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Kemppi A7 350, Integration Manual

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Kemppi A7 350 Integration Manual Download Page 34

34

A7 MIG Welder

© Kemppi Oy 2020

2002

INTEGRA

TION GUIDE

5.6.5  KEMPPI5: A7 MIG Welder table for pulse process control

Interface mode = 16. Table size = 18 bytes

Byte

Bit

Control (Robot -> Welder)

Status (Welder -> Robot)

0

WireFeedSpeed

WeldingCurrent

1
2

Voltage / FineTuning

WeldingVoltage

3
4

MemoryChannel

ErrorNumber

5

Dynamics

WeldingWireFeedSpeed

6

0

StartWelding

Ready

1

SimulationMode

PowerSourceReady

2

WireInch

CycleOn

3

WireRetract

ArcOn

4

GasBlow

GasFlowOk

5

AirBlow

(Not in use)

6

TouchSensorToolSel

(Not in use)

7

TouchSensorOn

TouchSensed

7

0

OnlineControl

GateDoorOpen

1

ErrorReset

Error

2

WireFeederSelect

CollisionDetected

3

Watchdog

(Not in use)

4

HotStartOn

(Not in use)

5

CraterFillOn

(Not in use)

6

(Not in use)

(Not in use)

7

(Not in use)

(Not in use)

8

0

DigitalOutput1

DigitalInput1

1

DigitalOutput2

DigitalInput2

2

DigitalOutput3

DigitalInput3

3

DigitalOutput4

DigitalInput4

4

DigitalOutput5

DigitalInput5

5

DigitalOutput6

DigitalInput6

6

DigitalOutput7

DigitalInput7

7

DigitalOutput8

DigitalInput8

Byte

Bit

Control (Robot -> Welder)

Status (Welder -> Robot)

9

PulseCurrent

TAST

10
11

PulseBaseCurrent

GasFlowRate

12
13

PulseFrequency

MotorCurrent

14

WeldingProcess

15

PulseLength

(Not in use)

16
17

(Not in use)

Summary of Contents for A7 350

Page 1: ...350 450 1920310 2002 A7 MIG Welder A7 MIG Welder EN INTEGRATION GUIDE...

Page 2: ...he Web user interface 20 4 1 Configuring the network settings 20 4 2 Opening the web user interface 21 5 System configuration 22 5 1 Welding system sensors and devices 22 5 1 1 General settings 22 5 1...

Page 3: ...ldingVoltage 47 6 2 3 WeldingWireFeedSpeed 47 6 2 4 MotorCurrent 47 6 2 5 GasFlowRate 47 6 2 6 ErrorNumber 47 6 2 7 WeldingMemoryChannel 48 6 2 8 TAST 48 6 2 9 WeldingProcess 48 6 2 10 Ready 48 6 2 11...

Page 4: ...notice Do not copy record reproduce or transmit the contents of this guide without prior permission from Kemppi The web user interface server part of the robot interface unit is meant to be used only...

Page 5: ...face unit use the recesses at both ends of the robot interface unit After installation make sure all cables and hoses have enough space to move and are attached properly Remember that the cable plugs...

Page 6: ...6 A7 MIG Welder Kemppi Oy 2020 2002 INTEGRATION GUIDE Fieldbus Figure 3 1 Connection diagram gas cooled system Fieldbus Figure 3 2 Connection diagram water cooled system...

Page 7: ...ectrical cable The power source unit can be connected to a 400 V 3 power supply If changing the power cable take the following facts into consideration The cable enters the machine through the inlet r...

Page 8: ...e described later in this document Figure 3 3 Peripheral connector pinout A Motor B Motor C Supply 24 V D Wire inch input E Collision sensor input F Touch sensor output for gas nozzle 50 200 V G Tacho...

Page 9: ...rate properly the push pull torch must be configured for use The configuration is described in Subsection 5 1 4 General robot settings M A B Figure 3 4 Push pull motor connection S M A B G J I Figure...

Page 10: ...sensor See the manual of the robot mount for more information The welder system supports two types of collision sensors an opening action switch sensor and a closing action switch sensor The opening...

Page 11: ...asurement input connector at the rear of the power source Connect the cable to the arc measurement output connector at the wire feeder For using the arc voltage calibration connect a separate earth ca...

Page 12: ...e robot interface unit Do not use any other control cable connectors 3 8 3 Welding cable The welding cable delivers welding power from the power source to the welding head At the wire feeder connect t...

Page 13: ...ure 3 13 Installing a fieldbus adapter Ensure that it sits properly in its place Tighten the two screws on the module after you have placed it into the slot Connect a suitable fieldbus cable to the co...

Page 14: ...n this situation The touch sensor voltage is automatically lowered to a safety level max 110 V After a gate door switch action the system is recovered automatically Both inputs have a separate three p...

Page 15: ...ut can be used for better response For connection of fast status output the robot must have at least one hardware input available Connect the fast output to the touch sensor fast status output connect...

Page 16: ...IG Welder supports two wire feeders one operational at the time This feature is enabled by an optional extension kit The extension kit is installed inside the robot interface unit The kit includes a w...

Page 17: ...n by amber LED lights After successful installation switch the power source off and close the robot interface unit Follow these steps to install the extension kit 7 Unscrew four screws two from the fr...

Page 18: ...01 X7 X4 X4 X7 A105 A102 15 Plug a touch sensor cable between the switching card A105 input and the touch sensor card output A102 X2 X5 A102 A101 X2 X5 A105 A102 16 Plug a bus cable between the switch...

Page 19: ...in serial In parallel the water flow can differ between the torches and may cause damage to the torch The extension kit includes support for water valves Should you want to use valves to control the c...

Page 20: ...you specify the IP settings manually When the DHCP client is switched on it takes some time for the client to establish a connection to the DHCP server and retrieve the address information Usually the...

Page 21: ...the address bar for example http 10 0 0 20 If the network cable is connected and the network settings are configured properly the network browser opens the web user interface and redirects to the weld...

Page 22: ...ling up the cooling system Choose AUTO for normal operation with a water cooled system Welding cable length Set the welding cable length in meters The cable length includes the welding and welding cab...

Page 23: ...m indicates that the gas flow is OK Gas type integrated gas sensor Set the type of the shielding gas used in your configuration This value must be changed every time the gas type is changed The gas ty...

Page 24: ...parameter to be OFF to prevent possible false detection Switch type Select the type of the switch used in your collision sensor The switch can be either OPENING or CLOSING See Figure 3 8 Opening acti...

Page 25: ...elding system stops welding if the robot stops sending fieldbus data The robot must perform continuous transitions on the Watchdog signal of the digital robot interface within the timeout period 5 1 9...

Page 26: ...GWelder system and a welding robot is based on input output tables I O tables exchanged between the machines by fieldbus cyclic I O transmission The tables contain binary level functions that the robo...

Page 27: ...ltage status function WeldingCurrent status function For more information on these functions see Chapter 6 Digital robot interface I O reference To set up the scaling values go to Welding settings Wel...

Page 28: ...in accuracy of one decimal digit thus the calculation loses less significant digits and produces final values which may not exactly match with the target values Example By means of its specification o...

Page 29: ...r all users including the Admin user is 0000 four zeroes Require users to change their PIN code at the first login To continue with user configuration log in to the web user interface by providing the...

Page 30: ...system it is a good idea to make a system backup file The backup file can save significant time if the memory channels welding system settings user settings and or network settings need to be restore...

Page 31: ...0 Watchdog WeldingWireFeedSpeed 1 ErrorReset 2 AirBlow 3 Not in use 4 Not in use 5 DigitalOutput1 6 DigitalOutput2 7 DigitalOutput3 5 6 2 KEMPPI2 KempArc Pulse customized table Interface mode 13 Tabl...

Page 32: ...0 Dynamics CycleOn 1 ArcOn 2 TouchSensed 3 PowerSourceReady 4 Error 5 Ready 6 LocalRemote 7 AutoManual 6 0 StartWelding GateDoorOpen 1 SimulationMode DigitalInput2 2 WireInch DigitalInput3 3 WireRetra...

Page 33: ...Sel Not in use 7 TouchSensorOn TouchSensed 7 0 OnlineControl GateDoorOpen 1 ErrorReset Error 2 WireFeederSelect CollisionDetected 3 Watchdog Not in use 4 HotStartOn Not in use 5 CraterFillOn Not in us...

Page 34: ...t in use 7 TouchSensorOn TouchSensed 7 0 OnlineControl GateDoorOpen 1 ErrorReset Error 2 WireFeederSelect CollisionDetected 3 Watchdog Not in use 4 HotStartOn Not in use 5 CraterFillOn Not in use 6 No...

Page 35: ...se Not in use 8 WireFeedSpeed WeldingCurrent 9 10 Voltage FineTuning WeldingVoltage 11 12 Not in use Not in use 13 14 Not in use Not in use 15 5 6 7 CUST2 Customer specific table Interface mode 5 Tabl...

Page 36: ...4 Customer specific table Interface mode 7 Table size 10 bytes Byte Bit Control Robot Welder Status Welder Robot 0 0 WeldingAllowed PowerSourceReady 1 ErrorReset Error 2 StartWelding ArcOn 3 Simulatio...

Page 37: ...cleOn 3 Not in use MainCurrentOn 4 Not in use CollisionDetected 5 Not in use PowerSourceReady 6 Not in use Ready 7 Not in use Not in use 2 0 Not in use WireStuck 1 Not in use TouchSensed 2 Not in use...

Page 38: ...X X X X X Voltage 16 80 460 1 0 1 V X X X X X X X X X X FineTuning 16 0 180 1 0 1 X X X X X X X X X X Dynamics 8 0 18 1 1 X X X X X MemoryChannel 7 8 0 199 1 8 8 8 8 8 8 7 8 8 8 PulseCurrent 16 99 800...

Page 39: ...d speed value is calculated from the setup value by means of the value scaling formula This value has an effect only when the OnlineControl signal is set 1 and it overrides the corresponding memory ch...

Page 40: ...rol signal is cleared 0 the fine tuning from the active memory channel is used 6 1 4 Dynamics This 8 bit function controls the dynamics of the synergic curve for all processes exceptWiseRoot The root...

Page 41: ...ble and disable the StartWelding signal When the value is 1 welding allowed the StartWelding signal controls welding start and stop When the value is set to 0 welding disallowed the StartWelding signa...

Page 42: ...has no effect during welding or simulated welding 6 1 17 TouchSensorToolSel This signal function sets the selection of the touch sensing tool between the welding wire and the gas nozzle if the tool i...

Page 43: ...ror reset on rising edge 6 1 22 HotStartOn This signal function controls a hot start on and off if the hot start is enabled to be controlled by a robot from the web user interface or from the setup pa...

Page 44: ...I O table Min Max Step Units KEMPPI 1 KEMPPI 2 KEMPPI 3 KEMPPI 4 KEMPPI 5 CUST1 CUST2 CUST3 CUST4 CUST5 1 13 14 15 16 3 5 6 7 9 Status values WeldingCurrent 16 0 1024 1 1 A X X X X X X X X X X Welding...

Page 45: ...eady 1 X X X X X X X X X X PowerSourceReady 1 X X X X X X X X CoolingUnitOk 1 X ProgramSaved 1 X RobotHasControl 1 X CycleOn 1 X X X X X X X X X X ArcOn 1 X X X X X X X X X X GasFlowOk 1 X X X X X X X...

Page 46: ...T3 CUST4 CUST5 1 13 14 15 16 3 5 6 7 9 Status bits DigitalInput1 1 X X X X X DigitalInput2 1 X X X X X X X X X DigitalInput3 1 X X X X X X X DigitalInput4 1 X X X X X X X DigitalInput5 1 X X X X X X X...

Page 47: ...user setup In non scaled mode The minimum value is 0 0 0 m min The maximum value is 250 25 0 m min The minimum step is 1 0 1 m min In scaled mode The minimum value is 0 0 0 m min The maximum value is...

Page 48: ...and errors are resolved 1 Welding system ready 6 2 11 PowerSourceReady This signal function indicates the status of the power source The power source is ready to start welding when it is not currently...

Page 49: ...ithin the limits set by a user 0 Wire feed speed too low or too high 1 Wire feed speed within the limits This function is not implemented in the A7 MIG Welder The status is always OK 1 6 2 22 TouchSen...

Page 50: ...e weld 0 Wire is OK 1 Wire is stuck This function is not implemented in the A7 MIG Welder The status is always OK 0 6 2 27 GateDoorOpen This signal function indicates whether the gate door is open or...

Page 51: ...Digital robot interface function timing B StartWelding CycleOn ArcOn B StartWelding CycleOn ArcOn Symbol Description Min Typical Max Units A Cycle on time 6 17 40 ms B Arc establishment time 17 Pre ga...

Page 52: ...time 3 14 20 ms B MIG logic process 5 ms B Setup time Gas valve on 1 ms B Setup time Pre gas time going 1 ms B Setup time Set wire feed on 1 ms B Setup time Set power source on 1 ms B Setup time Cree...

Page 53: ...interface function timing A B StartWelding CycleOn ArcOn Symbol Description Min Typical Max Units A Arc off time 51 51 94 ms B Cycle off time 347 Post gas time 10 Pre gas time 44 ms The minimum cycle...

Page 54: ...ArcOn D F2 Symbol Description Min Typical Max Units A Weld start response time 3 3 20 ms B MIG logic process 4 ms B Setup time Post gas time going 1 ms B Setup time Set power source off 1 ms B Setup t...

Page 55: ...ry channel data Load curve data MemoryChannel Apply curve data A B C Active value Ready to weld Ready to weld Welding system T Symbol Description Min Typical Max Units T Total time 380 392 500 ms A Me...

Page 56: ...ol data setup time 27 30 50 ms Switching offline memory channel mode Welding system Load setup file Online Memory channel mode Robot mode Load memory channel data Load curve data Apply new data C D B...

Page 57: ...onse time 3 ms B Wire feeder motor acceleration time 3 s The wire feeder reacts on controls immediately after startup The acceleration time depends on the selected wire feed speed Stop timing Welding...

Page 58: ...Ready B New tool Ready Touch sensor Symbol Description Min Typical Max Units A Control response time 3 ms B Relay action time 5 ms Touch response timing B Short circuit touch Fast status output TouchS...

Page 59: ...ing system STOPPED Operating ERROR Error ErrorNumber EMERGENCY STOP 133 NO ERROR 0 D Symbol Description Min Typical Max Units A Hardware response time 500 s B Error setup time 10 ms C Welding system s...

Page 60: ...And you know...

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