EWM

HIGHTEC WELDING GmbH

Dr. Günter-Henle-Straße 8 • D-56271 Mündersbach
Fon +49 2680 181-0 • Fax +49 2680 181-244
www.ewm.de • info@ewm.de

GB Operating instructions
Interface for digital welding power sources

BUSINT X11

N. B. These operating instructions must be read before commissioning.

Failure to do so may be dangerous.
Machines may only be operated by personnel who are familiar with the appropriate safety
regulations.

The machines bear the conformity mark and thus comply with the
• EC Low Voltage Directive (2006/95/ EG)
• EC EMC Directive (2004/108/ EG)

In compliance with IEC 60974, EN 60974, VDE 0544 the machines can be used in environments
with an increased electrical hazard.

The content of the operating instructions does not constitute grounds for any claims on the part
© of the buyer.
The copyright to these operating instructions remains with the manufacturer.
Reprinting, including extracts, only with written approval.

© 2009 Subject to alteration. Item No.: 099-008225-EWM01 Revised: 05.08.2009

 Mündersbach, 25 February 2009

Dear customer,

Thank you for your order.

Premium quality – made in Germany and with a three-year warranty.

The machines from EWM are impressive, with innovative technology, exceptional user-friendliness and
the most up to date inverter and control systems. This makes welding possible that is simple, efficient
and resource-saving as well as being highly economical!

Perfection doesn't happen by coincidence: Every single component is 100% tested and the machine is
“free welded” before it is delivered.

Our comprehensive service offer and the highly developed modern EWM quality management system
guarantee worldwide premium quality “Made in Germany” and a three-year warranty.
Continual further development and optimisation has made us Germany’s market leader in the
manufacture of light arc welding machines. We have manufacturing, training and service locations
throughout the world to advise you and provide you with a comprehensive range of services.

The accompanying operating instructions contain everything about commissioning the machine, notes
regarding safety, maintenance and care, technical data as well as information regarding the warranty. It
is very important to observe all our instructions in order to achieve optimal welding results with the
machine and to ensure many years of safe operation.

Thank you for the trust that you have placed in us. We look forward to a long-term and, above all,
successful partnership with you.

Yours faithfully

EWM HIGHTEC WELDING GmbH

Bernd Szczesny
Executive management
Machine and Company Data

Please enter the EWM machine data and your company’s data in the appropriate fields.

EWM HIGHTEC WELDING GMBH

D-56271 MÜNDERSBACH
TYP: SNR:

ART: PROJ:

GEPRÜFT/CONTROL: CE

Name of Customer / company Name of Customer / company

Adress Adress

Post code / Place Post code / Place

Country Country

Stamp / Signature of EWM-distibutor Stamp / Signature of EWM-distibutor

Date of purchase Date of purchase

3
Contents
Notes on the use of these operating instructions

1 Contents
1 Contents ..................................................................................................................................................4
2 Safety instructions .................................................................................................................................8
2.1 Notes on the use of these operating instructions...........................................................................8
2.2 General.........................................................................................................................................10
3 General ..................................................................................................................................................11
3.1 Revision........................................................................................................................................11
3.2 Introduction ..................................................................................................................................11
3.3 System overview ..........................................................................................................................11
4 Commissioning.....................................................................................................................................12
4.1 General connection of the BUSINTX11 .......................................................................................12
4.1.1 The system bus ............................................................................................................12
4.1.2 Power supply ................................................................................................................12
4.1.2.1 Internal ..........................................................................................................12
4.1.2.2 External .........................................................................................................12
4.1.3 Connection of fast actual value signals ........................................................................13
4.1.4 Collision protection connection.....................................................................................13
4.2 Basic configuration using plug-in jumpers ...................................................................................13
4.2.1 Selecting fast actual value signals................................................................................13
4.3 Selecting the actuation profile......................................................................................................13
4.4 Field bus connection and configuration .......................................................................................14
4.4.1 Interbus-S optical fibre..................................................................................................14
4.4.1.1 Field bus connection .....................................................................................14
4.4.1.2 Baud rate.......................................................................................................14
4.4.1.3 Status display ................................................................................................14
4.4.1.4 Data capacity.................................................................................................14
4.4.2 CAN Open ....................................................................................................................15
4.4.2.1 Module specification......................................................................................15
4.4.2.2 Module, position of the operating elements ..................................................15
4.4.2.3 Meaning of the LEDs.....................................................................................15
4.4.2.4 Connection of the CANopen module.............................................................16
4.4.2.5 Setting the baud rate .....................................................................................16
4.4.2.6 Setting the subscriber address......................................................................16
4.4.2.7 EDS configuration file....................................................................................16
4.4.3 CAN DeviceNet.............................................................................................................17
4.4.3.1 Module specification......................................................................................17
4.4.3.2 Module, position of the operating elements ..................................................17
4.4.3.3 Meaning of the LEDs.....................................................................................17
4.4.3.4 Connection of the CAN DeviceNet module ...................................................18
4.4.3.5 Network settings............................................................................................18
4.4.3.6 EDS configuration file....................................................................................18
4.4.4 Profibus.........................................................................................................................19
4.4.4.1 Module specification......................................................................................19
4.4.4.2 Module, position of the operating elements ..................................................19
4.4.4.3 Meaning of the LEDs.....................................................................................19
4.4.4.4 Connection of the Profibus module ...............................................................20
4.4.4.5 Setting the subscriber address......................................................................20
4.4.4.6 Baud rate.......................................................................................................21
4.4.4.7 Network termination ......................................................................................21
4.4.4.8 GSD file .........................................................................................................21
4.5 Switching on the BUSINTX11 ......................................................................................................22
4.6 Field bus configuration .................................................................................................................22

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Notes on the use of these operating instructions

5 Operative mode .................................................................................................................................... 23

5.1 Pre-selecting a JOB ..................................................................................................................... 23
5.2 Program operation ....................................................................................................................... 23
5.3 JOB mode .................................................................................................................................... 23
5.4 Advanced control signal operation............................................................................................... 24
5.5 Operating modes ......................................................................................................................... 25
5.5.1 Non-latched operation ..................................................................................................25
5.5.2 Special, non-latched .....................................................................................................25
5.6 Welding types .............................................................................................................................. 26
5.7 Monitoring function....................................................................................................................... 26
5.7.1 Monitoring function .......................................................................................................26
5.7.2 Display options .............................................................................................................27
5.7.3 Monitoring parameters .................................................................................................27
5.7.4 Special features of the monitoring function ..................................................................28
5.8 Other signals................................................................................................................................ 29
5.8.1 JOB pre-selection .........................................................................................................29
5.8.2 Program pre-selection ..................................................................................................29
5.8.3 Acknowledge error........................................................................................................29
5.8.4 Gas test 1 .....................................................................................................................29
5.8.5 Wire Inching..................................................................................................................29
5.8.6 Reverse wire inching ....................................................................................................29
5.8.7 Cold wire on..................................................................................................................29
5.8.8 Start auxiliary process ..................................................................................................29
5.8.9 Position search .............................................................................................................29
5.8.10 Blow out torch...............................................................................................................29
5.8.11 Robot ready ..................................................................................................................29
5.8.12 Welding simulation .......................................................................................................30
5.8.13 JOB mode.....................................................................................................................30
5.8.14 User-defined output ......................................................................................................30
5.8.15 WF switching ................................................................................................................30
5.8.16 TANDEM operation (PHOENIX only) ...........................................................................30
5.9 Check-back of the process parameters .......................................................................................30
5.9.1 I > 0 (Current flows signal) ...........................................................................................30
5.9.2 User-defined inputs ......................................................................................................30
5.9.3 Process active ..............................................................................................................30
5.9.4 Main current signal .......................................................................................................30
5.9.5 Collision protection .......................................................................................................30
5.9.6 Ready for welding.........................................................................................................31
5.9.7 Sticking ......................................................................................................................... 31
5.9.8 Error number ................................................................................................................31
5.9.9 Actual welding voltage value ........................................................................................31
5.9.10 Actual welding current value ........................................................................................31
5.9.11 Actual wire feed speed value .......................................................................................31
5.9.12 Actual motor current value ...........................................................................................31
5.9.13 Parameter monitoring ...................................................................................................31
5.9.14 I > 0 Auxiliary process ..................................................................................................31
5.9.15 Process signals diagram ..............................................................................................31
5.10 Signals for matching with the positioning device .........................................................................33
5.10.1 Ignition time: TZ-Zünd ..................................................................................................33
5.10.2 TZ-Set........................................................................................................................... 33
5.10.3 Arc interruption time for TZ-LIBO .................................................................................34
5.10.4 The return time TZ-RESET ..........................................................................................35
5.11 Fusing detection........................................................................................................................... 35
5.12 Position search ............................................................................................................................ 35
5.13 Welding seam tracking ................................................................................................................ 36
5.14 Welding simulation....................................................................................................................... 36
5.15 Process fast shut-down ............................................................................................................... 36
5.16 Process safety shut-down............................................................................................................ 36

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Contents
Notes on the use of these operating instructions

5.17 JOB safety switching....................................................................................................................37

6 The diagnostics interface ....................................................................................................................38
6.1 PC system requirements..............................................................................................................38
6.2 Commissioning.............................................................................................................................38
6.3 Scope of diagnostics ....................................................................................................................38
7 Profiles for PHOENIX MIG/MAG systems ..........................................................................................39
7.1 Profiles for the Interbus-S (copper), Interbus-S LWL (FSMA) and Interbus-S (Rugged Line)
modules........................................................................................................................................39
7.1.1 Default profile (switch position 0)..................................................................................39
7.2 Profiles for the CANopen module ................................................................................................44
7.2.1 Reis Robotics profile (switch position 0).......................................................................44
7.3 Profiles for the CAN DeviceNet module.......................................................................................49
7.3.1 Default profile (switch position 0)..................................................................................49
7.3.2 Profile 1 (switch position 1)...........................................................................................53
7.4 Profiles for the Profibus DP module.............................................................................................58
7.4.1 Default profile (switch position 0)..................................................................................58
7.4.2 Flexible profile (switch position 1).................................................................................62
7.4.3 Compatible profile (switch position 2)...........................................................................66
8 Profiles for TETRIX TIG and plasma systems ...................................................................................70
8.1 Profiles for the CANopen module ................................................................................................70
8.1.1 Default profile 1 (switch position 0)...............................................................................70
8.1.2 Profile 1 (switch position 1, program mode) .................................................................73
8.1.3 Profile 2 (switch position 2, control signal mode) .........................................................77
8.2 Profiles for the CAN DeviceNet module.......................................................................................83
8.2.1 Default profile (switch position 0)..................................................................................83
8.2.2 Profile 1 (switch position 1)...........................................................................................86
8.2.3 Profile 2 (switch position 2, program mode) .................................................................90
8.2.4 Profile 3 (switch position 3, control signal mode) .........................................................93
8.3 Profiles for the Profibus/Interbus module.....................................................................................98
8.3.1 Default profile (switch position 0)..................................................................................98
8.3.2 Profile 1 (switch position 1, program mode) ...............................................................101
8.3.3 Profile 2 (switch position 2, control signal mode) .......................................................104
8.4 Profile on the Interbus Module ...................................................................................................109
8.4.1 Default profile (switch position 0)................................................................................109
8.4.2 Profile 1 (switch position 1, program mode) ...............................................................112
8.4.3 Profile 2 (switch position 2, control signal operation, slow pulses).............................115
8.4.4 Profile 3 (switch position 3, control signal operation, fast pulses) ..............................119
9 Special field bus features when setting up the field bus modules ...............................................123
9.1 CAN DeviceNet ..........................................................................................................................123
9.1.1 Connections................................................................................................................123
9.1.2 Example for I/O data...................................................................................................123
9.1.3 Example of a connection assignment.........................................................................124
9.2 Profibus DP ................................................................................................................................124
9.2.1 The watchdog .............................................................................................................124
9.2.2 DP features.................................................................................................................124
10 Operating problems, causes and remedies.....................................................................................125
10.1 Operating displays (LEDs) .........................................................................................................125
10.2 Error messages on the system ..................................................................................................126
11 Overview of plug configurations ......................................................................................................128
11.1 X4, digital inputs.........................................................................................................................128
11.2 X5, digital outputs.......................................................................................................................128
11.3 X7, analogue inputs ...................................................................................................................128
11.4 X10, diagnostics interface ..........................................................................................................129
11.5 X15, external power supply........................................................................................................129

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Notes on the use of these operating instructions

12 Overview of jumper assignments BUSINTX11 Rev00 ....................................................................130

13 Overview of machine software functions (firmware) .....................................................................131
13.1 PHOENIX machine software (firmware) ....................................................................................131
13.2 TETRIX machine software (firmware)........................................................................................131
14 Warranty..............................................................................................................................................132
14.1 General Validity..........................................................................................................................132
14.2 Warranty Declaration .................................................................................................................133
15 Circuit diagrams.................................................................................................................................134

Item No.: 099-008225-EWM01 7

Safety instructions
Notes on the use of these operating instructions

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

CAUTION
Working and operating procedures which must be followed precisely to avoid damaging
or destroying the product.
• The safety information includes the "CAUTION" keyword in its heading without a general
warning symbol.
• The hazard is explained using a symbol at the edge of the page.

NOTE
Special technical points which users must observe.
• Notes include the "NOTE" keyword in the heading without a general warning symbol.
• Notes are highlighted using a "hand" symbol at the edge of the page.

8 Item No.: 099-008225-EWM01

 Safety instructions
Notes on the use of these operating instructions

Instructions and lists detailing step-by-step actions for given situations can be recognised via bullet
points, e.g.:
• Insert the welding current lead socket into the relevant socket and lock.

Symbol Description
Press

Do not press

Turn

Switch

0
1 Switch off machine

0
1 Switch on machine

ENTER (enter the menu)

NAVIGATION (Navigating in the menu)

EXIT (Exit the menu)

Time display (example: wait 4s/press)

Interruption in the menu display (other setting options possible)

Tool not required/do not use

Tool required/use

Item No.: 099-008225-EWM01 9

Safety instructions
General

2.2 General
WARNING
Risk of accidents if these safety instructions are not observed!
Non-observance of these safety instructions is potentially fatal!
• Carefully read the safety information in this manual!
• Observe the accident prevention regulations in your country.
• Inform persons in the working area that they must observe the regulations!
Validity of this document!
This document is only valid in combination with the operating instructions for the power
source being used (welding machine)!
• Read the operating instructions, in particular the safety instructions for the power source
(welding machine)!

CAUTION
Obligations of the operator!
In the European Economic Area (EEA), the relevant national version of the basic
guidelines must be followed and observed!
• National version of the basic guidelines (89/391/EEC) as well as the relevant individual
guidelines.
• In particular the Directive (89/655/EEC) on the minimum regulations for safety and health
protection when staff members are using equipment during work.
• The accident prevention regulations of the relevant country (e.g. in Germany, BGV D 1).
• Check at regular intervals that users are working in a safety-conscious way!
Damage due to the use of non-genuine parts!
The manufacturer's warranty becomes void if non-genuine parts are used!
• Only use system components and options (power sources, welding torches, electrode
holders, 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
machine is switched off.

10 Item No.: 099-008225-EWM01

 General
Revision

3 General
3.1 Revision
Revision Date Change
1.0 26.02.2006 Draft version
1.1 04.08.2006 Official instructions
1.2 23.08.2006 Addition of profiles, overview of interfaces, TETRIX functionality
1.3 23.01.2007 Support for the Profibus DP module
1.4 27.07.2009 Addition of profiles and functions to the software version
042-00897-00002 or 042-00926-00002
3.2 Introduction
The operating instructions below describe the commissioning and functionality of the field bus interface
BUSINTX11 in combination with specific field busses. The interface is intended for operation on digital
power sources in the PHOENIX (MIG/MAG) or TETRIX (TIG) machine series. Separate interfaces are
available for both power source systems. A BUSINTX11 for a PHOENIX system does not have the same
functionality as a BUSINTX11 for a TETRIX system. These are two different interfaces which cannot be
used interchangeably! An interface designed for a TETRIX system does not function on a PHOENIX
power source.
The BUSINTX11 has numerous options for actuation, and these are supported in full by the PC300
welding parameter software. It is advisable to use the PC300 software to set up the BUSINTX11
wherever possible.
3.3 System overview
The table below gives an overview of the interfaces currently available in relation to the welding systems:
Field bus PHOENIX TETRIX
CANopen X X (1)
CAN DeviceNet X X (1)
Interbus FSMA X X (1)
Interbus Rugged Line X X (1)
Profibus X X (1)

(1)
Only in the switching cabinet variant

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Commissioning
General connection of the BUSINTX11

4 Commissioning
This chapter describes for you the commissioning process of the BUSINTX11, step-by-step, as well as its
operating functions.
4.1 General connection of the BUSINTX11
4.1.1 The system bus
The BUSINTX11 is integrated into the PHOENIX/TETRIX welding system using a digital system bus. The
connection can be made in two different ways, depending on the type of installation for the control:
• Connection via the 15-pole SUB-D plug X12 when installing the BUSINTX11 on the power source (in
the suspended casing on the rear of the power source).
• Connection via the 7-pole X13 binder plug connector using the round cable control line. This is the
preferred connection method for external assembly of the BUSINTX11, e.g. in a switching cabinet.
In general with external assembly, it is important to ensure that the bus cabling for connecting the
BUSINTX11 to the relevant field bus is as far away as possible from potential sources of interference
(such as HF-carrying cables or cables under load), as otherwise there is a risk of bus assemblies being
damaged by the effects of excess voltages.
4.1.2 Power supply
4.1.2.1 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.
4.1.2.2 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

NOTE
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.

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 Commissioning
Basic configuration using plug-in jumpers

4.1.3 Connection of fast actual value signals

The BUSINTX11 normally supplies actual process values with an update of approx. 30ms for the process
voltage, current, wire speed and motor current process values.
For seam tracking, however, fast signals are required for voltage and current. With the PHOENIX and
TETRIX, these can be provided via the interface for mechanised welding on the BUSINTX11:
Plug Pin Signal
X7 2 Actual process voltage value
X7 3 Actual process current value
X7 4 Reference mass (GND)

NOTE
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
separately!

4.1.4 Collision protection connection

A corresponding signal can be connected to the BUSINTX11 for connecting and powering a torch
collision protection signal on the field bus:
Plug Pin Signal
X4 1 Powering an external collision contact
X4 2 Feedback signal from collision contact

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

4.2 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
during operation.
4.2.1 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
4.3 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
independently of the field bus type, welding system and development status. These are selected using a
selector switch S1 with 16 positions.

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Commissioning
Field bus connection and configuration

4.4 Field bus connection and configuration

Different steps are required for commissioning, depending on the field bus, and these steps are described
below.
4.4.1 Interbus-S optical fibre
No address setting is required for the configuration of the Interbus subscriber as this is given by the
position of the subscriber in the Interbus. The subscriber identifies with the ID3 as a module with digital
I/O.
4.4.1.1 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 4-1
4.4.1.2 Baud rate
The module baud rate can be selected between 500kBaud and 2Mbaud using a jumper.

Figure 4-2
4.4.1.3 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 4-3
4.4.1.4 Data capacity
The data capacity to be configured on the Interbus is based on the data profile being used. See also
chapter “Profiles for PHOENIX MIG/MAG systems”.

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 Commissioning
Field bus connection and configuration

4.4.2 CAN Open

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

Figure 4-4
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
4.4.2.3 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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Commissioning
Field bus connection and configuration

4.4.2.4 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 4-5
4.4.2.5 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.
4.4.2.6 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
carried out in decimal format:
Example: Address 42 = left-hand switch position 4 (x10) + right-hand switch position 2 (x1)

Figure 4-6
4.4.2.7 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 Hightec Welding GmbH if required.

16 Item No.: 099-008225-EWM01

 Commissioning
Field bus connection and configuration

4.4.3 CAN DeviceNet

4.4.3.1 Module specification
The CAN DeviceNet module is implemented in accordance with the ODVA specifications as a
communication adapter (profile no.12) and behaves as a group 2 server on the network.
The data modes Polled, Bit-Strobed and COS/Cyclic are supported.
4.4.3.2 Module, position of the operating elements
The CAN-DeviceNet module has a variety of operating elements arranged on the PCB side:

Figure 4-7
Element no. Meaning
2 CAN DeviceNet interface
3 Configuration switch
4 Status displays
4.4.3.3 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
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 4-8

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Commissioning
Field bus connection and configuration

4.4.3.4 Connection of the CAN DeviceNet module

The field bus is connected via a 5-pole panel connector as follows:
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 4-9

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

4.4.3.5 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 Switch 4 Switch 5 Switch 6 Switch 7 Switch 8
(MSB) (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

4.4.3.6 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.

NOTE
For the remaining steps in the setup process, please refer to the "Special field bus
features when setting up the field bus modules" chapter.

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 Commissioning
Field bus connection and configuration

4.4.4 Profibus
4.4.4.1 Module specification
The Profibus module supports cyclical data exchange according to the PROFIBUS-DP EN 50 170
specification (DIN 19245).
4.4.4.2 Module, position of the operating elements
The Profibus module has a variety of operating elements arranged on the PCB side:

Figure 4-10
4.4.4.3 Meaning of the LEDs
The module is fitted with a block of 4 LEDs that signal the status of the module during operation:
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
possible
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.

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Commissioning
Field bus connection and configuration

4.4.4.4 Connection of the Profibus module

The field bus is connected via a 9-pole SUB-D plug connector (socket) as follows:
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 4-11
4.4.4.5 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
carried out in decimal format:
Example: Address 42 = left-hand switch position 4 (x10) + right-hand switch position 2 (x1)

Figure 4-12

NOTE
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.

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 Commissioning
Field bus connection and configuration

4.4.4.6 Baud rate

The module is equipped with automatic baud rate detection and therefore requires no additional setting
work.
The following baud rates are supported:
9.6kbit/s, 19.2kbit/s, 93.75kbit/s, 187.5kbit/s, 500kbit/s, 1.5Mbit/s, 3Mbit/s, 6Mbit/s, 12Mbit/s
4.4.4.7 Network termination
The Profibus network must be terminated on the line terminals to avoid signal reflections on the bus
medium. 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
external 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”.
4.4.4.8 GSD file
The subscriber configuration is carried out via the GSD file supplied.

NOTE
For the remaining steps in the setup process, please refer to the "Special field bus
features when setting up the field bus modules" chapter.

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Commissioning
Switching on the BUSINTX11

4.5 Switching on the BUSINTX11

The interface is either switched to ‘ready for operation’ status by switching on the connected power
source or by switching on the external power supply (if fitted). The module runs through a variety of steps
for self-diagnostics and tests the readiness of individual components.
If an error is detected in this process, it is displayed via a combination of flashing signals from LEDs 7 and
8. The module is then either not ready for operation, or only to a limited degree.
The error display is initiated via a flashing code with signals of 1s duration from LED 7. The number of the
subsequent flashing signals (approx. 2Hz) from LED 8 then produces the error code:
Number of flash Number of Meaning
codes from LED7 flash codes
(error type) from LED8
(error)
1 1 Error determining the module configuration
1 2 For internal use only
1 3 Error initialising the operating memory
2 1 Field bus module is not fitted or is faulty
2 2 Error initialising the module
2 3 Module is not supported by the current software version
2 4 Profile set is not assigned; the default profile will be transferred
and the interface is ready for operation despite the error display
3 1 Unsupported power source type; an attempt has been made to
operate a TETRIX power source on a BUSINTX11 PHOENIX or
vice versa
The error code is repeated cyclically, whereby the sequence starts at LED7 again.
When the diagnostics are successfully completed, no flash code is output on LEDs 7 and 8. If the power
source is switched on, LEDs 11 and 12 should start to flash at high frequency in a short period of time.
The module is now ready for configuration via the field bus.
4.6 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.

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 Operative mode
Pre-selecting a JOB

5 Operative mode
5.1 Pre-selecting a JOB
The PHOENIX has a wide range of adjustable parameters available which are managed using what are
known as JOBs. The corresponding welding task is defined using a JOB. A total of 255 JOBs can be set
(1 to 255).
The JOB pre-selection can only be carried out by the machine if the “Machine JOB pre-selection” bit has
been set (set automatically in some actuation profiles and does not appear in the actuation profile). Only
then can a valid JOB be specified. If the JOB pre-selection is deactivated, a JOB can be specified by the
M31x control unit for the PHOENIX.
JOBs can be pre-selected only when the system is at a standstill (no welding operation). If the
PLC occupies a different JOB number at runtime, however, the set JOB number is stored
temporarily in the module and the switching is carried out when the welding process is ended.
There is no switching if a completed switching has been cancelled again during the welding
process.
5.2 Program operation
Up to 16 programs can be pre-selected in the PHOENIX. Each program directly specifies an assignment
to a wire feed value, a voltage correction, as well as a dynamic value (PHOENIX) and welding current
and cold wire for TETRIX systems, which are stored in the relevant JOB set on the power source.
Program numbers 1-15 stand for pre-programmed values.
Program 0 is a special case and is intended for what is known as control signal operation. Here the
values for WF, correction voltage and dynamics for PHOENIX systems and for welding current and cold
wire for TETRIX system are specified directly via “analogue” input signals.
If these bytes are assigned other values during normal program operation (1-15), the new parameters are
stored temporarily in the module and transferred to the power source during the changeover to program
0.
The program can only be selected if the “Machine program pre-selection” bit (is automatically set in some
actuation profiles and does not appear in the actuation profile) has been activated.
5.3 JOB mode
The JOB mode is available as an alternative operating type. In program mode or control signal mode, the
settings for welding type (normal welding/pulses) and operating mode (non-latched/non-latched special)
are carried out via individual actuation signals. In JOB mode these settings are permanently stored in the
power source using program numbers and can be pre-selected directly using those numbers. Every
program is also assigned the superpulse function. The JOB mode is set via the relevant signal and as an
alternative can be permanently set via jumper JP4.
The JOB mode can only be changed when the system is at a standstill.

NOTE
Job mode can also be activated via jumper JP4 if the signal is not included in the data
profile.

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Operative mode
Advanced control signal operation

5.4 Advanced control signal operation

The control signal operation has been improved in comparison to software version 01. The expanded
control signal operation is activated automatically once a specific software version is available in the
power source (see also chapter 13). With TETRIX systems, the BUSINT X11 has a range of further
control voltages in addition to the main current and cold wire.
A new signal has been defined for motor on/off. For the inching function this means that there is a signal
independent of the inching signal which can be used to realise separate inching functions together with
the control signal specification for the cold wire.

NOTE
The "Motor on" function is not available with PHOENIX systems!
The "Motor on" signal takes priority over the signals for inching and reverse inching!

The manual gas control function is controlled in the same way on PHOENIX and TETRIX systems and
permits separate gas pre-flows and post-flows.
A safety function is used to ensure the following aspects with regard to the gas:
• If no gas has been activated at the beginning of the process, it is switched on automatically
• The gas cannot be deactivated whilst a process is running; if the gas is required to be deactivated, the
gas is shut off automatically when the process is switched off. This corresponds to a gas post-flow
duration of 0.
The control of the cold wire in TETRIX systems means that any function can be carried out in the
process. The responses of the cold wire are as follows:
• If the motor is activated without nominal value (motor on), the motor is not started; if the process is
then ended, this does not result in any motor action
• The motor starts once "Motor on" has been issued and there is a nominal value in force. If the motor
signal is removed in the process, the wire is retracted immediately with the retraction that can be set
on the PC300.NET.
• If the nominal value is set to 0 in the process with the motor activated, the motor will remain without
retraction. Another nominal value then restarts the motor.
• If the wire in the process has been triggered to retract due to the control signal being removed, the
wire is moved forwards again by the advance path (that can also be set as required) after the
adjustable delay time elapses. This means that the wire is then in the optimum position once again.

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 Operative mode
Operating modes

5.5 Operating modes

There are 2 different operating modes available.
It is necessary to define the program sequence in order to understand the operating modes. The program
sequence describes a series of welding program steps which are processed in sequence, starting with
ignition, and ending with the end of the welding process.
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
(depending on the operating mode)
Reduction program P3
This program is used in the “Superpulses” welding type for the PHOENIX and for the “Thermal pulses”
type for the TETRIX. It is activated alternately with the main welding program currently active and an
adjustable 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.
5.5.1 Non-latched operation
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.
5.5.2 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
(according 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 now also be switched over during welding operation from software
version 01. This means that the non-latched special mode can be modified in a flexible way.

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Operative mode
Welding types

5.6 Welding types

In welding mode a distinction is made between different modes (depending on the welding system).
The welding type can be changed both when the system is at a standstill and during operation. In JOB
mode the relevant information on the welding type is taken from the active program for the current JOB.
5.7 Monitoring function
The BUSINTX11 is able to monitor the welding process continuously using a special monitoring function.
Various signals are available for this purpose, depending on the module operating modes.
The monitoring function is only available for PHOENIX systems.
Activating the monitoring function
Activates the monitoring function.
Parameters
There are currently 4 welding parameters used for monitoring:
• Welding voltage
• Welding current
• Wire feed speed
• Maximum armature current of the wire conveyor drive
A separate response time can be specified for 2 of the parameters. Each individual monitoring parameter
is assigned a separate tolerance value.
5.7.1 Monitoring function
Different nominal values for the welding voltage, welding current and wire feed are set for the process
using the relevant PHOENIX operating mode. Each tolerance parameter specifies for the process value
being monitored a tolerance field within which it may vary. The motor current is treated here as a
maximum value; the check carried out is only whether or not that value is exceeded.
If a parameter goes outside its assigned tolerance range for the defined response time, an alarm
message is generated in the system. This message is of a passive nature and does not affect the welding
process. The decision to continue or cancel the welding process is made by the higher lever control. The
alarm message for the individual parameter is cancelled when the actual value moves back into the
tolerance range.
Individual monitoring channels can be shut down in a targeted way by parameterising the tolerance
values to the value 0.

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 Operative mode
Monitoring function

5.7.2 Display options

An alarm message is generated in one of two ways:
• Output via collective indication output (relay) on the module (see chapter 10.2)
• Output of the individual channels via the field bus data with the following assignments:
Bit no. 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.
5.7.3 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
tolerance/max. motor current; this common response time can be set in the range 10ms to 20s in 10ms
increments.

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Operative mode
Monitoring function

5.7.4 Special features of the monitoring function

Duration
The parameter monitoring takes place only in the static conditions (main welding and reduction welding
programs), which prevents error messages from dynamic alterations, such as for ramp overruns.
Fault reduction
A hysteresis method on the monitoring limits prevents the message generator “fluctuating” in the
tolerance band limit ranges.
Parameter
The settings for the monitoring function are stored per JOB and are stored as follows in the program
sequence:

Figure 5-1
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
monitoring 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.

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 Operative mode
Other signals

5.8 Other signals

5.8.1 JOB pre-selection
Permits the specification of welding tasks (JOBs) by the machine. With the signal not set, the setting of
the JOB must be carried out via another control (e.g. M31x). With an active signal the setting of the JOB
is transferred (signal is automatically set in some actuation profiles and is not then visible in the profile).
5.8.2 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
Program mode chapter). With a signal not set, program 1 is permanently set by the control (signal is
automatically set in some actuation profiles and is not then visible in the profile).
5.8.3 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 also the
error list in chapter “Error messages on the system “).
5.8.4 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.
5.8.5 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.
5.8.6 Reverse wire inching
Permits the retraction of the wire; can only be switched over when the system is at a standstill. Before
activation, the “Wire inching” needs to be cleared.
5.8.7 Cold wire on
In TETRIX systems with cold wire equipment, the cold wire is started with this signal.
The signal can be used together with the nominal value in control signal mode to create separate inching
functions.
5.8.8 Start auxiliary process
Starts an auxiliary process where applicable. To initiate the start signal, set the “Robot ready” signal first.
5.8.9 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 also chapter “Position search”).
5.8.10 Blow out torch
Allows a secondary gas to be activated/deactivated manually (compressed air is normally used to blow
out the torch). The signal can only be issued when the system is at a standstill.
5.8.11 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 also chapter “Process fast shut-down”).

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Operative mode
Check-back of the process parameters

5.8.12 Welding simulation

Activates the simulation of the welding process signals for the actual programming/testing of automation
controls without active welding process with complete signal exchange (see also chapter “Welding
simulation”).
5.8.13 JOB mode
In this mode the information for operating type and welding type are not taken from individual actuation
signals, but rather from the welding program actuated.
5.8.14 User-defined output
This signal can be used to activate the user-defined relay output on the module.
5.8.15 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”
option).
5.8.16 TANDEM operation (PHOENIX only)
This function is available as an optional software and in PHOENIX systems permits the control of one
power source in each case (for TANDEM systems, 2 BUSINTX11 are required). The input signal is used
to determine which power source is the documented power source in the TANDEM combination.
On non-actuation, the power source is configured as the slave.
5.9 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
chapter “Status display”).
5.9.1 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 stoppage
(see also chapter “Signals for matching with the positioning device”)
The signal can be reset by a fault during the welding process.
5.9.2 User-defined inputs
There are 3 additional inputs with 24V logic which can be used by the user. The signals are filtered using
a time constant of approx. 50ms.
The signals are also processed further with an external power supply when the welding machine has
been switched off.
The inputs are not isolated.
5.9.3 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.
5.9.4 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.
5.9.5 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.

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Check-back of the process parameters

5.9.6 Ready for welding

The system is ready for welding and accepts a start signal from the PLC. The signal is reset in the event
of errors. When switching a job, the signal is reset for a duration of approx. 200 ms.
From software version 0.0.A.X, the signal is no longer reset during the process!
5.9.7 Sticking
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 also chapter “Fusing detection” for
more information). With TETRIX systems with retrofitted sensor voltage, it is also possible to detect the
fusing of the electrode in TIG processes.
5.9.8 Error number
Indicates a system error together with the “Collective error” status signal (see also chapter “Operating
problems, causes and remedies”). System errors must be acknowledged before re-starting.
Some system errors cannot be acknowledged due to their severity.
5.9.9 Actual welding voltage value
Transfer of the actual welding voltage of the process. The value is updated every 30ms.
5.9.10 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.
5.9.11 Actual wire feed speed value
Transfer of the current wire speed for the process. Value is updated every 30ms.
5.9.12 Actual motor current value
Transfer of the actual motor current for the wire conveyor system. Value is updated every 30ms.
5.9.13 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 (for details, see chapter Monitoring
function).
5.9.14 I > 0 Auxiliary process
Feedback from the auxiliary process to the PLC. Set when the auxiliary process is activated or reset, if
the auxiliary process has been deactivated.
5.9.15 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:

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Check-back of the process parameters

Pstart
Pend
I PA
t

t
A
t

B
t
I>0
t
C
t
D*
t

Figure 5-2
Legend
Description
A Start signal
B Main current
C Process active
D* Ready for welding
* From version 0.0.A.0 the signal can be used during the welding process.

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 Operative mode
Signals for matching with the positioning device

5.10 Signals for matching with the positioning device

Experience has shown that the signal matching between the welding power source and the positioning
device is very important. If interference occurs suddenly due to a loss of signal (e.g. arc interruption), or if
intermittent signals occur, the positioning device can itself enter an error status condition. Often it is
difficult to move the positioning device back to the basic position.
For this reason, multiple parameters for improved matching have been introduced specifically for the
process start phase and for the process in progress.
5.10.1 Ignition time: TZ-Zünd
Detecting a failed ignition process is very important during the process start phase (especially with
tandem processes with more than one power source).
The ignition phase is evaluated using an adjustable ignition time. A successful ignition process is
detected if a stable flow of current occurs for more than the set time period after ignition. The I>0 signal is
saved in this phase. However, if there is no ignition process for the duration of the failed ignition time, an
ignition 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.
5.10.2 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 5-3
Legend
Description
A Start signal
B Internal start
C Ignition time elapse
D Ignition error message
E Automatic cut-out

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Operative mode
Signals for matching with the positioning device

5.10.3 Arc interruption time for TZ-LIBO

For the work process it is desirable that the process runs without interference. However, in poor
conditions it is likely that welding interference will occur, and this results in intermittent signals for the
duration of the process. 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 process 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 5-4
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

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 Operative mode
Fusing detection

5.10.4 The return time TZ-RESET

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

NOTE
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
Parameters TZ-SET and TZ-RESET are currently only available for PHOENIX systems. In
TETRIX systems, these values are specified as follows:
• TZ-SET = 30 ms
• TZ-RESET = 30 ms

5.11 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,
approx. 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.
5.12 Position search
The position search function can only be used in combination with the “Actual fast external values” option
and is activated via jumper JP2:
JP 2 Function
- Actual values via system bus (factory setting)
X Actual values are expected via plug X7, position search enabled
X – Jumper plugged in
Ideally the BUSINTX11 in the “External extension housing” variant should be fitted on the power source
for this purpose; this will ensure the simple and safe transmission of the actual values to the module
(short paths without interference). When using the switching cabinet variant, a shielded cable should
always be used to connect the actual values.
The function can only be activated via the relevant release signals when the system is at a standstill (no
welding operation).
On workpiece contact, a fast detection and forwarding of the status to the field bus is carried out via the “
I>0” signal.

Item No.: 099-008225-EWM01 35

Operative mode
Welding seam tracking

5.13 Welding seam tracking

A traditional task for robot welding systems is track correction for the weld seam during the process,
which is required due to component tolerances.
The actual process values supplied in the system are normally updated every 30ms.
A higher data rate is required for reliable seam tracking. This is supported by BUSINTX11 with a fast,
optional actual value recording device for welding voltage and welding current, which needs to be
purchased separately.
5.14 Welding simulation
The simulation is normally used in setup mode by positioning devices. The process signals “I > 0”, “Ready
for welding”, “Process active” and “Main current signal” are simulated. All signals are reproduced with the
exact time-based course of the process chain. This means that the simulation is also suitable for
determining production cycle times.
The function can only be activated via the relevant release signals when the system is at a standstill (no
welding operation).
The simulation is released by activating the “Welding simulation” actuation signal.
No actual process values are simulated.
With TETRIX systems the I>0 signal is also simulated for the auxiliary process.
5.15 Process fast shut-down
In some circumstances, an immediate shut-down of the process is desirable, which cannot be
implemented 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.
5.16 Process safety shut-down
The BUSINTX11 is equipped with monitoring specific to the field bus, which is used to determine the
status 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.

36 Item No.: 099-008225-EWM01

 Operative mode
JOB safety switching

5.17 JOB safety switching

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

Item No.: 099-008225-EWM01 37

The diagnostics interface
PC system requirements

6 The diagnostics interface

To support commissioning processes and the analysis of signal sequences, the BUSINTX11 has a
diagnostics interface that is connected to a PC USB port and can be evaluated using the EWM-Analyzer
software.
6.1 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
6.2 Commissioning
To commission the diagnostics interface, first connect the connection cable for the PC USB port
(consisting of filter boxes SECINTX10USB, item no. 090-008190-XXXXX and connection cable PCV5-I,
item no. 094-001205-XXXXX) to the PC and the required adapter cable for connection to the 6-pole
Minifit socket X10 on the BUSINTX11 using adapter cable item no. 094-013051-XXXXX. When using a
BUSINTX11 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!
6.3 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
therefore 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!

38 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the Interbus-S (copper),
Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

7 Profiles for PHOENIX MIG/MAG systems

The BUSINTX11 has a selection option for what are known as signal profiles which can be selected via a
selector switch with 16 settings.
The number of profiles available depends on the field bus standard being used and on the module
software 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.
7.1 Profiles for the Interbus-S (copper),
Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules
7.1.1 Default profile (switch position 0)
The module uses a data capacity of 6 words (12 bytes) for input data and output data.
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas test 1 Manual check via the blow-out valve
Bit allocation:
0 Blow-out valve off
1 Blow-out valve on

Item No.: 099-008225-EWM01 39

Profiles for PHOENIX MIG/MAG systems
Profiles for the Interbus-S (copper),
Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

Actuation data
Byte Bit no. Function Description
no.
0 7 Blow-out Manual check of the auxiliary gas
Bit allocation:
0 Gas supply off
1 Gas supply on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 JOB mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation off
1 Simulation active
2 0-3 Program number specification Select a program number in the range 0-15
2 7 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 WF specification, high-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
5 0-7 WF specification, low-byte Specify the wire speed in program 0

40 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the Interbus-S (copper),
Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

Actuation data
Byte Bit no. Function Description
no.
6 0-7 Correction specification, Specify the voltage correction in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
7 - Correction specification, Specify the voltage correction in program 0
low byte
8 0-7 Dynamics specification, Specifies the dynamic in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
9 - Dynamics specification, Specifies the dynamic in program 0
low byte
10 - - -
11 - - -

Item No.: 099-008225-EWM01 41

Profiles for PHOENIX MIG/MAG systems
Profiles for the Interbus-S (copper),
Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

Process data
Byte Bit no. Function Description
no.
0 0 I>0 Current-flows signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Fusing Wire fusion message from process
Bit allocation:
0 Wire is free
1 Wire is fused onto the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Indicates the completion of the welding process
Bit allocation Process ended (after gas post-flows)
0 Process running
1
0 7 Reserved
1 0-7 Error Error number of an error which has occurred

2 0-7 Monitoring Bit field for displaying alarm messages during

welding parameter monitoring
Status =0, no alarm
Status =1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire-feed speed
3 WF motor current
4-7 Reserved
3 0-7 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0V signal on the input = signal low
24V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte Range: 0 to 0x7FFF
corresponds to 0.0V to 100.0V

42 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the Interbus-S (copper),
Interbus-S LWL (FSMA) and Interbus-S (Rugged Line) modules

Process data
Byte Bit no. Function Description
no.
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte
6 0-7 Actual welding current value, Current actual value for the welding current
high byte Range: 0 to 0x7FFF
corresponds to 0A to 1000A
7 0-7 Actual welding current value, Current actual value for the welding current
low byte
8 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
high byte Range: 0 to 0x7FFF
corresponds to 0.0m/min to 40.0m/min
9 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
low byte
10 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
Range: 0 to 0x7FFF
corresponds to 0.0A to 25.5A
11 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system

Item No.: 099-008225-EWM01 43

Profiles for PHOENIX MIG/MAG systems
Profiles for the CANopen module

7.2 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
signals) and the standard Tx-PDOs 1 to 3 (no. 1 for digital and nos. 2 and 3 for analogue data).
7.2.1 Reis Robotics profile (switch position 0)
The module uses a data capacity of 6 words (12 bytes) for the input data and 7 words (14 bytes) for the
output data.
Rx-PDO 1 Cob ID = 200h + address
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3-4 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 5 Reserved
0 6 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
0 7 Reserved
1 0 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
1 1 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement

44 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the CANopen module

Rx-PDO 1 Cob ID = 200h + address

Byte Bit no. Function Description
no.
1 4 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 5 Blow-out Manual check via the blow-out valve
Bit allocation:
0 Blow-out valve off
1 Blow-out valve on
1 6 Reserved
1 7 WF switching (optional) Switches over between two wire feed units
Bit allocation:
0 Wire feed unit 1 is active
1 Wire feed unit 2 is active
2 0-7 JOB number specification Select a JOB number in the range of
1-255
3 0-3 Program number specification Select a program number in the range 0-15

4-6 Not allocated

7 Welding simulation
Bit allocation: Welding simulation switched off
0 Welding simulation activated
1
4 0 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function

Item No.: 099-008225-EWM01 45

Profiles for PHOENIX MIG/MAG systems
Profiles for the CANopen module

Rx-PDO 2 Cob ID = 300h + address

Byte Bit no. Function Description
no.
0 0-7 WF specification, low-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
1 0-7 WF specification, high-byte Specify the wire speed in program 0
2 0-7 Correction specification, Specify the voltage correction in program 0
high-low Range: 0 to 0 x 7FFF
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
3 - Correction specification, Specify the voltage correction in program 0
high byte
4 0-7 Dynamics specification, Specifies the dynamic in program 0
low byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
5 - Dynamics specification, Specifies the dynamic in program 0
high byte
6 - Not allocated
7 - Not allocated

46 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the CANopen module

Tx-PDO 1 Cob ID = 180h + address

Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Reserved
0 2 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 3 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 6 Reserved
0 7 Reserved
1 0-7 Error Error number of an error which has occurred

2 0-7 Not used

3 0 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
1-7 Not allocated
4 0-7 Monitoring* Bit field for displaying alarm messages during
welding parameter monitoring
Status = 0, no alarm
Status = 1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire feed speed
3 WF motor current
4-7 Reserved

*
From software version 0.0.10.X, the signals are allocated here!

Item No.: 099-008225-EWM01 47

Profiles for PHOENIX MIG/MAG systems
Profiles for the CANopen module

Tx-PDO 2 Cob ID = 280h + address

Byte Bit no. Function Description
no.
0 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
1 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
2 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
3 0-7 Actual welding current value, Current actual value for the welding current
high byte
4 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
5 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
6 0-7 Monitoring* Bit field for displaying alarm messages during
welding parameter monitoring
Status = 0, no alarm
Status = 1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire feed speed
3 WF motor current
4-7 Reserved
7 0-7 Not allocated
*
Up to software version 0.0.9.X, the signals are allocated here!

Tx-PDO 3 Cob ID = 380h + address

Byte Bit no. Function Description
no.
0 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
1 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
2-7 0-7 Not allocated

48 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

7.3 Profiles for the CAN DeviceNet module

7.3.1 Default profile (switch position 0)
The module uses a data capacity of 5 words (10 bytes) for the input data and 6 words (12 bytes) for the
output data.
The data can only be assigned to a single connection in this profile.
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 7 Blow-out Manual check via the blow-out valve
Bit allocation:
0 Blow-out valve off
1 Blow-out valve on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on

Item No.: 099-008225-EWM01 49

Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

Actuation data
Byte Bit no. Function Description
no.
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 Job mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 0-15
2 7 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 WF specification, low-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
5 0-7 WF specification, high-byte Specify the wire speed in program 0
6 0-7 Correction specification, Specify the voltage correction in program 0
low byte Range: 0 to 255
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
7 - Correction specification, Specify the voltage correction in program 0
high byte
8 0-7 Dynamics specification, Specifies the dynamic in program 0
low byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
9 - Dynamics specification, Specifies the dynamic in program 0
high byte

50 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

The data can only be assigned to a single connection in this profile.

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation Process ended (after gas post-flows)
0 Process running
1
0 7 Reserved
1 0-7 Error Error number of an error which has occurred

2 0-7 Monitoring Bit field for displaying alarm messages during

welding parameter monitoring
Status = 0, no alarm
Status = 1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire feed speed
3 WF motor current
4-7 Reserved
3 0-7 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
Input 3 is not available with 0 V signal on the input = signal low
the seam tracking option 24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V

Item No.: 099-008225-EWM01 51

Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

Process data
Byte Bit no. Function Description
no.
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x7 FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

52 Item No.: 099-008225-EWM01

 Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

7.3.2 Profile 1 (switch position 1)

The module uses a data capacity of 5 words (10 bytes) for the input data and 6 words (12 bytes) for the
output data, distributed across 2 connections.
The following data with 4 bytes is assigned to connection 1 (output 1):
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
Bit allocation: Manual check via the blow-out valve
0
1 Blow-out valve off
Blow-out valve on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on

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Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

Actuation data
Byte Bit no. Function Description
no.
1 3 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 Job mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 0-15
2 7 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function
3 0-7 JOB number specification Select a JOB number in the range
1-255

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

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

Actuation data
Byte Bit no. Function Description
no.
0 0-7 WF specification, low-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
1 0-7 WF specification, high-byte Specify the wire speed in program 0
2 0-7 Correction specification, Specify the voltage correction in program 0
low byte Range: 0 to 255
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
3 - Correction specification, Specify the voltage correction in program 0
high byte
4 0-7 Dynamics specification, Specifies the dynamic in program 0
low byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
5 - Dynamics specification, Specifies the dynamic in program 0
high byte

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Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

The following data with 4 bytes are assigned to connection 1 (input 1):
Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation Process ended (after gas post-flows)
0 Process running
1
0 7 Reserved
1 0-7 Error Error number of an error which has occurred

2 0-7 Monitoring Bit field for displaying alarm messages during

welding parameter monitoring
Status = 0, no alarm
Status = 1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire feed speed
3 WF motor current
4-7 Reserved
1 to 3 on bits 0 to 2
Input 3 is not available with
the seam tracking option

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the CAN DeviceNet module

The following data with 8 bytes are assigned to connection 2 (input 2):
Process data
Byte Bit no. Function Description
no.
0 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
1 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
2 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
3 0-7 Actual welding current value, Current actual value for the welding current
high byte
4 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
5 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
6 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
7 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

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Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

7.4 Profiles for the Profibus DP module

7.4.1 Default profile (switch position 0)
The module uses a data capacity of 10 bytes for input data and 11 bytes for output data and should be
used if all input and output data is required.
Actuation data
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3 Select operating mode Select between non-latched/special non-latched
Bit allocation:
0 Non-latched operating mode
1 Special non-latched operating mode
0 4 Reserved -
0 5 JOB mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
0 6 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
0 7 Error reset Acknowledgement signal for system error
1 0 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
1 1 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Actuation data
Byte Bit no. Function Description
no.
1 4 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
Bit allocation: Manual check via the blow-out valve
0
1 Blow-out valve off
Blow-out valve on
1 6 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation off
1 Simulation active
2 0-3 Program number specification Select a program number in the range 0-15
2 7 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 WF specification, high-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
5 0-7 WF specification, low-byte Specify the wire speed in program 0
6 0-7 Correction specification, Specify the voltage correction in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
7 - Correction specification, Specify the voltage correction in program 0
low byte
8 0-7 Dynamics specification, Specifies the dynamic in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
9 - Dynamics specification, Specifies the dynamic in program 0
low byte

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Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Process data
Byte Bit no. Function Description
no.
0 0 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 1 User-defined input 1 Signal status of the digital input
Logic:
0V signal on the input = signal low
24V on the input = signal high
0 2 Process active Indicates the completion of the welding process
Bit allocation Process ended (after gas post-flows)
0 Process running
1
0 3 I>0 Current-flows signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 4 Collision signal Signals the triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 6 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 7 Fusing Wire fusion message from process
Bit allocation:
0 Wire is free
1 Wire is fused onto the workpiece
1 0-7 Error Error number of an error which has occurred

2 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte Range: 0 to 0x7FFF
corresponds to 0.0V to 100.0V
3 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte
4 0-7 Actual welding current value, Current actual value for the welding current
high byte Range: 0 to 0x7FFF
corresponds to 0A to 1000A
5 0-7 Actual welding current value, Current actual value for the welding current
low byte
6 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
high byte Range: 0 to 0x7FFF
corresponds to 0.0m/min to 40.0m/min

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Process data
Byte Bit no. Function Description
no.
7 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
low byte
8 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
Range: 0 to 0x7FFF
corresponds to 0.0A to 25.5A
9 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
10 0-7 Monitoring Bit field for displaying alarm messages during
welding parameter monitoring
Status =0, no alarm
Status =1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire-feed speed
3 WF motor current
4-7 Reserved

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Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

7.4.2 Flexible profile (switch position 1)

The module uses a data capacity of 10 bytes for input data and 11 bytes for output data. The JOB mode
can only be activated via the jumper in this profile. The data is arranged so that data required on the
Profibus can be grouped via the module programming.
The program and JOB selection bits can be used to pre-select the actuation type for programs and JOBs.
Actuation data
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3 Select operating mode Select between non-latched/special non-latched
Bit allocation:
0 Non-latched operating mode
1 Special non-latched operating mode
0 4 Machine program pre- The program is selected by the machine
selection
Bit allocation: Program 1 is permanently set
0 Programs 0-15 can be selected
1
0 5 Machine job pre-selection Select the selection mode for Jobs
Bit allocation:
0 Job pre-selection via operating panel (M31X)
1 JOB pre-selection from machine (field bus)
0 6 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
0 7 Error reset Acknowledgement signal for system error
1 0 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
1 1 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Actuation data
Byte Bit no. Function Description
no.
1 3 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 4 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
Bit allocation: Manual check via the blow-out valve
0
1 Blow-out valve off
Blow-out valve on
1 6 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation off
1 Simulation active
2 0-3 Program number specification Select a program number in the range 0-15
2 7 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 WF specification, high-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
5 0-7 WF specification, low-byte Specify the wire speed in program 0
6 0-7 Correction specification, Specify the voltage correction in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
7 - Correction specification, Specify the voltage correction in program 0
low byte
8 0-7 Dynamics specification, Specifies the dynamic in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
9 - Dynamics specification, Specifies the dynamic in program 0
low byte

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Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Process data
Byte Bit no. Function Description
no.
0 0 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 1 User-defined input 1 Signal status of the digital input
Logic:
0V signal on the input = signal low
24V on the input = signal high
0 2 Process active Indicates the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 3 I>0 Current-flows signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 4 Collision signal Signals the triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 6 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 7 Fusing Wire fusion message from process
Bit allocation:
0 Wire is free
1 Wire is fused onto the workpiece
1 0-7 Error Error number of an error which has occurred
2 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte Range: 0 to 0x7FFF
corresponds to 0.0V to 100.0V
3 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte
4 0-7 Actual welding current value, Current actual value for the welding current
high byte Range: 0 to 0x7FFF
corresponds to 0A to 1000A
5 0-7 Actual welding current value, Current actual value for the welding current
low byte
6 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
high byte Range: 0 to 0x7FFF
corresponds to 0.0m/min to 40.0m/min
7 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
low byte

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Process data
Byte Bit no. Function Description
no.
8 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
Range: 0 to 0x7FFF
corresponds to 0.0A to 25.5A
9 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
10 0-7 Monitoring Bit field for displaying alarm messages during
welding parameter monitoring
Status =0, no alarm
Status =1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire-feed speed
3 WF motor current
4-7 Reserved

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Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

7.4.3 Compatible profile (switch position 2)

The module uses a data capacity of 10 bytes for input data and 11 bytes for output data.
The profile can be used to replace previously used BUSINTX10 Profibus interfaces. The profile is fully
compatible for this purpose.
Actuation data
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
0 2 Select welding mode Select between normal/pulse welding
Bit allocation:
0 Normal welding active
1 Pulse welding active
0 3&4 Select operating mode Select between non-latched/latched/special non-
Bit allocation: latched/special latched
Bit1 Bit0
0 0
0 1 Non-latched operating mode
1 0 Latched operating mode
1 1 Special latched operating mode
Special non-latched operating mode
0 5 Machine program pre- The program is selected by the machine
selection
Bit allocation: Program 1 is permanently set
0 Programs 0-15 can be selected
1
0 6 Machine JOB pre-selection Select the selection mode for JOBs
Bit allocation:
0 JOB pre-selection via operating panel (M31X)
1 JOB pre-selection from machine (field bus)
0 7 Error reset Acknowledgement signal for system error
1 0 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
1 1 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Actuation data
Byte Bit no. Function Description
no.
1 4 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
Bit allocation: Manual check via the blow-out valve
0
1 Blow-out valve off
Blow-out valve on
1 6 Check monitoring function Activate/deactivate welding parameter monitoring
Bit allocation: Monitoring deactivated
0 Monitoring activated
1
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation off
1 Simulation active
2 0-3 Program number specification Select a program number in the range 0-15
2 7 Specification of master power Activates the master/slave power source in a
source with TANDEM TANDEM system
systems (optional)
Bit allocation:
0 System adopts slave function
1 System adopts master function
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 WF specification, high-byte Specify the wire speed in program 0
Range: 0 to 0 x 7FFF
0 corresponds to WF-MIN
0 x 7FFF corresponds to 25.0 m/min
5 0-7 WF specification, low-byte Specify the wire speed in program 0
6 0-7 Correction specification, Specify the voltage correction in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -10.0 V
0 x 4000 corresponds to 0 V
0 x 7FFF corresponds to +10.0 V
7 - Correction specification, Specify the voltage correction in program 0
low byte
8 0-7 Dynamics specification, Specifies the dynamic in program 0
high byte Range: 0 to 0 x 7FFF
0 corresponds to -40
0 x 4000 corresponds to 0
0 x 7FFF corresponds to +40
9 - Dynamics specification, Specifies the dynamic in program 0
low byte

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Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Process data
Byte Bit no. Function Description
no.
0 0 Not allocated
0 1 User-defined input 1 Signal status of the digital input
Logic:
0V signal on the input = signal low
24V on the input = signal high
0 2 Process active Indicates the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 3 I>0 Current Flows signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 6 Not allocated
0 7 Fusing Wire fusion message from process
Bit allocation:
0 Wire is free
1 Wire is fused onto the workpiece
1 0-7 Error Error number of an error which has occurred
2 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte Range: 0 to 0x7FFF
corresponds to 0.0V to 100.0V
3 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte
4 0-7 Actual welding current value, Current actual value for the welding current
high byte Range: 0 to 0x7FFF
corresponds to 0A to 1000A
5 0-7 Actual welding current value, Current actual value for the welding current
low byte
6 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
high byte Range: 0 to 0x7FFF
corresponds to 0.0m/min to 40.0m/min
7 0-7 Actual wire feed speed value, Current actual value for the wire feed speed
low byte
8 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
Range: 0 to 0x7FFF
corresponds to 0.0A to 25.5A
9 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system

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 Profiles for PHOENIX MIG/MAG systems
Profiles for the Profibus DP module

Process data
Byte Bit no. Function Description
no.
10 0-7 Monitoring Bit field for displaying alarm messages during
welding parameter monitoring
Status =0, no alarm
Status =1, alarm
Bit allocation:
0 Welding voltage
1 Welding current
2 Wire-feed speed
3 WF motor current
4-7 Reserved

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Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

8 Profiles for TETRIX TIG and plasma systems

8.1 Profiles for the CANopen module
In general the module uses the standard Rx-PDOs 1 and 2 (no. 1 for digital and no. 2 for analogue
signals) and the standard Tx-PDOs 1 to 3 (no. 1 for digital and nos. 2 and 3 for analogue data).
8.1.1 Default profile 1 (switch position 0)
The module uses a data capacity of 4 words (8 bytes) for input data and 8 words (16 bytes) for output
data, program number must be set > 0!
Rx-PDO 1 Cob ID = 200h + address
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2&3 Select welding mode Select between the various TETRIX pulse modes
Bit allocation: Normal welding active
0 0 Pulses active, changeover between main and
0 1 secondary pr.
1 0 AC special pulses, in AC mode only
1 1 Thermal DC pulses
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 7 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on

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 Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Rx-PDO 1 Cob ID = 200h + address

Byte Bit no. Function Description
no.
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 4 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 5 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 6 JOB mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 1-15

4-6 Reserved
2 7 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 I specification, low-byte Specification of the welding current, the scaling is
always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 I specification, high-byte Specification of the welding current
6 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.00 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
7 - WF cold wire specification, Specification of the wire value
high byte

Item No.: 099-008225-EWM01 71

Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Tx-PDO 1 Cob ID = 180h + address

Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Sticking message from process
Bit allocation:
0 Electrode/cold wire is free
1 Electrode/cold wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation: (plasma arc)
0 No current flowing
1 Current flows, auxiliary arc stationary
1 0-7 Error Error number of an error which has occurred
2 0-7 Reserved
3 0-7 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high

72 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Tx-PDO 2 Cob ID = 280h + address

Byte Bit no. Function Description
no.
0 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
1 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
2 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
3 0-7 Actual welding current value, Current actual value for the welding current
high byte
4 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
5 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
6 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
7 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

8.1.2 Profile 1 (switch position 1, program mode)

The module uses a data capacity of 4 words (8 bytes) for input data and 8 words (16 bytes) for output
data.
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on

Item No.: 099-008225-EWM01 73

Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Byte Bit no. Function Description

no.
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated
1 3 Reserved
1 4 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 5 Reserved
1 6 Reserved
1 7 Reserved
2 0-3 Program number specification Select a program number in the range 1-15

4-7 Not allocated

3 0-7 JOB number specification Select a JOB number in the range
1-255

74 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Tx-PDO 1 Cob ID = 180h + address

Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Sticking message from process
Bit allocation:
0 Electrode/cold wire is free
1 Electrode/cold wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation: (plasma arc)
0 No current flowing
1 Current flows, auxiliary arc stationary
1 0-7 Error Error number of an error which has occurred
2 0-7 Reserved
3 0-7 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high

Item No.: 099-008225-EWM01 75

Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Tx-PDO 2 Cob ID = 280h + address

Byte Bit no. Function Description
no.
0 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
1 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
2 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
3 0-7 Actual welding current value, Current actual value for the welding current
high byte
4 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
5 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
6 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
7 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

76 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

8.1.3 Profile 2 (switch position 2, control signal mode)

The module uses a data capacity of 16 words (32 bytes) for input data and 8 words (16 bytes) for output
data.
Rx-PDO 1 Cob ID = 200h + address
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated

Item No.: 099-008225-EWM01 77

Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Rx-PDO 1 Cob ID = 200h + address

Byte Bit no. Function Description
no.
1 3 Reserved
1 4 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 5 Cold wire on Check via optional cold wire
Bit allocation:
0 Cold wire off
1 Cold wire on
1 6&7 Select welding mode Select between the various TETRIX pulse modes
Bit allocation: Normal welding active
0 0 Pulses active, changeover between main and
0 1 secondary pr.
1 0 AC special pulses, in AC mode only
1 1 Thermal DC pulses
2 0-7 Reserved
3 0-7 JOB number specification Select a JOB number in the range of
1-255

Rx-PDO 2 Cob ID = 300h + address

Byte Bit no. Function Description
no.
0 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
1 0-7 Main current specification, Specification of the welding current
high-byte
2 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
3 - WF cold wire specification Specification of the wire value
high byte
4 0-7 Secondary current Specification of the welding current, the scaling is
specification, low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Secondary current Specification of the welding current
specification, high-byte

78 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Rx-PDO 3 Cob ID = 400h + address

Byte Bit no. Function Description
no.
0 0-7 Pulse time specification, low- Specification of the pulse time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
1 0-7 Pulse time specification, high- Specification of the pulse time for metallurgic
byte pulsing
2 0-7 Pause time specification, low- Specification of the pause time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
3 0-7 Pause time specification, Specification of the pause time for metallurgic
high-byte pulsing
4 Decrease time specification, Specification of the decrease time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
5 0-7 Decrease time specification, Specification of the decrease time for metallurgic
high-byte pulsing
6 0-7 Raising time specification, Specification of the raising time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
7 0-7 Raising time specification, Specification of the raising time for metallurgic
high-byte pulsing

Rx-PDO 4 Cob ID = 400h + address

Byte Bit no. Function Description
no.
0 0-7 Shielding gas specification, Shielding gas specification
low-byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 20.0 l/min
1 0-7 Shielding gas specification, Shielding gas specification
high-byte
2 0-7 Plasma gas specification, low- Specification of the plasma gas
byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.0 l/min
3 0-7 Plasma gas specification, Specification of the plasma gas
high-byte
4 0-7 Frequency specification, low- Specification of the frequency for thermal
byte pulsing
Range: 0 to 0 x 7FFF
0 corresponds to 50 Hz
0 x 7FFF corresponds to 2500 Hz
5 0-7 Frequency specification, high- Frequency specification
byte
6 0-7 Balance specification, low- Specification of the balance for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 1%
0 x 7FFF 100%

Item No.: 099-008225-EWM01 79

Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Rx-PDO 4 Cob ID = 400h + address

Byte Bit no. Function Description
no.
7 0-7 Balance specification, high- Balance specification
byte

80 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Tx-PDO 1 Cob ID = 180h + address

Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Sticking message from process
Bit allocation:
0 Electrode/cold wire is free
1 Electrode/cold wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 Collision or transmitter not connected
1 No collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation: (plasma arc)
0 No current flowing
1 Current flows, auxiliary arc stationary
1 0-7 Error Error number of an error which has occurred
2 0-7 Reserved
3 0-7 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high

Item No.: 099-008225-EWM01 81

Profiles for TETRIX TIG and plasma systems
Profiles for the CANopen module

Tx-PDO 2 Cob ID = 280h + address

Byte Bit no. Function Description
no.
0 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
1 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
2 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
3 0-7 Actual welding current value, Current actual value for the welding current
high byte
4 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
5 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
6 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
7 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

82 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

8.2 Profiles for the CAN DeviceNet module

8.2.1 Default profile (switch position 0)
The module uses a data capacity of 4 words (8 bytes) for input data and
6 words (12 bytes) for output data.
The data can only be assigned to a single connection in this profile.
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2&3 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 7 Gas test 2 Manual check of the auxiliary gas
Bit allocation:
0 Gas supply off
1 Gas supply on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on

Item No.: 099-008225-EWM01 83

Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Actuation data
Byte Bit no. Function Description
no.
1 3 Start auxiliary process Start signal for the auxiliary process (plasma)
Bit allocation:
0 Auxiliary process off
1 Auxiliary process on
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 JOB mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 0-15
2 4-6 Reserved
2 7 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
3 0-7 JOB number specification Select a JOB number in the range
1-255
4 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Main current specification, Specify the wire speed in program 0
high-byte
6 0-7 WF cold wire specification, Specifies the welding current in program 0
low byte Range: 0 to 255
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
7 0-7 WF cold wire specification, Specifies the wire value in program 0
high byte

84 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

The data can only be assigned to a single connection in this profile.

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A

Item No.: 099-008225-EWM01 85

Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Process data
Byte Bit no. Function Description
no.
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
8.2.2 Profile 1 (switch position 1)
The module uses a data capacity of 2 words (4 bytes) for input data and output data.
The data can only be assigned to a single connection in this profile.
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2&3 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on

86 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Actuation data
Byte Bit no. Function Description
no.
0 7 Gas test 2 Manual check of the auxiliary gas
Bit allocation:
0 Gas supply off
1 Gas supply on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 2 Reverse inching Signal for wire reverse inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
1 3 Start auxiliary process Start signal for the auxiliary process (plasma)
Bit allocation:
0 Auxiliary process off
1 Auxiliary process on
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 JOB mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 0-15
2 4-6 Reserved
2 7 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
3 0-7 JOB number specification Select a JOB number in the range
1-255

Item No.: 099-008225-EWM01 87

Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

The data can only be assigned to a single connection in this profile.

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Status of the user-defined inputs
0 corresponds to input status not active
1 corresponds to input status active
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte

88 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Process data
Byte Bit no. Function Description
no.
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

Item No.: 099-008225-EWM01 89

Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

8.2.3 Profile 2 (switch position 2, program mode)

The module uses a data capacity of 2 words (4 bytes) for input data and 6 words (12 bytes) for output
data.
The data can only be assigned to a single connection in this profile.
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated

90 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Byte Bit no. Function Description

no.
1 3 Reserved
1 4 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 5 to 7 Reserved
2 0-3 Program number specification Select a program number in the range 1-15

4-7 Not allocated

3 0-7 JOB number specification Select a JOB number in the range of
1-255

The data can only be assigned to a single connection in this profile.

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used

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Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Process data
Byte Bit no. Function Description
no.
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

92 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

8.2.4 Profile 3 (switch position 3, control signal mode)

The module uses a data capacity of 13 words (26 bytes) for input data and 6 words (12 bytes) for output
data.
The data can only be assigned to a single connection in this profile.
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated

Item No.: 099-008225-EWM01 93

Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Byte Bit no. Function Description

no.
1 3 Reserved
1 4 Cold wire on Check via optional cold wire
Bit allocation:
0 Cold wire off
1 Cold wire on
1 5 Reserved
1 6&7 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
2 0 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Main current specification, Specification of the welding current
high-byte
6 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
7 - WF cold wire specification, Specification of the wire value
high byte
8 0-7 Secondary current Specification of the welding current, the scaling is
specification, low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
9 0-7 Secondary current Specification of the welding current
specification, high-byte
10 0-7 Plasma gas specification, low- Specification of the plasma gas
byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.0 l/min
11 0-7 Plasma gas specification, Specification of the plasma gas
high-byte
12 0-7 Shielding gas specification, Shielding gas specification
low-byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 20.0 l/min

94 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Byte Bit no. Function Description

no.
13 0-7 Shielding gas specification, Shielding gas specification
high-byte
14 0-7 Pulse time specification, low- Specification of the pulse time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
15 0-7 Pulse time specification, high- Specification of the pulse time for metallurgic
byte pulsing
16 0-7 Pause time specification, low- Specification of the pause time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
17 0-7 Pause time specification, Specification of the pause time for metallurgic
high-byte pulsing
18 Decrease time specification, Specification of the decrease time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
19 0-7 Decrease time specification, Specification of the decrease time for metallurgic
high-byte pulsing
20 0-7 Raising time specification, Specification of the raising time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
21 0-7 Raising time specification, Specification of the raising time for metallurgic
high-byte pulsing
22 0-7 Frequency specification, low- Specification of the frequency for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 50 Hz
0 x 7FFF corresponds to 2500 Hz
23 0-7 Frequency specification, high- Frequency specification
byte
24 0-7 Balance specification, low- Specification of the balance for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 1%
0 x 7FFF 100%
25 0-7 Balance specification, high- Balance specification
byte
The data can only be assigned to a single connection in this profile.
Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready

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Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Process data
Byte Bit no. Function Description
no.
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
96 Item No.: 099-008225-EWM01
 Profiles for TETRIX TIG and plasma systems
Profiles for the CAN DeviceNet module

Process data
Byte Bit no. Function Description
no.
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

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Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

8.3 Profiles for the Profibus/Interbus module

8.3.1 Default profile (switch position 0)
The module uses a data capacity of 4 words (8 bytes) for input data and
6 words (12 bytes) for output data.
The data can only be assigned to a single connection in this profile.
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2&3 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 7 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on

98 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Actuation data
Byte Bit no. Function Description
no.
1 3 Start auxiliary process Start signal for the auxiliary process (plasma)
Bit allocation:
0 Auxiliary process off
1 Auxiliary process on
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 JOB mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 0-15
2 4-6 Reserved
2 7 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Main current specification, Specify the wire speed in program 0
high-byte
6 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
7 0-7 WF cold wire specification, Specifies the wire value in program 0
high byte

Item No.: 099-008225-EWM01 99

Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

The data can only be assigned to a single connection in this profile.

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A

100 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Process data
Byte Bit no. Function Description
no.
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
8.3.2 Profile 1 (switch position 1, program mode)
The module uses a data capacity of 2 words (4 bytes) for input data and 6 words (12 bytes) for output
data.
Rx-PDO 1 Cob ID = 200h + address
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas test 1 Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on

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Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Rx-PDO 1 Cob ID = 200h + address

Byte Bit no. Function Description
no.
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated
1 3 Reserved
1 4 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 5 Reserved
2 0-3 Program number specification Select a program number in the range 1-15

4-7 Not allocated

3 0-7 JOB number specification Select a JOB number in the range of
1-255

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified

102 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Process data
Byte Bit no. Function Description
no.
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

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Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

8.3.3 Profile 2 (switch position 2, control signal mode)

The module uses a data capacity of 13 words (26 bytes) for input data and 6 words (12 bytes) for output
data.
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated
1 3 Reserved

104 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Byte Bit no. Function Description

no.
1 4 Reserved
1 5 Reserved
1 6&7 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
2 0 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
2 1 Cold wire on Check via optional cold wire
Bit allocation:
0 Cold wire off
1 Cold wire on
2 2–7 Reserved
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Main current specification, Specification of the welding current
high-byte
6 0-7 Secondary current Specification of the welding current, the scaling is
specification, low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
7 0-7 Secondary current Specification of the welding current
specification, high-byte
8 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
9 - WF cold wire specification, Specification of the wire value
high byte
10 0-7 Plasma gas specification, low- Specification of the plasma gas
byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.0 l/min
11 0-7 Plasma gas specification, Specification of the plasma gas
high-byte

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Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Byte Bit no. Function Description

no.
12 0-7 Shielding gas specification, Shielding gas specification
low-byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 20.0 l/min
13 0-7 Shielding gas specification, Shielding gas specification
high-byte
14 0-7 Pulse time specification, low- Specification of the pulse time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
15 0-7 Pulse time specification, high- Specification of the pulse time for metallurgic
byte pulsing
16 0-7 Pause time specification, low- Specification of the pause time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
17 0-7 Pause time specification, Specification of the pause time for metallurgic
high-byte pulsing
18 Decrease time specification, Specification of the decrease time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
19 0-7 Decrease time specification, Specification of the decrease time for metallurgic
high-byte pulsing
20 0-7 Raising time specification, Specification of the raising time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
21 0-7 Raising time specification, Specification of the raising time for metallurgic
high-byte pulsing
22 0-7 Frequency specification, low- Specification of the frequency for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 50 Hz
0 x 7FFF corresponds to 2500 Hz
23 0-7 Frequency specification, high- Frequency specification
byte
24 0-7 Balance specification, low- Specification of the balance for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 1%
0 x 7FFF 100%
25 0-7 Balance specification, high- Balance specification
byte
The data can only be assigned to a single connection in this profile.
Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary

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 Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Process data
Byte Bit no. Function Description
no.
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min

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Profiles for TETRIX TIG and plasma systems
Profiles for the Profibus/Interbus module

Process data
Byte Bit no. Function Description
no.
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

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 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

8.4 Profile on the Interbus Module

8.4.1 Default profile (switch position 0)
The module uses a data capacity of 6 words (12 bytes) for input data and output data.
Actuation data
Byte Bit no. Function Description
no.
0 0&1 Select operating mode Select between non-latched/special non-latched
Bit allocation:
Bit1 Bit0
0 0 Non-latched operating mode
0 1 Not used
1 0 Not used
1 1 Special non-latched operating mode
0 2&3 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
0 4 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 5 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 6 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 7 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
1 0 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
1 1 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
1 2 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Actuation data
Byte Bit no. Function Description
no.
1 3 Start auxiliary process Start signal for the auxiliary process (plasma)
Bit allocation:
0 Auxiliary process off
1 Auxiliary process on
1 4 Error reset Acknowledgement signal for system error
1 5 User-defined output Switches the user-defined relay output on the bus
Bit allocation: module
0 Relay not switched
1 Relay switched
1 6 Job mode Signal activates the JOB mode function
Bit allocation:
0 JOB mode switched off
1 JOB mode active
1 7 Welding simulation Activates the Simulate Welding function
Bit allocation:
0 Simulation active
1 Simulation off
2 0-3 Program number specification Select a program number in the range 0-15

4-6 Reserved
2 7 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 I specification, low-byte Specification of the welding current, the scaling is
always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 I specification, high-byte Specify the wire speed in program 0
6 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
7 0-7 WF cold wire specification, Specifies the wire value in program 0
high byte
8-11 0-7 Reserved

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 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding "Ready" signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Reserved
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Process data
Byte Bit no. Function Description
no.
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

8.4.2 Profile 1 (switch position 1, program mode)

The module uses a data capacity of 6 words (12 bytes) for input data and output data.
Byte Bit no. Function Description
no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement

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 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Byte Bit no. Function Description

no.
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated
1 3 Reserved
1 4 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
1 5 to 7 Reserved
2 0-3 Program number specification Select a program number in the range 1-15

4-7 Not allocated

3 0-7 JOB number specification Select a JOB number in the range of
1-255
4-11 0-7 Reserved

Process data
Byte Bit no. Function Description
no.
0 0 I>0 ""Current flows"" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Process data
Byte Bit no. Function Description
no.
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system

114 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

8.4.3 Profile 2 (switch position 2, control signal operation, slow pulses)

The module uses a data capacity of 10 words (20 bytes) for input data and output data.

NOTE
In the profile, fast pulses can be selected but not parameterised. This must be taken into
account during actuation!

Byte Bit no. Function Description

no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Byte Bit no. Function Description

no.
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated
1 3 Reserved
1 4 Reserved
1 5 Reserved
1 6&7 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
2 0 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
2 1 Cold wire on Check via optional cold wire
Bit allocation:
0 Cold wire off
1 Cold wire on
2 2–7 Reserved
3 0-7 JOB number specification Select a JOB number in the range of
1-255
4 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Main current specification, Specification of the welding current
high-byte
6 0-7 Secondary current Specification of the welding current, the scaling is
specification, low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
7 0-7 Secondary current Specification of the welding current
specification, high-byte
8 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
9 - WF cold wire specification, Specification of the wire value
high byte

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 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Byte Bit no. Function Description

no.
10 0-7 Pulse time specification, low- Specification of the pulse time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
11 0-7 Pulse time specification, high- Specification of the pulse time for metallurgic
byte pulsing
12 0-7 Pause time specification, low- Specification of the pause time for metallurgic
byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
13 0-7 Pause time specification, Specification of the pause time for metallurgic
high-byte pulsing
14 Decrease time specification, Specification of the decrease time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
15 0-7 Decrease time specification, Specification of the decrease time for metallurgic
high-byte pulsing
16 0-7 Raising time specification, Specification of the raising time for metallurgic
low-byte pulsing
Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.00 s
17 0-7 Raising time specification, Specification of the raising time for metallurgic
high-byte pulsing
18 & 19 0-7 Reserved

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Process data
Byte Bit no. Function Description
no.
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
12-19 0-7 Reserved

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 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

8.4.4 Profile 3 (switch position 3, control signal operation, fast pulses)

The module uses a data capacity of 10 words (20 bytes) for input data and output data.

NOTE
In the profile, slow and AC special pulses can be selected, but not parameterised. This
must be taken into account during actuation!

Byte Bit no. Function Description

no.
0 0 Start Start signal to initiate the welding process
Bit allocation:
0 Signal stop on system
1 Signal start on system
0 1 Robot ready Safety signal for rapid shut-down
Bit allocation:
0 No ready message from robot, no start possible,
rapid shut-down carried out in the process
1 Robot ready message, start is possible
0 2 Gas 1 on Manual check of the process gas supply
Bit allocation:
0 Gas supply off
1 Gas supply on
0 3 Gas 2 on Manual check via auxiliary gas (e.g. plasma gas)
Bit allocation:
0 Gas supply off
1 Gas supply on
0 4 Inching Signal for wire inching function on the wire feed
Bit allocation: drive
0 Inching off
1 Inching on
0 5 Reverse inching Signal for reverse wire inching function
Bit allocation:
0 Reverse inching off
1 Reverse inching on
0 6 Position search Activates the position search function for the
Bit allocation: workpiece
0 Position search off
1 Position search on
0 7 Error reset Acknowledgement signal for system error
Bit allocation:
0 Signal must have positive edge for
1 acknowledgement
1 0 Start auxiliary process Start signal to initiate the auxiliary process
Bit allocation:
0 Auxiliary process is shut down
1 Auxiliary process is started
1 1 User-defined output Switches the user-defined relay output
Bit allocation: On the bus module
0 Relay not switched
1 Relay switched

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Byte Bit no. Function Description

no.
1 2 Welding simulation
Bit allocation:
0 Welding simulation switched off
1 Welding simulation activated
1 3 Reserved
1 4 Reserved
1 5 Reserved
1 6&7 Select welding mode Select pulse mode
Bit allocation:
Bit1 Bit0
0 0 Normal welding active
0 1 Thermal pulses active
1 0 AC special pulses active (only with AC systems)
1 1 Fast pulses active
2 0 WF switching (optional) Switches between 2 wire drive units
Bit allocation:
0 WF case 1 is active
1 WF case 2 is active
2 1 Cold wire on Check via optional cold wire
Bit allocation:
0 Cold wire off
1 Cold wire on
2 2-7 Reserved
3 0-7 JOB number specification Select a JOB number in the range
1-255
4 0-7 Main current specification, Specification of the welding current, the scaling is
low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
5 0-7 Main current specification, Specification of the welding current
high-byte
6 0-7 Secondary current Specification of the welding current, the scaling is
specification, low-byte always 100% dependent on the system current in
question:
Range: 0 to 0 x 7FFF
0 corresponds to RANGE-MIN
0 x 7FFF corresponds to the max. system current
7 0-7 Secondary current Specification of the welding current
specification, high-byte
8 0-7 WF cold wire specification, Specification of the wire value
low byte Range: 0 to 0 x 7FFF
0 corresponds to 0.0 m/min
0 x 7FFF corresponds to 10.0 m/min or 5.00 m/min
depending on the cold wire feed
9 - WF cold wire specification, Specification of the wire value
high byte

120 Item No.: 099-008225-EWM01

 Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Byte Bit no. Function Description

no.
10 0-7 Plasma gas specification, low- Specification of the plasma gas
byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 10.0 l/min
11 0-7 Plasma gas specification, Specification of the plasma gas
high-byte
12 0-7 Shielding gas specification, Shielding gas specification
low-byte Range: 0 to 0 x 7FFF
0 x 7FFF corresponds to 20.0 l/min
13 0-7 Shielding gas specification, Shielding gas specification
high-byte
14 0-7 Frequency specification, low- Specification of the frequency for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 50 Hz
0 x 7FFF corresponds to 2500 Hz
15 0-7 Frequency specification, high- Frequency specification
byte
16 0-7 Balance specification, low- Specification of the balance for thermal pulsing
byte Range: 0 to 0 x 7FFF
0 corresponds to 1%
0 x 7FFF 100%
17 0-7 Balance specification, high- Balance specification
byte
18 & 19 0-7 Reserved

Process data
Byte Bit no. Function Description
no.
0 0 I>0 "Current flows" signal from process
Bit allocation:
0 No current flowing
1 Current flows, arc stationary
0 1 Ready for welding Ready signal from process
Bit allocation:
0 System not ready
1 System is ready
0 2 Sticking Wire sticking message from process
Bit allocation:
0 Wire is free
1 Wire sticks to the workpiece
0 3 Error General fault message from process
Bit allocation:
0 No error
1 Fault occurred and not rectified
0 4 Collision signal Signals triggering of the collision protection
Bit allocation:
0 No collision
1 Collision

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Profiles for TETRIX TIG and plasma systems
Profile on the Interbus Module

Process data
Byte Bit no. Function Description
no.
0 5 Main current signal Displays the status of the program sequence
Bit allocation:
0 Process is outside the main current phase
1 Process running in the main program
0 6 Process active Signals the completion of the welding process
Bit allocation
0 Process ended (after gas post-flows)
1 Process running
0 7 I > 0 Auxiliary process "Current flows" signal from auxiliary process
Bit allocation:
0 No current flowing
1 Current flowing, auxiliary process active
1 0-7 Error Error number of an error which has occurred
2 0-7 Not used
3 0-2 User-defined inputs Signal status of the digital input
1 to 3 on bits 0 to 2 Logic:
0 V signal on the input = signal low
24 V on the input = signal high
4 0-7 Actual welding voltage value, Current actual value for the welding voltage
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 V to 100.0 V
5 0-7 Actual welding voltage value, Current actual value for the welding voltage
high byte
6 0-7 Actual welding current value, Current actual value for the welding current
low byte Range: 0 to 0 x 7FFF
corresponds to 0 A to 1000 A
7 0-7 Actual welding current value, Current actual value for the welding current
high byte
8 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
low byte Range: 0 to 0 x 7FFF
corresponds to 0.0 m/min to 40.0 m/min
9 0-7 Actual wire feed speed value , Current actual value for the wire feed speed
high byte
10 0-7 Actual motor current value Current actual value for the motor current from the
low byte wire feed system
Range: 0 to 0 x 7FFF
corresponds to 0.0 A to 25.5 A
11 0-7 Actual motor current value Current actual value for the motor current from the
high byte wire feed system
12-19 0-7 Reserved

122 Item No.: 099-008225-EWM01

 Special field bus features when setting up the field
bus modules
CAN DeviceNet

9 Special field bus features when setting up the field bus

modules
9.1 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:
9.1.1 Connections
The module can be configured using what are known as connections. The number of useable
connections 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”
parameters via the configuration tool.
Here, “InputX length” stands for process status data and “OutputX length” for actuation data.
9.1.2 Example for I/O data

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

Item No.: 099-008225-EWM01 123

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

9.1.3 Example of a connection assignment

In the example above, 12 bytes of connection 1 are assigned and configured as “Polled”.
9.2 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.
9.2.1 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.
9.2.2 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
application.

124 Item No.: 099-008225-EWM01

 Operating problems, causes and remedies
Operating displays (LEDs)

10 Operating problems, causes and remedies

10.1 Operating displays (LEDs)
LED no. Function Description
1 +15 V voltage Voltage supply +15 V
Allocation:
Off Voltage missing/faulty
On Voltage OK
2 -15 V voltage Voltage supply -15 V
Allocation:
Off Voltage missing/faulty
On Voltage OK
3 +5 V voltage Voltage supply +5 V
Allocation:
Off Voltage missing/faulty
On Voltage OK
4 +24 V voltage Voltage supply +24 V
Allocation:
Off Voltage missing/faulty
On Voltage OK
5 Relay status Displays the status of the monitoring
Welding monitoring
Allocation:
Off Welding monitoring within tolerance
On Welding monitoring shows a tolerance infringement
6 Status Displays the status of the relay freely available to the user
User-defined
Relay
Allocation:
Off Relay is off
On Relay is applied
7 Start/stop Display status Start/Stop signal on welding machine
Allocation:
Off Stop signal active
On Start signal active
8 I>0 Display of the "Welding current flows" signal
Allocation:
Off No current flowing
On Current flows, arc stationary
9 Process active Display for process running
Allocation:
Off Process ended
On Process running
10 Error Display of a system fault in PHOENIX/TETRIX machine
Allocation:
Off No error
On Fault 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 Display for internal system bus
Allocation:
Off System bus not active, system shut down
Flashes System bus active

Item No.: 099-008225-EWM01 125

Operating problems, causes and remedies
Error messages on the system

10.2 Error messages on the system

The following error messages are output via the bus interface on the higher level control:

Error Meaning Relevance Error can be reset

number to system
(value)
General system error
4 Wire supply error PHOENIX/TETRIX Yes
5 Inverter temperature error/inverter emergency PHOENIX/TETRIX No, resets itself
stop circuit
6 Excess mains voltage PHOENIX/TETRIX No, switch off
machine
7 Insufficient mains voltage PHOENIX/TETRIX No, switch off
machine
8 Water deficiency PHOENIX/TETRIX No, switch off
machine
9 Gas error PHOENIX/TETRIX Yes
10 Excess secondary circuit voltage PHOENIX/TETRIX No, switch off
machine
11 Productive conductor error PHOENIX/TETRIX No, switch off
machine
12 Fast system stop PHOENIX/TETRIX Yes
13 Internal error, please contact EWM PHOENIX/TETRIX No, switch off
machine

Error of external system units

17 Error in pilot current module TETRIX Yes
18 Wire feed problem in cold wire unit TETRIX Yes
19 Gas error, external gas 1 TETRIX Yes
20 Gas error, external gas 2 TETRIX Yes
21 Error in flow of external coolant circuit TETRIX Yes
22 Error in external network TETRIX Yes
23 Excess temperature of external coolant circuit TETRIX Yes
24 External HF choke excess temperature TETRIX Yes

Specific error in AC systems

33-36, 40 Specially detected error, please contact EWM TETRIX No, switch off
machine
37 The safety device of the inverse rectifier has TETRIX No, switch off
been triggered machine
38 Excess temperature in inverse rectifier TETRIX Yes
Process error
49 Ignition process error PHOENIX/TETRIX Yes
50 Arc interruption error PHOENIX/TETRIX Yes
51 Emergency stop/excess temperature PHOENIX/TETRIX No, resets itself
52 WF missing in MIG/MAG system or is not PHOENIX Yes
correctly configured

126 Item No.: 099-008225-EWM01

 Operating problems, causes and remedies
Error messages on the system

Error Meaning Relevance Error can be reset

number to system
(value)
53 In a system with the option for WF case PHOENIX Yes
switching, an attempt has been made to
switch to a WF which does not exist
99 No connection to the welding power source PHOENIX/TETRIX No, resets itself
(e.g. system shut down)

255 Unknown error(1) PHOENIX/TETRIX Yes

The error numbers displayed on operating units are different from those transmitted via the field
bus.

(1)
An error has been assigned by the system which cannot be assigned. This situation can occur
with differences in the software versions between the power source and interface.

Item No.: 099-008225-EWM01 127

Overview of plug configurations
X4, digital inputs

11 Overview of plug configurations

11.1 X4, digital inputs
The control has 4 digital inputs with 24V logic. 24V switches the input logically high,
0V switches the input logically low.
Pin no.: Function/Meaning Term in status data
X4/1 +24V
X4/2 Torch collision signal Torch collision
X4/3 User-defined input User-defined input 1
X4/4 0V
X4/5 User-defined input User-defined input 2
X4/6 User-defined input User-defined input 3

The inputs are not isolated.

Inputs 2 and 3 cannot be used in combination with the seam tracking option!
11.2 X5, digital outputs
The control has 2 floating relay contacts
Pin no.: Function/Meaning Term in actuation data
X5/1 Make contact Monitoring warning
X5/2 Break contact Monitoring warning
X5/3 Foot contact relay Monitoring warning
X5/4 Make contact User-defined output
X5/5 Break contact User-defined output
X5/6 Foot contact relay User-defined output

The relays should not be loaded with significant inductive or capacitive loads.
The relay contacts are designed for 8A at 250V AC.
11.3 X7, analogue inputs
The control has 2 analogue inputs for rapid detection of actual process values:
Pin no.: Function/Meaning Term in status data
X7/1 Reference +10V
X7/2 Uact, 0-10V (corresponds 0 to 100V) Actual welding voltage value
X7/3 Iact, 0-10V (corresponds 0 to Actual welding current value
1000A)
X7/4 Reference 0V

128 Item No.: 099-008225-EWM01

 Overview of plug configurations
X10, diagnostics interface

11.4 X10, diagnostics interface

This plug provides the diagnostics function via an RS232 interface. Please only use the cables available
from EWM Hightec Welding for connection to the PC.
Pin no.: Function/Meaning Term in status data
X10/1 Not used
X10/2 Reference 0V Reference mass to PC
X10/3 PC-TxD Transmit line from PC
X10/4 PC-RxD Receive line to PC
X10/5 Not used
X10/6 Not used
11.5 X15, external power supply
Pin no.: Function/Meaning Term in status data
X15/1 DC+ power supply External system supply voltage 24-30V
X15/2 0V reference Reference mass

Only the power supply provided by the manufacturer may be used.

Item No.: 099-008225-EWM01 129

Overview of jumper assignments BUSINTX11 Rev00
X15, external power supply

12 Overview of jumper assignments BUSINTX11 Rev00

JP No.: Function/Meaning Assignment
1 For internal use only, do not assign! Must not be completed
2 Fast analogue inputs(1) function 0 = analogue signal source is system bus
1 = analogue signal source are analogue inputs on
X7
3 Reserved
4 Activation of JOB mode(2) 0 = JOB mode not active
1 = JOB mode active
5 Pull-up function of digital inputs(3) 1-2 = normal signal assignment
2-3 = pull-up function, all signal pins from X4 are
connected with 15 k to 24 V
6 Diagnostic programming interface 1-2 = programming interface via X2 active
switching 2-3 = diagnostics interface via X10 active

(1)
Depending on the software version, various functions are available. In the standard software, a rapid
workpiece search is possible on the connection of Uactual on X7 with JP2 set. In the software with seam
tracking, the jumper must always be set and the analogue values must be connected to X7. From
software version 042-00897-00002, the signal source can be freely selected via JP2.

(2)
In data profiles identified with control signal operation, JP3 must not be set as otherwise it could be that
functions become blocked!

(3)
In the software version with seam tracking, this jumper must be set!

130 Item No.: 099-008225-EWM01

 Overview of machine software functions (firmware)
PHOENIX machine software (firmware)

13 Overview of machine software functions (firmware)

The table below provides information for each of the PHOENIX and TETRIX welding systems separately
relating to the relevant functionality of the interface machine software (firmware).
13.1 PHOENIX machine software (firmware)
Software- Item number Hardware Function
number platform
0.0.8.0 and 042-00897-00000 00 Initial version
earlier
0.0.9.0 042-00897-00001 00 Improved signal logic for I>0 and ignition monitoring
0.0.A.0 042-00897-00002 00 Introduction of TZ-SET and TZ-RESET
Improvement in the process signal logic
"Ready for welding" signal is no longer reset in the
process
TANDEM option available
Expansion of data profiles
Conversion of the CANOpen profile 0
Conversion to new Analyzer
Manual shielding gas control in control signal mode
from M320 version (0.6.0.0)
13.2 TETRIX machine software (firmware)
Software- Item number Hardware Function
number platform
0.0.8.0 and 042-00926-00000 00 Initial version
earlier
0.0.9.0 042-00926-00001 00 Improved signal logic for I>0 and ignition monitoring
0.0.A.0 042-00926-00002 00 Improvement in the process signal logic
"Ready for welding" signal is no longer reset in the
process
Expansion of data profiles
New control signals for pulse modes, shielding gas and
plasma gas
Conversion to new Analyzer
Manual actuation of shielding gas and cold wire in
control signal mode from T320 version (0.2.C.0)

Item No.: 099-008225-EWM01 131

Warranty
General Validity

14 Warranty
14.1 General Validity

3-year warranty
on all new EWM machines*:

• Power sources
• Wire feeds
• Cooling units
• Trolleys

* If these are operated with genuine EWM accessories (such as intermediate tube package, remote
control, remote control extension cable, coolant, etc.).

1-year warranty on:

• Used EWM machines
• Automation and mechanisation components
• Remote control
• Inverters
• Intermediate tube packages

6-month warranty on:

• Spare parts supplied separately (such as circuit boards, ignition units)

Manufacturer/supplier warranty on:

• All additional parts used by EWM, but manufactured by other companies (e.g. motors, pumps, fans,
torches, etc.)

Non-reproducible software errors and parts subject to mechanical ageing are excluded from the warranty
(e.g. wire feed unit, wire feed rollers, replacement and spare wire feed parts, wheels, solenoid valves,
workpiece leads, electrode holders, connection tubes, replacement torches and spare torch parts, mains
and control leads, etc.).

These terms shall apply without affecting the customer’s legal rights to a warranty and subject to our
General Terms and Conditions of Business and our terms on the warranty declaration. Agreements to the
contrary must be confirmed by EWM in writing.
Our General Terms and Conditions of Business are available for access anytime online at www.ewm.de.

NOTE
Performance specifications and guarantee only in connection with original spare and
replacement parts!

132 Item No.: 099-008225-EWM01

 Warranty
Warranty Declaration

14.2 Warranty Declaration

Your 3-year warranty

Regardless of statutory warranty rights and based on our General Terms and Conditions, EWM
HIGHTEC WELDING GmbH provides a 3-year warranty for its welding products starting on the date of
purchase. Different warranty periods apply to accessories and spare parts; please see the “General
Validity” section for these periods. Parts subject to wear are naturally exempt from the warranty.
EWM guarantees the error-free condition of the products in terms of materials and processing. If the
product proves to be defective in terms of materials or processing within the warranty period, you are
entitled to free repair or to replacement with an appropriate product, at our discretion. On receipt by EWM
the returned product becomes the property of EWM.

Condition
The prerequisite for receiving the full 3-year warranty is simply to operate the products in accordance with
the EWM operating instructions observing the relevant legal recommendations and guidelines and having
annual maintenance work and testing conducted by an EWM sales partner (see “Maintenance and
testing” chapter). This is because only machines that are maintained regularly function correctly in the
long term.

Making a claim
When making a claim under the warranty, please contact your EWM authorised sales partner only.

Warranty exclusions
No warranty claims can be accepted if the EWM products in question are not operated using genuine
EWM accessories (such as intermediate tube package, remote control, remote control extension cable,
coolant, etc.). The warranty does not apply to products that are damaged due to accidents, misuse,
improper operation, incorrect installation, use of force, disregard of the specifications and operating
instructions, inadequate maintenance (see chapter “Maintenance and testing”), exterior influences, acts of
God or personal misfortunes. Furthermore, it is not valid in the case of improper changes, repairs or
modifications. In addition, a claim for warranty does not exist in the case of partially or completely
dismantled products and interventions by persons who are not authorised by EWM, as well as in the case
of normal wear.

Limitation
All claims regarding fulfilment or non-fulfilment on the part of EWM from this declaration in connection
with this product are limited as follows to the replacement of the actual damages. EWM’s liability
stemming from this declaration in connection with this product is fundamentally limited to the amount that
the purchaser originally paid for the original purchase. This limitation does not apply to personal injuries
or damage to property caused by negligent behaviour on the part of EWM. In no way will EWM be
responsible for lost profits, indirect or subsequent damage. EWM is not liable for damages based on the
claims of third parties.

Place of jurisdiction
If the person making the claim is a business person, the sole place of jurisdiction for all disputes resulting
directly or indirectly from the contractual relationship shall be the headquarters or the branch office of the
supplier, at the discretion of the supplier. The purchaser gains ownership of the products supplied as
replacements within the framework of the warranty adjustment at the time of the exchange.

Item No.: 099-008225-EWM01 133

 Item No.: 099-008225-EWM01
Sig. Brennerkollision torch collision
Überwachung monitoring

Ausgang 1 user output 1

warning

Eingang 1 user input 1

Eingang 2 user input 2

Eingang 3 user input 3

+10V Uref. reference

Iist 0-10V = 0-1000A

Uist 0-10V=0-150V

Warnung

+24V

DV
0V

? T

? T

? T

? T

? T

? T
1

6
X7/1
X7/2
X7/3
X7/4
X7/5
X7/6
X7/7
X7/8
X7/9

X5/1
X5/2
X5/3
X5/4
X5/5
X5/6
X5/7
X5/8
X5/9

X4/1
X4/2
X4/3
X4/4
X4/5
X4/6
X4/7
X4/8
X7/10
X7/11
X7/12

X5/10
X5/11
X5/12
X7 X5 X4
Analog In/Out Digital Out Digital In
X2/1 X9/1
X2/2 X9/2
X2/3 X9/3
X2/4 X9/4
X2/5 X2 X9/5
X2/6 Programmierstecker X9/6
A1- X9
firmware update
X2/7 X9/7
X2/8
X2/9
IBUS-3 X9/8
X9/9
X2/10 X9/10
X9/11
Optional:
X9/12
X10/1
Vin+ X1/1
X10/2
0V X1/2
2
Vin-
X10/3 X10
PC-TxD X1/3
3
0V
X10/4 Diagnose X1 1
PC-RxD X1/4
4
0V 2
X10/5 diagnostics
+15V
SV IBUS3 3
Feldbusmodul
5
X10/6
-15V 6
field-bus module
+24V ext. X2/1
+24V ext.
0V X2/2
0V
34
X15 X14 X11 X13 X12
DC ext. 42VAC ext. System-Bus System-Bus XPE

XPE/1
XPE/2
X15/1
X15/2

X11/1
X11/2
X11/3
X11/4

X13/1
X13/2
X13/3
X13/4
X13/5
X13/6
X13/7
X14/1
X14/2
D-Sub.
Circuit diagrams

15polig

Vin+

Vin-
Circuit diagrams

Blatt: 1 / 1 Datum: Name: geprüft: This drawing is protected by copyright.

gezeichnet: 31.05.2005 NIEDENTHAL It may not be reproduced or utilised in any way
or communicated or forwarded to third parties
Änderung-1:
without our express permission!
Änderung-2:
Zeichnungsnummer:
Änderung-3: BUSINT X11 GRUNDMODUL
Änderung-4: INDUSTRIEBUS INTERFACE 4171-00
Warranty Declaration

Freigabe:
15

134