Welder operation sensor · current-draw detection · plug & play
BIOS-CT-01 – welding machine arc-on time sensor with no changes to the installation
A module plugged in between the power socket and the welder’s plug recognises from the current draw when the welder is actually working, and the data reaches your system via BIOS-IO-01 and the LAN.
- Non-invasive measurement: no interference with the welder’s controls, electronics or software
- Plug & play: adapter with a 5-pin three-phase connector up to 63 A between the power socket and the welder’s plug; self-installation, no electrician needed
- 4 detection thresholds: 3.02 A, 7.02 A, 10.54 A or 14.54 A – selected with DIP switches inside the module
- Real operating time: exceeding a defined current threshold means actual work (welding arc), not standby
- No additional power supply needed
- Works with BIOS-IO-01 (up to 4 CT-01 modules per IO-01) and with Scout MES
What is BIOS-CT-01?
BIOS-CT-01 is a sensor monitoring welding machine arc-on time: a measuring module that non-invasively detects the operation of welders and other equipment based on their current draw. The module is housed in a 5-pin three-phase connector rated up to 63 A and is plugged in as an adapter between the power socket and the welder’s plug – with no interference with its controls, electronics or software. Installation is simple and you can do it yourself, without an electrician.
The module automatically recognises when the welder starts and stops working. Exceeding a defined current threshold means actual work (welding arc), not just the machine’s standby state. The detection threshold is selected with DIP switches inside the module from four values: 3.02 A, 7.02 A, 10.54 A and 14.54 A. As a result, the system records real operating time based on physical energy use, without declared statuses or manual reporting.
BIOS-CT-01 has a cable that connects to an input of the BIOS-IO-01 module. Exceeding the threshold activates the BIOS-IO-01 input, and the module sends the information over the LAN, e.g. to Scout MES – see what welder operation monitoring in Scout MES looks like. One BIOS-IO-01 handles up to 4 BIOS-CT-01 modules. The module needs no additional power supply.
The manufacturer provides a two-year warranty on the device and post-warranty service for 10 years from the date the device is placed on the market.
It is the solution wherever other methods of integrating with a welder are impossible, expensive or not cost-effective.
BIOS-CT-01 specifications
| Parameter | Value |
|---|---|
| Function | current-draw detection (detecting equipment operation) |
| Detection thresholds | 3.02 A / 7.02 A / 10.54 A / 14.54 A – selected with DIP switches inside the module |
| Connector | three-phase, 5-pin, up to 63 A (socket–plug adapter) |
| Enclosure dimensions (63 A version) | 237 × 104 × 74 mm |
| Connection to BIOS-IO-01 | cable to a module input |
| Installation | plug & play, between the power supply and the equipment; self-installation, no electrician needed |
| Power supply | no additional power supply needed |
| Compatibility | BIOS-IO-01 (up to 4 BIOS-CT-01 per module) |
| Integration | via BIOS-IO-01 and the LAN, e.g. Scout MES |
| Warranty | 2 years; post-warranty service for 10 years from market launch |
BIOS-CT-01 photos
Where to use BIOS-CT-01 and how to connect it?
- monitoring the real operating time of welders,
- monitoring other three-phase equipment whose operation shows in its current draw,
- machines where integration with their controls is impossible or not worthwhile.
Connection
- Set the detection threshold with the DIP switches inside the module.
- Plug BIOS-CT-01 in between the power socket and the welder’s plug.
- Connect the BIOS-CT-01 cable to an input of the BIOS-IO-01 module (up to 4 CT-01 modules per IO-01).
- Connect BIOS-IO-01 to the LAN – the data goes to Scout MES or another system.
How does BIOS-CT-01 work?
- Plug & play – the module is plugged in as an adapter between the socket and the welder’s plug.
- Load detection – the module automatically detects the current draw.
- Operating threshold – exceeding the threshold set with the DIP switches (3.02 / 7.02 / 10.54 / 14.54 A) means actual work (arc), not standby.
- Signal to BIOS-IO-01 – exceeding the threshold activates the input; the concentrating module collects signals from up to 4 CT-01 modules.
- LAN → system – BIOS-IO-01 sends the data over the LAN, e.g. to Scout MES, which records the real operating time.
Downloads
Frequently asked questions about BIOS-CT-01
BIOS-CT-01 is a welding machine run sensor: a measuring module that recognises from the current draw when a welder or other equipment is actually working.
Just plug BIOS-CT-01 in between the power socket and the welder’s plug and connect it to a BIOS-IO-01 module. The system then records the real operating time based on current draw, without manual reporting.
No. The module is plugged in between the power socket and the welder’s plug, with no changes to the machine’s controls, electronics or software.
Exceeding the current threshold means actual work (welding arc), not just standby.
Four: 3.02 A, 7.02 A, 10.54 A or 14.54 A. The threshold is selected with DIP switches inside the module.
Three-phase, 5-pin, up to 63 A. The module is plugged in as an adapter between the socket and the equipment’s plug.
No. You can install the module yourself.
It needs no additional power supply.
With the BIOS-IO-01 module. The CT-01 cable connects to an input of BIOS-IO-01, which sends the data over the LAN. One BIOS-IO-01 handles up to 4 BIOS-CT-01 modules.
Yes. Data from the module goes via BIOS-IO-01 to Scout MES, which records the real operating time of welders.
Yes, the module is also suitable for other three-phase equipment whose operation shows in its current draw.
Request a quote
Want to monitor welder operation without modifying the machines? Write or call us and we will select the right solution and prepare a quote.
Phone: +48 880 366 728 · E-mail: info@bios-iot.com
Manufacturer: INTSOL sp. z o.o., ul. Radarowa 60, 02-137 Warszawa