Wire Sense

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User information
TPS/i Interface Signal Descriptions
EN-US
Signal description
42,0426,0227,EA 021-20052021
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
Table of contents
EN-US
General 5
Data Types Used 5
Behavior of the Power Source when an Interface is Connected 5
Availability of Functions 5
Signal Transmission Time 6
Safety 6
Digital Inputs 7
Welding start (Welding on) - Single Bit 7
Robot ready (Robot ready) - Single Bit 7
Working mode (Operating mode) - Single Bit 7
Gas on (Gas on) - Single Bit 9
Wire forward (Wire forwards) - Single Bit 9
Wire backward (Wire return) - Single Bit 10
Error reset (Reset error) 10
Touch sensing (TouchSensing) - Single Bit 11
Gas nozzle touch sensing (Gas nozzle position search) - Single Bit 12
Torch blow out (Blow out welding torch) - Single Bit 13
Welding simulation (Welding simulation) - Single Bit 13
Synchropulse on (SynchroPulse on) - Single Bit 13
WireBrake on (Wire brake on) - Single Bit 13
Torchbody Xchange (Change torch body) - Single Bit 13
Teach mode - Single Bit 14
ExtInput 1-8 (External input 1-8) - Single Bit 15
Job number (Job‑number) - Group Input 16
Welding characteristic (Characteristic number) - Group Input 16
Disable process control (Deactivate process-dependent correction) - Group Input 16
Processline select (Process line selection) - Group Input 16
TWIN mode (TWIN operating mode) - Group Input 17
Documentation mode (Documentation mode) - Single Bit 17
WireSense start - Single Bit 18
WireSense break - Single Bit 19
Analog Inputs 20
Wire feed speed command value (Wire speed set value) - Group Input / Analog Input 20
Arclength correction (arc length correction) - Group Input / Analog Input 20
Pulse-/ dynamic correction (Pulse/dynamic correction) - Group Input / Analog Input 21
Wire retract correction (Wire retraction correction) - Group Input / Analog Input 21
Seam number (Seam number) - Group Input / Analog Input 22
Welding speed (Welding speed) - Group Input / Analog Input 22
WireSense edge detection - Group Input / Analog Input 22
Wire forward / backward length (length specification wire threading / wire retraction) - Group Input / 23
Analog Input
Digital Outputs 25
Definition 25
Heartbeat power source (Heartbeat power source) - Single Bit 25
Power source ready (Power source ready) - Single Bit 25
Warning (Warning) - Single Bit 25
Process active (Process active) - Single Bit 26
Current flow (current flow) - Single Bit 26
Robot motion release (Robot motion release) - Single Bit 27
Arc stable/Touch signal (Arc stable/touch signal) - Single Bit 28
Main current signal (Main current signal) - Single Bit 31
Collisionbox active (CrashBox active) - Single Bit 31
Torchbody gripped (Torch body gripped) - Single Bit 31
Command value out of range (Set value out of range) - Single Bit 32
Correction out of range (Correction out of range) - Single Bit 32
Process Bit (Process bit) - Group Output 32
ExtOutput 1-8 (External output 1-8) - Single Bit 32
Touch signal (Touch signal) - Single Bit 33
Characteristic number valid (Characteristic number valid) - Single Bit 33
Sensor Status 1 (sensor status 1) - Single Bit 33
3
Wire stick workpiece (Wire stick workpiece) - Single Bit 34
Parameter selection internally (Internal parameter selection) - Single Bit 34
Limitsignal (Limit signal) - Single Bit 35
Main supply status (Mains voltage status) - Single Bit 35
Safety status - Single Bit 35
Twin synchronization active - Single Bit 36
System not ready - Single Bit 36
Notification (Notification) - Single Bit 36
Analog Outputs 37
Welding voltage (Welding voltage) - Group Output / Analog Output 37
Welding current (Welding current) - Group Output / Analog Output 37
Wire feed speed (Wire speed) - Group Output / Analog Output 38
Actual real value for seam tracking (Current actual value for seam tracking) - Group Output / Ana- 38
log Output
Motor current M1 (Motor current M1) - Group Output / Analog Output 40
Error number (Error number) - Group Output / Analog Output 41
Warning number (Warning number) - Group Output / Analog Output 41
WireSense position (wire position) - Group Output / Analog Output 41
Available Process Images 43
Process Image Types 43
Changing/Assigning Characteristic Numbers/Program Numbers (Retrofit Mode) 43
Information on the Use of the MIG/MAG Standard Manual, TIG, and Electrode Welding Processes 45
MIG/MAG Standard Manual 45
TIG 45
Electrode 45
Arc Break Monitoring 46
Arc Break Monitoring 46
Fronius Data Channel 48
Fronius Data Channel 48
Signal sequence when selected using "Job Mode" operating mode 49
Signal sequence when selected using "Characteristics Mode" operating mode 50
WireSense - more information 52
Process description WireSense (contour detection) 52
Process description WireSense edge detection (edge detection) 53
Signal curve of Edge Detection Mode on a level surface 54
Signal curve of Edge Detection Mode on a slanted surface 56
Signal curve of Sensing Mode for different surface geometries 58
Signal curve of WireSense break (during Sensing Mode) 60
Representation of the possible measurement range 61
Note on ignition timeout (Ignition Timeout) 62
Available signals for component scanning 63
Signal list 63
Limit Monitoring - functions and activation 64
Functions of Limit Monitoring 64
Available function packages 64
Prerequisites for the successful use of Limit Monitoring 65
Switch Limit Monitoring on / off 65
Detailed description of Limit Monitoring 66
Limit Monitoring - details on the individual welding parameters 67
Voltage monitoring 67
Current monitoring 68
Wirefeeder monitoring 68
Welding time monitoring 69
Energy monitoring 71
Setting of the reaction when exceeding or falling below the limits: 72
Setting of the reaction when exceeding or falling below the limits for the motor force 80
Smart Manager + OPT/i Jobs (4,067,002) 85
4
General
EN-US
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 wire 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 Type: Signed 16 Bit integer (15 bits +
bits 1 Sign Bit*)
Range: 0 to 65535 Rang -32768 to 32767
e:
0000 -10 (0000000000000000) 0000 0000 (0*000000000000000)
32767 0 (0111111111111111) 56 56 (0*000000000111000)
65535 +10 (1111111111111111) -64 -64 (1*111111111000000)
* = if the value entered has a negative
sign, the sign Bit is High – see markings
Behavior of the If a power source from the TPS/i series is connected to a robot interface, the settings on
Power Source the power source remain unchanged (2-step mode, special 2-step mode, etc.).
when an Interface
is Connected If a power source from the TPS series is connected to a robot interface, the power
source automatically selects 2-step mode.
Availability of As a result of updates, certain functions may be available on your device that are not
Functions described in this document, or vice versa.
5
Signal Transmis-
sion Time
Welding start
t
TPS/i
<10 ms
Process active
t
TPS/i
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.
Serious personal injury and damage to property may result.
▶ All the work and functions described in this document must only be carried out by
trained and qualified personnel.
▶ Read and understand this document.
▶ Read and understand all the Operating Instructions for the system components,
especially the safety rules.
6
Digital Inputs
EN-US
Welding start The rising edge of the Welding start signal starts the welding process.
(Welding on) - - The welding process runs for as long as the Welding start signal is active.
Single Bit Exceptions: The Robot ready signal is deactivated or the power source is reporting
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 The robot sets this signal as soon as it is ready to weld.
(Robot ready) - - If the signal is reset by the robot during welding, the welding process is ended in a
Single Bit controlled manner (without any crater filling routines).
- In addition, the Robot not ready error is output. This error must either be reset 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 operat-
ing mode, even if the Robot ready signal is not set.
Working mode This signal is used to select the operating mode of the power source.
(Operating mode)
- Single Bit 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 values and
material settings important for welding. This makes creating and saving 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
7
Description of special 2-step mode characteristics:
- To select welding parameters using the analog set values and the characteristic
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 special 2-
step mode characteristics.
HIGH LOW
Welding start
I
I
I-S I-E
S E
t
GPr t-S SL1 Main current SL2 t-E GPo
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 the welding parameters via the analog set values and the characteristic
number (characteristic ID), the correct characteristic number must be used. The
characteristic numbers can be found on the website for 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.
8
HIGH LOW
EN-US
Welding start
I I
t
GPr Main current GPo
2-step mode signal sequence
For MIG/MAG standard manual characteristics, the 2-step mode characteristics must be
used.
Gas on (Gas on) - The Gas on signal opens the gas solenoid valve and thus activates the gas flow.
Single Bit - 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 para-
meter 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 button on one of
the Fronius system components (power source, wirefeeder, torch hosepack, etc.).

- 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 The Wire forward signal activates the start of the wirefeeder.
(Wire forwards) - - The wire electrode is threaded into the hosepack without current or gas.
Single Bit - The wirefeeder can be activated independently of the operating mode (internal para-
- The signal corresponds to the wire threading button on the control panel of the
power source, on the wirefeeder, and on the torch hosepack. The precise function of
the wire threading button is described in the Operating Instructions of the respective
system components/the documentation of the whole welding system.
- As long as the Wire forward signal is set, the Wire backward signal cannot be set.
- The Wire forward signal can only be set if the Robot ready signal is set at the same
time. If this is not the case, wire threading must be controlled using the wire thread-
ing button on one of the Fronius system components (wirefeeder, torch hosepack,
etc.)
- The wire electrode can be threaded a maximum of 50 m (164 feet 0.5 inches)
(=safety stop)
9
The signal can be set in two ways:
- Pulse signal = wire electrode moves approx. 1 mm forwards
- Continuous signal = creep function – the wirefeeder is stopped as soon as the wire
electrode touches the welding material

- In single wire mode, the wire electrode of the active process line is fed
- In TWIN mode, both wire electrodes are fed
- If the TWIN operating mode changes during wirefeeding, the wirefeeding is adapted
in line with the change
Wire backward The Wire backward signal activates the retraction of the wire electrode.
(Wire return) - - It can be used to retract the wire electrode out of the welding torch completely or
Single Bit only by a specific length.
- The retraction can be activated independently of the operating mode (internal para-
- The signal corresponds to the wire-return button on the control panel of the power
source, on the wirefeeder, and on the torch hosepack. The precise function of the
wire-return button is described in the Operating Instructions of the respective system
components/the documentation of the whole welding system.
- As long as the Wire backward signal is set, the Wire forward signal cannot be set.
- The Wire backward signal can only be set if the Robot ready signal is set at the
same time. If this is not the case, retraction of the wire electrode must be controlled
using the wire-return button on one of the Fronius system components (wirefeeder,
torch hosepack, etc.)
- The wire electrode can be retracted a maximum of 50 m (164 feet 0.5 inches)
(=safety stop)
The signal can be set in two ways:

- Pulse signal = wire moves approx. 1 mm backwards
- Continuous signal = permanent wire retraction

- In single wire mode, the wire electrode of the active process line is fed
- In TWIN mode, both wire electrodes are fed
- If the TWIN operating mode changes during wirefeeding, the wirefeeding is adapted
in line with the change
Error reset (Reset If an error message is output on the power source, the error is reset using the Error reset
error) signal.
In order to reset the signal successfully, the signal must remain set for at least 10 ms.
WARNING!
Danger due to welding processes starting unexpectedly.

This can result in severe personal injury and damage to property.
▶ The cause of the error must always be resolved before the error message is reset
using the Error reset signal.
10
WARNING!
EN-US
Danger due to welding processes starting unexpectedly if the Error reset signal is
always active and the Welding start signal is set at the same time.
This can result in severe personal injury and damage to property.
▶ Ensure that the Welding start signal is not set during troubleshooting if the Error
reset signal is active at the same time.

The signal resets the error on both power sources.
Touch sensing
WARNING!
(TouchSensing) -
Single Bit Danger from electrical current. When Touch sensing is activated, a voltage of
approx. 70 V (up to 3 A) is applied to the wire electrode/gas nozzle.
May result in serious injuries or death.
▶ Do not touch the wire electrode and the torch body (gas nozzle, contact tip) when
Touch sensing is active.
▶ When Teach mode is active, do not touch any electrically conductive parts that are
touched by the wire electrode and the torch body (gas nozzle, contact tip, etc.).
The Touch sensing signal can be used to detect contact between the wire electrode or
the gas nozzle and the workpiece = short circuit between workpiece and wire electrode
or gas nozzle.
- If the Touch sensing signal is set, the control panel of the power source displays
touch and a voltage of approx. 70 V (current limited to 3 A) is applied to the wire
electrode/the gas nozzle.
- If a short circuit occurs, this is reported to the robot controller by the Arc stable sig-
nal / Touch signal (see page 28) and Touch signal (see page 33).
- The output of the Arc stable / Touch signals (see page 28) and Touch signal (see
page 33) lasts 0.3 seconds longer than the duration of the short circuit current.
- As long as the Welding start signal is set, the Touch sensing signal cannot be activ-
ated.
- The welding process can also be started if the TouchSensing signal is active. This
automatically deactivates the touch function.
- TouchSensing can be activated independently of the operating mode (internal para-
Touch sensing function/process:
11
delta u (rising voltage) --> delta t (time)
U Condition: voltage drop i.e. 1,5 volt (adjustable)
max. Open circuit voltage

depends on PowerSource type (i.e. 60V)
Touchvoltage
t
I
max. current aprox. 3A
Touchcurrent
t
digital I/O plus. 300ms * or as long as the wire touches the work piece
Output signal
< 15ms *
* timing depends Interface

t
digital I/O
Input signal
NOTE!
Risk of signal overlap.
This can lead to problems in connection with the Wirebrake option.
▶ After deactivating the Touch sensing signal, wait 4 seconds before setting another
signal.

- Touch sensing is always carried out using one wire electrode
- In single wire mode, the wire electrode of the active process line is used
- In TWIN mode, the wire electrode of the leading process line (Lead) is used
Gas nozzle touch If the position detection is carried out by touching the workpiece with the gas nozzle
sensing (Gas (instead of the wire electrode), the gas nozzle must be connected to the welding current
nozzle position lead using an RC circuit.
search) - Single
Bit The use of an RC circuit is required so that if the gas nozzle comes into contact with the
workpiece during welding:
- Unacceptable currents in the connection between the gas nozzle and the welding
current lead are avoided
- The welding process is not influenced
When contact is detected by the gas nozzle, the short circuit current only flows for
approx. 4 ms, until the capacitors in the RC circuit are charged. To ensure safe contact
detection by the robot controller, the Arc stable and Touch sensing signals are on for 0.3
s longer than the short circuit current.
12
EN-US
Torch blow out If the robot wirefeeder is fitted with an additional solenoid valve for compressed air, this
(Blow out weld- is controlled using the Torch blow out signal.
ing torch) - Single The signal is used to remove contaminations from the gas nozzle during torch cleaning.
Bit
Welding simula- The power source uses the Welding simulation signal to simulate an actual welding pro-
tion (Welding cess.
simulation) - - This allows the user to follow a welding path that has been programmed in the robot
Single Bit controller without any actual welding taking place
- All signals are set as if actual welding were taking place (without time dependencies,
no actual values)
• Arc stable
• Process active
• Main current signal
- No arc is ignited
- No wire electrode is fed
- The gas solenoid valve is not triggered
Synchropulse on The Synchropulse on signal activates/deactivates the SynchroPulse function set in the
(SynchroPulse power source. The signal can be set before or during welding.
on) - Single Bit
WireBrake on By activating the WireBrake on signal, the wire electrode is held by the OPT/i MHP
(Wire brake on) - WireBrake.
Single Bit OPT/i MHP WireBrake is a mechanical component that is installed between the torch
hosepack and the torch body.
WireBrake on can be activated independently of the operating mode (internal parameter

selection, special 2-step mode characteristics, Job Mode, etc.).
If OPT/i MHP WireBrake is detected in the system, the WireBrake on signal is automatic-
ally set in Touch sensing.
NOTE!
This may result in problems holding the wire electrode.
▶ It is not recommended to activate any other signals while the WireBrake on signal is
active.
▶ After deactivating the WireBrake on signal, wait 4 seconds before activating another
signal.
▶ A detailed description of the program sequence can be found in the Robacta TX
10i/G/W Operating Instructions.

WireBrake is not available for TWIN hosepacks.
Torchbody The Torchbody Xchange signal is only available in conjunction with a torch body change
Xchange (Change system.
torch body) - If the signal is High,, the torch body coupling is opened.
Single Bit
13
Torchbody Xchange can be activated independently of the operating mode (internal
parameter selection, S2-step mode characteristics, Job Mode).
NOTE!
This may result in problems changing the torch body.
▶ It is not recommended to activate any other signals while the Torchbody Xchange
signal is active.
▶ After deactivating the Torchbody Xchange signal, wait 3 seconds before activating
another signal.
▶ A detailed description of the program sequence can be found in the Operating
Instructions of the torch body change system.
Teach mode -
WARNING!
Single Bit
Danger from electrical current due to Teach mode being active. When Teach mode
is active, a voltage of approx. 70 V (up to 3 A) is applied to the wire electrode/
contact tip.
This may result in serious injuries or death.
▶ Do not touch the wire electrode and the contact tip when Teach mode is active.
▶ When Teach mode is active, do not touch any electrically conductive parts that are
touched by the wire electrode or the contact tip.
Teach mode can be used to create the robot program. Teach mode being activated (sig-
nal High) avoids the wire electrode becoming bent when setting up the robot.
Teach mode can be activated independently of the operating mode (internal parameter
selection, special 2-step mode characteristics, Job Mode, etc.).
Teach mode function:
- Ensure the desired distance (Stickout) to the

workpiece (cut the wire electrode to the correct
Stickout , etc.).
= 15 mm
(0.59 inch)
- If the distance between the gas nozzle and the

workpiece becomes smaller during robot move-
ment, the wirefeeder retracts the wire electrode –
this means that the wire electrode cannot be bent.
- If the distance between the gas nozzle and the
< 15 mm workpiece becomes bigger during robot move-
(0.59 inch) ment, the wirefeeder unwinds the wire electrode
to the set Stickout .
14
EN-US
- The wire electrode will not be unwound any fur-
ther once the set Stickout- value has been
= 155 mm reached, even if the wire electrode is no longer in
(0.59 inch) contact with the workpiece.
The Touch signal is set as follows when using Teach mode:

- As soon as the wire electrode touches the workpiece, the Touch signal is set to High
- Only when the wire electrode is no longer in contact with the workpiece is the Touch
signal set to Low
NOTE!
Danger from using Teach mode in conjunction with very soft wire electrodes.
This may result in unexpected welding results caused by bent wire electrodes.
▶ Using Teach mode with very soft wire electrodes may result in the wire electrodes
becoming bent. To prevent wire burn-back caused by the bent wire electrode,
unwind the wire electrode by approx. 50 cm (19.69 inches) before the start of weld-
ing and shorten it.

- In single wire mode, Teach mode is activated for the active process line
- In TWIN mode, Teach mode is activated for both process lines
ExtInput 1-8 Inputs used to control options, such as OPT/i RI FB REL.

(External input
1-8) - Single Bit - Max. voltage = DC 113 V / AC 68 V
- Max. current load 1 A
Example outputs: ExtInput1 = OPT_Output 1:
OPT/i RI External
FB REL Device
(1) (2) (3)
(1) Robot output

(2) Power source input
(3) Options output
15
- TWIN systems are only compatible with the OPT/i RI FB REL EXT 8I/8O option
- The signals are forwarded to both power sources and are then available at the out-
puts of the relay station used
Job number This signal is used to carry out welding using the welding parameters that are saved
(Job‑number) - under the selected job number (1-1000).
Group Input
Job number 0 can be used to select the job on the control panel of the power source.

Job numbers must be selected separately for both power sources.
Welding charac- This signal is used to specify the welding process using the characteristic number.
teristic (Charac-
teristic number) - Characteristic number 0 can be used to select the material setting and the welding pro-
Group Input cess on the control panel of the power source.
Examples of characteristic numbers:

- 2765 = G3Si1 / 1.2 mm / Ar 15-20%, CO2 / LSC
- 3189 = G3Si1 / 1.2 mm / Ar 15-20%, CO2 / PMC

Characteristic numbers must be selected separately for both power sources.
Disable process If this signal is active, a process-dependent correction (Process controlled correction sig-
control (Deactiv- nal) can be manually selected on the power source.
ate process-
dependent cor- Additional information for TWIN systems:
rection) - Group Process-dependent corrections must be activated separately for both power sources.
Input
Processline This signal is used to select the desired process line.

select (Process
line selection) - The signal is only available if:
Group Input - The OPT/i TPS Dual Head Robotics option is present in the power source
- Each process line has its own wirefeeder
Bit 1 Bit 0 Description

0 0 Wirefeeder 1 (factory setting)
0 1 Wirefeeder 2
1 0 Wirefeeder 3
16
Function information
- It is only possible to switch between the process lines using the robot
EN-US
- The inactive wirefeeders are only supplied with voltage, the system bus is switched
off. This has the following limitations:
• Available software updates will only be applied to the wirefeeder if the
wirefeeder is part of the process line selected
• The CAT signal of inactive wirefeeders is not evaluated
• It is not possible to carry out gas tests, wire threading, wire retraction, etc. on
the hosepacks of the inactive process lines
• The welding torch identification of hosepacks of the inactive process lines is not
read
• The remote controls of the inactive process lines are also inactive
TWIN mode This signal defines which TWIN mode will be used to operate the respective power
(TWIN operating source.
mode) - Group
Input The following can be specified using the signal
- Single wire / or TWIN welding
- Which process line is leading during TWIN welding (Lead)
- Which process line is active during single wire welding
The operating modes can be changed both before and during welding.

0 0 Single wire mode, line 1
0 1 TWIN mode, line 1 leading (Lead)
1 0 TWIN mode, line 2 leading (Lead)
1 1 Single wire mode, line 2
Value range for TWIN mode
Documentation The signal is used to select whether the weld seams are counted by the power source or
mode (Document- the robot.
ation mode) -
Single Bit Signal level = Low:
- The weld seams are counted by the power source.
- Each time welding is completed, the weld seam count increases by 1. Switching the
power source off and on again restarts the count at 0. In addition, it is also possible
to specify an initial value (starting the count at 10 instead of 0, for example).
• With the exception of: If the Fronius Data Channel is used, the number of weld
seams is specified using the Fronius Data Channel and not the power source.
Signal level = High:

- The number of weld seams is specified using the robot.
17
WireSense start -
WARNING!
Single Bit
Danger from electrical current. When the WireSense start signal is active, a
voltage of approx. 50 V (up to 1 A) is applied to the wire electrode/contact tip.
This may result in serious injuries or death.
▶ Do not touch the wire electrode and contact tip when the WireSense start signal is
active.
▶ Do not touch any electrically conductive parts that are touched by the wire electrode
or the contact tip when the WireSense start signal is active.
This signal starts one of the following two functions:

1. WireSense - Sensing Mode: used to scan the component surface / component geo-
metry (contour detection)
- This function is active when the Signal WireSense start is activated and a height
value less than 0.5 mm (0.019 inches) is specified for the WireSense edge
detection signal
- Edge detection is not active with this function
- The Touch signal is not output for this function
2. WireSense - Edge Detection Mode: used to detect a single edge
- This function is active when the Signal WireSense start is activated and a height
value greater than / equal to 0.5 mm (0.019 inches) is specified for the Wire-
Sense edge detection signal
- For more information, see WireSense edge detection - Group Input / Analog
Input on page 22
Other effects of the WireSense start signal:

- As soon as the signal is active, the forward and backward movement of the wire
electrode begins
- After the wire electrode has touched the workpiece for the first time, the point of the
first contact is used as a zero position (reference point) for the WireSense height
measurement
Safety functions with WireSense:

- If WireSense is already active (WireSense process already running), the wire elec-
trode can be conveyed a maximum of 25 mm (0.98 inches). If there is no workpiece
contact within the 25 mm (0.98 inches), wirefeeding is stopped.
- If WireSense is started for the first time (without previous workpiece contact), the
wire electrode can be conveyed a maximum of 450 mm (17.72 inches). If there is no
workpiece contact within 450 mm (17.72 inches), wirefeeding is stopped.
For more information on WireSense, see section WireSense - more information on

page 52.
18
EN-US
WireSense break - This signal only has an impact if the WireSense start signal is active at the same
- Single Bit time
- This signal is used to interrupt the WireSense process but at the same time to obtain
the reference point that was determined when the WireSense process was first star-
ted
• The WireSense break signal stops the wire movement while the WireSense
start signal is active - for example, to bridge larger distances between two work-
pieces (if the wire electrode is touching a workpiece while the WireSense break
signal is active, the wire electrode is still retracted to prevent bending)
• The reference point, which was determined when the WireSense process was
first started, remains stored while the WireSense break signal is active
• After the WireSense break signal is deactivated, the wire movement starts
again and the height measurement continues
- When the WireSense break signal is set, the Arc stable signal is deactivated at the
same time. As soon as the WireSense break signal is deactivated again, the Arc
stable is activated signal again.

page 52.
19
Analog Inputs
Wire feed speed As described below, the set value can be specified on a Digital Interface or an Analog
command value Interface.
(Wire speed set
value) - Group The following set value specifications apply to the MIG/MAG standard synergic,
Input / Analog MIG/MAG pulse synergic, MIG/MAG PMC, and MIG/MAG LSC welding processes.
Input
Digital Interface:
The wirefeeder set value is specified by entering a value between -32,768 and
+32,767 (SINT 16).
Value range Designation Min./max. possible value
-32,768 Wire speed -327.68 m/min (depending on wirefeeder)
+32,767 Wire speed +327.67 m/min (depending on wirefeeder)

The digital set value must be entered separately for both power sources.
Analog Interface:
The wirefeeder set value is specified through an analog method by entering a value
between 0 and 10 V.
0V Wire speed 0% (depending on wirefeeder)
10 V Wire speed 100% (depending on wirefeeder)

It is not possible to enter an analog set value on TWIN systems.
Job correction (specifications apply for Single- andTWIN welding):

- Factor = 100
- Data type SINT
- Specified as a percentage. Example: 15% = 1500 step change
Arclength correc- As described below, the value for the arc length correction can be specified on a Digital
tion (arc length Interface or an Analog Interface.
correction) -
Group Input / The following specifications apply to the MIG/MAG standard synergic, MIG/MAG pulse
Analog Input synergic, MIG/MAG PMC, and MIG/MAG LSC welding processes.
Digital Interface:
By entering a value between -32,768 and +32,767 (SINT 16) the arc length is correc-
ted, but the wire speed is not changed.
-32,768 Arc length correction -10% = shorter arc
0 Arc length correction 0% = saved value
+32,767 Arc length correction +10% = longer arc

20
Analog Interface:
EN-US
By entering a value between 0 and 10 V using an analog method, the arc length is cor-
rected, but the wire speed is not changed.
0V Arc length correction -10% = shorter arc
5V Arc length correction 0% = saved value
10 V Arc length correction +10% = longer arc

Job correction (specifications apply for Single- andTWIN welding):

- Factor = 10
- Data type SINT
- Specified as absolute value. Example: 1.5 = 150 step change
Pulse-/ dynamic As described below, the value for the pulse/dynamic correction can be specified on a
correction (Pulse/ Digital Interface or an Analog Interface.
dynamic correc-
tion) - Group The following specifications apply to the MIG/MAG standard synergic, MIG/MAG pulse
Input / Analog synergic, MIG/MAG PMC, and MIG/MAG LSC welding processes.
Input
Digital Interface:
Entering a value between -32,768 and +32,767 (SINT 16) specifies the pulse/dynamic
correction, the wire speed is not changed.
-32,768 Pulse/dynamic correction -10% = pulse/dynamic correction
0 Pulse/dynamic correction 0% = saved value
+32,767 Pulse/dynamic correction +10% = pulse/dynamic correction

Analog Interface:
Entering a value between 0 and 10 V using an analog method specifies the pulse/
dynamic correction, the wire speed is not changed.
0V Pulse/dynamic correction -10% = pulse/dynamic correction
5V Pulse/dynamic correction 0% = saved value
10 V Pulse/dynamic correction +10% = pulse/dynamic correction

Wire retract cor- As described below, the value for the wire retraction correction can be specified on a
rection (Wire Digital Interface or an Analog Interface.
retraction correc-
tion) - Group The following specifications apply to the MIG/MAG standard synergic, MIG/MAG pulse
Input / Analog synergic, MIG/MAG PMC, and MIG/MAG LSC welding processes.
Input
21
Digital Interface:
The wire retraction correction is specified by entering a value between 0 and 65,535
(UINT 16).
0 Wire retraction correction 0
65,535 Wire retraction correction +10

The digital value must be entered separately for both power sources.
Analog Interface:
The wire retraction correction is specified by using an analog method to enter a value
between 0 and 10 V.
0V Wire retraction correction 0
10 V Wire retraction correction +10

It is not possible to enter an analog value on TWIN systems.
Seam number The seam number of the respective welding process is specified using this value, for
(Seam number) - example for documentation purposes.
Group Input /
Analog Input For more detailed information regarding weld seam documentation, please refer to Doc-
umentation mode (Documentation mode) - Single Biton page 17.

The seam number for both power sources is specified at the same time.
Welding speed This value is used to transmit the robot's TCP speed.
(Welding speed) -
Group Input / Additional information for TWIN systems:
Analog Input The TCP speed for both power sources is transmitted at the same time.
WireSense edge Contour detection:

detection - Group - If a value less than 0.5 mm (0.019 inches) is specified with the WireSense edge
Input / Analog detection signal, the WireSense start signal is used for contour detection (Wire-
Input Sense - Sensing Mode)
• The surface of the component is scanned cyclically by the wire electrode and
the measured height value is output continuously
• The Touch signal is not active at the same time
22
Edge detection:
- If a value of 0.5 - 20 mm (0.019 - 0.787 inches) is specified with the WireSense edge
EN-US
detection signal, the WireSense start signal is used to detect and measure a single
edge
- The specified value (threshold value) defines the minimum edge height that can be
detected by the power source
• For example, if you use a 2 mm thick sheet that is welded with an overlap joint,
it is recommended to use this signal to specify 1.5 mm (0.059 inch) (it is not
recommended to always set the minimum value of 0.5 mm (0.019 inches), as
this setting may cause false detection. For example, this may be caused by
welding spatter, inaccurate robot movements, etc.)
• The Touch signal is output when an edge is detected
Digital Interface:
The threshold value for edge detection is specified by entering a value between 0 and
200 (UINT 16).
0 Threshold 0 mm (0 inches)
200 Threshold 20 mm (0.787 inches)

page 52.
Wire forward / Signal behavior:

backward length - The signal is active as soon as a value greater than or equal to 1 mm (0.039 inches)
(length specifica- is entered (0 = signal inactive).
tion wire thread- - If a value greater than or equal to 1 mm (0.039 inches) is specified, the wire elec-
ing / wire retrac- trode is only fed by the specified value when the signal Wire forward is set. After
tion) - Group reaching the preset value, the end of wirefeeding takes place automatically.
Input / Analog - As soon as the preset value is reached, the signal Touch signal (WORD 0 / Byte 0 /
Input Bit 7) is set and the signal Wire forward can be deactivated again. At the same time,
the signal Wire position indicates how far the wire electrode has been conveyed
- The value remains set for 1 second
- Tolerance = +/- 1 mm (0.039 inches)
- If the wire electrode touches the workpiece before the preset value has been
reached, the Touch signal (WORD 0 / Byte 0 / Bit 7) and additionally the signal Arc
stable / Touch signal (WORD 0 / Byte 0 / Bit 5) are set. The end of wirefeeding takes
place automatically.
- The wire electrode can be conveyed a maximum of 50 m (164 feet 0.5 inches)
(=safety stop)
If not all wire feeds of the welding system are synchronized (e.g. due to the combination
of a Robacta Drive drive unit and a Stand Alone unwind wirefeeder), inaccuracies of +/- 5
mm (0.196 inches) may occur in the specification of the wire electrode fed due to the
system.
As described below, the set value can be specified on a Digital Interface or an Analog
Interface.
The following set value specifications apply to the MIG/MAG standard synergic,
MIG/MAG pulse synergic, MIG/MAG PMC, and MIG/MAG LSC welding processes.
Digital Interface:
The set value for the length of wire to be fed is specified by entering a value between
-32,768 and +32,767 (UINT 16).
23
Value range Min./max. possible value
-32,768 1 mm (0.039 inches)
+32,767 10,000 mm (393.7 inches)

Analog Interface:
The set value for the length of wire to be fed is specified by entering an analog value
of 0 to 10 V.
Value range Min./max. possible value
0V 1 mm (0.039 inches)
10 V 10,000 mm (393.7 inches)

Signal course - set Wire forward length (= 25 Signal course - workpiece contact occurs
mm / 0.984 inches) could be reached according before the set Wire forward length (= 25 mm /
to plan: 0.984 inches) could be reached:
15 mm
(0.591 inch)
25 mm
(0.984 inch)
1 1
t t
2 2
t t
1 Second
3 3
t t
1 Second 1 Second
4 4
t t
1 Second
1 Second
5 5
t t
1 = Wire forward / backward length (Analog Input) | Bit 240 - 255 1 = Wire forward / backward length (Analog Input) | Bit 240 - 255
2 = Wire forward (Digital Input) | Bit 9 2 = Wire forward (Digital Input) | Bit 9
3 = Arc stable / Touch signal (Digital Output) | Bit 5 3 = Arc stable / Touch signal (Digital Output) | Bit 5
4 = Touch signal (Digital Input) | Bit 7 4 = Touch signal (Digital Input) | Bit 7
5 = WireSense Position (Analog Output) | Bit 256 - 271 5 = WireSense Position (Analog Output) | Bit 256 - 271
24
Digital Outputs
EN-US
Definition Digital outputs are signals from the power source to the robot.
(1) (2)
(1) Robot input

(2) Power source output
Heartbeat power As soon as the interface creates an authenticated connection to the power source, this
source (Heartbeat signal changes its activity with a frequency of 1 Hz (1 second High, 1 second Low, 1
power source) - second High, etc.).
Single Bit
As soon as the RI FB/i TWIN Controller establishes an authenticated connection to both
power sources, this signal changes its activity with a frequency of 1 Hz (1 second High, 1
second Low, 1 second High, etc.).
Power source - The signal is High when the power source is ready to weld
ready (Power - The signal is Low, if a fault occurs on the power source (Error) or a notification (Noti-
source ready) - fication) is issued
Single Bit - The signal can also be called a "common error", as it is set to Low for all types of
internal and external error

The signal is only set to High when both power sources are ready to weld.
Warning (Warn- - The signal is High when the power source issues a warning.
ing) - Single Bit - The signal remains High until the reason for the warning has been rectified.
- The signal automatically changes to Low, as soon as the reason for the warning has
been eliminated
- The signal has no effect on the welding process or the operability of the power
source (welding can be started; running process is not interrupted, etc.)

The signal is set to High as soon as one of the two power sources issues a warning.
25
Process active The Process active signal is set from the beginning of gas pre-flow to the end of gas
(Process active) - post-flow in order to inform the robot that welding is still taking place. This means that,
Single Bit for example, the dwell time of the robot can be synchronized at the end of the weld seam
to ensure that there is an ideal gas shield.
If the Welding start signal is set, the gas pre-flow time begins to count down, even before
the arc is ignited.
After extinguishing the arc, the gas post-flow time begins to count down.
High Low
Welding start
I
I-S I-E

t
(1)
(1) Process active (process active)

The signal is set as soon as one of the two power sources becomes active.
Current flow (cur- This signal is set as soon as the wire electrode touches the workpiece and current
rent flow) - Single begins to flow – the signal is High as soon as the workpiece is touched.
Bit
During welding the signal can fall to Low during all welding processes – the signal func-
tions in the same way for all welding processes.
High Low
Welding start
I
I-S I-E

t
(1)
(1) Current flow (current flow)

The signal is set to High as soon as one of the two wire electrodes becomes live.
26
EN-US
Robot motion The signal is active from the end of the starting current to the end of the gas post-flow.
release (Robot
motion release) - The starting current time begins as soon as Current flow is High. Even if Current flow is
Single Bit interrupted, the starting current time continues to run until the set end (the starting cur-
rent time does not reset).
If an arc monitoring time has been set, the Robot motion release signal is only reset if
the Current flow signal is inactive for longer than the set arc monitoring time.
High Low
Welding start
I
I-S I-E

t
(1)
(1) Robot motion release (Robot motion release)
At the start of welding, the signal is set to High in the following instance:
- Arc stable High
- Current flow High
- The starting current time has elapsed (not the slope time)
During welding, the signal is set to Low in the following instance:

- Arc stable Low
At the end of welding, the signal is set to Low in the following instance:
- Welding start Low
- The gas post-flow has ended

The signal is output separately for both process lines.
27
Arc stable/Touch - This signal is set as soon as the wire electrode touches the workpiece and current
signal (Arc flows, thus reporting to the robot controller that the arc is burning.
stable/touch sig-
nal) - Single Bit - If the Arc stable / Touch signal is active, the arc monitoring is also active. This is not
the case for the Current flow signal.
- If an arc monitoring time has been set, the Arc stable / Touch signal is only reset if
the Current flow signal is inactive for longer than the set arc monitoring time.
- The Arc stable / Touch signal is active as long as the arc is burning.
- The Arc stable / Touch signal is also set as soon as the wire electrode or the gas
nozzle comes into contact with the workpiece in Touch- mode (Touch sensing signal
is active).
- For more information about the Touch sensing signal, see Touch sensing (Touch-
Sensing) - Single Bit on page 11.
- When using WireSense, the Arc stable / Touch signal is set as soon as the wire
electrode comes into contact with the workpiece for the first time and the WireSense
process runs stable (For example, when the WireSense - Slaghammer function is
automatically triggered, the Arc stable / Touch signal is only set after the WireSense
- Slaghammer function has been successfully executed)
• For more information on WireSense, see section WireSense start - Single Bit
on page 18.
High Low
Welding start
I
I-S I-E

t
(1)
(1) Arc stable / Touch signal (arc stable/touch signal)
The signal functions differently depending on the welding process. See below for an
overview of the function of the signal in conjunction with the different welding processes.
MIG/MAG pulse synergic, MIG/MAG PMC, mixed processes:
Example of correct ignition at the start of welding
28
EN-US
(Start of Welding)
Ignition
U
Current flow I t
t
Arc stable
MIG/MAG pulse synergic, MIG/MAG PMC, mixed processes:
Example of incorrect ignition at the start of welding

(Start of Welding)
Ignition
I t
Current flow
t
Arc stable
MIG/MAG standard synergic, MIG/MAG standard manual, MIG/MAG LSC, MIG/MAG

CMT, MIG/MAG CMT Mix:
Example of correct ignition at the start of welding
29
I
(Start of Welding)
Ignition
U
Current flow t
t
Arc stable
MIG/MAG standard synergic, MIG/MAG standard manual, MIG/MAG LSC, MIG/MAG

CMT, MIG/MAG CMT Mix:
Example of incorrect ignition at the start of welding
I
(Start of Welding)
Ignition
150-200ms
t
Current flow
t
Arc stable
30
- In single wire mode, the signal is set as soon as the wire electrode comes into con-
EN-US
tact with the workpiece and current begins to flow
- In TWIN mode, the signal is set as soon as both wire electrodes come into contact
with the workpiece and current begins to flow
• If the input signal Wire forward or Touch sensing is active, the Arc stable / Touch
signal is set as soon as current starts to flow on one of the two wire electrodes
Main current sig- If welding is carried out with a defined starting current and a defined final current, the
nal (Main current Main current signal is set between the end of the starting current and the start of the final
signal) - Single current phases.
Bit
High Low
Welding start
I
I-S I-E
t
GPr t-S SL1 (1) SL2 t-E Po
(1) Main current signal (main current signal)

- In single wire mode, the signal is set as soon as the active process line starts weld-
ing using the main current
- In TWIN mode, the signal is set as soon as both process lines start welding using
the main current
Collisionbox act- If a collision occurs (with the workpiece, clamping device, etc.) while using the CrashBox,
ive (CrashBox the contact of the CrashBox is opened and the Collisionbox active signal is set to Low
active) - Single
Bit In this case, it is recommended that:
- immediate shutdown of the robot is initiated and
- the welding process is ended
The signal has no effect on the power source.
Torchbody This signal indicates that a Fronius torch body has been registered in the system.
gripped (Torch
body gripped) -
Single Bit
31
Command value This signal indicates that the „Wire feed speed command value“ input is outside of the
out of range (Set possible range.
value out of
range) - Single The signal is High if, for example:
Bit - The possible range is limited by the wirefeeder:
• Selected wire speed set value = 25 m/min
• Maximum wire speed set value based on characteristic = 25 m/min
• Maximum possible speed of the wirefeeder = 15 m/min
- The possible range is limited by the characteristic:
• Selected wire speed set value = 25 m/min
• Maximum wire speed set value based on characteristic = 15 m/min
• Maximum possible speed of the wirefeeder = 30 m/min

The signal is set as soon as one of the two process lines exceeds a defined range.
Correction out of This signal indicates that at least one of the selected corrections (for example, Arc length
range (Correction correction) is outside of the specified range.
out of range) -
Single Bit Additional information for TWIN systems:
The signal is set as soon as one of the selected corrections exceeds the defined range.
Process Bit (Pro- These signals indicate which welding process has been selected.
cess bit) - Group
Output Value range for welding process:
Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 Description
0 0 0 0 0 No internal mode selection or process
0 0 0 0 1 MIG/MAG pulsed synergic
0 0 0 1 0 MIG/MAG standard synergic
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
ExtOutput 1-8 Outputs used to control options, such as OPT/i RI FB REL.

(External output
1-8) - Single Bit - Max. voltage = DC 113 V / AC 68 V
- Max. current load 2 A
Example outputs: ExtOutput1 = OPT_Input 1
32
EN-US
OPT/i RI External
FB REL Device
(1) (2) (3)
(1) Robot input

(2) Power source output
(3) Options input

- TWIN systems are only compatible with the OPT/i RI FB REL EXT 8I/8O option
- If an input signal is set on one of the two power sources, the signal is also set on the
fieldbus output
Touch signal The signal is used for various functions and indicates that
(Touch signal) - - A workpiece is being touched in Touch-mode
Single Bit - The wire electrode is touching a workpiece while the Wire forward signal is active at
the same time
- When using the WireSense edge detection function, the set threshold value has
been reached and thus the required edge has been successfully detected.
• For more information on WireSense, see section WireSense - more informa-
tion on page 52.

- Only one of the two wire electrodes is monitored
- In single wire mode, only the active wire electrode is monitored
- In single wire mode, only the leading wire electrode (Lead) is monitored
Characteristic If the signal is High, the selected characteristic and the selected process are approved
number valid and can be used.
(Characteristic
number valid) -
Single Bit
Sensor Status 1 This signal indicates the status of the wire end option 4,100,869,CK.
(sensor status 1)
- Single Bit Signal level Description
High Wire electrode present
Low No wire electrode present
The signal is output as soon as the sensor of the option is detected in the system.
33
If there is no sensor in the system, the signal is set to High.

(sensor status 2)

(sensor status 3)

Wire stick work- The signal is High if a wire stick is detected on the workpiece. This signal is always out-
piece (Wire stick put regardless of other settings.
workpiece) -
Single Bit Additional information for TWIN systems:
The signal is set to High as soon as one of the two wire electrodes sticks.
Parameter selec- This signal indicates whether the parameter selection has been set to "internal".
tion internally
(Internal para- This setting can be applied:
meter selection) - - Using the Working mode signal/internal parameter selection or
Single Bit - On the power source itself: Defaults/Interface setup/Welding parameter.
34
The following signals can be set on the power source itself if the Parameter selection
internally High signal is active:
EN-US
- Welding process (MIG/MAG pulse synergic, MIG/MAG standard synergic, etc.)
- Operating mode (2-step mode, etc.)
- Characteristic/job number (depending on the welding process)
- Wire speed
- Arc length correction
- Pulse/dynamic correction
- Wire retraction
- Process-dependent correction
- SynchroPulse on/off

The signal is set to High as soon as parameter selection is set to "internal" on one of the
two process lines.
Limitsignal (Limit This signal indicates that the set limits for voltage, current, wirefeeder, welding time, and
signal) - Single energy input have been exceeded or not reached.
Bit
This signal is only available in Job Mode.
Requirements
- In the menu on the power source "Process parameters/Job/Optimize Job/Limit mon-
itoring/Limit reaction", the reaction is set to "Warning" or "Error"
- OPT/i Limit Monitoring approved for the power source

For more information on Limit Monitoring see section:

- Limit Monitoring - functions and activation from page 64 and
- Limit Monitoring - details on the individual welding parameters from page 67
Main supply This signal indicates whether a phase error has occurred on the power source (incorrect
status (Mains power supply to the power source).
voltage status) -
Single Bit If this error has occurred, the error numbers 6451 or 6515 will be shown on the display of
the power source or transmitted to the robot via the interface as an Error number signal

The signal is set to High as soon as a phase error occurs on one of the two power
sources.
Safety status - This signal indicates the status of the OPT/i Safety Stop PL d and OPT/i TPS External
Single Bit Stop options.

0 0 Reserve
0 1 Hold
1 0 Stop
1 1 Not installed/active
35
Twin synchroniz- The signal indicates that the synchronization between the two power sources is active.
ation active -
Single Bit
System not ready This signal indicates whether the welding system is ready for use:
- Single Bit - This signal is Low if there are no error messages in the welding system (all error
sources must be eliminated for the signal to change to Low)
- This signal is High as soon as a component of the welding system outputs an error
message
Examples of when this signal changes to High:

- A component of the welding system performs an update
- Emergency stop
- In conjunction with wire sensors (ring sensor, sensor on wire drum, etc.), for
example, errors 16828, 16837, 16838
If the following exceptions occur, the signal remains Low despite the error messages:
- The Robot ready signal is Low
- During the welding process, a welding torch detection problem occurs (BID error)
Notification (Noti- - The signal is High when the power source issues a notification.
fication) - Single - Notifications can arise, for example, due to set process limits, external sensors, etc.
Bit - The signal automatically interrupts the welding process
- Operation of the power source is possible while the signal is High
- The signal remains High until the reason for the notification has been resolved.
- The signal automatically changes to Low, as soon as the reason for the notification
has been eliminated

The signal is set to High as soon as one of the two power sources issues a notification.
36
Analog Outputs
EN-US
Welding voltage As described below, the current welding voltage actual value can be output on a Digital
(Welding voltage) Interface or an Analog Interface.
- Group Output /
Analog Output Digital Interface:
- During the welding process, the current welding voltage actual value will be out-
put as a value between 0 - 65,535 (UINT 16).
- The welding voltage set value is output when idling.
- The Hold value is output immediately after welding.
0 Welding voltage 0 V (set value/actual value/Hold value)
32,767 Welding voltage 327.67 V (set value/actual value/Hold value)

The digital actual value is output separately for both power sources.
Analog Interface:
- During the welding process, the current welding voltage actual value will be out-
put as a value between 0 - 10 V.
- The welding voltage set value is output when idling.
0V Welding voltage 0 V (set value/actual value/Hold value)
10 V Welding voltage 100 V (set value/actual value/Hold value)

The analog actual value is not output on TWIN systems.
Welding current As described below, the present welding current actual value can be output on a Digital
(Welding current) Interface or an Analog Interface.
- Group Output /
- During the welding process, the present welding current actual value will be out-
put as a value between 0 and 65,535 (UINT 16).
- The welding current command value is output when idling.
0 Welding current 0 A (set value/actual value/Hold value)
32,767 Welding current 3276.7 A (set value/actual value/Hold value)

Analog Interface:
- During the welding process, the present welding current actual value will be out-
put as a value between 0 - 10 V.
- The welding current command value is output when idling.
- The Hold- value is output immediately after welding.
37
0V Welding current 0 A (set value/actual value/Hold value)
10 V Welding current 1000 A (set value/actual value/Hold value)

Wire feed speed As described below, the current wire speed actual value can be output on a Digital Inter-
(Wire speed) - face or an Analog Interface.
Group Output /
- During the welding process, the current wire speed actual value will be output as
a value between -32,768 and +32,767 (SINT 16) .
- The wire speed set value is output when idling.
-32,768 Wire speed -327.68 m/min (set value/actual value/Hold
value)
+32,767 Wire speed +327.67 m/min (set value/actual value/Hold
value)

Analog Interface:
- During the welding process, the current wire speed actual value will be output
using an analog method as a value between 0 - 10 V.
- The wire speed set value is output when idling.
0V Wire speed 0 m/min (set value/actual value/Hold value)
10 V Wire speed depending on the wirefeeder used

Actual real value As described below, the current actual value for seam tracking can be output on a Digital
for seam tracking Interface or an Analog Interface.
(Current actual
value for seam This signal is output as standard when using MIG/MAG LSC and MIG/MAG PMC char-
tracking) - Group acteristics. The signal is available upon request for MIG/MAG pulse synergic and
Output / Analog MIG/MAG standard synergic characteristics.
Output
Digital Interface:
- During the welding process, the current actual value for seam tracking will be
output as a value between 0 and 65,535 (UINT 16).
- The Hold- value is output at the end of welding.
38
0 Current actual 0
EN-US
value for seam (depending on the position of the welding
tracking torch)
65,535 Current actual 10,000
value for seam (actual value/Hold- value)
tracking

Analog Interface:
- During the welding process, the current actual value for seam tracking will be
output using an analog method as a value between 0 - 10 V.
- The Hold- value is output at the end of welding.
0V Current actual 0
value for seam (depending on the position of the welding
tracking torch)
10 V Current actual 1
value for seam (actual value/Hold- value)
tracking

Weaving overview (current actual value for seam tracking, the values given are
for illustrative purposes only):
(1) - Stickout: 10 mm
(1) (2) (3)
- Wire speed: 7 m/min
- Arc length correction: 0
- Current actual value for seam
tracking: approx. 7650
Weaving function overview:

- The current actual value for seam tracking is calculated using the welding current
and the welding voltage
- The current actual value for seam tracking changes with the Stickout
- The current actual value for seam tracking is between 0 and 10,000:
• Stickout becomes shorter – signal increases
• Stickout becomes longer – signal reduces
39
Motor current M1 Motor current M1 is the motor current of the central motor in the welding system (drive
(Motor current unit of the welding torch, etc.). As described below, the present motor current actual
M1) - Group Out- value M1 can be output on a Digital Interface or an Analog Interface.
put / Analog Out-
put Digital Interface:
During the welding process, the present motor current actual value will be output as a
value between 0 and 65,535 (UINT 16).
0 Motor current 0 A (actual value)
+327.67 Motor current 327.67 A (actual value)

Analog Interface:
value between 0 - 10 V.
0V Motor current 0 A (actual value)
10 V Motor current 10 A (actual value)

Motor current M2 Motor current M2 is the motor current of the front motor in the welding system
(Motor current (wirefeeder, etc.). As described below, the present motor current actual value M2 can be
M2) - Group Out- output on a Digital Interface or an Analog Interface.
put / Analog Out-

Analog Interface:
During the welding process, the present motor current actual value will be issued as a
value between 0 and 10 V.

40
EN-US
Motor current M3 Motor current M3 is the motor current of the rear motor in the welding system (unwinding
(Motor current wirefeeder, etc.). As described below, the present motor current actual value M3 can be
M3) - Group Out- output on a Digital Interface or an Analog Interface.
put / Analog Out-

Analog Interface:
value between 0 - 10 V.

Error number This signal indicates the current error number on the power source and the robot control-
(Error number) - ler.
Group Output /
Analog Output Additional information for TWIN systems:
Warning number This signal indicates the current warning number on the power source and the robot con-
(Warning num- troller.
ber) - Group Out-
put / Analog Out- Additional information for TWIN systems:
put The signal is output separately for both process lines.
WireSense posi- This signal indicates:

tion (wire posi- 1. How high the edge found in WireSense - Edge Detection mode was
tion) - Group Out- 1. See also description WireSense edge detection - Group Input / Analog Input
put / Analog Out- on page 22
put 2. The current value of the height measurement in WireSense - Sensing Mode
2. See also description WireSense start - Single Bit on page 18
The wire electrode can move forward and backward to the first detected zero position
(reference point) by a maximum of 24 mm.
41
Digital Interface:
During the active WireSense process, the wire position is output in the range of ‑32768
to +32767 (SINT 16).
Value Range Designation Min./max. possible value
‑32768 Wire position -327.68 mm
+32767 Wire position +327.67 mm

page 52.
42
Available Process Images
EN-US
Process Image Dip switch
Types
8 7 6 5 4 3 2 1 Process image and configuration
OFF OFF - - - - - - Standard Image 320 Bit
OFF ON - - - - - - Economy Image 128 Bit
ON OFF - - - - - - Retrofit Image (scope dependent on bus module)
ON ON - - - - - - Not used
Changing/ For power sources in the TPS series, the material, the wire diameter, and the protective
Assigning Char- gas shield can be selected using the program number. A bit width of 8 bits was defined
acteristic Num- for this.
bers/Program It is possible to assign a program number to a characteristic number (1-255) so that the
Numbers (Retrofit 8-bit signal can be used in retrofit mode.
Mode)
Note down the IP address of the power source used:
1 Connect the power source to the computer (for example using a LAN cable)
2 Select "Defaults" in the left sidebar of

the power source control panel
3 Select "System" in the right sidebar of
3
the power source control panel
2 4 Press the "Information" button on the
power source control panel
5 Note down the displayed IP address

(example: 10.5.72.13)
1.9.0-16501.9508
xx.x.xxx.x
Access website of the power source in the internet browser:

6 Enter the IP address of the power source in the search bar of the Internet browser
and confirm
- The website of the power source is displayed
7 Enter username and password
Factory setting:
Username = admin
Password = admin
- The website of the power source is displayed
43
Note down the IDs of the desired characteristics:
8 On the power source website, select the "Synergic lines overview" tab
9 Note down the IDs of the characteristics that it should be possible to select using the
interface
10 On the power source website, select the tab for the interface used
For example: RI IO PRO/i
11 Under "Synergic line assignment", assign the program numbers (= bit numbers) the
desired characteristic IDs.
For example: Program number 1 = Synergic line ID 2501, Program number 2 = Syn-
ergic line ID 3246, etc.
- The assigned characteristics can then be called up using the interface and the
selected program numbers (=bit numbers)
12 Once all of the desired characteristic IDs have been assigned, select "Save assign-
ment"
- All of the program numbers with their assigned characteristic IDs are displayed
under "Actual assigned program numbers to synergic lines"
Website of the Power Source
44
Information on the Use of the MIG/MAG Standard
EN-US
Manual, TIG, and Electrode Welding Processes
MIG/MAG Stand- Use the MIG/MAG standard manual welding process:

ard Manual 1 Select 2-step mode characteristics
2 Select the MIG/MAG standard manual welding process using the appropriate char-
acteristic number
During the standard manual welding process, the wire speed and welding voltage para-
meters are set as follows:
- In order to set the Wire feed speed command value manual parameter, the Wire
feed speed command value analog input signal must be used
- In order to set the Welding voltage command value manual parameter, the Arc
length correction analog input signal must be used
- In order to set the Dynamic correction manual parameter, the Pulse-/dynamic cor-
rection analog input signal must be used
- In order to set the Wire retract correction manual parameter, the Wire retract correc-
tion analog input signal must be used
TIG Use the TIG welding process:

1 Select the TIG welding process using the appropriate characteristic number
Electrode Use the electrode welding process:

1 Select the electrode welding process using the appropriate characteristic number
45
Arc Break Monitoring
Arc Break Monit- The arc break monitoring is a function that can be activated on the power source. The
oring function becomes active when arc breaks occur.
If the arc break monitoring is activated, the Robot motion release signal is set to Low.
The following can be set in order to use the arc break monitoring:
- The break length after which the arc break monitoring becomes active
- In which way the arc break monitoring is activated
• With "Ignore"
• With "Error"
Process if the arc break monitoring reacts to an arc break with "Error" – arc break monit-
oring set to 200 ms:
- If the arc breaks for 190 ms, the arc break monitoring is not activated
- If the arc breaks for 210 ms, the power source reports an error message and stops
the welding process
Process if the arc break monitoring reacts to an arc break with "Ignore" – arc break mon-
itoring set to 200 ms:
- If the arc breaks for 190 ms, the arc break monitoring is not activated
- If an arc breaks for 210 ms, the Arc stable signal is set to Low by the arc break mon-
itoring. Whether the Welding start signal remains High or is set to Low by the robot
depends on the setting selected on the robot.
46
EN-US
(Digital Input)
Welding start
(1)
t
(Digital Output)
Current flow
arc break arc break

<190ms <200ms
t
(Digital Output)
Arc stable
Example of Arc Break Monitoring Behavior
(1) The status of the Welding start signal is dependent on:

- The arc break monitoring setting
- The robot setting (how the robot should react to the "Ignore" setting on the arc break
monitoring)
For the "Ignore" setting:

- The robot sets the Welding start signal to Low (= no reignition of the arc), or
- Leaves the Welding start signal on High (= reignition of the arc) – depending on the
robot setting
For the "Error" setting:

- An error message is output and the welding process is stopped
47
Fronius Data Channel
Fronius Data A variety of signals and data can be written and exchanged between the power source
Channel and a control unit (robot controller, etc.) via the Ethernet connection on the rear of the
power source (service port).
In order to be able to use the Fronius Data Channel, OPT/i Documentation must be
enabled for the power source.
On TWIN systems, the Ethernet connection socket on the power source of process line 1
must be used.
Available signals and data:

Number Designation Description Type of signal
1 Process active 1/0 Output
2 Current flow 1/0 Output
3 Article number String Input
4 Serial number String Input
5 Seam number Integer Input
A TCP socket connection must be estab-

lished for data transfer.
1 For this purpose, enter the IP address
of the power source service port and
the port number 4714.
Windows example (PuTTY)
48
Signal sequence when selected using "Job Mode"
EN-US
operating mode
Robot ready
Power source ready
Error number
Working mode
(Job mode)
(1)
Job number
(2)
Welding start
Process active
(3) (6)
Arc stable
(4)
Robot motion release
(5) (7)
Main current signal
(1) Wait time of at least 0.1 seconds
(3) Gas pre-flow time
(4) Starting current time
(5) Slope 1
(6) Gas post-flow time
(7) Slope 2 + final current time
49
Signal sequence when selected using "Character-
istics Mode" operating mode
Robot ready
Power source ready
Error number
Working mode
(2-step mode characteristics)
(1)
Welding characteristic
(2)
Wire feed speed
command value
Arclength correction
Pulse-/ dynamic correction
Wire retract correction
(3)
Welding start
Process active
(4) (7)
Arc stable
(5)
Robot motion release
(6) (8)
Main current signal
50
EN-US
(4) Gas pre-flow time
(5) Starting current time
(6) Slope 1
(7) Gas post-flow time
(8) Slope 2 + final current time
51
WireSense - more information
Process descrip-
WireSense Edge Detection = 0mm
tion WireSense
(OFF)
(contour detec- Input: BIT 256 - 271
tion)
WireSense start = High (ON)

Input: BIT 29
Wait for:
Arc stable = High (ON)
Output Bit 5
Start robot movement for

WireSense action
WireSense position = 0mm

Output: BIT 256 – 271 (max. +/-
24mm)
WireSense position = -5mm

Output: BIT 256 – 271 (max. +/-
24mm)

Output: BIT 256 – 271 (max. +/-
24mm)
WireSense start = Low (OFF)

Input: BIT 29
Wait for:
Arc stable = Low (OFF)
Output Bit 5
For more information on contour detection, see:

- Section WireSense start - Single Bit from page 18 and
- Section WireSense edge detection - Group Input / Analog Input from page 22
and
- Section WireSense break - Single Bit from page 19 and
52
EN-US
Process descrip-
WireSense Edge Detection = 3mm
tion WireSense
(ON)
edge detection Input: BIT 256 - 271
(edge detection)
WireSense start = High (ON)

Input: BIT 29
Wait for:
Arc stable = High (ON)
Output Bit 5
Start robot movement for

WireSense action
WireSense position = 0mm

Output: 256 – 271
Touch signal = High (On)

Output: BIT 7

Output: BIT 256 – 271
WireSense start = Low (OFF)

Input: BIT 29
Wait for:
Arc stable = Low (OFF)
Output Bit 5
For more information on edge detection, see:

- Section WireSense start - Single Bit from page 18 and
- Section WireSense edge detection - Group Input / Analog Input from page 22
and
- Section WireSense break - Single Bit from page 19 and
53
54
surface
Signal curve of
Edge Detection
Mode on a level
WireSense
WireSense Position Touch signal Arc stable WireSense start edge detection
(Analog Output) (Digital Output) (Digital Output) (Digital Input) (Analog Input)
(for example 2mm)

h in mm
*20 ms
h= -2,5mm
VRobot
250ms
100ms
1s
t
t
t
t
t
h=2,5mm
* The start time of the Arc stable / Touch signal signal may vary depending on the condi-
tion and electrical conductivity of the tip of the wire electrode. Two examples are shown
EN-US
below.
a) No slag on the tip of the wire electrode:
The WireSense process starts without the WireSense -Slaghammer function and the
Arc stable / Touch signal signal is output around 20 ms after the wire electrode
touches the workpiece
b) Slag on the tip of the wire electrode:

Before the WireSensefunction starts, the WireSense -Slaghammer function is auto-
matically activated to remove the slag residue from the tip of the wire electrode. The
Arc stable / Touch signal signal is only activated once the slag has been successfully
removed and the wire electrode and workpiece make proper electrical contact.
Therefore, the delay time for the Arc stable / Touch signal signal could be much
longer than 20 ms
55
56
Mode on a
Signal curve of
Edge Detection
slanted surface
WireSense
(for example 2mm)

h in mm
*20 ms
h= -2,5mm
VRobot
250ms
100ms
1s
t
t
t
t
t
h=2,5mm
EN-US
below.

longer than 20 ms
57
58
geometries
Signal curve of
different surface
Sensing Mode for
WireSense
*20 ms
VRobot
t
t
t
t
t
EN-US
below.

longer than 20 ms
59
60
Mode)
Signal curve of
(during Sensing
WireSense break
WireSense
WireSense Position Touch signal WireSense break Arc stable WireSense start edge detection
(Analog Output) (Digital Output) (Digital Input) (Digital Output) (Digital Input) (Analog Input)
Reference-Point
*20 ms
VRobot
t
t
t
t
t
t
EN-US
below.

longer than 20 ms
Representation of Minimum and maximum measurement range in conjunction with WireSense:

the possible
measurement
range
-24mm
max.
Reference-Point
+24mm
max.
Minimum and maximum possible wire movement in conjunction with WireSense:
61
max. CTWD*
or NTWD*
Reference-Point
+24mm
max.
*CTWD: Contact-Tip To Workpiece Distance
*NTWD: Nozzle To Workpiece Distance
Note on ignition If the ignition timeout is set to 30 mm, for example, but the end of the wire electrode is
timeout (Ignition more than 30 mm away from the workpiece, the WireSense function will not start suc-
Timeout) cessfully because the wire feed is stopped after 30 mm.
WireSense start
(2)
(1)
(1) For example, distance = 40 mm
(2) Ignition timeout setting = after 30 mm, for example
62
Available signals for component scanning
EN-US
Signal list WireSense (contour detection):
Signal designation Type of sig- Data type Factor Value range
nal
WireSense start
Input BIT
(BIT 29)
WireSense break
Input BIT
(BIT 30)
WORD
Wire position
Output (SINT) in 100 -327.68 to +327.67
(BIT 256-271)
mm
WireSense Edge Detection (edge detection):

nal
WireSense start
Input BIT
(BIT 29)
Touch signal BIT
Output
(BIT 7) (300 ms)
WireSense Edge WORD
Detection (BIT Input (UINT) in 10 0 to 20 mm
256-271) mm
WORD
Wire position
Output (SINT) in 100 -327.68 to +327.67
(BIT 256-271)
mm
Teach Mode:
nal
Teach Mode
Input BIT
(BIT 29)
WORD
Wire position
Output (SINT) in 100 -327.68 to +327.67
(BIT 256-271)
mm
Touch signal BIT
Output
(BIT 7) (300 ms)
63
Limit Monitoring - functions and activation
Functions of - Limit Monitoring monitors the welding parameters of the welding process.
Limit Monitoring - Limit Monitoring indicates whether the weld is performed within the predefined limit
values of the weld specification (= job set values).
- If Limit Monitoring determines that the actual values are outside the defined limits,
the weld seam should be checked.
• If the weld seam is OK in such a case, it is recommended to check the defined
limits and adjust them if necessary.
• If the weld seam is not OK in such a case, it is recommended to check the
welding parameters and adjust them if necessary.
- Limit Monitoring is only active in the main current phase
- Limit Monitoring is not active during the Slope- phases
- Limit Monitoring can only be used in conjunction with Job Mode
Limit Monitoring does not monitor the quality of the weld seam. As a result, Limit Monit-
oring does not provide any information on whether the weld seam is OK or not.
Limit Monitoring is available for the following processes:

- MIG/MAG standard synergic
- MIG/MAG pulse synergic
- MIG/MAG PMC
- MIG/MAG LSC
- CMT
It is not recommended to use Limit Monitoring for the following processes:

- MIG/MAG PMC Mix
- MIG/MAG LSC Mix
- CMT Cycle Step
- SynchroPulse welding with
- MIG/MAG standard synergic
- MIG/MAG pulse synergic
- MIG/MAG PMC
- MIG/MAG LSC
Available func- OPT/i Limit Monitoring (= required), 4,067,004

tion packages Among other things, to monitor:
- Voltage
- Current
- Wire speed
- Welding time
- Energy
OPT/i Jobs (= optional), 4,067,002

- Enables remote access (for example from a PC) to the power source (Smart Man-
ager). For example, the limit values of job parameters can be changed via the Smart
Manager; directly from the PC, without having to implement the setting at the power
source itself
OPT/i Documentation (= optional), 4,067,003

- Is used to export the welding data stored in the power source as a CSV file, in addi-
tion to the export as a PDF file available by default
- Enables the use of FroniusDataChannel, which is used for the exchange of Traceab-
ilitydata
64
EN-US
Prerequisites for 1. Job mode must be enabled for each power source
the successful 2. At least 1 job must be assigned to each weld seam
use of Limit Mon- - It is recommended to use several jobs per weld seam if significant influencing
itoring factors change during welding, such as robot speed, angle of attack of the weld-
ing torch, Stick-Out, etc.
3. Only create jobs when the correct welding parameters have already been determ-
ined
- If the welding parameters in the job are changed, the limits must also be adjus-
ted accordingly
4. Always set limits based on measured actual values (not based on set values). The
following options are available
- Read actual values on the display of the power source during welding
- Read actual values via the Smart Manger during welding
- Evaluation of the welding parameters by means of WeldCube Premium
Switch Limit
Monitoring on /
off
Limit Monitoring on
Limit Monitoring off
65
Detailed descrip- - Limit Monitoring is only active in the main current phase
tion of Limit Mon- - The data is recorded / checked every 50 ms during Limit Monitoring
itoring
- At point A, the upper voltage limit is exceeded; the time until the reaction of Limit
Monitoring begins to count constantly upwards
- At point B, the voltage falls below the upper limit again; the time until the reaction of
Limit Monitoring counts down to 0
- At point C, the upper voltage limit is exceeded again; the time until the reaction of
Limit Monitoring starts to count upwards constantly again
- At point D, the set time limit for the reaction of limit monitoring is reached
- The hysteresis time starts to run
- Point E shows the hysteresis of +20% to the set time value (time until reaction
from Limit Monitoring)
- A warning or an error is issued depending on the setting
- The Limitsignal (Word 1 / Byte 2 / Bit 19) changes to High
- At point F, the Limitsignal (Word 1 / Byte 2 / Bit 19) changes to Low
Functionality of Limit Monitoring for energy and welding duration:

- With energy monitoring, Limit Monitoring does not monitor each job individually, but
the entire weld seam - for more information see Energy monitoring from page 71
- With welding time monitoring, Limit Monitoring does not monitor each job individu-
ally, but the entire weld seam - for more information, see Welding time monitoring
from page 69
66
Limit Monitoring - details on the individual welding
EN-US
parameters
Voltage monitor- Serves to:

ing - Set the voltage set value and the desired limits
- Monitor the voltage actual value per weld seam / job
Voltage monitoring
Adjustable parameters:
(1) Voltage set value:

0 to 100 V
(2) Lower voltage limit:

-10 to 0 V
(3) Upper voltage limit:

0 to 10 V
(4) Time limit for the reaction of Limit Monitoring:

Off / 0 to 10 seconds
Explanation for setting from 0 to 10 seconds:

- If, for example, 5 seconds are set, Limit Monitoring will only react after a limit
has been exceeded or undershot continuously for 5 seconds
Explanation for "Off" setting:

- Limit Monitoring is disabled for this welding parameter
- There is no display of limit overruns
Possible error messages during voltage monitoring:

19 | Lower voltage limit undershot
20 | Upper voltage limit exceeded
67
Current monitor- Serves to:
ing - Set the current set value and the desired limits
- Monitor the current actual value per weld seam / job
Current monitoring
(1) Current set value:

0 to 100 A
(2) Lower current limit:

-10 to 0 A
(3) Upper current limit:

0 to 10 A



Possible error messages during current monitoring:

21 | Lower current limit undershot
22 | Upper current limit exceeded
Wirefeeder monit- Serves to:

oring - Set the wirefeeder set value and the desired limits
- Monitor the wirefeeder actual value per weld seam / job
68
EN-US
Wirefeeder monitoring
(1) Wirefeeder set value:

0 to 100 m/min
(2) Lower wirefeeder limit:

-10 to 0 m/min
(3) Upper wirefeeder limit:

0 to 10 m/min



Possible error messages during wirefeeder monitoring:

23 | Lower wirefeeder limit undershot
24 | Upper wirefeeder limit exceeded
Welding time Serves to:

monitoring - Set the welding time set value and the desired limits
- Monitor the welding time per weld seam / job
If a weld seam consists of 2 or more jobs, the welding time of the previously welded job
must be added for the jobs following in the welding sequence.
69
Example:
- A weld seam consists of 4 jobs, each with a duration of 4 seconds
- Limit Monitoring ignores the first 3 jobs and only records the last job
- For this reason, a welding time set value of at least 16 seconds must be set for the
last job (4 x 4 seconds) in order to prevent Limit Monitoring from unintentionally issu-
ing a message
Welding time monitoring
(1) Welding time set value:

0 to 999.9 seconds
(2) Lower welding time limit:

-50 to 0 seconds
(3) Upper welding time limit:

0 to 50 seconds



Possible error messages during welding time monitoring:

50 | Lower welding time limit not reached
51 | Upper welding time limit exceeded
70
EN-US
Energy monitor- Serves to:
ing - Set the energy set value and the desired limits
- Monitor the energy input per weld seam / job
If a weld seam consists of 2 or more jobs, the energy input of the previously welded job
must be added for the subsequent jobs in the weld sequence.
Example:
- A weld seam consists of 4 jobs, with an energy input of 40 kJ each
- Limit Monitoring ignores the first 3 jobs and only records the last job
- For this reason, an energy set value of at least 160 kJ must be set for the last job (4
x 40 kJ) in order to prevent Limit Monitoring from unintentionally issuing a notifica-
tion
Energy monitoring
(1) Energy set value:

0 to 9999.9 kJ
(2) Lower energy limit:

-10 to 0 kJ
(3) Upper energy limit:

0 to 10 kJ
(4) Energy monitoring:

On/Off
Possible error messages:

47 | Lower energy limit not reached
48 | Upper energy limit exceeded
71
Setting of the The setting is used for:
reaction when - Determination of how the power source reacts when the set limits are exceeded or
exceeding or fall- not reached
ing below the lim-
its: The following reactions are possible:
- Ignore
- Warning
- Error
The following is a description of each reaction.
Reaction when limits are exceeded or undershot = ignore:

- No reaction
- No entry in the logbook
Reaction when limits are exceeded or undershot = Ignore
Reaction when limits are exceeded or undershot = warning:

- Entry is made in the logbook
- The welding parameters affected by exceeding or falling below the limits are marked
in red
72
EN-US
Reaction when limits are exceeded or undershot = Warning
Overview of the entries in the logbook
73
Display of the individual sections in the logbook
Additional information on reactions of the power source to a warning:

- The power source indicates whether the limits have been overrun or undershot
- The overrun or undershoot is displayed until the end of welding
in red
Display of the warning with the welding parameters
74
EN-US
Display of the warning with the system data
Display of the warning with Job optimization
Additional information on reactions at the interface to a warning:

- During welding, the limit signal (WORD 1 / Byte 2 / Bit 19) reacts directly to exceed-
ing or falling below the limits
- If no overshoot or undershoot of the limits is detected, the Limitsignal Low
remains
- If an overshoot or undershoot of the limits is detected, the Limitsignal changes
to High
- As soon as the welding parameters are within the defined limits again, the Limit-
signal changes back to Low after 1 second
- No warning number is output at the interface (WORD 9 / Byte 18 - 19 / Bit 144 - 159)
75
Indicator on the interface; Limitsignal = Low
Anzeige am Interface; Limitsignal = High
Reaction when limits are exceeded or undershot = error:

- Power source stops the welding process
in red
76
EN-US
Reaction when limit exceeded / limit undershot = error
Error message
77
Logbook details
Additional information on reactions at the interface to an error:

- If no overshoot or undershoot of the limits is detected, the Limitsignal Low remains
- If an overshoot or undershoot of the limits is detected, the Limitsignal changes to
High
- Welding is stopped immediately
- The error number (= reason for the welding stop) can be read out at the inter-
face (WORD 8 / Byte 16 - 17 / Bit 128 - 134)
- As soon as the welding parameters are within the defined limits again, the Limitsig-
nal changes back to Low after 1 second
78
EN-US
Overview of the interface functionalities in case of exceeding or falling below the

limits:
79
Set reaction Limit signal Error number Warning num- Stop weld-
(WORD 1 / Byte (WORD 8 / Byte ber (WORD 9 / ing: yes /
2 / Bit 19) 16 - 17 / Bit 128 Byte 18 - 19 / no
- 134) Bit 144 - 159)
Ignore - - - -
Warning x - - -
Error x x - Yes
Setting of the General information

reaction when - Motor force monitoring is not linked to a job and is therefore always available
exceeding or fall- - In order to draw conclusions about the condition of the wire feed section (wear of the
ing below the lim- inner liner, condition of the motor, etc.), the motor force can be monitored and a cor-
its for the motor responding reaction can be set if the defined limits are exceeded or undershot
force - Motor force monitoring is available from version 2.3.1 of the power source onwards
- The motor force of the main motor M1 is monitored
- Motor force monitoring is also active during the threading process
The setting is used for:

- Determination of how the power source reacts when the set limit for the motor force
is exceeded or undershot
The following reactions are possible:

- Ignore
- Warning
- Errors
The following is a description of each reaction.
Reaction when limits are exceeded or undershot = ignore:

- No reaction at the power source
- No entry is made in the logbook
Reaction when limits are exceeded or undershot = Ignore
80
Reaction when limits are exceeded or undershot = warning:
EN-US
in red
Reaction when limits are exceeded or undershot = Warning
Display of the warning with the system data
Additional information on reactions at the interface to a warning:

- During welding the limit signal (WORD 1 / Byte 2 / Bit 19) reacts directly to exceed-
- If no overshoot or undershoot of the limits is detected, the Limitsignal Low
remains
- If an overshoot or undershoot of the limits is detected, the Limitsignal changes
to High
- As soon as the welding parameters are within the defined limits again, the Limit-
signal changes back to Low after 1 second
81
Reaction when limits are exceeded or undershot = error:

- Power source stops the welding process
in red
82
EN-US
Reaction when limits are exceeded or undershot = Error
Error message
83
Logbook details
Additional information on reactions at the interface to an error:

- If no overshoot or undershoot of the limits is detected, the Limitsignal Low remains
- If an overshoot or undershoot of the limits is detected, the Limitsignal changes to
High
- Welding is stopped immediately
- The error number (= reason for the welding stop) can be read out at the inter-
face (WORD 8 / Byte 16 - 17 / Bit 128 - 134)
- As soon as the welding parameters are within the defined limits again, the Limitsig-
nal changes back to Low after 1 second
84
EN-US
Smart Manager + If the function package OPT/i Jobs has been activated, the desired limits can also be
OPT/i Jobs defined via the Smart Manager:
(4,067,002)
85
Define limit in Smart Manager
Information on exceeding or falling below limits is also displayed in the Smart Manager :
Smart Manager
86
EN-US
Smart Manager
Display of overshooting or undershooting limits in the system data display of the Smart
Manager:
System data display in the Smart Manager
The welding parameters affected by exceeding or falling below the limits are marked in
red.
87
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www.fronius.com
Under www.fronius.com/contact you will find the addresses

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/ Perfect Charging / Perfect Welding / Solar Energy

Unsigned (UINT): Signed (SINT):

Additional information for TWIN systems:

Description of internal parameter selection:

Internal parameter selection can be used to select:

Special 2-step mode signal sequence

Description of Job Mode:

Description of 2-step mode characteristics:

2-step mode signal sequence

Additional information for TWIN systems:

Additional information for TWIN systems:

The signal can be set in two ways:

Additional information for TWIN systems:

Danger due to welding processes starting unexpectedly.

Additional information for TWIN systems:

Touch sensing function/process:

max. Open circuit voltage

* timing depends Interface

Additional information for TWIN systems:

WireBrake on can be activated independently of the operating mode (internal parameter

Additional information for TWIN systems:

Teach mode function:

- Ensure the desired distance (Stickout) to the

- If the distance between the gas nozzle and the

The Touch signal is set as follows when using Teach mode:

Additional information for TWIN systems:

ExtInput 1-8 Inputs used to control options, such as OPT/i RI FB REL.

Example outputs: ExtInput1 = OPT_Output 1:

(1) (2) (3)

(1) Robot output

Additional information for TWIN systems:

Examples of characteristic numbers:

Additional information for TWIN systems:

Processline This signal is used to select the desired process line.

Bit 1 Bit 0 Description

Bit 32 Bit 33 Description

Signal level = High:

This signal starts one of the following two functions:

Other effects of the WireSense start signal:

Safety functions with WireSense:

For more information on WireSense, see section WireSense - more information on

For more information on WireSense, see section WireSense - more information on

Additional information for TWIN systems:

Additional information for TWIN systems:

Job correction (specifications apply for Single- andTWIN welding):

Additional information for TWIN systems:

Additional information for TWIN systems:

Job correction (specifications apply for Single- andTWIN welding):

Additional information for TWIN systems:

Additional information for TWIN systems:

Additional information for TWIN systems:

Additional information for TWIN systems:

Additional information for TWIN systems:

WireSense edge Contour detection:

For more information on WireSense, see section WireSense - more information on

Wire forward / Signal behavior:

Additional information for TWIN systems:

Additional information for TWIN systems:

(1) Robot input

Additional information for TWIN systems:

Additional information for TWIN systems:

GPr t-S SL1 Main current SL2 t-E GPo

(1) Process active (process active)