• ROB 4000/5000 and ROB 5000 OC by TS/TPS power sources
• ROB TSt by TSt power sources
• ROB 5000 and ROB 5000 OC also by TSt power sources, but with the range of signals reduced to that of ROB TSt

 IMPORTANT! Risk of damage to robot interface and welding equipment. When Rob 5000/5000 OC is used in combination with the TSt power source, do not connect a plug to the 4-pin Molex sockets, X3 and X4.

 NOTE! TS/TPS power source: ROB 4000/5000 and ROB 5000 OC are only supported from firmware version 2.55.001 (power source) and higher. TSt power source: ROB TSt, ROB 5000 and ROB 5000 OC are only supported from firmware version 1.0040.20 (TSt power source) and higher. In the case of older firmware versions, an update is required.

Before commissioning the welding system, the welding circuit resistance must be determined (see power source operation instructions - section headed „Measuring the welding circuit resistance R“).

 The robot interfaces are designed for automatic welders and have analog and digital inputs and outputs. They are to be installed in an automatic welder and robot control cubicle (can also be surface-mounted).

• connection to power source via a standard LocalNet interface
• no modification to power source necessary
• in addition to the digital inputs and outputs:analog inputs and outputs for the transfer of process variables. Therefore independent of the bit width employed in the existing robot control
• simple replacement of power source
• simple plug-in connections
• very little wiring required
• mounted on DIN 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 using a 10-pin cable (43,0004,0459 / 0460 / 0509: 10-pin remote control cable 5/10/20 m) to a 10-pin LocalNet interface on the digital power source. If no LocalNet interface ports are available, the LocalNet passive distributor (4,100,261) can be used (e.g. between the power source and interconnecting hosepack).

A 1 m long LocalNet cable harness, including a 10-pin socket, is supplied with the robot interface. The 10-pin socket is used as a bushing through the side of the control cubicle. The “ROB 5000 LocalNet installation set” option (4,100,270: 10-pin connection socket with cable harness for the robot interface) is available if an additional LocalNet node (e.g. remote control) needs to be connected to the robot control.

A prefabricated 1.5m long cable harness is available for connecting the robot control to the robot interface (4,100,260: cable harness ROB 5000/ROB 5000 OC; 4,100,274: cable harness ROB 4000).

The cable harness on the interface side is terminated with Molex plugs and is ready for connection. The cable harness on the control side can be modified to match the termination system used on the robot control. The comprehensive labelling of the cable harness, with each identifier printed at several locations along the cable, simplifies the connection procedure.

To prevent faults, the length of the cable between the robot interface and the control must not exceed 1.5 m.

• The power source is controlled by analog command values (0-10 V for welding power and arc length correction)
• The welding programs must be selected on the power source control panel.

 The other robot interfaces have the following additional functions compared with the ROB 4000:

• Operating mode selected via the robot
• Welding program selected via the robot
• Job selected via the robot
• “Touch sensing” function
• Error reset
• Switching between several wirefeeders
• “Process active” signal
• “Main current” signal
• Command value for pulse correction and burn-back
• Actual value for welding voltage, motor current input and wirefeed speed
• Input for reserve parameters
• Output for reserve parameters

IMPORTANT! All digital inputs on the ROB 5000 OC are inverted.

• Mode selection via the robot
• Selection of operating points saved using the memory buttons
• Reset error
• “Process active” signal
• “Main current” signal

IMPORTANT! While the robot interface is connected to the LocalNet, “2-step mode” remains selected (display: 2-step mode).

Further information on the „special 2-step mode for robot interface“ can be found in the sections headed „MIG/MAG welding“ and „Operating mode parameters“ in the power source operating instructions.

On the OPEN COLLECTOR ROB 5000 OC robot interface, all digital input signals are inverted (inverse logic).

• ROB 4000/5000 to 24 V (High)
• ROB 5000 OC to GND (Low)

On the OPEN COLLECTOR ROB 5000 OC robot interface, all digital input signals are inverted (inverse logic).

• ROB 4000/5000 to 24 V (High)
• ROB 5000 OC to GND (Low)

• LOW (0) .. 0 - 2,5 V
• HIGH (1) .. 18 - 30 V

Ground: GND = X7/2 or X12/2

IMPORTANT! All signal statuses relate to the interface input, not the robot control.

The “Welding start” signal starts the welding process. The welding process continues until “Welding start” is reset.

• The digital input signal “Robot ready” is not set
• The digital output signal “Power source ready” is missing

• HIGH active on ROB 4000/5000 and ROB TSt: 24 V = power source ready for welding
• LOW active on ROB 5000 OC: 0 V = power source ready for welding

• LOW active on ROB 4000/5000 and ROB TSt: 0 V = “Quick stop” is set
• HIGH active on ROB 5000 OC: 24 V = “Quick stop” is set

• The “St | oP” error message appears on the control panel

NOTE! The “Quick stop” signal is intended to be used solely as a way of protecting the machine by shutting it down immediately. If additional personal protection is required, a suitable Emergency Stop button should be provided.

NOTE! „Quick stop“ ends the welding process without burn-back.

• “St | oP” appears on the control panel.

• Reset the “Quick stop” signal (set “Robot ready”)
• Set the “Source error reset” signal (ROB 5000 only)

NOTE! Commands and command values are not accepted when “Quick stop” is active.

The following operating modes are supported:

• analog command values (welding power, arc length correction, etc.)
• number of the desired standard program (for filler metal, shielding gas, wire diameter) from the welding program database

• analog command values (welding power, arc length correction, etc.)
• number of the desired pulsed arc program (for filler metal, shielding gas, wire diameter) from the welding program database

• Call up saved welding parameters using the corresponding job number.

Internal parameter selection (ROB 5000/ROB 5000 OC / ROB TSt)
Selecting welding parameters via the robot control programming interface is timeconsuming, especially when programming a job. The “Internal parameter selection” mode enables the required welding parameters to be selected from the power source control panel or via a remote control unit.

Internal parameter selection can also take place while welding is in progress. The signals required for the current welding operation continue to be sent from the robot control.

Manual (ROB 5000/ROB 5000 OC / ROB TSt)
If „Manual“ mode is activated, the parameters „Wirefeed speed“ and „Welding voltage“ are adjusted independently.

In all other modes, the values for parameters “Wirefeed speed” and “Welding voltage” are calculated using the analog input signal for the “Welding power command value”.

• Control the “Wirefeed speed” parameter using the analog input signal “Welding power command value”
  („Welding Power“ ... X2/1 + and X2/8 -)
• Control the „Welding voltage“ parameter using the analog input signal „Arc length correction command value“
  („Arc length correction“ ... X2/2 + and X2/9 -)

• TPS 4000/5000 .... 0-10 V corresponds to a welding voltage of 10 - 40 V
• TPS 2700 ................. 0-10 V corresponds to a welding voltage of 10 -34 V
• Control the “Arc force dynamic” parameter using the analog input signal “Pulse/dynamic correction”
  („Pulse correction“ ... X14/3 + and X14/11 -)

CC/CV (constant current/constant voltage; ROB 5000/ROB 5000 OC)

NOTE! “CC/CV” (constant current/constant voltage) mode is available as an option for the ROB 5000/ROB 5000 OC robot interface or the robot control field bus coupler.

• Software version 2.85.1 (power source)
• Software version 1.50.38 (wirefeeder)

The power source can be operated with either a constant welding current or a constant welding voltage.

• The following parameters can be selected for the left-hand display using the “Parameter selection” key: Welding current, wirefeed speed and F2 (motor current)
• In the right-hand display, the „Voltage“ parameter is the only additional one that can be selected using the „Parameter selection“ key.

• Processes using the „Process“ key
• Modes using the „Mode“ key
• Material using the „Material“ key
• Wire diameter using the „Wire diameter“ key

NOTE! The input signals listed below will be present when “CC/CV” mode is selected. These input signals assume different functions in this mode compared with other modes.

NOTE! The “Welding start” input signal only starts the welding current; the wirefeed is not started.

Signal level for analog input signals:
Even if CC/CV mode is selected, the signal level for the analog input signals is 0 to 10 V.
0 V ......... e.g. minimum welding current
10 V ....... e.g. maximum welding current

• Use the “Robot ready” input signal to set up the power source for welding
• Use the „Welding power command value“ input signal to specify the desired welding current
• Use the “Arc length correction” input signal to enter a value that the welding voltage is not to exceed.NOTE! If no maximum welding current is required, use the “Welding power command value” input signal to specify the highest possible welding current. Should a voltage occur that is higher than the specified welding voltage, it will not be possible to maintain the selected welding current.
• Use the “Pulse correction” input signal to set the required wirefeed speed
• Use the “Welding start” input signal to start the welding current
• Use the “Wire feed” input signal to start the wire feed

• Use the “Robot ready” input signal to set up the power source for welding
• Use the „Arc length correction“ input signal to specify the desired welding voltage
• Use the „Welding power command value“ input signal to enter a value that the welding current is not to exceed.NOTE! If no maximum welding current is required, use the “Welding power command value” input signal to specify the highest possible welding current. Should a current occur that is higher than the specified welding current, it will not be possible to maintain the selected welding voltage.
• Use the “Pulse correction” input signal to set the required wirefeed speed
• Use the “Welding start” input signal to start the welding current
• Start the wire feed with the “Wire feed” input signal

TIG
The TIG welding process with touchdown ignition has been selected. The required welding current is obtained from the analog “Welding power command value” input signal.

CMT/special process
The CMT welding process/special process has been selected. The required welding current is obtained from the analog “Welding power command value” input signal.

Depending on whether Twin Master bit 0 or Twin Master bit 1 is set, the Twin Master signal is sent to either power source 1 or power source 2. The frequency of the synchronised arcs will depend on the power source to which the Twin Master signal has been sent.

The “Gas test” signal starts the “Gas test” function (as does the “Gas test” key). The required gas flow can be set on the pressure regulator on the gas cylinder.

The gas test can be used to create an additional gas pre-flow during positioning.

IMPORTANT! If welding is in progress, the gas pre-flow and post-flow times are controlled by the power source. It is therefore not necessary to set the “Gas test” signal when welding!

The “Wire feed” signal enables the wire to be fed into the hosepack without the use of power or gas (as does the “Feeder inching” key).

The feeder inching speed is determined by the corresponding setting in the power source setup menu.

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.

NOTE! Den Do not allow long lengths of wire to be retracted, as the wire is not wound onto the wirespool.

NOTE! To reset an error, the “Source error reset” signal must be on for at least 10 ms.

Any error messages (“Source error”) that appear on the power source are reset using the “Source error reset” signal. However, the cause of the error must first be eliminated.

• ROB 4000/5000: 24 VDC (High)
• ROB 5000 OC: GND (Low)The error is then reset immediately after the cause has been rectified.

If a non-existent welding program (characteristic) is selected, an error message will likewise appear (“no | PrG”). However, this error must not be reset, since it resets itself once an occupied program location is selected.

The “Job/Program Select” signal allows the “Program number” signals to be used in different ways (Job/Program Bit 0 - 7, see next page)

IMPORTANT! In the case of the ROB TSt, “Job / Program Select” relates to the operating points saved using the memory buttons, where operating points can only be selected digitally.

• LOW (ROB 5000)
• HIGH (ROB 5000 OC),the required job is digitally selected by means of „Job/Program bit 0 - 7“. Select Job mode using mode bit 0-2.

• HIGH (ROB 5000)
• LOW (ROB 5000 OC),there is also the analog job selection option. Refer to the paragraphs on “Analog job selection” for more information.

In the case of standard program/pulsed arc or internal parameter selection, “Job/Program bit 0 - 7” is used to select the process (see the following section “Program number”). Select standard program/pulsed arc or internal parameter selection using mode bit 0-2.

In the case of internal parameter selection, „Job/Program bit 0 - 7“ is used to select the process (see the following section „Program number“). Select internal parameter selection with mode bit 0-2.

NOTE! The allocations are identical to those in the „Job number“ function (see next section). The choice between the “Job number” and “Program number” functions is made using mode bits 0 - 2.

The „Program number“ function is available if „Standard program“ or „Pulsed arc program“ was selected using mode bits 0 - 2.

If the welding parameters are not selected by job number, but by analog command values (welding power, arc length correction, etc.), the corresponding program (for filler metal, shielding gas, wire diameter, etc.) is selected from the welding program database using „Program number“.

NOTE! Program number „0“ allows a program to be selected at the power source control panel (using the „Material“ and „Wire diameter“ keys).

The available welding programs are listed in the figure below.

List of available welding programs (M0164)

NOTE! The allocations are identical to those in the “Program number” function. The choice between the “Job number” and “Program number” functions is made using mode bits 0 - 2.

The “Job number” function is available if “Job mode” was selected using mode bits 0 - 2.

When the “Job number” function is used, saved welding parameters are called up using the number of the corresponding job.

• ROB 5000/ROB 5000 OC
• Software version ROB 5000/ROB 5000 OC: 1.50.00
• Power source software version:3.24.70 (TS/TPS)
  1.004.20 (TSt)
• RCU 5000i remote control unit software version: 1.07.34

1. ROB 5000: “Job/Program Select” to “HIGH“
   ROB 5000 OC: “Job/Program Select” to “HIGH”
2. Mode bits 0 - 2 to “2” = “Job mode”

1. Pulse correction command value
2. Burn-back time correction command value

In job mode, the usual functions that these two input signals perform are absent. The two signals have therefore been given this additional analog job selection function.

IMPORTANT! More information about these two input signals can be found in the “Analog input signals” chapter

• are used to generate a numeric value for the corresponding job
• will be in the range 0-10 V
• subdivide this range into 16 steps, each of 0.625 V

1. Step = Voltage (V)/0.625 V
2. Part value 1 = Step * 16
   Example:
   1. Step = 6.25 V/0.625 V = 10
   2. Part value 1 = 10 * 16 = 160

1. Step = Voltage (V)/0.625 V
2. Part value 2 = Step
   Example:
   1. Step = 6.25 V/0.625 V = 10
   2. Part value 2 = 10

1. Job = Part value 1 (A) + Part value 2 (B)
   Example:
   1. 160 (A) + 10 (B) = 170

NOTE! The adjustable voltage range for a job is limited to steps of 0.625 V. In certain circumstances, the next job may be called up when specifying the limit value. This should ensure that the value for a job will be within the limit values.

e.g.:
Voltage range for job no. 1: 0.625 V - 1.25 V
Specified value for precisely selecting job no. 1: approx. 0.95 V

Examples of specified voltage values for selecting jobs

• use the highest step 16 for signal recognition
• therefore utilise an effective range of 0 - 9.375 V instead of 0 - 10 V

The highest selectable job is thus:
A: 9.375 V/0.625 V = 15, 15 * 16 = 240
B: 9.375 V/0.625 V = 15
C: 240 + 15 = 255

IMPORTANT! The total number of 255 jobs is only available in conjunction with the RCU 5000i remote control unit. If an RCU 5000i is not being used, there are 100 jobs (0-99) to choose from.

The “Welding simulation” signal allows a programmed welding path to be simulated; an arc, wire feed and shielding gas are not required. The digital output signals „Arc stable“, „Main current signal“ and „Process active“ are set just as if welding was actually being performed.

NOTE! The „TouchSensing“ function is supported from software version 2.65.001 onwards (power source).

The „Touch sensing“ signal can be used to indicate that the filler wire/gas nozzle has made contact with the workpiece (short-circuit between workpiece and filler 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 the „Digital output signals“ chapter).

NOTE! Output of the „arc stable“ signal takes about 0.2 s longer than the duration of the short-circuit current.

No welding can take place while the “Touch sensing” signal is set. If the robot control sets the „Touch sensing“ signal during a welding operation, welding is stopped at the end of the burn-back time (which can be specified in the power source setup menu). Position detection can be carried out. Position detection can be carried out.

NOTE! If the position is to be detected when the workpiece touches the gas nozzle (instead of the filler wire), connect the gas nozzle to the welding current lead using an RC element (see Fig.).

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

•  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 „arc stable“ signal lasts 0.5 s longer than the short-circuit current.

The „Blow through“ signal allows the user to control the compressed air supply. Compressed air is used for removing dust and shavings from the welding torch, e.g. after removing welding spatter at the torch cleaning station.

While the „SynchroPuls disable“ signal is set, the „SynchroPuls“ function is temporarily deactivated (optional).

The analog differential amplifier inputs on the robot interface ensure the robot interface and the analog outputs on the robot control are electrically isolated. Each input on the robot interface has its own negative potential.

If the robot control uses a common GND for its analog output signals, the negative potentials, i.e. the inputs on the robot interface, must be linked together.

The analog inputs described below are active at voltages from 0-10 V. If individual analog inputs are not allocated (e.g. for „Pulse correction command value“ or „Burnback command value“), the values set at the power source will be used.

The analog differential amplifier inputs on the robot interface ensure the robot interface and the analog outputs on the robot control are electrically isolated. Each input on the robot interface has its own negative potential.

If the robot control uses a common GND for its analog output signals, the negative potentials, i.e. the inputs on the robot interface, must be linked together.

The analog inputs described below are active at voltages from 0-10 V. If individual analog inputs are not allocated (e.g. for „Pulse correction command value“ or „Burnback command value“), the values set at the power source will be used.

Pin X2/1 ... Analog in + 0 to + 10 V
Pin X2/8 ... Analog in - (minus)

A voltage of 0 - 10 V is specified for the “Welding power command value”.
0 V ..... Minimum welding power
10 V ... Maximum welding power

Using the selected welding power, the power source determines the corresponding values for welding voltage and wirefeed speed. To assess the actual welding power, the “Welding current”, “Sheet thickness” and “a-dimension” parameters can also be displayed on the power source control panel.

NOTE! The named parameters are directly interlinked. If a parameter is altered using the “Welding power command value”, the other parameters are adjusted accordingly.

The “Welding power command value” can only be specified when “Standard program” or “Pulsed arc program” mode is selected.

Pin X2/2 ... Analog in + 0 to + 10 V
Pin X2/9 ... Analog in - (minus)

IMPORTANT! Arc length correction takes place by altering the welding voltage. A voltage of 0 - 10 V is specified for the “Arc length correction command value”.

A voltage of 0 - 10 V is specified for the “Arc length correction command value”.
0 V ..... actual welding voltage - 30% (minimum arc length)
5 V ..... actual welding voltage (neutral arc length)
10 V ... actual welding voltage + 30% (maximum arc length)

The “Arc length correction command value” can only be specified when “Standard program” or “Pulsed arc program” mode is selected.

Pin X14/3 .... Analog in + 0 to + 10 V
Pin X14/11 ...Analog in - (minus)

“Standard program” mode: The short-circuiting dynamic at the moment of droplet transfer is specified with a voltage of 0 - 10 V (arc force correction).

IMPORTANT! Pulsed arc is not available in combination with TSt power sources.

Pulsed arc program” mode: Droplet detachment force is specified with a voltage of 0 - 10 V (pulse correction).

“Standard program” mode
0 V ..... Minimum short-circuiting dynamic (arc hard and stable)
5 V ..... Neutral short circuiting dynamic (basic setting)
10 V ... Maximum short circuiting dynamic (soft, low-spatter arc)

Pulsed arc program” mode
0 V ..... Minimum droplet detachment force
5 V ..... Neutral droplet detachment force (basic setting)
10 V ... Maximum droplet detachment force

Pin X5/1 ... Analog in + 0 to + 10 V
Pin X5/1 ... Analog in - (minus)

The free wire length after welding has finished is determined by the burn-back time. The burn-back time is a result of the delay of the arc after wirefeed has ended. The longer the burn-back time, the shorter the free wire length.

A voltage of 0 - 10 V is specified for the „Burn-back time correction command value“.

NOTE! The „Burn-back time correction command value“ can only be specified when „Standard program“ or „Pulsed arc program“ mode is 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)

Pin X5/2 ... Analog in + 0 to + 10 V
Pin X5/9 ... Analog in - (minus)

NOTE! If the connection between the power source and the robot interface goes down, all digital and analog output signals on the robot interface will be set to “0”.

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

24 V SECONDARY is electrically isolated from the LocalNet. A suppressor circuit limits excess voltages to 100 V.

Use pin X14/1 to select which voltage is to be connected to the digital outputs of the robot interface.

• External voltage robot control (24 V): Connect the external voltage of the robot control digital output card to pin X14/1.
• Power source supply voltage (24 V SECONDARY): Place a jumper between X14/1 and X14/7.

NOTE! If the connection between the power source and the robot interface goes down, all digital and analog output signals on the robot interface will be set to “0”.

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

24 V SECONDARY is electrically isolated from the LocalNet. A suppressor circuit limits excess voltages to 100 V.

Use pin X14/1 to select which voltage is to be connected to the digital outputs of the robot interface.

• External voltage robot control (24 V): Connect the external voltage of the robot control digital output card to pin X14/1.
• Power source supply voltage (24 V SECONDARY): Place a jumper between X14/1 and X14/7.

Pin X2/12 .................. 24 V signal
Pin X7/2 or X12/2 ... GND

The „Arc stable“ signal is set as soon as a stable arc is present.

Pin X8/10 .................. 24 V signal
Pin X7/2 or X12/2 ... GND

When the robot control sets the “Welding start” digital input signal, the welding process begins with the gas pre-flow, followed by the actual welding operation and the gas postflow.

The power source sets the “Process active” signal from the start of the gas pre-flow to the end of the gas post-flow (Fig. 4).

• by ensuring the robot remains in position long enough
• at the start and end of the seam

Pin X8/9 .................... 24 V signal
Pin X7/2 or X12/2 ... GND

IMPORTANT! While the robot interface is connected to the LocalNet, “2-step mode” remains selected (display: 2-step mode).

• 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)

The main current signal is set between the starting current and final current phases (see Fig. 4).

IMPORTANT! Further information on the „special 2-step mode for robot interface“ can be found in the sections headed „MIG/MAG welding“ and „Operating mode parameters“ in the power source operating instructions.

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

Pin X14/10 ............... 24 V signal
Pin X7/2 or X12/2 ... GND

IMPORTANT! Limit signal is not available in combination with TSt power sources.

Pin X2/13 .................. 24 V signal
Pin X7/2 or X12/2 ... GND

The robot welding torch will normally have a cut-off switch. In the event of a collision, the contact in the cut-off switch opens and triggers the LOW active „Torch collision protection“ signal.

The robot control must shut down the robot immediately and stop the welding process using the “Quick stop” input signal.

Pin X2/14 .................. 24 V signal
Pin X7/2 or X12/2 ... GND

The “Power source ready” signal remains on as long as the power source is ready to weld.

The “Power source ready” signal is reset whenever an error occurs in the power source or the robot control sets the “Quick stop” signal.

The “Power source ready” signal can therefore be used to detect internal errors and errors in the robot.

IMPORTANT! If the connection between the power source and the robot interface goes down, all digital and analog output signals on the robot interface will be set to “0”.

The analog outputs on the robot interface are used for setting up the robot and for displaying and documenting process parameters.

IMPORTANT! If the connection between the power source and the robot interface goes down, all digital and analog output signals on the robot interface will be set to “0”.

The analog outputs on the robot interface are used for setting up the robot and for displaying and documenting process parameters.

Pin X5/4 ..... Analog out + 0 to +10 V
Pin X5/11 ... Analog out - (minus)

• 1 V on the analog output corresponds to a welding voltage of 10 V
• Actual “welding voltage” range ... 0 -100 V

IMPORTANT! When the power source is idle the “HOLD” value becomes the “Welding voltage command value” as soon as the welding operation is complete.

The user can enter correction boundaries for the arc length in the power source job correction menu. Due to the direct correlation between arc length and welding power, the correction boundaries also apply to the welding voltage on the ROB 4000/5000 and ROB 5000 OC.

IMPORTANT! If correction boundaries for the arc length were entered in the job correction menu using parameter “AL.c”, the welding voltage can only be specified within these boundaries.

Pin X2/3 ..... Analog out + 0 to +10 V
Pin X2/10 ... Analog out - (minus)

• 1 V on the analog output corresponds to a welding current of 100 A
• Actual “welding current” range .... 0 - 1000 A

IMPORTANT! When the power source is idle the “HOLD” value becomes the “Welding current command value” as soon as the welding operation is complete.

The user can enter correction boundaries for the welding power in the power source job correction menu. Due to the direct correlation between the welding power and welding current, the correction boundaries also apply to the welding current on the robot interface.

IMPORTANT! If correction boundaries for the welding power were entered in the job correction menu using parameters „PcH“ and „PcL“, the welding current can only be specified within these boundaries.

Pin X5/7 ..... Analog out + 0 to +10 V
Pin X5/14 ... Analog out - (minus)

• 1 V on the analog output corresponds to a current of 0.5 A
• Actual value for wire drive current” range ... 0 -5 A

IMPORTANT! The “actual value for wire drive current” provides information about the status of the wirefeeding system.

Pin X5/6 ..... Analog out + 0 to +10 V
Pin X5/13 ... Analog out - (minus)

• Actual “wirefeed speed” range ... 0 - Maximum speed

NOTE! When the power source is idle the “HOLD” value becomes the wirefeed speed as soon as the welding operation is complete.

IMPORTANT! The wirefeed speed is calculated from the speed of the motor (rpm).

• due to slip on the wire drive feed rollers

Pin X5/5 ..... Analog out + 0 to +10 V
Pin X5/12 ... Analog out - (minus)

Depending on the requirements of the robot application, not all the input and output signals (commands) available on the robot interface need be used. The various command subsets of the robot interface are illustrated in the following examples, which demonstrate how to connect the robot interface to the robot control. The I/O signals shown in bold represent the minimum command subset required in each instance.

Depending on the requirements of the robot application, not all the input and output signals (commands) available on the robot interface need be used. The various command subsets of the robot interface are illustrated in the following examples, which demonstrate how to connect the robot interface to the robot control. The I/O signals shown in bold represent the minimum command subset required in each instance.

• 0 - 10 V for welding power and arc length correction
• Selecting welding programs using the power source control panel

Reset error messages - ROB 4000:
In contrast to the ROB 5000, the ROB 4000 robot interface does not allow errors to be reset using the “Source error reset” signal. Error messages on the power source are reset automatically as soon as the error is rectified.

• 0 - 10 V for welding power, arc length correction, pulse correction and burn-back time correction
• Selecting welding programs using the power source control panel

Job selection via the robot:

• Reset error
• Select welding programs using the robot
• TWIN Master Signal (Twin Master bit 0 and 1)
• “Touch sensing” function
• “Process active” and main current signals
• “Gas test”, “Wire feed”, “Wire retract”, “Blow through” signals

Reset error messages - ROB 5000/ROB 5000 OC / ROB TSt:
Error messages on the power source are reset using the “Source error reset” signal. However, the cause of the error must first be eliminated.

• operating mode via the robot
• welding program via the robot
• job via the robot

• 0 - 10 V for welding power and arc length correction

Job selection via the robot:

In this example only the digital ROB 5000/ROB 5000 OC additional „Error reset“ function is used.

Reset error messages - ROB 5000/ROB 5000 OC:
Error messages on the power source are reset using the “Source error reset” signal. However, the cause of the error must first be eliminated.

NOTE! All inputs on the ROB 5000 OC (Open Collector) robot interface are inverted.

• operating mode via the robot
• welding program via the robot
• job via the robot

• 0 - 10 V for welding power, arc length correction, pulse correction and burn-back time correction

Job selection via the robot:

• Reset error
• “Touch sensing” function
• “Process active” signal
• “Gas test”, “Wire feed”, “Wire retract”, “Blow through” signals
• „TWIN Master bit 0“ and „TWIN Master bit 1“ signals

Reset error messages - ROB 5000/ROB 5000 OC:
Error messages on the power source are reset using the “Source error reset” signal. However, the cause of the error must first be eliminated.

NOTE! All inputs on the ROB 5000 OC (Open Collector) robot interface are inverse.

IMPORTANT! All signal statuses relate to the interface input, not the robot control.

IMPORTANT! All signal statuses relate to the interface input, not the robot control.

IMPORTANT! All signal statuses relate to the interface input, not the robot control.

IMPORTANT! All signal statuses relate to the interface input, not the robot control.

NOTE! Simultaneously selecting the „Job number“ signal or „Program number“ signal and the „Welding start“ signal can affect the ignition and the welding data documentation.

NOTE! Simultaneously selecting the „Job number“ signal or „Program number“ signal and the „Welding start“ signal can affect the ignition and the welding data documentation.

To select a job or program without changing the characteristics, Fronius recommends a time gap of at least 0.1 s between the „Job number“ or „Program number“ signal and the „Welding start“ signal.

To select a job or program with a change to the characteristics or operating mode as well, Fronius recommends a time gap of at least 0.3 - 0.6 s between the „Job number“ or „Program number“ signal and the „Welding start“ signal.

• at the power source: in the set-up menu on the RCU 5000i remote control
• at the robot control: Gas preflow_time

IMPORTANT! Do not use the „Gas purge_time“ parameter to set the time gap.

Error messages on the power source are reset using the “Source error reset” signal (not illustrated on this page). However, the cause of the error must first be eliminated.

Error messages on the power source are reset using the “Source error reset” signal (not illustrated on this page). However, the cause of the error must first be eliminated.

In contrast to the ROB 5000, the ROB 4000 robot interface does not allow errors to be reset using the “Source error reset” signal. Error messages on the power source are reset automatically as soon as the error is rectified.

A detailed description of the Service Codes that can be displayed can be found in the “Troubleshooting” chapter of your power source operating instructions.