busint x11 atcase;(phoenix, alpha q) - ewm ag · 2017. 3. 21. · operating instructions en...

Operating instructions

EN

Interface for digital welding power sources

BUSINT X11 ATCASE;(Phoenix, alpha Q)

099-008196-EW501 Observe additional system documents! 09.12.2015

General instructions

CAUTION

Read the operating instructions! The operating instructions provide an introduction to the safe use of the products. • Read the operating instructions for all system components! • Observe accident prevention regulations! • Observe all local regulations! • Confirm with a signature where appropriate.

In the event of queries on installation, commissioning, operation or special conditions at the installation site, or on usage, please contact your sales partner or our customer service department on +49 2680 181-0. A list of authorised sales partners can be found at www.ewm-group.com.

Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed accepted by the user on commissioning the equipment. The manufacturer is unable to monitor whether or not these instructions or the conditions and methods are observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect installation, improper operation or incorrect usage and maintenance or any actions connected to this in any way.

© EWM AG · Dr. Günter-Henle-Str. 8 · D-56271 Mündersbach, Germany The copyright to this document remains the property of the manufacturer. Reprinting, including extracts, only permitted with written approval. The content of this document has been prepared and reviewed with all reasonable care. The information provided is subject to change, errors excepted.

ContentsNotes on the use of these operating instructions

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1 Contents

1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 7 2.1 Notes on the use of these operating instructions .......................................................................... 7 2.2 Explanation of icons ....................................................................................................................... 8 2.3 General .......................................................................................................................................... 9

3 Intended use ......................................................................................................................................... 10 3.1 Applications .................................................................................................................................. 10 3.2 Revision ....................................................................................................................................... 10

4 Machine description – quick overview .............................................................................................. 11

5 Commissioning .................................................................................................................................... 12 5.1 General connection of the BUSINTX11 ....................................................................................... 12

5.1.1 The system bus ............................................................................................................ 12 5.1.2 Power supply ................................................................................................................ 12

5.1.2.1 Internal .......................................................................................................... 12 5.1.2.2 External ......................................................................................................... 12

5.1.3 Connection of fast actual value signals ........................................................................ 13 5.1.4 Collision protection connection ..................................................................................... 13

5.2 Basic configuration using plug-in jumpers ................................................................................... 13 5.2.1 Selecting fast actual value signals ............................................................................... 13 5.2.2 JOB mode selection ..................................................................................................... 13

5.3 Selecting the actuation profile ...................................................................................................... 13 5.4 Field bus connection and configuration ....................................................................................... 14

5.4.1 Interbus-S optical fibre ................................................................................................. 14 5.4.1.1 Field bus connection ..................................................................................... 14 5.4.1.2 Baud rate ....................................................................................................... 14 5.4.1.3 Status display ................................................................................................ 14 5.4.1.4 Data capacity ................................................................................................ 14

5.4.2 CAN Open .................................................................................................................... 15 5.4.2.1 Module specification...................................................................................... 15 5.4.2.2 Module, layout of display and operating elements ........................................ 15 5.4.2.3 Meaning of the LEDs .................................................................................... 15 5.4.2.4 Connection of the CANopen module ............................................................ 16 5.4.2.5 Setting the baud rate ..................................................................................... 16 5.4.2.6 Setting the subscriber address ..................................................................... 16 5.4.2.7 EDS configuration file ................................................................................... 16

5.4.3 CAN DeviceNet ............................................................................................................ 17 5.4.3.1 Module specification...................................................................................... 17 5.4.3.2 Module, layout of display and operating elements ........................................ 17 5.4.3.3 Meaning of the LEDs .................................................................................... 17 5.4.3.4 Connection of the CAN DeviceNet module ................................................... 18 5.4.3.5 Network settings ............................................................................................ 18 5.4.3.6 EDS configuration file ................................................................................... 18

5.4.4 Profibus ........................................................................................................................ 19 5.4.4.1 Module specification...................................................................................... 19 5.4.4.2 Module, layout of display and operating elements ........................................ 19 5.4.4.3 Meaning of the LEDs .................................................................................... 19 5.4.4.4 Connection of the Profibus module ............................................................... 20 5.4.4.5 Setting the subscriber address ..................................................................... 20 5.4.4.6 Baud rate ....................................................................................................... 21 5.4.4.7 Network termination ...................................................................................... 21 5.4.4.8 GSD file ......................................................................................................... 21

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5.4.5 Profinet.......................................................................................................................... 22

5.4.5.1 Module specification ...................................................................................... 22 5.4.5.2 Module, position of the display elements ...................................................... 22 5.4.5.3 Meaning of the LEDs ..................................................................................... 23 5.4.5.4 Connecting the Profinet module .................................................................... 23 5.4.5.5 Setting the subscriber address ...................................................................... 23 5.4.5.6 GSDXML file .................................................................................................. 23

5.4.6 EthernetIP ..................................................................................................................... 24 5.4.6.1 Module specification ...................................................................................... 24 5.4.6.2 Module, position of the display elements ...................................................... 24 5.4.6.3 Meaning of the LEDs ..................................................................................... 25 5.4.6.4 Connecting the EthernetIP module ............................................................... 25 5.4.6.5 Setting the subscriber address ...................................................................... 26

5.4.7 EtherCAT ...................................................................................................................... 29 5.4.7.1 Module specification ...................................................................................... 29 5.4.7.2 Module, layout of display and operating elements ........................................ 29 5.4.7.3 Meaning of the LEDs ..................................................................................... 30 5.4.7.4 EtherCAT module connection ....................................................................... 30 5.4.7.5 ESI configuration file ..................................................................................... 30

5.5 Data profile selection .................................................................................................................... 31 5.6 Switching on the BUSINTX11 ...................................................................................................... 31 5.7 Field bus configuration ................................................................................................................. 31

6 Operative mode .................................................................................................................................... 32 6.1 Pre-selecting a JOB ..................................................................................................................... 32 6.2 Program operation ....................................................................................................................... 32 6.3 JOB mode .................................................................................................................................... 32

6.3.1 Advanced control signal operation ............................................................................... 32 6.3.2 Operating modes .......................................................................................................... 33

6.3.2.1 Non-latched mode ......................................................................................... 33 6.3.2.2 Special, non-latched ...................................................................................... 33 6.3.2.3 Spot welding .................................................................................................. 33

6.4 Welding types ............................................................................................................................... 34 6.5 Monitoring function ....................................................................................................................... 34

6.5.1 Monitoring function ....................................................................................................... 34 6.5.2 Display options ............................................................................................................. 34 6.5.3 Monitoring parameters .................................................................................................. 34 6.5.4 Special features of the monitoring function .................................................................. 35

6.6 Other signals ................................................................................................................................ 36 6.6.1 JOB pre-selection ......................................................................................................... 36 6.6.2 Program pre-selection .................................................................................................. 36 6.6.3 Acknowledge error ........................................................................................................ 36 6.6.4 Gas test 1 ..................................................................................................................... 36 6.6.5 Wire Inching .................................................................................................................. 36 6.6.6 Reverse wire inching .................................................................................................... 36 6.6.7 Position search ............................................................................................................. 36 6.6.8 Blow out torch ............................................................................................................... 36 6.6.9 Robot ready .................................................................................................................. 36 6.6.10 Welding simulation ........................................................................................................ 36 6.6.11 JOB mode ..................................................................................................................... 36 6.6.12 User-defined outputs K1 to K4 ..................................................................................... 36 6.6.13 WF switching ................................................................................................................ 36 6.6.14 Tandem operation ......................................................................................................... 36 6.6.15 Inching mode ................................................................................................................ 37 6.6.16 superPuls ...................................................................................................................... 37 6.6.17 Liftarc ............................................................................................................................ 37 6.6.18 Spot welding on ............................................................................................................ 37

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6.7 Check-back of the process parameters ....................................................................................... 37

6.7.1 I > 0 (Current flows signal) ........................................................................................... 37 6.7.2 User-defined inputs ...................................................................................................... 37 6.7.3 Process active .............................................................................................................. 37 6.7.4 Main current signal ....................................................................................................... 37 6.7.5 Collision protection ....................................................................................................... 37 6.7.6 Ready for welding ......................................................................................................... 38 6.7.7 Sticking ......................................................................................................................... 38 6.7.8 Error number ................................................................................................................ 39 6.7.9 Warning number ........................................................................................................... 39 6.7.10 Actual welding voltage value ........................................................................................ 39 6.7.11 Actual welding current value ........................................................................................ 39 6.7.12 Actual wire feed speed value ....................................................................................... 39 6.7.13 Actual motor current value ........................................................................................... 39 6.7.14 Parameter monitoring ................................................................................................... 39 6.7.15 Process signals diagram .............................................................................................. 40 6.7.16 Signals for matching with the positioning device .......................................................... 41 6.7.17 Ignition time: TZ-Zünd .................................................................................................. 41 6.7.18 TZ-Set ........................................................................................................................... 41 6.7.19 Arc interruption time: TZ-LIBO ..................................................................................... 42 6.7.20 Return time, TZ-Reset .................................................................................................. 42

6.8 Fusing detection ........................................................................................................................... 43 6.9 Position search ............................................................................................................................ 43 6.10 Welding seam tracking ................................................................................................................ 43 6.11 Welding simulation ....................................................................................................................... 43 6.12 Process fast shut-down ............................................................................................................... 43 6.13 Process safety shut-down ............................................................................................................ 44 6.14 JOB safety switching.................................................................................................................... 44 6.15 Support of welding circuit alignment ............................................................................................ 44 6.16 Advanced JOB selection .............................................................................................................. 44

7 The diagnostics interface .................................................................................................................... 45 7.1 PC system requirements ............................................................................................................. 45

8 Commissioning .................................................................................................................................... 45 8.1 Scope of diagnostics .................................................................................................................... 45

9 Data profiles ......................................................................................................................................... 46 9.1 Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line)

modules ....................................................................................................................................... 46 9.1.1 Default profile (switch position 0) ................................................................................. 46 9.1.2 Profile for Multimatrix machines (switch position 1) ..................................................... 52

9.2 Profiles for the CANopen module ................................................................................................ 59 9.2.1 Reis Robotics profile (switch position 0)....................................................................... 59 9.2.2 Profile for Multimatrix machines (switch position 1) ..................................................... 66

9.3 Profiles for the CAN DeviceNet module....................................................................................... 73 9.3.1 Default profile (switch position 0) ................................................................................. 73 9.3.2 Profile 1 (switch position 1) .......................................................................................... 79 9.3.3 Profile for Multimatrix machines (switch position 2) ..................................................... 82

9.4 Profiles for the Profibus DP module ............................................................................................. 92 9.4.1 Default profile (switch position 0) ................................................................................. 92 9.4.2 Flexible profile (switch position 1) ................................................................................ 98 9.4.3 Compatible profile (switch position 2) ......................................................................... 104 9.4.4 Profile for Multimatrix machines (switch position 3) ................................................... 110

9.5 Profiles for the Profinet and Profinet-LWL modules .................................................................. 117 9.5.1 Reis Robotics profile (switch position 0)..................................................................... 117 9.5.2 Profile for Multimatrix machines (switch position 1) ................................................... 123

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9.6 EthernetIP module profiles ......................................................................................................... 130

9.6.1 Default profile (switch position 0) ................................................................................ 130 9.6.2 FANUC Robotics profile (switch position 1) ................................................................ 136 9.6.3 Notes on the profile ..................................................................................................... 141 9.6.4 Profile for Multimatrix machines (switch position 2) ................................................... 142 9.6.5 Profile for Multimatrix machines with FANUC robots (switch position 3) ................... 149 9.6.6 Notes on the profile ..................................................................................................... 155

9.7 Profiles for the EtherCAT module .............................................................................................. 156 9.7.1 Default profile (switch position 0) ................................................................................ 156 9.7.2 Profile for Multimatrix machines (switch position 1) ................................................... 162

10 Special field bus features when setting up the field bus modules ............................................... 169 10.1 CAN DeviceNet .......................................................................................................................... 169

10.1.1 Connections ................................................................................................................ 169 10.1.2 Example for I/O data ................................................................................................... 169 10.1.3 Example of a connection assignment ......................................................................... 170

10.2 Profibus DP ................................................................................................................................ 170 10.2.1 The watchdog ............................................................................................................. 170 10.2.2 DP features ................................................................................................................. 170

10.3 EtherCAT ................................................................................................................................... 171 10.3.1 Machine installation .................................................................................................... 171 10.3.2 Manual integration of a machine ................................................................................ 172 10.3.3 Search for a machine .................................................................................................. 172 10.3.4 Process data view ....................................................................................................... 172

11 Operating problems, causes and remedies ..................................................................................... 173 11.1 Operating displays (LEDs) ......................................................................................................... 173 11.2 Warnings (power source) ........................................................................................................... 174

12 Error messages on the system ......................................................................................................... 175 12.1 General system erors ................................................................................................................. 175 12.2 Process error .............................................................................................................................. 175

13 Overview of plug configurations ...................................................................................................... 176 13.1 X4, digital inputs ......................................................................................................................... 176 13.2 X5, digital outputs ....................................................................................................................... 176 13.3 X7, analogue inputs ................................................................................................................... 176 13.4 X10, diagnostics interface .......................................................................................................... 177 13.5 X15, external power supply ........................................................................................................ 177

14 Overview of the BUSINT X11 jumper assignment ........................................................................... 178

15 Configuration data overview ............................................................................................................. 179 15.1 Resetting the configuration data ................................................................................................ 180

16 Circuit diagrams ................................................................................................................................. 181

17 Appendix A .......................................................................................................................................... 182 17.1 Overview of EWM branches....................................................................................................... 182

Safety instructionsNotes on the use of these operating instructions

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2 Safety instructions 2.1 Notes on the use of these operating instructions

DANGER

Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. • The hazard is also highlighted using a symbol on the edge of the page.

WARNING

Working or operating procedures which must be closely observed to prevent serious and even fatal injuries. • Safety notes include the "WARNING" keyword in the heading with a general warning

symbol. • The hazard is also highlighted using a symbol in the page margin.

CAUTION

Working or operating procedures which must be closely observed to prevent possible minor personal injury. • The safety information includes the "CAUTION" keyword in its heading with a general

warning symbol. • The risk is explained using a symbol on the edge of the page.

CAUTION

Working and operating procedures which must be followed precisely to avoid damaging or destroying the product. • The safety information includes the "CAUTION" keyword in its heading without a general

warning symbol. • The hazard is explained using a symbol at the edge of the page.

Special technical points which users must observe.

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.: • Insert the welding current lead socket into the relevant socket and lock.

Safety instructions Explanation of icons

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2.2 Explanation of icons

Symbol Description

Special technical points which users must observe.

Correct

Wrong

Press

Do not press

Press and keep pressed

Turn

Switch

Switch off machine

Switch on machine

ENTER enter the menu

NAVIGATION Navigating in the menu

EXIT Exit the menu

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

l

0

l

0

Safety instructionsGeneral

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2.3 General

WARNING

Risk of accidents due to non-compliance with the safety instructions! Non-compliance with the safety instructions can be fatal! • Carefully read the safety instructions in this manual! • Observe the accident prevention regulations and any regional regulations! • Inform persons in the working area that they must comply with the regulations!

Validity of the document! This document is valid only in combination with the operating instructions for the product being used! • Read and observe the operating instructions for all system components, especially the

safety instructions!

CAUTION

Obligations of the operator! The respective national directives and laws must be observed for operation of the machine! • National implementation of the framework directive (89/391/EWG), as well as the

associated individual directives. • In particular, directive (89/655/EWG), on the minimum regulations for safety and health

protection when staff members use equipment during work. • The regulations regarding work safety and accident prevention for the respective country. • Setting up and operating the machine according to IEC 60974-9. • Check at regular intervals that users are working in a safety-conscious way. • Regular checks of the machine according to IEC 60974-4.

Damage due to the use of non-genuine parts! The manufacturer's warranty becomes void if non-genuine parts are used! • Only use system components and options (power sources, welding torches, electrode

holders, remote controls, spare parts and replacement parts, etc.) from our range of products!

• Only insert and lock accessory components into the relevant connection socket when the machine is switched off.

Intended use Applications

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3 Intended use

WARNING

Hazards due to improper usage! Hazards may arise for persons, animals and material objects if the equipment is not used correctly. No liability is accepted for any damages arising from improper usage! • The equipment must only be used in line with proper usage and by trained or expert staff! • Do not modify or convert the equipment improperly!

3.1 Applications The following operation instructions describe the commissioning and functionality of the BUSINT X11 fieldbus interface in combination with certain fieldbusses. The interface is intended for operation on digital power sources in the Phoenix and alpha Q machine series. BUSINT X11 has numerous options for actuation which are fully supported by the PC300.NET PC300.NET welding parameter software. We recommend to use the PC300.NET software wherever possible to PC300.NET configure BUSINT X11.

3.2 Revision Revision Date Change

1.0 06/01/2012 Draft version

1.1 15/11/2012 EtherCAT standard added

1.2 18/05/2015 Support of Multimatrix power sources

1.3 20/11/2015 Manual signals for superPuls and lift arc Selection of advanced JOBs for Multimatrix machines Support of welding circuit alignment Signalling of warnings Advanced error logic

Machine description – quick overviewRevision

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4 Machine description – quick overview

Figure 4-1

Item Symbol Description 0

1 System bus connection

2 Connection of diagnostics interface for Analyzer

3 Through-wiring to connect machine functions

2 System interface to connect the system interface for automated welding

5 Strain reliefs for bus/control cables

6 External voltage supply module

3 Connection for the bus supply

4 Switching voltage connection for hardware-targeted emergency shutdown of the system

Commissioning General connection of the BUSINTX11

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5 Commissioning This chapter describes for you the commissioning process of the BUSINTX11, step-by-step, as well as its operating functions.

5.1 General connection of the BUSINTX11 5.1.1 The system bus

BUSINT X11 is integrated into the welding system by means of a digital system bus. Depending on the control installation type, connection is possible in two ways: • Connection via the 15-pole SUB-D connector X12, if BUSINT X11 is mounted on the power source (in

an external housing at the rear side of the power source).

• Connection via the 7-pole connector X13 with control cable. This is the preferred connection method with external installation of BUSINT X11, e.g. in an electrical enclosure.

In general it is important to keep the bus cables for the connection of BUSINT X11 to the relevant fieldbus as far away as possible from any sources of interference (e.g. HF loaded or carrying cabling), as otherwise the bus assemblies may become damaged due to overvoltage.

5.1.2 Power supply 5.1.2.1 Internal

The interface is normally supplied with power via a standalone, isolated power supply via the system bus. The bus node remains addressable as long as the welding power source is switched on.

5.1.2.2 External So that the bus node remains functional even after the system is shut down (e.g. for continued operation of the user-defined inputs and outputs), an optional, external voltage of 24V DC must be used which is powered by a separate module!

Depending on the design of the control, the PCBs vary for the power supply. The table below clarifies the connection of the voltage:

System PCB Plug Pin Polarity

SV+/-15V/1A X5 1 +24V

X5 2 GND

SV IBUS3 X2 1 +24V

X2 2 GND

Depending on the field bus used, an external power supply is required (e.g. on the Interbus). When using the external power supply, the original EWM module must be used, otherwise the potential isolation within the system is cancelled. EWM accepts no responsibility for operating problems caused by this.

CommissioningBasic configuration using plug-in jumpers

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5.1.3 Connection of fast actual value signals The BUSINTX11 normally supplies actual process values with an update of approx. 30ms for the process voltage, current, wire speed and motor current process values. For seam tracking, however, fast signals are required for voltage and current. These can be provided via the interface for mechanised welding on the BUSINTX11:

Plug Pin Signal

X7 2 Actual process voltage value

X7 3 Actual process current value

X7 4 Reference mass (GND)

The interface for mechanised welding is supplied as standard for the PHOENIX, but not for the TETRIX. The use of fast actual value signals for the seam tracking is optional and must be ordered separately!

5.1.4 Collision protection connection A corresponding signal can be connected to the BUSINTX11 for connecting and powering a torch collision protection signal on the field bus:

Plug Pin Signal

X4 1 Powering an external collision contact

X4 2 Feedback signal from collision contact

A separate 24V signal is used for the collision protection. It is essential to ensure that the installation is free of short-circuits. The supply is short-circuit-proof, however the input becomes unusable for the duration of the short-circuit.

5.2 Basic configuration using plug-in jumpers These settings must be made before switching on the power source/external power source. The BUSINTX11 has a series of jumpers to configure various basic settings that cannot be changed during operation.

5.2.1 Selecting fast actual value signals To transmit fast actual process values for voltage to use the workpiece search function, jumper JP2 should be configured as follows:

JP 2 Function

- Actual values via system bus (factory setting)

X Actual values are expected via plug X7

X = Jumper plugged in

5.2.2 JOB mode selection If settings such as operating mode, welding type or superPuls are to be controlled using the program number, jumper JP4 has to be configured as follows:

JP 4 Function

- Data are applied from the manual actuation signals as usual.

X The program number controls the function directly.

X = Jumper plugged in

5.3 Selecting the actuation profile The profile must be selected before the power source is switched on. If the interface is supplied with power via the external power supply, this should also be enabled for a change of profile as well as for a shut-down of the welding power source. Various actuation profiles are available for connection to different controls for operating BUSINTX11 independently of the field bus type, welding system and development status. These are selected using a selector switch S1 with 16 positions.

Commissioning Field bus connection and configuration

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5.4 Field bus connection and configuration Different steps are required for commissioning, depending on the field bus, and these steps are described below.

5.4.1 Interbus-S optical fibre No address setting is required for the configuration of the Interbus subscriber as this is given by the position of the subscriber in the Interbus. The subscriber identifies with the ID3 as a module with digital I/O.

5.4.1.1 Field bus connection The field bus is connected via optical fibres using FSMA rapid-action connectors:

Plug Function

U7 Incoming interface, transmit line

U10 Incoming interface, receive line

U8 Outgoing interface, transmit line

U11 Outgoing interface, receive line

Figure 5-1

5.4.1.2 Baud rate The module baud rate can be selected between 500kBaud and 2Mbaud using a jumper.

Figure 5-2

5.4.1.3 Status display The status of the module on the Interbus is indicated as follows using a block of LEDs:

LED Signal Colour Meaning

1 CC/RC Green Cable connection OK, master is not in reset status

2 BA Green Bus is in data exchange

3 RD Yellow Remote bus shut down

4 TR Green PCP communication active

5 FO1 Yellow Warning for recipient of the bus input side

6 FO2 Yellow Warning for recipient of the bus output side

Figure 5-3

5.4.1.4 Data capacity The data width to be configured at the interbus depends on the data profile used.

CommissioningField bus connection and configuration

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5.4.2 CAN Open 5.4.2.1 Module specification

The CANopen module is based on the DS301 v4.02 standard. The data exchange is carried out via the first 3 standard PDOs (process data objects) 1 to 3.

5.4.2.2 Module, layout of display and operating elements The module is equipped with several display and operating elements at the side of the PCB:

2

3

1

4

5

Figure 5-4

Element no. Meaning

1 CANopen interface

2 Baud rate setting

3 10 digit subscriber address setting

4 1 digit subscriber address setting

5 Status LEDs

5.4.2.3 Meaning of the LEDs The module is fitted with a block of 4 LEDs that signal the status of the module during operation:

LED Status Meaning

RUN Off No operating voltage in the module

Single flashing Module in STOP mode

Flashing Module in PRE-OPERATIONAL mode

On Module in OPERATIONAL mode

POWER Off No operating voltage in the module

On Operating voltage present

ERROR Off No error

Single flashing Warning limit reached

ERROR Double flashing Error control event

Triple flashing Synchronisation error

On Bus switched off


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5.4.2.4 Connection of the CANopen module The field bus is connected via a 9-pole SUB-D plug connector (socket). The layout of the module signals (plugs) is as follows:

Pin Signal Function

2 CAN_L Low signal cable of the CAN difference signal

3 CAN_GND Reference mass of the CAN signal

5 CAN_SHLD Connection for cable shield

7 CAN_H High signal cable of the CAN difference signal

Male1 5

6 9

Figure 5-5

5.4.2.5 Setting the baud rate The field bus module must be set to the baud rate used on the network using a selector switch:

Selector switch setting Baud rate

1 10kbps

2 20kbps

3 50kbps

4 125kbps

5 250kbps

6 500kbps

7 800kbps

8 1Mbps

The baud rate setting is only active after switching on the supply voltage and after re-starting the module.

5.4.2.6 Setting the subscriber address The module must be assigned a unique address which is a one-off in the network before commissioning. This is carried out via two selector switches in a range of 1 to 99. The right-hand switch selects the single place digit, and the left-hand switch selects the tens place digit for the address setting. The setting is carried out in decimal format: Example: Address 42 = left-hand switch position 4 (x10) + right-hand switch position 2 (x1)

Figure 5-6

5.4.2.7 EDS configuration file The module settings can be modified via an EDS file. In this case, however, the option of configuration via the bus master is a requirement (not possible in all cases). A suitable EDS files can be provided by EWM AG if required.


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5.4.3 CAN DeviceNet 5.4.3.1 Module specification

The CAN DeviceNet module is implemented in accordance with the ODVA specifications as a communication adapter (profile no.12) and behaves as a group 2 server on the network. The data modes Polled, Bit-Strobed and COS/Cyclic are supported.

5.4.3.2 Module, layout of display and operating elements The CAN-DeviceNet module has a variety of operating elements arranged on the PCB side:

2

1

3

Figure 5-7

Element no. Meaning

1 CAN DeviceNet interface

2 Address switch

3 Status indicators


LED Status Meaning

1 – Not used - -

2 – Network status Off No operating voltage on the module/module not online

On – Green Connection OK, module connected

Flashing – Green Module is online but not connected

On – Red Critical connection error

Flashing – Red Connection timeout

3 – Module status Off No operating voltage

On – Green Module is ready for operation

Flashing – Green Data frame larger than configured

On – Red Critical error

Flashing – Red Error

4 – Reserved - -

Figure 5-8


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5.4.3.4 Connection of the CAN DeviceNet module The field bus is connected via a 5-pole panel connector as follows:

Pin Signal Function

1 V- Supply voltage reference mass

2 CAN_L Low signal cable of the CAN difference signal

3 CAN_SHLD Connection for cable shield

4 CAN_H High signal cable of the CAN difference signal

5 V+ +24V power supply

Figure 5-9

The 24V power supply is essential for operating the field bus!

5.4.3.5 Network settings In the DeviceNet, every subscriber must be assigned a unique and one-off address in the range of 0 to 63. Every subscriber must also be set to the same baud rate. Eight configuration switches are used to set the baud rate and address.

Address (MAC) The address is set as follows via switches 3 to 8:

MAC ID Switch 3 (MSB)

Switch 4 Switch 5 Switch 6 Switch 7 Switch 8 (LSB)

0 Off Off Off Off Off Off

1 Off Off Off Off Off On

2 Off Off Off Off On Off

3 Off Off Off Off On On

... ... ... ... ... ... ...

62 On On On On On Off

63 On On On On On On

Baud rate The baud rate is set via configuration switches 1 and 2:

Baud rate Switch 1 Switch 2

125k Off Off

250k Off On

500k On Off

Reserved On On

5.4.3.6 EDS configuration file The module settings can be modified via an EDS file. In this case, however, the option of configuration via the bus master is a requirement.

For further setup!


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5.4.4 Profibus 5.4.4.1 Module specification

The Profibus module supports cyclical data exchange according to the PROFIBUS-DP EN 50 170 specification (DIN 19245).

5.4.4.2 Module, layout of display and operating elements The Profibus module has a variety of operating elements arranged on the PCB side:

2

1

3

4

Figure 5-10

Element no. Meaning

1 Profibus interface

2 Terminating switch

3 Address switch

4 Status indicators


LED Status Meaning

1 - -

2 On – Green Module is connected to the Profibus, communication is possible

Off Module is not connected

3 On – Red Module is not connected to the Profibus, no communication is possible

Off Module is not connected

4 Flashing, 1Hz Error in configuration (1)

Flashing, 2Hz Error in parameter data (1)

Flashing, 4Hz Error when initialising the Profibus communication

Off No diagnostics active

(1) Pre-defined data length of the module does not match the network configuration.


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5.4.4.4 Connection of the Profibus module The field bus is connected via a 9-pole SUB-D plug connector (socket) as follows:

Pin Signal Function

3 B-signal Positive communication signal according to RS485

4 RTS Send request signal

5 GND Isolated reference mass for field bus

6 +5V Isolated reference voltage for field bus

8 A-signal Negative communication signal according to RS485

�

Figure 5-11

5.4.4.5 Setting the subscriber address The module must be assigned a unique address which is a one-off in the network before commissioning. This is carried out via two selector switches in a range of 1 to 99. The right-hand switch selects the single place digit, and the left-hand switch selects the tens place digit for the address setting. The setting is carried out in decimal format: Example: Address 42 = left-hand switch position 4 (x10) + right-hand switch position 2 (x1)

Figure 5-12

The settings for the network address must be set before the module is commissioned. Any subsequent change to the setting only becomes effective after the power is enabled and after switching the module back on.


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5.4.4.6 Baud rate The module is equipped with automatic baud rate detection and therefore requires no additional setting work. The following baud rates are supported: 9.6kbit/s, 19.2kbit/s, 93.75kbit/s, 187.5kbit/s, 500kbit/s, 1.5Mbit/s, 3Mbit/s, 6Mbit/s, 12Mbit/s

5.4.4.7 Network termination The Profibus network must be terminated on the line terminals to avoid signal reflections on the bus medium. To do this, the module has an appropriate configuration switch:

Switch position Setting

On Bus termination is switched on. Must be activated if the subscriber is on the first or last position and no external termination is being used.

Off Bus termination is switched off.

When using external termination (supported by various plugs, for example), the switch must be switched to “Off”.

5.4.4.8 GSD file The subscriber configuration is carried out via the GSD file supplied.

For further setup!


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5.4.5 Profinet 5.4.5.1 Module specification

The Profinet module supports cyclical data communication as a Profinet I/O device conforming to classes B and C, with classes 1, 2 and 3 in real-time communication.

5.4.5.2 Module, position of the display elements The Profinet module features several display elements, which are positioned at the front of the PCB:

2

1

3

Figure 5-13

Element Description

1 Ethernet connection 1


3 Status displays


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5.4.5.3 Meaning of the LEDs

Figure 5-14

The module features a 4 LED unit signalling the module status during operation:

Element Display Status Meaning

1 Connection/activity (1)

Green Connection established at connection 1

Green, flashing Receiving/sending data at connection 1

Off No connection at connection 1

2 Communication status

Green Online, run Connection established with I/O controller I/O controller in run mode

Green, flashes once Online, stop Connection established with I/O controller I/O controller in stop mode

Off Offline No connection with I/O controller

3 Module status Green Initialised, no error

Green, flashes once Diagnostic data available

Green, flashes twice Used by setup tools to identify the module

Red, flashes once Configuration error Number of modules exceeded I/O controller's I/O size too big

Red, flashes three times No station name available or no IP address assigned

Red, flashes four times Internal error

Off No voltage at module or not configured



Green, flashing Receiving/sending data at connection 2


5.4.5.4 Connecting the Profinet module The module is connected via a standard RJ-45 connector. The module features a dual switch with equal connections, i.e. port 1 and port 2 can be used for connection. This way, line structures can be created.

5.4.5.5 Setting the subscriber address A unique network address has to be assigned to the module before commissioning. With Profinet the address and station name of the module are assigned as part of the configuration by using a Profinet engineering system.

5.4.5.6 GSDXML file The member description is provided in the supplied GSDXML file.


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5.4.6 EthernetIP 5.4.6.1 Module specification

The EthernetIP module supports cyclical data communication as a communication adapter and also supports the "Common Industrial Protocol" (CIP).

5.4.6.2 Module, position of the display elements The EthernetIP module features several display elements, which are positioned at the front of the PCB:

2

1

3

4

Figure 5-15

Element Description



3 Address switch

4 Status indicators


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�

Figure 5-16

The module features a 4 LED unit signalling the module status during operation:

Element Display Status Meaning



Green, flashing Receiving/sending data at connection 1 with 100 MB

Yellow Receiving/sending data at connection 1 with 10 MB


2 Module status Off No voltage at module or not configured

Green Controlled by a controller in run mode

Green, flashing Module not configured or controller in idle mode

Red, flashing A resolvable error has occurred

Red An unresolvable error has occurred

3 Network status Off No supply voltage or no IP address has been assigned

Green Online, one or more connections have been established

Green, flashing Online, no connection has been established

Red Duplicate IP address

Red, flashing Timeout of one or more connections



Green, flashing Receiving/sending data at connection 2 with 100 MB

Yellow Receiving/sending data at connection 2 with 10 MB


5.4.6.4 Connecting the EthernetIP module The module is connected via a standard RJ-45 connector. The module features a dual switch with equal connections, i.e. port 1 and port 2 can be used for connection. This way, line structures can be created.


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5.4.6.5 Setting the subscriber address

Using the address switch

�

Figure 5-17

One method to set the IP address is to use the address switches provided by the module. In this case, the address range is limited to network 192.168.0.X, where X is the value which can be encoded by the address switch.

In the BCD code the 8 individual switches define the corresponding values of the last address, starting with switch 8. The values are 1, 2, 4, 8, 16, etc. This means the last address block of the IP address is built from the sum of the individual values of the activated switches.

As an example, the illustration shows address 192.168.0.213 built from: 128 + 64 + 16 + 4 + 1 .

Changes to the address switches will be applied the next time BUSINT X11 is switched on.

The IP address is provided by the switch configuration once one of the switches is activated. To use a different address allocation method, deactivate all switches.


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Using IPconfig

IPconfig searches the network for BUSINT X11 interfaces without the need to set a network address at the module first. All interfaces detected are listed. To make the search easier, the module returns "EWM BUSINT X11".

Select the module to be configured by double-clicking it.

�

Figure 5-18


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You can now enter the required settings in the address screen. If you want to use a DHCP server you can enable that option as well.

The "Change password" option enables the password function. If used, access via IPconfig is protected by a password. To apply the settings, click the "Set" button.

�

Figure 5-19

The summary screen should now show the module with the changed address data. The module is now configured.

�

Figure 5-20


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5.4.7 EtherCAT 5.4.7.1 Module specification

The EtherCAT interface supports the DS301 v4.02 specification and uses the CANopen over Ethernet standard as application interface. Data is exchanged via process data objects. The interface has two RJ-45 connections to support direct line topologies, eliminating the need for an Ethernet switch to integrate the system.

5.4.7.2 Module, layout of display and operating elements

2

1

3

Figure 5-21

Element no. Meaning

1 Ethernet port 1 (input)

2 Ethernet port 2 (output)

3 Status indicators


30 099-008196-EW50109.12.2015


�

Figure 5-22

The module is equipped with a block of 4 LEDs indicating the module status during operation:

LED Status Meaning

Link/Activity1 Off No connection at input 1

Green Connection at input 1

Green, flashing Data communication at input 1

RUN Off Machine is in initialisation state

Green, flashing Machine is in PRE-OPERATIONAL state

Green, flashing, single

Machine is in SAFE-OPERATIONAL state

Green Machine is in OPERATIONAL state

ERR Off EtherCAT communication functioning correctly

Red, flashing General configuration error

Red, flashing, single EtherCAT slave has changed state by itself

Red, flashing, double Time monitoring error of the Synch manager

Red Time monitoring error of the application

Link/Activity2 Off No connection at input 2

Green Connection at input 2

Green, flashing Data communication at input 2

5.4.7.4 EtherCAT module connection The field bus is connected via an RJ-45 connector.

5.4.7.5 ESI configuration file All module settings are defined automatically via the EtherCAT master. To that end, a configuration file has to be installed in the engineering program

CommissioningData profile selection

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5.5 Data profile selection The profile must be selected before the power source is switched on. If the interface is supplied with power via the external power supply, this should also be enabled for a change of profile as well as for a shut-down of the welding power source. Various actuation profiles are available for connection to different controls for operating BUSINTX11 independently of the field bus type, welding system and development status. These are selected using a selector switch S1 with 16 positions.

5.6 Switching on the BUSINTX11 The interface is put into operational mode by switching on the connected power source or the external voltage supply (if present). The module then runs a sequence of self-diagnostic steps and checks the readiness of individual components. Depending on the fieldbus type the initialisation phase can take a while. To indicate this status, LEDs 7 to 10 flash from left to right. When the initialisation is complete, LEDs 7 to 10 no longer light up. If an error is detected this is indicated by a combination of flashes by LEDs 7 and 8. In this case the module is not or only partly ready for operation.

Indication of the error starts with a flashlight code by LED 7 with signals lasting 1 s. The number of the following flash signals (approx. 2 Hz) of LED 8 represents the error code.

Number of flash signals LED 7 (error type)

Number of flash signals LED 8 (error)

Meaning

1 1 Error determining module configuration

1 2 For internal use only

1 3 Error initialising operating memory

2 1 Fieldbus module does not exist or is damaged

2 2 Error initialising memory

2 3 Module not supported by current software version

2 4 Set profile not assigned; the default profile will be applied and the interface is ready for operation despite the error indication

3 1 Power source type not supported; an attempt has been made to operate a Tetrix power source with a BUSINT X11 Phoenix or vice versa

The error code is cyclically repeated, with the sequence starting again at LED 7. When the diagnosis has been completed successfully, LEDs 7 and 8 do not light up. If the power source is switched on, LEDs 11 and 12 should start flashing with a high frequency after a short period. The module is now ready for configuration via the fieldbus.

5.7 Field bus configuration This is carried out in conformity with the relevant standards via specific parameters which are normally transferred to the field bus module, or synchronised, using the bus master. Please also see the relevant operating instructions for the field bus master for more information.

Operative mode Pre-selecting a JOB

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6 Operative mode 6.1 Pre-selecting a JOB

The PHOENIX has a wide range of adjustable parameters available which are managed using what are known as JOBs. The corresponding welding task is defined using a JOB. A total of 255 JOBs can be set (1 to 255). The JOB pre-selection can only be carried out by the machine if the “Machine JOB pre-selection” bit has been set (set automatically in some actuation profiles and does not appear in the actuation profile). Only then can a valid JOB be specified. If the JOB pre-selection is deactivated, a JOB can be specified by the M31x control unit for the PHOENIX.

JOBs can be pre-selected only when the system is at a standstill (no welding operation). If the PLC occupies a different JOB number at runtime, however, the set JOB number is stored temporarily in the module and the switching is carried out when the welding process is ended. There is no switching if a completed switching has been cancelled again during the welding process.

6.2 Program operation Up to 16 programs can be preselected at the power source. Each program is directly linked to "analogue" default values, which are saved in the JOB set at the power source. Program numbers 1–15 represent predefined values. The special program 0 is designed for the so-called pilot signal operation. The "analogue" default values are predefined using separate input signals. If other values are assigned to these bytes during normal program operation (1–15), these new parameters are cached in the module and applied to the power source when operation is switched to program 0.

Program actuation is only possible if the "Automaton program preselection" bit (automatically set in some actuation profiles, does not appear in the actuation profile) has been activated.

6.3 JOB mode As another operating mode, JOB operation is available. With program or pilot signal operation, welding type and operating mode are set using different control signals. With JOB operation, these settings are predefined by the program numbers in the power source and can be directly preselected. In addition, each program is assigned the super pulsing functionality. JOB operation is set via the corresponding signal. Alternatively, it can be predefined via jumper JP4. Changes to the JOB operation setting can only be made when the system is switched off.

Job mode can also be activated via jumper JP4 if the signal is not included in the data profile.

6.3.1 Advanced control signal operation Advanced pilot signal operation is activated automatically once software version 0.6.0.0 or later is available in the power source. The manual gas actuation function enables individual gas pre- and post-flows.

A safety function ensures the following aspects with regard to the gas: • If no gas has been activated at the start of the process, it is switched on automatically. • If the gas cannot be deactivated while a process is running, it is shut off automatically when the

process is switched off. This corresponds to a gas post-flow duration of 0.

Operative modeJOB mode

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6.3.2 Operating modes There are 2 different operating modes available. It is necessary to define the program sequence in order to understand the operating modes. The program sequence describes a series of welding program steps which are processed in sequence, starting with ignition, and ending with the end of the welding process.

Start/Stop signal Signal=1 starts the system, 0 ends the welding process. Depending on the operating mode selected, the process is ended immediately (non-latched) or following an end program (non-latched special).

Gas pre-flows/gas post-flows Defined connection or shut-down of the process gas supply at the start and after the welding process.

Start program Special program which becomes active in the relevant operating mode (non-latched special) once the gas pre-flows and ignition phase are complete. This program can be assigned a separate wire feed speed, voltage correction and a dynamic value.

Main welding program P2.x The main welding program operation follows the completion of the start program/ignition phase (depending on the operating mode)

Reduction program P3 This program is used in the “Superpulses” welding type for the PHOENIX and for the “Thermal pulses” type for the TETRIX. It is activated alternately with the main welding program currently active and an adjustable frequency is activated during the changeover. This permits special control by reducing the power for the time in which the secondary program is running.

End program Special program which initiates the conclusion of the welding process after the main welding program. This is activated after the end program ramp time elapses (only with the non-latched special operating mode).

Wire burn-back Defined burn-back of the welding wire at the end of the welding process (can be defined as part of a JOB). Only of relevance for MIG/MAG processes.

I > 0 signal Feedback signal for indicating “Current flows” and final, stable burn phase. It is generally used to trigger the positioning device.

6.3.2.1 Non-latched mode Gas pre-flows are initiated when the start signal is issued. The ignition program is activated once these are complete. Following successful ignition, the power source is in main welding program P2.x (according to the setting in the program), and the signal I>0 is set. If a Stop is issued, wire burn-back and gas post-flows are activated in sequence and the welding process is ended; I>0 is cancelled once the arc has been extinguished.

6.3.2.2 Special, non-latched Gas pre-flows are initiated when the start signal is issued. The ignition program is activated once these are complete. Following successful ignition, the power source will be in the ignition program; the signal I>0 is set. This runs for the time specified in the JOB and activates the main welding program P2.x (according to the setting in the program).

If a Stop is issued, first the end program is activated, followed by the wire burn-back and gas post-flows, and the welding process is ended; I>0 is cancelled once the arc has been extinguished. The transitions from ignition program to the main program and from the main program to the end program are controlled via ramps, where the output is carried over from one program to another.

The operating modes can also be switched over during welding operation. This means that the non-latched special mode can be modified in a flexible way.

6.3.2.3 Spot welding Sequence as for special non-latched, but the process duration is defined by the set ain process duration (t2). The process then finishes automatically.

Operative mode Welding types

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6.4 Welding types In welding mode a distinction is made between different modes (depending on the welding system). The welding type can be changed both when the system is at a standstill and during operation. In JOB mode the relevant information on the welding type is taken from the active program for the current JOB.

6.5 Monitoring function BUSINT X11 can permanently monitor the welding process using a dedicated monitoring function. Depending on the module operating modes different signals are available.

Activating the monitoring function To activate the monitoring function.

Parameter At present, 4 welding parameters are assigned for monitoring: • Welding voltage • Welding current • Wire feed speed (at present for MIG/MAG systems only)

• Maximum armature current of the wire feeder For 2 parameters at a time a separate response time can be set. An individual tolerance value is assigned to each monitoring parameter.

6.5.1 Monitoring function The different power source operating modes are used to assign nominal values for welding voltage, welding current and wire feed value to the process. Each tolerance parameter defines a tolerance range for the monitored process value. The engine current is treated as a maximum value; monitoring only encompasses checking whether this value is exceeded. If a parameter is out of range for a period that exceeds the defined response time, an alarm is triggered in the system. This is a passive alarm only and does not affect the welding process. Whether to cancel or continue the welding process is determined by the higher level control. The alarm for the parameter in question is reverted once the actual value is back in range.

It is possible to disable individual monitoring channels by setting the tolerance value to 0.

6.5.2 Display options An alarm message is generated in one of two ways: • Output via collective indication output (relay) on the module- See 6.5 Monitoring function chapter • Output of the individual channels via the field bus data with the following assignments:

Bit no. Parameter

0 Welding voltage

1 Welding current

2 Wire-feed speed

3 Max. motor current exceeded

The relay output is set immediately when one of the monitoring parameters exceeds its tolerance range. The relay is equipped with a reset delay, it is only shut down if no error has been indicated for approx. 0.5s.

6.5.3 Monitoring parameters The following signal specifications can be defined within a JOB:

Parameter Range specification

Voltage tolerance Specify in the range 0% to 50% of the nominal value

Current tolerance Specify in the range 0% to 50% of the nominal value

WF tolerance Specify in the range 0% to 50% of the nominal value

Maximum motor current Specify in the range 0 to 5.0A

A response time is assigned to the parameters for voltage tolerance/current tolerance and WF tolerance/max. motor current; this common response time can be set in the range 10ms to 20s in 10ms increments.

Operative modeMonitoring function

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6.5.4 Special features of the monitoring function Duration The parameter monitoring takes place only in the static conditions (main welding and reduction welding programs), which prevents error messages from dynamic alterations, such as for ramp overruns.

Fault reduction A hysteresis method on the monitoring limits prevents the message generator “fluctuating” in the tolerance band limit ranges.

Parameter The settings for the monitoring function are stored per JOB and are stored as follows in the program sequence:

Figure 6-1

Notes on usage Unstable processes due to the conditions require more in-depth consideration in monitoring. This means that the monitoring can be improved in terms of reliability by the relevant parameterisation of response time or by increasing the tolerance value for one individual channel. Where applicable, deactivating an individual process channel or the temporary deactivation of the monitoring function during the welding process should be considered. When using the superpulses welding type, the monitoring needs to be parameterised as very tolerant, as the system behaviour in this operating mode can be very dynamic depending on the parameters and a short response time will cause rather undesirable events in this case.

The nominal process values are always specified by the system. With very small tolerance values set, from time to time the calculated tolerance value can move below the relevant parameter resolution. In this type of situation, the resultant tolerance value is limited to a minimum value.

Operative mode Other signals

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6.6 Other signals 6.6.1 JOB pre-selection

Permits the specification of welding tasks (JOBs) by the machine. With the signal not set, the setting of the JOB must be carried out via another control (e.g. M31x). With an active signal the setting of the JOB is transferred (signal is automatically set in some actuation profiles and is not then visible in the profile).

6.6.2 Program pre-selection Permits the specification of power stages defined by the machine. If the signal is set, a power stage is pre-selected in accordance with the specification from the Program (special feature with program 0, - See 6.2 Program operation chapter). With a signal not set, program 1 is permanently set by the control (signal is automatically set in some actuation profiles and is not then visible in the profile).

6.6.3 Acknowledge error An active error is reset using this signal. For a correct function, the signal must be sloped.

Not all errors need to be acknowledged; some events reset themselves automatically- See 12 Error messages on the system chapter.

6.6.4 Gas test 1 Allows the shielding gas to be activated/deactivated manually. The signal can only be issued when the system is at a standstill (exception: extended control signal operation). The signal can be used to extend the gas pre-flow duration programmed permanently in the job, or to control it manually.

6.6.5 Wire Inching Manual activation of the main wire feed for inching the welding wire into the tube/torch package. Signal can only be issued when the system is at a standstill. Before activation any “reverse wire inching” signal present must be cleared.

6.6.6 Reverse wire inching Permits the retraction of the wire; can only be switched over when the system is at a standstill. Before activation, the “Wire inching” needs to be cleared.

6.6.7 Position search This signal is used in combination with a soft-collision detection of the welding torch (torch tube) with the workpiece. With an active signal, a touch of the workpiece is detected. The detection functions only in non-welding operation- See 6.6.7 Position search chapter.

6.6.8 Blow out torch Enables manual activation/deactivation of a second gas (in most cases compressed air to clean the torch). The signal can only be issued when the system is switched off.

6.6.9 Robot ready Ready for operation signal for indicating the positioning device on the welding power source. Signal must be set before the start of welding- See 6.12 Process fast shut-down chapter.

6.6.10 Welding simulation Activates the simulation of the welding process signals for the actual programming/testing of automation controls without active welding process with complete signal exchange- See 6.6.10 Welding simulation chapter.

6.6.11 JOB mode In this mode the information for operating type and welding type are not taken from individual actuation signals, but rather from the welding program actuated.

6.6.12 User-defined outputs K1 to K4 With these signals the user-defined relay outputs K1 to K4 can be activated at the module as long as they are not predefined for control-specific tasks.

6.6.13 WF switching This signal can be used to change over 2 wire feed drive units when the system is at a standstill. By default, WF number 1 active after switching on (see also the operating manual on the “WF switching” option).

6.6.14 Tandem operation This function is available as an optional software and in Phoenix systems enables the control of one power source each (for TANDEM systems, 2 BUSINT X11 are required). The input signal is used to determine which power source is the secondary power source in the TANDEM combination.

Operative modeCheck-back of the process parameters

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If not actuated the power source is configured as the master.

6.6.15 Inching mode This mode is used to set the inching type in the system. If the signal is set, the nominal wire feed speed value active at the interface is used for inching and reverse inching. If no nominal value is active, the JOB's minimum nominal value for the system is used. If the signal is not set, the default ramp is used for inching.

The inching mode has to be supported by the wire feeder's operating software.

6.6.16 superPuls Switches the superPuls welding type on. superPuls can only be switched on or off when no welding is performed. In the advanced JOB mode activated by JP4 this signal is blocked.

6.6.17 Liftarc This signal switches ignition to lift arc automaton mode. The ignition is parameterised using a suitable control or PC300.NET software.

6.6.18 Spot welding on Activates the spot welding mode, regardless of the operating mode selected. This is an automatic special non-latched sequence.

6.7 Check-back of the process parameters During operation, a variety of parameters are transferred to the higher level control via the field bus. Some of these parameters are available as a visual signal on the module in the form of LEDs- See 5.4.1.3 Status display chapter.

6.7.1 I > 0 (Current flows signal) Used to feed back the welding process to the PLC. The signal is normally set by the process after the arc has been ignited and cancelled after the arc has been extinguished. For improved signal matching with the higher level control, the signal is stored for a certain period during welding in the event of a stoppage- See 6.7.16 Signals for matching with the positioning device chapter.

The signal can be reset by a fault during the welding process.

6.7.2 User-defined inputs There are 4 additional user-defined inputs with 24-V logic. The signals are filtered with a time constant of approx. 50 ms.

If the module is equipped with an external voltage supply the signals will be processed even after the welding machine has been switched off. The signals can be used as required as long as they are not predefined for control-specific tasks.

The inputs are not isolated.

6.7.3 Process active In order to indicate the end of the welding process to the higher level control, this signal is reset when the system is in idle mode. During the welding process the signal is set to 1.

6.7.4 Main current signal Used specifically in non-latched special operating mode to trigger the positioning device to the end of the ignition program, or the start of the end program.

6.7.5 Collision protection Indicates the status from a collision protection device connected to the module. The signal has a wire break-proof design, which means that it is still active even if the sensor is not active. This should be taken into account when designing the system and programming the machine. The signal is treated with high priority to ensure rapid processing and also continues to be processed with an external power supply to the module when the welding machine has been shut down.

Operative mode The wire touches the workpiece, or is fused to the workpiece. Virtually no current flows via the workpiece. The detection is carried out at the end of the welding process- See 0

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6.7.6 Ready for welding The system is ready for welding and accepts a start signal from the PLC. The signal is reset in case of errors. When switching a JOB, the signal is reset for a duration of approx. 200 ms.

6.7.7 Sticking

The wire touches the workpiece, or is fused to the workpiece. Virtually no current flows via the workpiece. The detection is carried out at the end of the welding process- See 0

Operative modeThe wire touches the workpiece, or is fused to the workpiece. Virtually no current flows via

the workpiece. The detection is carried out at the end of the welding process- See 0

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Fusing detection chapter.

6.7.8 Error number In combination with the status signal "collective error", indicates a system error. System errors have to be acknowledged before attempting a restart.

In the advanced error functionality all existing errors are signalled successively for a duration of 1 second each. At the end of an error sequence, signalling starts again with the lowest error number.

Some system errors cannot be acknowledged due to their severity.

6.7.9 Warning number Signals system warnings which don't automatically cause a process stop. In case of multiple warnings a time-based sequence is issued as with error numbers.

6.7.10 Actual welding voltage value Transfer of the actual welding voltage of the process. The value is updated every 30ms.

6.7.11 Actual welding current value Transfers the actual welding current in the process; value is updated every 30ms.

When using the configuration with fast actual value detection, the values for voltage and current are updated every 5ms in the corresponding configuration of the field bus. This should be taken into account when designing the field bus system and the transfer cycles.

6.7.12 Actual wire feed speed value Transfer of the current wire speed for the process. Value is updated every 30ms.

6.7.13 Actual motor current value Transfer of the actual motor current for the wire conveyor system. Value is updated every 30ms.

6.7.14 Parameter monitoring Display of the status for the parameters being monitored. Signals are normally set to 0 if the monitoring is inactive or the parameter in question is within the tolerance band- See 6.5 Monitoring function chapter.

Operative mode The wire touches the workpiece, or is fused to the workpiece. Virtually no current flows via the workpiece. The detection is carried out at the end of the welding process- See 0

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6.7.15 Process signals diagram To explain the process signals, a description of the non-latched special operating mode is given below. In non-latched operating mode, the start and end programs are left out as appropriate.

t

t

t

I PA

Pend

Pstart

t

t

I > 0

A

B

C

D

t

t

t

Figure 6-2

Legend Description

A Start signal

B Main current

C Process active

D Ready for welding

Operative modeThe wire touches the workpiece, or is fused to the workpiece. Virtually no current flows via

the workpiece. The detection is carried out at the end of the welding process- See 0

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6.7.16 Signals for matching with the positioning device Experience has shown that the signal matching between the welding power source and the positioning device is very important. If interference occurs suddenly due to a loss of signal (e.g. arc interruption), or if intermittent signals occur, the positioning device can itself enter an error status condition. Often it is difficult to move the positioning device back to the basic position. For this reason, multiple parameters for improved matching have been introduced specifically for the process start phase and for the process in progress.

6.7.17 Ignition time: TZ-Zünd Detecting a failed ignition process is very important during the process start phase (especially with tandem processes with more than one power source). The ignition phase is evaluated using an adjustable ignition time. A successful ignition process is detected if a stable flow of current occurs for more than the set time period after ignition. The I>0 signal is saved in this phase. However, if there is no ignition process for the duration of the failed ignition time, an ignition error is issued to the cascade control. The process will be shut down automatically.

The ignition monitoring can be shut off by setting TZ-ZUND to the value 0.

6.7.18 TZ-Set To specify the duration of the stable arc burn time, the parameter TZ-Set was defined. If the arc burns stably in the ignition phase for this period, the signal I>0 is stored.

Figure 6-3

Legend Description

A Start signal

B Internal start

C Ignition time elapse

D Ignition error message

E Automatic cut-out

Operative mode

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6.7.19 Arc interruption time: TZ-LIBO For the work process it is desirable that the process runs without interference. However, in poor conditions it is likely that welding interference will occur, and this results in intermittent signals for the duration of the process. Depending on the cascade control logic implemented, this results in undesirable standstills in the positioning device. To counteract this, the interface has a time-controlled recording feature for arc interruptions. If an interruption is detected, an adjustable time period runs, during which the I>0 signal sent to the cascade control is stored. After this time elapses, the I>0 signal is retracted, and the control is provided with a response time (e.g. for a re-start). After max. 5 s elapses, an automatic cut-out of the process is carried out with an "arc interruption" error message. The arc interruption monitoring can be shut down by setting TZ-LIBO to the value 0. The diagram shows the detection of an arc interruption.

Figure 6-4

Legend Description

A Short misfire within the detection period

B Start signal

C Internal start

D Start of arc interruption detection

E Expiry of memory time for I>0 signal

F Automatic cut-out and arc interruption error message

6.7.20 Return time, TZ-Reset Most positioning equipment uses the I>0 signal to optimise the cycle time to trigger the positioning equipment after the process. This often makes it more difficult to reliably detect sticking. An adjustable time TZ-RESET can be used to set the period after which the I>0 signal is reset after the process is shut down.

If both TZ-SET and TZ-RESET are set to the value 0, the original process signal I>0 is permitted through to the higher level control unfiltered. This can be desirable if the control has its own process signal monitoring

Operative modeFusing detection

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6.8 Fusing detection Reliable fusion detection of the welding wire is especially important in automated processes to protect the workpiece and positioning device, including the welding equipment, against damage. For this reason the BUSINTX11 has intelligent fusion detection which uses the sensor voltage from the PHOENIX for wire fusion detection.

The fusion detection is carried out automatically for a narrow time window at the end of the process, approx. 200ms after extinguishing the arc. The detection duration depends on the setting of the gas post-flow duration, but is a maximum of 1s. If fusion is detected, the signal is displayed until the system is re-started. If the wire is cut off from the workpiece before the next start, the signal is withdrawn permanently.

The use of the fusion function for TETRIX systems is only possible following retrofitting/fitting with a sensor voltage and the relevant equipment on the torch being used.

6.9 Position search The position search function can be executed with either the system bus data or the quick external actual values:

JP 2 Function

- Actual values via system bus (factory setting)

X Actual values expected via connector X7, enable position search

X – jumper connected Ideally the BUSINT X11 variant "External mounting housing" should be installed at the power source to ensure quick and safe transfer of the actual values to the module (short distances without interferences). When using the "Electrical enclosure" variant a shielded cable has to be used to connect the actual values.

This function can only be enabled when the system is switched off (no welding operation) using the correct enable signal. In case of contact with the workpiece the state is quickly detected and transmitted to the fieldbus via signal "I > 0".

To improve the detection accuracy on corroded surfaces the existing sensor voltage can be increased to 60 V DC using an optional PCB. This option is selected via the EWM configuration program.

6.10 Welding seam tracking A traditional task for robot welding systems is track correction for the weld seam during the process, which is required due to component tolerances. The actual process values supplied in the system are normally updated every 30ms. A higher data rate is required for reliable seam tracking. This is supported by BUSINTX11 with a fast, optional actual value recording device for welding voltage and welding current, which needs to be purchased separately.

6.11 Welding simulation Simulation is usually used for the setup of traversing devices. The process signals simulated are "I > 0", "Ready for welding", "Process active" and "Main current". All signals are recreated with the exact time sequence of the process chain, which means simulation can also be used to determine the production cycle times. This function can only be enabled when the system is switched off (no welding operation) using the correct enable signal. The simulation is enabled by activating the "welding simulation" actuation signal.

Process actual values are not simulated.

6.12 Process fast shut-down In some circumstances, an immediate shut-down of the process is desirable, which cannot be implemented in the non-latched special operating mode, for example, with the program sequence programmed for that mode, or by simply removing the start signal. The “Robot ready” actuation signal is used to trigger a fast process shut-down via the software. The signal must always be set before the start signal (otherwise there is no start). If the signal is shut down in the welding process, the process is ended immediately with the wire burn-back of the wire electrode and the “Fast stop” error is issued on the field bus. Before re-starting welding, “Robot ready” needs to be set first and then the error acknowledged.

Operative mode Process safety shut-down

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6.13 Process safety shut-down The BUSINTX11 is equipped with monitoring specific to the field bus, which is used to determine the status of the module on the field bus. If the field bus communication is interrupted during the continuous welding process, a safety shut-down of the welding process is carried out following a response time of approx. 2s. The user-defined output and the monitoring output are also reset in the process. The welding process can be continued after restoring the field bus communication.

6.14 JOB safety switching Power sources for mechanised MIG/MAG welding (PHOENIX) or mechanised TIG/PLASMA welding do not normally use data records (JOBs) which are used for the electrode welding process. However, if a data record of this type is contained in the JOB database and is selected accidentally, there is an automatic system start (not by the interface), in which there is open circuit voltage on the torch system (wire feeds are not activated). In this case, there is a risk of secondary accidents caused by direct contact with live torch parts.

To prevent the risk of accidents, the BUSINTX11 automatically switches to a JOB suitable for the welding system when an unsuitable JOB has been selected on the robot side (e.g. TIG or electrode with the PHOENIX). No switching is carried out if the user switches to an unsuitable JOB using the control unit (e.g. M310). In this case, the system will switch back to a JOB selected by the robot when the next start signal is issued.

6.15 Support of welding circuit alignment If the power source software supports this function, welding circuit alignment is possible. The alignment is actuated using an existing control unit. BUSINT X11 supports alignment by allowing the alignment to be activated using a set start or inching signal with the alignment mode being enabled. If this operation is successful, the resulting welding circuit alignment is shown on the control unit. Unsuccessful measurement is signalled as well. For the duration of the activated alignment the normal welding start is blocked.

6.16 Advanced JOB selection The power sources of the Multimatrix series and later enable the selection of up to 256 JOBs. Depending on the power source type, not all JOBs can be selected. When attempting to select such a JOB, the JOB is not selected and the interface issues a warning which is sent to the SPC and displayed on the machine control.

The diagnostics interfacePC system requirements

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7 The diagnostics interface To support commissioning processes and the analysis of signal sequences, the BUSINTX11 has a diagnostics interface that is connected to a PC USB port and can be evaluated using the EWM-Analyzer software.

7.1 PC system requirements The following requirements must be met to operate the PC software: • Min. 1.7 GHz CPU • 512 MB RAM (1 GB recommended for long-term recording) • 300 MB free hard drive space

• Min. WIN XP with Service Pack 2

8 Commissioning To commission the diagnostics interface, first connect the connection cable for the PC USB port (consisting of filter boxes SECINTX10USB, item no. 090-008190-XXXXX and connection cable PCV5-I, item no. 094-001205-XXXXX) to the PC and the required adapter cable for connection to the 6-pole Minifit socket X10 on the BUSINTX11 using adapter cable item no. 094-013051-XXXXX. When using a BUSINTX11 ATCASE, the adapter cable is not necessary as the connection cable can be inserted directly into the casing.

Jumper 6 must be inserted in position 2-3 for operation! Start the program, use the Windows device manager to identify and set the assigned COM port. The diagnostics are now ready for operation!

8.1 Scope of diagnostics Various information can be determined using the EWM Analyzer software. In profile view, the BUSINTX11 is displayed with the preset data profile. The relevant status of the input or output can therefore be read off immediately (system diagnostics). For expanded signal analysis based on time, there is a diagnostics and monitor view of the recorded data available. The current software status of the BUSINTX11 can also be easily determined. For more information on the Analyzer, please also see the relevant operating instructions!

Data profiles Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

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9 Data profiles The BUSINTX11 has a selection option for what are known as signal profiles which can be selected via a selector switch with 16 settings.

The number of profiles available depends on the field bus standard being used and on the module software version. The profiles described below therefore represent a minimum of the available functionality in each case and are being updated on a continuous basis. A newly selected profile is only applied once the module has been isolated from any supply voltage and supplied with power again. In cases where a switch position to which no profile is assigned is selected, the default profile is activated for the module and an error message is displayed on the module (but not on the field bus). The module is still ready for operation, however.

Depending on the profile, it may be that different signals in the description are not present or are not used.

9.1 Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

9.1.1 Default profile (switch position 0) The module uses a data capacity of 6 words (12 bytes) for input data and output data.

Actuation data (PLC output data) Byte no.

Bit no. Function Description

0 0&1

Operating mode selection Bit assignment: Bit1 Bit0 0 0 0 1 1 0 1 1

Selection of non-latched/special non-latched Non--latched operating mode Not in use Not in use Special non--latched operating mode

0 2

Welding mode selection Bit assignment: 0 1

Selection of normal/pulsed welding Normal welding active Pulsed welding active

0 3

Monitoring function check Bit assignment: 0 1

Activate/deactivate welding parameter monitoring Monitoring deactivated Monitoring activated

0 4

Start Bit assignment: 0 1

Start signal to initiate the welding process Signal stop at system Signal start at system

0 5

Robot ready Bit assignment: 0 1

Safety signal for emergency shutdown If the robot does not signal readiness, it cannot be started and the process is shutdown Robot signals readiness, start is possible

Data profilesProfiles for the Interbus-S (copper),

Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

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Byte no.


0 6

Gas test 1 Bit assignment: 0 1

Manual control over shielding gas valve Shielding gas valve off Shielding gas valve on

0 7

Cleaning Bit assignment: 0 1

Control over cleaning valve Cleaning off Cleaning on

1 0

Inching Bit assignment: 0 1

Signal for wire inching function on the wire feeder Inching deactivated Inching activated

1 1

Position search Bit assignment: 0 1

Activates the position search function for the workpiece Position search deactivated Position search activated

1 2

Reverse inching Bit assignment: 0 1

Signal for reverse wire inching function Reverse inching deactivated Reverse inching activated

1 3

WF switching (optional) Bit assignment: 0 1

Switches between two wire feeders Wire feeder 1 is active Wire feeder 2 is active

1 4

Error reset Handshake signal for system errors Signal needs a positive ramp

1 5

User-defined output Bit assignment: 0 1

Actuates the user-defined relay output K2 at the bus module Relay not actuated Relay actuated

1 6

JOB mode Bit assignment: 0 1

Signal activates the JOB mode function JOB mode deactivated JOB mode activated

1 7

Welding simulation Bit assignment: 0 1

Activates the "simulate welding" function Simulation deactivated Simulation active

2 0-3

Program number default

Selection of a JOB number in the range of 1–15


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Byte no.


2 4-7

Actuation relay K1 Actuation relay K3 Actuation relay K4 Bit assignment: 0 1 Slave power source default for TANDEM systems (optional) Bit assignment: 0 1

Actuation of user-defined outputs Relay not actuated Relay actuated System assumes master function (default) System assumes slave function

3 0-7

JOB number default Select a JOB number in the range of 1–255

4 0-15

Wire feed default, high byte Specifies the wire feed speed in program 0 Range: 0 to 0 x 7FFF 0 corresponds to WF MIN 0 x 7FFF corresponds to 25.0 m/min

Wire feed default, low byte Specifies the wire feed speed in program 0

6 0-15

Correction default, High byte

Specifies the voltage correction in program 0 Range: 0 to 0 x 7FFF 0 corresponds to -10.0 V 0 x 4000 corresponds to 0 V 0 x 7FFF corresponds to +10.0V

Correction default, Low byte

Specifies the voltage correction in program 0

8 0-15

Dynamics default, High byte

Specifies the dynamics in program 0 Range: 0 to 0 x 7FFF 0 corresponds to -40 0 x 4000 corresponds to 0 0 x 7FFF corresponds to +40

Dynamics default, Low byte

Specifies the dynamics in program 0

10 0-15

Reserved



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Process data (PLC input data) Byte no.


0 0

I > 0 Bit assignment: 0 1

"Current flows" signal from process Current does not flow Current flows, arc active

0 1

Ready for welding Bit assignment: 0 1

Ready signal from process System not ready System ready

0 2

Sticking Bit assignment: 0 1

Wire sticking notification from process Wire free Wire sticks to the workpiece

0 3

Error Bit assignment: 0 1

General error message from process No error An error occurred and has not been resolved

0 4

Collision signal Bit assignment: 0 1

Signals that collision protection has been triggered Collision or transmitter not connected No collision

0 5

Main current signal Bit assignment: 0 1

Displays the status of the program sequence Process past main current phase Process in main program

0 6

Process active Bit assignment: 0 1

Signals the completion of the welding process Process completed (after gas post-flow) Process running

0 7

Reserved

1 0-7

Error Error number of an error that has occurred


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Byte no.


2 0-7

Monitoring Bit assignment: 0 1 2 3 4 Characteristics range alert Bit assignment: 0 WF nominal value in characteristics range 1 WF nominal value not in characteristics range 5–6 Reserved 7 Tracking signal

Bit field to display alarm messages for welding parameter monitoring Status = 0, no alarm Status = 1, alarm Welding voltage Welding current Wire feed speed WF engine current Signals whether the nominal value predefined by the control is within the characteristics range (in preparation) Control signal to check the synchronising signal used to condition the measuring signals of the power source; signal should toggle in the process

3 0-3

User-defined inputs Bit assignment: 0 1 Input assignment: Input X4/3 Input X4/5 Input X4/7 Input X4/8

Load user-defined inputs 0 V signal at the input = signal low 24 V at the input = signal high Only available if not used as detection input for increased sensor voltage

3 4-7

Reserved

4 0-15

Welding voltage actual value, high byte

Current actual value of the welding voltage Range: 0 to 0 x 7FFF corresponds to 0.0V to 100.0V

Welding voltage actual value, low byte

Current actual value of the welding voltage

6 0-15

Welding current actual value, high byte

Current actual value of the welding current Range: 0 to 0 x 7FFF corresponds to 0A to 1000A

Welding current actual value, low byte

Current actual value of the welding current



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Byte no.


8 0-15

Actual value Wire feed speed High byte

Current actual value of the wire feed speed Range: 0 to 0 x 7FFF corresponds to 0.0 m/min to 40.0 m/min

Actual value Wire feed speed Low byte

Current actual value of the wire feed speed

10 0-15

Engine current actual value High-Byte

Current actual value of the wire feeder's engine current Range: 0 to 0 x 7FFF corresponds to 0.0 A to 25.5 A

Engine current actual value Low byte

Current actual value of the wire feeder's engine current


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9.1.2 Profile for Multimatrix machines (switch position 1) The module uses data with a width of 14 bytes (7 words) for actuation and process data.



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0





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Byte no.


1 1



1 2



1 3



1 4


1 5

Relay K2 actuation (only when the sensor voltage option has not been configured) Bit assignment 0 1

Actuation of the user-defined outputs Relay not actuated Relay actuated

1 6

Reserved

1 7



2 0-3

Program number default Selection of a JOB number in the range of 1–15

2 4

Relay K1 actuation Bit assignment 0 1


2 5



2 6




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Byte no.


2 7

Master power source default with TANDEM systems (optional) Bit assignment: 0 1

Activates the master/slave power source in a TANDEM system System assumes master function System assumes slave function

3 0-7


4 0

JOB bit 8 Bit assignment: 0 1

JOB range expansion With the JOB number default, JOBs in the range of 1 to 255 can be selected With the JOB number default, JOBs in the range of 256 to 510 can be selected

4 1-3

Reserved

4 4

Spot welding on Bit assignment 0 1

Current operating mode active Spot welding operating mode active

4 5

Inching mode Bit assignment: 0 1

Signal for inching mode type selection Standard system ramp active Constant for 3.0 m/min or nominal value application from WFNominal pilot signal

4 6

superPuls on Bit assignment 0 1

Control via superPuls function superPuls off superPuls on

4 7

Lift arc on Bit assignment 0 1

Control via lift arc function Lift arc off Lift arc on

5 0-7

Reserved

6 0-15


Wire feed default, low byte

Specifies the wire feed speed in program 0



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Byte no.


8 0-15





10 0-15





12 0-15

Reserved


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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7


2 0

Voltage monitoring Bit field to display alarms when monitoring welding parameters Status = 0, no alarm Status = 1, alarm



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Byte no.


2 1

Current monitoring Bit field to display alarms when monitoring welding parameters Status = 0, no alarm Status = 1, alarm

2 2

Wire feed speed monitoring

Bit field to display alarms when monitoring welding parameters Status = 0, no alarm Status = 1, alarm

2 3

Wire feed motor current monitoring


2 4

Range warning monitoring


2 5-7

Reserved

3 0

User-defined input X4/3 Bit assignment: 0 1

Load user-defined input 0 V signal at the input = signal low 24 V at the input = signal high

3 1



3 2



3 3



3 4-7

Reserved

4 0-7

Warning

Number of a warning issued


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Byte no.


5 0-7

Reserved

6 0-15





8 0-15





10 0-15





12 0-15





Data profilesProfiles for the CANopen module

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9.2 Profiles for the CANopen module In general the module uses the standard Rx-PDOs 1 and 2 (no. 1 for digital and no. 2 for analogue signals) and the standard Tx-PDOs 1 to 3 (no. 1 for digital and nos. 2 and 3 for analogue data).

9.2.1 Reis Robotics profile (switch position 0) Actuation data (PLC output data) Byte no.


RxPDO 1 CobID = 200h + Adr

0 0



0 1



0 2



0 3, 4



0 5

Reserved

0 6



0 7

Reserved

1 0



1 1



Data profiles Profiles for the CANopen module

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Byte no.



1 2



1 3


1 4



1 5



1 6

Reserved

1 7



2 0-7


3 0-3


3 4-6

Reserved

3 7



4 0



4 1-2

Reserved


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Byte no.



4 3



4 4-7

Actuation relay K1 Actuation relay K2 (only when no sensor voltage option has been configured) Actuation relay K3 Actuation relay K4 Bit assignment: 0 1

Actuation of user-defined outputs Relay not actuated Relay actuated

5 0-7

Reserved

6 0-7

Reserved

7 0-7

Reserved


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0 0-15

Wire feed default, low byte Specifies the wire feed speed in program 0 Range: 0 to 0 x 7FFF 0 corresponds to WF MIN 0 x 7FFF corresponds to 25.0 m/min

Wire feed default, high byte Specifies the wire feed speed in program 0

2 0-15





4 0-15





6 0-15

Reserved


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TxPDO 1 CobID = 180h + Adr

0 0



0 1

Reserved

0 2



0 3



0 4



0 5



0 6

Reserved

0 7

Reserved

1 0-7


2 0-7

Reserved

3 0



3 1-7

Reserved


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Byte no.



4 0-3

Monitoring Bit assignment: 0 1 2 3 4 Characteristics range alert Bit assignment: 0 WF nominal value in characteristics range 1 WF nominal value not in characteristics range 5-7 Reserved

Bit field to display alarm messages for welding parameter monitoring Status = 0, no alarm Status = 1, alarm Welding voltage Welding current Wire feed speed WF engine current Signals whether the nominal value predefined by the control is within the characteristics range (in preparation)

4 4-7

Reserved

5 0-3


Load user-defined inputs 0 V signal at the input = signal low 24 V at the input = signal high

5 4-7

Reserved

6 0-7

Reserved

7 0-7

Reserved




0 0-15






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Byte no.



2 0-15





4 0-15





6 0-15

Reserved




0 0-15





2 0-15

Reserved

4 0-15

Reserved

6 0-15

Reserved


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0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0




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Byte no.



1 1



1 2



1 3



1 4


1 5



1 6

Reserved

1 7



2 0-3


2 4



2 5



2 6




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Byte no.



2 7



3 0-7


4 0



4 1-4

Reserved

4 5



4 6



4 7



5 0-7

Reserved

6 0-7

Reserved

7 0-7

Reserved


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0 0-15



2 0-15





4 0-15





6 0-15

Reserved


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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7


2 0



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Byte no.



2 1


2 2



2 3



2 4



2 5-7

Reserved

3 0



3 1



3 2



3 3



3 4-7

Reserved

4 0-7

Warning Number of a warning issued


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Byte no.



5 4-7

Reserved

6 0-7

Reserved

7 0-7

Reserved




0 0-15





2 0-15





4 0-15





6 0-15





Data profilesProfiles for the CAN DeviceNet module

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9.3 Profiles for the CAN DeviceNet module 9.3.1 Default profile (switch position 0)

The module uses a data width of 5 words (10 bytes) for actuation data and 6 words (12 bytes) for process data.



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0



Data profiles Profiles for the CAN DeviceNet module

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Byte no.


1 1



1 2



1 3



1 4


1 5



1 6



1 7



2 0-3


2 4-7



3 0-7



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Byte no.


4 0-15



6 0-15





8 0-15






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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7



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Byte no.


2 0-7



3 0-7



4 0-15





6 0-15





8 0-15






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Byte no.


10 0-15






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9.3.2 Profile 1 (switch position 1) The module uses a data width of 5 words (10 bytes) for actuation data and 6 words (12 bytes) for process data, split into 2 connections. The following data with 4 bytes are assigned to connection 1 (output 1):



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0




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Byte no.


1 1



1 2



1 3



1 4


1 5



1 6



1 7



2 0-3


2 4-7



3 0-7



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The following data with 6 bytes are assigned to connection 2 (output 2):



0 0-15



2 0-15





4 0-15






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0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0




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Byte no.


1 1



1 2



1 3



1 4


1 5



1 6

Reserved

1 7



2 0-3


2 4



2 5



2 6




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Byte no.


2 7



3 0-7


4 0



4 1-3

Reserved

4 4



4 5



4 6



4 7



5 0-7

Reserved

6 0-15





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Byte no.


8 0-15





10 0-15





12 0-15

Reserved


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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7


2 0


2 1



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Byte no.


2 2



2 3



2 4



2 5-7

Reserved

3 0



3 1



3 2



3 3



3 4-7

Reserved

4 0-7


5 0-7

Reserved


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Byte no.


6 0-15





8 0-15





10 0-15





12 0-15






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The following data with 4 bytes are assigned to connection 1 (input 1):



0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7



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Byte no.


2 0-7



3 0-3



3 4-7

Reserved

The following data with 8 bytes are assigned to connection 2 (input 2):



0 0-15





2 0-15






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Byte no.


4 0-15





6 0-15





Data profiles Profiles for the Profibus DP module

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9.4 Profiles for the Profibus DP module 9.4.1 Default profile (switch position 0)

The module uses a data capacity of 10 bytes for input data and 11 bytes for output data and should be used if all input and output data is required.



0 0



0 1



0 2



0 3

Operating mode selection Bit assignment: 0 1

Selection of non-latched/special non-latched Non--latched operating mode Special non--latched operating mode

0 4

Automaton program preselection Bit assignment: 0 1

Selection of the program by automaton Program 1 is predefined Programs 0–15 can be selected

0 5

Automaton JOB mode Bit assignment: 0 1

Selection JOB selection mode JOB preselection via operating panel (M31X) JOB preselection by automaton (fieldbus)

0 6



0 7


1 0



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Byte no.


1 1



1 2



1 3



1 4



1 5



1 6



1 7



2 0-3


2 4-7




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4 0-15



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8 0-15






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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7



1 0-7


2 0-15






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4 0-15





6 0-15





8 0-15





10 0-4

Monitoring Bit assignment: 0 1 2 3 4 Characteristics range alert Bit assignment: 0 WF nominal value in characteristics range 1 WF nominal value not in characteristics range


10 5



10 6




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Byte no.


10 7




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9.4.2 Flexible profile (switch position 1) The module uses a data capacity of 10 bytes for input data and 11 bytes for output data. The JOB mode can only be activated via the jumper in this profile. The data is arranged so that data required on the Profibus can be grouped via the module programming. The program and JOB selection bits can be used to pre-select the actuation type for programs and JOBs.



0 0



0 1



0 2



0 3

Operating mode selection Bit assignment: 0 1

Selection of non-latched/special non-latched Non--latched operating mode Special non--latched operating mode

0 4



0 5



0 6



0 7


1 0




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2 0-3


2 4-7




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0 0



0 1



0 2



0 3



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0 7



1 0-7


2 0-15






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10 0-4



10 5



10 6




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10 7




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9.4.3 Compatible profile (switch position 2) The module uses a data capacity of 10 bytes for input data and 11 bytes for output data. The profile can be used to replace previously used BUSINTX10 Profibus interfaces. The profile is fully compatible for this purpose.



0 0



0 1



0 2



0 3, 4



0 5



0 6



0 7


1 0




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0 0

Reserved

0 1



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0 6

Reserved

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1 0-7


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1 0




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2 6




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0 7

Reserved

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2 5-7

Reserved

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3 4-7

Reserved

4 0-7


5 0-7

Reserved


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Data profilesProfiles for the Profinet and Profinet-LWL modules

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9.5 Profiles for the Profinet and Profinet-LWL modules 9.5.1 Reis Robotics profile (switch position 0)

The module uses a data width of 7 words (14 bytes) for actuation and process data.



0 0



0 1



0 2



0 3, 4



0 5

Reserved

0 6



0 7

Reserved

1 0



1 1



Data profiles Profiles for the Profinet and Profinet-LWL modules

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Byte no.


1 2



1 3


1 4



1 5



1 6



1 7



2 0-7


3 0-3,4-6,7


Reserved



4 0



4 1-7

Reserved


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Byte no.


5 0-3

Actuation relay K1 Actuation relay K2 (only when no sensor voltage option has been configured) Actuation relay K3 Actuation relay K4 Bit assignment: 0 1

Actuation of user-defined outputs Relay not actuated Relay actuated

5 4-7

Reserved

6 0-15



8 0-15





10 0-15





12 0-15

Reserved


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0 0



0 1

Reserved

0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7


2 0-7

Reserved

3 0



3 1-7

Reserved


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5 0-3



5 4-7

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8 0-15






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0 0&1



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0 7



1 0




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4 0



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Reserved

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0 7

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2 0


2 1



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2 5-7

Reserved

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3 4-7

Reserved

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5 0-7

Reserved


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Data profiles EthernetIP module profiles

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9.6 EthernetIP module profiles 9.6.1 Default profile (switch position 0)

The module uses a data width of 7 words (14 bytes) for actuation and process data.



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0



Data profilesEthernetIP module profiles

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1 1



1 2



1 3



1 4


1 5



1 6



1 7



2 0-3


2 4,5,6,7



3 0-7



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4 2-7

Reserved

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Reserved

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10 0-15





12 0-15

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0 0



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0 7

Reserved

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3 4-7

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Reserved

5 0-7

Reserved

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8 0-15






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12 0-15






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9.6.2 FANUC Robotics profile (switch position 1) The module uses a data width of 7 words (14 bytes) for actuation and process data.



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0




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1 4


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2 4,5,6,7



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4 1



4 2-7

Reserved

5 0-7

Reserved

6 0-15



8 0-15





10 0-15





12 0-15

Reserved


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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7



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Byte no.


2 0-7



3 0-3



3 4-7

Reserved

4 0-7

Reserved

5 0-7

Reserved

6 0-15


Current actual value of the welding voltage Range: 0 x 7FFF to 0 x 0 corresponds to 0.0V to 100.0V



8 0-15


Current actual value of the welding current Range: 0 x 7FFF to 0 x 0 corresponds to 0A to 1000A




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Byte no.


10 0-15


Current actual value of the wire feed speed Range: 0 x 7FFF to 0 corresponds to 0.0 m/min to 40.0 m/min



12 0-15

Engine current actual value High byte

Current actual value of the wire feeder's engine current Range: 0 x 7FFF to 0 x 0 corresponds to 0.0 A to 25.5 A



9.6.3 Notes on the profile The process actual values are adapted to the negative FANUC logic. A process value of 0 is output with the maximum value, but the maximum process value is output with the value 0.


142 099-008196-EW50109.12.2015




0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0




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1 3



1 4


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1 6

Reserved

1 7



2 0-3


2 4



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2 6




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3 0-7


4 0



4 1-3

Reserved

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Reserved

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12 0-15

Reserved


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0 0



0 1



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0 3



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0 7

Reserved

1 0-7


2 0


2 1



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Byte no.


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2 4



2 5-7

Reserved

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3 1



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Reserved

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5 0-7

Reserved


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9.6.5 Profile for Multimatrix machines with FANUC robots (switch position 3) The module uses data with a width of 14 bytes (7 words) for actuation and process data.



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0




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Byte no.


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3 0-7


4 0



4 1-3

Reserved

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4 6



4 7



5 0-7

Reserved

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0 0



0 1



0 2



0 3



0 4



0 5



0 6



0 7

Reserved

1 0-7


2 0


2 1



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2 3



2 4



2 5-7

Reserved

3 0



3 1



3 2



3 3



3 4-7

Reserved

4 0-7


5 0-7

Reserved


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Byte no.


6 0-15





8 0-15


Current actual value of the welding current Range: 0 x 7FFF to 0 x 0 corresponds to 0A to 1000A



10 0-15


Current actual value of the wire feed speed Range: 0 x 7FFF to 0 corresponds to 0.0 m/min to 40.0 m/min



11 7

Reserved

12 0-15

Engine current actual value High byte

Current actual value of the wire feeder's engine current Range: 0 x 7FFF to 0 x 0 corresponds to 0.0 A to 25.5 A



9.6.6 Notes on the profile The process actual values are adapted to the negative FANUC logic. A process value of 0 is output with the maximum value, but the maximum process value is output with the value 0.

Data profiles Profiles for the EtherCAT module

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9.7 Profiles for the EtherCAT module 9.7.1 Default profile (switch position 0)

The module uses a data width of 5 words (10 bytes) for actuation data and 6 words (12 bytes) for process data.



0 0&1



0 2



0 3



0 4



0 5



0 6



0 7



1 0



Data profilesProfiles for the EtherCAT module

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Byte no.


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1 2



1 3



1 4


1 5



1 6



1 7



2 0-3


2 4-7



3 0-7



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0 0



0 1



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0 3



0 4



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0 6



0 7

Reserved

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2 1



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Reserved

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Reserved

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Reserved


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Special field bus features when setting up the field bus modules

CAN DeviceNet

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169

10 Special field bus features when setting up the field bus modules

10.1 CAN DeviceNet Field bus subscribers in the CAN DeviceNet are normally integrated using an EDS file (Electronic Data Sheet). This configuration file permits access to the module configuration.

The BUSINTX11 DeviceNet is supplied together with the file BUSINTX11.EDS. The module configuration is carried out as follows:

10.1.1 Connections The module can be configured using what are known as connections. The number of useable connections depends on the profile being used. Each usable connection has a defined quantity of input data and output data. The data position of the profile always starts with the first byte of a relevant connection. Each connection can in theory be assigned to another connection type (Polled, COS, Strobed). However, each connection type can only be assigned once (separated for input data and output data). The number of data items available per connection can be read out using the “InputX length” and “OutputX length” parameters via the configuration tool.

Here, “InputX length” stands for process status data and “OutputX length” for actuation data.

10.1.2 Example for I/O data

In the example above, the profile selected is offered for connection 1, 10 bytes of actuation data and 12 bytes of process data.

Special field bus features when setting up the field bus modules Profibus DP

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10.1.3 Example of a connection assignment

In the example above, 12 bytes of connection 1 are assigned and configured as “Polled”.

10.2 Profibus DP The Profibus node is integrated into the field bus using a GSD file. Here the data is structured in the form of modules which can have different lengths. It is advisable to distribute the modules according to the logical block size of the data. For example, word capacity for nominal and actual values or by bytes for data with byte capacity.

10.2.1 The watchdog Each DP node can be monitored using a watchdog to secure the data traffic. It is essential that this function is activated as otherwise the targeted shut-down of the system will no longer function in the event of an interruption to the field bus master.

10.2.2 DP features Using watchdog monitoring, the system can be shut down in the event of interruption. In this process, all I/Os are set to 0 and “FASTSTOP” is detected on the system.

The restart behaviour of the slave when restoring the connection can be configured in the DP features. Caution is required with the following configuration:

Feature Setting

Re-start behaviour of the node Automatic re-start

Response from the master None

If the error that has occurred is reset on an operating panel before the field bus is re-started, the welding process can be re-started if the start is still present. Always ensure in an error situation of this type that all outputs of the node have been reset in the application.

Special field bus features when setting up the field bus modules

EtherCAT

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171

10.3 EtherCAT Machines are installed in the engineering system of the EtherCAT masters in the EtherCAT standard, using XML-based configuration files called ESI (EtherCAT Slave Information). In addition to the basic settings required for safe operation these configurations contain one special feature.

Different machines with similar properties are defined as "devices". Corresponding to the three machine variants Phoenix, Tetrix, and Tetrix Plasma there are three different configuration files for BUSINT X11. In these files, an individual machine is assigned to each data profile, which is detected when an automatic search is carried out.

10.3.1 Machine installation To install a machine, open the master install functionality and select the correct file depending on the interface type (BUSINT X11 Phoenix, BUSINT X11 Tetrix or BUSINT X11 Plasma).

Figure 10-1

Figure 10-2

Special field bus features when setting up the field bus modules EtherCAT

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10.3.2 Manual integration of a machine Open the corresponding dialog in the engineering system and you will see that for each supported data profile there is one device available. Select the required data profile according to the reference and set the data profile control accordingly.

To ensure proper functioning the control setting and the selected entry have to match.

10.3.3 Search for a machine Most engineering systems offer an automatic search function for EtherCAT machines. The result will show the detected machine along with the data profile set. If a non-existent data profile has been set at the data control, profile 0 will be selected automatically.

Figure 10-3

10.3.4 Process data view Once the machine has been installed, its data image shows the data allocation in blocks to allow for a general orientation.

Figure 10-4

Operating problems, causes and remediesOperating displays (LEDs)

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11 Operating problems, causes and remedies 11.1 Operating displays (LEDs)

LED no. Function Description 1 +15V voltage

Assignment: Off On

Voltage supply +15 V Voltage missing/damaged Voltage OK

2 -15V voltage Assignment: Off On

Voltage supply -15V Voltage missing/damaged Voltage OK

3 +5 V voltage Assignment: Off On

Voltage supply +5V Voltage missing/damaged Voltage OK

4 +24V voltage Assignment: Off On

Voltage supply +24V Voltage missing/damaged Voltage OK

5, 6, 13, 14 Relay status Assignment: Off On

Shows the status of relays K1 to K4 Relay inactive Relay active

7 Start/stop Assignment: Off On

Start/stop display status at the welding machine Stop signal active Start signal active

8 I > 0 Assignment: Off On

Display of the "Welding current flows" signal Current does not flow Current flows, arc active

9 Process active Assignment: Off On

Display of the running process Process completed Process running

10 Error Assignment: Off On

Display of a system error No error Error active With the "Seam tracking" software option, the synchronous signal from the power source is signalled in the welding process by flashing.

11 & 12 System bus status Assignment: Off Flashing

Display for internal system bus System bus not active, system switched off System bus is active

15 & 16 External control bus status Assignment: Off Quick flashing

Display for the external control bus Control bus not in use Control bus active

Operating problems, causes and remedies Warnings (power source)

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11.2 Warnings (power source) A warning is denoted by the letter A on the machine display, or Att in case of multiple machine

displays. The possible cause of the warning is signalled by the respective error code (see table).

The display of possible error numbers depends on the machine version (interfaces/functions).

• If multiple errors occur, these are displayed in succession. • Document machine errors and inform service staff as necessary.

Warning code Possible cause Remedy

1 Machine excess temperature Allow the machine to cool down

2 Half-wave failures Check process parameters

3 Welding torch cooling warning Check coolant level and refill if necessary

4 Gas warning Check gas supply

5 See warning number 3 -

6 Welding consumable (wire electrode) fault

Check wire feeding (with machines with filler wire)

7 CAN bus failure Inform service

32 Drive encoder fault Inform service

33 Drive is operating under overload conditions

Adjust mechanical load

34 Unknown JOB Select alternative JOB

These messages can be reset by pressing a context-dependent push-button with the icon.

Error messages on the systemGeneral system erors

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175

12 Error messages on the system 12.1 General system erors

Error number (value)

Meaning Relevance to system

Error can be reset

4 Wire feed error Phoenix/alpha Q/Tetrix

Yes

5 Inverter/inverter emergency stop circuit temperature error

Phoenix/alpha Q/Tetrix

No, automatic reset

6 Excess mains voltage Phoenix/alpha Q/Tetrix

No, switch off machine

7 Insufficient mains voltage Phoenix/alpha Q/Tetrix


8 Low water level Phoenix/alpha Q/Tetrix


9 Gas error Phoenix/alpha Q/Tetrix

Yes

10 Excess secondary circuit voltage Phoenix/alpha Q/Tetrix


11 Protective conductor error Phoenix/alpha Q/Tetrix


12 System quick stop Phoenix/alpha Q/Tetrix

Yes

13 Internal error, please contact EWM Phoenix/alpha Q/Tetrix


12.2 Process error Error number (value)

Meaning Relevance to system

Error can be reset

49 Process ignition error Phoenix/alpha Q/Tetrix

Yes

50 Arc break error Phoenix/alpha Q/Tetrix

Yes

51 Emergency stop/excess temperature Phoenix/alpha Q/Tetrix

No, automatic reset

52 Double wire feeder missing in the MIG/MAG system or incorrect configuration

Phoenix/alpha Q Yes

53 Switching to a non-existent double wire feeder has been attempted in a system supporting the function to switch double wire feeders.

Phoenix/alpha Q Yes

54 Reducing the open circuit voltage to the set values failed for power sources with voltage reduction device.

Phoenix/alpha Q No

99 No connection to power source (i.e. system switched off)

Phoenix/alpha Q/Tetrix

No, automatic reset

255 Unknown error(1) Phoenix/alpha Q/Tetrix

Yes

(1) An error has been assigned by the system which cannot be assigned. This situation can occur with differences in the software versions between the power source and interface.

Overview of plug configurations X4, digital inputs

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13 Overview of plug configurations 13.1 X4, digital inputs

The control has 6 digital inputs with 24 V logic. 24 V sets the input logically high. 0 V sets the input logically low.

PIN no.: Function/meaning Term in status data

X4/1 +24V

X4/2 Torch collision signal Torch collision

X4/3 User-defined input User-defined input 1

X4/4 0V


X4/6 Input for seam tracking synchronising signal



The inputs are not isolated. Input X4/6 is used only in combination with the seam tracking option!

13.2 X5, digital outputs The control has 4 potential-free relay contacts

PIN no.: Function/meaning Term in actuation data

X5/1 Break contact Depending on configuration

X5/2 Make contact Depending on configuration

X5/3 Relay bottom contact Depending on configuration










The relays may not be subjected to high inductive or capacitive loads. The relay contacts are designed for 10 A at 250 V AC.

13.3 X7, analogue inputs The control has 2 analogue inputs for rapid detection of actual process values:

Pin no.: Function/Meaning Term in status data

X7/1 Reference 0V

X7/2 Uact, 0-10V (corresponds 0 to 100V) Actual welding voltage value

X7/3 Iact, 0-10V (corresponds 0 to 1000A)

Actual welding current value

X7/4 Reference 0V

Overview of plug configurationsX10, diagnostics interface

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13.4 X10, diagnostics interface This connector provides the diagnostics function via an RS232 interface. Only use the cable available from EWM AG to connect to the PC.

PIN no.: Function/meaning Explanation

X10/1 Voltage supply Voltage supply from PC

X10/2 Reference 0 V Reference earth to PC

X10/3 PC-TxD Sending line from PC

X10/4 PC-RxD Receiving line to PC

X10/5 Not in use

X10/6 Not in use

13.5 X15, external power supply Pin no.: Function/Meaning Term in status data

X15/1 DC+ power supply External system supply voltage 24-30V

X15/2 0V reference Reference mass

Only the power supply provided by the manufacturer may be used.

Overview of the BUSINT X11 jumper assignment X15, external power supply

178 099-008196-EW50109.12.2015

14 Overview of the BUSINT X11 jumper assignment JP no.: Function/meaning Assignment

1 For internal use only, do not assign! Must not be set

2 Fast analogue inputs function 0 = analogue signal source is system bus 1 = analogue signal source are analogue inputs on X7

3 Reserved

4 Activation of JOB mode(1) 0 = JOB mode not active 1 = JOB mode active

6 Switching, diagnostics/programming interface

1-2 = programming interface via X2 active 2-3 = diagnostics interface via X10 active

(1) In data profiles with pilot signal operation, JP4 must not be set as otherwise functions may be blocked!

Configuration data overviewX15, external power supply

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15 Configuration data overview Which configuration data can be set in BUSINT X11 depends on the firmware version. If EWM-Konfig does not show a current parameter in the software, make sure the parameter files for this program are up to date. Following parameters can be defined:

Parameter Setting Meaning Available from SW

Option workpiece search

standard Option

For this function the default sensor voltage of 15 V is used For this function the additional Touch1 hardware with 60 V search voltage is actuated

0.0.2.0

Inching mode System External

In MAG systems inching is carried out with the system ramp from 1.0 to 6.0 m/min Inching is carried out using the analogue WF value to create individual inching functions

0.0.2.0

web server active web server active No web server

Enables this function for interfaces with web server option Deactivates an existing web server

0.0.2.0

Suppress missing wire feeder

show error suppress error

For MAG systems a WF mechanism is required for the process by default An error caused by a missing WF mechanism is suppressed

0.0.2.0

Byte notation Intel Motorola

Interpretation or display of all words with low/high byte Interpretation or display of all words with high/low byte

0.0.2.0

Polarity wire stick signal

positive negative

Signal is active when sticking is detected Signal is active when no sticking is detected

0.0.2.0

Forbidden job switching

granted denied

With MAG systems, switching to a TIG JOB is not allowed Switching is allowed

0.0.2.0

Web server authentication

No password Password required

The web server can be accessed without a password A password is required to access the web server

0.0.2.0

Analog values swap bytes

low/high byte high/low byte

Corresponding interpretation of the "analogue" nominal values/ display of the "analogue" actual values

0.0.2.0

Configuration data overview Resetting the configuration data

180 099-008196-EW50109.12.2015

Parameter Setting Meaning Available from SW

Style type real values default style Fanuc style

Analogue actual values are output as standard 15-bit values Output is in the form of inverted values with 13-bit resolution for FANUC controllers

0.0.2.0

Configuration relais K1 Monitoring output KUKA touch output User output

Standard function, builds an ORed output for process monitoring Output used for quick output of the workpiece search function Output can be directly manipulated via the fieldbus

0.0.2.0

Touch threshold voltage

Value in the range of 1.0 V to 15.0 V

Defines a detection span for the workpiece search function, in which contact is detected.

0.0.2.0

DeviceNet UCMM function

Group 2 slave only UCMM function active

The interface behaves as a group 2 slave during establishment of the connection Alternatively, the interface can establish connections via UCMM

0.0.2.0

Factory reset Off Configuration

The setting has no function The machine will be reset to the factory settings, effective on the next start of the machine.

0.0.3.0

Actual value output Actual values Nominal values

Output of actual values after the process has finished. Output of the nominal values applied in the system after the process has finished.

0.0.3.0

15.1 Resetting the configuration data If required, the set configuration parameters can be reset to the factory settings without using the PC software. In that case, please carry out the following steps:

Set jumper JP1.

Switch off power source and interrupt the external voltage supply, if present.

Switch power source back on again, LEDs 7 to 10 should be flashing simultaneously.

Switch off power source and remove jumper JP1.

Switch power source back on again.

Circuit diagramsResetting the configuration data

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16 Circuit diagrams

NC

A BN

C

CN

C

DN

C

EN

ot/A

us

FN

C

GN

C

HU

ist

JN

C

KN

ah

tsu

ch

e

LN

C

MN

C

NN

C

PN

C

RN

ot/A

us

S0

V

TIist

US

ign

al B

ren

ne

rko

llis

ion

V+

24

V1

X1-

+24V US2

GND US2

13

14

A1

A2

3 T

X 7

- 0

0 2

- 1

A B

0 0

K2-

13

14

A1

A2

3 T

X 7

- 0

0 2

- 1

A B

0 0

K1-

+2

4V

0V

0V

+2

4V

Optional:

Optional:

Optional:

+5V

CA

N

0V

CA

N

CA

N-H

CA

N-L

X1/1

X1/2

X1/3

X1/4

X1

X2/1

X2/2

X2/3

X2/4

X2

X3/1

X3/2

X3

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X6/6

X6/5

X6/4

X6/3

X6/2

X6/1

X4/2

X4/1

X4

X6

X5

S V

+ -

1 5

V

A2-

Vin+

0V

VC

C

0V

PC

-TX

D

PC

-RX

D

Suchen ein

42VAC

Uist

Iist

0V

Nahtsuche

Sig. Brennerkollision

Erkennung Werkstück

NC

1 2P

C-R

XD

30V

4N

C

5N

C

6P

C-T

XD

7V

CC

8N

C

9N

C

X2-

Vin+

0V

Optional:

X12-

1 2 3 4 5 6 7 8 9

10

11

12

13

14

15

16

17

18

CA

N-H

+5V

CA

N

NC

NC

NC

NC

+24V

1 NC

42V

AC

CA

N-L

0V

CA

N NC

NC

NC

NC

Erk

ennung W

erk

stü

ck N

C

Suchen e

in

+24V1

X3-

23

1

X2/1

0

X2/9

X2/8

X2/7

X2/6

X2/5

X2/4

X2/3

X2/2

X2/1

Pro

gra

mm

iers

tecker

X2

X10/1

X10/2

X10/3

X10/4

X10/5

X10/6

Dia

gnose

X10

X15

X15/1

X15/2

341 32

X1

X7/12

X7/11

X7/10

X7/9

X7/8

X7/7

X7/6

X7/5

X7/4

X7/3

X7/2

X7/1

X7

X5/12

X5/11

X5/10

X5/9

X5/8

X5/7

X5/6

X5/5

X5/4

X5/3

X5/2

X5/1

X5

Dig

ital O

ut

X4/8

X4/7

X4/6

X4/5

X4/4

X4/3

X4/2

X4/1

X4

X11/1

X11/2

X11/3

X11/4

X11

Syste

m-B

us

X13

X13/2

X13/3

X13/4

X13/1

X13/6

X13/7

X13/5

D-S

ub

.

15

po

lig

Syste

m-B

us

X12

Dig

ital In

X9/1

X9

42V

AC

ext.

X14

X14/1

X14/2

DC

ext.

X17

X17/4

X17/3

X17/2

X17/1

X9/1

2

X9/1

1

X9/1

0

X9/9

X9/8

X9/7

X9/6

X9/5

X9/4

X9/3

X9/2

I B

U S

- 3

A1-

Fe

ldb

usm

od

ul

fie

ld-b

us m

od

ule

Analo

g In

K1

K3

K4

0V

0V

Eingang 3 / user input 3



0V

+24V

US

1

GN

D U

S1

+24V

US

2

GN

D U

S2

PE

+24V

US

1

GN

D U

S1

+24V

US

2

GN

D U

S2

PE

firm

wa

re u

pd

ate

dia

gn

ostics

0V

Datu

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Nam

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gezeic

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25.0

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10

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11

16.0

1.20

12

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DEN

THA

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NIE

DEN

THA

L

NIE

DEN

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TER

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2

busint x11 atcase;(phoenix, alpha q) - ewm ag · 2017. 3. 21. · operating instructions en...

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