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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
2
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
2
web interface and control by a PLC.
• W8
2
with a U8
2
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
2
instruction manual or U8
2
instruction manual
• Robo Feed / Feed Control instruction manual
Delivered with the ESAB PLC integration solution:
• This integration manual
2 INTRODUCTION
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© ESAB AB 2014
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
2
is available in several versions, this manual describes
W8
2
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
2
/U8
2
configurations:
• W8
2
web interface and control by a PLC.
• W8
2
with a U8
2
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.
W8
2
fieldbus version.
External fieldbus connection W8
2
.
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
2
for Profibus-DP is a slave node that can be read and written to, from a Profibus-DP
master. The W8
2
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
2
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
W8
2
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
2
. They can be connected/disconnected by
switch SW1. Only the internal CAN bus has terminating resistors mounted.
NOTE!
When the W8
2
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
2
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.
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1. Connection between W8
2
and power source. Internal CAN to power source.
2. Connection between W8
2
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
2
and web interface. Ethernet cable.
1. Connection between W8
2
and power source. Internal CAN to power source.
2. Connection between W8
2
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
2
and web interface. Ethernet cable.
/