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OPT/i RI IO TWIN RET
Operating instructions
Robot option
EN-US
42,0426,0380,EA 002-17122020
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
LED descriptions 9
LEDs on BK1250 9
LEDs on EK1122 12
LEDs on CX8190 13
Converting and installing the interface 17
Safety 17
Converting the interface 17
Installing the interface 19
Input and output signals OPT/i RI IO TWIN RET Job 21
Input signals (from robot to power source) 21
Value range for Config Bit 22
Value Range for Working Mode 22
Value range for Operating mode TWIN System 22
Output signals (from power source to robot) 22
Input and output signals OPT/i RI IO TWIN RET Synergic / Job 24
Input signals (from robot to power source) 24
Value range for Config Bit 25
Value Range for Working Mode 25
Value range for Operating mode TWIN System 25
Output signals (from power source to robot) 26
EN-US
3
General
Device concept With the robot interface OPT/i RI IO TWIN RET, interfaces 4,100,397 and 4,100,398 can
be converted for operation with a TPS/i power source.
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.
4,044,054
OPT/i RI IO TWIN RET Job
Used for conversion of 4,100,397
for internal mode and job mode
4,044,055
OPT/i RI IO TWIN RET Synergic/Job
Used for conversion of 4,100,398
for internal mode, job mode and characteristic selection with specification of set
values and corrections possible
4,044,054 and 4,044,055
4
System overview
(6)(5)(2) (3)(1) (4)
EN-US
(1) Robot controls
(2) OPT/i RI IO TWIN RET
(3) EtherCat-cable between RI FB PRO/i TWIN Controller and OPT/i RI IO TWIN
RET
(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 RET (in different versions)
- EtherCAT-cable, for connection to the Twin Controller
- This document
- 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
LED descriptions
(2)
(1)
(3)
(5)
(6)
(4)
LEDs on BK1250
BK1250
EN-US
LED designa-
tion
(1) Run off Init The bus coupler is in initialization state
(2) Link / Act off - No connection / communication with the E-bus
(3) Error off - No error
(4) Power supply off - No operating voltage present on the bus coupler
Display Status Description
flashes Pre-Operational The bus coupler is in the pre-operational state
single flash Safe-Opera-
tional
on Operational The bus coupler is in the operational state
flickers Bootstrap A firmware is being loaded
flashes linked Connection / communication with the E-bus
flashes Err-Operational
No Communication
on - + 24 V DC operating voltage present on the bus
The bus coupler is in the safe-operational state
established
PLC error / Lost Frames
coupler
(5) Power-contact off - No operating voltage present on the power con-
tacts
on - + 24 V DC operating voltage present on the
power contacts
(6) I/O-Run off - Communication bus inactive
on - Communication bus active
9
(7)
(7) LED I/O-Error
BK1250
Display Reason
Description Remedy
for error
Steady, constant flashing
EMC problems - Check power supply for under- or over-voltage
peaks
- Take EMC measures
- If there is a communication bus error, the error
can be located by restarting (switching the
coupler off and on again)
1 pulse 0 EEPROM-checksum error - Reset factory settings using the KS2000 con-
figuration software (Menu "Online -> Coupler > Services -> Factory Settings")
1 Overflow in code buffer - Insert fewer bus terminals. Too many entries in
the table for a programmed configuration
2 Unknown data type - Software update of the bus coupler is needed
2 pulses 0 Programmed configura-
tion, incorrect table entry
n (n>0) Table comparison (bus
- Check that programmed configuration is correct
- Incorrect table entry
terminal n)
3 pulses 0 Communication bus com-
mand error
- No bus terminal inserted
- 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. Continue this until the
faulty bus terminal is found
4 pulses 0 Communication bus data
error, break behind the
bus coupler
n Break behind bus terminaln- Check whether or not the 9010 bus end ter-
5 pulses n Communication bus error
during register communication with bus terminal n
14 pulses n nth bus terminal has an
incorrect format
15 pulses n Number of bus terminals
no longer matches
10
- Check whether or not the n+1 bus terminal is
inserted correctly, replace if necessary
minal is inserted
- Replace nth bus terminal
- Restart bus coupler. If the error reoccurs,
replace the bus terminal
- Restart bus coupler. If the error reoccurs, reset
the factory settings using the KS2000 configuration software
(7) LED I/O-Error
Display Reason
for error
16 pulses n Length of communication
Description Remedy
bus data no longer
matches
EN-US
- Restart bus coupler. If the error reoccurs, reset
the factory settings using the KS2000 configuration software
11
LEDs on EK1122
(1)
(2)
(2)
(2)
(2)
EK1122
LED designa-
Display Status Description
tion
(1) Run off INIT Initialization of the terminal
flashes 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
flickers BOOTSTRAP Function for firmware updates on terminal
(2) Link / Act off - No connection on the EtherCAT-strand
on linked EtherCAT-participant connected
flashes active Communication with EtherCAT-participants
12
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.
13
(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).
14
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.
15
16
Converting and installing the interface
(1)
EN-US
Safety
Converting 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.
▶
Disconnect the cable harness of the existing interface from all components (robot,
1
external power supply, etc.)
Remove the existing interface from the DIN rail
2
Remove the KL9010 terminal (1) and store it for further use
3
17
(2)(2)(3)(6)(4) (1)
Remove the two KL6021 terminals (2)
4
- The two KL6021 terminals (2) are no longer required
- The KL3064 terminal (3) is not present on all systems. If the terminal is present,
do not remove the terminal and continue using it.
Remove the cables from the BC9000 terminal (4) and connect them to the KL1250
5
terminal of OPT/i RI IO TWIN RET
- Use the same pin assignment
Remove the bus coupler and terminal BC9000 (4)
6
- The terminal block (6) is now ready for mounting on OPT/i RI IO TWIN RET (7)
18
(6)(7) (1)
(8)
(9)
(13)(12)
(10) (10)
(11) (11)
EN-US
Installing the
interface
Mount the existing terminal block (6) on OPT/i RI IO TWIN RET (7)
7
Mount the KL9010 terminal (1) on the terminal block (6)
8
Only if OPT/i RI IO TWIN RET is used with interface 4,100,398:
9
a) Disconnect connectors (10) and (11) from one another
b) Remove the cable from slot (12) and insert it into slot (13)
c) Reconnect connectors (10) and (11)
Connect connectors (8) and (9)
10
- The interface is now fully converted and can be installed - see next section
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 OPT/i RI IO TWIN RET and to the robot
3
controller
- In doing so, make sure that the signal lines are no longer than 1.5 m (4.92 ft)
19
(1)
(2)
RI FB PRO/i TWIN Controller
Connect the connection (1) of OPT/i RI IO TWIN RET and the bus module in the RI
4
FB PRO/i TWIN Controller with an EtherCat-cable
- In doing so, make sure that the EtherCat-cable is no longer than 20 m (65.62 ft)
For information on installing the RI FB PRO/i TWIN Controller, refer to the corres-
5
ponding Operating Instructions
20
Input and output signals OPT/i RI IO TWIN RET Job
Input signals
(from robot to
power source)
EN-US
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 Welding Start 0 V / 24 V Digital Input
2 5 Robot ready 0 V / 24 V Digital Input
2 2 Working mode Bit 0 0 V / 24 V See following
2 6
2 3 Operating mode TWIN System
2 7 Operating mode TWIN System
Connection
Signal
Working mode Bit 1 0 V / 24 V Digital Input
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 Con-
fig Bit on page
22
table Value
Range for
Working Mode
on page 22
See following
table Value
range for
Operating
mode TWIN
System on
page 22
Type of sig-
nal
Digital Input
Digital Input
Digital Input
2 4 Gas on 0 V / 24 V Digital Input
2 8 Wire forward 0 V / 24 V Digital Input
3 1 Wire backward 0 V / 24 V Digital Input
3 5 Error quit 0 V / 24 V Digital Input
3 2 Touch sensing 0 V / 24 V Digital Input
3 6 Torch blow out 0 V / 24 V Digital Input
3 3 Welding simulation 0 V / 24 V Digital Input
3 7 Working mode Bit 2 0 V / 24 V Digital Input
3 4 Reserved
3 8 Reserved
4 1 Job number Bit 0 0 V / 24 V Digital Input
4 5 Job number Bit 1 0 V / 24 V Digital Input
4 2 Job number Bit 2 0 V / 24 V Digital Input
21
Terminal
Connection
Signal
Signal
level
Value range /
activity
Type of sig-
nal
4 6 Job number Bit 3 0 V / 24 V Digital Input
4 3 Job number Bit 4 0 V / 24 V Digital Input
4 7 Job number Bit 5 0 V / 24 V Digital Input
4 4 Job number Bit 6 0 V / 24 V Digital Input
4 8 Job number Bit 7 0 V / 24 V Digital Input
Value range for
Config Bit
Value Range for
Working Mode
Config bit
7 6 5 4 3 2 1 0 Configuration
0 V 0 V 0 V 0 V 0 V 0 V 0 V +24 V Retrofit Job
0 V 0 V 0 V +24 V 0 V 0 V 0 V 0 V Retrofit Synergic /
Job
Value range for Config bit
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
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
5 1 Current flow 0 V / 24 V Digital Output
22
Terminal
Connection
Signal
Signal
level
Value range /
activity
Type of sig-
nal
5 5 Process active 0 V / 24 V Digital Output
5 2 Main current signal 0 V / 24 V Digital Output
5 6
5 3 Power source ready 0 V / 24 V Digital Output
5 7 Limit signal, power source 1 + 2 0 V / 24 V Digital Output
5 4 Reserved
5 8 Reserved
Collisionbox active 0 V / 24 V
0 = collision or
cable break
Digital Output
EN-US
23
Input and output signals OPT/i RI IO TWIN RET
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 Welding Start 0 V / 24 V Digital Input
2 5 Robot ready 0 V / 24 V Digital Input
2 2 Working mode Bit 0 0 V / 24 V See following
2 6
2 3 Operating mode TWIN System
2 7 Operating mode TWIN System
Connection
Signal
Working mode Bit 1 0 V / 24 V Digital Input
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 Con-
fig Bit on page
25
table Value
Range for
Working Mode
on page 25
See following
table Value
range for
Operating
mode TWIN
System on
page 25
Type of sig-
nal
Digital Input
Digital Input
Digital Input
2 4 Gas on 0 V / 24 V Digital Input
2 8 Wire forward 0 V / 24 V Digital Input
3 1 Wire backward 0 V / 24 V Digital Input
3 5 Error quit 0 V / 24 V Digital Input
3 2 Touch sensing 0 V / 24 V Digital Input
3 6 Torch blow out 0 V / 24 V Digital Input
3 3 Welding simulation 0 V / 24 V Digital Input
3 7 Working mode Bit 2 0 V / 24 V Digital Input
3 4 Reserved
3 8 Reserved
4 1 Job number Bit 0 0 V / 24 V Digital Input
4 5 Job number Bit 1 0 V / 24 V Digital Input
24
Terminal
Connection
Signal
Signal
level
Value range /
activity
Type of sig-
nal
4 2 Job number Bit 2 0 V / 24 V Digital Input
4 6 Job number Bit 3 0 V / 24 V Digital Input
4 3 Job number Bit 4 0 V / 24 V Digital Input
4 7 Job number Bit 5 0 V / 24 V Digital Input
4 4 Job number Bit 6 0 V / 24 V Digital Input
4 8 Job number Bit 7 0 V / 24 V Digital Input
6 1 Power, Power Source 1 0 V – 10 V Analog Input
6 5 Arclength correction, Power
source 1
0 V – 10 V Analog Input
6 2 Power, Power Source 2 0 V – 10 V Analog Input
6 6 Arclength correction, Power
source 2
Value range for
Config bit
0 V – 10 V Analog Input
Config Bit
7 6 5 4 3 2 1 0 Configuration
EN-US
Value Range for
Working Mode
Value range for
Operating mode
TWIN System
0 V 0 V 0 V 0 V 0 V 0 V 0 V +24 V Retrofit Job
0 V 0 V 0 V +24 V 0 V 0 V 0 V 0 V Retrofit Synergic /
Job
Value range for Config bit
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
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
25
Output signals
(from power
source to robot)
Terminal
5 1 Current flow 0 V / 24 V Digital Output
5 5 Process active 0 V / 24 V Digital Output
5 2 Main current signal 0 V / 24 V Digital Output
5 6
5 3 Power source ready 0 V / 24 V Digital Output
5 7 Limit signal, power source 1 + 2 0 V / 24 V Digital Output
5 4 Reserved
5 8 Reserved
Connection
Signal
Collisionbox active 0 V / 24 V
Signal
level
Value range /
activity
0 = collision or
cable break
Type of sig-
nal
Digital Output
26
EN-US
27
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