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
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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
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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.
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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.
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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.
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