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Rev. 1.100459 578 074 GB 080115
ESAB Profibus I/O Profile
Large Memory Model
Aristot
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TOCe
Rights reserved to alter specifications without notice.
1 FIELDBUS INTRODUCTION 3.........................................
1.1 Introduction to Profibus DP 3.................................................
1.2 Network overview 3.........................................................
1.3 Technical features for Profibus DP 3...........................................
2 MODULE OVERVIEW 4...............................................
2.1 Mechanical Overview 4......................................................
2.2 Protocol and Supported Functions 4...........................................
2.3 Physical Interface 5.........................................................
2.4 Configuration and Indications 5...............................................
3 INSTALLATION AND CONFIGURATION 5..............................
3.1 Fieldbus connectors 5.......................................................
3.2 Configuration 6.............................................................
3.3 Indications 6................................................................
4 FUNCTIONAL I/O DATA MAP 8........................................
4.1 IN I/O from Controller to Welding Equipment 8..................................
4.2 OUT I/O from Welding Equipment to Controller 8................................
5 FUNCTIONAL DESCRIPTION OF I/O 9.................................
5.1 IN I/O from Controller to Welding Equipment 9..................................
5.2 OUT I/O from Welding Equipment to Controller 11................................
Appendix 1 15..........................................................
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1 FIELDBUS INTRODUCTION
This section provides information about the Profibus organization and network.
1.1 Introduction to Profibus DP
Profibus has an international user organisation called Profibus International, PI, and
local national organizations, PNO. Technical questions regarding the fieldbus should
be addressed to your local Profibus User Group in the instance. Address list is
available on the Profibus Internet Site; www.profibus.com.
For general help on Profibus, contact Profibus international on e--mail;
Profibus_internati[email protected]. Profibus --DP is normally used in industrial
automation, to transfer fast data for motor controllers, MMI, I/O units and other
industrial equipments.
1.2 Network overview
The media for the fieldbus is a shielded copper cable consisting of a twisted pair.
The baudrate for the bus is between 9.6 kbaud to max 12 Mbaud. The Profibus--DP
network is able to carry 126 nodes and the total amount of data for Profibus--DP is
244 Byte per module.
PLEASE NOTE: Node number 126 is only for commissioning purposes and should
not be used to exchange user data.
The figure below gives an overview of a Profibus--DP network.
1.3 Technical features for Profibus DP
The table below gives a summary of the technical features and the figure on the next
side shows the bus cycle tim e of a Profibus--DP system.
Summary of technical features of Profibus DP
Transmission technique:
PROFIBUS DIN 19245 Part 1
S EIA RS 485 twisted pair cable of fiber optic
S 9.6 kbit/s up to 12 Mbit/s, max distance 200m at 1.5
Mbit/s extendible with repeaters
Medium Access: hybrid medium access
protocol according to DIN 19245 Part 1
S Mono – Master or Multi – Master systems supported
S Master and Slave Devices, max 126 stations possible
Communications: Peer – to – Peer ( user
data transfer ) or Multicast (synchronisation)
S Cyclic Master – Slave transfer and acyclic Master –
Master data transfer
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Summary of technical features of Profibus DP
Operation Modes: S Operate: cyclic transfer of input and output data
S Clear: inputs are read and outputs are cleared
S Stop: only Master – Master functions are possible
Synchronization: enables synchronization of
the input and/or outputs of all DP--Slaves
S Sync – Mode: Outputs are synchronized
S Freeze – Mode: Inputs are synchronized
Functionality: S Cyclic user data transfer between DP--Master(s) and
DP--Slaves
S Activation or deactivation of individual DP--Slaves
S Checking of the configuration of the DP--Slaves
S Powerful diagnostics mechanisms, 3 hierarchical levels
of the diagnosis messages
S Synchronization of inputs and/or outputs
S Address assignments for the DP --Slaves over the bus
with Master Class 2
S Configuration of the DP--Master (DPM1) over the bus
S Max 244 bytes input and output data per DP--Slave,
typical 32 bytes.
Security and protection mechanisms: S All messages are transmitted with Hamming Distance
HD=4
S Watchdog timer at the DP--Slaves
S Access protection for the inputs/outputs at the DP –
Slaves
S Data transfer monitoring with configurable timer DP
–Master (DPM1)
Cabling and Installation: S Connecting or disconnecting of stations without affection
of other stations
2 MODULE OVERVIEW
This section provides an overview over the module and describes the technical
features.
2.1 Mechanical Overview
The U8 for Profibus--DP is a slave node that can be read and written to, from a
Profibus--DP master. The U8 for Profibus--DP will not initiate communication to other
other nodes, it will only respond to incoming comm ands.
2.2 Protocol and Supported Functions
S Fieldbus type: PROFIBUS--DP EN 50 170 (DIN 19245)
S Protocol version: ver. 1.10
S Protocol stack supplier: SIEMENS
S Extended functions supported: Diagnostics and User Parameter data accessed
via m ailbox telegram.
S Auto baudrate detection supported. Baudrate range: 9.6 kbit – 12 Mbit.
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2.3 Physical Interface
S Transmission media: Profibus bus line, type A or B specified in EN50170
S Topology: M aster – Slave communication
S Fieldbus connectors: 9 pin female DSUB as standard
S Cable: Shielded copper cable, Twisted pair
S Isolation: The bus is galvanically separated from the other electronics with an on
board DC/DC converter. Bus signals ( A--line and B--line ) are isolated via opto
couplers.
S Profibus --DP communication ASIC: SPC3 chip from SIEMENS.
2.4 Configuration and Indications
S Addess range: 1--99
S Cyclic I/Odata size: 7 – 56 bytes, configurable
S Bus termination switch on board
S LED indicators: ON--line, OFF--line, Fieldbus related diagnostics
S I/O data transm ission: The module only supports cyclic I/O data transmission.
Acyclic data transmission (DP--V1) will be available in a later state.
3 INSTALLATION AND CONFIGURATION
3.1 Fieldbus connectors
The Profibus--DP standard EN 50170 (DIN 19245) recommend the use of a 9 pin
female D--sub connector. Depending on the protection class and type of application,
other connector designs are also allowed.
Guideline: If the m odule should be used with larger data transfer rates than 1500
kbit/s, the D--sub connector is recommended to use.
D- SUB connector
D--SUB Screw Te rminal Name
Housing Shield Connected to PE
1 Not connected --
2 Not connected --
3 B-- Line Positive RxD/TxD according to RS 485 specifiction
4 RTS Request To Send*
5 GND Isolated GND from RS 485 side*
6 +5 V BUS Isolated +5 V from RS 485 side*
7 Not connected --
8 A-- Line Negative RxD/TxD according to RS 485 specifiction
9 Not connected --
* +5 V BUS and GND BUS are used for bus termination. Some devices, like optical transceivers
(RS 485 to fibre optics) might require external power supply from these pins. PTS is used in some
equipment to determine the direction of transmission. In this application only A--Line, B--Line and
Shield are used.
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3.2 Configuration
Baudrate
The baudrate on a Profibus--DP network is set during configuration of the master
and only one baudrate is possible in a Profibus--DP installation. The U8 Profibus--DP
has an auto baudrate detection function and the user does not have to configure the
baudrate on the module.
Baudrates supported by the U8 Profibus--DP are:
Baudrates supported by the U8
Profibus --DP
9.6 kbit/s
19.2 kbit/s
93.75 kbit/s
187.5 kbit/s
500 kbit/s
1.5 Mbit/s
3 Mbit/s
6 Mbit/s
12 Mbit/s
Termination
The end node in a Profibus--DP network has to be terminated to avoid reflections on
the bus line. The circuit board inside the U8 Profibus--DP is equipped with a
termination switch to accomplish this in an easy way.
If the U8 is the first or the last node in a network the switch should be at “ON”.
Otherwise it should be in “OF F” position.
PLEASE NOTE: If an external termination connector is used the switch must be in
OFF position.
Node Address
Before configuring the U8 Profibus--DP module the node address has to be set. This
is done with two rotary switches on the module inside the U8, this enables address
settings from 1 – 99 in decimal format.
Looking at the front of the circuit board, the leftmost switch is used for the ten setting
and the rightmost switch is used for the setting of the integers.
Example:
Address = ( Left Switch Setting x 10 ) + ( Right Switch Setting x 1 )
PLEASE NOTE: The node address can not be changed during operation.
GSD- file
Each device on a Profibus--DP network is associated with a GSD file, containing all
necessary information about the device. This file is used by the network
configuration program during configuration of the network.
The latest version of this file can be received by contacting ESAB.
3.3 Indications
The circuit board is equipped with four LED’s mounted at the front and one LED on
the board, used for debugging purposes. The function of the LED’s are described in
the table and figure below.
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LED no. Indication Description
1 -- Not Use d
2 Green Indicates that the module is On --Line on the fieldbus.
Green – Module is On--Line and data exchange is
possible.
Turned Off – Module is not On --Line.
3 Red Indicates that the module is Off--Line on the fieldbus.
Red – Module is Off--Line and no data exchange is
possible.
Turned Off – Module is Off--Line
4 Red F ieldbus Diagnostics
Indicates certain faults on the fieldbus side.
Flashing Red 1 Hz – Error in configuration: IN
and/or OUT length set during initialization of the
module is not equal to the length set during
configuration of the network.
Flashing Red 2 Hz – Error in User Parameter Data:
The length/contents of the user parameter set during
initialization of the module is not equal to the
length/contents set during configuration of the
network.
Flashing Red 4 Hz – Error in initialization of the
Profibus communication ASIC.
Turned Off – No diagnostic present.
There is also one additional Bicolour Watchdog LED on the circuit board inside the
U8. T his LED is for internal use only.
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4 FUNCTIONAL I/O DATA MAP
4.1 IN I/O from Controller to Welding Equipment
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Byte 0 Weld On Quick Stop Emerg. Stop Inching Gas purge Clean Inch Reverse (Reset Error)
Byte 1 Wire Feed 1 Wire Feed 2 Wire Feed 3 Wire Feed 4 Analog Active (Si m ulation) (Rel Wire) Touch sense
Byte 2 Reserved
Byte 3 Reserved
Byte 4 Reserved
Byte 5 Reserved
Byte 6 Reserved
Byte 7 Reserved
Byte 8 Voltage Low Byte(SINT)
Byte 9 Voltage High Byte (SINT)
Byte 10 Wire Feed Speed Low Byte(USINT)
Byte 11 Wire Feed Speed High Byte (USINT)
Byte 12 Reserved
Byte 13 Reserved
Byte 14 Reserved
Byte 15 Reserved
Byte 16 Weld Data Number
Byte 17 Reserved
Byte 18 Reserved
Byte 19 Reserved
Byte 20 Reserved
Byte 21 Reserved
Byte 22 Reserved
Byte 23 Reserved
4.2 OUT I/O from Welding Equipment to Controller
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Byte 0 Weld Busy Arc Ackn. TS resp
Byte 1 Error Type 1 Error Type 2 Error Type 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
Byte 8 Voltage Low Byte (Measured)
Byte 9 Voltage High Byte (Measured)
Byte 10 Current Low Byte (Measured)
Byte 11 Current High Byte (Measured)
Byte 12 Power Low Byte (Measured)
Byte 13 Power High Byte (Measured)
Byte 14 Reserved
Byte 15 Reserved
Byte 16 Voltage Low Byte(SINT)
Byte 17 Voltage High Byte (SINT)
Byte 18 Wire Feed Speed Low Byte(USINT)
Byte 19 Wire Feed Speed High Byte (USINT)
Byte 20 Synergic Voltage Low Byte (SINT)
Byte 21 Synergic Voltage High Byte (SINT)
Byte 22 Reserved
Byte 23 Reserved
Byte 24 Weld Data Number
Byte 25 Reserved
Byte 26 Reserved
Byte 27 Reserved
Byte 28 Reserved
Byte 29 Reserved
Byte 30 Reserved
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Bit 7Bit 6Bit 5Bit 4Bit 3Bit 2Bit 1Bit 0
Byte 31 Reserved
Byte 32 Weld Data Unit Error Mask
Byte 33 Weld Data Unit Error Mask
Byte 34 Weld Data Unit Error Mask
Byte 35 Weld Data Unit Error Mask
Byte 36 Weld Data Unit Error Mask
Byte 37 Weld Data Unit Error Mask
Byte 38 Reserved
Byte 39 Reserved
Byte 40 Power Source Error Mask
Byte 41 Power Source Error Mask
Byte 42 Power Source Error Mask
Byte 43 Power Source Error Mask
Byte 44 Power Source Error Mask
Byte 45 Power Source Error Mask
Byte 46 Reserved
Byte 47 Reserved
Byte 48 Wire Feeder Error Mask
Byte 49 Wire Feeder Error Mask
Byte 50 Wire Feeder Error Mask
Byte 51 Wire Feeder Error Mask
Byte 52 Wire Feeder Error Mask
Byte 53 Wire Feeder Error Mask
Byte 54 Reserved
Byte 55 Reserved
5 FUNCTIONAL DESCRIPTION OF I/O
5.1 IN I/O from Controller to Welding Equipment
Weld Status Bits
Weld On
This bit starts a Welding procedure. Before a welding procedure is started the Quick
Stop bit and Emergency stop bits are checked.
Quick Stop
This bit performs a Quick Stop if the Equipment is in a welding procedure. This
means that the Welding Equipment will do a normal stopping procedure without
Craterfilling.
This function is used when a fast stop is requir e d but it will handle Burnback the
normal way to avoid that the wire is left frozen in the weld pool. This bit will also
block a start command.
Emergency Stop
This bit performs a Emergency Stop if the Equipment is in a Welding procedure. This
means that the welding equipment will shut off the arc, wire feeding and gas flow
without any burnback time. This bit will also block a start command.
Inching
This bit makes the wire feeder to start feed the wire without activating the power
source. The feeder will feed the wire at the adjusted speed. If this bit is activated
during a welding procedure, this command will be ignored.
If both Weld On and Inching is activated at the same time the equipment will ignore
the Inch command and start a welding procedure.
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Gas Purge
The gas control works in parallel with the regular gas--handling timers, which means
that the gas inputs can be left unused.
A weld start will always start with opening the gas valve if it isn’t already opened. In
similar fashion the end of gas post flow timer will always close the gas valve if it isn’t
already closed.
Accordingly when you what this input to control the gas valve operations the gas pre
flow time shall be set at minimum and the gas post flow time shall be set at
maximum.
Clean
This bit controls a valve for spatter cleaning gas. The function is not implemented in
the current version of the system.
Inch Reverse
This input bit will control backward--jogging movement to position the wire end before
weld start. This function is not implemented in the current version of the system.
Wire Feed 1-- 4
These bits are used to change active wire feeder. If more than one is activated the
wire feeder with the lowest I/O number will be activated. If non are activated it will
default to the lowest numbered feeder that are present in the system.
Release Wire
This function will execute a current pulse to burn off a wire that is frozen in the weld
pool if previous weld is ended in a not normal way. The release pulse is only
executed if ”Weld On” is off. This function is not implemented in the current version
of the system.
Touch Sense
When this input is activated the power source will output a weak power to detect if
there is contact in the welding circuit. As long as this function is engaged the output
bit ”Touch Sense Response” will be changed according to the condition in the
welding circuit. This function is not implemented in the current version of the system.
Reset Error
This input bit will reset the error indication. Only error indications that do not have
any other way of resetting than reboot of the system are affected by this reset. This
function is not implemented in the current version of the system.
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Weld Data Number
This byte is used to recall a complete set of weld data from the weld data m emory in
the Weld Data Unit. A complete set of weld data includes all settings that can be
made in the Weld Data Unit.
Among a large number of setting values this includes:
S Wire Type
S Wire Dimension
S Gas Type
S Use of synergic m ode or non--synergic mode
S Pulse Welding or Dip/Spray Welding
S Start Data
S Stop Data
Numerical Welding Parameters
Voltage
This 16--bit signed value is used to adjust the voltage value. The scaling factor is 100
so if 20 V is wanted, the value should be 2000. The resolution within the machine is
¼ V. This means that if you set 10,6 V the value displayed will be 10,5 V.
If the machine is in non --syner gic mode the equipment will simply use t he value set.
If the equipment is in synergic mode the machine will use the value as an offset from
the synergic value. T he synergic value can be read from the output I/O area.
Wire Feed Speed
This 16--bit unsigned value is used to adjust the wire feed value. The scaling factor is
100 so if 15 m/min is wanted, the value should be 1500. The resolution within the
machine is ¼ m/min.
5.2 OUT I/O from Welding Equipment to Controller
Weld Status Bits
Weld Busy
This signal indicates that the welding equipment is occupied with welding. If a stuck
wire or a burn through will break the welding circuit then the power source will go on
trying to weld until it gets a stop command.
A condition that makes the Arc acknowledge signal to fall does not stop the welding
equipment from continuing the attempts to weld.
As a default value, the weld busy signal is activated when the gas preflow begins
until the gas postflow stops. By chosing Weld Busy in the configuration menu, it is
possible to choose to have the weld busy signal activated when the power source
outputs power, until the gas postflow stops. In the menu you can also choose to have
the weld busy signal activated when the power source outputs power, until the power
source shuts down the power output.
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Arc Acknowledge
This signal will be activated when the arc is established at a weld start and it will fall
when voltage and current variations indicate that there can not be welding any
longer.
The criteria for arc established is that the process control has passed its start
procedure which means that it is not enough with just a short--circuit to fulfill the
criteria. Typical delay times from first contact to Arc acknowledge (wire feed time till
first contact not included) is in the range 2 to 20 ms. In case of a bad start the Arc
acknowledge signal will be more delayed.
The Arc acknowledge signal will stay on until either the weld is interrupted or the
welding is stopped the normal way.
At a normal stop the Arc acknowledge signal will fall when the f inalizing procedures
are ended ( i.e. craterfill, burnback) and the power source cuts the arc.
An interrupted weld is detected if abnormal conditions during welding makes the
weld process control deviate significantly from a normal working point. A certain
filtering time is used for this detection.
One example is if the wire is stuck and the Power Source keeps an arc between
workpiece and contact nozzle so that a normal current detection would indicate that
current is flowing and arc is assumed OK. In this case the Arc acknowledge signal
will fall due to that the weld controller has deviated to much from normal welding
conditions.
Touch Sense Response
This output bit will indicate contact in welding circuit as long as input bit ”Touch
Sense ” is active It will be ”0” all other time. This function is not implemented in the
current version of the system.
Error of type 1--8
There is an error of the indicated type in one of the error masks. Which err o r that will
be caught can be configured with a service function. With this feature it is possible to
configure, for example, one error type to be a general error and another error type to
be gas error and so on.
As a default the error types are configured as follows:
Error type 1 Error type
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
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Reset
Error
Error type
8
Error type
7
Error type
6
Error type
5
Error type
4
Error type
3
Error type
2
Error type 1
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.
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 that are outside limits, this value will be set to the nearest allowed value.
Wire Feed Speed
This 16--bit signed value indicates which wire feed speed the wire feeder is using. If
a value is set that ar e outside limits, this value will be set to the nearest allowed
value.
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Synergic Voltage
This 16 --bit unsigned value indicates the result of the calculations preformed by the
welding equipment. This value is only valid when running in synergic mode.
Measured Valu es
Voltage
This value is measured by the welding equipment. In pulse welding it can be
configured if the value presented should be the average value or the pulse value.
Current
This value is measured by the welding equipment.
Power
This value is measured by the welding equipment.
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.
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 c urrent
8 DC Voltage 1*
9 DC Voltage 2*
10 DC Voltage 3*
11 Current--servo / Wire speed --servo
12 Communication error ( warning -- internal bus )
14 Communication error ( bus off -- internal bus )
15 Message lost ( internal bus )
17 Lost contact with MEK
18 Lost contact with LUD
19 Error in battery--driven memory
20 Unaccepted setting values
21 Incompatible setting values
22 Spill in transmit buffer
23 Spill in receive buffer
25 Incompatible weld data format
26 Watchdog
27 No more wire detected
28 Stack overflow
29 No more water flow
30 Lost contact with TIG--card
31 No answer from display card
32 Error detected in gas flow
33 Hardware check failed in fieldbus interface
34 Memory test failed in fieldbus interface
35 Initialisation failed in fieldbus interface
36 Watchdog timeout in fieldbus interface
37 Fieldbus interface initialisation lost.
38 Bus Off in fieldbus interface.
39 Lost contact with analog remote node.
*)
Unit DC voltage 1 DC voltage 2 DC voltage 3
SLUD 3 V (batt)
LUD +15VC --15V +15VB
MEK 15V 20V
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Dubai
Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA
LLC ESAB
Moscow
Tel: +7 095 543 9281
Fax: +7 095 543 9280
LLC ESAB
St Petersburg
Tel: +7 812 336 7080
Fax: +7 812 336 7060
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
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