/ Battery Charging Systems / Welding Technology / solar Electronics

installation instructions

Ethernet / IP DE

Ethernet / IP externally Robot option

42,0410,1870 002-26092012
0
Dear Reader

DE
introduction Thank you for your trust and congratulations on your new, technically high- grade Fronius product. This guide will help you
to familiarize yourself with this. By reading the manual carefully and you will learn of the numerous possibilities of your new
Fronius product. Just so you can benefit from its advantages as possible.

Please also note the safety and make for more safety at your product. Careful handling with your product supports its
long-lasting quality and reliability. These are essential prerequisites for out- standing results.

1
2
Table of Contents

DE
General ................................................. .................................................. ............................................ 5
Safety ................................................. .................................................. ........................................... 5
Device concept ................................................. .................................................. ................................... 5
Operating principle ................................................. .................................................. ................................. 5
Connections on Interface - TSt device series ............................................ .............................................. 5
Example ................................................. .................................................. .......................... 6
Application example for external variant .............................................. .............................................. 6
Notes on installing the external variant ............................................ ............................................ 7
Connect fieldbus coupler .............................................. .................................................. .................... 8th

Safety ................................................. .................................................. ........................................... 8th

Safety ................................................. .................................................. ........................................... 8th

General ................................................. .................................................. ....................................... 8th

Connections on the fieldbus coupler BK9105 ............................................ ................................................ 8th

Connections on the fieldbus coupler BK9105 - external version ......................................... ...................... 9

Connecting Interface Ethernet / IP ............................................. .................................................. .......... 9
Ethernet / IP cable and connector ............................................ .................................................. .... 9
Set IP address .............................................. .................................................. ................................. 11
Overview................................................. .................................................. ............................................ 11
Setting the IP address via BootP Server ........................................... .................................................. 11
Setting the IP address via ARP ............................................ .................................................. ............. 12
Setting the IP address via KS2000 ............................................ .................................................. ........ 13
Fault diagnosis, troubleshooting ............................................... .................................................. ............. 14
Safety ................................................. .................................................. ........................................... 14
See the fieldbus coupler BK9105 ............................................ .................................................. .. 14
LEDs for diagnosing the Spannugsversorgung ............................................. ......................................... 14
LED on RJ5 port ............................................. .................................................. ......................... 15
LEDs for fieldbus diagnosis ............................................. .................................................. .................. 15
LEDs for the diagnosis of K-Bus ........................................... .................................................. ................ 16
Characteristics of data transmission and technical data ............................................ ........................ 18
Characteristics of data transmission ............................................... .................................................. .. 18
Safety device ................................................. .................................................. ........................ 18
Technical data of the fieldbus coupler BK9105 ........................................... .................................... 18
Signal Description Ethernet / IP .............................................. .................................................. ................ 19
General ................................................. .................................................. ....................................... 19
Operating modes of the power source ............................................... .................................................. ............. 19
Operating modes of the power source - TSt device series ............................................ ...................................... 19
Overview................................................. .................................................. ............................................ 19
Input and output signals for MIG / MAG .......................................... .................................................. ....... 20
Input signals (from the robot to the current source) ........................................... ...................................... 20
Output signals (from the power source to the robot) .......................................... ............................... 21
Input and output signals for MIG / MAG - TSt device series ....................................... ............................... 23
Input signals (from the robot to the current source) ........................................... ...................................... 23
Output signals (from the power source to the robot) .......................................... ............................... 24
Input and output signals for TIG ............................................ .................................................. .............. 25
General ................................................. .................................................. ....................................... 25
Input signals (from the robot to the current source) ........................................... ...................................... 25
Setting pulse range TIG ............................................... .................................................. ............... 26
Output signals (from the power source to the robot) .......................................... ............................... 26
Input and output signals for CC / CV .......................................... .................................................. ............ 28
General ................................................. .................................................. ....................................... 28
Input signals (from the robot to the current source) ........................................... ...................................... 28
Output signals (from the power source to the robot) .......................................... ............................... 29
Inputs and outputs for standard manual .......................................... ............................................. 31
General ................................................. .................................................. ....................................... 31
Input signals (from the robot to the current source) ........................................... ...................................... 31
Output signals (from the power source to the robot) .......................................... ............................... 32
Setting I / O communication between Ethernet / IP and ControlLogix5000 ...................................... ....... 34
Create SoftLogix5860 controller ............................................... .................................................. ........ 34

3
 Create SoftLogix5800 EtherNet / IP module ............................................ ............................................... 35
configure RSLogix 5000 ................................................ .................................................. ................. 36

attachment 41

Circuit diagram: Ethernet / IP ............................................. .................................................. ............................... 42

Circuit diagram: Ethernet / IP external ............................................ .................................................. ..................... 43

4
General

DE
safety
WARNING! All works cited in this manual may only be carried out by trained personnel. All functions described
in this instruction manual may be applied only by trained personnel. All work described only and features
described only apply if the following documents have been read and understood:

- this manual
- All operating instructions for system components, especially the safety rules

device concept EtherNet / IP is a globally accepted industrial communication network based on Ethernet.

EtherNet / IP extends Ethernet to a modern industrial protocol (CIP, the Common Industrial Protocol) as an application
layer for automation applications.

The robot interface Ethernet / IP is characterized by low physical volume and high modularity. The simple and space-saving
assembly on a standardized C-rail so-as the direct wiring of actuators and sensors without cross connections between the
terminals, standardizes the installation. The uniform labeling concept facilitates additional installation.

principle of operation connecting the BK9105 Bus Coupler used in Fronius Ethernet / IP robot interface
Ethernet / IP with the Beckhoff Bus Terminals K (KLxxxx). A station composed of a bus coupler BK9105, any number of up
to 64 K-modules (with K-Bus exten- sion up to 255) and one end terminal.

The Bus Coupler recognizes the connected terminals and automatically generates the supply order to the process image of
the Ethernet / IP system. With the RJ45 Ethernet interface of the bus coupler is connected to the network.

instrument series TSt overall

- Connections on Interface (1) Connection LocalNet OUT
for Annschließen the antenna gain antenna
hight-hose package

(2) Connection LocalNet-IN

connecting the power source

(3) Connecting EtherNet RJ 45 - X1

(2) (1) (3)

5
application example

(4) (5)

(6)

(3)

(7)
(2)

(8)
(1)

(9)
(10)

(1) Cooling unit (2) (6) (7) welding torch

Power source (3) Robot control (8)
Ethernet / IP Interface (4) Welding wire drum (9)
Connection hose package (5) Robot (10)
wire feed Data cable Ethernet / IP

Application example for

external version

(6)
(1)

(7)
(2)

(3) (8) (9)

(4) (10)

(5)

(1) Robot controller (2) (6) The wire feed (7)

(3) Ethernet / IP Interface Welding torch (8)
external version Connection hose package (9)
Data cable Ethernet / IP (4) Robot (10)
Current source (5) Welding wire barrel
cooling unit

6
Installation Procedure NOTE! When installing the external version of the Ethernet / IP fieldbus coupler BK9105 following guidelines

DE
for the external version should be followed:
- The laying of the cable is disconnected from mains susceptible lines to successes gen

- The installation of the fieldbus coupler has obligations separately from mains affected managerial
or be made components
- The fieldbus coupler shall only be installed on one against dirt and water pro- tected place

- It is to ensure that the 24V supply voltage is safely isolated from circuits with higher voltage.

7
Connecting the fieldbus coupler

safety
WARNING! An electrical shock may be fatal. Before starting work, all equipment and components involved

- turn off
- unplug
- secure against reconnection.

safety
WARNING! An electrical shock may be fatal. Before opening the device
- Power switch in position - O - turn
- Isolate unit
- secure against reconnection
- ensuring by means of a suitable measuring device that electrically Charged components (eg capacitors)
are discharged

WARNING! Incorrect work may sonen- serious Per- and cause property damage. The following activities may
be carried out by trained personnel! The chapter "Si cherheitsvorschriften" must be observed.

General Connecting the interface Ethernet / IP via the integrated fieldbus coupler BK9105.

Connections on the
ATTENTION! Risk of property damage. Make sure before starting work that the cable for the external power
fieldbus coupler BK9105
supply of the interface are dead and until the completion of all work subject to stress.

(1) Connecting EtherNet RJ 45 - Port1

(1) (2) Connecting EtherNet RJ 45 - Port2

(4)
(2) (3) Dip switch
for setting the IP address

(4) Connectors DC IN
for connecting the external power supply

(3)

NOTE! The external power supply must not follow through current source ER. For the external power supply
robot or control the verwen-.

8th
Connections on the

DE
fieldbus coupler BK9105 (4) (1) EtherNet connection RJ 45 - Port1 (2)
- external version
EtherNet connection RJ 45 - Port2 (3)
(5)
Dip switch
for setting the IP address
(1)
(4) LocalNet connection (5)
(2)
ground wire
(3)

interface
1 close LocalNet connector from the power source at
include Ethernet / IP
terminal LocalNet-IN (2) Toggle
Toggle

2 LocalNet plug from the connecting hose assembly

at the connection LocalNet-OUT (1) Connect

NOTE! As long as the robot interface

reconnected to the LocalNet automatically
remains the mode "2-step mode" overall selects
(display: Operating mode 2-step mode).

Information on the "Special-2-cycle operation for robot

(2) (1) (3)
interface" can be found in the manual of the power source.

3 Data-input cable to the connector EtherCAT EtherNet

RJ 45 - close X1 (3) Toggle

Ethernet / IP cable and Use to connect the Ethernet / IP devices only Ethernet cables Any artwork least category 5 (CAt5) according to EN 50173 or
plug connectors ISO / IEC 11,801th Ethernet / IP uses 4 cores of the cable for signal transmission.

Ethernet / IP uses RJ45 connector. The pin assignment is for Ethernet stan- dard (ISO / IEC 8802-3) compatible.

9
 Pin code colour annotation

1 yellow TD + (Transmission Data positive pole)

2 Orange TD (Transmission Data negative pole) 3

1 8th

White RD + (Receiver Data positive pole)

4 - Not normally used; the Signalvollständig- ensure ness, these pins are the
connectedness and end a filter circuit to the protective earth (PE) together.
5 -

6 blue RD (Receiver Data negative pole)

7 - Not normally used; the Signalvollständig- ensure ness, these pins are the
connectedness and end a filter circuit to the protective earth (PE) together.
8th -

Due to the automatic cable detection (Auto-crossing) you can switch between Ethernet / IP devices from Beckhoff and
balanced (1: 1) finished as also use cross-over cable.

The following Beckhoff cables and connectors are suitable for use on Ethernet / IP systems:

- ZB9010 (Industrial Ethernet / Ethernet / IP cable, fixed installation CAT 5e, 4-wire)
- ZB9020 (Industrial Ethernet / Ethernet / IP cable for conveyor chains CAT 5e, 4-ad-rig)

- ZS1090-0003 (RJ45 connector, 4-pole, IP 20, assembled in the field)

- ZS1090-0005 (RJ45 plug, 8-pole (Gigabit suitable), IP 20, assembled in the field)
- ZK1090-9191-0001 (0.17m Ethernet / IP patch cable)
- ZK1090-9191-0005 (0.5m Ethernet / IP patch cable)
- ZK1090-9191-0010 (1.0m Ethernet / IP patch cable)
- ZK1090-9191-0020 (2.0m Ethernet / IP patch cable)
- ZK1090-9191-0030 (3.0m Ethernet / IP patch cable)
- ZK1090-9191-0050 (5.0m Ethernet / IP patch cable)

10
Setting the IP address

DE
Overview The IP address can be set in three different ways:
- a BootP Server
- via the ARP command in the DOS window
- with the KS2000 configuration software

These are described in more detail below.

"Set IP address" is composed of the following sections:

- Setting the IP address via BootP Server
- Setting the IP address using ARP
- Setting the IP address via KS2000

provide IP address via

1 Ethernet cable to the fieldbus coupler BK9105
BootP Server On
connect DIP switches as shown

2345 678 9 10
ON1

3 Beckhoff BootP Server "Start" button Wait in the "New

Mac Address" the found MAC address BK9105
4
appears double click on the found MAC address
5

7 The new Mac address type entry with the "OK"

button sawn off confirm device

8

10 Switch DIP switch as shown adjust device

11
11

2345 678 9 10
ON1

11
 The IP address is now permanently in the fieldbus Kopp- ler
BK9105 stored and displayed in the lower part of the
window.

Setting the IP address

From the factory the fieldbus coupler with different IP addresses will be delivered. The current IP address of the fieldbus
using ARP
coupler is recognizable by the DIP switch setting:

Factory setting Fronius (setting with BootP Server) IP address: 192.168.0.2

ON1
2345 678 9 10
Default Beckhoff IP address: 172.16.17.255

2345 678 9 10
ON1

1 Set the current (old) IP address record DIP switch as

shown (all OFF)
2

The DIP switches now have no address function.

2345 678 9 10
ON1

3 Open DOS prompt

4 The command "ping" with the old IP address to execute an entry in the ARP-Ta belle produce

5 ARP table read with the command "ARP -a" identify associated

MAC address

6 The command "ARP -d" using the old IP address to run the Felsbus coupler BK9105 from the table to delete

7 The command "ARP -s" create a new entry with the command "ping -l 123" the new IP address is valid A brief LED

flash NS error indicates that the fieldbus coupler will be addressed via ARP and the DIP switches have no function.
8

for example:
1. C:> ping 192.168.0.2 or 172.16.17.xxx
2. C:> arp
172.16.17.255 00-01-05-00-11-22
3. C:> arp -d 172.16.17.255
4. C:> arp -s 172.16.44.44 00-01-05-00-11-22
5. C:> ping -l 123 172.16.44.44

12
Setting the IP address NOTE! Setting the IP address using the KS2000 configuration software is possible with version 3.2.8 of

DE
via KS2000 the software.

Example IP address: 172nd 16th 17th 255th

Byte 1 Byte 2 Byte 3 Byte 4

- The setting of the fourth byte of the IP address via the big DIP switch
- The setting of the first three bytes of the IP address via the KS2000 configuration software. This offers two options:

- a dialog box
- by directly writing to the registers

example,
for example:

In this
mass

value
4th byte = 201

1 Switch 9 + 10 of the DIP switch to OFF switch 1-8

ON1

1 ON 1 2 of the DIP switch to the desired fourth byte of the IP

OFF 0 4 addressed se Setting Switch on
2345

2
OFF 0 8

ON 8 16

OFF 0 32 3
OFF 0 64
678

ON ON 64 128

128

- OFF -
9 10

- OFF -

Σ = 201

4 Set the bytes 1-3 of the IP address via the

configuration software KS2000 If the setting by

table 100 loading the Write tab, the adjacent assignments are
in Table 100th
Register Low Byte High Byte

0 IP Byte 1 Byte 2 IP

1 IP byte 3 Not used

13
Fault diagnosis, troubleshooting,

safety
WARNING! An electrical shock may be fatal. Before starting work on the interface all devices and components
involved
- turn off
- unplug
- secure against reconnection.

See the fieldbus coupler

(1) (2) (3) (4)
BK9105

(9)

(10)

(9)

(10)

(5) (6) (7) (8)

(1) LED status NS green

for fieldbus diagnosis
(2) LED NS Error red

(3) LED Us green

for the diagnosis of the power supply
(4) LED Up green

(5) MS LED Error red

for fieldbus diagnosis
(6) MS LED Status green

(7) LED I / O Error red

to diagnose the K-bus
(8th) LED I / O Run green

(9) LED Link / Active green to diagnose the Ethernet / IP state machine / PLC

(10) Not used - -

LEDs for diagnostic se

LED display importance
the supply Spannugs-
Us Out No operating voltage at the bus coupler available

Shines 24 VDC operating voltage at the bus coupler existing the

up Out No power supply to the Powerkontak- th available

Shines 24 VDC power supply to the present Powerkontak- th

14
LED circuit on
LED display importance

DE
RJ5-arrival
Link / Active LED Off no connection

On connection available

Blinking communication available

LEDs for fieldbus

LED Status LED NS NS Error importance
diagnosis
Flashes (0.5 sec.) From IP address okay

Out Out no IP address (DIP switches)

On Out On-line

Flashing (0.1 sec.) From Offline PLC Stop

Out Flashes (0.5 sec.) Time-out

Out On IP address conflict

MS LED status (error MS LED Error

code) (Error argument) Meaning

On Out no mistake

1 Blinking too little input data

2 Blinking too many input data

3 Blinking too little output data

4 Blinking too many output data

5 Blinking Wrong Assembly Instance ?????

6 Blinking second master

Fault indicator LEDs MS and MS Error Status:

The error indication is based on a flash sequence. In the following example, the purchase will show the error shown "too
many input data".

1. MS LED flashes quickly errror MS LED

status is OFF
MS Error 2. LED lights MS Error MS LED status shows the error
code (2 blinks)
MS status
3. Both LEDs are OFF
1. Second Third 4th 4. LED MS Error shows the Fehlerargu- ment (5
Flashes) MS LED status is OFF
Display example "too many input data"

15
LEDs for diagnostic se
LED I / O Run display importance remedy
of K-Bus
Out K-Bus inactive -

Shines K-Bus active -

Error indication of the LEDs I / O Run and I / O Error:

The error indication is based on a flash sequence. The following example will show the arrival of the error "Table 5
Comparison bus terminal" shown.

1. I / O LED flashes quickly LED errror I / O

Run is OFF
I / O Error 2. LED I / O errror LED lights I / O Run shows the
error code (2 x flashing)
I / O Run
3. Both LEDs are OFF
1. Second Third 4th 4. LED I / O errror shows the Fehlerargu- ment (5 x
flashing) LED I / O is OFF Run
Display example "Tabellenvergelich Bus Terminal 5"

LED I / O Error

error
display argument importance remedy

Blinking EMC problems - Power supply for overvoltage or

overvoltage peaks team control

- EMC measures ergrei- fen

- If a K-Bus error is present, the error

can be obtained by restarting (initial
and How-dereinschalten of Kopp-
ler) are located

1 Implus 0 EEPROM checksum sum Factory settings with the KS2000

error configuration software (menu "on-line ->
coupler -> Services -> Manufacturer
setting")

1 Overflow Code buffer Fewer Bus STE CKEN. In prog.

Configuration has too many entries in the
table

2 Unknown Data Type Software update for the Bus

Coupler

2 Impluse 0 Programmed con- figuration Check programmed configuration for

incorrect table entry correctness

n Table comparison (Bus provide false table entry right

(N> 0) Terminal n)

16
LED I / O Error

error

DE
display argument importance remedy

3 pulses 0 K-Bus command error - No Bus Terminal inserted overall

- One of the bus modules is faulty;

Halve Terminals attached and
check whether the error in the
remaining Bus Terminals is still
present. continue to do this until the
defective Bus Terminal is located
me.

4 pulses 0 K-Bus data error, break Check whether the n + 1 Bus Terminal is
behind the bus coupler correctly, if necessary replace

n Break behind Bus Check whether the bus terminals

Terminal n terminal 9010 is connected

5 pulses n K-Bus error in re-gister com- exchange nth bus terminal

munication with Bus Terminal
n

6 Impluse 0 Initialization fieldbus coupler exchange 1

internal data error 2 4 8 16

14 pulses n n- nth Bus Terminal has the Start the Bus Coupler again, if the error
wrong format occurs again then exchange the Bus.

15 pulses n Number of bus terminals Start the Bus Coupler again, if the
men no longer correct problem persists, contact the
manufacturers setting using the KS2000
configuration software

16 pulses n Length of the K-bus DA th is Start the Bus Coupler again, if the
no longer correct problem persists, contact the
manufacturers setting using the KS2000
configuration software

17
Characteristics of data transmission and technical data

transfer properties of the

transmission technology Ethernet / IP
data transmission
network topology Star / line

transmission medium Shielded Twisted Pair cable (4 x 2)

Class 5 (100 Mbaud) Category 3
(10 Mbps)

transfer rate 10 to 100 MBaud

bus connection EtherNet RJ 45

Process data width 12 bytes

Process data format INTEL

safety device In unusual data transfer all inputs and outputs are reset and the power source is in the state "Stop". After recovered data
transmission resumption of the process carried out by the following signals:

- Signal "robot ready"

- Signal "Acknowledge sources Disorder"

Technical data of the

logs Ethernet / IP
fieldbus coupler BK9105
baud rate 10 to 100 MBaud

configuration KS2000 configuration software or TwinCAT

System Manager

bus connection 2 x RJ45

power supply 24 VDC (-15% / + 20%)

current consumption 100 mA

permissible ambient temperature during operation 0 ° C to + 55 ° C

permissible ambient temperature during storage - 25 ° C to + 85 ° C

Permissible relative humidity 95%, non-condensing

Dimensions (W x H x D) approximately 49 mm x 100 mm x 70 mm

Assembly on 35 mm mounting rail according to EN 50022

Vibration / shock resistance according to EN 60068-2-6 / EN 60068-2-27,

EN 60068-2-29

EMC resistance burst / EN 61000-6-2 / EN 61000-6-4

protection IP 20

Mounting position any

18
Signal Description Ethernet / IP

DE
General
The following signal descriptions apply for an interface with a communication
terminal KL 6021-0010 (standard version EADERSHIP)

KL6021-0010
BK9105

KL9010
There is also the possibility of installing more terminals in a robot interface. The number, however, is limited by the housing
size.

NOTE! When installing additional terminals, the process data image changes.

Depending on the set mode, the Interface Ethernet / IP can transmit various input and output signals.

Operating modes of the

operating mode E037 E036 E035
power source
MIG / MAG standard welding 0 0 0

MIG / MAG pulse arc welding 0 0 1

job operation 0 1 0

Parameter selection internally 0 1 1

MIG / MAG standard manual welding 1 0 0

CC / CV 1 0 1

TIG welding 1 1 0

CMT / Special Process 1 1 1

Operating modes of the

operating mode E037 E036 E035
power source - TSt device
series MIG / MAG standard welding 0 0 0

flag operation 0 1 0

Parameter selection internally 0 1 1

MIG / MAG standard manual welding 1 0 0

Overview "Signal Description Ethernet / IP" is composed of the following sections:

- Input and output signals for MIG / MAG
- Input and output signals for MIG / MAG - TSt device series
- Input and output signals for WIG
- Input and output signals for CC / CV
- Inputs and outputs for standard manual

19
Input and output signals for MIG / MAG

Input signals (from the

Ser. No. signal name Area activity
robot to the power
source) E001 - E032 Status Byte - -

E033 A welding - High

E034 robots ready - High

E035 Modes Bit 0 - High

E036 Mode bit 1 - High

E037 Modes Bit 2 - High

E038 Master ID Twin - High

E039 Not used - -

E040 Not used - -

E041 gas test - High

E042 wire lead - High

E043 Wire return - High

E044 Acknowledge Source Disruption - High

E045 position Search - High

E046 Brenner blow - High

E047 Not used - -

E048 Not used - -

E049 - E056 job number 0 - 99 -

E057 - E063 program number 0 - 127 -

E064 welding simulation - High

With RCU 5000i and mode Job operation

E049 - E063 job number 0-999

E064 welding simulation - High

Power (desired value) 0 - 65535 (0% - -

100%)

E065 - E072 Low Byte - -

E073 - E080 High Byte - -

Arc length correction (setpoint) 0 - 65535 (-30% - + -

30%)

E081 - E088 Low Byte - -

E089 - E096 High Byte - -

E097 - E104 pulse / dynamic correction (setpoint) 0 - 255 (-5% - + -

5%)

E105 - E112 backfire (setpoint) 0 - 255 (-200 ms - +200 ms)

20
 Ser. No. signal name Area activity

DE
E113 Synchro pulse disable - High

E114 SFI disable - High

E115 Pulse / dynamic correction disable - High

E116 Backfire disable - High

E117 Performance full-range (0-30 m) - High

E118 Not used - -

E119 - E128 welding speed 0-1023 (0-1023 cm / -

min)

Output signals (source

Ser. No. signal name Area activity
for robots ter of the
current) A001 - A032 Control Byte - -

A033 Arc stable - High

A034 limit signal - High

(Only in conjunction with RCU5000i)

A035 process active - High

A036 Main power signal - High

A037 Torch collision protection - High

A038 Power source ready - High

A039 ready for communication - High

A040 reserve - -

A041 - A048 Error number 0 - 255 -

A049 - A056 Not used - -

A057 Solid fire-control (solid fire - High

dissolved)

A058 Not used - -

A059 Robot access - High

(Only in conjunction with RCU 5000i)

A060 wire available - High

A061 Short timeout - High

A062 Data Documentation Ready - High

A063 Not used - -

A064 Power out of range - -

Welding voltage (actual value) 0 - 65535 (0 - -

100 V)

A065 - A072 Low Byte - -

A073 - A080 High Byte - -

Welding current (actual value) 0 - 65535 (0 - -

1000 A)

A081 - A088 Low Byte - -

A089 - A096 High Byte - -

21
 Ser. No. signal name Area activity

A097 - A104 motor current (actual value) 0 - 255 (0 - -

5 A)

A105 - A112 Not used - -

Wire speed (actual value) 0 - 65535 -

(-327.68 - +327.67 m / min)

A113 - A120 Low Byte - -

A121 - A128 High Byte - -

22
Input and output signals for MIG / MAG - TSt instrument series

DE
Input signals (from the
Ser. No. signal name Area activity
robot to the power
source) E001 - E032 Status Byte - -

E033 A welding - High

E034 robots ready - High

E035 Modes Bit 0 - High

E036 Mode bit 1 - High

E037 Modes Bit 2 - High

E038 Not used - -

E039 Not used - -

E040 Not used - -

E041 gas test - High

E042 wire lead - High

E043 Wire return - High

E044 Acknowledge Source Disruption - High

E045 position Search - High

E046 Brenner blow - High

E047 Not used - -

E048 Not used - -

E049 - E056 flag number 0 - 99 -

E057 - E063 Not used - -

E064 Not used - -

Power (desired value) 0 - 65535 (0% - -

100%)

E065 - E072 Low Byte - -

E073 - E080 High Byte - -

Arc length correction (setpoint) 0 - 65535 (-30% - + -

30%)

E081 - E088 Low Byte - -

E089 - E096 High Byte - -

E097 - E104 dynamic correction (setpoint) 0 - 255 (-5% - + -

5%)

E105- E112 Not used - -

E113 Not used - -

E114 Not used - -

23
 Ser. No. signal name Area activity

E115 Dynamic correction disable - High

E116 Not used - -

E117 Performance full-range (0-30 m) - High

E118 Not used - -

E119 - E128 Not used - -

Output signals (source

Ser. No. signal name Area activity
for robots ter of the
current) A001 - A032 Control Byte - -

A033 Arc stable - High

A034 Limiting the power limit - High

A035 process active - High

A036 Main current signal - High

A037 Torch collision protection - High

A038 Power source ready - High

A039 ready for communication - High

A040 Not used - -

A041 - A048 Not used - -

A049 - A063 Not used - -

A064 Power out of range - -

Welding voltage (actual value) 0 - 65535 (0 - -

100 V)

A65 - A72 low byte - -

A73 - A80 high byte - -

Welding current (actual value) 0 - 65535 (0 - -

1000 A)

A81 - A88 low byte - -

A89 - A96 high byte - -

A97 - A104 motor current (actual value) 0 - 255 (0 - -

5 A)

A105 - A112 Not used - -

Wire speed (actual value) 0 - 65535 -

(-327.68 - +327.67 m / min)

A113 - A120 Low Byte - -

A121 - A128 High Byte - -

24
Input and output signals for WIG

DE
General The following signal descriptions apply only in connection with a power source of the TS / TPS, MW / DD device series.

Input signals (from the

Ser. No. signal name Area activity
robot to the power
source) E001 - E032 Status Byte - -

E033 A welding - High

E034 robots ready - High

E035 Modes Bit 0 - High

E036 Mode bit 1 - High

E037 Modes Bit 2 - High

E038 Master ID Twin - High

E039 Not used - -

E040 Not used - -

E041 gas test - High

E042 wire lead - High

E043 Wire return - High

E044 Acknowledge Source Disruption - High

E045 position Search - High

E046 KD disable - High

E047 Not used - -

E048 Not used - -

E049 - E056 job number 0 - 99 -

E057 DC / AC - High

E058 DC / DC + - High

E059 cap-shaping - High

E060 disable pulses - High

E061 Pulse range selection Bit 0 - High

E062 Pulse area selecting Bit 1 - High

E063 Pulse range selector bit 2 - High

E064 welding simulation - High

Main current (desired value) 0 - 65535 (0 - -

I Max)

E065 - E072 Low Byte - -

E073 - E080 High Byte - -

25
 Ser. No. signal name Area activity

External parameter (desired value) 0 - 65535 -

E081 - E088 Low Byte - -

E089 - E096 High Byte - -

E097 - E104 basic current (nominal value) 0 - 255 (0% - -

100%)

E105 - E112 Duty Cycle (setpoint) 0 - 255 (10% - -

90%)

E113 Not used - -

E114 Not used - -

E115 Basic current disable - High

E116 Duty Cycle disable - High

E117 - 118 Not used - -

E119 - E128 wire speed Fd.1 (setpoint) 0-1023 (0 - vD Max) -

Setting pulse area WIG

operating mode E63 E62 E61

Setting the pulse range on the power source 0 0 0

Setting pulse disabled 0 0 1

0.2 to 2 Hz 0 1 0

2-20 Hz 0 1 1

20-200 Hz 1 0 0

200 - 2000 Hz 1 0 1

Output signals (source

Ser. No. signal name Area activity
for robots ter of the
current) A001 - A032 Control Byte - -

A033 Arc stable - High

A034 Not used - -

A035 process active - High

A036 Main current signal - High

A037 Torch collision protection - High

A038 Power source ready - High

A039 ready for communication - High

A040 reserve - -

A041 - A048 Error number 0 - 255 -

A049 - A056 Not used - -

A057 Not used - -

26
Ser. No. signal name Area activity

A058 RF active - High

DE
A059 Not used - -

A060 wire available - High

A061 Not used - -

A062 Not used - -

A063 pulse high - High

A064 Not used - -

Welding voltage (actual value) 0 - 65535 (0 - -

100 V)

A065 - A072 Low Byte - -

A073 - A080 High Byte - -

Welding current (actual value) 0 - 65535 (0 - -

1000 A)

A081 - A088 Low Byte - -

A089 - A096 High Byte - -

A97 - A104 motor current (actual value) 0 - 255 (0 - -

5 A)

A104 - A112 arc length (actual value) 0 - 255 -

(AVC)

Wire speed (actual value) 0 - 65535 -

(-327.68 - +327.67 m / min)

A113 - A120 Low Byte - -

A121 - A128 High Byte - -

27
Input and output signals for CC / CV

General The following signal descriptions apply only in connection with a power source of the TS / TPS, MW / DD device series.

Input signals (from the

Ser. No. signal name Area activity
robot to the power
source) E001 - E032 Status Byte - -

E033 A welding - High

E034 robots ready - High

E035 Modes Bit 0 - High

E036 Mode bit 1 - High

E037 Modes Bit 2 - High

E038 Master ID Twin - High

E039 Not used - -

E040 Not used - -

E041 gas test - High

E042 wire lead - High

E043 Wire return - High

E044 Acknowledge Source Disruption - High

E045 position Search - High

E046 Brenner blow - High

E047 Not used - -

E048 Not used - -

E049 - E056 job number 0 - 99 -

E057 - E063 program number 0 - 127 -

E064 welding simulation - High

With RCU 5000i and mode Job operation

E049 - E063 job number 0-999

E064 welding simulation - High

Welding current (desired value) 0 - 65535 (0 - -

I Max)

E065 - E072 Low Byte - -

E073 - E080 High Byte - -

Wire speed (target value) 0 - 65535 (0.5 - -

vD Max)

E081 - E088 Low Byte - -

E089 - E096 High Byte - -

28
 Ser. No. signal name Area activity

E097 - E104 welding voltage (setpoint) 0 - 255 (0 - -

DE
50 V)

E105 - E112 Not used - -

E113 Synchro pulse disable - High

E114 SFI disable - High

E115 Welding voltage disable - High

E116 Not used - -

E117 Performance full-range (0-30 m) - High

E118 Not used - -

E119 - E128 welding speed 0-1023 (0-1023 cm / -

min)

Output signals (source

Ser. No. signal name Area activity
for robots ter of the
current) A001 - A032 Control Byte - -

A033 Arc stable - High

A034 limit signal - High

(Only in conjunction with RCU5000i)

A035 process active - High

A036 Main current signal - High

A037 Torch collision protection - High

A038 Power source ready - High

A039 ready for communication - High

A040 reserve - -

A041 - A048 Error number 0 - 255 -

A049 - A056 Not used - -

A057 Solid fire-control (solid fire - High

dissolved)

A058 Not used - -

A059 Robot access - High

(Only in conjunction with RCU 5000i)

A060 wire available - High

A061 Short timeout - High

A062 Data Documentation Ready - High

A063 Not used - -

A064 Power out of range - -

Welding voltage (actual value) 0 - 65535 (0 - -

100 V)

A065 - A072 Low Byte - -

A073 - A080 High Byte - -

29
 Ser. No. signal name Area activity

Welding current (actual value) 0 - 65535 (0 - -

1000 A)

A081 - A088 Low Byte - -

A089 - A096 High Byte - -

A97 - A104 motor current (actual value) 0 - 255 (0 - -

5 A)

A104 - A112 Not used - -

Wire speed (actual value) 0 - 65535 -

(-327.68 - +327.67 m / min)

A113 - A120 Low Byte - -

A121 - A128 High Byte - -

30
Inputs and outputs for standard manual

DE
General The following signal descriptions apply only in connection with a power source of the TS / TPS, MW / DD device series.

Input signals (from the

Ser. No. signal name Area activity
robot to the power
source) E001 - E032 Status Byte - -

E033 A welding - High

E034 robots ready - High

E035 Modes Bit 0 - High

E036 Mode bit 1 - High

E037 Modes Bit 2 - High

E038 Master ID Twin - High

E039 Not used - -

E040 Not used - -

E041 gas test - High

E042 wire lead - High

E043 Wire return - High

E044 Acknowledge Source Disruption - High

E045 position Search - High

E046 Brenner blow - High

E047 Not used - -

E048 Not used - -

E049 - E056 job number 0 - 99 -

E057 - E063 program number 0 - 127 -

E064 welding simulation - High

With RCU 5000i and mode Job operation

E049 - E063 job number 0-999

E064 welding simulation - High

Wire speed (target value) 0 - 65535 (0.5 - -

vD Max)

E065 - E072 Low Byte - -

E073 - E080 High Byte - -

Welding voltage (target value) 0 - 65535 -

(10-40 V)

E081 - E088 Low Byte - -

E089 - E096 High Byte - -

31
 Ser. No. signal name Area activity

E097 - E104 dynamic correction (setpoint) 0 - 255 (0 -

- 10)

E105 - E112 backfire (setpoint) 0 - 255 (-200 ms - +200 ms)

E113 Synchro pulse disable - High

E114 SFI disable - High

E115 Pulse / dynamic correction disable - High

E116 Backfire disable - High

E117 Performance full-range (0-30 m) - High

E118 Not used - -

E119 - E128 welding speed 0-1023 (0-1023 cm / -

min)

Output signals (source

Ser. No. signal name Area activity
for robots ter of the
current) A001 - A032 Control Byte - -

A033 Arc stable - High

A034 limit signal - High

(Only in conjunction with RCU5000i)

A035 process active - High

A036 Main current signal - High

A037 Torch collision protection - High

A038 Power source ready - High

A039 ready for communication - High

A040 reserve - -

A041 - A048 Error number 0 - 255 -

A049 - A056 Not used - -

A057 Solid fire-control (solid fire - High

dissolved)

A058 Not used - -

A059 Robot access - High

(Only in conjunction with RCU 5000i)

A060 wire available - High

A061 Short timeout - High

A062 Data Documentation Ready - High

A063 Not used - -

A064 Power out of range - -

Welding voltage (actual value) 0 - 65535 (0 - -

100 V)

A065 - A072 Low Byte - -

A073 - A080 High Byte - -

32
Ser. No. signal name Area activity

Welding current (actual value) 0 - 65535 (0 - -

DE
1000 A)

A081 - A088 Low Byte - -

A089 - A096 High Byte - -

A097 - A104 motor current (actual value) 0 - 255 (0 - -

5 A)

A105 - A112 Not used - -

Wire speed (actual value) 0 - 65535 -

(-327.68 - +327.67 m / min)

A113 - A120 Low Byte - -

A121 - A128 High Byte - -

33
Setting I / O communication between Ethernet / IP and
ControlLogix5000

SoftLogix5860
1 Open Window "SoftLogix Chassis Monitor"
controller investor
gen
2 click the right mouse button on column 1

"Select Module" screen appears

3 Select "1789-L60 controller SoftLogix5860" and

click "OK"

Window "General" appears

4 complete data and click "Next"

Window "NT System" appears

5 complementary information and click "Finish"

"SoftLogix Chassis Monitor" window appears

34
Create SoftLogix5800
1 click the right mouse button on column 2

DE
EtherNet / IP Mo- dul

"Select Module" screen appears

2 Select "EtherNet / IP SoftLogix5800 EtherNet / IP"

and click "OK"

"Select Device" window appears

3 Select dates and click "Next"

Window "General" appears

4 complementary information and click "Finish"

"SoftLogix Chassis Monitor" window appears

35
configure RSLogix
1 Open program RSLogix 5000: Creating Start /
5000
Programs / Rockwell Software / RSLogix 5000
Enterprise Series New Controller: File / New /
Controller
2

"New Controller" window appears

3 complete data and click "OK" The controller

properties and the following data structure is
reasonable:

- controller
- tasks
- Motion Groups
- Data Types
- I / O Configuration

4 Click the folder "I / O Configuration" with the right mouse button on "Backplane, 1789-A17 / A Virtual Chassis" "New
Module" Select

36
"Select Module" screen appears

6 Select "EtherNet / IP SoftLogix5800 EtherNet / IP"

DE
and click "OK"

Window "major revision" is displayed

7 Enter a value for major revision and click "OK"

Window "New Module" is displayed

8th Select complementary data "Open modules pro-

perties" and click "OK"

Window "Module Properties" is displayed

9 add or change data on tab "RSNetWorx" alternating

clauses
10

11 Select "View and edit the EtherNet / IP net- work"

and "OK" button in "Backplane, 1789-A17 / A Virtual
Chassis" the new module is reasonable shows

37
 12 click the right mouse button on "EtherNet" "New Module" Select

13

"Select Module" screen appears

14 Select "ETHERNET MODULE Generic EtherNet

Module" and "OK" clinical CKEN

Window "New Module" is displayed

15 Select complementary data "Open modules pro-

perties" and click "OK"

Window "Module Properties" is displayed

16 on "Connection" alternating clauses

17 complete data and click "OK"

38
 DE
18 Select the menu item "Communications" command "Go Online"

Window "Connected to go online" is shown Toggle

19 Click "Download"

Window "Download" is displayed

20 Click The configuration is transferred to

ControlLogix5000 "Download"

39
 Window "RSLogix 5000" appears

21 Click "Yes"

After the online switching are the Controller folder the controller tags for supply Verfü-.

40
attachment
Circuit diagram: Ethernet / IP

42
Circuit diagram: Ethernet / IP externally

- X1
1
+ A1.1-X1 + A1.1 + A1.2 + A1.3
2 1
BKxxxx KL6021 KL9010
10 Base-T 100
Ethernet / IP Port

2
3 Ethernet / IP BusCoupler RS422 Serial Interface Bus End Terminal
3

4 4

TxD RUN
POWER

POWER
Base-Tx

5
5
6

RxD
7

8
7
0V 1 5
8

+ 24V + 2 6

- - 3 7

PE PE 4 8
3

4
- X3.1
1

- R1 -C1 - C2-R2
JABCDEFGHI
-X6

RXDRXD
NC GND

TXDNC

TXD +
NC

NC

+ 24V
+

43
 FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0) 7242 241-0
Fax: +43 (0) 7242 241-3940
E-mail: [email protected]
www.fronius.com

www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our sales and service partners and Locations