Robotic Arc Welding Manual - Motoman Robotics · Robotic Arc Welding Manual 1-2 MOTO MAN 1.2 System...

Motoman, Incorporated 805 Liberty LaneWest Carrollton, OH 45449TEL: (937) 847-6200FAX: (937) 847-627724-Hour Service Hotline: (937) 847-3200

Motoman XRC Controller

Robotic ArcWelding Manualfor Kobelco Power Sources

Part Number: 144077-1Release Date: March 26, 2007Document Status: Final

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Inc.

©2007 by MOTOMANAll Rights Reserved

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TABLE OF CONTENTS

Section PageLIST OF FIGURES ...................................................................................................................................ii

LIST OF TABLES.....................................................................................................................................ii

1 INTRODUCTION1.1 About this Document .................................................................................................... 1-11.2 System Configuration ................................................................................................... 1-2

1.2.1 System Components ....................................................................................... 1-31.2.2 MRC/XRC Controller ...................................................................................... 1-31.2.3 Kobelco SensArc PC350 Power Supply .......................................................... 1-41.2.4 Kobelco SensArc UC350/500 Power Supply .................................................. 1-41.2.5 Kobelco SensArc ES350/500 Power Supply ................................................... 1-41.2.6 Kobelco SensArc LS350 Power Supply .......................................................... 1-41.2.7 Wire Feeding System ...................................................................................... 1-41.2.8 Robot .............................................................................................................. 1-51.2.9 Water Circulator .............................................................................................. 1-51.2.10 Work Cell ........................................................................................................ 1-5

1.3 Reference to Other Documentation................................................................................ 1-51.4 Equipment and Component Specifications ................................................................... 1-61.5 Installation .................................................................................................................... 1-7

1.5.1 Connecting the Welding Cables ...................................................................... 1-81.5.2 Connecting the Voltage Detection Cables ....................................................... 1-91.5.3 Connecting Welder to the Controller ............................................................... 1-91.5.4 Connecting the Water and Gas Hoses ........................................................... 1-10

1.6 Reference to Other Documentation.............................................................................. 1-101.7 Customer Service Information .................................................................................... 1-10

2 SAFETY2.1 Introduction .................................................................................................................. 2-12.2 Standard Conventions .................................................................................................. 2-22.3 General Safeguarding Tips............................................................................................ 2-32.4 Mechanical Safety Devices ........................................................................................... 2-32.5 Installation Safety ......................................................................................................... 2-42.6 Programming Safety ..................................................................................................... 2-42.7 Operation Safety ........................................................................................................... 2-52.8 Maintenance Safety....................................................................................................... 2-6

3 THEORY OF OPERATION3.1 General System Operation ............................................................................................ 3-13.2 SensArc Technology ..................................................................................................... 3-2

MOTOMAN i Robotic Arc Welding Manual

Section Page4 OPERATION

4.1 Controls and Indicators ................................................................................................ 4-14.1.1 Power Source Settings .................................................................................... 4-14.1.2 Adjusting Feed Roll Tension ........................................................................... 4-2

4.2 Tips for Successful Welding ......................................................................................... 4-34.2.1 Machine Settings ............................................................................................ 4-34.2.2 Penetration Command .................................................................................... 4-44.2.3 Amperage Command ...................................................................................... 4-44.2.4 Voltage Command .......................................................................................... 4-44.2.5 Voltage Sensing .............................................................................................. 4-4

4.3 Using Enhanced Files (for the PC350) .......................................................................... 4-54.3.1 Setting Up Enhanced Arc Files ........................................................................ 4-5

5 TROUBLESHOOTING5.1 Troubleshooting ........................................................................................................... 5-1

APPENDIX A - DRAWINGS

APPENDIX B - SPARE PARTS/CONSUMABLE PARTS

APPENDIX C - MANUAL WELD PACKAGE

APPENDIX D - WELDER CONDITION FILES

INDEX

LIST OF FIGURESFigure Page

Figure 1-1 Typical Kobelco Welding System .............................................................................. 1-2Figure 1-2 Installing Input Power ............................................................................................... 1-8Figure 1-3 Location of Wirefeed and Positioner Connections on Power Source ........................ 1-9Figure 3-1 Sensarc Control ........................................................................................................ 3-2Figure 3-2 Spatter Generation..................................................................................................... 3-3Figure 3-3 Effect of Alternating Current on Penetration............................................................... 3-4Figure 4-1 Typical Control Panel on the Kobelco Power Source ................................................ 4-1Figure 4-2 Adjusting Feed Roll Tension ..................................................................................... 4-3Figure 4-3 Enhanced Arc Start File ............................................................................................. 4-5Figure 4-4 Enhanced Arc Start Timing Chart .............................................................................. 4-6

LIST OF TABLESTable Page

Table 1-1 Equipment and Component Specifications .................................................................. 1-6Table 4-1 Control Panel Settings ................................................................................................. 4-2Table 5-1 Troubleshooting Chart ................................................................................................. 5-1

Robotic Arc Welding Manual ii MOTOMAN

SECTION 1

INTRODUCTION1.1 About this Document

This manual contains information regarding the Kobelco welding systemmanufactured by Motoman, Inc. of West Carrollton, Ohio. It includes proceduresfor proper use, operation, and maintenance of the welding system. The manual isdivided into the following sections:

SECTION 1 - INTRODUCTIONProvides general information regarding this manual, descriptions of the weldingsystem and its components, technical specifications, installation, a list of referencedocuments, and customer service information.

SECTION 2 - SAFETYDescribes the conventions used to identify precautionary text throughout thismanual. The section also contains a list of general cautions and warnings thatapply to many of the procedures described in this manual.

SECTION 3 - THEORY OF OPERATIONProvides general welding principles. The discussion identifies specific problemsand requirements, how the welding system works, and how it addresses thespecific welding requirements.

SECTION 4 - OPERATIONProvides instructions for the proper use and operation of the Kobelco weldingsystem. Instructions provided include procedures to prepare the system for use,controls and indicators, and instructions for creating arc taper enhancedconditions.

SECTION 5 - TROUBLESHOOTINGThe information provided in this section helps the user identify and remedyproblems found during operation and welding.

APPENDICESAppendix A - Diagrams: Contains electrical, mechanical, and layout drawingsrelated to the Kobelco welding system and its components.

Appendix B - Spare Parts/Consumable Parts: Lists recommended spare parts/consumables for various components of the Kobelco welding system.

Appendix C - Manual Weld Package: Includes the drawings and instructions forconverting the Kobelco UC 350 for manual welding.

MOTOMAN 1-1 Robotic Arc Welding Manual

INTRODUCTION

Robotic Arc Welding Manual 1-2

MOTO

MAN

1.2 System Configuration

The Kobelco welding system is an integrated package of tools and componentsdesigned for specific welding requirements. The system includes the followingcomponents and optional equipment (refer to Figure 1-1):

Figure 1-1 Typical Kobelco Welding System

• Motoman robot manipulator (UP6. SK45X) and controller• Welding equipment, including the following:

• Kobelco SENSARC® welding power source, with wire feeder • Motoman Tough Gun torch, with voltage sensing lead• Wire Spool Dereeler Kit• 30 KVA Transformer (for 200 volt welders)

K

F

F

L

L

M

J

J

A

C

MOTOMAN

E

D

D

E

H

H

B

B

G

SERVO ONREADY

REMOTE

PLAY

(OFF)

(ON)

TEACH

MODE

EMERGENCY STOP

EDIT LOCK

ALARM

HOLD

START

YASNAC XRC SK16X

YASKAWA ELECTRIC CORPORATION

MADE IN JAPAN

NJX03-1

P/N

DATE

SERIAL NO.

POWER SUPPLY

YASNAC XRCTYPE

ENCM-RX6003

200/220V50/60HZ

3PHASE3.0KVA

SSM179-2-10-1

10-1998

16

ONTRIP

OPE

N/RE

SET

OFF

THE MANIPULATOR AND THE CONTROLLER

SHOULD HAVE THE SAME ORDER NUMBER

ORDER. NO. SSM179-1-7

N.J1S30G

K

CA

UC

500

SENSARC

KOBELCO

OBELCO

A

V

POWERALARM ON

OFFCONTROLPOWER

M

ROBOTCONTROLLER

GAS REGULATORAND TANK

GASHOSE

WIREFEEDER

TORCH

AC480V

30KVATRANSFORMER

FILLERWIRE

WELDING POWERSOURCE

WATERCIRCULATOR

FEEDER CABLE

(+) POWERCABLE

(-) POWERCABLE

BASEMETAL

POSITIONER

(-) VOLTAGEDETECTIONCABLE

DISTRIBUTIONBOX(CUSTOMERSUPPLIED)

AC200V

INTRODUCTION

Options for the welding system include:• Water circulator• Nozzle cleaner• Bulk wire delivery package

The robot controller controls the operation of the welding system. It coordinatesthe operation of the various system components. The controller executesinstruction sequences provided in a job file. As the controller steps through theseries of instructions, it directs the movement of the torch, controls the positioner,and operates the welding power supply.

The robot moves the welding torch and supply lines through a series ofprogrammed steps. The controller controls the speed, direction, and position of therobot as it moves from point to point.

The controller communicates weld signals through a cable to an interface board(MEW02-1) mounted in the welder cabinet. The controller sends analog voltagesfor amperage, voltage, and penetration control (for PC350 only), along with asignal to energize the contactor to weld. The Kobelco power source communicatesto the controller when the arc is established, when there is a fault condition, orwhen the wire is stuck to the puddle.

1.2.1 System ComponentsThe following paragraphs contain brief descriptions of each of the Kobelcowelding system components. Figure 1-1 shows a typical system layout.

1.2.2 MRC/XRC ControllerThe controller provides the following basic functions:

• Power ON

• Job creation

• Playback

• Process control

• Power OFF

From the operator's panel you can perform the following tasks:

• Select the robot operating mode

• Turn on servo power

• Select cycle mode

• Start and hold automatic operation

In addition, the controller provides the following capabilities:

• Connection to external devices through the RS232 serial interface port

• Input/output signal processing

Included with the controller is a programming pendant which is used to operate themanipulator and teach the robot series of motions and operations. Use theprogramming pendant to perform the following tasks:

• Input and edit motion data

• Input and edit process data

MOTOMAN 1-3 Robotic Arc Welding Manuall

INTRODUCTION

The controller also monitors the status of the system components. Various safetyfeatures of the aluminum welding system and the associated cell operate throughthe controller. Under emergency conditions the controller shuts down the system.

The controller is equipped with enhanced welding software functions designed tocontrol heat flow when welding aluminum. These functions can be activated andused for MIG welding applications.

1.2.3 Kobelco SensArc PC350 Power SupplyThe Kobelco SensArc PC350 is a variable polarity (AC-pulsed), penetration-controllable, high-efficiency welding system which prevents burn-through whenwelding thin materials. Use of reverse polarity, electrode positive (DCEP) [andoccasionally straight polarity, electrode negative (DCEN)] is common in thewelding industry. However, when welding thin materials, reverse polarity weldingoften results in burn-through and sound joints are hard to obtain, which impedesproductivity. Straight polarity welding produces extremely shallow penetration,which prevents burn-through, but insufficient penetration often occurs, whichlimits applications.

The PC350 Kobelco power source alternately repeats the DCEP pulse current andthe DCEN current to weld thin materials. Controlling the ratio of these two polarcurrents enables the free selection of penetration depth at the same setting as thewire feed rate.

1.2.4 Kobelco SensArc UC350/500 Power SupplyThe UC350/500 series power sources are inverter power supplies with excellentprice versus performance ratio. The UC power source is suited to light gage sheetmetal with superior short circuit arc characteristics. The UC500 can be used forthicker materials.

1.2.5 Kobelco SensArc ES350/500 Power Supply The Kobelco SensArc ES350/500 is a waveform-controlled, high-efficiencywelding system for welding thin or thick materials. The SensArc current controlfeature provides low spatter and a stable arc throughout current ranges.

1.2.6 Kobelco SensArc LS350 Power SupplyThe Kobelco SensArc LS350 is a wave-form controlled, high-efficiency weldingsystem for welding thin materials. The LS350 provides lower spatter levels thanthe UC power supply and improved arc control. The LS350 has shown better gapfilling capability than the ES/US series.

1.2.7 Wire Feeding SystemThe Kobelco SensArc wire feed system is controlled by the power supply andconsists of the following components:

• Kobelco 4-roll wire feeder• Torch adapter block• Side-mounting bracket and spool holder• Motoman Tough Gun Torch, with voltage sensing wire

The system handles.045" (1.2mm) – and 1/16"(1.6mm) wire. Drive rolls areavailable for.035" (1.03mm) wire. The UC series power supply requires a differentfeeder.

Robotic Arc Welding Manual 1-4 MOTOMAN

INTRODUCTION

1.2.8 Robot The Kobelco system includes a six-axis manipulator. The robot can reach belowits own base, and can travel in an arc approximately 340˚ around the base.However, it is possible to restrict the base axis with stopping bolts. These robotscan be floor-, wall-, or ceiling-mounted. Motoman robots use brushless AC motorswith absolute position encoders.

A combination of capacitance and lithium batteries in both robot and controllerassemblies protects program position data for up to a year. The life expectancy forthe lithium battery is approximately three years.

Power for the robot manipulator is supplied through the controller. A 4.5 KVAisolation transformer converts the 230, 460 or 575 V delta input to a 208 V wyeoutput. Refer to the manipulator manual that came with your system.

1.2.9 Water CirculatorThe water circulator supplies cooling water to the Motoman torch. This unit cansupply coolant to the welding torch from up to 25 to 30 feet away. The watercirculator motor and pump are enclosed in a hood. The bronze water pump is arotary gear type with a stainless steel shaft. The pump discharge has a safety reliefvalve that bypasses the welding torch when discharge back pressure exceeds apredetermined setting.

1.2.10 Work CellA complete system typically includes certain work cell components. Thesecomponents are not properly part of the Kobelco welding system, but rather relateditems supplied separately. Some of these items are safety mats, interlocks, arcscreens, fencing, and positioners. The number and type of components requireddepend on your specific application.

1.3 Reference to Other DocumentationFor additional information refer to the following:

• Motoman UP6 Manipulator Manual (P/N 142104-1)• Motoman SK16X Manipulator Manual (P/N 142105-1)• Motoman Operator's Manual for Arc Welding (P/N 142098-1)• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)• Com-Arc III Instruction Manual (P/N 132753-1)• Vendor manuals for system components not manufactured by Motoman


INTRODUCTION

1.4 Equipment and Component SpecificationsSpecifications for the Kobelco welding system and its components are listed inTable 1-1. Additional information is provided in the various vendor manualssupplied with the system.

Table 1-1 Equipment and Component Specifications

Characteristic Specification

Power Requirements Welding gas Electrical service (robot) Electrical service (welding)

Generally CO2 or Argon/CO2 mix12.8A at 230 VAC, 3 Phase 6.3A at 460 VAC, 3 Phase60.0A at 200 VAC, 3 Phase, 50/60 Hz., input cable 14 mm2 (#6AWG), input line variations ±10% (for all line voltages)

Operating Environment Temperature range Humidity Vibration Other

0 - 40 ˚C20 - 80% (non-condensing)Less than 0.5 GFree from corrosive gases or liquids, explosive gases, and excessive electrical noise

Kobelco SensArc Max. average output current Duty Cycle Min. average output current Voltage adjust range for CV

350A at 60% or 500A at 100%270A at 100%40A15 - 36 Volts

SensArc Wire Feed Unit Wire Feed Rate Applicable Wire Diameter

Max. 16 m/min (529 ipm)1.2 mmØ – 1.6 mmØ (.045 inch – 1/16 inch) or0.8mm – 1.0mm (.030 inch – .035 inch)

Motoman Water-cooled Tough Gun Torch (with voltage sensing lead

Motoman Air-cooled Tough Gun Torch (with voltage sensing lead

450A - CO2350A - AR, AR/O2, AR/CO2(based on the following:Power supply output U=14+0.05xIWater flow 0.9 l/min minimumWatercooler rating of 1900 W at 2 l/min at 22 ˚C ambient)

500A - CO2300A - mixed

Square D 30 KVA Transformer (for 200 volt welder only) Input Output

480/460V, 3-phase208V, 3-phase

Water Circulator Input power Capacity Output

115V AC (230V AC optional),50/60 Hz 3 Gal.Continuous operation for at least three hours at full rated current.Duty cycle is based on a coolant temperature rise of 37 ˚C (66 ˚F) above a 23 ˚C (74 ˚F) ambient.


INTRODUCTION

1.5 InstallationThe Motoman welding system is shipped with the torch and wire feeder installedon the robot. Standard installation instructions (for robot, MRC, work cell, andcommon base) are located in the installation manual shipped with your particularsystem. The instructions provided here are specific to the installation of thewelding system. Refer to Figure 1-1 for a typical Kobelco welding systeminterconnection diagram.

CAUTION!Supply voltage must be within the range shown in Table 1-1.Exceeding this range could damage equipment.The welding system uses a 30 KVA transformer to "step down" the 480/460 Vsupply voltage from the plant main power supply to the 208 V input needed for theKobelco welding power supply. Below are instructions for installing power fromthe transformer to the power supply. Detailed instructions for grounding yourWorld system (including the positioner and earth ground) are located in theinstallation manual provided with your particular system.

NOTE: Stepdown transformers (such as Square D transformers) usually have primary taps ± 5 foradjusting to primary voltages. If 400-volt input is either high or low, use the primary tap toselect the nearest actual voltage used.

1. Ensure main power is disconnected at main power distribution box.2. Power input terminals and ground terminal are located behind access panel

on the right side of the power supply. Remove top cover and right accesspanel.

3. Insert 3-phase input cables and grounding cable (Item J, Figure 1-1) fromtransformer through access hole in rear panel of power supply.

4. Install input power and grounding cables, as shown in Figure 1-2.


INTRODUCTION

Figure 1-2 Installing Input Power

1.5.1 Connecting the Welding CablesThe location and length of the welding cables are very important to the optimumperformance of the Kobelco welding system. Keep welding cables as short aspossible and as close together as possible. If possible, tie weld cables together andsplit apart at last possible point. Do not coil excess cable, as this will affectperformance.

1. Connect the (+) welding power cable (Item D, Figure 1-1) from the positiveterminal on the welding power source to the power plug adapter on the frontof the wire feeder (see Figure 1-3).

2. Connect (-) welding power cable (Item M, Figure 1-1) from the negativeterminal on the welding power source to the positioner (see Figure 1-3).

CAUTION!

200 VAC3 PHASE

GROUNDCABLE

UC

500

SENSARC

KOBELCO

OBELCO

A

V

POWERALARM ON

OFFCONTROLPOWER


INTRODUCTION

Figure 1-3 Location of Wirefeed and Positioner Connections on Power Source

1.5.2 Connecting the Voltage Detection Cables The Kobelco power source requires the use of two voltage sensing cables, one tomonitor the voltage at the torch and one to monitor the voltage at the work. It isimportant to connect the voltage detection cables correctly, as the power supplyuses feedback from the cables to control the output current, voltage, and arccondition. Incorrect placement will result in open circuit voltage to the torch, noarc at wire (wire will curl), or bad welds.

The Motoman Tough Gun torch is shipped with a positive voltage detection wirealready installed in the torch block, as close to the arc voltage as possible. Theother end of this 18-gauge wire protrudes from the rear of the torch.

1. To finish installing the torch voltage detection, connect the feeder cable (ItemH, Figure 1-1) from the wire feed connection on the power source to theconnection on the rear of the wire feeder (see Figure 1-3). Connect the 8-gauge wire (yellow #205, with Nichifu connector) from the power sourcecable to the 18-gauge voltage detection wire protruding from the rear of thetorch. Run the torch voltage detection cable as close to the wire feed powercable as possible.

2. Connect the negative voltage detection cable (Item L, Figure 1-1), to thepositioner, as close to the work as possible (see Figure 1-3). This locationshould have the same weld potential as the welding circuit. Run this cable asclose to the weld ground cable as possible. Do not connect this cable to thesame point as the weld ground.

1.5.3 Connecting Welder to the Controller1. Connect the Welco control cable (Item K, Figure 1-1) from the power source

to the panel on the right side of the controller.2. Connect the inch/reverse cable (Item C, Figure 1-1) from the power source to

the panel on the right side of the controller.

KOBELCOMOTOMAN

(-) POWER CABLE(TO BASE METAL) (+) POWER CABLE

(TO TORCH)CON2 FEEDER CABLE(FROM FEEDER)

CON1 (-) VOLTAGE DETECTION CABLE(FROM BASE METAL)


INTRODUCTION

1.5.4 Connecting the Water and Gas HosesFill water circulator with antifreeze mixed with distilled water.

CAUTION!Use only the antifreeze provided by Motoman. Automotive anti-freeze contains stop-leak additives that will clog the small torchwater-cooling ports and damage the gaskets in the pump.Two water hoses (one red and one blue) are already connected to the rear of thetorch.

1. Connect blue WATER-OUT hose (Item A, Figure 1-1) from the torch to theconnection on the water circulator marked WATER-OUT.

2. Connect red WATER-IN hose (Item B, Figure 1-1) from the torch to theconnection on the water circulator marked WATER-IN.

3. Connect the gas hose (Item E, Figure 1-1) from the torch to the gas supply.

1.6 Reference to Other Documentation For additional information refer to the following:

• Motoman Manipulator Manual

• Motoman Operator's Manual for Arc Welding (Part Number142098-1)

• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)

• Tregaskiss Tough Gun Technical Guide for Robotic Quick-Change MIGGuns

• Tregaskiss Tough Gun Technical Guide for Robotic Safety Clutch

1.7 Customer Service InformationIf you are in need of technical assistance, contact the Motoman service staff at(937) 847-3200. Please have the following information ready before you call:

• Robot Type (UP6 or SK16X)

• Application Type (welding)

• System Type (Kobleco)

• Software Version (5.101A)

• Robot Serial Number (located on the back side of the robot arm)

• Robot Sales Order Number (located on back side of XRC controller)


SECTION 2

SAFETY2.1 Introduction

.

We suggest that you obtain and review a copy of the ANSI/RIA National SafetyStandard for Industrial Robots and Robot Systems. This information can beobtained from the Robotic Industries Association by requesting ANSI/RIAR15.06. The address is as follows:

Robotic Industries Association900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: 313/994-6088FAX: 313/994-3338

Ultimately, the best safeguard is trained personnel. The user is responsible forproviding personnel who are adequately trained to operate, program, and maintainthe robot cell. The robot must not be operated by personnel who have not beentrained!We recommend that all personnel who intend to operate, program, repair, or usethe robot system be trained in an approved Motoman training course and becomefamiliar with the proper operation of the system.

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming Safety (Section 2.6)

• Operation Safety (Section 2.7)

• Maintenance Safety (Section 2.8)

It is the purchaser's responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are metand followed.

MOTOMAN 2-1 Kobelco Welding Manual

SAFETY

2.2 Standard ConventionsThis manual includes information essential to the safety of personnel andequipment. As you read through this manual, be alert to the four signal words:

• DANGER

• WARNING

• CAUTION

• NOTE

Pay particular attention to the information provided under these headings whichare defined below (in descending order of severity).

DANGER!Information appearing under the DANGER caption concerns theprotection of personnel from the immediate and imminent hazardsthat, if not avoided, will result in immediate, serious personal injuryor loss of life in addition to equipment damage.

WARNING!Information appearing under the WARNING caption concerns theprotection of personnel and equipment from potential hazards thatcan result in personal injury or loss of life in addition to equipmentdamage.

CAUTION!Information appearing under the CAUTION caption concerns theprotection of personnel and equipment, software, and data fromhazards that can result in minor personal injury or equipmentdamage.

NOTE: Information appearing in a NOTE caption provides additional information which is helpful inunderstanding the item being explained.

Kobelco Welding Manual 2-2 MOTOMAN

SAFETY

2.3 General Safeguarding TipsAll operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. General safeguardingtips are as follows:

• Improper operation can result in personal injury and/or damage to theequipment. Only trained personnel familiar with the operation of this robot,the operator's manuals, the system equipment, and options and accessoriesshould be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmersmust have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be madewithin the standard voltage and current ratings of the robot I/O (Inputs andOutputs).

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it isnot in use.

• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, uselockout/tagout procedures during equipment maintenance. Refer also toSection 1910.147 (29CFR, Part 1910), Occupational Safety and HealthStandards for General Industry (OSHA).

2.4 Mechanical Safety DevicesThe safe operation of the robot, positioner, auxiliary equipment, and system isultimately the user's responsibility. The conditions under which the equipmentwill be operated safely should be reviewed by the user. The user must be aware ofthe various national codes, ANSI/RIA R15.06 safety standards, and other localcodes that may pertain to the installation and use of industrial equipment.Additional safety measures for personnel and equipment may be requireddepending on system installation, operation, and/or location. The following safetymeasures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

Check all safety equipment frequently for proper operation. Repair or replace anynon-functioning safety equipment immediately.


SAFETY

2.5 Installation SafetySafe installation is essential for protection of people and equipment. Thefollowing suggestions are intended to supplement, but not replace, existing federal,local, and state laws and regulations. Additional safety measures for personnel andequipment may be required depending on system installation, operation, and/orlocation. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, localcodes, and ANSI/RIA R15.06 safety standards are permitted to install theequipment.

• Identify the work envelope of each robot with floor markings, signs, andbarriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entryinto the work envelope.

• Eliminate areas where personnel might get trapped between a moving robotand other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching andmaintenance procedures.

2.6 Programming SafetyAll operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. Programming tips areas follows:

• Any modifications to PART 1 of the MRC controller PLC can cause severepersonal injury or death, as well as damage to the robot! Do not make anymodifications to PART 1. Making any changes without the writtenpermission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require specialpasswords. Special passwords are for Motoman use only. YOURWARRANTY WILL BE VOID if you use these special passwords.

• Back up all programs and jobs onto a floppy disk whenever program changesare made. To avoid loss of information, programs, or jobs, a backup mustalways be made before any service procedures are done and before anychanges are made to options, accessories, or equipment.

• The concurrent I/O (Input and Output) function allows the customer tomodify the internal ladder inputs and outputs for maximum robotperformance. Great care must be taken when making these modifications.Double-check all modifications under every mode of robot operation toensure that you have not created hazards or dangerous situations that maydamage the robot or other parts of the system.

• Improper operation can result in personal injury and/or damage to theequipment. Only trained personnel familiar with the operation, manuals,electrical design, and equipment interconnections of this robot should bepermitted to operate the system.


SAFETY

• Inspect the robot and work envelope to be sure no potentially hazardousconditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place.

• Check the E-STOP button on the teach pendant for proper operation beforeprogramming.

• Carry the teach pendant with you when you enter the workcell.

• Be sure that only the person holding the teach pendant enters the workcell.

• Test any new or modified program at low speed for at least one full cycle.

2.7 Operation SafetyAll operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. Operation tips are asfollows:

• Be sure that only trained personnel familiar with the operation of this robot,the operator's manuals, the system equipment, and options and accessoriesare permitted to operate this robot system.

• Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

• Inspect the robot and work envelope to ensure no potentially hazardousconditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.


• Do not enter the robot cell while it is in automatic operation. Programmersmust have the teach pendant when they enter the cell.


• This equipment has multiple sources of electrical supply. Electricalinterconnections are made between the controller, external servo box, andother equipment. Disconnect and lockout/tagout all electrical circuits beforemaking any modifications or connections.

• All modifications made to the controller will change the way the robotoperates and can cause severe personal injury or death, as well as damage therobot. This includes controller parameters, ladder parts 1 and 2, and I/O(Input and Output) modifications. Check and test all changes at slow speed.


SAFETY

2.8 Maintenance SafetyAll operators, programmers, plant and tooling engineers, maintenance personnel,supervisors, and anyone working near the robot must become familiar with theoperation of this equipment. All personnel involved with the operation of theequipment must understand potential dangers of operation. Maintenance tips areas follows:

• Do not perform any maintenance procedures before reading andunderstanding the proper procedures in the appropriate manual.

• Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.


• Back up all your programs and jobs onto a floppy disk whenever programchanges are made. A backup must always be made before any servicing orchanges are made to options, accessories, or equipment to avoid loss ofinformation, programs, or jobs.

• Do not enter the robot cell while it is in automatic operation. Programmersmust have the teach pendant when they enter the cell.


• Be sure all safeguards are in place.

• Use proper replacement parts.

• This equipment has multiple sources of electrical supply. Electricalinterconnections are made between the controller, external servo box, andother equipment. Disconnect and lockout/tagout all electrical circuits beforemaking any modifications or connections.

• All modifications made to the controller will change the way the robotoperates and can cause severe personal injury or death, as well as damage therobot. This includes controller parameters, ladder parts 1 and 2, and I/O(Input and Output) modifications. Check and test all changes at slow speed.

• Improper connections can damage the robot. All connections must be madewithin the standard voltage and current ratings of the robot I/O (Inputs andOutputs).


SECTION 3

THEORY OF OPERATIONThis section covers the theory of operation of the overall aluminum weldingsystem and specifically discussing the following items:

• Gas metal arc welding (GMAW) applications

• Properties of aluminum and the effects these properties have on the weldingprocess

• Features of the aluminum welding system that address specific problems orconcerns involved in the welding process

• The Kobelco dual inverter, AC GMAW power source and wire feed system

3.1 General System OperationThe Kobelco SensArc is a spray pulse machine designed to spray one droplet ofmetal across the arc with each pulse of current. The frequency of pulsing isdetermined by constant monitoring of actual arc conditions rather thanprogrammable pulse conditions. The result of this constant monitoring of theconditions of the droplets and arc – combined with a voltage sensing wire thatconstantly monitors welding voltage across the contact tip and base metal – iscurrent wave form control.

Wave form control ensures efficient arc-start and arc-end. At the end of a weld, thepower source controls the current according to the gradually reducing wire speed.When the arc becomes longer than the determined length, the power sourceinterrupts current and waits until the next short circuit. When the next short circuitoccurs, the current is turned on again to break the bridge. This procedure isrepeated until the wire stops and prevents a droplet from growing at the wire end.

Spatter generation frequently occurs when arc strikes just after the droplet, causinga short circuit to the molten pool, or at the moment droplet transfer in completedand the arc restrikes. In either case, the strong force at the moment of the arcstriking, which blows off the droplet or molten pool, is the main cause of spatter.To lower the amount of spatter, the Kobelco lowers the welding current at themoment the droplet causes a momentary short circuit to the molten pool or at themoment the arc restrikes.

The Kobelco power source provides AC current for MIG welding. Most MIGwelding is done DCEP (reverse polarity) which provides deep penetration into theworkpiece. DCEN (straight polarity) provides higher deposition, but the bead isconvex and does not penetrate the base metal. The Kobelco has penetration controlwhich varies the ratio of DCEN to DCEP polarity. This capability allows weldingthinner materials (down to 1.0 mm), extended gap conditions (about 1 x thickness),and higher travel speeds without burn through. (Refer to paragraph 3.2.2 for moredetails on AC pulsed MIG metal transfer.)

The Kobelco SensArc receives welding current, voltage, and penetration controlcommands between zero and 14 volts from the robot control panel, and accordingto the control command, automatically adjusts welding current, voltage, andpenetration.


THEORY OF OPERATION

3.2 SensArc TechnologyKobelco power sources use SensArc technology for monitoring the arc andadjusting the current in real time. The result is a dramatic reduction in spatter,especially when using straight CO2 gas.

SensArc technology is suited to light gage materials and short circuit transfer.When the wire shorts to the workpiece, the power source switches to ConstantCurrent mode (CC). In CC mode, the current is ramped up and held at a specificcurrent. The level of the current is determined by the switches for wire size andgas type. Arc voltage is monitored via sensing leads to the torch and workpiece.When the droplet transfer is about to take place, the cross section of the wire willreduce (pinch down). This phenomenon is sensed by the welder. At the pointwhen the wire is about to transfer, the current is quickly reduced. Transfer at ahigh current will magnetically propel the droplet and create spatter. Reducing thecurrent with SensArc reduces the amount of spatter.

The SensArc principle is illustrated in Figure 3-1. Instead of using apreprogrammed pulse schedule, the welder reacts to the actual arc conditions inreal time. Note that the time during the "short" period varies. During welding,several factors effect transfer and therefore there are guarantees that transfer willtake place in a fixed time. During the "arc period", the welding control changes toConstant Voltage (CV) for better arc stability.

Figure 3-1 SensArc ControlKobelco welders are synergic. For any given amperage setting, the weld powersupply will provide an optimum arc voltage setting. To use the setting from thepower source, enter an arc voltage or AVP setting of 100%. The 100% setting willalways send a 7 volt (VWELD=7.00) command to the welder. The arc length canbe "trimmed" by adjusting the percentage up or down. It is most common to adjustthe welder between 90-98% for robotic welding.

CU

RR

EN

T W

AV

E F

OR

M

SHORT

ONE CYCLESTART END START

ARCING PERIOD SHORT

START

ARC

SHORTING PERIODLENGTHENS FOR

FOR LARGER DROPLET


THEORY OF OPERATION

The Kobelco product line includes a variety of welders; the ES350/ES500, theLS350, the PC350, and the UC350/UC500. The 350 amp units are rated at 60%duty cycle and are 270 amps at 100% duty. The 500 amp welders are 100% dutycycle. The UC series represents a model change from the ES series. The two unitsweld nearly identically. These welders are designed as lower cost units. Whilethey operate on the principle shown in Figure 3-1, the switching time to reduce thecurrent is limited.

The LS350 and PC350 feature a patented secondary circuit. When they lower thecurrent at the end of the short, they switch to a secondary circuit with lowerinductance so the current can drop quicker and lower. The result is less spatter asshown in Figure 3-2. The curve of the PC350 with straight CO2 gas demonstratesthat spatter levels are lower than domestic machines with mixed gas.

Figure 3-2 Spatter GenerationIn addition to the low spatter levels, the PC350 has the unique capability of varyingthe polarity. Most GMAW welding is done with DCEP (Reverse) polarity. Thisconcentrates the heat in the workpiece and gives maximum penetration. Whenwelding with DCEN (Straight) polarity, the heat is concentrated in the wire andthis increases deposition but also leaves little penetration and a convex bead. Inaddition to analog commands for amperage and voltage, the PC350 has a thirdanalog for penetration control. This 0-14 volt analog can vary the amount ofDCEN polarity from 0-100%. The result is the ability to deposit the same sizeweld, but reduce the heat into the workpiece. This allows the PC350 to weldmaterials down to 1.0 mm thick and greatly improves its ability to fill gaps. Theprinciple of the PC350 is illustrated in Figure 3-3.

Spatter Generation (200 amps, 50 cm/min)

18 19 20 21 22 23 24 25 26 27 28 29 30

Voltage

PC-350 (CO2 100%)

Brand H - mix

Brand M - mix

Brand L - mix

ES 350 - mix

LS 350 - mix

Brand M

Brand L

Brand H

ES 350

PC 350 -CO2ES 350


THEORY OF OPERATION

Figure 3-3 Effect of Alternating Current on Penetration

DCEP DCEN


SECTION 4

OPERATIONThis section identifies the controls and indicators used to operate the system undernormal conditions. It also contains set-up instructions for preparing the aluminumwelding system for operation, and includes instructions for setting up enhanced arcstart files, using the slope up/down function, and a set of welding tips to helpsimplify the aluminum welding process.

4.1 Controls and IndicatorsKobelco provides a family of welding power sources with various controls. Shownhere are some typical controls and indicators. See OEM manuals for more detailson a specific welder.

4.1.1 Power Source SettingsThe controls for the power source are shown in Figure 4-1. The settings are listedin Table 4-1.

NOTE: Under normal circumstances, the Crater controls, shown below, are fully operational. However,when the Kobelco Power Source is used with a Motoman robot, Crater control becomes afunction of the weld program controlled by the MRC.

Figure 4-1 Typical Control Panel on the Kobelco Power Source

A

V

POWERALARM ON

OFFCONTROLPOWER

AMMETER

VOLTMETER

0

_

ON

OFF

ON

OFF

CO2

MAG

FLOW

AUTO

SOLOFON Ø16

Ø14Ø12

GAS FLOW

WIRE DIA

WIRE TYPE

GAS

PENETRATION

CRATER ALARMINDICATOR

CURRENTINPUTCABLEHEATWATER

FUSE

CRATER VOLTAGE

CRATER CURRENT

A V

POWER

ALARM

ON

OFFCONTROLPOWER

AMMETER VOLTMETER

0

_

ON

OFF

ON

OFF

CO2

MAG

FLOW

AUTO

SOLO

FON

Ø16Ø14Ø12

GAS FLOWWIRE DIAWIRE TYPEGASPENETRATION

CRATER

ALARMINDICATOR

CURRENTINPUTCABLEHEATWATER FUSE

CRATER VOLTAGECRATER CURRENT


OPERATION

4.1.2 Adjusting Feed Roll Tension1. Release the wire feed pressure handle and open the pressure arm (see Figure

4-3).2. Adjust pressure handle to the recommended setting for wire type and size.3. Guide the wire through the center wire guide and into the torch.4. Close the pressure arm and close the pressure handle.5. Using the programming pendant, inch wire to the tip of the torch until it

extends about 10 mm from the end of the tip.

Table 4-1 Control Panel Settings

Control Setting

POWER Turns power Off/On. When programming the robot, make sure switch is in the On position.

GAS FLOW Set to FLOW to purge gas; set to AUTO for auto-matic gas control. Checks the gas flow rate.

CRATER Always set to Off; On is disabled in system which uses robot controller.

WIRE DIAMETER Set to proper size.

WIRE TYPE

CRATER CURRENT, VOLTAGE, and PENETRATION

Disabled in system which uses robot controller.

GAS TYPE Set to CO2 for straight CO2 or MAG for Argon mix-tures.


OPERATION

Figure 4-2 Adjusting Feed Roll Tension

4.2 Tips for Successful Welding4.2.1 Machine Settings

Kobelco welders can weld with 3/64 in. (1.2 mm) or 1/16 in. (1.6 mm) wirediameters. This setting also effects peak current and pulse frequency.

The motor torque limiter setting prevents birds nests in the feeder. Use the charton the Kobelco front panel as a guide for initial setting. Initially, set the motortorque limiter low and if a feed error occurs, increase the setting slightly. If a birdsnest occurs, then reduce the setting slightly. Cancel the feed error by pressing theinch key on the programming pendant or cycling power on the welder. Do not inchwire when there is a feed fault. Inching acts like an override and may cause a birdsnest if there is indeed a feed problem. Excessive tripping of this feed fault mayindicate a worn tip or liner, but don’t change either hastily.

The gas purge switch checks gas purge. The crater switch and knobs for cratersettings are not active for robotic use.

PRESSURE ARM

PRESSUREHANDLE

PRESSUREHANDLEKNOB

TORCH

WIRE

CENTERWIREGUIDE

10 mm

TIP OFTORCH

PRESSURE ADJUSTMENT


OPERATION

4.2.2 Penetration Command• Set Analog #3 to 8.0 volts when penetration control is required.

• Do not set Analog #3 less than 1.0 volt as the small ratio of straight polaritycan cause arc instability. Most applications use penetration values in the 3-7volt range. A 14.0 volt value will give 60% straight polarity which mightcause some arc instability.

• Penetration control is advantageous for welding material 1-2 mm thick,maintaining optimal welding gap conditions, and maintaining fillet profile athigh speeds.

• Set the amperage command to get the desired size weld and then add thepenetration command to reduce the penetration. The amperage may need tobe fine tuned for weld size and arc voltage is adjusted for desired arc length.

• The power source meter reads average amperage. Therefore, when thepenetration command (percentage of DCEN polarity) is increased, the meterwill decrease even though wire feed remains constant.

4.2.3 Amperage CommandThe controller is set-up to send a 0-14 volt analog reference to the welder,depending on what amperage is present in the Arc Start File. This amperage-to-analog ratio is set-up as a table in the Welder Condition File. This data variesdepending on wire size and type. Refer to Appendix D for amperage-to-analogratio data.

4.2.4 Voltage CommandThe Kobelco is a synergic welder with a preset voltage value for any givenamperage command. This is referred to as Unified mode in the Welder ConditionFile. Instead of entering direct voltage values like 24.0 volts, enter the voltage as apercentage of the welders preset voltage.For any amperage setting, select the preset voltage value by entering 100% arcvoltage. The arc length can be trimmed by decreasing or increasing from thisvalue. Most applications range between 90%-100% arc voltage settings.

4.2.5 Voltage Sensing• The Kobelco does not have a programmable pulse, it uses information sensed

at the arc through the voltage sensing leads and reacts in real time. It is veryimportant that these voltage sensing leads be properly connected and somesimple precaution followed:

• Don't coil the weld leads! This will add inductance and contribute to arcinstability.

• Do use a replacement torch from Tregaskiss with the voltage sensing leadattached to the torch block (18 gauge wire extending from rear handle oftorch).

• Avoid connecting the negative voltage sensing lead to the weld ground point.The flow of welding current can create a voltage drop which will be sensedby the welder.

• Try to connect the negative voltage to a point at the same potential as theweld circuit, such as the fixture or positioner frame. Connect it as close tothe arc as possible as bearings and bolting details can create voltage drop.


OPERATION

• Keep the voltage sensing lead adjacent to the weld lead for as long a distanceas possible (wire tie to lead).

• Keep the positive and negative weld leads adjacent to each other for as long adistance as possible. Refer to the Kobelco Operators manual for moreinformation.

4.3 Using Enhanced Files (for the PC350)Enhanced arc files (see Figure 4-4) can be used to program ramping weldparameters. Standard arc start files store parameter settings and initiate the arcwith a single instruction. The standard arc start configuration for steel provides anamperage and voltage setting and a "dwell" time after arc start to allow a puddle tobuild before the torch begins to travel. The standard arc start configuration contains32 arc start and 4 arc end files. An enhanced arc start file allows a second set ofweld parameters which can "dwell" a specified time or distance from the startpoint. The enhanced configuration contains 20 arc start files and 10 arc end files.

Enhanced welding files are not compatible with the Com-Arc III seam trackingoption. There are also some limitations for using enhanced files with a dual robotcontroller, as enhanced files will allocate 8 analog channels between the tworobots, which requires 4 MEOW boards which leaves only one slot for I/O.

4.3.1 Setting Up Enhanced Arc FilesThe enhanced arc start condition files allow you to pause and/or travel with thestarting conditions and allows you to set analogs 3 and 4. The Kobelco PC-350power source uses analog 3 to set the penetration control. Figure 4-6 shows anenhanced arc start file and Figure 4-7 is a signal timing chart that illustrates thedifference between the "pause" and the "distance" start settings.

Figure 4-3 Enhanced Arc Start File

ARC START CONDITION FILE (ENHANCED)

COND NO. : 99

VOLT% CHECK : " DONE # NOT DONE

COMMENT :

RETRY : " OK # NON

SPEED : 100cm/min

(START CONDITION)

CURRENT : 150A

VOLTAGE : 99%

ANALOG OUTPUT 3 CMD : 0.00V


ROBOT PAUSE TIME : 0.10sec

ROBOT MOVE DISTANCE : 10.0mm

(MAIN CONDITION)

CURRENT : 120A

VOLTAGE : 97%




OPERATION

Figure 4-4 Enhanced Arc Start Timing ChartThe standard arc end file configuration provides a single set of parameters forcrater fill along with a dwell timer, as well as a single step parameter at the end.The enhanced arc end files provide two step parameters and two dwell timers.These are advantageous when filling craters during aluminum welding.

NOTE: Kobelco PC-350 welding systems are shipped with enhanced files as standard.

WAITING TIMEFOR ARC ESTABLISHFROM WELDER

ROBOTPAUSETIME

ROBOTMOVEDISTANCE

MAIN CONDITION

ARC ON COMMAND

ROBOT MOTION

START CONDITION

ARC ESTABLISHED SIGNALFROM POWER SUPPLY

CURRENT, VOLTAGE, ANDANALOG OUTPUT REFERENCEFROM PREVIOUS COMMAND


SECTION 5

TROUBLESHOOTING5.1 Troubleshooting

Table 5-1 lists the error indicators on the Kobelco power supply and provides briefinstructions for locating the cause of the error. It also identifies common problemsthat occur during aluminum welding. When troubleshooting welding problems,refer to the schematic shown in Figure 5-1 to locate robot/welder interfaceconnections.

To troubleshoot your system, identify the type of problem and look for it in thePROBLEM column. Next to this column is a list of probable causes. For eachprobable cause, one or more remedies is suggested.

Be aware that sometimes more than one problem can occur at the same time. Afteridentifying and resolving a problem, test the system thoroughly to make sure noother problems exist.

WARNING!When an error indicator illuminates on the Kobelco power source(except HEAT), turn OFF the Kobelco Power Switch and cut off powerat the main disconnect. Be sure to wait at least two minutes beforeopening power supply cabinet.

Table 5-1 Troubleshooting Chart

Problem Probable Cause Solution

INV lamp illuminates Current overload through inverter transistor.

Turn the power OFF and then ON again. If the error recurs, call Motoman Service Depart-ment.

CURRENT lamp illuminates This lamp illuminates if a cur-rent exceeding the power supply rating runs through the load for more than 2 seconds.

Torch tip is shorting to base metal.

There is a short between output cables.

Turn the power OFF.

Check for a short circuit between the weld tip and the base metal.

Turn power OFF and check for a short between output cables.


TROUBLESHOOTING

INPUT lamp illuminates Supply voltage exceeds 200 V or open phase is occurring.

Fuses F1 or F2 (on frontpanel) are blown.

If fuses aren't blown, measure primary voltage for each phase to determine if one is missing.

CNC connector inside power supply cabinet is not connected properly.

Turn power OFF and check that input voltage is 200 V ± 10% or if open phase has occurred.

Replace blown fuse and per-form a trial weld.If F1 or F2 blows again, call Motoman Service Depart-ment.

If one phase is missing, recover missing phase.

Check connection. (200VAC±10% - CN200)(220VAC±10% - CN220)

HEAT lamp illuminates(Over Heat)

The welding power supply is exceeding its specified duty cycle.

Air vent is blocked.

With the power ON, allow the power source to run until the internal temperature drops suf-ficiently.

Make sure there is adequate clearance between air vent and other equipment that may obstruct air flow.

CABLE lamp illuminates The wire feeder cable is shorted to other cables or ground.

FU1 or FU2 (on CVA2) is blown.

Turn power OFF and check for contact between cables.

Replace fuse(s).

REV lamp illuminates REV supply voltage is out of range. If REV error occurs dur-ing welding, you will lose con-trol of weld penetration.

Make sure torch and base metal cables are as close together and parallel as possi-ble. If you can't weld at all during a REV error, call Moto-man Service Department.

Table 5-1 Troubleshooting Chart - continued



TROUBLESHOOTING

Wire feed is erratic Resistance inside conduit is too high.

Wire feed power is weak and erratic.

Check the condition of the torch, liner, and examine con-dition of tip to ensure it is not damaged.

Ensure wire feed pressure lever is set appropriately.

Check that drive feed rolls are not slippery or clogged with wire chips and oil.

Check that drive roll is appro-priate for wire size.

Arc does not establish Arc voltage feedback is inappro-priate.

Voltage is not applied between contact tip and base metal.

Weld wire is not feeding cor-rectly.

Check that negative terminal of arc voltage detection cable is connected correctly.

Check that welding cables are connected correctly.

See remedy under "Wire feed is not smooth."

Arc stays at open circuit volt-age

Positive voltage sensing cable is not connected properly.

Check that wires to feed motor are not loose. Check connec-tion of cable between torch and feeder cable. Check con-nection at rear of torch (unthread cover on rear of torch to remove).

Arc start is erratic Current is not flowing smoothly.

Contact tip is wrong size, weld wire is not contacting top portion of tip, or weld wire is straight.

Arc voltage is too low. EN ratio is too high. Welding speed is too fast. Wire RUN-IN speed is too fast.

Check that no insulating mate-rial (e.g. coating) exists on surface of base metal.

Check that base metal has fully contacted the fixture.

Use appropriate size tip, and make sure weld wire contacts top portion of tip. Replace worn tip.

Increase voltage, decrease AN #3, or decrease weld and RUN-IN speed. Do not set AN #3 between 0.01 and 0.99 Volts.




TROUBLESHOOTING

Arc is erratic Wire feed is incorrect.

Arc voltage feedback is incor-rect.

See "Wire feed is erratic."

Verify that torch is not over-heating. Check water flow pressure and cable connec-tions.

Verify that negative voltage detection cable and welding cable are wired and connected correctly. Make sure negative voltage detection cable is as close to weld cable as possi-ble, but not connected at the same point.

Shielding gas is insufficient or doesn't flow.

Main valve for the gas cylinder is closed or incorrect pressure is supplied.

Flow switch on front panel is not set to FLOW.

Check that gas valve is open and that pressure gauge reads correctly.

Set switch to FLOW. If gas still doesn't flow, call Moto-man Service Department.

Burn back occurs Arc length is too long.

Robot setting is wrong.

Wire feed is erratic.

Check welding speed and ensure it is not too slow and that arc voltage is not too high.

Correct setting.

See remedies under "Wire feed is erratic."

Burn-through occurs Work piece accuracy is poor.

Welding conditions are not cor-rect.

Check that gap is not too large and that it does not vary.

Check that base metal is not distorted during welding.

Ensure forward welding is used.

Check welding current and arc voltage and ensure they are not too high.

Increase penetration control (AN #3).




TROUBLESHOOTING

Blow holes and pits are formed when welding

Insufficient shielding.

Parts or wire are contaminated.

Parameters are not set correctly.

Ensure the distance between the nozzle and the base metal is not too large.

Verify that the gas flow rate is adjusted correctly.

Make sure parts do not have excessive oil. Change wire spool.

Increase torch push (lead) angle to decrease arc voltage.

Penetration is insufficient Welding conditions are not cor-rect.

Weld joint characteristics are not correct.

Check that arc start conditions and main welding conditions are set separately. (Do not increase EN ratio excessively for arc start when welding with PC-350.)

Check welding target posi-tions when welding materials with greatly different heat capacity and conductivity.




TROUBLESHOOTING

NOTES


APPENDIX A

DRAWINGSThis section contains the following drawings for the Kobelco welding system:

Drawing Number Title Sheet Number142348-2 Robot, XRC 1

142350-2 Robot, XRC 1

142745-1 UC 350, Power Source Kit, 460V 1




142750-2 LS 350, Power Source Kit 1

142751-1 PC 350, Power Source Kit 1

137308-4 Cable, Kobelco Power Supply to XRC 1

137309-6 Cable, Weldco 4

MOTOMAN A-1 Robotic Arc Welding Manual

DRAWINGS

NOTES

Robotic Arc Welding Manual A-2 MOTOMAN

APPENDIX B

SPARE PARTS/CONSUMABLE PARTSIncluded here are the spare parts lists for the UC, ES, and PC Series Kobelcowelding power sources. Also included is a parts list for wirefeeders RF301BMRand RF202YAM.

MOTOMAN B-1 Robotic Arc Welding Manual

SPARE PARTS/CONSUMABLE PARTS

NOTES

Robotic Arc Welding Manual B-2 MOTOMAN

APPENDIX C

MANUAL WELD PACKAGEIncluded here are the drawings and instructions for converting the Kobelco UC 350 and AL 350 for manual welding.

Drawing Number Title Sheet Number141526-1 Manual Weld Package, UC 350 1

142311-1 Manual Weld Package, AL 350 1

MOTOMAN C-1 Robotic Arc Welding Manual

MANUAL WELD PACKAGE

NOTES

Robotic Arc Welding Manual C-2 MOTOMAN

APPENDIX D

WELDER CONDITION FILESUse the table below to set up amperage and voltage data for the PC 350 (0.35 steelwire, CO2 gas, and15 mm stick out) in the welder condition file:

Use the table below to set up amperage and voltage data for the UC 350 (0.45 steelwire, CO2 gas, and15 mm stick out) in the welder condition file:

A-Weld Settings V-Weld Settings

Volts Meter Current V-Weld Meter Voltage

2.0 60 3.0 88%

4.0 110 7.0 100%

5.0 130 11.0 112%

7.0 165

8.0 180

9.0 190

10.0 210

14.0 270

A-Weld Settings V-Weld Settings

Volts Meter Current V-Weld Meter Voltage

2.0 50 3.0 88%

4.0 120 7.0 100%

5.0 170 11.0 112%

7.0 200

8.0 230

9.0 275

10.0 300

14.0 400

MOTOMAN D-1 Robotic Arc Welding Manual

WELDER CONDITION FILES

NOTES

Robotic Arc Welding Manual D-2 MOTOMAN

INDEX
AANSI/RIA, 1
CCustomer Service Information, 10

EEquipment Description, 1

GGeneral Safeguarding Tips, 3

IInstallation Safety, 4Introduction, 1

MMaintenance, 1Maintenance Safety, 6Mechanical Safety Devices, 3

OOperation Safety, 5Optional Equipment, 4

PPeriodic Maintenance, 1Programming Safety, 4

RReference to Other Documentation, 5Robotic Industries Association, 1

SSafety, 1Standard Conventions, 2System drawings, 1System Layout, 3System Overview, 2

XXRC Controller, 2

MOTOMAN Robotic Arc Welding Manual

INDEX

MOTOMAN Robotic Arc Welding Manual

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