Product Manual 504 869-102 2002-10-24 Welding Equipment/M2001 A140E/A314E/A324E-L Flexible(LAW/RPA), ARCITEC(LRB/LRC)
The information in this document is subject to change without notice and should be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB be liable for damages of any nature from the use of this document. This document and parts thereof must not be reproduced or copied without ABB´s written permission, and the contents thereof must not be imparted to a third party nor be used for any unauthorized purpose.
504 106-502 CONTENTS Page 1 General ......................................................................................................................... 2 Safety ............................................................................................................................ 7 2.1 General............................................................................................................... 7 2.2 Manufacturer’s declaration ..........................................................
504 106-502 6.6 6.7 6.8 Options for Increased Functionality................................................................... Software Maintenance........................................................................................ Service and Programming Aids ......................................................................... 6.8.1 CAN-Assist, Art. no. 502 800-880 ........................................................ 6.8.2 Indication unit for PIB, Art. no. 505 100-001 .......................
Welding equipment General 1 General This manual is made up of a safety section, technical description of the wire feed system A140E/A314E/A324E-L, information on installation and operating the system and schematics. Another separate manual contains the spare parts list. The manuals can either be purchased as freestanding documents or as optional sections to the Product Manual for the IRBP welding robot system.
Welding equipment General 6 Allmänt-svetsutr_eng.
Welding equipment Safety 2 Safety 2.1 General The purchaser/user of ABB’s robot welding equipment is responsible that the equipment is installed and used in the manner stated by the supplier. Also adhere to the standards and safety directives of respective countries. Read carefully through all the manuals supplied, especially the section covering safety, before unpacking, setting up, or using the station.
Welding equipment a3(tiff) Safety Figure 1 Manufacturer’s declaration. 8 Säkerhet-svetsutr_eng.
Welding equipment Safety 2.3 Installation • When unpacking, check that all the equipment has been supplied and that it has not been damaged during transportation. Damaged or broken equipment can mean a safety risk. • Remove all packaging after unpacking to avoid the risk of fire. Leave suitable packaging for recycling. • Ensure that the equipment, or parts of it, do not tip or fall over when unpacking or transporting. • “Secure” the load before it is taken from the packaging.
Welding equipment Safety If possible, carry out spatter cleaning in a special area where welding spatter and oil can be collected. Welding spatter and oil on the floor brings about a risk of slipping. 2.5 Fire risk There is a risk of fire in connection with welding. Ensure the area around the workplace is free from inflammable material. Clean the area regularly. Follow local directives for welding. Make sure all connections in the welding current circuit are correctly tightened.
Welding equipment Technical Description 3 Technical Description The welding equipment A140E/A314E/A324E-L (E for Extended range) is adapted for the control from the IRB 140/1400/2400 robot with the S4Cplus control system. Together with the AW software in the robot and the PIB process interface the system has the following characteristics: • Large working area,- With an optical tachometer, with a high frequency resolution in the wire feed unit, a stable wire feed is obtained, across the speed range: 0.
Welding equipment Technical Description Robot Welding System "Flexible Interface" for power sources RPA, LAW and LAF. A140E/A314E A324E-PIB Power source RPA LAW LAF S4Cplus CANbus Device Net gas/water sensor Option TC BullsEye collision sensor PIB Option Smartac Control cabinet Figure 2 Overview of "Flexible Interface" connections.
Welding equipment Technical Description A140E/A314E/ A324E-PIB S4Cplus gas/water sensor PIB Option Smartac CANbus Option Power source LRC TC Bullseye collision sensor Control cabinet Figure 4 Overview of "ARCITEC" connections LRC. Teknbeskr_eng.
Welding equipment Technical Description Incorporated components A140E 1 Wire feed mechanism mounted and fitted with a Euro-socket for connecting the welding gun. 2 Connections for media. 3 Cable for the power source - control cabinet, valid for separate power source. 4 Separate power source 5 Power source, integrated in separate cabinet, placed under the control cabinet (not in picture).
Welding equipment Technical Description Incorporated components A314E/A324E-L 1 Wire feed mechanism mounted on the robot arm and fitted with a Eurosocket for connecting the welding gun. 2 Attachment for the wire feed mechanism and cables. 3 Hoses for gas, water and compressed air, as well as cables for signal and power supplies. 4 Cable for the welding current. 5 Cable for the power source - control cabinet, valid for separate power source. 6 Separate power source (with Flexible Interface).
Welding equipment Technical Description 3.1 Wire feed system A140E/A314E/A324E-L There are two options of wire feed systems: bobbin or marathon pac. A314E/A324E-L should be used for gas arc welding. 3.2 Wire feed system A314E/A324E-L The wire feed system A314E/A324E-L meets Arc Welding & Application Equipment’s recommended layout setup. This means the robot has a full working area within a section of ±150° for A314E/A324E-L, around axle 1. Great care should be exercised outside of this sector, e.g.
Welding equipment Technical Description 3.2.1 Wire feed unit Wire is fed using two pairs of feed rollers, see Figure 8, which are linked to each other. The power from the motor is transferred to the rollers via a pinion on the motor shaft. The two upper rollers (1) are spring-loaded. The pressure between the upper and lower rollers can be adjusted individually using an adjuster screw (2). All rollers are fitted with sleeve bearings. The lower feed rollers (3) have grooves for two different wire diameters.
Welding equipment Technical Description Replacement - Repair When refitting the drive motor in the event of replacement or repair of the motor the motor shaft must be centered in relation to the two feed rollers, using the centering device (art. no. 500 332-001) in order to avoid wear as regards teeth and bearings. Dismantling 1 Remove the two drive rollers. 2 Dismount the driving gear and the three Allen screws. The drive motor can now be lifted out.
Welding equipment Technical Description 3.2.3 Main data Wire diameters Max. wire feed unit Permitted ambient temperature 0.8 mm - 1.6 mm 30 m/min. 0ºC - +40ºC 3.3 PIB Process Interface Board The PIB is an I/O unit particularly adapted for welding robot systems and handles the communication between the robot control system and the welding equipment. The PIB is described in detail in chapter 6 of this manual. Teknbeskr_eng.
Welding equipment Technical Description 20 Teknbeskr_eng.
Welding equipment Installation 4 Installation 4.1 Configuration of Welding Equipment 4.1.1 Flexible Interface/ ARCITEC (LRB/LRC) On delivery the equipment is configured according to applicable configuration data which are stored on the disk that comes with the delivery. The data can be read and modified by way of the robot programming unit. See chapter 6.5. For the definition of configuration data, see “Appendix 1” on page 57.
Welding equipment Installation 4.2 Installation of the wire feed system The cables are connected as follows (see Figure 10): 1 Feeder cable 1, A140E, Feed unit - Control cabinet 23-pole connection at both ends Feeder cable 1, A314E/A324E, Foot of the robot - Control cabinet 23-pole connection at both ends 2 Feeder cable 2, A140E Feed unit - Control cabinet 12-pole connection at Wire feed unit and 19-pole connection at Control cabinet.
Welding equipment 504806a01 Installation Figure 11 Circuit diagram, Wire feed unit A140E/A314E/A324E-L_PIB Installation_eng.
Welding equipment Installation Kopplingstabell kablar/ Connection table, cables Control cabinet XP106 Feed unit Circuit diagram Figure 11 PIB TB6 FEED 1 Feeder Cable 1, A140E/A314E/A324E-L Signalbeskrivning/ Signal Description A B Färg Colour Gun Reset B B Vit White Gun Crash Sensor N N Brun Brown Current Sensor P P Grön Green Water Flow Sensor D D Gul Yellow Gas Flow Sensor F F Grå Gray Tacho + K K Rosa Pink Tacho - (Encoder Tacho input) L L Blå Blue Manual Wire
Welding equipment Installation Control cabinet XP105 Feed unit Circuit diagram Figure 11 PIB TB5 FEED 2 Feeder Cable 2, A140E/A314E/A324E-L Signalbeskrivning/ Signal Description A B Färg Colour Motor + A A Vit White Motor + B B Brun Brown Motor + C C Grön Green Motor - D D Gul Yellow Motor - E E Grå Gray Motor - H H Rosa Pink PneumaticSpatter Cleaning (42/115VAC) G G Blå Blue Gas Valve (42/115 VAC) K K Röd Red Arc Voltage Gun M M Svart Black Smartac 1
Welding equipment Installation 4.3 Connection of Power Sources LAW Power source LAW is connected to terminal XP107 on the Control cabinet. Control cabinet XP107 Power source PIB TB3 Control cable LAW Signalbeskrivning/ Signal Denomination Part/Core A B 42V AC 1 B A Start PS 2 F B Ref. 3 K C 0V 4 L D Weld-/Weld Object 5 N F Arc Voltage Gun 6 H G NC SH Shield A 503215A1 B XP107 Control cabinet LAW EXT.
Welding equipment Installation RPA Power source RPA is connected to terminal XP107 on the Control cabinet. Control cabinet XP107 Power source PIB TB3 Control cable RPA Signalbeskrivning/ Signal Denomination Part/Core A B 0V wh (par/pair 1) B B Start PS bu (par/pair 1) E C Ref. wh (par/pair 2) - A byglas med D/ A bridged with D 0V or (par/pair 2) A D byglas med A/ D bridged with A WELD-/WELDOBJ. SH F NC XS WELD SH B 503218C1 A XP107 Control cabinet RPA XS WELD EXT.
Welding equipment Installation LAF Power source LAF is connected to terminal XP107 on the control cabinet. Control cabinet XP107 Power source PIB TB3 S(ENSE cable) wire to weld object Control cable LAF Signalbeskrivning/ Signal Denomination A B Startingång: Anslutning för yttre slutande kontakt mellan A och B./ Start: External closing contact between A and B. A A Startingång: Anslutning för yttre slutande kontakt mellan A och B./ Start: External closing contact between A and B.
Welding equipment Installation LRC Power source LRC is connected to terminal XP107 on the Control cabinet. Control cabinet XP107 Power source PIB TB3 Control cable LRC Signalbeskrivning/ Signal Denomination Part/Core A B Spare 1 D 1 Spare 2 E 2 Ext. enable 3 F 3 Ext. enable 4 C 4 Welding minus (OKC) 5 M 5 Welding measure - (Ext.) 6 J 6 Welding measure + (Ext.) 7 H 7 SH SH PE A 503354A1 B XP107 Control cabinet LRC EXT.
Welding equipment Installation 4.4 Installation of accessories 4.4.1 Cooling unit OCE 2 (included in welding gun set PKI 500R and Binzel WH 455D) 1 Connect the cable bundle to the cooling unit as follows: - Red water hose to the cooling unit’s return connection IN. - Blue water hose to the cooling unit’s feed connection OUT. - Air hose to the compressed air supply. - Gas hose to the gas cylinder.
Welding equipment Installation 4.4.2 Torch Cleaner TC For LAW, RPA, LAF ARCITEC: Mechanical torch cleaner TC is connected to terminal XP108 on the control cabinet.
Welding equipment Installation 32 Installation_eng.
Welding equipment Maintenance 5 Maintenance 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. 5.0.1 Wire feed unit Make a visual inspection of the equipment and correct errors, if any, for reliable operation. 1 Purge the inside of the feed unit as necessary by compressed air at reduced pressure.
Welding equipment Maintenance 34 Underhåll-svetsutr_eng.
PIB Process Interface Board 6 PIB Process Interface Board 6.1 General The PIB is an I/O unit with integrated wire feed regulator communicating directly with the ABB robot control system S4Cplus for control and monitoring of the robot welding. The configuration is done in the same way as for a standard I/O unit. The PIB characteristics are determined by the transfer of configuration parameters for power sources and feed units.
PIB Process Interface Board 6.2 Voltage Version - Power Supply - Article Number PIB is available in two voltage versions: - for feed units with voltage supply to the final stage of the feed unit regulator of max. 42V AC/ 10A, article no. 501 700-880. - for feed units with voltage supply to the final stage of the feed unit regulator of max. 115V AC/ 3.5A, article no. 501700-881. They are marked Low voltage or High voltage. See Figure 20.
PIB Process Interface Board 6.4 Marking and Version Handling Figure 20 shows the location and disposition of the article and manufacturing numbers. This marking indicates the hardware version of PIB – not the software one. The software version is indicated under the configuration menu in the programming unit for the robot as a non-editable four digit number. The number is automatically updated when the software version is changed.
PIB Process Interface Board 6.5 Configuration Programmable parameters enable the adaptation to different types of welding equipment. The configuration parameters determine: - the control properties - the scale factors - the offset values - the max. and min. values, etc. Flexible • A manual standard power source enabling remote control by way of analogue references and with the on/off function, for example LAW 350R/ 500R, RPA 400, LAF, Miller Delta Weld, etc.
PIB Process Interface Board 6.7 Software Maintenance PIB is equipped with a programming terminal and programming switches for loading the software into the program memory on the PIB, see Figure 21. Replacement of the software is only demanded in exceptional cases, for example, after a software revision or functional upgrade and ought to be carried out by the PIB supplier or by trained ABB personnel. This type of programming should not be confused with loading configuration parameters.
PIB Process Interface Board 6.8 Service and Programming Aids 6.8.1 CAN-Assist, Art. no. 502 800-880 PC based tool that in Passive Mode allows listening to the CAN-bus traffic in the Weld system during the current process. In Master Mode, with the connection to the robot master disconnected, the I/Ofunction in the different units in the system can be activated, parameters loaded or changed. CAN-Assist is supplied as a package with hardware and a CD containing software and documentation. 6.8.
PIB Process Interface Board When the error is corrected a message appears to confirm the this. If a two errors occur at the same time and the first error is not corrected this is shown during the next restart. If the second error is corrected the previous error returns during the next start. If both errors are eliminated at the same time only the last one is confirmed. Table Error messages From PIB with version numbers -503.
PIB Process Interface Board 6.10 Connecting Cable Shields The metal bar on the upper side of the PIB is provided with holes for the fitting of 2 cable clamps coming with the delivery of the PIB. The clamps are to be screwed tightly onto the metal bar. In order for the PIB to function correctly it is important that the shield connections are made precisely. See Figure 22. This mainly applies to the two cables from the wire feed unit. If possible, they should be routed at some distance from each other.
PIB Process Interface Board 6.11 Safety 6.11.1 Personal Safety Moving parts which according to the EU machinery directives might cause personal injury are interlocked via the robot holding device and emergency circuit. Such functions are manual wire feed and mechanical cleaning of the gun. Figure 23 on page 50 shows the build-up of the PIB interlocking system.
PIB Process Interface Board The start of the running of the program is blocked until acknowledged. Trying to start before acknowledgement will result in the Run Chain relay opening and the G-stop chain breaking. The reset procedure must then be repeated. To prevent the PIB remaining in the reset function - due to circuit interruption, for example - and to ensure that a further collision will stop the robot, the reset time is limited to 1 minute.
PIB Process Interface Board 6.12 Signal Connections See also Figure 19 on page 35 and Figure 23 on page 50. TB stands for Terminal Block. 6.12.1 Table - Signal Connections TB1 - Power Supply and Interlocking Function, Voltage Designation Out In Explanation 1 Motor Supply AC Power supply for the motor regulator, interlocked 42V max. for PIB 501700-880 115V max.
PIB Process Interface Board TB2 - CAN bus Connection Designation Function, Voltage Out In Explanation 1 Sys 0V DC System 0 (=Robot I/O noll) 2 CAN Low Serial comm. CAN Low * 3 Ground DC Ground, screen 4 CAN High Serial comm.
PIB Process Interface Board TB3 - Connection to Power Source Designation Function, Voltage Out In Explanation 1 Start Power Source A Closing contact x Control relay for power source (or cooling fan, ARCITEC) 2 Start Power Source B Closing contact x Control relay for power source (or. cooling fan, ARCITEC) 3 Weld ref. Analog 0-15 V x Reference for welding voltage 4 Ref. Common Analog common x Reference zero 5 Induct.
PIB Process Interface Board TB5 - Connection 1 to Wire Feed Unit Designation Function, Voltage Out In Explanation 0-60/0-170V DC x Motor voltage x Motor voltage 1 Motor + 2 Motor - 3 Pneum Spatter Cleaning 42V AC x To solenoid valve for Pneumatic spatter cleaning 4 Gas Valve 42V AC x To solenoid valve for shielding gas 5 Arc Voltage Gun 0-70V DC 6 Smartac 1 40V DC x Search voltage for Smartac Sensor 1 7 42V AC Phase x Supply voltage for Push feed unit 8 42V AC Common Z
PIB Process Interface Board TB6 - Connection 2 to Wire Feed Unit Designation Function, Voltage Out In Explanation 1 Gun reset 24V DC x Resetting the collision sensor 2 Gun Crash 24V DC x Collision sensor 3 Current Sense 24V DC x Welding current sensor 4 Water Flow 24V DC x Water flow sensor 5 Gas Flow 24V DC x Gas flow sensor 6 NC NC 7 Encoder TG INPUT DC Puls x DC- or AC-tacho/input for encoder tacho 8 Man.
PIB Process Interface Board 502540s4c+ 6.12.2 Elementary Diagram - Power Supply and Interlocking Figure 23 Elementary Diagram, Power Supply, Safety and Interlocking. 50 PIB-M2001_eng.
PIB Process Interface Board 6.13 Technical Specification 6.13.1 Mechanical Data Dimensions: 257x196x72.5 mm Weight: 2.1 kg Enclosure class: IP 20 6.13.2 Electrical Data Power supply: See Figure 24 on page 52 - Transformers. Digital outputs: Continuous load/output: max. 350 mA. Total output load: max. 1.6 A, < 70°C. Tripping of overload protection per output: 370 mA. Remark: Regarding capacitive load > 0.05 uF a temporary overload can arise at the start causing the overload protection to trip.
PIB Process Interface Board 6.14 Transformers Article No. 501 714-001/-002 brun/brown gul/yellow röd/red 42V 7.5A Uo=43.5V 230V 50Hz 28V 3A Uo=28.9V gul/yellow vit/white 0-230V 0-28V 0-115V 115V 2.7A Uo=118.9V orange vit/white 28V 3A S2 Uo=28.9V vit/white gul/yellow orange S1 28V 7.5A svart/black Uo=28.9V P1 HV -002 R=2,2 Ohm 10W R=2,2 Ohm 10W 230V 50Hz LV -001 High Voltage Low Voltage gul/yellow 0-28V 0-28-42V 501714c1 0-230V Marking vit/white Figure 24 Transformers.
PIB Process Interface Board 6.15 SmartacPIB 6.15.1 General Smartac/PIB is a further development of the ABB joint search device Smartac. Mechanically and electrically it is integrated with the ABB welding interface PIB (Process Interface Board). smartac The unit has two sensor inputs, which can be activated one at a time or simultaneously. Figure 25 smartac-pib The unit is a so-called "Add-on" unit and is connected to the PIB by way of a 32-pole connector of the Euro type, see Figure 30.
PIB Process Interface Board 6.15.2 Sensors In the welding system A314/A324 containing PIB, the input for sensor 1 is connected to the gas cup of the welding gun, whereas sensor input 2 is connected to the welding nozzle for searching by way of the welding wire. Using sensor 2 it is usually necessary to disconnect the welding circuit to avoid current diversion through the power source resulting in too low search voltage. Searching with sensor 2 is only used for special applications. 6.15.
PIB Process Interface Board Sensitivity (Sensor Detection Sensitivity) The adjustable parameter Sensor Detection Sens determines the sensitivity of the sensor. Configuration range: 0-25.5V in steps of 0.1V. The Smartac trigger level is locked by the message doSE_REF=1 from the robot according to the following: Trigger level = the present search voltage - the Sensor Detection Sens value. Under normal conditions reliable search is achieved using values > = 1V.
PIB Process Interface Board Delivery data 53 65 185 mm Product number ABB Version number 15 503400A1 22 xxxxxxx-xxxx xxxxxxx xxxxxx Serial number Date of testing 10 ABB article number Figur 27 Smartac unit. Figur 28 Smartac indication unit 56 PIB-M2001_eng.
Welding equipment Appendix 1 7 Appendix 1 Configuration parameters The configuration parameters are defined for 3 demands: 1 They should be an integer in order to simplify handling in the microprocessor in the PIB. 2 The integer should be large enough so that the desired accuracy and resolution are obtained. 3 Programming from the robot should be possible to be expressed in actual quantities, for example, 21.4 m/min for the wire speed, 32.2 V for the welding voltage, etc.
Welding equipment Appendix 1 Transfer of parameters between the robot and PIB, The configuration parameters are sent from the robot’s system parameter memory to the PIB each time the system voltage is switched on. If the parameters are equal to those already in the PIB no writing to the PIB is carried out.
Welding equipment Appendix 1 7.0.1 Table Configuration parameters Parameter name Parameter name in teach pendant Parameter behavior Parameter range/ denomination Software Revision SoftwareRevison Current software revison (readonly) - Motor Max Voltage MotorMaxVoltage Maximum allowed voltage for the DC-motor connected. {0...110} V Motor Current Limit MotorCurrentLim Maximum allowed current for the DC-motor connected. {0...100} 0.
Welding equipment Appendix 1 *Process Equipment Reference Convers., Flexible ProcEquipRef Conv Conversion factor between the process quantity in the set value and the reference voltage {1000...30000}e-3 Process quantity / Vref *Process Equipment Reference Offset, Flx. ProcEquipRef Offset Offset value for the process. Given in process quantity units. {0...1000} 0.1 V *Process Equipment Max Reference Voltage ProcEquipMaxRef Maximum allowed reference voltage. {0...1000} 0.
Welding equipment Appendix 2 8 Appendix 2 Manual wire feed with PIB and S4Cplus, possibilities and limitations: Manual wire feed can be carried out in three different ways: 1 By pushing in the non-locking push button for manual wire feed on the welding gun or on the front of the wire feed unit. 2 By activating the function Manual wire feed from the robot’s programming unit in test mode under: Program window\Arcweld\Manual wirefeed.
Welding equipment Appendix 2 2. Limitation for reasons of personal safety. 3. Note: The reference only applies as long as aoFEED is not changed by any other function: The methods 1 and 2 or execution of a program with another value. After using methods 1 or 2 the reference is reset. 62 Appendix2eng_Man trådmatning.
Welding equipment Appendix 3 9 Appendix 3 System accuracy: verification and trimming possibilities. Wire feed: Feed unit A140E/A314E/A324E-L A check of the wire feed unit’s accuracy ought to be carried out by measuring the motor tachometer’s pulse frequency and not by measuring the fed wire and time measurement in order to avoid errors, due to wire slip and errors during starting and stopping.
Welding equipment Appendix 3 m/min Hz m/min Hz m/min Hz 3.0 619 13.0 2684 23.0 4749 3.5 723 13.5 2787 23.5 4852 4.0 826 14.0 2891 24.0 4955 4.5 929 14.5 2994 24.5 5059 5.0 1032 15.0 3097 25.0 5162 5.5 1136 15.5 3200 25.5 5265 6.0 1239 16.0 3304 26.0 5368 6.5 1342 16.5 3407 26.5 5471 7.0 1445 17.0 3510 27.0 5575 7.5 1549 17.5 3613 27.5 5678 8.0 1652 18.0 3716 28.0 5781 8.5 1755 18.5 3820 28.5 5884 9.0 1858 19.0 3923 29.
Welding equipment Appendix 4 10 Appendix 4 Smartac; Optimising the search circuit The function of the Smartac is, to a great extent, dependent on the insulation characteristics of the search circuit. 1 Water cooled gun Distilled water or demineralizized water should be used for the best function. The welding gun should be filled with the water when searching. In other words: The cooling pump should be switched on.
Welding equipment Appendix 4 - Perform searching in this way so that the risk of the wrong sensor coming into contact first with the workpiece is minimised. 66 Appendix4eng_Smartac_sökfel.
504 869-102
