This page describes how to integrate and set up communication between GYS Neopulse power sources and SmoothTool X.
Hardware Configuration
SmoothTool X is compatible with the GYS Neopulse series of MIG/MAG pulse power sources. To set up communication between the software and a power source, the following items are required:
- One of the compatible GYS power source models:
- GYS Neopulse 320 C
- GYS Neopulse 400 CW
- GYS Neopulse 400 G
- GYS Neopulse 500 G
- If in doubt, contact your local GYS supplier or the Smooth Robotics team.
- A Smart Automation Module (SAM-1N) from GYS, fitted with an Anybus EtherNet/IP communication module (GYS ref. 062078). The robot does not talk to the Neopulse directly — all communication goes through the SAM-1N.
- DB9 cable from the power source to the SAM-1N.
- Ethernet RJ45 cable from the SAM-1N to the robot.
Note
All four Neopulse models are driven through the same integration and share the same parameters and value ranges. Pick the tile that matches the machine in your cell; the difference is only in the name shown in SmoothTool X.
Installing the modules
If the machine does not already have them, fit the two modules before wiring anything:
- Install the SAM-1N module for your Neopulse model, following the SAM-1N installation manual.
- Install the Anybus EtherNet/IP communication module (ref. 062078) in the SAM-1N, as described in section 4 B), Mounting the Anybus communication module, of the same manual.
Then connect the power source to the SAM-1N with the DB9 cable, following section 4 D), Module wiring between GYS welding machine and SAM-1N module, of the SAM-1N installation manual. Connect the SAM-1N to the robot with the Ethernet cable.
Mode of operation
Two DIP switches behind the SAM-1N’s cover set how the module exposes the machine’s parameters:
- S3 — set to ON (down). This enables access to the generator parameters.
- S4 — set to OFF (up). S4 is only active when S3 is ON.
IP Address
SmoothTool X communicates with the Neopulse over the EtherNet/IP protocol. Select a valid IP address for the SAM-1N. The address must be on the same subnet as the robot.
GYS documents three ways to set it, described in full in SAM-1N IP address setup:
-
The encoder wheel — the wheel behind the SAM-1N’s cover sets the last byte of a fixed default address. Setting it to 8 gives the module 192.168.0.8, with subnet mask 255.255.255.0 and DHCP off. Setting it to 0 gives 0.0.0.0.
-
The HMS IPconfig utility — connect a computer to the SAM-1N, refresh the device list, select the SAM-1N, and set the IP address, gateway and subnet mask, then click Apply.
-
The module’s web page — browse to the SAM-1N’s current IP address and open the Configuration page. Set DHCP to Disabled and fill in at least IP Address and Subnet Mask, then click Save Settings.
Whichever method is used, the SAM-1N must be restarted for the new address to take effect.
Note
The robot itself must also have an IP address on that subnet. If the robot network is not configured yet, SmoothTool X prompts you to set it up when you save the power source.
Software Configuration
Once the hardware is configured, add and connect the GYS Neopulse in SmoothTool X.
Add the GYS Neopulse
Tap SmoothTool X Settings from the Application view. In the sidebar, under Components, tap Power Sources, then tap Add new power source.
In the Add power source dialog, select the GYS tile and choose your model — GYS Neopulse 320 C, GYS Neopulse 400 CW, GYS Neopulse 400 G, or GYS Neopulse 500 G — then tap Add power source.
Configure the GYS Neopulse
Fill in the configuration fields:
| Field | Description |
|---|---|
| Custom name | A name to identify this power source. |
| Power source IP address | The IP address you set for the power source interface. The robot uses this address to communicate with the power source. Ensure it is set correctly; otherwise the robot cannot connect. |
| No. wire feeder | Which wire feed unit the machine drives — 1 or 2. This is the unit’s designation on the machine, not a count of the units fitted. |
| Manage welding using | Whether the machine is driven by Wire feed speed (default) or by Current. This also decides the unit of the weld value in the program nodes — see Manage welding using below. |
| Cooling method | Cooling unit command — Off, On, or Auto (default). |
| Default job number | The job the machine is set to when SmoothTool X connects, before any program node overrides it. Must be between 1 and 500. |
| Configure parameters in the software | Controls whether program nodes override the power source parameters at runtime — see Configure parameters in the software below. |
When done, tap Done to save the power source.
Note
No. wire feeder, Manage welding using, Cooling method, and Default job number describe the welding cell itself, so they are sent to the machine whenever SmoothTool X connects — regardless of the Configure parameters in the software setting. If you change any of them while the power source is connected, the new values are sent immediately.
Caution
Set No. wire feeder and Cooling method to match the machine. A value the Neopulse rejects is reported back as a power source error instead of a successful connection.
Manage welding using
The Manage welding using setting decides which value the machine is driven by, and therefore what the weld value in a program node means:
- Wire feed speed (default) — the weld value in a program node is a Voltage correction, in volts (V).
- Current — the weld value in a program node is a Current correction, in amps (A).
The field in the program node changes its label and unit to match, so check this setting before entering weld values.
Configure parameters in the software
The Configure parameters in the software toggle controls how welding parameters are applied:
- Disabled (default) — the power source keeps the parameters set on the machine; program nodes do not override them.
- Enabled — program nodes override the power source parameters at runtime, letting you set welding parameters per node from the weld node’s Power source tab.
Connect to the GYS Neopulse
Back on the Power Sources page, expand the new entry, tap Selected to make it the active power source, then tap Connect. When the connection is established, a connection status tag is shown on the entry.
Programming with SmoothTool X and GYS Neopulse
When Configure parameters in the software is enabled, you can adjust the welding parameters per node from the program tree.
Select a weld node (e.g. Weld Seam) in the program tree and open its Power source tab. The parameters apply when the program reaches that node.
The node selects a job stored on the power source, and can optionally apply corrections on top of that job.
| Identifier | Description |
|---|---|
| Job number | The job stored on the power source that this node runs. Between 1 and 500. |
| Fine tuning | Applies the values below as offsets on top of the machine’s job. While fine tuning is off, the machine keeps the job’s own settings and the fields below are inactive. |
| Voltage or Current | (Fine tuning only) Correction applied to the job’s welding voltage (V) or current (A), depending on the Manage welding using setting of the power source. |
| Wire feed speed | (Fine tuning only) Correction applied to the job’s wire feed speed, in m/min. |
| Arc length | (Fine tuning only) Correction applied to the job’s arc length, in volts (V). |
| Inductance | (Fine tuning only) Correction applied to the job’s inductance. |
| Transfer parameters | Sends the current parameters to the power source. Available once connected. |
Note
The fine-tuning values are corrections, not absolute settings, so they can be negative as well as positive. With Fine tuning off they are not sent to the machine at all.
Manual power source controls
The manual controls live in the Power source popover, opened from the button in the operator screen toolbar.
When connected to the GYS Neopulse, the following manual controls are available:
| Control | Description |
|---|---|
| Forward | Feeds the welding wire forward. |
| Gas | Opens the gas valve for the duration of the press. |
| Error reset | Sends a reset-error signal to the power source. |
| Release panel | Hands control of the machine’s own front panel back to the operator. |
Note
While SmoothTool X drives the Neopulse, the machine is held in robot mode and its front panel is locked. Tap Release panel to operate the machine directly. It is a one-shot action, not a switch: the panel is locked again the next time SmoothTool X sends anything to the power source — a manual control, a parameter transfer, or a program run.
Warning
Connected to a power source that provides the option to control the wire. Do not use these functions without ensuring no harm can come to people or material. Make sure the area around the welding torch is clear before use.
Simulation
The Simulation toggle at the top of the popover runs the program as a dry run: the robot executes the full program and motion path, but the power source does not weld (no arc, wire feed, or gas). Use it to test a program safely, then turn it off to weld for real.