OM-169 510 June 1995 Processes Plasma Arc (PAW) Welding Description Automatic Welding Robot PAW Interface Visit our website at www.MillerWelds.
EMF INFORMATION NOTE Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields The following is a quotation from the General Conclusions Section of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA-BP-E-53 (Washington, DC: U.S. Government Printing Office, May 1989): “. . .
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY A. General Information presented in this manual and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment. 1-2.
IMPORTANT: When installing or operating plasma arc welding equipment, refer to the Plasma Welding Console Owner’s Manual and Welding Torch Owner’s Manual for specific precautionary information that applies to this equipment. 3-1. FIELD INSTALLATION INSTRUCTIONS FOR PAW INTERFACE PANEL TO COMPUTER INTERFACE (Figure 3-1 And Figure 3-2) WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts.
Robot Arm Shock Sensor Leads Insulator Plate Shock Sensor Welding Gun Body Torch Mounting Bracket Torch Clamp Mounting Bracket Clamp ST-800 733 Figure 3-3. MRH2 Shock Sensor Unit Assembly And Installation Output Hub Bracket L-Bracket Insulating Block Shock Sensor Leads Welding Gun Body Shock Sensor Angle Bracket Clamp Torch Mounting Bracket Angle Bracket Torch Clamp ST-800 778 Figure 3-4.
5. g. Connect lead 23 from PAW interface panel to terminal A on terminal strip 2T. 2. Install supplied insulator plate to robot arm with screws removed in Step 1. h. Route plug 30/31 from PAW interface panel through center baffle in computer interface. Disconnect plug PLG10 from plug PLG11 and connect PLG 30/31 to PLG 10/11. 3. Assemble shock sensor, mounting bracket, and torch clamp as shown in Figure 3-3. 4. Install shock sensor unit to the insulator plate installed in Step 2 with supplied screws.
MOVING PARTS can cause serious injury. • Keep away from moving parts. HOT SURFACES can cause severe burns. • Allow cooling period before servicing. Sleeve A. MRH2 Models Green And Black Connections 1. If applicable, remove the existing wire feed motor/reed relay mounting bracket and stabilizer brace from the robot (refer to robot Owner’s Manual for bracket and brace locations). Reinstall the two lifting brackets only (see robot Owner’s Manual and Figure 3-10). 2.
Robot Control LEFT SIDE RIGHT SIDE Blank Cover Plates (Both Rows) Blank Cover Plates S-0782 Figure 3-6. View Of Left And Right Sides Of Robot Control WARNING: ELECTRIC SHOCK can kill. ELECTROSTATIC DISCHARGE (ESD) can damage circuit boards. • Do not touch live electrical parts. • Shut down welding power source and Robot Control, and disconnect input power employing lockout/tagging procedures before inspecting high-frequency filter.
Robot Control Side Panel Screw Star Washer Filter Box Cord Nut ST-152 641 Figure 3-7. Installation Of Securing Hardware For Filter Box q. Route supplied 35 ft. (10.5 m) shielded shock sensor cable under the torch cable securing straps on the outside of the protective casing so that the two leads with friction connectors are located near the shock sensor. r. Connect plug on end of cord to filter box receptacle. s.
Interlock Board TB2 CN68 TB1 (IN) 1 2 3 4 5 6 7 8 L CN69 Terminal Block TB1 CN67 CN80 F2 (1A) ESTOP CN38 LED301 ESTOP LED202 ESTOP LED203 CN73 CN37 CN22 LED204 LED303 SHOCK LED302 LED205 JP301 SHOCK LED101 LED305 INCOM INCOM TB1 LAMP FC11 9 LED304 AUTO F3 (3A) JP501 10 TEACH 11 JP304 JP303 JP302 ST#1 CN33 CN32 CN28 CN31 12 ST#2 CN41 LED401 13 LED402 LED602 LED403 LED601 LED603 LED404 CN46 JP601 JP602 JP603 LED405 JP306 ST#3 14 STOP 15 SV.
Robot Control Torch Cable Support Bracket Torch Cable In Protective Case Outlet Cable Support Arm Clamps High Frequency Filter Box DC Welding Power Source Ground Rod No.1 Shock Sensor Cable Lifting Bracket Ground Cable Securing Bolt Location Shock Sensor Cable Welding Gun Body PAW/Computer Interface Torch Braided Ground Cable Coolant System Ground Rod No.2 115VAC Input Power Cord WC 100B Plasma Welding Console ST-800 734 Figure 3-10. MRH2 Robot PAW System B. MRV2 Models 1.
Servo Light Box Robot Control Cable Hanger Torch Cable In Protective Case Welding Gun Body Torch Cable Support Bracket High Frequency Filter Box Shock Sensor Cable DC Welding Power Source Shock Sensor Cable Ground Rod No.1 Torch Braided Ground Cable PAW/Computer Interface Coolant System 115VAC Input Power Cord WC 100B Plasma Welding Console Ground Rod No.2 Braided Ground Cable ST-800 735-A Figure 3-11. MRV2 Robot PAW System 3. 4. 3-6.
1 2 3 C O N T. 1CR 4 5 CSR 6 7 8 9 10 11 12 13 14 15 PSR PILOT PILOT PLASMA SHIELD ST-800 736 Figure 3-12. Terminal Strip TB1 Location Inside WC 100B Console 3-8. PAW INTERFACE PANEL – WELDING POWER SOURCE – PAW CONSOLE CONNECTIONS (Figure 3-1, Figure 3-10, And Figure 3-11) WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts. • Shut down robot and welding power source, and disconnect input power employing lockout/tagging procedures before inspecting or installing.
g. Yellow lead to terminal 14. 9. Route cable from welding power source negative (–) weld output receptacle through opening in rear of WC 100B console. Route end of cable to shunt, located where torch cable bus bar is connected, and connect cable to shunt at end opposite from bus bar. 10. Route cable from welding power source positive (+) weld output receptacle and connect end of cable to workpiece. 11. Reinstall WC 100B wrapper. a.
SECTION 4 – ROBOT PROGRAM MODIFICATIONS IMPORTANT: The robot program must be changed to accommodate plasma arc welding. The program is factory set to accommodate factory installed plasma arc welding equipment. The following information pertains to the robot Owner’s Manual and must be followed when field installing plasma arc welding equipment. WARNING: ELECTRIC SHOCK can kill. • Do not touch live electrical parts.
MRV2 Robot MRH2 Robot Robot Arm Sleeve Sleeve Robot Arm Scribe Marks Scribe Marks Torch Head Assembly Torch Head Assembly ST-800 747-A Figure 4-2. Marking Position Of Torch Head Assembly 4-4. SYSTEM SETUP FOR MRH2 AND MRV2 WITH C2 ROBOT CONTROL Set welding power source specifications in user parameters for the Plasma Arc Welding (PAW) process according to the following instructions. 1.
T E A C H S E R V O O F F E D I T T E A C H 2. Press the FUNCTION APPLICATION P A R M T E R 3. F I L E Press the F1 C H EC K F1 M O D E S E R V O O F F M A N A G E B Y Press the FUNCTION APPLICATION T E A C H M O D E S E R V O O F F Press F4 B Y A R C– S F4 M E M O R Y > O F P A R A M E T E R K E Y W E L D I / O A U T O > key for additional functions to appear on the display. S E L E C T 5. S Y S .
A X I S P OW E R M L 4 S O U R C E W I R E T E A C H S E R V O O F F G M A W . 0 3 5 . 0 4 5 . 0 6 2 S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2 G T A W – 1 0 0 . 0 3 5 . 0 4 5 . 0 6 2 G T A W – 3 0 0 . 0 3 5 . 0 4 5 . 0 6 2 U S E R M O DI F Y R E G I S T 6. R E G I S T E R Use the INCREMENT + S C _ E D I T or DECREMENT _ key and forward or back DISPLAY SE- LECT key to select GTAW-300 by setting a wire size selection.
A X I S P OW E R M L 4 S O U R C E W I R E T E A C H S E R V O O F F G M A W . 0 3 5 . 0 4 5 . 0 6 2 S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2 G T A W – 1 0 0 . 0 3 5 . 0 4 5 . 0 6 2 G T A W – 3 0 0 . 0 3 5 . 0 4 5 . 0 6 2 U S E R M O DI F Y R E G I S T 9. Press the F2 A X I S F2 R E G I S T E R S C _ E D I T key to select the MODIFY function. R A T I N G M L 4 T Y P E S E P A .
A X I S M L 4 R A T I N G T E A C H S E P A . R A T I N G O F F Press the RECORD A X I S RECORD M L 4 13. Use the INCREMENT + T I G 3 0 0 A 2 5 6 i . A F T E R S E T T I N G key. R E F . D I S P . R E F . 5 0 A 1 . 5 V 5 0 i . 2 . 0 V 2 . 1 5 0 A 4 . 5 V 1 0 2 i . 4 . 0 V 3 . 2 0 0 A 6 . 0 V 1 5 3 i . 6 . 0 V 4 . 2 5 0 A 7 . 5 V 2 0 5 i . 8 . 0 V 5 . 3 0 0 A 1 0 . 0 V 2 5 6 i . 1 0 . 0 V 1 . O F F S Y N E R . R A T I N G R E C O R D D I S P .
14. Press the RECORD RECORD key. S E L E C T T E A C H M O D E S E R V O O F F S E N S O R 15. B Y T Y P E F U N C T I O N A R C– S O F P A R A M E T E R K E Y T O U C H – S W – C H A R A S – D A T A > Check settings of weld characteristics as follows: a. Press the F4 A X I S F4 key to select the W–CHARA function. M L 4 P OW E R S O U R C E W I R E T E A C H S E R V O O F F G M A W . 0 3 5 . 0 4 5 . 0 6 2 S Y N E R G I C . 0 3 5 . 0 4 5 . 0 6 2 G T A W – 1 0 0 .
A X I S M L 4 D I S P . T E A C H S E R V O 16. O F F Press the RESET RESET M O D E S E R V O O F F S E N S O R 17. R E F . 5 A 0 . 0 V 5 0 i . 2 . 0 V 2 . 7 9 A 2 . 0 V 1 0 2 i . 4 . 0 V 3 . 1 9 0 A 5 . 0 V 1 5 3 i . 6 . 0 V 4 . 3 0 1 A 8 . 0 V 2 0 5 i . 8 . 0 V 5 . 3 7 5 A 1 0 . 0 V 2 5 6 i . 1 0 . 0 V key. B Y A R C– S Press the TEACH MODE D I S P . 1 . S E L E C T T E A C H R E F .
SECTION 5 – ELECTRICAL DIAGRAMS SC-169 456 Figure 5-1.
SB-169 458 Figure 5-2. Circuit Diagram For Robot PAW Interface Panel SB-169 459-A Figure 5-3.
SA-146 608-A Figure 5-4. Circuit Diagram For High-Frequency Filter SA-146 609-B Figure 5-5.
SECTION 6 – HF IN PLASMA ARC WELDING mod6.2* 5/94 WARNING HIGH-FREQUENCY RADIATION can interfere with radio navigation, safety services, computers, and communications equipment. • • • • • Have only qualified person familiar with electronic equipment perform this installation. The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation. If notified by the FCC about interference, stop using the equipment at once.
7 Welding Zone 3 50 ft (15 m) 50 ft (15 m) 5 1 6 2 9 4 9 Ground All Metal Objects And All Wiring In Welding Zone Using #12 AWG Wire Ground Workpiece If Required By Codes 8 Nonmetal Building 9 9 11 Metal Building 10 S-0755 1 Plasma Arc Welding Power Source Ground metal machine case, line disconnect device, input supply, and workpiece (if required).
SECTION 7 – PARTS LIST Dia. Mkgs. Part No. Description Quantity Spectrum Interface . CR10,11 . 052 964 . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . D1 . . . . 169 465 . . DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . D2 . . . . 169 467 . . DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dia. Mkgs. Part No. Description Quantity Spectrum Interface (Continued) . . . . . . . . . . . 169 452 . . . . . . . . . . . 602 173 . . . . . . . . . . . 141 564 . . . . . . . . . . . 146 002 . . . . . . . . . . . 169 454 . . . . . . . . . ♦171 042 . . . . . . . . . . . 143 352 . . . . . . . . . . . 169 453 . . . . . . . . . . . 157 173 . . . . . . . . . . . 141 409 . . . . . . . . . . . 141 449 . . . . . . . . . . +139 465 . . . . . . . . . . . 134 464 . . . . . . . . . . . 602 969 . . . . . . . . . .
Notes
