Mach | M20.04 | Software Installation, Arc Welding System, IRC5 M2004

Software Installation, Arc Welding System, IRC5 M2004
Software Installation
Arc Welding System M2004
IRC5
3HEA 801232-001 February 2005
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.
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© ABB Automation Technologies AB
Article number: 3HEA 801232-001 February 2005
ABB Automation Technologies AB
Arc Welding Products
SE-69582 Laxå
Sweden
Contents
Software
Installation
3HEA 801232-001
February 2005
1 Introduction
1.1 Software
1.1.1 Upgrading software installations
1.1.2 Installation and configuration
1.1.3 Drive unit
1
3
5
6
1.2 Reference document
6
2 Booting functions
3HEA 801232-001 February 2005
1
7
2.1 General
2.1.1 Change active controller system
7
7
2.2 System builder in RobotStudioOnline
2.2.1 Backup & Restore
9
9
2.3 Creating a new system
2.3.1 Procedures
10
10
2.4 Add BaseWare Key
2.4.1 General
2.4.2 Procedures
12
12
12
2.5 Add drive Module Key
2.5.1 General
2.5.2 Procedure
13
13
13
2.6 Add Additional Options Key
2.6.1 General
2.6.2 Procedures
14
14
14
2.7 Modify Options
2.7.1 General
2.7.2 Procedure
16
16
16
2.8 Add parameter Data
2.8.1 General
2.8.2 Procedure
17
17
17
2.9 Add files to Home directory
2.9.1 General
2.9.2 Procedures
18
18
18
2.10 Finish
2.10.1 General
2.10.2 Procedure
19
19
19
2.11 Download to controller
2.11.1 General
2.11.2 Procedure
20
20
20
i
3 System directory structure
3.1 MediaPool
23
4 Arc welding configuration
25
4.1 Introduction
ii
23
25
3HEA 801232-001 February 2005
Introduction
Software
1 Introduction
1.1 Software
General
An arc welding system which is delivered by ABB Automation Technologies AB is
at delivery booted with a configuration that is customized for the delivery. In most
cases there is also a set of software drivers for the equipment loaded. There might
still be reasons to use this installation description. Obvious examples are:
• A system is to be installed at the customer site.
• The RobotWare software is to be replaced.
• The loaded software must be replaced.
• The configuration is to be changed.
• A stalled system has to be restarted.
• To change the language.
Before the installation activity is started, the programmer must read the safety information in
the System Manual, section Introduction and safety, chapter Safety.
Delivered system software
The following software is supplied for the arc welding system:
• Diskette Arc Welding System Configuration Diskette, which contains the arc
welding configuration supplied.
• CD disk containing RobotWare och RobotStudioOnline
The diskettes that contain the control program must not be modified in anyway.
This can result in the deactivation of safety functions such as reduced speed.
3HEA 801232-001 February 2005
1
Introduction
Software
All installations
System parameters that are changed after the booting with the Arc Welding System Configuration Diskette must be saved on your own user diskette
Before the software installation is started:
Action
Info/Illustration
1. Position all robot and positioner axes in
their zero positions.
2. Write down the commutation and calibration offsets for all motors. Robot and
external axes.
3. Save all system parameters, system
modules and program modules on diskette.
Alternatively:
4. Make a backup of the system.
See documetation for the Robot system!
2
3HEA 801232-001 February 2005
Introduction
Upgrading software installations
1.1.1 Upgrading software installations
General
When delivered, the system is installed with configuration files and rapid modules
that are adapted to suit the station in question.
On certain occasions it may be necessary to add to and modify the rapid modules,
for example, when the station is customized.
Backup
To ensure that everything runs smoothly when a backup copy needs to be restored,
it is a good idea to transfer one’s own software to an external optional disk. If this is
not done, unnecessarily long operational stoppages can occur.
See the example “Installation of own rapid modules and configuration files” on
page 3.
Installation of own rapid modules and configuration files
Example
Install.CMD
Add your own lines at the end of the file when there is a need to complement and
change the rapid modules, for example, when customer adaptation of the station is
made.
copy -from $BOOTPATH/Code/rapid.sys -to system/rapid.sys
config -filename $BOOTPATH/SYS/rapid.cfg -domain SYS
Figure 1. Example, install.CMD
In the example Figure 1., the file copies RAPID.SYS to %HOME%/system/rapid,
and loads the file into memory in accordance with the settings in the file
RAPID.CFG, which should be created. See the examples Figure 2. of what this file
can look like.
Example
rapid.cfg
# [File: rapid.cfg]
SYS:CFG_1.0:3:0::
CAB_TASK_MODULES:
-File "HOME:/system/rapid.sys" -ModName "myMod"
Figure 2. Example, rapid.cfg
3HEA 801232-001 February 2005
3
Introduction
Upgrading software installations
When the system is started, in this example, the file RAPID.SYS will be loaded and
ready to use in the system without having to use manual commands of the type FILE
-> Load module. This ensures that the correct things are in memory when a backup
is restored and minimizes the risk of mistakes by the operator.
Signal names
All signal names in RAPID programs and system modules must match the signal
names in the system parameters.
If not, the signal names in the RAPID programs and system modules must be
changed. The signal names in the system configuration should not be changed as
these are based on a global standard.
Modules
All system modules and program modules that contain Seamdata, Welddata and
Weavedata ought to be converted to XRG-format (=> XRG-files).
See documetation for the Robot system!
4
3HEA 801232-001 February 2005
Introduction
Installation and configuration
1.1.2 Installation and configuration
“Arc Welding System Configuration” Diskette
An “Arc Welding System Configuration” diskette is enclosed with each system that
is delivered by ABB Automation Technologies AB.
The name of disc is:
• “3HEAXXX-XXXXX (robot number)” + revision number.
Each Arc Welding System configuration diskette is, when it is manufactured, designated for:
• one particular robot serial number or
• one particular license number.
It is not authorized to be used in any other robot system than that printed on the diskette label.
Content of the
diskette
The “Arc Welding System Configuration Diskette” contains only options acc. to
specification.
For example:
• I/O-board options.
• Addresses and names for all user signals needed for the delivered system.
• Configuration options for positioners in the delivered system.
• Configuration for arc process equipment in the delivered system.
• Configuration options for delivered sensors.
• Default configuration options for welding functions.
See “Arc welding configuration” on page 25.
• Drivers, where appropriate, for positioner, operators panel and safety.
User´s configuration
In cases where there are complementary requirements, it is recommended to use
make a new one and, add or change configuration components, and save the lot on
a user´s configuration diskette. See “Arc welding configuration” on page 25.
3HEA 801232-001 February 2005
5
Introduction
Drive unit
Installation procedure
As mentioned in ABB Robotics manuals the pc application System builder in
RobotStudioOnline is used to create and download systems to the controller.
When a system is created or updated the external option can be added. The way to
do it is described in “Booting functions” on page 7.
1.1.3 Drive unit
Combinations and connections
The table below specifies to which axis computers the selectable drive unit combinations shall be connected.
Combinations
Axis
1
computer Art.number
Type
Positioner type
397 Ext. Axes DC4U Pre- DC4U Prepared 1
pared Drives
Drives
DSQC 358G
IRBP L/T, RTT
397 Ext. Axes DC4U + GU DC4U
1
DSQC 358G
IRBP A/B/D/K/R;
IRBP L/T+RTT
1
DSQC 346U
GU
1.
The corresponding article numbers can be seen on the respective drive units in the
control module.
1.2 Reference document
Reference
Description
Online
Getting Started IRC5 and RobotStudio
Document Id
Software installation and start 3HAC021564-001
up information.
Operator’s manual IRC5 with FlexPendant How to operate the robot sys- 3HAC16590-1
tem with a FlexPendant.
6
Operator's Manual RobotStudioOnline
(RSO)
How to install, configure and
manage RobotWare on the
robot's controller, as well as
programming and supervising the robot, from a PC.
Product manual for Robot IRB
Installation instructions for
hardware and controller software. Instructions for start-up
and calibration.
RAPID Overview
An overview of the RAPID
programming language.
3HAC 18236-1
3HEA 801232-001 February 2005
Booting functions
General
2 Booting functions
2.1 General
Installation
The installation of the robot software is done:
• From an external PC.
• From a diskette (the robot controller need to bee equipped with a diskette
drive).
From an external
PC
The application handling the booting of the RobotWare is called System builder in
RobotStudioOnline.
There are two ways to establish connection with the robot:
1. The robots are connected to a local network (the LAN output on the robot)
making it possible to run System builder in RobotStudioOnline to come into
contact with the hard disk of the robots from a PC connected to the same
network. This is applicable when there is more than one robot at the same
place.
2. From a computer with direct connection to the service output of the robot
network.
2.1.1 Change active controller system
X-start
A restart must be implemented to be able to load new software.
An X-start will exit the running system, store system data on the mass storage memory, and then execute the BootServer to present the Start window. Any system stored
in the mass storage memory, may then be selected.
When X-start is executed, all the saved system data is reset (in a similar way as with
a warm start).
See documetation for the Robot systemet!
3HEA 801232-001 February 2005
7
Booting functions
Change active controller system
Option diskettes
The option diskettes required to load Arc Welding Products’s configurations and
software are system/station specific. The diskettes are used as storage media.
The option diskettes are created by ABB Automation Technologies AB. Drivers for
calibrating and executing positioners, BullsEye, Tool Service Center, and SmarTac
are loaded automatically using an option diskette(s).
8
3HEA 801232-001 February 2005
Booting functions
System builder in RobotStudioOnline
2.2 System builder in RobotStudioOnline
General
System builder in RobotStudioOnline is used to create and install the controller
software in the IRC5 robot controller. With System builder, you can:
• Create a new system
• Update an existing system
• Down load a system to the controller using Ethernet connection
• Create Boot Disks to transfer the system to the Controller
Software key
In order to block the software and make it possible to boot only the options paid for,
a special key in the form of a character string is used. The key is supplied with each
robot.
This key is only to be found on the RobotWare CD supplied with each robot.
Creating a new
system
Questions during the booting, are now replied to in System builder in RobotStudioOnline.
Also our Arc Welding System Configuration Diskette is transferred to the system
by way of System builder .
The following data are needed to create a new system:
• Robot serial number
• Key for software
• diskette “Arc Welding System Configuration Diskette”
• type of DC link, i.e. type of rectifier and drive unit.
For information, see “Creating a new system” on page 10
2.2.1 Backup & Restore
Backup is primarily intended for making backup copies of the welding programs
and not of the application software. The application software should be booted
according to the instructions in “Upgrading software installations” on page 3.
When the installation is finished and the welding programs have been created, we
recommend that a backup safety copy of the system is made so that it is easy to
restore the system in the event of a fault. When changes are made to the system, it
is a good idea to make a backup safety copy so that the current safety copy always
reflects the latest status of the station.
See documetation for the Robot system!
3HEA 801232-001 February 2005
9
Booting functions
Creating a new system
2.3 Creating a new system
2.3.1 Procedures
Following procedures details how to create a new system.
Action
10
1.
Open System Builder in
RobotStudioOnline (RSO).
2.
Create a new system. Click on “Create
New”.
3.
Start the creation wizard by clicking
“Next”.
Info/Illustration
3HEA 801232-001 February 2005
Booting functions
Procedures
Action
4.
Info/Illustration
First give your system a name and a location where you want to save it.
3HEA 801232-001 February 2005
11
Booting functions
Add BaseWare Key
2.4 Add BaseWare Key
2.4.1 General
The Controller Key is delivered on a CD with your controller. The media pool is the
location of your RobotWare program versions. The key and program are the main
building blocks of your system.
2.4.2 Procedures
Following procedure details how to add the BaseWare key.
12
Action
Info/Illustration
1.
Enter your controller key.
You can also select your key file by
browsing the disk
2.
Select your Mediapool and the RobotWare version that you want to use. Click
“Next”.
3HEA 801232-001 February 2005
Booting functions
Add drive Module Key
2.5 Add drive Module Key
2.5.1 General
Each drive key corresponds to a specific drive module in your system. The drive
module connected to the first ethernet port in the control module will be refered to
as “Drive#1”.
2.5.2 Procedure
Following procedure details how to add the drive module key.
Action
1.
Info/Illustration
Enter your drive module key and add it to
the list by clicking on the “Æ” button.
If you are installing a Multi Arc system you have to repeat this once for every drive
module.
2.
When you have added all your drive keys
click “Next”.
3HEA 801232-001 February 2005
13
Booting functions
Add Additional Options Key
2.6 Add Additional Options Key
2.6.1 General
To add options other than the RobotWare options, a new key for each option needs
to be entered.
2.6.2 Procedures
Following procedure details how to add the additional options key.
Action
14
1.
Locate the “extkey.kxt” file in the external
option disk directory in your Mediapool.
Use the “…” button.
2.
Click on the “extkey.kxt” file and then click
“Open”.
Info/Illustration
3HEA 801232-001 February 2005
Booting functions
Procedures
Action
3.
Click on “Æ” to add in to the list.
4.
Click “Next”.
3HEA 801232-001 February 2005
Info/Illustration
15
Booting functions
Modify Options
2.7 Modify Options
2.7.1 General
Options with sub options can be expanded to each level where you can make a
selection. The RobotWare key and the additional keys determine which options are
available.
2.7.2 Procedure
Following procedure details how to modify options.
Action
16
1.
Make sure that all your options are
checked and that the right robot and drive
configuration is selected.
2.
Click “Next”.
Info/Illustration
3HEA 801232-001 February 2005
Booting functions
Add parameter Data
2.8 Add parameter Data
2.8.1 General
Enter the path to the parameter data files directory. Select the files to add and click
the add button. You can add one parameter data file for each topic: moc.cfg, eic.cfg,
proc.cfg and sio.cfg
2.8.2 Procedure
Following procedure details how to add extra parameter data.
Action
1.
Add extra parameter data.
2.
Click “Next”.
3HEA 801232-001 February 2005
Info/Illustration
17
Booting functions
Add files to Home directory
2.9 Add files to Home directory
2.9.1 General
Browse for files to be added in the Home directory of the system. The selected files
will be downloaded to the controller together with the system.
2.9.2 Procedures
Following procedure details how to add files to home directory.
Action
18
1.
Add files to your system “HOME”.
2.
Click “Next”.
Info/Illustration
3HEA 801232-001 February 2005
Booting functions
Finish
2.10 Finish
2.10.1 General
The controller system “SystemX” will be created at selected directory when this
wizard is exited with “Finish”
2.10.2 Procedure
Foolowing procedure details how to finish the configuration.
Action
1.
Info/Illustration
Click Next to finish the system.
3HEA 801232-001 February 2005
19
Booting functions
Download to controller
2.11 Download to controller
2.11.1 General
When the system is configured, the system must be downloaded to the IRC5 controller.
2.11.2 Procedure
The Following procedure details how to download the selected system to the IRC5
controller.
Action
20
1.
Select the system.
2.
Click on “Download to Controller”.
3.
Select the controller that you want to
download to.
Info/Illustration
3HEA 801232-001 February 2005
Booting functions
Procedure
Action
4.
If your controller system does not appear
in the list you can specify the IP address
in the textbox below.
5.
Test the connection by clicking on Test
Connection.
6.
Click on Load to download the system if
the test went OK.
7.
Click on OK.
8.
The download will start.
9.
When the download is finished click on
Yes to restart the controller.
3HEA 801232-001 February 2005
Info/Illustration
21
Booting functions
Procedure
22
3HEA 801232-001 February 2005
System directory structure
MediaPool
3 System directory structure
3.1 MediaPool
General
System builder i RobotStudioOnline uses a directory called MediaPool for storing all
the different programs/options available.
The MediaPool usually used is found under:
• c:\Program\ or \Program Files\ABB Industrial IT\Robotics IT.
When a program is imported by way of Import Program the new program will automatically be stored in this file.
See documetation for the Robot system!
New RobotWare
When a new RobotWare is released from Robotics it is to be entered under the
Media Pool used. The new version will then automatically be used when creating a
new system.
This can be done in two different ways:
1. Reinstalling System builder including RobotWare. In this way you will get the
new release of both the System builder and RobotWare systems.
2. Copying the new RobotWare release over to the Media Pool.
See documetation for the Robot system!
System
When a new system is created it will be stored in the System file under:
• c:\Program\ or \Program Files\ABB Industrial IT\Robotics IT\System\+”name
of system”
To prevent the file gradually getting too big it is advisable to eliminate items now
and then.
See documetation for the Robot system!
3HEA 801232-001 February 2005
23
System directory structure
MediaPool
24
3HEA 801232-001 February 2005
Arc welding configuration
Introduction
4 Arc welding configuration
4.1 Introduction
General
This chapter is intended to give the user some hints regarding arc welding configuration.
The user can then change the configuration in order to meet individual requirements.
• It is recommended to save this user configuration on a separate User Configuration disk.
Reference
document
Document
Described in:
Document id
General process parameters for IRC5
Application manual
3HAC 16591-1
Revision -
About the ARCITEC IRC5 Arc welding system
There are a few arc welding functions that can be controlled by the ArcWare software or by the power source software. These functions are:
• Ignition
• Burnback
• Craterfill
The power source functions are to be thought of as first choice since they are easiest
to program and more pre-programmed for specified purposes. They are pre-programmed as synergic relationships, which affects the static working point as well as
dynamic behavior.
Reference
document
Document
Described in:
Document id
Programing Arcitec IRC5
Programing manual
3HEA801234-001
3HEA 801232-001 February 2005
25
Arc welding configuration
Introduction
Data structure
The structure of seam data, weld data and weave data must be matching the current
arc weld configuration. This will always be the case when the data are created in
current (=active) configuration.
If required, convert Seam data, Weld data and Weave data in system modules and
program modules.
See documetation for the Robot system!
26
3HEA 801232-001 February 2005
3HEA 801232-001 February 2005
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3HEA
3HEA801232-001
801232-001February
February 2005
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