ESAB Robot integration Integrator manual

Category
Welding System
Type
Integrator manual

This manual is also suitable for

ESAB Robot Integration

ESAB Robot Integration is a powerful tool that can help you to improve the efficiency and productivity of your robotic welding operations. With ESAB Robot Integration, you can:

  • Control your welding system remotely from a variety of devices, including smartphones, tablets, and laptops.
  • Monitor and adjust welding parameters in real time.
  • Troubleshoot welding problems quickly and easily.
  • Track welding data to improve quality and productivity.

ESAB Robot Integration is compatible with a wide range of welding systems, including those from ESAB, Fronius, Lincoln Electric, and Miller Electric. It is also compatible with a variety of robot controllers, including those from ABB, FANUC, KUKA, and Yaskawa.

ESAB Robot Integration

ESAB Robot Integration is a powerful tool that can help you to improve the efficiency and productivity of your robotic welding operations. With ESAB Robot Integration, you can:

  • Control your welding system remotely from a variety of devices, including smartphones, tablets, and laptops.
  • Monitor and adjust welding parameters in real time.
  • Troubleshoot welding problems quickly and easily.
  • Track welding data to improve quality and productivity.

ESAB Robot Integration is compatible with a wide range of welding systems, including those from ESAB, Fronius, Lincoln Electric, and Miller Electric. It is also compatible with a variety of robot controllers, including those from ABB, FANUC, KUKA, and Yaskawa.

ESAB - Kuka
Integration manual
0463 368 074 GB 20171018
Robot integration,
InterfaceW82Anybus
TABLE OF CONTENTS
0463 368 074 © ESAB AB 2017
1
READ THIS FIRST......................................................................................... 3
2
DOCUMENTATION OVERVIEW.................................................................... 4
3
INTRODUCTION............................................................................................ 5
3.1 General ...................................................................................................... 5
3.2 Supported equipment .............................................................................. 5
4
W82 ANYBUS................................................................................................ 7
4.1 Fieldbus connection................................................................................. 7
4.2 W82 DeviceNet.......................................................................................... 7
4.2.1 DeviceNet network ................................................................................. 8
4.2.2 Tap for DeviceNet at Weld Data Unit...................................................... 8
4.2.3 Termination............................................................................................. 9
4.2.4 Position of SW1 on the welding data board, 24AP1............................... 10
4.2.5 24AP6 Fieldbus board - DeviceNet ........................................................ 11
4.2.6 Fieldbus connector ................................................................................. 11
4.2.7 Configuration .......................................................................................... 11
4.2.8 Baud rate................................................................................................ 13
4.2.9 Node address (Mac ID) .......................................................................... 13
4.2.10 LED indicators ........................................................................................ 13
4.3 W82 Ethercat............................................................................................. 14
4.3.1 EtherCat network.................................................................................... 14
4.3.2 24AP8 Fieldbus board - EtherCAT ......................................................... 15
4.3.3 LED indicators ........................................................................................ 15
5
INSTALLATION OF HARDWARE ................................................................. 17
5.1 Installing W82 ........................................................................................... 17
6
CROSS REFERENCE ETHERCAT AND DEVICENET................................. 22
7
FUNCTIONAL DESCRIPTION OF I/O........................................................... 25
7.1 Input from controller to welding equipment .......................................... 25
7.1.1 Weld status bits ...................................................................................... 25
7.1.2 Weld data number .................................................................................. 26
7.1.3 Numerical welding parameters............................................................... 26
7.2 Output from Welding Equipment to Controller...................................... 27
7.2.1 Weld Status Bits ..................................................................................... 27
7.2.2 Default error types.................................................................................. 28
7.2.3 Weld Data Number ................................................................................. 29
7.2.4 Numerical Welding Parameters.............................................................. 29
7.2.5 Measured Values.................................................................................... 29
7.2.6 Error Mask.............................................................................................. 29
Rights reserved to alter specifications without notice.
1 READ THIS FIRST
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© ESAB AB 2017
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 the "SPARE PARTS" chapter.
This manual contains details of design changes that have been made up to and including
February 2017.
2 DOCUMENTATION OVERVIEW
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© ESAB AB 2017
2 DOCUMENTATION OVERVIEW
The documentation structure is shown below. This manual is the ESAB - Kuka integration
manual.
3 INTRODUCTION
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© ESAB AB 2017
3 INTRODUCTION
3.1 General
This manual is intended to guide a system integrator, when integrating ESAB equipment with
an Kuka robotic solution.
3.2 Supported equipment
Power source
Mig 5000i / 5000iw, Mig 4004i Pulse, Mig 4002c / 4002cw, Mig 5002c / 5002cw, Mig 6502c /
6502cw.
Wire feeding systems
For hollow wrist robots like KR 5-2 arc HW, KR 16 arc HW and KR 16 L8-3 arc HW, 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.
Robot controller
Supported robot controller is KR C4.
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 EtherCat
and DeviceNet version.
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.
3 INTRODUCTION
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© ESAB AB 2017
W8
2
Anybus version
4 W82 ANYBUS
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© ESAB AB 2017
4 W82 ANYBUS
4.1 Fieldbus connection
External fieldbus connection via Anybus.
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 connect
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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© ESAB AB 2017
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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© ESAB AB 2017
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 0V for the internal CAN bus (0V_CAN_ext for
the external CAN bus) via 47nF 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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© ESAB AB 2017
4.2.4 Position of SW1 on the welding data board, 24AP1
4 W82 ANYBUS
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© ESAB AB 2017
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 24VDC, but will operate as intended as long as the
supply voltage is within the DeviceNet-allowed 11 to 25V 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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© ESAB AB 2017
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 W82 ANYBUS
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© ESAB AB 2017
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
125k OFF OFF
250k OFF ON
500k 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.
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
4 W82 ANYBUS
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© ESAB AB 2017
Colour Frequency Description
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
4.3 W82 Ethercat
EtherCat is used to control valves, sensors, I/O units and automation equipment in industrial
automation.
4.3.1 EtherCat network
W8
2
in EtherCat network.
4 W82 ANYBUS
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© ESAB AB 2017
4.3.2 24AP8 Fieldbus board - EtherCAT
4.3.3 LED indicators
LED 1 - Link/Activity 1
Colour Frequency Description
Off - No link sensed on Ethernet port 1
Green Steady on Link sensed on Ethernet port 1
Green Flickering Exchanging packets on Ethernet port 1
LED2 - RUN
Colour Frequency Description
Off - The device is in INIT state
Green Blinking The device is in PRE-OPERATIONAL state
Green Single flash The device is in SAFE-OPERATIONAL state
Green Steady on The device is in OPERATIONAL state
LED 3 - ERR
Colour Frequency Description
Off - EtherCat communication is in working condition
Red Blinking General configuration error
Red Single flash Slave device application has changed the EtherCat state
autonomously: Parameter 'Change' in the AL status
register is set to 01 (change/error)
Red Double flash Sync manager watchdog timeout
Red Steady on Application watchdog timeout
4 W82 ANYBUS
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© ESAB AB 2017
LED 4 - Link/Activity 2
Colour Frequency Description
Off - No link sensed on Ethernet port 2
Green Steady on Link sensed on Ethernet port 2
Green Flickering Exchanging packets on Ethernet port 2
5 INSTALLATION OF HARDWARE
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© ESAB AB 2017
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 Kuka before delivery to the
site.
5.1 Installing W82
Connections and control devices
1. Indicating lamp
Orange indicating lamp - Overheating
2. Fieldbus
Connection for communication with robot system
3. Measure
Connection for measurement cable for arc voltage feedback and emergency stop
signal, measurement kit
4. Internal CAN
Connections for communication with ESAB wire feed unit and control panel
5. LAN
Connection to network, Ethernet
6. CAN to welding power source
Connection for communication with welding power source
7. USB
USB memory connection
5 INSTALLATION OF HARDWARE
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© ESAB AB 2017
Mounting W82 on Mig 5000i
On the power source, remove the two screws holding 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 according to the picture.
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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© ESAB AB 2017
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 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.
5 INSTALLATION OF HARDWARE
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© ESAB AB 2017
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 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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ESAB Robot integration Integrator manual

Category
Welding System
Type
Integrator manual
This manual is also suitable for

ESAB Robot Integration

ESAB Robot Integration is a powerful tool that can help you to improve the efficiency and productivity of your robotic welding operations. With ESAB Robot Integration, you can:

  • Control your welding system remotely from a variety of devices, including smartphones, tablets, and laptops.
  • Monitor and adjust welding parameters in real time.
  • Troubleshoot welding problems quickly and easily.
  • Track welding data to improve quality and productivity.

ESAB Robot Integration is compatible with a wide range of welding systems, including those from ESAB, Fronius, Lincoln Electric, and Miller Electric. It is also compatible with a variety of robot controllers, including those from ABB, FANUC, KUKA, and Yaskawa.

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