Arctool Remote Arc Enable & Wire Feed-Direct

3.
5 WELD I/O Page 1 of 27
3.5 WELD I/O

3.5.1 Overview
ArcTool supports several different types of connections to the welding equipment and the choice is governed by the specific
equipment chosen for your application. The welding equipment can be connected to the robot controller with analog and digital
I/O, DeviceNet, or ArcLink I/O.
Analog and Digital I/O hardware is the traditional way to connect a robot and a welding power supply. Typically a Process I/O
board and a standard weld cable are used. Modular I/O (Model A) is also used, but less often. The Lincoln Electric PowerWave
450, Invertec STT II, and Miller Electric AutoInvision and AutoDeltaweld series use the analog and digital I/O interface. Welding
equipment that uses the Process I/O board connects to the welding input and output signals on the CRW1 connector. See
Figure 3.6 Process I/O Weld Cable Pinout .
DeviceNet is another method to connect to some models of Lincoln Electric weld equipment. Instead of individual connections
for each signal, analog and digital I/O signals are transmitted over a 5 wire CAN (Controller Area Network) network using serial
communication. Explicit messaging is also used to exchange setup information. A DeviceNet DNP scanner from SS
Technologies and a PC-104 Motherboard are required. The Miller Auto Axcess or Fronius TPS power sources might have a
DeviceNet interface.
ArcLink I/O is the newest robotic interface to Lincoln Electric weld equipment. ArcLink is a CAN 2.0B based serial
communication network similar to DeviceNet. It requires the same interface boards that are used with DeviceNet but has
different DIP switch settings and cabling. ArcLink has a substantially richer interface than DeviceNet, allowing for tighter
integration and faster control from ArcTool.
Each of these interface methods is detailed in the following sections.
Figure 3.6 Process I/O Weld Cable Pinout
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3.5 WELD I/O Page 2 of 27
If your system requires more I/O, additional process I/O boards can be added or Modular I/O is available. Refer to 6.
INPUT/OUTPUT (I/O) SETUP for more information about process and modular I/O.
Note
For weld equipment connected with analog and digital I/O,
ICOM3 on the process I/O board must be set to the B
position. Otherwise, the Arc Detect input will not be received
by the ArcTool software and the Arc Start Fail error will occur.
Refer to the Controller Maintenance Manual for the location of
ICOM3 jumper on the process I/O board.
Caution
You must set the ICOM3 jumper with the controller
power OFF. Otherwise, you will cause an
inconsistent signal polarity.
The I/O Weld monitor screen displays the items in Table 3.7 I/O Weld Screen Items .
Table 3.7 I/O Weld Screen Items
ITEM DESCRIPTION
WELD SIGNAL This item displays the different kinds of weld signals.
TYPE This item displays the port type.
# This item displays the port number.
SIM This item displays whether the I/O weld signal is simulated or unsimulated.
STATUS This item displays the kind of status of the I/O weld signal.
You can use the I/O Weld Config screen to configure weld input and output signals.
Table 3.8 I/O Weld Config Screen Items
ITEM DESCRIPTION
Selected Weld Input or Output This item is an analog or digital input or output signal from the controller to the weld
Signal equipment.
3.5.2 I/O Configuration
The ArcTool software automatically configures all I/O information: numbering, rack locations, and slot locations. Process I/O
boards are always assigned a rack location of 0. DeviceNet I/O is assigned to rack location 81, 82, 83, or 84 depending on how
may DeviceNet channels are installed in your system. ArcLink I/O is assigned to rack location 90, 91, 92, or 93 depending on
how many ArcLink channels are installed in your system. For a description of rack and slot, refer to Section 6.2 .
 If your system contains multiple process I/O boards, the process I/O board closest to the MAIN CPU is considered slot 1
and its I/O is numbered first.
 If your system contains both process I/O boards and modular I/O, all process I/O boards are numbered starting at slot 1.
 If your system contains only modular I/O, the rack closest to the Main CPU board is the first rack. Slots are numbered from
left to right.
 If your system contains both process I/O and ArcLink or DeviceNet I/O, the I/O is numbered starting with the lowest rack
number.
For example, if your ArcTool system contained one process I/O board with 40 digital inputs and a one digital input modular I/O
unit with 40 digital inputs, the process I/O board digital inputs would be numbered 1-40 and the modular I/O digital inputs would
be numbered 41-80.
Another example is a system configured with one process I/O board and one ArcLink I/O channel. In this case the weld I/O is
assigned above the Process I/O because the ArcLink Rack number is higher than Process I/O (Process I/O rack 0, ArcLink I/O
rack 90.)
3.5.3 Weld I/O Timing Charts
Figure 3.7 MIG Welding Timing Chart shows the arc welding timing sequence for MIG welding. Refer to Section 3.4 for
information on setup that affects the timing sequence.
Figure 3.7 MIG Welding Timing Chart
Figure 3.8 TIG Welding Timing Chart
3.5.4 Welding Input Signals
You can use the I/O Weld In screen to
 View the status of the input signals
 Simulate input signals
 Force input signals only if the input signal is first simulated.
 Add a description or name to an unused input signal
 Change the pre-assigned port number or port type
Arc welding input signals are pre-assigned when you select the welding equipment during installation. If you are using a Lincoln
Electric PowerWave x55/R series power supply connected via ArcLink, you can re-assign the Gas Fault, Wire Fault, and Water
Fault inputs. See 6. INPUT/OUTPUT (I/O) SETUP for more details on re-assigning this I/O.
Note
The analog (AI[] and digital (DI[]) inputs displayed on the weld
input screen are also displayed on the analog and digital I/O
screens.
Table 3.9 Arc Welding Input Signals lists and describes each arc welding input signal.
Use Procedure 3.4 Setting Up Arc Welding I/O to set up arc welding I/O. Refer to Appendix A ERROR CODES AND
RECOVERY and refer to Section 3.3 for more information.
Table 3.9 Arc Welding Input Signals
input signal description

Voltage
This item is an analog signal feedback to the controller that causes the display of the actual voltage the
Not available for
weld interface and power supply are using to weld.
Lincoln STT
welding equipment
Current
Not available for

Lincoln STT This item is an analog signal feedback to the controller that causes the display of the actual current the
welding equipment weld interface and power supply are using to weld.
This item is an analog signal to the controller that causes the display of the actual wire feed speed the
Wire feed speed
This item is an input from the weld equipment to the controller. It indicates that the arc has been detected
and welding is in process. This signal is monitored at an Arc Start.
The Arc Detect signal must be ON before the weld will continue. . If it is not ON at the start of the
weld, the error message "ARC-013 Arc start failed" could appear.
Arc detect
The Arc Detect input signal is also monitored during welding if the arc loss function is set to enabled on
the SETUP Weld System screen. If the Arc Detect signal turns OFF, the arc has been lost. This is
reported as an error, the robot is stopped, and the program is paused. The error message is "ARC-018
Lost arc detect during welding."
This item is a fault input from the weld equipment to the controller. It indicates a lack of shielding gas.
Gas fault The Gas Fault signal is usually connected to a pressure or flow switch. This signal is monitored if the gas
shortage function is set to enabled on the SETUP Weld System screen. The error message, "ARC-005
Gas fault" could appear.
This item is a fault input from the weld equipment to the controller. It indicates either a problem in feeding
the wire or the lack of wire on the spool. You must set up a switch to monitor the wire.
Wire fault
The Wire Fault signal is monitored during welding if the wire shortage function is set to enabled on the
SETUP Weld System screen. If a wire fault occurs, it must be corrected before program execution can
continue. The error message, "ARC-006 Wire fault" could appear.
This item is a fault input from the weld equipment or torch cooler equipment to the controller. It indicates a
problem with the water cooler or hoses. It is typically connected to a customer-supplied flow switch. This
Water fault
signal is monitored during welding if coolant shortage is set to enabled on the setup weld screen. The
error message, "ARC-007 Water fault" could appear. Refer to the Error Code Manual for more information.
This item is a fault input from the weld equipment to the controller. It indicates a power supply failure or
Power fault loss of power. This is monitored during welding if the power supply failure function is set to enabled on the
setup weld screen. The error message, "ARC-008 Power supply fault" could appear. Refer to the Error
Code Manual for more information.

This item is an input to the controller that indicates that the weld wire is fused to the work piece after the
Wire Stick
arc is extinguished.
This item is an input to the controller used to enable or disable welding. It is active only during remote
operations (REMOTE is ON). This signal is typically connected to a remote keyswitch or CMND ENBL on
Arc enable
a remote operator panel. By default, this input is not assigned. It can be assigned to a digital input using
the I/O Weld In screen.
Remote inch fwd This item is an input to the controller used to inch the wire forward.
Remote inch bwd This item is an input to the controller used to inch the wire backward.
Note
Gas, wire, water, and power might be external inputs
requiring customer-supplied switches. FANUC Robotics does
not supply these switches as standard items.
3.5.5 Welding Output Signals
You can use the I/O Weld Out screen to
 View the status of the output signals
 Simulate output signals
 Force output signals. You can force an output signal that is either simulated or not simulated. If the output signal is
simulated, forcing the output has no affect on weld equipment. If the output signal is not simulated, the weld
equipment turns on and off when forced.
Arc welding output signals are pre-assigned when you select the welding equipment during installation. . If you are using a
Lincoln Electric PowerWave x55/R series power supply connected via ArcLink, you can only re-assign the Gas Start output.
Note
The analog (AO[] and digital (DO[]) outputs displayed on the
weld output screen are also displayed on the analog and
digital I/O screens.
Note
During testing, you can use the TEST CYCLE screen to
enable or disable arc welding signals. If you enable these
signals, and then later disable them, you must unsimulate the
signals using the I/O Weld Out screen or the UNSIM ALL I/O
item on the FCTN menu.
The output signals will vary depending on the kind of weld equipment you are using. Table 3.10 Arc Welding Output Signals lists
and describes each arc welding output signal.
Use Section 3.5.6 to set up arc welding I/O. Refer to Section 3.4 . Also refer to Section 3.5.8 and Section 3.12 for more
information.
Table 3.10 Arc Welding Output Signals
Analog Output Signal Description

Voltage (only present if you have selected General MIG (Volts &
This item is an analog output from the controller to the weld
Wire Feed Speed) welding equipment or you are using a Lincoln
equipment that controls the welding voltage. It is scaled to
Electric PowerWave x55/R power source with a CV (Constant
the range of the power supply.
Voltage) process mode.)
Current (Only present if you have selected General MIG (Amps &
equipment that controls the welding current. It is scaled to
Volts) welding equipment or TIG equipment.)
Wire Feed (This item will appear with General MIG equipment This item is an analog output from the controller to the weld
(Volts & Wire Feed Speed) or CV process modes. In some equipment that controls the speed of the wire feeder. It is
Lincoln Electric process modes this is known as “Workpoint”.) scaled to the range of the power supply.
equipment that controls the welding trim. (Trim is generally a

Trim (Present for Pulsed GMAW welding power supplies) reference parameter for arc length.) It is scaled to the range
of the power supply.
Peak Current equipment that controls the welding peak current. It is
scaled to the range of the power supply.
Back Current equipment that controls the welding background current. It is
This item is a reference parameter controlling the time to
Tailout (Only present for Lincoln Electric STT II process)
decay from peak pulse to background pulse current.
This item is a reference parameter that controls the STT
Hot Start (Only present for Lincoln Electric STT II process)
process mode re-strike current.
Digital Output Signal Description
This item is an output from the controller to the weld
Weld start
equipment to start welding.
Gas start equipment to cause a gas valve to open and gas flow to
begin.
Inch forward equipment to advance the wire when you press the WIRE+
key on the teach pendant.
Inch backward equipment to retract the wire when you press the WIRE- key
on the teach pendant.
Wire stick alarm
equipment to indicate a wire stick is detected.
Feed Forward
equipment to advance the wire during welding .
Feed Backward
equipment to retract the wire during welding .
Program Select 1
Program Select 2
These items define three outputs that determine which weld
Program Select 3 controller program is selected.
3.5.6 Setting Up Arc Welding I/O
Use the following procedures to set up arc welding I/O:
 Procedure 3.4 Setting Up Arc Welding I/O Setting Up Arc Welding I/O
 Procedure 3.5 Configuring Analog Input and Output Signals (AI/AO) Configuring Analog Input and Output Signals (AI/AO)
 Procedure 3.6 Reconfiguring Weld Input and Output Signals (WI/WO) Reconfiguring Weld Input and Output Signals
(WI/WO)
 Procedure 3.8 Using Spare Weld Signals (WI/WO) and Adding Comments Using Spare Weld Signals (WI/WO) and
Adding Comments
Procedure 3.4 Setting Up Arc Welding I/O
Steps
1. Press MENUS.
2. Select I/O.
3. If the I/O Weld screen is not displayed, press F1, [TYPE].
4. Select Weld. You will see either the weld input or output screen. See the following screens for example.
Note
The signal names, port types, and port numbers you see will
vary depending on the kind of weld equipment you are using.
Note
The port types and port numbers shown in this screen
represent a MIG welding application that uses a process I/O
board.
I/O Weld In
WELD SIGNAL TYPE # SIM STATUS
1 [Voltage ] AI[ 1] U 0.0
2 [Current ] AI[ 2] U 0.0
3 [ ] WI[ 1] U OFF
4 [Arc detect ] WI[ 2] U ON
5 [Gas fault ] WI[ 3] U OFF
6 [Wire fault ] WI[ 4] U OFF
7 [Water fault ] WI[ 5] U OFF
8 [Power fault ] WI[ 6] U OFF
To change between the display of the input and output screens, press F3, IN/OUT. See the following screen for an
example.
I/O Weld Out

1 [Voltage ] AO[ 1] U 0.0
2 [Wire feed ] AO[ 2] U 0.0
3 [Weld start ] WO[ 1] U OFF
4 [Gas start ] WO[ 2] U ON
5 [ ] WO[ 3] U OFF
6 [Inch forward ] WO[ 4] U OFF
7 [Inch backward ] WO[ 5] U OFF
8 [Wire stick alarm] WO[ 6] U OFF
Note
represent a Pulsed GMAW process mode when using a
Lincoln Electric PowerWave x55/R weld power supply.
I/O Weld In
1 [Arc Voltage ] AI[ 1] U 0.0

2 [Arc Current ] AI[ 2] U 0.0
3 [Wire Feed ] AI[ 3] U 0.0
4 [Arc detect ] DI[25] U OFF
5 [Gas fault ] DI[27] U OFF
6 [Wire fault ] DI[28] U OFF
7 [Water fault ] DI[29] U OFF
8 [Power fault ] DI[30] U OFF
9 [Wirestick ] DI[31] U OFF
10 [Arc Enable ] [**] * ***
example.
I/O Weld Out

1 [WFS ] AO[ 1] U 0.0
2 [Trim ] AO[ 2] U 0.0
3 [Arc Control ] AO[ 3] U 0.0
4 [Weld start ] DO[25] U OFF
5 [Gas start ] DO[26] U OFF
6 [Inch forward ] DO[28] U OFF
7 [Inch backward ] DO[29] U OFF
8 [Feed forward ] DO[30] U OFF
9 [Feed backward ] DO[31] U OFF
10 [Wire stick alarm] [**] * ***
11 [Proc select 1 ] [**] * ***
11 [Proc select 2 ] [**] * ***
11 [Proc select 3 ] [**] * ***
5. To simulate or not simulate I/O , move the cursor to the SIM column next to the I/O that you want to affect:
 Press F4, SIMULATE to simulate I/O.
 Press F5, UNSIM to not simulate I/O.
Warning
Any arc welding output that is forced and is not
simulated actually turns equipment on or off. Make
sure all personnel and unnecessary equipment are

out of the workcell and that all safeguards are in
place; otherwise, you could injure personnel or
damage equipment.
6. To force a digital output , move the cursor to the STATUS column next to the output that you want to affect:
 To force ON , press F4, ON.
 To force OFF , press F5, OFF.
Procedure 3.5 Configuring Analog Input and Output Signals (AI/AO)
Steps
Note
Do NOT use the following procedure for any Lincoln Electric
PowerWave x55/R welding power supply. The Lincoln
Equipment connected with ArcLink is automatically
configured and scaled properly based on the process mode
selection in the Weld Equipment Setup menu.
1. Display the I/O Weld Out screen. ( Procedure 3.4 Setting Up Arc Welding I/O , Step 1 through Step 4 )
2. Move the cursor to the analog signal you want to configure.
3. Press NEXT, >, and then press F3, CONFIG. See the following screen for an example.
I/O Weld Out
1 AO[ 1 ] ^
(Volts) |
|
2 10.000 +----------------*
| |
| |
3 0.000 | |
+* |
|+---------------+
4 0.000 50.000
Voltage (Volts)
4. Move the cursor to the item you want to adjust, type the new value, and press ENTER. You can adjust the following items:
 Analog port number
 Analog signal range - maximum
 Analog signal range - minimum
 Welding range - minimum
 Welding range - maximum
5. To determine if the assignment is valid, press F3, VERIFY.
 If the assignment is valid, the message, "Port assignment is valid," is displayed.
 If the assignment is not valid, the message, "Port assignment is invalid," is displayed.
6. To return to the I/O Weld screen, press F2, MONITOR, or press PREV.
Figure 3.9 Analog Signal Scaling Example
Reconfiguring Weld Input and Output Signals (WI/WO)
If you are not using process I/O or are not able to use the standard I/O definition assigned by ArcTool, you can reconfigure the
port type and port number of each digital weld signal. Use Procedure 3.6 Reconfiguring Weld Input and Output Signals (WI/WO)
to reconfigure weld input and output signals.
Note
If you are using Lincoln Electric PowerWave x55/R welding
equipment, you can only re-assign the port type and I/O
number to specific welding inputs and outputs. See
Procedure 3.7 Reconfiguring Weld Input and Output Signals
for Lincoln Electric PowerWave x55/R Equipment for more
details.
Procedure 3.6 Reconfiguring Weld Input and Output Signals (WI/WO)
Steps
1. Display the I/O Weld In or I/O Weld Out screen. ( Procedure 3.4 Setting Up Arc Welding I/O , Step 1 through Step 4 )
2. Move the cursor to the WI or WO signal you want to re-configure.
I/O Weld Out

WELD SIGNAL TYPE #
1 [Weld start ] WO[ 3]
4. To change the port type,
a. Move the cursor to the port type (WO, for example).
b. Press F4, [CHOICE].
c. Select the signal type you want and press ENTER.
5. To define the port number, move the cursor to the port number, type the number you want, and press ENTER.
Note
Setting an input or output port number to zero is a useful
means of de-assigning I/O. For example, if you need to de-
activate the Remote Arc Enable feature, you set the port
number to zero and cycle power.
Procedure 3.7 Reconfiguring Weld Input and Output Signals for Lincoln Electric PowerWave x55/R Equipment
Reconfiguring the weld input and output signals with Lincoln Electric PowerWave x55/R series weld equipment connected with
ArcLink is restricted to the Gas, Wire, and Water inputs and the Gas Start output. Use the following procedure to reconfigure
these inputs and outputs.
Steps
1. Press the MENU hardkey followed by Next, and System.
2. Press Type and select item 2, Variables.
3. Move the cursor to $AWELEWC and press Enter
4. Move the cursor to $USR_DEF_DO and enter 2 to re-assign the Gas Start Output signal.
5. Move the cursor to $USR_DEF_DI and enter one of the following numbers:
 Gas Fault = 2
 Wire Fault = 4
 Water Fault = 8
To enable reconfiguration of more than one of these inputs, add the number together. For example, to override the
ArcLink assignment of the gas fault and water fault inputs, enter 10 (2 + 8) in the $USR_DEF_DI field.
6. Cycle power on the controller for this change to take effect.
Using Spare Weld Signals (WI/WO) and Adding Comments
You can use the weld inputs and outputs (WI/WO) located on the process I/O board not used by ArcTool in your application
programs. You can also add comments or names to the signals. Use Procedure 3.8 Using Spare Weld Signals (WI/WO) and
Adding Comments to use spare weld signals (WI/WO) and add comments.
Procedure 3.8 Using Spare Weld Signals (WI/WO) and Adding Comments
Steps
2. Move the cursor the spare signal you want to use.
I/O Weld Out

WELD SIGNAL TYPE #
4. To add a weld signal comment , press ENTER and use the appropriate teach pendant keys to type the comment. When
you are finished, press ENTER.
3.5.7 Remote Arc Enable
Arc enable is an input to the controller to enable or disable welding. It is active only during remote operations (when REMOTE is
ON). The arc enable input is unassigned by default. You can assign an input to enable or disable welding during remote
operations. Use Procedure 3.9 Configuring the Arc Enable Input to configure the arc enable input.
Procedure 3.9 Configuring the Arc Enable Input
Steps
1. Press MENUS.
2. Select I/O.
3. Press F1, [TYPE].
4. If the I/O Weld screen is not displayed, press F1, [TYPE], and select Weld.
5. Press F3, IN/OUT, until the I/O Weld In screen is displayed.
6. Move the cursor the Arc enable input.
I/O Weld In
WELD SIGNAL TYPE #
1 [Arc enable ] DI[ 8]
a. Move the cursor to the port type (DI, for example).
12. To unassign remote arc enable, set the port number to zero.
13. If you have made any changes to the configuration of the arc enable input, you must turn off the controller and then turn
it on for the changes to take effect.
3.5.8 Direct Wire Feed Control
Direct wire feed control provides two weld outputs to control the wire feed motor and direction during welding: feed forward and
feed backward.
Note
If you are using Lincoln PowerWave x55/R equipment
connected with ArcLink, direct wire feed control is enabled
automatically and should not be changed..
Note
Direct wire feed control is effective only if the weld controller

is configured to use the wire feed signals during welding.
Enabling Direct Wire Feed Control
By default, direct wire feed control is disabled. If you are using Lincoln Electric PowerWave x55/R welding equipment connected
with ArcLink, direct wire feed control is enabled. In this case, the feed forward/backward setting is automatically setup and
should not be changed. You enable and disable direct wire feed control using the "Feed forward/backward" entry on the SETUP
Weld Equipment screen, shown in Figure 3.10 Enabling Wire Feed Control on the SETUP Weld Equipment Screen . Direct wire
feed control is enabled when the value is ENABLED; otherwise, it is disabled.
Figure 3.10 Enabling Wire Feed Control on the SETUP Weld Equipment Screen
SETUP Weld Equip

Welder: General Purpose MIG (Volts, WFS)
Process: MIG
Process control: VLT+WFS
Feeder: General Purpose
1 WIRE+ WIRE- speed: 50 IPM
2 Feed forward/backward: DISABLED
3 Wire stick reset: ENABLED
4 Wire stick reset tries: 1
Timing
5 Arc start error time: 2.00 sec
6 Arc detect time: .06 sec
7 Arc loss error time: .25 sec
8 Gas detect time: .05 sec
9 Gas purge time: 0.00 sec
10 Gas preflow time: 0.00 sec
11 Gas postflow time: 0.00 sec
Wire feed control is available for both MIG and TIG welding.
Assigning Direct Wire Feed Control Outputs
If you want to use direct wire feed control, you must assign the direct wire feed control outputs:
 Feed forward - Controls wire feed in the forward direction
 Feed backward - Controls wire feed in the backward direction
Use Procedure 3.10 Assigning Wire Feed Control Outputs to assign wire feed control outputs.
Procedure 3.10 Assigning Wire Feed Control Outputs
Steps
1. Press MENUS.
2. Select I/O.
5. Press F3, IN/OUT, until the I/O Weld Out screen is displayed.
6. Move the cursor to a wire feed control output. See the following screen for an example.
I/O Weld Out
5 [ ] WO[ 3] U OFF
9 [ ] WO[ 7] U OFF
10 [ ] WO[ 8] U OFF
11 [Burnback ] WO[ 0] U ***
12 [Feed forward ] WO[ 0] U ***
13 [Feed backward ] WO[ 0] U ***
I/O Weld Out
WELD SIGNAL TYPE #
1 [Feed backward ] WO[ 0]
8. Move the cursor to the port number.
9. Type the port number you want to assign and press ENTER.
10. Press PREV or press F2, MONITOR.
The output signal is assigned.
11. Repeat Step 6 through Step 10 for both wire feed control outputs.
After you have assigned both signals, the screen will be similar to the following.
I/O Weld Out

5 [ ] WO[ 3] U OFF
9 [Feed forward ] WO[ 7] U OFF
10 [Feed backward ] WO[ 8] U OFF
12 [ ] WO[ 0] U ***
13 [ ] WO[ 0] U ***
3.5.9 Remote Wire Inch Control
You can define two digital input signals for remote control of wire inching. The signals names appear in the I/O Weld In screen
when the remote wire inch function is enabled.
12 [Remote inch fwd ] DI[ 1] U OFF
Use Procedure 3.11 Enabling Remote Wire Inch to enable this feature. Then, use Procedure 3.12 Configuring Remote Inch
Inputs to define the input signals. Finally, use Procedure 3.13 Setting Remote Wire Inch Speed to set the remote inch speed
prior to using this function.
Procedure 3.11 Enabling Remote Wire Inch
1. Press MENUS.
2. Select SETUP.
4. Select Weld System. You will see the SETUP Weld System screen. At the bottom of this screen you will find the following
items.
SETUP Weld System

19/19
Other Functions
14 On-The-Fly: ENABLED
15 Weld from teach pendant: ENABLED
16 Runin: DISABLED
17 Wire burnback/retract: DISABLED
18 Remote gas purge: DISABLED
19 Remote wire inch: ENABLED
5. Move the cursor to remote wire inch and use the function keys to enable or disable this function.
Procedure 3.12 Configuring Remote Inch Inputs
1. Press MENUS.
2. Select I/O.
5. Move the cursor to the Remote inch fwd input.
I/O Weld In
WELD SIGNAL TYPE #
11 [Remote inch fwd ] DI[ 1]
 If the assignment is valid, the message, “Port assignment is valid,” is displayed.
 If the assignment is not valid, the message, “Port assignment is invalid,” is displayed.
12. Repeat steps Step 5 through Step 11 for the Remote inch bwd signal.
13. If you have made any changes to the configuration of either input, you must turn off the controller and then turn it on
again for the changes to take effect.
Procedure 3.13 Setting Remote Wire Inch Speed
1. Press MENUS.
2. Select SETUP.
4. Select Weld Equip. You will see the SETUP Weld Equip screen. In this screen you will find the following items.

2 Remote wire inch speed: 250 IPM
5. Move the cursor to Remote wire inch speed and set the value.
3.5 WELD I/O

3.5.1 Overview
Note
Caution
ITEM DESCRIPTION
ITEM DESCRIPTION
Signal equipment.
left to right.
number.
be numbered 41-80.
rack 90.)
Note
screens.

Voltage
Not available for
Lincoln STT
welding equipment
Current
Not available for

Wire feed speed
Arc detect
Wire fault
Water fault

Wire Stick
Arc enable
Note
Note
Note
information.


Weld start
begin.
Wire stick alarm
Feed Forward
Feed Backward
Program Select 1
Program Select 2
(WI/WO)
Adding Comments
Steps
1. Press MENUS.
2. Select I/O.
Note
Note
board.
I/O Weld In
3 [ ] WI[ 1] U OFF
example.
I/O Weld Out

5 [ ] WO[ 3] U OFF
Note
I/O Weld In

10 [Arc Enable ] [**] * ***
example.
I/O Weld Out

1 [WFS ] AO[ 1] U 0.0
2 [Trim ] AO[ 2] U 0.0
11 [Proc select 1 ] [**] * ***
11 [Proc select 2 ] [**] * ***
11 [Proc select 3 ] [**] * ***
Warning

damage equipment.
Steps
Note
I/O Weld Out
1 AO[ 1 ] ^
(Volts) |
|
2 10.000 +----------------*
| |
| |
3 0.000 | |
+* |
|+---------------+
4 0.000 50.000
Voltage (Volts)
Note
details.
Steps
I/O Weld Out

WELD SIGNAL TYPE #
Note
Steps
 Gas Fault = 2
 Wire Fault = 4
 Water Fault = 8
Steps
I/O Weld Out

WELD SIGNAL TYPE #
Steps
1. Press MENUS.
2. Select I/O.
I/O Weld In
WELD SIGNAL TYPE #
feed backward.
Note
Note

SETUP Weld Equip

Process: MIG
Timing
Steps
1. Press MENUS.
2. Select I/O.
I/O Weld Out
5 [ ] WO[ 3] U OFF
9 [ ] WO[ 7] U OFF
10 [ ] WO[ 8] U OFF
I/O Weld Out
WELD SIGNAL TYPE #
I/O Weld Out

5 [ ] WO[ 3] U OFF
12 [ ] WO[ 0] U ***
13 [ ] WO[ 0] U ***
1. Press MENUS.
2. Select SETUP.
items.
SETUP Weld System

19/19
Other Functions
16 Runin: DISABLED
1. Press MENUS.
2. Select I/O.
I/O Weld In
WELD SIGNAL TYPE #
1. Press MENUS.
2. Select SETUP.

3.5 WELD I/O

3.5.1 Overview
Note
Caution
ITEM DESCRIPTION
ITEM DESCRIPTION
Signal equipment.
left to right.
number.
be numbered 41-80.
rack 90.)
Note
screens.

Voltage
Not available for
Lincoln STT
welding equipment
Current
Not available for

Wire feed speed
Arc detect
Wire fault
Water fault

Wire Stick
Arc enable
Note
Note
Note
information.


Weld start
begin.
Wire stick alarm
Feed Forward
Feed Backward
Program Select 1
Program Select 2
(WI/WO)
Adding Comments
Steps
1. Press MENUS.
2. Select I/O.
Note
Note
board.
I/O Weld In
3 [ ] WI[ 1] U OFF
example.
I/O Weld Out

5 [ ] WO[ 3] U OFF
Note
I/O Weld In

10 [Arc Enable ] [**] * ***
example.
I/O Weld Out

1 [WFS ] AO[ 1] U 0.0
2 [Trim ] AO[ 2] U 0.0
11 [Proc select 1 ] [**] * ***
11 [Proc select 2 ] [**] * ***
11 [Proc select 3 ] [**] * ***
Warning

damage equipment.
Steps
Note
I/O Weld Out
1 AO[ 1 ] ^
(Volts) |
|
2 10.000 +----------------*
| |
| |
3 0.000 | |
+* |
|+---------------+
4 0.000 50.000
Voltage (Volts)
Note
details.
Steps
I/O Weld Out

WELD SIGNAL TYPE #
Note
Steps
 Gas Fault = 2
 Wire Fault = 4
 Water Fault = 8
Steps
I/O Weld Out

WELD SIGNAL TYPE #
Steps
1. Press MENUS.
2. Select I/O.
I/O Weld In
WELD SIGNAL TYPE #
feed backward.
Note
Note

SETUP Weld Equip

Process: MIG
Timing
Steps
1. Press MENUS.
2. Select I/O.
I/O Weld Out
5 [ ] WO[ 3] U OFF
9 [ ] WO[ 7] U OFF
10 [ ] WO[ 8] U OFF
I/O Weld Out
WELD SIGNAL TYPE #
I/O Weld Out

5 [ ] WO[ 3] U OFF
12 [ ] WO[ 0] U ***
13 [ ] WO[ 0] U ***
1. Press MENUS.
2. Select SETUP.
items.
SETUP Weld System

19/19
Other Functions
16 Runin: DISABLED
1. Press MENUS.
2. Select I/O.
I/O Weld In
WELD SIGNAL TYPE #
1. Press MENUS.
2. Select SETUP.


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3.

5 WELD I/O Page 1 of 27

3.5 WELD I/O

Each of these interface methods is detailed in the following sections.

Figure 3.6 Process I/O Weld Cable Pinout

Table 3.7 I/O Weld Screen Items

Table 3.8 I/O Weld Config Screen Items

3.5.2 I/O Configuration

3.5.3 Weld I/O Timing Charts

Figure 3.7 MIG Welding Timing Chart

Figure 3.8 TIG Welding Timing Chart

3.5.4 Welding Input Signals

You can use the I/O Weld In screen to

 View the status of the input signals

 Simulate input signals

 Force input signals only if the input signal is first simulated.

 Add a description or name to an unused input signal

 Change the pre-assigned port number or port type

Table 3.9 Arc Welding Input Signals

input signal description

Not available for

Code Manual for more information.

3.5.5 Welding Output Signals

You can use the I/O Weld Out screen to

 View the status of the output signals

 Simulate output signals

 Add a description or name to an unused input signal

 Change the pre-assigned port number or port type

Table 3.10 Arc Welding Output Signals

Analog Output Signal Description

This item is an analog output from the controller to the weld

equipment that controls the welding trim. (Trim is generally a

3.5.6 Setting Up Arc Welding I/O

Use the following procedures to set up arc welding I/O:

Procedure 3.4 Setting Up Arc Welding I/O

3. If the I/O Weld screen is not displayed, press F1, [TYPE].

I/O Weld Out

1 [Arc Voltage ] AI[ 1] U 0.0

I/O Weld Out

 Press F4, SIMULATE to simulate I/O.

 Press F5, UNSIM to not simulate I/O.

sure all personnel and unnecessary equipment are

 To force ON , press F4, ON.

 To force OFF , press F5, OFF.

Procedure 3.5 Configuring Analog Input and Output Signals (AI/AO)

2. Move the cursor to the analog signal you want to configure.

 Analog port number

 Analog signal range - maximum

 Analog signal range - minimum

 Welding range - minimum

 Welding range - maximum

5. To determine if the assignment is valid, press F3, VERIFY.

 If the assignment is valid, the message, "Port assignment is valid," is displayed.

Figure 3.9 Analog Signal Scaling Example

Reconfiguring Weld Input and Output Signals (WI/WO)

Procedure 3.6 Reconfiguring Weld Input and Output Signals (WI/WO)

2. Move the cursor to the WI or WO signal you want to re-configure.

I/O Weld Out

4. To change the port type,

a. Move the cursor to the port type (WO, for example).

b. Press F4, [CHOICE].

c. Select the signal type you want and press ENTER.

6. To determine if the assignment is valid, press F3, VERIFY.