ESAB Robot Integration ESAB - Motoman Integrator manual
- Category
- Welding System
- Type
- Integrator manual
ESAB Robot Integration ESAB - Motoman is a robot integration tool that allows you to control a robot with a welding power source. With ESAB Robot Integration ESAB - Motoman, you can:
- Control all aspects of the welding process, including weld parameters, wire feed speed, and travel speed.
- Monitor the welding process and receive diagnostic information.
- Create and store welding programs.
- Integrate the welding robot with other automation equipment, such as conveyors and part feeders.
ESAB Robot Integration ESAB - Motoman is a robot integration tool that allows you to control a robot with a welding power source. With ESAB Robot Integration ESAB - Motoman, you can:
- Control all aspects of the welding process, including weld parameters, wire feed speed, and travel speed.
- Monitor the welding process and receive diagnostic information.
- Create and store welding programs.
- Integrate the welding robot with other automation equipment, such as conveyors and part feeders.
ESAB - Motoman
Integration manual
0740 800 223 GB 20170622
Robot integration
TABLE OF CONTENTS
0740 800 223 © ESAB AB 2017
1
READ THIS FIRST......................................................................................... 4
1.1 Documentation overview ......................................................................... 4
2
INTRODUCTION............................................................................................ 5
2.1 Supported equipment .............................................................................. 5
2.1.1 Power source ......................................................................................... 5
2.1.2 Wire feeding systems ............................................................................. 5
2.1.3 Interface unit........................................................................................... 5
2.2 Schematic system design ....................................................................... 6
3
W82 ANYBUS................................................................................................ 7
3.1 Fieldbus connection................................................................................. 7
3.2 W82 DeviceNet.......................................................................................... 7
3.2.1 DeviceNet network ................................................................................. 8
3.2.2 Tap for DeviceNet at Weld Data Unit...................................................... 8
3.2.3 Termination............................................................................................. 9
3.2.4 Position of SW1 on the welding data board, 24AP1............................... 10
3.2.5 24AP6 Fieldbus board - DeviceNet ........................................................ 11
3.2.6 Fieldbus connector ................................................................................. 11
3.2.7 Configuration .......................................................................................... 11
3.2.8 Baud rate................................................................................................ 12
3.2.9 Node address (Mac ID) .......................................................................... 12
3.2.10 LED indicators ........................................................................................ 13
4
INSTALLATION OF HARDWARE ................................................................. 14
4.1 Installing W82 ........................................................................................... 14
5
CONFIGURATION EXAMPLE ....................................................................... 19
5.1 Signals out ................................................................................................ 19
5.2 Signals in................................................................................................... 20
5.3 Cross reference Anybus.......................................................................... 21
6
FUNCTIONAL DESCRIPTION OF I/O........................................................... 24
6.1 Input from controller to welding equipment .......................................... 24
6.1.1 Weld status bits ...................................................................................... 24
6.1.2 Weld data number .................................................................................. 25
6.1.3 Numerical welding parameters............................................................... 25
6.2 Output from Welding Equipment to Controller...................................... 26
6.2.1 Weld Status Bits ..................................................................................... 26
6.2.2 Default error types.................................................................................. 27
6.2.3 Weld Data Number................................................................................. 28
6.2.4 Numerical Welding Parameters.............................................................. 28
6.2.5 Measured Values.................................................................................... 28
6.2.6 Error Mask.............................................................................................. 28
7
SERVICE INSTRUCTIONS............................................................................ 29
TABLE OF CONTENTS
0740 800 223 © ESAB AB 2017
7.1 What is ESD? ............................................................................................ 29
8
SPARE PARTS .............................................................................................. 30
8.1 Ordering spare parts................................................................................ 30
Rights reserved to alter specifications without notice.
1 READ THIS FIRST
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© ESAB AB 2017
1 READ THIS FIRST
Maintenance and repair work must be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault-tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit boards
are divided into numbered blocks, which are described individually in more detail in the
description of operation. Component names in the wiring diagram are listed in the component
description.
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”, page30.
This manual contains details of design changes that have been made up to and including
February 2017.
1.1 Documentation overview
The documentation structure. This manual is the ESAB - Motoman integration manual.
2 INTRODUCTION
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© ESAB AB 2017
2 INTRODUCTION
This manual is intended to guide a system integrator in his work when integrating ESAB
equipment with a Motoman robotic solution.
2.1 Supported equipment
2.1.1 Power source
Mig 5000i / 5000iw, Mig 4004i Pulse, Mig 4002c / 4002cw, Mig 5002c / 5002cw, Mig 6502c.
2.1.2 Wire feeding systems
For hollow wrist robots like MA1400 and MA1900 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.
2.1.3 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 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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© ESAB AB 2017
2.2 Schematic system design
W8
2
Anybus version
3 W82 ANYBUS
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© ESAB AB 2017
3 W82 ANYBUS
External fieldbus connection via DeviceNet, CANopen or Profibus DP.
W8
2
fieldbus version
3.1 Fieldbus connection
External fieldbus connection to W8
2
3.2 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.
3 W82 ANYBUS
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3.2.1 DeviceNet network
W8
2
in DeviceNet network
3.2.2 Tap for DeviceNet at Weld Data Unit
3 W82 ANYBUS
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© ESAB AB 2017
3.2.3 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”.
3 W82 ANYBUS
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3.2.4 Position of SW1 on the welding data board, 24AP1
3 W82 ANYBUS
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© ESAB AB 2017
3.2.5 24AP6 Fieldbus board - DeviceNet
3.2.6 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 25VDC range.
3.2.7 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”.
3 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.
3.2.8 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
3.2.9 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
3 W82 ANYBUS
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3.2.10 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
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 INSTALLATION OF HARDWARE
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4 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 Motoman before delivery to
the site.
4.1 Installing W82
Connections and control devices
W8
2
Anybus
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
4 INSTALLATION OF HARDWARE
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© ESAB AB 2017
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 W8
2
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”.
4 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 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.
4 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.
4 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.
5 CONFIGURATION EXAMPLE
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5 CONFIGURATION EXAMPLE
This section describes examples of signals and cross references and is ment to be used for
reference.
5.1 Signals out
This table lists examples of signals from robot to W8
2
.
Motoman ESAB Description
ARC On Weld On Start/Stop welding equipment
Quick Stop Quick Stop Quick stop of welding equipment
without end data
EM Stop Emerg. Stop Emergency stop
Inching Inching Start/Stop wire feeding
Gas Purge Gas Purge Start/Stop Gas flow
Clean Clean Start/Stop compressed Air flow
Inch Reverse Inch Reverse Start/Stop reversing wire feed
Remote mode Remote Active Remote active Enabled/Disabled
WF 1 Wire Feed 1 Enable/Disable wire feeder 1
WF 2 Wire Feed 2 Enable/Disable wire feeder 2
WF 3 Wire Feed 3 Enable/Disable wire feeder 3
WF 4 Wire Feed 4 Enable/Disable wire feeder 4
Analog Active Analog Active Wirefeed & Voltage reference
controlled from FP instead of weld data
number.
Release Wire Release Wire Execute a current pulse to burn of the
wire if frozen in weld pole.
Touch Sense Touch Sense Turns on the possibility to search using
wire or gas cup. Used with search instr.
Welding Data Weld Data Number
Recalls a complete set of weld data
Bit 2 Weld Data Number
Bit 4 Weld Data Number
Bit 8 Weld Data Number
Bit 16 Weld Data Number
Bit 32 Weld Data Number
Bit 64 Weld Data Number
Bit 128 Weld Data Number
Voltage Low Byte Voltage Low Byte Value of Voltage reference. Only used if
AnalogOn is enabled.
Voltage High Byte Voltage High Byte
Wire Feed Low Byte Wire Feed Speed Low Byte Value of Wire feed speed reference.
Only used if AnalogOn is enabled.
Wire Feed High Byte Wire Feed Speed High Byte
5 CONFIGURATION EXAMPLE
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© ESAB AB 2017
5.2 Signals in
This table lists examples of signals from W8
2
to robot.
Motoman ESAB Description
Weld Busy Weld Busy This signal indicates that the welding
equipment I occupied with welding
Arc Ackn. Arc Acknowledge This signal will be activated when the
arc is established at a weld start.
TS Resp. TouchSense Response This signal indicates contact with wire
or gas cup if TouchSenseOn is
enabled.
Remote Mode Remote Active Indicates that remote active is on.
WFU 1 Active WFU 1 Active Wire feeder 1 active.
WFU 2 Active WFU 2 Active Wire feeder 2 active.
WFU 3 Active WFU 3 Active Wire feeder 3 active.
WFU 4 Active WFU 4 Active Wire feeder 4 active.
Error Type 1 Error Type 1
See U8
2
manual for future information
regarding the error bit mask.
Error Type 2 Error Type 2
Error Type 3 Error Type 3
Error Type 4 Error Type 4
Error Type 5 Error Type 5
Error Type 6 Error Type 6
Error Type 7 Error Type 7
Error Type 8 Error Type 8
Error WDU Error WDU If active there is an error in the Weld
Data Unit.
Error PS Error PS If active there is an error in the Power
Source.
Error WF Error WFU If active there is an error in the active
Wire Feeder.
Open Gas Valve Gas Active Indicates that gas is flowing thru gas
flow sensor.
Collision detect Collision detect Indicates robot collision.
Syn On/Off Synergy Active Indicates that synergy is active.
Wire Active Inching Active Indicates that Wire Feeder is active.
Voltage Mesured Low
Byte
Voltage Low
Byte(Measured)
This is the measured voltage from the
welding equipment.
Voltage Mesured High
Byte
Voltage High
Byte(Measured)
Current Mesured Low
Byte
Current Low
Byte(Measured)
This is the measured current from the
welding equipment.
Current Mesured High
Byte
Current High
Byte(Measured)
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ESAB Robot Integration ESAB - Motoman Integrator manual
- Category
- Welding System
- Type
- Integrator manual
ESAB Robot Integration ESAB - Motoman is a robot integration tool that allows you to control a robot with a welding power source. With ESAB Robot Integration ESAB - Motoman, you can:
- Control all aspects of the welding process, including weld parameters, wire feed speed, and travel speed.
- Monitor the welding process and receive diagnostic information.
- Create and store welding programs.
- Integrate the welding robot with other automation equipment, such as conveyors and part feeders.
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