 Robotics America Quick Reference Document [Page 1 of 1 ]

3900 West Hamlin Road

Rochester Hills, Michigan 48309-3253 
Date : Robot Models Supported: 

Rev:   Software Required 

    

    

     

                  

          

      

* Note: This document is provided as a courtesy and contains condensed and/or summarized information tailored to assist you with a specific issue. For additional and/or
detailed information, you must refer to the appropriate FANUC Robotics Manual or eDoc which specifically applies to the robotics system(s) at your location.

 All Rights Reserved.

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION THAT IS CONFIDENTIAL TO FANUC ROBOTICS

TO THE EXTENT PERMITTED BY LAW, THE INFORMATION CONTAINED HEREIN, INCLUDING, WITHOUT LIMITATION, ALL INTERNET SITES REFERENCED HEREIN, IS PROVIDED "AS IS", WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT
LIMITED TO, WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, RELIABILITY OR ACCURACY.
NEITHER FANUC ROBOTICS NOR ANYONE WHO HELPED DEVELOP, CREATE OR DELIVER THE INFORMATION CONTAINED HEREIN IS LIABLE FOR ANY DAMAGES, INCLUDING, WITHOUT LIMITATION, INDIRECT, INCIDENTAL, SPECIAL OR CONSEQUENTIAL DAMAGES, RELATED TO
YOUR USE OF OR INABILITY TO USE THE INFORMATION OR FOR THE RESULTS OR CONSEQUENCES OF ANY ATTEMPT BY YOU TO ADAPT ANY OF THE INFORMATION FOR YOUR PARTICULAR PURPOSES OR NEEDS. IT REMAINS YOUR RESPONSIBILITY TO TAKE ALL STEPS
NECESSARY TO ENSURE THE SAFETY OF YOUR PERSONNEL IN YOUR WORKPLACE AND YOUR ORGANIZATION'S COMPLIANCE WITH ALL SAFETY REGULATIONS.
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

FANUC / Fronius
DeviceNet Single Interface
R-J3iB V6.40-1P or higher ArcTool software

1
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Power Source Functional Overview

– The Fronius power supply has 3 basic modes of operation;
• Synergic
• Pulsed Synergic
• Job Mode
– The operating mode is selected from the robot
– ARC Tool controls the welding process through weld schedules
– Changes can be made while welding without interruption of the arc
– Process scaling is required
– Productivity and error recover features are supported
– Through robot I/O advanced features of the power source can be
enabled or disabled
• Syrcno Pulse
• Spatter Free Ignition

2
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Overview of Synergic &Pulsed Synergic Welding Modes:

– When operating in either of these modes the robot has control of the welding
output from the robot pendant.
Weld Equipment 1
– Group Output [4] changes the Power or WFS values
– Group Output [5] changes the Pulse or Trim values
– Group Output [6] changes the Pulse Dynamic setting
– Group Output [7] changes the Stub Burn Off command

3
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Overview of Job Mode:

– Job mode is used when welding parameters for a particular weld are stored
internally on the Fronius power source.
– Job Mode limits the control that the robot has over the welding process.
– There are 99 total jobs that can be stored and retrieved by the robot.
– When operating in Job mode the robot can make weld process adjustments,
however the percent of process change is controlled by the welding power
source.
– Group Output [4] is used to adjust the welding power.
• Adjustments are in the form of percent with a maximum adjustment of
+/- 100% of the stored range.
– Group Output [5] is used to adjust the arc length or Trim.
• Adjustments are in the form of percent with a maximum adjustment of
+/- 100% of the stored range.

Note:
Disable Run-in, Burn-Back and Wire Stick on the robot when welding in
Job Mode.

4
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

FANUC / Fronius
DeviceNet Hardware / Software

5
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Fronius Device Net (BECKHOFF)

Fronius DeviceNet Hardawre Settings: Power supplied to module from devicenet connector
Red +24 / Black Ground
– The Beckhoff module gets is low voltage
power from robot.
• Jumper +24V and 0V from the
DeviceNet connector to the
BECKHOFF module.

Set Baud Rate = 2

– Set the Baud rate off the BECKHOFF

module to equal “2”

Add Terminating Resistor

– Install a 120terminating between the

Can High and Can Low terminals

6
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

FANUC Device Net I/0:

– Install a DeviceNet PCB board in the robot controller
– Set the DIP switch settings so that this device is board “1” = all off
– Load the Device Net software option
– Confirm Board List
– Confirm Device Name and MAC ID

7
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Multi Process must be enabled prior to selecting Fronius power supply

Enable Multi Process
$AWSCFG
$MULTI_PROC = TRUE

8
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Load Fronius Software Option

Warning:
Multi Process must be enabled prior to selecting Fronius power supply
Device Net option must be loaded and configured correctly

• Perform a controlled start

• Set manufacture to equal Fronius
• Set model to equal “TS/TPS \ with \ DNET”
• The software will automatically load and configure the appropriate I/O
• Perform a cold start on the controller

9
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

FANUC / Fronius
Power Supply Configuration

10
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Select Fronius program number to match the welding process

– GO[3] selects the active FRONIUS program number
– Adjust value of GO[3] accordingly until correct welding process is selected on
the Fronius front panel
– Fronius determines the available programs
– Green LED indicates selection

Example:
Setting GO[3] = 7
Selects .045” wire ER 70 S-3/6 (Ar/CO2)

11
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Create a program to run at power up

– The purpose is to establish a base Job# as well as define the active weld program
– Input the program name into $PWR_NORMAL = “SET_FPS”
– Input the program name into $PWR_SEMI = “SET_FPS”

Example Program:

– If the value of GO[2]=0 an error will occur when using JOB mode
– The value of GO[3] establishes the wire diameter and alloy to be used
– When the value of GO[3] is changed new scaling values are requir ed

12
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Determine WFS scaling values for Synergic Mode

– Utilize multi-process and select item 1 = Synergic
– Verify the LED for Synergic is lit on the Fronius power source
– Utilize multi-process and select item 4 = Setup No Weld
– Verify LED on the red dial is lit on the power source
– On the Fronius power source
– Press the green #2 button
– Press again until item #12 LED is lit
– Use the red thumb wheel item #1
– Rotate both directions to determine ranges

13
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Set the robot Analog Scaling ranges for process 1 - Synergic

– Select weld process 1
– Synergic

– Enter the Weld Output Screen

– Select GO[4]
– Press next and then config.
– Enter the determined WFS Range for the Synergic mode selected
– Select GO[5] and confirm the range is +/- 30
– Press next and then config. confirm min max ranges correct

Display does not represent actual values

14
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Determine the WFS scaling values for Pulse Synergic Mode

– Utilize multi-process and select item 2 = Pulse Synergic
– Verify the LED for Pulse Synergic is lit on the Fronius power source
– Utilize multi-process and select item 4 = No Weld
– Verify LED on the red dial is lit on the power source
– On the Fronius power source
– Press the green #2 button
– Press again until item #12 LED is lit
– Use the red thumb wheel item #1
– Rotate both directions to determine ranges

15
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Set the robot Analog Scaling ranges for process 2 - Pulse Synergic
– Select weld process 2
– Pulse Synergic

– Enter the Weld Output Screen

– Select GO[4]
– Press next and then config.
– Enter the determined WFS Range for the Pulse Syn. mode selected
– Select GO[5] and confirm the range is +/- 30
– Press next and then config. Confirm min max ranges correct

Display does not represent actual values

16
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Set the robot Analog Scaling ranges for process 3 - JOB Mode
– Select weld process 3
– Job Mode

– Enter the Weld Output Screen

– Select GO[4]
– Press next and then config.
– Confirm the range is +/- 100
– Select GO[5]
– Press next and then config.
– Confirm the range is +/- 100

17
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Advanced process control form the robot

– Ability to enable / disable Pulse Correction through I/O

– Ability to enable / disable Burn Back through I/O
– Ability to enable / disable Spatter Free Ignition through I/O
– Ability to enable / disable Syncro Pulse through I/O

18
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Disable Wire Stick check on the Fronius Power source

– Reference the Fronius Interface manual and navigate to the Set-Up
menu Level 2
– Cursor through the menu until “Stc” is displayed
– Use the adjusting dial and change the setting on “Stc” to read OFF

– Failure to set this setting to off may result in false wire stic k alarms when
switching from Twin wire to single wire

19
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

FANUC / Fronius
I/O Verification and Robot Settings

20
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Robot Group Output

– Group Outputs are used to communicate between the robot and the power source
– Loading and selecting the Fronius interface option defines the GO assignments
Typical Configuration
– GO[1] = Power source operating mode (Synergic, Pulse Synergic, Job Mode, Manual,
– GO[2] = Job Number when executing in Job Mode
– GO[3] = Fronius Program
– GO[4] = E1 Power
– GO[5] = E1 Trim
– GO[6] = E1 Pulse Dynamic Corr.
– GO[7] = E1 Burn-off

21
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Group I/O
– Actual mapping may be different
depending on system configuration

22
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Digital I/O - Outputs

– Actual mapping may be different
depending on system configuration

23
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Digital I/O - Inputs

– Actual mapping may be
different depending on
system configuration

24
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Weld I/O
– Actual mapping may be different depending on system configuration

Note:
– Gas Fault GI [1] = Fronius EQ1 power source fault

Inversed Signals:
– Power Supply Ready = Inversed
– Wire Stick = Inversed

Representation of Job Mode

25
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Weld System Configuration

– Select Menu on the TP
• Set-Up
- Weld System
- Set accordingly

Fronius controls Burn-back

– Disable at robot

26
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Weld Schedules
– Weld Schedules are used to
select Fronius process
• Synergic
• Pulse Synergic
• Job Mode
– The active process
determines the configuration
of the weld schedule detail
screen
– Weld schedules are dynamic
and the configuration changes
to support the Fronius welding
mode

27
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Weld Schedule

Job Mode Details

1. Weld Schedule = Weld Schedule
2. Process select = Fronius operating mode
3. Power Correction = Fronius E1 Job override
4. Arc Length Corr. = Fronius E1 Job override
5. Job Number = Active Job to weld with
6. Travel Speed = Robot Travel Speed
7. Delay Time = Arc End Delay Time

28
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

Weld Schedule
Synergic and Pulse Synergic Details
1. Weld Schedule = Weld Schedule
2. Process select = Fronius operating mode
3. Wire Feed = Fronius E1 WFS
4. Arc Length Corr. = Fronius E1 trim
5. Pulse Correction = Pulse Dynamic correction
6. Burnback correction. = Burn off time
7. Travel Speed = Robot Travel Speed
8. Delay Time = Arc End Delay Time

29
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

• Configure the “Fronius Weld Equipment” to communicate with the

Robot correctly
– Enter Level 1 setup on the Fronius power source
– Press and hold (21)
– Press (4)
• Enter level 1 Setup

30
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

• Level 1 settings
– Set GPr and GPo to minimal
=0
• Use robot pre-flow or post-
flow if necessary
– Fdc = Auto
– Fdi = Set to desired
– bbc = 0
– F=0
• Setting a frequency value
enables SyncroPulse
• Job Mode is most
commonly used to weld
with SyncroPulse settings
– dFd = 0
• Used with SyncroPulse
– AL.2 = 0
– dYn = 0

31
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

• “Fronius Weld Equipment” Enter Level 2 settings

32
 FANUC / FRONIUS DeviceNet Single Interface Rev.2 (10-24-07)

• Level 2 settings
– C-C = Aut
– Stc = Off

• Measure Line Resistance

– Follow Fronius documentation

33