ABB Fronius TPS 320i Instructions for use

ROBOTICS
Application manual
Fronius TPS 320i/400i/500i/600i with
RI-FB inside/i interface

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Application manual
Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface
21A
Document ID: 3HAC065012-001
Revision: C
© Copyright 2004-2021 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2004-2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
7Overview of this manual ...................................................................................................................
8Safety ................................................................................................................................................
91 Introduction to Fronius TPS/i interface
112 Installation
112.1 Prerequisites ....................................................................................................
132.2 Hardware setup ................................................................................................
172.3 Software setup .................................................................................................
172.3.1 Software setup overview ...........................................................................
182.3.2 Fronius TPS/i package .............................................................................
202.3.3 System parameters .................................................................................
242.3.4 Units .....................................................................................................
272.4 Best practice ....................................................................................................
293 Fronius interface modes
293.1 Overview .........................................................................................................
323.2 Setting up limits in job mode with correction ...........................................................
354 Weld editor interface
354.1 Introduction ......................................................................................................
384.2 Weld editor in Program mode ..............................................................................
454.3 Weld editor in Job mode .....................................................................................
514.4 Weld editor in Job mode with correction ................................................................
574.5 Weld parameters ...............................................................................................
584.6 How to edit welddata using the PartData concept ....................................................
635 The Fronius TPS/i RobotStudio Add-In
635.1 Introduction ......................................................................................................
645.2 Overview of the Fronius TPS/i Add-In ....................................................................
696 Customize widget screen
737 Fronius EtherNet/IP configuration
747.1 Installation .......................................................................................................
757.2 Fronius power supply settings .............................................................................
757.2.1 Changing the Fronius power supply network settings .....................................
777.2.2 Changing the network settings for IRC5 controller communication ...................
797.3 IRC5 controller configuration ...............................................................................
797.3.1 Changing the IRC5 communication settings .................................................
827.3.2 Accessing the Fronius service port from ABB controller .................................
837.3.3 Adding or removing synergic lines from RobotStudio .....................................
85Index
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Table of contents

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Overview of this manual
About this manual
This manual describes the options Fronius TPS/i interface and Weld editor and
contains instructions to configure it.
This manual should be read before installing and commissioning of a Robotic Arc
Welding system with a Fronius TPS/i power source.
Who should read this manual?
This manual is intended for:
• Personnel responsible for installations and configurations of fieldbus
hardware/software
• Personnel responsible for I/O system configuration
• System integrators
Prerequisites
The reader should have the required knowledge of:
• Mechanical installation work
• Electrical installation work
• System parameter configuration
References
Document IDReference
3HAC032104-001Operating manual - RobotStudio
3HAC050988-001Application manual - Arc and Arc Sensor
3HAC050917-001Technical reference manual - RAPID Instructions, Functions and Data
types
3HAC050948-001Technical reference manual - System parameters
42,0426,0114,ENFronius Operating Instructions TPS 320i/400i/500i/600i
Revisions
DescriptionRevision
First revision.A
Released with RobotWare 6.11.
• New information regarding simulated PROFINET device in section
Software setup on page 17.
• Information about TCP Speed Control updated in section System
parameters on page 20.
• Information regarding firmware updated in section Introduction to
Fronius TPS/i interface on page 9.
B
Released with 21A.
• New section: Fronius EtherNet/IP configuration on page 73
• Updated the section Setup of PROFINET devices on page 17.
C
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© Copyright 2004-2021 ABB. All rights reserved.
Overview of this manual

Safety
Safety regulations
Before beginning mechanical and/or electrical installations, ensure you are familiar
with the safety information in the product manuals for the robot.
The integrator of the robot system is responsible for the safety of the robot system.
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Safety

1 Introduction to Fronius TPS/i interface
About Fronius TPS 320i / 400i / 500i / 600i IRC5 interface
This guide describes the ABB Robotics IRC5 interface for:
• Fronius TPS 320i/400i/500i/600i with RI-FB Inside/i interface
The power source must meet the following requirements:
• Firmware 1.7.4 or above
• RI FB Inside/I interface for D-Net / Profi-Bus / Profi-Net or EtherNet/IP
• Firmware 2.3.0 or above is needed for Job mode with correction.
Overview
The MIG/MAG power sources TPS 320i, TPS 400i, TPS 500i and TPS 600i are
completely digitized, microprocessor-controlled inverter power sources. The
modular design and potential for system add-ons ensure a high degree of flexibility.
The devices can be adapted to any specific situation.
xx1900002381
TPSi power sources contain a selection of welding processes, procedures and
welding characteristics that enable a wide range of materials to be processed in
the most effective way.
Summary of MIG/MAG pulse synergic welding
MIG/MAG pulse synergic welding is a pulsed-arc process with controlled material
transfer. In the base current phase, the energy supply is reduced to such an extent
that the arc is only just stable, and the surface of the workpiece is preheated. In
the pulsing current phase, a precise current pulse ensures the targeted detachment
of a droplet of welding material. This principle guarantees a low-spatter weld and
precise working across the entire power range, as unwelcome short circuits with
simultaneous droplet explosion and uncontrolled welding spatter are virtually
eliminated.
Summary of MIG/MAG standard synergic welding
The MIG/MAG standard synergic welding process is a MIG/MAG welding process
across the entire power range of the power source with the following arc types:
DescriptionArc type
Droplet transfer takes place during a short circuit in the lower power range.Short circuit
arc
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1 Introduction to Fronius TPS/i interface

DescriptionArc type
The droplet increases in size on the end of the wire electrode and is trans-
ferred in the mid power range during the short circuit.
Intermediate
arc
A short circuit-free transfer of material in the high-power range.Spray arc
Summary of the PMC process
PMC (Pulse Multi Control) is a pulsed arc welding process with high-speed data
processing, precise recording of the process status and improved droplet
detachment. Faster welding possible with a stable arc and even fusion penetration.
Summary of the LSC / LSC Advanced process
LSC (Low Spatter Control)
LSC (Low Spatter Control) is a new, low-spatter dip transfer arc process. The
current is reduced before breaking the short-circuit bridge; re-ignition takes place
at significantly lower welding current values.
LSC Advanced
The TPS 400i LSC ADV is required for the LSC Advanced process. The TPS 400i
LSC ADV accelerates the reduction in current and improves the LSC properties.
The LSC Advanced process is predominantly used when the welding circuit
inductivity is higher.
Summary of SynchroPulse welding
SynchroPulse is available for all processes (standard/pulsed/LSC/PMC). Due to
the cyclical change of welding power between two operating points, SynchroPulse
achieves a flaking seam appearance and non-continuous heat input.
Summary of CMT process
A special CMT (Cold Metal Transfer) drive unit is required for the CMT process.
The reversing wire movement in the CMT process results in a droplet detachment
with improved dip transfer arc properties. The advantages of the CMT process are
as follows:
• Low heat input
• Less spattering
• Reduced emissions
• High process stability
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1 Introduction to Fronius TPS/i interface
Continued

2 Installation
2.1 Prerequisites
Robot controller software
Robot system prerequisites:
• IRC5 robot controller with main computer DSQC1000 or above
• RobotWare version 6.05 or higher with the following options:
- [633-4] RobotWare Arc
- [637-1] Production Screen
• One of the following Industrial Networks:
- [709-1] DeviceNet Master/Slave
- [841-1] EtherNet/IP Scanner/Adapter
- [888-2] PROFINET Controller/Device
- [969-1] PROFIBUS Controller
• The following option is recommended in order to use the Partdata concept
within the welddata editor:
- [812-1] Production Manager
RobotStudio software
RobotStudio version 6.06 or higher.
Limitations
Note
Currently, only the first Arc System is supported with this interface. If you have
more than one welder connected per robot, you must use the Arc Sub-option
Standard I/O Welder.
Tuning of weld speed and weld parameters is no longer supported by RobotWare
Arc GUI.
Note
The Fronius TPS/i web browser interface is a licensed option from Fronius.
To be able to connect to the Fronius TPSi Welder via the web browser interface in
the RobotStudio Add-in, this option is needed. Contact Fronius for more information
regarding this.
Fronius TPS/i Add-In
The Fronius TPS/i Add-In consists of the following software components:
• Ready to weld interface to control a TPS 320i, TPS 400i, TPS 500i and TPS
600i welder
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2 Installation
2.1 Prerequisites

• RobotStudio Add-In to select different weld modes (synergic lines) used with
the welder
• Graphical weld data editor
• Graphical weave and track data editor
• Graphical application for manual functions such as:
- Process blocking
- Wire feed (Forward/Backward)
- Purge gas
Graphical widget displaying run-time data.
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2 Installation
2.1 Prerequisites
Continued

2.2 Hardware setup
Overview
The ABB preferred connection to the welder is to connect the LAN port of the
welder either to LAN2 or WAN on the IRC5 controller. This is not mandatory, but
it is a convenient way to set up the system since you have access to the welder
and the robot controller from RobotStudio.
Note
This connection is only used with the RobotStudio Add-In to download the
supported weld modes (also known as Synergic lines) and the Joblist.
Furthermore, it is possible to get access to the welders web page from
RobotStudio by launching a web browser.
Note
The I/O based communication to the welder which is needed to control the welder
is done via a fieldbus interface and not through the LAN port of the welder.
A switch must be added if the system is a MultiMove system, or if the LAN port is
connected to a remote system such as the Fronius WeldCube (documentation and
data analysis tool).
It is recommended that switches used in the I/O network support Quality of Service
(QoS). I/O devices mark their packets with a priority value. The priority value is
used in order to get better I/O data throughput and shorter delays on the network.
Switches and routers are then able to differentiate the I/O devices critical from the
other non-critical traffic. To do this, the switches and routers must support Quality
of Service.
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2 Installation
2.2 Hardware setup

Intended use of WAN and LAN ports
The WAN port is a public network interface to the controller, typically connected
to the factory network with a public IP address provided by the network
administrator.
The LAN ports are intended for connecting network based process equipment to
the controller, for example industrial networks, cameras, and welding equipment.
LAN 2 can only be used as a private network to the IRC5 controller.
xx1900002386
Connecting to the IRC5 controller
Connect an Ethernet cable between the robot controller LAN2 port and the TPS/i
welder Ethernet port. The following illustration shows an overview of the computer
unit.
xx1900002385
LAN2X4
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2 Installation
2.2 Hardware setup
Continued

Welder LAN port
The LAN port (Service port) is located on the back of the welder. If you connect
the welder to the IRC5 controller, make sure to use a static IP address and turn
off DHCP.
xx1900002382
IP address on welder
The IP address of the welder can be changed on the front panel with the following
steps:
1 Go to Defaults,System and select Network settings.
xx1900002383
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2 Installation
2.2 Hardware setup
Continued

2The network setup overview is displayed. If DHCP is enabled, the IP address,
Network mask and Standard gateway network parameters are greyed out
and cannot be adjusted. In order to change the IP address, DHCP must be
disabled.
xx1900002384
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2 Installation
2.2 Hardware setup
Continued

2.3 Software setup
2.3.1 Software setup overview
Setup of PROFINET devices
This information is valid if PROFINET is selected in the fieldbus selection in
Installation Manager.
From version 1.05 of the Fronius TPSi Add-in, the PROFINET setup is
pre-configured and ready to use. The only thing that the user needs to do, is to
change the IP of the welder if needed.
The IPPNIO.xml file is created during the installation the Robot system, and is
copied to the HOME folder of the system.
The latest version of the Fronius TPSi GSDML file is copied to the HOME/GSDML
folder on the system.
The default IP addresses for the welders are:
IP addressWelder
192.168.0.2T_ROB1
192.168.0.3T_ROB2
192.168.0.4T_ROB3
192.168.0.5T_ROB4
The IP address can be changed from the I/O Configurator:
xx2100000509
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2 Installation
2.3.1 Software setup overview

2.3.2 Fronius TPS/i package
Downloading of Fronius TPS/i package
1 Download and install the Fronius TPS/i package from the Add-Ins tab in
Robotstudio. (Common tags: RobotWare-Addin). Start the Installation
Manager and build your robot system.
Note
Do not forget to add the Fronius TPS/i product in the Products tab. You
do not need a license for the package.
xx1900002395
2 As the TPS/i package is an add-in, RW-Add-In loaded Welder must be
selected in the Drive Module section (Option tab) for each associated welding
robot.
xx1900002396
3 Select the Install Power Supply option for each welding robot, and select
the fieldbus. If the system has the SmarTac option, you can select Include
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2 Installation
2.3.2 Fronius TPS/i package

SmarTac Config. This will load configuration files to use the Fronius touch
sense function.
xx1900002397
4 Apply your settings and download the system to the controller.
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2 Installation
2.3.2 Fronius TPS/i package
Continued

2.3.3 System parameters
Overview
The Fronius Equipment Class and settings are automatically activated after the
controller is booted with the TPS/i Add-in.
This option has advanced support for the Fronius TPS 320i/400i/500i/600i power
source that includes support for two welding modes:
• Job mode
• Program mode
• Job mode with correction
Note
TCP Speed Control is currently not supported by Fronius for the TPS/i power
source. However, the TCP speed of the robot is available on an analog output
(aoFrXSimTcpSpeed) and is logged by Fronius documentation logbook in their
web interface.
Fronius Equipment Properties
The Fronius Equipment Properties can be defined in RobotWare Arc.
DescriptionData TypeParameter
The name of the Fronius Equipment Properties.stringName
The name of the Equipment Standard IO to use.stringUse Equipment
Standard IO
The name of the Equipment Standard IO to use.stringUse Fronius Equip-
ment IO
The mode of the welder. The following modes are
available:
• Job mode
• Program mode
• Job mode with correction
Default value: Job mode
stringMode
Specifies if ignition data specified in seamdata is
to be used at the start of the weld phase. At the
start it is often beneficial to define higher weld
data values for a better ignition. If the ignition data
parameter is changed, the contents of seamdata
will also change.
boolIgnition on
Default value: FALSE
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2 Installation
2.3.3 System parameters