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Welding System
TPS/i
Fronius TPS/i User Manual
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Ignition
(Start of Welding)
U
I
t
t
t
Current flow
Arc stable
MIG/MAG pulse synergic, MIG/MAG 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, MIG/MAG
CMT
, MIG/MAG CMT Mix:
Example of correct ignition at the start of welding
29
EN-US
28
30
Table of Contents
Table of Contents
3
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
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
Sensor Status 2 (Sensor Status 2) - Single Bit
34
Sensor Status 3 (Sensor Status 3) - Single Bit
34
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
Motor Current M1 (Motor Current M1) - Group Output / Analog Output
40
Motor Current M2 (Motor Current M2) - Group Output / Analog Output
40
Motor Current M3 (Motor Current M3) - Group Output / Analog Output
41
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
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
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Fronius TPS/i Specifications
General
Brand
Fronius
Model
TPS/i
Category
Welding System
Language
English
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