Lincoln Electric IM542-D Interface Circuit DESCRIP- Tions, Power Wave Circuits, Wire Stick Detect

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C-3

C-3

ROBOTIC INTERFACE

2.17 DUAL PROCEDURE SWITCH COM- MAND

This is an active low output from the robot con- troller used to activate the dual procedure switch. When the Power Wave is running a dual proce- dure overlay this output is used to switch between procedures. If the output is held high by the robot controller then procedure A is active, and if the output is held low then procedure B is active.

2.18 WIRE STICK DETECT

This is a resistance measuring input to the robot controller used to detect a wire stick. The intended use for this resistance check is to mea- sure the resistance between the output terminals of the weld equipment. This is not directly possi- ble with a Power Wave because the resistance between the output studs is always 40 Ohms or less. Additional circuits have been added to allow the wire stick detect to work properly although it is not directly measuring the resis- tance between the output studs. If a resistance of approximately 100 Ohms or less is found then a wire stick error is reported by the robot con- troller.

3.INTERFACE CIRCUIT DESCRIP- TIONS

CAUTION

All of the signals between the Power Wave and the robot controller were designed to operate in a shielded cable. No surge or high frequency protection has been added to the circuitry.

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3.1 ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS

The following signals are referenced to the robot con- troller’s 24V supply unless otherwise noted. The total allowable load on the 24V supply is 0.7A.

The following is a brief description of the electrical characteristics, for a full description see the Fanuc electrical connections manual.

3.1.1 DIGITAL OUTPUTS

 

Rated Voltage:

24VDC

Maximum Applied Voltage:

30VDC

Maximum Load Current:

0.2A

Transistor Type:

Open collec-

 

tor NPN

3.1.2 DIGITAL INPUTS

 

Maximum Input Voltage:

28VDC

High Input Voltage:

20 to 28VDC

Low Input Voltage:

0 to 4VDC

Input Impedance:

3.3K Ohms

Response Time:

5 to 20mS

3.1.3ANALOG OUTPUTS

Weld equipment analog outputs are isolated from the robot controller 24V supply.

Maximum Output Range:

0 to 10V

Load Impedance:

3.3K Ohms

 

or more

3.1.4 ANALOG INPUTS

 

Maximum Input Range:

0 to 10V

3.1.5WIRE STICK DETECT

The wire stick detect output is isolated from the robot controller 24V supply.

Maximum Output Voltage:

15VDC

Maximum Output Current:

85mA

4.POWER WAVE CIRCUITS

4.1VOLTAGE COMMAND

The voltage command from the robot controller (DACH1) is directly connected to the TIG analog input on the display board of the Power Wave. This signal is not connected to the robot or control ground.

Maximum Input Range:

0 to 10V

Typical Zero Offset:

0.55 to 0.65V

Typical Range:

9.0V

Input Impedance:

200KΩ

4.2WIRE FEED SPEED COMMAND

The wire feed speed command from the robot con- troller (DACH2) is directly connected to the WF1 ana- log input on the display board of the Power Wave. This signal is not connected to the robot or control ground.

Maximum Input Range:

0 to 10V

Typical Zero Offset:

0.55 to 0.65V

Typical Range:

9.0V

Input Impedance:

200KΩ

4.3TOUCH SENSE SIGNAL

The touch sense signal is generated by active high miscellaneous output #4 (bit #3) on the control board. The signal is then isolated from the control ground, inverted, and tied to the robot controller welding input 1 (WDI1). The active state table is responsible for set-

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 ViiiSection F Section ESection G SeriesTechnical Specifications Power Wave InstallationPower Wave AwgiecHigh Frequency Precautions Safety PrecautionsSelect Suitable Location Input ConnectionsInput Fuse and Supply Wire Considerations Input Power ConnectionsInput Voltage Reconnect Procedure Ground ConnectionsOutput Connections Wire Feeder ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operation Safety InstructionsOperating Instructions Save process information if desired Select your process informationGeneral Description Case Front Controls Controls and SettingsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName 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 Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Figure B.7 Setup Overlay Setup Overlay+/- Polarity KEY Wire Feeder Setup DescriptionPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsFlux Cored ARC Welding Fcaw and Gmaw Procedures Overview of Welding ProceduresPulse Procedures Wave ControlGmaw Table B.3 Adjustble ParametersFcaw Overload Protection Pulse WeldingThermal Protection Current ProtectionRobotic Interface Robot Signal DescriptionsInterface Description GAS Fault Touch Sense SignalWire Fault Water FaultDual Procedure Switch COM- Mand Power Wave CircuitsWire Stick Detect Robot Controller Electrical CharacteristicsGAS Fault Touch Sense Command ARC DetectWater Fault Power Fault Dual Procedure Switch CommandWeld System Setup Robot Controller SetupWeld Equipment Setup Touch Sensing SetupConnections Power Wave Interface BoardArctool Welding Inputs and Outputs Miscellaneous ConnectionsWater Cooler Usage AccessoriesRecommended Coolants Priming the CoolerFor the Latest L9777 Wire Feed Unit Dimension PrintType Connecting Wire Feed Unit to Power Source Mounting the Wire Feed Unit Electrode RoutingSteel Wire Sizes Roll Procedure to Install Drive Roll and Guide TubesAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Requires Installation of 2 51MM K162H Spindle KIT Feeding Electrode and Brake AdjustmentTo Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode Avoiding Wire Feeding Problems Wire Reel Mounting 50 22.7kg and 60lb 27.2kg CoilsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxConnector for 1/16 5/64 1.6 2.0 mm Wire Switch RequirementsRoutine and Periodic Maintenance MaintenanceInput Filter Capacitor DIS Charge Procedure Figure D.1 Resistor Locations Locate the #9 and #12 terminals, identified by Discharge labels, on each of the four SwitchConnected 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 HOW to USE Troubleshooting Guide TroubleshootingED Tests Authorized Field Service Facility Troubleshooting GuideSists, contact your local Lincoln 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 New Lessons in Arc Welding How To Read Shop DrawingsNeed Welding Training? Basic CoursePrecaucion Aviso DE
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