Miller Welding Manuel utilisateur

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Processes

Description

Plasma Arc (PAW) Welding

OM-169 510

June1995

AutomaticWelding

Robot PAW Interface

OM-169 510 – 6/95

EMF INFORMATION

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): “. . . there is now a very

large volume of scientific findings based on experiments at the

cellularlevelandfromstudieswithanimalsandpeoplewhichclearly

establish that low frequency magnetic fields can interact with, and

produce changes in, biological systems. While most of this work is

of very high quality, the results are complex. Current scientific

understanding does not yet allow us to interpret the evidence in a

single coherent framework. Even more frustrating, it does not yet

allow us to draw definite conclusions about questions of possible

riskor toofferclear science-basedadvice onstrategies tominimize

or avoid potential risks.”

To reduce magnetic fields in the workplace, use the following

procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as

practical.

5. Connect work clamp to workpiece as close to the weld as

possible.

About Pacemakers:

The above procedures are among those also normally

recommended for pacemaker wearers. Consult your doctor for

complete information.

Considerations About Welding And The Effects Of Low Frequency Electric And

Magnetic Fields

NOTE

mod10.1 4/93

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1. General Information And Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. Safety Alert Symbol And Signal Words 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Description 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Field Installation Instructions For PAW Interface Panel To Computer Interface 2. . . . . . . . . .

3-2. Shock Sensor Unit Assembly And Installation To Robot 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. High-Frequency Protection For Torch Cable 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Torch And Torch Cable Installation To Robot 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Ground Cable Connections 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Torch Cable Internal Connections To Plasma Welding Console 10. . . . . . . . . . . . . . . . . . . . . . .

3-7. PAW Interface Panel – Computer Interface Connection 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8. PAW Interface Panel – Welding Power Source – PAW Console Connections 11. . . . . . . . . . .

3-9. Computer Interface – Input Power Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Gas Set/Pilot Arc Start Push Button 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-11. Remote Gas Set/Pilot Arc Start Switch Connections 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – ROBOT PROGRAM MODIFICATIONS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Setting Up Plasma (Non-Standard) Torch For MRH2Robot 13. . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Setting Up Plasma Torch For MRV2Robot 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Marking Position Of Torch Head Assembly 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4. System Setup For MRH2And MRV2With C2 Robot Control 14. . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – ELECTRICAL DIAGRAMS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5-1. Circuit Diagram For Robot PAW System 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5-2. Circuit Diagram For Robot PAW Interface Panel 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5-3. Wiring Diagram For Robot PAW Interface Panel 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5-4. Circuit Diagram For High-Frequency Filter 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 5-5. Wiring Diagram For High-Frequency Filter 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – HF IN PLASMA ARC WELDING 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 – PARTS LIST 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-169 510 Page 1

SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS

1-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la-

bels, tags, and plates on the unit pertains to equipment

design, installation, operation, maintenance, and trou-

bleshooting which should be read, understood, and fol-

lowed for the safe and effective use of this equipment.

B. Safety

The installation, operation, maintenance, and trouble-

shooting of plasma arc welding equipment requires

practicesandprocedureswhichensurepersonalsafety

and the safety of others.

Read and follow safety information in the Plasma Weld-

ing Console Owner’s Manual and Welding Torch Own-

er’s Manual, as well as the other Owner’s Manuals for

thissystem,toensurethesafeinstallationandoperation

of the Plasma Arc Welding system.

1-2. SAFETY ALERT SYMBOL AND SIGNAL

WORDS

The following safety alert symbol and signal words are

used throughout this manual to call attention to and

identify different levels of hazard and special instruc-

tions. This safety alert symbol is used with the signal

words WARNING and CAUTION to call atten-

tion to the safety statements.

WARNING statements identify procedures or

practices which must be followed to avoid seri-

ous personal injury or loss of life.

CAUTION statements identify procedures or

practiceswhichmustbefollowedtoavoidminor

personal injury or damage to this equipment.

IMPORTANT

statements identify special instructions

necessary for the most efficient operation of this equip-

ment.

SECTION 2 – INTRODUCTION

2-1. DESCRIPTION

The robot PAW interface panel is a control designed to

be used with a Thermal Dynamics WC 100B plasma

welding console and a plasma arc welding torch

PWM-3A, MILLER Computer Interface, and MRH2or

MRV2robot system for the Plasma Arc Welding (PAW)

process.

SECTION 3 – INSTALLATION

PAW Interface

Panel

Plug PLG21 Connects

To Computer Interface

Receptacle RC8

(See Section 3-7)

Receptacle RC20

(See Section 3-8)

Computer

Interface

Computer Interface

Input Power Receptacle RC11

Location (See Section 3-9 And

Computer Interface Owner’s Manual)

ST-800 732

Receptacle RC21

(See Section 3-8)

Gas Set/Pilot Arc

Start Push Button

Figure 3-1. PAW Interface Panel

OM-169 510 Page 2

IMPORTANT:

When installing or operating plasma arc

welding equipment, refer to the Plasma Welding Con-

sole Owner’s Manual and Welding Torch Owner’s

Manual for specific precautionary information that ap-

plies to this equipment.

3-1. FIELD INSTALLATION INSTRUCTIONS FOR

PAW INTERFACE PANEL TO COMPUTER IN-

TERFACE (Figure 3-1 And Figure 3-2)

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Shut down robot and welding power source,

and disconnect input power employing lock-

out/tagging procedures before beginning

this installation.

Lockout/tagging procedures consist of pad-

locking line disconnect switch in open position,

removing fuses from fuse box, or shutting off

andred-taggingcircuitbreaker orotherdiscon-

necting device.

CAUTION: ELECTROSTATIC DISCHARGE

(ESD) can damage circuit boards.

•

Put on properly grounded wrist strap BE-

FORE handling circuit boards.

•

Perform work only at a static-safe work area.

INCORRECT INSTALLATION or misaligned

plugs can damage circuit board.

•

Be sure that plugs are properly installed and

aligned.

EXCESSIVE PRESSURE can break circuit

board.

•

Useonly minimal pressureand gentle move-

ment when disconnecting or connecting

boardplugsandremovingorinstallingboard.

IMPORTANT:

All directions, such as left or right, are

with respect to the operator facing the Computer Inter-

face front panel. Retain all hardware removed during

this procedure for reinstallation unless specifically told

otherwise.

1. Remove Computer Interface top cover and left

side panel.

2. Remove side panel from PAW Interface panel.

3. InstallPAWInterfaceframeontoleft sidepanelof

Computer Interface with sheet metal screws re-

moved in Step 1 (see Figure 3-1).

4. Make the following internal connections to the

Computer Interface (see Figure 3-2).

a. RemovejumperlinkbetweenterminalsBandC

on terminal strip 2T.

b. Connectlead26fromtheInterfacepaneltoter-

minal B on terminal strip 2T.

c. Connectlead 60fromthe Interfacepanelto top

mounting screw on filter FL1.

d. Connect green lead from the Interface panel to

the ground stud located directly above terminal

strip 2T.

IMPORTANT:

Removetheoutsidestarwasherfromthe

ground stud to make room for the green lead terminal.

e. RemoveplugPLG3fromreceptacleRC1onIn-

terface Board PC4.

f. Connect plug PLG10 from the PAW Interface

panel to Interface Board PC4 receptacle RC1

whereplugPLG3wasremovedinStep4e(plug

PLG3 is not connected for this application).

Ground Stud

Location

Motor Control

Board PC2

Terminal

Strip 2T

Filter FL1

Mounting Screw

Location

Interface

Board PC4

Voltage Control

Board PC1

PC4 Receptacle RC1

Location

Left Side View Of

Computer Interface

Ref. ST-139 887-C

PC4 Switch S1 Location

Figure 3-2. Computer Interface Internal Connections

OM-169 510 Page 3

Robot Arm

Insulator

Plate

Shock Sensor Leads

Shock Sensor

Torch

Mounting

Torch Clamp

ST-800 733

Bracket

Mounting

Bracket

Clamp

Welding Gun

Body

Figure 3-3. MRH2Shock Sensor Unit Assembly And Installation

Shock Sensor

Torch Mounting

ST-800 778

Angle Bracket

Bracket

Torch Clamp

L-Bracket

Insulating Block

Angle Bracket

Clamp

Output Hub

Bracket

Shock Sensor

Leads

Welding Gun

Body

Figure 3-4. MRV2Shock Sensor Unit Assembly And Installation

OM-169 510 Page 4

g. Connect lead 23 from PAW interface panel to

terminal A on terminal strip 2T.

h. Route plug 30/31 from PAW interface panel

throughcenterbaffleincomputerinterface.Dis-

connectplug PLG10fromplugPLG11andcon-

nect PLG 30/31 to PLG 10/11.

5. Locate switch S1 on Interface Board PC4 (see

Figure 3-2). Remove varnish and potting com-

poundfromS1andplacethetwoDIPswitcheson

S1 in the following positions:

a. S1-1 (Disable Voltage Ramp) in OFF position.

b. S1-2 (Disable Stick Checking) in ON position.

6. Reinstall side panel onto PAW Interface panel.

7. Install supplied top cover onto the Computer In-

terface – PAW Interface panel.

3-2. SHOCK SENSOR UNIT ASSEMBLY AND

INSTALLATION TO ROBOT (Figure 3-3 And

Figure 3-4)

WARNING: ELECTRIC SHOCK can kill.

•

Do not touch live electrical parts.

•

Shut down robot and welding power source,

and disconnect input power employing lock-

out/tagging procedures before inspecting or

installing.

Lockout/tagging procedures consist of padlock-

ing line disconnect switch in open position, re-

moving fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect-

ing device.

MOVING PARTS can cause serious injury.

•

Keep away from moving parts.

HOT SURFACES can cause severe burns.

•

Allow cooling period before servicing.

To assemble and install the shock sensor unit, refer to

Figure 3-3 or Figure 3-4 and proceed as follows:

A. MRH2Models

1. Ifapplicable,removeexistinggun/torchandinsu-

lator plate from robot arm.

2. Install supplied insulator plate to robot arm with

screws removed in Step 1.

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.

B. MRV2Models

1. If applicable, remove existing shock sensor from

robot arm.

2. Assemble shock sensor, mounting bracket, and

torch clamp as shown in Figure 3-4.

3. Install shock sensor unit to robot insulating block

with screws removed in Step 1.

3-3. HIGH-FREQUENCY PROTECTION FOR

TORCH CABLE

The Pilot mode switch on the WC 100B console pro-

vides a selection for the pilot arc mode of operation. If

plasma arc welding is performed with the switch in the

NORMAL position, the optional shield sleeving should

be installed on the torch cable.

The optional shield sleeving is for covering the torch

cable to prevent high frequency from interfering with ro-

bot operations.

IMPORTANT:

When installing shield sleeving, be sure

end with lead and attached ring terminal is at console

end of the torch cable.

To install shield sleeving, proceed as follows:

1. Unscrew sleeve from torch head assembly

(see Figure 3-5).

2. Disconnect fittings and remove torch head as-

sembly.

3. Insert torch cable into shield sleeving at end with

lead and attached ring terminal.

4. Slide shield sleeving over torch cable until end of

torch cable exits opposite end of shield sleeving.

5. Reconnect fittings from torch cable to torch head

assembly (match color-coded markings).

6. Checkforcoolantleaksatfittingsbyturningonre-

circulating coolant system. Tighten fittings if nec-

essary.

OM-169 510 Page 5

ST-800 836

Sleeve

Green And Black

Connections

Yellow And Red

Connections

Torch Head

Assembly

Figure 3-5. Connections At Torch Head Assembly

7. Screw sleeve onto torch head assembly.

8. Secure shield sleeving to torch cable using sup-

plied clamp.

3-4. TORCH AND TORCH CABLE INSTALLATION

TO ROBOT (Figure 3-3 Thru 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 lock-

out/tagging procedures before inspecting or

installing.

Lockout/tagging procedures consist of padlock-

ing line disconnect switch in open position, re-

moving fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect-

ing device.

MOVING PARTS can cause serious injury.

•

Keep away from moving parts.

HOT SURFACES can cause severe burns.

•

Allow cooling period before servicing.

A. MRH2Models

1. If applicable, remove the existing wire feed mo-

tor/reed relay mounting bracket and stabilizer

brace from the robot (refer to robot Owner’s

Manual for bracket and brace locations). Rein-

stall the two lifting brackets only (see robot Own-

er’s Manual and Figure 3-10).

2. If applicable, remove the wire feed hub support

from the robot (refer to robot Owner’s Manual for

hubsupportlocation).Installsuppliedtorchcable

support bracket in location where hub support

was secured (see Figure 3-10).

3. The torch cable is enclosed in a black protective

case. Secure torch in torch clamp.

IMPORTANT:

Before operating, see Section 4 and ro-

bot Owner’s Manual for instructions for absolute offset

adjustment. When doing this procedure, remove the

shield cup and tip from torch and install the supplied

brass tip gauge.

4. If applicable, remove the existing clamps sus-

pendedfromtheoutletcable support arm and re-

place them with the two supplied clamps. Route

torchcable throughnewclampsso thereisabout

3-1/2 ft. (1 m) of cable between the top of the

shock sensor and the first clamp (see

Figure 3-10).

5. Route torch cable through torch cable support

bracket tray and secure with rubber straps.

6. Route remaining end of torch cable to the WC

100Bweldingpanelfor internal connections (see

Step 3, Section 3-6B).

7. The supplied high frequency filter box prevents

noise interference at the shock sensor circuit in

the Robot Control. To install the filter, proceed as

follows:

OM-169 510 Page 6

LEFT SIDE RIGHT SIDE

Robot Control

S-0782

Blank Cover Plates

(Both Rows)

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 employ-

ing lockout/tagging procedures before in-

specting high-frequency filter.

Lockout/tagging procedures consist of padlock-

ing line disconnect switch in open position, re-

moving fuses from fuse box, or shutting off and

red-tagging circuit breaker or other disconnect-

ing device.

•

Put on properly grounded wrist strap BE-

FORE handling circuit boards or making con-

nections inside Robot Control.

•

Transport circuit boards in proper static-

shielding carriers or packages.

•

Perform work only at a static-safe work area.

a. Open Robot Control cabinet door using the two

suppliedkeys,androtatethepowerswitchhan-

dlebeyondtheOFF position to theReset/Open

position.

b. SelectandremoveablankcoverplatefromRo-

bot Control for installing high-frequency filter

(see Figure 3-6).

c. Remove screws securing cover to high-fre-

quency filter box, and remove cover from box.

d. Insert cord attached to box through opening in

RobotControlsidepanelwherecoverplatewas

removed.

e. Place a supplied external star washer over

each screw, and thread screws into mounting

holes in side panel (see Figure 3-7).

f. Tighten screws until star washers flatten and

penetrate through paint into metal surface.

g. Place remaining star washers over threaded

portion of each screw extending out from side

panel inside Robot Control, and install nut on

each screw.

h. Tighten nuts until star washers flatten and

penetrate through paint into metal surface.

i. Reinstall and secure cover onto filter box.

j. Route high-frequency cord inside Robot Con-

trol to Interlock board on left side panel of cabi-

net.

k. Route black and white leads to terminal block

TB1 (see Figure 3-9).

l. Connect black lead to terminal 4 on TB1.

m. Connect white lead to terminal 5 on TB1.

n. Close and secure Robot Control cabinet door.

o. Disconnect friction terminals on leads of exist-

ing shock sensor cord from shock sensor leads

at welding gun body (see Figure 3-8).

p. Remove existing shock sensor cord by discon-

necting plug from receptacle on robot.

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