The „Welding start“ signal starts the welding process. The welding process continues until „Welding start“ is reset. Exceptions:

• „Robot ready“ signal deactivated
• Power source warning of internal error (e.g.: overtemperature, water shortage, etc.).

If the Robot interface has been plugged in, the power source will automatically be in 2-step mode.

The „Welding start“ signal starts the welding process. The welding process continues until „Welding start“ is reset. Exceptions:

• „Robot ready“ signal deactivated
• Power source warning of internal error (e.g.: overtemperature, water shortage, etc.).

If the Robot interface has been plugged in, the power source will automatically be in 2-step mode.

Robot sets signal once it is ready to start welding. If the robot resets the signal during welding, the power source ends the welding process. The robot control outputs error number 38. "-St oP-" appears on the power source display.

The "Robot ready" signal is reset once the power source is switched on.

The Master selection twin signal determines which power source will act as master and which as slave.

The "Gas test" signal operates the gas solenoid valve. It corresponds to the gas test button on the power source or wirefeeder control panel. It sets the required gas-flow rate on the pressure regulator.

The "Wire feed" signal starts the wirefeed and corresponds to the "Feeder inching" button on the power source control panel or wirefeeder. The wire is fed into the hosepack without any accompanying current or gas.
The feeder inching speed is determined by the corresponding setting in the power source setup menu.

Time-path of the wire speed when the digital input signal "Wire inching" is set

(1)	Wire inching signal

• Signal remains for up to one second: irrespective of what value has been set, the wire speed (2) remains at 1 m/min or 39.37 ipm for the first second.
• Signal remains for up to 2.5 seconds: after one second has elapsed, the wire speed (2) increases at a uniform rate over the next 1.5 seconds.
• Signal remains for more than 2.5 seconds: after 2.5 seconds, the wire is fed at a constant rate equal to the wire speed set for the Fdi welding parameter.

The "Wire retract" signal causes the wire to be retracted. The wire speed is determined by the corresponding setting in the power source setup menu.

Time-path of the wire speed when the digital input signal "Wire inching" is set

(1)	Wire inching signal

• Signal remains for up to one second: irrespective of what value has been set, the wire speed (2) remains at 1 m/min or 39.37 ipm for the first second.
• Signal remains for up to 2.5 seconds: after one second has elapsed, the wire speed (2) increases at a uniform rate over the next 1.5 seconds.
• Signal remains for more than 2.5 seconds: after 2.5 seconds, the wire is fed at a constant rate equal to the wire speed set for the "Fdi" welding parameter.

The “Touch sensing“ signal can be used to indicate that the welding wire/gas nozzle has made contact with the workpiece (short-circuit between workpiece and welding wire/gas nozzle).
If the “Touch sensing“ signal is set, the control panel on the power source shows “touch“. There will be a voltage of 30 V on the filler wire/gas nozzle (current limited to 3 A).
The fact that a short-circuit has occurred is transmitted to the robot control via the “arc stable“ signal (see “Output signals“).

No welding can take place while the “Touch sensing“ signal is set. To interrupt the welding process for position detection:

1. Set the “Touch sensing“ signal using the robot control
2. Power source stops welding after the set burn-back time has elapsed (can be set in the power source set-up menu)
3. Carry out position detection

The use of an RC element is mandatory so that if the gas nozzle touches the workpiece during welding,

• there are no excessive currents across the gas nozzle - welding current lead connection
• the welding process is not affected

If the gas nozzle makes contact, the short-circuit current flows for approx. 4ms until the RC element capacitors are charged. To ensure contact by the robot control is always detected, the current flow signal lasts 0.5 s longer than the short-circuit current..

RC element for connecting the welding current lead to the gas nozzle

(1)	Welding current lead
(2)	Gas nozzle

If an additional solenoid valve for compressed air is installed in the robot feeder, it can be controlled by the “Torch blow out“ command. The “Torch blow out“ signal is used to clear the gas nozzle of dirt after cleaning the torch.

When a fault occurs, this remains until the robot control sends the "Source error reset" signal to the power source. The reason for the fault must first however be rectified. As the signal level is controlled, it does not react to a rising edge. If the source error reset signal is always HIGH, any error that occurs is reset immediately after it has been rectified.

If a non-programmed characteristic is selected, "no | PrG" appears on the displays. The robot control turns off the "power source ready" signal. To reset, select an occupied program location.

Using this 8-bit signal, the welding operation is carried out with the welding parameters saved under the selected job number. By selecting job number 0, the job can be selected on the control panel.

iWelding does not take place in job mode. If power, arc length correction, pulse correction and burn-back are all specified, the filler metal, gas and wire diameter used are specified via this program number.

To select the program on the power source control panel, select program number 0 on the robot control.

The power source simulates a „real“ welding process using the „Welding simulation“ command. A welding path programmed in the robot control can therefore be simulated without actually welding. All signals are set, just like the real thing (arc stable, process active, main current signal)..However, the following do not occur:

• Arc ignition
• Wire feed
• Activation of gas solenoid valve.

The “SynchroPuls disable“ signal deactivates the SynchroPuls function in the power source if required. The signal can be set before or during welding.

The “SFI disable“ signal deactivates the SFI function in the power source if required. The signal can only be set before welding begins.

In synergic mode, the power, arc length correction, arc-force dynamic/pulse correction and burn-back (command values) must be specified from the robot. If the „Pulse/dynamic correction disable“ signal is set, the internal command value in the power source is used, rather than that in the interface..

If the “Full power range“ signal is set, the welding power is not specified in the same way as in synergic mode, i.e. from vDmin - vDmax (0 - 100%) of the selected characteristic, but uses an absolute value between 0 - 30 m/min (0 - 100%). The maximum wirefeed speed of the connected wirefeeder is not taken into account.

In synergic mode, the robot must specify the command values for power, arc length correction, arc-force dynamic/pulse correction and burn-back. If the “Burn-back disable“ signal is set, the internal power source (not interface) command value is used.

By specifying a value between 0 - 65535 (0-100 %), the welding power is set to the selected characteristic. This setting is only active in program standard and program pulsed-arc modes.

The arc length is corrected by specifying a value between 0 - 65535 (-30 % to +30 %). The arc voltage is then changed, but not the wire speed.

This setting is only active when program standard and program pulsed-arc modes are used.

By specifying a value between 0 - 255 (-5 % to +5 %), the arc-force dynamic (standard) or droplet detachment force (pulse) is corrected.

This setting is only active when program standard and program pulsed-arc modes are used.

By specifying a value between 0 - 255 (-200 ms to +200 ms), the length of wire left free after welding is corrected. The shorter the burn-off time, the longer the free wire length.

This setting is only active when program standard and program pulsed-arc modes are used..

When the signal is set, the power source independently calculates the wire feed speed (power).
The calculation is based on the following values:

• the selected characteristic (Synergic mode)
• the desired a-dimension of the weld seam (fillet weld)
• he actual robot speed value

The set value of the a-dimension (0-20) is determined from the power signal. If the calculated power is outside of the characteristic range, the “Power out of range“ signal is output.

The “KD disable” signal facilitates the changeover from internal to external control of the cold-wire feed unit:

• “KD disable“ not set = “KD enable“:
  Internal control of the cold-wire feed unit via the power source
• “KD disable“ set:
  External control of the cold-wire feed unit via the robot interface

External or internal control of the cold-wire feed unit affects the following functions:

• Wire feed
• Wire retract

The “KD disable” signal facilitates the changeover from internal to external control of the cold-wire feed unit:

• “KD disable“ not set = “KD enable“:
  Internal control of the cold-wire feed unit via the power source
• “KD disable“ set:
  External control of the cold-wire feed unit via the robot interface

External or internal control of the cold-wire feed unit affects the following functions:

• Wire feed
• Wire retract

If option 4,101,039 “I-set TIG interference suppression external box“ is installed on the interface (external box), a cold-wire feeder must not be connected to the LocalNet sockets of the interface.
Instead, a cold-wire feeder must be connected directly to the TIG power source via a passive distributor, to ensure trouble-free operation.

The “AC/DC“ signal is for selecting the corresponding operating mode.

The “DC- / DC+“ signal is for selecting the corresponding operating mode.

The cap-shaping signal enables automatic cap-shaping when the AC welding process is selected. For optimum results, this function takes account of the pre-set electrode diameter. The automatic cap-shaping function ensures that the optimum cap is formed during welding start-up.

The “Pulse disable“ signal deactivates the pulse function in the power source if required.

The “Pulse range selection bit 0, bit 1, bit 2“ signal is for setting the pulse frequency range.

By specifying a value between 0 - 65535 (0-100 %), the main current is set to the selected characteristic.

The “External parameter (set value)“ signal allows a freely definable parameter to be activated.

By specifying a value between 0 - 255 (0 % to 100 %), the welding current is reduced to the base current in TIG pulse mode.

Alters the ratio of pulse duration to base current duration when the pulse frequency has been selected. Value range 0 - 255 (10 % to 100 %).

The “Duty cycle disable“ signal deactivates the “Duty cycle (set value)“ function in the power source if required.

The “Base current disable“ signal deactivates the “Base current (set value)“ function in the power source if required.

The signal is for controlling the wirefeed speed when using a cold-wire feed unit.

This signal activates the high frequency ignition. The HF pulses depend on the value set in the power source. (Setting range: 0.01 s - 0.4 s).

The “Pulse disable“ signal deactivates the pulse function in the power source if required.

The “Pulse disable“ signal deactivates the pulse function in the power source if required.

The “Pulse range selection bit 0, bit 1, bit 2“ signal is for setting the pulse frequency range.

By specifying a value between 0 - 65535 (0-100 %), the main current is set to the selected characteristic.

The “External parameter (set value)“ signal allows a freely definable parameter to be activated.

By specifying a value between 0 - 255 (0% to 100%), the process current is reduced to the base current in HAP pulse mode.

Alters the ratio of pulse duration to base current duration when the pulse frequency has been selected. Value range 0 - 255 (10 % to 100 %).

The “Duty cycle disable“ signal deactivates the “Duty cycle (set value)“ function in the power source if required.

The “Base current disable“ signal deactivates the “Base current (set value)“ function in the power source if required.

This signal activates the high frequency ignition. The HF pulses depend on the value set in the power source. (Setting range: 0.01 s - 0.4 s).

This signal is set if the arc is stable after welding has started. The signal informs the robot control that ignition was successful and the arc is present.

This signal is set if the arc is stable after welding has started. The signal informs the robot control that ignition was successful and the arc is present.

This signal is only available when connected to the RCU5000i remote control unit. The signal is set if there is a limit exceed of actual wirefeed speed value, motor current, welding current and welding voltage.

Robot sets the “Welding start“ signal:

• Gas pre-flow time elapses
• Arc ignites
• Arc goes out.
• Gas post-flow time elapses.
• Robot resets signal

Informs the robot that welding is still in progress. So, for example, to ensure optimum gas shielding, the length of time the robot remains in position can be synchronised at the end of the weld seam.

This signal shows the main current phase.

For the most part, the robot torch is fitted with a collision cut-off box attached to the front of the holder on the robot arm. As soon as the robot arm meets a solid obstacle (component, clamping device, etc.), contact with the collision cut-off box is interrupted and signalled to the system. The control must stop the robot immediately.

If the power source is ready to weld, this output is switched to HIGH. The signal goes out and error number 38 is output if:

• an error occurs on the power source
• there is no “power source ready” signal

The exact cause of the error is transmitted to the field bus by means of an error number.

As a rule, the field bus node is supplied externally, e.g. via the robot control. The “Communication ready“ signal informs the robot control that the power source is ready for data communication.

When an error occurs (“power source ready“ signal not illuminated), the error number can help to isolate the cause of the error.

If welding is not finished properly, the wire can be welded to the workpiece. The power source detects the stuck wire and extinguishes the “Robot ready“ signal. Welding continues once the welded wire is released.

The “Robot access“ signal shows whether internal or external parameter setting is selected.

If no welding wire is detected by the wire-end sensor, the “wire available“ signal is shown as low.

This signal shows that the short circuit time has been exceeded (greater than 78 ms).

This signal shows that data documentation is operational via RCU receiver.

The “Pulse high“ signal is for pulse synchronisation (robot)

During welding, transmits the welding voltage measured (between 0 - 100 V). The value on the field bus is between 0 - 65535. In idle, the HOLD value becomes the welding voltage command value immediately after welding.

During welding, transmits the welding current measured (between 0 - 1000 A). The value on the field bus is between 0 - 65535. In idle, the HOLD value becomes the welding current command value immediately after welding.

During welding, transmits the motor current measured (between 0-5 A). The value on the field bus is between 0 - 255.

This specially filtered welding voltage signal is the real value for AVC control (0 - 50 V).

During the welding process, the actual wirefeed speed value measured (0 - vDmax) is transmitted. The value on the field bus is between 0 - 255. In idle the wire command value is transmitted.

The “Power outside range“ signal is set if the “Full power range“ signal is set and the wirefeed speed command value on the selected characteristic lies above or below the possible wirefeed speed.

(1)	Power out of range
(2)	Synergic mode 0 - 100 %
(3)	Full power range 0 - 100 %

* vDmin and vDmax depend on which wirefeeder is connected

After an error has occurred („power source ready“ signal goes out), the error number (A09 - A16) helps isolate the cause of the error. The following errors may be transmitted: