I am having trouble getting weld voltage, wire ipm set properly. We have an older ABB 2400 and trying to weld a lever arm with a 1/2 in hole to a 1/2 in stainless steel shaft. at the moment seam data for start is 21.6 volts and 285 ipm, weld data 1 is WS 8, Voltage 21.5, wire fd is 295, wd2 is WS 14, voltage is 21.3 and WF is 285. Using 309L stainless wire and C25 gas. constantly getting arc outs at start and going from WD1 to WD2.
Please don't get to technical with the robot language I have no formal training just fly by the seat of my pants with this thing for the last 6 years.
Welding a grey cast iron arm to a stainless steel shaft
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Rob H. -
June 28, 2016 at 6:45 PM -
Thread is marked as Resolved.
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It could be a number of things...
Which power source do you have ?
When you mention arc-out, what type of errors do you get, Arc Ignition fail, Arc Supervision, both or others ?
There's not a whole lot of difference between WD1 and WD2 so that shouldn't cause a supervision error (assuming you're changing on the fly and that they're not two completely separate welds).
Can you attach the EIO.cfg and PROC.cfg files from a backup (located in the SYSPAR folder).
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With a bit of manual re-programing i managed to get rid of the issue between WD1 and WD2.
Power source is an old Hobart Arc-Master 501
Controller is S4
I get both 110008 Ign Failure and 110003 Arc Supervision
Plus I get error code 50056 if i leave the robot idle for more than 4 minutes, which mean I have to take it out of automatic mode and either manually jog it till it decides it's clear or shut robot down wait 3 minutes to clear issue.
When it does this the torch head drops about 4 to 5 inches, and sometimes when i go to manually jog the robot I get a load screech, sounds like metal on metal. -
Still vague with information.
1) What wire diameter are you using.
2) How much wire stickout is programmed? Is the stickout consistent along the entire weldpath?
3) What type of weld joint and weld position are you welding?
4) I assume you welding a tight radius so is ArcC ending with ArcC/Off instructions being programmed or are all the intermediate points ArcL ending with ArcL/Off?
5) What is the gas Cfm at the gas cup?If the arc isn't stable at the beginning of the weld it has nothing to do with the transition between wd1 and wd2. This is most likely seamdata and inefficient settings for ignition voltage and ignition wirefeed. I would look at that. The weld process must be stable at ignition and through out the weld. Have you look at the arc under a weld hood? How is the arc length?
What axis is producing the 50056 Joint Collision error? It sounds like you have a worn brake or warped brake. Is this an IRB2400 classic (M94A system) or second generation IRB2400 (M96 and later)? I would guess the system is an IRB2400 classic. If that's the case the brakes on the motors are adjustable. Generally 12/1000 to 15/1000 of an inch brake gap should be present around the entire brake surface. This is about the width of a business card.