Migatronic Tig - Plasma Welding machine /Fanuc robot Interface

Adapted for RJ3 Controller: 76119997-1

Adapted for RJ2 Controller: 76119999-1

Setup & Jumper configuration

AUTOMATION A/S +45 96 96 27 00

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 Table of Contents:
JUMPERS. ................................................................................................................................................................................................................................... 3

LED INDICATORS..................................................................................................................................................................................................................... 4

CONNECTIONS IN FRONT OF THE INTERFACE. ............................................................................................................................................................ 5

CONNECTIONS ON BACKSIDE OF THE INTERFACE. .................................................................................................................................................... 7

INTERFACE SCHEMATIC ...................................................................................................................................................................................................... 8

ACCESSORIES ........................................................................................................................................................................................................................... 9

ILLUSTRATION 1: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER....................... 11

ILLUSTRATION 2: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER....................... 12

ILLUSTRATION 3: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL............................................................................................... 13

ILLUSTRATION 4: THE WELDING MACHINE GIVES THE ARC DETECT SIGNAL............................................................................................... 14

ILLUSTRATION 5: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL. ............................................................................................ 15

ILLUSTRATION 6: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL. ............................................................................................ 16

ILLUSTRATION 7: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL. ............................................................................................ 17

ILLUSTRATION 8: THE ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL. ............................................................................................ 18

ILLUSTRATION 9: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER. ....... 19

ILLUSTRATION 10: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL THROUGH THE COLD WIRE FEEDER. ..... 20

ILLUSTRATION 11: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL. ............................................................................. 21

ILLUSTRATION 12: THE AC/DC ARC DETECTOR BOX GIVES THE ARC DETECT SIGNAL. ............................................................................. 22

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Jumpers.

1
2 Jumper 2 (J2)
3

1
2 Jumper 3 (J3)
3

3 2 1
Jumper 1 (J1)

J1: Arc detect mode, only 8 pole plug.

1&2: Low on pin “E”=arc on
2&3: High on pin “E” = arc on

J2: Supply for 8911 remote control.

1&2: Wire feeder supplies the remote control
2&3: Welding machine supplies the remote control

J3: With/without remote control.

1&2: Remote control installed
2&3: No remote control

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Led indicators.

1 6

12
7
2 9 10
11 4 5

3 8

Pos.1: Current output signal, PWM signal (Yellow)

Pos.2: Wire speed output signal, PWM signal (Yellow)

Pos.3: Start welding input from robot (Yellow)

Pos.4: Start wire/wire on input from robot (Yellow)
Pos.5: Wire + input signal from robot (Yellow)
Pos.6: Wire – input signal from robot )Yellow)
Pos.7: Arc on signal from 6 pole plug, input signal (Yellow)
Pos.8: Arc on signal from 8 pole plug, input signal (Yellow)

Pos.9: Start welder output signal (Red)

Pos.10: Start/wire on, output signal (Red)
Pos.11: Arc on, output signal to the robot (Red)

Pos. 12: +24V DC from robot OK (Green)

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Connections in front of the interface.

1: Start wirefeeder / welding machine output.

Via this connector, the KT-4 wire feeder is started.
This connector also can supply the interface with the Arc Detect signal.

Pinconnections:
2: Relay output. Start welding machine or wire feeder.
3: Arc Detect signal. Input to interface.
5: 0V / Gnd.
6: Relay output. Start welding machine or wire feeder.

Other pins not connected.

2: Connection to welding machine´s remote input.

This plug should only be connected if no wire feeder is connected.

Pinconnections:
A: Current information 0-10V to welding machine.
B: 0V/GND (REF.0V)
E: Arc Detect signal from welding machine. 0V = Arc ON.
G: Supply voltage. Voltage = 18VAC or 24VAC, depending on welding machine.
H: Supply voltage common.

Other pins not connected.

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3: Connector to KT4 wire feeder.

Pin connections:
A: Current information 0-10V DC. From interface to welding machine.
B: 0V/GND (REF.0V).
C: Wirefeeder ground/ connected to the chassis in wirefeeder.
D: Direction signal wire. “0” = wire forward. “1” = Wire return.
E: Start wire request from wirefeeder. Output from KT-4 wire feeder.
F: Start wire: Input on KT-4 wire feeder. “0” = Stop wire. “1” = Start wire.
G: +24V / DC to remote control. Max. 200mA. Short circuit protected.
H: 0V / GND to remote control.
M: Wirespeed information 0 to 10V. From remote control to wire feeder.
V: Interface ground / connected to chassis in interface.

Other pins not connected.

4: Connector to remote control from interface.

Remote control type 8911 can be used.

Pin connections:
A: Current information 0-10V DC. From interface to welding machine.
B: 0V/GND (REF.0V).
C: Wirefeeder ground/ connected to the chassis in wirefeeder.
D: Direction signal wire. “0” = wire forward. “1” = Wire return.
E: Start wire request from wirefeeder. Output from KT-4 wire feeder.
F: Start wire: Input on KT-4 wire feeder. “0” = Stop wire. “1” = Start wire.
G: +24V / DC to remote control. Max. 200mA. Short circuit protected.
H: 0V / GND to remote control.
J: Enable Basis Current. A “0” on this input, will force the remote control to enable
basis current. A ”1” will enable the remote control to carry out it’s normal
procedure.
K: 0V/GND.
L: 0V/GND.
M: Wirespeed information 0 to 10V. From remote control to wire feeder.
N: Wire +. “0” = Jog wire.
P: Wire -. “0” = Jog wire direction.
R: Disable puls current. “0” = No current pulsation.
S: Disable step wire. “0” = Constant wire. “1” = Wire when current is high.
T: Wire speed information 0 to 10V, from robot.
U: Current information 0 to 10V, from robot.
V: Interface ground / connected to chassis in remote control.

Other pins not connected.

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Connections on backside of the interface.

Pin numbers and names in parenthesis refer to connectors on a Fanuc robot’s RJ2 or RJ3
controller.

1: Welding current + (CRW1-23, WDO1).

2: Wire speed + (CRW1-3, DACH2).
3: NC.
4: 0V / Ground in robot (CRW1-20, GND).
5: Arc Detect output from interface to robot (CRW1-6, WDI2).
6: Disable pulse current (CRW1-28, WDO6).
7: Wire +, jog wire forward (CRW1-26, WDO4).
8: Start weld (CRW1-23, WDO1).
9: Welding current – (CRW1-2, CAMDA1).
10: Wire speed – (CRW1-4, CAMDA2).
11: Enable basis current (CRM2B-33, SDO1).
12: +24VDC from robot (CRW1-34, +24VE).
13: Disable step wire (CRW1-29, WDO7).
14: Wire -, jog wire backward (CRW1-27, WDO5).
15: Start wire (CRW1-25, WDO3).

All inputs to the interface via this connector, except analogue inputs, requires NPN open
collector output type, or relay contact - switching to 0V.
All outputs from the interface via this connector, are NPN open collector type.

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Interface Schematic

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Accessories

6 pole cable between RS interface and arc detector box.

The cable must be full connected.
Male / female.
Length standard 3 meters .

No. 74341020-1

6 pole cable between RS interface and cold wire feeder.

The cable must be full connected.
Male / male.
Length standard 5 meters .

No. 74341021-1

6 pole cable. Start welding machine.

Male / male. Only pin 2 & 6 is connected.
Length standard 5 meters.

No. 74320002-1

8 pole cable between RS interface and welding machine.

The cable must be full connected.
Length standard 5 meters.
Male / male.

No. 74340003-0

19 pole cable between RS interface and cold wire feeder.

Also used between RS interface and 8911 remote control.
Length standard 6 meters.
The cable must be full connected. Male / male.

No. 74341011-1

Remote control 8911

Controls welding current, cold wire speed and pulse timing.

No. 76118911-1
Arc detector box.
Usable only for DC welding
Detects current > 20A

No. 76118817-1

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 Arc detector box.

WIRE FEEDER
Can also be used for AC welding

WELDING MACHINE
Detects current > 5A
WELDING +

GROUND
76118818-1
No. 76118818-1

19-Pin plug with bridges. Use when the system is equipped with wire
feeder, and NOT equipped with remote control.

No. 17210090-1

10 /
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 Illustration 1: The welding machine gives the arc detect signal through the cold wire feeder.
RS interface jumpers: J1: 2&3, J2: 1&2, J3: 1&2

To be used in connection with: Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).

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 Illustration 2: The welding machine gives the arc detect signal through the cold wire feeder.
RS interface jumpers: J1: 2&3, J2: 1&2, J3: 2&3

To be used in connection with: Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).
Note! 19-Pin plug (part no.17210090-1), must be inserted in the remote control connector, at the
interface.

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 Illustration 3: The welding machine gives the arc detect signal.
RS interface jumpers: J1: 1&2, J2: 2&3, J3: 1&2

To be used in connection with: Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).

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 Illustration 4: The welding machine gives the arc detect signal.
RS interface jumpers: J1: 1&2, J2: 2&3, J3: 2&3

To be used in connection with: Plasma commander DC, Tig Commander/Navigator DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).

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 Illustration 5: The arc detector box gives the arc detect signal.
RS interface jumpers: J1: 2&3, J2: 1&2, J3: 1&2

To be used in connection with: Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire ”E” in the 8 pole
Cable between the welding machine and the cold wire feeder.

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 Illustration 6: The arc detector box gives the arc detect signal.
RS interface jumpers: J1: 2&3, J2: 1&2, J3: 2&3

To be used in connection with: Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire ”E” in the 8 pole
cable between the welding machine and the cold wire feeder.
Note! 19-Pin plug (part no.17210090-1) must be inserted in the remote control connector at the
interface.

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 Illustration 7: The arc detector box gives the arc detect signal.
RS interface jumpers: J1: 2&3, J2: 2&3, J3: 2&3

To be used in connection with: Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire ”E” in the 8 pole
Cable between the welding machine and RS interface.

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 Illustration 8: The arc detector box gives the arc detect signal.
RS interface jumpers: J1: 2&3, J2: 2&3, J3: 2&3

To be used in connection with: Pilot 1600/2400, BDH Tig. DC welding only. It can be necessary to remove wire ”E” in the 8 pole
cable between the welding machine and RS interface.

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 Illustration 9: The AC/DC Arc detector box gives the arc detect signal through the cold wire feeder.
RS interface jumpers: J1: 1&2, J2: 1&2, J3: 1&2

To be used in connection with: Plasma commander AC/DC, Tig Commander/Navigator AC/DC.

It can be necessary to apply PTC1 in the control unit on the welding machine
(Analogue machines only).

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 Illustration 10: The AC/DC Arc detector box gives the arc detect signal through the cold wire feeder.
interface jumpers: J1: 1&2, J2: 2&3, J3: 2&3

To be used in connection with: Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).
Note! 19-Pin plug (part no.17210090-1) must be inserted in the remote control connector at the
interface.

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 Illustration 11: The AC/DC Arc detector box gives the arc detect signal.
interface jumpers: J1: 1&2, J2: 2&3, J3: 1&2

To be used in connection with: Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).

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 Illustration 12: The AC/DC Arc detector box gives the arc detect signal.
interface jumpers: J1: 1&2, J2: 2&3, J3: 2&3

To be used in connection with: Plasma commander AC/DC, Tig Commander/Navigator AC/DC. It can be necessary to apply PTC1
in the control unit on the welding machine (Analogue machines only).

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