ARC ON Command Failures

Understanding the ARC ON Sequence

Initiating an arc involves a coordinated sequence between the robot controller and the welding power source.

• Weld Enable signal: The robot controller sends a weld enable signal to the power source, indicating readiness to start welding
• Arc Start Command: Upon receiving the weld enable signal, the robot issues an arc start command.
• Power Source Response: The welding power source, upon receiving the arc start command, initiates the arc and sends an arc established signal back to the robot.
• Arc Monitoring: The robot monitors the arc established signal to confirm successful arc initiation.

If any step in this sequence fails, the arc will not initiate, leading to ARC ON Command Failure.

Common Causes of ARC ON Command Failures

1. Incorrect I/O Mapping: Ensure that the input/output signals between the robot and the welding power source are correctly mapped. Incorrect mapping can prevent the arc start command from reaching the power source.
2. Safety Interlocks: Active safety interlocks, such as open safety gates or triggered emergency stops, can inhibit the arc initiation. Verify that all safety conditions are met and that the system is in a safe state for welding.
3. Power Source Not in External/Remote Mode: The welding power source must be set to remote mode to accept commands from the robot controller. If it's in local mode, it won't respond to the robot's arc start command.
4. Faulty Cables or Connections: Damaged or loose cables between the robot controller and the welding power source can disrupt signal transmission. Inspect all connections for integrity.
5. Software Configuration Errors: Incorrect settings in the robot's software, such as improper job configurations or incorrect arc start parameters, can lead to command failures. Review and verify all relevant software settings.

Troubleshooting Step

1. Verify I/O Signal Mapping: Check the robot's I/O configuration to ensure that the arc start and arc established signals are correctly assigned and functioning.
2. Check Safety Conditions: Confirm that all safety devices are in the correct state, and no emergency stops are active. Ensure that the system is in a mode that allows welding operations.
3. Inspect Power Source Mode: Ensure that the welding power source is set to external/remote mode and is ready to receive commands from the robot controller.
4. Examine Physical Connections: Inspect all cables and connectors between the robot controller and the welding power source for signs of damage or disconnection.
5. Review Software Settings: Examine the robot's job configurations and arc start parameters for correctness. Make necessary adjustments to align with the welding process requirements.