YASKAWA YRC1000 User manual

MANUAL NO.
HW1484216 2
YRC1000 OPTIONS
INSTRUCTIONS
FOR WELDCOM FUNCTION:
ARC WELDING/DIGITAL I/F 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)
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DANGER
• This manual explains the endless 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". To ensure correct and safe operation, carefully read
"Chapter 1. Safety".
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.
• YASKAWA is not responsible for incidents arising from
unauthorized modification of its products. Unauthorized
modification voids the product warranty.
NOTICE
• YASKAWA may 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.
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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”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
DANGER
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.
WARNING
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.
CAUTION
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
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.
NOTE
To ensure safe and efficient operation at all times, be sure
to follow all instructions, even if not designated as “DAN-
GER”, “WARNING” and “CAUTION".
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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 and 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 result in personal injury caused
by unintended manipulator movement.
Fig. : Release of Emergency Stop
TURN
• Observe the following precautions when performing a teaching
operation within the P-point maximum envelope of the manipulator:
– 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 result in personal injury caused
by improper or unintended manipulator movement.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator 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
Injury may result if any person should enter the P-point maximum
envelope of the manipulator 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 YRC1000 and on the
right of the programming pendant.
• Read and understand the Explanation of the Warning Labels before
operating the manipulator.
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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.
In this manual, the equipment is designated as follows.
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 unattented on the manipulator, on a
fixture, or on the floor, 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.
Equipment Manual Designation
YRC1000 controller YRC1000
YRC1000 programming pendant Programming pendant
Cable between the manipulator and the
controller
Manipulator cable
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Descriptions of the programming pendant keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming
Pendant
Character Keys
/Symbol Keys
The keys which have characters or symbols
printed on them are denoted with [ ].
e.g. [ENTER]
Axis Keys
/Numeric Keys
[Axis Key] and [Numeric Key] 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, e.g. [SHIFT]+[COORD].
Mode Switch Mode Switch can select three kinds of modes
that are denoted as follows: REMOTE, PLAY or
TEACH.
(The switch names are denoted as symbols)
Button The three buttons on the upper side of the
programming pendant are denoted as follows:
START, HOLD, or EMERGENCY STOP.
(The button names are denoted as symbols)
Displays The menu displayed in the programming
pendant is denoted with { }.
e.g. {JOB}
E
M
E
R
G
E
N
C
Y
S
T
O
P
Numeric keys
Axis keys
Enter key
Mode switch*
Start button* Hold button*
Emergency stop button
Shift key
Page key
Coordinate key
PLAY
REMOTE
TEACH
START
*The button/switch names
are denoted as symbols.
HOLD
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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.
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Contents
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1 Functional Overview........................................................................................................................ 1-1
1.1 Overview ............................................................................................................................ 1-1
2 Setup............................................................................................................................................... 2-1
2.1 Setup Flow ......................................................................................................................... 2-1
2.2 Upgrading YRC1000 System Software.............................................................................. 2-1
2.2.1 Individual Data Backup ......................................................................................... 2-1
2.2.2 Upgrading System Software ................................................................................. 2-1
2.3 Setting and Confirmation of Hardware Configuration ........................................................ 2-2
2.3.1 Removing Unnecessary EW Board ...................................................................... 2-2
2.3.2 Station Number when EW Board is Left ............................................................... 2-2
2.4 Connection of Welding Power Source and YRC1000........................................................ 2-3
2.4.1 Standard Connection (When connecting one welding power source of
digital interface to YRC1000)................................................................................ 2-3
2.4.2 When Connecting to YRC1000 the Multiple Welding Power Sources of
Digital Interfaces and also Other Devices with Data Transmission Function
using Ethernet Function........................................................................................ 2-4
2.5 System Configuration......................................................................................................... 2-5
2.5.1 I/O Module Setting Check after Changing EW Board Station Number Setting..... 2-6
2.5.2 Setting of Optional Function “Network Function” .................................................. 2-7
2.5.3 Setting of Optional Function “WELDCOM Function” ............................................ 2-9
2.5.4 Detailed Setting of Welding Power Source......................................................... 2-11
2.5.5 I/O Module Setting Check after Adding Virtual EW Module................................ 2-13
2.5.6 Setting of Optional Function "MotoPlus Function"
(When Welder is FroniusTPSi) ........................................................................... 2-15
2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)....................... 2-16
2.5.8 Setting of Parameter (When Welder is MOTOWELD)........................................ 2-17
2.5.9 Setting of Parameter (When Welder is FroniusTPS) .......................................... 2-19
2.5.10 Setting of Parameter (When Welder is FroniusTPSi) ....................................... 2-21
2.5.11 Optional Parameters for Fronius TPS............................................................... 2-24
2.5.12 Optional Parameter for FroniusTPSi................................................................. 2-24
3 Operation of Welding Condition File Edit Window .......................................................................... 3-1
3.1 Overview ............................................................................................................................ 3-1
3.2 Display of Welding Condition File Edit Window ................................................................. 3-1
3.3 MOTOWELD Type: Operation of Top Window .................................................................. 3-2
3.4 MOTOWELD Type: Operation of Weld type Window ........................................................ 3-3
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3.5 MOTOWELD Type: Operation of Customize Window ....................................................... 3-4
3.6 MOTOWELD Type: Operation of Maintenance Window ................................................... 3-7
3.7 MOTOWELD Type: Operation of Welder Parameter Window........................................... 3-8
3.8 FroniusTPS Type: Operation of Top Window .................................................................... 3-9
3.9 FroniusTPS Type: Operation of Program No. setting Window ........................................ 3-10
3.10 FroniusTPS Type: Operation of Param. setting Window ............................................... 3-11
3.11 FroniusTPSi Type: Operation of Top Window ............................................................... 3-12
3.12 FroniusTPSi Type: Operation of Select Synergic Window ............................................ 3-13
3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window ............................... 3-13
4 Job Preparation for Welding ........................................................................................................... 4-1
4.1 Job Preparation for Welding .............................................................................................. 4-1
5 Synchro-welding Function [Compatible Welder : MOTOWELD-X350] ........................................... 5-1
5.1 Setting of “Synchro-welding”..............................................................................................5-2
6 Alarm and Error............................................................................................................................... 6-1
6.1 Alarm ................................................................................................................................. 6-1
6.2 Error................................................................................................................................. 6-24
6.3 Message .......................................................................................................................... 6-24
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1 Functional Overview
1.1 Overview
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1 Functional Overview
1.1 Overview
The WELDCOM function serves as a digital interface that communicates
via Ethernet with an arc welding power source. The function provides high
data rate transmission between YRC1000 and the welding power source,
enables the welding power source parameter to be set from the
programming pendant, and monitors graphically welding current and
voltage during welding.
The WELDCOM function can use either of the following four welding
power sources for connection.
MOTOWELD-EL350-AJ2E (manufactured by YASKAWA
ELECTRIC CORPORATION)
(AJ2E indicates that an Ethernet interface is incorporated.)
MOTOWELD-RP500 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(In the case of digital communication mode)
MOTOWELD-RL350 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(In the case of digital communication mode)
MOTOWELD-X350 (manufactured by YASKAWA ELECTRIC
CORPORATION)
MOTOWELD-X500 (manufactured by YASKAWA ELECTRIC
CORPORATION)
MOTOWELD-RD350S/S-AC (manufactured by YASKAWA
ELECTRIC CORPORATION)
MOTOWELD-RD500S (manufactured by YASKAWA ELECTRIC
CORPORATION)
( , , System version: YAS2.03.00(□)-00 or later)
TPS4000 CMT (manufactured by Fronius International GMBH)
(Only the model that incorporates the WeldCom interface)
TPSi (manufactured by Fronius International GMBH)
(System version: YAS1.34.00(□)-00 or later)
(Only the model that incorporates the WeldCom interface)
Programming a job is available using general arc welding
commands.
ARCSET ASF#( ),
ARCON ASF#( ),
ARCOF AEF#( )
Welding conditions are set in a welding start condition file or a
welding end condition file specified in an arc welding command.
The welding start condition file or welding end condition file has the
edit window that provides the setting window for a digital interface,
enabling users to check or edit parameters to be set in welding
power source.
The parameter to be set in the edit window of the welding condition
file is saved in the dedicated condition file, "Welding type file" and
"Digital welder condition file", where the data can be loaded and
saved with the external memory function.
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1 Functional Overview
1.1 Overview
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TCP Speed Function
This is the function only for TPS4000 CMT welding with bead leg length
kept constant by changing the feeding rate according to the welding speed.
(NOTE)
• When using TCP Speed, you must add the ARATION and ARATIOF
commands to the welding section for the welding speed to be output
in analog.
Ex. ARATION BV 7.00 SPD 512
• To use TCP Speed, special software must be installed on TPS4000
CMT.
• TCP Speed cannot be used with the TPS of the US specification.
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2 Setup
2.1 Setup Flow
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2Setup
2.1 Setup Flow
Setup the YRC1000 with the following procedure.
2.2 Upgrading YRC1000 System Software
The communication interface with the MOTOWELD-X350, RD350S/S-AC,
and RD500S is incorporated into the YAS2.03.00(□)-00 or later version of
system software of YRC1000.
The communication interface with the Fronius TPSi is incorporated into
the YAS1.34.00(□)-00 or later version of system software of YRC1000.
If the YRC1000 is connected to the above welding power source and the
version of the system software installed in the YRC1000 is earlier than the
corresponding version, upgrade the system software using the following
procedures.
2.2.1 Individual Data Backup
Save all the individual data including job and condition files to initialize the
system after the upgrade. Also, save the system configuration file in the
maintenance mode.
2.2.2 Upgrading System Software
See the YRC1000 Options Upgrade Procedure Manual (HW1483594) for
procedures on upgrading system software.
Setting and confirmation of hardware configuration
Connection of welding power source and YRC1000
System configuration
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2 Setup
2.3 Setting and Confirmation of Hardware Configuration
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2.3 Setting and Confirmation of Hardware Configuration
2.3.1 Removing Unnecessary EW Board
The WELDCOM is connected to the welding power source using the
digital interface via Ethernet communication. This does not require the EW
board (AEW01, AEW02, etc.) for an analog interface, so remove the EW
board.
2.3.2 Station Number when EW Board is Left
A digital interface requires a virtual EW module, not an actual EW board.
The virtual EW module also has a station number. If leaving an EW board
unremoved for other welding power sources, set the actual EW board
station number so that it does not duplicate the virtual EW module station
number.
(Setting Example)
Replacing welding power source of analog interface with that of
digital interface
Remove the actual EW board, which will be unnecessary. (The station
number of the virtual EW module is set at the time of configuration.)
When connecting welding power source of digital interface as
Welder 1, and analog interface as Welder 2
Because the virtual EW module station number is set to the smallest
number at the time of configuration, set the EW board station number to
the second or later number.
SUPPLE
-MENT
In multiple robot systems, if some welding power source uses
digital interface and some uses analog interface, leave as
many EW boards as the necessary analog interfaces.
Welder1
AEW01
X
1
0
0
Y
C
P
0
1
Digital I/F
Power Source
Virt
ua
l
EW
Virtual
EW
Station Number: 01
Station Number: 01
YRC1000
ACP01
AEW01
YRC1000
ACP01
Station Number: 02
Station Number: 01
Welder1
Analog I/F
Power Source
Welder2
Digital I/F
Power Source
Virtual
EW
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2 Setup
2.4 Connection of Welding Power Source and YRC1000
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When applying digital interface to welder and using EW board as
general analog output board
Because the EW board is automatically set as welding application due
to the configuration restrictions, set the arc application to Arc + Arc.
Specifically, set as follows:
• Set the application setting of [Initialization] to "Arc + Arc", and set Arc
2 as not for use.
• In [OPTION FUNCTION - WELDCOM FUNC.], set Arc 1 to digital
interface.
2.4 Connection of Welding Power Source and YRC1000
2.4.1 Standard Connection (When connecting one welding power source of digital interface to
YRC1000)
• Connect a LAN cable to ACP01 for LAN (CN106).
CAUTION
• Use the LAN cable that comes with our arc welding robot package
MOTOPAC. (The system may not properly work with a LAN cable
other than this, and we are not responsible for any problems that
may occur.)
SUPPLE
-MENT
When preparing a LAN cable other than the cable above
• You can use either cross cable or straight cable.
• Use a cable with the connector that has a metal cover for
noise suppression and with the cable shield grounded to
the metal cover.
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2 Setup
2.4 Connection of Welding Power Source and YRC1000
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2.4.2 When Connecting to YRC1000 the Multiple Welding Power Sources of Digital Interfaces
and also Other Devices with Data Transmission Function using Ethernet Function
As shown in the following figure, connect the LAN cable to ACP01 for LAN
(CN106) using a switching hub.
CAUTION
• Use the industrial switching hub that we recommend. (The system
may not properly work with a hub other than this, and we are not
responsible for any problems that may occur.)
• Our recommended switching hub: Model EDS-205 (manufactured
by MOXA)
YRC1000
CN106
for LAN
HUB
ACP01
(You can use either cross cable or straight cable.)
Welder1
Digital I/F
Power Source
Welder2
Digital I/F
Power Source
Welder3
Digital I/F
Power Source
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2 Setup
2.5 System Configuration
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2.5 System Configuration
The following figure illustrates the configuration procedure outline. The
following and later pages explain the detailed procedure of each setting.
Note that the initialization processing after system upgrade is omitted.
[Initialization] entry
[2.5.3] Setting of Optional Function
"WELDCOM Function"
Start
Did you upgrade
system software?
End
[2.5.1] I/O Module Setting Check
after Changing EW Board
Station Number Setting
[SETUP] entry
[SETUP] entry
Language, model, I/O module, ...
Initialization processing of each items
:
N O
[2.5.4] Detailed Setting of
Welding Power Source
[2.5.6] Setting of Optional
Function "MotoPlus Function"
* When the welder is FroniusTPSi;
[2.5.7] Loading of Dedicated
MotoPlus Application
[2.5.8] Setting of Parameter
[2.5.5] I/O Module Setting Check
after Adding Virtual EW Module
[2.5.2] Setting of Optional Function
"Network Function"
For Fronius welding power source,
change the "ARC WELDING" setting
from "STANDARD" to "ENHANCED"
Y E S
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2 Setup
2.5 System Configuration
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2.5.1 I/O Module Setting Check after Changing EW Board Station Number Setting
The EW board removal and station number change performed in the
chapter 2.4 “Connection of Welding Power Source and YRC1000”
changes the I/O module setting. The setting changes must be recognized
with [Setting] in the maintenance mode.
1. Start the YRC1000 while pressing [MAIN MENU]
– Start the YRC1000 in maintenance mode.
2. Select {SYSTEM} → {SECURITY} → “MANAGEMENT MODE”.
– A password must be entered after selecting “MANAGEMENT
MODE”.
3. Select {SYSTEM} → {SETUP} → “IO MODULE”.
4. Press the [Enter] key to check the I/O module connection status.
– If no EW board is connected, the board column displays “NONE” as
follows.
5. A confirmation dialog box appears. Select {YES}.
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2.5 System Configuration
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2.5.2 Setting of Optional Function “Network Function”
The WELDCOM function uses the network function (optional function).
Set the network function by following the procedure below.
1. Select {SYSTEM} → {SETUP} → “OPTION FUNCTION”, and then
"DETAIL" of "LAN INTERFACE SETTING".
2. Change the setting of "DEVICE" from "NOT USED" to "MANUAL
SETTING".
– Set the Network (Ethernet) function to enable.
3. After setting "IP ADDRESS SETTING" to "MANUAL SETTING",
change "IP ADDRESS" to "192.168.255.200".
• Set “SUBNET MASK” to “255.255.255.0”.
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2.5 System Configuration
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4. After the setting above is completed, press the [ENTER] key. When a
confirmation dialog appears, select {Yes} to confirm the setting.
5. Select {SYSTEM} → {SETUP} → “OPTION FUNCTION”, and then
"DETAIL" of "NETWORK FUNCTION SETTING".
6. Change the setting of "ETHERNET" from "NOT USED" to "USED".
7. After the setting above is completed, press the [ENTER] key. When a
confirmation dialog appears, select {Yes} to confirm the setting.
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2 Setup
2.5 System Configuration
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2.5.3 Setting of Optional Function “WELDCOM Function”
Set the WELDCOM function by following the procedure below.
1. Select {SYSTEM} → {SETUP} → “OPTION FUNCTION”, and then
"DETAIL" of "WELDCOM FUNC. (ARC DIGITAL I/F)".
2. The WELDER SETUP window appears.
When multiple applications (welders) are set, you can navigate among
welder numbers with the upper or lower cursor.
– When the application setting is arc and no actual EW board exists,
only one line is displayed with *** for the items.
<Explanation of each item>
• The window displays as many lines as the number of applications.
• ST#: The station number of EW module corresponding to the weld-
ers
• TYPE: Kind of EW module (EX: AEW02, AEW01-1, etc.)
• <Second board>: Displayed when two EW boards are used in the
enhanced mode.
• DIGITAL I/F TYPE: Displays the type of welding power source con-
nected. (Either MOTOWELD, Fronius TPS, or
FroniusTPSi)
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