Daihen OTC ALMEGA FD Series User manual

No. 1L22152V-E-2
series
INSTRUCTIONMANUAL
INTERFACE PANEL
■Read and follow these instructions and all safety blocks carefully.
■Have only trained and qualified persons install, operate, or service this unit.
■Give this manual to the operator.
■For help, call your distributor.

Be Sure to Read Instruction Manuals Before Use
Thank you for selecting DAIHEN arc welding robot Almega series.
Almega series are the robots with high performance and various functions developed by making full use of the
latest technology. Since the knowledge of welding peculiar to a welding machine maker is applied to both
hardware and software, we are sure that each user can be fully satisfied
In order to use the superior performance and the abundant functions safely and fully, be sure to read the
following instruction manuals including this manual and other attached documents, and understand the
knowledge of the machines, safety information, and notes thoroughly.
Instruction manuals related to the manipulator “V/B/H series”, and the robot control unit “FD11” are as follows.
■Standard Manuals
Instruction Manual Type Instruction
Manual No. Main Contents
QUICK START 1L21700A Point on Safety, Transportation and Installation,
Turning the power on/off and manual operation, etc.
SETUP
1L21700B
Safety precautions, installing & connecting method,
starting up, periodical inspection, solution at the time
of failure
CONTROLLER MAINTENANCE 1L21700K Specifications of controller, explanation of each parts
and maintenance, parts list, etc.
MANIPULATOR
（ NB4 / NB4L / NB15 / NV6 / NV6L / NV20 / NH5 ） 1L11130A Specifications or maintenance of manipulator, parts
list, etc.
MANIPULATOR
（ NV50 ） 1L11312A Specifications or maintenance of manipulator, parts list, etc.
MANIPULATOR
（ NV166 / NV210 ） 1L11306A Specifications or maintenance of manipulator, parts
list, etc.
BASIC OPERATIONS
1L21700C
Explanation of manual operation, teaching, automatic
operation, file utilities, backing-up data, basic
operations of Arc/Spot welding application, etc.
EXTERNAL INPUT/OUTPUT
1L21700H Interfacing method with external control device, list of
I/O signals and start/halt the automatic operation, etc.
Software PLC 1L21700J Create program,Input/output relay lists,List of
command words, etc.
CONTROL AND MAINTENANCE
FUNCTION 1L21700L Edit logging,User Check,Troubleshooting, etc.
■Application Manuals
Instruction Manual Type Instruction
Manual No. Main Contents
APPLICATION MANUAL
(ARC WELDING) 1L21700F Basic settings, functions for arc welding, teaching technic, etc.
APPLICATION MANUAL
(SPOT WELDING) 1L21700E Basic settings, functions for arc welding, teaching
technic, etc.
Instruction manuals are available other than the above for each optional function that you have purchased.
[Notes] 1. Specifications and information contained in these manuals are subject to change at any time without notice.
2. The screen display of a teach pendant shown in the manual are described as examples, which may be different from the actual
ones.
3. Although we cautiously compiled this standard specifications to eliminate as much error as possible, we do not take any
responsibility for damages resulting from neither direct nor indirect errors.
4. The manual is a part of robot products. When transferring or selling off a robot, be sure to append the manual.
5. No part of this manual may be reproduced without permission.
6. Prohibited altering or remodeling
- Do not alter or remodel our products.
- You may get injured or have your equipment damaged because of fire, failure or malfunction caused by altering or
remodeling the product.
The warranty does not cover any altered or remodeled products.
- 1 -

Notice
Notes on Safety
Before installation, operation, be sure to read "Chapter 1 Points on Safety" in SETUP manual and other attached
documents thoroughly and acquire all the knowledge of machines, safety information, and precautions.
Furthermore, before maintenance, inspection, and trouble scene, be sure to read CONTROLLER
MAINTENANCE manual and MANIPULATOR manual and other attached documents thoroughly and acquire all
the knowledge of machines, safety information, and precautions.
If operating machines in a wrong way, the accident resulting in various ranks of injury or death, or damage may
occur.
In order to call attention to wrong handling, the following four ranks of safety notes (“DANGER”, “WARNING”,
“CAUTION”, and “IMPORTANT”) are provided.
DANGER
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury and where the degree of the urgency
(imminence) of the warning given for the danger to occur is at the high end of the
scale (including high-level danger).
- 2 -
WARNING
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of death or serious injury.
CAUTION
Cases where a mistake made in handling is likely to cause the user to be exposed to
the danger of minor injuries or of property damage only.
The following symbol is also used for particularly important checkpoints:
IMPORTANT
This is a particularly important checkpoint.
Note that even the matters which are described as CAUTION can result in serious accident depending on the conditions.
Be sure to keep the safety notes since they describe very important matters.
The meanings of “Serious injury”, “Minor injury”, and “Damage” described above are as follows.
Serious injury ：Injury which has the aftereffect by loss of eyesight, an injury, the burn (high/low
temperature), an electric shock, fracture, poisoning, etc. and that which requires
hospitalization and long-term treatment as an outpatient.
Minor injury ： Injury which does not require either hospitalization or long-term treatment as an outpatient,
a burn (high temperature, low temperature), and an electric shock.
Damage ： Direct and indirect damage in connection with damage of property and equipment.

Table of Contents
1
Table of Contents
Chapter 1 Outline
1.1 General Description of Interface Panel Function....................................................................... 1-1
1.1.1 General description ........................................................................................................... 1-1
1.1.2 Specification ...................................................................................................................... 1-1
1.1.3 Signal attributes................................................................................................................. 1-2
1.2 Operations from Designing Screens to Using Them ................................................................. 1-3
1.2.1 Designing screens ............................................................................................................. 1-3
1.2.2 Deciding on the operation method .................................................................................... 1-4
1.2.3 Operation........................................................................................................................... 1-4
Chapter 2 Condition Settings
2.1 Condition Settings...................................................................................................................... 2-1
2.1.1 Select whether the screen is displayed ............................................................................. 2-1
2.1.2 Display the screen with input signal .................................................................................. 2-2
2.1.3 Setting of the initial status of the common switch.............................................................. 2-2
2.1.4 Setting of Enable/Disable of functionless code switch name setting ................................ 2-3
2.1.5 Setting of signal duplication check .................................................................................... 2-4
2.1.6 Setting of Enable/Disable of operations of f keys on touch panel ..................................... 2-4
2.1.7 Controlling the common switch using an input signal ....................................................... 2-5
2.1.8 Checking the status of the common switch ....................................................................... 2-6
2.1.9 Setting of softkey output signal for general purpose usage .............................................. 2-6
Chapter 3 Screen Design
3.1 Screen Design Basics................................................................................................................ 3-1
3.1.1 Number of screens and layout of operation switches ....................................................... 3-1
3.1.2 Reserved switch in upper right-hand corner...................................................................... 3-1
3.2 Operation Switch Design ........................................................................................................... 3-2
3.2.1 Basic operations for operation switch design .................................................................... 3-2
3.2.2 Round lamps and square lamps........................................................................................ 3-7
3.2.3 Push buttons...................................................................................................................... 3-8
3.2.4 Flash push buttons ............................................................................................................ 3-9
3.2.5 Selector switches (ON/OFF)............................................................................................ 3-10
3.2.6 Selector switches (2-contact type)................................................................................... 3-10
3.2.7 Displays ........................................................................................................................... 3-11
3.2.8 Digital switches (data input).............................................................................................3-12
3.3 Editing Using an External Personal Computer ........................................................................ 3-13
3.3.1 Outline .............................................................................................................................3-13
3.3.2 Editing using a personal computer ..................................................................................3-13
3.3.3 Loading screens designed using a personal computer (Import) .....................................3-18
3.3.4 Writing screens for editing by a personal computer (Export) ..........................................3-20
Chapter 4 Utilization of the Interface Panel

Table of Contents
2
4.1 Basic Operation ......................................................................................................................... 4-1
4.1.1 Opening the interface panel and changing the pages....................................................... 4-1
4.1.2 Using operation switches................................................................................................... 4-3

Chapter 1 Outline
This chapter gives a general description of the interface panel function. This is an
extremely useful function that enables the push buttons, lamps, etc. to be
displayed on the touch panel of the teach pendant.
1.1 General Description of Interface Panel Function ........................................1-1
1.1.1 General description...............................................................................1-1
1.1.2 Specification..........................................................................................1-1
1.1.3 Signal attributes ....................................................................................1-2
1.2 Operations from Designing Screens to Using Them...................................1-3
1.2.1 Designing screens ................................................................................1-3
1.2.2 Deciding on the operation method........................................................1-4
1.2.3 Operation..............................................................................................1-4

1.1 General Description of Interface Panel Function
1-1
1.1 General Description of Interface Panel Function
1.1.1 General description
By laying out the push buttons, lamps, etc. on the touch panel type of teach pendant, the interface panel function
assists the interlocking with the line controller and controlling of the peripheral equipments. The layout of the
operation switches, indicator lamps, etc., which used to be actualized by hardware circuits, on the touch panel type
of teach pendant helps to reduce costs.
Operation items (icons)
Interface panel
Can be laid out in
any way
Function keys Operation switches
Fig. 1.1.1 Outline of interface panel function
1.1.2 Specification
An overview of the interface panel function specifications is given in Table 1.1.1 Specifications of interface panel function.
Since a total of 248 switches can be designed exactly as desired on up to 8 screens, screens can be designed
flexibly to suit the applications.
Table 1.1.1 Specifications of interface panel function
Item Specification
Teach pendant Teach pendant with touch panel specifications required
Number of screens
(panels) Max. 8
Number of soft keys Max. 31 keys per screen x 8 screens = 248 keys
Size of soft keys 80 (L) x 80 (W) dots, fixed
(A 6-digit indicator is double-sized in width)
Function keys
All function keys can be laid out.
Types of operation items
that can be laid out Operation switches
Lamps (round, square)
Push buttons
Flash push buttons
Selector switches (ON/OFF type, contacts type)
Displays (3 digits, 6-digits)
Digital switches (3 digits, 6-digits)
Title No more than 16 full-size characters or 32 half-size characters
Colors Lighted colors, extinguished colors or base colors selected from 16 colors

1.1 General Description of Interface Panel Function
1-2
Item Specification
Editing method Recorded with teach pendant
Editing also possible on a personal computer using commercially available
text editor
Display method Single-action touch ON/OFF display operation using dedicated key
Display also possible with input signals
1.1.3 Signal attributes
An overview of the input/output signals involved with the interface panel function is shown in Fig. 1.1.2 Overview of
input/output signals used by interface panel.
As with the "starting," "servo ON" and other status output signals, the logical output signals are allocated for use as
the interface panel outputs, that is to say, as the signals which are output to the external device when the push
buttons and selector switches are operated.
Similarly, as with the "start" instruction, "servo ON" instruction and other status input signals, the logical input signals are
allocated for use as the interface panel inputs, that is to say, as the input signals which are used for the lamp, display and
other indications, and in addition, logical output signals and internal control variables can be displayed as well. (Not only
the input signals from external sources but the output signals of the controller itself can be displayed.)
Internal control
variables
Interface panel outputs
Push buttons, selector switches, etc.
Interface panel inputs
Lamps, displays, etc.
"Start" instruction, "servo ON" instruction
and other status output signals
General-purpose output signals
General-purpose input signals
"Start" instruction, "servo ON" instruction
and other status input signals
2048 logical input signals
Software
PLC
2048 logical output signals
2048 external input signals2048 external output signals
Status input signalsStatus output signals
Individually
set
Fig. 1.1.2 Overview of input/output signals used by interface panel
It is not possible to operate the logical input signals directly by operating the interface panel outputs, that is to say,
the push buttons, selector switches, etc. on the panel. (The "start" instruction and "servo ON" instruction cannot be
executed from the interface panel.)
However, as is shown in the figure, when a software PLC is used, the fore-mentioned restrictions do not apply, and
any of the interface panel input/outputs can be connected to any input/output signals.
Output signals, which have been already allocated, cannot be set to the output signals of the interface panel. By
contraries, output signals set with the interface panel cannot be allocated as output signals having different
functions.
Signal which is already allocated to the other purpose usage can be allocated to the interface panel display
(duplicate allocation). Refer to “2.1.5 Setting of signals duplication check” for detail.

1.2 Operations from Designing Screens to Using Them
1-3
1.2 Operations from Designing Screens to Using Them
This section provides an outline of the procedure to be followed starting with the design of the interface panel
screens and ending with their use.
1.2.1 Designing screens
There are two ways to design an interface panel screen. One way is to use the robot controller, and the other is to
use an external personal computer.
It is also possible to use both methods (by using one of them to change the screens designed by the other).
Table 1.2.1 Two methods of designing screens
Item General description
Designing screens using the
robot controller The layout, button types, colors and other factors can easily be set by following the menu guide. There is no need to bother about the constants
file format.
Designing screens using an
external personal computer Since the design information is stored in text files (INI format), a commercially available text editor is used to edit the information in
accordance with the prescribed rules.
When a completed file is loaded into the robot controller, its syntax and
other features are checked.
The setting information of the interface panel screens is divided into two constants files (the controller general
constants file and I/O constants file) and stores the files in the memory. This is because the information does not only
involve the screen display but it extends to the input/output signals as well. However, when designing the interface
panel screens with a commercially available text editor that runs on an external personal computer, one file (interface
panel file AC**IFP.CON), in which only the interface panel screen information is defined, is created. This interface
panel file is not referenced directly when it is displayed.
By way of operations referred to as reading (import) and writing (export), the interface panel file is converted into two
constants files in the internal memory.
AC**IFP.CON
I/O
constants
files
Controller
general
constants
files
Read
Write
The setting information on the interface panel screens is
divided into the control unit general constants files and
I/O constants files, and stored in the memory.
Interface panel files edited
by personal computer
(using a commercially
available text editor)
Direct editing
Interface
panel
files
Displa
Fig. 1.2.1 Designing screens using an external personal computer
When the setting information on the interface panel screen which was set using one robot controller is to be copied
into a multiple number of other robot controllers, it is easier to use the interface panel file.

1.2 Operations from Designing Screens to Using Them
1-4
1.2.2 Deciding on the operation method
Define the method to be used to open the interface panel screen, the default values of the common switches and
other contents.
1.2.3 Operation
Open the interface panel screen, and check the lamp lighting/extinguishing, switch ON/OFF operations, etc.

Chapter 2 Condition Settings
This chapter describes how to set conditions for using the interface panel
screens.
2.1 Condition Settings.......................................................................................2-1
2.1.1 Select whether the screen is displayed.................................................2-1
2.1.2 Display the screen with input signal......................................................2-2
2.1.3 Setting of the initial status of the common switch..................................2-2
2.1.4 Setting of Enable/Disable of functionless code switch name setting.....2-3
2.1.5 Setting of signal duplication check........................................................2-4
2.1.6 Setting of Enable/Disable of operations of f keys on touch panel .........2-4
2.1.7 Controlling the common switch using an input signal............................2-5
2.1.8 Checking the status of the common switch...........................................2-6
2.1.9 Setting of softkey output signal for general purpose usage...................2-6

2.1 Condition Settings
2-1
2.1 Condition Settings
This section describes how to open the interface panel screen, how to perform initial setting of the switch reserved
by the system (selector switch to enable/disable the operation), etc.
2.1.1 Select whether the screen is displayed
Select whether the interface panel itself is used (enabled to be displayed) or not (disabled to be displayed).
1 Select <Constant Setting> in the teach mode.
Select [22 I/F Panel on Touch Screen] from the menu which is displayed.
>> The interface panel constants menu such as the one shown below appears.
2 Select [1 Touch Panel Conditions].
>> A setting screen such as the one shown below appears.
Align the cursor with "Interface Panel," and select the "Use" setting using the
[ENABLE] and [Left] or [Right] cursor keys.
Settings Details
Use The interface panel itself can be displayed.
Not use Even if an operation to open the interface panel is performed, the
screen is not displayed. When an erroneous manipulation should be
avoided, such as during peripheral devices setup, set to <Not Use>.
＋
3
4 Upon completion of the settings, press f12 <Complete>.
The settings are saved in the constants files (S**SIGL.CON I/O constants file and
C**CTRL.CON controller general constants file).
(To stop editing at any time, press the [RESET/R] key.)

2.1 Condition Settings
2-2
2.1.2 Display the screen with input signal
Define the method to open the interface panel screen.
The teach pendant has dedicated keys used normally to open the interface panel screen, but it is also possible to
open and close the screen with input signals from the external source.
Select and allocate the input signals to be used.
On the same setting screen, align the cursor with "Auto Disp", and set the desired
status.
Settings Details
Enabled Auto display of the interface panel screen is enabled by the external
input signal.
Disabled Auto display of the interface panel screen is disabled by the external
input signal.
1
When the "AutoDisp" is enabled, allocate here the input signals to be used to
control display of the interface panel screen.
Align the cursor with "InputSignal", and allocate 4-bit page selection signals and a
strobe signal (a signal which determines the timing at which the signal is read).
>> A 4-bit page selection signal is interpreted as a binary data. The signal 1 is the
lowest, and the signal 4 is the highest. If all bits are set to off, the page number is set
to 0, that is to say, the interface panel screen is closed.
The timing at which the page selection signals and the strobe signal are input is
shown below.
More than 10msec
Page selection
signal 1 to 4
STRB signal
After entering the page bits (4-bit page selection signal), input the
STRB (strobe) signal, and hold the status of the page bits signal for at
least 10ms after the STRB signal has turned ON. Hold the STRB
signal for at least 20ms.
More than 20msec
2
Fig. 2.1.1 Automatic display of the interface panel
Even if "AutoDisp" is disabled, it is still possible to allocate input signals. However, the
input signals allocated when "AutoDisp" is disabled cannot be used as general-purpose
input signals.
3By pressing f8 <Input Ref>, the allocation of the input signals can be checked.
4Upon completion of the settings, press f12 <Complete>.
2.1.3 Setting of the initial status of the common switch
Set the initial status of "selector switch for enabling/disabling operations" always provided at upper right-hand corner
(1H) of each page by the system.

2.1 Condition Settings
2-3
Fig. 2.1.2 Selector switch for enabling/disabling operations always provided
at upper right-hand corner of each page
On the same setting screen, align the cursor with "Common Switch", and set the
desired status.
Settings Details
Previous No. Restore the status in which the power is previously turned off.
Disabled The switch is always set to "Disabled" when the power is turned on.
1
Put the cursor on “Common switch ON direction”, and set it to the desired status.
Settings Details
Left Inhibit operations on the left side.
Right Inhibit operations on the right side.
2
Put the cursor on “Common switch operation method”, and set it to the desired
status.
Settings Details
Standard Enable operation without pressing the [ENABLE] key.
Enable No operations are enabled unless the [ENABLE] key is pressed.
3
4Upon completion of settings mentioned above, press the f12 <Complete> key.
2.1.4 Setting of Enable/Disable of functionless code switch name setting
Using the “Interface panel design” menu, make setting of whether or not the name setting of switches, to which the
functionless code (0) is set, is to be enabled.
On the same setting screen, put the cursor on “Functionless code name setting”,
and set it to the desired status.
Settings Details
Hide Make setting so that the name setting of switch, to which the
functionless code has been set, will not be displayed. The name
setting will also be disabled.
Display Make setting so that the name setting of switch, to which the
functionless code has been set, will be displayed. The name setting
will also be enabled.
1
2Upon completion of settings mentioned above, press the f12 <Complete> key.

2.1 Condition Settings
2-4
2.1.5 Setting of signal duplication check
This function is used to make setting of whether or not it is to be checked that input signal numbers and output signal
numbers to be set with the interface panel or T/P keys duplicate signal numbers that have been allocated by other
functions.
On the same setting screen, put the cursor on “Signal duplicate check”, and set it
to the desired status.
1
Settings Details
Unused Make setting so that no errors occur even if the signal numbers that
have been allocated by other functions are used for the interface
panel setting.
Used Make setting so that the warning screen will be displayed to disable
the setting if the signal numbers that have been allocated by other
functions are used for the interface panel setting.
Upon completion of settings mentioned above, press the f12 <Complete> key.
2
2.1.6 Setting of Enable/Disable of operations of f keys on touch panel
Make setting of whether the operations of soft keys, which have been allocated to f1 to f12, are to be enabled or
disabled on the touch panel.
On the same setting screen, put the cursor on “F key on TP”, and set it to the
desired status.
1
Settings Details
Enabled Make setting so that the soft keys, which have been allocated to f1 to
f12, can be operated by pressing icons on the touch panel. In this
case, pressing f1 to f12 or f key icons on the touch panel makes it
possible to operate the soft keys, respectively.
Disabled Make setting so that the soft keys, which have been allocated to f1 to
f12, cannot be operated even by pressing the icons on the touch
panel. In this case, only pressing f1 to f12 makes it possible to
operate the soft keys, respectively.
Upon completion of settings mentioned above, press the f12 <Complete> key.
2

2.1 Condition Settings
2-5
2.1.7 Controlling the common switch using an input signal
This function is used to control the [Operation Disabled / Enabled switch] (Common switch) located on the most
upper right side on the screen by the external input signal.
When it is not necessary to control the common switch using the external input signal, this setting is unnecessary.
But, if it is necessary to confirm the status of the common switch from external devices, please refer to [2.1.8
Checking the status of the common switch].
On the same screen, put cursor on [Signal of common SW], and set it to the
desired status.
1
Settings Details
Disabled The touch panel controls common switch.
Enabled Common switch is controlled by the external input signals.
(1)
When enabled, the following settings are disabled.
[The status of the common switch when turning ON the primary power]
This depends on the signal status at the timing of the power ON.
[Operation of the common switch]
Because the common switch is controlled by the input signal, the
operation for this switch on the touch panel is ignored.
(2)
When enabled, the graphical icon of the switch on the most upper right side is
displayed like shown below. (Hatched icon)
2If [Signal of common SW] is set to [Enabled], please allocate an input signal that is
used to control the common switch on this screen. Put the cursor to [Input of
common SW], and allocate one input signal.
When the allocated signal is OFF, the common switch is [Disabled]
When the allocated signal is ON, the common switch is [Enabled]
3By pressing f8 <Input Ref>, the allocation of the input signals can be checked.
4Upon completion of settings mentioned above, press f12 <Complete> key.
IMPORTANT
When controlling the Disabled/Enabled status of the common switch using the input signal,
there would be a possibility in which the operator presses the button in mistake. Therefore,
please use the function carefully considering the enabling conditions etc.

2.1 Condition Settings
2-6
2.1.8 Checking the status of the common switch
This function is used to check the status of the [Operation Disabled / Enabled switch] (Common switch) located on
the most upper right side on the screen from the external devices.
1To check the status of the common switch from the external devices, allocate an
output signal on this screen. Put the cursor to [Output of common SW], and
allocate one output signal.
When the allocated signal is OFF, the common switch is [Disabled]
When the allocated signal is ON, the common switch is [Enabled]
2By pressing f9 <Output Ref>, the allocation of the output signals can be checked.
3Upon completion of settings mentioned above, press f12 <Complete> key.
2.1.9 Setting of softkey output signal for general purpose usage
Make setting of whether or not output signals assigned to the output usage softkeys (indicated in Table 2.1.1 set for
interface panel or T/P keys) can be also available to use as the general purpose usage output signals. When used
for general purpose usage, this signal cab be controlled ON/OFF by the function recorded in the robot program step.
Table 2.1.1 Function that can be used for general purpose usage
code description code description
3002 Push Buttons (alternation type) 3010 Selector switch (ON/OFF)
3003 Push Button (momentary type) 3030 Input 3digits
3004 Flash Push Button (alternation type) 3030 Input 6digits (only for interface panel)
3005 Flash Push Button (momentary type)
(notes) Double contact selector switch can not be used for general purpose usage.
On the same screen, put cursor on [Softkey outsignal general use], and set it to
the desired status.
1
Settings Details
Unused Output signals assigned for softkey are used for fixed output signals.
(These signals can not be controlled ON/OFF by the function
recorded in the robot program step.)
Used Output signals assigned for softkey are used for general purpose
output signals.
(Notes) If this is set to “Used”, duplicate signal setting is now possible in case
that plural softkeys indicated in Table 2.1.1 are defined. But it is not possible to
define with application signals at the same time.
Upon completion of settings mentioned above, press f12 [Complete] key.
2
CAUTION
When this is set to “Used”,
Both robot program and softkey operation can control ON/OFF of one signal. Beware in mind
to avoid mis-operation with using enable key and or so.
CAUTION
When this is set to “Used” and same output signal is assigned to the duplicate (different)
softkey, Unexpected softkey may change its status because of the softkey’s own ON/OFF
control or the operation of softkey.
When duplicate setting is made, bear in mind to consider those control sequence clearly.