ESAB ABB Pulse Analog Interface Robotic Interface User manual

Brand: ESAB

Model: ABB Pulse Analog Interface Robotic Interface

Category: Welding System

Type: User manual

ABB PULSE ANALOG INTERFACE

ROBOTIC INTERFACE

APPLICATION:

MIG AND PULSE MIG WELDING

ROBOT ANALOG INT P/N

ABB RI-1P PULSE 34380

INSTRUCTION MANUAL

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation

and safe practices for arc 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 (Section I) before installing or operating this

equipment.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

F-15-151-B

September, 2000

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels

and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This

equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts

that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or

replacement become necessary, the manufacturer recommends that a telephone or written request for service advice

be made to the Authorized Distributor from whom purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user

of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty

maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility

designated by the manufacturer.

TABLE OF CONTENTS

SECTION TITLE PAGE

PARAGRAPH

SECTION 1 SAFETY ................................................................................................................................... 3

SECTION 2 DESCRIPTION ........................................................................................................................ 7

2.1 Introduction .............................................................................................................................. 7

2.2 Description ............................................................................................................................... 7

SECTION 3 EQUIPMENT............................................................................................................................ 8

3.1 Equipment Required................................................................................................................. 8

3.2 Optional Accessories ............................................................................................................... 9

SECTION 4 OPERATION .......................................................................................................................... 10

4.1 Mounting/Connecting Equipment ........................................................................................... 10

4.2 Control/Indicators ................................................................................................................... 10

4.3 Operation ............................................................................................................................... 11

SECTION 5 TROUBLESHOOTING .......................................................................................................... 15

5.1 Introduction ............................................................................................................................ 15

5.2 Troubleshooting Guide ........................................................................................................... 15

5.3 Diagnostic Mode .................................................................................................................... 18

5.4 Hot Start Adjustment .............................................................................................................. 18

SECTION 6 REPLACEMENT PARTS ....................................................................................................... 21

6.1 General .................................................................................................................................. 21

Parts....................................................................................................................................... 22

WARNING: These Safety Precautions are for

your protection. They summarize precaution-

ary 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 equip-

ment 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 weld-

ing 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 ex-

plosions. Therefore:

1. Remove all combustible materials well away from the

work area or cover the materials with a protective non-

flammable 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 pro-

duce 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.

SAFETY PRECAUTIONS

10/98

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 neces-

sary.

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 Asso-

ciation, 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 move-

ment 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 dam-

aged 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 mis-

take the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS —

May be dangerous. Electric current flow-

ing through any conductor causes lo-

calized Electric and Magnetic Fields

(EMF). Welding and cutting current cre-

ates EMF around welding cables and

welding machines. Therefore:

1. Welders having pacemakers should consult their physi-

cian before welding. EMF may interfere with some pace-

makers.

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.

FUMES AND GASES -- Fumes and

gases, can cause discomfort or harm,

particularly in confined spaces. Do

not breathe fumes and gases. Shield-

ing 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 posi-

tive mechanical ventilation is provided. Do not breathe

fumes from these materials.

2. Do not operate near degreasing and spraying opera-

tions. 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 im-

prove 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

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders, if

mishandled, can rupture and violently

release gas. Sudden rupture of cylin-

der, 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 regu-

lator 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 con-

nected. Secure and move cylinders by using suitable

hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and flames.

Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,

"Precautions for Safe Handling of Compressed Gases in

Cylinders", which is available from Compressed Gas

Association, 1235 Jefferson Davis Highway, Arlington,

VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or

improperly maintained equipment can

cause injury or death. Therefore:

1. Always have qualified personnel perform the installa-

tion, 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 elec-

tric 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, Mi-

ami, 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 Tung-

sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal Arc

Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand-

book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for

Welding and Cutting of Containers That Have Held

Hazardous Substances."

MEANING OF SYMBOLS - As used through-

out 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.

SP98-10

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SECTION 2

DESCRIPTION

2.1 INTRODUCTION

The Analog Interface is a state-of-the art microproces-

sor control designed to interface with robot computer

controllers using analog-system programming. Wire

diameter and material are manually set by the operator.

After wire feed speed is determined, the Analog Inter-

face utilizes a pre-programmed relationship between

wire diameter/material and wire feed speed/arc voltage

to establish arc voltage for the selected wire diameter

and material. Since pulsed MIG welding is predomi-

nantly used, arc voltage is usually determined by the

frequency of the pulses as well as the pulse amplitude

and width. For additional general information, refer to

Table 2-1, Specifications.

Table 2-1. Specifications

Input Requirements 115 V ac, 7 A,

50/60 Hz, 1 PH

Dimensions

Height 15.5 in. (394 mm)

Depth 8 in. (200 mm)

Width 13 in. (330 mm)

Weight (approximate) 20 lbs (9.1 kg)

2.2 DESCRIPTION

Operation of the Analog Interface begins when logic

inputs from the robot controller are received at the Logic

Interface (L/I) board through connector J3. These

signals control the initiation and termination of the

welding process as well as individual functions such as

purge and wire feed. Simultaneous application of the

JOG, CONTACTOR, and GAS PURGE signals (collec-

tively known as the "start" signal) initiates welding.

Through the use of optocouplers within the L/I board,

the logic inputs are isolated from the robot for safety and

then sent to the MPU board for processing. The MPU

consists of D-A converters, counters, timers, and other

processing circuits used to analyze and respond to

most interface inputs. The L/I board also contains

twelve LEDs to indicate which inputs and outputs have

been enabled. This greatly enhances troubleshooting

efficiency by allowing the technician to determine

whether the fault is within the robot controller (no inputs)

or the Analog Interface (no outputs).

Before welding, the robot may need to determine its

relative position to the workpiece. This is accomplished

by a process utilizing the TOUCH REQ (Touch Re-

quest) signal from the robot controller. First, the robot

controller enables the TOUCH REQ input to the L/I

board. This causes the Current Detector board to

supply a +20 V dc bias voltage to the weld wire. When

the wire comes into contact with the workpiece, a short

circuit is formed and the WIRE CONTACT LED will

illuminate as a signal is fed back to the robot to signify

this contact.

The robot controller regulates power source voltage

levels and wire feed speed by sending two analog

signals (in the range of 0-10 V dc) to the Analog

Interface (A/I) board at the same time the "start" signal

is applied. Port 22 of the A/I board controls the wire feed

speed, and Port 21 controls arc voltage via the MPU

board. Since these signals are referenced to the robot's

common when received, their reference must be

changed to the Analog Interface's common before

processing can begin. This changeover occurs in the

A/I board. An 8-bit A-D converter is then used to

produce a digital output (0-250) from these analog

signals. After being sent to the MPU for processing, this

digital input is multiplied by four to obtain a 0-1000 range

(corresponding to the robot's 0-10 V dc input). A similar

process is used to compute the arc voltage.

Wire feed speed is controlled by a full-wave SCR bridge

located on the "J" Governor board. Pulses from the

Tachometer Board, located behind the wire feed motor,

are continuously sent to the MPU board as a reference

to monitor motor speed. The MPU board then counts

these pulses and regulates wire feed speed by sending

a reference signal (0-10 V dc) to the "J" Governor board

via the I/O board. The I/O board provides reference

signals (0 - 10 V dc) to the power source and logic

signals to operate the gas solenoid and contactor as

well.

Arc voltage from connector J6 is filtered in the I/O board

before being sent to the MPU for comparison with the

analog signal from the robot.

Background current for the welding arc is adjustable

between 15 and 100 A. This current level is controlled

by a D-A converter in the I/O board responding to

commands from the MPU.

All incoming signals to the Analog Interface are filtered

by the filter board.

SECTION 3

EQUIPMENT

3.1 EQUIPMENT REQUIRED

A. Analog Interface ........................................ 34380

B. EH-10A Digital Welding Head (20-999 ipm). Each

model includes motor w/gear box, accessory sup-

port and tach feedback unit

1. EH-10AD Plug on Housing .......... 0558001535

2. Motor Ext. Cable, 25-ft ........................ 996808

3. Motor Ext. Cable, 3-ft, ......................... 000107

4. Accessory Support, 2-Roll Drive ...........49V51

5. Accessory Support, 4-Roll Drive ......... 600216

6. Insulator Ring ....................................... 60N90

C. Feed rolls, outlet guides and other wire feed acces-

sories for wire sizes and types that will be used.

(See Table 3-1; Feed Rolls and Outlet Guides)

D. DIGIPULSE 450 Power Source or other suitable

power source

E. A control cable (J1-welding control to power source

cable):

1. 30-ft, 19-cond w/19-pin Amphenols ....... 30780

2. 60-ft, 19-cond w/19-pin Amphenols ....... 30781

3. 6-ft, 19-cond w/19-pin Amphenols......... 30686

F. A robot torch and accessories with capacity rated

for your application.

G. Gas control equipment:

1. R-5007 inert gas regulator/flowmeter. 998124

2. R-5008 CO

regulator/flowmeter ........ 998125

3. 12.5-ft standard duty gas hose ............ 40V77

4. 25-ft standard duty gas hose ...............34V38

5. 12.5 ft heavy duty gas hose ................. 19416

6. 25-ft heavy duty gas hose .................... 19415

(use heavy duty hose for CO

gas)

7. Gas Hose Coupler .............................. 11N17

H. When using a water cooled torch, some of the

following items may be required to supply and drain

the cooling water:

1. 12.5 ft water hose ................................40V76

2. 25-ft water hose ................................. 406196

3. Water Hose Coupling ......................... 11N18

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

1/4 NTP hose ..................................... 11N16

I. Voltage pickup lead (J6-Interface Control to torch);

provides accurate arc voltage feedback to the

Control, 25-ft, 1-cond. cable ...................... 34070

J. Plumbing box:

1. Paddle wheel flow switch w/flow sight

indicator ............................................... 34158

2. Standard flow switch ............................ 34159

K. Plumbing box control cable (J4-Interface to plumb-

ing box; 3-ft, 6-cond) ................................. 34199

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

L. Wire Inlet Guide (provided in Accessory Pkg. P/N

504245) .................................................... 11N53

Table 3-1. Feed Rolls and Outlet Guides

Wire Size

In (mm)

Two Roll Drive

Feed Roll

Four Roll Drive

Feed Roll Kit*

Outlet

Guide

Soft

.035 (.9)

3/64 (1.2)

1/16 (1.6)

2075304(U)

2075301(U)+

2075298

999321(U)

999322(U)

999323(U)

29N13**

Hard

.035 (.9)

.045 (1.2)

.052 (1.3)

1/16 (1.6)

2075303(V)

2075302(V)

2075330(V)

2075299(V)

999326(V)

999327(V)

999328(V)

999329(V)

993860

39N15

Cored Hard

.035 (.9)

.045 (1.2)

.052 (1.3)

1/16 (1.6)

19761 (Serr.)

2075261 (Serr.)

999330 (Serr.)

999331 (Serr.)

999332 (Serr.)

993860

39N15

U = U-groove V = V-groove Serr. = serrated

*Includes a center wire guide and 2 upper and 2 lower

feed rolls.

**Requires outlet guide insert as follows:

For .035 wire use 993902.

For 3/64 wire use 05N57.

For 1/16 wire use 12N57.

+Recommend U-Groove Pressure Roll 2075346 be

used.

SECTION 3

EQUIPMENT

3.2 OPTIONAL ACCESSORIES

The following may be utilized to enhance performance

of the Analog Interface:

Torch Saver II; flow switch plus water filter assembled

to protect water cooled torch against coolant loss,

3/8 gpm .....................................................40V51

Torch Coolant Recirculator;

WC-5B, 115 V ac, 60 Hz ........................... 19947

WC-8B vertical, 115 V ac, 60 Hz, upright .. 30743

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

Digital Ammeter Kit ....................................... 34560

Wire Wiper Accessory, effectively cleans and lubri-

cates wire:

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

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

Wiper Holder, used w/opt. wire

straightener ............................................. 598763

Wire Support Equipment; mount to fixture to hold wire

coils or spools:

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

Spindle Assembly, mounts to Arm .......... 948259

Standard Wire Reel, hold 65 lbs coils ..... 995570

H.D. Wire Reel, holds 65 lbs coils ............. 19V89

Spool Enclosure Kit, covers

12-in spools ............................................ 600240

SECTION 4

OPERATION

4.1 MOUNTING/CONNECTING EQUIP-

MENT

For interconnection information on the Analog Interface

with all required and/or optional accessories, see Fig-

ures 4-1.

Since the operating controls for the Analog 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.

Additional connections and/or adjustments can be found

as follows:

• Torch connections are provided in their re-

spective instruction booklets.

• Installing feed rolls and wire spools, and ad-

justing the accessory support cable can be

found in the Digital Welding Head booklet F-

12-873.

4.2 CONTROLS/INDICATORS

A. Front Panel Controls/Indicators (refer to Figure

4-2).

1. POWER Switch. This switch applies 115 V ac

power as indicated by light on switch.

2. PURGE/RESET Switch. A momentary "on"

switch, this switch provides a dual function

when actuated:

a. Prior to starting the welding sequence, it

actuates the gas solenoid and lets the

operator "purge" the shielding gas line of

the torch.

b. After starting the welding sequence - if an

abort "shutdown" condition occurs (indi-

cated by flashing digital display), the Purge/

Reset switch can be actuated and the

control will automatically "reset".

3. JOG Switch. This switch is used to feed the

wire in the forward direction without actuating

the welding power source. If held down, the

wire feed speed will be 50 IPM for the first 2

seconds, after which time it will switch over to

the preset speed. To increase or decrease this

preset speed, use the INC-DEC key under the

IPM window while the motor is running and the

speed value is displayed.

4. SETUP-WEAVE SETUP-RUN Select Switch.

This three-position rotary switch is only used

for robot control operation, and provides three

modes; Run, Setup, and Weave functions.

This switch should always be placed in its RUN

position for the actual robot welding sequence.

5. Digital Readout Windows. Three individual 3-

digit windows labeled AMPS (optional amme-

ter), IPM and VOLTS are provided to display

actual welding current, preset or actual weld-

ing parameters (wire feed speed and welding

voltage) and time parameters as follows:

NOTE

The numbers displayed prior to application of the "start"

signal represent reference values. The numbers dis-

played after application show actual measured values.

a. AMP Digital Readout. This window is

normally blank unless the optional Amme-

ter Kit is provided to monitor actual welding

current. When installed, the window dis-

plays dc current (AMPS) in a range from 0-

999 amps in one amp increments.

b. IPM Digital Readout. This window is pri-

marily used to display wire feed speed

from 20 to 999 inches per minute in one

inch increments. However, with the appro-

priate function selector actuated, this win-

dow can also display the following:

-- a code number indicating the type of

material which is programmed; for

example, 1 indicates steel; 3 is alumi-

num; 5 is stainless; and 6 is silicon

bronze, etc.

-- cold wire inch speed from 20 to 999

inches per minute in one-inch incre-

ments

c. VOLTS Digital Readout. This window is

primarily used to display arc voltage in

VOLTS from 12 to 50 V dc in one tenth volt

SECTION 4

OPERATION

increments. However, with the appropri-

ate toggle selector actuated, this window

can also display the following:

-- a number indicating the wire diameter

size; for example, 35 indicates .035"

dia., 45 is .045" dia., and 63 is .063"

dia. (1/16" dia.)

-- the arc voltage indicates the com-

puted arc voltage for a given wire

speed. The computed arc voltage can

be readjusted +/-10 volts to fine tune

the welding arc.

9. NO PROGRAM (LED) Light will illuminate only

if you select a wire type (Material) and size

(Diameter) that is not programmed in the con-

trol. In addition, if the light is on, the wire feeder

and power source are disabled.

10. Input/Output Robot Function (LED) Lights will

indicate the specific function(s) being used at

the appropriate time in a welding sequence.

A. INPUTS FROM ROBOT: CONTACTOR,

SHORT ARC, GAS PURGE, SPRAY, JOG,

and TOUCH REQ.

B. OUTPUTS TO ROBOT: ARC EST,

ABORT, and WIRE CONTACT.

11. Circuit Breaker. A 7 ampere circuit breaker

provides protection to the 115 volt control cir-

cuit 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.

B. Inside Panel Controls (refer to Figure 4-3).

1. WIRE DIA/MATERIAL Switch. Activating this

switch allows you to select one of the pre-

programmed wire material types and one of

the pre-programmed wire sizes.

NOTE

Some models are set at the factory for a single welding

condition and do not have this feature.

Table 4-1.

Recommended Shielding Gas

Wire Material Welding Arc Mode

Code # Type Short Arc Spray Arc Pulse Arc

10*

Carbon Steel

Alternate Stl.

4043 Aluminum

5356 Aluminum

308 Stainless

Silicon Bronze

Inconel 82

CO2/C25

C-25

A1025

C-5/C-8

Stargon/C-8

Argon

1%/2%O2

Argon

C-5

Stargon/C-5

Argon

Pulse SS

Argon

*These codes are reserved for special custom applica-

tions.

2. DA/FREQ Switch. (Diagnostic Purposes Only)

After welding initialization, the DA/FREQ switch

will display the actual pulse frequency and the

contents of the speed D-A in pulse mode.

When using conventional MIG welding, the

switch is only useful during actual welding

when it displays the contents of the voltage and

speed D-As.

4.3 OPERATION

A. Select wire diameter and material as follows:

1. To select the type of material, index the INC

position of the INC/DEC toggle switch below

the IPM window until the desired code number

indicating material type (1 and 2 for steel, 3 and

4 for aluminum, 5 for stainless, or 6 for silicon

bronze) appears in the IPM window. Refer to

Table 4-1 for material codes and shielding gas

recommendations.

2. Select the wire diameter to be used by indexing

the INC position of the INC/DEC toggle switch

below the VOLTS window until the desired

numbers indicating wire size (23 for .023" dia.,

30 for .030" dia., 35 for .035" dia., 45 for .045"

dia., or 63 for 1/16" dia.) appear in the VOLTS

window.

SECTION 4

OPERATION

Figure 4-1. Interconnection Diagram (Typical Robot System)

B. Program wire feed speed and arc voltage for an

optimum welding condition. Use of the factory set

parameters will ensure a good baseline weld from

which minor adjustments can be made. The follow-

ing paragraphs describe the programming of the

wire feed speed and the arc voltage using the two

analog inputs from the robot.

1. The scaling for the speed control should be set

with minimum and maximum speed values of

0 and 1000, respectively. The reference volt-

age for minimum and maximum values should

be set to 0 volt and 10 volts, respectively. This

will provide a reading that will directly agree

with the programmed information. For ex-

ample, a setting of 300 on the teach pendant

will result in an actual wire feed speed of 300

IPM.

2. The arc voltage control will be done in a totally

different manner. Since this control is a syner-

gic control, the arc voltage will be a function of

the wire feed speed. Therefore, as the robot

increases the wire feed speed the arc voltage

will automatically increase based on a pre-

programmed relationship between speed and

arc voltage. To change this arc voltage without

changing the wire feed speed, the robot will

have to change the reference voltage on the

voltage port.

Set up scaling for the voltage port with 0 V as

the minimum and 100 as the maximum value,

corresponding to a 0 volt and 10 volt reference

voltage, respectively. To make the first test

weld, it is recommended that the programmed

value be 50 V, which will provide a reference

value of 5 volts to the control.

As a weld is made, the arc voltage correspond-

ing to the 50 V input can be observed. If the arc

is too “hot”, the programmed value may be

changed from 50 to 45. This will cause aver-

age arc voltage to drop by 1.25 volts. A

reduction of 1 count on the programmed value

will reduce the arc voltage by 1/4 volt. Set the

reference for the best weld results.

C. Generate "start" signal from robot. Once the arc is

established, the ARC EST signal is sent to the

robot, which in turn, begins the movement of the

robot arm. If the ARC EST signal is lost, the robot

will send a stop signal to the Interface and termi-

nate the weld.

NOTE

Burnback, preflow gas, and postflow gas are controlled

by the robot and cannot be programmed in the "panel"

mode from the Analog Interface.

SECTION 4

OPERATION

Figure 4-2. Analog Interface Door

SECTION 4

OPERATION

Figure 4-3. Analog Interface Hinged Panel

SECTION 5

TROUBLESHOOTING

5.1 INTRODUCTION

Listed below are a number of trouble symptoms, each

followed by the checks or action suggested to deter-

mine the cause. Listing of checks and/or actions is in

"most probable" order, but is not necessarily 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 compo-

nents when removing a PC board. Always place boards

on a "static free" surface. If a PC board is determined

to be the problem, check with your ESAB supplier for a

trade-in or a new PC board. Supply the distributor with

the part number of the PC board (and pre-program

number, as described in beginning of paragraph 5.2) 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.

5.2 TROUBLESHOOTING GUIDE

Energize the power source and the Analog Interface.

Immediately after the Interface is energized , a number

(e.g. :3) will appear in the IPM readout window for only

1 second. This number identifies the current program

(E-PROMS) used in your Interface. When a program

is changed, the new E-PROMS will automatically iden-

tify the new program number being used. If a revision

is made to an existing program, a number .1, .2, .3, etc.

indicating the numerical revision will also appear in the

VOLTS readout window simultaneously.

A. Numeric display does not appear when power

is applied, or numbers are completely incor-

rect.

1. Perform the following system reset to clear

the memory.

a. Turn off the Interface's 115 volt power

switch.

b. Using one hand, hold both of the INC/

DEC toggle switches in the INC posi-

tion while reapplying 115-volt power

with the other hand.

c. Almost immediately after the power

has been turned on, release the INC/

DEC toggle switches to the neutral

(spring-return center) position. The

IPM window will display 0 and the volts

window will display a value greater

than 0.

2. Make sure the LED display board harness/

plug is plugged into the P5 receptacle on

the MPU board.

3. Check that 115 V ac is present across

terminals T1-1 and T1-3, if present; power

switch and circuit breaker are O.K..

4. Check for plus (+) 5 volts between termi-

nals 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.

5. Check the input and output voltage of the

regulator (VR).

a. The input should be approximately 11

volts across capacitor on regulator

socket. If voltage is not present, re-

place I/O board.

b. If voltage is present, replace VR.

6. Check RAM battery voltage on I/O board

(see Figure 5-1). If potential is less than

3.5 volts, replace battery.

B. Numeric display is present but cannot be var-

ied.

1. Change to "panel" mode by disconnecting

Jumper 1 (refer to Figure 6-3).

2. Set up wire feed speed and arc voltage

(refer to Section 4).

3. Ensure the key wiring harness plug is

properly connected to receptacle P6 on

the MPU board.

4. If the above does not resolve the problem,

replace the MPU board.

5. Reconnect Jumper 1.

SECTION 5

TROUBLESHOOTING

C. Correct numeric display is present, but wire

feed motor does not run.

1. Check to make sure all required (and/or

optional) accessories are correctly as-

sembled as described in section 3.

2. Make sure the power source is connected,

plug P2 and P3 are securely connected to

the I/O board, and then release the clapper

arm (pressure roll) on the accessory sup-

port assembly.

a. Operate the JOG switch. If motor

does not run; replace "J" Governor, I/

O, and MPU boards respectively.

b. If motor feeds backwards due to

mounting orientation of the motor, re-

verse brown and white wires at T1-5

and T1-6 on the lower side of terminal

strip T1.

c. If the motor inches, but does not run

when a weld is attempted, check the

composite "start" signal. If motor still

does not run, check if power supply is

providing open-circuit voltage of 72

volts to the control. If OCV is not being

supplied, motor will not run. Check the

power source for trouble.

d. Check that +/-12 V dc is provided from

the power source on T1-16 and T1-17

to T1-24 common, respectively.

D. Correct numeric display is present, but wire

feed motor runs at incorrect speed.

1. Check tachometer assembly mounted on

the end of EH-10 wire feed motor.

2. Make sure the tach disc is securely fas-

tened 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.

3. If all items in steps 1. and 2. are satisfac-

tory, and motor speed is still incorrect,

possible causes are as follows:

a. Defective MPU board.

b. Defective I/O board.

c. Defective "J" Governor board.

E. Numeric display is present, wire feed motor

runs correctly, but robot does not weld.

1. If "start" signal LEDs (JOG, CONTACTOR,

and GAS PURGE) are not illuminated,

check interconnection between interface,

power source, and robot controller.

2. Check for continuity in wires between in-

terface and robot controller. If fault is

outside of connector J3, refer to robot

manual for further troubleshooting.

F. VOLTS display reads zero as robot attempts to

weld.

NOTE

If VOLTS display reads zero when arc is present, STOP

WELD IMMEDIATELY. Otherwise, torch damage may

result.

1. Trace the voltage pickup wiring from the

power source to J6-A of the Interface.

2. If no reading is displayed, check for arc

voltage feed-back between terminals TP1

and TP2 test points on the I/O PC board.

This voltage signal should correspond to

that shown on the power supply voltmeter.

3. Check that the 5-pin plug is securely con-

nected to the P3 receptacle on the MPU

board.

4. Remove the Current Detector board to

gain access to the P3 plug (harness) on

the MPU PC board. Disconnect plug P3

from its MPU board socket and check for

+/-12 volt power source output between

plug pins P3-1 and P3-2 (for +12 V) and

between plug pins P3-4 and P3-2 (for

-12 V) respectively. If voltage is present,

but still no reading, replace the MPU board.

G. CONTROL SHUTDOWN -- The Interface will

flash the parameter (VOLTS or IPM) that can-

not be maintained.

These symptoms may occur when the re-

quested parameters cannot be maintained by

the Interface. Other possible reasons for a

shutdown are as follows:

SECTION 5

TROUBLESHOOTING

e. If both of the preceding conditions

(steps c. and d.) are satisfactory, but

the arc is still poor, the problem is

either in the interconnecting cable, the

welding setup, or in the power source.

If possible, substitute a cable or power

source (known to be good) to check

out the possible problem; if these are

not available, check calibration of the

I/O board by following the procedures

listed in paragraph 5.3 (Diagnostic

Mode).

f. If unit still aborts on volts after all

previous steps, refer to paragraph 5-4

(Hot Start Adjustment).

H. Weld is poor, ropy, and erratic.

1. Check the MPU board's measurement of

the arc voltage as follows:

a. Using a calibrated meter, measure

potential across TP1 and TP2 on the I/

O board (see Figure 5-1).

b. Verify that this reading equals the volt-

age shown in the VOLTS window.

2. If the MPU board is reading the arc voltage

incorrectly, calibrate as follows:

a. Set switch SW1-1 on MPU board to

the ON position.

b. Connect an accurate meter between

TP1 and TP2 on the I/O board to

measure the arc voltage.

c. Strike an arc and adjust it for a stable

condition. While the arc is in progress,

adjust potentiometer R23 on the MPU

board with a narrow blade screwdriver

until the Interface reads the same as

the external meter.

d. Reset switch SW1-1 to the OFF posi-

tion.

NOTE

SW1-1 must be reset to the OFF position before

welding can occur.

1. IPM (speed) abort and possible causes:

a. Defective J-governor board.

b. Defective Tachometer board.

c. Defective I/O board.

d. Defective MPU board.

e. Initial "hot start" parameters incorrectly

set. Refer to paragraph 5.4 (Hot Start

Adjustment).

Contact ESAB Group Engineering Service for further

assistance (803-669-4411).

2. VOLTS (voltage) abort and possible

causes: The source of this problem may

be located in the wire feeder or the power

source. To determine which, check the

wire feeder as follows:

a. Set the wire feeder for synergic opera-

tion in the pulse welding mode by

operating SW1-1 on Bank 1 of the

MPU board (see Figure 5-2).

b. Set unit to the panel mode by discon-

necting Jumper 1.

c. Using the robot to initiate a weld, mea-

sure the potential between T1-15 (+)

and T1-24 (control signal to the power

source). Note that as the arc voltage

setting is increased, the potential be-

tween T1-15 and T1-24 also increases,

and will range from 0 to 10 V dc. If it

does not, replace the I/O and/or MPU

board. If the potential is present and

responding to the voltage change set-

ting, continue with step d.

d. Now measure the control voltage, for

the background current, between T1-

24 and pin J1-J of the amphenol con-

nector. This measurement can be

taken without striking an arc. The

potential will be in a range from 1 to 2.5

volts. If it is not, replace the I/O and/or

MPU board. If the background poten-

tial is present, continue with step e.

SECTION 5

TROUBLESHOOTING

I. Welds are okay in short arc and spray mode

but poor in pulse mode.

-- Check calibration of the I/O board follow-

ing the procedures listed in paragraph 5-3

(Diagnostic Mode).

J. Analog Interface is not accurately responding

to robot commands (e.g. Robot requests 350

IPM, but Interface displays 300 or 400 IPM).

-- Check calibration of A/I boards as follows:

1. Check for 5 volts on port 22 of the A/I board

and for a speed of 500 in the IPM window.

If 500 IPM is not displayed, adjust R5

(SPEED) on A/I board until 500 IPM is

displayed (see Figure 5-3).

2. Set switch SW1-1 on MPU board to the ON

position. Check for 5 volts on port 21 of the

A/I board and a display of 100 in the

VOLTS window. If 100 VOLTS is not

displayed, adjust R8 (VOLTAGE) on A/I

board until 100 VOLTS is displayed (see

Figure 5-3). Reset SW1-1 to the OFF

position.

NOTE

SW1-1 must be reset to the OFF position before

welding can occur.

5.3 DIAGNOSTIC MODE

Depress the WIRE DIA/MATERIAL key and hold the

IPM INC/DEC key in its down position for 2.5 seconds

until a zero (0) appears in the IPM window. (The 2.5

seconds will prevent accidental zeroing of the Material

code.)

Now release both keys. The display windows will

change to show a background current value (from 0 to

100) in the IPM window, and a pulse height value (from

0.1 to 10) in the VOLTS window. These numbers can

be changed by their respective INC/DEC switches.

To check the calibration of the I/O board, connect a

voltmeter from T1-24 to T1-15 (positive). Provide start

signal from robot and check the measured voltage

against the number displayed in the VOLTS window -

they should both be the same (for example: for a setting

of 5.0, the I/O board should be 5 V dc). If the measured

potential is different, the I/O board should either be

recalibrated (by a qualified technician) by adjusting R54

until reading agrees with preset value (should be done

at 5 volts), or the board should be replaced.

Next, enter a value of 40 in the IPM window. Check the

potential from T1-24(-) to pin J1-J of the Amphenol

connector for a reading of 2 V dc. If 2 +.1 V dc is not

present, replace the I/O board. If all of these readings

are correct, check the power source by using the

"calibration procedure" described in Inverter Control

Board (ICB) Troubleshooting in the Power Supply

manual F-15-014.

5.4 HOT START ADJUSTMENT

The Analog Interface is preset at the factory to provide

optimum starting characteristics for most welding con-

ditions. However, due to factors such as border line

parameters (for a given wire type and size), welding

technique, shielding gas, or wire feed speed, you may

have to readjust the factory-set settings to provide a hot

start in which the initial starting voltage is slightly higher

than actual welding voltage (arc voltage) and the initial

speed is somewhat lower than the selected wire feed

speed desired. The hot start condition will be termi-

nated after 0.3 seconds. The following procedure

should be used.

A. Program the welding condition you need in the IPM

(wire feed speed) and VOLTS (arc voltage) win-

dows, and fine-tune these parameters until you

have the welding arc desired - At this point do not

concern yourself with the "arc starts".

B. If after the welding condition is fine-tuned, but the

"arc starts" are unsatisfactory, proceed as follows:

1. During an actual weld, actuate and hold the

WIRE DIA/MATERIAL 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 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.

SECTION 5

TROUBLESHOOTING

4. These adjustments should provide 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 expe-

rience unstable starts, is to simply check the

start characteristic numbers (while welding) to

make sure they are within the ranges de-

scribed in the preceding steps.

C. If you continue experiencing problems, refer to the

beginning of Section 5 for Troubleshooting proce-

dures.

NOTE

Training and Troubleshooting Courses are available for

maintenance and repair of this and other ESAB Group

equipment. For details, contact ESAB Welding &

Cutting Products, P.O. Box 100545, Ebenezer Road,

Florence, SC 29501-0545; Telephone (803) 669-4411.

Attention: Technical Training Coordinator.

IO PCB - 674994

Battery

MPU PCB - 18158

Dip Switch

E-Prom

Logic Interface PCB - 31440

PC BOARD IDENTIFICATION

SECTION 5

TROUBLESHOOTING

Filter Board - 31421

“J” Governor PCB - 994236

A/I PCB - 31452

Current Detect - 31419

PC BOARD IDENTIFICATION

SECTION 6

REPLACEMENT PARTS

Replacement parts may be ordered from your ESAB

distributor. Refer to the Communication Guide located

on the last page of this manual for a list of customer

service phone numbers.

6.1 General

Replacement parts are illustrated on the following

figures. When ordering replacement parts, order by

part number and part name, as listed. Always provide

the series or serial number of the unit on which the

parts will be used. The serial number is stamped on

the unit nameplate.

SECTION 6

REPLACEMENT PARTS

Figure 6-1. Analog Interface

4, 5, 6

Item

No.

Qty

Req.

Part

No. Description

Ckt.

Symbol

31745

32084

952586

680359

950282

95464

2062363

950295

950874

2062272

CABINET, SILK SCREENED

DOOR, SILK SCREENED

LATCH, CABINET

SWITCH, ROTARY

KNOB

DIODE, 50 V, 1 A (1N4001)

SWITCH, ROCKER

CIRCUIT BREAKER, 7A

SWITCH, ROCKER, DPST

WSW

SW-5

SW-4

MLS

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ESAB ABB Pulse Analog Interface Robotic Interface User manual

Brand: ESAB

Model: ABB Pulse Analog Interface Robotic Interface

Category: Welding System

Type: User manual

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ESAB ABB Pulse Analog Interface Robotic Interface User manual

ESAB ABB Pulse Analog Interface Robotic Interface User manual

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