Fronius TPS 320i Applications Manual
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Fronius TPS 320i Applications Manual

Fronius TPS 320i Applications Manual

With ri-fb inside/i interface, by abb
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ROBOTICS
Application manual
Fronius TPS 320i/400i/500i/600i with
RI-FB inside/i interface

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Summary of Contents for Fronius TPS 320i

  • Page 1 ROBOTICS Application manual Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface...
  • Page 2 Trace back information: Workspace Main version a564 Checked in 2024-02-07 Skribenta version 5.5.019...
  • Page 3 Application manual Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface Fronius for OmniCore Document ID: 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damage to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Adding or removing synergic lines from RobotStudio ..........Torch Collision RAPID reference Instructions ...................... 7.1.1 FroniusDataChannel - send data to the power source ........ Index Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
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  • Page 7: Overview Of This Manual

    Overview of this manual Overview of this manual About this manual This manual describes the options Fronius TPS/i interface and Weld editor and contains instructions to configure it. This manual should be read before installing and commissioning of a Robotic Arc Welding system with a Fronius TPS/i power source.
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  • Page 9: Introduction To Fronius Tps/I Interface

    Firmware 2.3.0 or above is needed for Job mode with correction. Overview The MIG/MAG power sources TPS 320i, TPS 400i, TPS 500i and TPS 600i are completely digitized, microprocessor-controlled inverter power sources. The modular design and potential for system add-ons ensure a high degree of flexibility.
  • Page 10 The advantages of the CMT process are as follows: • Low heat input • Less spattering • Reduced emissions • High process stability Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 11: Installation

    The Fronius TPS/i web browser interface is a licensed option from Fronius. To be able to connect to the Fronius TPSi Welder via the web browser interface in the RobotStudio Add-in, this option is needed. Contact Fronius for more information regarding this.

  • Page 12: Hardware Setup

    Switches and routers are then able to differentiate the I/O devices critical from the other non-critical traffic. To do this, the switches and routers must support Quality of Service. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 13 Connect an Ethernet cable between the robot controller X4 port and the TPS/i welder Ethernet port. The following illustration shows an overview of the computer unit. xx2300001963 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 14 The IP address of the welder can be changed on the front panel with the following steps: 1 Go to Defaults, System and select Network settings. xx1900002383 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 15 Network mask and Standard gateway network parameters are greyed out and cannot be adjusted. In order to change the IP address, DHCP must be disabled. xx1900002384 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 16: Configure The Fieldbus

    This section describes how to configure the communication between the ABB robot controller and the Fronius E/IP power supply. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 17: Installation

    • 2 Ethernet cables Software installation The Fronius TPSi RobotStudio Add-In is available for free and can be downloaded from the RobotStudio Add-Ins Tab (Common tags: RobotStudio-Addin) and install Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A...

  • Page 18: Fronius Power Supply Settings

    2.3.1.2.1 Changing the Fronius power supply network settings Change the network settings Follow these steps to change the Fronius power supply network settings: 1 On the Fronius power supply touch screen, tap Defaults and then select the System tab. Select Network settings: xx2100000469 2 In the Network settings menu, clear the DHCP check box to enable editing of the menu items.
  • Page 19 Continued 3 In field IP address, enter the IP address to be used. Note If you access the Fronius webpage through the ABB service port, set the IP address to 192.168.125.65. 4 Tap Store to save the new settings. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A ©...
  • Page 20 2 From a web browser address bar, enter the defined IP address (for example 192.168.125.65). 3 In the Fronius TPS/i browser, log on to the system using the default username "admin" and default password "admin". xx2100000471 4 In the Fronius web browser, select tab RI FB INSIDE/i.
  • Page 21 OK to confirm the changes. as needed or use the default "Factory" settings. • Select Restore factory settings and to use the default factory settings. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 22: Robot Controller Configuration

    3 In the Configuration – I/O System window, select EtherNet/IP Device and select the the Fronius power supply to be configured. xx2100000474 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 23 2 Installation 2.3.1.3.1 Changing the robot communication settings Continued 4 In the Instance Editor, enter the Address (192.168.125.160) for the Fronius EtherNet/IP device and select OK. xx2100000475 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A ©...
  • Page 24 Continued 5 In the Instance Editor, set the Service Port IP to 192.168.125.165 and select xx2100000476 6 Restart the controller. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 25 2.3.1.3.2 Accessing the Fronius service port from ABB controller 2.3.1.3.2 Accessing the Fronius service port from ABB controller Accessing the Fronius service port Follow these steps to access the Fronius web page from the OmniCore X4 port: xx2100000478 1 Define the Fronius network settings (192.168.125.165), see...

  • Page 26: Fronius Profinet Configuration

    This information is valid if PROFINET is selected in the fieldbus selection in the Modify Installation dialog. The Fronius TPS/I Add-in Fronius TPS/I for OmniCore will provide a pre-defined ProfiNet configuration. The welder should be connected to the I/O Network (LAN port, X4).
  • Page 27 ProfiNet network. This is done in the IO Engineering tool. Open IO Engineering and right-click on PROFINET. xx2300001968 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 28 Welder IP address Station name System name 192.168.0.2 iofroniustpsi1 ioFroniusTPSi1 192.168.0.3 iofroniustpsi2 ioFroniusTPSi4 192.168.0.4 iofroniustpsi3 ioFroniusTPSi3 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 29 2 Installation 2.3.2 Fronius PROFINET configuration Continued xx2300001967 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 30: Fronius Tps/I Package

    2.4 Fronius TPS/i package 2.4 Fronius TPS/i package Downloading of Fronius TPS/i package 1 Download and install the Fronius TPS/i package from the Add-Ins tab in Robotstudio. (Common tags: RobotWare-Addin). Start the Modify Installation dialog and modify your robot system.

  • Page 31: System Parameters

    Overview The Fronius Equipment Class and settings are automatically activated after the controller is booted with the TPS/i Add-in. This option has advanced support for the Fronius TPS 320i/400i/500i/600i power source that includes support for the following welding modes: •...
  • Page 32 Override On bool Specifies the visibility of the org value compon- ents in welddata. Default value: TRUE Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 33 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 34 Digital output signal for indication of wire feed errors. A high signal means that an error has oc- curred. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 35 Job number to be used in Job Mode and Job Mode with Correction. ModePort GO signalgo Work mode selection. Error Code GI signalgi Error code indication. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 36: Units

    At the bottom of the Fronius TPSi RS Add-in xx1900002387 • In the Process Configuration xx1900002388 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 37 If the unit type should be changed, change it on all these places. Example: Change from Metric to Imperial units. xx1900002391 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 38 RobotStudio Add-in. The reason for that is that the RAPID file which is created during the WeldMode search, is stored with unit information. xx1900002394 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 39: Best Practice

    5 Transfer the data to the controller. 6 Create a weld program. 7 Step through the program and use the Fronius weld editor to edit/tune the data. 8 Run the program and watch the run-time data in the weld info widget.
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  • Page 41: Fronius Interface Modes

    3 Fronius interface modes 3.1 Overview Interface modes Currently the Fronius TPS/i welder interface has support for the following modes, that will be customized by selecting the mode in system parameters. Note A warm-start is mandatory if the modes are changed.
  • Page 42 3 Fronius interface modes 3.1 Overview Continued The configuration editor in RobotStudio xx2300001962 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 43: Setting Up Limits In Job Mode With Correction

    This can be done either via the Welder display or via the Web interface. Job mode with correction limits via the welder display xx1900002402 xx1900002403 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 44 3.2 Setting up limits in job mode with correction Continued Job mode with correction limits via the web interface xx1900002400 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 45: Weldeditor

    Synergic Line number or Job number. Starting the WeldEditor The WeldEditor can be started from the home tab on the FlexPendant. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 46: Weld Editor In Program Mode

    The time (in seconds) it takes to pre-flow the weld object with protective gas, also called gas pre-flow. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 47 To copy the current weld phase mode settings, toggle Use Weld Phase Mode off, on, and then off again. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 48 MIG/MAG LSC welding processes (-10% = pulse-/dynamic correction, 0% = value from line, +10% = pulse-/dynamic correction) Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 49 MIG/MAG LSC welding processes. (-10% = pulse-/dynamic correction, 0% = value from line, +10% = pulse-/dynamic correction) Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 50 MIG/MAG PMC and MIG/MAG LSC welding processes. The value can be applied between 0 – 10 mm. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 51 \Weave must be used with the arc instructions to weave. For more information, see Application manual - ArcWare for OmniCore. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 52 Orientation The weave orientation angle, horizontal-vertical to the seam. An angle of zero degrees results in symmetrical weaving. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 53: Weld Editor In Job Mode

    The time (in seconds) it takes to pre-flow the weld object with protective gas, also called gas pre-flow. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 54 To copy the current weld phase mode settings, toggle Use Weld Phase Mode off, on, and then off again. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 55 Tap the Weld tab to view or modify heat phase parameters. Note The weld phase parameters can only be modified in manual mode. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 56 To copy the current weld phase mode settings, toggle Use Weld Phase Mode off, on, and then off again. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 57 MIG/MAG Standard Synergic • MIG/MAG PMC • MIG/MAG LSC • MIG/MAG Standard Manual • Electrode • Weave parameters Weave parameters on page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 58: Weld Editor In Job Mode With Correction

    The time (in seconds) it takes to pre-flow the weld object with protective gas, also called gas pre-flow. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 59 To copy the current weld phase mode settings, toggle Use Weld Phase Mode off, on, and then off again. xx2300001980 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 60 Tap the Weld tab to view or modify heat phase parameters. Note The weld phase parameters can only be modified in manual mode. xx2300001981 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 61 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 62 In this mode, the Arc Length Correction can be adjusted in the range of +/- 10 steps in 0.1 increments. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 63: Weld Parameters

    ArcLength Correction (+-10 steps) Weave parameters that can be tuned in all modes: • Length • Width • Height • Bias Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
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  • Page 65: The Fronius Tps/I Robotstudio Add-In

    The FroniusTPS/i RobotStudio Add-In does not require a RobotStudio license. The add-in will be automatically installed with the TPS/i package which can be downloaded in the add-in section in RobotStudio. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 66: Overview Of The Fronius Tps/I Add-In

    Note The Fronius TPS/i add-in is used to select the weld modes to be used in the robot from among the many weld modes available in the welder. This simplifies choosing weld modes for the user and allows engineering staff to select only the weld modes they want the user to use.
  • Page 67 (Standard, Pulse, LSC, PMC and CMT). In addition, filters for Gas Type, Wire Size, Wire Type and Characteristic can be applied. xx1900002431 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 68 Auto Update Controller is not checked. (Update must be done by clicking Update Controller). Apply the settings. Cancel Cancel the settings. Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 69 PC. These are the files that will be transferred to the controller. xx1900002430 Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 70 C:\Users\XXXXXXXX\Documents\RobotStudio\FroniusTPSiUtility\Systemname\ SynergicLines\T_ROB1 If the files are copied, you can start selecting the weld modes and download them to the controller. Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 71: Adding Or Removing Synergic Lines From Robotstudio

    Synergic lines can be edited from the Add-Ins window in RobotStudio. 1 In the Add-Ins window, open the Fronius Add-in window: xx2100000480 2 In the Fronius Add-in window, select the Settings to be used, such as Metric, Imperial, EN standard (European standards) or AWS standard. Continues on next page...
  • Page 72 5 The Fronius TPS/i RobotStudio Add-In 5.3 Adding or removing synergic lines from RobotStudio Continued 3 In the Fronius Add-in window, click Search weld modes. The Fronius Weld Mode Search window is displayed: xx2100000479 4 In section Weld Mode Search Criteria, define the welding parameters (wire size, gas, wire type) and process (CV, Pulse, PMC) upon which the search should be based.

  • Page 73: Torch Collision

    6 Torch Collision General The Fronius TPS/i Add-In provides a feature for torch collision supervision by using a collision switch. A digital input (high active if no collision) is monitored and in case of a torch collision the program execution is stopped, and motors are turned off.
  • Page 74 110351 The collision switch got activated momentarily in auto mode Warning but is no longer active Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.

  • Page 75: Rapid Reference

    Communication to the power source is done via TCP on port number 4714. To establish a connection the firewall manager must allow RapidSockets on the network. IP Setting The IP address can be changed in the Process configuration type Fronius TPS/i Arc Equipment Properties. xx2300001984 Continues on next page...
  • Page 76 ArcL Location14,v100,sm11,wd_5 \Weave:=wv111,z5,tWeldGun; ArcL Location15,v100,sm11,wd_6 \Weave:=wv111,z5,tWeldGun; ArcLEnd Location20,v100, sm11, wd_3, fine, tWeldGun; MoveL Location10, v500,fine,tWeldGun; ENDPROC Continues on next page Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 77 7 RAPID reference 7.1.1 FroniusDataChannel - send data to the power source Continued Fronius Smart Manager example xx2300001985 xx2300001986 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
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  • Page 79: Index

    Fronius TPS/i Add-In, 65 references, 7 hardware, 12 PROFINET, 26 interface modes, 41 system parameters, 31 limitations, 11 WeldEditor, 45 Application manual - Fronius TPS 320i/400i/500i/600i with RI-FB inside/i interface 3HAC089028-001 Revision: A © Copyright 2004-2024 ABB. All rights reserved.
  • Page 82 ABB AB Robotics & Discrete Automation S-721 68 VÄSTERÅS, Sweden Telephone +46 10-732 50 00 ABB AS Robotics & Discrete Automation Nordlysvegen 7, N-4340 BRYNE, Norway Box 265, N-4349 BRYNE, Norway Telephone: +47 22 87 2000 ABB Engineering (Shanghai) Ltd. Robotics &...

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