ABB IRBP A Instructions for use

Application manual
Signal description for arc welding products

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Application manual
Signal description for arc welding products
Document ID: 3HAC050975-001
Revision: -
© Copyright 2004-2016 ABB. All rights reserved.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.
© Copyright 2004-2016 ABB. All rights reserved.
ABB AB
Robotics Products
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
8Product documentation, IRC5 ..........................................................................................................
10Safety ................................................................................................................................................
111 General I/O description
132 Signal configuration
132.1 Signal configuration, B_AW_PROC_40 .................................................................. 152.2 Process interface ESAB, robot 2, B_AW_PROC_41 ................................................. 172.3 Process interface ESAB Aristo™ Mig, external equipment, B_AW_OPT_14 ..................
193 Positioner interface IRBP A
234 Positioner interface IRBP B/D
275 Positioner interface IRBP C
296 Positioner interface IRBP K/R
337 Positioner interface IRBP L
378 Operator interface IRBP
399 Safety interface SIB V for positioner B/C/D/K/R
4310 Safety interface SIB V for positioner A/L/S
47Index
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Table of contents

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Overview of this manual
About this manual
This manual explains the signals used for arc welding products from ABB Robotics.
Usage
This manual can be used either as a reference to find out if an option is the right
choice for solving a problem, or as a description of the signals.
Who should read this manual?
This manual is intended for:
• installation personnel
• robot programmers
Prerequisites
The reader should...
• be familiar with industrial robots and their terminology
• be familiar with the RAPID programming language
• be familiar with system parameters and how to configure them.
Reference documents
Document IDReferences
3HAC050947-001Technical reference manual - RAPID overview
3HAC050917-001Technical reference manual - RAPID Instructions, Functions
and Data types
3HAC050948-001Technical reference manual - System parameters
Revisions
DescriptionRevision
Released with RobotWare 6.03.-
Application manual - Signal description for arc welding products 7
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© Copyright 2004-2016 ABB. All rights reserved.
Overview of this manual

Product documentation, IRC5
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed
are valid for IRC5 robot systems.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with exploded views (or references to separate spare parts
lists).
• Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe reference information for robotics
products.
•Technical reference manual - Lubrication in gearboxes: Description of types
and volumes of lubrication for the manipulator gearboxes.
•Technical reference manual - RAPID overview: An overview of the RAPID
programming language.
•Technical reference manual - RAPID Instructions, Functions and Data types:
Description and syntax for all RAPID instructions, functions, and data types.
•Technical reference manual - RAPID kernel: A formal description of the
RAPID programming language.
•Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
Continues on next page
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© Copyright 2004-2016 ABB. All rights reserved.
Product documentation, IRC5

Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and trouble shooters.
The group of manuals includes (among others):
•Operating manual - Emergency safety information
•Operating manual - General safety information
•Operating manual - Getting started, IRC5 and RobotStudio
•Operating manual - Introduction to RAPID
•Operating manual - IRC5 with FlexPendant
•Operating manual - RobotStudio
•Operating manual - Trouble shooting IRC5, for the controller and manipulator.
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© Copyright 2004-2016 ABB. All rights reserved.
Product documentation, IRC5
Continued

Safety
Safety of personnel
When working inside the robot controller it is necessary to be aware of
voltage-related risks.
A danger of high voltage is associated with the following parts:
• Devices inside the controller, for example I/O devices, can be supplied with
power from an external source.
• The mains supply/mains switch.
• The power unit.
• The power supply unit for the computer system (230 VAC).
• The rectifier unit (400-480 VAC and 700 VDC). Capacitors!
• The drive unit (700 VDC).
• The service outlets (115/230 VAC).
• The power supply unit for tools, or special power supply units for the
machining process.
• The external voltage connected to the controller remains live even when the
robot is disconnected from the mains.
• Additional connections.
Therefore, it is important that all safety regulations are followed when doing
mechanical and electrical installation work.
Safety regulations
Before beginning mechanical and/or electrical installations, ensure you are familiar
with the safety regulations described in Operating manual - General safety
information1.
1This manual contains all safety instructions from the product manuals for the manipulators and the controllers.
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© Copyright 2004-2016 ABB. All rights reserved.
Safety

1 General I/O description
General
This description covers all signals in a standard arc welding system based on the
standard process interface delivered by ABB Robotics.
By using the arc welding system configuration add-in, the I/O configuration for the
selected process equipment 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 devices as standard:
• Simulated I/O device
• Process interface device
• Digital I/O device
• Software I/O device
Unused I/O device places can be equipped with other I/O devices, as described in
the product specification.
Usage
The number of I/O signals to be used is determined by the welding cell
configuration:
• Welding equipment
• Positioners
• Operator panel
• Cleaning equipment
• Search sensor
• Other options
To minimize the number of I/O devices and signals, a simulated I/O device is used
for some system signals and operator ready signals. The operator ready function
is handled using I/O cross connections with logical conditions.
System configuration
The complete I/O configuration for a specific system setup is obtained during the
boot sequence. After start-up, we recommend creating a backup of the system to
save the system configuration.
Related information
Physical connections of I/O signals are shown in the electrical drawing for the
signal interface (inside the controller cabinet).
I/O devices, CAN-bus connection, and address keying are described in the product
manual for the robot controller.
Continues on next page
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© Copyright 2004-2016 ABB. All rights reserved.
1 General I/O description

Electrical data is described in the product specification for the robot.
Note
Signals without names in the following tables are not configured.
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1 General I/O description
Continued

2 Signal configuration
2.1 Signal configuration, B_AW_PROC_40
Introduction
This chapter describes the standard process configuration delivered by ABB
Robotics. Process Interface DeviceNet for ESAB Aristo™ Mig and W8.
Board configuration
BusBoard typeNameAddress
CAN DeviceNetESAB_W8B_AW_PROC_4040
VirtualSimulated digital I/OB_SIM_AW
Digital outputs
DescriptionName
Activate power sourcedoWeld
Quick stop of power sourcedoQuickStop
Emergency stop of power sourcedoEmStop
Activate wire feederdoFeed
Activate gas valvedoGas
Activate air cleaning of torchdoAir
Activate wire feeder reversedoFeedBwd
Activate tactile search modedoTouchSenseActive
Digital inputs
DescriptionNameDevice Map
Arc establisheddiArcEst48
Weld establisheddiWeldEst49
Search contact establisheddiTouchSenseContact50
Wire feed unit 1 selecteddiWF1Selected52
Wire feed unit 2 selecteddiWF2Selected53
Wire feed unit 3 selecteddiWF3Selected54
Wire feed unit 4 selecteddiWF4Selected55
Error codediError156
Error codediError257
Error codediError358
Error codediError459
Error codediError560
Error codediError661
Error codediError762
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2 Signal configuration
2.1 Signal configuration, B_AW_PROC_40

DescriptionNameDevice Map
Error codediError863
Error in weld data unitdiWduError64
Error in power sourcediPsError65
Error in wire feed unitdiWfError66
Torch collision detecteddiCollisionDetect69
Group outputs
DescriptionNameDevice Map
Activate wire feed unitgoWireFeeder8-11
Activate schedule number in
power source
goSchedule16-31
Analog inputs
DescriptionNameDevice Map
Measured voltageaiVoltage1
Measured currentaiCurrent2
Measured poweraiPower3
Simulated I/O signals
Simulated outputs
DescriptionNameDevice Map
Activate manual wire feedsoFeed10
Simulated inputs
DescriptionNameDevice Map
Wire oksiWire20
Water oksiWater30
Gas oksiGas40
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2 Signal configuration
2.1 Signal configuration, B_AW_PROC_40
Continued

2.2 Process interface ESAB, robot 2, B_AW_PROC_41
I/O board configuration, robot 2
This chapter describes the standard process configuration delivered by ABB
Robotics. Process Interface DeviceNet for ESAB Aristo™ Mig and W8.
Board configuration
BusBoard typeNameAddress
CAN DeviceNetESAB_W8B_AW_PROC_4141
VirtualSimulated digital I/OB_SIM_AW
Digital outputs
DescriptionNameDevice Map
Activate power sourcedoWeld_20
Quick stop of power sourcedoQuickStop_21
Emergency stop of power
source
doEmStop_22
Activate wire feederdoFeed_23
Activate gas valvedoGas_24
Activate air cleaning of torchdoAir_25
Activate wire feeder reversedoFeedBwd_26
Activate tactile search modedoTouchSenseActive_215
Digital inputs
DescriptionNameDevice Map
Arc establisheddiArcEst_248
Weld establisheddiWeldEst_249
Search contact establisheddiTouchSenseContact_250
Wire feed unit 1 selecteddiWF1Selected_252
Wire feed unit 2 selecteddiWF2Selected_253
Wire feed unit 3 selecteddiWF3Selected_254
Wire feed unit 4 selecteddiWF4Selected_255
Error codediError1_256
Error codediError2_257
Error codediError3_258
Error codediError4_259
Error codediError5_260
Error codediError6_261
Error codediError7_262
Error codediError8_263
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2 Signal configuration
2.2 Process interface ESAB, robot 2, B_AW_PROC_41

DescriptionNameDevice Map
Error in weld data unitdiWduError_264
Error in power sourcediPsError_265
Error in wire feed unitdiWfError_266
Torch collision detecteddiCollisionDetect_269
Group outputs
DescriptionNameDevice Map
Activate wire feed unitgoWireFeeder_28-11
Activate schedule number in
power source
goSchedule_216-31
Analog inputs
DescriptionNameDevice Map
Measured voltageaiVoltage_21
Measured currentaiCurrent_22
Measured poweraiPower _23
Simulated I/O signals
Simulated outputs
DescriptionNameDevice Map
Activate manual wire feedsoFeed_211
Simulated inputs
DescriptionNameDevice Map
Wire oksiWire_221
Water oksiWater_231
Gas oksiGas_241
16 Application manual - Signal description for arc welding products
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2 Signal configuration
2.2 Process interface ESAB, robot 2, B_AW_PROC_41
Continued

2.3 Process interface ESAB Aristo™ Mig, external equipment, B_AW_OPT_14
Introduction
This chapter describes the standard process configuration delivered by ABB
Robotics. Process Interface DeviceNet for ESAB Aristo™ Mig, external equipment,
Torch Cleaner, Wire Cutter, and BullsEye.
Board configuration
BusBoard typeNameAddress
CAN DeviceNetDigital I/O boardB_AW_OPT_1441
Digital outputs
DescriptionNameConnectionDevice Map
Mechanical torch
cleaning
doMCLN_TCHX1:10
Torch lubricationdoMLUB_TCHX1:21
Wire cutterdoWIRE_CUTX1:32
Mechanical torch
cleaning (robot 2)
doMCLN_TCH_2X1:43
Torch lubrication (ro-
bot 2)
doMLUB_TCH_2X1:54
Wire cutter (robot 2)doWIRE_CUT_2X1:65
Digital inputs
DescriptionNameConnectionDevice Map
Torch cleaning fin-
ished
diMCLN_FINX3:10
BullsEye sensorsen1X3:21
Torch cleaning fin-
ished (robot 2)
diMCLN_FIN_2X3:32
BullsEye sensor (ro-
bot 2)
sen2X3:43
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2 Signal configuration
2.3 Process interface ESAB Aristo™ Mig, external equipment, B_AW_OPT_14

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3 Positioner interface IRBP A
IRBP A
xx0900000830
I/O board configuration for positioner
Relay out-
puts
Analog
outputs
Digital in-
puts
Digital
outputs
Digital in-
puts
Board
type
NameAddress
Simulated
digital I/O
B_POS_SIM-
---127Digital I/O
DRVIO_1i
Internal
bus
iThe number relates to the drive module where the I/O board is located, the example shows drive
module 1.
Simulated outputs and inputs for B_POS_SIM
Simulated outputs
DescriptionNameDeviceMap
Activate mechanical unit 1soACT_STN10
Activate mechanical unit 2soACT_STN21
Simulated inputs
DescriptionNameDeviceMap
Mechanical unit 1 activatedsiSTN1_ACT0
Mechanical unit 2 activatedsiSTN2_ACT1
I/O signal configuration for DRVIO_1
Digital outputs TB4
Connected to
unit
DescriptionNameDeviceMapOutput
PositionerActivate mechan-
ical unit 1
doACT_K101
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3 Positioner interface IRBP A

Connected to
unit
DescriptionNameDeviceMapOutput
PositionerActivate mechan-
ical unit 2
doACT_K212
PositionerActivate mechan-
ical unit 3
doACT_K323
PositionerActivate mechan-
ical unit 4
doACT_K434
45
PositionerActivate release
break 1
doACT_K1156
PositionerActivate release
break 2
doACT_K1267
PositionerActivate release
break 3
doACT_K1378
PositionerActivate release
break 4
doACT_K1489
910
1011
1112
0V Output13
24V Output 1-1214
Digital inputs TB3
Connected to
unit
DescriptionNameDeviceMapInput
PositionerMechanical unit
1 activated
diK1_ACT01
PositionerMechanical unit
2 activated
diK2_ACT12
PositionerMechanical unit
3 activated
diK3_ACT23
PositionerMechanical unit
4 activated
diK4_ACT34
45
56
67
0 V input 1-78
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3 Positioner interface IRBP A
Continued