ESAB CANopen I/O Profile User manual

Brand: ESAB

Model: CANopen I/O Profile

Type: User manual

This manual is also suitable for

ESAB CANopen I/O Profile

Rev. 1.100459 572 074 GB 080115

ESAB CANopen I/O Profile

Aristot

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TOCe

Rights reserved to alter specifications without notice.

1 INTRODUCTION TO CANopen 3......................................

1.1 Network overview 3.........................................................

1.2 Technical features for CANopen 3.............................................

2 UNIT OVERVIEW 4...................................................

2.1 Functional overview 4........................................................

2.2 Mechanical overview 4.......................................................

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

3.1 Fieldbus connector 5........................................................

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

3.3 LED indicators 6............................................................

3.4 EDS file 7..................................................................

4 I/O DATA MAP 7.....................................................

4.1 IN I/O from Controller to Welding Equipment 7..................................

4.2 OUT I/O from Welding Equipment to Controller 7................................

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 15..........................................................

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1 INTRODUCTION TO CANopen

CANopen is an open communication profile based on the Controller Area Network

(CAN) bus system. It is internationally standardized in ISO 11898.

CANopen has an international user organization called CAN in Automation (CiA). For

further information regarding CANopen matters not associated with this ESAB

product, please contact CiA on e--mail: headquarters@can--cia.dewww.can.cia.de.

There is also information of a general kind available on the Internet at .

1.1 Network overview

The m edia of the fieldbus system is a shielded copper cable consisting of one

twisted pair of communication cable and two cables for external power supply. As

standard, the CANopen Esab products do not use external power supply.

The power supply for the bus is galvanically isolated with a DC/DC converter inside

the Esab equipment. The number of devices participating in each network is logically

limited by CANopen to 128, but physically the present generation of drives allows up

to 64 nodes in one network segment.

The baud rate can be changed from 10 kbit/s to 1Mbit/s at discrete levels. The

maximum possible size of the network for any particular data rate is limited by the

signal transit time required on the bus medium corresponding to the following table:

The baud rate and the node address for the welding node is set inside the Control

box (see chapter XX). The CANopen protocol supports both master--slave and

slave--slave communications. The data on the CANopen bus is updated when a

change is made or on request from another node.

1.2 Technical features for CANopen

Here follows a short list of some important features with the CANopen

communication standard:

CANopen specific cable (twisted pair).

S Access intelligence in low--level devices.

S Master--Slave and Peer--to--Peer capabilities.

S Selectable baud rates from 10kbit/s to 1Mbit/s.

S Max distance 5000m.

S Node removal without damaging the network.

S Use of scaled and open--styled connectors.

S Provision for the typical request /response oriented network communications.

S Provision for the efficient movement of I/O data.

S Fragmentation for moving larger bodies of information.

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2 UNIT OVERVIEW

This chapter provides an overview over the ESAB Aristo CANopen unit.

2.1 Functional overview

The ESAB unit for CANopen is a slave node that can be read and written to from a

CANopen master/slave. Via the host connector, the unit is connected to an

application that gets instant connection to a CANopen network.

2.2 Mechanical overview

DIP- switches and inditation LED

Connection box

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3 INSTALLATION AND CONFIGURATION

3.1 Fieldbus connector

9--pin male D--sub connector

Connector

Signal Description

1 -- Reserved

2 CAN_L CAN_L Bus line (dominant low)

3 CAN_GND CAN ground

4 -- Reserved

5 CAN_SHIEL

Optional CAN Shield

6 GND Optional ground

7 CAN_H CAN_H Bus line (dominant

high)

8 -- Reserved

9 CAN_V+ Optional CAN external power

supply

3.2 Configuration

Node Address

The Network node address is set with two rotary switches inside the Weld Data Unit

(ADDRESS_HIGH and ADDRESS_LOW), see Figure 1. Possible node addresses is

between 1--99 in decimal format. ADDRESS_HIGH is the one in the middle and

ADDRESS_LOW is the one to the right.

The node address is calculated in the following way:

Node address = ADDRESS_HIGH * 10 + ADDRESS_LOW * 1

Note: PDO 3 – 8 only have default COB--ID’s if the node address is less than 64.

Note: T he node address can only be changed during operation.

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Baudrate

The baud rate is configured with one decimal rotary switch inside the Weld Data

Unit. See table below for supported baud rates. Th e baud rate switch is the one to

the left.

Switch

setting

Baudrate

0 Not available

1 10 kbit/s

2 20 kbit/s

3 50 kbit/s

4 125 kbit/s

5 250 kbit/s

6 500 kbit/s

7 800 kbit/s

8 1 Mbit/s

9 Not available

Termination

CANopen uses standard CAN termination on the first and last node on the network.

The termination resistor should be 120 ohm. This should be connected between

CAN_H and CAN_L on the bus.

Note that the termination resistor is only used when the m achine is the first or last on

the bus.

3.3 LED indicators

The node inside the Weld Data Unit is equipped with four bi--color status and

indication LED’s mounted at the front of the m odule.

During start--up a LED, test will be performed to make sure the LED’s are working.

Test sequence is: Red – Green – Off.

There is also an additional bi--color Watchdog LED on the module inside the Weld

Data Unit for development purposes.

LED 2

Color Frequency Description

Green 1Hz Module in ‘Pre--Operation’ state

Green 2Hz Module in ‘Prepared’ state

Green Steady on Module in ‘Operational’ state

Red 1Hz Bus initialization failed

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LED 3

Color Frequency Description

Green 1Hz Bus off / Error Passive

Green Steady on Bus Running

Red 1Hz Other Error

Off -- Power off or module not

initialized

LED 4

Color Frequency Description

Off -- No power to device

Green Steady on Module has power

3.4 EDS file

This file is used to configuring the network. If standard configuration is used this file

is not required. If a standard CANopen configurator is used an EDS file is required.

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

4I/ODATAMAP

4.1 IN I/O from Controller to Welding Equipment

Receive PDO 1, COB--ID 200 h + Node Address

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 Wire Feed 3 W ire Feed 4 Touch sense (Simulation) (Rel Wire) Analog Active

Byte 2 Weld Data Number

Byte 3 Reserved

Byte 4 Reserved

Byte 5 Reserved

Byte 6 Reserved

Byte 7 Reserved

Receive PDO 2, COB--ID 300 h + Node Address

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

Byte 0 Voltage Low Byte(SINT)

Byte 1 Voltage High Byte (SINT)

Byte 2 Wire Feed Speed Low Byte(USINT)

Byte 3 Wire Feed Speed High Byte (USINT)

Byte 4 Reserved

Byte 5 Reserved

Byte 6 Reserved

Byte 7 Reserved

4.2 OUT I/O from Welding Equipment to Controller

Transmit PDO 1 , COB--ID 180 h + Node Add ress

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

Byte 2 Error WDU Error PS Error WF

Byte 3 Reserved

Byte 4 Reserved

Byte 5 Reserved

Byte 6 Reserved

Byte 7 Reserved

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Transmit PDO 2 , COB--ID 280 h + Node Add ress

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

Byte 0 Voltage Low Byte (Measured)

Byte 1 Voltage High Byte (Measured)

Byte 2 Current Low Byte (Measured)

Byte 3 Current High Byte (Measured)

Byte 4 Power Low Byte (Measured)

Byte 5 Power High Byte (Measured)

Byte 6 Reserved

Byte 7 Reserved

Transmit PDO 3 , COB--ID 1C0h + Node Address

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

Byte 0 Voltage Low Byte(SINT)

Byte 1 Voltage High Byte (SINT)

Byte 2 Wire Feed Speed Low Byte(USINT)

Byte 3 Wire Feed Speed High Byte (USINT)

Byte 4 Synergic Voltage Low Byte (SINT)

Byte 5 Synergic Voltage High Byte (SINT)

Byte 6 Reserved

Byte 7 Reserved

Transmit PDO 4 , COB--ID 2C0h + Node Address

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

Byte 0 Weld Data Number

Byte 1 Reserved

Byte 2 Reserved

Byte 3 Reserved

Byte 4 Reserved

Byte 5 Reserved

Byte 6 Reserved

Byte 7 Reserved

Transmit PDO 5 , COB--ID 3C0h + Node Address

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

Byte 0 Weld Data Unit Error Mask

Byte 1 Weld Data Unit Error Mask

Byte 2 Weld Data Unit Error Mask

Byte 3 Weld Data Unit Error Mask

Byte 4 Weld Data Unit Error Mask

Byte 5 Weld Data Unit Error Mask

Byte 6 Reserved

Byte 7 Reserved

Transmit PDO 6 , COB--ID 440h + Node Add ress

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

Byte 0 Power Source Error Mask

Byte 1 Power Source Error Mask

Byte 2 Power Source Error Mask

Byte 3 Power Source Error Mask

Byte 4 Power Source Error Mask

Byte 5 Power Source Error Mask

Byte 6 Reserved

Byte 7 Reserved

Transmit PDO 7, COB--ID 4C0h + Node Add ress

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

Byte 0 Wire Feeder Error Mask

Byte 1 Wire Feeder Error Mask

Byte 2 Wire Feeder Error Mask

Byte 3 Wire Feeder Error Mask

Byte 4 Wire Feeder Error Mask

Byte 5 Wire Feeder Error Mask

Byte 6 Reserved

Byte 7 Reserved

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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 required 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, wir e 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 wir e 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 equipm ent 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 not already is opened by

activating the input. In similar fashion th e end of gas post flow timer will always close

the gas valve if it is not already closed by deactivating the gas input.

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. T he function is not implemented in

the current ver sion of the system.

Inch Reverse

This input bit will contr o l 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 p r e sent 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. T he 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 o f the system.

Reset Error

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

any other way of r esetting than r eboot of the system are affected by this reset. This

function is not im plem ented 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 m achine will always use the values on the Wire Feed Speed and Voltage inputs

in this mode. When using the Normal m ode the machine will set the Wire F e ed

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 memory 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 mode 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. T he scaling factor is 100

so if 20 V is wanted, the value should be 2000. T he 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--synergic mode the equipment will simply use the value set.

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

the synergic value. T he synergic value can be r ead 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 t hen 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 m o re delayed.

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

welding is stopped the nor mal way. At a normal stop the Arc acknowledge signal will

fall when the finalizing procedures are ended (i.e. cr a ter fill, 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 we lding

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 a n error o f the indicated type in one of the err or masks. Which error 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.

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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 ar e 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 lim its, 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 Values

Voltage

This value is m easured 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 m easured by the welding equipment.

Power

This value is m easured by the welding equipment.

Error Mask, Weld Data Unit

This error mask indicates which errors that are presently activated in the Weld Data

Unit. These error codes can be interpreted with the table in Appendix 1.

Error Mask, Power Source

This error mask indicates which errors that are presently activated in the Power

Source. These error codes can be interpreted with the table in Appendix 1.

-- 1 4 --

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Error Mask, Wire F eed er

This error mask indicates which errors that are presently activated in the Wire Feed

Unit. These error codes can be interpreted with the table in Appendix 1.

Appendix 1

-- 1 5 --

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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 current 

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

ESAB AB

SE--695 81 LAXÅ

SWEDEN

Phone +46 584 81 000

www.esab.com

060517

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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 CANopen I/O Profile User manual

Brand: ESAB

Model: CANopen I/O Profile

Type: User manual

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ESAB CANopen I/O Profile

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ESAB CANopen I/O Profile User manual

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