TECHNICAL INSTRUCTIONS PUBLICATION HMC-410 ROBOTIC INTERFACE KIT For the Following Specs: ABB Interface Kit • 870236-1 Fanuc Interface Kit • 870236-2 870236-3 Comau Interface Kit • OWNER’S MANUAL Number 430429-457 (Rev AA) Revised 13 June, 2002 IMPORTANT: Read these instructions before installing, operating, or servicing this system. THERMAL ARC INC., TROY, OHIO 45373-1085, U.S.A.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY UNTIL CONSULTING YOUR DOCTOR. DO NOT LOSE THESE INSTRUCTIONS. READ OPERATING/INSTRUCTION MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS EQUIPMENT.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS Instruction 830001 FUMES AND GASES can be hazardous to your health. Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. 1. Keep your head out of the fumes. Do not breath the fumes. 2. If inside, ventilate the area and/or use exhaust at the arc to remove welding fumes and gases. 3. If ventilation is poor, use an approved air-supplied respirator. WELDING can cause fire or explosion.
ARC WELDING SAFETY INSTRUCTIONS AND WARNINGS ENGINE FUEL can cause fire or explosion. Engine fuel is highly flammable. 1. Stop engine before checking or adding fuel. MOVING PARTS can cause injury. Moving parts, such as fans, rotors, and belts can cut fingers and hands and catch loose clothing. SPARKS can cause BATTERY GASES TO EXPLODE; BATTERY ACID can burn eyes and skin. Batteries contain acid and generate explosive gases. STEAM AND PRESSURIZED HOT COOLANT can burn face, eyes, and skin.
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PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 PRECAUTIONS DE SECURITE EN SOUDAGE A L’ARC LE SOUDAGE A L ARC EST DANGEREUX PROTEGEZ-VOUS, AINSI QUE LES AUTRES, CONTRE LES BLESSURES GRAVES POSSIBLES OU LA MORT. NE LAISSEZ PAS LES ENFANTS S’APPROCHER, NI LES PORTEURS DE STIMULATEUR CARDIAQUE (A MOINS QU’ILS N’AIENT CONSULTE UN MEDECIN). CONSERVEZ CES INSTRUCTIONS. LISEZ LE MANUEL D’OPERATION OU LES INSTRUCTIONS AVANT D’INSTALLER, UTILISER OU ENTRETENIR CET EQUIPEMENT.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 SELECTION DES NUANCES DE FILTRES OCULAIRES POUR LA PROTECTION DES YEUX EN COUPAGE ET SOUDAGE ( selon AWS A 8.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC LE SOUDAGE PEUT CAUSER UN INCENDIE OU UNE EXPLOSION L’arc produit des étincellies et des projections. Les particules volantes, le métal chaud, les projections de soudure et l’équipement surchauffé peuvent causer un incendie et des brûlures. Le contact accidentel de l’électrode ou du fil-électrode avec un objet métallique peut provoquer des étincelles, un échauffement ou un incendie. 1. Protégez-vous, ainsi que les autres, contre les étincelles et du métal chaud.
PRECAUTIONS DE SECURITE EN SOUDAGE A L'ARC Instruction 830002 D ES PIECES EN MO UVEM EN T PEUVENT CAUSER DES BLESSURES. Des pièces en mouvement, tels des ventilateurs, des rotors et des courroies peuvent couper doigts et mains, ou accrocher des vêtements amples. 1. Assurez-vous que les portes, les panneaux, les capots et les protecteurs soient bien fermés. 2. Avant d’installer ou de connecter un système, arrêtez le moteur.
430429-457 HMC-410 ROBOTIC INTERFACE KIT Technical Instruction Publication This publication documents the operation of the HMC-410 Robotic Interface Kit. This manual should be used in conjunction with the Owner’s Manual for the HMC-410 (430429-445). No attempt has been made to duplicate the information from that manual into this manual. Description The HMC-410 Robotic Interface Kit allows the HMC-410 to be adapted for easy interfacing to various robotic systems.
430429-457 Power Source Robotic Interface Kit Installation When the robotic interface is to be used with an Arc-Master or Power-Master power source, install the supplied 870210 wire stick voltage supply board into the power source.
430429-457 To install the 870210 in to the Power-Master power supply: (1) Remove power from the Power-Master power supply (2) Remove the cover from the Power-Master power supply (3) Locate the 830266 control board on the top deck of the Power-Master (4) Locate the J3 connector labeled OPTIONAL WIRE STICK (5) Place the 870210 board onto that connector, ensuring that the standoffs are properly latched onto the 830266 board.
430429-457 HMC-410 Robotic Interface Kit Robot Connection Installation The ABB kit interfaces with the ABB SJ2 control via the 24 pin Amphenol (from the 870236-1 kit) found on the back of the HMC-410. The Fanuc kit interfaces with the Fanuc R-J2 control via the 37 pin Amphenol (from the 870236-2 kit) found on the back of the HMC-410. The Comau kit interfaces with the Comau robot control via the 37 pin Amphenol (from the 870236-3 kit), that is attached to the Comau robot control via a custom cable assembly.
430429-457 Input Common: JP1 Source (Position 1,2): Current Sourcing (PNP) Outputs from Robot (Default - ABB) Sink (Position 2,3): Current Sinking (NPN) Outputs from Robot The inputs can accept inputs from 5 to 24 Volts, AC or DC. Output Common: JP2 Source (Position 1,2): Current Sourcing (PNP) Outputs to Robot (Default - ABB) Sink (Position 2,3): Current Sinking (NPN) Outputs to Robot The outputs can sink or source up to 200mA / 60 Volts max.
430429-457 The inputs can accept inputs from 5 to 24 Volts, AC or DC. Operation The kit uses 2 soft-switches for robotic mode selection (ROB) and wire stick check enable (ELS). The ROB soft-switch dictates the operational characteristics of the system and thus is fairly involved. The following chart can be used to help identify which mode is required for a particular setup.
430429-457 Pin Name Description E Contactor When the robot control puts +24 VDC on this line with respect to pin J, the HMC-410 will close the contactor on the power source it is attached to, producing an output voltage on the output terminals. F Wire On When the robot control puts +24 VDC on this line with respect to pin J, the HMC-410 will run the wire at the speed set in the INCH SPEED window on the HMC-410. If EEE is selected for INCH SPEED, the speed will be set by the voltage on pins W and X.
430429-457 Pin Name Description Y VOLT - Analog return Z VOLT + This line is a 0 to 10 VDC analog signal, which corresponds to a 0 to 44.0 volts arc voltage (or pulse frequency reference, sometimes called trim, setting). When this mode is selected, the HMC-410 displays different information depending on if the equipment is in standby or welding. When the HMC-410 is in standby, the top 2 displays show the arc time and the bottom display shows the inching wire feed speed (both forward and reverse).
430429-457 Pin Name Description F Wire On When the robot control puts +24 VDC on this line with respect to pin J, the HMC-410 will feed the welding wire. If the power source contactor is on or the INCH SPEED window is programmed to EEE, the speed is set by the robot. Otherwise, the speed is set in the INCH SPEED window. G Gas On When the robot control puts +24 VDC on this line with respect to pin J, the HMC-410 will purge the gas lines.
430429-457 Pin Name Description Z VOLT + This line is a 0 to 10 VDC analog signal, which corresponds to a 0 to 44.0 volts arc voltage (or pulse frequency reference, sometimes called trim, setting). This mode effectively has the HMC-410 run as the master weld control. The robot controls the welder with a master Weld On/Off control. The HMC-410 can control the welding parameters of wire feed speed and arc voltage / pulse frequency for the whole weld, or for some parts of the weld.
430429-457 Pin Name Description L Weld Amps Feedback + This line is a 0 to 10 VDC analog signal, which corresponds to 1.0 Volts DC = 100 Arc Amps. M Weld Amps Feedback - Analog return N Wire Stick Ckt + Robot wire stick sensing input. P Wire Stick Ckt - Robot wire stick sensing input return. R Weld On/Off When the robot control shorts this line to 0 VDC Common, the HMC-410 will initiate a weld and continue it for as long as the voltage is present.
430429-457 Pin Name Description d Arc Detect Input When the HMC-410 shorts this line to 0 VDC Common, there is an arc established by the welder. This control may also be activated if it’s running in the dry run test mode. e Gas Shortage Input When this line is shorted to 0 VDC Common, there is an absence of adequate shielding gas. f Wire Shortage Input When this line is shorted to 0 VDC Common, there is an shortage of welding wire.
430429-457 3 (Comau): This mode selects the Comau control. When used with the 37 Pin Amphenol Board (870244), the following signals on the Comau Harting Connector interface are supported: Pin Name Description D11 WFS + This line is a 0 to 10 VDC analog signal, which corresponds to a 0 to 888 inches / minute wire feed speed. D12 WFS - Analog return D13 Shield D14 VOLT + This line is a 0 to 10 VDC analog signal, which corresponds to a 0 to 44.
430429-457 This mode effectively has the HMC-410 run as the master weld control. The robot controls the welder with a master Weld On/Off control. The HMC-410 can control the welding parameters of wire feed speed and arc voltage / pulse frequency for the whole weld, or for some parts of the weld. For example, the HMC-410 could control the run-in speed and voltage, a 1/2 second start level, then use the settings from the robot for the ‘main weld’.
430429-457 Postflow Time: .7 Seconds The way that these settings interact with the robot is shown in Figure 5. Once the torch is positioned over the weld location, the robot initiates the arc with the Master Weld On/Off signal. At that point, the HMC-410 pre-purges the gas for 1/2 second, then initiates the arc with the settings for the runin segment.
430429-457 When ELS is set to ON, any time the wire shorts out to the work (is stuck to the work), the power source senses this condition and will display an error on the HMC-410, and close the wire stuck relay out of the HMC-410 Robotic Interface Amphenol. When ELS is set to OFF, this condition is ignored. Maintenance Refer to the HMC-410 Owner’s Manual for maintenance of the HMC-410 control box. Refer to the 170896 Feedhead Technical Instruction Publication for details on maintenance of the feedhead.
430429-457 DIAGRAMS • Note the Model and Assembly numbers shown on the equipment nameplate. • Locate these numbers in the table below. • Use only those diagrams and instructions that are applicable. MODEL HMC-410 ROBOTIC INTERFACE KIT June 13, 2002 ASSEMBLY NO.
