Kemppi DCM User manual

DCM Kemppi Cobotics
Operating manual - EN
DIGITAL CONNECTIVITY MODULE (DCM) /
Kemppi Cobotics
Operating manual
© Kemppi 11922170 / 2325

DCM Kemppi Cobotics
Operating manual - EN
CONTENTS
1. General 3
1.1 Equipment description 4
2. Installation 6
2.1 Mounting on equipment 7
2.2 Connecting cables 9
2.3 Installing Kemppi Cobotics application 10
3. Operation 11
3.1 Pairing with mobile device 12
3.2 DCM settings 13
3.3 Status information 14
3.4 Fieldbus control tables 16
3.4.1 Setting control bit states to start welding 20
3.5 Timing diagrams 21
3.5.1 Welding start and stop timing 21
3.5.2 Memory channel change timing 22
3.5.3 Wire inch timing 22
3.6 Resetting 23
3.7 Updating DCM 24
4. Technical data 25
5. Ordering codes 26
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DCM Kemppi Cobotics
Operating manual - EN
1. GENERAL
Kemppi's Digital Connectivity Module (DCM) is a small single-board computer connected directly to the welding power
source or wire feeder. Together with the Kemppi Cobotics application, it forms a connection between the welding equip-
ment and robot / cobot (collaborative robot) via the Modbus TCP fieldbus (in the setup, DCM is a Modbus TCP slave
device).
DCM uses wireless Bluetooth technology for communicating with the mobile device.
DCM for Cobotics is compatible with the following Kemppi welding equipment:
•X5 FastMig (Auto, AP and APC control panels)
>> Firmware version: 1.44
•Master M 353, 355
>> Firmware version: 1.10
Important notes
Read the instructions through carefully. For your own safety, and that of your working environment, pay particular atten-
tion to the safety instructions delivered with the equipment.
Items in the manual that require particular attention in order to minimize damage and harm are indicated with the
below symbols. Read these sections carefully and follow their instructions.
Note: Gives the user a useful piece of information.
Caution: Describes a situation that may result in damage to the equipment or system.
Warning: Describes a potentially dangerous situation. If not avoided, it will result in personal damage or fatal injury.
DISCLAIMER
While every effort has been made to ensure that the information contained in this guide is accurate and com-
plete, no liability can be accepted for any errors or omissions. Kemppi reserves the right to change the spe-
cification of the product described at any time without prior notice. Do not copy, record, reproduce or transmit
the contents of this guide without prior permission from Kemppi.
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DCM Kemppi Cobotics
Operating manual - EN
1.1 Equipment description
1. Function button
2. 3 LED indicators
3. CAN connection (5-pin, M12 bus connector)
4. USB connector *
5. Power connector *
6. Ethernet connector
7. Mounting tape.
* Not needed for normal operation. DCM is powered through the CAN connection.
LEDs explained
a. Red / yellow / green:Additional notification light. (A)
b. Green:Lit when the power is on. (B)
c. Blue:Blinks infrequently when ready and available, blinks more frequently when in "beacon mode", is lit con-
tinuously when a mobile device with the Kemppi Cobotics App is connected. (C)
Additional requirements
•Mobile device with wireless connection support running Android 7.1 or newer(Android 8.0 is recommended) and
Kemppi Cobotics application
•Internet connection available for the mobile device running the Kemppi Cobotics application.
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DCM Kemppi Cobotics
Operating manual - EN
EQUIPMENT IDENTIFICATION
Serial number
Serial number of the device is marked on the rating plate or in another distinctive location on the device.
Quick Response (QR) code
The serial number and other device-related identification information may also be saved in the form of a QR
code (or a barcode) on the device. Such code can be read by a smartphone camera or with a dedicated code
reader device providing fast access to the device-specific information.
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DCM Kemppi Cobotics
Operating manual - EN
2. INSTALLATION
Do not power on the equipment before the installation is complete.
Before installation
Check the contents of the packages and make sure the parts are not damaged.
"Mounting on equipment" on the next page
"Connecting cables" on page9
"Installing Kemppi Cobotics application" on page10
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DCM Kemppi Cobotics
Operating manual - EN
2.1 Mounting on equipment
The DCM device can be fixed on the side of a power source or a wire feeder either with the factory-fitted mounting tape
or with an optional DIN rail.
The mounting tape can be used on any clean and suitable surface. The mounting tape counterparts are attached
together on delivery.
Do not detach the mounting tape counterpart from the DCM device before fixing. This way the mounting tape coun-
terparts are positioned correctly on the installation surface.
Install the DCM device the connectors facing down. This also prevents e.g. dust and impurities from getting into the
connectors.
Fixing with mounting tape
1. Clean the installation surface (where the DCM device is to be fixed).
2. Remove the cover wrappings from the mounting tape counterpart to reveal the adhesive surface. Leave the mount-
ing tape counterparts still attached.
3. Press the DCM device firmly against the installation surface so that the glue sticks.
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DCM Kemppi Cobotics
Operating manual - EN
4. Let the mounting tape's adhesive cure for 30 minutes.
5. Due to the velcro-type mounting tapes, it is now possible to detach and attach the DCM device if needed.
Mounting on DIN rail (optional)
Note that the rail installation typically requires drilling fixing holes on the fixing surface for the rail itself. This is not
covered by this instruction.
The rear of the DCM box has a groove for the standard DIN rail fixing:
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DCM Kemppi Cobotics
Operating manual - EN
2.2 Connecting cables
The DCM requires a CAN and an Ethernet cable to be connected.
Unused DCM connectors are covered. Leave the covers in place.
1. Connect the CAN cable to the power source or wire feeder.
2. Connect the other end of the CAN cable to the DCM (1). Secure the cable by turning the cable coupling firmly on
the connector threads.
3. Connect the Ethernet cable to the DCM (2). Connect the other end of the Ethernet cable to e.g. the robot controller.
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DCM Kemppi Cobotics
Operating manual - EN
2.3 Installing Kemppi Cobotics application
Kemppi Cobotics application is used for configuring DCM network settings and for viewing the communication between
the robot and the welding system. Welding settings are configured in the welding system's control panel.
For Kemppi Cobotics application, a DCM firmware version 1.00.92.0 or newer is required. (For welding equipment firm-
ware versions, refer to "General" on page3.)
1. Scan the QR code below or search for 'Kemppi Cobotics' in Google's Play Store.
2. Install the application.
3. Open the application.
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DCM Kemppi Cobotics
Operating manual - EN
3. OPERATION
"Pairing with mobile device" on the next page
"DCM settings" on page13
"Status information" on page14
"Fieldbus control tables" on page16
"Timing diagrams" on page21
"Resetting" on page23
"Updating DCM" on page24
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Operating manual - EN
3.1 Pairing with mobile device
In order to activate the DCM, a mobile device running the Kemppi Cobotics application must be connected to the DCM
via a wireless connection.
1. Ensure that the green LED(B) is lit and that the blue LED (C) blinks infrequently on the DCM device. For more inform-
ation, refer to "Equipment description" on page4.
2. Open the Kemppi Cobotics application on your mobile device. The application automatically starts searching avail-
able DCM devices.
3. On the list, select the DCM and welding equipment you wish to connect to.
If there are several DCM devices available to choose from and you are uncertain which is which, you can press the
function button on the DCM device briefly (1 sec.) to turn on its beacon. A blue indicator is shown next to the device
in question.
Once the connection is made, the blue LED (C) on the DCM device is lit continuously. Notice that only one mobile device
can be connected to the DCM at a time.
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DCM Kemppi Cobotics
Operating manual - EN
3.2 DCM settings
This section describes how to configure the DCM settings with the Kemppi Cobotics application.
1. Select the parameter for adjusting.
>> Depending on the parameter to be adjusted, refer also to the Settings parameters table below for more details.
2. Enable the Modbus TCP interface by setting the 'Modbus TCP interface' to ON.
Tip: You can go back to the list of devices by clicking the device information bar at the top of the device view.
DCM settings
Parameter Value Description
Modbus TCP interface ON/OFF Enables or disables the Modbus TCP fieldbus interface used for
the communication between the welding equipment and the
robot.
DCM IP address Default = 192.168.0.10 IP address of the DCM.
Subnet mask 0.0.0.0 ...
255.255.255.255
Default = 255.255.255.0
DCM subnet mask.
Gateway E.g. 192.168.0.1 / Empty IPv4 address of the gateway (if used).
Watchdog timeout 0 ... 65535 ms
Default = 0 (OFF)
When the watchdog timeout is set, the robot must toggle the
watchdog control bit between states 1 and 0 continuously
when the robot control mode is enabled. If the robot stops tog-
gling, a watchdog timeout occurs, and the welding system
stops and gives a watchdog error.
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DCM Kemppi Cobotics
Operating manual - EN
3.3 Status information
In the Kemppi Cobotics application you can view the communication between the welding system and the robot.
Parameter Description
General
Communication
OK
Green light: Communication between the welding system and the robot has been established.
No light: Communication between the welding system and the robot has not been established.
Power source
System ready Green light: The welding system is ready for welding. All system devices are correct and working.
No light: The welding system is not ready for welding.
Power source
ready
Green light: The power source is ready to start a new weld.
No light: The power source is not ready to start a new weld.
Arc ON Green light: The welding arc is established.
No light: The welding arc is not established.
Cycle ON Green light: The welding cycle is in progress (the pre gas and post gas phases are included in the welding
cycle).
No light: The welding cycle is complete.
Robot
Welding allowed Safeguards the StartWelding bit so that welding cannot be started if the robot is not ready.
Green light: The robot is ready to start a new weld.
No light: The robot is not ready to start a new weld.
Robot control Green light: Certain functions, such as wire inch and gas test, switch to robot mode in the welding equip-
ment and the welding gun trigger is disabled.
No light: No functions are in robot mode and the welding gun trigger is enabled.
Start welding Starts welding or simulation if the simulation mode is ON.
Green light: The robot has requested welding or simulation.
No light: The robot has not requested welding or simulation.
Simulation Green light: The simulation mode is ON. During welding in the simulation mode the arc is not lit and wire is
not fed. In this mode the operation of the Arc ON and Cycle ON bits is simulated without an ignited arc. The
StartWelding bit controls simulation.
No light: The simulation mode is OFF. The StartWelding bit controls welding.
Gas blow Green light: The shielding gas valve is open for gas blow.
No light: The shielding gas valve is closed.
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Wire inch forward Green light: The wire inch forward function is ON.
No light: The wire inch forward function is OFF.
Wire inch back-
ward
Green light: The wire inch backward function is ON.
No light: The wire inch backward function is OFF.
For the Modbus TCP fieldbus control tables and the control and status parameters, refer to "Fieldbus control tables" on
the next page.
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3.4 Fieldbus control tables
This section describes the Modbus TCP fieldbus control tables.
For information on setting the control bit states for starting welding, refer to "Setting control bit states to start welding"
on page20.
Fieldbus control tables
"Kemppi Cobot" fieldbus control table, control parameters:
Register (word) Coil Data type Bit Control parameter (from cobot to welding machine)
00 Bit 0 StartWelding
1 Bit 1 RobotReadyToWeld
2 Bit 2 (Not in use)
3 Bit 3 GasBlow
4 Bit 4 WireInchForward
5 Bit 5 WireInchBackward
6 Bit 6 SimulationOn
7 Bit 7 RobotControlMode
8 Bit 8 Watchdog
9 Bit 9 (Not in use)
10 Bit 10 (Not in use)
11 Bit 11 (Not in use)
12 Bit 12 (Not in use)
13 Bit 13 (Not in use)
14 Bit 14 (Not in use)
15 Bit 15 (Not in use)
1UINT16 MemoryChannel
2UINT16 (Not in use)
3UINT16 (Not in use)
4UINT16 (Not in use)
"Kemppi Cobot" fieldbus control table, status parameters:
Register (word) Discrete input Data type Bit Status parameter (from welding machine to cobot)
00 Bit 0 WeldingSystemReady
1 Bit 1 PowerSourceReady
2 Bit 2 ArcOn
3 Bit 3 CycleOn
4 Bit 4 WeldingVoltageAdjustOn
5 Bit 5 Error
6 Bit 6 WorkMemoryChannel
7 Bit 7 WatchdogTriggered
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8 Bit 8 WeldingSystemAccess
9 Bit 9 (Not in use)
10 Bit 10 (Not in use)
11 Bit 11 (Not in use)
12 Bit 12 (Not in use)
13 Bit 13 (Not in use)
14 Bit 14 (Not in use)
15 Bit 15 (Not in use)
1UINT16 TAST
2UINT16 WeldingWireFeedSpeed
3UINT16 WeldingVoltage
4UINT16 WeldingCurrent
5UINT16 ErrorNumber
6UINT16 UserNumber
7UINT16 ActiveMemoryChannel
8UINT16 WeldingArcVoltage
9UINT16 WatchdogTimeoutValue
10 UINT16 WeldingProcess
Control information
Control information from the cobot to the welding system is transmitted as parameters and individual bits (signals) in
the fieldbus control table.
Control parameters:
Parameter name Description Parameter
value
Raw (bus)
value
WireFeedSpeed Controls the wire feed speed. 0.5 ... 25.0
m/min
5 ... 250
Voltage/FineTuning Controls the welding voltage for the MIG process. For other welding
processes FineTuning function is used instead.
Voltage:
8.0 ... 46.0 V
FineTuning:
-10...+10
Voltage: 80 ...
460
FineTuning:
0...200
WeldingCurrent Controls the TIG welding current. 3 ... 500 A 3 ... 500
MemoryChannel Controls the active memory channel. 0 ... 100 0 ... 100
Control bits:
Control bit name Description Bit state 0 Bit state 1 Requirements
StartWelding Starts the welding sequence. If the sim-
ulation mode is ON (SimulationOn = 1),
this controls the simulation sequence
instead.
Welding / sim-
ulation OFF
Welding / sim-
ulation ON
RobotControlMode =
1
and WeldingAllowed
= 1
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Operating manual - EN
RobotReadyToWeld Safeguards the StartWelding bit so that
welding cannot be started if the robot is
not ready.
Robot is not
ready to weld
(StartWelding
disabled)
Robot is ready
to weld
(StartWelding
enabled)
RobotControlMode =
1
OnlineControl Enables robot-controlled values for wire
feed speed and voltage/fine tuning.
When the robot is in online mode and
uses the WireFeedSpeed and
Voltage/FineTuning control functions,
the corresponding values in the active
memory channel are overridden.
When the robot is in offline mode, it
gives full control to the welding system
and the values from the active memory
channel are used.
Offline control
(values from
memory chan-
nel are used)
Online control
(robot controls
certain welding
parameters)
RobotControlMode =
1
GasBlow Opens the shielding gas valve for testing
/ purging purposes. During welding the
gas valve is controlled automatically, so
during welding this bit has no effect.
Gas blow OFF Gas blow ON RobotControlMode =
1
WireInchForward Feeds the welding wire forward. The wire
is fed at the speed of 1.0 m/min for 3
seconds and then 5.0 m/min.
Wire inch for-
ward OFF
Wire inch for-
ward ON
RobotControlMode =
1
WireInchBackward Feeds the welding wire backwards. The
wire is fed at the speed of 1.0 m/min for 3
seconds and then stepped to 5.0 m/min.
Wire inch back-
ward OFF
Wire inch back-
ward ON
RobotControlMode =
1
SimulationOn Turns the welding simulation mode ON
and OFF. During simulated welding the
arc is not established.
No simulation
mode: Normal
welding
sequence
Simulation
mode: Sim-
ulated welding
sequence (arc is
not lit)
RobotControlMode =
1
RobotControlMode Defines whether the robot has control of
the welding equipment. When the robot
controls the welding equipment, the
welding gun trigger is disabled.
Robot control
mode disabled.
Robot cannot
control the weld-
ing equipment,
welding gun
trigger is
enabled.
Robot control
mode enabled.
Robot can con-
trol the welding
equipment, the
welding gun
trigger is dis-
abled.
Watchdog If you set a value for the watchdog
timeout parameter (in the Kemppi Cobot-
ics application), the robot must toggle
the watchdog control bit between states
1 and 0 continuously when the robot
control mode is enabled. If the robot
stops toggling, a watchdog timeout
occurs (WatchdogTriggered bit state =
1), and the welding system stops and
gives a watchdog error.
- - RobotControlMode =
1
Status information
Status information from the welding system to the robot is transmitted as parameters and individual bits (signals) in the
fieldbus control table.
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Status parameters:
Parameter name Description Parameter
value
Raw
(bus)
value
WeldingWireFeedSpeed Measured welding wire feed speed. 0 ... 25.5
m/min
0 ... 255
WeldingVoltage Measured welding (terminal) voltage. 0 ... 6553.5 V 0 ...
65535
WeldingCurrent Measured welding current. 0 ... 65535 A 0 ...
65535
TAST TAST (Through Arc Seam Tracking) value.
TAST is used for providing precise welds depending on specific weld
characteristics or in setups where the position of the work piece varies
during repetitive tasks.
0 ... 65535 0 ...
65535
ErrorNumber System error / warning number. 0 ... 65535 -
UserNumber Current user number. 0 ... 10 0 ... 10
ActiveMemoryChannel Current memory channel number. 0 ... 99 0 ... 99
WeldingArcVoltage Measured welding arc voltage. 0 ...6553.5 V 0 ...
65535
WatchdogTimeoutValue Watchdog timeout defined by the user. 0 ... 65535 0 ...
65535
WeldingProcess Current welding process. 0 ... 18
0 = Unknown
1 = MIG
2 = 1-MIG
3 = Pulse MIG
4 = DPulse
MIG
9 = WiseRoot
10 =
WiseThin
11 =
WiseRoot+
14 = WiseTh-
in+
16 = MAX
Speed
17 = MAX
Cool
18 = MAX
Position
0 ... 18
Status bits:
Status bit name Description Bit state 0 Bit state 1
WeldingSystem Ready Indicates whether the welding system is ready
to be used for welding. The system is ready
when all necessary devices are present and no
error is active.
Welding system is not
ready
Welding system is
ready
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PowerSourceReady Indicates whether the power source is ready to
start a new weld. The power source is ready
when the robot has not requested welding and
crater fill is not ongoing.
Power source is busy Power source is ready
for a new weld
ArcOn Indicates whether welding arc is established. No welding arc Welding arc estab-
lished
CycleOn Indicates whether welding cycle is ongoing. The
welding cycle includes also pre gas, creep start,
crater fill and post gas phases.
Welding cycle not act-
ive
Welding cycle active
WeldingVoltageAdjustOn Describes whether the Voltage/FineTuning para-
meter controls the welding voltage or the fine
tuning value.
Voltage/FineTuning
parameter controls
the fine tuning value
Voltage/FineTuning
parameter controls
the welding voltage
value
Error Indicates whether there is an error in the system
that prevents welding.
No error or only a
warning
Error in welding sys-
tem
WorkMemoryChannel Indicates whether the current channel is a work-
ing channel.
Normal memory chan-
nel
Working memory
channel
WatchdogTriggered Bit state 1 indicates that the watchdog timeout
has been exceeded and the welding system has
stopped.
OK Watchdog timeout
has occurred
WeldingSystemAccess Indicates whether the Modbus TCP server has
access to control the welding system’s para-
meters.
No access (the weld-
ing parameters are
read-only)
Full access to welding
system parameters
3.4.1 Setting control bit states to start welding
This section describes the control bits and their states required to start welding with the robot.
1. Set the control bit RobotControlMode to state 1.
>> Sets the welding machine to the robot control mode.
2. Set the control bit RobotReadyToWeld to state 1.
>> The robot allows welding and gives the welding machine permission to ignite the arc.
3. To ignite the arc, set the control bit StartWelding to state 1. If you want to simulate the welding sequence without
igniting the arc, set the control bit SimulationOn to state 1.
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