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1 PW-455R Analog Interface Instruction Guide
1PW-455R Analog Interface Instruction Guide
2PART A ...............................................................................................................................................4
1 General Description......................................................................................................................4
2 Recommended Processes and Equipment ....................................................................................4
2.1 Recommended Processes ......................................................................................................42.2 Process Limitations ...............................................................................................................42.3 Recommended Equipment / Interface ...................................................................................42.4 Equipment Limitations..........................................................................................................5
3 Design Features ............................................................................................................................5
3.1 Platform Commonalties.........................................................................................................53.2 Operational Features and Controls ........................................................................................53.3 Specifications ........................................................................................................................63.4 Regulatory Requirements as Required for Market................................................................6
4 Construction Information .............................................................................................................6
4.1 Wiring Information ...............................................................................................................64.2 Software Requirements: ........................................................................................................9
PART B .............................................................................................................................................10
1. Installation ..................................................................................................................................10
1.1 Non-Standard Safety Information .......................................................................................101.2 Location...............................................................................................................................101.3 Input and Grounding Connections ......................................................................................101.4 Output Cables, Connections and Limitations......................................................................101.5 System Configuration..........................................................................................................111.6 I/O Module DeviceNet Configuration.................................................................................11
2 Operating Instructions ................................................................................................................11
2.1 Startup Sequence.................................................................................................................112.2 Display Operation ...............................................................................................................112.3 Local Procedure \ Weld Parameter Set-Up (MSP - Mode Select Panel) ............................122.4 Special Access Modes (Through MSP - Mode Select Panel) .............................................172.5 Making a Weld....................................................................................................................18
3 Application Information .............................................................................................................26
3.1 Interface Description ...........................................................................................................263.2 Robot Signal Descriptions...................................................................................................273.3 Power Wave Circuit Descriptions .......................................................................................293.4 Electrical Characteristics.....................................................................................................313.5 Robot Controller Setup .......................................................................................................343.6 PW-455R Analog Interface Cable Definition .....................................................................35
4 Maintenance ...............................................................................................................................36
4.1 Non-Standard Safety Information .......................................................................................364.2 Routine Maintenance ..........................................................................................................364.3 Periodic Maintenance..........................................................................................................364.4 Machine Calibration Specification......................................................................................36
5 Troubleshooting Guide...............................................................................................................38
5.1 I/O Run (Rn) & IO Err (Er) Status LED's on DeviceNet Coupler ......................................385.2 MS (Module Status) Red & Green Status LED's on DeviceNet Coupler ...........................385.3 NS (Network Status) Red & Green Status LED's on DeviceNet Coupler ..........................395.4 Digital I/O Status Indicators................................................................................................40
35.5 Troubleshooting Chart ........................................................................................................41
6 Component location and replacement parts list..........................................................................42
6.1 Bill of Materials (L10412-18) .............................................................................................42
4PART A
1 GENERAL DESCRIPTION
The PW455R Analog Interface is designed to emulate the PW450 Robotic Interface. It isprimarily intended for use with a Fanuc robot using ArcTool software (V1.30P or higher)with optional Touch Sensing and Through Arc Seam Tracking (TAST). The interfaceresponds to all of the ArcTool welding inputs and outputs except wire fault and wire stickalarm. All of the circuitry for Touch Sensing is internal to the Powerwave; no externalpower supply is required. The current signal for TAST is supplied by the Powerwaveanalog output. No external current sensor is required. The interface does not control wirefeed speed and welding voltage independently. Rather, the Powerwave will always operatein a synergic mode and the welding voltage is programmed as a function of the wire feedspeed. ArcTool software was designed to control wire feed speed and voltageindependently. Since the Powerwave system uses an arc length trim, the voltage cannotbe directly controlled. The welding voltage setting in the robot controller is interpreted bythe Powerwave as a trim setting. Any ArcTool function which tries to set the voltage tozero and control the wire feed speed is actually only setting the arc length trim to theminimum. Refer to the Operation section for a complete description of arc length trim.Any function that tries to set the wire feed speed to zero and control the voltage is limitedby the minimum speed of the selected process. (Note: This phenomenon will occur as atruncation of the speed, rather than a re-scaling based on the process.)
Note:The PW455R Analog Interface is compatible with the PW455R, PW455M, and PW655M.The following text details the PW455R application, but applies to all machines unlessotherwise noted.
2 RECOMMENDED PROCESSES AND EQUIPMENT
2.1 Recommended Processes
Any synergic process currently available to the PW455R platform.
2.2 Process Limitations
As noted in the General Description, the analog inputs are scaled for minimum tomaximum WFS and TRIM. Therefore, without re-scaling, only synergic processes arecompatible with this interface. This is consistent with the PW450 analog interfaceoperation.
2.3 Recommended Equipment / Interface
This Analog Interface is intended for use with the PW455R, PW455M and PW655Mwelding machines. It provides a method to interface these machines to equipment thatdoes not support their preferred digital interface platform (i.e. ArcLink, Device Net,Ethernet). For commonality, the interface has been defined to emulate the PW450 RoboticInterface, and as a result does limit some of the high-end features of the equipment.
52.4 Equipment Limitations
The use of this interface is limited to the PW455R, PW455M, and PW655M powersources. Further, due to reasons sighted previously, it is currently limited to the use offully synergic processes only.
Additionally, it requires that the machine be equipped with a DeviceNet Gateway PCBD(Standard in the PW455R, Optional in the PW455M & PW655M). Completing theinstallation requires reprogramming the board to support the Analog Interface hardware.Once configured to support the Analog Interface, all other DeviceNet and extendedfunctions are disabled.
3 DESIGN FEATURES
3.1 Platform Commonalties
The PW455R Analog Interface is designed for use with the PW455R power source family.It emulates the PW450R Robotic Interface in function, and utilizes the same 37 pin MS-type connector. Therefore, it allows the PW455R to serve as a direct replacement inPW450R applications.
3.2 Operational Features and Controls
The primary function of the PW455R Analog Interface is to provide a means to connect thePW455R family of power sources to equipment that does not support the preferred digitalinterface platform (i.e. ArcLink, Device Net, Ethernet). The interface is equipped withanalog, and discreet digital I/O as noted below
Input Signals Output SignalsTRIM ( 010V Analog signal ) Voltage ( 010V Analog signal)WFS ( 010V Analog signal) Current ( 010V Analog signal)Arc Start (Trigger) Arc DetectGas Flow Gas FaultTouch Sense Command Touch Sense DetectCold Inch FWD Short DetectCold Inch REV Water FaultDual Procedure Abnormal Operation / Power Fault)
In addition, the interface includes a MSP style option panel used to set the weld parametersnot controlled via the I/O. These parameters include the Weld Mode, Run In, Arc Control,Burnback, and Cold Inch WFS functions. A method has also been included by which thedual procedure set up function can be executed, and the active procedure can be displayed.For additional information regarding this option panel, see Part B of this report.
63.3 Specifications
Input Voltage 24VDC 10%Input Current (max. with all I/O activated) < 300mADigital Inputs (low side switching) Type: Sourcing
Voff (Logic 0) 15 to 30 VDCVon (Logic 1) -3 to 5 VDCInput Impedance 4.8k (typ.)
Digital Outputs (low side switching) Type: SinkingVon (typical on state saturation) 0 1.0 VDCIL (max. load) 0.5 AMPS (short circuit protected)
Analog InputsRange 0 10 VDCMaximum Input 35 VDC
Analog OutputsMaximum Range 0 10 VDC
Operating Temperature 0C to +40CNet Weight N/ADimensions N/AAgency Approvals As Required by Application
3.4 Regulatory Requirements as Required for Market
Due to the flexible nature of this product, regulatory requirements and approvals will bedetermined, and sought as required by the application.
4 CONSTRUCTION INFORMATION
4.1 Wiring Information
The following wiring information is provided as a guide for assembly of the interface. The37 pin Amphenol to I/O block connections as well as the miscellaneous I/O blockconnections are listed in chart form. Where applicable PW450R lead numbering scheme isused for consistency. A complete wiring diagram has also been included detailing theremaining connections from the Gateway PC Board to the interface.
4.1.1 Wiring from 37 Pin Input Connector to Wago I/O Block
Module ModuleContact
PW-455 Analog InterfaceSignal Description
Lead # 37 PinAmphenol(MS Style28-21P)
Fanuc Signal Name (Desc.) / Type
306 6 24V Input 534 r +24 VDC (Robot Power)306 7 Common 535 a O VDC (Robot Common)408 (#1) 1 Arc Start 518
518ARC
WDO1 (Weld Cycle Start) / OutputMotoman Trigger Connection / Output
408 (#1) 5 Gas Purge 520 S WDO2 (Gas Valve On) / Output408 (#1) 4 Touch Sense 529 T WDO3 (Touch Sense Command) / Output408 (#1) 8 Cold Inch Forward 524 U WDO4 (Feed Forward) / Output408 (#2) 1 Cold Inch Reverse 525 V WDO5 (Feed Reverse) / Output408 (#2) 5 Dual Procedure Select 523 X WDO7 (Dual Procedure Select) / Output408 (#2) 4 NOT REQUIRED 546 Z WDO8 (Spare) / Output516 1 Touch Sensed 533 c WDI1 (Touch Sense Detect) / Input516 5 Arc Detect 519 d WDI2 (Arc Detect) / Input516 4 Gas Fault 521 e WDI3 (Gas Shortage) / Input
7516 8 Water Fault 528 g WDI5 (Water Shortage) / Input467 1 Trim Input 530 A DACH1 (Weld Volts CMD) / Analog Out467 --- NOT REQUIRED --- B COMDA1 (Common) / Analog Out467 5 WFS Input 531 E DACH2 (Weld WFS CMD) / Analog Out467 7 Analog Common (Isolated) 536 F COMDA2 (Common) / Analog Out550 1 Voltage Feedback 515 J ADCH1(Weld Voltage) / Analog In550 --- NOT REQUIRED --- K COMAD1 (Common) / Analog In550 5 Current Feedback 516 L ADCH2 (Weld Amps) / Analog In550 --- NOT REQUIRED --- M COMAD2 (Common) / Analog In509 1 Inverter Fault 517 h WDI6 (Pwr Supply Fail) / Input509 5 Wire Stick + 526 N WDI+ (+Wire Stick Detect) / Input509 6 Wire Stick (Common) 527 P WDI- (-Wire Stick Detect) / Input
4.1.2 Additional Wiring Information
Item From ToMisc. Wire for Wago I/O Block Pin 1 on module 306 Pin 2 on module 306Misc. Wire for Wago I/O Block Pin 5 on module 306 Pin 3 on module 306Misc. Wire for Wago I/O Block Pin 6 on module 306 V+ on the DeviceNet ConnectorMisc. Wire for Wago I/O Block Pin 3 on module 306 V- on the DeviceNet ConnectorMisc. Wire for Wago I/O Block Pin 3 on module 516 Pin 2 on module 509Misc. Wire for Wago I/O Block Pin 7 on module 516 Pin 7 on module 550M19902-1 (BOM Item 16 ) DeviceNet Gateway PCB (J71) MSP Style PanelMisc. Wire (+24V) DeviceNet Gateway PCB (J75-5) V+ on the DeviceNet ConnectorMisc. Wire (COMMON) DeviceNet Gateway PCB (J75-2) V- on the DeviceNet ConnectorMisc. Wire (CAN High) DeviceNet Gateway PCB (J75-1) CAN-H on the DeviceNet ConnectorMisc. Wire (CAN Low) DeviceNet Gateway PCB (J75-4) CAN-L on the DeviceNet ConnectorTerminating Resistor (BOM Item 19) CAN-H on the DeviceNet Connector CAN-L on the DeviceNet Connector
84.1.3 System Wiring Diagram
Wiring Per Tables
37 Pin Amphenol(MS Style 28-21P)
(+15V) J71-1 (+5 SPI) J71-2
(/SS) J71-3 (CS1) J71-4 (CS2) J71-5 (CS3) J71-6
(MISO) J71-7 (SCK) J71-8
(MOSI) J71-9 (Common/Shield) J71-10
MSP3 PANEL
(signals feed through)
Dual Display
9 Conductor Shielded Cable (LECo. M19902-1)
Gateway PC Board
(Device Net)-or-
(Ethernet)
(DN+) J75-5 (BUSS_H) J75-1 (BUSS_L) J75-4
(DN_COM) J75-2
+24VDCCAN HIGH
CAN LOWCOMMON
WAGO I/O BLOCK(750 Series)
**
Fieldbus connector. Series 231 (MCS)(supplied w/ 750-306 DeviceNet coupler)
LECo. S24017-6 connector
121 Terminating Resistor
94.2 Software Requirements:
The Gateway PC Board will need to be reprogrammed to enable the analog interfacefunctionality. The software required would depend on the Gateway PC Board versioninstalled in the power source. In general, the PC Board assembly number defines both thehardware and the software. Therefore by definition, the reprogrammed board will becomea new part number, and will have to be identified as such with a new I.D. sticker on theoutside of the PC board tray. The base and dash numbers (i.e. Sxxxxx-x) define the entireassembly for support and parts order issues. Software only is defined as the completeassembly number with a "/S" suffix (i.e. Sxxxxx-x/S).
The base software numbers are defined in the parts list, and categorized by the type ofGateway PC Board they are compatible with. The latest dash number software shouldalways be used, as it supersedes all previous versions.
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PART B
1. INSTALLATION
1.1 Non-Standard Safety Information
WARNING! ELECTRIC SHOCK CAN KILL.ONLY QUALIFIED PERSONNEL SHOULD PERFORM THISINSTALLATION.
TURN OFF INPUT POWER TO THE POWER SOURCE AT THEDISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THISEQUIPMENT. TURN OFF THE INPUT POWER TO ANY OTHEREQUIPMENT CONNECTED TO THE WELDING SYSTEM AT THEDISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THEEQUIPMENT.
DO NOT TOUCH ELECTRICALLY HOT PARTS. ALWAYS CONNECT THE POWERWAVE GROUNDING LUG
(LOCATED INSIDE THE RECONNECT INPUT ACCESS DOOR) TO APROPER SAFETY (EARTH) GROUND.
ALWAYS CONNECT THE ANALOG INTERFACE ENCLOSURE TO APROPER SAFETY (EARTH) GROUND. WHEN MOUNTED TO THEPOWERWAVE, BOND THE ANALOG INTERFACE ENCLOSURE TOTHE CASE OF THE POWERWAVE.
1.2 Location
Do not use Analog Interface in outdoor environments. It should not be subjected to fallingwater, nor should any parts of it be submerged in water. Doing so may cause improperoperation as well as pose a safety hazard. The best practice is to keep the machine in a dry,sheltered area.
Degree of Environmental Protection: IP21S
1.3 Input and Grounding Connections
The analog interface is powered solely by the 24VDC robotic supply, and draws less than300mA. Typically this supply is reference to earth ground. It is therefore recommendedthat the enclosure be properly grounded. Consult local and national electric codes forproper grounding methods.
1.4 Output Cables, Connections and Limitations
All of the signals between the Analog Interface and the robot controller were designed tooperate in a shielded cable. No surge or high frequency protection has been added to thecircuitry. Therefore a shielded cable (LECO S22320-64RP) is required from the AnalogInterface to the robot controller. The drain lead of the shielded cable must be bonded to theAnalog Interface enclosure.
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1.5 System Configuration
Configuring a limited set of system variables can modify the response time and displaymodes of the Analog Interface. For more information, see the "Special Access Modes"section.
1.6 I/O Module DeviceNet Configuration
The I/O Module DeviceNet address is configured at the factory for proper operation, andshould not require adjustment in the field. The DeviceNet baud rate should be set to 125Kand the DeviceNet address of the I/O Module should be set to 50, the table below showsthe switch settings for this configuration.
Switch Number Position Function1 Off DeviceNet Address Switch 1 - Least Significant Bit2 On DeviceNet Address Switch 23 Off DeviceNet Address Switch 34 Off DeviceNet Address Switch 45 On DeviceNet Address Switch 56 On DeviceNet Address Switch 67 Off DeviceNet Baud Rate8 Off DeviceNet Baud Rate
2 OPERATING INSTRUCTIONS
2.1 Startup Sequence
When power is applied to the Powerwave, rotating dashes will appear on the displays.This should continue for about 30 seconds. During this startup period the system isconfiguring itself and initializing variables. When the initialization period is complete, theWeld Mode for the currently selected procedure should be displayed.
2.2 Display Operation
The standard PF-10 style dual display is supported by the software in a method that doesnot require it to be present for the interface to function properly. This method allows thedisplay to be an optional or standard feature depending on the application requirements. Ingeneral, it functions in a manner consistent with the PW450 display.
The PW450R displays Weld Mode, WFS and TRIM (S-VOLTS) during the idle state, andVoltage, Current, and WFS while welding. Due to the hardware constraints, the PW455RAnalog Interface cannot display both Current and WFS simultaneously. A systemconfiguration variable is used to determine which will be displayed. The factory defaultconfiguration will be set to display actual Current. See the "Special Access Modes"section for more information regarding the display variable configurations.
The following statements define the default display operation.
Initially the display defaults to the minimum WFS and TRIM (S-VOLTS) setvalues for the chosen process regardless of the analog input.
Changes to the WFS and TRIM (S-VOLTS) set points during the idle statewill not be reflected on the display.
During the weld, the actual Voltage and Current* will dynamically displayed.The appropriate parameter indicator LEDs will blink to denote actual valuesare being displayed.
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After the weld, the last recorded actual values of Voltage and Current* will bedisplayed for approximately 5 seconds. Both the appropriate parameterindicator LEDs and digits will blink during this time.
After the actual display timer has elapsed the last recorded set points forWFS and TRIM (S-VOLTS) will be displayed, and denoted by the appropriatesolid color parameter indicator LEDs.
*Special Note:The system can be configured to display actual WFS while welding. See the"Special Access Modes" section for more information regarding the displayvariable configurations.
2.3 Local Procedure \ Weld Parameter Set-Up (MSP - Mode Select Panel)
The standard MSP3 style hardware has been utilized to set basic weld parameters on thePW455R Analog Interface. It is required to input procedure information that is notavailable through the robot's analog interface. These parameters include the Weld Mode,Run In, Arc Control, Burnback, and Cold Inch WFS functions. In addition, a method hasbeen included by which the dual procedure set up function can be executed, and the activeprocedure can be displayed.
The following information includes a functional description of each available feature.Refer to the sample nameplate below as a reference. The item numbers on the samplecorrespond to the list of functions. All functions will be limited to 2-Step operation, andwill not be compatible with modes defined as CC (i.e. those requiring a separate on/offswitch). Except where noted, only attributes/parameters for the active procedure (A or B)are adjustable during welding (i.e. when the weld sequencer is active).
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Features:
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DISPLAY:Displays the value of the attribute/parameter to be adjusted. Theattribute/parameter is determined via the active LED indicator.
SET SWITCH:The set switch is used to change the attribute/parameter values on the DISPLAY.Moving the switch up increases the displayed value, while moving the switchdown decreases the displayed value.
If the switch is held in either direction for more than 1 second will cause the leastsignificant digit to begin increment/decrement at a rate of 6 counts/second. Not allattributes will use the accelerated rate change. Except where noted below, thevalue of the selected attribute/parameter will not roll over when its high or lowlimit is reached. Except where noted below, the machine will immediately beginusing new attribute values as soon as they are changed.
SELECT SWITCH:The select switch is used to select the active attribute/parameter (WELD MODE,RUN IN, etc.) as indicated by the discrete LEDs. Moving the switch up advancesthe active indicator LED upward, while moving the switch down advances theindicator LED downward.
If the switch is held in either direction, the indicator LED will advance oneposition, pause momentarily (1 second), then advance at a constant rate (onceevery 150 ms) in the appropriate direction until the switch is released. If theindicator position reaches the top or bottom, it will not wraparound.
WELD MODE:The weld mode LED indicator is enabled via the parameter SELECT SWITCH.The value of the weld mode is indicated on the DISPLAY, and is adjustable viathe SET SWITCH. Valid weld mode numbers can range from 0 to 255.However, the actual attainable modes are determined by the contents of the weldtable (weld software) version residing in the power source. In addition, there isspecial filtering built into the Analog Interface operating software that blocks thenon supported mode types (CC and Non-Synergic CV) from being displayed dueto their incompatibility with this interface. If no valid mode types are found, themode display will show "Err", and the main display will show "---- ----".
Mode "0" is a special development mode used by WaveDesigner, and will notappear unless a WaveDesigner file has been loaded into the power source. WhenMode "0" is downloaded, the Analog Interface will automatically recognize it andmake it the active mode (in the Idle state only).
The mode numbers will NOT roll over to the lowest or highest weld modes in thetable when the mode number limits are reached. Every weld mode in the weldtable will be available to the user except for the test modes** (e.g. mode 200). Themachine will change to the selected weld mode after two seconds of Set switchinactivity. During a pending weld mode change, the SELECT and SET functionswill be disabled, and the main display will show dashes ("---- ----") until the newmode becomes valid. In the default display configuration (PW450R emulationmode), the WFS and Trim will be set to their minimum values until the first weldis made. The "Display Analog Inputs" configuration will display WFS and Trimvalues based on the actual analog input values, except during a pending weldchange as noted above.
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See the "Special Access Modes" section for more information regarding thedisplay variable configurations.
The Weld Mode in a given procedure (A or B) can only be changed when the weldsequencer is idle (i.e. when the trigger input is inactive, and the entire weldsequence is complete). On the fly mode changes during welding can only beexecuted via procedure change (i.e. A to B).
The last active Weld Mode of each procedure (A and B) will be saved in EEPROMat power down so that they can be restored upon the next power up of the machine.The initial default weld mode of each procedure will be the lowest available non-CC mode number in the weld table.
PROCEDURE SELECT:The procedure select LED indicator is enabled via the parameter SELECTSWITCH. The procedure (A or B) is indicated on the DISPLAY, and is selectablevia the SET SWITCH. This feature is intended exclusively for purpose of dualprocedure set-up. Selecting A or B on the display allows the user to set-up theindividual procedures without changing the active procedure input from the robot.
The Analog Interface MSP procedure selection takes priority when the weldsequencer is idle (i.e. when the trigger input is inactive, and the entire weldsequence is complete). During this time the selected procedure is indicated by asolid LED in the procedure indicator box.
When the weld sequencer is active, the external input from the robot will overridethe procedure select function, and determine the active procedure. During thistime the active procedure will be indicated by a flashing LED in the procedureindicator box. Because the external input takes priority when the weld sequenceris active, only the active procedure can be adjusted during welding.
The value of the procedure select attribute (A or B) will be saved in EEPROM atpower down so that it can be restored upon the next power up of the machine. Theinitial default value of the procedure select attribute will be procedure A.
PROCEDURE INDICATORS:The active procedure LEDs are provided as a means to indicate the selectedprocedure. These LEDs are indicators only, and are NOT affected by theSELECT switch. At no time will more than one LED be lit in the procedureindicator box.
When the weld sequencer is inactive (i.e. when the trigger input is inactive, and theentire weld sequence has completed), the system will default to the procedure set-up mode. The procedure (A or B) as determined by the PROCEDURE SELECTparameter will be indicated by a solid LED in the procedure indicator box.
When the weld sequencer is active, the external input from the robot will overridethe dual procedure set-up function, and determine the active procedure. Duringthis time, the active procedure will be indicated by a flashing LED in the procedureindicator box. The flashing will serve as an indication that the weld sequencer, andthe external procedure input are active.
RUN IN:The Run In LED indicator is enabled via the parameter SELECT SWITCH. Thevalue of the Run In or strike speed is indicated on the DISPLAY, and isadjustable via the SET SWITCH. The Run In (Strike) speed range is 50 to 150
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IPM for the low range gearbox, and 75 to 150 IPM for the high range gearbox.Setting the Run In speed to OFF will result in a Run In (Strike) speed equal tothe SET WFS as determined by the WFS analog input.
A separate Run In value will be maintained for each procedure (A and B). Thesevalues will be saved in EEPROM at power down so that they can be restored uponthe next power up of the machine. The initial default Run In value of eachprocedure (A and B) will be the minimum WFS available based on the speed rangeof the gearbox.
The maximum allowable Run In (Strike WFS) has been reduced to 150 IPM,primarily because our research has shown that strike speeds in excess of this valueprovide little or no benefit to starting. Limiting the value is employed as a methodto direct the operator toward the correct use of the feature.
ARC CONTROL:The Arc Control LED indicator is enabled via the parameter SELECT SWITCH.The value of the Arc Control is indicated on the DISPLAY, and is adjustable viathe SET SWITCH. Arc Control, also known as Wave Control, typically allowsthe operator to vary the arc characteristics from soft to harsh in all weldmodes. See the PW-455R instruction manual, for a detailed description of how theArc Control affects each mode.
It is typically adjustable from -10.0 to +10.0, with a nominal setting of "00.0". Thenominal setting of 00.0 will be displayed as OFF. The step changes will be in 0.1increments. The Arc Control attribute will be available only when Wave Control 1(WC1) is defined in the selected Weld Mode.
The Analog Interface is only equipped to support Arc Control (a.k.a. WC1). WC2thru WC4 are not supported, and will default to their nominal values if assigned inthe individual weld files.
A separate Arc Control value will be maintained for each procedure (A and B).These values will be saved in EEPROM at power down so that they can berestored upon the next power up of the machine. The initial default Arc Controlsetting of each procedure will be OFF (00.0).
BURNBACK:The Burnback LED indicator is enabled via the parameter SELECT SWITCH.The value of the Burnback time is indicated on the DISPLAY, and is adjustablevia the SET SWITCH. The Burnback feature allows weld current to flow for aspecified time after the trigger has been released, and the wire drive motor hasstopped. When the Burnback timer expires the output current will be turned off.
The Burnback time will be scaled from 0 (OFF) to 0.25 seconds in 0.01-secondincrements. When the timer is OFF Burnback will be completely disabled. Whenthe timer is a non-zero value, the Burnback workpoint will equal the Weldworkpoint.
A separate Burnback time will be maintained for each procedure (A and B). Thesevalues will be saved in EEPROM at power down so that they can be restored uponthe next power up of the machine. The initial default Burnback setting of eachprocedure will be OFF (0.00).
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WELD MODE SELECTION GUIDE:The Weld Mode Selection Guide is provided as a reference, to aid in the selectionof the proper weld mode number. However, the available weld modes aredetermined solely by the weld table (welding software) residing in the powersource. Therefore, some modes listed on the selection guide may not appear asvalid choices when setting the WELD MODE number. By the same token,numbers may be displayed when setting the WELD MODE that does not appearon the selection guide. In addition, non-supported mode types such as CC andNon-Synergic CV will not be displayed even if they are present in the weld table(weld software) due to incompatibility issues with the interface.
COLD INCH WFS:The Cold Inch LED indicator is enabled via the parameter SELECT SWITCH.The value of the Cold Inch WFS is indicated on the DISPLAY, and is adjustablevia the SET SWITCH. The single Cold Inch WFS applies to both directions(forward and reverse), and will be maintained independent of the proceduresettings (i.e. will not be part of A and B). The Cold Inch WFS range is 50 to 800IPM for the low range gearbox, and 75 to 1200 IPM for the high range gearbox.The Cold Inch WFS is a coarse setting, and will therefore advance by 10's.
The last active Cold Inch WFS value will be saved in EEPROM at power down sothat it can be restored upon the next power up of the machine. The initial defaultCold Inch WFS will be 80 IPM.
2.4 Special Access Modes (Through MSP - Mode Select Panel)
There are two special display access modes available. The Display Variable Mode isused to display and set certain configuration variables. The I/O Diagnostic Mode is usedto test the DeviceNet I/O inputs and outputs. Both of these modes are only accessibleduring power-up and can not be entered once normal operation has begun.
2.4.1 Entering the Special Access Mode
1. Turn the power off to the Powerwave.2. Choose the desired Special Access Mode
To select the Display Variable Mode - Hold the SELECT SWITCH in the up positionand power-up the PowerWave.
To select the I/O Diagnostic Mode - Hold the SET SWITCH in the up position andpower-up the Powerwave.
3. Wait until the rotating dashes are shown on the display, the select switch can now bereleased.
4. After the PowerWave is done initializing the rotating dashes will stop and it should display"nodE" on the display if the Display Variable mode was selected or it will display "AI 1" ifthe I/O Diagnostic mode was selected.
2.4.2 Selecting an item and Exiting the Special Access mode.
After the a Special Access Mode is selected (see above), then used the SELECTSWITCH to select which item to view or which test to perform. Pressing the SELECTSWITCH up and down to move through the listed items. Note that the display does notautomatically scroll, the user must keep toggling the select switch to move through thelisted items.
Once the item to display has been selected, press the SET SWITCH up or down to displayand change the value associated with the item. Note the value of some items will change
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immediately when the SET SWITCH is activated, while others will display only theirstatus.
To exit a special access mode, keep toggling the select switch down until the display shows"donE", then toggle the SET SWITCH once to exit the section.
2.4.3 Display Variables
Item DescriptionNodE Used to access the Test Weld Modes When set to "all" this variable will enable the user to select
weld modes 200 and greater.Sno0 Displays the Software Version of the Control BoardSno1 Displays the Software Version of the Gateway BoardSno2 Displays the Software Version of the Feedhead BoardAnhs Sets the Hysteresis of the Analog Inputs - Sets all three hysteresis values in the Gateway PC board
at once (attributes 610, 611, and 612). This function is used to filter out small fluctuations on theanalog inputs (i.e. the analog input value must change by this amount before it is converted andaccepted as a new value).
Asbu Sets the Analog Scans between Update rate For example, if the value is set to 50, then every 50thanalog value from the Device Net I/O block will be converted. Therefore, increasing this numberwill limit the number of conversions done by the Gateway PC Board. While decreasing the numberwill increase the response time.
CAUTION: While increasing the response time may be desirable, excessive noise on the analogsignal could drive the CPU load beyond a safe level, and have adverse effects on the system.
EF Sets the Event Meter Frequency rateEFC Sets the Metering Time Constant (attribute 30758 in the Weld Controller)DAI Display Analog Inputs - If true, the analog inputs for the WFS and TRIM (S-VOLTS) are
displayed real time during the idle state. The default setting holds the last valid set points from theweld (required for applications where analog outputs are only active during the weld).
ConF Display Configuration: "0" => Displays actual current value during the weld (default). "1" => Displays actual WFS during the weld.
2.4.4 I/O Diagnostic Modes
Item DescriptionAI 1 Displays value from Analog Input 1AI 2 Displays value from Analog Input 2AO 1 Used to send out a voltage on Analog Output 1AO 2 Used to send out a voltage on Analog Output 1d In Display a hexadecimal value representing the states of the Digital InputsdO 1 Used to turn off and on Digital Output 1dO 2 Used to turn off and on Digital Output 2dO 3 Used to turn off and on Digital Output 3dO 4 Used to turn off and on Digital Output 4dO 5 Used to turn off and on Digital Output 5dO 6 Used to turn off and on Digital Output 6
2.5 Making a Weld
The serviceability of a product or structure utilizing the welding programs is and must be the soleresponsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Companyaffect the results obtained in applying these programs. These variables include, but are not limited to,welding procedure, plate chemistry and temperature, weldment design, fabrication methods and servicerequirements. The available range of a welding program may not be suitable for all applications, and thebuild/user is and must be solely responsible for welding program selection.
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The following steps are presented as a general guide for operating the Powerwave. The flexibilityof the Power Wave system lets the user customize operation for the best performance.
First, consider the desired welding process and the part to be welded. Choose an electrodematerial, diameter, shielding gas and process (GMAW, GMAW-P, GMAW-STT, etc.). **Non-synergic and CC modes are NOT supported in the PW-455R Analog Interface.
Second, find the program in the welding software that best matches the desired welding process.The standard software shipped with the Power Waves encompasses a wide range of commonprocesses and will meet most needs. If a special welding program is desired, contact the localLincoln Electric sales representative.
To make a weld, the Power Wave needs to know the desired welding parameters. Theseparameters may originate from several different sources. The Analog Interface uses a combinationof sources. The robot provides WFS and Trim/Synergic Volt settings, while other settings likeWeld Mode and Arc Control are set at the Mode Select Panel on the interface itself. These settingsare then communicated digitally, via ArcLink, from the interface to the control section of the powersource.
2.6.1 General Welding Adjustments
1. WFS / AMPS:
In synergic welding modes (synergic CV, pulse GMAW, STT) WFS (wire feed speed) isthe dominant control parameter, controlling all other variables. The user adjusts WFSaccording to factors such as weld size, penetration requirements, heat input, etc. ThePowerwave then uses the WFS setting to adjust its output characteristics (output voltage,output current) according to pre-programmed settings contained in the Powerwave. Innon-synergic modes, the WFS control behaves more like a conventional CV power sourcewhere WFS and voltage are independent adjustments. Therefore to maintain the arccharacteristics, the operator must adjust the voltage to compensate for any changes made tothe WFS. In constant current modes (stick, TIG) this control adjusts the output current, inamps.
2. VOLTS / TRIM:
In constant voltage modes this control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW only) the user can change the Trim settingto adjust the arc length. It is adjustable from 0.500 to 1.500 (50 to 150 on the teachpendant). A Trim setting of 1.000 (100 on the teach pendant) is a good starting point formost conditions.
PW455R ONLY: In STT modes, the user can adjust the Trim setting to change the overallheat input to the weld.
3. WELDING MODE:
May be selected by a mode number (10, 24, 71, etc.). Selecting a welding modedetermines the output characteristics of the Powerwave power source. The WeldingSoftware loaded in the Powerwave will determine available modes. A complete list ofavailable modes is shipped with each power source. For a more complete description ofthe welding modes available in the Powerwave, see the explanation below.
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4. ARC CONTROL:
Also known as Wave Control. Typically allows operator to vary the arc characteristicsfrom soft to harsh in all weld modes. It is adjustable from -10.0 to +10.0, with anominal setting of 00.0 (The nominal setting of 00.0 may be displayed as OFF on somePower Feed wire feeder control panels). See the Welding Mode descriptions, below, fordetailed explanations of how the Arc Control affects each mode.
2.6.2 CV Welding
Synergic CV:
For each wire feed speed, a corresponding voltage is preprogrammed into the machinethrough special software at the factory. The nominal preprogrammed voltage is the bestaverage voltage for a given wire feed speed, but may be adjusted to preference. When thewire feed speed changes, the Powerwave automatically adjusts the voltage levelcorrespondingly to maintain similar arc characteristics throughout the WFS range.
Non Synergic CV:
This type of CV mode behaves more like a conventional CV power source. Voltage andWFS are independent adjustments. Therefore to maintain the arc characteristics, theoperator must adjust the voltage to compensate for any changes made to the WFS.
All CV Modes:
Arc Control, often referred to as wave control, adjusts the inductance of the waveshape.The wave control adjustment is similar to the pinch function in that it is inverselyproportional to inductance. Therefore, increasing wave control greater than 0.0 results in aharsher, colder arc while decreasing the wave control to less than 0.0 provides a softer,hotter arc.
CURRENT WAVE FORM (CV)
Wave Control 0.00
Wave Control +10.0
Wave Control -10.0
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2.6.3 Pulse Welding
Pulse welding procedures are set by controlling an overall arc length variable. Whenpulse welding, the arc voltage is highly dependent upon the waveform. The peak current,background current, rise time, fall time and pulse frequency all affect the voltage. Theexact voltage for a given wire feed speed can only be predicted when all the pulsingwaveform parameters are known. Using a preset voltage becomes impractical, and insteadthe arc length is set by adjusting trim.
Trim adjusts the arc length and ranges from 0.50 to 1.50, with a nominal value of 1.00.Trim values greater than 1.00 increase the arc length, while values less than 1.00 decreasethe arc length.
Most pulse welding programs are synergic. As the wire feed speed is adjusted, thePowerwave will automatically recalculate the waveform parameters to maintain similar arcproperties.
The Powerwave utilizes adaptive control to compensate for changes in electrical stick-out while welding. (Electrical stick-out is the distance from the contact tip to the workpiece.) The Powerwave waveforms are optimized for a 0.75 (19mm) stick-out. Theadaptive behavior supports a range of stickouts from 0.50 (13mm) to 1.25 (32mm). Atvery low or high wire feed speeds, the adaptive range may be less due to reaching physicallimitations of the welding process.
Arc Control, often referred to as wave control, in pulse programs usually adjusts the focusor shape of the arc. Wave control values greater than 0.0 increase the pulse frequencywhile decreasing the background current, resulting in a tight, stiff arc best for high speedsheet metal welding. Wave control values less than 0.0 decrease the pulse frequency whileincreasing the background current, for a soft arc good for out-of-position welding.
CURRENT WAVE FORM (PULSE)
Wave Control 0.0Wave Control +10.0
Wave Control -10.0
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2.6.4 STT Welding Parameters and Guidelines
The STT process in the Powerwave is neither a constant current (CC) nor a constantvoltage (CV). The Powerwave is a current controlled machine that is capable of changingthe electrode current quickly in order to respond to the instantaneous requirements of thearc to optimize performance. By sensing changes in welding voltage, and hence theelectrode state, the power source will supply varying output currents to minimize spatter.
The Peak and Background currents are two such current outputs that can be adjusted. PeakCurrent controls the Arc Length, and Background Current controls the Bead Contour.Tailout control is available to increases Power in the Arc, and the Wire Feed Speedcontrols the overall deposition rate.
PEAK CURRENTThe Peak Current control acts similar to an arc pinch control. Peak current serves toestablish the arc length and promote good fusion. Higher peak current levels will cause thearc to broaden momentarily while increasing the arc length. If set too high, globular typetransfer will occur. Setting this level to low will cause instability and wire stubbing. Inpractice, this current level should be adjusted for minimum spatter and puddle agitation.Increased travel speeds sometimes require higher peak currents.
Adjust Arc Length with Peak Current
Note: In 100% CO2 shielding gas applications the peak current level should be set greaterthan in a corresponding application using a gas blend with a high percentage of Argon.Longer initial arc lengths with 100% CO 2 are required to reduce spatter.
BACKGROUND CURRENTThe Background Current provides the control for the overall heat input to the weld.Adjusting this level too high will cause a large droplet to form, and globular type transferto occur resulting in increased spatter. Adjusting this level to low will cause wire stubbingand also poor wetting of the weld metal. This is similar to a low voltage setting on astandard CV machine
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Adjust Bead Shape using Background Current
Note: Background Current levels for applications using 100% CO2 is less than similarprocedures involving gas blends with high percentages of Argon. This is a result of thegreater heat generated in the 100% CO2 arc. (100% CO2 is 35 volts/cm and 100% Argonis 20 volts/cm. 75% Argon, 25% CO2 is about 24 volts/cm.
TAILOUTThe tail out provides additional heat without the molten droplet becoming too large.Increase as necessary to add Heat to the arc without increasing arc length. (This willallow for faster travel speeds and produce improved wetting). As tailout is increased, thepeak and/or background current is usually reduced.
OPTIMIZING WELDING ARC PERFORMANCEFor optimum spatter reduction, the arc should be concentrated on the puddle with a 3/8" to1/2" stickout.
Contact Tip to Work Distance
( Reference Source: IM582 - Invertec STT II, August 2001 Rev.)
Synergic and Non-Synergic STT Welding (New Style)The pictures illustrate the weld current waveshape for the STT process. They are notdrawn to scale, and are intended only for the purpose of showing how the variables effectthe waveform.
Peak Current AdjustmentARC CONTROL (a.k.a. Wave Control 1, or WC1) adjusts the arc length in the STTmode. This is accomplished by changing the amplitude of the PEAK portion of thecurrent waveform. The Arc Control value is adjusted in terms of actual peak AMPS.
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CURRENT WAVE FORM (STT)
Background Current AdjustmentTRIM adjusts the heat input in the STT mode. This is done by changing theBACKGROUND portion of the current waveform. Increasing the Trim adds more energyto the weld, and makes the weld puddle hotter. Reducing the Trim removes energy fromthe weld. The Trim value is adjusted in terms of actual background AMPS.
CURRENT WAVE FORM (STT)
Tailout AdjustmentTailout is a means to introduce additional heat without the molten droplet becoming toolarge. Increased Tailout results in more heat. The Analog Interface does not supportadjustment of this variable, and therefore, it will default to its nominal setting as defined inthe individual weld mode.
CURRENT WAVE FORM (STT)
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Synergic STT Welding (Old Style)
The pictures illustrate the waveshape of current for the STT process. They are not drawnto scale, and are intended only for the purpose of showing how the variables effect thewaveform.
TRIM in a Synergic STT mode changes the heat input by adjusting the tailout andbackground portion of the waveform. Trim values greater than 1.0 add more energy to theweld and make the weld puddle hotter; trim values less than 1.0 reduce energy to weld. Anominal value of 1.0 will work for most applications. For the processes designated as openroot, the tailout is fixed, and the trim affects only the background level.
CURRENT WAVE FORM (STT)
ARC CONTROL, also referred to as wave control, adjusts the arc length in the STTmode. This is accomplished by changing the peak portion of the current waveform. Awave control value of +10.0 maximizes the arc length by increasing the peak current, whilea wave control of -10.0 minimizes the arc length by decreasing the peak current. Thenominal value is "OFF" (0.0), and should work for most applications.
CURRENT WAVE FORM (STT)
Trim 1.00Trim 1.50
Trim 0.50HEAT INPUT
ARC LENGTHWave Control 0.0Wave Control +10.0
Wave Control -10.0
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3 APPLICATION INFORMATION
3.1 Interface Description
This PW455R Analog Interface is designed to emulate the PW450 Robotic Interface. It isprimarily intended for use with a Fanuc robot using ArcTool software (V1.30P or higher)with Touch Sensing and Through Arc Seam Tracking (TAST). The interface responds toall of the ArcTool welding inputs and outputs except wire fault and wire stick alarm. Allof the circuitry for Touch Sensing is internal to the Powerwave, no external power supplyis required. The current signal for TAST is supplied by the Powerwave analog output, noexternal current sensor is required. The interface does not control wire feed speed andwelding voltage independently. Rather, the Powerwave will always operate in a synergicmode 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 Powerwave system uses an arc length trim, the voltage cannot be directlycontrolled. The welding voltage settings in the robot controller are interpreted by thePowerwave as a trim setting. Any ArcTool function which tries to set the voltage to zeroand 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 functionthat tries to set the wire feed speed to zero and control the voltage is limited by theminimum speed of the selected process. (Note: This phenomenon will occur as atruncation of the speed, rather than a re-scaling based on the process.)
The following is a list of functions that do not work as intended by Fanuc due to thesynergic operation of the Powerwave:
WELDING VOLTAGEIn this interface all welding voltage settings must be thought of as an arc length trim. Thisarc length trim will increase or decrease the arc voltage for a specific wire feed speed setpoint. The scaling in the robot controller is setup to allow voltage numbers between 50 and150. A voltage number in the robot controller of 100 equals the nominal voltage (no trimadjustment) for the selected wire feed speed. If the arc length needs to be increased thenthe voltage trim number is increased. For example, if a voltage number of 115 is used thenthe arc voltage will increase too approximately 15% above the nominal voltage for the wirefeed speed set point in use.
WIRE BURNBACK FUNCTIONThe burnback function controlled by the robot controller will not operate properly. Thefunction was setup to use a wire feed speed of zero while setting the welding voltage tosome level. The system will produce the minimum wire feed speed for the selectedprocedure and a voltage trim for that selected wire feed speed set point. The solution tothis problem is already built into the Powerwave. The Powerwave can be configured toautomatically execute its own burnback routine. A burnback time can be set independentlyfor each procedure (A or B) on the control panel provided with the PW455R AnalogInterface.
WIRE STICK RESET FUNCTIONThe 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 feedspeed of zero while setting the welding voltage to some level. For the same reasons aswire burnback it will not operate properly. If any wire stick problems occur, the burnbacktime is adjustable on the control panel provided with the PW455R Analog Interface. Thesetting is very reliable, and can be optimized for each welding procedure (A or B).
COLD WIRE INCHING FUNCTION
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The cold inching wire feed speed cannot be changed by the robot controller. It is alwaysset to 80 IPM. A variable cold inching speed is not possible with the current architectureof the interface.
3.2 Robot Signal Descriptions
VOLTAGE COMMANDThis is an analog output from the robot controller with a maximum range of 0 to 10V.Since the Powerwave is always running in the synergic mode an output voltage cannot beset. The voltage command is used as a voltage trim for the active workpoint. The voltagecommand limits in the robot controller are entered as 50 to 150V. This is done so that thenominal trim setting (100V) is not confused with a welding voltage.
WIRE FEED SPEED COMMANDThis is an analog output from the robot controller with a maximum range of 0 to 10V. Thewire feed speed command sets both the wire feed speed and the synergic output of thePowerwave. The wire feed speed command limits in the robot controller are entered as 50to 800 IPM for a standard drive head and 75 to 1200 IPM for a high speed drive head.
For reference, the wire feed speed command limits in the PW450 system were 50 to 770IPM for a standard drive head and 80 to 1100 IPM for a high speed drive head.
TOUCH SENSE SIGNALThis is an active low input to the robot controller that indicates that the welding electrodehas touched the work piece. To initiate touch sensing, the TOUCH SENSE COMMANDmust be held low by the robot controller. Then the Powerwave monitors the currentthrough the electrode to determine if it is touching the work piece. If THE TOUCHSENSE COMMAND is held low and the electrode is touching the work piece then thetouch sense signal will be held low to report a touch to the robot controller.
ARC DETECTThis is an active low input to the robot controller that indicates that a welding arc has beendetected. The Powerwave monitors the arc voltage and current to determine if an arc isestablished. If an arc is not established then the arc detect signal is held high to report anerror to the robot controller.
GAS FAULTThis is an active low input to the robot controller that indicates that the shielding gas ismissing. The Powerwave has an external connection (Shutdown 2) available for aNORMALLY CLOSED gas pressure or flow switch. If a switch is installed and the gasfault function is enabled then gas loss errors will be reported to the robot controller.
WIRE FAULTThis is an active low input to the robot controller that indicates a wire feeding problem orthe lack of welding wire. This signal is not connected in the Powerwave.
WATER FAULTThis is an active low input to the robot controller that indicates a water-cooling problem.The Powerwave monitors the water cooling flow through its SHUTDOWN INPUT todecide if a water fault has occurred. If the water coolant flow drops below the lowthreshold then the water fault signal is held low to report an error to the robot controller.
POWER FAULTThis is an active low input to the robot controller that indicates a power fault in thePowerwave. If for some reason the Powerwave loses power or goes offline, then thepower fault signal is held low to report an error to the robot controller.
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VOLTAGE FEEDBACKThis is an analog input to the robot controller with a maximum range of 0 to 10V. The ArcLink attribute for voltage in the PW455R is converted to an analog signal, and isolated toproduce the voltage feedback signal. Scaling is adjustable.
For reference, in the PW450 interface, a voltage feedback signal of 7.620V (typical) isequal to an arc voltage of 80.0V.
CURRENT FEEDBACKThis is an analog input to the robot controller with a maximum range of 0 to 10V. TheArcLink attribute for current in the PW455R is converted to an analog signal, and isolatedto produce the current feedback signal. Scaling is adjustable.
For reference, in the PW450 interface, a current feedback signal of 8.317V (typical) isequal to an arc current of 750A.
WELD STARTThis is an active low output from the robot controller that commands the Powerwave tostart an arc.
GAS STARTThis is an active low output from the robot controller that commands the Powerwave toopen the shielding gas solenoid. In the PW455R, this signal is logically ORed with thegas controller in the PW455R Weld Sequencer. By this method, preflow, postflow, andpurge functions can be controlled by the Robot without conflicting with the gas controllerin the PW455R Weld Sequencer.
TOUCH SENSE COMMANDThis is an active low output from the robot controller that commands the Powerwave toturn on Touch Sensing. When touch sensing is enabled the Powerwave regulates a pulsevoltage waveform while monitoring the current through the electrode. If current flowsthrough the electrode then the TOUCH SENSE SIGNAL is held low to report a touch tothe robot controller.
WIRE+This is an active low output from the robot controller that commands the Powerwave tocold inch wire at 80 IPM.
WIRE-This is an active low output from the robot controller that commands the Powerwave tocold inch wire at -80 IPM.
WIRE STICK ALARMThis is an active low output from the robot controller used to indicate a wire stick. Thissignal is not connected in the Powerwave.
DUAL PROCEDURE SWITCH COMMANDThis is an active low output from the robot controller used to activate the dual procedureswitch. The PW455R is dual procedure capable, and this output is used to switch betweenprocedures. 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. An LED on the PW455R Interfacewill indicate the active procedure (A or B).
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WIRE STICK DETECTThis is a resistance measuring input to the robot controller used to detect a wire stick. Theintended use for this resistance check is to measure the resistance between the outputterminals of the weld equipment. If a resistance of approximately 100 Ohms or less isfound (by the Robot) then a wire stick error is reported by the robot controller.
This measurement is not directly possible with a Powerwave because the resistancebetween the output studs is always 40 Ohms or less. Additional circuits have been addedto allow the wire stick detect to work properly although it is not directly measuring theresistance between the output studs. This circuitry will provide a low impedance pathbetween the WDI+ and WDI- connections on the robot to indicate a wire stick.
NOTE: The WDI- connection is referenced to Robot GND on the Powerwave Interface PCBoard.
3.3 Power Wave Circuit Descriptions
VOLTAGE COMMANDThe voltage command from the robot controller (DACH1) is scaled and converted from ananalog to a digital signal in the PW455R Interface. The digital signal becomes the ArcLink attribute value for TRIM in the PW455R Weld Sequencer.
Maximum Input Range: 0 to 10VFactory Programmed Range: 0.6 to 9.6VInput Impedance: 130K Ohms (typ.)
For reference, in the PW450, the voltage command from the robot controller (DACH1)was directly connected to the TIG analog input on the display board of the PW450. Thissignal was not connected to the robot or control ground.
WIRE FEED SPEED COMMANDThe wire feed speed command from the robot controller (DACH2) is scaled and convertedfrom an analog to a digital signal in the PW455R Interface. The digital signal becomes theArc Link attribute value for SET WFS in the PW455R Weld Sequencer.
Maximum Input Range: 0 to 10VFactory Programmed Range: 0.6 to 9.6VInput Impedance: 130K Ohms (typ.)
For reference, in the PW450, the wire feed speed command from the robot controller(DACH2) was directly connected to the WF1 analog input on the display board of thePowerwave. This signal was not connected to the robot or control ground.
TOUCH SENSE SIGNALTo initiate Touch Sensing, the TOUCH SENSE COMMAND must be held low by therobot controller. When Touch Sensing is enabled the Powerwave regulates a pulse voltagewaveform while monitoring the current through the electrode. If current flows through theelectrode, the isolated TOUCH SENSE SIGNAL is held low to report a touch to therobot controller at welding input 1 (WDI1).
NOTE: The active state table was responsible for setting and clearing the TOUCH SENSESIGNAL in the PW450.
ARC DETECT
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The arc detect signal is generated from the Arc Detect Attribute in the PW455R WeldSequencer. The Arc Detect Attribute will detect a minimum arc of 10V and 25A. Thesignal is isolated from the control ground and tied to the robot controller welding input 2(WDI2).
GAS FAULTThe gas fault signal is generated by an external gas flow or pressure sensor. The normallyclosed signal is fed into the Shutdown 2 input on the front of the PW455R. When ashutdown is detected, an isolated low signal is sent to the robot controller welding input 3(WDI3).
For reference, in the PW450, this signal is not connected to anything on the interfaceboard. The signal (WDI3) is simply rerouted from the robot connector (P82) to themiscellaneous connector (P84). A gas fault is generated when this signal is tied to therobot ground.
WATER FAULTThe water fault signal is generated by the water flow sensor in the K1767 water cooler orequivalent. The normally closed signal is fed into the Shutdown 1 Input on the front ofthe PW455R. When a shutdown is detected, an isolated low signal is sent to the robotcontroller welding input 5 (WDI5).
POWER FAULTIf for some reason the Powerwave loses power or goes offline, then the power faultsignal is generated. The signal is isolated from the control ground and tied to the robotcontroller welding input 6 (WDI6). Ideally, this signal should function properly even if thePW455R is not turned on.
VOLTAGE FEEDBACKThis is an analog input to the robot controller with a range of 0 to 10V. The factoryprogrammed full range is 0.6 to 9.6V (representing 0 to 80V). The ArcLink attribute forvoltage in the PW455R is converted to an analog signal, scaled, and isolated to produce thevoltage feedback signal. The signal is then tied to the robot controller analog input 1(ADCH1).
For reference, this signal is scalable at the robot, but in the PW450 interface, a voltagefeedback signal of 7.620V (typical) is equal to an arc voltage of 80.0V
CURRENT FEEDBACKThis is an analog input to the robot controller with a range of 0 to 10V. The factoryprogrammed full range is 0.6 to 9.6V (representing 0 to 750A). The ArcLink attribute forcurrent in the PW455R is converted to an analog signal, and isolated to produce the currentfeedback signal. The signal is then tied to the robot controller analog input 2 (ADCH2).
For reference, this signal is scalable at the robot, but in the PW450 interface, a currentfeedback signal of 8.317V (typical) is equal to an arc current of 750A.
WELD STARTThe weld start command is generated by active low welding output 1 (WDO1). The signalis then isolated from the robot ground, inverted, and tied to the interface trigger input.
GAS STARTThe gas start command is generated by active low welding output 2 (WDO2). The signalis then isolated from the robot ground and tied to the interface gas start (purge) input. Thissignal is logically ORed with the gas controller in the PW455R Weld Sequencer. By
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this method, preflow, postflow, and purge functions can be controlled by the Robot withoutconflicting with the gas controller in the PW455R Weld Sequencer.
TOUCH SENSE COMMANDThe Touch Sense command is generated by active low welding output 3 (WDO3). Thesignal is then inverted and isolated from the robot ground and tie to the interface TouchSense input. (see also TOUCH SENSE SIGNAL)
WIRE+ & WIRE-These two signals work together to cold inch the wire at 80 IPM. The forward wire inchcommand is generated by active low welding output 4 (WDO4). The reverse wire inchcommand is generated by active low welding output 5 (WDO5). When either of the twosignals is received an isolated inch command is generated. Logically, the signals mustoperate in a mutually exclusive fashion. If both signals are low at the same time then thefirst one to be recognized will determine the direction of travel. No damage will be causedby driving both signals low at the same time.
For reference, in the PW450, when either of the two signals is received an isolated inchcommand was generated and tied to the interface wire inching input. At the same time themotor drive relays switched to the correct direction. The default direction for the motordrive relays was forward, if both the signals were low at the same time then the motordrive relays were set for reverse. No damage would be caused by driving both signals lowat the same time.
DUAL PROCEDURE SWITCH COMMANDThe dual procedure switch command is generated by active low welding output 7(WDO7). The signal is then isolated from the robot ground and tied to the interface dualprocedure input.
WIRE STICK DETECTThe wire stick detect is a low impedance signal provided by a solid state relay output(SSR) with a maximum on state impedance of 3.2 ohms. The Powerwave uses it's touchsense routine to determine if a wire stick is present at the end of the weld and sets the SSRon/off status accordingly. The SSR output is tied to the robot controller wire stick detectinputs (WDI+ & WDI-). The robot controller samples this signal after the Arc Establishsignal changes from true to false.
NOTE: The WDI- connection is referenced to Robot GND on the Powerwave Interface PCBoard.
3.4 Electrical Characteristics
All of the signals between the Powerwave and the robot controller were designed tooperate in a shielded cable. No surge or high frequency protection has been added to thecircuitry.
3.4.1 ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS
The following signals are referenced to the robot controllers 24V supply (Robot GND)unless otherwise noted. The total allowable load on the 24V supply is 0.7A. Thefollowing is a brief description of the electrical characteristics, for a full description see theFanuc electrical connections manual.
DIGITAL OUTPUTS (Sinking)Rated Voltage: 24VDCMaximum Applied Voltage: 30VDC
Output
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Maximum Load Current: 0.2ATransistor Type: Open collector NPNSaturation Voltage at On: 1.0V
DIGITAL INPUTS (Sourcing)Maximum Input Voltage: 28VDCHigh Input Voltage: 20 to 28VDCLow Input Voltage: 0 to 4VDCInput Impedance: 3.3K OhmsResponse Time: 5 to 20ms
ANALOG OUTPUTSMaximum Output Range: 0 to 10VRequired Load Impedance: 3.3K Ohms (minimum)Weld equipment analog outputs are isolatedfrom the robot controller 24V supply (Robot GND).
ANALOG INPUTSMaximum Input Range: 0 to 10VInput Impedance: Not Published
WIRE STICK DETECT (WDI+ to WDI-)
Maximum Output Voltage: 20VDCMaximum Output Current: 85mAMaximum Impedance Threshold: 100The wire stick detect output is isolated from therobot controller 24V supply (Robot GND).
3.4.2 PW455R ANALOG INTERFACE ELECTRICAL CHARACTERISTICS
The following signals are referenced to the robot controllers 24V supply unless otherwisenoted. The total allowable load on the 24V supply is 0.7A. The following is a briefdescription of the electrical characteristics.
DIGITAL OUTPUTS (Sinking)Rated Voltage: 24VDCMaximum Applied Voltage: 30VDCMaximum Load Current: 0.5A (Short Circuit Protected)Transistor Type: Open collector NPNSaturation Voltage at On: 1.0V
DIGITAL INPUTS (Sourcing)Maximum Input Voltage: 30VDCHigh Input Voltage: 15 to 30VDCLow Input Voltage: -3 to 5VDCTypical Response Time: 3 ms
ANALOG OUTPUTS
3.3K
24V
Input
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Maximum Output Range: 0 to 10VFactory Programmed Range: 0.6 to 9.6VRequired Load Impedance: 5K Ohms (min.)Typical Conversion Time: 2 ms
ANALOG INPUTSMaximum Input Range: 0 to 10VFactory Programmed Range: 0.6 to 9.6VInput Impedance: 130K Ohms (typ.)Typical Conversion Time: 2 msThe Fanuc Robot analog outputs are isolatedfrom the robot controller 24V supply. If Required,these signals may be tied to the Robot GND at thePW-455R Interface.
WIRE STICK DETECT OUTPUT (WDI+ to WDI-)
Rated Voltage: 230VDCMaximum Applied Voltage: 275VDCMaximum Load Current: 0.3ATransistor Type: SSRMaximum On State Resistance: 3.2 OhmsMaximum Speed: 5 ms (1.65 ms typ.)The negative wire stick detect output (WDI-)is tied to Robot GND at the PW-455R Analog Interface.
MS-628
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3.5 Robot Controller Setup
MONITORING FUNCTIONS1 Arc loss ENABLED2 Gas shortage DISABLED3 Wire shortage DISABLED4 Wire stick ENABLED5 Power supply failure ENABLED6 Coolant shortage ENABLED
WELD RESTART FUNCTION7 Return to path DISABLED8 Overlap distance 0mm9 Return to path speed 200mm/s
SCRATCH START FUNCTION10 Scratch start DISABLED11 Distance 5mm12 Return to start speed 12mm/s
ON-THE-FLY FUNCTION13 On-The-Fly ENABLED14 Voltage increment 1.0V15 Wire feed increment 5.0IPM16 Current increment 5.0A
OTHER FUNCTIONS17 Weld from teach pendant ENABLED18 Run in DISABLED19 Wire burnback/retract DISABLED
WELD EQUIPMENT SETUP1 Weld process MIG2 Remote arc enable DI 03 Weld power control Wire FD4 Wire feed control AO5 Wire+ Wire- speed 80IPM6 Wire feed speed units IPM
WELD RUN IN7 Voltage 50.0V8 Current 250.0A9 Wire feed 200IPM10 Time 0.00s
WIRE BURNBACK/RETRACT11 Voltage 50.0V12 Current 250.0A13 Wire feed 0IPM14 Time 0.00s
TIMING15 Arc start error time 2.00s16 Arc detect time 0.10s17 Arc loss error time 0.30s
TIMING (cont.)18 Gas detect time 0.05s19 Gas purge time 1.00s20 Gas preflow time 0.50s21 Gas postflow time 0.00s
WIRE STICK FUNCTION22 Reset DISABLED23 Reset tries 124 Voltage 50.0V25 Time 0.00s
VOLTAGE OUTPUT SCALING26 Minimum reference 0.60V27 Maximum reference 9.60V28 Minimum output 50.0V29 Maximum output 150.0V
CURRENT OUTPUT SCALING30 Minimum reference 0.00V31 Maximum reference 10.0032 Minimum output 0.0A33 Maximum output 400.0A
WIRE FEED SPEED OUTPUT SCALING34 Minimum reference 0.60V35 Maximum reference 9.60V36 Minimum output 50(75)IPM37 Maximum output
800(1200)IPM
VOLTAGE INPUT SCALING38 Minimum reference 0.60V39 Maximum reference 9.60V40 Minimum output 0.0V41 Maximum output 80.0V
CURRENT INPUT SCALING42 Minimum reference 0.60V43 Maximum reference 9.60V44 Minimum output 0.0A45 Maximum output 750A
SYSTEM VARIABLES$AWEUPR $WSTK_ENA_DLY 0.10s
TOUCH SENSING SETUPSensor port type WISensor port number 1Circuit port type WOCircuit port number 3
35
3.6 PW-455R Analog Interface Cable Definition
PW-455Analog Interface
Input / OutputPW-455
Signal Description
37 Pin Amphenol(MS Style 28-21P)
Fanuc Signal Name Fanuc Robot
Controller(34 Pin Honda)
Comments Additional Notes
INPUT(Analog) TRIM (Voltage) Command P82-A DACH1 (Voltage command) CRW1-1 Note ScalingINPUT(Analog) (see comments) P82-F COMDA1 CRW1-2 COMDA1 common to COMDA2 at Robot or in Cable?INPUT(Analog) WFS command P82-E DACH2 (WFS command) CRW1-3 Note ScalingINPUT(Analog) WFS command GND P82-F COMDA2 (WFS command GND) CRW1-4 COMDA1 common to COMDA2 at Robot or in Cable?
Isolated from Robot GND, but tied to ?? on Display BD.
OUTPUT (Digital) Touch Sense Detect P82-c WDI1 (Touch sense signal) CRW1-5OUTPUT (Digital) Arc Detect P82-d WDI2 (Arc detect) CRW1-6OUTPUT (Digital) Gas Fault P82-e WDI3 (Gas fault) CRW1-7 Generated via external Gas Fault input (P84 in PW-450)
------ No Connection P82-f WDI4 CRW1-8OUTPUT (Digital) Water Fault P82-g WDI5 (Water fault) CRW1-9OUTPUT (Digital) Abnormal Operation / Power Fault P82-h WDI6 (Power fault) CRW1-10
------ No Connection P82-j WDI7 CRW1-11------ No Connection P82-k WDI8 CRW1-12
OUTPUT (Analog) Voltage Feedback P82-J ADCH1 (Voltage feedback) CRW1-13 Note Scaling Referenced to Robot GND on the PW-450 Interface Bd. IsRobot GND tied to COMAD1 in Robot or Cable?
------ No Connection P82-K COMAD1 CRW1-14OUTPUT (Analog) Current Feedback P82-L ADCH2 (Current feedback) CRW1-15 Note Scaling Referenced to Robot GND on the PW-450 Interface Bd. Is
Robot GND tied to COMAD2 in Robot or Cable?------ No Connection P82-M COMAD2 CRW1-16------ ------ ------ No Connection CRW1-17------ ------ ------ No Connection CRW1-18
ROBOT GND Robot GND P82-a 0V (Robot GND) CRW1-19------ No Connection P82-b 0V CRW1-20------ No Connection P82-m 0V CRW1-21------ No Connection P82-n 0V CRW1-22
INPUT (Digital) Arc Start Command (Trigger) P82-R (Fanuc){P82-C (Motoman)}
WDO1 (Weld start) CRW1-23 Motoman version of PW-450 had alternate trigger location.
INPUT (Digital) Gas Flow Command P82-S WDO2 (Gas start) CRW1-24INPUT (Digital) Touch Sense Command P82-T WDO3 (Touch sense command) CRW1-25INPUT (Digital) Cold Inch FWD P82-U WDO4 (Wire+) CRW1-26 80 IPM Fixed SpeedINPUT (Digital) Cold Inch REV P82-V WDO5 (Wire-) CRW1-27 80 IPM Fixed Speed
------ No Connection P82-W WDO6 CRW1-28INPUT (Digital) Dual Procedure Command P82-X WDO7 (Dual procedure switch command) CRW1-29INPUT (Digital) SPARE P82-Z WDO8 (Spare robot output) CRW1-30
OUTPUT(see comments)
Short Detect Signal (+) P82-N WDI+ (Wire stick detect) CRW1-31 Short Detect (+) & (-) combine to provide a High/LowImpedance Output for Robot Wire Stick Detect Circuitry.
Short Detect (-) is tied to the Robotic GND on the PW-450Interface Board
OUTPUT(see comments)
Short Detect Signal (-) P82-P WDI- (Wire stick detect) CRW1-32
ROBOT POWER +24V Robot PWR P82-r +24V (Robot PWR) CRW1-33 Tied together in Robot or Cable?ROBOT POWER +24V Robot PWR P82-r +24V (Robot PWR) CRW1-34
------ No Connection P82-H ------ ------------ No Connection P82-s ------ ------------ No Connection P82-B ------ ------------ No Connection P82-D ------ ------------ No Connection P82-G ------ ------------ No Connection P82-p ------ ------
36
4 MAINTENANCE
4.1 Non-Standard Safety Information
WARNING! ELECTRIC SHOCK CAN KILL.
WARNING: ELECTRIC SHOCK CAN KILL.
ONLY QUALIFIED PERSONNEL SHOULD SERVICE THISINSTALLATION. TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH ORFUSE BOX BEFORE WORKING ON THIS EQUIPMENT DO NOT TOUCH ELECTRICALLY HOT PARTS
4.2 Routine Maintenance
Routine maintenance consists of periodically inspecting the interface and cabling forloose or broken connections, worn switches, and signs of improper cable strain relief.Light cleaning is also recommended, using a low-pressure airstream, to removeaccumulated dust and dirt from the intake and outlet louvers, and the cooling channels inthe machine.
4.3 Periodic Maintenance
Calibration of the PW455R is critical to its operation and can adversely affect theperformance of the system. Generally speaking the calibration will not need adjustment.However, neglected or improperly calibrated machines may not yield satisfactory weldperformance. To ensure optimal performance, the calibration of output Voltage andCurrent should be checked yearly.
4.4 Machine Calibration Specification
The Powerwave's output Voltage, Current, and WFS are calibrated at the factory.Generally speaking the machine calibration will not need adjustment. However, if theweld performance changes, or the yearly calibration check reveals a problem, contact theLincoln Electric Company for the calibration software utility.
The calibration procedure itself requires the use of a grid, and certified actual meters forvoltage and current. The accuracy of the calibration will be directly affected by theaccuracy of the measuring equipment you use. Detailed instructions are available withthe utility.
Once the Powerwave calibration has been verified, the analog feedback calibrationbetween the Robot to the Analog Interface should also be checked and adjusted asrequired. All analog adjustments must be made at the Robot.
37
4.4.1 Analog I/O Scaling
Scaling of the analog I/O has been preset at the factory and cannot be changed. Scalingshould be adjusted at the robot based on the following information. Scaling for both theAnalog Inputs & Outputs is based on a range of 0.6 Volts to 9.6 Volts. The table belowsummarizes the full-scale voltage feedback and command voltage ranges. The CommandTrim Voltage column shows the internal representation of trim how it is stored in thesequencer. For the Command Wire Feed Speed (WFS) voltage, "Low" represents thelow range feedhead gearbox, and "High" represents the high range feedhead gearbox.
Feedback Voltage Cmd WFS Voltage Wago A/D CountsVoltsVolts Current
Cmd Trim VoltageLow High Hex Decimal
0.0 0 0 - - - 0 00.6 0 0 -32,768 50 75 0x07AE 1966
1.73 10 94 -24,576 144 216 0x1614 56522.85 20 188 -16,384 238 356 0x247B 93393.98 30 282 -8,192 332 497 0x32E0 13,0245.10 40 375 0 425 638 0x4147 16,7116.23 50 469 8,192 519 779 0x4FAD 20,3977.35 60 563 16,384 613 919 0x5E14 24,0848.48 70 657 24,575 717 1060 0x6C7A 27,7709.60 80 750 32,767 800 1200 0x7AE0 31,45610.0 - - - - - 0x7FFF 32,767
38
5 TROUBLESHOOTING GUIDE
5.1 I/O Run (Rn) & IO Err (Er) Status LED's on DeviceNet Coupler
LED CONDITIONI/O ERR
(RED)I/O RUN(GRN)
DEVICESTATUS
DESCRIPTION
OFF ON Normal Normal Operating Condition. I/O Runon - Field Bus OK
BLINKING BLINKING Startup Normal Startup Sequence, both shouldstop blink after a couple of seconds
BLINKING OFF Field BusFault
A field bus fault has been detected
5.2 MS (Module Status) Red & Green Status LED's on DeviceNet Coupler
LED CONDITIONI/O RUN(GRN)
I/O ERR(RED)
DEVICESTATUS
DESCRIPTION
OFF OFF No Power There is no power applied to the deviceON OFF Normal The device is operating in a Normal
ConditionBLINKING OFF Device in
StandbyThe device needs commissioning dueto the configuration is missing,incomplete, or incorrect
OFF BLINKING Minor Fault Recoverable FaultOFF ON Unrecoverable
FaultThe device has an unrecoverable fault;may need replacing
BLINKING BLINKING Self Testing The Device is in Self Test
39
5.3 NS (Network Status) Red & Green Status LED's on DeviceNet Coupler
LED CONDITIONI/O RUN(GRN)
I/O ERR(RED)
DEVICESTATUS
DESCRIPTION
OFF OFF No Power, NotOn-Line
The device might not be powered or thedevice might not have completed theDup Mac Id test yet & is not on-line.
ON OFF Normal Online and allocated to a Master,Normal Condition
BLINKING OFF Online, NotConnected
Device is online, but not connected tomaster
OFF BLINKING ConnectionTime-Out
One or more I/O connections are in theTimed-Out state
OFF ON Critical LinkFailure
Detected communication error -Duplicate Mac Id or Bus-off
40
5.4 Digital I/O Status Indicators
41
5.5 Troubleshooting Chart
Problem Corrective ActionDisplay shows rotatingdashes
During startup the display should display do this for about 30 seconds. If thiscontinues, then this is an indication the Gateway board did not get mapped by thecontrol board. Check the ArcLink connection between the Gateway & ControlBoards, the Gateway is not finding the Control board.
No Display Make sure the Display is connected to the Gateway's SPI connector and the Gatewayboard is powered up with the correct main software & parameter file.
Switches do not work Check to see if the switches wiring is plugged into the bottom of the display cardMode display shows:
"Err"
-and-
Main display shows:"---- ----"
No valid mode types are present in the power source. Non-Synergic and CC Modes arenot compatible with the Analog Interface.
No LED's are lit on theI/O block
Check the 24V power coming in from the Robot/PLC. This also powers theDeviceNet communications and should light up Led 2 on the Gateway board if there is24 volts present.
False or dimly lit I/OBlock indicators
Make sure the 37-pin communication cable shield from the Robot is properlyterminated (connected to case ground at the Analog Interface).
42
6 COMPONENT LOCATION AND REPLACEMENT PARTS LIST
6.1 Bill of Materials (L10412-18)
The following information details the PW455R Analog Interface implementation by theLincoln Electric Automation Division. The table below indicates the bill of material forthe L10412-18 Analog Interface kit for the PW455R. Other kits exist depending on whatpower source the interface is mounted on and application. This list may be used to orderparts if necessary.
Item #: LECO #: Description: Qty.:1 S23395-1 DeviceNet Coupler 12 S23395-2 4 Channel Digital Input 23 S23395-3 4 Channel Digital Output 14 S23395-4 2 Channel Analog Input 15 S23395-5 2 Channel Analog Output 16 S23395-6 End Module 17 S23395-7 2 Channel Digital Output 18* S25390-1 Minimaster Gateway Software 19 M19790-1A0 MSP3 Option Panel 1
10* T10800-49 Toggle Switch 211 S18250-796 Plug & Lead Assembly 112* S23391-1 Overlay Decal 113 L11130-3D0 SPI Display PCBD 114 M19902-1 SPI Shielded Cable Assembly 115 M17803 Plug & Lead Assembly 37-Pin 116* S23383-6 121 Ohm Terminating Resistor 117 S23394-3 Cable Assembly to Dnet Board 118 L10412-17 Sheetmetal Enclosure 119 L10421-1 Interface Box Cover Plate 120 L10421-2 Power Source Mounting Plate 1
*Not shown in component layout in section 2.1.1.
43
2.1.1 Component Layout
1-7
11
9
14
13
15
17
18
19
20
GENERAL DESCRIPTIONRECOMMENDED PROCESSES AND EQUIPMENTRecommended ProcessesProcess LimitationsRecommended Equipment / InterfaceEquipment Limitations
3DESIGN FEATURESPlatform CommonaltiesOperational Features and ControlsSpecifications3.4Regulatory Requirements as Required for Market
4CONSTRUCTION INFORMATIONWiring Information4.1.1 Wiring from 37 Pin Input Connector to Wago I/O BlockAdditional Wiring Information4.1.3 System Wiring Diagram
4.2Software Requirements:
INSTALLATION1.1Non-Standard Safety Information1.2Location1.3Input and Grounding Connections1.4Output Cables, Connections and Limitations1.5System Configuration1.6I/O Module DeviceNet Configuration
OPERATING INSTRUCTIONS2.1 Startup Sequence2.2Display Operation2.3Local Procedure \ Weld Parameter Set-Up (MSP - Mode Select Panel)2.4Special Access Modes (Through MSP - Mode Select Panel)2.4.1 Entering the Special Access Mode2.4.2Selecting an item and Exiting the Special Access mode.2.4.3Display Variables2.4.4I/O Diagnostic Modes
2.5Making a Weld2.6.1General Welding Adjustments2.6.2 CV Welding2.6.3Pulse Welding2.6.4STT Welding Parameters and Guidelines
3APPLICATION INFORMATION3.1Interface Description3.2Robot Signal Descriptions3.3Power Wave Circuit Descriptions3.4Electrical Characteristics3.4.1ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS3.4.2PW455R ANALOG INTERFACE ELECTRICAL CHARACTERISTICS
3.5Robot Controller Setup3.6PW-455R Analog Interface Cable Definition
4MAINTENANCE4.1Non-Standard Safety Information4.2Routine Maintenance4.3Periodic Maintenance4.4Machine Calibration Specification4.4.1 Analog I/O Scaling
5TROUBLESHOOTING GUIDE5.1 I/O Run (Rn) & IO Err (Er) Status LED's on DeviceNet Coupler5.2 MS (Module Status) Red & Green Status LED's on DeviceNet Coupler5.3 NS (Network Status) Red & Green Status LED's on DeviceNet Coupler5.4 Digital I/O Status Indicators5.5 Troubleshooting Chart
6COMPONENT LOCATION AND REPLACEMENT PARTS LIST6.1Bill of Materials (L10412-18)*Not shown in component layout in section 2.1.1.2.1.1 Component Layout
