ABB ESAB W82 Use and care manual

0740 800 220 20130308
ESAB - ABB
Robot integration
Interface W82Integrated and W82Anybus
Integration manual

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Rights reserved to alter specifications without notice.
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............................................................

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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, W82Integrated and W82Anybus.
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
Delivered with the
ABB robot
Delivered in the box with
the wire feeder mounting kit
Delivered with the ESAB
robot package
Power source
Instruction manual
W82
Instruction manual
RoboFeed / FeedControl
Instruction manual
RoboFeed / FeedControl
Assembly instruction
ESAB – ABB
Integration manual
ABB – robot
Product manual “This manual”

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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 W82is available in several versions. This manual
describes the following versions:
SW82Integrated
SW82Anybus
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
STATIC ELECTRICITY can damage circuit
boards and electronic components.
SObserve precautions for handling electrostatic-
sensitive devices.
SUse proper static-proof bags and boxes.
ESD

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Schematic system design
W82Integrated version
ESAT vis LAN
ESAT via LAN
W82Anybus version
ESAT via LAN
Termination
120 ohm
ss

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W82INTEGRATED VERSION
External CAN bus interface integrated in welding data board 24AP1. DeviceNet
communication is used.
Internal CAN to Power Source
External CAN bus connection to robot
W82integrated 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.

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DeviceNet network (Integrated version)
W82Integrated 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).

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Location of SW1 and SW2 on the welding data board, 24AP1
SW1
SW2

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W82ANYBUS
External fieldbus connection via DeviceNet, CANopen or Profibus DP.
W82 fieldbus version
Fieldbus connection
External fieldbus connection to W82

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W82DeviceNet
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
W82in DeviceNet network

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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 W82is is located as the last node in the internal bus network, use
termination on the CAN bus:
SSet termination switch SW1 to position “ON”. The CAN bus will be terminated
with 120 ohm at 24AP1.
SWith external termination, set termination switch SW1 to position “OFF”.

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Position of SW1 on the welding data board, 24AP1.
SW1

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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.

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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:
S125 kbit/s
S250 kbit/s
S500 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

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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

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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 U82is not supported together with the W82integrated version. The ABB Teach
Pendant is used for communicating with the power source.
Installing W82
Connections and control devices
W82Integrated W82Anybus
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

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Mounting W82 on Mig 5000i
SOn the power source, remove the two screws that holds the rear handle.
SRemove handle.
SPlace the interface box onto the welding power source.
SPlace handle on top of the interface box.
SFasten interface box and handle with the two screws.
Mounting W82on Mig 4002c, Mig 5002c and Mig 6502c
SOn the power source, use the “keyholes” that is normally used for the chain
holding the gas tube.
SPlace the interface box onto the welding power source.
SFasten 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”.

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Installing the cables (W82Integrated)
ABB
Teach pendant
RoboFeed
Mig 5000i/iw
1Connection between welding W82and power source. External CAN to power source.
2Connection between W82and robot control cabinet. External fieldbus CAN to robot control cabinet.
3Connection between welding power source and wire feed unit. Internal CAN.
4Connection 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 (W82Anybus)
RoboFeed
Mig 5000i/iw
1Connection between welding W82and power source. External CAN to power source.
2Connection between W82and robot control cabinet. External fieldbus CAN to robot control cabinet.
3Connection between welding power source and wire feed unit. Internal CAN.
4Connection between welding power source and control panel. Internal CAN.
Note! When using a wire feed unit other than RoboFeed, install a separate arc voltage feedback to
the measurement contact on the control unit.

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Installing the cables (W82Anybus) continued
Mig 4004i Pulse
RoboFeed
1
3
2
4
1Connection between welding W82and power source. External CAN to power source.
2Connection between W82and robot control cabinet. External fieldbus CAN to robot control cabinet.
3Connection between welding power source and wire feed unit. Internal CAN:
4Connection between welding power source and control panel. Internal CAN.
Note! When using a wire feed unit other than RoboFeed, install a separate arc voltage feedback to
the measurement contact on the control unit.
Mig 4002 c/cw
Mig 5002 c/cw
Mig 6502 c/cw
RoboFeed
1
3
2
4
1Connection between welding W82and power source. External CAN to power source.
2Connection between W82and robot control cabinet. External fieldbus CAN to robot control cabinet.
3Connection between welding power source and wire feed unit. Internal CAN.
4Connection between welding power source and control panel. Internal CAN.
Note! When using a wire feed unit other than RoboFeed, install a separate arc voltage feedback to
the measurement contact on the control unit.

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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:
Sdi = Digital input
Sdo = Digital output
Sgi = group input
Sgo = group output
Sai = analog input
Sao = analog output
Xxxx:
SSignal description
Yyyy:
SSignal action
SignalLabel = <Description>
Category = “ArcWelding”