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RI FB/i Yaskawa WeldCom 2.0
RI MOD/i CC Modbus TCP-2P
Operating instructions
EN-US
42,0426,0218,EA 029-11012022
Table of contents
General 5
Safety 5
Device Concept 5
Block Diagram 6
Scope of Supply 6
Required Tools and Materials 6
Installation Requirements 6
Connections and Indicators 7
Connections on the Robot Interface 7
Pin Assignment of M12 Connection 7
LEDs on Robot Interface PCB 8
LEDs for Power Supply Diagnosis 9
LEDs for Network Connection Diagnosis 9
Connections and indicators on RJ 45 module 10
Examples of How the M12 Connection Is Used 12
Examples of How the M12 Connection Is Used 12
Technical data 13
Environmental Conditions 13
Robot Interface Technical Data 13
Data Transfer Properties 13
Configuration Parameters 14
Configuration of robot interface 15
General 15
Configuring the Process Image 15
Setting the IP Address 15
Configuring the Robot Interface 16
Installing the Robot Interface 17
Safety 17
Preparation 17
Fitting the M12 Connection 18
Routing the Data Cable 19
Installing the Robot Interface 20
Final Tasks 20
Installing the Bus Module 21
Safety 21
Installing the Bus Module 21
Input and output signals 22
Data types 22
Input Signals 22
Value range Process line selection 25
Value Range for TWIN Mode 25
Value Range for Documentation mode 26
Value range Working mode 26
Value Range for Command value selection 26
Output signals 27
Value Range for Welding Process and Process Image 30
Assignment of Sensor Statuses 1–3 30
Value range Safety status 30
TAG Table 31
Retrofit Image Input and Output Signals 34
Input signals 34
Value Range for Operating Mode 35
Output Signals 37
TAG Table 38
Modbus – General Information 40
Protocol Description 40
Data Coding 40
Application Data Unit (ADU) 41
Modbus Functions 42
03 (03) Read Holding Register 42
EN-US
3
06 (06) Write Single Register 43
16 (10) Write Multiple Register 44
23 (17) Read/Write Multiple Register 46
103 (67) Read Holding Register Float 47
104 (68) Write Single Register Float 48
4
General
(3)(1) (2) (5)(4)
Robot
Control
(6) (7) (8)
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried out by
▶
technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equipment
▶
and all system components.
WARNING!
Danger from electrical current.
This can result in serious personal injury and damage to property.
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.
▶
WARNING!
Danger from unplanned signal transmission.
This can result in serious personal injury and damage to property.
Do not transfer safety signals via the interface.
▶
Device Concept The robot interface serves as an interface between the power source and standardized
bus modules supporting a wide range of communication protocols.
Fronius may factory-fit the robot interface in the power source but it can also be retrofitted by appropriately trained and qualified personnel.
(1) Robot control system
(2) SpeedNet data cable
(3) Robot interface
(4) Power source
5
Block Diagram
Spider NT241
RI FB/i Yaskawa
WeldCom 2.0
Data
24 V
Module
(1)
(2)
(4)
(5)
(3)
(5) Cooling unit
(6) Interconnecting hosepack
(7) Wirefeeder
(8) Robot
Scope of Supply
Required Tools
and Materials
(1) RI FB/i Yaskawa WeldCom 2.0
(2) Data cable
4-pin
(3) M12 connection (5-pin)
with connection cable
(4) Cable ties
(5) 2 screws for M12 connection
(6) These Operating Instructions
(not pictured)
- Screwdriver TX8
- Screwdriver TX20
- Screwdriver TX25
- Diagonal cutting pliers
Installation Requirements
The robot interface may only be installed in the designated opening on the rear of the
power source.
6
Connections and Indicators
(2) (3)
(1)
(1) (2)
(3)(4)
(5)
EN-US
Connections on
the Robot Interface
Pin Assignment
of M12 Connection
(1) Power supply connection
2-pin
(2) SpeedNet data cableconnection
4-pin
(3) Bus module connection
WeldCom 2.0 Retrofit
(1) CAT signal CAT signal
(2) Touched Arc stable
(3) CAT signal GND CAT signal GND
(4) Touched GND Arc stable GND
(5) n.c (not connected)
7
LEDs on Robot
(14)
(13)
(12)
(11)
(2)
(1)
(9)
(10)
(8)
(7)
(3) (4)
(5) (6)
Interface PCB
(1) ETH1 LED Green For diagnosing the network connection.
For details, see section below titled "LEDs
(2) ETH2 LED Orange
for Network Connection Diagnosis"
(3) LED 3 Green
No function
(4) LED 4 Green
- Flashes at 4 Hz = No SpeedNet connection
(5) LED 5 Green
- Flashes at 20 Hz = Establishing
SpeedNet connection
- Flashes at 1 Hz = SpeedNet connection established
Lights up when an internal error occurs.
(6) LED 6 Red
Remedy: Restart the robot interface. If this
does not resolve the issue, inform the service team.
(7) +3V3 LED Green For diagnosing the power supply.
For details, see section below titled "LEDs
(8) +24V LED Green
for Power Supply Diagnosis"
(9) DIG OUT 2 LED Green Digital output 2. LED lights up when active
(10) DIG OUT 1 LED Green Digital output 1. LED lights up when active
8
(11) LED 11 Green
LEDs for Power
Supply Diagnosis
(12) LED 12 Green
(13) LED 13 Green
(14) LED 14 Green
LED Indicator Meaning Cause
Off
+24V
Lights up
Off
+3V3
Lights up
No supply voltage available for
interface
24 VDC supply voltage
present on robot interface
No operating voltage present
on robot interface
3 VDC operating voltage
present on robot interface
No function
- Robot interface power
supply not established
- Power supply cable faulty
- 24 VDC supply voltage
not present
- Robot interface power
supply unit is faulty
EN-US
LEDs for Network
Connection Diagnosis
LED Indicator Meaning Cause
- No network connection
ETH1
ETH2
Off No network connection
Lights up
Flashes Data transfer in progress
Off Transmission speed 10 Mbit/s
Lights up
Network connection established
Transmission speed
100 Mbit/s
established for interface
- Network cable faulty
9
Connections and
(12)(11)(10)
(14)(13)
(9)
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
indicators on RJ
45 module
(11) RJ-45 Ethernet connection 2
(12) RJ-45 Ethernet connection 1
(13) Link/Activity LED 1
(14) Network status LED
(1) TX+
(2) TX-
(3) RX+
(6) RX-
(4) Not normally used; to ensure
(5)
(7)
(8)
signal completeness, these pins
must be interconnected and,
after passing through a filter circuit, must terminate at the
ground conductor (PE).
(9) Link/Activity LED 2
(10) Module status LED
Network Status LED:
Status Meaning
Off No IP address or exception state
Lights up green At least one Modbus message received
Flashes green Waiting for first Modbus message
Lights up red IP address conflict, serious error
Flashes red Connection timeout. No Modbus message was received
within the period defined for the "Process active timeout"
Module Status LED:
Status Meaning
Off No supply voltage
Lights up green Normal operation
Lights up red Major error (exception state, serious fault, etc.)
Flashes red Minor error
Alternates between red
Firmware update in progress
and green
10
Link/Activity LED:
Status Meaning
Off No connection, no activity
Lights up green Connection established (100 Mbit/s)
Flickers green Activity (100 Mbit/s)
Lights up yellow Connection established (10 Mbit/s)
Link/Activity LED:
Status Meaning
Flickers yellow Activity (10 Mbit/s)
EN-US
11
Examples of How the M12 Connection Is Used
1 2
34
5
Pin 1 / M12
Pin 3 / M12
Pin 3 / M12
Pin 1 / M12
High-active =
Low-active =
+ 24 V from
+ 24 V from
+ 24 V
DC
/ 20 mA
+ 24 V
DC
/ 20 mA
uP
uP
max. 100 V
LED (10)
V
CC
V
CC
LED (10)
max. 100 V
Pin 2 / M12
Pin 4 / M12
Pin 4 / M12
Pin 2 / M12
High-active =
Low-active =
+ 24 V from
+ 24 V from
+ 24 V
DC
/ 20 mA
+ 24 V
DC
/ 20 mA
uP
uP
max. 100 V
max. 100 V
LED (9)
LED (9)
V
CC
V
CC
Examples of How
the M12 Connection Is Used
M12 Connection on Power Source
12
CAT signal (DIG OUT 1)
WeldCom 2.0 = Touched, Retrofit = Arc Stable (DIG OUT 2)
Technical data
EN-US
Environmental
Conditions
Robot Interface
Technical Data
CAUTION!
A risk is posed by 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: -10 °C to +40 °C (14 °F to 104 °F)
- During transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- Up to 50% at 40 °C (104 °F)
- Up to 90% 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).
Power supply Internal (24 V)
Degree of protection IP 23
Data Transfer
Properties
RJ-45 Connection
Transmission technology:
Ethernet
Medium (4 x 2 twisted-pair copper cable):
Category 5 (100 Mbit/s) or higher
Transmission speed:
10 Mbit/s or 100 Mbit/s
Bus connection:
Ethernet RJ-45
M12 Connection
Voltage:
24 V
Current load per output:
Max. 20 mA
13
Configuration
Parameters
In some robot control systems, it may be necessary to state the configuration
parameters described here so that the bus module can communicate with the
robot.
Parameter Value
Vendor Name Fronius International GmbH
Product Code 0340
hex
(832
dec
)
Major / Minor Revision V1.00
Vendor URL www.fronius.com
Product Name yaskawa-weldcom2-0-modbus-tcp
Model Name yaskawa-weldcom2-0
User Application Name Fronius welding controller for the series TPS/i WeldCom2.0
(ModbusTCP)
14
Configuration of robot interface
(1)
(2)
EN-US
General
Configuring the
Process Image
The DIP switch on the robot interface is
used to configure:
- The process image (standard image,
retrofit image)
- The IP address
Default setting for process image:
Positions 7 and 8 of DIP switch set to OFF
(1) = standard image = Weldcom V2.0
Default setting for IP address =
192.168.255.210:
- Positions 6, 5, 3, and 1 of DIP switch
set to OFF (1)
- Positions 2 and 4 of DIP switch set to
ON (2)
DIP Switch
8 7 6 5 4 3 2 1 Configuration
OFF OFF
OFF ON
- - - - - -
- - - - - -
Standard image
(Weldcom V2.0)
Not used
Setting the IP Address
ON OFF
ON ON
- - - - - -
- - - - - -
Retrofit image
(Weldcom TPS series)
Not used
The process image defines the volume of data transferred and the system compatibility.
You can set the IP address as follows:
- Via the DIP switch within the range defined by 192.168.255.2xx
(xx = DIP switch setting = 01 to 55)
Setting the Address via the DIP Switch:
DIP Switch
IP Address
8 7 6 5 4 3 2 1
- -
- -
OFF OFF OFF OFF OFF ON
OFF OFF OFF OFF ON OFF
192.168.255.201
192.168.255.202
:
- -
- -
ON ON OFF ON ON OFF
ON ON OFF ON ON ON
192.168.255.254
192.168.255.255
The IP address can be set via positions 1 to 6 of the DIP switch.
The configuration is carried out in binary format. In decimal format, the setting range is
01 through 55.
15
The following IP address is set via the DIP switch on delivery:
- IP address: 192.168.255.210
- Subnet mask: 255.255.255.0
- Default gateway: 0.0.0.0
Configuring the
Robot Interface
Set the DIP switch in accordance with the desired configuration
1
NOTE!
Risk due to invalid DIP switch settings.
This may result in malfunctions.
Whenever changes are made to the DIP switch settings, the interface must be re-
▶
started. This is the only way for the changes to take effect.
Restart the interface = interrupting and restoring the power supply or executing the
▶
relevant function on the website of the power source (SmartManager).
16
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