ed xk Lockout 6 17 18 22 24 26 47 55 5151 exa lug xii 6 31 32 47 i curren XII XIII See Also Troubleshooting M serviceable gt 0 1 D shield 05 Deadband 6 18 20 47 48 51 53 Mein board 31 47 51 Slide EA Delay 6 17 18 22 24 48 51 53 55 maintained CT source o coco s diagram 31 47 51 Maintenance 31 32 Specifications 6 8 9 diagrams gt 47 MAN xi Standard 4 6 9 11 22 42 43 60 61 3 4 17 19 23 51 manual xi 31 47 static electricity discharge ZEILE Downslope ee 18 54 Manual 8 31 Stroke Length Drive 9 851 Mode 7 17 18 20 22 24 47 49 53 55 Driver 47 48 51 52 momentary i duration 0 xiij motor Technicians s s 51 dust 31 32 N festpolhts w Theory gt s ok ow c E Non Standard 8 TIG 3 4 13 17 18 53 67 electrolytic 51 torch xi 32 Electro Magnetic Ir Interference 51 O Touch 6 23 24 47 48 EMI 45 wb ON 31 47 51 52 Touchsense amp 24 enclosure gt gt 4 6 31 51 output xiii Tracking 6 8 9 Equipment 3 16 travel xii 32 Example 65 P Troubleshooting 47 50 Exploded EP 32 36 42 44 ET Tungsten 3 6 20 48 51 53 55 F
32. 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 312X 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 X 1 1 4 FEK 9 1 000 EA 0600 0091 AVC OVERLAY PLATE 10 1 000 EA 0600 0224 DOOR amp HINGE AVC 5 CONTROL 12 1 000 EA 0600 0459 AVC 5 REMOTE INTRFC CABLE ASSY 13 1 000 EA 0600 0458 AVC 5 DRIVE CABLE ASSY 14 1 000 EA 0600 0104 AVC 5 MICROPROCESSOR BOARD ASY 15 5 000 EA 0600 0277 KNOB SMALL AP AUTOMATION 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 37 DRAWINGS AND PARTS LISTS 201327 001 REV B Power Switch A De w y wire FIGURE 35 POWER SWITCH ASSEMBLY EXPLODED VIEW TABLE 7 POWER SWITCH ASSEMBLY PARTS LIST P3 18 gauge 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 28V 4 1 000 EA 2208 0181 CONN RECT PLUG 8CKT 5 6 000 EA 2212 0018 TERMINAL CRIMP PIN 18 24 GA 38 201327 001 REV B DRAWINGS AND PARTS LISTS
33. 9 AVC 5 Auxiliary Remote Interface Cable Schematic beginning on page 62 LOCKOUT INPUTS The Lockout Modes are described in the previous section see Figure 22 AVC 5 Remote Lockout Re lay Figure 19 AVC 5 Remote Lockout Supply and Figure 24 AVC 5 Remote Lockout Two Supplies beginning on page 24 One input is provided for Lockout The inputs are optically isolated and require an input of 5 to 35VDC 12 5mA to be activated Special consideration needs to be given to input volt Lockout Signal D Blk f Wht Lockout Signal Power Supply Lockout Signal B Voltage is present when Lockout to be Enabled FIGURE 19 AVC 5 REMOTE LOCKOUT SUPPLY 22 201327 001 REV B INSTALLATION ages greater than 35V If your inputs are greater than 35V consult the factory for assistance It is also pos sible to operate the inputs with contact closures 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 supply is shown in Figure 19 AVC 5 Remote Lockout Sup ply and Figure 24 AVC 5 Remote Lockout Two Supplies Figure 22 AVC 5 Remote Lockout Re lay shows the same setup only with a power supply that provides contact closures rather than voltage out puts REMOTE SET POINT VOLTAGE INPUT The AVC 5 is capab
34. B INSTALLATION Pressed Start Button Up Controller Servo Down True Tungsten Touches the Work Arc Voltage Welding Power Source with Lift Arc Circuit Arc Amperage Lift Start Process Flow Adjusts Up and Down to track Voltage Tungsten is in Contact with the work Gas Preflow FIGURE 23 AVC 5 PROCESS TIMELINE EXAMPLE ONE 25 INSTALLATION 201327 001 REV B Lockout Signal D f Wht 7 K 14 Lockout Signal Lockout Signal B _ ie Downslope I Lockout Signal _ ie Low Pulse Voltage is present when Lockout to be Enabled FIGURE 24 AVC 5 REMOTE LOCKOUT TWO SUPPLIES e Bik Drive Up P Red Up Logic Ground Drive Down EN a d 2 FIGURE 25 AVC 5 REMOTE UP DOWN DRIVE 26 201327 001 REV B INSTALLATION Pressed Start Button Up Controller Servo Down True Tungsten Touches the Work Arc Voltage Welding Power Source Arc Amperage HF Start Process Flow Adjusts Up and Down to track Voltage Tungsten is in Contact with the Work Gas Preflow FIGURE 26 AVC 5 PROCESS TIMELINE EXAMPLE TWO 27 INSTALLATION 201327 001 REV B P5 Remote Mushroom Switch AN Drive Up P
35. Capability us Remote Inputs 1 gt Output to Remote 0 to 10V 2 2 0 to 10V Amperage Reference 3 Remote Common 4 Output Start 5 Gas Purge 6 Output Disable e 7 Chassis Ground 8 Final Slope Coll 9 Final Slope Em e 10 Pulse Lockout Coll e 11 Pulse Lockout Em e 12 Valid Arc Coll 13 Valid Arc Em 5 1 3 2 Carriage Control Start TB6 1 115 220 2 VAC LE 5 Magnetic Arc Control TB7 1 115 220 2 115 220VAC gt Models 60 70A PE 80A 90A or gt 1 A Inhibit h AP Automation EMEN sS Model MA 20 2 Inhibit Return 40 3 TB7 FIGURE 51 AVC 5 SYSTEM INTERFACE EXAMPLE CONT 65 SCHEMATICS AND BLOCK DIAGRAMS 201327 001 REV B 66 201327 001 REV B 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 5 and AVC 5 drive units and torch assembly Two ver sions 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 5 and AVC 5 drive unit and torch assembly DRIVE CABLE EXTENSION The Drive Cable Extension extends the cable be tween the drive unit and the contro
36. ECTIONS 15 DESCRIPTION OF EQUIPMENT 201327 001 REV B 918 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 5 CONTROL UNIT MOUNTING DIMENSIONS 16 201327 001 REV B OPERATION OPERATION GENERAL OPERATIONAL DESCRIPTION The AVC 5 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 continue to do so unless Lockout is activated or the arc is extinguished The following sections de scribe in detail the various modes of operation NOTE In all modes of operation the Up pushbuttons on
37. ER SOURCE 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 tion the AVC 5 energizes the K2 relay This relay is used to turn on the magnetic arc control system and the carriage control The DWF 3 4 has been given the start signal via the relay but since the DWF 3 4 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 5 and the Upslope time of the welding power source so that the wire begins at the time the welding power source reaches peak current and the AVC 5 begins tracking the arc voltage At this time the system is fully active welding is being performed the AVC 5 is tracking the arc voltage wire is being added to the weld pupple the part is being rotated or the torch is being moved depending upon your welding fixture and the magnetic arc control is oscillating the arc Stop Sequence The stop sequence is automated but requires the op erator to press the Process Stop pushbutton to begin the sequence Once the pushbutton has been pressed the welding power source no longer has a output start signal and begins do
38. ES 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 4 Cold Wire Feeder 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 AV C 5 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 Emergency Stop using a mushroom style switch Process Stop using a pushbutton switch The Emergency Stop switch stops the output amper age of the wel
39. EXAMPLE 64 FIGURE 51 AVC 5 SYSTEM INTERFACE EXAMPLE CONT 65 OPTIONAL EQUIPMENT 67 201327 001 REV B SAFETY SAFETY SAFETY PRECAUTIONS THIS MANUAL HAS BEEN DESIGNED FOR EXPE RIENCED WELDING AND CUTTING EQUIPMENT OPERATORS AND MUST BE READ COMPLETELY BEFORE USING THIS EQUIPMENT IF YOU LACK EXPERIENCE OR ARE UNFAMILIAR WITH THE PRACTICES AND SAFE OPERATION OF WELDING AND CUTTING EQUIPMENT PLEASE CONSULT YOUR FOREMAN DO NOT ATTEMPT TO INSTALL OPERATE OR PERFORM MAINTENANCE ON THIS EQUIPMENT UNLESS YOU ARE QUALIFIED AND HAVE READ AND UNDERSTOOD THIS MANUAL IF IN DOUBT ABOUT INSTALLING OR OPERATING THIS EQUIPMENT CONTACT YOUR DISTRIBUTOR OR THE CUSTOMER SERVICE DEPARTMENT OF ARC PRODUCTS DEFINITIONS Throughout this manual NOTE CAUTION WARNING and DANGER are inserted to call attention to particular information The methods used to identify these highlights and the purpose for which each is used are as follows Operational procedural and background in formation which aids the operator in the use of the machine helps the service personnel in the performance of maintenance and prevents damage to the equipment z gt m CAUTION An operational procedure which if not fol lowed may cause minor injury to the opera tor service personnel and or bystanders WARNING An operational procedure which if not fol lowed may cause severe injury
40. Exploded views of the drive assemblies beginning on page 42 in Figures 39 and 40and their parts lists in Tables 11 and 12 are provided to aid in parts ordering and replacement beginning on page 43 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 Pro
41. HSC SBZ 37 8 000 EA 970015 608 SCR 1 4 20X 62 HSC SBZ 38 4 000 EA 970015 520 SCR 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 EA 2410 0472 NUT LOCK CONDUIT 1 2INCH NOT SHOWN 43 201327 001 REV B DRAWINGS AND PARTS LISTS FIGURE 40 AVC 5 COMPACT DRIVE ASSEMBLY EXPLODED VIEW 44 201327 001 REV B DRAWINGS AND PARTS LISTS TABLE 12 AVC 5 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 10 334 202 047 SBZ 8 1 000 EA 930014 401 CONN CIRC BUSHING 220 ID 8 2 000 EA 974010 006 WSR SL 1 4 489 263 062 SBZ 9 1 000 EA 1050 0150 HOUSING 11 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
42. J5 and J6 y Ground Stud Ground Sense Lead Red Sense Lead AVC 5 Drive Torch Clamps Li n gt Electrode Workpiece Workpiece Sheilding Gas Earth Ground PE TIG or Plasma Welding Power Source FIGURE 6 INTERCONNECTION DIAGRAM 10 201327 001 REV B DESCRIPTION OF EQUIPMENT 2215 Direction nl of Travel Y FIGURE 7 AVC 5 STANDARD DRIVE ASSEMBLY MOUNTING DIMENSIONS 11 201327 001 REV B DESCRIPTION OF EQUIPMENT 301SHY3N 5 27 338 6330 29 X 82 3NN PZ 9L1 9 310H DNILNNOM 19310Hd A9Nanoaud 7VNINU3L Qv31 ISN3S HO8OJ FIGURE 8 AVC 5 COMPACT DRIVE ASSEMBLY MOUNTING DIMENSIONS 12 201327 001 REV B DESCRIPTION OF EQUIPMENT Red Sense Lead lt gt From AVC FIGURE 9 AVC 5 SENSE LEAD TIG TORCH CONNECTION DESCRIPTION OF EQUIPMENT 201327 001 REV B Red Sense Lead From AVC FIGURE 10 AVC 5 SENSE LEAD PLASMA TORCH CONNECTIONS 14 201327 001 REV B DESCRIPTION OF EQUIPMENT AVC Drive Cable Red Torch Sense Lead Work Piece Binding Post ANC Drive Junction Box Assembly AVC 5 Drive Top View FIGURE 11 AVC 5 DRIVE WORK PIECE CONN
43. MOTE VOLTAGE SET POINT INTERNAL VOLTAGE FIGURE 30 AVC 5 REMOTE VOLTAGE SET POINT EXTERNAL VOLTAGE MAINTENANCE DRAWINGS AND PARTS LISTS FIGURE 31 AVC 5 MICRO CONTROLLER BOARD LAYOUT FIGURE 32 AVC 5 POWER BOARD LAYOUT FIGURE 33 VOLTAGE SELECTOR SWITCH ASSEMBLY EXPLODED VIEW FIGURE 34 AVC 5 CONTROL EXPLODED VIEW FIGURE 35 POWER SWITCH ASSEMBLY EXPLODED VIEW FIGURE 36 TRANSFORMER ASSEMBLY EXPLODED VIEW FIGURE 37 AVC DRIVE CABLE ASSEMBLY EXPLODED VIEW FIGURE 38 AVC REMOTE INTERFACE CABLE EXPLODED VIEW FIGURE 39 AVC 5 STANDARD DRIVE ASSEMBLY EXPLODED VIEW FIGURE 40 AVC 5 COMPACT DRIVE ASSEMBLY EXPLODED VIEW FIGURE 41 AVC AUX REMOTE INTERFACE CABLE EXPLODED VIEW TROUBLESHOOTING FIGURE 42 AVC 5 SIGNAL FLOW CIRCUIT DESCRIPTIONS EXAMPLE SYSTEM INTERFACE TABLE OF FIGURES 201327 001 REV B SCHEMATICS AND BLOCK DIAGRAMS 57 FIGURE 43 AVC 5 COMPACT DRIVE BLOCK DIAGRAM 57 FIGURE 44 AVC 5 CONTROL BLOCK DIAGRAM 58 FIGURE 45 AVC 5 CONTROL BLOCK DIAGRAM CONT 59 FIGURE 46 AVC 5 STANDARD DRIVE BLOCK DIAGRAM 60 FIGURE 47 AVC 4 STANDARD DRIVE BLOCK DIAGRAM 61 FIGURE 48 AVC 5 REMOTE INTERFACE CABLE SCHEMATIC 62 FIGURE 49 AVC 5 AUXILIARY REMOTE INTERFACE CABLE SCHEMATIC 63 FIGURE 50 AVC 5 SYSTEM INTERFACE
44. anual DESCRIPTION OF EQUIPMENT 201327 001 REV B FIGURE 4 AVC 5 STANDARD DRIVE ASSEMBLY TABLE 3 AVC 5 STANDARD DRIVE ASSEMBLY SPECIFICATIONS 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 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 201327 001 REV B DESCRIPTION OF EQUIPMENT FIGURE 5 AVC 5 COMPACT DRIVE ASSEMBLY TABLE 4 AVC 5 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 Drive System Precision Ball Screw and Nut running on mi cro slides Drive Cable Standard Length 10 3 M Sense Lead Standard Length 3 1 M Weights 1 25 4 mm Drive Assembly 12 165 5 4 Kg 201327 001 REV B DESCRIPTION OF EQUIPMENT AVC 5 Control Input Power Earth Ground PE Drive Cable J4 Optional Remote Interface Cable s
45. ding power source and commands an up drive signal to the AVC 5 Arc Voltage Controller The Up drive signal to the AVC 5 during a welding cycle immediately de energizes both K1 and K2 re lays and thereby stops the remaining equipment inter faced in this example NOTE It is 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 on the welding power source 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 prevent wire from feeding during the entire welding cycle if de sired This can also be accomplished by turning off the DWF 3 4 or by selecting the Off position on the start switch on the front panel of the DWF 3 4 Arc Voltage Control Section An additional Lockout Switch could be installed to pro vide a means of preventing the AVC 5 from tracking the arc during a welding
46. ducts Sales and or Technical Service departments Part numbers for the AVC 5 system are given in the Draw ing and Parts Lists Section and should be used for or dering purposes Please consult this manual or contact Arc Products for further information 67 OPTIONAL EQUIPMENT 201327 001 REV B 68 201327 001 REV B INDEX INDEX IC xi xiii 6 8 9 47 Qualified 51 Integrated Circuits rt 47 input 21 Radio Fre quency Interference 51 Installation 21 30 A insulated xi d D adequate xii xiii Integrated Circuits 47 af 4 18 22 24 Adjustment gt 32 interface 51 Remote 6 7 23 24 26 28 29 41 46 49 51 Arc gt 3 6 7 17 20 31 48 51 53 56 67 emote Interface 64 53 55 62 63 Requirements 31 B J Retract 6 18 19 51 53 55 gt s s i Jog 6 REI 4 Jaa 7 C rod a P x E z xii K Cable 68 34 3247 K1 17 20 5455 camage xl K2 18 54 55 Safety Center cp oos ea 32 Information gt xi CMOS NNNM L Schedule 32 Compact 4 T 9 12 22 44 45 51 57 schematics 47 51 contamination gt 05 31 secondary s s 51 Continuously 48 2 Ge NS Cai ir 24683 liquid Selector 21 ontro 4 6 8 Sensitivity 6
47. e 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 ex ample 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 50VDC 52 201327 001 REV B EXAMPLE SYSTEM INTERFACE EXAMPLE SYSTEM INTERFACE AVC 5 SYSTEM INTERFACE EXAMPLE The following describes the design and interface in tent and the operation of the system of Figure 50 AVC 5 System Interface Example beginning on page 64 DESIGN INTENT The design intent of the example interface wiring of the AVC 5 and other equipment in the diagram is to provide a sample interface for typical TIG applications using an AVC 5 Arc Voltage Control System The ba sic components of the complete welding system is il lustrated in the diagram and include the following Welding Power Source with Automation Interface Capability Cyclomatic DWF 3 or AP Automation DWF 4 Cold Wire Feed System Cyclomatic Model 80A or an AP Automation MA 20 Magnetic Arc Control System An output connection for a carraige controller A
48. ect filter 10 or greater and cover plates to protect your eyes face neck and ears from the sparks and rays of the cutting welding arc when cutting welding or observing cut ting welding Warn bystanders not to watch the arc and not to expose themselves to the cutting welding arc rays or to hot metal B wear flameproof gauntlet type gloves a heavy long sleeve shirt cuff less trousers high topped shoes and a welding helmet or cap for hair protection to protect the skin from arc rays and hot sparks or hot metal C Protect other nearby personnel from arc rays and hot sparks with a suitable non flam mable partition D Always wear safety glasses or goggles when in a cutting or welding area Use safety glasses with side shields or goggles when chipping slag or grinding Chipped slag is hot and may travel a considerable distance By standers should also wear safety glasses or goggles E Compressed gas oylinders are potentially dangerous refer to the suppliers for proper handling procedures F wear ear plugs or other ear protection de vices when operating cutting or welding equip ment FIRE SAFETY HOT SLAG OR SPARKS CAN CAUSE A SERIOUS FIRE WHEN IN CONTACT WITH COMBUSTIBLE SOLIDS LIQUIDS OR GASES ye Move all combustible materials well away from the cutting area or completely cover ma terials with a non flammable covering Com bustible materials include but are not limited to wood clothing sawdust ga
49. ecting the maximum Deadband setting makes the AVC 5 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 5 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 AVC 5 control will correct the arc length to return the voltage back into the 3 volt win dow Burn Through Protection Feature Initiated 13 5V 1 5 Volt Deadband Window 11 5V Areveis 1 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 AVC 5 will correct for errors in the voltage when the voltage exceeds the 2 volt win dow 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 4 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 ful
50. ed 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 AN C 5 drive retracts away from the work piece This eliminates the AVC 5 Control from diving into the work piece which would normally happen when a burn though occurs The AVC 5 must then be reset to continue operation 19 OPERATION 201327 001 REV B NOTE The Burn Through Protection feature will follow 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 O to 09 inches To set the arc gap pre positioning the operator must select the desired gap length and manually drive the AVC 5 Drive head down until it touches the work piece at which time the AVC 5 Drive automatically backs off to the pre selected Start Arc Gap setting NOTE During Pre positioning the operator must hold down the Down
51. ed and stable before voltage tracking begins S8 DC WELDING HIGH FREQ START ES FIGURE 14 HF START MODE AND DC WELDING AC WELDING LIFT START Lift Start Lift Start is a process patent pending in which a 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 5 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 17 and Figure 16 Lift Start Start Mode and DC Welding on page 18 for DIP Switch Settings required for Lift Start Arc Starting in AC and DC Welding Modes S8 AC WELDING LIFT START FIGURE 15 LIFT START START MODE AND AC WELDING DC WELDING HIGH FREQ START 17 OPERATION 201327 001 REV B The advantage of using the Lift Start method com pared to the HF method of starting a TIG welding arc is that HF noise is not emitted from the area that could harm sensitive electronic equipment In addi tion the tungsten inclusion into the weld is reduced and even elimi
52. eference in the following installation instructions DRIVE ASSEMBLY MOUNTING Mount the AVC 5 drive unit to allow positioning of the weld torch above the weld joint Refer to Figure 7 AVC 5 Standard Drive Assembly Mounting Dimen sions on page 11 for the mounting hole pattern for the standard drive If a compact drive is to be used it co mes in two pieces the drive motor assembly and the high frequency protect unit For the compact drive as sembly see Figure 8 AVC 5 Compact Drive Assem bly Mounting Dimensions on page 12 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 5 drive should be mounted so that adequate space around the drive is provided to accommodate the various parameters of operation i 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 provided for this purpose The red sense lead must be connected to the conducting body of the torch A binding screw is
53. en Preheat Time set Time so that the power source begins on the AVC 5 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 5 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 e Adjust the Touchsense calibration as Touchsense Feature but does drive adjustment necessary page 24 up after the down drive signal is re moved Touchsense is out of calibration i e Adjust the Touchsense calibration un ao 122 drives LP the power source may have a low til the AVC 5 System stops driving up Problem 9 output impedance causing the AVC 5 page 24 to the voltage sense leads on the System to sense a short between the ANC Drive tungsten and the workpiece Not enough Start Delay Time seton Increase the Start Delay Time to allow the AVC 5 to allow for the arc to es the arc to become stable and to allow tablish and become stable Upslope of the welding amperage to complete Deadbandis set to narrow causing the Burn Through Protection Feature Increase the Deadband setting to be initiated Clockwise to prevent the Problem 10 AVC 5 Y bal shuts the arc as Starting Arc Gap
54. eter of the electrode and the type of material being welded This provides a smooth consistent arc start without tungsten inclusion The Lift Start feature is enabled by a DIP switch set ting on the micro controller board on the inside of the AN C 5 Control unit allowing easy selection DESCRIPTION OF EQUIPMENT 201327 001 REV B The AVC 5 controls AC welding as well as DC weld ing applications without any additional components 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 i e motor stepper drivers The three connectors located on the bottom of the unit provide for connection of the drive cable and two remote interface cables
55. from P S T Red Arc Established Signal from P S Common U Protect Arm d Logic Ground G Earth Ground PE F FIGURE 48 AVC 5 REMOTE INTERFACE CABLE SCHEMATIC 62 201327 001 REV B SCHEMATICS AND BLOCK DIAGRAMS P6 K1 B Contact o e Drive Up E gt Wht K1 B Common B e Drive Down D i K2 B Common o 5 Protect Arm H e Blu K2 B N O Contact J e lls Yel K2 B N C Contact L e Blk e M Brn o J Grn K1 B N C Contact C Red Logic Ground o Earth Ground PE F FIGURE 49 AVC 5 AUXILIARY REMOTE INTERFACE CABLE SCHEMATIC 63 SCHEMATICS AND BLOCK DIAGRAMS 201327 001 REV B DyvF 4 Control 20VDC Out Remote Remote ut art art 5 5 inhibit Inhibit Forward Jog Digital Ground Reverse Jog Pot Reference Wire Feed Ref viper Analog Ground 5 Control Remo Protec Down Dri Logi Output Lockout Sig Output Re K1 B K1 B Common K1 B K2 B e Set a Set A ou Drive DC nal O Con C Con Coni um nal act K2 B Common K2 B C Con Drive Up act Logic Ground Down Drive Protect Arm Upper Section be mounted away from Junction Box to accommodate a remate console using Sheilded Cable Cold W
56. hsense 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 Touchsense calibration needs drive assembly adjustment Adjust the Touchsense Calibration as necessary page 24 47 TROUBLESHOOTING 201327 001 REV B PROBLEM DESCRIPTION CAUSE SOLUTION System is set for the wrong Mode Verify the AVC 5 System is set up for i e Welding with DC and AVC 5 the correct welding mode AVC 5 System doesn t track or show or AC Mode Or vice versa Check the sense leads are securely Problem 6 voltage on the front panel while Sense leads not connected or are connected wedling Bose Verfiy the Voltage Preset is set be Voltage Preset is improperly set tween 5 to 50VDC while pressing the Preset button e 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 5 to account for prepurge to include the gas pre purge and to and tungsten preheat causing the allow approximately 2 seconds of T AVC 5 to drive up before the power Tungsten Pre Heat as a starting Problem 7 The arc doesn t start using Lift Start source starts producing Lift Start point Mode on the AVC 5 System amperage Decrease the Tungsten Pre Heat Too much Tungst
57. iisssis 55 A fat A Z 4 I 414 ze 4 4 lt FIGURE 43 AVC 5 COMPACT DRIVE BLOCK DIAGRAM 57 SCHEMATICS AND BLOCK DIAGRAMS 201327 001 REV B Power Switch S1 uf 5 Micro Controller Board Assembly Org To Wht Yel 717 5 o 2 s 55 Wht Pan 44 mo 33 o 220 Wht 111 P2 J2 Blu 5 5 66 10110 11111 1242 3113 14 Red R m 5 BE a lt 10 16 20 18 14 14 Secondary 2 110 110 Primary E lt 22 Voltage Selector 52 Red 6 6 CN ub 5 25 g s Ke 220 2 1 110 ug 4 4 3 2a 1 WE Wht 11 96 Fi EMI RFI Bik Or a2 White L Filter X 7322 9 4 Black N Wht 313 Green Gm 110 230VAC FE 60 50Hz 5 Power Board Assembly PE Chassis Ground Stud FIGURE 44 AVC 5 CONTROL BLOCK DIAGRAM 58 201327 001 REV B SCHEMATICS AND BLOCK DIAGRAMS 6
58. impedance may be greater which re quire no adjustment to the AVC 5 Control unit Other power sources having an impedance of less than 10Q do require adjustments to the Touchsense circuit indicated by the AVC 5 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 Touchsense Calibration R22 10 With all of the equipment installed and the AVC 5 connected to the welding power source adjust this potentiometer until the AV 5 Drive just stops driving then turn the potenti ometer one half turn counter clockwise While calibrating the Touchsense circuit or anytime the AVC 5 system is at idle pressing and holding the Start Delay and Voltage Preset buttons the AVC 5 front panel will display the Touchsense calibration set ting in DC volts This displayed voltage indicates the voltage a short circuit between the tungsten and the work piece must go below to accurately sense a short or a Touch This is useful in troubleshooting the AVC 5 in the initial setup or when a different weld ing power source is used N C we Contacts of a Relay or Switch Um Red Output Voltage i Wht Lockout Signal B Bik Output Voltage Lockout Signal D N O FIGURE 22 AVC 5 REMOTE LOCKOUT RELAY 24 201327 001 REV
59. in Welding and Cutting B Bulletin No F4 1 Recommended Safe Practices for the Preparation for Welding and Cutting Containers and Piping that have held Hazardous Substances C OSHA Safety and Health Standards 29CFR 1910 available from the United States Department of Labor Washington DC 20210 D NFPA Standard 51B Fire Prevention in Use of Cutting and Welding Processes avail able from the National Fire Protection Associ ation 470 Atlantic Avenue Boston MA 00210 NEMA Standards Publication No EW1 1989 Electric Arc Welding Apparatus approved as ANSI C87 1 1989 Available from xiii SAFETY 201327 001 REV B National Electrical Manufacturers Association 155 E 44th Street New York NY 10017 201327 001 REV B AVC Arc Voltage Control System 201327 001 REV B 201327 001 REV B DESCRIPTION OF EQUIPMENT DESCRIPTION OF EQUIPMENT The AP Automation AVC 5 Arc Voltage Control sys tem is a precision microprocessor controlled arc volt age control unit for use with the Gas Tungsten Arc Welding process GTAW also known as TIG 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 Au tomatic corrections 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 fea
60. 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 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 Welding Torch Shown i Arc i Voltage Arc Length 1 Weld Puddle FIGURE 1 ARC VOLTAGE CONTROL THEORY 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 3 ARC VOLTAGE CONTROL SYSTEM The AVC 5 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 AVC 5 system is our pat ented Lift Start process The AVC 5 will start an arc without any High Frequency using a welding power Source with a touch start or Lift Arc an ITW trade mark starting process The feature enables reliable automated non High Frequency HF arc starting on all metals The AVC 5 commands the torch to touch the work piece then tungsten is preheated for an adjustable time unique to the diam
61. ions to move the torch up or down in order to keep the actual arc voltage at the desired voltage pre set by the operator If the actual arc voltage drops be low the preset voltage the Micro controller drive the torch upward until the actual arc voltage is at the de sired voltage level Likewise if the actual arc voltage goes up the AVC 5 will drive downward to keep the actual arc voltage at the desired level The actual arc voltage is brought to the micro control ler through the Power board through several filters to reject noise and to steady the typically erractic arc voltage The voltage is also scaled down to an ac 51 CIRCUIT DESCRIPTIONS 201327 001 REV B ceptable 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 preset se lected by the operator and decisions are made main tain the desired arc voltage 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 pulses the motor in a certain pattern to drive the rotate the motor clockwise or counter clockwise depending upon th
62. ire Feeder For Rev Wire Feed Speed Arc Voltage Set Point Arc Voltage Control Protect Arm Dn Pulse Inhibit Disable Shown Opt al k x aae x l gt LO 2 m P3 ul DAT Cn B gt P5 a O CO Cn co 0 P6 TES TOC AIDE voltage supply does not exceed 104DC FIGURE 50 AVC 5 SYSTEM INTERFACE EXAMPLE This resistor and Zener Diode is used to scale the voltage to the potentiometer so that the 64 201327 001 REV B SCHEMATICS AND BLOCK DIAGRAMS es M Process Control ET sg Power Source EM Stop Stop Switch Gas Switch Opt Maintained Amperage Purge No _ N C pi E NC E di O ql pee Welding Power Source 1718 1920 212223 242526 __ 272829 50 31 w Automation Interface N
63. is set to high caus mon Feature 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 DESCRIPTION VALUES TP A DESCRIPTION VALUES U18 11 12 VDC 12 VDC 40 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 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 48 201327 001 REV B TROUBLESHOOTING TABLE 18 VOLTAGE PRESET SELECTION TABLE 17 RECOMMENDED SPARE PARTS S1 POS PANEL MODE REMOTE MODE ITEM PART DESCRIPTION 1 OFF ON 1 2 1373 3041 Fuse 2 Amps 2 ON OFF 2 1 2100 0086 Power Lamp 3 1 0600 0304 5 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 Power Board Panel Circuit
64. l unit The maxi mum cable length is 80 feet NOTE There are several cable extension lengths available Please consult the factory for more information regarding the cable length needed for your specific application MAGNETIC ARC CONTROL SYSTEMS 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 can increase grain refinement of the base and filler mate rial Contact Arc Products Sales or Technical Service departments for additional information and assistance in the proper selection of components COLD WIRE FEED SYSTEMS Cold Wire Feed Systems offered by Arc Products Au tomation provide reliable accurate delivery of filler wire to the weld puddle Offered in two styles a stan dard and a compact version the systems are capable of delivering up to 300 ipm of filler wire from sizes of 020 to 062 Contact Arc Products Sales or Techni cal Service departments for additional information and assistance in the proper selection of components ORDERING INFORMATION Arc Products manufactures a variety of equipment for use in automatic welding processes and manufac tures turn key automated welding systems for a broad range of applications Detailed information and litera ture may be obtained by consulting Arc Pro
65. le of having the set point voltage Set by an external voltage supplied from other equip ment rather than from the front panel potentiometer To use the Remote Set Point mode it must first be se lected using the DIP Switch S1 inside the unit on the Micro controller board see Figure 31 AVC 5 Mi cro Controller Board Layout on page 33 for DIP switch locations and Figure 21 Panel Voltage Preset DIP Switch Selection and Figure 20 Remote Voltage Pre set DIP Switch Selection beginning on page 23 This DIP Switch has two positions and they must be posi tioned so that only one is in the On position NOTE Both DIP Switches must not be set in the same position i 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 REMOTE VOLTAGE SELECT ONE PANEL VOLTAGE PRESET 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 resultant set point voltage will be 0 to 50VDC of actual welding arc voltage The formula fpr scaling the input voltage is as follows Preset Volts Desired Arc Volts X 2 If the input voltage is not from 0 to 10VDC you may need to adjust the scaling
66. ly Counterclockwise sets the Sensitivity to minimum Likewise adjusting the Sensi tivity clockwise sets it to maximum A compromise should be made when using the Sensi tivity setting Setting the Sensitivity to maximum will cause the AVC 5 system to overcompensate for arc voltage errors causing erratic type drive movement which can be detrimental to the weld Setting this fea ture to minimum can also have ill effects on the weld by causing the AVC 5 system to be sluggish in re sponse to arc voltage errors In setting up the AVC 5 system for the first time it is 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 5 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 feature is initiated the AVC 5 system will stop tracking the arc voltage go into Retract mode and then into Manual mode To utilize this feature proper electrical interfacing with the welding power source is requir
67. nated using this method compared to scratch starting the arc using the tungsten electrode S8 AC WELDING m DC WELDING HIGH FREQ START m LIFT START FIGURE 16 LIFT START START MODE AND DC WELDING AUTOMATIC MANUAL MODES Manual mode The manual mode of operation is in effect whenever the torch voltage is outside the voltage range of oper ation of 5 to 50VDC 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 Voltage Sense Range of 5 50VDC which indicates that an arc is present Prior to the arc voltage coming into range the AVC 5 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 assembly is pressed the AVC 5 will reset back to the manual mode of operation NOTE This is important to note for the AVC 5 to reset and the arc to extinguished the AVC 5 must control the contactor of the power source This Up drive signal can be used to act as a stop sig nal again on the front panel the remote
68. nd a 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 TABLE 19 AVC 5 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 From there additional wiring installed by the customer would be used to interconnect the descrete compo nents of the system e welding power source mag netic arc controller etc TABLE 20 DWF 3 4 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 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
69. nds Inhibit Final Taper Input Signal set Normally Open Start Sequence To start the system be sure the above parameters are Set properly To start the welding process press the AVC 5 Drive Down pushbutton on the console until the AVC 5 drives the torch down to the work piece and the tungsten makes contact The Protect Arm LED on the AVC 5 front panel will light At this time the AVC 5 s K1 relay is energized turning on the welding power source and giving the start sig nal to the DWF 3 4 wire feeder because of start delay on the DWF 3 4 wire feeding doesn t start until the time expires The power source starts pre purge and then Lift Arc output current The AVC 5 has also be gan the Tungten Preheat timer Once the Tungsten Preheat timer has expired the AVC 5 control drives the torch up momentarily until an arc is established After the arc is established the AVC 5 immediately starts the Start Delay Timer The welding power Source 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 5 and the weld ing power source s Upslope timer have completed the welding power source has reached peak welding amperage The AVC 5 begins tracking the arc volt age keeping the voltage at the desired level In addi TABLE 23 WELDING POW
70. ng the AVC 5 would be disabled or locked out during the low pulse so that the AVC 5 will only track the voltage of the high pulse In Downsloping of the welding amperage at the end of the welding cycle the AVC 5 should be locked out to prevent the AVC 5 system from correcting for the volt age decreasing during the Downslope process It may also be desirable to be able to manually Lock out the AVC 5 during setup and initial installation 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 5 operation The user can select the desired parameters depending on the welding pro cess requirements These parameters are selected 18 201327 001 REV B OPERATION using 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 1 volt to 1 5 volts This window is considered an acceptable error of voltage by the AVC 5 Control system and sel
71. ntrol ON but nothing works the control unit Power Driver Board voltages are not Check Power Driver Board voltage present 12VDC Drive may be at its stroke limits Jog the drive in the opposite direction Drive be binding due to too much Remove weight from the drive Problem 3 Drive assembly doesn t drive up or weight on the drive assembly assembly down in Manual Mode only Mounting hardware or other obstruc Verify drive is free and clear to move tion is interfering with the drive up and down movement Deaband and Sensitivity Adjustments Adjust Deadband and Sensitivity set are not set properly tings to a more accurate setting i e Lockout is Enabled Lockout LEDis 5nd Sensitivity more Clockwigs Lit System doesnt ack Detection hasbeen in ress a ceca Button Disable 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 Sen sitivity 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 E AC Welding and Figure 14 HF Start is contaminated or the Mode and DC Welding on page 17 AVC 5 System doesn t preform a Clean the tungsten and workpiece as Problem 5 starting arc gap i e Touc
72. of the voltage measured by the controller to achieve a reading of 0 to 50VDC on the front panel This is accomplished by adjusting the potentiometer R26 labeled REM while the remote input voltage signal is present WARNING The Remote Preset Voltage input must be present at the AVC 5 Control prior to the AVC 5 receiving the Drive Down signal for Touch Sense to occur NOTE No other calibrations inside the control is re quired by the operator except the R22 Trim pot labeled Touchsense Calibration S1 ni REMOTE VOLTAGE PRESET SELECT ONE EX PANEL VOLTAGE PRESET Shown in Panel Voltage Preset Mode FIGURE 21 PANEL VOLTAGE PRESET DIP SWITCH SELECTION 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 NOTE The set point range is limited to 5 to 50V If a re mote set point voltage and scale factor are cho sen 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 5 The AVC 5 System will not function operated in this manner 23 INSTALLATION 201327 001 REV B SYSTEM VISUAL CHECK Before operation begins verify that all system inter
73. parts list rt AT U BE xi xiii 6 8 9 factory 22 222 31 periodic uu Upslope 48 54 faulty gt lt s 9 Xi Plasma 3 4 14 55 67 V Field Power 6 7 31 34 38 47 49 51 53 55 56 fuse holder gt 4 31 power switch os 4 31 Vies x 5454 5 p e 49 Precautions xi voltage 47 51 G Pre heat 51 ground xi xiii 51 Preset 23 24 48 49 51 53 55 W se ee 3 Weights 8 primary 51 l m 4 ds sa a x Problem 47 48 2 do f de dom 34 Programmable Logic Controllers xiii ing held xiii 31 32 Protect 6 19 20 47 48 54 55 HF 6 17 18 20 24 47 53 Pulse 18 54 55 Z zero N E 24 69 rc Products Lincoln Electric Company ARC PRODUCTS INC 1245 30TH STREET SAN DIEGO CA 92154 3477 619 628 1022 619 628 1028 FAX sales arc products com service arc products com www ap automation com www arc products com 201237 001 Rev B September 2011
74. per Function Holds the torch firmly to the drive assembly Test Clean dirt from bracket and torch Check the torch to be sure it is held tight If not tighten bolts that hold the torch to the bracket 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 32 201327 001 REV B DRAWINGS AND PARTS LISTS DRAWINGS AND PARTS LISTS TREO HOMO DL Ee e _ sa ss TI ta Ces 0 0 ie siga E m CE 3578 IS a BLASHA CUTTING OC HELA HG LIFT START E 2002 Arc Products Diego LEA UEL DING HIGH FREG START REMOTE LOLTAGE PEESET PANEL PRESET 10 2002 G24 ppp 10 0 ne E E Ti TER Pal br atian P N 0600 0105 Rev Microcontroller Board Assembly P N 0600 0104 Rev A
75. place defective assemblies or parts Service personnel employed by the user should be fa miliar with electrical and electronic equipment or else service problems should be corrected by factory au thorized representatives CONTROL UNIT ASSEMBLY The control unit assembly see Figure 34 AVC 5 Control Exploded View and Table 6 AVC 5 Control Parts List beginning on page 36 consists of an enclo sure 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 caution in oper ating the unit if it has been inadvertently exposed to excessive dust or liquid contamination since such conditions may cause electrical shorting and or mal functioning of the electrical electronics assemblies The user should consult with the factory if such condi tions have occurred Repair of the control unit assem bly is generally limited to a remove and replace 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 war ranty WARNING When repairing the control unit assembly disconnect A C power from the unit be fore opening the access door and turn the po
76. r Board Layout on page 34 is a drawing 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 illustrates very simply the flow of signals in the AVC 5 control system The Power board contains control circuitry for the sys tem and also performs primary input voltage and con trol voltage regulation Input voltage to the control unit is supplied to the Power board through a fuse and Radio Frequency Interference and Electro Magnetic Interference RFI EMI filter and voltage selector switch mounted on the bottom of the enclosure The system will operate from 110 220 VAC 50 60 Hz at less than 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 sec ondaries at 14VAC a 16VAC secondary winding a 18VAC 31VAC tapped secondary and a 10VAC sec ondary winding used for the Microcontroller board discussed later beginning on page 51 The voltage is rectified on the board and filtered through electrolytic capacitors The resultant 40VDC and 25VDC is used as the source voltage for the motor driver circuit All voltages are referenced to power ground at C41 minus side
77. rc Voltage Control Board FIGURE 31 AVC 5 MICRO CONTROLLER BOARD LAYOUT 33 201327 001 REV B DRAWINGS AND PARTS LISTS 619 222 22 23 12 512 mu 02 ZI 022952 4559 3NIYO 129 4012313S 39917100 Il 282 259 482 052 680 1 8 071 310434 S zu gt 2 y E 071 310438 XhV 1 n ZA is n 5 s s 5 D 2 o o S 3 8 gt sl ia Z c 5 5 gt gt D RT p 8 SO NS Wu 10 sa T T F azien E 60 2 2 a pe Ir 2002 11 Y ASH EOTO 0090 N d p4eog Sr vr 10 0 212 AZZ 3 zit 1 Su WYO JSNU gt 1908 HAUUO ASNUUL 301 0701 8 e HOLIMS Y3M0d Ca Lu 912 x m EE 2 i a 922 Or 10 0 0 0 O O0 E ES DL is 72 ST i r 2 3272 r w 272 3 yd 2s za 9 0 0 255 PI 42 055 cS med I a N O F o X 614 9 2 914 301 070001 218 EH dh zz 0 zs Co Q nd 1070 n 855 al 301 622 d 618 396 hy T Bed 41767022 P n 058 62 N ron dc q 24 29 _ tt gt say ron 95 LI VOOFNT 091 929 1 2010 0090 N d hIquessy 4 4enog 1943409 Day FIGURE 32
78. rements 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 V Max in DC Welding Min to 1 5 V 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 in Start Delay 0 0 to 12 5 sec Burn Through Detection 2 0 Voltage above Pre Set Voltage initiates 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 201327 001 REV B DESCRIPTION OF EQUIPMENT FIGURE 3 AVC 5 SYSTEM COMPONENTS DESCRIPTION PART MODELS Control Unit 0600 0101 AVC 5 Arc Voltage Control 0600 0009 Standard AVC 5 6 Drive Assembly Drive Assembly Or Or 1040 0031 Compact AVC 5 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 5 Operators and Service M
79. soline kerosene paints solvents natural gases acetylene pro pane and similar articles B Do not weld cut or perform other hot work on used barrels drums tanks or other con tainers until they have been completely cleaned There must be no substances in the container which might produce flammable or toxic vapors C For fire protection have suitable extin guishing equipment handy for instant use WELDING AND CUTTING FUMES AND GASES PARTICULARLY IN CONFINED SPACES CAN CAUSE DISCOMFORT AND PHYSICAL HARM IF INHALED OVER AN EXTENDED PERIOD OF TIME At all times provide adequate ventilation in the welding and cutting area by either natural or mechanical means Do not weld or cut on galvanized zinc lead beryllium or cadmium materials unless positive mechanical ventila tion is provided to prevent inhaling fumes and gases from these materials B Do not weld or cut in locations close to chlorinated hydrocarbon vapors coming from degreasing or spraying operations The heat of arc rays can react with solvent vapors to form phosgene a highly toxic gas and other irritant gases you develop momentary eye nose throat irritation during welding or cutting it is an indication that the ventilation is not ade quate Stop work and take the necessary steps to improve ventilation in the welding or cutting area Do not continue to weld or cut if physical discomfort persists D Use an air supplied respirator if
80. t of other user serviceable items is to be performed according to normal maintenance and re pair standards usually involving the removal of mounting hardware unplugging the old part subassembly mounting the replacement part and reconnecting 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 cable 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 mainte nance 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 31 MAINTENANCE 201327 001 REV B 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
81. tures designed into the AVC 5 Arc Voltage Control system makes it a truly innovative product suited to the customer s needs ARC VOLTAGE CONTROL THEORY The Arc Products Automation AVC 5 Arc Voltage Control System or other arc voltage length controls 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 i e the and sense leads As current increases or decreases through the resis tor or component the voltage drop across also in creases or decreases proportionately Likewise in a welding arc if the arc length increases i e the torch moving away from the work piece the arc voltage also increases 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 AVC 5 system also measures the voltage across a resistor at two points In the AVC 5 system s case the resistor is a welding 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 5 system measures the volt age 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
82. ventilation is not adequate to remove all fumes and gases E Beware of gas leaks Welding or cutting gases containing argon are denser than air and will replace air when used in confined spaces Do not locate gas cylinders in con fined spaces When not in use shut OFF the gas supply at its source Refer to AWS Standard 749 1 for specific ventilation recommendations 201327 001 REV B SAFETY ADDITIONAL SAFETY HAZARDS FIRE AND EXPLOSION ta Fire and Explosion can result from placing units on over or near combustible surfaces Do not install units on over or near com bustible surfaces Do not install unit near flammables FALLING EQUIPMENT Falling Equipment can cause serious per sonal injury and equipment damage Use lifting eyes to lift unit only not running gear gas cylinders or any other accesso ries Use equipment of adequate capacity to lift units If using fork lifts to move units be sure forks are long enough to extend beyond opposite side of the unit HOT PARTS Hot parts can cause severe burns TIKAN R Do not touch hot parts bare handed Allow cooling period before working on gun or torch MOVING PARTS Moving Parts can cause injury Keep away from moving parts such as fans Keep all doors panels covers and guards closed and securely in place Keep away from pinch points such as me chanical slides drive rolls carriage
83. wer switch OFF Assemblies and parts which are authorized for user replacement are listed in Table 6 AVC 5 Control Parts List on page 37 Replacement should be per formed after the user has determined that the part or assembly to be replaced is the cause of a system problem see Troubleshooting on page 47 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 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 con nection 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 enclo sure standoffs may result Replacemen
84. wnsloping the amperage for the preset time of 3 5 seconds As the welding power source downslopes a lockout signal is provided to the AVC 5 to prevent the torch from moving during the amperage downslope and for the remainder of the weld cycle until the arc extinguished 54 201327 001 REV B EXAMPLE SYSTEM INTERFACE In addition the Remote Start signal to the DWF 3 4 has been removed and stops feeding wire If you d like wire to feed during a portion of this time set the Stop Delay Timer to a time less than the welding power source s downslope timer The Model 80A Magnetic Arc Control system is also stopped from oscillating the arc Ifthe MA 20 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 5 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 extinguishes the AVC 5 de energizes both the K1 amp K2 relays The carriage stops and upon the AVC 5 retract feature completing the system resets and is ready to begin again Before 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 FEATUR

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