ESAB Pulse Analog Robotic Interface User manual

Brand: ESAB

Model: Pulse Analog Robotic Interface

Category: Welding System

Type: User manual

F-15-081-D

July, 2001

Be sure this information reaches the operator.

Extra copies are available through your supplier.

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.

INSTRUCTION MANUAL

PULSE ANALOG

ROBOTIC INTERFACE

APPLICATION:

MIG and PULSE MIG WELDING

Analog Item

Robot Interface Number Model

Motoman Pulse 36342 RI-3P

Hitachi Pulse 31678 RI-4P

Kawasaki/Fanuc Pulse 31676 RI-2P

REIS Pulse 0558001377 RI-6P

SPECIFICATIONS

Input Requirements ................... 7 amps, 115vac, 50/60 Hz 1 ph

Dimensions Height ............................ 15-1/2" (394mm)

Depth .................................... 8" (200mm)

Width ................................... 13" (330mm)

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

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

11/95

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.

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 im-

properly 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, 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 Weld-

ing and Cutting of Containers That Have Held Hazardous

Substances."

This symbol appearing throughout this manual

means Attention! Be Alert! Your safety is

involved.

The following definitions apply to DANGER, WARNING,

CAUTION found throughout this manual:

Used to call attention to immediate haz-

ards which, if not avoided, will result in

immediate, serious personal injury or

loss of life.

Used to call attention to potential haz-

ards which could result in personal injury

or loss of life.

Used to call attention to hazards which

could result in minor personal injury.

TEACH Option (for Pulse version only)

This optional kit for the ESAB PULSE analog interface

adds the highest degree of flexibility by enabling the user

to "teach" the Analog Interface custom synergic pulse

parameters for user specific weld applications. Refer to

instruction manual F-15-519 Teach Mode Operating

Instructions for Pulse Analog Interface.

Also available from ESAB;

ESAB CONVENTIONAL Analog Interface

This version of the ESAB Analog Interface offers simple

operation in all modes of conventional MIG welding

including flux cored welding with an exceptionally high

degree of precision. The welding parameters are set by

providing wire speed and voltage signals from the robot.

The interface then sets and precisely regulates the

actual welding parameters.

2. How To Assemble a Robotic Welding System

Robotic welding systems can become quite complex

considering all the equipment required to outfit a work

cell. The following lists the main welding equipment

items to be considered for operation. Consult your

ESAB Sales Literature and the following pages for

specific equipment item numbers. Then use this check

list to be sure that you have all of the required items.

I. FEATURES

ESAB Analog Robot Interface

In general, these microprocessor controls are de-

signed to interface with robot controllers using analog-

system programming and are capable of all modes of

conventional mig and flux cored welding. The ESAB

ANALOG ROBOTIC 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 ANALOG ROBOTIC

INTERFACE and robot controller such as start/stop

signals, shielding gas control, wire touch work, weld

enable, etc.

ESAB PULSE Analog Interface

This version of the ESAB Analog Interface offers all of

the features above plus “synergic” operation in all Mig

modes including Pulsed Mig. This simplifies the opera-

tion even further and can actually increase the overall

performance of the robot cell. The interface is factory

programmed for six (6) materials and five (5) wire sizes;

select material type, wire size, Mig mode (short, spray

or pulse) and the PULSE INTERFACE automatically

sets optimum welding parameters based on wire feed

speed.

Figure 1 - Typical Robot System

EQUIPMENT & HARDWARE CHECK LIST

ESAB Analog Interface ....................................... ❑

ESAB Welding Power Source ............................. ❑

Voltage Pickup Lead (pulse units only) ............... ❑

Power Source Control Cable .............................. ❑

ESAB EH-10A Wire Feed System ...................... ❑

Wire Feed Rolls .................................................. ❑

Motor Extension Cable ....................................... ❑

Wire Inlet Guide .................................................. ❑

Wire Outlet Guide ............................................... ❑

Wire Spool Support ............................................ ❑

Wire Spool Cover ............................................... ❑

Wire Conduit ...................................................... ❑

Wire Conduit Fittings .......................................... ❑

ESAB Plumbing Box ........................................... ❑

Plumbing Box Cable ........................................... ❑

ESAB Water Cooler ............................................ ❑

Water Cooled Welding Torch ............................. ❑

Torch Adapter ..................................................... ❑

Contact Tips ....................................................... ❑

Torch Wire Liner ................................................. ❑

ESAB Flowmeter/Regulator ................................ ❑

Gas Hoses and Fittings ...................................... ❑

Water Hoses and Fittings ................................... ❑

Welding Cables .................................................. ❑

TYPICAL SYSTEM COMPONENTS

Analog Interfaces

31675 Fanuc - Conventional MIG

31677 Hitachi - Conventional MIG

36341 Motoman - Conventional MIG

31676 Kawasaki/Fanuc - Pulse

31678 Hitachi - Pulse

36342 Motoman - Pulse

0558001377 REIS - Pulse

34696 SI - Pulse

34560 Optional Digital DC Ammeter Kit

Interface to Power Source Cables

30686 J1 Control Cable - 6 ft.

30780 J1 Control Cable - 30 ft.

30781 J1 Control Cable - 60 ft.

34070 Pickup Lead (Digipulse only)

Drive Motor & Wire Accessories

679774 EH-10A Digital Motor

49V51 2 Roll Accessory Support

600216 4 Roll Accessory Support

60N90 Insulator Ring (Required)

996808 Motor Control Cable - 25 ft.

996497 EH-10A Motor Mounting Bracket

948259 Spool Spindle Assembly

634288 Reel Support Arm

995570 Coil Adapter

19V89 Coil Adapter HD

20572 CC Torch Adapter

950574 Conduit Assy. 10 ft.

950575 Conduit Connector - Male

679302 Adapter

950576 Conduit Connector - Female

600240 Spool Cover - Clear

34V74 Wire Straightener (order inlet below)

11N53 Inlet Guide

995570 Standard Wire Reel, up to 60 Ibs spools

19V89 H.D. Wire Reel, 65 Ibs coils

600240 Spool Enclosure Kit, 12-in spools

Wire Wiper Accessory

598537 Felt Wiper, pkg. of 10

598764 Wiper Holder

598763 Wiper Holder, used w/opt. wire straight

Power Sources (230/460 vac 60 hz.)

31120 Digipulse 450i

31950 SVI450i

36377 V 352

36000 V 452

36004 V 652 cvcc

Water Accessories

34749 PB-3 Plumbing Box

34199 Plumbing Box Cable - 3.5 ft.

34845 Plumbing Box Cable - 25 ft.

33739 WC-8C Upright Water Circulator

33540 WC-9 EHD Water Circulator

40V76 Water Hose - 12.5'

406196 Water Hose - 25'

11N18 Water Hose Coupler

11N16 5/8-18 RH to 1/4 NPT Adapter

Drive Rolls - Two Roll System

2075303 .035" - “V” Hard Wire

2075302 .045" - “V” Hard Wire

19761 .045" - “V” Serrated - Flux core

2075261 .052" - “V” Serrated - Flux core

2075261 .062" - “V” Serrated - Flux core

Drive Roll Kits - Four Roll System

999326 .035" - “V” Hard Wire

999327 .045" - “V” Hard Wire

999330 .045" - “V” Serrated - Flux core

999331 .052" - “V” Serrated - Flux core

999332 .062" - “V” Serrated - Flux core

39N15 Outlet Guide .035" - .062"

Shielding Gas Accessories

21557 R-33 Flow Regulator - Argon Mix

21558 R-33 Flow Regulator - CO2

21505 R-36 Flow Regulator - Argon Mix

999149 R-76 Flow Regulator - CO2

40V77 Gas Hose - 12.5'

19416 Gas Hose - 12.5' Heavy duty for CO2

11N17 Gas Hose Coupler

Figure 2.

C. MOUNTING/CONNECTING THE EQUIPMENT

Analog Interface

The operating controls for the ESAB Analog Interface

are located on and behind the front cover. The box

should be positioned within easy reach of the Robot

operator on a vertical surface using the mounting holes

provided.

Welding Power Source

The welding power supply should be mounted as close

to the robot as posible. Distances less than 20 feet are

recommended. The power source must have at least

18" of free air space in all directions to maintain ad-

equate unrestricted cooling air flow. Both welding cable

leads (torch and work) must be a minimum size of No.

4/0 welding cable, and should be kept as close to the

same length as possible. Cables must be run next to

each other and tywrapped every couple of feet to

minimize cable reactance.

Wire Feed Motor

The wire feed motor & accessory support can be

mounted directly on the robot arm or on a stand close

to the robot. The shortest possible welding torch is

recommenced for best wire feed results.

Figure 3. - Wire Feed Delivery System

IMPORTANT: The wire drive motor can be mounted as

a left or right hand drive. Once operational, check for

proper rotation. If rotation is incorrect, simply re-

verse the orange and blue wires on T1-5 and T1-6.

Wire Delivery System

The wire delivery system, whether it be a spool, coil, reel

or drum must be kept as close to the robot as possible.

Distances less than 10' are recommended. Every effort

must be made to keep the wire delivery system clean

and the wire conduit free from twists and sharp bends.

IMPORTANT: Wire delivery and feeding is the most

frequent encountered problem in MIG welding and is

sometimes difficult to uncover.

Plumbing Box

The plumbing box should be mounted directly below the

Analog interface with the water cooler.

Once all of the equipment is securely mounted, connect

the control cables, hoses and wire hardware as shown

in the interconnection diagram titled Typical Robot

System (Fig. 1) and the Wire Feed Delivery System

(Fig.2).

Figure 5. HITACHI J3 Pin Configuration

Figure 4. Motoman J3 Pin Configuration

ROBOT to INTERFACE CABLE - J3

In all cases, the control cable from the robot controller

to the ESAB Analog Interface (J3) is supplied by the

robot manufacturer. The connector and pin configura-

tion of this cable has been designed by the robot

manufacturer to their specifications. The ESAB Analog

Interface receptacle (J3) has been configured to accept

the standard control cable from the specified robot.

Questions concerning pin configurations should be

directed to the specific robot manufacturer.

The following figures are the typical J3 control cable pin

configurations for the Motoman, Fanuc, and Hitachi

robots.

Additional information on connections and/or adjust-

ments can be found as follows:

INSTRUCTION LITERATURE

EH-1OA Digital Welding Head ................... F-12-873

Teach Mode Operating Instructions ........... F-15-519

Figure 6. FANUC J3 Pin Configuration

III. CONTROL FUNCTIONS & OPERATION

IMPORTANT

Some of the controls and features covered follow-

ing are not required or used in “all” of the robots,

and these exceptions will be specifically noted in

the text as they occur.

A. FRONT PANEL CONTROLS

For location of front panel controls, see Fig. 8.

1. Power-Switch. Pulling-out the mushroom-style red

button of this switch turns power "on" to 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 de-energize.

NOTE: Immediately after the control is turned on,

numbers that identify the EPROM “program”

in the control are displayed in the IPM and

VOLTS windows. These numbers only ap-

pear for one second.

2. PURGE/RESET Switch. A momentary “on” switch,

that provides a dual function when actuated.

a. Prior to starting the welding sequence, it actu-

ates 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

Fig. 8 - Location Front Panel Controls

Figure 7. REIS ROBOT INTERFACE

Control Cable from Robot

PIN Designations

tor actuated, this window can also display the

following:

-- PREFLOW Time from .1 to 99.9 seconds in

one tenth of a second increments.

-- MATERIAL A code number that indicates the

type of material which is programmed for the

welding modes: for example 1 indicates Steel, 3

is Aluminum, 5 is Stainless, and 6 is Silicon

Bronze

-- SPOT Welding time from 1 to 999 cycles

in one cycle increments or in seconds where 60

cycles equal one/second (must be set to zero for

continuous seam welding)

-- COLD INCH Speed in IPM from 20 to 999

inches per minute in one-inch increments

NOTE: With the 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 read Actual wire speed.

c. Volts Digital Readout. This window is primarily

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

-- WIRE DIA. A number that indicates the diam-

eter of the wire which is preprogrammed for

welding: for example, 35 indicates .035" dia., 45

is .045 dia., and 63 is 1/16" dia. (.063" dia.)

-- ARC VOLTAGE Indicates the computed arc

voltage for a given wire speed. The computed arc

voltage can be readjusted +/-10 volts to fine tune

the welding arc.

NOTE: With the Panel-Robot switch in PANEL and

Power switch turned “on”, and welding, the

VOLTS window will continuously read actual

welding voltage.

-- BURNBACK TIME. If set manually, will over-

ride the automatic adaptive anti-stick feature.

This time period can be set in one-cycle (60

cycles = 1 sec.) increments. When set to “zero”,

the Automatic Adaptive Anti-stick feature will be

operational.

7. NO PROGRAM Indicator (L.E.D.) This light indi-

cates that a wire type (Material) and size (Diameter)

that is not programmed in the control. In addition, if

a start is attempted in which the light lit, the power

supply will not energize and the unit will not feed

wire.

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

Primarily these lights function when the control is

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 a flash-

ing digital display), the Purge/Reset switch can

be actuated and the control will automatically “re-

set”.

3. INCH Up-Down Switch. This switch is used to “cold

inch” the wire, up or down, at a preset speed which

you have programmed. 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.

IMPORTANT: Cold inching is only possible when

the weld Start-Stop rocker switch is

in its “stop” (or off) position.

4. Start-Stop Switch. If the Control is to be used in its

Panel position for manual operation, the Start-Stop

rocker switch is used to initiate the welding sequence

in the START position, and to terminate the welding

sequence in the STOP position.

If the Analog Control is to be used for Robot opera-

tion, the Start-Stop switch must be left in the STOP

position.

5. Pulse-Short - Spray Selector. This three-position

rotary switch allows you to select the mig welding

process mode you wish to use - Pulsed arc, Short

Arc, or Spray Arc.

The welding process can also be selected by the

Robot. Contact ESAB if this feature is desired.

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 param-

eters (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 pro-

vided to monitor actual welding current. When

installed, the window displays d.c. current (AMPS)

in a range from 0-999 amperes in one amp incre-

ments.

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 selec-

5a 5b

Fig. 8 - Inside Panel Controls

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. Remem-

ber, some of the following Input/Output func-

tions are not required or utilized in all Robot

models.

Inputs From Robot: WELD Start, Gas Purge, Inch

Up, Inch Down, and System Enable.

Outputs To Robot: Ready, Arc Established, Abort/

Arc Out, Wire Clear, and WIRE CONTACT.

9. 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.

B. INSIDE PANEL CONTROLS

For location of inside panel controls, see Fig. 8

1. Synergic-Adaptive Switch. This switch, if provided

allows selection of "synergic or adaptive" logic

modes. The operating characteristics of synergic

vs adaptive logic in the welding operation are

covered in more detail in section V B. Only a short

summary is given here.

In the "synergic" mode, the control will display various

numbers to indicate wire type, size, feed rate and times

such as pre, post flow burnback, etc. In place of the arc

voltage, an arbitrary number (100) will appear regard-

less of the set speed. This number appears in the

VOLTS window prior to welding. This value (preset

@100) can be readjusted, within a range from 0 to 200,

to "fine-tune" the operating arc length of the selected

welding condition. By reducing the number below 100

(minimum 0), you will reduce the arc length. Conversely,

by increasing this value above 100 (maximum 200) you

can increase the arc length. The difference between

the set number and "100" will represent the devia-

tion in hertz between the factory suggested fre-

quency and the actual adjusted frequency if you are

in the pulse mode. This can be either positive or

negative. After the arc is struck, the number will be

replaced by the actual welding arc voltage.

The Control can also operate in the adaptive mode,

where the arc is continuously monitored by a closed

loop feedback circuit to maintain the programmed arc

voltage. In the adaptive mode, a computed arc voltage

(unique to your preprogrammed welding selection) will

be displayed in the VOLTS window before welding if

the analog input voltage from the robot is present.

Once the arc is struck, the control will measure the

actual welding voltage and change the output of the

power source to maintain the preset value. In this

manner, the power supply automatically compensates

for variations in stickout or weld joint geometry. Further,

all of the precalculated arc voltages programmed in the

control can be readjusted +/- 10 Volts to "fine-tune" the

welding arc.

2. 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 setup and operated from the

Analog Control itself.

3. Spot/Burnback - Wire Dia./Material Selector.

Operating this toggle allows you to select the follow-

ing:

a. Activating the SPOT/BURNBACK switch (hold-

ing in the up position) allows you to preset either

or both of these times into all three modes of

operation; however, once preset, the times

automatically become part of the three operating

modes. In other words, switching weld modes

maintains the setting.

The SPOT mode allows you to preset “timed-

arc” periods (from . 1 to 99.9 seconds) in the

IPM window using its Inc./Dec. toggle switch.

This feature is primarily used in the PANEL MODE.

When a spotweld time is preset, all “continuous-

type” welding programs are “temporarily disabled”.

To resume normal (continuous) operation, the

spot time has to be set to 0.

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 incre-

ments (60 cycles/sec); and when preset, it will

override the automatic adaptive anti-stick

feature in the three welding modes. If automatic

anti-stick operation is desired, the preset Burn-

back time must be set back to “zero”. For PULSE

operation, the use of the manual burnback setting

is recommended.

b. Activating the WIRE DIA/MATERIAL switch (down

position) allows you to select one of the six pre-

programmed wire material types and one of five

preprogrammed wire sizes. This selection is

necessary for proper operation in all 3 modes;

short, spray and pulse welding. To select the

type of wire Material, use the Inc./Dec. toggle

switch below the IPM window until the desired

code number indicating material type (1 and 2 for

steel, 5 for stainless, 3 and 4 for aluminum, or 6

for silicon bronze) appears in the IPM window.

Now select the Wire Diameter size to be used by

indexing the INC position of the Inc./Dec.

toggle switch below the VOLTS window until

the desired pair of 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.) appears

in the VOLTS window. These values must be set

for both the panel and robot mode.

NOTE: Actuating the Wire Dia/Material switch while

the system is welding, allows you to check

for proper servo operation of the unit. The

Speed (approx 110) and Voltage (approx. 90)

servo settings will appear, simultaneously, in

their respective IPM and VOLTS windows.

Read more about this feature in the "Hot Start"

section.

4. Inc./Dec. Set-Up Switches. Two control switches

are provided to preset the required

welding parameters from the Analog Interface con-

trol panel.

a. “IPM” Increase/Decrease Control. This switch

is primarily used to set and/or vary the wire feed

speed (IPM), along with its other functions; Pre-

flow, Material, Spot and Inch. With the appropri-

ate function selector actuated, each parameter

setting will be displayed in the digital window

directly above this switch.

b. “VOLTS” Increase/Decrease Control. This

switch is primarily used to set and/or vary the

Arc Volts, along with all its other

functions: Postflow, Wire Dia., and Burnback.

With the appropriate function selector actuated,

each parameter setting will be displayed in the

digital window directly above this switch.

5. TEST Toggle Switches -- ANALOG INPUT and

AMPS. These two toggles provide a convenient way

of test-sequencing the program parameters to ei-

ther diagnose a problem, or to test the control

without actually striking a welding arc as follows:

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

tion (momentary up, maintain down) switch

that allows the user to test the operation of the

Analog Interface board when the unit is set to

SYNERGIC in the robot mode . In its normal

Analog position the switch provides continuity to

the Robot Input signals, both voltage and speed.

When the toggle is raised and held in its momen-

tary TEST position, a 5-volt analog signal will be

connected to both the speed and voltage termi-

nals of the Analog Input board. With the

ROBOT/PANEL switch in the ROBOT position,

the speed and voltage display windows should

now reflect the digital equivalent of approxi-

mately *500 IPM and approximately 100

volts**. If these numbers appear, the

analog interface board is functioning properly.

*NOTE: For MOTOMAN robots this will display ap-

proximately 357 IPM and 36 volts.

**NOTE: The 100 will be present only in synergic

mode.

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

tained contact) switch that allows the user to test

the control. The AMPS position (toggle down) is

the “normal” location for all welding operation.

To test the control, place the Amps/Test

toggle in its TEST position. This provides an arc

detection signal required to sequence through

the welding cycle. The ARC ESTABLISHED indi-

cator will be lit while the switch is in this position.

With this accomplished, open up the accessory

support clapper to release wire feed pressure

and place the “Start-Stop” switch in the START

position. The control will sequence through the

programmed welding cycle (preflow, weld,

postflow,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 shutdown with both windows “flash-

ing” within 2-seconds after receiving the “Start”

signal.

6. Teach Pulse Parameter Switch (XRT model only).

This switch allows you to program Pulse Height

(PH), Pulse Width (PW), Pulse Background (PB),

and Pulse Frequency (PF) "teach" parameters into

material codes 11 thru 15. These features and

operating functions are fully covered in XRT supple-

mental booklet F-15-519.

IV. OPERATION

1. Robot Mode - To operate the control in the Robot

mode;

A. Select a wire diameter and a material as follows:

1. Set the type of material, using 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. Set the wire diameter using 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.

3. Set burnback time, by operating the SPOT/BURN-

BACK key and entering a number into the volts

window. A good number to start with would be 4 or

5 cycles.

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 following

paragraphs describe the programming of the wire

feed speed and the arc voltage using the two analog

inputs from the robot.

1. Speed The scaling for the speed input should be

set with minimum and maximum speed values of

0 and 1000, respectively. The reference voltage

for minimum and maximum values should be set

to 0 volt and 10 volts, respectively. This will provide

a speed readout that will directly agree with the

programmed information. For example, a setting

of 300 on the teach pendant will result in an actual

wire feed speed of 300 IPM.

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

totally different manner. Since this control is a

synergic control, the arc voltage will be a function

of the wire feed speed based on the material type

/wire size program selected. Therefore, as the

robot increases the wire feed speed the arc volt-

age will automatically increase based on a

preprogrammed 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 to the voltage

port.

Set up scaling for the voltage port with 0 V as the

minimum and 100 as the maximum value, corre-

sponding 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 corresponding

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 average 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 terminate the

weld.

V. PULSE/SPRAY/SHORT ARC WIRE SPEED

RECOMMENDATIONS

1. General

The listings in the following tables give approximate

wire feed speed ranges (IPM) for the various types of

wire diameters and materials which have been

preprogrammed in these controls.

2. Material Code Operating Tips (Where Applicable)

a. Carbon Steel (Code #1) and Alternate Steel (Code

#2). The Code #2 parameters are very similar to

the Code #1 parameters; however, Code #2 has

wider Pulse Widths and higher Pulse Background

settings. The arc characteristics will appear to be

"softer" than Code #1. Arc penetration could also

be slightly less do to the lower pulse peak used.

This type arc characteristic might be used on

applications requiring improved bead wetting.

Operation Note: Excessive resistances in the

welding system, caused by water cooled torches or

excessively long welding cables, can produce pulse

peak currents below that which is required for stable

droplet detachment. This condition can be recog-

nized by occasional large droplets propelled across

the arc. Some short circuiting and spatter could also

result. Long arc lengths can also cause less than

optimum performance. The arc length should be

Table III for Typical "Short Arc" Wire Speed Ranges

Wire Material Wire Diameter & Wire Speed Range

Code # Type .023* .030* .035 .045 .063

1 Carbon Steel 175- 180- 130- 130- N

500 600 600 450

2* Alternate Stl. 125- 175- 100- 100- NP

350 350 300 250

3* 4043 Allum. NP NP NP NP NP

4 5356 Alum. NP NP NP NP NP

5 308 Stainless 250- 100- 75- 50- NP

450 400 300 250

6* Sil. Bronze NP NP NP NP NP

7**

8**

9**

10**

* Additional wire Materials and Diameters provided in for Xr and XRT models.

** These codes are reserved for custom applications in Xr/XRT models only.

NP Not programmed.

Table IV for Typical "Spray Arc" Wire Speed Ranges

Wire Material Wire Diameter & Wire Speed Range

Code # Type .023* .030* .035 .045 .063

1 Carbon Steel 800- 525- 425- 275- 170-

999 900 800 550 275

2* Alternate Stl. 800- 525- 425- 275- 170-

999 900 800 550 275

3* 4043 Allum. NP 400- 400- 200- 200-

800 600 500 300

4 5356 Alum. NP 450- 450- 300- 250-

750 750 500 450

5 308 Stainless 750- 450- 350- 250- 150-

950 650 650 550 300

6* Sil. Bronze NP 400- 400- 300- NP

550 550 500

7**

8**

9**

10**

* Additional wire Materials and Diameters provided in for Xr and XRT models.

** These codes are reserved for custom applications in Xr/XRT models only.

NP Not programmed.

Table V for Typical "Pulse Arc" Wire Speed Ranges

Wire Material Wire Diameter & Wire Speed Range

Code # Type .023* .030* .035 .045 .063

1 Carbon Steel 150- 115- 85- 55- 75-

700 550 700 450 250

2* Alternate Stl. 140- 150- 140- 70- 70-

700 500 700 400 220

3* 4043 Allum. NP 225- 225- 130- 100-

500 500 300 250

4 5356 Alum. NP 225- 250- 170- 150-

500 500 500 300

5 308 Stainless 150- 100- 100- 60- 55

700 500 450 450 260

6* Sil. Bronze 225- 250- 175- 125- NP

500 500 500 500

7**

8**

9**

10**

* Additional wire Materials and Diameters provided in for Xr and XRT models.

** These codes are reserved for custom applications in Xr/XRT models only.

NP Not programmed.

kept short for best arc stability and puddle control.

Too short an arc length will produce spatter and less

than optimum arc stability. If a globular type transfer

occurs, check for high resistance in the welding

current.

b. Aluminum 4043 (code #3) and 5356 (code #4).

Each alloy and diameter has been set for best

arc performance and puddle control. The wire

feed speed of 4043 3/64-inch diameter (.045) is

limited to 300 ipm at which point the pulses begin

to overlap and spray arc results. If higher wire

feed speeds are required on this alloy, switch to

Code #4 (5356 .045) and adjust the arc voltage

for stable arc performance. This action will ex-

tend the wire feed speed to approximately 600

ipm.

c. 308 Stainless Steel (Code #5). The stainless

steel pulse parameters are based on gases

(listed below). These gases improve the bead

wetting of stainless steel as compared to the 1%

and 2% oxygen mixtures. The program can still

be used with the oxygen mixtures. but a small

adjustment in arc voltage will be necessary. 1.

Linde "Pulse Blend SS"

2. 2-1/2% - CO

, 1%-H

, Bal. Argon

Operation Note: Arc starting with stainless steel

can be inconsistent at times due to the higher

resistivity of the alloy and other variables. Some-

times increasing the voltage will improve starting. A

weld technique adjustment might also help. When

striking the arc, immediately move out of the puddle

and begin traveling. A hesitation in travel at the start

causes the puddle to build under the arc while the

control is trying to adjust for arc voltage. Eliminating

the puddle build-up helps the voltage control circuit

establish the proper arc length more quickly.

d. Silicon Bronze (Code #6). The welding perfor-

mance of silicone bronze alloys currently sold

can vary widely. Small differences in chemistry,

cleanliness, and feedability can affect the pulse

welding characteristics. To overcome instability

problems, be sure wire feeding is steady and

slack in the liner is minimized. Use tip-to-work

distances slightly longer than normal if arc

instability occurs.

B. WELDING IN PULSE, SPRAY OR SHORT ARC

MODE

All three processes can be used in either synergic or

adaptive mode. Following is a summary of the two

modes of operation:

SYNERGIC OPERATION

To put the control into the SYNERGIC mode of opera-

tion, use the synergic/adaptive switch if provided. If the

optional switch is not present, close switch #1 of Dip

Switch SW1.

Fig. 9 - MPU P.C. Board

Synergic Pulse Arc Welding makes use of a relation-

ship between wire feed speed and pulse frequency

which is programmed into the interface control for each

material type and wire size. See typical graph for .045

dia. steel wire.

As the wire feed rate increases, so does the frequency

and since the arc voltage is also related to the frequency

the arc voltage will also increase proportionately.

For each combination of material type and diameter the

graphs will be somewhat different; i.e., the slope of the

line and the intercept will vary, but the general principle

will not change.

The equations that relate frequency and speed; or arc

voltage and speed are stored in the program for most

of the commonly used materials and wire diameters. If

the user selects a particular material and wire size by

entering the code of the material and the diameter of the

wire into the control, the program will search for that

combination. If it is not found, the NO PROGRAM light

will be lit. If program parameters do exist for the

particular combination, all the user need to enter is the

wire feed speed desired and the proper frequency will

automatically be computed by the control.

As the wire feed speed increases, the control will

automatically increase the pulse frequency to maintain

a stable arc. The welding current (heat) can be changed

by increasing or decreasing the IPM without readjusting

voltage. Changes in tip to work will affect arc length.

If the welding arc is too long, or two short an adjustment

of the frequency (arc voltage) can be made to fine tune

the arc. In the synergic mode of operation prior to

striking an arc the display will show the preset IPM in the

"Speed" window and a reference number in the "Volts"

window. After the arc is struck, the actual speed and arc

voltage will be displayed. If the factory set frequency is

used (no fine tuning of the arc was made) the number

displayed prior to striking an arc will be 100. If a change

was made to increase the frequency (arc voltage) the

number will be greater than 100; vice verse, if the

frequency was decreased the resulting reference num-

ber will be less than 100. These numbers will only be

present if the analog control voltage from the robot is

output without the start signal.

The difference between the number displayed and the

number 100 is the amount of change in Hz; that the

control will add or subtract from the factory set fre-

quency. As an example, if at a given speed the number

100 was changed to 85 the new frequency will be (100

- 85); i.e., 15 Hz lower than the factory set value,

lowering the arc voltage by about 1.5 volts.

Once the 100 number is changed, the resulting offset

(100 ± X) will be in effect for any material at any speed.

In effect the curve has been shifted without altering the

slope, by the amount of the offset either in the positive

(numbers greater than 100), or in the negative direction

for numbers less than 100.

Synergic Spray Arc and Short Arc:

Just as in pulse welding, in the short and spray arc

welding as well, a relationship exists between arc

voltage and wire speed for any given wire size and type.

In this mode the unit will operate like a conventional

welder however the arc voltage is set by the weld

control program and changes in tip to work will affect

arc length. The voltage can be read during welding

and increased or decreased to obtain a stable welding

condition based on the wire feed speed used. If the wire

feed speed is changed, the program will calculate the

new voltage necessary to maintain a stable arc.

Just as in the synergic pulse mode, to run at factory set

conditions the display in the "Volts" window should be

100; to increase or decrease the arc voltage, the

number has to be raised or lowered.

ADAPTIVE OPERATION

Pulse Arc Welding:

Adaptive Pulse Mode of Operation

The adaptive mode of operation is also based on a

relationship. In this case the relationship is between

wire feed speed and arc voltage.

Location For

"Dip"" Switch 1 (SW1)

weld using the preprogrammed parameters and fine

tuning them for special requirements, but if this is not

possible, the XRT unit allows the teaching of five

schedules which can be set up and memorized.

For a detailed description of teaching in the PANEL

mode refer to instruction manual F-15-519 Teach Mode

Operating Instructions for Pulse Analog Interface XRT.

V. TROUBLESHOOTING

Be sure that all primary power to the machine has

been externally disconnected. Open wall discon-

nect 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 deter-

mine 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 compo-

nents when removing a PC board. Always place p.c.

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.

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 set

of numbers will appear in the IPM and VOLTS

windows and will only be displayed for one sec-

ond. These numbers identify the current program

(E-PROMS) used in your control. When a pro-

gram is changed, the new EPROM will automati-

cally 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

revision 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.

As the wire feed speed increases, the control will

automatically increase the pulse frequency to maintain

the arc voltage set in the control VOLTS window.

Changes in tip to work will not affect arc length.

Increasing the speed will require an increase in the arc

voltage which in pulse welding will require an increase

in the frequency. These relationships of speed vs. arc

voltage for the commonly used wires are programmed

into the control's EPROM. Just as in the synergic mode

as a material type and wire dia. is entered into the

control, the program will search for the combination. If

it is not found the NO PROGRAM light will be lit.

If it's a valid combination, all the user has to input is the

desired wire feed speed. The program will compute and

display the factory set voltages for the set speed. If fine

tuning is required simply increase or decrease the

displayed voltage value, either before the arc is struck

or during the actual weld.

Spray Arc and Short Arc:

In this mode, the unit will control the power supply to

maintain the arc voltage set up in the VOLTS window of

the control. Changes in tip to work will not change arc

length. The voltage can be preset before welding and

changed during welding to obtain a stable welding

condition based on the wire feed speed used. If the wire

feed speed is changed, then the program will calculate

the new voltage necessary to maintain a stable arc.

Welding can be initiated either from the robot by means

of a START signal, or from the panel with the START/

STOP switch. The panel mode is normally used for

setup and test mode prior to automatic robot welding.

To start welding under robot control, the START/STOP

switch must be in the STOP position, otherwise

welding will not start. This is a safety feature to prevent

arc start without the operator's knowledge.

The system will shut down if the preset wire speed or arc

voltage parameters cannot be maintained due to ab-

normal conditions. If this occurs, the parameters caus-

ing the system shutdown will be signaled by a flashing

digital display and the welding sequence must be

restarted by actuating the PURGE/RESET rocker

switch. Also, a shutdown occurs if an arc is not estab-

lished within 2 seconds after the START signal is

received from the robot. In such a case, both the

VOLTS and IPM displays will be flashing and an "abort"

signal is sent to the robot.

XRT UNITS

The XRT version has all the capabilities of the XR

version, but additionally includes a "Teach" mode to

permit welding of materials and conditions that are not

programmed. It is generally preferable to attempt to

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 set-

tings, - the memory must be cleared. This condi-

tion might occur after a bad lightning storm, ex-

tremely bad power line surges, etc. To clear the

memory, do the following:

(1) Turn "off" the unit's 115-volt Power switch.

(2) Using one hand, hold both of the Inc/Dec

toggle switches in the INC position while reap-

plying 110-volt power with the other hand.

(3) 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 (if synergic),

the indicating a successful reset or clearing

has taken place.

f. You can now enter the desired information as

described in this booklet.

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 regula-

tor "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 termi-

nals T1-12 and T1-10. If voltage is not present,

replace VR, voltage regulator.

3. Display is present, but cannot be varied (panel

operation only).

a. Check normal setup procedures described in

Section V, 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. Motor does not run.

a. Check to make sure all required (and/or optional)

accessories are correctly assembled as described

in Section III.

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 Assem-

bly.

(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

start signal is generated, check the start/stop

switch circuit components, or in the Robot

mode, the presence of the Robot start signal..

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

T1-24 common, respectively.

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

boards respectively.

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 p.c. board.

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

is still incorrect, replace MPU board.

6. Motor runs backwards.

The wire drive motor can be mounted as a left or right

hand drive. Reversing the mounting orientation of

the motor will cause it to appear to run backwards.

This is corrected by simply reversing the orange and

blue wires on T1-5 and T1-6 on the lower side of

terminal strip T1.

7. Arc VOLTS display reads zero after Start is oper-

ated.

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

to the P3 receptacle on the MPU board.

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

feedback between terminals TP1 and TP2 test

points on the I/O p.c. board (see Fig. 8A). 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 on the 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 P3-4

and P3-2 (for - 12v.) respectively. If voltage is

present, but the display is still zero replace the

MPU board. If either +6, +12 or -12 is missing,

replace the I/O board.

Fig. 9A - Input/Output (I/O) P.C. Board, P/N 674994

8. Control Shut-Down - either preset VOLTS or IPM

displays will flash. The control will flash the

parameter VOLTS or IPM that cannot be main-

tained.

These symptoms can occur if the preset conditions,

IPM or VOLTS, cannot be maintained by the control.

a. IPM (speed) abort and possible causes:

(1) Initial "hot start" parameters incorrectly set. For

proper adjustment, refer to Setup Procedures

following V-C-11.

(2) Defective J-governor board.

(3) Defective Motor tachometer board.

(4) Defective I/O board.

(5) Defective MPU board.

Contact ESAB Engineering Services for further

assistance at: voice (843-664-4416)

toll free fax (800-446-5693).

b. VOLTS (voltage) abort and possible causes:

This problem may be caused by the wire feed

system or the power source. To determine which;

(1) Set the wire feeder for synergic operation in the

Pulse welding mode.

(2) 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 increases, 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 (3) following.

(3) Now measure the control voltage, for the back-

ground current, between T1-24 and pin J1-J of

the amphenol connector. 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

potential is present, continue with step (4)

following.

(4) If both of the preceding conditions (steps 2 and 3)

are okay, but the arc is still unsatisfactory,

theproblem is either in the interconnecting cable,

thewelding setup, or in the power source. If

possible, substitute a cable or power supply

(known to be good) to check out the possible

problem; if these are not available, continue with

the wire feeder "calibration test" in step 8 follow-

ing.

8. Erratic arc especially evident in the Pulse mode.

This could be caused by insufficient pulse height.

To check this, make the following "calibration

test" of the I/O board and power source using the

Diagnostic mode.

VI. DIAGNOSTIC MODE

To set up the control in the diagnostic mode, simulta-

neously depress the Wire /Dia Mat'l. 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 windows, 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 or to T1-15 (positive). Operate

the Start switch, 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 8.0, the I/O board should be 8 vdc.). If the measured

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

recalibrated (by a qualified technician) or the board

should be replaced.

Next, check the potential from T1-24 (-) to pin J1-J of

the amphenol connector for a display of 40 in the IPM

windows. The measured reading should be 2 vdc. If it

is not, replace the I/O board. If all of these readings are

correct, check the power supply by using the "calibra-

tion procedure" described in Inverter Control Board

(ICB) Troubleshooting in the Power Supply manual F-

15-014.

NOTE: Training and Troubleshooting Courses are

available for maintenance and repair of this

and other ESAB- equipment. For details,

contact ESAB- Welding & Cutting Systems,

P.O. Box F-6000, Florence, SC 29501; Tele-

phone (843) 669-4411. Attention: Technical

Training Coordinator.

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 window

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. In the "synergic mode", the voltage window will

always display the number 100 and cannot be

adjusted. To help determine which logic mode

(adaptive or synergic) is used, visually check the

adapt/syn and the SW1-1 switch.

4. In the adaptive mode, 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.

VII. REPLACEMENT PARTS DATA

1. All replacement parts are keyed on the illustra-

tions which follow. Order replacement parts by part

number and part name, as shown on illustrations.

DO NOT ORDER BY PART NUMBER ALONE.

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.

D-31636

Fig. 10 - Schematic - Pulse Analog Interface (Sheet 1 of 3)

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ESAB Pulse Analog Robotic Interface User manual

Brand: ESAB

Model: Pulse Analog Robotic Interface

Category: Welding System

Type: User manual

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ESAB Pulse Analog Robotic Interface User manual

ESAB Pulse Analog Robotic Interface User manual

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