ESAB ESAB Profibus I/O Profile - Small Memory Model User manual

Brand: ESAB

Model: ESAB Profibus I/O Profile - Small Memory Model

Type: User manual

This manual is also suitable for

Profibus I/O Profile - Small Memory Model

Rev. 1.100459 571 074 GB 080115

ESAB Profibus I/O Profile

Small Memory Model

Aristot

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TOCe

Rights reserved to alter specifications without notice.

1 FIELDBUS INTRODUCTION 3.........................................

1.1 Introduction to Profibus DP 3.................................................

1.2 Network overview 3.........................................................

1.3 Technical features for Profibus DP 3...........................................

2 MODULE OVERVIEW 4...............................................

2.1 Mechanical Overview 4......................................................

2.2 Protocol and Supported Functions 4...........................................

2.3 Physical Interface 5.........................................................

2.4 Configuration and Indications 5...............................................

3 INSTALLATION AND CONFIGURATION 5..............................

3.1 Fieldbus connectors 5.......................................................

3.2 Configuration 5.............................................................

3.3 Indications 6................................................................

4 FUNCTIONAL I/O DATA MAP 8........................................

4.1 IN I/O from Controller to Welding Equipment 8..................................

4.2 OUT I/O from Welding Equipment to Controller 8................................

5 FUNCTIONAL DESCRIPTION OF I/O 9.................................

5.1 IN I/O from Controller to Welding Equipment 9..................................

5.2 OUT I/O from Welding Equipment to Controller 11................................

Appendix 1 14..........................................................

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1 FIELDBUS INTRODUCTION

This section provides information about the Profibus organization and network.

1.1 Introduction to Profibus DP

Profibus has an international user organisation called Profibus International, PI, and

local national organizations, PNO. Technical questions regarding the fieldbus should

be addressed to your local Profibus User Group in the instance. Address list is

available on the Profibus Internet Site; www.profibus.com.

For general help on Profibus, contact Profibus international on e--mail;

Profibus_internati[email protected]

. Profibus --DP is normally used in industrial

automation, to transfer fast data for motor controllers, MMI, I/O units and other

industrial equipments.

1.2 Network overview

The media for the fieldbus is a shielded copper cable consisting of a twisted pair.

The baudrate for the bus is between 9.6 kbaud to max 12 Mbaud. The Profibus--DP

network is able to carry 126 nodes and the total amount of data for Profibus--DP is

244 Byte per module.

PLEASE NOTE: Node number 126 is only for commissioning purposes and should

not be used to exchange user data.

The figure below gives an overview of a Profibus--DP network.

1.3 Technical features for Profibus DP

The table below gives a summary of the technical features and the figure on the next

side shows the bus cycle tim e of a Profibus--DP system.

Summary of technical features of Profibus DP

T ransmission technique:

PROFIBUS DIN 19245 Part 1

S EIA RS 485 twisted pair cable of fiber optic

S 9.6 kbit/s up to 12 Mbit/s, max distance 200m at

1.5 Mbit/s extendible with repeaters

Medium Access: hybrid medium access

protocol according to DIN 19245 Part 1

S Mono – Master or Multi – Master systems

supported

S Master and Slave Devices, max 126 stations

possible

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Summary of technical features of Profibus DP

Communications: Peer – to – Peer

(user data transfer ) or Multicast

(synchronisation)

S Cyclic Master – Slave transfer and acyclic Master

– Master data transfer

Operation Modes: S Operate: cyclic transfer of input and output data

S Clear: inputs are read and outputs are cleared

S Stop: only Master – Master functions are possible

Synchronization: enables

synchronization of the input and/or

outputs of all DP--Slaves

S Sync – Mode: Outputs are synchronized

S Freeze – Mode: Inputs are synchronized

Functionality: S Cyclic user data transfer between DP--Master(s)

and DP--Slaves

S Activation or deactivation of individual DP--Slaves

S Checking of the configuration of the DP--Slaves

S Powerful diagnostics mechanisms, 3 hierarchical

levels of the diagnosis messages

S Synchronization of inputs and/or outputs

S Address assignments for the DP--Slaves over the

bus with Master Class 2

S Configuration of the DP--Master (DPM1) over the

bus

S Max 244 bytes input and output data per

DP--Slave, typical 32 bytes.

Security and protection mechanisms: S All messages are transmitted with Hamming

Distance HD=4

S W atchdog timer at the DP--Slaves

S Access protection for the inputs/outputs at the DP

– Slaves

S Data transfer monitoring with configurable timer

DP –Master (DPM1)

Cabling and Installation: S Connecting or disconnecting of stations without

affection of other stations

2 MODULE OVERVIEW

This section provides an overview over the module and describes the technical

features.

2.1 Mechanical Overview

The U8 for Profibus--DP is a slave node that can be read and written to, from a

Profibus--DP master. The U8 for Profibus--DP will not initiate communication to other

other nodes, it will only respond to incoming comm ands.

2.2 Protocol and Supported Functions

S Fieldbus type: PROFIBUS--DP EN 50 170 (DIN 19245)

S Protocol version: ver. 1.10

S Protocol stack supplier: SIEMENS

S Extended functions supported: Diagnostics and User Parameter data accessed

via m ailbox telegram.

S Auto baudrate detection supported. Baudrate range: 9.6 kbit – 12 Mbit.

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2.3 Physical Interface

S Transmission media: Profibus bus line, type A or B specified in EN50170

S Topology: M aster – Slave communication

S Fieldbus connectors: 9 pin female DSUB as standard

S Cable: Shielded copper cable, Twisted pair

S Isolation: The bus is galvanically separated from the other electronics with an on

board DC/DC converter. Bus signals ( A--line and B--line ) are isolated via opto

couplers.

S Profibus --DP communication ASIC: SPC3 chip from SIEMENS.

2.4 Configuration and Indications

S Addess range: 1--99

S Cyclic I/Odata size: 7 – 56 bytes, configurable

S Bus termination switch on board

S LED indicators: ON--line, OFF--line, Fieldbus related diagnostics

S I/O data transm ission: The module only supports cyclic I/O data transmission.

Acyclic data transmission (DP--V1) will be available in a later state.

3 INSTALLATION AND CONFIGURATION

3.1 Fieldbus connectors

The Profibus--DP standard EN 50170 (DIN 19245) recommend the use of a 9 pin

female D--sub connector. Depending on the protection class and type of application,

other connector designs are also allowed.

Guideline: If the m odule should be used with larger data transfer rates than 1500

kbit/s, the D--sub connector is recommended to use.

D- SUB connector

D--SUB Screw Te rminal Name

Housing Shield Connected to PE

1 Not connected --

2 Not connected --

3 B-- Line Positive RxD/TxD according to RS 485

specifiction

4 RTS Request To Send*

5 GND Isolated GND from RS 485 side*

6 +5 V BUS Isolated +5 V from RS 485 side*

7 Not connected --

8 A-- Line Negative RxD/TxD according to RS 485

specifiction

9 Not connected --

* +5 V BUS and GND BUS are used for bus termination. Some devices, like optical transceivers (RS 485 to fibre optics)

might require external power supply from these pins. PTS is used in some equipment to determine the direction of transmission.

In this application only A--Line, B--Line and Shield are used.

3.2 Configuration

Baudrate

The baudrate on a Profibus--DP network is set during configuration of the master

and only one baudrate is possible in a Profibus--DP installation. T he U8

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Profibus --DP has an auto baudrate detection function and the user does not have to

configure the baudrate on the module.

Baudrates supported by the U8 Profibus--DP are:

Baudrates supported by the U8 Profibus-- DP

9.6 kbit/s

19.2 kbit/s

93.75 kbit/s

187.5 kbit/s

500 kbit/s

1.5 Mbit/s

3 Mbit/s

6 Mbit/s

12 Mbit/s

Termination

The end node in a Profibus--DP network has to be terminated to avoid reflections on

the bus line. The circuit board inside the U8 Profibus--DP is equipped with a

termination switch to accomplish this in an easy way.

If the U8 is the first or the last node in a network the switch should be at “ON”.

Otherwise it should be in “OF F” position.

PLEASE NOTE: If an external termination connector is used the switch must be in

OFF position.

Node Address

Before configuring the U8 Profibus--DP module the node address has to be set. This

is done with two rotary switches on the module inside the U8, this enables address

settings from 1 – 99 in decimal format.

Looking at the front of the circuit board, the leftmost switch is used for the ten setting

and the rightmost switch is used for the setting of the integers.

Example:

Address = ( Left Switch Setting x 10 ) + ( Right Switch Setting x 1 )

PLEASE NOTE: The node address can not be changed during operation.

GSD- file

Each device on a Profibus--DP network is associated with a GSD file, containing all

necessary information about the device. This file is used by the network

configuration program during configuration of the network.

The latest version of this file can be received by contacting ESAB.

3.3 Indications

The circuit board is equipped with four LED’s mounted at the front and one LED on

the board, used for debugging purposes. The function of the LED’s are described in

the table and figure below.

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LED no. Indication Description

1 -- Not Used

2 Green Indicates that the module is On--Line on the

fieldbus.

Green – Module is On--Line and data

exchange is possible.

Turned Off – Module is not On--Line.

3 Red Indicates that the module is Off--Line on the

fieldbus.

Red – Module is Off--Line and no data

exchange is possible.

Turned Off – Module is Off--Line

4 Red Fieldbus Diagnostics

Indicates certain faults on the fieldbus side.

Flashing Red 1 Hz – Error in configuration: IN

and/or OUT length set during initialization of

the module is not equal to the length set during

configuration of the network.

Flashing Red 2 Hz – Error in User Parameter

Data: The length/contents of the user

parameter set during initialization of the

module is not equal to the length/contents set

during configuration of the network.

Flashing Red 4 Hz –Errorininitializationof

the Profibus communication ASIC.

Turned Off – No diagnostic present.

There is also one additional Bicolour Watchdog LED on the circuit board inside the

U8. T his LED is for internal use only.

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4 FUNCTIONAL I/O DATA MAP

4.1 IN I/O from Controller to Welding Equipment

Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7

Byte 0 Weld On Quick Stop Emerg. Stop Inching Gas purge Clean Inch Reverse (Reset Error)

Byte 1 Wire Feed 1 Wire Feed 2 W ire Feed 3 Wire Feed 4 Anal og Active (Simulation) (Rel Wire) Touch Sense

Byte 2 Weld Data Number

Byte 3 Reserved

Byte 4 Reserved

Byte 5 Reserved

Byte 6 Reserved

Byte 7 Reserved

Byte 8 Voltage Low Byte(SINT)

Byte 9 Voltage High Byte (SINT)

Byte 10 Wire Feed Speed Low Byte(USINT)

Byte 11 Wire Feed Speed High Byte (USINT)

Byte 12 Reserved

Byte 13 Reserved

Byte 14 Reserved

Byte 15 Reserved

4.2 OUT I/O from Welding Equipment to Controller

Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7

Byte 0 Weld Busy Arc Ackn. TS resp

Byte 1 Error Type 1 Error Ty pe 2 Error Ty pe 3 Error Ty pe 4 Error Type 5 Error Type 6 Error Type 7 Error Type 8

Byte 2 Error WDU Error PS Error WF

Byte 3 Voltage Low Byte (Measured)

Byte 4 Voltage High Byte (Measured)

Byte 5 Current Low Byte (Measured)

Byte 6 Current High Byte (Measured)

Byte 7 Power Low Byte (Measured)

Byte 8 Power High Byte (Measured)

Byte 9 Weld Data Number

Byte 10 Voltage Low Byte(SINT)

Byte 11 Voltage High Byte (SINT)

Byte 12 Wire Feed Speed Low Byte(USINT)

Byte 13 Wire Feed Speed High Byte (USINT)

Byte 14 Synergic Voltage Low Byte (SINT)

Byte 15 Synergic Voltage High Byte (SINT)

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5 FUNCTIONAL DESCRIPTION OF I/O

5.1 IN I/O from Controller to Welding Equipment

Weld Status Bits

Weld On

This bit starts a Welding procedure. Before a welding procedure is started the Quick

Stop bit and Emergency stop bits are checked.

Quick Stop

This bit performs a Quick Stop if the Equipment is in a welding procedure. This

means that the Welding Equipment will do a normal stopping procedure without

Craterfilling.

This function is used when a fast stop is requir e d but it will handle Burnback the

normal way to avoid that the wire is left frozen in the weld pool. This bit will also

block a start command.

Emergency Stop

This bit performs a Emergency Stop if the Equipment is in a Welding procedure. This

means that the welding equipment will shut off the arc, wire feeding and gas flow

without any burnback time. This bit will also block a start command.

Inching

This bit makes the wire feeder to start feed the wire without activating the power

source. The feeder will feed the wire at the adjusted speed. If this bit is activated

during a welding procedure, this command will be ignored.

If both Weld On and Inching is activated at the same time the equipment will ignore

the Inch command and start a welding procedure.

Gas Purge

The gas control works in parallel with the regular gas--handling timers, which means

that the gas inputs can be left unused.

A weld start will always start with opening the gas valve if it isn’t already opened. In

similar fashion the end of gas post flow timer will always close the gas valve if it isn’t

already closed.

Accordingly when you what this input to control the gas valve operations the gas pre

flow time shall be set at minimum and the gas post flow time shall be set at

maximum.

Clean

This bit controls a valve for spatter cleaning gas. The function is not implemented in

the current version of the system.

Inch Reverse

This input bit will control backward--jogging movement to position the wire end before

weld start. This function is not implemented in the current version of the system.

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Wire Feed 1-- 4

These bits are used to change active wire feeder. If more than one is activated the

wire feeder with the lowest I/O number will be activated. If non are activated it will

default to the lowest numbered feeder that are present in the system.

Release Wire

This function will execute a current pulse to burn off a wire that is frozen in the weld

pool if previous weld is ended in a not normal way. The release pulse is only

executed if ”Weld On” is off. This function is not implemented in the current version

of the system.

Touch Sense

When this input is activated the power source will output a weak power to detect if

there is contact in the welding circuit. As long as this function is engaged the output

bit ”Touch Sense Response” will be changed according to the condition in the

welding circuit. This function is not implemented in the current version of the system.

Reset Error

This input bit will reset the error indication. Only error indications that do not have

any other way of resetting than reboot of the system are affected by this reset. This

function is not implemented in the current version of the system.

Analog Active

This input is used to switch between analog active mode and normal mode. When

using the Analog Active mode the machine will not use the pre--stored values for

Wire Feed Speed and Voltage when a new Weld Data Set is selected.

The machine will always use the values on the Wire Feed Speed and Voltage inputs

in this mode. When using the Norm a l mode the machine will set the Wir e Feed

Speed and Voltage to the values stored in the set.

If the inputs for Wire Feed Speed and Voltage are changed after the Weld Data Set

is changed the machine will use the new values.

Weld Data Number

This byte is used to recall a complete set of weld data from the weld data m emory in

the Weld Data Unit. A complete set of weld data includes all settings that can be

made in the Weld Data Unit.

Among a large number of setting values this includes:

S Wire Type

S Wire Dimension

S Gas Type

S Use of synergic m ode or non--synergic mode

S Pulse Welding or Dip/Spray Welding

S Start Data

S Stop Data

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Numerical Welding Parameters

Voltage

This 16--bit signed value is used to adjust the voltage value. The scaling factor is 100

so if 20 V is wanted, the value should be 2000. The resolution within the machine is

¼ V. This means that if you set 10,6 V the value displayed will be 10,5 V.

If the machine is in non --syner gic mode the equipment will simply use the value set.

If the equipment is in synergic mode the machine will use the value as an offset from

the synergic value. T he synergic value can be read from the output I/O area.

Wire Feed Speed

This 16--bit unsigned value is used to adjust the wire feed value. The scaling factor is

100 so if 15 m/min is wanted, the value should be 1500. The resolution within the

machine is ¼ m/min.

5.2 OUT I/O from Welding Equipment to Controller

Weld Status Bits

Weld Busy

This signal indicates that the welding equipment is occupied with welding. If a stuck

wire or a burn through will break the welding circuit then the power source will go on

trying to weld until it gets a stop command.

A condition that makes the Arc acknowledge signal to fall does not stop the welding

equipment from continuing the attempts to weld.

As a default value, the weld busy signal is activated when the gas preflow begins

until the gas postflow stops. By chosing Weld Busy in the configuration menu, it is

possible to choose to have the weld busy signal activated when the power source

outputs power, until the gas postflow stops. In the menu you can also choose to have

the weld busy signal activated when the power source outputs power, until the power

source shuts down the power output.

Arc Acknowledge

This signal will be activated when the arc is established at a weld start and it will fall

when voltage and current variations indicate that there can not be welding any

longer.

The criteria for arc established is that the process control has passed its start

procedure which means that it is not enough with just a short--circuit to fulfill the

criteria. Typical delay times from first contact to Arc acknowledge (wire feed time till

first contact not included) is in the range 2 to 20 ms. In case of a bad start the Arc

acknowledge signal will be more delayed.

The Arc acknowledge signal will stay on until either the weld is interrupted or the

welding is stopped the normal way.

At a normal stop the Arc acknowledge signal will fall when the f inalizing procedures

are ended ( i.e. craterfill, burnback) and the power source cuts the arc.

An interrupted weld is detected if abnormal conditions during welding makes the

weld process control deviate significantly from a normal working point. A certain

filtering time is used for this detection.

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One example is if the wire is stuck and the Power Source keeps an arc between

workpiece and contact nozzle so that a normal current detection would indicate that

current is flowing and arc is assumed OK. In this case the Arc acknowledge signal

will fall due to that the weld controller has deviated to much from normal welding

conditions.

Touch Sense Response

This output bit will indicate contact in welding circuit as long as input bit ”Touch

Sense ” is active It will be ”0” all other time. This function is not implemented in the

current version of the system.

Error of type 1--8

There is an error of the indicated type in one of the error masks. Which err o r that will

be caught can be configured with a service function. With this feature it is possible to

configure, for example, one error type to be a general error and another error type to

be gas error and so on.

As a default the error types are configured as follows:

Error type 1 Error type

Error type

Reset

Error

Error 1   

Error 2   

Error 3   

Error 4    

Error 5  

Error 6  

Error 7   

Error 8   

Error 9   

Error 10   

Error 11   

Error 12   

Error 13 

Error 14   

Error 15   

Error 16 

Error 17   

Error 18   

Error 19   

Error 20   

Error 21   

Error 22   

Error 23   

Error 24 

Error 25  

Error 26   

Error 27   

Error 28   

Error 29  

Error 30   

Error 31   

Error 32  

Error 33   

Error 34   

Error 35   

Error 36   

Error 37   

Error 38   

Error 39  

ErrorinWeldDataUnit

Change in Weld Data Unit Errors. Is set to 1 when there is a change in the Weld

Data Unit bit mask. Does not matter if a specific error arises or disappears.

-- 1 3 --

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Error in Power Source Unit

Change in Power Source Unit Errors. Is set to 1 when there is a change in the Weld

Data Unit bit mask. Does not matter if a specific error arises or disappears.

Error in Wire Feed Unit

Change in Wire Feed Unit Errors. Is set to 1 when there is a change in the Weld

Data Unit bit mask. Does not matter if a specific error arises or disappears.

Weld Data Number

This byte is updated every time there has been a successful recall of a Weld Data

Set. In case that the desired Weld Data Set does not exist in the Weld Data Memory,

the old number will remain.

Note that if the controller recall a Weld Data Set and the Operator uses the Weld

Data Unit to change any individual parameter, the Weld Data in the Operating Weld

Data Memory and the Weld Data in the Weld Data Set indicated by this byte will not

be consistent.

Numerical Welding Parameters

Voltage

This 16--bit unsigned value indicates which voltage the welding machine is using. If a

value is set with RPDO 2 that are outside limits, this value will be set to the nearest

allowed value.

Wire Feed Speed

This 16--bit signed value indicates which wire feed speed the wire feeder is using. If

a value is set with RPDO 2 that are outside limits, this value will be set to the nearest

allowed value.

Synergic Voltage

This 16 --bit unsigned value indicates the result of the calculations preformed by the

welding equipment. The difference between this value and the voltage is the offset

set with RPDO2. This value is only valid when running in synergic mode.

Measured Valu es

Voltage

This value is measured by the welding equipment. In pulse welding it can be

configured if the value presented should be the average value or the pulse value.

Current

This value is measured by the welding equipment.

Power

This value is measured by the welding equipment.

Appendix 1

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Appendix 1

Specification of error codes in LUD

Error code Description SLUD LUD MEK

1 EPROM   

2 RAM   

3 External RAM 

4 Power supply voltage 5V   

5 High DC voltage 

6 High temperature 

7 High primary c urrent 

8 DC Voltage 1*  

9 DC Voltage 2*  

10 DC Voltage 3* 

11 Current--servo / Wire speed--servo  

12 Communication error ( warning -- internal bus )   

14 Communication error ( bus off -- internal bus ) 

15 Message lost ( internal bus )   

17 Lost contact with MEK 

18 Lost contact with LUD 

19 Error in battery--driven memory 

20 Unaccepted setting values 

21 Incompatible setting values 

22 Spill in transmit buffer 

23 Spill in receive buffer 

25 Incompatible weld data format 

26 Watchdog  

27 No more wire detected 

28 Stack overflow   

29 No more water flow 

30 Lost contact with TIG--card 

31 No answer from display card 

32 Error detected in gas flow 

33 Hardware check failed in fieldbus interface 

34 Memory test failed in fieldbus interface 

35 Initialisation failed in fieldbus interface 

36 Watchdog timeout in fieldbus interface 

37 Fieldbus interface initialisation lost. 

38 Bus Off in fieldbus interface. 

39 Lost contact with analog remote node. 

Unit DC voltage 1 DC voltage 2 DC voltage 3

SLUD 3 V (batt)

LUD +15VC --15V +15VB

MEK 15V 20V

-- 1 5 --

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www.esab.com

060517

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Tel: +1 843 669 44 11

Fax: +1 843 664 57 48

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 5308 9922

Fax: +86 21 6566 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. ESABindo Pratama

Jakarta

Tel: +62 21 460 0188

Fax: +62 21 461 2929

JAPAN

ESAB Japan

Tokyo

Tel: +81 3 5296 7371

Fax:+81352968080

MALAYSIA

ESAB (Malaysia) Snd Bhd

Selangor

Tel: +60 3 8027 9869

Fax:+60380274754

SINGAPORE

ESAB Asia/Pacific Pte Ltd

Singapore

Tel:+6568614322

Fax: +65 6861 31 95

SOUTH KOREA

ESAB SeAH Corporation

Kyungnam

Tel: +82 55 269 8170

Fax: +82 55 289 8864

UNITED ARAB EMIRATES

ESAB Middle East FZE

Dubai

Tel: +971 4 887 21 11

Fax: +971 4 887 22 63

Representative offices

BULGARIA

ESAB Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt

Dokki--Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Office

Bucharest

Tel/Fax: +40 1 322 36 74

RUSSIA

LLC ESAB

Moscow

Tel: +7 095 543 9281

Fax: +7 095 543 9280

LLC ESAB

St Petersburg

Tel: +7 812 336 7080

Fax: +7 812 336 7060

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

www.esab.com

ESAB ESAB Profibus I/O Profile - Small Memory Model User manual

Brand: ESAB

Model: ESAB Profibus I/O Profile - Small Memory Model

Type: User manual

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Profibus I/O Profile - Small Memory Model

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ESAB ESAB Profibus I/O Profile - Small Memory Model User manual

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ESAB ESAB Profibus I/O Profile - Small Memory Model User manual

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