FRONIUS TPS/i Bedienungsanleitung

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TPS/i Interface Signal Descriptions

EN-US

User information

Signal description

42,0426,0227,EA 021-20052021

Table of contents

General 5

Data Types Used 5

Behavior of the Power Source when an Interface is Connected 5

Availability of Functions 5

Signal Transmission Time 6

Safety 6

Digital Inputs 7

Welding start (Welding on) - Single Bit 7

Robot ready (Robot ready) - Single Bit 7

Working mode (Operating mode) - Single Bit 7

Gas on (Gas on) - Single Bit 9

Wire forward (Wire forwards) - Single Bit 9

Wire backward (Wire return) - Single Bit 10

Error reset (Reset error) 10

Touch sensing (TouchSensing) - Single Bit 11

Gas nozzle touch sensing (Gas nozzle position search) - Single Bit 12

Torch blow out (Blow out welding torch) - Single Bit 13

Welding simulation (Welding simulation) - Single Bit 13

Synchropulse on (SynchroPulse on) - Single Bit 13

WireBrake on (Wire brake on) - Single Bit 13

Torchbody Xchange (Change torch body) - Single Bit 13

Teach mode - Single Bit 14

ExtInput 1-8 (External input 1-8) - Single Bit 15

Job number (Job‑number) - Group Input 16

Welding characteristic (Characteristic number) - Group Input 16

Disable process control (Deactivate process-dependent correction) - Group Input 16

Processline select (Process line selection) - Group Input 16

TWIN mode (TWIN operating mode) - Group Input 17

Documentation mode (Documentation mode) - Single Bit 17

WireSense start - Single Bit 18

WireSense break - Single Bit 19

Analog Inputs 20

Wire feed speed command value (Wire speed set value) - Group Input / Analog Input 20

Arclength correction (arc length correction) - Group Input / Analog Input 20

Pulse-/ dynamic correction (Pulse/dynamic correction) - Group Input / Analog Input 21

Wire retract correction (Wire retraction correction) - Group Input / Analog Input 21

Seam number (Seam number) - Group Input / Analog Input 22

Welding speed (Welding speed) - Group Input / Analog Input 22

WireSense edge detection - Group Input / Analog Input 22

Wire forward / backward length (length specification wire threading / wire retraction) - Group Input /

Analog Input

Digital Outputs 25

Definition 25

Heartbeat power source (Heartbeat power source) - Single Bit 25

Power source ready (Power source ready) - Single Bit 25

Warning (Warning) - Single Bit 25

Process active (Process active) - Single Bit 26

Current flow (current flow) - Single Bit 26

Robot motion release (Robot motion release) - Single Bit 27

Arc stable/Touch signal (Arc stable/touch signal) - Single Bit 28

Main current signal (Main current signal) - Single Bit 31

Collisionbox active (CrashBox active) - Single Bit 31

Torchbody gripped (Torch body gripped) - Single Bit 31

Command value out of range (Set value out of range) - Single Bit 32

Correction out of range (Correction out of range) - Single Bit 32

Process Bit (Process bit) - Group Output 32

ExtOutput 1-8 (External output 1-8) - Single Bit 32

Touch signal (Touch signal) - Single Bit 33

Characteristic number valid (Characteristic number valid) - Single Bit 33

Sensor Status 1 (sensor status 1) - Single Bit 33

EN-US

Sensor Status 2 (sensor status 2) - Single Bit 34

Sensor Status 3 (sensor status 3) - Single Bit 34

Wire stick workpiece (Wire stick workpiece) - Single Bit 34

Parameter selection internally (Internal parameter selection) - Single Bit 34

Limitsignal (Limit signal) - Single Bit 35

Main supply status (Mains voltage status) - Single Bit 35

Safety status - Single Bit 35

Twin synchronization active - Single Bit 36

System not ready - Single Bit 36

Notification (Notification) - Single Bit 36

Analog Outputs 37

Welding voltage (Welding voltage) - Group Output / Analog Output 37

Welding current (Welding current) - Group Output / Analog Output 37

Wire feed speed (Wire speed) - Group Output / Analog Output 38

Actual real value for seam tracking (Current actual value for seam tracking) - Group Output / Ana-

log Output

Motor current M1 (Motor current M1) - Group Output / Analog Output 40

Motor current M2 (Motor current M2) - Group Output / Analog Output 40

Motor current M3 (Motor current M3) - Group Output / Analog Output 41

Error number (Error number) - Group Output / Analog Output 41

Warning number (Warning number) - Group Output / Analog Output 41

WireSense position (wire position) - Group Output / Analog Output 41

Available Process Images 43

Process Image Types 43

Changing/Assigning Characteristic Numbers/Program Numbers (Retrofit Mode) 43

Information on the Use of the MIG/MAG Standard Manual, TIG, and Electrode Welding Processes 45

MIG/MAG Standard Manual 45

TIG 45

Electrode 45

Arc Break Monitoring 46

Fronius Data Channel 48

Signal sequence when selected using "Job Mode" operating mode 49

Signal sequence when selected using "Characteristics Mode" operating mode 50

WireSense - more information 52

Process description WireSense (contour detection) 52

Process description WireSense edge detection (edge detection) 53

Signal curve of Edge Detection Mode on a level surface 54

Signal curve of Edge Detection Mode on a slanted surface 56

Signal curve of Sensing Mode for different surface geometries 58

Signal curve of WireSense break (during Sensing Mode) 60

Representation of the possible measurement range 61

Note on ignition timeout (Ignition Timeout) 62

Available signals for component scanning 63

Signal list 63

Limit Monitoring - functions and activation 64

Functions of Limit Monitoring 64

Available function packages 64

Prerequisites for the successful use of Limit Monitoring 65

Switch Limit Monitoring on / off 65

Detailed description of Limit Monitoring 66

Limit Monitoring - details on the individual welding parameters 67

Voltage monitoring 67

Current monitoring 68

Wirefeeder monitoring 68

Welding time monitoring 69

Energy monitoring 71

Setting of the reaction when exceeding or falling below the limits: 72

Setting of the reaction when exceeding or falling below the limits for the motor force 80

Smart Manager + OPT/i Jobs (4,067,002) 85

General

Data Types Used UINT 16 (Unsigned Integer) = Whole number in the range from 0 to 65,535

SINT 16 (Signed Integer) = Whole number in the range from -32,768 to 32,767

Conversion examples:

- For a positive value (SINT 16) = desired wire speed x factor = 12.3 m/min x 100 =

1230dec = 04CEhex

- For a positive value (SINT 16) = desired arc length correction x factor = -6.4 x 10 =

-64dec = FFC0hex

Unsigned (UINT): Signed (SINT):

Type: Unsigned 16 Bit integer = 16

bits

Type: Signed 16 Bit integer (15 bits +

1 Sign Bit*)

Range: 0 to 65535 Rang

-32768 to 32767

0000 -10 (0000000000000000) 0000 0000 (0*000000000000000)

32767 0 (0111111111111111) 56 56 (0*000000000111000)

65535 +10 (1111111111111111) -64 -64 (1*111111111000000)

* = if the value entered has a negative

sign, the sign Bit is High – see markings

Behavior of the

Power Source

when an Interface

is Connected

If a power source from the TPS/i series is connected to a robot interface, the settings on

the power source remain unchanged (2-step mode, special 2-step mode, etc.).

If a power source from the TPS series is connected to a robot interface, the power

source automatically selects 2-step mode.

Availability of

Functions

As a result of updates, certain functions may be available on your device that are not

described in this document, or vice versa.

EN-US

Signal Transmis-

sion Time

TPS/i t

TPS/i

<10 ms

Welding start

Process active

Representation of the signal transmission time; the signals shown are for illustrative purposes only

Safety WARNING!

Danger from incorrect operation and work that is not carried out properly.

Serious personal injury and damage to property may result.

▶All the work and functions described in this document must only be carried out by

trained and qualified personnel.

▶Read and understand this document.

▶Read and understand all the Operating Instructions for the system components,

especially the safety rules.

Digital Inputs

Welding start

(Welding on) -

Single Bit

The rising edge of the Welding start signal starts the welding process.

- The welding process runs for as long as the Welding start signal is active.

Exceptions: The Robot ready signal is deactivated or the power source is reporting

an error (for example: overtemperature, too little coolant, etc.).

- The Welding start signal can be activated independently of the operating mode

(internal parameter selection, special 2-step mode characteristics, Job Mode, etc.).

- Touch mode cannot be activated as long as the Welding start signal remains set.

Additional information for TWIN systems:

- In single wire mode, the welding process is started on the active power source

- In TWIN mode, the welding process is started on both power sources

Robot ready

(Robot ready) -

Single Bit

The robot sets this signal as soon as it is ready to weld.

- If the signal is reset by the robot during welding, the welding process is ended in a

controlled manner (without any crater filling routines).

- In addition, the Robot not ready error is output. This error must either be reset on the

power source control panel or using the robot interface.

- It is still possible to specify the set values in the internal parameter selection operat-

ing mode, even if the Robot ready signal is not set.

Working mode

(Operating mode)

- Single Bit

This signal is used to select the operating mode of the power source.

Value range for operating mode:

Bit 4

Bit 3

Bit 2

Bit 1

Bit 0

Description

0 0 0 0 0 Internal parameter selection

0 0 0 0 1 Special 2-step mode characteristics

0 0 0 1 0 Job mode

0 1 0 0 0 2-step mode characteristics

Description of internal parameter selection:

- The control panel or a remote control can be used to specify all the set values and

material settings important for welding. This makes creating and saving jobs easy.

- The robot outputs all other signals.

- These values can also be specified during welding.

Internal parameter selection can be used to select:

- 4-step mode

- Special 4-step mode

- Electrode

- TIG

EN-US

Description of special 2-step mode characteristics:

- To select welding parameters using the analog set values and the characteristic

number (characteristic ID), the correct characteristic number must be used. The

characteristic numbers can be found on the website of the power source, in the

characteristics overview.

- The welding process is also defined using the characteristic number (MIG/MAG

standard synergic, MIG/MAG pulse synergic, MIG/MAG LSC, MIG/MAG PMC,

MIG/MAG CMT, etc.).

- Only characteristics that have previously been approved for the power source can

be selected.

- The parameters from the start of welding/end of welding are used in the special 2-

step mode characteristics.

I-S I-E

GPr GPoSL1 Main current SL2

t-S

Welding start

t-E

HIGH LOW

Special 2-step mode signal sequence

Description of Job Mode:

- The welding parameters are selected using the data saved in the jobs.

- The EasyJob function is deactivated as soon as a CC module (an RI IO/i or a RI IO

PRO/i) is connected.

- There is no job with the number 0. Job number 0 can be used to select the job on

the control panel of the power source.

Description of 2-step mode characteristics:

- To select the welding parameters via the analog set values and the characteristic

number (characteristic ID), the correct characteristic number must be used. The

characteristic numbers can be found on the website for the power source, in the

characteristics overview.

- The welding process is also defined using the characteristic ID (MIG/MAG standard

synergic, MIG/MAG pulse synergic, MIG/MAG LSC, MIG/MAG PMC, MIG/MAG

CMT, etc.).

- Only characteristics that have previously been approved for the power source can

be selected.

GPr GPoMain current

HIGH LOW

Welding start

2-step mode signal sequence

For MIG/MAG standard manual characteristics, the 2-step mode characteristics must be

used.

Gas on (Gas on) -

Single Bit

The Gas on signal opens the gas solenoid valve and thus activates the gas flow.

- As long as the signal is High, the gas solenoid valve remains open.

- The gas flow can be activated independently of the operating mode (internal para-

meter selection, special 2-step mode characteristics, Job Mode, etc.).

- During welding, the gas pre-flow and the gas post-flow are controlled by the power

source. It is therefore not necessary to activate the gas pre-flow and gas post-flow

separately.

- If the Gas on High signal is set before the Welding start signal, the gas pre-flow of

the power source is not active.

- The Gas on signal can only be set if the Robot ready signal is set at the same time.

If this is not the case, the gas flow must be activated by pressing a button on one of

the Fronius system components (power source, wirefeeder, torch hosepack, etc.).

Additional information for TWIN systems:

- In single wire mode with a Single-torch body, the gas solenoid valve of the active

process line is opened

- In TWIN mode, both gas solenoid valves are opened

- When welding with a TWIN torch body, both gas solenoid valves are always opened

Wire forward

(Wire forwards) -

Single Bit

The Wire forward signal activates the start of the wirefeeder.

- The wire electrode is threaded into the hosepack without current or gas.

- The wirefeeder can be activated independently of the operating mode (internal para-

meter selection, special 2-step mode characteristics, Job Mode, etc.).

- The signal corresponds to the wire threading button on the control panel of the

power source, on the wirefeeder, and on the torch hosepack. The precise function of

the wire threading button is described in the Operating Instructions of the respective

system components/the documentation of the whole welding system.

- As long as the Wire forward signal is set, the Wire backward signal cannot be set.

- The Wire forward signal can only be set if the Robot ready signal is set at the same

time. If this is not the case, wire threading must be controlled using the wire thread-

ing button on one of the Fronius system components (wirefeeder, torch hosepack,

etc.)

- The wire electrode can be threaded a maximum of 50 m (164 feet 0.5 inches)

(=safety stop)

EN-US

The signal can be set in two ways:

- Pulse signal = wire electrode moves approx. 1 mm forwards

- Continuous signal = creep function – the wirefeeder is stopped as soon as the wire

electrode touches the welding material

Additional information for TWIN systems:

- In single wire mode, the wire electrode of the active process line is fed

- In TWIN mode, both wire electrodes are fed

- If the TWIN operating mode changes during wirefeeding, the wirefeeding is adapted

in line with the change

Wire backward

(Wire return) -

Single Bit

The Wire backward signal activates the retraction of the wire electrode.

- It can be used to retract the wire electrode out of the welding torch completely or

only by a specific length.

- The retraction can be activated independently of the operating mode (internal para-

meter selection, special 2-step mode characteristics, Job Mode, etc.).

- The signal corresponds to the wire-return button on the control panel of the power

source, on the wirefeeder, and on the torch hosepack. The precise function of the

wire-return button is described in the Operating Instructions of the respective system

components/the documentation of the whole welding system.

- As long as the Wire backward signal is set, the Wire forward signal cannot be set.

- The Wire backward signal can only be set if the Robot ready signal is set at the

same time. If this is not the case, retraction of the wire electrode must be controlled

using the wire-return button on one of the Fronius system components (wirefeeder,

torch hosepack, etc.)

- The wire electrode can be retracted a maximum of 50 m (164 feet 0.5 inches)

(=safety stop)

The signal can be set in two ways:

- Pulse signal = wire moves approx. 1 mm backwards

- Continuous signal = permanent wire retraction

Additional information for TWIN systems:

- In single wire mode, the wire electrode of the active process line is fed

- In TWIN mode, both wire electrodes are fed

- If the TWIN operating mode changes during wirefeeding, the wirefeeding is adapted

in line with the change

Error reset (Reset

error)

If an error message is output on the power source, the error is reset using the Error reset

signal.

In order to reset the signal successfully, the signal must remain set for at least 10 ms.

WARNING!

Danger due to welding processes starting unexpectedly.

This can result in severe personal injury and damage to property.

▶The cause of the error must always be resolved before the error message is reset

using the Error reset signal.

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