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YASKAWA MOTOMAN Series Instructions Manual
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YASKAWA MOTOMAN Series Instructions Manual

For arc welding diagnosis function
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YRC1000 OPTIONS
INSTRUCTIONS
FOR ARC WELDING DIAGNOSIS FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
YRC1000 INSTRUCTIONS
YRC1000 OPERATOR'S MANUAL (GENERAL) (SUBJECT SPECIFIC)
YRC1000 MAINTENANCE MANUAL
YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)
188614-1CD
0
MANUAL NO.
1/42

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Summary of Contents for YASKAWA MOTOMAN Series

  • Page 1 YRC1000 OPTIONS INSTRUCTIONS FOR ARC WELDING DIAGNOSIS FUNCTION Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN- INSTRUCTIONS YRC1000 INSTRUCTIONS YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC) YRC1000 MAINTENANCE MANUAL YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS) 188614-1CD MANUAL NO.

  • Page 2: Contents

    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 HW1485704 NOTES FOR SAFE OPERATION Read this manual carefully before installation, operation, maintenance, or inspection of the YRC1000. In this manual, the Notes for Safe Operation are classified as “DANGER”, “WARNING”, “CAUTION”, or “NOTICE”. Indicates an imminently hazardous DANGER situation which, if not avoided, will result in death or serious injury.
  • Page 4 HW1485704 DANGER • Before operating the manipulator, make sure the servo power is turned OFF by performing the following operations. When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF. – Press the emergency stop buttons on the front door of the YRC1000, on the programming pendant, on the external control device, etc.
  • Page 5 Definition of Terms Used Often in This Manual The MOTOMAN is the YASKAWA industrial robot product. The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.
  • Page 6 HW1485704 Descriptions of the programming pendant keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters or symbols Pendant /Symbol Keys printed on them are denoted with [ ]. e.g. [ENTER] Axis Keys [Axis Key] and [Numeric Key] are generic /Numeric Keys...
  • Page 7 HW1485704 Description of the Operation Procedure In the explanation of the operation procedure, the expression "Select • • • " means that the cursor is moved to the object item and [SELECT] is pressed, or that the item is directly selected by touching the screen. Registered Trademark In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or...

  • Page 8: Table Of Contents

    HW1485704 Contents 1 Outline of Arc Welding Diagnosis Function..................1-1 1.1 Function Outline......................... 1-1 2 Operation Outline ..........................2-1 2.1 Operation Process of Arc Welding Diagnosis Function ............. 2-1 2.1.1 JOB Setting......................2-1 2.1.2 Data Setting for Arc Welding Diagnosis..............2-3 2.1.3 Displaying / Non-displaying Arc Weld Diagnosis Window ........
  • Page 9 HW1485704 Contents 8.1 Alarm List........................... 8-1 8.2 Error Dialogue List ......................8-1 HW1485704 9/42...

  • Page 10: Outline Of Arc Welding Diagnosis Function

    HW1485704 Outline of Arc Welding Diagnosis Function Function Outline Outline of Arc Welding Diagnosis Function Function Outline This function diagnoses if the welding bead is normal or abnormal based on the data such as welding current waveforms or welding voltage waveforms.

  • Page 11: Parameter

    HW1485704 Outline of Arc Welding Diagnosis Function Function Outline Arc welding diagnosis function can be used in the following versions. YRC1000: YAS2.71.00A-00 or later DX200: DN.2.81.00A_00 or later MOTOWELD-X350: 1.20-020-E or later MOTOWELD-X500: 1.20-020-F or later NOTE MOTOWELD-RL350: 1.00-070-A or later (When using RL350, change to C Parameter C39 of weld- Also, if the weld diagnosis ing power source to100.

  • Page 12: Operation Outline

    HW1485704 Operation Outline Operation Process of Arc Welding Diagnosis Function Operation Outline Operation Process of Arc Welding Diagnosis Function To use the arc welding diagnosis function, set each item after completing welding conditioning. NOTE When the welding condition, the welding speed, or the welding teaching point, etc.
  • Page 13 HW1485704 Operation Outline Operation Process of Arc Welding Diagnosis Function When the welding diagnosis function has been enabled after upgrading, to show the bead number, perform “RESET NOTE INSTRUCTION” or change “LANGUAGE LEVEL” in the management mode. HW1485704 13/42...

  • Page 14: Data Setting For Arc Welding Diagnosis

    HW1485704 Operation Outline Operation Process of Arc Welding Diagnosis Function 2.1.2 Data Setting for Arc Welding Diagnosis Set the register address of data to use the welding diagnosis on the APPLICATION CONDITION SETTING window. To show the APPLICATION CONDITION SETTING window, set the security to the management mode.
  • Page 15 HW1485704 Operation Outline Operation Process of Arc Welding Diagnosis Function Specify the register address of the following data on the APPLICATION CONDITION SETTING window. Name Initial Value Register address for sampling welding voltage value Register address for sampling welding current value Register address for sampling welding feed speed value output Register address for sampling welding feed load value output Bead number output register address...

  • Page 16: Displaying / Non-Displaying Arc Weld Diagnosis Window

    HW1485704 Operation Outline Operation Process of Arc Welding Diagnosis Function 2.1.3 Displaying / Non-displaying Arc Weld Diagnosis Window Under the Main Menu, select the sub menu, {ARC WELDING} - {ARC WELD DIAG.}, and the following window appears. To close the window, press {CLOSE}.

  • Page 17: Preparation For Arc Weld Diagnosis Window

    HW1485704 Operation Outline Preparation for Arc Weld Diagnosis Window Preparation for Arc Weld Diagnosis Window Set the Arc Weld diagnosis window settings in accordance with the following flow chart. Start Arc weld diagnosis window Select diagnosis mode Score mode Current out-of-range mode Selection of JOB Selection of JOB Selection of bead number...

  • Page 18: Diagnosis Mode Setting

    HW1485704 Operation Outline Preparation for Arc Weld Diagnosis Window 2.2.1 Diagnosis Mode Setting Press {Setting} on the Arc Weld diagnosis window, the following window appears. Select either {Score mode} or {Current out-of-range mode} as the Diagnosis mode. If the Diagnosis mode is changed, the data of the Arc Weld NOTE diagnosis window is initialized.

  • Page 19: Operating Arc Weld Diagnosis Window

    HW1485704 Operating Arc Weld Diagnosis Window Selection of JOB Operating Arc Weld Diagnosis Window Selection of JOB Move the cursor as shown below on the Arc Weld diagnosis window. Press [ENTER] to select the JOB. HW1485704 19/42...

  • Page 20: Selection Of Bead Number

    HW1485704 Operating Arc Weld Diagnosis Window Selection of Bead Number Selection of Bead Number Move the cursor as shown below on the Arc Weld diagnosis window. Press [ENTER] to select the bead number. HW1485704 20/42...

  • Page 21: Setting Of Threshold For Determining Error

    HW1485704 Operating Arc Weld Diagnosis Window Setting of Threshold for Determining Error Setting of Threshold for Determining Error Move the cursor as shown below on the Arc Weld diagnosis window. Press [ENTER] to set the threshold for determining error. For the score mode: The initial value is 60% or less.

  • Page 22: Setting Of Error Output Mode And Signal Number

    HW1485704 Operating Arc Weld Diagnosis Window Setting of Error Output Mode and Signal Number Setting of Error Output Mode and Signal Number Move the cursor as shown below on the Arc Weld diagnosis window. Press [ENTER] to set the error output mode. Next, move the cursor to the signal number to set the general output number.

  • Page 23: Setting Of Standard Current And Standard Voltage

    HW1485704 Operating Arc Weld Diagnosis Window Setting of Standard Current and Standard Voltage Setting of Standard Current and Standard Voltage  Score mode For the score mode, the normal welding effective value is registered as “STD. Curr” and “STD. Volt”. The registered JOB welding position is welded.
  • Page 24 HW1485704 Operating Arc Weld Diagnosis Window Setting of Standard Current and Standard Voltage The reference data is registered to "STD. Curr" and "STD. Volt". When multiple welding points exist, all reference data can be registered collectively.  Current out-of-range mode For the current out-of-range mode, the welding start conditions are input as "STD.

  • Page 25: Changing Of Standard Current And Standard Voltage

    HW1485704 Operating Arc Weld Diagnosis Window Changing of Standard Current and Standard Voltage Changing of Standard Current and Standard Voltage When the welding condition, the welding speed, the wave- NOTE form parameter, or the welding teaching point, etc. have been changed, make sure to change the reference. ...
  • Page 26 HW1485704 Operating Arc Weld Diagnosis Window Changing of Standard Current and Standard Voltage The data of "AVG. Curr" and "AVG. Volt" are registered to the reference data. Current out-of-range mode  For the current out-of-range mode, change "STD. Curr" and "STD. Volt" when changing the welding conditions.

  • Page 27: Enable/Disable Of Diagnosis

    HW1485704 Operating Arc Weld Diagnosis Window Enable/Disable of Diagnosis Enable/Disable of Diagnosis When starting the diagnosis, check the checkbox of “Start diagnosis”. A diagnosis can be enabled or disabled during arc interruption, such as an alarm or an emergency stop, or when restarting an arc. Press {Setting} on the Arc Weld diagnosis window.
  • Page 28 HW1485704 Operating Arc Weld Diagnosis Window Enable/Disable of Diagnosis To enable a diagnosis when welding is interrupted or when an arc is restarted, select "Enable". To disable the diagnosis, select "Disable". When selecting “Enable”, the data before welding interrup- NOTE tion is deleted and the data since the welding restart is acquired.

  • Page 29: Saving Of Arc Welding Diagnosis Data

    HW1485704 Saving of Arc Welding Diagnosis Data Saving of Arc Welding Diagnosis Data Saving of Arc Welding Diagnosis Data Saving of Arc Welding Diagnosis Data Data displayed on the Arc Weld diagnosis window can be saved in the external memory. Data can be saved by following methods. •...
  • Page 30 HW1485704 Saving of Arc Welding Diagnosis Data Setting for Saving of Arc Welding Diagnosis Data (Automatic) The Configuration window appears as follows. Production counter The D variable is used in the production counter. Specify the D variable number other than 0. Increment the counter with the MASTER JOB, etc.

  • Page 31: Saving Data

    HW1485704 Saving of Arc Welding Diagnosis Data Setting for Saving of Arc Welding Diagnosis Data (Automatic) Data save signal The process of saving data to the external memory will start when the dedicated output signal or general output signal changes from OFF to ON. Save the data after completing all welding of one work.
  • Page 32 HW1485704 Saving of Arc Welding Diagnosis Data Setting for Saving of Arc Welding Diagnosis Data (Automatic) AVG. Data clear signal Use this signal when deleting the acquired effective data and newly acquiring data. The effective data will be cleared when the dedicated input signal or general input signal changes from OFF to ON.
  • Page 33 HW1485704 Saving of Arc Welding Diagnosis Data Setting for Saving of Arc Welding Diagnosis Data (Automatic) When saving the data in the folder created in the USB, set the cursor to “USB Memory”. Press the right button of the programming pendant and a folder appears.

  • Page 34: Setting For Saving Of Arc Welding Diagnosis Data (Manual)

    HW1485704 Saving of Arc Welding Diagnosis Data Setting for Saving of Arc Welding Diagnosis Data (Manual) Setting for Saving of Arc Welding Diagnosis Data (Manual) A data of the arc welding diagnosis can be saved manually. Press {Save (USB)} on the Arc weld diagnosis window. In manual saving, the data is saved in the USB.

  • Page 35: Retry Saving Of Data

    HW1485704 Saving of Arc Welding Diagnosis Data Retry Saving of Data Retry Saving of Data The saving in the external memory can be failed depending on the timing. If a backup fails, a retry is carried out every retry period selected as beforehand.
  • Page 36 HW1485704 Saving Format of Arc Welding Diagnosis Data Saving Data Saving Format of Arc Welding Diagnosis Data Saving Data The file format is common when saving the arc welding diagnosis data to the external memory. 1) ARCTBL DATA Function: Shows the type of data. Notation: ARCTBL DATA Description: Shows the arc welding diagnosis data.
  • Page 37 HW1485704 Saving Format of Arc Welding Diagnosis Data Saving Data 8) Base Current Function: Shows the standard current. Notation: 0 A to 550 A 9) Base Voltage Function: Shows the standard voltage. Notation: 0 V to 50 V 10) Execution Current Function: Shows the average current.
  • Page 38 HW1485704 Concurrent I/O Ladder Specific Input Signal Concurrent I/O Ladder I/O signals for the arc welding diagnosis function are as follows. Specific Input Signal 40606 40605 Clear Signal of Save Signal of Common welder Arc Welding Diagnosis Arc Welding Diagnosis Data Data ...
  • Page 39 HW1485704 Parameter SC Parameter Parameter SC Parameter Table 7-1: Parameter List Number Content Initial Value Setting Range S4C1082 Retry time for saving of the arc welding diagnosis data 10 - 3600 [unit: second] S4C1083 Retry count for saving of the arc welding diagnosis data [unit: times] ...

  • Page 40: Ap Parameter

    HW1485704 Parameter AP Parameter AP Parameter Parameter Content Initial Value AxP144 Starting delay time for average value calculation unit: ms AxP145 System reserved AxP146 Bead number output register address 166+20* (Welder No.-1) AxP147 Register address for effective current value (average) output 167+20* (Welder No.-1) AxP148 Register address for effective voltage value (average) output...

  • Page 41: Alarm / Error / Inform

    HW1485704 Alarm / Error / Inform Alarm List Alarm / Error / Inform Alarm List Alarm Number Message Sub Code Details Remedy 4297 WELDING Welder No.*1000 + Determined as (1) Check the welding bead. BEAD ERROR data No. (1 to 400) welding bead (2) Check the welding failure with the...

  • Page 42: Hw1485704

    FOR ARC WELDING DIAGNOSIS FUNCTION HEAD OFFICE 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan Phone +81-93-645-7703 Fax +81-93-645-7802 YASKAWA America Inc. (Motoman Robotics Division) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Europe GmbH Robotics Divsion )

This manual is also suitable for:

Yrc1000