EWM BUSINT X11 Operating Instructions Manual
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EWM BUSINT X11 Operating Instructions Manual

EWM BUSINT X11 Operating Instructions Manual

Interface for digital welding power sources
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Operating instructions
Interface for digital welding power sources
BUSINT X11
N. B. These operating instructions must be read before commissioning.
Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.
The machines bear the conformity mark and thus comply with the
•
EC Low Voltage Directive (2006/95/ EG)
•
EC EMC Directive (2004/108/ EG)
In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.
The content of the operating instructions does not constitute grounds for any claims on the part
©
of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.
© 2009
Subject to alteration.
Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon +49 2680 181-0 • Fax +49 2680 181-244
Item No.: 099-008225-EWM01
HIGHTEC WELDING GmbH
www.ewm.de
•
info@ewm.de
Revised: 05.08.2009
EWM

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Summary of Contents for EWM BUSINT X11

  • Page 1 Operating instructions Interface for digital welding power sources BUSINT X11 N. B. These operating instructions must be read before commissioning. Failure to do so may be dangerous. Machines may only be operated by personnel who are familiar with the appropriate safety regulations.
  • Page 2 Perfection doesn't happen by coincidence: Every single component is 100% tested and the machine is “free welded” before it is delivered. Our comprehensive service offer and the highly developed modern EWM quality management system guarantee worldwide premium quality “Made in Germany” and a three-year warranty.
  • Page 3 Machine and Company Data Please enter the EWM machine data and your company’s data in the appropriate fields. EWM HIGHTEC WELDING GMBH D-56271 MÜNDERSBACH TYP: SNR: ART: PROJ: GEPRÜFT/CONTROL: Name of Customer / company Name of Customer / company Adress...

  • Page 4: Table Of Contents

    Contents Notes on the use of these operating instructions Contents 1 Contents ..............................4 2 Safety instructions ..........................8 Notes on the use of these operating instructions................8 General............................10 3 General ..............................11 Revision............................11 Introduction ..........................11 System overview ..........................11 4 Commissioning.............................12 General connection of the BUSINTX11 ..................12 4.1.1 The system bus ......................12 4.1.2...
  • Page 5 Contents Notes on the use of these operating instructions 5 Operative mode ............................ 23 Pre-selecting a JOB ........................23 Program operation ........................23 JOB mode ............................ 23 Advanced control signal operation....................24 Operating modes ......................... 25 5.5.1 Non-latched operation ....................25 5.5.2 Special, non-latched .....................25 Welding types ..........................
  • Page 6 Contents Notes on the use of these operating instructions 5.17 JOB safety switching........................37 6 The diagnostics interface ........................38 PC system requirements......................38 Commissioning..........................38 Scope of diagnostics ........................38 7 Profiles for PHOENIX MIG/MAG systems ..................39 Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules............................39 7.1.1 Default profile (switch position 0)..................39...
  • Page 7 Contents Notes on the use of these operating instructions 12 Overview of jumper assignments BUSINTX11 Rev00 ..............130 13 Overview of machine software functions (firmware) ..............131 13.1 PHOENIX machine software (firmware) ..................131 13.2 TETRIX machine software (firmware)..................131 14 Warranty..............................132 14.1 General Validity..........................132 14.2 Warranty Declaration .........................133 15 Circuit diagrams..........................134 Item No.: 099-008225-EWM01...

  • Page 8: Safety Instructions

    Safety instructions Notes on the use of these operating instructions Safety instructions Notes on the use of these operating instructions DANGER Working or operating procedures which must be closely observed to prevent imminent serious and even fatal injuries. • Safety notes include the "DANGER" keyword in the heading with a general warning symbol. •...
  • Page 9 Safety instructions Notes on the use of these operating instructions Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet points, e.g.: • Insert the welding current lead socket into the relevant socket and lock. Symbol Description Press Do not press...

  • Page 10: General

    Safety instructions General General WARNING Risk of accidents if these safety instructions are not observed! Non-observance of these safety instructions is potentially fatal! • Carefully read the safety information in this manual! • Observe the accident prevention regulations in your country. •...

  • Page 11: General

    General Revision General Revision Revision Date Change 26.02.2006 Draft version 04.08.2006 Official instructions 23.08.2006 Addition of profiles, overview of interfaces, TETRIX functionality 23.01.2007 Support for the Profibus DP module 27.07.2009 Addition of profiles and functions to the software version 042-00897-00002 or 042-00926-00002 Introduction The operating instructions below describe the commissioning and functionality of the field bus interface BUSINTX11 in combination with specific field busses.

  • Page 12: Commissioning

    Depending on the field bus used, an external power supply is required (e.g. on the Interbus). When using the external power supply, the original EWM module must be used, otherwise the potential isolation within the system is cancelled. EWM accepts no responsibility for operating problems caused by this.

  • Page 13: Connection Of Fast Actual Value Signals

    Commissioning Basic configuration using plug-in jumpers 4.1.3 Connection of fast actual value signals The BUSINTX11 normally supplies actual process values with an update of approx. 30ms for the process voltage, current, wire speed and motor current process values. For seam tracking, however, fast signals are required for voltage and current. With the PHOENIX and TETRIX, these can be provided via the interface for mechanised welding on the BUSINTX11: Plug Signal...

  • Page 14: Field Bus Connection And Configuration

    Commissioning Field bus connection and configuration Field bus connection and configuration Different steps are required for commissioning, depending on the field bus, and these steps are described below. 4.4.1 Interbus-S optical fibre No address setting is required for the configuration of the Interbus subscriber as this is given by the position of the subscriber in the Interbus.

  • Page 15: Can Open

    Commissioning Field bus connection and configuration 4.4.2 CAN Open 4.4.2.1 Module specification The CANopen module is based on the DS301 v4.02 standard. The data exchange is carried out via the first 3 standard PDOs (process data objects) 1 to 3. 4.4.2.2 Module, position of the operating elements The CANopen module has a variety of operating elements arranged on the PCB side:...

  • Page 16: Connection Of The Canopen Module

    The module settings can be modified via an EDS file. In this case, however, the option of configuration via the bus master is a requirement (not possible in all cases). A suitable EDS files can be provided by EWM Hightec Welding GmbH if required. Item No.: 099-008225-EWM01...

  • Page 17: Can Devicenet

    Commissioning Field bus connection and configuration 4.4.3 CAN DeviceNet 4.4.3.1 Module specification The CAN DeviceNet module is implemented in accordance with the ODVA specifications as a communication adapter (profile no.12) and behaves as a group 2 server on the network. The data modes Polled, Bit-Strobed and COS/Cyclic are supported.

  • Page 18: Connection Of The Can Devicenet Module

    Commissioning Field bus connection and configuration 4.4.3.4 Connection of the CAN DeviceNet module The field bus is connected via a 5-pole panel connector as follows: Signal Function Supply voltage reference mass CAN_L Low signal cable of the CAN difference signal CAN_SHLD Connection for cable shield CAN_H...

  • Page 19: Profibus

    Commissioning Field bus connection and configuration 4.4.4 Profibus 4.4.4.1 Module specification The Profibus module supports cyclical data exchange according to the PROFIBUS-DP EN 50 170 specification (DIN 19245). 4.4.4.2 Module, position of the operating elements The Profibus module has a variety of operating elements arranged on the PCB side: Figure 4-10 4.4.4.3 Meaning of the LEDs...

  • Page 20: Connection Of The Profibus Module

    Commissioning Field bus connection and configuration 4.4.4.4 Connection of the Profibus module The field bus is connected via a 9-pole SUB-D plug connector (socket) as follows: Signal Function B-signal Positive communication signal according to RS485 Send request signal Isolated reference mass for field bus Isolated reference voltage for field bus A-signal Negative communication signal according to RS485...

  • Page 21: Baud Rate

    Commissioning Field bus connection and configuration 4.4.4.6 Baud rate The module is equipped with automatic baud rate detection and therefore requires no additional setting work. The following baud rates are supported: 9.6kbit/s, 19.2kbit/s, 93.75kbit/s, 187.5kbit/s, 500kbit/s, 1.5Mbit/s, 3Mbit/s, 6Mbit/s, 12Mbit/s 4.4.4.7 Network termination The Profibus network must be terminated on the line terminals to avoid signal reflections on the bus...

  • Page 22: Switching On The Busintx11

    Commissioning Switching on the BUSINTX11 Switching on the BUSINTX11 The interface is either switched to ‘ready for operation’ status by switching on the connected power source or by switching on the external power supply (if fitted). The module runs through a variety of steps for self-diagnostics and tests the readiness of individual components.

  • Page 23: Operative Mode

    Operative mode Pre-selecting a JOB Operative mode Pre-selecting a JOB The PHOENIX has a wide range of adjustable parameters available which are managed using what are known as JOBs. The corresponding welding task is defined using a JOB. A total of 255 JOBs can be set (1 to 255).

  • Page 24: Advanced Control Signal Operation

    (see also chapter 13). With TETRIX systems, the BUSINT X11 has a range of further control voltages in addition to the main current and cold wire.

  • Page 25: Operating Modes

    Operative mode Operating modes Operating modes There are 2 different operating modes available. It is necessary to define the program sequence in order to understand the operating modes. The program sequence describes a series of welding program steps which are processed in sequence, starting with ignition, and ending with the end of the welding process.

  • Page 26: Welding Types

    Operative mode Welding types Welding types In welding mode a distinction is made between different modes (depending on the welding system). The welding type can be changed both when the system is at a standstill and during operation. In JOB mode the relevant information on the welding type is taken from the active program for the current JOB.

  • Page 27: Display Options

    Operative mode Monitoring function 5.7.2 Display options An alarm message is generated in one of two ways: • Output via collective indication output (relay) on the module (see chapter 10.2) • Output of the individual channels via the field bus data with the following assignments: Bit no.

  • Page 28: Special Features Of The Monitoring Function

    Operative mode Monitoring function 5.7.4 Special features of the monitoring function Duration The parameter monitoring takes place only in the static conditions (main welding and reduction welding programs), which prevents error messages from dynamic alterations, such as for ramp overruns. Fault reduction A hysteresis method on the monitoring limits prevents the message generator “fluctuating”...

  • Page 29: Other Signals

    Operative mode Other signals Other signals 5.8.1 JOB pre-selection Permits the specification of welding tasks (JOBs) by the machine. With the signal not set, the setting of the JOB must be carried out via another control (e.g. M31x). With an active signal the setting of the JOB is transferred (signal is automatically set in some actuation profiles and is not then visible in the profile).

  • Page 30: 5.8.12 Welding Simulation

    Operative mode Check-back of the process parameters 5.8.12 Welding simulation Activates the simulation of the welding process signals for the actual programming/testing of automation controls without active welding process with complete signal exchange (see also chapter “Welding simulation”). 5.8.13 JOB mode In this mode the information for operating type and welding type are not taken from individual actuation signals, but rather from the welding program actuated.

  • Page 31: Ready For Welding

    Operative mode Check-back of the process parameters 5.9.6 Ready for welding The system is ready for welding and accepts a start signal from the PLC. The signal is reset in the event of errors. When switching a job, the signal is reset for a duration of approx. 200 ms. From software version 0.0.A.X, the signal is no longer reset during the process! 5.9.7 Sticking...
  • Page 32 Operative mode Check-back of the process parameters start I > 0 Figure 5-2 Legend Description Start signal Main current Process active Ready for welding * From version 0.0.A.0 the signal can be used during the welding process. Item No.: 099-008225-EWM01...

  • Page 33: Signals For Matching With The Positioning Device

    Operative mode Signals for matching with the positioning device 5.10 Signals for matching with the positioning device Experience has shown that the signal matching between the welding power source and the positioning device is very important. If interference occurs suddenly due to a loss of signal (e.g. arc interruption), or if intermittent signals occur, the positioning device can itself enter an error status condition.

  • Page 34: 5.10.3 Arc Interruption Time For Tz-Libo

    Operative mode Signals for matching with the positioning device 5.10.3 Arc interruption time for TZ-LIBO For the work process it is desirable that the process runs without interference. However, in poor conditions it is likely that welding interference will occur, and this results in intermittent signals for the duration of the process.

  • Page 35: 5.10.4 The Return Time Tz-Reset

    Operative mode Fusing detection 5.10.4 The return time TZ-RESET Most positioning equipment uses the I>0 signal to optimise the cycle time to trigger the positioning equipment after the process. This often makes it more difficult to reliably detect sticking. An adjustable time TZ-RESET can be used to set the period after which the I>0 signal is reset after the process is shut down.

  • Page 36: Welding Seam Tracking

    Operative mode Welding seam tracking 5.13 Welding seam tracking A traditional task for robot welding systems is track correction for the weld seam during the process, which is required due to component tolerances. The actual process values supplied in the system are normally updated every 30ms. A higher data rate is required for reliable seam tracking.

  • Page 37: Job Safety Switching

    Operative mode JOB safety switching 5.17 JOB safety switching Power sources for mechanised MIG/MAG welding (PHOENIX) or mechanised TIG/PLASMA welding do not normally use data records (JOBs) which are used for the electrode welding process. However, if a data record of this type is contained in the JOB database and is selected accidentally, there is an automatic system start (not by the interface), in which there is open circuit voltage on the torch system (wire feeds are not activated).

  • Page 38: The Diagnostics Interface

    PC system requirements The diagnostics interface To support commissioning processes and the analysis of signal sequences, the BUSINTX11 has a diagnostics interface that is connected to a PC USB port and can be evaluated using the EWM-Analyzer software. PC system requirements The following requirements must be met to operate the PC software: •...

  • Page 39: Profiles For Phoenix Mig/Mag Systems

    Profiles for PHOENIX MIG/MAG systems Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules Profiles for PHOENIX MIG/MAG systems The BUSINTX11 has a selection option for what are known as signal profiles which can be selected via a selector switch with 16 settings.
  • Page 40 Profiles for PHOENIX MIG/MAG systems Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules Actuation data Byte Bit no. Function Description Blow-out Manual check of the auxiliary gas Bit allocation: Gas supply off Gas supply on Inching Signal for wire inching function on the wire feed drive...
  • Page 41 Profiles for PHOENIX MIG/MAG systems Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules Actuation data Byte Bit no. Function Description Correction specification, Specify the voltage correction in program 0 high byte Range: 0 to 0 x 7FFF 0 corresponds to -10.0 V 0 x 4000 corresponds to 0 V 0 x 7FFF corresponds to +10.0 V...
  • Page 42 Profiles for PHOENIX MIG/MAG systems Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules Process data Byte Bit no. Function Description I > 0 Current-flows signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding Ready signal from process Bit allocation:...
  • Page 43 Profiles for PHOENIX MIG/MAG systems Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules Process data Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage low byte Actual welding current value, Current actual value for the welding current high byte Range: 0 to 0x7FFF...

  • Page 44: Profiles For The Canopen Module

    Profiles for PHOENIX MIG/MAG systems Profiles for the CANopen module Profiles for the CANopen module In general the module uses the standard Rx-PDOs 1 and 2 (no. 1 for digital and no. 2 for analogue signals) and the standard Tx-PDOs 1 to 3 (no. 1 for digital and nos. 2 and 3 for analogue data). 7.2.1 Reis Robotics profile (switch position 0) The module uses a data capacity of 6 words (12 bytes) for the input data and 7 words (14 bytes) for the...
  • Page 45 Profiles for PHOENIX MIG/MAG systems Profiles for the CANopen module Rx-PDO 1 Cob ID = 200h + address Byte Bit no. Function Description Position search Activates the position search function for the Bit allocation: workpiece Position search off Position search on Blow-out Manual check via the blow-out valve Bit allocation:...
  • Page 46 Profiles for PHOENIX MIG/MAG systems Profiles for the CANopen module Rx-PDO 2 Cob ID = 300h + address Byte Bit no. Function Description WF specification, low-byte Specify the wire speed in program 0 Range: 0 to 0 x 7FFF 0 corresponds to WF-MIN 0 x 7FFF corresponds to 25.0 m/min WF specification, high-byte Specify the wire speed in program 0...
  • Page 47 Profiles for PHOENIX MIG/MAG systems Profiles for the CANopen module Tx-PDO 1 Cob ID = 180h + address Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Reserved Process active Signals the completion of the welding process...
  • Page 48 Profiles for PHOENIX MIG/MAG systems Profiles for the CANopen module Tx-PDO 2 Cob ID = 280h + address Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage low byte Range: 0 to 0 x 7FFF corresponds to 0.0 V to 100.0 V Actual welding voltage value, Current actual value for the welding voltage...

  • Page 49: Profiles For The Can Devicenet Module

    Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module Profiles for the CAN DeviceNet module 7.3.1 Default profile (switch position 0) The module uses a data capacity of 5 words (10 bytes) for the input data and 6 words (12 bytes) for the output data.
  • Page 50 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module Actuation data Byte Bit no. Function Description Reverse inching Signal for reverse wire inching function Bit allocation: Reverse inching off Reverse inching on WF switching (optional) Switches between 2 wire drive units Bit allocation: WF case 1 is active WF case 2 is active...
  • Page 51 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module The data can only be assigned to a single connection in this profile. Process data Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding...
  • Page 52 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module Process data Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage high byte Actual welding current value, Current actual value for the welding current low byte Range: 0 to 0 x 7FFF corresponds to 0 A to 1000 A...

  • Page 53: Profile 1 (Switch Position 1)

    Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module 7.3.2 Profile 1 (switch position 1) The module uses a data capacity of 5 words (10 bytes) for the input data and 6 words (12 bytes) for the output data, distributed across 2 connections. The following data with 4 bytes is assigned to connection 1 (output 1): Actuation data Byte...
  • Page 54 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module Actuation data Byte Bit no. Function Description WF switching (optional) Switches between 2 wire drive units Bit allocation: WF case 1 is active WF case 2 is active Error reset Acknowledgement signal for system error User-defined output Switches the user-defined relay output on the bus...
  • Page 55 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module The following data with 6 bytes is assigned to connection 2 (output 2): Actuation data Byte Bit no. Function Description WF specification, low-byte Specify the wire speed in program 0 Range: 0 to 0 x 7FFF 0 corresponds to WF-MIN 0 x 7FFF corresponds to 25.0 m/min...
  • Page 56 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module The following data with 4 bytes are assigned to connection 1 (input 1): Process data Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding...
  • Page 57 Profiles for PHOENIX MIG/MAG systems Profiles for the CAN DeviceNet module The following data with 8 bytes are assigned to connection 2 (input 2): Process data Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage low byte Range: 0 to 0 x 7FFF corresponds to 0.0 V to 100.0 V...

  • Page 58: Profiles For The Profibus Dp Module

    Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Profiles for the Profibus DP module 7.4.1 Default profile (switch position 0) The module uses a data capacity of 10 bytes for input data and 11 bytes for output data and should be used if all input and output data is required.
  • Page 59 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Actuation data Byte Bit no. Function Description Position search Activates the position search function for the Bit allocation: workpiece Position search off Position search on Bit allocation: Manual check via the blow-out valve Blow-out valve off Blow-out valve on Check monitoring function...
  • Page 60 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Process data Byte Bit no. Function Description Error General fault message from process Bit allocation: No error Fault occurred and not rectified User-defined input 1 Signal status of the digital input Logic: 0V signal on the input = signal low 24V on the input = signal high...
  • Page 61 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Process data Byte Bit no. Function Description Actual wire feed speed value, Current actual value for the wire feed speed low byte Actual motor current value Current actual value for the motor current from the wire feed system high byte Range: 0 to 0x7FFF...

  • Page 62: Flexible Profile (Switch Position 1)

    Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module 7.4.2 Flexible profile (switch position 1) The module uses a data capacity of 10 bytes for input data and 11 bytes for output data. The JOB mode can only be activated via the jumper in this profile. The data is arranged so that data required on the Profibus can be grouped via the module programming.
  • Page 63 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Actuation data Byte Bit no. Function Description User-defined output Switches the user-defined relay output on the bus module Bit allocation: Relay not switched Relay switched Position search Activates the position search function for the Bit allocation: workpiece Position search off...
  • Page 64 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Process data Byte Bit no. Function Description Error General fault message from process Bit allocation: No error Fault occurred and not rectified User-defined input 1 Signal status of the digital input Logic: 0V signal on the input = signal low 24V on the input = signal high...
  • Page 65 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Process data Byte Bit no. Function Description Actual motor current value Current actual value for the motor current from the wire feed system high byte Range: 0 to 0x7FFF corresponds to 0.0A to 25.5A Actual motor current value Current actual value for the motor current from the...

  • Page 66: Compatible Profile (Switch Position 2)

    Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module 7.4.3 Compatible profile (switch position 2) The module uses a data capacity of 10 bytes for input data and 11 bytes for output data. The profile can be used to replace previously used BUSINTX10 Profibus interfaces. The profile is fully compatible for this purpose.
  • Page 67 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Actuation data Byte Bit no. Function Description Position search Activates the position search function for the Bit allocation: workpiece Position search off Position search on Bit allocation: Manual check via the blow-out valve Blow-out valve off Blow-out valve on Check monitoring function...
  • Page 68 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Process data Byte Bit no. Function Description Not allocated User-defined input 1 Signal status of the digital input Logic: 0V signal on the input = signal low 24V on the input = signal high Process active Indicates the completion of the welding process Bit allocation...
  • Page 69 Profiles for PHOENIX MIG/MAG systems Profiles for the Profibus DP module Process data Byte Bit no. Function Description Monitoring Bit field for displaying alarm messages during welding parameter monitoring Status =0, no alarm Status =1, alarm Bit allocation: Welding voltage Welding current Wire-feed speed WF motor current...

  • Page 70: Profiles For Tetrix Tig And Plasma Systems

    Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module In general the module uses the standard Rx-PDOs 1 and 2 (no. 1 for digital and no. 2 for analogue signals) and the standard Tx-PDOs 1 to 3 (no.
  • Page 71 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Rx-PDO 1 Cob ID = 200h + address Byte Bit no. Function Description Reverse inching Signal for reverse wire inching function Bit allocation: Reverse inching off Reverse inching on Start auxiliary process Start signal to initiate the auxiliary process Bit allocation:...
  • Page 72 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Tx-PDO 1 Cob ID = 180h + address Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding Ready signal from process Bit allocation:...

  • Page 73: Profile 1 (Switch Position 1, Program Mode)

    Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Tx-PDO 2 Cob ID = 280h + address Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage low byte Range: 0 to 0 x 7FFF corresponds to 0.0 V to 100.0 V Actual welding voltage value, Current actual value for the welding voltage...
  • Page 74 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Byte Bit no. Function Description Reverse inching Signal for reverse wire inching function Bit allocation: Reverse inching off Reverse inching on Position search Activates the position search function for the Bit allocation: workpiece Position search off...
  • Page 75 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Tx-PDO 1 Cob ID = 180h + address Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding Ready signal from process Bit allocation:...
  • Page 76 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Tx-PDO 2 Cob ID = 280h + address Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage low byte Range: 0 to 0 x 7FFF corresponds to 0.0 V to 100.0 V Actual welding voltage value, Current actual value for the welding voltage...

  • Page 77: Profile 2 (Switch Position 2, Control Signal Mode)

    Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module 8.1.3 Profile 2 (switch position 2, control signal mode) The module uses a data capacity of 16 words (32 bytes) for input data and 8 words (16 bytes) for output data.
  • Page 78 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Rx-PDO 1 Cob ID = 200h + address Byte Bit no. Function Description Reserved WF switching (optional) Switches between 2 wire drive units Bit allocation: WF case 1 is active WF case 2 is active Cold wire on Check via optional cold wire...
  • Page 79 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Rx-PDO 3 Cob ID = 400h + address Byte Bit no. Function Description Pulse time specification, low- Specification of the pulse time for metallurgic byte pulsing Range: 0 to 0 x 7FFF 0 x 7FFF corresponds to 10.00 s Pulse time specification, high- Specification of the pulse time for metallurgic...
  • Page 80 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Rx-PDO 4 Cob ID = 400h + address Byte Bit no. Function Description Balance specification, high- Balance specification byte Item No.: 099-008225-EWM01...
  • Page 81 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Tx-PDO 1 Cob ID = 180h + address Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding Ready signal from process Bit allocation:...
  • Page 82 Profiles for TETRIX TIG and plasma systems Profiles for the CANopen module Tx-PDO 2 Cob ID = 280h + address Byte Bit no. Function Description Actual welding voltage value, Current actual value for the welding voltage low byte Range: 0 to 0 x 7FFF corresponds to 0.0 V to 100.0 V Actual welding voltage value, Current actual value for the welding voltage...

  • Page 83: Profiles For The Can Devicenet Module

    Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Profiles for the CAN DeviceNet module 8.2.1 Default profile (switch position 0) The module uses a data capacity of 4 words (8 bytes) for input data and 6 words (12 bytes) for output data.
  • Page 84 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Actuation data Byte Bit no. Function Description Start auxiliary process Start signal for the auxiliary process (plasma) Bit allocation: Auxiliary process off Auxiliary process on Error reset Acknowledgement signal for system error User-defined output Switches the user-defined relay output on the bus...
  • Page 85 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module The data can only be assigned to a single connection in this profile. Process data Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary...

  • Page 86: Profile 1 (Switch Position 1)

    Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Process data Byte Bit no. Function Description Actual welding current value, Current actual value for the welding current high byte Actual wire feed speed value , Current actual value for the wire feed speed low byte Range: 0 to 0 x 7FFF corresponds to 0.0 m/min to 40.0 m/min...
  • Page 87 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Actuation data Byte Bit no. Function Description Gas test 2 Manual check of the auxiliary gas Bit allocation: Gas supply off Gas supply on Inching Signal for wire inching function on the wire feed drive Bit allocation: Inching off...
  • Page 88 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module The data can only be assigned to a single connection in this profile. Process data Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary...
  • Page 89 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Process data Byte Bit no. Function Description Actual wire feed speed value , Current actual value for the wire feed speed low byte Range: 0 to 0 x 7FFF corresponds to 0.0 m/min to 40.0 m/min Actual wire feed speed value , Current actual value for the wire feed speed...

  • Page 90: Profile 2 (Switch Position 2, Program Mode)

    Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module 8.2.3 Profile 2 (switch position 2, program mode) The module uses a data capacity of 2 words (4 bytes) for input data and 6 words (12 bytes) for output data.
  • Page 91 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Byte Bit no. Function Description Reserved WF switching (optional) Switches between 2 wire drive units Bit allocation: WF case 1 is active WF case 2 is active 5 to 7 Reserved Program number specification...
  • Page 92 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Process data Byte Bit no. Function Description User-defined inputs Signal status of the digital input 1 to 3 on bits 0 to 2 Logic: 0 V signal on the input = signal low 24 V on the input = signal high Actual welding voltage value, Current actual value for the welding voltage...

  • Page 93: Profile 3 (Switch Position 3, Control Signal Mode)

    Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module 8.2.4 Profile 3 (switch position 3, control signal mode) The module uses a data capacity of 13 words (26 bytes) for input data and 6 words (12 bytes) for output data.
  • Page 94 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Byte Bit no. Function Description Reserved Cold wire on Check via optional cold wire Bit allocation: Cold wire off Cold wire on Reserved 6 & 7 Select welding mode Select pulse mode Bit allocation: Bit1...
  • Page 95 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Byte Bit no. Function Description Shielding gas specification, Shielding gas specification high-byte Pulse time specification, low- Specification of the pulse time for metallurgic byte pulsing Range: 0 to 0 x 7FFF 0 x 7FFF corresponds to 10.00 s Pulse time specification, high- Specification of the pulse time for metallurgic...
  • Page 96 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Process data Byte Bit no. Function Description Sticking Wire sticking message from process Bit allocation: Wire is free Wire sticks to the workpiece Error General fault message from process Bit allocation: No error Fault occurred and not rectified...
  • Page 97 Profiles for TETRIX TIG and plasma systems Profiles for the CAN DeviceNet module Process data Byte Bit no. Function Description Actual motor current value Current actual value for the motor current from the wire feed system high byte Item No.: 099-008225-EWM01...

  • Page 98: Profiles For The Profibus/Interbus Module

    Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Profiles for the Profibus/Interbus module 8.3.1 Default profile (switch position 0) The module uses a data capacity of 4 words (8 bytes) for input data and 6 words (12 bytes) for output data. The data can only be assigned to a single connection in this profile.
  • Page 99 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Actuation data Byte Bit no. Function Description Start auxiliary process Start signal for the auxiliary process (plasma) Bit allocation: Auxiliary process off Auxiliary process on Error reset Acknowledgement signal for system error User-defined output Switches the user-defined relay output on the bus module...
  • Page 100 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module The data can only be assigned to a single connection in this profile. Process data Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary...

  • Page 101: Profile 1 (Switch Position 1, Program Mode)

    Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Process data Byte Bit no. Function Description Actual welding current value, Current actual value for the welding current high byte Actual wire feed speed value , Current actual value for the wire feed speed low byte Range: 0 to 0 x 7FFF corresponds to 0.0 m/min to 40.0 m/min...
  • Page 102 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Rx-PDO 1 Cob ID = 200h + address Byte Bit no. Function Description Error reset Acknowledgement signal for system error Bit allocation: Signal must have positive edge for acknowledgement Start auxiliary process Start signal to initiate the auxiliary process...
  • Page 103 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Process data Byte Bit no. Function Description Collision signal Signals triggering of the collision protection Bit allocation: No collision Collision Main current signal Displays the status of the program sequence Bit allocation: Process is outside the main current phase Process running in the main program...

  • Page 104: Profile 2 (Switch Position 2, Control Signal Mode)

    Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module 8.3.3 Profile 2 (switch position 2, control signal mode) The module uses a data capacity of 13 words (26 bytes) for input data and 6 words (12 bytes) for output data.
  • Page 105 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Byte Bit no. Function Description Reserved Reserved 6 & 7 Select welding mode Select pulse mode Bit allocation: Bit1 Bit0 Normal welding active Thermal pulses active AC special pulses active (only with AC systems) Fast pulses active WF switching (optional) Switches between 2 wire drive units...
  • Page 106 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Byte Bit no. Function Description Shielding gas specification, Shielding gas specification low-byte Range: 0 to 0 x 7FFF 0 x 7FFF corresponds to 20.0 l/min Shielding gas specification, Shielding gas specification high-byte Pulse time specification, low-...
  • Page 107 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Process data Byte Bit no. Function Description Ready for welding Ready signal from process Bit allocation: System not ready System is ready Sticking Wire sticking message from process Bit allocation: Wire is free Wire sticks to the workpiece...
  • Page 108 Profiles for TETRIX TIG and plasma systems Profiles for the Profibus/Interbus module Process data Byte Bit no. Function Description Actual wire feed speed value , Current actual value for the wire feed speed high byte Actual motor current value Current actual value for the motor current from the wire feed system low byte Range: 0 to 0 x 7FFF...

  • Page 109: Profile On The Interbus Module

    Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Profile on the Interbus Module 8.4.1 Default profile (switch position 0) The module uses a data capacity of 6 words (12 bytes) for input data and output data. Actuation data Byte Bit no.
  • Page 110 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Actuation data Byte Bit no. Function Description Start auxiliary process Start signal for the auxiliary process (plasma) Bit allocation: Auxiliary process off Auxiliary process on Error reset Acknowledgement signal for system error User-defined output Switches the user-defined relay output on the bus module...
  • Page 111 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Process data Byte Bit no. Function Description I > 0 "Current flows" signal from process Bit allocation: No current flowing Current flows, arc stationary Ready for welding "Ready" signal from process Bit allocation: System not ready System is ready...

  • Page 112: Profile 1 (Switch Position 1, Program Mode)

    Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Process data Byte Bit no. Function Description Actual wire feed speed value , Current actual value for the wire feed speed low byte Range: 0 to 0 x 7FFF corresponds to 0.0 m/min to 40.0 m/min Actual wire feed speed value , Current actual value for the wire feed speed...
  • Page 113 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Byte Bit no. Function Description Start auxiliary process Start signal to initiate the auxiliary process Bit allocation: Auxiliary process is shut down Auxiliary process is started User-defined output Switches the user-defined relay output Bit allocation: On the bus module...
  • Page 114 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Process data Byte Bit no. Function Description Main current signal Displays the status of the program sequence Bit allocation: Process is outside the main current phase Process running in the main program Process active Signals the completion of the welding process Bit allocation...

  • Page 115: Profile 2 (Switch Position 2, Control Signal Operation, Slow Pulses)

    Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module 8.4.3 Profile 2 (switch position 2, control signal operation, slow pulses) The module uses a data capacity of 10 words (20 bytes) for input data and output data. NOTE In the profile, fast pulses can be selected but not parameterised.
  • Page 116 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Byte Bit no. Function Description Welding simulation Bit allocation: Welding simulation switched off Welding simulation activated Reserved Reserved Reserved 6 & 7 Select welding mode Select pulse mode Bit allocation: Bit1 Bit0...
  • Page 117 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Byte Bit no. Function Description Pulse time specification, low- Specification of the pulse time for metallurgic byte pulsing Range: 0 to 0 x 7FFF 0 x 7FFF corresponds to 10.00 s Pulse time specification, high- Specification of the pulse time for metallurgic byte...
  • Page 118 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Process data Byte Bit no. Function Description Main current signal Displays the status of the program sequence Bit allocation: Process is outside the main current phase Process running in the main program Process active Signals the completion of the welding process Bit allocation...

  • Page 119: Profile 3 (Switch Position 3, Control Signal Operation, Fast Pulses)

    Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module 8.4.4 Profile 3 (switch position 3, control signal operation, fast pulses) The module uses a data capacity of 10 words (20 bytes) for input data and output data. NOTE In the profile, slow and AC special pulses can be selected, but not parameterised.
  • Page 120 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Byte Bit no. Function Description Welding simulation Bit allocation: Welding simulation switched off Welding simulation activated Reserved Reserved Reserved 6 & 7 Select welding mode Select pulse mode Bit allocation: Bit1 Bit0...
  • Page 121 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Byte Bit no. Function Description Plasma gas specification, low- Specification of the plasma gas byte Range: 0 to 0 x 7FFF 0 x 7FFF corresponds to 10.0 l/min Plasma gas specification, Specification of the plasma gas high-byte...
  • Page 122 Profiles for TETRIX TIG and plasma systems Profile on the Interbus Module Process data Byte Bit no. Function Description Main current signal Displays the status of the program sequence Bit allocation: Process is outside the main current phase Process running in the main program Process active Signals the completion of the welding process Bit allocation...

  • Page 123: Special Field Bus Features When Setting Up The Field Bus Modules

    Special field bus features when setting up the field bus modules CAN DeviceNet Special field bus features when setting up the field bus modules CAN DeviceNet Field bus subscribers in the CAN DeviceNet are normally integrated using an EDS file (Electronic Data Sheet).

  • Page 124: Example Of A Connection Assignment

    Special field bus features when setting up the field bus modules Profibus DP 9.1.3 Example of a connection assignment In the example above, 12 bytes of connection 1 are assigned and configured as “Polled”. Profibus DP The Profibus node is integrated into the field bus using a GSD file. Here the data is structured in the form of modules which can have different lengths.

  • Page 125: Operating Problems, Causes And Remedies

    Operating problems, causes and remedies Operating displays (LEDs) Operating problems, causes and remedies 10.1 Operating displays (LEDs) LED no. Function Description +15 V voltage Voltage supply +15 V Allocation: Voltage missing/faulty Voltage OK -15 V voltage Voltage supply -15 V Allocation: Voltage missing/faulty Voltage OK...

  • Page 126: Error Messages On The System

    Excess temperature of external coolant circuit TETRIX External HF choke excess temperature TETRIX Specific error in AC systems 33-36, 40 Specially detected error, please contact EWM TETRIX No, switch off machine The safety device of the inverse rectifier has TETRIX...
  • Page 127 Operating problems, causes and remedies Error messages on the system Error Meaning Relevance Error can be reset number to system (value) In a system with the option for WF case PHOENIX switching, an attempt has been made to switch to a WF which does not exist No connection to the welding power source PHOENIX/TETRIX No, resets itself...

  • Page 128: Overview Of Plug Configurations

    Overview of plug configurations X4, digital inputs Overview of plug configurations 11.1 X4, digital inputs The control has 4 digital inputs with 24V logic. 24V switches the input logically high, 0V switches the input logically low. Pin no.: Function/Meaning Term in status data X4/1 +24V X4/2...

  • Page 129: X10, Diagnostics Interface

    X10, diagnostics interface 11.4 X10, diagnostics interface This plug provides the diagnostics function via an RS232 interface. Please only use the cables available from EWM Hightec Welding for connection to the PC. Pin no.: Function/Meaning Term in status data X10/1...

  • Page 130: Overview Of Jumper Assignments Busintx11 Rev00

    Overview of jumper assignments BUSINTX11 Rev00 X15, external power supply Overview of jumper assignments BUSINTX11 Rev00 JP No.: Function/Meaning Assignment For internal use only, do not assign! Must not be completed Fast analogue inputs function 0 = analogue signal source is system bus 1 = analogue signal source are analogue inputs on Reserved Activation of JOB mode...

  • Page 131: Overview Of Machine Software Functions (Firmware)

    Overview of machine software functions (firmware) PHOENIX machine software (firmware) Overview of machine software functions (firmware) The table below provides information for each of the PHOENIX and TETRIX welding systems separately relating to the relevant functionality of the interface machine software (firmware). 13.1 PHOENIX machine software (firmware) Software-...

  • Page 132: Warranty

    • Wire feeds • Cooling units • Trolleys * If these are operated with genuine EWM accessories (such as intermediate tube package, remote control, remote control extension cable, coolant, etc.). 1-year warranty on: • Used EWM machines • Automation and mechanisation components •...

  • Page 133: Warranty Declaration

    This limitation does not apply to personal injuries or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the claims of third parties.

  • Page 134: Circuit Diagrams

    Circuit diagrams Warranty Declaration Circuit diagrams X15/1 X7/1 Vin+ +10V Uref. reference X7/2 X15/2 Vin- Uist 0-10V=0-150V X7/3 Iist 0-10V = 0-1000A X7/4 X7/5 X7/6 X7/7 X7/8 X7/9 X14/1 X7/10 X14/2 X7/11 X7/12 X11/1 X11/2 X5/1 X11/3 X11/4 X5/2 Warnung warning X5/3 Überwachung monitoring...

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