F-15-081-D

July, 2001

INSTRUCTION MANUAL

PULSE ANALOG
ROBOTIC INTERFACE

APPLICATION:
MIG and PULSE MIG WELDING
Analog Item
Robot Interface Number Model
Motoman Pulse 36342 RI-3P
Hitachi Pulse 31678 RI-4P
Kawasaki/Fanuc Pulse 31676 RI-2P
REIS Pulse 0558001377 RI-6P

SPECIFICATIONS
Input Requirements ................... 7 amps, 115vac, 50/60 Hz 1 ph
Dimensions Height ............................ 15-1/2" (394mm)
Depth .................................... 8" (200mm)
Width ................................... 13" (330mm)
Weight (approx.) ............... 20 lbs (9.1 kg)

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe
practices for electric welding equipment, we urge you to read our booklet, "Precautions and Safe Practices for Arc Welding,
Cutting and Gouging," Form 52-529. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do
NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not
fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions on
page 2 and 3 before installing or operating this equipment.

Be sure this information reaches the operator.

Extra copies are available through your supplier.
 SAFETY PRECAUTIONS
WARNING: These Safety Precautions are for
your protection. They summarize precaution-
ary information from the references listed in
Additional Safety Information section. Before
performing any installation or operating procedures, be
sure to read and follow the safety precautions listed below
as well as all other manuals, material safety data sheets,
labels, etc. Failure to observe Safety Precautions can result
in injury or death.
PROTECT YOURSELF AND OTHERS --
Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits
ultraviolet (UV) and other radiation and
can injure skin and eyes. Hot metal can cause burns.
Training in the proper use of the processes and equip-
ment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work
area, even if welding helmets, face shields, and goggles
are also required.
2. Use a face shield fitted with the correct filter and cover
plates to protect your eyes, face, neck, and ears from
sparks and rays of the arc when operating or observing
operations. Warn bystanders not to watch the arc and
not to expose themselves to the rays of the electric-arc
or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless trousers, high-topped shoes, and a weld-
ing helmet or cap for hair protection, to protect against
arc rays and hot sparks or hot metal. A flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, or pockets. Sleeves and collars should be
kept buttoned, and open pockets eliminated from the
front of clothing
5. Protect other personnel from arc rays and hot sparks
with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and ex-
plosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective non-
flammable covering. Combustible materials include wood,
cloth, sawdust, liquid and gas fuels, solvents, paints and
coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or
crevices in floors or wall openings and cause a hidden
smoldering fire or fires on the floor below. Make certain
that such openings are protected from hot sparks and
metal.“
3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might pro-
duce flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire extinguisher. Be sure you are trained in its
use.
2
5. Do not use equipment beyond its ratings. For example,
overloaded welding cable can overheat and create a fire
hazard.
6. After completing operations, inspect the work area to
make certain there are no hot sparks or hot metal which
could cause a later fire. Use fire watchers when neces-
sary.
7. For additional information, refer to NFPA Standard 51B,
"Fire Prevention in Use of Cutting and Welding Pro-
cesses", available from the National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269.
ELECTRICAL SHOCK -- Contact with live
electrical parts and ground can cause
severe injury or death. DO NOT use AC
welding current in damp areas, if move-
ment is confined, or if there is danger of
falling.
1. Be sure the power source frame (chassis) is connected
to the ground system of the input power.
2. Connect the workpiece to a good electrical ground.
3. Connect the work cable to the workpiece. A poor or
missing connection can expose you or others to a fatal
shock.
4. Use well-maintained equipment. Replace worn or dam-
aged cables.
5. Keep everything dry, including clothing, work area, cables,
torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from
work and from ground.
7. Do not stand directly on metal or the earth while working
in tight quarters or a damp area; stand on dry boards or
an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mis-
take the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flow-
ing through any conductor causes lo-
calized Electric and Magnetic Fields
(EMF). Welding and cutting current cre-
ates EMF around welding cables and
welding machines. Therefore:
1. Welders having pacemakers should consult their physi-
cian before welding. EMF may interfere with some pace-
makers.
2. Exposure to EMF may have other health effects which are
unknown.
3. Welders should use the following procedures to minimize
exposure to EMF:
A. Route the electrode and work cables together. Secure
them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work
cables. Route cables on the same side of your body.
D. Connect the work cable to the workpiece as close as
possible to the area being welded.
E. Keep welding power source and cables as far away
from your body as possible.
11/95
 FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shield-
ing gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by
natural or mechanical means. Do not weld, cut, or gouge
on materials such as galvanized steel, stainless steel,
copper, zinc, lead, beryllium, or cadmium unless posi-
tive mechanical ventilation is provided. Do not breathe
fumes from these materials.
2. Do not operate near degreasing and spraying opera-
tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic
gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation
while operating, this is an indication that ventilation is not
adequate. Stop work and take necessary steps to im-
prove ventilation in the work area. Do not continue to
operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specific ventilation recommendations.
CYLINDER HANDLING -- Cylinders, if
mishandled, can rupture and violently
release gas. Sudden rupture of cylin-
der, valve, or relief device can injure or
kill. Therefore:
1. Use the proper gas for the process and use the proper
pressure reducing regulator designed to operate from
the compressed gas cylinder. Do not use adaptors.
Maintain hoses and fittings in good condition. Follow
manufacturer's operating instructions for mounting regu-
lator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain
or strap to suitable hand trucks, undercarriages, benches,
walls, post, or racks. Never secure cylinders to work
tables or fixtures where they may become part of an
electrical circuit.
3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames.
Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases in
Cylinders", which is available from Compressed Gas
Association, 1235 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or im-
properly maintained equipment can cause
injury or death. Therefore:
1. Always have qualified personnel perform the installa-
tion, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to
perform such work.
2. Before performing any maintenance work inside a power
source, disconnect the power source from the incoming
electrical power.
3. Maintain cables, grounding wire, connections, power cord,
and power supply in safe working order. Do not operate
any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces, wet
conditions such as water puddles, oil or grease, corrosive
atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and
in good repair.
6. Use equipment only for its intended purpose. Do not
modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for elec-
tric arc welding and cutting equipment, ask
your supplier for a copy of "Precautions and
Safe Practices for Arc Welding, Cutting and
Gouging", Form 52-529.
The following publications, which are available from the
American Welding Society, 550 N.W. LeJuene Road, Miami,
FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"
2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"
3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"
4. AWS C5.3 - "Recommended Practices for Air Carbon Arc
Gouging and Cutting"
5. AWS C5.5 - "Recommended Practices for Gas Tungsten
Arc Welding“
6. AWS C5.6 - "Recommended Practices for Gas Metal Arc
Welding"“
7. AWS SP - "Safe Practices" - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, "Recommended Safe Practices for Weld-
ing and Cutting of Containers That Have Held Hazardous
Substances."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate haz-
ards which, if not avoided, will result in
immediate, serious personal injury or
loss of life.
Used to call attention to potential haz-
ards which could result in personal injury
or loss of life.
Used to call attention to hazards which
could result in minor personal injury.
3
I. FEATURES
ESAB Analog Robot Interface
In general, these microprocessor controls are de-
signed to interface with robot controllers using analog-
system programming and are capable of all modes of
conventional mig and flux cored welding. The ESAB
ANALOG ROBOTIC INTERFACE receives analog
parameter inputs from a robot controller, processes
these signals and accurately controls the welding
power supply and wire feeding system. Other data is
exchanged between the ESAB ANALOG ROBOTIC
INTERFACE and robot controller such as start/stop
signals, shielding gas control, wire touch work, weld
enable, etc.
ESAB PULSE Analog Interface
This version of the ESAB Analog Interface offers all of
the features above plus “synergic” operation in all Mig
modes including Pulsed Mig. This simplifies the opera-
tion even further and can actually increase the overall
performance of the robot cell. The interface is factory
programmed for six (6) materials and five (5) wire sizes;
select material type, wire size, Mig mode (short, spray
or pulse) and the PULSE INTERFACE automatically
sets optimum welding parameters based on wire feed
speed.
Figure 1 - Typical Robot System
4
TEACH Option (for Pulse version only)
This optional kit for the ESAB PULSE analog interface
adds the highest degree of flexibility by enabling the user
to "teach" the Analog Interface custom synergic pulse
parameters for user specific weld applications. Refer to
instruction manual F-15-519 Teach Mode Operating
Instructions for Pulse Analog Interface.
Also available from ESAB;
ESAB CONVENTIONAL Analog Interface
This version of the ESAB Analog Interface offers simple
operation in all modes of conventional MIG welding
including flux cored welding with an exceptionally high
degree of precision. The welding parameters are set by
providing wire speed and voltage signals from the robot.
The interface then sets and precisely regulates the
actual welding parameters.
2. How To Assemble a Robotic Welding System
Robotic welding systems can become quite complex
considering all the equipment required to outfit a work
cell. The following lists the main welding equipment
items to be considered for operation. Consult your
ESAB Sales Literature and the following pages for
specific equipment item numbers. Then use this check
list to be sure that you have all of the required items.
EQUIPMENT & HARDWARE CHECK LIST Wire Conduit ...................................................... ❑
Wire Conduit Fittings .......................................... ❑
ESAB Analog Interface ....................................... ❑ ESAB Plumbing Box ........................................... ❑
ESAB Welding Power Source ............................. ❑ Plumbing Box Cable ........................................... ❑
Voltage Pickup Lead (pulse units only) ............... ❑ ESAB Water Cooler ............................................ ❑
Power Source Control Cable .............................. ❑ Water Cooled Welding Torch ............................. ❑
ESAB EH-10A Wire Feed System ...................... ❑ Torch Adapter ..................................................... ❑
Wire Feed Rolls .................................................. ❑ Contact Tips ....................................................... ❑
Motor Extension Cable ....................................... ❑ Torch Wire Liner ................................................. ❑
Wire Inlet Guide .................................................. ❑ ESAB Flowmeter/Regulator ................................ ❑
Wire Outlet Guide ............................................... ❑ Gas Hoses and Fittings ...................................... ❑
Wire Spool Support ............................................ ❑ Water Hoses and Fittings ................................... ❑
Wire Spool Cover ............................................... ❑ Welding Cables .................................................. ❑

TYPICAL SYSTEM COMPONENTS

Analog Interfaces Power Sources (230/460 vac 60 hz.)
31675 Fanuc - Conventional MIG 31120 Digipulse 450i
31677 Hitachi - Conventional MIG 31950 SVI450i
36341 Motoman - Conventional MIG 36377 V 352
31676 Kawasaki/Fanuc - Pulse 36000 V 452
31678 Hitachi - Pulse 36004 V 652 cvcc
36342 Motoman - Pulse
0558001377 REIS - Pulse Water Accessories
34696 SI - Pulse 34749 PB-3 Plumbing Box
34560 Optional Digital DC Ammeter Kit 34199 Plumbing Box Cable - 3.5 ft.
34845 Plumbing Box Cable - 25 ft.
Interface to Power Source Cables 33739 WC-8C Upright Water Circulator
30686 J1 Control Cable - 6 ft. 33540 WC-9 EHD Water Circulator
30780 J1 Control Cable - 30 ft. 40V76 Water Hose - 12.5'
30781 J1 Control Cable - 60 ft. 406196 Water Hose - 25'
34070 Pickup Lead (Digipulse only) 11N18 Water Hose Coupler
Drive Motor & Wire Accessories 11N16 5/8-18 RH to 1/4 NPT Adapter
679774 EH-10A Digital Motor Drive Rolls - Two Roll System
49V51 2 Roll Accessory Support 2075303 .035" - “V” Hard Wire
600216 4 Roll Accessory Support 2075302 .045" - “V” Hard Wire
60N90 Insulator Ring (Required) 19761 .045" - “V” Serrated - Flux core
996808 Motor Control Cable - 25 ft. 2075261 .052" - “V” Serrated - Flux core
996497 EH-10A Motor Mounting Bracket 2075261 .062" - “V” Serrated - Flux core
948259 Spool Spindle Assembly
634288 Reel Support Arm Drive Roll Kits - Four Roll System
995570 Coil Adapter 999326 .035" - “V” Hard Wire
19V89 Coil Adapter HD 999327 .045" - “V” Hard Wire
20572 CC Torch Adapter 999330 .045" - “V” Serrated - Flux core
950574 Conduit Assy. 10 ft. 999331 .052" - “V” Serrated - Flux core
950575 Conduit Connector - Male 999332 .062" - “V” Serrated - Flux core
679302 Adapter 39N15 Outlet Guide .035" - .062"
950576 Conduit Connector - Female
600240 Spool Cover - Clear Shielding Gas Accessories
34V74 Wire Straightener (order inlet below)
11N53 Inlet Guide 21557 R-33 Flow Regulator - Argon Mix
995570 Standard Wire Reel, up to 60 Ibs spools 21558 R-33 Flow Regulator - CO2
19V89 H.D. Wire Reel, 65 Ibs coils 21505 R-36 Flow Regulator - Argon Mix
600240 Spool Enclosure Kit, 12-in spools 999149 R-76 Flow Regulator - CO2
40V77 Gas Hose - 12.5'
Wire Wiper Accessory 19416 Gas Hose - 12.5' Heavy duty for CO2
598537 Felt Wiper, pkg. of 10 11N17 Gas Hose Coupler
598764 Wiper Holder
598763 Wiper Holder, used w/opt. wire straight

5
6
Figure 2.
C. MOUNTING/CONNECTING THE EQUIPMENT
Analog Interface
The operating controls for the ESAB Analog Interface
are located on and behind the front cover. The box
should be positioned within easy reach of the Robot
operator on a vertical surface using the mounting holes
provided.
Welding Power Source
The welding power supply should be mounted as close
to the robot as posible. Distances less than 20 feet are
recommended. The power source must have at least
18" of free air space in all directions to maintain ad-
equate unrestricted cooling air flow. Both welding cable
leads (torch and work) must be a minimum size of No.
4/0 welding cable, and should be kept as close to the
same length as possible. Cables must be run next to
each other and tywrapped every couple of feet to
minimize cable reactance.
Wire Feed Motor
The wire feed motor & accessory support can be
mounted directly on the robot arm or on a stand close
to the robot. The shortest possible welding torch is
recommenced for best wire feed results.
Figure 3. - Wire Feed Delivery System
IMPORTANT: The wire drive motor can be mounted as
a left or right hand drive. Once operational, check for
proper rotation. If rotation is incorrect, simply re-
verse the orange and blue wires on T1-5 and T1-6.
Wire Delivery System
The wire delivery system, whether it be a spool, coil, reel
or drum must be kept as close to the robot as possible.
Distances less than 10' are recommended. Every effort
must be made to keep the wire delivery system clean
and the wire conduit free from twists and sharp bends.
IMPORTANT: Wire delivery and feeding is the most
frequent encountered problem in MIG welding and is
sometimes difficult to uncover.
Plumbing Box
The plumbing box should be mounted directly below the
Analog interface with the water cooler.
Once all of the equipment is securely mounted, connect
the control cables, hoses and wire hardware as shown
in the interconnection diagram titled Typical Robot
System (Fig. 1) and the Wire Feed Delivery System
(Fig.2).
7
ROBOT to INTERFACE CABLE - J3 Figure 5. HITACHI J3 Pin Configuration
In all cases, the control cable from the robot controller
to the ESAB Analog Interface (J3) is supplied by the
robot manufacturer. The connector and pin configura-
tion of this cable has been designed by the robot
manufacturer to their specifications. The ESAB Analog
Interface receptacle (J3) has been configured to accept
the standard control cable from the specified robot.
Questions concerning pin configurations should be
directed to the specific robot manufacturer.

The following figures are the typical J3 control cable pin

configurations for the Motoman, Fanuc, and Hitachi
robots.

Additional information on connections and/or adjust-

ments can be found as follows:

INSTRUCTION LITERATURE
EH-1OA Digital Welding Head ................... F-12-873
Teach Mode Operating Instructions ........... F-15-519

Figure 4. Motoman J3 Pin Configuration

Figure 6. FANUC J3 Pin Configuration

8
 Figure 7. REIS ROBOT INTERFACE
8 7

b c
o

Control Cable from Robot 6

J3
PIN Designations

2 3 4
1 10

Fig. 8 - Location Front Panel Controls

III. CONTROL FUNCTIONS & OPERATION

IMPORTANT
Some of the controls and features covered follow-
ing are not required or used in “all” of the robots,
and these exceptions will be specifically noted in
the text as they occur.

A. FRONT PANEL CONTROLS

For location of front panel controls, see Fig. 8.

1. Power-Switch. Pulling-out the mushroom-style red

button of this switch turns power "on" to the control as
indicated by the illuminated display windows. To turn
power "off", simply push-in red button and the display
windows and control will de-energize.

NOTE: Immediately after the control is turned on,

numbers that identify the EPROM “program”
in the control are displayed in the IPM and
VOLTS windows. These numbers only ap-
pear for one second.

2. PURGE/RESET Switch. A momentary “on” switch,

that provides a dual function when actuated.

a. Prior to starting the welding sequence, it actu-

ates the gas solenoid and lets you “purge” the
shielding gas line of the torch. At the same time,
the IPM and VOLTS windows will also display

9
 the preset times (in seconds) for gas preflow and
gas postflow respectively.
b. After starting the welding sequence - if an abort
“shutdown” condition occurs (indicated by a flash-
ing digital display), the Purge/Reset switch can
be actuated and the control will automatically “re-
set”.
3. INCH Up-Down Switch. This switch is used to “cold
inch” the wire, up or down, at a preset speed which
you have programmed. If held down, the wire feed
speed will be 50 IPM for the first 2 seconds, after
which time it will switch over to the preset speed. To
increase or decrease this preset speed, use the INC-
DEC key under the IPM window while the motor is
running and the speed value is displayed.
IMPORTANT: Cold inching is only possible when
the weld Start-Stop rocker switch is
in its “stop” (or off) position.
4. Start-Stop Switch. If the Control is to be used in its
Panel position for manual operation, the Start-Stop
rocker switch is used to initiate the welding sequence
in the START position, and to terminate the welding
sequence in the STOP position.
If the Analog Control is to be used for Robot opera-
tion, the Start-Stop switch must be left in the STOP
position.
5. Pulse-Short - Spray Selector. This three-position
rotary switch allows you to select the mig welding
process mode you wish to use - Pulsed arc, Short
Arc, or Spray Arc.
The welding process can also be selected by the
Robot. Contact ESAB if this feature is desired.
6. Digital Readout Windows. Three individual 3-
digit windows labeled AMPS (optional ammeter),
IPM and VOLTS are provided to display actual
welding current, preset or actual welding param-
eters (wire feed speed and welding voltage) and
time parameters as follows:
a. AMP Digital Readout. This window is normally
blank unless the optional Ammeter Kit is pro-
vided to monitor actual welding current. When
installed, the window displays d.c. current (AMPS)
in a range from 0-999 amperes in one amp incre-
ments.
b. IPM Digital Readout. This window is primarily
used to display wire feed speed in IPM from 20
to 999 inches per minute in one inch increments.
However, with the appropriate function selec-
10
tor actuated, this window can also display the
following:
-- PREFLOW Time from .1 to 99.9 seconds in
one tenth of a second increments.
-- MATERIAL A code number that indicates the
type of material which is programmed for the
welding modes: for example 1 indicates Steel, 3
is Aluminum, 5 is Stainless, and 6 is Silicon
Bronze
-- SPOT Welding time from 1 to 999 cycles
in one cycle increments or in seconds where 60
cycles equal one/second (must be set to zero for
continuous seam welding)
-- COLD INCH Speed in IPM from 20 to 999
inches per minute in one-inch increments
NOTE: With the Panel/Robot switch in “PANEL” and
Power switch turned “on”, but not welding, the
IPM window will continuously read Preset
wire speed. When the arc is struck, the IPM
window will read Actual wire speed.
c. Volts Digital Readout. This window is primarily
used to display arc voltage in VOLTS from 12 to
50 vdc in one tenth volt increments. However,
with the appropriate toggle selector actuated,
this window can also display the following:
-- POST FLOW Time from .1 to 99.9 seconds in
one tenth of a second increments
-- WIRE DIA. A number that indicates the diam-
eter of the wire which is preprogrammed for
welding: for example, 35 indicates .035" dia., 45
is .045 dia., and 63 is 1/16" dia. (.063" dia.)
-- ARC VOLTAGE Indicates the computed arc
voltage for a given wire speed. The computed arc
voltage can be readjusted +/-10 volts to fine tune
the welding arc.
NOTE: With the Panel-Robot switch in PANEL and
Power switch turned “on”, and welding, the
VOLTS window will continuously read actual
welding voltage.
-- BURNBACK TIME. If set manually, will over-
ride the automatic adaptive anti-stick feature.
This time period can be set in one-cycle (60
cycles = 1 sec.) increments. When set to “zero”,
the Automatic Adaptive Anti-stick feature will be
operational.
7. NO PROGRAM Indicator (L.E.D.) This light indi-
cates that a wire type (Material) and size (Diameter)
that is not programmed in the control. In addition, if
a start is attempted in which the light lit, the power
supply will not energize and the unit will not feed
wire.
8. Input/Output Robot Function (L.E.D.) Lights.
Primarily these lights function when the control is
 1 4a
4b 6 In the "synergic" mode, the control will display various
numbers to indicate wire type, size, feed rate and times
such as pre, post flow burnback, etc. In place of the arc
voltage, an arbitrary number (100) will appear regard-
less of the set speed. This number appears in the
VOLTS window prior to welding. This value (preset
@100) can be readjusted, within a range from 0 to 200,
to "fine-tune" the operating arc length of the selected
welding condition. By reducing the number below 100
(minimum 0), you will reduce the arc length. Conversely,
by increasing this value above 100 (maximum 200) you
can increase the arc length. The difference between
the set number and "100" will represent the devia-
tion in hertz between the factory suggested fre-
quency and the actual adjusted frequency if you are
in the pulse mode. This can be either positive or
negative. After the arc is struck, the number will be
replaced by the actual welding arc voltage.

The Control can also operate in the adaptive mode,

2 3 5a 5b
Fig. 8 - Inside Panel Controls
used in the ROBOT mode; however two Output
LED’s, ARC ESTABLISHED AND ABORT/ARC
OUT, will also function in the panel mode. The
appropriate light or lights will energize to indicate
the specific function(s) being used at the
appropriate time in a welding sequence. Remem-
ber, some of the following Input/Output func-
tions are not required or utilized in all Robot
models.
where the arc is continuously monitored by a closed
loop feedback circuit to maintain the programmed arc
voltage. In the adaptive mode, a computed arc voltage
(unique to your preprogrammed welding selection) will
be displayed in the VOLTS window before welding if
the analog input voltage from the robot is present.
Once the arc is struck, the control will measure the
actual welding voltage and change the output of the
power source to maintain the preset value. In this
manner, the power supply automatically compensates
for variations in stickout or weld joint geometry. Further,
all of the precalculated arc voltages programmed in the
control can be readjusted +/- 10 Volts to "fine-tune" the
welding arc.

Inputs From Robot: WELD Start, Gas Purge, Inch
Up, Inch Down, and System Enable.
Outputs To Robot: Ready, Arc Established, Abort/
Arc Out, Wire Clear, and WIRE CONTACT.
9. Reset Circuit Breaker. A seven (7) ampere circuit
breaker provides protection to the 115 volt
control circuit and the wire feed motor. If an
overload occurs, the breaker will trip and suspend
all operation. To restore service, simply depress the
breaker button on the front panel.
B. INSIDE PANEL CONTROLS
For location of inside panel controls, see Fig. 8
1. Synergic-Adaptive Switch. This switch, if provided
allows selection of "synergic or adaptive" logic
modes. The operating characteristics of synergic
vs adaptive logic in the welding operation are
covered in more detail in section V B. Only a short
summary is given here.
2. Robot-Panel Toggle Switch - This two-position
switch is used to set the “location” from which this
control is to be setup and operated. The ROBOT
position allows the control to be set up and operated
from the Robot; while the PANEL position allows the
welding sequence to be setup and operated from the
Analog Control itself.
3. Spot/Burnback - Wire Dia./Material Selector.
Operating this toggle allows you to select the follow-
ing:
a. Activating the SPOT/BURNBACK switch (hold-
ing in the up position) allows you to preset either
or both of these times into all three modes of
operation; however, once preset, the times
automatically become part of the three operating
modes. In other words, switching weld modes
maintains the setting.
The SPOT mode allows you to preset “timed-
arc” periods (from . 1 to 99.9 seconds) in the
IPM window using its Inc./Dec. toggle switch.

11
 This feature is primarily used in the PANEL MODE.
When a spotweld time is preset, all “continuous-
type” welding programs are “temporarily disabled”.
To resume normal (continuous) operation, the
spot time has to be set to 0.
At the same time (or independently), you can also
preset a manual BURNBACK time into the VOLTS
window using its Inc./Dec. toggle switch. The
Burnback time is adjustable in one cycle incre-
ments (60 cycles/sec); and when preset, it will
override the automatic adaptive anti-stick
feature in the three welding modes. If automatic
anti-stick operation is desired, the preset Burn-
back time must be set back to “zero”. For PULSE
operation, the use of the manual burnback setting
is recommended.
b. Activating the WIRE DIA/MATERIAL switch (down
position) allows you to select one of the six pre-
programmed wire material types and one of five
preprogrammed wire sizes. This selection is
necessary for proper operation in all 3 modes;
short, spray and pulse welding. To select the
type of wire Material, use the Inc./Dec. toggle
switch below the IPM window until the desired
code number indicating material type (1 and 2 for
steel, 5 for stainless, 3 and 4 for aluminum, or 6
for silicon bronze) appears in the IPM window.
Now select the Wire Diameter size to be used by
indexing the INC position of the Inc./Dec.
toggle switch below the VOLTS window until
the desired pair of numbers indicating wire size
(23 for .023" dia., 30 for .030" dia., 35 for .035"
dia., 45 for .045" dia., or 63 for 1/16" dia.) appears
in the VOLTS window. These values must be set
for both the panel and robot mode.
NOTE: Actuating the Wire Dia/Material switch while
the system is welding, allows you to check
for proper servo operation of the unit. The
Speed (approx 110) and Voltage (approx. 90)
servo settings will appear, simultaneously, in
their respective IPM and VOLTS windows.
Read more about this feature in the "Hot Start"
section.
4. Inc./Dec. Set-Up Switches. Two control switches
are provided to preset the required
welding parameters from the Analog Interface con-
trol panel.
a. “IPM” Increase/Decrease Control. This switch
is primarily used to set and/or vary the wire feed
speed (IPM), along with its other functions; Pre-
flow, Material, Spot and Inch. With the appropri-
ate function selector actuated, each parameter
12
setting will be displayed in the digital window
directly above this switch.
b. “VOLTS” Increase/Decrease Control. This
switch is primarily used to set and/or vary the
Arc Volts, along with all its other
functions: Postflow, Wire Dia., and Burnback.
With the appropriate function selector actuated,
each parameter setting will be displayed in the
digital window directly above this switch.
5. TEST Toggle Switches -- ANALOG INPUT and
AMPS. These two toggles provide a convenient way
of test-sequencing the program parameters to ei-
ther diagnose a problem, or to test the control
without actually striking a welding arc as follows:
a. The Test/Analog Input toggle is a two-posi-
tion (momentary up, maintain down) switch
that allows the user to test the operation of the
Analog Interface board when the unit is set to
SYNERGIC in the robot mode . In its normal
Analog position the switch provides continuity to
the Robot Input signals, both voltage and speed.
When the toggle is raised and held in its momen-
tary TEST position, a 5-volt analog signal will be
connected to both the speed and voltage termi-
nals of the Analog Input board. With the
ROBOT/PANEL switch in the ROBOT position,
the speed and voltage display windows should
now reflect the digital equivalent of approxi-
mately *500 IPM and approximately 100
volts**. If these numbers appear, the
analog interface board is functioning properly.
*NOTE: For MOTOMAN robots this will display ap-
proximately 357 IPM and 36 volts.
**NOTE: The 100 will be present only in synergic
mode.
b. The Test/Amps toggle is a two-position (main-
tained contact) switch that allows the user to test
the control. The AMPS position (toggle down) is
the “normal” location for all welding operation.
To test the control, place the Amps/Test
toggle in its TEST position. This provides an arc
detection signal required to sequence through
the welding cycle. The ARC ESTABLISHED indi-
cator will be lit while the switch is in this position.
With this accomplished, open up the accessory
support clapper to release wire feed pressure
and place the “Start-Stop” switch in the START
position. The control will sequence through the
programmed welding cycle (preflow, weld,
postflow,etc.).
Please note that if you inadvertently leave
the switch in the amps position instead of setting
the Test position (when testing the control), the
 control will shutdown with both windows “flash-
ing” within 2-seconds after receiving the “Start”
signal.
6. Teach Pulse Parameter Switch (XRT model only).
This switch allows you to program Pulse Height
(PH), Pulse Width (PW), Pulse Background (PB),
and Pulse Frequency (PF) "teach" parameters into
material codes 11 thru 15. These features and
operating functions are fully covered in XRT supple-
mental booklet F-15-519.
IV. OPERATION
1. Robot Mode - To operate the control in the Robot
mode;
A. Select a wire diameter and a material as follows:
1. Set the type of material, using the INC/DEC toggle
switch below the IPM window until the desired
code number indicating material type (1 and 2 for
steel, 3 and 4 for aluminum, 5 for stainless, or 6 for
silicon bronze) appears in the IPM window. Refer
to Table 4-1 for material codes and shielding gas
recommendations.
2. Set the wire diameter using the INC/DEC toggle
switch below the VOLTS window until the desired
numbers indicating wire size (23 for .023" dia., 30
for .030" dia., 35 for .035" dia., 45 for .045" dia., or
63 for 1/16" dia.) appear in the VOLTS window.
3. Set burnback time, by operating the SPOT/BURN-
BACK key and entering a number into the volts
window. A good number to start with would be 4 or
5 cycles.
B. Program wire feed speed and arc voltage for an
optimum welding condition. Use of the factory set
parameters will ensure a good baseline weld from
which minor adjustments can be made. The following
paragraphs describe the programming of the wire
feed speed and the arc voltage using the two analog
inputs from the robot.
1. Speed The scaling for the speed input should be
set with minimum and maximum speed values of
0 and 1000, respectively. The reference voltage
for minimum and maximum values should be set
to 0 volt and 10 volts, respectively. This will provide
a speed readout that will directly agree with the
programmed information. For example, a setting
of 300 on the teach pendant will result in an actual
wire feed speed of 300 IPM.
2. Voltage The arc voltage control will be done in a
totally different manner. Since this control is a
synergic control, the arc voltage will be a function
of the wire feed speed based on the material type
/wire size program selected. Therefore, as the
robot increases the wire feed speed the arc volt-
age will automatically increase based on a
preprogrammed relationship between speed and
arc voltage. To change this arc voltage without
changing the wire feed speed, the robot will have
to change the reference voltage to the voltage
port.
Set up scaling for the voltage port with 0 V as the
minimum and 100 as the maximum value, corre-
sponding to a 0 volt and 10 volt reference voltage,
respectively. To make the first test weld, it is
recommended that the programmed value be 50
V, which will provide a reference value of 5 volts
to the control.
As a weld is made, the arc voltage corresponding
to the 50 V input can be observed. If the arc is too
"hot", the programmed value may be changed
from 50 to 45. This will cause average arc voltage
to drop by 1.25 volts. A reduction of 1 count on the
programmed value will reduce the arc voltage by
1/4 volt. Set the reference for the best weld
results.
C. Generate "start" signal from robot. Once the arc
is established, the ARC EST signal is sent to the
robot, which in turn, begins the movement of the
robot arm. If the ARC EST signal is lost, the robot will
send a stop signal to the Interface and terminate the
weld.
V. PULSE/SPRAY/SHORT ARC WIRE SPEED
RECOMMENDATIONS
1. General
The listings in the following tables give approximate
wire feed speed ranges (IPM) for the various types of
wire diameters and materials which have been
preprogrammed in these controls.
2. Material Code Operating Tips (Where Applicable)
a. Carbon Steel (Code #1) and Alternate Steel (Code
#2). The Code #2 parameters are very similar to
the Code #1 parameters; however, Code #2 has
wider Pulse Widths and higher Pulse Background
settings. The arc characteristics will appear to be
"softer" than Code #1. Arc penetration could also
be slightly less do to the lower pulse peak used.
This type arc characteristic might be used on
applications requiring improved bead wetting.
Operation Note: Excessive resistances in the
welding system, caused by water cooled torches or
excessively long welding cables, can produce pulse
peak currents below that which is required for stable
droplet detachment. This condition can be recog-
nized by occasional large droplets propelled across
the arc. Some short circuiting and spatter could also
result. Long arc lengths can also cause less than
optimum performance. The arc length should be
13
 kept short for best arc stability and puddle control. Table III for Typical "Short Arc" Wire Speed Ranges
Too short an arc length will produce spatter and less Wire Material Wire Diameter & Wire Speed Range
than optimum arc stability. If a globular type transfer Code # Type .023* .030* .035 .045 .063
occurs, check for high resistance in the welding
1 Carbon Steel 175- 180- 130- 130- N
current. 500 600 600 450
2* Alternate Stl. 125- 175- 100- 100- NP
b. Aluminum 4043 (code #3) and 5356 (code #4). 350 350 300 250
3* 4043 Allum. NP NP NP NP NP
Each alloy and diameter has been set for best 4 5356 Alum. NP NP NP NP NP
arc performance and puddle control. The wire 5 308 Stainless 250- 100- 75- 50- NP
feed speed of 4043 3/64-inch diameter (.045) is 450 400 300 250
6* Sil. Bronze NP NP NP NP NP
limited to 300 ipm at which point the pulses begin 7**
to overlap and spray arc results. If higher wire 8**
feed speeds are required on this alloy, switch to 9**
10**
Code #4 (5356 .045) and adjust the arc voltage * Additional wire Materials and Diameters provided in for Xr and XRT models.
for stable arc performance. This action will ex- ** These codes are reserved for custom applications in Xr/XRT models only.
tend the wire feed speed to approximately 600 NP Not programmed.

ipm.
Table IV for Typical "Spray Arc" Wire Speed Ranges
Wire Material Wire Diameter & Wire Speed Range
c. 308 Stainless Steel (Code #5). The stainless
Code # Type .023* .030* .035 .045 .063
steel pulse parameters are based on gases 1 Carbon Steel 800- 525- 425- 275- 170-
(listed below). These gases improve the bead 999 900 800 550 275

wetting of stainless steel as compared to the 1% 2* Alternate Stl. 800- 525- 425- 275- 170-
999 900 800 550 275
and 2% oxygen mixtures. The program can still 3* 4043 Allum. NP 400- 400- 200- 200-
be used with the oxygen mixtures. but a small 800 600 500 300

adjustment in arc voltage will be necessary. 1. 4 5356 Alum. NP 450- 450- 300- 250-
750 750 500 450
Linde "Pulse Blend SS" 5 308 Stainless 750- 450- 350- 250- 150-
2. 2-1/2% - CO2, 1%-H2, Bal. Argon 950 650 650 550 300
6* Sil. Bronze NP 400- 400- 300- NP
550 550 500
Operation Note: Arc starting with stainless steel 7**
can be inconsistent at times due to the higher 8**

resistivity of the alloy and other variables. Some- 9**

10**
times increasing the voltage will improve starting. A * Additional wire Materials and Diameters provided in for Xr and XRT models.
weld technique adjustment might also help. When ** These codes are reserved for custom applications in Xr/XRT models only.

striking the arc, immediately move out of the puddle NP Not programmed.

and begin traveling. A hesitation in travel at the start

causes the puddle to build under the arc while the Table V for Typical "Pulse Arc" Wire Speed Ranges
control is trying to adjust for arc voltage. Eliminating Wire Material Wire Diameter & Wire Speed Range
the puddle build-up helps the voltage control circuit Code # Type .023* .030* .035 .045 .063
establish the proper arc length more quickly.
1 Carbon Steel 150- 115- 85- 55- 75-
700 550 700 450 250
d. Silicon Bronze (Code #6). The welding perfor- 2* Alternate Stl. 140- 150- 140- 70- 70-

mance of silicone bronze alloys currently sold 700 500 700 400 220
3* 4043 Allum. NP 225- 225- 130- 100-
can vary widely. Small differences in chemistry, 500 500 300 250
cleanliness, and feedability can affect the pulse 4 5356 Alum. NP 225- 250- 170- 150-

welding characteristics. To overcome instability 500 500 500 300

5 308 Stainless 150- 100- 100- 60- 55
problems, be sure wire feeding is steady and 700 500 450 450 260
slack in the liner is minimized. Use tip-to-work 6* Sil. Bronze 225- 250- 175- 125- NP

distances slightly longer than normal if arc 500 500 500 500
7**
instability occurs. 8**
9**
10**
* Additional wire Materials and Diameters provided in for Xr and XRT models.
** These codes are reserved for custom applications in Xr/XRT models only.
NP Not programmed.

14
B. WELDING IN PULSE, SPRAY OR SHORT ARC
MODE
All three processes can be used in either synergic or
adaptive mode. Following is a summary of the two
modes of operation:
SYNERGIC OPERATION
To put the control into the SYNERGIC mode of opera-
tion, use the synergic/adaptive switch if provided. If the
optional switch is not present, close switch #1 of Dip
Switch SW1.
Location For
"Dip"" Switch 1 (SW1)
Fig. 9 - MPU P.C. Board
Synergic Pulse Arc Welding makes use of a relation-
ship between wire feed speed and pulse frequency
which is programmed into the interface control for each
material type and wire size. See typical graph for .045
dia. steel wire.
As the wire feed rate increases, so does the frequency
and since the arc voltage is also related to the frequency
the arc voltage will also increase proportionately.
For each combination of material type and diameter the
graphs will be somewhat different; i.e., the slope of the
line and the intercept will vary, but the general principle
will not change.
The equations that relate frequency and speed; or arc
voltage and speed are stored in the program for most
of the commonly used materials and wire diameters. If
the user selects a particular material and wire size by
entering the code of the material and the diameter of the
wire into the control, the program will search for that
combination. If it is not found, the NO PROGRAM light
will be lit. If program parameters do exist for the
particular combination, all the user need to enter is the
wire feed speed desired and the proper frequency will
automatically be computed by the control.
As the wire feed speed increases, the control will
automatically increase the pulse frequency to maintain
a stable arc. The welding current (heat) can be changed
by increasing or decreasing the IPM without readjusting
voltage. Changes in tip to work will affect arc length.
If the welding arc is too long, or two short an adjustment
of the frequency (arc voltage) can be made to fine tune
the arc. In the synergic mode of operation prior to
striking an arc the display will show the preset IPM in the
"Speed" window and a reference number in the "Volts"
window. After the arc is struck, the actual speed and arc
voltage will be displayed. If the factory set frequency is
used (no fine tuning of the arc was made) the number
displayed prior to striking an arc will be 100. If a change
was made to increase the frequency (arc voltage) the
number will be greater than 100; vice verse, if the
frequency was decreased the resulting reference num-
ber will be less than 100. These numbers will only be
present if the analog control voltage from the robot is
output without the start signal.
The difference between the number displayed and the
number 100 is the amount of change in Hz; that the
control will add or subtract from the factory set fre-
quency. As an example, if at a given speed the number
100 was changed to 85 the new frequency will be (100
- 85); i.e., 15 Hz lower than the factory set value,
lowering the arc voltage by about 1.5 volts.
Once the 100 number is changed, the resulting offset
(100 ± X) will be in effect for any material at any speed.
In effect the curve has been shifted without altering the
slope, by the amount of the offset either in the positive
(numbers greater than 100), or in the negative direction
for numbers less than 100.
Synergic Spray Arc and Short Arc:
Just as in pulse welding, in the short and spray arc
welding as well, a relationship exists between arc
voltage and wire speed for any given wire size and type.
In this mode the unit will operate like a conventional
welder however the arc voltage is set by the weld
control program and changes in tip to work will affect
arc length. The voltage can be read during welding
and increased or decreased to obtain a stable welding
condition based on the wire feed speed used. If the wire
feed speed is changed, the program will calculate the
new voltage necessary to maintain a stable arc.
Just as in the synergic pulse mode, to run at factory set
conditions the display in the "Volts" window should be
100; to increase or decrease the arc voltage, the
number has to be raised or lowered.
ADAPTIVE OPERATION
Pulse Arc Welding:
Adaptive Pulse Mode of Operation
The adaptive mode of operation is also based on a
relationship. In this case the relationship is between
wire feed speed and arc voltage.
15
As the wire feed speed increases, the control will
automatically increase the pulse frequency to maintain
the arc voltage set in the control VOLTS window.
Changes in tip to work will not affect arc length.
Increasing the speed will require an increase in the arc
voltage which in pulse welding will require an increase
in the frequency. These relationships of speed vs. arc
voltage for the commonly used wires are programmed
into the control's EPROM. Just as in the synergic mode
as a material type and wire dia. is entered into the
control, the program will search for the combination. If
it is not found the NO PROGRAM light will be lit.
If it's a valid combination, all the user has to input is the
desired wire feed speed. The program will compute and
display the factory set voltages for the set speed. If fine
tuning is required simply increase or decrease the
displayed voltage value, either before the arc is struck
or during the actual weld.
Spray Arc and Short Arc:
In this mode, the unit will control the power supply to
maintain the arc voltage set up in the VOLTS window of
the control. Changes in tip to work will not change arc
length. The voltage can be preset before welding and
changed during welding to obtain a stable welding
condition based on the wire feed speed used. If the wire
feed speed is changed, then the program will calculate
the new voltage necessary to maintain a stable arc.
Welding can be initiated either from the robot by means
of a START signal, or from the panel with the START/
STOP switch. The panel mode is normally used for
setup and test mode prior to automatic robot welding.
To start welding under robot control, the START/STOP
switch must be in the STOP position, otherwise
welding will not start. This is a safety feature to prevent
arc start without the operator's knowledge.
The system will shut down if the preset wire speed or arc
voltage parameters cannot be maintained due to ab-
normal conditions. If this occurs, the parameters caus-
ing the system shutdown will be signaled by a flashing
digital display and the welding sequence must be
restarted by actuating the PURGE/RESET rocker
switch. Also, a shutdown occurs if an arc is not estab-
lished within 2 seconds after the START signal is
received from the robot. In such a case, both the
VOLTS and IPM displays will be flashing and an "abort"
signal is sent to the robot.
XRT UNITS
The XRT version has all the capabilities of the XR
version, but additionally includes a "Teach" mode to
permit welding of materials and conditions that are not
programmed. It is generally preferable to attempt to
16
weld using the preprogrammed parameters and fine
tuning them for special requirements, but if this is not
possible, the XRT unit allows the teaching of five
schedules which can be set up and memorized.
For a detailed description of teaching in the PANEL
mode refer to instruction manual F-15-519 Teach Mode
Operating Instructions for Pulse Analog Interface XRT.
V. TROUBLESHOOTING
Be sure that all primary power to the machine has
been externally disconnected. Open wall discon-
nect switch or circuit breaker before attempting
inspection or work inside of the power supply.
Listed below are a number of trouble symptoms, each
followed by the checks or action suggested to deter-
mine the cause. Listing of checks and/or actions is in
"most probable" order, but is not necessary 100%
exhaustive. Always follow this general rule: Do not
replace a printed circuit (PC) board until you have made
all the preceding checks. Always put the power switch
in "off" position before removing or installing a PC
board. Take great care not to grasp or pull on compo-
nents when removing a PC board. Always place p.c.
boards on a "static free" surface. If a printed circuit (PC)
board is determined to be the problem, check with your
ESAB- supplier for a trade-in on a new PC board.
Supply the distributor with the part number of the PC
board (and preprogram number, as described in step 1-
c. following) as well as the serial number of the wire
feeder. Do not attempt to repair the PC board yourself.
Warranty on a PC board will be null and void if repaired
by customer or an unauthorized repair shop.
1. General
a. Check interconnection between control and
power supply and robot.
b. Energize the power supply and the control.
c. Immediately after the control is turned "on", a set
of numbers will appear in the IPM and VOLTS
windows and will only be displayed for one sec-
ond. These numbers identify the current program
(E-PROMS) used in your control. When a pro-
gram is changed, the new EPROM will automati-
cally identify the new program number being
used. If a revision is made to an existing program
a number .1, .2, .3, etc. indicating the numerical
revision will also appear in the VOLTS readout
window simultaneously.
d. After the one (1) second delay; the preset "Weld"
parameters will be displayed in the IPM and
VOLTS windows.
 e. If the control is not functioning properly (or as
described above); for example, the numbers that
appear in one or both of the display windows are
meaningless (all zeros, eights, decimals, etc.), or
are completely incorrect in relation to your set-
tings, - the memory must be cleared. This condi-
tion might occur after a bad lightning storm, ex-
tremely bad power line surges, etc. To clear the
memory, do the following:
(1) Turn "off" the unit's 115-volt Power switch.
(2) Using one hand, hold both of the Inc/Dec
toggle switches in the INC position while reap-
plying 110-volt power with the other hand.
(3) Almost immediately after the Power has been
turned "On", release the Inc/Dec toggle
switches to the neutral (spring-return center)
position and the windows should display the
following; IPM = 0, VOLTS - 100 (if synergic),
the indicating a successful reset or clearing
has taken place.
f. You can now enter the desired information as
described in this booklet.
2. No preset displays appear in windows.
a. Make sure the LED Display board harness/plug is
plugged into the P5 receptacle on the MPU board.
b. Check that 115 vac is available across terminals
T1-1 and T1-3, if present; switch closed.
c. Check for plus (+) 5 volts between terminals T1-
10 and T1-12; if voltage is present, replace the
MPU board. If voltage is not present, check the
voltage regulator (VR). The voltage regulator is
located on the bottom panel of the control box.
d. Check the input and output voltage of the regula-
tor "VR".
(1) The input should be approx. 11 volts across
capacitor on regulator socket. If voltage is not
present, replace I/O board.
(2) The output should be 5 volts between termi-
nals T1-12 and T1-10. If voltage is not present,
replace VR, voltage regulator.
3. Display is present, but cannot be varied (panel
operation only).
a. Check normal setup procedures described in
Section V, then;
b. Make sure the key wiring harness plug is properly
connected to receptacle P6 on the MPU board.
c. If the above does not resolve the problem, replace
the MPU board.
4. Motor does not run.
a. Check to make sure all required (and/or optional)
accessories are correctly assembled as described
in Section III.
b. Make sure that power supply is connected, plug
P2 is securely connected to receptacle P2 on the
I/O Board, and then release the clapper arm
(pressure roll) on the Accessory Support Assem-
bly.
(1) Operate the control INCH switch. If motor
does not run; replace I/O and MPU boards
respectively.
(2) If the motor inches, but does not run when the
start signal is generated, check the start/stop
switch circuit components, or in the Robot
mode, the presence of the Robot start signal..
If motor still does not run, check if power
supply is providing open-circuit voltage of 72
volts to the control - if o.c.v. is not being
supplied, motor will not run. Check the
power supply for trouble.
(3) Also check that the +/- 12 vdc are provided
from the power supply on T1-16 and T1-17 to
T1-24 common, respectively.
(4) If power supply O.K., replace the I/O and MPU
boards respectively.
5. Motor runs, but not at right speed.
a. Check tachometer assembly mounted on the end
of EH-10 wire feed motor.
b. Make sure the tach disc is securely fastened to
the motor shaft and that the strobe markings are
not scratched. Check that the disc is properly
centered in the strobe pickup on the p.c. board.
c. If all items in step b. are in order, and motor speed
is still incorrect, replace MPU board.
6. Motor runs backwards.
The wire drive motor can be mounted as a left or right
hand drive. Reversing the mounting orientation of
the motor will cause it to appear to run backwards.
This is corrected by simply reversing the orange and
blue wires on T1-5 and T1-6 on the lower side of
terminal strip T1.
7. Arc VOLTS display reads zero after Start is oper-
ated.
a. Check that the 5-pin plug is securely connected
to the P3 receptacle on the MPU board.
b. If no reading is displayed, check for arc voltage
feedback between terminals TP1 and TP2 test
points on the I/O p.c. board (see Fig. 8A). This
voltage signal should correspond to that shown
on the power supply voltmeter.
c. If voltage still reads zero, trace the voltage pickup
wiring from the power supply to J6 on the control.
d. Remove the current detector 31419 board to gain
access to the P3 plug (harness) on the MPU p.c.
board. Disconnect the P3 plug from its MPU
board socket and, using a meter check for +/- 12
volt power supply output between plug pins P3-1
and P3-2 (for +12v.) and between plug pins P3-4
and P3-2 (for - 12v.) respectively. If voltage is
present, but the display is still zero replace the
MPU board. If either +6, +12 or -12 is missing,
replace the I/O board.
17

Fig. 9A - Input/Output (I/O) P.C. Board, P/N 674994
8. Control Shut-Down - either preset VOLTS or IPM
displays will flash. The control will flash the
parameter VOLTS or IPM that cannot be main-
tained.
These symptoms can occur if the preset conditions,
IPM or VOLTS, cannot be maintained by the control.
a. IPM (speed) abort and possible causes:
(1) Initial "hot start" parameters incorrectly set. For
proper adjustment, refer to Setup Procedures
following V-C-11.
(2) Defective J-governor board.
(3) Defective Motor tachometer board.
(4) Defective I/O board.
(5) Defective MPU board.
Contact ESAB Engineering Services for further
assistance at: voice (843-664-4416)
toll free fax (800-446-5693).
b. VOLTS (voltage) abort and possible causes:
This problem may be caused by the wire feed
system or the power source. To determine which;
(1) Set the wire feeder for synergic operation in the
Pulse welding mode.
(2) Strike an arc and while welding, measure the
potential between T1-15 and T1-24. Note that as
the arc voltage setting is increased, the potential
between T1-15 and T1-24 also increases, and
will range from 0 to 10 vdc. If it does not, replace
the I/O and/or MPU board. If the potential is
present and responding to the voltage change
setting, continue with step (3) following.
(3) Now measure the control voltage, for the back-
ground current, between T1-24 and pin J1-J of
the amphenol connector. This measurement can
be taken without striking an arc. The potential will
be in a range from 1 to 2.5 volts. If it is not, replace
the I/O and/or MPU board. If the background
potential is present, continue with step (4)
following.
18
(4) If both of the preceding conditions (steps 2 and 3)
are okay, but the arc is still unsatisfactory,
theproblem is either in the interconnecting cable,
thewelding setup, or in the power source. If
possible, substitute a cable or power supply
(known to be good) to check out the possible
problem; if these are not available, continue with
the wire feeder "calibration test" in step 8 follow-
ing.
8. Erratic arc especially evident in the Pulse mode.
This could be caused by insufficient pulse height.
To check this, make the following "calibration
test" of the I/O board and power source using the
Diagnostic mode.
VI. DIAGNOSTIC MODE
To set up the control in the diagnostic mode, simulta-
neously depress the Wire /Dia Mat'l. key and hold the
IPM Inc/Dec key in its down position for 2.5 seconds
until a zero (0) appears in the IPM window. (The 2.5
seconds will prevent accidental zeroing of the Material
code.)
Now release both keys. The display windows will change
to show a BACKGROUND current value (from 0 to 100)
in the IPM windows, and a PULSE HEIGHT value (from
0.1 to 10) in the VOLTS window. These numbers can
be changed by their respective INC/DEC switches.
To check the calibration of the I/O board, connect a
voltmeter from T1-24 or to T1-15 (positive). Operate
the Start switch, and check the measured voltage
against the number displayed in the VOLTS window -
they should both be the same (for example: for a setting
of 8.0, the I/O board should be 8 vdc.). If the measured
potential is different, the I/O board should either be
recalibrated (by a qualified technician) or the board
should be replaced.
Next, check the potential from T1-24 (-) to pin J1-J of
the amphenol connector for a display of 40 in the IPM
windows. The measured reading should be 2 vdc. If it
is not, replace the I/O board. If all of these readings are
correct, check the power supply by using the "calibra-
tion procedure" described in Inverter Control Board
(ICB) Troubleshooting in the Power Supply manual F-
15-014.
NOTE: Training and Troubleshooting Courses are
available for maintenance and repair of this
and other ESAB- equipment. For details,
contact ESAB- Welding & Cutting Systems,
P.O. Box F-6000, Florence, SC 29501; Tele-
phone (843) 669-4411. Attention: Technical
Training Coordinator.
HOT START ADJUSTMENT
The Analog Interface is preset at the factory to provide
optimum starting characteristics for most welding con-
ditions. However, due to factors such as border line
parameters (for a given wire type and size), welding
technique, shielding gas, or wire feed speed, you may
have to readjust the factory-set settings to provide a hot
start in which the initial starting voltage is slightly higher
than actual welding voltage (arc voltage) and the initial
speed is somewhat lower than the selected wire feed
speed desired. The hot start condition will be termi-
nated after 0.3 seconds. The following procedure should
be used.
A. Program the welding condition you need in the IPM
(wire feed speed) and VOLTS (arc voltage) win-
dows, and fine-tune these parameters until you have
the welding arc desired - At this point do not concern
yourself with the "arc starts".
B. If after the welding condition is fine-tuned, but the
"arc starts" are unsatisfactory, proceed as follows:
1. During an actual weld, actuate and hold the WIRE
DIA/MATERIAL switch and observe the numbers
displayed in the IPM and VOLTS windows.
2. For proper starts, the number in the IPM window
should be 105 to 115. If it is not, adjust the INC/
DEC toggle (below the IPM window) until the
displayed number reads about 110.
3. In the "synergic mode", the voltage window will
always display the number 100 and cannot be
adjusted. To help determine which logic mode
(adaptive or synergic) is used, visually check the
adapt/syn and the SW1-1 switch.
4. In the adaptive mode, the number in the VOLTS
window should be in the range of 90 to 100. Again,
if it is not, adjust the INC/DEC toggle (below the
VOLTS window) until the displayed number reads
about 95.
VII. REPLACEMENT PARTS DATA
1. All replacement parts are keyed on the illustra-
tions which follow. Order replacement parts by part
number and part name, as shown on illustrations.
DO NOT ORDER BY PART NUMBER ALONE.
2. Always state the series or serial number of the
machine on which the parts are to be used. The
serial number is stamped on the unit nameplate.
19
20
D-31636

Fig. 10 - Schematic - Pulse Analog Interface (Sheet 1 of 3)

 D-31636

21
Fig. 11 - Schematic Diagram - Analog Interface Sheet 2 of 3
22
D-31636

Fig. 12 - Schematic - Pulse Analog Interface (Sheet 3 of 3)

 1

11
13
7

(PSW)
12
16
3 14
(CB)
(MLS) (SW4) (SW5) (SW1)

9 10 15
2 6 4 5

FRONT VIEW - CABINET COVER BOTTOM VIEW - CABINET

FIGURE 9, ROBOTIC ANALOG INTERFACE MICROPROCESSOR CONTROL

(See Code List for Model P/N's)
Replacement Parts List for Figure 9.
ITEM QTY PART MODEL/CODE
NO. REQ. NO. DESCRIPTION Nos.

- - 31676 ANALOG INTERFACE CONTROL FOR KAWASAKI/FANUC A

- - 31678 ANALOG INTERFACE CONTROL FOR HITACHI B
- - 36341 ANALOG INTERFACE CONTROL FOR MOTOMAN C
- - 0558001377 ANALOG INTERFACE CONTROL FOR REIS D
1 1 950416 CABINET LOCK A-D
2 1 950915 POWER SW. OPERATOR A-D
1 950916 POWER SW. CONTACT A-D
1 950917 POWER SW. BUTTON A-D
3 1 2062270 START-STOP ROCKER SW. (SW1) A-D
4 1 950295 PURGE/RESET ROCKER SW. (SW4) A-D
5 1 2062363 INCH. ROCKER SW. (SW5) A-D
6 1 950874 CIRCUIT BREAKER, 7-AMP (CB) A-D
7 1 680359 PULSE-SPRAY-SHORT ROTARY SW. (PSW) A-D
1 950282 PULSE-SPRAY-SHORT SW. KNOB A-D
8 1 680359 RUN-SETUP-WEAVE ROTARY SW C
1 950282 RUN-SETUP-WEAVE SW. KNOB C
9 1 950763 ROBOT CONNECTOR A
1 993973 ROBOT CONNECTOR B
1 599800 ROBOT CONNECTOR C
1 0558001428 ROBOT CONNECTOR D
10 1 31727 ROBOT CONNECTOR PLATE ADAPTOR A
1 31671 ROBOT CONNECTOR PLATE ADAPTOR B,C
1 0558001403 ROBOT CONNECTOR PLATE ADAPTOR D
11 1 950762 19-PIN RECEPTACLE - POWER SUPPLY A-D
12 1 996514 5-SOCKET RECEPTACLE - MOTOR TACH. A-D
13 1 993952 6-SOCKET RECEPTACLE - PLUMBING BOX A-D
14 1 598397 3-PIN RECEPTACLE - VOLTAGE PICKUP A-D
15 1 950159 VOLTAGE REGULATOR A-D
1 950158 TRANSISTOR SOCKET (TO3) A-D
1 995544 CAPACITOR (C4) - 1UF, 35 WVDC A-D
16 1 96W85 STRAIN RELIEF D

23
 7 6 10

4
1 & 2 (P1) 3 1 (P3)

J GOV DETECTOR
COMPONENT SIDE COMPONENT SIDE
5
SW3 SW6
17 MPU
15 COMPONENT SIDE
I/O
COMPONENT SIDE
18 SW12 16
SW11 SW7 SW10 SW9

COMPONENT SIDE COMPONENT SIDE

VIEW B - B
7-Ref. 6-Ref.

13 12 11 7-Ref 9 8

FIGURE10, ANALOG INTERFACE, INSIDE CONTROL PANEL

Replacement Parts List for Figure 10.

ITEM QTY PART MODEL/CODE

NO. REQ. NO. DESCRIPTION Nos.

- - 31676 ANALOG INTERFACE CONTROL FOR KAWASAKI/FANUC A

- - 31678 ANALOG INTERFACE CONTROL FOR HITACHI B
- - 36341 ANALOG INTERFACE CONTROL FOR MOTOMAN C
- - 0558001377 ANALOG INTERFACE CONTROL FOR REIS D
1 2 636608 22-PIN P.C. BD. RECEPTACLES (P1 & P3) A-D
2 1 17145315 RESISTOR 15K-2W (R1 BET. P1-13 & P1-16) A-D
3 1 994236 J-GOV. P.C. BD. ASSEMBLY A-D
4 1 31419 CURR. DETECTOR P.C. BD. ASSEMBLY A-D
5 1 950328 LATCH A-D
6 1 675269 VOLTS/IPM DISPLAY P.C. BD. ASSEMBLY A-D
7 1 See F-14-220 OPTIONAL DIG. D.C. AMETER KIT A-D
8 1 950229 AMP. TEST SWITCH (SW. 9) A-D
9 1 950789 ANALOG INPUT TEST SWITCH (SW-10) A-D
10 2 950087 INC./DEC. SWITCHES (SW-3 & SW-6) A-D
11 1 950087 WIRE DIA./MAT'L.- SPOT/B.B. SWITCH (SW-7) A-D
12 1 950229 ROBOT-PANEL SWITCH (SW-11) A-D
13 1 675450 ANALOG INTERFACE P.C. BD. ASSEMBLY A-D
15 1 950087 PULSE PH/PW-P8/PF SWITCH (SW-12) A-D
16 1 674994 INPUT/OUTPUT (I/O) P.C. BD. ASSEMBLY A-D
17 1 18146 MPU P.C. BD. ASSY. A,D
1 18149 MPU P.C. BD. ASSY. B
1 38096 MPU P.C. BD. ASSY. C
18 1 31441 LOGIC INTERFACE P.C. BD. ASSY A,D
1 31440 LOGIC INTERFACE P.C. BD. ASSY. B,C

24
 3

5
1

8&9

10

6 7

FIGURE 11, ANALOG INTERFACE, INNER CABINET COMPONENTS

Replacement Parts List for Figure 11.

ITEM QTY PART MODEL/CODE
NO. REQ. NO. DESCRIPTION Nos.

- - 31676 ANALOG INTERFACE CONTROL FOR KAWASAKI/FANUC A

- - 31678 ANALOG INTERFACE CONTROL FOR HITACHI B
- - 36341 ANALOG INTERFACE CONTROL FOR MOTOMAN C
- - 0558001377 ANALOG INTERFACE CONTROL FOR REIS D
1 1 31412 ANALOG TO ANALOG P.C. BD. ASSY A-D
2 2 995103 24-PT. TERMINAL BOARD (T1 & T2) A-D
3 1 17240003 RESISTOR 3-OHM, 25W (R1) A-D
4 1 951089 D.C. RELAY (REV RLY) A-D
5 1 996556 400V. BRIDGE (BR) A-D
6 1 994303 TRANSFORMER (CTR-3) A-D
7 1 30684 TRANSFORMER ASSY (CTR-1 & 2) A-D
8 1 996918 FILTER NETWORK (FN-1) A-D
9 1 2075712 INSULATOR A-D
10 1 31421 FILTER BOARD (FB) A-D

25
 NOTES

26
NOTES

27
 ESAB Welding & Cutting Products, Florence, SC Welding Equipment
COMMUNICATION GUIDE - CUSTOMER SERVICES

A. CUSTOMER SERVICE QUESTIONS:

Order Entry Product Availability Pricing Delivery
Order Changes Saleable Goods Returns Shipping Information

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Telephone: (800)362-7080 / Fax: (800) 634-7548

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Telephone: (800) 235-4012/ Fax: (888) 586-4670

B. ENGINEERING SERVICE: Telephone: (843) 664-4416 / Fax : (800) 446-5693

Welding Equipment Troubleshooting Hours: 7:30 AM to 5:00 PM EST
Warranty Returns Authorized Repair Stations

C. TECHNICAL SERVICE: Telephone: (800) ESAB-123/ Fax: (843) 664-4452

Part Numbers Technical Applications Hours: 8:00 AM to 5:00 PM EST
Performance Features Technical Specifications Equipment Recommendations

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Hours: 7:30 AM to 4:00 PM EST

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F. WELDING EQUIPMENT TRAINING:

Telephone: (843)664-4428 / Fax: (843) 679-5864
Training School Information and Registrations Hours: 7:30 AM to 4:00 PM EST

G. WELDING PROCESS ASSISTANCE:

Telephone: (800) ESAB-123 / Fax: (843) 664-4454 Hours: 7:30 AM to 4:00 PM EST

H. TECHNICAL ASST. CONSUMABLES:

Telephone : (800) 933-7070 Hours: 7:30 AM to 5:00 PM EST

IF YOU DO NOT KNOW WHOM TO CALL

Telephone: (800) ESAB-123/ Fax: (843) 664-4452/ Web:http://www.esab.com

Hours: 7:30 AM to 5:00 PM EST

F-15-081-D 7/01