F-15-081-DJuly, 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 safepractices 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. DoNOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do notfully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions onpage 2 and 3 before installing or operating this equipment.

INSTRUCTION MANUAL

PULSE ANALOGROBOTIC INTERFACE

APPLICATION:MIG and PULSE MIG WELDING

Analog ItemRobot Interface Number ModelMotoman Pulse 36342 RI-3PHitachi Pulse 31678 RI-4PKawasaki/Fanuc Pulse 31676 RI-2PREIS Pulse 0558001377 RI-6P

SPECIFICATIONSInput Requirements ................... 7 amps, 115vac, 50/60 Hz 1 phDimensions Height ............................ 15-1/2" (394mm)

Depth .................................... 8" (200mm)Width ................................... 13" (330mm)Weight (approx.) ............... 20 lbs (9.1 kg)

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WARNING: These Safety Precautions are foryour protection. They summarize precaution-ary information from the references listed inAdditional Safety Information section. Before

performing any installation or operating procedures, besure to read and follow the safety precautions listed belowas well as all other manuals, material safety data sheets,labels, etc. Failure to observe Safety Precautions can resultin injury or death.

PROTECT YOURSELF AND OTHERS --Some welding, cutting, and gougingprocesses are noisy and require earprotection. The arc, like the sun, emitsultraviolet (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 workarea, even if welding helmets, face shields, and gogglesare also required.

2. Use a face shield fitted with the correct filter and coverplates to protect your eyes, face, neck, and ears fromsparks and rays of the arc when operating or observingoperations. Warn bystanders not to watch the arc andnot to expose themselves to the rays of the electric-arcor hot metal.

3. Wear flameproof gauntlet type gloves, heavy long-sleeveshirt, cuffless trousers, high-topped shoes, and a weld-ing helmet or cap for hair protection, to protect againstarc rays and hot sparks or hot metal. A flameproof apronmay also be desirable as protection against radiatedheat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,trouser cuffs, or pockets. Sleeves and collars should bekept buttoned, and open pockets eliminated from thefront of clothing

5. Protect other personnel from arc rays and hot sparkswith a suitable non-flammable partition or curtains.

6. Use goggles over safety glasses when chipping slag orgrinding. Chipped slag may be hot and can fly far.Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat fromflames and arcs can start fires. Hot slagor sparks can also cause fires and ex-plosions. Therefore:

1. Remove all combustible materials well away from thework area or cover the materials with a protective non-flammable covering. Combustible materials include wood,cloth, sawdust, liquid and gas fuels, solvents, paints andcoatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks orcrevices in floors or wall openings and cause a hiddensmoldering fire or fires on the floor below. Make certainthat such openings are protected from hot sparks andmetal.“

3. Do not weld, cut or perform other hot work until theworkpiece has been completely cleaned so that thereare no substances on the workpiece which might pro-duce flammable or toxic vapors. Do not do hot work onclosed containers. They may explode.

4. Have fire extinguishing equipment handy for instant use,such as a garden hose, water pail, sand bucket, orportable fire extinguisher. Be sure you are trained in itsuse.

SAFETY PRECAUTIONS

11/95

5. Do not use equipment beyond its ratings. For example,overloaded welding cable can overheat and create a firehazard.

6. After completing operations, inspect the work area tomake certain there are no hot sparks or hot metal whichcould 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 liveelectrical parts and ground can causesevere injury or death. DO NOT use ACwelding current in damp areas, if move-ment is confined, or if there is danger offalling.

1. Be sure the power source frame (chassis) is connectedto 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 fatalshock.

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 fromwork and from ground.

7. Do not stand directly on metal or the earth while workingin tight quarters or a damp area; stand on dry boards oran 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 andwelding 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 areunknown.

3. Welders should use the following procedures to minimizeexposure 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.

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FUMES AND GASES -- Fumes andgases, can cause discomfort or harm,particularly in confined spaces. Donot breathe fumes and gases. Shield-ing gases can cause asphyxiation.Therefore:

1. Always provide adequate ventilation in the work area bynatural or mechanical means. Do not weld, cut, or gougeon materials such as galvanized steel, stainless steel,copper, zinc, lead, beryllium, or cadmium unless posi-tive mechanical ventilation is provided. Do not breathefumes from these materials.

2. Do not operate near degreasing and spraying opera-tions. The heat or arc rays can react with chlorinatedhydrocarbon vapors to form phosgene, a highly toxicgas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritationwhile operating, this is an indication that ventilation is notadequate. Stop work and take necessary steps to im-prove ventilation in the work area. Do not continue tooperate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)for specific ventilation recommendations.

CYLINDER HANDLING -- Cylinders, ifmishandled, can rupture and violentlyrelease gas. Sudden rupture of cylin-der, valve, or relief device can injure orkill. Therefore:

1. Use the proper gas for the process and use the properpressure reducing regulator designed to operate fromthe compressed gas cylinder. Do not use adaptors.Maintain hoses and fittings in good condition. Followmanufacturer's operating instructions for mounting regu-lator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chainor strap to suitable hand trucks, undercarriages, benches,walls, post, or racks. Never secure cylinders to worktables or fixtures where they may become part of anelectrical circuit.

3. When not in use, keep cylinder valves closed. Havevalve protection cap in place if regulator is not con-nected. Secure and move cylinders by using suitablehand 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 inCylinders", which is available from Compressed GasAssociation, 1235 Jefferson Davis Highway, Arlington,VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or im-properly maintained equipment can causeinjury 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 toperform such work.

2. Before performing any maintenance work inside a powersource, disconnect the power source from the incomingelectrical power.

3. Maintain cables, grounding wire, connections, power cord,and power supply in safe working order. Do not operateany equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keepequipment away from heat sources such as furnaces, wetconditions such as water puddles, oil or grease, corrosiveatmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position andin good repair.

6. Use equipment only for its intended purpose. Do notmodify it in any manner.

ADDITIONAL SAFETY INFORMATION -- Formore information on safe practices for elec-tric arc welding and cutting equipment, askyour supplier for a copy of "Precautions andSafe Practices for Arc Welding, Cutting andGouging", Form 52-529.

The following publications, which are available from theAmerican 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 HazardousSubstances."

This symbol appearing throughout this manualmeans Attention! Be Alert! Your safety isinvolved.

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 inimmediate, serious personal injury orloss of life.

Used to call attention to potential haz-ards which could result in personal injuryor loss of life.

Used to call attention to hazards whichcould result in minor personal injury.

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TEACH Option (for Pulse version only)This optional kit for the ESAB PULSE analog interfaceadds the highest degree of flexibility by enabling the userto "teach" the Analog Interface custom synergic pulseparameters for user specific weld applications. Refer toinstruction manual F-15-519 Teach Mode OperatingInstructions for Pulse Analog Interface.

Also available from ESAB;ESAB CONVENTIONAL Analog InterfaceThis version of the ESAB Analog Interface offers simpleoperation in all modes of conventional MIG weldingincluding flux cored welding with an exceptionally highdegree of precision. The welding parameters are set byproviding wire speed and voltage signals from the robot.The interface then sets and precisely regulates theactual welding parameters.

2. How To Assemble a Robotic Welding SystemRobotic welding systems can become quite complexconsidering all the equipment required to outfit a workcell. The following lists the main welding equipmentitems to be considered for operation. Consult yourESAB Sales Literature and the following pages forspecific equipment item numbers. Then use this checklist to be sure that you have all of the required items.

I. FEATURESESAB Analog Robot InterfaceIn general, these microprocessor controls are de-signed to interface with robot controllers using analog-system programming and are capable of all modes ofconventional mig and flux cored welding. The ESABANALOG ROBOTIC INTERFACE receives analogparameter inputs from a robot controller, processesthese signals and accurately controls the weldingpower supply and wire feeding system. Other data isexchanged between the ESAB ANALOG ROBOTICINTERFACE and robot controller such as start/stopsignals, shielding gas control, wire touch work, weldenable, etc.

ESAB PULSE Analog InterfaceThis version of the ESAB Analog Interface offers all ofthe features above plus “synergic” operation in all Migmodes including Pulsed Mig. This simplifies the opera-tion even further and can actually increase the overallperformance of the robot cell. The interface is factoryprogrammed for six (6) materials and five (5) wire sizes;select material type, wire size, Mig mode (short, sprayor pulse) and the PULSE INTERFACE automaticallysets optimum welding parameters based on wire feedspeed.

Figure 1 - Typical Robot System

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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 COMPONENTSAnalog Interfaces

31675 Fanuc - Conventional MIG31677 Hitachi - Conventional MIG36341 Motoman - Conventional MIG31676 Kawasaki/Fanuc - Pulse31678 Hitachi - Pulse36342 Motoman - Pulse0558001377 REIS - Pulse34696 SI - Pulse34560 Optional Digital DC Ammeter Kit

Interface to Power Source Cables30686 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 Accessories679774 EH-10A Digital Motor49V51 2 Roll Accessory Support600216 4 Roll Accessory Support60N90 Insulator Ring (Required)996808 Motor Control Cable - 25 ft.996497 EH-10A Motor Mounting Bracket948259 Spool Spindle Assembly634288 Reel Support Arm995570 Coil Adapter19V89 Coil Adapter HD20572 CC Torch Adapter950574 Conduit Assy. 10 ft.950575 Conduit Connector - Male679302 Adapter950576 Conduit Connector - Female600240 Spool Cover - Clear34V74 Wire Straightener (order inlet below)11N53 Inlet Guide995570 Standard Wire Reel, up to 60 Ibs spools19V89 H.D. Wire Reel, 65 Ibs coils600240 Spool Enclosure Kit, 12-in spools

Wire Wiper Accessory598537 Felt Wiper, pkg. of 10598764 Wiper Holder598763 Wiper Holder, used w/opt. wire straight

Power Sources (230/460 vac 60 hz.)31120 Digipulse 450i31950 SVI450i36377 V 35236000 V 45236004 V 652 cvcc

Water Accessories34749 PB-3 Plumbing Box34199 Plumbing Box Cable - 3.5 ft.34845 Plumbing Box Cable - 25 ft.33739 WC-8C Upright Water Circulator33540 WC-9 EHD Water Circulator40V76 Water Hose - 12.5'406196 Water Hose - 25'11N18 Water Hose Coupler11N16 5/8-18 RH to 1/4 NPT Adapter

Drive Rolls - Two Roll System2075303 .035" - “V” Hard Wire2075302 .045" - “V” Hard Wire19761 .045" - “V” Serrated - Flux core2075261 .052" - “V” Serrated - Flux core2075261 .062" - “V” Serrated - Flux core

Drive Roll Kits - Four Roll System999326 .035" - “V” Hard Wire999327 .045" - “V” Hard Wire999330 .045" - “V” Serrated - Flux core999331 .052" - “V” Serrated - Flux core999332 .062" - “V” Serrated - Flux core39N15 Outlet Guide .035" - .062"

Shielding Gas Accessories

21557 R-33 Flow Regulator - Argon Mix21558 R-33 Flow Regulator - CO221505 R-36 Flow Regulator - Argon Mix999149 R-76 Flow Regulator - CO240V77 Gas Hose - 12.5'19416 Gas Hose - 12.5' Heavy duty for CO211N17 Gas Hose Coupler

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Figu

re 2

.

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C. MOUNTING/CONNECTING THE EQUIPMENT

Analog InterfaceThe operating controls for the ESAB Analog Interfaceare located on and behind the front cover. The boxshould be positioned within easy reach of the Robotoperator on a vertical surface using the mounting holesprovided.

Welding Power SourceThe welding power supply should be mounted as closeto the robot as posible. Distances less than 20 feet arerecommended. The power source must have at least18" of free air space in all directions to maintain ad-equate unrestricted cooling air flow. Both welding cableleads (torch and work) must be a minimum size of No.4/0 welding cable, and should be kept as close to thesame length as possible. Cables must be run next toeach other and tywrapped every couple of feet tominimize cable reactance.

Wire Feed MotorThe wire feed motor & accessory support can bemounted directly on the robot arm or on a stand closeto the robot. The shortest possible welding torch isrecommenced for best wire feed results.

Figure 3. - Wire Feed Delivery System

IMPORTANT: The wire drive motor can be mounted asa left or right hand drive. Once operational, check forproper rotation. If rotation is incorrect, simply re-verse the orange and blue wires on T1-5 and T1-6.

Wire Delivery SystemThe wire delivery system, whether it be a spool, coil, reelor drum must be kept as close to the robot as possible.Distances less than 10' are recommended. Every effortmust be made to keep the wire delivery system cleanand the wire conduit free from twists and sharp bends.IMPORTANT: Wire delivery and feeding is the mostfrequent encountered problem in MIG welding and issometimes difficult to uncover.

Plumbing BoxThe plumbing box should be mounted directly below theAnalog interface with the water cooler.

Once all of the equipment is securely mounted, connectthe control cables, hoses and wire hardware as shownin the interconnection diagram titled Typical RobotSystem (Fig. 1) and the Wire Feed Delivery System(Fig.2).

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Figure 5. HITACHI J3 Pin Configuration

Figure 4. Motoman J3 Pin Configuration

ROBOT to INTERFACE CABLE - J3In all cases, the control cable from the robot controllerto the ESAB Analog Interface (J3) is supplied by therobot manufacturer. The connector and pin configura-tion of this cable has been designed by the robotmanufacturer to their specifications. The ESAB AnalogInterface receptacle (J3) has been configured to acceptthe standard control cable from the specified robot.Questions concerning pin configurations should bedirected to the specific robot manufacturer.

The following figures are the typical J3 control cable pinconfigurations for the Motoman, Fanuc, and Hitachirobots.

Additional information on connections and/or adjust-ments can be found as follows:

INSTRUCTION LITERATUREEH-1OA Digital Welding Head ................... F-12-873Teach Mode Operating Instructions ........... F-15-519

Figure 6. FANUC J3 Pin Configuration

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1 3210 4

b co

7

6

8

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III. CONTROL FUNCTIONS & OPERATION

IMPORTANTSome 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 inthe text as they occur.

A. FRONT PANEL CONTROLSFor location of front panel controls, see Fig. 8.

1. Power-Switch. Pulling-out the mushroom-style redbutton of this switch turns power "on" to the control asindicated by the illuminated display windows. To turnpower "off", simply push-in red button and the displaywindows 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 andVOLTS 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” theshielding 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

J3PIN Designations

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tor actuated, this window can also display thefollowing:-- PREFLOW Time from .1 to 99.9 seconds inone tenth of a second increments.-- MATERIAL A code number that indicates thetype of material which is programmed for thewelding modes: for example 1 indicates Steel, 3is Aluminum, 5 is Stainless, and 6 is SiliconBronze-- SPOT Welding time from 1 to 999 cyclesin one cycle increments or in seconds where 60cycles equal one/second (must be set to zero forcontinuous seam welding)-- COLD INCH Speed in IPM from 20 to 999inches per minute in one-inch increments

NOTE: With the Panel/Robot switch in “PANEL” andPower switch turned “on”, but not welding, theIPM window will continuously read Presetwire speed. When the arc is struck, the IPMwindow will read Actual wire speed.

c. Volts Digital Readout. This window is primarilyused to display arc voltage in VOLTS from 12 to50 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 inone tenth of a second increments-- WIRE DIA. A number that indicates the diam-eter of the wire which is preprogrammed forwelding: for example, 35 indicates .035" dia., 45is .045 dia., and 63 is 1/16" dia. (.063" dia.)-- ARC VOLTAGE Indicates the computed arcvoltage for a given wire speed. The computed arcvoltage can be readjusted +/-10 volts to fine tunethe welding arc.

NOTE: With the Panel-Robot switch in PANEL andPower switch turned “on”, and welding, theVOLTS window will continuously read actualwelding voltage.

-- BURNBACK TIME. If set manually, will over-ride the automatic adaptive anti-stick feature.This time period can be set in one-cycle (60cycles = 1 sec.) increments. When set to “zero”,the Automatic Adaptive Anti-stick feature will beoperational.

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, ifa start is attempted in which the light lit, the powersupply will not energize and the unit will not feedwire.

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 andgas 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 “coldinch” the wire, up or down, at a preset speed whichyou have programmed. If held down, the wire feedspeed will be 50 IPM for the first 2 seconds, afterwhich time it will switch over to the preset speed. Toincrease or decrease this preset speed, use the INC-DEC key under the IPM window while the motor isrunning and the speed value is displayed.

IMPORTANT: Cold inching is only possible whenthe weld Start-Stop rocker switch isin its “stop” (or off) position.

4. Start-Stop Switch. If the Control is to be used in itsPanel position for manual operation, the Start-Stoprocker switch is used to initiate the welding sequencein the START position, and to terminate the weldingsequence 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 STOPposition.

5. Pulse-Short - Spray Selector. This three-positionrotary switch allows you to select the mig weldingprocess mode you wish to use - Pulsed arc, ShortArc, or Spray Arc.

The welding process can also be selected by theRobot. 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 actualwelding current, preset or actual welding param-eters (wire feed speed and welding voltage) andtime 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. Wheninstalled, 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 primarilyused to display wire feed speed in IPM from 20to 999 inches per minute in one inch increments.However, with the appropriate function selec-

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1 4a 4b 6

2 3 5a 5b

Fig. 8 - Inside Panel Controls

used in the ROBOT mode; however two OutputLED’s, ARC ESTABLISHED AND ABORT/ARCOUT, will also function in the panel mode. Theappropriate light or lights will energize to indicatethe specific function(s) being used at theappropriate time in a welding sequence. Remem-ber, some of the following Input/Output func-tions are not required or utilized in all Robotmodels.

Inputs From Robot: WELD Start, Gas Purge, InchUp, 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 circuitbreaker provides protection to the 115 voltcontrol circuit and the wire feed motor. If anoverload occurs, the breaker will trip and suspendall operation. To restore service, simply depress thebreaker 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 providedallows selection of "synergic or adaptive" logicmodes. The operating characteristics of synergicvs adaptive logic in the welding operation arecovered in more detail in section V B. Only a shortsummary is given here.

In the "synergic" mode, the control will display variousnumbers to indicate wire type, size, feed rate and timessuch as pre, post flow burnback, etc. In place of the arcvoltage, an arbitrary number (100) will appear regard-less of the set speed. This number appears in theVOLTS 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 selectedwelding condition. By reducing the number below 100(minimum 0), you will reduce the arc length. Conversely,by increasing this value above 100 (maximum 200) youcan increase the arc length. The difference betweenthe set number and "100" will represent the devia-tion in hertz between the factory suggested fre-quency and the actual adjusted frequency if you arein the pulse mode. This can be either positive ornegative. After the arc is struck, the number will bereplaced by the actual welding arc voltage.

The Control can also operate in the adaptive mode,where the arc is continuously monitored by a closedloop feedback circuit to maintain the programmed arcvoltage. In the adaptive mode, a computed arc voltage(unique to your preprogrammed welding selection) willbe displayed in the VOLTS window before welding ifthe analog input voltage from the robot is present.Once the arc is struck, the control will measure theactual welding voltage and change the output of thepower source to maintain the preset value. In thismanner, the power supply automatically compensatesfor variations in stickout or weld joint geometry. Further,all of the precalculated arc voltages programmed in thecontrol can be readjusted +/- 10 Volts to "fine-tune" thewelding arc.

2. Robot-Panel Toggle Switch - This two-positionswitch is used to set the “location” from which thiscontrol is to be setup and operated. The ROBOTposition allows the control to be set up and operatedfrom the Robot; while the PANEL position allows thewelding sequence to be setup and operated from theAnalog 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 eitheror both of these times into all three modes ofoperation; however, once preset, the timesautomatically become part of the three operatingmodes. In other words, switching weld modesmaintains the setting.

The SPOT mode allows you to preset “timed-arc” periods (from . 1 to 99.9 seconds) in theIPM window using its Inc./Dec. toggle switch.

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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, thespot time has to be set to 0.

At the same time (or independently), you can alsopreset a manual BURNBACK time into the VOLTSwindow using its Inc./Dec. toggle switch. TheBurnback time is adjustable in one cycle incre-ments (60 cycles/sec); and when preset, it willoverride the automatic adaptive anti-stickfeature in the three welding modes. If automaticanti-stick operation is desired, the preset Burn-back time must be set back to “zero”. For PULSEoperation, the use of the manual burnback settingis recommended.

b. Activating the WIRE DIA/MATERIAL switch (downposition) allows you to select one of the six pre-programmed wire material types and one of fivepreprogrammed wire sizes. This selection isnecessary for proper operation in all 3 modes;short, spray and pulse welding. To select thetype of wire Material, use the Inc./Dec. toggleswitch below the IPM window until the desiredcode number indicating material type (1 and 2 forsteel, 5 for stainless, 3 and 4 for aluminum, or 6for 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 untilthe 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.) appearsin the VOLTS window. These values must be setfor both the panel and robot mode.

NOTE: Actuating the Wire Dia/Material switch whilethe system is welding, allows you to checkfor proper servo operation of the unit. TheSpeed (approx 110) and Voltage (approx. 90)servo settings will appear, simultaneously, intheir respective IPM and VOLTS windows.Read more about this feature in the "Hot Start"section.

4. Inc./Dec. Set-Up Switches. Two control switchesare provided to preset the requiredwelding parameters from the Analog Interface con-trol panel.

a. “IPM” Increase/Decrease Control. This switchis 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 windowdirectly above this switch.

b. “VOLTS” Increase/Decrease Control. Thisswitch is primarily used to set and/or vary the Arc Volts, along with all its otherfunctions: Postflow, Wire Dia., and Burnback. With the appropriate function selector actuated,each parameter setting will be displayed in thedigital window directly above this switch.

5. TEST Toggle Switches -- ANALOG INPUT andAMPS. These two toggles provide a convenient wayof 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) switchthat allows the user to test the operation of theAnalog Interface board when the unit is set toSYNERGIC in the robot mode . In its normalAnalog position the switch provides continuity tothe 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 beconnected to both the speed and voltage termi-nals of the Analog Input board. With theROBOT/PANEL switch in the ROBOT position,the speed and voltage display windows shouldnow reflect the digital equivalent of approxi-mately *500 IPM and approximately 100volts**. If these numbers appear, theanalog 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 synergicmode.

b. The Test/Amps toggle is a two-position (main-tained contact) switch that allows the user to testthe control. The AMPS position (toggle down) isthe “normal” location for all welding operation. To test the control, place the Amps/Testtoggle in its TEST position. This provides an arcdetection signal required to sequence throughthe welding cycle. The ARC ESTABLISHED indi-cator will be lit while the switch is in this position.With this accomplished, open up the accessorysupport clapper to release wire feed pressureand place the “Start-Stop” switch in the STARTposition. The control will sequence through theprogrammed welding cycle (preflow, weld,postflow,etc.).

Please note that if you inadvertently leavethe switch in the amps position instead of settingthe Test position (when testing the control), the

13

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 intomaterial codes 11 thru 15. These features andoperating functions are fully covered in XRT supple-mental booklet F-15-519.

IV. OPERATION

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

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 desiredcode number indicating material type (1 and 2 forsteel, 3 and 4 for aluminum, 5 for stainless, or 6 forsilicon bronze) appears in the IPM window. Referto Table 4-1 for material codes and shielding gasrecommendations.

2. Set the wire diameter using the INC/DEC toggleswitch below the VOLTS window until the desirednumbers indicating wire size (23 for .023" dia., 30for .030" dia., 35 for .035" dia., 45 for .045" dia., or63 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 voltswindow. A good number to start with would be 4 or5 cycles.

B. Program wire feed speed and arc voltage for anoptimum welding condition. Use of the factory setparameters will ensure a good baseline weld fromwhich minor adjustments can be made. The followingparagraphs describe the programming of the wirefeed speed and the arc voltage using the two analoginputs from the robot.

1. Speed The scaling for the speed input should beset with minimum and maximum speed values of0 and 1000, respectively. The reference voltagefor minimum and maximum values should be setto 0 volt and 10 volts, respectively. This will providea speed readout that will directly agree with theprogrammed information. For example, a settingof 300 on the teach pendant will result in an actualwire feed speed of 300 IPM.

2. Voltage The arc voltage control will be done in atotally different manner. Since this control is asynergic control, the arc voltage will be a functionof the wire feed speed based on the material type/wire size program selected. Therefore, as therobot increases the wire feed speed the arc volt-age will automatically increase based on a

preprogrammed relationship between speed andarc voltage. To change this arc voltage withoutchanging the wire feed speed, the robot will haveto change the reference voltage to the voltageport.

Set up scaling for the voltage port with 0 V as theminimum 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 isrecommended that the programmed value be 50V, which will provide a reference value of 5 voltsto the control.

As a weld is made, the arc voltage correspondingto the 50 V input can be observed. If the arc is too"hot", the programmed value may be changedfrom 50 to 45. This will cause average arc voltageto drop by 1.25 volts. A reduction of 1 count on theprogrammed value will reduce the arc voltage by1/4 volt. Set the reference for the best weldresults.

C. Generate "start" signal from robot. Once the arcis established, the ARC EST signal is sent to therobot, which in turn, begins the movement of therobot arm. If the ARC EST signal is lost, the robot willsend a stop signal to the Interface and terminate theweld.

V. PULSE/SPRAY/SHORT ARC WIRE SPEEDRECOMMENDATIONS

1. GeneralThe listings in the following tables give approximatewire feed speed ranges (IPM) for the various types ofwire diameters and materials which have beenpreprogrammed 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 tothe Code #1 parameters; however, Code #2 haswider Pulse Widths and higher Pulse Backgroundsettings. The arc characteristics will appear to be"softer" than Code #1. Arc penetration could alsobe slightly less do to the lower pulse peak used.This type arc characteristic might be used onapplications requiring improved bead wetting.

Operation Note: Excessive resistances in thewelding system, caused by water cooled torches orexcessively long welding cables, can produce pulsepeak currents below that which is required for stabledroplet detachment. This condition can be recog-nized by occasional large droplets propelled acrossthe arc. Some short circuiting and spatter could alsoresult. Long arc lengths can also cause less thanoptimum performance. The arc length should be

14

Table III for Typical "Short Arc" Wire Speed RangesWire Material Wire Diameter & Wire Speed RangeCode # Type .023* .030* .035 .045 .063

1 Carbon Steel 175- 180- 130- 130- N500 600 600 450

2* Alternate Stl. 125- 175- 100- 100- NP350 350 300 250

3* 4043 Allum. NP NP NP NP NP4 5356 Alum. NP NP NP NP NP5 308 Stainless 250- 100- 75- 50- NP

450 400 300 2506* Sil. Bronze NP NP NP NP NP7**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 RangesWire Material Wire Diameter & Wire Speed RangeCode # 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- NP550 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 RangesWire Material Wire Diameter & Wire Speed RangeCode # 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- 55700 500 450 450 260

6* Sil. Bronze 225- 250- 175- 125- NP500 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 lessthan optimum arc stability. If a globular type transferoccurs, check for high resistance in the weldingcurrent.

b. Aluminum 4043 (code #3) and 5356 (code #4).Each alloy and diameter has been set for bestarc performance and puddle control. The wirefeed speed of 4043 3/64-inch diameter (.045) islimited to 300 ipm at which point the pulses beginto overlap and spray arc results. If higher wirefeed speeds are required on this alloy, switch toCode #4 (5356 .045) and adjust the arc voltagefor stable arc performance. This action will ex-tend the wire feed speed to approximately 600ipm.

c. 308 Stainless Steel (Code #5). The stainlesssteel pulse parameters are based on gases(listed below). These gases improve the beadwetting of stainless steel as compared to the 1%and 2% oxygen mixtures. The program can stillbe used with the oxygen mixtures. but a smalladjustment in arc voltage will be necessary. 1.Linde "Pulse Blend SS"

2. 2-1/2% - CO2, 1%-H2, Bal. Argon

Operation Note: Arc starting with stainless steelcan be inconsistent at times due to the higherresistivity of the alloy and other variables. Some-times increasing the voltage will improve starting. Aweld technique adjustment might also help. Whenstriking the arc, immediately move out of the puddleand begin traveling. A hesitation in travel at the startcauses the puddle to build under the arc while thecontrol is trying to adjust for arc voltage. Eliminatingthe puddle build-up helps the voltage control circuitestablish the proper arc length more quickly.

d. Silicon Bronze (Code #6). The welding perfor-mance of silicone bronze alloys currently soldcan vary widely. Small differences in chemistry,cleanliness, and feedability can affect the pulsewelding characteristics. To overcome instabilityproblems, be sure wire feeding is steady andslack in the liner is minimized. Use tip-to-workdistances slightly longer than normal if arcinstability occurs.

15

B. WELDING IN PULSE, SPRAY OR SHORT ARCMODE

All three processes can be used in either synergic oradaptive mode. Following is a summary of the twomodes of operation:

SYNERGIC OPERATION

To put the control into the SYNERGIC mode of opera-tion, use the synergic/adaptive switch if provided. If theoptional switch is not present, close switch #1 of DipSwitch SW1.

Fig. 9 - MPU P.C. Board

Synergic Pulse Arc Welding makes use of a relation-ship between wire feed speed and pulse frequencywhich is programmed into the interface control for eachmaterial type and wire size. See typical graph for .045dia. steel wire.

As the wire feed rate increases, so does the frequencyand since the arc voltage is also related to the frequencythe arc voltage will also increase proportionately.

For each combination of material type and diameter thegraphs will be somewhat different; i.e., the slope of theline and the intercept will vary, but the general principlewill not change.

The equations that relate frequency and speed; or arcvoltage and speed are stored in the program for mostof the commonly used materials and wire diameters. Ifthe user selects a particular material and wire size byentering the code of the material and the diameter of thewire into the control, the program will search for thatcombination. If it is not found, the NO PROGRAM lightwill be lit. If program parameters do exist for theparticular combination, all the user need to enter is thewire feed speed desired and the proper frequency willautomatically be computed by the control.

As the wire feed speed increases, the control willautomatically increase the pulse frequency to maintaina stable arc. The welding current (heat) can be changedby increasing or decreasing the IPM without readjustingvoltage. Changes in tip to work will affect arc length.

If the welding arc is too long, or two short an adjustmentof the frequency (arc voltage) can be made to fine tunethe arc. In the synergic mode of operation prior tostriking 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 arcvoltage will be displayed. If the factory set frequency isused (no fine tuning of the arc was made) the numberdisplayed prior to striking an arc will be 100. If a changewas made to increase the frequency (arc voltage) thenumber will be greater than 100; vice verse, if thefrequency was decreased the resulting reference num-ber will be less than 100. These numbers will only bepresent if the analog control voltage from the robot isoutput without the start signal.

The difference between the number displayed and thenumber 100 is the amount of change in Hz; that thecontrol will add or subtract from the factory set fre-quency. As an example, if at a given speed the number100 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 theslope, by the amount of the offset either in the positive(numbers greater than 100), or in the negative directionfor numbers less than 100.

Synergic Spray Arc and Short Arc:

Just as in pulse welding, in the short and spray arcwelding as well, a relationship exists between arcvoltage and wire speed for any given wire size and type.In this mode the unit will operate like a conventionalwelder however the arc voltage is set by the weldcontrol program and changes in tip to work will affectarc length. The voltage can be read during weldingand increased or decreased to obtain a stable weldingcondition based on the wire feed speed used. If the wirefeed speed is changed, the program will calculate thenew voltage necessary to maintain a stable arc.

Just as in the synergic pulse mode, to run at factory setconditions the display in the "Volts" window should be100; to increase or decrease the arc voltage, thenumber has to be raised or lowered.

ADAPTIVE OPERATION

Pulse Arc Welding:

Adaptive Pulse Mode of OperationThe adaptive mode of operation is also based on arelationship. In this case the relationship is betweenwire feed speed and arc voltage.

Location For"Dip"" Switch 1 (SW1)

16

weld using the preprogrammed parameters and finetuning them for special requirements, but if this is notpossible, the XRT unit allows the teaching of fiveschedules which can be set up and memorized.

For a detailed description of teaching in the PANELmode refer to instruction manual F-15-519 Teach ModeOperating Instructions for Pulse Analog Interface XRT.

V. TROUBLESHOOTING

Be sure that all primary power to the machine hasbeen externally disconnected. Open wall discon-nect switch or circuit breaker before attemptinginspection or work inside of the power supply.

Listed below are a number of trouble symptoms, eachfollowed 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 notreplace a printed circuit (PC) board until you have madeall the preceding checks. Always put the power switchin "off" position before removing or installing a PCboard. 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 yourESAB- supplier for a trade-in on a new PC board.Supply the distributor with the part number of the PCboard (and preprogram number, as described in step 1-c. following) as well as the serial number of the wirefeeder. Do not attempt to repair the PC board yourself.Warranty on a PC board will be null and void if repairedby customer or an unauthorized repair shop.

1. Generala. 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 VOLTSwindows 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 beingused. If a revision is made to an existing programa number .1, .2, .3, etc. indicating the numericalrevision will also appear in the VOLTS readoutwindow simultaneously.

d. After the one (1) second delay; the preset "Weld"parameters will be displayed in the IPM andVOLTS windows.

As the wire feed speed increases, the control willautomatically increase the pulse frequency to maintainthe 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 arcvoltage which in pulse welding will require an increasein the frequency. These relationships of speed vs. arcvoltage for the commonly used wires are programmedinto the control's EPROM. Just as in the synergic modeas a material type and wire dia. is entered into thecontrol, the program will search for the combination. Ifit is not found the NO PROGRAM light will be lit.

If it's a valid combination, all the user has to input is thedesired wire feed speed. The program will compute anddisplay the factory set voltages for the set speed. If finetuning is required simply increase or decrease thedisplayed voltage value, either before the arc is struckor during the actual weld.

Spray Arc and Short Arc:

In this mode, the unit will control the power supply tomaintain the arc voltage set up in the VOLTS window ofthe control. Changes in tip to work will not change arclength. The voltage can be preset before welding andchanged during welding to obtain a stable weldingcondition based on the wire feed speed used. If the wirefeed speed is changed, then the program will calculatethe new voltage necessary to maintain a stable arc.

Welding can be initiated either from the robot by meansof a START signal, or from the panel with the START/STOP switch. The panel mode is normally used forsetup and test mode prior to automatic robot welding.To start welding under robot control, the START/STOPswitch must be in the STOP position, otherwisewelding will not start. This is a safety feature to preventarc start without the operator's knowledge.

The system will shut down if the preset wire speed or arcvoltage parameters cannot be maintained due to ab-normal conditions. If this occurs, the parameters caus-ing the system shutdown will be signaled by a flashingdigital display and the welding sequence must berestarted by actuating the PURGE/RESET rockerswitch. Also, a shutdown occurs if an arc is not estab-lished within 2 seconds after the START signal isreceived from the robot. In such a case, both theVOLTS 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 XRversion, but additionally includes a "Teach" mode topermit welding of materials and conditions that are notprogrammed. It is generally preferable to attempt to

17

e. If the control is not functioning properly (or asdescribed above); for example, the numbers thatappear in one or both of the display windows aremeaningless (all zeros, eights, decimals, etc.), orare 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 thememory, 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 beenturned "On", release the Inc/Dec toggleswitches to the neutral (spring-return center)position and the windows should display thefollowing; IPM = 0, VOLTS - 100 (if synergic),the indicating a successful reset or clearinghas taken place.

f. You can now enter the desired information asdescribed 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 theMPU board. If voltage is not present, check thevoltage regulator (VR). The voltage regulator islocated 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 notpresent, 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 (paneloperation 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 describedin Section III.

b. Make sure that power supply is connected, plugP2 is securely connected to receptacle P2 on theI/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 boardsrespectively.

(2) If the motor inches, but does not run when thestart signal is generated, check the start/stopswitch circuit components, or in the Robotmode, the presence of the Robot start signal..If motor still does not run, check if powersupply is providing open-circuit voltage of 72volts to the control - if o.c.v. is not beingsupplied, motor will not run. Check thepower supply for trouble.

(3) Also check that the +/- 12 vdc are providedfrom the power supply on T1-16 and T1-17 toT1-24 common, respectively.

(4) If power supply O.K., replace the I/O and MPUboards 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 arenot scratched. Check that the disc is properlycentered in the strobe pickup on the p.c. board.

c. If all items in step b. are in order, and motor speedis still incorrect, replace MPU board.

6. Motor runs backwards.The wire drive motor can be mounted as a left or righthand drive. Reversing the mounting orientation ofthe motor will cause it to appear to run backwards.This is corrected by simply reversing the orange andblue wires on T1-5 and T1-6 on the lower side ofterminal 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 testpoints on the I/O p.c. board (see Fig. 8A). Thisvoltage signal should correspond to that shownon the power supply voltmeter.

c. If voltage still reads zero, trace the voltage pickupwiring from the power supply to J6 on the control.

d. Remove the current detector 31419 board to gainaccess to the P3 plug (harness) on the MPU p.c.board. Disconnect the P3 plug from its MPUboard socket and, using a meter check for +/- 12volt power supply output between plug pins P3-1and P3-2 (for +12v.) and between plug pins P3-4and P3-2 (for - 12v.) respectively. If voltage ispresent, but the display is still zero replace theMPU board. If either +6, +12 or -12 is missing,replace the I/O board.

18

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

8. Control Shut-Down - either preset VOLTS or IPMdisplays will flash. The control will flash theparameter 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 Proceduresfollowing 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 furtherassistance 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 feedsystem or the power source. To determine which;

(1) Set the wire feeder for synergic operation in thePulse welding mode.

(2) Strike an arc and while welding, measure thepotential between T1-15 and T1-24. Note that asthe arc voltage setting is increased, the potentialbetween T1-15 and T1-24 also increases, andwill range from 0 to 10 vdc. If it does not, replacethe I/O and/or MPU board. If the potential ispresent and responding to the voltage changesetting, continue with step (3) following.

(3) Now measure the control voltage, for the back-ground current, between T1-24 and pin J1-J ofthe amphenol connector. This measurement canbe taken without striking an arc. The potential willbe in a range from 1 to 2.5 volts. If it is not, replacethe I/O and/or MPU board. If the backgroundpotential 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. Ifpossible, substitute a cable or power supply(known to be good) to check out the possibleproblem; if these are not available, continue withthe 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 "calibrationtest" of the I/O board and power source using theDiagnostic mode.

VI. DIAGNOSTIC MODE

To set up the control in the diagnostic mode, simulta-neously depress the Wire /Dia Mat'l. key and hold theIPM Inc/Dec key in its down position for 2.5 secondsuntil a zero (0) appears in the IPM window. (The 2.5seconds will prevent accidental zeroing of the Materialcode.)

Now release both keys. The display windows will changeto show a BACKGROUND current value (from 0 to 100)in the IPM windows, and a PULSE HEIGHT value (from0.1 to 10) in the VOLTS window. These numbers canbe changed by their respective INC/DEC switches.

To check the calibration of the I/O board, connect avoltmeter from T1-24 or to T1-15 (positive). Operatethe Start switch, and check the measured voltageagainst the number displayed in the VOLTS window -they should both be the same (for example: for a settingof 8.0, the I/O board should be 8 vdc.). If the measuredpotential is different, the I/O board should either berecalibrated (by a qualified technician) or the boardshould be replaced.

Next, check the potential from T1-24 (-) to pin J1-J ofthe amphenol connector for a display of 40 in the IPMwindows. The measured reading should be 2 vdc. If itis not, replace the I/O board. If all of these readings arecorrect, 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 areavailable for maintenance and repair of thisand other ESAB- equipment. For details,contact ESAB- Welding & Cutting Systems,P.O. Box F-6000, Florence, SC 29501; Tele-phone (843) 669-4411. Attention: TechnicalTraining Coordinator.

19

HOT START ADJUSTMENT

The Analog Interface is preset at the factory to provideoptimum starting characteristics for most welding con-ditions. However, due to factors such as border lineparameters (for a given wire type and size), weldingtechnique, shielding gas, or wire feed speed, you mayhave to readjust the factory-set settings to provide a hotstart in which the initial starting voltage is slightly higherthan actual welding voltage (arc voltage) and the initialspeed is somewhat lower than the selected wire feedspeed desired. The hot start condition will be termi-nated after 0.3 seconds. The following procedure shouldbe 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 havethe welding arc desired - At this point do not concernyourself 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 WIREDIA/MATERIAL switch and observe the numbersdisplayed in the IPM and VOLTS windows.

2. For proper starts, the number in the IPM windowshould be 105 to 115. If it is not, adjust the INC/DEC toggle (below the IPM window) until thedisplayed number reads about 110.

3. In the "synergic mode", the voltage window willalways display the number 100 and cannot beadjusted. To help determine which logic mode(adaptive or synergic) is used, visually check theadapt/syn and the SW1-1 switch.

4. In the adaptive mode, the number in the VOLTSwindow should be in the range of 90 to 100. Again,if it is not, adjust the INC/DEC toggle (below theVOLTS window) until the displayed number readsabout 95.

VII. REPLACEMENT PARTS DATA

1. All replacement parts are keyed on the illustra-tions which follow. Order replacement parts by partnumber and part name, as shown on illustrations.DO NOT ORDER BY PART NUMBER ALONE.

2. Always state the series or serial number of themachine on which the parts are to be used. Theserial number is stamped on the unit nameplate.

20

D-3

1636

Fig.

10

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emat

ic -

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e A

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g In

terf

ace

(She

et 1

of 3

)

21

D-3

1636

Fig.

11

- Sch

emat

ic D

iagr

am -

Anal

og In

terfa

ce S

heet

2 o

f 3

22

D-3

1636

Fig.

12

- Sch

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ic -

Puls

e A

nalo

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et 3

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23

FRONT VIEW - CABINET COVER BOTTOM VIEW - CABINET

7

1

3

2 546

(PSW)

(SW4)(MLS) (SW5) (SW1)(CB)

13

14

15109

11

12

FIGURE 9, ROBOTIC ANALOG INTERFACE MICROPROCESSOR CONTROL(See Code List for Model P/N's)

Replacement Parts List for Figure 9.

ITEM QTY PART MODEL/CODENO. REQ. NO. DESCRIPTION Nos.

- - 31676 ANALOG INTERFACE CONTROL FOR KAWASAKI/FANUC A- - 31678 ANALOG INTERFACE CONTROL FOR HITACHI B- - 36341 ANALOG INTERFACE CONTROL FOR MOTOMAN C- - 0558001377 ANALOG INTERFACE CONTROL FOR REIS D1 1 950416 CABINET LOCK A-D2 1 950915 POWER SW. OPERATOR A-D

1 950916 POWER SW. CONTACT A-D1 950917 POWER SW. BUTTON A-D

3 1 2062270 START-STOP ROCKER SW. (SW1) A-D4 1 950295 PURGE/RESET ROCKER SW. (SW4) A-D5 1 2062363 INCH. ROCKER SW. (SW5) A-D6 1 950874 CIRCUIT BREAKER, 7-AMP (CB) A-D7 1 680359 PULSE-SPRAY-SHORT ROTARY SW. (PSW) A-D

1 950282 PULSE-SPRAY-SHORT SW. KNOB A-D8 1 680359 RUN-SETUP-WEAVE ROTARY SW C

1 950282 RUN-SETUP-WEAVE SW. KNOB C9 1 950763 ROBOT CONNECTOR A

1 993973 ROBOT CONNECTOR B1 599800 ROBOT CONNECTOR C1 0558001428 ROBOT CONNECTOR D

10 1 31727 ROBOT CONNECTOR PLATE ADAPTOR A1 31671 ROBOT CONNECTOR PLATE ADAPTOR B,C1 0558001403 ROBOT CONNECTOR PLATE ADAPTOR D

11 1 950762 19-PIN RECEPTACLE - POWER SUPPLY A-D12 1 996514 5-SOCKET RECEPTACLE - MOTOR TACH. A-D13 1 993952 6-SOCKET RECEPTACLE - PLUMBING BOX A-D14 1 598397 3-PIN RECEPTACLE - VOLTAGE PICKUP A-D15 1 950159 VOLTAGE REGULATOR A-D

1 950158 TRANSISTOR SOCKET (TO3) A-D1 995544 CAPACITOR (C4) - 1UF, 35 WVDC A-D

16 1 96W85 STRAIN RELIEF D

16

24

7 6 10

15

5

18

89111213

SW3 SW6

SW12

SW9SW11 SW7 SW10

7-Ref

J GOV DETECTORCOMPONENT SIDE COMPONENT SIDE

COMPONENT SIDE

COMPONENT SIDEI/O

MPU

COMPONENT SIDE COMPONENT SIDE

3

6-Ref.7-Ref.

16

17

1 & 2 (P1)

VIEW B - B

41 (P3)

FIGURE10, ANALOG INTERFACE, INSIDE CONTROL PANEL

Replacement Parts List for Figure 10.

ITEM QTY PART MODEL/CODENO. REQ. NO. DESCRIPTION Nos.

- - 31676 ANALOG INTERFACE CONTROL FOR KAWASAKI/FANUC A- - 31678 ANALOG INTERFACE CONTROL FOR HITACHI B- - 36341 ANALOG INTERFACE CONTROL FOR MOTOMAN C- - 0558001377 ANALOG INTERFACE CONTROL FOR REIS D1 2 636608 22-PIN P.C. BD. RECEPTACLES (P1 & P3) A-D2 1 17145315 RESISTOR 15K-2W (R1 BET. P1-13 & P1-16) A-D3 1 994236 J-GOV. P.C. BD. ASSEMBLY A-D4 1 31419 CURR. DETECTOR P.C. BD. ASSEMBLY A-D5 1 950328 LATCH A-D6 1 675269 VOLTS/IPM DISPLAY P.C. BD. ASSEMBLY A-D7 1 See F-14-220 OPTIONAL DIG. D.C. AMETER KIT A-D8 1 950229 AMP. TEST SWITCH (SW. 9) A-D9 1 950789 ANALOG INPUT TEST SWITCH (SW-10) A-D

10 2 950087 INC./DEC. SWITCHES (SW-3 & SW-6) A-D11 1 950087 WIRE DIA./MAT'L.- SPOT/B.B. SWITCH (SW-7) A-D12 1 950229 ROBOT-PANEL SWITCH (SW-11) A-D13 1 675450 ANALOG INTERFACE P.C. BD. ASSEMBLY A-D15 1 950087 PULSE PH/PW-P8/PF SWITCH (SW-12) A-D16 1 674994 INPUT/OUTPUT (I/O) P.C. BD. ASSEMBLY A-D17 1 18146 MPU P.C. BD. ASSY. A,D

1 18149 MPU P.C. BD. ASSY. B1 38096 MPU P.C. BD. ASSY. C

18 1 31441 LOGIC INTERFACE P.C. BD. ASSY A,D1 31440 LOGIC INTERFACE P.C. BD. ASSY. B,C

25

3

4

51

2

8 & 9

10

6 7

FIGURE 11, ANALOG INTERFACE, INNER CABINET COMPONENTS

Replacement Parts List for Figure 11.ITEM QTY PART MODEL/CODENO. REQ. NO. DESCRIPTION Nos.

- - 31676 ANALOG INTERFACE CONTROL FOR KAWASAKI/FANUC A- - 31678 ANALOG INTERFACE CONTROL FOR HITACHI B- - 36341 ANALOG INTERFACE CONTROL FOR MOTOMAN C- - 0558001377 ANALOG INTERFACE CONTROL FOR REIS D1 1 31412 ANALOG TO ANALOG P.C. BD. ASSY A-D2 2 995103 24-PT. TERMINAL BOARD (T1 & T2) A-D3 1 17240003 RESISTOR 3-OHM, 25W (R1) A-D4 1 951089 D.C. RELAY (REV RLY) A-D5 1 996556 400V. BRIDGE (BR) A-D6 1 994303 TRANSFORMER (CTR-3) A-D7 1 30684 TRANSFORMER ASSY (CTR-1 & 2) A-D8 1 996918 FILTER NETWORK (FN-1) A-D9 1 2075712 INSULATOR A-D

10 1 31421 FILTER BOARD (FB) A-D

26

NOTES

27

NOTES

F-15-081-D 7/01

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