PW-455R Analog Interface Instruction For Robots

PW-455R Analog Interface Instruction Guide
PART A ...............................................................................................................................................4
1
General Description......................................................................................................................4
Recommended Processes and Equipment ....................................................................................4

2.1
2.2
2.3
2.4
Design Features ............................................................................................................................5

3.1
3.2
3.3
3.4
Recommended Processes ......................................................................................................4

Process Limitations ...............................................................................................................4
Recommended Equipment / Interface ...................................................................................4
Equipment Limitations..........................................................................................................5
Platform Commonalties.........................................................................................................5
Operational Features and Controls........................................................................................5
Specifications ........................................................................................................................6
Regulatory Requirements as Required for Market................................................................6
Construction Information .............................................................................................................6

4.1
4.2
Wiring Information ...............................................................................................................6

Software Requirements: ........................................................................................................9
PART B .............................................................................................................................................10
1.
Installation ..................................................................................................................................10
1.1
1.2
1.3
1.4
1.5
1.6
Operating Instructions ................................................................................................................11

2.1
2.2
2.3
2.4
2.5
Interface Description ...........................................................................................................26

Robot Signal Descriptions...................................................................................................27
Power Wave Circuit Descriptions .......................................................................................29
Electrical Characteristics.....................................................................................................31
Robot Controller Setup .......................................................................................................34
PW-455R Analog Interface Cable Definition .....................................................................35
Maintenance ...............................................................................................................................36
4.1
4.2
4.3
4.4
Startup Sequence.................................................................................................................11
Display Operation ...............................................................................................................11
Local Procedure \ Weld Parameter Set-Up (MSP - Mode Select Panel) ............................12
Special Access Modes (Through MSP - Mode Select Panel) .............................................17
Making a Weld....................................................................................................................18
Application Information .............................................................................................................26

3.1
3.2
3.3
3.4
3.5
3.6
Non-Standard Safety Information .......................................................................................10

Location...............................................................................................................................10
Input and Grounding Connections ......................................................................................10
Output Cables, Connections and Limitations......................................................................10
System Configuration..........................................................................................................11
I/O Module DeviceNet Configuration.................................................................................11
Non-Standard Safety Information .......................................................................................36

Routine Maintenance ..........................................................................................................36
Periodic Maintenance..........................................................................................................36
Machine Calibration Specification......................................................................................36
Troubleshooting Guide...............................................................................................................38
5.1
5.2
5.3
5.4
I/O Run (Rn) & IO Err (Er) Status LED's on DeviceNet Coupler ......................................38
MS (Module Status) Red & Green Status LED's on DeviceNet Coupler ...........................38
NS (Network Status) Red & Green Status LED's on DeviceNet Coupler ..........................39
Digital I/O Status Indicators................................................................................................40
2
5.5
6
Troubleshooting Chart ........................................................................................................41
Component location and replacement parts list..........................................................................42

6.1
Bill of Materials (L10412-18) .............................................................................................42
PART A
1
GENERAL DESCRIPTION
The PW455R Analog Interface is designed to emulate the PW450 Robotic Interface. It is
primarily intended for use with a Fanuc robot using ArcTool software (V1.30P or higher)
with optional Touch Sensing and Through Arc Seam Tracking (TAST). The interface
responds to all of the ArcTool welding inputs and outputs except wire fault and wire stick
alarm. All of the circuitry for Touch Sensing is internal to the Powerwave; no external
power supply is required. The current signal for TAST is supplied by the Powerwave
analog output. No external current sensor is required. The interface does not control wire
feed speed and welding voltage independently. Rather, the Powerwave will always operate
in a synergic mode and the welding voltage is programmed as a function of the wire feed
speed. ArcTool software was designed to control wire feed speed and voltage
independently. Since the Powerwave system uses an arc length trim, the voltage cannot
be directly controlled. The welding voltage setting in the robot controller is interpreted by
the Powerwave as a trim setting. Any ArcTool function which tries to set the voltage to
zero and control the wire feed speed is actually only setting the arc length trim to the
minimum. Refer to the Operation section for a complete description of arc length trim.
Any function that tries to set the wire feed speed to zero and control the voltage is limited
by the minimum speed of the selected process. (Note: This phenomenon will occur as a
truncation of the speed, rather than a re-scaling based on the process.)
Note:
The PW455R Analog Interface is compatible with the PW455R, PW455M, and PW655M.
The following text details the PW455R application, but applies to all machines unless
otherwise noted.
RECOMMENDED PROCESSES AND EQUIPMENT
2.1
Recommended Processes
Any synergic process currently available to the PW455R platform.
2.2
Process Limitations
As noted in the General Description, the analog inputs are scaled for minimum to
maximum WFS and TRIM. Therefore, without re-scaling, only synergic processes are
compatible with this interface. This is consistent with the PW450 analog interface
operation.
2.3
Recommended Equipment / Interface

This Analog Interface is intended for use with the PW455R, PW455M and PW655M
welding machines. It provides a method to interface these machines to equipment that
does not support their preferred digital interface platform (i.e. ArcLink, Device Net,
Ethernet). For commonality, the interface has been defined to emulate the PW450 Robotic
Interface, and as a result does limit some of the high-end features of the equipment.
2.4
Equipment Limitations
The use of this interface is limited to the PW455R, PW455M, and PW655M power
sources. Further, due to reasons sighted previously, it is currently limited to the use of
fully synergic processes only.
Additionally, it requires that the machine be equipped with a DeviceNet Gateway PCBD
(Standard in the PW455R, Optional in the PW455M & PW655M). Completing the
installation requires reprogramming the board to support the Analog Interface hardware.
Once configured to support the Analog Interface, all other DeviceNet and extended
functions are disabled.
DESIGN FEATURES
3.1
Platform Commonalties
The PW455R Analog Interface is designed for use with the PW455R power source family.
It emulates the PW450R Robotic Interface in function, and utilizes the same 37 pin MStype connector. Therefore, it allows the PW455R to serve as a direct replacement in
PW450R applications.
3.2
Operational Features and Controls

The primary function of the PW455R Analog Interface is to provide a means to connect the
PW455R family of power sources to equipment that does not support the preferred digital
interface platform (i.e. ArcLink, Device Net, Ethernet). The interface is equipped with
analog, and discreet digital I/O as noted below
Input Signals
TRIM ( 010V Analog signal )
WFS ( 010V Analog signal)
Arc Start (Trigger)
Gas Flow
Touch Sense Command
Cold Inch FWD
Cold Inch REV
Dual Procedure
Output Signals
Voltage ( 010V Analog signal)
Current ( 010V Analog signal)
Arc Detect
Gas Fault
Touch Sense Detect
Short Detect
Water Fault
Abnormal Operation / Power Fault)
In addition, the interface includes a MSP style option panel used to set the weld parameters
not controlled via the I/O. These parameters include the Weld Mode, Run In, Arc Control,
Burnback, and Cold Inch WFS functions. A method has also been included by which the
dual procedure set up function can be executed, and the active procedure can be displayed.
For additional information regarding this option panel, see Part B of this report.
3.3
Specifications
Input Voltage
Input Current (max. with all I/O activated)
Digital Inputs (low side switching)
Voff (Logic 0)
Von (Logic 1)
Input Impedance
Digital Outputs (low side switching)
Von (typical on state saturation)
IL (max. load)
Analog Inputs
Range
Maximum Input
Analog Outputs
Maximum Range
Operating Temperature
Net Weight
Dimensions
Agency Approvals
3.4
24VDC 10%
< 300mA
Type: Sourcing
15 to 30 VDC
-3 to 5 VDC
4.8kW (typ.)
Type: Sinking
0 1.0 VDC
0.5 AMPS (short circuit protected)
0 10 VDC
35 VDC
0 10 VDC
0C to +40C
N/A
N/A
As Required by Application
Regulatory Requirements as Required for Market

Due to the flexible nature of this product, regulatory requirements and approvals will be
determined, and sought as required by the application.
CONSTRUCTION INFORMATION
4.1
Wiring Information
The following wiring information is provided as a guide for assembly of the interface. The
37 pin Amphenol to I/O block connections as well as the miscellaneous I/O block
connections are listed in chart form. Where applicable PW450R lead numbering scheme is
used for consistency. A complete wiring diagram has also been included detailing the
remaining connections from the Gateway PC Board to the interface.
4.1.1
Wiring from 37 Pin Input Connector to Wago I/O Block
Module
Module
Contact
PW-455 Analog Interface

Signal Description
306
306
408 (#1)
6
7
1
24V Input
Common
Arc Start
408 (#1)
408 (#1)
408 (#1)
408 (#2)
408 (#2)
408 (#2)
516
516
516
5
4
8
1
5
4
1
5
4
Gas Purge
Touch Sense
Cold Inch Forward
Cold Inch Reverse
Dual Procedure Select
NOT REQUIRED
Touch Sensed
Arc Detect
Gas Fault
Lead #
37 Pin
Amphenol
(MS Style
28-21P)
534
535
518
518A
520
529
524
525
523
546
533
519
521
r
a
R
C
S
T
U
V
X
Z
c
d
e
Fanuc Signal Name (Desc.) / Type
+24 VDC (Robot Power)

O VDC (Robot Common)
WDO1 (Weld Cycle Start) / Output
Motoman Trigger Connection / Output
WDO2 (Gas Valve On) / Output
WDO3 (Touch Sense Command) / Output
WDO4 (Feed Forward) / Output
WDO5 (Feed Reverse) / Output
WDO7 (Dual Procedure Select) / Output
WDO8 (Spare) / Output
WDI1 (Touch Sense Detect) / Input
WDI2 (Arc Detect) / Input
WDI3 (Gas Shortage) / Input
516
467
467
467
467
550
550
550
550
509
509
509
4.1.2
8
1
--5
7
1
--5
--1
5
6
Water Fault
Trim Input
NOT REQUIRED
WFS Input
Analog Common (Isolated)
Voltage Feedback
NOT REQUIRED
Current Feedback
NOT REQUIRED
Inverter Fault
Wire Stick +
Wire Stick (Common)
528
530
--531
536
515
--516
--517
526
527
g
A
B
E
F
J
K
L
M
h
N
P
WDI5 (Water Shortage) / Input

DACH1 (Weld Volts CMD) / Analog Out
COMDA1 (Common) / Analog Out
DACH2 (Weld WFS CMD) / Analog Out
COMDA2 (Common) / Analog Out
ADCH1(Weld Voltage) / Analog In
COMAD1 (Common) / Analog In
ADCH2 (Weld Amps) / Analog In
COMAD2 (Common) / Analog In
WDI6 (Pwr Supply Fail) / Input
WDI+ (+Wire Stick Detect) / Input
WDI- (-Wire Stick Detect) / Input
Additional Wiring Information
Item
Misc. Wire for Wago I/O Block
M19902-1 (BOM Item 16 )
Misc. Wire (+24V)
Misc. Wire (COMMON)
Misc. Wire (CAN High)
Misc. Wire (CAN Low)
Terminating Resistor (BOM Item 19)
From
Pin 1 on module 306
Pin 5 on module 306
Pin 6 on module 306
Pin 3 on module 306
Pin 3 on module 516
Pin 7 on module 516
DeviceNet Gateway PCB (J71)
DeviceNet Gateway PCB (J75-5)
CAN-H on the DeviceNet Connector
To
Pin 2 on module 306
Pin 3 on module 306
V+ on the DeviceNet Connector
V- on the DeviceNet Connector
Pin 2 on module 509
Pin 7 on module 550
MSP Style Panel
V+ on the DeviceNet Connector
V- on the DeviceNet Connector
CAN-H on the DeviceNet Connector
CAN-L on the DeviceNet Connector
CAN-L on the DeviceNet Connector
4.1.3
System Wiring Diagram
Dual Display
Gateway PC Board
(Device Net)
-or(Ethernet)
MSP3 PANEL
(signals feed through)
(+15V) J71-1
(+5 SPI) J71-2
(/SS) J71-3
(CS1) J71-4
(CS2) J71-5
(CS3) J71-6
(MISO) J71-7
(SCK) J71-8
(MOSI) J71-9
(Common/Shield) J71-10
9 Conductor Shielded Cable

(LECo. M19902-1)
Fieldbus connector. Series 231 (MCS)
(supplied w/ 750-306 DeviceNet coupler)
**
(DN+) J75-5
(BUSS_H) J75-1
+24VDC
CAN HIGH
(BUSS_L) J75-4
(DN_COM) J75-2
CAN LOW
COMMON
WAGO I/O BLOCK

(750 Series)
LECo. S24017-6 connector
121W Terminating Resistor

37 Pin Amphenol
(MS Style 28-21P)
Wiring Per Tables
4.2
Software Requirements:
The Gateway PC Board will need to be reprogrammed to enable the analog interface
functionality. The software required would depend on the Gateway PC Board version
installed in the power source. In general, the PC Board assembly number defines both the
hardware and the software. Therefore by definition, the reprogrammed board will become
a new part number, and will have to be identified as such with a new I.D. sticker on the
outside of the PC board tray. The base and dash numbers (i.e. Sxxxxx-x) define the entire
assembly for support and parts order issues. Software only is defined as the complete
assembly number with a "/S" suffix (i.e. Sxxxxx-x/S).
The base software numbers are defined in the parts list, and categorized by the type of
Gateway PC Board they are compatible with. The latest dash number software should
always be used, as it supersedes all previous versions.
PART B
1. INSTALLATION
1.1
Non-Standard Safety Information

WARNING! ELECTRIC SHOCK CAN KILL.
ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS

INSTALLATION.
TURN OFF INPUT POWER TO THE POWER SOURCE AT THE

DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THIS
EQUIPMENT. TURN OFF THE INPUT POWER TO ANY OTHER
EQUIPMENT CONNECTED TO THE WELDING SYSTEM AT THE
DISCONNECT SWITCH OR FUSE BOX BEFORE WORKING ON THE
EQUIPMENT.
DO NOT TOUCH ELECTRICALLY HOT PARTS.

ALWAYS CONNECT THE POWERWAVE GROUNDING LUG
(LOCATED INSIDE THE RECONNECT INPUT ACCESS DOOR) TO A
PROPER SAFETY (EARTH) GROUND.
ALWAYS CONNECT THE ANALOG INTERFACE ENCLOSURE TO A
PROPER SAFETY (EARTH) GROUND. WHEN MOUNTED TO THE
POWERWAVE, BOND THE ANALOG INTERFACE ENCLOSURE TO
THE CASE OF THE POWERWAVE.
1.2
Location
Do not use Analog Interface in outdoor environments. It should not be subjected to falling
water, nor should any parts of it be submerged in water. Doing so may cause improper
operation as well as pose a safety hazard. The best practice is to keep the machine in a dry,
sheltered area.
Degree of Environmental Protection: IP21S
1.3
Input and Grounding Connections

The analog interface is powered solely by the 24VDC robotic supply, and draws less than
300mA. Typically this supply is reference to earth ground. It is therefore recommended
that the enclosure be properly grounded. Consult local and national electric codes for
proper grounding methods.
1.4
Output Cables, Connections and Limitations

All of the signals between the Analog Interface and the robot controller were designed to
operate in a shielded cable. No surge or high frequency protection has been added to the
circuitry. Therefore a shielded cable (LECO S22320-64RP) is required from the Analog
Interface to the robot controller. The drain lead of the shielded cable must be bonded to the
Analog Interface enclosure.
10
1.5
System Configuration
Configuring a limited set of system variables can modify the response time and display
modes of the Analog Interface. For more information, see the "Special Access Modes"
section.
1.6
I/O Module DeviceNet Configuration

The I/O Module DeviceNet address is configured at the factory for proper operation, and
should not require adjustment in the field. The DeviceNet baud rate should be set to 125K
and the DeviceNet address of the I/O Module should be set to 50, the table below shows
the switch settings for this configuration.
Switch Number
1
2
3
4
5
6
7
8
Position
Off
On
Off
Off
On
On
Off
Off
Function
DeviceNet Address Switch 1 - Least Significant Bit
DeviceNet Address Switch 2
DeviceNet Baud Rate
DeviceNet Baud Rate
OPERATING INSTRUCTIONS
2.1
Startup Sequence
When power is applied to the Powerwave, rotating dashes will appear on the displays.
This should continue for about 30 seconds. During this startup period the system is
configuring itself and initializing variables. When the initialization period is complete, the
Weld Mode for the currently selected procedure should be displayed.
2.2
Display Operation
The standard PF-10 style dual display is supported by the software in a method that does
not require it to be present for the interface to function properly. This method allows the
display to be an optional or standard feature depending on the application requirements. In
general, it functions in a manner consistent with the PW450 display.
The PW450R displays Weld Mode, WFS and TRIM (S-VOLTS) during the idle state, and
Voltage, Current, and WFS while welding. Due to the hardware constraints, the PW455R
Analog Interface cannot display both Current and WFS simultaneously. A system
configuration variable is used to determine which will be displayed. The factory default
configuration will be set to display actual Current. See the "Special Access Modes"
section for more information regarding the display variable configurations.
The following statements define the default display operation.
Initially the display defaults to the minimum WFS and TRIM (S-VOLTS) set
values for the chosen process regardless of the analog input.
Changes to the WFS and TRIM (S-VOLTS) set points during the idle state
will not be reflected on the display.
During the weld, the actual Voltage and Current* will dynamically displayed.
The appropriate parameter indicator LEDs will blink to denote actual values
are being displayed.
11
After the weld, the last recorded actual values of Voltage and Current* will be
displayed for approximately 5 seconds. Both the appropriate parameter
indicator LEDs and digits will blink during this time.
After the actual display timer has elapsed the last recorded set points for
WFS and TRIM (S-VOLTS) will be displayed, and denoted by the appropriate
solid color parameter indicator LEDs.
*Special Note:
The system can be configured to display actual WFS while welding. See the
"Special Access Modes" section for more information regarding the display
variable configurations.
2.3
Local Procedure \ Weld Parameter Set-Up (MSP - Mode Select Panel)

The standard MSP3 style hardware has been utilized to set basic weld parameters on the
PW455R Analog Interface. It is required to input procedure information that is not
available through the robot's analog interface. These parameters include the Weld Mode,
Run In, Arc Control, Burnback, and Cold Inch WFS functions. In addition, a method has
been included by which the dual procedure set up function can be executed, and the active
procedure can be displayed.
The following information includes a functional description of each available feature.
Refer to the sample nameplate below as a reference. The item numbers on the sample
correspond to the list of functions. All functions will be limited to 2-Step operation, and
will not be compatible with modes defined as CC (i.e. those requiring a separate on/off
switch). Except where noted, only attributes/parameters for the active procedure (A or B)
are adjustable during welding (i.e. when the weld sequencer is active).
12
Features:
4
5
7
8
1
9
6
3
2
10
13
DISPLAY:
SET SWITCH:
Displays the value of the attribute/parameter to be adjusted. The

attribute/parameter is determined via the active LED indicator.
The set switch is used to change the attribute/parameter values on the DISPLAY.
Moving the switch up increases the displayed value, while moving the switch
down decreases the displayed value.
If the switch is held in either direction for more than 1 second will cause the least
significant digit to begin increment/decrement at a rate of 6 counts/second. Not all
attributes will use the accelerated rate change. Except where noted below, the
value of the selected attribute/parameter will not roll over when its high or low
limit is reached. Except where noted below, the machine will immediately begin
using new attribute values as soon as they are changed.
SELECT SWITCH:
The select switch is used to select the active attribute/parameter (WELD MODE,
RUN IN, etc.) as indicated by the discrete LEDs. Moving the switch up advances
the active indicator LED upward, while moving the switch down advances the
indicator LED downward.
If the switch is held in either direction, the indicator LED will advance one
position, pause momentarily (1 second), then advance at a constant rate (once
every 150 ms) in the appropriate direction until the switch is released. If the
indicator position reaches the top or bottom, it will not wraparound.
WELD MODE:
The weld mode LED indicator is enabled via the parameter SELECT SWITCH.
The value of the weld mode is indicated on the DISPLAY, and is adjustable via
the SET SWITCH. Valid weld mode numbers can range from 0 to 255.
However, the actual attainable modes are determined by the contents of the weld
table (weld software) version residing in the power source. In addition, there is
special filtering built into the Analog Interface operating software that blocks the
non supported mode types (CC and Non-Synergic CV) from being displayed due
to their incompatibility with this interface. If no valid mode types are found, the
mode display will show "Err", and the main display will show "---- ----".
Mode "0" is a special development mode used by WaveDesigner, and will not
appear unless a WaveDesigner file has been loaded into the power source. When
Mode "0" is downloaded, the Analog Interface will automatically recognize it and
make it the active mode (in the Idle state only).
The mode numbers will NOT roll over to the lowest or highest weld modes in the
table when the mode number limits are reached. Every weld mode in the weld
table will be available to the user except for the test modes** (e.g. mode 200). The
machine will change to the selected weld mode after two seconds of Set switch
inactivity. During a pending weld mode change, the SELECT and SET functions
will be disabled, and the main display will show dashes ("---- ----") until the new
mode becomes valid. In the default display configuration (PW450R emulation
mode), the WFS and Trim will be set to their minimum values until the first weld
is made. The "Display Analog Inputs" configuration will display WFS and Trim
values based on the actual analog input values, except during a pending weld
change as noted above.
14
See the "Special Access Modes" section for more information regarding the
display variable configurations.
The Weld Mode in a given procedure (A or B) can only be changed when the weld
sequencer is idle (i.e. when the trigger input is inactive, and the entire weld
sequence is complete). On the fly mode changes during welding can only be
executed via procedure change (i.e. A to B).
The last active Weld Mode of each procedure (A and B) will be saved in EEPROM
at power down so that they can be restored upon the next power up of the machine.
The initial default weld mode of each procedure will be the lowest available nonCC mode number in the weld table.
PROCEDURE SELECT:
The procedure select LED indicator is enabled via the parameter SELECT
SWITCH. The procedure (A or B) is indicated on the DISPLAY, and is selectable
via the SET SWITCH. This feature is intended exclusively for purpose of dual
procedure set-up. Selecting A or B on the display allows the user to set-up the
individual procedures without changing the active procedure input from the robot.
The Analog Interface MSP procedure selection takes priority when the weld
sequencer is idle (i.e. when the trigger input is inactive, and the entire weld
sequence is complete). During this time the selected procedure is indicated by a
solid LED in the procedure indicator box.
When the weld sequencer is active, the external input from the robot will override
the procedure select function, and determine the active procedure. During this
time the active procedure will be indicated by a flashing LED in the procedure
indicator box. Because the external input takes priority when the weld sequencer
is active, only the active procedure can be adjusted during welding.
The value of the procedure select attribute (A or B) will be saved in EEPROM at
power down so that it can be restored upon the next power up of the machine. The
initial default value of the procedure select attribute will be procedure A.
PROCEDURE INDICATORS:
The active procedure LEDs are provided as a means to indicate the selected
procedure. These LEDs are indicators only, and are NOT affected by the
SELECT switch. At no time will more than one LED be lit in the procedure
indicator box.
When the weld sequencer is inactive (i.e. when the trigger input is inactive, and the
entire weld sequence has completed), the system will default to the procedure setup mode. The procedure (A or B) as determined by the PROCEDURE SELECT
parameter will be indicated by a solid LED in the procedure indicator box.
When the weld sequencer is active, the external input from the robot will override
the dual procedure set-up function, and determine the active procedure. During
this time, the active procedure will be indicated by a flashing LED in the procedure
indicator box. The flashing will serve as an indication that the weld sequencer, and
the external procedure input are active.
RUN IN:
The Run In LED indicator is enabled via the parameter SELECT SWITCH. The
value of the Run In or strike speed is indicated on the DISPLAY, and is
adjustable via the SET SWITCH. The Run In (Strike) speed range is 50 to 150
15
IPM for the low range gearbox, and 75 to 150 IPM for the high range gearbox.
Setting the Run In speed to OFF will result in a Run In (Strike) speed equal to
the SET WFS as determined by the WFS analog input.
A separate Run In value will be maintained for each procedure (A and B). These
values will be saved in EEPROM at power down so that they can be restored upon
the next power up of the machine. The initial default Run In value of each
procedure (A and B) will be the minimum WFS available based on the speed range
of the gearbox.
The maximum allowable Run In (Strike WFS) has been reduced to 150 IPM,
primarily because our research has shown that strike speeds in excess of this value
provide little or no benefit to starting. Limiting the value is employed as a method
to direct the operator toward the correct use of the feature.
ARC CONTROL:
The Arc Control LED indicator is enabled via the parameter SELECT SWITCH.
The value of the Arc Control is indicated on the DISPLAY, and is adjustable via
the SET SWITCH. Arc Control, also known as Wave Control, typically allows
the operator to vary the arc characteristics from soft to harsh in all weld
modes. See the PW-455R instruction manual, for a detailed description of how the
Arc Control affects each mode.
It is typically adjustable from -10.0 to +10.0, with a nominal setting of "00.0". The
nominal setting of 00.0 will be displayed as OFF. The step changes will be in 0.1
increments. The Arc Control attribute will be available only when Wave Control 1
(WC1) is defined in the selected Weld Mode.
The Analog Interface is only equipped to support Arc Control (a.k.a. WC1). WC2
thru WC4 are not supported, and will default to their nominal values if assigned in
the individual weld files.
A separate Arc Control value will be maintained for each procedure (A and B).
These values will be saved in EEPROM at power down so that they can be
restored upon the next power up of the machine. The initial default Arc Control
setting of each procedure will be OFF (00.0).
BURNBACK:
The Burnback LED indicator is enabled via the parameter SELECT SWITCH.
The value of the Burnback time is indicated on the DISPLAY, and is adjustable
via the SET SWITCH. The Burnback feature allows weld current to flow for a
specified time after the trigger has been released, and the wire drive motor has
stopped. When the Burnback timer expires the output current will be turned off.
The Burnback time will be scaled from 0 (OFF) to 0.25 seconds in 0.01-second
increments. When the timer is OFF Burnback will be completely disabled. When
the timer is a non-zero value, the Burnback workpoint will equal the Weld
workpoint.
A separate Burnback time will be maintained for each procedure (A and B). These
values will be saved in EEPROM at power down so that they can be restored upon
the next power up of the machine. The initial default Burnback setting of each
procedure will be OFF (0.00).
16
10
WELD MODE SELECTION GUIDE:
11
COLD INCH WFS:
The Weld Mode Selection Guide is provided as a reference, to aid in the selection
of the proper weld mode number. However, the available weld modes are
determined solely by the weld table (welding software) residing in the power
source. Therefore, some modes listed on the selection guide may not appear as
valid choices when setting the WELD MODE number. By the same token,
numbers may be displayed when setting the WELD MODE that does not appear
on the selection guide. In addition, non-supported mode types such as CC and
Non-Synergic CV will not be displayed even if they are present in the weld table
(weld software) due to incompatibility issues with the interface.
The Cold Inch LED indicator is enabled via the parameter SELECT SWITCH.
The value of the Cold Inch WFS is indicated on the DISPLAY, and is adjustable
via the SET SWITCH. The single Cold Inch WFS applies to both directions
(forward and reverse), and will be maintained independent of the procedure
settings (i.e. will not be part of A and B). The Cold Inch WFS range is 50 to 800
IPM for the low range gearbox, and 75 to 1200 IPM for the high range gearbox.
The Cold Inch WFS is a coarse setting, and will therefore advance by 10's.
The last active Cold Inch WFS value will be saved in EEPROM at power down so
that it can be restored upon the next power up of the machine. The initial default
Cold Inch WFS will be 80 IPM.
Special Access Modes (Through MSP - Mode Select Panel)
2.4
There are two special display access modes available. The Display Variable Mode is
used to display and set certain configuration variables. The I/O Diagnostic Mode is used
to test the DeviceNet I/O inputs and outputs. Both of these modes are only accessible
during power-up and can not be entered once normal operation has begun.
2.4.1
Entering the Special Access Mode
1. Turn the power off to the Powerwave.

2. Choose the desired Special Access Mode
To select the Display Variable Mode - Hold the SELECT SWITCH in the up position
and power-up the PowerWave.
To select the I/O Diagnostic Mode - Hold the SET SWITCH in the up position and
power-up the Powerwave.
3. Wait until the rotating dashes are shown on the display, the select switch can now be
released.
4. After the PowerWave is done initializing the rotating dashes will stop and it should display
"nodE" on the display if the Display Variable mode was selected or it will display "AI 1" if
the I/O Diagnostic mode was selected.
2.4.2
Selecting an item and Exiting the Special Access mode.

After the a Special Access Mode is selected (see above), then used the SELECT
SWITCH to select which item to view or which test to perform. Pressing the SELECT
SWITCH up and down to move through the listed items. Note that the display does not
automatically scroll, the user must keep toggling the select switch to move through the
listed items.
Once the item to display has been selected, press the SET SWITCH up or down to display
and change the value associated with the item. Note the value of some items will change
17
immediately when the SET SWITCH is activated, while others will display only their
status.
To exit a special access mode, keep toggling the select switch down until the display shows
"donE", then toggle the SET SWITCH once to exit the section.
2.4.3
Display Variables
Item
NodE
Sno0
Sno1
Sno2
Anhs
Asbu
EF
EFC
DAI
ConF
2.4.4
CAUTION: While increasing the response time may be desirable, excessive noise on the analog
signal could drive the CPU load beyond a safe level, and have adverse effects on the system.
Sets the Event Meter Frequency rate
Sets the Metering Time Constant (attribute 30758 in the Weld Controller)
Display Analog Inputs - If true, the analog inputs for the WFS and TRIM (S-VOLTS) are
displayed real time during the idle state. The default setting holds the last valid set points from the
weld (required for applications where analog outputs are only active during the weld).
Display Configuration:
"0" => Displays actual current value during the weld (default).
"1" => Displays actual WFS during the weld.
I/O Diagnostic Modes
Item
AI 1
AI 2
AO 1
AO 2
d In
dO 1
dO 2
dO 3
dO 4
dO 5
dO 6
2.5
Description
Used to access the Test Weld Modes When set to "all" this variable will enable the user to select
weld modes 200 and greater.
Displays the Software Version of the Control Board
Displays the Software Version of the Gateway Board
Displays the Software Version of the Feedhead Board
Sets the Hysteresis of the Analog Inputs - Sets all three hysteresis values in the Gateway PC board
at once (attributes 610, 611, and 612). This function is used to filter out small fluctuations on the
analog inputs (i.e. the analog input value must change by this amount before it is converted and
accepted as a new value).
Sets the Analog Scans between Update rate For example, if the value is set to 50, then every 50th
analog value from the Device Net I/O block will be converted. Therefore, increasing this number
will limit the number of conversions done by the Gateway PC Board. While decreasing the number
will increase the response time.
Description
Displays value from Analog Input 1
Displays value from Analog Input 2
Used to send out a voltage on Analog Output 1
Used to send out a voltage on Analog Output 1
Display a hexadecimal value representing the states of the Digital Inputs
Used to turn off and on Digital Output 1
Making a Weld
The serviceability of a product or structure utilizing the welding programs is and must be the sole
responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company
affect the results obtained in applying these programs. These variables include, but are not limited to,
welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service
requirements. The available range of a welding program may not be suitable for all applications, and the
build/user is and must be solely responsible for welding program selection.
18
The following steps are presented as a general guide for operating the Powerwave. The flexibility
of the Power Wave system lets the user customize operation for the best performance.
First, consider the desired welding process and the part to be welded. Choose an electrode
material, diameter, shielding gas and process (GMAW, GMAW-P, GMAW-STT, etc.). **Nonsynergic and CC modes are NOT supported in the PW-455R Analog Interface.
Second, find the program in the welding software that best matches the desired welding process.
The standard software shipped with the Power Waves encompasses a wide range of common
processes and will meet most needs. If a special welding program is desired, contact the local
Lincoln Electric sales representative.
To make a weld, the Power Wave needs to know the desired welding parameters. These
parameters may originate from several different sources. The Analog Interface uses a combination
of sources. The robot provides WFS and Trim/Synergic Volt settings, while other settings like
Weld Mode and Arc Control are set at the Mode Select Panel on the interface itself. These settings
are then communicated digitally, via ArcLink, from the interface to the control section of the power
source.
2.6.1
General Welding Adjustments

1. WFS / AMPS:
In synergic welding modes (synergic CV, pulse GMAW, STT) WFS (wire feed speed) is
the dominant control parameter, controlling all other variables. The user adjusts WFS
according to factors such as weld size, penetration requirements, heat input, etc. The
Powerwave then uses the WFS setting to adjust its output characteristics (output voltage,
output current) according to pre-programmed settings contained in the Powerwave. In
non-synergic modes, the WFS control behaves more like a conventional CV power source
where WFS and voltage are independent adjustments. Therefore to maintain the arc
characteristics, the operator must adjust the voltage to compensate for any changes made to
the WFS. In constant current modes (stick, TIG) this control adjusts the output current, in
amps.
2. VOLTS / TRIM:
In constant voltage modes this control adjusts the welding voltage.
In pulse synergic welding modes (pulse GMAW only) the user can change the Trim setting
to adjust the arc length. It is adjustable from 0.500 to 1.500 (50 to 150 on the teach
pendant). A Trim setting of 1.000 (100 on the teach pendant) is a good starting point for
most conditions.
PW455R ONLY: In STT modes, the user can adjust the Trim setting to change the overall
heat input to the weld.
3. WELDING MODE:
May be selected by a mode number (10, 24, 71, etc.). Selecting a welding mode
determines the output characteristics of the Powerwave power source. The Welding
Software loaded in the Powerwave will determine available modes. A complete list of
available modes is shipped with each power source. For a more complete description of
the welding modes available in the Powerwave, see the explanation below.
19
4. ARC CONTROL:
Also known as Wave Control. Typically allows operator to vary the arc characteristics
from soft to harsh in all weld modes. It is adjustable from -10.0 to +10.0, with a
nominal setting of 00.0 (The nominal setting of 00.0 may be displayed as OFF on some
Power Feed wire feeder control panels). See the Welding Mode descriptions, below, for
detailed explanations of how the Arc Control affects each mode.
2.6.2
CV Welding
Synergic CV:
For each wire feed speed, a corresponding voltage is preprogrammed into the machine
through special software at the factory. The nominal preprogrammed voltage is the best
average voltage for a given wire feed speed, but may be adjusted to preference. When the
wire feed speed changes, the Powerwave automatically adjusts the voltage level
correspondingly to maintain similar arc characteristics throughout the WFS range.
Non Synergic CV:
This type of CV mode behaves more like a conventional CV power source. Voltage and
WFS are independent adjustments. Therefore to maintain the arc characteristics, the
operator must adjust the voltage to compensate for any changes made to the WFS.
All CV Modes:
Arc Control, often referred to as wave control, adjusts the inductance of the waveshape.
The wave control adjustment is similar to the pinch function in that it is inversely
proportional to inductance. Therefore, increasing wave control greater than 0.0 results in a
harsher, colder arc while decreasing the wave control to less than 0.0 provides a softer,
hotter arc.
CURRENT WAVE FORM (CV)
Wave Control +10.0

Wave Control 0.00
Wave Control -10.0
20
2.6.3
Pulse Welding
Pulse welding procedures are set by controlling an overall arc length variable. When
pulse welding, the arc voltage is highly dependent upon the waveform. The peak current,
background current, rise time, fall time and pulse frequency all affect the voltage. The
exact voltage for a given wire feed speed can only be predicted when all the pulsing
waveform parameters are known. Using a preset voltage becomes impractical, and instead
the arc length is set by adjusting trim.
Trim adjusts the arc length and ranges from 0.50 to 1.50, with a nominal value of 1.00.
Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease
the arc length.
Most pulse welding programs are synergic. As the wire feed speed is adjusted, the
Powerwave will automatically recalculate the waveform parameters to maintain similar arc
properties.
The Powerwave utilizes adaptive control to compensate for changes in electrical stickout while welding. (Electrical stick-out is the distance from the contact tip to the work
piece.) The Powerwave waveforms are optimized for a 0.75 (19mm) stick-out. The
adaptive behavior supports a range of stickouts from 0.50 (13mm) to 1.25 (32mm). At
very low or high wire feed speeds, the adaptive range may be less due to reaching physical
limitations of the welding process.
Arc Control, often referred to as wave control, in pulse programs usually adjusts the focus
or shape of the arc. Wave control values greater than 0.0 increase the pulse frequency
while decreasing the background current, resulting in a tight, stiff arc best for high speed
sheet metal welding. Wave control values less than 0.0 decrease the pulse frequency while
increasing the background current, for a soft arc good for out-of-position welding.
CURRENT WAVE FORM (PULSE)
Wave Control -10.0

Wave Control 0.0
Wave Control +10.0
21
2.6.4 STT Welding Parameters and Guidelines

The STT process in the Powerwave is neither a constant current (CC) nor a constant
voltage (CV). The Powerwave is a current controlled machine that is capable of changing
the electrode current quickly in order to respond to the instantaneous requirements of the
arc to optimize performance. By sensing changes in welding voltage, and hence the
electrode state, the power source will supply varying output currents to minimize spatter.
The Peak and Background currents are two such current outputs that can be adjusted. Peak
Current controls the Arc Length, and Background Current controls the Bead Contour.
Tailout control is available to increases Power in the Arc, and the Wire Feed Speed
controls the overall deposition rate.
PEAK CURRENT
The Peak Current control acts similar to an arc pinch control. Peak current serves to
establish the arc length and promote good fusion. Higher peak current levels will cause the
arc to broaden momentarily while increasing the arc length. If set too high, globular type
transfer will occur. Setting this level to low will cause instability and wire stubbing. In
practice, this current level should be adjusted for minimum spatter and puddle agitation.
Increased travel speeds sometimes require higher peak currents.
Adjust Arc Length with Peak Current
Note: In 100% CO2 shielding gas applications the peak current level should be set greater
than in a corresponding application using a gas blend with a high percentage of Argon.
Longer initial arc lengths with 100% CO 2 are required to reduce spatter.
BACKGROUND CURRENT
The Background Current provides the control for the overall heat input to the weld.
Adjusting this level too high will cause a large droplet to form, and globular type transfer
to occur resulting in increased spatter. Adjusting this level to low will cause wire stubbing
and also poor wetting of the weld metal. This is similar to a low voltage setting on a
standard CV machine
22
Adjust Bead Shape using Background Current
Note: Background Current levels for applications using 100% CO2 is less than similar
procedures involving gas blends with high percentages of Argon. This is a result of the
greater heat generated in the 100% CO2 arc. (100% CO2 is 35 volts/cm and 100% Argon
is 20 volts/cm. 75% Argon, 25% CO2 is about 24 volts/cm.
TAILOUT
The tail out provides additional heat without the molten droplet becoming too large.
Increase as necessary to add Heat to the arc without increasing arc length. (This will
allow for faster travel speeds and produce improved wetting). As tailout is increased, the
peak and/or background current is usually reduced.
OPTIMIZING WELDING ARC PERFORMANCE
For optimum spatter reduction, the arc should be concentrated on the puddle with a 3/8" to
1/2" stickout.
Contact Tip to Work Distance
( Reference Source: IM582 - Invertec STT II, August 2001 Rev.)

Synergic and Non-Synergic STT Welding (New Style)
The pictures illustrate the weld current waveshape for the STT process. They are not
drawn to scale, and are intended only for the purpose of showing how the variables effect
the waveform.
Peak Current Adjustment
ARC CONTROL (a.k.a. Wave Control 1, or WC1) adjusts the arc length in the STT
mode. This is accomplished by changing the amplitude of the PEAK portion of the
current waveform. The Arc Control value is adjusted in terms of actual peak AMPS.
23
CURRENT WAVE FORM (STT)
Background Current Adjustment

TRIM adjusts the heat input in the STT mode. This is done by changing the
BACKGROUND portion of the current waveform. Increasing the Trim adds more energy
to the weld, and makes the weld puddle hotter. Reducing the Trim removes energy from
the weld. The Trim value is adjusted in terms of actual background AMPS.
Tailout Adjustment
Tailout is a means to introduce additional heat without the molten droplet becoming too
large. Increased Tailout results in more heat. The Analog Interface does not support
adjustment of this variable, and therefore, it will default to its nominal setting as defined in
the individual weld mode.
24
Synergic STT Welding (Old Style)

The pictures illustrate the waveshape of current for the STT process. They are not drawn
to scale, and are intended only for the purpose of showing how the variables effect the
waveform.
TRIM in a Synergic STT mode changes the heat input by adjusting the tailout and
background portion of the waveform. Trim values greater than 1.0 add more energy to the
weld and make the weld puddle hotter; trim values less than 1.0 reduce energy to weld. A
nominal value of 1.0 will work for most applications. For the processes designated as open
root, the tailout is fixed, and the trim affects only the background level.
Trim 1.50
Trim 1.00
Trim 0.50
HEAT INPUT
ARC CONTROL, also referred to as wave control, adjusts the arc length in the STT
mode. This is accomplished by changing the peak portion of the current waveform. A
wave control value of +10.0 maximizes the arc length by increasing the peak current, while
a wave control of -10.0 minimizes the arc length by decreasing the peak current. The
nominal value is "OFF" (0.0), and should work for most applications.
Wave Control +10.0

Wave Control
0.0
Wave Control -10.0
25
ARC LENGTH
APPLICATION INFORMATION
3.1
Interface Description
This PW455R Analog Interface is designed to emulate the PW450 Robotic Interface. It is
primarily intended for use with a Fanuc robot using ArcTool software (V1.30P or higher)
with Touch Sensing and Through Arc Seam Tracking (TAST). The interface responds to
all of the ArcTool welding inputs and outputs except wire fault and wire stick alarm. All
of the circuitry for Touch Sensing is internal to the Powerwave, no external power supply
is required. The current signal for TAST is supplied by the Powerwave analog output, no
external current sensor is required. The interface does not control wire feed speed and
welding voltage independently. Rather, the Powerwave will always operate in a synergic
mode and the welding voltage is programmed as a function of the wire feed speed.
ArcTool software was designed to control wire feed speed and voltage independently.
Since the Powerwave system uses an arc length trim, the voltage cannot be directly
controlled. The welding voltage settings in the robot controller are interpreted by the
Powerwave as a trim setting. Any ArcTool function which tries to set the voltage to zero
and control the wire feed speed is actually only setting the arc length trim to the minimum.
Refer to the Operation section for a complete description of arc length trim. Any function
that tries to set the wire feed speed to zero and control the voltage is limited by the
minimum speed of the selected process. (Note: This phenomenon will occur as a
truncation of the speed, rather than a re-scaling based on the process.)
The following is a list of functions that do not work as intended by Fanuc due to the
synergic operation of the Powerwave:
WELDING VOLTAGE
In this interface all welding voltage settings must be thought of as an arc length trim. This
arc length trim will increase or decrease the arc voltage for a specific wire feed speed set
point. The scaling in the robot controller is setup to allow voltage numbers between 50 and
150. A voltage number in the robot controller of 100 equals the nominal voltage (no trim
adjustment) for the selected wire feed speed. If the arc length needs to be increased then
the voltage trim number is increased. For example, if a voltage number of 115 is used then
the arc voltage will increase too approximately 15% above the nominal voltage for the wire
feed speed set point in use.
WIRE BURNBACK FUNCTION
The burnback function controlled by the robot controller will not operate properly. The
function was setup to use a wire feed speed of zero while setting the welding voltage to
some level. The system will produce the minimum wire feed speed for the selected
procedure and a voltage trim for that selected wire feed speed set point. The solution to
this problem is already built into the Powerwave. The Powerwave can be configured to
automatically execute its own burnback routine. A burnback time can be set independently
for each procedure (A or B) on the control panel provided with the PW455R Analog
Interface.
WIRE STICK RESET FUNCTION
The wire stick reset function controlled by the robot controller will not operate properly.
This function is very similar to the burnback function. It was intended to use a wire feed
speed of zero while setting the welding voltage to some level. For the same reasons as
wire burnback it will not operate properly. If any wire stick problems occur, the burnback
time is adjustable on the control panel provided with the PW455R Analog Interface. The
setting is very reliable, and can be optimized for each welding procedure (A or B).
COLD WIRE INCHING FUNCTION
26
3.2
The cold inching wire feed speed cannot be changed by the robot controller. It is always
set to 80 IPM. A variable cold inching speed is not possible with the current architecture
of the interface.
Robot Signal Descriptions
VOLTAGE COMMAND
This is an analog output from the robot controller with a maximum range of 0 to 10V.
Since the Powerwave is always running in the synergic mode an output voltage cannot be
set. The voltage command is used as a voltage trim for the active workpoint. The voltage
command limits in the robot controller are entered as 50 to 150V. This is done so that the
nominal trim setting (100V) is not confused with a welding voltage.
WIRE FEED SPEED COMMAND
This is an analog output from the robot controller with a maximum range of 0 to 10V. The
wire feed speed command sets both the wire feed speed and the synergic output of the
Powerwave. The wire feed speed command limits in the robot controller are entered as 50
to 800 IPM for a standard drive head and 75 to 1200 IPM for a high speed drive head.
For reference, the wire feed speed command limits in the PW450 system were 50 to 770
IPM for a standard drive head and 80 to 1100 IPM for a high speed drive head.
TOUCH SENSE SIGNAL
This is an active low input to the robot controller that indicates that the welding electrode
has touched the work piece. To initiate touch sensing, the TOUCH SENSE COMMAND
must be held low by the robot controller. Then the Powerwave monitors the current
through the electrode to determine if it is touching the work piece. If THE TOUCH
SENSE COMMAND is held low and the electrode is touching the work piece then the
touch sense signal will be held low to report a touch to the robot controller.
ARC DETECT
This is an active low input to the robot controller that indicates that a welding arc has been
detected. The Powerwave monitors the arc voltage and current to determine if an arc is
established. If an arc is not established then the arc detect signal is held high to report an
error to the robot controller.
GAS FAULT
This is an active low input to the robot controller that indicates that the shielding gas is
missing. The Powerwave has an external connection (Shutdown 2) available for a
NORMALLY CLOSED gas pressure or flow switch. If a switch is installed and the gas
fault function is enabled then gas loss errors will be reported to the robot controller.
WIRE FAULT
This is an active low input to the robot controller that indicates a wire feeding problem or
the lack of welding wire. This signal is not connected in the Powerwave.
WATER FAULT
This is an active low input to the robot controller that indicates a water-cooling problem.
The Powerwave monitors the water cooling flow through its SHUTDOWN INPUT to
decide if a water fault has occurred. If the water coolant flow drops below the low
threshold then the water fault signal is held low to report an error to the robot controller.
POWER FAULT
This is an active low input to the robot controller that indicates a power fault in the
Powerwave. If for some reason the Powerwave loses power or goes offline, then the
power fault signal is held low to report an error to the robot controller.
27
VOLTAGE FEEDBACK
This is an analog input to the robot controller with a maximum range of 0 to 10V. The Arc
Link attribute for voltage in the PW455R is converted to an analog signal, and isolated to
produce the voltage feedback signal. Scaling is adjustable.
For reference, in the PW450 interface, a voltage feedback signal of 7.620V (typical) is
equal to an arc voltage of 80.0V.
CURRENT FEEDBACK
This is an analog input to the robot controller with a maximum range of 0 to 10V. The
ArcLink attribute for current in the PW455R is converted to an analog signal, and isolated
to produce the current feedback signal. Scaling is adjustable.
For reference, in the PW450 interface, a current feedback signal of 8.317V (typical) is
equal to an arc current of 750A.
WELD START
This is an active low output from the robot controller that commands the Powerwave to
start an arc.
GAS START
open the shielding gas solenoid. In the PW455R, this signal is logically ORed with the
gas controller in the PW455R Weld Sequencer. By this method, preflow, postflow, and
purge functions can be controlled by the Robot without conflicting with the gas controller
in the PW455R Weld Sequencer.
TOUCH SENSE COMMAND
turn on Touch Sensing. When touch sensing is enabled the Powerwave regulates a pulse
voltage waveform while monitoring the current through the electrode. If current flows
through the electrode then the TOUCH SENSE SIGNAL is held low to report a touch to
the robot controller.
WIRE+
cold inch wire at 80 IPM.
WIREThis is an active low output from the robot controller that commands the Powerwave to
cold inch wire at -80 IPM.
WIRE STICK ALARM
This is an active low output from the robot controller used to indicate a wire stick. This
signal is not connected in the Powerwave.
DUAL PROCEDURE SWITCH COMMAND
This is an active low output from the robot controller used to activate the dual procedure
switch. The PW455R is dual procedure capable, and this output is used to switch between
procedures. If the output is held high by the robot controller then procedure A is active,
and if the output is held low then procedure B is active. An LED on the PW455R Interface
will indicate the active procedure (A or B).
28
WIRE STICK DETECT

This is a resistance measuring input to the robot controller used to detect a wire stick. The
intended use for this resistance check is to measure the resistance between the output
terminals of the weld equipment. If a resistance of approximately 100 Ohms or less is
found (by the Robot) then a wire stick error is reported by the robot controller.
This measurement is not directly possible with a Powerwave because the resistance
between the output studs is always 40 Ohms or less. Additional circuits have been added
to allow the wire stick detect to work properly although it is not directly measuring the
resistance between the output studs. This circuitry will provide a low impedance path
between the WDI+ and WDI- connections on the robot to indicate a wire stick.
NOTE: The WDI- connection is referenced to Robot GND on the Powerwave Interface PC
Board.
3.3
Power Wave Circuit Descriptions

VOLTAGE COMMAND
The voltage command from the robot controller (DACH1) is scaled and converted from an
analog to a digital signal in the PW455R Interface. The digital signal becomes the Arc
Link attribute value for TRIM in the PW455R Weld Sequencer.
Maximum Input Range: 0 to 10V
Factory Programmed Range: 0.6 to 9.6V
Input Impedance: 130K Ohms (typ.)
For reference, in the PW450, the voltage command from the robot controller (DACH1)
was directly connected to the TIG analog input on the display board of the PW450. This
signal was not connected to the robot or control ground.
WIRE FEED SPEED COMMAND
The wire feed speed command from the robot controller (DACH2) is scaled and converted
from an analog to a digital signal in the PW455R Interface. The digital signal becomes the
Arc Link attribute value for SET WFS in the PW455R Weld Sequencer.
For reference, in the PW450, the wire feed speed command from the robot controller
(DACH2) was directly connected to the WF1 analog input on the display board of the
Powerwave. This signal was not connected to the robot or control ground.
TOUCH SENSE SIGNAL
To initiate Touch Sensing, the TOUCH SENSE COMMAND must be held low by the
robot controller. When Touch Sensing is enabled the Powerwave regulates a pulse voltage
waveform while monitoring the current through the electrode. If current flows through the
electrode, the isolated TOUCH SENSE SIGNAL is held low to report a touch to the
robot controller at welding input 1 (WDI1).
NOTE: The active state table was responsible for setting and clearing the TOUCH SENSE
SIGNAL in the PW450.
ARC DETECT
29
The arc detect signal is generated from the Arc Detect Attribute in the PW455R Weld
Sequencer. The Arc Detect Attribute will detect a minimum arc of 10V and 25A. The
signal is isolated from the control ground and tied to the robot controller welding input 2
(WDI2).
GAS FAULT
The gas fault signal is generated by an external gas flow or pressure sensor. The normally
closed signal is fed into the Shutdown 2 input on the front of the PW455R. When a
shutdown is detected, an isolated low signal is sent to the robot controller welding input 3
(WDI3).
For reference, in the PW450, this signal is not connected to anything on the interface
board. The signal (WDI3) is simply rerouted from the robot connector (P82) to the
miscellaneous connector (P84). A gas fault is generated when this signal is tied to the
robot ground.
WATER FAULT
The water fault signal is generated by the water flow sensor in the K1767 water cooler or
equivalent. The normally closed signal is fed into the Shutdown 1 Input on the front of
the PW455R. When a shutdown is detected, an isolated low signal is sent to the robot
controller welding input 5 (WDI5).
POWER FAULT
If for some reason the Powerwave loses power or goes offline, then the power fault
signal is generated. The signal is isolated from the control ground and tied to the robot
controller welding input 6 (WDI6). Ideally, this signal should function properly even if the
PW455R is not turned on.
VOLTAGE FEEDBACK
This is an analog input to the robot controller with a range of 0 to 10V. The factory
programmed full range is 0.6 to 9.6V (representing 0 to 80V). The ArcLink attribute for
voltage in the PW455R is converted to an analog signal, scaled, and isolated to produce the
voltage feedback signal. The signal is then tied to the robot controller analog input 1
(ADCH1).
For reference, this signal is scalable at the robot, but in the PW450 interface, a voltage
feedback signal of 7.620V (typical) is equal to an arc voltage of 80.0V
CURRENT FEEDBACK
This is an analog input to the robot controller with a range of 0 to 10V. The factory
programmed full range is 0.6 to 9.6V (representing 0 to 750A). The ArcLink attribute for
current in the PW455R is converted to an analog signal, and isolated to produce the current
feedback signal. The signal is then tied to the robot controller analog input 2 (ADCH2).
For reference, this signal is scalable at the robot, but in the PW450 interface, a current
feedback signal of 8.317V (typical) is equal to an arc current of 750A.
WELD START
The weld start command is generated by active low welding output 1 (WDO1). The signal
is then isolated from the robot ground, inverted, and tied to the interface trigger input.
GAS START
The gas start command is generated by active low welding output 2 (WDO2). The signal
is then isolated from the robot ground and tied to the interface gas start (purge) input. This
signal is logically ORed with the gas controller in the PW455R Weld Sequencer. By
30
this method, preflow, postflow, and purge functions can be controlled by the Robot without
conflicting with the gas controller in the PW455R Weld Sequencer.
TOUCH SENSE COMMAND
The Touch Sense command is generated by active low welding output 3 (WDO3). The
signal is then inverted and isolated from the robot ground and tie to the interface Touch
Sense input. (see also TOUCH SENSE SIGNAL)
WIRE+ & WIREThese two signals work together to cold inch the wire at 80 IPM. The forward wire inch
command is generated by active low welding output 4 (WDO4). The reverse wire inch
command is generated by active low welding output 5 (WDO5). When either of the two
signals is received an isolated inch command is generated. Logically, the signals must
operate in a mutually exclusive fashion. If both signals are low at the same time then the
first one to be recognized will determine the direction of travel. No damage will be caused
by driving both signals low at the same time.
For reference, in the PW450, when either of the two signals is received an isolated inch
command was generated and tied to the interface wire inching input. At the same time the
motor drive relays switched to the correct direction. The default direction for the motor
drive relays was forward, if both the signals were low at the same time then the motor
drive relays were set for reverse. No damage would be caused by driving both signals low
at the same time.
DUAL PROCEDURE SWITCH COMMAND
The dual procedure switch command is generated by active low welding output 7
(WDO7). The signal is then isolated from the robot ground and tied to the interface dual
procedure input.
WIRE STICK DETECT
The wire stick detect is a low impedance signal provided by a solid state relay output
(SSR) with a maximum on state impedance of 3.2 ohms. The Powerwave uses it's touch
sense routine to determine if a wire stick is present at the end of the weld and sets the SSR
on/off status accordingly. The SSR output is tied to the robot controller wire stick detect
inputs (WDI+ & WDI-). The robot controller samples this signal after the Arc Establish
signal changes from true to false.
NOTE: The WDI- connection is referenced to Robot GND on the Powerwave Interface PC
Board.
3.4
Electrical Characteristics
All of the signals between the Powerwave and the robot controller were designed to
operate in a shielded cable. No surge or high frequency protection has been added to the
circuitry.
3.4.1
ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS

The following signals are referenced to the robot controllers 24V supply (Robot GND)
unless otherwise noted. The total allowable load on the 24V supply is 0.7A. The
following is a brief description of the electrical characteristics, for a full description see the
Fanuc electrical connections manual.
DIGITAL OUTPUTS (Sinking)
Rated Voltage: 24VDC
Maximum Applied Voltage: 30VDC
31
Output
Maximum Load Current: 0.2A

Transistor Type: Open collector NPN
Saturation Voltage at On: 1.0V
24V
DIGITAL INPUTS (Sourcing)
Maximum Input Voltage: 28VDC
High Input Voltage: 20 to 28VDC
Low Input Voltage: 0 to 4VDC
Input Impedance: 3.3K Ohms
Response Time: 5 to 20ms
3.3K
Input
ANALOG OUTPUTS
Maximum Output Range: 0 to 10V
Required Load Impedance: 3.3K Ohms (minimum)
Weld equipment analog outputs are isolated
from the robot controller 24V supply (Robot GND).
ANALOG INPUTS
Input Impedance: Not Published
WIRE STICK DETECT (WDI+ to WDI-)
Maximum Output Voltage: 20VDC
Maximum Output Current: 85mA
Maximum Impedance Threshold: 100W
The wire stick detect output is isolated from the
robot controller 24V supply (Robot GND).
3.4.2
PW455R ANALOG INTERFACE ELECTRICAL CHARACTERISTICS

The following signals are referenced to the robot controllers 24V supply unless otherwise
noted. The total allowable load on the 24V supply is 0.7A. The following is a brief
description of the electrical characteristics.
DIGITAL OUTPUTS (Sinking)
Maximum Load Current: 0.5A (Short Circuit Protected)
Transistor Type: Open collector NPN
Saturation Voltage at On: 1.0V
DIGITAL INPUTS (Sourcing)
Maximum Input Voltage: 30VDC
High Input Voltage: 15 to 30VDC
Low Input Voltage: -3 to 5VDC
Typical Response Time: 3 ms
ANALOG OUTPUTS
32
Maximum Output Range: 0 to 10V

Required Load Impedance: 5K Ohms (min.)
Typical Conversion Time: 2 ms
ANALOG INPUTS
Typical Conversion Time: 2 ms
The Fanuc Robot analog outputs are isolated
from the robot controller 24V supply. If Required,
these signals may be tied to the Robot GND at the
PW-455R Interface.
WIRE STICK DETECT OUTPUT (WDI+ to WDI-)
Maximum Load Current: 0.3A
Transistor Type: SSR
Maximum On State Resistance: 3.2 Ohms
Maximum Speed: 5 ms (1.65 ms typ.)
The negative wire stick detect output (WDI-)
is tied to Robot GND at the PW-455R Analog Interface.
33
MS-628
3.5
Robot Controller Setup
MONITORING FUNCTIONS
1 Arc loss
2 Gas shortage
3 Wire shortage
4 Wire stick
5 Power supply failure
6 Coolant shortage
ENABLED
DISABLED
DISABLED
ENABLED
ENABLED
ENABLED
WELD RESTART FUNCTION

7 Return to path
8 Overlap distance
9 Return to path speed
DISABLED
0mm
200mm/s
SCRATCH START FUNCTION

10 Scratch start
DISABLED
11 Distance
5mm
12 Return to start speed
12mm/s
ON-THE-FLY FUNCTION
13 On-The-Fly
14 Voltage increment
15 Wire feed increment
16 Current increment
ENABLED
1.0V
5.0IPM
5.0A
OTHER FUNCTIONS
17 Weld from teach pendant
18 Run in
19 Wire burnback/retract
ENABLED
DISABLED
DISABLED
WELD EQUIPMENT SETUP

1 Weld process
2 Remote arc enable
3 Weld power control Wire
4 Wire feed control
5 Wire+ Wire- speed
6 Wire feed speed units
MIG
DI 0
FD
AO
80IPM
IPM
WELD RUN IN
7 Voltage
8 Current
9 Wire feed
10 Time
50.0V
250.0A
200IPM
0.00s
WIRE BURNBACK/RETRACT
11 Voltage
12 Current
13 Wire feed
14 Time
50.0V
250.0A
0IPM
0.00s
TIMING
15 Arc start error time
16 Arc detect time
17 Arc loss error time
2.00s
0.10s
0.30s
TIMING (cont.)
18 Gas detect time
19 Gas purge time
20 Gas preflow time
21 Gas postflow time
0.05s
1.00s
0.50s
0.00s
WIRE STICK FUNCTION

22 Reset
23 Reset tries
24 Voltage
25 Time
DISABLED
1
50.0V
0.00s
VOLTAGE OUTPUT SCALING

26 Minimum reference
27 Maximum reference
28 Minimum output
29 Maximum output
0.60V
9.60V
50.0V
150.0V
CURRENT OUTPUT SCALING

32 Minimum output
33 Maximum output
0.00V
10.00
0.0A
400.0A
WIRE FEED SPEED OUTPUT SCALING

0.60V
9.60V
36 Minimum output
50(75)IPM
37 Maximum output
800(1200)IPM
VOLTAGE INPUT SCALING
40 Minimum output
41 Maximum output
0.60V
9.60V
0.0V
80.0V
CURRENT INPUT SCALING

44 Minimum output
45 Maximum output
0.60V
9.60V
0.0A
750A
SYSTEM VARIABLES
$AWEUPR $WSTK_ENA_DLY 0.10s
TOUCH SENSING SETUP
Sensor port type
Sensor port number
Circuit port type
Circuit port number
34
WI
1
WO
3
3.6
PW-455R Analog Interface Cable Definition
PW-455
Analog Interface
Input / Output
PW-455
Signal Description
37 Pin Amphenol
(MS Style 28-21P)
INPUT(Analog)
TRIM (Voltage) Command
INPUT(Analog)
(see comments)
P82-F
COMDA1
CRW1-2
INPUT(Analog)
WFS command
P82-E
DACH2 (WFS command)
CRW1-3
INPUT(Analog)
WFS command GND
P82-F
COMDA2 (WFS command GND)
CRW1-4
OUTPUT (Digital)
Touch Sense Detect
P82-c
WDI1 (Touch sense signal)
CRW1-5
OUTPUT (Digital)
Arc Detect
P82-d
WDI2 (Arc detect)
CRW1-6
OUTPUT (Digital)
Gas Fault
P82-e
WDI3 (Gas fault)
CRW1-7
------
No Connection
P82-f
WDI4
CRW1-8
P82-A
Fanuc Signal Name
DACH1 (Voltage command)
Fanuc
Robot
Controller
(34 Pin Honda)
CRW1-1
Note Scaling
OUTPUT (Digital)
Water Fault
P82-g
WDI5 (Water fault)
CRW1-9
OUTPUT (Digital)
Abnormal Operation / Power Fault
P82-h
WDI6 (Power fault)
CRW1-10
------
No Connection
P82-j
WDI7
CRW1-11
------
No Connection
P82-k
WDI8
CRW1-12
OUTPUT (Analog)
Voltage Feedback
P82-J
ADCH1 (Voltage feedback)
CRW1-13
------
No Connection
P82-K
COMAD1
CRW1-14
OUTPUT (Analog)
Current Feedback
P82-L
ADCH2 (Current feedback)
CRW1-15
------
No Connection
P82-M
COMAD2
CRW1-16
------
------
------
No Connection
CRW1-17
------
------
------
No Connection
CRW1-18
CRW1-19
ROBOT GND
Robot GND
P82-a
0V (Robot GND)
------
No Connection
P82-b
0V
CRW1-20
------
No Connection
P82-m
0V
CRW1-21
------
No Connection
P82-n
0V
CRW1-22
INPUT (Digital)
Arc Start Command (Trigger)
P82-R (Fanuc)
{P82-C (Motoman)}
WDO1 (Weld start)
CRW1-23
Comments
Additional Notes
COMDA1 common to COMDA2 at Robot or in Cable?

Note Scaling
COMDA1 common to COMDA2 at Robot or in Cable?
Isolated from Robot GND, but tied to ?? on Display BD.
Generated via external Gas Fault input (P84 in PW-450)
Note Scaling
Referenced to Robot GND on the PW-450 Interface Bd. Is

Robot GND tied to COMAD1 in Robot or Cable?
Note Scaling
Referenced to Robot GND on the PW-450 Interface Bd. Is

Robot GND tied to COMAD2 in Robot or Cable?
Motoman version of PW-450 had alternate trigger location.
INPUT (Digital)
Gas Flow Command
P82-S
WDO2 (Gas start)
CRW1-24
INPUT (Digital)
Touch Sense Command
P82-T
WDO3 (Touch sense command)
CRW1-25
INPUT (Digital)
Cold Inch FWD
P82-U
WDO4 (Wire+)
CRW1-26
80 IPM Fixed Speed
INPUT (Digital)
Cold Inch REV
P82-V
WDO5 (Wire-)
CRW1-27
80 IPM Fixed Speed
------
No Connection
P82-W
WDO6
CRW1-28
INPUT (Digital)
Dual Procedure Command
P82-X
WDO7 (Dual procedure switch command)
CRW1-29
INPUT (Digital)
SPARE
P82-Z
WDO8 (Spare robot output)
CRW1-30
OUTPUT
(see comments)
Short Detect Signal (+)
P82-N
WDI+ (Wire stick detect)
CRW1-31
OUTPUT
(see comments)
Short Detect Signal (-)
P82-P
WDI- (Wire stick detect)
CRW1-32
ROBOT POWER
+24V Robot PWR
P82-r
+24V (Robot PWR)
CRW1-33
ROBOT POWER
+24V Robot PWR
P82-r
+24V (Robot PWR)
CRW1-34
------
No Connection
P82-H
------
------
------
No Connection
P82-s
------
------
------
No Connection
P82-B
------
------
------
No Connection
P82-D
------
------
------
No Connection
P82-G
------
------
------
No Connection
P82-p
------
------
Short Detect (+) & (-) combine to provide a High/Low

Impedance Output for Robot Wire Stick Detect Circuitry.
Short Detect (-) is tied to the Robotic GND on the PW-450

Interface Board
Tied together in Robot or Cable?
35
MAINTENANCE
4.1
Non-Standard Safety Information

WARNING! ELECTRIC SHOCK CAN KILL.
WARNING: ELECTRIC SHOCK CAN KILL.

ONLY QUALIFIED PERSONNEL SHOULD SERVICE THIS
INSTALLATION.
TURN THE INPUT POWER OFF AT THE DISCONNECT SWITCH OR
FUSE BOX BEFORE WORKING ON THIS EQUIPMENT
DO NOT TOUCH ELECTRICALLY HOT PARTS
4.2
Routine Maintenance
Routine maintenance consists of periodically inspecting the interface and cabling for
loose or broken connections, worn switches, and signs of improper cable strain relief.
Light cleaning is also recommended, using a low-pressure airstream, to remove
accumulated dust and dirt from the intake and outlet louvers, and the cooling channels in
the machine.
4.3
Periodic Maintenance
Calibration of the PW455R is critical to its operation and can adversely affect the
performance of the system. Generally speaking the calibration will not need adjustment.
However, neglected or improperly calibrated machines may not yield satisfactory weld
performance. To ensure optimal performance, the calibration of output Voltage and
Current should be checked yearly.
4.4
Machine Calibration Specification

The Powerwave's output Voltage, Current, and WFS are calibrated at the factory.
Generally speaking the machine calibration will not need adjustment. However, if the
weld performance changes, or the yearly calibration check reveals a problem, contact the
Lincoln Electric Company for the calibration software utility.
The calibration procedure itself requires the use of a grid, and certified actual meters for
voltage and current. The accuracy of the calibration will be directly affected by the
accuracy of the measuring equipment you use. Detailed instructions are available with
the utility.
Once the Powerwave calibration has been verified, the analog feedback calibration
between the Robot to the Analog Interface should also be checked and adjusted as
required. All analog adjustments must be made at the Robot.
36
4.4.1
Analog I/O Scaling

Scaling of the analog I/O has been preset at the factory and cannot be changed. Scaling
should be adjusted at the robot based on the following information. Scaling for both the
Analog Inputs & Outputs is based on a range of 0.6 Volts to 9.6 Volts. The table below
summarizes the full-scale voltage feedback and command voltage ranges. The Command
Trim Voltage column shows the internal representation of trim how it is stored in the
sequencer. For the Command Wire Feed Speed (WFS) voltage, "Low" represents the
low range feedhead gearbox, and "High" represents the high range feedhead gearbox.
Volts
0.0
0.6
1.73
2.85
3.98
5.10
6.23
7.35
8.48
9.60
10.0
Feedback Voltage
Volts
Current
0
0
0
0
10
94
20
188
30
282
40
375
50
469
60
563
70
657
80
750
-
Cmd Trim Voltage

-32,768
-24,576
-16,384
-8,192
0
8,192
16,384
24,575
32,767
-
37
Cmd WFS Voltage

Low
High
50
75
144
216
238
356
332
497
425
638
519
779
613
919
717
1060
800
1200
-
Wago A/D Counts

Hex
Decimal
0
0
0x07AE
1966
0x1614
5652
0x247B
9339
0x32E0
13,024
0x4147
16,711
0x4FAD
20,397
0x5E14
24,084
0x6C7A
27,770
0x7AE0
31,456
0x7FFF
32,767
TROUBLESHOOTING GUIDE
5.1
I/O Run (Rn) & IO Err (Er) Status LED's on DeviceNet Coupler
LED CONDITION
I/O ERR
I/O RUN
(RED)
(GRN)
OFF
ON
5.2
BLINKING
BLINKING
BLINKING
OFF
DEVICE
STATUS
Normal
Startup
Field Bus
Fault
DESCRIPTION
Normal Operating Condition. I/O Run
on - Field Bus OK
Normal Startup Sequence, both should
stop blink after a couple of seconds
A field bus fault has been detected
MS (Module Status) Red & Green Status LED's on DeviceNet Coupler
LED CONDITION
I/O RUN
I/O ERR
(GRN)
(RED)
OFF
OFF
ON
OFF
BLINKING
OFF
OFF
OFF
BLINKING
ON
BLINKING
BLINKING
DEVICE
STATUS
No Power
Normal
Device in
Standby
Minor Fault
Unrecoverable
Fault
Self Testing
38
DESCRIPTION
There is no power applied to the device
The device is operating in a Normal
Condition
The device needs commissioning due
to the configuration is missing,
incomplete, or incorrect
Recoverable Fault
The device has an unrecoverable fault;
may need replacing
The Device is in Self Test
5.3
NS (Network Status) Red & Green Status LED's on DeviceNet Coupler
LED CONDITION
I/O RUN
I/O ERR
(GRN)
(RED)
OFF
OFF
DEVICE
STATUS
DESCRIPTION
No Power, Not
On-Line
The device might not be powered or the

device might not have completed the
Dup Mac Id test yet & is not on-line.
Online and allocated to a Master,
Normal Condition
Device is online, but not connected to
master
One or more I/O connections are in the
Timed-Out state
Detected communication error Duplicate Mac Id or Bus-off
ON
OFF
Normal
BLINKING
OFF
OFF
BLINKING
OFF
ON
Online, Not
Connected
Connection
Time-Out
Critical Link
Failure
39
5.4
Digital I/O Status Indicators
40
5.5
Troubleshooting Chart
Problem
Display shows rotating
dashes
No Display
Switches do not work
Mode display shows:
"Err"
Corrective Action
During startup the display should display do this for about 30 seconds. If this
continues, then this is an indication the Gateway board did not get mapped by the
control board. Check the ArcLink connection between the Gateway & Control
Boards, the Gateway is not finding the Control board.
Make sure the Display is connected to the Gateway's SPI connector and the Gateway
board is powered up with the correct main software & parameter file.
Check to see if the switches wiring is plugged into the bottom of the display card
No valid mode types are present in the power source. Non-Synergic and CC Modes are
not compatible with the Analog Interface.
-andMain display shows:

"---- ----"
No LED's are lit on the
I/O block
False or dimly lit I/O
Block indicators
Check the 24V power coming in from the Robot/PLC. This also powers the
DeviceNet communications and should light up Led 2 on the Gateway board if there is
24 volts present.
Make sure the 37-pin communication cable shield from the Robot is properly
terminated (connected to case ground at the Analog Interface).
41
COMPONENT LOCATION AND REPLACEMENT PARTS LIST
6.1
Bill of Materials (L10412-18)

The following information details the PW455R Analog Interface implementation by the
Lincoln Electric Automation Division. The table below indicates the bill of material for
the L10412-18 Analog Interface kit for the PW455R. Other kits exist depending on what
power source the interface is mounted on and application. This list may be used to order
parts if necessary.
Item #:
LECO #:
Description:
Qty.:
1
2
3
4
5
6
7
8*
9
10*
11
12*
13
14
15
16*
17
18
19
20
S23395-1
S23395-2
S23395-3
S23395-4
S23395-5
S23395-6
S23395-7
S25390-1
M19790-1A0
T10800-49
S18250-796
S23391-1
L11130-3D0
M19902-1
M17803
S23383-6
S23394-3
L10412-17
L10421-1
L10421-2
DeviceNet Coupler
4 Channel Digital Input
4 Channel Digital Output
2 Channel Analog Input
2 Channel Analog Output
End Module
2 Channel Digital Output
Minimaster Gateway Software
MSP3 Option Panel
Toggle Switch
Plug & Lead Assembly
Overlay Decal
SPI Display PCBD
SPI Shielded Cable Assembly
Plug & Lead Assembly 37-Pin
121 Ohm Terminating Resistor
Cable Assembly to Dnet Board
Sheetmetal Enclosure
Interface Box Cover Plate
Power Source Mounting Plate
1
2
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
*Not shown in component layout in section 2.1.1.
42
2.1.1 Component Layout
15
20
17
18
1-7
14
19
9
13
11
43

PW-455R Analog Interface Instruction For Robots

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PW-455R Analog Interface Instruction For Robots

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PW-455R Analog Interface Instruction Guide

Recommended Processes and Equipment ....................................................................................4

Design Features ............................................................................................................................5

Recommended Processes ......................................................................................................4

Construction Information .............................................................................................................6

Wiring Information ...............................................................................................................6

Operating Instructions ................................................................................................................11

Interface Description ...........................................................................................................26

Application Information .............................................................................................................26

Non-Standard Safety Information .......................................................................................10

Non-Standard Safety Information .......................................................................................36

Troubleshooting Chart ........................................................................................................41

Component location and replacement parts list..........................................................................42

Bill of Materials (L10412-18) .............................................................................................42

RECOMMENDED PROCESSES AND EQUIPMENT

Recommended Equipment / Interface

Operational Features and Controls

Regulatory Requirements as Required for Market

Wiring from 37 Pin Input Connector to Wago I/O Block

PW-455 Analog Interface

Fanuc Signal Name (Desc.) / Type

+24 VDC (Robot Power)

WDI5 (Water Shortage) / Input

Additional Wiring Information

System Wiring Diagram

9 Conductor Shielded Cable

WAGO I/O BLOCK

LECo. S24017-6 connector

121W Terminating Resistor

Wiring Per Tables

Non-Standard Safety Information

ONLY QUALIFIED PERSONNEL SHOULD PERFORM THIS

TURN OFF INPUT POWER TO THE POWER SOURCE AT THE

DO NOT TOUCH ELECTRICALLY HOT PARTS.

Input and Grounding Connections

Output Cables, Connections and Limitations

I/O Module DeviceNet Configuration

Local Procedure \ Weld Parameter Set-Up (MSP - Mode Select Panel)

Displays the value of the attribute/parameter to be adjusted. The

WELD MODE SELECTION GUIDE:

COLD INCH WFS:

Entering the Special Access Mode

1. Turn the power off to the Powerwave.

Selecting an item and Exiting the Special Access mode.

I/O Diagnostic Modes

General Welding Adjustments

Wave Control +10.0

Wave Control -10.0

Wave Control -10.0

2.6.4 STT Welding Parameters and Guidelines

Adjust Bead Shape using Background Current

( Reference Source: IM582 - Invertec STT II, August 2001 Rev.)

CURRENT WAVE FORM (STT)

Background Current Adjustment

Synergic STT Welding (Old Style)

Wave Control +10.0

Wave Control -10.0

WIRE STICK DETECT

Power Wave Circuit Descriptions

ROBOT CONTROLLER ELECTRICAL CHARACTERISTICS

Maximum Load Current: 0.2A

PW455R ANALOG INTERFACE ELECTRICAL CHARACTERISTICS

Maximum Output Range: 0 to 10V