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Fronius TPS/i, User Information

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Signal Transmis-
sion Time

TPS/i

t

t

TPS/i

<10 ms

Welding start

Process active

Representation of the signal transmission time; the signals shown are for illustrative purposes only

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

Summary of Contents for TPS/i

Page 1: ...l chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TPS i Interface Signal Descriptions EN US User information Signal description 42...

Page 2: ......

Page 3: ...peed 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...

Page 4: ...ndard 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 Signa...

Page 5: ...000000000000000 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...

Page 6: ...NG 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 b...

Page 7: ...ing the welding process is ended in a controlled manner without any crater filling routines In addition the Robot not ready error is output This error must either be reset on the power source control...

Page 8: ...ing start t E HIGH LOW Special 2 step mode signal sequence Description of Job Mode The welding parameters are selected using the data saved in the jobs The EasyJob function is deactivated as soon as a...

Page 9: ...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...

Page 10: ...ntation 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 sa...

Page 11: ...as 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 ga...

Page 12: ...d In TWIN mode the wire electrode of the leading process line Lead is used Gas nozzle touch sensing Gas nozzle position search Single Bit If the position detection is carried out by touching the workp...

Page 13: ...ing WireBrake on Wire brake on Single Bit By activating the WireBrake on signal the wire electrode is held by the OPT i MHP WireBrake OPT i MHP WireBrake is a mechanical component that is installed be...

Page 14: ...re 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...

Page 15: ...ing 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 u...

Page 16: ...ting and the welding pro 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 Additional information f...

Page 17: ...re 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 Bit...

Page 18: ...is 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 informati...

Page 19: ...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...

Page 20: ...V Wire speed 0 depending on wirefeeder 10 V Wire speed 100 depending on wirefeeder Additional information for TWIN systems It is not possible to enter an analog set value on TWIN systems Job correctio...

Page 21: ...pulse dynamic correction the wire speed is not changed Value range Designation Min max possible value 32 768 Pulse dynamic correction 10 pulse dynamic correction 0 Pulse dynamic correction 0 saved val...

Page 22: ...process is specified using this value for example for documentation purposes For more detailed information regarding weld seam documentation please refer to Doc umentation mode Documentation mode Sin...

Page 23: ...inches is specified the wire elec trode is only fed by the specified value when the signal Wire forward is set After reaching the preset value the end of wirefeeding takes place automatically As soon...

Page 24: ...ard length 25 mm 0 984 inches could be reached according to plan Signal course workpiece contact occurs before the set Wire forward length 25 mm 0 984 inches could be reached 1 Second 1 Second 1 2 3 4...

Page 25: ...er source is ready to weld The signal is Low if a fault occurs on the power source Error or a notification Noti fication is issued The signal can also be called a common error as it is set to Low for...

Page 26: ...1 Main current SL2 t t S t E High Low 1 Welding start 1 Process active process active Additional information for TWIN systems The signal is set as soon as one of the two power sources becomes active C...

Page 27: ...signal is inactive for longer than the set arc monitoring time I S I E I GPr GPo SL1 Main current SL2 t t S t E High Low 1 Welding start 1 Robot motion release Robot motion release At the start of wel...

Page 28: ...ormation 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 w...

Page 29: ...AG PMC mixed processes Example of incorrect ignition at the start of welding Ignition Start of Welding U I t t t Current flow Arc stable MIG MAG standard synergic MIG MAG standard manual MIG MAG LSC M...

Page 30: ...ent flow Arc stable t 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 Ignition Start of Welding U I t t...

Page 31: ...final current phases I S I E I GPr Po SL1 SL2 t t S t E High Low 1 Welding start 1 Main current signal main current signal Additional information for TWIN systems In single wire mode the signal is se...

Page 32: ...Correction out of range Correction out of range Single Bit This signal indicates that at least one of the selected corrections for example Arc length correction is outside of the specified range Addit...

Page 33: ...reached and thus the required edge has been successfully detected For more information on WireSense see section WireSense more informa tion on page 52 Additional information for TWIN systems Only one...

Page 34: ...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 If there is no sensor in the system the signal...

Page 35: ...ction the reaction is set to Warning or Error OPT i Limit Monitoring approved for the power source Additional information for TWIN systems The signal is output separately for both process lines For mo...

Page 36: ...ple 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 prob...

Page 37: ...ossible value 0 V Welding voltage 0 V set value actual value Hold value 10 V Welding voltage 100 V set value actual value Hold value Additional information for TWIN systems The analog actual value is...

Page 38: ...s 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 The Hol...

Page 39: ...al information for TWIN systems The analog actual value is not output on TWIN systems Weaving overview current actual value for seam tracking the values given are for illustrative purposes only 1 2 3...

Page 40: ...actual value Additional information for TWIN systems The analog actual value is not output on TWIN systems Motor current M2 Motor current M2 Group Out put Analog Out put Motor current M2 is the motor...

Page 41: ...al value Additional information for TWIN systems The analog actual value is not output on TWIN systems Error number Error number Group Output Analog Output This signal indicates the current error numb...

Page 42: ...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 For more information on WireS...

Page 43: ...l can be used in retrofit 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 3 2 1 2 Select Defaults in the left sidebar of...

Page 44: ...ent 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 ca...

Page 45: ...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 t...

Page 46: ...rocess 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 21...

Page 47: ...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 Lo...

Page 48: ...led 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 Pr...

Page 49: ...ing mode Job mode 1 Job number Welding start Process active Arc stable Robot motion release Main current signal 3 2 6 4 5 7 1 Wait time of at least 0 1 seconds 2 Wait time of at least 0 1 seconds 3 Ga...

Page 50: ...source ready Error number Working mode 2 step mode characteristics 1 2 Welding characteristic Welding start Process active Arc stable Robot motion release Main current signal Wire feed speed command...

Page 51: ...e of at least 0 1 seconds 2 Wait time of at least 0 1 seconds 3 Wait time of at least 0 1 seconds 4 Gas pre flow time 5 Starting current time 6 Slope 1 7 Gas post flow time 8 Slope 2 final current tim...

Page 52: ...271 max 24mm WireSense position 7mm Output BIT 256 271 max 24mm WireSense start Low OFF Input BIT 29 Wait for Arc stable High ON Output Bit 5 Start robot movement for WireSense action Wait for Arc st...

Page 53: ...se position 5mm Output BIT 256 271 WireSense start Low OFF Input BIT 29 Wait for Arc stable High ON Output Bit 5 Start robot movement for WireSense action Wait for Arc stable Low OFF Output Bit 5 For...

Page 54: ...l surface WireSense Position Analog Output Touch signal Digital Output Arc stable Digital Output WireSense start Digital Input WireSense edge detection Analog Input VRobot h 2 5mm 20 ms 250ms 100ms h...

Page 55: ...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 activ...

Page 56: ...ed surface WireSense Position Analog Output Touch signal Digital Output Arc stable Digital Output WireSense start Digital Input WireSense edge detection Analog Input t t t t t VRobot h 2 5mm 20 ms h i...

Page 57: ...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 activ...

Page 58: ...ng Mode for different surface geometries t t t t t VRobot 20 ms WireSense Position Analog Output Touch signal Digital Output Arc stable Digital Output WireSense start Digital Input WireSense edge dete...

Page 59: ...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 activ...

Page 60: ...ensing Mode t t t t t t VRobot 20 ms WireSense Position Analog Output Touch signal Digital Output WireSense break Digital Input Arc stable Digital Output WireSense start Digital Input WireSense edge d...

Page 61: ...e 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 ac...

Page 62: ...ition Timeout If the ignition timeout is set to 30 mm for example but the end of the wire electrode is more than 30 mm away from the workpiece the WireSense function will not start suc cessfully becau...

Page 63: ...ge detection Signal designation Type of sig nal Data type Factor Value range WireSense start BIT 29 Input BIT Touch signal BIT 7 Output BIT 300 ms WireSense Edge Detection BIT 256 271 Input WORD UINT...

Page 64: ...de 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 no...

Page 65: ...te 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 me...

Page 66: ...e 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...

Page 67: ...imit 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 afte...

Page 68: ...or 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 Li...

Page 69: ...r 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 wirefeed...

Page 70: ...9 9 seconds 2 Lower welding time limit 50 to 0 seconds 3 Upper welding time limit 0 to 50 seconds 4 Time limit for the reaction of Limit Monitoring Off 0 to 10 seconds Explanation for setting from 0 t...

Page 71: ...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...

Page 72: ...ns 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...

Page 73: ...Reaction when limits are exceeded or undershot Warning Overview of the entries in the logbook 73 EN US...

Page 74: ...rce 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 The welding parameters affected by exceedi...

Page 75: ...y 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...

Page 76: ...ge am Interface Limitsignal High Reaction when limits are exceeded or undershot error Power source stops the welding process Entry is made in the logbook The welding parameters affected by exceeding o...

Page 77: ...Reaction when limit exceeded limit undershot error Error message 77 EN US...

Page 78: ...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...

Page 79: ...Indicator on the interface Limitsignal Low Anzeige am Interface Limitsignal High Overview of the interface functionalities in case of exceeding or falling below the limits 79 EN US...

Page 80: ...an be monitored and a cor responding reaction can be set if the defined limits are exceeded or undershot Motor force monitoring is available from version 2 3 1 of the power source onwards The motor fo...

Page 81: ...ation 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 lim...

Page 82: ...ge am Interface Limitsignal High Reaction when limits are exceeded or undershot error Power source stops the welding process Entry is made in the logbook The welding parameters affected by exceeding o...

Page 83: ...Reaction when limits are exceeded or undershot Error Error message 83 EN US...

Page 84: ...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...

Page 85: ...erface Limitsignal Low Anzeige am Interface Limitsignal High Smart Manager OPT i Jobs 4 067 002 If the function package OPT i Jobs has been activated the desired limits can also be defined via the Sma...

Page 86: ...Define limit in Smart Manager Information on exceeding or falling below limits is also displayed in the Smart Manager Smart Manager 86...

Page 87: ...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 a...

Page 88: ...INTERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and lo...

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