Rights reserved to alter specifications without notice.
TOCe
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1INTRODUCTION TO CANopen
CANopen is an open communication profile based on the Controller Area Network
(CAN) bus system. It is internationally standardized in ISO 11898.
CANopen has an international user organization called CAN in Automation (CiA). For
further information regarding CANopen matters not associated with this ESAB
product, please contact CiA on e--mail: headquarters@can--cia.dewww.can.cia.de.
There is also information of a general kind available on the Internet at .
1.1Network overview
The media of the fieldbus system is a shielded copper cable consisting of one
twisted pair of communication cable and two cables for external power supply. As
standard, the CANopen Esab products do not use external power supply.
The power supply for the bus is galvanically isolated with a DC/DC converter inside
the Esab equipment. The number of devices participating in each network is logically
limited by CANopen to 128, but physically the present generation of drives allows up
to 64 nodes in one network segment.
The baud rate can be changed from 10 kbit/s to 1Mbit/s at discrete levels. The
maximum possible size of the network for any particular data rate is limited by the
signal transit time required on the bus medium corresponding to the following table:
The baud rate and the node address for the welding node is set inside the Control
box (see chapter XX). The CANopen protocol supports both master--slave and
slave--slave communications. The data on the CANopen bus is updated when a
change is made or on request from another node.
1.2Technical features for CANopen
Here follows a short list of some important features with the CANopen
communication standard:
S
CANopen specific cable (twisted pair).
SAccess intelligence in low--level devices.
SMaster--Slave and Peer--to--Peer capabilities.
SSelectable baud rates from 10kbit/s to 1Mbit/s.
SMax distance 5000m.
SNode removal without damaging the network.
SUse of scaled and open--styled connectors.
SProvision for the typical request /response oriented network communications.
SProvision for the efficient movement of I/O data.
SFragmentation for moving larger bodies of information.
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2UNIT OVERVIEW
This chapter provides an overview over the ESAB Aristo CANopen unit.
2.1Functional overview
The ESAB unit for CANopen is a slave node that can be read and written to from a
CANopen master/slave. Via the host connector, the unit is connected to an
application that gets instant connection to a CANopen network.
2.2Mechanical overview
DIP- switches and inditation LED
Connection box
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3INSTALLATION AND CONFIGURATION
3.1Fieldbus connector
9--pin male D--sub connector
Connector
pin
1--Reserved
2CAN_LCAN_L Bus line (dominant low)
3CAN_GNDCAN ground
4--Reserved
5CAN_SHIELDOptional CAN Shield
6GNDOptional ground
7CAN_HCAN_H Bus line (dominant
8--Reserved
9CAN_V+Optional CAN external power
SignalDescription
high)
supply
3.2Configuration
Node Address
The Network node address is set with two rotary switches inside the Weld Data Unit
(ADDRESS_HIGH and ADDRESS_LOW), see Figure 1. Possible node addresses is
between 1--99 in decimal format. ADDRESS_HIGH is the one in the middle and
ADDRESS_LOW is the one to the right.
The node address is calculated in the following way:
Note: PDO 3 – 8 only have default COB--ID’s if the node address is less than 64.
Note: The node address can only be changed during operation.
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Baudrate
The baud rate is configured with one decimal rotary switch inside the Weld Data
Unit. See table below for supported baud rates. The baud rate switch is the one to
the left.
Switch
setting
0Not available
110 kbit/s
220 kbit/s
350 kbit/s
4125 kbit/s
5250 kbit/s
6500 kbit/s
7800 kbit/s
81 Mbit/s
9Not available
Baudrate
Termination
CANopen uses standard CAN termination on the first and last node on the network.
The termination resistor should be 120 ohm. This should be connected between
CAN_H and CAN_L on the bus.
Note that the termination resistor is only used when the machine is the first or last on
the bus.
3.3LED indicators
The node inside the Weld Data Unit is equipped with four bi--color status and
indication LED’s mounted at the front of the module.
During start--up a LED, test will be performed to make sure the LED’s are working.
Test sequence is: Red – Green – Off.
There is also an additional bi--color Watchdog LED on the module inside the Weld
Data Unit for development purposes.
LED 2
ColorFrequencyDescription
Green 1HzModule in ‘Pre--Operation’ state
Green 2HzModule in ‘Prepared’ state
Green Steady onModule in ‘Operational’ state
Red1HzBus initialization failed
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LED 3
ColorFrequencyDescription
Green1HzBus off / Error Passive
GreenSteady onBus Running
Red1HzOther Error
Off--Power off or module not
initialized
LED 4
ColorFrequencyDescription
Off--No power to device
Green Steady onModule has power
3.4EDS file
This file is used to configuring the network. If standard configuration is used this file
is not required. If a standard CANopen configurator is used an EDS file is required.
The latest version of the EDS file can be received by contacting ESAB.
Byte 1Error Type 1Error Type 2Error Type 3Error Type 4Error Type 5Error Type 6Error Type 7Error Type 8
Byte 2Error WDUError PSError WF
Byte 3Reserved
Byte 4Reserved
Byte 5Reserved
Byte 6Reserved
Byte 7Reserved
Byte 0Voltage Low Byte(SINT)
Byte 1Voltage High Byte (SINT)
Byte 2Wire Feed Speed Low Byte(USINT)
Byte 3Wire Feed Speed High Byte (USINT)
Byte 4Synergic Voltage Low Byte (SINT)
Byte 5Synergic Voltage High Byte (SINT)
Byte 6Reserved
Byte 7Reserved
Bit 0Bit 1Bit 2Bit 3Bit 4Bit 5Bit 6Bit 7
Transmit PDO 4, COB--ID 2C0h + Node Address
Byte 0Weld Data Number
Byte 1Reserved
Byte 2Reserved
Byte 3Reserved
Byte 4Reserved
Byte 5Reserved
Byte 6Reserved
Byte 7Reserved
Bit 0Bit 1Bit 2Bit 3Bit 4Bit 5Bit 6Bit 7
Transmit PDO 5, COB--ID 3C0h + Node Address
Byte 0Weld Data Unit Error Mask
Byte 1Weld Data Unit Error Mask
Byte 2Weld Data Unit Error Mask
Byte 3Weld Data Unit Error Mask
Byte 4Weld Data Unit Error Mask
Byte 5Weld Data Unit Error Mask
Byte 6Reserved
Byte 7Reserved
This bit starts a Welding procedure. Before a welding procedure is started the Quick
Stop bit and Emergency stop bits are checked.
Quick Stop
This bit performs a Quick Stop if the Equipment is in a welding procedure. T his
means that the Welding Equipment will do a normal stopping procedure without
Craterfilling.
This function is used when a fast stop is required but it will handle Burnback the
normal way to avoid that the wire is left frozen in the weld pool. This bit will also
block a start command.
Emergency Stop
This bit performs a Emergency Stop if the Equipment is in a Welding procedure. This
means that the welding equipment will shut off the arc, wire feeding and gas flow
without any burnback time. This bit will also block a start command.
Inching
This bit makes the wire feeder to start feed the wire without activating the power
source. The feeder will feed the wire at the adjusted speed. If this bit is activated
during a welding procedure, this command will be ignored.
If both Weld On and Inching is a ctivated at the same time the equipment will ignore
the Inch command and start a welding procedure.
Gas Purge
The gas control works in parallel with the regular gas handling timers which means
that the gas inputs can be left unused.
A weld start will always start with opening the gas valve if it not already is opened by
activating the input. In similar fashion the end of gas post flow timer will always close
the gas valve if it is not already closed by deactivating the gas input.
Accordingly when you what this input to control the gas valve operations the gas pre
flow time shall be set at minimum and the gas post flow time shall be set at
maximum.
Clean
This bit controls a valve for spatter cleaning gas. The function is not implemented in
the current version of the system.
Inch Reverse
This input bit will control backward--jogging movement to position the wir e end before
weld start. This function is not implemented in the current version of the system .
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Wire Feed 1--4
These bits are used to change active wire feeder. If more than one is activated the
wire feeder with the lowest I/O number will be activated. If non are activated it will
default to the lowest numbered feeder that are present in the system.
Release Wire
This function will execute a current pulse to burn off a wire that is frozen in the weld
pool if previous weld is ended in a not normal way. The release pulse is only
executed if ”Weld On” is off. This function is not implemented in the current version
of the system.
Touch Sense
When this input is activated the power source will output a weak power to detect if
there is contact in the welding circuit. As long as this function is engaged the output
bit ”Touch Sense Response” will be changed according to the condition in the
welding circuit. This function is not implemented in the current version of the system .
Reset Error
This input bit will reset the error indication. Only error indications that do not have
any other way of resetting than reboot of the system are affected by this reset. This
function is not implemented in the current version of the system.
Analog Active
This input is used to switch between analog active mode and normal mode. When
using the Analog Active mode the machine will not use the pre--stored values for
Wire Feed Speed and Voltage when a new Weld Data Set is selected.
The machine will always use the values on the Wire Feed Speed and Voltage inputs
in this mode. When using the Normal mode the machine will set the Wire Fe ed
Speed and Voltage to the values stored in the set.
If the inputs for Wire Feed Speed and Voltage are changed after the Weld Data Set
is changed the machine will use the new values.
Weld Data Number
This byte is used to recall a complete set of weld data from the weld data memory in
the Weld Data Unit. A complete set of weld data includes all settings that can be
made in the Weld Data Unit.
Among a large number of setting values this includes:
SWire Type
SWire Dimension
SGas Type
SUse of synergic mode or non--synergic mode
SPulse Welding or Dip/Spray Welding
SStart Data
SStop Data
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Numerical Welding Parameters
Voltage
This 16--bit signed value is used to adjust the voltage value. The scaling factor is 100
so if 20 V is wanted, the value should be 2000. The resolution within the machine is
¼ V. This means that if you set 10,6 V the value displayed will be 10,5 V.
If the machine is in non--synergic mode the equipment will simply use the value set.
If the equipment is in synergic mode the machine will use the value as an offset from
the synergic value. The synergic value can be read from the output I/O area.
Wire Feed Speed
This 16--bit unsigned value is used to adjust the wire feed value. The scaling factor is
100 so if 15 m/min is wanted, the value should be 1500. The resolution within the
machine is ¼ m/min.
5.2OUT I/O from Welding Equipment to Controller
Weld Status Bits
Weld Busy
This signal indicates that the welding equipment is occupied with welding. If a stuck
wire or a burn through will break the welding circuit then the power source will go on
trying to weld until it gets a stop command.
A condition that makes the Arc acknowledge signal to fall does not stop the welding
equipment from continuing the attempts to weld.
As a default value, the weld busy signal is activated when the gas preflow begins
until the gas postflow stops. By chosing Weld Busy in the configuration menu, it is
possible to choose to have the weld busy signal activated when the power source
outputs power, until the gas postflow stops. In the menu you can also choose to have
the weld busy signal activated when the power source outputs power, until the power
source shuts down the power output.
Arc Acknowledge
This signal will be activated when the arc is established at a weld start and it will fall
when voltage and current variations indicate that there can not be welding any
longer.
The criteria for arc established is that the process control has passed its start
procedure which means that it is not enough with just a short--circuit to fulfill the
criteria. Typical delay times from first contact to Arc acknowledge (wire feed time till
first contact not included) is in the r ange 2 to 20 ms. In case of a bad start the Arc
acknowledge signal will be more delayed.
The Arc acknowledge signal will stay on until either the weld is interrupted or the
welding is stopped the normal way. At a normal stop the Arc acknowledge signal will
fall when the finalizing procedures are ended (i.e. craterfill, burnback) and the power
source cuts the arc.
An interrupted weld is detected if abnormal conditions during welding makes the
weld process control deviate significantly from a normal working point. A certain
filtering time is used for this detection.
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One example is if the wire is stuck and the Power Source keeps an arc between
workpiece and contact nozzle so that a normal current detection would indicate that
current is flowing and arc is assumed OK. In this case the Arc acknowledge signal
will fall due to that the weld controller has deviated to much from normal welding
conditions.
Touch Sense Response
This output bit will indicate contact in welding circuit as long as input bit ”Touch
Sense ” is active It will be ”0” all other time. This function is not implemented in the
current version of the system.
Error of type 1--8
There is an error of the indicated type in one of the err o r masks. Which error that will
be caught can be configured with a service function. With this feature it is possible to
configure, for example, one error type to be a general error and another error type to
be gas error and so on.
As a default the error types are configured as follows:
Change in Weld Data Unit Errors. Is set to 1 when there is a change in the Weld
Data Unit bit mask. Does not matter if a specific error arises or disappears.
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Error in Power Source Unit
Change in Power Source Unit Errors. Is set to 1 when there is a change in the Weld
Data Unit bit mask. Does not matter if a specific error arises or disappears.
Error in Wire Feed Unit
Change in Wire F eed Unit Errors. Is set to 1 when there is a change in the Weld
Data Unit bit mask. Does not matter if a specific error arises or disappears.
Weld Data Number
This byte is updated every time there has been a successful recall of a Weld Data
Set. In case that the desired Weld Data Set does not exist in the Weld Data Memory,
the old number will remain.
Note that if the controller recall a Weld Data Set and the Operator uses the Weld
Data Unit to change any individual parameter, the Weld Data in the Operating Weld
Data Memory and the Weld Data in the Weld Data Set indicated by this byte will not
be consistent.
Numerical Welding Parameters
Voltage
This 16--bit unsigned value indicates which voltage the welding machine is using. If a
value is set with RPDO 2 that are outside limits, this value will be set to the nearest
allowed value.
Wire Feed Speed
This 16--bit signed value indicates which wire feed speed the wire feeder is using. If
a value is set with RPDO 2 that are outside limits, this value will be set to the nearest
allowed value.
Synergic Voltage
This 16--bit unsigned value indicates the result of the calculations preformed by the
welding equipment. The difference between this value and the voltage is the offset
set with RPDO2. This value is only valid when running in synergic mode.
Measured Values
Voltage
This value is measured by the welding equipment. In pulse welding it can be
configured if the value presented should be the average value or the pulse value.
Current
This value is measured by the welding equipment.
Power
This value is measured by the welding equipment.
Error Mask, Weld Data Unit
This error mask indicates which errors that are presently activated in the Weld Data
Unit. These error codes can be interpreted with the table in Appendix 1.
Error Mask, Power Source
This error mask indicates which errors that are presently activated in the Power
Source. These error codes can be interpreted with the table in Appendix 1.
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Error Mask, Wire Feeder
This error mask indicates which errors that are presently activated in the Wire Feed
Unit. These error codes can be interpreted with the table in Appendix 1.
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Appendix 1
Specification of error codes in LUD
Error codeDescriptionSLUDLUDMEK
1EPROM
2RAM
3External RAM
4Power supply voltage 5V
5High DC voltage
6High temperature
7High primary current
8DC Voltage 1*
9DC Voltage 2*
10DC Voltage 3*
11Current--servo / Wire speed--servo
12Communication error ( warning -- internal bus )
14Communication error ( bus off -- internal bus )