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
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