Lincoln Electric IM542-D manual Power Wave Interface Board, Miscellaneous Connections, Nov97

Page 40

C-6

C-6

ROBOTIC INTERFACE

6. CONNECTIONS

6.1 POWER WAVE INTERFACE BOARD

J101-1

+Serial loop

CTRL J27-1

J101-2

High speed sense 1

P83-K

J101-3

High speed sense 2

P83-L

J101-4

-Serial loop

CTRL J27-4

 

 

 

J103-1

+42VDC

Full wave bridge

J103-2

-42VDC

Full wave bridge

J103-3

Touch 2-4 output (2)

PROT J34-4

J103-4

Touch 2-4 output (4)

PROT J34-7

J103-5

Tach PWR

P83-G

J103-6

Tach signal

P83-F

J103-7

Tach GND

P83-H

J103-8

Motor+

P83-A

J103-9

Motor-

P83-B

J103-10

Weld 2-4 output (2)

PROT J34-11

J103-11

Weld 2-4 output (4)

PROT J34-14

J103-12

Gas solenoid+

P83-C

J103-13

Gas solenoid-

P83-D

J103-14

67 Sense lead

P83-N

J103-15

 

 

J103-16

 

 

 

 

 

J104-1

Voltage signal

CTRL J21-4

J104-2

Current signal

CTRL J21-7

J104-3

Water PWR

D.K. J16-4

J104-4

+output signal

SNUB J60-3

J104-5

-output signal

SNUB J61-4

J104-6

Water signal

D.K. J16-5

J104-7

Control GND

CTRL J24-11

J104-8

TRIM command

D.K. J10-12 (TIG)

J104-9

WFS command

D.K. J10-2 (WF1)

J104-10

Display analog GND

D.K. J10-13

J104-11

Water GND

D.K. J16-12

J104-12

67 Sense lead

SNUB J60-8

 

 

 

J105-1

Isolated voltage signal

P82-J (ADCH1)

J105-2

Isolated current signal

P82-L (ADCH2)

J105-3

Abnormal operation signal

P82-h (WDI6)

J105-4

Arc start command

P82-[ ]* (WDO1)

J105-5

Arc detect signal

P82-d (WDI2)

J105-6

Gas flow command

P82-S (WDO2)

J105-7

Gas shortage signal

P82-e (WDI3)

J105-8

DPS command

P82-X (WDO7)

J105-9

Positive inch command

P82-U (WDO4)

J105-10

Negative inch command

P82-V (WDO5)

J105-11

Short detect signal (+)

P82-N (WDI-)

J105-12

Short detect signal (-)

P82-P (WDI-)

J105-13

Isolated water signal

P82-g (WDI5)

J105-14

Touch sense command

P82-T (WDO3)

J105-15

Voltage command

P82-A (DACH1)

J105-16

WFS command

P82-E (DACH2)

 

 

 

J106-1

Touch sense signal

CTRL J24-4

J106-2

Isolated touch sense signal

P82-c (WDI1)

J106-3

Robot +24V

P82-r (+24E)

J106-4

Robot GND

P82-a (0V)

J106-5

Robot analog GND

P82-F (COMDA2)

J106-6

Spare robot output

P82-Z (WDO8)

J106-7

Gas shortage input

P84-A

J106-8

Gas shortage GND

P84-B

6.2ARCTOOL WELDING INPUTS AND OUTPUTS

CRW1-1

 

DACH1

Voltage command

P82-A

CRW1-2

 

COMDA1

 

P82-F

CRW1-3

 

DACH2

WFS command

P82-E

CRW1-4

 

COMDA2

WFS command GND

P82-F

CRW1-5

 

WDI1

(Touch sense signal)

P82-c

CRW1-6

 

WDI2

Arc detect

P82-d

CRW1-7

 

WDI3

Gas fault

P82-e

CRW1-8

 

WDI4

 

P82-f

CRW1-9

 

WDI5

Water fault

P82-g

CRW1-10

 

WDI6

Power fault

P82-h

CRW1-11

 

WDI7

 

P82-j

CRW1-12

 

WDI8

 

P82-k

CRW1-13

 

ADCH1

Voltage feedback

P82-J

CRW1-14

 

COMAD1

 

P82-K

CRW1-15

 

ADCH2

Current feedback

P82-L

CRW1-16

 

COMAD2

 

P82-M

CRW1-17

 

 

 

 

CRW1-18

 

 

 

 

CRW1-19

 

0V

Robot GND

P82-a

CRW1-20

 

0V

 

P82-b

CRW1-21

 

0V

 

P82-m

CRW1-22

 

0V

 

P82-n

CRW1-23

 

WDO1

Weld start

P82-R

CRW1-24

 

WDO2

Gas start

P82-S

CRW1-25

 

WDO3

(Touch sense

P82-T

 

 

 

 

command)

 

CRW1-26

 

WDO4

Wire+

P82-U

CRW1-27

 

WDO5

Wire-

P82-V

CRW1-28

 

WDO6

 

P82-W

CRW1-29

 

WDO7

(Dual procedure switch

P82-X

 

 

 

 

command)

 

CRW1-30

 

WDO8

(Spare robot output)

P82-Z

CRW1-31

 

WDI+

Wire stick detect

P82-N

CRW1-32

 

WDI-

Wire stick detect

P82-P

CRW1-33

 

+24V

Robot PWR

P82-r

CRW1-34

 

+24V

Robot PWR

P82-r

 

 

 

 

 

P82-H

 

 

 

 

 

P82-s

 

P82-R

Fanuc models

 

 

 

* P82-C Motoman models

6.3 MISCELLANEOUS CONNECTIONS

P84-A

Gas shortage input

P84-B

Gas shortage GND

POWER WAVE 450

Nov97

 

Page 39 Page 41
Image 40
Page 39 Page 41
Contents Safety Depends on You For use with machines having Code NumbersSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcThank You Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Vii Section CViii Section DSection E Section FSection G SeriesInstallation Technical Specifications Power WavePower Wave AwgiecSafety Precautions High Frequency PrecautionsSelect Suitable Location Input ConnectionsInput Power Connections Input Fuse and Supply Wire ConsiderationsInput Voltage Reconnect Procedure Ground ConnectionsWire Feeder Connections Output ConnectionsWork and Electrode Cable Connections Water Cooler ConnectionsPower Wave 450 Robotic Dimensions Power Wave 450 Robotic Operation Safety InstructionsOperating Instructions Select your process information Save process information if desiredGeneral Description Controls and Settings Case Front ControlsOperating Overlays Installing AN OverlayOverview Overlay Overlay TypesName PULSE, GMAW, FCAW, and STICK/TIG Process Selection Overlay Overlay ID Number =Operation Then Robotic Interface Weld from MEMORY, Dual Procedure Overlay Select a Memory LocationOperation Recall from Memory KEY Memory Location Numbers Limits Overlay OptionalSET Limit KEY Limit UP / Down Keys Operation Setup Overlay Figure B.7 Setup OverlayWire Feeder Setup Description +/- Polarity KEYPositive Polarity Voltage Sensing Table B.1 Positive Voltage Sensing OptionsOverview of Welding Procedures Flux Cored ARC Welding Fcaw and Gmaw ProceduresPulse Procedures Wave ControlGmaw Table B.3 Adjustble ParametersFcaw Pulse Welding Overload ProtectionThermal Protection Current ProtectionRobotic Interface Robot Signal DescriptionsInterface Description Touch Sense Signal GAS FaultWire Fault Water FaultPower Wave Circuits Dual Procedure Switch COM- MandWire Stick Detect Robot Controller Electrical CharacteristicsTouch Sense Command ARC Detect GAS FaultWater Fault Power Fault Dual Procedure Switch CommandRobot Controller Setup Weld System SetupWeld Equipment Setup Touch Sensing SetupPower Wave Interface Board ConnectionsArctool Welding Inputs and Outputs Miscellaneous ConnectionsAccessories Water Cooler UsageRecommended Coolants Priming the CoolerFor the Latest L9777 Wire Feed Unit Dimension PrintType Mounting the Wire Feed Unit Electrode Routing Connecting Wire Feed Unit to Power SourceProcedure to Install Drive Roll and Guide Tubes Steel Wire Sizes RollAluminum Wire Sizes Drive Roll and Guide Tube KitsIdle Roll Pressure Setting Feeding Electrode and Brake Adjustment Requires Installation of 2 51MM K162H Spindle KITTo Mount a 50-60lb 22.7-27.2kg Coil Wire Loading of 13-14lb 6kg Innershield CoilsFeeding Electrode Wire Reel Mounting 50 22.7kg and 60lb 27.2kg Coils Avoiding Wire Feeding ProblemsPeriodic Maintenance of Wire Drive Unit Wire Drive Motor and GearboxSwitch Requirements Connector for 1/16 5/64 1.6 2.0 mm WireRoutine 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 G3503- Installation or SER Vice Tool Usage Removing and Installing the G3503 CoolerG3503- Cooler Periodic Maintenance G3503- Cooler ServiceFigure 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 How To Read Shop Drawings New Lessons in Arc WeldingNeed Welding Training? Basic CoursePrecaucion Aviso DE
Top Page Image Contents