ABB-ESAB Robot Integration Manual

ESAB - ABB
Robot integration
Interface W82 Integrated and W82 Anybus
Integration manual
0740 800 220 20130308

READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DOCUMENTATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Supported equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Schematic system design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
W82 INTEGRATED VERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DeviceNet (Integrated version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Network connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DeviceNet network (Integrated version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location of SW1 and SW2 on the welding data board, 24AP1 . . . . . . . . . . . . . . . . . . . . . . . 8
W82 ANYBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fieldbus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
W82 DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DeviceNet network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Tap for DeviceNet at Weld Data Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Position of SW1 on the welding data board, 24AP1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
24AP4 Fieldbus board - DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fieldbus connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Baud rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Node address (Mac ID) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LED indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION OF HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Regarding U82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installing W82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONFIGURATION EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
IO configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Signals out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Signals in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Process definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Cross reference Integrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cross reference Anybus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SERVICE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
What is ESD? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Ordering spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Rights reserved to alter specifications without notice.
TOCe -2-
READ THIS FIRST
Installation must be performed by an experienced person, and electrical work only by
a trained electrician. Use only recommended replacement parts.
This integration manual is intended for use by technicians with electrical/electronic
training for help in connection with installation and integration of robotic equipment
with ESAB products.
Use the spare parts list as a guide to where the components are located in the
equipment. The spare parts list is published as a separate document, see page 33.
This manual contains details of design changes that have been made up to and
including March 2013.
HOW TO USE THIS MANUAL

This manual describes two different interfaces, W82 Integrated and W82 Anybus.
Only read and use the information applicable for your chosen interface.
DOCUMENTATION OVERVIEW
The documentation structure. This manual is the ESAB - ABB integration manual.
Delivered in the box with the unit
Power source W 82 RoboFeed / FeedControl

Instruction manual Instruction manual Instruction manual
Delivered with the Delivered with the ESAB Delivered in the box with
ABB robot robot package the wire feeder mounting kit
ESAB – ABB
ABB – robot RoboFeed / FeedControl
Integration manual
Product manual Assembly instruction
“This manual”
-3- S0740 800 220/E20130308/P34

cr09_00 © ESAB AB 2013
INTRODUCTION
This manual is intended to guide a system integrator, when integrating ESAB
equipment with an ABB robotic solution.
Supported equipment
Power source
Power sources for Integrated system: Mig 5000i / Mig5000iw
Power sources for Anybus system: Mig 5000i / 5000iw, Mig 4004i Pulse, Mig 4002c /
4002cw, Mig 5002c / 5002cw, Mig 6502c / 6502cw
Wire feed system

For hollow wrist robots like IRB1520ID, 1600ID and 2600ID it is recommended to use
drive unit RoboFeed 3004HW and electronic unit Feed Control Box 3004HW.
For robots with traditional upper arms it is recommended to use wire feed system
RoboFeed 3004W. RoboFeed 3004W contains both a mechanical drive unit and
electronics.
Interface unit
W82
The interface unit is installed between a welding equipment and an automation
equipment, such as robots. The W82 is available in several versions. This manual
describes the following versions:
S W82 Integrated
S W82 Anybus
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
ESD S Use proper static-proof bags and boxes.
-4- S0740 800 220/E20130308/P34

cr09_00 © ESAB AB 2013
Schematic system design
W82 Integrated version
ESAT vis LAN
ESAT via LAN
W82 Anybus version
ESAT via LAN
ss
Termination
120 ohm
-5- S0740 800 220/E20130308/P34

cr09_00 © ESAB AB 2013
W82 INTEGRATED VERSION
External CAN bus interface integrated in welding data board 24AP1. DeviceNet
communication is used.
External CAN bus connection to robot Internal CAN to Power Source
W82 integrated version
DeviceNet (Integrated version)

DeviceNet is used to control valves, sensors, I/O units and automation equipment in
industrial automation. DeviceNet communication link is based on a broadcast-
oriented, communication protocol, the Controller Area Network (CAN).
This protocol has I/O response and high reliability even for demanding applications,
for example control of brakes.
Network connection
To secure a reliable communication on the bus, the “drop lines” are restricted in the
DeviceNet standard to maximum length of 6 meters (20 ft.). Note that a correct
termination of the bus is also essential for a reliable communication.
-6- S0740 800 220/E20130308/P34

cr09_01 © ESAB AB 2013
DeviceNet network (Integrated version)
W82 Integrated version in the network
Termination
DeviceNet uses the CAN bus with terminating resistors at each end of the bus. The
value of the terminating resistor should be 120 ohm. This should be connected
between CAN_H and CAN_L on the bus. Midpoint is connected to 0V for the internal
CAN bus (0V_CAN_ext for the external CAN bus) via a 47nF capacitor.
Terminating resistors are included in the W82. They can be connected/disconnected
by the switches, SW1 and SW2. Both the external CAN bus and the internal CAN
bus have terminating resistors mounted.
Note! When external termination of the buses are used, the termination switches
shall be set in OFF position (disabled).
-7- S0740 800 220/E20130308/P34

cr09_01 © ESAB AB 2013
Location of SW1 and SW2 on the welding data board, 24AP1
SW1
SW2
-8- S0740 800 220/E20130308/P34

cr09_01 © ESAB AB 2013
W82 ANYBUS
External fieldbus connection via DeviceNet, CANopen or Profibus DP.
W82 fieldbus version
Fieldbus connection
External fieldbus connection to W82
-9- S0740 800 220/E20130308/P34

cr09_01_1 © ESAB AB 2013
W82 DeviceNet
DeviceNet is used to control valves, sensors, I/O units and automation equipment in
industrial automation. The DeviceNet communication link is based on a
broadcast-oriented, communication protocol, the Controller Area Network (CAN).
This protocol has I/O response and a high reliability even for demanding
applications, for example control of brakes.
Network connection
To secure a reliable communication on the bus, the “drop lines” are restricted in the
DeviceNet standard to a maximum length of 6 metres (20 ft).
Note! Correct termination of the bus is essential for a reliable communication.
DeviceNet network
W82 in DeviceNet network
- 10 -
cr09_01_2
Tap for DeviceNet at Weld Data Unit
Termination
DeviceNet uses the CAN bus with terminating resistors at each end of the bus. The
terminating resistor should be 120 ohm. This should be connected between CAN_H
and CAN_L on the bus. Midpoint is connected to 0V for the internal CAN bus
(0V_CAN_ext for the external CAN bus) via 47nF capacitors.
Terminating resistors are included in the W82. They can be connected/disconnected
by switch SW1. Only the internal CAN bus has terminating resistors mounted.
Note! When the W82 is is located as the last node in the internal bus network, use
termination on the CAN bus:
S Set termination switch SW1 to position “ON”. The CAN bus will be terminated
with 120 ohm at 24AP1.
S With external termination, set termination switch SW1 to position “OFF”.
- 11 -
cr09_01_2
Position of SW1 on the welding data board, 24AP1.
SW1
- 12 -
cr09_01_2
24AP4 Fieldbus board - DeviceNet
Fieldbus connector
5-pin plug-able screw terminal fieldbus connector (Phoenix type)
Connector pin Signal Description

1 V- Negative supply voltage
2 CAN_L CAN_L bus line
3 SHIELD Cable shield
4 CAN_H CAN_H bus line
5 V+ Positive supply voltage
The bus interface shall be supplied with 24VDC, but will operate as intended as long
as the supply voltage is within the DeviceNet-allowed 11 to 25V DC range.
- 13 -
cr09_01_2
Configuration
A connection to the node is set up towards the assembly object with a bus
configuration tool or directly from a master.
Node address (Mac ID) and baud rate are configured with dip-switches (see picture
of fieldbus board). The range for node address is between 0-63 and baud rate is
between 0 and 2 (0 = 125 kbit/s, 1 = 250 kbit/s and 2 = 500 kbit/s).
When a DIP-switch is in ”ON” or ”Closed” position, the node interprets it as a logic ”1”.
Baud rate
There are three different baud rates for DeviceNet:
S 125 kbit/s
S 250 kbit/s
S 500 kbit/s.
DIP-switches 1 and 2 are used for baud rate setting.
Baud rate, bits/s Sw 1 Sw 2

125k OFF OFF
250k OFF ON
500k ON OFF
Reserved ON ON
Node address (Mac ID)

Switches 3 to 8 are used to set the node address (0-63). Switch 3 is the MSB, and
switch 8 is LSB.
Address Sw 3 Sw 4 Sw 5 Sw 6 Sw 7 Sw 8
0 OFF OFF OFF OFF OFF OFF
1 OFF OFF OFF OFF OFF ON
2 OFF OFF OFF OFF ON OFF
3 OFF OFF OFF OFF ON ON
      
62 ON ON ON ON ON OFF
63 ON ON ON ON ON ON
- 14 -
cr09_01_2
LED indicators
The fieldbus board is equipped with four bi-colour LED's at the front of the board
showing the status.
LED 1 and 4 are reserved for future use.
LED 2 - Network status

Colour Frequency Description
Off - Not powered / Not on line
Green Steady on Link OK, On line, Connected
Green Flashing On line, Not connected
Red Steady on Critical link failure
Red Flashing Connection timeout
LED 3 - Module status
Colour Frequency Description
Off - No power to device
Green Steady on Device operational
Green Flashing Data size bigger than configured
Red Steady on Unrecoverable fault
Red Flashing Minor fault
Watchdog LED
The fieldbus board includes a bi-colour watchdog LED, indicating the status of the
module.
Colour Frequency Indication
Red - Unspecified internal error, or running in bootloader mode
Red 1 Hz RAM failure
Red 2 Hz ASIC or FLASH failure
Red 4 Hz DPRAM failure
Green 1 Hz Module initialised and running OK
Green 2 Hz Module not initialised
- 15 -
cr09_01_2
INSTALLATION OF HARDWARE
The installation chapter will describe how to connect the different components. The
ESAB integrated software in the robot controller should be installed by ABB before
delivery to the site.
Regarding U82
The U82 is not supported together with the W82 integrated version. The ABB Teach
Pendant is used for communicating with the power source.
Installing W82
Connections and control devices
W82 Integrated W82 Anybus
1. Indicating lamp
Orange indicating lamp - Overheating
2. Fieldbus
Connection for communication with robot system
3. Measure
Connection for measurement cable for arc voltage feedback and emergency
stop signal, measurement kit
4. Internal CAN
Connections for communication with ESAB wire feed unit and control panel
5. LAN
Connection to network, Ethernet
6. CAN to welding power source
Connection for communication with welding power source
7. USB
USB memory connection
- 16 -
cr09_02
Mounting W82 on Mig 5000i
S On the power source, remove the two screws that holds the rear handle.
S Remove handle.
S Place the interface box onto the welding power source.
S Place handle on top of the interface box.
S Fasten interface box and handle with the two screws.
Mounting W82 on Mig 4002c, Mig 5002c and Mig 6502c

S On the power source, use the “keyholes” that is normally used for the chain
holding the gas tube.
S Place the interface box onto the welding power source.
S Fasten interface box with the two screws.
Installing the wire feeder and control unit
Mount the feeder unit and controller according to the mounting instruction that
comes in the same box as the units.
Power source
Unpack and install the power source according to the user manual.
Installing the welding gun

Unpack and install the welding gun according to the user manual.
Installing the bobbin holder

Unpack and install the bobbin holder according to the user manual, refer to the
assembly instruction for Robot Bobbin Kit “RoboFeed 3004HW”.
- 17 -
cr09_02
Installing the cables (W82 Integrated)
RoboFeed
Mig 5000i/iw
ABB
Teach pendant
1 Connection between welding W82 and power source. External CAN to power source.
2 Connection between W82 and robot control cabinet. External fieldbus CAN to robot control cabinet.
3 Connection between welding power source and wire feed unit. Internal CAN.
4 Connection between ABB teach pendant, single point of programming, and robot control cabinet.
Note! When using a wire feed unit other than RoboFeed, install a separate arc voltage feedback to
the measurement contact on the control unit.
Installing the cables (W82 Anybus)
RoboFeed
Mig 5000i/iw
4 Connection between welding power source and control panel. Internal CAN.
- 18 -
cr09_02
Installing the cables (W82 Anybus) continued
RoboFeed
Mig 4004i Pulse
4 1
3
2
3 Connection between welding power source and wire feed unit. Internal CAN:
RoboFeed
Mig 4002 c/cw

Mig 5002 c/cw
Mig 6502 c/cw
4 1
3
2
- 19 -
cr09_02
CONFIGURATION EXAMPLE
This section describes examples of IO configurations, process definitions and cross
references and is ment to be used for reference and as examples.
IO configuration
Unit type
Name = ESAB_W82_Integrated
Name = ESAB_W82_Anybus
Unit
Name = ESAB_W82
IO
Name = typeXxxxYyyy
Description of signal naming convention (if more than 1 robot a prefix is added
explaining which robot the signal belongs to).
Type:
S di = Digital input
S do = Digital output
S gi = group input
S go = group output
S ai = analog input
S ao = analog output
Xxxx:
S Signal description
Yyyy:
S Signal action
SignalLabel = <Description>
Category = “ArcWelding”
- 20 -
cr09_02
Signals out
This table lists examples of signals from robot to W82
ABB ESAB Description

doWeld doWeldOn Start/Stop welding equipment
doQuickStop doQuickStop Quick stop of welding equipment
without end data
doEmStop doEmergencyStop Emergency stop
doFeed doWireFeedOn Start/Stop wire feeding
doGas doGasPurgeOn Start/Stop Gas flow
doAir doAirCleanOn Start/Stop compressed Air flow
doFeedBwd doWireFeedReverseOn Start/Stop reversing wire feed
doRemoteActiveOn Remote active Enabled/Disabled
goWireFeeder doWireFeeder1On Enable/Disable wire feeder 1
doWireFeeder2On Enable/Disable wire feeder 2
doAnalogOn Wirefeed & Voltage reference
controlled from FP instead of weld
data number.
Rel_Wire doReleaseWireOn Execute a current pulse to burn of
the wire if frozen in weld pole.
doTouchSenseActive doTouchSenseOn Turns on the possibility to search
using wire or gas cup. Used with
search instr
goSchedule goWeldDataNumber Recalls a complete set of weld
data
aoMigVoltRef aoWeldVoltageRef Value of Voltage reference. Only
used if AnalogOn is enabled.
aoMigWfRef aoWireFeedSpeedRef Value of Wire feed speed refer
ence. Only used if AnalogOn is en
abled.
- 21 -
cr09_02
Signals in
This table lists examples of signals from W82 to robot

diWeldEst diWeldingActive This signal indicates that the weld
ing equipment I occupied with
welding
diArcEst diArcEstablished This signal will be activated when
the arc is established at a weld
start.
diTouchSenseContact diTouchSenseResponse This signal indicates contact with
wire or gas cup if TouchSenseOn
is enabled.
diRemoteActive diRemoteActive Indicates that remote active is on.
diWF1Selected diWireFeeder1Active Wire feeder 1 active.
diError1 diErrorType1 See U82 manual for future inform
ation regarding the error bit mask
diWduError diWDUErrorActive If active there is an error in the
Weld Data Unit.
diPsError diPSErrorActive If active there is an error in the
Power Source
diWfError diWFErrorActive If active there is an error in the
active Wire Feeder.
diGasActive diGasActive Indicates that gas is flowing thru
gasflow sensor.
diCollisionDetect diCollisionDetected Indicates robot collision.
diSynergyActive Indicates that synergy is active.
diWireFeedActive Indicates that Wire Feeder is act
ive.
aiVoltage aiMeasuredVoltage This is the measured voltage from
the welding equipment.
- 22 -
cr09_02
aiCurrent aiMeasuredCurrent This is the measured current from
aiPower aiMeasuredPower This is the measured power from
giWeldDataNumber This is updated every time there
has been a successful recall of a
weld data set.
aiWeldVoltageRef This value indicates which voltage
the welding machine is using
aiWireFeedSpeedRef This value indicates which wire
feed speed the welding machine is
using.
aiSynergicVoltage This value indicates the result of
the calculations done by the weld
ing equip.
- 23 -
cr09_02
Process definitions
The following tables lists examples of settings for the system and the equipment.
ARC_SYSTEM
Parameter Value Information
Name ARC1
Use Arc System Properties ARC1
Use Arc Error Handler Default
Induvidual Robot Properties Act FALSE
ive
ARC_SYSTEM_PROPERTIES
Name ARC1
Units SI_UNITS
Restart On TRUE
Restart Distance 5
Number of retries 3
Scrape On TRUE
Scrape Optional On TRUE
Scrape Width 3
Scrape Direction 90
Scrape Cycle Time 0.2
Ignition Move delay On FALSE
Motion Timeout 3
Weave Sync On TRUE
ARC_ROBOT_PROPERTIES
Name ARC1_T_ROB1
Units SI_UNITS
Restart On TRUE
Restart Distance 5
Number of Retries 3
Scrape On TRUE
Scrape Optional On TRUE
Scrape Width 3
Scrape Direction 90
Scrape Cycle Time 0.2
Ignition Move delay On FALSE
Motion Timeout 3
Weave Sync On TRUE
- 24 -
cr09_02
ARC_UNITS
Name SI_UNITS
Arc Length units mm
Arc Velocity units mm/s
Arc Feed units mm/s

Name US_UNITS
Arc Length units inch
Arc Velocity units ipm
Arc Feed units ipm

Name WELD_UNITS
Arc Length units mm
Arc Velocity units mm/s
Arc Feed units m/min
ARC_EQUIPMENT
Name ARC1_EQUIP_T_ROB1
Welder Type StandardIO
Loaded in Robot T_ROB1
Use Arc Equipment Class stdIO_T_ROB1
Use Arc Equipment Properties MIG1
ARC_EQUIPMENT_CLASS
Name stdIO_T_ROB1
Equipment Class File Name awEquipSTD
Path RELEASE:/options/arc/WeldEquip/Code/
ARC_EQUIPMENT_PROPERTIES
Name MIG1
Use Arc Equipment IO DI MIG1
Use Arc Equipment IO DO MIG1
Use Arc Equipment IO AO MIG1
Use Arc Equipment IO AI MIG1
Use Arc Equipment IO GO MIG1
Preconditions ON TRUE
Ignition On FALSE
Heat On FALSE
- 25 -
cr09_02
Fill On FALSE
Burnback On FALSE
Burnback Voltage On FALSE
Rollback On FALSE
Rollback Wirefeed On FALSE
Autoinhibit On FALSE
Welder Robot TRUE
Heat As Time FALSE
Override On FALSE
Schedport Type 3
Arc Preset 0.2
Ignition Timeout 2
Weld Off Timeout 10
Time to feed 15mm wire 0.33
ARC_EQUIPMENT_DIGITAL_INPUTS
Name MIG1
ManFeedInput TRUE
WeldInhib TRUE
WeaveInhib TRUE
TrackInhib TRUE
SupervInhib TRUE
StopProc TRUE
ArcEst diArcEstablished
ArcEstLabel TRUE
ArcEst2 TRUE
ArcEstLabel2 TRUE
WeldOk diWeldingActive
WeldOkLabel TRUE
VoltageOk TRUE
VoltageOkLabel TRUE
CurrentOK TRUE
CurrentOKLabel TRUE
WaterOk siWater
WaterOkLabel TRUE
WirefeedOk siWire
WirefeedOkLabel TRUE
GasOK siGas
GasOkLabel TRUE
- 26 -
cr09_02
GunOk NO_SIGNAL
GunOkLabel TRUE
WirestickErr TRUE
WirestickErrLabel TRUE
USERIO1 TRUE
USERIO1Label TRUE
USERIO2 TRUE
USERIO2Label TRUE
USERIO3 TRUE
USERIO3Label TRUE
USERIO4 TRUE
USERIO4Label TRUE
USERIO5 TRUE
USERIO5Label TRUE
ARC_EQUIPMENT_DIGITAL_OUTPUTS
Name MIG1
AWError doQuickStop
GasOn doGasPurgeOn
WeldOn doWeldOn
FeedOn doWireFeedOn
FeedOnBwd doWireFeedReverseOn
SchedStrobe TRUE
ProcessStopped TRUE
SupervArc TRUE
SupervVolt TRUE
SupervCurrent TRUE
SupervWater TRUE
SupervGas TRUE
SupervFeed TRUE
SupervGun TRUE
- 27 -
cr09_02
ARC_EQUIPMENT_ANALOG_OUTPUTS
Name MIG1
VoltReference aoWeldVoltageRef
FeedReference aoWireFeedSpeedRef
CurrentReference TRUE
ControlPort TRUE
VoltReference2 TRUE
FeedReference2 TRUE
ControlPort2 TRUE
ARC_EQUIPMENT_ANALOG_INPUTS
Name MIG1
VoltageMeas aiMeasuredVoltage
CurrentMeas aiMeasuredCurrent
ARC_EQUIPMENT_GROUP_OUTPUTS
Name MIG1
SchedulePort goWeldDataNumber
ModePort TRUE
- 28 -
cr09_02
Cross reference Integrated
This table lists examples of cross references for W82 integrated.
Robot W82
Signal Name Type Adress Signal Name Type Byte Bit
doWeld DO 0 Weld On IN 0 0
doQuickStop DO 1 Quick Stop IN 0 1
doEmStop DO 2 Emerg. Stop IN 0 2
doFeed DO 3 Inching IN 0 3
doGas DO 4 Gas Purge IN 0 4
doAir DO 5 Clean IN 0 5
doFeedBwd DO 6 Inch Reverse IN 0 6
Remote Active IN 0 7
goWireFeeder GO 811 Wire Feed 14 IN 1 03
Analog Active IN 1 4
Not Used IN 1 5
Release Wire IN 1 6
doTouchSenseActive DO 15 Touch Sense IN 1 7
goSchedule GO 1623 Weld Data Number IN 2 07
… GO 2431 <reserved> IN 3 07
3239 <reserved> IN 4 07
6479 Voltage Low Byte IN 8 07
Voltage High Byte IN 9 07
8095 Wire Feed Speed Low Byte IN 10 07
Wire Feed Speed High Byte IN 11 07
diWeldEst DI 49 Weld Busy OUT 0 0
diArcEst DI 48 Arc Acknowledge OUT 0 1
diTouchSenseContact DI 50 TouchSense OUT 0 2
Response
51 Remote Active OUT 0 3
diWF1Selected DI 52 WFU 1 Active OUT 0 4
diError1 DI 56 Error Type 1 OUT 1 0
- 29 -
cr09_02
Robot W82
diWduError DI 64 Error WDU OUT 2 0
diPsError DI 65 Error PS OUT 2 1
diWfError DI 66 Error WFU OUT 2 2
0 <not used> OUT 2 3
0 Gas Active OUT 2 4
diCollisionDetect DI 69 Collision Detect OUT 2 5
0 Synergy Active OUT 2 6
0 Inching Active OUT 2 7
aiVoltage AI 07 Voltage Low Byte(Measured) OUT 3 07
815 Voltage High Byte(Measured) OUT 4 07
aiCurrent AI 1623 Current Low Byte(Measured) OUT 5 07
2431 Current High Byte(Measured) OUT 6 07
aiPower AI 3239 Power Low Byte(Measured) OUT 7 07
4047 Power High Byte(Measured) OUT 8 07
Weld Data Number OUT 9 07
Voltage Low Byte(SINT) OUT 10 07
Voltage High Byte(SINT) OUT 11 07
Wire Feed Speed Low Byte(USINT) OUT 12 07
Wire Feed Speed High Byte(USINT) OUT 13 07
Synergic Voltage Low Byte(SINT) OUT 14 07
Synergic Voltage High Byte(SINT) OUT 15 07
- 30 -
cr09_02
Cross reference Anybus
This table lists examples of cross references for W82 Anybus.
ABB W82
doWeldOn OUT 0 Weld On IN 0 0
doQuickStop OUT 1 Quick Stop IN 0 1
doEmergencyStop OUT 2 Emerg. Stop IN 0 2
doWireFeedOn OUT 3 Inching IN 0 3
doGasPurgeOn OUT 4 Gas Purge IN 0 4
doAirCleanOn OUT 5 Clean IN 0 5
doWireFeedReverseOn OUT 6 Inch Reverse IN 0 6
doRemoteActiveOn OUT 7 Remote Active IN 0 7
doWireFeeder1On OUT 8 Wire Feed 1 IN 1 0
doAnalogOn OUT 12 Analog Active IN 1 4
doReleaseWireOn OUT 14 Release Wire IN 1 6
doTouchSenseOn OUT 15 Touch Sense IN 1 7
goWeldDataNumber OUT(GO) 1623 Weld Data Number IN 2 07
aoWeldVoltageRef OUT(AO) 6479 Voltage Low Byte IN 8 07
aoWeldVoltageRef Voltage High Byte IN 9 07
aoWireFeedSpeedRef OUT(AO) 8095 Wire Feed Speed Low Byte IN 10 07
aoWireFeedSpeedRef Wire Feed Speed High Byte IN 11 07
diWeldingActive IN 0 Weld Busy OUT 0 0
diArcEstablished IN 1 Arc Acknowledge OUT 0 1
diTouchSenseResponse IN 2 TouchSense Response OUT 0 2
diRemoteActive IN 3 Remote Active OUT 0 3
diWireFeeder1Active IN 4 WFU 1 Active OUT 0 4
diErrorType1 IN 8 Error Type 1 OUT 1 0
diWDUErrorActive IN 16 Error WDU OUT 2 0
- 31 -
cr09_02
ABB W82
diPSErrorActive IN 17 Error PS OUT 2 1
diWFErrorActive IN 18 Error WFU OUT 2 2
diGasActive IN 20 Gas Active OUT 2 4
diCollisionDetected IN 21 Collision Detect OUT 2 5
diSynergyActive IN 22 Synergy Active OUT 2 6
diWireFeedActive IN 23 Inching Active OUT 2 7
aiMeasuredVoltage IN(AI) 2439 Voltage Low Byte(Measured) OUT 3 07
aiMeasuredVoltage Voltage High Byte(Measured) OUT 4 07
aiMeasuredCurrent IN(AI) 4055 Current Low Byte(Measured) OUT 5 07
aiMeasuredCurrent Current High Byte(Measured) OUT 6 07
aiMeasuredPower IN(AI) 5671 Power Low Byte(Measured) OUT 7 07
aiMeasuredPower Power High Byte(Measured) OUT 8 07
giWeldDataNumber IN(GI) 7279 Weld Data Number OUT 9 07
aiWeldVoltageRef IN(AI) 8095 Voltage Low Byte(SINT) OUT 10 07
aiWeldVoltageRef Voltage High Byte(SINT) OUT 11 07
aiWireFeedSpeedRef IN(AI) 96111 Wire Feed Speed Low Byte(USINT) OUT 12 07
aiWireFeedSpeedRef Wire Feed Speed High Byte(USINT) OUT 13 07
aiSynericVoltage IN(AI) 112127 Synergic Voltage Low Byte(SINT) OUT 14 07
aiSynericVoltage Synergic Voltage High Byte(SINT) OUT 15 07
- 32 -
cr09_02
SERVICE INSTRUCTIONS
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic-
sensitive devices.
ESD S Use proper static-proof bags and boxes.
What is ESD?
A sudden transfer or discharge of static electricity from one object to another. ESD
stands for Electrostatic Discharge.
How does ESD damage occur?

ESD can cause damage to sensitive electrical components, but is not dangerous to
people. ESD damage occurs when an ungrounded person or object with a static
charge comes into contact with a component or assembly that is grounded. A rapid
discharge can occur, causing damage. This damage can take the form of immediate
failure, but it is more likely that system performance will be affected and the
component will fail prematurely.
How do we prevent ESD damage?

ESD damage can be prevented by awareness. If static electricity is prevented from
building up on you or on anything at your work station, then there cannot be any
static discharges. Nonconductive materials (e.g. fabrics), or insulators (e.g. plastics)
generate and hold static charge, so you should not bring unnecessary nonconductive
items into the work area.
It is obviously difficult to avoid all such items, so various means are used to drain off
any static discharge from persons to prevent the risk of ESD damage. This is done
by simple devices: wrist straps, connected to ground, and conductive shoes.
Work surfaces, carts and containers must be conductive and grounded. Use only
antistatic packaging materials. Overall, handling of ESD-sensitive devices should be
minimized to prevent damage.
SPARE PARTS
The spare parts list is published in a separate document that can be downloaded
from the Internet: www.esab.com
Product Filename
Aristo W82 0459 839 038
Ordering spare parts

Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
- 33 - S0740 800 220/E20130308/P34

cr09f2 © ESAB AB 2013
ESAB subsidiaries and representative offices
Europe NORWAY North and South America SOUTH KOREA

AS ESAB ESAB SeAH Corporation
AUSTRIA Larvik ARGENTINA Kyungnam
ESAB Ges.m.b.H Tel: +47 33 12 10 00 CONARCO Tel: +82 55 269 8170
Vienna-Liesing Fax: +47 33 11 52 03 Buenos Aires Fax: +82 55 289 8864
Tel: +43 1 888 25 11 Tel: +54 11 4 753 4039
Fax: +43 1 888 25 11 85 POLAND Fax: +54 11 4 753 6313 UNITED ARAB EMIRATES
ESAB Sp.zo.o. BRAZIL ESAB Middle East FZE
BELGIUM Katowice Dubai
S.A. ESAB N.V. ESAB S.A.
Tel: +48 32 351 11 00 Contagem-MG Tel: +971 4 887 21 11
Brussels Fax: +48 32 351 11 20 Fax: +971 4 887 22 63
Tel: +32 2 745 11 00 Tel: +55 31 2191 4333
Fax: +32 2 745 11 28 Fax: +55 31 2191 4440
PORTUGAL Africa
BULGARIA ESAB Lda CANADA
Lisbon EGYPT
ESAB Kft Representative Office ESAB Group Canada Inc.
Tel: +351 8 310 960 ESAB Egypt
Sofia Missisauga, Ontario
Fax: +351 1 859 1277 Dokki-Cairo
Tel/Fax: +359 2 974 42 88 Tel: +1 905 670 02 20
Tel: +20 2 390 96 69
Fax: +1 905 670 48 79
ROMANIA Fax: +20 2 393 32 13
THE CZECH REPUBLIC
ESAB Romania Trading SRL MEXICO
ESAB VAMBERK s.r.o. SOUTH AFRICA
Bucharest ESAB Mexico S.A.
Vamberk ESAB Africa Welding & Cutting Ltd
Tel: +40 316 900 600 Monterrey
Tel: +420 2 819 40 885 Durbanvill 7570 - Cape Town
Fax: +40 316 900 601 Tel: +52 8 350 5959
Fax: +420 2 819 40 120 Tel: +27 (0)21 975 8924
Fax: +52 8 350 7554
DENMARK RUSSIA
Aktieselskabet ESAB LLC ESAB USA
ESAB Welding & Cutting Products Distributors
Herlev Moscow
Florence, SC For addresses and phone
Tel: +45 36 30 01 11 Tel: +7 (495) 663 20 08
Tel: +1 843 669 44 11 numbers to our distributors in
Fax: +45 36 30 40 03 Fax: +7 (495) 663 20 09
Fax: +1 843 664 57 48 other countries, please visit our
FINLAND SLOVAKIA home page
ESAB Oy ESAB Slovakia s.r.o. Asia/Pacific www.esab.com
Helsinki Bratislava AUSTRALIA
Tel: +358 9 547 761 Tel: +421 7 44 88 24 26 ESAB South Pacific
Fax: +358 9 547 77 71 Fax: +421 7 44 88 87 41 Archerfield BC QLD 4108
Tel: +61 1300 372 228
FRANCE SPAIN
Fax: +61 7 3711 2328
ESAB France S.A. ESAB Ibérica S.A.
Cergy Pontoise Alcalá de Henares (MADRID)
CHINA
Tel: +33 1 30 75 55 00 Tel: +34 91 878 3600
Shanghai ESAB A/P
Fax: +33 1 30 75 55 24 Fax: +34 91 802 3461
Shanghai
Tel: +86 21 2326 3000
GERMANY SWEDEN
Fax: +86 21 6566 6622
ESAB GmbH ESAB Sverige AB
Solingen Gothenburg INDIA
Tel: +49 212 298 0 Tel: +46 31 50 95 00 ESAB India Ltd
Fax: +49 212 298 218 Fax: +46 31 50 92 22 Calcutta
Tel: +91 33 478 45 17
ESAB international AB
GREAT BRITAIN Fax: +91 33 468 18 80
Gothenburg
ESAB Group (UK) Ltd Tel: +46 31 50 90 00
Waltham Cross INDONESIA
Fax: +46 31 50 93 60
Tel: +44 1992 76 85 15 P.T. ESABindo Pratama
Fax: +44 1992 71 58 03 SWITZERLAND Jakarta
ESAB AG Tel: +62 21 460 0188
ESAB Automation Ltd Fax: +62 21 461 2929
Andover Dietikon
Tel: +44 1264 33 22 33 Tel: +41 1 741 25 25 JAPAN
Fax: +44 1264 33 20 74 Fax: +41 1 740 30 55 ESAB Japan
Tokyo
HUNGARY UKRAINE Tel: +81 45 670 7073
ESAB Kft ESAB Ukraine LLC Fax: +81 45 670 7001
Budapest Kiev
Tel: +36 1 20 44 182 Tel: +38 (044) 501 23 24 MALAYSIA
Fax: +36 1 20 44 186 Fax: +38 (044) 575 21 88 ESAB (Malaysia) Snd Bhd
USJ
ITALY Tel: +603 8023 7835
ESAB Saldatura S.p.A. Fax: +603 8023 0225
Bareggio (Mi)
Tel: +39 02 97 96 8.1 SINGAPORE
Fax: +39 02 97 96 87 01 ESAB Asia/Pacific Pte Ltd
Singapore
THE NETHERLANDS Tel: +65 6861 43 22
ESAB Nederland B.V. Fax: +65 6861 31 95
Amersfoort
Tel: +31 33 422 35 55
Fax: +31 33 422 35 44
www.esab.com
© ESAB AB 110915

ABB-ESAB Robot Integration Manual

Uploaded by

Copyright:

Available Formats

ABB-ESAB Robot Integration Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ABB-ESAB Robot Integration Manual

Uploaded by

Copyright:

Available Formats

ESAB - ABB

0740 800 220 20130308

Rights reserved to alter specifications without notice.

HOW TO USE THIS MANUAL

Delivered in the box with the unit

Power source W 82 RoboFeed / FeedControl

-3- S0740 800 220/E20130308/P34

Wire feed system

-4- S0740 800 220/E20130308/P34

ESAT vis LAN

ESAT via LAN

W82 Anybus version

ESAT via LAN

-5- S0740 800 220/E20130308/P34

External CAN bus connection to robot Internal CAN to Power Source

W82 integrated version

DeviceNet (Integrated version)

-6- S0740 800 220/E20130308/P34

W82 Integrated version in the network

-7- S0740 800 220/E20130308/P34

-8- S0740 800 220/E20130308/P34

W82 fieldbus version

External fieldbus connection to W82

-9- S0740 800 220/E20130308/P34

W82 in DeviceNet network

Connector pin Signal Description

Baud rate, bits/s Sw 1 Sw 2

Node address (Mac ID)

LED 2 - Network status

W82 Integrated W82 Anybus

Mounting W82 on Mig 4002c, Mig 5002c and Mig 6502c

Installing the welding gun

Installing the bobbin holder

Installing the cables (W82 Anybus)

Mig 4004i Pulse

Mig 4002 c/cw

ABB ESAB Description

This table lists examples of signals from W82 to robot

ABB ESAB Description

Parameter Value Information

Parameter Value Information

How does ESD damage occur?

How do we prevent ESD damage?

Ordering spare parts

- 33 - S0740 800 220/E20130308/P34

Europe NORWAY North and South America SOUTH KOREA

You might also like