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OPT/i RI IO TWIN
Operating instructions
Robot option
EN-US
42,0426,0314,EA 003-16122020
Table of contents
General 4
Device concept 4
System overview 5
System requirements 5
Scope of supply 5
Safety 5
Technical data and environmental conditions 7
Technical data 7
Environmental conditions 7
EtherCAT information 8
Data transfer properties 8
Assigning the EtherCAT Address 8
Position of bus terminals 9
Position of bus terminals on OPT/i RI IO TWIN Job 9
Position of bus terminals on OPT/i RI IO TWIN Synergic/Job 9
LED descriptions 10
LEDs on EK1110 10
LEDs on CX8190 11
Installing the interface 15
Safety 15
Installing the interface 15
Input and output signals OPT/i RI IO TWIN Job 16
Input signals (from robot to power source) 16
Value Range for Config Bit 17
Value range for Operating mode TWIN System 17
Output signals (from power source to robot) 17
Assignment of Sensor Statuses 1–3 18
Input and output signals OPT/i RI IO TWIN Synergic / Job 19
Input signals (from robot to power source) 19
Value Range for Config Bit 21
Value range for Operating mode TWIN System 21
Value Range for Working Mode 21
Output signals (from power source to robot) 21
Assignment of Sensor Statuses 1–3 22
EN-US
3
General
Device concept The OPT/i RI IO TWIN robot interface converts digital and analog inputs and outputs to
EtherCAT.
This allows robot control units with digital and analog inputs and outputs to be connected
to a TPS/i TWIN welding system.
The interface is available in the versions listed below.
4,044,051
OPT/i RI IO TWIN Job
for internal mode and job mode for internal mode, job mode and charac-
4,044,051 OPT/i RI IO TWIN Job
OPT/i RI IO TWIN Synergic/Job
teristic selection with specification of set
values and corrections possible
4,044,052
4,044,052 OPT/i RI IO TWIN Synergic/Job
4
System overview
(6)(5)(2) (3)(1) (4)
EN-US
(1) Robot control unit
(2) OPT/i RI IO TWIN
(3) EtherCat-cable between RI FB PRO/i TWIN Controller and the interface
OPT/i RI IO TWIN Job / OPT/i RI IO TWIN Synergic/Job
(4) RI FB PRO/i TWIN Controller
(5) SpeedNet-cable between RI FB PRO/i TWIN Controller and power source 1
(6) SpeedNet-cable between RI FB PRO/i TWIN Controller and power source 2
System requirements
Scope of supply The scope of supply is made up of the following components:
Safety
To operate the interface, the following components must be present in the TPS/i welding
system:
- RI FB PRO/i TWIN Controller
- RI MOD/i CC EtherCAT (built into the RI FB PRO/i TWIN Controller)
- Interface OPT/i RI IO TWIN (in different versions)
- This document
- Cable harness for connection to the robot control unit
- DIN rail, for mounting the interface in the automatic or robot switch cabinet
- EtherCAT cable, for connection to the RI FB PRO/i TWIN Controller
WARNING!
Danger from incorrect operation and work that is not carried out properly.
Serious injury and damage to property may result.
All the work and functions described in this document must only be carried out by
▶
trained and qualified personnel.
Read and understand this document.
▶
Read and understand all the Operating Instructions for the system components,
▶
especially the safety rules.
5
WARNING!
Danger from unplanned signal transmission.
Serious injury and damage to property may result.
Do not transfer safety signals via the interface.
▶
6
Technical data and environmental conditions
EN-US
Technical data
Environmental
conditions
Supply voltage + 24 V (-15 % / +20 %)
CAUTION!
Danger from prohibited environmental conditions.
This can result in severe damage to equipment.
Only store and operate the device under the following environmental conditions.
▶
Temperature range of ambient air:
- during operation: -25 °C to 60 °C (-13 °F to 140 °F)
- during transport and storage: -25 °C to 60 °C (-13 °F to 140 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- without condensation up to 95 % at 20 °C (68 °F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6500 ft).
Protect the device from mechanical damage during storage and operation.
7
EtherCAT information
Data transfer
properties
Assigning the
EtherCAT
Address
Transfer technology:
EtherCAT
Medium:
When selecting the cable and plug, IEC 61784‑5‑12 for the planning and installation of
EtherCAT systems must be observed.
The EMC tests were carried out by the manufacturer with an original Beckhoff cable
(ZK1090-9191-xxxx).
Transmission speed:
100 Mbit/s
Bus connection:
RJ45 Ethernet
Application layer:
CANopen
The EtherCAT address is assigned by the master.
8
Position of bus terminals
1 | EL1008
2 | EL1008
3 | EL1008
4 | EL2008
5 | EL2008
6 | EL2008
1 | EL1008
2 | EL1008
3 | EL1008
4 | EL1008
5 | EL1008
6 | EL2008
7 | EL2008
8 | EL2008
9 | EL3068
Position of bus
terminals on
OPT/i RI IO TWIN
Job
EN-US
Position of bus
terminals on
OPT/i RI IO TWIN
Synergic/Job
9
LED descriptions
(2)
(1)
LEDs on EK1110
EK1110
LED designa-
tion
(1) Run Off INIT Initialization of the terminal
(2) Link / Act Off - No connection on the EtherCAT-strand
Display Status Description
Slow flashing PREOP Mailbox communication and different standard
settings set
Single flash SAFEOP Check of the channels of the Sync manager and
the distributed clocks. Outputs remain in safe
state
On OP Normal operating state; mailbox and process
data communication is possible
Fast flashing BOOTSTRAP Function for firmware updates on terminal
On linked EtherCAT-participant connected
Flashes active Communication with EtherCAT-participant
10
LEDs on CX8190
(1)
(2)
(3)
EN-US
CX8190
LED designa-
Display Description
tion
(1) TC Green TwinCAT is in run mode.
Red TwinCAT is in stop mode.
Blue TwinCAT is in config mode.
(2) WD - No function ex works.
The LED can be configured for user-specific diagnostic messages.
(3) ERR Red / Off Lights up red when switching on and when loading software. Goes
out if everything is okay.
The LED can be configured for user-specific diagnostic messages.
11
(4)
(6)
(5)
(7)
CX8190
LED designa-
Display Description
tion
(4) Us 24V Green Power supply for basic CPU module. LED lights up when the power
supply is correct.
(5) Up 24V Green Power supply of the terminal bus. LED lights up when the power
supply is correct.
(6) K-BUS-RUN Green Communication bus diagnosis. The LED lights up when there are
no errors. No errors means that communication with the fieldbus
system is also error-free.
(7) K-BUS-ERR Red Communication bus diagnosis. The LED flashes to indicate an
error. The LED flashes with two different frequencies (fast flashing
and slow flashing).
The error code and reason for the error can be determined by the
frequency and number of flashing pulses.
In the case of the reason for the error, the number of flashing
pulses indicates the position of the last bus terminal before the
error. Passive bus terminals, such as a supply terminal, are not
counted.
After troubleshooting, it is recommended to disconnect the power
supply for a short time (reset).
12
Structure of the error display:
1. Fast flashing = start of the error sequence
2. First slow sequence = error code
3. No display = pause, the LED is off
4. Second slow sequence = reason for the error
See the following table for error identification.
Error code Reason
for error
Steady, constant flashing
3 pulses 0 K-Bus-command error - No bus terminal inserted
- EMC problems - Check power supply for under- or overvoltage
Description Remedy
peaks
- Take EMC measures
- If there is a K-Bus-error, the error can be localized by restarting the power supply (switch the
power supply off and on again)
- One of the bus terminals is faulty, remove half
of the inserted bus terminals and check
whether or not there is still an error with the
remaining bus terminals. Repeat this process
until the faulty bus terminal is found.
EN-US
4 pulses
5 pulses n K-Bus-error during
6 pulses 0 Initialization error - Replace the Embedded PC.
7 pulses 0 Process data lengths of
0 K-Bus-data error, break
behind the power supply
unit
n Break behind bus terminaln- Ensure that the bus terminal n+1 is correctly
register communication
with bus terminal n
1 Internal data error - Hardware reset of the Embedded PC (switch
8 Internal data error - Hardware reset of the Embedded PC (switch
the target and actual configuration do not match.
- Check that the 9010 bus end terminal is inserted
inserted behind the power supply unit; replace
if necessary
- Replace bus terminal at position n
off and on again).
off and on again).
- Check configuration and bus terminals for consistency.
13
14
Installing the interface
(1)
(1)
OPT/i RI IO TWIN Job
OPT/i RI IO TWIN Synergic/Job
RI FB PRO/i TWIN Controller
RI FB PRO/i TWIN Controller
EN-US
Safety
Installing the
interface
WARNING!
Danger from electrical current.
Could result in serious injury or death.
Before starting work, switch off all devices and components involved, and discon-
▶
nect them from the grid.
Secure all devices and components involved so they cannot be switched back on.
▶
Mount the interface on a DIN rail
1
- it is recommended that the interface is mounted in a horizontal position on a DIN
rail in an automatic or robot switch cabinet
- the interface may be mounted in a non-horizontal position on the DIN rail. In this
case, only operate the interface up to a maximum ambient temperature of +50
°C (140 °F)
Ground the interface properly
2
Connect the supplied cable harness to the interface and to the robot control unit
3
- in doing so, make sure that the signal lines are no longer than 1.5 m (4.92 ft)
Connect the connection (1) on the interface and the bus module in RI FB PRO/i
4
TWIN Controller with an EtherCAT cable
- in doing so, make sure that the EtherCat-cable is no longer than 20 m (65.62 ft)
15
Input and output signals OPT/i RI IO TWIN Job
Input signals
(from robot to
power source)
Terminal
1 1 Config bit 0 0 V/24 V
1 5 Config bit 1 0 V/24 V Digital Input
1 2 Config bit 2 0 V/24 V Digital Input
1 6 Config bit 3 0 V/24 V Digital Input
1 3 Config bit 4 0 V/24 V Digital Input
1 7 Config bit 5 0 V/24 V Digital Input
1 4 Config bit 6 0 V/24 V Digital Input
1 8 Config bit 7 0 V/24 V Digital Input
2 1 Operating mode TWIN System
2 5 Operating mode TWIN System
2 2 Welding Start 0 V/24 V Increasing Digital Input
2 6 Robot ready 0 V/24 V High Digital Input
Connection
Signal
Bit 0
Bit 1
Signal
level
0 V/24 V
0 V/24 V Digital Input
Value range /
Activity
See following
table Value
Range for
Config Bit on
page 17
See following
table Value
range for
Operating
mode TWIN
System on
page 17
Type of sig-
nal
Digital Input
Digital Input
2 3 Gas on 0 V/24 V Increasing Digital Input
2 7 Wire forward 0 V/24 V Increasing Digital Input
2 4 Wire backward 0 V/24 V Increasing Digital Input
2 8 Error quit 0 V/24 V Increasing Digital Input
3 1 Touch sensing 0 V/24 V High Digital Input
3 5 Torch blow out 0 V/24 V Increasing Digital Input
3 2 Welding Simulation 0 V/24 V High Digital Input
3 6 Teach mode 0 V/24 V High Digital Input
3 3 Job number Bit 0 0 V/24 V 0 - 7 Digital Input
3 7 Job number Bit 1 0 V/24 V 0 - 7 Digital Input
3 4 Job number Bit 2 0 V/24 V 0 - 7 Digital Input
3 8 Job number Bit 3 0 V/24 V 0 - 7 Digital Input
16
Value Range for
Config Bit
Config Bit
7 6 5 4 3 2 1 0 Configuration
0 V 0 V 0 V 0 V 0 V 0 V +24 V +24 V OPT/i RI IO TWIN
Job
0 V 0 V 0 V 0 V 0 V +24 V 0 V 0 V OPT/i RI IO TWIN
Synergic / Job
Value range for Config bit
EN-US
Value range for
Bit 1 Bit 0 Function power source 1 Function power source 2
Operating mode
TWIN System
0 0 Single mode OFF
0 1 TWIN Lead TWIN Trail
1 0 TWIN Trail TWIN Lead
1 1 OFF Single mode
Value range for TWIN System Mode
Output signals
(from power
source to robot)
Terminal
Connection
Signal
Signal
level
Value range /
Activity
Type of sig-
nal
4 1 Heartbeat power source 0 V/24 V 1 Hz Digital Output
4 5 Power source ready 0 V/24 V High Digital Output
4 2 Warning 0 V/24 V High Digital Output
4 6 Notification 0 V/24 V High Digital Output
4 3 Process active 0 V/24 V High Digital Output
4 7 Current flow 0 V/24 V High Digital Output
4 4 Arc stable-/touch signal 0 V/24 V High Digital Output
4 8 Main current signal 0 V/24 V High Digital Output
5 1 Touch signal 0 V/24 V High Digital Output
5 5 Collisionbox active
0 V/24 V
0 = collision or
cable break
Digital Output
5 2 Wire stick workpiece 0 V/24 V High Digital Output
5 6 Reserve
5 3 Robot Motion Release, Power
source 1
5 7 Robot Motion Release, Power
source 2
0 V/24 V
0 V/24 V
High Digital Output
High Digital Output
5 4 Limit signal, power source 1 0 V/24 V High Digital Output
17
Terminal
5 8 Limit signal, power source 2 0 V/24 V High Digital Output
Connection
Signal
Signal
level
Value range /
Activity
Type of sig-
nal
6 1 Sensor status 1, Power Source 1 0 V/24 V
6 5 Sensor status 2, Power Source 1 0 V/24 V Digital Output
6 2 Sensor status 3, Power Source 1 0 V/24 V Digital Output
6 6 Sensor status 1, Power Source 2 0 V/24 V Digital Output
6 3 Sensor status 2, Power Source 2 0 V/24 V Digital Output
6 7 Sensor status 3, Power Source 2 0 V/24 V Digital Output
6 4 Command value out of range 0 V/24 V High Digital Output
6 8 Correction out of range 0 V/24 V High Digital Output
Assignment of
Sensor Statuses
1–3
Bit 2 Bit 1 Bit 0 Description
0 0 1 OPT/i WF R wire end
0 1 0 OPT/i WF R DE wire drum
1 0 0 OPT/i WF R DE ring sensor
See table
Assignment
of Sensor
Statuses 1–3
on page 18
Digital Output
18
Input and output signals OPT/i RI IO TWIN Synergic / Job
Input signals
(from robot to
power source)
Terminal
1 1 Config bit 0 0 V/24 V
1 5 Config bit 1 0 V/24 V Digital Input
1 2 Config bit 2 0 V/24 V Digital Input
1 6 Config bit 3 0 V/24 V Digital Input
1 3 Config bit 4 0 V/24 V Digital Input
1 7 Config bit 5 0 V/24 V Digital Input
1 4 Config bit 6 0 V/24 V Digital Input
1 8 Config bit 7 0 V/24 V Digital Input
2 1 Operating mode TWIN System
2 5 Operating mode TWIN System
Connection
Signal
Bit 0
Bit 1
Signal
level
0 V/24 V
0 V/24 V Digital Input
Value range /
Activity
See following
table Value
Range for
Config Bit on
page 21
See following
table Value
range for
Operating
mode TWIN
System on
page 21
Type of sig-
nal
Digital Input
Digital Input
EN-US
2 2 Welding Start 0 V/24 V Increasing Digital Input
2 6 Robot ready 0 V/24 V High Digital Input
2 3 Gas on 0 V/24 V Increasing Digital Input
2 7 Wire forward 0 V/24 V Increasing Digital Input
2 4 Wire backward 0 V/24 V Increasing Digital Input
2 8 Error quit 0 V/24 V Increasing Digital Input
3 1 Touch sensing 0 V/24 V High Digital Input
3 5 Torch blow out 0 V/24 V Increasing Digital Input
3 2 Welding Simulation 0 V/24 V High Digital Input
3 6 Teach mode 0 V/24 V High Digital Input
3 3 Working mode Bit 0 0 V/24 V
3 7 Working mode Bit 1 0 V/24 V Digital Input
3 4 Working mode Bit 2 0 V/24 V Digital Input
3 8 Job number Bit 3 0 V/24 V Digital Input
See following
table Value
Range for
Working Mode
on page 21
Digital Input
19
Terminal
Connection
Signal
Signal
level
Value range /
Activity
Type of sig-
nal
4 1 Welding characteristic- / Job
number Bit 0
4 5 Welding characteristic- / Job
number Bit 1
4 2 Welding characteristic- / Job
number Bit 2
4 6 Welding characteristic- / Job
number Bit 3
4 3 Welding characteristic- / Job
number Bit 4
4 7 Welding characteristic- / Job
number Bit 5
4 4 Welding characteristic- / Job
number Bit 6
4 8 Welding characteristic- / Job
number Bit 7
5 1 Welding characteristic- / Job
number Bit 8
5 5 Welding characteristic- / Job
number Bit 9
0 V/24 V
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 to 65,535
0 V/24 V Digital Input
0 V/24 V Digital Input
Digital Input
5 2 Welding characteristic- / Job
number Bit 10
5 6 Welding characteristic- / Job
number Bit 11
5 3 Welding characteristic- / Job
number Bit 12
5 7 Welding characteristic- / Job
number Bit 13
5 4 Welding characteristic- / Job
number Bit 14
5 8 Welding characteristic- / Job
number Bit 15
9 1
9 5 Arclength correction, Power
9 2
Wire feed speed command
value, Power source 1
source 1
Wire feed speed command
value, Power source 2
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
0 V/24 V Digital Input
-327.68 to
0 V – 10 V
0 V – 10 V -10.0 to 10.0 Analog Input
0 V – 10 V
327.67
[m/min]
-327.68 to
327.67
[m/min]
Analog Input
Analog Input
9 6 Arclength correction, Power
source 2
9 3 Pulse-/dynamic correction,
Power source 1
20
0 V – 10 V -10.0 to 10.0 Analog Input
0 V – 10 V -10.0 to 10.0 Analog Input
Terminal
Connection
Signal
Signal
level
Value range /
Activity
Type of sig-
nal
9 7 Wire retract correction, Power
source 1
9 4 Pulse-/dynamic correction,
Power source 2
9 8 Wire retract correction, Power
source 2
Value Range for
Config Bit
Config Bit
7 6 5 4 3 2 1 0 Configuration
0 V 0 V 0 V 0 V 0 V 0 V +24 V +24 V OPT/i RI IO TWIN
0 V 0 V 0 V 0 V 0 V +24 V 0 V 0 V OPT/i RI IO TWIN
Value range for Config bit
0 V – 10 V 0.0 to 10.0 Analog Input
0 V – 10 V -10.0 to 10.0 Analog Input
0 V – 10 V 0.0 to 10.0 Analog Input
Job
Synergic / Job
EN-US
Value range for
Operating mode
TWIN System
Value Range for
Working Mode
Bit 1 Bit 0 Function power source 1 Function power source 2
0 0 Single mode OFF
0 1 TWIN Lead TWIN Trail
1 0 TWIN Trail TWIN Lead
1 1 OFF Single mode
Value range for TWIN System Mode
Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Description
0 0 0 0 0 Internal parameter selection
0 0 0 0 1 Special 2-step mode characteristics
0 0 0 1 0 Job mode
0 1 0 0 0 2-step mode characteristics
Value range for operating mode
Output signals
(from power
source to robot)
Terminal
Connection
Signal
Signal
level
Value range /
Activity
Type of sig-
nal
6 1 Heartbeat power source 0 V/24 V 1 Hz Digital Output
21
Terminal
6 5 Power source ready 0 V/24 V High Digital Output
6 2 Warning 0 V/24 V High Digital Output
6 6 Notification 0 V/24 V High Digital Output
6 3 Process active 0 V/24 V High Digital Output
6 7 Current flow 0 V/24 V High Digital Output
6 4 Arc stable-/touch signal 0 V/24 V High Digital Output
6 8 Main current signal 0 V/24 V High Digital Output
7 1 Touch signal 0 V/24 V High Digital Output
Connection
Signal
Signal
level
Value range /
Activity
Type of sig-
nal
7 5 Collisionbox active
7 2 Wire stick workpiece 0 V/24 V High Digital Output
7 6 Torch body gripped 0 V/24 V High Digital Output
7 3 Robot Motion Release, Power
source 1
7 7 Robot Motion Release, Power
source 2
7 4 Limit signal, power source 1 0 V/24 V High Digital Output
7 8 Limit signal, power source 2 0 V/24 V High Digital Output
8 1 Sensor status 1, Power Source 1 0 V/24 V
8 5 Sensor status 2, Power Source 1 0 V/24 V Digital Output
8 2 Sensor status 3, Power Source 1 0 V/24 V Digital Output
8 6 Sensor status 1, Power Source 2 0 V/24 V Digital Output
8 3 Sensor status 2, Power Source 2 0 V/24 V Digital Output
8 7 Sensor status 3, Power Source 2 0 V/24 V Digital Output
8 4 Command value out of range 0 V/24 V High Digital Output
8 8 Correction out of range 0 V/24 V High Digital Output
0 V/24 V
0 V/24 V
0 V/24 V
0 = collision or
cable break
High
High
See table
Assignment
of Sensor
Statuses 1–3
on page 22
Digital Output
Digital Output
Digital Output
Digital Output
Assignment of
Sensor Statuses
1–3
22
Bit 2 Bit 1 Bit 0 Description
0 0 1 OPT/i WF R wire end
0 1 0 OPT/i WF R DE wire drum
1 0 0 OPT/i WF R DE ring sensor
EN-US
23
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