ESAB Retrofit I/O Interface Motoman – Aristo

GB

AH 0736c

Valid for serial no. 606-xxx-xxxx0459 916 001 GB 20110518

Aristo

Retrofit I/O

Interface Motoman

Instruction manual

- 2 -

- 3 -

TOCe

Rights reserved to alter specifications without notice.

1 SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 INTRODUCTION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 TECHNICAL DATA 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 Location 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 Connection instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 Connections and control devices 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 Function description 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 MAINTENANCE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 Inspection and cleaning 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Fault-tracing 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 ORDERING SPARE PARTS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIAGRAM 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ORDERING NUMBER 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS LIST 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ACCESSORIES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1 SAFETY

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or

near the equipment observes all the relevant safety precautions. Safety precautions must meet the

requirements that apply to this type of equipment. The following recommendations should be ob

served in addition to the standard regulations that apply to the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the equip

ment. Incorrect operation of the equipment may lead to hazardous situations which can result in in

jury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:

S its operation

S location of emergency stops

S its function

S relevant safety precautions

S welding and cutting

2. The operator must ensure that:

S no unauthorized person is stationed within the working area of the equipment when it is

started up.

S no-one is unprotected when the arc is struck

3. The workplace must:

S be suitable for the purpose

S be free from drafts

4. Personal safety equipment

S Always wear recommended personal safety equipment, such as safety glasses, flame-proof

clothing, safety gloves.

S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become

trapped or cause burns.

5. General precautions

S Make sure the return cable is connected securely.

S Work on high voltage equipment may only be carried out by a qualified electrician.

S Appropriate fire extinquishing equipment must be clearly marked and close at hand.

S Lubrication and maintenance must not be carried out on the equipment during operation.

GB

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WARNING

Read and understand the instruction manual before installing or operating.

Arc welding and cutting can be injurious to yourself and others. Take precausions when welding and

cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard

data.

ELECTRIC SHOCK - Can kill

S Install and earth the unit in accordance with applicable standards.

S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

S Insulate yourself from earth and the workpiece.

S Ensure your working stance is safe.

FUMES AND GASES - Can be dangerous to health

S Keep your head out of the fumes.

S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone

and the general area.

ARC RAYS - Can injure eyes and burn skin.

S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

S Protect bystanders with suitable screens or curtains.

FIRE HAZARD

S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE - Excessive noise can damage hearing

S Protect your ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

ESAB can provide you with all necessary welding protection and accessories.

CAUTION

Read and understand the instruction manual before

installing or operating.

CAUTION

This product is solely intended for arc welding.

Dispose of electronic equipment at the recycling facility!

In observance of European Directive 2002/96/EC on Waste Electrical and Electronic

Equipment and its implementation in accordance with national law, electrical and/or

electronic equipment that has reached the end of its life must be disposed of at a

recycling facility.

As the person responsible for the equipment, it is your responsibility to obtain

information on approved collection stations.

For further information contact the nearest ESAB dealer.

GB

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2 INTRODUCTION

Retrofit I/O Interface Motoman checks and converts the CAN bus signals from the

power source to the welding robot and is used for CAN bus controlled power

sources, such as Aristo Mig 4000i/5000i with Aristo U8 I/O.

Retrofit I/O Interface Motoman converts analog and digital signals to field bus

communication (CAN) and from field bus signals to digital and analog signals.

2.1 Equipment

Retrofit I/O Interface Motoman is supplied with an instruction manual and control

cable.

3 TECHNICAL DATA

Retrofit I/O Interface Motoman

Mains voltage 42 V 50 - 60 Hz

Mains voltage 2 (from robot) 24 V DC

Fuse 1 A

External power source robot +/- 15V to robot

Robot connection 23 pin connection socket

Weight 6.1 kg

Dimensions (l x w x h) 365 x 351 x 110 mm

Protection class IP23

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

4 INSTALLATION

The installation must be executed by a professional.

CAUTION

This product is intended for industrial use. In a domestic environment this product may

cause radio interference. It is the user's responsibility to take adequate precautions.

WARNING

When welding in an environment with increased electrical danger, only power

sources intended for this environment may be used. These power sources are

marked with the symbol

GB

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4.1 Location

Retrofit I/O Interface Motoman is installed above the power source. Remove the

rubber mat (C) on the power source and then slide the flange of the interface box (A)

into the side profiles (B) of the power source, see the illustration below.

IMPORTANT! Screw the 3 screws into place on the front of the interface box,

sufficiently hard in the screw threads that electrical connection is made. Check that

electrical connection has been established.

4.2 Connection instructions

Complete descriptions of the power source / wire feed unit are available in separate instruction

manuals.

GB

- 8 -

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5 OPERATION

General safety regulations for the handling of the equipment can be found on

page 4. Read through before you start using the equipment!

5.1 Connections and control devices

1 Indicator lamp (WHITE), power supply

from robot.

4 Connection for operating cable from power

source (12-pin CAN bus)

2 Connection for signals to/from the robot's

welding gun (23-pin socket connector)

5 Connection (negative) for arc voltage

detection (1 pin socket plug)

3 Fuse / 1A 24 VDC from robot

5.2 Function description

Retrofit I/O Interface Motoman is connected to the robot cabinet and the power

source.

When the Interface box is connected to Aristo Mig 4000i or Aristo Mig 5000i with

Aristo U8 I/O with part number 0456 290 992 or higher.

The type plate is located on the

rear side of the Interface box.

6 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

CAUTION

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any faults.

GB

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6.1 Inspection and cleaning

Regularly check that the interface box has electrical connection with the power

source and that the connections are correctly connected and not faulty.

6.2 Fault-tracing

S Has the indicator lamp (white) on the front gone out?

Check that the fuse is intact.

S Ensure that the wiring is correctly located in its connectors.

Complete descriptions of the power source, wire feed unit and control panel are available in separate

instruction manuals.

7 ORDERING SPARE PARTS

Retrofit I/O Interface Motoman is designed and tested in accordance with the interna

tional and European standards 60974- 1 and 60974- 10. It is the obligation of the servi

ce unit which has carried out the service or repair work to make sure that the product

still conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

* * *

NOTE! 8. FUNCTION DESCRIPTION OF I/O SIGNALS is only in English and is

primarily meant for the integrator and installation of the Interface box on page

NO TAG.

GB

Diagram

InterfaceBox

Aristo

XP1

A

146

X4

6

4

B

145

5

2

K

4

CAN High

L

3

CAN Low

E

1

C1

F

162

R2

.7

5

C

144

G

019

XS2

022

R2

A1

A2

21

W147

R1

A1

A2

143

21

3

711

X5

11

113

025

342

307

612

12

123

HL1

X1

X2

AntiCollision

XP3

F

342 025

2

815

Weld busy

G

221

1

314

KL91

7

ComV

VSupplytoRobot

E

101

J1

1

J4

6

603

3

ComV

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D

102

2

5

505

1

Wire-1V

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C

103

3

4

401

5

Voltage-1V

KL2134

:2

6

24VR

7

VR

2

24VR

3

VR

8

Reserve

4

Reserve

5

Remote active

1

Weld busy

Extern negative arc voltage

KL3062

6 mm2

- 10 -

br05 diag

Robot

AP1

KL2134

:1

6

24VR

7

VR

2

24VR

3

OVR

RemoteActive

S

005

8

CollisionDetect

WeldEquip.Ready

Z

104

4

3

304

4

MachineError=V

Touchsenserespons

T

105

5

2

205

1

TouchSenseResp

ArcStartConformed

Y

106

6

1

1001

5

ArcAcknow.

KL1408

Memory8

J

001

J2

1

J5

18

1808

8

Memory8

Memory4

H

002

2

17

1704

4

Memory4

Memory2

V

003

3

16

1607

7

Memory2

Memory1

U

004

4

15

1503

3

Memory1

5

14

1405

6

WireFeeder

6

3

2

Reserve

7

12

5

Reserve

SearchSensorActive

W

008

8

11

1101

1

Touch sense

9

1

1008

KL1408

8

Reserve

AP3

TC1

AnalogueActive

P

010

1

9

904

4

AnalogActive

RobotAlarm

X

R1

.8

3

11

8

807

7

QuickStop

111

-15V

D1

6

SpatterCleaning

N

012

12

7

703

3

Air purge

A5

19Vac

2

R

013

13

6

606

6

ReverseWire

A3

V

D2

7

ManualWire

L

014

14

5

502

2

Inching

A2

19Vac

+15V

D4

8

ManalGas

M

015

15

4

405

5

GasPurge

42VAC

ArcOn

K

016

16

3

301

1

WeldOn

D6

9

9

BK5151

C

V

1

C2

V

19Vac

4

VSupplyFromRobot

B

017

17

2

200

VR

D5

11

1

24VSupplyFromRobot

A

218

1A

FU1

018

18

1

124

24VR

24V

24

C1

24V

19VAC

J3

1

J6

2

V

7

CAN high

4

2

1

1124

24V

2

CAN low

3

V

1

:1

:2

1200

011

- 11 -

br05 diag

Retrofit I/O Interface Motoman

Ordering number

- 12 -

br05 order

AH 0736c

Ordering no. Denomination Type Notes

0461 090 882 Retrofit I/O Interface

Interface Robot

For Motoman

0459 916 001 Instruction manual

Retrofit I/O Interface

Motoman

Retrofit I/O Interface Motoman

Spare parts list

- 13 -

br05sp1

Item Qty Ordering no. Denomination Notes

101 1 0461 095 001 Cover

102 1 0461 110 881 Gable back 48p 1x12p

103 3 0452 116 004 Relay 2VX 24VDC

104 3 0452 116 008 Socket

105 1 0368 543 005 Panel plug 23-pol

106 1 0461 092 001 Chassi

107 1 0458 681 891 Cable D-sub compl.

108 1 0467 911 884 Capacitor

109 1 0456 686 880 Clamp

110 1 0368 543 003 Burndy plug M/C Mount 12 way

- 50 0323 945 004 Contact pins (W) Min. 50 pcs

111 1 0443 740 007 Sign bracket

112 1 0457 800 001 Insulation

113 1 0366 285 001 Protection cap 12-pol

114 1 0193701 001 Fuse holder knob

115 1 0567 900 132 Fuse 1A

116 1 0193 701 002 Fuse holder

117 1 0461 098 001 Adapter plate

118 1 0192 576 003 Lamp 24V White

119 1 0461 092 880 Gable front

20 0194 179 327 Screw MRT Ground-cutter M5x12 - Min 50 pcs.

Retrofit I/O Interface Motoman

- 14 -

br05sp1

Retrofit I/O Interface Motoman

- 15 -

br05sp2

Item Qty Ordering no. Denomination Notes

MOUNTING PLATE

201 1 0461 097 001 Mounting plate

202 1 0194 204 001 Terminal Bud coupler BK5151

203 2 0194 205 001 Terminal Digital input KL1408

204 2 0194 205 002 Terminal Digitial output KL2134

205 1 0194 205 003 Terminal Analog input KL3062

206 1 0194 205 004 Terminal Bus End KL9010

207 1 0194 179 327 Screw, MRT Ground-cutter M5x12

208 1 0191 548 009 Flat pin 6.3 x 0.8 M6

209 1 0487 427 880 Printed Circuit Board

210 1 0319 828 003 Transformer WFU

211 1 0192 790 102 Circuit Card holder 6.3 mm

212 1 0487 385 880 Printed Circuit Board TIG

213 2 0192 547 002 Quick-Act lock nut B6

Retrofit I/O Interface Motoman

- 16 -

br05sp2

Retrofit I/O Interface Motoman

Accessories

- 17 -

br05acc

AristoPendant U8 I/O (Motoman) . . . . . . . . . . . . . . . 0456 290 992

Control cable, Retrofit I/O Interface (5 m) . . . . . . .

Control cable, Retrofit I/O Interface (10 m) . . . . .

0455 076 885

0455 076 881

Extension cable (AristoPendant U8, 5 m) . . . . . . . .

Extension cable (AristoPendant U8, 10 m . . . . . . .

0456 280 881

0456 280 882

Control cable

Retrofit I/O to power source (1,7 m) . . . . . . . . . . . . 0456 527 891

- 18 -

notes

NOTES

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

- 19 -

notes

NOTES

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

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Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna-Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Brussels

Tel: +32 2 745 11 00

Fax: +32 2 745 11 28

BULGARIA

ESAB Kft Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Vamberk

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Herlev

Tel: +45 36 30 01 11

Fax: +45 36 30 40 03

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel: +33 1 30 75 55 00

Fax: +33 1 30 75 55 24

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 218

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel: +36 1 20 44 182

Fax: +36 1 20 44 186

ITALY

ESAB Saldatura S.p.A.

Bareggio (Mi)

Tel: +39 02 97 96 8.1

Fax: +39 02 97 96 87 01

THE NETHERLANDS

ESAB Nederland B.V.

Amersfoort

Tel: +31 33 422 35 55

Fax: +31 33 422 35 44

NORWAY

AS ESAB

Larvik

Tel: +47 33 12 10 00

Fax: +47 33 11 52 03

POLAND

ESAB Sp.zo.o.

Katowice

Tel: +48 32 351 11 00

Fax: +48 32 351 11 20

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 8 310 960

Fax: +351 1 859 1277

ROMANIA

ESAB Romania Trading SRL

Bucharest

Tel: +40 316 900 600

Fax: +40 316 900 601

RUSSIA

LLC ESAB

Moscow

Tel: +7 (495) 663 20 08

Fax: +7 (495) 663 20 09

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel: +421 7 44 88 24 26

Fax: +421 7 44 88 87 41

SPAIN

ESAB Ibérica S.A.

Alcalá de Henares (MADRID)

Tel: +34 91 878 3600

Fax: +34 91 802 3461

SWEDEN

ESAB Sverige AB

Gothenburg

Tel: +46 31 50 95 00

Fax: +46 31 50 92 22

ESAB international AB

Gothenburg

Tel: +46 31 50 90 00

Fax: +46 31 50 93 60

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

UKRAINE

ESAB Ukraine LLC

Kiev

Tel: +38 (044) 501 23 24

Fax: +38 (044) 575 21 88

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem-MG

Tel: +55 31 2191 4333

Fax: +55 31 2191 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 2326 3000

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 45 670 7073

Fax: +81 45 670 7001

MALAYSIA

ESAB (Malaysia) Snd Bhd

USJ

Tel: +603 8023 7835

Fax: +603 8023 0225

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 6861 43 22

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Africa

EGYPT

ESAB Egypt

Dokki-Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

SOUTH AFRICA

ESAB Africa Welding & Cutting Ltd

Durbanvill 7570 - Cape Town

Tel: +27 (0)21 975 8924

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.com

ESAB Retrofit I/O Interface Motoman – Aristo - For Motoman, Retrofit I/O Interface Motoman – Aristo® - For Motoman User manual

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