GYS SAM-1N (SMART AUTOMATION MODULE) Owner's manual

Brand: GYS

Model: SAM-1N (SMART AUTOMATION MODULE)

Category: Power generators

Type: Owner's manual

This manual is also suitable for

1-48

73502_V1_08/10/2020

www.gys.fr

SAM-1N

TABLE OF CONTENTS

1. GENERAL POINTS ..............................................................................................................................................3

A) Revision ...............................................................................................................................................................................3

B) Introduction ......................................................................................................................................................................... 3

C) Product and communication network compatibility .................................................................................................................. 3

2. SAFETY INSTRUCTIONS TIG AND MIG ................................................................................................4-8

3. PRODUCT PRESENTATION ............................................................................................................................8

4. PRODUCT INSTALLATION ......................................................................................................................9-16

A) Handling of ESD-sensitive parts ............................................................................................................................................. 9

B) Connecting the Anybus communication module .................................................................................................................... 10

C) Connecting the SAM-1N to a GYS generator .........................................................................................................................11

D) Wiring of the module between the GYS generator and the SAM-1N module ............................................................................ 12

E) Connecting SAM-1N to the communication network .............................................................................................................. 12

F) Use of HF process ..............................................................................................................................................................12

G) SWO function (Safe Welding Off) ........................................................................................................................................ 13

I) Electrical safety ........................................................................................................................................................... 13

II) Diagram of safety operating principle ............................................................................................................................ 13

III) Adjusting the safety function ........................................................................................................................................ 13

IV) SWO (Safe Welding Off) and feedback wiring ................................................................................................................ 14

V) Electrical characteristics of the Inputs/Outputs of terminal block X5 ................................................................................14

VI) Setting the Emergency STOP indicator .......................................................................................................................... 15

H) Inputs/Outputs integrated in SAM-1N ............................................................................................................................. 15-16

5. SETTINGS .......................................................................................................................................................... 17

A) C2 switch settings ..............................................................................................................................................................17

B) Adjustment of encoding wheels C3 - C4 ............................................................................................................................... 17

6. START UP ........................................................................................................................................................... 18

7. FIELDBUS CONNECTION AND CONFIGURATION ...................................................................... 19-28

A) ProNET ....................................................................................................................................................................... 19-20

B) EtherNET/IP.................................................................................................................................................................. 20-21

C) ModbusTCP ................................................................................................................................................................... 22-23

D) Setting the IP address ........................................................................................................................................................23

E) DeviceNET .................................................................................................................................................................... 23-24

F) CANopen ...........................................................................................................................................................................25

G) CANopen and Devicenet settings ......................................................................................................................................... 26

H) EtherCAT ...................................................................................................................................................................... 27-28

8. INTERNET PAGE ....................................................................................................................................... 29-33

A) Home page ........................................................................................................................................................................ 29

B) Settings access page .......................................................................................................................................................... 29

C) Page Statut ........................................................................................................................................................................30

D) Conguration page ............................................................................................................................................................. 31

E) SMTP page ........................................................................................................................................................................31

F) Changing a parameter from the web page ...................................................................................................................... 32-33

9. WELDING PROCESSES .......................................................................................................................... 33-40

A) Diagram of a welding cycle .................................................................................................................................................33

B) Diagram of a welding cycle in tracking mode ........................................................................................................................ 34

C) Diagram of a welding cycle in simulation mode ................................................................................................................ 34-35

D) Diagram of a weld rework ................................................................................................................................................... 35

E) Diagram in case of error .....................................................................................................................................................35

F) Parameter curves in DC TIG ................................................................................................................................................ 36

G) Parameter curves in AC TIG ................................................................................................................................................ 37

H) Parameter curves in standard MIG/MAG mode ................................................................................................................. 38-39

I) Parameter curves in pulsed MIG/MAG mode ......................................................................................................................... 40

10. MAINTENANCE ................................................................................................................................................ 41

A) Replacing the battery .........................................................................................................................................................41

B) Replacing Anybus module ...................................................................................................................................................41

C) Update ..............................................................................................................................................................................42

D) List of defects ....................................................................................................................................................................43

SAM-1N

1. GENERAL POINTS

A) REVISION

Revision Date Modication SAM rmware version

1.0 15/09/2020 Creation 1.0

1.01 27/11/2020 Modication 1.0

B) INTRODUCTION

This document describes the commissioning and connection of SAM-1N within a PLC or robot network. The Smart Automation Module

(SAM-1N) is a communication solution between compatible GYS welding powersources and most PLCs/robots. SAM-1N converts the

internal communication language of GYS machines into machine language for complete PLC/robot management.

SAM-1N is designed to operate without changing its code, even if the welding process and communication network are changed.

The module provides access to almost all the parameters of the welding generator, allowing total control of the process by an auto-

maton or a robot. The generator will be integrated into a machine and will be controlled by the internal control elements (automaton,

HMI, ....).

SAM-1N transmits data on the current weld. This makes it possible to adjust the welding parameters by means of programming.

A generator can be used for several applications. The change will be made either by calling up JOBs pre-loaded in the generator or

by selecting options in the user program of the machine in which the generator will be integrated.

The generator/SAM-1N assembly can be reassigned to a new system without modifying it (integration into a new machine, replace-

ment of a PLC or robot, automation of a process, etc).

C) PRODUCT AND COMMUNICATION NETWORK COMPATIBILITY

The module provides access to almost all the parameters of the welding generator, allowing total control of the process by an auto-

maton or a robot. Compatible GYS products are the following:

TIG PROCESS :

TITAN 400 DC / TITANIUM 400 AC/DC

MIG/MAG PROCESS :

NEOPULSE 320C / 400G / 500G

SAM-1N supports the following communication protocols:

Network File Id Version Ref. GYS

Ethernet IP EDS Available 0 0 062078

ModbusTCP N/A 0 0 063013

Pronet GSDML Available 0 0 062085

EtherCAT ESI Available 0 0 063006

Devicenet EDS Available 0 0 062092

CANopen EDS Available 0 0 062108

SAM-1N

2. TIG AND MIG SAFETY INSTRUCTIONS

WARNING - SAFETY RULES

GENERAL INSTRUCTIONS

Read and understand the following safety instructions before use. Any modication or

updates that are not specied in the instruction’s manual should not be undertaken.

The manufacturer is not liable for any injury or damage due to non-compliance with the instructions featured in this manual. In the

event of problems or uncertainties, please consult a qualied person to ensure the installation is carried our correctly.

ENVIRONMENT

This equipment must only be used for welding operations in accordance with the limits indicated on the descriptive panel and/or in

the user manual. Safety instructions must be followed. In case of improper or unsafe use, the manufacturer cannot be held liable.

This equipment must be used and stored in a room free from dust, acid, ammable gas or any other corrosive agent. Operate the

machine in an open, or well-ventilated area.

Operating temperature:

Use between -10 and +40°C (+14 and +104°F).

Storage between -20 and +55°C (-4 and 131°F).

Air humidity:

Lower or equal to 50% at 40°C (104°F).

Lower or equal to 90% at 20°C (68°F).

Altitude:

Up to 1000 meters above sea level (3280 feet).

INDIVIDUAL PROTECTION & GENERAL

Arc welding can be dangerous and can cause serious injury or even death.

Welding exposes the user to dangerous heat, arc rays, electromagnetic elds, risk of electric shock, noise and gas fumes. People

wearing pacemakers are advised to consult a doctor before using the welding machine.

To protect oneself as well as others, ensure the following safety precautions are taken:

In order to protect you from burns and radiation, wear practical clothing. Clothes must be insulating, dry, reproof,

in good condition and cover the whole body.

Wear protective gloves which guarantee electrical and thermal insulation.

Use sufcient welding protective gear for the whole body: hood, gloves, jacket, trousers... (varies depending on the

application/operation). Protect the eyes during cleaning operations. Contact lenses are prohibited during use.

It may be necessary to install reproof welding curtains to protect the area against arc rays, weld spatter and sparks.

Inform the people around the working area to never look at the arc nor the molten metal, and to wear protective

clothes.

Ensure ear protection is worn by the operator if the work exceeds the authorised noise limit (the same applies to any

person in the welding area).

Keep hands, hair and clothes away from moving parts such as fans, and engines.

Never remove the safety covers from the cooling unit when the machine is plugged in. The manufacturer is not liable

for any injury or damage due to non-compliance with the safety precautions.

Parts that have just been welded will be hot and may cause burns when touched. During maintenance work on the

torch or the electrode holder, you should make sure it’s cold enough and wait at least 10 minutes before any inter-

vention. When using a water-cooled torch, make sure that the cooling unit is switched on to avoid any burns that

could potentially be caused by the liquid.

It is important to secure the working area before leaving it to ensure protection of the goods and the safety of people.

SAM-1N

WELDING FUMES AND GAS

Fumes, gas and dust produced during welding are hazardous to health. It is mandatory to ensure adequate venti-

lation and/or extraction to keep fumes and gas away from the work area in accordance with the specic regulations

in your country.

Check that the air supply is effective by referring to the recommended safety regulations.

Precautions must be taken when welding in small areas, and the operator will need supervision from a safe distance. Welding specic

pieces of metal containing lead, cadmium, zinc, mercury or beryllium can be extremely toxic. The user will also need to remove the

grease from the workpiece before welding.

Gas cylinders must be stored in an open or ventilated area. They must be stored vertically and held by a support or trolley to limit

the risk of fall.

Do not weld in areas where grease or paint are stored.

FIRE AND EXPLOSION RISKS

Protect the entire welding area. Flammable materials must be moved to a minimum safe distance of 11 meters.

A re extinguisher must be readily available near the welding operation.

Be careful of weld spatter and sparks. If care is not taken there is a risk of re or an explosion.

Keep people, ammable materials/objects and containers that are under pressure at a safe distance.

Welding in closed containers or pipes should be avoided and , if they are opened, they must be emptied of any ammable or explosive

material (oil, fuel, gas ...).

Grinding operations should not be carried out close to the power supply or near to any ammable materials.

GAS BOTTLE

Gas leaking from cylinders can lead to asphyxiation if present in high concentration around the work area (ventilation

required).

Transport must be done safely: cylinders closed and welding machine switched off. They must be stored vertically

and held by a support to limit the risk of falling.

Close the cylinder when not in use. Beware of temperature variations and exposure to sunlight.

The cylinder must not come into contact with a ame, electric arc, torch, earth clamp or all other sources of heat.

Always keep gas cylinders away from electrical circuits, and therefore never weld a cylinder under pressure.

Be careful when opening the valve on the gas bottle, it is necessary to remove the tip of the valve and make sure

the gas meets your welding requirements.

ELECTRIC SAFETY

The machine must be connected to an earthed electrical supply. Use the recommended fuse size.

An electrical discharge can directly or indirectly cause serious or deadly accidents.

Do not touch any live part of the machine (internally or externally) when it is connected to the power (including Torches, earth cable,

cables or electrodes) as they are connected to the welding circuit.

Before opening the device, it is imperative to disconnect it from the mains and wait 2 minutes, so that all the capacitors are discharged.

Do not touch the torch or electrode holder and the earth clamp at the same time.

Damaged cables and torches must be changed by a qualied technician. Make sure that the cable cross section is adequate with the

usage (extensions and welding cables). Always wear dry clothes which are in good condition in order to be isolated from the welding

circuit. Wear insulating shoes, regardless of the workplace/environment in which you work in.

EMC CLASSIFICATION

This Class A machine is not intended to be used on a residential site where the electric current is supplied by the

domestic low-voltage power grid. There may be potential difculties in ensuring electromagnetic compatibility at

these sites, due to conducted interferences as well as radiation.

This equipment complies with the IEC 61000-3-11 standard.

This equipment does not comply with IEC 61000-3-12 and is intended to be connected to private low-voltage

systems interfacing with the public supply only at the medium- or high-voltage level. On a public low-voltage

power grid, it is the responsibility of the installer or user of the device to ensure, by checking with the operator

of the distribution network, which device can be connected.

SAM-1N

ELECTROMAGNETIC INTERFERENCES

The electric currents owing through a conductor cause electrical and magnetic elds (EMF). The welding current

generates an EMF eld around the welding circuit and the welding equipment.

The EMF elds may disrupt some medical implants, such as pacemakers. Protection measures should be taken for people wearing

medical implants. For example, access restrictions for passers-by or an individual risk evaluation for the welders.

All welders should take the following precautions in order to minimise exposure to the electromagnetic elds (EMF) generated by the

welding circuit::

• position the welding cables together – if possible, attach them;

• keep your head and torso as far as possible from the welding circuit;

• never enroll the cables around your body;

• never position your body between the welding cables. Hold both welding cables on the same side of your body;

• connect the earth clamp as close as possible to the area being welded;

• do not work too close to, do not lean and do not sit on the welding machine

• do not weld when you’re carrying the welding machine or its wire feeder.

People wearing pacemakers are advised to consult their doctor before using this device.

Exposure to electromagnetic elds while welding may have other health effects which are not yet known.

RECOMMANDATIONS TO ASSES THE AREA AND WELDING INSTALLATION

Overview

The user is responsible for installing and using the arc welding equipment in accordance with the manufacturer’s instructions. If

electromagnetic disturbances are detected, it is the responsibility of the user of the arc welding equipment to resolve the situation

with the manufacturer’s technical assistance. In some cases, this remedial action may be as simple as earthing the welding circuit.

In other cases, it may be necessary to construct an electromagnetic shield around the welding power source and around the entire

piece by tting input lters. In all cases, electromagnetic interferences must be reduced until they are no longer bothersome.

Welding area assessment

Before installing the machine, the user must evaluate the possible electromagnetic problems that may arise in the area where the

installation is planned.

In particular, it should consider the following:

a) the presence of other power cables (power supply cables, telephone cables, command cable, etc...)above, below and on the sides

of the arc welding machine.

b) television transmitters and receivers ;

c) computers and other hardware;

d) critical safety equipment such as industrial machine protections;

e) the health and safety of the people in the area such as people with pacemakers or hearing aids;

f) calibration and measuring equipment

g)The isolation of the equipment from other machinery.

The user will have to make sure that the devices and equipments that are in the same room are compatible with each other. This

may require extra precautions;

h) make sure of the exact hour when the welding and/or other operations will take place.

The surface of the area to be considered around the device depends on the the building’s structure and other activities that take place

there. The area taken in consideration can be larger than the limits determined by the companies.

Welding area assessment

Besides the welding area, the assessment of the arc welding systems intallation itself can be used to identify and resolve cases of

disturbances. The assessment of emissions must include in situ measurements as specied in Article 10 of CISPR 11: 2009. In situ

measurements can also be used to conrm the effectiveness of mitigation measures.

RECOMMENDATION ON METHODS OF ELECTROMAGNETIC EMISSIONS REDUCTION

a. National power grid: The arc welding machine must be connected to the national power grid in accordance with the manufacturer’s

recommendation. If interferences occur, it may be necessary to take additional preventive measures such as the ltering of the power

suplly network. Consideration should be given to shielding the power supply cable in a metal conduit. It is necessary to ensure the

shielding’s electrical continuity along the cable’s entire length. The shielding should be connected to the welding current’s source to

ensure good electrical contact between the conduct and the casing of the welding current source.

SAM-1N

b. Maintenance of the arc welding equipment: The arc welding machine should be be submitted to a routine maintenance

check according to the manufacturer’s recommendations. All accesses, service doors and covers should be closed and properly locked

when the arc welding equipment is on.. The arc welding equipment must not be modied in any way, except for the changes and

settings outlined in the manufacturer’s instructions. The spark gap of the arc start and arc stabilization devices must be adjusted and

maintained according to the manufacturer’s recommendations.

c. Welding cables: Cables must be as short as possible, close to each other and close to the ground, if not on the ground.

d. Electrical bonding : consideration shoud be given to bonding all metal objects in the surrounding area. However, metal objects

connected to the workpiece increase the riskof electric shock if the operator touches both these metal elements and the electrode. It

is necessary to insulate the operator from such metal objects.

e. Earthing of the welded part : When the part is not earthed - due to electrical safety reasons or because of its size and its

location (which is the case with ship hulls or metallic building structures), the earthing of the part can, in some cases but not

systematically, reduce emissions It is preferable to avoid the earthing of parts that could increase the risk of injury to the users or

damage other electrical equipment. If necessary, it is appropriate that the earthing of the part is done directly, but in some countries

that do not allow such a direct connection, it is appropriate that the connection is made with a capacitor selected according to national

regulations.

f. Protection and plating : The selective protection and plating of other cables and devices in the area can reduce perturbation

issues. The protection of the entire welding area can be considered for specic situations.

TRANSPORT AND TRANSIT OF THE WELDING MACHINE

Do not use the cables or torch to move the machine. The welding equipment must be moved in an upright position.

Do not place/carry the unit over people or objects.

Never lift the machine while there is a gas cylinder on the support shelf. A clear path is available when moving the item.

The removal of the wire reel from the machine is recommended before undertaking any lifting operation.

EQUIPMENT INSTALLATION

• Put the machine on the oor (maximum incline of 10°.)

• Ensure the work area has sufcient ventillation for welding, and that there is easy access to the control panel.

• The machine must not be used in an area with conductive metal dusts.

• The machine must be placed in a sheltered area away from rain or direct sunlight.

• The machine protection level is IP23, which means :

- Protection against acess to dangerous parts from solid bodies of a ≥12.5mm diameter and,

- Protection against the rain inclined at 60° towards the vertical.

These devices can be used outside in accordance with the IP23 protection index.

The power cables, extensions and welding cables must be fully uncoiled to prevent overheating.

The manufacturer does not incur any responsability regarding damages to both objects and persons that result

from an incorrect and/or dangerous use of the machine.

Stray welding currents/voltages may destroy earth conductors, damage electrical equipment or cause components

to warm up which may cause a re.

• All welding connections must be rmly secured, check regularly !

• Check that the metal piece xation is strong and without any electrical problems !

• Attach or hang all the electrically conductive elements, such as the trolley and slinging equipment, in order to insulate them

• Do not place any electrical equipment, such as drills or grinders, on top of the welding machine without insulating them !

• Always place welding torches or electrodes holders on an insulated surface when they’re not in use !

MAINTENANCE / RECOMMENDATIONS

• Maintenance should only be carried out by a qualied person. Annual maintenance is recommended.

• Ensure the machine is unplugged from the mains, and wait for two minutes before carrying out maintenance

work. DANGER High Voltage and Currents inside the machine.

• Remove the casing 2 or 3 times a year to remove any excess dust. Take this opportunity to have the electrical

connections checked by a qualied person, with an insulated tool.

• Regularly check the condition of the power supply cable. If the power cable is damaged, it must be replaced

by the manufacturer, its after sales service or an equally qualied person.

• Ensure the ventilation holes of the device are not blocked to allow adequate air circulation.

• Do not use this equipment to thaw pipes, to charge batteries, or to start any engine.

SAM-1N

3. PRODUCT PRESENTATION

The following gures show the names of the SAM-1N LEDs and connections:

View from above

LX1

LX3

EMERGENCY STOP

4 5 6

Description of the elements accessible on SAM-1N:

1- Male DB9 connector for GIN between the generator and the SAM-1N module

2- DB9 female connector between the SAM-1N module and other external modules

3- Connection to the control system

4- Source connection indicator

5- Indicator light for connection to the control system

6- Security status indicator light

7- Connection protection cover (access to terminal blocks X4 and X5 of the optional inputs/outputs and safety)

8- Protective cover for settings

Back view

1 32 4 5

On the back of the SAM-1N, you can access the settings of some parameters by unscrewing the protective cover:

1- C1 : Mini USB for SAV (RS485)

2- C2 : Setting switch (see 5.a )

3- C3 : Adjusting the transmission speed (see 7. g )

4- C4 : Node identication or IP address (see 7. d )

5- C5 : USB-A port for an update by USB key (supplied) (cf 10. p )

SAM-1N

Front view

1 2

Dismantling the ap 7 gives access to the option connection terminals:

1- X4 : Input/output connection terminal block (CF chapter 4. h.)

2- X5 : Safety connection terminal block (CF chapter 4. g)

4. PRODUCT INSTALLATION

A) HANDLING OF ESD-SENSITIVE PARTS

Before carrying out any work, switch off the product and disconnect it from the power supply.

Static electricity can damage electronic equipment. Use a grounded antistatic wrist strap, an ankle strap, or equivalent

safety device to prevent electrostatic damage (ESD) when installing this product.

Electrostatic damage can irreparably damage the generator and/or the product. To protect electronic components from electrostatic

damage, place this product on an antistatic surface, such as an antistatic discharge mat, antistatic bag or disposable antistatic mat.

Keep ESD-sensitive components in their original shipping packaging.

Hold the ESD-sensitive workpiece by its ends. Do not touch its pins.

Do not place the ESD-sensitive part on a non-conductive material or on a metal table. If

the ESD-sensitive part has to be removed for any reason, rst place it in a special ESD bag.

The appliance covers and metal tables are electrically grounded. They increase the risk of

damage because they are a discharge path from the body via the ESD-sensitive part (large

metal objects can be discharge paths without being earthed).

Be very careful when working with ESD-sensitive parts in cold weather and when the envi-

ronment is heated, as low humidity increases static electricity.

SAM-1N

B) MOUNTING THE ANYBUS COMMUNICATION MODULE

The Anybus communication module denes the industrial communication network and connects SAM-1N to it. It is essential for the

functioning of the product.

To mount the Anybus communication module follow the instructions below:

EtherNet/IP 062078

DeviceNet 062092

EtherCAT 063006

CANopen 062108

Modbus 063013

PROFINET 062085

0,5 Nm

4,3 lb.in

2X T8

If the Anybus communication module is incorrectly plugged in, it will not work.

The LX3 LED will not illuminate when the product is started.

SAM-1N

MOUNTING OF SAM-1N ON A GYS GENERATOR

There are 2 options for xing SAM-1N:

Fixing with the supplied Velcro fastener:

Velcro®

Fixing by means of 4 screws (not supplied) using the 4 oblong holes provided on the SAM-1N module in order to

allow xing on a support:

150

10025

Ø5.5

189

175

SAM-1N

D) WIRING BETWEEN THE GYS GENERATOR AND THE SAM-1N MODULE

DB9

In order to connect SAM-1N to a generator, KIT-NUM MIG-1 (062993) must rst

be installed in case of MIG/MAG process or KIT-NUM TIG-1 (037960) in case of

TIG process.

Please refer to the installation manuals of the NUM-kits for their installation.

Generator off, connect SAM-1N to the GYS generator via the supplied DB9 cable

(between the DB9 output of the generator and the X1 input of SAM-1N).

NB: If it is necessary to deport the SAM-1N in an electrical enclosure, use a DB9

cable with a maximum length of 10 metres (DB9 Male-Female extension type,

straight link, shielded cable and twisted wire pairs).

E) CONNECTING SAM-1N TO THE COMMUNICATION NETWORK

Connect the Anybus X3 communication module installed in the SAM-1N to

the communication network of your installation using a suitable cable (not

supplied, see module and network specications Chap 7.).

F) USE OF AN HF PROCESS

When using an HF process, connect the ground termi-

nal of the SAM-1N to a screw of the generator via the

supplied cable and the cable gland (see pictures):

SAM-1N connected to the earth of the product

If SAM-1N is installed in an electrical enclosure, connect the ground cable to the cabinet ground.

SAM-1N

G) SWO FUNCTION (SAFE WELDING OFF)

The «Safe Welding Off» function is mainly used to prevent the current or voltage generator from starting. It acts directly on the

power of the generator in a very short time.

The function is also used to stop the generator safely in case of an emergency stop. This avoids abruptly interrupting the power

supply to the generator in the event of a problem. It should be borne in mind that a break in the power supply downstream of the

generator under load is dangerous and can damage the equipment.

I. Electrical safety

The «Safe Welding Off» function does not provide electrical isolation, therefore before working on the generator, it must be electri-

cally isolated by switching off the power supply and isolating the generator locally (padlocking procedure).

II. Diagram of safety operating principle

Safety

PLC

Output

IN 1

Power Control

INPUT (FPGA)

Power Control

(FPGA)

Power Stage

(FET, Relay, ...)

OUT 1

Safety

PLC

Input

I/O I/O

POWER

Shutdown

Message (GIN)

I/O

GYS

III. Adjusting the safety function

A switch on the side of the SAM-1N, behind cover plate 8, is provided to set the safety function of the SAM-1N. You just have to act

on switch 1 and change its position (in high OFF state or in low ON state).

Switch settings table:

DIP Switch Name Position Status

S1 Security activation

OFF Security not activated

ON Security enabled

S2 Not used

SAM-1N

IV. SWO (Safe Welding Off) and feedback wiring

If switch 1 is set to the ON position and switch 2 to the OFF position, it will be necessary to wire the safety device. A terminal block

dedicated to the safety function SWO (Safe Welding Off) is available under the connection protection cover 7 of SAM-1N.

Generator

SAM-1N

Power

+ -

A1A2

GIN

A1A2

24V DC

A2 A1 S13 S14

1 2 3 4

It is also necessary to apply the modication on the KIT-NUM of the generator to take into

account the SWO function on SAM-1N, refer to the KIT-NUM manual.

It is also necessary to apply the modication on the KIT-NUM of the generator to take into account the SWO function of SAM-1N,

refer to the KIT-NUM manual.

The feedback (terminals S13 and S14) is a 24 VDC digital positive logic output (it is active when it is high).

The feedback output (S13-S14) is only activated if the SWO input is activated.

The feedback output (S13-S14) will switch to OFF if a discrepancy occurs between the SWO input (A1-A2) and the welding station

feedback or if the SWO input is disabled (switch 1 in OFF position).

It is recommended to use a shielded cable to make the connection between the safety module

and terminal block X5. Maximum wire cross-section will be 28-16AWG - 1.5mm².

V. Electrical characteristics of the Inputs/Outputs of terminal block X5

EXIT

(feedback)

ENTRY

Type of insulation Dry contact Relay

Connection

3- S13 NO contact

4- S14 Vdc

1- AU_A2: Mass

2- AU_A2: Vcc

Voltage range 20 to 30 VDC

20 to 30 VDC

Logic threshold 15VDC

Maximum low voltage at 3 V

Rated current at 24 VDC Max 2A 10mA

Response time

at rated voltage

8ms 4ms

maximum time

16ms 8ms

Test impulse train

< 1ms at frequency below 100Hz

No reaction No reaction

SAM-1N

VI. Setting the Emergency STOP indicator

An indicator called EMERGENCY STOP LED is located on the top of the SAM-1N and informs about the status of the safety function.

Summary and descriptions of the states of the DEL EMERGENCY STOP:

LED colour Status

Fixed blue N/A

Extinguished / or white Emergency stop not activated

Red Emergency stop engaged

Green Emergency stop not engaged

Flashing red 2 Hz Generator switched off

H) INPUTS/OUTPUTS INTEGRATED IN SAM-1N

The SAM-1N module also has 4 digital inputs and 4 digital outputs that can be controlled directly from the PLC or the robot.

They are accessible under the protective cover of the SAM-1N connections and are to be connected to the terminal board X4 (sup-

plied).

They allow local connection of inputs (such as sensors, buttons, etc.) as well as actuators (such as indicators, solenoid valves,

relays, etc.) without having to add a PLC input and output module.

If parameter 3_03 Copy_CD_Touch is enabled, outputs 1 and 2 are assigned to report Colli-

sion and TouchSense detections respectively.

Marking of the input/output terminal block (top view): Diagram of terminal block X4:

X4 X5

1.1

1.2

1.3

1.4

24V

DO1

DO2 DO3 DO4 DI1 DI2 DI3 DI4 MASS

The outputs are to be connected between terminals 1 to 5 and are arranged as follows:

- Terminal 1: 24 VDC power supply common to the outputs

- Terminal 2: Output No. 1

- Terminal 3: Output No. 2

- Terminal 4: Output No. 3

- Terminal 5: Output No. 4

The inputs are to be connected to terminals 6 to 10 and are arranged as follows:

- Terminal 6: Input n° 1 24VDC

- Terminal 7: Input n° 2 24VDC

- Terminal 8: Input n° 3 24VDC

- Terminal 9: Input n° 4 24VDC

- Terminal 10: Ground 0 VDC common to the inputs

It is recommended to make the connection between the safety module and terminal block X4

using a shielded cable. Maximum wire cross-section will be 28-16AWG - 1.5mm².

SAM-1N

Summary and technical characteristics of the digital inputs and outputs SAM :

Output Input

Type of insulation

Contact SEC 24V DC

1 - 24VDC

2-5 - DO1 – DO4 (NO)

Insulated 500 VDC Photocoupler

6-9 - DI1 - DI4 (NO)

10 - Ground (0V)

ON Voltage Vmin/Vmax +20V à +30 V 15VDC – 28VDC

OFF Voltage Vmin/Vmax 0VDC – 5 VDC

Input impédance 800 KOhm

Rated current at +24 V Max 2A 10 mA

Connection example :

SAM-1N

5. ADJUSTABLE SETTINGS

On the back of the SAM-1N there are several adjustment elements for setting the parameters of the module.

To access it, unscrew the two Torx20 screws and remove the protective cover.

A) C2 SWITCH SETTINGS

To change a setting, toggle the white switch up (OFF state) or down (ON state).

Status of C2 switch settings:

DIP Switch Name Position Status

S1 Security activation

OFF Security not activated

ON Security enabled

S2 Not used

Type of parameter

access

OFF Full access to parameters

ON Limited access to parameters

S4 Mode of operation

OFF JOB_ACCESS

ON ADVANCED_ACCESS

The setting of switch S1 is described in paragraph 4. g) III.

Switch S3 in the third position is used to set the access mode to the generator parameters, the OFF position gives access to all

parameters (FULL). The ON position gives limited access to the parameters (JOB or ADVANCED).

The fourth switch S4 is only active if the third switch is in the ON position. It sets the desired parameter set. In the OFF position,

the station will be in JOB_ACCESS (calling up JOBs pre-recorded in the generator memory). In the ON position, the station will be

in ADVANCED_ACCESS (SAM-1N receives the welding parameters from the PLC/robot).

If a change in the type of access or operation mode is made, it will cause the parameter

addresses to be reassigned when the SAM-1N is restarted.

B) ADJUSTMENT OF ENCODING WHEELS C3 - C4

The two encoder wheels are used to set the communication parameters of the SAM-1N according to the inserted Anybus communi-

cation module.

Settings C3: Transmission speed (see: Ch. 7. g)

C4 settings: IP address or node address (see: Chap.7. d and g)

SAM-1N

6. SYSTEM SETUP

This chapter details the commissioning of the SAM-1N interface and describes its functions.

Voltage supply

SAM-1N is powered via the X1 connector. Depending on the number of elements connected to SAM-1, a (future) Power Supplier

may be required.

Depending on the type of communication network (Connector X3), an external power supply may also be required (DeviceNET,

CANopen ...).

The use of SAM-1N’s digital I/O (Terminal Board X4) requires an external 24V DC power supply.

Switching on the power supply

As soon as the generator is switched on, SAM-1N will start and the LX1 LED ashes red. A self-diagnosis of the elements on the

network is carried out at start-up. When SAM-1N is started, the LX1 indicator turns green.

In case of a problem on the SAM-1N or the generator, the LX1 LED lights up red and an error code is available on the generator

HMI or on the SAM-1N web interface depending on the inserted communication module.

If a USB key containing an update is present on one of the USB ports, it will be done automatically at startup.

The LX1 indicator will blink red during the update.

LX1 indicator denition

The LX1 light indicates the general status of SAM-1N, below is a summary of the different states:

LED colour Status

Fixed blue Generator not ready

Extinguished / or white SAM-1N not connected

Flashing red 20 Hz Initialisation

Red Fault detected

Green NTR

Setting the LX3 indicator

The LX3 LED indicates the status of the communication with the logic controller connected to the Anybus communication module:

LED colour Status

Flashing blue 2 Hz Waiting for automaton/robot connection

Flashing blue 20 Hz Initialisation

Off Anybus module not connected

Red Error in the automaton/robot connection

Green xed NTR

SAM-1N

7. FIELDBUS CONNECTION AND CONFIGURATION

A) PROFINET

SAM-1N can be connected to a ProNET network with the optional Anybus communication module (ref 062085).

GYS offers an electronic GSDML conguration le that can be downloaded from its website in order to interface SAM-1N with a

control unit in a ProNET structure. This XML-based GSD le describes the features and functions of SAM-1N. It contains all the

parameter data necessary for the use of SAM-1N within your structure.

Technical specications of the communication module Anybus - ProNET:

1 43 2

1- Network status LED

2- Module status LED

3- Connection activity LED (port 1)

4- Connection activity LED (port 2)

Description of the status of the network indicator 1:

LED colour Status Comments

OFF Ofine

No power supply

No connection to the I/O controller

Green Online (RUN)

Connection to the controller established

Controller in RUN state

Green - 1 ash Online (OFF)

Connection to the controller established

Controller in STOP state or bad data

Synchronisation not completed

Flashing green Flashing Used by the system tool to identify the network node.

Red Fatal error Major internal error

Red - 1 ash Station name error Unassigned station name

Red - 2 ashes IP address error Unassigned IP address

Red - 3 ashes Conguration error Identication different from actual identication

Description of the module 2 status indicator:

LED colour Status Comments

OFF Not initialized No power supply or module being started or NW_INIT status

Green Normal operation Status output module NW_INIT

Green - 1 ash Diagnostic event A diagnostic event is present

Red Error Module in exceptional state

OFF Fatal error Major internal error

Alternating red/green Firmware update

Do not switch off the module, switching off during this phase can

destroy the module.

SAM-1N

Description of the status of the connection activity indicator 3 and 4:

LED colour Status Comments

OFF No connection No communication

Green Connection established Ethernet connection established, no communication present

Green - 1 ash Active connection Ethernet connection established, communication in progress

Connecting the pins of the RJ45 ProNET socket:

1 8

Pin Description

4, 5, 7, 8 Connected to ground

6 RD-

3 RD+

2 TD-

1 TD+

Armouring Cable armouring

For more information, go to: https://www.probus.com

B) ETHERNET/IP

SAM-1N can be connected to an EtherNET/IP network with the optional Anybus communication module (ref 062078).

GYS offers an EDS electronic data le downloadable from its website to interface SAM-1N into an EtherNET/IP network. This le

contains all the information on SAM-1N settings.

The EtherNET/IP protocol has two modes of communication:

The explicit and the implicit:

- With explicit communication, the parameters are directly accessible at the correct addresses. All parameters to be read or written

are accessible.

- With implicit communication, address information does not exist. The parameters are used / interpreted to link the information

between the devices.

Technical specications of Anybus - EtherNET/IP communication module:

1 65 2

3 4

1 - Network status LED

2 - LED module status

3 - Ethernet interface 1, Port 1

4 - Ethernet Interface 2, Port 2

5 - Connection activity LED (port 1)

6 - Connection activity LED (port 2)

Description of the status of the network indicator 1:

LED colour Comments

OFF No IP address

Green Online, 1 connection or more established (CIP class 1 or 3)

Flashing green Online, no connection established

Red Duplicate IP address, major fault

Red ashing Expired connections (CIP class 1 or 3)

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GYS SAM-1N (SMART AUTOMATION MODULE) Owner's manual

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Model: SAM-1N (SMART AUTOMATION MODULE)

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