Manual for

R-30iB Fronius welder connect function

TABLE OF CONTENTS
Chapter 1 SETUP 2
1.1 INTRODUCTION 2
1.2 OVERVIEW 2
1.3 PREPARATION AND INITIAL SETTING 2
1.3.1 Examination for using range of I/O 2
1.3.2 Deletion of unused Ethernet I/O 3
1.3.3 Preparation for DeviceNet communication 4
1.3.4 Setting of Multi-Process and Multi Equipment 5
1.3.5 Modification of displaying range of digital I/O 6
1.4 SETTING OF WELDER MANUFACTURER 6
1.5 SETTING AND CONFIRMATION 8
AFTER SETTING OF WELDER MANUFACTURER 8
1.5.1 Setting of Robot Ethernet IP address 8
1.5.2 Setting of Fronius welder IP address 10
1.5.3 Setting of Ethernet IP scanner 10
1.5.4 Confirmation of weld I/O 12
1.5.5 Confirmation of polarity of digital input signal 12
1.5.6 Confirmation of group I/O 13
1.5.7 Confirmation of digital I/O 13
1.5.8 Setting of system variables 13

Chapter 2 OPERATION 15
2.1 OVERVIEW 15
2.2 OPERATION FOR WELDING 16
2.2.1 Setting of Weld Procedure 16
2.2.2 Creation of welding TP program 18

Chapter 3 OTHER SETTINGS 19

3.1 TOUCH SENSOR 19

APPENDIX 1 (ERROR CODE) 20

APPENDIX 2 (LIST OF DEGITAL I/O) 21
APPENDIX 3 (LIST OF FRONIUS WELD PROGRAM) 25

A-97606-1370 1
1 SETUP
1.1 INTRODUCTION
Fanuc ArcTool software can communicate with the Fronius welder by using the
Fronius weld equipment library option (A05B-xxxx-R653). As shown in following
table, four kinds of communications are supported according to each welder
model.

Welder Model Description

ROB 5000 This model is communicated by using the FANUC
Process I/O board (In this manual, a detailed setting
method has not been described).
TWIN This model is communicated by using the DeviceNet (In
this manual, a detailed setting method has not been
described).
TS/TPS DeviceNet hardware and DeviceNet interface master
（DeviceNet） option that is software option (A05B-xxxx-J753) are
required in this configuration.
TS/TPS There is no necessary hardware at the robot side. The
（Ethernet） Ethernet IP scanner option that is software option (A05B-
xxxx-R785) is required.

1.2 OVERVIEW
The setting for communicating the Fronius welder is performed when the
manufacturer and model are selected at the controlled start as well as the setting
in another manufacturer. However, there are some preparations and initial
settings that should be performed before selecting the manufacturer and models
(Please refer to Section 1.3).

1.3 PREPARATION AND INITIAL SETTING

1.3.1 Examination for using range of I/O
DeviceNet or Ethernet communication for the Fronius welder requires a lot of
digital I/O and group I/O. If CELL I/O or PLC or other I/O will be constructed, it is
necessary to setup those beforehand. In the setting of I/O for communicating with
the Fronius welder, user can specify the start point of using digital I/O range. On
the other hand, automatic I/O assignment also can be performed (available I/O
range is automatically searched).

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1.3.2 Deletion of unused Ethernet I/O
In the case of Ethernet communication, Ethernet IP scanner option is required.
When this option is ordered, some digital I/O are assigned by default as the slot 1
adaptor type. The assignment is normally not required. If it is not required, please
delete the assignment by performing the following procedure. It is necessary to
perform this procedure before selecting the welder manufacturer / model at the
controlled start.

Procedure:
1. Press MENU key and select [I/O]. Press F1[TYPE] and select
[Ethernet/IP]. The following screen is displayed.

I/O EtherNet/IP
EtherNet/IP List(Rack 89) 1/32
Description TYP Enable Status Slot
Connection1 ADP TRUE OFFLINE 1
Connection2 ADP FALSE OFFLINE 2

[ TYPE ] PING CONFIG HELP

2. Move the cursor to the third row of the first line. Change the [Connection1]
to FALSE.
3. Move the cursor to the first row of the first line. Press F4[CONFIG]. The
following screen is displayed.
I/O EtherNet/IP
Adapter configuration : 1/3

Description : Connection1
Input size (words) : 4
Output size(words) : 4
Alarm Severity : WARN

Scanner IP : ****************
API O=>T : 0
API T=>O : 0

[ TYPE ] PREV HELP

4. Press F3[PREV] after changing [Input size (words)] and [Output size
(words)] to 0.

A-97606-1370 3
 5. Press F1[TYPE] and select [Digital]. Press F2[CONFIG] after displaying
the digital output signal screen by pressing the F2[IN/OUT]. The following
screen is displayed.
I/O Digital Out
1/2
# RANGE RACK SLOT START STAT.
1 DO[ 1- 64] 89 1 1 ACTIV
2 DO[ 65- 512] 0 0 0 UNASG

[ TYPE ] MONITOR IN/OUT DELETE HELP

6. Move the cursor to the line of rack 89 assignment and press F4[DELETE]
for deleting the assignment.
7. Display the digital input signal screen by pressing F3[IN/OUT].
8. Move the cursor to the line of rack 89 assignment and press F4[DELETE]
for deleting the assignment.
9. Cycle power the robot controller.

1.3.3 Preparation for DeviceNet communication

In the case of DeviceNet communication, DeviceNet board hardware and
DeviceNet interface master software option (A05B-xxxx-J753) are required in the
robot side. Please refer to the following table about the DIP switch of DeviceNet
board.
Board number DIP switch of DeviceNet board
(= EQ number) 1 2 3 4 5 6
1 OFF OFF OFF OFF OFF OFF
2 OFF ON OFF OFF OFF OFF
3 OFF OFF ON OFF OFF OFF
4 OFF ON ON OFF OFF OFF

On the other hand, Fronius DeviceNet hardware (BECKHOFF) is required in the

welder side. The following figure is setting example of BECKHOFF BK5200.
Please refer to the Fronius welder manual about the detailed information or the
setting of other devices.

A-97606-1370 4
 Setting of BECKHOFF BK5200
DIP #2 is ON

24V DC power
Ω)
Set terminator (120Ω
is supplied from
the DeviceNet
connector

Connect to the
DeviceNet board of robot side

Please complete the preparation of hardware and the physical connection for
DeviceNet communication in the both robot side and welder side.

1.3.4 Setting of Multi-Process and Multi Equipment

In the Fronius welder configuration, ArcTool multi-process function is used.
Various operating mode of Fronius welder is selected / switched by the multi-
process. Please enable the multi-process function at ArcTool setup screen of the
controlled start menu. If the system is multi equipment configuration (robot
controller has two or more welder), please change the number of weld equipment
at the same time (there is no problem even if those settings are not performed
simultaneously). However, please note that selecting of welder manufacturer /
model must not be performed here yet. Normally, selecting of welder
manufacturer must still be “General Purpose” yet.
ArcTool Setup

8 Multi-process: DISABLED
9 Weld ID: DISABLED
10 Number of weld schedules: 32
11 Number of weld equipment: 1

[ TYPE ] HELP

Please perform the cold start after performing the setting of multi-process and
multi equipment.

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1.3.5 Modification of displaying range of digital I/O
A lot of digital I/O are used for the communication with Fronius welder
(DeviceNet communication uses DI 104 points and DO 96 points, Ethernet
communication uses DI 296 points and DO 296 points). When the system has
two or more weld equipment, there is a case that the number of those I/O
exceeds the maximum number of I/O that can be displayed in digital I/O screen
(this is 512 in the default setting). The maximum number of I/O that can be
displayed in I/O screen can be changed by the following procedure.

Procedure:
1. Perform the controlled start.
2. Press the MENU key and select the [PROGRAM SETUP]. The following
screen is displayed.
Program Limits Setup 1/14

1 User Tasks 4
2 Numeric Registers 200
3 Position Registers 100
4 String Registers 25
5 Macros 150
6 User Alarms 10
7 Trace Length 200
8 Num. Dig. Ports 512
9 Error Severity Table 20

3. Move the cursor to [Num. Dig. Ports] and change it to the desired points
(The maximum is 4096).

1.4 SETTING OF WELDER MANUFACTURER

Please perform the setup of welder manufacturer / model by the following
procedure.

Condition:
• In the case of ROB 5000, process I/O hardware is connected
• In the case of DeviceNet communication, DeviceNet hardware is
connected
• In the case of DeviceNet communication, DeviceNet software option is
ordered
• In the case of Ethernet communication, Ethernet IP scanner option is
ordered
• Fronius weld equipment library option is ordered
• All preparations and initial settings described in Section 1.3 are completed

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Procedure:
1. Perform the controlled start. The following screen is displayed.
ArcTool Setup
1 F Number: F00000

2 Welding setup: USA

3 Wire speed units: IPM
4 Weld speed units: IPM
5 Weld speed: 50

6 Manufacturer: General Purpose

7 Model: MIG (Volts, Amps)

[ TYPE ] CHECK HELP

2. Move the cursor to [Manufacturer] and press F4[CHOICE]. Select the

[Fronius]. ArcTool internal auto setup process is performed. [Model] is
selected to ROB 5000 by default.
3. When other models are used, move the cursor to [Model] and press
F4[CHOICE]. Following menu is displayed, so select the desired model.
1
1 ROB 5000
2 TS/TPS with DNet
3 TWIN with DNet
4 TS/TPS with ENet

4. When the DeviceNet communication is selected in the step 3, the

following left screen is displayed. When ENTER key is pressed, the input
of MAC ID is required so input “2” (For more detail, please refer to FANUC
DeviceNet manual and Fronius welder manual).
On the other hand, the following right screen is displayed when the
Ethernet communication is selected in the step 3. Move the cursor to
[YES] and press ENTER key.
Switches on the Beckhoff Fronius Enet I/O Range
Bus Coupler set the MACID.
The FULL range is 296 pts.
Read or set the switches, The SHORT range is 128 pts.
Then enter the MACID next.
Use the FULL range (296 pts)?
[ O.K ] [ YES ] NO

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 Continuously, the following screen is displayed.
Fronius I/O Setup

You can specify a start point

or begin checking at point 1.

Specify an I/O start point?

[ YES ] NO
If the start point of digital I/O range that is used in the communication with
Fronius welder is not specified, select [NO]. In this case, it is automatically
assigned to the first area where have enough I/O points that are required.
If the start point of digital I/O range is specified, select [YES] and enter the
desired point. In both the automatic assignment case and the manual
assignment case, please note that the start point becomes the value that
added 1 to multiple of 8 (1, 9, 17, F).
5. The following screen is displayed. Perform cycle power the robot controller
after pressing the ENTER key for closing the following screen.
To reverse the polarity of
the WIRESTICK input and the
POWER SUPPLY READY input
please CYCLE POWER and then
use the CHECK key (F3).

[ OK ]
Robot controller start up with controlled start again. Press F3[CHECK].

6. The procedure for setting of welder manufacturer / model is complete.

Perform cold start from the FCTN menu.

1.5 SETTING AND CONFIRMATION

AFTER SETTING OF WELDER MANUFACTURER
There are some necessary settings after setting of welder manufacturer / model

1.5.1 Setting of Robot Ethernet IP address

In the case of Ethernet communication, it is necessary to set the IP address of
robot controller Ethernet port. If the system is connected to the network such as
Cell I/O, it is necessary to divide the network from the network for communicating
the Fronius welder. Normally, the Ethernet port #2 of the robot controller is used
for communicating with the Fronius welder.

A-97606-1370 8
Procedure:
1. Press MENU key and select [SETUP]. Press F1[TYPE] and select [Host
Comm]. The following screen is displayed.

SETUP Protocols
1/8
Protocol Description
1 TCP/IP TCP/IP Detailed Setup
2 TELNET Telnet Protocol
3 SM Socket Messaging Device
4 PROXY Proxy Server
5 PPP Point to Point Protocol
6 PING Ping Protocol
7 HTTP HTTP Authentication
8 FTP File Transfer Protocol

[ TYPE ] DETAIL [ SHOW ]

2. Move the cursor to the first line (TCP/IP) and press F3[DETAIL]. The
following screen is displayed.
SETUP Host Comm
1/40
TCP/IP
Robot name : ROBOT
Port#1 IP addr: ****************
Subnet Mask : 255.255.255.0
Board address : ****************
Router IP addr: ****************

Host Name (LOCAL) Internet Address

1 ********** ******************
2 ********** ******************
3 ********** ******************
4 ********** ******************

[ TYPE ] PORT PING HELP >

3. Change display to screen for port #2 by pressing F3[PORT].

4. Move the cursor to [Port#2 IP addr] and press ENTER key.
5. Enter “192.168.0.2” (This is address corresponding to the default IP
address of Fronius welder. For more detail, please refer to the next
Subsection).
6. Confirm that the space is not included in the inputted IP address.
7. Press F8[INIT] and select [YES] in the displayed screen. The Port #2 is
initialized and new IP address is applied (This procedure is also performed
by the cycle power).

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1.5.2 Setting of Fronius welder IP address
In the case of Ethernet communication, it is necessary to set the IP address of
Fronius welder. This is a setting of Fronius welder side. Though the IP address of
the welder is set by RCU (Remote Control Unit) or Fronius PC application that is
connected to welder, please refer to the Fronius welder manual for more detail.

Though the IP address of robot controller Ethernet port #2 is set to “192.168.0.1”

and the subnet mask is set to “255.255.255.0” (This is not changed from the
default value) in the Subsection 1.5.1, those are address matched to the
following default IP address of welder.
IP address : 192.168.0.2
Subnet Mask : 255.255.255.0

Though it is possible to set any IP address, the subnet mask of welder must be
same as the subnet mask that is set at the robot side.
Please refer to the following information that is a setting example for configuring
the network with default subnet mask “255.255.255.0”.

192.168.0.1 (IP address of robot Ethernet port that is for connecting to welder)
192.168.0.2 (IP address of welder 1)
192.168.0.3 (IP address of welder 2) * Only multi equipment configuration
192.168.0.4 (IP address of welder 3) * Only multi equipment configuration
192.168.0.5 (IP address of welder 4) * Only multi equipment configuration

1.5.3 Setting of Ethernet IP scanner

In the case of Ethernet communication, it is necessary to set the Ethernet IP
scanner option of the robot software function corresponding to the IP address of
welder.

A-97606-1370 10
Procedure:
1. Press MENU key and select [I/O]. Press F1[TYPE] and select
[EtherNet/IP]. The following screen is displayed.

I/O EtherNet/IP
EtherNet/IP List (Rack 89) 1/32
Description TYP Enable Status Slot
Fronius_EQ1 SCN TRUE OFFLINE 1
Connection2 ADP FALSE OFFLINE 2
Connection3 ADP FALSE OFFLINE 3
Connection4 ADP FALSE OFFLINE 4
Connection5 ADP FALSE OFFLINE 5

[ TYPE ] PING CONFIG HELP

2. Move the cursor to the third row of the first line. Change the [Fronius EQ1]
to FALSE.
3. Move the cursor to the first row of the first line and press F4[CONFIG].
The following screen is displayed.
I/O EtherNet/IP
Scanner configuration : 1/10
Description : Fronius_EQ1
Name/IP address : ***********
Vendor Id : 90
Device Type : 12
Product code : 14
Input size (bytes) : 37
Output size (bytes) : 37
RPI (ms) : 20
Assembly instance(input) : 100
Assembly instance(output) : 150
Configuration instance : 1

[ TYPE ] ADV PREV ANALOG HELP

4. Set the welder IP address that is set at the Subsection 1.5.2 to the
[Name/IP address].
5. Press F3[PREV].
6. Move the cursor to the third row of the first line. Change the [Fronius EQ1]
to TRUE.
7. Power OFF both the robot controller and the welder.
8. Confirm that the Ethernet connection between the robot controller
Ethernet port and the welder. After that, power ON both the robot
controller and the welder.
9. Confirm that the status of [Fronius EQ1] is “RUNNING” after displaying the
Ethernet/IP screen (screen of step 1).

A-97606-1370 11
 I/O EtherNet/IP
EtherNet/IP List (Rack 89) 1/32
Description TYP Enable Status Slot
Fronius_EQ1 SCN TRUE RUNNING 1
Connection2 ADP FALSE OFFLINE 2

10. Press RESET key. Robot controller establishes the communication with
the welder.

1.5.4 Confirmation of weld I/O

Though the weld I/O is automatically assigned, please confirm the assignment is
correct. The example of weld I/O assignment is shown below. This example is
that the start point of digital I/O range that is used for communicating with the
Fronius welder is 1 in the Section 1.4.
I/O Weld In I/O Weld Out
WELD SIGNAL TYPE#SIM STATUS WELD SIGNAL TYPE#SIM STATUS
1 [Voltage ] GI[ 2] U 0.0 1 [Wire feed ] GO[ 4] U 0.0
2 [Current ] GI[ 3] U 0.0 2 [Arc length corr ] GO[ 5] U 0.0
3 [Motor current ] GI[ 4] U 0.0 3 [Pulse correction] GO[ 6] U 0.0
4 [Wire Feed Speed] GI[ 5] U 0.0 4 [Burnback corr ] GO[ 7] U 0.0

5 [Arc detect ] DI[ 1] U OFF 5 [Weld start ] DO[ 1] U OFF

6 [Power fault ] DI[ 6] U OFF 6 [Gas start ] DO[ 9] U OFF
7 [Wirestick ] DI[25] U OFF 7 [Inch forward ] DO[10] U OFF
8 [Inch backward ] DO[11] U OFF
8 [Gas fault ] [**] * ***
9 [Wire fault ] [**] * *** 9 [Operating mode ] GO[ 1] U OFF
10[Water fault ] [**] * *** 10[Program number ] GO[ 3] U OFF

1.5.5 Confirmation of polarity of digital input signal

It is necessary to set two digital input signals (Power fault and Wirestick) to
inverse polarity. Though this setting is automatically performed, please confirm
those are correct.

Procedure:
1. Press MENU key and select [I/O]. Press F1[TYPE] and select [Weld].
2. Display the weld input I/O screen by pressing F3[IN/OUT].
3. Move the cursor to [Power fault] and press F8[CONFIG].
4. Confirm the polarity is INVERSE. If not, set the polarity to INVERSE.
5. Press PREV key. Display is returns to the weld input I/O screen.
6. Move the cursor to [Wirestick] and press F8[CONFIG].
7. Perform the step 4 again.

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1.5.6 Confirmation of group I/O
Though the group I/O is automatically assigned, please confirm the assignment
is correct. The example of the assignment is shown below.
I/O Group In I/O Group Out
# SIM VALUE 1/100 # SIM VALUE 1/100
GI[ 1] U 0 [EQ1 Fron Err Cod] GO[ 1] U 0 [EQ1 Oper Mode ]
GI[ 2] U 0 [EQ1 Weld Fdbk 1 ] GO[ 2] U 0 [EQ1 Job Number ]
GI[ 3] U 0 [EQ1 Weld Fdbk 2 ] GO[ 3] U 0 [EQ1 Prg Number ]
GI[ 4] U 0 [EQ1 Weld Fdbk 3 ] GO[ 4] U 0 [EQ1 Weld Cmnd 1 ]
GI[ 5] U 0 [EQ1 Weld Fdbk 4 ] GO[ 5] U 0 [EQ1 Weld Cmnd 2 ]
GI[ 6] * * [ ] GO[ 6] U 0 [EQ1 Weld Cmnd 3 ]
GI[ 7] * * [ ] GO[ 7] U 0 [EQ1 Weld Cmnd 4 ]
GI[ 8] * * [ ] GO[ 8] * * [ ]

1.5.7 Confirmation of digital I/O

Though the digital I/O is automatically assigned, please confirm the assignment
is correct. Fronius communication uses many digital I/O. There are I/O with /
without a comment descriptions. Please note that the signal of no comment
description does not mean unused signal. The APPENDIX 2 shows the list of
digital I/O of Ethernet communication. Even if the DeviceNet communication, it
can be referred because the comment descriptions are the same as the case of
Ethernet communication.

1.5.8 Setting of system variables

Though some system variables are automatically set for the welding of Fronius
welder, there are settings required by manual. Please confirm those are correct.

$AWSPCR.$GAS_CHECK = FALSE
In the Fronius welder configuration, it is not necessary to check the gas fault
status (The gas check is controlled by the group input signal of “Fron Err Cod”).
So it is disabled.

$AWSPCR.$WIRE_CHECK = FALSE
In the Fronius welder configuration, the checking of wire fault is not supported.
So it is disabled.

$AWSPCR.$BBACK_ENABL = FALSE
The burnback process of weld end timing is controlled by the Fronius welder. So
the burnback process of ArcTool is disabled.

$AWEPCR[eq].$AE_HOLD_AO = TRUE
The ArcTool must keep the welding output commands during the burnback
process of Fronius welder. This is a setting for it.

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$AWEIOEX[eq].$PROC_ACTIVE.$PORT_NUM
.$PORT_TYPE
The port number of process active signal (This is the third digital input signal in
the I/O range that is used for the communication with Fronius welder) is set to
this system variable of $PORT_NUM. $PORT_TYPE is set to 1 (“1” means digital
input signal). The role of those settings are described later.

$AWEPCR[eq].$AE_CHK_DI = TRUE
By this setting, the robot waits finishing the weld end process until the process
active signal (this is a signal set to $AWEIOEX[eq].$PROC_ACTIVE) becomes
OFF after the burnback process. When the process active signal does not
becomes OFF though the time of $AWEUPR[eq].$MAX_END_TIM is passed, the
alarm of ARC-251 is posted.

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2 OPERATION
2.1 OVERVIEW
There are concepts called “Operating Mode” and “Welding Program” in the
Fronius welder. There are four modes as the main Operation Modes, please refer
to the following table. One Operation Mode is assigned to each Weld Procedure.
The Operation Mode number of selected Weld Procedure is output as GO[1]
(Oper Mode).
Operation Mode Description
Synergic This is short circuit welding mode. The welding output is decided
based on the weld schedule that is set in the robot.
Pulsed Synergic This is pulse welding mode. The welding output is decided based
on the weld schedule that is set in the robot.
CMT This is CMT (Cold Metal Transfer) welding mode. The welding
output is decided based on the weld schedule that is set in the robot.
Job Mode Unlike above-mentioned three modes, the welding output is
decided based on the weld schedule that is set in the Fronius welder
(this is called “JOB” in the Fronius system). Though the robot
basically commands the JOB number only, the robot can also
command only fine tuning of the JOB welding. In that case, the
robot commands to the welder by %. Then, the weld schedule of
JOB is fine tuned by %.
When this mode is used, it is necessary to disable the ArcTool
runin and burnback and wirestick processes.

Welding Program is a Fronius welding characteristic file that is prepared

corresponding to wire material / wire diameter / shield gas. Please refer to the
APPENDIX 3 about the list of Welding Program.

In the case of Synergic and Pulsed Synergic and CMT mode, One Welding
Program is assigned to each Weld Procedure. The Welding Program number of
selected Weld Procedure is output as GO[3] (Prg Number).

In the case of JOB mode, One Welding Program is assigned to each JOB.
Please note that GO[3] (Prg Number) must be 0 because Welding Program is set
by JOB. When JOB welding is performed though GO[3] (Prg Number) is not 0,
the robot stops by the alarm just before executing the weld start instruction.
Besides, this manual does not have an explanation for the setting procedure of
JOB. Please refer to the Fronius welder manual about it.

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2.2 OPERATION FOR WELDING
2.2.1 Setting of Weld Procedure
This Subsection explains the setting procedure of Weld Procedure for the
welding with Fronius welder. About the basic operation in the Weld Procedure
screen, please refer to the Section 3.5 of R-30iB/R-30iB Mate CONTROLLER
Arc Welding Function OPERATOR’S MANUAL.

Procedure:
1. Press MENU key and select [-- NEXT --]. Select [DATA].
2. Press F1[TYPE] and select [Weld Procedure]. The following screen is
displayed.

DATA Weld Procedure 1

1/3
+ Procedure 1 [ ]
+ Mode [Synergic ]
+ Schedules

[ TYPE ] DETAIL [ CMND ] [ VIEW ] HELP

3. Move the cursor to the comment field of [Mode] line and press the
F4[CHOICE]. The following menu is displayed.
2
1 1 CMT (Not used)
1 Synergic 2
2 Pulsed-Synergic 3
3 Job Mode 4
4 Setup (NO-WELD) 5
5 Manual Mode 6
6 CC/CV (Not used) 7
7 TIG (Not used) 8 -- next page --
8 -- next page --

4. Select the desired Operation Mode.

A-97606-1370 16
 5. In the case of Synergic and Pulsed-Synergic and CMT Operation Mode,
“+” is displayed at the first position of [Mode] line. Move the cursor to the
area of “+” and press ENTER key or F2[DETAIL]. The Mode tree view is
expanded and the following screen is displayed. Enter the desired
Welding Program number. Refer to the APPENDIX 3 about the list of
Welding Program.
DATA Weld Procedure 1
1/3
+ Procedure 1 [ ]
- Mode [Synergic ]
Program: 6

+ Schedules

[ TYPE ] DETAIL [ CMND ] [ VIEW ] HELP

Besides, it is not necessary to set the Welding Program number in the

case of JOB Operation Mode because the Welding Program is set by JOB
(“+” is not displayed at the first position of [Mode] line).

6. Continuously, the weld schedule is set at the Weld Procedure screen.

However, it is not necessary to perform this step if user wants to teach the
weld schedule in TP program directly (For more detail, please refer to the
next Subsection).
Set each weld commands (Wire feed speed, Arc length correction, etcF),
those changes according to the selected Operation Mode. Refer to the
Fronius welder manual about the meaning of each weld commands.
Though weld schedule is basically decided by JOB in the case of JOB
mode, the robot can also command only fine tuning of the JOB welding by
using % unit. There is a command of “JOB number” in the JOB mode.
ENTER the JOB number here.

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2.2.2 Creation of welding TP program
In the welding TP program, weld start and weld end instructions are taught.
There are following two kinds of formats in those instructions.

Indirect : This is method for using weld schedule that is set at the step 6
in previous Subsection.
Direct : This is method for teaching weld schedule directly in TP program.
Weld Start Instruction
Indirect : Weld Start [ Weld Procedure number, Weld schedule number ]
Direct : Weld Start [ Weld Procedure number, Command1, Command2, … ]

Weld End Instruction

Indirect : Weld End [ Weld Procedure number, Weld schedule number ]
Direct : Weld End [ Weld Procedure number, Command1, Command2, … , delay ]

The kind of each commands and the number of the command changes according
to the selected Operation Mode / Welding Program. Please refer to the Fronius
welder manual about the meaning of each command.

The sample TP program is shown below.

＜Indirect method＞
＞ ＜Direct method＞
1:J P[1] 100% FINE;
2:L P[2] 100mm/sec FINE
: Weld Start [1,1];
3:L P[3] 80cm/min FINE
: Weld End [1,2];
4:L P[4] 100mm/sec CNT100;
5:J P[1] 100% FINE;
＞
1:J P[1] 100% FINE;
2:L P[2] 100mm/sec FINE
: Weld Start [1, 150.0IPM
150.0IPM,
IPM, 0.00%, 0.000%, 0.0ms];
3:L P[3] 80cm/min FINE
: Weld End [1, 130.0IPM
130.0IPM,
IPM, 1.00%, 0.000%, 0.1ms, 0.3s];
4:L P[4] 100mm/sec CNT100;
5:J P[1] 100% FINE;

A-97606-1370 18
3 OTHER SETTINGS
3.1 TOUCH SENSOR
When the touch sensor function (A05B-xxxx-J536) is ordered, this function can
be used in the Fronius configuration. The touch sensor function uses a wirestick
input signal and a touch sense output signal in the digital I/O range that is used
for communicating with Fronius welder (those are DI[25] and DO[13] in the I/O
list of the APPENDIX 2). Please set the touch sensor I/O by performing the
following procedure.

Procedure:
1. Press MENU key and select [SETUP].
2. Press F1[TYPE] and select [Touch I/O]. The following screen is displayed.
Touch I/O Setup
1/4
NAME VALUE

1 Sensor port type: DI

2 Sensor port number: 25
3 Circuit port type: DO
4 Circuit port number: 13

3. Set the wirestick input signal and a touch sense output signal in the digital
I/O range that is used for communicating with Fronius welder.

A-97606-1370 19
 APPENDIX 1 (ERROR CODE)
[Fron err cod] of the group input signal is assigned to the 8 bit error number from
the Fronius welder. When this error happens, ARC-124 alarm is posted in the
robot side. This alarm message shows the weld equipment number that error
happens or the binary information of error code, error text, etc.

As an example, the alarm of the error code 1 is shown below.

ARC-124 EQ1 E:1 Fronius no prg selected

It is necessary to refer the Fronius welder manual about the detail of the
generated alarm.

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 APPENDIX 2 (LIST OF DEGITAL I/O)
Table.1 Digital Input Signal [ 1 - 150 ]
1 EQ1 Arc Detect 51 EQ1 Weld Fdbk 2 3 101 EQ1 Weld Fdbk 4 5
2 EQ1 Limit Signal 52 EQ1 Weld Fdbk 2 4 102 EQ1 Weld Fdbk 4 6
3 EQ1 Proc Active 53 EQ1 Weld Fdbk 2 5 103 EQ1 Weld Fdbk 4 7
4 EQ1 Main Current 54 EQ1 Weld Fdbk 2 6 104 EQ1 Weld Fdbk 4 8
5 EQ1 Torch Collision 55 EQ1 Weld Fdbk 2 7 105 EQ1 Weld Fdbk 4 9
6 EQ1 PS NOT Ready 56 EQ1 Weld Fdbk 2 8 106 EQ1 Weld Fdbk 4 10
7 EQ1 PS Comm OK 57 EQ1 Weld Fdbk 2 9 107 EQ1 Weld Fdbk 4 11
8 EQ1 Reserved OFF 58 EQ1 Weld Fdbk 2 10 108 EQ1 Weld Fdbk 4 12
9 EQ1 Err Code 1 59 EQ1 Weld Fdbk 2 11 109 EQ1 Weld Fdbk 4 13
10 EQ1 Err Code 2 60 EQ1 Weld Fdbk 2 12 110 EQ1 Weld Fdbk 4 14
11 EQ1 Err Code 4 61 EQ1 Weld Fdbk 2 13 111 EQ1 Weld Fdbk 4 15
12 EQ1 Err Code 8 62 EQ1 Weld Fdbk 2 14 112 EQ1 Weld Fdbk 4 16
13 EQ1 Err Code 16 63 EQ1 Weld Fdbk 2 15 113
14 EQ1 Err Code 32 64 EQ1 Weld Fdbk 2 16 114
15 EQ1 Err Code 64 65 EQ1 Weld Fdbk 3 1 115
16 EQ1 Err Code 128 66 EQ1 Weld Fdbk 3 2 116
17 EQ1 Fronuis Spare 67 EQ1 Weld Fdbk 3 3 117
18 EQ1 Fronuis Spare 68 EQ1 Weld Fdbk 3 4 118
19 EQ1 Fronuis Spare 69 EQ1 Weld Fdbk 3 5 119
20 EQ1 Fronuis Spare 70 EQ1 Weld Fdbk 3 6 120
21 EQ1 Fronuis Spare 71 EQ1 Weld Fdbk 3 7 121 EQ1 ROB Input 1
22 EQ1 Fronuis Spare 72 EQ1 Weld Fdbk 3 8 122 EQ1 ROB Input 2
23 EQ1 Fronuis Spare 73 123 EQ1 ROB Input 3
24 EQ1 Fronuis Spare 74 124 EQ1 ROB Input 4
25 EQ1 Wirestick 75 125
26 EQ1 Fronuis Spare 76 126
27 EQ1 Fronuis Spare 77 127
28 EQ1 Fronuis Spare 78 128
29 EQ1 Fronuis Spare 79 129 EQ1 WFS High
30 EQ1 Fronuis Spare 80 130 EQ1 WFS Low
31 EQ1 Fronuis Spare 81 131 EQ1 Current High
32 EQ1 Fronuis Spare 82 132 EQ1 Current Low
33 EQ1 Weld Fdbk 1 1 83 133 EQ1 Voltage High
34 EQ1 Weld Fdbk 1 2 84 134 EQ1 Voltage Low
35 EQ1 Weld Fdbk 1 3 85 135 EQ1 Main motor
36 EQ1 Weld Fdbk 1 4 86 136 EQ1 PPU motor
37 EQ1 Weld Fdbk 1 5 87 137 EQ1 Weld Speed High
38 EQ1 Weld Fdbk 1 6 88 138 EQ1 Weld Speed Low
39 EQ1 Weld Fdbk 1 7 89 139
40 EQ1 Weld Fdbk 1 8 90 140
41 EQ1 Weld Fdbk 1 9 91 141
42 EQ1 Weld Fdbk 1 10 92 142
43 EQ1 Weld Fdbk 1 11 93 143
44 EQ1 Weld Fdbk 1 12 94 144
45 EQ1 Weld Fdbk 1 13 95 145
46 EQ1 Weld Fdbk 1 14 96 146
47 EQ1 Weld Fdbk 1 15 97 EQ1 Weld Fdbk 4 1 147
48 EQ1 Weld Fdbk 1 16 98 EQ1 Weld Fdbk 4 2 148
49 EQ1 Weld Fdbk 2 1 99 EQ1 Weld Fdbk 4 3 149
50 EQ1 Weld Fdbk 2 2 100 EQ1 Weld Fdbk 4 4 150

A-97606-1370 21
 Table.2 Digital Input Signal [ 151 - 296 ]

151 201 251

152 202 252
153 203 253
154 204 254
155 205 255
156 206 256
157 207 257 EQ1 TAG Read Status
158 208 258 EQ1 TAG Write Status
159 209 259
160 210 260
161 211 261
162 212 262
163 213 263
164 214 264
165 215 265 EQ1 TAG Address
166 216 266
167 217 267
168 218 268
169 219 269
170 220 270
171 221 271
172 222 272
173 223 273
174 224 274
175 225 275
176 226 276
177 227 277
178 228 278
179 229 279
180 230 280
181 231 281 EQ1 TAG Value
182 232 282
183 233 283
184 234 284
185 235 285
186 236 286
187 237 287
188 238 288
189 239 289
190 240 290
191 241 291
192 242 292
193 243 293
194 244 294
195 245 295
196 246 296
197 247
198 248
199 249
200 250

A-97606-1370 22
 Table.3 Digital Output Signal [ 1 - 150 ]

1 EQ1 Weld Start 51 EQ1 Weld Cmnd 2 3 101

2 EQ1 Robot Ready 52 EQ1 Weld Cmnd 2 4 102
3 EQ1 OP Mode 1 53 EQ1 Weld Cmnd 2 5 103
4 EQ1 OP Mode 2 54 EQ1 Weld Cmnd 2 6 104
5 EQ1 OP Mode 4 55 EQ1 Weld Cmnd 2 7 105
6 EQ1 Master/Slct Twin 56 EQ1 Weld Cmnd 2 8 106
7 EQ1 Master/Slct Twin 57 EQ1 Weld Cmnd 2 9 107
8 EQ1 Reserved OFF 58 EQ1 Weld Cmnd 2 10 108
9 EQ1 Gas Start 59 EQ1 Weld Cmnd 2 11 109
10 EQ1 Inch Forward 60 EQ1 Weld Cmnd 2 12 110
11 EQ1 Inch Backward 61 EQ1 Weld Cmnd 2 13 111
12 EQ1 Error Reset 62 EQ1 Weld Cmnd 2 14 112
13 EQ1 Touch Sense ON 63 EQ1 Weld Cmnd 2 15 113 EQ1 Disable Synchro Pul
14 EQ1 Blow Out Torch 64 EQ1 Weld Cmnd 2 16 114 EQ1 Disable SFI
15 EQ1 Unused DO 1 65 EQ1 Weld Cmnd 3 1 115 EQ1 Disable Pulse Corr
16 EQ1 Unused DO 2 66 EQ1 Weld Cmnd 3 2 116 EQ1 Disable Burnback Co
17 EQ1 Job Number 1 67 EQ1 Weld Cmnd 3 3 117 EQ1 Full power range
18 EQ1 Job Number 2 68 EQ1 Weld Cmnd 3 4 118
19 EQ1 Job Number 3 69 EQ1 Weld Cmnd 3 5 119
20 EQ1 Job Number 4 70 EQ1 Weld Cmnd 3 6 120
21 EQ1 Job Number 5 71 EQ1 Weld Cmnd 3 7 121 EQ1 ROB Output 1
22 EQ1 Job Number 6 72 EQ1 Weld Cmnd 3 8 122 EQ1 ROB Output 2
23 EQ1 Job Number 7 73 123
24 EQ1 Job Number 8 74 124
25 EQ1 Prg Number 1 75 125
26 EQ1 Prg Number 2 76 126
27 EQ1 Prg Number 3 77 127
28 EQ1 Prg Number 4 78 128
29 EQ1 Prg Number 5 79 129 EQ1 Part CHR 1
30 EQ1 Prg Number 6 80 130
31 EQ1 Prg Number 7 81 EQ1 Weld Cmnd 4 1 131
32 EQ1 Sim Welding 82 EQ1 Weld Cmnd 4 2 132
33 EQ1 Weld Cmnd 1 1 83 EQ1 Weld Cmnd 4 3 133
34 EQ1 Weld Cmnd 1 2 84 EQ1 Weld Cmnd 4 4 134
35 EQ1 Weld Cmnd 1 3 85 EQ1 Weld Cmnd 4 5 135
36 EQ1 Weld Cmnd 1 4 86 EQ1 Weld Cmnd 4 6 136
37 EQ1 Weld Cmnd 1 5 87 EQ1 Weld Cmnd 4 7 137 EQ1 Part CHR 2
38 EQ1 Weld Cmnd 1 6 88 EQ1 Weld Cmnd 4 8 138
39 EQ1 Weld Cmnd 1 7 89 139
40 EQ1 Weld Cmnd 1 8 90 140
41 EQ1 Weld Cmnd 1 9 91 141
42 EQ1 Weld Cmnd 1 10 92 142
43 EQ1 Weld Cmnd 1 11 93 143
44 EQ1 Weld Cmnd 1 12 94 144
45 EQ1 Weld Cmnd 1 13 95 145 EQ1 Part CHR 3
46 EQ1 Weld Cmnd 1 14 96 146
47 EQ1 Weld Cmnd 1 15 97 147
48 EQ1 Weld Cmnd 1 16 98 148
49 EQ1 Weld Cmnd 2 1 99 149
50 EQ1 Weld Cmnd 2 2 100 150

A-97606-1370 23
 Table.4 Digital Output Signal [ 151 - 296 ]

151 201 EQ1 Part CHR 10 251

152 202 252
153 EQ1 Part CHR 4 203 253
154 204 254
155 205 255
156 206 256
157 207 257 EQ1 TAG Read
158 208 258 EQ1 TAG Write
159 209 EQ1 Part CHR 11 259
160 210 260
161 EQ1 Part CHR 5 211 261
162 212 262
163 213 263
164 214 264
165 215 265 EQ1 TAG Address
166 216 266
167 217 267
168 218 268
169 EQ1 Part CHR 6 219 269
170 220 270
171 221 271
172 222 272
173 223 273
174 224 274
175 225 275
176 226 276
177 EQ1 Part CHR 7 227 277
178 228 278
179 229 279
180 230 280
181 231 281 EQ1 TAG Value
182 232 282
183 233 283
184 234 284
185 EQ1 Part CHR 8 235 285
186 236 286
187 237 287
188 238 288
189 239 289
190 240 290
191 241 291
192 242 292
193 EQ1 Part CHR 9 243 293
194 244 294
195 245 295
196 246 296
197 247
198 248
199 249
200 250

A-97606-1370 24
 APPENDIX 3
(LIST OF FRONIUS WELD PROGRAM)
NOTE
This information is reprinted from the Fronius welder manual. This information is
corresponding to the Fronius welder, so there is a possibility that the contents
changes according to the modification of Fronius specification. Please refer to the
Fronius welder manual about the recent or more detailed information.

Prg Mode (Ref.Nr) Wire Gas

Number * Number of welder inside
Material Dia.
01 S(736) C(1214) G3Si1 0.8 C1 100% CO2
02 S(737) C(1149) G3Si1 1.0 C1 100% CO2
03 S(744) C(1098) G3Si1 1.2 C1 100% CO2
04 S(98) G3Si1 1.6 C1 100% CO2
05 (SP) C(1027) G3Si1 0.9 C1 100% CO2
06 S(734) P(74) C(1019) G3Si1 0.8 M21 Ar + 18% CO2
07 S(603) P(346) C(1170) G3Si1 1.0 M21 Ar + 18% CO2
08 S(783) P(378) C(1220) G3Si1 1.2 M21 Ar + 18% CO2
09 S(97) P(417) G3Si1 1.6 M21 Ar + 18% CO2
10 (SP) C(1053) G3Si1 1.0 M21 Ar + 18% CO2
11 C(1184) G3Si1 1.0 M21 Ar + 18% CO2
12 S(93) P(92) A DUR 600 1.0 M21 Ar + 18% CO2
13 S(43) P(112) A DUR 600 1.2 M21 Ar + 18% CO2
14 S(44) P(106) A DUR 600 1.6 M21 Ar + 18% CO2
15 (SP) C(1185) G3Si1 1.0 M21 Ar + 18% CO2
17 S(132) P(131) C(1076) AlSi5 1.0 l1 100% Ar
18 S(16) P(116) C(876) AlSi5 1.2 l1 100% Ar
19 S(189) P(190) AlSi5 1.6 l1 100% Ar
20 (SP) C(880) AlSi5 1.2 l1 100% Ar
22 S(14) P(408) C(1070) AlMg5 1.0 l1 100% Ar
23 S(15) P(191) C(879) AlMg5 1.2 l1 100% Ar
24 S(187) P(188) AlMg5 1.6 l1 100% Ar
25 (SP) C(875) AlMg4,5Mn 1.2 l1 100% Ar
26 C(1111) CuAl8 1.0 l1 100% Ar
27 S(133) P(134) Al99.5 1.0 l1 100% Ar
28 S(264) P(209) Al99.5 1.2 l1 100% Ar
29 S(36) P(140) Al99.5 1.6 l1 100% Ar
30 (SP) C(881) AlSi5 1.2 l1 100% Ar
31 S(18) P(71) CuAl8 0.8 l1 100% Ar
32 S(103) P(143) C(883) CuAl8 1.0 l1 100% Ar
33 S(20) P(113) C(970) CuAl8 1.2 l1 100% Ar
34 S(21) P(147) CuAl8 1.6 l1 100% Ar

A-97606-1370 25
35 (SP) C(1182) CuSi3 1.0 l1 100% Ar
36 C(920) CuSi3 0.8 l1 100% Ar
37 S(104) P(405) C(878) CuSi3 1.0 l1 100% Ar
38 S(153) P(342) C(918) CuSi3 1.2 l1 100% Ar
39 C(1183) CuSi3 1.0 l1 100% Ar
40 (SP) C(884) CuSi3 1.0 l1 100% Ar
41 S(9) P(76) C(960) CrNi19 9 0.8 M12 Ar + 2.5% CO
42 S(101) P(414) C(877) CrNi19 9 1.0 M12 Ar + 2.5% CO
43 S(11) P(415) C(928) CrNi19 9 1.2 M12 Ar + 2.5% CO
44 S(40) P(107) CrNi19 9 1.6 M12 Ar + 2.5% CO
45 (SP) C(882) CrNi19 9 1.0 M12 Ar + 2.5% CO
46 S(149) P(148) CrNi18 8 0.8 M12 Ar + 2.5% CO
47 S(102) P(421) CrNi 18 8 6 1.0 M12 Ar + 2.5% CO
48 S(33) P(345) CrNi 18 8 6 1.2 M12 Ar + 2.5% CO
49 S(41) P(150) CrNi 18 8 1.6 M12 Ar + 2.5% CO
53 S(25) P(114) FCW Rutil 1.2 M21 Ar + 18% CO2
54 S(26) P(88) FCW Rutil 1.6 M21 Ar + 18% CO2
55 (SP) C(1176) G3Si1 1.2 M21 Ar + 18% CO2
58 S(27) P(84) FCW Basisch 1.2 M21 Ar + 18% CO2
59 S(28) P(90) FCW Basisch 1.6 M21 Ar + 18% CO2
60 (SP) C(1092) FCW Hardfacing 1.2 C1 100% CO2
63 S(31) P(83) FCW Metall 1.2 M21 Ar + 18% CO2
64 S(30) P(89) FCW Metall 1.6 M21 Ar + 18% CO2
65 (SP) C(1093) FCW Hardfacing 1.2 M21 Ar + 18% CO2
68 S(23) P(79) FCW CrNi 1.2 M21 Ar + 18% CO2
69 S(24) P(87) FCW CrNi 1.6 M21 Ar + 18% CO2
71 C(959) CrNi 19 9 0.8 M12 Ar + 2.5% CO
75 (SP) C(929) CrNi 19 9 1.2 M12 Ar + 2.5% CO
80 (SP) C(873) CuAl 5 Ni2 1.0 l1 100% Ar

Mode : S F Standard program

P F Pulse program
C F Cold Metal Transfer
F SFI (Spatter Free Ignition option)

A-97606-1370 26