Migatronic Automation CoWelder Sigma Select 400C... manual 

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 1
Instruction Handbook
Translated from original
Name CoWelder™
Model/type 79115030 UR10E/Sigma Select 400C Synergic
79115031 UR10E/Sigma Select 400C W Synergic
79115032 UR10E/Sigma Select 400C Pulse
79115033 UR10E/Sigma Select 400C W Pulse
79115034 UR10E/Sigma Select IAC 400 Synergic
79115035 UR10E/Sigma Select IAC 400 W Synergic
Function Collaborative welding robot
Keep this operating manual at the
operator's workstation!

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 2
Contents
1 Machine Data ............................................................................................................................ 4
1.1 Introduction ......................................................................................................................... 4
1.2 General Information ............................................................................................................ 4
1.2.1 Manufacturer ................................................................................................................ 4
1.2.2 Machine ....................................................................................................................... 4
1.2.3 Type Plate .................................................................................................................... 4
1.2.4 Technical Data ............................................................................................................. 5
1.2.5 EC Declaration ............................................................................................................. 5
2 Safety Instructions ..................................................................................................................... 6
2.1 Illustration of Safety Notes .................................................................................................. 6
2.2 Warning about Special Risks .............................................................................................. 6
2.3 Intended Use ....................................................................................................................... 7
2.4 Reasonably foreseeable Misuse ......................................................................................... 8
2.5 Restructure or Modification of the Machine ........................................................................ 9
2.6 Spare Parts, Wearing Parts and Consumables .................................................................. 9
2.7 Risks involved in Operating the Machine ............................................................................ 9
2.8 Noise and Vibrations ........................................................................................................... 9
2.9 Employer’s Responsibilities .............................................................................................. 10
2.10 Operators’ Responsibilities ............................................................................................ 10
2.11 Operators’ Qualifications ............................................................................................... 10
2.12 Residual Risks ............................................................................................................... 10
2.13 Operators’ Areas of Operation ...................................................................................... 11
2.14 Signs displayed on the Machine .................................................................................... 11
2.15 Personal Safety ............................................................................................................. 12
2.15.1 Protective Equipment ................................................................................................. 12
2.15.2 Precautionary Measures ............................................................................................ 12
2.16 Emergency situations .................................................................................................... 12
2.17 Safety and Protective Equipment .................................................................................. 13
2.18 The Positioning of Emergency Stops ............................................................................ 13
2.18.1 Emergency Stops ...................................................................................................... 13
2.19 Check of Safety and Protective Equipment ................................................................... 13
2.19.1 Check of Emergency Stops ....................................................................................... 13
2.20 Transport, Handling and Storage .................................................................................. 14
2.20.1 Means of Transport .................................................................................................... 15
2.20.2 Prior to Transport ....................................................................................................... 15
2.20.3 Transporting the Machine .......................................................................................... 15
3 Operating Instructions ............................................................................................................. 16
3.1 Setting the TCP
................................................................................................................. 16
3.1.1 TCP Position .............................................................................................................. 17
3.1.2 TCP Orientation ......................................................................................................... 21
3.1.3 Test TCP settings ...................................................................................................... 23
3.2 Programming the robot ..................................................................................................... 25
3.3 MigaWeld (Basis Software) ............................................................................................... 31
3.3.1 MigaWeld Program tree ............................................................................................. 31
3.3.2 MigaWeld program features ...................................................................................... 32
3.3.3 MigaWeld installation page ........................................................................................ 41
3.4 Miga Weave (Option) ........................................................................................................ 42
3.5 Miga Offset (Option) .......................................................................................................... 43
3.6 Miga Tack (Option) ........................................................................................................... 44
3.7 Miga Smart Tool ................................................................................................................ 45
3.8 Delete/Update Migatronic software on the CoWelder ....................................................... 48

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 3
3.9 Update Robot software ..................................................................................................... 48
3.9.1 Update Robot software .............................................................................................. 50
3.9.2 Delete Migatronic Software on the CoWelder ............................................................ 51
3.9.3 New MigaWeld software ............................................................................................ 53
3.9.4 Reinstalling MigaWeld software on a CoWelder ........................................................ 54
4 Description of Functions .......................................................................................................... 57
4.1 Machine Structure ............................................................................................................. 57
4.2 Process Description .......................................................................................................... 58
5 Assembly and Disassembly ..................................................................................................... 58
5.1 Assembly Instructions ....................................................................................................... 58
5.1.1 Unpacking the Machine ............................................................................................. 58
5.1.2 Assembling the Machine ............................................................................................ 58
5.2 Disassembly Instructions .................................................................................................. 64
6 Environmental Conditions ........................................................................................................ 64
7 Cleaning and Maintenance ...................................................................................................... 65
7.1 Cleaning ............................................................................................................................ 65
7.1.1 Teach Pendant .......................................................................................................... 65
7.1.2 Control Box ................................................................................................................ 65
7.1.3 Machine Parts ............................................................................................................ 66
7.1.4 Painted Surfaces ....................................................................................................... 66
7.1.5 Aluminium Surfaces ................................................................................................... 66
7.1.6 Other Parts and Surfaces .......................................................................................... 66
7.2 Maintenance ..................................................................................................................... 66
7.2.1 Repair and Maintenance ............................................................................................ 66
7.2.2 Tools required to carry out Service ............................................................................ 66
7.2.3 Preventive Maintenance ............................................................................................ 66
7.3 Function Tests .................................................................................................................. 69
7.3.1 Test Safety Function .................................................................................................. 69
7.3.2 Test Freedrive ............................................................................................................ 69
7.3.3 Test Backdrive Mode ................................................................................................. 70
7.3.4 Verify Safety Settings ................................................................................................ 71
7.4 Visual Inspection ............................................................................................................... 71
8 Spare parts .............................................................................................................................. 72
8.1 Spare parts CoWelder ...................................................................................................... 72
8.2 Spare parts UR10E Robot ................................................................................................ 74
8.3 Contact for Freedrive ........................................................................................................ 74
8.4 Fan housing and filter for Control Box .............................................................................. 75
8.5 Miga Smart Tool ................................................................................................................ 76
8.6 Abirob A ECO 360 kit with hose ........................................................................................ 77
8.7 Abirob W500 22gr kit with hose ........................................................................................ 77
8.8 Start box ............................................................................................................................ 78
9 Version Control ........................................................................................................................ 79
10 Migatronic ServiceTeam .......................................................................................................... 79

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 4
1 Machine Data
1.1 Introduction
This is a user guide to a robot plant with a UR10E robot for welding, hereinafter referred to as ”the
machine”.
The user guide shall ensure proper installation, use, handling and maintenance of the machine.
The user guide shall be kept at the operator’s workplace and be easily accessible for operators and
maintenance staff.
The employer (owner of the machine) is responsible for ensuring that operators and persons carrying
out service, maintenance or repair of the machine read the user guide or, at the minimum, the
sections relevant to their tasks. The employer shall also provide sufficient training of staff in
operating the machine.
Operators and persons carrying out service, maintenance or repair of the machine are required to
seek information in the user guide on their own initiative.
Operators are required to read any user guides and data sheets for additional or integral equipment
supplied with the machine, such as robot and welding machine.
1.2 General Information
1.2.1 Manufacturer
Company details: Migatronic Automation A/S
Knøsgårdvej 112
DK-9440 Aabybro
1.2.2 Machine
Machine Name: CoWelder™
1.2.3 Type Plate

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 5
1.2.4 Technical Data
1.2.5 EC Declaration
Mechanical Data
UR10E Robot incl. mount and suspension Measurement 750 x 600 x 2500 mm
Welding machine Measurement 700 x 260 x 735 mm
Cooling Unit Mål 207 x 260 x 680 mm
UR10E Robot incl. mount and suspension Weight 125 kg
Welding machine Weight 53 kg
Cooling Unit Vægt 20 kg
Electrical Data
Robot Operating voltage 230V+N+PE, 50 Hz
Control voltage 24 VDC
External mains fuse 16 A
Welding machine Operating voltage 3x400+N, 50-60 Hz
Customer’s mains fuse 20 A

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 6
2 Safety Instructions
2.1 Illustration of Safety Notes
A pictogram and a describing signal word illustrate the safety notes.
Pictogram Signal Word Description
HAZARD Immediate hazard that may cause serious physical
injury or death.
WARNING Possible hazardous situation that may cause
serious physical injury or death.
NOTE Possible hazardous situation that may cause minor
physical injury or damage to equipment.
INFORMATION Useful hints and information.
IMPORTANT Special behaviour or action required to ensure
proper handling of the machine.
2.2 Warning about Special Risks
A pictogram and a description warn about special risks. See examples below:
Risk of electric voltage Risk of warm surfaces Wear safety footwear
No entry for persons
using pacemakers
Wear welding helmet Wear protective gloves

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 7
2.3 Intended Use
The machine, consisting of a Universal Robots robot arm, a Migatronic power source and a welding
torch, are designed for welding simple workpieces, irrespective of quantity and frequency.
The CoWelder, a collaborative robot interacting with one operator, is designed for manual feeding
only.
Cycle capacity: depends on use
Welding speed: up to 400 mm per second
Workpieces are to be transported to and from the robot by the operator.
Use of this machine for purposes other than intended is NOT permissible.
Other preconditions:
• Operators have read this user guide prior to operating the machine
• Compliance with all instructions in the user guide
• Compliance with all inspection and maintenance requirements
• Use of original spare parts only
Only specially trained staff must carry out transport, commissioning, disposal, troubleshooting and
repair.
Trained staff can operate the machine.
Maintenance and service on the electric system must only be carried out by specially trained staff or
staff trained in carrying out service on electric equipment, or under the surveillance of specially
authorised persons.
According to regulations, it is the owner's responsibility to supply the machine's welding area with
high-efficient extraction. It is also the owner's responsibility to protect the operator and passers-by
from UV radiation.
IMPORTANT
Use the machine in safe and perfect condition only!
IMPORTANT
We strongly recommend you to back up all programmes of robot and welding
machine.
Migatronic Automation cannot be held responsible for any loss of data that may
occur whatever the cause!

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 8
2.4 Reasonably foreseeable Misuse
Any use other than described under ”Intended Use” is considered improper use. The operator is fully
responsible for damage caused by improper use. The manufacturer does not take on any
responsibility.
When starting up the machine, make sure that there are no persons in its working range.
Do not manually interrupt any automatic functions or attempt to manually push, remove or otherwise
handle objects at any time during operation.
Observe permissible standard values for noise, dust and vibration during operation.
Ensure sufficient respect distance around the CoWelder to avoid collisions.
Working temperature: 0-40°
Moisture: 10-80% RH (non-condensing)
Keep the working area clean and tidy.
Remove immediately any oil or liquid spillage.
Do not step on the machine.
WARNING
For safety reasons the following maximum values must be kept as low as possible:
Force: Max110N and 140N/cm²
Power: Max 80 W
Speed: Max 400 mm/s
Momentum: 8 kg m/s
WARNING
Programming and correct setting of the CoWelder’s TCP (Tool Center Point) is
owner’s/user’s responsibility at all times.
An incorrectly set TCP will adversely affect the welding performance and does not
guarantee the functionality of the virtual safety setting.
WARNING
4 virtual fences limit the three-dimensional safe working range of the robot, so that
the TCP cannot exceed the dimensions of the welding table.
Do not mount the UR10E robot on a welding table smaller than 3000x1700mm
If you intend to mount the robot on a smaller welding table, the virtual fencings
must be adjusted to the actual size of the welding table.
Please contact your Migatronic contact person for more information.
Keep warning signs and signals visible. Replace at once any damaged or removed signs or signals.
WARNING
Do not use the machine under the following operating conditions:
 Explosive atmosphere
 Technical values exceeding specifications for normal operation

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 9
2.5 Restructure or Modification of the Machine
Arbitrary modifications or alterations voids the manufacturer's warranty and responsibility for
damages resulting thereof. The manufacturer of the change takes over all responsibilities and
obligations regarding compliance with Council Directive 2006/42 / EC - Machinery Directive.
2.6 Spare Parts, Wearing Parts and Consumables
Use of spare parts and wearing parts from any third-party manufacturers may involve a risk. Use
only original parts or parts approved by the manufacturer.
The manufacturer undertakes no responsibility for damage caused by the use of non-original or non-
approved spare parts, wearing parts or consumables.
2.7 Risks involved in Operating the Machine
Operating the machine may involve a risk and affect:
• Operator’s and other persons’ lives and health
• The machine itself or other tangible assets.
Proper use of the machine depends on knowledge of this user guide.
IMPORTANT
The user guide shall be kept at the operator’s workplace and be easily
accessible for operators and maintenance staff.
Other special attention points:
 Compliance with accident prevention regulations.
 Compliance with safety, health and environmental regulations.
 In case of malfunctions, stop operating the machine. Do not resume
work until after repair.
 Mandatory safety instructions must be complete and kept at the
workplace.
2.8 Noise and Vibrations
Prior to start-up of the machine check that its noise level complies with standards. The sound
pressure level should not exceed 70 dB(A) near operating areas.
Reduce electromagnetic noise by keeping cables for positive and negative electrode closely
together, preferably at floor level. Keep cable lengths to a minimum.

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 10
2.9 Employer’s Responsibilities
The employer must make sure that the operators of the machine:
• have knowledge of basic regulations for safety at work and accident prevention
• have received training in operating the machine
• have read and understood this user guide.
The employer is also responsible for the machine operators using personal protective equipment in
accordance with applicable requirements and regulations.
2.10 Operators’ Responsibilities
Prior to operating the machine, operators (persons intended to operate the machine) are responsible
for:
• complying with basic regulations for safety at work and accident prevention
• reading and understanding Illustration of Safety Notes/Safety Notes in this user guide
In case of any questions, please contact the manufacturer.
2.11 Operators’ Qualifications
Operator
Task
Specially
instructed
operators
Instructed
operators
Specially trained operators
(mechanic/electric)
Transport X -- --
Commissioning X -- --
Troubleshooting/Repair X -- X
Change of tools -- X --
Use -- X --
Maintenance -- -- X
Disposal/Reuse X -- --
2.12 Residual Risks
The structure of the machine is based on advanced technology and approved safety regulations.
Operators must receive training in risks and required precautions.
The following residual risks apply:
Warning: Risk of burns
Touching and using the welding torch may cause burns. Use of protective gloves
and clothes is mandatory.
Warning: Injury caused by welding wire
Touching, using and setting the welding wire may cause injury. Use of protective
gloves, clothes and welding helmet/protective goggles is mandatory. Protective
equipment must have suitable mechanical strength.
Warning: Welding fumes
Fumes and gases formed during welding are hazardous to health. Proper use of
suitable extraction (supplied by the user) is mandatory during welding.

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 11
Warning: UV radiation
UV radiation may cause eye injuries or eye irritation. Use of welding
helmet/protective goggles is mandatory. Surroundings (other operators, visitors
etc.) must be shielded, using e.g. welding curtain according to EN 1598
(owner/operator’s responsibility).
Warning: Weld spatter
Weld spatter may cause burns or eye injuries. Use of protective gloves, clothes
and welding helmet/protective goggles is mandatory. Other operators, visitors etc.
must be kept at a suitable distance from the robot or otherwise protected against
weld spatter (owner/operator’s responsibility).
HAZARD:
No entry to the machine’s safety area when the machine is in operation.
HAZARD:
Pay attention to residual energy in the machine’s electric systems in case of power
supply failure.
2.13 Operators’ Areas of Operation
2.14 Signs displayed on the Machine
HAZARD
No entry for persons using pacemakers, metallic implants etc.
Robot teach pendant Start box Remote control of the welding
machine

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 12
2.15 Personal Safety
2.15.1 Protective Equipment
Operators must wear the following protective equipment:
SAFETY FOOTWEAR
Wear safety footwear
PROTECTIVE GLOVES
Avoid burns. Use protective gloves for handling welding torch and welded
workpieces!
SAFETY GLASSES
Use of safety glasses required
WELDING HELMET
The arc emits radiation, which is harmful to the human eye. Even short-term
radiation may cause permanent injury. Use safety glasses in the welding helmet
to protect the eyes against radiation from infrared, visible and ultra-violet light.
2.15.2 Precautionary Measures
NOTE
Tie-up or cover long hair and do not wear ties, jewellery and loose clothing.
WARNING
Protect passers-by against radiation, weld spatter and warm metal.
2.16 Emergency situations
Risk of open fire:
Keep the machine clean and do not leave flammable materials inside the
machine.
Procedure in case of fire in the machine:
 Evacuate the area
 Call the fire department
 Disconnect power to the machine
 Use Co2 carbon dioxide extinguisher to limit / extinguish the fire.
Warning
Avoid using water; it will destroy the electric system.
We recommend installing a Co2 carbon dioxide extinguisher nearby the machine.

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 13
2.17 Safety and Protective Equipment
Defective safety and protective equipment may cause hazardous situations, in which case
• the power supply to the machine must be switched off immediately
• the machine must be secured against restart
• the machine must be disconnected from the power supply
Important
Use the machine only when all protective equipment is present and in working
condition!
2.18 The Positioning of Emergency Stops
2.18.1 Emergency Stops
Emergency stops 1 and 2 disconnect:
 Robot
 Arc
2.19 Check of Safety and Protective Equipment
Check all safety equipment at regular intervals.
Safety and protective equipment Control interval
Permanent fencing Visual control when switching on the machine
2.19.1 Check of Emergency Stops
Safety equipment Control interval
Emergency stop Weekly
Emergency stop 1
Emergency stop 2

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 14
2.20 Transport, Handling and Storage
Make the machine ready for transport and secure all parts to ensure safe transport. Take
precautionary measures. During lifting operations, attachment points must ensure balancing of the
machine/machine parts. Attached equipment or parts not intended for lifting must not have lifting
points.
WARNING
Protect your back and other parts of your body when lifting the equipment. Use
correct lifting equipment. Observe all relevant lifting instructions.
Prior to transport:
Press the button on the back of the Teach
pendant to switch on the robot. Place foam or
bubble wrap between the joints to protect the
robot against transport damage. Fold the joints
to a minimum and switch off the robot.
Transport position

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 15
2.20.1 Means of Transport
Travelling crane crab, lifting hooks and forklift truck are suitable for transporting the machine.
2.20.2 Prior to Transport
Preparation:
• Identify the attachment points for lifting
• Make sure that the load is balanced
• Remove any obstacles from the defined route of transport
• Keep unauthorised persons away from the route of transport and place of assembly. Seal off
the area, if necessary.
2.20.3 Transporting the Machine
Lifting points, as shown in the figure, must be used when lifting the welding machine.
Do not lift the machine in the handle!
Do not lift the welding machine with mounted gas cylinder!
Transport the robot on a pallet. Lift the robot from the pallet by the hoist rings mounted on the self-
balancing table mount.
WARNING
Take care not to damage the robot during lifting.
• Lift the machine parts carefully
• Place the machine slowly and carefully onto the welding table

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 16
3 Operating Instructions
3.1 Setting the TCP
Set the TCP (Tool Center Point) to ensure safety and correct robot programming function.
Set the TCP prior to welding and reset correctly if the torch position is changed.
WARNING
Programming and correct setting of the CoWelder’s TCP (Tool Center Point) is
owner’s/user’s responsibility at all times.
An incorrectly set TCP will adversely affect the welding performance and does
not guarantee the functionality of the virtual safety setting.
WARNING
4 virtual fencings limit the three-dimensional safe working range of the robot, so
that the TCP cannot exceed the dimensions of the welding table.
Do not mount the UR10E robot on a welding table smaller than
3000x1700mm.
If you intend to mount the robot on a smaller welding table, the virtual fencings
must be adjusted to the actual size of the welding table.
Please contact your Migatronic contact person for more information.

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 17
3.1.1 TCP Position
Press Installation
Press TCP under general
Select TCP_1 and press
Set as default
Press Wizard
Press Set point 1
Use the Freedrive button, arrows or Teach button point the tip of the wire precisely on a selected
fixed point. See picture.
When the robot is pointed at the fixed point, then press OK

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 18
Press Set point 2
Use the Freedrive button, arrows or Teach button to point the tip of the wire precisely on a selected
fixed point. See picture
When the robot is pointed at the fixed point, then press OK
Press Set point 3

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 19
Use the Freedrive button, arrows or Teach button to point the tip of the wire precisely on a selected
fixed point. See picture
When the robot is pointed at the fixed point, then press OK
Press Set point 4
Use the Freedrive button, arrows or Teach button to point the tip of the wire precisely on a selected
fixed point. See picture
When the robot is pointed at the fixed point, then press OK

Name CoWelder™
Product UR10E Sigma Select
Version A – 9.7.2021
Drawn up by: CTM
Side 20
Press Set
Information: If you can´t find the text, use
the scroll bar to scroll down to the bottom
Press Save, followed by Save All
and then press Save