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YRC1000 MAINTENANCE MANUAL YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS) The YRC1000 operator's manual above corresponds to specific usage. Be sure to use the appropriate manual. The YRC1000 operator's manual above consists of "GENERAL" and "SUBJECT SPECIFIC". The YRC1000 alarm codes above consists of "MAJOR ALARMS" and "MINOR ALARMS".
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• 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.
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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 situation which, if not avoided, will result in death or serious injury.
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Use facilities that comply with the Safety Standards for Laser Beams (IEC 60825-1). Note that Yaskawa does not guarantee the safety of facilities that comply with the Safety Standards for Laser Beams (IEC 60825-1). Make the final decision regarding the safety of your facilities after considering them carefully.
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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.
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Check for damage to insulation and sheathing of external wires. • Always return the programming pendant to the hook on the YRC1000 cabinet after use. If the programming pendant is left unattended on the manipulator, on a fixture, or on the floor, etc., the Enable Switch may be activated due to surface irregularities of...
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Touching hot work or hot jigs immediately after welding with bare hands may result in burns. 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 the manipulator cables.
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Descriptions of the programming pendant, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters printed on them Pendant /Symbol Keys are denoted with [ ]. ex. [ENTER] Axis Keys "Axis Keys" and "Number Keys" are generic Number Keys names for the keys for axis operation and number input.
System configuration diagram ..............1-12 1.2.1. System configuration for the CAN specification Laser Head made by Yaskawa Control Inc................1-12 1.2.2. System configuration for the laser head made by TRUMPF Inc..1-13 Operation of the remote laser function from the pendant ........2-14 2.1.
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5.5. Sample welding programs................. 5-58 Descriptions of each function ................6-59 6.1. Analog output settings for the laser oscillator (Yaskawa head only) ... 6-59 6.2. Laser power output timing correction function (all heads) ......6-59 6.3. Welding start timing and monitoring method (all heads) ......6-60 6.3.1.
1. Overview of the remote laser function system 1.1. Remote laser function The remote laser function (on the fly) controls the position of the laser head (Trumpf Pro and Yaskawa Control laser heads) while the robot moves and performs laser welding. Laser Head (Trumpf and Yaskawa Control)
Overview of the remote laser function system 1.2 System configuration diagram 1.2. System configuration diagram 1.2.1. System configuration for the CAN specification Laser Head made by Yaskawa Control Inc. CAN specification Laser Head made by Yaskawa Control Inc. YRC1000 ...
Overview of the remote laser function system 1.2 System configuration diagram 1.2.2. System configuration for the laser head made by TRUMPF Inc. Laser Head made by TRUMPF Inc. YRC1000 Laser Oscillator Part name Part No. I/O cable or device net cable Prepared by the customer ...
Operation of the remote laser function from the pendant 2.1 Pendant key 2. Operation of the remote laser function from the pendant 2.1. Pendant key 2-14 HW1486273 14 / 95...
• Green pointer (when using the Yaskawa Control laser head) This visible light is used in teaching to focus the laser on the work. The robot is moved up and down along the Z-axis to adjust the distance between focal points so that the guide laser and green pointer match up.
Operation of the remote laser function from the pendant 2.3 Laser head coordinate system • Welding laser This is a laser focused on the work when actually welding in playback. 2.3. Laser head coordinate system The diagram below shows the laser head coordinate system. 2-16 HW1486273 16 / 95...
Operation of the remote laser function from the pendant 2.4 Operating the remote laser 2.4. Operating the remote laser The remote laser guide laser focuses on the work and the robot control device programming pendant is used to move the guide laser. To move the laser beam, the current position window and record position window must be open.
Operation of the remote laser function from the pendant 2.4 Operating the remote laser DF (defocus) adjusts the focal length in the direction of the laser beam axis. The DF positive direction is the direction in which the focal point approaches the head.
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Operation of the remote laser function from the pendant 2.4 Operating the remote laser * If you have not yet registered any remote laser welding position registration files, no remote laser welding position registration files will be shown. Chapter 3 explains how to register a file.
Remote laser welding position registration files 2.4 Operating the remote laser 3. Remote laser welding position registration files Remote laser welding position registration files are files to register welding positions for use when performing laser welding. While the robot is moving, you can view the remote laser record position file specified with the RL_ON command and perform laser welding on the positions registered in the file.
Remote laser welding position registration files 3.1 Creating files 3.1. Creating files (1) Select {OPTION} {LASER RECORD POS}. (2) Select {DATA} {CREATE}. (3) In the window for registering a new position file, enter the desired file number and the number of points.
Remote laser welding position registration files 3.2 Registering welding positions 3.2. Registering welding positions 3.2.1. Description of each setting Item Details Turn ON or OFF the point for the opened point number. While {WELDING POINT turned OFF, the relevant welding path will not be executed. ON/OFF} * It can only be turned on when a welding start point and welding end point have been registered.
Remote laser welding position registration files 3.2 Registering welding positions 3.2.2. Method for registering welding positions • When {AUTO INPUT END POINT} is ON (1) Move the guide laser to the welding start point, and match the cursor on the monitor with the welding start point.
Remote laser welding position registration files 3.3 Registering or deleting position data 3.3. Registering or deleting position data Button or key on the monitor Details REGISTER Register the entered data. Return to the remote laser record position file ...
Remote laser welding position registration files 3.4 Adding points 3.4. Adding points (1) To add a new point before the point displayed in the remote laser record position window, select {EDIT} {NEW POINT}. (2) A dialog box will appear with the message, "Welding point is inserted.
Remote laser welding position registration files 3.5 Deleting points 3.5. Deleting points (1) To delete the point displayed in the remote laser record position window, select {EDIT} {DELETE POINT}. (2) A dialog box will appear with the message, "Welding point is deleted. OK?" Click {YES}. (3) The point displayed will be deleted and the numbers for all subsequent points will move up by one.
Remote laser welding position registration files 3.6 Erasing points 3.6. Erasing points (1) To erase the point displayed in the remote laser record position window, select {EDIT} {ERASE POINT}. (2) A dialog box will appear with the message, "Welding point is cleared. OK?" Click {YES}. (3) The data for the point displayed will be erased.
Remote laser welding position registration files 3.7 Copying points 3.7. Copying points (1) To copy the point displayed in the remote laser record position window, select {EDIT} {COPY POINT}. (2) The data for the point displayed will be copied. 3.8.
Remote laser welding position registration files 3.9 Parallel shift 3.9. Parallel shift (1) To perform a parallel shift in point positions, from the remote laser record position window, select {UTILITY} {PARALLEL SHIFT}. (2) Enter the range of points, coordinates (base or tool), and shift volume for the parallel shift and select {EXECUTE}.
Remote laser welding position registration files 3.10 Deleting remote laser welding position registration files 3.10. Deleting remote laser welding position registration files (1) From the remote laser record position file selection window, place the cursor over the registration file to delete and select {DATA} ...
Remote laser welding position registration files 3.11 Changing the number of points in remote laser welding position registration files 3.11. Changing the number of points in remote laser welding position registration files (1) From the remote laser record position file selection window, place the cursor over the file for which you want to change the number of points that can be registered and select {EDIT} ...
Remote laser welding position registration files 3.12 Copying remote laser welding position registration files 3.12. Copying remote laser welding position registration files (1) To copy a remote laser record position file, from the remote laser record position file selection window, place the cursor over the file to copy and select {EDIT} ...
Remote laser welding position registration files 3.14 Teaching during welding position registration 3.14. Teaching during welding position registration To perform welding by circular interpolation (explained in detail in 4.2.2), register the welding position to be directly below the scanner. If the position is registered while the scanner is on an incline with respect to the work, the face of the drawn circle will also be on an incline.
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Remote laser welding position registration files 3.14 Teaching during welding position registration When the welding position is directly below the scanner, the focus will automatically be aligned with the registered position during automatic operation. 3-34 HW1486273 34 / 95...
Remote laser welding condition registration files 4.1 File setup 4. Remote laser welding condition registration files Remote laser welding condition registration files are files to register welding conditions for use when performing laser welding. Remote laser welding condition registration files can be viewed within the remote laser record position file specified with the RL_ON command while the robot is moving to perform laser welding.
Remote laser welding condition registration files 4.2 Interpolation of welding lines 4.2. Interpolation of welding lines You can specify 15 welding paths in a single remote laser record conditions file. Register welding conditions from welding path No. 01 in order starting from the small path number.
Remote laser welding condition registration files 4.2 Interpolation of welding lines 4.2.1. Linear interpolation Weld in a straight line from the welding start point to the welding end point. 4.2.2. Circular interpolation Weld in a circular motion with the welding start point position as the circle's center at the specified radius.
Remote laser welding condition registration files 4.2 Interpolation of welding lines When the program calculates the position for the automatic end point based on the above parameter settings, if the setting is outside the setting range, after the start point is registered during remote laser welding position registration, the following error will occur when the program attempts to calculate the end point.
Remote laser welding condition registration files 4.2 Interpolation of welding lines 4.2.4. Character-shaped interpolation Characters can be specified as a letter (A to Z) or number (0 to 9). If unspecified, the character will be [A]. Place the cursor on the character and press [SELECT] to bring up the keyboard window.
Remote laser welding condition registration files 4.2 Interpolation of welding lines 4.2.5. User file interpolation You can weld arbitrary shapes created with special purpose software included on the delivery CD. Place the cursor over the file number and press [SELECT] to specify numbers 1 to 10.
Remote laser welding condition registration files 4.2 Interpolation of welding lines 4.2.6. Wobbling When performing laser welding for a lap joint or butt weld, the diameter of the spot for the laser to focus is small, so wobbling is sometimes performed. Wobbling is an interpolation method that ensures a sufficient bead width by spinning the laser focal point while moving it along the welding line.
Remote laser welding condition registration files 4.2 Interpolation of welding lines 4.2.7. Square interpolation Square-shaped welding with sides of radius R can be performed. The square size is specified by L1 and L2 for the distance from the center. The size of the specified radius R may not exceed half the height of each side. (Possible range: L1 ≥...
Remote laser welding condition registration files 4.3 Setting the capable range 4.3. Setting the capable range If the path taught is within the remote laser welding start range, the remote laser function performs welding within the remote laser unit movement limits. In the remote laser record conditions window, you can set the desired welding range for each path.
Remote laser welding condition registration files 4.4 Setting DF (defocus) 4.4. Setting DF (defocus) In the remote laser record conditions window, you can set the welding start point DF and welding end point DF for each welding path. DF (defocus) is a function that adjusts the focal length in the laser beam axis direction. 4-44 HW1486273 44 / 95...
Remote laser welding condition registration files 4.5 Registering timers and slope control 4.5. Registering timers and slope control {START TIMER}: For the designated time period, the laser power remains OFF and the laser stays in position at the registered start point until the specified period of time elapses and welding begins.
Remote laser welding condition registration files 4.6 Registering or canceling position data 4.6. Registering or canceling position data Button or key on the monitor Details REGISTER Register the data entered. Return to the remote laser record position file ...
Remote laser welding condition registration files 4.7 Adding paths 4.7. Adding paths (1) To add a new path before the path displayed in the remote laser record conditions window, select {EDIT} {INSERT PATH}. (2) A dialog box will appear with the message, "Welding path is inserted.
Remote laser welding condition registration files 4.8 Deleting paths 4.8. Deleting paths (1) To delete the path displayed in the remote laser record conditions window, select {EDIT} {DELETE PATH}. (2) A dialog box will appear with the message, "Welding path is deleted. OK?" Click {YES}. (3) The path displayed will be deleted and the numbers for all subsequent paths will move up by one.
Remote laser welding condition registration files 4.9 Erasing paths 4.9. Erasing paths (1) To erase the path displayed in the remote laser record conditions window, select {EDIT} {CLEAR PATH}. (2) A dialog box will appear with the message, "Welding path is cleared. OK?" Click {YES}. (3) The data for the path being displayed will be erased.
Remote laser welding condition registration files 4.10 Copying paths 4.10. Copying paths (1) To copy the path displayed, in the remote laser record conditions window for the path being displayed, select {EDIT} {COPY PATH}. (2) The data for the path being displayed will be copied.
Remote laser welding condition registration files 4.12 Batch changing welding conditions 4.12. Batch changing welding conditions (1) From the remote laser record conditions window, place the cursor over the file in which you want to change all welding conditions, then select {EDIT} {CHANGE ALL}.
Remote laser welding condition registration files 4.14 Copying files 4.14. Copying files (1) To copy a remote laser record conditions file, from the remote laser record conditions file selection window, place the cursor over the file to copy and select {EDIT} ...
Remote laser welding condition registration files 4.16 How to scan arbitrary shape files 4.16. How to scan arbitrary shape files (1) Insert an SD card or USB memory stick that contains arbitrary shape file data into the programming pendant. (2) Select {EX. MEMORY} {LOAD}. (3) Select {FILE/GENERAL DATA}.
Remote laser welding programs 5.1 Using macro commands 5. Remote laser welding programs 5.1. Using macro commands To use a macro command, select [INFORM LIST] {MACRO} and choose the macro command you want to use. Macro command name Details Turns the laser ON and starts (open welding file) LASER_ON processing.
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Remote laser welding programs 5.2 Macro command for turning on the laser (LASER_ON) 5.2. Macro command for turning on the laser (LASER_ON) RLPOS FILE NO.: Welding position file number (1 to 999) to open with the laser ON. START POINT NO.: Point number (the maximum is the number of points in the position file) from which to start welding within the set position file.
Remote laser welding programs 5.4 Macro command for communication with the laser oscillator (L_READY) 5.4. Macro command for communication with the laser oscillator (L_READY) LASER PRG NO: The program number set with the laser oscillator. Enter the above value and press [ENTER] to write the data to the program.
Remote laser welding programs 5.5 Sample welding programs 5.5. Sample welding programs The following is an example of a program for performing remote laser welding. Robot Position Robot Position Robot Position Robot Position In the example job, point No. 5 and point No. 6 in the remote laser record position file No. 1 are welded between robot position ...
6.1. Analog output settings for the laser oscillator (Yaskawa head only) * This function is available when using the remote laser with a Yaskawa Control head. You can set analog output settings for the laser oscillator being used with the equipment.
Descriptions of each function 6.3 Welding start timing and monitoring method (all heads) 6.3. Welding start timing and monitoring method (all heads) 6.3.1. Welding start timing There are two ways to monitor welding start timing. You can specify the method with the following S1E parameter. Parameter Name Details...
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Descriptions of each function 6.3 Welding start timing and monitoring method (all heads) When S1E66 = 1 (entire path) 6-61 HW1486273 61 / 95...
Descriptions of each function 6.3 Welding start timing and monitoring method (all heads) 6.3.2. Setting exceptional states for signals When points on paths other than the first path are outside the motion range, outside the welding start range, or outside the laser power upper limit, or when welding is interrupted, this function immediately turns ON the set generic output signal without waiting for the LASER_OF command.
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Descriptions of each function 6.3 Welding start timing and monitoring method (all heads) laser power command has exceeded the upper limit Point number output Register number to output the point register upon a laser number when the laser power S1E80 power upper limit warning command has exceeded the upper limit...
6.4 Pincushion correction function (Yaskawa head only) 6.4. Pincushion correction function (Yaskawa head only) * This function is available when using the remote laser with a Yaskawa Control head. This function corrects the XYZ coordinate distance equivalence in the scanner motion range for differences arising from errors in scanner assembly.
6.6 Scanner abnormality monitoring function (Yaskawa head only) 6.6. Scanner abnormality monitoring function (Yaskawa head only) * This function is available when using the remote laser with a Yaskawa Control head. This function monitors errors from the galvano driver for the head so that the system can issue alarms.
List of alarms 6.6 Scanner abnormality monitoring function (Yaskawa head only) 7. List of alarms Alarm Message Cause Response code 0 to 199 Parameter error There is an error in Set the value for the sensor [decimal data] the value set for a...
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List of alarms 6.6 Scanner abnormality monitoring function (Yaskawa head only) [decimal data] moves properly. If it is broken, contact Yaskawa. • Check if the CAN data A CAN communication error cable has become was detected. disconnected or replace the cable.
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List of alarms 6.6 Scanner abnormality monitoring function (Yaskawa head only) [decimal data] function processing. Welding position There is a mistake in the file teach file number number specified in the error RL_ON command. Check the file number. Welding position...
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List of alarms 6.6 Scanner abnormality monitoring function (Yaskawa head only) with the arbitrary shape file. Tool file load timeout Check if there is a problem with the tool data settings. Tool file load error Check if there is a problem with the tool data settings.
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List of alarms 6.6 Scanner abnormality monitoring function (Yaskawa head only) • Check if the CAN data cable has become disconnected or replace the cable. Remote laser home Check the S1E parameter position check CAN settings. sending error Remote laser...
S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) 8. S1E parameters 8.1. Yaskawa Control 3D 3.67x head (8MC33A-3C001A) * Orange-colored cells are parameters that must be set to match the equipment. Item Details Unit Remarks Default Laser application Set when there is a...
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) (head -Z-axis direction) [μm] Amount of Sets the amount of 1000 jogging/inching guide laser movement movement for inching during teaching. (speed 1) [μm/s] Low jog movement Sets the guide laser 1000 speed during teaching.
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) Register Sends the point Register 0 = No output specification for the number that is outside number outside motion range the motion range to the point number specified register. Generic output...
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) Home position Moves the guide laser 0: OFF motion during laser to the home position 1: ON pointer ON when the laser pointer is ON. Control of welding Limits the welding...
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) CAN data check Checks communication [ms] 0 = OFF function with the laser head. End of welding move Specifies the laser 0: No to origin specification head movement at the movement end of welding.
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) position return OFF position return. specification d0: X-axis, d2: Y-axis d3: Z-axis, d4: DF Specification to Releases the function 0: Operation release the function to turn off Z-axis invalid to turn off Z-axis...
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) offset with no straight (clockwise rotation line scanning around the tool Z-axis is positive) Alarm 'Laser tracking Turns ON the specified Generic output 0 = OFF processing error [54]' generic output when...
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) oscillation angle calculation calculation coefficient Maximum galvano This is the maximum * Unmodifiable 51700 oscillation angle (X) X-axis mirror oscillation angle. Minimum galvano This is the minimum * Unmodifiable 13836 oscillation angle (X) X-axis mirror oscillation angle.
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S1E parameters 8.1 Yaskawa Control 3D 3.67x head (8MC33A-3C001A) deviation (256 pulses) Bottom byte: Number of successive attempts (times) Alarm OFF bit Turns OFF individual d0: Thermo 1 laser head alarms. d1: Thermo 2 d2: X d3: Y d4: Z...
S1E parameters 8.2 Trumpf PFO head 8.2. Trumpf PFO head Item Details Unit Remarks Default Laser application Set when there is a laser * Unmodifiable 96 specification application. Laser power input limit Limits the laser power Varies by 6000 input value. oscillator specifications Welding speed input...
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CAN-compatible laser Specifies whether the 3D 0: Not * Unmodifiable 0 head scanner is compatible CAN-compatible. 1: Compatible (Yaskawa Control head) Welding start position Limits the scanner speed [mm/s] 4000 limit acceptable speed up to the welding start point. Generic output...
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S1E parameters 8.2 Trumpf PFO head outside start range the welding start point is alarm not in the motion range Register specification Sends the point number Register 0 = No output for the outside start that is outside the start number range point number range to the specified...
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S1E parameters 8.2 Trumpf PFO head Laser power upper Controls the upper limit 0 = No upper limit for laser output values. limit Not required due to control with S1E001. Generic output Turns ON the specified Generic 0 = No output specification for the generic output when the output number...
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S1E parameters 8.2 Trumpf PFO head specification function position tool Y component [μm] Mirror standby position Forced mirror standby specification function position tool Z component Electricity cutoff Specification for the Generic input 0 = OFF function generic input signal to signal request forced laser power OFF...
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S1E parameters 8.2 Trumpf PFO head Specification for Generic generic output for the output number continuous point no welding warning Specification of the Register 0 = OFF register for the number number of continuous points not welded Generic input Generic input 0 = OFF specification for number...
S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) 8.3. Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) * Orange-colored cells are parameters that must be set to match the equipment. Item Details Unit Remarks Default Laser application Set when there is a laser...
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) (speed 1) [μm/s] Low jog movement Sets the guide laser 1000 speed during teaching. (speed 2) [μm/s] Medium jog Sets the guide laser 8000 movement speed during teaching. (speed 3) [μm/s]...
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) alarm outside the motion range. Register specification Sends the point number Register 0 = No output for the outside start that is outside the start number range point number range to the specified register.
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) limit for laser output values. limit Not required due to control with S1E001 Generic output Turns ON the specified Generic 0 = No output specification for the generic output when the...
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) position specification position tool Y component function [μm] Mirror standby Forced mirror standby position specification position tool Z component function Electricity cutoff Specification for the Generic input 0 = OFF function...
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) Specification for Generic generic output for the output continuous point no number welding warning Specification of the Register 0 = OFF register for the number number of continuous points not welded...
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) lattice Z size spacing for pincushion correction data. Pincushion correction Turns ON pincushion 0: OFF, 1: ON function specification correction. X angle data Data used in calculation 0.01 * Unmodifiable 291270...
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S1E parameters 8.3 Yaskawa Control 3D 3.8x Head (8MC44A-3C001A) Formula selection Selects the formula to 0: 2D * Unmodifiable 1 use. 1: 3D Z-axis coefficient 1 Data used in calculation * Unmodifiable -37872300 (integer) Z-axis coefficient 1 Data used in calculation...
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* Unmodifiable 1 1: Yes Defocus sign reversal Data used in calculation 0: No * Unmodifiable 1 1: Yes * Blue-colored cells are parameters whose settings differ from those of the Yaskawa Control 3.67x head (8MC33A-3C001A). 8-94 HW1486273 94 / 95...