YASKAWA MOTOMAN DX100 User manual

Part Number: 166465-1CD
Revision: 1
MOTOMAN DX100 CONTROLLER
WITH ROBOTIC ARC WELDING
INSTRUCTIONS
FOR MILLER
®
AUTO-AXCESS DI/E DIGITAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN-MANIPULATOR INSTRUCTIONS
MOTOMAN OPERATORS MANUAL FOR ARC WELDING
MOTOMAN CONCURRENT I/O MANUAL
DX100 CONTROLLER MANUAL
DX100 MAINTENANCE MANUAL
The operator’s manual above corresponds to specific usage. Be sure to use the appropriate manual.
Vendor manuals for system components not manufactured by Motoman
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MANDATORY
• This manual explains the starting point detecting function of the
DX100 system. Read this manual carefully and be sure to
understand its contents before handling the DX100.
• General items related to safety are listed in Section 1 of the DX100
instructions. To ensure correct and safe operation, carefully read
the section before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• 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.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
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Notes for Safe Operation
Read this manual carefully before installation, operation, maintenance, or
inspection of the Yaskawa Motoman robot.
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
NOTE
To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as "CAUTION"
and "WARNING".
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WARNING
• Before operating the manipulator, check that servo power is turned
OFF by pressing the emergency stop button on the programming
pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop button does not function.
Figure 1: Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Figure 2: Release of Emergency Stop
TURN
• Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Ensure that there is a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning on the power for the controller.
– Moving the manipulator with the programming pendant.
– Running the system in the check mode.
– Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop button is located on the programming pendant.
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WARNING
• Since detected voltage (200V), welding current, and welding
voltage are applied to the starting point detecting unit, install the unit
securely so that it does not fall.
• Failure to observe this warning may result in an electric shock or
damage to the unit.
• Before connecting the inter-unit cables and the welding cables, be
sure to turn OFF the power supply to the controller and the welder.
• Failure to observe this warning may result in an electric shock.
• Special attention should be paid during starting point detection,
since 200 V
DC
is applied across the wire and the workpiece
(welding jig).
• Failure to observe this warning may result in an electric shock.
• Do not place any object directly on the cable of the starting point
detecting unit.
• Failure to observe this warning may result in an injury or damage
caused by the disconnection of the cable.
• Attach the cable of the starting point detecting unit for the wire
feeder with the wire stand, to protect it from robot movement. If
interference between the cable and the peripheral devices are
unavoidable, cover the cable with a rubber plate or spiral tube, etc.
• Failure to observe this warning may result in an electric shock, an
injury, or damage to the cable.
• Do not lay the cable of the starting point detecting unit directly on
the floor, but install them in a pit or duct or shield the cable with a
protective cover.
• Failure to observe this warning may result in an injury or damage to
the cable.
• Since a high current flows through the welding cable, separate it
from the cables of the control circuit system. If the cables cannot be
separated, take preventative measures such as using metallic ducts
or tubes on the cables of the control circuit system.
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Definition of Terms Used Often in This Manual
The Yaskawa Motoman manipulator is an industrial robot product.
The manipulator usually consists of the controller, the programming
pendant, and supply cables.
In this manual, the equipment is designated as follows:
CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the cabinet
of the controller after use.
• The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator.
Equipment Manual Designation
DX100 controller DX100
DX100 programming pendant Programming pendant
Cable between the manipulator and the
controller Manipulator cable
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Descriptions of the programming pendant, buttons, and displays are
shown as follows:
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 the SELECT key 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 bland names for each company or
corporation. The indications of (R) and TM are omitted.
Equipment Manual Designation
Programming
Pendant Character Keys The keys which have characters printed on them are denoted with
[ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol
printed on them are not denoted
with [ ] but depicted with a small
picture.
ex. [page key]
The cursor key is an exception,
and a picture is not shown.
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}
GO
BACK
PAGE
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Table of Contents
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Table of Contents
1 Introduction .....................................................................................................................................1-1
1.1 About This Document ........................................................................................................1-1
1.2 System Configuration.........................................................................................................1-2
1.2.1 Major Components ...............................................................................................1-3
1.3 Reference Documentation.................................................................................................1-3
1.4 Customer Support Information...........................................................................................1-4
2 Safety..............................................................................................................................................2-1
2.1 Introduction........................................................................................................................2-1
2.2 Important Advisory Information..........................................................................................2-2
2.3 General Safeguarding Tips................................................................................................2-2
2.4 Mechanical Safety Devices................................................................................................2-3
2.5 Installation Safety...............................................................................................................2-3
2.6 Programming, Operation, and Maintenance Safety...........................................................2-4
3 Equipment Description....................................................................................................................3-1
3.1 Robot and Controller..........................................................................................................3-1
3.2 Auto-Axcess DI/E Digital Power Supply.............................................................................3-1
3.3 Software.............................................................................................................................3-2
3.4 Miller AA-40G Wire Feeder................................................................................................3-2
3.5 Miller-Motoman Pendant Interface (HMI) Software............................................................3-2
3.5.1 Starting the HMI Software.....................................................................................3-3
3.5.2 Welcome Screen ..................................................................................................3-3
3.5.3 Home Screen.......................................................................................................3-5
3.5.4 Program Selection Screen....................................................................................3-5
3.5.5 Program Sequence Setup Screen........................................................................3-7
3.5.6 Live Weld Data Screen.........................................................................................3-9
3.5.7 To Modify or Add a Welder.................................................................................3-10
3.5.8 Error Preferences ...............................................................................................3-11
3.5.9 Lock/Unlock Editing............................................................................................3-12
3.5.10 Backup & Load Settings ...................................................................................3-13
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4 Theory of Operation........................................................................................................................4-1
4.1 Miller HMI...........................................................................................................................4-2
4.2 Pulse Mode........................................................................................................................4-3
5 Operation........................................................................................................................................5-1
5.1 Set-Up Overview................................................................................................................ 5-1
5.1.1 Welder Condition File ...........................................................................................5-1
5.1.2 Arc Start Files.......................................................................................................5-2
5.1.3 Arc End Files........................................................................................................5-2
5.1.4 Calibration Verification..........................................................................................5-3
5.1.5 Selecting Weld Programs.....................................................................................5-4
5.2 Robot Job Programming....................................................................................................5-5
5.2.1 Weld Program Selection.......................................................................................5-5
5.3 Welder Front Panel Display...............................................................................................5-5
5.4 Troubleshooting.................................................................................................................5-6
6 Miller Auto-Axcess E Digital............................................................................................................6-1
6.1 Setting Proportional Speed Instruction..............................................................................6-1
6.1.1 The "R*-SET-PROPORTIONAL-SPD.JBI"...........................................................6-1
6.2 MACRO Job Settings.........................................................................................................6-3
6.2.1 MILLER-PROG-SEL Macro..................................................................................6-4
6.2.2 MILLER-STRT-PART Macro................................................................................6-5
6.2.3 MILLER-CHNG-WELD Macro..............................................................................6-7
6.2.4 MILLER-END-PART Macro..................................................................................6-8
6.2.5 Example Weld Job Structure................................................................................6-9
6.3 Error Reporting................................................................................................................6-10
6.3.1 Weld Error Reporting..........................................................................................6-10
6.3.2 Part Error Reporting ...........................................................................................6-11
Revision History................................................................................................................................A-1
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1 Introduction
1.1 About This Document
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1 Introduction
1.1 About This Document
This manual provides information about a Yaskawa Motoman's robotic arc
welding system using the Miller
®
Auto-Axcess DI/E Digital power sources.
The use of this manual is for welding personnel who have received
operator training from Yaskawa Motoman, and are familiar with the
operation of their Yaskawa Motoman robot. For more detailed information,
refer to the manuals listed in Section 1.3 “Reference Documentation”. This
manual contains the following sections:
CHAPTER 1 - INTRODUCTION
This chapter provides general information about the Auto-Axcess DI/E
Digital power source and its components, technical specifications, a list of
reference documents, and customer service information.
CHAPTER 2 - SAFETY
This chapter describes the conventions used to identify precautionary text
throughout this manual. This chapter also contains a list of general
cautions and warnings that apply to many of the procedures described in
this manual.
CHAPTER 3 - EQUIPMENT DESCRIPTION
This chapter provides instructions for basic setup and integration of a
Yaskawa Motoman welding system with a Auto-Axcess DI/E Digital power
source. This chapter also provides procedures for start-up and calibration.
CHAPTER 4 - THEORY OF OPERATION
This chapter describes general arc welding principles, how the welding
system works, and identifies specific welding problems and requirements.
CHAPTER 5 - OPERATION
This chapter provides instructions for basic operation of the Auto-Axcess
arc welding system. This chapter also provides procedures for start-up.
Sample robot programs are also included here.
CHAPTER 6 - MILLER AUTO-AXCESS E DIGITAL
This chapter provides Miller AUTO-AXCESS E Digital instructions for
macro jobs and error reporting.
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1.2 System Configuration
1.2 System Configuration
The Auto-Axcess DI/E Digital arc welding system is an integrated package
of tools and components designed for specific welding requirements. A
typical system includes the following components and optional equipment.
Fig. 1-1: Typical Auto-Axcess Welding System
SERVOON
READY
REMOTE
PLAY
(OFF) (ON)
TEACH
MODE EMERGENCYSTOP
EDITLOCK ALARM
HOLD START
ON
TRIP
O
P
E
N
/
O
F
F
ROBOT
CONTROLLER
GAS REGULATOR
AND TANK
(CUSTOMER-SUPPLIED)
3
MILLER
POWER
SOURCE
WATER
CIRCULATOR
(OPTIONAL)
ROBOT
DISTRIBUTION BOX
(CUSTOMER SUPPLIED)
WORK PIECE
WIREFEEDER
1
2
5
4
6
7
Cable Chart
1 Power Source Control Cable (DeviceNet/Ethernet)
2 Feeder Control Cable
3 Weld Positive
4 Voltage Sense Cable
5 Shock Sensor Cable
6 Gas Hose
7 Weld Negative
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1 Introduction
1.3 Reference Documentation
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1.2.1 Major Components
A typical system includes the following major components:
• Yaskawa Motoman manipulator and controller
• Welding equipment, including the following:
• Auto-Axcess DI/E Digital power source
• Miller AA-40GB wire feeder
• Welding torch
• Optional welding equipment:
• Water circulator
• Program devices - Palm Pilot with a RS232 adaptor (DI only)
• Nozzle cleaner
• Bulk wire delivery package
• PC/Laptop/HMI for web-page access (E Digital only)
1.3 Reference Documentation
For additional information refer to the following:
• Yaskawa Motoman Manipulator Manual
• Yaskawa Motoman Operator's Manual for Arc Welding
(P/N 155490-1CD)
• Yaskawa Motoman Concurrent I/O Manual (P/N 155491-1CD)
• Yaskawa Motoman DX100 Operators Manual (P/N 155494-1CD)
• Yaskawa Motoman DX100 Maintenance Manual (P/N 155492-1CD)
• DX100 Independent/Coordinated Control Manual (P/N 156431-1CD)
• DX100 INFORM User’s Manual (P/N 155493-1CD)
• Vendor manuals for system components not manufactured by Yas-
kawa Motoman.
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1.4 Customer Support Information
1.4 Customer Support Information
If you need assistance with any aspect of your Miller
®
Auto-Axcess DI/E
Digital system, please contact Yaskawa Motoman Customer Support at
the following 24-hour telephone number:
For routine technical inquiries, you can also contact Yaskawa Motoman
Customer Support at the following e-mail address:
When using e-mail to contact Yaskawa Motoman Customer Support,
please provide a detailed description of your issue, along with complete
contact information. Please allow approximately 24 to 36 hours for a
response to your inquiry.
Please have the following information ready before you call:
[e-mail]
NOTE
Please use e-mail for routine inquiries only. If you have an
urgent or emergency need for service, replacement parts,
or information, you must contact Yaskawa Motoman
Customer Support at the telephone number shown above.
• System Auto-Axcess DI/E Digital
• Robots MA1400/MA1900/MA3100...
• Power Supply Miller AAuto-Axcess DI/E Digital
(300, 450, or 675)
• Primary Application Welding
• Controller DX100
• Software Version Access this information on the
Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}
• Robot Serial Number Located on the robot data plate
• Robot Sales Order Number Located on the DX100 controller
data plate
[phone]
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2 Safety
2.1 Introduction
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2 Safety
2.1 Introduction
The purchaser is responsible for following all local, county, state, and
national codes, regulations, rules, or laws relating to safety and safe
operating conditions for each installation.
We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the robot
system. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the robot cell. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE ROBOT SYSTEM!
We recommend approved Motoman training courses for all personnel
involved with the operation, programming, or repair of the robot system.
The training course familiarizes personnel with the safe and correct
operation of the robot system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming, Operation, and Maintenance Safety (Section 2.6)
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2.2 Important Advisory Information
2.2 Important Advisory Information
In this manual, the Notes for Safe Operation are classified as
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Even items described as “CAUTION” may result in a serious accident in
some situations.
2.3 General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance
personnel, supervisors, and anyone working near the robot must become
familiar with the operation of this equipment. All personnel involved with
the operation of the equipment must understand potential dangers of
operation. General safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this robot, the operator's manuals, the system equipment, options,
and accessories should operate this robot system.
• Do not enter the robot cell while it is in automatic operation.
Programmers must have the teach pendant when they enter the
robot cell.
• Improper connections can damage the robot. Make sure all
connections are within the standard voltage and current ratings of
the robot I/O (Inputs and Outputs).
• Place the robot in Emergency Stop (E-Stop) mode when not in use.
• In accordance with ANSI/RIA R15.06-1999, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
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2 Safety
2.4 Mechanical Safety Devices
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2.4 Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and
system is ultimately the user's responsibility. The user should review the
conditions for safe operations of the equipment. The user must be aware
of the various national codes, ANSI/RIA R15.06-2012 safety standards,
and other local codes that may pertain to the installation and use of
industrial equipment. Additional safety measures for personnel and
equipment may be required depending on system installation, operation,
and/or location. The following safety equipment is provided as standard:
• Safety fences and barriers
• Light curtains and/or safety mats
• Door interlocks
• Emergency stop palm buttons located on operator station, robot
controller, and programming pendant
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.
2.5 Installation Safety
Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace,
existing federal, local, and state laws and regulations. Additional safety
measures for personnel and equipment may be required depending on
system installation, operation, and/or location. Installation tips are as
follows:
• Be sure that only qualified personnel familiar with national codes,
local codes, and ANSI/RIA R15.06-2012 safety standards are
permitted to install the equipment.
• Identify the work envelope of each robot with floor markings, signs,
and barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against
unauthorized entry into the work envelope.
• Eliminate areas where personnel might get trapped between a
moving robot and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching
and maintenance procedures.
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2.6 Programming, Operation, and Maintenance Safety
2.6 Programming, Operation, and Maintenance Safety
All operators, programmers, plant and tooling engineers, maintenance
personnel, supervisors, and anyone working near the robot must become
familiar with the operation of this equipment. Improper operation can
result in personal injury and/or damage to the equipment. Only trained
personnel familiar with the operation, manuals, electrical design, and
equipment interconnections of this robot should program, operate, and
maintain the system. All personnel involved with the operation of the
equipment must understand potential dangers of operation.
• Inspect the robot and work envelope to be sure no potentially
hazardous conditions exist. Be sure the area is clean and free of
water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Do not enter the robot cell while it is in automatic operation. Be sure
that only the person holding the programming pendant enters the
workcell.
• Check the E-Stop button on the programming pendant for proper
operation before programming. The robot must be placed in
Emergency Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to PART 1, System Section, of the robot controller
concurrent I/O program can cause severe personal injury or death,
as well as damage to the robot! Do not make any modifications to
PART 1, System Section. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require
special passwords. Special passwords are for Motoman use only.
YOUR WARRANTY WILL BE VOID if you use these special
passwords.
• The robot controller allows modifications of PART 2, User Section, of
the concurrent I/O program and modifications to controller
parameters for maximum robot performance. Great care must be
taken when making these modifications. All modifications made to
the controller will change the way the robot operates and can cause
severe personal injury or death, as well as damage the robot and
other parts of the system. Double-check all modifications under
every mode of robot operation to ensure that you have not created
hazards or dangerous situations.
• Check and test any new or modified program at low speed for at
least one full cycle.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
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2.6 Programming, Operation, and Maintenance Safety
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• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the robot. All connections must
be made within the standard voltage and current ratings of the robot
I/O (Inputs and Outputs).
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3.1 Robot and Controller
3 Equipment Description
This chapter contains brief descriptions of The Miller
®
Auto-Axcess DI/E
Digital welding system components.
3.1 Robot and Controller
The robot controller coordinates the operation of the various welding
system components. The controller executes instruction sequences
provided in a robot job file. As the controller steps through the series of
instructions, it directs the movement of the torch, and operates the
welding power supply. The robot moves the welding torch and supply lines
through a series of programmed steps. The controller sets the speed,
direction, and position of the robot as it moves from point to point. It
communicates weld signals through a digital interface board mounted in
the controller cabinet. The controller sends command values for wire feed
speed, voltage/arc length, arcon and arcoff. The robot also selects one of
eight weld programs by setting three outputs. The Auto-Axcess DI/E
Digital power source communicates to the controller when the arc is
established, when there is a fault condition, or when the wire is stuck to
the puddle. The power source also communicates the fault type back to
the DX100.
This enhanced interface also features a pendant application which allows
weld data to be assigned to the eight weld programs. It also provides
functionality similar to Millers’ File Manager Software.
3.2 Auto-Axcess DI/E Digital Power Supply
The Auto-Axcess DI/E Digital power source is a three-phase, high-
frequency, multi-process inverter welder. The welder operates at either 50
or 60 Hz frequency and 190 to 630 volts AC or DC.
Auto-Line
™ automatically adjusts to line voltage, so no external
adjustments are necessary. The power source has multi-process MIG
capability consisting of standard MIG (GMAW), standard pulse MIG
(GMAW-P), Accu-Pulse (GMAW-P), Accu-Speed (GMAW-P),
Accu-Curve (GMAW-P), as well as a RMD (GMAW-SC) mode. (RMD is a
paid option on the DI welders and is standard on the Axcess E Digital
welders)
Accu-Pulse reduces burn through problems, increases welding travel
speeds, and is superior to pulse mode when welding with short arc
lengths. For even shorter arc lengths on steel Accu-Speed is available.
Accur-Curve has a softer pulse that can be used on aluminum. The
optional RMD (Regulated Metal Deposition) process is a short circuit
transfer process in which the power source alters the welding current to
improve the droplet transfer while minimizing spatter levels. It is limited to
use at wire speeds below 250 ipm (depending on electrode diameter) on
thin gauge steel applications.
The Auto-Axcess DI uses a DeviceNet interface and is compatible with the
DX100 controller.
The Auto-Axcess E Digital has the ability to use either a DeviceNet or
EtherNetIP interface. The DeviceNet interface (on the E Digital machine)
provides the same interface functionality and control as the Auto-Axcess
DI/E Digital. The EtherNetIP implementation of the Axcess E Digital
provides additional robot control for process monitoring control.
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3 Equipment Description
3.3 Software
3-2
166465-1CD
166465-1CD
Auto-Axcess DI/E Digital
Features:
• Broad range of input power (190 to 630 V
AC
, single or 3-phase),
automatically selected by Auto-Line.
• Sharp Start
™ feature provides consistent arc starts by assuring a
ball is not left on the wire when welding stops
• Eight remote selectable programs from the robot
• 115 V
AC
, 10 Amp auxiliary duplex power receptacle
• Multiple MIG modes of operation
• World-class product support from Miller Electric
• Quick-change feed rolls
3.3 Software
The Auto-Axcess DI/E Digital comes standard with many programs for
carbon steel, aluminum, and stainless welding, including Accu-Pulse,
standard or adaptive pulse, Accu-Speed, Accu-Curce, conventional MIG,
and RMD (included free-of charge on Auto-Axcess E Digital machines.)
The standard Yaskawa interface provides an array of functionality
including allowing the user to customize the arc starting and ending
timing.
3.4 Miller AA-40G Wire Feeder
The AA-40G Wire Feeder is an open frame-type wire feeder equipped
with four (4) geared (0.045 in.) feed rolls as standard. The feeder is rated
at 650 amps 100 percent duty cycle and weighs 7.5 kg. The wire feed
speed range is 50-1400 ipm, with a default maximum of 999 ipm. If a wire
feed speed greater than 1000 ipm is necessary, the data in the welder
condition file must be reset.
3.5 Miller-Motoman Pendant Interface (HMI) Software
This Interface Software connects the DX100 Controller to each of the
welding units (up to 4) that are part of the system. The HMI software
allows the operator to set the Auto-Axcess DI/E Digital parameters from
the DX100 programming pendant.
This software is standard with the Auto-Axcess/DX100 system.
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