YASKAWA MOTOMAN DX100 Instruction Manual
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YASKAWA MOTOMAN DX100 Instruction Manual

YASKAWA MOTOMAN DX100 Instruction Manual

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MOTOMAN DX100 CONTROLLER
WITH ROBOTIC ARC WELDING
INSTRUCTIONS
®
FOR MILLER
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MANIPULATOR INSTRUCTIONS
MOTOMAN OPERATORS MANUAL FOR ARC WELDING
MOTOMAN CONCURRENT I/O MANUAL
DX100 CONTROLLER MANUAL
DX100 MAINTENANCE MANUAL
The operator's manual above corresponds to specific usage. Be sure to use the appropriate manual.
Vendor manuals for system components not manufactured by Motoman
AUTO-AXCESS DI/E DIGITAL
Part Number:
166465-1CD
Revision:
1
1/56

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  • Page 1 MOTOMAN DX100 CONTROLLER WITH ROBOTIC ARC WELDING INSTRUCTIONS ® FOR MILLER AUTO-AXCESS DI/E DIGITAL Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN-MANIPULATOR INSTRUCTIONS MOTOMAN OPERATORS MANUAL FOR ARC WELDING...
  • Page 2 If such modification is made, the manual number will also be revised. • If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.
  • Page 3 Auto-Axcess DI/E Digital Notes for Safe Operation Read this manual carefully before installation, operation, maintenance, or inspection of the Yaskawa Motoman robot. In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”. Indicates a potentially hazardous...
  • Page 4 166465-1CD Auto-Axcess DI/E Digital WARNING • Before operating the manipulator, check that servo power is turned OFF by pressing the emergency stop button on the programming pendant. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is OFF.
  • Page 5 166465-1CD Auto-Axcess DI/E Digital WARNING • Since detected voltage (200V), welding current, and welding voltage are applied to the starting point detecting unit, install the unit securely so that it does not fall. • Failure to observe this warning may result in an electric shock or damage to the unit.
  • Page 6 Read and understand the Explanation of Warning Labels in the DX100 Instructions before operating the manipulator. Definition of Terms Used Often in This Manual The Yaskawa Motoman manipulator is an industrial robot product. The manipulator usually consists of the controller, the programming pendant, and supply cables.
  • Page 7 166465-1CD Auto-Axcess DI/E Digital Descriptions of the programming pendant, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters Pendant printed on them are denoted with [ ]. ex. [ENTER] Symbol Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small...

  • Page 8: Table Of Contents

    166645-1CD Auto-Axcess DI/E Digital Table of Contents Table of Contents 1 Introduction ............................. 1-1 1.1 About This Document ......................1-1 1.2 System Configuration......................1-2 1.2.1 Major Components ....................1-3 1.3 Reference Documentation ....................1-3 1.4 Customer Support Information................... 1-4 2 Safety .............................. 2-1 2.1 Introduction ........................
  • Page 9 166645-1CD Auto-Axcess DI/E Digital Table of Contents 4 Theory of Operation ........................4-1 4.1 Miller HMI........................... 4-2 4.2 Pulse Mode........................4-3 5 Operation ............................5-1 5.1 Set-Up Overview........................ 5-1 5.1.1 Welder Condition File ................... 5-1 5.1.2 Arc Start Files ....................... 5-2 5.1.3 Arc End Files ......................

  • Page 10: Introduction

    Introduction 1.1 About This Document Introduction About This Document This manual provides information about a Yaskawa Motoman's robotic arc ® welding system using the Miller Auto-Axcess DI/E Digital power sources. The use of this manual is for welding personnel who have received operator training from Yaskawa Motoman, and are familiar with the operation of their Yaskawa Motoman robot.

  • Page 11: System Configuration

    166465-1CD Auto-Axcess DI/E Digital Introduction 1.2 System Configuration System Configuration The Auto-Axcess DI/E Digital arc welding system is an integrated package of tools and components designed for specific welding requirements. A typical system includes the following components and optional equipment. Fig.

  • Page 12: Major Components

    • Yaskawa Motoman Operator's Manual for Arc Welding (P/N 155490-1CD) • Yaskawa Motoman Concurrent I/O Manual (P/N 155491-1CD) • Yaskawa Motoman DX100 Operators Manual (P/N 155494-1CD) • Yaskawa Motoman DX100 Maintenance Manual (P/N 155492-1CD) • DX100 Independent/Coordinated Control Manual (P/N 156431-1CD) •...

  • Page 13: Customer Support Information

    Digital system, please contact Yaskawa Motoman Customer Support at the following 24-hour telephone number: (937) 847-3200 For routine technical inquiries, you can also contact Yaskawa Motoman Customer Support at the following e-mail address: techsupport@motoman.com When using e-mail to contact Yaskawa Motoman Customer Support, please provide a detailed description of your issue, along with complete contact information.

  • Page 14: Safety

    166465-1CD Auto-Axcess DI/E Digital Safety 2.1 Introduction Safety Introduction The purchaser is responsible for following all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation. We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA R15.06-2012).

  • Page 15: Important Advisory Information

    166465-1CD Auto-Axcess DI/E Digital Safety 2.2 Important Advisory Information Important Advisory Information In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”. Indicates a potentially hazardous WARNING situation which, if not avoided, could result in death or serious injury to personnel.

  • Page 16: Mechanical Safety Devices

    166465-1CD Auto-Axcess DI/E Digital Safety 2.4 Mechanical Safety Devices Mechanical Safety Devices The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The user should review the conditions for safe operations of the equipment. The user must be aware of the various national codes, ANSI/RIA R15.06-2012 safety standards, and other local codes that may pertain to the installation and use of industrial equipment.

  • Page 17: Programming, Operation, And Maintenance Safety

    166465-1CD Auto-Axcess DI/E Digital Safety 2.6 Programming, Operation, and Maintenance Safety Programming, Operation, and Maintenance Safety All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. Improper operation can result in personal injury and/or damage to the equipment.
  • Page 18 166465-1CD Auto-Axcess DI/E Digital Safety 2.6 Programming, Operation, and Maintenance Safety • Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual. • Use proper replacement parts. • Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

  • Page 19: Equipment Description

    166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.1 Robot and Controller Equipment Description ® This chapter contains brief descriptions of The Miller Auto-Axcess DI/E Digital welding system components. Robot and Controller The robot controller coordinates the operation of the various welding system components.

  • Page 20: Software

    Accu-Pulse, standard or adaptive pulse, Accu-Speed, Accu-Curce, conventional MIG, and RMD (included free-of charge on Auto-Axcess E Digital machines.) The standard Yaskawa interface provides an array of functionality including allowing the user to customize the arc starting and ending timing.

  • Page 21: Starting The Hmi Software

    Interface (HMI) application is loaded onto the DX100 programming pendant. This screen configures the system for the number of welders, type of communication, addressing, and passwords being used. NOTE This screen is usually set up by Yaskawa Motoman. 166465-1CD 21/56...
  • Page 22 166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software Fig. 3-3: Welcome Screen 1. Number of Welders: Enter the number of welders attached to the system (1- 4). 2. Manager Password: Factory Default is 99999999 (eight 9’s). Enter the password (up to eight characters) for management rights.

  • Page 23: Home Screen

    166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software 3.5.3 Home Screen The Home Screen (Fig. 3-4) will take you to the various applications shown on each button. These screens are described in more detail later. Fig. 3-4: Home Screen 1.
  • Page 24 166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software Fig. 3-5: Program Selection Screen 1. View data for: If more than one welder is connected to the system, select the welder you wish to view. 2. Program 1, 2, 3, 4, 5, 6, 7, 8: Select the required welding program. Only those programs that are used need to the configured.

  • Page 25: Program Sequence Setup Screen

    Digital. Pre-Flow, Run-in WFS, and Start power begin with an Arcon command. Crater Fill, Retract and Post flow start NOTE when the Arcoff command is issued. Yaskawa Motoman recommends the welding sequencing be done in AcrStart Files to ensure timing is coordinated with the robot motion.
  • Page 26 166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software 4. Pre-Flow: Sets the shielding gas pre-flow time. If enabled, the gas will come on for the specified length of time before the wire will start to feed. This will add cycle time at the Arc Start.

  • Page 27: Live Weld Data Screen

    166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software 3.5.6 Live Weld Data Screen The Live Weld Data screen (Fig. 3-7) displays Voltage, Current, Wire Feed Speed (WFS), Travel Speed , and Heat Input . It also displays the status (On/Off) of the wire feeder, gas solenoid, and weld contactor.

  • Page 28: To Modify Or Add A Welder

    166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software 9. Gas: Red=Gas solenoid off. Green=Gas solenoid on. 10. Contactor: Red=welder in standby. Green=Gun Switch is on. 11. View All Welders: Displays the Viewing Weld Data for All Welders screen () on top of the Live Weld Data screen.

  • Page 29: Error Preferences

    These errors are global within the Auto-Axcess DI/E Digital. They affect all eight weld programs. The Yaskawa/Miller interface includes a mapping of Miller error codes into the DX100 controller. Welder errors will generate a user alarm on the robot with the error message displayed. Welder alarm history can be viewed under user alarms (see chapter 5.4 “Troubleshooting”...

  • Page 30: Lock/Unlock Editing

    166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software Fig. 3-10: Error preference Screen 3.5.9 Lock/Unlock Editing The Lock/Unlock Editing screen (Fig. 3-11) is used to set various levels of security and lock the Miller Auto-Axcess DI front panel. Fig.

  • Page 31: Backup & Load Settings

    166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software 1. Operator Mode Change: This button toggles the HMI between the Operator/Manager Mode - The default setting is “Operator Mode”. In the Operator Mode, all the screens can be viewed, but the “Save” buttons are disabled and no data can be changed.
  • Page 32 166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software Fig. 3-12: Backup & Load Setting Screen 3.5.10.1 To Backup Settings 1. Memory Card Selection: Select when the Backup is to stored on either a CF or a USB. 2.
  • Page 33 166465-1CD Auto-Axcess DI/E Digital Equipment Description 3.5 Miller-Motoman Pendant Interface (HMI) Software 9. Copy INI to CF/USB: To backup the INI file, insert a memory card and touch this button. This creates a copy of the INI file on the memory card.

  • Page 34: Theory Of Operation

    166465-1CD Auto-Axcess DI/E Digital Theory of Operation Theory of Operation The Auto-Axcess is a Gas Metal Arc Welding (GMAW) power supply capable of non-pulsed, or MIG, and pulsed (GMAW-P) modes of operation. The DX100 utilizes a DeviceNet interface to the Auto-Axcess. This interface provides two basic levels of controls: •...

  • Page 35: Miller Hmi

    166465-1CD Auto-Axcess DI/E Digital Theory of Operation 4.1 Miller HMI Auto-Axcess has 8 program locations for different process settings. The process can be changed between welds or even during welding by setting I/O commands in the robot program to select a different program. There are 3 outputs from the robot to the welder for selecting schedules.

  • Page 36: Pulse Mode

    166465-1CD Auto-Axcess DI/E Digital Theory of Operation 4.2 Pulse Mode Auto-Axcess functions as a Master on the DeviceNet network. The robot is a slave and other devices should not be connected to this network, unless they are for monitoring purposes. The digital interface utilizes a total of 9 bytes and would have been addressed by Motoman for your exact cell configuration.

  • Page 37: Operation

    • Verifying the welder calibration • Selecting weld programs 5.1.1 Welder Condition File The Welder Condition file is set as follows (this has been preset by Yaskawa Motoman): POWER SUPPLY: A/V Table 5-1: Welder Output <CURRENT OUTPUT <WELDING VOLTAGE OUTPUT>...

  • Page 38: Arc Start Files

    166465-1CD Auto-Axcess DI/E Digital Operation 5.1 Set-Up Overview 5.1.2 Arc Start Files VOLTAGE: In the welding modes that require an Arc Length value (Pulse, Accupulse, . . .) the Voltage parameter is set to 1/2 the required setting. That is: Arc Length = 2 X Voltage Setting Example: Arc Length value required is 50...

  • Page 39: Calibration Verification

    166465-1CD Auto-Axcess DI/E Digital Operation 5.1 Set-Up Overview 5.1.4 Calibration Verification The Digital Interface uses direct settings, no special NOTE procedures like AutoCal are required. To verify power supply calibration: 1. Insert an ARCSET command into a job. 2. Select the ARCSET command from the instruction side of the job line. 3.

  • Page 40: Selecting Weld Programs

    166465-1CD Auto-Axcess DI/E Digital Operation 5.1 Set-Up Overview 5.1.5 Selecting Weld Programs Eight separate weld programs can be defined for the Miller Auto-Axcess DI. Each program can be configured for weld mode (MIG, Pulse, AccuPulse, Accu-Speed, Accu-Curve, RMD), wire type (Steel, Aluminium, etc.), diameter, and shield gas type.

  • Page 41: Robot Job Programming

    166465-1CD Auto-Axcess DI/E Digital Operation 5.2 Robot Job Programming Table 5-3: Universal Outputs Auto Universal Outputs Axcess OGH#(12) OUT#0045 OUT#0046 OUT#0047 Program# Robot Job Programming 5.2.1 Weld Program Selection The robot selects one of the eight weld programs by setting three outputs. Typically a binary value (0-7), referenced by a DOUT instruction, is programmed into the robot job.

  • Page 42: Troubleshooting

    Unknown Error, and the Miller Auto-Axcess must be checked to determine the exact error. For other service related problems, call Yaskawa Motoman Customer Service (937) 847-3200. The following is a list of User Alarms and messages displayed for welder #1 on the programming pendant.

  • Page 43: Miller Auto-Axcess E Digital

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.1 Setting Proportional Speed Instruction Miller Auto-Axcess E Digital The Miller Auto-Axcess welder combines the Miller Auto-Axcess welder with a powerful and feature packed process monitoring tool called "CenterPoint". "CenterPoint" is a PC application which is used to set-up weld processes and limits.
  • Page 44 166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.1 Setting Proportional Speed Instruction Fig. 6-1: Setting Proportional-Speed 166465-1CD 44/56...

  • Page 45: Macro Job Settings

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings MACRO Job Settings The Auto-Axcess EtherNetIP interface allows the robot to communicate the welder letting it know where the robot physically is within the welding sequence. The robot can also instruct the welder what the "Part ID" and "Weld ID"...

  • Page 46: Miller-Prog-Sel Macro

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings 6.2.1 MILLER-PROG-SEL Macro Use this macro routine to specify the weld program at the start of a weld or change the weld program mid-weld. It also allows adjustment of the arc characteristics for the specified program.

  • Page 47: Miller-Strt-Part Macro

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings 6.2.2 MILLER-STRT-PART Macro Use this macro to signal the start of a new part. It starts the cycle timers within the welder and allows identification of the "Part ID" that's going to be welded.
  • Page 48 166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings Fig. 6-4: MILLER-STRT-PART Screen 166465-1CD 48/56...

  • Page 49: Miller-Chng-Weld Macro

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings 6.2.3 MILLER-CHNG-WELD Macro The "Miller-Chng-Weld" macro is used to ensure 100% synchronization between the robot's motion and the current weld's identifier or can be used to allow out-of-sequence welding. This may be needed when processing parts that are affected by heat-input and could warp because of heat-input.

  • Page 50: Miller-End-Part Macro

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings 6.2.4 MILLER-END-PART Macro The "Miller-End-Part" macro is used to signal the completion of a part. This causes the robot to stop accumulating cycle time and display any "Part Errs" if they occurred during the course of the part. •...

  • Page 51: Example Weld Job Structure

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.2 MACRO Job Settings 6.2.5 Example Weld Job Structure See Fig.6-7 Example Weld Job Structure for an example of a weld job structure. Fig. 6-7: Example Weld Job Structure 1. Starts the cycle timers and specifies Part ID:5 and Starting Weld ID:13 (Weld and Prt errors are set within the "Detail Edit"...

  • Page 52: Error Reporting

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.3 Error Reporting Error Reporting 6.3.1 Weld Error Reporting Weld Error Reporting: Based on the "Enable Weld Errs" made in the "MILLER-PART-START" macro. The power source can alarm at the completion of a weld and trigger a robot-based user alarm notifying the user of the weld fault.

  • Page 53: Part Error Reporting

    166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.3 Error Reporting Fig. 6-9: Below voltage, over wirefeed speed, below duration Weld Error Example 6.3.2 Part Error Reporting Based on the "Enable Part Errs" setting made in the "MILLER-PART- START" macro, the robot can stop production with an user alarm if one of the welds or the part processing chracteristics is outside of the predefined limits.
  • Page 54 166465-1CD Auto-Axcess DI/E Digital Miller Auto-Axcess E Digital 6.3 Error Reporting Fig. 6-10: Example of a Part Error Process Fault 6-12 166465-1CD 54/56...

  • Page 55: Revision History

    166465-1CD Auto-Axcess DI/E Digital Revision History Revision History Date CEN / Revision Reason For Revision Initials 9/10/2013 32748 Original Release 7/31/2014 14-1014M 1 Revised part number on manual from 166645-1CD to 166465-1CD 166465-1CD 55/56...
  • Page 56 MOTOMAN DX100 CONTROLLER WITH ROBOTIC ARC WELDING INSTRUCTIONS ® FOR MILLER AUTO-AXCESS DI/ E DIGITAL Specifications are subject to change without notice for ongoing product modifications and improvements. MANUAL NO. 166465-1CD 56/56...

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