esab - abb robot integration connection..... 9 w82 devicenet ..... 10 devicenet network..... 10 tap...

0740 800 220 20130308

ESAB - ABB

Robot integrationInterface W82 Integrated and W82 Anybus

Integration manual

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Rights reserved to alter specifications without notice.

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

HOW TO USE THIS MANUAL 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DOCUMENTATION OVERVIEW 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supported equipment 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schematic system design 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

W82 INTEGRATED VERSION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DeviceNet (Integrated version) 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network connection 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DeviceNet network (Integrated version) 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Termination 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Location of SW1 and SW2 on the welding data board, 24AP1 8. . . . . . . . . . . . . . . . . . . . . . .

W82 ANYBUS 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fieldbus connection 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

DeviceNet network 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Termination 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Position of SW1 on the welding data board, 24AP1. 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24AP4 Fieldbus board - DeviceNet 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fieldbus connector 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Configuration 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Baud rate 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Node address (Mac ID) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

INSTALLATION OF HARDWARE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regarding U82 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installing W82 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONFIGURATION EXAMPLE 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IO configuration 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signals out 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signals in 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Process definitions 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cross reference Integrated 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cross reference Anybus 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE INSTRUCTIONS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

What is ESD? 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPARE PARTS 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordering spare parts 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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READ THIS FIRST

Installation must be performed by an experienced person, and electrical work only bya trained electrician. Use only recommended replacement parts.

This integration manual is intended for use by technicians with electrical/electronictraining for help in connection with installation and integration of robotic equipmentwith ESAB products.

Use the spare parts list as a guide to where the components are located in theequipment. The spare parts list is published as a separate document, see page 33.

This manual contains details of design changes that have been made up to andincluding March 2013.

HOW TO USE THIS MANUAL

This manual describes two different interfaces, W82 Integrated and W82 Anybus.Only read and use the information applicable for your chosen interface.

DOCUMENTATION OVERVIEW

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

Delivered in the box with the unit

Delivered with the

ABB robot

Delivered in the box with

the wire feeder mounting kit

Delivered with the ESAB

robot package

Power source

Instruction manual

W 82

Instruction manual

RoboFeed / FeedControl

Instruction manual

RoboFeed / FeedControl

Assembly instruction

ESAB – ABB

Integration manualABB – robot

Product manual“This manual”

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INTRODUCTION

This manual is intended to guide a system integrator, when integrating ESABequipment with an ABB robotic solution.

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

For robots with traditional upper arms it is recommended to use wire feed systemRoboFeed 3004W. RoboFeed 3004W contains both a mechanical drive unit andelectronics.

Interface unit

W82

The interface unit is installed between a welding equipment and an automationequipment, such as robots. The W82 is available in several versions. This manualdescribes the following versions:

� W82 Integrated

� W82 Anybus

CAUTION

Read and understand the instruction manual beforeinstalling or operating.

CAUTIONSTATIC ELECTRICITY can damage circuitboards and electronic components.

� Observe precautions for handling electrostatic-sensitive devices.

� Use proper static-proof bags and boxes.ESD

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Schematic system design

W82 Integrated version

ESAT vis LAN

ESAT via LAN

W82 Anybus version

ESAT via LAN

Termination

120 ohm

ss

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W82 INTEGRATED VERSION

External CAN bus interface integrated in welding data board 24AP1. DeviceNetcommunication is used.

Internal CAN to Power SourceExternal CAN bus connection to robot

W82 integrated version

DeviceNet (Integrated version)

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

Network connection

To secure a reliable communication on the bus, the “drop lines” are restricted in theDeviceNet standard to maximum length of 6 meters (20 ft.). Note that a correcttermination of the bus is also essential for a reliable communication.

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DeviceNet network (Integrated version)

W82 Integrated version in the network

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 connectedbetween CAN_H and CAN_L on the bus. Midpoint is connected to 0V for the internalCAN bus (0V_CAN_ext for the external CAN bus) via a 47nF capacitor.

Terminating resistors are included in the W82. They can be connected/disconnectedby the switches, SW1 and SW2. Both the external CAN bus and the internal CANbus have terminating resistors mounted.

Note! When external termination of the buses are used, the termination switchesshall be set in OFF position (disabled).

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

SW1

SW2

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W82 ANYBUS

External fieldbus connection via DeviceNet, CANopen or Profibus DP.

W82 fieldbus version

Fieldbus connection

External fieldbus connection to W82

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W82 DeviceNet

DeviceNet is used to control valves, sensors, I/O units and automation equipment inindustrial automation. The DeviceNet communication link is based on abroadcast-oriented, communication protocol, the Controller Area Network (CAN).

This protocol has I/O response and a high reliability even for demandingapplications, for example control of brakes.

Network connection

To secure a reliable communication on the bus, the “drop lines” are restricted in theDeviceNet standard to a maximum length of 6 metres (20 ft).

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

DeviceNet network

W82 in DeviceNet network

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Tap for DeviceNet at Weld Data Unit

Termination

DeviceNet uses the CAN bus with terminating resistors at each end of the bus. Theterminating resistor should be 120 ohm. This should be connected between CAN_Hand 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 W82. They can be connected/disconnectedby switch SW1. Only the internal CAN bus has terminating resistors mounted.

Note! When the W82 is is located as the last node in the internal bus network, usetermination on the CAN bus:

� Set termination switch SW1 to position “ON”. The CAN bus will be terminatedwith 120 ohm at 24AP1.

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

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

SW1

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24AP4 Fieldbus board - DeviceNet

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

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Configuration

A connection to the node is set up towards the assembly object with a busconfiguration tool or directly from a master.

Node address (Mac ID) and baud rate are configured with dip-switches (see pictureof fieldbus board). The range for node address is between 0-63 and baud rate isbetween 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”.

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

Node address (Mac ID)

Switches 3 to 8 are used to set the node address (0-63). Switch 3 is the MSB, andswitch 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

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LED indicators

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

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

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INSTALLATION OF HARDWARE

The installation chapter will describe how to connect the different components. TheESAB integrated software in the robot controller should be installed by ABB beforedelivery to the site.

Regarding U82

The U82 is not supported together with the W82 integrated version. The ABB TeachPendant is used for communicating with the power source.

Installing W82

Connections and control devices

W82 Integrated W82 Anybus

1. Indicating lampOrange indicating lamp - Overheating

2. FieldbusConnection for communication with robot system

3. MeasureConnection for measurement cable for arc voltage feedback and emergencystop signal, measurement kit

4. Internal CANConnections for communication with ESAB wire feed unit and control panel

5. LANConnection to network, Ethernet

6. CAN to welding power sourceConnection for communication with welding power source

7. USBUSB memory connection

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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 chainholding 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 thatcomes in the same box as the units.

Power source

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

Installing the welding gun

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

Installing the bobbin holder

Unpack and install the bobbin holder according to the user manual, refer to theassembly instruction for Robot Bobbin Kit “RoboFeed 3004HW”.

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Installing the cables (W82 Integrated)

ABBTeach pendant

RoboFeed

Mig 5000i/iw

1 Connection between welding W82 and power source. External CAN to power source.

2 Connection between W82 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 tothe measurement contact on the control unit.

Installing the cables (W82 Anybus)

RoboFeed

Mig 5000i/iw




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


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Installing the cables (W82 Anybus) continued

Mig 4004i Pulse

RoboFeed

13

2

4



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



Mig 4002 c/cwMig 5002 c/cwMig 6502 c/cw

RoboFeed

1

3

2

4






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CONFIGURATION EXAMPLE

This section describes examples of IO configurations, process definitions and crossreferences and is ment to be used for reference and as examples.

IO configuration

Unit type

Name = ESAB_W82_Integrated

Name = ESAB_W82_Anybus

Unit

Name = ESAB_W82

IO

Name = typeXxxxYyyy

Description of signal naming convention (if more than 1 robot a prefix is added explaining which robot the signal belongs to).

Type:

� di = Digital input

� do = Digital output

� gi = group input

� go = group output

� ai = analog input

� ao = analog output

Xxxx:

� Signal description

Yyyy:

� Signal action

SignalLabel = <Description>

Category = “ArcWelding”

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Signals out

This table lists examples of signals from robot to W82

ABB ESAB Description

doWeld doWeldOn Start/Stop welding equipment

doQuickStop doQuickStop Quick stop of welding equipmentwithout end data

doEmStop doEmergencyStop Emergency stop

doFeed doWireFeedOn Start/Stop wire feeding

doGas doGasPurgeOn Start/Stop Gas flow

doAir doAirCleanOn Start/Stop compressed Air flow

doFeedBwd doWireFeedReverseOn Start/Stop reversing wire feed

doRemoteActiveOn Remote active Enabled/Disabled

goWireFeeder doWireFeeder1On Enable/Disable wire feeder 1

doWireFeeder2On Enable/Disable wire feeder 2



doAnalogOn Wirefeed & Voltage referencecontrolled from FP instead of welddata number.

Rel_Wire doReleaseWireOn Execute a current pulse to burn ofthe wire if frozen in weld pole.

doTouchSenseActive doTouchSenseOn Turns on the possibility to searchusing wire or gas cup. Used withsearch instr

goSchedule goWeldDataNumber Recalls a complete set of welddata

aoMigVoltRef aoWeldVoltageRef Value of Voltage reference. Onlyused if AnalogOn is enabled.

aoMigWfRef aoWireFeedSpeedRef Value of Wire feed speed reference. Only used if AnalogOn is enabled.

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Signals in

This table lists examples of signals from W82 to robot

ABB ESAB Description

diWeldEst diWeldingActive This signal indicates that the welding equipment I occupied withwelding

diArcEst diArcEstablished This signal will be activated whenthe arc is established at a weldstart.

diTouchSenseContact diTouchSenseResponse This signal indicates contact withwire or gas cup if TouchSenseOnis enabled.

diRemoteActive diRemoteActive Indicates that remote active is on.

diWF1Selected diWireFeeder1Active Wire feeder 1 active.




diError1 diErrorType1 See U82 manual for future information regarding the error bit mask








diWduError diWDUErrorActive If active there is an error in theWeld Data Unit.

diPsError diPSErrorActive If active there is an error in thePower Source

diWfError diWFErrorActive If active there is an error in theactive Wire Feeder.

diGasActive diGasActive Indicates that gas is flowing thrugasflow sensor.

diCollisionDetect diCollisionDetected Indicates robot collision.

diSynergyActive Indicates that synergy is active.

diWireFeedActive Indicates that Wire Feeder is active.

aiVoltage aiMeasuredVoltage This is the measured voltage fromthe welding equipment.

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ABB DescriptionESAB

aiCurrent aiMeasuredCurrent This is the measured current fromthe welding equipment.

aiPower aiMeasuredPower This is the measured power fromthe welding equipment.

giWeldDataNumber This is updated every time therehas been a successful recall of aweld data set.

aiWeldVoltageRef This value indicates which voltagethe welding machine is using

aiWireFeedSpeedRef This value indicates which wirefeed speed the welding machine isusing.

aiSynergicVoltage This value indicates the result ofthe calculations done by the welding equip.

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Process definitions

The following tables lists examples of settings for the system and the equipment.

ARC_SYSTEM

Parameter Value Information

Name ARC1

Use Arc System Properties ARC1

Use Arc Error Handler Default

Induvidual Robot Properties Act

ive

FALSE

ARC_SYSTEM_PROPERTIES


Name ARC1

Units SI_UNITS

Restart On TRUE

Restart Distance 5

Number of retries 3

Scrape On TRUE

Scrape Optional On TRUE

Scrape Width 3

Scrape Direction 90

Scrape Cycle Time 0.2

Ignition Move delay On FALSE

Motion Timeout 3

Weave Sync On TRUE

ARC_ROBOT_PROPERTIES


Name ARC1_T_ROB1

Units SI_UNITS

Restart On TRUE

Restart Distance 5

Number of Retries 3

Scrape On TRUE

Scrape Optional On TRUE

Scrape Width 3

Scrape Direction 90

Scrape Cycle Time 0.2

Ignition Move delay On FALSE

Motion Timeout 3

Weave Sync On TRUE

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ARC_UNITS


Name SI_UNITS

Arc Length units mm

Arc Velocity units mm/s

Arc Feed units mm/s


Name US_UNITS

Arc Length units inch

Arc Velocity units ipm

Arc Feed units ipm


Name WELD_UNITS

Arc Length units mm

Arc Velocity units mm/s

Arc Feed units m/min

ARC_EQUIPMENT


Name ARC1_EQUIP_T_ROB1

Welder Type StandardIO

Loaded in Robot T_ROB1

Use Arc Equipment Class stdIO_T_ROB1

Use Arc Equipment Properties MIG1

ARC_EQUIPMENT_CLASS


Name stdIO_T_ROB1

Equipment Class File Name awEquipSTD

Path RELEASE:/options/arc/WeldEquip/Code/

ARC_EQUIPMENT_PROPERTIES


Name MIG1

Use Arc Equipment IO DI MIG1

Use Arc Equipment IO DO MIG1

Use Arc Equipment IO AO MIG1

Use Arc Equipment IO AI MIG1

Use Arc Equipment IO GO MIG1

Preconditions ON TRUE

Ignition On FALSE

Heat On FALSE

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Parameter InformationValue

Fill On FALSE

Burnback On FALSE

Burnback Voltage On FALSE

Rollback On FALSE

Rollback Wirefeed On FALSE

Autoinhibit On FALSE

Welder Robot TRUE

Heat As Time FALSE

Override On FALSE

Schedport Type 3

Arc Preset 0.2

Ignition Timeout 2

Weld Off Timeout 10

Time to feed 15mm wire 0.33

ARC_EQUIPMENT_DIGITAL_INPUTS


Name MIG1

ManFeedInput TRUE

WeldInhib TRUE

WeaveInhib TRUE

TrackInhib TRUE

SupervInhib TRUE

StopProc TRUE

ArcEst diArcEstablished

ArcEstLabel TRUE

ArcEst2 TRUE

ArcEstLabel2 TRUE

WeldOk diWeldingActive

WeldOkLabel TRUE

VoltageOk TRUE

VoltageOkLabel TRUE

CurrentOK TRUE

CurrentOKLabel TRUE

WaterOk siWater

WaterOkLabel TRUE

WirefeedOk siWire

WirefeedOkLabel TRUE

GasOK siGas

GasOkLabel TRUE

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Parameter InformationValue

GunOk NO_SIGNAL

GunOkLabel TRUE

WirestickErr TRUE

WirestickErrLabel TRUE

USERIO1 TRUE

USERIO1Label TRUE

USERIO2 TRUE

USERIO2Label TRUE

USERIO3 TRUE

USERIO3Label TRUE

USERIO4 TRUE

USERIO4Label TRUE

USERIO5 TRUE

USERIO5Label TRUE

ARC_EQUIPMENT_DIGITAL_OUTPUTS


Name MIG1

AWError doQuickStop

GasOn doGasPurgeOn

WeldOn doWeldOn

FeedOn doWireFeedOn

FeedOnBwd doWireFeedReverseOn

SchedStrobe TRUE

ProcessStopped TRUE

SupervArc TRUE

SupervVolt TRUE

SupervCurrent TRUE

SupervWater TRUE

SupervGas TRUE

SupervFeed TRUE

SupervGun TRUE

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ARC_EQUIPMENT_ANALOG_OUTPUTS


Name MIG1

VoltReference aoWeldVoltageRef

FeedReference aoWireFeedSpeedRef

CurrentReference TRUE

ControlPort TRUE

VoltReference2 TRUE

FeedReference2 TRUE

ControlPort2 TRUE

ARC_EQUIPMENT_ANALOG_INPUTS


Name MIG1

VoltageMeas aiMeasuredVoltage

CurrentMeas aiMeasuredCurrent

ARC_EQUIPMENT_GROUP_OUTPUTS


Name MIG1

SchedulePort goWeldDataNumber

ModePort TRUE

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Cross reference Integrated

This table lists examples of cross references for W82 integrated.

Robot W82

Signal Name Type Adress Signal Name Type Byte Bit

doWeld DO 0 Weld On IN 0 0

doQuickStop DO 1 Quick Stop IN 0 1

doEmStop DO 2 Emerg. Stop IN 0 2

doFeed DO 3 Inching IN 0 3

doGas DO 4 Gas Purge IN 0 4

doAir DO 5 Clean IN 0 5

doFeedBwd DO 6 Inch Reverse IN 0 6

Remote Active IN 0 7

goWireFeeder GO 811 Wire Feed 14 IN 1 03

Analog Active IN 1 4

Not Used IN 1 5

Release Wire IN 1 6

doTouchSenseActive DO 15 Touch Sense IN 1 7

goSchedule GO 1623 Weld Data Number IN 2 07

… GO 2431 <reserved> IN 3 07

3239 <reserved> IN 4 07




6479 Voltage Low Byte IN 8 07

Voltage High Byte IN 9 07

8095 Wire Feed Speed Low Byte IN 10 07

Wire Feed Speed High Byte IN 11 07

diWeldEst DI 49 Weld Busy OUT 0 0

diArcEst DI 48 Arc Acknowledge OUT 0 1

diTouchSenseContact DI 50 TouchSense

Response

OUT 0 2

51 Remote Active OUT 0 3

diWF1Selected DI 52 WFU 1 Active OUT 0 4




diError1 DI 56 Error Type 1 OUT 1 0





- 30 -cr09_02

W82Robot

BitByteTypeSignal NameAdressTypeSignal Name




diWduError DI 64 Error WDU OUT 2 0

diPsError DI 65 Error PS OUT 2 1

diWfError DI 66 Error WFU OUT 2 2

0 <not used> OUT 2 3

0 Gas Active OUT 2 4

diCollisionDetect DI 69 Collision Detect OUT 2 5

0 Synergy Active OUT 2 6

0 Inching Active OUT 2 7

aiVoltage AI 07 Voltage Low Byte(Measured) OUT 3 07

815 Voltage High Byte(Measured) OUT 4 07

aiCurrent AI 1623 Current Low Byte(Measured) OUT 5 07

2431 Current High Byte(Measured) OUT 6 07

aiPower AI 3239 Power Low Byte(Measured) OUT 7 07

4047 Power High Byte(Measured) OUT 8 07

Weld Data Number OUT 9 07

Voltage Low Byte(SINT) OUT 10 07

Voltage High Byte(SINT) OUT 11 07

Wire Feed Speed Low Byte(USINT) OUT 12 07

Wire Feed Speed High Byte(USINT) OUT 13 07

Synergic Voltage Low Byte(SINT) OUT 14 07

Synergic Voltage High Byte(SINT) OUT 15 07

- 31 -cr09_02

Cross reference Anybus

This table lists examples of cross references for W82 Anybus.

ABB W82

Signal Name Type Adress Signal Name Type Byte Bit

doWeldOn OUT 0 Weld On IN 0 0

doQuickStop OUT 1 Quick Stop IN 0 1

doEmergencyStop OUT 2 Emerg. Stop IN 0 2

doWireFeedOn OUT 3 Inching IN 0 3

doGasPurgeOn OUT 4 Gas Purge IN 0 4

doAirCleanOn OUT 5 Clean IN 0 5

doWireFeedReverseOn OUT 6 Inch Reverse IN 0 6

doRemoteActiveOn OUT 7 Remote Active IN 0 7

doWireFeeder1On OUT 8 Wire Feed 1 IN 1 0




doAnalogOn OUT 12 Analog Active IN 1 4

doReleaseWireOn OUT 14 Release Wire IN 1 6

doTouchSenseOn OUT 15 Touch Sense IN 1 7

goWeldDataNumber OUT(GO) 1623 Weld Data Number IN 2 07

aoWeldVoltageRef OUT(AO) 6479 Voltage Low Byte IN 8 07

aoWeldVoltageRef Voltage High Byte IN 9 07

aoWireFeedSpeedRef OUT(AO) 8095 Wire Feed Speed Low Byte IN 10 07

aoWireFeedSpeedRef Wire Feed Speed High Byte IN 11 07

diWeldingActive IN 0 Weld Busy OUT 0 0

diArcEstablished IN 1 Arc Acknowledge OUT 0 1

diTouchSenseResponse IN 2 TouchSense Response OUT 0 2

diRemoteActive IN 3 Remote Active OUT 0 3

diWireFeeder1Active IN 4 WFU 1 Active OUT 0 4




diErrorType1 IN 8 Error Type 1 OUT 1 0








diWDUErrorActive IN 16 Error WDU OUT 2 0

- 32 -cr09_02

W82ABB

Signal Name BitByteTypeSignal NameAdressType

diPSErrorActive IN 17 Error PS OUT 2 1

diWFErrorActive IN 18 Error WFU OUT 2 2

diGasActive IN 20 Gas Active OUT 2 4

diCollisionDetected IN 21 Collision Detect OUT 2 5

diSynergyActive IN 22 Synergy Active OUT 2 6

diWireFeedActive IN 23 Inching Active OUT 2 7

aiMeasuredVoltage IN(AI) 2439 Voltage Low Byte(Measured) OUT 3 07

aiMeasuredVoltage Voltage High Byte(Measured) OUT 4 07

aiMeasuredCurrent IN(AI) 4055 Current Low Byte(Measured) OUT 5 07

aiMeasuredCurrent Current High Byte(Measured) OUT 6 07

aiMeasuredPower IN(AI) 5671 Power Low Byte(Measured) OUT 7 07

aiMeasuredPower Power High Byte(Measured) OUT 8 07

giWeldDataNumber IN(GI) 7279 Weld Data Number OUT 9 07

aiWeldVoltageRef IN(AI) 8095 Voltage Low Byte(SINT) OUT 10 07

aiWeldVoltageRef Voltage High Byte(SINT) OUT 11 07

aiWireFeedSpeedRef IN(AI) 96111 Wire Feed Speed Low Byte(USINT) OUT 12 07

aiWireFeedSpeedRef Wire Feed Speed High Byte(USINT) OUT 13 07

aiSynericVoltage IN(AI) 112127 Synergic Voltage Low Byte(SINT) OUT 14 07

aiSynericVoltage Synergic Voltage High Byte(SINT) OUT 15 07

S0740 800 220/E20130308/P34© ESAB AB 2013

- 33 -cr09f2

SERVICE INSTRUCTIONS

What is ESD?

A sudden transfer or discharge of static electricity from one object to another. ESDstands for Electrostatic Discharge.

How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous topeople. ESD damage occurs when an ungrounded person or object with a staticcharge comes into contact with a component or assembly that is grounded. A rapiddischarge can occur, causing damage. This damage can take the form of immediatefailure, but it is more likely that system performance will be affected and thecomponent will fail prematurely.

How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented frombuilding up on you or on anything at your work station, then there cannot be anystatic discharges. Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics)generate and hold static charge, so you should not bring unnecessary nonconductiveitems into the work area. It is obviously difficult to avoid all such items, so various means are used to drain offany static discharge from persons to prevent the risk of ESD damage. This is doneby simple devices: wrist straps, connected to ground, and conductive shoes.

Work surfaces, carts and containers must be conductive and grounded. Use onlyantistatic packaging materials. Overall, handling of ESD-sensitive devices should beminimized to prevent damage.

CAUTIONSTATIC ELECTRICITY can damage circuitboards and electronic components.

� Observe precautions for handling electrostatic-sensitive devices.

� Use proper static-proof bags and boxes.ESD

SPARE PARTS

The spare parts list is published in a separate document that can be downloadedfrom the Internet: www.esab.com

Product Filename

Aristo W82 0459 839 038

Ordering spare parts

Spare parts may be ordered through your nearest ESAB dealer, see the last page ofthis publication.

www.esab.com

110915© ESAB AB

ESAB subsidiaries and representative offices

Europe

AUSTRIAESAB Ges.m.b.H Vienna-Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

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ESAB international AB Gothenburg Tel: +46 31 50 90 00 Fax: +46 31 50 93 60

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North and South America

ARGENTINACONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

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Asia/Pacific

AUSTRALIAESAB South PacificArcherfield BC QLD 4108Tel: +61 1300 372 228Fax: +61 7 3711 2328

CHINAShanghai ESAB A/PShanghaiTel: +86 21 2326 3000Fax: +86 21 6566 6622

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UNITED ARAB EMIRATESESAB Middle East FZEDubai Tel: +971 4 887 21 11Fax: +971 4 887 22 63

Africa

EGYPTESAB Egypt Dokki-CairoTel: +20 2 390 96 69 Fax: +20 2 393 32 13

SOUTH AFRICAESAB Africa Welding & Cutting LtdDurbanvill 7570 - Cape TownTel: +27 (0)21 975 8924

DistributorsFor addresses and phonenumbers to our distributors inother countries, please visit ourhome page

www.esab.com

esab - abb robot integration connection..... 9 w82 devicenet ..... 10 devicenet network..... 10 tap...

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