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ting and clearing the miscellaneous output #4.
4.4
ARC DETECT
The arc detect signal is generated from the voltage and
current signals on the control board. The arc detect cir-
cuit is calibrated to detect a minimum arc of 15V and
30A. The signal is isolated from the control ground and
tied to the robot controller welding input 2 (WDI2).
4.5
GAS FAULT
This signal is not connected to anything on the inter-
face board. The signal (WDI3) is simply re-routed from
the robot connector (P82) to the miscellaneous con-
nector (P84). A gas fault is generated when this signal
is tied to the robot ground.
4.6
WATER FAULT
The water fault signal is generated by an active high
(w/low water pressure reading) signal on the display
board. The signal is then isolated from the display
ground, inverted, and tied to the robot controller weld-
ing input 5 (WDI5).
4.7
POWER FAULT
The power fault signal is generated by checking the
12.8V supply on the interface board. If the supply volt-
age on the interface board drops below ≈11.2V then a
power fault signal is generated. The signal is then iso-
lated from the control ground and tied to the robot con-
troller welding input 6 (WDI6).
4.8
VOLTAGE FEEDBACK
The arc voltage feedback signal is generated on the
control board. The interface board then filters, multi-
plies by 2, and isolates the signal from the control
ground. The signal is then tied to the robot controller
analog input 1 (ADCH1). A voltage feedback signal of
7.62V is equal to an arc voltage of 80V.
4.9
CURRENT FEEDBACK
The arc current feedback signal is generated on the
control board. The interface board then filters, multi-
plies by 4, and isolates the signal from the control
ground. The signal is then tied to the robot controller
analog input 2 (ADCH2). A current feedback signal of
8.32V is equal to an arc current of 750A.
4.10 WELD START
The weld start command is generated by active low
welding output 1 (WDO1). The signal is then isolated
from the robot ground, inverted, and tied to the inter-
face trigger input.
4.11 GAS START
The gas start command is generated by active low
welding output 2 (WDO2). The signal is then isolated
from the robot ground and tied to the gas solenoid dri-
ver.
ROBOTIC INTERFACE
4.12 TOUCH SENSE COMMAND
The touch sense command is generated by active low
welding output 3 (WDO3). The signal is then inverted
and isolated from the robot ground with an output
made to conduct 24VAC. The 24VAC connection is the
wire feeder 2 trigger.
4.13 WIRE+ & WIRE-
These two signals work together to cold inch the wire
at ±80IPM. The forward wire inch command is gener-
ated by active low welding output 4 (WDO4). The
reverse wire inch command is generated by active low
welding output 5 (WDO5). When either of the two sig-
nals is received an isolated inch command is generat-
ed and tied to the interface wire inching input. At the
same time the motor drive relays switch to the correct
direction. The default direction for the motor drive
relays is forward, if both the signals are low at the same
time then the motor drive relays are set for reverse. No
damage will be caused by driving both signals low at
the same time.
4.14 DUAL PROCEDURE SWITCH COMMAND
The dual procedure switch command is generated by
active low welding output 7 (WDO7). The signal is then
isolated from the robot ground and tied to the interface
dual procedure input.
4.15 WIRE STICK DETECT
The wire stick detect signal is generated by a voltage
check across the output studs. The robot controller
samples this signal a predetermined time after the Arc
Enable signal changes from enabled to disabled. The
signal is then isolated from the control ground and tied
to the robot controller wire stick detect inputs (WDI+ &
WDI-).
POWER WAVE 450
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Table of Contents
Troubleshooting
