LogoDeviceNet, DeviceNet Twin
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    • Imprint
    • Terms and Conditions
    • Data privacy statement
    • 014-02032023
    • General
      • Safety
      • Basics
      • Machine concept
      • Interface connections - TS/TPS, MW/TT range
      • For your information
      • Application example - TS/TPS, MW/TT range
      • Instructions for installing the external version of the interface
    • Connecting and configuring the field bus coupler
      • Safety
      • Connections on the field bus coupler
      • Connecting the field bus coupler
      • Slave address configuration BK5250
      • Baud rate configuration BK5200
    • Data transmission properties
      • Transmission technology
      • Safety feature
    • Troubleshooting
      • Safety
      • General remarks
      • K bus / operating status LEDs (local errors)
      • Field bus status LEDs
    • DeviceNet/DeviceNet Twin signal description
      • General
      • Power source modes - TS/TPS, MW/TT series
      • Overview
    • Input and output signals for MIG/MAG - TS/TPS, MW/TT range
      • Input signals (from robot to power source)
      • Output signals (from power source to robot)
    • Input and output signals for TIG - TS/TPS, MW/TT range
      • Input signals (from robot to power source)
      • TIG pulsing range settings
      • Output signals (from power source to robot)
    • Input and output signals for CC/CV - TS/TPS, MW/TT range
      • Input signals (from robot to power source)
      • Output signals (from power source to robot)
    • Input and output signals for standard manual - TS/TPS, MW/TT range
      • Input signals (from robot to power source)
      • Output signals (from power source to robot)
    • Input and output signals for MIG/MAG Twin Device-Net (4.100.400) - TS/TPS, MW/TT range
      • Input signals (from robot to power source input)
      • Output signals (from power source to robot)
    • Input and output signals for MIG/MAG Twin DeviceNet John Deere (4.100.400.800) - TS/TPS, MW/TT range
      • Input signals (from robot to power source)
      • Output signals (from power source to robot)
    • Configuration examples
      • General remarks
      • Configuration examples
    • Technical data
      • DeviceNet coupler BK5250
      • DeviceNet coupler BK5200
    • Circuit diagrams

    DeviceNet, DeviceNet Twin

    Connections on the field bus coupler
    Elements on the field bus coupler
    Overview
    Input and output signals
    Configuration examples
    Spare parts

    General

    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 device and all system components.

    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 device and all system components.

    Basics

     DeviceNet is an open, CAN-based system. CAN was developed several years ago by the company R. Bosch for data transmission in motor vehicles. There are now millions of CAN chips in use. A disadvantage of using CAN in automation applications is that it contains no definitions for the application layer. CAN only defines the physical and data protection layer.

    DeviceNet employs a standard application layer that makes the CAN protocol useful for industrial applications. As an independent association, the ODVA (Open DeviceNet Vendor Association) supports manufacturers and users of the DeviceNet system. ODVA ensures that all devices that meet the specification work together in one system, whether or not each device is manufactured by the same company.
    By means of the bit arbitration process, CAN basically offers the option of operating communications networks using master/slave and multimaster access procedures. The bus coupler BK5200 (software version B2) supports master/slave operation (polling mode), where the bus coupler functions as slave. In future versions, the bus coupler will also support multimaster operation.

    Machine concept

     The DeviceNet is characterised by its small footprint and high degree of modularity. The fact that it can simply be fitted to a standardised C-rail (thus saving space) and employs direct cabling of actuators and sensors without any interconnections between the terminals makes installation very straightforward. The uniform labelling concept further simplifies the installation.

    Interface connections - TS/TPS, MW/TT range

    Interface connections
    (1)
    Strain-relief device with cable glands
    for the DeviceNet data line and the power supply for the field bus coupler
    (2)
    LocalNet connection
    for connecting the interconnecting hosepack

    For your information

    IMPORTANT! While the robot interface is connected to the LocalNet, „2-step mode“ remains selected (display: 2-step mode).

    Further information on the „special 2-step mode for robot interface“ can be found in the sections headed „MIG/MAG welding“ and „Mode welding parameters“ in the power source operating instructions.

    Application example - TS/TPS, MW/TT range

    (1)
    Power source
    (2)
    DeviceNet
    (3)
    Interconnecting hosepack
    (4)
    Wire-feed unit
    (5)
    Welding torch
    (6)
    Robot
    (7)
    Welding wire drum
    (8)
    Robot control
    (9)
    DeviceNet data cable
    (10)
    Cooling unit

    Instructions for installing the external version of the interface

    IMPORTANT! The following guidelines must be followed when installing the external version of the interface:

    • The cables must be routed separately from mains leads
    • The field bus coupler must be installed separately from the mains leads or components
    • The field bus coupler may only be installed somewhere that provides protection from dirt and water
    • Make sure that the 24 V supply voltage is safely isolated from higher-voltage circuits.

    Connecting and configuring the field bus coupler

    Safety

    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 disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    Safety

    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 disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    Connections on the field bus coupler

    Elements on the field bus coupler BK5250
    Elements on the field bus coupler BK5200
    (1)
    DeviceNet connection
    (2)
    Address selector / Baud rate setting
    (3)
    Connections for external power supply

    IMPORTANT! External power supply must not come via the power source. Use the robot or control for the external power supply..

    Connecting the field bus coupler

    CAUTION!

    Danger from electrical current.

    This can result in severe damage to property.

    Before starting work, ensure that the cables for the external power supply to the interface are and remain de-energised until all work is complete.

    1Remove the interface lid
    2Remove the strain-relief device from the interface
    3Feed the DeviceNet data line and cable for the external power supply through the cable gland in the strain-relief device
    The bus cable consists of one 2x2 core twisted-pair and screened line. Of the two pairs of wires, one is responsible for
    • data transfer
    • and one for the power supply (currents up to 8 A possible, depending on the cable)
    IMPORTANT! Maximum permitted cable length depends on the Baud rate. Depending on the Baud rate chosen, cable lengths can be:
    • max. 100 m at the highest Baud rate (500 kBaud)
    • max. 500 m at the lowest Baud rate (125 kBaud)

    The DeviceNet bus cable is connected using the 5-pin plug provided. Pin 1 is located on the top of the bus coupler.

    4Connect the data lines to pin 2 and pin 4 as shown in the illustration below (observe polarity)

    NOTE! In order to avoid reflections and any transmission problems, fit resistors to both ends of the field bus cable.
    5Connect power supply to pin 1 and pin 5 (observe polarity)
    6Connect
    - pin 1 to terminal X1/24 V
    - pin 5 to terminal X1/0 V

    IMPORTANT! Both voltages must be connected before the field bus coupler can be used.

    DeviceNet connection with pin assignments

     

    BK5200

    BK5250

    Vendor ID

    108

    108

    Device Type

    12

    12

    Produkt Code

    5200

    5250

    DeviceNet Group

    Group 2

    Group 2

    MajRev

    3

    1

    MinRev

    0

    1

    ProdName

    -

    BK5250 V01.01

    7Make the electrical connection between the „insulated DIN rail“ (1) and the bus cable shield (2).

    IMPORTANT! Use only „insulated“ DIN rails when fitting the field bus coupler. Ensure that the DIN rail has no electrical contact with the earth of the power source.
    Connecting the DIN rail to the bus cable shield - TS/TPS, MW/TT series
    8Check that the shield is connected to the robot earth
    9Connect the external power supply from the robot or control system to the connections for the external power supply on the field bus coupler
    10Attach the DeviceNet data line and cable for the external power supply to the cable gland in the strain-relief device using cable ties
    11Attach the strain-relief device to the interface using the original fixings. Ensure that the strain-relief device assumes its original position
    For the TS/TPS, MW/TT series:
    12Connect the LocalNet plug on the interconnecting hosepack to the LocalNet connection on the interface

    Slave address configuration BK5250

    Set slave address using the two rotary selector switches.
    Default setting = 11
    All addresses are permitted, each address may only appear once on the network.

    1Ensure that all devices and components have been switched off and disconnected from the mains
    2Ensure that the interface has been disconnected from the mains
    3Move switch to desired position using a screwdriver
    • Values on the upper switch represent units
    • Values on the lower switch represent tens

    IMPORTANT! Ensure that the switches engage properly

    Example

    Setting address 34:
    • Upper rotary selector switch S520: 4
    • Lower rotary selector switch S521: 3
    4Using the original screws, fit the interface lid back into its original position

    Baud rate configuration BK5200

    IMPORTANT! Set the bus coupler node number and Baud rate before starting up the bus coupler.

    1Ensure that all devices and components have been switched off and disconnected from the mains
    2Ensure that the interface has been disconnected from the mains
    3Set MAC ID using DIP switches 1 to 6:
    • Switch 1 = least significant bit (20)
    • Switch 6 = most significant bit (25)

    The bit is set if the switch is in the ON position

    The MAC ID can be in the range 0 to 63.

    The Baud rate is set using switches 7 and 8. The following table contains information about the different Baud rate settings.

    Baud rate setting

    1

    2

    3

    4

    5

    6

    7

    8

    125 kBd

    -

    -

    -

    -

    -

    -

    off

    off

    250 kBd

    -

    -

    -

    -

    -

    -

    on

    off

    500 kBd

    -

    -

    -

    -

    -

    -

    off

    on

    (Default) 125 kBd

    -

    -

    -

    -

    -

    -

    on

    on

    4Using the original screws, fit the interface lid back into its original position

    Data transmission properties

    Transmission technology

    Network topology
    Linear bus, bus termination at both ends (121 Ohm), spur lines are possible

    Medium
    Screened 2x2 core twisted-pair cable, must be screened.

    Number of stations
    max. 64 nodes

    Max. bus length
    depends on the Baud rate:
    100 m at 500 kBit/s, 250 m at 250 kBit/s, 500 m at 125 kBit/s

    Transmission speed
    500 kBit/s, 250 kBit/s, 125 kBit/s

    Connector
    Open Style connector, 5-pin

    Operating modes
    Bit strobe, polling, cyclic, „Change of State“ (COS)

    Process data width
    96 bits (Standard configuration)

    Process data format
    Intel

    Transmission technology

    Network topology
    Linear bus, bus termination at both ends (121 Ohm), spur lines are possible

    Medium
    Screened 2x2 core twisted-pair cable, must be screened.

    Number of stations
    max. 64 nodes

    Max. bus length
    depends on the Baud rate:
    100 m at 500 kBit/s, 250 m at 250 kBit/s, 500 m at 125 kBit/s

    Transmission speed
    500 kBit/s, 250 kBit/s, 125 kBit/s

    Connector
    Open Style connector, 5-pin

    Operating modes
    Bit strobe, polling, cyclic, „Change of State“ (COS)

    Process data width
    96 bits (Standard configuration)

    Process data format
    Intel

    Safety feature

    The field bus nodes are equipped with a shutdown monitor so the power source can interrupt the process if data transmission drops out. If there is no data transmission within 700ms, all inputs and outputs are reset and the power source goes into „Stop“. Once data transmission has been re-established, the following signals resume the process:

    • “Robot ready” signal
    • “Source error reset” signal

    Troubleshooting

    Safety

    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 disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    Safety

    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 disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    General remarks

    Elements on the field bus coupler BK5250
    (1)
    LED ADR (Module)
    (2)
    LED RUN (Module)
    (3)
    LED TX overflow (Net)
    (4)
    LED overflow (Net)
    (5)
    LED bus coupler supply
    (6)
    LED power contacts supply
    (7)
    LED K bus RUN
    (8)
    LED K bus ERR
    Elements on the field bus coupler BK5200
    (9)
    Operating status LEDs
    (10)
    Field bus status LEDs
    (11)
    Supply LEDs
    • left-hand LED ... monitors the field bus coupler power supply
    • right-hand LED... monitors the power contact supply

    If an error occurs, the field bus status/operating status LEDs signal the type of error and where it occurred.

    WICHTIG! In some cases, the field bus coupler does not complete the flashing sequence once the error has been rectified. Restart the field bus coupler by switching the supply voltage off and on again, or by resetting the software.

    K bus / operating status LEDs (local errors)

    The K bus LEDs (operating status LEDs) monitor local communications between the field bus coupler and field bus terminals. The green LED lights when there are no errors. The red LED flashes at two different intervals if a terminal bus error occurs.

    Flash code
    1. Rapid flashing:
      Start of the error code
       
    2. First slow pulse:
      Type of error
       
    3. Second slow pulse:
      Error location

    IMPORTANT! The number of pulses indicates the location of the last field bus terminal prior to where the error occurred. Passive field bus terminals (e.g. supply terminals) are not counted.

    Error code

    Error argument

    Description

    1 pulse

    0

    EEPROM check sum error

     

    1

    Inline code buffer overflow

     

    2

    Unknown data type

    2 pulses


    0

    Programmed configuration
    Incorrect table entry/bus coupler

     

    n (n<0)

    Terminal(s) table comparison incorrect

    3 pulses

    0

    Terminal bus command error

    4 pulses

    0

    Terminal bus data error

     

    n (n<0)

    Break behind terminal(s) (0:coupler)

    5 pulses

    n (n<0)

    Terminal bus error during register communication with terminal(s)

    6 pulses

    0

    Special field bus error

     

    n (n<0)

     

    IMPORTANT! When an error occurs during operation, the error code is not immediately indicated on the LEDs. The bus coupler must be requested to perform a diagnosis of the bus terminals. The diagnosis request is generated after switching on, or is requested by the master.

    Field bus status LEDs

    The field bus status LEDs indicate the operating status of the field bus.

    Module

    Status

    LED „MS RUN“, green LED
    - flashes
    - is steady


    Configuration incorrect
    Status OK

    LED „MS OVERFL“, red LED
    - flashes
    - is steady


    Receive queue overflow
    Status OK

    Network

    Status

    LED „NS CONNECT“, green LED
    - flashes


    Bus coupler ready to communicate, but not yet assigned to the master

    LED „NS BUS OFF“, green LED
    - is steady


    Bus coupler is assigned to the master, data exchange taking place

    LED „NS BUS OFF“, red LED
    - flashes
    - is steady


    I/O connection timeout
    BUS OFF: CAN error, node with identical node address

    DeviceNet/DeviceNet Twin signal description

    General

    The following signal descriptions apply to an interface with a KL 6021-0010 communication terminal (standard version)

    Extra terminals can also be installed in a robot interface. However, the number that can be installed is limited by the size of the housing.

    IMPORTANT! When installing extra terminals, the process data image changes.

    General

    The following signal descriptions apply to an interface with a KL 6021-0010 communication terminal (standard version)

    Extra terminals can also be installed in a robot interface. However, the number that can be installed is limited by the size of the housing.

    IMPORTANT! When installing extra terminals, the process data image changes.

    Power source modes - TS/TPS, MW/TT series

    Depending on the selected mode, the DeviceNet/DeviceNet Twin interface can transfer a wide variety of input and output signals.

    Mode

    E05

    E04

    E03

    MIG/MAG standard synergic welding

    0

    0

    0

    MIG/MAG pulsed arc welding

    0

    0

    1

    Job mode

    0

    1

    0

    Internal parameter selection

    0

    1

    1

    TIG

    1

    1

    0

    CC/CV

    1

    0

    1

    Standard manual welding

    1

    0

    0

    CMT/special process

    1

    1

    1

    Overview

    ‘DeviceNet/DeviceNet Twin’ signal description is composed of the following sections:
    • Input and output signals for MIG/MAG - TS/TPS, MW/TT range
    • Input and output signals for TIG - TS/TPS, MW/TT range
    • Input and output signals for CC/CV - TS/TPS, MW/TT range
    • Input and output signals for standard manual - TS/TPS, MW/TT range
    • Input and output signals for MIG/MAG Twin DeviceNet - TS/TPS, MW/TT range
    • Input and output signals for MIG/MAG Twin DeviceNet John Deere - TS/TPS, MW/TT range

    Input and output signals for MIG/MAG - TS/TPS, MW/TT range

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 operating modes

    -

    High

    E04

    Bit 1 operating modes

    -

    High

    E05

    Bit 2 operating modes

    -

    High

    E06

    Master selection Twin

    -

    High

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow through

    -

    High

    E15 - E 16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i remote control unit and in Job mode

    E17 - E23

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

    Power (command value)

    0 - 65535
    (0 % - 100 %)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

    Arc length correction (command value)

    0 - 65535
    (-30 % - +30 %)

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

    E65 - E72

    Pulse/dynamic correction (command value)

    0 - 255
    (-5 % - +5 %)

    -

    E73 - E80

    Burn-back (command value)

    0 - 255
    (-200 ms - +200 ms)

    -

    E81

    Synchro Puls disable

    -

    High

    E82

    SFI disable

    -

    High

    E83

    Pulse/dynamic correction disable

    -

    High

    E84

    Burn-back disable

    -

    High

    E85

    Full power range (0 - 30 m)

    -

    High

    E86

    Not in use

    -

    -

    E87 - E96

    Welding speed

    0 - 1023
    (0 - 1023 cm/min)

    -

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 operating modes

    -

    High

    E04

    Bit 1 operating modes

    -

    High

    E05

    Bit 2 operating modes

    -

    High

    E06

    Master selection Twin

    -

    High

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow through

    -

    High

    E15 - E 16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i remote control unit and in Job mode

    E17 - E23

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

    Power (command value)

    0 - 65535
    (0 % - 100 %)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

    Arc length correction (command value)

    0 - 65535
    (-30 % - +30 %)

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

    E65 - E72

    Pulse/dynamic correction (command value)

    0 - 255
    (-5 % - +5 %)

    -

    E73 - E80

    Burn-back (command value)

    0 - 255
    (-200 ms - +200 ms)

    -

    E81

    Synchro Puls disable

    -

    High

    E82

    SFI disable

    -

    High

    E83

    Pulse/dynamic correction disable

    -

    High

    E84

    Burn-back disable

    -

    High

    E85

    Full power range (0 - 30 m)

    -

    High

    E86

    Not in use

    -

    -

    E87 - E96

    Welding speed

    0 - 1023
    (0 - 1023 cm/min)

    -

    Output signals (from power source to robot)

    Seq. no.

    Signal designation

    Field

    Activity

    A01

    Arc stable

    -

    High

    A02

    Limit signal (only with RCU 5000i)

    -

    High

    A03

    Process active

    -

    High

    A04

    Main current signal

    -

    High

    A05

    Torch collision protection

    -

    High

    A06

    Power source ready

    -

    High

    A07

    Communication ready

    -

    High

    A08

    Spare

    -

    -

    A09 - A16

    Error number

    0 - 255

    -

    A17 - A24

    Not in use

    -

    -

    A25

    Wire stick control
    (wire released from weldpool)

    -

    High

    A26

    Not in use

    -

    -

    A27

    Robot access (only with RCU 5000i)

    -

    High

    A28

    Wire available

    -

    High

    A29

    Timeout short circuit

    -

    High

    A30

    Data documentation ready

    -

    High

    A31

    Not in use

    -

    -

    A32

    Power outside range

    -

    -

     

     

     

    Welding voltage (real value)

    0 - 65535
    (0 - 100 V)

    -

    A33 - A40

    Low byte

    -

    -

    A41 - A48

    High byte

    -

    -

     

     

     

    Welding current (real value)

    0 - 65535
    (0 - 1000 A)

    -

    A49 - A56

    Low byte

    -

    -

    A57 - A64

    High byte

    -

    -

     

     

     

    A65 - A72

    Motor current (real value)

    0 - 255
    (0 - 5 A)

    -

    A73 - A80

    Not in use

    -

    -

     

    Wire feed speed (actual value)

    0 - 65535
    (-327.68 - +327.67 m/min)

     

    A81 - A88

    Low byte

    -

    -

    A89 - A96

    High byte

    -

    -

    Input and output signals for TIG - TS/TPS, MW/TT range

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 modes

    -

    High

    E04

    Bit 1 modes

    -

    High

    E05

    Bit 2 modes

    -

    High

    E06

    Master selection twin

    -

    -

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Cold wire disable

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25

    DC / AC

    -

    High

    E26

    DC- / DC+

    -

    High

    E27

    Cap shaping

    -

    High

    E28

    Pulse disable

    -

    High

    E29

    Pulse range bit 0

    -

    High

    E30

    Pulse range bit 1

    -

    High

    E31

    Pulse range bit 2

    -

    High

    E32

    Welding simulation

    -

    High

     

    Main current (command value)

    0 - 65535
    (0 bis Imax)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

     

    External parameter (command value)

    0 - 65535

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

     

    E65 - E72

    Base current (command value)

    0 - 255
    (0% - 100%)

    -

    E73 - E80

    Duty cycle (command value)

    0 - 255
    (10% - 90%)

    -

    E81 - E82

    Not in use

    -

    -

    E83

    Base current disable

    -

    High

    E84

    Duty cycle disable

    -

    High

    E85 - E86

    Not in use

    -

    -

    E87 - E96

    Wire speed Wfi (command value)

    0 - 1023
    (0 - vDmax)

    -

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 modes

    -

    High

    E04

    Bit 1 modes

    -

    High

    E05

    Bit 2 modes

    -

    High

    E06

    Master selection twin

    -

    -

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Cold wire disable

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25

    DC / AC

    -

    High

    E26

    DC- / DC+

    -

    High

    E27

    Cap shaping

    -

    High

    E28

    Pulse disable

    -

    High

    E29

    Pulse range bit 0

    -

    High

    E30

    Pulse range bit 1

    -

    High

    E31

    Pulse range bit 2

    -

    High

    E32

    Welding simulation

    -

    High

     

    Main current (command value)

    0 - 65535
    (0 bis Imax)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

     

    External parameter (command value)

    0 - 65535

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

     

    E65 - E72

    Base current (command value)

    0 - 255
    (0% - 100%)

    -

    E73 - E80

    Duty cycle (command value)

    0 - 255
    (10% - 90%)

    -

    E81 - E82

    Not in use

    -

    -

    E83

    Base current disable

    -

    High

    E84

    Duty cycle disable

    -

    High

    E85 - E86

    Not in use

    -

    -

    E87 - E96

    Wire speed Wfi (command value)

    0 - 1023
    (0 - vDmax)

    -

    TIG pulsing range settings

    Operating mode

    E31

    E30

    E29

    Set pulsing range on the power source

    0

    0

    0

    Pulse setting range deactivated

    0

    0

    1

    0.2 - 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 (from power source to robot)

    Seq. no.

    Signal designation

    Field

    Activity

    A01

    Arc stable

    -

    High

    A02

    Not in use

    -

    -

    A03

    Process active

    -

    High

    A04

    Main current signal

    -

    High

    A05

    Torch collision protection

    -

    High

    A06

    Power source ready

    -

    High

    A07

    Communication ready

    -

    High

    A08

    Spare

    -

    -

    A09 - A16

    Error number

    0 - 255

     

    A17 - A25

    Not in use

    -

    -

    A26

    High frequency active

    -

    High

    A27

    Not in use

    -

    -

    A28

    Wire available

    -

    High

    A29 - A30

    Not in use

    -

    -

    A31

    Pulse high

    -

    High

    A32

    Not in use

    -

    -

     

     

     

     

    Welding voltage (real value)

    0 - 65535
    (0 - 100 V)

    -

    A33 - A40

    Low byte

    -

    -

    A41 - A48

    High byte

    -

    -

     

     

     

     

    Welding current (actual value)

    0 - 65535
    (0 - 1000 A)

    -

    A49 - A56

    Low byte

    -

    -

    A57 - A64

    High byte

    -

    -

     

     

     

     

    A65 - A72

    Motor current (actual value)

    0 - 255
    (0 - 5 A)

    -

    A73 - A80

    Arc length (actual value) (AVC)

    0 - 255

    -

     

     

     

     

     

    Wire feed speed (actual value)

    0 - 65535
    (-327.68 - +327.67 m/min)

    -

    A81 - A88

    Low byte

    -

    -

    A89 - A96

    High byte

    -

    -

    Input and output signals for CC/CV - TS/TPS, MW/TT range

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 operating modes

    -

    High

    E04

    Bit 1 operating modes

    -

    High

    E05

    Bit 2 operating modes

    -

    High

    E06

    Master selection twin

    -

    High

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow through

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i remote control unit and in Job mode

    E17 - E31

    Job number

    0 - 999

     

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    Welding current (command value)

    0 - 65535
    (0 - Imax)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

     

    Wire speed (command value)

    0 - 65535
    (0,5 - vDmax)

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

     

    E65 - E72

    Welding voltage (command value)

    0 - 255
    (0 - 50 V)

    -

    E73 - E80

    Not in use

    -

    -

    E81

    Synchro Puls disable

    -

    High

    E82

    SFI disable

    -

    High

    E83

    Welding voltage disable

    -

    High

    E84

    Not in use

    -

    -

    E85

    Full power range (0 - 30 m)

    -

    High

    E86

    Not in use

    -

    -

    E87 - E96

    Welding speed

    0 - 1023
    (0 - 1023 cm/min)

    -

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 operating modes

    -

    High

    E04

    Bit 1 operating modes

    -

    High

    E05

    Bit 2 operating modes

    -

    High

    E06

    Master selection twin

    -

    High

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow through

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i remote control unit and in Job mode

    E17 - E31

    Job number

    0 - 999

     

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    Welding current (command value)

    0 - 65535
    (0 - Imax)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

     

    Wire speed (command value)

    0 - 65535
    (0,5 - vDmax)

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

     

    E65 - E72

    Welding voltage (command value)

    0 - 255
    (0 - 50 V)

    -

    E73 - E80

    Not in use

    -

    -

    E81

    Synchro Puls disable

    -

    High

    E82

    SFI disable

    -

    High

    E83

    Welding voltage disable

    -

    High

    E84

    Not in use

    -

    -

    E85

    Full power range (0 - 30 m)

    -

    High

    E86

    Not in use

    -

    -

    E87 - E96

    Welding speed

    0 - 1023
    (0 - 1023 cm/min)

    -

    Output signals (from power source to robot)

    Seq. no.

    Signal designation

    Field

    Activity

    A01

    Arc stable

    -

    High

    A02

    Limit signal (only with RCU 5000i)

    -

    High

    A03

    Process active

    -

    High

    A04

    Main current signal

    -

    High

    A05

    Torch collision protection

    -

    High

    A06

    Power source ready

    -

    High

    A07

    Communication ready

    -

    High

    A08

    Spare

    -

    -

    A09 - A16

    Error number

    0 - 255

    -

    A17 - A24

    Not in use

    -

    -

    A25

    Wire stick control
    (wire released from weldpool)

    -

    High

    A26

    Not in use

    -

    -

    A27

    Robot access (only with RCU 5000i)

    -

    High

    A28

    Wire available

    -

    High

    A29

    Timeout short circuit

    -

    High

    A30

    Data documentation ready

    -

    High

    A31

    Not in use

    -

    -

    A32

    Power outside range

    -

    -

     

     

     

     

    Welding voltage (real value)

    0 - 65535
    (0 - 100 V)

    -

    A33 - A40

    Low byte

    -

    -

    A41 - A48

    High byte

    -

    -

     

     

     

     

    Welding current (real value)

    0 - 65535
    (0 - 1000 A)

    -

    A49 - A56

    Low byte

    -

    -

    A57 - A64

    High byte

    -

    -

     

     

     

     

    A65 - A72

    Motor current (real value)

    0 - 255
    (0 - 5 A)

    -

    A73 - A80

    Not in use

    -

    -

     

     

     

     

    Wire feed speed (actual value)

    (-327.68 - +327.67 m/min)

    -

    A81 - A88

    Low byte

    -

    -

    A89 - A96

    High byte

    -

    -

    Input and output signals for standard manual - TS/TPS, MW/TT range

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 operating modes

    -

    High

    E04

    Bit 1 operating modes

    -

    High

    E05

    Bit 2 operating modes

    -

    High

    E06

    Master selection twin

    -

    High

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow through

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i remote control unit and in Job mode

    E17 - E31

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

    Wire speed (command value)

    0 - 65535
    (0.5 - vDmax)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

     

    Welding voltage (command value)

    0 - 65535
    (10 - 40 V)

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

     

    E65 - E72

    Dynamic correction (command value)

    0 - 255
    (0 - 10)

    -

    E73 - E80

    Burn-back (command value)

    0 - 255
    (-200 ms - +200 ms)

    -

    E81

    Synchro Puls disable

    -

    High

    E82

    SFI disable

    -

    High

    E83

    Dynamic correction disable

    -

    High

    E84

    Burn-back disable

    -

    High

    E85

    Full power range (0 - 30 m)

    -

    High

    E86

    Not in use

    -

    -

    E87 - E96

    Welding speed

    0 - 1023
    (0 - 1023 cm/min)

    -

    Input signals (from robot to power source)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 operating modes

    -

    High

    E04

    Bit 1 operating modes

    -

    High

    E05

    Bit 2 operating modes

    -

    High

    E06

    Master selection twin

    -

    High

    E07 - E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow through

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i remote control unit and in Job mode

    E17 - E31

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

    Wire speed (command value)

    0 - 65535
    (0.5 - vDmax)

    -

    E33 - E40

    Low byte

    -

    -

    E41 - E48

    High byte

    -

    -

     

     

     

     

     

    Welding voltage (command value)

    0 - 65535
    (10 - 40 V)

    -

    E49 - E56

    Low byte

    -

    -

    E57 - E64

    High byte

    -

    -

     

     

     

     

    E65 - E72

    Dynamic correction (command value)

    0 - 255
    (0 - 10)

    -

    E73 - E80

    Burn-back (command value)

    0 - 255
    (-200 ms - +200 ms)

    -

    E81

    Synchro Puls disable

    -

    High

    E82

    SFI disable

    -

    High

    E83

    Dynamic correction disable

    -

    High

    E84

    Burn-back disable

    -

    High

    E85

    Full power range (0 - 30 m)

    -

    High

    E86

    Not in use

    -

    -

    E87 - E96

    Welding speed

    0 - 1023
    (0 - 1023 cm/min)

    -

    Output signals (from power source to robot)

    Seq. no.

    Signal designation

    Field

    Activity

    A01

    Arc stable

    -

    High

    A02

    Limit signal (only with RCU 5000i)

    -

    High

    A03

    Process active

    -

    High

    A04

    Main current signal

    -

    High

    A05

    Torch collision protection

    -

    High

    A06

    Power source ready

    -

    High

    A07

    Communication ready

    -

    High

    A08

    Spare

    -

    -

    A09 - A16

    Error number

    0 - 255

    -

    A17 - A24

    Not in use

    -

    -

    A25

    Wire stick control
    (wire released from weldpool)

    -

    High

    A26

    Not in use

    -

    -

    A27

    Robot access (only with RCU 5000i)

    -

    High

    A28

    Wire available

    -

    High

    A29

    Timeout short circuit

    -

    High

    A30

    Data documentation ready

    -

    High

    A31

    Not in use

    -

    -

    A32

    Power outside range

    -

    High

     

     

     

     

    Welding voltage (real value)

    0 - 65535
    (0 - 100 V)

    -

    A33 - A40

    Low byte

    -

    -

    A41 - A48

    High byte

    -

    -

     

     

     

     

    Welding current (real value)

    0 - 65535
    (0 - 1000 A)

    -

    A49 - A56

    Low byte

    -

    -

    A57 - A64

    High byte

    -

    -

     

     

     

     

    A765- A72

    Motor current (real value)

    0 - 255
    (0 - 5 A)

    -

    A73 - A80

    Not in use

    -

    -

     

     

     

     

    Wire feed speed (actual value)

    0 - 65535 -
    (-327.68 - +327.67 m/min)

    -

    A81 - A88

    Low byte

    -

    -

    A89 - A96

    High byte

    -

    -

    Input and output signals for MIG/MAG Twin Device-Net (4.100.400) - TS/TPS, MW/TT range

    Input signals (from robot to power source input)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 modes

    -

    High

    E04

    Bit 1 modes

    -

    High

    E05

    Bit 2 modes

    -

    High

    E06

    Master selection twin
    Power source 1

    -

    High

    E07

    Master selection twin
    Power source 2

    -

    High

    E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow out

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i and in Job mode

    E17 - E31

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

    E33 - E48

    Power (command value)
    power source 1

    0 - 65535
    (0 - 100 %)

    -

    E49 - E64

    Arc length correction (command value)
    power source 1

    0 - 65535
    (-30 % - +30 %)

    -

    E65 - E72

    Pulse/dynamic correction (command value)
    power source 1

    0 - 255
    (-5 % - +5 %)

    -

    E73 - E80

    Burn-back (command value)
    power source 1

    0 - 255
    (-200 - +200 ms)

    -

    E81 - E96

    Not in use

    -

    -

    E97 - E112

    Power (command value)
    power source 2

    0 - 65535
    (0 - 100 %)

    -

    E113 - 128

    Arc length correction (command value)
    power source 2

    0 - 65535
    (-30 % - +30 %)

    -

    E129 - 136

    Pulse/dynamic correction (command value)
    power source 2

    0 - 255
    (-5 % - +5 %)

    -

    E137 - 144

    Burn-back (command value)
    power source 2

    0 - 255
    (-200 - +200 ms)

    -

    E145 - 152

    Not in use

    -

    -

    E153 - 160

    Standard I/O KL2134

    -

    -

    Input signals (from robot to power source input)

    Seq. no.

    Signal designation

    Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 modes

    -

    High

    E04

    Bit 1 modes

    -

    High

    E05

    Bit 2 modes

    -

    High

    E06

    Master selection twin
    Power source 1

    -

    High

    E07

    Master selection twin
    Power source 2

    -

    High

    E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow out

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i and in Job mode

    E17 - E31

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

    E33 - E48

    Power (command value)
    power source 1

    0 - 65535
    (0 - 100 %)

    -

    E49 - E64

    Arc length correction (command value)
    power source 1

    0 - 65535
    (-30 % - +30 %)

    -

    E65 - E72

    Pulse/dynamic correction (command value)
    power source 1

    0 - 255
    (-5 % - +5 %)

    -

    E73 - E80

    Burn-back (command value)
    power source 1

    0 - 255
    (-200 - +200 ms)

    -

    E81 - E96

    Not in use

    -

    -

    E97 - E112

    Power (command value)
    power source 2

    0 - 65535
    (0 - 100 %)

    -

    E113 - 128

    Arc length correction (command value)
    power source 2

    0 - 65535
    (-30 % - +30 %)

    -

    E129 - 136

    Pulse/dynamic correction (command value)
    power source 2

    0 - 255
    (-5 % - +5 %)

    -

    E137 - 144

    Burn-back (command value)
    power source 2

    0 - 255
    (-200 - +200 ms)

    -

    E145 - 152

    Not in use

    -

    -

    E153 - 160

    Standard I/O KL2134

    -

    -

    Output signals (from power source to robot)

    Seq. no.

    Signal designation

    Field

    Activity

    A01

    Arc stable

    -

    High

    A02

    Limit signal (only with RCU 5000i)

    -

    High

    A03

    Process active

    -

    High

    A04

    Main current signal

    -

    High

    A05

    Torch collision protection

    -

    High

    A06

    Power source ready

    -

    High

    A07

    Communication ready

    -

    High

    A08

    Spare

    -

    -

    A09 - A16

    Error number power source 1

    0 - 255

    -

    A17 - A24

    Error number power source 2

    0 - 255

    -

    A25

    Wire stick control (wire released from weldpool)

     

    High

    A26

    Not in use

    -

    -

    A27

    Robot access (only with RCU 5000i)

     

    High

    A28

    Wire available

    -

    High

    A29 - A32

    Not in use

    -

    -

    A33 - A48

    Welding voltage (real value)

    0 - 65535

    -

    A49 - A64

    Welding current (real value)
    power source 1

    0 - 65535
    (0 - 1000 A)

    -

    A65 - A72

    Motor current (real value)
    power source 1

    0 - 255
    (0 - 5 A)

    -

    A73 - A80

    Not in use

    -

    -

    A81 - A96

    Wire speed (real value)
    power source 1

    0 - 65535
    (-327.68 - +327.67 m/min)

    -

    A97 - 112

    Welding voltage (real value) power source 2

    0 - 65535
    (0 - 100 V)

    -

    A113 - 128

    Welding current (real value)
    power source 2

    0 - 65535
    (0 - 1000 A)

    -

    A129 - 136

    Motor current (real value)
    power source 2

    0 - 255
    (0 - 5 A)

    -

    A137 - 144

    Not in use

    -

    -

    A145 - 160

    Wire speed (real value)
    power source 2

    0 - 65535
    (-327.68 - +327.67 m/min)

    -

    A161 - 168

    Not in use

    -

    -

    A169 - 172

    Standard I/O KL1114

    -

    -

    Input and output signals for MIG/MAG Twin DeviceNet John Deere (4.100.400.800) - TS/TPS, MW/TT range

    Input signals (from robot to power source)

     Seq. no.

    Signal designation

     Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 modes

    -

    High

    E04

    Bit 1 modes

    -

    High

    E05

    Bit 2 modes

    -

    High

    E06

    Master selection twin power source 1

    -

    High

    E07

    Master selection twin power source 2

    -

    High

    E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow out

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number power source 1

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i and in Job mode

    E17 - E31

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

    E33 - E48

    Power (command value)
    power source 1

    0 - 65535
    (0 - 100 %)

    -

    E49 - E64

    Arc length correction (command value)
    power source 1

    0 - 65535
    (-30 % - +30 %)

    -

    E65 - E72

    Pulse/dynamic correction (command value)
    power source 1

    0 - 255
    (-5 % - +5 %)

    -

    E73 - E80

    Burn-back (command value)
    power source 1

    0 - 255
    (-200 - +200 ms)

    -

    E81 - E96

    Power (command value)
    power source 2

    0 - 65535
    (0 - 100 %)

    -

    E97 - 112

    Arc length correction (command value)
    power source 2

    0 - 65535
    (-30 % - +30 %)

    -

    E113 - 120

    Pulse/dynamic correction (command value)
    power source 2

    0 - 255
    (-5 % - +5 %)

    -

    E121 - 128

    Burn-back (command value)
    power source 2

    0 - 255
    (-200 - +200 ms)

    -

    E129 - 136

    Standard I/O KL2134

    -

    -

    E137 - 144

    Job number power source 2

    0 - 99

    -

    Input signals (from robot to power source)

     Seq. no.

    Signal designation

     Field

    Activity

    E01

    Welding start

    -

    High

    E02

    Robot ready

    -

    High

    E03

    Bit 0 modes

    -

    High

    E04

    Bit 1 modes

    -

    High

    E05

    Bit 2 modes

    -

    High

    E06

    Master selection twin power source 1

    -

    High

    E07

    Master selection twin power source 2

    -

    High

    E08

    Not in use

    -

    -

    E09

    Gas test

    -

    High

    E10

    Wire inching

    -

    High

    E11

    Wire retract

    -

    High

    E12

    Source error reset

    -

    High

    E13

    Touch sensing

    -

    High

    E14

    Torch blow out

    -

    High

    E15 - E16

    Not in use

    -

    -

    E17 - E24

    Job number power source 1

    0 - 99

    -

    E25 - E31

    Program number

    0 - 127

    -

    E32

    Welding simulation

    -

    High

     

     

     

     

     

    With RCU 5000i and in Job mode

    E17 - E31

    Job number

    0 - 999

    -

    E32

    Welding simulation

    -

    High

    E33 - E48

    Power (command value)
    power source 1

    0 - 65535
    (0 - 100 %)

    -

    E49 - E64

    Arc length correction (command value)
    power source 1

    0 - 65535
    (-30 % - +30 %)

    -

    E65 - E72

    Pulse/dynamic correction (command value)
    power source 1

    0 - 255
    (-5 % - +5 %)

    -

    E73 - E80

    Burn-back (command value)
    power source 1

    0 - 255
    (-200 - +200 ms)

    -

    E81 - E96

    Power (command value)
    power source 2

    0 - 65535
    (0 - 100 %)

    -

    E97 - 112

    Arc length correction (command value)
    power source 2

    0 - 65535
    (-30 % - +30 %)

    -

    E113 - 120

    Pulse/dynamic correction (command value)
    power source 2

    0 - 255
    (-5 % - +5 %)

    -

    E121 - 128

    Burn-back (command value)
    power source 2

    0 - 255
    (-200 - +200 ms)

    -

    E129 - 136

    Standard I/O KL2134

    -

    -

    E137 - 144

    Job number power source 2

    0 - 99

    -

    Output signals (from power source to robot)

     Seq. no.

    Signal designation

     Field

    Activity

    A01

    Arc stable

    -

    High

    A02

    Limit signal (only with RCU 5000i)

    -

    High

    A03

    Process active

    -

    High

    A04

    Main current signal

    -

    High

    A05

    Torch collision protection

    -

    High

    A06

    Power source ready

    -

    High

    A07

    Communication ready

    -

    High

    A08

    Spare

    -

    -

    A09 - A16

    Error number power source 1

    0 - 255

    -

    A17 - A24

    Error number power source 2

    0 - 255

    -

    A25

    Wire stick control (wire released from weldpool)

     

    High

    A26

    Not in use

    -

    -

    A27

    Robot access (with RCU 5000i)

     

    High

    A28

    Wire available

    -

    High

    A29 - A32

    Not in use

    -

    -

    A33 - A48

    Welding voltage (real value)
    power source 1

    0 - 65535
    (0 - 100 V)

    -

    A49 - A64

    Welding current (real value)
    power source 1

    0 - 65535
    (0 - 1000 A)

    -

    A65 - A72

    Motor current (real value)
    power source 1

    0 - 255
    (0 - 5 A)

    -

    A73 - A80

    Not in use

    -

    -

    A81 - A96

    Wire speed (real value) power source 1

    0 - 65535
    (-327,68 - +327,67 m/min)

    -

    A97 - A112

    Welding voltage (real value) power source 2

    0 - 65535
    (0 - 100 V)

    -

    A113 - 128

    Welding current (real value)
    power source 2

    0 - 65535
    (0 - 1000 A)

    -

    A129 - 136

    Motor current (real value)
    power source 2

    0 - 255
    (0 - 5 A)

    -

    A137 - 144

    Not in use

    -

    -

    A145 - 160

    Wire speed (real value)
    power source 2

    0 - 65535
    (-327,68 - +327,67 m/min)

    -

    A161 - 168

    Not in use

    -

    -

    A169 - 172

    Standard I/O KL1114

    -

    -

    Configuration examples

    General remarks

    Terminals can be either bit-oriented (digital) or byte-oriented (analog/complex).
    • digital terminals: KL1114, KL2134, KL2612
    • analog terminals: KL4001
    • complex terminals: KL 6021

    The process image first shows the byte-oriented terminals, with the bit-oriented terminals behind. With terminals of the same type, their position is also significant. Due to the different ways of installing the terminals, it is not possible to show a generally applicable process image. Therefore, each installation set is described in signal order, with E97/A97 at the beginning.

    IMPORTANT! The correct process image can only be determined using the terminals that are actually plugged in.

    General remarks

    Terminals can be either bit-oriented (digital) or byte-oriented (analog/complex).
    • digital terminals: KL1114, KL2134, KL2612
    • analog terminals: KL4001
    • complex terminals: KL 6021

    The process image first shows the byte-oriented terminals, with the bit-oriented terminals behind. With terminals of the same type, their position is also significant. Due to the different ways of installing the terminals, it is not possible to show a generally applicable process image. Therefore, each installation set is described in signal order, with E97/A97 at the beginning.

    IMPORTANT! The correct process image can only be determined using the terminals that are actually plugged in.

    Configuration examples

    Arrangement of signals when using the component number installation set (4,100,458)

    Input

    Remarks

    Range

    Activity

    Power source

     

     

    E97 - E104

    Not in use

    -

    -

    E105 - E112

    Character 1

    32 - 254

    -

    E113 - E120

    Character 2

    32 - 254

    -

    E121 - E128

    Character 3

    32 - 254

    -

    E129 - E136

    Character 4

    32 - 254

    -

    E137 - E144

    Character 5

    32 - 254

    -

    E145 - E152

    Character 6

    32 - 254

    -

    E153 - E160

    Character 7

    32 - 254

    -

    E161 - E168

    Character 8

    32 - 254

    -

    E169 - E176

    Character 9

    32 - 254

    -

    E177 - E184

    Character 10

    -

    -

    E185 - E192

    Character 11

    32 - 254

    -

    Output

    Remarks

    Range

    Activity

    Power source

     

     

    A97 - A192

    Not in use

    -

    -

     

    Signal assignments when using the external I/O field bus installation set (4,100,287)

    Input

    Remarks

    Range

    Activity

    Power source

     

     

    E97

    Digital out 1 - KL2134 / 1

    -

    High

    E98

    Digital out 2 - KL2134 / 5

    -

    High

    E99

    Digital out 3 - KL2134 / 4

    -

    High

    E100

    Digital out 4 - KL2134 / 8

    -

    High

    Output

    Remarks

    Range

    Activity

    Power source

     

     

    A97

    Digital in 1 - KL1114 / 1

    -

    High

    A98

    Digital in 2 - KL1114 / 5

    -

    High

    A99

    Digital in 3 - KL1114 / 4

    -

    High

    A100

    Digital in 4 - KL1114 / 8

    -

    High

     

    Signal assignments when using the twin-head field bus installation set (4,100,395)

    Input

    Remarks

    Range

    Activity

    Power source

     

     

    E97

    Digital out 1 - KL2612 / 1

    -

    High

    E98

    Digital out 2 - KL2612 / 5

    -

    High

     

    Signal assignments when using the external field bus installation set 2AO/4DO (4,100,462)

    Input

    Remarks

    Range

    Activity

    Power source

     

     

    E97 – E112

    Analog out 1 KL4001 / 1

    0 – 32767
    (0 - 10 V)

    -

    E113 – E128

    Analog out 2 KL4001 / 1

    0 – 32767
    (0 - 10 V)

    -

    E129

    Digital out 1 - KL2134 / 1

    -

    High

    E130

    Digital out 2 - KL2134 / 5

    -

    High

    E131

    Digital out 3 - KL2134 / 4

    -

    High

    E132

    Digital out 4 - KL2134 / 8

    -

    High

    Technical data

    DeviceNet coupler BK5250

    Power supply

    24 V DC (20 to 29 V DC)
    via 11 - 25 V bus cable
    (acc. to DeviceNet specification)

    Current-input

    approx. 100 mA

    Electrical isolation

    500 Veff
    (K bus / supply voltage)

    Number of bus terminals

    64

    Peripheral bytes

    512 input bytes
    512 output bytes

    Configuration interface

    available for KS2000

    Baud rates

    Standard-compliant:
    125 kBaud, 250 kBaud, 500 kBaud

    Electrical strength

    500 Veff
    (power contact / supply voltage)

    Operating temperature

    0 °C to +55 °C

    Storage temperature

    -25 °C to +85 °C

    Relative humidity

    95 % without condensation

    Vibration/shock resistance

    as per IEC 68-2-6/IEC 68-2-27

    EMC resistance Burst / ESD

    as per EN 50082 (ESD, Burst) / EN50081

    Installation position

    any

    Protection

    IP20

    VendCode

    108

    VendName

    Beckhoff Industrie Elektronik

    ProdType

    12

    ProdTypeStr

    Communications adapter

    ProdCode

    5250

    ProdName

    BK5250 V01.01

    MajRev

    1

    MinRev

    1

     

    DeviceNet coupler BK5250

    Power supply

    24 V DC (20 to 29 V DC)
    via 11 - 25 V bus cable
    (acc. to DeviceNet specification)

    Current-input

    approx. 100 mA

    Electrical isolation

    500 Veff
    (K bus / supply voltage)

    Number of bus terminals

    64

    Peripheral bytes

    512 input bytes
    512 output bytes

    Configuration interface

    available for KS2000

    Baud rates

    Standard-compliant:
    125 kBaud, 250 kBaud, 500 kBaud

    Electrical strength

    500 Veff
    (power contact / supply voltage)

    Operating temperature

    0 °C to +55 °C

    Storage temperature

    -25 °C to +85 °C

    Relative humidity

    95 % without condensation

    Vibration/shock resistance

    as per IEC 68-2-6/IEC 68-2-27

    EMC resistance Burst / ESD

    as per EN 50082 (ESD, Burst) / EN50081

    Installation position

    any

    Protection

    IP20

    VendCode

    108

    VendName

    Beckhoff Industrie Elektronik

    ProdType

    12

    ProdTypeStr

    Communications adapter

    ProdCode

    5250

    ProdName

    BK5250 V01.01

    MajRev

    1

    MinRev

    1

     

    DeviceNet coupler BK5200

    Power supply

    24 V DC (20 to 29 V DC)
    via 11 - 25 V bus cable
    (acc. to DeviceNet specification)

    Current-input

    approx. 100 mA

    Electrical isolation

    500 Veff
    (K bus / supply voltage)

    Number of bus terminals

    64

    Peripheral bytes

    512 input bytes
    512 output bytes

    Configuration interface

    available for KS2000

    Baud rates

    Standard-compliant:
    125 kBaud, 250 kBaud, 500 kBaud

    Electrical strength

    500 Veff
    (power contact / supply voltage)

    Operating temperature

    0 °C to +55 °C

    Storage temperature

    -25 °C to +85 °C

    Relative humidity

    95 % without condensation

    Vibration/shock resistance

    as per IEC 68-2-6/IEC 68-2-27

    EMC resistance Burst / ESD

    as per EN 50082 (ESD, Burst) / EN50081

    Installation position

    any

    Protection

    IP20

    VendCode

    108

    VendName

    Beckhoff Industrie Elektronik

    ProdType

    12

    ProdTypeStr

    Communications adapter

    ProdCode

    5200

    MajRev

    3

    MinRev

    0

     

    Circuit diagrams