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Yaskawa WeldCom Interface
for DX100
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V 1.0 / Nov. 2009 - Hummelbrunner A.
Yaskawa WeldCom Interface
WeldCom ASF (ArcStart file):
Select wire type / wire diameter / gas type / weld process (Weld user file 1 - 16)
In „Synergic Mode“ select: (ArcStart condition file 1 - 1000)
- Start current / main current / synchropulse parameter
- Gas preflow & gas postflow etc.
In Job Mode Select: (Fronius Job# 1-99)
- Job number
Two or Powersources possible at :
- Powersource 1 use ArcStart condition file 1 - 500
- Powersource 2 use ArcStart condition file 501 - 1000
WeldCom AEF (ArcEnd file):
Select wire type / wire diameter / gas type / weld process (Weld user file 1 - 16)
In „Synergic Mode“ select: (ArcStart condition file 1 - 1000)
- End current 1 / end current 2
In Job Mode Selct: (Fronius Job# 1-99)
- Job number
Two or Powersources possible at :
- Powersource 1 use ArcEnd condition file 1 - 500
- Powersource 2 use ArcEnd condition file 501 - 1000
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Programming example Std./Puls/CMT-Mode for DX100 Controller
Current
Mainparameter
from ASF #40
Mainparameter
from ASF #112
Startparameter
from ASF #40
arcstart ASF # 40
ASF - ArcStart condition file:
ASF 1 - 500 --> Used for P.S.1
ASF 501 - 1000 --> Used for P.S. 2
Endparam.
from AEF #1
Endparam. 1
Endparam.
from AEF #1
Endparam. 2
arcset ASF #112 Acond = 1
Acond = 0
Robot use only the Startparameter from ASF
(Change of Weld user file is possible i.e. CMT/Puls)
arcend AEF #1
time
If you don‘t like to use the ArcEnd parameter 2
disable the parameter
Robot waits at the same point for the adjusted time
ArcStart condition file stors (1 - 1000):
Acond = 1
* Startparameter
Robot use only the Mainparameter from ASF
* Mainparameter
(Change of Weld user file is possible i.e. CMT/Puls)
ArcEnd condition file stors (1 - 1000):
* Endparameter 1
* Endparameter 2
Weld user file stors (1 - 16):
* Program setting (Puls/Std./CMT)
* Gas/Wire setting
* Synchropulse setting
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Programming example Std./Puls/CMT-Mode for DX100 Controller
Current
Mainparameter
from ASF #40
Mainparameter
from ASF #112
Startparameter
from ASF #40
arcstart ASF # 40
Endparam.
from AEF #1
Endparam. 1
Endparam.
from AEF #1
Endparam. 2
arcset ASF #112 Acond = 1
arcend AEF #1
time
ASF - ArcStart condition file:
ASF 1 - 500 --> Used for P.S.1
ASF 501 - 1000 --> Used for P.S. 2
ArcStart cond. file stors (1 - 1000):
* Startparameter
* Mainparameter
ArcEnd cond. file stors (1 - 1000):
* Endparameter 1
* Endparameter 2
Robot Speed always comes from ASF - MainCond. !
(If A1P005 parameter is set to 1)
Attention:
* Please don‘t use gaspurge time longer than 1.6 sec.
because after 2 sec the arc confirmation fault will appear!
* Fronius start parameter/end parameter will be overwritten
by controller in Std./Puls/CMT-Mode
If you don‘t like a
second end parameter disable the check box
Weld user file stors (1 - 16):
* Program setting (Puls/Std./CMT)
* Gas/Wire setting
* Synchropulse setting
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Programming example Std./Puls/CMT-Mode with slope for DX100 Controller
Current
Mainparameter
from ASF #40
Mainparameter
from ASF #112
Startparameter
from ASF #40
Endparam.
from AEF #1
Endparam. 2
arcset ASF #112 Acond = 1
arcstart ASF # 40
ASF - ArcStart condition file:
ASF 1 - 500 --> Used for P.S.1
ASF 501 - 1000 --> Used for P.S. 2
Endparam.
from AEF #1
Endparam. 1
Acond = 0
Robot uses only the Startparameter from ASF
(Change of Weld user file is possible i.e. CMT/Puls)
arcend AEF #1
time
If you don‘t like to use the ArcEnd parameter 2
disable the function
Robot waits at the same point for the adjustet time
Arc Start condition file stors (1 - 1000):
Acond = 1
* Startparameter
Robot uses only the Mainparameter from ASF
* Mainparameter
(Change of Weld user file is possible i.e. CMT/Puls)
Arc End condition file stors (1 - 1000):
* Endparameter 1
* Endparameter 2
Weld user file stors (1 - 16):
* Program setting (Puls/Std./CMT)
* Gas/Wire setting
* Synchropulse setting
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Programming example Std./Puls/CMT-Mode with slope for DX100 Controller
Current
Mainparameter
from ASF #40
Mainparameter
from ASF #112
Startparameter
from ASF #40
arcstart ASF # 40
Endparam.
from AEF #1
Endparam. 1
Endparam.
from AEF #1
Endparam. 2
arcset ASF #112 Acond = 1
arcend AEF #1
time
ASF - ArcStart condition file:
ASF 1 - 500 --> Used for P.S.1
ASF 501 - 1000 --> Used for P.S. 2
ArcStart condition file stors (1 - 1000):
* Startparameter
* Mainparameter
ArcEnd condition file stors (1 - 1000):
* Endparameter 1
* Endparameter 2
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Programming example Job-Mode for DX100 Controller
Start time and
Start current from Job 1 Slope time from Job 1 Main current from Job 1
Job slope
Main current from Job 12
End time and
Slope time from Job 56 End current from Job 56
Current
ASF #2 =
Job 12
ASF #1 =
Job 1
arcstart ASF #1
ASF - ArcStart condition file:
ASF 1 - 500 --> Used for P.S.1
ASF 501 - 1000 --> Used for P.S. 2
arcset ASF #2 Acond = 1
AEF #3 =
Job 56
arcend AEF #3
time
Acond = 1
Robot uses only the
Correction parameter from ASF
ArcStart condition file stors (1 - 1000:
* Job number
ArcEnd condition file stors (1 - 1000):
* Job number
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Programming example Job-Mode for DX100 Controller
Current
Start time and
Start current from Job 1 Slope time from Job 1 Main current from Job 1
Job slope
Main current from Job 12
ASF #2 =
Job 12
ASF #1 =
Job 1
arcstart ASF #1
Attention:
* Please don‘t use gaspurge time longer
than 1.6 sec. because after 2 sec the arc
confirmation fault will appear!
arcset ASF #2 Acond = 1
End time and
Slope time from Job 56 End current from Job 56
AEF #3 =
Job 56
arcend AEF #3
time
Robot Speed always comes from ASF - MainCond. !
(If A1P005 parameter is set to 1)
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Wire stick control:
* Enable Wire stick function at NX Controller;
* Enable Wire stick function at Fronius powersource
* In the unlightly event that the wire sticks now to the weldpool the
Controller should restart the powersource.
Change parameter during welding:
* Switch to „Play mode“
* Go to „Utility“ and select „Cond Adjustment“
--> Current will adjust the wire feed speed
--> Voltage will adjust Arc-length correction
increase the parameter with „ 3 “ Key
decrease the parameter with „ - “ Key
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Retry Mode:
If you enable this the Controller restarts the Power Source if you
have no ignition.
To set up this function go to the „Arc Auxiliary Cond“ file
Arc failure restart:
This describes what the Power Source does if you loose the arc
during welding.
To set up this function go to the „Arc Auxiliary Cond“ file
Change the language:
Press „Shift“ & „Area“ Key
Welding after „Hold“:
If you are in Automatic Mode and you press „HOLD“ the Controller stops immediately.
After you press „START“ the Controller should restart welding. If he doesn´t restart please check the „A1P9“ Parameter.
A1P9 --> „1“ If you press „START“ Controller starts moving without welding
A1P9 --> „0“ If you press „START“ Controller starts moving with welding
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Speed data input:
If you like to switch form m/min or cm/min to inch/min
Got to: Setup / Operate Condition setting
Arc Monitor:
Possibility to visualize current/voltage and wire feed speed
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Welding in TeachMode (Please load „xxxxxxxx“):
First you have to enable this function:
Go to Parameter FD70 and set this parameter to „1“
Second step is go to „Management Mode“:
Welding in TeachMode is only possible in „Management Mode“
Password for „Management Mode“ is „999999999“
Third step is enable welding in TeachMode:
If following Key is „ON“ welding in TeachMode is possible:
* „USAGE“ Key
* „Weld ON/OFF“
Welding speed from „Program“ or from „ASF/AEF:
First you have to enable this function:
Go to Parameter - A1P005
This Parameter is standard “0“ --> this means that the welding speed comes from the „Program“ regardless
which speed is set at ASF/AEF file
If you set this parameter to „1“ --> this means that the welding speed comes from ASF/AEF regardless
which speed is set in the „Program“
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Signals for Power Source 1:
* OT# 2044 - Gas Test
* OT# 2047 - Wire inching
* OT# 2048 - Wire retract
* OT# xxxx - Torch blow out
* OT# xxxx - Master selection Twin
* IN# xxxx - Wire available
* IN# xxxx - Limit Signal only with RCU5000
All this Signals are mapped standard to the „Universal
Inputs/Outputs“. If a signal i.e.: „arc start“ is required,
we can map this with the „concurrent I/O ladder“ by our own.
i.e.:
# 01287
# 30050
Switch of Welding in Automatic Mode:
* Go to „Utility“ and „Setup special run“
* „Check-Run“ change to „Valid“
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Gas preflow during moving:
Gas preflow from TPSxxxx:
The gas preflow time is controlled by Controller, the Controller
purche the gas during moving to the start position for desired gas
preflow time.
The gas preflow time is controlled by PowerSource, the Controller
stops for desired gas preflow time.
Gas purge on during
robot movement
Robot waits desired gas
preflow time before moving
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Features for DX100 Controller
Frontpanel selection:
Standard Fronius Frontpanel:
US Fronius Frontpanel:
CMT Fronius Frontpanel:
RCU 5000:
Remote Frontpanel:
WeldCom Frontpanel:
User cannot select different Frontpanel Types
User can choose Frontpanel Type
RCU 5000 has priority
over the other Frontpanels
WeldCom Version NS1.40 - Seiichiro Fukushima & Kazuhiro Yasutomi & Hummelbrunner A.
Yaskawa WeldCom Interface
Touch sensing with WeldCom Interface NX/DX Controller
Requirements:
* WeldCom Interface (I-Kit Ethernet inside 4,045,983 & Software Config WeldCom 4,062,011
* ROB 3000 - 4,100,254 or
High Speed touch sensing - 4,100,419
How to connect:
ROB 3000:
Bridge DI2 - Quick Stop - Pin 10 to 11
Yaskawa Controller:
Connect DO2 - Current Flow Signal - Pin 7 - „+ 24V2“ to Robot system input terminal block (MXT)
Pin 8 - „AXDIN1“ to Robot system input terminal block (MXT)
Bridge on terminal block (MXT) „AXDIN COM“ to „0 24V“
WeldCom - Seiichiro Fukushima & Hummelbrunner A.
Yaskawa WeldCom Interface
Touch sensing with WeldCom Interface NX/DX Controller
How to use:
For touch sensing use the „SRCH (search Instruction)
If you don‘t see the „SRCH“ command in the instruction menue check if following menue is enabled:
Got to:
Setup
Teach Condition
Language level to „expanded“
WeldCom - Seiichiro Fukushima & Hummelbrunner A.
Modbus
Protocol description
The MODBUS application data unit is built by the client that initiates a MODBUS transaction. The function indicates to the server what kind of action to perform. The MODBUS
application protocol establishes the format of a request initiated by a client.
The function code field of a MODBUS data unit is coded in one byte. Valid codes are in
the range of 1 ... 255 decimal (128 – 255 reserved for exception responses). When a
message is sent from a Client to a Server device the function code field tells the server
what kind of action to perform.
Sub-function codes are added to some function codes to define multiple actions.
The data field of messages sent from a client to server devices contains additional
information that the server uses to take the action defined by the function code. This can
include items like discrete and register addresses, the quantity of items to be handled,
and the count of actual data bytes in the field.
The data field may be nonexistent (of zero length) in certain kinds request, in this case
the server does not require any additional information. The function code alone specifies
the action.
If no error occurs related to the MODBUS function requested in a properly received
MODBUS ADU the data field of a response from a server to a client contains the data
requested. If an error related to the MODBUS function requested occurs, the field
contains an exception code that the server application can use to determine the next
action to be taken.
For example a client can read the ON / OFF states of a group of discrete outputs or
inputs or it can read/write the data contents of a group of registers.
When the server responds to the client, it uses the function code field to indicate either a
normal (error-free) response or that some kind of error occurred (called an exception
response). For a normal response, the server simply echoes the original function code.
Data encoding
MODBUS uses a ‘big-Endian’ representation for addresses and data items. This means
that when a numerical quantity larger than a single byte is transmitted, the most significant byte is sent first.
Register size
16 Bit 0x1234
Value
the first byte sent is
3
0x12 then 0x34
Application Data
Unit (ADU)
This section describes the encapsulation of a MODBUS request or response when it is
carried on a MODBUS UDP network.
MPAP Header
Function code
Data
MPAP Header description:
Transactions Identifier
It is used for transaction pairing, the MODBUS server copies in the response the transaction identifier of the request.
Length:
Description:
Client:
Server:
2 Byte
Identification of a MODBUS Request / Response transaction
Initialized by the client
Recopied by the server from the received request
Protocol Identifier
It is used for intra-system multiplexing. The MODBUS protocol is identified by the value
0.
Length:
Description:
Client:
Server:
2 Byte
0 = Modbus protocol
Initialized by the client
Recopied by the server from the received request
Length
The length field is a byte count of the following field, including the Unit Identifier, Function
code and the data field.
Length:
Description:
Client:
Server:
2 Byte
Number of following bytes
Initialized by the client
-
Unit Identifier
This field is used for intra-system routing purpose. It is typically used to communicate to
a MODBUS or MODBUS+ serial line slave through a gateway between an Ethernet
network and a MODBUS serial line. This field is set by the MODBUS Client in the request and must be returned with the same value in the response by the server.
Length:
Description:
Client:
Server:
1Byte
Identification of a remote slave connected on a serial line or on other
buses
Initialized by the client
Recopied by the server from the received request
Important! All MODBUS/UDP ADU are sent via UDP on registered port 502.
4
Exception codes
Code 0x01 Illegal Function
The function code received in the query is not an allowable action for the server (or
slave). This may be because the function code is only applicable to newer devices, and
was not implemented in the unit selected. It could also indicate that the server (or slave)
is in the wrong state to process a request of this type, for example because it is unconfigured and is being asked to return register values.
Code 0x02 Illegal Data
Address
The data address received in the query is not an allowable address for the server (or
slave). More specifically, the
combination of reference number and transfer length is invalid. For a controller with 100
registers, a request with offset 96 and length 4 would succeed, a request with offset 96
and length 5 will generate exception 02.
Code 0x03 Illegal Data Value
A value contained in the query data field is not an allowable value for server (or slave).
This indicates a fault in the
structure of the remainder of a complex request, such as that the implied length is
incorrect. It specifically does NOT mean that a data item submitted for storage in a
register has a value outside the expectation of the application program, since the
MODBUS protocol is unaware of the significance of any particular value of any particular
register.
Code 0x04 Slave Device
Failure
An unrecoverable error occurred while the server was attempting to perform the requested action.
What is the reason for this error:
License Gateway Level 1 (4,061,115) not installed in the power source
Modbus protocol not activated (UniveralBusSteuerung -> Config)
Wrong Firewall IP address Modbus
Code 0x06 Slave Device
Busy
The server (or slave) is engaged in processing a long-duration command. The client (or
master) should retransmit the message later when the server (or slave) is free.
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