GB
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:
S
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
pin
Signal Description
1 -- Reserved
2 CAN_L CAN_L Bus line (dominant low)
3 CAN_GND CAN ground
4 -- Reserved
5 CAN_SHIEL
D
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
2
Error type
3
Error type
4
Error type
5
Error type
6
Error type
7
Error type
8
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.
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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
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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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