ESAB PAV and GMH User manual

Valid for serial no. 845--xxx--xxxx0740 801 026 2012-04-16

PAV and GMH

Service manual

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Rights reserved to alter specifications without notice.

ENGLISH 3..............................................

ENGLISH

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TOCe

1 READ THIS FIRST 4..................................................

1.1 General 4..................................................................

2SAFETY 5...........................................................

3 Gen eral 7...........................................................

3.1 Versions 7.................................................................

3.2 Block Diagram 8............................................................

4 Configuration and adjustment 9......................................

4.1 General 9..................................................................

4.2 Reset function GMH, PAV 9..................................................

4.3 Selection of sensor for GMH 10................................................

4.4 Connection of Inductive sensor 11..............................................

4.5 Adjusting the sensor fingers working area 12.....................................

4.6 Adjusting the inductive sensors working area 13..................................

4.7 Adjusting the joint tracking regulation speed 14...................................

4.8 Adjusting the manual jog speed 14.............................................

4.9 Jumpers 15..................................................................

4.10 LED indications 17...........................................................

5 Connection of motor cables 18........................................

6 Connection limit switch 19............................................

6.1 General 19..................................................................

7 Con n ectio n emergency stop 20........................................

7.1 General 20..................................................................

7.2 GMH/ PAV with portable control box to an external Emergency chain 22.............

7.3 GMH/ PAV with portable control box to PEH Emergency chain 23..................

7.4 GMH/ PAV with portable control box to PEK Emergency chain 24...................

7.5 GMH/ PAV with control panel to an external Emergency chain 25...................

7.6 GMH/ PAV with control panel to PEH Emergency chain 26.........................

7.7 GMH/ PAV with control panel to PEK Emergency chain 27.........................

8 Component list 28....................................................

8.1 General 28..................................................................

9 Diagram 29...........................................................

10 MOTOR CONTROL CARD AP1 35......................................

10.1 General 35..................................................................

10.2 Supply voltage 36............................................................

10.3 IO 40.......................................................................

10.4 CAN 43.....................................................................

11 Mo to r drive card AP2 44..............................................

11.1 General 44..................................................................

11.2 Supply voltage 45............................................................

11.3 IO 47.......................................................................

11.4 Motor drive card AP2 48......................................................

12 Maintenance 50......................................................

12.1 General 50..................................................................

SPARE PARTS LIST 51..................................................

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1READTHISFIRST

1.1 General

This service manual is intended for use by technicians with electrical/electronic

training, for help in connection with fault-tracing and/or repair.

This manual contains details of all design changes that have been made up to and

including October 2008.

For further informa tion, see instruction manual “0460 671 xxx” for GMH

and “0460 670 xxx“ for PAV.

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2SAFETY

Users of ESAB welding equipm ent have the ultimate responsibility for ensuring that

anyone who works on or near the equipment observes all the relevant safety pre-

cautions. Safety precautions must meet the requirements that apply to this type of

welding equipment. The following recommendations should be observed in addition

to the standard regulations that apply to the workplace.

All work m ust be carried out by trained personnel well-acquainted with the oper-

ation of the welding equipment. Incorrect operation of the equipment may lead to

hazardous situations which can result in injury to the operator and damage to the

equipment.

1. Anyone who uses the welding equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding

2. The operator must ensure that:

S no unauthorised person is stationed within the working area of the equipment

when it is started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from draughts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety

glasses, flame-proof clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns.

5. General precautions

S Make sure the r eturn cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified

electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close

at hand.

S Lubrication and maintenance must not be carried out on the equipment dur-

ing operation.

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WARNING

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAU-

TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE

BASED ON MANUFACTURERS’ HAZARD DATA.

ELECTRIC SHOCK -- Can kill

S Install and earth the welding unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES -- Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE -- Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

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3 General

The PAV and GMD joint tracking equipment are designed to allow positioning and

joint tracking with automatic welding equipment on all types of joints that have a

guide edge which the tracking finger can follow.

The equipment is designed for ESAB standard servo slides and can control one or

two servo motors simultaneously.

FAA is a general motor driver, built into the electrical cabinet.

3.1 Versions

3.1.1 GMH

S Joint tracking Unit with MMC.

S Joint tracking Unit with remote control

S Joint tracking Unit for in building in C&B applications

3.1.2 PAV

S Joint tracking Unit with MMC.

S Joint tracking Unit with remote control

S Joint tracking Unit for in building in C&B applications

3.1.3 FAA

S General motor driver for C&B applications.

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3.2 Block Diagram

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4 Configuration and adjustment

4.1 General

The ESAT service tool is used to configurate and adjust the joint tracking equipment.

For a more detailed description, read the separate manual for the

ESAT ESAB Software Administration Tool.

4.2 Reset function GMH, PAV

General reset or Hardware reset must be carried out when changing product ID for

the circuit card.

4.2.1 ESAT General reset

A General reset is made by calling the ESAT service function:

1. Select “Service functions”

2. Set Service fu n ctio n = 4 Reset

3. Set Argument 2 = General reset.

The following takes place when a General reset is carried out:

S The circuit card' s "flash" memory is reset.

S Factory settings are set depending on the machine type selected.

4.2.2 Hardware reset

The hardware r eset can be carried out without CAN-communication operating on the

circuit card.

To reset the hardware:

1. Turn the machine OF F .

2. Place a jumper between CN23:1, CN23:2 and CN23:3.

3. Turn the machine ON

4. Wait until the LED indicator D10 indicates with a green flashing light.

5. Turn the machine OF F

6. Restore the jumper on CN 23. Place the jumper between CN23:1 and CN23:2.

The following takes place when a Hardware reset is carried out:

S The circuit card' s "flash" memory is reset.

S Factory settings are set depending on the machine type selected.

S Resets the bus speed to 500 kb/sec

S Sets the node address to 6.

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4.2.3 Changing product ID (= Machine type code)

The ESAT function, "Assign machine type code" can be used to change to another

product ID, for products on page 10.

To change product id:

1. Select “Service functions”

2. Set Service fu n ction = 29. Assign machine type code.

3. Select the product code you want to activate.

4. Restart the machine. The new product ID is read during start-up.

5. Perform a General reset or a Hardware reset, see on page 9.

4.3 Selection of sensor for GMH

The GMH can be used together with two different types of sensors.

One is ESAB's standard sensor finger, the other is an inductive sensor.

The GMH leaves the factory set for use with ESAB's sensor finger.

If an inductive sensor is to be used, the following procedure must be taken:

1. Connect the inductive sensor

2. Select the product code you want to activate.

The “Assign machine type co d e” can be changed with ESAT service function

29.

3. Restart the equipment

4. Reset with ESAT service function 4 “Reset” and Set default settings.

4.3.1 The following machine type codes are available

Value Product

1 MechTig

2 GMH with finger sensor

3 PAV

4 GMH with inductive sensor

5 FAA

6 PAL

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4.4 Connection of Inductive sensor

When using the Inductive sensor, connect the jumpers X1:15-16 and X1:16-19.

See the figure below.

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4.5 Adjusting the sensor fingers working area

Automatic joint tracking is only possible when the sensor finger is in the working area

or in the ideal position. If the sensor finger is outside the working area the joint

tracking system will be stopped.

If a long cable is used the sensor fingers signal may be so low that the sensor is

always outside of the working area. In this case an adjustment of the working area

must be made.

4.5.1 Adjusting the parameter ”working area max”

The factory setting for the parameter ”working area max” is 700.

1. Let the sensor finger hang free in the air and read the parameter working area

max with ESAT. If the parameter ”working area max” is below 700 the sensor

finger will always be inside the working area.

2. If necessary write a value of about 50 below the parameter value that has been

read in point 1 (see above). Do a test run.

The figure below describes the different joint tracking modes.

Horizontal

V ertical

1024

0

Total working

range

Ideal working

position 450

Out of working range 700

Joint tracking mode

Horizontal

V ertical

1024

0

Total working

range

Ideal working position 450

vertical, 600 horizontal

Out of working range 700

Joint tracking mode

Horizontal

V ertical

1024

0

Total working

range

Ideal working position 450

vertical, 500 horizontal

Out fo working range 700

Joint tracking mode

Horizontalal

V ertical

1024

0

Total working

range

Ideal working position 450

vertical, 400 horizontal

Out of working range 700

Joint tracking mode

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4.6 Adjusting the inductive sensors working area

ESAT service function 102 is used to adjust the inductive sensors working area (the

same as for the sensor finger).

The following parameters are possible to adjust.

4.6.1 Working distance Up/Down

S Set's the working distance (ideal position) over the plate in 1/100mm. The

working distance must be between max and min limit.

S Min value 700 (7mm)

S Max value 1400 (14mm)

S Factory setting 1100 (11mm)

4.6.2 Working distance Left/Right

S Set's the working distance (ideal position) to the edge in 1/100mm. The working

distance m ust be between max and min limit.

S Min value 700 (7mm)

S Max value 1400 (14mm)

S Factory setting 1100 (11mm)

4.6.3 Working area min limit

S Set's the working area min limit in 1/100mm. The working area min limit must be

lower than the working are m ax limit.

S Min value 700 (7mm)

S Max value 1400 (14mm)

S Factory setting 700 (7mm)

4.6.4

Working area max limit

S Set's the working area max limit in 1/100mm. The working area max limit must

be higher than the working area min limit.

S Min value 700 (7mm)

S Max value 1400 (14mm)

S Factory setting 1400 (14mm)

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4.7 Adjusting the joint tracking regulation speed

Gain

S The “Gain” factor sets how fast the regulation is when seeking the ideal position.

S The factory setting is 8.

S Observe that if the G ain value is to great it will lead to an unstable regulation.

S Max Value 255 (fast regulation)

S Min value 1 (slow regulation)

4.8 Adjusting the manual jog speed

Jog high speed

S Set's how fast the motor speed shall be when driving the motors with the

Joystick in high speed mode.

S The factory settings are 150. 60V*150/256=35V motor voltage

S Min value 1

S Max value 250

Jog low speed

S Set's how fast the motor speed shall be when driving the motors with the

Joystick in low speed mode.

S The factory settings are 80. 60V*80/256=18V motor voltage.

S Min value 1

S Max value 250

4.8.1 Parameter list GMH/PAV

Sensor

finger

Inductive

Sensor

Param.

Nr

Name Setting area Factory

setting-

PAV

Factory

Setting

GMH

Factory

Setting

GMH

400 GMH set register RW 0 0

401 Working area Max 0-1024 RW 700 1712

402 Working Area Min 0-1024 RW 0 1012

403 Target position/ Working

distance

0-1024 RW 450 1414

422 Target position search Right 0-1024 RW 600

423 Target position search Left 0-1024 RW 400

424 Target position H+V 0-1024 RW 500 1412

425 Jog speed high data set1 0+32768” RW 200 200 200

426 Jog speed high data set2 0+32768” RW 200 200 200

427 Jog speed low data set1 0+32768” RW 80 80 80

428 Jog speed low data set2 0+32768” RW 80 80 80

430 GMH Finger 0,10 R

449 GMH status register R

1030 Pos Gain ”0 - +32768” RW 8 4

9004 Product ID RW 3 2 4

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4.9 Jumpers

To locate the jumpers on AP1 see the figure below.

LED--

indication

Jumper CN23

Application/ reset

Jumper CN29

End resistor CAN

Jumper CN19, CN20

Power supply for I/O

Figure 2 (AP1)

4.9.1 I/O supply

The jumpers CN19 and CN20 are assembled between pin 5 and 6. T he input signal

is then 24 V DC on contact CN16 and CN17.

The input signals in CN16 and CN17 can be configured for use as encoder inputs.

This is done when the motor card machine id is a mech control, PEK or FAA unit.

Then the Jumpers are used to select encoder power supply, 5V, 15V or 24VDC.

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4.9.2 End resistor CAN

The jumper between CN29:1 and CN29:2 connects the end resistor in the CAN

circuit.

4.9.3 Application mode software

To change the software from boot mode to application mode the jumper between

CN23:1 and CN23:2 is assembled.

4.9.4 Reset

To reset the software:

S Turn the machine off and place a jumper between CN23:1, CN23:2 and CN23:3.

S Turn the machine on and wait 5 seconds, or until the LED's indicate that the

reset is ready.

S Turn the machine off and place the jumper between CN23:1 and CN23:2.

S Turn the machine on.

N.B. ESAT canalsobeusedtoReset.

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4.10 LED indications

Four LED's indicate the status of the motor cards software.

LED indication

Event Indicator 1

D10

Indicator 2

D11

Indicator 3

D12

Power on and boot program execution started

Red Off Off

Boot program has established contact, received

Id-message *

Red Red Red

Application started

Green Green Green

Application initiated (operationable)

Green Off Off

Application running (flashing 0,25-4 Hz)

Flashing

Green

Off Off

Watchdog timeout - Red -

Non recoverable communication error (CAN busoff) - -

Red

Program loading started Off Green Off

Program loading in progress (Flashing)

Green/Off Off Off

Program loading ok

Green Green Off

Progam loading failed

Red Green Off

Default value setted in Attribute memory

Red Green Red

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5 Connection of motor cables

CN6 Connection,

ver tical motor

CN7 Connection,

horizontal motor

Figure 3 (AP2)

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6 Connection limit switch

6.1 General

When using the limit switch together with GMH and PAV

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7 Connection emergency stop

7.1 General

7.1.1 GMH/ PAV with portable control box (remote control).

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ESAB PAV and GMH User manual

ESAB PAV and GMH User manual

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