ESAB Robot integration Integrator manual

ESAB - ABB

Integration manual

0740 800 220 GB 20171018

Robot integration,

InterfaceW82Integrated

andW82Anybus

TABLE OF CONTENTS

0740 800 220 © ESAB AB 2017

1

READ THIS FIRST......................................................................................... 4

1.1 How to use this manual ........................................................................... 4

1.2 Documentation overview ......................................................................... 4

2

INTRODUCTION............................................................................................ 5

2.1 Supported equipment .............................................................................. 5

2.2 Schematic system design ....................................................................... 6

3

W82 INTEGRATED VERSION....................................................................... 7

3.1 DeviceNet (Integrated version) ............................................................... 7

3.2 Network connection ................................................................................. 7

3.3 DeviceNet network (Integrated version)................................................. 8

3.4 Termination ............................................................................................... 8

3.5 Location of SW1 and SW2 on the welding data board, 24AP1............. 9

4

W82 ANYBUS................................................................................................ 10

4.1 Fieldbus connection................................................................................. 10

4.2 W82 DeviceNet.......................................................................................... 10

4.2.1 DeviceNet network ................................................................................. 11

4.2.2 Tap for DeviceNet at Weld Data Unit...................................................... 11

4.2.3 Termination............................................................................................. 12

4.2.4 Position of SW1 on the welding data board, 24AP1............................... 13

4.2.5 24AP6 Fieldbus board - DeviceNet ........................................................ 14

4.2.6 Fieldbus connector ................................................................................. 14

4.2.7 Configuration .......................................................................................... 14

4.2.8 Baud rate................................................................................................ 15

4.2.9 Node address (Mac ID) .......................................................................... 15

4.2.10 LED indicators ........................................................................................ 15

5

INSTALLATION OF HARDWARE ................................................................. 17

5.1 Regarding U82 .......................................................................................... 17

5.2 Installing W82 ........................................................................................... 17

6

CONFIGURATION EXAMPLE ....................................................................... 23

6.1 IO configuration........................................................................................ 23

6.2 Signals out ................................................................................................ 23

6.3 Signals in................................................................................................... 24

6.4 Process definitions .................................................................................. 26

6.5 Cross reference Integrated...................................................................... 30

6.6 Cross reference Anybus.......................................................................... 32

7

FUNCTIONAL DESCRIPTION OF I/O........................................................... 34

7.1 Input from controller to welding equipment .......................................... 34

7.1.1 Weld status bits ...................................................................................... 34

7.1.2 Weld data number .................................................................................. 35

7.1.3 Numerical welding parameters............................................................... 35

TABLE OF CONTENTS

0740 800 220 © ESAB AB 2017

7.2 Output from Welding Equipment to Controller...................................... 36

7.2.1 Weld Status Bits ..................................................................................... 36

7.2.2 Default error types.................................................................................. 37

7.2.3 Weld Data Number................................................................................. 38

7.2.4 Numerical Welding Parameters.............................................................. 38

7.2.5 Measured Values.................................................................................... 38

7.2.6 Error Mask.............................................................................................. 38

8

SERVICE INSTRUCTIONS............................................................................ 39

8.1 What is ESD? ............................................................................................ 39

9

SPARE PARTS .............................................................................................. 40

9.1 Ordering spare parts................................................................................ 40

Rights reserved to alter specifications without notice.

1 READ THIS FIRST

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1 READ THIS FIRST

Installation must be performed by an experienced person, and electrical work only by a

trained electrician. Use only recommended replacement parts.

This integration manual is intended for use by technicians with electrical/electronic training

for help in connection with installation and integration of robotic equipment with ESAB

products.

Use the spare parts list as a guide to where the components are located in the equipment.

The spare parts list is published as a separate document, see “SPARE PARTS”, page40.

This manual contains details of design changes that have been made up to and including

February 2017.

1.1 How to use this manual

This manual describes two different interfaces, W8

2

Integrated and W8

2

Anybus.

Only read and use the information applicable for your chosen interface.

1.2 Documentation overview

The documentation structure. This manual is the ESAB - ABB integration manual.

2 INTRODUCTION

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2 INTRODUCTION

This manual is intended to guide a system integrator, when integrating ESAB equipment with

an ABB robotic solution.

2.1 Supported equipment

Power source

Power sources for Integrated system: Mig 5000i / Mig5000iw

Power sources for Anybus system: Mig 5000i / 5000iw, Mig 4004i Pulse, Mig 4002c /

4002cw, Mig 5002c / 5002cw, Mig 6502c / 6502cw

Wire feed system

For hollow wrist robots like IRB1520ID, 1600ID and 2600ID it is recommended to use drive

unit RoboFeed 3004HW and electronic unit Feed Control Box 3004HW.

For robots with traditional upper arms it is recommended to use wire feed system RoboFeed

3004W. RoboFeed 3004W contains both a mechanical drive unit and electronics.

Interface unit

W8

2

The interface unit is installed between a welding equipment and an automation equipment,

such as robots. The W8

2

is available in several versions. This manual describes the following

versions:

• W8

2

Integrated

• W8

2

Anybus

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling electrostatic

sensitive devices.

• Use proper static-proof bags and boxes.

2 INTRODUCTION

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2.2 Schematic system design

W82 Integrated version

W82 Anybus version

3 W82 INTEGRATED VERSION

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3 W82 INTEGRATED VERSION

External CAN bus interface integrated in welding data board 24AP1. DeviceNet

communication is used.

W8

2

integrated version

3.1 DeviceNet (Integrated version)

DeviceNet is used to control valves, sensors, I/O units and automation equipment in

industrial automation. DeviceNet communication link is based on a broadcast- oriented,

communication protocol, the Controller Area Network (CAN).

This protocol has I/O response and high reliability even for demanding applications, for

example control of brakes.

3.2 Network connection

To secure a reliable communication on the bus, the “drop lines” are restricted in the

DeviceNet standard to maximum length of 6 meters (20 ft.). Note that a correct termination of

the bus is also essential for a reliable communication.

3 W82 INTEGRATED VERSION

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3.3 DeviceNet network (Integrated version)

W8

2

Integrated version in the network

3.4 Termination

DeviceNet uses the CAN bus with terminating resistors at each end of the bus. The value of

the terminating resistor should be 120 ohm. This should be connected between CAN_H and

CAN_L on the bus. Midpoint is connected to 0 V for the internal CAN bus (0 V_CAN_ext for

the external CAN bus) via a 47 nF capacitor.

Terminating resistors are included in the W8

2

. They can be connected/disconnected by the

switches, SW1 and SW2. Both the external CAN bus and the internal CAN bus have

terminating resistors mounted.

NOTE!

When external termination of the buses are used, the termination switches shall

be set in OFF position (disabled).

3 W82 INTEGRATED VERSION

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3.5 Location of SW1 and SW2 on the welding data board, 24AP1

4 W82 ANYBUS

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4 W82 ANYBUS

External fieldbus connection via DeviceNet, CANopen or Profibus DP.

W8

2

fieldbus version

4.1 Fieldbus connection

External fieldbus connection to W8

2

4.2 W82 DeviceNet

DeviceNet is used to control valves, sensors, I/O units and automation equipment in

industrial automation. The DeviceNet communication link is based on a broadcast-oriented,

communication protocol, the Controller Area Network (CAN).

This protocol has I/O response and a high reliability even for demanding applications, for

example control of brakes.

Network connection

To secure a reliable communication on the bus, the “drop lines” are restricted in the

DeviceNet standard to a maximum length of 6 metres (20 ft).

NOTE!

Correct termination of the bus is essential for a reliable communication.

4 W82 ANYBUS

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4.2.1 DeviceNet network

W8

2

in DeviceNet network

4.2.2 Tap for DeviceNet at Weld Data Unit

4 W82 ANYBUS

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4.2.3 Termination

DeviceNet uses the CAN bus with terminating resistors at each end of the bus. The

terminating resistor should be 120 ohm. This should be connected between CAN_H and

CAN_L on the bus. Midpoint is connected to 0 V for the internal CAN bus (0 V_CAN_ext for

the external CAN bus) via 47 nF capacitors.

Terminating resistors are included in the W8

2

. They can be connected/disconnected by

switch SW1. Only the internal CAN bus has terminating resistors mounted.

NOTE!

When the W8

2

is located as the last node in the internal bus network, use

termination on the CAN bus:

• Set termination switch SW1 to position “ON”. The CAN bus will be

terminated with 120 ohm at 24AP1.

• With external termination, set termination switch SW1 to position “OFF”.

4 W82 ANYBUS

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4.2.4 Position of SW1 on the welding data board, 24AP1

4 W82 ANYBUS

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4.2.5 24AP6 Fieldbus board - DeviceNet

4.2.6 Fieldbus connector

5-pin plug-able screw terminal fieldbus connector (Phoenix type)

Connector pin Signal Description

1 V- Negative supply voltage

2 CAN_L CAN_L bus line

3 SHIELD Cable shield

4 CAN_H CAN_H bus line

5 V+ Positive supply voltage

The bus interface shall be supplied with 24VDC, but will operate as intended as long as the

supply voltage is within the DeviceNet-allowed 11 to 25VDC range.

4.2.7 Configuration

A connection to the node is set up towards the assembly object with a bus configuration tool

or directly from a master.

Node address (Mac ID) and baud rate are configured with dip-switches (see picture of

fieldbus board). The range for node address is between 0-63 and baud rate is between 0 and

2 (0 = 125 kbit/s, 1 = 250 kbit/s and 2 = 500 kbit/s).

When a DIP-switch is in ”ON” or ”Closed” position, the node interprets it as a logic ”1”.

4 W82 ANYBUS

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Configuration of fieldbus board - DeviceNet

Configuration of the DeviceNet fieldbus board is performed from the U8

2

control panel as

follows:

1. From the MAIN menu, select the CONFIGURATION menu.

2. From the CONFIGURATION menu, select I/O UNIT.

3. From I/O UNIT, select ANYBUS.

4. Restart the welding power source.

The configuration of the DeviceNet fieldbus board is now completed.

4.2.8 Baud rate

There are three different baud rates for DeviceNet:

• 125 kbit/s

• 250 kbit/s

• 500 kbit/s

DIP-switches 1 and 2 are used for baud rate setting.

Baud rate, bits/s Sw 1 Sw 2

125 k OFF OFF

250 k OFF ON

500 k ON OFF

Reserved ON ON

4.2.9 Node address (Mac ID)

Switches 3 to 8 are used to set the node address (0–63). Switch 3 is the MSB, and switch 8

is LSB.

Address Sw 3 Sw 4 Sw 5 Sw 6 Sw 7 Sw 8

0 OFF OFF OFF OFF OFF OFF

1 OFF OFF OFF OFF OFF ON

2 OFF OFF OFF OFF ON OFF

3 OFF OFF OFF OFF ON ON

... ... ... ... ... ... ...

62 ON ON ON ON ON OFF

63 ON ON ON ON ON ON

4.2.10 LED indicators

The fieldbus board is equipped with four bi-colour LED's at the front of the board showing the

status.

4 W82 ANYBUS

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LED 1 and 4 are reserved for future use.

LED 2 - Network status

Colour Frequency Description

Off - Not powered / Not on line

Green Steady on Link OK, On line, Connected

Green Flashing On line, Not connected

Red Steady on Critical link failure

Red Flashing Connection timeout

LED 3 - Module status

Colour Frequency Description

Off - No power to device

Green Steady on Device operational

Green Flashing Data size bigger than configured

Red Steady on Unrecoverable fault

Red Flashing Minor fault

Watchdog LED

The fieldbus board includes a bi-colour watchdog LED, indicating the status of the module.

Colour Frequency Indication

Red - Unspecified internal error, or running in bootloader

mode

Red 1 Hz RAM failure

Red 2 Hz ASIC or FLASH failure

Red 4 Hz DPRAM failure

Green 1 Hz Module initialised and running OK

Green 2 Hz Module not initialised

5 INSTALLATION OF HARDWARE

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5 INSTALLATION OF HARDWARE

The installation chapter will describe how to connect the different components. The ESAB

integrated software in the robot controller should be installed by ABB before delivery to the

site.

5.1 Regarding U82

The U8

2

is not supported together with the W8

2

integrated version. The ABB Teach Pendant

is used for communicating with the power source.

5.2 Installing W82

Connections and control devices

W8

2

Integrated W8

2

Anybus

1. Indicating lamp

Orange indicating lamp - Overheating

2. External CAN and termination option

3. Fieldbus

Connection for communication with robot system

4. Measure

Connection for measurement cable for arc voltage feedback and emergency stop

signal, measurement kit

5. Internal CAN

Connections for communication with ESAB wire feed unit and control panel

6. LAN

Connection to network, Ethernet

7. CAN to welding power source

Connection for communication with welding power source

8. USB

USB memory connection

5 INSTALLATION OF HARDWARE

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Mounting W82 on Mig 5000i

• On the power source, remove the two screws that holds the rear handle.

• Remove handle.

• Place the interface box onto the welding power source.

• Place handle on top of the interface box.

• Fasten interface box and handle with the two screws.

Mounting W82 on Mig 4002c, Mig 5002c and Mig 6502c

• On the power source, use the “keyholes” that is normally used for the chain holding

the gas tube.

• Place the interface box onto the welding power source.

• Fasten interface box with the two screws.

Installing the wire feeder and control unit

Mount the feeder unit and controller according to the mounting instruction that comes in the

same box as the units.

Power source

Unpack and install the power source according to the user manual.

Installing the welding torch

Unpack and install the welding torch according to the user manual.

Installing the bobbin holder

Unpack and install the bobbin holder according to the user manual, refer to the assembly

instruction for Robot Bobbin Kit “RoboFeed 3004HW”.

5 INSTALLATION OF HARDWARE

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Installing the cables (W82 Integrated)

1. Connection between welding W8

2

and power source. External CAN to power source.

2. Connection between W8

2

and robot control cabinet. External fieldbus CAN to robot

control cabinet.

3. Connection between welding power source and wire feed unit. Internal CAN.

4. Connection between ABB teach pendant, single point of programming, and robot

control cabinet.

NOTE!

When using a wire feed unit other than RoboFeed, install a separate arc voltage

feedback to the measurement contact on the control unit.

5 INSTALLATION OF HARDWARE

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Installing the cables (W82 Anybus)

1. Connection between welding W8

2

and power source. External CAN to power source.

2. Connection between W8

2

and robot control cabinet. External fieldbus CAN to robot

control cabinet.

3. Connection between welding power source and wire feed unit. Internal CAN.

4. Connection between welding power source and control panel. Internal CAN.

NOTE!

When using a wire feed unit other than RoboFeed, install a separate arc voltage

feedback to the measurement contact on the control unit.

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