The robot interfaces ROB 4000/5000 and ROB 5000 OC, hereafter referred to as robot interfaces, are designed for automatic welders and have analog and digital inputs and outputs. The robot interfaces are to be installed in an automatic welder and robot control cubicle (can also be surface-mounted).

Advantages

• 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
• installed 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 made-up, 1.5m long cable harness is available for connecting the robot control to the robot interface (4,100,260: cable harness ROB 5000; 4,100,274: cable harness ROB 4000).

The cable harness on the interface side is terminated with Molex plugs and is already made-up. 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.

ROB 4000 (4,100,239)

• The power source is controlled by analog command values (0-10 V for welding current)
• The operating mode must be selected on the power source control panel.
  

Additional functions ROB 5000 (4,100,255), ROB 5000 OC (4,100,474)

• Operating mode selected via the robot
• Job selected via the robot
• “Touch sensing” function
• Reset error
• “Process active” signal
• “Main current” signal
• Command values for welding currents and wirefeed speeds
• Actual value for welding voltage, motor current input and wirefeed speed
• Additional analog parameters

More information about operating modes can be found in the power source operating instructions.

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

• 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).
Wiring of the digital input signals:

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

Signal level:

• LOW ........ 0 - 2.5 V
• HIGH ....... 18 - 30 V

Ground: GND = X7/2 or X12/2

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

Exception:

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

„Robot ready“ is

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

„Quick stop“ is

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

The “Quick stop” signal stops the welding process immediately

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

“Quick stop” is active as soon as the power source is switched on

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

Prepare the power source for welding:

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

Signal level when BIT 0 - BIT 2 are set

The following operating modes are supported:

Job mode (ROB 5000/ROB 5000 OC)
Call up saved welding parameters using the corresponding job number.

Internal parameter selection (ROB 5000/ROB 5000 OC)
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.

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

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

Restrictions compared to other operating modes:

The following parameters can be selected for the left-hand display using the “Parameter selection” key:

• welding current
  

Available input signals:

The input signals and their functions:

• Analog input signal “Welding current” ... Specifies the welding current
• Analog input signal “External parameter 1” ... Specifies the welding voltage
• Analog input signal “Base current” ... Specifies the wirefeed speed
• Digital input signal “Welding start” ... Starts the welding current
• The welding current remains on for as long as the signal is set
• Digital input signal “Wire feed” ... Starts the wire feed at the specified speed
• The wire feed remains on for as long as the signal is set
• Digital input signal “Wire retract” ... Starts a wire retract at the specified speed
• The wire retract remains on for as long as the signal is set
• Digital input signal “Robot ready” ... remains unchanged
• Digital input signal “Gas test” ... remains unchanged

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

Specifying a command value for the welding current:

• Use the “Robot ready” input signal to set up the power source for welding
• Use the “Welding current” input signal to specify the required welding current
• Use the “External parameter 1” input signal to enter a value that the welding voltage is not to exceed.
  IMPORTANT! If no maximum welding voltage is required, use the “External Parameter 1” input signal to specify the highest possible welding voltage.
  
  Should a voltage occur that is higher than the specified welding voltage, it will not be possible to maintain the selected welding current.
  

• Set the required wirefeed speed using the “Base current” input signal
• Use the “Welding start” input signal to start the welding current
• Start the wire feed with the “Wire feed” input signal

Specifying a command value for the welding voltage:

• Use the “Robot ready” input signal to set up the power source for welding
• Use the “External parameter 1” input signal to enter the required welding voltage
• Use the “Welding current” 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 current” 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.
  
• Set the required wirefeed speed using the “Base current” input signal
• Use the “Welding start” input signal to start the welding current
• Start the wire feed with the “Wire feed” input signal

TIG
TIG welding is selected. The required welding current is obtained from the analog „Welding current“ input signal.

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 inching“ signal enables the filler wire to be fed into the hosepack without the use of current or gas (as does the „Feeder inching“ key).

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

IMPORTANT! To facilitate the exact positioning of the filler wire, the following procedure is executed when the „wire inching“ signal is set:

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 the value that 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, the wire speed (2) increases at a uniform rate over the next 1.5 seconds.
• Signal remains for more than 2.5 seconds: After a total of 2.5 seconds, the wire starts to be fed at a constant rate equal to the speed set for the parameter „Fdi“.

IMPORTANT! If the digital input signal „Cold wire disable“ is also set, then the analog output signal „wire speed“ applies, rather than „Fdi“. The digital input signal „wire inching“ starts immediately with the analog command value for the wire speed. In this case, the figure does not apply.

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.

IMPORTANT! To facilitate the exact positioning of the filler wire, the following procedure is executed when the „wire retract“ signal is set

Time-path of the wire speed when the digital input signal „Wire retract“ is set

(1)	Wire retract signal

• Signal remains for up to one second: Irrespective of the value that 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, the wire speed (2) increases at a uniform rate over the next 1.5 seconds.
• Signal remains for more than 2.5 seconds: After a total of 2.5 seconds, the wire starts to be fed at a constant rate equal to the speed set for the parameter „Fdi“.

IMPORTANT! If the digital input signal „Cold wire disable“ is also set, then the analog output signal „wire speed“ applies to the retract speed, rather than „Fdi“. The digital input signal „wire retract“ starts retracting the wire immediately with the analog command value for the wire speed. In this case, Fig. 3 does not apply.

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.

If the robot control has no digital signal for resetting, always set the “Source error reset“ signal to

• ROB 4000/5000: 24 VDC (High)
• ROB 5000 OC: GND (Low)

The error is then reset immediately after the cause has been rectified.

Example: if there is not enough coolant, the “No | H2O” Service code will not be displayed if the signal is set. This can result in damage to the water-cooled welding torch.

Remedies: Only use the “Source error reset” signal as a short pulse to reset the error.

The „Job/program select“ signal allows the „Program number“ signals to be used in different ways (Job/program bit 0 -7, see next page)

In job mode, if „Job/Program Select“ is

• 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.

IMPORTANT! In job mode (mode bit 0-2), if „Job/Program Select“ is

• LOW (ROB 5000)
• HIGH (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 internal parameter selection or TIG, „Job/program bit 0 -7“ is used to select the process (see the following section „Program number“). Select internal parameter selection or TIG with mode bit 0-2.

Example ROB 5000:

• X11/5 is not set (= 0)
• X11/6 is not set (= 0)
• X11/7 is set (= 1)
• Frequency range 20 - 200 Hz selected

Example ROB 5000 OC:

• X11/5 is not set (= 1)
• X11/6 is not set (= 1)
• X11/7 is set (= 0)
• Frequency range 20 - 200 Hz selected

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.

System requirements for analog job selection are as follows:

• ROB 5000 / ROB 5000 OC
• Software version ROB 5000/ROB 5000 OC: 1.50.00
• Power source software version: 3.24.70
• RCU 5000i remote control unit software version: 1.07.34

Activate analog job selection as follows:

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

Analog job selection enables job numbers to be selected using the following analog input signals:

1. Base current
2. Duty cycle

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.

Both analog input signals

• 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

A: Part value 1 for “Base current” input signal:
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

B: Part value 2 for “Duty cycle” input signal:
3. Step = Voltage (V)/0.625 V
4. Part value 2 = Step
Example
3. Step = 6.25 V/0.625 V = 10
4. Part value 2 = 10

C: Selected job:
5. Job = Part value 1 (A) + Part value 2 (B)
Example
5. 160 (A) + 10 (B) = 170

IMPORTANT! Both analog input signals

• 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

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.

The “Touch sensing” signal can be used to indicate that the tungsten electrode has made contact with the workpiece (short-circuit between workpiece and electrode).

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 tungsten electrode (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).

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.

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

• “KD disable” not set = “KD enable”:
  internal control of the cold-wire feeder via the power source
• “KD disable” set:
  external control of the cold-wire feeder via the robot interface

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

• Wire feed
• Wire retract

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, 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, 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 current command value”.

0 V ........ Minimum welding current
10 V ...... Maximum welding current

The command value for “Welding current” cannot be entered while in Job mode.

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

A voltage of 0 - 10 V is specified for external parameter 1.

0 V ........ External parameter 1 - minimum value
10 V ...... External parameter 1 - maximum value

IMPORTANT! The power source operating instructions contain a much more detailed description of the external parameter, as well as the functions it can perform.

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

A voltage of 0 - 10 V is specified for the “Base current command value”.

0 V ........ Minimum base current
10 V ...... Maximum base current

Pin X5/1....... Analog in + 0 to + 10 V
Pin X5/8....... Analog in - (minus)

A voltage of 0 - 10 V is specified for the “Duty cycle command value”.

0 V ........ Minimum duty cycle
10 V ...... Maximum duty cycle

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

If a cold-wire feeder is being used: the “External parameter 2” analog input is currently only used to specify a value for the wirefeed speed.

A voltage of 0 - 10 V is specified for the wirefeed speed command value.

The following applies in each instance:
0 V ........ Minimum wirefeed speed
10 V ...... Maximum wirefeed speed

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.

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.

The “Process active” signal ensures optimum gas shielding

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

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

The following are defined in the power source setup menu:

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

The main current signal is set between the starting current and final current phases.

IMPORTANT! More information can be found in the power source operating instructions

Digital output signals „Process active“ and „Main current signal“

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

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 “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.

Pin X5/15.................... 24 V signal
Pin X7/2 or X12/2....... GND

The „High frequency active“ signal remains present as long as the high frequency is active.

Pin X5/16.................... 24 V signal
Pin X7/2 or X12/2....... GND

In pulse mode (f_Puls < 5 Hz) the „PULSE HIGH“ signal is active with every HIGH pulse.

„PULSE HIGH“ signal active

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

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)

The actual “welding voltage” value is indicated by a voltage of 0 - 10 V on the analog output

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

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

The actual “Welding current” value is indicated by a voltage of 0 - 10 V on the analog output

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

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

The actual “motor current” value is indicated by a voltage of 0 - 10 V on the analog output

• 1 V on the analog output corresponds to a motor current of 0.5 A
• Actual “motor current” range .... 0 - 5 A

IMPORTANT! The actual “Motor current” value provides information about the status of the wirefeed system.

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

The wirefeed speed is indicated by a voltage of 0 - 10 V on the analog output

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

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

The wirefeed speed passed to the control may differ from the real speed

• due to slip on the motor feed rollers

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

The Arc length analog output (AVC) is used for interfacing to an AVC device (automatic voltage control).

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 interfaces 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 interfaces 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.

Example of the most important analog and digital commands for controlling the power source using analog command values

• 0 - 10 V for welding current 1 and 2
• Selection of the process on the power source control panel

Reset error messages - ROB 4000:
In contrast to the ROB 5000/ROB 5000 OC, 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.

Example of the use of the ROB 5000 command set for controlling the power source using analog command values

• 0 - 10 V for welding current

Job selection via the robot:

The ROB 5000/ROB 5000 OC has the following additional digital functions

• Reset error
• Selection of process and operating mode from the robot
• “Touch sensing” function
• “Process active” and main current signals
• External parameters
• “Gas test”, “Wire feed”, “Wire retract”, “Command value switchover” 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.

Application example MODE 2 and QUICK STOP on ROB 5000 OC

Example of the most important analog and digital commands:

• Selection of process and operating mode from the robot
• Job selected via the robot
• 0 - 10 V for main current
• 0 - 10 V for external parameter 1
• 0 - 10 V for base current
• 0 - 10 V for duty cycle

Job selection via the robot:

The ROB 5000/ROB 5000 OC has the following additional digital functions

• Reset error
• “Touch sensing” function
• “Process active” signal
• „Gas test“, „Wire feed“, „Wire retract“ 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.

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/ROB 5000 OC, 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.