rpc manual.pdf

Product manualArc welding function package

RPC IRC 5

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Product manualArc welding function package

RPC IRC 5

Document ID: 3HAC 039787-001

Revision: -

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d.

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

Copyright 2010 ABB All right reserved.

ABBCNAUS

ShangHai, China

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d. Overview 5

1 Safety 7

1.1 About safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71.2.1 Safety symbols, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71.2.2 DANGER - Ensure that the main power switch is turned off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91.2.3 WARNING - The unit is sensitive to ESD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.2.4 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2 Technical description 14

2.1 Overview of welding equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.2 Principle design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152.2.1 Welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152.2.2 Robot welding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

2.4 Power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182.4.2 Power source components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.4.3 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5 Wire feed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222.5.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.5.2 Wire feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232.5.3 Control and indicating devices on the wire feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 DeviceNet installation 26

3.1 Connection of welding equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263.1.1 Installing DeviceNet card and cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.1.2 Locating the power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313.1.3 Connecting to mains power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.1.4 Starting the power source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333.1.5 Power source indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.2 Connections on wire feed unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353.2.1 Cables and hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363.2.2 Connection of feed cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.3 Configuration of welding equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

3.4 Installation of accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413.4.1 TSC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413.4.2 Adjusting the brake hub (bobbin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.5 Before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

4 Operating of welding equipment 46

4.1 Power source (RPC S series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464.1.1 Control panel parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464.1.2 Adjusting MIG dynamics (Arc Force) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484.1.3 Gas test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494.1.4 Wire feed test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504.1.5 Retrieving weld data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514.1.6 Selecting the welding process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 524.1.7 Optional MIG features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533HAC 039787-001 Revision: - 3

4.1.8 Memory features (Memory button) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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d.4.1.9 Synergetic 1-MIG welding and Wise-MIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.1.10 Setup features of the control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.2 Power source (RPC P series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624.2.1 Control panel parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 624.2.2 Getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 644.2.3 Setup panel K60 main menu list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 664.2.4 Welding parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 674.2.5 Welding functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 704.2.6 Welding software delivery profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.3 Wire feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

4.4 Manual wire feed in IRC5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

4.5 Programming power source in IRC5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

5 Maintenance 83

5.1 Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

5.2 Wire feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .845.2.1 Daily maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 845.2.2 Period maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 855.2.3 Service shop maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 865.2.4 Disposal of the machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5.3 Wire feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

5.4 Before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

6 Trouble shooting 91

6.1 Power source (RPC S series). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .916.1.1 Overload (Yellow indicator lit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 916.1.2 Control cable connector fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 926.1.3 Electric network over-voltage or under-voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 936.1.4 Missing phase in the electric network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946.1.5 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

6.2 Power source (RPC P series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .986.2.1 Basic trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 986.2.2 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

6.3 Changing wire feed motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

6.4 Before commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

7 Spare parts list 104

7.1 Power source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

7.2 Wire feed unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

7.3 Cable and hose set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

8 Circuit diagram 107

8.1 Main circuit diagram (A314F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

8.2 Main circuit diagram (S Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

8.3 Main circuit diagram (P Series) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1094 3HAC 039787-001 Revision: -

Overview Overview

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d.Overview

About this manualThis manual provides information on:

Mechanical/electrical installation

Operation

Repair/maintenance

Read through all included manuals carefully, especially the sections about safety before you start to unpack, install and use the station.

UsageThis manual is intended for use in conjunction with:

Installation

Operation

Maintenance

Repairs

Who should read this manual?The manual is intended for:

Operators

Installation personnel

Repair and maintenance personnel

PrerequisitesReaders of this manual must be:

Familiar with industrial robots and the relevant terminology.

Familiar with the equipment.

Skilled in mechanical and electrical installation/maintenance/repairs.

Reference

Reference Document ID

Application Manual - Arc and Arc sensor 3HAC16591-1

Instruction Manual and Spare Parts List - Welding torch PKI 504 888-102

Product Manual - Welding torch PSF 501 032-502

Product Specification/Spare Parts List - Torch cleaner TC96 501 105-502

Product Specification - TSC 502 311-5023HAC 039787-001 Revision: - 5

Overview Overview

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d.Revisions

Revision Description

- First edition.6 3HAC 039787-001 Revision: -

1 Safety1 Safety

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d.1 Safety

1.1 About safety

OverviewA robot is heavy and extremely powerful regardless of its speed. A stoppage or longer stop can be followed by rapid, dangerous movements. Even if the robot's pattern of movement is predetermined, an external signal can affect the movement sequence, resulting in unanticipated movement.It is therefore important that all safety instructions are observed when entering a safety supervised area.

1.2 Safety instructions

1.2.1 Safety symbols, general

Overview WARNING!All personnel working with the welding robot system must have full understanding of the appli-cation safety instructions.

Safety instructions can be found in the AW system manual for all steps that involve risk for personal injury or material damage. In addition, they are included in the instructions for each step. General warnings, where the intention is to avoid problems, are only included in the pertinent instructions.

User environment WARNING!FUMES AND GASES - Can be hazardous to your health!It is the responsibility of the buyer/user to ensure that national statutes regarding the working environment are respected. The following should be implemented:

Reference document

Action

Make sure that satisfactory exhaust devices are installed and used.

Make sure that there is sufficient lighting over the workplace.

If possible use environment-friendly shielding gas and vegetable oil for splatter cleaning.

Document Document ID

AW SystemManual, Introduction and Safety 3HEA 801 212-0013HAC 039787-001 Revision: - 7

1 Safety1.2.1 Safety symbols, general

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d.Warning symbols (signals)

Symbol explanationsThe different types of warnings are set out in the following chapters according to the table below:

Symbol Name Meaning

DANGER Warning that serious or life-threatening personal injury and/or serious damage to the product will occur if the instructions are not followed.

WARNING Warns of the risk of personal injury or serious damage to the product. Always follow the instructions that accom-pany this symbol.

ELECTRIC SHOCK Warns of possible electric shock that can cause life-threatening or serious personal injury. Always follow the instructions that accompany this symbol.

CAUTION Draws your attention to the fact that damage to the prod-uct may occur if an action is not performed or is performed incorrectly.

ELECTROSTATIC DISCHARGE (ESD)

The ESD symbol indicates a risk of static electricity that may cause serious damage to the product.

NOTE Information about important parts.

TIP This symbol refers to an instruction providing further infor-mation on a particular step.8 3HAC 039787-001 Revision: -

1 Safety1.2.2 DANGER - Ensure that the main power switch is turned off.

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d.1.2.2 DANGER - Ensure that the main power switch is turned off.

DescriptionWork with high voltage entails a potential lethal hazard. Persons subjected to high voltages can suffer heart failure, burns or other serious injuries. To avoid such injuries, never begin a job without first eliminating the risks to safety. These are described below.

Elimination

Action Info/illustration

1. Turn off the main power switch on the control module.

2. Turn off the main power switch on the drive module.

3. Single robot stations. All voltage is lost when the main switch on the drive module (DM1) is switched off.3HAC 039787-001 Revision: - 9

1 Safety1.2.3 WARNING - The unit is sensitive to ESD.

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d.1.2.3 WARNING - The unit is sensitive to ESD.

DescriptionESD (electrostatic discharge) is the transfer of electrostatic charges between two objects with varying charges, either through direct contact or through an electrical field.The discharge contains very little electricity and is therefore not hazardous to human beings; however, electronics can be damaged by the high voltages.

Elimination

Location of attachment point for ESD braceletButton (A/B) for the ESD bracelet is located on the computer unit in the control module. The location is shown in the following figure.

Figure 1 Location of attachment point for ESD bracelet

Action Info/Illustration

1. Use an ESD bracelet. The bracelet must be regularly tested to ensure that it is undamaged and functions properly.

2. Use an ESD-protected floor mat.

The mat must be grounded through a voltage regulating resistor.

3. Use an ESD-protected table mat.

The mat shall provide a controlled discharge of static electricity and must be grounded.

Item Name

A Attachment point for ESD bracelet in the control module.

B Attachment point for ESD bracelet in the drive module.10 3HAC 039787-001 Revision: -

1 Safety1.2.4 General safety instructions

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d.1.2.4 General safety instructions

ABB welding equipments conform to international safety standards. Safety is an important issue in equipment design and manufacturing. Therefore, ABB welding solutions are unpar-alleled in safety. There are, however, always certain hazards involved in using welding equip-ment. Therefore, to ensure your personal safety and the safety of your working environment, carefully read the safety instructions below and respect them.

Use of personal protective equipment The arc and its reflecting radiation damage unprotected eyes. Shield your eyes and

face appropriately before you start welding or observe welding. As the welding current increases, the welding face screen lens darkness should also increase.

Arc radiation and spatters burn unprotected skin. Always wear protective gloves, clothing and footwear when welding.

Always wear hearing protection if the ambient noise level exceeds the allowable limit (e.g., 85 dB).

General operating safety Exercise caution when handling parts heated during welding. For example: the tip of

the welding torch or gun, and the end of the welding rod and the work piece. The tem-perature of items burn unprotected skin.

Never wear any welding device on the shoulder during welding and never suspend it y the carrying strap during welding.

Do not expose the machine to high temperatures, as this may cause damage.

Keep intermediate and earth return cables as close to each other as possible through-out their length. Straighten any loops in the cables as this limits inductive effects on welding performance. This also minimizes your exposure to harmful magnetic fields, which may, for example, interfere with a pacemaker.

Do not wrap the welding cables around your body.

In environments classified as dangerous, only use S-marked welding equipments with a safe idle voltage level. These work environments include, for example, humid, hot or small spaces, where the user may be directly exposed to the surrounding conductive materials.

Spatter and fire safety Welding is always classified as hot work, so pay particular attention to the fire safety

regulations during welding and after it.

Remember that fire can break out from sparks, even several hours after the welding work is completed.

Protect the environment from welding spatter. Remove combustible materials, such as flammable liquid from the welding vicinity, and supply the welding site with adequate fire fighting equipment.

In special welding jobs, be prepared for hazards such as fire or explosion when weld-ing inside enclosed work spaces, such as tanks and vessels. Ensure you have author-ity to work.

Never direct the sparks or cutting spray of a grinder toward the welding machine or flammable materials.

Beware of hot objects or spatter falling on the machine when working above. Welding in flammable or explosive sites is absolutely forbidden.3HAC 039787-001 Revision: - 11


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d.General electric safety Only connect the welding machine to an earthed electric network. Note the recom-

mended mains fuse size.

Do not take the welding machine inside a container, vehicle or similar work piece unless authorized to do so.

Do not place the welding machine on a wet surface and do not work on a wet surface.

Do not allow the mains cable to be directly exposed to water.

Ensure cables or welding torches are not squashed by heavy objects and that they are not exposed to sharp edges or a hot work piece.

Make sure that faulty and damaged welding torches are changed immediately as they may cause electrocution or fire.

Remember that the cable, plugs and other electric devices may be installed or replaced only by an electrical contractor or engineer authorized to perform such oper-ations.

Turn off the welding machine when it is not in use.

Welding power circuit Insulate yourself from the welding circuit by using dry and undamaged protective

clothing.

Never touch the work piece and welding rod, welding wire, welding electrode or con-tact tip at the same time.

Do not put the welding torch or ground cable on the welding machine or other electric equipment.

Welding fumes Ensure proper ventilation and avoid inhaling the fumes.

Ensure a sufficient supply of fresh air, particularly in closed spaces. You can also ensure an adequate supply of clean breathing air by using a filtered fresh-air mask.

Take extra precautions when working on metals or surface-treated materials contain-ing, for example, lead, cadmium, zinc, mercury or beryllium.

Transportation, lifting and suspension Never pull or lift the machine by the welding torch or other cables. Always use the lift-

ing points or handles designed for that purpose.

Only use a transport unit designed for the equipment. Try to transport the machine in an upright position, if possible.

Never lift a gas cylinder and the welding machine at the same time. There are sepa-rate provisions for gas cylinder transportation.

Never use a welding machine when suspended unless the suspension device has been designed and approved for that particular purpose.

Do not exceed the maximum allowable load of suspension beams or the transporta-tion trolley of welding equipment. It is recommended that the wire coil be removed dur-ing lifting or transportation.

Environment Welding equipment is not recommended for use in rain or snow - see manual. Protect

the equipment against rain and strong sunlight. Always store the machine in a dry and 12 3HAC 039787-001 Revision: -

clean space.


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d. Protect the machine from sand and dust during use and in storage. The recom-mended

Operating temperature range is -20 to +40C. The machine's operation efficiency decreases and it becomes more prone to damage if used in temperatures in excess of 40C.

Place the machine so that it is not exposed to hot surfaces, sparks or spatter.

Make sure the airflow to and from the machine is unrestricted.

EMC classification of this product is class A in accordance with electromagnetic com-patibility standards CISPR 11 and IEC 60974-10, and therefore the product is designed to be used in an industrial environment only.

WARNING!This class A equipment is not intended for use in residential locations where the electrical power is provided by a public low-voltage supply system. In those locations it may be difficult to ensure the electromagnetic compatibility due to conducted and radiated disturbances.

Arc welding equipments cause electromagnetic disturbance. To minimize the harmful effects, strictly use the equipment according to the operating manual and other recom-mendations.

Gas bottles and pneumatic devices Adhere to the instructions for handling pneumatic devices and gas bottles.

Make sure that gas bottles are used and stored in properly ventilated spaces.

A leaking gas bottle may replace the breathable air, causing suffocation.

Before use, make sure that the gas bottle contains gas suitable for the intended weld-ing purpose.

Always fix the gas bottle securely in an upright position, against a bottle wall rack or purpose-made bottle cart.

Never move a gas bottle when the regulator or flow adjuster is in place. Replace the valve cover during transportation. Close the bottle valve after use.3HAC 039787-001 Revision: - 13

2 Technical description2 Technical description

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d.2 Technical description

2.1 Overview of welding equipment

OverviewThe robotic arc welding package, RPC, is designed to offer high quality welds with minimum downtime. The package includes ABB's fifth generation IRC5 controller, the touch screen interface FlexPendant, RobotWare Arc programming software and an IRB1410 industrial robot to deliver an integrated solution for hassle-free arc welding. The package is suited for MIG (Metal Inert Gas) and MAG (Metal Active Gas) welding automation.Together with the AW software in the robot, the package has the following characteristics:

Intended forThe welding equipment should only be used for MIG/MAG welding according to instructions in the documentation.

NOTE! With all other usage of the equipment, ABB disclaims all responsibility and any claims for damages or warranty undertakings.

WARNING!The equipment is not intended for use in explosive environments.

NOTE!For the detailed information about the welding equipment, please refer toTechnical manual - RPC series.

Type Description

Power source Efficient and powerful 400 A synergic and 350A pulse power sources

Lightweight, compact and modular design

Synergic programs library for the most common materials

90/100 memory channels for different welding parameters

SmarTac function as a standard feature(SmarTac RobotWare Arc software option: 657-1 SmarTac - IO version is needed and ordered separately)

wire feed Four wheel wire drive mechanism with metallic feed rolls in A314F unit

Gas valve in the A314F unit

the wide speed range: 0 m/min. 25 m/min.

Accuracy Fully digital communication by DeviceNet to guarantee great accu-racy.

Safety Easy to service, error codes to advice the user to solve problems14 3HAC 039787-001 Revision: -

2 Technical description2.2 Principle design

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d.2.2 Principle design

2.2.1 Welding equipment

ComponentsThe welding equipment consists of:

Components Type

Wire feed system A314F

Welding power source RPC S series / RPC P series

Options The following options are available for the welding equipment: weld guide

torch cleaner TSC

wire cutter

automatic TCP-gauging BullsEye3HAC 039787-001 Revision: - 15

2 Technical description2.2.2 Robot welding system

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d.2.2.2 Robot welding system

Overview of robot welding system

Figure 2 Overview of robot welding system

Pos Description Pos Description

1 Control module(IRC5) 3 Wire feed unit(A314F)

2 Welding power source(RPC)16 3HAC 039787-001 Revision: -

2 Technical description2.3 Components

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d.2.3 Components

OverviewThe welding equipment can include the following components:

Wire feed unit mounted on the robot arm and fitted with an Euro-socket for connecting the welding torch.

Attachment for the wire feed mechanism and cables.

Hoses for gas and compressed air, as well as cables for signal and power supplies.

Cable for the welding current.

Cable for the power source.

Welding power source.

IRB 1410 with welding equipment

Figure 3 IRB 1410 with welding equipment


1 Welding power source(RPC) 5 Wire conduit

2 Attachment 6 Controller cabinet and FlexPendant

3 Cable and hose set 7 Welding gun

4 Wire feed unit3HAC 039787-001 Revision: - 17

2 Technical description2.4 Power source

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d.2.4 Power source

2.4.1 Overview

RPC series power sources (S series / P series) are designed for demanding professional use. S series are suitable for synergic 1-MIG/MAG, Wise-MIG and basic MIG/MAG;P series are suitable for synergic pulsed MIG/MAG, synergic double pulsed MIG/MAG syn-ergic 1-MIG/MAG, Wise-MIG and basic MIG/MAG.The Wise-MIG process is an optional feature intended for welding automation. It must be acquired separately .18 3HAC 039787-001 Revision: -

2 Technical description2.4.2 Power source components

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d.2.4.2 Power source components

Front Panel Rear Panel

Figure 4 Overview of RPC S-series components

Front Panel Rear Panel

Figure 5 Overview of RPC P-series components


1 Control panel 8 Fuse for control cable connection (6.3 A slow)

2 Main switch 9 Control cable connection (parallel)

3 Signal light (I/O) 10 Mains cable

4 Thermal warning light 11 Robot control

5 Earthing cable connection 12 Wire feed

6 Welding cable connection (parallel) 13 Throughput

7 Control cable connection (parallel) 14 Analog3HAC 039787-001 Revision: - 19

2 Technical description2.4.3 Technical specifications

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d.2.4.3 Technical specifications

Synergic power sources S- 300 S- 400(Standard) S- 500

Mains voltage 3 ~ 50 / 60 Hz

400 V -15 %...+20 400 V -15 %...+20 400 V -15 %...+20

Rated power 60% ED 500 A / 39 V

Rated power 80% ED 400 A / 34 V

Rated power 100% ED 300 A / 29 V 380 A / 33 V 430 A / 35.5 V

Connection cable / fuse delayed

4 x 6 S 5m / 20 A 4 x 6 S 5m / 25 A 4 x 6 S 5m / 35 A

Load ability 40C 60% ED

500 A


400 A


300 A 380 A 430 A

Welding current range MMA

10 A 350 A 10 A 450 A 10 A 500 A

Welding voltage range MIG

10 V 37 V 10 V 39 V 10 V 42 V

Open circuit voltage 50 V 50 V 50 V

Idle power 25 W

Power factor at max. cur-rent

0.9

Efficiency at max. current 87 %

Operating temperature range

-20+40C -20+40C -20+40C

EMC class A A A

Degree of protection IP23C IP23C IP23C

Voltage for auxiliary devices

50 V 50 V 50 V

External dimensions 590 x 230 x 500 mm

590 x 230 x 500 mm 590 x 230 x 500 mm

Weight 35 kg 36 kg 37 kg20 3HAC 039787-001 Revision: -

2 Technical description2.4.3 Technical specifications

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d.Pulse power sources P- 350(Standard) P- 450

Mains voltage 3 ~ 50 / 60 Hz 400 V -15%...+20% 400 V -15%...+20%

Rated power 60% ED 22,1 kVA

Rated power 80% ED 16,0 kVA

Rated power 100% ED 15,3 kVA 17,8 kVA

Connection cable / fuse delayed 4 x 6 S 5m / 25 A 4 x 6 S 5m / 35 A

Load ability 40C 60% ED 450 A

Load ability 40C 80% ED 350 A

Load ability 40C 100% ED 330 A 380 A

Welding current range MMA 10 A 350 A 10 A 450 A

Welding voltage range MIG 10 V 50 V 10 V 50 V

Welding voltage MMA ( max ) 49 V 53 V

Open circuit voltage 50 V 50 V

Open circuit power 100 W 100 W

Power factor at max. current 0.85 0.9

Efficiency at max. current 88 % 88 %

Operating temperature range -20+40C- -20+40C

EMC class A A

Degree of protection IP23S IP23S

Voltage for auxiliary devices 50 V/100W 50 V/100W

External dimensions 590 x 230 x 430mm 590 x 230 x 430mm

Weight 36 kg 36 kg3HAC 039787-001 Revision: - 21

2 Technical description2.5 Wire feed system

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d.2.5 Wire feed system

2.5.1 Overview

NOTE!A314F should be used for gas arc welding.It is intended to be mounted directly on the robot IRB 1410, which results in a short cable bundle and a good wire feed, furthermore, a smaller floor area is required.

BobbinIf a bobbin is used it may be necessary to adjust the brake hub. See 3.4.2 Adjusting the brake hub (bobbin) on page 44

Working areaThe wire feed system A314F meets Arc Welding & Application Equipment's recommended layout setup.This means the robot has a full working area within a section of 150 for A314F, around axis 1.CAUTION!Great care should be exercised outside of this sector, e.g.when programming, otherwise the welding equipment can be damaged.

Technical specifications

A314F

Operating voltage 50 VDC

Rated power 100 W

Load ability 40C 80%ED 600 A

Load ability 40C 100%ED 500 A

Wire feed speed 025 m/min

Filler wires Fe, SS 0,81,6 mm

Flux cored wire 0,81,6 mm

Al 1,01,6 mm

Welding gun connector Euro

Operating temperature range -20+40C

EMC class A

Degree of protection IP23S

External dimensions 269 x 175 x 169 mm

Weight 4,5 kg22 3HAC 039787-001 Revision: -

2 Technical description2.5.2 Wire feed unit

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d.2.5.2 Wire feed unit

Overview

Figure 6 Overview of wire feed unit

Feed rollersWire is fed using two pairs of feed rollers; seeFigure 6 Overview of wire feed unit , which are linked to each other. The two upper rollers (1) are spring-loaded. The power from the motor is transferred to the rollers via a pinion on the motor shaft.The pressure between the upper and lower rollers can be adjusted individually using an adjuster screw (2). All rollers are fitted with sleeve bearings. The lower feed rollers (3) have grooves for two different wire diameters. The rollers are turned so that the marking for the required wire diameter is facing forwards.

MotorThe motor (4) is of a permanent magnetized type and is equipped with an optical tachometer meter for accurate speed control.

BobbinWhen the bobbin is used, the wire liner is fitted directly to the feed mechanism and is locked by the screw (5).


1 Upper feed rollers 4 Motor(on the back)

2 Adjuster screws 5 Screws

3 Lower feed rollers3HAC 039787-001 Revision: - 23

2 Technical description2.5.3 Control and indicating devices on the wire feed unit

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d.2.5.3 Control and indicating devices on the wire feed unit

Overview

Figure 7 Front-Side of the wire feed unit

Wire inch switchWhen the switch is pressed, the wire feed engine starts but the gas valve does not open and the power source is not activated. The wire feed pace is 2 m/min for the first two seconds, and then 10 m/min. When the button is released, the wire feed stops.

Type Description

Wire inch switch Switch for manual wire feed (inch).

AIR connector Compressed AIR connecting to the welding torch.

Torch connector (Euro type) Connection for the welding torch.


1 Wire inch switch 3 Torch connector (Euro type)

2 AIR connector24 3HAC 039787-001 Revision: -

2 Technical description2.5.3 Control and indicating devices on the wire feed unit

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d.Torch connector (Euro type)

Figure 8 Connection of Welding Torch

The A and B pins are originally not connected and without a function, but they can be inter-nally connected to have either Wire Inch or Weld Start function when closed. Connector body is the power source plus (+) pole for MIG welding torch.3HAC 039787-001 Revision: - 25

3 DeviceNet installation3 DeviceNet installation

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d.3 DeviceNet installation

3.1 Connection of welding equipment

3.1.1 Installing DeviceNet card and cable

Overview of the DeviceNet card

Figure 9 Overview of DeviceNet card

DeviceNet connectorThe module supports both 5.08mm and 3.84mm pluggable screw connectors to board con-nector.

Figure 10 DeviceNet connector


A DeviceNet connector C Network status LEDs

B Configuration switches26 3HAC 039787-001 Revision: -

3 DeviceNet installation3.1.1 Installing DeviceNet card and cable

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d.MAC ID & Baud rate configurationOn a DeviceNet network, each node must be assigned its own unique Mac ID. The Mac ID is a value between 0 and 63 used to identify each node. The Mac ID and Baud rate settings can be set using a physical DIP-switch..Switches 1 and 2 specify the baud rate, while switches 3 though 8 specify the Mac ID:

Figure 11 MAC ID and Baud rate configuration

ABB default configuration:For the first power source: Baud rate: 500K Address: 30

For the second power source: Baud rate: 500K Address: 31

For the third power source: Baud rate: 500K Address: 32

Pos Signal Description

1 V- Negative supply voltage (DC 0V)

2 CAN_L CAN_L bus line

3 SHIELD Cable shield

4 CAN_H CAN_H bus line

5 V+ Positive supply voltage (DC 24V)3HAC 039787-001 Revision: - 27


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d.For the fourth power source: Baud rate: 500K Address: 33

Installing the DeviceNet card and DeviceNet cable


1. Remove the cover of the con-trol unit on top of the power source by unscrewing the cover screws.

2. Put DeviceNet card on top of the interface card and attach with two M3 nuts.

3. Connect the DeviceNet cable (CAN IN) with the DeviceNet card through the Robot-Con-trol hole on the rear panel then make the fix plate attached the rear panel with four M4 screws.

4. Install power supply for inter-face card.use built-in harness, connect X22-1 to Pos. 5 of DevinceNet connectorconnect X22-1 to Pos. 1 of DevinceNet connector28 3HAC 039787-001 Revision: -


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d.Figure 12 DeviceNet cable

Signal description

NOTE!Separate the field bus cable for the welding robot from the mains cables, as they may interfere with the control logic operation.

5. Connect the cable (A35.X1.P/X2.P) for Devi-ceNet to terminal A35.X1 or A35.X2 in IRC5 controller cabinet by entering in the gland plate at the bottom of it. NOTE!Each end of the DeviceNet bus must be terminated with a 121 ohm resistor. The two terminating resistors should be as far apart as possible.

6. Put the control unit cover back in place.


Signal description Terminal Color

V- 1 Black

CAN_L 2 Blue

DRAIN (NC) 3 Gray

CAN_H 4 White

V+ 5 Red3HAC 039787-001 Revision: - 29


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d.Network status of LEDsThese leds indicate run time status and errors to the user.

LED State Meaning description

Network Status (NS) Off Not powered, not on line

Green On line, one or more connections established

Green, flashing On line, no connections estab-lished

Red Critical link failure

Red, flashing One or more connections timed out

Alternating Red/Green Device self-test in progress

Module Status (MS) Off No power

Green Normal operation

Green, flashing Auto baud in progress

Red Major fault

Red, flashing Minor fault

Alternating Red/Green Device self-test in progress30 3HAC 039787-001 Revision: -

3 DeviceNet installation3.1.2 Locating the power source

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d.3.1.2 Locating the power source

Place the machine on a sturdy, level surface that is dry and does not release dust or other impurities to the suction air through the fan grill.Notes for positioning of the machine

Preferably, place the machine somewhat above floor level.

The surface inclination may not exceed 15 degrees.

There must be at least 20 cm of free space in front of and behind the machine for cool-ing air circulation.

Protect the machine against heavy rain and direct sunshine.

Ensure the free circulation of the cooling air.

The protection class of the machine, IP23C, allows water spray to hit the machine's outer covering at a maximum angle of 60 degrees.

NOTE!Never aim the spray of sparks from a grinding machine toward the power source.3HAC 039787-001 Revision: - 31

3 DeviceNet installation3.1.3 Connecting to mains power

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d.3.1.3 Connecting to mains power

PRC power sources are delivered as standard with 5 meters of mains power cable. No mains plug is fitted at the ABB factory.

NOTE!If local country based regulations state an alternative power cable is required, the mains cable must be replaced in conformity with the regulations. Connection and installation of the mains cable and plug should only be carried out by a suitably qualified person.

Remove the machine cover plate to enable mounting of a mains cable. RPC power sources can be connected to the mains supply of 400 V 3~.If changing the mains cable take into consideration the following:The cable is entered into the machine through the inlet ring on the rear panel of the machine and fastened with a cable clamp. The phase conductors of the cable are coupled to connectors L1, L2 and L3. The earth protection colored green-yellow is coupled to the marked connector.

NOTE!Do not connect the neutral conductor if you are using a 5-lead cable.In cables of S type there is a protective grounding conductor colored green-yellow.32 3HAC 039787-001 Revision: -

3 DeviceNet installation3.1.4 Starting the power source

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d.3.1.4 Starting the power source

Start the power source by turning the main switch (2) on the front panel to the "I" position. The standby indicator (3) turns on.

NOTE!Always turn the device on and off using the main switch, not via the mains socket.

The cooling fan is started for a moment when the main switch is turned to the 'I' position. The fan turns off after a while and then restarts during welding when the machine has warmed up sufficiently. The fan continues running even after up to 10 minutes of welding, depending on the temperature of the machine.3HAC 039787-001 Revision: - 33

3 DeviceNet installation3.1.5 Power source indicators

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d.3.1.5 Power source indicators

The following indicators can be found on the front panel of the power source: When the green mains indicator (3) is on, the power source is in standby mode. This

indicator is on when the machine is connected to the mains supply with the main switch in the I position.

When the yellow overheating indicator (4) is on, the machine has overheated. When the indicator turns off, the machine can be used again.

When indicator (4) blinks, the machine has encountered a failure. Attempt to remedy the problem according to the instructions in chapter6 Trouble shooting on page 91. If the failure cannot be eliminated, turn off the machine, and turn it on again. If the failure persists, write down any fault code that may be shown on the display and contact authorized ABB service agent.34 3HAC 039787-001 Revision: -

3 DeviceNet installation3.2 Connections on wire feed unit

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d.3.2 Connections on wire feed unit

Overview

Figure 13 Connections on wire feed unit


1 Wire guide input 4 Shield gas connection

2 Feeder cable connecter 5 Compressed gas connection

3 Welding cable connection3HAC 039787-001 Revision: - 35

3 DeviceNet installation3.2.1 Cables and hoses

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d.3.2.1 Cables and hoses

Safety

WARNING!All personnel working with the welding robot system must be fully conversant with the applica-ble safety instructions that are available.

Overview of connections RPC

Figure 14 Overview of connections RPC

Cables and Hoses

Figure 15 Overview of cable and hoses


1 Compressed Air hose 4 Welding cable (positive)

2 Shield gas hose 5 DeviceNet cable

3 Feeder cable 6 Welding cable (negative)36 3HAC 039787-001 Revision: -

3 DeviceNet installation3.2.1 Cables and hoses

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d.The cables and hoses are connected as follows. For more information, see Figure 13 Connec-tions on wire feed unit on page 35.

Cable/House Type Connection

DeviceNet cable The cable is connected between the IRC5 controller and the power source. See Installing the DeviceNet card and DeviceNet cable on page 28

Feeder cable(Signal cable)

A314F The cable is connected between the wire feed unit and the power source, See 3.2.2 Connection of feed cable on page 38

Shield gas hose Red hose Connected to the central gas supply or to the gas cylin-der.

Compressed Air hose

PVC-slang A connected to the compressed air supply, system pres-sure, approx, 6 bar.

Wire guide input

The welding wire is taken to the wire feed through a metallic wire guide adapter. Push the wire guide to the end of the adapter and screw in with the top fixing locks. Attach the wire guide input at the end of the adapter to serve as the bend support for the wire guide and to pre-vent the wire from bending too heavily. Fix the wire guide input with the bottom fixing locks.

Current cable

Connect the current cable from the wire feed unit to the power source.3HAC 039787-001 Revision: - 37

3 DeviceNet installation3.2.2 Connection of feed cable

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d.3.2.2 Connection of feed cable

Block diagram

Figure 16 Block diagram feed cable 1

Feeder cable

Figure 17 Feeder Cable

Signal descriptionSignal description for control signal cable (24 way MIL connector):


1 Control feeder cable on A314F 2 Wire feed connector on power source


A To the wire feed unit (Socket) B To the power source (Pin)

Pos Signal Type Level Note

A Wire feed motor + Output 0+24 V Wire feed motor voltage +

B Wire feed motor - Output 0 V Wire feed motor voltage -

C Gas valve + Output 0+24 V Gas valve control voltage +

D Gas valve - Output 0 V Gas valve control voltage -

E nc.

F nc.

G nc.38 3HAC 039787-001 Revision: -

3 DeviceNet installation3.2.2 Connection of feed cable

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d.H nc.

J nc.

K Tacho +5 V Output +5 V Tacho supply voltage

L Tacho GND Output 0 V Tacho supply GND

M Tacho signal Input 0 / +5 V Tacho signal from wire feed

N nc.

P Isolated +24 V Output 24V Analog supply voltage

Q Isolated GND Output 0 V Analog supply GND

R nc.

S nc.

T Wire inch Input 0+24 V Wire test feed

U Throughput4 Input 0+24 V

V Throughput5 Input 0+24 V

W nc.

X nc.

Y nc.

Z Throughput6 Input 0+24 V

Pos Signal Type Level Note3HAC 039787-001 Revision: - 39

3 DeviceNet installation3.3 Configuration of welding equipment

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d.3.3 Configuration of welding equipment

OverviewOn delivery the equipment is configured according to the applicable configuration data which is stored on the disk that comes with the delivery.

The data can be read and modified by way of the robot FlexPendant.

Installation disk

NOTE!As the disk is unique for the equipment supplied it should be stored in a safe place. The program number indicated on the disk corresponds to the configuration in question, and should be referred to in case of service matters regarding the function of the welding equip-ment.

The configuration file on the installation disk contains configuration data for the welding equipment.

Reload configuration dataIn case this configuration data must be reloaded, proceed in one of the following ways:

Default configurationIn ABB default configuration, the power source is controlled by robot in the way of schedule/memory channel (sometime it's also called as job) and the power source is recommended working in 1-MIG mode.

Alternate Description

Reboot the robot The original configuration will be restored.

Loading using the FlexPendant In those cases where individual parameters need to be changed compared to the original configuration.

Loading a new configuration file (EIO:CFG) Executed by way of the robot instruction:

System Parameters\File\Add or Replace Parameters\ "file".cfg.40 3HAC 039787-001 Revision: -

3 DeviceNet installation3.4 Installation of accessories

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d.3.4 Installation of accessories

3.4.1 TSC

NOTE!NOTE!TSC communicates with robot controller by standard IO communication. Basically it needs three digital outputs and two digital inputs. For detailed information refer to Product Specifi-cation - TSC.

Connect the TSC

Here is the example configuration file for TSC for reference.EIO.CFG_1.0:5:0:## using the spare DOI ports of ABB standard IO unit (d651)# which is installed in the PIB Box. If using another IO unit,# this definition can be used as the reference.EIO_UNIT: -Name "B_PROC_10" -UnitType "d651" -Bus "DeviceNet1" -DN_Address 10EIO_SIGNAL: -Name "doTS1_SpOn" -SignalType "DO" -Unit "B_PROC_10" -UnitMap "35" -Name "doTS1_St" -SignalType "DO" -Unit "B_PROC_10" -UnitMap "38" -Name "doTS1_AiBl" -SignalType "DO" -Unit "B_PROC_10" -UnitMap "39" -Name "diTS1_ClOp" -SignalType "DI" -Unit "B_PROC_11" -UnitMap "7" -Name "diBE_SENSE" -SignalType "DI" -Unit "B_PROC_10" -UnitMap "8"


1 Installation NOTE!

Cable entry can easily be made through the gland plate (DeviceNet cable used) at the bottom of the control cab-inet.

2 Configuration IO ports The IO ports belong to the ABB standard IO board, which is the one installed in the controller cabinet. Refer to IO configuration file.

3 Connect line to respective port of standard IO board

Connection needs to be done according to the IO config-uration file.3HAC 039787-001 Revision: - 41

#

3 DeviceNet installation3.4.1 TSC

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d.Block diagram

Figure 18 Block diagram control cable TSC

Cable for TSC

Figure 19 Cable for TSC

Signal description


1 TSC 3 Terminal block of IO board

2 Control module

Signal description Color A(TSC) A(BINZEL) B(I/O Unit)

24V DC White 4 6

0V DC Brown 2&8 3,4&5

Lubrication Green 11 8

Cleaning Yellow 10 7

Wire cutter Gray 1 NC

Cleaning finished Pink 7 9

BullsEye Blue 16 10

Shield SC NC NC PE42 3HAC 039787-001 Revision: -

3 DeviceNet installation3.4.1 TSC

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d.Reference document

Document Document ID

Product Specification/Spare Parts List - Torch cleaner TC96 501 105-502

Product Specification - TSC 502 311-5023HAC 039787-001 Revision: - 43

3 DeviceNet installation3.4.2 Adjusting the brake hub (bobbin)

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d.3.4.2 Adjusting the brake hub (bobbin)

Adjusting the brake hubIf a bobbin is used, it may be necessary to adjust the brake hub.

WARNING!At high wire speed and when the bobbin is new, the wire can roll off when the wire feed unit stops. To correct this, change the brake hub's preset value of 5 kpcm (= 0.5 Nm).

Tips!If the wire feed speed is so high that this adjustment does not have any effect, Marathon Pac should be used.


1. Localize the brake hub (1).

2. Turn the knob (2) on the rake hub until the arrows are in line with each other(Locked bobbin position).

3. The springs (3) on each side of the knob are screwed in at the same time to increase the braking force.44 3HAC 039787-001 Revision: -

3 DeviceNet installation3.5 Before commissioning

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d.3.5 Before commissioning

Before commissioningCAUTION!All guards and all safety equipment must be positioned before the station is commissioned.This should be especially observed in connection with maintenance and service.

Before commissioning, the following should be checked:

Action

1. Check that no tools have been forgotten.

2. Check that the fixture and workplace are well secured.

3. Check that all parts and guards are in place and that they are well secured.

4. Check that all functions are correct.3HAC 039787-001 Revision: - 45

4 Operating of welding equipment4 Operating of welding equipment

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d.4 Operating of welding equipment

4.1 Power source (RPC S series)RPC S series power source is designed to be used only with A314F wire feed unit and RF 59 control panel. Normally ABB will offer RPC S-400 as a flagship model.

4.1.1 Control panel parts

Figure 20 Overview of control panel (RPC S series)

The control panel is used for controlling and monitoring the operation of the power source and the wire feed. The buttons are used for adjusting functions. The displays and indicators reflect the operating modes of the machine.

Function Description

Esc button Use the Esc button to move to the previous menu level.

Displays The control panel displays show adjustable operation parameters, their values, and the units of measure.During welding, display P2 shows the welding current value that is currently in use, while display P6 shows the welding voltage.

Control knobs

The left-hand control knob P11 allows the adjustment of the speed of wire feed-ing. The selected speed is shown on the display on the left-hand side.The right-hand side control knob P13 allows for controlling the welding voltage in MIG and 1-MIG processes, in which case the selected voltage is shown on the right-hand side display, and the base current in Wise-MIG processes, in which case the adjustment range is +/- 50.These control knobs are also used for specifying the operating parameters. A parameter for adjustment is selected with the left-hand knob, while the value of the parameter is selected with the right-hand knob.

P2 Shows welding current and voltage.46 3HAC 039787-001 Revision: -

P3 Adjusting MIG dynamics (Arc Force).

4 Operating of welding equipment4.1.1 Control panel parts

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d.P4 The gas test button opens the gas valve without activating the wire feed or power source.

P5 When you press the wire inch button, the wire feed engine starts but the gas valve does not open and the power source is not activated.

P6 Shows welding current and voltage.

P8 Entering to machine setup-functions press setup button (about 5 s.)

P9 The welding process selector allows you to select the welding process you want to use.

P10 To use an additional MIG feature.

P11 Select the parameter to adjust using the left-hand side control knob P11 or the button P10 and then set the parameter value with the right-hand side control knob P13.

P13 Select the parameter to adjust using the left-hand side control knob P11 or the button P10 and then set the parameter value with the right-hand side control knob P13.

Function Description3HAC 039787-001 Revision: - 47

4 Operating of welding equipment4.1.2 Adjusting MIG dynamics (Arc Force)

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d.4.1.2 Adjusting MIG dynamics (Arc Force)

When you press button P3, you can adjust the MIG welding dynamics of the machine by means of the right-hand knob.

Type Description

MIG or 1-MIG When using the MIG or 1-MIG welding process, the welding dynamics setting affects the features of the welding arc and the amount of welding spatter as shown below:

The value 0 is the recommended basic setting.

Use values -1...-9 if you want a softer arc and fewer spatters.

Use values 1...9 if you want a rougher and more stable arc. This set-ting is useful when you are using 100% CO2 shielding gas when welding steel.

Wise-MIG When using the Wise-MIG process, the welding dynamics setting affects the forming pulse as shown below:

Use values -1...-30 if you want a softer arc and smaller penetration.

Use values 1...30 if you want a rougher and greater penetration.48 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.1.3 Gas test

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d.4.1.3 Gas test

The gas test button P4 opens the gas valve without activating the wire feed or power source. By default, gas flows for 20 seconds. The gas flow time remaining is shown on the display.The right-hand knob allows you to set the default gas flow time, between 10 and 60 seconds, and store the new default value in the machine's memory. To stop the gas test, press the ESC button.3HAC 039787-001 Revision: - 49

4 Operating of welding equipment4.1.4 Wire feed test

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d.4.1.4 Wire feed test

When you press the Wire inch button, P6, the wire feed engine starts but the gas valve does not open and the power source is not activated. The wire feed pace is 2 m/min for the first two seconds, and then 10 m/min.When the button is released, the wire feed stops. The machine automatically goes back to the normal state after approximately 3 seconds from release of the button or immediately when you press the ESC button.50 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.1.5 Retrieving weld data

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d.4.1.5 Retrieving weld data

The weld data function allows you to return to the welding current and voltage used during the previous session, with the weld data feature. To use the feature, press buttons P4 and P5 simultaneously.3HAC 039787-001 Revision: - 51

4 Operating of welding equipment4.1.6 Selecting the welding process

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d.4.1.6 Selecting the welding process

The welding process selector button P9 allows you to select the welding process you want to use. You can select one of the following processes:

Normal MIG welding

1-MIG welding (Default)

Wise-MIG (Optional)

In normal MIG welding, the wire-feed speed and the welding voltage are adjusted separately.Unlike the above, the 1-MIG and Wise-MIG processes are synergetic welding processes where the welding voltage and other welding parameters are interconnected so that the weld-ing power and arc length are adjusted to attain optimal welding values.The Wise-MIG process is an optional feature intended for welding automation. It must be acquired separately and is therefore not available in all configurations.52 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.1.7 Optional MIG features

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d.4.1.7 Optional MIG features

The standard welding machine delivery includes three additional MIG features that facilitate welding and improve weld quality. These additional features are creep start, hot start and crater fill.To use an additional MIG feature, press the feature selector button P10. Press the selector button repeatedly to use one or several features. Only the additional features allowed for the welding method you have chosen will be available.

Creep startThe purpose of the creep start feature is to make controlled weld start easier and smoothen the initial stage of welding, for example when welding with high wire feed speeds. At the beginning, the machine will use a slow wire feed speed until the wire touches the work piece and the current starts flowing.Creep start is available for normal MIG welding and the synergetic 1-MIG welding.

Hot startThe purpose of hot start is to reduce start faults, for example when welding aluminum or other materials with particularly good thermal conductivity. In this scenario, there is a fixed pre-gas time at the beginning of the welding, after which the welding power briefly rises above the specified power level. The power and time parameters for hot start can be specified in the SETUP settings.Hot start is available for synergetic 1-MIG welding.

Crater fillThe purpose of crater fill is to facilitate controlled finishing of welding and to reduce the welding faults caused by the final crater. When you press the welding gun trigger completely down at the end of welding, the welding power is reduced to a preset crater fill level. To end the crater fill stage, release the gun trigger. The crater fill parameters can be specified in the SETUP settings. Crater fill is available for synergetic 1-MIG welding.

Specifying the SETUP settings for additional featuresSelect the parameter to adjust using the left-hand side control knob P11 or the button P10 and then set the parameter value with the right-hand side control know P13. The value you spec-ified is instantly stored in the control panel memory. The following table lists the parameter values that can be specified for additional MIG features.

Parameter Displayed Values Factory settingDescription

Creep start level

Cre 10 ... 170 % 50 % Percent of wire feed speed default:10% refers to slow start,170% refers to fast start

Hot start level

Hot -50 ... 75 % 30 % Percent of welding power:-50% refers to cold start3HAC 039787-001 Revision: - 53

+75% refers to hot start

4 Operating of welding equipment4.1.7 Optional MIG features

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d.NOTE!In crater fill, the initial value of the welding power must be greater than the final value, and therefore the adjustment ranges for the initial and final values are restricted automatically, if necessary.

Figure 21 Crater fill time

Hot start time

H2t 0 ... 9.9 s 1.2 s The duration of the hot start in sec-onds.

Crater fill start level

CrS 10 ... 90 % 90 % The welding power at the begin-ning of the crater-fill stage as a per-centage of the welding power preset value.

Crater fill end level

CrL 10 ... 90 % 30 % The welding power at the end of the crater-fill stage as a percent-age of the welding power preset value.

Crater fill time

Crt 0...9.9 s 2 s The duration of the crater fill stage in seconds.

Parameter Displayed Values Factory settingDescription54 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.1.8 Memory features (Memory button)

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d.4.1.8 Memory features (Memory button)

Use the control panel memory features to store welding parameters you use into the machine's memory for easy use later without the need to readjust all parameters. The control panel has 90 memory positions, numbered 0...89.You can store the welding parameters you use, i.e., the wire feed speed and the welding voltage. You can also store additional feature settings, such as creep start or crater fill set-tings.

Storing welding parameters in memory

If you want to change the welding parameters stored in a welding channel, go to the SET mode by pressing the MEMORY button. Now select the parameters you want and store them by pressing SAVE.You can also store the welding parameters with the SET button when the memory feature is in the OFF state, i.e., when the MEMORY indicators are not on.To clear the data in a memory channel, press the MEMORY and CH buttons simultaneously when the control panel is in the SET mode (the SET indicator is on).

Using stored welding parameters

Step Description

1. Press the MEMORY button twice. If a memory channel is free, the SET indicator starts flashing. In other cases the indicator will be turned on constantly.(If the memory is empty, one push of the button is enough.)

2. Select the memory channel you want using the CH button.

3. Specify the welding settings you want and store the selections by pressing SAVE.

4. Press the MEMORY button twice. The ON indicator light will turn on and the welding parameters you selected are activated.

5. Start welding.

Step Description

1. Press the MEMORY button to turn on the ON indicator.

2. Select the memory channel you want from the robot.

3. Start welding.3HAC 039787-001 Revision: - 55

4 Operating of welding equipment4.1.9 Synergetic 1-MIG welding and Wise-MIG welding

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d.4.1.9 Synergetic 1-MIG welding and Wise-MIG welding

In synergetic 1-MIG welding, the machine selects the optimal welding parameters suitable to the filler wire and shield gas using the programs, or synergetic curves, stored in the control panel. The welder controls the welding by adjusting the welding power and arc length.The synergetic Wise-MIG process (advanced auto arc) is a synergetic welding process devel-oped for the special needs of robotic welding with welding characteristics optimized particu-larly for welding automation.

Selecting a welding programBefore you start welding, find the welding program suitable to your filler wire and shield gas in the tables below and then activate the program as follows:

MIG programs in the RPC S-400

Step Description

1. Press the SYNERGIC PROGRAM button P7 for more than 1 second. This will acti-vate program selection and the control panel displays start flashing.

2. Select the material group with the left-hand side control knob and the welding pro-gram for the material group with the right-hand side control knob according to the tables below. The program you selected is immediately recorded in the memory.

3. Press ESC button or the SYNERGIC PROGRAM button P7 to exit the menu.

1-MIG, Fe group

Program number Wire,mm Maerials Shied gas

101 0.8 Fe Ar+18%-25%CO2102 0.9 Fe Ar+18%-25%CO2103 1.0 Fe Ar+18%-25%CO2104 1.2 Fe Ar+18%-25%CO2106 1.6 Fe Ar+18%-25%CO2111 0.8 Fe CO2112 0.9 Fe CO2113 1.0 Fe CO2114 1.2 Fe CO2116 1.6 Fe CO2121 0.8 Fe Ar+8%CO2122 0.9 Fe Ar+8%CO2123 1.0 Fe Ar+8%CO2124 1.2 Fe Ar+8%CO2126 1.6 Fe Ar+8%CO2152 0.9 FEMC Ar+18%-25%CO2154 1.2 FEMC Ar+18%-25%CO256 3HAC 039787-001 Revision: -


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d.164 1.2 FEMC CO2174 1.2 FEFC rutile Ar+18%-25%CO2184 1.2 FEFC rutile CO2194 1.2 FEFC rutile Ar+18%-25%CO2

1-MIG, SS group


201 0.8 SS-316 Ar+2%CO2202 0.9 SS-316 Ar+2%CO2203 1.0 SS-316 Ar+2%CO2204 1.2 SS-316 Ar+2%CO2206 1.6 SS-316 Ar+2%CO2211 0.8 SS-316 Ar+30%He+1%O2212 0.9 SS-316 Ar+30%He+1%O2213 1.0 SS-316 Ar+30%He+1%O2214 1.2 SS-316 Ar+30%He+1%O2216 1.6 SS-316 Ar+30%He+1%O2221 0.8 SS-309 Ar+2%CO2222 0.9 SS-309 Ar+2%CO2223 1.0 SS-309 Ar+2%CO2224 1.2 SS-309 Ar+2%CO2231 0.8 SS-309 Ar+30%He+1%O2232 0.9 SS-309 Ar+30%He+1%O2233 1.0 SS-309 Ar+30%He+1%O2234 1.2 SS-309 Ar+30%He+1%O2242 0.9 FC-316 Ar+18%-25%CO2244 1.2 FC-316 Ar+18%-25%CO2252 0.9 FC-316 CO2254 1.2 FC-309L Ar+18%-25%CO2

1-MIG, AI group


303 1.0 Al-5356 Ar

304 1.2 Al-5356 Ar

1-MIG, Fe group

Program number Wire,mm Maerials Shied gas3HAC 039787-001 Revision: - 57

306 1.6 Al-5356 Ar


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d.313 1.0 Al-4043 Ar

314 1.2 Al-4043 Ar

316 1.6 Al-4043 Ar

1-MIG, SPE group


401 0.8 CuSi 3 Ar

402 0.9 CuSi 3 Ar

403 1.0 CuSi 3 Ar

404 1.2 CuSi 3 Ar

411 0.8 CuSi 3 Ar+2%CO2412 0.9 CuSi 3 Ar+2%CO2413 1.0 CuSi 3 Ar+2%CO2421 0.8 CuAL 8 Ar

423 1.0 CuAL 8 Ar

424 1.2 CuAL 8 Ar

Wise-MIG, Fe group


903 1.0 Fe Ar+18%-25%CO2904 1.2 Fe Ar+18%-25%CO2913 1.0 Fe CO2914 1.2 Fe CO2

Wise-MIG, SS group


923 1.0 SS-316 Ar+2%CO2924 1.2 SS-316 Ar+2%CO2933 1.0 SS-316 Ar+30%He+1%O2934 1.2 SS-316 Ar+30%He+1%O2

1-MIG, AI group

Program number Wire,mm Maerials Shied gas58 3HAC 039787-001 Revision: -


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d.Using the welding program

Step Description

1. Select the welding process 1-MIG with the P9 button.

2. Press the SYNERGIC PROGRAM button to display the material group and the weld-ing program number. Make sure that the welding program corresponds to the filler wire and shield gas you use.

3. Check the wire type and shield gas for the welding program in the table below.

4. Adjust the welding power with the left-hand side knob and the arc length with the right-hand side knob.3HAC 039787-001 Revision: - 59

4 Operating of welding equipment4.1.10 Setup features of the control panel

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d.4.1.10 Setup features of the control panel

The machine has a number of additional features, or parameters, whose settings can be spec-ified with the control panel's SETUP, function as follows:

All welding processes have their own SETUP parameters. For example, adjusting the post current for synergetic MIG welding does not affect the post-current of normal MIG welding.The tables below show the additional features available in this welding machine and their possible values.

Normal MIG welding parameters and their values

Synergetic MIG welding parameters and their values

Step Description

1. Press and hold down the SETUP button P10 for at least 5 seconds.

2. Select the parameter to adjust using the left-hand side control knob. The parameter name is shown in display 2.

3. Specify the parameter value with the right-hand side control knob. The selected value is shown in the display P6. The parameters value is immediately stored in the mem-ory.

4. You can exit the SETUP mode by pressing and holding down the SETUP button again for at least 5 seconds or by briefly pressing the ESC button.


Pre gas time PrG 0.0 ... 9.9 s 0.0 s Pre-gas time 0 ... 9.9 s.

Post gas time

PoG Aut, 0.1 ... 32.0 s 1,0 Post gas timeAut=Automatic, depending on welding current 0.1 ... 32 s

Creep start level

Cre 10 ... 170% 50 % Percentage of wire feed speed, 10% refers to slow start, 170% to accelerated start

Post current time

PoC -9 ... +9 0 Post-welding current time


Cablecompensa-tion

CAL -5.0... 9.0 V/100 A 1.0 V/100 A

Cable compensation (MIG) for voltage losses.

Restore fac-tory settings

FAC OFF, PAn, All OFF Restores factory settings if you select ON and exit the menu.60 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.1.10 Setup features of the control panel

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d.Checking the parameters in the MEMORY ON stateYou can check parameter values in the MEMORY ON state by pressing the button of the parameter you want. The parameter value will be shown in the display. You can not modify parameter values in the MEMORY ON state.

Scaling SCA 0 ... 5000 5000 A coefficient with which the val-ues in the welding machine are scaled to the scale used by the robot.

Parameter Displayed Values Factory settingDescription3HAC 039787-001 Revision: - 61

4 Operating of welding equipment4.2 Power source (RPC P series)

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d.4.2 Power source (RPC P series)RPC P series power source is designed to be used only with A314F wire feed unit and KF 62 control panel. Normally ABB will offer RPC P-350 as a flagship model.Welding applications vary, so the equipment must adapt. RPC P-350 features K60 interface, a clear and logical LCD menu display. Arc Wizard menu allows the operator to refine, adapt and manage the arc process and system function before, during and after welding.

4.2.1 Control panel parts

Figure 22 Overview of control panel (RPC P series)

The following information details K 60 panel operation and set-up.

Pos Description

1 Switch K60 ON/OFF by long pressing on this button (approximately 5 seconds). Also returns channel information display by short press.

2 Welding channel (job) selection. There are 100 memory channels available. If the channel is empty you can create a new (job) channel by pressing the key below the LCD screen text stating NEW.

3 MENU button for entering the main menu list. Proceed following the LCD screen menu guidance.

4 Potentiometer for making adjustments to selected values

5 Up/down arrow keys for moving vertically in the menu structure

6 Pre-programmed menu shortcut keys F1 for displaying channel information

F3 for selecting another parallel connected wire feed sub system as a setup target.

7 LCD menu display

8 Soft key buttons. Function according to the menu location/task.62 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.2.1 Control panel parts

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d.Button functions:

Item Description

ON / OFF Button Short Press: Panel returns to default start-up display view (Channel info display).Long Press: When setup panel (K 60) is ON => Setup panel and all KF 62 panels are turned OFF. When setup panel is OFF => Setup panel and all KF 62 panels are turned ON.Pressed while machine is turning ON: Restore to factory shortcut. Panel will ask confirmation to restore factory setting.If Setup panel is OFF and some other KF 62 panel is turned ON the Setup Panel turns also ON and will be linked automatically to this KF panel (WF# function).

F1 Button F1 button gives further information of selected memory channel.Pressed while machine is turned ON: Restore language selection to Eng-lish.

F3 Button (WF#) F3 button can be used to select Wire feed.Panel allows selecting only those WF numbers that are found connected on the system.

Channel +/- Memory channel selection.

Up/Down Button Moving Up/Down in menu.

Right/Left selec-tion buttons (Soft Keys)

Button function depends on where in menu you are.3HAC 039787-001 Revision: - 63

4 Operating of welding equipment4.2.2 Getting started

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d.4.2.2 Getting started

First select your language (The default menu language is English)

New channel (job) numberRPC P-350 is designed for production jobs as well as varied specialist operation. Main weld-ing set-up is made through the K60 menu and recorded to a 'Channel (Job) Number' of your choice.

NOTE!If the machine is new and no welding has been completed before, follow these steps.A. Switch on power source (May require long press of panel ON/OFF button - 5 sec).

1. Press and select NEW button.

2. Create New Channel - Press SELECT button.

3. Choose weld process and press SELECT button.

B. Then follow the steps from item 4 in the list below.

Editing an existing channel (job) number

Step Description

1. Connect mains power and switch on power source. If this is the initial system activa-tion you may need to press and hold the large orange ON/OFF button on K 60 panel. Top left-Long Press (Approximately 5 seconds).

2. Now press button marked 'MENU' to display MAIN MENU listing. There are 8 x items in this MAIN MENU list. As you select each item in the list, the reference number (Bottom middle display) will change e.g. 2/7 or 5/7 etc, showing which menu item you have selected. (You can cycle from first to last or last to first in a loop in all menu lists, if you wish). A black arrow marks your menu item selected.

3. MENU items are selected via the UP-DOWN buttons marked with orange arrows. These buttons are situated underneath the encoder knob to the right of the panel. Move the 'black arrow cursor' up and down the menu lists. Press down arrow button selecting item 5/7 marked LANGUAGE. Press soft key button underneath the word SELECT.

4. Make your language choice as detailed above, and then press the SELECT/SAVE button (right-hand button next to MENU button). Your language choice is now con-firmed and will remain selected unless you change it later.

Step Description

1. Press button marked 'MENU' to show MAIN MENU listing.

2. SELECT 'Edit Channel'- Press SELECT button.

3. SELECT 'Select Weld Curve'- Press SELECT button.

4. Choose and SELECT Process. MIG/1-MIG/Pulse MIG/Double Pulse MIG or Curve Number List -Press SELECT button.

5 Choose and SELECT material group - Press SELECT button.

6 Choose and SELECT material grade - Press SELECT button.

7 Choose and SELECT filler wire diameter - Press SELECT button.64 3HAC 039787-001 Revision: -

8 Choose and SELECT shielding Gas - Press SELECT button.

4 Operating of welding equipment4.2.2 Getting started

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d.Ready to weld: Your basic welding selection and set-up is now complete. You are ready to weld, providing you select the corresponding channel 'Job' number on the KF 62 remote control panel. Set your welding power and arc length and weld.

NOTE!If you SELECT'MIG' (i.e. Basic MIG/MAG selection in the above listing) you will automatically jump from item 4 to item 9. When you have saved your channel 'Job' number selection, you will have access to basic MIG/MAG welding on this channel. Voltage and wire feed speed are then selected in the normal way.

9 Choose and SELECT curve - Press SELECT button. (Note: The curve(s) presented in this view are based on your previous selections from items 4 through to 8.)

10 Choose and SAVE memory channel number. Memory channel selections are made using either the White +/- buttons OR Orange UP-DOWN buttons - Press SAVE but-ton.

Step Description3HAC 039787-001 Revision: - 65

4 Operating of welding equipment4.2.3 Setup panel K60 main menu list

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d.4.2.3 Setup panel K60 main menu list

K60 Main Menu List

Parameter Value range Factory setting Description

Edit channel For making changes to existing welding channel

Weld data For checking out the values of the last weld

Special settings For adjusting special welding parameters

System config menu For device configuration and information

Language For selecting yourmenu lan-guage

Select feed (WF#) For selecting another parallel wire feed as a setup target

Test menu

Wire inch 1 20 m/min 1 m/min Adjustment with the control knob

Gas test Press the button

K 60 robot menu list

Interface version 1 99 1 Signal frame selection

Voltage scaling 0 5000 0

WSF scaling 0 5000 0

Current scaling 0 5000 0

EM stop logic 0 or 1 0 Power source all function stopped

Door switch on 0 or 1 0 Welding stops, machine stays alive

LimitFunctions menu

Current tol 50 A not in use in interface version 1

Voltage tol 5.0 V not in use in interface version 1

CurrentToltime 1.0 s not in use in interface version 1

WSF tol time 1.0 s not in use in interface version 1

Gun menu not in use in interface version 1

Front pull ON or OFF OFF66 3HAC 039787-001 Revision: -

4 Operating of welding equipment4.2.4 Welding parameters

C

opyr

ight

201

0 A

BB

. All

right

s res

erve

d.4.2.4 Welding parameters

MIG (In Edit Channel menu 2/6)

Parameter Value range Factory setting Description

WFS 0.7 25 m/min 0.05 m/min steps when WFS < 5 m/min and

rpc manual.pdf

Documents

overview of welding

welding functions

welding process

welding parameters

operating of welding

wire feed system

wire feed test

programming power source