Miller Electric Welding User Manual

0 (0)

OM-169 510

June 1995

Processes

Plasma Arc (PAW) Welding

Description

Automatic Welding

Robot PAW Interface

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www.Miller-

Welds.com

mod10.1 4/93

EMF INFORMATION

NOTE

Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields

The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields ±

Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): ª. . . there is now a very large volume of scientific findings based on experiments at the cellular level and from studies with animals and people which clearly establish that low frequency magnetic fields can interact with, and produce changes in, biological systems. While most of this work is of very high quality, the results are complex. Current scientific understanding does not yet allow us to interpret the evidence in a single coherent framework. Even more frustrating, it does not yet allow us to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.º

To reduce magnetic fields in the workplace, use the following procedures:

1.Keep cables close together by twisting or taping them.

2.Arrange cables to one side and away from the operator.

3.Do not coil or drape cables around the body.

4.Keep welding power source and cables as far away as practical.

5.Connect work clamp to workpiece as close to the weld as possible.

About Pacemakers:

The above procedures are among those also normally recommended for pacemaker wearers. Consult your doctor for complete information.

TABLE OF CONTENTS

SECTION 1 ± SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1-1.

General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

1-2.

Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

SECTION 2 ± INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

2-1.

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

SECTION 3 ± INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

3-1.

Field Installation Instructions For PAW Interface Panel To Computer Interface . . . . . . . . . .

2

3-2.

Shock Sensor Unit Assembly And Installation To Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

3-3.

High-Frequency Protection For Torch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

3-4.

Torch And Torch Cable Installation To Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

3-5.

Ground Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

3-6.

Torch Cable Internal Connections To Plasma Welding Console . . . . . . . . . . . . . . . . . . . . . . .

10

3-7.

PAW Interface Panel ± Computer Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

3-8.

PAW Interface Panel ± Welding Power Source ± PAW Console Connections . . . . . . . . . . .

11

3-9.

Computer Interface ± Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

3-10.

Gas Set/Pilot Arc Start Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

3-11.

Remote Gas Set/Pilot Arc Start Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

SECTION 4 ± ROBOT PROGRAM MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

4-1.

Setting Up Plasma (Non-Standard) Torch For MRH2 Robot . . . . . . . . . . . . . . . . . . . . . . . . . .

13

4-2.

Setting Up Plasma Torch For MRV2 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

4-3.

Marking Position Of Torch Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

4-4.

System Setup For MRH2 And MRV2 With C2 Robot Control . . . . . . . . . . . . . . . . . . . . . . . . . .

14

SECTION 5 ± ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Figure 5-1. Circuit Diagram For Robot PAW System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

Figure 5-2. Circuit Diagram For Robot PAW Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Figure 5-3. Wiring Diagram For Robot PAW Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Figure 5-4. Circuit Diagram For High-Frequency Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Figure 5-5. Wiring Diagram For High-Frequency Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

SECTION 6 ± HF IN PLASMA ARC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

SECTION 7 ± PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26

OM-169 510 ± 6/95

SECTION 1 ± SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.

B. Safety

The installation, operation, maintenance, and troubleshooting of plasma arc welding equipment requires practices and procedures which ensure personal safety and the safety of others.

Read and follow safety information in the Plasma Welding Console Owner's Manual and Welding Torch Owner's Manual, as well as the other Owner's Manuals for this system, to ensure the safe installation and operation of the Plasma Arc Welding system.

1-2. SAFETY ALERT SYMBOL AND SIGNAL WORDS

The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions.

This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements.

WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life.

CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.

IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.

SECTION 2 ± INTRODUCTION

2-1. DESCRIPTION

The robot PAW interface panel is a control designed to be used with a Thermal Dynamics WC 100B plasma

welding console and a plasma arc welding torch PWM-3A, MILLER Computer Interface, and MRH2 or MRV2 robot system for the Plasma Arc Welding (PAW) process.

SECTION 3 ± INSTALLATION

PAW Interface

Panel

 

Computer

 

Interface

Plug PLG21 Connects

 

To Computer Interface

 

Receptacle RC8

 

(See Section 3-7)

 

 

Computer Interface

Gas Set/Pilot Arc

Input Power Receptacle RC11

Start Push Button

Location (See Section 3-9 And

 

Computer Interface Owner's Manual)

Receptacle RC21

 

(See Section 3-8)

 

Receptacle RC20

 

(See Section 3-8)

 

 

ST-800 732

 

Figure 3-1. PAW Interface Panel

OM-169 510 Page 1

IMPORTANT: When installing or operating plasma arc welding equipment, refer to the Plasma Welding Console Owner's Manual and Welding Torch Owner's Manual for specific precautionary information that applies to this equipment.

3-1. FIELD INSTALLATION INSTRUCTIONS FOR PAW INTERFACE PANEL TO COMPUTER INTERFACE (Figure 3-1 And Figure 3-2)

WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down robot and welding power source, and disconnect input power employing lockout/tagging procedures before beginning this installation.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

CAUTION: ELECTROSTATIC DISCHARGE (ESD) can damage circuit boards.

Put on properly grounded wrist strap BEFORE handling circuit boards.

Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misaligned plugs can damage circuit board.

Be sure that plugs are properly installed and aligned.

EXCESSIVE PRESSURE can break circuit board.

Use only minimal pressure and gentle movement when disconnecting or connecting board plugs and removing or installing board.

IMPORTANT: All directions, such as left or right, are with respect to the operator facing the Computer Interface front panel. Retain all hardware removed during this procedure for reinstallation unless specifically told otherwise.

1.Remove Computer Interface top cover and left side panel.

2.Remove side panel from PAW Interface panel.

3.Install PAW Interface frame onto left side panel of Computer Interface with sheet metal screws removed in Step 1 (see Figure 3-1).

4.Make the following internal connections to the Computer Interface (see Figure 3-2).

a.Remove jumper link between terminals B and C on terminal strip 2T.

b.Connect lead 26 from the Interface panel to terminal B on terminal strip 2T.

c.Connect lead 60 from the Interface panel to top mounting screw on filter FL1.

d.Connect green lead from the Interface panel to the ground stud located directly above terminal strip 2T.

IMPORTANT: Remove the outside star washer from the ground stud to make room for the green lead terminal.

e.Remove plug PLG3 from receptacle RC1 on Interface Board PC4.

f.Connect plug PLG10 from the PAW Interface panel to Interface Board PC4 receptacle RC1 where plug PLG3 was removed in Step 4e (plug PLG3 is not connected for this application).

Left Side View Of

Computer Interface

 

Voltage Control

 

Board PC1

Motor Control

 

Board PC2

 

 

Interface

Ground Stud

Board PC4

 

Location

PC4 Switch S1 Location

 

Terminal

PC4 Receptacle RC1

Strip 2T

Location

 

Mounting Screw

 

Location

 

Filter FL1

Ref. ST-139 887-C

Figure 3-2. Computer Interface Internal Connections

OM-169 510 Page 2

Miller Electric Welding User Manual

Robot Arm

Shock Sensor Leads

Insulator

Shock Sensor

Plate

 

Welding Gun

Body

Torch

Mounting

Bracket

Torch Clamp

Mounting

Bracket

Clamp

ST-800 733

Figure 3-3. MRH2 Shock Sensor Unit Assembly And Installation

Output Hub

L-Bracket

Bracket

 

Insulating Block

Shock Sensor

Leads

Welding Gun

Shock Sensor

 

Body

 

Angle Bracket

 

Clamp

 

Torch Mounting

Angle Bracket

Bracket

 

 

Torch Clamp

ST-800 778

Figure 3-4. MRV2 Shock Sensor Unit Assembly And Installation

OM-169 510 Page 3

g.Connect lead 23 from PAW interface panel to terminal A on terminal strip 2T.

h.Route plug 30/31 from PAW interface panel through center baffle in computer interface. Disconnect plug PLG10 from plug PLG11 and connect PLG 30/31 to PLG 10/11.

5.Locate switch S1 on Interface Board PC4 (see Figure 3-2). Remove varnish and potting compound from S1 and place the two DIP switches on S1 in the following positions:

a.S1-1 (Disable Voltage Ramp) in OFF position.

b.S1-2 (Disable Stick Checking) in ON position.

6.Reinstall side panel onto PAW Interface panel.

7.Install supplied top cover onto the Computer Interface ± PAW Interface panel.

3-2. SHOCK SENSOR UNIT ASSEMBLY AND

INSTALLATION TO ROBOT (Figure 3-3 And

Figure 3-4)

WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down robot and welding power source, and disconnect input power employing lockout/tagging procedures before inspecting or installing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

MOVING PARTS can cause serious injury.

Keep away from moving parts.

HOT SURFACES can cause severe burns.

Allow cooling period before servicing.

To assemble and install the shock sensor unit, refer to Figure 3-3 or Figure 3-4 and proceed as follows:

A.MRH2 Models

1.If applicable, remove existing gun/torch and insulator plate from robot arm.

2.Install supplied insulator plate to robot arm with screws removed in Step 1.

3.Assemble shock sensor, mounting bracket, and torch clamp as shown in Figure 3-3.

4.Install shock sensor unit to the insulator plate installed in Step 2 with supplied screws.

B.MRV2 Models

1.If applicable, remove existing shock sensor from robot arm.

2.Assemble shock sensor, mounting bracket, and torch clamp as shown in Figure 3-4.

3.Install shock sensor unit to robot insulating block with screws removed in Step 1.

3-3. HIGH-FREQUENCY PROTECTION FOR TORCH CABLE

The Pilot mode switch on the WC 100B console provides a selection for the pilot arc mode of operation. If plasma arc welding is performed with the switch in the NORMAL position, the optional shield sleeving should be installed on the torch cable.

The optional shield sleeving is for covering the torch cable to prevent high frequency from interfering with robot operations.

IMPORTANT: When installing shield sleeving, be sure end with lead and attached ring terminal is at console end of the torch cable.

To install shield sleeving, proceed as follows:

1.Unscrew sleeve from torch head assembly (see Figure 3-5).

2.Disconnect fittings and remove torch head assembly.

3.Insert torch cable into shield sleeving at end with lead and attached ring terminal.

4.Slide shield sleeving over torch cable until end of torch cable exits opposite end of shield sleeving.

5.Reconnect fittings from torch cable to torch head assembly (match color-coded markings).

6.Check for coolant leaks at fittings by turning on recirculating coolant system. Tighten fittings if necessary.

OM-169 510 Page 4

Sleeve

Green And Black

Connections

Yellow And Red

Connections

Torch Head

Assembly

ST-800 836

Figure 3-5. Connections At Torch Head Assembly

7.Screw sleeve onto torch head assembly.

8.Secure shield sleeving to torch cable using supplied clamp.

3-4. TORCH AND TORCH CABLE INSTALLATION TO ROBOT (Figure 3-3 Thru Figure 3-11)

WARNING: ELECTRIC SHOCK can kill.

Do not touch live electrical parts.

Shut down robot and welding power source, and disconnect input power employing lockout/tagging procedures before inspecting or installing.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

MOVING PARTS can cause serious injury.

Keep away from moving parts.

HOT SURFACES can cause severe burns.

Allow cooling period before servicing.

A. MRH2 Models

1.If applicable, remove the existing wire feed motor/reed relay mounting bracket and stabilizer brace from the robot (refer to robot Owner's Manual for bracket and brace locations). Reinstall the two lifting brackets only (see robot Owner's Manual and Figure 3-10).

2.If applicable, remove the wire feed hub support from the robot (refer to robot Owner's Manual for hub support location). Install supplied torch cable support bracket in location where hub support was secured (see Figure 3-10).

3.The torch cable is enclosed in a black protective case. Secure torch in torch clamp.

IMPORTANT: Before operating, see Section 4 and robot Owner's Manual for instructions for absolute offset adjustment. When doing this procedure, remove the shield cup and tip from torch and install the supplied brass tip gauge.

4.If applicable, remove the existing clamps suspended from the outlet cable support arm and replace them with the two supplied clamps. Route torch cable through new clamps so there is about

3-1/2 ft. (1 m) of cable between the top of the shock sensor and the first clamp (see Figure 3-10).

5.Route torch cable through torch cable support bracket tray and secure with rubber straps.

6.Route remaining end of torch cable to the WC 100B welding panel for internal connections (see Step 3, Section 3-6B).

7.The supplied high frequency filter box prevents noise interference at the shock sensor circuit in the Robot Control. To install the filter, proceed as follows:

OM-169 510 Page 5

Robot Control

 

 

LEFT SIDE

 

 

 

 

 

 

RIGHT SIDE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Blank Cover Plates

Blank Cover Plates

(Both Rows)

 

S-0782

Figure 3-6. View Of Left And Right Sides Of Robot Control

WARNING: ELECTRIC SHOCK can kill. ELECTROSTATIC DISCHARGE (ESD) can damage circuit boards.

Do not touch live electrical parts.

Shut down welding power source and Robot Control, and disconnect input power employing lockout/tagging procedures before inspecting high-frequency filter.

Lockout/tagging procedures consist of padlocking line disconnect switch in open position, removing fuses from fuse box, or shutting off and red-tagging circuit breaker or other disconnecting device.

Put on properly grounded wrist strap BEFORE handling circuit boards or making connections inside Robot Control.

Transport circuit boards in proper staticshielding carriers or packages.

Perform work only at a static-safe work area.

a.Open Robot Control cabinet door using the two supplied keys, and rotate the power switch handle beyond the OFF position to the Reset/Open position.

b.Select and remove a blank cover plate from Robot Control for installing high-frequency filter (see Figure 3-6).

c.Remove screws securing cover to high-fre- quency filter box, and remove cover from box.

d.Insert cord attached to box through opening in

e.Place a supplied external star washer over each screw, and thread screws into mounting holes in side panel (see Figure 3-7).

f.Tighten screws until star washers flatten and penetrate through paint into metal surface.

g.Place remaining star washers over threaded portion of each screw extending out from side panel inside Robot Control, and install nut on each screw.

h.Tighten nuts until star washers flatten and penetrate through paint into metal surface.

i.Reinstall and secure cover onto filter box.

j.Route high-frequency cord inside Robot Control to Interlock board on left side panel of cabinet.

k.Route black and white leads to terminal block TB1 (see Figure 3-9).

l.Connect black lead to terminal 4 on TB1.

m.Connect white lead to terminal 5 on TB1.

n.Close and secure Robot Control cabinet door.

o.Disconnect friction terminals on leads of existing shock sensor cord from shock sensor leads at welding gun body (see Figure 3-8).

Robot Control side panel where cover plate was

p. Remove existing shock sensor cord by discon-

removed.

necting plug from receptacle on robot.

OM-169 510 Page 6

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