ESAB Standard Mig Analog Interface Control for Robotic Welding Systems Troubleshooting instruction

INSTRUCTIONS for F-15-080-A

May, 2001

STANDARD MIG ANALOG INTERFACE CONTROL

for

ROBOTIC WELDING SYSTEMS

This book covers the following interfaces:

ABB ......................................................... P/N 31679

Fanuc/Kawasaki ...................................... P/N 31675

Hitachi ..................................................... P/N 31677

REIS .............................................. P/N 0558001376

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.
You can get extra copoies through your supplier.

2

TABLE OF CONTENTS

Safety Precautions ............................................................................................................................. 4

Section I

Introduction .................................................................................................................................... 8

Section 2

Installation ...................................................................................................................................... 9

Section 3

Operation ..................................................................................................................................... 17

Section 4

Maintenance and Troubleshooting ............................................................................................... 20

Section 5

Replacement Parts....................................................................................................................... 28

3

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.

F15-660

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 Pro-

--

cesses", 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.

4

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.

5

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 de

6

levage, 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.

7

SECTION 1 INTRODUCTION

SPECIFICATIONS

Input Power Required ..............................................

........................... 7 amps, 115 Volts, 50/60 Hz, 1 ph

Height .......................................... 15.5 in. (394mm)

Depth................................................ 8-in. (200mm)

Width .............................................. 13-in. (330mm)

Weight (approx.) .............................. 20 lbs (9.1 kg)

1. INTRODUCTION

This state-of-the-art, microprocessor control is de­signed to interface with robot computer controllers
using analog-system programming. The ESAB ANA­LOG 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 INTERFACE and robot control­ler such as start/stop signals, shielding gas con­trol, wire touch work, weld enable, etc.

THE STANDARD MIG ANALOG INTERFACE Control
can be used for Mig applications such as short arc,
spray arc or flux cored wire welding. Welding param­eters can be preset at the INTERFACE Control (Panel
Mode) or totally controlled by signals from the robot
controller (Robot Mode).

IMPORTANT: This booklet covers the instructions

for various Standard Analog Con­trols used for the different Robot
vendors listed in Section 2.1 follow­ing. Some of the control's compo­nents and features described in the
text are not required or used in all of
the robots, and these exceptions
are specifically noted as they ap­pear in the instructions.

8

SECTION 2 INSTALLATION

2.0 HOW TO ASSEMBLE A TYPICAL ROBOT
MIG WELDING SYSTEM - FIGURE 2

2.1 Equipment Supplied

Select one of the following:
STANDARD MIG ANALOG INTERFACE Control;

Fanuc/Kawasaki ...................................... 31675

Hitachi ...................................................... 31677

Reis................................................ 0558001376

2.2 Equipment Required

2.2.1 Select an EH-10A Digital Welding Head (20-

999 ipm). Each model includes motor w/gear

box, accessory support tach feedback unit and
52" cable

a. EH-10A Digital Mtr ........................... 679774

b. Insulating Ring .................................. 60N90

c. Motor Control Cable, 25-ft. .............. 996808

c. 2 Roll Accessory Support ................. 49V51

d. 4 Roll Accessory Support ................ 600216

e. Extension cable, 25-ft, 6-cond.

(J2-control to welding head) ........ 996808

2.2.2 Select feed rolls, outlet guides and other wire

feed accessories for wire sizes and types that
will be used. (See Table 1; Feed Rolls and Outlet
Guides)

2.2.3 Select a DC power supply suitable for your appli-

cation:

The STANDARD MIG ANALOG INTERFACE
requires an electronic controlled power supply:

a. Transformer/SCR type power supplies:

453cv; 230/460vac, 3-Ph .................. 37969

653cvcc; 230/460vac, 3-Ph .............. 37829

b. Inverter type power supplies:

SVI-450i cv/cc; 230/460vac, 3-Ph. .... 31950

2.2.4 Select a control cable (J1-welding control to

power supply cable). A 19 PIN to 19 PIN Cable
for Standard and Inverter Power Supplies:

6-ft, Control Cable .................................. 30686

30-ft, Control Cable ................................ 30780

60-ft, Control Cable ................................ 30781

The cable will be the same for all power sources
of 6-ft, 30-ft and 60-ft length.

2.2.5 Select gas control equipment:

a. R-5007 inert gas reg./flowmeter ...... 998124

b. R-5008 CO2 reg./flowmeter .............. 998125

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

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

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

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

(use heavy duty hose for CO2 gas)

g. Gas Hose Coupler ............................ 11N17

2.2.6 When using a water cooled torch, some of the
following items may be required to supply and
drain the cooling water:

a. 12.5 ft water hose ............................. 40V76

b. 25-ft water hose ............................... 406196

c. Water Hose Coupling ....................... 11N18

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

to 1/4 NPT hose.......................... 11N16

Table 1

Wire Size/ Two Roll Drive Four Roll Drive Outlet
Type in. Feed Roll Feed Roll Kit* Guide

Soft

.030 2075304 (U) 999320 (U) 29N13**
.035 2075304 (U) 999321 (U) 29N13**
3/64 2075301 (U)+ 999322 (U) 29N13**
1/16 2075298 (U)++ 999323 (U) 29N13**

3/32 2075297 (U) 999324 (U) 29N13**

Hard

.023 17998 (V) — 999745
.030 2075300 (V) 999325 (V) 993860(a)
.035 2075303 (V) 999326 (V) 993860(a)
.045 2075302 (V) 999327 (V) 39N15(b)
.052 2075330 (V) 999328 (V) 39N15(b)
1/16 2075299 (V) 999329 (V) 39N15(b)

Cored

.035 19761 (Serr.) — 993860(a)
.045 19761 (Serr.) 999330 (Serr.) 39N15(b)
.052 2075261 (Serr.) 999331 (Serr.) 39N15(b)
1/16 2075261 (Serr.) 999332 (Serr.) 39N15(b)
5/64 2075261 (Serr.) 999333 (Serr.) 62N17
3/32 2075257 (Serr.) 999334 (Serr.) 62N17
7/64 2075257 (Serr.) 999335 (Serr.) 39N16
1/8 2075255 (Serr.) 999336 (Serr.) 39N17

Requires guide bushing P/N 17997.

*Includes a center wire guide and 2 upper and 2 lower feed rolls.
** Requires outlet guide insert as follows: For .030, .035 wire use 993902.
(a) Includes replaceable sleeve (995651) For 3/64 wire use 05N57.
(b) Includes replaceable sleeve (995692) For 1/16 wire use 12N57.

+ Recommend U-Groove Pressure Roll 2075346 be used.
++ Recommend U-Groove Pressure Roll 2075348 be used.

For 3/32 wire use 05N58.

2.3 Optional Accessories

1. Digital DC Ammeter Kit, LED display of welding

current up to 999 amps .................................. 679111

2. Plumbing Box; contains solenoid valves, for shield-

ing gas and torch coolant, and coolant pressure
switch to protect against inadequate cooling water

............................................................34749

3. Cable Assemblies:

Plumbing Box Control Cable (J4-Interface Control to
Plumbing Box);

a. 3.5-ft, 6-cond. cable .................................34199

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

4. Torch Coolant Recirculator:

a. WC-8C vertical, 115vac, 60 Hz, upright... 33739

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

6. Wire Wiper Accessory; effectively cleans and lub-

ricates wire:

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

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

9

SECTION 2 INSTALLATION

c. Wiper Holder, use w/opt. wire straightener .......

......................................................... 598763

7. Wire Conduit & Mounting Accessories; a spool or
coil of wire can be mounted 10-ft (or multiples of 10­ft) from the EH-10A Weld Head using the following
accessories:
a. Quick-Change Flexible Conduit, 10-ft ... 950574
b. Conduit Connector (male), connects to end of

conduit .................................................. 950575

c. Conduit Connector (female); required when con-

necting two (2) sections of Flexible Conduit

......................................................... 950576

8.Wire Support Equipment; mount to fixture to hold
wire coils or spools:

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

b. Spindle Assembly, mounts to Arm .......... 34323

c. H.D. Wire Reel, hold 65 lbs coils ........... 19V89

d. Spool Enclosure Kit, covers 12-in spools .........

......................................................... 600240

9.Optional Voltage Pickup Lead (J6-Interface con-

trol to torch); provides arc voltage feedback to

control; 25-ft, 1-cond. cable .................... 680847*

*CAUTION: Consult with the ESAB Factory be-

fore connecting this option, otherwise serious dam­age to the power supply can occur.

2.4 Mounting/Connecting The Equipment

For complete Interconnection Diagram information on
the Interface Control with all required and/or optional
accessories, see Figures 1, 2 and 3.

Since the operating controls for the Standard 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.

As shown in Figure 2, the wire-feed motor/accessory
support and the plumbing box are designed to be
mounted on the Robot itself.

IMPORTANT: Make sure you read notes 1 and 2

(located on Figure 2) relating to the
wire feed motor, and plumbing box,
respectively.

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

Torch connections are provided in their respective
instruction booklets.

Figure 1 - Wire Feed Flexible Conduit Extension

10

POWER SUPPLY CONTROL
CABLE ASSYS.

GAS HOSE

STANDARD ANALOG INTERFACE CONTROL

25-FT. MOTOR - TACH
CABLE ASSY.

PLUMBING BOX
CABLE ASSY.

REG. FLOMTR.

WATER

ADAPTORS

(Supplied by Robot Mfr.)

*CAUTION: CONSULT
WITH FACTORY BEFORE
USING. OTHERWISE
DAMAGE TO POWER
SUPPLY WILL OCCUR.

SINGLE-PIN MOLEX TO BE
INSTALLED ON PICK-UP
LEAD & CONNECTRED TO
MOLEX PLUG ON MT-450W
& MIG-41 TORCHES.

WATER HOSE ASSYS.

OPTION 25-FT.
VOLTAGE PICKUP LEAD

PLUMBING BOX

TORCH GAS-IN

TORCH WATER-IN

SEE NOTE
NO. 2
PRESSURE
SWITCH

TORCH POWER

WATER-OUT

POWER SUPPLY

#4/0 WELDING CABLES (BY
CUSTOMER) TO PLUMBING BOX/
TORCH ALND WORK PIECE

WIRE REEL SPINDLE
AND SUPPORT

WIRE STRAIGHTNER

WIRE FEED CONDUIT
EXTENSION ACCESSORIES

MOTOR-TACH LEADS

WIRE FEED MOTOR
TACH. ACCESSORY
SUPPORT

TORCH

CONDUIT

ROBOT
TORCH

WORK

NOTES:

1. If wire feed runs backwards, reverse motor direction as follows: In the control, disconnect the blue wire (RLY-7) from T1­5 and connect it to T1-6; disconnect orange wire (RLY-9) from T1-6 and connect it to T1-5.

2. The WSV in the Plumbing Box is hooked-up for "continuous waterflow", and the pressure switch (PS) is factory connected
to normally-close (N.C.) position - if the normally-open (N.O.) is desired, move wire to position shown dotted.

Figure 2 - InterconnectionDiagram

11

ROBOT RECEPTACLE/CABLE CONNECTIONS

AT “J3” CONNECTOR ON INTERFACE

CONTROL (See Fig. 2)

N
P
Q
R
S
T
U
V
W
X
Y
Z

U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
m
n
r

ROBOT INTERFACE

¨ INPUTS FROM ROBOT
® OUTPUTS TO ROBOT

WIRE CONTACT
WELDER READY
COMMON B

SPATTER CLEAN
INCH UP

COMMON
SPEED REF.
COMMON

VOLTAGE REF.

ABB ROBOT INTERFACE

INCH FWD.
INCH REV.

COMMON ROBOT
COMMON ROBOT

TOUCH SENSE

+24V ROBOT

24 VOLT

LEGEND

®
®
®

¨
¨

¨
¨
¨
¨

¨

¨

¨
¨

®

®

¨

A

ARC ESTAB

B
C

COMMON A

D

START

E

INCH DOWN

F

PURGE

G

WIRE TOUCH REQ

H

PRESS SWITCH

J
K

INHIBIT WELD

L

INHIBIT WEAVE

M

VOLTAGE INPUT

A

SPEED COMMON

B
C
D

SPEED INCH

E

VOLT COMMON

F
G
H
I
J
K
L
M

WIRE CLEAR

N
P

START

R

PURGE

S

TOUCH WORK ENABLE

T

Control Cable from Robot

J3

PIN Designations

®

>

®
¨
¨
¨
¨

®
®

¨
¨

>

¨
¨

¨
¨

®

¨
¨
¨

FANUC/KAWASAKI ROBOT INTERFACE

INCH FWD.

N

INCH REV.

P

TOUCH REQUEST

Q
R
S
T
U

SPEED

V

COMMON SPD.

W

VOLTAGE

X

COMMON VLT.

Y
Z

¨
¨
¨

¨

¨
¨
¨

+24 VOLTS

A

READY

B

ARC EST.

C

ARC OUT ABORT

D

WIRE CLEAR

E
F
G
H
J
K
L
M

-24 V
START

HITACHI ROBOT INTERFACE

Figure 3 - Specific Robot Interface Connections to Analog Control

®

>

®
®
®
®

®
¨

REIS ROBOT INTERFACE

12

SECTION 2 INSTALLATIONS

2.5 CONTROL FUNCTIONS

IMPORTANT

Some of the control and features covered in the
following are not required or used in “all” of the
robots, and these exceptions will be specifically
noted in the text as they occur

2.5.1 Front Panel Controls

For location of controls, see Figure 4 following.

2.5.2 Power-Switch

Pulling-out the mushroom-style red button of this switch
turns power “on” into 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 deenergize.

NOTE: Immediately after the control is turned “on” a

number will appear in the IPM window (e.g. 3)
and another number will appear in the VOLTS
window, and these numbers will only be dis­played for 1-second. This information identifies
the E-Prom “program” used in your control. The
number shown in the VOLTS windows will be in
decimal for (e.g., .1, .2, .3 etc.)

2.5.3 Gas Purge/Reset Rocker

A momentary “on” switch, this rocker provides a dual
function when actuated.

a. Prior to starting the welding sequence, it actuates

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 the preset
times (in seconds) for gas preflow and gas postflow
respectively.

b. After starting the welding sequence -- if an abort

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

2.5.4 INCH Up-Down Rocker

This switch is used to “cold inch” the wire, up or down,
at a preset speed which you have programmed. If you
wish to change the preset cold-wire inch speed, you
must actuate this switch (Up or Down) while simulta­neously operating the “Inc.-Dec.” toggle under the IPM
display on inside panel. Information for cold inch
comes from the robot, if an analog signal is present,
otherwise the information is from the panel setting.

Fig. 4 - Location Front Panel Controls

IMPORTANT: Cold inching is only possible when

the weld Start-Stop rocker switch
is in its “stop” (or off) position.

2.5.5 Start-Stop Rocker

The functional operation of this two-position (no neu­tral) switch is dependent upon the positioning of the
Robot-Panel switch located on the inside panel of this
control.

If the Analog Control is to be used for Robot
operation, the Start-Stop rocker must be left in its
STOP position.

If the Control is to be used in its Panel position for
manual operation; the Start-Stop rocker is used
to initiate the welding sequence in its START
position, and terminates the welding sequence
in its STOP position.

2.5.6 Digital Readout Windows

Three individual 3-digit 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:

a. AMP Digital Readout. This window is normally

blank unless the optional Ammeter Kit is pro­vided tomonitor actual welding current. When
installed, the window displays d.c. current
(AMPS) in a range from 0-999 amperes in
one amp increments.

13

SECTION 2 INSTALLATIONS

b. IPM Digital Readout. This window is primarily

used to display wire feed speed in IPM 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:

-- PREFLOW Time from .1 to 99.9 seconds in
one tenth of a second increments

-- SPOT welding time from 1 to 999 cycles in one
cycle increments or in seconds where 60
cycles equals one second (must be set to
zero forcontinuous seam welding)

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

NOTE: With the inside Panel/Robot switch in “Panel”

and Power switch turned “on”, but not weld­ing, the IPM window will continuously read
Preset wire speed. When the arc is struck, the
IPM window will then continuously read Ac­tual welding wire speed.

c. Volts Digital Readout. This window is pri-

marily used to display arc voltage in VOLTS
from 12 to 50 vdc in one tenth volt increments.
However, with the appropriate toggle selector
actuated, this window can also display the fol­lowing:

-- POST FLOW Time from .1 to 99.9 seconds in
one tenth of a second increments.

-- manual BURNBACK time. Manually adjust­able burnback time period which when
preset will override the automatic adaptive
anti-stick feature. This time period will be set in
one-cycle (60-cycle = 1 sec.) increments. When
set to “zero”, the Automatic Adaptive Anti-stick
feature will be operational.

-- accumulative welding arc hours (A.H.) usage
record in one-tenth of an hour increments.

NOTE: With the inside Panel-Robot switch in

PANEL and Power switch turned “on”, but not
welding, the VOLTS window will continuously
read Preset voltage. When the arc is struck,
the VOLTS window will then continuously
read Actual welding voltage.

2.5.6 Panel-Robot (L.E.D.) Lights. These lights indi­cate the “location” from which this control is being
operated; either the PANEL location or the
ROBOT location. The appropriate light will ener­gize as soon as the control is turned “on”.

2.5.7 Input/Output Robot Function (L.E.D.) Lights.

Primarily these lights only function when the con­trol is used in the ROBOT mode; however two
Output LED’s, Arc Established and Abort/Arc
Out, will also function in the panel mode. The
appropriate light or lights will energize to indicate
the specific function(s) being used at the
appropriate time in a welding sequence. Re-

member, some of the following Input/Out­put functions are not required or utilized in
all Robot models:

LED Input From Robot: Weld Start, Contactor

(ASEA only), Gas Purge, Inch Up, Inch Down, and
Touch Request.

LED Input To Robot: Ready, Arc Established,
Abort/Arc Out, Wire Stick, and Wire Contact.

2.5.8 Reset Circuit Breaker. A seven (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.

2.6 Inside Panel Controls

For location of inside panel controls, see Figure 5.

2.6.1 Robot-Panel Toggle Switch - This two-posi­tion switch is used to set the “location” from
which this control is to be setup and operated.
The ROBOT position allows the control to be set
up and operated from the Robot; while the
PANEL position allows the welding sequence to
be set-up and operated from the Analog Control
itself.

2.6.2 Spot/Burnback - A.H./Inch Set Selector. Operat­ing this toggle allows you to select the following:

a. Activating the SPOT/BURNBACK time mode

(down position) allows you to preset either or
both of these welding features. However, once
preset, these features automatically become
part of the operating mode (Panel or Robot).

The SPOT mode allows you to preset “timed-arc”
periods (from 1 to 999 cycles) in the IPM window using
its Inc./Dec. toggle switch. When a spotweld time is
preset into the control, all “continuous-type” welding
programs are “temporarily disabled.” To resume nor­mal (continuous) operation, you must deactivate the
spotweld program by keying its “time” parameter back
to zero (000).

14

SECTION 2 INSTALLATIONS

to 115 (with 110 being the norm) in the IPM
window, and from 90 to 100 (with 95 being
the norm) in the VOLTS window. If your
weld starts are not acceptable, please refer
to page 12 (Hot Start Adjustment) for a simple
adjustment procedure that will enhance good
starting. If you are experiencing inordinate
speed and/or voltage aborts, please refer to
Section VII. (Troubleshooting) for checking
and resetting servo functions.

2.6.3 Inc./Dec Set-Up Switches

Two set-up control switches are provided to preset the
individual welding parameters required for the se­lected welding operation, as follows:

“IPM” Increase/Decrease Control. This toggle switch

Figure 5 - Inside Panel Controls

At the same time (or independently), you can also
preset a manual BURNBACK time into the VOLTS
window using its Inc./Dec. toggle switch. The Burnback
time is adjustable in one cycle increments (60 cycles/
sec); and when preset, it will override the automatic
adaptive anti-stick feature in either the Panel or
Robot modes of operation. If automatic anti-stick
operation is desired, the preset Burnback time must be
set back to “zero”.

b. The A.H. (Arc Hours)/Inch Set selector is only

functional when the wire feeder is not operating.
When actuated in its up position you can pro­gram a coldwire INCH PRE-SET speed in the
IPM window by operating its Inc/Dec toggle switch,
or you can observe the total accumulated
ARC HOUR usage record displayed in the
VOLTS window. To “zero-out” the arc hour record,
“toggle-down” the Inc/Dec switch below the Volts
window.

NOTE: Actuating this position (Arc Hours/Inch Preset)

during an actual weld allows you to check the
factory-preset numbers that will determine the
quality of starts (hot, cold, etc.) for your preset
welding condition. These numbers are preset
to provide optimum starting characteristics re­quired for most welding applications. This is a
diagnostic tool available to the experienced
operator or serviceman and need not be acti­vated during a normal operation unless you
are experiencing weld starting problems, or
weld condition (speed and/or voltage abort­ing problems. The factory-set “starting condi­tion” is represented by numbers that are dis­played, on command, in the digital IPM and
VOLTS windows. For good welds and starts,
these numbers should be in a range from 105

is primarily used to set and/or vary the wire feed speed
(IPM), along with its other functions; re-flow, Spot and
Inch. With the appropriate function selector actuated
each parameter set- ting will be displayed in the
digital window directly above this toggle.

"VOLTS" Increase/Decrease Control.

This toggle switch is primarily used to set and/or vary
the arc Volts, along with all its other functions; Postflow,
Burnback and to “zero” the A.H. accumulation. With the
appropriate function selector actuated, each param­eter setting will be displayed in the digital window
directly above this toggle

2.6.4 TEST Toggle Switches -- ANALOG IN­PUT and AMPS.
These two toggles provide a convenient way of

test-sequencing the program parameters to
either diagnose a problem, or to demonstrate the
control without actually striking a welding arc
as follows:

a. The Test/Analog Input toggle is a two-

position (momentary up, maintain down)
switch that allows the user to test the proper
operation of the Analog Interface board. In
its normal Analog position the switch
provides continuity to the actual Robot
Input signals, both voltage and speed.
When the toggle is raised and held in its
momentary TEST position, a 5-volt analog
signal will be connected to both the speed
and voltage terminals of the Analog Input
board. Assuming that the Robot-Panel
toggle switch is in the Robot position, the
speed and voltage display windows should
now reflect the digital equivalent of ap­proximately 500 IPM and approximately 25
volts. If these numbers appear, the analog
interface board is functioning properly.

15

SECTION 2 INSTALLATIONS

b. The Test/Amps toggle is a two-position

(maintain contacts) switch that allows the
user to test/demonstrate the control. The
AMPS position (toggle down) is the “normal”
location for all actual welding operations. To
test or demonstrate the control, place the
Amps/Test toggle in its TEST position. This
provides an arc detection signal required to
sequence through the welding cycle. With
this accomplished, open up the accessory

support clapper to release wire feed pressure
and place the “Start-Stop” rocker in the START
position. The control will sequence through
the programmed welding cycle (preflow, weld,
post-flow, etc.).

Please note that if you inadvertently leave
the switch in the amps position instead of
setting the Test position (when testing the
control), the control will shut-down with both
windows “flashing” within 2-seconds after
receiving the “Start” signal.

16

SECTION 3 OPERATIONS

3.0 SETTING UP PROGRAM PARAMETERS

To preset a typical welding schedule that can be used
in either the PANEL or ROBOT location modes do the
following:

Typical Welding (Parameters):

Cold Wire Inch Speed ................................. 75 IPM

Wire Feed Speed ...................................... 185 IPM

Arc Voltage .............................................. 17.9 Volts

Spot Weld Time ...................................... 45 Cycles

Preflow Time ....................................... 1.2 Seconds

Postflow Time......................................3.1 Seconds

Burnback Time .......................................... 7 Cycles

3.1 Preliminary Power Supply Checks

Before programming the control, make sure that the
power supply is properly set-up as follows:

- Check the rear panel of the power supply to make
sure that only the control cable is connected - the
remaining “stick control receptacle/cable” must be
disconnected.

- Depending on the welding process, set the power
supply INDUCTOR control pot as follows:

For SHORT ARC mode , set Inductance potenti­ometer to 5 and adjust for best performance when
welding.

For SPRAY ARC modes set Inductance at MINI­MUM.

3.2.1 The Wire Feed Speed parameter (185 ipm) -
is set differently for Panel and Robot mode operation
as follows:

3.2.2 For PANEL weld-test operation-- To set a
Wire Feed Speed parameter of 185 ipm, raise and

hold the toggle of the left Inc./Dec. switch in its IN­CREASE position until 185 appears in the IPM window.
Notice that this parameter setting will start at zero and
immediately jump to 20 and then rapidly increases (1
ipm at a time) until the 185 ipm setting is reached. If you
overshoot the planned setting, simply “bump” the DE­CREASE position of the left Inc./Dec. toggle to obtain
the exact IPM setting.

3.2.3 For ROBOT welding operation -- the robot
control will send an appropriate analog input signal to
the microprocessor to set the wire feed speed param­eter of 185 ipm.

3.2.4 Arc Voltage must be preset by the operator and
is dependent on the setting of the Panel-Robot switch as
follows:

3.2.5 For PANEL weld-test operation -- Using the
right-side Inc./Dec. toggle switch (on the inside panel),
set an Arc Voltage parameter of 17.9 volts. Raise and
hold the toggle switch in its INCREASE position until

17.9 appears in the VOLTS window. Notice that this
parameter setting will start at zero and immediately
jump to 12 and then rapidly increases (1/10 volt at a
time) until the 17.9 volt setting is reached. If you over­shoot the planned setting, simply “bump” the DE­CREASE position of the right toggle switch to obtain the
exact VOLT setting.

3.2 Program Parameters

A. Pull-out the Power Switch button to energize the

control. The display windows will light up.

B. Although the welding parameters can be set with

the Panel-Robot switch in either position, it is sug­gested that the PANEL position be used so that the
program can be weld tested prior to switching
over the ROBOT for actual analog input signals
to run the operation.

C. Place the Start-Stop rocker switch in the STOP

position -- the Stop position is “normal” for all Robot
operation; however, the Start position must be used
to energize the system for weld testing or welding
without using the Robot interface.

3.2.6 For Robot welding operation -- The robot
control will send an appropriate analog input signal to
the microprocessor to set the required arc voltage pa­rameter of 17.9 volts.

3.2.7 If a cold-wire INCH parameter (of 75 ipm) is
desired -- Actuate the A.H. toggle to its “up” position and

hold it while simultaneously operating the inside Inc./
Dec. toggle until 75 appears in the IPM window. Note
that the cold inch setting starts at 50 ipm and rapidly in
increments (1 ipm at a time) until the 75 ipm setting is
reached.

3.2.8 If shielding gas Preflow and Postflow times
(of 1.2 seconds and 3.1 seconds, respectively) are
desired, actuate the Purge/Reset rocker on the front

cover and hold it. Simultaneously actuate the inside left
Inc./Dec. toggle switch to its INC position until the
digital window directly above displays the desired Gas

17

SECTION 3 OPERATIONS

Preflow (in sec.) setting. Now, actuate the inside-right
Inc./Dec. toggle switch to its INC position desired Gas
Postflow (in sec.) setting. Both of these parameter times
will start at zero and rapidly increase (1/10 second at a
time) until the desired times are achieved. If neither of

these features are desired, or if they are to be
controlled by the Robot, both of these time param­eters must be set to zero.

3.2.9 If either Spotwelding and/or manual
Burnback times (of 45 cycles and 7 cycles, respec­tively) are desired, actuate the Spot/Burnback toggle

switch to its “down” position and hold it. Simulta­neously activate the left Inc./Dec. toggle switch to its
INC position until the digital window directly above dis­plays the desired SPOT time (in cycles) setting. Now
actuate the right Inc./Dec. toggle switch to its INC
position until the digital window directly above dis­plays the desired BURNBACK time (in cycles) setting.
Both of these parameter times will start at zero and
rapidly increase (1 cycle at a time) until the desired
cycles are achieved. If neither of these features are

desired, or if they are to be controlled by the
Robot, their “times” must be set to zero (0). Release
all switches.

Remember -- if a manual Burnback function is
programmed, it will override the normal “automatic
adaptive anti-stick” feature in either welding mode.

b. If after the welding condition is fine-tuned, the

arc starts are unsatisfactory, proceed as follows:

(1) During the weld, actuate and hold the A.H./

Inch Preset switch and observe the numbers
displayed in the IPM and VOLTS windows.

(2) For proper starts, the number in the IPM win-

dow should be in the range from 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.

(4) These adjustments to the control should pro-

vide 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 thepreceding steps.

3.2.10. Assuming all desired parameters have
been programmed, place the control’s Start-Stop switch

in its START position to weld-test the programmed
parameters. If your weld starts are not acceptable, refer
to the following Hot Start Adjustment procedures that
will enhance starting.

3.3 Hot Start Adjustment Procedures

The control is preset at the factory to provide the
optimum starting characteristics for most welding con­ditions. However, due to factors such as incorrect pa­rameters, welding technique, shielding gas, or wire feed
speed, you may have to readjust the factory-set calibra­tions to provide a hot start characteristic in which the
initial starting voltage will be slightly higher than actual
welding voltage (arc voltage) and speed which initially is
somewhat lower than the desired wire feed speed.

To set-up the control to provide this, do the following:

a. Program the welding condition you need in the IPM

(wire feed speed) and VOLTS (arc volt age)
windows, and fine-tune these parameters until you
have the welding arc desired - Do not at this point
concern yourself with the “arc starts”, this follows.

c. If you continue experiencing problems, refer to the

Troubleshooting procedures.

d. If the weld test is satisfactory, the control can now be

placed in the Robot mode.

For ROBOT welding operation w/Robot interface,

the control’s Start-Stop switch must always remain in
the Stop position, and the Robot controls the welding
sequence.

3.4 WELDING OPERATION

3.4.1 Welding In Robot Position

All functions are controlled from the Robot. The
sequence is as follows:

Assuming the Robot controller sends the appropriate
analog signals to preset the Analog Control with the
desired wire speed (IPM) and arc voltage (VOLTS), the
microprocessor is programmed to operate from the
Robot Control.

18

SECTION 3 OPERATIONS

(a) Initiate shielding gas requirements (purge,

pre/postflow), and an input logic signal will
illuminate the control’s GAS LED to indicate
this function.

(c) If provided in the Robot, actuate the desired

Inch Up or Inch Down Robot controls to
position the wire above the workpiece (the
wire will feed at the preset rate). The appro­priate input logic signal will illuminate one of
the control’s LED’s to indicate which func­tion, INCH UP or INCH DOWN, is being
performed. When completed, the LED will
go “off”.

If the cold INCH function is not provided in the Robot
simply operate the control’s up/down INCH rocker
switch on the front cover to position the wire above the
workpiece. (If you wish to change the cold wire inch
speed rate; simply press the desired Up/Down Inch
direction to INC. or DEC. the cold wire speed rate).

(d) To start welding, initiate the Robot’s Cycle

Start control to energize the wire feed
motor, input logic signal(s) will illuminate
the Cycle Start LED and the Arc Estab­lished LED after the wire strikes the work­piece. The preset/actual wire speed and
arc voltage will also be displayed in their
appropriate windows.

(f) To stop welding, operate the Robot’s

cyclestop, contactor-stop, and gas-stop
controls, respectively, to terminate the weld.

The system will also shutdown if the
preset wire speed or arc voltage param­eters cannotbe maintained due to an ab­normal condition; a flashing digital display
will indicate parameter.

The weld will also terminate if a start signal
is pro vided and 2-seconds later the arc
is still not established. This condition is
indicated by both windows flashing.

Do not allow metal-to-metal contact between the
control box and a metal surface connected in any
way to a welding ground. With such contact, a poor
welding ground connection may create a difference
in potential that sends part of the welding current
through the safety ground wiring in the control
cable and wire feeder, resulting in burnout of that
wiring and/or damage to the circuitry. If the safety
ground burns out, the operator may be exposed to
115V shock hazard.

19

SECTION 4 MAINTENANCE & TROUBLESHOOTING

4.0 TROUBLESHOOTING

Be sure that all primary power to the machine has
been externally disconnected. Open wall discon­nect switch or circuit breaker before attempting
inspection or work inside of the power supply.

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 necessary 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 PC
boards on a “static free” surface. If a printed circuit (PC)
board is determined to be the problem, check with your
ESAB supplier for a trade-in on a new PC board. Supply
the distributor with the part number of the PC board
(and preprogram number, as described in step 1-c.
following) 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.

4.1 General

a. Check interconnection between control and

power supply and robot.
b. Energize the power supply and the control.
c. Immediately after the control is turned “on”, a

number (e.g. :3) will appear in the IPM readout

window and will only be displayed for 1-second.

This number identifies the current program (E-

PROMS) used in your control. 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 re-

vision will also appear in the VOLTS readout

window simultaneously.
d. After the one (1) second delay; the preset “Weld”

parameters will be displayed in the IPM and

VOLTS windows.
e. If the control is not functioning properly (or as

described above); for example, the numbers that

appear in one or both of the display windows

are meaningless (all zeros, eights, decimals,

etc.), or are completely incorrect in relation to

your settings, - the memory must be cleared.

This condition might occur after a bad lightning

storm, extremely bad power line surges, etc. To

clear the memory, do the following:

(1) Place the Run-Set key switch in its SET position

(if provided).
(2) Turn “off” the unit’s 115-volt Power switch.
(3) Using one hand, hold both of the Inc/Dec toggle

switches in the INC position while reapplying

110-volt power with the other hand.
(4) Almost immediately after the Power has been

turned “On”, release the Inc/Dec toggle switches

to the neutral (spring-return center) position

and the windows should display the following;

IPM = 0, VOLTS - 100, the indicating a suc-

cessful reset or clearing has taken place.

f. You can now enter the desired information as

described in this booklet.

4.2 No preset displays appear in windows.

a. Make sure the LED Display board harness/plug is

plugged into the P5 receptacle on the MPU board.

b. Check that 115 vac is available across terminals

T1-1 and T1-3, if present; switch closed.

c. 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.

d. Check the input and output voltage of the regulator

“VR”.

(1)The input should be approx. 11 volts across

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

(2)The output should be 5 volts between terminals

T1-12 and T1-10. If voltage is not present, re­place VR, voltage regulator.

Figure 6 - Input/Output (I/O) P.C. Board, P/N 674956

20

SECTION 4 MAINTENANCE & TROUBLESHOOTING

4.3 Present display is provided, but cannot be
varied.

a. Check normal setup procedures described in

Section IV, then;

b. Make sure the key wiring harness plug is properly

connected to receptacle P6 on the MPU board.

c. If the above does not resolve the problem, replace

the MPU board.

4.4 Motor does not run.

a. Check to make sure all required (and/or op-

tional) accessories are correctly assembled as de­scribed in Section II.

b. Make sure that power supply is connected, plug P2

is securely connected to receptacle P2 on the I/O
Board, and then release the clapper arm
(pressure roll) on the Accessory Support Assem­bly.

(1) Operate the control INCH switch. If motor does

not run; replace I/O and MPU boards respec­tively.

(2) If the motor inches, but does not run when the

torch switch is operated (energized), check
the start/stop switch circuit components. If motor
still does not run, check if power supply is pro­viding open-circuit voltage of 72 volts to the
control - if o.c.v. is not being supplied, motor
will not run. Check the power supply for trouble.

(3) Also check that the +/- 12 vdc are provided from

the power supply on T1-16 and T1-17 to T124
common, respectively.

(4) If power supply O.K., replace the I/O and MPU

boards respectively.

4.5 Motor runs, but not at right speed.

a. Check tachometer assembly mounted on the

end of EH-10 wire feed motor.

b. 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.

c. If all items in step b. are in order, and motor

speed is still incorrect, replace MPU board.

4.6 Arc VOLTS display reads zero after Start is
operated.

a. Check that the 5-pin plug is securely connected to

the P receptacle on the MPU board.

b. If no reading is displayed, check for arc voltage

feed-back between terminals TP1 and TP2 test
points on the I/O p.c. board (see Fig. 6). This
voltage signal should correspond to that shown on
the power supply voltmeter.

c. If voltage still reads zero, trace the voltage pickup

wiring from the power supply to J6 or control.

d. Remove the current detector 31419 board to gain

access to the P3 plug (harness) on the MPU p.c.
board. Disconnect the P3 plug from its MPU board
socket and, using a meter check for +/- 12 volt
power supply output between plug pins P3-1 and
P3-2 (for +12v.) and between plug pins P3-4and
P3-2 (for - 12v.) respectively. If voltage is present,
replace the MPU board.

4.7 Control Shut-Down - either preset VOLTS or
IPM displays will flash. The control will flash the
parameter VOLTS or IPM that cannot be main­tained.

These symptoms can occur if the preset conditions,
IPM or VOLTS, cannot be maintained by the con­trol.

a. IPM (speed) abort (IPM window flashes) and

possible causes:

(1) Initial “hot start” parameters incorrectly set. For

proper adjustment, refer to Set-up Procedures

following IV-B-10.
(2) Defective J-governor board.
(3) Defective Motor tachometer board.
(4) Defective I/O board.
(5) Defective MPU board.

b. VOLTS (voltage) abort (VOLT window flashes)

and possible causes:

This problem may be located in the wire feeder or
the power source. To determine this, check the
wire feeder as follows.

(1) Strike an arc and while welding, measure the

potential between T1-15 and T1-24. Note that

as the arc voltage setting is increased, the

potential between T1-15 and T1-24 also in-

creases, and will range from 0 to 10 vdc. 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 (2) following.
(2) If the arc is still unsatisfactory, the problem is

either in the interconnecting cable, the welding

setup, or in the power source. If possible, sub-

stitute a cable or power supply (known to

be good) to check out the possible problem.

21

Schematic Diagram - Analog Interface Sheet 1 of 3

D-31636

22

D-31636

Schematic Diagram - Analog Interface Sheet 2 of 3

23

Schematic Diagram - Analog Interface Sheet 3 of 3

D-31636

24

D-31644

Wiring Diagram - Analog Interface Skeletal - Sheet 1 of 3

25

D-31644

Wiring Diagram - Analog Interface Skeletal - Sheet 2 of 3

26

D-31644

Wiring Diagram - Analog Interface Skeletal - Sheet 3 of 3

27

SECTION 5 REPLACEMENT PARTS

5.0 REPLACEMENT PARTS DATA

5.1 All replacement parts are keyed on the
illustrations which follow. Order replacement parts
by part number and part name, as shown on illustra­tions. DO NOT ORDER BY PART NUMBER
ALONE.

Revision History

Edition "A" (5/2001) includes the REIS Model of the Standard Mig Analog Interface and updates the Equipment
Required listing in Section 2.

5.2 Always state the series or serial number of the
machine on which the parts are to be used. The
serial number is stamped on the unit nameplate.

28

SECTION 5 REPLACEMENT PARTS

1

12

13

4, 5

6

14

See
NOTE 1

3

3.50

.50

15

CB

+

+

SW-5

SW-1

+

MLS SW-4

+ + + +

19

17

10

J1

J3

J2

2

11

8

16

18

J4

J6

VR

7

BOTTOM VIEW - CABINET

FRONT VIEW - CABINET COVER

FIGURE 7, STANDARD MIG ANALOG INTERFACE MICROPROCESSOR CONTROL

(See Code List for Model P/N’s)

Replacement Parts List for Figure 7.

ITEM QTY PART MODEL/CODE
NO. REQ. NO. DESCRIPTION Nos.

- - 31675 STANDARD MIG ANALOG INTERFACE CONTROL - FANUC/KAWASI A

- - 31677 STANDARD MIG ANALOG INTERFACE CONTROL - HITACHI B

- - 31679 STANDARD MIG ANALOG INTERFACE CONTROL - ABB C

- - 0558001376 STANDARD MIG ANALOG INTERFACE CONTROL - REIS D
1 1 31635 ANALOG INTERFACE SKELETAL A - D
2 1 951159 PLUG HOLE C - D
3 1 954079 LABEL ESAB 1.50 X 4.00 A - D
4 1 954075 NAME PLATE A - C
5 1 65609503 RIVET BLIND A - C
6 1 96W85 STRAIN A - C
7 1 0558001403 PLATE ADAPTOR D

8 1 950763 ROBOT CONNECTOR MALE INSERT - J3 A

10 1 950762 19-PIN RECEPTACLE - POWER SUPPLY - J1 A - C
11 1 996514 5-SOCKET RECEPTACLE - MOTOR TACH. - J2 A - C
12 1 993952 6-SOCKET RECEPTACLE - PLUMBING BOX - J4 A - C
13 1 598397 3-PIN RECEPTACLE - VOLTAGE PICKUP - J6 A - C
14 1 950159 VOLTAGE REGULATOR - VR A - C

15 1 950915 POWER SW. OPERATOR A - D

16 1 2062270 START-STOP ROCKER SW. (SW1) A - D
17 1 950295 PURGE/RESET ROCKER SW. (SW4) A - D
18 1 2062363 INCH. ROCKER SW. (SW5) A - D
19 1 950874 CIRCUIT BREAKER, 7-AMP (CB) A - D

1 31671 PLATE ADAPTOR B-C
1 31727 PLATE ADAPTOR A

1 993973 ROBOT CONNECTOR MALE INSERT - J3 B
1 599800 ROBOT CONNECTOR MALE INSERT - J3 C
1 0558001428 ROBOT CONNECTOR MALE INSERT - J3 D

1 950158 TRANSISTOR SOCKET (T0-3) A - C
1 995544 CAPACITOR (C4) - 1UF, 35 WVDC A - C

1 950916 POWER SW. CONTACT A - D
1 950917 POWER SW. BUTTON A - D

29

SECTION 5 REPLACEMENT PARTS

5

16

SW3 SW6

SW7

SW11

11

7-REF.

6

SW10 SW9

9

10

8

13

7

12

FIGURE 8, STANDARD MIG ANALOG INTERFACE, INSIDE CONTROL PANEL

Replacement Parts List for Figure 8.

ITEM QTY PART MODEL/CODE
NO. REQ. NO. DESCRIPTION Nos.

- - 31675 STANDARD MIG ANALOG INTERFACE CONTROL - GMF A

- - 31677 STANDARD MIG ANALOG INTERFACE CONTROL - HITACHI B

- - 31679 STANDARD MIG ANALOG INTERFACE CONTROL - ABB C

- - 0558001376 STANDARD MIG ANALOG INTERFACE CONTROL - REIS D
1 2 636608 22-PIN P.C. BD. RECEPTACLES (P1 & P3) A - D
2 1 17145315 RESISTOR 15K OHM, 2W (R1 BET. P1-13 & P1-16) A - D
3 1 994236 J-GOV. P.C. BD. ASSEMBLY A - D
4 1 31419 CURR. DETECTOR P.C. BD. ASSEMBLY A - D
5 1 950328 LATCH A - D
6 1 675269 VOLTS/IPM DISPLAY P.C. BD. ASSEMBLY A - D
7 1 See F-14-220 OPTIONAL DIG. D.C. AMETER KIT (Inclds; Display

8 1 950229 AMP. TEST SWITCH (SW. 9) A - D
9 1 950789 ANALOG INPUT TEST SWITCH (SW-10) A - D

10 2 950087 3 POSITION TOGGLE SWITCH 125V A - D
11 1 950087 A.H./INCH-SPOT/B’BACK SWITCH (SW7) A - D
12 1 950229 ROBOT-PANEL SWITCH (SW-11) A - D
13 1 675450 ANALOG INTERFACE P.C. BD. ASSEMBLY A - D
14 1 674956 INPUT/OUTPUT (I/O) P.C. BD. ASSEMBLY A ­15 1 18145 MPU P.C. BD. ASSY. GMF - STD A

1 18148 MPU P.C. BD. ASSY. HITACHI - STD B
1 18151 MPU P.C. BD. ASSY. ASEA - STD C

16 1 31441 LOGIC INTERFACE P.C. BD. ASSY. A

1 31440 LOGIC INTERFACE P.C. BD. ASSY. B, C

CONTROL & P.C. Bds.) A - D

30

SECTION 5 REPLACEMENT PARTS

FIGURE 9, STANDARD MIG ANALOG INTERFACE, INNER CABINET COMPONENTS

Replacement Parts List for Figure 9.

ITEM QTY PART MODEL/
NO. REQ. NO. DESCRIPTION CODE Nos.

- - 31675 STANDARD MIG ANALOG INTERFACE CONTROL - GMF A

- - 31677 STANDARD MIG ANALOG INTERFACE CONTROL - HITACHI B

- - 31679 STANDARD MIG ANALOG INTERFACE CONTROL - ABB C

- - 0558001376 STANDARD MIG ANALOG INTERFACE CONTROL - REIS D
1 1 31412 ANALOG TO ANALOG P.C. BD. ASSY A - D
2 2 995103 24-PT. TERMINAL BOARD (T1 & T2) A - D
3 1 17240003 RESISTOR 3-OHM, 25W (R1) A - D
4 1 951089 D.C. RELAY (REVRLY) A - D
5 1 996556 400V. BRIDGE (BR) A - D
6 1 994303 TRANSFORMER (CTR-3) A - D
7 1 30684 TRANSFORMER ASSY. (CTR-1 & 2) A - D
8 1 996918 FILTER NETWORK (FN-1) A - D
9 1 2075712 INSULATOR A - D

10 1 31421 FILTERBOARD (FB) A - D

31

ESAB Welding & Cutting Products, Florence, SC Welding Equipment

COMMUNICATION GUIDE - CUSTOMER SERVICES

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Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
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Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
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D. LITERATURE REQUESTS: Telephone: [phone] / Fax: [phone]

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

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

F-15-080-A 5/2001 Printed in U.S.A.

ESAB Welding & Cutting Products

PO Box 100545 Florence SC 29501-0545