Ethernet/IP Customer Interface
for TX Control
US_StandardDCE Bitmap
TE Customer Interface
©
Stanley Engineered Fastening
49201 Gratiot Ave
Chesterfield, MI 48051
Telephone: 586-949-0550
Website: www.stanleyengineeredfastening.com
1
Revision Date: 6/16/2017
Revision 3.0
TE Customer Interface
Table of Contents
Table of Contents
Table of Contents
1.0
Overview of Inputs and Outputs
2.0
Overview of Safety Circuit Operation
2
3
5
2.1
Safety Circuit Description
3.0
Overview of Customer Interface Hardware
5
7
3.1
MSP Board
3.1.1
Overview of PCB Components
3.1.2
LED Functions
7
8
9
3.2
HMS Anybus Board
3.2.1
Network Status LED Functions
12
12
3.3
Customer Interface External Connector
4.0
Overview of Safety Circuit Hardware
13
14
4.1
Safety Circuit Board -DSC
4.1.1
LED Functions
14
16
4.2
Safety Circuit/Power External Connector
5.0
Robot/PLC Configuration
17
18
5.1
EDS File
6.0
Signal Descriptions
18
26
6.1
Inputs to TX Control
26
6.2
Outputs to TX Control
7.0
Signal Diagrams
29
32
7.1
Weld in Tolerance
32
7.2
Weld out of Tolerance
32
7.3
Dry Cycle with Part
33
7.4
Dry Cycle without Part
33
7.5
External Feed
34
7.6
Reset
34
7.7
Force Weld Complete
8.0
Service Support
9.0
Revision Log
Revision Date: 6/20/2023
Revision 3.0
35
36
36
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TE Customer Interface
Overview of Inputs and Outputs
1.0 Overview of Inputs and Outputs
Inputs to TX Control
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
3
Byte 0
Start Weld Cycle Outlet 1
Start Weld Cycle Outlet 2
Start Weld Cycle Outlet 3
Start Weld Cycle Outlet 4
Start Weld Cycle Outlet 5
Start Feed Cycle Outlet 1
Start Feed Cycle Outlet 2
Start Feed Cycle Outlet 3
Byte 1
Start Feed Cycle Outlet 4
Start Feed Cycle Outlet 5
Stud ID: 20
Stud ID: 21
Stud ID: 22
Stud ID: 23
Stud ID: 24
Stud ID: 25
Byte 2
Stud ID: 26
Reserved
Restart
Force Weld Complete
Operation Mode: 20
Operation Mode: 21
Docking
Reserved
Byte 3
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Outputs from TX Control
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Byte 0
No Fault Outlet 1
Weld Complete Outlet 1
Head Back Outlet 1
SOW Outlet 1
Weld in Tolerance Outlet 1
No Fault Outlet 2
Weld Complete Outlet 2
Head Back Outlet 2
Byte 1
SOW Outlet 2
Weld in Tolerance Outlet 2
No Fault Outlet 3
Weld Complete Outlet 3
Head Back Outlet 3
SOW Outlet 3
Weld in Tolerance Outlet 3
No Fault Outlet 4
Byte 2
Weld Complete Outlet 4
Head Back Outlet 4
SOW Outlet 4
Weld in Tolerance Outlet 4
No Fault Outlet 5
Weld Complete Outlet 5
Head Back Outlet 5
SOW Outlet 5
Byte 3
Weld in Tolerance Outlet 5
Maintenance Warning
Fill Level Warning
Ready for Automation
Ready to Weld
Fault Group: 20
Fault Group: 21
Fault Group: 22
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Overview of Inputs and Outputs
Byte 4
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Byte 5
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Byte 6
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Byte 7
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Revision Date: 6/20/2023
Revision 3.0
Bit 0
Bit 1
Bit 2
Bit 3
Bit 4
Bit 5
Bit 6
Bit 7
Byte 4
Fault Code: 20
Fault Code: 21
Fault Code: 22
Fault Code: 23
Fault Code: 24
Fault Code: 25
Fault Code: 26
Fault Code: 27
Byte 5
Fault Code: 28
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Byte 6
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Byte 7
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
4
TE Customer Interface
Overview of Safety Circuit Operation
2.0 Overview of Safety Circuit Operation
2.1 Safety Circuit Description
Connector XD21 on the TX weld control is designed to control the Emergency Stop and
Protection Circuit. Enclosed with each controller is NA165716 connector assembly to
be used at the customers discretion to override these functions.
Warning: The use of the jumpers will eliminate the function of the Emergency Stop and
Protection Circuit as outlined in the Stanley I/O specifications for the TX weld controller.
Normal automated operations should utilize the Stanley I/O specifications for external
control of the Emergency Stop and Protection Circuit.
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TE Customer Interface
Overview of Safety Circuit Operation
Revision Date: 6/20/2023
Revision 3.0
6
TE Customer Interface
Overview of Customer Interface Hardware
3.0 Overview of Customer Interface Hardware
3.1 MSP Board
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TE Customer Interface
Overview of Customer Interface Hardware
3.1.1 Overview of PCB Components
Identifier
X100
Piggyback Connection
X200
Piggyback Connection
X110
Serial Debug
X111
Serial Zigbee
X113
Serial RS232
X120
USB EKS
X121
USB Switch
X122
USB Wi-Fi
X130
USB Micro-B for Programming
X140
CFast card
X150
Customer Network
X151
HMI
X152
Second LMC pair for SWS
X160 & 161
Display
X170 & 171
HMS Anybus Brick Module
X172
HMS Anybus Network Interface
X180
Fan connector
X210
STM32 Serial Debug
X220
STM32 ETM/Reset
X230
STM32 Boot Mode
X231
STM32 Production Mode
X250 & 251
PCB Edge Legacy
X252
PCB Edge Tool Connector
X300
Internal Supply In
X310
External Supply In
X320
External HMI
Revision Date: 6/20/2023
Revision 3.0
Description
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TE Customer Interface
Overview of Customer Interface Hardware
3.1.2 LED Functions
TQM:
Pin
LED 1 (grün)
LED 2 (grün)
LED 3 (grün)
LED 4 (grün)
LED 5 (grün)
LED 6 (grün)
LED 7 (grün)
LED 8 (rot)
9
Funktion
Aktiv wenn Prozess-Management startet, blinkt nach erfolgreichem Start
Aktiv nach Verbindungsaufbau zwischen Prozess- und Daten-Management
Nicht genutzt
Nicht genutzt
Nicht genutzt
Nicht genutzt
Nicht genutzt
Nicht genutzt
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TE Customer Interface
Overview of Customer Interface Hardware
STM32:
Pin
Funktion
LED 1
(green)
Heart-Beat
LED 2
(green)
LED 3
(green)
-
LED 4
(green)
LED 5
(green)
-
LED 6
(green)
LED 7
(green)
LED 8 (red)
-
-
-
Hinweis auf Problem (z.B. Verbindung)
Supply:
Pin
Funktion
24V UNBUF
24V BUF
12V
5V
3V3
12VE
3V3E
Voltage OK
Voltage OK
Voltage OK
Voltage OK
Voltage OK
Voltage OK
Voltage OK
Dipswitch Functions-Microswitch TQM
Pin
Funktion
DIP 1
DIP 2
DIP 3
DIP 4
DIP 5
DIP 6
DIP 7
DIP 8
Debug Service disable
ON: Operating System only /
OFF: Autostart of PM, DM, HMI
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TE Customer Interface
Overview of Customer Interface Hardware
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TE Customer Interface
Overview of Customer Interface Hardware
3.2 HMS Anybus Board
3.2.1 Network Status LED Functions
LED
Network Status
State
Off
Green
Green, flashing
Red
Red, flashing
Red/Green
Off
Green
Green, flashing
Module Status
Red
Red, flashing
Link (Activity)
Revision Date: 6/20/2023
Revision 3.0
Red/Green
Off
Meaning
Not powered or no IP address
On line, connection established
On line, no connection established
Fatal Error (Duplicate IP address)
Connection timed out
Device self test in progress
No power
Controlled by a Scanner in Run state
Not configured, or Scanner in Idle
state
A major unrecoverable fault has been
detected
A minor recoverable fault has been
detected
Device self test in progress
Link not sensed
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TE Customer Interface
Overview of Customer Interface Hardware
Activity
Green
Green, Flashing
Link sensed
A packet is being sent or received
3.3 Customer Interface External Connector
The user connection point for the Customer Interface is a 4 pin Female Micro as seen
above. Below are the pin descriptions.
Pin Number
13
Description
1
TxData + (White/Orange)
2
RxData + (White/Blue)
3
TxData - (Orange)
4
RxData (Blue)
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TE Customer Interface
Overview of Safety Circuit Hardware
4.0 Overview of Safety Circuit Hardware
4.1 Safety Circuit Board -DSC
Revision Date: 6/20/2023
Revision 3.0
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TE Customer Interface
Overview of Safety Circuit Hardware
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TE Customer Interface
Overview of Safety Circuit Hardware
4.1.1 LED Functions
Pin
Funktion
ERR
Off:
OK, No Error
On:
Operating Voltage Error
Flashing 0.5Hz: Diagnostic error
OK
DSC is operational
SL1I On:
Safety-Line IN CH1: SL_FULL_SPEED
Flashing 0.5Hz: Safety-Line IN CH1: SL_RED_SPEED
Off:
Safety-Line In CH1: SL_SAFE_STATE
SL2I On:
Safety-Line IN CH2: SL_FULL_SPEED
Flashing 0.5Hz: Safety-Line IN CH2: SL_RED_SPEED
Off:
Safety-Line In CH12 SL_SAFE_STATE
SL1O On:
Safety-Line OUT CH1: SL_FULL_SPEED
Flashing 0.5Hz: Safety-Line OUT CH1:
SL_RED_SPEED
Off:
Safety-Line OUT CH1: SL_SAFE_STATE
SL2O On:
Safety-Line OUT CH2: SL_FULL_SPEED
Flashing 0.5Hz: Safety-Line OUT CH2:
SL_RED_SPEED
Off:
Safety-Line OUT CH2: SL_SAFE_STATE
5V0
5V Supply voltage
Revision Date: 6/20/2023
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TE Customer Interface
Overview of Safety Circuit Hardware
4.2 Safety Circuit/Power External Connector
The user connection point for the safety circuit/24VDC is a Harting HAN36. Below are
the pin descriptions.
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TE Customer Interface
Robot/PLC Configuration
5.0 Robot/PLC Configuration
The following settings should be used when adding this control to your Ethernet/IP
Network.
•
•
•
•
Input Length: 8 Bytes
Output Length: 8 Bytes
I/O Connection Type: Polled
Assembly Instances
o Config: 197
o Output: 150
o Input: 100
The next section (5.1) contains a copy of the EDS file associated with this control. You can
use it as reference or copy it into a file with the file extension ”.eds” in order to load the
Ethernet/IP configuration for the TX into your robot or PLC.
5.1 EDS File
[File]
DescText = "TX Stud Welding System";
CreateDate = 11-11-2022;
CreateTime = 08:30:22;
ModDate = 11-11-2022;
ModTime = 08:30:22;
Revision = 1.00;
[Device]
VendCode = 873;
VendName = "Tucker GmbH";
ProdType = 43;
ProdTypeStr = "Generic Device (keyable)";
ProdCode = 880;
MajRev = 1;
MinRev = 40;
ProdName = "TX Stud Welding System";
Catalog = "SEF Systems";
[Device Classification]
Class1 = EtherNetIP;
[Params]
Param3 =
0,
,
,
0x0000,
0xC8,
$
$
$
$
$
Reserved (always 0)
Link path size
Link path
Descriptor
Data type (Unsigned 32–bit integer
4,
$ Data size
value)
Revision Date: 6/20/2023
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TE Customer Interface
Robot/PLC Configuration
"RPI range",
"",
"",
1000,
3200000,
10000,
,
,
,
,
,
,
,
,
;
$
$
$
$
$
$
$
$
$
$
$
$
$
$
$
Parameter name
Units string
Help string
Minimum value
Maximum value
default value
Scaling multiplier (not used)
Scaling divider (not used)
Scaling base (not used)
Scaling offset (not used)
Multiplier link (not used)
Divisor link (not used)
Base link (not used)
Offset link (not used)
Decimal precision (not used)
[Assembly]
Revision = 2;
MaxInst = 150;
Number_Of_Static_Instances = 6;
Max_Number_Of_Dynamic_Instances = 0;
Object_Name = "Assembly Object";
Object_Class_code = 0x00000004;
Assem3 =
"Heartbeat, Input Only",$ Name
,
$ Path
0,
$ Size
0x0001,
$ Descriptor
,
$ Reserved
,
$ Reserved
0,
$ Member size
;
$ Member reference
Assem4 =
"Heartbeat, Listen Only",$ Name
,
$ Path
0,
$ Size
0x0001,
$ Descriptor
,
$ Reserved
,
$ Reserved
0,
$ Member size
;
$ Member reference
Assem6 =
"Heartbeat, Input Only Extended",$ Name
,
$ Path
0,
$ Size
0x0001,
$ Descriptor
,
$ Reserved
,
$ Reserved
0,
$ Member size
;
$ Member reference
Assem7 =
"Heartbeat, Listen Only Extended",$ Name
,
$ Path
0,
$ Size
0x0001,
$ Descriptor
,
$ Reserved
,
$ Reserved
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TE Customer Interface
Robot/PLC Configuration
0,
;
Assem150 =
"Consuming Data",
,
8,
0x0001,
,
,
64,
;
Assem100 =
"Producing Data",
,
8,
0x0001,
,
,
64,
;
$ Member size
$ Member reference
$
$
$
$
$
$
$
$
Name
Path
Size
Descriptor
Reserved
Reserved
Member size
Member reference
$
$
$
$
$
$
$
$
Name
Path
Size
Descriptor
Reserved
Reserved
Member size
Member reference
[Connection Manager]
Revision = 1;
MaxInst = 1;
Number_Of_Static_Instances = 1;
Max_Number_Of_Dynamic_Instances =
Object_Name = "Connection Manager
Object_Class_code = 0x00000005;
Connection1 =
0x04030002,
$
$
$
state
$
$
0x77640405,
$
$
$
$
run/idle header
$
connection is pure data and is modeless
$
point-to-point
$
multicast, point-to-point
$
scheduled
$
scheduled
Param3,
$
8,
$
Assem150,
$
Param3,
$
8,
$
Assem100,
$
,
$
Revision Date: 6/20/2023
Revision 3.0
0;
Object";
Trigger and transport mask
Supported transport classes: class 1
Supported triggers: cyclic, change of
Application type: exclusive-owner
Direction: client
Connection parameters
O->T supported size type(s): Fixed
T->O supported size type(s): Fixed
O->T real time transfer format: 32-bit
T->O real time transfer format:
O->T supported connection type(s):
T->O supported connection type(s):
O->T supported priorities: low, high,
T->O supported priorities: low, high,
O->T RPI
O->T size
O->T format
T->O RPI
T->O size
T->O format
Proxy config size (not used)
20
TE Customer Interface
Robot/PLC Configuration
,
$ Proxy config format (not used)
,
$ Target config size (no config data)
,
$ Target config format (not used)
"Exclusive owner",
$ Connection name string
"",
$ Help string
"20 04 24 00 2C 96 2C 64";$ Path
Connection2 =
0x01030002,
$ Trigger and transport mask
$ Supported transport classes: class 1
$ Supported triggers: cyclic, change of
state
0x77240305,
$
$
$
$
$
$
Application type: listen-only
Direction: client
Connection parameters
O->T supported size type(s): Fixed
T->O supported size type(s): Fixed
O->T real time transfer format:
heartbeat
$ T->O real time transfer format:
connection is pure data and is modeless
$ O->T supported connection type(s):
point-to-point
$ T->O supported connection type(s):
multicast
$ O->T supported priorities: low, high,
scheduled
$ T->O supported priorities: low, high,
scheduled
Param3,
$ O->T RPI
0,
$ O->T size
Assem4,
$ O->T format
Param3,
$ T->O RPI
8,
$ T->O size
Assem100,
$ T->O format
,
$ Proxy config size (not used)
,
$ Proxy config format (not used)
,
$ Target config size (no config data)
,
$ Target config format (not used)
"Listen only",
$ Connection name string
"",
$ Help string
"20 04 24 00 2C 04 2C 64";$ Path
Connection3 =
0x02030002,
$ Trigger and transport mask
$ Supported transport classes: class 1
$ Supported triggers: cyclic, change of
state
0x77640305,
$
$
$
$
$
$
Application type: input-only
Direction: client
Connection parameters
O->T supported size type(s): Fixed
T->O supported size type(s): Fixed
O->T real time transfer format:
heartbeat
$ T->O real time transfer format:
connection is pure data and is modeless
$ O->T supported connection type(s):
point-to-point
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Robot/PLC Configuration
$ T->O supported connection type(s):
multicast, point-to-point
$ O->T supported priorities: low, high,
scheduled
$ T->O supported priorities: low, high,
scheduled
Param3,
$ O->T RPI
0,
$ O->T size
Assem3,
$ O->T format
Param3,
$ T->O RPI
8,
$ T->O size
Assem100,
$ T->O format
,
$ Proxy config size (not used)
,
$ Proxy config format (not used)
,
$ Target config size (no config data)
,
$ Target config format (not used)
"Input only",
$ Connection name string
"",
$ Help string
"20 04 24 00 2C 03 2C 64";$ Path
Connection4 =
0x01030002,
$ Trigger and transport mask
$ Supported transport classes: class 1
$ Supported triggers: cyclic, change of
state
0x77240305,
$
$
$
$
$
$
Application type: listen-only
Direction: client
Connection parameters
O->T supported size type(s): Fixed
T->O supported size type(s): Fixed
O->T real time transfer format:
heartbeat
$ T->O real time transfer format:
connection is pure data and is modeless
$ O->T supported connection type(s):
point-to-point
$ T->O supported connection type(s):
multicast
$ O->T supported priorities: low, high,
scheduled
$ T->O supported priorities: low, high,
scheduled
Param3,
$ O->T RPI
0,
$ O->T size
Assem7,
$ O->T format
Param3,
$ T->O RPI
8,
$ T->O size
Assem100,
$ T->O format
,
$ Proxy config size (not used)
,
$ Proxy config format (not used)
,
$ Target config size (no config data)
,
$ Target config format (not used)
"Listen only extended", $ Connection name string
"",
$ Help string
"20 04 24 00 2C 07 2C 64";$ Path
Connection5 =
0x02030002,
$ Trigger and transport mask
$ Supported transport classes: class 1
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Robot/PLC Configuration
$ Supported triggers: cyclic, change of
state
0x77640305,
$
$
$
$
$
$
Application type: input-only
Direction: client
Connection parameters
O->T supported size type(s): Fixed
T->O supported size type(s): Fixed
O->T real time transfer format:
heartbeat
$ T->O real time transfer format:
connection is pure data and is modeless
$ O->T supported connection type(s):
point-to-point
$ T->O supported connection type(s):
multicast, point-to-point
$ O->T supported priorities: low, high,
scheduled
$ T->O supported priorities: low, high,
scheduled
Param3,
$ O->T RPI
0,
$ O->T size
Assem6,
$ O->T format
Param3,
$ T->O RPI
8,
$ T->O size
Assem100,
$ T->O format
,
$ Proxy config size (not used)
,
$ Proxy config format (not used)
,
$ Target config size (no config data)
,
$ Target config format (not used)
"Input only extended", $ Connection name string
"",
$ Help string
"20 04 24 00 2C 06 2C 64";$ Path
[Capacity]
MaxIOConnections = 4;
MaxMsgConnections = 6;
TSpec1 =
TxRx,
1,
1000;
TSpec2 =
TxRx,
256,
1000;
$ 1000 packets per sec @ 1 bytes
$ Connection size
$ Packets per second
$ 1000 packets per sec @ 256 bytes
$ Connection size
$ Packets per second
[DLR Class]
Revision = 3;
MaxInst = 1;
Number_Of_Static_Instances = 1;
Max_Number_Of_Dynamic_Instances = 0;
Class_Attributes = 1;
Instance_Attributes =
1,
2,
10,
12;
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TE Customer Interface
Robot/PLC Configuration
Class_Services =
0x01,
0x0E;
Instance_Services =
0x01,
0x0E;
Object_Name = "DLR Object";
Object_Class_code = 0x00000047;
Ring_Supervisor_Capable = No;
[QoS Class]
Revision = 1;
MaxInst = 1;
Number_Of_Static_Instances = 1;
Max_Number_Of_Dynamic_Instances = 0;
Class_Attributes = 1;
Instance_Attributes =
1,
2,
3,
4,
5,
6,
7,
8;
Class_Services = 0x0E;
Instance_Services =
0x0E,
0x10;
Object_Name = "QoS Object";
Object_Class_code = 0x00000048;
[TCP/IP Interface Class]
Revision = 4;
MaxInst = 1;
Number_Of_Static_Instances = 1;
Max_Number_Of_Dynamic_Instances = 0;
Class_Attributes =
1,
2,
3,
6,
7;
Instance_Attributes =
1,
2,
3,
4,
5,
6,
8,
9,
10,
11,
13;
Class_Services =
0x01,
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TE Customer Interface
Robot/PLC Configuration
0x0E;
Instance_Services =
0x01,
0x0E,
0x10;
Object_Name = "TCP/IP Interface Object";
Object_Class_code = 0x000000F5;
[Ethernet Link Class]
Revision = 4;
MaxInst = 3;
Number_Of_Static_Instances = 3;
Max_Number_Of_Dynamic_Instances = 0;
Class_Attributes =
1,
2,
3,
6,
7;
Instance_Attributes =
1,
2,
3,
4,
5,
6,
7,
8,
9,
10,
11;
Class_Services =
0x01,
0x0E;
Instance_Services =
0x01,
0x0E,
0x10,
0x4C;
Object_Name = "Ethernet Link Object";
Object_Class_code = 0x000000F6;
InterfaceLabel1 = "Port 1";
InterfaceLabel2 = "Port 2";
InterfaceLabel3 = "Internal";
InterfaceType1 = 2;
InterfaceType2 = 2;
InterfaceType3 = 1;
25
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Signal Descriptions
6.0 Signal Descriptions
This section describes the functions and operations associated with the various bits of the
input and output map.
6.1 Inputs to TX Control
Start Weld Cycle Outlet #
Byte 0, Bit 0-4
Offset
Function
Signal
Note
Starts the Weld Cycle on the specified outlet.
Active High
Initiates the Weld Cycle specified by the Operation Mode bits. See
Descriptions of Operation Modes for details on each type of cycle.
This signal must remain active until the Weld Complete signal is
issued from the Control. After the Weld Complete has been received
the signal can be dropped low.
Start Feed Cycle Outlet #
Byte 0, Bit 5-7; Byte 1, Bit 0-1
Offset
Function
Signal
Note
Starts the Feed Cycle on the specified outlet.
Active High; Pulsed 200 ms
Initiates the Feed Cycle which supplies a stud to the weld head. It
can only be activated while in “Dry Cycle with Part” and “Automatic”
Operation Modes. This is meant to be used in External Feeding
Configurations only. After Weld Complete is received this bit should
be pulsed to feed for the next cycle.
Stud ID
Offset
Byte 1, Bit 2-7; Byte 2, Bit 0
Function
Signal
Note
Select the Program used to weld when Start Weld is set.
Active High
These bits need to be set in order to specify the program to use. The
desired program number should be set before the Start Weld Signal
is sent. For example if you set Stud ID to 1 and set Start Weld for
outlet 1 then the Control would use the Stud ID named “1-001” on
the touchpad. If you sent Start Weld for outlet 2 then it would use “2001” and so on. (Format: Outlet-Program Number)
Revision Date: 6/20/2023
Revision 3.0
26
TE Customer Interface
Signal Descriptions
Restart
Offset
Byte 2, Bit 2
Function
Signal
Note
Retries the current Weld Cycle once a fault has been cleared.
Active High; Pulsed 200 ms
In the event of a fault where no weld was made the user can use the
Restart bit to start the Weld Cycle from where it left off. This should
only be used after the user has inspected the system and remedied
the fault condition. Restart will only retry the weld if Weld Start is on
when it is pulsed, otherwise it will simply clear the fault. Upon a
successful restart the Weld Complete bit should come on at the end
of the cycle.
Force Weld Complete
Byte 2, Bit 3
Offset
Function
Signal
Note
27
A faulted Weld Cycle is aborted and Weld Complete is set.
Active High; Pulsed 200 ms
In the event of a fault where a weld was made the user can use
Force Weld Complete to finish the current Weld Cycle. This should
only be used after the user has inspected the system and remedied
the fault condition. Force Weld Complete will only finish the Weld
Cycle if Weld Start is on when it is pulsed, otherwise it will simply
clear the fault. Upon a successful Force Weld Complete the Weld
Complete bit should come on at the end of the cycle.
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Signal Descriptions
Operation Mode
Byte 2, Bit 4-5
Offset
Function
Signal
Note
Used to determine which of four operations are carried out when
Start Weld is sent.
Active High
These bits should be set previous to the Start Weld being set and
remain set for the duration of the cycle that is being executed. The
four modes are described below. Each of them executes a different
type of cycle when Start Weld is set. Set the Operation Mode bits to
the binary representation of the Mode value in the table below
before applying Start Weld.
Mode
0
1
2
3
Name and Description
Robot Positioning: Weld Head will remain in Forward
position as long as ‘Start Weld’ signal is set.
Dry Cycle with Part: Initiates a test cycle without
switching on weld current. A part is fed.
Dry Cycle without Part: Initiates a test cycle without
switching on weld current. No part is fed.
Automatic: Performs a complete Weld Cycle with weld
current on.
Docking
Offset
Byte 2, Bit 6
Function
Signal
Note
Puts the control into Docking Mode allowing for a Tool Change.
Active High
This bit should be set to put the control in Docking Mode. Once
Ready for Automation goes low a Tool Change can then be
performed. Once the new tool has been connected this bit should be
dropped. Once Ready for Automation goes High again you can start
welding again.
Revision Date: 6/20/2023
Revision 3.0
28
TE Customer Interface
Signal Descriptions
6.2 Outputs to TX Control
No Fault Outlet #
Byte 0, Bit 0; Byte 0, Bit 5; Byte 1, Bit 2; Byte 1, Bit 7; Byte 2, Bit 4
Offset
Function
Signal
Note
Tells the operator if the control is faulted on the specified outlet.
Active High
This bit is normally set to indicate that no fault is present. Once it
drops the fault number can be viewed via the Fault Code bits. Once
the fault is remedied and reset the bit will be set high again.
Weld Complete Outlet #
Byte 0, Bit 1; Byte 0, Bit 6; Byte 1, Bit 3; Byte 2, Bit 0; Byte 2, Bit 5
Offset
Function
Signal
Note
Tells the operator that the Weld Cycle has been completed on the
specified outlet.
Active High
This bit is set once the specified Weld Cycle has been completed,
After which the Start Weld bit can be dropped. Weld Complete will
drop on the falling edge of the Weld Start bit.
Head Back Outlet #
Byte 0, Bit 2; Byte 0, Bit 7; Byte 1, Bit 4; Byte 2, Bit 1; Byte 2, Bit 6
Offset
Function
Signal
Note
Tells the operator if the Weld Head is in the rear position on the
specified outlet.
Active High
This bit is set if the Weld Head is in the rear position. No movement
of the work piece or the robot should take place unless the Weld
Head is in the rear position.
SOW Outlet #
Byte 0, Bit 3; Byte 1, Bit 0; Byte 1, Bit 5; Byte 2, Bit 2; Byte 2, Bit 7
Offset
Function
Signal
Note
29
Tells the operator that the stud has contacted the work piece on the
specified outlet.
Active High
This bit is set when the Stud has contacted the work piece thus
completing the weld circuit.
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Signal Descriptions
Weld in Tolerance Outlet #
Byte 0, Bit 4; Byte 1, Bit 1; Byte 1, Bit 6; Byte 2, Bit 3; Byte 3, Bit 0
Offset
Function
Signal
Note
Tells the operator whether the last weld was within the tolerance
limits specified.
Active High
This bit is normally set indicating a weld is within the specified
tolerance limits (WIP). It drops to indicate that a weld outside the
tolerance limits (WOP) has occurred. It should be checked after
Weld Complete is set. It will retain state until the next Weld Cycle
occurs.
Maintenance Warning
Byte 3, Bit 1
Offset
Function
Signal
Note
Tells the operator when Maintenance is required.
Active High
This bit is set when the weld counters indicate that system
maintenance is required. It will remain active till the counter is
cleared on the touchpad.
Fill Level Warning
Byte 3, Bit 2
Offset
Function
Signal
Note
Tells the operator when the feeder fill level is low.
Active High
This bit is set when the feeder detects a low level of studs. This
indicates that refilling should occur. Once the stud level has been
increased the bit will be dropped.
Ready for Automation
Byte 3, Bit 3
Offset
Function
Signal
Note
Tells the operator when the control is ready.
Active High
This bit is set when the control is turned on and all connected
systems are initialized. If you trip the protection circuit then this bit
will drop until the control leaves the protection state.
Revision Date: 6/20/2023
Revision 3.0
30
TE Customer Interface
Signal Descriptions
Ready to Weld
Byte 3, Bit 4
Offset
Function
Signal
Note
Tells the operator when the control is ready to weld.
Active High
This bit is set when the control is in Automatic Mode and the control
is armed to weld. This bit should be checked after switching into
Automatic Mode before any welds are made.
Fault Group
Offset
Byte 3, Bit 5-7
Function
Signal
Note
Tells the operator the existing fault type.
Active High
These bits are binary encoded with their meaning listed below.
0: None
1: System
2: Welding
3: Weld Tool
4: Feeder
5: Stud Divider
6: Customer Interface
7: None
Fault Code
31
Offset
Byte 4, Bit 0-7; Byte 5, Bit 0
Function
Signal
Note
Tells the operator the existing fault code.
Active High
These bits form a binary encoded integer. You can view more
details on the fault such as a description on the touchpad attached
to the control. See Appendix A for translation table from this fault
code to Fault Number displayed on Touchpad.
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Signal Diagrams
7.0 Signal Diagrams
7.1 Weld in Tolerance
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
I : Stud ID
Set to 3 (Automatic Mode)
Set to Valid Program Number
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
7.2 Weld out of Tolerance
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
I : Stud ID
Set to 3 (Automatic Mode)
Set to Valid Program Number
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
Revision Date: 6/20/2023
Revision 3.0
32
TE Customer Interface
Signal Diagrams
7.3 Dry Cycle with Part
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
Set to 1 (Dry Cycle with Part)
I : Stud ID
Set to Valid Program Number
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
7.4 Dry Cycle without Part
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
I : Stud ID
Set to 2 (Dry Cycle Without Part)
Set to Valid Program Number
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
33
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Signal Diagrams
7.5 External Feed
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
Set to 3 (Automatic Mode)
Set to Valid Program Number
I : Stud ID
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
200ms
I : Start Feed
7.6 Reset
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
Set to 3 (Automatic Mode)
Set to Valid Program Number
I : Stud ID
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
O : Fault Code
0
Current Fault Code
0
200ms
I : Restart
Revision Date: 6/20/2023
Revision 3.0
34
TE Customer Interface
Signal Diagrams
7.7 Force Weld Complete
O : Ready for Automation
O : Ready to Weld
I : Operation Mode
Set to 3 (Automatic Mode)
Set to Valid Program Number
I : Stud ID
I : Start Weld Cycle
O : Head Back
O : SOW (Stud on Work)
O : Weld Complete
O : Weld in Tolerance
O : No Fault
O : Fault Code
0
Current Fault Code
0
200ms
I : Force Weld Complete
35
Revision Date: 6/20/2023
Revision 3.0
TE Customer Interface
Service Support
8.0 Service Support
Our service department is available for technical support.
Please contact 586-949-0550 ext. 306.
9.0 Revision Log
Author (s)
P. Are
Revision Date: 6/20/2023
Revision 3.0
Date
Description
6/20/2023 Initial release for TX
Revision
1.0
36