ESAB ABB Pulse Analog Interface Robotic Interface Instruction manual

ABB PULSE ANALOG INTERFACE

ROBOTIC INTERFACE

F-15-151-B

September, 2000

APPLICATION:
MIG AND PULSE MIG WELDING

ROBOT ANALOG INT P/N
ABB RI-1P PULSE 34380

INSTRUCTION MANUAL

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation
and safe practices for arc welding equipment, we urge you to read our booklet, "Precautions and Safe Practices
for Arc Welding, Cutting, and Gouging", Form 52-529. Do NOT permit untrained persons to install, operate, or
maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully
understand these instructions. If you do not fully understand these instructions, contact your supplier for
further information. Be sure to read the Safety Precautions (Section I) before installing or operating this
equipment.

Be sure this information reaches the operator.
You can get extra copies through your supplier.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels
and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts
that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or
replacement become necessary, the manufacturer recommends that a telephone or written request for service advice
be made to the Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user
of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty
maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility
designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 SAFETY ................................................................................................................................... 3

SECTION 2 DESCRIPTION ........................................................................................................................ 7

2.1 Introduction .............................................................................................................................. 7

2.2 Description ............................................................................................................................... 7

SECTION 3 EQUIPMENT............................................................................................................................ 8

3.1 Equipment Required................................................................................................................. 8

3.2 Optional Accessories ............................................................................................................... 9

SECTION 4 OPERATION .......................................................................................................................... 10

4.1 Mounting/Connecting Equipment ........................................................................................... 10

4.2 Control/Indicators ................................................................................................................... 10

4.3 Operation ............................................................................................................................... 11

SECTION 5 TROUBLESHOOTING .......................................................................................................... 15

5.1 Introduction ............................................................................................................................ 15

5.2 Troubleshooting Guide ........................................................................................................... 15

5.3 Diagnostic Mode .................................................................................................................... 18

5.4 Hot Start Adjustment .............................................................................................................. 18

SECTION 6 REPLACEMENT PARTS ....................................................................................................... 21

6.1 General .................................................................................................................................. 21

Parts....................................................................................................................................... 22

2

SAFETY PRECAUTIONS

WARNING: These Safety Precautions are for

your protection. They summarize precaution­ary information from the references listed in

Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.

PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip­ment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work

area, even if welding helmets, face shields, and goggles
are also required.

2. Use a face shield fitted with the correct filter and cover

plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeve

shirt, cuffless trousers, high-topped shoes, and a weld­ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing

5. Protect other personnel from arc rays and hot sparks

with a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or

grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex­plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non­flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or

crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“

3. Do not weld, cut or perform other hot work until the

workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro­duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,

such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.

5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.

6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces­sary.

7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro­cesses", available from the National Fire Protection Asso­ciation, Batterymarch Park, Quincy, MA 02269.

ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move­ment is confined, or if there is danger of
falling.

1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.

2. Connect the workpiece to a good electrical ground.

3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.

4. Use well-maintained equipment. Replace worn or dam­aged cables.

5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from
work and from ground.

7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mis­take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow­ing through any conductor causes lo­calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre­ates EMF around welding cables and
welding machines. Therefore:

1. Welders having pacemakers should consult their physi­cian before welding. EMF may interfere with some pace­makers.

2. Exposure to EMF may have other health effects which are
unknown.

3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure

them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work

cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as

possible to the area being welded.
E. Keep welding power source and cables as far away

from your body as possible.

3

10/98

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.
Therefore:

1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless posi­tive mechanical ventilation is provided. Do not breathe
fumes from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im­prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.

5. WARNING: This product, when used for welding or

cutting, produces fumes or gases which
contain chemicals known to the State of
California to cause birth defects and, in
some cases, cancer. (California Health &

Safety Code

CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin­der, valve, or relief device can injure or
kill. Therefore:

1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu­lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.

§25249.5 et seq.)

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

1. Always have qualified personnel perform the installa­tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.

2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.

3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do not
operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position
and in good repair.

6. Use equipment only for its intended purpose. Do not
modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec­tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.

The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Mi­ami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

5. AWS C5.5 - "Recommended Practices for Gas Tung­sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."

MEANING OF SYMBOLS - As used through­out this manual: Means Attention! Be Alert!
Your safety is involved.

Means immediate hazards which, if
not avoided, will result in immediate,
serious personal injury or loss of life.

Means potential hazards which could
result in personal injury or loss of life.

Means hazards which could result in
minor personal injury.

4

SP98-10

PRÉCAUTIONS DE SÉCURITÉ

AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.

1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:

a. Portez un écran facial adéquat muni des plaques

protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.

AVERTISSEZ les personnes se trouvant à proximité

de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.

b. Portez des gants ignifugés à crispins, une tunique

épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.

c. Les étincelles ou les projections de métal incandes-

cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.

d. Protégez des étincelles et du rayonnement de l’arc

électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.

e. Ne jamais omettre de porter des lunettes de sécurité

lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.

f. Le gougeage à l’arc et le soudage à l’arc au plasma

produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.

2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:

a. Éloigner suffisamment tous les matériaux combus-

tibles du secteur où l’on exécute des soudures ou des
coupes à l’arc, à moins de les recouvrir complètement
d’une bâche non-inflammable. Ce type de matériaux
comprend notamment le bois, les vêtements, la sciure,
l’essence, le kérosène, les peintures, les solvants, le
gaz naturel, l’acétylène, le propane et autres sub­stances combustibles semblables.

b. Les étincelles ou les projections de métal incandes-

cent peuvent tomber dans des fissures du plancher ou
dans des ouvertures des murs et y déclencher une
ignition lente cachée. Veiller à protéger ces ouvertures
des étincelles et des projections de métal.

c. N’exécutez pas de soudures, de coupes, d’opérations

de gougeage ou autres travaux à chaud à la surface
de barils, bidons, réservoirs ou autres contenants
usagés, avant de les avoir nettoyés de toute trace de
substance susceptible de produire des vapeurs
inflammables ou toxiques.

d. En vue d’assurer la prévention des incendies, il

convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur portatif.

e. Une fois le travail à l’arc terminé, inspectez le secteur

de façon à vous assurer qu’aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
ultérieurement un feu.

3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.

a. Ne laissez jamais de surfaces métalliques sous ten-

sion venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.

b. Si vous devez effectuer un travail sur une surface

métallique ou dans un secteur humide, veillez à assu­rer votre isolation corporelle en portant des gants secs
et des chaussures à semelles de caoutchouc et en
vous tenant sur une planche ou une plate-forme
sèche.

c. Mettez toujours à la terre le poste de soudage/coupage

en le reliant par un câble à une bonne prise de terre.

d. N’utilisez jamais de câbles usés ou endommagés. Ne

surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.

e. Mettez l’équipement hors tension lorsqu’il n’est pas en

service. une mise à la masse accidentelle peut en effet
provoquer une surchauffe de l’équipement et un dan­ger d’incendie. Ne pas enrouler ou passer le câble
autour d’une partie quelconque du corps.

f. Vérifiez si le câble de masse est bien relié à la pièce en

un point aussi proche que possible de la zone de
travail. Le branchement des câbles de masse à
l’ossature du bâtiment ou en un point éloigné de la
zone de travail augmente en effet le risque de pas­sage d’un courant de sortie par des chaînes delevage

5

9/97

des câbles de grue ou divers chemins électriques.

g. Empêchez l’apparition de toute humidité, notamment

sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.

4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des mal­aises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:

a. Assurez en permanence une aération adéquate de

l’emplacement de travail en maintenant une ventila­tion naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.

b. N’effectuez jamais de travaux de soudage ou de

coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et d’autres
gaz irritants, à partir des vapeurs de solvant.

c. Une irritation momentanée des yeux, du nez ou de la

gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtez­vous de travailler afin de prendre les mesures néces­saires à l’amélioration de la ventilation. Ne poursuivez
pas l’opération entreprise si le malaise persiste.

d. Certaines commandes comportent des canalisations

où circule de l’hydrogène. L’armoire de commande est
munie d’un ventilateur destiné à empêcher la forma­tion de poches d’hydrogène, lesquelles présentent un
danger d’explosion; ce ventilateur ne fonctionne que
si l’interrupteur correspondant du panneau avant se
trouve placé en position ON (Marche). Veillez à
manœuvrer cette commande en vérifiant si le
couvercle est bien en place, de façon à assurer
l’efficacité de la ventilation ainsi réalisée. Ne jamais
débrancher le ventilateur.

e. Les fumées produites par l’opération de soudage ou

de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un dispositif
adéquat de ventilation de type aspirant, afin d’élimi­ner du voisinage de l’opérateur tout dégagement de
fumée visible.

f. Consultez les recommandations particulières en

matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.

5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner des

dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:

a. Efforcez-vous de toujours confier à un personnel qua-

lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.

b. Ne procédez jamais à une tâche d’entretien

quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.

c. Maintenez en bon état de fonctionnement les câbles,

le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il présente
une défectuosité quelconque.

d. Prenez soin du poste de soudage et de coupage et des

équipements accessoires. Gardez-les à l’écart des
sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri des
traces d’huile ou de graisse, des atmosphères corro­sives et des intempéries.

e. Laissez en place tous les dispositifs de sécurité et tous

les panneaux de l’armoire de commande en veillant à
les garder en bon état.

f. Utilisez le poste de soudage/coupage conformément à

son usage prévu et n’effectuez aucune modification.

6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--

Pour obtenir des informations complémentaires sur les

règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret N°
52529 “Precautions and Safe Practices for Arc Weld­ing, Cutting and Gouging” publié par ESAB. Nous
conseillons également de consulter les publications
sui-vantes, tenues à votre disposition par l’American
Welding Society, 550 N.W. LeJuene Road, Miami, FL
32126:

a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc

Welding “AWS A6. 1.

c. “Safe Practices for Welding and Cutting Containers

That Have Held Combustibles” AWS-A6.0.

d. “Recommended Safe Practices for Plasma Arc Cutting”

AWS-A6. 3.

e. “Recommended Safe Practices for Plasma Arc Weld-

ing” AWS-C5. 1.

f. “Recommended Safe Practices for Air Carbon Arc

Gouging and Cutting” AWS-C5. 3.

g. “Code For Safety in Welding and Cutting”

CSA-Standard W117. 2.

9/97

6

SECTION 2

DESCRIPTION

2.1 INTRODUCTION

The Analog Interface is a state-of-the art microproces­sor control designed to interface with robot computer
controllers using analog-system programming. Wire
diameter and material are manually set by the operator.
After wire feed speed is determined, the Analog Inter­face utilizes a pre-programmed relationship between
wire diameter/material and wire feed speed/arc voltage
to establish arc voltage for the selected wire diameter
and material. Since pulsed MIG welding is predomi­nantly used, arc voltage is usually determined by the
frequency of the pulses as well as the pulse amplitude
and width. For additional general information, refer to
Table 2-1, Specifications.

Table 2-1. Specifications

Input Requirements 115 V ac, 7 A,

50/60 Hz, 1 PH

Height 15.5 in. (394 mm)

Dimensions

Weight (approximate) 20 lbs (9.1 kg)

Depth 8 in. (200 mm)

Width 13 in. (330 mm)

2.2 DESCRIPTION

Operation of the Analog Interface begins when logic
inputs from the robot controller are received at the Logic
Interface (L/I) board through connector J3. These
signals control the initiation and termination of the
welding process as well as individual functions such as
purge and wire feed. Simultaneous application of the
JOG, CONTACTOR, and GAS PURGE signals (collec­tively known as the "start" signal) initiates welding.
Through the use of optocouplers within the L/I board,
the logic inputs are isolated from the robot for safety and
then sent to the MPU board for processing. The MPU
consists of D-A converters, counters, timers, and other
processing circuits used to analyze and respond to
most interface inputs. The L/I board also contains
twelve LEDs to indicate which inputs and outputs have
been enabled. This greatly enhances troubleshooting
efficiency by allowing the technician to determine
whether the fault is within the robot controller (no inputs)
or the Analog Interface (no outputs).

quest) signal from the robot controller. First, the robot
controller enables the TOUCH REQ input to the L/I
board. This causes the Current Detector board to
supply a +20 V dc bias voltage to the weld wire. When
the wire comes into contact with the workpiece, a short
circuit is formed and the WIRE CONTACT LED will
illuminate as a signal is fed back to the robot to signify
this contact.

The robot controller regulates power source voltage
levels and wire feed speed by sending two analog
signals (in the range of 0-10 V dc) to the Analog
Interface (A/I) board at the same time the "start" signal
is applied. Port 22 of the A/I board controls the wire feed
speed, and Port 21 controls arc voltage via the MPU
board. Since these signals are referenced to the robot's
common when received, their reference must be
changed to the Analog Interface's common before
processing can begin. This changeover occurs in the
A/I board. An 8-bit A-D converter is then used to
produce a digital output (0-250) from these analog
signals. After being sent to the MPU for processing, this
digital input is multiplied by four to obtain a 0-1000 range
(corresponding to the robot's 0-10 V dc input). A similar
process is used to compute the arc voltage.

Wire feed speed is controlled by a full-wave SCR bridge
located on the "J" Governor board. Pulses from the
Tachometer Board, located behind the wire feed motor,
are continuously sent to the MPU board as a reference
to monitor motor speed. The MPU board then counts
these pulses and regulates wire feed speed by sending
a reference signal (0-10 V dc) to the "J" Governor board
via the I/O board. The I/O board provides reference
signals (0 - 10 V dc) to the power source and logic
signals to operate the gas solenoid and contactor as
well.

Arc voltage from connector J6 is filtered in the I/O board
before being sent to the MPU for comparison with the
analog signal from the robot.

Background current for the welding arc is adjustable
between 15 and 100 A. This current level is controlled
by a D-A converter in the I/O board responding to
commands from the MPU.

All incoming signals to the Analog Interface are filtered
by the filter board.

Before welding, the robot may need to determine its
relative position to the workpiece. This is accomplished
by a process utilizing the TOUCH REQ (Touch Re-

7

SECTION 3

EQUIPMENT

3.1 EQUIPMENT REQUIRED

A. Analog Interface ........................................ 34380

B. EH-10A Digital Welding Head (20-999 ipm). Each

model includes motor w/gear box, accessory sup­port and tach feedback unit

1. EH-10AD Plug on Housing .......... 0558001535

2. Motor Ext. Cable, 25-ft ........................ 996808

3. Motor Ext. Cable, 3-ft, ......................... 000107

4. Accessory Support, 2-Roll Drive ...........49V51

5. Accessory Support, 4-Roll Drive ......... 600216

6. Insulator Ring ....................................... 60N90

C. Feed rolls, outlet guides and other wire feed acces-

sories for wire sizes and types that will be used.

(See Table 3-1; Feed Rolls and Outlet Guides)

D. DIGIPULSE 450 Power Source or other suitable

power source

E. A control cable (J1-welding control to power source

cable):

1. 30-ft, 19-cond w/19-pin Amphenols ....... 30780

2. 60-ft, 19-cond w/19-pin Amphenols ....... 30781

3. 6-ft, 19-cond w/19-pin Amphenols......... 30686

F. A robot torch and accessories with capacity rated

for your application.

I. Voltage pickup lead (J6-Interface Control to torch);

provides accurate arc voltage feedback to the

Control, 25-ft, 1-cond. cable ...................... 34070

J. Plumbing box:

1. Paddle wheel flow switch w/flow sight

indicator ............................................... 34158

2. Standard flow switch ............................ 34159

K. Plumbing box control cable (J4-Interface to plumb-

ing box; 3-ft, 6-cond) ................................. 34199

25-ft., 6-cond. ................................ 34845

L. Wire Inlet Guide (provided in Accessory Pkg. P/N

504245) .................................................... 11N53

Table 3-1. Feed Rolls and Outlet Guides

Wire Size

In (mm)

Soft

.035 (.9)
3/64 (1.2)
1/16 (1.6)

Hard

.035 (.9)
.045 (1.2)
.052 (1.3)
1/16 (1.6)

Two Roll Drive

Feed Roll

2075304(U)
2075301(U)+
2075298

2075303(V)
2075302(V)
2075330(V)
2075299(V)

Four Roll Drive
Feed Roll Kit*

999321(U)
999322(U)
999323(U)

999326(V)
999327(V)
999328(V)
999329(V)

Outlet
Guide

29N13**
29N13**
29N13**

993860
39N15
39N15
39N15

G. Gas control equipment:

1. R-5007 inert gas regulator/flowmeter. 998124

2. R-5008 CO2 regulator/flowmeter ........ 998125

3. 12.5-ft standard duty gas hose ............ 40V77

4. 25-ft standard duty gas hose ............... 34V38

5. 12.5 ft heavy duty gas hose ................. 19416

6. 25-ft heavy duty gas hose .................... 19415

(use heavy duty hose for CO2 gas)

7. Gas Hose Coupler .............................. 11N17

H. When using a water cooled torch, some of the

following items may be required to supply and drain
the cooling water:

1. 12.5 ft water hose ................................40V76

2. 25-ft water hose ................................. 406196

3. Water Hose Coupling ......................... 11N18

4. Water Adaptor, connects 5/8-18 (LH) hose to

1/4 NTP hose ..................................... 11N16

Cored Hard

.035 (.9)
.045 (1.2)
.052 (1.3)
1/16 (1.6)

U = U-groove V = V-groove Serr. = serrated

19761 (Serr.)
19761 (Serr.)
2075261 (Serr.)
2075261 (Serr.)

999330 (Serr.)
999331 (Serr.)
999332 (Serr.)

*Includes a center wire guide and 2 upper and 2 lower
feed rolls.

**Requires outlet guide insert as follows:

For .035 wire use 993902.
For 3/64 wire use 05N57.

For 1/16 wire use 12N57.
+Recommend U-Groove Pressure Roll 2075346 be
used.

8

993860
39N15
39N15
39N15

SECTION 3

EQUIPMENT

3.2 OPTIONAL ACCESSORIES

The following may be utilized to enhance performance
of the Analog Interface:

Torch Saver II; flow switch plus water filter assembled

to protect water cooled torch against coolant loss,

3/8 gpm .....................................................40V51

Torch Coolant Recirculator;

WC-5B, 115 V ac, 60 Hz ........................... 19947

WC-8B vertical, 115 V ac, 60 Hz, upright .. 30743

Wire Straightener; 3-roll adjustable ............... 34V74

Digital Ammeter Kit ....................................... 34560

Wire Wiper Accessory, effectively cleans and lubri-

cates wire:

Felt Wiper, pkg. of 10 .............................. 598537

Wiper Holder, mounts to outlet guide ...... 598764

Wiper Holder, used w/opt. wire

straightener ............................................. 598763

Wire Support Equipment; mount to fixture to hold wire

coils or spools:

Spindle Support Arm ............................... 634288

Spindle Assembly, mounts to Arm .......... 948259

Standard Wire Reel, hold 65 lbs coils ..... 995570

H.D. Wire Reel, holds 65 lbs coils ............. 19V89

Spool Enclosure Kit, covers

12-in spools ............................................ 600240

9

SECTION 4

OPERATION

4.1 MOUNTING/CONNECTING EQUIP­MENT

For interconnection information on the Analog Interface
with all required and/or optional accessories, see Fig­ures 4-1.

Since the operating controls for the Analog Interface
are located on and behind the front cover, the box
should be positioned within easy reach of the robot
operator. The control is designed to be mounted on a
vertical surface on or near the robot using the mounting
holes provided.

Additional connections and/or adjustments can be found
as follows:

• Torch connections are provided in their re­spective instruction booklets.

• Installing feed rolls and wire spools, and ad­justing the accessory support cable can be
found in the Digital Welding Head booklet F­12-873.

seconds, after which time it will switch over to
the preset speed. To increase or decrease this
preset speed, use the INC-DEC key under the
IPM window while the motor is running and the
speed value is displayed.

4. SETUP-WEAVE SETUP-RUN Select Switch.
This three-position rotary switch is only used
for robot control operation, and provides three
modes; Run, Setup, and Weave functions.
This switch should always be placed in its RUN
position for the actual robot welding sequence.

5. Digital Readout Windows. Three individual 3­digit windows labeled AMPS (optional amme­ter), IPM and VOLTS are provided to display
actual welding current, preset or actual weld­ing parameters (wire feed speed and welding
voltage) and time parameters as follows:

NOTE

The numbers displayed prior to application of the "start"
signal represent reference values. The numbers dis­played after application show actual measured values.

4.2 CONTROLS/INDICATORS

A. Front Panel Controls/Indicators (refer to Figure

4-2).

1. POWER Switch. This switch applies 115 V ac
power as indicated by light on switch.

2. PURGE/RESET Switch. A momentary "on"
switch, this switch provides a dual function
when actuated:

a. Prior to starting the welding sequence, it

actuates the gas solenoid and lets the
operator "purge" the shielding gas line of
the torch.

b. After starting the welding sequence - if an

abort "shutdown" condition occurs (indi­cated by flashing digital display), the Purge/
Reset switch can be actuated and the
control will automatically "reset".

3. JOG Switch. This switch is used to feed the
wire in the forward direction without actuating
the welding power source. If held down, the
wire feed speed will be 50 IPM for the first 2

a. AMP Digital Readout. This window is

normally blank unless the optional Amme­ter Kit is provided to monitor actual welding
current. When installed, the window dis­plays dc current (AMPS) in a range from 0­999 amps in one amp increments.

b. IPM Digital Readout. This window is pri-

marily used to display wire feed speed
from 20 to 999 inches per minute in one
inch increments. However, with the appro­priate function selector actuated, this win­dow can also display the following:

-- a code number indicating the type of
material which is programmed; for
example, 1 indicates steel; 3 is alumi­num; 5 is stainless; and 6 is silicon
bronze, etc.

-- cold wire inch speed from 20 to 999
inches per minute in one-inch incre­ments

c. VOLTS Digital Readout. This window is

primarily used to display arc voltage in
VOLTS from 12 to 50 V dc in one tenth volt

10

SECTION 4

increments. However, with the appropri­ate toggle selector actuated, this window
can also display the following:

-- a number indicating the wire diameter

-- the arc voltage indicates the com-

size; for example, 35 indicates .035"
dia., 45 is .045" dia., and 63 is .063"
dia. (1/16" dia.)

puted arc voltage for a given wire
speed. The computed arc voltage can
be readjusted +/-10 volts to fine tune
the welding arc.

OPERATION

Table 4-1.

Recommended Shielding Gas

Wire Material Welding Arc Mode

Code # Type Short Arc Spray Arc Pulse Arc

1
2
3
4
5
6
7*
8*
9*
10*

Carbon Steel
Alternate Stl.
4043 Aluminum
5356 Aluminum
308 Stainless
Silicon Bronze
Inconel 82

CO2/C25
C-25

-

­A1025

-

C-5/C-8
Stargon/C-8
Argon
Argon
1%/2%O2
Argon

C-5
Stargon/C-5
Argon
Argon
Pulse SS
Argon

9. NO PROGRAM (LED) Light will illuminate only
if you select a wire type (Material) and size
(Diameter) that is not programmed in the con­trol. In addition, if the light is on, the wire feeder
and power source are disabled.

10. Input/Output Robot Function (LED) Lights will
indicate the specific function(s) being used at
the appropriate time in a welding sequence.

A. INPUTS FROM ROBOT: CONTACTOR,

SHORT ARC, GAS PURGE, SPRAY, JOG,
and TOUCH REQ.

B. OUTPUTS TO ROBOT: ARC EST,

ABORT, and WIRE CONTACT.

11. Circuit Breaker. A 7 ampere circuit breaker
provides protection to the 115 volt control cir­cuit and the wire feed motor. If an overload
occurs, the breaker will trip and suspend all
operation. To restore service, simply depress
the breaker button on the front panel.

B. Inside Panel Controls (refer to Figure 4-3).

*These codes are reserved for special custom applica­tions.

2. DA/FREQ Switch. (Diagnostic Purposes Only)
After welding initialization, the DA/FREQ switch
will display the actual pulse frequency and the
contents of the speed D-A in pulse mode.
When using conventional MIG welding, the
switch is only useful during actual welding
when it displays the contents of the voltage and
speed D-As.

4.3 OPERATION

A. Select wire diameter and material as follows:

1. To select the type of material, index the INC
position of the INC/DEC toggle switch below
the IPM window until the desired code number
indicating material type (1 and 2 for steel, 3 and
4 for aluminum, 5 for stainless, or 6 for silicon
bronze) appears in the IPM window. Refer to
Table 4-1 for material codes and shielding gas
recommendations.

1. WIRE DIA/MATERIAL Switch. Activating this
switch allows you to select one of the pre­programmed wire material types and one of
the pre-programmed wire sizes.

NOTE

Some models are set at the factory for a single welding
condition and do not have this feature.

2. Select the wire diameter to be used by indexing
the INC position of the INC/DEC toggle switch
below the VOLTS window until the desired
numbers indicating wire size (23 for .023" dia.,
30 for .030" dia., 35 for .035" dia., 45 for .045"
dia., or 63 for 1/16" dia.) appear in the VOLTS
window.

11

SECTION 4

OPERATION

B. Program wire feed speed and arc voltage for an

optimum welding condition. Use of the factory set
parameters will ensure a good baseline weld from
which minor adjustments can be made. The follow­ing paragraphs describe the programming of the
wire feed speed and the arc voltage using the two
analog inputs from the robot.

1. The scaling for the speed control should be set
with minimum and maximum speed values of
0 and 1000, respectively. The reference volt­age for minimum and maximum values should
be set to 0 volt and 10 volts, respectively. This
will provide a reading that will directly agree
with the programmed information. For ex­ample, a setting of 300 on the teach pendant
will result in an actual wire feed speed of 300
IPM.

2. The arc voltage control will be done in a totally
different manner. Since this control is a syner­gic control, the arc voltage will be a function of
the wire feed speed. Therefore, as the robot
increases the wire feed speed the arc voltage
will automatically increase based on a pre­programmed relationship between speed and
arc voltage. To change this arc voltage without
changing the wire feed speed, the robot will
have to change the reference voltage on the
voltage port.

Set up scaling for the voltage port with 0 V as
the minimum and 100 as the maximum value,
corresponding to a 0 volt and 10 volt reference
voltage, respectively. To make the first test
weld, it is recommended that the programmed
value be 50 V, which will provide a reference
value of 5 volts to the control.

As a weld is made, the arc voltage correspond­ing to the 50 V input can be observed. If the arc
is too “hot”, the programmed value may be
changed from 50 to 45. This will cause aver­age arc voltage to drop by 1.25 volts. A
reduction of 1 count on the programmed value
will reduce the arc voltage by 1/4 volt. Set the
reference for the best weld results.

C. Generate "start" signal from robot. Once the arc is

established, the ARC EST signal is sent to the
robot, which in turn, begins the movement of the
robot arm. If the ARC EST signal is lost, the robot
will send a stop signal to the Interface and termi­nate the weld.

NOTE

Burnback, preflow gas, and postflow gas are controlled
by the robot and cannot be programmed in the "panel"
mode from the Analog Interface.

Figure 4-1. Interconnection Diagram (Typical Robot System)

12

SECTION 4

OPERATION

Figure 4-2. Analog Interface Door

13

SECTION 4

OPERATION

Figure 4-3. Analog Interface Hinged Panel

14

SECTION 5

TROUBLESHOOTING

5.1 INTRODUCTION

Listed below are a number of trouble symptoms, each
followed by the checks or action suggested to deter­mine the cause. Listing of checks and/or actions is in
"most probable" order, but is not necessarily 100%
exhaustive. Always follow this general rule: Do not
replace a printed circuit (PC) board until you have made
all the preceding checks. Always put the power switch
in "off" position before removing or installing a PC
board. Take great care not to grasp or pull on compo­nents when removing a PC board. Always place boards
on a "static free" surface. If a PC board is determined
to be the problem, check with your ESAB supplier for a
trade-in or a new PC board. Supply the distributor with
the part number of the PC board (and pre-program
number, as described in beginning of paragraph 5.2) as
well as the serial number of the wire feeder. Do not
attempt to repair the PC board yourself. Warranty on a
PC board will be null and void if repaired by customer or
an unauthorized repair shop.

5.2 TROUBLESHOOTING GUIDE

Energize the power source and the Analog Interface.
Immediately after the Interface is energized , a number
(e.g. :3) will appear in the IPM readout window for only
1 second. This number identifies the current program
(E-PROMS) used in your Interface. When a program
is changed, the new E-PROMS will automatically iden­tify the new program number being used. If a revision
is made to an existing program, a number .1, .2, .3, etc.
indicating the numerical revision will also appear in the
VOLTS readout window simultaneously.

DEC toggle switches to the neutral
(spring-return center) position. The
IPM window will display 0 and the volts
window will display a value greater
than 0.

2. Make sure the LED display board harness/
plug is plugged into the P5 receptacle on
the MPU board.

3. Check that 115 V ac is present across
terminals T1-1 and T1-3, if present; power
switch and circuit breaker are O.K..

4. Check for plus (+) 5 volts between termi­nals T1-10 and T1-12; if voltage is present,
replace the MPU board. If voltage is not
present, check the voltage regulator (VR).
The voltage regulator is located on the
bottom panel of the control box.

5. Check the input and output voltage of the
regulator (VR).

a. The input should be approximately 11

volts across capacitor on regulator
socket. If voltage is not present, re­place I/O board.

b. If voltage is present, replace VR.

6. Check RAM battery voltage on I/O board
(see Figure 5-1). If potential is less than

3.5 volts, replace battery.

A. Numeric display does not appear when power

is applied, or numbers are completely incor­rect.

1. Perform the following system reset to clear
the memory.

a. Turn off the Interface's 115 volt power

switch.

b. Using one hand, hold both of the INC/

DEC toggle switches in the INC posi­tion while reapplying 115-volt power
with the other hand.

c. Almost immediately after the power

has been turned on, release the INC/

B. Numeric display is present but cannot be var-

ied.

1. Change to "panel" mode by disconnecting
Jumper 1 (refer to Figure 6-3).

2. Set up wire feed speed and arc voltage
(refer to Section 4).

3. Ensure the key wiring harness plug is
properly connected to receptacle P6 on
the MPU board.

4. If the above does not resolve the problem,
replace the MPU board.

5. Reconnect Jumper 1.

15

SECTION 5

TROUBLESHOOTING

C. Correct numeric display is present, but wire

feed motor does not run.

1. Check to make sure all required (and/or
optional) accessories are correctly as­sembled as described in section 3.

2. Make sure the power source is connected,
plug P2 and P3 are securely connected to
the I/O board, and then release the clapper
arm (pressure roll) on the accessory sup­port assembly.

a. Operate the JOG switch. If motor

does not run; replace "J" Governor, I/
O, and MPU boards respectively.

b. If motor feeds backwards due to

mounting orientation of the motor, re­verse brown and white wires at T1-5
and T1-6 on the lower side of terminal
strip T1.

c. If the motor inches, but does not run

when a weld is attempted, check the
composite "start" signal. If motor still
does not run, check if power supply is
providing open-circuit voltage of 72
volts to the control. If OCV is not being
supplied, motor will not run. Check the
power source for trouble.

d. Check that +/-12 V dc is provided from

the power source on T1-16 and T1-17
to T1-24 common, respectively.

D. Correct numeric display is present, but wire

feed motor runs at incorrect speed.

1. Check tachometer assembly mounted on
the end of EH-10 wire feed motor.

2. Make sure the tach disc is securely fas­tened to the motor shaft and that the strobe
markings are not scratched. Check that
the disc is properly centered in the strobe
pickup on the PC board.

E. Numeric display is present, wire feed motor

runs correctly, but robot does not weld.

1. If "start" signal LEDs (JOG, CONTACTOR,
and GAS PURGE) are not illuminated,
check interconnection between interface,
power source, and robot controller.

2. Check for continuity in wires between in­terface and robot controller. If fault is
outside of connector J3, refer to robot
manual for further troubleshooting.

F. VOLTS display reads zero as robot attempts to

weld.

NOTE

If VOLTS display reads zero when arc is present, STOP
WELD IMMEDIATELY. Otherwise, torch damage may
result.

1. Trace the voltage pickup wiring from the
power source to J6-A of the Interface.

2. If no reading is displayed, check for arc
voltage feed-back between terminals TP1
and TP2 test points on the I/O PC board.
This voltage signal should correspond to
that shown on the power supply voltmeter.

3. Check that the 5-pin plug is securely con­nected to the P3 receptacle on the MPU
board.

4. Remove the Current Detector board to
gain access to the P3 plug (harness) on
the MPU PC board. Disconnect plug P3
from its MPU board socket and check for
+/-12 volt power source output between
plug pins P3-1 and P3-2 (for +12 V) and
between plug pins P3-4 and P3-2 (for

-12 V) respectively. If voltage is present,
but still no reading, replace the MPU board.

3. If all items in steps 1. and 2. are satisfac­tory, and motor speed is still incorrect,
possible causes are as follows:

a. Defective MPU board.

b. Defective I/O board.

c. Defective "J" Governor board.

G. CONTROL SHUTDOWN -- The Interface will

flash the parameter (VOLTS or IPM) that can­not be maintained.

These symptoms may occur when the re­quested parameters cannot be maintained by
the Interface. Other possible reasons for a
shutdown are as follows:

16

SECTION 5

TROUBLESHOOTING

1. IPM (speed) abort and possible causes:

a. Defective J-governor board.

b. Defective Tachometer board.

c. Defective I/O board.

d. Defective MPU board.

e. Initial "hot start" parameters incorrectly

set. Refer to paragraph 5.4 (Hot Start
Adjustment).

Contact ESAB Group Engineering Service for further
assistance (803-669-4411).

2. VOLTS (voltage) abort and possible
causes: The source of this problem may
be located in the wire feeder or the power
source. To determine which, check the
wire feeder as follows:

a. Set the wire feeder for synergic opera-

tion in the pulse welding mode by
operating SW1-1 on Bank 1 of the
MPU board (see Figure 5-2).

b. Set unit to the panel mode by discon-

necting Jumper 1.

c. Using the robot to initiate a weld, mea-

sure the potential between T1-15 (+)
and T1-24 (control signal to the power
source). Note that as the arc voltage
setting is increased, the potential be­tween T1-15 and T1-24 also increases,
and will range from 0 to 10 V dc. If it
does not, replace the I/O and/or MPU
board. If the potential is present and
responding to the voltage change set­ting, continue with step d.

d. Now measure the control voltage, for

the background current, between T1­24 and pin J1-J of the amphenol con­nector. This measurement can be
taken without striking an arc. The
potential will be in a range from 1 to 2.5
volts. If it is not, replace the I/O and/or
MPU board. If the background poten­tial is present, continue with step e.

e. If both of the preceding conditions

(steps c. and d.) are satisfactory, but
the arc is still poor, the problem is
either in the interconnecting cable, the
welding setup, or in the power source.
If possible, substitute a cable or power
source (known to be good) to check
out the possible problem; if these are
not available, check calibration of the
I/O board by following the procedures
listed in paragraph 5.3 (Diagnostic
Mode).

f. If unit still aborts on volts after all

previous steps, refer to paragraph 5-4
(Hot Start Adjustment).

H. Weld is poor, ropy, and erratic.

1. Check the MPU board's measurement of
the arc voltage as follows:

a. Using a calibrated meter, measure

potential across TP1 and TP2 on the I/
O board (see Figure 5-1).

b. Verify that this reading equals the volt-

age shown in the VOLTS window.

2. If the MPU board is reading the arc voltage
incorrectly, calibrate as follows:

a. Set switch SW1-1 on MPU board to

the ON position.

b. Connect an accurate meter between

TP1 and TP2 on the I/O board to
measure the arc voltage.

c. Strike an arc and adjust it for a stable

condition. While the arc is in progress,
adjust potentiometer R23 on the MPU
board with a narrow blade screwdriver
until the Interface reads the same as
the external meter.

d. Reset switch SW1-1 to the OFF posi-

tion.

NOTE

SW1-1 must be reset to the OFF position before
welding can occur.

17

SECTION 5

TROUBLESHOOTING

I. Welds are okay in short arc and spray mode

but poor in pulse mode.

-- Check calibration of the I/O board follow­ing the procedures listed in paragraph 5-3
(Diagnostic Mode).

J. Analog Interface is not accurately responding

to robot commands (e.g. Robot requests 350
IPM, but Interface displays 300 or 400 IPM).

-- Check calibration of A/I boards as follows:

1. Check for 5 volts on port 22 of the A/I board
and for a speed of 500 in the IPM window.
If 500 IPM is not displayed, adjust R5
(SPEED) on A/I board until 500 IPM is
displayed (see Figure 5-3).

2. Set switch SW1-1 on MPU board to the ON
position. Check for 5 volts on port 21 of the
A/I board and a display of 100 in the
VOLTS window. If 100 VOLTS is not
displayed, adjust R8 (VOLTAGE) on A/I
board until 100 VOLTS is displayed (see
Figure 5-3). Reset SW1-1 to the OFF
position.

NOTE

SW1-1 must be reset to the OFF position before
welding can occur.

5.3 DIAGNOSTIC MODE

potential is different, the I/O board should either be
recalibrated (by a qualified technician) by adjusting R54
until reading agrees with preset value (should be done
at 5 volts), or the board should be replaced.

Next, enter a value of 40 in the IPM window. Check the
potential from T1-24(-) to pin J1-J of the Amphenol
connector for a reading of 2 V dc. If 2 +.1 V dc is not
present, replace the I/O board. If all of these readings
are correct, check the power source by using the
"calibration procedure" described in Inverter Control
Board (ICB) Troubleshooting in the Power Supply
manual F-15-014.

5.4 HOT START ADJUSTMENT

The Analog Interface is preset at the factory to provide
optimum starting characteristics for most welding con­ditions. However, due to factors such as border line
parameters (for a given wire type and size), welding
technique, shielding gas, or wire feed speed, you may
have to readjust the factory-set settings to provide a hot
start in which the initial starting voltage is slightly higher
than actual welding voltage (arc voltage) and the initial
speed is somewhat lower than the selected wire feed
speed desired. The hot start condition will be termi­nated after 0.3 seconds. The following procedure
should be used.

A. Program the welding condition you need in the IPM

(wire feed speed) and VOLTS (arc voltage) win­dows, and fine-tune these parameters until you
have the welding arc desired - At this point do not
concern yourself with the "arc starts".

Depress the WIRE DIA/MATERIAL key and hold the
IPM INC/DEC key in its down position for 2.5 seconds
until a zero (0) appears in the IPM window. (The 2.5
seconds will prevent accidental zeroing of the Material
code.)

Now release both keys. The display windows will
change to show a background current value (from 0 to

100) in the IPM window, and a pulse height value (from

0.1 to 10) in the VOLTS window. These numbers can
be changed by their respective INC/DEC switches.

To check the calibration of the I/O board, connect a
voltmeter from T1-24 to T1-15 (positive). Provide start
signal from robot and check the measured voltage
against the number displayed in the VOLTS window ­they should both be the same (for example: for a setting
of 5.0, the I/O board should be 5 V dc). If the measured

B. If after the welding condition is fine-tuned, but the

"arc starts" are unsatisfactory, proceed as follows:

1. During an actual weld, actuate and hold the
WIRE DIA/MATERIAL switch and observe the
numbers displayed in the IPM and VOLTS
windows.

2. For proper starts, the number in the IPM win­dow should be 105 to 115. If it is not, adjust the
INC/DEC toggle (below the IPM window) until
the displayed number reads about 110.

3. Similarly, the number in the VOLTS window
should be in the range of 90 to 100. Again, if it
is not, adjust the INC/DEC toggle (below the
VOLTS window) until the displayed number
reads about 95.

18

SECTION 5

TROUBLESHOOTING

4. These adjustments should provide good arc
starts to a legitimate welding condition.

5. A good "rule-of-thumb" to follow whenever you
set up a new welding condition and you expe­rience unstable starts, is to simply check the
start characteristic numbers (while welding) to
make sure they are within the ranges de­scribed in the preceding steps.

C. If you continue experiencing problems, refer to the

beginning of Section 5 for Troubleshooting proce­dures.

Battery

NOTE

Training and Troubleshooting Courses are available for
maintenance and repair of this and other ESAB Group
equipment. For details, contact ESAB Welding &
Cutting Products, P.O. Box 100545, Ebenezer Road,
Florence, SC 29501-0545; Telephone [phone].
Attention: Technical Training Coordinator.

Logic Interface PCB - 31440

Dip Switch

PC BOARD IDENTIFICATION

IO PCB - 674994

E-Prom

MPU PCB - 18158

19

SECTION 5

PC BOARD IDENTIFICATION

Current Detect - 31419

TROUBLESHOOTING

“J” Governor PCB - 994236

A/I PCB - 31452

Filter Board - 31421

20

SECTION 6

6.1 General

REPLACEMENT PARTS

Replacement parts are illustrated on the following
figures. When ordering replacement parts, order by
part number and part name, as listed. Always provide
the series or serial number of the unit on which the
parts will be used. The serial number is stamped on
the unit nameplate.

Replacement parts may be ordered from your ESAB
distributor. Refer to the Communication Guide located
on the last page of this manual for a list of customer
service phone numbers.

21

SECTION 6

REPLACEMENT PARTS

1

2

3

4, 5, 6

Ite m

No.

1
2
3
4
5
6
7
8
9

10

Qty

Req.

1
1
1
1
1
1
1
1
1
1

10

Figure 6-1. Analog Interface

Part

No. Description

31745

32084
952586
680359
950282

95464

2062363

950295
950874

2062272

9

CABINET, SILK SCREENED
DOOR, SILK SCREENED
LATCH, CABINET
SWITCH, ROTARY
KNOB
DIODE, 50 V, 1 A (1N4001)
SWITCH, ROCKER
SWITCH, ROCKER
CIRCUIT BREAKER, 7A
SWITCH, ROCKER, DPST

8

7

Ckt.

Symbol

WSW

SW-5
SW-4

CB

MLS

22

SECTION 6

REPLACEMENT PARTS

1

2

3

4

5

6 (3 places)

Ite m

No.

1
2
3
4
5
6
7
8
9

Qty

Req.

1
1
1
1
1

3

1
1
1

9

Figure 6-2. Analog Interface (Inside View)

Part

No. Description

677991
680273
950328

31440
675269
950087

30684
994303

31421

LENS
LENS
LATCH
P/C BOARD, LOGIC INTERFACE
P/C BOARD ASSY, DISPLAY
SWITCH, SPDT (ON)-OFF-(ON)
TRANSFORMER ASSY
TRANSFORMER
FILTER BOARD

8

7

Ckt.

Symbol

L/I

SW-1,3,7

CTR1, 2

CTR3

FB

23

SECTION 6

REPLACEMENT PARTS

1

7

REF: JUMPER 1

2

3

4

Ite m

No.

1
2
3
4
5
6
7

Qty

Req.

1
1
1
1
1
1
1

5

6

Figure 6-3. Analog Interface (Inside View w/Swingout Chassis)

Part

No. Description

17240003

18158

674994

31452

994236

31419

995103

BRAKE RESISTOR, 3 OHM, 25 W
P/C BOARD, MPU
P/C BOARD, I/O
P/C BOARD ASSY, A/I
P/C BOARD ASSY, J GOV
P/C BOARD ASSY, CURRENT DET.
TERMINAL STRIP (24-POSITION)

Ckt.

Symbol

R1

MPU

I/O

T1

24

SECTION 6

REPLACEMENT PARTS

1

2

Ite m

No.

3

Qty

Req.

4

Figure 6-4. Analog Interface (Bottom View)

Part

No. Description

5

6, 7, 8

Ckt.

Symbol

9

1
2
3
4
5
6
7
8
9

1
1
1
1
1
1
1
1
1

950762
996514

31671
599800
598397
950159
950158
995544
993952

RECEPTACLE (19-PIN)
RECEPTACLE (5-SOCKET)
MOUNTING PLATE
RECEPTACLE (24-SOCKET)
RECEPTACLE (3-PIN)
VOLTAGE REGULATOR, +5 VOLTS
SOCKET, TRANSISTOR (TO3)
C A PA C ITO R, 1 µF, TA NTA LUM
RECEPTACLE (6-SOCKET)

25

J1

J2

J3
J6

VR

C4

J4

SECTION 6

REPLACEMENT PARTS

NOTE

30

SECTION 6

REPLACEMENT PARTS

NOTE

31

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

Telephone: [phone] / Fax: [phone]

Telephone: [phone] / Fax: [phone]

Telephone: [phone]/ Fax: [phone]

B. ENGINEERING SERVICE: Telephone: [phone] / Fax : [phone]

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: [phone]

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]

E. WELDING EQUIPMENT REPAIRS: Telephone: [phone] / Fax: [phone]

Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST

F. WELDING EQUIPMENT TRAINING:

Telephone: [phone] / Fax: [phone]
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 / Fax: [phone] Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : [phone] Hours: 7:30 AM to 5:00 PM EST

Eastern Distribution Center

Central Distribution Center

Western Distribution Center

Hours: 7:30 AM to 4:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: [phone]/ Web:http://www.esab.com

F-15-151-B 9/2000 Printed in U.S.A.

Hours: 7:30 AM to 5:00 PM EST

ESAB Welding & Cutting Products

PO Box 100545 Florence SC 29501-0545