FIELD BUS

INSTRUCTIONS AND
INSTALLATION MANUAL

S.p.A
Via Meucci, 27 - 40024 Castel S. Pietro Terme – Bologna ITALY
Pho. +390516954411 – Fax +390516954490 – http://www.tecna.net

DISTRIBUTOR:
DOCUMENT NUMBER: MAN 4214

EDITION: FEBRUARY 2012

 S.p.A. FIELD BUS Installation Manual

This page is intentionally left blank.

2/36
Installation Manual FIELD BUS S.p.A.

TABLE OF CONTENTS:

CHAPTER 1 – INTRODUCTION ............................................................................................................5

1.1 – FIELD BUS ............................................................................................................................................5
1.2 – TECNA WELDING CONTROL UNITS TO BE USED ............................................................................5
1.3 – HOW TO INTERFACE A TECNA WELDING CONTROL UNIT .............................................................5

CHAPTER 2 – INSTALLATION AND CONFIGURATION OF THE FIELD BUS CONTROL BOARD...6

2.1 – SELECTORS CONFIGURATION..........................................................................................................6
2.1.1 – TRANSFER SPEED ..................................................................................................................................... 6
2.1.2 – FUNCTIONING MODALITY.......................................................................................................................... 6
2.1.3 – NETWORK ADDRESS SELECTION ............................................................................................................ 8
2.2 – CONTROL BOARD CAN CABLE TERMINATION ................................................................................8
2.3 – CONTROL BOARD’S TECHNICAL FEATURES...................................................................................9

CHAPTER 3 – FUNCTIONING DESCRIPTION ..................................................................................10

3.1 – CONTROL UNIT STATUS...................................................................................................................10
3.2 – ADI MAPPING .....................................................................................................................................11
3.3 – DESCRIPTION OF THE PARAMETERS PROGRAMMING (WITH PROFIBUS ONLY).....................11

CHAPTER 4 – ADI MAPPING FOR TECNA CONTROL UNITS..........................................................12

4.1 – CYCLIC ADI.........................................................................................................................................12
4.1.1 – INPUT SIGNALS DESCRIPTION .............................................................................................................. 12
4.1.2 – INPUTS MAPPING ..................................................................................................................................... 13
4.1.3 – OUTPUT SIGNALS DESCRIPTION ........................................................................................................... 15
4.1.4 – OUTPUTS MAPPING ................................................................................................................................. 15
4.1.5 – PROFIBUS MODULE MAPPINGS ............................................................................................................. 16
4.2 – ACYCLIC ADI (WITH PROFIBUS ONLY)............................................................................................17
4.2.1 – CONTROL UNIT STATUS.......................................................................................................................... 17
4.2.2 – WELDING DATA......................................................................................................................................... 23
4.2.3 – CONTROL UNIT’S PROGRAMMING ......................................................................................................... 27

CHAPTER 5 – PROGRAMMING FLOWCHART..................................................................................35

CAPITOLO 6 – TECHNICAL FEATURES............................................................................................36

3/36
 S.p.A. FIELD BUS Installation Manual

This page is intentionally left blank.

TECNA Specifications subject to change without notice.

Any part of the present document can be reproduced neither spread in any form, electronic or mechanic way for any purpose without written
permission.

is a registered trademark.

4/36
Installation Manual FIELD BUS S.p.A.

CHAPTER 1 – INTRODUCTION

1.1 – FIELD BUS

The term Field Bus refers to a single Master and multi slave communication network. Since it requires the
positioning in a sole cable, it allows the reduction of the wiring which is required by the network nodes. Usually it
is used for connecting a Master, like a remote PLC, to l /O.

1.2 – TECNA WELDING CONTROL UNITS TO BE USED

The interface for the Field Bus can be exclusively used together with the control units which may be connected
to the CAN serial interface board (Item 50274).
The following list summarises the control units which are currently convenient to be connected:

TE550 - Item 50275;

TE553 - Item 50281;
TE560 - Item 50324;
TE700 - Item 50276;
INVERTER - Item 50280;

1.3 – HOW TO INTERFACE A TECNA WELDING CONTROL UNIT

The TECNA control board (Item 50287) allows the use of the Field Bus for the programming (on INVERTER
1500R with PROFIBUS only), the l/O signals management and the welding data recall from the TECNA control
units, which are provided with the CAN interface board.
This device is connected as an interface between the welding control unit and the Field Bus as it is shown in the
following pictures:

Field Bus

welding control unit CAN Field Bus - TECNA

with CAN output communication Bridge
cable Item.50287

The connection between the control unit and the Field Bus module will be guaranteed through the CAN interface
and the CAN serial communication cable, which has to satisfy the requirement of appropriate length.
The choice of the cable to be used will be established according to the customer’s specifications.

5/36
 S.p.A. FIELD BUS Installation Manual

CHAPTER 2 – INSTALLATION AND CONFIGURATION OF THE FIELD BUS CONTROL

BOARD
Before supplying the field bus module, it is necessary to configure the network address, the data transfer speed
and the operative functioning modality, besides the choice of the electric termination of the CAN communication
network. All these adjustments have to be carried out by means of selectors which are present inside the
module. Paying attention not to damage any components, it is necessary to open the shells in order to reach the
selectors (S1, S2, S3, S4) present on the control board.

J5: CAN TERMINATION

All the internal adjustments relevant to the network address selection, to the field bus data
transfer speed as well as to the operative functioning mode have to be carried out and
completed before the switching on of the control board.

2.1 – SELECTORS CONFIGURATION

The different meanings of the selectors as well as their relevant adjustments will be following described:

2.1.1 – TRANSFER SPEED

When a module for DEVICENET or CANOPEN is used on the control board, it is necessary to adjust the data
transfer speed according to the Master speed they are connected to.
The S1-1 and S1-2 selectors allow to set the speed as it is shown in the following table:
S1-1 S1-2 Field bus speed
OFF OFF 125K
ON OFF 250K
OFF ON 500K
For all the other bus types supported by the control board, the speed is automatically set in accordance with the
Master transfer speed.

2.1.2 – FUNCTIONING MODALITY

The S1-3 and S1-4 selectors allow to configure the Bridge working mode as shown in the following table:

S1-3 S1-4 Working mode

OFF OFF UNIVERSAL - NO PROGRAMMING
INVERTER - WITH PROGRAMMING
OFF ON
(see the instructions at the following page)*
ON OFF NO CONFIGURATION ALLOWED
ON ON NO CONFIGURATION ALLOWED

When both the S1-3 and S1-4 selectors are set on OFF, the Bridge can be connected to any supported control
unit without further configurations. Thanks to the Field Bus it will be possible to control the inputs as well as the
outputs of the control unit but it won’t be possible to carry the programming phase out.

6/36
Installation Manual FIELD BUS S.p.A.

* Should the Bridge be connected to an INVERTER, properly setting the S1-3 and S1-4 selectors, it would
be possible to carry also this very control unit programming out by means of the Field Bus.

For this mode of operation, it is also necessary to properly amend the selectors on the
boards of the INVERTER as it is shown below.

Adjust the selector SW1 which is on the board 50280 of the inverter on the address 1 instead of 2.

Adjust the selectors on the board 50256 of the inverter on the address 1 instead of 2.

7/36
 S.p.A. FIELD BUS Installation Manual

2.1.3 – NETWORK ADDRESS SELECTION

By using more devices connected in a sole network, it is necessary to assign them a univocal network address,
so to avoid conflicts during the communication.
By using the S3 and S4 selectors it is possible to set the node address within the network. Having a 8-bit
dedicated register, the network address can assume values included in the domain [0 - 255].

Ex. of possible configurations for the network address:

S4-4 S4-3 S4-2 S4-1 S3-4 S3-3 S3-2 S3-1 Address

- - - - - - - X 1
- - - - - - X X 3
- - - - X X X X 15
- - - X - - - - 16
- - X - - - - - 32
- X - - - - - - 64
X - - - - - - - 128

Currently, the S2 selector is not used.

2.2 – CONTROL BOARD CAN CABLE TERMINATION

For its correct use, the CAN serial communication needs the electrical termination both on the first as well as on
the last connector of the realised wiring. This is due to the fact that in a real transmission line, if the transmitter’s
output resistance and the receiver’s input resistance are not aligned to the characteristic impedance of the used
line, the propagated signal will be reflected by the receiver, causing interferences which are not to neglect. In
this case, it can be said that the transmission lines have to be “adapted” or “completed”.
The connector J5 is present on the control board in order to carry this kind of operation out (by default the
termination results to be closed).

OPEN TERMINATION CLOSED TERMINATION (default)

8/36
Installation Manual FIELD BUS S.p.A.

2.3 – CONTROL BOARD’S TECHNICAL FEATURES

The TECNA control board (Item. 50287) is the communication interface between the welding control unit, which
represents the slave unit, and an external Master unit, such as for example a PLC on Profibus cable.
On the 9-pole male side connector, it will be connected the CAN communication cable coming from the welding
control unit, whilst on the 9-pole female connector of the upper front, it will be the Master unit to be interfaced.
The interface can be supplied both at 24 Vac as well as at 24 VDC.

The interface must be switched on and off simultaneously with the control unit that it is
connected to. It is suggested to supply the two devices with the same power transformer.

PIN DESCRIPTION
1 24Vac / 24VDC
2 GND
3 24Vac / 24VDC

9/36
 S.p.A. FIELD BUS Installation Manual

CHAPTER 3 – FUNCTIONING DESCRIPTION

The TECNA control board (Item. 50287), from a functional and logic point of view, transmits the information that
are exchanged both between the reference Master unit and the slave unit as well as the other way around. To
this very end, it uses two different communication sessions:

Cyclic communication
Acyclic communication

During a cyclic communication session, the inserted data will be those ones that are read and written in a
continuous way, and it is the case of the welding control unit I/O signals.

During an acyclic communication session, the transmitted data will be those ones whose recall is relatively not
very frequent, such as for example the working programme parameters or those data relevant to the different
kinds of menu present on the reference unit, status words or welding data.

Both these data typologies are classified as ADIs and they are allocated in a dedicated memory space.

3.1 – CONTROL UNIT STATUS

The control unit can have two different operative status; a STOP status correspondent to a logic “0” and a RUN
status correspondent to a logic “1”.
In the cyclic ADIs, an input (REQUESTED STATUS) and an output (CURRENT STATUS) relevant to the
representation of the welding control unit’s functioning status are present.

When the control unit is set on RUN,

it is possible:
to use the digital or physical inputs of the control unit in order to carry welding cycles out;
to read the control unit status (after a FAIL condition only);
to read the data relevant to the last carried out welding cycle.

but it is not possible to access the programming parameters of the control unit itself.

When the control unit is set on STOP,

It is possible:
to read the control unit’s status (after a FAIL condition only);
to read the data relevant to the last carried out welding cycle;
to perform the programming of the control unit’s functioning parameters

but it is not possible to modify the digital inputs status, except for the REQUESTED STATUS and ENABLE
commands. If the ENABLE input is deactivated (logic “0”), the control unit will use the physical inputs; at the
same time, during the STOP phase the physical inputs status will remain ignored.
As a consequence, it is not possible to perform welding cycles when the control unit is set on STOP.

After having programmed the control unit's operating parameters, the entered data are
saved in it only on switching from the STOP status to the RUN status. If power is cut to
the control unit before then, data associated with the relevant programming will be lost
and the control unit will remain configured with previously stored data.

In order to perform the switching between the two control unit’s functioning states, it is necessary to change the
REQUIRED STATUS input status till the CURRENTLY STATUS output assumes a logic value equal to the value
of the REQUIRED STATUS input. As long as the input and the output do not have the same value, the
control unit’s functioning status remains the one shown on the CURRENTLY STATUS.

10/36
Installation Manual FIELD BUS S.p.A.

3.2 – ADI MAPPING

The following table shows a general mapping of both cyclic and acyclic ADIs within the available memory space.
The address in the left column represents the starting address expressed in decimal system, from which its
relevant ADIs are mapped into a specific entry.

ADI DESCRIPTION
0 Cyclic ADI
Reading and writing access always permitted.
10 Control Status
Only reading access always permitted.
17 Programming menu ID to be accessed
Reading and Writing access permitted when the control unit is set on STOP only
18 Number of the affected weld programme
Reading and Writing access permitted when the control unit is set on STOP only
19 Not implemented
Only Reading access permitted when the control unit is set on STOP only
20 Welds data
Only Reading access permitted when the control unit is set on RUN only
100 Data relative to selected ID menu
Reading and Writing access permitted when the control unit is set on STOP only

3.3 – DESCRIPTION OF THE PARAMETERS PROGRAMMING (WITH PROFIBUS ONLY)

When the control unit is set on STOP, it is possible to perform the programming of the control unit’s functioning
parameters. All the menus containing the programming parameters are mapped in a memory space that is kept
for the acyclic ADI starting from the n.100 up to the address n.250 address for a total amount of maximum 150
simultaneously available parameters. Within this memory space, it is possible to access a programming menu at
a time, whose data will be mapped starting from the address n.100.
In order to select the menu to be accessed, it is necessary to write the menu ID itself in the 17 ADI.
The writing of the required ID makes the data relevant to the selected menu available in the memory space
starting from the address n.100.

The data modified in the previously recalled menu are saved in the control unit:
every time a menu is recalled through the 17 ADI;
after the switching from the STOP functioning status to the RUN status.

Every time a menu is recalled through the 17 ADI, the data which have been modified in the previously recalled
menu are saved in the control unit. The data relevant to a menu are saved in the control unit after the switching
from the STOP functioning status to the RUN status also.

In order to access the programming menu (ID 30) of the welding parameters, it is necessary to use the 18 ADI
for selecting the program that has to be available starting from the ADI whose address is 100.

In order to access the programming menu (ID 30) of the welding parameters, it is necessary to use also the 18
ADI. After the selection of the menu type to be worked on through the 17 ADI, it is necessary to write in the 18
ADI which program you want to operate on; after writing the programme number, the data relevant to the
required programme will be available starting from the ADI whose address is 100.

The data saving relevant to the modified programming parameters happens as follows:
through the 17 ADI when it is required the access to a different menu in comparison with the planned
menu;
through the 18 ADI when it is required the access to a welding program which is different in comparison
with the currently charged on the acyclic ADI one;
in the switching from the STOP status to a RUN status.

11/36
 S.p.A. FIELD BUS Installation Manual

CHAPTER 4 – ADI MAPPING FOR TECNA CONTROL UNITS.

4.1 – CYCLIC ADI
The cyclic ADIs make the control unit’s inputs and outputs available through the Field Bus. The unused bytes
are not mapped. Every bit matches with an input; by convenience if the bit is equal to 1, its relevant input results
to be active, if the bit is equal to 0, the input results to be disabled.

The inputs and outputs marked with (*) are digital repetitions of physical input signals present on the control unit.
Should more information relevant to the use of these lines be required, it is advisable to refer to the control unit’s
manual.

4.1.1 – INPUT SIGNALS DESCRIPTION

The ENABLE command is used in order to make the control unit able to receive either the physical inputs or the
virtual inputs:
when the input ENABLE is equal to “0” the control unit ignores the logical inputs status and relies its
functioning on the physical inputs present on the control board

when the input ENABLE is equal to “1” the control unit ignores the physical inputs present on the control
board and relies its functioning on the status of the logical inputs, which have been received via Bus
Field.
The input REQUESTED STATUS indicates the control unit’s status which is requested by the Master. In case
further information concerning this function is required, it is advisable to consult paragraph 3.1 – CONTROL
UNIT’S STATUS.

The RESTART input command is considered by the control unit during the switching on only and it is ignored
afterwards.

The ERROR RESET command resets possible further error conditions that the control unit could face. The input
is active when the control unit’s status is set on RUN whilst it is ignored when it is set on STOP. Also, the input
START does not have to be active. In order to reset the errors, it is necessary to switch the input from 0 to 1
and back to 0 afterwards; when this operation has been completed, the ADIs relevant to the control status will be
updated.

The DRESSING RESET command produces the signal of electrodes’s carried out dressing after the DRESSING
ALARM has been enabled by the control unit.
The input is active when the control unit’s status is set on RUN whilst it is ignored when it is set on STOP. Also,
the input START does not have to be active. In order to produce the signal of carried out DRESSING, it is
necessary to switch the input from 0 to 1 and back to 0 afterwards.

The ELECTRODES RESET command produces the signal of electrodes’s carried out replacement, after the
ELECTRODES REPLACEMENT ALARM output has been enabled by the control unit.
The input is active when the control unit is set on RUN whilst it is ignored when it is set on STOP. Also the input
START does not have to be active.
In order to produce the signal of carried out replacement, it is necessary to switch the input from 0 to 1 and back
to 0 afterwards.

12/36
Installation Manual FIELD BUS S.p.A.

The following table shows the lists relevant to the inputs and outputs present on the control units.

4.1.2 – INPUTS MAPPING

TE550 / TE553
BYTE 0
BIT 7 START input (*) Active when set on RUN only
BIT 6 AUX input (*) Active when set on RUN only
BIT 5 DOUBLE STROKE input (*) Active when set on RUN only
BIT 4 START 2 input (*) Active when set on RUN only
BIT 3 RIC 1 input (*) Active when set on RUN only
BIT 2 RIC 2 input (*) Active when set on RUN only
BIT 1 RIC 3 input (*) Active when set on RUN only
BIT 0 RIC 4 input (*) Active when set on RUN only
BYTE 1
BIT 7 # Not mapped
BIT 6 RIC 5 input (*) Active when set on RUN only
BIT 5 # Not mapped
BIT 4 # Not mapped
BIT 3 ELECTRODES RESET command Active when set on RUN only
BIT 2 ERRORS RESET command Active when set on RUN only
BIT 1 WELD – NO WELD input (*) Active when set on RUN only
BIT 0 DRESSING RESET command Active when set on RUN only
BYTE 2
BIT 2 RESTART input (*) Active when set on RUN only
BIT 1 REQUESTED STATUS command Active when set on RUN and STOP
BIT 0 ENABLE command Active when set on RUN and STOP

TE560
BYTE 0
BIT 7 START input (*) Active when set on RUN only
BIT 6 AUX input (*) Active when set on RUN only
BIT 5 OPEN input (*) Active when set on RUN only
BIT 4 START 2 input (*) Active when set on RUN only
BIT 3 RIC 1 input (*) Active when set on RUN only
BIT 2 RIC 2 input (*) Active when set on RUN only
BIT 1 EXT. RIC 1 input (*) Active when set on RUN only
BIT 0 EXT. RIC 2 input (*) Active when set on RUN only
BYTE 1
BIT 7 EXT. RIC 4 input (*) Active when set on RUN only
BIT 6 EXT. RIC 5 input (*) Active when set on RUN only
BIT 5 SAFETY input (*) Active when set on RUN only
BIT 4 EXT. RIC 3 Input (*) Active when set on RUN only
BIT 3 ELECTRODES RESET command Active when set on RUN only
BIT 2 ERRORS RESET command Active when set on RUN only
BIT 1 WELD – NO WELD input (*) Active when set on RUN only
BIT 0 DRESSING RESET command Active when set on RUN only
BYTE 2
BIT 2 RESTART input (*) Active when set on RUN only
BIT 1 REQUIRED STATUS command Active when set on RUN and STOP
BIT 0 ENABLE command Active when set on RUN and STOP

13/36
 S.p.A. FIELD BUS Installation Manual

TE700
BYTE 0
BIT 7 START input (*) Active when set on RUN only
BIT 6 AUX input (*) Active when set on RUN only
BIT 5 DOUBLE STROKE input (*) Active when set on RUN only
BIT 4 START 2 input (*) Active when set on RUN only
BIT 3 RIC 1 input (*) Active when set on RUN only
BIT 2 RIC 2 input (*) Active when set on RUN only
BIT 1 RIC 3 input (*) Active when set on RUN only
BIT 0 RIC 4 input (*) Active when set on RUN only

BYTE 1
BIT 7 RIC 6 input (*) Active when set on RUN only
BIT 6 RIC 5 input (*) Active when set on RUN only
BIT 5 RIC 8 input (*) Active when set on RUN only
BIT 4 RIC 7 input (*) Active when set on RUN only
BIT 3 SPOTS COUNTER RESET command Active when set on RUN only
BIT 2 ERRORS RESET command Active when set on RUN only
BIT 1 WELD – NO WELD input (*) Active when set on RUN only
BIT 0 DRESSING RESET command Active when set on RUN only
BYTE 2
BIT 2 RESTART input (*) Active when set on RUN only
BIT 1 REQUIRED STATUS command Active when set on RUN and STOP
BIT 0 ENABLE command Active when set on RUN and STOP

INVERTER 1500R
BYTE 0
BIT 7 START input (*) Active when set on RUN only
BIT 6 WELD – NO WELD input (*) Active when set on RUN only
BIT 5 WELD 2 – RIC 5 input (*) Active when set on RUN only
BIT 4 RIC 1 input (*) Active when set on RUN only
BIT 3 RIC 2 input (*) Active when set on RUN only
BIT 2 RIC 3 input (*) Active when set on RUN only
BIT 1 RIC 4 input (*) Active when set on RUN only
BIT 0 SPOTS COUNTER RESET 1 input (*) Active when set on RUN only
BYTE 1
BIT 7 SPOTS COUNTER RESET 2 input (*) Active when set on RUN only
BIT 6 SPOTS COUNTER RESET 3 input (*) Active when set on RUN only
BIT 5 SPOTS COUNTER RESET 4 input (*) Active when set on RUN only
BIT 4 ERRORS RESET command Active when set on RUN only
BIT 3 DRESSING RESET 1 command Active when set on RUN only
BIT 2 DRESSING RESET 2 command Active when set on RUN only
BIT 1 DRESSING RESET 3 command Active when set on RUN only
BIT 0 DRESSING RESET 4 command Active when set on RUN only
BYTE 2
BIT 7 RIC 6 input (*) Active when set on RUN only
BIT 6 RIC 7 input (*) Active when set on RUN only
BIT 5 RIC 8 input (*) Active when set on RUN only
BIT 4 # Not mapped
BIT 3 # Not mapped
BIT 2 # Not mapped
BIT 1 REQUIRED STATUS command Active when set on RUN and STOP
BIT 0 ENABLE command Active when set on RUN and STOP

14/36
Installation Manual FIELD BUS S.p.A.

4.1.3 – OUTPUT SIGNALS DESCRIPTION

The outputs status is modified every time an output changes its status; furthermore it is
constantly updated every time the ADIs relevant to the control units' outputs are written.

The CURRENT STATUS output indicates the control unit’s status. For more information with regards to this
function, it is worthwhile to consult the paragraph 3.1 – CONTROL UNIT STATUS.

The logical output PLC_SINC represents a synchronism signal which has been sent outgoing from the control
unit during a welding cycle. As for the LOCK signal, it is activated during the PRE-WELDING phase (if it exists),
during the SLOPE UP and WELD phases and it is deactivated before the HOLD time.
This signal is present both when the control unit is set on WELD and when it is set on NO WELD.

The two logical outputs LOCK and END represent respectively the functions of INTERBLOCK and CYCLE END
for the relative control unit.
The signal LOCK is present when the control unit is set on WELD only, whilst the signal END is always present
at the end of any welding cycle.

The TERM- FLUX output reproduces the physical input status of the thermostat and/or the protection fluxostat.

The WELD READY indicates the moment (when shifting to the descent front) when all the data relevant to the
just performed welding are available.

The FAIL output is usually disabled during the normal functioning of the control unit and it activates only when it
occurs that particular circumstances prevent the control from proper functioning.

4.1.4 – OUTPUTS MAPPING

TE550 / TE553 / TE560

BYTE 3
BIT 7 PLC_SINC output
BIT 6 WRONG output (*)
BIT 5 #
BIT 4 TERM – FLUX output (*)
BIT 3 EMERGENCY output (*)
BIT 2 EV1 output (*)
BIT 1 EV2 output (*)
BIT 0 EV3 output (*)
BYTE 4
BIT 7 EV4 output (*)
BIT 6 AUX3 output (*)
BIT 5 ELECTRODES CHANGE ALARM output (*)
BIT 4 DRESSING ALARM output (*)
BIT 3 #
BIT 2 #
BIT 1 LOCK output
BIT 0 END output
BYTE 5
BIT 2 WELD READY output
BIT 1 CURRENT STATUS output
BIT 0 FAIL output

15/36
 S.p.A. FIELD BUS Installation Manual

TE700
BYTE 3
BIT 7 PLC_SYNC output
BIT 6 WRONG (*)output
BIT 5 INVERTER READY output (*)
BIT 4 TERM – FLUX output (*)
BIT 3 EMERGENCY output (*)
BIT 2 EV1 output (*)
BIT 1 EV2 output (*)
BIT 0 EV3 output (*)
BYTE 4
BIT 7 EV4 output (*)
BIT 6 AUX3 output (*)
BIT 5 END LIFE output (*)
BIT 4 PRE WARNING output (*)
BIT 3 LOCK-END output
BIT 2 #
BIT 1 #
BIT 0 #
BYTE 5
BIT 2 WELD READY output
BIT 1 CURRENT STATUS output
BIT 0 FAIL output

INVERTER 1500R
BYTE 3
BIT 7 PLC SYNC output
BIT 6 WRONG output (*)
BIT 5 READY output (*)
BIT 4 H2O VALVE output (*)
BIT 3 THERMOSTAT output (*)
BIT 2 EMERGENCY output (*)
BIT 1 LOCK
BIT 0 #
BYTE 5
BIT 2 WELD READY output
BIT 1 CURRENT STATUS output
BIT 0 FAIL output

4.1.5 – PROFIBUS MODULE MAPPINGS

Slot number Id. DP Ordination number / Identification Address Input Address Output
1 160 Output 1 byte 256
2 160 Output 1 byte 257
3 160 Output 1 byte 258
4 144 Input 1 byte 256
5 144 Input 1 byte 257
6 144 Input 1 byte 258
7 144 Input 1 byte 259
8 144 Input 1 byte 260
9 144 Input 1 byte 261

16/36
Installation Manual FIELD BUS S.p.A.

4.2 – ACYCLIC ADI (WITH PROFIBUS ONLY)

4.2.1 – CONTROL UNIT STATUS

ADI 10:
It contains the control unit’s operating status instructions, its size is 1 byte and its values vary between 0 and
255. It is equal to 0 when the control unit works properly.

TE550
ADI MEANING RANGE CONVERSION FACTOR
10 Functioning status 0 - 250 1 open relay 1
(Error code) 2 closed relay 1
3 open relay 2
4 closed relay 2
5 defect on both relays
6 crc inner memory
7 network synchronism failure
8 out of limits 50-60 network frequency
9 short- circuited solenoid valve
101 emergency failure
102 thermostat or fluxostat
103 current alarm
104 spots max number - electrodes replacement
105 solenoid valves over-temperature
106 min current limit
107 max current limit
108 min conduction limit
109 max conduction limit
110 reached energy in min time
111 not reached energy in max time
112 current signal failure
113 electrodes voltage failure
114 off the scale current
115 off the scale voltage
116 finished spots – electrodes dressing
117 worn electrodes – use new ones
118 released start – not finished spot
119 position sensor zero procedure
120 position sensor quote fail
121 position sensor modified structure
122 position sensor fail communication
123 non programmable position sensor
124 min thickness limit
125 max thickness limit
126 min indentation limit
127 max indentation limit
128 position sensor not found
129 pressure sensor’s measurement

17/36
 S.p.A. FIELD BUS Installation Manual

200 energy modality - min > max time

201 min > max current limit
202 min > max conduction limit
203 total impulses number > max welding time
204 not programmable if active dressings
205 not programmable if active stepper
206 current parameter superior to the range
207 dressing offset > increased value
208 maximum current limit superior to the range
209 min > max thickness limit
210 min > max indentation limit
211 not programmable when active seam welding
212 not programmable when active butt weld
213 not programmable if high-speed function is active
214 min > max pressure limit

TE560
ADI MEANING RANGE CONVERSION FACTOR
10 Functioning Status 0 - 250 1 open relay 1
( Error code) 2 closed relay 1
3 open relay 2
4 closed relay 2
5 defect on both relays
6 crc inner memory
7 network synchronism failure
8 out of limits 50-60 network frequency
9 short- circuited solenoid valve
101 emergency failure
102 thermostat or fluxostat
103 current alarm
104 spots max number – electrodes replacement
105 solenoid valves over-temperature
106 min current limit
107 max current limit
108 min conduction limit
109 max conduction limit
110 reached energy in the min time
111 not reached Energy in the max time
112 current signal failure
113 electrodes voltage failure
114 off the scale current
115 off the scale voltage
116 finished spots – electrodes dressing
117 worn electrodes – use new ones
118 released start – not finished spot
119 position sensor zero procedure

18/36
Installation Manual FIELD BUS S.p.A.

120 position sensor quote fail

121 position sensor modified structure
122 position sensor fail communication
123 non programmable position sensor
124 min thickness limit
125 max thickness limit
126 min indentation limit
127 max indentation limit
128 position sensor not found
200 Energy modality - min > max time
201 min > max current limit
202 min > max conduction limit
203 total impulses number > maximum welding time
204 not programmable if active dressings
205 not programmable if active stepper
206 current parameter superior to the range
207 dressing offset > increased value
208 max current limit superior to the range
209 warning release safety button
210 warning release open button
211 min > max thickness limit
212 min > max indentation limit

19/36
 S.p.A. FIELD BUS Installation Manual

TE553
ADI MEANING RANGE CONVERSION FACTOR
10 Functioning Status 0 - 250 1 open relay 1
( Error code) 2 closed relay 1
3 open relay 2
4 closed relay 2
5 defect on both relays
6 crc inner memory
7 network synchronism failure
8 out of limits 50-60 network frequency
9 short- circuited solenoid valve
101 emergency failure
102 thermostat or fluxostat
103 current alarm
104 spots max number – electrodes replacement
105 solenoid valves over-temperature
106 min current limit
107 max current limit
108 min conduction limit
109 max conduction limit
110 reached energy in the min time
111 not reached energy in the max time
112 current signal failure
113 electrodes voltage failure
114 off the scale current
115 off the scale voltage
116 finished spots – electrodes dressing
117 worn electrodes – use new ones
118 released start – not finished spot
119 diodes protection
120 aux 3 input
121 position sensor zero procedure
122 position sensor quote fail
123 position sensor modified structure
124 position sensor fail communication
125 non programmable position sensor
126 min thickness limit
127 max thickness limit
128 min indentation limit
129 max indentation limit
130 position sensor not found
200 energy modality - min > max time
201 min > max current limit
202 min > max conduction limit
203 total impulses number > maximum welding time
204 not programmable if active dressings
205 not programmable if active stepper

20/36
Installation Manual FIELD BUS S.p.A.

206 current parameter superior to the range

207 dressing offset > increased value
208 max current limit superior to the range
209 min > max thickness limit
210 min > max indentation limit

TE700
ADI MEANING RANGE CONVERSION FACTOR
10 Functioning Status See Inverter see Inverter
11 Inverter 0 Status See Inverter see Inverter
12 Inverter 1 Status See Inverter see Inverter
13 Inverter 2 Status See Inverter see Inverter

21/36
 S.p.A. FIELD BUS Installation Manual

INVERTER 1500R
ADI MEANING RANGE CONVERSION FACTOR
10 Functioning Status 0-2 0 resettable error
(Error Code) 1 non resettable error
2 Wait “Ready reset” from the Inverter
11 Inverter Status 0 0-2 0 Error occurred in NO- WELD
(Work condition) 1 Error occurred in WELD
2 Status being modified
12 Inverter Status 1 1–4 1 (1 – 4)
(Tool Number)
13 Inverter Status 2 1 – 35 1 failed charge – thermostat failure
(Error Code) 2 CRC EEPROM Error
3 START signal at the end of the charge
4 IGBT driver error
5 thermostat failure
6 control unit’s welding record failure at the end of the welding
cycle
7 primary current measurement failure
8 secondary current measurement failure
9 electrodes voltage measurement failure
10 diodes active thermic protection
11 transformer active thermic protection
12 reached energy before the min time
13 non reached energy in the max time
14 finished stepper
15 necessity to perform the diodes dressing
16 necessity to replace the caps
17 NSPOTMAX reached
18 damaged Rogowsky
19 fail communication
20 Fail init sensore di posizione
21 non consistent program with hardware configuration -
position sensor failure
22 position sensor zero procedure failure
23 position sensor’s communication fail
24 Fail - quote measurement – negative quote
25 Fail - thickness lower than the min limit
26 Fail – greater than the max limit
27 Fail - DYNAMIC mode
28 Fail - not carried out R compensation
29 Fail - initial R less than the min. limit
30 Fail - initial R over max. limit
31 non consistent welding mode with ENE or DYNAMIC
32 reached displacement before min T
33 reached displacement after max T
34 Mains pressure lower than the min limit
35 Mains pressure greater than the max limit

22/36
Installation Manual FIELD BUS S.p.A.

4.2.2 – WELDING DATA

ADI 20:

It contains the data relevant to the last welding cycle which has been carried out by the control unit; in case the
information are not read by the Master before the following welding cycle is performed, these information will be
overwritten with the new data provided by the control unit. They are 16 bit unsigned integers.

TE550
ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT UNIT
20 Program number 1 - 250 1 (1 – 250) -
21 Cycles 0 - 995 10 (0 – 99,5) ~
22 Current 0 - 18000 100 (0 – 180,00) KA
23 Degrees 0 - 180 1 (0 – 180) °
24 Energy 0 - 60000 1 (0 – 60000) J
25 Spots 0 - 65000 1 (0 – 65000) -
26 Limits 0 - 12 0 no set up limits -
1 min. I limit
2 ok I limit
3 max. I limit
4 min. degrees limit
5 ok degrees limit
6 max. degrees limit
7 ok energy limit
8 Energy limit max. time
9 Energy limit min. time
10 ok indentation limit
11 max indentation limit
12 low indentation limit
27 Thickness 0 - 65534 1000 (0 – 65,534) mm
28 Indentation 0 - 9999 1000 (0 – 9,999) mm
29 Pressure 0 - 100 10 (0 – 10,0) Bar

23/36
 S.p.A. FIELD BUS Installation Manual

TE560
ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT UNIT
20 Program number 1 - 250 1 (1 – 250) -
21 cycles 0 - 995 10 (0 – 99,5) ~
22 Current 0 - 9000 100 (0 – 90,00) KA
23 degrees 0 - 180 1 (0 – 180) °
24 Energy 0 - 60000 1 (0 – 60000) J
25 Spots 0 - 65000 1 (0 – 65000) -
26 Limits 0-9 0 No set up limits -
1 min. I limit
2 ok I limit
3 max. I limit
4 min. degrees limit
5 ok degrees limit
6 max. degrees limit
7 ok Energy limit
8 max. T Energy limit
9 min. T Energy limit
27 Thickness 0 - 65534 1000 (0 – 65,534) mm
28 Indentation 0 - 9999 1000 (0 – 9,999) mm
29 Pressure 0 - 100 10 (0 – 10,0) Bar

24/36
Installation Manual FIELD BUS S.p.A.

TE553
ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT
UNIT
20 Program number 1 - 250 1 (1 – 250) -
21 Cycles 0 - 995 10 (0 – 99,5) ~
22 current 0 - 2000 10 (0 – 200.0) KA
23 Energy 0 - 60000 1 (0 – 60000) J
24 Spots 0 - 65000 1 (0 – 65000) -
25 Limits 0-9 0 no set up limits -
1 min. I limit
2 ok I limit
3 max. I limit
4 min. degrees limit
5 ok degrees limit
6 max. degrees limit
7 ok Energy limit
8 max T Energy limit
9 min T Energy limit
26 Thickness 0 - 65534 1000 (0 – 65,534) mm
27 Indentation 0 - 9999 1000 (0 – 9,999) mm

TE700 / INVERTER 1500R

ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT
UNIT
20 Program number 1 - 301 1 (1 – 301) -
21 Not used - - -
22 Not used - - -
23 Not used - - -
24 Not used - - -
25 Not used - - -
26 Not used - - -
27 Not used - - -
28 Not used - - -
29 welding tool number 1-4 1 (1 - 4) -
30 Welding time 0 - 65535 1 (0 - 65535) ms
31 Welding current 0 - 20000 100 (0 - 200.00) KA
32 Energy 0 - 60000 1 (0 - 60000) J
33 Medium Ro 0 - 1000 10 (0 - 100.0) %
34 Spots 0 - 65535 1 (0 - 65535) -
35 Pre-welding time 0 - 65535 1 (0 - 65535) ms
36 Pre-welding current 0 - 20000 100 (0 – 200.00) KA
37 Post welding time 0 - 65535 1 (0 - 65535) ms
38 Post welding current 0 - 20000 100 (0 – 200.00) KA
39 Welding time 2 0 - 65535 1 (0 - 65535) ms
40 Welding current 2 0 - 20000 100 (0 – 200.00) KA
41 Limits 0 - 24 0 No set up limits -
25/36
 S.p.A. FIELD BUS Installation Manual

4 low current
5 high current
6 OK current
7 low RO
8 high RO
9 OK RO
10 low secondary voltage
11 high secondary voltage
12 OK secondary voltage
13 low power
14 high power
15 OK power
16 low Energy
17 high Energy
18 OK Energy
19 low indentation
20 high indentation
21 OK indentation
22 low end R
23 high end R
24 OK end R
42 Power 0 - 60000 100 (0 - 600.00) KW
43 Voltage 0 - 2000 100 (0 - 20.00) V
44 Thermal level 0 - 1000 10 (0 - 100.0) %
45 End Resistance 0 - 60000 10 (0 - 6000.0) uOhm
46 Currently Incremental Step 1-7 1 (1 - 7) -
47 Incremental step number 1-7 1 (1 - 7) -
48 Incremental stepper 1 0 - 2000 10 (0 - 200.0) %
49 Incremental Ending 1 0 - 200 1 (0 - 200) %
50 Incremental stepper 2 0 - 2000 10 (0 - 200.0) %
51 Incremental Ending 2 0 - 200 1 (0 - 200) %
52 Dressing limits 0-4 0 deactivated Dressing -
1 ending life electrodes warning
2 Warning dressing
3 Dressing
4 ending life electrodes
53 Spots dressing 0 - 60000 1 (0 - 60000) -
54 Dressing current position 0 - 60000 1 (0 - 60000) -
55 Thickness 0 - 60000 1000 (0 - 60.000) mm
56 Indentation 0 - 60000 10000 (0 – 6.0000) mm
57 Initial resistance 0 - 60000 1 (0 - 60000) uOhm

26/36
Installation Manual FIELD BUS S.p.A.

4.2.3 – CONTROL UNIT’S PROGRAMMING

In the following table different programmable parameters as well as their relevant ADIs have been reported:

SETUP MENU – ID 1:

INVERTER 1500R
MEASUREMEN
ADI MEANING RANGE CONVERSION FACTOR
T UNIT
100 Inverter size 50 – 4000 1 (50 – 4000) A
101 TA turns 500 – 2000 1 (500 – 2000) -
102 Operating frequency 1–4 1 1000 Hz
2 2000
3 3000
4 4000
103 Adjustment type 1-2 1 secondary adjustment -
2 primary adjustment
104 External Set point 1-3 1 Deactivated -
2 activated on current profile
3 external sensor pressure input
105 The voltage to electrodes 1-2 1 Deactivated -
2 activated
106 Tansformer primary 1-2 1 Deactivated -
thermal current 2 60000 A
107 Transformer thermal Time 1–2 1 Deactivated -
Constant 2 60000 sec
108 Diods thermal Protection 1–7 1 Deactivated -
2 2 * 56DN
3 4 * 56DN
4 8 * 56DN
5 2 * 65DN
6 4 * 65DN
7 8 * 65DN
109 Rogowsky Test 1–2 1 Deactivated -
2 Activated
110 Welding Transformers 1-4 1 (1 – 4) -
Number
111 Transformer 1 turn 1 - 200 1 (1 – 200) -
112 Transformer 1 max. 200 - 20000 100 (2.00 – 200.00) KA
current
113 Transformer 2 turn 1 - 200 1 (1 – 200) -
114 Transformer 2 max 200 - 20000 100 (2.00 – 200.00) KA
current
115 Transformer 3 turn 1 - 200 1 (1 – 200) -
116 Transformer 3 max 200 - 20000 100 (2.00 – 200.00) KA
current
117 Transformer 4 turn 1 - 200 1 (1 – 200) -
118 Transformer 4 max 200 - 20000 100 (2.00 – 200.00) KA
current
119 Autoretain 1–2 1 Activated -
2 Deactivated

27/36
 S.p.A. FIELD BUS Installation Manual

120 Spot – Seams functioning 1–2 1 Seams -

2 Spot
121 Pre-welding functioning 1–2 1 activated -
2 Deactivated
122 Post welding functioning 1–2 1 Activated -
2 Deactivated
123 Welding functioning 2 1–2 1 Activated -
2 Deactivated
124 Dynamic par 1 1 – 15 1 (1 – 15) X
125 Dynamic par 2 30 – 200 1 (30 – 200) %
126 Quality switch 1-4 1 Quality Off -
2 Quality R
3 Quality T
4 Quality R+T

STEPPER MENU – ID 3:

INVERTER 1500R
ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT
UNIT
100 Tool number 1–4 1 (1 – 4) -
101 Welding parameter stepper - 1–3 1 no stepper -
tool 1 2 L1 law stepper
3 L2 law stepper
102 Welding time stepper - tool 1 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
103 Quote stepper - tool 1 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
104 Tot. incremental steps - tool 1 1–7 1 (1 – 7) -
105 Spots 1 tool 1 0 – 10000 1 (0 – 10000) -
106 Spots 2 tool 1 0 – 5000 1 (0 – 5000) -
107 Spots 3 tool 1 0 – 5000 1 (0 – 5000) -
108 Spots 4 tool 1 0 – 5000 1 (0 – 5000) -
109 Spots 5 tool 1 0 – 5000 1 (0 – 5000) -
110 Spots 6 tool 1 0 – 5000 1 (0 – 5000) -
111 Spots 7 tool 1 0 – 5000 1 (0 – 5000) -
112 Stepper 1 law 1 tool 1 0 – 50 1 (0 – 50) %
113 Stepper 1 law 2 tool 1 0 – 50 1 (0 – 50) %
114 Stepper 2 law 1 tool 1 0 – 50 1 (0 – 50) %
115 Stepper 2 law 2 tool 1 0 – 50 1 (0 – 50) %
116 Stepper 3 law 1 tool 1 0 – 50 1 (0 – 50) %
117 Stepper 3 law 2 tool 1 0 – 50 1 (0 – 50) %
118 Stepper 4 law 1 tool 1 0 – 50 1 (0 – 50) %
119 Stepper 4 law 2 tool 1 0 – 50 1 (0 – 50) %
120 Stepper 5 law 1 tool 1 0 – 50 1 (0 – 50) %
121 Stepper 5 law 2 tool 1 0 – 50 1 (0 – 50) %
122 Stepper 6 law 1 tool 1 0 – 50 1 (0 – 50) %
123 Stepper 6 law 2 tool 1 0 – 50 1 (0 – 50) %

28/36
Installation Manual FIELD BUS S.p.A.

124 Stepper 7 law 1 tool 1 0 – 50 1 (0 – 50) %

125 Stepper 7 law 2 tool 1 0 – 50 1 (0 – 50) %
126 Welding parameter stepper - 1–3 1 no stepper -
tool 2 2 L1 law stepper
3 L2 law stepper
127 Welding time stepper - tool 2 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
128 Quote stepper - tool 2 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
129 Tot. number incremental 1–7 1 (1 – 7) -
steps - tool 2
130 Spots 1 tool 2 0 – 10000 1 (0 – 10000) -
131 Spots 2 tool 2 0 – 5000 1 (0 – 5000) -
132 Spots 3 tool 2 0 – 5000 1 (0 – 5000) -
133 Spots 4 tool 2 0 – 5000 1 (0 – 5000) -
134 Spots 5 tool 2 0 – 5000 1 (0 – 5000) -
135 Spots 6 tool 2 0 – 5000 1 (0 – 5000) -
136 Spots 7 tool 2 0 – 5000 1 (0 – 5000) -
137 Stepper 1 law 1 tool 2 0 – 50 1 (0 – 50) %
138 Stepper 1 law 2 tool 2 0 – 50 1 (0 – 50) %
139 Stepper 2 law 1 tool 2 0 – 50 1 (0 – 50) %
140 Stepper 2 law 2 tool 2 0 – 50 1 (0 – 50) %
141 Stepper 3 law 1 tool 2 0 – 50 1 (0 – 50) %
142 Stepper 3 law 2 tool 2 0 – 50 1 (0 – 50) %
143 Stepper 4 law 1 tool 2 0 – 50 1 (0 – 50) %
144 Stepper 4 law 2 tool 2 0 – 50 1 (0 – 50) %
145 Stepper 5 law 1 tool 2 0 – 50 1 (0 – 50) %
146 Stepper 5 law 2 tool 2 0 – 50 1 (0 – 50) %
147 Stepper 6 law 1 tool 2 0 – 50 1 (0 – 50) %
148 Stepper 6 law 2 tool 2 0 – 50 1 (0 – 50) %
149 Stepper 7 law 1 tool 2 0 – 50 1 (0 – 50) %
150 Stepper 7 law 2 tool 2 0 – 50 1 (0 – 50) %
151 Welding parameter stepper - 1–3 1 no stepper -
tool 3 2 L1 law stepper
3 L2 law stepper
152 Welding time stepper - tool 3 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
153 Quote stepper - tool 3 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
154 Tot. number incremental 1–7 1 (1 – 7) -
steps - tool 3
155 Spots 1 tool 3 0 – 10000 1 (0 – 10000) -
156 Spots 2 tool 3 0 – 5000 1 (0 – 5000) -
157 Spots 3 tool 3 0 – 5000 1 (0 – 5000) -
158 Spots 4 tool 3 0 – 5000 1 (0 – 5000) -
159 Spots 5 tool 3 0 – 5000 1 (0 – 5000) -
160 Spots 6 tool 3 0 – 5000 1 (0 – 5000) -
161 Spots 7 tool 3 0 – 5000 1 (0 – 5000) -
29/36
 S.p.A. FIELD BUS Installation Manual

162 Stepper 1 law 1 tool 3 0 – 50 1 (0 – 50) %

163 Stepper 1 law 2 tool 3 0 – 50 1 (0 – 50) %
164 Stepper 2 law 1 tool 3 0 – 50 1 (0 – 50) %
165 Stepper 2 law 2 tool 3 0 – 50 1 (0 – 50) %
166 Stepper t 3 law 1 tool 3 0 – 50 1 (0 – 50) %
167 Stepper 3 law 2 tool 3 0 – 50 1 (0 – 50) %
168 Stepper 4 law 1 tool 3 0 – 50 1 (0 – 50) %
169 Stepper 4 law 2 tool 3 0 – 50 1 (0 – 50) %
170 Stepper 5 law 1 tool 3 0 – 50 1 (0 – 50) %
171 Stepper 5 law 2 tool 3 0 – 50 1 (0 – 50) %
172 Stepper 6 law 1 tool 3 0 – 50 1 (0 – 50) %
173 Stepper 6 law 2 tool 3 0 – 50 1 (0 – 50) %
174 Stepper 7 law1 tool 3 0 – 50 1 (0 – 50) %
175 Stepper 7 law 2 tool 3 0 – 50 1 (0 – 50) %
176 Welding parameter stepper - 1–3 1 no stepper -
tool 4 2 L1 law stepper
3 L2 law stepper
177 Welding time stepper - tool 4 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
178 Quote stepper - tool 4 1–3 1 no stepper -
2 L1 law stepper
3 L2 law stepper
179 Tot. number incremental 1–7 1 (1 – 7) -
steps - tool 4
180 spots 1 tool 4 0 – 10000 1 (0 – 10000) -
181 spots 2 tool 4 0 – 5000 1 (0 – 5000) -
182 spots 3 tool 4 0 – 5000 1 (0 – 5000) -
183 spots 4 tool 4 0 – 5000 1 (0 – 5000) -
184 Spots 5 tool 4 0 – 5000 1 (0 – 5000) -
185 spots 6 tool 4 0 – 5000 1 (0 – 5000) -
186 spots7 tool 4 0 – 5000 1 (0 – 5000) -
187 Stepper 1 law 1 tool 4 0 – 50 1 (0 – 50) %
188 Stepper 1 law 2 tool 4 0 – 50 1 (0 – 50) %
189 Stepper 2 law1 tool 4 0 – 50 1 (0 – 50) %
190 Stepper 2 law 2 tool 4 0 – 50 1 (0 – 50) %
191 Stepper 3 law 1 tool 4 0 – 50 1 (0 – 50) %
192 Stepper 3 law 2 tool 4 0 – 50 1 (0 – 50) %
193 Stepper 4 law 1 tool 4 0 – 50 1 (0 – 50) %
194 Stepper 4 law 2 tool 4 0 – 50 1 (0 – 50) %
195 Stepper 5 law 1 tool 4 0 – 50 1 (0 – 50) %
196 Stepper 5 law 2 tool 4 0 – 50 1 (0 – 50) %
197 Stepper 6 law 1 tool 4 0 – 50 1 (0 – 50) %
198 Stepper 6 law 2 tool 4 0 – 50 1 (0 – 50) %
199 Stepper 7 law 1 tool 4 0 – 50 1 (0 – 50) %
200 Stepper 7 law 2 tool 4 0 – 50 1 (0 – 50) %

30/36
Installation Manual FIELD BUS S.p.A.

DRESSING MENU – ID 10:

INVERTER 1500R
ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT
UNIT
100 tool Number 1–4 1 (1 – 4) -
101 Dressing tool 1 1–2 1 Deactivated -
2 Activated
102 Dressing number - tool 1 1–7 1 (1 – 7) -
103 Dressing Spots - tool 1 1 – 999 1 (1 – 999) -
104 Dressing stepper - tool 1 1 – 99 1 (1 – 99) %
105 dressing pre-warning spots - tool 1 0 – 25 1 (0 – 25) -
106 Electrodes pre- warning spots - 0 – 999 1 (0 – 999) -
tool 1
107 Dressing Offset - tool 1 0 – 99 1 (0 – 99) %
108 Dressing tool 2 1–2 1 Deactivated -
2 Activated
109 Dressing number- tool 2 1–7 1 (1 – 7) -
110 Dressing spots- tool 2 1 – 999 1 (1 – 999) -
111 Dressing stepper - tool 2 1 – 99 1 (1 – 99) %
112 Dressing pre warning spots - tool 2 0 – 25 1 (0 – 25) -
113 Electrodes pre warning spots - tool 0 – 999 1 (0 – 999) -
2
114 Dressing Offset - tool 2 0 – 99 1 (0 – 99) %
115 Dressing tool 3 1–2 1 Deactivated -
2 Activated
116 Dressing number tool 3 1–7 1 (1 – 7) -
117 Dressing spots tool 3 1 – 999 1 (1 – 999) -
118 Dressing stepper tool 3 1 – 99 1 (1 – 99) %
119 Dressing pre warning spots - tool 3 0 – 25 1 (0 – 25) -
120 Electrodes pre warning spots - tool 0 – 999 1 (0 – 999) -
3
121 Dressing Offset - tool 3 0 – 99 1 (0 – 99) %
122 Dressing tool 4 1–2 1 Deactivated -
2 Activated
123 Dressing stepper - tool 4 1–7 1 (1 – 7) -
124 Dressing Spots- tool 4 1 – 999 1 (1 – 999) -
125 Dressing stepper - tool 4 1 – 99 1 (1 – 99) %
126 Dressing pre warning spots - tool 4 0 – 25 1 (0 – 25) -
127 Electrodes pre warning spots - 0 – 999 1 (0 – 999) -
tool 4
128 Dressing Offset - tool 4 0 – 99 1 (0 – 99) %

31/36
 S.p.A. FIELD BUS Installation Manual

PROGRAMME MENU - ID 30:

INVERTER 1500R
MEASUREMEN
ADI MEANING RANGE CONVERSION FACTOR
T UNIT
100 Programme Number 1 – 301 1 (1 – 301) -
101 Working mode 1–6 1 IK -
2 RO
3 VEK
4 PWK
5 ENE
6 DYN
102 Control mode 1–6 1 NO -
2 CURR
3 RO
4 VE
5 PW
6 ENE
103 Not implemented - - -
104 Pre welding time 0 – 1000 1 (0 – 1000) ms
105 Pre welding current 30 – 20000 100 (0.30 – 200.00) KA
106 Pre welding Ro 50 – 1000 10 (5.0 – 100.0) %
107 Pre welding V 20 – 2000 100 (0.20 – 20.00) V
108 Pre welding P 20 – 60000 100 (0.20 – 600.00) KW
109 Not implemented - - -
110 Not implemented - - -
111 Cold time 1 0 – 1000 1 (0 – 1000) ms
112 slope up time 0 – 1000 1 (0 – 1000) ms
113 Welding time 1 1 – 1000 1 (1 – 1000) ms
114 Min welding time 1 1 – 1000 1 (1 – 1000) ms
115 Max welding time 1 1 – 1000 1 (1 – 1000) ms
116 Welding current 1 30 - 20000 100 (0.30 – 200.00) KA
117 Welding Ro 1 50 - 1000 10 (5.0 – 100.0) %
118 Welding V 1 20 – 2000 100 (0.20 – 20.00) V
119 Welding P 1 20 – 60000 100 (0.20 – 600.00) KW
120 Welding energy 1 0 - 60000 1 (0 – 60000) J
121 Quality R 0-3 0 Deactivated -
1 Pre check
2 Post check
3 Pre + Post check
122 Welding Imax 1 200 - 20000 100 (2.00 – 200.00) KA
123 Cold time 2 0 - 1000 1 (0 – 1000) ms
124 Impulses number 0-9 1 (0 – 9) -
125 Welding time 2 0 - 1000 1 (0 – 1000) ms
126 Welding current 2 30 - 20000 100 (0.30 – 200.00) KA
127 Welding Ro 2 50 - 1000 10 (5.0 – 100.0) %
128 Welding V 2 20 – 2000 100 (0.20 – 20.00) V

32/36
Installation Manual FIELD BUS S.p.A.

129 Welding P 2 20 – 60000 100 (0.20 – 600.00) KW

130 Not implemented - - -
131 Not implemented - - -
132 slope down time 0 – 1000 1 (0 – 1000) ms
133 Cold time 3 0 - 1000 1 (0 – 1000) ms
134 Post welding time 0 – 1000 1 (0 – 1000) ms
135 Post welding current 30 – 20000 100 (0.30 – 200.00) KA
136 Post welding Ro 50 – 1000 10 (5.0 – 100.0) %
137 Post welding V 20 – 2000 100 (0.20 – 20.00) V
138 Post welding P 20 – 60000 100 (0.20 – 600.00) KW
139 Min. pressure limit 5 - 100 10 (0.5 – 10.0) Bar
140 Max pressure limit 5 - 100 10 (0.5 – 10.0) Bar
141 Min. I limit 30 - 20000 100 (0.30 – 200.00) KA
142 Max I limit 30 - 20000 100 (0.30 – 200.00) KA
143 min Ro limit 50 – 1000 10 (5.0 – 100.0) %
144 Max Ro limit 50 – 1000 10 (5.0 – 100.0) %
145 Min V limit 20 - 2000 100 (0.20 – 20.00) V
146 max V limit 20 - 2000 100 (0.20 – 20.00) V
147 Min E limit 0 – 60000 1 (0 – 60000) J
148 max E limit 0 – 60000 1 (0 – 60000) J
149 Min P limit 20 – 60000 100 (0.20 – 600.00) KW
150 Max P limit 20 – 60000 100 (0.20 – 600.00) KW
151 welding tool number 1–4 1 (1 – 4) -
152 Quality T 1–7 1 deactivated sensor -
2 thickness only
3 Identation only
4 Thickness + identation
5 zero Procedure
6 welding end
7 thickness +welding end
153 Min. thickness 0 – 6000 100 (0 – 60.00) mm
154 Max thickness 0 – 6000 100 (0 – 60.00) mm
155 Min. indentation 0 - 6000 100 (0 – 6.000) mm
156 Max indentation 0 - 6000 100 (0 – 6.000) mm

All the parameters are 16 bit unsigned integers. For more details relevant to the parameters meaning, please
refer to the control unit manual.

33/36
 S.p.A. FIELD BUS Installation Manual

POSITION SENSOR MENU– ID 39:

INVERTER 1500R
ADI MEANING RANGE CONVERSION FACTOR MEASUREMENT
UNIT
100 Position sensor 1–2 1 Deactivated -
2 Activated
101 set up sensors number 1–4 1 (1 – 4) -
102 SN 1 sensor 1 0 – 9999 1 (0 – 9999) -
103 SN 2 sensor 1 0 – 9999 1 (0 – 9999) -
104 ID sensor 1 100 – 200 1 (100 – 200) -
105 Delay sensor 1 0 – 1000 1 (0 – 1000) ms
106 SN 1 sensor 2 0 – 9999 1 (0 – 9999) -
107 SN 2 sensor 2 0 – 9999 1 (0 – 9999) -
108 ID sensor 2 100 – 200 1 (100 – 200) -
109 Delay sensor 2 0 – 1000 1 (0 – 1000) ms
110 SN 1 sensor 3 0 – 9999 1 (0 – 9999) -
111 SN 2 sensor 3 0 – 9999 1 (0 – 9999) -
112 ID sensor 3 100 – 200 1 (100 – 200) -
113 Delay sensor 3 0 – 1000 1 (0 – 1000) ms
114 SN 1 sensor 4 0 – 9999 1 (0 – 9999) -
115 SN 2 sensor 4 0 – 9999 1 (0 – 9999) -
116 ID sensor 4 100 – 200 1 (100 – 200) -
117 Delay sensor 4 0 – 1000 1 (0 – 1000) ms

34/36
Installation Manual FIELD BUS S.p.A.

CHAPTER 5 – PROGRAMMING FLOWCHART

In order to be able to switch from the programming status to the welding status and the other way around, it is
necessary to follow the steps reported in the following flowchart.

35/36
 S.p.A. FIELD BUS Installation Manual

CAPITOLO 6 – TECHNICAL FEATURES

POWER SUPPLY: 24Vac +/- 10%

FREQUENCY: 50/60Hz +/- 1%

CONSUMPTION: 0,1A

MAX ALTITUDE: 1000m

RELATIVE HUMIDITY: dal 40% al 80%

WORK TEMPERATURE: 0°C a 50°C / 32°F a 122°F

WEIGHT: 156g / 0,344 lb

PROTECTION RATING: IP40

36/36