BUSINT X11 ATCASE (Phoenix, alpha Q)Operating instructions . Interface for digital wel EN ding power...

Operating instructions

EN

Interface for digital welding power sources

BUSINT X11 ATCASE (Phoenix, alpha Q)

099-008196-EW501 Observe additional system documents! 27.11.2019

General instructions

WARNING

Read the operating instructions!

The operating instructions provide an introduction to the safe use of the products.

• Read and observe the operating instructions for all system components, especially the sa-

fety instructions and warning notices!

• Observe the accident prevention regulations and any regional regulations!

• The operating instructions must be kept at the location where the machine is operated.

• Safety and warning labels on the machine indicate any possible risks.

Keep these labels clean and legible at all times.

• The machine has been constructed to state-of-the-art standards in line with any applicable

regulations and industrial standards. Only trained personnel may operate, service and re-

pair the machine.

• Technical changes due to further development in machine technology may lead to a dif-

fering welding behaviour.

In the event of queries on installation, commissioning, operation or special conditions at the

installation site, or on usage, please contact your sales partner or our customer service

department on +49 2680 181-0.

A list of authorised sales partners can be found at www.ewm-group.com/en/specialist-dealers.

Liability relating to the operation of this equipment is restricted solely to the function of the equipment. No

other form of liability, regardless of type, shall be accepted. This exclusion of liability shall be deemed ac-

cepted by the user on commissioning the equipment.

The manufacturer is unable to monitor whether or not these instructions or the conditions and methods

are observed during installation, operation, usage and maintenance of the equipment.

An incorrectly performed installation can result in material damage and injure persons as a result. For this

reason, we do not accept any responsibility or liability for losses, damages or costs arising from incorrect

installation, improper operation or incorrect usage and maintenance or any actions connected to this in

any way.

© EWM AG

Dr. Günter-Henle-Strasse 8

56271 Mündersbach Germany

Tel.: +49 2680 181-0, Fax: -244

Email: [email protected]

www.ewm-group.com

The copyright to this document remains the property of the manufacturer.

Copying, including extracts, only permitted with written approval.

The content of this document has been prepared and reviewed with all reasonable care. The information

provided is subject to change; errors excepted.

Contents Notes on the use of these operating instructions

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1 Contents 1 Contents .................................................................................................................................................. 3

2 Safety instructions ................................................................................................................................. 7 2.1 Notes on the use of these operating instructions .......................................................................... 7 2.2 Explanation of icons ....................................................................................................................... 8 2.3 General .......................................................................................................................................... 9

3 Intended use ......................................................................................................................................... 10 3.1 Applications .................................................................................................................................. 10 3.2 Revision ....................................................................................................................................... 10

4 Machine description – quick overview .............................................................................................. 11 4.1 BUSINTX11 ATCASE .................................................................................................................. 11

5 Commissioning .................................................................................................................................... 12 5.1 General connection ...................................................................................................................... 12

5.1.1 System Bus .................................................................................................................. 12 5.1.2 Power supply ................................................................................................................ 12

5.1.2.1 Internal .......................................................................................................... 12 5.1.2.2 External ......................................................................................................... 12

5.1.3 Connection of fast actual value signals ........................................................................ 12 5.1.4 Collision protection connection ..................................................................................... 13

5.2 Basic configuration using plug-in jumpers ................................................................................... 13 5.2.1 Selecting fast actual value signals ............................................................................... 13 5.2.2 JOB mode selection ..................................................................................................... 13

5.3 Selecting the actuation profile ...................................................................................................... 13 5.4 Field bus connection and configuration ....................................................................................... 13

5.4.1 Interbus-S optical fibre ................................................................................................. 13 5.4.1.1 Field bus connection ..................................................................................... 14 5.4.1.2 Baud rate ....................................................................................................... 14 5.4.1.3 Status display ................................................................................................ 14 5.4.1.4 Data capacity ................................................................................................ 14

5.4.2 CAN Open .................................................................................................................... 14 5.4.2.1 Module specification...................................................................................... 14 5.4.2.2 Module, layout of display and operating elements ........................................ 15 5.4.2.3 Meaning of the LEDs .................................................................................... 15 5.4.2.4 Connection of the CANopen module ............................................................ 16 5.4.2.5 Setting the baud rate ..................................................................................... 16 5.4.2.6 Setting the subscriber address ..................................................................... 16 5.4.2.7 EDS configuration file ................................................................................... 16

5.4.3 CAN DeviceNet ............................................................................................................ 16 5.4.3.1 Module specification...................................................................................... 16 5.4.3.2 Module, layout of display and operating elements ........................................ 17 5.4.3.3 Meaning of the LEDs .................................................................................... 17 5.4.3.4 Connection of the CAN DeviceNet module ................................................... 18 5.4.3.5 Network settings ............................................................................................ 18 5.4.3.6 EDS configuration file ................................................................................... 18

5.4.4 Profibus ........................................................................................................................ 18 5.4.4.1 Module specification...................................................................................... 18 5.4.4.2 Module, layout of display and operating elements ........................................ 19 5.4.4.3 Meaning of the LEDs .................................................................................... 19 5.4.4.4 Connection of the Profibus module ............................................................... 20 5.4.4.5 Setting the subscriber address ..................................................................... 20 5.4.4.6 Baud rate ....................................................................................................... 20 5.4.4.7 Network termination ...................................................................................... 20 5.4.4.8 GSD file ......................................................................................................... 20

5.4.5 Profinet ......................................................................................................................... 21 5.4.5.1 Module specification...................................................................................... 21 5.4.5.2 Module, position of the display elements ...................................................... 21 5.4.5.3 Meaning of the LEDs .................................................................................... 22 5.4.5.4 Connecting the Profinet module .................................................................... 22 5.4.5.5 Setting the subscriber address ..................................................................... 22


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5.4.5.6 GSDXML file .................................................................................................. 22 5.4.6 EtherNet/IP and Modbus/TCP ...................................................................................... 23

5.4.6.1 Module specification ...................................................................................... 23 5.4.6.2 Module, position of the display elements ...................................................... 23 5.4.6.3 Meaning of the LEDs ..................................................................................... 24 5.4.6.4 Connecting the EthernetIP module ............................................................... 24 5.4.6.5 Setting the subscriber address ...................................................................... 25

5.4.7 EtherCAT ...................................................................................................................... 26 5.4.7.1 Module specification ...................................................................................... 26 5.4.7.2 Module, layout of display and operating elements ........................................ 27 5.4.7.3 Meaning of the LEDs ..................................................................................... 27 5.4.7.4 EtherCAT module connection ....................................................................... 27 5.4.7.5 ESI configuration file ..................................................................................... 28

5.5 Data profile selection .................................................................................................................... 28 5.6 Switching on the BUSINTX11 ...................................................................................................... 28 5.7 Field bus configuration ................................................................................................................. 28

6 Operative mode .................................................................................................................................... 29 6.1 Pre-selecting a JOB ..................................................................................................................... 29 6.2 Program operation ....................................................................................................................... 29

6.2.1 JOB mode ..................................................................................................................... 29 6.2.2 Advanced control signal operation ............................................................................... 29 6.2.3 Operating modes .......................................................................................................... 30

6.2.3.1 Non-latched mode ......................................................................................... 30 6.2.3.2 Special, non-latched ...................................................................................... 30 6.2.3.3 Spot welding .................................................................................................. 30

6.3 Welding types ............................................................................................................................... 31 6.4 Monitoring function ....................................................................................................................... 31

6.4.1 Monitoring function ....................................................................................................... 31 6.4.2 Display options ............................................................................................................. 31 6.4.3 Monitoring parameters .................................................................................................. 31 6.4.4 Special features of the monitoring function .................................................................. 32

6.5 Other signals ................................................................................................................................ 32 6.5.1 JOB pre-selection ......................................................................................................... 32 6.5.2 Program pre-selection .................................................................................................. 33 6.5.3 Acknowledge error ........................................................................................................ 33 6.5.4 Gas test 1 ..................................................................................................................... 33 6.5.5 Wire Inching .................................................................................................................. 33 6.5.6 Reverse wire inching .................................................................................................... 33 6.5.7 Position search ............................................................................................................. 33 6.5.8 Blow out torch ............................................................................................................... 33 6.5.9 Robot ready .................................................................................................................. 33 6.5.10 Welding simulation ........................................................................................................ 33 6.5.11 JOB mode ..................................................................................................................... 33 6.5.12 User-defined outputs K1 to K4 ..................................................................................... 33 6.5.13 WF switching ................................................................................................................ 33 6.5.14 Tandem operation ......................................................................................................... 33 6.5.15 Inching mode ................................................................................................................ 34 6.5.16 superPuls ...................................................................................................................... 34 6.5.17 Liftarc ............................................................................................................................ 34 6.5.18 Spot welding on ............................................................................................................ 34 6.5.19 Positionweld on ............................................................................................................. 34

6.6 Check-back of the process parameters ....................................................................................... 34 6.6.1 I > 0 (Current flows signal) ............................................................................................ 34 6.6.2 User-defined inputs ....................................................................................................... 34 6.6.3 Process active .............................................................................................................. 34 6.6.4 Main current signal ....................................................................................................... 34 6.6.5 Collision protection ....................................................................................................... 34 6.6.6 Ready for welding ......................................................................................................... 34 6.6.7 Sticking ......................................................................................................................... 35 6.6.8 Range signal ................................................................................................................. 35


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6.6.9 Error number ................................................................................................................ 35 6.6.10 Warning number ........................................................................................................... 35 6.6.11 Actual welding voltage value ........................................................................................ 35 6.6.12 Actual welding current value ........................................................................................ 35 6.6.13 Actual wire feed speed value ....................................................................................... 35 6.6.14 Actual motor current value ........................................................................................... 35 6.6.15 Parameter monitoring ................................................................................................... 35 6.6.16 Process signals diagram .............................................................................................. 36

6.7 Signals for matching with the positioning device ......................................................................... 36 6.7.1 Ignition time: TZ-Zünd .................................................................................................. 37 6.7.2 TZ-Set ........................................................................................................................... 37 6.7.3 Arc interruption time: TZ-LIBO ..................................................................................... 38 6.7.4 Return time, TZ-Reset .................................................................................................. 38

6.8 Fusing detection ........................................................................................................................... 39 6.8.1 Position search ............................................................................................................. 39

6.9 Welding seam tracking ................................................................................................................ 39 6.10 Welding simulation ....................................................................................................................... 39 6.11 Process fast shut-down ............................................................................................................... 39 6.12 Process safety shut-down ............................................................................................................ 40 6.13 JOB safety switch ........................................................................................................................ 40 6.14 Support of welding circuit alignment ............................................................................................ 40 6.15 Advanced JOB selection .............................................................................................................. 40 6.16 Incorrect selections in the system ................................................................................................ 41 6.17 Setting non-synergy characteristics ............................................................................................. 41

7 The diagnostics interface .................................................................................................................... 42 7.1 PC system requirements ............................................................................................................. 42

8 Commissioning .................................................................................................................................... 43 8.1 Scope of diagnostics .................................................................................................................... 43

9 Data profiles ......................................................................................................................................... 44 9.1 Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line)

modules ....................................................................................................................................... 44 9.1.1 Default profile (switch position 0) ................................................................................. 44 9.1.2 Profile for Multimatrix machines (switch position 1) ..................................................... 48

9.2 Profiles for the CANopen module ................................................................................................ 52 9.2.1 Reis Robotics profile (switch position 0)....................................................................... 52 9.2.2 Profile for Multimatrix machines (switch position 1) ..................................................... 57

9.3 Profiles for the CAN DeviceNet module....................................................................................... 62 9.3.1 Default profile (switch position 0) ................................................................................. 62 9.3.2 Profile 1 (switch position 1) .......................................................................................... 66 9.3.3 Profile for Multimatrix machines (switch position 2) ..................................................... 68

9.4 Profiles for the Profibus DP module ............................................................................................. 74 9.4.1 Default profile (switch position 0) ................................................................................. 74 9.4.2 Flexible profile (switch position 1) ................................................................................ 78 9.4.3 Compatible profile (switch position 2) ........................................................................... 82 9.4.4 Profile for Multimatrix machines (switch position 3) ..................................................... 85

9.5 Profiles for the Profinet and Profinet-LWL modules .................................................................... 89 9.5.1 Reis Robotics profile (switch position 0)....................................................................... 89 9.5.2 Profile for Multimatrix machines (switch position 1) ..................................................... 93

9.6 Profiles for the EtherNet/IP module ............................................................................................. 97 9.6.1 Default profile (switch position 0) ................................................................................. 97 9.6.2 FANUC Robotics profile (switch position 1) ............................................................... 101 9.6.3 Notes on the profile .................................................................................................... 104 9.6.4 Profile for Multimatrix machines (switch position 2) ................................................... 105 9.6.5 Profile for Multimatrix machines with FANUC robots (switch position 3) ................... 109 9.6.6 Notes on the profile .................................................................................................... 112

9.7 Profiles for the Modbus/TCP module ......................................................................................... 113 9.7.1 Default profile (switch position 0) ............................................................................... 113

9.8 Profiles for the EtherCAT module .............................................................................................. 117 9.8.1 Default profile (switch position 0) ............................................................................... 117 9.8.2 Profile for Multimatrix machines (switch position 1) ................................................... 121


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10 Special field bus features when setting up the field bus modules ............................................... 125 10.1 CAN DeviceNet .......................................................................................................................... 125

10.1.1 Connections ................................................................................................................ 125 10.1.2 Example for I/O data ................................................................................................... 125 10.1.3 Example of a connection assignment ......................................................................... 126

10.2 Profibus DP ................................................................................................................................ 126 10.2.1 The watchdog ............................................................................................................. 126 10.2.2 DP features ................................................................................................................. 126

10.3 EtherCAT ................................................................................................................................... 127 10.3.1 Machine installation .................................................................................................... 127 10.3.2 Manual integration of a machine ................................................................................ 128 10.3.3 Search for a machine .................................................................................................. 128 10.3.4 Process data view ....................................................................................................... 128

10.4 Modbus....................................................................................................................................... 129

11 Rectifying faults.................................................................................................................................. 130 11.1 Operating displays (LEDs) ......................................................................................................... 130 11.2 Warnings (power source) ........................................................................................................... 131 11.3 Error messages on the system .................................................................................................. 132

11.3.1 General system erors ................................................................................................. 132 11.3.2 Process error .............................................................................................................. 132

12 Jumper assignment overview ........................................................................................................... 133 12.1 BUSINT X11 ............................................................................................................................... 133

13 Configuration data overview ............................................................................................................. 134 13.1 BUSINT X11 ............................................................................................................................... 134 13.2 Resetting the configuration data ................................................................................................ 136

14 Service documents ............................................................................................................................ 137 14.1 Circuit diagrams ......................................................................................................................... 137

15 Appendix ............................................................................................................................................. 138 15.1 Searching for a dealer ................................................................................................................ 138

Safety instructions Notes on the use of these operating instructions

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2 Safety instructions

2.1 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.

• The hazard is also highlighted using a symbol on the edge of the page.

WARNING Working or operating procedures which must be closely observed to prevent serious

and even fatal injuries.

• Safety notes include the "WARNING" keyword in the heading with a general warning sym-

bol.

• The hazard is also highlighted using a symbol in the page margin.

CAUTION Working or operating procedures which must be closely observed to prevent possible

minor personal injury.

• The safety information includes the "CAUTION" keyword in its heading with a general warn-

ing symbol.

• The risk is explained using a symbol on the edge of the page.

Technical aspects which the user must observe to avoid material or equipment damage.

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.

Safety instructions Explanation of icons

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2.2 Explanation of icons

Symbol Description Symbol Description

Indicates technical aspects which the

user must observe.

Activate and release / Tap / Tip

Switch off machine

Release

Switch on machine

Press and hold

Switch

Incorrect / Invalid

Turn

Correct / Valid

Numerical value – adjustable

Input

Signal light lights up in green

Navigation

Signal light flashes green

Output

Signal light lights up in red

Time representation (e.g.: wait 4 s /

actuate)

Signal light flashes red

Interruption in the menu display (other

setting options possible)

Tool not required/do not use

Tool required/use

Safety instructions General

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2.3 General

WARNING

Risk of accidents due to non-compliance with the safety instructions!

Non-compliance with the safety instructions can be fatal!

• Carefully read the safety instructions in this manual!

• Observe the accident prevention regulations and any regional regulations!

• Inform persons in the working area that they must comply with the regulations!

CAUTION

Obligations of the operator!

The respective national directives and laws must be complied with when operating the

machine!

• Implementation of national legislation relating to framework directive 89/391/EEC on the

introduction of measures to encourage improvements in the safety and health of workers at

work and associated individual guidelines.

• In particular, directive 89/655/EEC concerning the minimum safety and health requirements

for the use of work equipment by workers at work.

• The regulations applicable to occupational safety and accident prevention in the country

concerned.

• Setting up and operating the machine as per IEC 60974.-9.

• Brief the user on safety-conscious work practices on a regular basis.

• Regularly inspect the machine as per IEC 60974.-4.

The manufacturer's warranty becomes void if non-genuine parts are used!

• Only use system components and options (power sources, welding torches, electrode hold-ers, remote controls, spare parts and replacement parts, etc.) from our range of products!

• Only insert and lock accessory components into the relevant connection socket when the ma-chine is switched off.

These operating instructions are part of the complete documentation and valid only in

combination with all other parts of these instructions! Read and observe the operating

instructions for all system components, especially the safety instructions!

Intended use Applications

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3 Intended use

WARNING

Hazards due to improper usage!

The machine has been constructed to the state of the art and any regulations and

standards applicable for use in industry and trade. It may only be used for the welding

procedures indicated at the rating plate. Hazards may arise for persons, animals and

material objects if the equipment is not used correctly. No liability is accepted for any

damages arising from improper usage!

• The equipment must only be used in line with its designated purpose and by trained or

expert personnel!

• Do not improperly modify or convert the equipment!

3.1 Applications The following operation instructions describe the commissioning and functionality of the BUSINT X11

fieldbus interface in combination with certain fieldbusses. The interface is intended for operation on digital

power sources in the Phoenix and alpha Q machine series.

BUSINT X11 has numerous options for actuation which are fully supported by the PC300.NET

PC300.NET welding parameter software. We recommend to use the PC300.NET software wherever pos-

sible to PC300.NET configure BUSINT X11.

3.2 Revision Revision Date Change

1.0 06/01/2012 Draft version

1.1 15/11/2012 EtherCAT standard added

1.2 18/05/2015 Support for Multimatrix power sources

1.3 20/11/2015 Manual signals for superPuls and lift arc

Selection of advanced JOBs for Multimatrix machines

Support for welding circuit alignment

Signalling of warnings

Advanced error logic

1.4 01/08/2018 Modbus protocol added

1.5 31/10/2019 Warning messages 13 and 37 added

Other signals updated

Feedback of the process parameters updated

Incorrect selections in the system added

Data profiles, Multimatrix updated

Overview of configuration data was updated

1.6 27/11/2019 Operation was updated

Overview of configuration data was updated

General corrections / improvements

Machine description – quick overview BUSINTX11 ATCASE

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4 Machine description – quick overview

4.1 BUSINTX11 ATCASE

Figure 4-1

Item Symbol Description 0

1 Switching voltage connection for hardware-targeted emergency shutdown of the

system

6 External voltage supply module

2 Connection for the bus supply

5 Strain reliefs for bus/control cables

3 System interface to connect the system interface for automated welding

2 Connection of diagnostics interface for Analyzer

3 Through-wiring to connect machine functions

4 System bus connection

Commissioning General connection

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5 Commissioning This chapter describes for you the commissioning process of the BUSINTX11, step-by-step, as well as its

operating functions.

5.1 General connection

5.1.1 System Bus

BUSINT X11 is integrated into the welding system by means of a digital system bus.

Depending on the control installation type, connection is possible in two ways:

• Connection via the 15-pole SUB-D connector X12, if BUSINT X11 is mounted on the power source (in

an external housing at the rear side of the power source).

• Connection via the 7-pole connector X13 with control cable. This is the preferred connection method

with external installation of BUSINT X11, e.g. in an electrical enclosure.

In general it is important to keep the bus cables for the connection of BUSINT X11 to the relevant fieldbus

as far away as possible from any sources of interference (e.g. HF loaded or carrying cabling), as other-

wise the bus assemblies may become damaged due to overvoltage.

5.1.2 Power supply

5.1.2.1 Internal

The interface is normally supplied with power via a standalone, isolated power supply via the system bus.

The bus node remains addressable as long as the welding power source is switched on.

5.1.2.2 External

So that the bus node remains functional even after the system is shut down (e.g. for continued operation

of the user-defined inputs and outputs), an optional, external voltage of 24V DC must be used which is

powered by a separate module!

Depending on the design of the control, the PCBs vary for the power supply. The table below clarifies the

connection of the voltage:

System PCB Plug Pin Polarity

SV+/-15V/1A X5 1 +24V

X5 2 GND

SV IBUS3 X2 1 +24V

X2 2 GND

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.

5.1.3 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. These can be provided via

the interface for mechanised welding on the BUSINTX11:

Plug Pin Signal

X7 2 Actual process voltage value

X7 3 Actual process current value

X7 4 Reference mass (GND)

The interface for mechanised welding is supplied as standard for the PHOENIX, but not for the TETRIX.

The use of fast actual value signals for the seam tracking is optional and must be ordered sepa-rately!

Commissioning Basic configuration using plug-in jumpers

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5.1.4 Collision protection connection

A corresponding signal can be connected to the BUSINTX11 for connecting and powering a torch collisi-

on protection signal on the field bus:

Plug Pin Signal

X4 1 Powering an external collision contact

X4 2 Feedback signal from collision contact

A separate 24V signal is used for the collision protection. It is essential to ensure that the instal-lation is free of short-circuits. The supply is short-circuit-proof, however the input becomes un-usable for the duration of the short-circuit.

5.2 Basic configuration using plug-in jumpers These settings must be made before switching on the power source/external power source.

The BUSINTX11 has a series of jumpers to configure various basic settings that cannot be changed dur-

ing operation.

5.2.1 Selecting fast actual value signals

To transmit fast actual process values for voltage to use the workpiece search function, jumper JP2

should be configured as follows:

JP 2 Function

- Actual values via system bus (factory setting)

X Actual values are expected via plug X7

X = Jumper plugged in

5.2.2 JOB mode selection

If settings such as operating mode, welding type or superPuls are to be controlled using the program

number, jumper JP4 has to be configured as follows:

JP 4 Function

- Data are applied from the manual actuation signals as usual.

X The program number controls the function directly.

X = Jumper plugged in

5.3 Selecting the actuation profile The profile must be selected before the power source is switched on. If the interface is supplied

with power via the external power supply, this should also be enabled for a change of profile as

well as for a shut-down of the welding power source.

Various actuation profiles are available for connection to different controls for operating BUSINTX11 in-

dependently of the field bus type, welding system and development status. These are selected using a

selector switch S1 with 16 positions.

5.4 Field bus connection and configuration Different steps are required for commissioning, depending on the field bus, and these steps are described

below.

5.4.1 Interbus-S optical fibre

No address setting is required for the configuration of the Interbus subscriber as this is given by the posi-

tion of the subscriber in the Interbus. The subscriber identifies with the ID3 as a module with digital I/O.

Commissioning Field bus connection and configuration

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5.4.1.1 Field bus connection

The field bus is connected via optical fibres using FSMA rapid-action connectors:

Plug Function

U7 Incoming interface, transmit line

U10 Incoming interface, receive line

U8 Outgoing interface, transmit line

U11 Outgoing interface, receive line

Figure 5-1

5.4.1.2 Baud rate

The module baud rate can be selected between 500kBaud and 2Mbaud using a jumper.

Figure 5-2

5.4.1.3 Status display

The status of the module on the Interbus is indicated as follows using a block of LEDs:

LED Signal Colour Meaning

1 CC/RC Green Cable connection OK, master is not in reset status

2 BA Green Bus is in data exchange

3 RD Yellow Remote bus shut down

4 TR Green PCP communication active

5 FO1 Yellow Warning for recipient of the bus input side

6 FO2 Yellow Warning for recipient of the bus output side

Figure 5-3

5.4.1.4 Data capacity

The data width to be configured at the interbus depends on the data profile used.

5.4.2 CAN Open

5.4.2.1 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.


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5.4.2.2 Module, layout of display and operating elements

The module is equipped with several display and operating elements at the side of the PCB:

Figure 5-4

Element no. Meaning

1 CANopen interface

2 Baud rate setting

3 10 digit subscriber address setting

4 1 digit subscriber address setting

5 Status LEDs

5.4.2.3 Meaning of the LEDs

The module is fitted with a block of 4 LEDs that signal the status of the module during operation:

LED Status Meaning

RUN Off No operating voltage in the module

Single flashing Module in STOP mode

Flashing Module in PRE-OPERATIONAL mode

On Module in OPERATIONAL mode

POWER Off No operating voltage in the module

On Operating voltage present

ERROR Off No error

Single flashing Warning limit reached

ERROR Double flashing Error control event

Triple flashing Synchronisation error

On Bus switched off


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5.4.2.4 Connection of the CANopen module

The field bus is connected via a 9-pole SUB-D plug connector (socket). The layout of the module signals

(plugs) is as follows:

Pin Signal Function

2 CAN_L Low signal cable of the CAN difference signal

3 CAN_GND Reference mass of the CAN signal

5 CAN_SHLD Connection for cable shield

7 CAN_H High signal cable of the CAN difference signal

Figure 5-5

5.4.2.5 Setting the baud rate

The field bus module must be set to the baud rate used on the network using a selector switch:

Selector switch setting Baud rate

1 10kbps

2 20kbps

3 50kbps

4 125kbps

5 250kbps

6 500kbps

7 800kbps

8 1Mbps

The baud rate setting is only active after switching on the supply voltage and after re-starting the

module.

5.4.2.6 Setting the subscriber address

The module must be assigned a unique address which is a one-off in the network before commissioning.

This is carried out via two selector switches in a range of 1 to 99. The right-hand switch selects the single

place digit, and the left-hand switch selects the tens place digit for the address setting. The setting is car-

ried out in decimal format:

Example: Address 42 = left-hand switch position 4 (x10) + right-hand switch position 2 (x1)

Figure 5-6

5.4.2.7 EDS configuration file

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 AG if required.

5.4.3 CAN DeviceNet


The CAN DeviceNet module is implemented in accordance with the ODVA specifications as a communi-

cation 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.


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The CAN-DeviceNet module has a variety of operating elements arranged on the PCB side:

Figure 5-7

Element no. Meaning

1 CAN DeviceNet interface

2 Address switch

3 Status indicators



LED Status Meaning

1 – Not used - -

2 – Network status Off No operating voltage on the module/module not online

On – Green Connection OK, module connected

Flashing – Green Module is online but not connected

On – Red Critical connection error

Flashing – Red Connection timeout

3 – Module status Off No operating voltage

On – Green Module is ready for operation

Flashing – Green Data frame larger than configured

On – Red Critical error

Flashing – Red Error

4 – Reserved - -

Figure 5-8


18 099-008196-EW501 27.11.2019

5.4.3.4 Connection of the CAN DeviceNet module

The field bus is connected via a 5-pole panel connector as follows:

Pin Signal Function

1 V- Supply voltage reference mass

2 CAN_L Low signal cable of the CAN difference signal

3 CAN_SHLD Connection for cable shield

4 CAN_H High signal cable of the CAN difference signal

5 V+ +24V power supply

Figure 5-9

The 24V power supply is essential for operating the field bus!

5.4.3.5 Network settings

In the DeviceNet, every subscriber must be assigned a unique and one-off address in the range of 0 to

63. Every subscriber must also be set to the same baud rate.

Eight configuration switches are used to set the baud rate and address.

Address (MAC)

The address is set as follows via switches 3 to 8:

MAC ID Switch 3

(MSB)

Switch 4 Switch 5 Switch 6 Switch 7 Switch 8

(LSB)

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

Baud rate

The baud rate is set via configuration switches 1 and 2:

Baud rate Switch 1 Switch 2

125k Off Off

250k Off On

500k On Off

Reserved On On

5.4.3.6 EDS configuration file

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.

For further setup > see 10 chapter!

5.4.4 Profibus


The Profibus module supports cyclical data exchange according to the PROFIBUS-DP EN 50 170 speci-

fication (DIN 19245).


099-008196-EW501 27.11.2019 19


The Profibus module has a variety of operating elements arranged on the PCB side:

Figure 5-10

Element no. Meaning

1 Profibus interface

2 Terminating switch

3 Address switch

4 Status indicators



LED Status Meaning

1 - -

2 On – Green Module is connected to the Profibus, communication is possible

Off Module is not connected

3 On – Red Module is not connected to the Profibus, no communication is possi-

ble

Off Module is not connected

4 Flashing, 1Hz Error in configuration (1)

Flashing, 2Hz Error in parameter data (1)

Flashing, 4Hz Error when initialising the Profibus communication

Off No diagnostics active

(1) Pre-defined data length of the module does not match the network configuration.


20 099-008196-EW501 27.11.2019

5.4.4.4 Connection of the Profibus module

The field bus is connected via a 9-pole SUB-D plug connector (socket) as follows:

Pin Signal Function

3 B-signal Positive communication signal according to RS485

4 RTS Send request signal

5 GND Isolated reference mass for field bus

6 +5V Isolated reference voltage for field bus

8 A-signal Negative communication signal according to RS485

Figure 5-11


The module must be assigned a unique address which is a one-off in the network before commissioning.

This is carried out via two selector switches in a range of 1 to 99. The right-hand switch selects the single

place digit, and the left-hand switch selects the tens place digit for the address setting. The setting is car-

ried out in decimal format:

Example: Address 42 = left-hand switch position 4 (x10) + right-hand switch position 2 (x1)

Figure 5-12

The settings for the network address must be set before the module is commissioned. Any

subsequent change to the setting only becomes effective after the power is enabled and after

switching the module back on.

5.4.4.6 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

5.4.4.7 Network termination

The Profibus network must be terminated on the line terminals to avoid signal reflections on the bus me-

dium. To do this, the module has an appropriate configuration switch:

Switch position Setting

On Bus termination is switched on.

Must be activated if the subscriber is on the first or last position and no exter-

nal termination is being used.

Off Bus termination is switched off.

When using external termination (supported by various plugs, for example), the switch must be

switched to “Off”.

5.4.4.8 GSD file

The subscriber configuration is carried out via the GSD file supplied.

For further setup > see 10 chapter!


099-008196-EW501 27.11.2019 21

5.4.5 Profinet


The Profinet module supports cyclical data communication as a Profinet I/O device conforming to classes

B and C, with classes 1, 2 and 3 in real-time communication.

5.4.5.2 Module, position of the display elements

The Profinet module features several display elements, which are positioned at the front of the PCB:

Figure 5-13

Element Description

1 Ethernet connection 1


3 Status displays


22 099-008196-EW501 27.11.2019


Figure 5-14

The module features a 4 LED unit signalling the module status during operation:

Element Display Status Meaning

1 Connection/activity

(1)

Green Connection established at connection 1

Green, flashing Receiving/sending data at connection 1

Off No connection at connection 1

2 Communication

status

Green Online, run

Connection established with I/O controller

I/O controller in run mode

Green, flashes once Online, stop

Connection established with I/O controller

I/O controller in stop mode

Off Offline

No connection with I/O controller

3 Module status Green Initialised, no error

Green, flashes once Diagnostic data available

Green, flashes twice Used by setup tools to identify the module

Red, flashes once Configuration error

Number of modules exceeded

I/O controller's I/O size too big

Red, flashes three times No station name available or no IP address

assigned

Red, flashes four times Internal error

Off No voltage at module or not configured

4 Connection/activity

(2)

Green Connection established at connection 2

Green, flashing Receiving/sending data at connection 2

Off No connection at connection 2

5.4.5.4 Connecting the Profinet module

The module is connected via a standard RJ-45 connector.

The module features a dual switch with equal connections, i.e. port 1 and port 2 can be used for connec-

tion.

This way, line structures can be created.


A unique network address has to be assigned to the module before commissioning.

With Profinet the address and station name of the module are assigned as part of the configuration by us-

ing a Profinet engineering system.

5.4.5.6 GSDXML file

The member description is provided in the supplied GSDXML file.


099-008196-EW501 27.11.2019 23

5.4.6 EtherNet/IP and Modbus/TCP


The EthernetIP module supports cyclical data communication as a communication adapter and also sup-

ports the "Common Industrial Protocol" (CIP).

5.4.6.2 Module, position of the display elements

The EthernetIP module features several display elements, which are positioned at the front of the PCB:

Figure 5-15

Element Description



3 Address switch

4 Status indicators


24 099-008196-EW501 27.11.2019


Figure 5-16

The module is equipped with a block of 4 LEDs indicating the module status during operation:

Element Display Status Meaning

1 Connection /

activity (1)

Green Connection established at port 1

Green flashing Receive / send data to port 1 with 100MBit

Yellow Receive / send data to port 1 with 10MBit

Off No connection at port 1

2 Module status Off No voltage on the module or not configured

Green Controlled by a controller in RUN mode

Green, flashing Module not configured or controller in IDLE

mode

Red, flashing A correctable error has occurred

Red An uncorrectable error has occurred

3 Network status

EtherNet/IP

Off No power or no IP address assigned

Green Online, one or more connection(s) establis-

hed

Green, flashing Online, no connections established

Red Duplicate IP Address

Red, flashing One or more connections have expired

3 Network status

Modbus/TCP

Off no connections established

Green, flashing Connections are established

4 Connection /

activity (2)

Green Connection established at port 2

Green flashing Receive / send data to port 2 with 100MBit

Yellow Receive / send data to port 2 with 10MBit

Off No connection at port 2

5.4.6.4 Connecting the EthernetIP module

The module is connected via a standard RJ-45 connector.

The module features a dual switch with equal connections, i.e. port 1 and port 2 can be used for connec-

tion.

This way, line structures can be created.


099-008196-EW501 27.11.2019 25


Using the address switch

Figure 5-17

One method to set the IP address is to use the address switches provided by the module.

In this case, the address range is limited to network 192.168.0.X,

where X is the value which can be encoded by the address switch.

In the BCD code the 8 individual switches define the corresponding values of the last address, starting

with switch 8. The values are 1, 2, 4, 8, 16, etc.

This means the last address block of the IP address is built from the sum of the individual values of the

activated switches.

As an example, the illustration shows address 192.168.0.213 built from:

128 + 64 + 16 + 4 + 1 .

Changes to the address switches will be applied the next time BUSINT X11 is switched on.

The IP address is provided by the switch configuration once one of the switches is activated. To

use a different address allocation method, deactivate all switches.

Using IPconfig

IPconfig searches the network for BUSINT X11 interfaces without the need to set a network address at

the module first.

All interfaces detected are listed.

To make the search easier, the module returns "EWM BUSINT X11".

Select the module to be configured by double-clicking it.

Figure 5-18


26 099-008196-EW501 27.11.2019

You can now enter the required settings in the address screen. If you want to use a DHCP server you can

enable that option as well.

The "Change password" option enables the password function.

If used, access via IPconfig is protected by a password.

To apply the settings, click the "Set" button.

Figure 5-19

The summary screen should now show the module with the changed address data.

The module is now configured.

Figure 5-20

5.4.7 EtherCAT


The EtherCAT interface supports the DS301 v4.02 specification and uses the CANopen over Ethernet

standard as application interface. Data is exchanged via process data objects. The interface has two RJ-

45 connections to support direct line topologies,

eliminating the need for an Ethernet switch to integrate the system.


099-008196-EW501 27.11.2019 27


Figure 5-21

Element no. Meaning

1 Ethernet port 1 (input)

2 Ethernet port 2 (output)

3 Status indicators


Figure 5-22

The module is equipped with a block of 4 LEDs indicating the module status during operation:

LED Status Meaning

Link/Activity1 Off No connection at input 1

Green Connection at input 1

Green, flashing Data communication at input 1

RUN Off Machine is in initialisation state

Green, flashing Machine is in PRE-OPERATIONAL state

Green, flashing, sin-

gle

Machine is in SAFE-OPERATIONAL state

Green Machine is in OPERATIONAL state

ERR Off EtherCAT communication functioning correctly

Red, flashing General configuration error

Red, flashing, single EtherCAT slave has changed state by itself

Red, flashing, double Time monitoring error of the Synch manager

Red Time monitoring error of the application

Link/Activity2 Off No connection at input 2

Green Connection at input 2

Green, flashing Data communication at input 2

5.4.7.4 EtherCAT module connection

The field bus is connected via an RJ-45 connector.

Commissioning Data profile selection

28 099-008196-EW501 27.11.2019

5.4.7.5 ESI configuration file

All module settings are defined automatically via the EtherCAT master. To that end, a configuration file

has to be installed in the engineering program

5.5 Data profile selection The profile must be selected before the power source is switched on. If the interface is supplied

with power via the external power supply, this should also be enabled for a change of profile as

well as for a shut-down of the welding power source.

Various actuation profiles are available for connection to different controls for operating BUSINTX11 in-

dependently of the field bus type, welding system and development status. These are selected using a

selector switch S1 with 16 positions.

5.6 Switching on the BUSINTX11 The interface is put into operational mode by switching on the connected power source or the external

voltage supply (if present). The module then runs a sequence of self-diagnostic steps and checks the

readiness of individual components.

Depending on the fieldbus type the initialisation phase can take a while. To indicate this status, LEDs 7 to

10 flash from left to right. When the initialisation is complete, LEDs 7 to 10 no longer light up.

If an error is detected this is indicated by a combination of flashes by LEDs 7 and 8. In this case the mod-

ule is not or only partly ready for operation.

Indication of the error starts with a flashlight code by LED 7 with signals lasting 1 s. The number of the fol-

lowing flash signals (approx. 2 Hz) of LED 8 represents the error code.

Number of flash

signals LED 7 (er-

ror type)

Number of

flash signals

LED 8 (error)

Meaning

1 1 Error determining module configuration

1 2 For internal use only

1 3 Error initialising operating memory

2 1 Fieldbus module does not exist or is damaged

2 2 Error initialising memory

2 3 Module not supported by current software version

2 4 Set profile not assigned; the default profile will be applied and the

interface is ready for operation despite the error indication

3 1 Power source type not supported; an attempt has been made to

operate a Tetrix power source with a BUSINT X11 Phoenix or vice

versa

The error code is cyclically repeated, with the sequence starting again at LED 7.

When the diagnosis has been completed successfully, LEDs 7 and 8 do not light up. If the power source

is switched on, LEDs 11 and 12 should start flashing with a high frequency after a short period.

The module is now ready for configuration via the fieldbus.

5.7 Field bus configuration This is carried out in conformity with the relevant standards via specific parameters which are normally

transferred to the field bus module, or synchronised, using the bus master.

Please also see the relevant operating instructions for the field bus master for more information.

Operative mode Pre-selecting a JOB

099-008196-EW501 27.11.2019 29

6 Operative mode

6.1 Pre-selecting a JOB The power source has a range of adjustable parameters that are managed through so-called jobs. The

welding task is defined via a JOB. A total of up to 510 JOBs can be set.

The job preselection can only be made from the machine if the “Job preselection machine” bit has been

set (is set automatically in some control profiles and does not appear in the control profile). Only then can

a valid JOB be specified. If the job preselection is disabled, a JOB can be specified from an operating unit

(if available).

The job preselection is only possible when the system is shutdown (no welding operation).

However, if the PLC uses another job number during runtime, the set job number will be stored

temporarily in the module and the switchover will take place at the end of the welding process.

There will be no switchover if a switchover was cancelled during the welding process.

6.2 Program operation Up to 16 programs can be preselected at the power source. Each program is directly linked to "analogue"

default values, which are saved in the JOB set at the power source. Program numbers 1–15 represent

predefined values.

The special program 0 is designed for the so-called pilot signal operation. The "analogue" default values

are predefined using separate input signals.

If other values are assigned to these bytes during normal program operation (1–15), these new parame-

ters are cached in the module and applied to the power source when operation is switched to program 0.

Program actuation is only possible if the "Automaton program preselection" bit (automatically set in some

actuation profiles, does not appear in the actuation profile) has been activated.

6.2.1 JOB mode

JOB mode is available as a further operating mode. During program or control signal operation, the set-

tings for welding type and operating mode are made using individual control signals. In JOB mode, these

settings are permanently stored in the power source using the program numbers and can be preselected

using them. In addition, the superPuls is assigned to each program. The JOB mode is set by means of

the corresponding signal and can be set permanently via jumper JP4 as an alternative.

The JOB mode can only be changed during the system standstill.

JOB mode can also be using via the JP4 jumper if the signal is not contained in the data profile.

6.2.2 Advanced control signal operation

Advanced pilot signal operation is activated automatically once software version 0.6.0.0 or later is availa-

ble in the power source.

The manual gas actuation function enables individual gas pre- and post-flows.

A safety function ensures the following aspects with regard to the gas:

• If no gas has been activated at the start of the process, it is switched on automatically.

• If the gas cannot be deactivated while a process is running, it is shut off automatically when the pro-

cess is switched off. This corresponds to a gas post-flow duration of 0.

Operative mode Welding types

30 099-008196-EW501 27.11.2019

6.2.3 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 ig-

nition, and ending with the end of the welding process.

Start/Stop signal

Signal=1 starts the system, 0 ends the welding process. Depending on the operating mode selected, the

process is ended immediately (non-latched) or following an end program (non-latched special).

Gas pre-flows/gas post-flows

Defined connection or shut-down of the process gas supply at the start and after the welding process.

Start program

Special program which becomes active in the relevant operating mode (non-latched special) once the gas

pre-flows and ignition phase are complete. This program can be assigned a separate wire feed speed,

voltage correction and a dynamic value.

Main welding program P2.x

The main welding program operation follows the completion of the start program/ignition phase (depen-

ding on the operating mode)

Reduction program P3

This program is used in the “Superpulses” welding type for the PHOENIX and for the “Thermal pulses” ty-

pe for the TETRIX. It is activated alternately with the main welding program currently active and an ad-

justable frequency is activated during the changeover. This permits special control by reducing the power

for the time in which the secondary program is running.

End program

Special program which initiates the conclusion of the welding process after the main welding program.

This is activated after the end program ramp time elapses (only with the non-latched special operating

mode).

Wire burn-back

Defined burn-back of the welding wire at the end of the welding process (can be defined as part of a

JOB). Only of relevance for MIG/MAG processes.

I > 0 signal

Feedback signal for indicating “Current flows” and final, stable burn phase. It is generally used to trigger

the positioning device.

6.2.3.1 Non-latched mode

Gas pre-flows are initiated when the start signal is issued. The ignition program is activated once these

are complete. Following successful ignition, the power source is in main welding program P2.x (according

to the setting in the program), and the signal I>0 is set.

If a Stop is issued, wire burn-back and gas post-flows are activated in sequence and the welding process

is ended; I>0 is cancelled once the arc has been extinguished.

6.2.3.2 Special, non-latched

Gas pre-flows are initiated when the start signal is issued. The ignition program is activated once these

are complete. Following successful ignition, the power source will be in the ignition program; the signal

I>0 is set. This runs for the time specified in the JOB and activates the main welding program P2.x (ac-

cording to the setting in the program).

If a Stop is issued, first the end program is activated, followed by the wire burn-back and gas post-flows,

and the welding process is ended; I>0 is cancelled once the arc has been extinguished.

The transitions from ignition program to the main program and from the main program to the end program

are controlled via ramps, where the output is carried over from one program to another.

The operating modes can also be switched over during welding operation. This means that the

non-latched special mode can be modified in a flexible way.

6.2.3.3 Spot welding

Sequence as for special non-latched, but the process duration is defined by the set ain process duration

(t2). The process then finishes automatically.

Operative mode Welding types

099-008196-EW501 27.11.2019 31

6.3 Welding types In welding operation, a distinction is made between different modes (depending on the welding system).

The welding type can be switched both when the system is at a standstill and during operation. During

JOB mode, the respective information on the welding type is taken from the active program of the current

JOB.

6.4 Monitoring function BUSINT X11 can permanently monitor the welding process using a dedicated monitoring function. De-

pending on the module operating modes different signals are available.

Activating the monitoring function

To activate the monitoring function.

Parameter

At present, 4 welding parameters are assigned for monitoring:

• Welding voltage

• Welding current

• Wire feed speed (at present for MIG/MAG systems only)

• Maximum armature current of the wire feeder

For 2 parameters at a time a separate response time can be set. An individual tolerance value is as-

signed to each monitoring parameter.

6.4.1 Monitoring function

The different power source operating modes are used to assign nominal values for welding voltage, weld-

ing current and wire feed value to the process. Each tolerance parameter defines a tolerance range for

the monitored process value. The engine current is treated as a maximum value; monitoring only encom-

passes checking whether this value is exceeded.

If a parameter is out of range for a period that exceeds the defined response time, an alarm is triggered in

the system. This is a passive alarm only and does not affect the welding process. Whether to cancel or

continue the welding process is determined by the higher level control. The alarm for the parameter in

question is reverted once the actual value is back in range.

It is possible to disable individual monitoring channels by setting the tolerance value to 0.

6.4.2 Display options

An alarm message is generated in one of two ways:

• Output via collective indication output (relay) on the module > see 6.4 chapter

• Output of the individual channels via the field bus data with the following assignments:

Bit no. Parameter

0 Welding voltage

1 Welding current

2 Wire-feed speed

3 Max. motor current exceeded

The relay output is set immediately when one of the monitoring parameters exceeds its tolerance

range. The relay is equipped with a reset delay, it is only shut down if no error has been indicated

for approx. 0.5s.

6.4.3 Monitoring parameters

The following signal specifications can be defined within a JOB:

Parameter Range specification

Voltage tolerance Specify in the range 0% to 50% of the nominal value

Current tolerance Specify in the range 0% to 50% of the nominal value

WF tolerance Specify in the range 0% to 50% of the nominal value

Maximum motor current Specify in the range 0 to 5.0A

A response time is assigned to the parameters for voltage tolerance/current tolerance and WF toler-

ance/max. motor current; this common response time can be set in the range 10ms to 20s in 10ms in-

crements.

Operative mode Other signals

32 099-008196-EW501 27.11.2019

6.4.4 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” in the tole-

rance band limit ranges.

Parameter

The settings for the monitoring function are stored per JOB and are stored as follows in the program se-

quence:

Figure 6-1

Notes on usage

Unstable processes due to the conditions require more in-depth consideration in monitoring. This means

that the monitoring can be improved in terms of reliability by the relevant parameterisation of response

time or by increasing the tolerance value for one individual channel.

Where applicable, deactivating an individual process channel or the temporary deactivation of the moni-

toring function during the welding process should be considered.

When using the superpulses welding type, the monitoring needs to be parameterised as very tolerant, as

the system behaviour in this operating mode can be very dynamic depending on the parameters and a

short response time will cause rather undesirable events in this case.

The nominal process values are always specified by the system. With very small tolerance values set,

from time to time the calculated tolerance value can move below the relevant parameter resolution. In this

type of situation, the resultant tolerance value is limited to a minimum value.

6.5 Other signals

6.5.1 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).

Operative mode Other signals

099-008196-EW501 27.11.2019 33

6.5.2 Program pre-selection

Permits the specification of power stages defined by the machine. If the signal is set, a power stage is

pre-selected in accordance with the specification from the Program (special feature with program

0, > see 6.2 chapter). With a signal not set, program 1 is permanently set by the control (signal is auto-

matically set in some actuation profiles and is not then visible in the profile).

6.5.3 Acknowledge error

An active error is reset using this signal. For a correct function, the signal must be sloped.

Not all errors need to be acknowledged; some events reset themselves

automatically > see 11.3 chapter.

6.5.4 Gas test 1

Allows the shielding gas to be activated/deactivated manually. The signal can only be issued when the

system is at a standstill (exception: extended control signal operation). The signal can be used to extend

the gas pre-flow duration programmed permanently in the job, or to control it manually.

6.5.5 Wire Inching

Manual activation of the main wire feed for inching the welding wire into the tube/torch package. Signal

can only be issued when the system is at a standstill. Before activation any “reverse wire inching” signal

present must be cleared.

6.5.6 Reverse wire inching

Permits the retraction of the wire; can only be switched over when the system is at a standstill. Before ac-

tivation, the “Wire inching” needs to be cleared.

6.5.7 Position search

This signal is used in combination with a soft-collision detection of the welding torch (torch tube) with the

workpiece. With an active signal, a touch of the workpiece is detected. The detection functions only in

non-welding operation > see 6.8.1 chapter.

6.5.8 Blow out torch

Enables manual activation/deactivation of a second gas (in most cases compressed air to clean the

torch). The signal can only be issued when the system is switched off.

6.5.9 Robot ready

Ready for operation signal for indicating the positioning device on the welding power source. Signal must

be set before the start of welding > see 6.11 chapter.

6.5.10 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 6.10 chapter.

6.5.11 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.

6.5.12 User-defined outputs K1 to K4

With these signals the user-defined relay outputs K1 to K4 can be activated at the module as long as they

are not predefined for control-specific tasks.

6.5.13 WF switching

This signal can be used to change over 2 wire feed drive units when the system is at a standstill. By

default, WF number 1 active after switching on (see also the operating manual on the “WF switching” op-

tion).

6.5.14 Tandem operation

This function is available as an optional software and in Phoenix systems enables the control of one pow-

er source each (for TANDEM systems, 2 BUSINT X11 are required). The input signal is used to deter-

mine which power source is the secondary power source in the TANDEM combination.

If not actuated the power source is configured as the master.

Operative mode Check-back of the process parameters

34 099-008196-EW501 27.11.2019

6.5.15 Inching mode

This mode is used to set the inching type in the system. If the signal is set, the nominal wire feed speed

value active at the interface is used for inching and reverse inching.

If no nominal value is active, the JOB's minimum nominal value for the system is used.

If the signal is not set, the default ramp is used for inching.

The inching mode has to be supported by the wire feeder's operating software.

6.5.16 superPuls

Switches the superPuls welding type on. superPuls can only be switched on or off when no welding is

performed. In extended JOB mode (activated with jumper JP4), this signal is blocked.

6.5.17 Liftarc

This signal switches ignition to lift arc automaton mode. The ignition is parameterised using a suitable

control or PC300.NET software.

6.5.18 Spot welding on

Activates the spot welding mode, regardless of the operating mode selected. This is an automatic special

non-latched sequence.

6.5.19 Positionweld on

Activates the specific welding type if supported by the system.

6.6 Check-back of the process parameters During operation, a variety of parameters are transferred to the higher level control via the field bus.

Some of these parameters are available as a visual signal on the module in the form of

LEDs > see 5.4.1.3 chapter.

6.6.1 I > 0 (Current flows signal)

Used to feed back the welding process to the PLC. The signal is normally set by the process after the arc

has been ignited and cancelled after the arc has been extinguished. For improved signal matching with

the higher level control, the signal is stored for a certain period during welding in the event of a stoppa-

ge > see 6.7 chapter.

The signal can be reset by a fault during the welding process.

6.6.2 User-defined inputs

There are 4 additional user-defined inputs with 24-V logic. The signals are filtered with a time constant of

approx. 50 ms.

If the module is equipped with an external voltage supply the signals will be processed even after the

welding machine has been switched off.

The signals can be used as required as long as they are not predefined for control-specific tasks.

The inputs are not isolated.

6.6.3 Process active

In order to indicate the end of the welding process to the higher level control, this signal is reset when the

system is in idle mode. During the welding process the signal is set to 1.

6.6.4 Main current signal

Used specifically in non-latched special operating mode to trigger the positioning device to the end of the

ignition program, or the start of the end program.

6.6.5 Collision protection

Indicates the status from a collision protection device connected to the module. The signal has a wire

break-proof design, which means that it is still active even if the sensor is not active. This should be taken

into account when designing the system and programming the machine.

The signal is treated with high priority to ensure rapid processing and also continues to be processed with

an external power supply to the module when the welding machine has been shut down.

6.6.6 Ready for welding

The system is ready for welding and accepts a start signal from the PLC. The signal is reset in case of er-

rors. When switching a JOB, the signal is reset for a duration of approx. 200 ms.

Operative mode Check-back of the process parameters

099-008196-EW501 27.11.2019 35

6.6.7 Sticking

The wire touches the workpiece, or is fused to the workpiece. Virtually no current flows via the workpiece.

The detection is carried out at the end of the welding process > see 6.8 chapter.

6.6.8 Range signal

Set if a value or function is specified that cannot be carried out by the system > see 6.16 chapter.

6.6.9 Error number

In combination with the status signal "collective error", indicates a system error > see 11 chapter. System

errors have to be acknowledged before attempting a restart.

In the advanced error functionality all existing errors are signalled successively for a duration of 1 second

each. At the end of an error sequence, signalling starts again with the lowest error number.

Some system errors cannot be acknowledged due to their severity.

6.6.10 Warning number

Signals system warnings which don't automatically cause a process stop. In case of multiple warnings a

time-based sequence is issued as with error numbers.

6.6.11 Actual welding voltage value

Transfer of the actual welding voltage of the process. The value is updated every 30ms.

6.6.12 Actual welding current value

Transfers the actual welding current in the process; value is updated every 30ms.

When using the configuration with fast actual value detection, the values for voltage and current

are updated every 5ms in the corresponding configuration of the field bus. This should be taken

into account when designing the field bus system and the transfer cycles.

6.6.13 Actual wire feed speed value

Transfer of the current wire speed for the process. Value is updated every 30ms.

6.6.14 Actual motor current value

Transfer of the actual motor current for the wire conveyor system. Value is updated every 30ms.

6.6.15 Parameter monitoring

Display of the status for the parameters being monitored. Signals are normally set to 0 if the monitoring is

inactive or the parameter in question is within the tolerance band > see 6.4 chapter.

Operative mode Signals for matching with the positioning device

36 099-008196-EW501 27.11.2019

6.6.16 Process signals diagram

To explain the process signals, a description of the non-latched special operating mode is given below. In

non-latched operating mode, the start and end programs are left out as appropriate.

Figure 6-2

Legend

Description

A Start signal

B Main current

C Process active

D Ready for welding

6.7 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. Often it is diffi-

cult to move the positioning device back to the basic position.

For this reason, multiple parameters for improved matching have been introduced specifically for the pro-

cess start phase and for the process in progress.

Operative mode Signals for matching with the positioning device

099-008196-EW501 27.11.2019 37

6.7.1 Ignition time: TZ-Zünd

Detecting a failed ignition process is very important during the process start phase (especially with tan-

dem processes with more than one power source).

The ignition phase is evaluated using an adjustable ignition time. A successful ignition process is detec-

ted if a stable flow of current occurs for more than the set time period after ignition. The I>0 signal is sa-

ved in this phase. However, if there is no ignition process for the duration of the failed ignition time, an ig-

nition error is issued to the cascade control. The process will be shut down automatically.

The ignition monitoring can be shut off by setting TZ-ZUND to the value 0.

6.7.2 TZ-Set

To specify the duration of the stable arc burn time, the parameter TZ-Set was defined. If the arc burns

stably in the ignition phase for this period, the signal I>0 is stored.

Figure 6-3

Legend

Description

A Start signal

B Internal start

C Ignition time elapse

D Ignition error message

E Automatic cut-out

Operative mode Fusing detection

38 099-008196-EW501 27.11.2019

6.7.3 Arc interruption time: TZ-LIBO

For the work process it is desirable that the process runs without interference. However, in poor conditi-

ons it is likely that welding interference will occur, and this results in intermittent signals for the duration of

the process. Depending on the cascade control logic implemented, this results in undesirable standstills

in the positioning device. To counteract this, the interface has a time-controlled recording feature for arc

interruptions. If an interruption is detected, an adjustable time period runs, during which the I>0 signal

sent to the cascade control is stored. After this time elapses, the I>0 signal is retracted, and the control is

provided with a response time (e.g. for a re-start). After max. 5 s elapses, an automatic cut-out of the pro-

cess is carried out with an "arc interruption" error message.

The arc interruption monitoring can be shut down by setting TZ-LIBO to the value 0.

The diagram shows the detection of an arc interruption.

Figure 6-4

Legend

Description

A Short misfire within the detection period

B Start signal

C Internal start

D Start of arc interruption detection

E Expiry of memory time for I>0 signal

F Automatic cut-out and arc interruption error message

6.7.4 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 ti-

me TZ-RESET can be used to set the period after which the I>0 signal is reset after the process is shut

down.

If both TZ-SET and TZ-RESET are set to the value 0, the original process signal I>0 is permitted

through to the higher level control unfiltered. This can be desirable if the control has its own

process signal monitoring

Operative mode Fusing detection

099-008196-EW501 27.11.2019 39

6.8 Fusing detection Reliable fusion detection of the welding wire is especially important in automated processes to protect the

workpiece and positioning device, including the welding equipment, against damage.

For this reason the BUSINTX11 has intelligent fusion detection which uses the sensor voltage from the

PHOENIX for wire fusion detection.

The fusion detection is carried out automatically for a narrow time window at the end of the process, ap-

prox. 200ms after extinguishing the arc. The detection duration depends on the setting of the gas post-

flow duration, but is a maximum of 1s.

If fusion is detected, the signal is displayed until the system is re-started.

If the wire is cut off from the workpiece before the next start, the signal is withdrawn permanently.

The use of the fusion function for TETRIX systems is only possible following retrofitting/fitting

with a sensor voltage and the relevant equipment on the torch being used.

6.8.1 Position search

The position search function can be executed with either the system bus data or the quick external actual

values:

JP 2 Function

- Actual values via system bus (factory setting)

X Actual values expected via connector X7, enable position search

X – jumper connected

Ideally the BUSINT X11 variant "External mounting housing" should be installed at the power source to

ensure quick and safe transfer of the actual values to the module (short distances without interferences).

When using the "Electrical enclosure" variant a shielded cable has to be used to connect the actual val-

ues.

This function can only be enabled when the system is switched off (no welding operation) using the cor-

rect enable signal.

In case of contact with the workpiece the state is quickly detected and transmitted to the fieldbus via sig-

nal "I > 0".

To improve the detection accuracy on corroded surfaces the existing sensor voltage can be increased to

60 V DC using an optional PCB. This option is selected via the EWM configuration program.

6.9 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. This is supported by BUSINTX11 with a fast, op-

tional actual value recording device for welding voltage and welding current, which needs to be pur-

chased separately.

6.10 Welding simulation Simulation is usually used for the setup of traversing devices. The process signals simulated are "I > 0",

"Ready for welding", "Process active" and "Main current". All signals are recreated with the exact time se-

quence of the process chain, which means simulation can also be used to determine the production cycle

times.

This function can only be enabled when the system is switched off (no welding operation) using the cor-

rect enable signal.

The simulation is enabled by activating the "welding simulation" actuation signal.

Process actual values are not simulated.

6.11 Process fast shut-down In some circumstances, an immediate shut-down of the process is desirable, which cannot be implemen-

ted in the non-latched special operating mode, for example, with the program sequence programmed for

that mode, or by simply removing the start signal. The “Robot ready” actuation signal is used to trigger a

fast process shut-down via the software. The signal must always be set before the start signal (otherwise

there is no start). If the signal is shut down in the welding process, the process is ended immediately with

the wire burn-back of the wire electrode and the “Fast stop” error is issued on the field bus. Before re-

starting welding, “Robot ready” needs to be set first and then the error acknowledged.

Operative mode Process safety shut-down

40 099-008196-EW501 27.11.2019

6.12 Process safety shut-down The BUSINTX11 is equipped with monitoring specific to the field bus, which is used to determine the sta-

tus of the module on the field bus. If the field bus communication is interrupted during the continuous

welding process, a safety shut-down of the welding process is carried out following a response time of

approx. 2s.

The user-defined output and the monitoring output are also reset in the process.

The welding process can be continued after restoring the field bus communication.

6.13 JOB safety switch 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 sys-

tem (wire feeds are not activated). In this case, there is a risk of secondary accidents caused by direct

contact with live torch parts.

To prevent the risk of accidents, the BUSINTX11 automatically switches to a JOB suitable for the welding

system when an unsuitable JOB has been selected on the robot side (e.g. TIG or electrode with the

PHOENIX).

No switching is carried out if the user switches to an unsuitable JOB using the control unit (e.g. M310). In

this case, the system will switch back to a JOB selected by the robot when the next start signal is issued.

6.14 Support of welding circuit alignment If the power source software supports this function, welding circuit alignment is possible. The alignment is

actuated using an existing control unit. BUSINT X11 supports alignment by allowing the alignment to be

activated using a set start or inching signal with the alignment mode being enabled. If this operation is

successful, the resulting welding circuit alignment is shown on the control unit. Unsuccessful measure-

ment is signalled as well. For the duration of the activated alignment the normal welding start is blocked.

6.15 Advanced JOB selection The power sources of the Multimatrix series and later enable the selection of up to 256 JOBs. Depending

on the power source type, not all JOBs can be selected. When attempting to select such a JOB, the JOB

is not selected and the interface issues a warning which is sent to the SPC and displayed on the machine

control.

Operative mode Incorrect selections in the system

099-008196-EW501 27.11.2019 41

6.16 Incorrect selections in the system BUSINT X11 is a universal interface for use on various EWM welding systems. These welding systems

may have system limitations regarding the use of processes or other functions.

The range signal has been defined to report back as faulty various selections made by the PLC that can-

not be carried out in the system due to the given restrictions. This signal is set as soon as one of the

following states occurs:

Cause Effect

In control signal operation, a value is specified

that lies outside the characteristic curve.

This value is automatically limited according to the

characteristic curve.

A JOB (characteristic curve) has been selected

that is not supported by the system.

The requested JOB is not selected.

Pulsed welding is activated on a power source

that is not pulse-capable.

The selection is ignored.

Positionweld is activated but not supported by

the welding system.

The selection is ignored.

6.17 Setting non-synergy characteristics In the data sets of the MIG/MAG power sources are non-synergic characteristics that allow the absolute

setting of the process voltage. The specification of the voltage correction for setting the process voltage is

reinterpreted. The setting range is currently between 11V and 49V and can vary depending on the chara-

cteristic. However, it is always possible to set a value of 38V.

The diagnostics interface PC system requirements

42 099-008196-EW501 27.11.2019

7 The diagnostics interface To support commissioning processes and the analysis of signal sequences, the BUSINTX11 has a diag-

nostics interface that is connected to a PC USB port and can be evaluated using the EWM-Analyzer soft-

ware.

7.1 PC system requirements The following requirements must be met to operate the PC software:

• Min. 1.7 GHz CPU

• 512 MB RAM (1 GB recommended for long-term recording)

• 300 MB free hard drive space

• Min. WIN XP with Service Pack 2

Commissioning Scope of diagnostics

099-008196-EW501 27.11.2019 43

8 Commissioning To start the diagnostic interface, the USB cable must first be connected to the USB port of the PC (con-

sisting of filter box SECINT X10 DSUB, part no. 090-008190-XXXXX and connection cable PCV5-

I/9POLIG/5M, part no. 094-001205-XXXXX) and to the 6-pole Minifit socket X10 on the BUSINT X11 u-

sing the required adapter cable ADAPTER DSUB 9POL/MINIFIT 6POL, part no. 094-013051-XXXXX.

When using a BUSINT X11 ATCASE, the adapter cable is not necessary as the connection cable can be

inserted directly into the casing.

Jumper 6 must be inserted in position 2-3 for operation!

Start the program, use the Windows Device Manager to identify and set the assigned COM port.

The diagnostics are now ready for operation!

8.1 Scope of diagnostics Various information can be determined using the EWM Analyzer software. In profile view, the

BUSINTX11 is displayed with the preset data profile. The relevant status of the input or output can there-

fore be read off immediately (system diagnostics). For expanded signal analysis based on time, there is a

diagnostics and monitor view of the recorded data available. The current software status of the

BUSINTX11 can also be easily determined.

For more information on the Analyzer, please also see the relevant operating instructions!

Data profiles Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

44 099-008196-EW501 27.11.2019

9 Data profiles The BUSINTX11 has a selection option for what are known as signal profiles which can be selected via a

selector switch with 16 settings.

The number of profiles available depends on the field bus standard being used and on the module soft-

ware version. The profiles described below therefore represent a minimum of the available functionality in

each case and are being updated on a continuous basis.

A newly selected profile is only applied once the module has been isolated from any supply voltage and

supplied with power again.

In cases where a switch position to which no profile is assigned is selected, the default profile is activated

for the module and an error message is displayed on the module (but not on the field bus). The module is

still ready for operation, however.

Depending on the profile, it may be that different signals in the description are not present or are not

used.

9.1 Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

9.1.1 Default profile (switch position 0)

The module uses a data capacity of 6 words (12 bytes) for input data and output data.

Actuation data (PLC output data)

Byte

no.

Bit no. Function/description Bit assignment

0 0/1

Operating mode selection Bit1 / Bit0

0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used

1 / 1 Non-latched-Special

0 2

Selection of pulsed welding 0 switched off (standard welding)

1 switched on

0 3

Selection of welding parame-

ter monitoring (monitor func-

tion)

0 switched off

1 switched on

0 4

Start signal welding process 0 switched off

1 switched on

0 5

Safety signal for fast shut-

down (robot ready)

0 No ready signal from the robot, no start possib-

le, fast shut-down occurs in the process

1 Robot reports ready, start is possible

0 6

Shielding gas valve (gas

test 1)

0 switched off

1 switched on

0 7

Blow-out (blow-out valve) 0 switched off

1 switched on

1 0

Wire inching 0 switched off

1 switched on

1 1

Position search workpiece 0 switched off

1 switched on

Data profiles Profiles for the Interbus-S (copper),

Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

099-008196-EW501 27.11.2019 45

Byte

no.


1 2

Wire return 0 switched off

1 switched on

1 3

Switching wire feed unit (opti-

onal)

0 Wire feed unit 1 active


1 4

Error reset - acknowledge-

ment signal for system error

Signal must have positive edge

1 5

Relay output K2 0 switched off

1 switched on

Function K2 - only if option sensor voltage is not used

1 6

JOB operation 0 switched off

1 switched on

1 7

Welding simulation 0 switched off

1 switched on

2 0-3

Selection program Range 0-15

2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7

System default master/slave

with TANDEM system (optio-

nal)

0 Master function (default)

1 Slave function

3 0-7

Selection JOB Range 1-510

4 0-15

Specifies the wire feed speed

in program 0

0 to 0x7FFF (High-Byte first)

0 equivalent to DV-MIN

0x7FFF equivalent to 25.0 m/min

6 0-15

Correction default,

High byte

Specifies the voltage correction in program 0

Range: 0 to 0 x 7FFF

0 corresponds to -10.0 V

0 x 4000 corresponds to 0 V

0 x 7FFF corresponds to +10.0V

8 0-15

Specifies the dynamics in

program 0


0 equivalent to -40

0 x 4000 equivalent to 0

0 x 7FFF equivalent to +40

10 0-15

Reserved


46 099-008196-EW501 27.11.2019

Process data (PLC input data)

Byte

no.


0 0

I > 0 ("Current flows" signal

from process)

0 No current flow

1 Current flows, arc stationary

0 1

Welding readiness (ready

signal from process)

0 System not ready

1 System is ready

0 2

Wire stick (“Wire stick” signal

from process)

0 Wire is free

1 Wire sticks to the workpiece

0 3

Error (general error message

from process)

0 No error

1 Error occurred and not resolved

0 4

Collision signal (signals trip-

ping of collision sensor)

0 Collision or transducer not connected

1 No collision

0 5

Main current signal (Displays

the status of the program

sequence)

0 Process is outside the main current phase

1 Process is running in the main program

0 6

Process active (Signals the

completion of the welding

process)

0 Process completed (after gas post-flows)

1 Process is running

0 7

Reserved

1 0-7

Error Error number of an error that occurred

2 0-7

Monitoring (bit field for displaying alarm messages during monitoring)

2 0

Welding voltage 0 no alarm

1 Alarm

2 1

Welding current 0 no alarm

1 Alarm

2 2

Wire feed speed 0 no alarm

1 Alarm

2 3

Motor current wire feeder 0 no alarm

1 Alarm

2 4

Range warning characteristics 0 No alarm (wire feeder target is within the range

of the characteristic)

1 Alarm (wire feeder target is outside the charac-

teristic)

Signal indicates whether the nominal value specified by the control system is within

the range of the characteristic (in preparation)



099-008196-EW501 27.11.2019 47

Byte

no.


2 5-6

Reserved

2 7

Tracking signal 0 no alarm

1 Alarm

Control signal to check the synchronization signal for processing the measuring

signals of the power source, signal should toggle in the process.

3 0-3

User-defined voltage inputs

X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high

X4/5 only available if not used as detecting input for increased sensor voltage.

3 4-7

Reserved

4 0-15

Welding voltage (current ac-

tual value)


equivalent to 0.0 V to 100.0 V

6 0-15

Welding current (current actu-

al value)


equivalent to 0 A to 1000 A

8 0-15

Wire feed speed (current ac-

tual value)


equivalent to 0.0 m/min to 40.0 m/min

10 0-15

Motor current wire feed me-

chanism (current actual value)


equivalent to 0.0 A to 25.5 A


48 099-008196-EW501 27.11.2019

9.1.2 Profile for Multimatrix machines (switch position 1)

The module uses data with a width of 14 bytes (7 words) for actuation and process data.


Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on




099-008196-EW501 27.11.2019 49

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0

JOB range extension 0 JOBs within the range of 1 to 255 can be selec-

ted

1 JOBs within the range of 256 to 510 can be

selected

4 1-2

Reserved

4 3

Positionweld 0 switched off

1 switched on

Reserved

4 4

Spot welding operating mode 0 Current operating mode active

1 Spot welding operating mode enabled

4 5

Wire inching mode 0 Standard system ramp active

1 3.0 m/min constant or application of wire feeder

target control signal

4 6

superPuls function 0 Disabled

1 Enabled

4 7

Lift arc function 0 Disabled

1 Enabled

5 0-7

Reserved

6 0-15


in program 0





50 099-008196-EW501 27.11.2019

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm



099-008196-EW501 27.11.2019 51

Byte

no.


2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7

Warning Number of a warning issued

5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15





Data profiles Profiles for the CANopen module

52 099-008196-EW501 27.11.2019

9.2 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 sig-

nals) and the standard Tx-PDOs 1 to 3 (no. 1 for digital and nos. 2 and 3 for analogue data).

9.2.1 Reis Robotics profile (switch position 0)


Byte

no.


RxPDO 1 CobID = 200h + Adr

0 0


1 switched on

0 1


down (robot ready)




0 2


1 switched on

0 3/4


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 5

Reserved

0 6



tion)

0 switched off

1 switched on

0 7

Reserved

1 0


test 1)

0 switched off

1 switched on

1 1


1 switched on

1 2


1 switched on

1 3




1 4


1 switched on

1 5


1 switched on


099-008196-EW501 27.11.2019 53

Byte

no.



1 6

Reserved

1 7


onal)



2 0-7


3 0-3


3 4-6

Reserved

3 7


1 switched on

4 0



nal)


1 Slave function

4 1-2

Reserved

4 3



4 4-7

Actuation of user-defined

outputs (K1-K4)

0 Relay not actuated

1 Relay actuated


5 0-7

Reserved

6 0-7

Reserved

7 0-7

Reserved


Byte

no.



0 0-15


in program 0





54 099-008196-EW501 27.11.2019

Byte

no.



2 0-15

Correction default,

High byte






4 0-15


program 0


0 equivalent to -40



6 0-15

Reserved


Byte

no.


TxPDO 1 CobID = 180h + Adr

0 0


from process)

0 No current flow


0 1

Reserved

0 2



process)



0 3



sequence)



0 4




1 No collision

0 5



0 System not ready

1 System is ready

0 6

Reserved

0 7

Reserved

1 0-7


2 0-7

Reserved

3 0


from process)

0 Wire is free



099-008196-EW501 27.11.2019 55

Byte

no.



3 1-7

Reserved

4 0-7


4 0


1 Alarm

4 1


1 Alarm

4 2


1 Alarm

4 3


1 Alarm

4 4




teristic)



4 5-7

Reserved

5 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


5 4-7

Reserved

6 0-7

Reserved

7 0-7

Reserved


Byte

no.



0 0-15


tual value)



2 0-15


al value)




56 099-008196-EW501 27.11.2019

Byte

no.



4 0-15


tual value)



6 0-15

Reserved


Byte

no.



0 0-15





2 0-15

Reserved

4 0-15

Reserved

6 0-15

Reserved


099-008196-EW501 27.11.2019 57




Byte

no.



0 0


1 switched on

0 1


down (robot ready)




0 2


1 switched on

0 3/4


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 5


1 Enabled

0 6



tion)

0 switched off

1 switched on

0 7


1 Enabled

1 0


test 1)

0 switched off

1 switched on

1 1


1 switched on

1 2


1 switched on

1 3




1 4


1 switched on

1 5


1 switched on


58 099-008196-EW501 27.11.2019

Byte

no.



1 6




1 7

Reserved

2 0


3 0


ted


selected

3 1-6

Reserved

3 7


1 switched on

4 0-1

Reserved

4 2


1 switched on

4 3



4 4-7


outputs (K1-K4)


1 Relay actuated

5 0-7

Reserved

6 0-3


6 4-7

Reserved

7 0-7

Reserved


Byte

no.



0 0-15


in program 0





099-008196-EW501 27.11.2019 59

Byte

no.



2 0-15

Correction default,

High byte






4 0-15


program 0


0 equivalent to -40



6 0-15

Reserved


Byte

no.



0 0


from process)

0 No current flow


0 1

Reserved

0 2



process)



0 3



sequence)



0 4




1 No collision

0 5



0 System not ready

1 System is ready

0 6

Warning Number of a warning issued > see 11.2 chapter

0 7

Reserved

1 0


2 0

Reserved

3 0


from process)

0 Wire is free



60 099-008196-EW501 27.11.2019

Byte

no.



3 1

Reserved

3 2

Reserved

4 0


1 Alarm

4 1


1 Alarm

4 2


1 Alarm

4 3


1 Alarm

4 4




teristic)

4 5

Reserved

5 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high

5 4

Reserved

6 0


7 0-7

Reserved


Byte

no.



0 0-15


tual value)



2 0-15


al value)



4 0-15


tual value)




099-008196-EW501 27.11.2019 61


Byte

no.



0 0-15





Data profiles Profiles for the CAN DeviceNet module

62 099-008196-EW501 27.11.2019

9.3 Profiles for the CAN DeviceNet module


The module uses a data width of 5 words (10 bytes) for actuation data and

6 words (12 bytes) for process data.


Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on


099-008196-EW501 27.11.2019 63

Byte

no.


1 6


1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0-15


in program 0




6 0-15

Correction default,

High byte






8 0-15


program 0


0 equivalent to -40




Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision


64 099-008196-EW501 27.11.2019

Byte

no.


0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm

2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-7


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


4 0-15


tual value)



6 0-15


al value)



8 0-15


tual value)




099-008196-EW501 27.11.2019 65

Byte

no.


10 0-15






66 099-008196-EW501 27.11.2019

9.3.2 Profile 1 (switch position 1)


6 words (12 bytes) for process data, split into 2 connections.

The following data with 4 bytes are assigned to connection 1 (output 1):


Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on


099-008196-EW501 27.11.2019 67

Byte

no.


1 6


1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

3 0-7


The following data with 6 bytes are assigned to connection 2 (output 2):


Byte

no.


0 0-15


tual value)



2 0-15


al value)



4 0-15


tual value)




68 099-008196-EW501 27.11.2019




Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on



099-008196-EW501 27.11.2019 69

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0


ted


selected

4 1-2

Reserved

4 3


1 switched on

Reserved

4 4



4 5




4 6


1 Enabled

4 7


1 Enabled

5 0-7

Reserved

6 0-15


in program 0





70 099-008196-EW501 27.11.2019

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm


099-008196-EW501 27.11.2019 71

Byte

no.


2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7


5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15





The following data with 4 bytes are assigned to connection 1 (input 1):


Byte

no.


0 0


from process)

0 No current flow



72 099-008196-EW501 27.11.2019

Byte

no.


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm

2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-6

Reserved

2 7


1 Alarm


099-008196-EW501 27.11.2019 73

Byte

no.




3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

The following data with 8 bytes are assigned to connection 2 (input 2):


Byte

no.


0 0-15


tual value)



2 0-15


al value)



4 0-15


tual value)



6 0-15





Data profiles Profiles for the Profibus DP module

74 099-008196-EW501 27.11.2019

9.4 Profiles for the Profibus DP module


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.


Byte

no.


0 0


1 switched on

0 1


down (robot ready)




0 2


1 switched on

0 3

Operating mode selection 0 Operating mode non-latched

1 Operating mode non-latched Special

0 4

Reserved

0 5


1 switched on

0 6


onal)



0 7




1 0


test 1)

0 switched off

1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


1 switched on

1 4


1 switched on

1 5


1 switched on


099-008196-EW501 27.11.2019 75

Byte

no.


1 6



tion)

0 switched off

1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0-15


in program 0




6 0-15

Correction default,

High byte






8 0-15


program 0


0 equivalent to -40




Byte

no.


0 0


from process)

0 No error


0 1

User-defined voltage input

X4/3

0 V Signal low

24 V Signal high

0 2



process)



0 3


from process)

0 No current flow



76 099-008196-EW501 27.11.2019

Byte

no.


0 4




1 No collision

0 5



0 System not ready

1 System is ready

0 6



sequence)



0 7


from process)

0 Wire is free


1 0-7


2 0-15


tual value)



4 0-15


al value)



6 0-15


tual value)



8 0-15





10 0-4


10 0


1 Alarm

10 1


1 Alarm

10 2


1 Alarm

10 3


1 Alarm

10 4




teristic)




099-008196-EW501 27.11.2019 77

Byte

no.


10 5-7


X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


78 099-008196-EW501 27.11.2019

9.4.2 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 Pro-

fibus can be grouped via the module programming.

The program and JOB selection bits can be used to pre-select the actuation type for programs and JOBs.


Byte

no.


0 0


1 switched on

0 1


down (robot ready)




0 2


1 switched on

0 3

Operating mode selection 0 Operating mode non-latched

1 Operating mode non-latched Special

0 4

Program preselection machi-

ne (the program is selected

from the machine)

0 Program 1 is permanently set

1 Program is selectable from 0 to 15

0 5

Machine JOB mode (selection

of JOBs selection mode)

0 JOB preselection via operating front (M31X)

1 JOB preselection from the machine (fieldbus)

0 6


onal)



0 7




1 0


test 1)

0 switched off

1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


1 switched on

1 4


1 switched on


099-008196-EW501 27.11.2019 79

Byte

no.


1 5


1 switched on

1 6



tion)

0 switched off

1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0-15


in program 0




6 0-15

Correction default,

High byte






8 0-15


program 0


0 equivalent to -40




Byte

no.


0 0


from process)

0 No error


0 1


X4/3

0 V Signal low

24 V Signal high

0 2



process)




80 099-008196-EW501 27.11.2019

Byte

no.


0 3


from process)

0 No current flow


0 4




1 No collision

0 5



0 System not ready

1 System is ready

0 6



sequence)



0 7


from process)

0 Wire is free


1 0-7


2 0-15


tual value)



4 0-15


al value)



6 0-15


tual value)



8 0-15





10 0-4


10 0


1 Alarm

10 1


1 Alarm

10 2


1 Alarm

10 3


1 Alarm

10 4




teristic)


099-008196-EW501 27.11.2019 81

Byte

no.




10 5-7


X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


82 099-008196-EW501 27.11.2019

9.4.3 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 BUSINT X10 Profibus interfaces. The profile is fully

compatible for this purpose.


Byte

no.


0 0


1 switched on

0 1


1 switched on

0 2


1 switched on

0 3/4


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 5

Program preselection machi-

ne (the program is selected

from the machine)

0 Program 1 is permanently set

1 Program is selectable from 0 to 15

0 6

Machine JOB mode (selection

of JOBs selection mode)

0 JOB preselection via operating front (M31X)

1 JOB preselection from the machine (fieldbus)

0 7




1 0


test 1)

0 switched off

1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4


1 switched on

1 5


1 switched on


099-008196-EW501 27.11.2019 83

Byte

no.


1 6



tion)

0 switched off

1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0-15


in program 0




6 0-15

Correction default,

High byte






8 0-15


program 0


0 equivalent to -40




Byte

no.


0 0

Reserved

0 1


X4/3

0 V Signal low

24 V Signal high

0 2



process)



0 3


from process)

0 No current flow



84 099-008196-EW501 27.11.2019

Byte

no.


0 4




1 No collision

0 5



0 System not ready

1 System is ready

0 6

Reserved

0 7


from process)

0 Wire is free


1 0-7


2 0-15


tual value)



4 0-15


al value)



6 0-15


tual value)



8 0-15





10 0-4


10 0


1 Alarm

10 1


1 Alarm

10 2


1 Alarm

10 3


1 Alarm

10 4




teristic)



10 5-7


X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


099-008196-EW501 27.11.2019 85




Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on



86 099-008196-EW501 27.11.2019

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0


ted


selected

4 1-2

Reserved

4 3


1 switched on

Reserved

4 4



4 5




4 6


1 Enabled

4 7


1 Enabled

5 0-7

Reserved

6 0-15


in program 0





099-008196-EW501 27.11.2019 87

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm


88 099-008196-EW501 27.11.2019

Byte

no.


2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7


5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15





Data profiles Profiles for the Profinet and Profinet-LWL modules

099-008196-EW501 27.11.2019 89

9.5 Profiles for the Profinet and Profinet-LWL modules

9.5.1 Reis Robotics profile (switch position 0)

The module uses a data width of 7 words (14 bytes) for actuation and process data.


Byte

no.


0 0


1 switched on

0 1


down (robot ready)




0 2


1 switched on

0 3/4


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 5

Reserved

0 6



tion)

0 switched off

1 switched on

0 7

Reserved

1 0


test 1)

0 switched off

1 switched on

1 1


1 switched on

1 2


1 switched on

1 3




1 4


1 switched on

1 5


1 switched on

1 6


1 switched on


90 099-008196-EW501 27.11.2019

Byte

no.


1 7


onal)



2 0-7


3 0-3


3 4-6

Reserved

3 7


1 switched on

4 0



nal)


1 Slave function

4 1-7

Reserved

5 0-3


outputs (K1-K4)


1 Relay actuated

5 4-7

Reserved

6 0-15


in program 0




8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow



099-008196-EW501 27.11.2019 91

Byte

no.


0 1

Reserved

0 2



process)



0 3



sequence)



0 4




1 No collision

0 5


from process)

0 No error


0 6



0 System not ready

1 System is ready

0 7

Reserved

1 0-7


2 0-7

Reserved

3 0


from process)

0 Wire is free


3 1-7

Reserved

4 0-7


4 0


1 Alarm

4 1


1 Alarm

4 2


1 Alarm

4 3


1 Alarm

4 4




teristic)


92 099-008196-EW501 27.11.2019

Byte

no.




4 5-6

Reserved

4 7


1 Alarm



5 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high

5 4-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15






099-008196-EW501 27.11.2019 93




Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on



94 099-008196-EW501 27.11.2019

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0


ted


selected

4 1-2

Reserved

4 3


1 switched on

Reserved

4 4



4 5




4 6


1 Enabled

4 7


1 Enabled

5 0-7

Reserved

6 0-15


in program 0





099-008196-EW501 27.11.2019 95

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm


96 099-008196-EW501 27.11.2019

Byte

no.


2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7


5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15





Data profiles Profiles for the EtherNet/IP module

099-008196-EW501 27.11.2019 97

9.6 Profiles for the EtherNet/IP module




Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on


98 099-008196-EW501 27.11.2019

Byte

no.


1 6


1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0




4 1



4 2-7

Reserved

5 0-7

Reserved

6 0-15


in program 0




8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


099-008196-EW501 27.11.2019 99


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm

2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)




100 099-008196-EW501 27.11.2019

Byte

no.


2 5-6

Reserved

2 7


1 Alarm



3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7

Reserved

5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15






099-008196-EW501 27.11.2019 101

9.6.2 FANUC Robotics profile (switch position 1)



Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on


102 099-008196-EW501 27.11.2019

Byte

no.


1 6


1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0




4 1



4 2-7

Reserved

5 0-7

Reserved

6 0-15


in program 0




8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


099-008196-EW501 27.11.2019 103


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm

2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)




104 099-008196-EW501 27.11.2019

Byte

no.


2 5-6

Reserved

2 7


1 Alarm



3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7

Reserved

5 0-7

Reserved

6 0-15


tual value)

0x7FFF to 0x0 (equivalent to 0.0 V to 100.0 V,

High-Byte first)

8 0-15


al value)

0x7FFF to 0x0 (equivalent to 0 A to 1000 A,

High-Byte first)

10 0-15


tual value)

0x7FFF to 0x0 (equivalent to 0.0 m/min to

40.0 m/min, High-Byte first)

12 0-15



0x7FFF to 0x0 (equivalent to 0.0 A to 25.5 A,

High-Byte first)

9.6.3 Notes on the profile

The process actual values are adapted to the negative FANUC logic. A process value of 0 is output with

the maximum value, but the maximum process value is output with the value 0.


099-008196-EW501 27.11.2019 105




Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on



106 099-008196-EW501 27.11.2019

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0


ted


selected

4 1-2

Reserved

4 3


1 switched on

Reserved

4 4



4 5




4 6


1 Enabled

4 7


1 Enabled

5 0-7

Reserved

6 0-15


in program 0





099-008196-EW501 27.11.2019 107

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm


108 099-008196-EW501 27.11.2019

Byte

no.


2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7


5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15






099-008196-EW501 27.11.2019 109

9.6.5 Profile for Multimatrix machines with FANUC robots (switch position 3)



Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on



110 099-008196-EW501 27.11.2019

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0


ted


selected

4 1-2

Reserved

4 3


1 switched on

Reserved

4 4



4 5




4 6


1 Enabled

4 7


1 Enabled

5 0-7

Reserved

6 0-15


in program 0





099-008196-EW501 27.11.2019 111

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0


1 Alarm

2 1


1 Alarm


112 099-008196-EW501 27.11.2019

Byte

no.


2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7


5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)

0x7FFF to 0x0 (equivalent to 0 A to 1000 A,

High-Byte first)

10 0-15


tual value)

0x7FFF to 0x0 (equivalent to 0.0 m/min to

40.0 m/min, High-Byte first)

11 7

Reserved

12 0-15



0x7FFF to 0x0 (equivalent to 0.0 A to 25.5 A,

High-Byte first)

9.6.6 Notes on the profile

The process actual values are adapted to the negative FANUC logic. A process value of 0 is output with

the maximum value, but the maximum process value is output with the value 0.

Data profiles Profiles for the Modbus/TCP module

099-008196-EW501 27.11.2019 113

9.7 Profiles for the Modbus/TCP module


The module uses data with a width of 8 words for actuation and status data.

Control data (output data PLC)

Re

gis

ter

no

.

Wo

rd n

o.

Bit

no

.

Co

il n

o.

Function/description Bit assignment

1024 0 0 16399 Non-latched operating mode Bit1 / Bit0

0 / 0 Non-latched

0 / 1 Not used

0 1 16398 Special non-latched operating mode 1 / 0 Not used

1 / 1 Non-latched special

0 2 16397 Selection of pulsed welding 0 switched off (standard welding)

1 switched on

0 3 16396 Selection of welding parameter mo-

nitoring (monitor function)

0 switched off

1 switched on

0 4 16395 Start signal welding process 0 switched off

1 switched on

0 5 16394 Safety signal for fast shut-down (ro-

bot ready)

0 No ready signal from the robot, no

start possible, fast shut-down oc-

curs in the process

1 Robot reports ready, start is pos-

sible

0 6 16393 Shielding gas valve (gas test 1) 0 switched off

1 switched on

0 7 16392 Blow-out (blow-out valve) 0 switched off

1 switched on

0 8 16391 Wire inching 0 switched off

1 switched on

0 9 16390 Position search workpiece 0 switched off

1 switched on

0 10 16389 Wire return 0 switched off

1 switched on

0 11 16388 Switching wire feeder (optional) 0 Wire feeder 1 active

1 Wire feeder 2 active

0 12 16387 Error reset - acknowledgement sig-

nal for system error


0 13 16386 Relay output K1 0 switched off

1 switched on

0 14 16385 Reserved

0 15 16384 Welding simulation 0 switched off

1 switched on

1025 1 0 16415 Relay output K2 0 switched off

1 switched on


114 099-008196-EW501 27.11.2019

Re

gis

ter

no

.

Wo

rd n

o.

Bit

no

.

Co

il n

o.



1 switched on


1 switched on

1 3 16412 System default master/slave with

TANDEM system (optional)


1 Slave function

1 4 16410 Spot welding operating mode 0 switched off

1 switched on

1 5 16409 Wire inching mode 0 switched off

1 switched on

1 6 16408 superPuls function 0 switched off

1 switched on

1 7 16399 Lift arc function 0 switched off

1 switched on

1 8-15 16398 Reserved

1026 2 0 16397 Positionweldon 0 switched off

1 switched on

1026 2 1-15 16397 Reserved

1027 3 0-4 16396 Selection program Range 0-15

1028 4 0-8 16395 Selection JOB Range 1-510

1029 5 0-14 16394 Specifies the wire feed speed in

program 0

0 to 0x7FFF (high byte first)



1030 6 0-14 16393 Specifies the voltage correction in

program 0

0 to 0x7FFF (high byte first)

0 equivalent to -10.0 V

0x4000 corresponds to 0 V

0x7FFF corresponds to +10.0 V

1031 7 0-14 16392 Specifies the dynamics in program 0 0 to 0x7FFF (high byte first)

0 equivalent to -40

0x4000 equivalent to 0

0x7FFF equivalent to +40


099-008196-EW501 27.11.2019 115

Process data (input data PLC)

Re

gis

ter

no

Wo

rd n

o

Bit

no

.

Co

il n

o


0 0 0 15 I > 0 ("Current flows" signal from process) 0 No current flow


0 1 14 Welding readiness (ready signal from

process)

0 System not ready

1 System is ready

0 2 13 Wire stick (“Wire stick” signal from pro-

cess)

0 Wire is free


0 3 12 Error (general error message from pro-

cess)

0 No error


0 4 11 Collision signal (signals tripping of collisi-

on sensor)

0 Collision or transducer not

connected

1 No collision

0 5 10 Main current signal (Displays the status of

the program sequence)

0 Process is outside the main cur-

rent phase

1 Process is running in the main

program

0 6 9 Process active (Signals the completion of

the welding process)

0 Process completed (after gas

post-flows)


0 7-11 Monitoring (Bit field to display alarms when monitoring welding parameters)

0 7 8 Characteristic range warning - signal indi-

cates whether the nominal value specified

by the control system is within the range

of the characteristic

0 No alarm (wire feeder target is

within the range of the charac-

teristic)

1 Alarm (wire feeder target is outs-

ide the characteristic)

0 8 7 Welding voltage 0 no alarm

1 Alarm

0 9 6 Welding current 0 no alarm

1 Alarm

0 10 5 Wire feed speed 0 no alarm

1 Alarm

0 11 4 Motor current wire feeder 0 no alarm

1 Alarm

0 12 3 User-defined voltage input X4/3 0 V Signal low

24 V Signal high

0 13 2 User-defined voltage input X4/5 (only

available if not used as detecting input for

increased sensor voltage)

0 V Signal low

24 V Signal high


24 V Signal high


24 V Signal high

1 1 0-15 Reserve


116 099-008196-EW501 27.11.2019

Re

gis

ter

no

Wo

rd n

o

Bit

no

.

Co

il n

o


2 2 0-7 Error Error number of an error that occur-

red

3 3 0-7 Warning Warning code of an issued warning

4 4 0-14 Welding voltage (current actual value) 0 to 0x7FFF (High-Byte first)


5 5 0-14 Welding current (current actual value) 0 to 0x7FFF (High-Byte first)


6 6 0-14 Wire feed speed (current actual value) 0 to 0x7FFF (High-Byte first)

equivalent to 0.0 m/min to

40.0 m/min

7 7 0-14 Motor current wire feed mechanism (cur-

rent actual value)



Data profiles Profiles for the EtherCAT module

099-008196-EW501 27.11.2019 117

9.8 Profiles for the EtherCAT module



6 words (12 bytes) for process data.


Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on


118 099-008196-EW501 27.11.2019

Byte

no.


1 6


1 switched on

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0-15


in program 0




6 0-15

Correction default,

High byte






8 0-15


program 0


0 equivalent to -40




Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision


099-008196-EW501 27.11.2019 119

Byte

no.


0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm

2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-6

Reserved

3 0-7


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


4 0-15


tual value)



6 0-15


al value)



8 0-15


tual value)




120 099-008196-EW501 27.11.2019

Byte

no.


10 0-15






099-008196-EW501 27.11.2019 121




Byte

no.


0 0/1


0 / 0 Non-latched

0 / 1 Not used

1 / 0 Not used


0 2


1 switched on

0 3



tion)

0 switched off

1 switched on

0 4


1 switched on

0 5


down (robot ready)




0 6


test 1)

0 switched off

1 switched on

0 7


1 switched on

1 0


1 switched on

1 1


1 switched on

1 2


1 switched on

1 3


onal)



1 4




1 5


1 switched on



122 099-008196-EW501 27.11.2019

Byte

no.


1 6

Reserved

1 7


1 switched on

2 0-3


2 4-6

Relay output

K1, K3 and K4

0 switched off

1 switched on

2 7



nal)


1 Slave function

3 0-7


4 0


ted


selected

4 1-2

Reserved

4 3


1 switched on

Reserved

4 4



4 5




4 6


1 Enabled

4 7


1 Enabled

5 0-7

Reserved

6 0-15


in program 0





099-008196-EW501 27.11.2019 123

Byte

no.


8 0-15

Correction default,

High byte






10 0-15


program 0


0 equivalent to -40



12 0-15

Reserved


Byte

no.


0 0


from process)

0 No current flow


0 1



0 System not ready

1 System is ready

0 2


from process)

0 Wire is free


0 3


from process)

0 No error


0 4




1 No collision

0 5



sequence)



0 6



process)



0 7

Reserved

1 0-7


2 0-7


2 0


1 Alarm


124 099-008196-EW501 27.11.2019

Byte

no.


2 1


1 Alarm

2 2


1 Alarm

2 3


1 Alarm

2 4




teristic)



2 5-7

Reserved

3 0-3


X4/3, X4/5, X4/7 and X4/8

0 V Signal low

24 V Signal high


3 4-7

Reserved

4 0-7


5 0-7

Reserved

6 0-15


tual value)



8 0-15


al value)



10 0-15


tual value)



12 0-15





Special field bus features when setting up the field bus modules

CAN DeviceNet

099-008196-EW501 27.11.2019 125

10 Special field bus features when setting up the field bus mod-ules

10.1 CAN DeviceNet Field bus subscribers in the CAN DeviceNet are normally integrated using an EDS file (Electronic Data

Sheet). This configuration file permits access to the module configuration.

The BUSINTX11 DeviceNet is supplied together with the file BUSINTX11.EDS.

The module configuration is carried out as follows:

10.1.1 Connections

The module can be configured using what are known as connections. The number of useable connec-

tions depends on the profile being used. Each usable connection has a defined quantity of input data and

output data. The data position of the profile always starts with the first byte of a relevant connection.

Each connection can in theory be assigned to another connection type (Polled, COS, Strobed). However,

each connection type can only be assigned once (separated for input data and output data). The number

of data items available per connection can be read out using the “InputX length” and “OutputX length” pa-

rameters via the configuration tool.

Here, “InputX length” stands for process status data and “OutputX length” for actuation data.

10.1.2 Example for I/O data

Figure 10-1

In the example above, the profile selected is offered for connection 1, 10 bytes of actuation data and 12

bytes of process data.

Special field bus features when setting up the field bus modules Profibus DP

126 099-008196-EW501 27.11.2019

10.1.3 Example of a connection assignment

Figure 10-2

In the example above, 12 bytes of connection 1 are assigned and configured as “Polled”.

10.2 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.

It is advisable to distribute the modules according to the logical block size of the data. For example, word

capacity for nominal and actual values or by bytes for data with byte capacity.

10.2.1 The watchdog

Each DP node can be monitored using a watchdog to secure the data traffic.

It is essential that this function is activated as otherwise the targeted shut-down of the system will no

longer function in the event of an interruption to the field bus master.

10.2.2 DP features

Using watchdog monitoring, the system can be shut down in the event of interruption. In this process, all

I/Os are set to 0 and “FASTSTOP” is detected on the system.

The restart behaviour of the slave when restoring the connection can be configured in the DP features.

Caution is required with the following configuration:

Feature Setting

Re-start behaviour of the node Automatic re-start

Response from the master None

If the error that has occurred is reset on an operating panel before the field bus is re-started, the welding

process can be re-started if the start is still present.

Always ensure in an error situation of this type that all outputs of the node have been reset in the applica-

tion.


EtherCAT

099-008196-EW501 27.11.2019 127

10.3 EtherCAT Machines are installed in the engineering system of the EtherCAT masters in the EtherCAT standard, u-

sing XML-based configuration files called ESI (EtherCAT Slave Information).

In addition to the basic settings required for safe operation these configurations contain one special fea-

ture.

Different machines with similar properties are defined as "devices".

Corresponding to the three machine variants Phoenix, Tetrix, and Tetrix Plasma there are three different

configuration files for BUSINT X11.

In these files, an individual machine is assigned to each data profile, which is detected when an automatic

search is carried out.

10.3.1 Machine installation

To install a machine, open the master install functionality and select the correct file depending on the in-

terface type (BUSINT X11 Phoenix, BUSINT X11 Tetrix or BUSINT X11 Plasma).

Figure 10-3

Figure 10-4

Special field bus features when setting up the field bus modules EtherCAT

128 099-008196-EW501 27.11.2019

10.3.2 Manual integration of a machine

Open the corresponding dialog in the engineering system and you will see that for each supported data

profile there is one device available.

Select the required data profile according to the reference and set the data profile control accordingly.

To ensure proper functioning the control setting and the selected entry have to match.

10.3.3 Search for a machine

Most engineering systems offer an automatic search function for EtherCAT machines.

The result will show the detected machine along with the data profile set.

If a non-existent data profile has been set at the data control, profile 0 will be selected automatically.

Figure 10-5

10.3.4 Process data view

Once the machine has been installed, its data image shows the data allocation in blocks to allow for a

general orientation.

Figure 10-6


Modbus

099-008196-EW501 27.11.2019 129

10.4 Modbus Access to data via the Modbus takes place in two ways.

The output and input data is accessed word by word (16 bits) by means of registers.

Bit values are accessed bit-wise by means of so-called coils. Access takes place via

default access services in Modbus.

In principle, access can take place word-wise or bit-wise throughout the entire data range.

The Motorola Notation with the High-Byte in front applies to word access.

It is important to note that the numbering of registers and coils depending on the manufacturer begins

with 0 or with

1. This shall be considered in the interpretation.

The following Modbus services are supported for access services:

1, 2, 3, 4, 5, 6, 15, 16, 22 and 23

The following exception codes are supported for the data connections:

0x01 invalid function The requested function code is not supported

0x02 invalid data address The accessed data address does not exist or is not within

the defined range

0x03 invalid data value An attempt was made to transfer invalid data values

Rectifying faults Operating displays (LEDs)

130 099-008196-EW501 27.11.2019

11 Rectifying faults

11.1 Operating displays (LEDs) LED no. Function Description

1 +15V voltage

Assignment:

Off

On

Voltage supply +15 V

Voltage missing/damaged

Voltage OK

2 -15V voltage

Assignment:

Off

On

Voltage supply -15V


Voltage OK

3 +5 V voltage

Assignment:

Off

On

Voltage supply +5V


Voltage OK

4 +24V voltage

Assignment:

Off

On

Voltage supply +24V


Voltage OK

5, 6, 13, 14 Relay status

Assignment:

Off

On

Shows the status of relays K1 to K4

Relay inactive

Relay active

7 Start/stop

Assignment:

Off

On

Start/stop display status at the welding machine

Stop signal active

Start signal active

8 I > 0

Assignment:

Off

On

Display of the "Welding current flows" signal

Current does not flow

Current flows, arc active

9 Process active

Assignment:

Off

On

Display of the running process

Process completed

Process running

10 Error

Assignment:

Off

On

Display of a system error

No error

Error active

With the "Seam tracking" software option, the synchronous signal

from the power source is signalled in the welding process by

flashing.

11 & 12 System bus status

Assignment:

Off

Flashing

Display for internal system bus

System bus not active, system switched off

System bus is active

15 & 16 External control bus

status

Assignment:

Off

Quick flashing

Display for the external control bus

Control bus not in use

Control bus active

Rectifying faults Warnings (power source)

099-008196-EW501 27.11.2019 131

11.2 Warnings (power source) Depending on the display options of the machine display, a warning message is displayed as follows:

Display type - machine control Display

Graphic display

two 7-segment displays

one 7-segment display

The cause of the warning is indicated by a corresponding warning number (see table).

The display of possible error numbers depends on the machine version (interfaces/functions).

• If multiple errors occur, these are displayed in succession.

• Document machine errors and inform service staff as necessary.

No. Warning Possible cause

1 Excess temperature A shutdown is imminent due to excess temperature.

4 Shielding gas [2] Check shielding gas supply.

5 Coolant flow [3]

Flow rate (<= 0.7l/min / <= 0.18 gal./min) [1]

6 low wire Only a small amount of wire is left on the spool.

7 CAN bus failure Wire feeder not connected, automatic circuit-breaker of wire

feed motor (reset the tripped automatic circuit-breaker by ac-

tuating).

8 Welding circuit The welding circuit inductance is too high for the selected

welding task.

10 Partial inverter One of several partial inverters is not supplying welding cur-

rent.

11 Excess temperature, coolant [3]

Coolant (>= 65°C / >= 149°F) [1]

12 Welding monitor The actual value of a welding parameter is outside the spe-

cified tolerance field.

13 Contact error The resistance in the welding circuit is too high. Check earth

connection.

32 Tacho error Fault of wire feeder, permanent overload of the wire drive.

33 WF excess current Overcurrent detection of the main WF drive.

34 JOB unknown JOB selection was not performed because the JOB number is

unknown.

35 WF excess current slave Overload of the slave WF drive (front drive push/push system

or intermediate drive).

36 Slave tacho error Fault of wire feeder, permanent overload of the slave WF drive

(front drive push/push system or intermediate drive).

37 FST bus failure Wire feeder not connected, automatic circuit-breaker of wire

feed motor (reset the tripped automatic circuit-breaker by ac-

tuating).

[1] factory setting

[2] option

[3] only machine series Titan XQ

Rectifying faults Error messages on the system

132 099-008196-EW501 27.11.2019

11.3 Error messages on the system

11.3.1 General system erors

Error num-

ber

(value)

Meaning Relevance

System

Error can be reset

4 Wire feed error

Titan XQ / Phoenix

/ alpha Q / Tetrix

Yes

5 Inverter/inverter emergency stop circuit tem-

perature error

No, automatic reset

6 Mains overvoltage No, switch off ma-

chine

7 Mains undervoltage No, switch off ma-

chine

8 Low water level No, switch off ma-

chine

9 Gas error Yes

10 Secondary circuit overvoltage No, switch off ma-

chine

11 Protective conductor error No, switch off ma-

chine

12 System quick stop

Yes

13 Internal error, please inform EWM No, switch off ma-

chine

11.3.2 Process error

Error num-

ber

(value)

Meaning Relevance

System

Error can be reset

49 Process ignition error Titan XQ / Phoenix

/ alpha Q / Tetrix

Yes

50 Arc break error Yes

52 Emergency stop / excess temperature No, automatic reset

53 Double wire feeder missing in the MIG/MAG

system or incorrect configuration

Titan XQ / Phoenix

/ alpha Q

Yes

54 Switching to a non-existent double wire feeder

has been attempted in a system supporting

the function to switch double wire feeders.

Yes

55 Reducing the open circuit voltage to the set

values failed for power sources with voltage

reduction device.

No

56 WF excess current

57 Mains phase failure

58 Encoder error slave

59 Voltage short circuit after switching on

60 Incompatible device

61 Welding monitor

99 No connection to power source (i.e. system

switched off)

Titan XQ / Phoenix

/ alpha Q / Tetrix

No, automatic reset

Jumper assignment overview BUSINT X11

099-008196-EW501 27.11.2019 133

12 Jumper assignment overview

12.1 BUSINT X11 JP no.: Function/meaning Assignment

1 For internal use only - do not use!

2 Fast analogue inputs function

0 = analogue signal source is system bus

1 = analogue signal source are analogue inputs on

X7

3 Reserved

4 Activation of JOB mode [1]

0 = ------- No JOB mode active

1 = Job mode active

6 Diagnostics/programming interface

switching

1-2 = programming interface via X2 active

2-3 = diagnostics interface via X10 active

[1] Data profiles identified with control signal operation, must not JP4 be set as otherwise it could be that

functions become blocked!

Configuration data overview BUSINT X11

134 099-008196-EW501 27.11.2019

13 Configuration data overview

13.1 BUSINT X11 Which configuration data can be set in BUSINT X11 depends on the firmware version. If EWM-Konfig

does not show a current parameter in the software, make sure the parameter files for this program are up

to date.

Following parameters can be defined:

Parameter Setting Meaning Available

from SW

Option workpiece se-

arch

standard

Option

For this function the default

sensor voltage of 15 V is used

For this function the additional

Touch1 hardware with 60 V

search voltage is actuated

0.0.2.0

Inching mode System

External

In MAG systems inching is

carried out with the system

ramp from 1.0 to 6.0 m/min

Inching is carried out using the

analogue WF value to create

individual inching functions

0.0.2.0

web server active web server active

No web server

Enables this function

for interfaces with

web server option

Deactivates an existing

web server

0.0.2.0

Suppress missing wire

feeder

show error

suppress error

For MAG systems a WF me-

chanism is required for the

process by default

An error caused by a missing

WF mechanism is suppressed

0.0.2.0

Byte notation Intel

Motorola

Interpretation or display

of all words with low/high byte

Interpretation or display

of all words with high/low byte

0.0.2.0

Polarity wire stick sig-

nal

positive

negative

Signal is active when

sticking is detected

Signal is active when no

sticking is detected

0.0.2.0

Forbidden job swit-

ching

granted

denied

With MAG systems, switching

to a TIG JOB is not

allowed

Switching is

allowed

0.0.2.0

Web server authentica-

tion

No password

Password required

The web server can be

accessed without a password

A password is required to ac-

cess the web server

0.0.2.0

Analog values swap

bytes

low/high byte

high/low byte

Corresponding interpretation

of the "analogue" nominal va-

lues/

display of the "analogue"

actual values

0.0.2.0

Configuration data overview BUSINT X11

099-008196-EW501 27.11.2019 135

Parameter Setting Meaning Available

from SW

Style type real values default style

Fanuc style

Analogue actual values are

output as standard 15-bit valu-

es

Output is in the form of inver-

ted values with 13-bit resoluti-

on for FANUC controllers

0.0.2.0

Configuration relais K1 Monitoring output

KUKA touch output

User output

Standard function, builds an

ORed output for

process monitoring

Output used for quick

output of the workpiece

search function

Output can be directly

manipulated via the fieldbus

0.0.2.0

Touch threshold volta-

ge

Value in the range of 1.0 V to

15.0 V

Defines a detection span for

the workpiece search function,

in which contact is detected.

0.0.2.0

DeviceNet UCMM

function

Group 2 slave only

UCMM function active

The interface behaves as a

group 2 slave during estab-

lishment of the connection

Alternatively, the interface can

establish connections via

UCMM

0.0.2.0

Factory reset Off

Configuration

The setting has no function

The machine will be reset to

the factory settings, effective

on the next start of the machi-

ne.

0.0.3.0

Actual value output Actual values

Nominal values

Output of actual values after

the process has finished.

Output of the nominal values

applied in the system after the

process has finished.

0.0.3.0

Fast measuring mode Process dependent

Always mean values

The seam tracking option pro-vides a fast, process-synchronous measurement mode. By default, the signals are processed synchronously to the process. The measured values are averaged using a time constant.

0.0.4.0

Fast actual-value cycle

Value in the range of from 2ms

to 500ms

Parameters for the function of fast measurement mode

0.0.4.0

Mode analyser Strict

Tolerant

Stopping the data transfer when changing the scaling of parameters A recording in progress is not interrupted despite changes in the scaling of a parameter

0.0.4.0

Configuration data overview Resetting the configuration data

136 099-008196-EW501 27.11.2019

13.2 Resetting the configuration data If required, the set configuration parameters can be reset to the factory settings without using the PC

software.

In that case, please carry out the following steps:

Set jumper JP1.

Switch off power source and interrupt the external voltage supply, if present.

Switch power source back on again, LEDs 7 to 10 should be flashing simultaneously.

Switch off power source and remove jumper JP1.

Switch power source back on again.

Service documents Circuit diagrams

099-008196-EW501 27.11.2019 137

14 Service documents

14.1 Circuit diagrams

Figure 14-1

Appendix Searching for a dealer

138 099-008196-EW501 27.11.2019

15 Appendix

15.1 Searching for a dealer Sales & service partners

www.ewm-group.com/en/specialist-dealers

"More than 400 EWM sales partners worldwide"

BUSINT X11 ATCASE (Phoenix, alpha Q)Operating instructions . Interface for digital wel EN ding power...

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