Product Manual Welding equipment and wire feed system A314E/316E/324E-L IRC5 3HEA 801219-002 2005-05
The information in this document is subject to alteration without prior notice and should not be regarded as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes no responsibility for errors that may occur in this document. ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this document or the software or hardware described in this document.
Contents Welding equipment and wire feed system 3HEA 801219-002 2005-06 1 Introduction 1 2 Safety 3 2.1 General 3 2.2 Safety insrtructions 3 2.2.1 DANGER – Ensure that the main power switch is turned off. 5 2.2.2 WARNING – The unit is sensitive to ESD. 6 3 Technical Description 3.1 General 7 3.2 Welding equipment 8 3.3 Principle design 3.3.1 Robot Welding System 9 10 3.4 Components 13 3.5 Wire feed systemA314E/316E/A324E-L 3.5.1 General 3.5.2 Wire feed unit 3.5.
5 Maintenance 5.1 Wire feed unit 5.1.1 Before commissioning 6 Repair 35 35 36 37 6.1 Changing wire feed motor 6.1.1 Before commissioning 37 38 7 PIB Process Interface Board 39 7.1 General 7.1.1 Overview 39 40 7.2 Technical Specification 7.2.1 Mechanical Data 7.2.2 Electrical Data 7.2.3 Environmental Data 41 41 41 42 7.3 Safety 7.3.1 Personal Safety 7.3.2 Machine safety 7.3.3 Collision Sensor 7.3.4 Electronics 43 43 44 45 47 7.4 Versions and options 7.4.1 Voltage versions 48 48 7.
Appendix A: Appendix B: 65 A - 1:Configuration parameters 65 A - 2:Table - Configuration parameters. 68 A - 3:Loading of configuration file 71 73 B - 1:System accuracy: verification and trimming possibilities.
iv 3HEA 801219-002 2005-05
Introduction 1 Introduction About this manual This manual provides information on: • Mechanical/electrical installation. • Operation • Repair/maintenance. Read through all included manuals carefully, especially the sections about safety before you start to unpack, install and use the station.
Introduction 2 3HEA 801215-001 Rev.
Safety 2 Safety 2.1 General A robot is heavy and extremely powerful regardless of its speed. A stoppage or longer stop can be followed by rapid, dangerous movements. Even if the robot's pattern of movement is predetermined, an external signal can affect the movement sequence, resulting in unanticipated movement. It is therefore important that all safety instructions are observed when entering a safety supervised area. 2.
Safety Reference document Document Described in: Related safety instructions. AW System manual, chapter introduction and safety Warning symbols (signals) Symbol explanations The different types of warnings are set out in the following chapters according to the table below: Symbol Name Meaning Danger Warning that serious or life-threatening personal injury and/or serious damage to the product will occur if the instructions are not followed.
Safety DANGER – Ensure that the main power switch is turned off. 2.2.1 DANGER – Ensure that the main power switch is turned off. Description Work with high voltage entails a potential lethal hazard. Persons subjected to high voltages can suffer heart failure, burns or other serious injuries. To avoid such injuries, never begin a job without first eliminating the risks to safety. These are described below. Elimination Action 1. Turn off the main power switch at the control module. 2.
Safety WARNING – The unit is sensitive to ESD. 2.2.2 WARNING – The unit is sensitive to ESD. Description ESD (electrostatic discharge) is the transfer of electrostatic charges between two objects with varying charges, either through direct contact or through an electrical field. The discharge contains very little electricity and is therefore not hazardous to humans, however, electronics can be damaged by the high voltages. Elimination Action Info/Illustration 1. Use an ESD bracelet.
Technical Description Principle design 3 Technical Description 3.1 General The welding equipment A314E/316E/A324E-L (E for Extended range) is adapted for the control from the IRB 140/1400/2400 robot with the IRC5 control system. Together with the AW software in the robot and the PIB process interface the system has the following characteristics: Working area With an optical tachometer, with a high frequency resolution in the wire feed unit, a stable wire feed is obtained, across the speed range: 0.
Technical Description Welding equipment 3.2 Welding equipment Intended for The welding equipment should only be used for MIG/MAG welding and according to instructions in the documentation. With all other usage of the equipment. ABB disclaims all responsibility and any claims for damages or warranty undertakings The equipment is not intended for use in explosive environments.
Technical Description Principle design 3.
Technical Description Robot Welding System 3.3.1 Robot Welding System Welding power source LRC 430 5 A314E/A316E/ A324E-PIB IRC5 PIB Option Option Smartac TC Bullseye LRC CANbus 1 2 3 4 Figure 2.
Technical Description Principle design Welding power source MigRob 500 5 A314E/A316E A324E-PIB IRC5 PIB Option Option Smartac CANbus TC Bullseye M igRob 500 1 2 3 4 Figure 3.
Technical Description Robot Welding System Welding power source RPB A314E/A316E A324E-PIB 5 IRC5 Option RPB CANbus Device Net TC BullsEye PIB Option Smartac 1 2 3 4 Figure 4.
Technical Description Principle design 3.4 Components General The welding equipment can include the following components: • Wire feed unit mounted on the robot arm and fitted with a Euro-socket for connecting the welding torch. • Attachment for the wire feed mechanism and cables. • Hoses for gas, water and compressed air, as well as cables for signal and power supplies. • Cable for the welding current. • Cable for the power source • Welding power source Overview 4 5 3 2 1 Figure 5.
Technical Description Wire feed systemA314E/316E/A324E-L 3.5 Wire feed systemA314E/316E/A324E-L 3.5.1 General There are two options of wire feed systems: • Bobbin • Marathon pac. A314E/316E/A324E-L should be used for gas arc welding. It is intended to be mounted directly on the robot IRB 1400/IRB1600/IRB 2400L, which results in a short cable bundle and a good wire feed, furthermore, a smaller floor area is required. Bobbin If a bobbin is used it may be necessary to adjust the brake hub.
Technical Description Principle design 3.5.2 Wire feed unit 2 4 1 5 1 3 3 j5000841 6 Figure 6. Wire feed unit Pos Description Pos Description 1 Upper feed roller 4 Motor 2 Adjuster screw 5 Inlet guide 3 Lower feed roller 6 Screw Feed rollers Wire is fed using two pairs of feed rollers, see Figure 8, which are linked to each other. The two upper rollers (1) are spring-loaded. The power from the motor is transferred to the rollers via a pinion on the motor shaft.
Technical Description Control and indicating devices on the wire feed unit 3.5.3 Control and indicating devices on the wire feed unit Type Description WIRE FEED Switch for manual wire feed. RESET (Option) Switch for resetting the torch collision sensor. AIR AIR connection to the welding torch. IN Connection for water (blue hose). Applies to water cooled torches. OUT Connection for water (red hose). Applies to water cooled torches. Euro-socket Connection for the welding torch.
Installation Connection of welding equipment 4 Installation 4.1 Connection of welding equipment All personnel working with the welding robot system must be fully conversant with the applicable safety instructions that are available. The cables and hoses are connected as follows. For more information, see Figure 12. Cable/Hose Type Connection Feeder cable 1 (signal cable) A314E/316E/ 324E-L Foot of the robot - Control module 23-pole connection at both ends. Figure 8.
Installation Overview Cable/Hose Type Connection Air in PVC-slang D14/8 Connected to the compressed air supply, system pressure, approx., 6 bar. Wire guide input (1) for bobin for Marathon Pac Welding cable (2) 1 95 m2 2 Figure 11. Wire feed unit Current cable Connect the current cable from the wire feed unit to the power source. 4.1.1 Overview 1 8 2 6 5 4 j5000843 7 3 Figure 12.
Installation Circuit diagram 4.1.2 Circuit diagram 504806c01 Figure 13.
Installation Connection of feeder cables 4.1.3 Connection of feeder cables Feeder cable 1, signal cable (FEED 1) Block diagram 2 XP106 PIB TB6 FEED 1 1 3 Figure 14. Block diagram Feeder cable 1 Pos Description Pos 1 Wire feed unit, circuit diagram see Figure 13. 3 2 Connection Description Control module Feeder cable 1 EXT. FEED 1 A XP106 xxx xxx xxxx B 503281A1 A314/E316/A324E-L IRB-CS Robot foot Figure 15. Feeder cable 1, A314E/A316E/A324E-L.
Installation Connection of feeder cables Signal description Signal description for feeder cable 1 A314E/A316E/A324E-L: Signal description A B Color Gun Reset Gun Crash Sensor Current Sensor Water Flow Sensor Gas Flow Sensor Tacho + Tacho - (Encoder Tacho input) Manual Wire Feed 24 VDC Supply 0 VDC (24 VDC) / Encoder Tacho Common Motor Temperature Auxiliary Motor ADM Tacho (+) Encoder Tacho input ADM Tacho (-) +5V Encoder Tacho Spare (not used) B B N N P P D D F F K K L L A A J J C
Installation Connection of feeder cables Feeder cable 2, power cable (FEED 2) Block diagram 2 1 2 XP105 PIB TB5 FEED 2 3 1 Figure 16. Block diagram Feeder cable 2 Pos Description Pos 1 Wire feed unit, circuit diagram see Figure 13. 3 2 Connection Description Control module Feeder cable 2 EXT. FEED 2 xxx xxx xxxx A B XP105 503284A A314E/A316E/A324E-L IRB-CP Robotfoot Figure 17. Feeder cable 2, A314E/A316E/A324E-L.
Installation Connection of feeder cables Signal description Signal description for feeder cable 2 A314E/A316E/A324E-L Signal description A B Color Motor + A A White Motor + B B Brown Motor + C C Green Motor - D D Yellow Motor - E E Gray Motor - H H Pink Pneumatic Spatter Cleaning (42/115VAC) G G Blue Gas Valve (42/115 VAC) K K Red Arc Voltage Gun M M Black Smartac 1 L L Violet Aux Motor Supply (42/115 VAC phase) J J Gray/Pink Aux Motor Supply (42/115 VAC com
Installation Configuration of Welding Equipment 4.2 Configuration of Welding Equipment 4.2.1 General On delivery the equipment is configured according to the applicable configuration data which is stored on the disk that comes with the delivery. The data can be read and modified by way of the robot FlexPendant. 4.2.2 Installation disk As the disk is unique for the equipment supplied it should be stored in a safe place.
Installation Connection of Welding Power Sources 4.3 Connection of Welding Power Sources 4.3.1 Welding power source LRC 430 Block diagram Power source LRC/MigRob is connected to terminal A12.X2 on the control module. 1 2 A12.X2 PIB TB3 3 Figure 18. Block diagram LRC/ MigRob Pos Description Pos Description 1 Welding power source 3 Control module 2 Terminal Control cable B 6 A A Cable LRC Signal Ext. 3HEA800788 - 001 XXX - XXX 1 Cable LRC Signal Ext.
Installation Welding power source LRC 430 Signaldescription Signal description for control cable LRC/MigRob: Signal description Part/Core A B Spare 1 D 1 Spare 2 E 2 Ext. enable 3 F 3 Ext. enable 4 C 4 Welding minus (OKC) 5 M 5 Welding measure - (Ext.) 6 J 6 Welding measure + (Ext.) 7 H 7 Shield SH SH PE Connecting CAN-bus/ DeviceNet Action 1. Connect the CAN-bus from welding power source to output X107 on the control module.
Installation Welding power source RPB 4.3.2 Welding power source RPB Block diagram Power source RPB is connected to terminal XS107 on the control module. .. 2 XS107 PIB TB3 1 3 Pos Description Pos Description 1 Welding power source 2 Control module 2 Terminal Control cable B A XP107 RPB EXT. CABLE PS RPB 505826-8XX xxx xxx xxxx 503218C1 XS weld Smartac Figure 21.
Installation Reference documents Signaldescription Signal description for control cable RPB: Signal description Part/Core A B 0V wh (par 1) B B Start PS bu (par 1) C E Ref. wh (par 2) A bridged with D - 0V or (par 2) D bridged with A A WELD-/WELDOBJ. F - Shield SH NC XS WELD 4.3.3 Reference documents Document Document ID.
Installation Installation of accessories 4.4 Installation of accessories 4.4.1 Cooling unit OCE 2 C The cooling unit is included in welding torch set PKI 500R and Binzel WH 455D Connect the cable bundle Connect the cable bundle to the cooling unit as follows: • Red water hose to the cooling unit’s return connection IN. • Blue water hose to the cooling unit’s feed connection OUT. • Air hose to the compressed air supply. • Gas hose to the gas cylinder.
Installation Cooling unit OCE 2 Action 2. Connect the cable from the cooling unit to relay A12.K11 inside the control module. Info/Illustration 2 Figure 23. Terminals in control module Fill the cooling unit with water See the separate manual under section “Cooling unit” for a description of the cooling unit. Action 1. Fill the cooling unit with water and any anti-freeze. Distilled water is recommended 2.
Installation Torch cleaner 4.4.2 Torch cleaner Action Info/Illustration 1. Cable entry can easily be made through the cover on the control module for process options. 1 Figure 24. Cable inlets on control module 2. Connect the Torch cleaner to terminal A12.X1 2 Figure 25. Terminals in control module Block diagram . 2 A12.X1 PIB TB4 1 3 Figure 26.
Installation Torch cleaner A B A12.X1 EXT. CABLE TCH-CLEAN xxx xxx xxxx 503293A01 Cable for Torch cleaner Figure 27. Cable for torch cleaner Signal description Pos Description Pos Description A Torch cleaner B Control module Signal description for Torch cleaner.
Installation Adjusting the brake hub (bobbin) 4.5 Adjusting the brake hub (bobbin) If a bobbin is used it may be necessary to adjust the brake hub. At high wire speed and when the bobbin is new, the wire can roll off when the wire feed unit stops. To correct this, change the brake hub’s preset value of 5 kpcm (= 0.5 Nm). Action Info/Illustration 1. Localize the brake hub (1). 1 2. Turn the knob (2) on the brake hub until the arrows are in line with each other (locked bobbin position). 3.
Installation Before commissioning 4.6 Before commissioning ! All guards and all safety equipment must be positioned before the station is commissioned. This should be especially observed in connection with maintenance and service. Before commissioning, the following should be checked: Action 34 1 Check that no tools have been forgotten. 2 Check that the fixture and workplace are well secured. 3 Check that all parts and guards are in place and that they are well secured.
Maintenance Wire feed unit 5 Maintenance This work must only be carried out by persons trained in the complete installation, and who are aware of the special risks involved with its different parts. ! Disconnect the mains supply and (if possible) secure the switch before starting work on the equipment. In some cases however, it is necessary to work with the mains supply switched on, special care and safe working methods must be used.
Maintenance Before commissioning Regularly Action Info/Illustration 1. Make a visual inspection of the equipment. • Correct errors, if any, for reliable operation. 2. Purge the inside of the feed unit as necessary by compressed air at reduced pressure. 3. Clean the grooves in the feed rollers and the bore of the outlet nozzle. To ensure satisfactory wire feeding the grooves in the feed rollers should be cleaned at regular intervals. 4.
Repair Changing wire feed motor 6 Repair 6.1 Changing wire feed motor 2 4 1 5 1 3 j5000841 6 Figure 29. Wire feed unit Pos Description Pos Description 1 Upper feed roller 4 Motor 2 Adjuster screw 5 Inlet guide 3 Lower feed roller 6 Screw Dismounting Action 1. Release both feed rollers. 2. Remove the drive wheel and the three cap screws. 3. Lift out the motor.
Repair Before commissioning Mounting When replacing or repairing the drive motor the drive motor shaft must be centered to both the feed rollers with a centering device to avoid wear on the cogs and bearings. Action 1. Fit the new motor. 2. Center the motor’s drive shaft to both feed rollers by means of the centering device. 3. Fit the drive wheel and the three cap screws. 4. Fit the two drive rollers. Centering device Designation Order number Centering device 500 332-001 6.1.
PIB Process Interface Board General 7 PIB Process Interface Board 7.1 General The PIB is an I/O unit with integrated wire feed regulator communicating directly with the ABB robot control system IRC5 for control and monitoring of the robot welding. The configuration is done in the same way as for a standard I/O unit. The PIB characteristics are determined by the transfer of configuration parameters for power sources and feed units.
PIB Process Interface Board Overview 7.1.1 Overview 7 6 5 4 3 2 1 0 8 9 10 PIB.wmf 1 11 Figure 30. Terminals on PIB 40 Pos Description Pos id 1 Terminal for power supply and interlocking A121.TB1 2 Terminal for CAN-bus/DeviceNet A121.TB2 3 Terminal for TSC A121.TB4 4 Terminal for wire feed (signal) A121.TB6 5 Terminal for wire feed (motor) A121.TB5 6 Terminal for welding power source A121.TB3 7 Terminal A121.
PIB Process Interface Board Technical Specification 7.2 Technical Specification 7.2.1 Mechanical Data Type Data Dimensions: 257x196x72.5 mm Weight: 2.1 kg Enclosure class: IP 20 7.2.2 Electrical Data Type Description Data Power supply: Figure 31. on page 49 -Transformers Digital outputs: Continuous load/output: max 350 mA Total output load: max 1.6 A, < 70°C Tripping of overload protection per output 370 mA Remark: Regarding capacitive load > 0.
PIB Process Interface Board Environmental Data 7.2.3 Environmental Data 42 Temperature data: Storage Operation According to: Cold: -40ºC, 16 h +5ºC, 2 h.
PIB Process Interface Board Safety 7.3 Safety 7.3.1 Personal Safety Moving parts which according to the EU machinery directives might cause personal injury are interlocked via the robot holding device and emergency circuit. Such functions are: • Manual wire feed • Mechanical cleaning of the torch. Interlocking Figure 37. shows the build-up of the PIB interlocking system.
PIB Process Interface Board Machine safety 7.3.2 Machine safety Collision Detection The Collision detection robot function is set as standard on the A314E/316E/324EL systems. Important! The mechanical safety bracket function on PIB must be deactivated through the connection of +24V to PIB input TB 6.2. A lack of this signal will be interpreted as a collision by PIB and the wire feed will be blocked.
PIB Process Interface Board Collision Sensor 7.3.3 Collision Sensor General The PIB is designed to be used with a welding torch with collision sensor. In normal status the sensor is to supply 24V DC to the PIB input TB6.2. The collision sensor controls the Run Chain relay in the PIB. The relay is of the twopole type and is integrated in the general stop chain (G-stop) of the robot. In normal status the relay is active.
PIB Process Interface Board Collision Sensor Limitations To prevent the PIB remaining in the reset function - due to circuit interruption, for example - and to ensure that a further collision will stop the robot, the reset time is limited to 1 minute. After that the G-stop is interrupted again and the reset procedure must be repeated. What is said above applies both to manual running of the robot and to running by way of the program.
PIB Process Interface Board Electronics 7.3.4 Electronics Design PIB is designed to withstand the short-circuiting of the outputs and overloading of the motor regulator. The overloaded output is switched off. The function resumes when the power supply is switched on again after the power supply to the PIB has first been cut and the overload eliminated. Motor regulator The motor regulator is protected by a current limiter on the drive stage.
PIB Process Interface Board Versions and options 7.4 Versions and options 7.4.1 Voltage versions PIB is available in two voltage versions, see table bellow and Figure 32. for more information. Voltage version Description Ordering no. Wire feed units with voltage supply to the final stage of the feed unit regulator of max. 42V AC/ 10A 501 700-880 005-Low voltage Wire feed units with voltage supply to the final stage of the feed unit regulator of max. 115V AC/ 3.
PIB Process Interface Board Voltage versions Transformers There are transformers available for the particular voltage. They are to be connected to terminal XT21 for 230V AC/ 3.15A in the control module. . Version Article number Low voltage (LV) 501 714-001 High voltage (HV) 501 714-002 brun/brown gul/yellow 230V 50Hz 28V 3A Uo=28.9V vit/white 0-115V 0-28V 0-28V 0-28-42V orange vit/white 28V 3A S2 Uo=28.9V vit/white gul/yellow 115V 2.7A Uo=118.
PIB Process Interface Board Marking and Version Handling 7.5 Marking and Version Handling Hardware version Figure 32. shows the location and disposition of the article and manufacturing numbers. This marking indicates the hardware version of PIB – not the software one. Extra marking High voltage Low voltage Product for ABB High voltage 006 Low voltage 005 Version number ABB Welding 501 700-881 5601 006-1900 DAT: 2003-08-26 SNR: 1836280 Testing date Serial number Märkning.
PIB Process Interface Board Options 7.6 Options 7.6.1 Smartac smartac på PIB.jpg The unit is an “Add on” unit and is connected to the PIB by way of a 32-pole connector of the Euro type, see Figure 30. smartac.jpg Figure 33. Smartac connected to PIB Figure 34.
PIB Process Interface Board Configuration 7.7 Configuration 7.7.1 General Programmable parameters enable the adaptation to different types of welding equipment. The configuration parameters determine: • the control properties • the scale factors • the offset values • the max. and min. values, etc. 7.7.
PIB Process Interface Board Installation 7.8 Installation 7.8.1 Adaptation to IRC5 control system General PIB includes two program versions, depending on the robot system. Which program version is active is determined by the TB9 jumper. IRC5 Bygling_TB9_överblick.jpg For robot systems from IRC5 the TB9 jumper shall be open (removed or parked on one of the pins). The jumper in this position supports: • The transfer of configuration data from the robot FlexPendant.
PIB Process Interface Board Connecting Cable Shields At delivery All PIB equipment delivered separately or as spare parts is pre-configured for ARCITEC/ LRA and wire feeder A314 (jumper TB9 closed) on delivery. Type of delivery Description Complete system When a complete system is delivered the TB9 position is determined. Spare part or component For use together with IRC5 the jumper is removed and the parameter transfer takes place according to “IRC5” on page 53. 7.8.
PIB Process Interface Board Signal Connections 7.8.3 Signal Connections For more information see Figure 30. on page 40, and Figure 37. on page 59. TB stands for Terminal Block. 7.8.4 Table - Signal Connections TB1, Power Supply and Interlocking Designation Function, Voltage 1 Motor Supply AC Power supply for the motor regulator, interlocked 42V max. for PIB 501700-880 115V max.
PIB Process Interface Board Table - Signal Connections TB2, CAN bus Connection Designation Function, Voltage Out In 1 Sys 0V DC System 0 (=Robot I/O zero 2 CAN Low Serial communic. CAN Low 1 3 Ground DC Ground, screen 4 CAN High Serial communic.
PIB Process Interface Board Table - Signal Connections TB4 Connection to torch cleaner and TCP detector Designation Function, Voltage Out In Explanation 1 24V DC Supply x 2 0V DC Supply, zero x 3 Lubrication Digital 24V DC x Lubrication for cleaning reamer 4 Cleaning Digital 24V DC x Cleaning reamer 5 Wire Cutter Digital 24V DC x Cutting the wire 6 Cleaning finished Digital 24V DC x Cleaning finished 7 Bulls Eye Digital 24V DC x TCP search stop In Explanation TB5 Con
PIB Process Interface Board Table - Signal Connections TB6 Connection 2 to Wire Feed Unit Designation Function, Voltage 1 Gun reset 2 In Explanation 24V DC x Resetting the collision sensor Gun Crash 24V DC x Collision sensor 3 Current Sense 24V DC x Welding current sensor 4 Water Flow 24V DC x Water flow sensor 5 Gas Flow 24V DC x Gas flow sensor 6 NC NC 7 Encoder TG INPUT DC Puls x DC- or AC-tacho/input for encoder tacho 8 Man.
PIB Process Interface Board Elementary Diagram - Power Supply and Interlocking 502540s4c+ 7.8.5 Elementary Diagram - Power Supply and Interlocking Figure 37. Elementary Diagram - Power Supply, safety and Interlocking.
PIB Process Interface Board Manual wire feed with PIB and IRC5 7.9 Manual wire feed with PIB and IRC5 7.9.1 Possibilities and limitations Manual wire feed can be carried out in three different ways: • By pushing in the non-locking push button for manual wire feed on the welding torch or on the front of the wire feed unit. • By activating the function Manual wire feed from the robot's Flexpendant in test mode under: Program window\Arcweld\Manual wirefeed.
PIB Process Interface Board Possibilities and limitations Explanation The table below shows the differences between the methods.: Method Explanation 1 The arc weld function “Manual Wire feed” in the robot is called from PIB. The robot input diMAN_WF is activated. The robot activates the output doFEED with a reference in aoFEED that increases as a function of the time the wire feed button is pressed in. The function is active as long as the button is pressed in. The speed is limited to max. 6 m/min.
PIB Process Interface Board Service and Programming Aids 7.10 Service and Programming Aids 7.10.1 CAN-Assist, art no. 502 800-880 Passive Mode PC based tool that in Passive Mode allows listening to the CAN-bus traffic in the Weld system during the current process. Master Mode In Master Mode, with the connection to the robot master disconnected, the I/Ofunction in the different units in the system can be activated, parameters loaded or changed.
PIB Process Interface Board Diagnostics – Error Handling 7.11 Diagnostics – Error Handling 7.11.1 Light-emitting diodes The PIB is fitted with two light-emitting diodes according to the DeviceNet specification. . Description NS (Network Status), indicates the function of the CAN bus. MS (Module Status), indicates the PIB function. 1 Lysdioder.jpg Light-emitting diode 2 Figure 38.
PIB Process Interface Board In the event of an error on PIB Error Handling Indication Description Green light Indicates correct function Red light Indicates incorrect function Changing light During the initiation phase, which can take a few seconds, the light of the diodes changes. 7.11.2 In the event of an error on PIB In the event of an error on PIB an error message is given to the FlexPendant as a warning to call action, see “Error messages” on page 64.
Configuration parameters Appendix A: A - 1: Configuration parameters The configuration parameters are defined for 3 demands: 1. They should be an integer in order to simplify handling in the microprocessor in the PIB. 2. The integer should be large enough so that the desired accuracy and resolution are obtained. 3. Programming from the robot should be possible to be expressed in actual quantities, for example, 21.4 m/min. for the wire speed, 32.2 V for the welding voltage, etc.
Configuration parameters The conversion factor for the wire feed with AC-tacho: The conversion factor is obtained from k0 =g x n x 100/(p x D x 60) [Hz/m/min.
Configuration parameters Transfer of parameters between the robot and PIB The configuration parameters are sent from the robot's system parameter memory to the PIB each time the system voltage is switched on. If the parameters are equal to those already in the PIB no writing to the PIB is carried out.
Table - Configuration parameters. A - 2: Table - Configuration parameters. The table contains all the parameters defined for PIB. They are shown and can be edited from the robot's FlexPendant. All parameters are not implemented as standard. Parameters that are implemented and which must have the correct value to function correctly are marked by an asterisk and bold type.
Table - Configuration parameters. Parameter name Parameter name Parameter behavior in FlexPendant Parameter range/ denomination *Motor Tacho Conver- MotorTachoConv For AC: 100 Frequency in Hz for 1 {0...65535} sion Factor motor speed quantity. 20650 (Used as standard value) For DC: 10000 Voltage in V for 1 AC (tacho type 0): 0.01 Hz / motor motor speed quantity. speed quantity AC fast (tacho type 2): 0.
Table - Configuration parameters. Parameter name Parameter name Parameter behavior in FlexPendant Parameter range/ denomination *Sensor Search Voltage Valid Limit, Smartac SensorSearchVoltValidLim Defines the lowest allowed search {0...40} V voltage for start of search.
Loading of configuration file A - 3: Loading of configuration file #************************************************************** # # (c) ABB Automation Technologies AB, # Arc Welding Products # # File: ESABMig_FhpE.cfg # Description: # ArcWeld PIB EIO-parameter configuration for PowerSource # ESABMig 400t/500t and WireFeeder A314E/A324E # with DC Pulsed Tacho. # Speed range 0.5 to 30 m/min. # Created: # Written by: # Version 1.0 # 1.
Loading of configuration file 72 3HEA 801219-002 2005-05
System accuracy: verification and trimming possibilities. Appendix B: B - 1: System accuracy: verification and trimming possibilities. Wire feed: Feed unit A314E/316E/A324E-L A check of the wire feed unit's accuracy ought to be carried out by measuring the motor tachometer's pulse frequency and not by measuring the fed wire and time measurement in order to avoid errors, due to wire slip and errors during starting and stopping.
System accuracy: verification and trimming possibilities. Relation between the frequency and wire speed 74 m/min. Hz m/min. Hz m/min.
System accuracy: verification and trimming possibilities. Welding power sources General When using PIB to control the power source with an analog reference (Flexible Mode) the reference characteristics are determined by the parameters: • ProcEquipRefConv (gain), • ProcEquipRefOffset (offset) and • ProcEquipMaxRef (Max): When replacing PIB or the power source the weld result can deviate from previous result depending on the tolerances in the analog circuits in PIB and the power source.
System accuracy: verification and trimming possibilities.
3HEA 801219-002 2005-05
