Product manual - IRB 1520ID arc welding equipment

ABB Robotics
Product manual
Arc welding equipment for IRB 1520ID
Trace back information:
Workspace R13-2 version a3
Checked in 2013-10-15
Skribenta version 4.0.378
Product manual
Arc welding equipment for IRB 1520ID
IRC5
Document ID: 3HAC043438-001
Revision: A
© Copyright 2012-2013 ABB. All rights reserved.
The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2012-2013 ABB. All rights reserved.
ABB AB
Robotics Products
Se-721 68 Västerås
Sweden
Table of contents
Table of contents
1
Overview of this manual ...................................................................................................................
7
Safety
9
1.1
1.2
1.3
1.4
2
3
9
10
10
11
12
12
15
16
17
18
20
20
21
22
23
23
25
25
27
28
29
29
31
32
33
34
35
Technical description
37
2.1
2.2
2.3
37
38
39
41
42
42
44
Overview of welding equipment ...........................................................................
Principle design ................................................................................................
Components ....................................................................................................
2.3.1 Power source .........................................................................................
2.3.2 Wire feeder system ..................................................................................
2.3.2.1 Overview ...................................................................................
2.3.2.2 Wire feeder unit ...........................................................................
Installation
49
3.1
49
49
51
52
54
57
58
58
60
61
3.2
3.3
3.4
4
Introduction to safety information .........................................................................
General safety information ..................................................................................
1.2.1 Introduction to general safety information ....................................................
1.2.2 Safety in the manipulator system ...............................................................
1.2.3 Safety risks ............................................................................................
1.2.3.1 Safety risks during installation and service work on manipulators .........
1.2.3.2 CAUTION - Hot parts may cause burns! ...........................................
1.2.3.3 Safety risks related to tools/work pieces ..........................................
1.2.3.4 Safety risks during operational disturbances .....................................
1.2.3.5 Risks associated with live electric parts ...........................................
1.2.4 Safety actions .........................................................................................
1.2.4.1 Safety fence dimensions ...............................................................
1.2.4.2 Fire extinguishing ........................................................................
1.2.4.3 Safe use of the FlexPendant ..........................................................
1.2.5 Safety stops ...........................................................................................
1.2.5.1 What is an emergency stop? ..........................................................
Safety related instructions ..................................................................................
1.3.1 Safety signals in the manual ......................................................................
1.3.2 DANGER - First test run may cause injury or damage! ...................................
1.3.3 DANGER - Make sure that the main power has been switched off! ....................
Arc welding related safety ...................................................................................
1.4.1 Special safety instructions ........................................................................
1.4.2 Protective equipment ...............................................................................
1.4.3 Light barriers ..........................................................................................
1.4.4 Risk of fire .............................................................................................
1.4.5 Risk of explosion .....................................................................................
1.4.6 Risk of electric shock ...............................................................................
Connecting the welding equipment .......................................................................
3.1.1 Installing the DeviceNet card and cable .......................................................
3.1.2 Installing the power source .......................................................................
3.1.3 Connecting the cables and hoses ...............................................................
3.1.3.1 Connecting the feeder cable ..........................................................
Configurating the welding equipment ....................................................................
Installing accessories .........................................................................................
3.3.1 Torch cleaner (TSC) .................................................................................
3.3.2 Adjusting the brake hub of the bobbin .........................................................
Before commissioning ........................................................................................
Operation
63
4.1
63
64
67
4.2
Power source ...................................................................................................
4.1.1 Programming the power source .................................................................
Wire feeder unit ................................................................................................
3HAC043438-001 Revision: A
5
© Copyright 2012-2013 ABB. All rights reserved.
Table of contents
5
Maintenance
69
5.1
5.2
5.3
5.4
5.5
5.6
69
70
71
72
73
75
Introduction ......................................................................................................
Daily maintenance .............................................................................................
Service shop maintenance ..................................................................................
Power source ...................................................................................................
Wire feed unit ...................................................................................................
Before commissioning ........................................................................................
Index
77
6
3HAC043438-001 Revision: A
© Copyright 2012-2013 ABB. All rights reserved.
Overview of this manual
Overview of this manual
About this manual
This manual contains instructions for:
•
electrical installation and configuration of the welding equipment
•
maintenance of the welding equipment.
Usage
This manual should be used during:
•
installation
•
maintenance work
Who should read this manual?
This manual is intended for:
•
installation personnel
•
maintenance personnel
•
repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
•
be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information on how to avoid
personal injuries and damage to the product.
Technical description
Overview of the welding equipment.
Installation
Required information about electrical installation of the welding
equipment.
Operation
Programming instructions for the power source and the wire
feeder unit.
Maintenance
Procedures that describe how to perform maintenance of the
welding equipment.
References
Documentation referred to in the manual, is listed in the table below.
Document name
Document ID
Product manual - IRB 1520
3HAC043435-001
Circuit diagram - IRB 1520
3HAC039498-007
Product specification - IRB 1520
3HAC043437-001
Application manual - Torch services
3HAC024847-001
Continues on next page
3HAC043438-001 Revision: A
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© Copyright 2012-2013 ABB. All rights reserved.
Overview of this manual
Continued
Document name
Document ID
Product manual - IRC5
3HAC021313-001
Operating manual - IRC5 with FlexPendant
3HAC16590-1
Operating manual - KempArc SYN 300/400/500, DT 400
1920130 -001
Revisions
Revision
Description
-
First edition.
A
This revision contains the following updates:
• The lower feed rollers in the wire feeder system are redesigned
to contain one groove only, see Wire feeder system on page 42
and Wire feed unit on page 73.
8
3HAC043438-001 Revision: A
© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.1 Introduction to safety information
1 Safety
1.1 Introduction to safety information
Overview
The safety information in this manual is divided into two categories:
•
General safety aspects, important to attend to before performing any service
work on the robot. These are applicable for all service work and are found
in General safety information on page 10.
•
Specific safety information, pointed out in the procedures. How to avoid and
eliminate the danger is either described directly in the procedure, or in specific
instructions in the section Safety related instructions on page 25.
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.1 Introduction to general safety information
1.2 General safety information
1.2.1 Introduction to general safety information
Definitions
This section details general safety information for personnel performing installation,
repair and maintenance work.
Sections
The general safety information is divided into the following sections.
Contents
Containing
General information
•
•
•
safety, service
limitation of liability
related information
Safety risks lists dangers relevant when
working with the product. The dangers are
split into different categories.
•
•
safety risks during installation or service
risks associated with live electrical parts
Safety actions describes actions which
may be taken to remedy or avoid dangers.
•
•
fire extinguishing
safe use of the FlexPendant
Safety stops describes different types of
stops.
•
•
•
•
stopping functions
description of emergency stop
description of safety stop
description of safeguarding
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.2 Safety in the manipulator system
1.2.2 Safety in the manipulator system
Validity and responsibility
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the manipulator is installed.
The users of ABB industrial manipulators are responsible for ensuring that the
applicable safety laws and regulations in the country concerned are observed and
that the safety devices necessary to protect people working with the manipulator
system are designed and installed correctly. Personnel working with manipulators
must be familiar with the operation and handling of the industrial manipulator as
described in the applicable documents, for example:
•
Operating manual - IRC5 with FlexPendant
•
Product manual
Connection of external safety devices
Apart from the built-in safety functions, the manipulator is also supplied with an
interface for the connection of external safety devices. An external safety function
can interact with other machines and peripheral equipment via this interface. This
means that control signals can act on safety signals received from the peripheral
equipment as well as from the manipulator.
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial manipulator will not cause injury or damage
even if all safety instructions are complied with.
Related information
Type of information
Detailed in document
Installation of safety devices Product manual for the manipulator
Changing operating modes
Section
Installation and
commissioning
Operating manual - IRC5 with FlexPend- Operating modes
ant
Restricting the working space Product manual for the manipulator
3HAC043438-001 Revision: A
Installation and
commissioning
11
© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
1.2.3 Safety risks
1.2.3.1 Safety risks during installation and service work on manipulators
Overview
This section includes information on general safety risks to be considered when
performing installation and service work on the manipulator.
These safety instructions have to be read and followed by any person who deals
with the installation and maintenance of the manipulator. Only persons who know
the manipulator and are trained in the operation and handling of the manipulator
are allowed to maintain the manipulator. Persons who are under the influence of
alcohol, drugs or any other intoxicating substances are not allowed to maintain,
repair, or use the manipulator.
General risks during installation and service
• The instructions in the product manual in the chapter Installation and
commissioning must always be followed.
•
Emergency stop buttons must be positioned in easily accessible places so
that the manipulator can be stopped quickly.
•
Those in charge of operations must make sure that safety instructions are
available for the installation in question.
•
Those who install the manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.
Spare parts and special equipment
ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such products could
negatively affect the structural properties of the manipulator and as a result of that
affect the active or passive safety operation. ABB is not liable for damages caused
by the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the manipulator
system.
Nation/region specific regulations
To prevent injuries and damages during the installation of the manipulator, the
regulations applicable in the country concerned and the instructions of ABB
Robotics must be complied with.
Non-voltage related risks
• Make sure that no one else can turn on the power to the controller and
manipulator while you are working with the system. A good method is to
always lock the main switch on the controller cabinet with a safety lock.
•
Safety zones, which must be crossed before admittance, must be set up in
front of the manipulator's working space. Light beams or sensitive mats are
suitable devices.
Continues on next page
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1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Continued
•
Turntables or the like should be used to keep the operator out of the
manipulator's working space.
•
The axes are affected by the force of gravity when the brakes are released.
In addition to the risk of being hit by moving manipulator parts, there is a risk
of being crushed by the parallel arm (if there is one).
•
Energy stored in the manipulator for the purpose of counterbalancing certain
axes may be released if the manipulator, or parts thereof, are dismantled.
•
When dismantling/assembling mechanical units, watch out for falling objects.
•
Be aware of stored heat energy in the controller.
•
Never use the manipulator as a ladder, which means, do not climb on the
manipulator motors or other parts during service work. There is a serious
risk of slipping because of the high temperature of the motors and oil spills
that can occur on the manipulator.
To be observed by the supplier of the complete system
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
•
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Complete manipulator
Safety risk
Hot components!
Description
CAUTION
Motors and gears are HOT after running the
manipulator! Touching motors and gears may
result in burns!
With a higher environment temperature, more
surfaces on the manipulator will get HOT and
may also result in burns.
Removed parts may result in collapse of
manipulator!
WARNING
Take any necessary measures to ensure that
the manipulator does not collapse as parts
are removed, e.g. secure the lower arm according to repair instruction if removing motor, axis 2.
Removed cables to the measurement system
WARNING
If the internal cables for the measurement
system have been disconnected during repair
or maintenance, then the revolution counters
must be updated.
Continues on next page
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.3.1 Safety risks during installation and service work on manipulators
Continued
Cabling
Safety risk
Cable packs are sensitive to mechanical
damage!
Description
CAUTION
The cable packs are sensitive to mechanical
damage! They must be handled with care,
especially the connectors, in order to avoid
damaging them!
Gearboxes and motors
Safety risk
Gears may be damaged if excessive force
is used!
Description
CAUTION
Whenever parting/mating motor and gearbox,
the gears may be damaged if excessive force
is used!
Safety risk
Description
Dangerous balancing device!
WARNING
Do not under any circumstances, deal with
the balancing device in any other way than
that detailed in the product documentation!
For example, attempting to open the balancing device is potentially lethal!
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1 Safety
1.2.3.2 CAUTION - Hot parts may cause burns!
1.2.3.2 CAUTION - Hot parts may cause burns!
Description
During normal operation, many manipulator parts become hot, especially the drive
motors and gears. Sometimes areas around these parts also become hot. Touching
these may cause burns of various severity.
Because of a higher environment temperature, more surfaces on the manipulator
get hot and may result in burns.
Elimination
The instructions below detail how to avoid the dangers specified above:
Action
1
Always use your hand, at some distance, to
feel if heat is radiating from the potentially
hot component before actually touching it.
2
Wait until the potentially hot component has
cooled if it is to be removed or handled in any
other way.
Info
3HAC043438-001 Revision: A
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.3.3 Safety risks related to tools/work pieces
1.2.3.3 Safety risks related to tools/work pieces
Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered manipulator are prohibited.
Without the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.
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1 Safety
1.2.3.4 Safety risks during operational disturbances
1.2.3.4 Safety risks during operational disturbances
General
•
The industrial manipulator is a flexible tool that can be used in many different
industrial applications.
•
All work must be carried out professionally and in accordance with the
applicable safety regulations.
•
Care must be taken at all times.
Qualified personnel
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
3HAC043438-001 Revision: A
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.3.5 Risks associated with live electric parts
1.2.3.5 Risks associated with live electric parts
Voltage related risks, general
Work on the electrical equipment of the manipulator must be performed by a
qualified electrician in accordance with electrical regulations.
•
Although troubleshooting may, on occasion, need to be carried out while the
power supply is turned on, the robot must be turned off (by setting the mains
switch to OFF) when repairing faults, disconnecting electric leads and
disconnecting or connecting units.
•
The mains supply to the robot must be connected in such a way that it can
be turned off from outside the robot’s working space.
•
Make sure that one else can turn on the power to the controller and
manipulator while you are working with the system. A good method is to
always lock the main switch on the controller cabinet with a safety lock.
The necessary protection for the electrical equipment and manipulator system
during construction, commissioning, and maintenance is guaranteed if the valid
regulations are followed.
All work must be performed:
•
by qualified personnel
•
on machine/manipulator system in deadlock
•
in an isolated state, disconnected from power supply, and protected against
reconnection
Voltage related risks, IRC5 controller
A danger of high voltage is associated with, for example, the following parts:
•
Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in
the controller.
•
Units such as I/O modules, can be supplied with power from an external
source.
•
The mains supply/mains switch
•
The transformers
•
The power unit
•
The control power supply (230 VAC)
•
The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: Capacitors!)
•
The drive unit (400/700 VDC)
•
The drive system power supply (230 VAC)
•
The service outlets (115/230 VAC)
•
The customer power supply (230 VAC)
•
The power supply unit for additional tools, or special power supply units for
the machining process.
•
The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
•
Additional connections.
Continues on next page
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.3.5 Risks associated with live electric parts
Continued
Voltage related risks, manipulator
A danger of high voltage is associated with the manipulator in:
•
The power supply for the motors (up to 800 VDC).
•
The user connections for tools or other parts of the installation (max. 230
VAC).
See chapter Installation on page 49.
Voltage related risks, tools, material handling devices, etc.
Tools, material handling devices, etc., may be live even if the robot system is in
the OFF position. Power supply cables which are in motion during the working
process may be damaged.
3HAC043438-001 Revision: A
19
© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.4.1 Safety fence dimensions
1.2.4 Safety actions
1.2.4.1 Safety fence dimensions
General
Install a safety cell around the manipulator to ensure safe manipulator installation
and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the
load being handled by the manipulator is dropped or released at maximum speed.
Determine the maximum speed from the maximum velocities of the manipulator
axes and from the position at which the manipulator is working in the work cell
(see the section Robot motion in the Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the manipulator.
20
3HAC043438-001 Revision: A
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1 Safety
1.2.4.2 Fire extinguishing
1.2.4.2 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the
manipulator system (manipulator or controller)!
3HAC043438-001 Revision: A
21
© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.4.3 Safe use of the FlexPendant
1.2.4.3 Safe use of the FlexPendant
Enabling device
The enabling device is a manually operated, constant pressure push-button which,
when continuously activated in one position only, allows potentially hazardous
functions but does not initiate them. In any other position, hazardous functions are
stopped safely.
The enabling device is of a specific type where you must press the push-button
only half-way to activate it. In the fully in and fully out positions, manipulator
operation is impossible.
Note
The enabling device is a push-button located on the side of the FlexPendant
which, when pressed halfway in, switches the system to MOTORS ON. When
the enabling device is released or pushed all the way in, the manipulator switches
to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:
•
The enabling device must never be rendered inoperational in any way.
•
During programming and testing, the enabling device must be released as
soon as there is no need for the manipulator to move.
•
Anyone entering the manipulator working space must always bring the
FlexPendant with him/her. This is to prevent anyone else from taking control
of the manipulator without his/her knowledge.
Hold-to-run function
The hold-to-run function allows movement when a button connected to the function
is actuated manually and immediately stops any movement when released. The
hold-to-run function can only be used in manual mode.
How to operate the hold-to-run function for IRC5 is described in Operating
manual - IRC5 with FlexPendant.
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1 Safety
1.2.5.1 What is an emergency stop?
1.2.5 Safety stops
1.2.5.1 What is an emergency stop?
Definition of emergency stop
An emergency stop is a state that overrides any other manipulator control,
disconnects drive power from the manipulator motors, stops all moving parts, and
disconnects power from any potentially dangerous functions controlled by the
manipulator system.
An emergency stop state means that all power is disconnected from the manipulator
except for the manual brake release circuits. You must perform a recovery
procedure, i.e, resetting the emergency stop button and pressing the Motors On
button, in order to return to normal operation.
The manipulator system can be configured so that the emergency stop results in
either:
•
An uncontrolled stop, immediately stopping the manipulator actions by
disconnecting power from the motors.
•
A controlled stop, stopping the manipulator actions with power available to
the motors so that the manipulator path can be maintained. When completed,
power is disconnected from the motors.
The default setting is an uncontrolled stop. However, controlled stops are preferred
since they minimize extra, unnecessary wear on the manipulator and the actions
needed to return the manipulator system back to production. Please consult your
plant or cell documentation to see how your manipulator system is configured.
Note
The emergency stop function may only be used for the purpose and under the
conditions for which it is intended.
Note
The emergency stop function is intended for immediately stopping equipment
in the event of an emergency.
Note
Emergency stop should not be used for normal program stops as this causes
extra, unnecessary wear on the manipulator.
For how to perform normal program stops, see section Stopping programs in
Operating manual - IRC5 with FlexPendant.
Continues on next page
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© Copyright 2012-2013 ABB. All rights reserved.
1 Safety
1.2.5.1 What is an emergency stop?
Continued
Classification of stops
The safety standards that regulate automation and manipulator equipment define
categories in which each type of stop applies:
If the stop is...
... then it is classified as...
uncontrolled
category 0 (zero)
controlled
category 1
Emergency stop devices
In a manipulator system there are several emergency stop devices that can be
operated in order to achieve an emergency stop. There are emergency stop buttons
available on the FlexPendant and on the controller cabinet (on the Control Module
on a Dual Cabinet Controller). There can also be other types of emergency stops
on your manipulator. Consult your plant or cell documentation to see how your
manipulator system is configured.
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1 Safety
1.3.1 Safety signals in the manual
1.3 Safety related instructions
1.3.1 Safety signals in the manual
Introduction to safety signals
This section specifies all dangers that can arise when doing the work described
in this manual. Each danger consists of:
•
A caption specifying the danger level (DANGER, WARNING, or CAUTION)
and the type of danger.
•
A brief description of what will happen if the operator/service personnel do
not eliminate the danger.
•
Instruction about how to eliminate danger to simplify doing the work.
Danger levels
The table below defines the captions specifying the danger levels used throughout
this manual.
Symbol
Designation
Significance
DANGER
Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
impact, fall from height, and so on.
WARNING
Warns that an accident may occur if the instructions
are not followed that can lead to serious injury, possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk
of crushing, impact, fall from height, etc.
ELECTRICAL
SHOCK
Warns for electrical hazards which could result in
severe personal injury or death.
CAUTION
Warns that an accident may occur if the instructions
are not followed that can result in injury and/or
damage to the product. It also applies to warnings
of risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping, impact, fall from height, etc. Furthermore, it applies to
warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.
xx0200000022
xx0100000002
xx0200000024
xx0100000003
ELECTROSTATIC Warns for electrostatic hazards which could result
DISCHARGE (ESD) in severe damage to the product.
xx0200000023
Continues on next page
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1 Safety
1.3.1 Safety signals in the manual
Continued
Symbol
Designation
Significance
NOTE
Describes important facts and conditions.
TIP
Describes where to find additional information or
how to do an operation in an easier way.
xx0100000004
xx0100000098
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1 Safety
1.3.2 DANGER - First test run may cause injury or damage!
1.3.2 DANGER - First test run may cause injury or damage!
Description
Since performing a service activity often requires disassembly of the robot, there
are several safety risks to take into consideration before the first test run.
Elimination
Follow the procedure below when performing the first test run after a service
activity, such as repair, installation, or maintenance.
Action
1
Remove all service tools and foreign objects from the robot and its working area
2
Check that the fixture and workpiece are well secured, if applicable
3
Install all safety equipment properly
4
Make sure all personnel are standing at a safe distance from the robot, that is out of
its reach behind safety fences, and so on
5
Pay special attention to the function of the part previously serviced
Collision risks
CAUTION
When programming the movements of the manipulator always check potential
collision risks before the first test run.
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1 Safety
1.3.3 DANGER - Make sure that the main power has been switched off!
1.3.3 DANGER - Make sure that the main power has been switched off!
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
dangers, do not proceed working before eliminating the danger as detailed below.
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1 Safety
1.4.1 Special safety instructions
1.4 Arc welding related safety
1.4.1 Special safety instructions
Welding robot system
The following points should be observed in all work in or around the welding robot
system:
•
Consider the welding robot equipment as a single unit.
•
The welding robot system consists of many different parts, which in addition
to the robot, also includes positioners and other peripheral equipment.
•
The entire system communicates via electrical signals and can therefore
bring about movements in completely different components to those directly
affected.
Workplace
The following points should be observed in all work in or around the workplace:
•
Make sure that the workplace is in order before the system is put into
operation. If malfunctions are discovered on or in the system, these must be
rectified before starting.
•
Consult trained personnel or the system manager if your own knowledge is
insufficient to implement the measures.
Before operation
The following points should be observed before putting the welding robot system
into operation:
•
All guards and all safety equipment must be fitted before the robot system
is started.
•
The safety equipment must not be disengaged, bypassed or in any other
way modified so that it does not provide the intended protection.
•
Test running with the operating mode selector (key switch) in the 100%
position should only be carried out by qualified personnel who are aware of
the risks this involves.
During operation
The following points should be observed when the welding robot system is in
operation:
•
Do not remain within the risk zone (the robot and positioner working area)
when the system is operational. If it is absolutely essential that you remain
within the risk zone in order to carry out the work, the following must be
observed.
•
Never work alone in the risk zone when the system is in operation. One
person should stand outside the risk zone to stop the equipment if a hazard
arises while work is being carried out inside the risk zone.
•
Exercise extreme care when operating the robot/positioner. Always remember
that these can perform unexpected movements when executing a program.
Continues on next page
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1 Safety
1.4.1 Special safety instructions
Continued
Even when the robot system seems to perform the same movement pattern
over and over again for an extended period, the pattern can suddenly change.
•
Be aware that weld splatter represents a fire and burn risk
During maintenance work
The following points should be observed before beginning maintenance work:
•
Take the robot system's FlexPendant with you when entering the risk zone
so that no one else can start the robot system. When the continuous pressure
switch on the FlexPendant is released, the robot system is put into standby
mode with the motors shut off.
•
Be sure to release the continuous pressure switch when the robot or
positioner does not need to be operated.
•
The robot system will be in standby mode with the motors shut off. The
operating mode selector (key switch) on the control cabinet's control panel
will be in the "Manual reduced speed <250 mm/s" position, and the continuous
pressure switch on the Flex- Pendant must then be used to operate the robot
system. In this mode the robot and positioner movements are limited to a
speed of no more than 250 mm/s.
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1 Safety
1.4.2 Protective equipment
1.4.2 Protective equipment
General
Do not wear loose-fitting garments or belts, bracelets, etc., that can become
entangled in the robot or positioner. Always use the prescribed personal protective
equipment.
Personal protective equipment
Personnel should have the following protective equipment:
Equipment
Description
Safety goggles
Protect the eyes against loose particles,
sharp edges and sharp components.
Welding helmet with welding glass
Protect the eyes and skin against radiation
and burn injuries.
Dry and undamaged gloves
Protect against radiation and burn injuries,
as well as electric shocks.
Dry and undamaged protective clothing
Protect against radiation and burn injuries,
as well as electric shocks.
Shoes with insulated soles
Protect against radiation and burn injuries,
as well as electric shocks.
Ear protection
Protects hearing when using certain welding
settings.
Protective screens and curtains
Protect other persons located in the vicinity
of the station.
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1 Safety
1.4.3 Light barriers
1.4.3 Light barriers
Light barriers function
The light barriers in the robot system are used to stop the robot and positioner if
anyone enters the risk zone where moving parts are activated. The light barriers
can, where appropriate, be replaced by hatches, sliding doors or gates.
Pre reset
A pre-reset button is located inside the service area. It is used in connection with
resetting the safety circuits for the light barriers. The pre-reset prevents
unintentional starting when the operator is inside the service area.
Action
1
Press the pre-reset button (this permits a pre-reset of the safety circuits for the light
barriers of 10 seconds).
2
Press and hold the start button (operator ready button) on the operator panel within
10 seconds.
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1 Safety
1.4.4 Risk of fire
1.4.4 Risk of fire
WARNING
There is a risk of fire in connection with welding.
Safety measures
The following points should be observed:
•
Observe local fire regulations for welding.
•
Clean the area around the workplace regularly and ensure that the area is
free of combustible material.
•
Check that all connections in the welding current circuit are properly
tightened. Poor contact can result in inferior welding results and a risk of
fire.
•
Check that the cables are correctly dimensioned. Cables that are
underdimensioned can constitute a fire risk due to overheating.
Fire extinguishing
Use carbon dioxide (CO2) if the equipment catches fire.
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1 Safety
1.4.5 Risk of explosion
1.4.5 Risk of explosion
Gas cylinders
There is a great risk of the gas cylinders exploding in the event of a fire. Observe
local safety instructions with regard to the handling and storing of gas cylinders.
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1 Safety
1.4.6 Risk of electric shock
1.4.6 Risk of electric shock
WARNING
The welding wire is live during the welding process even before the arc is ignited.
Safety measures
The following points should be observed:
•
Do not mix up the phase and grounding conductors when connecting the
equipment to the mains supply.
•
The workpiece, fixtures and positioner are usually in direct contact with the
welding circuit, and should therefore be regarded as live.
•
Do not touch live parts of the equipment with your bare hands or with damp
gloves.
•
Equip the operator station with an insulating mat.
•
The welding circuit shall not be grounded without necessary measures being
taken to ensure proper functioning of the grounding conductor.
•
The welding circuit must not be broken during the welding process.
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2 Technical description
2.1 Overview of welding equipment
2 Technical description
2.1 Overview of welding equipment
Content
The welding equipment is adapted to an industrial robot and is controlled by the
IRC5 control system and Arc Welding software.
The welding equipment consists of:
•
An external power source, installed between the robot and the controller.
•
A wire feeder unit, installed on the robot.
•
A bobbin, installed on the robot.
Usage
The welding equipment should only be used for MIG (Metal Inert Gas) and MAG
(Metal Active Gas) welding. Only use the equipment according to the instructions
in this manual.
WARNING
The equipment is not intended for use in explosive environments.
Note
ABB disclaims all responsibility and any claims for damages or warranty
undertakings, if equipment is used in other areas than MIG/MAG welding
Accuracy
Fully digital communication by DeviceNet.
Safety
If an error occurs an error code is displayed on the FlexPendant to help the user
to solve problems.
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2 Technical description
2.2 Principle design
2.2 Principle design
Robot welding system
xx1100000396
1
Control module (IRC5)
2
Welding power source
3
Wire feeder unit (A314F LH)
Technical data
Together with the AW software in the robot, the welding equipment consists of and
has the following characteristics:
Type
Description
Power source, RPC S Series / RPC P Series 400 A synergic and 350 A pulse power
sources.
Lightweight, compact and modular design.
Synergic programs library for the most common materials.
90/100 memory channels for different welding
parameters.
SmarTac function as a standard feature.
Wire feeder system, A314F LH
Four wheel wire drive mechanism with
metallic feed rolls.
Gas valve.
Speed range: 0 m/min. – 25 m/min.
Options
Weld guide
Torch cleaner, TSC
Wire cutter
Automatic TCP-gauging BullsEye
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2 Technical description
2.3 Components
2.3 Components
Example of welding equipment
The welding equipment can include the following components:
•
Welding power source.
•
Wire feeder unit mounted on the robot arm and fitted with a Euro-socket for
connecting the welding torch.
•
Attachment for the wire feeder mechanism and cables.
•
Hoses for gas and compressed air, as well as cables for signal and power
supplies.
•
Cable for the welding current.
•
Cable for the power source.
Industrial robot with welding equipment
4
3
7
5
2
6
1
8
12
10
11
9
xx1100000485
1
Welding power source (RPC)
2
Attachment
3
Cable and Hose set
4
Wire feeder unit
5
Wire conduit
6
Bobin
7
Welding gun
8
Welding Base Cable Harness
9
Current cable
10
Welding signal Floor Cable
Continues on next page
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2 Technical description
2.3 Components
Continued
11
Returncable 95 mm²
12
Cable DeviceNet
Continues on next page
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2 Technical description
2.3.1 Power source
2.3.1 Power source
Welding applications
The RPC Series power sources are suitable for synergic MIG/MAG, synergic
1-MIG/MAG and basic MIG/MAG welding. The power sources support the three
welding processes:
•
Normal MIG welding
•
1-MIG welding (Default)
•
Wise-MIG (Optional)
In normal MIG welding the wire-feed speed and the welding voltage are adjusted
separately.
Unlike the above, 1-MIG and Wise-MIG processes are synergetic welding processes
where the welding voltage and other welding parameters are interconnected so
that the welding power and arc length are adjusted to attain optimal welding values.
The Wise-MIG process is an optional feature intended for welding automation. It
must be acquired separately and is therefore not available in all configurations.
More information
The power source is described more in detail in Operating manual - KempArc.
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2 Technical description
2.3.2.1 Overview
2.3.2 Wire feeder system
2.3.2.1 Overview
Usage
The wire feed system A314F LH is intended to be mounted directly on the robot,
which results in a short cable bundle and a good wire feed. Furthermore, a smaller
floor area is required.
Note
A314F LH should be used for gas arc welding
Bobbin
If a bobbin is used it may be necessary to adjust the brake hub, see Adjusting the
brake hub of the bobbin on page 60.
Working area
The wire feeder system A314F LH meets Arc Welding and Application Equipment’s
recommended layout setup. This means that the robot has a full working area
within a section of ±170° for A314F LH around axis 1.
The orientation of the bobbin and the wire conduit bracket should be adjusted
according to the working range of axis 2 and axis 3. If not adjusted, the lifetime of
the wire conduit will be reduced greatly due to sharp bends. The default orientation
of the bobbin and the wire conduit bracket is upward. Adjust the orientation so that
there doesn´t occur any sharp bends on the wire.
CAUTION
Great care should be exercised outside of this sector, for example when
programming, otherwise the welding equipment can be damaged
Technical specifications
A314F LH
Data
Operating voltage
50 VDC
Rated power
100 W
Load ability 40°C 80% ED
600 A
Load ability 40°C 100% ED
500 A
Wire feeder speed
0 - 25 m / min
Diameter of filler wire, Fe, SS, Flux cored wire 0.8 - 1.6 mm
Diameter of filler wire, Al
1.0 - 1.6 mm
Welding gun connector
Binzel ROBO Power Connector (RPC)
Operating temperature range
-20ºC to +40ºC
EMC class
A
Continues on next page
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2 Technical description
2.3.2.1 Overview
Continued
A314F LH
Data
Protection class
IP23S
External dimensions
269 x 175 x 169 mm
Weight
3.6 kg
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2 Technical description
2.3.2.2 Wire feeder unit
2.3.2.2 Wire feeder unit
Illustration
xx1100000398
1
Upper feed rollers
2
Adjuster screw
3
Lower feed rollers
4
Motor (On the back)
5
Screws
6
ROBO Torch connector
Feed rollers
Wire is fed using two pairs of feed rollers which are linked to each other. The two
upper rollers are spring-loaded. The power from the motor is transferred to the
rollers via a pinion on the motor shaft.
The pressure between the upper and lower rollers can be adjusted individually
using an adjuster screw. All rollers are fitted with sleeve bearings. The lower feed
rollers have a groove for one wire diameter. The default wire diameter is 1.2 mm.
The whole rollers must be replaced if another wire diameter is used.
Motor
The motor is of a permanent magnetized type and is equipped with an optical
tachometer meter for accurate speed control.
Continues on next page
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2 Technical description
2.3.2.2 Wire feeder unit
Continued
Bobbin
When the bobbin is used the wire liner is fitted directly to the feed mechanism and
is locked by screws.
Connections and switches on the wire feeder unit (Inlet side)
1
xx1100000412
1
Wire feed inlet
Continues on next page
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2 Technical description
2.3.2.2 Wire feeder unit
Continued
Connections and switches on the wire feeder unit (Outlet side)
xx1100000399
1
Wire in switch (Switch for manual wire feed (inch.)
2
Air connector (Compressed air connection to the welding torch)
3
Torch connector (Binzel ROBO Power Connector) connection for the welding
torch.
4
Control connector
5
Shielding gas connector IN (for 8mm hose)
6
Shielding gas connector OUT (for 6mm hose)
Wire inch switch
When the switch is pressed the wire feeder motor starts but the gas valve does
not open and the power source is not activated. The wire feed pace is 2 m/min for
the first two seconds, and then 10 m/min. When the button is released, the wire
feeder stops.
Continues on next page
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2 Technical description
2.3.2.2 Wire feeder unit
Continued
Torch connector
xx1100000400
1
Hole for torch pin
2
Wire liner
3
Hole for wire
4
Lock screw for torch pin
5
Lock screw for cable lug
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3 Installation
3.1.1 Installing the DeviceNet card and cable
3 Installation
3.1 Connecting the welding equipment
3.1.1 Installing the DeviceNet card and cable
Overview
DeviceNet is used for communication between the robot controller IRC5 and the
power source. The card is installed in the power source according to the Operating
manual - KempArc. This section contains information about the DeviceNet card.
DeviceNet card design
xx1100000401
A
DeviceNet Connector
B
Configuration Switches
C
Network Status LEDs
1
(Not used)
2
Network Status (NS)
3
Module Status (MS)
4
(Not used)
Continues on next page
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3 Installation
3.1.1 Installing the DeviceNet card and cable
Continued
DeviceNet connector
The module supports both 5.08 mmm and 3.84 mm pluggable screw connectors
to board connector.
MAC ID and Baud rate configuration
On a DeviceNet network, each node must be assigned its own unique Mac ID. The
Mac ID is a value between 0 and 63 used to identify each node. The Mac ID and
Baud rate settings can be set using a physical DIP-switch.
Switches 1 and 2 specify the baud rate, while switches 3 through 8 specify the Mac
ID.
xx1100000409
ABB Default configuration:
For the first power source: Baud rate: 500K Address: 30.
For the second power source: Baud rate: 500K Address: 31
For the third power source: Baud rate: 500K Address: 32
For the fourth power source: Baud rate: 500K Address: 33
1
2
3
4
5
xx1100000402
Signal
Description
1
V-
Negative supply voltage (DC 0V)
2
CAN_L
CAN_L bus line
3
SHIELD
Cable shield
4
CAN_H
CAN_H bus line
5
V+
Positive supply voltage (DC 24V)
50
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3 Installation
3.1.2 Installing the power source
3.1.2 Installing the power source
Installing the power source
Refer to the Operating manual for the power source to:
Action
1
Locate the power source at an appropriate
installation location.
2
Connect the power source to the electric
network.
3
Connect the welding and earthing cables.
4
Install the field bus card and the field bus
cable (DeviceNet card and DeviceNet cable).
Additional information is found in xx.
Note
Requirements and detailed instructions for all of the steps above are found in the
Operating manual - KempArc.
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3 Installation
3.1.3 Connecting the cables and hoses
3.1.3 Connecting the cables and hoses
WARNING
All personnel working with the welding robot system must have a full
understanding of the applicable safety instructions.
Connection layout
xx1100000403
1
Compressed air hose
2
Shield gas hose
3
Feeder cable
4
Welding cable (positive)
5
DeviceNet cable
6
Welding cable (negative)
Continues on next page
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3 Installation
3.1.3 Connecting the cables and hoses
Continued
Connection points for cables and hoses
The cables and hoses are connected as follows.
Cable / house
Type
DeviceNet cable
Connection points
Connect the cable between the IRC5 controller and the
power source.
Connect the connector CAN IN to the DeviceNet card
through the Robot Control hole on the power sources
rear panel.
Connect the connectors A35.X1.P/X2.P to terminal
A35.X1 or A35.X2 in the IRC5 controller, by entering
through the gland plate XS.7.
Note
Each end of the DeviceNet bus must be terminated with
a 121 ohm resistor. The two terminating resistors should
be as far apart as possible.
xx1100000404
Feeder cable
(signal cable)
A314F LH
Signal description
Terminal
Color
V-
1
Black
CAN L
2
Blue
DRAIN (NC)
3
Gray
CAN H
4
White
V+
5
Red
Connect the cable between the wire feeder unit and the
power source, through the robot base.
Shield gas hose Black house
Connect the hose between the central gas supply or
the gas cylinder and the wire feeder unit.
Compressed air
hose
Connect to the compressed air supply. System pressure:
approximately 6 bar.
Wire guide input
The welding wire is taken to the wire feeder through a
metallic wire guide adapter. Push the wire guide to the
end of the adapter and screw in with the top fixing locks.
Attach a wire guide input at the end of the adapter to
serve as a bend support for the wire guide and to prevent the wire from bending too heavily. Fix the wire
guide input with the bottom fixing locks.
Current cable
Connect the current cable from the wire feeder unit to
the power source.
Continues on next page
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3 Installation
3.1.3.1 Connecting the feeder cable
3.1.3.1 Connecting the feeder cable
Connection on robot base and on wire feeder A314F LH
3
1
2
1
2
3
xx1100000431
1
Control feeder cable to A314F LH, connection on robot base and on wire feeder
Continues on next page
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3 Installation
3.1.3.1 Connecting the feeder cable
Continued
2
Connection, gas feed on robot base and on wire feeder
3
Connection, current cable on robot base and on wire feeder
Feeder cable (floor cable for welding signal)
B
A
VIEW B
VIEW A
xx1100000408
A
To the power source (pin)
B
To the robot base (socket)
Signal description
Signal description for feeder cable for control signal (24 way MIL connector)
Connector to power source (MS4106A24-28P-689) Signal Cable
3HAA2513-2/1
Conector to
robot base
3HAC022151003
Pin
Signal
Pin
A
Wire feed mo- input
tor +
0 V to Wire feed mo- BU
+24 V tor voltage +
B
Wire feed mo- input
tor -
0V
C
Gas valve +
input
0 V / Gas valve
+24 V control
voltage +
Grey
AWG24
C
D
Gas valve -
input
0V
Gas valve
control
voltage -
White AWG24
D
E
nc.
-
-
-
-
-
nc.
F
nc.
-
-
-
-
-
nc.
G
nc.
-
-
-
-
-
nc.
H
nc.
-
-
-
-
-
nc.
J
nc.
-
-
-
-
-
nc.
K
Tacho +5 V
input
+5 V
Tacho supply White AWG26
voltage
Blue
G
L
Tacho GND
input
0V
Tacho supply White AWG26
GND
Green
H
M
Tacho signal output 0 V /
+5 V
Tacho signal White AWG26
from wire
Yellow
feeder
J
N
nc.
-
nc.
P
Isolated +24 V input
Type
-
Level Note
-
Wire Wire type
color
AWG24
A
Wire feed mo- Violet AWG24
tor voltage -
B
-
-
+24 V Analog supply Black AWG24
voltage
E
Continues on next page
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3 Installation
3.1.3.1 Connecting the feeder cable
Continued
Connector to power source (MS4106A24-28P-689) Signal Cable
3HAA2513-2/1
Conector to
robot base
3HAC022151003
Pin
Signal
Pin
Q
Isolated GND input
0V
Analog supply Yellow AWG24
GND
Green
F
R
nc.
-
-
-
-
-
nc.
S
nc.
-
-
-
-
-
nc.
T
Wire inch
output 0 V / Wire test feed OrAWG26
+24 V
ange
Green
K
U
Thruougput4 output 0 V / Free for future Blue AWG26
+24 V use
Green
M
V
Thruougput5 output 0 V / Free for future Violet AWG26
+24 V use
Green
N
W
nc.
-
-
-
-
-
nc.
X
nc.
-
-
-
-
-
nc.
Y
nc.
-
-
-
-
-
nc.
Z
Thruougput6 output 0 V / Gasnozzle
+24 V sensing
Type
Level Note
Wire Wire type
color
White AWG26
Red
56
L
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3 Installation
3.2 Configurating the welding equipment
3.2 Configurating the welding equipment
Overview
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.
Installation disk
The configuration file on the installation disk contains configuration data for the
welding equipment.
Note
As the disk is unique for the equipment supplied, it should be stored in a safe
place. The program number indicated on the disk corresponds to the configuration
in question, and should be referred to in case of service matters regarding the
function of the welding equipment.
Reload configuration data
In case the configuration data must be reloaded, proceed in one of the following
ways:
Alternative
Description
Reboot the robot
The original configuration will be restored.
Loading by using the FlexPendant
Use this alternative if individual parameters
need to be changed compared to the original
configuration.
Loading a new configuration file
(EIO:CFG) Executed by way of the robot instruction:
System Parameters\File\Add or Replace
Parameters\ "file".cfg.
Default configuration
In ABB default configuration, the power source is controlled by the robot in the
way of schedule/memory channel (sometime called as job) and the power source
is recommended to work in 1-MIG mode.
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3 Installation
3.3.1 Torch cleaner (TSC)
3.3 Installing accessories
3.3.1 Torch cleaner (TSC)
Note
The torch cleaner (TSC) communicates with the IRC5 controller by standard I/O
communication. Basically it needs three digital outputs and two digital inputs.
For detailed information refer to Product Specification - TSC.
Connecting the torch cleaner
Action
1
Note
Install the torch cleaner.
xx1100000413
Cable entry can easily be made through
the gland plate (DeviceNet cable used) at
the bottom of the control cabinet.
2
Configurate the I/O ports.
The I/O ports belong to the ABB standard
I/O board, which is the one installed in
the controller. Refer to the I/O configuration file.
3
Connect the line to the port of standard I/O
board.
Connection needs to be done according
to the I/O configuration file.
Example of configuration file
Here is an example of the configuration file for torch cleaner, as for reference:
EIO.CFG_1.0:5:0:
#
# using the spare DOI ports of ABB standard IO unit (d651)
# which is installed in the PIB Box. If using another IO unit,
# this definition can be used as the reference.
EIO_UNIT:
-Name "B_PROC_10" -UnitType "d651" -Bus "DeviceNet1" -DN_Address 10
EIO_SIGNAL:
-Name "doTS1_SpOn" -SignalType "DO" -Unit "B_PROC_10" -UnitMap "35"
-Name "doTS1_St" -SignalType "DO" -Unit "B_PROC_10" -UnitMap "38"
-Name "doTS1_AiBl" -SignalType "DO" -Unit "B_PROC_10" -UnitMap "39"
-Name "diTS1_ClOp" -SignalType "DI" -Unit "B_PROC_11" -UnitMap "7"
-Name "diBE_SENSE" -SignalType "DI" -Unit "B_PROC_10" -UnitMap "8"
#
Continues on next page
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3 Installation
3.3.1 Torch cleaner (TSC)
Continued
Block diagram
2
TB
1
3
xx1100000414
1
TSC
2
Control module
3
Terminal block of IO board
Cable for torch cleaner
xx1100000415
Signal description
Signal description Color
A (TSC)
A (BINZEL)
24V DC
White
4
6
0V DC
Brown
2 and 8
3,4 and 5
Lubrication
Green
11
8
Cleaning
Yellow
10
7
Wire cutter
Gray
1
NC
Cleaning finished Pink
7
9
BullsEye
Blue
16
10
Shield
SC
NC
NC
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B (I/O Unit)
PE
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3 Installation
3.3.2 Adjusting the brake hub of the bobbin
3.3.2 Adjusting the brake hub of the bobbin
Introduction
If a bobbin is used it may be necessary to adjust the brake hub.
WARNING
At high wire speed and when the bobbin is new, the wire can roll off when the
wire feeder unit stops. To avoid this, change the brake hub’s preset value of 5
kpcm (= 0.5 Nm).
Adjusting the brake hub of the bobbin
Action
1
Note
Localize the brake hub (1).
xx1100000416
2
Turn the knob (2) on the brake hub until the
arrows are in line with each other (locked
bobbin position).
xx1100000417
3
The springs (3) on each side of the knob are
screwed in at the same time to increase the
braking force.
Tip
If the wire feed speed is so high that this adjustment does not have any effect,
Marathon Pac should be used
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3 Installation
3.4 Before commissioning
3.4 Before commissioning
Actions before commissioning
DANGER
Make sure all safety requirements are met when performing the first test run.
These are further detailed in the section DANGER - First test run may cause
injury or damage! on page 27.
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4 Operation
4.1 Power source
4 Operation
4.1 Power source
Operating the power source
RPC S series power source is designed to be used only with A314F LH wire feeder
unit and RF 59 control panel. Normally ABB will offer RPC S-400.
Refer to the Operating manual - KempArc for instructions of how to operate the
power source and to learn more about its control panel and functions.
RPC P series power source is designed to be used only with A314F LH wire feeder
unit and KF 62 control panel. Normally ABB will offer RPC P-350. Welding
applications vary, so the equipment must adapt. RPC P-350 features K60 interface,
a clear and logical LCD menu display. Arc Wizard menu allows the operator to
refine, adapt and manage the arc process and system function before, during and
after welding.
Refer to the Operating manual - KempArc for instructions of how to operate the
power source and to learn more about its control panel and functions.
Continues on next page
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4 Operation
4.1.1 Programming the power source
4.1.1 Programming the power source
Default configuration
In the default configuration from ABB, the power source is controlled by the robot
in the way of schedule/memory channel and the power source is recommended
to work in 1-MIG mode.
Before programming
Before programming in IRC5, a set of welding parameters for the seam to be welded
needs to be stored in a selected memory channel. See Operating manual - KempArc
for details.
Programming - setting the welding speed and the schedule number
When programming in IRC5, usually in the component welddata, it is only necessary
to set welding speed and schedule number. Welding voltage and wire feed speed
is saved in the selected schedule/memory channel.
xx1100000418
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4 Operation
4.1.1 Programming the power source
Continued
Optional programming - setting the welding voltage and wire feed speed
It is possible to also specify the welding voltage and wire feed speed directly, which
will override the value in the selected memory channel, but these two values only
take effect when the signal doRpcOnline is set to 1.
Step 1 - set signal doRpcOnloine to 1
Choose one of the two methods.
Method
Description
1
On the FlexPendant, in manual mode.
1 On the ABB menu, tap I/O units.
2 Tap RpcArcDN1.
3 Select doRpcOnline from the list of I/O signals and set it to 1.
xx1100000419
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4 Operation
4.1.1 Programming the power source
Continued
Method
Description
2
In a RAPID program:
Add instruction for setting "doRpcOnline" to 1.
xx1100000423
Step 2 - set the voltage and wire feed speed
Action
3
Set welding voltage and wire feed speed in the welddata, as shown in the figure:
xx1100000424
During welding, the specified welding voltage and wire feed speed override the
value in the selected memory channel.
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4 Operation
4.2 Wire feeder unit
4.2 Wire feeder unit
Threading the wire and adjusting tightness
Refer to Operating manual - KempArc for instructions of how to thread the wire
and adjust the tightness.
Manual wire feed - different methods
Method
Description
1
Push the button for manual wire feed on the front of the wire feeder unit.
2
Activate the function Manual wire feed (Forward or Backward) from the robot's
FlexPendant in test mode under the following window: ABB Menu\RobotWare
Arc\Manual functions.
xx1100000425
Note
If tapping the “Stickout “button from the robot's FlexPendant in test mode, the
wire feeder will feed 15 mm wire every time.
Continues on next page
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4 Operation
4.2 Wire feeder unit
Continued
Method
Description
3
Activate the robot output (doRpc1WireInch or doRpc1WireRetract) from the robot's FlexPendant in test mode under the following window: ABB Menu\I/O
Units\RpcArcDN1.
xx1100000426
Explanations for the different methods of manual wire feed
The table shows the differences between the methods.
Method
Explanation
1
When the Wire inch button is pressed, the wire feeder motor starts but the gas
valve does not open and the power source is not activated. The wire feed pace
is 2 m/min for the first two seconds, and then 10 m/min. When the button is released, the wire feeder stops.
2
The arc weld function “Manual Wire feed” is called from the robot's programming
unit. The robot activates the output (doRpc1WireInch or doRpc1WireRetract)
and the function is the same as when the Manual feed button on the wire feeder
unit is pressed in. The function is active as long as the button is hold.
3
The function is active as long as the output signal (doRpc1WireInch or
doRpc1WireRetract) is set to 1.
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5 Maintenance
5.1 Introduction
5 Maintenance
5.1 Introduction
Planning maintenance
Please consider the utilisation level and working environment of the equipment
when planning routine maintenance.
Unnecessary downtime and equipment failure are avoided with correct operation
of the equipment and with regular maintenance.
Safety
WARNING
This work must only be carried out by persons trained in the complete installation,
who are aware of the particular risks associated with its different parts.
DANGER
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.
CAUTION
Only use genuine spare parts and extra accessories that are recommended by
ABB.
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5 Maintenance
5.2 Daily maintenance
5.2 Daily maintenance
Daily maintenance procedures
• Check the overall condition of the welding gun. Remove welding spatter from
the contact tip and clean the gas nozzle. Replace worn or damaged parts.
Only use original ABB spare parts.
•
Check the condition and connection of the welding circuit components:
welding gun, earth return cable and clamp, sockets and connectors.
•
Check the condition of the feed rolls, needle bearings and shafts. Clean and
lubricate bearings and shafts with a small quantity of light machine oil if
necessary. Assemble, adjust and test function.
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5 Maintenance
5.3 Service shop maintenance
5.3 Service shop maintenance
General
ABB Service Workshops complete maintenance according to their ABB service
agreement.
The major points in the maintenance procedure are listed as follows:
•
Cleaning of the machine
•
Checking and maintenance of the welding tools
•
Checking of connectors, switches and potentiometers
•
Checking of electric connections
•
Checking of mains cable and plug
•
Damaged parts or parts in bad condition are replaced by new ones
•
Maintenance testing.
•
Operation and performance values of the machine are checked, and when
necessary adjusted by means of software and test equipment.
•
ABB Service Workshops can also test and load firm ware and welding
software.
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5 Maintenance
5.4 Power source
5.4 Power source
Maintenance information
See Operating manual - KempArc for both periodical and regular maintenance and
for information about disposal of the machine.
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5 Maintenance
5.5 Wire feed unit
5.5 Wire feed unit
Illustration of the wire feed unit
xx1100000398
1
Upper feed rollers
2
Adjuster screws
3
Lower feed rollers
4
Motor (On the back)
5
Inlet guide and screws
Regular maintenance
Action
Note
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 To ensure satisfactory feed of the wire,
bore of the outlet nozzle.
the grooves in the feed rollers should
be cleaned at regular intervals.
4 Purge the wire conduit by compressed air when
changing the wire and as necessary.
When the wire conduit is worn out, replace it.
5 Use filler wire that is free of impurities.
Dirt can cause slipping.
Changing the wire
There is a groove in the feed rollers, for a specified wire diameter.
Replace the feed rollers to change the groove if changing the wire diameter.
Continues on next page
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5 Maintenance
5.5 Wire feed unit
Continued
Note
The bearings of the motor and the gearbox are permanently lubricated and
maintenance-free.
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5 Maintenance
5.6 Before commissioning
5.6 Before commissioning
DANGER
Make sure all safety requirements are met when performing the first test run.
These are further detailed in the section DANGER - First test run may cause
injury or damage! on page 27.
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Index
Index
responsibility and validity, 11
fence dimensions, 20
fire extinguishing, 21
FlexPendant, 22
introduction, 9
manipulator system, 11
service, 11
signals, 25
signals in manual, 25
symbols, 25
test run, 27
safety risk
electric parts, 18
hot parts, 15
installation, 12
operational disturbance, 17
service work, 12
tools, 16
voltage, 18
work pieces, 16
safety signals
in manual, 25
signals
safety, 25
symbols
safety, 25
S
V
C
carbon dioxide extinguisher, 21
connection
external safety devices, 11
D
danger levels, 25
E
emergency stop
definition, 23
devices, 24
enabling device, 22
F
fence dimensions, 20
fire extinguishing, 21
H
hold-to-run, 22
R
safety
emergency stop, 23
validity and responsibility, 11
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ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics
Discrete Automation and Motion
Box 265
N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.
5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
www.abb.com/robotics
3HAC043438-001, Rev A, en
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