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Operating
Instructions

___________
RI FB Inside/i
RI MOD/i CC-M40 EtherCAT

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module

Operating instructions

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module - QR Code 1 42,0410,1915               034-17072024

General

Safety

Warning Icon 100 WARNING!

Incorrect operation and faulty work can cause serious personal injury and material damage.
All work and functions described in this document must be performed only by trained specialist personnel who have read and understood the following documents in full:
▶ this document
▶ the Operating Instructions of the robot interface “RI FB Inside/i”
▶ all documents relating to system components, especially the safety rules


Connections and Indicators

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module - a1

(1)TX+
(2)TX-
(3)RX+
(6)RX-
(4), (5)Not normally used; to ensure signal completeness, these pins must be interconnected and, after passing through a filter circuit, must terminate at the ground conductor (PE).
(7), (8)Not normally used; to ensure signal completeness, these pins must be interconnected and, after passing through a filter circuit, must terminate at the ground conductor (PE).
(9)Connection/Activity LED – EtherCAToutput
(10)ERR LED (error)
(11)EtherCAToutput
(12)EtherCATinput
(13)Connection/Activity LED – EtherCATinput
(14)RUN LED (operation)
RUN LED (operation)
This indicates the status of the CoE communication.
(CoE = CANopen over EtherCAT)
StatusMeaning
OffEtherCAT device in ‘init’ status (or no supply voltage)
Lights up greenEtherCAT device in ‘operational’ status
Flashes greenEtherCAT device in ‘pre-operational’ status
Flashes green (briefly)EtherCAT device in ‘safe-operational’ status
Lights up redIf the Run LED and Error LED light up red, this indicates a serious event which places the interface in an exception state. Fronius A - 1 Contact the service team
ERR LED (error)
StatusMeaning
OffNo error (or no supply voltage)
Flashes redIncorrect configuration
The status change received from the master is not possible due to invalid register or object settings.
Flashes red (twice)Application watchdog timeout
Sync manager watchdog timeout
Lights up redApplication controller failure
Anybus module in EXCEPTION
Connection/Activity LED
StatusMeaning
OffNo connection (or no supply voltage)
Lights up greenConnection detected, no activity
Flickers greenConnection detected, activity present

Data Transfer Properties
Transfer technology:
EtherCAT
Medium:
When selecting the cable, plug, and terminating resistors, the 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

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.

ParameterValueDescription
Vendor ID0000 02C1hex (705dec)Fronius International GmbH
Product Code0001 0301hex
(66305dec)
0001 0302hex
(66306dec)
0001 0303hex
(66307dec)
Economy image
Standard image
Retrofit image
Device nameFronius-FB-Inside-EtherCAT

Hot-Connect application

The master uses a device ID to uniquely identify a slave. Changing a defective device during operation is called a hot connect application. A preconfigured device can then be added to the network and its device ID can be assigned the same device ID that was used to name the defective device. If there are two or more identical devices in the network, this can prevent cables from being swapped.

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module - a2

(1) Enter device ID

Configuration of robot interface

Dip switch function

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module - a3

The dip switch (1) on the RI FB Inside/i robot interface is used to configure the process data width.

At the factory all positions of the (1) dipswitch are set to OFF (3).
This corresponds to the binary value 0.

The position (2) corresponds to the binary value 1.


Configuration of the process data width
Dip switchConfiguration
87654321
OFFOFFStandard image
320 Bit
OFFONEconomy image
128 Bit
ONOFFRetro Fit
Scope dependent on bus module
ONONNot used

The process data width defines the scope of the transferred data volume.

The kind of data volume that can be transferred depends on
– the robot controls
– the number of welding machines
– the type of welding machines

– “Intelligent Revolution”
– “Digital Revolution” (Retro Fit)


Configuring the Node Address

The EtherCAT address is assigned by the master.

Input and output signals

Data types

The following data types are used:
UINT16 (Unsigned Integer)
Whole number in the range from 0 to 65535
SINT16 (Signed Integer)
Whole number in the range from -32768 to 32767

Conversion examples:
– for a positive value (SINT16)
e.g. desired wire speed x factor
12.3 m/min x 100 = 1230dec = 04CEhex

– for a negative value (SINT16)
e.g. arc correction x factor
-6.4 x 10 = -64dec = FFC0hex


Availability of Input Signals

The input signals listed below are available from firmware V4.1.x for all Inside/i systems.


Input signals (from robot to power source)
AddressSignalActivity / data typeRangeFactorProcess image
RelativeAbsoluteStandardEconomy
WORDBYTEBITBIT
0000Welding StartIncreasing
11Robot readyHigh
22Working mode Bit 0HighSee table Value Range for Working Mode on page 36
33Working mode Bit 1High
44Working mode Bit 2High
55Working mode Bit 3High
66Working mode Bit 4High
77
108Gas onIncreasing
19Wire forwardIncreasing
210Wire backwardIncreasing
311Error quitIncreasing
412Touch sensingHigh
513Torch blow outIncreasing
614Processline selection Bit 0HighSee table Value range Process line selection on page 37
715Processline selection Bit 1High
12016Welding simulationHigh
117Welding process MIG/MAG: 1)

Synchro pulse on

High
Welding process WIG: 2)

TAC on

High
218Welding process WIG: 2)

Cap shaping

High
319— 
420— 
521Booster manualHigh
622Wire brake onHigh
723Torchbody XchangeHigh
3024
125Teach modeHigh
226
327
428
529Wire sense startIncreasing
630Wire sense breakIncreasing
731
24032TWIN mode Bit 0HighSee table Value Range for TWIN Mode on page 37
133TWIN mode Bit 1High
234
335
436
537Documentation modeHighSee table Value Range for Documentation Mode on page 37
638
739
5040
141
242
343
444
545
646
747Disable process controlled correctionHigh
36048
149
250
351
452
553
654
755
7056ExtInput1 => OPT_Output 1High
157ExtInput2 => OPT_Output 2High
258ExtInput3 => OPT_Output 3High
359ExtInput4 => OPT_Output 4High
460ExtInput5 => OPT_Output 5High
561ExtInput6 => OPT_Output 6High
662ExtInput7 => OPT_Output 7High
763ExtInput8 => OPT_Output 8High
48-90-764–79Welding characteristic- / Job numberUINT160 to 10001
510-110-780-95Welding process MIG/MAG: 1)

Constant Wire: Wire feed speed command value

SINT16-327,68 to 327,67 [m/min]100
Welding process WIG: 2)

Main- / Hotwire current command value

UINT160 to 6553,5 [A]10
For job-mode: 

Power correction

SINT16-20,00 to 20,00 [%]100
612-130-796-111Welding process MIG/MAG: 1)

Arclength correction

SINT16-10,0 to 10,0 [Schritte]10
Welding process MIG/MAG Standard-Manuel: 

Welding voltage

UINT160,0 to 6553,5 [V]10
Welding process WIG: 2)

Wire feed speed command value

SINT16-327,68 to 327,67 [m/min]100
For job-mode: 

Arclength correction

SINT16-10,0 to 10,0 [Schritte]10
Welding process Constant Wire: 

Hotwire current

UINT160,0 to 6553,5 [A]10
714-150-7112-127Welding process MIG/MAG: 1)

Pulse-/dynamic correction

SINT16-10,0 to 10,0 [steps]10
Welding process MIG/MAG Standard-Manuel: 

Dynamic

UINT160,0 to 10,0 [steps]10
Welding process WIG: 2)

Wire correction

SINT16-10,0 to 10,0 [steps]10
816-170-7128-143Welding process MIG/MAG: 1)

Wire retract correction

UINT160,0 to 10,0 [steps]10ü
Welding process WIG: 2)

Wire retract end

UINT16OFF, 1 to 50 [mm]1
918-190-7144-159Welding speedUINT160,0 to 1000,0 [cm/min]10
1020-210-7160-175Process controlled correctionSee table Value range for Process controlled correction on page 37
1122-230-7176-191Welding process WIG: 2)

Wire positioning start

1224-250-7192-207
1326-270-7208-223
1428-290-7224-239
1530-310-7240-255Wire forward / backward lengthUINT16OFF / 1 to 65535 [mm]1
1632-330-7256-271Wire sense edge detectionUINT16OFF / 0,5 to 20,0 [mm]10
1734-350-7272-287
1836-370-7288-303
1938-390-7304-319Seam numberUINT160 to 655351

1) MIG/MAG Puls-Synergic, MIG/MAG Standard-Synergic, MIG/MAG Standard-Manuel, MIG/MAG PMC, MIG/MAG, LSC
2) WIG coldwire, WIG hotwire


Value Range for Working Mode
Bit 4Bit 3Bit 2Bit 1Bit 0Description
00000Internal parameter selection
00001Special 2-step mode characteristics
00010Job mode
010002-step mode characteristics
010012-step MIG/MAG standard manual
10000Idle Mode
10001Stop coolant pump
11001R/L-Measurement

Value range for operating mode


Value range Process line selection
Bit 1Bit 0Description
00Process line 1 (default)
01Process line 2
10Process line 3
11Reserved

Value range for process line selection


Value Range for TWIN Mode
Bit 1Bit 0Description
00TWIN Single mode
01TWIN Lead mode
10TWIN Trail mode
11Reserved

Value range for TWIN mode


Value Range for Documentation Mode
Bit 0Description
0Seam number of welding machine (internal)
1Seam number of robot (Word 19)

Value range for documentation mode


Value range for Process controlled correction
ProcessSignalActivity / data typeValue range configuration rangeUnitFactor
PMCArc length stabilizerSINT16-327.8 to +327.7
0.0 to +5.0
Volts10

Value range for process-dependent correction


Availability of Output Signals

The output signals listed below are available from firmware V4.1.x for all Inside/i systems.


Output Signals (from Power Source to Robot)
AddressSignalActivity / data typeRangeFactorProcess image
RelativeAbsoluteStandardEconomy
WORDBYTEBITBIT
0000Heartbeat PowersourceHigh/Low1 Hz
11Power source readyHigh
22WarningHigh
33Process activeHigh
44Current flowHigh
55Arc stable- / touch signalHigh
66Main current signalHigh
77Touch signalHigh
108Collisionbox activeHigh0 = collision or cable break
19Robot Motion ReleaseHigh
210Wire stick workpieceHigh
311
412Short circuit contact tipHigh
513Parameter selection internallyHigh
614Characteristic number validHigh
715Torch body grippedHigh
12016Command value out of rangeHigh
117Correction out of rangeHigh
218
319LimitsignalHigh
420
521
622Main supply statusLow
723
3024Sensor status 1HighSee table Assignment of Sensor Statuses 1-4 on page 41
125Sensor status 2High
226Sensor status 3High
327Sensor status 4High
428
529
630
731
24032
133
234
335Safety status Bit 0HighSee table Value range Safety status on page page 42
436Safety status Bit 1High
537
638NotificationHigh
739System not readyHigh
5040
141
242
343
444
545
646
747
36048Process Bit 0HighSee table Value Range for Process Bit on page 42
149Process Bit 1High
250Process Bit 2High
351Process Bit 3High
452Process Bit 4High
553
654Touch signal gas nozzleHigh
755TWIN synchronization activeHigh
7056ExtOutput1 <= OPT_Input1High
157ExtOutput2 <= OPT_Input2High
258ExtOutput3 <= OPT_Input3High
359ExtOutput4 <= OPT_Input4High
460ExtOutput5 <= OPT_Input5High
561ExtOutput6 <= OPT_Input6High
662ExtOutput7 <= OPT_Input7High
763ExtOutput8 <= OPT_Input8High
48-90-764-79Welding voltageUINT160.0 to 655.35 [V]100
510-110-780-95Welding currentUINT160.0 to 6553.5 [A]10
612-130-796-111Wire feed speedSINT16-327.68 to 327.67 [m/ min]100
714-150-7112-127Actual real value for seam trackingUINT160 to 6.553510000
816-170-7128-143Error numberUINT160 to 655351
918-190-7144-159Warning numberUINT160 to 655351
1020-210-7160-175Motor current M1SINT16-327.68 to 327.67 [A]100
1122-230-7176-191Motor current M2SINT16-327.68 to 327.67 [A]100
1224-250-7192-207Motor current M3SINT16-327.68 to 327.67 [A]100
1326-270-7208-223
1428-290-7224-239
1530-310-7240-255
1632-330-7256-271Wire positionSINT16-327.68 to 327.67 [mm]100
1734-350-7272-287
1836-370-7288-303
1938-390-7304-319

Assignment of Sensor Statuses 1-4
SignalDescription
Sensor status 1OPT/i WF R wire end (4,100,869)
Sensor status 2OPT/i WF R wire drum (4,100,879)
Sensor status 3OPT/i WF R ring sensor (4,100,878)
Sensor status 4Wire buffer set CMT TPS/i (4,001,763)

Assignment of sensor statuses


Value range Safety status
Bit 1Bit 0Description
00Reserve
01Hold
10Stop
11Not installed / active

Value range Safety status


Value Range for Process Bit
Bit 4Bit 3Bit 2Bit 1Bit 0Description
00000No internal parameter selection or process
00001MIG/MAG pulse synergic
00010MIG/MAG standard synergic
00011MIG/MAG PMC
00100MIG/MAG LSC
00101MIG/MAG standard manual
00110Electrode
00111TIG
01000CMT
01001ConstantWire
01010ColdWire
01011DynamicWire

Value Range for Process Bit


Value Range for Function status
Bit 1Bit 0Description
00Inactive
01Idle
10Finished
11Error

Value range for function status

Retrofit Image Input and Output Signals

Input Signals

The signals listed below are available from firmware V1.6.0 for all Inside/i systems.

Serial no.Signal designationRangeAction
E01Welding onHigh
E02Robot readyHigh
E03Operating mode bit 0See table Value range for operating modes on page 44High
E04Operating mode bit 1High
E05Operating mode bit 2High
E06
E07
E08
E09Gas testHigh
E10Wire forwardHigh
E11Wire backwardHigh
E12Error quitHigh
E13Position searchHigh
E14Purge welding torchHigh
E15
E16
E17 – E24Job number0 to 99
E25 – E31Program number1 to 127
E32Welding simulationHigh
Only in Job mode (E17 – E32):
E17 – E31Job number0 to 999
E32Welding simulationHigh
E33 – E40Output set value – Low byte0 to 65535
(0 to 100%)
E41 – E48Output set value – High byte
E49 – E56Arc length correction, set value Low byte0 to 65535
(-30 to +30%)
E57 – E64Arc length correction, set value High byte
E65 – E72Pulse or dynamic correction0 to 255
(-5 to +5%)
E73 – E80
E81 – E88
E89 – E96
E97 – E104Welding speed – Low byte0 to 65535
(0 to 6553.5 cm/min)
E105 – E112Welding speed – High byte
E113SynchroPulse onHigh
E114
E115
E116
E117Output full range (0 to 30 m)High
E118
E119
E120
E121 – E128
E129 – E296

 


Value range for operating modes
Bit 2Bit 1Bit 0Description
000MIG/MAG Synergic welding
001MIG/MAG Synergic welding
010Job mode
011Internal parameter selection

Output Signals

The signals listed below are available from firmware V1.6.0 for all Inside/i systems.

Seq. noSignal designationRangeAction
A01Arc stableHigh
A02Limit signalHigh
A03Process activeHigh
A04Main current signalHigh
A05Welding torch collision protectionHigh
A06Power source readyHigh
A07Communication readyHigh
A08Life Cycle Toggle Bit (250ms) High
A09 – A16
A17 – A24
A25
A26
A27
A28Wire present
A29Short circuit time exceededHigh
A30
A31
A32Power out of rangeHigh
A33 – A40Welding voltage actual value – Low byte0 to 65535
(0 to 100 V)
A41 – A48Welding voltage actual value – High byte
A49 – A56Welding current actual value – Low byte0 to 65535
(0 to 1000 A)
A57 – A64Welding current actual value – High byte
A65 – A72Motor current0 to 255
(0 to 5 A)
A73 – A80
A81 – A88
A89 – A96
A97 – A104Wire speed – Low byte0 to vDmax
A105 – A112Wire speed – High byte
A113 – A120
A121 – A128
A129 – A296

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module - QR Code 2

spareparts.fronius.com

Fronius - SPARE PARTS

Fronius International GmbH
FroniusstraBe 1
4643 Pettenbach
Austria
contact@fronius.com
www.fronius.com

At www.fronius.com/contact you will find the contact details of all Fronius subsidiaries and Sales & Service Partners.

Documents / Resources

Fronius RI FB Inside CC-M40 EtherCAT The Bus Module [pdf] Instruction Manual
42, 0410, 1915, RI FB Inside CC-M40 EtherCAT The Bus Module, RI FB, Inside CC-M40 EtherCAT The Bus Module, EtherCAT The Bus Module, Bus Module, Module

References

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