Migatronic Tig - Plasma Welding machine /Fanuc robot Interface Adapted for RJ3 Controller: 76119997-1 Adapted for RJ2 Controller: 76119999-1 Setup & Jumper configuration AUTOMATION A/S +45 96 96 27 00 U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 1 / 22
Table of Contents: JUMPERS.... 3 LED INDICATORS... 4 CONNECTIONS IN FRONT OF THE INTERFACE.... 5 CONNECTIONS ON BACKSIDE OF THE INTERFACE.... 7 INTERFACE SCHEMATIC... 8 ACCESSORIES... 9 ILLUSTRATION 1: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER... 11 ILLUSTRATION 2: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER... 12 ILLUSTRATION 3: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL... 13 ILLUSTRATION 4: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL... 14 ILLUSTRATION 5: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL.... 15 ILLUSTRATION 6: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL.... 16 ILLUSTRATION 7: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL.... 17 ILLUSTRATION 8: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL.... 18 ILLUSTRATION 9: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER... 19 ILLUSTRATION 10: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER... 20 ILLUSTRATION 11: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL.... 21 ILLUSTRATION 12: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL.... 22 U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 2 / 22
Jumpers. 1 2 3 Jumper 2 (J2) 1 2 3 Jumper 3 (J3) 3 2 1 Jumper 1 (J1) J1: Arc detect mode, only 8 pole plug. 1&2: Low on pin E =arc on 2&3: High on pin E = arc on J2: Supply for 8911 remote control. 1&2: Wire feeder supplies the remote control 2&3: Welding machine supplies the remote control J3: With/without remote control. 1&2: Remote control installed 2&3: No remote control U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 3 / 22
Led indicators. 1 6 2 11 12 7 9 10 4 5 3 8 Pos.1: Pos.2: Pos.3: Pos.4: Pos.5: Pos.6: Pos.7: Pos.8: Pos.9: Pos.10: Pos.11: Pos. 12: Current output signal, PWM signal (Yellow) Wire speed output signal, PWM signal (Yellow) Start welding input from robot (Yellow) Start wire/wire on input from robot (Yellow) Wire + input signal from robot (Yellow) Wire input signal from robot )Yellow) Arc on signal from 6 pole plug, input signal (Yellow) Arc on signal from 8 pole plug, input signal (Yellow) Start welder output signal (Red) Start/wire on, output signal (Red) Arc on, output signal to the robot (Red) +24V DC from robot OK (Green) U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 4 / 22
Connections in front of the interface. 1 2 3 4 1: Start wirefeeder / welding machine output. Via this connector, the KT-4 wire feeder is started. This connector also can supply the interface with the Arc Detect signal. Pinconnections: 2: Relay output. Start welding machine or wire feeder. 3: Arc Detect signal. Input to interface. 5: 0V / Gnd. 6: Relay output. Start welding machine or wire feeder. Other pins not connected. 2: Connection to welding machine s remote input. This plug should only be connected if no wire feeder is connected. Pinconnections: A: Current information 0-10V to welding machine. B: 0V/GND (REF.0V) E: Arc Detect signal from welding machine. 0V = Arc ON. G: Supply voltage. Voltage = 18VAC or 24VAC, depending on welding machine. H: Supply voltage common. Other pins not connected. U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 5 / 22
3: Connector to KT4 wire feeder. Pin connections: A: Current information 0-10V DC. From interface to welding machine. B: 0V/GND (REF.0V). C: Wirefeeder ground/ connected to the chassis in wirefeeder. D: Direction signal wire. 0 = wire forward. 1 = Wire return. E: Start wire request from wirefeeder. Output from KT-4 wire feeder. F: Start wire: Input on KT-4 wire feeder. 0 = Stop wire. 1 = Start wire. G: +24V / DC to remote control. Max. 200mA. Short circuit protected. H: 0V / GND to remote control. M: Wirespeed information 0 to 10V. From remote control to wire feeder. V: Interface ground / connected to chassis in interface. Other pins not connected. 4: Connector to remote control from interface. Remote control type 8911 can be used. Pin connections: A: Current information 0-10V DC. From interface to welding machine. B: 0V/GND (REF.0V). C: Wirefeeder ground/ connected to the chassis in wirefeeder. D: Direction signal wire. 0 = wire forward. 1 = Wire return. E: Start wire request from wirefeeder. Output from KT-4 wire feeder. F: Start wire: Input on KT-4 wire feeder. 0 = Stop wire. 1 = Start wire. G: +24V / DC to remote control. Max. 200mA. Short circuit protected. H: 0V / GND to remote control. J: Enable Basis Current. A 0 on this input, will force the remote control to enable basis current. A 1 will enable the remote control to carry out it s normal procedure. K: 0V/GND. L: 0V/GND. M: Wirespeed information 0 to 10V. From remote control to wire feeder. N: Wire +. 0 = Jog wire. P: Wire -. 0 = Jog wire direction. R: Disable puls current. 0 = No current pulsation. S: Disable step wire. 0 = Constant wire. 1 = Wire when current is high. T: Wire speed information 0 to 10V, from robot. U: Current information 0 to 10V, from robot. V: Interface ground / connected to chassis in remote control. Other pins not connected. U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 6 / 22
Connections on backside of the interface. 1 Pin numbers and names in parenthesis refer to connectors on a Fanuc robot s RJ2 or RJ3 controller. 1: Welding current + (CRW1-23, WDO1). 2: Wire speed + (CRW1-3, DACH2). 3: NC. 4: 0V / Ground in robot (CRW1-20, GND). 5: Arc Detect output from interface to robot (CRW1-6, WDI2). 6: Disable pulse current (CRW1-28, WDO6). 7: Wire +, jog wire forward (CRW1-26, WDO4). 8: Start weld (CRW1-23, WDO1). 9: Welding current (CRW1-2, CAMDA1). 10: Wire speed (CRW1-4, CAMDA2). 11: Enable basis current (CRM2B-33, SDO1). 12: +24VDC from robot (CRW1-34, +24VE). 13: Disable step wire (CRW1-29, WDO7). 14: Wire -, jog wire backward (CRW1-27, WDO5). 15: Start wire (CRW1-25, WDO3). All inputs to the interface via this connector, except analogue inputs, requires NPN open collector output type, or relay contact - switching to 0V. All outputs from the interface via this connector, are NPN open collector type. U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 7 / 22
Interface Schematic U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 8 / 22
Accessories 6 pole cable between RS interface and arc detector box. The cable must be full connected. Male / female. Length standard 3 meters. No. 74341020-1 6 pole cable between RS interface and cold wire feeder. The cable must be full connected. Male / male. Length standard 5 meters. No. 74341021-1 6 pole cable. Start welding machine. Male / male. Only pin 2 & 6 is connected. Length standard 5 meters. No. 74320002-1 8 pole cable between RS interface and welding machine. The cable must be full connected. Length standard 5 meters. Male / male. No. 74340003-0 19 pole cable between RS interface and cold wire feeder. Also used between RS interface and 8911 remote control. Length standard 6 meters. The cable must be full connected. Male / male. No. 74341011-1 Remote control 8911 Controls welding current, cold wire speed and pulse timing. No. 76118911-1 Arc detector box. Usable only for DC welding Detects current > 20A No. 76118817-1 U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 9 / 22
76118818-1 WIRE FEEDER GROUND WELDING MACHINE WELDING + Arc detector box. Can also be used for AC welding Detects current > 5A No. 76118818-1 19-Pin plug with bridges. Use when the system is equipped with wire feeder, and NOT equipped with remote control. No. 17210090-1 22 U:\RS_INTFS\WORD\OPSTILL.DOC 29/04/2011 15:48 PH/CL 10 /
Illustration 1: The welding machine gives the arc detect signal through the cold wire feeder. RS interface jumpers: J1: 2&3, J2: 1&2, J3: 1&2 Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). 11/22
Illustration 2: The welding machine gives the arc detect signal through the cold wire feeder. RS interface jumpers: J1: 2&3, J2: 1&2, J3: 2&3 Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). Note! 19-Pin plug (part no.17210090-1), must be inserted in the remote control connector, at the interface. 12/22
Illustration 3: The welding machine gives the arc detect signal. RS interface jumpers: J1: 1&2, J2: 2&3, J3: 1&2 Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). 13/22
Illustration 4: The welding machine gives the arc detect signal. RS interface jumpers: J1: 1&2, J2: 2&3, J3: 2&3 Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). 14/22
Illustration 5: The arc detector box gives the arc detect signal. RS interface jumpers: J1: 2&3, J2: 1&2, J3: 1&2 Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire E in the 8 pole Cable between the welding machine and the cold wire feeder. 15/22
Illustration 6: The arc detector box gives the arc detect signal. RS interface jumpers: J1: 2&3, J2: 1&2, J3: 2&3 Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire E in the 8 pole cable between the welding machine and the cold wire feeder. Note! 19-Pin plug (part no.17210090-1) must be inserted in the remote control connector at the interface. 16/22
Illustration 7: The arc detector box gives the arc detect signal. RS interface jumpers: J1: 2&3, J2: 2&3, J3: 2&3 Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire E in the 8 pole Cable between the welding machine and RS interface. 17/22
Illustration 8: The arc detector box gives the arc detect signal. RS interface jumpers: J1: 2&3, J2: 2&3, J3: 2&3 Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire E in the 8 pole cable between the welding machine and RS interface. 18/22
Illustration 9: The AC/DC Arc detector box gives the arc detect signal through the cold wire feeder. RS interface jumpers: J1: 1&2, J2: 1&2, J3: 1&2 Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). 19/22
Illustration 10: The AC/DC Arc detector box gives the arc detect signal through the cold wire feeder. interface jumpers: J1: 1&2, J2: 2&3, J3: 2&3 Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). Note! 19-Pin plug (part no.17210090-1) must be inserted in the remote control connector at the interface. 20/22
Illustration 11: The AC/DC Arc detector box gives the arc detect signal. interface jumpers: J1: 1&2, J2: 2&3, J3: 1&2 Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). 21/22
Illustration 12: The AC/DC Arc detector box gives the arc detect signal. interface jumpers: J1: 1&2, J2: 2&3, J3: 2&3 Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1 in the control unit on the welding machine (Analogue machines only). 22/22