YASKAWA YRC1000 User manual

HW1486273 1 / 95
MANUAL No.
1
YRC1000 OPTIONS
INSTRUCTIONS
FOR REMOTE LASER 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)
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 "MINORALARMS".
189214-1CD
0

ii HW1486273 2 / 95
DANGER
•This manual explains the Remote Laser function of the YRC1000 system. Read
this manual carefully and be sure to understand its contents before handling the
YRC1000. Any matter, including operation, usage, measures, and an item to use,
not described in this manual must be regarded as "prohibited" or "improper".
•General information related to safety are described in "Chapter 1. Safety" of the
YRC1000 INSTRUCTIONS. To ensure correct and safe operation, carefully read
"Chapter 1. Safety" of the YRC1000 INSTRUCTIONS.
CAUTION
•In some drawings in this manual, protective covers or shields are removed to show
details. Make sure that all the covers or shields are installed in place before
operating this product.
•YASKAWAis not responsible for incidents arising from unauthorized modification
of its products. Unauthorized modification voids the product warranty.
NOTICE
•The drawings and photos in this manual are representative examples and
differences may exist between them and the delivered product.
•YASKAWAmay modify this model without notice when necessary due to product
improvements, modifications, or changes in specifications. 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.

iii HW1486273 3 / 95
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. Safety Signs
identified by the signal word DANGER should be used
sparingly and only for those situations presenting the most
serious hazards.
Indicates a potentially hazardous situation which, if not
avoided, will result in death or serious injury. Hazards
identified by the signal word WARNING present a lesser
degree of risk of injury or death than those identified by the
signal word DANGER.
Indicates a hazardous situation, which if not avoided, could
result in minor or moderate injury. It may also be used
without the safety alert symbol as an alternative to
"NOTICE".
NOTICE is the preferred signal word to address practices
not related to personal injury. The safety alert symbol
should not be used with this signal word. As an alternative
to "NOTICE", the word "CAUTION" without the safety alert
symbol may be used to indicate a message not related to
personal injury.
Even items described as "CAUTION" may result in a serious accident in some situations.
At any rate, be sure to follow these important items.
To ensure safe and efficient operation at all times, be sure to follow all
instructions, even if not designated as "DANGER", "WARNING" and
"CAUTION".

iv HW1486273 4 / 95
Precautions for the laser
DANGER
This function performs processing mainly with infrared light lasers.
These infrared lights are invisible laser light sources and are classified as Class 4
according to International Electrotechnical Commission (IEC) 60825-1:2014 ' Safety of
laser products - Part 1: Equipment classification and requirements.'
Class 4 lasers are considered dangerous if the skin or eyes are directly exposed to a
laser beam even momentarily, and even diffuse reflected light can harm the skin or
eyes. There is also a risk of fire. Always keep out of the processing room during
processing.
This function also uses Class 2 red laser pointer light to indicate the processing
position.
Class 2 lasers are considered safe lasers because danger can be avoided by an
aversion reaction of the eyes (blinking). However, there is deemed to be a potential
risk when observing a direct laser beam with optical instruments.
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.
Description of laser classes
Class
Description of the degree of risk
Class 1
Safe under any reasonably foreseeable operating conditions.
Class 1M
Same as Class 1, except for an increased risk when using
optical instruments.
Class 2
Low power. Normally safe due to the protection afforded to the
eyes by aversion reactions (e.g., blinking).
Class 2M
Same as Class 2, except for an increased risk when using
optical instruments.
Class 3R
Increased risk with direct intrabeam exposure.
Class 3B
Always dangerous with direct intrabeam exposure.
Class 4
High power. Even diffuse reflection is dangerous.
* Excerpt from IEC 60825-1:2014. Class 1C is medical use, so it is omitted in the table
above. Be sure to read the standard's original text prior to actual application.

v HW1486273 5 / 95
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.
- Disconnect the safety plug of the safety fence.
(when in the play mode or in the remote mode)
If operation of the manipulator cannot be stopped in an emergency, personal injury
and/or equipment damage may result.
Fig.: Emergency Stop Button
•Before releasing the emergency stop, make sure to remove the obstacle or error
caused the emergency stop, if any, and then turn the servo power ON.
Failure to observe this instruction may cause unintended movement of the
manipulator, which may result in personal injury.
Fig.: Release of Emergency Stop
•Observe the following precautions when performing a teaching operation within the
manipulator's operating range:
- Be sure to perform lockout by putting a lockout device on the safety fence
when going into the area enclosed by the safety fence. In addition, the
operator of the teaching operation must display the sign that the operation is
being performed so that no other person closes the safety fence.
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Always keep in mind emergency response measures against the
manipulator's unexpected movement toward a person.
- Ensure a safe place to retreat in case of emergency.
Failure to observe this instruction may cause improper or unintended movement of the
manipulator, which may result in personal injury.
•Confirm that no person is present in the manipulator's operating range and that the
operator is in a safe location before:
- Turning ON the YRC1000 power
- Moving the manipulator by using the programming pendant
- Running the system in the check mode
- Performing automatic operations
Personal injury may result if a person enters the manipulator's operating range during
operation. Immediately press an emergency stop button whenever there is a
problem. The emergency stop buttons are located on the front panel of the

vi HW1486273 6 / 95
YRC1000 and on the right of the programming pendant.
•Read and understand the Explanation of the Warning Labels before operating the
manipulator.
DANGER
•Teaching should only be carried out by personnel who have attended all of the
following training sessions.
- Robot operation training
- Training on lasers that comply with the guidelines for JIS C6802 users
If personnel who have not attended these training sessions perform teaching, there is
a risk of major injury or property damage due to unintended actions.
WARNING
•Perform the following inspection procedures prior to conducting manipulator
teaching. If there is any problem, immediately take necessary steps to solve it,
such as maintenance and repair.
- Check for a problem in manipulator movement.
- 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
where it is left, and the servo power may be turned ON. In addition, in case the
operation of the manipulator starts, the manipulator or the tool may hit the
programming pendant left unattended, which may result in personal injury and/or
equipment damage.

vii HW1486273 7 / 95
CAUTION
•Perform welding after confirming that the galvano laser head is being supplied with
air and cooling water in accordance with the specifications.
Performing welding without air supply increases the possibility of spattering on the
protective glass, which shortens the service life.
Performing welding without supplying cooling water causes the optical components'
temperature to increase, which may result in laser head malfunction or reduced
welding quality.
•Do not perform welding if the protective glass is cracked or dirty.
If welding is performed with cracked or dirty protective glass, the laser may diffuse in
an unintended direction and/or the protective glass may absorb the laser energy,
resulting in laser head malfunction or damage to peripheral devices.
•Do not touch hot work or hot jigs immediately after welding with bare hands.
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 YASKAWAindustrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the programming
pendant, and the manipulator cables.
In this manual, the equipment is designated as follows:
Equipment
Manual Designation
YRC1000 controller
YRC1000
YRC1000 programming pendant
Programming pendant
Cable between the manipulator and the
controller
Manipulator cable

viii HW1486273 8 / 95
Descriptions of the programming pendant, buttons, and displays are shown as follows:
Equipment
Manual Designation
Programming
Pendant
Character Keys
/Symbol Keys
The keys which have characters printed on them
are denoted with [ ].
ex. [ENTER]
Axis Keys
Number Keys
"Axis Keys" and "Number Keys" are generic
names for the keys for axis operation and
number input.
Keys pressed
simultaneously
When two keys are to be pressed simultaneously,
the keys are shown with a "+" sign between
them, ex. [SHIFT]+[COORD]
Displays
The menu displayed in the programming pendant
is denoted with { }.
ex. {JOB}
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 corporation. The
indications of (R) and TM are omitted.

ix HW1486273 9 / 95
Contents
1. Overview of the remote laser function system................................................... 1-11
1.1. Remote laser function............................................................................... 1-11
1.2. 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
2. Operation of the remote laser function from the pendant...................................2-14
2.1. Pendant key .............................................................................................2-14
2.2. Types of lasers .........................................................................................2-15
2.3. Laser head coordinate system..................................................................2-16
2.4. Operating the remote laser .......................................................................2-17
2.4.1. Operating the remote laser current position window...........................2-17
2.4.2. Operating the remote laser record position window............................2-18
3. Remote laser welding position registration files.................................................3-20
3.1. Creating files ............................................................................................3-21
3.2. Registering welding positions....................................................................3-22
3.2.1. Description of each setting ................................................................3-22
3.2.2. Method for registering welding positions............................................3-23
3.3. Registering or deleting position data.........................................................3-24
3.4. Adding points............................................................................................3-25
3.5. Deleting points..........................................................................................3-26
3.6. Erasing points...........................................................................................3-27
3.7. Copying points..........................................................................................3-28
3.8. Pasting points...........................................................................................3-28
3.9. Parallel shift..............................................................................................3-29
3.10. Deleting remote laser welding position registration files.............................3-30
3.11. Changing the number of points in remote laser welding position registration
files 3-31
3.12. Copying remote laser welding position registration files.............................3-32
3.13. Pasting remote laser welding position registration files..............................3-32
3.14. Teaching during welding position registration ............................................3-33
4. Remote laser welding condition registration files...............................................4-35
4.1. File setup..................................................................................................4-35
4.2. Interpolation of welding lines.....................................................................4-36
4.2.1. Linear interpolation............................................................................4-37
4.2.2. Circular interpolation..........................................................................4-37
4.2.3. C-shaped interpolation ......................................................................4-38
4.2.4. Character-shaped interpolation..........................................................4-39
4.2.5. User file interpolation.........................................................................4-40
4.2.6. Wobbling...........................................................................................4-41
4.2.7. Square interpolation..........................................................................4-42
4.3. Setting the capable range.........................................................................4-43
4.4. Setting DF (defocus).................................................................................4-44
4.5. Registering timers and slope control.........................................................4-45

x HW1486273 10 / 95
4.6. Registering or canceling position data.......................................................4-46
4.7. Adding paths ............................................................................................4-47
4.8. Deleting paths...........................................................................................4-48
4.9. Erasing paths ...........................................................................................4-49
4.10. Copying paths...........................................................................................4-50
4.11. Pasting paths............................................................................................4-50
4.12. Batch changing welding conditions ...........................................................4-51
4.13. Erasing remote laser welding condition registration files............................4-52
4.14. Copying files.............................................................................................4-53
4.15. Pasting files..............................................................................................4-53
4.16. How to scan arbitrary shape files ..............................................................4-54
4.17. How to back up arbitrary shape files..........................................................4-54
5. Remote laser welding programs .......................................................................5-55
5.1. Using macro commands...........................................................................5-55
5.2. Macro command for turning on the laser (LASER_ON) .............................5-56
5.3. Macro command for turning off the laser (LASER_OF)..............................5-56
5.4. Macro command for communication with the laser oscillator (L_READY) ..5-57
5.5. Sample welding programs.........................................................................5-58
6. 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. Welding start timing...........................................................................6-60
6.3.2. Setting exceptional states for signals.................................................6-62
6.4. Pincushion correction function (Yaskawa head only) .................................6-64
6.5. Scanner and communication handshake function (Yaskawa head only) ....6-64
6.6. Scanner abnormality monitoring function (Yaskawa head only) .................6-65
7. List of alarms....................................................................................................7-66
8. S1E parameters...............................................................................................8-71
8.1. Yaskawa Control 3D 3.67x head (8MC33A-3C001A).................................8-71
8.2. Trumpf PFO head.....................................................................................8-80
8.3. Yaskawa Control 3D 3.8x Head (8MC44A-3C001A)..................................8-86

1Overview of the remote laser function system
1.1 Remote laser function
1-11 HW1486273 11 / 95
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)

1Overview of the remote laser function system
1.2 System configuration diagram
1-12 HW1486273 12 / 95
1.2. System configuration diagram
1.2.1. System configuration for the CAN specification Laser Head made by Yaskawa Control
Inc.
No.
Name of part
Part No.

I/O cable or device net cable
(Dependent on oscillator specifications)
Prepared by the customer

CAN data cable (base to CAN-DAC)
HS1370057

ACP02+ASL01 circuit board for remote laser
JANCD-ACP02-E
JANCD-ASL01-E

CAN-DAC conversion unit
CAN-DAC

Analog cable
HS1480292

CAN data cable (head to CAN-DAC)
HS0371378
Galvano power cable
HS0471730
* CAN-DAC requires a separate 100 or 200 VAC (single phase) power supply.
YRC1000






CAN specification Laser
Head made by Yaskawa
Control Inc.
Laser Oscillator

1Overview of the remote laser function system
1.2 System configuration diagram
1-13 HW1486273 13 / 95
1.2.2. System configuration for the laser head made by TRUMPF Inc.
No.
Part name
Part No.

I/O cable or device net cable
(Dependent on oscillator specifications)
Prepared by the customer

CAN data cable (base to head)
HS0371378

ACP02+ASL01 circuit board for remote laser
JANCD-ACP02-E
JANCD-ASL01-E
YRC1000

Laser Oscillator
Laser Head made by
TRUMPF Inc.



2Operation of the remote laser function from the pendant
2.1 Pendant key
2-14 HW1486273 14 / 95
2. Operation of the remote laser function from the pendant
2.1. Pendant key

2Operation of the remote laser function from the pendant
2.2 Types of lasers
2-15 HW1486273 15 / 95
2.2. Types of lasers
DANGER
Do not approach the area being irradiated by the laser or look directly at the laser.
Always perform laser welding inside a light-blocked partition where no people are
present.
Different types of lasers can be used with this function.
•Guide laser
This visible red light is used in teaching. The guide laser is used to teach the welding
start position and end position.
•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.
[INTERLOCK] + [5]: Green pointer ON
[INTERLOCK] + [8]: Green pointer OFF
•Cross laser (when using the Trumpf 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.
[INTERLOCK] + [5]: Cross laser ON
[INTERLOCK] + [8]: Cross laser OFF

2Operation of the remote laser function from the pendant
2.3 Laser head coordinate system
2-16 HW1486273 16 / 95
•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.
Z
Y
X

2Operation of the remote laser function from the pendant
2.4 Operating the remote laser
2-17 HW1486273 17 / 95
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.
2.4.1. Operating the remote laser current position window
(1) From the main menu, select {OPTION} {LASER CURRENT POS}.
* The remote axis coordinates indicate the coordinates according to the laser head's
unique coordinate system.
* The base axis coordinates indicate the remote laser's focal position in terms of
coordinates according to the robot's base coordinate system.
(2) The following key combinations can be used to move the guide laser.
Key combination
Action
[INTERLOCK] + [X+]
Move the guide laser in the remoteaxisX-axispositive direction.
[INTERLOCK] + [X-]
Movethe guide laserin the remote axis X-axis negative direction.
[INTERLOCK] + [Y+]
Move the guide laser in the remote axisY-axispositive direction.
[INTERLOCK] + [Y-]
Move the guide laser in the remote axisY-axis negative
direction.
[INTERLOCK] + [Z+]
Move the guide laser in the remote axisZ-axis positive direction.
[INTERLOCK] + [Z-]
Move the guide laser in the remote axis Z-axisnegative
direction.
[INTERLOCK] + [e+]
Move the guide laser in the DF (defocus) positive direction.
[INTERLOCK] + [e-]
Move the guide laser in the DF (defocus) negative direction.
[INTERLOCK] + [6]
Return the guide laser to the origin.

2Operation of the remote laser function from the pendant
2.4 Operating the remote laser
2-18 HW1486273 18 / 95
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.
2.4.2. Operating the remote laser record position window
(1) From the main menu, select {OPTION} {LASER RECORD POS}.
(2) Open the desired remote laser record position file.
WD
DF = 0
DF > 0
Laser
Laser
Head
Head

2Operation of the remote laser function from the pendant
2.4 Operating the remote laser
2-19 HW1486273 19 / 95
* 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.
(3) The remote axis will automatically move to the focal point.
* However, it will not return to the focal point on axes specified with the following SE
parameters.
The initial value is 0, and all axes automatically move to the focal point.
No.
Details
Setting
SxE164
Specification of the
axis to turn off home
position return
Bit specification (returning to the home position is
turned off when raised)
d0: X-axis, d1: Y-axis, d2: Z-axis, d3: DF
(4) The following key combinations can be used to move the guide laser.
Key combination
Action
[INTERLOCK] + [4]
Have the guide laser orbit the welding range circle.
[INTERLOCK] + [8]
Stop the guide laser's orbiting.
* From the remote laser record position window, use [INTERLOCK] + [Z] or
[INTERLOCK] + [e] to turn off Z-axis lens operation (to prevent mistakenly teaching the
focal length).
Note that this function can be turned off with the following SE parameters.
The initial value is 0, and Z-axis lens operation is off.
No.
Details
Setting
SxE165
Function to turn off
Z-axis operation
Cancel setting
0: Turn off Z-axis operation when using the record
position file window.
1: Turn on Z-axis operation when using the record
position file window.

3Remote laser welding position registration files
2.4 Operating the remote laser
3-20 HW1486273 20 / 95
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.
From 1 to 999 remote laser welding position registration files can be registered.
A single remote laser record position file can register up to 999 points.
Note that the maximum number of points for all files combined is 2,000 points.
Remote Laser Welding
Position Registration File
File 1
File 2
File 3
File n
Point m
Point 3
Point 2
Point 1
Points (points in file n)