ESAB Robot integration Integrator manual

Brand: ESAB

Model: Robot integration

Category: Welding System

Type: Integrator manual

This manual is also suitable for

Interface W82 Anybus ESAB - KUKA

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 - Kuka

Integration manual

0463 368 074 GB 20171018

Robot integration,

InterfaceW82Anybus

TABLE OF CONTENTS

0463 368 074 © ESAB AB 2017

READ THIS FIRST......................................................................................... 3

DOCUMENTATION OVERVIEW.................................................................... 4

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

3.1 General ...................................................................................................... 5

3.2 Supported equipment .............................................................................. 5

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

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

5.1 Installing W82 ........................................................................................... 17

CROSS REFERENCE ETHERCAT AND DEVICENET................................. 22

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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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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2 DOCUMENTATION OVERVIEW

The documentation structure is shown below. This manual is the ESAB - Kuka integration

manual.

3 INTRODUCTION

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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

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

such as robots. The W8

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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Anybus version

4 W82 ANYBUS

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4 W82 ANYBUS

4.1 Fieldbus connection

External fieldbus connection via Anybus.

External fieldbus connection to W8

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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4.2.1 DeviceNet network

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 0V for the internal CAN bus (0V_CAN_ext for

the external CAN bus) via 47nF capacitors.

Terminating resistors are included in the W8

. They can be connected/disconnected by

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

NOTE!

When the W8

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 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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Configuration of fieldbus board - DeviceNet

Configuration of the DeviceNet fieldbus board is performed from the U8

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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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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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

in EtherCat network.

4 W82 ANYBUS

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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

Red Double flash Sync manager watchdog timeout

Red Steady on Application watchdog timeout

4 W82 ANYBUS

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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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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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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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Installing the cables W82 Anybus

1. Connection between welding W8

and power source. External CAN to power source.

2. Connection between W8

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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1. Connection between welding W8

and power source. External CAN to power source.

2. Connection between W8

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

Brand: ESAB

Model: Robot integration

Category: Welding System

Type: Integrator manual

This manual is also suitable for

Interface W82 Anybus ESAB - KUKA

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.

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ESAB Robot integration Integrator manual

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ESAB Robot integration Integrator manual

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