INTEGRATION GUIDE 1920870 1826 EN A3 A7 MIG Welder
CONTENTS 3.1 3.2 3.3 3.4 3.5 3.6 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 3 Integration step by step. . . . . . . . . . . . . . . . . . . ................................................. 3 Hardware installation. . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 5.1.10 TouchSensorToolSel....................................................................
INTRODUCTION 2. The A3 MIG Welder is a complete welding system for robotic welding applications. To ensure safe and efficient integration of the welding system, follow these simple steps: This guide, together with the A3 MIG Welder operating manual, instructs you on how to set up the system and perform the necessary cable connections and setup configuration to get the system running. 1.
3. HARDWARE INSTALLATION 3.1 Procedures before use 3.2 System overview The product is packed in specially designed transport cartons. Unpack the products from the cartons, and check that they have not been damaged during transportation. Check that the contents are complete, and nothing is missing. Fieldbus The product’s packaging material is recyclable. INTEGRATION GUIDE When moving the welding machine, never pull it by the welding-gun or other cables.
3.3 Power source The power plug The power source comes without a plug for connection to the electrical grid. Attach a plug suitable for your power-supply standard to the power cable. Check the connections, attach the plug to a socket, and switch the electrical power on from the welding power source to verify that the machine works properly. Place the machine on a sturdy, level surface that is dry and will not allow dust or other impurities to enter the machine´s cooling air flow.
3.4 Wire feeder Use a mounting bracket to mount the wire feeder securely on the robot arm. See the illustrated instructions included in the product delivery package. Filler wire Connect the wire liner to the filler wire inlet on the rear of the wire feeder. Connect the other end of the wire liner to the wire drum or spool and run the wire up to the wire feeder either manually or by using wire inch functionality at the wire drum. Peripheral connector A. B. C. D. E. F. G.
3.6 Interconnection cable set The collision sensor is an external device that protects the torch neck from bending and being damaged. It is integrated into the mount between the robot arm and the welding torch. The sensor sends a signal to the robot to stop welding when a collision is detected at the welding head. The interconnection cable set comprises several cables and hoses wrapped in a plastic spiral sleeve.
3.7 Fieldbus communication 3.6.2 Welding cable The welding cable delivers welding power from the power source to the welding head. At the wire feeder, connect the cable to the screw terminal on the front of the unit. At the power source, connect the cable to the (+) connector at the rear of the power source unit. This welding system supports DeviceNet communication Table 3.
SYSTEM CONFIGURATION This section describes the settings that are typically made once or that are otherwise necessary for integration to be completed successfully. It does not describe those settings that affect welding quality and are modified based on the welding operation. For more information on the operation-based settings, see the A3 MIG Welder Operating manual. Use the control panel and the DIP switches to perform the system configuration within the integration.
4.2 Configure DeviceNet fieldbus Watchdog on/off Baud rate Mac ID Use the DIP switches to set the watchdog on and off. The robot must support the watchdog feature. Use the DIP switches to select the baud rate of the fieldbus communication according to the capability of the robot Use the DIP switches to select the Mac ID (slave address) to be used in the communication with the robot.
4.3 Power up the system Enter to the setup menu in the control panel to configure the power source. 4.4 Configure welding cable compensation Adjust the CAL parameter in the setup menu to set the welding cable compensation. Set the cable compensation for voltage losses in the welding cables. Scaling formula Example The scaling uses the formula By means of its specification one robot uses the value range 0-1023 for adjusting the welding voltage. The voltage range in the welding system is 10.0-48.0 V.
5. DIGITAL ROBOT INTERFACE 5.1 Control functions Table 6.1: Control functions in the A7 MIG Welder system Value range Control values WireFeedSpeed 16 10 250 0.1 m/min Voltage 16 100 480 0.1 V FineTuning 16 0 100 0.1 MemoryChannel 8 0 89 1 Control signals SimulationMode 1 StartWelding 1 WireInch 1 WireRetract 1 GasBlow 1 TouchSensorToolSel 1 TouchSensorOn 1 OnlineControl 1 Watchdog 1 ErrorReset 1 5.1.
5.1.5 SimulationMode This 16-bit function controls the fine tuning of the synergic voltage for all processes except the MIG process. For the MIG process the Voltage value is used instead. The value is given in scaled or non-scaled mode, depending on the user setup. The fine tuning is scaled using the robot scaling value. The range of the fine-tuning value depends on the selected process. In non-scaled mode, 1-MIG process: • The minimum setup value is 0 (-9.0). • The maximum setup value is 180 (9.0).
5.1.11 TouchSensorOn 5.1.13 Watchdog This signal function feeds the welding wire backwards. The wire is fed at the speed of 1.0 m/min for 3 seconds and then stepped to 5.0 m/min. • 0 = Wire retract off • 1 = Wire retract on This signal function sets the touch sensor power source and the touch detection device to be on. The touch voltage depends on the configuration. For more information, see A3 MIG Welder Operating manual.
5.2 Status functions Table 5.2 Status functions in the A3 MIG Welder system Step Max. Bits Min. Function Units Value range Status values WeldingCurrent 16 0 1000 1 1A WeldingVoltage 16 0 1000 1 0.1 V ErrorNumber 8 0 255 1 Status signals Ready 1 PowerSourceReady 1 CycleOn 1 ArcOn 1 TouchSensed 1 Error 1 CollisionDetected 1 5.2.1 WeldingCurrent 5.2.2 WeldingVoltage This 16-bit function represents the average welding current measured during the process.
5.2.6 CycleOn 5.2.9 Error This 8-bit function represents a non-zero error code if there is a warning or an error active in the system. Otherwise the value is zero. The error number is an enumeration that represents the reason for the error. Refer to the A3 MIG Welder operating manual for more information about reasons for errors. See also the description for the Error status signal.
5.4 Timing diagrams Table size = 8 bytes Control (Robot -> Welder) Status (Welder -> Robot) 5.4.
Symbol Description Min Typical Max Units A Arc off time 51 51 94 ms B Cycle off time 347 * Post-gas time + 10 Pre-gas time + 44 ms INTEGRATION GUIDE * The minimum cycle-off time is determined by power-source shutdown time, when the post-gas time is less than 300 ms. 5.4.
5.4.
5.4.5 Wire inch and retract timing 5.4.6 Touch sensor timing Startup timing Startup timing A B Wire fe eding off Start Description Feeding 1.0 m/ min Min Touch sensor Feeding 5.0 m/min Typical Max Units Symbol Power off RI Startup phase Description Min A Startup response time * 3 ms A Startup response time B Wire feeder motor acceleration time ** 3 s B Power-on cycle time (voltage setup time) * The wire feeder reacts on controls immediately after startup.
Touch response timing 5.4.
And you know. userdoc.kemppi.
