OM-169 510
June 1995
Processes
Plasma Arc (PAW) Welding
Description
AutomaticWelding
Robot PAW Interface
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EMF INFORMATION
Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields
NOTE
The following is a quotation from the General Conclusions Section
of the U.S. Congress, Office of Technology Assessment, Biological
To reduce magnetic fields in the workplace, use the following
procedures:
Effects of Power Frequency Electric
&
Magnetic Fields
–
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around the body.
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.
Government Printing Office, May 1989): “. . . there is now a very
large volume of scientific findings based on experiments at the
cellularlevelandfromstudieswithanimalsandpeoplewhichclearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us to draw definite conclusions about questions of possible
risk or to offer clear science-based advice on strategies to minimize
or avoid potential risks.”
4. Keep welding power source and cables as far away as
practical.
5. Connect work clamp to workpiece as close to the weld as
possible.
About Pacemakers:
The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.
mod10.1 4/93
TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1-1.
1-2.
General Information And Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbol And Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
SECTION 2 – INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
Field Installation Instructions For PAW Interface Panel To Computer Interface . . . . . . . . . .
Shock Sensor Unit Assembly And Installation To Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High-Frequency Protection For Torch Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torch And Torch Cable Installation To Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torch Cable Internal Connections To Plasma Welding Console . . . . . . . . . . . . . . . . . . . . . . . 10
PAW Interface Panel – Computer Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PAW Interface Panel – Welding Power Source – PAW Console Connections . . . . . . . . . . . 11
Computer Interface – Input Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2
4
4
5
9
3-10. Gas Set/Pilot Arc Start Push Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3-11. Remote Gas Set/Pilot Arc Start Switch Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SECTION 4 – ROBOT PROGRAM MODIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2
4-1.
4-2.
4-3.
4-4.
Setting Up Plasma (Non-Standard) Torch For MRH Robot . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2
Setting Up Plasma Torch For MRV Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Marking Position Of Torch Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
System Setup For MRH And MRV With C2 Robot Control . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2
2
SECTION 5 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 5-1. Circuit Diagram For Robot PAW System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 5-2. Circuit Diagram For Robot PAW Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 5-3. Wiring Diagram For Robot PAW Interface Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 5-4. Circuit Diagram For High-Frequency Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 5-5. Wiring Diagram For High-Frequency Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SECTION 6 – HF IN PLASMA ARC WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OM-169 510 – 6/95
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SECTION 1 – SAFETY PRECAUTIONS AND SIGNAL WORDS
1-1.
GENERAL INFORMATION AND SAFETY
1-2.
SAFETY ALERT SYMBOL AND SIGNAL
WORDS
A. General
The following safety alert symbol and signal words are
used throughout this manual to call attention to and
identify different levels of hazard and special instruc-
tions.
Information presented in this manual and on various la-
bels, tags, and plates on the unit pertains to equipment
design, installation, operation, maintenance, and trou-
bleshooting which should be read, understood, and fol-
lowed for the safe and effective use of this equipment.
This safety alert symbol is used with the signal
words WARNING and CAUTION to call atten-
tion to the safety statements.
B. Safety
WARNING statements identify procedures or
practices which must be followed to avoid seri-
ous personal injury or loss of life.
The installation, operation, maintenance, and trouble-
shooting of plasma arc welding equipment requires
practices and procedures which ensure personal safety
and the safety of others.
CAUTION statements identify procedures or
practices which must be followed to avoid minor
personal injury or damage to this equipment.
Read and follow safety information in the Plasma Weld-
ing Console Owner’s Manual and Welding Torch Own-
er’s Manual, as well as the other Owner’s Manuals for
thissystem, toensurethesafeinstallationandoperation
of the Plasma Arc Welding system.
IMPORTANT statements identify special instructions
necessary for the most efficient operation of this equip-
ment.
SECTION 2 – INTRODUCTION
2-1.
DESCRIPTION
welding console and a plasma arc welding torch
2
PWM-3A, MILLER Computer Interface, and MRH or
2
The robot PAW interface panel is a control designed to
be used with a Thermal Dynamics WC 100B plasma
MRV robot system for the Plasma Arc Welding (PAW)
process.
SECTION 3 – INSTALLATION
PAW Interface
Panel
Computer
Interface
Plug PLG21 Connects
To Computer Interface
Receptacle RC8
(See Section 3-7)
Computer Interface
Input Power Receptacle RC11
Location (See Section 3-9 And
Computer Interface Owner’s Manual)
Gas Set/Pilot Arc
Start Push Button
Receptacle RC21
(See Section 3-8)
Receptacle RC20
(See Section 3-8)
ST-800 732
Figure 3-1. PAW Interface Panel
OM-169 510 Page 1
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IMPORTANT: When installing or operating plasma arc
welding equipment, refer to the Plasma Welding Con-
sole Owner’s Manual and Welding Torch Owner’s
Manual for specific precautionary information that ap-
plies to this equipment.
IMPORTANT: All directions, such as left or right, are
with respect to the operator facing the Computer Inter-
face front panel. Retain all hardware removed during
this procedure for reinstallation unless specifically told
otherwise.
1. Remove Computer Interface top cover and left
side panel.
3-1.
FIELD INSTALLATION INSTRUCTIONS FOR
PAW INTERFACE PANEL TO COMPUTER IN-
TERFACE (Figure 3-1 And Figure 3-2)
2. Remove side panel from PAW Interface panel.
3. Install PAW Interface frame onto left side panel of
Computer Interface with sheet metal screws re-
moved in Step 1 (see Figure 3-1).
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before beginning
this installation.
4. Make the following internal connections to the
Computer Interface (see Figure 3-2).
a. Remove jumper link between terminals B and C
on terminal strip 2T.
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
b. Connect lead 26 from the Interface panel to ter-
minal B on terminal strip 2T.
c. Connect lead 60 from the Interface panel to top
mounting screw on filter FL1.
CAUTION: ELECTROSTATIC DISCHARGE
(ESD) can damage circuit boards.
• Put on properly grounded wrist strap BE-
d. Connect green lead from the Interface panel to
the ground stud located directly above terminal
strip 2T.
FORE handling circuit boards.
• Perform work only at a static-safe work area.
INCORRECT INSTALLATION or misaligned
plugs can damage circuit board.
IMPORTANT: Removetheoutsidestarwasherfromthe
ground stud to make room for the green lead terminal.
• Be sure that plugs are properly installed and
e. Remove plug PLG3 from receptacle RC1 on In-
terface Board PC4.
aligned.
EXCESSIVE PRESSURE can break circuit
board.
• Use only minimal pressure and gentle move-
ment when disconnecting or connecting
board plugs and removing or installing board.
f. Connect plug PLG10 from the PAW Interface
panel to Interface Board PC4 receptacle RC1
where plug PLG3 was removed in Step 4e (plug
PLG3 is not connected for this application).
Left Side View Of
Computer Interface
Voltage Control
Board PC1
Motor Control
Board PC2
Interface
Board PC4
Ground Stud
Location
PC4 Switch S1 Location
PC4 Receptacle RC1
Location
Terminal
Strip 2T
Mounting Screw
Location
Filter FL1
Ref. ST-139 887-C
Figure 3-2. Computer Interface Internal Connections
OM-169 510 Page 2
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Robot Arm
Shock Sensor Leads
Insulator
Plate
Shock Sensor
Welding Gun
Body
Torch
Mounting
Bracket
Torch Clamp
Mounting
Bracket
Clamp
ST-800 733
2
Figure 3-3. MRH Shock Sensor Unit Assembly And Installation
Output Hub
Bracket
L-Bracket
Insulating Block
Shock Sensor
Leads
Shock Sensor
Welding Gun
Body
Angle Bracket
Clamp
Angle Bracket
Torch Mounting
Bracket
Torch Clamp
ST-800 778
2
Figure 3-4. MRV Shock Sensor Unit Assembly And Installation
OM-169 510 Page 3
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g. Connect lead 23 from PAW interface panel to
terminal A on terminal strip 2T.
2. Install supplied insulator plate to robot arm with
screws removed in Step 1.
3. Assemble shock sensor, mounting bracket, and
torch clamp as shown in Figure 3-3.
h. Route plug 30/31 from PAW interface panel
throughcenterbaffleincomputerinterface. Dis-
connect plug PLG10 from plug PLG11 and con-
nect PLG 30/31 to PLG 10/11.
4. Install shock sensor unit to the insulator plate
installed in Step 2 with supplied screws.
2
5. Locate switch S1 on Interface Board PC4 (see
Figure 3-2). Remove varnish and potting com-
pound from S1 and place the two DIP switches on
S1 in the following positions:
B. MRV Models
1. If applicable, remove existing shock sensor from
robot arm.
2. Assemble shock sensor, mounting bracket, and
torch clamp as shown in Figure 3-4.
a. S1-1 (Disable Voltage Ramp) in OFF position.
b. S1-2 (Disable Stick Checking) in ON position.
6. Reinstall side panel onto PAW Interface panel.
3. Install shock sensor unit to robot insulating block
with screws removed in Step 1.
3-3.
HIGH-FREQUENCY PROTECTION
TORCH CABLE
FOR
7. Install supplied top cover onto the Computer In-
terface – PAW Interface panel.
The Pilot mode switch on the WC 100B console pro-
vides a selection for the pilot arc mode of operation. If
plasma arc welding is performed with the switch in the
NORMAL position, the optional shield sleeving should
be installed on the torch cable.
3-2.
SHOCK SENSOR UNIT ASSEMBLY AND
INSTALLATION TO ROBOT (Figure 3-3 And
Figure 3-4)
WARNING: ELECTRIC SHOCK can kill.
The optional shield sleeving is for covering the torch
cable to prevent high frequency from interfering with ro-
bot operations.
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before inspecting or
installing.
IMPORTANT: When installing shield sleeving, be sure
end with lead and attached ring terminal is at console
end of the torch cable.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
To install shield sleeving, proceed as follows:
1. Unscrew sleeve from torch head assembly
(see Figure 3-5).
2. Disconnect fittings and remove torch head as-
sembly.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
3. Insert torch cable into shield sleeving at end with
lead and attached ring terminal.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
4. Slide shield sleeving over torch cable until end of
torch cable exits opposite end of shield sleeving.
To assemble and install the shock sensor unit, refer to
Figure 3-3 or Figure 3-4 and proceed as follows:
5. Reconnect fittings from torch cable to torch head
assembly (match color-coded markings).
2
A. MRH Models
6. Checkforcoolantleaksatfittingsbyturningonre-
circulating coolant system. Tighten fittings if nec-
essary.
1. If applicable, remove existing gun/torch and insu-
lator plate from robot arm.
OM-169 510 Page 4
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MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
Sleeve
2
A. MRH Models
1. If applicable, remove the existing wire feed mo-
tor/reed relay mounting bracket and stabilizer
brace from the robot (refer to robot Owner’s
Manual for bracket and brace locations). Rein-
stall the two lifting brackets only (see robot Own-
er’s Manual and Figure 3-10).
Green And Black
Connections
2. If applicable, remove the wire feed hub support
from the robot (refer to robot Owner’s Manual for
hub support location). Install supplied torch cable
support bracket in location where hub support
was secured (see Figure 3-10).
Yellow And Red
Connections
3. The torch cable is enclosed in a black protective
case. Secure torch in torch clamp.
Torch Head
Assembly
IMPORTANT: Before operating, see Section 4 and ro-
bot Owner’s Manual for instructions for absolute offset
adjustment. When doing this procedure, remove the
shield cup and tip from torch and install the supplied
brass tip gauge.
ST-800 836
Figure 3-5. Connections At Torch Head Assembly
4. If applicable, remove the existing clamps sus-
pended from the outlet cable support arm and re-
place them with the two supplied clamps. Route
torch cable through new clamps so there is about
3-1/2 ft. (1 m) of cable between the top of the
shock sensor and the first clamp (see
Figure 3-10).
7. Screw sleeve onto torch head assembly.
8. Secure shield sleeving to torch cable using sup-
plied clamp.
3-4.
TORCH AND TORCH CABLE INSTALLATION
TO ROBOT (Figure 3-3 Thru Figure 3-11)
5. Route torch cable through torch cable support
bracket tray and secure with rubber straps.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before inspecting or
installing.
6. Route remaining end of torch cable to the WC
100B welding panel for internal connections (see
Step 3, Section 3-6B).
7. The supplied high frequency filter box prevents
noise interference at the shock sensor circuit in
the Robot Control. To install the filter, proceed as
follows:
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
OM-169 510 Page 5
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Robot Control
LEFT SIDE
RIGHT SIDE
Blank Cover Plates
(Both Rows)
Blank Cover Plates
S-0782
Figure 3-6. View Of Left And Right Sides Of Robot Control
WARNING: ELECTRIC SHOCK can kill.
e. Place a supplied external star washer over
each screw, and thread screws into mounting
holes in side panel (see Figure 3-7).
ELECTROSTATIC DISCHARGE (ESD) can
damage circuit boards.
• Do not touch live electrical parts.
f. Tighten screws until star washers flatten and
penetrate through paint into metal surface.
• Shut down welding power source and Robot
Control, and disconnect input power employ-
ing lockout/tagging procedures before in-
specting high-frequency filter.
g. Place remaining star washers over threaded
portion of each screw extending out from side
panel inside Robot Control, and install nut on
each screw.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
• Put on properly grounded wrist strap BE-
FORE handling circuit boards or making con-
nections inside Robot Control.
h. Tighten nuts until star washers flatten and
penetrate through paint into metal surface.
i. Reinstall and secure cover onto filter box.
• Transport circuit boards in proper static-
j. Route high-frequency cord inside Robot Con-
trol to Interlock board on left side panel of cabi-
net.
shielding carriers or packages.
• Perform work only at a static-safe work area.
k. Route black and white leads to terminal block
TB1 (see Figure 3-9).
a. Open Robot Control cabinet door using the two
supplied keys, and rotate the power switch han-
dle beyond the OFF position to the Reset/Open
position.
l. Connect black lead to terminal 4 on TB1.
m. Connect white lead to terminal 5 on TB1.
n. Close and secure Robot Control cabinet door.
b. Select and remove a blank cover plate from Ro-
bot Control for installing high-frequency filter
(see Figure 3-6).
o. Disconnect friction terminals on leads of exist-
ing shock sensor cord from shock sensor leads
at welding gun body (see Figure 3-8).
c. Remove screws securing cover to high-fre-
quency filter box, and remove cover from box.
d. Insert cord attached to box through opening in
RobotControlsidepanelwherecoverplatewas
removed.
p. Remove existing shock sensor cord by discon-
necting plug from receptacle on robot.
OM-169 510 Page 6
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Robot Control
Side Panel
Star Washer
Screw
Filter Box
Cord
Nut
ST-152 641
Figure 3-7. Installation Of Securing Hardware For Filter Box
q. Route supplied 35 ft. (10.5 m) shielded shock
sensor cable under the torch cable securing
straps on the outside of the protective casing so
that the two leads with friction connectors are
located near the shock sensor.
r. Connect plug on end of cord to filter box recep-
tacle.
s. Connect friction connectors or plug on remain-
ing end of cord to shock sensor leads or recep-
tacle at shock sensor.
Shock Sensor
Leads
Welding
Gun
Body
Welding
Gun
Body
ST-141 731 / ST-137 518
Figure 3-8. Welding Gun/Torch Shock Sensor Leads
OM-169 510 Page 7
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TB2
Interlock
Board
CN68
CN80
CN69
CN67
Terminal
Block TB1
TB1 (IN)
F2
(1A)
1
ESTOP
CN38
LED301
LED202
2
ESTOP
CN73
CN37
3
LED203
LED204
ESTOP
CN22
LED303
LED302
4
SHOCK
LED205
5
JP301
SHOCK
LED101
LED305
6
INCOM
7
INCOM
TB1
8
L
FC11
LAMP
LED304
F3 (3A)
9
AUTO
JP501
10
TEACH
JP304 JP303 JP302
CN28
11
ST#1
CN33 CN32 CN31
12
ST#2
CN41
LED401
LED402
LED403
13
ST#3
LED602
LED601 LED603
14
STOP
LED404
CN46
JP601 JP602 JP603
LED405
JP306
15
LED406
SV. ON
CN45
16
SV. ON
CN70 CN71 CN72 CN40
JP701
LED501
LED503
LED502
DSW1
SW1
CN47
F4 (2A)
S-0729 / S-0727
Figure 3-9. Function Control Terminal Block TB1 On Interlock Board Inside Robot Control
OM-169 510 Page 8
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Torch
Cable In
Protective Case
Torch Cable
Support Bracket
Outlet Cable
Support Arm
Robot Control
Clamps
High Frequency
Filter Box
DC Welding
Power Source
Shock Sensor
Cable
Lifting
Bracket
Ground
Rod No.1
Ground Cable
Securing Bolt
Location
Shock
Sensor
Cable
Welding Gun
Body
Torch
PAW/Computer
Interface
Braided Ground
Cable
Ground
Rod No.2
Coolant
System
WC 100B
Plasma
Welding
Console
115VAC Input
Power Cord
ST-800 734
2
Figure 3-10. MRH Robot PAW System
2
B. MRV Models
adjustment. Install positioning gauge (universal J-bar
2
2
forMRH orI-barforMRV )ontorobotoutputhubbrack-
et. Remove the shield cup and tip from torch and install
the supplied brass tip gauge.
1. Remove the outlet cable support arm and wire
drive assembly from the robot Axis 3 housing.
2. Install supplied torch cable support bracket onto
robot Axis 3 housing using the existing mounting
holes. Position supplied insulator plate between
bracket and robot, align holes and secure with
supplied hardware (see Figure 3-11).
6. Route remaining end of torch cable to the WC
100B welding panel for internal connections (see
Step 3, Section 3-6B).
7. Install supplied high frequency filter box accord-
2
ing to instructions for MRH (see Section 3-4A).
3. Install supplied servo light box onto robot Axis 3
housing directly in front of torch cable support
bracket using the existing mounting holes (see
Figure 3-7). Position supplied insulator plate be-
tween light box and robot, align holes and secure
with supplied hardware. Connect plug on light
box cord to nearby matching receptacle located
on the side of the Axis 3 housing. The receptacle
on the light box is not used for this application.
3-5.
GROUND
CABLE
CONNECTIONS
(Figure 3-10 And Figure 3-11)
IMPORTANT: If welding power source is equipped with
a plastic case, only one ground cable is necessary for
connecting to robot base.
See Figure 3-10 or Figure 3-11 and install three sup-
plied flat, braided ground cables as follows:
4. Install cable hanger assembly with tool balancer
onto robot Axis 3 housing.
1. Connect one end of the ground cables to the cus-
tomer-supplied ground rod (see robot Owner’s
Manual).
5. The torch cable is enclosed in a black protective
case. Secure torch in torch clamp using supplied
shim. Position torch handle so that there is
approximately 4 in. (96 mm) between the bottom
of the torch clamp and the torch tip. Clamp torch
cable to tool balancer on cable hanger and route
cable through support bracket.
2. Connectremainingendofonegroundcabletoro-
bot base as follows:
a. Locate unused threaded hole on robot base.
b. To ensure good electrical conduction, scrape
away enough paint from around the hole so that
the ground cable terminal will touch bare metal.
IMPORTANT: Before operating, see Section 4 and ro-
bot Owner’s Manual for instructions for absolute offset
c. Attach ground cable terminal to base with sup-
plied 12 mm bolt.
OM-169 510 Page 9
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Cable
Hanger
Servo
Light
Box
Torch Cable
In Protective
Case
Welding
Gun
Body
Robot Control
Torch Cable
Support Bracket
High Frequency
Filter Box
Shock Sensor
Cable
DC Welding
Power
Source
Shock
Sensor
Cable
Ground
Rod No.1
Torch
Braided
Ground
Cable
PAW/Computer
Interface
Ground
Rod No.2
Coolant
System
WC 100B
Plasma
Welding
Console
Braided
Ground
Cable
115VAC Input
Power Cord
ST-800 735-A
2
Figure 3-11. MRV Robot PAW System
3. Route remaining end of another ground cable to
the plasma welding console. Connect ground
cable together with the lead from the shield sleev-
ing after completing internal connections (see
Section 3-8).
To make torch cable internal connections, proceed as
follows:
1. Remove WC 100B wrapper.
2. Route torch cable through strain relief on front
panel.
4. Route remaining end of the last ground cable to
the welding power source. Connect ground cable
to welding power source case unless welding
power source is equipped with a plastic case,
then no connection is necessary.
3. Connect 2 cables and 2 hoses to torch mounting
panel. The color-coded cables and hoses match
the color-coded connectors as follows:
a. Red to red
3-6.
TORCH CABLE INTERNAL CONNECTIONS
TO PLASMA WELDING CONSOLE
(Figure 3-12)
b. Yellow to yellow
c. Black to black
WARNING: ELECTRIC SHOCK can kill.
d. Green to green
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before inspecting or
installing.
4. Reinstall WC 100B wrapper.
3-7.
PAW INTERFACE PANEL – COMPUTER IN-
TERFACE CONNECTION (Figure 3-1,
Figure 3-10, And Figure 3-11)
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
Connect plug PLG21 attached to cord extending from
the PAW Interface panel front panel to weld current relay
receptacle RC8 on the Computer Interface front panel.
Make connections as follows: align keyway, insert plug,
and rotate threaded collar fully clockwise.
MOVING PARTS can cause serious injury.
• Keep away from moving parts.
HOT SURFACES can cause severe burns.
• Allow cooling period before servicing.
OM-169 510 Page 10
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1
2
3
4
5
6
7
8
9
10
11
12 13
14
15
C
O
N
T.
1CR
PILOT
CSR
PSR
PILOT
PLASMA
SHIELD
ST-800 736
Figure 3-12. Terminal Strip TB1 Location Inside WC 100B Console
3-8.
PAW INTERFACE PANEL – WELDING POW-
ER SOURCE – PAW CONSOLE CONNEC-
4. Connect plug on remaining end of cord from re-
ceptacle RC20 to receptacle labeled Remote
Control on front of WC 100B console.
TIONS (Figure 3-1, Figure 3-10,
Figure 3-11)
And
5. Locate supplied cord with matching plug for PAW
interface panel receptacle RC21 and connect
plug to receptacle.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
6. Remove wrapper from WC 100B console. Route
cord to rear of WC 100B console. Insert cord
through strain relief and route end of cord to ter-
minal strip TB1 (see Figure 3-12).
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before inspecting or
installing.
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
7. Remove jumper leads from terminals on TB1 as
follows:
a. 10 and 11
b. 12 and 13
c. 13 and 14
Make connections to units as follows:
8. Connectterminalconnectorsonremainingendof
cord to terminals as follows:
1. Locate supplied cord with matching plug for weld-
ing power source Remote 14 receptacle and con-
nect plug to receptacle.
a. Green lead to terminal 5
b. Orange lead to terminal 6
c. Brown lead to terminal 10
d. Blue lead to terminal 11
e. White lead to terminal 12
f. Black and red leads to terminal 13
OM-169 510 Page 11
2. Connect plug on remaining end of cord from Re-
mote 14 receptacle to receptacle labeled Power
Supply Control on rear of WC 100B console.
3. Locate supplied cord with matching plug for PAW
interface panel receptacle RC20 and connect
plug to receptacle.
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g. Yellow lead to terminal 14.
To purge the plasma torch gas line, proceed as follows:
9. Route cable from welding power source negative
(–) weld output receptacle through opening in
rear of WC 100B console. Route end of cable to
shunt, located where torch cable bus bar is con-
nected, and connect cable to shunt at end oppo-
site from bus bar.
1. Turn on input power to welding power source and
WC 100B console.
2. Place Run/Set switch in the Set position.
3. Press the Gas Set/Pilot Arc Start push button.
10. Route cable from welding power source positive
(+) weld output receptacle and connect end of
cable to workpiece.
IMPORTANT: Gas flow and pilot arc stop when an
Emergency Stop button is pressed.
11. Reinstall WC 100B wrapper.
3-11. REMOTE GAS SET/PILOT ARC START
SWITCH CONNECTIONS
a. Remove paint from around right front screw
hole on right side of wrapper,
b. Connect ring terminal, located on end of lead
from shield sleeving, to wrapper using screw
that secures right front side of wrapper.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before inspecting or
installing.
3-9.
COMPUTER INTERFACE – INPUT POWER
CONNECTIONS (Figure 3-1, Figure 3-10,
And Figure 3-11)
Lockout/tagging procedures consist of padlock-
ing line disconnect switch in open position, re-
moving fuses from fuse box, or shutting off and
red-tagging circuit breaker or other disconnect-
ing device.
Connect plug on supplied input power cord to 14-pin in-
put power receptacle RC11 on the Computer Interface
front panel as follows: align keyway, insert plug, and ro-
tate threaded collar fully clockwise. Connect input pow-
er plug on other end of cord to a 115 volts ac external
supply.
To make remote Gas Set/Pilot Arc Start switch connec-
tions, proceed as follows:
3-10. GAS SET/PILOT ARC START PUSH BUTTON
1. Remove side panel from PAW Interface panel.
IMPORTANT: Thoroughly purge plasma torch gas line
before starting pilot arc.
2. Route one end of a 2-conductor, customer-sup-
plied cord through strain relief on rear of PAW In-
terface panel.
This button starts shielding gas flow when the Run/Set
switch on the WC 100B welding panel is in the Set posi-
tion. When the switch is in Run position, pressing the
button starts shielding gas flow and 5 seconds later
plasma gas flows and the pilot arc ignites.
3. Installing terminal connectors for connecting to
terminal strip 6T onto leads at end of cord inside
PAW Interface panel. Install a normally open mo-
mentary contact switch to remaining end of cord.
WARNING: PLASMA ARC can cause injury.
• Keep away from the torch tip.
4. Connect leads to terminals 6TB and 6TD. Tighten
strain relief.
• Pilot arc can cause burns – keep away from
torch tip when pilot arc is present.
5. Reinstall side panel onto PAW Interface panel.
The pilot arc can be intermittent or continuous
depending on the application. ALWAYS point
torch away from personnel and toward work
when starting the pilot arc or leaving the pilot arc
on continuously.
IMPORTANT: The remote Gas Set/Pilot Arc Start
switch operates the same as the front panel push button
switch (see Section 3-10).
OM-169 510 Page 12
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SECTION 4 – ROBOT PROGRAM MODIFICATIONS
IMPORTANT: The robot program must be changed to
Attaches To Bottom
Of Axis 5 Housing
accommodate plasma arc welding. The program is fac-
tory set to accommodate factory installed plasma arc
welding equipment. The following information pertains
to the robot Owner’s Manual and must be followed when
field installing plasma arc welding equipment.
Indexing Pin
Rod
Scribe around rod below
lower bar to record height.
WARNING: ELECTRIC SHOCK can kill.
• Do not touch live electrical parts.
• Shut down robot and welding power source,
and disconnect input power employing lock-
out/tagging procedures before inspecting or
installing.
Tighten screw and setscrew
when torch tip is touching
lower bar.
Scribe Marks
Screw
Lockout/tagging procedures consist of pad-
locking line disconnect switch in open position,
removing fuses from fuse box, or shutting off
and red-tagging circuit breaker or other discon-
necting device.
Scribe marks where
torch tip touches
lower bar.
Setscrew
ST-146 220
Lower Bar
Figure 4-1. Scribe Marks on Universal J-Bar
4-1.
SETTING UP PLASMA (NON-STANDARD)
TORCH FOR MRH ROBOT (Figure 4-1)
2
5. Position lower bar of universal J-bar so that it
touches torch tip gauge, and scribe marks on the
J-bar to indicate exact torch position as shown in
Figure 4-1.
It is necessary to use the robot Owner’s Manual in addi-
tion to this manual to complete the proper installation of
the torch.
6. RemoveuniversalJ-bar, andretainforfutureuse.
IMPORTANT: Follow entire procedure in presented or-
der.
2
4-2.
SETTING UP PLASMA TORCH FOR MRV
ROBOT (Figure 4-1)
1. Check System Data settings against the test
sheet supplied with the unit. These should match
before beginning installation.
The plasma torch does not require any changes to data
in PARMTER/SYSTEM/TOOL PARAMETER. The stan-
dard I-bar is used for adjusting torch position and for
position recovery after a robot crash. Mount plasma arc
welding torch, install tip gauge, and follow mounting ad-
justment procedures according to instructions in Sec-
tion 4 – System Set Up in the robot Owner’s Manual.
Loosen torch clamp setscrews and position torch so that
tip gauge touches I-bar reference point. Retighten set-
screw.
2. Mount plasma arc welding torch according to
Section 3-3 of this manual. Make sure that sup-
plied brass tip gauge and holder have been
installed on torch.
3. Do tool center point adjustment according to Sec-
tion 4.6 of the robot Owner’s Manual.
4. The universal J-bar is included to record exact
torch position so that it is possible to recover posi-
tion in case of a robot crash. Install universal J-
bar as follows:
After completing torch adjustment procedure, remove
tip gauge and reinstall cup onto end of torch.
4-3.
MARKING POSITION OF TORCH HEAD AS-
SEMBLY (Figure 4-2)
a. Remove 2 screws and cover plate from bottom
of Axis 5 gear housing.
When the mounting adjustment procedure is complete,
place scribe marks on the torch head assembly and
sleeve to mark the torch head assembly position for fu-
ture alignment adjustments.
b. Install universal J-bar onto Axis 5 by aligning in-
dex pin with hole in housing, and securing with
supplied screws.
OM-169 510 Page 13
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2
2
MRV Robot
MRH Robot
Robot
Arm
Sleeve
Robot
Arm
Sleeve
Scribe
Marks
Scribe
Marks
Torch
Head
Assembly
Torch
Head
Assembly
ST-800 747-A
Figure 4-2. Marking Position Of Torch Head Assembly
2
2
4-4.
SYSTEM SETUP FOR MRH AND MRV WITH C2 ROBOT CONTROL
Set welding power source specifications in user parameters for the Plasma Arc Welding (PAW) process according to
the following instructions.
1. Turn on Robot Control input power by placing the power switch handle on the Robot Control cabinet door in the
ON position, and the following displays will appear as shown:
W E L C O M E
C O O P E R A T I V E
E L E C T R I C
D I A G N O S I S
T O
D I A G N O S I S
M I L L E R
M I L L E R
C O N T R O L
C o .
M f g .
S T A R T
’ 9 2 – 0 7 – 3 1
0 8 : 3 0
W E L C O M E
T O
D I A G N O S I S
M I L L E R
C O O P E R A T I V E
C O N T R O L
S T E P
1 , 2 ,
O F
3 ,
I N I T I A L
4 , 5 ,
D I A G N O S I S
’ 9 2 – 0 7 – 3 1
0 8 : 3 0
OM-169 510 Page 14
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T E A C H
S E R V O
T E A C H
O F F
E D I T
F I L E
A L L O T
L O C K
>
2. Press the FUNCTION APPLICATION
key for additional functions to appear on the display.
P A R M T E R
3. Press the F1
C H E C K
M A N A G E
S Y S . S E T
M E M O R Y
>
F1
key for the PARMTER function.
S E L E C T
T Y P E
O F
P A R A M E T E R
T E A C H
S E R V O
S Y S T E M
M O D E
B Y
F U N C T I O N
K E Y
O F F
S W I T C H
W E L D
I / O
A U T O
>
4. Press the FUNCTION APPLICATION
key for additional functions to appear on the display.
S E L E C T
T Y P E
O F
P A R A M E T E R
T E A C H
S E R V O
M O D E
B Y F U N C T I O N
K E Y
O F F
S E N S O R
5. Press F4
A R C – S
T O U C H – S
W – C H A R A
S – D A T A
>
F4
key for the W–CHARA function to set welding characteristics.
OM-169 510 Page 15
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A X I S
M L 4
P O W E R
S O U R C E
W I R E
T E A C H
G M A W
. 0 3 5
. 0 3 5
. 0 3 5
. 0 3 5
. 0 4 5
. 0 6 2
. 0 6 2
. 0 6 2
. 0 6 2
S Y N E R G I C
G T A W – 1 0 0
G T A W – 3 0 0
. 0 4 5
. 0 4 5
. 0 4 5
S E R V O
O F F
U S E R
M O D I F Y
R E G I S T E R
S C _ E D I T
R E G I S T
+
_
6. Use the INCREMENT
or DECREMENT
key and forward
or back
DISPLAY SE-
LECT key to select GTAW-300 by setting a wire size selection.
A X I S
M L 4
P O W E R
S O U R C E
W I R E
T E A C H
G M A W
. 0 3 5
. 0 3 5
. 0 3 5
. 0 3 5
. 0 4 5
. 0 6 2
. 0 6 2
. 0 6 2
. 0 6 2
S Y N E R G I C
G T A W – 1 0 0
G T A W – 3 0 0
. 0 4 5
. 0 4 5
. 0 4 5
S E R V O
O F F
U S E R
M O D I F Y
R E G I S T E R
S C _ E D I T
R E G I S T
F1
7. Press the F1
key for the REGIST function to register the change in Robot Control memory.
S E L E C T
T Y P E
O F
P A R A M E T E R
T E A C H
S E R V O
S E N S O R
M O D E
B Y F U N C T I O N
K E Y
O F F
A R C – S
T O U C H – S
W – C H A R A
S – D A T A
>
F4
8. To check settings, press the F4
key for the W–CHARA function.
OM-169 510 Page 16
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A X I S
M L 4
P O W E R
S O U R C E
W I R E
T E A C H
G M A W
. 0 3 5
. 0 3 5
. 0 3 5
. 0 3 5
. 0 4 5
. 0 6 2
. 0 6 2
. 0 6 2
. 0 6 2
S Y N E R G I C
G T A W – 1 0 0
G T A W – 3 0 0
. 0 4 5
. 0 4 5
. 0 4 5
S E R V O
O F F
U S E R
M O D I F Y
R E G I S T E R
S C _ E D I T
R E G I S T
F2
9. Press the F2
key to select the MODIFY function.
A X I S
M L 4
R A T I N G
O F
P O W E R
S O U R C E
T E A C H
$ W T B D 3 1
T Y P E
R A T I N G
S E P A .
S Y N E R .
T I G
C U R R E N T
2 0 0 A
2 5 6 i .
S E R V O
O F F
W – F E E D E R
R A T I N G
P U S H
R E C O R D
A F T E R
S E T T I N G
+
_
10. Use the INCREMENT
or DECREMENT
key to select RATING CURRENT parameter.
A X I S
M L 4
R A T I N G
O F
P O W E R
S O U R C E
T E A C H
$ W T B D 3 1
T Y P E
R A T I N G
S E P A .
S Y N E R .
T I G
C U R R E N T
2 0 0 A
2 5 6 i .
S E R V O
O F F
W – F E E D E R
R A T I N G
P U S H
R E C O R D
A F T E R
S E T T I N G
11. Use the numerical keys to amperage to the maximum current output of the welding power source.
OM-169 510 Page 17
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A X I S
M L 4
R A T I N G
O F
P O W E R
S O U R C E
T E A C H
$ W T B D 3 1
T Y P E
R A T I N G
S E P A .
S Y N E R .
T I G
C U R R E N T
3 0 0 A
2 5 6 i
S E R V O
O F F
W – F E E D E R
R A T I N G
.
P U S H
R E C O R D
A F T E R
S E T T I N G
RECORD
12. Press the RECORD
key.
A X I S
M L 4
D I S P .
1 . 5 0 A
R E F .
1 . 5 V
4 . 5 V
6 . 0 V
7 . 5 V
1 0 . 0 V
D I S P .
R E F .
2 . 0 V
4 . 0 V
6 . 0 V
8 . 0 V
1 0 . 0 V
T E A C H
5 0 i
1 0 2 i
1 5 3 i
2 0 5 i
2 5 6 i
.
.
.
.
.
2 . 1 5 0 A
3 . 2 0 0 A
4 . 2 5 0 A
5 . 3 0 0 A
S E R V O
O F F
+
_
13. Use the INCREMENT
or DECREMENT
key and forward
or back
DISPLAY SE-
LECT key to change the scaling of the amperage and reference voltage.
A X I S
M L 4
D I S P .
R E F .
0 . 0 V
2 . 0 V
5 . 0 V
8 . 0 V
1 0 . 0 V
D I S P .
R E F .
2 . 0 V
4 . 0 V
6 . 0 V
8 . 0 V
1 0 . 0 V
T E A C H
1 .
2 .
5 A
5 0 i
1 0 2 i
1 5 3 i
2 0 5 i
2 5 6 i
.
.
.
.
.
7 9 A
3 . 1 9 0 A
4 . 3 0 1 A
5 . 3 7 5 A
S E R V O
O F F
OM-169 510 Page 18
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RECORD
14. Press the RECORD
key.
S E L E C T
T Y P E
O F
P A R A M E T E R
T E A C H
S E R V O
S E N S O R
M O D E
B Y F U N C T I O N
K E Y
O F F
A R C – S
T O U C H – S
W – C H A R A
S – D A T A
>
15. Check settings of weld characteristics as follows:
F4
a. Press the F4
key to select the W–CHARA function.
A X I S
M L 4
P O W E R
S O U R C E
W I R E
T E A C H
G M A W
. 0 3 5
. 0 3 5
. 0 3 5
. 0 3 5
. 0 4 5
. 0 4 5
. 0 4 5
. 0 4 5
. 0 6 2
. 0 6 2
. 0 6 2
. 0 6 2
S Y N E R G I C
G T A W – 1 0 0
G T A W – 3 0 0
S E R V O
O F F
U S E R
M O D I F Y
R E G I S T E R
S C _ E D I T
R E G I S T
b. Press the F2
F2
key to select the MODIFY function.
A X I S
M L 4
R A T I N G
O F
P O W E R
S O U R C E
T E A C H
$ W T B D 3 1
T Y P E
R A T I N G
W – F E E D E R
S E P A .
C U R R E N T
R A T I N G
S Y N E R .
T I G
3 0 0 A
2 5 6 i
S E R V O
O F F
.
P U S H
R E C O R D
A F T E R
S E T T I N G
RECORD
c. Press the RECORD
key.
OM-169 510 Page 19
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A X I S
M L 4
D I S P .
R E F .
0 . 0 V
2 . 0 V
5 . 0 V
8 . 0 V
1 0 . 0 V
D I S P .
R E F .
2 . 0 V
4 . 0 V
6 . 0 V
8 . 0 V
1 0 . 0 V
T E A C H
1 .
2 .
5 A
5 0 i
1 0 2 i
1 5 3 i
2 0 5 i
2 5 6 i
.
.
.
.
.
7 9 A
3 . 1 9 0 A
4 . 3 0 1 A
5 . 3 7 5 A
S E R V O
O F F
RESET
16. Press the RESET
key.
S E L E C T
T Y P E
O F
P A R A M E T E R
T E A C H
S E R V O
S E N S O R
M O D E
B Y
F U N C T I O N
K E Y
O F F
A R C – S
T O U C H – S
W – C H A R A
S – D A T A
>
TEACH
MODE
17. Press the TEACH MODE
key to return to the beginning of the Teach mode.
T E A C H
S E R V O
T E A C H
O F F
E D I T
F I L E
A L L O T
L O C K
>
OM-169 510 Page 20
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SECTION 5 – ELECTRICAL DIAGRAMS
SC-169 456
Figure 5-1. Circuit Diagram For Robot PAW System
OM-169 510 Page 21
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SB-169 458
Figure 5-2. Circuit Diagram For Robot PAW Interface Panel
SB-169 459-A
Figure 5-3. Wiring Diagram For Robot PAW Interface Panel
OM-169 510 Page 22
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SA-146 608-A
Figure 5-4. Circuit Diagram For High-Frequency Filter
SA-146 609-B
Figure 5-5. Wiring Diagram For High-Frequency Filter
OM-169 510 Page 23
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SECTION 6 – HF IN PLASMA ARC WELDING
WARNING
mod6.2* 5/94
HIGH-FREQUENCYRADIATIONcaninterferewithradionavigation, safetyservices, computers,
and communications equipment.
• Have only qualified person familiar with electronic equipment perform this installation.
• The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the
installation.
• If notified by the FCC about interference, stop using the equipment at once.
• Have the installation regularly checked and maintained.
• Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and
shielding as shown in Figure 6-3 to minimize the possibility of interference.
1
1
2
Plasma Arc Torch
High-Frequency Voltage
Used inside torch to ionize gap
between electrode and tip to help
start the pilot arc.
2 High
Frequency (HF)
3
4
5
6
Electrode
Pilot Arc
Tip
6
3
5
Shield Cup
Plasma Arc Welding (PAW)
4
Ref. S-0753
Figure 6-1. High Frequency In Plasma Arc Welding (PAW)
1
Sources Of Direct
High-Frequency Radiation
Welding Zone
High-frequency source (Plasma
Arc Welding power source),
cables, torch, work clamp, work-
piece, and work table.
3
50 ft
(15 m)
3
2
Sources Of Conduction Of
High Frequency
3
Input power cable, line disconnect
device, and input supply wiring.
3
2
3
Sources Of Reradiation Of
High Frequency
1
Ungrounded metal objects, light-
ing, wiring, water pipe and fixtures,
external phone and power lines.
2
1
1
S-0754
Figure 6-2. Sources Of High-Frequency Radiation From Incorrect Installation
OM-169 510 Page 24
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7
Welding Zone
3
50 ft
(15 m)
50 ft
(15 m)
5
1
6
2
9
4
9
Ground All
Metal Objects
And All Wiring
In Welding Zone
Using #12 AWG Wire
Ground
Workpiece
If Required
By Codes
8
Nonmetal Building
9
9
11
Metal Building
10
S-0755
1
Plasma Arc Welding Power Source
5
Conduit Joint Bonding And Grounding
9
Grounding Rod
Electrically join (bond) all conduit sections
usingcopperstrapsorbraidedwire.Ground
conduit every 50 ft (15 m).
Ground metal machine case, line discon-
nect device, input supply, and workpiece (if
required).
Consult the National Electrical Code for
specifications.
6
Water Pipe And Fixtures
Ground water pipe every 50 ft (15 m).
External Power Or Telephone Lines
10 Windows And Doorways
2
Center Point Of Welding Zone
Midpoint between high-frequency source
and welding torch.
Cover all windows and doorways with
grounded copper screen of not more than
1/4 in (6.4 mm) mesh.
7
Locate high-frequency source at least 50 ft
(15 m) away from power and phone lines.
3
Welding Zone
A circle 50 ft (15 m) from center point in all
directions.
8
Metal Building Panel Bonding
Methods
11 Overhead Door Track
Ground the track.
Bolt or weld building panels together, install
copper straps or braided wire across
seams, and ground frame.
4
Torch And Work Cables
Keep cables close together.
Figure 6-3. Correct Installation
OM-169 510 Page 25
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SECTION 7 – PARTS LIST
Dia.
Mkgs.
Part
No.
Description
Quantity
Spectrum Interface
. CR10,11 . 052 964 . . RELAY, encl 24VDC DPDT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . D1 . . . . 169 465 . . DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . D2 . . . . 169 467 . . DIODE, w/leads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PB1 . . . 113 333 . . SWITCH, PB MC NO SPST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PC10 . . 140 510 . . CIRCUIT CARD, RF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 110 375 . . STAND-OFF SUPPORT, PC card No. 6 screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. PLG10 . . 115 094 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. PLG11 . . 115 092 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. PLG12 . . 115 093 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. PLG21 . . 047 544 . . CONNECTOR, circ 4 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. PLG30 . . 131 054 . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. PLG31 . . 135 635 . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 114 656 . . . . CONNECTOR, rect pin 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 039 828 . . CONNECTOR, circ clamp str rlf sz 14-14S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 049 455 . . CABLE, port No. 18 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3ft
. . . . . . . . . . . 139 040 . . BUSHING, strain relief .231/.394 ID x .733mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. RC20,26 . 145 706 . . CIRCUIT CARD/CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . RC21 . . 077 175 . . CONNECTOR, circ 11 pin sz 20 rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . TD1 . . . 169 460 . . TIMER, w/resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6T . . . . 038 839 . . BLOCK, term 20A 5P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 169 462 . . CASE SECTION, front/bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 139 454 . . PANEL, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . . NAMEPLATE, (order by model and serial number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 241 . . CABLE, port No. 18 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35ft
. . . . . . . . . . . 146 212 . . CONNECTOR, circ 10 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 138 033 . . CONNECTOR, circ clamp str rlf sz 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 073 516 . . CONNECTOR, circ 11 skt plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 116 964 . . CONNECTOR, circ clamp str rlf sz 20-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 097 426 . . CABLE, shld No. 18ga 10/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ft
. . . . . . . . . . . 169 455 . . CABLE, interconnecting 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 141 162 . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 731 . . . . . . CONNECTOR, circ pin push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . 079 739 . . . . . . CONNECTOR, circ clamp str rlf sz 17-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 110 015 . . . . CABLE, port No. 18 7/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ft
. . . . . . . . . . . 048 598 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 079 534 . . . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
. . . . . . . . . . . 079 739 . . . . CONNECTOR, circ clamp str rlf sz 17-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 169 464 . . CABLE, interconnecting 15ft (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 047 636 . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 079 535 . . . . . . CONNECTOR, circ pin push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . 079 739 . . . . CONNECTOR, circ clamp str rlf sz 17-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 120 104 . . . . CABLE, shld No. 18ga 6/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15ft
. . . . . . . . . . . 146 211 . . . . CONNECTOR, circ 8 pin plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 073 296 . . . . CONNECTOR, circ clamp str rlf sz 20-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 141 224 . . CABLE, pwr interface (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 152 370 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 079 534 . . . . . . CONNECTOR, circ skt push-in 14-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
. . . . . . . . . . . 143 922 . . . . . . CONNECTOR, circ clamp str rlf sz 17-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 604 825 . . . . CABLE, port No. 18 3/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16ft
. . . . . . . . . . . 073 690 . . . . PLUG, str grd armd 2P3W 15A 125V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 073 476 . . CLAMP, strap rbr 5 holes .375 wide x 4.625 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OM-169 510 Page 26
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Dia.
Mkgs.
Part
No.
Description
Quantity
Spectrum Interface (Continued)
. . . . . . . . . . . 169 452 . . SHOCK SENSOR, w/cover (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 602 173 . . . . SCREW, set stl sch 10-32 x .250 cup point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 141 564 . . CABLE, grd machine to rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 146 002 . . TORCH GAUGE, universal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 169 454 . . TIP GAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . ♦171 042 . . SHIELD, plasma welding torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 143 352 . . CLAMP, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . 169 453 . . BRACKET, mtg torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 157 173 . . HOLDER, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 141 409 . . INSULATOR, plate torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 141 449 . . PANEL, side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . +139 465 . . COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 464 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 602 969 . . PLUG, protective No. 6 plastic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 146 696 . . HF FILTER BOX, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . PC1 . . . 140 510 . . . . CIRCUIT CARD, RF filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 201 . . . . STAND-OFF SUPPORT, PC card .312/.375 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. PLG10 . . 115 092 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
. PLG20 . . 115 093 . . . . CONNECTOR & SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 113 746 . . . . . . CONNECTOR, rect skt 24-18ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . . 600 340 . . . . CABLE, port No. 16 2/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4ft
. . . RC1 . . . 139 268 . . . . CONNECTOR, circ 10skt rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 148 104 . . . . CASE SECTION, front/bottom/rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 148 103 . . . . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 139 040 . . . . BUSHING, strain relief .231/.394 ID x .733mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 107 983 . . . . BLANK, snap-in nyl .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . 148 943 . . LIGHT BOX, servo (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 171 . . . . CABLE, shock sensor and lights (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . RC1 . . . 048 282 . . . . . . CONNECTOR w/SOCKETS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 079 534 . . . . . . . CONNECTOR, circ skt push-in 14-18ga Amp 66358-6 . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . 604 571 . . . . . . CABLE, port No. 18 4/c (order by ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1ft
. . . . . . . . . . . 010 116 . . . . . . GROMMET, rbr .375 ID x .500mtg hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . PLG1 . . 134 860 . . . . . . CONNECTOR & PINS, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 184 . . . . . . . CONNECTOR, rect pin 20-16ga JST SLM-41T-1.3E . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . . 117 160 . . . . . . PILOT LAMP, (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . *115 276 . . . . . . . BULB, LED red 28V min bayonet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 144 629 . . . . . . BRACKET, shock sensor and lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 518 . . HANGER, cable assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 529 . . INSULATOR, cable hanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 159 599 . . SUPPORT, cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 149 442 . . BRACKET, mtg torch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 135 090 . . INSULATING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 170 395 . . BLOCK, angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 170 396 . . CLAMP, block angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 170 397 . . BRACKET, offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 137 063 . . SPRING, ext .625 OD x .062 wire x 4.500 lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 119 622 . . CABLE CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . 134 011 . . INSULATOR, bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
*Recommended Spare Parts.
♦OPTIONAL
BE SURE TO PROVIDE MODEL AND SERIAL NUMBER WHEN ORDERING REPLACEMENT PARTS.
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Notes
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