FRO­NIUS TPS/i Operation manual

User
Information
TPS/i Interface Signal Descriptions
42,0426,0227,EA 027-08072022
EN-US User information

Table of contents
General 6
Data types used 6
Behavior of the Power Source when an Interface is Connected 6
Availability of Functions 6
Signal Transmission Time 7
Safety 7
Digital Inputs 8
Welding start (Welding on) - Single Bit 8
Robot ready (Robot ready) - Single Bit 8
Working mode (Operating mode) - Single Bit 8
Gas on (Gas on) - Single Bit 10
Wire forward (Wire forwards) - Single Bit 10
Wire backward (Wire return) - Single Bit 11
Error reset (Reset error) 12
Touch sensing (TouchSensing) - Single Bit 12
Torch blow out (Blow out welding torch) - Single Bit 14
Welding simulation (Welding simulation) - Single Bit 14
Synchropulse on (SynchroPulse on) - Single Bit 14
WireBrake on (Wire brake on) - Single Bit 14
Torchbody Xchange (Change torch body) - Single Bit 15
Teach mode - Single Bit 15
ExtInput 1-8 (External input 1-8) - Single Bit 16
Job number (Job‑number) - Group Input 17
Welding characteristic (Characteristic number) - Group Input 17
Disable process control (Deactivate process-dependent correction) - Group Input 18
Processline select (Process line selection) - Group Input 18
TWIN mode (TWIN operating mode) - Group Input 18
Contact tip short circuit detection on (contact tip short circuit detection on) - Single Bit 19
Documentation mode (Documentation mode) - Single Bit 19
WireSense start - Single Bit 19
WireSense break - Single Bit 20
Analog Inputs 21
Wire feed speed command value (Wire speed set value) - Group Input / Analog Input 21
Arclength correction (arc length correction) - Group Input / Analog Input 21
Pulse-/ dynamic correction (Pulse/dynamic correction) - Group Input / Analog Input 22
Hotwire current (Hot-wire amperage) - Group Input / Analog Input 23
Wire retract correction (Wire retraction correction) - Group Input / Analog Input 23
Seam number (Seam number) - Group Input / Analog Input 24
Welding speed (Welding speed) - Group Input / Analog Input 24
WireSense edge detection - Group Input / Analog Input 24
Wire forward / backward length (length specification wire threading / wire retraction) -
Group Input / Analog Input
25
Digital Outputs 27
Definition 27
Heartbeat power source (Heartbeat power source) - Single Bit 27
Power source ready (Power source ready) - Single Bit 27
Warning (Warning) - Single Bit 27
Process active (Process active) - Single Bit 28
Current flow (current flow) - Single Bit 28
Robot motion release (Robot motion release) - Single Bit 29
Arc stable /Touch signal (Arc stable/touch signal) - Single Bit 30
Main current signal (main current signal) - Single Bit 33
Collisionbox active (CrashBox active) - Single Bit 34
Torchbody gripped (Torch body gripped) - Single Bit 34
Command value out of range (set value out of range) - Single Bit 34
Correction out of range (Correction out of range) - Single Bit 34
Process Bit (Process bit) - Group Output 34
ExtOutput 1-8 (External output 1-8) - Single Bit 35
Touch signal (Touch signal) - Single Bit 36
Characteristic number valid (Characteristic number valid) - Single Bit 36
3
EN-US

Sensor Status 1 (sensor status 1) - Single Bit 36
Sensor Status 2 (sensor status 2) - Single Bit 37
Sensor Status 3 (sensor status 3) - Single Bit 37
Sensor Status 4 (sensor status 4) - Single Bit 37
Wire stick workpiece (Wire stick workpiece) - Single Bit 37
Short circuit contact tip (contact tip short circuit) - Single Bit 38
Parameter selection internally (Internal parameter selection) - Single Bit 38
Limitsignal (Limit signal) - Single Bit 38
Main supply status (Mains voltage status) - Single Bit 39
Safety status - Single Bit 39
Twin synchronization active - Single Bit 39
System not ready - Single Bit 39
Touch signal gas nozzle - Single Bit 40
Notification (Notification) - Single Bit 40
Analog Outputs 41
Welding voltage (Welding voltage) - Group Output / Analog Output 41
Welding current (Welding current) - Group Output / Analog Output 41
Wire feed speed (Wire speed) - Group Output / Analog Output 42
Actual real value for seam tracking (Current actual value for seam tracking) - Group Out-
put / Analog Output
42
Motor current M1 (Motor current M1) - Group Output / Analog Output 44
Motor current M2 (Motor current M2) - Group Output / Analog Output 45
Motor current M3 (Motor current M3) - Group Output / Analog Output 45
Error number (Error number) - Group Output / Analog Output 46
Warning number (Warning number) - Group Output / Analog Output 46
Wire position (wire position) - Group Output / Analog Output 46
Available Process Images 47
Process Image Types 47
Changing/assigning characteristic numbers/program numbers (Retro Fit mode) 47
Information on the use of the MIG/MAG standard manual, TIG, electrode, and ConstantWire
welding processes
49
MIG/MAG standard manual 49
TIG 49
Electrode 49
ConstantWire 49
Arc Break Monitoring 50
Arc break monitoring 50
Fronius Data Channel 52
Fronius Data Channel 52
Signal sequence when selected using "Job Mode" operating mode 53
Signal sequence when selected using "Characteristics Mode" operating mode 54
WireSense - more information 56
Process description WireSense (contour detection) 56
Process description WireSense edge detection (edge detection) 57
Signal curve of Edge Detection Mode on a level surface 58
Signal curve of Edge Detection Mode on a slanted surface 60
Signal curve of Sensing Mode for different surface geometries 62
Signal curve of WireSense break (during Sensing Mode) 64
Representation of the possible measurement range 65
Note on ignition timeout (Ignition Timeout) 66
Available signals for component scanning 67
Signal list 67
Limit Monitoring - functions and activation 68
Functions of Limit Monitoring 68
Available function packages 68
Prerequisites for the successful use of Limit Monitoring 69
Switch Limit Monitoring on / off 69
Detailed description of Limit Monitoring 70
Limit Monitoring - details on the individual welding parameters 71
Voltage monitoring 71
Current monitoring 72
Wirefeeder monitoring 72
Welding time monitoring 73
Energy monitoring 75
4

Setting of the reaction when exceeding or falling below the limits: 76
Setting of the reaction when exceeding or falling below the limits for the motor force 84
Smart Manager + OPT/i Jobs (4,067,002) 89
5
EN-US

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 wirefeeder 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 65,535 Rang
e:
-32,768 to 32,767
0000 -10 (00000000000000
00)
0000 0000 (0*0000000000000
00)
32,767 0 (0111111111111111
)
56 56 (0*00000000011100
0)
65,535 +10 (1111111111111111
)
-64 -64 (1*111111111000000
)
* = if the value entered has a negative
sign, the sign is Bit High – see mark-
ings.
Behavior of the
Power Source
when an Inter-
face is Connec-
ted
If a power source from the TPS/i series is connected to a robot interface, the set-
tings 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.
6

Signal Transmis-
sion Time
TPS/i t
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.
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 equip-
ment and all system components.
7
EN-US

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 re-
porting 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 (Ro-
bot 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 re-
set 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
operating 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 val-
ues and material settings important for welding. This makes creating and sav-
ing 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.
8

Description of special 2-step mode characteristics:
-To select welding parameters using the analog set values and the character-
istic 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 spe-
cial 2-step mode characteristics.
I
I-S I-E
I
SE
GPr GPoSL1 Main current SL2
t
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 welding parameters using the analog set values and the character-
istic 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 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.
9
EN-US

t
II
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
parameter 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 but-
ton 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.
10

-The wire electrode is threaded into the hosepack without current or gas.
-The wirefeeder can be activated independently of the operating mode (in-
ternal parameter 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 Instruc-
tions 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 threading 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).
The signal can be set in two ways:
-Pulse signal = wire electrode moves approx. 1 mm (0.039 inches) 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 com-
pletely or only by a specific length.
-The retraction can be activated independently of the operating mode (intern-
al parameter 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 weld-
ing 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 (0.039 inches) 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.
11
EN-US

Error reset (Re-
set error)
If an error message is output on the power source, the error is reset using the Er-
ror 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.
WARNING!
Danger due to welding processes starting unexpectedly if the Error reset signal
is always active and the Welding start signal is set at the same time.
This can result in severe personal injury and damage to property.
▶Ensure that the Welding start signal is not set during troubleshooting if the
Error reset signal is active at the same time.
Additional information for TWIN systems:
The signal resets the error on both power sources.
Touch sensing
(TouchSensing) -
Single Bit
CAUTION!
Danger from unexpected electric shock.
When Touch sensing is activated, a voltage of approx. 70 V (up to 3 A) is applied
to the wire electrode/gas nozzle.
If touched, a harmless but perceptible electric shock can be transmitted. An in-
voluntary reaction to this shock can cause injuries.
▶Do not touch the wire electrode and the torch body (gas nozzle, contact tip)
when Touch sensing is active.
▶When Teach mode is active, do not touch any electrically conductive parts
that are touched by the wire electrode and the torch body (gas nozzle, con-
tact tip, etc.).
The Touch sensing signal can be used to detect contact between the wire elec-
trode or the gas nozzle and the workpiece = short circuit between workpiece and
wire electrode or gas nozzle.
-If the Touch sensing signal is set, the control panel of the power source dis-
plays touch and a voltage of approx. 70 V (current limited to 3 A) is applied
to the wire electrode/the gas nozzle.
-If a short circuit occurs, this is reported to the robot controller by the Arc
stable signal / Touch signal (see page 30) and Touch signal (see page 36).
-The output of the Arc stable / Touch signals (see page 30) and Touch signal
(see page 36) lasts 0.3 seconds longer than the duration of the short circuit
current.
-As long as the Welding start signal is set, the Touch sensing signal cannot be
activated.
-The welding process can also be started if the TouchSensing signal is active.
This automatically deactivates the touch function.
-TouchSensing can be activated independently of the operating mode (intern-
al parameter selection, special 2-step mode characteristics, Job Mode, etc.).
12

Touch sensing function/process:
t
t
t
U
plus. 300ms * or as long as the wire touches the work piece
I
< 15ms *
t
* timing depends Interface
delta u (rising voltage) --> delta t (time)
Condition: voltage drop i.e. 1,5 volt (adjustable)
max. Open circuit voltage
depends on PowerSource type (i.e. 60V)
max. current aprox. 3A
digital I/O
digital I/O
Touchvoltage
Touchcurrent
Output signal
Input signal
NOTE!
Risk of signal overlap.
This can lead to problems in connection with the Wirebrake option.
▶After deactivating the Touch sensing signal, wait 4 seconds before setting
another signal.
Additional information for TWIN systems:
-Touch sensing is started on both power sources, but is only ever carried out
on one wire electrode.
-In single wire mode, the wire electrode of the active process line is used.
-In TWIN mode, the wire electrode of the leading process line (Lead) is used -
only when the wire electrode of the Lead-power source is touched are the
Touch Sensing signals generated.
13
EN-US

Additional information for Touch sensing with the gas nozzle:
-If the position detection is carried out by touching the workpiece with the
gas nozzle (instead of the wire electrode), the gas nozzle must be connected
to the welding current lead using an RC circuit or the Touch Sensing Adv. op-
tion.
-The use of an RC circuit is required so that if the gas nozzle comes into con-
tact with the workpiece during welding:
-Unacceptable currents in the connection between the gas nozzle and the
welding current lead are avoided.
-The welding process is not influenced.
-When the position is detected by contact with the gas nozzle, the short cir-
cuit current flows until the capacitors of the RC circuit are charged (a few
milliseconds). To ensure safe position detection by the robot controller, the
Arc stable and Touch sensing signals are on for 300 milliseconds longer than
the short circuit current.
Torch blow out
(Blow out weld-
ing torch) -
Single Bit
If the robot wirefeeder is fitted with an additional solenoid valve for compressed
air, this is controlled using the Torch blow out signal.
The signal is used to remove contaminations from the gas nozzle during torch
cleaning.
Welding simula-
tion (Welding
simulation) -
Single Bit
The power source uses the Welding simulation signal to simulate an actual weld-
ing process.
-This allows the user to follow a welding path that has been programmed in
the robot controller without any actual welding taking place.
-All signals are set as if actual welding were taking place (no actual values)
-Process active
-Current flow
-Arc stable
-Robot motion release
-Main current signal.
-No arc is ignited (Welding start signal).
-No wire electrode is moved (Wire forward and Wire backward signal).
-The gas solenoid valve is not triggered ( Gas on signal).
-The gas purging valve is not triggered ( Torch blow out signal).
Synchropulse on
(SynchroPulse
on) - Single Bit
The Synchropulse on signal activates/deactivates the SynchroPulse function set
in the power source. The signal can be set before or during welding.
WireBrake on
(Wire brake on) -
Single Bit
By activating the WireBrake on signal, the wire electrode is held by the OPT/i
MHP WireBrake.
OPT/i MHP WireBrake is a mechanical component that is installed between the
torch hosepack and the torch body.
WireBrake on can be activated independently of the operating mode (internal
parameter selection, special 2-step mode characteristics, Job Mode, etc.).
If OPT/i MHP WireBrake is detected in the system, the WireBrake on signal is
automatically set in Touch sensing.
14

NOTE!
Risk of signal overlap.
This may result in problems holding the wire electrode.
▶It is not recommended to activate any other signals while the WireBrake on
signal is active.
▶After deactivating the WireBrake on signal, wait 4 seconds before activating
another signal.
▶A detailed description of the program sequence can be found in the Robacta
TX 10i/G/W Operating Instructions.
Additional information for TWIN systems:
WireBrake is not available for TWIN hosepacks.
Torchbody
Xchange
(Change torch
body) - Single Bit
The Torchbody Xchange signal is only available in conjunction with a torch body
change system.
If the signal is High,, the torch body coupling is opened.
Torchbody Xchange can be activated independently of the operating mode (in-
ternal parameter selection, S2-step mode characteristics, Job Mode).
NOTE!
Risk of signal overlap.
This may result in problems changing the torch body.
▶It is not recommended to activate any other signals while the Torchbody
Xchange signal is active.
▶After deactivating the Torchbody Xchange signal, wait 3 seconds before ac-
tivating another signal.
▶A detailed description of the program sequence can be found in the Operat-
ing Instructions of the torch body change system.
Teach mode -
Single Bit WARNING!
Danger from electrical current due to Teach mode being active. When Teach
mode is active, a voltage of approx. 70 V (up to 3 A) is applied to the wire elec-
trode/contact tip.
This may result in serious injuries or death.
▶Do not touch the wire electrode and the contact tip when Teach mode is act-
ive.
▶When Teach mode is active, do not touch any electrically conductive parts
that are touched by the wire electrode or the contact tip.
Teach mode can be used to create the robot program. Teach mode being activ-
ated (signal High) avoids the wire electrode becoming bent when setting up the
robot.
Teach mode can be activated independently of the operating mode (internal
parameter selection, special 2-step mode characteristics, Job Mode, etc.).
Teach mode function:
15
EN-US

= 15 mm
(0.59 inch)
-Ensure the desired distance (Stickout) to the
workpiece (cut the wire electrode to the cor-
rect Stickout , etc.).
< 15 mm
(0.59 inch)
-If the distance between the gas nozzle and
the workpiece becomes smaller during robot
movement, the wirefeeder retracts the wire
electrode – this means that the wire elec-
trode cannot be bent.
-If the distance between the gas nozzle and
the workpiece becomes bigger during robot
movement, the wirefeeder unwinds the wire
electrode to the set Stickout .
= 15 mm= 5 mm= 5 mm= 5
(0.59 inch)
mm
-The wire electrode will not be unwound any
further once the set Stickout-value has been
reached, even if the wire electrode is no
longer in contact with the workpiece.
The Touch signal is set as follows when using Teach mode:
-As soon as the wire electrode touches the workpiece, the Touch signal is set
to High.
-Only when the wire electrode is no longer in contact with the workpiece is
the Touch signal set to Low.
NOTE!
Danger from using Teach mode in conjunction with very soft wire electrodes.
This may result in unexpected welding results caused by bent wire electrodes.
▶Using Teach mode with very soft wire electrodes may result in the wire elec-
trodes becoming bent. To prevent wire burn-back caused by the bent wire
electrode, unwind the wire electrode by approx. 50 mm (1.97 inch) before the
start of welding and shorten it.
Additional information for TWIN systems:
-In single wire mode, Teach mode is activated for the active process line.
-In TWIN mode, Teach mode is activated for both process lines
-The scanning frequency of the wire electrode at a component contact
with the Lead-power source is higher than the scanning frequency with
the Trail-power source.
ExtInput 1-8
(External input
1-8) - Single Bit
Inputs used to control options, such as OPT/i RI FB REL.
-Max. voltage = DC 113 V / AC 68 V
-Max. current load 1 A
Example outputs: ExtInput1 = OPT_Output 1.
16

The inputs have no effect on other signals (for example Robot ready, etc.)
OPT/i RI
FB REL
(1)
External
Device
(2) (3)
(1) Robot output
(2) Power source input
(3) Options output
Additional information for TWIN systems:
-TWIN systems are only compatible with the OPT/i RI FB REL EXT 8I/8O op-
tion.
-The signals are forwarded to both power sources and are then available at
the outputs of the relay station used.
Job number
(Job‑number) -
Group Input
This signal is used to carry out welding using the welding parameters that are
saved under the selected job number (1-1000).
Job number 0 can be used to select the job on the control panel of the power
source.
Additional information for TWIN systems:
Job numbers must be selected separately for both power sources.
Welding charac-
teristic (Charac-
teristic number)
- Group Input
This signal is used to specify the welding process using the characteristic num-
ber.
Characteristic number 0 can be used to select the material setting and the weld-
ing process on the control panel of the power source.
Examples of characteristic numbers:
-2765 = G3Si1 / 1.2 mm / Ar 15-20%, CO2 / LSC
-3189 = G3Si1 / 1.2 mm / Ar 15-20%, CO2 / PMC
Additional information for TWIN systems:
Characteristic numbers must be selected separately for both power sources.
17
EN-US

Disable process
control (Deactiv-
ate process-de-
pendent correc-
tion) - Group In-
put
If this signal is active, a process-dependent correction (Process controlled cor-
rection signal) can be manually selected on the power source.
Additional information for TWIN systems:
Process-dependent corrections must be activated separately for both power
sources.
Processline se-
lect (Process line
selection) -
Group Input
This signal is used to select the desired process line.
The signal is only available if:
-The OPT/i TPS Dual Head Robotics option is present in the power source.
-Each process line has its own wirefeeder.
Bit 1 Bit 0 Description
0 0 Wirefeeder 1 (factory setting)
0 1 Wirefeeder 2
1 0 Wirefeeder 3
Function information:
-It is only possible to switch between the process lines using the robot.
-The inactive wirefeeders are only supplied with voltage, the system bus is
switched off. This has the following limitations:
-Available software updates will only be applied to the wirefeeder if the
wirefeeder is part of the process line selected.
-The CAT signal of inactive wirefeeders is not evaluated.
-It is not possible to carry out gas tests, wire threading, wire retraction,
etc. on the hosepacks of the inactive process lines.
-The welding torch identification of hosepacks of the inactive process
lines is not read.
-The remote controls of the inactive process lines are also inactive.
TWIN mode
(TWIN operating
mode) - Group
Input
This signal defines which TWIN mode will be used to operate the respective
power source.
The following can be specified using the signal:
-Single wire / or TWIN welding.
-Which process line is leading during TWIN welding (Lead).
-Which process line is active during single wire welding.
The operating modes can be changed both before and during welding.
Bit 32 Bit 33 Description
0 0 Single wire mode, line 1
0 1 TWIN mode, line 1 leading (Lead)
1 0 TWIN mode, line 2 leading (Lead)
1 1 Single wire mode, line 2
Value range for TWIN mode
18

Contact tip short
circuit detection
on (contact tip
short circuit de-
tection on) -
Single Bit
If this signal is set to High, a short circuit check between the two contact tips in
the TWIN welding torch starts.
-If a short circuit is detected, the signal Short circuit contact tip is set high.
This signal is only available for TWIN systems operating in TWIN mode (not avail-
able for single wire operation).
Documentation
mode (Docu-
mentation mode)
- Single Bit
The signal is used to select whether the weld seams are counted by the power
source or the robot.
Signal level = Low:
-The weld seams are counted by the power source.
-Each time welding is completed, the weld seam count increases by 1. Switch-
ing the power source off and on again restarts the count at 0. In addition, it
is also possible to specify an initial value (starting the count at 10 instead of
0, for example).
-With the exception of: If the Fronius Data Channel is used, the number
of weld seams is specified using the Fronius Data Channel and not the
power source.
Signal level = High:
-The number of weld seams is specified using the robot.
WireSense start
- Single Bit WARNING!
Danger from electrical current. When the WireSense start signal is active, a
voltage of approx. 50 V (up to 1 A) is applied to the wire electrode/contact tip.
This may result in serious injuries or death.
▶Do not touch the wire electrode and contact tip when the WireSense start
signal is active.
▶Do not touch any electrically conductive parts that are touched by the wire
electrode or the contact tip when the WireSense start signal is active.
This signal starts one of the following two functions:
1.Function WireSense - Sensing Mode (= contour detection): Used for scan-
ning the component surface / component geometry
-This function is active when the Signal WireSense start is activated and a
height value less than 0.5 mm (0.019 inches) is specified for the Wire-
Sense edge detection signal.
-Edge detection (WireSense - Edge Detection Mode function) is not active
with this function.
-The Touch signal is not output for this function.
2.WireSense - Edge Detection Mode function (= edge detection): Used to de-
tect a single edge
-This function is active when the Signal WireSense start is activated and a
height value greater than / equal to 0.5 mm (0.019 inches) is specified
for the WireSense edge detection signal.
-For more information, see WireSense edge detection - Group Input /
Analog Input on page 24.
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EN-US

Other effects of the WireSense start signal:
-As soon as the signal is active, the forward and backward movement of the
wire electrode begins.
-After the wire electrode has touched the workpiece for the first time, the
point of the first contact is used as a zero position (reference point) for the
WireSense height measurement.
Safety functions with WireSense:
-If WireSense is already active (WireSense process already running), the wire
electrode can be conveyed a maximum of 25 mm (0.98 inches). If there is no
workpiece contact within 25 mm (0.98 inches), wirefeeding is stopped.
-If WireSense is started for the first time (without previous workpiece con-
tact), the wire electrode can be conveyed a maximum of 450 mm (17.72
inches). If there is no workpiece contact within 450 mm (17.72 inches),
wirefeeding is stopped.
For more information on WireSense, see section WireSense - more information
from page 56.
Additional information for TWIN systems:
-In single wire mode, WireSense is only activated and evaluated for the active
process line.
-In TWIN mode, WireSense is activated for both process lines. Please note
the following:
-The Touch signal, which can be output at the WireSense edge detection,
is only triggered by the Lead-power source.
-The position signals during contour detection(WireSense - Sensing
Mode) are output at the interface with two individual output signals sim-
ultaneously - with the Signal Wire position for power source 1 and power
source 2.
WireSense break
- Single Bit
-This signal only has an impact if the WireSense start signal is active at the
same time.
-This signal is used to interrupt the WireSense process but at the same time
to obtain the reference point that was determined when the WireSense pro-
cess was first started.
-The WireSense break signal stops the wire movement while the Wire-
Sense start signal is active - for example, to bridge larger distances
between two workpieces (if the wire electrode is touching a workpiece
while the WireSense break signal is active, the wire electrode is still re-
tracted to prevent bending).
-The reference point, which was determined when the WireSense process
was first started, remains stored while the WireSense break signal is act-
ive.
-After the WireSense break signal is deactivated, the wire movement
starts again and the height measurement continues.
-When the WireSense break signal is set, the Arc stable signal is disabled at
the same time. As soon as the WireSense break signal is deactivated again,
the Arc stable signal is reactivated.
For more information on WireSense, see section WireSense - more information
from page 56.
Additional information for TWIN systems:
-In single-wire operation, WireSense break nur die Drahtelektrode der aktiven
Prozesslinie stops.
-In TWIN mode, WireSense break beide Drahtelektroden stops.
20