Bedienungsanleitung

D
Roboterinterface

Operating Instructions
GB
Robot interface

Instructions de service
ROB 4000 / 5000 MIG/MAG F
Interface robot

42,0410,0699 042003
Contents
General remarks ........................................................................................................................................... 3
Basic requirements .................................................................................................................................. 3
Safety ....................................................................................................................................................... 3
Machine concept ...................................................................................................................................... 3
Features of the ROB 4000 / ROB 5000 ................................................................................................... 4
Application example of robot interface ROB 4000 / 5000 ........................................................................ 4
Additional remark ..................................................................................................................................... 5
Digital input signals (signals from the robot) ................................................................................................. 5
Caracteristic parameters .......................................................................................................................... 5
Arc ON ..................................................................................................................................................... 5
Roboter Ready / Quick stop ..................................................................................................................... 5
Operating bit 0 - 2 (Mode 0 - 2) ................................................................................................................ 6
Twin Master Signal (Twin Master Bit 0 and 1; ROB 5000) ....................................................................... 9
Gas Test ................................................................................................................................................... 9
Wire inch (Wire feed) ............................................................................................................................... 9
Wire retract ............................................................................................................................................ 10
Source error reset (ROB 5000) .............................................................................................................. 10
Job / Program select (ROB 5000, not active) ......................................................................................... 10
Program number (Job/Program Bit 0 - 7) (ROB 5000) ............................................................................ 11
Job number (Job/Program Bit 0 - 7) (ROB 5000) ................................................................................... 12
Welding simulation ................................................................................................................................. 12
Touch Sensing (ROB 5000) ................................................................................................................... 12
Torch blow through (Blow through) ........................................................................................................ 13
Analogue Input signals (signals from the robot) .......................................................................................... 14
General .................................................................................................................................................. 14
Welding power command value (Welding power) .................................................................................. 14
Arc-length correction command value (Arc length correction) ............................................................... 15
Pulse / Arc force correction command value (Puls Correction; ROB 5000) ........................................... 15
Burn-back time correction command value (Burn back time correction; ROB 5000) ............................. 15
Analogue input for reserve parameter (robot welding speed - ROB 5000, not active) ........................... 16
Digital output signals (signals to the robot) ................................................................................................. 16
General .................................................................................................................................................. 16
Current flow signal ................................................................................................................................. 16
Process active signal (ROB 5000) ......................................................................................................... 16
Main current signal (ROB 5000) ............................................................................................................. 17
Limit signal (not active) .......................................................................................................................... 17
Collision protection ................................................................................................................................. 17
Power source ready ............................................................................................................................... 18
Analogue output signals (signals to the robot) ............................................................................................ 18
General .................................................................................................................................................. 18
Welding voltage actual value (ROB 5000) ............................................................................................. 18
Welding current actual value .................................................................................................................. 18
Actual value for wire-drive current consumption (Motor current - ROB 5000) ........................................ 19
Wirefeed speed (ROB 5000) .................................................................................................................. 19
Analogue output for Reserve parameter (Arc length - ROB 5000, not active) ..................................... 19
Application examples .................................................................................................................................. 20
General .................................................................................................................................................. 20
Basic Version (analogue) - ROB 4000 .................................................................................................. 20
High-End Version (analogue) - ROB 500 ............................................................................................... 21
Basic Version (digital) - ROB 5000 ......................................................................................................... 22
High-End Version (digital) - ROB 5000 ................................................................................................... 24
Terminal diagram ........................................................................................................................................ 26
Wiring of inputs and outputs ........................................................................................................................ 27
Signal pattern (selection by program number) ............................................................................................ 28

1
Signal pattern (selection by Job number) .................................................................................................... 29
Fault diagnosis and rectification .................................................................................................................. 30
Resetting error messages - ROB 5000 .................................................................................................. 30
Resetting error messages - ROB 4000 .................................................................................................. 30
Displayed service codes ........................................................................................................................ 30
Fronius Worldwide

2
General remarks

Basic require- Note! The robot interface ROB 4000 / 5000 is only supported from software
ments version 2.55.001 upwards (power source). Older software versions will need to
be updated.

Before starting to use the welding system, you must find out the welding-circuit resis-
tance (see the section headed “Determining the welding-circuit resistance” in the opera-
ting instructions for the power source).

Safety
Warning! Operating the equipment incorrectly and work that is not carried out
correctly can cause serious injury and damage. Do not use the functions
described here until you have read and completely understood all of the follo-
wing documents:
- this “Operating Instructions“ manual
- the instruction manual of the power source being used, especially the
“Safety rules“

Machine concept The robot interface ROB 4000 / 5000 is an automatic-welder interface and robot inter-
face with analogue and digital inputs and outputs. The ROB 4000 / 5000 is designed to
be installed in an automatic-welder or robot control cubicle (can also be retrofitted).

Advantages:
- Linked up to power source via standardised LocalNet interface
- No need for any modifications to the power source
- In addition to the digital inputs and outputs:
Analogue inputs and outputs for transmitting process variables
(= independence from the bit-width of data processing in the existing robot control)
- Power source can easily be changed
- Simple plug-in connections
- Limited amount of wiring and cabling needed
- Assembled using DIN top-hat rail
- Housing dimensions (L x W x H) = 160 x 90 x 58 mm
- High degree of interference immunity during data transmission

The robot interface is connected via a 10-pole interconnecting cable (43,0004,0459 /

0460 / 0509: 10-pole remote-control cable 5 / 10 / 20 m) to a 10-pole LocalNet connec-
tion on the digital power source. If there is no free LocalNet connection available, the
LocalNet passive distributor (4,100,261) can be used (e.g. between the power source
and the interconnecting hosepack).

A 1 m long LocalNet cable harness, including a 10-pole connection socket, is supplied

along with the robot interface. The 10-pole connection socket also serves as a lead-
through piece through the wall of the control cubicle. To connect up an additional Local-
Net user (e.g. remote control) in the vicinity of the robot control, we offer the optional
“Installation kit ROB 5000 LocalNet” (4,100,270: 10-pole connection socket with cable
harness for the robot interface).

For linking up the robot control with the robot interface, a pre-assembled, 1.5m long
cable harness is available (4,100,260: ROB 5000 cable harness; 4,100,274: ROB 4000
cable harness).

3
Machine concept The ROB 4000 / 5000 end of the cable harness is pre-assembled complete with Molex
(continued) plugs, ready for connection. At the control-unit end, the cable harness can be individually
tailored to the connection requirements of the robot power source. The detailed labelling
on the cable harness, with each designation being printed several times over along the
entire length of the cable, makes the job of connecting up the cables much easier.

In order to prevent any malfunctions, the cables between the robot interface and the
control unit should not be more than 1.5 m long.

Features of the ROB 4000 (4,100,239)

ROB 4000 / ROB - The power source is addressed by means of analogue command values (0-10 V for
5000 welding power and arc-length correction)
- The welding programs must be selected on the operating panel of the power source

Extra ROB 5000 functions (4,100,255)

- Operating-mode selection via the robot
- Welding program selection via the robot
- Job selection via the robot
- “Touch sensing” function
- Error re-set
- Switchover facility between several wirefeeders
- “Process active” signal
- “Main current” signal
- Command value for pulse correction and burn-back time
- Actual value for welding voltage, wire-drive current consumption and wirefeed speed
- Input for reserve parameter
- Output for reserve parameter

Application (9) (3) (12) (7) (8)

example of robot
interface ROB
4000 / 5000

Roboter-
interface
in out

Control

(11) (2) (1) (10) (4) (5)

Fig.1 Application example of robot interface ROB 4000 / 5000

Legend:
(1) Power source (7) Wire drive
(2) Cooling unit (8) Welding torch
(3) Robot interface ROB 4000 / 5000 (9) Interconnecting hosepack
(4) Robot control (10) LocalNet interconnecting cable
(5) Robot control cubicle (11) LocalNet passive distributor
(6) Robot (12) Wire spool

4
Additional remark As long as the robot interface is connected to the LocalNet, the “2-step mode”
automatically remains selected (display: 2-step mode).

For more information on the “Special 2-step mode for robot interface”, please see the
sections headed “MIG/MAG welding” and “Parameter mode” in the power-source opera-
ting instructions.

Digital input signals (signals from the robot)

Caracteristic Signal level:

parameters - LOW ........ 0 - 2,5 V
- HIGH ....... 18 - 30 V

Reference potentia: GND = X7/2 or X12/2

Arc ON Plug X2/4 ............................. 24 V

Plug X7/2 or X12/2 .............. GND

The “Arc ON” signal starts the welding process. As long as the “Arc ON” signal is pre-
sent, the welding process will remain active.

Exception:
- The digital input signal “Robot ready” is absent
- The digital output signal “Power source ready” is absent

Roboter Ready / Plug X2/5 ............................. Signal 24 V

Quick stop Plug X7/2 or X12/2 .............. GND

“Roboter ready” is HIGH-active

- 24V is required in order for the power source to be ready for welding

“Quick-Stop” is LOW-active
- 24V absent: “Quick-Stop” is initialised

The “Quick-Stop” signal stops the welding process immediately

- The error message “St | oP” is displayed on the operating panel

Note! For safety reasons the “Quick-Stop“ signal is exclusively provided as

quick stop to protect the machine. If an additional protection of persons is
requested, still use an appropriate emergency-stop switch.

Note! “Quick-Stop” terminates the welding operation without wire burn-back.

After the power source is switched on, “Quick-Stop” is active immediately

- “St | oP” is displayed on the operating panel.

Make the power source ready for welding:

- Deactivate the “Quick-Stop” signal (initialise “Robot ready”)
- Initialise the signal “Source error reset” (only on ROB 5000)

5
Operating bit 0 - Note! If “Quick-Stop” is active, neither commands nor command-value instruc-
2 (Mode 0 - 2) tions will be accepted.
„MODE 0“ „MODE 1“ „MODE 2“ Plug X2/6 ............................. Signal 24 V,
Standard program 0 0 0 BIT 0
Plug X8/1 ............................. Signal 24 V,
Pulsed arc
program 1 0 0
BIT 1 (ROB 5000)
Plug X8/2 ............................. Signal 24 V,
Job mode 0 1 0 BIT 2 (ROB 5000)
Parameter Plug X7/2 bzw. X12/2 .......... GND
selection (internal) 1 1 0

Manual 0 0 1

CC / CV 1 0 1

TIG 0 1 1

The following modes are supported:

Standard program
The welding parameters are selected by means of:
- analogue command values (welding power, arc-length correction, ...)
- the number of the desired standard program (for material, shielding gas, wire
diameter) from the welding-program databank

Pulsed arc program

The welding parameters are selected by means of:
- analogue command values (welding power, arc-length correction, ...)
- the number of the desired pulsed arc-program (for material, shielding gas, wire
diameter) from the welding-program databank

Job mode (ROB 5000)

To retrieve stored welding parameters with reference to the number of the “Job” in
question.

Parameter selection (internal) (ROB 5000)

Selecting welding parameters via the programming interface of the robot control is
difficult and time-consuming - especially when programming a job. The “Parameter
selection ( internal)” mode enables you to select the required welding parameters via the
operating panel of the power source or via a remote control unit.

Internal parameter selection can also be performed during welding. The signals needed
for the present welding process are still specified by the robot control.

Manual (ROB 5000)

When the “Manual” mode is activated, the “Wirefeed speed” and “Welding voltage”
parameters can be set independently of one another.

In all other modes, the values for the “Wirefeed speed” and “Welding voltage” parame-
ters are computed from the analogue input signal for the “Welding power command
value”.

In the “Manual” mode, the “Wirefeed speed” and “Welding voltage” parameters are
adjusted as follows:
- The “Wirefeed speed” parameter is addressed via the analogue input signal for the
“Welding power command value”
(“Welding Power” ... X2/1 + and X2/8 -)
- The “Welding voltage” parameter is addressed via the analogue input signal for the
“Arc-length correction command value”
(“Arc length correction” ... X2/2 + and X2/9 -)

6
Operating bit 0 - Note! In the “Manual” mode, the input signal “Arc-length correction command
2 (Mode 0 - 2) value” (0 - 10 V) has the following welding-voltage setting range available to it:
(continued) - TPS 4000 / 5000 ..... 0- 10 V corresponds to 10 - 40 V welding voltage
- TPS 2700 ................ 0 - 10 V corresponds to 10 - 34 V welding voltage

- The “Arc force” parameter is addressed via the analogue input signal for the “Pulse /
Arc-force correction”
(“Pulse correction” ... X14/3 + and X14/11 -)

CC /CV (Constant current / Constant voltage; ROB 5000)

Note! The operating mode “CC /CV” (Constant current/Constant voltage) is

offered as an option for the robot interface ROB 5000 or the field -bus coupler
for robot control.

System requirements:
- Software-Version 2.85.1 (power source)
- Software-Version 1.50.38 (wire feeder)

It is possible to operate the power source with a choice of constant welding voltage or
constant welding current.

Limitations compared with the other operating modes:

Only the following parameters can be selected for the left hand display using the “Para-
meter selection button”:
- Welding current, wirespeed and F2 (wire drive current consumption)

Only the Welding Voltage parameter can be selected for the right hand display using the
“Parameter selection button”.

The following functions can also not be selected:

- Welding processes using the “Process button”
- Operating modes using the “Mode button”
- Type of material using the “Material button”
- Wire-diameter using the “Wire-diameter button”

Input signals available:

Note! The following input signals listed are available when the “CC / CV”
operating mode is selected. The input signals take over altered functions
compared with the remaining operating modes.

The following list contains the input signals and their functions:

- Analogue input signal “Welding power” ... specifies the welding current

- Analogue input signal “Arc length correction” ... specifies the welding voltage

- Analogue input signal “Pulse / Arc force correction” ... specifies the wirespeed

- Digital input signal “Arc on” ... start of welding current

- The welding current is active as long as the signal remains set

7
Operating bit 0 - - Digital input signal “Wire feed” ... start of wire feed with the specified wirespeed
2 (Mode 0 - 2) - The wire feed is active as long as the signal remains set
(continued)
- Digital input signal “Wire retract” ... start of a wire retract action at the specified
speed
- The wire retract action is active as long as the signal remains set

- Digital input signal “Robot ready” ... reamains unchanged

- Digital input signal “Gas test” ... remains unchanged

Note! Only the welding current is started using the input signal “Arc on” but not
wire feed.

Signal level for analogue input signals:

The signal level for the analogue input signals remains at 0 to 10V even when the
oprating mode CC / CV is selected.

0 V ......... e.g. minimum welding current

10 V ....... e.g. maximum welding current

Specifying a command value for the welding current:

- Make the power source available for welding using the input signal “Robot ready”
- Specify welding current required using the input signal “Welding power command
value”
- Specify a value to which the welding voltage is to be limited using the input signal
“Arc-length correction”

Important! Set the largest possible welding voltage using the input signal “Arc- length
correction” if no special limit to the welding voltage is required.

If a welding voltage occured that is higher than that set, the selected welding current
would not be maintained.

- Set the required wirespeed using the “Pulse / Arc force correction” input signal
- Start the welding current using the “Arc on” input signal
- Start the wire feed using the “Wire feed” input signal

Specifying a command value for the welding voltage:

- Make the power source available for welding using the input signal “Robot ready”
- Specify welding voltage required using the input signal “Arc length correction”
- Specify a value to which the welding current is to be limited using the input signal
“Welding power”

Note! Set the largest possible welding current using the input signal “Welding
power” if no special limit to the welding current is required.

8
Operating bit 0 - If a welding current occured that is higher than that set, the selected welding voltage
2 (Mode 0 - 2) would not be maintained.
(continued)
- Set the required wirespeed using the “Pulse / Arc force correction” input signal
- Start the welding current using the “Arc on” input signal
- Start the wire feed using the “Wire feed” input signal

TIG
The TIG welding process with contact arc initiation has been selected. The default
welding current is based on the analog input signal “Welding power“.

Twin Master „Twin Master Bit 0“ „Twin Master Bit 1“ Plug X8/3 ............................. Signal 24 V,
Signal (Twin Power source 1 1 0 BIT 0
Master Bit 0 and Plug X8/4 ............................. Signal 24 V,
Power source 2 0 1
1; ROB 5000) BIT 1
Plug X7/2 or X12/2 .............. GND
Depending on whether the Twin Master Bit 0 or the Twin Master Bit 1 is set, the Twin
Master Signal is either assigned to the Power source 1 or Power source 2. The frequen-
cy of the sychronized single arcs are based on the assigned Twin Master Signal.

Gas Test Plug X2/7 ............................. Signal 24 V

Plug X7/2 or X12/2 .............. GND

The “Gas test” signal activates the “Gas test” function (as does the “Gas-test” button).
You can set the required gas-flow rate on the pressure regulator on the gas cylinder.

The gas test can also be used for an additional gas pre-flow during positioning.

Important! As long as the welding process is active, the gas pre-flow and post-flow
times are controlled by the power source. For this reason, it is not necessary to initialise
the "Gas test" signal during the welding process!

Wire inch (Wire

Warning! Risk of injury due to emerging welding wire, so keep the welding
feed)
torch away from face and body.

Plug X2/11 ........................... Signal 24 V

Plug X7/2 or X12/2 .............. GND

The “Wire inch” signal allows the wire to be fed into the torch hosepack with no flow of
gas or current (as does the “Inch-in” button).

The inching-in speed will depend upon the setting made for this in the Set-up Menu of
the power source.

9
Wire retract Plug X14/6 ........................... Signal 24 V
Plug X7/2 and X12/2 ........... GND

The “Wire retract” signal causes the wire to be retracted (pulled back). The wire retrac-
tion speed will depend upon the setting made for this in the Set-up Menu of the power
source.

Note! Only retract the wire by very short lengths, as the wire is not wound back
onto the spool when it is retracted.

Source error Plug X8/5 ............................. Signal 24 V

reset (ROB 5000) Plug X7/2 and X12/2 ........... GND

Note! The error can only be acknowledged properly if the “Source error reset”
signal remains initialised for at least 10 ms.

If an error message occurs at the power source (“Source error”), the error is reset by the
“Source error reset” signal. Before this, however, the cause of the error must be found
and put right.

If the robot control does not have a digital signal for re-setting, the “Source error reset”
signal can always be linked to 24 VDC on the robot control. The error is then re-set as
soon as the cause of the error has been remedied.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. If the “Source error reset” signal is always set to 24 V, the “Arc
on” signal must not be initialised while the error is being remedied, as the
welding process would begin again immediately after the remedying of the
error.

If a non-existent welding program (characteristic) is selected, this also triggers an error

message (“no | PrG”). However, you do not need to acknowledge this error, as it re-sets
itself as soon as an occupied program location is selected.

Job / Program Plug X8/6 ............................. Signal 24 V

select (ROB 5000, Plug X7/2 and X12/2 ........... GND
not active)
The signal “Job / Program Select“ allows a different use of the signals “Program Num-
ber“ (Job/Program Bit 0 - 7, see following page).

In the case of “Job / Program Select“ to “LOW“ the requested job is selected by means
of “Job/Program Bit 0 - 7“.

In the case of “Job / Program Select“ to “HIGH“ the requested welding program number
is selected by means of “Job/Program Bit 0 - 7“.

10
Program number Note! The assignment is identical to the “Job number” function (see following
(Job/Program Bit section). Selection as between the “Program number” and “Job number” func-
0 - 7) (ROB 5000) tions is effected with the operating bits 0 - 2.

The “Program number” function is available when “Standard program” or “Pulsed arc
program” has been selected with the operating bits 0 - 2.

Where the welding parameters are not selected with reference to the number of a job,
but to analogue command values (welding power, arc-length correction, ...), then the
respective program (for material, shielding gas, wire diameter, ...) is selected from the
welding-program databank by means of “Program number”.

Plug Signal Program Bit Note! Program number “0” allows

X11/1 24 V 0 the user to select a program on
the operating panel of the power
X11/2 24 V 1
source (using the “Material” and
X11/3 24 V 2 “Wire diameter” buttons).
X11/4 24 V 3
The available welding programs are listed
X11/5 24 V 4 in Fig.2.
X11/6 24 V 5

X11/7 24 V 6

X11/8 24 V 7

X7/2 / X12/2 GND

Fig.2 List of available welding programs (figured M0164)

11
Job number (Job/ Plug Signal Job-Bit Note! The assignment is identical
Program Bit 0 - 7) X11/1 24 V 0 to the “Program number” func-
(ROB 5000) tion. Selection as between the
X11/2 24 V 1
“Job number” and “Program
X11/3 24 V 2 number” functions is effected with
the operating bits 0 - 2.
X11/4 24 V 3

X11/5 24 V 4 The “Job number” function is available

X11/6 24 V 5 when “Job mode” has been selected with
the operating bits 0 - 2.
X11/7 24 V 6

X11/8 24 V 7 With the “Job number” function, stored

welding parameters can be retrieved with
X7/2 / X12/2 GND
reference to the number of the respective
job.

Welding simulati- Plug X14/2 ........................... Signal 24 V

on Plug X7/2 and X12/2 ........... GND

The “Welding simulation” signal makes it possible to “weld” along a programmed welding
path but without any arc, wirefeed or shielding gas. The digital output signals “Current
flow signal”, “Main current signal” and “Process active” are initialised in the same way as
during a real welding operation.

Touch Sensing Plug X8/7 ............................. Signal 24 V

(ROB 5000) Plug X7/2 or X12/2 .............. GND

Note! The “TouchSensing” function is supported from software version 2.65.001

(power source) upwards.

The “Touch sensing” signal tells the user when the welding wire or gas nozzle is touching
the workpiece (short circuit between workpiece and welding wire or gas nozzle).

When the “Touch sensing” signal is initialised, “Touch” appears on the operating panel of
the power source. A voltage of 30 V (current limited to 3A) is applied to the welding wire
or the gas nozzle, as the case may be .

The short circuit is reported to the robot control by the current-flow signal (see the
section headed “Digital output signals”).

Note! The current-flow signal is outputted for 0.2 s longer than the duration of
the short circuit current.

As long as the “Touch sensing” signal remains initialised, no welding can take place. If
the robot control initialises the “Touch sensing” signal during welding, the welding opera-
tion is aborted after the burn-back time has elapsed (this can be adjusted in the Set-up
Menu of the power source). It is now possible for position recognition (touch-sensing) to
be carried out.

Note! If position recognition to be carried out by touching the workpiece with the
gas nozzle (instead of with the welding wire), link the gas nozzle to the welding-
current cable via a resistor-capacitor (RC) element (see Fig.3).

12
Touch Sensing 2,2 uF / 160 V / 10 %
(ROB 5000)
(continued)
C
Welding current cable Gas nozzle
C

4,7 uF / 160 V / 10 %
R

10 kOhm / 1 W / 10 %
Fig.3 RC element for linking the welding-current cable to the gas nozzle

It is necessary to use a RC element in order to prevent the following problems occurring

during welding if the gas nozzle should happen to touch the workpiece:
- unpermissible currents flowing across the link between the gas-nozzle and the
welding-current cable
- any influencing of the welding process

If touch-sensing occurs via the gas nozzle, the short circuit current only flows for approx.
4 ms, until the capacitors of the RC element are recharged. In order to ensure reliable
touch-sensing by the robot control, the current-flow signal is applied for 0.5 s longer than
the short-circuit current.

Torch blow Plug X14/5 ........................... Signal 24 V

through (Blow Plug X7/2 and X12/2 ........... GND
through)
The signal “Blow Through“ allows the activation of the compressed-air supply. The
compressed air is used to clean the welding torch from dust and chips, e.g. after the
removal of welding spatter in the torch cleaning station.

13
Analogue Input signals (signals from the robot)

General The analogue difference-amplifier inputs on the robot interface ensure that the robot
interface is galvanically insulated from the analogue outputs of the robot control. Each of
the inputs on the robot interface has its own negative potential.

If the robot control only has one common GND for its analogue output signals, then the
negative potentials of the inputs on the robot interface must be linked to one another!

The analogue inputs described below are active with voltages of 0-10 V. If individual
analogue inputs remain unassigned (e.g. for “Pulse correction command value” or “Burn-
back time command value”), then the values set at the power source are accepted and
used.

Welding power Plug X2/1 ............................. Analogue in + 0 to + 10 V

command value Plug X2/8 ............................. Analogue in - (minus)
(Welding power)
The “Welding power command value” is defined with a voltage of 0 - 10 V.

0 V ........ Minimum welding power

10 V ...... Maximum welding power

On the basis of the welding power that has been selected, the power source determines
various values, including the appropriate values for welding voltage and wirefeed speed.
The parameters “Welding current”, “Sheet thickness” and “a-dimension” can also be
displayed on the operating panel of the power source as a measure of the actual welding
power.

Note! The stated parameters are directly interlinked. If a parameter is altered by

means of the “Welding power command value”, the other parameters will also
be adjusted at the same time.

The “Welding power command value” can only be defined if the “Standard program” or
“Pulsed-arc program” mode has been selected.

14
Arc-length cor- Plug X2/2 ............................. Analogue in + 0 to + 10 V
rection command Plug X2/9 ............................. Analogue in - (minus)
value (Arc length
correction) Note! The arc-length correction is effected by changing the actual welding
voltage.

Der “Sollwert Lichtbogenlängenkorrektur” wird mit einer Spannung von 0 - 10 V vorgege-

ben.

0V ......... actual welding voltage - 30% (minimum arc length)

5V ......... actual welding voltage (neutral arc length)
10V ....... actual welding voltage + 30% (maximum arc length)

The “Arc-length correction command value” can only be defined if the “Standard pro-
gram” or “Pulsed-arc program” mode has been selected.

Pulse / Arc force Plug X14/3 ................. Analogue in + 0 to + 10 V

correction com- Plug X14/11 ............... Analogue in - (minus)
mand value (Puls
Correction; ROB “Standard program” mode: The short-circuiting dynamics at the instant of droplet transfer
5000) are defined by a voltage of 0 - 10 V (arc-force correction).

“Pulsed-arc program” mode: The droplet detachment force is defined by a voltage of 0 -

10 V (pulse correction).

“Standard program” mode:

0 V ........ Minimum arc force (hard and stable arc)
5 V ........ Neutral arc force (basic setting)
10 V ...... Maximum arc force (soft arc with little or no spatter)

“Pulsed-arc program” mode:

0 V ........ Minimum droplet detachment force
5 V ........ Neutral droplet detachment force (basic setting)
10 V ...... Maximum droplet detachment force

Burn-back time Plug X5/1 ............................. Analogue in + 0 to + 10 V

correction com- Plug X5/8 ............................. Analogue in - (minus)
mand value (Burn
back time correc- The wire stick-out length after the end of welding is determined by the wire burn-back
tion; ROB 5000) time. The wire burn-back time is defined by the dwell-time of the arc after the end of
wire-feeding. The longer the wire burn-back time, the shorter the wire stick-out length will
be.

The “Burn-back time correction command value” is defined by a voltage of 0 - 10 V.

Note! The “Burn-back time correction command value” can only be defined if
the “Standard program” or “Pulsed-arc program” mode has been selected.

0 V ........ Minimum burn-back time (basic setting - 0.2 s)

5 V ........ Neutral burn-back time (basic setting)
10 V ...... Maximum burn-back time (basic setting + 0.2 s)

15
Analogue input Plug X5/2 ............................. Analogue in + 0 to + 10 V
for reserve Plug X5/9 ............................. Analogue in - (minus)
parameter (robot
welding speed -
ROB 5000, not
active)

Digital output signals (signals to the robot)

General Note! If the link between the power source and the robot interface has been
interrupted, all digital / analogue output signals will be set to “0” at the robot
interface.

The power-source supply voltage (24 V SECONDARY) is available in the robot interface.

24 V SECONDARY is galvanically insulated from the LocalNet. A suppressor circuit

limits unpermissible voltage levels to 100 V.

On Plug X14/1, select which voltage will be switched to the digital outputs of the robot
interface.

- External voltage for robot control (24 V): Apply the external voltage of the robot-
control digital output card to Pin X14/1.
- Power-source supply voltage (24 V SECONDARY): Attach a jumper between
X14/1 and X14/7.

Current flow Plug X2/12 ........................... Signal 24 V

signal Plug X7/2 or X12/2 .............. GND

The current-flow signal is initialised as soon as there is a stable arc after the beginning
of arc ignition.

Process active Plug X8/10 ........................... Signal 24 V

signal (ROB Plug X7/2 bzw. X12/2 .......... GND
5000)
When the robot control initialises the digital input signal “Arc ON”, the welding process
begins with the gas pre-flow, followed by the welding operation itself and then the gas
post-flow.

From the beginning of the gas pre-flow until the end of the gas post flow, the power
source initialises the “Process active” signal (Fig.4).

The “Process active” signal helps to ensure optimum gas shielding:

- by ensuring that the robot dwells sufficiently long at the beginning and end
of the weld seam

16
Main current Plug X8/9 ............................. Signal 24 V
signal (ROB Plug X7/2 or X12/2 .............. GND
5000)
Note! As long as the robot interface is connected to the LocalNet, the “2-step
mode” automatically remains selected. (Display shows: 2-step mode).

The following are defined in the power-source set-up menu:

- Starting-current phase with starting current (I-S), starting-current duration (t-S) and
slope (SL)
- Final-current phase with final current (I-E), final-current duration (t-E) and slope (SL)

Between the starting-current and final-current phase, the main-current signal is initialised
(Fig.4).

Important! For more detailed information on the “Special 2-step mode for robot inter-
face”, please see the sections headed “MIG/MAG welding” and “Parameter mode” in the
Operating Instructions for the power source.

„Prozess active“

I „Main current signal“

Final current (I-E)

Gas pre-flow time (GPr)

Welding current

Slope (SL)
Starting current (I-S)

Slope (SL)

Fig.4 Digital output signals “Process active” and “Main current signal”

Limit signal (not Plug X14/10 ......................... Signal 24 V

active) Plug X7/2 or X12/2 .............. GND

Collision protec- Plug X2/13 ........................... Signal 24 V

tion Plug X7/2 or X12/2 .............. GND

In most cases, the robot-torch has a cut-out box. In the event of a collision, the contact
in the cut-out box opens and triggers the LOW-active signal “Collision protection”.

The robot control must initiate an immediate robot standstill and interrupt the welding
process via the LOW-active input signal “Quick stop”.

17
Power source Plug X2/14 ........................... Signal 24 V
ready Plug X7/2 or X12/2 .............. GND

The “Power source ready” signal remains initialised for as long as the power source is
ready for welding.

As soon as an error message occurs at the power source, or the “Quick stop” signal is
initialised by the robot control, the “Power source ready” signal will cease to be applied.

This means that the “Power source ready” signal can detect both internal power-source
errors and robot errors.

Analogue output signals (signals to the robot)

General Note! If the link between the power source and the robot interface has been
interrupted, all digital / analogue output signals will be set to “0” at the robot
interface.

The analogue outputs at the robot interface are for setting up the robot and for displaying
and documenting process parameters.

Welding voltage Plug X5/4 ............................. Analogue out + 0 to + 10 V

actual value PLUG X5/11 ........................ Analogue out - (minus)
(ROB 5000)
The “Welding voltage actual value” is transmitted to the analogue output with a voltage
of 0 - 10 V
- 1 V at the analogue output corresponds to 10 V welding voltage
- Range for “Welding voltage actual value” .... 0 - 100 V

Note! When the power source is idle, the “Welding voltage command value” is
transmitted. Immediately after welding, the “HOLD value” is transmitted.

In the job correction menu of the power source it is possible to specify the correction
limits for the arc length. Based on the direct connection between arc length and welding
efficiency, the correction limits also apply to the welding voltage default on the ROB 4000
/ 5000.

Important! If the arc length was specified in the job correction menu by means of the
“AL.c“ parameter, the welding voltage default can only be carried out within these limits.

Welding current Plug X2/3 ............................. Analogue out + 0 to +10 V

actual value Plug X2/10 ........................... Analogue out - (minus)

The “Welding current actual value” is transmitted to the analogue output with a voltage of
0 - 10 V
- 1 V at the analogue output corresponds to 100 A welding current
- Range for “Welding current actual value”.... 0 - 1000 A

Note! When the power source is idle, the “Welding current command value” is
transmitted. Immediately after welding, the “HOLD value” is transmitted.

18
Welding current In the job correction menu of the power source it is possible to specify the correction
actual value limits for the welding efficiency. Based on the direct connection between welding efficien-
(continued) cy and welding current, the correction limits also apply to the welding current default on
the ROB 4000 / 5000.

Important! If the correction limits for the welding efficiency were specified in the job
correction menu by means of the “PcH“ and “PcL“ parameters, the welding current
default can only be carried out within these limits.

Actual value for Plug X5/7 ............................. Analogue out + 0 to + 10 V

wire-drive current Plug X5/14 ........................... Analogue out - (minus)
consumption
(Motor current - The “Motor current actual value” is transmitted to the analogue output with a voltage of 0
ROB 5000) - 10 V
- 1 V at the analogue output corresponds to 0.5 A current consumption
- Range for “Motor current actual value” .... 0 - 5 A

Important! The “Motor current actual value” gives an indication of the status of the
wirefeed system.

Wirefeed speed Plug X5/6 ............................. Analogue out + 0 to + 10 V

(ROB 5000) Plug X5/13 ........................... Analogue out - (minus)

The wirefeed speed is transmitted to the analogue output with a voltage of 0 - 10 V

- Range for “Wirefeed speed actual value” .... 0 - maximum wirefeed speed

Note! When the power source is idle, the “Wirefeed speed” is transmitted.
Immediately after welding, the “HOLD value” is transmitted.

Important! The wirefeed speed is determined from the motor speed of the wire drive.

The transmitted wirefeed speed may deviate from the real wirefeed speed
- due to possible slippage on the feeder rollers of the wire drive

Analogue output Plug X5/ 5 ............................ Analoge out + 0 to + 10 V

for Reserve Plug X5/12 ........................... Analogue out - (minus)
parameter (Arc
length - ROB
5000, not active)

19
Application examples

General Depending on the requirements made by the robot application, it may not be necessary
to use all the input and output signals (commands) that the robot interface makes
available. The following examples of how to link the robot interface with the robot control
will illustrate the various different scopes of commands that are possible with the ROB
4000 / 5000.

Basic Version Example of the most important analogue and digital commands where the power source
(analogue) - ROB is addressed via analogue command values
4000 - 0 - 10 V for welding power and arc-length correction
- welding programs are selected via the power-source operating panel

Resetting error messages - ROB 4000:

Unlike the ROB 5000, the ROB 4000 robot interface does not permit error acknowledge-
ment by means of the “Source error reset” signal. Error messages at the power source
are re-set automatically as soon as the error has been remedied.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. The “Arc on” signal must not be initialised while the error is being
remedied, as the welding process would then begin again immediately after the
remedying of the error.

Resetting error messages - ROB 5000:

Error messages from the power source are re-set via the “Source error reset” signal (not
illustrated on this page). The cause of the error must be remedied first, however.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. If the “Source error reset” signal is always set to 24 V, the “Arc
on” signal must not be initialised while the error is being remedied, as the
welding process would then begin again immediately after the remedying of the
error.

20
High-End Version Example of utilisation of the scope of Table for job selection via the robot:
(analogue) - ROB commands available on the ROB 5000
„MODE 0“ „MODE 1“ „MODE 2“
500 where the power source is addressed via
analogue command values Standard program 0 0 0
- 0 - 10 V for welding power, arc-length Pulsed-arc
correction, pulse correction and burn- program 1 0 0
back time
Job mode 0 1 0
- welding programs are selected via the
power-source operating panel Parameter
selection internal 1 1 0

Manual 0 0 1

CC / CV 1 0 1

TIG 0 1 1

The following extra digital functions are available on the ROB 5000
- Error re-set
- Welding programs are selected digitally via the robot
- TWIN Master signal (Twin Master Bit 0 and 1)
- Funktion „Positionssuchen“
- “Process active” and ”Main current signal”
- “Gas test”, “Wire inch”, “Wire retract” and “Blow through” signals

Resetting error messages - ROB 5000:

Error messages from the power source are re-set via the “Source error reset” signal.
The cause of the error must be remedied first, however.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. If the “Source error reset” signal is always set to 24 V, the “Arc
on” signal must not be initialised while the error is being remedied, as the
welding process would then begin again immediately after the remedying of the
error.

21
High-End Version
(analogue) - ROB
500
(continued)

Basic Version Example of the most important analogue Table for job selection via the robot:
(digital) - ROB and digital commands where the
„MODE 0“ „MODE 1“ „MODE 2“
5000 - mode
- welding program and Standard program 0 0 0
- job Pulsed-arc
are selected digitally via the robot program 1 0 0

Job mode 0 1 0
In addition to the addressing of the power
source via analogue command values Parameter
selection (internal) 1 1 0
- 0 - 10 V for welding power and arc-
length correction Manual 0 0 1

CC / CV 1 0 1

TIG 0 1 1

In this example, only the digital ROB 5000 extra function “Error re-set” is used..

Resetting error messages - ROB 5000:

Error messages from the power source are re-set via the “Source error reset” signal.
The cause of the error must be remedied first, however.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. If the “Source error reset” signal is always set to 24 V, the “Arc
on” signal must not be initialised while the error is being remedied, as the
welding process would then begin again immediately after the remedying of the
error.

22
Basic Version
(digital) - ROB
5000
(continued)

23
High-End Version Example of utilisation of the full scope of Table for job selection via the robot:
(digital) - ROB commands available on the ROB 5000
„MODE 0“ „MODE 1“ „MODE 2“
5000 where the
- mode Standrad program 0 0 0
- welding program and Pulsed arc
- job program 1 0 0
are selected digitally via the robot Job mode 0 1 0

In addition to the addressing of the power Parameter

selection (internal) 1 1 0
source via analogue command values
- 0 - 10 V for welding power, arc-length Manual 0 0 1
correction, pulse correction and burn- CC / CV 1 0 1
back time
TIG 0 1 1

The following extra digital functions are available on the ROB 5000
- Error re-set
- “Touch sensing” function
- “Process active”
- “Gas test”, “Wire inch”, “Wire retract” and “Blow through” signals
- Signals „TWIN Master Bit 0“ and „TWIN Master Bit 1“

Resetting error messages - ROB 5000:

Error messages from the power source are re-set via the “Source error reset” signal.
The cause of the error must be remedied first, however.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. If the “Source error reset” signal is always set to 24 V, the “Arc
on” signal must not be initialised while the error is being remedied, as the
welding process would then begin again immediately after the remedying of the
error.

24
High-End Version
(digital) - ROB
5000
(continued)

25
Terminal diagram

26
Wiring of inputs and outputs

Fig.5 Wiring of a digital output

Fig.6 Wiring of a digital input

Fig.7 Wiring of an analogue output

Fig.8 Wiring of an analogue input

27
Signal pattern (selection by program number)

Operating bit 0 (Mode 0)

(Standard program / 1
Pulsed arc program)
0

Welding power
command value 10 V

0V

Arc-length correction
command value 10 V

0V
Pulse correction
command value 10 V

0V

Roboter ready
1

Source error reset

1

Program number
(Job / Program Bit 1
0 - 7)
0

Arc ON
1

Process active signal

1

Current flow signal

1

Main current signal

1

Power source ready

1

Gas pre-flow time Start current Welding current Final current Gas postflow time

28
Signal pattern (selection by Job number)

Roboter ready
1

Source error reset

1

Operating bit 1 (Mode 1)

(Job mode) 1

Job number
(Job / Program BIT 1
0 - 7)
0

Arc ON
1

Process active signal

1

Current flow signal

1

Main current signal

1

Power source ready

1

Gas pre-flow time Start current Welding current Final current Gas postflow time

29
Fault diagnosis and rectification

Resetting error Error messages from the power source are re-set via the “Source error reset” signal
messages - ROB („Source error reset“; is not figured at this page). The cause of the error must be reme-
5000 died first, however.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. If the “Source error reset” signal is always set to 24 V, the “Arc
on” signal must not be initialised while the error is being remedied, as the
welding process would then begin again immediately after the remedying of the
error.

Resetting error Unlike the ROB 5000, the ROB 4000 robot interface does not permit error acknowledge-
messages - ROB ment by means of the “Source error reset” signal. Error messages at the power source
4000 are re-set automatically as soon as the error has been remedied.

Warning! Danger of injury and damage due to a welding process that starts
unexpectedly. The “Arc on” signal must not be initialised while the error is being
remedied, as the welding process would then begin again immediately after the
remedying of the error.

Displayed service For a detailed description of the displayed service codes please refer to the Chapter
codes “Fauld diagnosis and rectification“ in the operating instructions of your power source.

30
Table Decimal / Binary / Hexadecimal
Zahl B I T 0 B I T 1 B I T 2 B I T 3 B I T 4 B I T 5 B I T 6 B I T 7 Hex Zahl B I T 0 B I T 1 B I T 2 B I T 3 B I T 4 B I T 5 B I T 6 B I T 7 Hex Zahl B I T 0 B I T 1 B I T 2 B I T 3 B I T 4 B I T 5 B I T 6 B I T 7 Hex Zahl B I T 0 B I T 1 B I T 2 B I T 3 B I T 4 B I T 5 B I T 6 B I T 7 Hex

0 0 0 0 0 0 0 0 0 00 36 0 0 1 0 0 1 0 0 24 72 0 0 0 1 0 0 1 0 48 108 0 0 1 1 0 1 1 0 6C

1 1 0 0 0 0 0 0 0 01 37 1 0 1 0 0 1 0 0 25 73 1 0 0 1 0 0 1 0 49 109 1 0 1 1 0 1 1 0 6D

2 0 1 0 0 0 0 0 0 02 38 0 1 1 0 0 1 0 0 26 74 0 1 0 1 0 0 1 0 4A 110 0 1 1 1 0 1 1 0 6E

3 1 1 0 0 0 0 0 0 03 39 1 1 1 0 0 1 0 0 27 75 1 1 0 1 0 0 1 0 4B 111 1 1 1 1 0 1 1 0 6F

4 0 0 1 0 0 0 0 0 04 40 0 0 0 1 0 1 0 0 28 76 0 0 1 1 0 0 1 0 4C 112 0 0 0 0 1 1 1 0 70

5 1 0 1 0 0 0 0 0 05 41 1 0 0 1 0 1 0 0 29 77 1 0 1 1 0 0 1 0 4D 113 1 0 0 0 1 1 1 0 71

6 0 1 1 0 0 0 0 0 06 42 0 1 0 1 0 1 0 0 2A 78 0 1 1 1 0 0 1 0 4E 114 0 1 0 0 1 1 1 0 72

7 1 1 1 0 0 0 0 0 07 43 1 1 0 1 0 1 0 0 2B 79 1 1 1 1 0 0 1 0 4F 115 1 1 0 0 1 1 1 0 73

8 0 0 0 1 0 0 0 0 08 44 0 0 1 1 0 1 0 0 2C 80 0 0 0 0 1 0 1 0 50 116 0 0 1 0 1 1 1 0 74

9 1 0 0 1 0 0 0 0 09 45 1 0 1 1 0 1 0 0 2D 81 1 0 0 0 1 0 1 0 51 117 1 0 1 0 1 1 1 0 75

10 0 1 0 1 0 0 0 0 0A 46 0 1 1 1 0 1 0 0 2E 82 0 1 0 0 1 0 1 0 52 118 0 1 1 0 1 1 1 0 76

11 1 1 0 1 0 0 0 0 0B 47 1 1 1 1 0 1 0 0 2F 83 1 1 0 0 1 0 1 0 53 119 1 1 1 0 1 1 1 0 77

12 0 0 1 1 0 0 0 0 0C 48 0 0 0 0 1 1 0 0 30 84 0 0 1 0 1 0 1 0 54 120 0 0 0 1 1 1 1 0 78

13 1 0 1 1 0 0 0 0 0D 49 1 0 0 0 1 1 0 0 31 85 1 0 1 0 1 0 1 0 55 121 1 0 0 1 1 1 1 0 79

14 0 1 1 1 0 0 0 0 0E 50 0 1 0 0 1 1 0 0 32 86 0 1 1 0 1 0 1 0 56 122 0 1 0 1 1 1 1 0 7A

15 1 1 1 1 0 0 0 0 0F 51 1 1 0 0 1 1 0 0 33 87 1 1 1 0 1 0 1 0 57 123 1 1 0 1 1 1 1 0 7B

16 0 0 0 0 1 0 0 0 10 52 0 0 1 0 1 1 0 0 34 88 0 0 0 1 1 0 1 0 58 124 0 0 1 1 1 1 1 0 7C

17 1 0 0 0 1 0 0 0 11 53 1 0 1 0 1 1 0 0 35 89 1 0 0 1 1 0 1 0 59 125 1 0 1 1 1 1 1 0 7D

18 0 1 0 0 1 0 0 0 12 54 0 1 1 0 1 1 0 0 36 90 0 1 0 1 1 0 1 0 5A 126 0 1 1 1 1 1 1 0 7E

19 1 1 0 0 1 0 0 0 13 55 1 1 1 0 1 1 0 0 37 91 1 1 0 1 1 0 1 0 5B 127 1 1 1 1 1 1 1 0 7F

20 0 0 1 0 1 0 0 0 14 56 0 0 0 1 1 1 0 0 38 92 0 0 1 1 1 0 1 0 5C 128 0 0 0 0 0 0 0 1 80

21 1 0 1 0 1 0 0 0 15 57 1 0 0 1 1 1 0 0 39 93 1 0 1 1 1 0 1 0 5D 129 1 0 0 0 0 0 0 1 81

22 0 1 1 0 1 0 0 0 16 58 0 1 0 1 1 1 0 0 3A 94 0 1 1 1 1 0 1 0 5E 130 0 1 0 0 0 0 0 1 82

23 1 1 1 0 1 0 0 0 17 59 1 1 0 1 1 1 0 0 3B 95 1 1 1 1 1 0 1 0 5F 131 1 1 0 0 0 0 0 1 83

24 0 0 0 1 1 0 0 0 18 60 0 0 1 1 1 1 0 0 3C 96 0 0 0 0 0 1 1 0 60 132 0 0 1 0 0 0 0 1 84

25 1 0 0 1 1 0 0 0 19 61 1 0 1 1 1 1 0 0 3D 97 1 0 0 0 0 1 1 0 61 133 1 0 1 0 0 0 0 1 85

26 0 1 0 1 1 0 0 0 1A 62 0 1 1 1 1 1 0 0 3E 98 0 1 0 0 0 1 1 0 62 134 0 1 1 0 0 0 0 1 86

27 1 1 0 1 1 0 0 0 1B 63 1 1 1 1 1 1 0 0 3F 99 1 1 0 0 0 1 1 0 63 135 1 1 1 0 0 0 0 1 87

28 0 0 1 1 1 0 0 0 1C 64 0 0 0 0 0 0 1 0 40 100 0 0 1 0 0 1 1 0 64 136 0 0 0 1 0 0 0 1 88

29 1 0 1 1 1 0 0 0 1D 65 1 0 0 0 0 0 1 0 41 101 1 0 1 0 0 1 1 0 65 137 1 0 0 1 0 0 0 1 89

30 0 1 1 1 1 0 0 0 1E 66 0 1 0 0 0 0 1 0 42 102 0 1 1 0 0 1 1 0 66 138 0 1 0 1 0 0 0 1 8A

31 1 1 1 1 1 0 0 0 1F 67 1 1 0 0 0 0 1 0 43 103 1 1 1 0 0 1 1 0 67 139 1 1 0 1 0 0 0 1 8B

32 0 0 0 0 0 1 0 0 20 68 0 0 1 0 0 0 1 0 44 104 0 0 0 1 0 1 1 0 68 140 0 0 1 1 0 0 0 1 8C

33 1 0 0 0 0 1 0 0 21 69 1 0 1 0 0 0 1 0 45 105 1 0 0 1 0 1 1 0 69 141 1 0 1 1 0 0 0 1 8D

34 0 1 0 0 0 1 0 0 22 70 0 1 1 0 0 0 1 0 46 106 0 1 0 1 0 1 1 0 6A 142 0 1 1 1 0 0 0 1 8E

35 1 1 0 0 0 1 0 0 23 71 1 1 1 0 0 0 1 0 47 107 1 1 0 1 0 1 1 0 6B 143 1 1 1 1 0 0 0 1 8F
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