FANUC / Fronius

Ethernet Single Interface

R-30iA V7.30/P19 or higher ArcTool software
 Fronius Ethernet Interface Setup

• Requirements
– Ethernet IP Scanner Option
– Fronious Weld Equipment Option
– ARC Tool 7.30/P19
– MultiProcess Enabled

Note:
When converting from an existing equipment library select
general purpose equipment / cold start before selecting the
Fronius library
Power Source Functional Overview
– The Fronius power supply has 3 basic modes of operation;
• Synergic
• Pulsed Synergic
• Job Mode
– The operating mode is selected from the robot (group output)
– ARC Tool controls the welding process through weld schedules
– Changes can be made while welding without interruption of the arc
– When welding in any mode other then Job Mode Process scaling is
required
– Productivity and error recover features are supported
– Through robot I/O advanced features of the power source can be
enabled or disabled
• Synrco Pulse
• Spatter Free Ignition
Overview of Synergic &Pulsed Synergic Welding Modes:
– When operating in either of these modes the robot has control of the welding output
from the robot pendant. And weld parameters are adjusted through weld schedules.
– Scaling the Fronius Synergic Line is required. (Scaling instructions slide 12)
Weld Equipment 1
– Group Output [4] changes the Power or WFS values
– Group Output [5] changes the Pulse or Trim values
– Group Output [6] changes the Pulse Dynamic setting
– Group Output [7] changes the Stub Burn Off command
Overview of Job Mode:
– Job mode is used when welding parameters for a particular weld are
stored internally on the Fronius power source.
– Job Mode limits the control that the robot has over the welding process.
– There are 99 total jobs that can be stored and retrieved by the robot.
– When operating in Job mode the robot can make weld process
adjustments, however the degree of process change is controlled by the
welding power source.
• Group Output [4] is used to adjust the welding power.
• Adjustments are in the form of percent with a maximum adjustment of
+/- 100% of the stored range.
– Group Output [5] is used to adjust the arc length or Trim.
• Adjustments are in the form of percent with a maximum adjustment of
+/- 100% of the stored range.

Note:
Disable Run-in, Burn-Back and Wire Stick on the robot when welding
in Job Mode.
 Fronius Ethernet Interface Setup
• Multi-Process is Enabled • ArcTool\Setup\\\\\\\\\\\\\\\\\\\\E3
• 1/10
• General Purpose weld library was • 1 F Number: F00000\\\\
selected to clear previous •
• 2 Welding setup: USA
equipment assignments • 3 Wire speed units: IPM
• 4 Weld speed units: IPM
• 5 Weld speed: 50
Controlled Start •
• 6 Manufacturer: Fronius
– Select • 7 Model: TS/TPS with ENet
• Manufacture = Fronious
• Model: TS/TPS with ENet

After selecting the model the

software will ask for a starting I/O
value or it will scan the current
I/O assignments and assign the
Fronius option to the first
available large enough block.

– Cold Start
 Fronius Ethernet Interface Setup

• Robot I/P Port Assignments

– Setup Host Com
• Select F3 / Port 2
• Manually input the I/P address
for the robot
• Robot IP = 192.168.2.161

The welding equipment should be

on a separate network from cell
interface. Port 2 is typically
reserved for communication to the
welding equipment

• Select PREV to exit

 Fronius Ethernet Interface Setup
• Ethernet / IP Assignment
– Select I/O
• Ethernet I/P
• To make Changes to Config
• Set Enable to = False

– Move the cursor to Highlight Fronius

EQ1 and select F4 CONFIG
• Set the IP address of the scanner
• Set Fronius equipment to be the
same
– Equipment 1 = 192.168.2.162
– Equipment 2 = 192.168.2.163
– Equipment 3 = 192.168.2.164
– Equipment 4 = 192.168.2.165

– Press F3 PREV to return to the IP

List screen
• Set the Enable bit to True
• The status should change to
running
 Fronius Ethernet Interface Setup

• Inverse Fronius Weld Inputs

– Go to Weld Inputs screen
– Inverse the following Signal Polarities
• Power fault = Inverse
• Wirestick = Inverse

– From the weld input screen

• Cursor down to power fault
– Press the Teach Pendant key labeled
Next
– Press F3 CONFIG
– Cursor down to Polarity
– Press F4 to set to INVERSE
• Repeat Steps for Wirestick
• Cycle Power to activate changes
Select Fronius program number to match the welding process
– GO[3] selects the active FRONIUS program number
– Adjust value of GO[3] accordingly until correct welding process is
selected on the Fronius front panel
– Fronius determines the available programs
– Green LED indicates selection

Example:
Setting GO[3] = 7
Selects .045” wire ER 70 S-3/6 (Ar/CO2)
 Fronius Ethernet Interface Setup
• Create SET_FPS Program
– Create program SET_FPS with the
group mask all asterisks
– Assign Group 2 and Group 3 Output
Values
• Group 2 (JOB Number) should equal
anything other then zero
• Group 3 (Prg Number) should equal
the value of the synergic line you
intend to use for welding
– This value will vary and is dependant
on the welding process
– Switching the synergic line selection
will require the scaling values to be
adjusted for non Job mode welding
– Assign SET_FPS to run
automatically upon power
• COLD START Autoexec program =
SET_FPS
• HOT START Autoexec program =
SET_FPS
• SET_FPS will not run if it was last selected
before power cycle. Choose a different
program before cycling power to assure
SET_FPS runs at power up
 Scaling Weld Outputs
Determine WFS scaling values for Synergic Mode
– Utilize multi-process and select item 1 = Synergic
– Verify the LED for Synergic is lit on the Fronius power source
– Utilize multi-process and select item 4 = Setup No Weld
– Verify LED on the red dial is lit on the power source
• If your are using a CMT machine the LED will not light - use the dial on the Fronius
wire feeder to determine the upper and lower limits for the selected synergic line
– On the Fronius power source
– Press the green #2 button
– Press again until item #12 LED is lit (WFS)
– Use the red thumb wheel item #1
– Rotate both directions to determine
the upper and lower range of the
WFS for the selected synergic line
 Scaling Weld Outputs

Set the robot Analog Scaling ranges for process 1 - Synergic

– Select weld process 1
– Synergic

– Enter the Weld Output Screen

– Select GO[4]
– Press next and then config.
– Enter the determined WFS Range for the Synergic mode selected
– Select GO[5] and confirm the range is +/- 30
– Press next and then config. confirm min max ranges correct

Display does not represent actual values

 Scaling Weld Outputs
Determine the WFS scaling values for Pulse Synergic Mode
– Utilize multi-process and select item 2 = Pulse Synergic
– Verify the LED for Pulse Synergic is lit on the Fronius power source
– Utilize multi-process and select item 4 = No Weld
– Verify LED on the red dial is lit on the power source
• If your are using a CMT machine the LED will not light use the dial on the Fronius
wire feeder to determine the upper and lower limits for the selected synergic line
– On the Fronius power source
– Press the green #2 button
– Press again until item #12 LED is lit (WFS)
– Use the red thumb wheel item #1
– Rotate both directions to determine
the upper and lower range of the
WFS for the selected synergic line
 Scaling Weld Outputs
Set the robot Analog Scaling ranges for process 2 - Pulse Synergic
– Select weld process 2
– Pulse Synergic

– Enter the Weld Output Screen

– Select GO[4]
– Press next and then config.
– Enter the determined WFS Range for the Pulse Syn. mode selected
– Select GO[5] and confirm the range is +/- 30
– Press next and then config. Confirm min max ranges correct

Display does not represent actual values

 Fronius Ethernet Interface I/O Verification

• Verifying Ethernet/IP Settings

– Advanced Configuration
• The configuration is automatically
set, this step is just to verify
settings are correct.
 Fronius Ethernet Interface I/O Verification

• Verifying Group Output Settings

– Advanced Configuration
• The configuration is automatically
set, this step is just to verify
settings are correct.
 Fronius Ethernet Interface I/O Verification

• Verifying Group Input Settings

– Advanced Configuration
• The configuration is automatically
set, this step is just to verify
settings are correct.
 Fronius Ethernet Interface I/O Verification

• Verifying I/O Assignments

– Digital Outputs Config:
• Automatically configured
• Fronius requires 296 I/O points for
each equipment mapped
• Systems with 4 equipments will
need the allocated I/O range
expanded
 Fronius Ethernet Interface I/O Verification

• Verifying I/O Assignments

– Digital Outputs:
• Automatically configured

Equipment 1 mapping I/O points

• 73 - 80 = not used
• 89 – 112 = not used
• 117 – 296 = not used
 Fronius Ethernet Interface I/O Verification

• Verifying I/O Assignments

– Digital Input Config:
• Automatically configured
• Fronius requires 296 I/O points for
each equipment mapped
• Systems with 4 equipments will
need the allocated I/O range
expanded
 Fronius Ethernet Interface I/O Verification

• Verifying I/O Assignments

– Digital Inputs:
• Automatically configured

Equipment 1 mapping I/O points

• 17 - 80 = Fronious Spare
• 27 – 32 = Fronious Spare
• 73 – 96 = not used
• 113-296 = not used
 Fronius Ethernet Interface I/O Verification

• Verifying I/O Assignments

– Weld Outputs:
• Automatically configured

Equipment 1 Weld I/O mapping

 Fronius Ethernet Interface I/O Verification

• Verifying I/O Assignments

– Weld Inputs:
• Automatically configured

Confirm Signal Polarity

8) Power fault = Inverse
9) Wirestick = Inverse