ESAB ESAB PLC Integration Installation guide

Brand: ESAB

Model: ESAB PLC Integration

Category: Welding System

Type: Installation guide

Integration manual

0463 393 001 GB 20140428

ESAB PLC Integration

TABLE OF CONTENTS

0463 393 001 © ESAB AB 2014

1 READ THIS FIRST................................................................................................ 4

2 INTRODUCTION................................................................................................... 5

2.1 Supported equipment ..........................................................................................5

2.2 Schematic system design ...................................................................................5

3 W82 ANYBUS....................................................................................................... 6

3.1 Fieldbus connection ............................................................................................ 6

3.2 W82 Profibus ........................................................................................................ 6

3.2.1 Profibus network ................................................................................................ 7

3.2.2 Tap for Profibus at Weld Data Unit.....................................................................7

3.2.3 Termination......................................................................................................... 8

3.2.4 24AP4 Fieldbus board - Profibus .......................................................................8

3.2.5 Fieldbus connector............................................................................................. 9

3.2.6 Configuration...................................................................................................... 9

3.2.7 LED indication .................................................................................................. 10

3.2.8 GSD files .......................................................................................................... 10

3.2.9 Functional I/O Data Map – Profibus DP ........................................................... 11

3.3 W82 DeviceNet ................................................................................................... 11

3.3.1 DeviceNet network ........................................................................................... 11

3.3.2 Tap for DeviceNet at Weld Data Unit ............................................................... 12

3.3.3 Position of SW1 on the welding data board, 24AP1 ........................................ 14

3.3.4 24AP4 Fieldbus board - DeviceNet.................................................................. 15

3.3.5 Fieldbus connector........................................................................................... 15

3.3.6 Configuration.................................................................................................... 15

3.4 Baud rate............................................................................................................. 15

3.5 Node address (Mac ID) ......................................................................................16

3.6 LED indication ....................................................................................................16

3.7 EDS files.............................................................................................................. 17

4 INSTALLATION OF HARDWARE ...................................................................... 18

4.1 Installing W82 ..................................................................................................... 18

5 FUNCTIONAL DESCRIPTION OF I/O................................................................ 22

5.1 In I/O from controller to welding equipment....................................................22

5.1.1 Weld status bits................................................................................................ 22

5.1.2 Weld data number............................................................................................ 23

5.1.3 Numerical welding parameters......................................................................... 24

5.2 Out I/O from Welding Equipment to Controller ...............................................24

5.2.1 Weld Status Bits............................................................................................... 24

5.2.2 Default error types............................................................................................ 26

5.2.3 Weld Data Number...........................................................................................26

5.2.4 Numerical Welding Parameters ....................................................................... 27

5.2.5 Measured Values ............................................................................................. 27

5.2.6 Error Mask........................................................................................................ 27

TABLE OF CONTENTS

0463 393 001 © ESAB AB 2014

6 FUNCTIONAL I/O DATA MAP - PROFIBUS DP ................................................28

7 CONFIGURATION EXAMPLE ............................................................................ 30

7.1 Overview ............................................................................................................. 30

GSD FILE...................................................................................................................33

EDS FILE ................................................................................................................... 39

Rights reserved to alter specifications without notice.

1 READ THIS FIRST

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1 READ THIS FIRST

CAUTION!

Read and understand the instruction manual before

installing or operating.

CAUTION!

STATIC ELECTRICITY can damage circuit boards and

electronic components.

• Observe precautions for handling

electrostaticsensitive devices.

• Use proper static-proof bags and boxes.

This integration manual is intended for use by technicians with electrical/electronic training

for integration of PLC to W8

interface.

The integration must be performed by an experienced person, and electrical work only by a

trained electrician.

The customer can chose between two configuration systems:

• W8

web interface and control by a PLC.

• W8

with a U8

pendant in presentation mode.

The spare parts lists for the different units can be used as guides where the components are

located in the equipment. The spare parts list is publisched as separate documents, see the

ordering numbers in the instruction manuals for each unit.

This manual contains details of design changes that have been made up to and including

mars 2014.

Documentation overview

Delivered in the box with the unit:

• Power source instruction manual

• W8

instruction manual or U8

instruction manual

• Robo Feed / Feed Control instruction manual

Delivered with the ESAB PLC integration solution:

• This integration manual

2 INTRODUCTION

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2 INTRODUCTION

This manual is intended to guide a system integrator in his work when integrating ESAB

equipment with a PLC solution.

2.1 Supported equipment

Power source

Mig 5000i / 5000iw, Mig 4004i Pulse, Mig 4002c / 4002cw, Mig 5002c / 5002cw, Mig 6502c.

Wire feeding systems

Aristo® RoboFeed 3004w, Aristo® RoboFeed 3004hw, Aristo® FeedMech 4804w including

Feed Control.

Interface unit

The interface unit is installed between a welding equipment and an automation equipment,

such as PLC applications. The W8

is available in several versions, this manual describes

and PLC integration. Both profibus and devicenet is described in the following chapters.

2.2 Schematic system design

W82 anybus

The schematic below describes both the web interface/PCL and W8

/U8

configurations:

• W8

web interface and control by a PLC.

• W8

with a U8

pendant in presentation mode.

3 W82 ANYBUS

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3 W82 ANYBUS

3.1 Fieldbus connection

External fieldbus connection via Profibus DP and DeviceNet.

fieldbus version.

External fieldbus connection W8

3.2 W82 Profibus

Profibus DP is used to control valves, sensors and I/O units in industrial automation

solutions.

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

national organizations called PNO.

Technical questions regarding the fieldbus should be addressed to your local Profibus User

Group in the instance. For general help on Profibus, contact your local PI Competence

center, PICC. Address list is available on the Profibus Internet Site: http://www.profibus.com

Network overview

Media transmission for the fieldbus is a shielded copper cable consisting of a twisted pair.

The baud rate 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.

NOTE!

Node number 126 is only for commissioning purposes and should not be used to

exchange user data.

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Correct termination of the bus is essential for a reliable communication.

3.2.1 Profibus network

3.2.2 Tap for Profibus at Weld Data Unit

Module overview

The W8

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

master. The W8

for Profibus-DP will not initiate communication to other other nodes, it will

only respond to incoming commands.

Protocol and supported functions

• PROFIBUS-DP, standardized within IEC 61158-6

• PROFIBUS DP -V0 communication

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• Automatic baud rate detection

• Baud rate 9.6 kbit – 12 Mbit

Physical interface

• Master - Slave communication

• 9 pin female DSUB connector

• Shielded copper cable, twisted pair

• 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

Configuration and indications

• Adress range: 1–99

• Cyclic I/O data size: configurable 7–56 bytes

• Bus termination switch on board

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

3.2.3 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 Profibus DP is equipped with a termination switch to

accomplish this in an easy way.

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

Otherwise it should be in “OFF” position.

NOTE!

If an external termination connector is used the switch should be in OFF position.

3.2.4 24AP4 Fieldbus board - Profibus

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3.2.5 Fieldbus connector

Female 9-pin D-sub

Connector pin Signal Description

Housing Shield Connected to protective earth (PE)

1 - Not connected

2 - Not connected

3 B-line Positive RxD/TxD according to RS 485 specification

4 RTS Request to send (RTS). RTS is used in some

equipment to determine the direction of transmission. In

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

5 GND BUS Isolated GND from RS 485 side

6 +5 V BUS Isolated +5 V from RS 485 side. +5V BUS and GND

BUS are used for devices , like optical transceivers (RS

485 to fibre optics) that might require external power

supply from these pins. This device is not allowed to

load more than 80 mA from these power pins.

7 - Not connected

8 A-line Negative RxD/TxD according ro RS 485 specification

9 - Not connected

3.2.6 Configuration

Baud rate

The baud rate on a Profibus DP network is set during configuration of the master. Only one

baud rate is possible in a Profibus DP installation. The W8

Profibus DP has an auto baud

rate detection function and the user does not have to configure the baud rate on the module.

Baud rates supported by the Profibus DP are:

9.6 kbit/s 187.5 kbit/s 3 Mbit/s

19.2 kbit/s 500 kbit/s 6 Mbit/s

93.75 kbit/s 1.5 Mbit/s 12 Mbit/s

Node address

Before configuring the Profibus DP module the node

address has to be set. This is done with the two address

switches on the module inside, it is possible to set from 1

– 99 in decimal format.

Seen from the front of the circuit board, the left switch is used for the ten setting and the right

switch is used for the setting of the integers. Example of setting:

When the left switch is set to 4 and the right switch is set to 2, the node address will be 42.

NOTE!

The node address cannot be changed during operation.

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3.2.7 LED indication

The circuit board is equipped with four LEDs mounted at

the front and one LED on the board, used for debugging

purposes.

The function of the LEDs are described in the table and

figure below. There is also one additional Bicolour

Watchdog LED on the circuit board inside. This LED is only

for internal use.

LED 1 - Reserved

LED 2 - Fieldbus Online

Status Description

Off Bus not online (or no power)

Green Bus online, data exchange possible

LED 3 - Fieldbus Offline

Status Description

Off Bus not offline (or no power)

Red Bus offline

LED 4 - Fieldbus Diagnostics

Status Frequency Description

Off - No diagnostics present (or no power)

Red, flashing 1 Hz Error in configuration data

Red, flashing 2 Hz Error in parameter data

Red, flashing 4 Hz Error in initialisation of the PROFIBUS communication

ASIC

Red, flashing 8 Hz Watchdog timeout (internal error)

Watchdog LED

The fieldbus board includes a bi-colour watchdog LED, indicating the status of the module.

Colours Frequency Indication

Red - Unspecified internal error, or running in bootloader mode

Red 1 Hz RAM failure

Red 2 Hz ASIC or FLASH failure

Red 4 Hz DPRAM failure

Green 1 Hz Module initialised and running OK

Green 2 Hz Module not initialised

3.2.8 GSD files

GSD files for the Anybus-S Profibus DP module

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

necessary information about the device.

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This file is used by the network configuration program during configuration of the network.

The latest version of this file can be received on http://hms.se/support/support_home.asp

The article number for the Profibus fieldbus board used is AB4005 version 2.

HMSB1003.gsd revision 2.03 used to the module with FW version 2.x.

For GSD files for the Anybus-S Profibus DP module see chapter "GSD file".

Configure the Profibus slave module

1. Make sure that the node address on the profibus fieldbus board is set.

2. Make sure that the termination switch is correctly set.

The termination switch should be set to "ON" if:

a) The module is the last node on the network, that is the physical end of the bus.

b) No other termination is used at this end of the network.

The termination switch should be set to "OFF" if:

a) Ther are other nodes on both sides of the module in the network.

b) The module is the last node on the network and a PROFIBUS-SUB connector is

used which is equipped with a built in and activated termination.

3. Set up the PLC and master hardware.

4. Download and import the GSD file to the configuration tool.

5. Include the Anybus module to the network as a slave.

6. Configure the Anybus module, set up node address and input/output data area sizes.

7. Download the configuration to the PLC.

8. When the PLC is set to run mode the Anybus module will go on line and start data

exchange.

3.2.9 Functional I/O Data Map – Profibus DP

For functional I/O Data Map for Profibus DP see chapter "FUNCTIONAL I/O DATA MAP -

PROFIBUS DP".

3.3 W82 DeviceNet

DeviceNet is used to control valves, sensors and I/O units in industrial automation solutions.

User organization

DeviceNet has a user organization, the Open DeviceNet Vendor Association (ODVA), which

assists members of matters concerning DeviceNet.

For further information, please contact ODVA http://www.odva.org

Network connection

To secure a reliable communication on the bus, the “drop lines” are restricted in the

DeviceNet standard to a maximum length of 6 metres (20 ft).

NOTE!

Correct termination of the bus is essential for a reliable communication.

3.3.1 DeviceNet network

in DeviceNet network.

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3.3.2 Tap for DeviceNet at Weld Data Unit

External fieldbus termination

DeviceNet uses the CAN bus with terminating resistors at each end of the bus. The

terminating resistor should be 120 ohm. This should be connected between CAN_H and

CAN_L on the bus.

Internal fieldbus termination

Terminating resistors are included in the W8

. They can be connected/disconnected by

switch SW1. Only the internal CAN bus has terminating resistors mounted.

NOTE!

When the W8

is is located as the last node in the internal bus network, use

termination on the CAN bus:

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• Set termination switch SW1 to position “ON”. The CAN bus will be terminated with 120

ohm at 24AP1.

• With external termination, set termination switch SW1 to position “OFF”.

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3.3.3 Position of SW1 on the welding data board, 24AP1

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3.3.4 24AP4 Fieldbus board - DeviceNet

3.3.5 Fieldbus connector

Connector pin Signal Description

1 V- Negative supply voltage

2 CAN_L CAN_L bus line

3 SHIELD Cable shield

4 CAN_H CAN_H bus line

5 V+ Positive supply voltage

3.3.6 Configuration

A connection to the node is set up towards the assembly object with a bus configuration tool

or directly from a master.

Node address (Mac ID) and baud rate are configured with dip-switches (see picture of

fieldbus board). The range for node address is between 0-63 and baud rate is between 0 and

2 (0 = 125 kbit/s, 1 = 250 kbit/s and 2 = 500 kbit/s).

When a DIP-switch is in ”ON” or ”Closed” position, the node interprets it as a logic ”1”.

3.4 Baud rate

There are three different baud rates for DeviceNet:

• 125 kbit/s

• 250 kbit/s

• 500 kbit/s

1-2 Baudrate switches are used for baud rate setting.

Baud rate, bits/s Sw 1 Sw 2

125k OFF OFF

250k OFF ON

500k ON OFF

Reserved ON ON

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3.5 Node address (Mac ID)

3-8 Node address switches are used to set the node address (0-63). Switch 3 is the MSB,

and switch 8 is LSB.

Address Sw 3 Sw 4 Sw 5 Sw 6 Sw 7 Sw 8

0 OFF OFF OFF OFF OFF OFF

1 OFF OFF OFF OFF OFF ON

2 OFF OFF OFF OFF ON OFF

3 OFF OFF OFF OFF ON ON

... ... ... ... ... ... ...

62 ON ON ON ON ON OFF

63 ON ON ON ON ON ON

3.6 LED indication

The fieldbus board is equipped with four bi-colour LED's at the front of the board showing the

status.

LED 1 and 4 are reserved for future use.

LED 2 - Network status

Colour Frequency Description

Off - Not powered / Not on line

Green Steady on Link OK, On line, Connected

Green Flashing On line, Not connected

Red Steady on Critical link failure

Red Flasching Connection timeout

LED 3 - Module status

Colour Frequency Description

Off - No power to device

Green Steady on Device operationel

Green Flashing Data size bigger than configured

Red Steady on Unrecoverable fault

Red Flasching Minor fault

Watchdog LED

The fieldbus board includes a bi-colour watchdog LED, indicating the status of the module.

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Colour Frequency Description

Red - Unspecified internal error, or running in

bootloader mode

Red 1 Hz RAM failure

Red 2 Hz ASIC or FLASH failure

Red 4 Hz DPRAM failure

Green 1 Hz Module initialised and running OK

Green 2 Hz Module not initialised

3.7 EDS files

EDS files for the DeviceNet module

Each device in a DeviceNet network is associated with a EDS file. The EDS file contains all

necessary information about the device.

This file is used by the network configuration program during configuration of the network.

The latest version of the EDS file can be received on

http://hms.se/support/support_home.asp

The article number for the DeviceNet fieldbus board used is AB4004.

For EDS files see chapter "EDS FILES" at the end of this manual.

Configure the DeviceNet module

1. Make sure that the baud rate of the DeviceNet module and the PLC is set to the same

rate.

2. Make sure that the EDS file is installed.

3. Configure the network.

4. Configure the I/O size and mapping.

4 INSTALLATION OF HARDWARE

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4 INSTALLATION OF HARDWARE

The installation chapter will describe how to connect the different components.

4.1 Installing W82

Connections and control devices

W82 anybus

1. Indicating lamp

Orange indicating lamp - Overheating

2. Fieldbus

Connection for communication with PLC system

3. Measure

Connection for measurement cable for arc voltage feedback and emergency stop signal,

measurement kit

4. Internal CAN

Connections for communication with ESAB wire feed unit and control panel

5. LAN

Connection to network, Ethernet

6. CAN to welding power source

Connection for communication with welding power source

7. USB

USB memory connection

NOTE!

Do not remove the USB if using W8

webb interface!

4 INSTALLATION OF HARDWARE

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Mounting W82 on Mig 5000i

• On the power source, remove the two screws holding the rear handle.

• Remove handle.

• Place the interface box onto the welding power source.

• Place handle on top of the interface box.

• Fasten interface box and handle with the two screws.

Mounting W82 on Mig 4002c, Mig 5002c and Mig 6502c

• On the power source, use the “keyholes” that is normally used for the chain holding the

gas tube.

• Place the interface box onto the welding power source.

• Fasten interface box with the two screws.

Installing the wire feeder and control unit

Mount the feeder unit and controller according to the mounting instruction that comes in the

same box as the units.

Power source

Unpack and install the power source according to the user manual.

Installing the welding torch

Unpack and install the welding gun according to the user manual.

Installing the bobbin holder

Unpack and install the bobbin holder according to the user manual, refer to the assembly

instruction for Robot Bobbin Kit “RoboFeed 3004 HW”.

Installing the cable W82 Anybus

NOTE!

When using a wire feed unit other than RoboFeed, install a separate arc voltage

feedback to the measurement contact on the control unit.

4 INSTALLATION OF HARDWARE

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1. Connection between W8

and power source. Internal CAN to power source.

2. Connection between W8

and PLC. External fieldbus to PLC.

3. Connection between welding power source and wire feed unit. Internal CAN.

4. Connection between welding power source and control panel. Internal CAN.

5. Connection between W8

and web interface. Ethernet cable.

1. Connection between W8

and power source. Internal CAN to power source.

2. Connection between W8

and PLC. External fieldbus to PLC.

3. Connection between welding power source and wire feed unit. Internal CAN.

4. Connection between welding power source and control panel. Internal CAN.

5. Connection between W8

and web interface. Ethernet cable.

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ESAB ESAB PLC Integration Installation guide

Brand: ESAB

Model: ESAB PLC Integration

Category: Welding System

Type: Installation guide

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ESAB ESAB PLC Integration Installation guide

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