INSTRUCTION MANUAL
PULSE ANALOG
ROBOTIC INTERFACE
APPLICATION:
MIG and PULSE MIG WELDING
Analog Item
Robot Interface Number Model
Motoman Pulse 36342 RI-3P
Hitachi Pulse 31678 RI-4P
Kawasaki/Fanuc Pulse 31676 RI-2P
REIS Pulse 0558001377 RI-6P
F-15-081-D
July, 2001
SPECIFICATIONS
Input Requirements ................... 7 amps, 115vac, 50/60 Hz 1 ph
Dimensions Height ............................ 15-1/2" (394mm)
Depth .................................... 8" (200mm)
Width ................................... 13" (330mm)
Weight (approx.) ............... 20 lbs (9.1 kg)
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for electric 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 on
page 2 and 3 before installing or operating this equipment.
Be sure this information reaches the operator.
Extra copies are available through your supplier.
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.
2
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.
11/95
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.
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.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause
injury or death. Therefore:
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."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or
loss of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
Used to call attention to hazards which
could result in minor personal injury.
3
I. FEATURES
ESAB Analog Robot Interface
In general, these microprocessor controls are designed to interface with robot controllers using analogsystem programming and are capable of all modes of
conventional mig and flux cored welding. The ESAB
ANALOG ROBOTIC INTERFACE receives analog
parameter inputs from a robot controller, processes
these signals and accurately controls the welding
power supply and wire feeding system. Other data is
exchanged between the ESAB ANALOG ROBOTIC
INTERFACE and robot controller such as start/stop
signals, shielding gas control, wire touch work, weld
enable, etc.
ESAB PULSE Analog Interface
This version of the ESAB Analog Interface offers all of
the features above plus “synergic” operation in all Mig
modes including Pulsed Mig. This simplifies the operation even further and can actually increase the overall
performance of the robot cell. The interface is factory
programmed for six (6) materials and five (5) wire sizes;
select material type, wire size, Mig mode (short, spray
or pulse) and the PULSE INTERFACE automatically
sets optimum welding parameters based on wire feed
speed.
TEACH Option (for Pulse version only)
This optional kit for the ESAB PULSE analog interface
adds the highest degree of flexibility by enabling the user
to "teach" the Analog Interface custom synergic pulse
parameters for user specific weld applications. Refer to
instruction manual F-15-519 Teach Mode Operating
Instructions for Pulse Analog Interface.
Also available from ESAB;
ESAB CONVENTIONAL Analog Interface
This version of the ESAB Analog Interface offers simple
operation in all modes of conventional MIG welding
including flux cored welding with an exceptionally high
degree of precision. The welding parameters are set by
providing wire speed and voltage signals from the robot.
The interface then sets and precisely regulates the
actual welding parameters.
2. How To Assemble a Robotic Welding System
Robotic welding systems can become quite complex
considering all the equipment required to outfit a work
cell. The following lists the main welding equipment
items to be considered for operation. Consult your
ESAB Sales Literature and the following pages for
specific equipment item numbers. Then use this check
list to be sure that you have all of the required items.
Figure 1 - Typical Robot System
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EQUIPMENT & HARDWARE CHECK LIST
ESAB Analog Interface ....................................... ❑
ESAB Welding Power Source ............................. ❑
Voltage Pickup Lead (pulse units only) ............... ❑
Power Source Control Cable .............................. ❑
ESAB EH-10A Wire Feed System ...................... ❑
Wire Feed Rolls .................................................. ❑
Motor Extension Cable ....................................... ❑
Wire Inlet Guide .................................................. ❑
Wire Outlet Guide ............................................... ❑
Wire Spool Support ............................................ ❑
Wire Spool Cover ............................................... ❑
TYPICAL SYSTEM COMPONENTS
Analog Interfaces
31675 Fanuc - Conventional MIG
31677 Hitachi - Conventional MIG
36341 Motoman - Conventional MIG
31676 Kawasaki/Fanuc - Pulse
31678 Hitachi - Pulse
36342 Motoman - Pulse
0558001377 REIS - Pulse
34696 SI - Pulse
34560 Optional Digital DC Ammeter Kit
Interface to Power Source Cables
30686 J1 Control Cable - 6 ft.
30780 J1 Control Cable - 30 ft.
30781 J1 Control Cable - 60 ft.
34070 Pickup Lead (Digipulse only)
Drive Motor & Wire Accessories
679774 EH-10A Digital Motor
49V51 2 Roll Accessory Support
600216 4 Roll Accessory Support
60N90 Insulator Ring (Required)
996808 Motor Control Cable - 25 ft.
996497 EH-10A Motor Mounting Bracket
948259 Spool Spindle Assembly
634288 Reel Support Arm
995570 Coil Adapter
19V89 Coil Adapter HD
20572 CC Torch Adapter
950574 Conduit Assy. 10 ft.
950575 Conduit Connector - Male
679302 Adapter
950576 Conduit Connector - Female
600240 Spool Cover - Clear
34V74 Wire Straightener (order inlet below)
11N53 Inlet Guide
995570 Standard Wire Reel, up to 60 Ibs spools
19V89 H.D. Wire Reel, 65 Ibs coils
600240 Spool Enclosure Kit, 12-in spools
Wire Wiper Accessory
598537 Felt Wiper, pkg. of 10
598764 Wiper Holder
598763 Wiper Holder, used w/opt. wire straight
Wire Conduit ...................................................... ❑
Wire Conduit Fittings .......................................... ❑
ESAB Plumbing Box ........................................... ❑
Plumbing Box Cable ........................................... ❑
ESAB Water Cooler ............................................ ❑
Water Cooled Welding Torch ............................. ❑
Torch Adapter ..................................................... ❑
Contact Tips ....................................................... ❑
Torch Wire Liner ................................................. ❑
ESAB Flowmeter/Regulator ................................ ❑
Gas Hoses and Fittings ...................................... ❑
Water Hoses and Fittings ................................... ❑
Welding Cables .................................................. ❑
Power Sources (230/460 vac 60 hz.)
31120 Digipulse 450i
31950 SVI450i
36377 V 352
36000 V 452
36004 V 652 cvcc
Water Accessories
34749 PB-3 Plumbing Box
34199 Plumbing Box Cable - 3.5 ft.
34845 Plumbing Box Cable - 25 ft.
33739 WC-8C Upright Water Circulator
33540 WC-9 EHD Water Circulator
40V76 Water Hose - 12.5'
406196 Water Hose - 25'
11N18 Water Hose Coupler
11N16 5/8-18 RH to 1/4 NPT Adapter
Drive Rolls - Two Roll System
2075303 .035" - “V” Hard Wire
2075302 .045" - “V” Hard Wire
19761 .045" - “V” Serrated - Flux core
2075261 .052" - “V” Serrated - Flux core
2075261 .062" - “V” Serrated - Flux core
Drive Roll Kits - Four Roll System
999326 .035" - “V” Hard Wire
999327 .045" - “V” Hard Wire
999330 .045" - “V” Serrated - Flux core
999331 .052" - “V” Serrated - Flux core
999332 .062" - “V” Serrated - Flux core
39N15 Outlet Guide .035" - .062"
Shielding Gas Accessories
21557 R-33 Flow Regulator - Argon Mix
21558 R-33 Flow Regulator - CO2
21505 R-36 Flow Regulator - Argon Mix
999149 R-76 Flow Regulator - CO2
40V77 Gas Hose - 12.5'
19416 Gas Hose - 12.5' Heavy duty for CO2
11N17 Gas Hose Coupler
5
Figure 2.
6
C. MOUNTING/CONNECTING THE EQUIPMENT
Analog Interface
The operating controls for the ESAB Analog Interface
are located on and behind the front cover. The box
should be positioned within easy reach of the Robot
operator on a vertical surface using the mounting holes
provided.
Welding Power Source
The welding power supply should be mounted as close
to the robot as posible. Distances less than 20 feet are
recommended. The power source must have at least
18" of free air space in all directions to maintain adequate unrestricted cooling air flow. Both welding cable
leads (torch and work) must be a minimum size of No.
4/0 welding cable, and should be kept as close to the
same length as possible. Cables must be run next to
each other and tywrapped every couple of feet to
minimize cable reactance.
Wire Feed Motor
The wire feed motor & accessory support can be
mounted directly on the robot arm or on a stand close
to the robot. The shortest possible welding torch is
recommenced for best wire feed results.
IMPORTANT: The wire drive motor can be mounted as
a left or right hand drive. Once operational, check for
proper rotation. If rotation is incorrect, simply re-
verse the orange and blue wires on T1-5 and T1-6.
Wire Delivery System
The wire delivery system, whether it be a spool, coil, reel
or drum must be kept as close to the robot as possible.
Distances less than 10' are recommended. Every effort
must be made to keep the wire delivery system clean
and the wire conduit free from twists and sharp bends.
IMPORTANT: Wire delivery and feeding is the most
frequent encountered problem in MIG welding and is
sometimes difficult to uncover.
Plumbing Box
The plumbing box should be mounted directly below the
Analog interface with the water cooler.
Once all of the equipment is securely mounted, connect
the control cables, hoses and wire hardware as shown
in the interconnection diagram titled Typical Robot
System (Fig. 1) and the Wire Feed Delivery System
(Fig.2).
Figure 3. - Wire Feed Delivery System
7
ROBOT to INTERFACE CABLE - J3
In all cases, the control cable from the robot controller
to the ESAB Analog Interface (J3) is supplied by the
robot manufacturer. The connector and pin configuration of this cable has been designed by the robot
manufacturer to their specifications. The ESAB Analog
Interface receptacle (J3) has been configured to accept
the standard control cable from the specified robot.
Questions concerning pin configurations should be
directed to the specific robot manufacturer.
The following figures are the typical J3 control cable pin
configurations for the Motoman, Fanuc, and Hitachi
robots.
Additional information on connections and/or adjustments can be found as follows:
INSTRUCTION LITERATURE
EH-1OA Digital Welding Head ................... F-12-873
Teach Mode Operating Instructions ........... F-15-519
Figure 4. Motoman J3 Pin Configuration
Figure 5. HITACHI J3 Pin Configuration
Figure 6. FANUC J3 Pin Configuration
8
Figure 7. REIS ROBOT INTERFACE
8
7
J3
PIN Designations
Control Cable from Robot
b
c
o
6
5
4
1
10
Fig. 8 - Location Front Panel Controls
2
3
III. CONTROL FUNCTIONS & OPERATION
IMPORTANT
Some of the controls and features covered following are not required or used in “all” of the robots,
and these exceptions will be specifically noted in
the text as they occur.
A. FRONT PANEL CONTROLS
For location of front panel controls, see Fig. 8.
1. Power-Switch. Pulling-out the mushroom-style red
button of this switch turns power "on" to the control as
indicated by the illuminated display windows. To turn
power "off", simply push-in red button and the display
windows and control will de-energize.
NOTE: Immediately after the control is turned on,
numbers that identify the EPROM “program”
in the control are displayed in the IPM and
VOLTS windows. These numbers only ap-
pear for one second.
2. PURGE/RESET Switch. A momentary “on” switch,
that provides a dual function when actuated.
a. Prior to starting the welding sequence, it actu-
ates the gas solenoid and lets you “purge” the
shielding gas line of the torch. At the same time,
the IPM and VOLTS windows will also display
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