Miller Electric Welding User Manual
OM-169 510
June 1995
Processes
Plasma Arc (PA W) Welding
Description
Automatic Welding
Robot PAW Interface
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www.MillerWelds.com
EMF INFORMATION
NOTE
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of T echnology Assessment,
Effects of Power Frequency Electric & Magnetic Fields –
Background Paper
Government Printing Office, May 1989): “. . . 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.”
, OTA-BP-E-53 (Washington, DC: U.S.
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
To reduce magnetic fields in the workplace, use the following
Biological
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mod10.1 4/93
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1 1. Remote Gas Set/Pilot Arc Start Switch Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 – ROBOT PROGRAM MODIFICATIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Setting Up Plasma (Non-Standard) Torch For MRH
2
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.
SECTION 2 – INTRODUCTION
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.
2-1. DESCRIPTION
The robot P AW interface panel is a control designed to
be used with a Thermal Dynamics WC 100B plasma
SECTION 3 – INSTALLATION
PAW Interface
Panel
Plug PLG21 Connects
To Computer Interface
Receptacle RC8
(See Section 3-7)
Gas Set/Pilot Arc
Start Push Button
Receptacle RC21
(See Section 3-8)
Receptacle RC20
(See Section 3-8)
welding console and a plasma arc welding torch
2
PWM-3A, MILLER Computer Interface, and MRH
or
MRV2 robot system for the Plasma Arc Welding (PAW)
process.
Computer
Interface
Computer Interface
Input Power Receptacle RC11
Location (See Section 3-9 And
Computer Interface Owner’s Manual)
Figure 3-1. PAW Interface Panel
ST-800 732
OM-169 510 Page 1
IMPORT ANT:
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.
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.
3-1. FIELD INSTALLATION INSTRUCTIONS FOR
P A W INTERF ACE 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 lock-
out/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.
1. Remove Computer Interface top cover and left
side panel.
2. Remove side panel from PAW Interface panel.
3. Install P AW 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 ter-
minal 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.
IMPORT ANT :
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 In-
terface 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).
OM-169 510 Page 2
Motor Control
Board PC2
Ground Stud
Location
Terminal
Strip 2T
Figure 3-2. Computer Interface Internal Connections
Left Side View Of
Computer Interface
Voltage Control
Board PC1
Interface
Board PC4
PC4 Switch S1 Location
PC4 Receptacle RC1
Location
Mounting Screw
Location
Filter FL1
Ref. ST-139 887-C
Robot Arm
Shock Sensor Leads
Insulator
Plate
Welding Gun
Body
Mounting
Bracket
Clamp
Shock Sensor
Torch
Mounting
Bracket
Figure 3-3. MRH2 Shock Sensor Unit Assembly And Installation
Torch Clamp
ST-800 733
Output Hub
Bracket
Welding Gun
Body
Angle Bracket
Clamp
Torch Mounting
Bracket
L-Bracket
Insulating Block
Shock Sensor
Leads
Shock Sensor
Angle Bracket
Torch Clamp
Figure 3-4. MRV2 Shock Sensor Unit Assembly And Installation
ST-800 778
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 PLG1 1 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 lock-
out/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:
2
A. MRH
1. If applicable, remove existing gun/torch and insu-
Models
lator 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.
2
B. MRV
1. If applicable, remove existing shock sensor from
2. Assemble shock sensor, mounting bracket, and
3. Install shock sensor unit to robot insulating block
3-3. HIGH-FREQUENCY PROTECTION FOR
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.
IMPORT ANT:
Models
robot arm.
torch clamp as shown in Figure 3-4.
with screws removed in Step 1.
TORCH CABLE
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
MOVING PARTS can cause serious injury.
•
Keep away from moving parts.
HOT SURFACES can cause severe burns.
•
Allow cooling period before servicing.
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 INST ALLATION
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 lock-
out/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.
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. T o install the filter , proceed as
follows:
OM-169 510 Page 5
Robot Control
LEFT SIDE RIGHT SIDE
Blank Cover Plates
(Both Rows)
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 employ-
ing 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 con-
nections 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 Ro-
bot 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
Robot Control side panel where cover plate was
removed.
OM-169 510 Page 6
Blank Cover Plates
S-0782
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 Con-
trol to Interlock board on left side panel of cabi-
net.
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 exist-
ing shock sensor cord from shock sensor leads
at welding gun body (see Figure 3-8).
p. Remove existing shock sensor cord by discon-
necting plug from receptacle on robot.
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