INTEGRATION GUIDE 1920310 1804 EN A7 MIG Welder 350, 450
CONTENTS 3.1 3.2 3.3 3.4 3.5 3.6 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................. 4 Integration step by step. . . . . . . . . . . . . . . . . . . ................................................. 4 Hardware installation. . . . . . . . . . . . . . . . . . . . . . . . ................................................. 5 3.15 Powering up.............................................................................
6.2.16 ArcOn.. ................................................................................................ 48 6.1.7 PulseBaseCurrent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............................................... 40 6.2.17 GasFlowOk. . ......................................................................................... 48 6.1.8 PulseFrequency.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...........................................
INTRODUCTION 2. The A7 MIG Welder is a complete welding system for automated welding applications. INTEGRATION STEP BY STEP To ensure safe and efficient integration of the welding system, follow these simple steps: This guide, together with the A7 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. INSTALL THE HARDWARE • Make sure that all the components are OK.
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. The welder system supports both gas- and water-cooled torches. An interconnection cable set without cooling hoses is available for gas-cooled torches (see Figure 3.1, “Connection diagram, gas cooled system”).
Fieldbus Figure 3.2: Connection diagram, water-cooled system Figure 3.
3.4 Cooling unit 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. Preferably, situate the machine in a suitable carriage unit so that it is above floor level. • The surface inclination may not exceed 15 degrees. • Ensure the free circulation of cooling air. There must be at least 20 cm of free space in front of and behind the machine for cooling-air circulation.
Filler wire Connect the wire liner to the filler wire inlet connector 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. For a push-pull welding torch, a collision sensor, and other peripheral devices, the wire feeder has a common 10-pin peripheral connector at the front of the wire feeder.
3.6 Welding torch 3.6.1 Mounting 3.6.4 Torch-cleaning with compressed air For the welding torch, the wire feeder is equipped with a Euro MIG torch connector. Push the torch connector into the Euro connector on the wire feeder, and tighten the collar. If you are using a water-cooled torch, connect the redand-blue marked cooling hoses to the corresponding hoses coming from the cooling unit in the interconnection cable set. For details, see Subsection 3.8.5, “Cooling hoses”.
3.7 Collision sensor The default way to use the touch sensor of the welder system is to use the welding wire as the touch tool. Alternatively, you can use the gas nozzle of the welding torch. If the gas nozzle is used for touch-sensing, connect pin F of the peripheral connector to the gas nozzle, using an extra wire (see Figure 3.7, “Touch sensor gas nozzle connection”). For instructions on how to configure the touch sensor, see the A7 MIG Welder Operating manual.
3.8 Interconnection cable set The interconnection cable set is available with and without cooling hoses. 3.8.1 The arc measurement cable The arc measurement cable is a part of the arc voltage measurement function, which is used to calibrate the actual arc voltage and power regardless of the welding cable diameter or length. Connect the cable to the arc measurement input connector at the rear of the power source. Connect the cable to the arc measurement output connector at the wire feeder.
3.8.5 Cooling hoses The wire feeder control cable provides power to the wire feeder and transmits the control data between the wire feeder and the robot interface unit. It also contains the touch sensor voltage line from the robot interface unit to the wire feeder. At the power source, the connector must be connected to the back of the robot interface unit. Do not use any other control cable connectors. 3.8.
3.9 Fieldbus communication Ethernet: EtherNet/IP EtherCAT PROFINET Modbus TCP Others: DeviceNet PROFIBUS DP-V1 Modbus RTU Figure 3.13: Installing a fieldbus adapter The choices are enabled by interchangeable Anybus CompactCom M30 modules manufactured by HMS. See the A7 MIG Welder Operating manual for the complete list of modules and their order codes. Table 3.
3.10 Ethernet (web user interface server) Connect the web user interface server to a laptop computer, to another PC, or to a local area network by using a CAT-5 or CAT-6 shielded Ethernet RJ-45 cable. The communication speed of the network is 100 Mbps (100Base-TX) and the maximum length of the cable is 90 m. Both crossover and direct cables are suitable. Both inputs have a separate three-pin connector at the rear of the robot interface unit. The connectors have identical pinout (see Figure 3.
3.12 Touch sensor status fast output In normal operation, the status of the touch sensor is passed to the robot via a fieldbus connection. However, fieldbus bus latency affects the efficiency of operation. To avoid delays, the hardware-based fast output can be used for better response. For connection of fast status output, the robot must have at least one hardware input available. The fast output requires an external 18–36 V power supply.
3.13 I/O device I/O device in the A7 MIG Welder system 1. 2. 3. 4. 5. Fieldbus Web user interface Control cable for I/O device I/O device 4/4 with connections I/O extension card 8/8 with connections The A7 I/O Device 4/4 is an optional digital control device with 4 inputs and 4 outputs. It can be extended by the A7 I/O Extension card 8/8 that has additional 4 inputs and 4 outputs, resulting in the total of 8 inputs and 8.
A7 I/O Device 4/4 with A7 I/O Extension card 8/8 261.5 mm 242.5 (±3) mm 9 11 8 110 mm Ø 6.2 mm 7 Figure 3.18: Box measures and fixing holes 1 2 6 4 5 3 Figure 3.17: I/O device with extension card 1. Aluminum case (IP44) 2. Holes for I/O cables (bunged by default) 3. Strain reliefs for I/O cables 4. Control cable connector 5. Status indicator lamp 6. Input connectors 1-4 7. Output connectors 1-4 8. Extension card 9. Flat band cable for the main card 10. Input connectors 5-8 11.
A7 I/O Device 4/4 main card 1 2 3 A7 I/O Extension Card 8/8 4 5 6 7 1 8 2 3 4 5 6 7 8 9 Figure 3.19: I/O extension card 1. 2. 3. 4. 5. 6. 7. 8. 9. Figure 3.18: I/O device main card 1. Input 1 connector 2. Input 2 connector 3. Input 3 connector 4. Input 4 connector 5. Output 1 connector 6. Output 2 connector 7. Output 3 connector 8. Output 4 connector 9.
The inputs have separate three-pole connectors, the first 4 inputs on the main card and the last 4 inputs on the extension card. The connectors have identical pinout (see Figure 3.20, “Input connector pinout”). The inputs are galvanically isolated from each other and from the other hardware of the I/O device. The inputs have individual short-circuit-protected +24 V DC power supplies, each providing up to 100 mA of continuous current.
3.13.3 Outputs 1 2 3 Figure 3.23: Driving a relay or a valve 1 1 2 2 3 3 Figure 3.24: Interfacing with a PLC Figure 3.22: Output connector pinout 1. Supply out +24V, 100 mA 2. Output signal 3. Supply GND 1 2 The outputs are capable of driving loads up to 100 mA and they are fully compatible with +24 V industrial logic. The output signal is pulled up by a 10 kΩ resistor. See the following figures for connection examples. The output configuration is described in Section 5.4, “Inputs and outputs”.
3.14 Dual wire feeder support Dual wire feeder support in the A7 MIG Welder system Fieldbus 1. 2. 3. 4. 5. 6. Dual wire feeder extension kit Extra control cable Extra welding cable Second wire feeder Web user interface Fieldbus 4 2 The A7 MIG Welder supports two wire feeders, one operational at the time. This feature is enabled by an optional extension kit. The extension kit is installed inside the robot interface unit.
Switch the power source off and install the extension kit into the robot interface unit. Ensure that all the cables are installed properly. Test the system by switching the power source on and selecting the wire feeder between the WF1 and WF2 from the setup panel or between the Wire feeder 1 and Wire feeder 2 from the web user interface. The extension card should indicate the selection by amber LED lights. After successful installation, switch the power source off and close the robot interface unit. 10.
13. Plug the primary wire feeder to the switching card A105 primary outputs (harness X3 to A105 X6 and harness X2 to A105 X3). 16. Plug a bus cable between the switching card A105 input and the mother board A101 output. X2 X2 A101 A101 X2 X2 X2 X3 X2 A105 A102 A105 14. Plug the secondary wire feeder to the switching card A105 secondary outputs. A102 17. Plug a flat band cable between the switching card A105 and the mother board A101. X4 X7 X10 A101 A101 X10 X4 X7 A105 X1 A102 15.
3.15 Powering up 3.14.2 Connect the second wire feeder Before powering up the welding system, check all cable connections. In water-cooled systems with two water-cooled torches the cooling water circulation must be equally distributed into both torches. It is recommended to connect the torches in serial. In parallel the water flow can differ between the torches and may cause damage to the torch. The extension kit includes support for water valves.
ACCESSING THE WEB USER INTERFACE 4.1 Configuring the network settings The web user interface starts up automatically on powerup. However, before one can access the Web UI from the computer connected to the web user interface server, the network settings must be properly configured from the setup panel. Go to the Main menu > Robot > Network settings, and configure the DHCP enabled, IP address, Subnet mask, and Gateway parameters to match your networking environment.
4.2 Opening the web user interface Figure 4.1: Enter the IP address in the network browser Figure 4.2: Welding display page The web user interface now ready for use. © Kemppi Oy 2018 26 A7 MIG Welder INTEGRATION GUIDE Open a network browser on your computer. Enter the IP address of the web user interface server in the address bar – for example, http://10.0.0.20.
SYSTEM CONFIGURATION This section describes the settings that are typically made only 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 on the basis of the welding operation. For more information on the operation-based settings, see the A7 MIG Welder operating manual. Use the web user interface to perform the system configuration within the integration.
5.1.3 Gas sensor settings Gas sensor Set the gas sensor to be ON or OFF, on the basis of the gas flow monitoring requirements of your system. INTEGRATION GUIDE Gas flow sensing level Set the gas flow sensing threshold, in liters per minute. When the gas flow exceeds this level, the system indicates that the gas flow is OK. Gas type (integrated gas sensor) Set the type of the shielding gas used in your configuration. This value must be changed every time the gas type is changed.
5.1.7 Emergency stop settings Interface mode Fast output polarity Consult Section 5.2, “The digital robot interface.” If you have connected the touch sensor status fast output to the robot, select either LOW-ACTIVE or HIGH-ACTIVE polarity for the output signal. If you are not using the fast output, this parameter is not required. Voltage scaling Consult Section 5.2, “The digital robot interface.” Wire feed speed scaling Consult Section 5.2, “The digital robot interface.” 5.1.
5.1.9 Welding system time Watchdog Set the welding system time and date by picking up the date from the pop-up calendar and typing the time to the particular field. If you want to synchronize the welding system time with the time of the browser, press the NOW button. If your robot supports the watchdog functionality, select the watchdog ON. Otherwise, set this feature OFF. Timeout Specify a timeout for the watchdog timer by using the slider. The minimum timeout value is 0.1 s and maximum is 5.0 s.
5.2 Digital robot interface 5.2.2 Selecting the proper I/O table To view the fieldbus information and to configure the settings, go to Settings > Fieldbus. Communication between the A7 MIG Welder system and a welding robot is based on input/output tables (I/O tables) exchanged between the machines by fieldbus cyclic I/O transmission. The tables contain binary-level functions that the robot uses for controlling and monitoring the welding system.
Interface mode I/O table name Description 0 1 (Not in use) KEMPPI1 2 3 Table size (bytes) KempArc Pulse default table 8 (Not in use) CUST1 4 Customer-specific table 16 (Not in use) 5 CUST2 Customer-specific table 6 6 CUST3 Customer-specific table 10 7 CUST4 Customer-specific table 10 8 9 (Not in use) CUST5 Customer-specific table 10 (Not in use) 11 (Not in use) 12 12 (Not in use) 13 KEMPPI2 KempArc Pulse Gate door switch alternative 8 14 KEMPPI3 KempArc Pulse TAST su
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 8.0–46.0 V. The operator of the robot wants to use robot’s full value range to achieve the best accuracy of the voltage control, thus the voltage scaling value should be configured to be the maximum value of the robot’s range (1023).
5.3 Users To create a new user, click on the text “Click to create a new user” in the user account bar and type a name for the user. Other options appear below. Select the role for the user by clicking on one of the buttons: WELDER, SUPERVISOR, or ADMINISTRATOR. After creating the user, click on the Save button, in the bottom bar, to save the changes. The user identification system is OFF by default. If you want to manage user access to the system, go to Settings > Users and switch user identification ON.
5.4.1 Inputs 5.4.2 Outputs Input 1–8 Output 1–8 Set the inputs 1–8 ON or OFF. When an input is set on, other options appear below. Configure the input by selecting the switch type, switching level, and error options. Set the outputs 1–8 ON or OFF by the means of hardware installation. When an output is set on, other options appear below. Configure the output by selecting polarity for the output signal. Switch type Indicate the type of the switch used in your input.
5.6 System backup Although the creation of memory channels is not within the scope of the integration guide, it is useful to create them before making a system backup. See the A7 MIG Welder operating manual for more information on the memory channels. After configuration of the system, it is a good idea to make a system backup file. The backup file can save significant time if the memory channels, welding system settings, user settings, and/or network settings need to be restored for any reason.
KEMPPI 3 KEMPPI 4 KEMPPI 5 CUST1 CUST2 CUST3 CUST4 CUST5 1 13 14 15 16 3 5 6 7 9 X X X X Control values WireFeedSpeed 16 5 Voltage 16 80 FineTuning 16 0 Dynamics 250 1 0.1 m/min 460 1 0.1 V X X X X X X X X X X 180 1 0.
6.1.2 Voltage DigitalOutput1 1 X X X X X X X DigitalOutput2 1 X X X X X X X X DigitalOutput3 1 X X X X X X X X DigitalOutput4 1 X X DigitalOutput5 1 X X DigitalOutput6 1 X X DigitalOutput7 1 X X DigitalOutput8 1 X X WireFeederSelect 1 X X X X In non-scaled mode: • The minimum setup value is 80 (8.0 V). • The maximum setup value is 460 (46.0 V). • The minimum step is 1 (0.1 V). 6.1.
6.1.4 Dynamics 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 voltage scaling value. This 8-bit function controls the dynamics of the synergic curve for all processes except WiseRoot+. The root process has no dynamic control.
6.1.8 PulseFrequency This 16-bit function controls the pulse current in the pulse process. This 16-bit function controls the pulse frequency in the pulse process. • The minimum setup value is 10 (1.0 Hz). • The maximum setup value is 5000 (500.0 Hz). • The minimum step is 1 (0.1 Hz). • The minimum setup value is 99 (99 A). • The maximum setup value is 800 (800 A). • The minimum step is 1 (1 A). 6.1.9 PulseLength 6.1.
6.1.15 GasBlow 6.1.18 TouchSensorOn This signal function controls the welding sequence. If SimulationMode is set to be on, it controls a simulation sequence instead. This signal function opens the shielding gas valve. The gas valve can be controlled during welding, but not during simulated welding. • 0 = Gas valve closed • 1 = Gas valve open This signal function sets the touch sensor power source and the touch detection device to be on. The touch voltage depends on the user settings.
6.1.23 CraterFillOn This signal function resets a watchdog timer in the robot interface unit on each transition. The signal takes an effect when the watchdog function is turned on from the web user interface or from the setup panel. If the watchdog functionality is on and the robot can’t maintain transitioning of this signal, the welding system goes into an error state. This prevents welding accidents if the robot loses control over the welding system.
6.2 Status functions The status functions are bit fields (values) and single bits (signals) in the I/O table. They are set by the welder system and read by the robot. Table 6.2: Status functions in the A7 MIG Welder system KEMPPI 3 KEMPPI 4 KEMPPI 5 CUST1 CUST2 CUST3 CUST4 CUST5 1 13 14 15 16 3 5 6 7 9 Status values WeldingCurrent WeldingVoltage 16 0 1024 1 1A X X X X X X X X X X X 16 80 460 1 0.1 V X X X X X 8/16 0 250 1 0.
KEMPPI 3 KEMPPI 4 KEMPPI 5 CUST1 CUST2 CUST3 CUST4 CUST5 1 13 14 15 16 3 5 6 7 9 Status bits Ready 1 X X X X X X X X PowerSourceReady 1 X X X X X CoolingUnitOk 1 X ProgramSaved 1 X RobotHasControl 1 CycleOn 1 X X X X X X X X X X ArcOn 1 X X X X X X X X X X GasFlowOk 1 X X X X X MainCurrentOn 1 X CurrentOk 1 X MotorCurrentOk 1 X WFSpeedOk 1 TouchSensed 1 X X X X X X X X X Error 1 X X X X X X X X X Colli
CUST1 CUST2 CUST3 CUST4 CUST5 14 15 16 3 5 6 7 9 Status bits DigitalInput1 1 X X X X X DigitalInput2 1 X X X X X X X DigitalInput3 1 X X X X X X X DigitalInput4 1 X X X X X X X DigitalInput5 1 X X X X X X DigitalInput6 1 X X X X DigitalInput7 1 X X DigitalInput8 1 X X X X X X X Deprecated status bits PanelLocked 1 0 0 X LocalRemote 1 1 1 X X X AutoManual 1 0 0 X X X © Kemppi Oy 2018 X 45 X X X X X A7 MIG Wel
6.2.4 MotorCurrent This 16-bit function represents the average welding current measured during the process. The value is in scaled or non-scaled mode, depending on the user setup. In non-scaled mode: • The minimum value is 0 A. • The maximum value is 1024 A. • The minimum step is 1 A. In scaled mode: • The minimum value is 0 (0 A). • The maximum value is the current scaling value, which is interpreted as 1024 A. • The minimum step is 1.
6.2.10 Ready 6.2.13 ProgramSaved This 8-bit function represents the currently active memory channel. • The minimum value is 0. • The maximum value is 199. • The minimum step is 1. This signal function indicates readiness of the welding system. The main power supply must be turned on, the system software booted up, and the system bus properly connected.
6.2.20 MotorCurrentOk 6.2.23 Error This signal function indicates the status of the welding arc. • 0 = Arc not established • 1 = Arc established This signal function indicates that the wire feeding motor current is below the system limit. • 0 = Motor current too high • 1 = Motor current OK This signal function indicates an error in the system (except the gate door open error). The signal is on (1) for an error; otherwise it is off (0). For warnings this signal remains off.
6.2.28 DigitalInput1 – DigitalInput8 This signal function is a common indicator for the tolerance status signals CurrentOk and WFSpeedOk. If one of the values is outside its tolerances, this signal is set (1). • 0 = Values within tolerances • 1 = At least one of the values outside the tolerances These eight signal functions indicate the status of the digital inputs in an external I/O device. • 0 = Input is inactive • 1 = Input is active This function is not implemented in the A7 MIG Welder.
6.3 I/O tables 6.3.2 KEMPPI2: KempArc Pulse customized table Byte 0 Interface mode = 1. Table size = 8 bytes.
6.3.
6.3.4 KEMPPI4: A7 MIG Welder default table Interface mode = 15. Table size = 16 bytes.
6.3.5 KEMPPI5: A7 MIG Welder table for pulse process control Interface mode = 16.
6.3.7 CUST2: Customer-specific table Interface mode = 3. Table size = 16 bytes. Interface mode = 5. Table size = 6 bytes.
6.3.9 CUST4: Customer-specific table Interface mode = 6. Table size = 8 bytes. Interface mode = 7. Table size = 10 bytes.
6.3.10 CUST5: Customer-specific table Interface mode = 9.
6.4 Timing diagrams 6.4.1 Welding startup timing Digital robot interface function timing INTEGRATION GUIDE B StartWelding CycleOn ArcOn Symbol Description Min Typical Max Units A Cycle-on time 6 17 40 ms B Arc establishment 17 time Pre-gas time + open-air distance + 23 Pre-gas time + 2050 * ms * The maximum time is limited by a wire feeding time-out.
Detailed in-system timing B1 F B2 C B3 B4 E1 G H1 E2 Symbol H StartWelding CycleOn ArcOn ML.WeldingStarted ML.SetGasValveOn ML.PreGasTimeGoing ML.PostGasTimeGoing ML.SetWireFeedOn ML.SetPowerSourceOn ML.CreepStartGoing ML.WeldingPhaseGoing PS.InUse PS.WireStuck PS.
6.4.2 Welding stop timing Digital robot interface function timing A B INTEGRATION GUIDE StartWelding CycleOn ArcOn 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 * The minimum cycle-off time is determined by power-source shutdown time, when the post-gas time is less than 300 ms.
Detailed in-system timing B1 B2 B3 B4 E C F1 F2 D Symbol Description A Weld start response time StartWelding B MIG logic process CycleOn B₁ ArcOn Min 3 Typical 3 Max Units 20 ms 4 ms Setup time (Post-gas time going) 1 ms B₂ Setup time (Set power source off ) 1 ms ML.WeldingStarted B₃ Setup time (Set wire feeding off ) 1 ms ML.SetGasValveOn B₄ Setup time (Set weld started off ) 1 ms ML.PreGasTimeGoing C Post-gas time 0 from curve userdefined ML.
6.4.
6.4.
6.4.5 Wire inch and retract timing Startup timing A B Start Feeding 1.0 m/ min Welding system Symbol Wire fe eding off Description Min INTEGRATION GUIDE WireInch, WireRetract Feeding 5.0 m/min Typical Max Units A Startup response time * 3 ms B Wire feeder motor acceleration time ** 3 s * The wire feeder reacts on controls immediately after startup. ** The acceleration time depends on the selected wire feed speed.
Touch response timing 6.4.
6.4.
And you know.
