Motoman - MRC MotoArc Weld - 142646-1

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Part Number: 142646-1

Release Date: March 30, 2001
Document Version: 2
Document Status: Final
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section Page
LIST OF FIGURES ..................................................................................................................................iii
LIST OF TABLES....................................................................................................................................iv
1 INTRODUCTION
1.1 About this Document .................................................................................................... 1-1
1.2 System Configuration ................................................................................................... 1-2
1.3 System Components..................................................................................................... 1-3
1.3.1 XRC Controller ............................................................................................... 1-3
1.3.2 Universal Weld Interface (UWI) ....................................................................... 1-4
1.3.3 Robot .............................................................................................................. 1-4
1.3.4 Wire Feed System ........................................................................................... 1-4
1.3.5 Torch .............................................................................................................. 1-4
1.3.6 Power Source ................................................................................................. 1-5
1.3.7 Water Circulator .............................................................................................. 1-5
1.3.8 Work Cell ........................................................................................................ 1-5
1.4 Equipment and Component Specifications ................................................................... 1-6
1.5 Reference to Other Documentation................................................................................ 1-7
1.6 Customer Service Information ...................................................................................... 1-7
2 SAFETY
2.1 Introduction .................................................................................................................. 2-1
2.2 Standard Conventions .................................................................................................. 2-2
2.3 General Safeguarding Tips............................................................................................ 2-3
2.4 Mechanical Safety Devices ........................................................................................... 2-3
2.5 Installation Safety ......................................................................................................... 2-4
2.6 Programming Safety ..................................................................................................... 2-4
2.7 Operation Safety ........................................................................................................... 2-5
2.8 Maintenance Safety....................................................................................................... 2-6
3 THEORY OF OPERATION
3.1 General System Operation ............................................................................................ 3-1
3.2 Gas Metal Arc Welding ................................................................................................. 3-2
3.2.1 The Consumable Welding Arc ........................................................................ 3-3
3.2.2 Metal Transfer Across the Arc ......................................................................... 3-5
3.2.3 Consumable Materials .................................................................................. 3-10
3.2.4 Weld Quality ................................................................................................. 3-10
4 OPERATION
4.1 Controls and Indicators ................................................................................................ 4-1
4.1.1 UWI Indicators ................................................................................................ 4-1
4.1.2 UWI Relay and LED Operation ........................................................................ 4-2
4.1.3 Motor Speed Control Indicators ...................................................................... 4-3
MOTOMAN xxiii Robotic Arc Welding Manual

Section Page
4.2 Shock Sensor Recovery ................................................................................................ 4-4
4.3 Setting Up Absolute Welding Values ............................................................................ 4-4
4.3.1 Setting the Absolute Welding Voltage Curve ................................................... 4-5
4.3.2 Setting the Absolute Welding Amperage Curve ............................................... 4-6
4.3.3 Setting Absolute Welding Amperage as Wire Feed Speed ............................... 4-7
4.3.4 Absolute Settings for MotoArc 350i/500i ........................................................ 4-8
4.4 Using Schedule Select with Pulsed Mode..................................................................... 4-9
4.5 Welder Condition Data File ......................................................................................... 4-10
4.5.1 Displaying a Welder Condition Data File ...................................................... 4-12
4.5.2 Selecting a Welder Condition Data File ......................................................... 4-12
4.5.3 Editing a Welder Name or Comment ............................................................. 4-12
4.5.4 Editing a Power Supply Setting ..................................................................... 4-13
4.5.5 Editing Wire Diameter, Extension, and Anti-Sticking and
Arc Shortage Stop ................................................................................ 4-13
4.5.6 Editing Welder Current or Voltage Data ........................................................ 4-13
4.5.7 Changing Welder Power Supply Analog Polarity .......................................... 4-13
4.5.8 Editing Welder Current or Voltage Adjustment .............................................. 4-13
4.6 Creating New Absolute Welding Amperage Data......................................................... 4-14
4.6.1 Welding Setup Procedure ............................................................................. 4-14
4.6.2 Weld Test for New Amperage Data ................................................................ 4-15
4.7 Creating New Absolute Welding Voltage Data............................................................. 4-16
4.7.2 Weld Test for New Voltage Data .................................................................... 4-17
4.8 Using Absolute Current Data Tables ........................................................................... 4-17
5 TROUBLESHOOTING
5.1 Equipment and Tools Required ..................................................................................... 5-1
5.2 Troubleshooting Procedures......................................................................................... 5-1
6 MAINTENANCE
6.1 UWI Replacement and Setup......................................................................................... 6-1
6.1.1 UWI Replacement ........................................................................................... 6-1
6.1.2 UWI Jumper Designations .............................................................................. 6-3
6.1.3 UWI Replacement Fuses ................................................................................. 6-3
6.1.4 UWI Replacement Relays ................................................................................ 6-4
6.2 Replacing the KXA Motor Speed Control ...................................................................... 6-5
6.3 Replacing the Torch ...................................................................................................... 6-5
6.4 Replacing the Shock Sensor ......................................................................................... 6-7
Robotic Arc Welding Manual xxiv MOTOMAN

Section Page
7 CALIBRATION
7.1 Defining Tool Center Point ........................................................................................... 7-1
7.1.1 Manual TCP Definition ................................................................................... 7-1
7.1.2 Automatic TCP Definition ............................................................................... 7-3
7.2 UWI Calibration for Welding Power Source
Analog Isolation .................................................................................................... 7-3
7.2.1 UWI Calibration Procedure for Welding Power Source ................................... 7-5
7.3 Calibrating the Wire Feed System................................................................................. 7-9
7.3.1 KXA Motor Speed Control ............................................................................ 7-10
7.4 UWI Calibration Procedure for Wire Feed System....................................................... 7-12
7.4.1 Final Test ...................................................................................................... 7-22
APPENDIX A - SPARE PARTS LIST
APPENDIX B - UWI WIRE FEEDER PARTS BREAKDOWN
APPENDIX C - BLANK CHARTS
INDEX
LIST OF FIGURES
Figure Page
Figure 1-1 Robotic ArcWelding System...................................................................................... 1-2
Figure 1-2 Robot and Wire Feed System .................................................................................... 1-5
Figure 3-1 Gas Metal Arc Welding.............................................................................................. 3-2
Figure 3-2 Consumable Electrode Welding Arc .......................................................................... 3-3
Figure 3-3 Spray Metal Transfer Mode ....................................................................................... 3-6
Figure 3-4 Short-Circuiting Transfer Mode ................................................................................ 3-7
Figure 3-5 Short-Circuiting Transfer Cycle................................................................................. 3-8
Figure 3-6 Pulsed-Spray Transfer Mode..................................................................................... 3-8
Figure 3-7 Pulsed-Spray Timing Chart....................................................................................... 3-9
Figure 4-1 UWI PC Board LED's and Relays............................................................................... 4-1
Figure 4-2 Absolute Welding Voltage Settings ........................................................................... 4-5
Figure 4-3 Voltage Data File Display .......................................................................................... 4-6
Figure 4-4 Absolute Welding Amperage Settings ....................................................................... 4-6
Figure 4-5 Amperage Data File Display ...................................................................................... 4-7
Figure 4-6 Absolute Welding Amperage Settings as Wire Feed Speed ....................................... 4-7
Figure 4-7 Weld Current as Wire Feed Speed for PWF4-600 Wire Feeder................................. 4-8
Figure 4-8 Pulse Frequency vs. Voltage Settings........................................................................ 4-9
Figure 4-9 Typical Welder Condition Data File Display ............................................................ 4-11
Figure 4-10 Typical Welder Condition Data File (Current) Display ............................................. 4-11
Figure 4-11 Typical Welder Condition Data File (Voltage) Display ............................................. 4-11
Figure 6-1 Universal Weld Interface............................................................................................ 6-1
Figure 6-2 UWI PC Board Connectors and Jumpers .................................................................. 6-2
Figure 6-3 Fuse and Relay Location on the UWI PC Board......................................................... 6-4
Figure 6-4 Replacing the KXA Motor Speed Control................................................................... 6-5
MOTOMAN xxv Robotic Arc Welding Manual
Figure Page
Figure 6-5 Replacing the Torch and Shock Sensor..................................................................... 6-6
Figure 7-1 Tool Center Point ...................................................................................................... 7-1
Figure 7-2 Entering Tool Dimensions for TCP............................................................................ 7-2
Figure 7-3 UWI PC Board Calibration Potentiometer (POT) Locations ....................................... 7-4
Figure 7-4 UWI PC Board Shorting Jumpers, Test Clip, and POT1 ............................................ 7-6
Figure 7-5 Welding Power Source Argument Chart .................................................................... 7-7
Figure 7-6 KXA Indicators and Controls ................................................................................... 7-11
Figure 7-7 KXA Motor Speed Controller Trim Pots................................................................... 7-14
Figure 7-8 UWI Board Shorting Jumpers, Test Clip, and POT5 ................................................ 7-14
Figure 7-9 KXA Plug PL7 ......................................................................................................... 7-15
Figure 7-10 KXA Plug PL7 and Connector TB2 .......................................................................... 7-16
Figure 7-11 UWI PC Board POT7 and POT8............................................................................... 7-17
Figure 7-12 AWELD Argument Chart for PWF4-600................................................................... 7-18
LIST OF TABLES
Table Page
Table 1-1 Equipment and Component Specifications .................................................................. 1-6
Table 4-1 UWI LED Indicators and Functions .............................................................................. 4-2
Table 4-3 UWI Relay and LED Operation ..................................................................................... 4-2
Table 4-4 KXA Motor Speed Control Indicators ........................................................................... 4-3
Table 4-5 Tools and Equipment for Testing Amperage .............................................................. 4-14
Table 4-6 Tools and Equipment for Testing Voltage .................................................................. 4-15
Table 4-7 Absolute Current Settings for PWF4 Wire Feeders ..................................................... 4-17
Table 5-1 Tools and Equipment for Troubleshooting ................................................................... 5-1
Table 5-2 Welding Troubleshooting Chart ................................................................................... 5-1
Table 6-1 UWI Plug and Socket Connectors ................................................................................ 6-2
Table 6-2 Replacement Fuses ...................................................................................................... 6-4
Table 6-3 Replacement Relays ..................................................................................................... 6-4
Table 7-1 Tools and Equipment for Calibration ........................................................................... 7-3
Table 7-2 Calibration Potentiometers .......................................................................................... 7-4
Table 7-3 Output Voltage Rating for All Welding Power Sources ................................................. 7-5
Table 7-4 MRC Argument Table for Power Source Volts and MotoArc Power Sources ................ 7-7
Table 7-6 KXA Motor Speed Controller Preset Positions ............................................................. 7-9
Table 7-7 KXA Motor Speed Control Voltage Measurements ..................................................... 7-12
Table 7-8 XRC Argument Table for PWF4-600 Wire Feeder ...................................................... 7-19
Robotic Arc Welding Manual xxvi MOTOMAN

SECTION 1
INTRODUCTION
1.1 About this Document
This manual provides both general and specific information about the gas metal
arc welding (GMAW) system manufactured by Motoman, Inc. It includes
procedures for the proper use, operation, and maintenance of a welding system
which includes a MotoArc power source, PWF wire feeder and a Universal Weld
Interface (UWI). This manual is divided into the following sections:
SECTION 1 - INTRODUCTION
Provides general information regarding this manual, descriptions of the welding
system and its components, technical specifications, installation, a list of reference
documents, and customer service information.
SECTION 2 - SAFETY
Describes the conventions used to identify precautionary text throughout this
manual. The section also contains a list of general cautions and warnings that
apply to many of the procedures described in this manual.
SECTION 3 - THEORY OF OPERATION
Provides general welding principles. The discussion identifies specific problems
and requirements, how the welding system works, and how it addresses the
specific welding requirements.
SECTION 4 - OPERATION
This section provides instructions for the proper use and operation of the GMAW
system. Instructions provided include step-by-step procedures to prepare the
system for use. Included are tips and techniques to overcome specific problems
related to gas metal arc welding.
SECTION 5 - TROUBLESHOOTING
The information provided in this section helps the user identify and remedy
problems found during operation and welding.
SECTION 6 - MAINTENANCE
This section defines procedures for adjusting GMAW system components,
including defining the tool center point and calibrating the Universal Weld
Interface (UWI) for welding power sources and wire feed systems.
SECTION 7 - CALIBRATION
This section provides instructions for repair and replacement of major GMAW
system components. It also provides instructions for cleaning and preventive
maintenance to optimize system operation and availability.
APPENDICES
Appendix A - Spare Parts List: Contains a variety of spare parts drawings
related to the gas metal arc welding system and its components.
Appendix B - UWI Wire Feeder Parts Breakdown: Contains a parts breakdown
of the individual components in the UWI wire feeder.
Appendix C - Blank Charts: Contains blank charts for calculating new absolute
amperage and voltage data.
MOTOMAN 1-1 Robotic Arc Welding Manual
INTRODUCTION
1.2 System Configuration

The gas metal arc welding system is an integrated package of tools and
components designed to meet specific welding requirements. The system includes
the following components and optional equipment (system configuration is shown
in Figure 1-1):
XRC CABINET
80
YASN 40
60 100
120
AC 20 140
TRIP
ON
XRC 160
SERVO
ON
READY
SK16X
OFF
MODE
PLAY
TEACH EMERGEN
SET
CY STOP
/RE
EN
OP
EDIT
LOCK
(OFF)
(ON)
REMOTE
ALARM
HOLD
START
ROBOT
THE
MANIPU
SHOULD LATOR
HAVE AND
ORDER. THE THE
SAME CONTRO
NO. ORDER LLER
SSM179
-1-7 NUMBER
N.J1S30
YASNAC
XRC
TYPE
POWER ENCM-RX60
SUPPLY
200/220V 03
50/60HZ
SERIAL
3PHASE
DATE NO.
MANIPULATOR
SSM179-2-1 3.0KVA
10-1998
YASKAWA 0-1
P/N
ELECTRIC 16
MADE CORPORA
IN JAPAN
TION
NJX03-1
POWER SOURCE
CONTROL CABLE CUSTOMER-SUPPLIED
WIRE FEEDER #1 WIRE FEEDER
CIRCUIT BREAKERS
GAS BOTTLE
10 AMP 10 AMP
AND REGULATOR
REMOTE
CONTROL
115 V 9A 115 V 9A
(SHOWN FOR
REFERENCE ONLY)
ELECTRICAL OUTLET
(for optional water circulator)
5
6
4
INPUT 7
POWER 3 A
V
ON
1
OFF
0
LOCAL
REMOTE
MOTOARC WATER
WELDING CIRCULATOR
POWER SOURCE
GROUNDING WELD
CABLE CONNECTION
(To Grounding Bolt
on Workpiece)
Figure 1-1 Robotic ArcWelding System
• Motoman robot manipulators and XRC controller

• Welding equipment, including the following:
• MotoArc welding power source
• Motoman Tough Gun® air-cooled or water-cooled torch
• Motoman Tough Gun® clutch
• Motoman PWF4-750 wire feeder
• Universal Welding Interface (UWI), with harness
• Side-mount MIG process package
Robotic Arc Welding Manual 1-2 MOTOMAN

INTRODUCTION
Options for the welding system include:

• Water circulator
• Torch cleaner
• Wire cutter
• Com-Arc III
The XRC controls the operation of the gas metal arc welding system. It
coordinates the operation of the various components of the system through
execution of instruction sequences provided in a job file. As the XRC steps
through the series of instructions, it directs the movement of the robot, controls the
wire feeding system, and operates the power supply.
The system's robot moves the welding torch and supply lines through a series of
programmed steps. The XRC controls the speed, direction, and position of the
robot as it moves from point to point.
The Universal Weld Interface (UWI) and the wire feeder system work together to
feed wire as required by the system. The interface receives control signals from
the XRC. It converts and scales these signals to produce the electrical outputs
required to control the speed and direction of the wire feeder system motor while
sending feedback signals to regulate the speed of the wire feed system.
The welding power supply provides power to the water-cooled/air-cooled torch.
This power supply operates under remote control of the XRC. The XRC turns the
power supply on and off and sets the analog reference for arc voltage. The XRC
also sets the weld schedule for pulse welding applications.
1.3 System Components

The following paragraphs contain brief descriptions of each of the MotoArc
welding system components. Figure 1-1 shows a typical system layout.
1.3.1 XRC Controller
The GMAW system includes an XRC controller and a programming pendant. The
XRC provides the following basic functions:
• Power ON
• Job creation
• Input and edit motion data
• Input and edit process data
• Playback
• Process control
• Power OFF
• Connection to external devices through the pendant’s serial interface port
• Input/output signal processing
The XRC controls the operation, and monitors the status, of the GMAW system's
components: the manipulator, power source, wire feeder, and torch. The various
safety features of the GMAW system and the associated cell operate through the
XRC. Under emergency conditions the XRC controls the shutdown of the robot
drive power, welding arc, positioner, or other devices connected. Refer to your
XRC Operator’s Manual for more information.

INTRODUCTION
1.3.2 Universal Weld Interface (UWI)

The UWI, which controls the power to the wire feed system, consists of a UWI PC
board, a transformer, and a KXA motor speed control. These components are
located on the door inside the XRC cabinet.
The UWI PC board handles welding inputs and outputs and sends the voltage
analog to the power supply. The UWI sends the wire feed analog to the KXA
motor speed control, which regulates the wire feed system.
1.3.3 Robot
The GMAW system includes a six-axis manipulator. The robot can reach below its
own base, and can travel in an arc approximately 340˚ around the base. However,
it is possible to restrict the base axis with stopping bolts. These robots can be
floor-, wall-, or ceiling-mounted. Motoman robots use brushless AC motors with
absolute position encoders.
A combination of capacitance and lithium batteries in both robot and controller
assemblies protects program position data for up to a year. The life expectancy for
the lithium battery is approximately three years.
Power for the robot manipulator is supplied through the controller. A 4.5 KVA
isolation transformer converts the 230, 460 or 575V delta input to a 208V wye
output. Refer to the manipulator manual that came with your system.
1.3.4 Wire Feed System
The wire feed system, as shown in Figure 1-2, consists of the following
components:
• Side-mounted wire spool
• Four-roll UWI pancake feeder (PWF4-600/750)
The wire feed system operates under the control of the KXA motor controller
through the UWI. The system handles solid and flux-cored wire, in sizes ranging
from .030 to 3/32. However, configurations to handle other wire sizes and types
are available. It is also possible to order components to modify an existing system.
A parts breakdown of the wire feeder is located in Appendix B.
1.3.5 Torch
The torch used with the GMAW system is a Motoman Tough Gun, air-cooled
robotic torch (water-cooled is an option), manufactured by Tregaskiss. The torch
features a quick-change gooseneck assembly, a keyed connector/valve module for
precise repeatability, and an aluminum rear housing assembly to protect fluid and
cable lines. Straight, 22˚ bend, and 45˚ bend changeable necks are available for
this torch as well as extended gun barrels.
The system comes equipped with the correct torch for the application specified. In
its standard configuration, the torch uses a 22˚ bend neck and handles 0.045 wire.
You can order replacement necks, as well as kits to modify an existing torch for
use with other wire sizes from the manufacturer. Motoman does not resell
Tregaskiss consumables. For a complete list of consumables, refer to the Tough
Gun Technical Guide for the torch provided with your system.
Also provided with the system is a Tough Gun Clutch, designed to protect the
robot, gun, and fixture during a crash. When the clutch detects a 1˚ deflection, it
will pivot and the robot will E-stop.

INTRODUCTION
PWF4 WIRE FEEDER
TOUGH GUN
TORCH
TOUGH GUN
CLUTCH
ROBOT
MANIPULATOR
WIRE SPOOL
ROBOT BASE
Figure 1-2 Robot and Wire Feed System

1.3.6 Power Source
The MotoArc 450/650 are SCR-controlled constant voltage (CV) power supplies.
They are suited to general purpose applications. The MotoArc 350i/500i are
inverter-controlled constant voltage (CV) power supplies with pulse welding
capability. The pulse parameters can be programmed with the optional MotoArc
pendant. The 500i can change process and pulse schedules from the XRC.
1.3.7 Water Circulator
The optional water circulator supplies cooling water to the water-cooled Tough
Gun torch. This unit can supply coolant to the welding torch from up to 50 feet
away. A special water/glycol anti-freeze is the recommended coolant. Do not use
automotive anti-freeze in the water circulator.
The water circulator motor and pump are enclosed in a hood. The bronze water
pump is a rotary gear type with a stainless steel shaft. The pump discharge has a
safety relief valve that bypasses the welding torch when discharge back–pressure
exceeds a predetermined setting.
1.3.8 Work Cell
In addition to the items above, a complete system typically includes certain work
cell components. These components are not specifically part of the GMAW
system, but are related items that are supplied separately. Some of these items
include safety mats, interlocks, arc screens, fencing, and positioners. The number
and type of components required depend on your specific application. If provided
by Motoman, operation and maintenance instructions for these other items is
supplied in the ArcWorld or FabWorld manuals.

INTRODUCTION
1.4 Equipment and Component Specifications

Specifications for the GMAW system and its components are listed in Table 1-1.
Additional information is provided in the various vendor manuals supplied with
the system.
Table 1-1 Equipment and Component Specifications
Characteristic Specification
Power Requirements
Welding gas As required
Electrical service (robot) Refer to manipulator manual
Electrical service (welding) Refer to MotoArc manual
Operating Environment
Temperature range 0 - 40 ˚C
Humidity 20 - 80% (non-condensing)
Vibration Less than 0.5 G
Other Free from corrosive gases or liquids, explosive gases,
and excessive electrical noise
MotoArc Power Source As Required
Wire Feed Unit

Wire Feed Rate 750 IPM (600 IPM optional)
Motor output rating 54 Watt @3000 RPM
Amp rating 6.6 @18V DC
Current limit 100% rated load Peak Current, 12 amp (fold back after
2 seconds to rated amp)
Torch
Air-cooled 500A - CO2
Water-cooled 450A - CO2
Square D 30 KVA Transformer

(for 200 volt welder only)
Input 480/460V, 3-phase
Output 208V, 3-phase
Water Circulator
Input power 115V AC (230V AC optional), 50/60 Hz
Capacity 5 gallons
Output Continuous operation for at least three hours at
full rated current. Duty cycle is based on a coolant
temperature rise of 37 ˚C (66 ˚F) above a 23 ˚C (74 ˚F)
ambient.

INTRODUCTION
1.5 Reference to Other Documentation

For additional information refer to the following:
• Motoman Manipulator Manual that came with your system.
• Motoman Operator's Manual for Arc Welding (P/N 142098-1)
• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)
• MotoArc 350i Power Source Manual (P/N 141203-1)
• MotoArc 450 Power Source Manual (P/N 141203-2)
• MotoArc 500i Power Source Manual (P/N 141203-3)
• MotoArc 650 Power Source Manual (P/N 141203-4)
• Vendor manuals for system components not manufactured by Motoman
1.6 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at
(937) 847-3200. Please have the following information ready before you call:
• Robot Type (UP6, SK16X, etc.)
• System Type (ArcWorld 1000, FabWorld, LaserWorld, etc.)
• Application Type (palletizing, welding, handling, etc.)
• Robot Serial Number (located on the back side of the robot arm)
• Order No. (located on the front of the controller)

INTRODUCTION
NOTES

SECTION 2
SAFETY
2.1 Introduction
.
It is the purchaser's responsibility to ensure that all local, county,

state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: 313/994-6088
FAX: 313/994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)

SAFETY
2.2 Standard Conventions

This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
• NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE: Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.

SAFETY
2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware of
the various national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following safety
measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.

SAFETY
2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing federal,
local, and state laws and regulations. Additional safety measures for personnel and
equipment may be required depending on system installation, operation, and/or
location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
2.6 Programming Safety

equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special
passwords. Special passwords are for Motoman use only. YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.

SAFETY
• Inspect the robot and work envelope to be sure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.
2.7 Operation Safety

equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
must have the teach pendant when they enter the cell.
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.

SAFETY
2.8 Maintenance Safety

equipment must understand potential dangers of operation. Maintenance tips are
as follows:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
must have the teach pendant when they enter the cell.
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).

SECTION 3
THEORY OF OPERATION
This section covers the theory of operation for the overall gas metal arc welding
system and specifically discusses the gas metal arc welding process.
3.1 General System Operation

The Universal Weld Interface (UWI) is a microprocessor-based control that uses
the ARCON logic to provide control for the wire feed system, the welding power
source, and the gas purge. The robot analog channels are isolated and scaled as
required for the welding power source and the wire feed system.
The UWI consists of a printed circuit (PC) board (microprocessor), a KXA motor
speed control, and a transformer. The KXA motor speed control regulates the
speed of the wire feed motor. The transformer steps 120V AC down to 24V AC for
input to the KXA.
The KXA motor speed control is a pulse-width-modulated, four-quadrant speed
controller. It is designed for fast-response print-type or disk-type motors. With the
control enabled, a positive analog input signal gives forward wire feed. A negative
input causes the wire feed motor to run in reverse. An input level of 0 volts stops
the wire feed motor. The motor speed control can operate in either speed or torque
mode, with either tachometer or EMF feedback. Selector switches on the speed
control circuit board set the mode of operation. When used with the PWF4 wire
feeders, the KXA unit operates in speed mode with tachometer feedback.
The KXA motor speed control operates on 24V AC provided through the UWI. It
has internal voltage rectifier and regulation circuits that supply the necessary DC
output to the wire feed motor. The motor speed control also has fault protection
features to guard against short circuits, excess current, and power supply failures.
Voltage clamping circuitry protects against excessive reverse EMF due to high
speed and high inertia reversals.
Jumpers on the UWI PC board provide compatibility for many different types of
welding power sources. Replaceable relays provide interface to the KXA motor
speed control and to auxiliary equipment and accessories. Test and calibration
points are provided for calibration and adjustment of the wire feeder's inch-
forward and inch-reverse speeds. When an ARCON command is received, the
following sequence is executed:
1. The KXA is enabled.
2. The welding power source is enabled.
3. The gas valve is enabled.
4. The wire feed command is given to the KXA.
5. Wire feed begins and the arc starts.

THEORY OF OPERATION
When the ARCOF command is executed, the reverse sequence occurs:

1. The wire feed command to the KXA is removed, stopping the feeder.
2. The welding power source disables immediately.
3. Burnback occurs, either as a function of the current and voltage settings in
the job or automatically, as a function of the welding power source "wire
sharpening circuit."
4. The gas valve is disabled.
5. The UWI is disabled.
6. Arc weld is complete.
The wire feeder can be inched forward or reverse at a fixed speed. The gas can be
purged independently of the wire feed. Robot Output #188 is reserved for purge,
Output #191 is reserved for inch forward, and Output #192 is reserved for inch
reverse. If the selected output groups are needed in other applications, these
outputs may be reassigned to different output number addresses. Contact
Motoman service for information about changing output addresses.
3.2 Gas Metal Arc Welding

The gas metal arc welding process establishes an arc between a continuously fed
filler metal electrode and the weld pool. To accomplish this, the electrode must
feed into the arc at a rate equal to that at which the electrode melts. The heat from
the arc melts the surface of the base metal and the end of the electrode. The molten
metal from the electrode transfers through the arc to the workpiece where it
becomes deposited weld metal. Under ideal conditions, the length of the arc
between the tip of the electrode and the weld pool remains constant.
An envelope of externally supplied inert gas or gas mixture shields the arc (see
Figure 3-1). The shielding gas surrounds the arc area to protect it from atmospheric
contamination. The GMAW system automatically maintains the welding arc,
feeds the electrode wire into the arc, and controls the travel and guidance of the
welding torch.
SHIELDING GAS
DIRECTION OF TRAVEL
MOLTEN WELD METAL NOZZLE
SOLIDIFIED WELD METAL ELECTRODE

BASE METAL
ARC
Figure 3-1 Gas Metal Arc Welding

THEORY OF OPERATION
3.2.1 The Consumable Welding Arc

The main function of the arc is to produce the heat required for the welding
process. It produces enough thermal energy to join metals by fusion. The arc also
produces a bright light, noise, and ionic bombardment which removes oxides from
the surface of the base metal. The consumable electrode welding arc is a
sustained, high current, low voltage, electrical discharge through a highly
conductive plasma (see Figure 3-2). The plasma operates at temperatures of
approximately 6000˚ C (10,000˚ F). It conducts current at levels ranging from
about 20 amps to over 500 amps, and has a voltage drop of between 10 to 50 volts.
The relation of potential (volts) to current (amps) is roughly linear, except at the
lowest current levels where an inverse relation exists.
ELECTRODE
POWER
FEEDER
SOURCE
( ) ELECTRODE WIRE
SHIELDING GAS
SHIELDING
GAS NOZZLE
ELECTRODE
CURRENT
ELECTRODE CONTACT TIP
EXTENSION
SHIELDING
GAS
ARC LENGTH ENVELOPE
OUTER
FLAME
PLASMA
Figure 3-2 Consumable Electrode Welding Arc

The length of the arc is affected by the arc voltage. A short length arc,
approximately equal to one diameter of the electrode, has the lowest voltage. The
medium length arc occurs at the medium voltage range. The long arc has a length
equal to about five times the diameter of the electrode. It also has the highest
voltage. A long arc tends to become uncontrollable and does not deposit metal.
If the gap is too long, the arc goes out; use a higher current to sustain a longer arc.
If the gap is too short, the arc shorts out; excessive arc voltage can cause the arc to
climb to the contact tip, and transfer from the workpiece to the tip.
Arc atmosphere also has an affect on arc voltage. Different gases or gas mixtures
cause arc voltage levels to change. A voltage increase based on the shielding
atmosphere produces a hotter arc. This increases the thermal energy in the arc,
which increases the rate of electrode melt-off slightly.

THEORY OF OPERATION
The two factors that most determine good quality welding and high productivity
welding are penetration into the base metal and the electrode melt-off rate. Both
penetration and melt-off rate are affected by the following:
• Current polarity and arc atmosphere
• Current level
• Melting point of the material being welded
• Size of the electrode wire
• Electrode extension
The polarity of the current flowing through the arc and the gas atmosphere
determine where the point of maximum heat occurs. In most gas metal arc
welding applications, the point of maximum heat occurs at the workpiece. This
results in deeper penetration and reduced electrode melt-off.
Penetration and melt-off rate are related to the welding current level. Although the
relationship is not linear, penetration and melt-off rate increase as welding current
increases. This reflects the relationship between current level and thermal energy.
Of the factors affecting melt-off rates, the most important is the melting point of
the metal or metals that make up the electrode. Another factor that affects the
melt-off rate is the size of the electrode. As the diameter of the electrode
decreases, its current density increases. Current density is the welding current
divided by the cross-sectional area of the electrode wire. At the same welding
current, a small electrode has a higher current density than a larger wire. Both the
melt-off rate and depth of penetration increase as current density increases.
The amount of electrode extension also affects the melt-off rate. The electrode
extension is the length of the electrode between the tip and the arc. Heat is
generated due to the electrode extension's resistance to the flow of current. As the
length of the extension increases, so does its resistance and consequently the
amount of heat generated. This results in a higher melt-off rate. The melt-off rate
depends on both electrode extension and welding current, since these two factors
are interrelated.
The heat generated in the electrode extension also has a preheating effect on the
electrode wire. Preheating the electrode increases the deposition rate. Too much
preheating, however, reduces the penetration of the arc. Since the amount of heat
generated in the extension can be quite high, it can cause the electrode wire to lose
its stiffness. This can make wire feeding more difficult.
In the arc welding process, successful operation requires a stable arc. To maintain
a stable sustained arc, the melting rate of the electrode must equal the feed rate of
the electrode into the arc. Many factors affect the electrode melt-off rate. The
purpose of the GMAW system is to balance these various factors and optimize the
welding process.

THEORY OF OPERATION
3.2.2 Metal Transfer Across the Arc

A number of forces interact to transfer the metal across the arc. Under varying
conditions, the amount, rate of transfer, and pattern of the transferred metal
changes. The transferred metal can range from small droplets, less than the
diameter of the electrode, to droplets much larger in diameter than the electrode.
The forces that control the transfer of molten metal across the arc gap are the
following:
• Surface tension
• Plasma jet
• Gravity
• Electromagnetic force
The surface tension of a liquid causes the surface to contract to the smallest
possible area. It tends to hold the droplet on the end of the melting electrode
regardless of the weld position. In this manner, it works against the transfer of
metal. Surface tension also holds the molten metal in the weld pool when welding
in the vertical and overhead positions.
A plasma jet flows from the tip of the electrode to the base metal along the center
of the arc column. This jet accelerates the drops of molten metal in flight towards
the workpiece. Under certain conditions, the plasma jet can interfere with the
transfer of liquid metal across the arc gap.
The effects of gravity, to some extent, depend on the welding position. Earth's
gravity tends to detach the drop of liquid metal downward from a horizontal or
vertical welding position. While welding in the overhead position, gravity tends to
hold the drop on the electrode. Earth's gravity has a noticeable effect only when
welding at lower current levels where the difference in mass, between the drop of
molten metal and the workpiece, causes a second gravitational effect. This force
pulls the drop of metal toward the greater mass of the workpiece.
Electromagnetic force creates the pinch-effect force, which helps to transfer metal
across the arc gap. While the flow of current through the electrode creates an
electromagnetic field, electromagnetic forces act on the drop of molten metal to
help detach it from the tip of the electrode. As the drop begins to separate from the
electrode, the pinch-effect force pushes the drop away from the electrode and
increases the rate of separation. At higher currents, electromagnetic forces within
the drop of metal cause it to become elongated. This gives the drop stiffness, and
projects it in line with the electrode regardless of the welding position. The mode
of metal transfer is related to the following:
• Type of metal
• Arc atmosphere
• Size, type, and polarity of electrode
• Characteristics of power source
• Welding position
• Welding current
• Current density
• Heat input

THEORY OF OPERATION
The four major types of metal transfer are:

• Spray transfer
• Globular transfer
• Short-circuit transfer
• Pulsed-spray metal transfer
In addition to the types of metal transfer listed above, there are intermediate modes
that occur in the transition zones between two major types. In these transition
zones, both types of transfer can occur simultaneously.
Spray Transfer
Spray transfer is a smooth mode metal transfer from the electrode to the molten
weld pool. Spray transfer occurs in an inert gas atmosphere, typically using a
shielding gas with a minimum of 80% argon. This transfer mode occurs at
relatively high current densities. Each different size of electrode requires a specific
minimum current level. The use of helium in the shielding gas reduces the current
level at which spray transfer occurs.
The molten metal droplets that form in this transfer mode are smaller than the
diameter of the electrode (see Figure 3-3). As current increases, the size of the
droplets decreases. An increase in current level also causes droplets to form and
transfer at a higher rate. Because of the high current densities involved, the
electromagnetic forces have the most effect on this mode of transfer. The pinch-
effect force on the tip of the electrode limits the size of the metal droplets. As a
result, only small droplets form, and transfer rates are relatively high. The
deposition rate and efficiency of spray transfer mode are relatively high. The arc is
smooth, stable, and stiff, and produces a weld bead that has a nice appearance and
good wash into the sides of the weld.
Figure 3-3 Spray Metal Transfer Mode

The weld process in spray transfer mode generates a large amount of heat. This
creates a large weld pool with good penetration. However, it also makes the weld
pool hard to control. In normal applications this limits the use of spray transfer to
flat or horizontal welding positions, and prevents its use when welding thin
materials. The wide spray arc also results in slower travel speeds.

THEORY OF OPERATION
Short-Circuiting Transfer
The short-circuiting transfer mode is a low energy mode of metal transfer. In
short-circuiting transfer, the melting tip of the electrode is supported by the
cathode jet and can grow to 1 1/2 times the diameter of the electrode. The
electrode feeds into the arc at such a high rate that the molten tip occasionally
comes in contact with the weld pool (see Figure 3-4). This causes a short circuit
across the gap between the electrode and weld pool, which extinguishes the weld
arc.
Figure 3-4 Short-Circuiting Transfer Mode

The surface tension of the weld pool draws the molten metal at the tip of the
electrode into the pool. The electrode separates from the weld pool and re-
establishes the arc. As the electrode comes into contact with the weld pool, the
high current density will occasionally cause the electrode to act as a fuse and
literally explode. The explosion will re-ignite the weld arc. This entire cycle
repeats at random frequency, but occurs so rapidly that it is not apparent (see
Figure 3-5).
The short-circuiting transfer mode allows all-position welding, and the welding of
thin materials. It uses a constant voltage power source that can provide the proper
rate of current increase needed to maintain a stable arc during the short circuit.
This process produces a small, easily-controlled weld pool. However, it can cause
cold lap defects and undercutting if weld parameters are not properly set. This
metal transfer mode also produces a small amount of spatter.

THEORY OF OPERATION
START END START

ONE CYCLE
CURRENT
0
SHORT ARCING PERIOD
EXTINCTION
EXTINCTION
IGNITION
VOLTAGE
Figure 3-5 Short-Circuiting Transfer Cycle

Pulsed-Spray Metal Transfer
The pulsed-spray metal transfer mode was introduced to overcome the limitations
of other metal transfer modes. Figure 3-6 illustrates this process. The pulsed-
spray transfer mode requires a special pulsing power source. The welding current
supplied by this power source varies between high (peak) and low (background)
levels (see Figure 3-7). The peak current occurs at a point above the transition
current, and supplies extra energy to transfer metal across the arc gap. The
background current has enough energy to sustain a stable arc, but not enough to
transfer the metal droplets. Theoretically, one drop of metal transfers across the
arc gap at the peak of each pulse cycle. The liquid metal droplets formed in this
process have a diameter approximately equal to that of the electrode. Metal
transfer across the arc gap occurs at a fixed frequency.
Figure 3-6 Pulsed-Spray Transfer Mode

THEORY OF OPERATION
The pulsed-spray transfer mode achieves spray transfer at a lower, average current
level. It uses an inert gas atmosphere, typically argon/oxygen or an argon-low
CO2 mix. The pulsed-spray transfer mode operates at lower heat input levels,
producing a smaller, controllable weld pool for more efficient welding of thin
materials. This mode also reduces the amount of spatter, producing a smooth weld
with good physical characteristics and appearance.
In pulsed-spray metal transfer, the GMAW system precisely regulates the variables
that affect the welding process. These variables are programmed into the welding
equipment and are based on the type of metal, electrode diameter, and type of
shielding gas. The pulse peak current and peak current duration are matched to the
background current (see Figure 3-7). When the system selects the appropriate
welding schedule, it also matches the shape of the pulse waveform, duration of the
peak pulse, and pulse frequency to the arc atmosphere and electrode feed rate for a
specific size and type of electrode.
Welding schedules serve as guides, and provide initial settings for use under
normal conditions. A specific application may require that an operator make
adjustments to a variable or combination of variables (using the programming
pendant) in order to achieve the desired result. When changing variables,
remember that changing the value of one variable often has an effect on another
variable.
TRANSITION
CURRENT METAL TRANSFER
PEAK CURRENT
CURRENT (DCEP)
AVERAGE
CURRENT
BACKGROUND CURRENT
0
TIME
Figure 3-7 Pulsed-Spray Timing Chart

THEORY OF OPERATION
3.2.3 Consumable Materials

Gas metal arc welding requires the use of two consumable materials: the filler
metal electrode and the shielding gas. The selection of the electrode and shielding
gas depends on the base metal and process variation in use for a particular
application. The choice of electrode is usually related to the strength requirements
of the deposited weld metal, as well as to its composition. The following factors
determine the selection of the electrode:
• Metal to be welded - The type or composition and mechanical properties of
the base metal are a prime consideration.
• Thickness and joint design - Thicker sections of base metal and complex joint
designs usually require filler metals high weld metal ductility.
• Surface conditions - The condition of the base metal surface has an effect on
the selection of the electrode wire.
• Specifications or service requirements - Specifications may require the use of
a specific electrode. In other cases, the requirements that the weldment will
encounter while in service must be considered.
The size of the electrode wire depends on the thickness of the material, welding
position, and the process variation.
The selection of the shielding gas depends on the type of electrode, the type of
base metal, the welding position, and the desired weld quality.
Refer to standard welding texts, technical guides, and AWS publications and
standards for more information regarding the selection of electrodes and shielding
gases.
3.2.4 Weld Quality
The quality of the weld depends on the following factors:
• Selection of electrode wire
• Cleanliness of the weld joint and wire
• Welding procedure
• Welding position
• Purity of the shielding gas mixture
Gas metal arc welding is a no-hydrogen welding process. Under ideal conditions
there should be no hydrogen in the shielding gas or any other welding component.
If hydrogen is present in the welding atmosphere, it will mix with the metal in the
molten weld pool. As the metal cools and solidifies, the hydrogen becomes
trapped in the metal and causes porosity. GMAW requires the use of welding
grade shielding gases, and clean, dry electrodes and surfaces.
Certain factors detract from the quality of the deposited metal weld. If the
surrounding atmosphere (drafts and breezes) comes in contact with the gas
shielding envelope, the result may be a dirty weld caused by oxidation, unstable
welding conditions, or gross porosity. Water vapor, oil, and other impurities can
also contaminate the weld atmosphere. These are present in impure shielding
gases, or dirty electrodes and surfaces.

SECTION 4
OPERATION
This section identifies the controls and indicators used to operate the system under
normal conditions. It also contains set-up instructions for preparing the welding
system for operation, as well as typical AWeld and VWeld set up.
4.1 Controls and Indicators

4.1.1 UWI Indicators
LED indicators on the UWI show the operating status of the unit. Figure 4-1
illustrates the location of the LED's and relays. Tables 4-1 and 4-2 list the
functions of the various LED's and relays.
RELAYS
LED13 and LED14 LED1 – LED4 and LED5 – LED12
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
FU3 FU2 J2 SW1 J3 J4 FU1
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1
C17 REG1 REG2 JMP8 3

INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
MOTOMAN UNIVERSAL WELDING
20 UWI INTERFACE C2 J7
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
C15
U2 RN4 9
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
VWELD POT3 JMP24 CR6 CR2
4
J10 JMP16 JMP25 LED10 D6 LED6 D2
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
3 AWELD JMP18 JMP31 CR7 CR8 CR3
JMP17 JMP32 LED11 D7 LED12 D8 LED7 D3
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12
JMP11 U6 5
D9
RN2
JMP10
U4 4
C5
ARC ON U1 U3
JMP6 JMP9
JMP8
R3
RN1
C17 REG1 REG2 JMP7

3
INCH
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
1
RN3
REV JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
JMP1
24 VAC
MOTOMAN C1
UNIVERSAL WELDING
CR4 CR5
REV A C3 LED8 D4 LED9 D5
130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
1 2 3 4
M+
M–
IN 1
FAULT
GND
DIF–OUT
GND
DIF–IN
+15V
ENABLE
CCW
CW
SYNC
GND
DIF+IN
GND
GND
IN 2
TACH
–15V
V+
V–
TB2
J5
+ – AC AC
3 4
TP
1
2
TCH EMF
TQ SP
OFFSET
TACH
2
INPUT
IR COMP
WARNING COMP
THIS EQUIPMENT HAS MULTIPLE SOURCES

OF ELECTRICAL SUPPLY. DISCONNECT AND
LOCKOUT/TAGOUT ALL ELECTRICITY
CAUTION REG GAIN
TO RECUCE THE RISK OF FIRE,

CUR. LIMIT
CONT
BEFORE SERVICING 479125-8 PK
REPLACE ONLY WITH FUSES OF

SAME TYPE AND RATING 479125-9
O. CURR
SUPPLY
POWER
I. LIMIT
FAULT
+15V
–15V
GND
AUX
+5V
Figure 4-1 UWI PC Board LED's and Relays

OPERATION
Table 4-1 UWI LED Indicators and Functions
INDICATOR NAME FUNCTION

LED1 ARCON Indicates arc on input
LED2 INCH-FWD Indicates inch forward input
LED3 INCH-REV Indicates inch reverse input
LED4 PURGE Indicates gas purge input
LED13 +5V DC OK Indicates +5 voltage input
LED14 +15V DC OK Indicates +15 voltage input
Table 4-2 UWI LED Indicators and Functions
INDICATOR RELAY FUNCTION

LED5 CR1 Indicates inch forward relay
LED6 CR2 Indicates inch reverse relay
LED7 CR3 Indicates feeder analog input
LED8 CR4 Indicates gas purge
LED9 CR5 Indicates power source enable
LED10 CR6 Indicates feeder enable
LED11 CR7 Indicates auxiliary feeder enable
LED12 CR8 Indicates auxiliary relay enable
4.1.2 UWI Relay and LED Operation

Table 4-3 describes the relays and LED indicators (see Figure 6-3) that light during
various UWI operations.
NOTE: When power is ON, the +5 volt and +15 volt LED's will be lit continuously.
Table 4-3 UWI Relay and LED Operation
OPERATION RELAY ON LED ON

Inch Forward – INCH-FWD
CR1 LED5
CR6 LED10
CR7 LED11 (no relay in socket)
Inch Reverse – INCH-REV

CR6 LED10
CR2 LED6
Purge – PURGE
CR4 LED8

OPERATION
Table 4-3 UWI Relay and LED Operation - continued
OPERATION RELAY ON LED ON

Arcon Condition – ARCON
CR3 LED7
CR4 LED8
CR5 LED9
CR6 LED10
CR7 LED11 (no relay n socket)
CR8 LED12 (no relay in socket)
4.1.3 Motor Speed Control Indicators

LED indicators (see Figure 7-6) on the KXA motor speed control show the
operating status of the unit. Table 4-4 lists the indicators and describes their
function.
Table 4-4 KXA Motor Speed Control Indicators
INDICATOR NAME DESCRIPTION

LED1 (Yellow) POWER Lights when power is ON.
LED2 (Red) FAULT Lights for any fault condition, as listed

below, and when the motor speed con-
trol is disabled. Fault condition can be
latched or unlatched.
LED3 (Red) VOLT Fault condition. Lights if the bus volt-

(Over Voltage) age exceeds an upper set limit. This
can happen if the input supply is wrong,
or if the regeneration clamp circuit
fails. This is a latched fault. The con-
trol remains disabled until the fault is
corrected.
LED4 (Red) O.CURR Fault condition. Lights when a ground

(Over Current) short or faulty component allows exces-
sive current flow. This is a latched
fault. The control remains disabled
until the fault is corrected.
LED5 (Red) I. LIMIT Lights when continuous current set

(Current Limit) point is exceeded. The control remains
disabled until the fault is corrected.
LED2, Over Temperature Fault condition. Lights when a temper-

LED3, ature sensor detects excessive heat in
LED4 the power output stage. This is a
(all lit at once latched fault. The indicator goes off
when the temperature falls below the
threshold of the sensor.
Note: If a latched fault occurs, the motor speed control must be reset even if the cause of the
fault has been corrected. To reset a fault you must do one of the following:
• Remove and then restore power.
• Remove and then restore the ENABLE signal.

OPERATION
4.2 Shock Sensor Recovery

When the robot collides with another object, the shock sensor engages, freezes
robot movement, and immediately triggers an EMERGENCY STOP condition.
Provided below are instructions for overriding the shock sensor to clear the E-
STOP condition.
CAUTION!
Do not operate the robot in override condition. The robot will not
respond to shock sensor signals. Damage to equipment can occur.
To override the shock sensor, proceed as follows:
1. Press TOP MENU on the programming pendant.
2. Select the ROBOT icon using the cursor keys. Press SELECT.
3. Cursor to OVERRUN-S.SENSOR and press the SELECT key.
4. Press RELEASE to release the shock sensor.
5. Turn servo power ON by holding the ENABLE switch on the programming
pendant and pressing SERVO ON.
NOTE: TEACH LOCK must be ON to turn servo power on in TEACH mode.
6. Move the manipulator clear of the impact operation.
7. Resume operation.
4.3 Setting Up Absolute Welding Values

This section contains instructions to setup absolute welding values. Welding
parameters for the controller are set using the following two methods:
• Absolute settings for volts and amperes
• AWELD and VWELD arguments
The preferred method for setting the welding parameters is to use absolute settings
for voltage and amperage; for example, ARCVOL 22 volts and ARCCUR 140
amps. Welders find this method easiest for most applications. Set absolute
conditions for amps in whole numbers or double integer variables. Using absolute
values requires calibration data to be entered in the welder condition file.
Conditions of welding currents, voltage, and timers can be set up using arc start,
arc end, and arc auxiliary condition files in the robot program. (Refer to Operator's
Manual for Arc Welding for additional information on arc condition files.)
Tables containing wire burnoff characteristics are available in welding manuals,
filler metal data sheets, and weld data books. These tables vary considerably
depending on the following:
• Welding currents
• Wire size/type
• Gas mixtures
• Wire extension
Therefore, setting up a table for special wires requires that test welds be completed
in order to determine the curve. Generally, wire burnoff characteristics are more
non-linear with higher mixtures of argon gas.
Another method for setting the welding parameters is to use argument tables (see
Section 7, Tables 7-8 and 7-9). For example, on a MotoArc power source, a
VWELD 7.00 represents 22 volts (see Table 7-4) and an AWELD 7.00 represents a

OPERATION
wire feed speed of 300 IPM (see Table 7-8) that provides about 140 amperes with
.035-inch-diameter ER70S-3 wire.
4.3.1 Setting the Absolute Welding Voltage Curve
The absolute welding voltage curve is easy to set up because it is usually linear.
The power source or arc voltage is directly proportional to the input command
voltage to the power source. With the MotoArc power source, "0" volts input gives
"0" volts output (0 = 0) and 10.00 volts input gives 44-arc volts. Motoman scales
the normal robot analog from 14.00 volts to 10.00 volts (14 = 10) to match the
power source. In special or non-regulated power sources, the curve may be non-
linear. You must develop the curve for that specific power source.
Using the blank Voltage Setting Graph in Appendix B, enter the absolute welding
data into an eight-point table, as shown in Figure 4-2. The table requires a
minimum of three settings. The controller uses a curve fit program and the
absolute data to estimate actual welding current and voltage. The first data point
should not be entered with a command value of "0" and a measured value of "0" in
the table. This will cause problems during actual welding.
Direct Set Voltage for XRC

14 14
8
13 13
12 7 12
11 11
10 6 10
9 9
Robot Argument Value

5
8 8
7 4 7
6 6
5 3 5
4 4
3 2 3
2 2
1
1 1
0 0
0 5 10 15 20 25 30 35 40 45
Direct Set Arc Voltage
Figure 4-2 Absolute Welding Voltage Settings
After the eight points have been selected on the chart, enter this data into the data
file display shown in Figure 4-3, which is located in the welder condition file.
(Refer to the Operator’s Manual for Arc Welding for additional information on
entering data into welder condition files.)
NOTE: Modifications to welder condition files must be done in management mode.

OPERATION
DATA EDIT DISPLAY UTILITY

L
WELDER CONDITION R1 C S
<WELDING VOLTAGE OUTPUT CHAR.>
RANGE : + ADJUST : 1.00
NO. REF.(V) MEASURE(%)
01 2.80 100
02 3.80 150
03 5.40 200
04 7.40 250
05 9.70 300
06 0.00 0
07 0.00 0
08 0.00 0
Figure 4-3 Voltage Data File Display

4.3.2 Setting the Absolute Welding Amperage Curve
Figure 4-4 shows typical amperage settings for .035-inch-diameter ER70S-3 wire.
These values will change for various wire types and size, and gases. Figure 4-5 is
an example of the welder condition file display for the chart shown in Figure 4-4.
Direct Amperage Set for XRC

600 14
8
13
500 12
7
11
.035" HB-25 (E70-3) WIRE,
Wire Feed Speed - IPM
C-25 GAS, DCEP 10

400 6
Robot Analog Value

9
8
5
300 7
6
4
5
200
3 4
3
100 2
2
1 1
0 0
0 20 40 60 80 100 120 140 160 180 200
Welding Current - Amps
Figure 4-4 Absolute Welding Amperage Settings

OPERATION

L
<WELDING CURRENT OUTPUT CHAR.>
RANGE: + ADJUST:1.00
NO. REF.(V) MEASURE(A)
01 2.80 100
02 3.80 150
03 5.40 200
04 7.40 250
05 9.70 300
06 0.00 0
07 0.00 0
08 0.00 0
Figure 4-5 Amperage Data File Display

4.3.3 Setting Absolute Welding Amperage as Wire Feed Speed
It is possible to set absolute welding amperage parameters as volts and wire feed
speed. To do this, use the left and right vertical axes on the blank Amperage
Setting Graph in Appendix B. Enter the command voltage value on the right side
corresponding to wire feed speed on the left side of the chart. Do not enter a
command value of "0" at the first power source data point even though the table
reflects a measured value of "0." The weld current now represents wire feed speed
and is linear, as shown in Figure 4-6. Enter weld current as shown in Figure 4-7.
Absolute Data for Wire Feed Speed

PWF4-600 and PWF4-750 Wire Feeders
750
700
650
600
550 PWF4-750
WIRE FEEDER
Wire Feed Speed
500
450
400
350
300 PWF4-600
WIRE FEEDER
250
200
150
100
50
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Wire Feed Argument Value
Figure 4-6 Absolute Welding Amperage Settings as Wire Feed Speed

OPERATION
NOTE: The data is entered in Measure(A) column, but in this case is actually wire feed speed.

L
01 2.80 100
02 3.80 150
03 5.40 200
04 7.40 250
05 9.70 300
06 0.00 0
07 0.00 0
08 0.00 0
Figure 4-7 Weld Current as Wire Feed Speed for PWF4-600 Wire Feeder
4.3.4 Absolute Settings for MotoArc 350i/500i
The MotoArc 350i and 500i power sources can operate in either GMAW
(standard) or pulsed mode. In GMAW mode, the voltage and amperage are set
directly and correspond to settings outlined in Section 4.3.1 and 4.3.2, respectively.
In pulsed mode, however, amperage may not match the settings shown in Section
4.3.2 and voltage is not controlled. The VWeld analog actually “trims” the pulse
frequency. This “timming” is subtle to the operator, as pulse frequency is used to
adjust the arc length just like the arc voltage is used in GMAW mode.
When using pulsed mode on the 350i or 500i, set the voltage table as outlined in
Section 4.3.1 and set the current data file for wire feed speed as shown in 4.3.3. In
pulsed mode, the MotoArc uses a pulse frequency scale of 0 – 440. In standard
GMAW mode, the operator can set the desired voltage (i.e., ARCVOL = 22.5
volts). In pulsed mode, the operator must enter the frequency reference of 225 as
ARCVOL = 22.5 volts (see Figure 4-8).
The amperage output in pulsed mode varies based on wire feed speed and the pulse
frequency setting. Setting the current condition file for wire feed speed provides a
consistent parameter in standard GMAW or pulsed mode. For example, a setting
of ARCCUR=250 would provide 250 ipm wire feed speed in both GMAW or
pulsed mode. The actual average amperage would vary between the two modes.
In pulsed mode, the power source meter reads the voltage while welding and the
frequency when the arc is off. To establish voltage and frequency parameters:
1. Set the welder program to “local” mode and weld a test bead.
2. While welding the test bead, adjust the voltage/frequency by turning the
knob on the front of the power source.
3. After welding the test bead, note the voltage or frequency value and enter it
in the weld file’s ARCVOL parameter.
4. Return the welder to “remote” mode.

OPERATION
Direct Set Pulse Frequency

0 50 100 150 200 250 300 350 400 450
14 14
8
13 13
12 7 12
11 11
10 6 10
9 9

5
8 8
7 4 7
6 6
5 3 5
4 4
3 2 3
2 2
1
1 1
0 0
0 5 10 15 20 25 30 35 40 45
Figure 4-8 Pulse Frequency vs. Voltage Settings
4.4 Using Schedule Select with Pulsed Mode

The MotoArc 500i is a multi-process welder with two outputs (A and B). When
Output A is OFF, the welder is in standard GMAW mode; when Output A is ON,
the welder is in pulsed mode. Output B is used to select TIG mode.
When the welder is operating in pulsed mode, the operator must select one of 12
pulsed schedules (schedule 1 is the default). Select the schedules by controlling
groups of four outputs in a binary fashion, using the DOUT OGH# instruction.
Actual system wiring will vary; however, every system should have outputs
labeled bit Ø, bit 1, bit 2, and bit 3. The robot can control groups of eight outputs
(DOUT OG#) or groups of four outputs (DOUT OGH#).
For example, outputs 1-8 could be group 1, and outputs 9-16 could be group 2.
Outputs 1-4 would be half group 1 (DOUT OGH#(1)) and outputs 5-8 would be
half group 2 (DOUT OGH#(2)). Assuming Mode A is wired to output 9 and the
schedule select outputs are wired to outputs 13-16, the following job example
would apply:

OPERATION
Line Step Instruction Description

000 000 NOP
001 001 MOVJ VJ=100
002 DOUT OT#9 ON Turn pulse ON.
003 DOUT OGH#(4) 4 Select schedule 4.
004 002 MOVJ VJ=50
005 ARCON ASF#1
006 003 MOVL .
007 004 MOVL
008 ARCOF AEF#1
009 005 MOVJ VJ=100
010 006 MOVJ VJ=100
011 DOUT OT#(9) OFF Turn pulse OFF.
012 007 MOVJ VJ=50
013 ARCON ASF#2
014 008 MOVL
015 009 MOVL
016 010 MOVL
017 ARCOF AEF#2
018 011 MOVJ
The above job would pulse weld with schedule 4 and then weld in standard
GMAW mode. Place outputs in each job to ensure the desired mode and schedule
are selected.
NOTE: Systems are often wired differently. Check the output diagnostic screen to verify the actual
output numbers on your system.
4.5 Welder Condition Data File

The welder condition data file has the following three segments (see Figures 4-8
through 4-10):
• Welder Condition Data File (Header)
• Welder Condition Data File (Current)
• Welder Condition Data File (Voltage)
Dual robot controllers will have a welder condition file for each welder (welder1
and welder2). Refer to the Operator's Manual for Arc Welding for additional
information about each welder condition data file segment.
NOTE: Although shown below, WIRE ANTI-STICKING and ARC SHORTAGE STOP are not shown
initially on the display. Use the ARROW DOWN key to move the cursor to display them.

OPERATION

L
WELDER NO. : 1
SETTING : DONE
WELDER NAME :
COMM.:
POWER SUPLY : A
SHIELDING GAS : CO2
WIRE DIA. : 1.2 mm
WIRE EXT. : 15 mm
WIRE ANTI-STICKING : 0.3 sec
ARC SHORTAGE STOP : 0.60 sec
Figure 4-9 Typical Welder Condition Data File Display

NOTE: The current table is not shown initially on the pendant display. Use the ARROW DOWN key to
move the cursor to display them.

L
01 2.80 100
02 3.80 150
03 5.40 200
04 7.40 250
05 9.70 300
06 0.00 0
07 0.00 0
08 0.00 0
Figure 4-10 Typical Welder Condition Data File (Current) Display

L
<WELDING VOLTAGE OUTPUT CHAR.>
RANGE : + ADJUST : 1.00
NO. REF.(V) MEASURE(%)
01 2.80 100
02 3.80 150
03 5.40 200
04 7.40 250
05 9.70 300
06 0.00 0
07 0.00 0
08 0.00 0
Figure 4-11 Typical Welder Condition Data File (Voltage) Display

OPERATION
4.5.1 Displaying a Welder Condition Data File

To display a welder condition data file, follow these steps:
1. From TOP MENU, cursor to the ArcWelding icon and press SELECT.
2. Cursor to WELDER CONDITION and press SELECT.
3. The active Welder Condition file will be displayed. Cursor up or down to
show active reference data.
4. Press the AREA key to highlight DATA in the top menu area of the screen.
Press SELECT and a menu drops down. Cursor to READ and press
SELECT.
5. The 24 preset WELDER CONDITION files will be displayed.
6. Cursor to a file and press SELECT to view its reference data.
7. Press the PAGE key to display the four USER files.
NOTE: Additional welders (WELDER2) may appear on dual robot systems.
4.5.2 Selecting a Welder Condition Data File
To select a welder condition data file, follow these steps:
1. Press the AREA key to highlight DATA in the top menu area of the screen.
Press SELECT and a menu drops down. Cursor to READ and press
SELECT.
2. The 24 preset WELDER CONDITION files will be displayed.
3. Cursor to a file and press SELECT to view its reference data.
4. Once you select a preset file, press the AREA key, cursor to the DATA and
press SELECT. From the drop down menu, select WRITE. This opens the
USER file (1-4).
5. Cursor to the desired USER file and press SELECT. This copies the welder
condition file you chose from the preset files into the USER file, allowing
you to make edits. This is similar to a “scratch pad” file that can be written to
the active file once editing has been completed.
NOTE: Although the active file may have previously been set to DONE, the program automatically sets
it now to NOT DONE.
4.5.3 Editing a Welder Name or Comment
The comment field can be used to note when data is generated, who generated it, or
other user information.
To edit a welder name or comment, follow these steps:
1. Follow the steps in Section 4.5.1 to display the welder condition file.
2. Cursor down to the WELDER name and press SELECT.
3. Use the alphanumeric display to create the desired name or comment on the
Input Buffer line.
4. Press Enter when finished.

OPERATION
4.5.4 Editing a Power Supply Setting

This function is used to define standard or synergic welders. In standard mode, the
condition files and arc files will display voltage as an actual value (=xx.x volts). In
synergic mode, voltage is displayed as a percentage of the trim value (=xxx%).
MotoArc welders are set up in standard mode (using actual voltage) while most
pulse welders are set up in synergic mode (using percentage).
To edit a power supply setting, follow these steps:
2. Cursor down to POWER SUPPLY and press SELECT.
3. A screen will appear which contains EXECUTE and CANCEL icons. Select
EXECUTE to toggle the power supply settings from volts to AVP (%) or
from APV to volts.
Arc Shortage Stop
Users should note the wire size, gas, and electrode extension, as amperage curves
vary with these parameters. These notes are for the user and have no effect on the
data entered. Anti-sticking and arc shortage stop are system timers and are
explained in the manipulator manual for the system.
To edit a wire diameter, etc., follow these steps:
2. Cursor down to Wire Diameter, Anti-Stick, etc. and press SELECT.
3. Enter the desired data into the Input Buffer line and press ENTER.
4.5.6 Editing Welder Current or Voltage Data
Instructions for setting this data is found in Section 4.3. To edit welder current or
voltage data, follow these steps:
2. Cursor down below the data initially visible and the welder table will appear.
3. Place the cursor on the data (Welder Current or Voltage) to be changed and
press SELECT.
4. Key in the desired data on the Input Buffer line and press ENTER.
4.5.7 Changing Welder Power Supply Analog Polarity
MotoArc welding power sources use a positive range (+) analog. Most other
power supplies also use a positive range. Refer to the power supply manual for
analog polarity setting.
4.5.8 Editing Welder Current or Voltage Adjustment
Welding power source calibration and characteristics may vary slightly between
models or units. Change the adjustment ratio to compensate for line voltage
changes or individual power source characteristics.
NOTE: If the weld voltage is lower than the set value in the table, the scale can be changed to 0.90 to
increase all values 10%. The maximum range of change is 0.80 to 1.20 (± 20% adjustment)
times the values in the table.

OPERATION
4.6 Creating New Absolute Welding Amperage Data

The absolute welding amperage data for MotoArc power sources is discussed in
Section 4.3.2. However, other power sources have different input voltages. If your
system is not equipped with a MotoArc power source, use the following procedure
to create absolute amperage data for your power source. Required test equipment
is listed in Table 4-5.
Table 4-5 Tools and Equipment for Testing Amperage
TOOL OR EQUIPMENT SPECIFICATION

Digital multimeter 4 digit resolution
(Fluke Model 87 or equivalent w/peak capture
Digital ammeter (DC/RMS) 0 - 400 amps
Tachometer 0 to 150 RPM ± 1 RPM
Micro test clip leads (as required) For connection to small test points
NOTE: When testing new weld data, use the same precision calibrated instruments for all power
sources. Digital voltmeters and ammeters can sometimes lead to errors and should be checked
against other standards. The wave shape of the DC welding current can cause meters to read
differently. A true RMS digital ammeter will correct for wave shape, but may indicate a slightly
lower value than normal welding power source DC meters.
4.6.1 Welding Setup Procedure
To conduct a weld current setup procedure, proceed as follows:
1. Set the power source for control from the robot.
2. Confirm the speed range of the wire feeder (usually 0-750 IPM).
3. Use weld material thick enough for max. current (1/4-inch plate, 250 amps).
4. Set gas flow.
5. Set torch tip to work-distance (normally 3/8" to 3/4") and position torch in a
normal weld attitude.
6. Set up a test job and set the travel speed to the correct speed for the
amperage.

OPERATION
4.6.2 Weld Test for New Amperage Data
DANGER!
• DO NOT LOOK AT THE ARC WITHOUT PROTECTION. Serious eye
injury will result from looking at exposed arc.
• Always be aware that the robot can make unexpected moves.
Unexpected robot moves can cause serious injury or death.
To conduct a weld test, proceed as follows:
1. Weld at eight different currents (WFS) and voltages. Use a new sample plate
for each test. Use AWELD values of 4, 6, 8, 10 or similar values during the
tests. Adjust voltage to proper length.
2. Record the voltage, wire feed speed (or use motor RPM and convert to IPM),
amperage, and other parameters such as gas flow, travel speed, torch angle,
etc., for reference. Note the values of AWELD and VWELD instructions.
3. Enter the measured amperage corresponding to the AWELD analog voltage
in the welder condition file.
4. If desired, plot the wire feed speed versus amperage for a particular wire.
Use the blank Amperage Setting Graph in Appendix B to plot the data.
5. Draw a smooth line through the points on the chart to generate the curve.
Usually the curve is more linear at the lower currents and has a sharper
upward bend at higher currents for .035-inch wire, as indicated by the chart
in Figure 4-4.
6. Up to eight points of data can be registered in the file. The file requires a
minimum of three lines. Exit the welder condition data file to save the
changes.
7. Weld at the various settings to confirm that the settings are accurate. If there
are major errors, the data in the table must be corrected so that it corresponds
to the actual measured values. Pick a normal travel speed for a given wire
size, current, and voltage.
NOTE: • The voltage values are linear with the argument values. Data from previous direct voltage
settings can be used if you use the same power source and it is a regulated type.
• Some non-regulated power sources or special power sources may have a slight non-linear
characteristic or minimum cut-off voltage. If this is the case, either perform the welding
voltage test with a high current load bank (0-400 amps) or weld an actual job to determine
actual weld values.

OPERATION
4.7 Creating New Absolute Welding Voltage Data

The absolute welding voltage data for MotoArc power sources is discussed in
Section 4.3.1. However, other power sources have varying output voltages. If
your system is not equipped with a MotoArc power source, use the following
procedure to create absolute voltage data for your power source. Required test
equipment is listed in Table 4-6.
Table 4-6 Tools and Equipment for Testing Voltage

Digital ammeter (DC/RMS) 0 - 400 amps
NOTE: When testing new weld data, use the same precision calibrated instruments for all power
sources. Digital voltmeters and ammeters can sometimes lead to errors and should be checked
against other standards. The wave shape of the DC welding current can cause meters to read
differently. A true RMS digital ammeter will correct for wave shape, but may indicate a slightly
lower value than normal welding power source DC meters.
4.7.1 Welding Setup Procedure
To conduct a welding setup procedure, proceed as follows:
1. Set the power source for control from the robot.
2. Confirm the speed range of the wire feeder (usually 0-750 IPM).
3. Use weld material thick enough for max. current (1/4-inch plate, 250 amps).
4. Set gas flow.
5. Set torch tip to work-distance (normally 3/8" to 3/4") and position the torch
in a normal weld attitude.
6. Set up a test job in XRC with travel speed set to the correct speed for the
amperage.

OPERATION
4.7.2 Weld Test for New Voltage Data
DANGER!
• DO NOT LOOK AT THE ARC WITHOUT PROTECTION. Serious eye
injury will result from looking at exposed arc.
• Always be aware that the robot can make unexpected moves.
Unexpected robot moves can cause serious injury or death.
To create new voltage data, follow these steps:
1. Weld at eight separate voltages as low and as high as possible.
2. Record the VWELD command and arc voltage (from power source) at each
setting.
3. Enter measured data corresponding to VWELD analog in the welder
condition file. If desired, use the blank Voltage Setting Graph in Appendix B,
plot the points and draw a straight line through them.
4. Modify Adjust Ratio to bring data close to actual.
NOTE: • If your system is equipped with Com-Arc, Adjust Ratio cannot be used to modify data.
• It is not possible to create absolute voltage data for a "pulse type" welding power source,
due to the non-linear characteristics of output voltage versus frequency. Refer to the power
source manual for voltage “trim” scales.
4.8 Using Absolute Current Data Tables

The absolute current data table (see Table 4-8) references wire types and sizes.
The actual absolute current setting will vary with gas type, wire extension, torch
angle, and base material and joint configuration. The data listed in Table 4-8 is
provided as a starting point for your own weld data. Actual welding current and
accuracy of the table will depend on many welding variables. To improve the
accuracy of the table data, weld on the actual parts under actual weld conditions.
Table 4-8 lists weld settings for the Motoman PWF4-750 and PWF4-600 wire feed
systems. Locate your wire size, shielding gas, and feeder model number. Then
weld using the settings indicated and confirm speeds. The PWF4-750 has a
maximum motor shaft speed of 150 RPM for a maximum of 750 IPM. The PWF4-
600 has a maximum motor shaft speed of 120 RPM for a maximum feed rate of
600 IPM (inches/minute). The following data only applies to the PWF4 Motoman
wire feeders.

OPERATION
Table 4-7 Absolute Current Settings for PWF4 Wire Feeders

.030" ER70S3 C-25 GAS .035" ER70S3 C-25 .045" ER70S3 C-25
HOBART HB-25 GAS HOBART HB-25 GAS HOBART HB-25
Point Ref Measure A Measure A Measure A Measure A Measure A Measure A
Volt PWF4-600 PWF4-750 PWF4-600 PWF4-750 PWF4-600 PWF4-750
1 1.75 27 35 50 63 75 95
2 3.50 70 85 90 105 140 175
3 5.25 92 115 115 135 190 235
4 7.00 122 150 140 160 240 300
5 8.25 135 165 155 175 275 240
6 10.50 160 200 175 195 320 400
7 12.25 175 215 190 213 350 435
8 14.00 190 230 200 250 365 *
.045" ER70S3 9-10% .052" ER70S6 C02 GAS 052" ER70S6 C-25
CO2 GAS HOBART HB-25 HOBART HB-28 GAS HOBART HB-28
1 1.75 100 125 85 105 470 115

2 3.50 180 225 175 215 190 230
3 5.25 230 285 250 310 250 310
4 7.00 295 365 330 400 300 375
5 8.25 325 405 380 470 330 410
6 10.50 370 460 460 * 370 460
7 12.25 400 * 525 * 405 500
8 14.00 420 * * * 430 535
1/16" ER70S3 C-25 GAS .045" ER70T1 C-25 1/16" ER70T1 C02 GAS
HOBART HB-28 GAS HOBART FABCO 86 HOBART FABCO RXR
1 1.75 110 135 60 75 110 137

2 3.50 220 275 110 135 210 260
3 5.25 300 375 155 190 290 360
4 7.00 380 475 195 240 370 460
5 8.25 420 525 220 275 410 500
6 10.50 515 630 270 335 * *
7 12.25 570 * 350 420 * *
8 14.00 605 * * * * *

OPERATION
Table 4-7 Absolute Current Settings for PWF4 Wire Feeders - continued
3/64 4043 ALUMINUM 1/16 4043 ALUMINUM .035" ER308L SS
ARGON GAS ARGON GAS 98-2 OXIDE
1 1.75 40 50 40 50 35 45
2 3.50 75 90 75 90 85 105
3 5.25 112 140 120 150 105 130
4 7.00 145 180 160 200 130 160
5 8.25 165 205 190 235 145 180
6 10.50 200 250 240 300 175 215
7 12.25 225 280 270 335 195 240
8 14.00 250 * 300 * 215 *
.045" 3098L SS .035" ER120S1
98-2 OXIDE 82-18 CO2
1 1.75 Measure A Measure A Measure A Measure A
PWF4-600 PWF4-750 PWF4-600 PWF4-750
2 3.50 75 90 40 50
3 5.25 130 160 95 115
4 7.00 175 215 130 160
5 8.25 220 275 160 200
*Indicates that no data is entered in the chart.

NOTE: Data displayed at high speeds may be beyond the wire capacity to weld at that setting. Follow
AWS recommendations for proper current settings for the type and diameter of wire.

OPERATION
NOTES

SECTION 5
TROUBLESHOOTING
5.1 Equipment and Tools Required
Table 5-1 list tools and equipment required for testing components in the arc
welding system.
Table 5-1 Tools and Equipment for Troubleshooting

Screwdrivers Small calibration screwdriver

00 Phillips
0 straight blade
5.2 Troubleshooting Procedures

Table 5-2 lists problems commonly encountered during welding, probable causes,
and suggested remedies. To troubleshoot the system, identify the type of problem
and look for it in the PROBLEM column. The next column lists probable causes
for the problem. For each probable cause, one or more remedies is suggested in
the SOLUTION column. Sometimes more than one problem can occur at the same
time. After you identify and resolve a problem, test the system thoroughly to make
sure that no other problems exist.
Table 5-2 Welding Troubleshooting Chart
Problem Probable Cause Solution

Part of the direct amperage Many welding handbooks con- Follow the procedure in
setting points are correct tain charts of wire feed speed Section 4.5 or 4.6 to create
but there is a major error at versus welding amperage. These data.
the higher currents. charts are usually developed
from typical data and CO2 gas
and at normal welding speeds.
Quite often, the high end scale of
the chart is not accurate using
Argon-CO2 Gas mixtures.
The table is set up for a maxi-

mum wire feed speed of 750 Calibrate power source and
IPM at a normal AWELD of wire feeder (refer to Sec-
14.00 volts input. If the analog tions 7.2 and 7.3).
value is not 14.00 volts or feed
motor speed calibration is off,
there will be an error at the
higher amperages.

TROUBLESHOOTING
Table 5-2 Welding Troubleshooting Chart - continued

There is no output voltage The range has been set incor- Change polarity. Refer to
control from the power rectly with a negative value section 4.5.7.
source. when it should be positive.
The power source may be in Set switch on power source

local mode. to remote mode.
The wire feed runs back- The wire feed RANGE com- Set the range to positive.
wards and there is no arc. mand is set to negative.
Alarm 4830 is displayed, No welder condition data file Follow the procedures in
indicating "Undefined exists for the welder you are Section 4.5 or 4.6 to create
Welder Condition File." using. the appropriate data, then
edit the welder condition
data file (refer to Section
4.5.6).
Alarm 4840 is displayed, The arc start condition file that Follow the procedure in the
indicating "Undefined Arc you are attempting to use does Operator's Manual for Arc
Start Condition File." not exist. Welding to create the arc
start condition file.
Alarm 4850 is displayed, The arc end condition file that Follow the procedure in the
indicating "Undefined Arc you are attempting to use does Operator's Manual for Arc
End Condition File." not exist. Welding to create the arc
end condition file.
Wire feed is erratic Alarm Welding voltage reference unit Match the welding voltage
4860 is displayed, indicat- and welding machine power sup- reference unit.
ing "Wrong Welder Selec- ply type do not match.
tion."
Alarm 4870 is displayed, Possible corruption of welder After alarm reset, execute
indicating "Fault (Welder condition data file. the operation again. For a
Condition File)." maintenance alarm code,
contact Motoman Service
Department.
Alarm 4880 is displayed, Possible corruption of arc start After alarm reset, execute
indicating "Fault (Arc Start condition file. the operation again. For a
Department.
Alarm 4890 is displayed, Possible corruption of arc end After alarm reset, execute
indicating "Fault (Arc End condition file. the operation again. For a
Department.
Alarm 4900 is displayed, Possible corruption of arc auxil- After alarm reset, execute
indicating "Fault (Arc Con- iary condition file. the operation again. For a
dition Supp. File)." maintenance alarm code,
Department.

TROUBLESHOOTING

No control of inch, purge, XEW02-1 cable plug is loose on Tighten both ends of the
or welding, and no LED's one or both ends (the XEW02-1 XEW02-1 cable plug.
lit on UWI PC board. provides partial voltage to the
UWI).
Purge from pendant doesn't Output #188 has not been Assign output to gas purge.
operate, but inch forward assigned to the pendant in the The LED on the UWI PC
does. XRC ladder. board should light when
the wire is inched forward,
reversed, or purge output is
turned on. The correspond-
ing relay LED should also
light.
The wire feed is very The conduit liner or contact tip Check to make sure tip and
erratic and intermittent. may be the wrong size. liner are correct size and
The motor feed rolls turn. that liner is properly seated
against the gas diffuser.
Replace if necessary.
The conduit liner is clogged with Replace conduit liner.

dirt.
Wire is tangled on the wire Check spool and untangle

spool. wire.
Motor feed rolls can't push the Remove top set of feed
wire. rolls and try to pull the wire
through the welding torch.
If you can't move the wire
through the feeder, con-
sider using knurled or gear/
cog type feed rolls to give
more pulling and pushing
force. However, these gears
will leave marks on the
wire that will cause rapid
tip and gun liner wear.
Wire feed, inch forward, or The transformer power fuse FU1 Check transformer fuse
inch reverse doesn't oper- (4A) is blown. FU1 on UWI PC board.
ate, but gas purge does. No Replace fuse if it is blown
yellow light on the motor (refer to Section 6.1.3).
speed control LED display.
The welding power supply is Turn on the welding power
turned off. The motor speed supply.
control is powered by the 24V
AC isolation transformer. The
transformer gets its 120V AC
from the welding power source.

TROUBLESHOOTING

Wire feed, inch forward, The gas valve fuse FU3 (.5A) is Replace the gas valve fuse
and inch reverse operate, blown. (The gas valve does not FU3 on the UWI PC board
but gas purge doesn't. The click when the purge is turned (refer to Section 6.1.3).
weld is very porous, as if on.)
there is no shielding gas.
The robot is in HOLD con- The shock sensor fuse FU2 Replace shock sensor fuse
tinuously and the pendant (.25A) is blown. FU2, on the UWI PC
displays "Impact Sensor board, after determining
Tripped." The impact sen- the reason for the short
sor is normal. (refer to Section 6.1.3).
The wire feed motor runs The polarity of the tachometer Measure the voltage across
forward at a very fast, input is reversed. The tach volt- UWI connector terminals
uncontrolled speed. age at plug PL7-6 should be neg- J2-3 (+) and J2-4 (-). The
ative in reference to PL7-4 meter should show a posi-
(COM). Refer to Table 7-7 for tive voltage. If necessary,
the proper voltage values. reverse the tachometer
leads at UWI connector J2.
The SPEED/TORQUE mode Ensure that the mode selec-

selector switch SW-2 is set for tor switch is set to the
torque mode. SPEED mode (refer to Fig-
ure 7-6).
Feed motor tachometer has
failed. Replace the motor or feed-
head assembly.

SECTION 6
MAINTENANCE
This section provides instructions for replacing major system components in the
GMAW welding system. Replacement instructions are provided for the UWI, the
KXA motor speed control, and the Motoman/Tregaskiss torch and shock sensor.
6.1 UWI Replacement and Setup

The UWI is mounted inside the door on the controller cabinet (see Figure 6-1). It
consists of the PC board, the KXA motor speed control, and transformer. Cables
to the UWI are routed from the receptacle plates located on the lower right side of
the XRC cabinet. Other cables are routed to their respective locations through the
wireways and tied in place. Table 6-1 lists UWI plug and socket connectors and
their descriptions. See Figure 6-2 for the connector and jumper locations on the
UWI PC board.
6.1.1 UWI Replacement
To remove the UWI from the XRC, proceed as follows:
WARNING!
Before you perform any work on the UWI, ensure welding power
source is turned off AND disconnected or serious personal injury or
loss of life, in addition to equipment damage, can result.
1. Turn off welding power source.
2. Open the XRC cabinet and locate the UWI board (see Figure 6-1).
UWI PC BOARD TRANSFORMER
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12
JMP11 U6 5
D9
RN2
JMP10
U4 4
C5
ARC ON U1 U3
JMP6 JMP9
JMP8
R3
RN1
C17 REG1 REG2 JMP7

3
INCH
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
1
RN3
REV JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
JMP1
24 VAC
MOTOMAN C1
UNIVERSAL WELDING
HONDA
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
1 2 3 4
M+
M–
IN 1
FAULT
GND
DIF–OUT
DIF–IN
GND
ENABLE
+15V
CCW
GND
GND
GND
SYNC
DIF+IN
TACH
CW
IN 2
–15V
V+
V–
TB2
KXA MOTOR
J5
+ – AC AC
SPEED CONTROL
3 4
TP
1
2
TCH EMF
TQ SP
OFFSET
TACH
2
INPUT
IR COMP
WARNING COMP

CAUTION REG GAIN

CUR. LIMIT
CONT

O. CURR
SUPPLY
POWER
I. LIMIT
FAULT
+15V
–15V
GND
AUX
+5V
Figure 6-1 Universal Weld Interface

MAINTENANCE
3. Remove the following plugs from the UWI PC board connectors (see Figure
6-2).
• Remove the "Honda" plug from connector J1.
• Remove wire feed motor plug from connector J2.
• Remove shock sensor plug from connector J3.
• Remove power source plug from connector J5.
4. Remove attaching hardware and the entire UWI from the controller cabinet
door.
JUMPERS 5-6 JUMPERS 7-12
J2 J3 J5
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1

INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV
RN3 JMP4
1
U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
J1 Y1
POT7 POT8 CR1
8
INCH-FWD INCH-REV
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
JUMPERS 13-20 JUMPERS 21-32
Figure 6-2 UWI PC Board Connectors and Jumpers
Table 6-1 UWI Plug and Socket Connectors

CONNECTOR DESCRIPTION
J1 20-pin Honda connector from the XEW02 board
J2 To wire feed motor, armature, tachometer, inch, gas control
J3 Shock sensor interface connections
J4 Auxiliary arc established
J5 Welding power source cable connections
J6 120V AC connections to transformer
J7 Connections to wire feeder controller

MAINTENANCE
Table 6-1 UWI Plug and Socket Connectors - continued
CONNECTOR DESCRIPTION
J8 Auxiliary relay connections
J9 Auxiliary meter connections
J10 Arc off detect, gas, wire shortage input
To install the Universal Welding Interface in the controller, proceed as follows:

1. Ensure jumper pins are configured correctly, as shown in Figure 6-2.
2. Install the UWI board, with attaching hardware, on the door inside the XRC.
3. Install the following plugs on UWI PC board connectors (see Figure 6-2).
• Install power source plug on connector J5.
• Install shock sensor plug on connector J3.
• Install wire feed motor plug on connector J2.
• Install the "Honda" plug on connector J1.
4. Calibrate the UWI as described in Section 7.
6.1.2 UWI Jumper Designations
Jumper designations are marked on the UWI PC board. When replacing a UWI
PC board, make sure the jumpers are on the pins indicated by X's, as shown in
Figure 6-2.
NOTE: Extra jumpers for special applications are placed in a cloth bag that is attached to the UWI.
6.1.3 UWI Replacement Fuses
WARNING!
Always replace fuses with exact type and voltage rating.
Table 6-2 lists the type, voltage ratings, and part numbers for replacement UWI
fuses. Figure 6-3 illustrates the location of the fuses.
NOTE: Extra fuses are placed in a cloth bag attached to the UWI. The fuse on the KXA motor speed
control board is rated at 12A @250V.

MAINTENANCE
FU3 FU2 FU1

RELAYS CR1-CR8
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1
INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
Figure 6-3 Fuse and Relay Location on the UWI PC Board
Table 6-2 Replacement Fuses
FUSE VALUE TYPE MFR P/N P/N DESCRIPTION

FU1 4A T-4A Wickmann 131265-1 Delay fuse for
19374K-4A feeder trans-
former
FU2 0.25A Micro-.25A Wickmann 130947-1 Impact (shock)

19303K- 250A sensor protection
FU3 0.50A Micro-.5A Wickmann 130947-2 DC gas valve

19303K- 500A protection
6.1.4 UWI Replacement Relays

Table 6-3 lists the type, voltage ratings, and part numbers for replacement UWI
relays. Figure 6-3 illustrates the location of the relays.
Table 6-3 Replacement Relays
RELAY MFR. MODEL RATING P/N USE

CR1-6 Takamisawa RY-5W-K 120V AC, 5A 130948-1 Standard
32V DC, 1A
CR7-8 Guardian A410-367021-30E 32V DC, 2A 130948-2 Optional

MAINTENANCE
6.2 Replacing the KXA Motor Speed Control

To replace the KXA motor speed control, proceed as follows:
1. Make sure that system power is off and disconnected.
2. Disconnect plug PL7 from connector J7 on UWI PC board (see Figure 6-4).
3. Disconnect the two transformer wires from TB3 terminals 1 and 2.
PLUG PL7
J7
10
9
8 FROM TRANSFORMER
7
6
5
4
3
2
1
1 2 3 4
TB2
GND
GND
DIF–OUT
DIF–IN
GND
GND
GND
CCW
ENABLE
+15V
FAULT
DIF+IN
TACH
IN 2
CW
–15V
IN 1
SYNC
M+
M–
V+
V–
TB2
J5
+ – AC AC
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12
JMP11 U6 5
D9
RN2
JMP10
U4 4
C5
ARC ON U1 U3
JMP6 JMP9
JMP8
R3
RN1
C17 REG1 REG2 JMP7

3
INCH
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
1
RN3
REV JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
JMP1
24 VAC
MOTOMAN UNIVERSAL WELDING C1
J7
HONDA
UWI INTERFACE C2
20 CR4 CR5
130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
1 2 3 4
M+
M–
IN 1
FAULT
GND
DIF–OUT
GND
DIF–IN
+15V
ENABLE
CCW
GND
GND
CW
SYNC
GND
DIF+IN
–15V
IN 2
TACH
V+
V–
TB2
J5
+ – AC AC
1 3 4
TP
TCH EMF
TQ SP
OFFSET
TACH
2
INPUT
IR COMP
WARNING COMP

CAUTION REG GAIN

CUR. LIMIT
CONT
BEFORE SERVICING. 479125-8 PK

SAME TYPE AND RATING. 479125-9
O. CURR
SUPPLY
POWER
I. LIMIT
FAULT
+15V
–15V
GND
AUX
+5V
Figure 6-4 Replacing the KXA Motor Speed Control

4. Remove the existing KXA motor speed control.
5. Install the new KXA motor speed control.
6. Connect plug PL7 to connector J7 on the UWI PC board.
7. Connect the two transformer wires to TB3 terminals 1 and 2 and secure the
two wires with wire ties.
8. Calibrate the motor speed control (refer to Section 7).
6.3 Replacing the Torch

The GMAW system may include either a Motoman Tough Gun air-cooled or
water-cooled torch. For detailed installation and operating information, refer to
the applicable Tregaskiss owner's manual. To remove the torch, proceed as
follows:
1. Loosen the two 3/16 Allen socket head screws located on the front of the gun
mount arm (see Figure 6-5).
2. Unthread the lower collar and remove the gun barrel.

MAINTENANCE
INSULATOR
SWITCH
SHOCK SENSOR
CABLE CONNECTION
SHOCK SENSOR
MOUNTING BOLTS (4)

DUST BOOT
TORCH KEYWAY
SENSOR
ALIGNMENT POST
GUN MOUNT ARM

GUN BARREL
ALLEN SCREWS
BUTTON HEAD
ALLEN SCREW
BOTTOM COLLAR (WEDGE NUT ON
OTHER SIDE)
TORCH LINER
GOOSENECK
Figure 6-5 Replacing the Torch and Shock Sensor

3. Loosen threaded collar on shock sensor cable and remove cable from sensor.
4. Grasp gun body firmly and carefully remove from the gun mount arm.
To install the torch, proceed as follows:
5. Grasp the gun body firmly and insert gun body into gun mount arm.
6. Install gun barrel, carefully threading gun liner into large opening in
gooseneck and aligning keyway.
7. Tighten lower collar securely.
8. Tighten the two 3/16 Allen socket head screws to clamp the torch gun in
place.

MAINTENANCE
6.4 Replacing the Shock Sensor

To remove the shock sensor, proceed as follows:
1. Remove the torch as instructed in Section 6.3, Steps 1 through 4, and place
safely aside.
2. Loosen and remove the button head Allen socket screw that secures the gun
mount arm to the sensor alignment post (see Figure 6-5).
3. Carefully remove gun mount arm from alignment post. Retain hardware and
make sure black wedge nut remains in place in the gun mount arm.
4. Peel down the rubber dust boot to access the 4 sensor mounting bolts on the
bottom of the sensor.
5. Loosen and remove the 4 mounting bolts and separate the sensor body from
the insulator disc.
To install the shock sensor, proceed as follows:
1. Peel down dust boot on replacement sensor. Position sensor on insulator
disc, aligning bolt holes and making sure switch points forward and aligns
with the zero mark on the T-axis.
2. Install mounting bolts, and tighten securely.
3. Roll rubber dust boot back in place.
4. Make sure that beveled edge of wedge nut (in gun mount arm) faces the
beveled surface of sensor alignment post. Install gun mount arm on sensor
alignment post.
5. Install and tighten button head Allen screw to secure gun mount arm to
sensor alignment post.
6. Install shock sensor cable and tighten collar.
7. Install torch as instructed in Section 6.3, Steps 5 through 8.

MAINTENANCE
NOTES

SECTION 7
CALIBRATION
This section defines procedures for adjusting GMAW system components,
including defining the tool center point and calibrating the Universal Weld
Interface (UWI) for welding power sources and wire feed systems. The GMAW
system should be calibrated periodically to ensure optimal performance or
whenever the UWI, KXA motor speed control, feed motor, or feed rolls have been
replaced.
7.1 Defining Tool Center Point

A well-defined Tool Center Point (TCP), also called Torch Center Point, is
necessary for most applications, especially any type of process work (see Figure 7-
1). A well-defined TCP allows easier teaching and a much more accurate travel
speed. An accurate TCP definition is a must for welding, sealing, and cutting.
FLANGE COORDINATES
Xf
Yf
Zf
TOOL COORDINATES
TOOL CENTER POINT
Zf
Figure 7-1 Tool Center Point

The XRC is capable of storing up to 24 different TCP's:
• The first TCP is called the Standard Tool, or Tool 0. Robots with one tool are
concerned only with the Standard Tool.
• The remaining 23 TCP's are called Universal Tools, or Tools 1-23. Robots
with multiple tools (such as two-handed grippers) use Universal Tools along
with the Standard Tool.
NOTE: The multiple tool function is customer controlled. Please refer to the XRC Concurrent I/O
Parameter Manual for files that may not be visible for your application.
There are two methods for defining the TCP: manual TCP definition and automatic
TCP definition. Automatic TCP definition typically produces more accurate
results.
7.1.1 Manual TCP Definition
Manual TCP definition is used when a tool has definite dimensions and orientation.
To define a TCP manually, enter the data directly in the tool file (refer to the
operator’s manual for more information).
To ensure accuracy of the TCP, use the rotate-about X, Y, and Z keys to roll, bend,
and twist the tool around the TCP. The TCP should not move more than
approximately 1.0 mm.

CALIBRATION
XF
YF
TOOL
FLANGE
COORDINATE
TCP
ZF
(EXAMPLE)
TOOL A
X 0.000 mm RX 0.000 deg.
Y 0.000 mm RY 0.000 deg.
Z 260.000 mm RZ 0.000 deg.
260 mm
TCP
ZF
TOOL B
X 0.000 mm RX 0.000 deg.
Y 0.000 mm RY -45.000 deg.
Z 260.000 mm RZ 0.000 deg.
260 mm
ZF
TCP
TOOL C
X 0.000 mm RX 0.000 deg.
Y 145.000 mm RY 0.000 deg.
Z 260.000 mm RZ 0.000 deg.
260 mm
145 mm
TCP
Figure 7-2 Entering Tool Dimensions for TCP

CALIBRATION
7.1.2 Automatic TCP Definition

Automatic TCP definition is used when a tool has a more complex geometry (for
example, angles or offsets). With the robot in a different orientation each time, five
TC points are defined. For the greatest accuracy, these five robot positions should
vary as much as possible. Orient the robot on the other three sides of the pointer
for the final three TC point definitions. To program a TCP automatically, refer to
the operator’s manual.
To ensure accuracy of the TCP, use the rotate-about X, Y, and Z keys to roll, bend,
and twist the tool around the TCP. The TCP should not move.

Analog Isolation
If a component of the UWI fails, the entire UWI board can be replaced; however,
this will require calibration for welding power source analog isolation. After the
failed component has been replaced, make sure that jumpers on the UWI PC board
are in the same location as the original unit (refer to Section 6.1.1) and calibrate
the UWI as indicated in the following paragraphs.
Motoman recommends that the GMAW system be calibrated using appropriate
system cables and welding power source under actual operating conditions. Refer
to Table 7-1 for recommended tools and equipment. Table 7-2 is a list of
calibration potentiometers, the locations of which are illustrated in Figure 7-3.
Table 7-1 Tools and Equipment for Calibration

(Fluke Model 87 or equivalent w/peak capture)

00 Phillips
0 straight blade
Micro test clip leads For connection to small test points

(as required)

CALIBRATION
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1
INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
POT1 – POT6 POT7 – POT8
Figure 7-3 UWI PC Board Calibration Potentiometer (POT) Locations
Table 7-2 Calibration Potentiometers

POTENTIOMETER DESCRIPTION
1 VWELD input calibration - normally set to scale ± 14 Vin to
give 10V DC out.
2 VWELD command output meter scale.
3 Arc voltage meter scale.
4 Ammeter/shunt meter scale.
5 AWELD input calibration - normally set for ± 14 Vin to give

10V DC out.
6 AWELD command output meter scale.
7 Inch forward wire feed set.
8 Inch reverse wire feed set.

CALIBRATION
7.2.1 UWI Calibration Procedure for Welding Power Source

The MotoArc power source and many other industry welding power sources
require an isolated, adjustable, 0-to-10V DC input for 44 volts of output at full
load rating. Welding power sources smaller than 600 amps may have a maximum
load voltage of less than 44 volts. The welding power source's maximum output is
determined by its rated amperage output, but the welding power source is
generally calibrated as if it is producing the maximum 44 volts. To calibrate the
welding power source, proceed as follows:
NOTE: Extra jumpers for special applications are placed in a cloth bag that is attached to the UWI.
1. Verify welding power source output voltage (refer to Table 7-3).
NOTE: • A welding power source in the 300- to 350-amp range may provide a higher-than-rated
voltage at a lower current. An example of this is when a power source will produce 40 volts
at 180 amps. This does not necessarily occur on all industry power sources.
• Some welding power sources (e.g., OTC, Panasonic, and some Miller) have a minimum
output and will not provide "0 volts output" at an analog of "0 volts input." On power
sources with afixed minimum output, you need to calibrate the entire voltage range and
"graph" the analog versus output voltage. Use the graph to develop the argument chart for
those power source characteristics.
Table 7-3 Output Voltage Rating for All Welding Power Sources
WELDING POWER SOURCE OUTPUT WELDING POWER SOURCE OUTPUT

(Amperage at Rated Amps) (Voltage at Rated Amps)
300 amps 32 volt
350 amps 34 volts
400 amps 36 volts
450 amps 38 volts
500 amps 40 volts
600 amps 44 volts
650 amps 44 volts
WARNING!
• Robots can move unexpectedly. Always be aware of the
possibility of robot movement. Unexpected operation can cause
serious injury or death.
• Ensure there is no feed roll tension or wire in the feeder. Wire
feed during this test and during calibration can cause hazardous
conditions and serious injury.
2. Create the following VWELD test job in the XRC. Make sure that your
movement instruction moves the robot to a safe position. Always replace
fuses with exact type and voltage rating.

CALIBRATION
Line Step Command Remarks

000 NOP Beginning of job
001 MOVJ VJ=12.5 Move should be to a safe position
002 VWELD 14.00 Sets power source voltage maximum
003 AWELD 0.00 Sets wire feed to zero
004 ARCON Turns arc on
005 TIMER T=120 Keeps command on 120 seconds
006 ARCOF Turns arc off
007 END End of job
3. Create a false arc-established signal to the robot by placing shorting jumpers

on jumper pins JMP7 and JMP10, then short the pins on J4 with a test clip, as
shown in Figure 7-4.
J4 JMP7 & JMP10 J5
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1

INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
VWELD POT1
Figure 7-4 UWI PC Board Shorting Jumpers, Test Clip, and POT1
4. Disconnect the weld electrode and ground cable from the welding power
source and remove the top set of feed rolls on the wire feeder.
5. Connect the welding power source to a resistance load bank, if available.
6. Plug the control cable into the power source and turn on the power source.
NOTE: The analog voltage input to the power source of 10.00 volts corresponds to a power source
output of 44.0 volts. "Zero volts input" corresponds to "0 volts output" on most MotoArc power
sources. Calibration for other brands of power sources will be different. In some cases, digital
meters on the power source will display the set voltage and load bank testing won’t be required.

CALIBRATION
7. Run the VWELD test job created in Step 2.

NOTE: The welding power source should show an open circuit voltage. The only way to confirm actual
arc voltage is to use a resistance load test bank capable of handling the maximum voltage and
amperage. The welding power source open circuit voltage may be higher than the normal
welding voltage set.
8. Measure across terminals 15 (positive) and 8 on the J5 connector on the UWI
PC board (see Figure 7-4).
9. Adjust VWELD POT1 to obtain 10.00 ± 0.02 volts.
10. Remove shorting jumpers from jumper pins JMP7 and JMP10, and remove
the test clip from J4 on the UWI PC board.
NOTE: • Some power sources do not go to "0" volts or a maximum of 44.
• The maximum power source output is a function of the power source rating.
Power Source Output vs XRC Argument

45
40
35
Power Source Output-Volts
30
25
20
POWER SOURCE
15 OUTPUT RATING
Rating Volts
300A 32V
10 400A 36V
450A 38V
500A 40V
600A 44V
5 650A 44V
0 2 4 6 8 10 12 14
Figure 7-5 Welding Power Source Argument Chart
NOTE: The analog output voltage is 14.00 at the pendant "VWELD" setting of 14.00. This is scaled to
10.00 volts on the UWI for power source input. The relationship is linear.

CALIBRATION
Table 7-4 MRC Argument Table for Power Source Volts and
MotoArc Power Sources
VWELD PS VWELD PS VWELD PS VWELD PS VWELD PS
Arg Volts Arg Volts Arg Volts Arg Volts Arg Volts
0.0 0.0 2.8 8.8 5.6 17.6 8.4 26.4 11.2 35.2
0.1 0.3 2.9 9.1 5.7 17.9 8.5 26.7 11.3 35.5
0.2 0.6 3.0 9.4 5.8 18.2 8.6 27.0 11.4 35.8
0.3 0.9 3.1 9.7 5.9 18.5 8.7 27.3 11.5 36.1
0.4 1.3 3.2 10.1 6.0 18.9 8.8 27.7 11.6 36.5
0.5 1.6 3.3 10.4 6.1 19.2 8.9 28.0 11.7 36.8
0.6 1.9 3.4 10.7 6.2 19.5 9.0 28.3 11.8 37.1
0.7 2.2 3.5 11.0 6.3 19.8 9.1 28.6 11.9 37.4
0.8 2.5 3.6 11.3 6.4 20.1 9.2 28.9 12.0 37.7
0.9 2.8 3.7 11.6 6.5 20.4 9.3 29.2 12.1 38.0
1.0 3.1 3.8 11.9 6.6 20.7 9.4 29.5 12.2 38.3
1.1 3.5 3.9 12.3 6.7 21.1 9.5 29.9 12.3 38.7
1.2 3.8 4.0 12.6 6.8 21.4 9.6 30.2 12.4 39.0
1.3 4.1 4.1 12.9 6.9 21.7 9.7 30.5 12.5 39.3
1.4 4.4 4.2 13.2 7.0 22.0 9.8 30.8 12.6 39.6
1.5 4.7 4.3 13.5 7.1 22.3 9.9 31.1 12.7 39.9
1.6 5.0 4.4 13.8 7.2 22.6 10.0 31.4 12.8 40.2
1.7 5.3 4.5 14.1 7.3 22.9 10.1 31.7 12.9 40.5
1.8 5.7 4.6 14.5 7.4 23.3 10.2 32.1 13.0 40.9
1.9 6.0 4.7 14.8 7.5 23.6 10.3 32.4 13.1 41.2
2.0 6.3 4.8 15.1 7.6 23.9 10.4 32.7 13.2 41.5
2.1 6.6 4.9 15.4 7.7 24.2 10.5 33.0 13.3 41.8
2.2 6.9 5.0 15.7 7.8 24.5 10.6 33.3 13.4 42.1
2.3 7.2 5.1 16.0 7.9 24.8 10.7 33.6 13.5 42.4
2.4 7.5 5.2 16.3 8.0 25.1 10.8 33.9 13.6 42.7
2.5 7.9 5.3 16.7 8.1 25.5 10.9 34.3 13.7 43.1
2.6 8.2 5.4 17.0 8.2 25.8 11.0 34.6 13.8 43.4
2.7 8.5 5.5 17.3 8.3 26.1 11.1 34.9 13.9 43.7
14.0 44.0

CALIBRATION
NOTE: With the XEW02 analog board, pendant argument resolution is much greater than shown in
Table 7-4. For every argument, power source volts will change approximately 0.03 volts. For
example:
VWELD Argument PS Volts

7.00 22.00
7.01 22.03
7.02 22.06
7.03 22.09
7.04 22.13
7.05 22.16
7.3 Calibrating the Wire Feed System

This section provides the instructions to calibrate the wire feed system by
adjusting the KXA motor speed control and the UWI interface. Calibrating the
wire feed system helps to optimize the overall operation and to ensure the
following conditions:
• AWELD command from the UWI interface to the motor speed control is
properly scaled.
• Motor speed control provides the appropriate output to drive the feed motor.
• Feedback and compensation circuits operate to maintain selected motor
speed.
• INCH FORWARD and INCH REVERSE functions operate at correct rates.
• Current limits are properly set.
Check the system calibration periodically to ensure optimal performance. Always
calibrate the system after replacement of the UWI, KXA speed motor control, feed
motor, or feed rolls.
Table 7-5 lists tools and equipment required during calibration. If necessary, you
can substitute tools of equal or greater capacity and accuracy.
Table 7-5 Tools and Equipment for Calibration

(Fluke Model 87 or equivalent w/peak capture)

00 Phillips
0 straight blade
Micro test clip leads (as For connection to small test points
required)
Table 7-6 lists the preset positions for the KXA controls, which are illustrated in
Figure 7-6.

CALIBRATION
Table 7-6 KXA Motor Speed Controller Preset Positions
ADJUSTMENT SET POINT FUNCTION

PEAK CURRENT 7 o'clock Set to 12.0 Amps peak
CONT. CURRENT 7 o'clock Set to 6.6 Amps
REG. GAIN 6 o'clock Mid-scale
COMP 6 o'clock Mid-scale
IR COMP No adjustment Not used
INPUT 1 2 o'clock Set to full CCW
INPUT 2 2 o'clock Set to full CCW

TACH Adjust at test 15 turn potentiometer
OFFSET Adjust at test 15 turn potentiometer
7.3.1 KXA Motor Speed Control

The KXA motor speed control has adjustment potentiometers (pots) and selector
switches (see Figure 7-6) used for calibration. The two selector switches are two-
position slide switches, which set the motor speed control's mode of operation.
One switch selects either tachometer (Tach) feedback or EMF sensing (with IR
compensation) speed control. The other switch selects either velocity (Speed) or
torque (Torq) mode of operation.
The OFFSET and TACH adjustment pots are multi-turn devices and cannot be
preset, but must be adjusted as part of the calibration procedure. These controls
provide the following functions:
• OFFSET sets the motor speed to 0 when the AWELD argument equals 0.
This adjustment eliminates any DC offset in the servo loop from internal or
external sources.
• TACH provides a gain adjustment that calibrates the motor speed to the
command signal. Turning the pot clockwise (CW) decreases gain and
increases the motor speed. Turning the pot counterclockwise (CCW)
increases gain and reduces the motor speed.

CALIBRATION
GROUND
CURRENT MONITOR
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
TACHOMETER
TP4 TP3 TP1 TP2

R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12
JMP11 U6 5
D9
RN2
JMP10
U4 4
C5
ARC ON U1 U3
JMP6 JMP9
JMP8
R3
RN1
3
TEST POINTS
C17 REG1 REG2 JMP7
I COMMAND
INCH
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
JMP1
24 VAC
20 UWI INTERFACE
C2 J7
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
7
SELECTOR
1 POT5 LED5 D1
J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
SWITCHES
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
1 2 3 4
M+
M–
IN 1
FAULT
GND
DIF–OUT
GND
DIF–IN
+15V
ENABLE
CCW
GND
CW
SYNC
DIF+IN
GND
GND
IN 2
TACH
–15V
V+
V–
TB2
J5
+ – AC AC
3 4
TP
1
2
TCH EMF
TQ SP
OFFSET
TACH
EMF Speed
Tach
2
INPUT
1
IR COMP
WARNING COMP

CAUTION REG GAIN
CUR. LIMIT
CONT

Torq
O. CURR
SUPPLY
POWER
I. LIMIT
FAULT
+15V
–15V
GND
AUX
+5V
OFFSET
TACH
INPUT 2
INPUT 1
IR COMP
COMP
REG GAIN
CURRENT LIMIT CONT
CURRENT LIMIT PEAK
Figure 7-6 KXA Indicators and Controls

The remaining adjustment pots are all single-turn devices. These controls provide
the following functions (see Figure 7-6):
• INPUT1 and INPUT2 provide input gain adjustment. Both of these
controls should be set to the extreme CCW position. This allows proper
setting of the analog voltage for the AWELD command.
• IR COMP does not operate in tachometer mode. The IR compensation
adjustment is used only with special feed motors (for example, the Binzel
torch motors) in EMF sensing mode.
• COMP and REG GAIN control the feedback loop of the KXA unit. These
controls are preset within an approximate range and fine tuned, if necessary,
during the calibration procedure.
• CURRENT LIMIT CONT sets the maximum continuous current to the
feeder motor. The continuous current setting can be adjusted from 0 amps at
the extreme CCW position to 8 amps at the extreme CW position.

CALIBRATION
• CURRENT LIMIT PEAK (see Figure 7-6) sets the peak current to the
feeder motor. The peak current increases from 0 amps at the extreme CCW
position to 16 amps at the extreme CW position. If the CURRENT LIMIT
PEAK pot is set lower than the CURRENT LIMIT CONT pot, the peak
current setting prevails. When performing the calibration procedures, be
sure to set PEAK CURRENT first.
Table 7-7 gives voltage values for different characteristics of the KXA motor speed
control. The Location column of each table identifies the test points (TP) where
you can measure the voltages. Refer to Figure 7-6 for test point locations.
Table 7-7 KXA Motor Speed Control Voltage Measurements
CHARACTERISTIC LOCATION VOLTAGE

PWF4-600:
Vin max. (AWELD = 14.00) PL7-4 (-) and PL7-5 (+) 10.00 ± 0.01V DC
Vin inch forward PL7-4 (-) and PL7-5 (+) 2.00 ± 0.01V DC
Vin inch reverse PL7-4 (-) and PL7-5 (+) -1.00 ± 0.01V DC
Vmtr (motor voltage)* PL7-7 (-) and PL7-8 (+) 15 ± 3V DC
Tachometer voltage† PL7-4 (-) and PL7-6 (+) 6.10 ± 0.5V DC
Volts AC TB3-1 and TB3-2 24 ± 3V AC
PWF4-750:
Vin max. (AWELD = 14.00) PL7-4 (-) and PL7-5 (+) 10.00 ± 0.01V DC
Vin inch forward PL7-4 (-) and PL7-5 (+) 2.00 ± 0.01V DC
Vin inch reverse PL7-4 (-) and PL7-5 (+) -1.00 ± 0.01V DC
Vmtr (motor voltage)* PL7-7 (-) and PL7-8 (+) 18 ± 3V DC
Tachometer voltage‡ PL7-4 (-) and PL7-6 (+) 8.02 ± 0.5V DC
Volts AC TB3-1 and TB3-2 24 ± 3V AC
*At AWELD = 14.00, Vin = 10.00. Motor volt. is approximate and depends on feeder load.
†At 120 RPM (600 IPM)
‡At 150 RPM (750 IPM)
7.4 UWI Calibration Procedure for Wire Feed System

Motoman robotic welding systems use either a PWF4-600 or PWF4-750 wire
feeder. The PWF4 wire feeder motor uses a fast response, print motor armature
with tachometer feedback which provides quick response to either load or
command changes. When properly calibrated, the PWF4-600 feed motor operates
at a maximum speed of 120 RPM; the PWF4-750 at a maximum of 150 RPM.
With a nominal feed roll circumference of 5.0 inches, this translates into maximum
wire feed rates of 600 and 750 inches per minute (IPM) respectively. Although the
procedures to calibrate either wire feeder are the same, the calibration values are
different. Be sure to use correct values for your wire feeder.

CALIBRATION
During normal operation, the controller supplies the AWELD analog signal that
drives the wire feed system. The AWELD argument has a value that ranges from 0
to ±14 V DC. A potentiometer (or optional isolator) on the UWI PC board scales
this signal to give 0 to ±10V DC. The UWI applies this command signal to the
input of the motor speed control through relay CR1.
To calibrate the UWI interface and the KXA motor speed control for proper wire
feed, proceed as follows.
DANGER!
Robots can move unexpectedly. Always be aware of the possibility
of robot movement. Unexpected operation can cause serious injury
or death.
WARNING!
• Unless instructed otherwise, make sure that there is no feed
tension or wire in the wire feeder. Wire feed activation during
these procedures can cause serious injury.
• Disconnect the weld cables from the welding power source. This
ensures that no voltage is present on the feed head, and helps
prevent unintended arcing.
1. Teach the robot the following test job. Make sure that your movement
instruction moves the robot to a safe position.
Line Step Command Remarks

000 NOP Beginning of job
001 MOVJ VJ=12.5 Move should be to a safe position
002 VWELD 0.00 Sets power source voltage to zero
003 AWELD 14.00 Sets wire feed to maximum

004 ARCON Turns arc on
005 TIMER T=120 Keeps command on 120 seconds
006 ARCOF Turns arc off
007 END End of job
2. Set the potentiometers on the motor speed controller to the preset positions,
as shown in Figure 7-7. These are approximate settings and will be adjusted
later.
3. Make sure the weld cables are disconnected from the welding power source.
Install mounting bolts, and tighten securely.

CALIBRATION
PRESET POTENTIOMETER POSITIONS

11 o'clock 2 o'clock
9 o'clock 3 o'clock
7 o'clock 5 o'clock
6 o'clock
PEAK CONT.
CURR. CURR. REG. GAIN COMP IR COMP INPUT 1 INPUT 2 TACH OFFSET
7 o'clock 7 o'clock 6 o'clock 6 o'clock No Adj. 2 o'clock 2 o'clock
min CCW min CCW
Figure 7-7 KXA Motor Speed Controller Trim Pots

4. Create a false arc-established signal to the robot by placing shorting jumpers
on jumper pins JMP7 and JMP10, then short the pins on J4 with a test clip, as
shown in Figure 7-8.
5. Run the test job created in Step 1. The feed rolls will start to rotate.
J4 JMP7 & JMP10
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1

INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
AWELD POT5
Figure 7-8 UWI Board Shorting Jumpers, Test Clip, and POT5
6. Set the tachometer adjustment as follows:
a) Measure the voltage across terminals 4 and 5 on plug PL7, which is
attached to connector J7 (see Figure 7-9).
b) Adjust AWELD POT5 (see Figure 7-8) on the UWI PC board until the
meter shows 10.00 ± 0.02 volts. Make sure that the feed motor output
shaft rotates.

CALIBRATION
PLUG PL7
J7
10
9
8 FROM TRANSFORMER
7
6
5
4
3
2
1
1 2 3 4
GND
GND
DIF–OUT
DIF–IN
GND
GND
GND
CCW
ENABLE
+15V
FAULT
DIF+IN
TACH
IN 2
CW
–15V
IN 1
SYNC
M+
M–
V+
V–
TB2
J5
+ – AC AC
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12
JMP11 U6 5
D9
RN2
JMP10
U4 4
C5
ARC ON U1 U3
JMP6 JMP9
JMP8
R3
RN1
C17 REG1 REG2 JMP7

3
INCH
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
1
RN3
REV JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
JMP1
24 VAC
J7
HONDA
UWI INTERFACE C2
20 CR4 CR5
130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
1 2 3 4
M+
M–
IN 1
FAULT
GND
DIF–OUT
GND
DIF–IN
+15V
ENABLE
CCW
GND
GND
CW
SYNC
GND
DIF+IN
–15V
IN 2
TACH
V+
V–
TB2
J5
+ – AC AC
1 3 4
TP
TCH EMF
TQ SP
OFFSET
TACH
2
INPUT
IR COMP
WARNING COMP

CAUTION REG GAIN

CUR. LIMIT
CONT

O. CURR
SUPPLY
POWER
I. LIMIT
FAULT
+15V
–15V
GND
AUX
+5V
Figure 7-9 KXA Plug PL7
WARNING!
Use caution when measuring the wire feed speed. Moving feed rolls
and potential pinch points can cause injuries.
c) Use a tachometer to measure the speed of the feed motor output shaft.
d) Adjust the TACH trim pot on the motor speed control board (see Figure
7-12) as required to obtain the following:
• PWF4-600 - 120 ± 1 RPM (This setting corresponds to a feed rate of
600 IPM.)
• PWF4-750 - 150 ± 1 RPM (This setting corresponds to a feed rate of
750 IPM.)
NOTE: If you do not have a precision tachometer, you can run the test job with wire in the feeder for a
timed period. Measure the length of wire fed during the test run and divide the length by the
number of seconds duration. Use as long a period as practical, but no less than 30 seconds to
avoid short time errors. If you hear a loud squeal from the motor or controller, you will need to
adjust the REGULATOR GAIN or COMP setting (refer to Step 9). Adjust either pot in the CCW
direction until the squeal stops. This will allow you to proceed with the calibration procedure.
7. Set the offset adjust as follows:
a) Change the test job to provide an AWELD of 0.0.
b) Run the test job. The feed motor should not rotate or it may rotate very
slowly.
c) Use a jumper lead to short terminals 4 and 5 on plug PL7 on the UWI PC
board (see Figure 7-10).
d) Measure voltage across test points TP4 (GROUND) and TP2 (I COM-
MAND) (see Figure 7-6).

CALIBRATION
WARNING!
Do not short the test points with the micro test leads.
e) Adjust the OFFSET trim pot (see Figure 7-7) until the meter shows 0.0 ±
0.01 volts. Make sure that the feed motor does not rotate.
f) Remove jumper lead from terminals 4 and 5 on PL-7 (see Figure 7-10).
8. Follow the steps below to set the motor continuous current adjustment.
a) Turn on the inch forward output #191 from the XRC diagnostics menu or
on the programming pendant.
PLUG PL7
J7
10
9
8 FROM TRANSFORMER
7
6
5
4
3
2
1
1 2 3 4
TB2
GND
GND
DIF–OUT
DIF–IN
GND
GND
GND
CCW
ENABLE
+15V
FAULT
DIF+IN
TACH
IN 2
CW
–15V
IN 1
SYNC
M+
M–
V+
V–
TB2
J5
+ – AC AC
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12
JMP11 U6 5
D9
RN2
JMP10
U4 4
C5
ARC ON U1 U3
JMP6 JMP9
JMP8
R3
RN1
C17 REG1 REG2 JMP7

3
INCH
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
1
RN3
REV JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
JMP1
24 VAC
J7
HONDA
UWI INTERFACE C2
20 CR4 CR5
130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
1 2 3 4
M+
M–
IN 1
FAULT
GND
DIF–OUT
GND
DIF–IN
+15V
ENABLE
CCW
GND
GND
CW
SYNC
GND
DIF+IN
–15V
IN 2
TACH
V+
V–
TB2
J5
+ – AC AC
1 3 4
TP
TCH EMF
TQ SP
OFFSET
TACH
2
INPUT
IR COMP
WARNING COMP

CAUTION REG GAIN

CUR. LIMIT
CONT

O. CURR
SUPPLY
POWER
I. LIMIT
FAULT
+15V
–15V
GND
AUX
+5V
Figure 7-10 KXA Plug PL7 and Connector TB2

b) Set the ammeter to the 12 Amp DC current scale.
c) Connect the ammeter across terminals 7 and 8 on PL7 (see Figure 7-10).
This shorts the output of the motor speed control through the ammeter.
There may be a slight spark when you short the meter leads across the
terminals.
d) Adjust the PEAK CURRENT trim pot so the meter shows 12 ± 0.2 Amps
(see Figure 7-7).
e) The motor speed control maintains the peak current level for only 2 to 3
seconds. If necessary, disconnect the ammeter and then repeat Steps c.
and d. until you get the correct peak current value.
f) After setting the proper peak current value, adjust the CONTINUOUS
CURRENT trim pot (see Figure 7-7) so the meter shows 6.6 ± 0.1 Amps.
g) Verify the current settings by measuring the voltage across test points
TP4 (GROUND) and TP3 (CURRENT MONITOR) (see Figure 7-6).
The meter shows 0.25 volts/amp (6.6 amps = 1.65 volts, 12 amps = 3.00
volts).
h) Turn off the inch forward output #191 from the XRC diagnostics menu
on the programming pendant.

CALIBRATION
9. If the PWF4 wire feeder makes a loud, squealing sound while operating, set
the compensation adjustments as follows, otherwise proceed to Step 10.
a) Slowly turn the REGULATOR GAIN trim pot (see Figure 7-7) to the left
(CCW) until the noise stops, then adjust the pot 1/8 turn to the right
(CW).
b) Slowly turn the COMP trim pot to the right (CW) until the noise starts
again.
c) Turn the COMP trim pot back to the left (CCW) until the noise stops.
Then turn the pot an additional 1/8 turn to the left (CCW).
NOTE: For additional information regarding the compensation adjustments, refer to your PMI KXA
Series Manual.
10. Inch speed has a range from close to zero to almost full speed. To set the
inch forward speed, do the following:
a) Turn on the inch forward output #191 from the programming pendant.
b) Measure the voltage across TB2 terminals 1 and 3 on the motor control
(see Figure 7-10). The meter should show 2.00 ±0.1 volts.
c) If necessary, adjust POT7 (see Figure 7-11) on the UWI PC board for a
voltage reading across TB2 terminals 1 and 3 (see Figure 7-10) of |2.00
±0.1 volts. This will give an output shaft speed of 24 ±1 RPM or 120
IPM.
d) Turn off the inch forward output #191 from the programming pendant.
J4 JMP7 & JMP10
11 10 9 8 7 6 5 4 3 2 1 3 2 1 2 1 15 14 13 12 11 10 9 8 7 6 J5
R2
5 4 3 2 1 J6
JMP5
1/2 A 1/4 A JMP12 5
JMP11 U6
D9
RN2
JMP10 4
C5
ARC ON U4 U1 U3
JMP6 JMP9
R3
RN1

INCH JMP7
R1
C12
FWD 2
C13
INCH
C8 C9 C10 C11
REV 1
RN3
JMP4 U5
C14
JMP3
+5V +15V PURGE
C7
JMP2
C1 JMP1
CR4 CR5
C3 LED8 D4 LED9 D5
REV A 130966-1 10
C4
U2 9
RN4
C15
Y1
POT7 POT8 CR1
INCH-FWD INCH-REV
8
AWELD
C6
POT5 LED5 D1
7
1 J1 VWELD
POT1 6
POT2 JMP21
U8 JMP22 5
JMP23
4
JMP15 JMP26 3
1 JMP14 POT4 JMP27
JMP13 JMP28 2
2 JMP20 JMP29
JMP19 POT6 JMP30 1
4
U9 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 SERIAL NUMBER
J9 J8
POT7 - INCH FORWARD POT8 - INCH REVERSE
Figure 7-11 UWI PC Board POT7 and POT8

CALIBRATION
11. To set the reverse inch speed, do the following:

a) Turn on the inch reverse output #192 from the programming pendant.
b) Measure the voltage across TB2 terminals 1 and 3 (see Figure 7-10) on
the motor control. The meter should show 1.00 ±0.1 volts.
c) If necessary, adjust POT8 (see Figure 7-11) on the UWI for a voltage
reading across TB2 terminals 1 and 3 (see Figure 7-10) of 2.00 ±0.1
volts. This will give an output shaft speed of 12 ±1 RPM or 60 IPM.
d) Turn off the inch reverse output #192 from the programming pendant.
12. On the UWI PC board, remove the shorting jumpers from jumper pins JMP7
and JMP10, and the test clip from J4 (see Figure 7-11).
13. The chart in Figure 7-12 illustrates the relation between wire feed rate and
the AWELD argument value for a PWF4-600 Wire Feeder. Notice that the
relation is highly linear; any increase or decrease in AWELD value causes a
corresponding change in wire feed rate. The KXA motor speed control
provides very precise and accurate speed control.
Wire Feeder Output vs XRC Argument

PWF4-600 Feeder
600 120
500 100
Wire Feed Speed - Inches per Minute
400 80
Motor RPM
300 p 60
200 40
100 20
0 0
0 2 4 6 8 10 12 14
Figure 7-12 AWELD Argument Chart for PWF4-600

CALIBRATION
Table 7-8 XRC Argument Table for PWF4-600 Wire Feeder

AWELD AWELD AWELD AWELD AWELD
Arg IPM Arg IPM Arg IPM Arg IPM Arg IPM
0.0 0.0 2.8 120.0 5.6 240.0 8.4 360.0 11.2 480.0
0.1 4.3 2.9 124.3 5.7 244.3 8.5 364.3 11.3 484.3
0.2 8.6 3.0 128.6 5.8 248.6 8.6 368.6 11.4 488.6
0.3 12.9 3.1 132.9 5.9 252.9 8.7 372.9 11.5 492.9
0.4 17.1 3.2 137.1 6.0 257.1 8.8 377.2 11.6 497.2
0.5 21.4 3.3 141.4 6.1 261.4 8.9 381.4 11.7 501.4
0.6 25.7 3.4 145.7 6.2 265.7 9.0 385.7 11.8 505.7
0.7 30.0 3.5 150.0 6.3 270.0 9.1 390.0 11.9 510.0
0.8 34.3 3.6 154.3 6.4 274.3 9.2 394.3 12.0 514.3
0.9 38.6 3.7 158.6 6.5 278.6 9.3 398.6 12.1 518.6
1.0 42.9 3.8 162.9 6.6 282.9 9.4 402.9 12.2 522.9
1.1 47.1 3.9 167.1 6.7 287.1 9.5 407.2 12.3 527.2
1.2 51.4 4.0 171.4 6.8 291.4 9.6 411.4 12.4 531.4
1.3 55.7 4.1 175.7 6.9 295.7 9.7 415.7 12.5 535.7
1.4 60.0 4.2 180.0 7.0 300.0 9.8 420.0 12.6 540.0
1.5 64.3 4.3 184.3 7.1 304.3 9.9 424.3 12.7 544.3
1.6 68.6 4.4 188.6 7.2 308.6 10.0 428.6 12.8 548.6
1.7 72.9 4.5 192.9 7.3 312.9 10.1 432.9 12.9 552.9
1.8 77.1 4.6 197.1 7.4 317.2 10.2 437.2 13.0 557.2
1.9 81.4 4.7 201.4 7.5 321.4 10.3 441.4 13.1 561.4
2.0 85.7 4.8 205.7 7.6 325.7 10.4 445.7 13.2 565.7
2.1 90.0 4.9 210.0 7.7 330.0 10.5 450.0 13.3 570.0
2.2 94.3 5.0 214.3 7.8 334.3 10.6 454.3 13.4 574.3
2.3 98.6 5.1 218.6 7.9 338.6 10.7 458.6 13.5 578.6
2.4 102.9 5.2 222.9 8.0 342.9 10.8 462.9 13.6 582.9
2.5 107.1 5.3 227.1 8.1 347.2 10.9 467.2 13.7 587.2
2.6 111.4 5.4 231.4 8.2 351.4 11.0 471.4 13.8 591.4
2.7 115.7 5.5 235.7 8.3 355.7 11.1 475.7 13.9 595.7
14.0 600.0

CALIBRATION
NOTE: With the XEW02 analog board, pendant argument resolution is much greater than shown in
Table 7-8. For every argument, the PWF4-600 wire feed speed will change approximately
0.42IPM. For example:
AWELD Argument Wire Feed Speed (IMP)

7.00 300.0
7.01 300.5
7.02 301.1
7.03 301.6
7.04 302.1
7.05 302.7
The chart in Figure 7-13 illustrates the relation between wire feed rate and the
AWELD argument value for a PWF4-750 Wire Feeder. Notice that the relation is
highly linear; any increase or decrease in AWELD value causes a corresponding
change in wire feed rate. The KXA motor speed control provides very precise and
accurate speed control.
PWF4-750 Wire Feeder Calibration

Feed Range 0 to 750 IPM
750 150
700 140
650 130
600 120
550 110
PWF4-750 Motor Speed

Wire Feed Speed - IPM
500 100
450 90
400 80
350 70
300 60
250 50
200 40
150 30
100 20
50 10
0 0
0 2 4 6 8 10 12 14
AWELD Argument Value
Figure 7-13 AWELD Argument Chart for PWF4-750

CALIBRATION
Table 7-9 XRC Argument Table for PWF4-600 Wire Feeder

AWELD AWELD AWELD AWELD AWELD
Arg IPM Arg IPM Arg IPM Arg IPM Arg IPM
0.0 0.0 2.8 150.0 5.6 300.0 8.4 450.0 11.2 600.0
0.1 5.4 2.9 155.4 5.7 305.4 8.5 455.4 11.3 605.4
0.2 10.7 3.0 160.7 5.8 310.7 8.6 460.7 11.4 610.7
0.3 16.1 3.1 166.1 5.9 316.1 8.7 466.1 11.5 616.1
0.4 21.4 3.2 171.4 6.0 321.4 8.8 471.4 11.6 621.4
0.5 26.8 3.3 176.8 6.1 326.8 8.9 476.8 11.7 626.8
0.6 32.1 3.4 182.1 6.2 332.1 9.0 482.1 11.8 632.1
0.7 37.5 3.5 187.5 6.3 337.5 9.1 487.5 11.9 637.5
0.8 42.9 3.6 192.9 6.4 342.9 9.2 492.9 12.0 642.9
0.9 48.2 3.7 198.2 6.5 348.2 9.3 498.2 12.1 648.2
1.0 53.6 3.8 203.6 6.6 353.6 9.4 503.6 12.2 653.6
1.1 58.9 3.9 208.9 6.7 358.9 9.5 508.9 12.3 658.9
1.2 64.3 4.0 214.3 6.8 364.3 9.6 514.3 12.4 664.3
1.3 69.6 4.1 219.6 6.9 369.6 9.7 519.6 12.5 669.6
1.4 75.0 4.2 225.0 7.0 375.0 9.8 525.0 12.6 675.0
1.5 80.4 4.3 230.4 7.1 380.4 9.9 530.4 12.7 680.4
1.6 85.7 4.4 235.7 7.2 385.7 10.0 535.7 12.8 685.7
1.7 91.1 4.5 241.1 7.3 391.1 10.1 541.1 12.9 691.1
1.8 96.4 4.6 246.4 7.4 396.4 10.2 546.4 13.0 696.4
1.9 101.8 4.7 251.8 7.5 401.8 10.3 551.8 13.1 701.8
2.0 107.1 4.8 257.1 7.6 407.1 10.4 557.1 13.2 707.1
2.1 112.5 4.9 262.5 7.7 412.5 10.5 562.5 13.3 712.5
2.2 117.9 5.0 267.9 7.8 417.9 10.6 567.9 13.4 717.9
2.3 123.2 5.1 273.2 7.9 423.2 10.7 573.2 13.5 723.2
2.4 128.6 5.2 278.6 8.0 428.6 10.8 578.6 13.6 728.6
2.5 133.9 5.3 283.9 8.1 433.9 10.9 583.9 13.7 733.9
2.6 139.3 5.4 289.3 8.2 439.3 11.0 589.3 13.8 739.3
2.7 144.6 5.5 294.6 8.3 444.6 11.1 594.6 13.9 744.6
14.0 750.0

CALIBRATION
NOTE: With the MXW02 analog board, pendant argument resolution is much greater than shown in
Table 7-9. For every argument, the PWF4-750 wire feed speed will change approximately 0.53
IPM. For example:
AWELD Argument Wire Feed Speed (IMP)

7.00 375.0
7.01 375.5
7.02 376.1
7.03 376.6
7.04 377.1
7.05 377.7
7.4.1 Final Test

The final test of the wire feeding is conducted under normal operating conditions
for your application
1. Load the system with the appropriate type and size of wire.
2. Engage the feeder rolls.
3. Press the inch forward button and make sure that the feed motor operates at
the proper feed rate.
4. Check for wire marking due to feed roll slippage.
5. Turn on inch forward output #191 on the programming pendant and make
sure that the motor operates at the proper feed rate.
6. Check for wire marking due to feed roll slippage.
7. Run a series of test jobs with AWELD values from 0.00 to 14.00. Use the
programming pendant to change the AWELD setting as the job runs.
8. Check for the following conditions at all operating speeds:
a) Wire marking due to feed roll slippage
b) Wire tangled in drive rollers (bird nesting)
c) Oscillation of feed motor
9. Set up the system for normal operation. Use the proper wire, gas type, and
base material.
10. Run a series of test jobs. Make sure that there is a minimum of arc hunting,
and that the arc is stable while welding.
11. Turn on the purge output #188 on the programming pendant, and confirm
that the gas valve turns on.

TABLE OF CONTENTS
Section Page
LIST OF FIGURES ..................................................................................................................................iii
LIST OF TABLES....................................................................................................................................iv
1 INTRODUCTION
1.1 About this Document .................................................................................................... 1-1
1.2 System Configuration ................................................................................................... 1-2
1.3 System Components..................................................................................................... 1-3
1.3.1 XRC Controller ............................................................................................... 1-3
1.3.2 Universal Weld Interface (UWI) ....................................................................... 1-4
1.3.3 Robot .............................................................................................................. 1-4
1.3.4 Wire Feed System ........................................................................................... 1-4
1.3.5 Torch .............................................................................................................. 1-4
1.3.6 Power Source ................................................................................................. 1-5
1.3.7 Water Circulator .............................................................................................. 1-5
1.3.8 Work Cell ........................................................................................................ 1-5
1.4 Equipment and Component Specifications ................................................................... 1-6
1.5 Reference to Other Documentation................................................................................ 1-7
1.6 Customer Service Information ...................................................................................... 1-7
2 SAFETY
2.1 Introduction .................................................................................................................. 2-1
2.2 Standard Conventions .................................................................................................. 2-2
2.3 General Safeguarding Tips............................................................................................ 2-3
2.4 Mechanical Safety Devices ........................................................................................... 2-3
2.5 Installation Safety ......................................................................................................... 2-4
2.6 Programming Safety ..................................................................................................... 2-4
2.7 Operation Safety ........................................................................................................... 2-5
2.8 Maintenance Safety....................................................................................................... 2-6
3 THEORY OF OPERATION
3.1 General System Operation ............................................................................................ 3-1
3.2 Gas Metal Arc Welding ................................................................................................. 3-2
3.2.1 The Consumable Welding Arc ........................................................................ 3-3
3.2.2 Metal Transfer Across the Arc ......................................................................... 3-5
3.2.3 Consumable Materials .................................................................................. 3-10
3.2.4 Weld Quality ................................................................................................. 3-10
4 OPERATION
4.1 Controls and Indicators ................................................................................................ 4-1
4.1.1 UWI Indicators ................................................................................................ 4-1
4.1.2 UWI Relay and LED Operation ........................................................................ 4-2
4.1.3 Motor Speed Control Indicators ...................................................................... 4-3
MOTOMAN xxiii Robotic Arc Welding Manual

Section Page
4.2 Shock Sensor Recovery ................................................................................................ 4-4
4.3 Setting Up Absolute Welding Values ............................................................................ 4-4
4.3.1 Setting the Absolute Welding Voltage Curve ................................................... 4-5
4.3.2 Setting the Absolute Welding Amperage Curve ............................................... 4-6
4.3.3 Setting Absolute Welding Amperage as Wire Feed Speed ............................... 4-7
4.3.4 Absolute Settings for MotoArc 350i/500i ........................................................ 4-8
4.4 Using Schedule Select with Pulsed Mode..................................................................... 4-9
4.5 Welder Condition Data File ......................................................................................... 4-10
4.5.1 Displaying a Welder Condition Data File ...................................................... 4-12
4.5.2 Selecting a Welder Condition Data File ......................................................... 4-12
4.5.3 Editing a Welder Name or Comment ............................................................. 4-12
4.5.4 Editing a Power Supply Setting ..................................................................... 4-13
Arc Shortage Stop ................................................................................ 4-13
4.5.6 Editing Welder Current or Voltage Data ........................................................ 4-13
4.5.7 Changing Welder Power Supply Analog Polarity .......................................... 4-13
4.5.8 Editing Welder Current or Voltage Adjustment .............................................. 4-13
4.6 Creating New Absolute Welding Amperage Data......................................................... 4-14
4.6.2 Weld Test for New Amperage Data ................................................................ 4-15
4.7 Creating New Absolute Welding Voltage Data............................................................. 4-16
4.7.2 Weld Test for New Voltage Data .................................................................... 4-17
4.8 Using Absolute Current Data Tables ........................................................................... 4-17
5 TROUBLESHOOTING
5.1 Equipment and Tools Required ..................................................................................... 5-1
5.2 Troubleshooting Procedures......................................................................................... 5-1
6 MAINTENANCE
6.1 UWI Replacement and Setup......................................................................................... 6-1
6.1.1 UWI Replacement ........................................................................................... 6-1
6.1.2 UWI Jumper Designations .............................................................................. 6-3
6.1.3 UWI Replacement Fuses ................................................................................. 6-3
6.1.4 UWI Replacement Relays ................................................................................ 6-4
6.2 Replacing the KXA Motor Speed Control ...................................................................... 6-5
6.3 Replacing the Torch ...................................................................................................... 6-5
6.4 Replacing the Shock Sensor ......................................................................................... 6-7
Robotic Arc Welding Manual xxiv MOTOMAN

Section Page
7 CALIBRATION
7.1 Defining Tool Center Point ........................................................................................... 7-1
7.1.1 Manual TCP Definition ................................................................................... 7-1
7.1.2 Automatic TCP Definition ............................................................................... 7-3
Analog Isolation .................................................................................................... 7-3
7.2.1 UWI Calibration Procedure for Welding Power Source ................................... 7-5
7.3 Calibrating the Wire Feed System................................................................................. 7-9
7.3.1 KXA Motor Speed Control ............................................................................ 7-10
7.4 UWI Calibration Procedure for Wire Feed System....................................................... 7-12
7.4.1 Final Test ...................................................................................................... 7-22
APPENDIX A - SPARE PARTS LIST
APPENDIX B - UWI WIRE FEEDER PARTS BREAKDOWN
APPENDIX C - BLANK CHARTS
INDEX
LIST OF FIGURES
Figure Page
Figure 1-1 Robotic ArcWelding System...................................................................................... 1-2
Figure 1-2 Robot and Wire Feed System .................................................................................... 1-5
Figure 3-1 Gas Metal Arc Welding.............................................................................................. 3-2
Figure 3-2 Consumable Electrode Welding Arc .......................................................................... 3-3
Figure 3-3 Spray Metal Transfer Mode ....................................................................................... 3-6
Figure 3-4 Short-Circuiting Transfer Mode ................................................................................ 3-7
Figure 3-5 Short-Circuiting Transfer Cycle................................................................................. 3-8
Figure 3-6 Pulsed-Spray Transfer Mode..................................................................................... 3-8
Figure 3-7 Pulsed-Spray Timing Chart....................................................................................... 3-9
Figure 4-1 UWI PC Board LED's and Relays............................................................................... 4-1
Figure 4-2 Absolute Welding Voltage Settings ........................................................................... 4-5
Figure 4-3 Voltage Data File Display .......................................................................................... 4-6
Figure 4-4 Absolute Welding Amperage Settings ....................................................................... 4-6
Figure 4-5 Amperage Data File Display ...................................................................................... 4-7
Figure 4-6 Absolute Welding Amperage Settings as Wire Feed Speed ....................................... 4-7
Figure 4-7 Weld Current as Wire Feed Speed for PWF4-600 Wire Feeder................................. 4-8
Figure 4-8 Pulse Frequency vs. Voltage Settings........................................................................ 4-9
Figure 4-9 Typical Welder Condition Data File Display ............................................................ 4-11
Figure 4-10 Typical Welder Condition Data File (Current) Display ............................................. 4-11
Figure 4-11 Typical Welder Condition Data File (Voltage) Display ............................................. 4-11
Figure 6-1 Universal Weld Interface............................................................................................ 6-1
Figure 6-2 UWI PC Board Connectors and Jumpers .................................................................. 6-2
Figure 6-3 Fuse and Relay Location on the UWI PC Board......................................................... 6-4
Figure 6-4 Replacing the KXA Motor Speed Control................................................................... 6-5
MOTOMAN xxv Robotic Arc Welding Manual
Figure Page
Figure 6-5 Replacing the Torch and Shock Sensor..................................................................... 6-6
Figure 7-1 Tool Center Point ...................................................................................................... 7-1
Figure 7-2 Entering Tool Dimensions for TCP............................................................................ 7-2
Figure 7-3 UWI PC Board Calibration Potentiometer (POT) Locations ....................................... 7-4
Figure 7-4 UWI PC Board Shorting Jumpers, Test Clip, and POT1 ............................................ 7-6
Figure 7-5 Welding Power Source Argument Chart .................................................................... 7-7
Figure 7-6 KXA Indicators and Controls ................................................................................... 7-11
Figure 7-7 KXA Motor Speed Controller Trim Pots................................................................... 7-14
Figure 7-8 UWI Board Shorting Jumpers, Test Clip, and POT5 ................................................ 7-14
Figure 7-9 KXA Plug PL7 ......................................................................................................... 7-15
Figure 7-10 KXA Plug PL7 and Connector TB2 .......................................................................... 7-16
Figure 7-11 UWI PC Board POT7 and POT8............................................................................... 7-17
LIST OF TABLES
Table Page
Table 1-1 Equipment and Component Specifications .................................................................. 1-6
Table 4-3 UWI Relay and LED Operation ..................................................................................... 4-2
Table 4-4 KXA Motor Speed Control Indicators ........................................................................... 4-3
Table 4-5 Tools and Equipment for Testing Amperage .............................................................. 4-14
Table 4-6 Tools and Equipment for Testing Voltage .................................................................. 4-15
Table 4-7 Absolute Current Settings for PWF4 Wire Feeders ..................................................... 4-17
Table 5-1 Tools and Equipment for Troubleshooting ................................................................... 5-1
Table 5-2 Welding Troubleshooting Chart ................................................................................... 5-1
Table 6-1 UWI Plug and Socket Connectors ................................................................................ 6-2
Table 6-2 Replacement Fuses ...................................................................................................... 6-4
Table 6-3 Replacement Relays ..................................................................................................... 6-4
Table 7-2 Calibration Potentiometers .......................................................................................... 7-4
Table 7-3 Output Voltage Rating for All Welding Power Sources ................................................. 7-5
Table 7-4 MRC Argument Table for Power Source Volts and MotoArc Power Sources ................ 7-7
Table 7-6 KXA Motor Speed Controller Preset Positions ............................................................. 7-9
Table 7-7 KXA Motor Speed Control Voltage Measurements ..................................................... 7-12
Robotic Arc Welding Manual xxvi MOTOMAN

APPENDIX A
SPARE PARTS LIST
This section contains the spare parts list for the welding package:
Item Name Part Number
Robot, UP6 142348-1
Robot, SK16X 142350-1
Water Circulator 470158
Transformer, 15 KVA 480V AC, XRC 479974-14
Feeder, 4-roll, pancake, UWI, 600-750”/min 130967-2
Interface, UWI w/power source harness kit 130969
Feedroll Kit 375980
MOTOMAN A-1 Robotic Arc Welding Manual

SPARE PARTS LIST
NOTES
Robotic Arc Welding Manual A-2 MOTOMAN

APPENDIX B
UWI WIRE FEEDER PARTS BREAKDOWN
This section contains the parts list for the UWI wire feeder, P/N 130967-2.
MOTOMAN B-1 Robotic Arc Welding Manual

Robotic Arc Welding Manual B-2 MOTOMAN


Item / Name Part Number / QTY
1 Plate, Feed Head, 4-Roll Assy. 375920-1 1
2 Plate, MTG, Feed Head 479237-1 1
3 Screw, PPH #10-32X1/2 130212-1 2
4 Pin, Spring, Plated 16DA-1202-11 1
6 Washer, Pressure Arm 375784A 2
7 Springs, Compression 400562-3B 2
8 Knob, Pressure Arm 376001A 2
9 Rod, Pressure Arm 375789-1 2
10 Cover, Motor Wrapper 479242-1 1
11 Tie, Cable, Plastic 3 7/8 in., White 400828-1 2
12 Cover, Motor, Lower 4-Roll Feeder Assy. 131283-1 1
13 Arm, Pressure, Wire Feed, 4-Roll 406846-1 1
14 Fitting, Pneumatic Coupling, 1/8 Pipe 472468-1 1
15 Washer, Lock IT, 1/2 132663-1 1
16 Adapter, Gas, Right Hand 372074-1 1
19 Washer, Lock, 1/4 130444-5 8
20 Washer, Flat, 1/4, SAE 130443-15 6
21 Washer, Insulating 375793-1 2
22 Screw, Retaining 407044-1 1
23 Adapter, Gas, Torch Inlet, K6/K10 HS 375795-2 1
24 Receptacle, Gun, Feed Head 375781-2 1
26 Shaft, Feed Roll 375790-1 2
27 Screw, HHC, 1/4-20X2, ZP, GR 5 130235-9 2
28 Ring, Retaining, External, 1/2 inch 16DA-4249-5 4
29 Washer, Flat 407108-1 4
30 Gear, Spur, Straight Tooth Feedroll Assy. Idler 375921-1 4
31 Screw, HHC, 1/4-20X1/2, ZP, GR 5 130235-2 2
32 Screw, SHC, 1/4-28X3/4, BLK-OX 479196-2 2
33 Ring, Retaining, External, 5/8 inch 405836-3 1
34 Gear, Spur, Straight Tooth Feedroll, Ins. DRV 406985-1 1
35 Screw, HHC, 1/4-20X1-1/2, ZP, GR 5 130235-8 1
36 Shim 407075-1 1
37 Shim 407075-2 2
38 Ring, Retaining, External, 3/4 inch, E-type 406639-2 1
39 Spacer, Feedhead, Locating 479268-1 1
40 Spacer, Feedhead 375840-1 3
41 Screw, FHSC, 1/4-20X1/2 130252-2 4
42 Motor, Gear, Print, P. Magnet 479002-1 1
43 Insert Tube, Tygon, 5/32 ID X 9/32 OD 40534 8ft
44 Nut, Hex Jam, 1/2-20, ZP 130442-5 1
45 Connector, Male 402927-1 1

Item / Name Part Number / QTY
47 Connector, Sq Flnge; Recpt; 4SKT 472482-6 1
48 Tube, Gas, 10-32 UNF-2A THD 375298-1 1
49 Knob, Gun Receptacle 407133-1 1
50 Spacer, Gun Receptacle 375787-1 1
55 Spacer, Feedhead 375792-1 3
56 Guide, Wire, Input, Rework Cold Wire Feeder 470771-1 1
57 Screw, HHC, M6X16 139965-2 4
58 Connector, BKHD, Recpt, 14 Pin 16-22 AWG 144693-12 1
60 Switch, Pushbutton, Momentary UWI 130958-1 1
61 Contact, Socket, 16-18 AWG 130277-10 3
62 Label, Electric Shock 407099-1 1
63 Label, Feeder, Moving Parts 406636-1 1
65 Spacer, Feed Roll, Insulator 375836-1 1
66 Screw, HHC, 3/8-16X3/4 131151-4 1
67 Washer, Flat, 3/8 SAE 130443-17 1
68 Washer, Lock, 3/8 130444-7 1
69 Screw PPH, #6-32X3/8 130209-1 4
70 Washer, Flat, #6, SAE 130443-12 6
71 Washer, Lock, #6 130444-2 2
73 Screw, SHC, #8-32X1 130062-6 12
75 Hose, Push On, Low Pressure 130534-34 .8ft
76 Fitting, Male Pipe to Hose 1/8 130534-3 2
77 Valve, Gas, 24VDC-7W 130829-1 1
78 Screw, PPH, #8-32X3/8 130210-1 2
79 Washer, Lock, #8 130444-3 2
82 Nut, Hex, #4-40, ZP 130441-1 4
83 Screw, PPH, #4-40X1/2 130208-2 4
84 Washer, Lock, Split, #4 130444-1 4
85 Washer, Lock, IT, #6 132660-1 2
87 Washer, Flat, #4, SAE 130443-11 8
88 Screw, HHC, 1/4-20X1-1/4, ZP, GR 5 130237-7 2
89 Screw, Pansf-tap, #6-32X3/8 Type F 131242-1 4
90 Adhesive, Loctite 242 132919-1 0
91 Screw, Pansf-tap, #6-32X3/8 Type F 131242-1 8
92 Wire, 18 AWG, Blue, UL1015/1230 141019-1 5ft
93 Wire, 18 AWG, Green/Yellow, UL1015/1230 141007-1 1ft
94 Tubing, Shrinkable, Clear, 1/8 inch 130827-4 .5ft
95 Terminal, Ring, 22-16 AWG, #6/M3.5 143152-3 1
96 Fitting, Guide, Wire Side Mount, Wire Feed 134203-1 1
97 Switch, Toggle, 2 Position, Sensor Override 134258-2 1
98 Wire, 22 AWG, RD/BL TWPR, UL1015/1230 141043-1 1.4ft
100 Washer, Lock, M6 479148-4 4
NOTES

APPENDIX C
BLANK CHARTS
750 14
700 13
650 12
600 11
550
Robot Analog Command

10
Wire Feed Speed-IPM
500
9
450
8
400
7
350
6
300
5
250
4
200
3
150
100 2
50 1
0 0
0 50 100 150 200 250 300 350 400 450 500
Weld Current-Amps
Blank Amperage Setting Graph
MOTOMAN C-1 Robotic Arc Welding Manual

BLANK CHARTS
14 14
13 13
12 12
11 11
10 10

9 9
8 8
7 7
6 6
5 5
4 4
3 3
2 2
1 1
0 0
0 5 10 15 20 25 30 35 40 45
Blank Voltage Setting Graph
Robotic Arc Welding Manual C-2 MOTOMAN

BLANK CHARTS
NOTES
MOTOMAN C-3 Robotic Arc Welding Manual

BLANK CHARTS
Robotic Arc Welding Manual C-4 MOTOMAN

INDEX
A M
Absolute Settings for MotoArc 350i/500i, 4-8 Maintenance, 5-1, 6-1
ANSI/RIA, 2-1 Maintenance Safety, 2-6
Automatic TCP Definition, 7-3 Manual TCP Definition, 7-1
Mechanical Safety Devices, 2-3
B
Metal Transfer Across the Arc, 3-5
Blank Charts, 25
Motor Speed Control Indicators, 4-3
C
O
Calibrating the Wire Feed System, 7-9
Operation Safety, 2-5
Calibration, 7-1
Optional Equipment, 1-4
Changing Welder Power Supply Analog Polarity, 4-13
Consumable Materials, 3-10 P
Controls and Indicators, 4-1 Power Source, 1-5
Creating New Absolute Welding Amperage Data, 4-14 Programming Safety, 2-4
Creating New Absolute Welding Voltage Data, 4-16 Pulsed-Spray Metal Transfer, 3-8
Customer Service Information, 1-7
R
D Reference to Other Documentation, 1-7
Defining Tool Center Point, 7-1 Replacing the KXA Motor Speed Control, 6-5
Displaying a Welder Condition Data File, 4-12 Replacing the Shock Sensor, 6-7
Replacing the Torch, 6-5
E
Robotic Industries Association, 2-1
Editing a Power Supply Setting, 4-13
Editing a Welder Name or Comment, 4-12 S
Editing Welder Current or Voltage Adjustment, 4-13 Safety, 2-1
Editing Welder Current or Voltage Data, 4-13 Selecting a Welder Condition Data File, 4-12
Editing Wire Diameter, Extension, and Anti-Sticking and Setting Absolute Welding Amperage as
Arc Shortage Stop, 4-13 Wire Feed Speed, 4-7
Equipment and Component Specifications, 1-6 Setting the Absolute Welding Amperage Curve, 4-6
Equipment Description, 3-1 Setting the Absolute Welding Voltage Curve, 4-5
Setting Up Absolute Welding Values, 4-4
G
Shock Sensor Recovery, 4-4
Gas Metal Arc Welding, 3-2
Short-Circuiting Transfer, 3-7
General Safeguarding Tips, 2-3
Spare Parts List, 23
General System Operation, 3-1
Spray Transfer, 3-6
I Standard Conventions, 2-2
Installation Safety, 2-4 System drawings, 23
Introduction, 1-1, 2-1 System Layout, 1-3
System Overview, 1-2
K
KXA Motor Speed Control, 7-10
MOTOMAN Robotic Arc Welding Manual

INDEX
T W
The Consumable Welding Arc, 3-3 Water Circulator, 1-5
Torch, 1-4 Weld Quality, 3-10
Troubleshooting Procedures, 5-1 Weld Test for New Amperage Data, 4-15
Weld Test for New Voltage Data, 4-17
U
Welder Condition Data File, 4-10
Using Absolute Current Data Tables, 4-17
Welding Setup Procedure, 4-14, 4-16
Using Schedule Select with Pulsed Mode, 4-9
Wire Feed System, 1-4
UWI, 6-1
Work Cell, 1-5
UWI Calibration for Welding Power Source
Analog Isolation, 7-3
UWI Calibration Procedure for Welding Power Source, 7-5
UWI Calibration Procedure for Wire Feed System, 7-12
UWI Indicators, 4-1
UWI Jumper Designations, 6-3
UWI Relay and LED Operation, 4-2
UWI Replacement, 6-1
UWI Replacement Fuses, 6-3
UWI Replacement Relays, 6-4
MOTOMAN Robotic Arc Welding Manual

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Part Number: 142646-1

MOTOMAN xxiii Robotic Arc Welding Manual

Robotic Arc Welding Manual xxiv MOTOMAN

Robotic Arc Welding Manual xxvi MOTOMAN

1.2 System Configuration

Figure 1-1 Robotic ArcWelding System

• Motoman robot manipulators and XRC controller

Robotic Arc Welding Manual 1-2 MOTOMAN

Options for the welding system include:

1.3 System Components

MOTOMAN 1-3 Robotic Arc Welding Manual

1.3.2 Universal Weld Interface (UWI)

Robotic Arc Welding Manual 1-4 MOTOMAN

PWF4 WIRE FEEDER

Figure 1-2 Robot and Wire Feed System

MOTOMAN 1-5 Robotic Arc Welding Manual

1.4 Equipment and Component Specifications

MotoArc Power Source As Required

Wire Feed Unit

Square D 30 KVA Transformer

Robotic Arc Welding Manual 1-6 MOTOMAN

1.5 Reference to Other Documentation

1.6 Customer Service Information

MOTOMAN 1-7 Robotic Arc Welding Manual

Robotic Arc Welding Manual 1-8 MOTOMAN

It is the purchaser's responsibility to ensure that all local, county,

MOTOMAN 2-1 Robotic Arc Welding Manual

2.2 Standard Conventions

Robotic Arc Welding Manual 2-2 MOTOMAN

2.3 General Safeguarding Tips

2.4 Mechanical Safety Devices

MOTOMAN 2-3 Robotic Arc Welding Manual

2.5 Installation Safety

2.6 Programming Safety

Robotic Arc Welding Manual 2-4 MOTOMAN

• Inspect the robot and work envelope to be sure no potentially hazardous

2.7 Operation Safety

MOTOMAN 2-5 Robotic Arc Welding Manual

2.8 Maintenance Safety

Robotic Arc Welding Manual 2-6 MOTOMAN

3.1 General System Operation

MOTOMAN 3-1 Robotic Arc Welding Manual

When the ARCOF command is executed, the reverse sequence occurs:

3.2 Gas Metal Arc Welding

MOLTEN WELD METAL NOZZLE

SOLIDIFIED WELD METAL ELECTRODE

Figure 3-1 Gas Metal Arc Welding

Robotic Arc Welding Manual 3-2 MOTOMAN

3.2.1 The Consumable Welding Arc

Figure 3-2 Consumable Electrode Welding Arc

MOTOMAN 3-3 Robotic Arc Welding Manual

Robotic Arc Welding Manual 3-4 MOTOMAN

3.2.2 Metal Transfer Across the Arc

MOTOMAN 3-5 Robotic Arc Welding Manual

The four major types of metal transfer are:

Figure 3-3 Spray Metal Transfer Mode

Robotic Arc Welding Manual 3-6 MOTOMAN

Figure 3-4 Short-Circuiting Transfer Mode

MOTOMAN 3-7 Robotic Arc Welding Manual

START END START

SHORT ARCING PERIOD

Figure 3-5 Short-Circuiting Transfer Cycle

Figure 3-6 Pulsed-Spray Transfer Mode

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