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OM-169 510
June 1995
Processes
Plasma Arc (PAW) Welding
Description
Automatic Welding
Robot PAW Interface
Visit our website at
www.Miller-
Welds.com
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EMF INFORMATION Considerations About Welding And The Effects Of Low Frequency Electric And NOTE Magnetic Fields The following is a quotation from the General Conclusions Section To reduce magnetic fields in the workplace, use the following procedures: of the U.S. Congress, Office of Technology Assessment, Biological Effects of Power Frequency Electric & Magnetic Fields – 1. Keep cables close together by twisting or taping them. Background Paper, OTA-BP-E-53 (Washington, DC: U.S. 2. Arrange cable
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SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS 1-1. GENERAL INFORMATION AND SAFETY 1-2. SAFETY ALERT SYMBOL AND SIGNAL WORDS A. General The following safety alert symbol and signal words are used throughout this manual to call attention to and Information presented in this manual and on various la- identify different levels of hazard and special instruc- bels, tags, and plates on the unit pertains to equipment tions. design, installation, operation, maintenance, and trou- bleshooting which shou
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IMPORTANT: When installing or operating plasma arc IMPORTANT: All directions, such as left or right, are welding equipment, refer to the Plasma Welding Con- with respect to the operator facing the Computer Inter- sole Owner’s Manual and Welding Torch Owner’s face front panel. Retain all hardware removed during Manual for specific precautionary information that ap- this procedure for reinstallation unless specifically told plies to this equipment. otherwise. 1. Remove Computer Interface top cov
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Robot Arm Shock Sensor Leads Insulator Shock Sensor Plate Welding Gun Body Torch Mounting Bracket Torch Clamp Mounting Bracket Clamp ST-800 733 2 Figure 3-3. MRH Shock Sensor Unit Assembly And Installation Output Hub L-Bracket Bracket Insulating Block Shock Sensor Leads Shock Sensor Welding Gun Body Angle Bracket Clamp Angle Bracket Torch Mounting Bracket Torch Clamp ST-800 778 2 Figure 3-4. MRV Shock Sensor Unit Assembly And Installation OM-169 510 Page 3
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g. Connect lead 23 from PAW interface panel to 2. Install supplied insulator plate to robot arm with terminal A on terminal strip 2T. screws removed in Step 1. 3. Assemble shock sensor, mounting bracket, and h. Route plug 30/31 from PAW interface panel torch clamp as shown in Figure 3-3. through center baffle in computer interface. Dis- connect plug PLG10 from plug PLG11 and con- 4. Install shock sensor unit to the insulator plate nect PLG 30/31 to PLG 10/11. installed in Step 2 with supplied
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MOVING PARTS can cause serious injury. • Keep away from moving parts. HOT SURFACES can cause severe burns. • Allow cooling period before servicing. Sleeve 2 A. MRH Models 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). Green And Black 2. If applicable, remove the wire feed h
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Robot Control LEFT SIDE RIGHT SIDE Blank Cover Plates Blank Cover Plates (Both Rows) S-0782 Figure 3-6. View Of Left And Right Sides Of Robot Control WARNING: ELECTRIC SHOCK can kill. e. Place a supplied external star washer over ELECTROSTATIC DISCHARGE (ESD) can each screw, and thread screws into mounting damage circuit boards. holes in side panel (see Figure 3-7). • Do not touch live electrical parts. f. Tighten screws until star washers flatten and • Shut down welding power source and Robot
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Robot Control Side Panel Star Washer Screw Filter Box Cord Nut ST-152 641 Figure 3-7. Installation Of Securing Hardware For Filter Box q. Route supplied 35 ft. (10.5 m) shielded shock r. Connect plug on end of cord to filter box recep- tacle. sensor cable under the torch cable securing straps on the outside of the protective casing so s. Connect friction connectors or plug on remain- that the two leads with friction connectors are ing end of cord to shock sensor leads or recep- located near th
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TB2 Interlock Board CN68 CN69 CN67 Terminal Block TB1 CN80 TB1 (IN) F2 (1A) 1 ESTOP CN38 LED301 2 ESTOP LED202 CN73 3 LED203 CN37 ESTOP CN22 LED204 LED303 4 SHOCK LED302 LED205 5 JP301 SHOCK LED101 LED305 6 INCOM 7 INCOM TB1 8 L FC11 LAMP LED304 9 AUTO JP501 F3 (3A) 10 TEACH JP304 JP303 JP302 11 ST#1 CN28 CN33 CN32 CN31 12 CN41 LED401 ST#2 LED402 13 LED602 ST#3 LED403 LED601 LED603 14 LED404 CN46 JP601 JP602 JP603 STOP LED405 JP306 15 LED406 SV. ON CN45 16 SV. ON CN70 CN71 CN72 CN40 JP701 LED501
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Torch Torch Cable Outlet Cable Cable In Support Bracket Support Arm Protective Case Robot Control Clamps High Frequency Filter Box DC Welding Power Source Shock Sensor Lifting Cable Ground Bracket Rod No.1 Ground Cable Securing Bolt Shock Location Sensor Cable Welding Gun Torch Body PAW/Computer Interface Braided Ground Cable Ground Rod No.2 Coolant WC 100B System 115VAC Input Plasma Power Cord Welding Console ST-800 734 2 Figure 3-10. MRH Robot PAW System 2 B. MRV Models adjustment. Install pos
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Cable Servo Hanger Torch Cable Welding Light In Protective Gun Box Robot Control Case Body Torch Cable Support Bracket High Frequency Filter Box Shock Sensor DC Welding Cable Power Shock Source Sensor Cable Ground Rod No.1 Torch Braided Ground Cable PAW/Computer Interface Ground Rod No.2 Coolant WC 100B System Plasma Braided Welding Ground Console Cable 115VAC Input Power Cord ST-800 735-A 2 Figure 3-11. MRV Robot PAW System 3. Route remaining end of another ground cable to To make torch cable i
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 C O N 1CR CSR PSR T. PILOT PILOT PLASMA SHIELD ST-800 736 Figure 3-12. Terminal Strip TB1 Location Inside WC 100B Console 3-8. PAW INTERFACE PANEL – WELDING POW- 4. Connect plug on remaining end of cord from re- ER SOURCE – PAW CONSOLE CONNEC- ceptacle RC20 to receptacle labeled Remote TIONS (Figure 3-1, Figure 3-10, And Control on front of WC 100B console. Figure 3-11) 5. Locate supplied cord with matching plug for PAW interface panel receptacle RC21 and conn
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g. Yellow lead to terminal 14. To purge the plasma torch gas line, proceed as follows: 9. Route cable from welding power source negative 1. Turn on input power to welding power source and (–) weld output receptacle through opening in WC 100B console. rear of WC 100B console. Route end of cable to shunt, located where torch cable bus bar is con- 2. Place Run/Set switch in the Set position. nected, and connect cable to shunt at end oppo- 3. Press the Gas Set/Pilot Arc Start push button. site from
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SECTION 4 – ROBOT PROGRAM MODIFICATIONS IMPORTANT: The robot program must be changed to Attaches To Bottom Of Axis 5 Housing accommodate plasma arc welding. The program is fac- tory set to accommodate factory installed plasma arc welding equipment. The following information pertains to the robot Owner’s Manual and must be followed when Indexing Pin field installing plasma arc welding equipment. Rod Scribe around rod below lower bar to record height. WARNING: ELECTRIC SHOCK can kill. • Do not
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2 2 MRV Robot MRH Robot Robot Arm Sleeve Robot Arm Sleeve Scribe Marks Scribe Marks Torch Torch Head Head Assembly Assembly ST-800 747-A Figure 4-2. Marking Position Of Torch Head Assembly 2 2 4-4. SYSTEM SETUP FOR MRH AND MRV WITH C2 ROBOT CONTROL Set welding power source specifications in user parameters for the Plasma Arc Welding (PAW) process according to the following instructions. 1. Turn on Robot Control input power by placing the power switch handle on the Robot Control cabinet door in
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TE A C H SE R V O O F F TE A C H E D ITFILE ALLOT LOCK > 2. Press the FUNCTION APPLICATION key for additional functions to appear on the display. P A R M T E R C H EC K MA N A G E S Y S . S E T MEM O R Y > F1 3. Press the F1 key for the PARMTER function. SE L E CT T YPE O F PA R A M E T E R TE A C H MO D E BY FU N C T I O N KEY SE R V O O F F SYS T E M SW I T C H W E L D I / O AU TO > 4. Press the FUNCTION APPLICATION key for additional functions to appear on the display. SE L E CT T YPE O F
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AX I S M L 4 POW E R S O URC E W I R E TE A C H GM AW . 035 . 045 . 062 S Y N E R G I C . 035 . 045 . 062 SE R V O O F F G T AW –100 . 035 . 045 . 062 G T AW –300 . 035 . 045 . 062 US ER RE G I S T ER RE G I S T M O DI F Y S C _ E D I T + _ 6. Use the INCREMENT or DECREMENT key and forward or back DISPLAY SE- LECT key to select GTAW-300 by setting a wire size selection. AX I S M L 4 POW E R S O URC E W I R E TE A C H GM AW . 035 . 045 . 062 S Y N E R G I C . 035 . 045 . 062 SE R V O O F F G
