Lincoln Electric IM542-D Robotic Interface, Interface Description, Robot Signal Descriptions

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ROBOTIC INTERFACE

1. INTERFACE DESCRIPTION

This interface is designed for a Power Wave 450 and a Fanuc robot using ArcTool software (V1.30P) with touch sensing and through arc tracking. The interface responds to all of the ArcTool welding inputs and out- puts except wire fault and wire stick alarm. All of the circuitry for touch sensing is internal to the Power Wave, no external power supply is required. The cur- rent signal for through arc tracking is supplied by the Power Wave, no external current sensor is required.

The interface does not control wire feed speed and welding voltage independently. Rather, the Power Wave is always operating in a synergic mode and the welding voltage is programmed as a function of the wire feed speed. ArcTool software was designed to control wire feed speed and voltage independently. Since the Power Wave system uses an arc length trim, the volt- age cannot be directly controlled. The welding voltage settings in the robot controller are interpreted by the Power Wave as a trim setting. Any ArcTool function which tries to set the voltage to zero and control the wire feed speed is actually only setting the arc length trim to the minimum. Refer to the Operation section for a complete description of arc length trim. Any function which tries to set the wire feed speed to zero and con- trol the voltage is actually only setting the wire feed speed to the minimum speed of the selected process. The following is a list of functions which do not work as intended by Fanuc due to the synergic operation of the Power Wave:

1.1 WELDING VOLTAGE

In this interface all welding voltage settings must be thought of as an arc length trim. This arc length trim will increase or decrease the arc volt- age for a specific wire feed speed setpoint. The scaling in the robot controller is setup to allow voltage numbers between 50 and 150. A voltage number in the robot controller of 100 equals the nominal voltage (no trim adjustment) for the selected wire feed speed. If the arc length needs to be increased then the voltage trim number is increased. For example, if a voltage number of 115 is used then the arc voltage will increase too approximately 15% above the nominal voltage for the wire feed speed setpoint in use.

1.2 WIRE BURNBACK FUNCTION

The burnback function controlled by the robot controller will not operate properly. The function was setup to use a wire feed speed of zero while setting the welding voltage to some level. The system will produce the minimum wire feed speed for the selected procedure and a voltage trim for that selected wire feed speed setpoint.

The solution to this problem is already built into the Power Wave. At every “arc end” the Power Wave automatically goes through its own burn- back routine.

1.3 WIRE STICK RESET FUNCTION

The wire stick reset function controlled by the robot controller will not operate properly. This function is very similar to the burnback function. It was intended to use a wire feed speed of zero while setting the welding voltage to some level. For the same reasons as wire burnback it will not operate properly. The burnback routines in the Power Wave have been optimized for each weld- ing procedure and are very reliable. If any wire stick problems occur, the burnback routines in the Power Wave can be programmed to correct the problem.

1.4 COLD WIRE INCHING FUNCTION

The cold inching wire feed speed cannot be changed by the robot controller. It is always set to 80 IPM. A variable cold inching speed is not possible with the current architecture of the inter- face.

2. ROBOT SIGNAL DESCRIPTIONS

2.1 VOLTAGE COMMAND

This is an analog output from the robot controller with a range of 0 to 10V. Since the Power Wave is always running in the synergic mode an output voltage cannot be set. The voltage command is used as a voltage trim for the active workpoint. The voltage command limits in the robot con- troller are entered as 50 to 150V. This is done so that the nominal trim setting (100V) is not con- fused with a welding voltage.

2.2 WIRE FEED SPEED COMMAND

This is an analog output from the robot controller with a range of 0 to 10V. The wire feed speed command sets both the wire feed speed and the synergic output of the Power Wave. The wire feed speed command limits in the robot con- troller are entered as 50 to 770I PM for a stan- dard drive head and 80 to 1100 IPM for a high speed drive head.

POWER WAVE 450

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Contents For use with machines having Code Numbers Safety Depends on YouCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéPlease Examine Carton and Equipment For Damage Immediately Thank YouTable of Contents Section C ViiSection D ViiiSeries Section ESection F Section GAwgiec InstallationTechnical Specifications Power Wave Power WaveInput Connections Safety PrecautionsHigh Frequency Precautions Select Suitable LocationGround Connections Input Power ConnectionsInput Fuse and Supply Wire Considerations Input Voltage Reconnect ProcedureWater Cooler Connections Wire Feeder ConnectionsOutput Connections Work and Electrode Cable ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operating Instructions Safety InstructionsOperation Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOverview Installing AN OverlayOperating Overlays Name Overlay TypesOverlay Overlay ID Number = PULSE, GMAW, FCAW, and STICK/TIG Process Selection OverlayOperation Then Select a Memory Location Robotic Interface Weld from MEMORY, Dual Procedure OverlayOperation SET Limit KEY Limit UP / Down Keys Limits Overlay OptionalRecall from Memory KEY Memory Location Numbers Operation Figure B.7 Setup Overlay Setup OverlayTable B.1 Positive Voltage Sensing Options Wire Feeder Setup Description+/- Polarity KEY Positive Polarity Voltage SensingWave Control Overview of Welding ProceduresFlux Cored ARC Welding Fcaw and Gmaw Procedures Pulse ProceduresFcaw Table B.3 Adjustble ParametersGmaw Current Protection Pulse WeldingOverload Protection Thermal ProtectionInterface Description Robot Signal DescriptionsRobotic Interface Water Fault Touch Sense SignalGAS Fault Wire FaultRobot Controller Electrical Characteristics Power Wave CircuitsDual Procedure Switch COM- Mand Wire Stick DetectPower Fault Dual Procedure Switch Command Touch Sense Command ARC DetectGAS Fault Water FaultTouch Sensing Setup Robot Controller SetupWeld System Setup Weld Equipment SetupMiscellaneous Connections Power Wave Interface BoardConnections Arctool Welding Inputs and OutputsPriming the Cooler AccessoriesWater Cooler Usage Recommended CoolantsType L9777 Wire Feed Unit Dimension PrintFor the Latest Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode RoutingDrive Roll and Guide Tube Kits Procedure to Install Drive Roll and Guide TubesSteel Wire Sizes Roll Aluminum Wire SizesIdle Roll Pressure Setting Requires Installation of 2 51MM K162H Spindle KIT Feeding Electrode and Brake AdjustmentFeeding Electrode Wire Loading of 13-14lb 6kg Innershield CoilsTo Mount a 50-60lb 22.7-27.2kg Coil Wire Drive Motor and Gearbox Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsAvoiding Wire Feeding Problems Periodic Maintenance of Wire Drive UnitConnector for 1/16 5/64 1.6 2.0 mm Wire Switch RequirementsInput Filter Capacitor DIS Charge Procedure MaintenanceRoutine and Periodic Maintenance Figure D.1 Resistor Locations Connected Discharge labels, on each of the four SwitchLocate the #9 and #12 terminals, identified by Preventive Maintenance Removing and Installing the G3503 Cooler G3503- Installation or SER Vice Tool UsageG3503- Cooler Service G3503- Cooler Periodic MaintenanceFigure D.4 General Component Locations ED Tests TroubleshootingHOW to USE Troubleshooting Guide Sists, contact your local Lincoln Troubleshooting GuideAuthorized Field Service Facility Play fans run Check circuit breaker 5-amp Observe Safety Guidelines Controls and Settings Power-up Inspect the overlay bar code Saved in memory are different Check for proper shielding gas Basic Course How To Read Shop DrawingsNew Lessons in Arc Welding Need Welding Training?Precaucion Aviso DE
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