100 Automation Way Miamisburg, OH 45342 937.847.6200 www.motoman.com info@motoman.com PRODUCT BULLETIN Product: Lincoln ArcLink XT Power Source Kits for DX200 (i400/r350/r500) with Production Monitoring Release Date: 7/29/10 Part Number: Description: Interface kits (required for inside DX200 Controller) 169498-1 Interface Kit, Lincoln ArcLink XT, DX200, Single Robot 169498-2 Interface Kit, Lincoln ArcLink XT, DX200, Dual Robot 169498-3 Interface Kit, Lincoln ArcLink XT, DX200, Triple Robot 169498-4 Interface Kit, Lincoln ArcLink XT, DX200, Quad Robot Standard MIG Robot Dress Kits (contain brackets and cables for robot) 168726-1 Robot Dress Kit, Lincoln, VA1400 II 169010-1 Robot Dress Kit, Lincoln, MA1440 169010-2 Robot Dress Kit, Lincoln, MA2010 169010-3 Robot Dress Kit, Lincoln, MA3120 AutoDrive SA (Servo Aluminum) Robot Dress Kits (contain brackets and cables for robot) 174412-1 Dress Kit, Arc Welding, DX200, MA1440, Lincoln ArcLink XT, SA System 174412-2 Dress Kit, Arc Welding, DX200, MA2010, Lincoln ArcLink XT, SA System Note: Some cables/hoses can vary in length. See Configuration Notes in table to see items necessary to complete weld package and Lincoln weld equipment and options. Description: Yaskawa Motoman has released robot dress kits for specific robot models and interface kits based on the number of welders in the system. The power source, feeder and feedroll kits can be added to the kit using Yaskawa Motoman part numbers or supplied by the customer for integration. Standard MIG Dress Kits: The dress kits offer cabling and brackets required to connect/mount the welding equipment to the respective robots, and it utilizes the robot s internal cabling and gas hose for transferring the feeder signals and shielding gas to the upper arm of the robot. The torch lead and water lines (if applicable) are routed up the side of the robot casting. The MA1440, VA1400 II and MA2010 robots are designed to use the AutoDrive 4R100 feeder (recommended for wire size 0.045 or less). The MA3120 can use either the 4R100 or larger 4R220 AutoDrive wire feeder (recommended for wire sizes greater than 0.045). Configuration Notes: Some cables/hoses may require different lengths based on system design, and they are not included in the robot dress kits. The following table indicates items added to configure a welding system. Power sources and other Lincoln content is shown in Power Wave Kit Requirements. Part number Description Default length Range 158902-x Ethernet cable, controller to power source 5.1 m (-3) 1.9-5.1 m 158027-x Feeder cable, power source to robot base, MA1440/2010 6 m (-4) 3-25 m 159116-x Feeder cable, power source to robot base, MA3120 6 m (-4) 3-25 m 145200-x Gas hose, supply to robot base 10 m (-6) 3-40 m 130887-x* Weld leads, 4/0 cable, ½ inch lug terminals 10.5 m (-4) 7.5-30 m * 2 required; 1 for power source to feeder (include length to reach feeder on upper arm) and 1 for work lead. It is possible to specify 2 cables with different lengths. Cables required for Auto Drive SA weld system. AutoDrive SA (Servo-Aluminum) Dress Kits: The AutoDrive SA feed system is a high-performance servo control feed system design for aluminum application where a clean starts and cosmetic weld appearance is key. The water-cooled feed system utilizes a push-pull feeder configuration to ensure high-performance wire speed control and unique starting features like Touch Retract. The integration of the push-pull feeder dictates that the torch
Page 2 of 8 AutoDrive SA (Servo-Aluminum) Dress Kits (continued): package and consumables must be supplied by Lincoln. The standard package from Yaskawa includes a 45-degree neck and 3/64" contact tips and liners. A 4-roll push feeder mounts where a traditional feeder would on the rear of the U-Axis. A 2-roll pull feeder then mounts to the wrist of the robot and is in constant communication with the push feeder to ensure that they are synchronized. The pull feeder, torch neck and shock sensor weigh 4.5 kg and leaves capacity for sensors to be added as needed. Both feeders have Inch, Retract and Purge buttons, while the pull feeder offers a unique and useful LED light for illuminating the part while teaching. Unique features of this feed system include: Touch Retract function that can be enabled via the teach pendant interface causing the wire to contact the part and retract the wire as the arc is being lit. This function eliminates spatter and rough starts with minimal cycle-time impact (100 ms longer than normal start). This feature can be enabled as needed depending on the ArcStart file being used. Ripple Effect is a software feature which will toggle the wirefeed speed between two settings (high and low) resulting in TIG-like weld appearance. The settings for the wirefeed speed, variances (high and low), and frequency are all made within an ArcStart file and can be changed weld-to-weld if needed or maintained for constant appearance. Key differences between the Standard MIG packages and the AutoDrive SA Packages AutoDrive SA packages will work with S-series welders without the use of an AutoDrive 19 control box. AutoDrive SA packages will work with R-series welders, if required, but the lower-cost S-series should be the first choice. The AutoDrive SA packages do NOT utilize the 3BC harness of the robot. Instead, their control cable is routed up the side of the robot alongside the weld cable (gas is still routed through the robot s casting). Supported Feeders in Lincoln Interface Touch Retract Ripple Effect
Page 3 of 8 Lincoln ArcLink XT Interface: Lincoln Electric s Power Wave digital ArcLink XT connectivity is high speed and Ethernet-based. Yaskawa Motoman has developed a Weldcom interface for the Power Wave machines that utilizes graphic-based ArcStart files and provides full functionality with Lincoln s built-in weld processes. This high-level interface queries the welder to present the user with the process library loaded in the machine, and presents weld settings with limits and units loaded from the Power Wave. The process library will be updated if new software is loaded into the power source or an STT or Advanced Module is added to the Power Wave. The high-speed Ethernet communication allows process changes on-the-fly while welding. The interface supports communication with Lincoln s Production Monitoring and CheckPoint functions. Weld profiles (200) can be set up from a PC with software from Lincoln; the teach pendant can be used to modify limits, set alarm conditions and view the results of each weld. The Ethernet communication permits multiple welders to be networked from a single controller, allowing two welders on one robot (Tandem-MIG) or multiple robots on a single controller (up to four). While designed for the higher speed ArcLink XT communication used in i400, R-series and S-series with AutoDrive 19 Control, this interface will also work with the Power Wave 455M and 655M power sources. The Ethernet-based Weldcom interface provides real-time communication between the robot and power source(s). This allows the robot controller to know exactly what processes are enabled in the welder, what the limits of those processes are, and in the event of synergic processes, it updates the limits as the workpoint changes. Unlike previous analog interfaces, the robot could only control two or three welding parameters, but the digital ArcLink XT interface allows control of all process-related parameters at the start, during and at the end of the weld. Selection of a Production Monitoring Profile is made in the Arc Start File. Screens are provided for editing Profile limits, displaying monitor results and controlling the robot s response to failed welds. A global setting permits the user to select if metric or imperial units are displayed on the pendant. A setup application is included to configure the power source from the robot and provide troubleshooting tools without the need for a PC. Multiple languages are supported in the Weldcom interface. The interface requires use of the ArcStart and ArcEnd files and has been designed to work with all existing arc welding features such as: Restart, Retry and Anti-stick. The DX controller offers 1,000 ArcStart and ArcEnd files which must be shared between multiple robots on the same controller. This interface does not allow the use of inline ArcOn commands (ARCON ARCCUR=XXXX ARCVOL=XX.X) and will not support the optional weld line shift function. Lincoln Weld Mode List: CV (Constant Voltage) For use on steel CV is the conventional mode for MIG welding. This general purpose MIG welding mode uses constant voltage for short arc, globular and spray transfer. Pulse For use on steel, stainless, aluminum and more Traditional MIG pulse mode uses a pulse for the metal transfer, which avoids a short and allows for a wide operating range, characterized by low to high wire feed speed, many different materials and virtually no spatter. Precision Pulse For use on steel and stainless This enhanced MIG pulse mode features a tight, focused arc for fast vertical up welding and outstanding out-of-position puddle control. Power Mode For use on steel, stainless and aluminum This enhanced MIG mode can deliver excellent arc stability with reduced spatter at high travels speeds, resulting from an extended short arc range at higher wire feed speed procedures. It also yields a tight and stable arc in spray transfer. RapidArc For use on steel and stainless RapidArc is an accelerated MIG pulse mode with a short arc compared to pulse and CV-spray for high travel speed applications. Pulse-on-Pulse For use on aluminum This arc modulation MIG pulse mode can deliver a TIG (GTAW)-like bead appearance. STT (Surface Tension Transfer ) For use on steel, stainless and high nickel This precision MIG short arc mode delivers premium and consistent root pass results on pipe with low reject rates and excellent gap bridging capabilities. STT can also be used to reduce spatter and control heat input on sheet metal applications. Requires STT module. Rapid X For use on steel and stainless Rapid X is a premium MIG pulse mode designed to deliver higher travels speeds and extremely low spatter levels with a short arc length. Requires STT module.
Page 4 of 8 Lincoln Weld Mode List (continued): AC Aluminum Pulse For use on aluminum GMAW aluminum welding results can be improved over traditional DC positive aluminum MIG welding. By switching the polarity of the arc, heat input is reduced and deposition rates are enhanced. Requires advanced module. Synchronized Tandem MIG For use on steel Synchronized tandem MIG overcomes deposition rate limitations of a single wire by using two wires and specific waveforms. The result is deposition rates nearly double rates possible with a single wire as well as faster travel speeds. Requires engineering support to spec complete robot, torch and power source package. Features: High-speed Ethernet interface utilizing two-way communication with power source via Lincoln s ArcLink XT protocol. High level implementation of Weld Results function with graphical display of weld parameters and Weld Results. Ability to edit limits in Profiles and control robot response to Weld Results from the teach pendant's color touch screen. Data is also mapped to robot variables and CIO for use in PLC controllers. Setup utility allows set up of Power Wave(s) on the Ethernet network from the robot teach pendant instead of a PC. This eases installation or replacement of power sources. Interface utilizes standard Ethernet port and does not require additional hardware. An additional welder can be networked to a single robot (Tandem-MIG), or multiple welders can be networked for multiple robots (up to four) from a single controller. PCs can be added to the network to access production monitoring data from the welders. Utilizes Weldcom ArcStart and ArcEnd files with graphic representation of preflow, starting condition, main conditions and multiple crater conditions. A total of 1,000 arc files are available and standard features such as Arc Retry and Arc Restart are supported. Full implementation of Power Wave s process library is supported; any process can be selected in ArcStart or ArcEnd file, and parameter naming, units and range is downloaded from the power source. If software on the welder is updated, the Motoman interface will allow full access to the updated process library. Complete access to Power Wave processes: CV, Pulse, Rapid-Arc, Power Mode, Pulse-on-Pulse and STT, AC or RapidX (with module option on R350/R500). Files present parameters in Lincoln terminology with allowable limits based on wire size and gas. CC, Stick and other processes are displayed, but not applicable to robot welding. The process list can be sorted to provide only those applicable to particular wire type, size and shielding gas. Units can be displayed in imperial or metric. Flexible process control through INFORM commands. Different processes and weld settings can be used for the arc start, during the weld or at the arc end by using the global file settings and the ARCON ASF(#), ARCSET ASF(#) or ARCOF AEF(#). Weld parameters can be tapered up or down using the ARCCTS ASF(#) or ARCCTE ASF(#). Welding robot is dressed with Yaskawa Motoman s standard GMAW package. This includes: mounting of wire feeder on the arm, wire feeder signals and shielding gas connected through internal harness, torch lead protected by leather sheathing, use of Lincoln power pin with Yaskawa Motoman s popular torch configurations. The Power Wave i400 is 400 Amps/60% duty cycle and 350 Amps/100% duty cycle. The R350 is rated at 350 Amps/40% duty cycle and 300 Amps/100% duty cycle. The R500 is rated at 500 Amps/40% duty cycle and 450 Amps/100% duty cycle. The S700 power source is rated at 700 Amps/100% duty cycle and requires the AutoDrive 19 feeder control for use with a robot. The interface supports GTAW/TIG welding with use of Dinse torch and cold wire feed unit. Requires STT module. Compatibility: DX200 controller (similar software for DX100 controller)
Page 5 of 8 Teach Pendant Screen Images: Monitoring Profiles can be edited on the pendant Production Monitoring results are displayed after each weld ArcStart and ArcEnd Process Selection Weld data can be viewed numerically and graphically Power Source Utility to map network setup ArcStart Starting Condition ArcStart Main Condition ArcEnd Crater Condition
Page 6 of 8 Drawing: Power Wave Kit Requirements: Standard MIG Dress Kits Lincoln P/N Motoman P/N Description Power Wave Power Source (1 required/robot) K2669-1 157917-1 Lincoln Power Wave i400 Power Source K3022-1 157917-2 Lincoln Power Wave R350 Power Source K3169-1 157917-6 Lincoln Power Wave R500 Power Source K3279-1 157917-7 Lincoln Power Wave S700 Power Source (AutoDrive 19 required) Optional STT Modules for STT and RapidX Processes (R350/R500) K2902-1 158237-1 STT Module for R350/ R500 K2912-1 158237-4 AC MIG/TIG/STT Advanced Module for R350/ R500 K940-25 158237-3 Sense lead for STT Module Feeders: Standard MIG Only (1 required/robot) K3002-1 157918-3 AutoDrive 4R100 (used for MA1440 & MA2010 robots, up to 0.045 wire) K2685-1 157918-2 AutoDrive 4R220 (used for MH & MA3120 robots, up to 1/16 solid wire) Drive Roll and Wire Guide Kits: Standard MIG Only (1 required/robot) Lincoln P/N Motoman P/N Description Wire Size in. (mm) KP1505-030S KP1505-035S KP1505-040S KP1505-045S KP1505-052S* KP1505-1/16S* KP1505-035C KP1505-045C KP1505-052C* KP1505-1/16C* KP1505-068* KP1505-5/64* KP1507-035A KP1507-040A KP1507-3/64A* KP1507-1/16A* A D 158246-1 158246-2 158246-3 158246-4 158246-5 158246-6 158247-1 158247-2 158247-3 158247-4 158247-5 158247-6 158248-1 158248-2 158248-3 158248-4 VIEW A B C Solid Steel Wire, Smooth V Groove Cored Steel Wire, Knurled V Groove Cored or Solid Steel Wire, Knurled V Groove Aluminum Wire, Smooth U Groove X A E Lincoln items to be supplied by customer or added to the kit by Yaskawa Motoman: A - power source B - feeder (4R100 is standard) C - wire drive feed roll kit D - optional module (R- or S-series) E - voltage sense cable X - items configured by length X.023 -.030 (0.6-0.8).035 (0.9).040 (1.0).040 -.045 (1.0-1.2).052 (1.4) 1/16 (1.6).030 -.035 (0.8-0.9).040 -.045 (1.0-1.2).052 (1.4) 1/16 (1.6).068 -.072 (1.8) 5/64 (2.0).035 (0.9).040 (1.0) 3/64 (1.2) 1/16 (1.6) * AutoDrive 4R220 only
Page 7 of 8 Power Wave Kit Requirements: AutoDrive SA (Servo Aluminum) Lincoln P/N Motoman P/N Description Power Wave Power Source (1 required/robot) K2823-3 157917-9 Lincoln Power Wave S350 Power Source K2904-1 157917-8 Lincoln Power Wave S500 Power Source K3279-1 157917-7 Lincoln Power Wave S700 Power Source Water Cooler Module (see Standard MIG table for other optional modules) K3086-2 158237-5 Water Cooler Module with flow switch Feeder and Torch SA (Servo Aluminum) kit K4147-MA1440 174393-1 Feeder, Lincoln, SA, One-Pak, MA1440 K4147-MA2010 174393-2 Feeder, Lincoln, SA, One-Pak, MA2010 Other items for kit in One-Pak Drive Rolls, 3/64 Std. MIG table Other Related Equipment Cables and gas hose to length 174394-x Water hoses (2 required) Lincoln P/N Motoman P/N Description N/A 158033-1 Lincoln ArcLink XT Interface Software (included in power source kits on page 1) K3004-1 170623-1 Lincoln AutoDrive 19 Feeder Control (for S-series power sources) K1543-8 173017-1 Control Cable, ArcLink (for AutoDrive 19) K2262-1 157917-3 Lincoln Power Wave 455M Robotic Power Source* K2263-1 157917-4 Lincoln Power Wave 455M w/stt Robotic Power Source* K1519-2 157917-5 Lincoln Power Wave 655R Robotic Power Source* K2207-2 158237-2 EtherNet/DeviceNet Board for Power Wave 455M N/A 143882-12 Lincoln Thread-in Power Pin N/A 158693-X* (-1 din-rail mounting, -2 w/panel) EtherNet Switch Kit, 8-Port (Required for multiple ArcLink XT welders or other Ethernet devices) N/A 155538-4 Managed EtherNet Switch (required for Power Wave 455/655 Power Sources) Optional Equipment Motoman P/N Description Digital Touch Sense (Approx. 60 VDC) 166735-1, -4 Accessory Kit, Digital* Touch Sense, DX200, Single - Quad 200 V Touch Sense 169523-1, -4 Accessory Kit, 200 V Touch Sense, DX200, Single - Quad 144388-1 Sensor Assembly, 200 V Touch Sense, TS-2 (Qty 1 per robot) 168714-x Cable Assembly, ComArc/TS, (3-10 m, 4 m std) (Qty 1 per robot) ComArc III with 200 V Touch Sense 169522-1, -4 Accessory Kit, ComArc (III or IV), DX200, Single - Quad 157918-2 Sensor Assembly, ComArc III (Qty 1 per robot) 168714-x Cable Assembly, ComArc/TS, (3-10 m, 4 m std), (Qty 1 per robot) * The 200 V ComArc IV touch sense circuit is not compatible with Lincoln power sources. The internal Lincoln circuitry (approx. 60 V) is recommended for touch sensing withe Power Waves. The older ComArc III, with blocking diode, would be required to perform 200 V touch sensing with Power Waves.
Page 8 of 8 Reference Information for Retrofit to Older Controllers: For controllers previous to DX100, an analog interface is required. It does not support Production Monitoring, but Lincoln has updated their analog interface to support multiple schedules with i400 and R350 power sources. Lincoln P/N Motoman P/N Description AD1359-1 159076-1 Lincoln Analog Interface N/A 137309-21 Interface Cable, Lincoln PW455M, 6.0 m N/A 155515-1 Interface Pigtail, I/O schedule select Please contact Customer Service for additional information regarding retrofit packages or to schedule field support for installation assistance. * All marks are the trademarks and registered trademarks of their respective owners.