/ Perfect Charging / Perfect Welding / Solar Energy

Operating Instructions
RI FB/i IGM V1.0 EN

RI MOD/i CC EtherCAT Robot option

RI MOD/i CC DeviceNet

42,0426,0236,EN 010-04102018
2
Contents

EN
General ...................................................................................................................................................... 5
Safety.................................................................................................................................................... 5
Device concept ..................................................................................................................................... 5
Block diagram ....................................................................................................................................... 5
Scope of supply .................................................................................................................................... 6
Required tools and materials ................................................................................................................ 6
Installation requirements....................................................................................................................... 6
Connection sockets and indicators on the robot interface ......................................................................... 7
Connection sockets on the robot interface............................................................................................ 7
LEDs on the robot interface PC board .................................................................................................. 7
LEDs for power supply diagnosis.......................................................................................................... 8
LEDs for network connection diagnosis................................................................................................ 8
Connection sockets and indicators on the EtherCAT bus module ............................................................. 9
Connection sockets and indicators ....................................................................................................... 9
Connection sockets and indicators on the DeviceNet bus module ............................................................ 11
Connection sockets and indicators ....................................................................................................... 11
EtherCAT technical data ............................................................................................................................ 12
Environmental conditions...................................................................................................................... 12
Robot interface technical data .............................................................................................................. 12
Data transfer properties ........................................................................................................................ 12
Configuration parameters ..................................................................................................................... 12
DeviceNet technical data ........................................................................................................................... 13
Environmental conditions...................................................................................................................... 13
Robot interface technical data .............................................................................................................. 13
Data transfer properties ........................................................................................................................ 13
Configuration parameters ..................................................................................................................... 13
Configuring the EtherCAT robot interface .................................................................................................. 14
General ................................................................................................................................................. 14
Adjusting the process data width .......................................................................................................... 14
Entering the EtherCAT address ............................................................................................................ 14
Configuring the DeviceNet robot interface ................................................................................................. 15
General ................................................................................................................................................. 15
Adjusting the process data width .......................................................................................................... 15
Setting the node address using the DIP switch(example) .................................................................... 15
Setting the node address ...................................................................................................................... 16
Power source website........................................................................................................................... 16
Opening and logging into the power source SmartManager................................................................. 16
Installing the robot interface....................................................................................................................... 17
Reliability............................................................................................................................................... 17
Preparation ........................................................................................................................................... 17
Route the data cable............................................................................................................................. 18
Install the robot interface....................................................................................................................... 19
And finally... .......................................................................................................................................... 19
Installing the bus module ........................................................................................................................... 20
Reliability............................................................................................................................................... 20
Installing the bus module ...................................................................................................................... 20
Input and output signals for EtherCAT standard image, IGM V1.0 ............................................................ 21
Data types............................................................................................................................................. 21
Availability of input signals (from robot to power source)...................................................................... 21
Input signals (from robot to power source) ........................................................................................... 22
Working mode range............................................................................................................................. 27
Documentation mode range.................................................................................................................. 27
Process controlled correction range ..................................................................................................... 27
Cooling unit operating mode range....................................................................................................... 28
Process controlled correction range 2 .................................................................................................. 28
Availability of output signals (from power source to robot) ................................................................... 29
Output signals (from power source to robot)......................................................................................... 29
Welding process range ......................................................................................................................... 34
Input and output signals for DeviceNet ...................................................................................................... 35
Data types............................................................................................................................................. 35

3
 Availability of input signals (from robot to power source)...................................................................... 35
Input signals (from robot to power source) ........................................................................................... 35
Working mode range............................................................................................................................. 38
Documentation mode range.................................................................................................................. 38
Process controlled correction range ..................................................................................................... 38
Process line selection range ................................................................................................................. 38
Availability of output signals (from power source to robot) ................................................................... 39
Output signals (from power source to robot)......................................................................................... 39
Assignment sensor status 1-3............................................................................................................... 42
Welding process range ......................................................................................................................... 42

4
General

EN
Safety
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage.
All functions described in this document may only be carried out by trained and
qualified personnel after they have fully read and understood the following docu-
ments:
- this document
- all the operating instructions for the system components, especially the safe-
ty rules

WARNING! Risk of serious injury or damage from unplanned signal transmission.

Safety signals must not be transferred via the interface.

Device concept The robot interface serves as the interface between the power source and standardised
bus modules for a wide range of communication protocols.
The robot interface can either be installed in the power source at the factory by Fronius or
at a later time by suitably trained technicians.

Robot
Control

(1) (2) (3) (4) (5) (6) (7) (8)

(1) Robot control (5) Cooling unit

(2) SpeedNet data cable (6) Interconnecting hosepack
(3) robot interface (7) Wire-feed unit
(4) Power source (8) Robot

Block diagram

Spider NT241 24 V
RI FB/i IGM V1.0

Module
Data

5
Scope of supply
(1) RI FB/i IGM V1.0
(1) (2) Data cable
4-pin
(2) (3) Two cable ties

(4) These operating instructions

(not shown)

(3)

Required tools - TX8 screwdriver

and materials - TX20 screwdriver
- TX25 screwdriver
- Diagonal cutting pliers

Installation re- The robot interface may only be installed in the opening provided for that purpose on the
quirements rear of the power source.

6
Connection sockets and indicators on the robot in-
terface

EN
Connection sock-
(1) Power supply connection socket
ets on the robot
(1) 2-pin
interface
(2) SpeedNet
data cable connection socket, 4-pin
(3) Bus module connection socket

(2) (3)

LEDs on the robot

interface PC
board

(3) (4) (7)

(8)
(1)
(2) (9) (10)

(5) (6)

(11)
(12)
(13)
(14)

(1) LED ETH1 green For diagnosing the network connection.

(2) LED ETH2 orange For details, see the "LEDs for network connec-
tion diagnosis" section below

7
 (3) LED 3 green
No function
(4) LED 4 green
(5) LED 5 green - Flashes at 4 Hz = not connected to
SpeedNet
- Flashes at 20 Hz = connection to Speed-
Net is being established
- Flashes at 1 Hz = connection to SpeedNet
is established
(6) LED 6 red Lights in the event of an internal fault.
Troubleshooting: Restart the robot interface. If
this does not remedy the problem, contact Af-
ter-Sales Service.
(7) LED +3V3 green For diagnosing the power supply.
(8) LED +24V green For details, see the "LEDs for power supply di-
agnosis" section below
(9) LED DIG OUT 2 green Digital output 2. LED comes on when active
(10) LED DIG OUT 1 green Digital output 1. LED comes on when active
(11) LED 11 green
(12) LED 12 green
No function
(13) LED 13 green
(14) LED 14 green

LEDs for power

LED Indication Meaning Cause
supply diagnosis
+24V Off No supply voltage to interface - Power supply not connect-
ed to robot interface
- Power supply cable faulty
On Robot interface connected to 24
VDC power supply
+3V3 Off No working voltage on robot in- - 24 VDC supply voltage ab-
terface sent
- Robot interface power sup-
ply unit faulty
On Robot interface connected to 3
VDC working voltage

LEDs for network

LED Indication Meaning Cause
connection diag-
nosis ETH1 Off Not connected to network - Network connection not
connected to interface
- Network cable faulty
On Connected to network
flashes Data transfer active
ETH2 Off Transfer speed 10 Mbit/s
On Transfer speed 100 Mbit/s

8
Connection sockets and indicators on the EtherCAT
bus module

EN
Connection sock-
Pin assignment RJ 45 EtherCAT con-
ets and indicators (10) (9)
nection socket:

(11) (1) TX+

(2) TX-
(3) RX+
(12) (6) RX-
(4) Not normally in use; to ensure signal
(5) integrity, these pins are connected
to each other and terminate via a fil-
(13) (8) (6) (4) (2) (7) ter circuit on the ground conductor
(14) (7) (5) (3) (1) (8) (PE).
(9) RJ 45 EtherCAT connection socket
1
(10) RJ 45 EtherCAT connection socket
2

Indicators
(11) LED ERR (error)
(12) LED connection/activity socket 2
(13) LED connection/activity socket 1
(14) LED RUN (operation)

LED RUN (operation)

Status Meaning
Off EtherCAT device status "init" (or no supply voltage)
Steady green EtherCAT device status "operational"
Flashing green EtherCAT device status "pre-operational"
Flashing green (briefly) EtherCAT device status "safe-operational"
Steady red When the Run LED and Error LED are lit, this indicates a fatal
event bringing the Interface to an exception state. Con-
tact After-Sales Service

9
 LED ERR (error)
Status Meaning
Off No error (or no supply voltage)
Flashing red Incorrect configuration
Status change received from master is not possible due to in-
valid register settings or object settings.
Flashing red (double) Application watchdog timeout
Sync manager watchdog timeout
Steady red Application controller failure
Anybus module in EXCEPTION

LED connection/activity (12+13)

Status Meaning
Off No connection (or no supply voltage)
Steady green Connection recognised, no activity present
Flickering green Connection recognised, activity present

10
Connection sockets and indicators on the DeviceNet
bus module

EN
Connection sock- DeviceNet connection socket
ets and indicators
Pin Signal Description
(6) (1) V- Supply voltage
(2) CAN_L CAN low bus line
(5)
(3) SHIELD Cable shield
(4)
(4) CAN_H CAN high bus line
(3)
(5) V+ Supply voltage
(2)
(1)
Indicators
(7)
(6) LED MS (module status)
(7) LED NS (network status)

LED MS (module status)

Status Meaning
Off No power
Steady green Normal operation
Flashing green Missing or incomplete configuration, commissioning required
Steady red Non-rectifiable error
Flashing red Rectifiable error
Alternating red/green Self-test running

LED NS (network status)

Status Meaning
Off Not online or no power
Steady green Online, one or more connections established
Flashing green Online, no connections established
Steady red Critical connection error
Flashing red Timeout on one or more connections
Alternating red/green Self-test running

11
EtherCAT technical data

Environmental
CAUTION! The device may be seriously damaged if it is operated or stored out-
conditions
side the specified environmental conditions.
Do not start the device unless you are sure that the environmental conditions will
be adhered to in all operating situations.

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Keep ambient air free from dust, acids, corrosive gases and substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft).

Robot interface
Power supply internal (24 V)
technical data
Protection class IP 23

Data transfer
Transmission technology EtherCAT
properties
Medium
When selecting cables, connectors and terminating resistors, observe IEC 61784-5-12
for planning and installation of EtherCAT systems.

EMC tests are carried out by the manufacturer with an original Beckhoff cable (ZK1090-
9191-xxxx).
Transmission speed 100 Mbit/s
Bus connection Ethernet RJ 45
Application layer CANopen

Configuration pa- With some robot control units, it may be necessary to enter the configuration parameters
rameters described here so that the bus module can communicate with the robot.

Parameter Value Description

Vendor ID 0000 02C1hex (705dec) Fronius International GmbH
Product Code 0001 0341hex (66369dec) Standard Image
Device Name Fronius FB-IGM-1-0-Ether- Fronius-FB-Inside-EtherCAT
CAT

12
DeviceNet technical data

EN
Environmental
CAUTION! The device may be seriously damaged if it is operated or stored out-
conditions
side the specified environmental conditions.
Do not start the device unless you are sure that the environmental conditions will
be adhered to in all operating situations.

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Keep ambient air free from dust, acids, corrosive gases and substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft).

Robot interface
Power supply internal (24 V)
technical data
Protection class IP 23

Data transfer
Network topology
properties
Linear bus, bus terminators at both ends (121 Ohm), spur lines are possible
Medium and maximum bus length
When selecting cables, connectors and terminating resistors, observe the ODVA recom-
mendation for the planning and installation of DeviceNet systems
Number of stations
Up to 64 nodes
Transmission speed
500 kBit/s, 250 kBit/s, 125 kBit/s
Process data width
Configurable at robot interface
See following section "Configuring the robot interface"

Configuration pa- With some robot control units, it may be necessary to enter the configuration parameters
rameters described here so that the bus module can communicate with the robot.

Parameter Value Description

Vendor ID 0534hex (1332dec) Fronius International GmbH
Device Type 000Chex (12dec) Communication adapter
Product Code 0440hex (1088dec) Fronius FB IGM 1.0 DeviceNet
Product Name Fronius FB-IGM-1-0-DeviceNet

13
Configuring the EtherCAT robot interface

General
The DIP-switch on the robot interface is
(2) used to set the process image (standard
image).

(1) Factory setting of process image:

Positions 7 and 8 of DIP switch in OFF po-
sition (1) = standard image = IGM V1.0

NOTE! Whenever the DIP switch settings are changed, the interface must be re-
started in order to activate the new settings.
(Restart = disconnect and then reconnect the power supply
or perform the respective function on the power source website)

Adjusting the pro-

DIP switch The amount of data transferred is defined
cess data width
8 7 6 5 4 3 2 1 Configuration by the process data width.

- - - - - - IGM image How much data can be transferred de-

OFF
OFF

832 bits pends on

- - - - - - Fronius standard im- - the robot control
OFF

age - the number of power sources

ON

320 bits - the type of power sources

- - - - - - Not used - "Intelligent Revolution"
ON OFF
ON ON

- "Digital Revolution" (Retro Fit)

- - - - - - Not used

Entering the Eth- NOTE! The EtherCAT address is specified by the master.
erCAT address

14
Configuring the DeviceNet robot interface

EN
General The DIP-switch on the robot interface is
(2) used to set:
- the process data width
- the node address
(1)

NOTE! Whenever the DIP switch settings are changed, the interface must be re-
started in order to activate the new settings.
(Restart = disconnect and then reconnect the power supply
or perform the respective function on the power source website)

Adjusting the pro-

DIP switch The amount of data transferred is defined
cess data width
8 7 6 5 4 3 2 1 Configuration by the process data width.

- - - - - - Not used
OFF
OFF

How much data can be transferred de-

pends on
- - - - - - Fronius standard im-
- the robot control
OFF

age
ON

- the number of power sources

320 bits
- the type of power sources
- - - - - - Not used - "Intelligent Revolution"
OFF
ON

- "Digital Revolution" (Retro Fit)

- - - - - - Fronius Retro Fit im-
age
ON
ON

96 bits

Setting the node

DIP switch The node address is set using DIP switch
address using the
8 7 6 5 4 3 2 1 Node address positions 1 to 6.
DIP switch
The setting is in binary format. This pro-
(example) - - 1
OFF
OFF
OFF
OFF
OFF

vides a setting range from 1 to 63 in deci-

ON

mal format.
- - 2
OFF
OFF
OFF
OFF

OFF
ON

- - 3
OFF
OFF
OFF
OFF
ON
ON

- - 62
ON OFF
ON ON
ON ON
ON ON
ON ON
ON ON

- - 63

15
Setting the node When delivered, node address 0 is set. There are two different ways to set the node ad-
address dress:
- Node addresses in the range from 1 to 63 can be set using the DIP switch.
- If node address 0 is left as it is on the DIP switch, node addresses in the range from
1 to 63 can also be set using the following configuration tools:
- the power source website
NOTE! If the node address is set to greater than 0 using the DIP switch,
when the robot interface is next restarted the corresponding node address in
the range from 1 to 63 is set.
Any previous node address set using a configuration tool will be overwritten.

NOTE! If settings have already been applied, there are two ways to reset all net-
work settings to the factory settings:
- Reset all DIP switches to 0 and restart the interface
or
- Use the Restore factory settings button on the power source website

Power source The power source has a separate website, the SmartManager.
website As soon as the power source is integrated into a network, the SmartManager can be called
up using the power source IP address.

Depending on the system configuration and software upgrades, the SmartManager the fol-
lowing entries:

- Overview - Function Packages

- Update - Job-Data
- Screenshot - Synergic lines overview
- Backup & Restore - RI FB INSIDE/i

Opening and log-

ging into the pow-
er source
SmartManager 1.9.0-16501.9508

3 xx.x.xxx.x

4
1

1 Settings / System / Information ==> Note down the IP address for the power source
2 Enter the IP address in the browser search field
3 Enter user name and password

Factory setting:
User name = admin
Password = admin

4 Confirm the displayed message

The power source SmartManager is displayed.

16
Installing the robot interface

EN
Reliability
WARNING! An electric shock can be fatal. Before starting the work described be-
low:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed

After opening the device, use a suitable measuring instrument to check that elec-
trically charged components (e.g. capacitors) have been discharged.

WARNING! An inadequate ground conductor connection can cause serious inju-

ry or damage. The housing screws provide a suitable ground conductor connec-
tion for earthing the housing and must NOT be replaced by any other screws that
do not provide a reliable ground conductor connection.

Preparation
1 2

1 2

3 4

3 4

17
 5

Route the data ca-

1 2

1 2
ble

18
Install the robot
1 2

1 2

EN
interface

And finally...
1 2

1 2

19
Installing the bus module

Reliability
WARNING! An electric shock can be fatal. Before starting the work described be-
low:
- turn the power source mains switch to the "O" position
- disconnect the power source from the mains
- ensure that the power source remains disconnected from the mains until all
work has been completed

WARNING! An inadequate ground conductor connection can cause serious inju-

ry or damage. The housing screws provide a suitable ground conductor connec-
tion for earthing the housing and must NOT be replaced by any other screws that
do not provide a reliable ground conductor connection.

Installing the bus

1 2

1 2
module

20
Input and output signals for EtherCAT standard im-
age, IGM V1.0

EN
Data types The following data types are used:
- UINT16 (unsigned integer)
Integer in the range 0 to 65535
- SINT16 (signed integer)
Integer in the range -32768 to 32767

Calculation examples:
- For positive value (SINT16)
e.g. required wire feed speed x factor
12.3 m/min x 100 =1230dec =04CEhex

- For negative value (SINT16)

e.g. required arc correction x factor
-6.4 x 10 = -64dec =FFC0hex

Availability of in- The following input signals are available from firmware V1.8.5 of the TPS/i power source.
put signals (from
robot to power
source)

21
Input signals
(from robot to
power source)

Address
Abso-
Relative lute

Factor
WORD

BYTE

Activity
BIT

BIT Signal Data type Range

0 0 Welding Start Rising
1 1 Robot ready High
2 2 Working mode Bit 0 High
3 3 Working mode Bit 1 High
0 See table Working
4 4 Working mode Bit 2 High
mode range on page 27
5 5 Working mode Bit 3 High
6 6 Working mode Bit 4 High
7 7 —
0
0 8 Gas on Rising
1 9 Wire forward Rising
2 10 Wire backward Rising
3 11 Error quit Rising
1
4 12 Touch sensing High
5 13 Torch blow out Rising
6 14 Processline selection Bit 0 High
7 15 Processline selection Bit 1 High
0 16 Welding Simulation High
1 17 Synchro pulse on High
2 18 SFI on High
3 19 SFI on High
2
4 20 —
5 21 —
6 22 Wire brake on High
7 23 Torchbody Xchange High
1
0 24 —
1 25 Teach mode High
2 26 —
3 27 —
3
4 28 —
5 29 —
6 30 —
7 31 —

22
 Address
Abso-

EN
Relative lute

Factor
WORD

BYTE

Activity
BIT

BIT Signal Data type Range

0 32 —
1 33 —
2 34 —
3 35 —

4 4 36 —
See table Documenta-
5 37 Documentation mode High tion mode range on
page 27
6 38 —
2 7 39 —
0 40 —
1 41 —
2 42 —
3 43 —
5 4 44 —
5 45 —
6 46 —
Disable process controlled correc-
7 47 High
tion
0 48 —
1 49 —
2 50 —
3 51 —
6
4 52 —
5 53 —
6 54 —
7 55 —
3
0 56 ExtInput1 => OPT_Output 1 High
1 57 ExtInput2 => OPT_Output 2 High
2 58 ExtInput3 => OPT_Output 3 High
3 59 ExtInput4 => OPT_Output 4 High
7
4 60 ExtInput5 => OPT_Output 5 High
5 61 ExtInput6 => OPT_Output 6 High
6 62 ExtInput7 => OPT_Output 7 High
7 63 ExtInput8 => OPT_Output 8 High
8 0-7 64-71 Welding characteristic- / Job num-
4 UINT16 0 to 1000 1
9 0-7 72-79 ber
10 0-7 80-87 -327.68 to 327.67
5 Wire feed speed command value SINT16 100
11 0-7 88-95 [m/min]
12 0-7 96-103
6 Arclength correction SINT16 -10.0 to 10.0 10
13 0-7 104-111

23
 Address
Abso-
Relative lute

Factor
WORD

BYTE

Activity
BIT

BIT Signal Data type Range

14 0-7 112-119
7 Pulse-/dynamic correction SINT16 -10.0 to 10.0 10
15 0-7 120-127
16 0-7 128-135
8 Wire retract correction UINT16 0.0 to 10.0 10
17 0-7 136-143
18 0-7 144-151 0 to 1000
9 Robot speed UINT 16 1
19 0-7 152-159 [cm/min]
20 0-7 160-167 See table Process con-
10 Process controlled correction High trolled correction
21 0-7 168-175 range on page 27
22 0-7 176-183
11 —
23 0-7 184-191
24 0-7 192-199
12 —
25 0-7 200-207
26 0-7 208-215
13 —
27 0-7 216-223
28 0-7 224-231
14 —
29 0-7 232-239
30 0-7 240-247
15 —
31 0-7 248-255
32 0-7 256-263
16 —
33 0-7 264-271
34 0-7 272-279
17 —
35 0-7 280-287
36 0-7 288-295
18 —
37 0-7 296-303
38 0-7 304-311
19 Seam number UINT16 0 to 65535 1
39 0-7 312-319

24
 Address
Abso-

EN
Relative lute

Factor
WORD

BYTE

Activity
BIT

BIT Signal Data type Range

0 320 Disable Start-End-Parameter High
1 321 Disable SFI-Parameter High
2 322 Disable SP-Parameter High
3 323 Disable Process-Mix-Parameter High
40 4 324 Disable gas-settings High
5 325 Disable delaytime flowsensor High
6 326 Disable inching value High
Disable process controlled correc-
7 327 High
20 tion 2
0 328 —
1 329 —
2 330 —
3 331 —
41
4 332 —
5 333 —
6 334 —
7 335 —
0 336 —
1 337 —
2 338 —
3 339 —
42
4 340 —
5 341 —
6 342 —
7 343 —
21
0 344 Cooling unit operating mode Bit 0 High See table Cooling unit
1 345 Cooling unit operating mode Bit 1 High operating mode range
2 346 Cooling unit operating mode Bit 2 High on page 28

3 347 —
43
4 348 —
5 349 —
6 350 —
7 351 —
44 0-7 352-359 0 to 9.9
22 Gas preflow UINT 16 10
45 0-7 360-367 [s]
46 0-7 368-375 0 to 60.0
23 Gas postflow UINT 16 10
47 0-7 376-383 [s]
48 0-7 384-391 0.5 to 25.0
24 Inching Value SINT 16 100
49 0-7 392-399 [m/min]

25
 Address
Abso-
Relative lute

Factor
WORD

BYTE

Activity
BIT

BIT Signal Data type Range

50 0-7 400-407 5 to 25
25 Delay time flow sensor UINT 16 1
51 0-7 408-415 [steps of 5]
52 0-7 416-423 0,5 to 30,0
26 Gas Command Value UINT 16 10
53 0-7 424-431 [l/min]
54 0-7 432-439 0,9 to 20,0
27 Gas factor UINT 16 100
55 0-7 440-447 [l/min]
56 0-7 448-455 5 to 100
28 Ignition time out UINT 16 1
57 0-7 456-463 [steps]
58 0-7 464-471 0 to 200
29 S2T-Starting current UINT 16 1
59 0-7 472-479 [%]
60 0-7 480-487 Off (0.0) /
30 S2T-Starting current time UINT 16 0.1 to 10.0 10
61 0-7 488-495 [s]
62 0-7 496-503 0 to 9.9
31 S2T Slope 1 UINT 16 10
63 0-7 504-511 [s]
64 0-7 512-519 0 to 9.9
32 S2T Slope 2 UINT 16 10
65 0-7 520-527 [s]
66 0-7 528-535 0 to 200
33 S2T End current UINT 16 1
67 0-7 536-543 [%]
68 0-7 544-551 Off (0.0) /
34 S2T End current time UINT 16 0.1 to 10.0 10
69 0-7 552-559 [s]
70 0-7 560-567
35 Start Arclength correction SINT 16 -10 to +10 10
71 0-7 568-575
72 0-7 576-583
36 End Arclength correction SINT 16 -10 to +10 10
73 0-7 584-591
74 0-7 592-599 Off (0.0) /
37 SFI Hotstart UINT 16 0.1 to 2.0 100
75 0-7 600-607 [s]
76 0-7 608-615
38 SP Delta wire feed UINT 16 0.1 to 6 10
77 0-7 616-623
78 0-7 624-631
39 SP Frequency UINT 16 0.5 to 3 10
79 0-7 632-639
80 0-7 640-647
40 SP Duty Cycle UINT 16 10 to 90 1
81 0-7 648-655
82 0-7 656-663
41 SP Arc length correction high SINT 16 -10 to +10 10
83 0-7 664-671
84 0-7 672-679
42 SP Arc length correction low SINT 16 -10 to +10 10
85 0-7 680-687
86 0-7 688-695 Process-Mix High power time cor-
43 SINT 16 -10 to +10 10
87 0-7 696-703 rection

26
 Address
Abso-

EN
Relative lute

Factor
WORD

BYTE

Activity
BIT

BIT Signal Data type Range

88 0-7 704-711 Process-Mix Low power time cor-
44 SINT 16 -10 to +10 10
89 0-7 712-719 rection
90 0-7 720-727
45 Process-Mix Low power correction SINT 16 -10 to +10 10
91 0-7 728-735
92 0-7 736-743 See table Process con-
46 Process controlled correction 2 High trolled correction
93 0-7 744-751 range 2 on page 28
94 0-7 752-759
47 —
96 0-7 760-767
96 0-7 768-775
48 —
97 0-7 776-783
98 0-7 784-791
49 —
99 0-7 792-799
100 0-7 800-807
50 —
101 0-7 808-815
102 0-7 816-823
51 —
103 0-7 824-831

Working mode
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0

range
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

Documentation
No. Description
mode range
00 Seam number of current source (internal)
01 Seam number of robot (Word 19)

Process con-
Process Signal Activity Setting range Unit Factor
trolled correction
data type
range
PMC Arc length stabiliser SINT16 -3276.8 to +3276.7 Volts 10
0.0 to +5.0

27
Cooling unit oper-

Bit 2
Bit 1
Bit 0
ating mode range
Description
0 0 0 auto
0 0 1 eco
0 1 0 on
0 0 0 off

Process con-
Process Signal Activity Setting range Unit Factor
trolled correction
data type
range 2
PMC, LSC Penetration stabilizer SINT16 -3276.8 to +3276.7 m/min 10
0.0 to +10.0

28
 Availability of The following output signals are available from firmware V1.8.5 of the TPS/i power source.

EN
output signals
(from power
source to robot)

Output signals
(from power
source to robot)

Address
Relative Absolute

Factor
WORD
BYTE

Activity
BIT

BIT Signal Data type Range

0 0 Heartbeat Powersource High / Low 1 Hz
1 1 Power source ready High
2 2 —
3 3 Process active High
0
4 4 Current flow High
5 5 Arc stable- / touch signal High
6 6 Main current signal High
7 7 Touch signal High
0 0 = collision or ca-
0 8 Collisionbox active Low
ble break
1 9 Robot Motion Release High
2 10 Wire stick workpiece High
1 3 11 —
4 12 —
5 13 Parameter selection internally High
6 14 —
7 15 Torch body gripped High

29
 Address
Relative Absolute

Factor
WORD
BYTE

Activity
BIT

BIT Signal Data type Range

0 16 Command value out of range High
1 17 Correction out of range High
2 18 —
3 19 —
2
4 20 —
5 21 —
6 22 Main supply status Low
7 23 —
1
0 24 —
1 25 —
2 26 —
3 27 —
3
4 28 —
5 29 —
6 30 —
7 31 —
0 32 —
1 33 —
2 34 —
3 35 —
4
4 36 —
5 37 —
6 38 —
7 39 —
2
0 40 —
1 41 —
2 42 —
3 43 —
5
4 44 —
5 45 —
6 46 —
7 47 —

30
 Address
Relative Absolute

EN
Factor
WORD
BYTE

Activity
BIT

BIT Signal Data type Range

0 48 Process Bit 0 High
1 49 Process Bit 1 High
See table Welding pro-
2 50 Process Bit 2 High
cess range on page 34
3 51 Process Bit 3 High
6
4 52 Process Bit 4 High
5 53 —
6 54 —
7 55 —
3
0 56 ExtOutput1 <= OPT_Input1 High
1 57 ExtOutput2 <= OPT_Input2 High
2 58 ExtOutput3 <= OPT_Input3 High
3 59 ExtOutput4 <= OPT_Input4 High
7
4 60 ExtOutput5 <= OPT_Input5 High
5 61 ExtOutput6 <= OPT_Input6 High
6 62 ExtOutput7 <= OPT_Input7 High
7 63 ExtOutput8 <= OPT_Input8 High
8 0-7 64-71
4 Welding voltage UINT16 0.0 to 655.35 [V] 100
9 0-7 72-79
10 0-7 80-87
5 Welding current UINT16 0.0 to 6553.5 [A] 10
11 0-7 88-95
12 0-7 96-103 -327.68 to 327.67
6 Wire feed speed SINT16 100
13 0-7 104-111 [m/min]
14 0-7 112-119 10,00
7 Actual real value for seam tracking UINT16 0 to 6.5535
15 0-7 120-127 0
16 0-7 128-135
8 Error number — UINT 16 0 bis 65535 1
17 0-7 136-143
18 0-7 144-151
9 —
19 0-7 152-159
20 0-7 160-167 -327.68 to 327.67
10 Motor current M1 SINT16 100
21 0-7 168-175 [A]
22 0-7 176-183 -327.68 to 327.67
11 Motor current M2 SINT16 100
23 0-7 184-191 [A]
24 0-7 192-199 -327.68 to 327.67
12 Motor current M3 SINT16 100
25 0-7 200-207 [A]
26 0-7 208-215
13 —
27 0-7 216-223
28 0-7 224-231
14 —
29 0-7 232-239
30 0-7 240-247
15 —
31 0-7 248-255

31
 Address
Relative Absolute

Factor
WORD
BYTE

Activity
BIT

BIT Signal Data type Range

32 0-7 256-263
16 —
33 0-7 264-271
34 0-7 272-279
17 —
35 0-7 280-287
36 0-7 288-295
18 —
37 0-7 296-303
38 0-7 304-311
19 —
39 0-7 312-319
0 320 Gas process line 1 pushed High
1 321 —
2 322 Wire feeder 1 available
3 323 Wire feeder 2 available
40
4 324 Wire feeder 3 available
5 325 —
6 326 —
7 327 —
20
0 328 —
1 329 —
2 330 —
3 331 —
41
4 332 —
5 333 —
6 334 —
7 335 —
42 0-7 336-343
21 —
43 0-7 344-351
44 0-7 352-359 -100 to +200
22 Cooler temperature SINT16 10
45 0-7 360-367 [°C]
46 0-7 368-375 -100 to +100
23 Cooler flow rate SINT16 100
47 0-7 376-383 [l/min]
48 0-7 384-391 0 to 6553.5
24 Real energy actual value UINT16 10
49 0-7 392-399 [kJ]
50 0-7 400-407 0 to 6553.5
25 Power value UINT16 10
51 0-7 408-415 [kW]
52 0-7 416-423
26
53 0-7 424-431 0 to 100,000
Hour meter power on UINT32 10
54 0-7 432-439 [h]
27
55 0-7 440-447

32
 Address
Relative Absolute

EN
Factor
WORD
BYTE

Activity
BIT

BIT Signal Data type Range

56 0-7 448-455
28
57 0-7 456-463 0 to 100,000
Hour meter current flow UINT32 10
58 0-7 464-471 [h]
29
59 0-7 472-479
60 0-7 480-487
30 —
61 0-7 488-495
62 0-7 496-503
31 —
63 0-7 504-511
64 0-7 512-519
32
65 0-7 520-527
66 0-7 528-535
33
67 0-7 536-543
68 0-7 544-551
34
69 0-7 552-559
70 0-7 560-567 0,0 to 100,0
35 MIG gas actual value UINT16 10
71 0-7 578-585 [l/min]
72 0-7 586-593
36 Feeder inching speed SINT16 -327,68 to 327,67 100
73 0-7 594-601
74 0-7 602-609
37 —
75 0-7 610-617
76 0-7 618-625
38 —
77 0-7 626-633
78 0-7 634-641
39 —
79 0-7 642-649
80 0-7 650-657
40 —
81 0-7 658-659
82 0-7 660-667
41 —
83 0-7 668-675
84 0-7 676-683
42 —
85 0-7 684-691
86 0-7 692-699
43 —
87 0-7 700-707
88 0-7 708-715
44 —
89 0-7 716-723
90 0-7 724-731
45 —
91 0-7 732-739
92 0-7 740-747
46 —
93 0-7 748-755
94 0-7 756-763
47 —
96 0-7 764-771

33
 Address
Relative Absolute

Factor
WORD
BYTE

Activity
BIT

BIT Signal Data type Range

96 0-7 772-779
48 —
97 0-7 780-787
98 0-7 788-795
49 —
99 0-7 796-803
10
0-7 804-811
0
50 —
10
0-7 812-819
1
10
0-7 820-827
2
51 —
10
0-7 828-835
3

Welding process
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0

range
Description
0 0 0 0 0 No process or internal parameter selection
0 0 0 0 1 MIG/MAG pulse
0 0 0 1 0 MIG/MAG Standard
0 0 0 1 1 MIG/MAG PMC
0 0 1 0 0 MIG/MAG LSC
0 0 1 0 1 MIG/MAG standard manual
0 0 1 1 0 Electrode
0 0 1 1 1 TIG

34
Input and output signals for DeviceNet

EN
Data types The following data types are used:
- UINT16 (unsigned integer)
Integer in the range 0 to 65535
- SINT16 (signed integer)
Integer in the range -32768 to 32767

Calculation examples:
- For positive value (SINT16)
e.g. required wire feed speed x factor
12.3 m/min x 100 =1230dec =04CEhex

- For negative value (SINT16)

e.g. required arc correction x factor
-6.4 x 10 = -64dec =FFC0hex

Availability of in- The following input signals are available from firmware V1.8.5 of the TPS/i power source.
put signals (from
robot to power
source)

Input signals
(from robot to
power source)

Process
Address image
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

0 0 Welding Start Rising
1 1 Robot ready High
2 2 Working mode Bit 0 High
3 3 Working mode Bit 1 High
0 See table Working
4 4 Working mode Bit 2 High
mode range on Page 38
5 5 Working mode Bit 3 High
6 6 Working mode Bit 4 High
7 7 —
0  
0 8 Gas on Rising
1 9 Wire forward Rising
2 10 Wire backward Rising
3 11 Error quit Rising
1
4 12 Touch sensing High
5 13 Torch blow out Rising
6 14 Processline selection Bit 0 High
7 15 Processline selection Bit 1 High

35
 Process
Address image
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

0 16 Welding Simulation High
1 17 Synchro pulse on High
2 18 —
3 19 —
2
4 20 —
5 21 —
6 22 Wire brake on High
7 23 Torchbody Xchange High
1  
0 24 —
1 25 Teach mode High
2 26 —
3 27 —
3
4 28 —
5 29 —
6 30 —
7 31 —
0 32 —
1 33 —
2 34 —
3 35 —
4 4 36 —
See table Documenta-
5 37 Documentation mode High tion mode range on
page 38
6 38 —
2 7 39 —  
0 40 —
1 41 —
2 42 —
3 43 —
5 4 44 —
5 45 —
6 46 —
Disable process controlled correc-
7 47 High
tion

36
 Process
Address image

EN
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

0 48 —
1 49 —
2 50 —
3 51 —
6
4 52 —
5 53 —
6 54 —
7 55 —
3  
0 56 ExtInput1 => OPT_Output 1 High
1 57 ExtInput2 => OPT_Output 2 High
2 58 ExtInput3 => OPT_Output 3 High
3 59 ExtInput4 => OPT_Output 4 High
7
4 60 ExtInput5 => OPT_Output 5 High
5 61 ExtInput6 => OPT_Output 6 High
6 62 ExtInput7 => OPT_Output 7 High
7 63 ExtInput8 => OPT_Output 8 High
8 0-7 64-71 Welding characteristic- / Job num-
4 UINT16 0 to 1000 1  
9 0-7 72-79 ber
10 0-7 80-87 -327.68 to 327.67
5 Wire feed speed command value SINT16 100  
11 0-7 88-95 [m/min]
12 0-7 96-103
6 Arclength correction SINT16 -10.0 to 10.0 10  
13 0-7 104-111
14 0-7 112-119
7 Pulse-/dynamic correction SINT16 -10.0 to 10.0 10  
15 0-7 120-127
16 0-7 128-135
8 Wire retract correction UINT16 0.0 to 10.0 10 
17 0-7 136-143
18 0-7 144-151 0.0 to 1000.0
9 Welding speed UINT16 10 
19 0-7 152-159 [cm/min]
20 0-7 160-167 See table Process con- 
10 Process controlled correction High trolled correction
21 0-7 168-175 range on page 38
22 0-7 176-183
11 — 
23 0-7 184-191
24 0-7 192-199
12 — 
25 0-7 200-207
26 0-7 208-215
13 — 
27 0-7 216-223
28 0-7 224-231
14 — 
29 0-7 232-239
30 0-7 240-247
15 — 
31 0-7 248-255

37
 Process
Address image
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

32 0-7 256-263
16 — 
33 0-7 264-271
34 0-7 272-279
17 — 
35 0-7 280-287
36 0-7 288-295
18 — 
37 0-7 296-303
38 0-7 304-311
19 Seam number UINT16 0 to 65535 1 
39 0-7 312-319

Working mode
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0

range
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

Documentation
No. Description
mode range
00 Seam number of current source (internal)
01 Seam number of robot (Word 19)

Process con-
Process Signal Activity Setting range Unit Factor
trolled correction
data type
range
PMC Arc length stabiliser SINT16 -327.8 to +327.7 Volts 10
0.0 to +5.0

Process line se-

No. Description
lection range
00 Processline 1 (default)
01 Processline 2
10 Processline 3
11 Reserved

38
 Availability of The following output signals are available from firmware V1.8.5 of the TPS/i power source.

EN
output signals
(from power
source to robot)

Output signals
(from power
source to robot)

Process
Address image
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

0 0 Heartbeat Powersource High / Low 1 Hz
1 1 Power source ready High
2 2 —
3 3 Process active High
0
4 4 Current flow High
5 5 Arc stable- / touch signal High
6 6 Main current signal High
7 7 Touch signal High
0 0 = collision or ca-  
0 8 Collisionbox active Low
ble break
1 9 Robot Motion Release High
2 10 Wire stick workpiece High
1 3 11 —
4 12 —
5 13 Parameter selection internally High
6 14 Characteristic number valid High
7 15 Torch body gripped High

39
 Process
Address image
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

0 16 Command value out of range High
1 17 Correction out of range High
2 18 —
3 19 Limit signal High
2
4 20 —
5 21 —
6 22 Main supply status Low
7 23 —
1  
0 24 Sensor status 1 High See table Assignment
1 25 Sensor status 2 High sensor status 1-3 on
2 26 Sensor status 3 High page 42

3 27 —
3
4 28 —
5 29 —
6 30 —
7 31 —
0 32 —
1 33 —
2 34 —
3 35 —
4
4 36 —
5 37 —
6 38 —
7 39 —
2  
0 40 —
1 41 —
2 42 —
3 43 —
5
4 44 —
5 45 —
6 46 —
7 47 —

40
 Process
Address image

EN
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

0 48 Process Bit 0 High
1 49 Process Bit 1 High
See table Welding pro-
2 50 Process Bit 2 High
cess range on page 42
3 51 Process Bit 3 High
6
4 52 Process Bit 4 High
5 53 —
6 54 —
7 55 —
3  
0 56 ExtOutput1 <= OPT_Input1 High
1 57 ExtOutput2 <= OPT_Input2 High
2 58 ExtOutput3 <= OPT_Input3 High
3 59 ExtOutput4 <= OPT_Input4 High
7
4 60 ExtOutput5 <= OPT_Input5 High
5 61 ExtOutput6 <= OPT_Input6 High
6 62 ExtOutput7 <= OPT_Input7 High
7 63 ExtOutput8 <= OPT_Input8 High
8 0-7 64-71
4 Welding voltage UINT16 0.0 to 655.35 [V] 100  
9 0-7 72-79
10 0-7 80-87
5 Welding current UINT16 0.0 to 6553.5 [A] 10  
11 0-7 88-95
12 0-7 96-103 -327.68 to 327.67
6 Wire feed speed SINT16 100  
13 0-7 104-111 [m/min]
14 0-7 112-119
7 Actual real value for seam tracking UINT16 0 to 6.5535 10000  
15 0-7 120-127
16 0-7 128-135
8 Error number UINT16 0 to 65535 1 
17 0-7 136-143
18 0-7 144-151
9 — 
19 0-7 152-159
20 0-7 160-167 -327.68 to 327.67
10 Motor current M1 SINT16 100 
21 0-7 168-175 [A]
22 0-7 176-183 -327.68 to 327.67
11 Motor current M2 SINT16 100 
23 0-7 184-191 [A]
24 0-7 192-199 -327.68 to 327.67
12 Motor current M3 SINT16 100 
25 0-7 200-207 [A]
26 0-7 208-215
13 — 
27 0-7 216-223
28 0-7 224-231
14 — 
29 0-7 232-239
30 0-7 240-247
15 — 
31 0-7 248-255

41
 Process
Address image
Relative Absolute

Economy
Standard
Factor
WORD
BYTE

Activity
BIT

BIT Signal data type Range

32 0-7 256-263
16 — 
33 0-7 264-271
34 0-7 272-279
17 — 
35 0-7 280-287
36 0-7 288-295
18 — 
37 0-7 296-303
38 0-7 304-311
19 — 
39 0-7 312-319

Assignment sen-
Sensor status Description
sor status 1-3
1 OPT/i WF R wire end
2 OPT/i WF R DE wire drum
3 OPT/i WF R DE ring sensor

Welding process
Bit 4
Bit 3
Bit 2
Bit 1
Bit 0

range
Description
0 0 0 0 0 No process or internal parameter selection
0 0 0 0 1 MIG/MAG pulse
0 0 0 1 0 MIG/MAG Standard
0 0 0 1 1 MIG/MAG PMC
0 0 1 0 0 MIG/MAG LSC
0 0 1 0 1 MIG/MAG standard manual
0 0 1 1 0 Electrode
0 0 1 1 1 TIG

42
 EN

43
 FRONIUS INTERNATIONAL GMBH
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Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
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