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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B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693
Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST Warranty Returns Authorized Repair Stations
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Repair Estimates Repair Status Hours: 7:30 AM to 3:30 PM EST
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Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST
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Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com
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
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