Kemppi A3 Quick setup guide

1920870
R01
A7 MIG WelderA3 MIG Welder
EN
INTEGRATION GUIDE

2A3 MIG Welder© Kemppi Oy 2020 R01
CONTENTS
1. Introduction..........................................................................................3
2. Integration step by step...................................................................3
3. Hardware installation ........................................................................4
3.1 Procedures before use ..............................................................................4
3.2 System overview .......................................................................................4
3.3 Power source .............................................................................................5
3.4 Wire feeder ................................................................................................6
3.5 Collision sensor .........................................................................................7
3.6 Interconnection cable set .........................................................................7
3.6.1 Wire feeder control cable .........................................................................7
3.6.2 Welding cable........................................................................................8
3.6.3 Shielding gas hose..................................................................................8
3.7 Fieldbus communication ..........................................................................8
3.8 Safety stop.................................................................................................8
4. System configuration ........................................................................9
4.1 Congure sensors and devices .................................................................9
4.2 Congure DeviceNet eldbus.................................................................10
4.3 Power up the system...............................................................................11
4.4 Congure welding cable compensation ................................................11
4.5 Congure robot scaling value.................................................................11
5. Digital robot interface.....................................................................12
5.1 Control functions ....................................................................................12
5.1.1 WireFeedSpeed....................................................................................12
5.1.2 Voltage...............................................................................................12
5.1.3 FineTuning ..........................................................................................13
5.1.4 MemoryChannel ..................................................................................13
5.1.5 SimulationMode...................................................................................13
5.1.6 StartWelding .......................................................................................13
5.1.7 WireInch .............................................................................................13
5.1.8 WireRetract .........................................................................................14
5.1.9 GasBlow .............................................................................................14
5.1.10TouchSensorToolSel..............................................................................14
5.1.11TouchSensorOn....................................................................................14
5.1.12OnlineControl......................................................................................14
5.1.13Watchdog ...........................................................................................14
5.1.14ErrorReset ...........................................................................................14
5.2 Status functions.......................................................................................15
5.2.1 WeldingCurrent....................................................................................15
5.2.2 WeldingVoltage ...................................................................................15
5.2.3 ErrorNumber .......................................................................................16
5.2.4 Ready.................................................................................................16
5.2.5 PowerSourceReady...............................................................................16
5.2.6 CycleOn..............................................................................................16
5.2.7 ArcOn.................................................................................................16
5.2.8 TouchSensed .......................................................................................16
5.2.9 Error...................................................................................................16
5.2.10CollisionDetected.................................................................................16
5.3 I/O table...................................................................................................17
5.4 Timing diagrams .....................................................................................17
5.4.1 Welding startup timing..........................................................................17
5.4.2 Welding stop timing .............................................................................17
5.4.3 Memory channel change timing..............................................................18
5.4.4 Online control timing............................................................................19
5.4.5 Wire inch and retract timing ...................................................................20
5.4.6 Touch sensor timing..............................................................................20
5.4.7 Safety stop response timing ...................................................................21
INTEGRATION GUIDE

3A3 MIG Welder© Kemppi Oy 2020 R01
INTEGRATION GUIDE
1. INTRODUCTION
The A3 MIG Welder is a complete welding system for robotic welding applications.
This guide, together with the A3 MIG Welder operating manual, instructs you on how to
set up the system and perform the necessary cable connections and setup conguration
to get the system running.
Important notes
Items in the manual that require particular attention for minimizing damage and harm
are indicated with the symbols below. Read these sections carefully, and follow their
instructions.
Note: A note item gives the user a useful piece of information.
Caution: Caution items describe a situation that may result in damage to the equipment
or system.
Warning: Warnings describe a potentially dangerous situation. If not avoided, it will
result in personal harm or fatal injury.
Disclaimer
While every eort has been made to ensure that the information contained in this guide
is accurate and complete, no liability can be accepted for any errors or omissions. Kemppi
reserves the right to change the specication of the product described, at any time,
without notice. Do not copy, record, reproduce, or transmit the contents of this guide
without prior permission from Kemppi.
2. INTEGRATION STEP BY STEP
To ensure safe and ecient integration of the welding system, follow these simple
steps:
1. INSTALL HARDWARE
• Make sure that all the components are OK.
• Attach all required equipment to the robot and to the
welding cell.
• Make all required cable connections.
2. CONFIGURE THE SYSTEM
• Congure the sensors and devices.
• Congure the eldbus.
• Power up the system.
• Congure the power source.
After completion of these steps, the system is ready for welding.
For detailed instructions on each of the steps, consult the corresponding section of
this document.

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3. HARDWARE INSTALLATION
3.1 Procedures before use
The product is packed in specially designed transport
cartons. Unpack the products from the cartons, and check
that they have not been damaged during transportation.
Check that the contents are complete, and nothing is
missing.
The product’s packaging material is recyclable.
When moving the welding machine, never pull it by the
welding-gun or other cables. For lifting the power source,
use the handles on top of the power source.
After installation, make sure all cables and hoses have
enough space to move and are attached properly.
Remember that the cable, plugs, and other electrical
devices may be installed or replaced only by a person
authorized to perform such operations.
3.2 System overview
Fieldbus
Figure 3.1: Connection diagram

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INTEGRATION GUIDE
3.3 Power source
Place the machine on a sturdy, level surface that is dry and will not allow dust or other
impurities to enter the machine´s cooling air ow. Preferably, situate the machine in a
suitable carriage unit so that it is above oor level.
• The surface inclination may not exceed 15 degrees.
• Ensure the free circulation of cooling air. There must be at least 20 cm of free
space in front of and behind the machine for cooling-air circulation.
• Protect the machine against heavy rain and direct sunshine.
Do not operate the machine in the rain.
Never aim the spray of sparks from a grinding machine toward the equipment.
Distribution network
All regular electrical devices without special circuits generate harmonic currents into
distribution network. High rates of harmonic current may cause losses and disturbance
to some equipment.
This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc
is greater than or equal to 4.7 MVA at the interface point between the user’s supply and
the public supply network. It is the responsibility of the installer or user of the equipment
to ensure, by consultation with the distribution network operator if necessary, that the
equipment is connected only to a supply with a short-circuit power Ssc greater than or
equal to 4.7 MVA.
Connecting the power source to the electric network
The A3 Power Source is connected to a 400-V three-phase network. The fuse size for 100%
load in a 400-V three-phase network with 4 x 6-mm² cable is 35 A delayed.
The machine is equipped with a ve-meter mains cable that comes without a plug. Before
use, check the mains cable and install a mains plug. If the cable does not comply with the
local electrical regulations, replace it with a compliant cable.
The mains cable or plug may be installed or replaced by only an electrical contractor or
installer authorised to perform such operations.
The power plug
The power source comes without a plug for connection to the electrical grid. Attach a
plug suitable for your power-supply standard to the power cable. Check the connections,
attach the plug to a socket, and switch the electrical power on from the welding power
source to verify that the machine works properly.
Switch the machine o and unplug it from the power socket before continuing to
further steps in the hardware installation.
If local or national regulations specify that an alternative power cable is required, the
cable must be replaced in conformity with the regulations. Connection and installation of the
power cable and plug should be carried out only by a suitably qualied person.
If changing the power cable, take the following facts into consideration:
• The cable enters the machine through the inlet ring on the rear panel and is
fastened in place with a cable clamp (05). The cover plate of the power source
must be removed to access the electrical cable connector.
• The phase conductors of the cable are coupled to connectors L1, L2, and L3.
• The protective ground line, colored green and yellow, is coupled to the marked
connector.
• If you are using ve-lead cable, do not connect the neutral conductor.
05
*
L3
L2
L1
*In S-type cables there is a protective grounding conductor, green-and-yellow striped.

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INTEGRATION GUIDE
3.4 Wire feeder
Use a mounting bracket to mount the wire feeder securely
on the robot arm. See the illustrated instructions included
in the product delivery package.
The wire feeder connections are described in the Sub-
section 3.6, “Interconnection cable set”.
Filler wire
Connect the wire liner to the ller wire inlet on the
rear of the wire feeder. Connect the other end of the
wire liner to the wire drum or spool and run the wire
up to the wire feeder either manually or by using wire
inch functionality at the wire drum.
Peripheral connector
For a collision sensor and the touch sensor, the wire feeder
has a common 7-pin peripheral connector at the front of
the wire feeder. The connections of the peripherals are
described later in this document.
Figure 3.3: Peripheral connector pinout
A. Collision sensor (+50 V)
B. Collision sensor signal
C. Touch sensor output for gas nozzle (+50…+200 V)
D. (Not connected)
E. (Not connected)
F. (Not connected)
G. (Not connected)
Table 3.1: Electrical characteristics for the peripheral supplies
Value Min. Typical Max. Unit
Supply voltage 36.0 48.0 70 V
Touch sensor output voltage*50 200 V
Touch sensor output current** 10 mA
*Touch sensor electrical characteristics are found in the A3 MIG Welder Operating manual.
** This is the short circuit current.

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INTEGRATION GUIDE
3.5 Collision sensor
The collision sensor is an external device that protects
the torch neck from bending and being damaged. It is
integrated into the mount between the robot arm and the
welding torch. The sensor sends a signal to the robot to
stop welding when a collision is detected at the welding
head.
Not all robot mounts feature a collision sensor. See the
manual of the robot mount for more information.
The welder system supports two types of collision
sensors, an opening-action switch sensor and a closing-
action switch sensor. The opening-action switch keeps
the relevant electrical circuit normally closed and opens
it on a collision, whereas the closing-action switch keeps
the electrical circuit normally open and closes it upon
a collision (see Figure 3.4, “Opening and closing action
switches”)
Figure 3.4: Opening-action (left) and closing-action (right)
switches
The switch type is congured by using the DIP switches.
See the Section 4,“System conguration” for details.
Connect the collision sensor to pins A and B of the
peripheral connector (see Figure 3.5, “Collision sensor
connection”).
A
B
Figure 3.9: Collision sensor connection
3.6 Interconnection cable set
The interconnection cable set comprises several cables
and hoses wrapped in a plastic spiral sleeve. The cable set
is used for delivering the welding power, shielding gas,
and control signals from the welding power source to the
wire feeder.
A B
C
Figure 3.6: Interconnection cable set (wire feeder end)
A. Welding power cable
B. Wire feeder control cable
C. Shielding gas hose
3.6.1 Wire feeder control cable
The wire feeder control cable provides power to the wire
feeder and transmits the control signals between the wire
feeder and the welding power source. It also contains the
touch sensor voltage line from the power source to the
wire feeder.
A
B
C
G
F
I
J
H
DE
Figure 3.7: Wire feeder control cable connector pinout
A. Power supply (+50 V)
B. Collision sensor
C. Touch sensor voltage (+50…+200 V)
D. Gas valve
E. Wire inch
F. Motor +
G. Motor –
H. Encoder +5V
I. Encoder GND
J. Encoder signal

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INTEGRATION GUIDE
At the wire feeder, make the connection to the
control cable connector.
At the power source, connect the cable to the
control cable connector at the rear of the power
source unit.
3.6.2 Welding cable
The welding cable delivers welding power from the power
source to the welding head.
At the wire feeder, connect the cable to the screw
terminal on the front of the unit.
At the power source, connect the cable to the (+)
connector at the rear of the power source unit.
3.6.3 Shielding gas hose
The shielding gas hose delivers the shielding gas to the
wire feeder. The wire feeder is equipped with a gas valve.
At the wire feeder, connect the hose to the shielding
gas snap connector.
Connect the other end of the hose to the shielding
gas supply.
3.7 Fieldbus communication
This welding system supports DeviceNet communication
Table 3.2: Kemppi Oy vendor ID and device description le
for the DeviceNet
Fieldbus Vendor ID Device description le
DeviceNet 1403 (integer) EDS
(Electronic Data Sheet)
The DeviceNet is wired into the 7-pin machine connector
located at the rear of the welding power source. It shares
the connector with a safety stop function (see Figure 3.8,
“Fieldbus connector pinout”).
Figure 3.8: Fieldbus connector pinout
Devicenet – Amphenol
1. D DeviceNet V- (GND)
2. C DeviceNet CAN_L
3. G DeviceNet Drain (Shield)
4. F DeviceNet CAN_H
5. E DeviceNet V+ (+24V)
Safety – Amphenol
1. A Safety stop signal
2. B Safety stop GND
The eldbus connector is clocked to avoid confusion
with other 7-pin connectors in the power source.
3.8 Safety stop
The safety stop is an input signal that halts the system
when the operator presses an emergency stop button.
The input is galvanically isolated from the other hardware
I/O of the welding power source. The signal shares the
same connector with the DeviceNet (see the Figure 3.8,
“Fieldbus connector pinout”).
The safety stop is congured by using the DIP switches.
A
B
Safety switch
Figure 3.9: Connecting safety stop switch

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4. SYSTEM CONFIGURATION
This section describes the settings that are typically
made once or that are otherwise necessary for integration
to be completed successfully. It does not describe those
settings that aect welding quality and are modied based
on the welding operation. For more information on the
operation-based settings, see the A3 MIG Welder Operating
manual.
Use the control panel and the DIP switches to perform
the system conguration within the integration.
4.1 Configure sensors and devices
Touch sensor output voltage
Use the DIP switches to set the touch sensing voltage
between +50…+200V. Change the value during operation
dependingon the work piecesurfaceproperties,if needed.
P2 switches 1-2 Voltage
ON
12345678
50 V
(default)
ON
12345678
80 V
ON
12345678
110 V
ON
12345678
200 V
Safety stop on/o
Use the DIP switches to set the emergency stop input on
and o. If you have installed an emergency stop switch
circuit for the system, set the emergency input to be on
accordingly. Otherwise, ensure that these parameters are
set to o to prevent possible false detection.
P2 switch 3 Safety stop
ON
12345678
Disabled (default)
ON
12345678
Enabled
Collision sensor on/o
Use the DIP switches to set the collision sensor on and o.
If you haven’t got a collision sensor installed in the system,
turn the sensor o to prevent possible false detections.
P2 switch 4 Collision sensor
ON
12345678
Disabled (default)
ON
12345678
Enabled
Collision sensor switch type
Use the DIP switches to select the switching type of
the collision sensor. The switch can be either opening
or closing. See Figure 3.4, “Opening and closing action
switches”.
P2 switch 5 Switch type
ON
12345678
Opening (default)
ON
12345678
Closing
Byte order
Use the DIP switches to select the byte order according to
the robot type.
P2 switch 6 Byte order
ON
12345678
Little-endian (default)
ON
12345678
Big-endian

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Watchdog on/o
Use the DIP switches to set the watchdog on and o. The
robot must support the watchdog feature.
P2 switch 6 Byte order
ON
12345678
Little-endian (default)
ON
12345678
Big-endian
4.2 Configure DeviceNet fieldbus
Baud rate
Use the DIP switches to select the baud rate of the eldbus
communication according to the capability of the robot
P1 switches 1-2 Baud rate
ON
12345678
125 kpbs
(default)
ON
12345678
250 kpbs
ON
12345678
500 kpbs
ON
12345678
(Reserved)
Mac ID
Use the DIP switches to select the Mac ID (slave address) to
be used in the communication with the robot.
P1 switches 3-8 Mac ID
ON
12345678
0 (default)
ON
12345678
1
ON
12345678
2
ON
12345678
3
...
ON
12345678
60
ON
12345678
61
ON
12345678
62
ON
12345678
63

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4.3 Power up the system
After setting up everything using the DIP switches, power
up the system for proceeding in the setup.
Enter to the setup menu in the control panel to congure
the power source.
4.4 Configure welding cable
compensation
Adjust the CAL parameter in the setup menu to set the
welding cable compensation. Set the cable compensation
for voltage losses in the welding cables.
4.5 Configure robot scaling value
The A3 MIG Welder supports value scaling between the
welding system and the robot for wire feed speed, welding
voltage, ne tuning, and welding current. This scaling is
required when the value range of the robot is limited, or
the robot cannot otherwise directly handle the values
provided by the welding system.
The following digital robot interface functions can be
scaled:
• WireFeedSpeed control function
• Voltage control function
• FineTuning control function
• WeldingVoltage status function
• WeldingCurrent status function
For more information on these functions, see Chapter 5,
”Digital robot interface”.
Adjust the sca parameter in the setup menu to set the
scaling value. Set the value 0 to turn the scaling o.
Scaling formula
The scaling uses the formula
ValueTARGET =
ScaleValue × ValueSOURCE
ValueMAX
where ValueMAX is the maximum value and ValueSOURCE is the
setup value.
The actual result of the setup value can be calculated by
using an inverted formula:
ValueSOURCE =
ValueMAX × ValueTARGET
ScaleValue
The division is performed in the digital robot interface
by using integers multiplied by 10. This results in accuracy of
one decimal digit, thus the calculation loses less signicant
digits and produces nal values which may not exactly
match with the target values.
Example
By means of its specication one robot uses the value
range 0-1023 for adjusting the welding voltage. The
voltage range in the welding system is 10.0-48.0 V. The
operator of the robot wants to use robot’s full value range
to achieve the best accuracy of the voltage control, thus
the voltage scaling value should be congured to be the
maximum value of the robot’s range (1023).
When the operator wants to use the welding voltage of
25 V, the robot control value is calculated thus:
ValueTARGET =
ScaleValue × ValueSOURCE
ValueMAX
= ≈ 532
1023 × 25.0
48.0
The actual voltage can be calculated by using the inverted
formula:
ValueSOURCE =
ValueMAX × ValueTARGET
ScaleValue
= ≈ 24.962
48.0 × 532
1023
Conclusion: The operator uses the control value 532 to
achieve the welding voltage of 25 V. The actual welding
voltage achieved by using this value is 24.9 V (the less
signicant digits are lost).

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5. DIGITAL ROBOT INTERFACE
5.1 Control functions
The control functions are bit elds (values) and single bits
(signals) in the I/O table. They are set by a robot and read
by the welding system.
Table 6.1: Control functions in the A7 MIG Welder system
Function Bits
Value range
Min. Max. Units
Control values
WireFeedSpeed 16 10 250 0.1 m/min
Voltage 16 100 480 0.1 V
FineTuning 16 0 100 0.1
MemoryChannel 8 0 89 1
Control signals
SimulationMode 1
StartWelding 1
WireInch 1
WireRetract 1
GasBlow 1
TouchSensorToolSel 1
TouchSensorOn 1
OnlineControl 1
Watchdog 1
ErrorReset 1
5.1.1 WireFeedSpeed
This 16-bit function controls the wire feed speed during
welding. The value is given in scaled or non-scaled mode,
depending on the user setup.
In non-scaled mode:
• The minimum setup value is 10 (1.0 m/min).
• The maximum setup value is 250 (25.0 m/min).
• The minimum step is 1 (0.1 m/min).
In scaled mode:
• The minimum setup value is 0 (0.0 m/min).
With this value, the welding system limits the
minimum speed to 1.0 m/min.
• The maximum setup value is the robot scaling
value, which is interpreted as 25.0 m/min.
• The minimum step is 1. The wire feed speed value
is calculated from the setup value by means of
the value scaling formula.
This value has an eect only when the OnlineControl
signal is set (1), and it overrides the corresponding memory
channel value. If the OnlineControl signal is cleared (0), the
wire feed speed from the active memory channel is used.
5.1.2 Voltage
This 16-bit function controls the welding voltage for the
MIG process. For other processes, the FineTuning function
is used instead. The value is given in scaled or non-scaled
mode, depending on the user setup.
In non-scaled mode:
• The minimum setup value is 100 (10.0 V).
• The maximum setup value is 480 (48.0 V).
• The minimum step is 1 (0.1 V).
In scaled mode:
• The minimum setup value is 0 (0.0 V). With this
value, the welding system limits the minimum
voltage to 10.0 V.
• The maximum setup value is the robot scaling
value, which is interpreted as 48.0 V.
• The minimum step is 1. The voltage is calculated
from the setup value by means of the value
scaling formula.
The value has an eect only when the OnlineControl
signal is set (1), and it overrides the corresponding memory
channel value. If the OnlineControl signal is cleared (0), the
value from the active memory channel is used.

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5.1.3 FineTuning
This 16-bit function controls the ne tuning of the synergic
voltage for all processes except the MIG process. For the
MIG process the Voltage value is used instead. The value
is given in scaled or non-scaled mode, depending on
the user setup. The ne tuning is scaled using the robot
scaling value. The range of the ne-tuning value depends
on the selected process.
In non-scaled mode, 1-MIG process:
• The minimum setup value is 0 (-9.0).
• The maximum setup value is 180 (9.0).
• The minimum technical step is 1 (0.1).
• The minimum signicant step is 5 (0.5).
In non-scaled mode, WiseRoot and WiseThin processes:
• The minimum setup value is 0 (-5.0).
• The maximum setup value is 100 (5.0).
• The minimum technical step is 1 (0.1).
• The minimum signicant step is 5 (0.5).
In scaled mode, 1-MIG process:
• The minimum setup value is 0 (-9.0).
• The maximum setup value is the robot scaling
value, which is interpreted as 9.0.
• The minimum step is 1. The ne tuning is
calculated from the setup value by means of the
value scaling formula.
In scaled mode, WiseRoot and WiseThin processes:
• The minimum setup value is 0 (-5.0).
• The maximum setup value is the robot scaling
value, which is interpreted as 5.0.
• The minimum step is 1. The ne tuning is
calculated from the setup value by means of the
value scaling formula
The value has an eect only when the OnlineControl
signal is set (1), and it overrides the corresponding memory
channel value. If the OnlineControl signal is cleared (0), the
ne tuning from the active memory channel is used.
5.1.4 MemoryChannel
This 8-bit function controls the active memory channel.
The system automatically brings all parameters from the
memory channel into use, including those for the welding
process, welding parameters, and welding functions.
There are up to 90 memory channels available in the
system. They are numbered 0 to 89. The memory channel
can be changed during welding.
• The minimum setup value is 0.
• The maximum setup value is 89. All values above
that are automatically interpreted as 89.
• The minimum step is 1.
5.1.5 SimulationMode
This signal function turns the simulation mode on and o.
In the simulation mode ArcOn, CycleOn, and the other
necessary signals are simulated locally to enable the
welding robot to act as in a normal welding operation.
Welding power remains o and wire is not fed during
simulation. The simulation mode is not allowed during
welding, so changing this signal during welding (or
simulation) has no eect.
• 0 = Simulation mode o. The StartWelding
function controls a normal welding sequence.
• 1 = Simulation mode on. The StartWelding
function controls a simulation sequence.
5.1.6 StartWelding
This signal function controls the welding sequence. If the
SimulationMode is set to be on, it controls a simulation
sequence instead.
• 0 = Welding / simulation o
• 1 = Welding / simulation on
5.1.7 WireInch
This signal function feeds the welding wire forwards. The
wire is fed at the speed of 1.0 m/min for 3 seconds and
then stepped to 5.0 m/min.
• 0 = Wire inch o
• 1 = Wire inch on
This signal has no eect during welding or simulated
welding.

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5.1.8 WireRetract
This signal function feeds the welding wire backwards.
The wire is fed at the speed of 1.0 m/min for 3 seconds
and then stepped to 5.0 m/min.
• 0 = Wire retract o
• 1 = Wire retract on
This signal has no eect during welding or simulated
welding.
5.1.9 GasBlow
This signal function opens the shielding gas valve. The gas
valve can be controlled during welding, but not during
simulated welding.
• 0 = Gas valve closed
• 1 = Gas valve open
5.1.10 TouchSensorToolSel
This signal function sets the selection of the touch sensing
tool between the welding wire and the gas nozzle.
• 0 = Welding wire as touch sensing tool
• 1 = Gas nozzle as touch sensing tool
5.1.11 TouchSensorOn
This signal function sets the touch sensor power source
and the touch detection device to be on.The touch voltage
depends on the conguration. For more information, see
A3 MIG Welder Operating manual.
• 0 = Touch sensor o
• 1 = Touch sensor on
This signal has no eect during welding or simulated
welding.
5.1.12 OnlineControl
This signal function enables robot-controlled values for
welding wire feed speed, voltage, and ne tuning. When
the robot is in online mode and uses the WireFeedSpeed,
Voltage, and FineTuning control functions, the corre-
sponding values in the active memory channel are over-
ridden. When the robot is in oine mode, it gives full con-
trol to the welding system and the values from the active
memory channel are used.
• 0 = Robot in oine mode. The wire feed speed,
voltage, and ne-tuning values are obtained from
the active memory channel.
• 1 = Robot in online mode and controlling the
wire feed speed, voltage, and ne tuning.
5.1.13 Watchdog
This signal function resets a watchdog timer in the robot
interface unit on each transition. The signal takes eect
when the watchdog function is turned on from the DIP
switches. If the watchdog functionality is on and the robot
can’t maintain transitioning of this signal, the welding
system goes into an error state. This prevents welding
accidents if the robot loses control over the welding
system.
5.1.14 ErrorReset
This signal function resets the ErrorNumber value and the
Error signal to zero on the rising edge of the signal when
there are no active errors in the system. If there are any
active errors, the signal has no eect. The error is active
when the error situation is not yet resolved.
• 0 = Normal operation
• 1 = Error reset (on rising edge)

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5.2 Status functions
The status functions are bit elds (values) and single bits
(signals) in the I/O table.They are set by the welder system
and read by the robot.
Table 5.2 Status functions in the A3 MIG Welder system
Function Bits
Value range
Min. Max. Step Units
Status values
WeldingCurrent 16 0 1000 1 1 A
WeldingVoltage 16 0 1000 1 0.1 V
ErrorNumber 8 0 255 1
Status signals
Ready 1
PowerSourceReady 1
CycleOn 1
ArcOn 1
TouchSensed 1
Error 1
CollisionDetected 1
5.2.1 WeldingCurrent
This 16-bit function represents the average welding
current measured during the process. The value is in
scaled or non-scaled mode, depending on the user setup.
In non-scaled mode:
• The minimum value is 0 A.
• The maximum value is 1000 A.
• The minimum step is 1 A.
In scaled mode:
• The minimum value is 0 (0 A).
• The maximum value is the robot scaling value,
which is interpreted as 1000 A.
• The minimum step is 1. The welding current is
calculated from the function value by means of
the value scaling formula.
5.2.2 WeldingVoltage
This 16-bit function represents the average welding
voltage measured during the process. The value is in
scaled or non-scaled mode, depending on the user setup.
In non-scaled mode:
• The minimum value is 0 (0.0 V).
• The maximum value is 1000 (100.0 V).
• The minimum step is 1 (0.1 V).
In scaled mode:
• The minimum value depends on the scaled value
range and is interpreted as 0.0 V.
• The maximum value is the robot scaling value,
which is interpreted as 100.0 V.
• The minimum step is 1. The welding voltage is
calculated from the function value by means of
the value scaling formula.

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5.2.3 ErrorNumber
This 8-bit function represents a non-zero error code if there
is a warning or an error active in the system. Otherwise
the value is zero. The error number is an enumeration that
represents the reason for the error. Refer to the A3 MIG
Welder operating manual for more information about
reasons for errors. See also the description for the Error
status signal. To clear this value, one must resolve the
error situation and reset the error by using the ErrorReset
control signal or from a user interface.
• The minimum value is 0 (no error).
• The maximum value is 255.
• The minimum step is 1.
5.2.4 Ready
This signal function indicates readiness of the welding
system. The main power supply must be turned on, the
system software booted up, the system bus properly
connected, and there are no active errors in the system.
• 0 = Welding system not ready.
• 1 = Welding system ready
5.2.5 PowerSourceReady
This signal function indicates the status of the power
source. The power source is ready to start welding when it
is not currently in use, when the robot has not requested
welding start and when crater ll is not active.
• 0 = Power source not ready yet for a new arc start
• 1 = Power source ready
5.2.6 CycleOn
This signal function indicates the status of the welding
cycle. The welding cycle starts at the beginning of the
pre-gas phase and ends at the end of the post-gas phase.
The signal indicates to the robot when it is safe to move
to the next position. However, the welding cycle does not
prevent starting of a new weld – a weld can be started
during the post-gas time.
• 0 = Welding cycle not active
• 1 = Welding cycle in progress
5.2.7 ArcOn
This signal function indicates the status of the welding arc.
• 0 = Arc not established
• 1 = Arc established
5.2.8 TouchSensed
This signal function indicates contact between the touch
tool and the welding piece. This feature is enabled and
disabled by the TouchSensorOn signal. The touch tool is
selected by the TouchSensorToolSel signal.
• 0 = Touch not detected
• 1 = Touch detected
5.2.9 Error
This signal function indicates an error in the system (except
the gate door open error). The signal is on (1) for an error;
otherwise it is o (0). For warnings this signal remains o.
See the ErrorNumber description for more information.
For clearing this bit, the error situation must be resolved
and the error reset by means of the ErrorReset signal or
from a user interface.
• 0 = Warning or no error
• 1 = Error in system
5.2.10 CollisionDetected
This signal function indicates the collision sensor status.
In addition to this function, a collision detection error
(Error 146 Collision detected) will be set when a collision is
detected. The collision sensor must be on for this function
to take eect. When the collision sensor is switched o,
this signal is always 0.
• 0 = Collision sensor switch is open.
• 1 = Collision sensor switch is closed

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5.3 I/O table
Table size = 8 bytes
Byte Bit Control (Robot -> Welder) Status (Welder -> Robot)
0WireFeedSpeed WeldingCurrent
1
2Voltage / FineTuning WeldingVoltage
3
4 MemoryChannel ErrorNumber
5(Not in use) (Not in use)
6 0 StartWelding Ready
1 SimulationMode PowerSourceReady
2 WireInch CycleOn
3 WireRetract ArcOn
4 GasBlow (Not in use)
5(Not in use) (Not in use)
6 TouchSensorToolSel (Not in use)
7 TouchSensorOn TouchSensed
7 0 OnlineControl (Not in use)
1 ErrorReset Error
2(Not in use) CollisionDetected
3 Watchdog (Not in use)
4(Not in use) (Not in use)
5(Not in use) (Not in use)
6(Not in use) (Not in use)
7(Not in use) (Not in use)
5.4 Timing diagrams
5.4.1 Welding startup timing
Digital robot interface function timing
B
StartWelding
CycleOn
ArcOn
B
StartWelding
CycleOn
ArcOn
Symbol Description Min Typical Max Units
A Cycle-on time 6 17 40 ms
B Arc establishment
time
17 Pre-gas time +
open-air distance +
23
Pre-gas time +
2050 *
ms
*The maximum time is limited by a wire feeding time-out.
5.4.2 Welding stop timing
Digital robot interface function timing
A
B
StartWelding
CycleOn
ArcOn

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Symbol Description Min Typical Max Units
A Arc o time 51 51 94 ms
B Cycle o time 347 *Post-gas time +
10
Pre-gas time +
44
ms
*The minimum cycle-o time is determined by power-source shutdown
time, when the post-gas time is less than 300 ms.
5.4.3 Memory channel change timing
Previous value
Load memory channel data Load curve data
MemoryChannel
Apply curve data
A B C
Active value
Ready to weldReady to weld
Welding system
T
Symbol Description Min Typical Max Units
T Total time 380 392 500 ms
A Memory channel loading time 170 174 240 ms
B Welding curve loading time 155 158 190 ms
C Data setup time 55 60 70 ms

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5.4.4 Online control timing
Switching online (robot-controlled mode)
Welding system Apply curve data
Online
Robot modeManual mode
Symbol Description Min Typical Max Units
A Control data setup time 27 30 50 ms
Switching oine (memory channel mode)
Welding system Load setup file
Online
Memory channel mode
Robot mode Load memory channel data Load curve data Apply new data
C DBA
T
Symbol Description Min Typical Max Units
T Total time 730 752 910 ms
A Setup le loading time 350 360 410 ms
B Memory channel loading time 170 174 240 ms
C Welding curve loading time 155 158 190 ms
D Data setup time 55 60 70 ms

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5.4.5 Wire inch and retract timing
Startup timing
Welding system Start
WireInch, WireRetract
Feeding 5.0 m/minWire feeding off
A
Feeding 1.0 m/min
B
Symbol Description Min Typical Max Units
A Startup response time *3 ms
B Wire feeder motor acceleration time ** 3 s
*The wire feeder reacts on controls immediately after startup.
** The acceleration time depends on the selected wire feed speed.
Stop timing
Welding system Stop
WireInch, WireRetract
Wire feeding offWire feeding on
A
Deceleration
Symbol Description Min Typical Max Units
A Stop response time 3 ms
B Wire feeder motor deceleration time *50 80 ms
*The deceleration time depends on the wire feed speed before stop.
5.4.6 Touch sensor timing
Startup timing
Touch sensor RI
TouchSensorOn
Voltage OKPower off
A
Startup phase
B
Symbol Description Min Typical Max Units
A Startup response time 3 ms
B Power-on cycle time (voltage setup
time)
150 ms
Touch tool change timing
Previous tool
RI Relay
TouchSensorToolSel
Ready
B
New tool
Ready
Touch sensor
Symbol Description Min Typical Max Units
A Control response time 3 ms
B Relay action time 5 ms