Tweco HMC-410 Manuel d'utilisateur

888IPM120VAC5060HzHMC-410Version No: AA.02 Issue Date: July 27, 2005 Manual #: 430429-445Operating Features:Art # A-04355AUTOMATIC &SEMI-A

HMC-4101-4July 27, 2005 WARNINGEngines can be dangerous. WARNINGENGINE EXHAUST GASES can kill.Engines produce harmful exhaust gases.1. Use equipm

HMC-410A-10July 27, 2005APPENDIX 6: SYSTEM OUTLINE 1 OF 2OUTLINE, SYSTEMHMC-410NONE1 OF 2FULLTLT DBB 8-14-97170921S1 8-14-97TLT TLT 1-16-92DWG DTD1-16

HMC-410July 27, 2005A-11APPENDIX 7: SYSTEM OUTLINE 2 OF 2OUTLINE, SYSTEMHMC-410NONE2FULLTLT DBB 8-14-97170921S2 8-14-97TLT TLT 1-16-92DWG DTD1-16-9215

Thermadyne USA82 Benning StreetWest Lebanon, NH 03784 USATelephone: (603) 298-5711800-752-7621Fax: 800-221-4401Email: [email protected]

World HeadquartersThermadyne Holdings CorporationSuite 300, 16052 Swingley Ridge RoadSt. Louis, MO 63017Telephone: (636) 728-3000Fascimile: (636) 728

HMC-4101-5July 27, 2005 WARNINGThis product, when used for welding orcutting, produces fumes or gases whichcontain chemicals know to the State ofCa

HMC-4101-6July 27, 20051.03 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC MISE EN GARDELE SOUDAGE A L’ARC EST DANGEREUXPROTEGEZ-VOUS, AINSI QUE LES

HMC-4101-7July 27, 200510.N’utilisez qu’une bonne prise de masse pour la mise àla terre de la pièce à souder.11.Ne touchez pas à l’électrode lorsqu’en

HMC-4101-8July 27, 20051. Eloignez la tête des fumées pour éviter de les respirer.2. A l’intérieur, assurez-vous que l’aire de soudage estbien ventilé

HMC-4101-9July 27, 2005 AVERTISSEMENTLES BOUTEILLES ENDOMMAGEES PEUVENTEXPLOSERLes bouteilles contiennent des gaz protecteurssous haute pression. De

HMC-4101-10July 27, 20054. Pour empêcher un démarrage accidentel pendantl’entretien, débranchez le câble d’accumulateur à laborne négative.5. N’approc

HMC-4101-11July 27, 20051.06 DECLARATION OF CONFORMITYManufacturer: Thermadyne CorporationAddress: 82 Benning StreetWest Lebanon, New Hampshire 03784U

HMC-4101-12July 27, 20051.07 LIMITED WARRANTYLIMITED WARRANTY: Thermal Arc®, Inc., A Thermadyne Company, hereafter, “Thermal Arc” warrants to customer

HMC-410July 27, 20052-1SECTION 2:INTRODUCTION2.01 How To Use This ManualThis Owner’s Manual applies to just specification or partnumbers listed on pag

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Arc product. We are proudto have you as our customer and will strive to provide you wi

HMC-4102-2July 27, 20052.04 Symbol ChartNote that only some of these symbols will appear on your model.Gas Tungsten Arc Welding (GTAW)Air Carbon Arc C

HMC-410July 27, 20052-32.05 General InformationThe HMC-410 is an automatic/semiautomatic controlpanel capable of precisely controlling a power source(

HMC-4102-4July 27, 2005Features BenefitsA. Provides input voltage compensationB. Provides current limit to the motorC. Provides overcurrent shutdownA.

HMC-410July 27, 20052-5Art # A-04356Figure 2-1A: Semiautomatic Configuration

HMC-4102-6July 27, 2005Art # A-04357Figure 2-1B: Automatic Configuration

HMC-410July 27, 20052-7Art # A-04358Figure 2-2: Front Panel ControlsNOTEIf the PSC softswitch is off, this LED will notlight. Refer to the Operation -

HMC-4102-8July 27, 2005NOTERefer to the Operation - Softswitch Descrip-tion chapter of this manual.13.LOWER DISPLAY — This display shows numericalinfo

HMC-410July 27, 20052-917.POWER ON/OFF SWITCH — This switch controls onlythe control panel and not the power source (weldingmachine). It is used as an

HMC-4102-10July 27, 200535.ERROR LED—When lit, the control panel has detectedan error. Refer to the Operation - Operational Faultssection of this manu

HMC-410July 27, 20052-112.08 Rear Panel ConnectionsRefer to Figure 2-3 for details.373839Remote Pendant(See HMC-410 AccessoriesAnd Option Descriptions

WARNINGSRead and understand this entire Manual and your employer’s safety practices before installing,operating, or servicing the equipment.While the

HMC-4102-12July 27, 2005Art # A-04360Figure 2-4: Fixture Electrical InterfacePin A (Purge Input) —If connected to Pin H, the controlpanel will allow t

HMC-410July 27, 20052-132.09 Power Source Interface DescriptionThe power source interface is used to supply operating power to the control panel and f

HMC-4102-14July 27, 20052.10 Hardware DescriptionThe HMC-410 is comprised of five major subassemblies.Each subassembly provides a distinct function, a

HMC-410July 27, 20052-15Push-buttonsLEDsNumeric DisplaysEncodersArt # A-04362Figure 2-6: Control/Display PCB Assembly

HMC-4102-16July 27, 2005Power Supply/Motor Control PCB Assembly(Refer to Figure 2-7)The Power Supply/Motor Control PCB Assembly (PS/MCBoard) has two f

HMC-410July 27, 20052-17THIS PAGE INTENTIONALLY LEFT BLANK

HMC-4102-18July 27, 2005Controller PCB Assembly(Refer to Figure 2-8)The Controller PCB Assembly (controller) is the maincontrol for the panel. It coll

HMC-410July 27, 20052-19Art # A-04364Figure 2-8: Controller Board Test Points and Jumpers

HMC-4102-20July 27, 2005Controller Board DIP SwitchThese switches will normally be set to the open position.All of these functions are controllable fr

HMC-410July 27, 20052-21FrontViewBackViewArt # A-04365Figure 2-10: Interface/Suppressor PCB Assembly

TABLE OF CONTENTSSECTION 1:SAFETY INSTRUCTIONS AND WARNINGS ... 1-11.01 Arc Welding Hazards ...

HMC-4102-22July 27, 2005

HMC-410July 27, 20053-1SECTION 3:INSTALLATION3.01 LocationWhen selecting an installation site, take care to avoidlocations exposed to high ambient tem

HMC-4103-2July 27, 20053.05 GroundingThe case of the HMC-410 control should be grounded forpersonnel safety. Where grounding is mandatory understate o

HMC-410July 27, 20054-1SECTION 4:OPERATIONThis chapter is organized to guide the user from setup, topower up, and to start up. The first section will

HMC-4104-2July 27, 2005Display Feature Description SettingsUPS, User Password The user’s password is programmed into UPS. The 0 TO 999 17+SPS Setting/

HMC-410July 27, 20054-3SoftwareDashDisplay Feature Description Settings NumberADJ Trim Enable This setting controls the ability of a user to change hi

HMC-4104-4July 27, 2005SoftwareDashDisplay Feature Description Settings NumberAHR Arc Hour When this switch is in the ON position, the Arc Hour Timer

HMC-410July 27, 20054-5SoftwareDashDisplay Feature Description Settings NumberBBE Burnback This setting may be ON or OFF. If ON, the system will opera

HMC-4104-6July 27, 2005SoftwareDashDisplay Feature Description Settings NumberROB Robotic This mode selects a robotic interface configuration as follo

HMC-410July 27, 20054-7SoftwareDashDisplay Feature Description Settings NumberNAR Arc Counter This softswitch enables a mode for the 410 where the 410

TABLE OF CONTENTS (continued)TABLE OF CONTENTSSECTION 5:SERVICE ...

HMC-4104-8July 27, 2005For the Random Schedule Enable feature, use the following table for selecting the correct schedule:Random Select 2(Auxiliary E

HMC-410July 27, 20054-9SoftwareDashNumber Feature Description-17 Wire Jogging The wire jog setting has been eliminated from the softswitches, but is s

HMC-4104-10July 27, 20054.03 System SetupIn order to properly utilize the HMC-410 control panel, itmust be configured correctly for the application an

HMC-410July 27, 20054-11Arc-Master Arc-Master Power Power Semi-autoSelection 350/500 351/501 Ultra Flex Fabstar 4030 Excel-Arc Master 500 Master 500P

HMC-4104-12July 27, 20054.04 HMC-410 Setup ChecklistRefer to Table 4-4Controller BoardJumpersA JP2 — Power Source Control Voltage Polarity ___B JP3 —

HMC-410July 27, 20054-134.05 ProgrammingProgramming for the HMC-410 is the process of settingweld parameters into long term memory for each weldschedu

HMC-4104-14July 27, 2005Cycle — one execution of a weld scheduleSchedule — collection of weld parameters describing a weld procedureSCHEDULESUB

HMC-410July 27, 20054-15Crater fillCrater fill is normally used to reduce heat input to thework and to fill the crater which is typically left at thet

HMC-4104-16July 27, 20054.06 SetupBefore attempting to operate this system, read andcarefully follow instructions in the manuals for the HMC-410, weld

HMC-410July 27, 20054-174.07 OperationThe HMC-410 may be used in an automatic orsemiautomatic welding configuration. Because of thedifferent requireme

TABLE OF CONTENTSAPPENDIX 6: SYSTEM OUTLINE 1 OF 2 ... A-10APPENDIX 7: SYSTEM OUTLINE 2 OF

HMC-4104-18July 27, 2005executing tries to advance to a segment that is OFF or isin the fourth sub segment, execution passes to the firstsub segment.T

HMC-410July 27, 20054-19Spot Hold Operation — Recycle count isprogrammed to oneTrigger pull and release through the first second of theweld segment (o

HMC-4104-20July 27, 2005

HMC-410May 5, 20055-1SECTION 5:SERVICE5.01 MaintenanceThe HMC-410 requires periodic maintenance to maximizeits life. The frequency of repairs given sh

HMC-4105-2July 27, 20055.04 Troubleshooting GuideA. Controller will not power up1. Power source is not turned on.a. Turn on the power source.2. Interc

HMC-410May 5, 20055-3E. No wire feed speed control, but programmingappears to be correct.1. Tachometer failure. The normal symptom of tachfailure is t

HMC-4105-4July 27, 2005H. Gas valve is stuck on or off.1. Interconnecting cable between control panel andfeedhead may have a bad connection or shortci

HMC-410May 5, 20055-5N. Auxiliary relays do not function.1. Interconnecting cable between control panel andfixture may have a bad connection or short

HMC-4105-6July 27, 20055.05 DiagnosticsEach test described in this section is selected in one oftwo ways: (1) with the DIP switch on the controller bo

HMC-410May 5, 20055-75.06 Built In Test (BIT) DefinitionSwitch Position1=OPEN, 0=CLOSEDTest No. Name Description SSSSSSSS123456781 POWER SOURCE The Po

HMC-4101-1July 27, 20051.01 Arc Welding Hazards WARNINGELECTRIC SHOCK can kill.Touching live electrical parts can cause fatalshocks or severe burns.

HMC-4105-8July 27, 2005Switch Position1=OPEN, 0=CLOSEDTest No. Name Description SSSSSSSS1234567826 DISPLAY LED17 LED17 (amps) is turned ON. 0010110027

HMC-410May 5, 20055-9Switch Position1=OPEN, 0=CLOSEDTest No. Name Description SSSSSSSS1234567844 Display Remote Stop Display B will display the state

HMC-4105-10July 27, 2005

HMC-410July 27, 20056-1SECTION 6:ACCESSORIES AND OPTIONDESCRIPTIONS6.01 Remote Pendant DescriptionThe remote pendant is an option for remote controlop

HMC-4106-2July 27, 20056.04 Control Cables:These control cables are used from the HMC-410 to thepower source, and for the HMC-410 to the feedhead, thu

HMC-410July 27, 20056-36.06 171238-19 Software KitsThe 171238-19 Software Kit has the following additional features (beyond all of the features descri

HMC-4106-4July 27, 20056.08 870236 Robotic Interface Kits870236-001 ABB Robotic Interface KitThis kit includes the components required to allow the HM

HMC-410July 27, 20056-56.09 870236-002 Fanuc Robotic Interface KitThis kit includes the components required to allow the HMC-410 to plug into the 37 p

HMC-4106-6July 27, 20056.10 870236-003 Comau Robotic Interface KitThis kit includes the components required to allow the HMC-410 to plug into the 64 p

HMC-410July 27, 20056-76.11 Other Available Options1. Wire Spool Kit 8700582. Wire Reel Kit 8700593. Wire Reel / Spool Support Assembly 870060-0014.

HMC-4101-2July 27, 200511.Do not touch electrode while in contact with the work(ground) circuit.12.Use only well-maintained equipment. Repair or repla

HMC-4106-8July 27, 2005

HMC-410July 27, 20057-1SECTION 7:GLOSSARYArc Established — A signal generated by the powersource indicating that an arc is struck from the wire tothe

HMC-4107-2July 27, 2005Multi Sub Segment Operation — This type of operationallows the weld parameters to automatically change duringa weld without sto

HMC-410July 27, 20058-1SECTION 8:PARTS LIST8.01 Equipment IdentificationAll identification numbers as described in the Introductionchapter must be fur

HMC-4108-2July 27, 20058.03 Parts List for the Control Box Assembly (1 of 2)ItemItemItemItemItemPartPartPartPartPartDescriptionDescriptionDescriptionD

HMC-410July 27, 20058-3Art # A-04370Figure 8-1: Control Box Assembly

HMC-4108-4July 27, 20058.03 Parts List for the Control Box Assembly (2 of 2)ItemItemItemItemItemPartPartPartPartPartDescriptionDescriptionDescriptionD

HMC-410July 27, 20058-5Art # A-04370Figure 8-1 Control Box Assembly

HMC-4108-6July 27, 20058.04 Parts List for the Remote PendantItemItemItemItemItemPartPartPartPartPartDescriptionDescriptionDescriptionDescriptionDescr

HMC-410July 27, 20058-7Art # A-04470Figure 8-2: Remote Pendant

HMC-4101-3July 27, 20056. Do not weld in locations near degreasing, cleaning, orspraying operations. The heat and rays of the arc canreact with vapors

HMC-4108-8July 27, 2005

HMC-410July 27, 2005A-1APPENDIX 1: GENERAL INFORMATION• Note the model and specification number shown on the equipment nameplate.• Locate these number

HMC-410A-2July 27, 2005APPENDIX 2: SCHEMATIC DIAGRAM 1 OF 4J2123456789101112131415161718DIGITAL +5 VDCTACH. SIGNAL+15 VDC UNREG.EXT. COM.EXT. +15 VDCG

HMC-410July 27, 2005A-3DIAGRAM, CONNECTION & SCHEMATICHMC-410NONE1 OF 4FULLATC DBB 11-3-99870241S1 11-3-99ATC ATC 11-3-99130TECH. PUB.870241DIGITA

HMC-410A-4July 27, 2005APPENDIX 3: SCHEMATIC DIAGRAM 2 OF 4J2123456789101112131415161718DIGITAL +5 VDCTACH. SIGNAL+15 VDC UNREG.EXT. COM.EXT. +15 VDCG

HMC-410July 27, 2005A-5DIAGRAM, CONNECTION & SCHEMATICHMC-410NONE1 OF 4FULLATC DBB 11-3-99870241S1 11-3-99ATC ATC 11-3-99130TECH. PUB.870241DIGITA

HMC-410A-6July 27, 2005APPENDIX 4: SCHEMATIC DIAGRAM 3 OF 4SEE SHEETS 1 AND 2 FOR STANDARD UNIT.OPTIONAL (ROBOTIC INTERFACE OPTIONS SHOWN ONLY)8J2121

HMC-410July 27, 2005A-7DIAGRAM, CONNECTION & SCHEMATICHMC-410 (W/ ROBOTIC INTERFACE OPTIONS)NONE3FULLATC DBB 11-3-99870241S3 11-3-99ATC ATC 11-3-9

HMC-410A-8July 27, 2005APPENDIX 5: SCHEMATIC DIAGRAM 4 OF 42928273130OPTIONAL (ROBOTIC INTERFACE OPTIONS SHOWN ONLY)SEE SHEETS 1 AND 2 FOR STANDARD U

HMC-410July 27, 2005A-9DIAGRAM, CONNECTION & SCHEMATICHMC-410 (W/ ROBOTIC INTERFACE OPTIONS)NONE4FULLATC DBB 11-3-99870241S4 11-3-99ATC ATC 11-3-9