Description I/O ESAB
ATAS unit
0470 023 805 GB 20230202
1 GENERAL DESCRIPTION
This is an interface for communication into the PEK system’s internal CAN bus.
For example:
• You can use it against an RCC-type remote control box to "move" out button functions
from PEK.
• Connect two different PEK systems that "talk" via inputs/outputs with each other via
the IO unit (for example Tandem).
• Between a PEK system and, for example, an external axis.
You can also use it against an RCC-type remote control box. The unit has 1 encoder input, 2 analogue
inputs, 1 analogue output, 16 digital inputs and 8 relay outputs.
2 OPERATING CONDITIONS
Ambient temperature: 5-50 °C
Max. humidity: 95%
Ingress protection grading: IP20
Voltage supply: 20-70VDC / 18-50VAC (maximum) 5W
3 CONNECTION TO THE I/O ESAB ATAS
UNIT
3.1 Voltage supply
VI+ 20-70V DC, 5 W / 18-50V AC, 5 W X10.1
0 V X10.2
VI+ 20-70V DC, 5 W / 18-50V AC, 5 W X11.1
0 V X11.2
3.2 Pulse sensor input
NOTE!
Only one jumper is permitted!
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3 CONNECTION TO THE I/O ESAB ATAS UNIT
Encoder-input, two (2) channels, frequency range 10 Hz–20 kHz
Pulse levels 5V/15V/24V (jumper):
Jumper J1 5V @ 100 mA
Jumper J2 15V @ 30 mA
Jumper J3 24V @ 20 mA (default)
0V encoder voltage X12.1
5V/12V/24V encoder voltage (bridging) X12.2
0N X12.3
0 X12.4
BN X12.5
B X12.6
AN X12.7
A X12.8
N.C. X12.9
Use 2 pcs. (A+B) or 4 pcs. (A+AN+B+BN) inputs.
3.3 CAN Interface Default 500 kbit/s
The baud rate can be changed using ESAT.
CAN H X14.1
CAN L X14.2
0V X14.3
CAN H X15.1
CAN L X15.2
0V X15.3
The 120 Ω terminating resistor must be positioned between CAN H and CAN L if the IO ATAS unit is
connected last on the CAN loop.
3.4 Node ID setting
Node ID is set via two switches. The switches represent two nibbles of hex bytes. The switches are
located on the right side of the module. The switches are read at start-up.
Example: Node ID 17 dec -> 0x11:
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3 CONNECTION TO THE I/O ESAB ATAS UNIT
Example: Node ID 25 dec -> 0x19:
3.5 Analogue input 1
No function at this time
Analogue input, two (2) channels, ten (10) bit resolution
Analogue input 1 0-5V X16.1
0V X16.2
N.C. X16.3
3.6 Analogue input 2
No function at this time
Analogue input 2 0-5V X17.1
0V X17.2
N.C. X17.3
3.7 Analogue output
Analogue output, one (1) channel, 0-10V @ 10 mA, twelve (12) bit resolution
Analogue out 0-10V X18.1
0V X18.2
3.8 Digital inputs
16 inputs
24V DC (18-30V DC)
Total max current for all inputs = 800 mA
3.8.1 Voltage supply digital inputs
US +24 V (18-30 V) Voltage in X20.1
0 V X20.2
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3 CONNECTION TO THE I/O ESAB ATAS UNIT
US +24 V (18-30 V) Voltage out
(jumperedinternallyfromX20)
0 V X21.2
X21.1
3.8.2 Inputs 16 pieces
Input 1 X22.1
Input 2 X22.2
Input 3 X22.3
Input 4 X22.4
US + Voltage out (jumpered internally from X20) X22.5
0 V X22.6
Input 5 X23.1
Input 6 X23.2
Input 7 X23.3
Input 8 X23.4
US + Voltage out (jumpered internally from X20) X23.5
0 V X23.6
Input 9 X24.1
Input 10 X24.2
Input 11 X24.3
Input 12 X24.4
US + Voltage out (jumpered internally from X20) X24.5
0 V X24.6
Input 13 X25.1
Input 14 X25.2
Input 15 X25.3
Input 16 X25.4
US + Voltage out (jumpered internally from X20) X25.5
0 V X25.6
3.9 Digital outputs
8 relay outputs
Nom. load: Max 130 V, 3 A AC / 30 V, 3 A DC per relay
Output 1+ Relay out + max 130 V 3 A AC / 30 V 3 A DC X26.1
Output 1- Relay out - X26.2
Output 2+ Relay out + X26.3
Output 2- Relay out - X26.4
Output 3+ Relay out + X26.5
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3 CONNECTION TO THE I/O ESAB ATAS UNIT
Output 3- Relay out - X26.6
Output 4+ Relay out + X26.7
Output 4- Relay out - X26.8
Output 5+ Relay out + X27.1
Output 5- Relay out - X27.2
Output 6+ Relay out + X27.3
Output 6- Relay out - X27.4
Output 7+ Relay out + X27.5
Output 7- Relay out - X27.6
Output 8+ Relay out + X27.7
Output 8- Relay out - X27.8
3.10 I/O ESAB ATAS unit number one connected
3.10.1 I/O ESAB ATAS unit 1 node ID 17
This node handles the crane's remote control and tandem welding.
Pulse sensor input
Speed feedback. PEK shows measured values. X12.1-X12.9
Analogue out
0 V X18.1
0-10 V speed reference X18.2
Inputs 16 pieces
Input number
Weld Start 1 X22.1
Weld Stop 2 X22.2
Manual movement square 3 X22.3
Manual movement triangle 4 X22.4
Wire feed up 5 X23.1
Wire feed down 6 X23.2
High speed 7 X23.3
Limit switch square 8 X23.4
Limit switch triangle 9 X24.1
Requested travel motion from "Tail" 10 X24.2
Axis 1/2, 1 = External, 0 = Boom 11 X24.3
Tandem “Tail” Weld start 12 X24.4
Cold wire (ICE) feed up 13 X25.1
Cold wire (ICE) feed down 14 X25.2
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3 CONNECTION TO THE I/O ESAB ATAS UNIT
Input number
Error from external equipment 15 X25.3
Step function switch 16 X25.4
Outputs 8 pieces
Output number
Roller bed indication 1 X26.2
Boom indication 2 X26.4
Welding current indication 3 X26.6
Tandem ”Tail”: Request travel motion 4 X26.8
Tandem ”Head”: Welding start tandem ”Tail” 4 X26.8
Direction: forward (roller bed) square (boom) 5 X27.2
Direction: backward (roller bed) triangle (boom) 6 X27.4
External axis indication 7 X27.6
Error indication 8 X27.8
3.11 I/O ESAB ATAS unit number two connected
3.11.1 I/O ESAB ATAS unit 2 node ID 25
Pulse sensor input
Speed feedback. PEK shows measured values. X12.1-X12.9
Analogue out
0 V X18.1
0-10 V Travel speed reference X18.2
Recall of welding data sets. When input 9 is activated, inputs 1-8 are blocked and used to select the
welding data set to be recalled. The inputs are interpreted as a binary number. Input 1 is LSB.
Inputs 16 pieces
Input number
Welding data set number 1 (value: 1) 1 X22.1
Welding data set number 2 (value: 2) 2 X22.2
Welding data set number 3 (value: 4) 3 X22.3
Welding data set number 4 (value: 8) 4 X22.4
Welding data set number 5 (value: 16) 5 X23.1
Welding data set number 6 (value: 32) 6 X23.2
Welding data set number 7 (value: 64) 7 X23.3
Welding data set number 8 (value: 128) 8 X23.4
Welding data set recall 9 X24.1
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4 DIAGNOSTIC LED
Outputs 8 pieces
Output number
Roller bed indication 1 X26.2
Boom indication 2 X26.4
Welding current indication 3 X26.6
Tandem ”Tail”: Request travel motion 4 X26.8
Tandem ”Head”: Weld Start 4 X26.8
Direction: forward (roller bed) square (boom) 5 X27.2
Direction: backward (roller bed) triangle (boom) 6 X27.4
External axis indication 7 X27.6
Error indication 8 X27.8
4 DIAGNOSTIC LED
Diagnostic LEDs are according to standard DS303.
CANOpen Run Led (green)
CAN Run LED Description Explanation
Flickering Not used
Flashing "PREOPERATIONAL" The unit is in "PREOPERATIONAL"
Single flash "STOPPED" The unit is in "STOPPED"
Double flash Not used
Triple flash Not used
Constantly lit "OPERATIONAL" The unit is in "OPERATIONAL"
CANOpen Error Led (yellow)
CAN Run LED Description Explanation
Not lit No error
Flickering Not used
Flashing Not used
Single flash Warning threshold reached Too many "Error frames"
Double flash Error check, event A "guard event" or "heartbeat event" has occurred
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5 DETAILED DESCRIPTION OF INPUTS/OUTPUTS ETC.
CAN Run LED Description Explanation
Triple flash Not used
Constantly lit "Bus Off" CAN controller is in "Bus Off"
5 DETAILED DESCRIPTION OF
INPUTS/OUTPUTS ETC.
5.1 Input 1-16 I/O ESAB ATAS unit 1
5.1.1 Input 1 Start
Remote connection, in PEK, must be selected in order for the input to work. The start input starts
welding when it goes from low to high, if the stop input is high.
5.1.2 Input 2 Stop
Remote connection, in PEK, must be selected in order for the input to work. The stop input stops
welding when the input is low. The stop input stops all movement in progress.
5.1.3 Input 3 Manual travel motion square (for active axis)
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal starts travel
motion in direction square if the limit switch square input is not active. The LED at the square symbol
lights up on the PEK box. Otherwise the same conditions as for travel motion square in the PEK box.
5.1.4 Input 4 Manual travel motion triangle (for active axis)
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal starts travel
motion in direction triangle if the limit switch triangle input is not active. The LED at the triangle symbol
lights up on the PEK box. Otherwise the same conditions as for travel motion triangle in the PEK box.
5.1.5 Input 5 wire feed up
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal feeds wire up.
Otherwise the same conditions as for start and stop in the PEK box.
5.1.6 Input 6 wire feed down
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal feeds wire down.
Otherwise the same conditions as for start and stop in the PEK box.
5.1.7 Input 7 High speed
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal gives high
speed. High speed/low speed is inactive during welding. The lamp is lit on the PEK box when high
speed is selected.
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5 DETAILED DESCRIPTION OF INPUTS/OUTPUTS ETC.
5.1.8 Input 8 Limit switch square
If the travel motion stops, welding is also interrupted, in that direction when the signal is low.
NOTE!
The motor board also has an input for limit switch square, it works in parallel with the I/O
ESAB ATAS unit’s input.
5.1.9 Input 9 Limit switch triangle
If the travel motion stops, welding is also interrupted, in that direction when the signal is low.
NOTE!
The motor board also has an input for limit switch triangle, it works in parallel with the I/O
ESAB ATAS unit’s input.
5.1.10 Input 10 Requested travel motion from "Tail"
Used as a travel motion controller if you want to run the motion from PEK "Tail" but it is PEK "Head"
that has the motion. For example, welding is in progress at "Tail", which is requesting that "Head" PEK
continue to execute the motion during Tandem welding. Input to I/O ESAB ATAS unit for PEK "Head".
5.1.11 Input 11 External axis/boom mode
Remote connection, in PEK, must be selected in order for the input to work. High signal selects
External axis and low signal selects Boom. External axis means that some other system takes care of
the "travel/rotational motion", such as a roller bed.
5.1.12 Input 12 Requested welding from "Head"
Function "Tandem" must be set to ON and "with I/O" must be set to ON in the machine configuration
menu. Power source "Head" requests start welding. Connects to the I/O ESAB ATAS unit for PEK
"Tail".
5.1.13 Input 13 Cold wire (ICE) feed up
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal feeds wire up.
NOTE!
The function ICE must be activated in PEK. Otherwise the same conditions as for start and
stop in the PEK box.
5.1.14 Input 14 Cold wire (ICE) feed down
Remote connection, in PEK, must be selected in order for the input to work. It is not possible to
execute this manoeuvre from PEK when the remote connection is active. High signal feeds wire down.
NOTE!
The function ICE must be activated in PEK. Otherwise the same conditions as for start and
stop in the PEK box.
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5 DETAILED DESCRIPTION OF INPUTS/OUTPUTS ETC.
5.1.15 Input 15 Error from external equipment
External equipment indicating an error. Welding etc. is then shut down. Prevents new welding start.
High signal gives an error.
5.1.16 Input 16 Step function switch
External axis, in PEK, must be selected in order for the input to work. Step function, in PEK, must be
activated in order for the input to work. Soft button AUTO STEP, in PEK, must be activated in order for
the input to work. At high signal, the welding head is moved one step sideways. For more details on
step function, see PEK manual.
5.2 Input 1-9 Welding data set I/O ESAB ATAS
unit2
Welding data set input 1-8. Set which welding data set you want to recall. Recall selected set with
input 9.
5.3 Outputs
5.3.1 Output 1 External axis selection
The output is set when the input "External axis mode/Boom mode" is set to "External axis" mode.
External axis means that some other system takes care of the "travel/rotational motion", such as a
roller bed.
5.3.2 Output 2 Boom selection
The output is set when the input "External axis mode/Boom mode" is set to "Boom" mode.
5.3.3 Output 3 Welding current is flowing
The output is high as long as the welding current is flowing.
5.3.4 Output 4 Request travel motion from PEK "Head"
during tandem welding
PEK "Tail" sets the output when welding starts and keeps it active until the power source stops the
welding. Output on I/O ESAB ATAS unit for PEK "Tail".
5.3.5 Output 4 Start of welding at Tandem from "Head" to
"Tail"
"Head" starts "Tail" via this I/O ESAB ATAS unit during Tandem welding. "Head" executes the motion
for the time it takes for "Tail" to get to the stop position. When "Tail" arrives it is stopped, but the travel
motion continues until PEK "Tail" communicates via the I/O ESAB ATAS unit that the travel motion
should be stopped.
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5.3.6 Output 5 Direction square
If "External axis"” mode is selected on input "External axis/Boom" mode.
• Is set high when you manually execute the travel/rotational motion in direction square.
• Is set high when you weld in direction square and:
1. During direct start, welding current must flow
2. During scratch start when welding start is selected
5.3.7 Output 5 Direction of rotation forward
Same as direction square but for roller bed
5.3.8 Output 6 Direction triangle
If "External axis"” mode is selected on input "External axis/Boom" mode.
• Is set high when you manually execute the travel/rotational motion in direction
triangle.
• Is set high when you weld in direction triangle and:
1. During direct start, welding current must flow
2. During scratch start when welding start is selected
5.3.9 Output 6 Direction of rotation backward
Same as direction triangle but for roller bed
5.3.10 Output 7 External axis
The output is set high if external axis is selected, such as a roller bed.
5.3.11 Output 8 Error indication
The output is set high if an error occurs in the PEK system.
5.4 Analogue out
5.4.1 Speed reference
Free 3 axis must be selected.
External movement mode active
Then the speed of travel/(rotational) motion must be given as a 0-10V signal.
5.5 Pulse sensor input
Speed feedback and position feedback
Step function uses this data. See PEK manual for more details on Step function.
PEK shows measured values.
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6 USE CASES
6 USE CASES
6.1 Detailed PEK information
For more detailed information on how to configure PEK, see the PEK manual.
6.2 Remote control via I/O ESAB ATAS unit
Activate remote control via soft button on PEK. If remote control has been selected, the buttons on
PEK for manual motor movements and the welding start button are inactive. The stop button on PEK
is working. The inputs for triangle/square on the IO device have, in this mode, the same function as
normally on PEK.
If you have selected remote control off and roller bed on, only the inputs for limit switches on the I/O
ESAB ATAS unit will function. Control of the outputs on the I/O ESAB ATAS unit is active.
6.3 Tandem two welding heads on one travel
motion
Configuration connection of Tandem via I/O ESAB ATAS unit
For more detailed information on how to configure PEK for "Head"/"Tail" see the PEK manual.
Usage
Start and stop of welding is done on PEK "Head", which then controls the "Tail" power source. When
starting at "Head", "Head" power source is started first, when "Tail" arrives at the start position, the
"Head" power source starts "Tail" via the I/O ESAB ATAS unit. When stopping PEK "Head", it ends its
welding process but travel motion continues until "Tail" reaches the stop position and stops the "Tail"
power source via the I/O ESAB ATAS unit. Travel motion continues until the "Tail" power source has
finished the welding process along with any stop phases. When the "Tail" power source signals weld
stop to PEK, it stops the travel motion via the I/O ESAB ATAS unit to "Head" PEK.
Connection
I/O ESAB ATAS unit "Head" I/O ESAB ATAS unit "Tail"
Output 4 Input 12
"Head" in Tandem Start X26.8-> Tandem "Tail" start X24.4
Input 10 Output 4
Requested travel motion from "Tail" X24.2<- "Tail". Request travel motion to "Head" X26.8
Configuration
• Select Tandem in "Machine configuration".
• "Head" is selected on PEK number 1 under "Machine configuration".
• Distance to "Tail" is set under "Machine configuration" on "Head" PEK.
• "Tail" is set on PEK number 2.
The distance to "Head" does not need to be programmed on "Tail" as "Head" takes care of this. It
calculates how long it should run after the stop depending on the travel speed, which depends on the
distance between "Head" and "Tail" that is set in "Machine configuration".
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6 USE CASES
6.4 Roller bed control via I/O ESAB ATAS unit
Usage
Start of welding with roller bed can either be done with start from PEK or start via the I/O ESAB ATAS
unit (in which case remote control on must be selected). If you choose remote control, the choice of
driving a boom or roller bed is also controlled via the I/O ESAB ATAS unit.
• Choose "Free 3 axis" in "Machine configuration".
• Choose roller bed in "Machine configuration".
• Ratios on wire motor and roller bed are set under "Machine configuration".
6.5 Recall of welding data set
Usage
If you have I/O ESAB ATAS unit with node ID 25
Example: Recall of welding data set no. 26 from PEK
Set input 2, 4, 5 high, i.e. welding data set no. 26 that you wish to "recall" from PEK.
"Recall" by also setting input 9 high
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ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone +46 (0) 31 50 90 00
http://manuals.esab.com
For contact information visit http://esab.com
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