Signal Description

Arc Welding Products IRC5 Design 2006

3HEA 802349-001 Rev . A

The information in this document is subject to alteration without prior notice and should not be regarded as an undertaking from ABB Automation Technologies AB. ABB Automation Technologies AB assumes no responsibility for errors that may occur in this document. ABB Automation Technologies AB bears no responsibility for damage that is a consequence of using this document or the software or hardware described in this document. The document, or parts of it, may not be reproduced or copied without prior permission from ABB Automation Technologies AB. It may neither be imparted to a third party nor otherwise be used without authorization. Infringement hereof will be subject to action in accordance with applicable laws. Further copies of this document can be obtained from ABB Automation Technologies AB at current prices.

2005 ABB Automation Technologies AB ABB Automation Technologies AB Robotics & Manufacturing SE-72168 Vsters Sweden

Contents
Signal Description Arc Welding Products IRC5 M2004

1 General I/O Description 2 Process Interface Arcitec/MigRob 2.1 I/O Board configuration 2.2 I/O Signals Configuration B_PROC_30 2.2.1 Digital outputs 2.2.2 Digital inputs 2.2.3 Analogue outputs 2.2.4 Analogue inputs 2.3 I/O Signals Configuration B_AW_PROC_40 2.3.1 Digital outputs 2.3.2 Digital inputs 2.3.3 Group outputs 2.3.4 Analogue inputs 2.4 I/O Signals Configuration B_AW_SIM 2.4.1 Digital output 3 Process Interface ARCITEC/MigRob, Robot 2 3.1 I/O Board configuration 3.2 I/O Signals Configuration B_PROC_31 3.2.1 Digital outputs 3.2.2 Digital inputs 3.2.3 Analogue outputs 3.2.4 Analogue inputs 3.3 I/O Signals Configuration B_AW_PROC_41 3.3.1 Digital outputs 3.3.2 Digital inputs 3.3.3 Group outputs 3.3.4 Analogue inputs 3.4 I/O Signals Configuration B_AW_SIM 3.4.1 Digital output 4 Process Interface RPB 4.1 I/O Board configuration 4.2 I/O Signals Configuration B_PROC_30 4.2.1 Digital outputs 4.2.2 Digital inputs 4.2.3 Analogue outputs 4.2.4 Analogue inputs 5 Process Interface RPB, Robot 2

1 3 3 4 4 5 5 5 6 6 6 6 7 7 7 9 9 10 10 11 11 11 12 12 12 12 13 13 13 15 15 16 16 17 17 17 19

3HEA 802349-001 Rev . A

5.1 I/O Board configuration 5.2 I/O Signals Configuration B_PROC_31 5.2.1 Digital outputs 5.2.2 Digital inputs 5.2.3 Analogue outputs 5.2.4 Analogue inputs 6 Process Interface Fronius 6.0.1 Process Interface DeviceNet for Fronius 6.1 I/O Board configuration 6.2 I/O Signals Configuration FRON_BOARD_40 6.2.1 Digital outputs 6.2.2 Digital inputs 6.2.3 Analogue outputs 6.2.4 Group outputs 6.2.5 Group input 6.3 I/O Signals Configuration BOARD20 6.3.1 Digital outputs 6.3.2 Digital inputs 7 Process Interface Fronius, Robot 2 7.0.1 Process Interface DeviceNet for Fronius 7.1 I/O Board configuration 7.2 I/O Signals Configuration FRON_BOARD_41 7.2.1 Digital outputs 7.2.2 Digital inputs 7.2.3 Analogue outputs 7.2.4 Group outputs 7.2.5 Group input 7.3 I/O Signals Configuration BOARD20 7.3.1 Digital outputs 7.3.2 Digital inputs 8 Positioner Interface IRBP A 8.1 I/O board Configuration for positioner 8.2 Simulated outputs for B_POS_SIM 8.2.1 Simulated outputs 8.2.2 Simulated inputs 8.3 I/O-Signals configuration for DRVIO_1 8.3.1 Digital outputs TB4 8.3.2 Digital inputs TB3 8.4 Configuration cross-connections 9 Positioner Interface IRBP B/D

19 20 20 21 21 21 23 23 23 24 24 26 26 26 27 27 27 27 29 29 29 30 30 31 32 32 32 33 33 33 35 35 36 36 36 37 37 37 38 39

ii

3HEA 802349-001 Rev . A

9.1 I/O board Configuration for positioner 9.2 Simulated outputs for B_POS_SIM 9.2.1 Simulated outputs 9.2.2 Simulated inputs 9.3 I/O-Signals configuration for DRVIO_1 9.3.1 Digital outputs TB4 9.3.2 Digital inputs TB3 9.4 Configuration cross-connections 10 Positioner Interface IRBP C 10.1 I/O board Configuration for positioner 10.2 Simulated outputs for B_POS_SIM 10.2.1 Simulated outputs 10.2.2 Simulated inputs 10.3 I/O-Signals configuration for DRVIO_1 10.3.1 Digital outputs TB4 10.3.2 Digital inputs TB3 10.4 Configuration cross-connections 11 Positioner Interface IRBP C Index 11.1 I/O board Configuration for positioner 11.2 Simulated outputs for B_POS_SIM 11.2.1 Simulated outputs 11.2.2 Simulated inputs 11.3 I/O-Signals configuration for B_POS_21 11.3.1 Digital outputs TB4 11.3.2 Digital inputs TB3 11.4 Configuration cross-connections 12 Positioner Interface IRBP K/R 12.1 I/O board configuration for positioner 12.2 Simulated outputs for B_POS_SIM 12.2.1 Simulated outputs 12.2.2 Simulated inputs 12.3 I/O-Signals configuration for DRVIO_1 12.3.1 Digital outputs TB4 12.3.2 Digital inputs TB3 12.4 Configuration cross-connections 12.4.1 K/R 3DU (3 axes) 12.4.2 K/R 1DU (1-axis) 13 Positioner Interface IRBP L

39 40 40 40 41 41 41 42 43 43 44 44 44 45 45 45 46 47 47 48 48 48 49 49 49 50 51 51 52 52 52 53 53 53 54 54 55 57

3HEA 802349-001 Rev . A

iii

13.1 I/O board configuration for positioner 13.2 Simulated outputs for B_POS_SIM 13.2.1 Simulated outputs 13.2.2 Simulated inputs 13.3 I/O-Signals configuration for DRVIO_1 13.3.1 Digital outputs TB4 13.3.2 Digital inputs TB3 13.4 Configuration cross-connections 14 Operator Interface IRBP 14.1 I/O board Configuration 14.2 System functions 14.2.1 Inputs 14.2.2 Outputs 14.3 I/O-Signals configuration for B_OP_SIM 14.3.1 Digital outputs 14.4 I/O Signals configuration for B_OP_21, B_OP_22 14.4.1 Digital outputs 14.4.2 Digital inputs 15 Safety interface SIB V for positioner B/C/D/K/R 15.1 I/O board Configuration SIB V 15.2 I/O-signal configuration for SIB_V_B1 15.2.1 Digital inputs 15.2.2 Digital inputs 15.2.3 Configuration cross-connections 16 Safety interface SIB V for positioner C Index 16.1 I/O board Configuration SIB V 16.2 I/O-signal configuration for SIB_V_B2 16.2.1 Digital inputs 16.2.2 Digital inputs 16.2.3 Configuration cross-connections 17 Safety interface SIB V for positioner A/L/S 17.1 I/O board Configuration SIB V 17.2 I/O-signal configuration for SIB_V_B3 17.2.1 Digital inputs 17.2.2 Configuration cross-connections

57 58 58 58 59 59 59 60 61 61 61 61 61 62 62 62 62 62 63 63 64 64 65 65 67 67 68 68 69 69 71 71 72 72 74

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3HEA 802349-001 Rev . A

General I/O Description

1 General I/O Description

General This description covers all signals in a standard Arc Welding System based on the standard process interface delivered byABB Automation Technology Products AB. By using the Arc Welding System Configuration diskette as a optional boot diskette, the I/O configuration for the selected process equipment, positioners and options will be installed.

Composition There are four standard I/O-places inside the cabinet. The system interface is equipped with the following I/O units as standard: Simulated I/O Board Process Interface Board Digital I/O Board Software I/O Board Unused I/O board places can be equipped with any I/O unit described in the Product Specification for the robot.

Usage The number of I/O signals to be used is determined by different welding cell configurations: Welding equipment Positioner(s) Operator panel Cleaning equipment Search sensor Other options To minimize the number of I/O units and signals, a simulated I/O board is used for some system signals and operator ready signals. The operator ready function is performed by using I/O cross connections with logical conditions.

3HEA 802349-001 Rev . A

General I/O Description

System configuration The complete I/O configuration for a specific system setup is obtained during the boot sequence. After boot-up, it is advisable to save the system configuration by making a back-up of the whole system. This shall be made in the service menu.

References Physical connections of I/O signals are shown in the electrical drawing for the signal interface (inside the robot control cubicle) in the System Manual. I/O units, CAN-bus connection and address keying are described in Installation and Commissioning in the "Connecting Signals" chapter in the Product Manual for the robot. Electrical data, see Product Specification for the robot.

Note: Signals without any names in the following tables are not configured.

3HEA 802349-001 Rev . A

Process Interface Arcitec/MigRob

I/O Board configuration

2 Process Interface Arcitec/MigRob

General This chapter describes the different standard process configurations delivered by ABB Automation Technologies AB.

Power source

Figure 1. Power source LRC/MigRob

2.1 I/O Board configuration

Address 30 40

Name B_PROC_30 B_AW_PROC_40 B_SIM_AW

Board type Process Interface Board Power source Simulated Digital I/O

Digital Inputs 16

Digital Outputs 16

Analogue Inputs 3

Analogue Outputs 3

3HEA 802349-001 Rev . A

Process Interface Arcitec/MigRob

I/O Signals Configuration B_PROC_30

2.2 I/O Signals Configuration B_PROC_30

2.2.1 Digital outputs

UnitMap Connection 48 48 49 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 TB5:4 TB5:12, TB5:13 TB5:3 TB5:10, TB5:11 TB6:12 TB4:3 TB4:4 TB4:5 TB11:4 TB5:14 TB5:16

Name doGAS doGAS doACLN_TCH doACLN_TCH doPIB6_12 doMLUB_TCH doMCLN_TCH doPIB4_5 doPIB11_4 doPIB5_14 doPIB5_16

Description Activate gas valve Activate gas valve

Type 42V AC closing contact

Connected to unit Welding equipment Welding equipment Welding equipment Welding equipment Torch cleaner Torch cleaner Welding equipment Internal search sensor Internal search sensor Internal search sensor Welding equipment

Activate air cleaning of 42V AC torch Activate air cleaning of closing torch contact Activate push motor Activate torch lubrication Activate mechanical cleaning Activate wire cutter Not used Tig mode Not used Activate power source CycleOn to PIB Select and activate sensor 1 Select and activate sensor 2 Set (=Lock) reference Acknowledge error in PIB Activate wire feeder 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC closing contact logical logical 24V DC logical 24V DC logical logical logical

TB3:1, TB3:2 doLRB_FAN TB5:6 TB5:9 doPIB_CYCLE_ON doSE1_SEL doSE2_SEL doSE_REF doERR_ACK doFEED

3HEA 802349-001 Rev . A

Process Interface Arcitec/MigRob

I/O Signals Configuration B_PROC_30

2.2.2 Digital inputs

UnitMap 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Connection Name TB6:4 TB6:5 TB6:3 TB4:6 TB4:7 TB6:2 TB6:1 TB6:8 diWR_EST diGA_EST diARC_EST diMCLN_FIN sen1 diGUN_OK diSE1_DET diSE2_DET diGUN_RESET diSE_VALID diERR_STROBE diMAN_WF diERROR_NO0 diERROR_NO1 diERROR_NO2 diERROR_NO3

Description Water established Gas established Not used Cleaning of torch finished Welding wire detect Gun in position Surface detected Surface detected Gun resetted Sensor valid Error indication Start manual wire feed Error code Error code Error code Error code

Type

Connected to unit

42V AC Welding equipment 42V AC Welding equipment 42V DC Welding equipment 42V DC Torch cleaner 42V DC BullsEye 42V DC Welding equipment logical logical logical logical 42V DCt logical logical logical logical Internal search sensor 1 Internal search sensor 2 Internal search sensor Welding equipment -

42V DC Welding equipment

2.2.3 Analogue outputs

UnitMap 0-15 16-31 32-47

Connection TB3:3, TB3

Name aoWD_REF

Description MIG/MAG: voltage reference Wire feed reference

Connected to unit Welding equipment Welding equipment Welding equipment

TB6:6, TB6:7, aoFEED_REF TB6:15, TB6:7 TB3:5, TB3:4

aoINDUCT_REF MIG/MAG: inductance reference

2.2.4 Analogue inputs

UnitMap 0-15 16-31 32-47

Connection TB3:7, TB3:8 TB11:1, TB11:2 TB6:13, TB6:14

Name aiWDM_VOLT aiWDM_CURR

Description Measured voltage Measured current

Connected to unit Welding equipment Welding equipment Welding equipment

aiWDM_SPEED Measured wire feed speed

3HEA 802349-001 Rev . A

Process Interface Arcitec/MigRob

I/O Signals Configuration B_AW_PROC_40

2.3 I/O Signals Configuration B_AW_PROC_40

2.3.1 Digital outputs

UnitMap 0 1 2

Name doWELD doQUICK_STOP doEmStop

Description Activate ARCITEC power source Quick stop of ARCITEC power source Emergency stop

2.3.2 Digital inputs

UnitMap 48 49 56 57 64 65 66 67 68 69 70 71

Name diARC_EST diWELD_EST diWDU_Err diPS_Err diERROR_1 diERROR_2 diERROR_3 diERROR_4 diERROR_5 diERROR_6 diERROR_7 diERROR_8

Description Arc established Power source welding Weld data unit error Control board error Error code Error code Error code Error code Error code Error code Error code Error code

2.3.3 Group outputs

UnitMap 8-11 16-31

Name goActWirFeed goCAN_SCHED

Description Activate wire feed unit Activate schedule number in ARCITEC power source

3HEA 802349-001 Rev . A

Process Interface Arcitec/MigRob

I/O Signals Configuration B_AW_SIM

2.3.4 Analogue inputs

UnitMap 0-15 16-31 32-47

Name aiVoltage aiCurrent aiPower

Description Voltage Current Power

2.4 I/O Signals Configuration B_AW_SIM

2.4.1 Digital output

UnitMap

Name doFEED_SIM

Description Activate wire feed

3HEA 802349-001 Rev . A

Process Interface Arcitec/MigRob

I/O Signals Configuration B_AW_SIM

3HEA 802349-001 Rev . A

Process Interface ARCITEC/MigRob, Robot 2

I/O Board configuration

3 Process Interface ARCITEC/MigRob, Robot 2

General This chapter describes the different standard process configurations delivered by ABB Automation Technologies AB.

Power source

Figure 2. Power source LRC/MigRob

3.1 I/O Board configuration

Address 31 41

Name B_PROC_31 B_AW_PROC_41 B_SIM_AW

Board type Process Interface Board Power source Simulated Digital I/O

Digital Inputs 16

Digital Outputs 16

Analogue Inputs 3

Analogue Outputs 3

3HEA 802349-001 Rev . A

Process Interface ARCITEC/MigRob, Robot 2

I/O Signals Configuration B_PROC_31

3.2 I/O Signals Configuration B_PROC_31

3.2.1 Digital outputs

UnitMap Connection 48 48 49 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 TB5:4 TB5:12, TB5:13 TB5:3 TB5:10, TB5:11 TB6:12 TB4:3 TB4:4 TB4:5 TB11:4 TB5:14 TB5:16

Name doGAS_2 doGAS_2 doACLN_TCH_2 doACLN_TCH_2 doPIB6_12_2 doMLUB_TCH_2 doMCLN_TCH_2 doPIB4_5_2 doPIB11_4_2 doPIB5_14_2 doPIB5_16_2

Description Activate gas valve Activate gas valve

Type 42V AC closing contact

Connected to unit Welding equipment Welding equipment Welding equipment Welding equipment Torch cleaner Torch cleaner Welding equipment Internal search sensor Internal search sensor Internal search sensor Welding equipment

Activate air cleaning of 42V AC torch Activate air cleaning of closing torch contact Activate push motor Activate torch lubrication Activate mechanical cleaning Activate wire cutter Not used Tig mode Not used Activate power source CycleOn to PIB Select and activate sensor 1 Select and activate sensor 2 Set (=Lock) reference Acknowledge error in PIB Activate wire feeder 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC closing contact logical logical 24V DC logical 24V DC logical logical logical

TB3:1, TB3:2 doLRB_FAN_2 TB5:6 TB5:9 doPIB_CYCLE_ON_ 2 doSE1_SEL_2 doSE2_SEL_2 doSE_REF_2 doERR_ACK_2 doFEED_2

10

3HEA 802349-001 Rev . A

Process Interface ARCITEC/MigRob, Robot 2

I/O Signals Configuration B_PROC_31

3.2.2 Digital inputs

UnitMap 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Connection Name TB6:4 TB6:5 TB6:3 TB4:6 TB4:7 TB6:2 TB6:1 TB6:8 diWR_EST_2 diGA_EST_2 diARC_EST_2 diMCLN_FIN_2 sen2 diGUN_OK_2 diSE1_DET_2 diSE2_DET_2 diGUN_RESET_2 diSE_VALID_2 diERR_STROBE_ 2 diMAN_WF_2 diERROR_NO0_2 diERROR_NO1_2 diERROR_NO2_2 diERROR_NO3_2

Description Water established Gas established Not used Cleaning of torch finished Welding wire detect Gun in position Surface detected Surface detected Gun resetted Sensor valid Error indication Start manual wire feed Error code Error code Error code Error code

Type

Connected to unit

42V AC Welding equipment 42V AC Welding equipment 42V DC Welding equipment 42V DC Torch cleaner 42V DC BullsEye 42V DC Welding equipment logical logical logical logical 42V DCt logical logical logical logical Internal search sensor 1 Internal search sensor 2 Internal search sensor Welding equipment -

42V DC Welding equipment

3.2.3 Analogue outputs

UnitMap 0-15 16-31 32-47

Connection TB3:3, TB3

Name aoWD_REF_2

Description MIG/MAG: voltage reference Wire feed reference

Connected to unit Welding equipment Welding equipment Welding equipment

TB6:6, TB6:7, aoFEED_REF_2 TB6:15, TB6:7 TB3:5, TB3:4

aoINDUCT_REF_2 MIG/MAG: inductance reference

3.2.4 Analogue inputs

UnitMap 0-15 16-31 32-47

Connection TB3:7, TB3:8 TB11:1, TB11:2 TB6:13, TB6:14

Name aiPDM_VOLT_2 aiPDM_CURR_2 aiPDM_SPEED_2

Description Measured voltage Measured current Measured wire feed speed

Connected to unit Welding equipment Welding equipment Welding equipment

3HEA 802349-001 Rev . A

11

Process Interface ARCITEC/MigRob, Robot 2

I/O Signals Configuration B_AW_PROC_41

3.3 I/O Signals Configuration B_AW_PROC_41

3.3.1 Digital outputs

UnitMap 0 1 2

Name doWELD_2 doQUICK_STOP_2 doEmStop_2

Description Activate ARCITEC power source Quick stop of ARCITEC power source Emergency stop

3.3.2 Digital inputs

UnitMap 48 49 56 57 64 65 66 67 68 69 70 71

Name diARC_EST_2 diWELD_EST_2 diWDU_Err_2 diPS_Err_2 diERROR_1_2 diERROR_2_2 diERROR_3_2 diERROR_4_2 diERROR_5_2 diERROR_6_2 diERROR_7_2 diERROR_8_2

Description Arc established Power source welding Weld data unit error Control board error Error code Error code Error code Error code Error code Error code Error code Error code

3.3.3 Group outputs

UnitMap 8-11 16-31

Name goActWirFeed_2 goCAN_SCHED_2

Description Activate wire feed unit Activate schedule number in ARCITEC power source

12

3HEA 802349-001 Rev . A

Process Interface ARCITEC/MigRob, Robot 2

I/O Signals Configuration B_AW_SIM

3.3.4 Analogue inputs

UnitMap 0-15 16-31 32-47

Name aiVoltage_2 aiCurrent_2 aiPower_2

Description Voltage Current Power

3.4 I/O Signals Configuration B_AW_SIM

3.4.1 Digital output

UnitMap

Name doFEED_SIM

Description Activate wire feed

3HEA 802349-001 Rev . A

13

Process Interface ARCITEC/MigRob, Robot 2

I/O Signals Configuration B_AW_SIM

14

3HEA 802349-001 Rev . A

Process Interface RPB

I/O Board configuration

4 Process Interface RPB

General This chapter describes the different standard process configurations delivered by ABB Automation Technologies AB.

Power source

Figure 3. Power source RPB

4.1 I/O Board configuration

Address 30

Name B_PROC_30

Board type Process Interface Board

Digital Inputs 16

Digital Outputs 16

Analogue Inputs 3

Analogue Outputs 3

3HEA 802349-001 Rev . A

15

Process Interface RPB

I/O Signals Configuration B_PROC_30

4.2 I/O Signals Configuration B_PROC_30

4.2.1 Digital outputs

UnitMap Connection 48 48 49 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 TB5:4 TB5:12, TB5:13 TB5:3 TB5:10, TB5:11 TB6:12 TB4:3 TB4:4 TB4:5 TB11:4 TB5:14 TB5:16

Name doGAS doGAS doACLN_TCH doACLN_TCH doPIB6_12 doMLUB_TCH doMCLN_TCH doPIB4_5 doPIB11_4 doPIB5_14 doPIB5_16

Description Activate gas valve Activate gas valve

Type 42V AC closing contact

Connected to unit Welding equipment Welding equipment Welding equipment Welding equipment Torch cleaner Torch cleaner Welding equipment Internal search sensor Internal search sensor Internal search sensor Welding equipment

Activate air cleaning of 42V AC torch Activate air cleaning of closing torch contact Activate push motor Activate torch lubrication Activate mechanical cleaning Activate wire cutter Not used Tig mode Not used Activate power source CycleOn to PIB Select and activate sensor 1 Select and activate sensor 2 Set (=Lock) reference Acknowledge error in PIB Activate wire feeder 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC closing contact logical logical 24V DC logical 24V DC logical logical logical

TB3:1, TB3:2 doWELD TB5:6 TB5:9 doPIB_CYCLE_ON doSE1_SEL doSE2_SEL doSE_REF doERR_ACK doFEED

16

3HEA 802349-001 Rev . A

Process Interface RPB

I/O Signals Configuration B_PROC_30

4.2.2 Digital inputs

UnitMap 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Connection Name TB6:4 TB6:5 TB6:3 TB4:6 TB4:7 TB6:2 TB6:1 TB6:8 diWR_EST diGA_EST diARC_EST diMCLN_FIN sen1 diGUN_OK diSE1_DET diSE2_DET diGUN_RESET diSE_VALID diERR_STROBE diMAN_WF diERROR_NO0 diERROR_NO1 diERROR_NO2 diERROR_NO3

Description Water established Gas established Not used Cleaning of torch finished Welding wire detect Gun in position Surface detected Surface detected Gun resetted Sensor valid Error indication Start manual wire feed Error code Error code Error code Error code

Type

Connected to unit

42V AC Welding equipment 42V AC Welding equipment 42V DC Welding equipment 42V DC Torch cleaner 42V DC BullsEye 42V DC Welding equipment logical logical logical logical 42V DCt logical logical logical logical Internal search sensor 1 Internal search sensor 2 Internal search sensor Welding equipment -

42V DC Welding equipment

4.2.3 Analogue outputs

UnitMap 0-15 16-31 32-47

Connection TB3:3, TB3

Name aoWD_REF

Description MIG/MAG: voltage reference Wire feed reference

Connected to unit Welding equipment Welding equipment Welding equipment

TB6:6, TB6:7, aoFEED_REF TB6:15, TB6:7 TB3:5, TB3:4

aoINDUCT_REF MIG/MAG: inductance reference

4.2.4 Analogue inputs

UnitMap 0-15 16-31 32-47

Connection TB3:7, TB3:8 TB11:1, TB11:2 TB6:13, TB6:14

Name aiPDM_VOLT aiPDM_CURR aiPDM_SPEED

Description Measured voltage Measured current Measured wire feed speed

Connected to unit Welding equipment Welding equipment Welding equipment

3HEA 802349-001 Rev . A

17

Process Interface RPB

I/O Signals Configuration B_PROC_30

18

3HEA 802349-001 Rev . A

Process Interface RPB, Robot 2

I/O Board configuration

5 Process Interface RPB, Robot 2

General This chapter describes the different standard process configurations delivered by ABB Automation Technologies AB.

Power source

Figure 4. Power source RPB

5.1 I/O Board configuration

Address 30

Name B_PROC_31

Board type Process Interface Board

Digital Inputs 16

Digital Outputs 16

Analogue Inputs 3

Analogue Outputs 3

3HEA 802349-001 Rev . A

19

Process Interface RPB, Robot 2

I/O Signals Configuration B_PROC_31

5.2 I/O Signals Configuration B_PROC_31

5.2.1 Digital outputs

UnitMap 48 48 49 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63

Connection TB5:4 TB5:12, TB5:13 TB5:3 TB5:10, TB5:11 TB6:12 TB4:3 TB4:4 TB4:5 TB11:4 TB5:14 TB5:16

Name doGAS_2 doGAS_2 doACLN_TCH_2 doACLN_TCH_2 doPIB6_12_2 doMLUB_TCH_2 doMCLN_TCH_2 doPIB4_5_2 doPIB11_4_2 doPIB5_14_2 doPIB5_16_2

Description Activate gas valve Activate gas valve

Type 42V AC closing contact

Connected to unit Welding equipment Welding equipment Welding equipment Welding equipment Torch cleaner Torch cleaner Welding equipment Internal search sensor Internal search sensor Internal search sensor Welding equipment

Activate air cleaning of 42V AC torch Activate air cleaning of closing torch contact Activate push motor Activate torch lubrication Activate mechanical cleaning Activate wire cutter Not used Tig mode Not used Activate power source CycleOn to PIB Select and activate sensor 1 Select and activate sensor 2 Set (=Lock) reference Acknowledge error in PIB Activate wire feeder 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC 42V DC closing contact logical logical 24V DC logical 24V DC logical logical logical

TB3:1, TB3:2 doWELD_2 TB5:6 TB5:9 doPIB_CYCLE_ON_ 2 doSE1_SEL_2 doSE2_SEL_2 doSE_REF_2 doERR_ACK_2 doFEED_2

20

3HEA 802349-001 Rev . A

Process Interface RPB, Robot 2

I/O Signals Configuration B_PROC_31

5.2.2 Digital inputs

UnitMap Connection Name 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 TB6:4 TB6:5 TB6:3 TB4:6 TB4:7 TB6:2 TB6:1 TB6:8 diWR_EST_2 diGA_EST_2 diARC_EST_2 diMCLN_FIN_2 sen2 diGUN_OK_2 diSE1_DET_2 diSE2_DET_2 diGUN_RESET_2 diSE_VALID_2 diMAN_WF_2 diERROR_NO0_2 diERROR_NO1_2 diERROR_NO2_2 diERROR_NO3_2

Description Water established Gas established Not used Cleaning of torch finished Welding wire detect Gun in position Surface detected Surface detected Gun resetted Sensor valid Start manual wire feed Error code Error code Error code Error code

Type

Connected to unit

42V AC Welding equipment 42V AC Welding equipment 42V DC Welding equipment 42V DC Torch cleaner 42V DC BullsEye 42V DC Welding equipment logical logical logical logical 42V DCt logical logical logical logical Internal search sensor 1 Internal search sensor 2 Internal search sensor Welding equipment -

42V DC Welding equipment

diERR_STROBE_2 Error indication

5.2.3 Analogue outputs

UnitMap 0-15 16-31 32-47

Connection TB3:3, TB3

Name aoWD_REF_2

Description MIG/MAG: voltage reference Wire feed reference

Connected to unit Welding equipment Welding equipment Welding equipment

TB6:6, TB6:7, aoFEED_REF_2 TB6:15, TB6:7 TB3:5, TB3:4

aoINDUCT_REF_2 MIG/MAG: inductance reference

5.2.4 Analogue inputs

UnitMap 0-15 16-31 32-47

Connection TB3:7, TB3:8 TB11:1, TB11:2 TB6:13, TB6:14

Name aiPDM_VOLT_2 aiPDM_CURR_2 aiPDM_SPEED_2

Description Measured voltage Measured current Measured wire feed speed

Connected to unit Welding equipment Welding equipment Welding equipment

3HEA 802349-001 Rev . A

21

Process Interface RPB, Robot 2

I/O Signals Configuration B_PROC_31

22

3HEA 802349-001 Rev . A

Process Interface Fronius

I/O Board configuration

6 Process Interface Fronius

General This chapter describes the different standard process configurations delivered by ABB Automation Technologies AB. 6.0.1 Process Interface DeviceNet for Fronius

Figure 5. Welding equipment Fronius

6.1 I/O Board configuration

Address 40 20

Name FRON_BOARD_40 BOARD20 (Option)

Board type DiviceNet I/O Digital I/O

Digital Inputs 96 16

Digital Outputs 96 16

Analogue Inputs 4

Analogue Outputs 4

3HEA 802349-001 Rev . A

23

Process Interface Fronius

I/O Signals Configuration FRON_BOARD_40

6.2 I/O Signals Configuration FRON_BOARD_40

6.2.1 Digital outputs

UnitMap Connection 0 1 2 A204:X4 A204:X4 A204:X4

Name doWeld doQstop doMODE_BIT1

Description Welding start High active

Type Output 1:Bit 0

Connected to unit Power source Power source Power source

Robot ready/ Fast stop Output 1:Bit 1 High active/ low active 000 Standard synergy 001 Pulsed synergy 010 Job mode 011 Param. selection Internal See system manual, flap 20. Output 1:Bit 2

3 4 8 9 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26

A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4

doMODE_BIT2 doMODE_BIT3 doGAS doFEED doFEED_BWD doRESET_ERR doTOUCH_SEN S Activate gas valve

Output 1:Bit 3 Output 1:Bit 4 Output 1:Bit 8 Activate wire feeder for- Output 1:Bit 9 ward Activate wire feeder reverse Resetting error

Power source Power source Power source Power source

Output 1:Bit 10 Power source Output 1:Bit 11, Power source Inverted Power source

A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4

do_AIR doJOB_BIT1 doJOB_BIT2 doJOB_BIT3 doJOB_BIT4 doJOB_BIT5 doJOB_BIT6 doJOB_BIT7 doJOB_BIT8 doPROG_BIT1 doPROG_BIT2 doPROG_BIT3

Activate air cleaning of Output 1:Bit 12 Power source torch Call job number 1 Call job number 2 Call job number 3 Call job number 4 Call job number 5 Call job number 6 Call job number 7 Call job number 8 Call in program (synergy) number 1 Call in program (synergy) number 2 Call in program (synergy) number 3 Output 2:Bit 0 Output 2:Bit 1 Output 2:Bit 2 Output 2:Bit 3 Output 2:Bit 4 Output 2:Bit 5 Output 2:Bit 6 Output 2:Bit 7 Output 2:Bit 8 Output 2:Bit 9 Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source

Output 2:Bit 10 Power source

24

3HEA 802349-001 Rev . A

Process Interface Fronius

I/O Signals Configuration FRON_BOARD_40

UnitMap Connection 27 28 29 30 31 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4

Name doPROG_BIT4 doPROG_BIT5 doPROG_BIT6 doPROG_BIT7 doWELD_SIM

Description Call in program (synergy) number 4 Call in program (synergy) number 5 Call in program (synergy) number 6 Call in program (synergy) number 7 Simulate welding, high active

Type

Connected to unit

Output 2:Bit 11 Power source Output 1:Bit 0 Output 1:Bit 1 Output 1:Bit 2 Output 1:Bit 3 Power source Power source Power source Power source

3HEA 802349-001 Rev . A

25

Process Interface Fronius

I/O Signals Configuration FRON_BOARD_40

6.2.2 Digital inputs

UnitMap 0 2 3 4 5 6 8 9 10 11 12 13 14 15

Connection Name A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 diARC_EST diPROC_ACTIVE diPOWER_ON diCOLL_SENS diPOWER_READY diCOMM_READY diERR_BIT1 diERR_BIT2 diERR_BIT3 diERR_BIT4 diERR_BIT5 diERR_BIT6 diERR_BIT7 diERR_BIT8

Description Welding current flow Welding process active Main current signal Torch in position Power source OK Communication OK Error number 0-255,

Type Input 1: Bit 0 Input 1: Bit 2 Input 1: Bit 3 Input 1: Bit 4 Input 1: Bit 5, Iverterad Input 1: Bit 6, Iverterad Input 1: Bit 8 Input 1: Bit 9 Input 1: Bit 10 Input 1: Bit 11 Input 1: Bit 12

Connected to unit Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source

Error number 0-255, see above Error number 0-255, see above

Input 1: Bit 13 Input 1: Bit 14 Input 1: Bit 15

6.2.3 Analogue outputs

UnitMap 1 2 3 4

Connection A204:X4 A204:X4 A204:X4 A204:X4

Name aoPower aoVoltage awPulseCorr awBurnBackCorr

Description Power reference Arc voltage correction Pulse/ Dynamic correction Burn back correction

Connected to unit Power source Power source Power source Power source

6.2.4 Group outputs

UnitMap 2-4 16-23 24-30

Connection A204:X4 A204:X4 A204:X4

Name goMODE goJOB goPROG

Description Select work mode Select job Select program/ synergy

Connected to unit Power source Power source Power source

26

3HEA 802349-001 Rev . A

Process Interface Fronius

I/O Signals Configuration BOARD20

6.2.5 Group input

UnitMap 1

Connection A204:X4

Name gi_error

Description Error codes

Connected to unit Power source

6.3 I/O Signals Configuration BOARD20

6.3.1 Digital outputs

UnitMap 9 10 11

Connection X2:1 X2:2 X2:3

Name doMCLN_TCH doMLUB_TCH doWIR_CUT

Description Activate mechanical cleaning Activate torch lubrication Activate wire cutter

Connected to unit TSC TSC TSC

6.3.2 Digital inputs

UnitMap 1

Connection X3:1

Name diMCLN_FIN

Description Cleaning of torch finished

Connected to unit TSC

3HEA 802349-001 Rev . A

27

Process Interface Fronius

I/O Signals Configuration BOARD20

28

3HEA 802349-001 Rev . A

Process Interface Fronius, Robot 2

I/O Board configuration

7 Process Interface Fronius, Robot 2

General This chapter describes the different standard process configurations delivered by ABB Automation Technologies AB. 7.0.1 Process Interface DeviceNet for Fronius

Figure 6. Welding equipment Fronius

7.1 I/O Board configuration

Address 41 20

Name FRON_BOARD_41 BOARD20 (Option)

Board type DeviceNet I/O Digital I/O

Digital Inputs 96 16

Digital Outputs 96 16

Analogue Inputs 4

Analogue Outputs 4

3HEA 802349-001 Rev . A

29

Process Interface Fronius, Robot 2

I/O Signals Configuration FRON_BOARD_41

7.2 I/O Signals Configuration FRON_BOARD_41

7.2.1 Digital outputs

UnitMap Connection 0 1 2 A204:X4 A204:X4 A204:X4

Name doWeld_2 doQstop_2 doMODE_BIT1_2

Description Welding start High active

Type Output 1:Bit 0

Connected to unit Power source Power source Power source

Robot ready/ Fast stop Output 1:Bit 1 High active/ low active 000 Standard synergy 001 Pulsed synergy 010 Job mode 011 Param. selection Internal See system manual, flap 20. Output 1:Bit 2

3 4 8 9 10 11 12 13 16 17 18 19 20 21 22 23 24 25 26

A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4

doMODE_BIT2_2 doMODE_BIT3_2 doGAS_2 doFEED_2 doFEED_BWD_2 doRESET_ERR_2 doTOUCH_SENS_2 Activate gas valve

Output 1:Bit 3 Output 1:Bit 4 Output 1:Bit 8 Activate wire feeder for- Output 1:Bit 9 ward Activate wire feeder reverse Resetting error

Power source Power source Power source Power source

Output 1:Bit 10 Power source Output 1:Bit 11, Power source Inverted Power source

A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4

do_AIR_2 doJOB_BIT1_2_2 doJOB_BIT2_2 doJOB_BIT3_2 doJOB_BIT4_2 doJOB_BIT5_2 doJOB_BIT6_2 doJOB_BIT7_2 doJOB_BIT8_2 doPROG_BIT1_2 doPROG_BIT2_2 doPROG_BIT3_2

Activate air cleaning of Output 1:Bit 12 Power source torch Call job number 1 Call job number 2 Call job number 3 Call job number 4 Call job number 5 Call job number 6 Call job number 7 Call job number 8 Call in program (synergy) number 1 Call in program (synergy) number 2 Call in program (synergy) number 3 Output 2:Bit 0 Output 2:Bit 1 Output 2:Bit 2 Output 2:Bit 3 Output 2:Bit 4 Output 2:Bit 5 Output 2:Bit 6 Output 2:Bit 7 Output 2:Bit 8 Output 2:Bit 9 Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source

Output 2:Bit 10 Power source

30

3HEA 802349-001 Rev . A

Process Interface Fronius, Robot 2

I/O Signals Configuration FRON_BOARD_41

UnitMap Connection 27 28 29 30 31 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4

Name doPROG_BIT4_2 doPROG_BIT5_2 doPROG_BIT6_2 doPROG_BIT7_2 doWELD_SIM_2

Description Call in program (synergy) number 4 Call in program (synergy) number 5 Call in program (synergy) number 6 Call in program (synergy) number 7 Simulate welding, high active

Type

Connected to unit

Output 2:Bit 11 Power source Output 1:Bit 0 Output 1:Bit 1 Output 1:Bit 2 Output 1:Bit 3 Power source Power source Power source Power source

7.2.2 Digital inputs

UnitMap 0 2 3 4 5 6 8 9 10 11 12 13 14 15

Connection Name A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 A204:X4 diARC_EST_2 diPROC_ACTIVE_2 diPOWER_ON_2 diCOLL_SENS_2 diPOWER_READY_2 diCOMM_READY_2 diERR_BIT1_2 diERR_BIT2_2 diERR_BIT3_2 diERR_BIT4_2 diERR_BIT5_2 diERR_BIT6_2 diERR_BIT7_2 diERR_BIT8_2

Description Welding current flow Welding process active Main current signal Torch in position Power source OK Communication OK Error number 0-255,

Type Input 1: Bit 0 Input 1: Bit 2 Input 1: Bit 3 Input 1: Bit 4 Input 1: Bit 5, Iverted Input 1: Bit 6, Iverted Input 1: Bit 8 Input 1: Bit 9 Input 1: Bit 10 Input 1: Bit 11 Input 1: Bit 12

Connected to unit Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source Power source

Error number 0-255, see above Error number 0-255, see above

Input 1: Bit 13 Input 1: Bit 14 Input 1: Bit 15

3HEA 802349-001 Rev . A

31

Process Interface Fronius, Robot 2

I/O Signals Configuration FRON_BOARD_41

7.2.3 Analogue outputs

UnitMap 1 2 3 4

Connection A204:X4 A204:X4 A204:X4 A204:X4

Name aoPower_2 aoVoltage_2 awPulseCorr_2 awBurnBackCorr_2

Description Power reference Arc voltage correction Pulse/ Dynamic correction Burn back correction

Connected to unit Power source Power source Power source Power source

7.2.4 Group outputs

UnitMap 2-4 16-23 24-30

Connection A204:X4 A204:X4 A204:X4

Name goMODE_2 goJOB_2 goPROG_2

Description Select work mode Select job Select program/ synergy

Connected to unit Power source Power source Power source

7.2.5 Group input

UnitMap 1

Connection A204:X4

Name gi_error_2

Description Error codes

Connected to unit Power source

32

3HEA 802349-001 Rev . A

Process Interface Fronius, Robot 2

I/O Signals Configuration BOARD20

7.3 I/O Signals Configuration BOARD20

7.3.1 Digital outputs

UnitMap 9 10 11

Connection X2:1 X2:2 X2:3

Name doMCLN_TCH_2 doMLUB_TCH_2 doWIR_CUT_2

Description Activate mechanical cleaning Activate torch lubrication Activate wire cutter

Connected to unit TSC TSC TSC

7.3.2 Digital inputs

UnitMap 1

Connection X3:1

Name diMCLN_FIN_2

Description Cleaning of torch finished

Connected to unit TSC

3HEA 802349-001 Rev . A

33

Process Interface Fronius, Robot 2

I/O Signals Configuration BOARD20

34

3HEA 802349-001 Rev . A

Positioner Interface IRBP A

I/O board Configuration for positioner

8 Positioner Interface IRBP A

General This chapter describes the I/O configurations for positioners delivered by ABB Technologies AB.

8.1 I/O board Configuration for positioner

Address -

Name B_POS_SIM

Board type Simulated digital I/O Digital I/O

Digital inputs

Digital outputs

Digital inputs

Analogue outputs

Relay outputs

Internal bus DRVIO_11

12

1. The number relates to the drive module where the I/O board is located, the example shows DM1.

Positioner type IRBP A

Figur 7 Positioner type IRBP A

3HEA 802349-001 Rev . A

35

Positioner Interface IRBP A

Simulated outputs for B_POS_SIM

8.2 Simulated outputs for B_POS_SIM

8.2.1 Simulated outputs

UnitMap 0 1

Name soACT_STN1 soACT_STN2

Description Activate mechanical unit 1 Activate mechanical unit 2

8.2.2 Simulated inputs

UnitMap 0 1

Name siSTN1_ACT siSTN2_ACT

Description Mechanical unit 1 activated Mechanical unit 2 activated

36

3HEA 802349-001 Rev . A

Positioner Interface IRBP A

I/O-Signals configuration for DRVIO_1

8.3 I/O-Signals configuration for DRVIO_1

8.3.1 Digital outputs TB4

Output 1 2 3 4 5 6 7 8 9 10 11 12 13 14

UnitMap 0 1 2 3 4 5 6 7 8 9 10 11

Name doACT_K1 doACT_K2 doACT_K3 doACT_K4 doACT_K11 doACT_K12 doACT_K13 doACT_K14

Description Activate mechanical unit 1 Activate mechanical unit 2 Activate mechanical unit 3 Activate mechanical unit 4 Activate release break 1 Activate release break 2 Activate release break 3 Activate release break 4

Connected to unit Positioner Positioner Positioner Positioner Positioner Positioner Positioner Positioner

0V Output 24V Output 1-12

8.3.2 Digital inputs TB3

Input 1 2 3 4 5 6 7 8

UnitMap 0 1 2 3 4 5 6

Name diK1_ACT diK2_ACT diK3_ACT diK4_ACT

Description Mechanical unit 1 activated Mechanical unit 2 activated Mechanical unit 3 activated Mechanical unit 4 activated

Connected to unit Positioner Positioner Positioner Positioner

0 V input 1-7

3HEA 802349-001 Rev . A

37

Positioner Interface IRBP A

Configuration cross-connections

8.4 Configuration cross-connections

STN1: soACT_STN1 & doACT_K1

soACT_STN1

&

doACT_K3

diK1_ACT diK3_ACT & siSTN1_ACT

doACT_K13

&

doACT_K11

STN2: soACT_STN2 & doACT_K2

soACT_STN2

&

doACT_K4

diK2_ACT diK4_ACT & siSTN2_ACT

doACT_K14

&

doACT_K12

Figure 8. Cross-connection

38

3HEA 802349-001 Rev . A

Positioner Interface IRBP B/D

I/O board Configuration for positioner

9 Positioner Interface IRBP B/D

General This chapter describes the I/O configurations for positioners delivered by ABB Technologies AB.

9.1 I/O board Configuration for positioner

Address

Name

Board type

Digital inputs

Digital outputs

Digital inputs

Analogue outputs

Relay outputs

B_POS_SIM

Simulated digital I/O Digital I/O 7 12 -

Internal bus DRVIO_11

1. The number relates to the drive module where the I/O board is located, the example shows DM1.

Positioner type IRBP B/D

Figur 9 Positioner type IRBP B/D

3HEA 802349-001 Rev . A

39

Positioner Interface IRBP B/D

Simulated outputs for B_POS_SIM

9.2 Simulated outputs for B_POS_SIM

9.2.1 Simulated outputs

UnitMap

Name

Description

0 1 2

soACT_STN1 soACT_STN2 soACT_INTCH

Activate mechanical unit 1 Activate mechanical unit 2 Activate mechanical unit 3

9.2.2 Simulated inputs

UnitMap

Name

Description

0 1 2

siSTN1_ACT siSTN2_ACT si_INTCH_ACT

Mechanical unit 1 activated Mechanical unit 2 activated Mechanical unit 3 activated

40

3HEA 802349-001 Rev . A

Positioner Interface IRBP B/D

I/O-Signals configuration for DRVIO_1

9.3 I/O-Signals configuration for DRVIO_1

9.3.1 Digital outputs TB4

Output

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0 1 2 3 4 5 6 7 8 9 10 11

doACT_K1 doACT_K2 doACT_K3 doACT_K4 doACT_K5 doACT_K11 doACT_K12 doACT_K13 doACT_K14 doACT_K15

Activate mechanical unit 1 Activate mechanical unit 2 Activate mechanical unit 3 Activate mechanical unit 4 Activate mechanical unit 5 Activate release break 1 Activate release break 2 Activate release break 3 Activate release break 4 Activate release break 5

Positioner Positioner Positioner Positioner Positioner Positioner Positioner Positioner Positioner Positioner

0V Output 24V Output 1-12

9.3.2 Digital inputs TB3

Input

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8

0 1 2 3 4 5 6

diK1_ACT diK2_ACT diK3_ACT diK4_ACT diK5_ACT

Mechanical unit 1 activated Mechanical unit 2 activated Mechanical unit 3 activated Mechanical unit 4 activated Mechanical unit 5 activated

Positioner Positioner Positioner Positioner Positioner

0 V input 1-7

3HEA 802349-001 Rev . A

41

Positioner Interface IRBP B/D

Configuration cross-connections

9.4 Configuration cross-connections

soACT_STN1 soACT_INTCH ! doACT_K1

soACT_STN1

&

doACT_K3

diK1_ACT diK3_ACT & siSTN1_ACT

soACT_STN2 soACT_INTCH ! doACT_K2

soACT_STN2

&

doACT_K4

diK2_ACT diK4_ACT & siSTN2_ACT

soACT_INTCH

&

doACT_K5

diK1_ACT diK2_ACT diK5_ACT & siINTCH_ACT

doACT_K13 doACT_K15 ! doACT_K11

doACT_K14 doACT_K15 ! doACT_K12

Figure 10. Cross-connections

42

3HEA 802349-001 Rev . A

Positioner Interface IRBP C

I/O board Configuration for positioner

10 Positioner Interface IRBP C

General This chapter describes the I/O configurations for positioners delivered by ABB Technologies AB.

10.1 I/O board Configuration for positioner

Address

Name

Board type

Digital inputs

Digital outputs

Analogue inputs

Analogue outputs

Relay outputs

B_POS_SIM

Simulated digital I/O Digital I/O 7 12 -

Internal bus DRVIO_11

1. The number relates to the drive module where the I/O board is located, the example shows DM1.

Positioner type IRBP C

Figur 11 Positioner type IRBP C

3HEA 802349-001 Rev . A

43

Positioner Interface IRBP C

Simulated outputs for B_POS_SIM

10.2 Simulated outputs for B_POS_SIM

10.2.1 Simulated outputs

UnitMap

Name

Description

soACT_STN1

Activate mechanical unit 1

10.2.2 Simulated inputs

UnitMap

Name

Description

siSTN1_ACT

Mechanical unit 1 activated

44

3HEA 802349-001 Rev . A

Positioner Interface IRBP C

I/O-Signals configuration for DRVIO_1

10.3 I/O-Signals configuration for DRVIO_1

10.3.1 Digital outputs TB4

Output

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0 1 2 3 4 5 6 7 8 9 10 11 0V Output 24V Output 1-12 doACT_K15 Activate release break 1 Positioner doACT_K5 Activate mechanical unit 1 Positioner

10.3.2 Digital inputs TB3

Input

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8

0 1 2 3 4 5 6 diK5_ACT diLS_1_INPOS diLS_2_INPOS 0 V input 1-7 Mechanical unit 1 activated Limit switch station 1 Limit switch station 2 Positioner Station interchange unit Station interchange unit

3HEA 802349-001 Rev . A

45

Positioner Interface IRBP C

Configuration cross-connections

10.4 Configuration cross-connections

soACT_STN1

&

doACT_K5

diK5_ACT

&

siSTN1_ACT

Figure 12. Cross-connections

46

3HEA 802349-001 Rev . A

Positioner Interface IRBP C Index

I/O board Configuration for positioner

11 Positioner Interface IRBP C Index

General This chapter describes the I/O configurations for positioners delivered by ABB Technologies AB.

11.1 I/O board Configuration for positioner

Address

Name

Board type

Digital inputs

Digital outputs

Analogue inputs

Analogue outputs

Relay outputs

B_POS_SIM

Simulated digital I/O Digital I/O 7 12 -

Internal bus DRVIO_11

1. The number relates to the drive module where the I/O board is located, the example shows DM1.

Positioner type IRBP C Index

Figur 13 Positioner type IRBP C Index

3HEA 802349-001 Rev . A

47

Positioner Interface IRBP C Index

Simulated outputs for B_POS_SIM

11.2 Simulated outputs for B_POS_SIM

11.2.1 Simulated outputs

UnitMap

Name

Description

soACT_STN1

Activate mechanical unit 1

11.2.2 Simulated inputs

UnitMap

Name

Description

siSTN1_ACT

Mechanical unit 1 activated

48

3HEA 802349-001 Rev . A

Positioner Interface IRBP C Index

I/O-Signals configuration for B_POS_21

11.3 I/O-Signals configuration for B_POS_21

11.3.1 Digital outputs TB4

Output

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0 1 2 3 4 5 6 7 8 9 10 11 0V Output 24V Output 1-12 doACT_K15 Activate release break 1 Positioner doACT_K5 Activate mechanical unit 1 Positioner

11.3.2 Digital inputs TB3

Input

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8

0 1 2 3 4 5 6

diLS_2_INPOS diLS_4_INPOS

Limit switch station 2 Limit switch station 4

Station interchange unit Station interchange unit

diK5_ACT diLS_1_INPOS diLS_3_INPOS 0 V input 1-7

Mechanical unit 1 activated Limit switch station 1 Limit switch station 3

Positioner Station interchange unit Station interchange unit

3HEA 802349-001 Rev . A

49

Positioner Interface IRBP C Index

Configuration cross-connections

11.4 Configuration cross-connections

soACT_STN1

&

doACT_K5

diK5_ACT

&

siSTN1_ACT

Figure 14. Cross-connections

50

3HEA 802349-001 Rev . A

Positioner Interface IRBP K/R

I/O board configuration for positioner

12 Positioner Interface IRBP K/R

General This chapter describes the I/O configurations for positioners delivered by ABB Technologies AB.

12.1 I/O board configuration for positioner

Address

Name

Board type

Digital inputs

Digital outputs

Analogue inputs

Analogue outputs

Relay outputs

B_POS_SIM

Simulated digital I/O Digital I/O 7 12 -

Internal bus DRVIO_11

1. The number relates to the drive module where the I/O board is located, the example shows DM1.

Positioner type IRBP K/R

Figur 15 Positioner type IRBP R/K

3HEA 802349-001 Rev . A

51

Positioner Interface IRBP K/R

Simulated outputs for B_POS_SIM

12.2 Simulated outputs for B_POS_SIM

12.2.1 Simulated outputs

UnitMap

Name

Description

0 1 2

soACT_STN1 soACT_STN2 soACT_INTCH

Activate mechanical unit 1 Activate mechanical unit 2 Activate mechanical unit 3

12.2.2 Simulated inputs

UnitMap

Name

Description

0 1 2

siSTN1_ACT siSTN2_ACT siINTCH_ACT

Mechanical unit 1 activated Mechanical unit 2 activated Mechanical unit 3 activated

52

3HEA 802349-001 Rev . A

Positioner Interface IRBP K/R

I/O-Signals configuration for DRVIO_1

12.3 I/O-Signals configuration for DRVIO_1

12.3.1 Digital outputs TB4

Output

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0 1 2 3 4 5 6 7 8 9 10 11

doACT_K1 doACT_K2

Activate mechanical unit 1 Activate mechanical unit 2

Positioner Positioner

doACT_K5 doACT_K11 doACT_K12

Activate mechanical unit 3 Activate release break 1 Activate release break 2

Positioner Positioner Positioner

doACT_K15

Activate release break 3

Positioner

0V Output 24V Output 1-12

12.3.2 Digital inputs TB3

Input

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8

0 1 2 3 4 5 6

diK1_ACT diK2_ACT

Mechanical unit 1 activated Mechanical unit 2 activated

Positioner Positioner

diK5_ACT diLS_1_INPOS diLS_2_INPOS 0 V input 1-7

Mechanical unit 3 activated Limit switch station 1 Limit switch station 2

Positioner Station interchange unit Station interchange unit

3HEA 802349-001 Rev . A

53

Positioner Interface IRBP K/R

Configuration cross-connections

12.4 Configuration cross-connections

12.4.1 K/R 3DU (3 axes)

soACT_STN1 soACT_INTCH ! doACT_K1

diK1_ACT

&

siSTN1_ACT

soACT_STN2 soACT_INTCH ! doACT_K2

diK2_ACT

&

siSTN2_ACT

soACT_INTCH

&

doACT_K5

diK1_ACT diK2_ACT diK5_ACT & siINTCH_ACT

doACT_K15

&

doACT_K11

doACT_K15

&

doACT_K12

Figure 16. Cross-connections 3DU

54

3HEA 802349-001 Rev . A

Positioner Interface IRBP K/R

Configuration cross-connections

12.4.2 K/R 1DU (1-axis)

soACT_STN1

&

doACT_K1

diK1_ACT

&

siSTN1_ACT

soACT_STN2

&

doACT_K2

diK2_ACT

&

siSTN2_ACT

soACT_INTCH

&

doACT_K5

diK5_ACT

&

siINTCH_ACT

Figure 17. Cross-connections 1DU, (1-axis)

3HEA 802349-001 Rev . A

55

Positioner Interface IRBP K/R

Configuration cross-connections

56

3HEA 802349-001 Rev . A

Positioner Interface IRBP L

I/O board configuration for positioner

13 Positioner Interface IRBP L

General This chapter describes the I/O configurations for positioners delivered by ABB Technologies AB.

13.1 I/O board configuration for positioner

Address

Name

Board type

Digital inputs

Digital outputs

Analogue inputs

Analogue outputs

Relay outputs

B_POS_SIM

Simulated digital I/O Digital I/O 7 12 -

Internal bus DRVIO_11

1. The number relates to the drive module where the I/O board is located, the example shows DM1.

Positioner type IRBP L

Figur 18 Positioner type IRBP L

3HEA 802349-001 Rev . A

57

Positioner Interface IRBP L

Simulated outputs for B_POS_SIM

13.2 Simulated outputs for B_POS_SIM

13.2.1 Simulated outputs

UnitMap

Name

Description

0 1

soACT_STN1 soACT_STN2

Activate mechanical unit 1 Activate mechanical unit 2

13.2.2 Simulated inputs

UnitMap

Name

Description

0 1

siSTN1_ACT siSTN2_ACT

Mechanical unit 1 activated Mechanical unit 2 activated

58

3HEA 802349-001 Rev . A

Positioner Interface IRBP L

I/O-Signals configuration for DRVIO_1

13.3 I/O-Signals configuration for DRVIO_1

13.3.1 Digital outputs TB4

Output

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8 9 10 11 12 13 14

0 1 2 3 4 5 6 7 8 9 10 11

doACT_K1 doACT_K2

Activate mechanical unit 1 Activate mechanical unit 2

Positioner Positioner

doACT_K11 doACT_K12

Activate release break 1 Activate release break 2

Positioner Positioner

0V Output 24V Output 1-12

13.3.2 Digital inputs TB3

Input

UnitMap

Name

Description

Connected to unit

1 2 3 4 5 6 7 8

0 1 2 3 4 5 6

diK1_ACT diK2_ACT

Mechanical unit 1 activated Mechanical unit 2 activated

Positioner Positioner

0 V input 1-7

3HEA 802349-001 Rev . A

59

Positioner Interface IRBP L

Configuration cross-connections

13.4 Configuration cross-connections

STN1: soACT_STN1 & doACT_K1

diK1_ACT

&

siSTN1_ACT

STN2: soACT_STN2 & doACT_K2

diK2_ACT

&

siSTN2_ACT

Figure 19. Cross-connections

60

3HEA 802349-001 Rev . A

Operator Interface IRBP

I/O board Configuration

14 Operator Interface IRBP

General This chapter describes the I/O configurations for operator panels delivered by ABB Technologies AB.

14.1 I/O board Configuration

Address

Name

Board type

Digital inputs

Digital outputs

Analogue outputs

Analogue outputs

21 22

B_OP_SIM B_OP_21 B_OP_22

Simulated digital I/O Digital I/O Digital I/O 12 12 7 7 -

14.2 System functions

14.2.1 Inputs

Signal name

Action

diPROG_START diPROG_STOP

Start Stop

14.2.2 Outputs

Signal name

Status

doCYCLE doMON doAUTO

CycleOn MotorOn AutoOn

3HEA 802349-001 Rev . A

61

Operator Interface IRBP

I/O-Signals configuration for B_OP_SIM

14.3 I/O-Signals configuration for B_OP_SIM

14.3.1 Digital outputs

UnitMap

Name

Description

10 11 12

doCYCLE doAUTO doMON

CycleOn AutoOn MotrorOn

14.4 I/O Signals configuration for B_OP_21, B_OP_22

14.4.1 Digital outputs

Output

UnitMap

Name

Description

1 2 3 4

0 1 2 3

doPROC1 doPROC2 doPERM_ENTR1 doPERM_ENTR1

Operator ready activated on station 1 Operator ready acitvated on station 2 Permit operator ready on station 1 Permit operator ready on station 2

14.4.2 Digital inputs

Input

Unit Map

Name

Description

1 2 3 4

0 1 2 3

diPROC1 diPROC2 diPROG_START diPROG_STOP

Operator ready OK on station 1 Operator ready OK on station 2 Program start Program stop

62

3HEA 802349-001 Rev . A

Safety interface SIB V for positioner B/C/D/K/R

I/O board Configuration SIB V

15 Safety interface SIB V for positioner B/C/D/K/R

General This chapter describes the different I/O configurations for standard equipment for asfety supervision SIB V, delevered by ABB Technologies AB.

15.1 I/O board Configuration SIB V

Address

Name

Board type

Digital inputs

Digital outputs

8 9* 8 9* 8 9*

SIB_V_B1 SIB_V_B1 SIB_V_B2 SIB_V_B2 SIB_V_B3 SIB_V_B3

Safety Interface Board Type 1 Safety Interface Board Type 1 Safety Interface Board Type 2 Safety Interface Board Type 2 Safety Interface Board Type 3 Safety Interface Board Type 3

56 56 56 56 56 56

*) Used as board No 2 in multi-stations applications or combinations between different types of positioners. Example: Robot weldihng station with one positioner type IRBP 250K and one positioner type IRBP 250L.

Exemple
1

3 4

Figur 20 Robot welding station with one positioner IRBP 250K and one positioner IRBP 250L
Pos Description Pos Description

1 2

Robot Travel track

3 4

IRBP 250L IRBP 250K

3HEA 802349-001 Rev . A

63

Safety interface SIB V for positioner B/C/D/K/R

I/O-signal configuration for SIB_V_B1

15.2 I/O-signal configuration for SIB_V_B1

CO NNECTO RS
R L 152 R L151 RL6 RL1 RL3 RL2 R L 45 RL4 RL13 R L163 R L133 R L 142 R L141

Figure 21. Unit for safety supervision SIB_V_B1

15.2.1 Digital inputs

UnitMap

Connection

Name

Description

Connected to unit

0 1 2 3 4 5 6 7 9 10

TB1:8 TB1:4 TB31:9, TB31:17 TB31:8, TB31:18 TB1:16 TB4:4 TB2:9 TB2:10 TB2:11 TB2:12

diASTOP_CHA diASTOP_CHB diRL1 diRL2 diRL3 diRL4 diRL13 diRL133 diRL141 diRL143

Run chain AS1Run chain AS2+ Channel 1 active Channel 2 active Reset/control of function safety circuits Activate entrance protection area 1 Indication station 1 at robot Indication station 1 at robot (inverted signal) Indication station 2 at robot Indication station 2 at robot (inverted signal)

Panel board/safety switch service door Panel board/safety switch service door Entrance protection area 1 Entrance protection area 1 Entrance protection area 1 Op-panel Station interchange Station interchange Station interchange Station interchange

64

3HEA 802349-001 Rev . A

Safety interface SIB V for positioner B/C/D/K/R

Digital inputs

15.2.2 Digital inputs

UnitMap Connection Name Description Connected to unit

16 17 24 25 26 27

TB1:1 TB1:5 TB111:10, TB31:2 TB111:8, TB31:4 TB111:11, TB31:5 TB111:13, TB31:6

diGSTOP_CHA diGSTOP_CHB diRL201 diRL202 diRL203 diRL204

Run chain GS2+ Run chain GS1Channel 1 active Channel 2 active Reset/control of function safety circuits Activate safety circuits service door

Panel board Panel board Safety switch service door Safety switch service door Safety switch service door Pushbutton service door

15.2.3 Configuration cross-connections

diRL1 diRL2 diRL3 & siSAFETY1_OK

Figure 22. Cross-connections for unit for safety supervision SIB_V_typ 1

3HEA 802349-001 Rev . A

65

Safety interface SIB V for positioner B/C/D/K/R

Configuration cross-connections

66

3HEA 802349-001 Rev . A

Safety interface SIB V for positioner C Index

I/O board Configuration SIB V

16 Safety interface SIB V for positioner C Index

General This chapter describes the different I/O configurations for standard equipment for asfety supervision SIB V, delevered by ABB Technologies AB.

16.1 I/O board Configuration SIB V

Address

Name

Board type

Digital inputs

Digital outputs

8 9* 8 9* 8 9*

SIB_V_B1 SIB_V_B1 SIB_V_B2 SIB_V_B2 SIB_V_B3 SIB_V_B3

Safety Interface Board Type 1 Safety Interface Board Type 1 Safety Interface Board Type 2 Safety Interface Board Type 2 Safety Interface Board Type 3 Safety Interface Board Type 3

56 56 56 56 56 56

*) Used as board No 2 in multi-stations applications or combinations between different types of positioners. Example: Robot weldihng station with one positioner type IRBP 250K and one positioner type IRBP 250L.

Exemple
1

3 4

Figur 23 Robot welding station with one positioner IRBP 250K and one positioner IRBP 250L
Pos Description Pos Description

1 2

Robot Travel track

3 4

IRBP 250L IRBP 250K

3HEA 802349-001 Rev . A

67

Safety interface SIB V for positioner C Index

I/O-signal configuration for SIB_V_B2

16.2 I/O-signal configuration for SIB_V_B2

CO NNECTO RS
R L 152 R L151 RL6 RL1 RL3 RL2 R L 45 RL4 RL13 R L163 R L133 R L 142 R L141

Figure 24. Unit for safety supervision SIB_V_B2

16.2.1 Digital inputs

UnitMap

Connection

Name

Description

Connected to unit

0 1 2 3 4 5 6 7 9 10

TB1:8 TB1:4 TB31:9, TB31:17 TB31:8, TB31:18 TB1:16 TB4:4 TB2:9 TB2:10 TB2:11 TB2:12

diASTOP_CHA diASTOP_CHB diRL1 diRL2 diRL3 diRL4 diRL13 diRL133 diRL141 diRL143

Run chain AS1Run chain AS2+ Channel 1 active Channel 2 active Reset/control of function safety circuits Activate entrance protection area 1 Indication station 1 at robot Indication station 1 at robot (inverted signal) Indication station 2 at robot Indication station 2 at robot (inverted signal)

Panel board/safety switch service door Panel board/safety switch service door Entrance protection area 1 Entrance protection area 1 Entrance protection area 1 Op-panel Station interchange Station interchange Station interchange Station interchange

68

3HEA 802349-001 Rev . A

Safety interface SIB V for positioner C Index

Digital inputs

16.2.2 Digital inputs

UnitMap Connection Name Description Connected to unit

11 12 13 14 16 17 24 25 26 27

TB2:13 TB2:14 TB2:15 TB2:16 TB1:1 TB1:5 TB111:10, TB31:2 TB111:8, TB31:4 TB111:11, TB31:5 TB111:13, TB31:6

diRL151 diRL153 diRL16 diRL163 diGSTOP_CHA diGSTOP_CHB diRL201 diRL202 diRL203 diRL204

Indication station 2 at robot Indication station 2 at robot (inverted signal) Indication station 4 at robot Indication station 4 at robot (inverted signal) Run chain GS2+ Run chain GS1Channel 1 active Channel 2 active Reset/control of function safety circuits Activate safety circuits service door

Station interchange Station interchange Station interchange Station interchange Panel board Panel board Safety switch service door Safety switch service door Safety switch service door Pushbutton service door

16.2.3 Configuration cross-connections

diRL1 diRL2 diRL3 & siSAFETY1_OK

Figure 25. Cross-connections for unit for safety supervision SIB_V_typ 2

3HEA 802349-001 Rev . A

69

Safety interface SIB V for positioner C Index

Configuration cross-connections

70

3HEA 802349-001 Rev . A

Safety interface SIB V for positioner A/L/S

I/O board Configuration SIB V

17 Safety interface SIB V for positioner A/L/S

General This chapter describes the different I/O configurations for standard equipment for asfety supervision SIB V, delevered by ABB Technologies AB.

17.1 I/O board Configuration SIB V

Address

Name

Board type

Digital inputs

Digital outputs

8 9* 8 9* 8 9*

SIB_V_B1 SIB_V_B1 SIB_V_B2 SIB_V_B2 SIB_V_B3 SIB_V_B3

Safety Interface Board Type 1 Safety Interface Board Type 1 Safety Interface Board Type 2 Safety Interface Board Type 2 Safety Interface Board Type 3 Safety Interface Board Type 3

56 56 56 56 56 56

*) Used as board No 2 in multi-stations applications or combinations between different types of positioners. Example: Robot weldihng station with one positioner type IRBP 250K and one positioner type IRBP 250L.

Exemple
1

3 4

Figur 26 Robot welding station with one positioner IRBP 250K and one positioner IRBP 250L
Pos Description Pos Description

1 2

Robot Travel track

3 4

IRBP 250L IRBP 250K

3HEA 802349-001 Rev . A

71

Safety interface SIB V for positioner A/L/S

I/O-signal configuration for SIB_V_B3

17.2 I/O-signal configuration for SIB_V_B3

CONNECTORS
RL43 RL43 RL2 RL45 RL4 RL15 RL3 RL1 RL12 RL11 RL10 RL14 RL9 RL5 RL44 RL6 RL7 RL8

Figure 27. Unit for safety supervision SIB_V_B3

17.2.1 Digital inputs

UnitMap

Connection

Name

Description

Connected to unit

0 1 2 3 4 5 6 7 9 10

TB1:8 TB1:4

diASTOP_CHA diASTOP_CHB

Run chain AS1Run chain AS2+ Channel 1 active Channel 2 active Reset/control of function safety circuits Channel 1 active Channel 2 active Reset/control of function safety circuits Channel 1 active Channel 2 active

Panel board/safety switch service door Panel board/safety switch service door Entrance protection area 1 Entrance protection area 1 Entrance protection area 1 Station indikation switch robot in area 2 Station indikation switch robot in area 2 Safety relays robot in area 2 Station indikation switch robot in area 1 Station indikation switch robot in area 1

TB31:2,TB31 diRL1 :15 TB31:1,TB31 diRL2 :16 TB31:9 TB33:14 TB33:15 diRL3 diRL11 diRL12 diRL15 TB33:12 TB33:13 diRL9 diRL10

72

3HEA 802349-001 Rev . A

Safety interface SIB V for positioner A/L/S

Digital inputs

UnitMap

Connection

Name

Description

Connected to unit

11 12 13 14 16 17 18 19 20 21 24 25 26 27 32 33 34 TB4:4 TB4:1 TB32:9

diRL14 diRL4 diRL5 diRL6

Reset/control of function safety circuits Activate entrance protection area 1 Activate entrance protection area 2 Reset/control of function safety circuits Channel 1 active Channel 2 active Run chain GS2+ area1 Run chain GS2+ area2 Run chain GS1- area 1 Run chain GS1- area 2 Channel 1 active Channel 2 active Reset/control of function safety circuits Activate safety circuits service door Channel 1 active Channel 2 active Reset/control of function safety circuits

Safety relays robot in area 1 Op-panel Op-panel Entrance protection area 2 Entrance protection area 2 Entrance protection area 2 Panel board Panel board Panel board Panel board Safety switch service door Safety switch service door Safety switch service door Pushbutton service door Home position switch Home position switch Home position switch

TB32:1,TB32 diRL7 :16 TB32:2,TB32 diRL8 :15 TB2:4, TB34:5 TB1:1, TB34:3 TB2:8, TB34:11 TB1:5, TB34:9 TB111:10, TB33:2 TB111:8, TB33:4 TB111:11, TB33:5 TB111:13, TB33:6 TB112:10, TB33:8 diGSTOP_CHA_1 diGSTOP_CHA_2 diGSTOP_CHB_1 diGSTOP_CHB_2 diRL201 diRL202 diRL203 diRL204 diRL401

TB112:8,TB3 diRL402 3:9 TB112:11*), TB112:12*) diRL403

3HEA 802349-001 Rev . A

73

Safety interface SIB V for positioner A/L/S

Configuration cross-connections

17.2.2 Configuration cross-connections

diRL1 diRL2 diRL3 & siSAFETY1_OK

diRL7 diRL8 diRL6 & siSAFETY2_OK

Figure 28. Cross-connections for unit for safety supervision SIB_V_typ 3

74

3HEA 802349-001 Rev . A

ABB
3HEA 802349-001 Rev . A