June 1997
Nal L40QOC-9
This insutruction manual describes basic operation of OSACOM SUPER 8700 ROBOT CONTROL UNIT Read and understand the entire contents of this manual, with special emphasis on the safety devices throughout the manual, before installing, operating or maintaining the Manipulator, Robot Control Unit, and its peripheral equipments. These equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Do not allow untrained persons to install, operate, or maintain these equipments. Contact your distributor i f you do not fully understand these instructions. Following Instruction manuals are provided for these equipments. These instruction manuals shall be referred where necessary in accordance with installation, operation and maintenance.
Model GOlS Model VOIS Model VlOS Model V20S Model V40S Model WOlS OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 INDUSTRIAL ROBOT
MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR CONTROLLER TEACH I NG INTERFACE WITH JIG OPTION SAFETY WARNING
I TRAINING COURSES 1 The equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Therefore, DAIHEN Corporation provides various training courses such as the SAFETY, OPERATION, MAINTENANCE and so on.For the details, contact your distributor or DAIHEN Corporation.
I LIMITED WARRANTY I DAIHEN Corporation warrants this equipment against defects in parts and workmanship, which have occurred under the appropriate service and maintenance conditions including the periodic inspection described in the manual, for shorter period of either 14 months after B/L date of shipment f rom Japan, or 2000 hours actual working time from the date of delivery of equipment to the original user. This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the original user. DAIHEN, a t its option, will repair or replace any equipments during the warranty period, which DAIHEN, upon inspection, shall determine to be defective in material and/or workmanship. The foregoing shall constitute the sole remedy any breach of DAIHEN's warranty.
DAIHEN MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN, INCLUDING WITHOUT LIMITATION THEREOF, WARRANTIES AS TO MARKETABILITY, MERCHANTABILITY, FOR A PARTICULAR PURPOSE OF USE, OR AGAINST INFRINGEMENT OF ANY PATENT. IN NO EVENT SHALL DAIHEN BE LIABLE FOR ANY DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF ANY PRODUCT.
~ F E T V WARNING
THE FOLLOWING ROBOTIC SAFETY SHALL BE KEPT STRICTLY.IF NOT, SERIOUS PERSONAL INJURY OR LOSS OF LIFE IS CAUSED.
A. GENERAL INFORMATION AND SAFETY
A.1 General
Information presented in this section and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.
A.2 Safety
The installation, operation, maintenance, and troubleshooting of arc welding robots require practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with the safety standard which is applied for your country such as ANSI/RIA document, "American National Standard For Industrial Robots Systems - Safety Requirements" and all other safety material found in this Section and throughout the entire manual. In addition, follow all other codes as applicable to the application. See Arc Welding Safety Precautions Sections in the welding power supply Owner's Manual for safety precautions regarding the operation of arc welding power supplies and welding equipment.
B. SAFETY ALERT SYMBOL AND SIGNAL WORDS
The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions.
This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements.
WARNING statements identify procedures o r practices which must be followed to avoid serious personal injury or loss of life.
CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.
IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.
C. G E N E R A L S A F E T Y REQUIREMENTS Read, understand and comply with the following safety rules a t robot maintenance.
1 KEEP OUT of robot working envelope when main power is on.
2 STAY ALERT when near robot.
3 KEEP INFORMED about status of robot and general working conditions.
4 HAVE AN EMERGENCY STOP BUTTON IN HAND whenever you are near the robot.
5 UNDERSTAND AND BE FAMILIAR WITH ROBOTIC MOVEMENTS. Robots are unique industrial devices and can present unexpected hazards t o personnel because of their movements.Unpredictable robot motion can occur in even the best designed areas of operation.
6 NEVER STAND with your back toward the robot.
7 NEVER PLACE yourself between robot work stations i f more than one work station is used.
8 THOROUGHLY TRAIN A L L PERSONNEL in robot operation and safety.
9 READ robot safety regulation of the country installed robot and PUT INTO EFFECT it.
10 DO NOT REMOVE, DESTROY, OR COVER the WARNING and CAUTION labels on Robot Control Unit and Manipulator.
SAFETY REOU l REMENTS FOR l NSTALLATlON (Figure D-I) The robot cell requires initial safety conditions that are vital for both personnel and equipment. Make safety provisions part of the basic cell design.lmplement the following during installation:
1 Brightly mark floor with distinctive areas identifying Zones 1 and 2 on Figure D-1.
2 Route all cables and hoses so that they will not be damaged and will not clutter the cell f loor space.
3 Protect welding system components from spatter, slag, heat, and the general welding environment by locating equipment to minimize exposure.
4 I f any welding components must be located in a high-exposure area, provide proper guards o r shields to minimize d i r t and spatter.
5 Consider all necessary jig requirements t o include turntables, sliding trays, etc., that will become a part of the application so that the operator does not have to enter the work envelope(Zone 1 ).
6 l nstall pressure-sensitive floor mats, proximity devices, l imit switches, light curtains, etc., t o suit the application and number of work stations so that Emergency Stop will occur i f there is any instruction o r violation of the robot work envelope.
7 Install chain fences and light batteries around other cell portions that are not t o be violated.
8 Locate Teach Pendant and Operation Box outside robot work envelope.
9 Provide proper Electrostatic Discharge(ESD) protection for electronic components in Robor Control Unit and Teach Pendant.
10 MAINTAIN SAFE INTEGRITY OF CELL A T A L L TIMES.
Zone 1 - Robot Work Envelope(Area) Zone 2 - Operator Work Area Zone 3 - Outer Area of Robotic Cell
IMPORTANT : See Instruction manual "MANIPULATOR" for vertical space requirements of robot.
Figure D-l Layout Considerations for a Typical Robotic Cell
OPERATOR SAFETY REQUIREMENT
Provide proper ventilation for welding areas.Supply fresh air i f required o r use approved breathing device.
Wear approved head and body protection (this includes, but is not limited to, protective headgear, gloves, and safety shoes).
Install approved filter lens into welding helmet to protect eyes f rom arc rays.
Press an EMERGENCY STOP button before entering robot area.
Stay alert for unexpected robot motion o r movement.
Provide arc guard curtains or shields around the welding area so that arc rays do not injure operator o r other personnel.
Keep robotic cell clean, neat, and orderly.
Close and secure all access doors and panels on components.
Unless i t is specifically necessary to enter the working area of robot system, t o avoid accident, no worker including the operator should enter the working area of robot system. When entering the working area of the robot system for teaching the robot, be sure to check the location and condition of the safety devices such as the EMERGENCY STOP button and DEADMAN SWITCH on the Teach Pendant. And place the EMERGENCY STOP button within the operator's reach for the robot should malfunction.
The robot is keeping the safety speed sufficiently during the teaching mode, however, there is a possibility that the operator is caught in the robot by slow speed.To avoid injury, pay attention to the following:
a) Space requirement for the robotic system cell must allow sufficient area to include installing robot system components, movement around the work envelope by one o r more operators into and out of the cell.
b) The operator should always have some predetermined escape place. c) Never block the escape place of the operator by the other person o r something. d) I f the operator o r the other worker realize the operator's danger, press the
EMERGENCY STOP button immediately. e) A t the worst, i t means that i f the operator was caught in the robot, take the
following procedure.
1) Press the Emergency Stop button immediately. 2) Turn of f the primary power switch of the Robot Control Unit. 3) To avoid fall the robot arm, l i f t the 2nd and 3rd axis of robot by wire ropes. 4) Turn on the primary power switch of the Robot Control Unit again.
(DO NOT TURN ON THE SERVO POWER.) 5) To release the brake, connect pin No. 1 and pin No.2 of terminal block on the
Interlock Board by jumping wire. For search the location of pins, see following Figure E-I.
6 ) To escape the person who was caught in the robot, move the robot arm (the Axis 2).
7) Disconnect the jumping wire, after person escaped.
While operating the system in the automatic operation mode, operator should leave the working area of the robot system.
Interlock board
Figure E-1 Location of Brake release pins
IF. SAFETY PROCEDURES DURING TEACHING (PROGRAMMING) Teaching (programming) often requires the operator to enter the robot work envelope. As a result, always do the following during teaching procedures:
1 Move robot slowly (see instruction manual "TEACHING" - Teaching for speed entry information).
2 Always assign and position a watchperson, with an Emergency Stop button in hand, to present and ready during teaching operations.
3 I f jig motion was programmed to operate from external output control, the jig could energize during teaching.Be careful and alert for jig motion.
SAFETY CHECKS AFTER ENTERING A PROGRAM
1 Have all unauthorized persons leave robotic cell.
2 Check the operation of all warning devices, such as lamps o r horns.
3 Check and be sure that the robot moves normally through its program sequences using the block operation mode(either step or continuous).
4 Check movement of all jigs, and be sure their operation is normal.
5 Check fo r proper operation of EMERGENCY STOP buttons.
H. SAFETY PROCEDURES BEFORE AUTOMATIC OPERATION
Before starting automatic robot operation, do the following:
1 Verify the correct program number allocation is assigned to the appropriate Starting Box(es).
2 Have all unauthorized persons leave the robotic cell area.
3 Close and secure all gates and guard doors, and energimlight fences, barriers, and curtains as applicable for the entire specific cell.
4 Place all jigs in their normal, start-work positions.
5 Place the robot in the axes origin or work origin position as required fo r the operation.
6 Remove all tools f rom the robot work envelope.
7 Place welding workpiece(s) into proper position(s).
8 Place all equipment switches in the proper positions.
I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION
During automatic operation, do the following:
1 Turn off main power o r press an EMERGENCY STOP button BEFORE entering the robot work envelope.Entry may be required fo r nozzle, tip, wire, o r gas adjustments o r replacements.
DO NOT ENTER WORK ENVELOPE UNLESS AN EMERGENCY STOP BUTTON IS PRESSED !
2 Be alert fo r jig movement initiated by an external control signal during operation.
3 Do not allow unauthorized persons to operate controls.
4 I f two or more Starting Boxes are used, be sure that the operators ful ly understand all procedures and cooperate with each other.
5 Press an EMERGENCY STOP button if any problem occurs.
6 Since this an arc welding operation, protect operator(s) f rom arc rays, fumes, and hot parts.
7 Be sure that the Automatic mode can only be selected a t a safe location outside the work envelope.
J. SAFETY PROCEDURES AT END OF WORK
1 Place robot welding torch into an area from which movement to axes origin o r work origin positions is possible without striking any objects.This may require manual operation with Teach Pendant.
2 Press an EMERGENCY STOP button to turn of f robot Servo power.
3 Turn off welding power source and all associated equipment. This includes jig power supplies as applicable.
4 Place line disconnect switches fo r Robot Control Unit and welding power supply in the OFF positions.
5 Allow robot and all equipment to cool.
6 Clean robot, jigs, and entire cell area.
7 Install protective covers over all equipment AFTER proper cooling has occurred to reduce dust and d i r t entry.
K. SAFETY PROCEDURES DURING BNSPECT18N, MAINTENANCE, ADJUSTMENT, AND SERVICING PROCEDURES
Since these procedures can involve entering the robot work envelope and may require that the main power and servo power are turned on, be sure to always do the following during any maintenance, adjustment, o r repair procedures:
1 Train all service personnel in the functions, operations, and jig movements of the specific robotic cell.
2 Allow only trained and qualified persons to service the robot.
3 Always assign and position a watchperson, with an EMERGENCY STOP button in hand, t o be present and ready during any servicing or adjustment procedures.
4 Determine in advance i f the procedure(s) requires an energized robot.When power is not required, turn it off.
5 Determine in advance i f the procedure can be done outside the work envelope.Always work outside the robot work envelope whenever possible.
6 Turn of f o r disable all jig(s) and external equipment not required fo r the specific procedure.
7 Provide proper Electrostatic Discharge (ESD) protection for circuit boards in Robot Control Unit and Teach Pendant.
8 When the procedure is finished, always correctly, securely, and carefully reconnect any wires and reinstall necessary hardware, plugs, covers, and panels.
L. ARC WELDING SAFETY PROCEDURES
Read and understand, and comply with all safety rules at beginning of welding power supply manual in addition to the following before beginning arc welding operations.
1 Prevent electric shock as follows:
1) INSTALL AND GROUND all equipment according to national, regional, and local codes.
2) DO NOT TOUCH live electrical parts.
3) WEAR DRY INSULATING GLOVES AND CLOTHING; be sure gloves have no holes.
4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing any equipment.
2 Provide proper protection from fumes and gases as follows:
1) KEEP YOUR HEAD out of the fumes.
2) USE FORCED EXHAUST VENTILATION at the arc.
3) VENTILATE CELL to prevent build-up of fumes and gases.
4) I f ventilation is inadequate, USE APPROVED BREATHING DEVICE.
5) READ AND FOLLOW WARNING LABELS on all containers of welding materials.
6 ) Before use, READ AND UNDERSTAND the manufacture's instructions, Material Safety Data Sheets (MSDSs), and your employer's safety practices.
3 Protect eyes and skin from arc rays ; protect ears from noise as follows:
1) WEAR PROPERLY FITTING WELDING HELMET with proper shade of fi lter lens (See ANSI 249.1 ).
2) INSTALL ARC PROTECTIVE CURTAINS between operator and the arc.
3) WEAR PROPER SAFETY GLASSES in work area a t all times.
4) WEAR PROPER EAR PROTECTION.
5) WEAR PROPER BODY PROTECTION to include woolen clothing, flame-proof apron and gloves, leather leggings, high boots and leather arm and shoulder gauntlets.
4 Prevent f ire and burns cause by hot metal, spatter, slag, and arc sparks as follows:
1) KEEP FLAMMABLE MATERIALS out of the robotic cell.
2) Have operator(s) keep their sleeves, pockets, and collars down and buttoned as applicable. Wear pants without cuffs.
3) WATCH for fire.
4) Have a f ire extinguisher nearby, and know how to use it.
5) Allow equipment and work to cool before handling.
5 Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs as follows:
1) FASTEN CYLINDERS SECURELY so they cannot fall (use insulated chain or equivalent).
2) INSULATE CYLINDERS from mounts so that they are never grounded o r part of an electrical circuit.
3) KEEP CYLINDERS AWAY from the welding arc and other heat sources.
4) LOCATE CYLINDERS AWAY from personnel and vehicle traff ic patterns.
6 Provide impact protection t o all persons in the cell as follows:
1) ALWAYS WEAR PROPER PROTECTIVE HEADGEAR, such as safety helmet, when in the robotic cell.
2) WEAR SHATTER-RESISTANT SAFETY GLASSES a t all times when in the robotic cel I.
7 Since magnetic fields from high currents can affect pacemaker operation, have wearers consult their doctor before going near arc welding operations.
8 TURN OFF robot and welding power source input power before entering work envelope o r working on welding power source.
9 Prevent EMC (Electro-Magnetic Compatibility) noise caused by welding arc as follows:
1) KEEP PRECISION DEVICES AWAY from the welding arc.
2) Supply primary power t o precision devices and welding power supply separately.
M. WARNING LABELS
DO NOT REMOVE, DESTROY, o r COVER the following labels on the Robot Control Unit and Manipulator. I f following labels become d i r ty o r peeled off, order spare ones immediately. The locations of these labels are shown in the instruction manual "MANIPULATOR" and "CONTROLLER".
KEEP OUT OF ROBOT AREA W E N MAIN POWER IS ON.
READ INSTRUCTION MANUAL.
A WARNING I
K e e p o u t of robot a r e a w h e n m a i n power is o n . R e a d Instruct ion M a n u a l .
D o N o t R e m o v e , Destrov, Or C o v e r This Label. 1 --
ARC WELDING can b e haza rdous . * Read and fo l low t f ~ i s label and the lristructton Manua l careful ly
Only quali f ied persons are to install, operate, or service this unit according to al l applicable codes and safety practices. Pacemaker wearers keep away. @ Keep children away.
@ Welding wire and drive parts rnay be a t welding voltage.
ELECTRIC SHOCK can kill. @ A lways wear dry insulating gloves. @ Insulate yourself f r o m the w o r k and the ground. @ D o not touch l ive electr ical parts. F, Disconnect input power before servicing.
Keep al l panels and covers securely in place.
FUMES AND GASES can be hazardous
@ Keep your head out of the fumes. @ Ventilate area, or use a breath ing dev ice . - Read Mater ia l Safety Data Sheets ( M S D S s ) and
1 I manufacturer's instructions for mater ia l used. I
WELDING can cause fire or explosion. @ D o not we ld near flammable material.
W a t c h for fire; keep extinguisher nearby. @ D o not locate unit over combustible surfaces. @ D o not we ld on closed containers.
/ ARC RAYS can burn eyes and skin: NOISE can damage hearing.
@ Wear welding he lmet w i t h correct filter.
@ Wear correct eye, ear, and body protection
label and the lnstrucr~on Manua l carefully.
e Do not touch l lve electrical pans
FUMES AND GASES can be hazardous ARC RAYS can burn eyes and s k ~ n . NOISE can damage hearing.
Do Not Remove, Dest roy , Or Cover This Label.
@ Keep a w a y f rom moving parts.
@ Keep hands, loose clothing, and tools away during operation.
P INCH POINTS can cause injury.
@ Keep away from pinch points during operation. @ Know and understand equipment operation before
use.
ELECTRIC SHOCK can kil l. @ Always wear dry insulating gloves. @ Insulate yourself from the work and the ground. @ Do not touch live electrical parts. '4 Disconnect input power before servicing. o Keep all panels and covers securely in place.
FALLING EQUIPMENT can cause serious parsonal injury and equipment damage. @ Lif t and move this unit only with proper
equtpment and correct procedures. @ Have only qualified persons ~nstall, operate. or
service this unit. Read Instruction Manual.
WARN ELECTR C SHOCK
@Do not touch live electrical parts.
@Disconnect all power before installing or servicing.
@Multiple sources of voltage may exist inside this enclosure.
A WARNING @Keep out of robot area when
main power is on. @#Do not locate this device
in robot work area. I I e Read Instruct ion Manual. I
A WARNING - ELECTRIC S H O C K can k i l l .
D o not touch l ive electrical parts.
Read this label and Instruction Manual carefully.
@ Disconnect all power before installing or servicing.
O n l y qualified persons are to install. operate. or service this equipment according to all codes and employer's safety practices.
.Wear dry insulating gloves and body protection.
s D o not locate over combustible surfaces.
@ Keep al l panels, covers. and guards securely in place.
@For protection against fire hazard. Replace only wi th the same type and rating of fuse.
NC8052
A WARNING @ Read manual for connection procedures.
@ Connect grounding conductor and input
conductors to proper terminals inside
unit-grounding conductor first.
B e sure grounding conductor goes to
a proper earth ground and has less
than 100 ohms of resistance.
Doublecheck grounding conductor,
input voltage, and frequency before I I applying power.
the connectors respectively. Wrong connection may damage the control unit
@Connect CN67, CM68, CN69, GPV-70, CN71 and CN72 of control cable to interlock ~ o a r d as following drawing.
@ Connect CN31, CN32 and CN33 of starting ox to interlock Board as in the .Following
@ CN69 and CN72 are for external axes such as positioner and slider, in case of a single mechanism (one manipulator) system, 6N69 and CN"7 are not connected.
@As for details of each cable connection,
CN33 CN32 CN31
NCDO66
P a r t I Basics
Chapter 1 Hints fo r Using This Manual 1.1 Instruction Manuals "Teaching" and " Options" .................................................................... 1- 1 1.2 The Organization of This Manual ........ 1- 1 1 3 Conventions Used in This Manual 1 - 2 1.4 Terms Used in This Manual .................................................................................................................... 1- 3
Chapter 2 Overview 2. 1 Control power (Controller) ................ 2- 1 2. 2 Operating Panel ................................................................................................................................................ 2- 2
2 . 3 Teaching Box ..................................................................................................................................................... 2- 3 2 . 3 . 1 Outside View of Teaching Box 2- 3 2 . 3 . 2 Teaching Box Keys 2- 4 2. 3 . 3 Function Keys 2- 9
2 3 4 Display Screen ......................................................................................................................................... 2 - 11 . . 2 . 3 . 5 Entering Numeric Values ............................................................................................................... 2 -15
2 4 Modes 2 -16 2 4 1 TEACH Mode .............................................................................................................................................. 2 - 16 . . 2 4 2 AUTO Mode 2 -16 . . 2 4 3 Initial Mode 2 - 16 . . 2 4 4 Mode Change ........................................................................................................................................... 2 - 16 . . 2 4 5 Mode Change Interlock ..................................................................................................................... 2 - 18 . .
Chapter 3 Basic Features and Functions for Operating OSACOM SUPER 8700 3 1 Turning On OSACOM SUPER 8700 ................................................................................................... 3- 1
3.2 ~~~~i~~ on the servo power ................................................................................................................... 3- 2 3.3 Operations for Manual Manipulation 3 - 3
3.3.1 Manual Manipulation 3 - 3
3 3 2 Changing Manual Speeds ................................................................................................................. 3- 3 . . 3.3.3 Switching between the Axis and Cartesian Movements .. 3- 4
3 4 Teaching (Creating Task Programs) 3- 5
3.4.1 Preparation for Teaching ................................................................................................................... 3- 6
3 4 2 Basic Teaching ............................................................................................................................................ 3- 7 . . 3 4 3 Keys Used for Teaching ..................................................................................................................... 3 - 11 . .
3.5 Block Operation 3- 12
3 6 Modifying Task Programs ......................................................................................................................... 3- 13
3 7 Adding and Deleting Instructions ....................................................................................................... 3 - 15 3.7.1 ~ d d i ~ ~ ti^^^ 3-15
3 7 2 Deleting Instructions .............................................................................................................................. 3 - 16 . . 3 8 Start Allocation 3- 17
3.9 Automatic Operation ...................................................................................................................................... 3 - 18
3 10 Shutting Off the Servo power (Emergency Stop) 3- 19 3 . 11 ~~~~i~~ off the control power 3-20
Chapter 4 Manual Manipulation 4.1 operations for ~~~~~l ~ ~ ~ i ~ ~ l ~ t i ~ ~ .... 4- 1
4.1.1 Changing Positions and Attitudes (Manual Manipulation) 4 - 1 4 . 1 . 2 Changing Manual Speed 4- 2
4.1 3 switchillg between coordinate systems 4- 2 4.1.4 Switching Mechanisms
(Not applicable to the Single Manipulator System) 4- 5 4.1.5 hi^^ and ~ ~ t ~ ~ ~ t i ~ ~ the wire ............................................................................................... 4- 5 4.1.6 Resetting External Control Output Signals 4- 6
4.2 ~~~i~~ ~ i ~ ~ ~ t i ~ ~ ~ 4 - 7 4.2 1 ~~i~ ~~~~~~~t 4- 7 4.2 2 cartesian ~~~~~~~t 4- 9
4.3 cartesian ~~~~~~~t N~~~ the singular point . 4-19
Chapter 5 Teaching 5.1 Creating and ~ i ~ ~ i ~ ~ ~~~k programs 5- 1
5 1. 1 Creating Task programs 5 - 1
5.1 2 ~ i ~ t i ~ ~ ~~~k programs ......................................................................................................................... 5 - 7 5.2 Teaching ti^^ Instructions 5- 8
5 2.1 positioning p 5 - 8 5.2 2 Linear Interpolations 5 - 10 5.2 3 Circular Interpolations 5 - 13 5.2.4 wait for ~i~~~ T ~ ~ ~ / N ~ operation 5 - 15
5 2.5 ~ ~ t ~ ~ ~ ~ l program J~~~ ........................................................................................................................ 5 - 7 5 2 6 ~ ~ t ~ ~ ~ ~ l program J~~~ ..................................................................................................................... 5 -24 . . 5.2 7 program Call 5 -27 5.2.8 End ...................................................................................................................................................................... 5 - 29
5 3 Teaching Task Instructions 5 - 30 5 3 1 A~~ start .......................................................................................................................................................... 5 - 30 . . 5 3 2 Arc End 5 - 34 . . 5 . 3 . 3 ~ ~ ~ h i ~ ~ / ~ ~ ~ ~ ~ ~ t i ~ ~ 5-37 5 . 3 . 4 Gas ON/OFF 5 - 38 5.3 5 Weaving Start 5 - 39 5 3.6 Weaving End 5 -46 5 3.7 External Control Input/Output 5-47
5.4 Block Operation .................................................................................................................................................... 5-53 5.4.1 ~ ~ ~ ~ ~ ~ d / ~ ~ ~ k ~ ~ ~ d ~ l ~ ~ k operations .................................................................................... 5-53 5.4.2 ~ l ~ ~ k ti^^^^^ operation 5-55 5.4.3 Block Operating Speeds 5 - 55 5.4.4 &&ing and starting ~ l ~ ~ k operation 5-56 5.4 5 Cancelling the Halted State of Block Operation 5-57 5.4.6 Sequence Jump 5 - 58
5.5 Adding and Deleting Instructions 5 - 59 5 . 5 . 1 Adding Instructions 5 -59 5 5.2 Deleting Instructions 5 -60
5 6 Changing Teaching Data 5 - 61 5 6 1 Changing Motion Instructions 5 - 61 . . 5.6.2 Changing parameters of Motion Instructions 5-62
Chapter 6 Automatic Operation 6.1 Automatic Operation ...................................................................................................................................... 6- 1 6.2 Automatic Operation by the Multi-station System ................................................................ 6- 3
6.2. 1 Start Allocation ........................................................................................................................................ 6- 4 6.2.2 Changing to Auto Mode and Starting Automatic Operation ................................ 6- 5 6.2 3 Start Reserving and Cancelling 6- 6
6.3 Automatic Operation by the Direct Program Entry System ......................................... 6- 8 6 4 Job End 6 - 11 6.5 Halt 6-11 6 6 Restart 6- 13
6.6.1 Restarting from Halted point ...................................................................................................... 6-13 6 6 2 Restarting from A Specified Start Point ............................................................................... 6-14 . . 6 .6. 3 Overlap Restarting 6 - 15
6 . 6 4 Restarting After Block Operation ............................................................................................... 6 - 16
6.6.5 Restarting from Halting during Execution of Task Instruction ....................... 6-17
Chapter 7 Editing Files 7 . 1 Selecting Files ..................................................................................................................................................... 7- 1 7.2 ~ d i t i ~ ~ welding condition ~ i l ~ ~ ........................................................................................................... 7- 3 7.3 Editing Weaving Condition Files .......................................................................................................... 7- 6
Chapter 8 File Operations 8 . 1 Listing Files ........................................................................................................................................................... 8- 1 8.2 Copying Files ........................................................................................................................................................ 8- 4 8.3 Deleting Files ....................................................................................................................................................... 8- 5 8.4 Renaming Files ..................................................................................................................................................... 8- 6 8.5 ~ ~ ~ t ~ i ~ t i ~ ~ on lj'ile operations 8- 7
Chapter 9 Cancelling Emergency Stop and Shock Sensor 9 . 1 Emergency Stop ................................................................................................................................................. 9- 1 9.2 ~ 1 ~ ~ ~ k sensor ........................................................................................................................................................ 9- 2
9.2.1 cancelling the ,-.hock sensor 9- 2
9.2.2 Before Automatic Operation and After Completion of tlie Job ......................... 9- 2 g 2 3 In Teach Mode ............................................................................................................................................ 9- 3 . . 9.2.4 Correcting Taught Positions Where the Shock Sensor Operates ...................... 9- 3
1 P a r t II App l i ca t ion Features and Funct ions
Chapter 1 Application Features and Function Used in Teach Mode 1.1 Application Features and Functions Used for Manual Operations ......................... 1- 1
1.1.1 Displaying Angles and Coordinates (Reading Positions) .. 1- 1 1 1 2 ~h~ H~~~ s top ti^^ ..................................................................................................................... 1 - 4 . . 1 . 1 3 The Work Enable Area 1 -. 5
1.1.4 The Reference Joint Angles a t the Start Enable Area ... 1- 5 1 . 1 . 5 setting ~~~~~l speeds 1 - 7
1.2 ~ ~ ~ l i ~ ~ t i ~ ~ ~~~t~~~~ and $'Unctions used for hi^^ .................................................. 1 - 9 1.2.1 Logical Check on Task Programs 1 - 9
1 . 2 . 2 Confirmation of Terminating Teaching 1 -. 21 1.2.3 setting the way of performing ~ l ~ ~ k operation ............................................................ 1-22
1.2 4 cursor ~ ~ d i ~ ~ t i ~ ~ of the state of ~ l ~ ~ k operation 1-24 1 .2, 5 setting j310ck operating speeds 1-25
1.2.6 Checking and Modifying Condition Files during Block Operation ................... 1-26
Chapter 2 User Parameters 2 . 1 Setting the System Status .......................................................................................................................... 2 - 3
2 . 1 . 1 Setting the Home position ............................................................................................................... 2 - 8 2.1 2 Setting the Work Enable Area (Soft Limit) 2- 10 2 1 3 Setting the Start Enable Area ........................................................................................................ 2-11 . . 2. 1 . 4 Registering Coordinate Systems ................................................................................................. 2-11
.............. 2.1.5 Setting Conditions for 3-dimensional Shift and Mirror Image Shift 2-12 2.1.6 Setting the ABSO Data Check Function 2-13
2.2 settillg the hi^^ B~~ K~~~ 2-14 2.3 setting the welding parameters 2-17
2.4 Setting the Parameters for External Control Signal Inputs/Outputs .................... 2-20 2.5 setting on ti^^ ~ ~ ~ t ~ i ~ t i ~ ~ ~ on ~ ~ t ~ ~ ~ t i ~ operation 2-22 2 6 Setting the Sensor Type 2 - 22 2.7 setting welding characteristic ~~t~ 2 -23
2.7.1 ~ ~ ~ i ~ ~ ~ ~ i ~ ~ welding characteristic ~~t~ ............................................................................. 2-24 2.7 2 ~ ~ d i f ~ i ~ ~ welding characteristic ~~t~ ................................................................................. 2-24
2.7.3 Creating User Welding Characteristic Data (User Registration) .................... 2-27 2 7 4 ~~t~~ to use ALMEGA FUZZY AUTO .................................................................................. 2-29 . . 2.7 5 ~~t~~ to use TIG ill^^ 2-31
Chapter 3 Application Features and Functions Used for Automatic Operation 3 1 Machine -Jock ........................................................................................................................................................ 3 - 1 3.2 D ~ ~ R ~ ~ 3 - 2 3.3 ~ ~ ~ - ~ ~ ~ ~ d ~ ~ t ~ ~ ~ t i ~ operation . 3 - 6
3.4 Checking the Star t Enable Area during Automatic Operation ...................................... 3- 8 3 5 path Function ....................................................................................................................................................... 3- . 8 3 6 Online Modification 3 - 10
3.7 Sequence Display during Automatic Operation ........................................................................ 3-11
Chapter 4 Shift 4. 1 parallel Shift 4 - 1 4.2 Cylindrical Shift 4- 3
....................................................................................................................... 4.3 Error Messages and Notes 4- 7
1 P a r t III Management
Chapter 1 External Storage 1 1 Connecting and Handling the External Storage 1- 1
1 . 2 Selecting External Storage Functions .............................................................................................. 1- 2 1 3 Formatting Floppy Disks 1 - 4
...................................................................................................................... 1 4 Listing Files 1- 5
1.5 Saving Files from the Controller to the External Storage . 1 - 6 1 . 5 1 Individual Saving 1 - 6 1.5.2 Batch Saving 1- 9 1 . 5 . 3 All Saving 1 - 11
1.6 Loading Files from the External Storage to the Controller ........................................... 1 - 13 .................................................................................................................................... 1 . 6 . 1 Individual Loading 1 - 13
1 .6.2 Batch Loading .............................................................................................................................................. 1 - 16 1.6.3 All Loading 1-19
1 7 Comparing Files ................................................................................................................................................. 1 - 21
1 . 7 . 1 Individual Comparison 1 - 2 1 1 . 7.2 ~ ~ t ~ h ~~~~~~i~~~ 1-24
............................................................................................................................................ 1 . 7 . 3 A]] ~~~~~~i~~~ 1 - 27 1.8 Deleting Files ....................................................................................................................................................... 1-29 1 g Restrictions on File Transfer 1 - 31 1 10 E~~~~ M~~~~~~~ for ~ ~ t ~ ~ ~ ~ l storage ........................................................................................... 1-32 1 11 Others ........................................................................................................................................................................ 1 - 34
. 1 . 11 . 1 Handling Floppy Disks 1 - 34 1 . 11 . 2 Notes External Storage 1 - 34
Chapter 2 Password .................................................................................................................................. 2 1 Entering the Password 2- 1
....................................................................................................................................... 2 2 Setting the password 2- 2
Chapter 3 Absolute Offset 3.1 Resetting the Encoders and Setting an Absolute Offset .................................................. 3- 1 3 2 Axis Alignment Marks on the Manipulator .................................................................................. 3- 5 3 3 The ABSO Data Check Feature ............................................................................................................... 3- 6
Chapter 5 Installing OSACOM SUPER 8700 Software Options 5 1 Installing Software Options ....................................................................................................................... 5- 1
5.2 ~ i ~ t i ~ ~ ~ ~ ~ t ~ l l ~ d software options ...................................................................................................... 5- 3
5 3 Deleting Installed Software Options .................................................................................................... 5- 4
Chapter 6 Troubleshooting 6.1 ~~~~t~~~ 6-15
6 . 1 . 1 ~ ~ t h i ~ ~ A~~~~~~ on the hi^^ B~~ 6-15 6.1.2 The Display on the Teaching Box Is Unsteady ............................................................... 6-16 6. 1 3 Initial Diagnosis Is Not Completed ........................................................................................... 6-17
6.1 4 The Servo Power Supply Cannot Be Turned ON 6-20 ......... 6.1.5 The Servo Power Supply Is Shut OFF Immediately When Turned ON 6-21
6. 1 . 6 Manual Manipulation Does Not Function 6-22
6.2 A ~ ~ i l ~ ~ ~ code and A ~ ~ i l ~ ~ ~ M~~~~~~ A~~ l)isplayed 6-23 6.2. 1 The Display of A Failure ................................................................................................................... 6-23 6.2.2 Logical Outputs for Failures .......................................................................................................... 6-26 6.2.3 shock sensor 6-27 6 2.4 Servo Power Shutoff ............................................................................................................................... 6-28 6.2 5 Software Limit / Link Software Limit 6-29 6 2.6 Overrun 6 -31 6 2.7 Communication Failures 6 - 32 6.2.8 Data Installation Failures ................................................................................................................ 6-34 6 .2.9 Memory Failures ..................................................................................................................................... 6-36 6.2. 10 setting E~~~~~ 6-37
6 2. 11 ABSO Data Failure .................................................................................................................................. 6-39 6.3 When Servo Failure Occurred 6 -40
6 3 1 How To See the Servo Failure Display 6-40 . . 6.3.2 Troubleshooting for Servo Failures .......................................................................................... 6-46
Hierarchical Diagram of Function key
Appendix 1 . Restrictions on the Overlap process 1
.................. 2 . The Relation Between a Minimum Circular Diameter and a Setting Speed 4 3. Restrictions on Weaving Frequency ............................................................................................................ 5 4 Tool parameters 10
Basics
L
Chapter 1 H in t s f o r Using Th is M a n u a l
This chapter provides hints for using this manual. including the
I organization. conventions. and terms . I
Contents
1. H i n t s f o r Using This Manual
1. 1 Instruction Manuals "Teaching" and "Options" Two instruction manuals a re provided to use OSACOM SUPER 8700 :
@ Teaching manual
Describes in detail various features and functions of OSACOM SUPER 8700 and
how to use them
Options manual
Describes in detail optional features and functions of OSACOM SUPER 8700 and
how to use them. Note that optional software and hardware a re required to use
them.
1. 2 The Organization of This Manual This manual consists of the following parts:
)II OSACOM SUPER 8700 Basics
This part describes basic features and functions used for operations such as
teaching and automatic operation.
EIll OSACOM SUPER 8700 Applications
This part describes application features and functions such as user parameters
and shift.
llBl OSACOM SUPER 8700 Management
This par t describes features and functions available for system manager to use an
external storage and initialize the system.
Hints for Using This Manual 1 - 1
I . 3 Conventions Used in This Manual
1. Appl icat ion Features and Function Used in Teach Mode 1. 1 Application Features and Functions Used for Manual Operations
1.1.1 Displaying Angles and Coordinates (Reading Positions)
OSACOM SUPER 8700 displays the joint angle of each axis of the manipulator
measured from the reference position and its coordinate value in the currently specified I I coordinate system.
@This feature is useful to modify the start enable area*' of ALMEGA G series or
W01, the home stop position*', and the work enable area".
@ Important 5
For ALMEGA V series, the angles read by this feature cannot be used to set
the s t a r t enable area (because the reference joint angles a t the s tar t enable
area a re different). For details, refer t o "The Reference Joint Angles for the
Start Enable Area", section 1.1.4. L J
Reading Positions
While you a re holding the keys I.)
down, the rotating angle of each d
axis and the coordinate value in the currently specified coordinate system a re displayed on the left and
I right sides of the screen, respectively.
Press F1 (LIST). rr)
F1 ... Displays the next page. F2 ... Display the previous
page. F3 ... Modify the Task
program the cursor indicates.
F4 ... Make a copy of the Task program the cursor indicate?
- Contains detailed explana tions, cautions, and notes about the feature or function. 0 describes for what purpose the feature or function is used.
Starts the explanation of operation.
The arrow indicates "the screen shown on the right appears when you operate in accordance with the operating procedure".
Joint each Coodinato value in the currently q m i f i d coordinate metam
F5 ... Deletes the Task program the cursor indicatesw
D F1 ... Rename the Task program the cursor indicates."
If more than 6 functions are contained in one layer, the following function keys are displayed in this manner.
* indicates a reference. See the bottom for more information.
1 - 2 Hints fo r Using This Manual
1 . 4 Terms Used in This Manual
The following is a list of terms used in this manual:
manipulator ....................
mechanism
teaching
Task program
Motion
instructions
A robot which welds or handles workpieces. Though
manipulator types of ALMEGA V series (V01, V10,
V20, and V40), G series (G01, and G03),
and W01 are available.
.. A mechanically independent unit, such a s a
manipulator, a positioner, and a slider.
To teach movements and welding works to the
manipulator.
A program which describes the sequential
operational procedure of movements and welding
works taught to the manipulator.
Instructions to not only teach movements
(positioning and interpolation) but also store
positions / attitudes to the manipulator.
Task instructions ......................... Instructions to store tasks (such a s welding,
weaving and signal outputs to external devices)
......................... sequence number A number with which the manipulator stores a point.
Sequence numbers are only given to Motion
instructions.
......................... coordinate system The space defined by the X, Y, and Z axes, which is
referenced when the manipulator moves. There a re
BASE, TOOL, WORK, and WORLD coordinate
systems.
top layer of TEACH ......................... Teach mode in which no teaching function or
mode feature has been selected.
function keys ......................... The keys to which the functions and features of
OSACOM SUPER 8700 or options are assigned.
Hints for Using This Manual 1 - 3
Chapter 2 Overview
This chapter describes each of the operating switches/buttons/
keys provided on Controller. Operating Box and Teaching Box. and
Teach mode and Auto mode .
Contents
2. Overview 2. 1 Control Power (Controller)
The control power switch is provided on the front face of controller. Holding the
handle a t the "ON" position causes the control power to be turned on
Turn the handle to the right and hold it a t the "ON"
position to turn on the control power.
Fig.2.1 The outside views of Controller and Control Power Handle
The controller must be operated by a t least two operators.
Ensure that one of the operators is ready to press the EMERGENCY STOP button in
emergency.
Overview 2 - 1
2. 2 Operating Panel
The operating panel is equipped with operating buttons indispensable for controlling
basic operations.
a * A U T O TEACH - - - - - - - - -. - - - - - - - - - , - - - - - - - - -
I I I 1
OSACOM 0
0 EMERGENCY
STOP button
(B) AUTO MODE
button
(C) TEACH MODE
button
(Dl SERVO POWER
button
(El START button
(F) STOP button
Fig.2.2. Operating Panel
Depress it when you want to stop the manipulator in
emergency. When depressed, the button is locked. To unlock
it, turn the button to the arrow.
Press it when you want to switch from Teach to Auto modes.
The lamp illuminates in Auto mode.
Press it when you want to switch from Auto to Teach modes.
The lamp illuminates in Teach mode.
Press it when you want to turn on the servo power.
The lamp illuminates when the servo power is turned on.
Press it when you s tar t automatic operation of a Task
program. Before starting, ensure that all personnel a re clear
off the danger area. The lamp illuminates during automatic
operation.
Press it when you want to halt automatic operation of the
Task program being running.
The lamp illuminates in the stopped state.
2 - 2 Overview
2 . 3 Teaching Box The following section provides general information of functions of the teaching box keys.
2.3. 1 Outside V iew of Teaching Box
ENABLE u READ DELETE RESET 000
( O S A C O M I
Fig.2.3 The operating parts of Teaching Box
Overview 2 - 3
2.3.2 Teaching Box Keys
* Numeric keys and Instruction selector keys
f [ Na KEY )
MODIFY key
WDI FY
* ADD key
RECORD key
RECORD 0 READ key
* DELETE key
DELETE 0
Used to enter numeric values and to select instructions. When a numeric value is entered, the LED lights.
Used to correct selecting or storing operations or clear the ALARM display which appears when misoperation occurs.
Used to add instructions. The LED on the upper left illuminates during adding operation.
Used to store data settings into the controller.
Used to read out data such a s coordinate values.
Used to delete instructions
RESET key
RESET 0 * SPEED SWITCH key
SPEED 0 COORDINATE SWITCH key
l NATES B * MECHANISM SELECTOR key
MECHA
FUNCTION SELECTOR key
FUNC- [L] * I NC/DEC keys
(UP/DOWN)
* LEFT/RIGHT keys
TEACH Mode keys
TEACH LZ]
Used to step one layer of function keys up, reset ERROR/ARARM, or cancel data settings.
Used to switch the speed display between of Manual operating speed and block operating speed.
Used to switch between the Cartesian and Joint movements used for manual manipulation.
Used to select an external axis. The numeric LED of Axis illuminates when the external axis operates. This key is effective only when external axis is connected.
Used to select a coordinate system in the cartesian movement o r to change over the Synchromotion state.
Used to increase/decrease manual/ block operating speeds, a welding current, etc. These keys are also used to select items you want to change or modify.
Used to select items you want to change or modify. These cursor keys are also used to make changes to data settings.
Used to switch from Auto to Teach Modes. The LED illuminates in Teach mode.
Overview 2 - 5
* Function CANDIDATE key
FUNCTION keys
TEACH
ENABLE
* QUICK INCREASE / DECREASE key
BACK LIGHT ON/OFF key
BACK-
Used to display a function o r functions following the 5th function if there are more than 6 functions assigned to the function keys.
Used to select functions displayed a t the bottom on the screen.
Used to perform manual manipulation and block operation.
Used to perform inching / retract a t high speed. This is also used to switch manual operating speed between Low speed (ML) and High speed (MH).
Used to switch ON/OFF the back light of the teaching box display part.
SENSOR rw:]
1/0 CONTROL ON/OFF SWITCH key - Used to change over between ON/OFF
of the external 1/0 control in the Teach mode. The LED a t the upper left illuminates when the external 1/0 control is executed.
* SENSOR ON/OFF SWITCH key
Used to change over between ON/OFF of Sensing performed in automatic operation. This is effective only when a sensor is connected. The LED a t the upper left illuminates when sensing is performed.
2 - 6 Overview
* WEAVE ON/OFF switch key
WELD ON/OFF switch key
* STOP key
Used to switch between weaving on and off. The LED on the upper left illuminates in the ON state.
Used to switch between welding on/off in automatic operation.The LED on the upper left illuminates in ON state.
Used to halt automatic operation. The LED on the upper Ieft illuminates in the stopped state of block or automatic operation.
BLOCK CONTINUE key Used to change over between continuous and single block operations. The LED a t the upper left illuminates in Continuous block operation.
* FORWARD/BACKWARD BLOCK keys
Used for block operation, sequence search, etc.
WIRE INCHING/RETRACT keys Used for inching/retracting the wire.
Overview 2 - 7
* AX1 S keys [rn)
EMERGENCY STOP button )I
LIGHT button ( LIGHT)
Used to turn on the servo power. To cancel overrun, perform manual manipulation by holding it down.
Used to light up when the operator has to check the target point of the welding wire tip in a dark place.
2 - 8 Overview
2.3.3 Function keys
This section describes the functions of the function keys.
(1) The organization of function keys
5 function keys a r e provided below the liquid crystal display. As shown below,
because the function keys a r e hierarchically organized, each time a function key is
pressed, functions assigned in the following lower layer a r e displayed:
When this function in selected
/ When this function in selected I
I When this function in selected
Fig.2.4. The organization of Function Keys
(2) Specifying function keys
The function corresponding to each function key is displayed a t the bottom on the
screen. Press function keys (F1 - F5) to select functions and data .
I Functions is displayed. I
Function Keys
To specify the function you want, press the relevant function key (F1 - F5)provided
below the display.
Overview 2 - 9
Only 5 functions are displayed on the screen a t one time. If the layer contains
more than 6 functions, the ">" is displayed next to the function key label a t the
right end.
allows you to call the function or functions following the 5th
function.
* If you want to step one layer up, press @ key
Even if you have selected a function in a lower layer, pressing key allows you
to return to the top layer of Teach mode. Note that this feature is not available when
you are using a function (such as Search and Sequence Jump) to edit a Task
program or are editing a Condition file.
2 - 1 0 Overview
2.3.4 Display Screen
The display screen shows the operation and information being currently executed.
This section describes each area on the display screen and also how to see various
information on the screen
(B) I
The display screen consist of the following areas:
( A ) Coordinate system display area
Where the movement coordinate system* being currently selected is
displayed:
(1) ~~i~ ~~~~~~~t AXIS
(2) Tool-side Base coordinate system .......... T.MECH
(3) Work-side Base coordinate system ........ W.MECH
(4) work coordinate system WORLD
(5) Tool coordinate system . TOOL
(6) Work coordinate system ............................. WORK
* :Refer to "Switching between Coordinate Systems", section 4.1.3 in part I.
Overview 2 - I 1
(B) Speed display area
Where a manual o r block operating speed is displayed
Manual operating speed MLO ML1 ML2 ML3 ML4 MH1 MH2 MH3 MH4 (Inching)
B-1 B-2 B-3 B-4 Block operating speed < Low High >
Press the key to change over between Manual / Block operating speeds.
(C) Mode display area
Where the mode* ' being currently selected is displayed:
Auto mode ......................... AUTO.
~~~~h mode . TEACH
Machine lock mode* .-.-- MACH LOCK (highlighted)
(D) File name display area
Where the file name which is in use for the operation being currently
performed, such as teaching, editing, or automatic operation is displayed.
(El The number of sequences display area
Where the number of sequences stored in the Task program being currently
executed is displayed:
When editing a new Work program ............... The number of already stored
sequences is displayed.
When modifying the Work program ............... The number of all sequences
stored in the Task program is
displayed.
(F) Servo Power State display area
Where the servo power state is displayed:
Turning on the servo power ..................... SERVO ON
Shutting off the servo power... .................. SERVO OFF (highlighted)
* 1 : Refer to "Modes", section 2.4 in part I.
* 2: Refer to "Machine Lock", section 3.1 in part 11.
2 - 1 2 Overview
( G ) Auxil iary display area
Where the operation being currently performed (such as, adding,
deleting, o r shift operation), information indicating path setting, and a n
error message due to misoperation a r e displayed.
(H) Main display area
Where the following information a r e displayed, depending on the function o r
feature in use:
* The contents of the file being taught o r edited
* Operating instructions t o the operator
* Operation results
(I) Function Keys display area
Where function keys a r e displayed. When more than 6 functions a r e available,
by pressing
" is displayed a t the right end. The rest of the functions a r e displayed
key.
(J) Synchromotion Status Display Area
Where synchromotion s ta tus is displayed "CRDN" is displayed if the
current status is Synchromotion.
Overview 2 - 1 3
(K) Message display area
Where general1 y various
da ta a r e displayed. *
When a n error , Alarm, or
Information occurs, its code,
message and recovery
action a r e highlighted. *
When the e r ro r is cleared,
the original display appears. *
0 0 1 P 6 0 % > 0 0 2 L l O O c m BASE M1
T.MECH ML4 TEACH P l l l SQNa = 2 SERVO ON
0 0 1 P 6 0% BASE MI > 0 0 2 L l O O c m BASE M1
fL SPEED : l O Om LAP :ON I
2 - 1 4 Overview
[ r n ! / I / O J J B R A N C H / J W \ p K E ' ] >
T.MECH ML4 TEACH P l l l SQNa = 2 SERVO ON
-
0 0 1 P 6096 BASE M1 > 0 0 2 L 1 0 0 ~ BASE M1
--.-=-
[iii55K1W/O/IBRANCHIW]I.DJIWEAVEJ >
2.3. 5 Entering Numeric Values
The sign "No. KEY" illuminates when numeric values can be entered.
RAT I ON R BRANCH B
Keep the following points in mind when entering numeric values:
Numerals as pa r t of a name 1 The numeral "0" must not be omitted:
- Program No., etc. 1 (Example) PO01 and ASCOl
- Sequence number
Integers
Time of the timer,etc.
Any integer can be entered as it is:
- Speed, etc
Real numbers
/ the decimal point:
(Example) 60cm + "6" and "0"
To enter real numbers, use numeric keys and
1 (Example) 0.5 sec 4 "0". .", and "5"
/ If the fraction is 0, you can omit the decimal
1 point and "0":
(Example) 10.0 4 "1" and "0"
Overview 2 - 1 5
2. 4 Modes Two modes, TEACH and AUTO modes, are available. The current mode is displayed a t
the Mode display area*' on the teaching box.
2.4.1 TEACH Mode In TEACH mode mainly teaching/editing of Task programs are performed.
Most of the functions and features except those used for automatic operation a re
available in this mode. As described in section 2.3.3, these functions are hierarchically
organized and assigned to the function keys.
For details of the organization, see the list of hierarchically organized function keys
provided a t the end of this manual.
2.4.2 AUTO Mode In AUTO mode automatic operation is performed to execute Task programs
created in Teach mode.
2.4.3 Initial Mode The default mode setting is TEACH, which is the initial mode when the control power
supply is turned on. You can change this setting to AUTO by changing the "INITIAL
MODE" setting*' in the user parameters for setting the system status.
2.4.4 Mode Change In order to execute Task programs by automatic operation, it is necessary to switch
from TEACH to AUTO modes. This switching operation is referred to a s a mode
change.
You can make a mode change only in the following conditions:
(1) Change from TEACH to AUTO modes
OSACOM SUPER 8700 is in the top layer of TEACH mode.
(2) Change from AUTO to TEACH mode
* The robot is ready to perform Automatic operation, or
The robot is in the stopped state of automatic operation, or
The robot has completed the Job.
If you change to TEACH before automatic operation is started, OSACOM SUPER 8700
enters the top layer of TEACH mode. If you change to TEACH in the stopped state, the
robot remains in the stopped state and the current Task program number, sequence
number, and instruction are held.
-
* 1: Refer to "Display Screen", section 2.3.4 in part I.
*2: Refer to "Setting the System Status", section 2.1 in part 2.
2 - 1 6 Overview
II Changing f rom TEACH to AUTO modes
1. Press F5 (LOCK) at the top
layer of TEACH mode. *
2. Press the AUTO MODE button
on the operating panel. * (Or set the AUTO MODE input
terminal ON.)
Now a mode change from
TEACH to AUTO has been
completed.
lIIl Changing f rom AUTO to TEACH modes 1. In the stopped state of
automatic operation, the screen
looks like the one shown on the
right: *
TEACH 2. Press . I
(Or press the TEACH MODE
button on the operating panel,
o r set the TEACH mode input
terminal ON.)
Now a Inode change from AUTO to
TEACH has been completed.
Overview 2 - 1 7
AXIS MH3 AUTO PO01 SQNa =999 SERVO ON HOLDING STN. 1
0 5 1 P 10 0 % BASE M 2 0 5 2 P 90% BASE M1
> 0 5 3 L 2501x1 BASE MI S 0 1 2 DL=O.OS
054 L 150m BASE M1 055 C1 1501x1 BASE MI
pi"Eq WSHI pT-7-q pi%-=] >
2.4. 5 ModeChangelnterlock
The mode change operation varies according to the ON/OFF settings of the Mode
Change Interlock function (Auto mode interlock o r Teach mode interlock).
Though you can make a mode change by simply pressing a button o r key, provided
the condition is met, you can select the Mode Change Interlock function to prevent a
careless mode change.
Table 2.1. Operating a Mode Change
Auto mode interlock I OFF I ON ( Default)
Teach mode
J,
Auto mode
(1) Press the AUTO
MODE button on the
operating panel, o r
(2) Set the Auto mode
input terminal ON
After you press F5
(LOCK) a t the top layer
of Teach mode o r set the
Auto mode interlock input
terminal ON,
(1) Press the AUTO
MODE button on the
operating panel, o r
(2) Set the AUTO Mode
input terminal ON.
Teach mode interlock OFF ( Default)
(1) Press on the w teaching box,
ON
teaching box while
I Or / holding down the
1 (2) Press the TEACH I TEACH MODE button
Auto mode 1 MODE button on the / on the operating panel,
;1
Teach mode
I operating panel, I Or
/ (2) Press on the
/ (3) Set the Teach mode / teachingbox while
input terminal ON. setting the Teach
mode input terminal
ON.
The Mode Change Interlock function can be set on/off in the user parameters for
setting the system status, "AUTO LOCK" and "TEACH LOCK"*.
* : Refer to "Setting the System Status", section 2.1 in par t 11.
2 - 1 8 Overview
Chapter 3 Basic Features and Func t ions f o r Opera t ing OSACOM SUPER 8700
This chapter describes a series of basic operations necessary for
turning on OSACOM SUPER 8700. teaching. automatic operation.
and turning it off . This chapter is intended to allow the user to understand how to
teach and how to s tar t automatic operation .
For detailed information of teaching and automatic operation.
refer to chapter 5 and chapter 6 respectively .
Contents
3 1 Turning On OSACOM SUPER 8700 ................................................................................................
3 2 Turning On the Servo Power .................................................................................................................
3.3 Operations for Manual Manipulation
3.3.1 Manual Manipulation ........................................................................................................................
3 3 2 Changing Manual Speeds ................................................................................................................. . .
3.3.3 Switching between the Axis and Cartesian Movements .......
3.4 Teaching (Creating Task Programs)
3.4.1 Preparation for Teaching
3.4.2 ~~~i~ hi^^ .......................................................................................................................................
3.4 3 Keys Used for Teaching
3.5 Block Operation ............................................................................................................................................
3.6 Modifying Task Programs
3.7 Adding and Deleting Instructions ....................................................................................................
3 7 1 Adding Instructions ............................................................................................................................. . . 3.7.2 Deleting Instructions
3.8 Start Allocation
3.9 Automatic Operation ..................................................................................................................................
3 . 10 Shutting Off the Servo power (Emergency Stop)
3 11 Turning Off the Control power
3. Basic Features and Funct ions f o r Opera t ing OSACOM SUPER 8700
3. 1 Turning On OSACOM SUPER 8700 OSACOM SUPER 8700 is turned on by holding the handle mounted on the front face a t
the "ON" position.
Then, the start-up screen appears on the display.
1. The start-up screen appears on
the display of the teaching box. II)
2. OSACOM SUPER 8700 s tar ts
initial diagnosis. .I)
3. When this operation is completed,
you can perform various operations
by using the teaching box. .I)
Basic Features and Functions fo r Operating OSACOM SUPER 8700 3 - 1
DIAGNOSIS
' 9 3-0 7-1 5 1 1 : 3 2
THANK YOU FOR WAKING ME UP! THIS I S OSACOM 8 7 0 0 CONTROLLER
START DIAGNOSIS 1, 2, 3, 4
3. 2 Tuning On the Servo Power Turn on the servo power to move the manipulator. Each of the operating panel and
teaching box is equipped with a servo power "ON" button. Before turning on the servo
power, ensure that all personnel a re clear off the manipulator working area.
. . I . I:,
Fig.3.1. Operating Panel
3
Fig.3.2. Teaching Box
The servo power is turned on by pressing the servo power ON button (SERVO ON
button). This causes the lamp of the servo power ON button on the operation panel to
light. The display a t the servo power status display area on the teaching box changes
from "SERVO OFF" to "SERVO ON".
3 - 2 Basic Features and Functions for Operating OSACOM SUPER 8700
3. 3 Operations for Manual Manipulation
3.3. 1 Manual Manipulation
Manual manipulation is performed to move the manipulator by using the teaching
box.
1. Press the Axis key while
The manipulator moves in the
direction specified by the AXIS
key you are pressing.
TEACH
ENABLE
2. It stops when the key is released.
MECHAN l SM
3.3.2 Changing Manual Speeds
You can select a speed for manual manipulation from among a total of 9 steps
including 4 low modes (ML1 - ML4) and 4 high modes (MH1 -MH4).
MLO ML1 ML2 ML3 ML4 MH1 MH2 MH3 MH4
Low High
To change a manual speed, use
The current manual speed is
displayed on the teaching box. @
To increase the speed, press
key.
To decrease the speed, press
key. iai
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 3
3 . 3 . 3 Switching between the Axis and Cartesian Movements
In manual manipulation, two types of movements, Axis and Cartesian movements,
a r e available; the former provides independent movements of each axis(joint) of the
manipulator, and the latter provides movements defined by a specified coordinate
system.
To switch between the Axis and CM)RD-
Cartesian movements, use (INATE,I key
Each time you press this key, you
can switch between AXIS/
CARTESIAN.
The current movement type is
displayed on the teaching box.
3 - 4 Basic Features and Functions for Operating OSACOM SUPER 8700
3. 4 Teaching (Creating Task Programs)
Teaching is performed to teach (store) the sequence necessary for a job such a s
welding work to the manipulator.
Details of a job which the manipulator should do are stored in a Task program.
To perform teaching, follow the steps below:
I Enter a Task program number. 1
I Enter a number you give to a Task program you want to create.
on/Task instructions.
Teach the manipulator Motion instructions to store positions and
attitudes and Job instructions to store data of a job such a s welding, etc.
The following are most often used instructions:
(Motion Instructions)
* P (Positioning) Instruction to store a position and attitude to the
manipulator
* L (Liner Interpolation) ... Instruction to store a position and attitude
1 to the manipulator and move it on the
linear path
C (Circular Interpolation) ... Instruction to store a position and
attitude to the manipulator and move it
on the circular path
(Task Instructions)
AS (Starts welding) ... Instruction to s tar t welding
* AE (Terminates welding) .-. Instruction to terminate welding
Block Operation (to check the path)
When teaching is completed, check the path of the manipulator by
performing block operation.
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 5
3.4. 1 Preparation for Teaching
Before carrying out teaching, enter a Task program number.
1. After initial diagnosis is
completed, turn on the servo
power. *
2. Press F1 (TEACH).
3. Enter a Task program number.
F o r example, enter "0","0","1"
by using numeric keys. *
Now you can s t a r t teaching Task
program P001.
AXIS ML4 TEACH
SERVO ON
[ m I m j m I I m / L O C l >
3 - 6 Basic Features and Functions for Operating OSACOM SUPER 8700
3.4.2 BasicTeaching
This section describes a basic teaching by using a simple teaching example.
STEP @ STEP 8
/ f e -. . -
/ . --.
/ . . /
. . / .. .
STEP @ / /
STEP a
Fig.3.3. Teaching Example
1. Enter the Task program number.
+
2. Perform manual manipulation to
step @. Teach Positioning
instruction "P".
(1) Press
(2) Set Speed by using numeric
keys.
(3) You can set Overlap ON/OFF
by pressing 10 1 key.
Basic Features and Funct ions f o r Operat ing OSACOM SUPER 8700 3 - 7
(4) Press @.
3. Teach step @ and as same
way as step @.
4. Teach Arc Start instruction "AS"
at Step 0.
AXIS ML4 TEACH I I
(1) Press .
P O 0 1 SQ Na= 1 SERVO ON
(2) Set welding conditions
> 0 0 1 P 1 0 0 % BASE MI
I P SPEED=l 0 D96 LAP :ON I
(current, voltage, and speed) by
using numeric keys and
(3) Press @.
5. Perform manual manipulation
up t o step @.
Teach linear Interpolation
instruction "L".
(1) Press .
(2) Set Speed by using numeric
keys.
The speed set here is a speed
of the manipulator in block
operation.
In automatic operation, the
manipulator moves a t the
welding speed set with "AS".
AXIS ML4 TEACH P O 0 1 SQ No.= 3 SERVO ON
3 - 8 Basic Features and Functions for Operating OSACOM SUPER 8700
0 0 1 P 1 0 0 % BASE MI 0 0 2 P 1 0 0 % BASE MI
> 0 0 3 P 5 0 % BASE MI
AS f3OA 20,OV. 6Dm I
T. MECH. ML4 TEACH PO 0 1 SQNo.= 3 SERVO ON
/ ]NUU/ j r n l r n I
0 0 1 P 1 0 0 % BASE M1 0 0 2 P 1 0 0 % BASE MI 0 0 3 P 5 0 % BASE M1 > AS 2 0 0 A 22.OV 8 Om
/LSPEED:LO#m .LAP:ON ' 1 r i - G z i - ~ ~ ~ ] ~ ~ ~ \ >
(3) You can set Overlap ON/OFF
by pressing 10) key.
(4) Press @ .
6. Perform manual manipulation
up t o step @. This position is the
middle point of a circle.
Teach Circular Interpolation
instruction "C" .
(1) Press .
(2) Set Speed and Overlap ON/
OFF as set for "L".
(31 Press @ .
7. Perform manual manipulation
up to step @. This position is the
end point of a circle.
Teach Circular Interpolation
instruction "C".
As we taught "C" a t step @,
press w. 8. Teach Arc End instruction "AE"
a t step 0.
(1) Press .
T.MECH.ML4 T E A C H PO 0 l S Q No.= 4 S E R V O O N
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 9
0 0 1 P 1 0 0 9 6 B A S E M 1 0 0 2 P 1 0 0 9 6 B A S E M1 0 0 3 P 1 0 0 % B A S E M I
A S 2OOA 22.OV 8Ocm > 0 0 4 * L 60cm B A S E M 1
1~ 2 S P E E D ' : 6 Orar" \ LAY : ON ]
T.MECH. ML4 T E A C H PO 0 1 SQNo,= 6 S E R V O O N
/ l ~ ~ l / ~ ~ /
A S 2 0 0 A 22.OV 8Ocm 0 0 4 * L 6 0 m B A S E M 1 0 0 5 * C 1 6 0 m B A S E M1 0 0 6 * C 2 6 O m B A S E M 1 > A E 1 5 0 c m 2 0 . 0 , 0 . 5 S . O . O S
LAY? 1 8 0 k ZO.~'V, , b . ' & s , ' 0 , 0 9 1
IASNUM.IIAENUMI(1-J
(2) Set welding conditions
(current, voltage, crater time,
and afterflow time) by using
numeric keys and
(3) Press @ .
9. Perform manual
manipulation up to step a. Press a , and set Speed and
Overlap ON/OFF as set for step
10. Perform manual
manipulation up to step @. In
this case, move the manipulator
until the LED of READY onthe
teaching box lights.
Press @
11. Teaching has been completed.
Press @ .
END will be automatically stored
to terminated teaching.
T.MECB. M L 4 TEACH PO01 SQ No.= 7 SERVO ON
004*L 60m BASE M1 005*C1 60m BASE MI 006*C2 60em BASE MI
AE 15Ona 20.0, 0.5s. 0.0s >007 P 7596 BASE MI
(P SPEED:X#0% \tAP:UN
T.MECH. M L 4 TEACH PO01 SQ No.= 8 SERVO ON
3 - 1 0 Basic Features and Functions for Operating OSACOM SUPER 8700
r i " z z x \ ~ ~ ~ l ~
005 *C1 60m BASE M1 006 *C2 60m BASE M1
AE 150m 20.OV 0.5s. 0.0 s. 0 07 P 75% BASE MI
>0 08 P 10096 BASE MI
IP $PEED:'X@O% %,*' LAP:ON 1
T.MPCH. M L 4 TEACH PO01 SQ Na= 9 SERVO ON
/ 7 ~ ~ / ~ ~ \
> 001 P 100% BASE M1 002 P 100% BASE MI 003 P 50% BASE M1
-I[ Jmlmm]>
3.4.3 Keys Used f o r Teaching
(1) @ key
Stores instructions, parameters, etc.
If the same instruction needs to be continuously taught, pressing RECORD key allows 0 you to re-teach the instruction you have just taught. Note that this teaching is
operational only when the last recorded instruction remains on the 7th line. If you
want to modify only parameters (speed, overlap ON/OFF, etc.), press
before you press RECORD . 0
The instruction you have just taught
AXIS ML4 TEACH P O 0 1 SQ No.= 2 SERVO ON
(2) @ key
Corrects entry errors.
0 0 1 P 1 0 0 % BASE M 1 > 0 0 2 P 1 0 0 % BASE M1
~ P E E D ~ I O O ! % .ta~;a~~":~,, 7
* If you press it immediately after you select a n instruction, you can cancel you
m / I I / OnBRANCil,,,,,,l,,,,,l >
selection.
* If you press it when entering a numeric value (e.g., because you have made an
entry error), you can re-enter
If you press it immediately after you press RECORD , the instruction you have just 0 stored is cancelled.
(3) @ key
Automatically enters END instruction, when pressed during a creation of a Task
program, a t the sequence following by the last sequence to terminate teaching.
(You do not need to teach END instruction.)
Then, you can perform block operation.
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 1 1
3. 5 Block Operation Block operation is performed to check the positions, attitudes, and paths in a Task
program created. This section explains how to perform block operation, using an
example Task program PO01 created in section 3.4.2:
1. When you have finished creating
Task program PO01 (by pressing
@ key), OSACOM SUPER 8700
is ready for block operation. * 2. Press while holding down
Q . w
Then, the manipulator starts to
move to the position of sequence 001.
Continue block operation by
pressing BLOCK
or 1 , I accordingly.
To halt the manipulator, release n @ .
Then. the LED of will light.
To execute instructions continuously, n-
push . n-
Then, the LED of 'g," will light. U The block continuous state is
cancelled when block operation is
halted. /?
To chande block operation speed,
push .
The display a t the Speed display
area will change to the Block
Operating Speed.
Select the speed by pressing
3 - 1 2 Basic Features and Functions for Operating OSACOM SUPER 8700
3. 6 Modifying Task Programs This section describes how to modify Task programs by using an example Task
program PO01 created in section 3.4.2.
(Example 11 Modifying positions and attitudes
Let us modify the position/attitude
of step 2 (Sequence 002):
1. Perform block operation up to
sequence 002. rrr)
2. Perform manual manipulation to
move the manipulator to the
position/attitude you want to store.
I'
STEP 2 \
=o
T.MECII. ML 4 TEACH P O 0 1 SQ Na= 9 SERVO ON
'b f )
STEP 3
0 0 1 P 1 0 0 % BASE M 1 > 0 0 2 P 1 0 0 % BASE M 1
0 0 3 P 5 0 % BASE M I AS 2 0 0 4 22.OV. 8 0 m
0 0 4 * L 6 0 w BASE M 1
3. Press @ ,
~ ~ I J ~ ~ I P A T H / ~ ]
Now, the position/attitude of step 2
have been modified. STEP I
/
4' \ \
P \ \
STEP 2
\\\ J P STEP 3
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 1 3
(Example 21 Modifying "P" to "L"
Let us modify the instruction of step
1. Perform block operation up to
sequence 003, and then press H
I T.MECI1. ML4 1 0 0 1 P 10096 BASE MI I
2. Press @ . Now, the Motion instruction of
step 3cSequence 003) has been
modified to "L".
(Example 3) Modifying welding conditions
Let us modify the welding
conditions of step 4:
1. Move the cursor to "AS" by
performing block operation, and
press . * 2. Set a current/voltage/welding
speed ( to modify).
3. Press @ .
Now, the welding conditions have
been modified.
Similarly, you can modify the
parameters (moving speed/
overlap ON/OFF) of Motion
instructions.
T.MECI-I.ML4 TEACH P O o 1 SQ Na= 9 SERVO ON
3 - 1 4 Basic Features and Functions fo r Operating OSACOM SUPER 8700
002 P 100% BASE M1 003 P 10096 BASE M1 >r AS p 2 0 04*L 6Om BASE M1 005*C1 6Om BASE M1 006*C2 60m BASE M1 m2 0- 0
T.MECH. ML4 TEACH PO01 SQ No.= 9 SERVO ON
j s E l ~ ~ ~ ~ l >
002 P 10 0% BASE M1 003 P 5096 BASE M1
> AS 18OA. 20. OV. 8Ocm 004*L 6 Om BASE M1 005*C1 60ca BASE M1 006*C2 60cm BASE MI
( sEARC/~JUMPj( /m- >
3. 7 Adding and Deleting Instructions 3. 7. 1 Adding Instructions
This section describes how to insert Positioning "P" between steps 002 and 003 in a n
example Task program PO01 created in section 3.4.2.
1. Perform block operation to the instruction (Sequence 002) which should be followed by an instruction you are adding.
2. Press rrr)
Then, the LED on the upper left
3. Move the manipulator to the position/attitude you want to add,
by performing manual manipulation.
4. Press the key of the instruction you want to add ( in this example). Set a speed and overlap ON/OFF
a s set to create a new program.
5. press @ . * Now, a new instruction "P" has been added. Repeating the operations 3 - 5 allows you to add instructions a s many as you want.
If you press immediately
after you press
cancel the instruction you have
just added.
6. To terminate the adding operation, press O@. + Then, the LED on the upper right
will light.
AXIS ML4 TEACH PO 0 1 SQ No.= 9 SERVO ON
0 0 1 P 1 0 0 % BASE M 1 > 0 0 2 P 1 0 0 % BASE M 1
0 0 3 P 5 0 % BASE M 1 AS 2 0 0 h 22.OV. 80cm
0 0 4 + L 6 0 w BASE M 1
AXIS ML4 TEACH PO 0 1 SQ No.= 9 SERVO O N
pxKcqIJUMP/ISHIFT//PATH//l>
0 0 1 P 1 0 0 % BASE M I > 0 0 2 P 1 0 0 % BASE M 1
AXIS ML4 TEACH P O 0 1 SQ No.= 10 SERVO O N
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 1 5
j M o T I O N / j I / O / m I W E L D / / W E A V E / >
0 0 1 P 1 0 0 9 6 BASE M I 0 0 2 P 1 0 0 % BASE M 1
> 0 0 3 P 2 0 9 6 BASE M 1
I P S P E E D = Z O % L A P :ON I
AXIS ML4 TEACH P O 0 1 SQ No,= 10 SERVO ON
jMoTIONIJ//OIIBRANCHI/WELD/rnj >
0 0 1 P 1 0 0 % BASE M 1 0 0 2 P 1 0 0 % BASE M 1
> 0 0 3 P 2 0 % BASE M 1 0 0 4 P 5 0 % BASE M 1
AS 2 0 0 h 22.OV. 8 0 m 0 0 5 * L 6 0 m BASE M I
/ S E A R l m I S H I F T / m / m l >
3. 7 .2 Deleting Instructions
This section describes how to delete step 3 in an example Task program PO01 created
in section 3.4.2.
I . Perform block operation to the
instruction (Sequence 002) which
should be followed by an
instruction you are deleting.
2. press 66;;r) . + w
Then, the area to be deleted will
be highlighted.
* To extend the area, press
To reduce the extended area,
* To cancel your deletion, press
3. Press F1 (EXECUTE). * Now, the highlighted area has
been deleted.
If you press wFY immediately 0 after you delete, your deletion will
be cancelled.
AXIS ML4 TEACH PO01 SQ No.= 9 SERVO ON
001 P 100% BASE M1 >002P 100% BASE MI 003 P 50% BASE M1
AS 200k 22.OV. 80cm 0 04XL 60cm BASE MI
AXIS ML4 TEACH PO 0 1 SQNo.= 9 SERVO ON RANGE FOR DEL.
3 - 1 6 Basic Features and Functions for Operating OSACOM SUPER 8700
/ p 7 x q ~ ~ ~ l >
001 P 100% BASE M1 >002 P 100% BASE MI I003 P 509' BASE A -cm 004XL 6Om BASE M1
AXIS ML4 TEACH PO01 SQ No.= 9 SERVO ON
pEiEq
001 P 100% BASE M1 >002 P 100% BASE M1
AS 200k 22.OV. 8Ocm 003*L 6 Om BASE M1 004*C 60m BASE M1
p T E z - i q / ~ j ~ ~ ~ ~ ~ >
3. 8 Start Allocation Before automatic operation is performed, it is necessary to allocate the created Task
programs to the Start button of each station.
This section explains how to do s tar t allocation:
1. Place OSACOM SUPER 8700 in
the top layer of TEACH mode. *
2. Press F4 (ALLOT).
Then, a list of Task programs
allocated to each station will be
displayed.
3. For example, let us allocate
PI23 to station 01.
Enter "1 ", "2", and "3" by
using numeric keys. *
4. Press @. Now, Task program PI23 has
been allocated to station 01.
Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 1 7
3. 9 Automatic Operation When you have finished s tar t allocation to each station, you can now star t automatic
operation.
1. Press F5 (LOCK) at the top
layer of Teach mode. *
2. Press the AUTO MODE button
on the operating panel. Now, the
mode has been switched to
AUTO. * To execute Task program PO01
allocated t o station 1, press the
START button on the operating
panel. +
To halt the manipulator, press the
STOP button on the operating panel
o r on the teaching box. +
To restart the manipulator, press
the START button on the operating
panel.
When the execution of the Task
program terminates (when the
robot completes the Job), the
display on the right appears. *
3 - 1 8 Basic Features and Functions for Operating OSACOM SUPER 8700
3.10 Shutting Of f the Servo Power (Emergency Stop)
When the EMERGENCY STOP button is pressed, the servo power is shut off, causing
the manipulator to immediately stop the motion.
Two EMERGENCY STOP buttons are provided; one is on the operating panel, and the
other is on the teaching box. (If you install a starting box or boxes, each starting box
is also equipped with an EMERGENCY STOP button.)
Cancellina the EMERGENCY STOP button
on the operating panel. 0 0
f ~ - & 7
I OK+ Turn to the button to the arrow.
Cancelling the EMERGENCY STOP button
-\1\ 1 on the teaching box
A Warning
To safeguard the operators, ensure that the EMERGENCY STOP button is always ready to be pressed.
Basic Features and Functions fo r Operating OSACOM SUPER 8700 3 - 1 9
3.1 I Turning Off the Control Power To turn off the control power, follow the steps below:
Now, the control power has been turned off.
Press the EMERGENCY STOP button on the operating panel o r teaching box to turn of f the servo power.
Turn the control power handle to the left, and hold it a t the OFF position.
3 - 2 0 Basic Features and Functions for Operating OSACOM SUPER 8700
Chapter 4 Manua l Man ipu la t ion
This chapter describes manual manipulation. Manual manipulation is performed to change positions and attitudes of the manipulator by operating the teaching box. This chapter gives detailed explanations of how to switch moving directions and speeds for manual manipulation, in addition to how to change positions and attitudes.
Contents
4 1 Operations for Manual Manipulation 4 - 1
4.1.1 Changing Positions and Attitudes (Manual Manipulation) ........................................ 4 - 1
4 1 2 Changing Manual Speed ...................................................................................................................... 4- 2 . . 4. 1 .3 Switching between Coordinate Systems 4- 2
4.1.4 Switching Mechanisms
(Not applicable to the Single Manipulator System) 4- 5
4 . 1 . 5 Inching and Retracting the Wire 4- 5
4.1.6 'pesetting ~ ~ t ~ ~ ~ ~ l control output signals ........................................................................ 4- 6
4.2 ~~~i~~ ~ i ~ ~ ~ t i ~ ~ ~ 4 - 7
4 2 1 Axis Movement ........................................................................................................................................... 4- 7 . . 4 2.2 Cartesian Movement 4 - 9
4 3 Cartesian Movement Near the Singular point ........................................................................... 4- 19
4. Manua l Man ipu la t ion 4. 1 Operations for Manual Manipulation
Manual manipulation is performed to change positions and attitudes of the
manipulator, slider and positioner by operating the teaching box. Also, operations
for changing coordinate systems and speeds are involved to perform manual
nlanipulation.
Changing positions and attitudes (Manual Manipulation)
* Changing the manual speed
* Switching between coordinate systems
* Switching between mechanisms
Inching and retracting the wire
- Resetting External Control Output Signals
4. 1. 1 Changing Positions and Attitudes (Manual Manipulation)
To perform manual manipulation, in addition to the servo power ON state, the
following conditions must exist:
AUTO mode
The robot is in the halted state or outside the Start Enabe area before automatic
operation is started or after the Job is completed.
TEACH mode
Block operation or absolute offset setting is not being performed.
II Manual Operation
1. Press the Axis key while holding
down 8 . 2. The manipulator moves in the direction
corresponding to the key being pressed.
3. When you release @ key, all axes
stop. w
For moving directions, refer to
"Moving Directions", section 4.2. in part 1.
TEACH ENABLE (I:
MECHAN l SM
Manual Manipulation 4 - 1
4.1.2 Changing the Manual Speed
A speed for manual manipulation can be selected from among 8 steps of 4 low speed
modes and 4 high speed modes, and inching speed (available only for Cartesian
movement). The speed is displayed a t the speed display area on the teaching box.
(Inching) < > Low Low speed mode High speed mode High
The maximum speed in the low speed mode (ML4) is 15m/min.
H Switching between speeds fo r manual manipulation
* TO increase:
Press 1 8 1 . If the speed is ML4, pressing
changes to MH1.
To decrease:
Press [vl. If the speed is MH1, pressing
changes to ML4.
Speed display area
l4
A X I S M L 4
T E A C H
S E R V O ON
4. 1.3 Switching between Coordinate Systems
In principle, two kinds of movements, Axis and Cartesian movements, a re available.
In the Cartesian movement, even if you press the same "AXIS" key, the direction varies
according to the coordinate system you select.
The following coordinate systems are available:
r Axis movement
Cartesian movement Base coordinate system*'
Tool coordinate system*'
Work coordinate s y ~ t e m * ~
World coordinate ~ y s t e m * ~
* 1: Refer to "Moving Directions", section 4.2 in part I.
* 2: Refer to Instruction Manual "Options"
4 - 2 Manual Manipulation
Coordinate systems that can be selected depend on the system configuration using a
single manipulator or multiple mechanisms:
Table 4.1 Coordinates Systems Available According to the System Configulations
Cartesian 1 ~ o o l 1 Q 1 Q I Q
Axis Movement I I I
0 : Available
0 : Can be set, but gives the same results a s the Base coordinate.
A : Can be set, in the case that Simultaneous control and Synchromotion a re mixed in
Single Manipulator System
@ 63 / Base 1 0
Movement
a system.
@
Note - 1) For Slider or Positioner, only the Axis Movement is available. 2) In a Single Manipulator system using an overhead or wall mounting type, the
World coordinate system is also available.
Multiple-Mechanism System
Work
World
- -
There are two ways of changing the coordinate system from Axis Movement to
each Cartesian Movements.
Simultaneous control
@
* The way of changing to registered Cartesian coordinate systems
Synchromotion
0
0
0
* The way of selecting out of 4 Cartesian coordinate systems - (By pressing key)
0
A
Manual Manipulation 4 - 3
63 0
(1) The way of changing - to registed cartesian coordinate systems
Each time you press ,,,,,, key, you can switch in order of Axis -+ m Cartesian coordinate 1 -+ Cartesian coordinate 2 + Axis -...
You can register Cartesian coordinate 1 and 2 in the user parameter for setting the
system status "ENTRY OF COORDINATES".
As the default settings for Cartesian coordinates 1 and 2 are Base coordinate
system and OFF, respectively, the coordinates system is switched in the order of
Axis + Base coordinate system -+ Axis.
(2) The way of selecting out of 4 Cartesian coordinate systems FUNC- By pressing a key, you select a Cartesian coordinate system you want one of 4
Cartesian coordinate systems(Base, Tool, Work, and World coordinate system).
63 Change coordinate systems you often use by above (1) way, and coordinate
system you do not register by above (2) way.
H Switching coordinate systems by key. - Each time you press
switch coordinate systems.
The current coordinate system is
displayed a t the coordinate system
display area on the teaching box.
FUNC- Switching coordinate systems by key.
FUNC- 1. Press in the state of being
able to perform manual operation.
4 - 4 Manual Manipulation
2. Press Fl(C0RDNAT). * F1 ... Base coordinate system F2 ... Tool coordinate system F3 ..- World coordinate system F4 Work coordinate system
3. Select the coordinate system by
using function key.
Now, you can switch coordinate
systems
4.1.4 Switching Mechanisms (Not applicable to the Single Manipulator System)
In the multiple-mechanism system which consist of manipulator and external axes
such a s slider o r positioner, mechanism should be selected by key during manual
operation.
For detail of switching mechanizms, refer to the Instruction Manual " Options",
depend on the control system(Simultaneously or Synchronous control) in use.
4. 1.5 Inching and Retracting the Wire
on the teaching box allows you to inch/retract the wire.
The operation to pull the wire out from the tip is referred to inching, and the operation
to pull it back is referred to a s retracting.
You can specify wire feed rates for inching and retract by setting
"INCH/RETRACT(HIGH) " and "INCH/RETRACT(LOW) " in the welding user
parameters. *
@ Notes 1) If the setting of "APPLICATION" in the user parameters for setting the
system status is "HANDLING", it is not possible to inch/retract the wire. 2) It is not possible to inch/retract the wire during automatic operation.
Perform these operations in Teach mode, or before automatic operation is started, or after the job is completed.
L
* : Refer to "Setting the Welding Parameters" section 2.3 in part I[.
Manual Manipulation 4 - 5
Inching and retracting
(Inching)
Press IF/. * For h i z e e d inching, press [ q w h i l e holding down a
Press IwI . IUI
* For high speed retracting, press while holding down
4.1.6 Resetting External Control Output Signals
You can set a group of External control output ports 0000 - 0099 to OFF
Any output ports 0100 - 0199 will not be changed.
Resetting external control output signals FUNC- . 1. Press In the state of being
able to perform manual operation.
2. Press F4(1/0 RST). * 3. Press Fl(C0NFIRM).
External control output port 0000
- 0099 will be OFF.
Any output ports 0100 - 0199 will not be changed.
4 - 6 Manual Manipulation
4. 2 Moving Directions This section describes how ALMEGA G series (GO1 and G03),WOl and V series (V01,
V10, V20, and V40) move when Axis and Cartesian manual manipulation is performed.
4.2. 1 Axis Movements
The axis corresponding to each Axis key moves independently.
Axis No. I Movement I Teaching Box Key
Upward and downward
Rotation 2 (left/right)
\' \
Rotation 1 (Axis
xis 2)
Torch angle (Axis 5)
Fig.4.1. Moving directions of ALMEGA G series and W01
Manual Manipulation 4 - 7
Axis No
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Movement
Rotation (left/right)
Lower a rm (forward/backward)
Upper a rm (upward and downward)
Wrist (swivel)
Wrist (bend)
Wrist (twist)
Bend
Teaching Box Key
Fig.4.2. Moving directions of ALMEGA V series
3)
xis 2)
4 - 8 Manual Manipulation
4.2.2 Cartesian Movement
This section describes the moving directions given in each of the Base and Tool
coordinate systems.
Cartesian movements a re divided into Base axis movements which define the position
of the torch tip and Wrist axis movements which define the torch attitude.
Furthermore, ALMEGA V series has two types of Wrist axis movements; Cartesian
movements by the Eulerian angle system and the R.P.Y. (Roll, Pitch, and Yaw) system.
You can specify either of them by setting "POSTURE MOTION" in the user
parameters for setting the system status.
In the Simultaneously Controlled system, if the manipulator is selected a s the moving
mechanism, the moving directions are the same a s those in the Single Manipulator
system.
For moving directions on the Work and World coordinate systems selected in the
Synchronous Motion Control system, refer to Instruction Manual "Options".
Manual Manipulation 4 - 9
(1) Base coordinate system
I A L M E G A G series (GO1 and G03) and WOll
(a) Base axis movements
Fig.4.3. Moving directions of Base axes in the Base coordinate system
(ALMEGA G series and W01)
4 - 1 0 Manual Manipulation
(b) Wrist axis movements
- Axis 4
The torch rotates around the perpendicular, with the torch tip being fixed.
I Perpendicular
Fig.4.4. Moving directions of Axis 4 in the Base coordinate system
(ALMEGA G series and W01) * Axis 5
The torch rotates on the plane of rotation of Axis 5, with the torch tip being
fixed
Fig.4.5. Moving directions of Axis 5 in the Base coordinate system
(ALMEGA G series and W01)
Manual Manipulation 4 - 1 1
(a) Base axis movements
Fig.4.6. Moving directions of Base axes in the Base coordinate system
(ALMEGA V series)
4 - 1 2 Manual Manipulation
(b) Wrist axis movements (the Eulerian angle system)
Axis 4
The center line of rotation of Axis 6
rotates around the Z axis, with the
torch tip being fixed.
Direction of Z axis
Fig.4.7. Moving directions of Axis 4
Axis 5
The torch rotates around the torch tip
on the plane formed by the torch line
and the Z axis, with the torch tip
being fixed. \ Torch line
Direction of Z axis "\ Fig.4.8. Moving directions of Axis 5
Axis 6
The torch rotates around the torch line
a t a constant torch attitude, with the '.
torch tip being fixed. \ \ Torch line
Fig.4.9. Moving directions of Axis 6
Center line of rotation of Axis 6 Direction of Z axis
, I Torch tip
w , - - Horizontal plane Axis / \ ' Torch line
Line of Axis 6 Moving direction of Wrist axes in the Base coordinate
(ALMEGA V series)
system
Manual Manipulation 4 - 1 3
(c) Wrist axis movements (the Roll/Pitch/Yaw system)
* Axis 4
Axis 4 rotates around the Z axis, with the tool center being fixed.
Fig.4.11. Moving directions of Axis 4
Axis 5
Axis 5 rotates around the Y axis, with the tool center being fixed.
Fig.4.12. Moving directions of Axis 5
Axis 6
Axis 6 rotates around the X axis, with the tool center being fixed.
Fig.4.13. Moving directions of Axis 6
4 - 1 4 Manual Manipulation
(2) Tool coordinate system
~ALMEGA G series (GO1 and G03) and WO1I
(a) Base axis movements
The direction in which the wire is retracted from the torch is defined a s the Z
axis, the angular reference position of Axis 4 (O0 ) is defined a s the Y axis, and
the axis perpendicular to the Z axis on the plane of rotation of Axis 5 is defined
as X axis. The X/Y/Z coordinate system is the right-hand coordinate system.
Since this coordinate system depends on the torch attitude, the direction of each
axis changes when the attitude changes. Z axis
system
Fig.4.15. Moving directions of Base axes in the Tool coordinate system
(ALMEGA G series and W01)
Manual Manipulation 4 - 1 5
Fig.4.16. Moving directions of Base axes a t different attitudes
4 - 1 6 Manual Manipulation
I ALMEGA V series]
(a) Base axis movements
I I I x axis
Fig.4.18. Moving directions of Base axes a t different attitudes
Manual Manipulation 4 - 1 7
(b) Wrist axis movements
* Axis 4
The torch rotates around the Z axis (torch line), with the torch tip being fixed.
Fig.4.19. Moving directions of Axis 4
Axis 5
The torch rotates around the Y axis, with the torch tip being fixed.
Fig.4.20. Moving directions of Axis 5
* Axis 6
The same as Axis 4.
Fig.4.21. Moving directions of Axis 6
4 - 1 8 Manual Manipulation
4. 3 Cartesian Movements Near the Singular Point If Cartesian manual manipulation or a linear or circular interpolation is performed
near the singular point, an expected axis o r axes may abruptly move. Therefore, for
manual manipulation near the singular point, use Axis movement. Also, be sure that any
linear and circular path do not pass near the singular point. In case a path does, the set
speed and the accuracy of the path a re not guaranteed.
he singular point of ALMEGA G series and ~ 0 1 )
* Position where Axes 2 and 3 are aligned
Fig.4.22 The singular point of ALMEGA G series and W01
/The singular point of ALMEGA V series/
ALMEGA V series has two attitudes called singular points.
The singular point of Axes 4 and 6 (See Fig.4.23.)
The attitude where the rotated axis of Axis 6 meets the extension line of the
rotated center axis of Axis 4.
Fig.4.23. The singular point of Axes 4 and 6
Manual Manipulation 4 - 1 9
The singular point of Axes 1 and 6 (See Fig.4.24.)
The attitude where the rotated axis of Axis 6 meets the extension line of the
rotated center axis of Axis 1.
Fig.4.24. The singular point of Axes 1 and 6
If a linear o r circular interpolation is performed a t an attitude near the singular
point in Cartesian manual manipulation, or automatic or block operation, this causes
Axes 2 and 3 to rotate a t a high speed. Because such movements are very dangerous,
OSACOM SUPER 8700 is equipped with a device to control them.
4 - 2 0 Manual Manipulation
When the manipulator moves to the shadowed area, all mechanisms stop their
movements and the following message is displayed on the teaching box:
I S. L I M I T 1 1 2 1 1 -+MANUAL O P E .
* When all mechanisms stop, it is not possible to perform Cartesian manual
manipulation in the direction approaching to the singular point.
When all mechanism stop, it is possible to perform both Cartesian and Axis
manual manipulations in directions away from the singular point.
This message is displayed also when both Axes 1 and 6 move beyond the soft
limit a t the same time. Therefore, when it appears, identify the cause from the
attitude of the manipulator; whether a ) o r b):
a ) The end of the upper a rm entered the area of the singular point.
b ) Both Axes 1 and 6 moved beyond the soft limit a t the same time.
Fig.4.25. The attitude near the singular point
Manual Manipulation 4 - 2 1
Chapter 5 Teaching
This chapter describes features of Motion instructions and Task
1 instructions. how to teach them. and block operation to check the I / positions and attitudes in a Task program created . 1
Contents
5. Teaching The teaching features are available by pressing the F1 key a t the top layer of Teach
mode, which allow the operator to create, modify, and list Task programs.
5. 1 Creating and Listing Task Programs
5.1.1 Creating Task Programs
This feature is used to create new Task programs. The created Task programs are
stored a s Task program files.
Task programs a re created in accordance with the following procedure:
Enter a Task program number. m ich do you select, Task instruction
Motion or Task inst I
I Motion instruction I 1 I
Set a manual speed accordingly.
I / Set each type of movement and I 1 1 coordinate system accordingly. I
/ Move the manipulator by manual 1 I 1 manipulation. I I I I
/ Store the Motion instruction 1 1 Store the Task instruction. 1
you want to tdrminate t e a c h i n a No
Perform block operation (to check the positions and attitudes)
Fig.5.1 The procedure for creating a Task program
Teaching 5 - 1
(1) Entering a Task program number
I t is necessary to give a number given to a Task program to be created. If you enter
an existing number, you are not creating a program but will modify its program o r
perform block operation. Though Task program numbers ranging from 1 through 999
are available, do not use 990 - 999 which are used for adjustment.
(2) Selecting a Motion or Task instruction
Move the manipulator to the position you want, and select the instruction by pressing
the data selector key on the teaching box (e.g., P to move by Positioning).(See Table 5.1.)
Instructions are divided into two groups:
Motion instructions
These are instructions to move the manipulator (for positioning and interpolation).
Sequence numbers are given to Motion instructions in order by creation.
The maximum of 999 sequences can be stored in one Task program.
Task Instructions
These are Instructions to execute welding, weaving, output signals to external devices,
etc.
The maximum of 9980 instructions can be stored in one Task program.
For details of how to teach each of Motion and Task instructions, refer to "Teaching
Motion Instructions", section 5.2., and "Teaching Task Instructions", section 5.3.
Important It is not possible to teach more than 9 Task instructions a t one time.
Entering a Task program number
1. Press F1 (TEACH) key at the
top layer of Teach mode. *
5 - 2 Teaching
2. Enter the number by using
numeric keys. rr)
You can now create a Task
program.
Teaching 5 - 3
Table 5.1 List of Motion/Task Instructions
L $ I Linear interpolation
Parameter
P $
Speed and Overlap on/off
Description Key
Linear interpolation with speed and Overlap rotation of attitude
Instruction
Positions Speed rate and Overlap on/ off
Center point of .circular interpolation with rotation of the attitude
LX * $
c 1 $
C2 $
End point of circular interpolation with rotation of the attitude
Rotating speed and Overlap on/off
Uniform interpolation
Center point of circular interpolation End point of circular inter polation
Rotating speed and Overlap on/off
Speed rate and Overlap ON/OFF
Speed and Overlap on/off
Speed and Overlap on/off
AS
AE
ICH
RTC
GS
GE
ASM L
AEM *
Starting welding
Terminating welding
Inching the wire
Retracting the wire
Turning gas ON
Turning gas OFF
Starting multi-pass welding
Ending multi-pass welding
Welding s tar t conditions
Crater condition
Inching time
Retracting time
Welding s tar t condition Weaving condition Offset condition
Crator condition Offset condition
WFP
WAX
WE
Starting weavin (Fixed pattern ?
Starting weaving (Axis)
1 Terminates weaving
Weaving conditions
Weaving conditions
Setting external control output Reseting external control output Waiting for external control input ON Waiting for external control input OFF
Output port number and delay time Output port number and delay time Input port number and input wait time Input port number and input wait time
5 - 4 Teaching
T $
BRANCH W
Waiting for time
$
Time
NOP $
PM $
Internal jump (Unconditional)
J P N $ Internal jump (ON condition)
J P F $
Point mark number
No operation
Point mark (Jump destination)
Internal jump (OFF condition)
J P C $
Point mark number and Input port
Point mark number
Internal jump (Counter condition)
Point mark number and Input port
Point mark number and Input port
JF $
J F N $
Task program number and Input port number
External jump (Unconditional)
JF F $
Task program number
External jump (ON condition)
External jump (OFF condition)
Task program number and Input port number
JF C $
$
External jump (Counter condition)
Calling program (Unconditional)
CL N $
Task program number and Input port number
Calling program (ON condition)
CL F $
Task program number
Calling program (OFF condition)
CL C $
Task program number and input port number
Calling program (Counter condition)
Task program number and input port number
Task program number and counter number
/ DEF 1 Setting counter value I Counter value
DEC
END
HP * $
Teaching 5 - 5
Decremental operation of counter value
HL * $
Counter value
Ending program
Synchronous positioning motion
Speed rate Overlap on/off
Synchronous linear interpolation
Speed Overlap on/off
Rotating speed Overlap on/off
HLO * $ Synchronous linear interpolation with rotation of attitude
HC * $
HO * $ Rotating speed Overlap on/off
Synchronous circular interpolation
Synchronous circular interpolation with rotation of attitude
HLX * $
ST * ET *
Speed rate Overlap ON/OFF
Speed Overlap on/off
Simultaneous uniform interpolation
Starting tracking
Ending tracking
/ SF1 * $ One-direction search Deviation store number
* $
Pattern search
Calling deviations
Wire extension
Storing deviation number in tracking Starting high speed touch sensing Ending high speed touch sensing Starting multi-pass section
Deviation store number
Ending multi-pass section
Pattern No.,
Deviation store number,
Search/Move Speeds, Reverse
direction on/off, and
Component on/off
Deviation call No.
Deviation store No.
Speed
Repeating times
* : Indicates Optional instructions. $ : Indicates Motion instructions. Instructions without $
are Task instructions.
EP * $
RT * $
5 - 6 Teaching
Specifying executing pass of task instruction Calculating rotated position
Executive condition
Rotational offset value, Axis number
5.1.2 Listing Task Programs
The List function allows the operator to list the created Task programs in order by
number. It is possible to list them in order by date by modifying the setting of "PRG.
LIST DISP." in the user parameters for setting the system status*'.
II Listing Task programs
1. Press F1 (TEACH) at the top
layer of Teach mode. II)
2. Press F1 (LIST). r)
F1 ... Displays the next page. F2 ... Display the previous
page. F3 . . . Modify the Task
program the cursor indicates.
F4 . .. Make a copy of the Task program the cursor indicates. *'
F5 ... Deletes the Task program the cursor indicates. * 3
F1 ... Rename the Task program the cursor indicates. * 4
3. To terminate, press I-ESET . 0 The list operation is terminated,
and you can enter Task program
numbers again.
* 1: Refer to "Setting the System Status", section 2.1 in part II. * 2: Refer to "Copying Files", section 8.2 in part I . * 3: Refer to "Deleting Files", section 8.3 in part I . *4: Refer to "Renaming Files", section 8.4 in part I .
Teaching 5 - 7
5. 2 Teaching Motion Instructions 5.2. 1 Positioning P
This instruction allows the operator to store positions and attitudes of the
manipulator. The manipulator moves to the taught position/attitude from the
immediately preceding stored position/attitude. The moving path of the manipulator
is not linear.
A speed is specified a t a speed rate (which is a rate to the maximum speed; 100 is the
maximum.) When only one axis is operated, it moves a t a specified speed. However,
when multiple axes are operated, the axis whose motion is the largest moves a t a
specified speed, and the other axes s tar t and stop synchronously with it.
As a parameter, Overlap ON/OFF is available. If ON is selected, the rise and fall of
a moving speed are overlapped.
@When you want to reduce a tact time (a time f rom the start of automatic operation
t i l l the completion of a job), select Overlap ON.
Overlap ON Overlap OFF
Fig.5.2 The paths given by setting Overlap ON/OFF
k n - . - L : - - 4 b i l U L I U I 1 \
1) The tact time can be reduced by setting Overlap ON. However, because there is a difference between the path in automatic operation and the path taught, take care to avoid interference with peripheral equipment such a s a jig. Also, because the overlap process is not performed in block operation, the manipulator may interfere with a jig in automatic operation even if this does not happen in block operation. Set Overlap OFF if interference with the jig is possible.
2 ) Even if Overlap OFF is set, this setting may not be effective, depending on the relation between the moving distance and speed, and also taught data.
i /
* : Refer to "Restrictions on Overlap Process", appendix 1 provided a t the end of this manual.
5 - 8 Teaching
II Teaching Positioning P
1. Move the manipulator, by
manual manipulation, to the
position and attitude you want to
teach.
2. Press B. F1 ... Speed 75% and Overlap ON F2 ... Speed 100% and Overlap ON F3 ... Speed 50% and Overlap ON F4 ... Speed 75% and Overlap OFF F5 ... Speed 100% and Overlap
OFF
3. Set a speed by using the function
key o r numeric keys.
4. Set Overlap ON or OFF, i f
necessary.
The default is "ON".
To change to "OFF" :
(2) Press F2 (OFF).
(3) Press @ .
Now, the Positioning instruction
"P" has been stored.
Teaching 5 - 9
5.2.2 Linear Interpolations L and L O
These instructions allow the operator to lineally move the tool tip of the manipulator
to the taught position/attitude from the immediately preceding stored position and
attitude.
(1) L
This instruction causes the tool tip of the manipulator to lineally move with
rotation of the attitude. A speed rate to a moving distance of the tool tip (cm/min)
is set. The entry range of speed is 1 - 999 cm/min. Note that, if a value over 900 cm/
min is set, moving speeds in block operation and automatic operation a re limited to
900 cm/min. If there is a manipulator such a s ALMEGA V40 on the work-side, the
maximum moving speed of work-side manipulator is 600 cm/min.
(2) LO
This instruction causes the attitude of the manipulator to rotate with linear motion
of the tool tip. A speed rate to a moving angle of the tool tip (deg/sec) is set. The
entry range of speed is 1 - 99.9deg/sec.
Note that, if a speed over 45.0deg/sec is set, moving speeds in block operation and
automatic operation are limited to 45 deg/sec.
Torch ----+ Linear movement (L) Rotation of the attitude (LO)
Fig.5.3. Comparison between L and LO
5 - 1 0 Teaching
As a parameter for each of L and LO, Overlap ON/OFF is available. For welding,
usually set overlap "ON". If overlap is set "OFF", th mentarily stop a t
that point during automatic operation.
I Manipulator stops I momentarity a t
the joint
Robot does not stop but takes a small short cut, which causes the path to round a t the joint.
Overlap ON Overlap OFF
Fig.5.4 The paths given by setting Overlap ON/OFF
Normally, to perform welding, set Overlap ON. If you do not want to make joints
around for cutting , set Overlap OFF.
) Important 1) The difference between overlap "ON" and "OFF" appears a t a joint but has no
affect on any other part of the path. 2) Even if Overlap "ON" is set, the setting may not be effective, depending on the
relation between the moving distance and speed, and also taught data. *
3) In the following cases, the manipulator cannot move a t specified speed. * The change of attitude is large compared to the moving distance. * The moving distance is short compared to the specified speed.
* :Refer to "Restiction on the overlap Process", Appendix 1 provided a t the end of
this manual.
Teaching 5 - 1 1
LFI Teaching Linear Interpolation L (LO) 1. Move the manipulator, by
manual manipulation, to the
F1 .. . Speed 60cm/min and Overlap ON
F2 ... Speed 100cm/min and Overlap ON
F3 .. . Speed 200cm/min and Overlap ON
F4 ... Speed 300cm/min and Overlap ON
F5 .. . Speed 100cm/min and Overlap OFF
position and attitude you want to teach.
F1 ... Speed 5.0deg/sec and Overlap ON
F2 ... Speed lO.Odeg/sec and Overlap ON
F3 ... Speed 15.0deg/sec and Overlap ON
F4 ... Speed 20.0deg/sec and Overlap ON
F5 ... Speed lO.Odeg/sec and Overlap OFF
I w~~~~w ~ ~ ~ ~ p i x x i q ~ ~ ~ ~ >
Pressing [> key causes L to 0
3. Set a speed by using the function
key or numeric keys.
2. Press a . ~lr)
I -a. o a ,-
1 5 . / ~ ~ ~ ~ ~ ~ >
4. Set Overlap ON or OFF, i f
change to LO instruction. +
necessary.
For details, see the steps for
Positioning "P" .
5. Press @ . Now, the Linear Interpolation
instruction "L" has been stored.
5 - 1 2 Teaching
5. 2. 3 Ci rcu la r interpolations C1, C2, CO1,and C02
These instructions allow the operator to circularly move the tool tip of the
manipulator to the taught position/attitude from the immediately preceding stored
position and attitude.
A circular a rc is defined by 3 points- a s tar t , middle, and end points.
Start point: any one of P , L, and LO of C1 o r C2
Middle point : C1 o r C03
* End point: C2 or C02
(1) C1
This instruction creates a circular arc by the present point and each taught point
of the immediately preceding and following Motion instructions.
(2) C2
This instruction creates a circular a rc by the present point and each taught point
of the 2 immediately preceding Motion instructions. P
Path of Circular Interpolation (C1) Path of Circular Interpolation (C2)
Fig.5.5 The paths of Circular Interpolations
(3) C01 and C02
The C01 and C02 a re circular interpolation instructions which cause rotation of
the attitude in addition to C1 and C2, respectively.
For setting moving speeds and Overlap ON/OFF, refer to the descriptions for L
and LO, section 5.2.2.
@ Inportant \
1) Teach all of a start , middle and end points to make a circular arc, with the same
type of coordinate system.
2) The diameter of the minimum circular arc varies according to the manipulator
type and the speed setting.* L J
* : Refer to "The Relation between a Minimum Circular Diameter and a Setting Speed"
Appendix 2 provided a t the end of this manual.
Teaching 5 - 1 3
CIII Teaching Linear Circular C (CO) 1. Move the manipulator, by
manual manipulation, to the
position and attitude you want to
teach.
2. Press .
F1 ... SpeedGOcm/min and Overlap ON
F2 . .. Speed 100cm/min and Overlap ON
F3 . .. Speed 200cm/min and Overlap ON
F4 . .. Speed 300cm/min and Overlap ON
F5 ... Switches between C1 and C2.
key causes C to
change to CO instruction. * F1 . .. Speed5.0deg/sec and Overlap
ON F2 ... Speed lO.Odeg/sec and
Overlap ON F3 ... Speed 15.0deg/sec and
Overlap ON F4 . .. Speed 20.0deg/sec and
Overlap ON F5 ... Switches between C01 and
C02.
LAP : ONA / 6 l [ O N j r ; i 0 0 c m O j S I m m / >
LAP : ON' ' 1 / 5 I d ] p . ' G i q ~ ~ ~ ] >
3. Set a speed by using the function
key and numeric keys.
4. Set Overlap ON or OFF, i f
necessary.
For details, see the steps for
Positioning "P" .
5. Press RECORD . 0 Now, the Circular Interpolation
"C" has been stored.
5 - 1 4 Teaching
5.2 .4 Wait fo r Timer Time T / No Operation NOP (1) Wait for Timer Time
This instruction allows the operator to stop execution of the Task program for a
specified time. Note that weaving and welding are carried on without being stopped.
(2) No Operation
This instruction allows the operator to specify no operation, and is used t o
synchronize between Motion instructions and Task instructions.
Like the case of Wait for Timer Time, weaving and welding a re carried on
without being stopped.
@Use this instruction when you want to teach more than 9 instructions continuously
o r do not want to simultaneously execute a series of external control inputs/
outputs.
II1 Teaching Wait for Timer Time " T " and No Operation "NOP"
1. Press a 2. Press the function key
corresponding to the instruction
you want.
Wait f o r Timer Time "T"
(1) Set a time by using numeric I
keys.
(2) Press RECORD key. 0
IIT TIMER- 2.0 sa. -..I
Now, the Wait Timer Time
instruction "T" has been stored.
Teaching 5 - 1 5
(1) Press F2 (NOP).
(2) Press @ .
Now, the No Operation instruction
"NOP" has been stored.
5 - 1 6 Teaching
5. 2 .5 Internal Program Jump PM(Point Mark), JP(JumP),
DEC (DECrement), and DEF(DEFine)
Though instructions a r e sequentially executed in block o r automatic operation, the
internal program jump functions allows the operator to shift execution to a desired
sequence. Jump conditions include the external control input state, counter, etc.
The following instructions a r e used to execute a n internal program jump:
* Internal Program Jump J P
* Point Mark (jump destination) PM
* Counter conditions for jump DEC and DEF
(1) Internal Program Jump J P
This instruction allows the operator to shift execution of a Task program to a
specified point mark (PM) within the program.
The Positioning instruction "P" is used to move to a point mark (PM). The speed
is the setting of "SPEED TO PM"* in the userparameters for setting the system
status.
Note that in block operation a block operating speed is applied.
The following jump conditions a r e available:
Unconditional jump
Jumps always to a specified point mark (PM).
* Jump according to the external control input s ta te
Jumps to a specified point mark (PM) if the jump condition exists when the
external control input s ta te is checked.
* Jump according to the internal counter
Jumps to a specified point mark when the internal counter reads 0.
(2) Point M a r k (Jump Destination) PM
The point mark is used to indicate the destination to jump within a program.
Up to 9 point marks can be taught in one Task program.
The following parameter is available:
* Point mark number: 1 - 9
* : Refer to "Setting the System Status", section 2.1 in par t 11.
Teaching 5 - 1 7
Important 1) As well as Positioning "P" , Point Mark has data of the position/attitude.
If multiple mechanisms a r e configured, this instruction has da ta of the positions/attitudes of all of them. However, these taught positions/attitudes a r e achieved only when the Internal Program Jump instruction is executed to move to the Point Mark.
2) If a point mark with the same number is taught within a Task program, only the point mark taught a t the lower sequence number is valid. In this event, e r ro r is not displayed. However, an er ror is detected when a logical check on Task program* is performed.
'.
(3) Internal Counter DEF and DEC These instructions a r e used to set a counter value and to perform a decremental operation of it.
(A) DEFine a counter value "DEF" This instruction allows the operator to define a counter value used as a
condition for instructions such a s Internal Program Jump/External Program Jump/Call.
The following parameters a r e available: * Counter number: 1 - 9 * Counter value : 1 - 999
Up to 9 counter numbers can be used in one program for automatic operation. One program for automatic operation means a program which is executed throughout the sequences until the job is complete. Therefore, this includes other programs if they a r e activated by the External Program Jump o r Call instructions.
The counter value specified by DEF is set only when the counter reads 0.
(B) DECrement of a counter value, "DEC" This instruction is used to perform a decremental operation of the counter
number by 1. The execution is ignored when the counter value is 0. The following parameter is available: * Counter number: 1 - 9
The counter number changes in the following conditions: When the controller is turned on =3 0 When the counter value is 0 and DEF is executed 3 the value specified by DEF When the counter value is larger than 0 and DEC is executed
=$ the value deducted is executed by 1 by DEC.
The counter value is held until the controller is turned off.
* : Refer to "Logical Check on Task Programs", section 1.2.1 in P a r t 2.
5 - 1 8 Teaching
[Example)
[Teaching data1
0 0 1 P 0 0 2 PM1 0 0 3 P 0 0 4 P 0 0 5 J P PM1 0 0 6 E N D
[Position]
The position of PM of sequence 2 differs
from those of sequences 1 and 3.
[Path] Positioning to sequences 3 and 4 from sequence 1 by performing block or automatic operation.
Positioning to the position of PM when the condition of JP1 is satisfied.
Execution of sequence 3 and the following sequences because PM1 is sequence 2.
Fig. 5.6 Paths by Internal Program Jump using a Point Mark (PM)
Teaching 5 - 1 9
f Example)
(1) When the state of external control input is a jump condition
To make a program, "Check the state of input port 7 before the program is
terminated + Repeat the operation if there is an input. Terminate the program if
no input." ,teach:
Sequence No
0 0 1 PM 1 +Specify point mark (PM) number 1.
0 0 5 J P N 0 0 7 , P M 1 +Jump to PM1 (sequence 001) if there is a n
0 0 6 E N D input a t input port 007.
(2) When the counter is a jump condition
To repeat the operation 5 times and terminate the Task program, teach:
Sequence No.
0 0 1 P
D E F # 2, 0 0 5 +Set counter 2 a t 5.
0 0 2 PMI
D E C # 2 +Decrement 1 to the value of counter 2 by 1.
0 0 5 J P # 2, P M 2 +Jump to PM2 (sequence 007) if counter 2 is 0, and
terminate automatic operation.
0 0 6 J P P M 1 +Jump to PMI (sequence 001) if counter 2 is not 0.
0 0 7 PM2 (Repeat sequences 001 - 005 5 times.)
0 0 8 E N D
When a~l tomat ic operation is performed, the operation from sequence 001 through
005 is repeated 5 times.
5 - 2 0 Teaching
II Teaching Internal Program Jump "JP" m
I . Press .
2. Press the F2 key (JP). 111)
F1 ... Jump when a specified input port is ON.
F2 ... Jump when a specified input port is OFF.
F3 ... Jump when the counter value is 0.
F4 ... Unconditional jump
Jump according to the external control input state
(1) Press the F1 key (JP ON) o r
the F2 key (JP OFF) r9
(2) Set the jump conditions; a
port number and a point mark
number for the destination.
Jump accordinn to the counter
(1) Press the F3 key (JP CNT)..I)
(2) Set the jump conditions; a
counter number and a point
mark number for the
destination.
Teaching 5 - 2 1
Unconditional iumr, -
(1) Press the F4 (UNCOND).
(2) Set a point mark number for
the destination.
3. Press RECORD key. 0 Now, the Internal Program Jump
" J P " instruction has been stored.
Teaching Point Mark "PM"
1. Press
2. PresstheF4 key (PM). *
3. Set a point mark number.
4. Press RECORD 0 Now, the Point Mark "PM"
instruction has been stored.
5 - 2 2 Teaching
II Teaching DEFine and DECrement a counter value
1. Press
2. Press the F5 key (COUNTER).
.I)
Teaching DEFine a counter value
(1) Press the F1 key (DEF). .9
(2) Set a counter number and a
counter value.
(3) Press @ .
Now, the DEFine counter value
"DEF" instruction has been
stored.
Teaching DECrement a counter value
(1) Press the F2 key (DEC). I 3
(2) Set a counter number.
(3) Press @ .
Now, the DECrement "DEC"
instruction has been stored.
Teaching 5 - 2 3
5.2.6 External Program Jump JF
This instruction is used to shift execution of a Task program to a specified Task
program. This allows the operator to sequentially run a number of Task programs.
The following jump conditions are available.
Unconditional jump
Jumps always to a specified Task program.
* Jump according to the external control input state
Jumps to a specified Task program if the condition is satisfied when the external
control input state is checked.
* Jump according to the internal counter
Jumps to a specified Task program when a specified counter reads 0.
Note \
When the Task program specified by Program Jump is executed and completed, all Task programs will be terminated (i.e., the Job End). Therefore, the instructions following Program Jump are not executed.
\ /
(Example]
Task programs PO01 and PO02 contain the following taught data:
P O 0 1 P - P - L - L - L - P - P - E N D
P O 0 2 P - P - L - L - P - P - E N D PO01 PO02
I' 7 P 4 \ P, EM) END \,,
, \
Y P' 7 1 I
\
I \
The doted lines and full lines indicate paths in the space and on the plane,
respectively, and the arrows indicate the order of execution.
Fig.5.7 The taught data and paths of Task programs PO01 and PO02 5 - 2 4 Teaching
(1) Unconditional Jump to PO02 after executing PO01
Teaching for PO01 :
P - P - L - L - L - P - P - J F P 0 0 2 - E N D
P ; p .--- \ --'--.P; 0, P, END
I END X\, 1
I I \
Y p'; I \ I I
1 p\
Fig. 5.8 Path made by jumping to PO02 after executing PO01
(2) Jump to PO02 after executing sequence 5 in PO01
Teaching for P001:
P - P - L - L - L - J F P O O 2 - P - P - E N D
L n o t executed
Fig.5.9 Path made by Jumping from within PO01
Teaching 5 - 2 5
Teaching Program Jump " JF " by specifying Task program numbers
by the direct entry
1. Press
Press the F2 key (JP). + F1 ... Jump when a specified
input port is ON. F2 . .. Jump when a specified
input port is OFF. F3 ... Jump when the counter
is 0. F4 .. . Unconditional jump
Jump according to the external control input state
(1) Press the F1 key (JF ON) o r
the F2 key (JF OFF). +
(2) Set the jump conditions; a
port number and a point mark
number for the destination.
Jump according to the counter
(1) Press the F3 key (JF C N T 1 . e
(2) Set the jump conditions; a
counter number and a point
mark number for the
destination.
Unconditional lump (1) Press the F4 (UNCOND). * (2) Set a point mark number for
the destination.
3. Press RECORD key. 0 Program Jump " JF" instruction
has been stored.
5 - 2 6 Teaching
5.2.7 Programcal l CL
The Call instruction is used to execute another Task program from within the Task
program being currently executed and return control to the original program after the
called program is executed. This allows the operator to sequentially run multiple Task
programs.
The following call conditions are available.
* Unconditional call
Calls always a specified Task program
Call according to the external control input state
Calls a specified Task program if the condition is satisfied when the external control
input state is checked.
Call according to the internal counter
Calls a specified Task program when a specified counter reads 0.
@ Important 1) When a called Task program has been executed, which does not cause Job
End, execution is returned to the instruction next to the Call instruction. However, if the External Program Jump instruction is used in a called Task program, all Task programs terminate (i.e, Job End) when the Task program a t the jump destination is complete.
2) It is possible to use CL in a called Task program, but such call is limited to a maximum of 4 layers. If you try to call over that, an error will occur.
L
(Example]
The following examples are given to explain the Call Program instruction by
using the Task programs used to explain the Program Jump instruction
(1) Executing PO02 by Unconditional Call after PO01
Teaching for P001:
P - P - L - L - L - P - P - C L P O O 2 - E N D
The path is the same as that shown in (Example] (1) for Program Jump.
Teaching 5 -'2 7
(2) Call PO02 after executing sequence 5 in PO01
Teaching for P001:
P - P - L - L - L - C L P O O 2 - P - P - E N D
Fig.5.10 Path made by Calling PO02 from within PO01
Teaching Cal l Program " C L " by specifying a Task program number
by the direct entry
1. Press
5 - 2 8 Teaching
2. Press the F2 key (JP). + [ O N I E r G F l C N T / [ ~ j
F1 ... Call when a specified input port is ON.
F2 ... Call when a specified input port is OFF.
F3 ... Call when the counter value is 0.
F4 ... Unconditional call
CaII according to the external control input state
(1) Press the F1 key (CL ON) o r
the F2 key (CL OFF) * I C L N PORT,. , # ' P R G F P , , ,]
r E - r T q I O F F I / C L C N T / r n j
(2) Set call conditions; a port
number and a Task program
number to be called.
CaII according to the counter
(1) Press the F3 key (CL CNT1.M
(2) Set call conditions; a counter
number and a Task program
number to be called.
Unconditional cal l
(1) Press the F4 (UNCOND).
(2) Set a Task program number
to be called.
3. Press @ key.
Now, the Call Program "CL"
instruction has been stored.
5.2.8 END
The END instruction is used to terminate execution of a Task program. This instruction causes the J o b complete process to be executed. It is possible to create multiple of END instructions in one Task program.
Ell Teaching the END instruction
Press .
2. Press @. Now, the END instruction has
been stored.
Teaching 5 - 2 9
5. 3 Teaching Task Instructions 5.3.1 A r c Start AS
This instruction is used to s tar t welding a t specified welding conditions o r modify
these conditions during a welding operation.
Welding conditions vary according to the type of welding power unit in use, which is * 1 set in advance a s a user parameter .
(1) Individual control type welding power unit
This is a type of welding power unit which individually controls the current
command and the voltage command. Welding conditions to enter include a current, a
voltage, and a welding speed.
(2) Synergic control type welding power unit This is a type of welding power unit which automatically outputs an optimum
voltage when a current command is given. Welding conditions to enter include a
current, a fine adjustment (-100 -+loo%), and a welding speed. Fine adjustment
is an amount of adjustment to be made to a voltage output by the power unit. Set a
fine adjustment to provide an appropriate welding condition. This setting is not
required if ALMEGA FUZZY AUTO is connected and used a s a synergic control type
Fuzzy power supply.
(3) TIG welding power unit
Welding conditions to enter include a welding current, a filler wire feed rate, and a
welding speed.
There a re two way of specifying welding conditions:
Specifying a Welding Condition file*2 which contains welding conditions
Directly entering numeric values
@If there are multiple areas which should be welded at the same welding conditions,
specifying a Welding Condition files allows you to save teaching time and correcting
time.
* 1: Refer to "Setting Welding Characteristic Data", section 2.7 in part I1
* 2: Refer to "Editing Welding Condition Files", section 7.2 in part I .
5 - 3 0 Teaching
0 Important 1) If the setting of "APPLICATION" in the user parameters for setting the system
status is "HANDLING", welding related operations and instructions are not executed.
2) The entry ranges of current, voltage, and filler wire feed sa te a re defined by the ratings set in welding characteristic data. If values larger than rated values a re entered, the rated values will be stored.
3) The preflow is not available for the standard TIG welding power sopply.
)111 Teaching the AS instruction
Setting Arc Start conditions by entering numeric values -
The display on the 7th line a t Individual control type
the main display area depends on
the type of welding power unit IAS 1 6 0 . 4 2 3 . 0 ~ som 1 used. *
The following explanation is
based on an individual control
type welding power unit. Synergic control type
A preflow time is set in
"PREFLOW TIME"' of the
user parameters for welding. TIG
The preflow is not available for 7 i'"" 8 om S ocat ' ---q the standard TIG welding power
2. Set a welding current by
using numeric keys.
If the condition displayed is O.K.,
proceed to operation 3 (setting a
welding voltage).
* : Refer to "Setting Welding Parameters", section 2.3 in part 11.
Teaching 5 - 3 1
3. Setting a welding voltage
The voltage optimum to the
current is automatically set only
if you are using an individual
control type welding power unit .
(2) Enter a value by using
numeric keys.
4. Set a welding speed.
If the condition displayed is O.K.
proceed to operation 5.
(1) Press
(2) Enter a value by numeric keys.
5. Press @ . Now, the Arc Start instruction
"AS" has been stored.
Setting A r c Start conditions by specifying a Welding Condition f i l e
1. Press @ and then F3
(AS FILE) * 2. Enter the file number by
numeric keys. +
Then, press F1 (COND), and the
specified file will be displayed. +
5 - 3 2 Teaching
AXIS MH1 TEACH P777 SQNa= 4 SERVO ON ASCO 1
WELDING CURRENT 1 8 0A WELDING VOLTAGE 2 0.OV WELDING SPEED 1 5 Om
p'.F"FI
If the specified file does not exist,
an Alarm message is displayed. .r)
N°FILEEXllAs r sTs FILE A s c o l > % , 3 *
-1
* F1 ... Displays the contents of another Condition file.
~ I F Y ... Re-enters a file 0 number.
3. Press
Now, the Arc Start instruction has
been stored.
If the specified Condition file does
not exist, an Alarm message is
displayed.
F1 ... Stores the specified Condition file.
F2 ... Displays the contents of another Condition file, if any. The display does not change if there are no other Condition file.
* m I F Y ... Re-enters a file number. 0 @ Important 3
If F1 (EXECUTE) is pressed, be sure to create the Condition file you specified later. Otherwise, Alarm will occur in block operation, and Error in automatic operation.
L /
Teaching 5 - 3 3
5.3.2 Arc End AE
The AE instruction is used to terminate welding with a crater process using the
specified arc end conditions. Crater process is a process to make a bead shape a t the
weld end part neat. Arc end conditions vary according to the type of welding power
unit in use.
(1) Individual control type welding power unit
Conditions to enter include a current, a voltage, a crater time (0.0-9.9sec.1, and an
postflow time (0.0-9.9 sec.). Postflow is a process to prevent oxidization a t the weld
end part by keeping a gas flow for a specified time after welding is completed.
(2) Synergic control type welding power unit
Conditions to enter include a current, a fine adjustment (- 100-+ loo%), a crater
time (0.0-9.9 sec.), and an postflow time (0.0-9.9 sec.).
(3) TIG welding power unit
Conditions to enter include a current, a wire retracting time, a crater time (0.0-9.9
sec.), and an postflow time (0.0-9.9 sec.). The afterfrow is not availlable for the
Standard TIG welding power supply.
1) The entry ranges of current and voltage are defined by the ratings set in
welding characteristic data. If values larger than rated values a re entered, the
rated values will be stored.
2) If you want to set a wire retracting time to use TIG filler, be sure to set
"WIRE RETRACT SPEED" * ' in the welding user parameters.
There are two way of specifying crater (Arc End) conditions:
Specifying a Arc End Condition file*' which contains crater conditions
Directly entering numeric values
* 1:Refer to "Setting Welding Parameters", section 2.3 in part I1
* 2: Refer to "Editing Welding Condition Files", section 7.2 in part I
5 - 3 4 Teaching
II Teaching the AE instruction
Setting A rc End conditions by entering numeric values
1. press . IIAE i s o A 9e.tw.bs.-
If the current sequence is a [NUMlIAENUMIJAS-m I welding section, AE will be
displayed.
The display on the 7th line a t Individual control type
the main display area depends on
the type of welding power unit
used. sr) Synergic control type
"6 + * * The following explanation is
based on an individual control TIG
type welding power unit.
2. Enter a current, a voltage, a
crater time, and an afterflow time
by numeric keys.
The voltage is automatically set
only if an individual control type
of welding power unit is used.
For automatic control, see the
description of AS.
3. Press Q
Now, the Arc End instruction "AE"
has been stored.
Teaching 5 - 3 5
Setting Arc End conditions by specifying a f i le - 1. Press and then F4
(AE FILE). +
2. Enter the file number by
numeric keys. Ir+)
3. Then, press F I (COND), and the
specified file will be displayed.
If the specified Condition file does
not exist, an Alarm message is
displayed.
AXIS MHI TEACH P777 SQ Aa= 4 SERVO ON AECO 1
* F1 ... Displays the contents of ,, another Condition file.
WELDING CURRENT 180A WELDING VOLTAGE 20.0V CRATER TIME 1.0 S . POSTFLOW TIME 0.0 s.
... Re-enters a file number.
/NEXT1
4. Press @ .
Now, the Arc End instruction "AE" has been stored.
If the specified Condition file does not exist, an Alarm message is displayed. *
* F1 ... Stores the specified Condition file.
F2 ... Displays the contents of another Condition file, if any. The display does not change if there are no other Condition files.
* ~JNJ~FY ... Re-enters a file number.
*OFILE I STS EXIl IEXECUTEJ pTYT-1
Important -. If F1 (EXECUTE) is pressed, be sure to create the Condition file you specified later. Otherwise, Alarm will occur in block operation, and Error in automatic operation.
5 - 3 6 Teaching
5.3.3 Inching/Retracting ICH/RTC
The ICH/RTC instructions a r e used to inch/retract the wire during automatic
operation.
Set a n inching time and a retracting time (ranging 0.0 - 99.9 sec. in the unit of 0.1 sec.).
The inching/retracting speeds a r e the settings of welding user parameters "INCH/
RETRACT(LOW) ".
) Important
1) During inching/retracting by ICH/RTC, the manipulator does not stop.
Also, welding by AS is not started until inching o r retracting is completed.
2) Incliing/retracing by ICH/RTC a re not executed:
* When is set OFF.
In a welding section, or
* When the operation is halted during inching/retracting and is restarted
(ICH and RTC a r e ignored when restarted.)
gl] Teaching the ICH/RTC instructions
1. Press , and then two
times. *
Inching
(1) Press F1 (ICH) II)
(2) Set an inching time by
numeric keys.
Retract
AXIS MH1 TEACH P7 7 7 SQ Na= 1 SERVO ON
(1) Press F2 (RTC) .r)
> 0 0 1 P 1 0 0 % BASE M1
[ A S ' . 'XSOA 23,OY 5Om 1
(2) Set a retracting time by
numeric keys.
2. Press @ . Now, the Inching/Retract
[ I C H j I R T C I I G I r n >
ins t r~~c t ions "1CHJ'/"RTC" have
been stored.
AXIS MHI TEACH P7 7 7 SQNa= 1 SERVO ON >001 P 10096 BASE M1
~ X C N Tl[ME=99,9sec ,i 1
Teaching 5-3 7
[CHI/RmIm >
AXIS MH1 TEACH P 7 7 7 SQKa= 1 SERVO ON >001 P 100% BASE MI
IBTC:TX,ME=~ ~ , 9 se c,, , , , r I * ,>> *
I I c H ] I R T C [ S I V l >
5.3.4 Gas ON/OFF GS/GE
The GS/GE instructions are used to start and end a preflow during automatic
operation. Preflow is started from the position taught with the Motion instruction
followed by GS. Preflow stops when the operation is halted during preflow and is
carried out again when restarted.
@ Important I Gas ON/OFF by GS/GE are not executed:
I * When is set OFF, or
In a welding section.
Teaching the GS/GE instructions
1. Pressing , and then
two times.
Gas ON
Press F3 (GS).
Gas OFF
Press F4 (GE).
2. Press . w Now, the Gas ON/OFF
instructions " GS"/" GE" have
been stored.
5 - 3 8 Teaching
5.3.5 Weaving Start WFP and WAX
The WFP and WAX are used to start weaving a t specified weaving conditions or
modify these conditions during a weaving operation.
The following two weaving types are available:
Weaving with fixed pattern WFP
* Weaving by axis WAX
There are two way of specifying weaving conditions:
* Specifying a Weaving Condition file* which contains welding conditions
Directly entering numeric values
@If there are multiple areas which are weaved a t the same weaving conditions,
specifying a Weaving Condition file allows you to save teaching time and correcting
time.
(1) Weaving with fixed pattern WFP
The WFP is used to perform weaving on the plane to the main path. The weaving
plane is perpendicular to the torch.
Weaving plane
(The perpendicular torch position) (The torch position a t 45' )
Fig.5.11 Weaving planes
* : Refer to "Editing Weaving ConditionsJ', section 7.3 in part I .
Teaching 5 - 3 9
The follo~ving parameters a re available:
Function type linear function o r sine curve
Amplitude(Ha1f cycle: Yl/Y2) 0.0 -- 50.0 mm
Frequency 0.0 - 10.0 Hz
Center stopping time 0.0 - 9.9 sec
1/4 cycle stopping time 0.0 - 9.9 sec
3/4 cycle stopping time 0.0 - 9.9 sec
Linear function Sine curve
1/4 cycle stopping time /
Center stopping time
Main path
. . . Y. . . . . . . . . . . . . . . . . . . . . . . . .
3/4 cycle stopping time
Fig.5.12 Parameters and Weaving path
Important 1) Weaving may not be performed in accordance with a specified frequency*.
2) The manipulator too stops during the period of each stopping time.
Therefore, if stopping time parameters a r e entered, the time required for
block operation o r automatic operation varies according to WEAVE
"ON"/"OFF".(The cycle time a t the "ON" setting becomes longer by the
total stopping time than that a t the "OFF".)
* : Refer to "Restriction on Weaving Frequency", appendix 3 provided a t the end of
this manual.
5 - 4 0 Teaching
(2) Weaving by axis WAX
The WAX is used to perform weaving by single vibration of each axis.
The following parameters a r e available:
Axis No. 1 - 6
Amplitude (Half cycle: Yl/Y2) 0.0 - 9.99 deg
Frequency 0.0 - 10.0 Hz
Center stopping time 0.0 -- 9.9 sec
1/4 cycle stopping time 0.0 -- 9.9 sec
3/4 cycle stopping time 0.0 -- 9.9 sec
I t is possible to set up to 3 axis numbers a t one time. If more than one axis
number is set, the parameter settings except amplitude, which can be set per axis,
a r e common to them.
~ 1 . ~ 2
Fig.5.13. Weaving by Axis 5 of ALMEGA G series
Teaching 5 - 4 1
Teaching the WFP instruction
Setting Weaving conditions by entering numeric values
1. Press .
2. Press F1 (FP NUM). *
3. Move the cursor by pressing
, and set parameters.
(1) Set a function type (linear
function o r sine curve) by the
function key.
(2) Set each half cycle of weaving
amplitude by numeric keys.
(3) Set a weaving frequency by
numeric keys.
(4) Set each stopping time (center,
1/4 cycle, and 3/4 cycle).
4. Press RECORD key 0 Now, the Weaving with Fixed
Pattern instruction "WFP" has been
stored.
5 - 4 2 Teaching
AXIS MH1 TEACH P7 7 7 SQ Ha= 2 SERVO ON
>FUNCTION pmE%q AMPLITUDE Y1 I. Onm AMPLITUDE Y2 1. Oaa FREQUENCY 5. OIE CENTER STOP 0.0 S . 1/4 FREQ STOP 0.0 S .
3/4 FREQ STOP 0.0 s.
[ L I N E A R / W I G /
Setting Weaving conditions by specifying a f i le
1. Press .
2. Press F2 (FP FILE). .I) 1 LWpP FI&E WPP i
/ m m F I L E I / A X p T T q l W E /
3. Enter the file number by
numeric keys. +
4. Then, press F1 (COND.), and
the specified file will be displayed.
*
If the specified Condition file does not exist, an Alarm message is displayed. rr)
* F1 ... Displays the contents of another Condition file,
* m l F Y ... Re-enters a file number.
5. Press @ .
AXIS MH1 TEACH P777 SQ Ha= 4 SERVO ON
Now, the Weaving with fixed pattern instruction "WFP" has been stored.
FUNCTION LINEAR AMPLITUDE Y1 I. Onm AMPLITUDE Y2 1.0ma FREQUENCY 5. 01%~ CENTER STOP 0.0 s. 1/4 FREQ STOP 0.0 S.
3/4 FREQ STOP 0.0 s.
piFx-y
dition file. * F2 ... Displays the contents of
another Condition file, if any. The display does not change if there a re no other Condition files.
m l F Y ... Re-enters a file number.
If the specified Condition file does not exist, a n Alarm message is displayed. +
Important \
If F1 (EXECUTE) is pressed, be sure to create the Condition file you specified later. Otherwise, Alarm will occur in block operation, and Error in automatic operation.
NOFILE EX I sTs
-1-
Teaching 5 --'4 3
* F1 ... Stores the specified Con
Teaching the WAX instruction
Setting Weaving conditions by entering numeric values
2. Press F3 (AX NUM.).
3. Move the cursor by pressing
and
set parameters.
(1) Set a weaving frequency by
numeric keys.
(2) Set a weaving axis number or
numbers and each amplitude.
Set amplitudes of the non
weaving axes a t 0.
(3) Set each stopping time (center,
1/4 cycle, and 3/4 cycle).
4. Press RECORD key 0 Now, the Weaving by Axis
instruction "WAX" has been stored.
A X I S MH1 TEACH P 7 7 7 SQ Ha= 5 SERVO ON
5 - 4 4 Teaching
FREQUENCY 5.0 l A X I S 4 Y l 0.OOd. Y 2 0.OOd. P A X I S 5 Y 1 O.OOd. Y 2 O.OOd. 3 A X I S 6 Y 1 0.OOd. Y 2 0.OOd. CENTER S T O P 0.0 S, 1/4 FREQ S T O P 0.0 S . 3/4 FREQ STOP 0.0 S .
Setting Weaving conditions by specifying a f i l e - I . Press M .
2. Press F4 (AX FILE). *
3. Enter the file number by
numeric keys. rr)
4. Then, press F2 (COND.), and
the specified file will be displayed.
sr)
If the specified Condition file does not exist, an Alarm message is displayed. sl)
F1 ... Displays the contents of another Condition file.
* ~ I F Y ... Re-enters a file number.
A X I S MH1 TEACH P 7 7 7 SQ Na= 5 SERVO ON WAX 0 1
5. Press @
FREQENCY 5.0 1 . A X I S 4 Y 1 0.OOd. Y 2 O.OOd 2 . A X I S 5 Y 1 O.OOd, Y 2 0.OOd 3 .AXIS 6 Y 1 0.OOd. Y 2 O.OOd CENTER S T O P 0.0 s. 1/4 FREQ S T O P 0.0 S . 3/4 FREQ S T O P 0.0 s.
Now, the Weaving by axis instruction "WAX" has been stored.
If the specified Condition file does not exist, an Alarm message is displayed. I)
* F1 ... Stores the specified Condition file.
F2 ... Displays the contents of another Condition file, if any. The display does not change if there are no other Condition.
M ~ D I F Y ... Re-enters a file 0 number.
Teaching 5 - 4 5
Important 3
If F1 (EXECUTE) is pressed, be sure to create the Condition file you specified later. Otherwise, Alarm will occur in block operation, and Error in automatic operation.
\ /
5.3.6 Weaving End WE
The WE instruction is used to terminate all weaving operations specified by the
Weaving Start instructions.
Bill Teaching the WE instruction
1. Press and then F5 (WE).
2. Press @.
Now, the Weaving End instruction
"WE" has been stored.
5 - 4 6 Teaching
5.3.7 External Control Input/Output S, R, N, F, PLS, and PLR
External Control Input/Output instructions a re divided into 2 groups:
* External Control Output instructions S and R
* External Control Input Wait instructions N and F
(1) External Control Output instructions
External control output instructions set a specified output port ON/OFF.
* Set an external control output S
Reset an external control output R
The following parameters are available:
* Output port number: 0000 - 0199
- Delay time: 00 - 99.9 sec. (unit of 0.1 sec.)
Setting a delay time allows holding execution of an instruction for the set time
after the immediately preceding Motion instruction is executed.
However, execution of a Task program is not held during the period of this waiting
time. If the operation is halted during the period of a delay time, the output is not
executed later.
Depending on output port numbers, operation varies when the mode is changed:
* Automatically reset output (0000-0099)
Automatically OFF when switching from Teach to Auto modes
* Automatically held output (0100-0199)
Not OFF even if the mode is changed. OFF when external control output OFF (R)
is executed.
You can also set output ports to OFF manually by using a teaching box. *
* : Refer to "Resetting External Control Output Signals", section 4.1.6 in par t I
Teaching 5 - 4 7
(2) External Control Input Wait instructions
These instructions check whether the specified input ports a r e in the specified
conditions o r not. If not, they hold execution of Task programs until the conditions
a r e satisfied.
Wait for an external control input ON N
Wait for a n external control input OFF F
The following parameters a r e available:
Input port number: 1000-1199
* Input waiting time: 0.1-99.9 sec. (unit of 0.1 sec.) and (infinity)
When the specified input port is not in the specified condition even if the specified
waiting time is over, input time out er ror will occur, which causes the operation to be
halted.
If (infinity) is set, execution of the Task program is held until a n input is
received, without monitoring of input waiting time.
(3) Teaching a series of S, N, and R (S, F, and R)
The use of SNR and SFR enables teaching 4 instructions by one time of operation:
SNR * S, N, NOP, R SFR + S, F, NOP, R
Input/output port numbers and input waiting time a r e specified when each of SFR
and SNR is taught. Remember that output port numbers for S and R must be the
same.
For the relation between output numbers and actual output circuits (output
terminals), refer to the instruction manual "Interface with Jig"
5 - 4 8 Teaching
Cautions \
1) All Task instructions taught between two Motion instructions are almost
simultaneously executed when execution of the Motion instruction followed by
them is complete during automatic operation. Especially, care should be taken
to teach external control input/output instructions.
(Example 11 (Example 21 (Example 31
001 P 001 P 001 P
S 0 0 1 S 0 0 1 S 0 0 1
S 0 0 2 S 0 0 2 N 0 0 1
S 0 0 3 R 0 0 1 R 0 0 1
S 0 0 4 S 0 0 3 002 P
002 P 002 P
(Example 1) Output ports 001 - 004 are simultaneously set ON.
(Example 21 Because SO01 and ROO1 are simultaneously executed, output
port 001 is not set. Only 002 and 003 are simultaneously set ON. If you want
to output 001, add a Timer instruction (T) with about 0.2 sec. immediately
before R001.
[Example 31 Like (Example 21 SO01 is not executed. In this case, add NOP
instruction after N001.
2) In a Task program like the following examples. External Control Output I instructions may not be executed: I
(Example 11 [Example 21
004 P Oo4 i r k the same or almost S 0 0 1
005 P same point. 005 N O P
R 0 0 1 R 0 0 1
In such cases, add a Timer instruction (T) with about 0.2 sec. between them.
Teaching 5 - 4 9
Teaching External Control Input/Output instructions
Press m. F1 ... External control output
I p-c--q~INPON/lOFF/ >
SET I 1
FZ ... External control output p-ii-z psFRI
RESET F3 ... External control input ON
WAIT F4 ... External control input
OFF WAIT
I> F1 ... Teaches a series of S, N, ' NOP, and R. FZ ... Teaches a series of S, F,
NOP, and R.
External Control Output instruction S
1. Press F1 (SET). * I 1
2. Enter the output port number by t
numeric keys.
3. Press, and then set the
delay time.
4. Press RECORD 0 Now, the External Control Output
instruction "S" has been stored
External Control Output instruction R
1. Press F2 (RESET). I
2. Set the output port number and
the delay time as set for SET.
3. Press @
Now, the External Control Output
instruction "R" has been stored.
5 - 5 0 Teaching
The Wait for External Control Input instruction N
2. Enter the input port number by
numeric keys.
1. Press F3 (INPON). I)
3. Press, and then set the
input waiting time.
LON PORTLTIMER-o 9. J
~ ~ T I I R E S E T I / ~ ~ ~
4. Press @ . 1 [ON PORT # O It0 TIMER= w 3. J ~~ This setting causes waiting for
ON input for the specified time. When a signal of the specified input port is switched ON o r F1 (ACCEPT) is pressed, the N instruction is stored. Then, the NOP instruction is
automatically stored following "N".
The Wait for External Control l n ~ u t instruction F
1. Press F4 (INP OFF).
2. Set the input port number by
numeric keys as set for N ( I NP
ON).
3. press @. +
This setting causes waiting for O F F input for the specified time. When a signal of the specified input port is switched O F F o r F1 (ACCEPT) is pressed, the F instruction is stored. Then, the NOP instruction is autoinatically stored following "F" .
Teaching 5 - 5 1
Teaching a series of S, N, and R (St F, and R) ,-----?
I . Press .
2. Set the port numbers to be output
(SET RESET) by numeric keys. * [SNK-OUT-I o o i ~ = 'T1ME=ocs
3. press 101, and then set the por t
number to wait fo r ON in the case
of SNR or the port number to wait
fo r OFF in the case of SFR by
numeric keys. * ~ S N R - O U T = I ~ # IN=O~BTIME-*SI
4. ~ r e s s / o ] , and set the input
waiting time.
5. press @ . * (ISNR OUT=I 8 @ INm0 6 0 TIME=~S,
/ACCEPT] This setting causes waiting for ON
(in the case of SNR) or for OFF (in
the case of SFR) for the specified
time. When a signal of the specified
input port is entered o r F1 (ACCEPT)
is pressed, SNR (or SFR) is stored.
5 - 5 2 Teaching
5. 4 Block Operation Block operation allows the operator to check positions/attitude taught in a Task
program by operating the teaching box.
To perform block operation, the following conditions must be satisfied:
* The SERVO is ON state.
* The current mode is TEACH.
Task program has been specified.
* The Search for Instructions feature* is not active.
5.4.1 Forward/Backward Block Operations
(1) Forward block operation
Forward block operation (as well a s automatic operation) allows the operator
to execute instructions in order by sequence number.
The forward operation stops a t END. If carried on further, it is performed from
sequence 1.
(2) Backward block operation
Backward block operation allows the operator to execute instructions in reverse
order by sequence number. The backward operation terminates a t sequence 1.
It is not possible to run back from sequence 1.
) Important 7 1) In block operation unlike automatic operation, some instructions a r e
not executed:
Instructions that are not executed in (forward or backward) block operation AS, AE, I CH, RTC, GS, GE, ST, ET, SF3, SF5, ASM. AEM. TSS, T S E
* Instructions that are not executed in backward block operation T, J P , JF, CL, SFO, SF 1 , SF2
Thus, In weaving sections, weaving can be performed (a t the same conditions a s those in forward block operation) in block operation.
If DEC is executed in backward operation, the counter value is added
Jh : Refer to "Searching for Instructions", section 5.7 in part I .
Teaching 5 - 5 3
2) When you are in a Task program a t the jump destination o r a called
program by performing operation such a s forward block operation,
backward operation allows you to go back up to the first sequence of
that program but no further. Therefore, in backward operation, it is
not possible to return to the original program.
\ /
Ell Operating a block operation
Finish creating a Task program
by pressing RESET or specify a 0 created Task program number.
You can now perform block
operation
2. Press [El (or El) while
holding @ down.
operation causes the halted state
to be entered. You can restart the
BLOCK operation by pressing 1 ,, 1 or
while holding @y
5 - 5 4 Teaching
5.4 .2 Block Continuous Operation
For continuous execution of instructions, specify block continuous operation. n -
BLOCK $4 key with1 ,, lor key shall be functioning instead ,of specifying block -.
continuous operation.
However, in this case, operation stops for a moment a t each instruction, which does
not occur in the case of continuous execution by specifying blocli continuous operation.
H Block continuous operation
The LED on the upper left will
illuminate to indicate the block ,\ : e n
continuous selection. * 2. Press and hold 63 MU , then,
press
If the n = is released during u
block operation, the LED to go
out and block continuous
operation is canceled.
5.4.3 Block Operating Speeds
In block operation, the manipulator operates a t a block operating speed only when it
executes Positioning instructions (P, HP, and PM). When executing other instructions-
Interpolation Instructions (L, LO, C, CO, etc.1-, it operates a t a taught speed like in
automatic operation.
In welding sections, the robot does not move a t a speed taught wit11 the Welding
instruction "AS" but move a t speed settings of L, C, etc. taught in welding sections.
4 step speed are provided for Block operation and can be switched over with the
teaching box.
B-1 B-2 B-3 B-4
Low High
However, it is not possible to change the speed during block operation.
Teaching 5 -.5 5
SPEED 0 1111 Switching between speeds for block operation
1. Press when the block
operation is not running.
The display a t the speed display
area will chande to the block
operating speed.
2. Select the speed by pressing
5.4.. 4 Halting and Starting Block Operation
Halting and restarting block operation during execution of a Weaving, External
Control Input/Output, or Timer instruction results in the following:
(1) Weaving instructions (WFP and WAX)
When block operation is halted in a weaving section, the center stop process being
performed.
Path after restarting
+ Mainpath
Center stop
Fig.5.14 The weaving path a t the time of halting/restarting (block operation)
The center stop means a return to the main ~a th (whe re weaving is not ~erforrned.1
(2) External Control Input/Output instructions (N, F, S, and R)
The input waiting time and delay time are aborted when the operation is halted,
and a re recounted from the beginning when restarted.
(3) Wait for Timer Time instruction (T)
The timer is stopped when the operation is halted, and is recounted from the
beginning when restarted.
5 6 Teaching
5.4 .5 Cancell ing the Halted State o f Block Operation The operator can cancel the halt s tate of block operation by operating the teaching
box.
@This feature allows the operator to add instructions in the halted state of block
operation.
@If the halted instruction, e.g., Timer or External Control Input/Output, has a long
time setting, this feature enables the operator to shit execution to the next
instruction immediately.
Caution 1
If you perform block operation after cancelling the halted state, the
manipulator s t a r t s to move to the next sequence from the stopped point.
Therefore, take care to avoid interference with the jig.
(Examplel When block operation is performed to run the following Task
program:
, , 1 0 0 % . , I r 0
250cm p Halted point -+ -"
250cm (007) I P 100 (012)
Fig.5.15 Movement after cancellation of the halted state of block operation
Block operation (forward) is halted between sequences 009 and 010 (a t the
halted point shown above), and then the halted state is cancelled. ON is
output to output port 100 immediately when the operation (forward block) is
restarted, and the manipulator moves to sequence 011.
II Cancelling ,\ the halted state
~ r e s s " m in the halted state. u
This causes the LED to go out. + r s ~ o p /
Now, the halted state has been
cancelled.
Teaching 5 - 5 7
5.4.6 Sequence Jump
The Sequence Jump allows the operator to move a mechanism to the position of a
specified sequence number.
@This feature is used when you want to run part of a Task program which contains
a number of sequences, by block operation.
Fig.5.16 A path given by Sequence Jump
Performing the Sequence Jump
1. Press F2 (JUMP).
2. Specify a destination sequence
number.
3. Holding 8 down, press
o r .
The mechanism will move to the
specified sequence.
5 - 5 8 Teaching
5. 5 Adding and Deleting lnstructions
5. 5. 1 Adding lnstructions
The Add feature allows the operator to add instructions. It is possible to
continuously add instructions, but not possible to store more than a series of 10 Task
instructions in one Task program.
Adding l nstructions
Here, let us try to add P a t the point after L of sequence number 86: 1. Move the cursor to the
instruction (sequence 086) which should be followed by the
instruction you want to add, by
performing block operation o r
executing the sequence jump. I)
2. Press B . * The LED on the upper left will
light.
3. Move the manipulator t o the position/attitude to be taught, by
manual manipulation.
4. Press the key of the instruction
to be added ( ).
Set a speed and Overlap ON/ OFF in the same manners a s those for creating data.
5. Press @ . * Now, P has been stored. If you want to add more instructions, repeat the above operation.
If you want to cancel the
addition, press ~ I F Y . 0 6. Press again to terminate
the operation.
The LED on the upper left will
light.
T.MECB. ML4 TEACH P 7 7 7 SQNo. =I32 SERVO ON ADDITION
Teaching 5 - 5 9
WE 0 8 4 P 1 0 0 % BASE Ml 0 8 5 L 1 5 0 m BASE M I
> 0 8 6 L 1 5 O m BASE M1
T.MECH.ML4 TEACH P 7 7 7 SQNo.=132 SERVO ON ADDITION
/ M O T m m l m m / >
0 8 4 P 1 0 0 % BASE M1 0 8 5 L 1 5 0 m BASE M1 0 8 6 L 1 5 0 m BASE M I
> 0 8 7 P 1 0 0 9 6 BASE M I
(PSPEED:IOO% L A P Z Q N ~
/MOTION/ I I /OIm] lmmI >
5. 5. 2 Deleting Instructions
The Delete feature alloivs the operator to delete instructions. It is possible to delete
n~ultiple instructions a t one time by specifying a range. However, deletion resulting in a
series of more than 10 Task instructions is not possible.
IIIf Deleting l nstructions
Here, let us t ry to delete L of sequence number 86:
1. Move the cursor to the
instruction (sequence 085) which
should be followed by the
instruction you want to delete,
by performing block operation or
executing the sequence jump. +
2. Press @ . w
The range to be deleted will be
If you want to extend the
T.MECII. ML4 TEACH P 7 7 7 S Q N a - 1 3 2 SERVO ON
BLOCK deletion range, press 1 ,, 1
WE 0 8 4 P 1 0 0 % B A S E M1
> 0 8 5 L 150cm B A S E M1 0 8 6 L 15Ocm B A S E M1 0 8 7 L 100cm B A S E M1 0 8 8 L 100cm B A S E M1
T.MECH. ML4 TEACH P 7 7 7 SQNo.=132 SERVO ON RANGEFOR DEL.
If you want to reduce it, press
* Pressing MOOIFY allows you to 0 cancel the deletion range you
~ j I J ] r z - i T E l ~ l ~ / >
WE 0 8 4 P 1 0 0 % B A S E M1
> 0 8 5 L 150cm B A S E M1 0 8 6 L i " I S 0 c m B A S E MI'^ 0 8 8 L 100cm B A S E M1
specified by pressing DELETE 0
-1
3. Press F3 (EXECUTE). +
Now, L of sequence 086 has been
deleted
If you press MOOIFY immediately 0 af ter deletion, you can cancel the
deletion.
5 - 6 0 Teaching
T.MECII. ML4 TEACH P 7 7 7 SQ No. = I 3 2 SERVO ON
WE 0 8 4 P 1 0 0 % B A S E M1
> 0 8 5 L 1 5 0 m B A S E M1 0 8 6 L 150cm B A S E M1 0 8 7 L 1OOcm B A S E M1 0 8 8 C 2 100cm B A S E M1
J S E A R C H / ) J p T i E / ~ ~ >
5. 6 Changing Teaching Data It is possible to change the following teaching data :
Motion instructions
Parameters of Motion instructions (i.e., speeds and overlap ON/OFF)
Positions/attitudes
Task instructions
Parameters of Task instructions
5. 6. 1 Changing Motion Instructions
It is possible to change P to L, o r L to P , but not a Motion instruction to a Task
instruction. It is not possible to change Motion instructions of the single manipulator
such as P, L, and C to Motion instructions of the multiple-manipulator such as HP, HL,
and HC.
I(( Changing Motion instructions
Here, let us t ry to change "L" of sequence 085 to "P":
1. Movethecursor to the
instruction to be changed
(sequence 085), by performing
block operation.
2. Press
3. Set a speed and Overlap ON/
OFF in the same manners as
those for creating new data.
4. Press @
Now, the change has been
completed.
Teaching 5 - 6 1
5.6. 2 Changing Parameters of Motion instructions
It is possible to change operating speeds and Overlap ON/OFF settings of Motion
instructions.
Changing Motion instructions
Here, let us try to change the parameters of "L" of sequence 085:
1. Move the cursor to the
instruction to be changed
(sequence 085), by performing
block operation.
3. Set a speed and Overlap ON/OFF
in the same manners as those for
creating new data.
4. press Q . +
Now, the change has been completed.
5. 6. 3 Changing Positions/Attitudes
T.MECkI. ML4 TEACH P 7 7 7 SQ Na=13 2 SERVOON
It is possible to change data of the position/attitude which a Motion instruction has.
WE 0 8 4 P 1 0 0 % BASE M 1
> 0 8 5 L l O O m BASE M1 0 8 6 L 1 5 Om BASE M 1 0 8 7 C 1 1 5 0 m BASE M I 0 8 8 C2 1 5 0 m BASE M 1
Changing positions/attitudes
rEEiqlJ[pl~[PATHAT( >
1. Move the cursor to the
instruction to be changed
(sequence 085), by performing
block operation. * 2. Move the manipulator to the
position/attitude you want, by
performing manual manipulation.
3. Press @ .
Now, the position/attitude
indicated by the cursor have been
changed.
T.MECt1. ML 4 TEACH P 7 7 7 SQ No.=132 SERVO ON
5 - 6 2 Teaching
WE 0 8 4 P 1 0 0 % BASE M I
> 0 8 5 L 1 5 0 m BASE M 1 0 8 6 L 1 5 0 m BASE M I 0 8 7 C1 1 5 0 m BASE M 1 0 8 8 C2 1 5 0 m BASE M 1
I T E E E ' q l J J ~ l ~ ~ ] >
5.6 .4 Changing Task Instructions It is possible to change Task instructions, such as Welding, Weaving, and External
Control Input/Output, to other Task instructions, but not Task instructions to Motion
instructions.
Changing Task instructions
Tliis section explains how to change S (SET) to N (ON WAIT):
1. Move thecu rso r t o the instruction to be changed. In this case, S (SET).
2. Press to change to N
3. Press F3 (INP ON) . Ir)
4. Set the port number and the input waiting time in same manners as those fo r creating new data.
5. Press @
T.MECH. ML4 TEACH P I 7 7 SQ N o ~ 1 3 2 SERVO ON
Now, the change has been completed.
WE 0 8 4 P 1 0 0 % BASE M I
, . ur,=u.u s , , , . .I 0 8 5 L 1 5 0 m BASE M I 0 8 6 L 150cm BASE M I 0 8 7 C 1 150cm BASE M I
T.MEC1-I. ML 4 TEACH P 7 7 7 SQ No71 3 2 SERVO ON
5.6.5 Changing Parameters of Task Instructions I t is possible to change parameters of Task instructions such a s Welding, Weaving, and
External Control Input/Output.
~ ~ p T i F T i q ~ \
WE 0 8 4 P 1 0 0 9 6 BASE M I > N 0 11 WT=m 0 8 5 L 1 5 0 m BASE M I 0 8 6 L 1 5 0 m BASE M I 0 8 7 C1 1 5 O m BASE M I
H Changing Parameters of Task instructions
This section explains how to change an output port number of external control output.
1. Move the cursor to the instruction to be changed (S in this example).
IrnIIJIpE'qIPATHJ/PATHl>
2. Press
3. Change the output port number.
T.MECI1. ML4 TEACH P 7 7 7 SQ Na=13 2 SERVO OFF
4. press @ . *
WE 0 8 4 P 1 0 0 % BASE M I
)I s i l 1 z I)LE.II . IIS ( 0 8 5 L 1 5 0 m BASE M1 0 8 6 L 1 5 Om BASE M I 0 8 7 C1 1 5 0 m BASE M I
Now, the change has been completed.
ISEARCH/IJ]/SHIFTIIPATHIW]>
Teaching 5 - 6 3
T.MECA. ML4 TEACH P 7 7 7 SQ Na=l3 2 SERVO ON
WE 0 8 4 P 1 0 0 % BASE M1 > S 0 1 0 DL=O.Os 0 8 5 L 1 5 0 m BASE M I 0 8 6 L 1 5 0 m BASE M I 0 8 7 C 1 1 5 0 m BASE M I
p%'KEq/ J r n I P A T H I r n l >
5. 7 Searching fo r Instructions The Search function is used to find a specified instructions in the Task program being
currently edited. This function allows the operator to change da ta such as welding
conditions without moving sequences. It can be used when the servo power is OFF.
Searching for the following instruction is possible:
Arc Star t (AS)/Arc End (AE)
* Weaving Star t (WFP and WAX)
a Tracking Star t (ST)/Tracking End (ET)
* Touch sensor related instructions (SFO, SF2, SF3, and SF51
External Control Input/Output (S, R , N, and F)
Program Jump/Call ( J P , J F , and CL)
Timer Wait (T)
OSACOM SUPER 8700 searches sequences below the cursor position. Therefore, it is
not possible t o search for instructions a t and above the cursor position.
After searching, you can add instructions, o r delete o r change the instruction you
specified. However, note that, if you add a Motion instruction, the position/attitude of
the manipulator where you a r e entering will be stored.
If you change the position/attitude, the position/attitude of the manipulator where
you a r e entering will not be stored. So, you can change only the parameters(i.e., Speed,
o r Lap on/off) of a Motion instruction.
5 - 6 4 Teaching
1(1 Searching fo r Instructions - 1. Press F1 (SEARCH) on the screen
which is displayed when block
operation is ~er formed. * 'Pressing o r allows
you to move sequences forward o r
backward without moving the
manipulator.
F1 ... Terminates the search. The position of the manipulator does not correspond to the current sequence.
F2 ... Searches for Arc Start / End instructions.
F3 ... Searches for Weaving Star t instructions.
F4 . . . Searches for Tracking Start/End instructions.
F5 .. . Searches for touch sensor related instructions.
F1 ... Searches for External Control Input/Output instructions.
F2 . .. Searches for Program Jump and Call instructions.
F3 ... Searches for Timer Time Wait instructions.
2. Select the instruction you want to
search for by using the function key.
In this example, press F2 key
(AS/AE).
OSACOM SUPER 8700 searches
for the specified instruction through
the Task program and displays it as
the current sequence. rQ
Teaching 5 - 6 5
T . M E C H . M L 4 TEACH P7 7 7 SQ NO-132 SERVOON SEARCH
092 P 1 0 0 % BASE M1 a093 L 1 5 0 m BASE MI > AS 180A 20.5s. 1.0s. 094*C1 150m BASE MI 095*C2 150m BASE M1 096*L 150m BASE M1
[ M A R K I I A S / A E I v l J S T / E T I m >
The sequence corresponding to the current position of the manipulator
is marked with @.
If the specified instruction does not exist, a message "NOT EXIST" appears a t the auxiliary display a rea on the current screen. *
This message will disappear af ter 1 second
3. Add, delete, o r change if necessary.
4. Press F1 (SO MARK) o r @ to terminate the search operat~on.
Pressing F1 (SQ MARK) causes the current sequence in the search mode to be treated as the current sequence. + Because the position of the manipulator differs from the data of the current sequence, take care when you perform block operation.
to terminate the
causes OSACOM SUPER 8700 to return to the original sequence. That is, the current sequence corresponds the position of the manipulator. *
T.MECII. M L 4 TEACH P7 7 7 SQ No.=1 3 2 SERVO ON SEARCH NOT^
092 P 100% BASE M1 >093 L 150m BASE M1
AS 180A 20.5V. 301x1
095*C2 150m BASE M1
WE 092 P 100% BASE M1
>093 L 150m BASE M1 AS 18OA 20.5V. 3Om
094*C1 150m BASE M1 095*C2 150m BASE M1
T.MECII .ML4 TEACH P7 7 7 SQNo.=l32 SERVO ON SEARCH
5 - 6 6 Teaching
j p T K i q M A R K / / ~ l ~ ~ ] >
092 P 100% BASE MI 093 L 150m BASE M1
> AS 180A 20.5V. 301x1 094*C1 15Om BASE MI 095*C2 150m BASE M I 096*L 150cm BASE M 1
Chapter 6 Automat ic Operat ion
/ Automatic operation is performed to execute Task programs . I I This chapter descrilies how to s tar t a Task program by I / Multi-station system or Direct program entry system. and how to I halt and restart the automatic operation .
Contents
6.1 Automatic Operation ..................................................................................................................................
6 2 Automatic Operation by the Multi-station System
6 2 1 Start Allocation ....................................................................................................................................... . .
6.2.2 Changing to Auto Mode and Starting Automatic Operation ..............................
6.2.3 Start Reserving and Callcelling ..................................................................................................
6.3 Automatic Operation by the Direct Program Entry System .......
6.4 Job End ...................................................................................................................................................................
6 5 Halt ......................................................................................................................................
6 6 Restart
6.6. 1 Restarting from Halted Point ....................................................................................................
6.6.2 Restarting from A Specified Start point ............................................................................
6 6.3 Overlap Restarting ................................................................................................................................
6.6.4 Restarting After Block Operation
6.6.5 Restarting from Halting during Execution of Task Instruction
6. A u t o m a t i c Operat ion
6. 1 Automatic Operation Automatic Operation is performed to execute Task programs specified from among the
created Task programs. To perform automatic operation, the following conditions must
be satisfied:
* The servo power is ON.
* The current mode is AUTO.
* Any one of Task program numbers 001 - 999 has been specified.
The manipulator exists in the Start Enable Area.
Depending on the attitude of the manipulator, automatic operation sometimes may not
be started. The range of the attitude which enables automatic operation to be started is
referred to as the Start Enable Area.
When the manipulator exists within the Start Enable Area, the LED of "READY" on
the teaching box lights.
The Start Enable Area varies according to the manipulator types.
Fig.6.1. The Start Enable Area of ALMEGA G series and W01
Automatic Operation 6 - 1
Fig.6.2. The Star t Enable Area of ALMEGA V series
The Star t Enable Area can be modified by setting "START ENABLE AREA" in the
user parameters for setting the system status.
* :Refer to "Setting the System Status", sevtion 2.1 in par t I1
6 - 2 Automatic Operation
6. 2 Automatic Operation by the Multi-station System The multi-station system allows the operator to s tar t a Task program and reserve,a
s tar t of another Task program by press the START button on the operating panel (or
starting box) installed a t each station. This feature enables multiple Task programs to
be sequentially started. Note that it is necessary to allocate Task program numbers to be
started in advance to the START button of each station.
Auto mode
In this system automatic operation is performed in accordance with the following
procedure:
Prepare the conditions to perform
automatic operation.
Teach mode
Press the START button. s Automatic operation 1
Perform star t allocation.
Y
Cancel auto mode interlock.
v
I - Start reservation I
-
I - Start cancellation I
Press the AUTO mode button.
Automatic Operation 6 - 3
- - Start reservation check
6.2. 1 Start Allocation
Storing a Task program number you want to s tar t to each station is referred to a s
Start Allocation. This operation is performed in Teach mode.
The allocated Task program numbers are held even after the control power is turned off.
H Setting start allocation
1. Press F4 (ALLOT) at the top
layer of Teach mode. *
2. Select the station number by I 4-) I
3. Enter the program number you
want t o start, by numeric keys.
4. When you finish the start
allocation, press RECORD key. 0 If you press RESET , YOU can 0
cancel all allocations you have set,
and the previous settings of Task
program numbers will be stored.
6 - 4 Automatic Operation
6.2.2 Changing to Auto Mode and Starting Automatic Operation
When you have finished the s tar t allocation, then you change to Auto mode and
perform automatic operation. Before changing to Auto, check that the manipulator
exists within the s tar t enable area.
II Changing to Auto mode and starting automatic operation
This step is not required if the
setting of "AUTO LOCK" * in the
user parameters for setting the
system status is OFF.
1. Press F5 (LOCK) at the top
layer of Teach mode. .I)
2. Press the AUTO button on the
operating panel (or set the auto
mode input of input terminal ON).
Ir)
In this condition, you can perform
AX1 S ML4 TEACH
the following operations:
AUTO MODE INTERLOCK CANCELLED
- -
Switching or W F F ON/OFF
* Changing to TEACH mode
Starting automatic operation
If the conditions to s tar t
automatic operation a re not ready,
error messages appear:
When the servo power is OFF
* Turn the servo power ON.
* : Refer to "Setting the System Status", section 2.1 in part 11, and "ModesJ', in section
2.4 in part I .
Automatic Operation 6 - 5
When the manipulator is outside
the start enable area * Move the manipulator to within
the start enable area by manual manipulation.
3. Press the START button. + Automatic operation will start .
6.2.3 Start Reservation and Cancellation (1) Making Start Reservations
When automatic operation is running a t another station, pressing the START
button of a station causes the Task program allocated to this station to enter the
reserved state. When pressed, the START button flickers. It is possible to make s ta r t
reservations for multiple stations. Reserved Task programs a r e automatically
started in sequence (in order by reservation) each time automatic operation is
finished a t one station.
The operator can list the reserved Task programs on the teaching box. OSACOM
SUPER 8700 displays station numbers and allocated Task program numbers in order
by reservation.
@ Note I
I It is not possible to reserve a Task program being currently running by automatic operation.
(2) Cancelling Start Reservations
The operator can cancel s tar t reservations of Task programs. Even if one of
multiple reservations is cancelled, the rest are still effective.
(Example)
Task program 001 (referred to as PO01 in the following) is running by automatic
operation, and P002, P003, and PO04 are reserved in this order.
When 003 is cancelled, automatic operation is performed to execute each of the
reserved PO02 and PO04 in this order after PO01 is completed.
6 - 6 Automatic Operation
II Making and cancelling start reservations
During automatic operation the
screen look like the one shown on
the right. I)
1. When automatic operation is
running a t another station, press
the START button on the
operating panel (or starting box).
The Task program allocated to
the station whose START button
was pressed, will enter the
reserved state.
2. I f you press F1 (RESERVE)
during automatic operation, you
can view the currently reserved
stations and Task program
numbers. @
You can return to the original
screen when tlie Task program
being currently running by
automatic operation is completed,
o r by pressing RESET 0 3. To cancel a start reservation,
press the START button of the
relevant station.
Automatic Operation 6.- 7
3 Automatic Operation by the Direct Program Entry System The direct program entry system allows the operator to s t a r t automatic operation by
directly specifying Task program numbers to specialized logical input ports. Automatic
operation is started when a Star t input signal is entered.
There a re two ways of specifying Task program numbers, for which specialized logical
input ports a r e provided:
BCD code entry
Binary code entry
(1) The BCD code entry
Task program numbers ranging from 001 through 799 a r e available.
The relation between specialized logical input ports and Task program numbers is
shown below:
Specialized logical input port
/ Hundred 1 Ten 1 One 1
(2) The binary code entry
Task programs numbers ranging from 001 through 999 a re available. Because of
binary entry, for example, when only specialized logical input number 3 receives a n
input, the program number is two cubed, 8. If multiple specialized logical input port
numbers, the total of each sum is the program number.
The relation between specialized logical input ports and Task program numbers is
shown below:
(Example)
Task program number
Specialized logical input port
1 1 1
0 1 0
[Example) Task program number
6 - 8 Automatic Operation
1 0 0 1
0 1 1 0
1 0 0 1 799
0 1 0 1 - 265
In this system automatic operations is performed according to the following procedure:
Cancel auto mode interlock.
Teach mode
Auto mode
- V
Prepare the conditions to
perform automatic operation.
-
Enter a Task program number.
Press the AUTO mode button.
(Auto Mode input ON)
1 Set the s t a r t input ON.
Automatic Operation 1 Changing to Auto mode and starting automatic operation
This step is not required if the setting of "AUTO LOCK" * in the user parameters for setting the system s ta tus is OFF.
1. Press F5 (LOCK) at the top layer
of Teach mode. .Is,
* : Refer to "Setting the System Status", section 2.1 in par t 11.
Automat i c Operat ion 6 - 9
AX1 S ML4 TEACH
AUTO MODE INTERLOCK CANCELLED
2. Press the AUTO button on the
operating panel (or set the auto
mode input of input terminal ON).
* In this condition, you can perform
the following operations:
* Inching/retracting
* Changing to Teach mode
* Starting automatic operation
If the conditions to s tar t
automatic operation are not ready,
error messages appear:
When the servo power is OFF * Turn the servo power ON.
When the man i~u la to r is outside
the start enable area * Move the manipulator to within
the start enable area by manual
manipulation.
3. Enter the Task program number
into specialized logical input ports.
4. Set the Start input ON. * Now, automatic operation is
started.
AUTO
SERVO ON
6 - 1 0 Automatic Operation
AUTO. START READY
PUSH START PB.
AUTO PO 0 1 SQ No.=9 9 9 SERVO ON PRESENT 5 3
AUTO RUNNING
6 . 4 Job End The termination of automatic operation of the specified Task program programs
(execution of the END instruction) is referred to a s Job End, which: - Stops the current weaving or welding process.
* Counts the throughput and reports it on the teaching box.
* Starts the next reserved Task program (if specified by the multi-station system).
The display at the time of Job End At the time of Job End the screen
looks like the one shown on the right.
Ir)
The figure on the 7th line a t the main display area shows the throughput. I t is possible to check it also in the operation of s tar t allocation (provided that the multi-station system is employed). The upper limit is 30000.
6. 5 Halt Automatic operation can be halted by a key operation or an external signal input in a
condition which enables continuation restart.
(1) Halt during welding * When the arc is not generated during a welding process
Immediately the welding process being stopped, the automatic operation halts. * During a crater process
After the current crater process being completed, the automatic operation halts. During a welding process except the above
Immediately the process being stopped, the automatic operation halts.
(2) Halt during weaving The center stop process being performed, the automatic operation halts.
Weaving path
\ Halted point
Fig.6.3 Center stop
The center stop means a return to the main path (where weaving is not performed).
Automatic Operation 6 - 1 1
(3) Halt during waiting for Timer time
Immediately the process being stopped, the automatic operation halts.
(4) Halt during an external control input or output
Waiting for external control input
Immediately the process being stopped, the automatic operation halts.
External control output with a delay timer setting
Immediately the process being stopped, the automatic operation halts.
(5) During inching or retracting
Immediately the inching o r retracting being stopped, automatic operation halts.
@ Note \
I Data contained in the logic table' are executed even in the halted state.
--
Halt when the Multi-station system is employed
Press o r the STOP button on u
the operation panel (or starting box).
The halted sequence is indicated on
the screen.
Halt when the Direct Program Entry system is employed
Set a Start input OFF. * The halted sequence is indicated on
the screen.
* : Refer to instruction manual "Interface with Jig"
6 - 1 2 Automatic Operation
6. 6 Restart
There a re several ways of restarting automatic operation:
- Restarting from a halted point
* Restarting after performing manual manipulation from a halted point and specifying
a s tar t point.
* Overlap Restarting
Restarting after performing block operation
Important \
1) When a s tar t reservation has been made by the multi-station system, in the halted state, pressing the START button of the reserved station causes the
I reservation to be cancelled.
2) In the Direct Program Entry system, setting the s tar t input ON allows you to restart automatic operation, but, in this case, the halted Task program will be restarted, but not the Task program you specified.
3) If automatic operation is halted when a Task program a t the jump destination o r a called program is running in accordance with the external control input condition in the original Task program, restarting causes the halted Task program to be executed, regardless of the state of the external control input.
6 .6.1 Restarting from A Halted Point
Restarting allows the operator to continue the operation from a halted point.
II1 Restarting when the Multi-station system is employed
Press the START button of the station where the Task program is in the halted state.
The Task program in the halted state will be restarted.
II Restarting when the Direct Program Entry system is employed Set the start input ON. Then, the Task program in the
halted state will be restarted.
Automatic Operation 6 - 1 3
6. 6.2 Restarting f rom A Specified Start Point
It is possible to restart automatic operation from another point by performing
manual manipulation from a halted point. In this case, the manipulator moves to the
target point from that point. The movement depends on data contained in the halted
sequence. For example, the manipulator moves by Linear Interpolation if the halted
sequence contains L, o r by Positioning if P.
+---Manipulator stops. (Stopped point) P , AS
Manual manipulation
Path when automatic operation is restarted
Fig. 6.4 Restarting from a specified s tar t point
If a s ta r t point is not specified after manual manipulation is performed, the
manipulator restarts the operation after returning to the stopped point by positioning
movement. The speed is the setting of "SPEED TO PM" in the user parameters for
setting the system status.
EIll Setting a start point
In the halted state, the screen
looks like the one shown on the
right. *
1. Press F3 (STRT PO). *
T.MECH. M H 3 AUTO P O 0 1 SQ No.=9 9 9 SERVO ON HOLDING STN 1
2. Move the manipulator by
manual manipulation.
0 5 1 P 1 0 0 % BASE M 1 0 5 2 P 9 0 % BASE M 1
> 0 5 3 L 2 5 0 ~ x 1 BASE M 1 S 0 1 2 D L = O . O s
0 5 4 L 1 5 0 m BASE M 1 0 5 5 C 1 1 5 0 m BASE M 1
T.MECII. M H 3 AUTO P O 0 1 SQ N0.=9 9 9 SERVO ON HOLD I NG STN 1
6 - 1 4 Automatic Operation
pzizivq / r s ' i T q P O / / R E T R E A T I I S Q ]
0 5 1 P 1 0 0 % BASE M 1 0 5 2 P 9 0 % BASE M 1
> 0 5 3 L 2 5 0 w BASE M I S 0 1 2 D L = O . O s
0 5 4 L 1 5 0 m BASE M 1 0 5 5 C l 1 5 0 m BASE M 1
PUSH F1 TO SET RESTART POINT.
iposSEi/
3. Press F1 (POS SET) -, the
START button on the operating
panel (or starting box).
The operation will be restarted
from the position you set.
6.6.3 Overlap Restarting
The overlap restarting is a way of restarting the operation after the manipulator is
moved back from a halted point by a given distance. A distance is set in "RESTART
RETRACT" of the user parameters for setting the system status.
This feature is available when the halted sequence contains an Interpolation
instruction, such a s L or C.
@ Important \
The overlap distance is up to the point in the previous sequence, and moving back further is not possible. In the following example, the manipulator travels back only 10mm even if the setting is 15mm.
Overlap restarting t---
-. I f Halted point
~--10mm-+l Moving direction
I Fig.6.5. Overlap Restarting I
Ell Specifying an overlap restarting
In the halted state, the screen looks like the one shown on the right: * 1. Press F4 (RETREAT).
2. Press the START button on the operation box (or starting box).
The operation will be restarted after the manipulator travels back the distance setting.
* : Refer to "Setting the System status", section 2.1 in part 11.
Automatic Operation 6 - 1 5
6. 6.4 Restarting After Block Operation
Before restarting the operation, it is possible to perform block operation in the
halted. However, performing a sequence jump is not possible.
Performing block operation in the halted state
In the halted state, the screen
looks like the one shown on the
right: *
1. Press F3 (STRT PO). * In this condition, you can do
block operation.
BLOCK 2 Press I or1 1 , while
3. Press F1(POS SET).
When you restart, the
manipulator moves from the point
where you stopped block operation.
If you want to change taught data,
use the Path function*.
@ Important If you want to specify a restart point after halting during execution of an Circular Interpolation instruction (C1 or C2), perform block operation. If you specify a restart point by manual manipulation, the circular path may change a t the time of restarting.
'.
* : Refer to "Path Function", section 3.5 in part II .
6 - 1 6 Automatic Operation
6. 6. 5 Restarting when Halting dur ing Execution of Task Instruction
(1) Halting during a welding process
Operations a t the time restarting are listed in the following table:
Table 6.1. Operations a t restating when halting during a welding process
During preflow
Haltinc Timing.
Resetting the preflow time and then performing preflow from the beginning.
Operation a t Restarting.
During wire-slow down by Scratch s tar t During crater Drocess During online modification*
Restarting with the current welding conditions from the halted point. Execution of the next instruction because the crater Drocess has been com~leted before halting. Restarting with the previous welding conditions not the welding conditions being modified
During any other 1 Restarting with the current welding conditions. welding process
(2) Halt during weaving
As the manipulator returns to a position on the main path when halted, it s tar ts
weaving from that position.
/ Weaving path Stop P sr
Center stop
Fig.6.6 Restarting weaving
(3) Halt during execution of Timer o r the waiting time of an external control input
Restarting causes the time to be recounted from the beginning.
(4) Halt during execution of Delay Timer of an external control output
Restarting causes the external control output instruction to be executed after the
manipulator return to the position of a Motion instruction which is taught
immediately before the external control output instruction (S and R)
* : Refer to "Online Modifications", section 3.6 in part I[.
Automatic Operation 6 - 1 7
Chap te r 7 Edi t ing Fi les
This chapter explains how to create Welding Condition files and
Weaving Condition files.
Contents
7. Ed i t i ng Fi les Task programs, Welding Condition data, etc. are treated a s files. Files that can be edited
and created are the following:
Table 7.1. Types of files that can be edited and created
Type of File Task program
Seauencer file 1 Instruction Manual "Interfacing with Jig"
Reference for Editing and Creating "Teaching", chapter 5 in part 1
Welding Condition file Weavincr Condition file
User Parameter file I "User Parameters", chapter 2 in part 2
"Editing Welding Condition Files", section 7.2. in this chapter "Editing Weaving Condition Files", section 7.2. in this c h a ~ t e r
Welding Characteristic file I "User Parameters", chapter 2 in part 2 System Parameter file I Not edited
Multi-pass Welding Condition file
Offset file Laser Sensor file
Not used
Instruction Manual "Options"
Welding Task file I Under development
This chapter gives detailed explanations of operations for editing Welding Condition files and Weaving Condition files. Once welding conditions and weaving conditions a re stored in files, you can use them for teaching by simply specifying file numbers, which allows you can save teaching time.
7. 1 Selecting Files Files a re selected by using the function keys to which various types of files have been
assigned.
II Select ing f i l es
1. Press F2 (EDIT) at the top layer
of Teach mode. * 2. Select, by the function key, the [JOB( (OFFSITI(SpiETx1
file type you want to edit. /S]EM/ F1 . . . Creates/corrects Task
programs. F2 .. . Edits Weaving Condition
files. (See section 7.3.) F3 ... Edits Weaving Pattern files.
(Under development) F4 ... Edits Arc Start Condition
files. (See section 7.2.) F5 ... Edits Arc End Condition
files. (See section 7.2.)
Editing Files 7 - 1
F1 ... Edits Welding Task files. (Under development)
F3 ... Edits Offset files. (Option)
F4 . . . Edits Sequencer files. F5 ... Edits Laser Sensor
files. (Option)
[ [ F . . Edits Multi-pass Arc Start Condition files.
(Not used) F2 ... Edits Multi-pass Arc
End Condition files. (Not used)
7 - 2 Editing Files
7. 2 Editing Welding Condition Files There a re 2 types of Welding Condition files:
- Arc Start Condition file(ASC file)
Arc End Condition file(AEC file)
If an existing file number is entered, OSACOM SUPER 8700 displays the contents of
that file.
If a new file number is entered, OSACOM SUPER 8700 displays the default settings.
Edit files accordingly.
numeric keys, and set condition
data.
II Editing Arc Start Condition files
For individual controlled power unit
1. Press F4 (AS FILE). *
(1) Move the cursor to the item you - want to modify, by using
I. 18Jor *
2 . Enter a file number by using
TEACH A S C -
(2) Enter the condition data by
ENTER F I L E NUMBER
using numeric keys.
For Synergic controlled power unit
Set condition data in the same
manner a s that for individually
coiltrolled power unit.
When you place the cursor (>) a t
"VOLT. ADJUST", you can switch
between + and-by pressing F1 (+/--I. Irr)
Editing Files 7 - 3
For TIG power unit
Set condition da ta in the same
manner as that for individually I > WELDING CURRENT 180A TEACH WIRE SPEED 5 Om ASCl 0 WELD SPEED 150m
controlled power unit * I I I
3. Press RECORD key to store the 0 condition data you entered.
If you want to cancel the data you
just entered, press RESET instead. 0 The previous setting will remain
unchanged.
If you press RESET when creating a 0 new file. the file will not be created.
2. Enter a file number by using
Editing Arc End Condition files
numeric keys, and set condition
1. Press F5 (AE FILE). *
data.
For individually controlled power unit
(1) Move the cursor to the item you
want t o modify, by u s i n g m l o r
TEACH AEC -
(2) Enter the condition data by
ENTER FILE NUMBER
using numeric keys. *
For Synergic controlled power unit
Set condition data in the same
manner as that for individually
controlled power unit.
When you place the cursor (>) at
"VOLT. ADJUST", you can switch
between+and- by pressing F1 (+/-I . *
7 - 4 Editing Files
I I > CRATER CURRENT 180A TEACH AEClO
CRATER VOLTAGE 2 0.OV CRATER TIME 1.0 s. POSTFLOW TIME 0.0 S .
For TIG power unit
Set condition data in the same I
3. Press RECORD key to store the 0
manner as that for individually
.r) controlled power unit.
condition data you entered.
If you want to cancel the da ta you
TEACH A E C l 0
just entered, press RESET instead. 0
> CRATER CURRENT 1 2 0 ~ WIRE RETRACT 1.0 s. CRATER T I M E 1.0 S. POSTFLOW T I M E 0.0 s.
The previous setting will remain
unchanged.
If you press RESET when creating 0 a new file, the file will not be
created.
Editing Files 7 - 5
7. 3 Editing Weaving Condition Files There a re 2 types of Weaving Condition files:
* Fixed Pattern Weaving file (WFP file)
Axis Weaving file (WAX file)
You cannot edit the other type of Weaving Condition file as it is under development. If
an existing file number is entered, OSACOM SUPER 8700 displays the contents of that
file on the Edit screen. If a new file number is entered, OSACOM SUPER 8700 displays
the default settings. Edit files accordingly.
H Editing Fixed Pattern Weaving files
1. Press F2 (WS FILE). *
2. Press F1 (FIXED). I ENTER F I L E NUMBER * I TEACH
3. Enter a file number by using
numeric keys, and set condition
data. * (1) Move the cursor to the item you
want t o modify, by using numeric
keys.
(2) Set the condition data.
Setting the type of function
Select linear function o r sine curve
as a weaving function by the function
key.
Setting an amplitude
Set each half cycle of an weaving
amplitude in the unit of O . l m m by using
numeric keys.
1/4 FREQ STOP 3 / 4 FREQ STOP
Setting a frequency
Set a weaving frequency in the unit
of 0.1 Hz by using numeric keys.
Set each stopping time
Set a s t ~ p p i n g time a t each point in
the unit of 0.lsec.
4. Press RECORD t o store the condition 0 data you entered.
If you want to cancel the da ta you
just entered, press RESET instead. 0 The previous setting will remain
unchanged.
If you press RESET when creating a 0 new file, the file will not be created.
H Setting Axis Weaving files
1. Press F2 (WS FILE).
2. Press F4 (JOINT)
3. Enter a file number by using
numeric keys, and set condition
data. * (1) Highlight the item you want to --
modify, by using M91c3 m, a n d m ] .
(2) Set the condition data.
Setting a frequency
Set a weaving frequency in the unit
of O.1Hz by using numeric keys.
Edit ing Fi les 7 - 7
TEACH WAX -
ENTER FILE NUMBER
Setting weaving axes and amplitudes
Set the numbers of weaving axes
and amplitudes by using numeric keys.
For n o n - ~ ~ e a ~ i n g axes, set the
aniplitudes a t 0. Note that the unit of
amplitude is a degree.
Setting each stopping time
Set stopping time a t each point in
the unit of 0.lsec.
4. Press flECORD to store the condition 0 data you entered.
If you want to cancel the data you
just entered, RESET instead. 0 The previous setting will remain
unchanged.
If you press RESET when creating a 0 new file, the file will not be created.
7 - 8 Editing Files
Chapter 8 File Operat ions
This chapter explains how to copy. delete. and rename files .
Contents
8. F i le Operat ions Functions used to deal with files include:
Edit (modify) files
* List files
* Copy files - Delete files - Rename files
Operations for editing files have been discussed in chapters 5 and 7. This chapter gives detailed explanations of file operations except editing files.
These functions a re operated from the List screen for each of the following file types: * Task program
Welding Condition file Weaving Condition file
* Sequencer file
Deviation Correction file (option)
* Offset file (option)
* Laser Sensor file (option) - Search Pattern file (option)
8. 1 Listing Files The List function allows the operator to list created files of the same file type. A list
contains, file type, creation dates, and life sizes (only for Task program files), in
addition to file names. Though files are listed in order by number, only Task programs
can be also listed in order by creation date.'
III Listing files
1. Press F3 (FILE) at the top layer
of Teach mode. I)
F1 ... Lists Task programs F2 ... List Welding Condition
files F3 ... List Weaving Condition
files F4 ... List Sequencer files F5 . . . List Deviation Correction
files
1 . List Offset files F2 ... List Laser Sensor files F3 ... List Search Pattern files
* : Refer to "Setting the System Status", section 2.1 in part 11.
File Operations 8 - 1
2. To select the file type you want to
list, press the relevant function key.
When F1 (TEACH) is pressed +
The Task programs a re listed.
When F2 (WELD) is pressed * The ASC files (Arc Star t Condition
files) and AEC files (Arc End Condition files) a re listed in this order.
When F3 (WEAVE) is pressed * The WFP files (Fixed Pattern
Weaving files) and WAX files (Axis Weaving files) a re listed in this order.
When F4 (SO) is pressed
The Sequencer files a r e listed
TEACH
LSERVO
FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE
> pm'q 66 92-04-01 PO02 5 5 92-03-29 PO 0 3 1 3 0 92-03-28
TEACH
L%ERYO OF^
/RoLL[ pixr-x] 1pFT-i-q -1 >
FILE LIST WELDING FILE FILE DATE >= 9 2-0 3-0 3 AECO 1 9 2-0 2-2 8 AECO 2 9 2-0 2-2 9 AECO 3 9 2-0 3-0 1 AECO 7 9 2-0 3-0 7
TEACH
L S E R Y O ~
8 - 2 File Operations
j r i z - i E q ~ I ~ T r n l / D E L / >
FILE LIST WEAVING FILE FILE DATE
>I?N_PPOII 9 2-0 3-0 3 WAX 0 2 9 2-0 3-2 1 WAXO 3 9 2-0 3-1 1
TEACH
SERVO OF^
[RoLL]IROLLDN]IEDm/m(DEL/ >
FILE LIST SQ PRG. FILE FILE DATE > SQFl 9 3-1 1-2 6 SQF 2 93-11-26 SQF 3 9 3-1 1-2 6
p i E K - i q ~ j ~ ~ ~ I >
3. Move the cursor (>) t o the file
you want, by pressing [a or I
, and select the operation you
want to perform, by the function
key.
F1 ... Moves one page forward. (The screen does not change if the last page is shown.)
F2 ... Moves one page back. (The screen does not change if the first page is shown.)
F3 ... Edits files. * F4 ... Copies files.
(See section 8.2.) F5 ... Deletes files.
(See section 8.3.)
a F1 ... Rename files. (See section 8.4.)
* : Refer to "Editing Files", chapter 7 in part I
File Operations 8 - 3
8. 2 Copying Files Tlie Copy function allows the operator to make copies of specified files.
If the specified file does not exist, a n error occurs. If a file with the same name already
exists, OSACOM SUPER 8700 asks you to confirm overwriting.
Copying f i les
1. Move the cursor (>) to the copy
source file by pressing
*
2. Press F4 (COPY).
TEACH
LSERVO OPF~
3. Enter the name of a file you want
to make, by numeric keys. *
FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE PO01 55 92-03-20 PO02 5 5 92-03-29
>-1 1 3 0 92-03-28 PO04 125 92-05-07 PO07 87 92-04-03
4. Press F1 (EXECUTE) to copy.
If the file name you specified
already exists, a message
"OVERWRITE ? " is displayed. * Select by the Function key:
/ R o L L l / R O L L l ~ l ~ j I D E L j >
F1 ... Overwrites. F2 .. . Specifies a file name
again without overwriting.
TEACH
[SERVO OFEJ
FILE COPY
COPY FILE 1031 TO P -
TEACH
SERVO OFF^
8 - 4 F i l e Operations
FILE COPY
COPY FILE
TO PO o 4
TEACH
LSERVO OFF^
-1
FILE COPY
COPY FILE
TO PO04
SAME FILE EXISTS. OVERWRITE?
/EXECUSEIpmm]
8. 3 Deleting Files The Delete function allows the operator to delete specified files.
Before deleting, OSACOM SUPER 8700 asks you to check the file name you specified.
If the specified file does not exist, a n er ror occurs.
IZI De le t i ng f i l e s
1. Move the cursor (>) to the file
you want to delete, by pressing
r)
2. Press F5 (DELI.
TEACH
SERVO O P F ~
3. Press F1 (EXECUTE). .I)
FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE P O 0 1 5 5 9 2 - 0 3 - 2 0 PO 0 2 5 5 9 2 - 0 3 - 2 9
>I- 1 3 0 9 2 - 0 3 - 2 8 PO 0 4 1 2 5 9 2 - 0 5 - 0 7 PO 0 7 8 7 9 2 - 0 4 - 0 3
4. After you check the file name,
p i F i r i q ~ D N / I E D ~ l ~ I ~ j >
press F1 (CONFIRM) to delete the
file.
If you want to cancel the deletion,
press RESET . 0
File Operations 8 - 5
TEACH
b ~ ~ ~ o OFFJ
FILE DELETION DELETE FILE Lm]
-1
8. 4 Renaming Files The Rename function allows the operator to rename specified files.
If the specified file does not exist, a n er ror occurs. If a file with the same name already
exists, OSACOM SUPER 8700 asks you to confirm overwriting.
Renaming fi les
1. Move the cursor (>) to the file
you want to rename, by pressing
2 . Press ~1 (RENAME). *
3. Enter the new name you want to
give, by numeric keys.
4. Press F1 (EXECUTE) to rename
the file. * If the file you specified already
exists, a message "OVERWRITE ? "
is displayed.
Select by the Function key:
F1 ... Overwrites. F2 ... Specifies a file name again
without overwriting.
8 - 6 File Operations
TEACH
~ E R V Q ~
FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE P O 0 l 5 5 9 2 - 0 3 - 2 0 P O 0 2 5 5 9 2 - 0 3 - 2 9
>= 1 3 0 9 2 - 0 3 - 2 8 P O 0 4 1 2 5 9 2 - 0 5 - 0 7 P O 0 7 8 7 9 2 - 0 4 - 0 3
TEACH
SERVO OFFJ
/RoLLUP/rROLLDNJIEDrnT//COPYIrnI >
FILE RENAMING ORIGINAL NAME
RENAME TO P O 0 4
SAME FILE EXISTS. OVERWRITE?
-\/NO]
8. 5 Restrictions on File Operations
- If you perform file operations (copy, delete, and rename) from the List screen and
then list files, the file o r files you dealt with may not be correctly listed (e.g., the file o r
files you have deleted may be listed or a copy of the file you have made may not be
listed). In this case, terminate List once and specify again.
* Depending on file types, some functions are not available. For details, see the list below:
0 : Operable, X : Inoperable
File Type
Task program
Welding Condition file Weaving Condition file Laser Sensor file
Sequencer file
Offset file
Deviation Correction file Search Pattern file User Parameter filee System Parameter file Welding Chara- cteristic file
* : Represents a figure.
0 Note Search Pattern file SF2M01-05 can not be deleted.
Table 8.1. Restrictions
File Name
P * * *
ASC* *. AEC* *
W A X * * , W F P * *
SRF *
SQF *
OFS* *
DEV * * *
SF2M * * USEMAIN,
etc.
# * * * - * * *
$ WTBD * *
File Operations 8 - 7
on file
Edit
0
0
x
x
0
0
0
operations
Copy
0
0
0
x
X
X
X
Delete
0 0 0 0
0 0 0 0
0
0 0 0 0
0
0 0 0 0
0
6
X
X
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C h a p t e r 9 Cance l l i ng E m e r g e n c y S t o p a n d S h o c k Sensor
1 This chapter explains how to cancel the emergency stop and the shock sensor. I
Contents
9 1 Emergency Stop ................................................................................................................................................. 9-1
9.2 shock sensor ......................................................................................................................................................... g - 2
9.2.1 ~ ~ ~ ~ ~ l l i ~ ~ the shock sensor 9-2
9.2.2 Before Automatic Operation and After Completion of the Job ......................... 9 - 2
g 2 3 In Teach Mode ............................................................................................................................................ g - 3 . .
9.2.4 Correcting Taught Positions Where the Shock Sensor Operates ...................... 9-3
9. Cancel l ing Emergency Stop and Shock Sensor 9. I Emergency Stop
When emergency stop is entered, the servo power is shut off and the manipulator
immediately stops.
Cancel I ing Emergency Stop
1. When emergency stop is entered,
the window shown on the right
appears on the screen. m)
2. Cancel the emergency stop. .I)
3. Turn the servo power on.
* To restart automatic operation,
press the START button.
In Teach mode, manual
manipulation is executable.
AXIS M L 4 TEACH P 7 7 7 SQ No.=132 ISERVO OFF^
Cancelling Emergency Stop and Shock Sensor 9 - 1
WE 0 8 4 P 1 0 0 % EhIERGENCSTOP
> 0 8 5 L 1 5 0 m 0 8 6 L IOOcat BASE M I 0 8 7 C I 1 5 0 m BASE M I 0 8 8 C 2 1 5 O m BASE M I
AXIS M L 4 TEACH P 7 7 7 SQ No.=132
~ B R V D QFFJ
pzEi"lIJlISHIFTJIPATH/JPATH] >
WE 0 8 4 P 1 0 0 % BASE M I
> 0 8 5 L 1 5 0 m BASE M I 0 8 6 L l O O m BASE M I 0 8 7 C I 1 5 0 ~ BASE M I 0 8 8 C 2 1 5 0 m BASE M 1
pziEqI JWISHIFT/IPATH//PATH>
9. 2 Shock Sensor The way of handling and recovering from Shock Sensor depends on the operating
condition of the manipulator a t the time the shock sensor operated.
9.2.1 Cancell ing the shock sensor
During Automatic Operation
1. When the shock sensor operates,
the servo power is shut of f and
the manipulator enters the halted
state. +
2 Press @ and then turn on
the servo power. nrl,
3. Cancel the shock sensor by
performing manual manipulation.
*
4. Pressing the START button
allows you to restart the
operation.
9 .2 .2 Before Automatic Operation and Af ter Completion o f the Job
Cancelling the shock sensor
1. Even i f the shock sensor
operates, the servo power is not
shut off. *
AUTO PO 0 1 SQ No.=999 SERVO ON
STN 1
0 5 1 P 100% 052 P 9096 SWOC@SBESOR
> a 5 3 L 250011 S 012 DL=O.Os
054 L 150m BASE MI 055 C1 150m BASE M1
2. Press @.
/p.EEq
AUTO
SERVO ON
IMPOSSIBLE TO AUT SNOCR ALARM
SHOCK SENSOR ON
9 - 2 Cancell ing Emergency Stop and Shock Sensor
AUTO
SERVO ON
IMPOSSIBLE TO AUT SHOCK SENSOR
SHOCK SENSOR ON
3. Cancel the shock sensor by
performing manual manipulation.
II)
9.2.3 In Teach Mode
(I11 Cancelling the shock sensor
1. Even if the shock sensor
operates, the servo power is not
shut off. 119
2. Cancel the shock sensor by
performing manual manipulation.
*
@ Note When the shock sensor operates, block operation cannot be performed.
9.2.4 Correcting Taught Positions Where the Shock Sensor Operates
The shock sensor may operate a t positions you taught. This sectio~l explains how to
correct such positions.
llBl Correcting taught positions where the shock sensor operates
1. Perform block operation up to
the sequence followed by the
sequence which contains the
position to be corrected. +
2. Press Fl(SEARCI-1)
Cancel l ing Emergency Stop and Shock Sensor 9 - 3
AXIS M H 3 TEACH P 7 7 7 SQ No.=1 3 2 SERVO ON
0 9 2 P 1 0 0 % BASE M 1 0 9 3 P 1 0 0 % BASE M I
> 0 9 4 L l o o m BASE M 1 AS ASCOl
0 9 5 * L 1 0 0 m BASE M I 0 9 6 * L l o o m BASE M I
[TEEGil JJ] rziKFi=/IPATH/ -1 >
3. Move the cursor, by pressing
[, to the sequence to be
corrected. *
4. Press F1 (SO MARK). *
AXIS MH3 TEACH P7 7 7 SQ Na=132 SERVO ON
5. Move the manipulator, by
a094 P 10096 BASE M I AS ASCOl
>095*L l0Ocm BASE M1 096*L 100m BASE M1 097*L 100m BASE MI
AE AECOI
AXIS MH3 TEACH P7 7 7 SQ No.=132 SERVO ON
manual manipulation, to the
[ s a M A R X / r n / I S / / S T / E T I I S / >
0 9 4 P 10096 BASE M1 AS ASCOl
>095*L 1 O O w BASE M1 096*L 10 0 m BASE M 1 097*L 1 O O m BASE M1
AE AECOl
position/attitude you want to
I s E A R C H / ~ ] j l / - - F T q ~ >
teach, and press RECORD . 0
9 - 4 Cancell ing Emergency Stop and Shock Sensor
ication Features and Functions b-
Chapter 1 Appl icat ion Fea tu re and Funct ions Used in Teach Mode
1 This chapter describes application features and functions. s u c l ~ as
1 the Read Positions feature and the Home Stop function. used in I Teach mode .
Contents
1.1 Application Features and Functions Used for Manual Operations .........
1 . 1. 1 Displaying Angles and Coordinates (Reading Positions)
1 1 2 The 'Home Stop Function ................................................................................................................... . . 1.1.3 The Work Enable Area
1.1.4 The Reference Joint Angles a t the Star t Enable Area
1 . 1 5 Setting Manual Speeds
1.2 Application Features and Functions Used for Teaching .................................................
1 . 2 . 1 Logical Check on Task Programs
1 2 2 Confirmation of Terminating Teaching ................................................................................ . .
1 2.3 setting the way of performing ~ l ~ ~ k operation ..........................................................
1.2.4 Cursor Indicatioll of the State of Block Operation
1 . 2.5 setting ~ l ~ ~ k operatillg speeds
1.2.6 Checking and Modifying Condition Files during Block Operation ..................
1. App l i ca t ion Features and Funct ion Used in Teach Mode 1. 1 Application Features and Functions Used for Manual Operations
1. 1. 1 Displaying Angles and Coordinates (Reading Positions)
OSACOM SUPER 8700 displays the joint angle of each axis of the manipulator
measured from the reference position and its coordinate value in the currently specified
coordinate system.
O T h i s feature is useful t o modi fy the s tar t enable area*' of A L M E G A G series o r
W01, the home stop position*', and the work enable area*3.
@ Important \
For AIJMEGA V series, the angles read by this feature cannot be used to set
the s t a r t enable a rea (because the reference joint angles a t the s t a r t enable
a rea a r e different). For details, refer to "The Reference Joint Angles for the
Star t Enable Area", section 1.1.4.
Reading Positions
In Teach mode, hold READ down together with 0 While you a r e holding the keys
down, the rotating angle of each
axis and the coordinate value in the
currently specified coordinate
system a r e displayed on the left and
right sides of the screen,
respectively. C o o r d ~ n a t c values in
J o i n t Angle 01 each ax i s the currently specificci
T.MECA. MH4 TEACH
SERVO ON
coord ina te sys tem
ANG IAXS : 3 6.5 COORDX: 9 8 1.7 2AXS:- 7.9 Y: 84.8 3AXS : -7 3.2 Z: 11.5 4AXS: 54.9 a : 18.2 5AXS: 86.4 b : 3.6
C :-180.1
The reference positions to display the angles a r e shown in Fig.l.1 and Fig.l.2.
I I
* 1: Refer to "The Reference Joint Angles a t the Star t Enable Area", section 1.1.4 in
this part .
* 2: Refer to "The Home Stop Function", section 1.1.2 in this par t
* 3: Refer to "The Work Enable Area", section 1.1.3 in this part .
Application Features and Functions Used in Teach Mode 1 - 1
Axis 4 ' 0"
The reference positions of Axes 1, 3, and 4
The reference position of Axis 2
0"
The reference position of Axis 5
Axis 1: 0" a t the front position
Axis 2: 0" a t the horizontal position
Axis 3: 0" a t the position where Axes 1 and 3 align.
Axis 4: 0" a t the position where Axes 3 and 4 align.
Axis 5: 0" a t the directly downward position.
Fig.l.1. The reference positions of ALMEGA G series and W01
1 - 2 Application Features and Functions Used in Teach Mode
The reference position of Axis 1
Axis 2
-I-
The reference position of Axis 4
The perpendicular line
The reference position of Axis 6
The reference positions of Axes 2, 3, and 5
Axis 1: 0" a t the front position
Axis 2: 0" a t the vertical position
Axis 3: 90" a t the angle between the upper and lower a rms
(The angle of Axis 3 is expressed as a n angle between the upper and lower arms.)
Axis 4: 0" a t the position where Axes 3 and 4 align.
Axis 5: 0" a t the position where Axes 3 and 4 align.
Axis 6: 0" a t the front position.
Fig.l.2. The reference positions of ALMEGA V series
Application Features and Functions Used in Teach Mode 1 - 3
1. 1 .2 The Home Stop Function The Home Stop function allows the operator to stop the manipulator during manual
maiiipulatioi~ a t a position which has been stored in advance. The home stop ON/OFF aind position a re set in "SPECIFIED POINT HOLD" of the user parameters for setting the system status*.
There a r e two way of setting the position: * Directly entering numeric values of the joint angles o r Base coordinate values a t
a stopping position to be stored. First , move the manipulator to the stopping position you want to store, by
performing manual manipulation, and read the joint angles o r Base coordinate values by using the read positions feature. Then, enter these values.
* Moving the manipulator to a stopping position to be stored. Move the manipulator to the stopping position you want to store, by manual
nlanipulation, and set that position as the home position. For details of how to set, refer to "Setting the Home Position" section 2.1.1. Axis 5 of ALMEGA G series and W01 has the default setting of the Home Position
(only when Axis movement is specified) shown below:
When Axis 5 positions directly downward, the operation stops. To move the manipulator in the same direction again, release the key once and press it again.
Perpendicular line
Fig.l.3 The Home position of ALMEGA G series and W01
@This feature is useful to f ix the torch attitude.
Note \
If the system has multiple mechanisms, the Home Stop feature is available only to the mechanism being selected.
\ J
* : Refer to "Setting the System Status", section 2.1 in this part .
1 - 4 Application Features and Functions Used in Teach Mode
1.1.3 The Work Enable Area
There is a limitation of the working range of each axis of the manipulator.
The a rea where the manipulator can work is referred to a s the Work Enable Area.
This a rea can be changed by modifying the setting of "MOVABLE AREA" * ' in the
user parameters for setting the system status. However, do not modify the settings of
the axes except Axis 1.
The default setting of Axis 1 is shown below:
Table 1.1. Default settings of the Axis 1 work enable a rea
Manipulator Type 1 Default Setting
1. 1.4 The Reference Joint Angles at the Start Enable Area
The Star t Enable Area can be changed by modifying the setting of "START ENABLE
AREA"*' in the user parameters fo r setting the system status.
In the case of ALMEGA V series, however, it is not possible to directly enter the
joint angles read by using the read posltion feature (but possible for ALMEGA G
series and W01).
The reference joint angles a t the Start Enable Area (ALMEGA V seris) a r e shown in
Fig.l.4.
* 1 and * 2: Refer to "Setting the System Status", section 2.1 in this par t .
Application Features and Functions Used in Teach Mode 1 - 5
The reference position of Axis 1
Axis 3 0"
The reference position of Axis 4
The perpendicular line
The reference position of Axis 6
The reference positions of Axes 2, 3, and 5
Axis 1: 0" a t the front position
Axis 2: 0" a t the vertical position
Axis 3: 0" when the upper a rm is parallel to the ground.
Axis 4: 0" a t the position where Axes 3 and 4 align.
Axis 5: 0" a t the position where Axes 3 and 4 align.
Axis 6: 0" a t the front position.
Fig.l.4. The reference positions of ALMEGA V series
1 - 6 Application Features and Functions Used in Teach Mode
1 .1 .5 Setting Manual Speeds
Though a total of 9 step manual speeds including 4 low speed modes (ML1 - ML4), 4
high speed (MH1 - MH4), and inching (MLO) a r e available, it is possible to set a
desired speed a t each step for both Axis and Cartesian movements.
However, do not modify the inching speed (MLO)
Axis manual speed
Set a ra te to the maximum positioning speed.
The setting range is 0.01 - 100.00%.
* Cartesian manual speed
Set a ra te to 100cm/sec.
The setting range is 0.01 - 100.00%
II( Setting manual speeds
1. Press D at the top layer of U Teach mode and then F4
(SYS SET). *
2. Press F5 (MANUAL). +
3. Place the cursor a t "MANUAL
SPEED", and then select the
item by the function key:
F1 ... Sets Axis manual speeds of mechanisms 1 and 2.
F2 ... Sets Axis manual speeds of mechanisms 3 and 4.
F3 ... Sets Cartesian manual speeds.
A X I S MH4 TEACH
SERVO ON
/ q / l / I m l m J >
Application Features and Functions Used in Teach Mode 1 - 7
A X I S MH4 TEACH
SERVO ON
SELECT MODIFYING PARAMETER
> MANUAL S P E E D P I T C H MOTION
/ROTATI//ROTAT2/TEKI
When F1 (ROTAT 1) is pressed
When F2 (ROTAT 2) is pressed
*
A X I S M H 4 T E A C H
SERVO O N
When F3 (CARTE.) is pressed
e
A X I S S P E E D MECHA. l/MECHA 2
ML1: /7 M H 1 : 47.5096 M L 2 : 15.00% M H z : 65.00% M L 3 : 32.50% M H 3 : 82.50% M L 4 : 30.0096 M H 4 : 100.00%
4. Highlight the speed step you
want t o modify, by using. /gl, , !=!, B] and t h R t e r
the speed by numeric keys.
Set Axis manual speed a t a rate
to the maximum positioning speed
o r Cartesian manual speed a t a
r a t e to 100cm/sec.
5. Press @ .
M L l : 1 2 . 6 M H l : 47.50% ML2: 15.00% M H 2 : 65.00%
ML4: 30.00% M H 4 : 100.00%
A X I S M H 4 T E A C H
SERVO ON
1 - 8 Application Features and Functions Used in Teach Mode
A X I S S P E E D MECHA. l/MECHA 2
M L 1 : \m$6 M H 1 : 62.5096 M L 2 : 25.0096 M H 2 : 75.0096 M L 3 : 37.50% M H 3 : 87.5096 M L 4 : 50.00% M H 4 : 100.00%
1. 2 Application Features and Functions Used for Teaching 1 .2 .1 Logical Check on Task Programs
The logical check on Task programs feature allows the operator to easily find
teaching errors in the Task programs. A Task program to check should be selected by
using the diagnostic function in Teach mode. If a teaching error is found, a Alarm
message is displayed. There are three types of Alarms; one still allows you to run
automatic operation, another requires you to correct taught data; otherwise automatic
operation will halt, and the other does not guarantee normal operation. For details of
the logical check items, and the Alarm messages, descriptions and solutions, see the
Alarm list.
0 NOTE 1
1) The range of logical check
A logical check is made on each Task program. Therefore, if a Task program
contains CL or JF instructions, a logical check is made on existence of any call
or jump destination programs but not on the contents.
[Example) PO01
0 0 1 P
AE
0 0 2 END / 0 0 3 END
For P001, Alarm that AE is outside welding section is given. But, for P002,
because the contents of the called program are not checked, Alarm is not given.
2) The checking order of logical check on Task programs
A logical check is made in order by storing of Task programs. Therefore, if a
JP instruction is contained in a Task program, Alarm may be given even if there
a re not any teaching errors.
AE is not executed due to the unconditional jump, and block and automatic
operations can be executed. However, if a logical check is made, Alarm that AE
is outside welding section is given.
(Example)
Application Features and Functions Used in Teach Mode 1 - 9
0 0 1 P 0 0 2 JP #1
AE
0 0 3 PM1 0 0 4 END
Making a logical check on Task programs
at the top layer of
Teach mode. * TEACH
ISERYO OF^
/ r t G i K q ~ ~ ~ ~ l >
2. Press F2 (CHECK). *
3. Press F5 (LGC MON). err),
I f you want to make a logical
check on all Task programs, press
F1 (PRG.AL) I f a desired program,
enter the Task program number by
numeric keys. * 4. Press F1 (EXECUTE).
A logical check on that program
will be started. * F5 . .. Cancels a logical check.
If the specified Task program is
not found, an er ror message will
appear. * In this event, press ~ J ~ F Y to 0
specify a Task program number
again.
TEACH
DIAGNOSIS /SERVO >OFF]
ENTER PROGRAM NUMBER
Plll
TEACH
DIAGNOSIS SERVO D F F ~
1 - 1 0 Application Features and Functions Used in Teach Mode
IpEi-Tq
Plll CHECK
TEACH
DIAGNOSIS SERVO OPEJ
/STOP]
ENTER PROGRAM NUMBER
Plll
NO FILE -.MOD1 FY
-1 *
5. If Alarm occurs, the relevant
sequence number and message a r e
displayed. .r)
Alarms a r e sequentially displayed on the screen, and a logical check stops when the screen is full with Alarms: *
F1 ... Restarts the logical check.
RESET . . . Cancels the logical 0 check.
6. When a logical check on one
Task program is complete, then
you can enter a Task program
number again.
(if you a r e specifying individual
Task programs). * If you make a logical check on
all Task programs, the screen
shown on the right will appear:
*
Press F1 (CONFIRM), so a
logical check on the next program
will be started.
TEACH
DIAGNOSIS ]SERVO OPFI
Application Features and Functions Used in Teach Mode 1 - 1 1
F 1 -. CONTINUATION
p%i'iGq
1 L i s t of A larm Messages (Logical Check on Task Programs) 1
This list contains Alarm messages that may appear during a logical check on Task
programs, descriptions and solutions. If Alarm occurs, refer to this list to change taught
data. Messages are listed alphabetically.
A E IS OUT OF WELDING
Description : AE exists outside a welding section.
Solution : Delete AE or teach AS before AE. If this is intentional and welding
failure does not occur, you do not need to take action.
AS IS IN T RACKING
Description : AS exists within a tracking section (ST - ET section).
Solution : Delete AS or teach AS before the tracking section.
I C 1 CL IS IN WELDING
Description : CL exists within a welding section.
Solution : Do not teach any Branch instruction within a welding section.
If this is intentional and welding failure does not occur, you do not
need to take action.
CL IS IN T RACKING
Description : CL exists within a Tracking section (ST -ET section).
Solution : Do not teach any Branch instruction within a tracking section.
If this is intentional and welding failure does not occur, you do not
need to take action.
CL IS IN CIRCULAR
Description : CL exists within a circular section.
Solution : Do not teach any Branch instruction within a circular section.
If this is intentional, you do not need to take action.
1 - 1 2 Application Features and Functions Used in Teach Mode
C L I S I N W E A V I N G
Description : CL exists within a weaving section.
Solution : Do not teach any Branch instruction within a weaving section.
If this is intentional, you do not need to take action.
C O I S I N W E L D I N G
Description : CO exists within a welding section.
Solution : Delete CO o r change to C. If this is intentional and welding failure
does not occur, you do not need t o take action.
C O I S I N W E A V I N G
Description : CO exists within a weaving section.
Solution : Delete CO o r change to C.
If this is intentional, you do not need to take action.
E N D I S I N W E A V I N G
Description : END exists within a weaving section.
Solution : Delete END o r add WE before END.
E N D I S I N T R A C K I N G
Description : END exists within a tracking section (ST- ET section).
Solution : Delete END or add AE before END. If this is intentional and welding
failure does not occur, you do not need to take action.
E N D I S I N W E L D I N G
Description : END exists within a welding section.
Solution : Delete END o r add AE before END.
E N D I S I N G S - G E
Description : END exists within a Gas ON/OFF section.
Solution : Delete END o r add GE before END.
Appl icat ion Features and Functions Used i n Teach Mode 1 - 1 3
E T I S O U T O F T R A C K I N G
Description : ET exists outside a tracking section (ST - ET section).
Solution : Delete ET o r add ST before ET.
(F11
F I R S T M O T I O N I S N O T H P
Description : The first Motion instruction is not HP in the multiple-mechanism
system.
Solution : Teach the first Motion instruction as HP.
Otherwise, the mechanism may interfere with each other a t first
Motion instruction.
F I R S T M O T I O N I S C P
Description : The first Motion instruction is CP Motion instruction (L, LO, C1, C2,
C01, o r C02).
Solution : Teach the first Motion instruction as P.
[ G I G E I S I N W E L D I N G
Description : GE exists within a welding section.
Solution : Do not teach GE within a welding section.
G E I S O U T O F G S - G E .
Description : GE exists outside a Gas ON/OFF section (GS - GE section).
Solution : Delete GE o r add GS before GE.
G S I S I N W E L D I N G
Description : GS exists within a welding section.
Solution : Do not teach GS within a welding section.
I C H I S I N W E L D I N G
Description : ICH exists within a welding section.
Solution : Do not teach ICH within a welding section.
1 - 1 4 Application Features and Functions Used in Teach Mode
K J l
J F I S I N W E A V I N G
Description : JF exists within a weaving section.
Solution : Do not teach any Branch instruction within a weaving section.
If this is intentional, you do not need to take action.
J F I S I N C I R C U L A R
Description : JF exists between Circular instructions.
Solution : Do not teach any Branch instruction within a circular section.
If this is intentional, you do not need to take action.
J F I S I N T R A C K I N G
Description : J F exists within a tracking section (ST- ET section).
Solution : Do not teach any Branch instruction within a tracking section.
If this is intentional and welding failure does not occur, you do not
need to take action.
J F I S I N W E L D I N G
Description : JF exists within a welding section.
Solution : Do not teach any Branch instruction within a welding section.
If this is intentional and welding failure does not occur, you do not
need to take action.
J P I S I N W E L D I N G
Description : JP exists within a welding section.
Solution : Do not teach ally Branch instruction within a welding section.
If this is intentional and welding failure does not occur, you do not
need to take action.
J P I S I N W E A V I N G
Description : JP exists within a weaving section.
Solution : Do not teach any Branch instruction within a weaving section
If this is intentional, you do not need to take action.
Application Features and Functions Used in Teach Mode 1 - 1 5
J P I S I N TRACK1 NG
Description : JP exists within a tracking section (ST- ET section)
Solution : Do not teach any Branch instruction within a tracking section.
If this is intentional and welding failure does not occur, you do not
need to take action.
J P I S I N CIRCULAR
Description : JP exists between Circular instructions.
Solution : Do not teach any Branch instruction within a circular section.
If this is intentional, you do not need to take action.
( L 1
LO IS IN WEAVING
Description : LO exists within a weaving section.
Solution : Delete LO or change to L.
If this is intentional and welding failure does not occur, you do not
need to take action.
LO IS IN WELDING
Description : LO exists within a welding section.
Solution : Delete LO or change to L.
If this is intentional and welding failure does not occur, you do not
need to take action.
EM1
MISMATCH OF WELDER TYPE
Description : Different types of power units (Individual, Synergistic, and TIG) were
specified for AS and AE.
Solution : Delete AS and AE whose types of power units are different, and teach
again.
1 - 1 6 Application Features and Functions Used in Teach Mode
M O T I O N D A T A A R E M I X E D
Description : Both Synchronous Motion instruction (HP, HL, etc) and Single Motion
instructions (P, L, etc) exist.
Solution : Teach with only Synchronus Motion instructions.
Otherwise, the mechanism may interfere with each other in block
operation.
C N 1 N O D E F B E F O R E D E C
Description : There is no DEF before DEC.
Solution : Delete DEC o r add DEF before DEC.
N O R E F . P O I N T O F C 1
Description : There is no reference point of C1.
Solution : Delete C i o r add a Motion instruction before and after C1.
N O R E F . P O I N T O F C 2
Description : There is no reference point of C2.
Solution : Delete C2 o r add a Motion instruction before C2.
N O T S A M E C C O O R D I N A T E S
Description : The coordinate systems for 3 circular point (s tar t , middle and end) do
not match.
Solution : Delete the wrong sequence and teach again.
N O J U M P P O I N T
Description : Point Mark o r Task program does not exist a t the jump destination.
Solution : Delete J P o r JF, o r add a Point Mark o r Task program a t the jump
destination.
N O C O N D I T I O N F I L E
Description : The specified Condition file does not exist.
Solution : Delete AS, AE, WFP, or WAX, o r create a Condition file.
Application Features and Functions Used in Teach Mode 1 - 1 7
N O P R O G R A M T O C A L L
Description : The Task program to call does not exist.
Solution : Delete CL o r create a Task program to call.
r.P1
P IS IN W E A V I N G
Description : P exists within a weaving section.
Solution : Delete P o r change to L.
If this is intentional, you do not need to take action.
P IS IN W E L D I N G
Description : P exists within a welding section.
Solution : Delete P o r change to L.
If this is intentionaI and welding failure does not occur, you do not
need to take action.
P M IS IN W E A V I N G
Description : PM exists within a weaving section.
Solution : Do not teach any Branch instruction within a welding section.
If this is intentional, you do not need t o take action.
P M IS IN C I R C U L A R
Description : PM exists between Circular instructions.
Solution : Do not teach any Branch instruction within a circular section.
If this is intentional, you do not need to take action.
P M IS R E P E A T E D
Description : A duplicate PM exists .
Solution : Delete a n unnecessary PM.
P M IS IN T R A C K I N G
Description : PM exists within a tracking section (ST - ET section).
Solution : Do not teach any Branch instruction within a tracking section.
If this is intentional, you do not need to take action.
1 - 1 8 Application Features and Functions Used in Teach Mode
P M I S I N W E L D I N G
Description : PM exists within a welding section.
Solution : Do not teach any Branch instruction within a welding section.
If this is intentional, you do not need to take action.
P M I S N O T L I N K E D
Description : There is PM which is not referenced.
Solution : Delete PM o r add J P .
CRI
R T C I S I N W E L D I N G
Description : RTC exists within a welding section.
Solution : Do not teach RTC within a welding section.
KSI
S F 0 I S I N W E A V I N G
Description : SF0 exists within a weaving section.
Solution : Do not teach S F 0 within a weaving section.
S F 0 I S I N W E L D I N G
Description : SF0 exists within a welding section.
Solution : Do not teach SF0 within a welding section.
S F 1 I S I N W E A V I N G
Description : SF1 exists within a weaving section.
Solutioii : Do not teach SF1 within a weaving section.
S F 1 I S I N W E L D I N G
Description : SF1 exists within a welding section.
Solution : Do not teach SF1 within a welding section.
S T I S O U T O F W E L D P A T H
Description : ST exists outside a welding and weaving.
Solution : Teach ST outside a welding and weaving section.
Application Features and Functions Used in Teach Mode 1 - 1 9
[ W l
WFP IS I N TRACKING
Description : WFP exists within a tracking section (ST - ET section).
Solution : Delete WFP or teach before the tracking section.
WAX IS I N TRACKING
Description : WAX exists within a tracking section (ST - ET section).
Solution : Delete WAX o r teach before the tracking section.
WE IS O U T O F WEAVING
Description : WE exists outside a weaving section (ST -ET section).
Solution : Delete WE o r teach a Weaving Star t instruction before WE.
1 - 2 0 Application Features and Functions Used in Teach Mode
1.2 .2 Confirmation of Terminating Teaching
This feature allows the operator to prevent termination of the teaching operation
caused by accidentally pressing the Reset key when creating Task programs.
OSACOM SUPER 8700 asks for confirmation to terminate teaching
This feature is set on/off by modifying the setting of "CNFRMNG TEACH END" in
the user parameters for setting the teaching box keys. (The default is OFF.)
(1) Confirmation of terminating teaching OFF
When the Reset key is pressed during teaching to create a new program, END
instruction is automatically inserted a t the last sequence to terminate teaching.
(2) Confirmation of terminating teaching ON
When the Reset key is pressed during teaching to create a new program,
OSACOM SUPER 8700 asks for confirmation of terminating teaching.
When the setting is ON
I f you press RESET when teaching 0 to create a new program, the screen
similar to the one shown on the
r ight appears : I)
F1 . .. Teminates teaching. F2 ... Returns to the Teaching
screen.
* : Refer to "Setting the Teaching Box Keys", section 2.2. in this part .
Application Features and Functions Used in Teach Mode 1 - 2 1
AXIS MH4 TEACH P 7 7 7 SQ No.= 3 SERVO ON
0 0 1 P 1 0 0 % BASE MI 0 0 2 P 1 0 0 % BASE M1
S 0 1 2 AS 25OA. 25.OV. 25Ocm
> 0 0 3 * L 25Ocm BASE M1
DO YOU WANT TO EXIT TEACHING?
-1/NOj
1.2.3 Setting the Way of Performing Block Operation The way of performing block operation can be set a s a user parameter.
Hold the way of performing block operation ON/OFF (the setting of the way of performing block operation) Continuous Block operation ON/OFF
(1) Hold the way of performing block operation (the setting of the way of performing
block operation)
This feature is set on/off by modifying the setting of "BLOCK OP. HOLD"" in the user parameters for setting the system status. Even if block operation is performed
in the same manner, the movement of the manipulator varies according to the ON
/OFF settings. Movements of the manipulator according to ON/OFF settings are a s follows:
Table 1.1 Key operations and Movements of the manipulator according to Hold
the way of performing block operation ON/OFF
When, without continuous
Key Operation
block operaton specified, 8 and m a r e
pressed.
* The mechanism stops
Hold Way of Performing Block Operation
a t a taught point.
ON
Releasing and
OFF ( Default)
BLOCK re-pressing / ,, I causes the mechanism to move to the next
/ taught point. I
BLOCK . If 1s still
kept pressed when the mechanism reaches a taught point, it moves to the next taught point.
When, with @ held, BLOCK . w
1s released - during forward block operation.
When Halt is operated during continuous
The mechanism stops immidiately .
The continuous state is held.
When continuous block operation is specified The mechanism carries on the continuous block operation.
* When continuous block operation is not specified The mechanism stops a t a taught point.
(Releasing E ~ ~ L E causes 8 the mechanism to
immediately stop.)
a The continuous state is cancelled.
block operation.
* : Refer to "Setting the System Status", section 1.2. in this part.
1 - 2 2 Application Features and Functions Used in Teach Mode
@ Note For movements in backward operation, refer to the above table.
(2) Continuous Block ON/OFF
This feature is set ON/OFF by modifying the setting of "CONT. BLOCK" in the
user parameter for setting teaching box keys.
The table below shows how the setting of this parameter works on the relation
beween a key operation and block operation:
Table 1.2 Continuos Block Operation ON/OFF
Continous Block O~era t i on ON/ OFF Key operation 1 ON (Default) OFF
When is pressed. 1 The continuous state / The continuous state is - 1 is entered, and the 1 not entered, and the LED
LED of on the
teaching box is illuminates.
of teaching box is not illumintaes.
Application Features and Functions Used in Teach Mode 1 - 2 3
1 .2 .4 Cursor Indicat ion o f the State of Block Operat ion
This teature allows the operator to judge by the cursor whether the manipulator is
a t a taught point of the current sequence or is moving to the next sequence.
This feature is set on/off by modifying the setting of "SPECIAL CURSOR DISP" *
in the user parameters for setting the teaching box keys.
63111 The Block operating state
If the setting of "SPECIAL
CURSOR DISP" is on, the screen
similar to the one shown on right
appears. 4 A new c u r s o r a is added. which
does not appear if the setting is off.
> : Indicates the current position. This is not displayed during
block operation o r in the
halted state.
: Indicates the target point
during block operation. This
flickers in the halted state.
A combination of these two
cursors allows you to identify the
current s ta te of block operation:
> I P ) ; 1 I State of Block Operation
TOOL M L 4 TEACH P7 7 7 SB No.=lO 0 SERVO ON
ON 1 ON I Halted s ta te (The manipulator is a t the taught ~ o i n t . 1
& 0 0 1 P 1 0 0 % BASE M I 0 0 2 P 8 0 % BASE M 1 0 0 3 L 1 5 0 m BASE M I
pl iE iq/J~~m/PATH>
@ Notes 1
OFF
OFF
1) Even if the user parameter setting is "ON1', the cursor does not appear if the Sequence Search function is selected. However, it becomes active when the Sequence Search function is terminated.
2) In bacliward block operation, the cursor does not indicate a target point.
* : Refer to "Setting the Teaching Box Keys", section 2.2. in this part .
ON
flicker
1 - 2 4 Application Features and Functions Used in Teach Mode
Block operating state
Halted state (The manipulator is not a t a taught point.)
1.2.5 Setting Block Operating Speeds
It is possible to set block operating speeds.
Speeds a r e set a t a ra te to the maximum Positioning speed in automatic operation
(setting range: 1 - 15%).
111 Setting a block operating speed
1. Press F4 (SYS. SET) at
the top layer of teach mode, and
then
2. Press F2 (BLOCK). II)
3. Set a block operating speed
by using [m] and numeric
keys.
4. Press a. Now, the block operating speed
has been set.
Applicat~on Features and Functions Used in Teach Mode 1 - 2 5
'1.2.6 Checking and Modifying Condition Files during Block Operation
If welding and weaving conditions are specified by using files, it is possible to check
o r modify data contained in a specified file.
Editing Condition files during block operation
1. Place the cursor a t the data in
the Condition file you want to
check. *
2. Press @ .
A X I S MH4 TEACH P 7 7 7 SQ Na=132 SERVO ON
3. Enter a condition by numeric
keys if you want to modify.
WE 0 9 2 P 1 0 0 % BASE MI
> A S A S C O 5 0 9 3 X L 15Om BASE MI 094XC1 1 5 0 m BASE M1 0 9 5 h C 2 1 5 0 m BASE M1
If you do not modify, press RESET . 0
p - c x i z i I J ~ l / P A T ~ / >
OSACOM SUPER 8700 will return
to the block operation screen.
4. If you want to modify, press
RECORD . 0 OSACOM SUPER 8700 will return
to the block operation screen.
1 - 2 6 Application Features and Functions Used i n Teach Mode
C h a p t e r 2 User P a r a m e t e r s
Contents
2 . 1 SettiIlg the System Status ........................................................................................................................... 2 - 3
2.1.1 setting the H~~~ position ................... 2 - 8
2.1.2 Setting the Work Enable Area (sof t Limit) 2 - 10
2 . 1 3 Setting the Start Enable Area ......................................................................................................... 2-11
2 1 4 Registering Coordinate Systems .................................................................................................... 2-11 . .
2.1.5 Setting Conditions for 3-dimensional Shift and Mirror Image Shift ............... 2-12
2 1 6 setting the ABSO ~~t~ check ti^^ ................................................................................... 2-13 . . 2 2 Setting the Teaching Box Keys 2- 14
2.3 setting the welding parameters 2-17
2.4 Setting the Parameters for External Control Signal Inputs/Outputs 2-20
2.5 setting ti^^ ~ ~ ~ t ~ i ~ t i ~ ~ ~ on ~ ~ t ~ ~ ~ t i ~ operation .................................................. 2-22
2.6 Setting the Sensor Type 2-22
2.7 setting welding characteristic ~~t~ .. 2-23
2 7 1 ~ ~ ~ i ~ t ~ ~ i ~ ~ welding characteristic ~~t~ ....................................................................... 2-24 . . 2.7.2 ~ ~ d i f ~ i ~ ~ welding characteristic ~~t~ 2-24
2.7.3 Creating User Welding Characteristic Data (User Registration) .................... 2-27
2 7.4 ~~t~~ to use ALMEGA FUZZY AUTO ................................................................................... 2-29
2.7.5 ~~t~~ to use TIG ill^^ ...................................................................................................................... 2-31
2. U s e r P a r a m e t e r s Setting user parameters allow the user to turn on/off various features and functions
relating to welding and movements.
If a parameter setting is changed, the new setting immediately becomes effective.
Selecting the User Parameters Setting Function 1. You start f rom the top layer of I I
Teach mode.
2. Press and then F1
Press the function key to select
the parameter type you want:
F 1 ... Sets the system status. ~ N S O R ] I p T F q ~ p i z Z E i I [ ~ ] (See section 2.1.)
F2 ... Sets the teaching box keys. (See section 2.2.)
F 3 ... Sets the welding parameters. (See section 2.3.)
F 4 ... Sets the parameters for external control signal inputs/outputs. (See section 2.4.)
F 5 ... Sets the motion restrictions in automatic operation. (See section 2.5.)
F1 . . Sets the sensor. (See section 2.6.)
F 2 ... Sets the arc sensor parameters. *
F 3 ... Sets the touch sensor parameters. *
F 4 ... Sets the welding characteristic data. (See section 2.7.)
F 5 ... Sets the sample data for arc sensor.*
* : Refer to the Arc Sensor instruction manual "Teaching".
User Parameters 2 - 1
11111 Setting User Parameters Any kinds of user parameters should be set in accordance with the following procedure:
/ Selecting a parameter type to set / -
Move the cursor by using [ml . The item indicated by the cursor is your object to set.
1 Moving pages 1 If there a r e multiple pages which contain parameters, OSACOM SUPER 8700 displays a
page number such a s "1/6" on the top right of the screen. The figure on the left of "/"
shows the current page, and the right shows the total number of pages. To move pages,
press F4 (ROLL DN) o r F5 (ROLL UP).
Changing da ta settings
* Alternative selection of "ON/OFF"
The current setting is highlighted. F1 (EDIT) toggles between ON and OFF
Selection from among multiple data settings
When you place the cursor a t the parameter you want to set, da ta settings you can
select a r e assigned to the function keys. Select the setting you want.
Numeric da ta
Enter a numeric value by using numeric keys. If you want to correct the value you
entered, press ~ I F Y key. 0 Storing da ta settings
To s tore the key. The setting you have stored immediately becomes
it is not stored.
Holding the setting item
When you select a user parameter type, the cursor indicates the previously set item
2 - 2 User Parameters
2. 1 Setting the System Status This section describes the parameters by page. [ I contains options, and ( ) contains
the default setting.
* Page 11'6
(1) Initial mode [TEACH/AUTOl (Teach mode)
Define whether the initial mode which is entered when the control power is turned
on should be Teach o r Auto mode.
AXIS ML4 TEACH
SERVO ON
(2) Auto mode interlock [ON/OFFl (ON)
For details of Auto mode interlock, refer to "Modes", section 2.4 in par t I .
SYSTEN 1 /6 >INITIAL MODE
p i ;;To AUTO LOCK TEACH LOCK ON CONTROL METHOD I m J REMOT APPLICATION PRG. LI ST DI SP 1-j DATE
(3) Teach mode interlock [ON/OFF] (OFF)
For details of Teach mode interlock, refer to "Modes", section 2.4 in pa r t I.
pzKi-Eq-1
(4) Control system [LOCAL/REMOTE]
At present, not available.
(5) Application [WELDING/HANDLINGl ((Welding)
Select Welding fo r welding/cutting applications, o r Material Handling for handling
application.
(6) List Task programs [By number/By date1 (By number)
Define how the Task programs should be listed; in order by number o r by creation
date.
User Parameters 2 - 3
* Page 2/6
(1) Interference soft limit check [ON/OFF]
At present, not available.
AXIS ML4 TEACH
SERVO ON
(2) Attitude movement (Wrist axis movement) [Eulerian/R.P.Y. 1
SYSTEN 2/6 INTERF. LIMIT OFF
>POSTURE MOTION RESTART RETRACT 0 lorn
SPEED TO PM 6 0% ONLINE AUTO SET OFF
Select Eulerian Angle for welding/cutting applications, or R.P.Y. for handling
application. For details of each movement, refer to "Operating Directions", section
/SETTING/ [piKrz-\/ROLLUP/
4.2 in part I . Note that R.P.Y. is not available for the use of ALMEGA G series and
(3) Overlap distance for restating automatic operation (Omin)
Set a travel back distance for restarting automatic operation.
For details of the overlap restart, see "Overlap Restart" section 6.6.3 in part I.
(4) Travel Speed to Point Mark (60%)
Set a speed a t which a manipulator moves to Point Mark (PM).
The setting is a rate to the maximum positioning speed and affects the following
speeds:
* A speed a t which the manipulator starts to move from the current position to the
sequence specified by using the Path function.
* A speed a t which the manipulator returns to the point where automatic
operation was restarted from the current position specified by performing
manual manipulation after automatic operation was halted.
(5) Automatic storing for online modification [ON/OFFI ~ ~ % >
The ON setting allows the operator to store the conditions updated online when
AE or the updated AS is executed, and the OFF setting does not. However,
regardless of ON or OFF, the updated conditions are stored when the Record key or
F4 (END) is pressed before the next AS or AE is executed.
2 - 4 User Parameters
* Page 3/6
(1) Home position
(ON only for Axis 5 of ALMEGA G series o r W01, and OFF for the others)
The ON setting allows the operator to halt manual manipulation a t a stored
position/attitude. For details of this function, see "The Home Stop function",
section 1.1.2 in this part, and for the setting procedure, see "Setting the Home
Position", section 2.1.1 in this part.
AXIS ML4 TEACH
SERVO ON
(2) Work enable area(Soft Limit)
The work enable area can be changed a s desired. For the default setting of the
work enable area, see "The Work Enable Area", section 1.1.3 in this part , and for the
setting procedure, see "Setting the Work Enable Area (Soft Limit)", section 2.1.2 in
this part.
SYSTEM 3/6 >SPECIFIED POINT HOLD MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER
(3) Start enable area
As well a s the work enable area, the s tar t enable area can be changed as desired.
For details, see "Automatic Operation", section 6.1 in part I , and for the setting
procedure, see "Setting the Start Enable Area", section 2.1.3 in this part.
p-EiKy pEirxq/ROLL/
(4) Moving Axis
At present, not available.
(5) Offset Adjustment
Do not modify this setting since OSACOM SUPER 8700 is provided with the preset
values.
(6) Tool parameters
OSACOM SUPER 8700 is provided with the data of a tool (such a s a torch) used.
Do not change the settings, unless you change the tool. When replacing the tool,
see "Tool Parameters", appendix 4. Note that, if the tool is changed, the Task
programs in service are not available.
User Parameters 2 - 5
Page 4/6 SELECTED UNITS -1
EXT. MEMORY
(1) ABSO data check function
Set the ABSO data check ON or OFF. If ON, set an allowance. For details of the
function, refer to "ABSO Data Check Function", section 3.3 in part 111, and for the
setting procedure, see "Setting the ABSO DATA Check Function", section 2.1.6 in this
part.
(2) Unit CMetric/Inchl (Metric)
It is possible to switch unit whether Metric or Inch.
(3) Hold the way of performing block operation (OFF)
This setting affects the way of performing block operation.
For details, refer to "Setting the Way of Performing Block Operation", section
1.2.3 in this part.
(4) Floppy disk type [2DD/2HDl C?J-ID)
Set the floppy disk type used for an external storage.
For details, refer to External Storage, chapter 1 in part III.
(5) Version display CON/OFFl (OFF)
This setting defines whether the control program versions a re displayed o r not
after the control power is turned on. Normally, set it OFF because this feature is
used by DAIHEN serviceman.
(6) External storage type [PC/FDDl (FDD)
Set the external storage type used. Select "FDD" for the use of external storage
unit (option, type: E5777), or "PC" for the use of a personal computer. Note that, if
you want to use a personal computer as an external storage, you need optional
software (PM-8700) and interface cable.
2 - 6 User Parameters
* Page 5/6
(1) Check the s t a r t enable area during automatic operation [ON/OFF] ((OFF)
For details of this feature, see "Checking the Star t Enable Area during Automatic
Operation", section 3.4 in this part .
(2) Teaching synchronous motion [ON/OFF]
For details, refer to Instruction manual "Options".
(3) Register of coordinate systems
(Base as Cartesian coordinate system 1, and OFF as 2)
I t is possible to register up to 2 coordinate systems which a r e switched each time - a is pressed. For details, see "Switching between Coordinate Systems" section
4.1.3 in par t I, and for the registering procedure, see "Registering Coordinate
Systems", 2.1.4 in this part.
* Page 6/6
(1) Conditions for 3-dimensional shift and mirror shift
For the default settings and the setting procedure, see "Setting Conditions for
3-dimensional Shift and Mirror Shift", section 2.1.5 in this part .
Note that 3-dimensional shift and mirror image a re options.
User Parameters 2 - 7
2. 1. 1 Setting the Home Position
For details of the Home Stop function, see "The Home Stop Function", section 1.1.2.
in this part .
Setting the Home position
1. Place the cursor at "SPECIFIED
POINT HOLD". I.)
2. Press F1 (SETTING). * Press the function key to select
the way of setting:
F1 ... Sets by entering a joint coordinate value (an angle of each axis).
F2 ... Sets by entering a Base coordinate value.
F3 ... Sets by moving the mechanism, by manual manipulation,to a position you want to store. Note that the angle of each joint is stored.
F4 ... Sets by moving the mechanism, by manual manipulation,to a position you want to store. Note that the Base coordinate value is stored.
When F1 (AX NUM) is pressed
(1) If the system consists of
multiple mechanisms, the
screen looks like the one
shown on the right. e
2 - 8 User Parameters
AXIS ML4 TEACH
SERVO ON
SYSTEM 3/6 >SPECIFIED POINT HOLD MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER
-1 jpcEEi- piKL-E-1
( 2 ) Select the mechanism you
want to set. * (3) Select the joint by pressing [m] , and then press F1
(EDIT) to select ON or OFF.
(4) Enter the angle by numeric
keys.
When F2 (COR NUM) is pressed
(1) If the system consists of
multiple mechanisms, the screen
looks like the one shown on the
right. +
(2) Select the mechanism you
want t o set. * (3) Select the coordinate [a
L - ?
component by pressing / fil, and then press F1 (EDIT)
to select ON or OFF.
(4) Enter the coordinate value by
numeric keys.
When F3 (AXIS) o r F4 (CORDNAT) is pressed
(1) The screen similar to the one
shown on the right appears. I)
(2) Move each mechanism t o the
position/attitude you want to
store.
Even i f the system consists
multiple systems, pressing RECORD 0 allows you to store data of all
axes a t one time.
3. I f you want to store the data,
press L&A . If not, press RESET "0
User Parameters 2 - 9
2. '1.2 Setting the Work Enable Area (Soft L imi t )
For details, refer to " The Work Enable Area", section 1.1.3 in this part .
Setting the work enable area
1. Place the cursor a t "MOVABLE
AREA". *
2. Press F1 (SETTING). * If the system consists of
multiple mechanisms, the screen
looks like the one shown on the
right.
Select the mechanism you want
to set. *
3. Select the axis by pressing [a] and the upper/lower
limits by pressing [w] .
F1 (+/-) toggles between the
signs.
4. Set the value by numeric keys.
AXIS ML4 TEACH
SERVO ON
5. Press @ .
SYSTEM 3/6 SPECIFIED POINT HOLD
>MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER
2 - 1 0 User Parameters
[ M I /ROLL1mUP/
2. 1.3 Setting the Star t Enable Area For details, refer to "Automatic Operation", section 6.1 in part I, and "The
Reference Joint Angles for the Start Enable Area", section 1.1.4 in this part .
Setting the start enable area
Follow the setting procedure for the Work Enable Area.
2. 1.4 Registering Coordinate Systems It is possible to register up to 2 most often-used coordinate systems.
Once coordinate systems are registered, they are switched in the order of Axis - Coordinate System 1 + Coordinate System 2 + Axis each time
II Registering coordinate systems
1. Place the cursor a t "ENTRY OF
COODINATES" and press F1
(SETTING). * F1 ... The Base coordinate
system F2 . . . The Tool coordinate
system F3 ... The World coordinate
system F4 ... The Work coordinate
system F5 ... The Hand coordinate
system (at present, not available)
F5 . .. OFF
2. Move the cursor by
and select the coordinate system
by the function key.
3. Press @ .
User Parameters 2 - 1 1
2. 1. 5 Setting Conditions for 3-dimensional Shift and M i r r o r Image Shift
In order to execute the 3-dimensional shift o r mirror image shift, it is necessary to
set conditions.
For details of these functions, refer to the instruction manual "Options"
Important \
Remember that a triangle formed a t an extremely small length o r dimension ra te causes degradation of shift accuracy.
L J
Table 2.1. Triangle Dimensional Conditions
Settinn shift conditions - 1. Place the cursor at "SHIFT
CONDITIONS" and press F1
(SETTING). *
Setting Range
10 -- 200
1 -660
Item
Length of the smallest side [ mm 1
Smallest angle [ deg 1
2. Move the cursor by [m]
Default
100
20
and set a value by numeric keys.
Largest angle C deg I Dimensional ra te [ % 1
(See Table 2.1.)
3. Press RECORD 0
140
90
2 - 1 2 User Parameters
60 -- 180
1 -699
2.1.6 Setting the ABSO Data Check Function
For details of this feature, refer to "The ABSO Data Check Function", section 3.3 in
pa r t III.
Bll Setting the ABSO data check function
1. Place the cursor a t "FUNC OF
ABSO DATA CHECK". *
2. Press F1 (SETTING). Ilr)
F1 ... Selects ON o r OFF.
Changing the allowance.
(1) Place the cursor "SET
CAPACITY ". I.)
(2) Press F1 (SETTING). r)
(3) Select the axis by
(4) Set the value by numeric key.
EXT. MEMORY
3. Press @
User Parameters 2 - 1 3
2. 2 Setting the Teaching Box Keys
This section describes the parameters by page. [ 1 contains options and (
contains the default setting.
- Page 1/3
(1) External Control Input/Output ON/OFF key [ON/OFFI (OFF)
Not available.
(2) Sensor ON/OFF key [0N/OFFI
Not available.
(3) Weave ON/OFF key [ON/OFFl (ON)
When this setting is ON, weaving ON/OFF is determined by the AND condition
between the WELD ON/OFF state on the teaching box and the logical input state.
(4) Weld ON/OFF key [ON/OFFl
See (3).
(5) Manual welding ON/OFF [ON/OFFI
At present, not available.
(6) Teaching box [Standard/Advancedl (Standard)
Do not modify the setting a s it is preset according to the teaching box provided.
2 - 1 4 User Parameters
* Page 2/3
(1) Continuous Block key [ON/OFFl (ON)
Set the Block continue key on/off. For details of movement, see "Setting the Way of
Performing Block Operation", section 1.2.3 in this part.
(2) Automatic printer output [ON/OFF]
At present, not available.
(3) Special error output ON/OFF [ON/OFFl (OFF)
For details of this feature, see "Trouble Shooting", chapter 6 in part E.
(4) Deadman switch [ON/OFFl (OFF)
When you a re using the teaching box equipped with a deadman switch, set this
parameter ON. Note that Deadman switch is an option.
(5) CRT [ON/OFFl (OFF)
If you use CRT, set this parameter ON. Note that CRT is an option.
(6) Confirmation of terminating teaching [ON/OFF] (OFF)
For details of this feature, see "Confirmation of Terminating Teaching", section 1.2.2
in this part.
User Parameters 2 - 1 5
Page 3/3
(1) Sequence display by the special cursor [ON/OFFl (OFF)
For details of this feature, see "Cursor Indication of The Block Operation",
section 1.2.4 in this part .
AXIS ML4 TEACH
SERVO ON
(2) Sequence display during automatic operation [ON/OFF] (OFF)
For details of this feature, see "Sequence Display during Automatic Operation",
section 3.7.
TEACH PENDANT 3 / 3 >SPECIAL CURSOR DISP SEQ DISP. IN AUTO ENDLESS ROTATE
(3) Endless rotation [AUTO/MANUAL/OFFI
This feature is a n option.
/EDITJ p ? z r E i q l m l
2 - I 6 User Parameters
2. 3 Setting the Welding Parameters This section describes parameters contained on each page. [ ] contains options and
( 1 contains the default setting.
* Page 1/4
(1) Wire slowdown ra te (0%)
Set a feed ra te of the wire, which is fed until the a r c s tar ts , a t % of the maximum
current command value. Note that you do not need to set this parameter if your
welding power unit is equipped with the wire slowdown feature.
AXIS ML4 TEACH
SERVO ON
(2) Hot s t a r t r a t e ( 0 % )
The hot s t a r t feature applies a n excessive welding voltage for a given time to
generate the a r c smoothly a t the beginning of welding. Set a ra te to the rated voltage.
Note that you do not need to set this parameter if your welding power unit is equipped
with the hot s t a r t feature.
APPLICATION - - 1 / 4 >WIRE SLOW DOWN 0 % HOT START RATIO = 0 % HOT START TIME = 0.0s BURNBACK TIME = 0.0s BURNBACK VOLT. = 0.OV STRT ERR CHECK TIME= 1.0 S
(3) Hot s t a r t time (0 sec.)
Set a time fo r which hot s t a r t is performed. Note that you do not need to set this
parameter if your welding power unit is equipped with the hot s t a r t feature.
/ROLLDN//ROLLl
(4) Burn back time (0 sec.)
The burn back feature applies a given voltage to prevent the wire from depositing
onto the base metal a t the end of welding. Set a time for which burn back is performed.
Note that you do not need to set this parameter if your welding power unit is equipped
with the burn back feature.
(5) Burn back voltage (OV)
Set a voltage to apply for burn back. Note that you do not need to set this
parameter if your welding power unit is equipped with the burn back feature.
(6) Arc s t a r t failure detecting time (1.3 sec.)
Set a time required for OSACOM SUPER 8700 to detect a r c s t a r t failure. When the
a r c does not s t a r t within the set time, the wire is retracted a s recovery action from a r c
s t a r t failure ( a t a maximum of 3 times) s o that a r c s t a r t can be retried.
User Parameters 2 - 1 7
* Page 2/4
(1) Arc outage time (0.5 sec.)
Set a time required for OSACOM SUPER 8700 to detect an outage a rc condition
during welding.
A X I S ML4 TEACH
SERVOON
(2) High inching/retracting speeds (100%))
High inching/retracting speeds a re speeds for inching/retracing with holding
d o w n .
A P P L I C A T I O N 2/4 ARC D I S C O N T I N U I T Y = 0 . 5 s I N C W R E T R A C T (HIGH) = 1 0 0 % I N C W R E T R A C T (LOW) = 6% P R E F L O W T I M E
>WIRE S T I C K CHECK tjG WIRE RETRACT S P E E D = Om
Set each a t % of the maximum command value
[EDlTI lROLLDN//ROLL]
(3) Low inching/retracting speeds (6%)
Low inching/retracting speeds a r e speeds for inching/retracting without holding
down
Set each a t % of the maximum command value.
(4) Preflow time (0%)
Set a preflow time which is a flow time before the a rc starts .
(5) Wire stick check ON/OFF
Set wire stick check ON/OFF
(6) Wire retracting speed (Ocm)
This parameter is available only when TIG filler is used.
Set a retracting speed which is applied a t the end of welding.
Important > Be sure to set this parameter if you use TIG filler. Otherwise, the wire will not be retracted because the default is "0".
2 - 1 8 User Parameters
* Page 3/4
(1) The way of teaching welding conditions [Numeral/File] (Numeral)
Select whether welding conditions are set by directly entering numeric value o r
specifying files.
This parameter is available only a t the first teaching of welding conditions after the
control power is turned on. Thereafter, the information a t the time of teaching is
displayed as the initial setting.
(2) The way of teaching weaving conditions [Numeral/File]
At present, not available.
* Page 4/4
(1) WIF time out check [ON/OFFl
Normally set this parameter ON
(2) Arc timing adjustment
Do not change the setting.
(ON)
(0.0 s)
AXIS ML4 TEACH
SERVO ON
User Parameters 2 - 1 9
APPLICATION >WIX TIMEOUT CHECK ON & ARC TIMING ADJ. = 0.0s
IEDlT] ]--
2. 4 Setting the Parameters for External Control Signal Inputs/0utputs
This section describes the parameters by page. [ ] contains options and ( )
contains the default setting.
(1) Sequencer file number in use (1 (SQFI))
This parameter is set to display the sequencer file being currently in use.
The sequencer file is automatically set when updated. You cannot change it here.
AXIS ML4 TEACH
SERVO ON
(2) Execution of external control inputs [ON/OFFl (ON)
Define whether execution of external control inputs is enabled or disabled. When the
setting is OFF, any external control input instructions are not executed. Jump and call
instructions such a s JP , JF , and CL conditioned on waiting for inputs result in the
same effects a s those of unconditional jump and call, respectively.
EXT. INPUT/OUTPUT 1/2 SQ PRG. NUMBER 1 EXT. INPUT EXT. CONTROL 1/0 g;g
>INPUT LOGIC NORMAL OUTPUT LOGIC NORMAL NOP AUTO INPUT OFF
(3) Execution of external control outputs [ON/OFFl (ON)
Define whether execution of external control outputs enabled or disable.
When the setting is OFF, any external control output instructions a re not executed.
~ N O R M A L J I I N V E R S E J I O l F j l R O L L m
(4) Input logic [ Normal/Reverse/OFF I (OFF)
Define whether the external control input instructions (N and F ) should be executed
normally a s taught or reversely during backward block operation.
Normal : Executes the external control input instructions as taught.
Reverse : Executes the external control input instructions which a re logically
reverse to those taught.
OFF : Disables execution of the external control input instructions.
0 Important The setting of execution of external control input (2) overrides.
2 - 2 0 User Parameters
(5) Output logic [ Normal/Reverse/OFF 1 (OFF)
Define whether the external control output instructions (S and R) should be executed
norlnally a s taught or reversely during backward block operation.
Normal : Executes the external control output instructions a s taught.
Reverse : Executes the external control output instructions which a re logically
reverse to those taught.
OFF : Disables execution of the control output instructions.
@ Important I The setting of execution of external control output instructions (3) overrides.
(6) Automatic insertion of NOP [ ON/OFF I (ON)
Define whether or not NOP is automatically inserted when ON Wait instruction (N)
or OFF wait instruction (F) is taught.
User Parameters 2 - 2 1
2. 5 Setting on Motion Restrictions on Automatic Operation
This section describes the parameters by page. [ 1 contains options and ( )
contains the default setting.
* Page 1/1
LOW SPEEED AUTO ON LOW SPEEED RATIO ON
(1) Machine lock [ON/OFFl (OFF)
For details, see "Machine Lock", section 3.1 in this part.
(2) Dry run [ON/OFFl (OFF)
For details, see "Dry Run", section 3.2 in this part.
(3) Interpolating speed in the Weld OFF state
At preset, not available.
(4) Low-speed automatic operation [ON/OFFI (OFF)
For details, see "Low-speed Automatic Operation", section 3.3 in this part.
(5) Speed rate of low-speed automatic operation (15%)
Set a speed of (4) a t a rate to the maximum speed (%I.
2. 6 Setting the Sensor Type
Here, set the sensor type you use.
Page 11'1
(1) Sensor type [Not used/Super arc sensor or Weave arc sensor/Laser sensor/
TIG arc sensor] (Not used)
Select your parameter.
AXIS ML4 TEACH
SERVO ON
2 - 2 2 User Parameters
SETTING OF SENSOR 1/1 >USING SENSOR =
r F i T T E - I / ~ ~ ]
7 Setting Welding Characteristic Data The output current and voltage of a welding power unit are determined by a command
voltage given to the welding power unit. When the welding power unit is used in
combination with a robot, this command voltage is output from a welding interface,
which is equivalent to a terminal voltage of a remote box employed when a welding
power unit is independently used.
Because the relation between an output current, an output voltage, and a command
voltage varies according to types of welding power units, the robot needs information
about "what degree of command voltage should be output from the welding interface in
order to output the welding conditions set by teaching". This information is called
welding characteristic data.
Because welding characteristic data vary depending on each welding power unit and a
welding process, the actual output value may slightly differ from the setting. Also, in
order to use a welding power unit which is not a DAIHEN product, the user needs to
create such data.
The features covered in the following sections are used to modify and create welding
characteristic data.
The standard welding characteristic data are listed below:
Table 2.2. Kinds of Welding Characteristic Data
Wire 1. 0 1. 2 1. 6
Power Unit
The default setting is ; CPVAS-350CO2, wire diameter of 0.8mm.
If you use any welding power units (except ALMEGA FUZZY AUTO") other than the
units listed, create characteristic data (User Characteristic Data).
It is possible to create up to 60 data*2.
* 1: Refer to "Notes to Use ALMEGA FUZZY AUTO", section 2.7.4 in this part.
* 2: Refer to "Creating User Characteristic Data (User Registration)", section 2.7.3 in
this part.
User Parameters 2 - 2 3
2. 7. 1 Registering Welding Characteristic Data
To use or modify the standard welding characteristic data, be sure to register them
in accordance with the following procedure:
Important \
If you want to use a created Task program after modifying the welding power and wire diameter settings, delete the welding conditions (AS and AE) once and add them again.
\ I
Registering welding characteristic data
(W-CHARA). * 2. Select a welding power unit by
using screen 1
3. Select the wire diameter by
using
4. Press F1 (REGIST).
2.7.2 Modi fy ing Welding Characteristic Data
The welding conditions depend on various elements such a s the length of a primary
power cable and a wire extension. Therefore, the actual output value may slightly
differ from the setting. In this case, modify welding characteristic data to adjust the
output.
In addition, if an individual control type of welding power unit is used, the voltage
controlled by the automatic voltage control feature (which automatically displays the
voltage adjusted to the output current when AS is taught) is calculated based on
welding characteristic data. Therefore, if you want to change the voltage, modify the
welding characteristic data.
2 - 2 4 User Parameters
Modifying welding characteristic data
To modifying welding characteristic data, follow the steps below. After modifying
data, follow the procedure in section 2.7.1 to register
1. Select the type of welding power
unit a t screen 1 by using
2. Select the wire diameter by
using . <Individual control type >
3. Press F2 (MODIFY). *
<Synergic control type>
4. Select the control type of
welding power unit (Individual,
Synergic, or TIG) by using
5. Move the cursor by
enter the current and the rated
voltage.
User Parameters 2 - 2 5
6. Press @ . IEl) <Individual control type >
<Synergic control type>
A X I S ML4 TEACH
SERVO ON
7. Modify the data by [/I
D I S P . REF. D I S P REF. 1. 5 0 A 2 . 4 V 3.OV 2.OV 2. l O O A 5.OV 7.OV 4.OV 3. 1 5 0 A 8 .6V 10.OV 7.OV 4. 2 0 0 A 12 .OV 20.OV 10.OV 5. 3 0 0 A 1 4 . 3 V 2 5 . 0 V 12.OV
1 < > 1 and numeric keys.
8. Press @ .
9. When you have finished making
modifications, register the new
data in accordance with the
procedure in section 2.7.1.
2 - 2 6 User Parameters
2. 7.3 Creating User Welding Characteristic Data (User Registration)
For the use of any welding power unit other than those listed in table 2.2, it is
necessary to create user welding characteristic data. Registering up to 60 da ta is
possible.
Welding characteristic da ta as well a s welding condition files a r e stored in a file.
Though file numbers ranging from 1 through 99 a re provided, use 40 - 99 ( a maximum
of 60 numbers) to create use welding characteristic da ta because 1 - 39 a re dedicated
to the standard welding characteristic data.
This section describes how to create user welding characteristic data based on a n
example of the following welding characteristic data:
Control type of welding power unit: Individual
Rated current 3 5 0 A
Rated voltage 3 6 V
Current command Voltage command Current setting [A] Voltage setting [V]
value [Vl value [V]
Point 1 5 0 .0 0. 5
Point 2 1 0 0 . 0 1. 8
Point 3 1 5 0 .0 3. 5
Point 4 2 0 0 .0 5. 3
Point 5 2 5 0 .0 7 .8
BI Creating user welding characteristic data
1. Place the cursor a t "USER
REGISTER" on screen 1.
2. Enter any number of 40 - 99 by
using numeric keys.
The number you entered is a
register number of the user welding
cl~aracteristic data you a re creating.
User Parameters 2 - 2 7
AXIS ML3 TEACH
SERVO ON
POWER SOURCE WIRE CPVAS-3 5 0 COr 0.8 1.0 1.2 CPVAS-3 5 OMAG 0.8 1.0 1.2 CPVAS-5 0 0COz 1.0 1.2 1.6 CPVAS-5OOMAG 1.0 1.2 1.6 USER REGISTER
(REGIST//MODIFYI
3. Press F2 (MODIFY).
4. Set "Individual" control type of
welding unit, "350" rated current,
and "36" rated voltage, and press
RECORD . 0 *
The welding characteristic data
of CPVAS-350 COz 0.8mm will be
displayed.
Modify welding characteristic
data of point 1 through point 5 by
using numeric keys.
5. Af ter you modify, press RECORD . 0 Irr)
Now, the user welding
characteristic data have been
created.
To use the created data,
register them.
6. Press F4 (W-CHARA). * 7. Move the cursor to "USER
REGISTER" and enter the number
given to the created user welding
characteristic data.
8. Press F2 (REGIST).
Now, the user welding
characteristic data have been
registered.
2 - 2 8 User Parameters
AXIS ML4 TEACH
SERVO ON
RATING OF POWER SOURCE $WTBD 1 1
>TYPE SYNER TIG RATING CURRENT 350A RATING VOLT. 36.0V
PUSH RECORD AFTER SETTING
AXIS ML4 TEACH
SERVO ON
- >
DISP. REF. DISP. REF. 1. 50A 2.4V 3.OV 2.OV 2. lOOA 5.OV 7.OV 4.OV 3. 150A 8.6V 10.OV 7.OV 4. 200A 12.OV 20.OV 10.OV 5. 300A 14.3V 25.OV 13.OV
2.7.4 Notes to Use ALMEGA FUZZY AUTO
(1) Setting welding characteristic data
Regardless of the wire diameter and the kind of gas in use (C02/MAG), select
"CPVAS-350C02" or "CPVAS-350 MAGH.Then, select the control type of welding
power unit (Individual or Synergic).
Ensure that the setting of the welding condition control switch on the front panel
(@ if Fig.2.1.) matches the control type of welding power unit you selected.
Table 2.3 Settings for the control type of welding power unit
Setting of the Welding Condition Control Switch
Individual
(2) The front panel of ALMEGA FUZZY AUTO
The outside view of ALMEGA FUZZY AUTO is shown below:
Setting of the Welding Characteristic Data
SEP A
Synergic
Fuzzy synergic
Fig.2.1 The outside view of Front Panel
SYNER
SYNER
@ ... A welding current/voltage setting knob, effective only when the current/voltage
control switch is set a t "Panel".
User Parameters 2 - 2 9
@ ... A switch which switches between the front panel side and the robot side to
control the welding current and voltage. If you change the setting, turned off
ALMEGA FUZZY AUTO and turn it on again.
When the setting is "Panel", the welding current and voltage set by Arc Start
instruction AS are ignored, and welding is performed a t the welding current
and voltage set a t the panel side.
When the setting is "Robot", the welding current and voltage set a t the panel
side are ignored, and welding is performed a t the welding current and voltage
set by Arc Start instruction AS.
@ ... A switch which sets a welding process and a wire diameter, which are the
following:
Setting on Panel
1
2
3
4
5
6
7
8
Wire Material
Solid wire
Solid wire
Solid wire
Solid wire
Solid wire
Solid wire
Core wire
Core wire
Wire Diameter
0.9m
l.Om
1.2m
0.9m
1. om
1.2m
1.2m
1.4 m
Gas
coz coz C 0 2
MAG MAG MAG C 0 2
C 0 z
@ ... A switch which sets a control type of welding power unit, which includes
Individual, synergic, and Fuzzy synergic:
a. Individual
Sets a welding current and a welding voltage individually.
b. Synergic
Outputs a welding voltage adjusted to a welding current setting.
It is necessary to set a voltage adjustment in order to output an
optimum welding voltage.
c. Fuzzy synergic
Outputs a voltage optimum to the welding condition by simply setting a
welding current.
Be sure that the control type of welding power unit set by this switch
matches the control type setting in the welding characteristic data.
For details of other switches and errors output to ALMEGA FUZZY AUTO, see the
instruction manual for ALMEGA FUZZY AUTO.
2 - 3 0 User Parameters
2.7. 5 Notes to Use T IG Fi l l e r
For the use of a TIG filler, it is necessary to modify welding characteristic da ta and
set a wire retracting speed.
(1) Modifying Welding characteristic data
Enter a speed setting and a speed command value.
Select the characteristics data of point 1 through point 5 according to the rated
wire feed ra te from the following list:
Table 2.4. Welding characteristic da ta for TIG filler
(2) Setting a wire retracting speed
Set "WIRE RETRACT SPEED1'* in the welding parameters.
Setting (cm/min)
6
* : Refer to "Setting the Welding Parameters", section 2.3. in this part .
User Parameters 2 - 3 1
Output value ( V )
0. 7
Chapter 3 Appl icat ion Features and Funct ions Used f o r Automat ic Operat ion
This chapter describes application features and functions used for
automatic operation and how to operate them, including Machine
Lock, Dry Run, Low-speed Automatic Operation, and Path Function.
Contents
3.1 Maclline Lock 3- 1
3.2 D~~ R~~ ..................................................................................................................................................................... 3- 2
3 3 Lowespeed Automatic Operation 3- 6
3.4 Checking the Star t Enable Area during Automatic Operation 3- 8
3 5 'path Function 3- 8
3.6 Online Modification ....................................................................................................................................... 3- 10
3.7 Sequellce Display durillg Automatic Operation ......................................................................... 3- 11
3. Appl ica t ion Features and Funct ions Used f o r Au toma t i c Operat ion
3. 1 Machine Lock The Machine Lock function is used to lock all mechanisms connected with OSACOM
SUPER 8700.
This function allows the operator to run Task programs in the actual cycle time
without operating the mechanism or mechanisms in order to check whether external
control input/output instructions were correctly taught in the programs. It can be set
ON/OFF by modifying the setting of "MACHINE LOCK"* in the user parameters for
setting the system status.
The ON Setting make each mechanism in the system inoperative.
4 ~ a u t ~ o n s \
1 ) Teach mode In Teach mode all features and functions except those to move each mechanism
are available. However, there are some restrictions, which are: * In ON setting of the machine lock function, any mechanisms do not operate even
if manual manipulation or block operation is performed. If a Motion instruction such a s P, L, or C is taught, the interrally calculated data of the position will be stored, but not the present position, because the controller performs arithmetic operations.
* Though any mechanisms do not operate in block operation, the normal cycle time is required to run the system.
2 ) Auto mode In Auto mode all features and functions except those to move each mechanism are
available. However, there are some restrictions, which are: Because welding and sensor instructions are executed in the inoperative state of the mechanism(s), be sure to set WELD ON/OFF key OFF and SENSOR ON/OFF key OFF. If not, errors occur.
* If the Emergency Stop or Shock Sensor operates during automatic operation and the servo power is shut off, OSACOM SUPER 8700 makes a computation to restart the manipulator from the current position. Therefore, in this event, an additional time is required, compared with the normal cycle time.
L /
* : Refer to "Setting Motion Restrictions on Automatic Operation", section 2.5 in this part.
Application Features and Functions Used for Automatic Operation 3 - 1
The screen display when the machine lock setting is ON
When the machine lock setting is ON,
the status is displayed on the screen
and logical output (0320) is set ON.
rrc)
A X I S MH4 I ~ C H LOCK[
SERVO ON
J T E A C H I ~ J ~ I ~ ~ l >
3. 2 Dry Run The Dry Run function is used to stop execution of features and functions except
movements of the mechanism(s) in automatic operation. This function allows the
operator to check whether the mechanismh) can operate a s taught, without executing
other controls.
In dry run, the following functions are not active:
(1) External control inputs/outputs (OSACOM SUPER 8700 holds data of the
logical output ports.)
(2) Welding
(3) Sensor
(4) Timer
However, because this function is available only in automatic operation, external
control outputs/inputs, timer, etc. are executed in block operation.
The dry run function is set ON/OFF by modifying the setting of "DRY RUN" * in the
user parameters for setting the system status.
* : Refer to "Setting Motion Restrictions on Automatic Operation", section 2.5 in this part.
3 - 2 Application Features and Functions Used for Automatic Operation
When the dry run is set, during automatic operation some instructions a re available and some are not, which are listed below: Execution 0 * Execute
X * * Not execute
Table 3.1. Mechanism control instructions
I I I
L 0 Liner interpolation with rotation of I M o t i o n I attitude 0 / Motion / Uniform interpolation l o
Execution
0
0
Description
Positioning
Liner interpolation
Instruction
P
L
Type
Motion
Motion
C 1
C 2
co 1
co 2
H P
H L
H L O
Motion
Motion
Motion
H C
H O
Application Features and Functions Used for Automatic Operation 3 - 3
Motion
Motion
,Motion
H L X
N O P
T
WF P
W A X
WE
R T
Center point of Circular interpolation
End point of Circular interpolation
Center oint of Circular interpolation with roration of attitude End point of Circular interpolation with rotation of attitude
Motion
0
0
0
0
Synchronous positioning motion
Synclironous linear interpolation Synchronous linear interpolation with rotation of attitude
, Motion
Motion
Motion
Task
Task
Task
Task -
0
0
0
Synchronous circular interpolation Synchronous circular interpolation
0
with rotation of attitude Silnultaneous uniform interpolation
No operation
Waiting for Timer time
Starting pattern weaving
Starting axis weaving
Ending weaving
Caluculating rotated position
0
0
6,
x
0
0
0
0
Table 3.2. Program control instructions
-
J F
C L
PM
E N D
Execution
0
D E F
D E C
MP S
Table 3.3. Sensor instructions I I I
Description
Internal program jump
Instruction
J P
Motion
Motion
Motion
Motion
Instruction I Type 1 Description / Execution
Type
Motion
Task
Task
Motion
Motion
External program jump
Calling program
Point mark
Ending program
Ending multi-pass section
Specifying executing pass of task ~nstruction E P
0
0
0
0
Defining counter
Decremental operation of counter value
Starting multi-pass section
0 X Task
-
S F 0
S F 1
0
0
0
S F 2
Motion
Motion
--
S F 3
S F 5
T S E / Task / Ending high speed touch sensor 1 X
Motion
T S S
Table 3.4. Welding control instructions I I I
Detecting Wire extension
One-direction search
S T Task Starting tracking x
Task
Task
Instruction 1 Type / Description I Execution
X
x
Pattern search
E T
I I I
Task
X
Calling deviations
Storing deviation number in tracking
1 Task 1 Inch
Task
x
x
Starting high speed touch sensor
A S
A E
x
Ending tracking
Task
Task
-
R T C
G S
AEM
x
G E
A S M
I Task I Ending multi-pass welding 1
Arc s tar t
Arc end
Task
Task
- -- -- -
3 - 4 Application Features and Functions Used for Automatic Operation
X
x
Task
Task
Retract
Turning gas ON
x
x
Turning gas OFF
Starting multi-pass welding
x
x
Table 3.5. External control input/output instructions
N 1 Task 1 Waiting for external control input ON I X
Instruction 1 Type I Description
S
R
F 1 Task 1 Waiting for external control input 04 X
Execution
%Motion means Motion instruction, and Task means Task instruction.
Task
Task
$ Cautions 1 ) If this function is set ON, the mechanisms move in a condition that external
control input/output do not function. Therefore, if external control inputs/outputs
Setting external control output
Reseting external control output
are used to control the jig, etc., take care to avoid interference with peripheral
X
X
equipment. 2 ) The dry run setting is displayed on LCD of teaching box when the Auto mode is
entered. However, because that display disappears once automatic operation is activated, it is not possible to identify later whether the function is effective o r not.
II Display when the dry run is set
When the dry run setting is ON, logical output port (0321) is set on.
When Auto mode is entered, a
message to perform automatic
operation for "DRY RUN" appears
on the teaching box rr)
Application Features and Functions Used for Automatic Operation 3 - 5
3. 3 Low-speed Automatic Operation The Low-speed Automatic Operation is used to perform automatic operation a t a
limited speed of positioning movement. This feature allows the operator to check taught
da ta a t a safety speed. A limited speed can be specified a t any rate to the maximum
speed by setting the user parameter.
Note that this function is only available to limit a speed of positioning movement in
automatic operation and not to block operating speed and a speed of interpolating
movement.
The speed of positioning movement is limited a t the following sections:
(1) The travel distance to a point taught with Positioning instruction P or HP
(referred to a s Positioning distance in the following)
(2) The travel distance to a point taught with Point Mark instruction PM used to
execute Internal Program Jump instruction J P
(referred to a s Point Mark distance in the following)
(3) The travel distance to a sequence specified to execute the Path function* ' (referred to a s Travel distance for Path function in the following)
(4) The travel distance to a halting point for restarting
(referred to a s Travel distance for restarting in the following)
This function is set on/off by modifying the setting of "LOW SPEED AUTO" *'.
The speed is set in a parameter "LOW SPEED RATIO".
The normal speed of positioning movement in automatic operation includes the
following :
Table 3.6. Speeds of positioning movement
Positioning
Positioning distance
Speed
Speed taught
Point Mark distance
* 1 : Refer to "Path Function", section 3.5.
* 2 : Refer to "Setting Motion Restrictions in Automatic Operation", section 2.5.
* 3 : Refer to "Setting the System Status", section 2.1.
The setting of "SPEED TO PM""3 in
Travel distance for Path function
Travel distance for restarting
3 - 6 Application Features and Functions Used for Automatic Operation
the user parameters for setting the system status
When this function is set on, making a comparison between the above rate and the
low-speed setting, OSACOM SUPER 8700 uses a lower rate.
(Example]
. Speed to point Mark 609,' 0
. Low-speed rate .............................................................. 30 %
Table 3.7. Speeds a t Low-speed Automatic Operation ON/OFF
( * 4) The manipulator moves a t the normal speed rate which is less than the
1 ) P (100%) 2 ) P ( 50%)
3 ) P ( 20%)
4 P ( 10%) 5 ) Point Mark distance
6 ) Travel distance for Path function
7 ) Travel distance for restarting
speed rate of low-speed automatic operation.
Notes
( * 1) The manipulator moves a t the speed rate taught.
( * 2) The manipulator moves a t the speed rate set a s a travel speed to point mark.
( * 3) The manipulator moves a t the speed rate of Low-speed automatic operation which is less than the normal rate.
OFF setting
(normal)
100% ( * 1)
50% ( * 1)
20% ( * 1)
10% ( * 1)
60% ( * 2)
60% ( * 2)
60% ( * 2 )
1) The low-speed automatic operation setting is displayed when the Auto mode is entered. However, because that display disappears once automatic operation is activated, it is not possible to identify later whether the function is effective o r not.
2) Each of the low-speed automatic operation , machine lock, and dry run can be independently set. For example, when machine lock and low-speed automatic operation are set a t the same time, both functions become effective; all mechanisms are locked and the cycle time becomes longer.
ON setting
30% ( * 3)
30% ( * 3 )
20% ( * 4)
10% ( * 4)
30% ( * 3)
30% ( * 3)
30% ( * 3)
llIl Display when the dry run is set
When the low-speed automatic operation setting is ON, logical output port(0317) is set on. When Auto mode is entered, a message to perform low-speed automatic operation appear on the teaching box. *
Application Features and Functions Used for Automatic Operation 3 - 7
3. 4 Checking the Start Enable Area during Automatic Operation This feature allows the operator to check "within or outside the s tar t enable area"
during automatic operation. Depending on the attitude of the manipulator, the
specialized logical output (0264) and the LED of START ENABLE on the teaching box
a re switched ON/OFF. This feature is set on/off by modifying the setting of "START
ENABLE IN AUTO " *'.
Important If this feature is set on, movements which continuously change the attitude between within and outside the s tar t enable area may cause these definitions to be reverse. However, this reverse condition is removed when the job is complete o r the operation is halted.
3. 5 Path Function The Path function allows the operator to s tar t automatic operation from a desired
sequence. A sequence is specified in Teach mode. If this function is set to s tar t automatic
operation, a check on the s tar t enable is not made. Therefore, starting automatic
operation from any position is possible. The manipulator moves with Positioning to a
specified sequence. The speed is the setting of "SPEED TO PM"*2 in the user parameter
for setting the system status.
[Examplel)
1 2 3 4 5 6 7 8 -+ Sequence No.
P , P , L , A S , L , L , A E , P , P , E N D
We assume that the manipulator is a t the position of sequence 6 in Teach mode. If
you specify sequence 4 to perform automatic operation using the path function :
(1) The manipulator performs positioning movement from sequence 6 to sequence 4.
(2) If WELD ON, the manipulator starts welding from sequence 4 and moves to
sequence 5 by L.
@ Notes
The path function is automatically cancelled when any one of the following operations is performed:
After entered, Auto mode is changed to Teach mode without automatic operation being started. The function key for s tar t allocation is selected (if the multi-station system is in use). The function key assigned for file operation is selected. Another Task program but not the Task program where the path function is activated.
* A new Task program is created or a Task program is modified by entering a Task program number o r from the List screen. @ or @ is pressed after path is set.
\
* 1, * 2 : Refer to "Setting the System Status", section 2.1 in this part.
3 - 8 Application Features and Functions Used for Automatic Operation
Setting the path function
1. In Teach mode, move the cursor to
the sequence you want to start.
F4 ... Sets the s tar t sequence. F5 ... Sets the s tar t sequence and
then enters to the top layer of Teach mode.
2. Press F4 (PATH) or F5
(PATH AT).
The path function is set.
When F4 (PATH) is pressed
.I)
When F5 (PATH AT) is pressed
Irr)
3. Change to AUTO mode.
4. Press the Start button.
Automatic operation will s tar t
from the sequence where you have
set by the path function.
Application Features and Functions Used for Automatic Operation 3 - 9
@ Note \
The path function is set by pressing either F4 (PATH) or F5 (PATH AT). The function of F5 , which is in principle the same a s that of F4, simplifies
operations following setting of the path function. i J
3. 6 Online Modification The Online Modification is used to modify welding conditions (current, voltage, and
speed) during automatic operation through the teaching box.
Updated conditions are stored in the following conditions:
(1) When RECORD is pressed 0 In this case, online modification operation can be carried out.
(2) When F4 (END) is pressed
In this case, the online modification terminates.
(3) When the setting of "ONLINE AUTO SET"* in the user parameter for setting the
system status is ON and
The welding section terminates (AE), or
AS is executed to modify welding condition
@ Important If automatic operation is halted, modifications you have made so fa r are not stored.
Clll Performing on-line modification -
1. During automatic operation, when
execution comes to a welding
section, the current welding
conditions a re displayed. * 2. Press F2 (AS ONLN). *
* : Refer to "Setting the System Status", section 2.1 in this part.
3 - 1 0 Application Features and Functions Used for Automatic Operation
3. Select the welding condition
(current, voltage, or speed) you
want t o modify, by the function key.
If you press F4 (END), OSACOM
SUPER 8700 stores the current
welding condition and terminates
the online modification.
4. Press to modify to the
optimum condition.
Pressing a t the same time
when pressing [m causes the
increment/decrement to enlarge.
3. 7 Sequence Display during Automatic Operation This feature is available by setting "SEQ. DISP. IN AUTO1'* in the user parameters for
setting the system status.
If this feature is set off, taught conditions are displayed only
* In Welding section and weaving section,
* In Arc sensor tracking section, or
During waiting for external control input or for timer time
If the feature is set on, conditions of all instructions are displayed during automatic
operation a s well a s block operation.
(1(1 The sequence display durin
When the setting of "SEQ. DISP
AUTO" is on, the screen during
automatic operation looks like the
shown on the right:
one
111)
natic o~era t ion
* : Refer to "Setting Teaching Box Keys", section 2.2 in this part.
Application Features and Functions Used for Automatic Operation 3 - 1 1
Chapter 4 Sh i f t
is used to move positions stored in a Task I I program. This chapter describes the parallel shift and the cyli~ldrical 1 / sh i f t For details of other shift functions such as 3-dimensional shift, 1 / refer to the instruction manual "Options". 1
Contents
4. S h i f t The following 6 types of shift functions a re available:
Parallel shift
Cylindrical shift
* External Axis shift (option)
3-dimensional shift (option)
* Mirror shift (option)
* Scale up/-down shift (option)
I t is possible t o shift a limited range of positions by specifying sequence numbers in a
Task program.
There a r e two ways of entering a n amount of shift; Manual entry and Numerical entry:
Manual entry * a Enters an amount by moving the mechanism from the reference
position to a specified position by manual manipulation.
A difference between 2 points is a n amount of shift.
Numerical entry * a Enters a value by numeric keys.
@ Note \
If a value is entered af ter manual manipulation is performed, the travel distance from a taught point is set as a n amount of shift.
L 1
4. 1 Parallel Shift A position is shifted in parallel to the reference coordinate system by a specified
amount. The reference coordinate system is the coordinate system which was used to
teach the current sequence.
Instruction I P P P
[fill
Coordinate System 1 Base World Tool Work
Sequence
When the current sequence is 001, the reference coordinate system is Base.
When the current sequence is 002, the reference coordinate system is World.
When the current sequence is 001! the reference coordinate system is Tool.
When the current sequence is 002, the reference coordinate system is Work.
0 0 1 0 0 2 0 0 3 0 0 4
S h i f t 4 - 1
Teaching path
Fig.4.l Parallel Shift
4 - 2 Shift
4. 2 Cylindrical Shift
This shift causes the manipulator to rotate around Axis 1 by a specified amount.
Teaching path
Fig.4.2. Cylindrical Shift
Shift 4 - 3
Operating the shift function
1. Perform block operation to the
sequence which contains the
reference position. Irr)
2 . Press F3 (SHIFT). rr)
3. Select a shift type by
1-1 . The selected shift type
will be highlighted.
Shift methods, "EXTERNAL"
"3-DIMENTION", "MIRROR
IMAGE" and "MGC/RDCfl, a r e
options. To use them, optional
software needs to be set.
4. Press F1 (EXECUTE). * For shift e r rors and solutions,
refer to section 4.3.
5. To specify a shift range, position
the cursor a t the "SHIFT AREA",
and enter a sequence number of
each of a start point and an end
point by numeric keys.
AXIS MH3 TEACH PI23 SQ No.=1 3 2 SERVOON
WE 092 P 10096 BASE MI
>093 L 150cn1 BASE M1 AS ASCOC
094hC1 150m BASE MI 095hC2 150m BASE M1
AXIS ML4 TEACH P12 3 SQ Na=13 2 SERVO ON SHIFT
4 - 4 Shift
I I C X J j J!m!ml>
SELECT SHIFT METHOD PARAL LE L_I 3-DIMENTION
EXTERNAL MGC/RDC
TOOL MECHA COODINATES. MECHA 1 SHIFT
AXIS M L 4 TEACH P123 SQ No.=13 2 SERVO ON SHIFT
-1
SET SHIFT PARAMETER
>SFT AREA:093 TO 099 SFT VAL. 1-A NUMERAL
SFT MTHD -, PARALLEL TOOL MECHA COODINATES, MECHA 1 SHIFT
-1
If a shift range is not specified,
positions of all sequences are
shifted.
6. Position the cursor a t the "SFT
VAL." .
Specifying an amount by manual entry
(1) Highlight "MANUAL", and then
move the manipulator t o the
position you want.
Cartesian movement is suitable
for the parallel shift, and Axis
movement for the cylindrical shift.
(2) Press F1 (EXECUTE).
Then, shift will be started
S~ecifv ina an amount by numerical entry
(1) Highlight "NUMERAL" by
and then press F1 (EXECUTE).
Parallel shift .I)
Move the cursor by m], and enter an amount of shift (mm)
by numeric keys.
F1 (+/-) toggles between the
signs.
Shift 4 - 5
AXIS MH3 TEACH P123 SQ Na=132 SERVO ON SHIFT
NUMERAL SHIFT INPUT
> X DIRECT 0.0 ma Y DIRECT 0.0 am Z DIRECT 0.0 ma
/+//xmTq
Cylindrical shift * Enter an amount of shift
(rotating angle) of Axis 1 by
numeric keys.
F1 (+/-) toggles between the
signs.
(2) Press F2 (EXECUTE).
Then, shift will be started
7. During a shift process, the screen
looks like the one shown on the
right * The shift completed sequences is
displayed on the screen.
8. When a shift process for all
sequences is complete, OSACOM
SUPER 8700 returns to the original
screen (block operation).
If you press ~ I F Y immediately 0 after the shift finishes, you can
make the shift invalid. * F1 ... Makes the shift valid.
F2 ... Makes the shift in valid.
AXIS MH3 TEACH PI23 SQ No.=l 3 2 SERVO ON SHIFT
ENTER SHIFT ANGLE
AXIS ML4 TEACH P12 3 SQ % = I 3 2 SERVO ON SHIFT
4 - 6 Shift
]+/-JIEXECUTEI
SHIFTING
COMPLETED SEQUENCE 0 0 8
AXIS ML4 TEACH PI 2 3 SQ No.=l 3 2 SERVO ON SHIFT
P123 SHIFT COMPLETED
r t Y - ' - T I r n l
4. 3 Error Messages and Notes
(1) Message
SOFT LIMIT, SEQUENCE * * * SHIFT IMPOSSIBLE
or ,
LINK LIMIT, SEQUENCE * * * SHIFT IMPOSSIBLE.
Description
The position of sequence * * * shifted beyond the soft limit o r the link soft
limit.
Solution
Pressing F1 allows you to continue the shift process without shifting that
position. Pressing RESET allows you to cancel the shift process. When this e r ro r 0 -
occurs, reduce the amount and shift again.
(2) Message
DATA ERROR, SEQUENCE * * * SHIFT IMPOSSIBLE
Description
To perform the shift in a system consisting of multiple mechanisms, any of the
instructions(such as HP and HL) which have positional da ta of all the mechanisms
is required in the shift range of the program. The error message will appear if the
above condition does not exist.
Solution
After pressing ju;o;;;), place an instruction which has positional da ta of all the w
mechanisms, in the shift range, o r add an ilzstruction such as HP to the shift range,
and t ry the shift operation again.
(3) Message
CALC.ABNO., SEQUENCE * * * SHIFT IMPOSSIBLE.
Description
The position of sequence * * * shifted beyond the work enable area.
Solution
Pressing F1 allows you to continue the shift process without shifting that
position. Pressing RESET allows you to cancel the shift process. When this er ror 0 occurs, reduce the amount and shift again.
Shift 4 - 7
14) Message
SHIFT RANGE ERROR+-MODIFY
Description
The shift range setting is wrong. (e.g. The specified sequence may not exist.)
Solution
, check the shift range, and perform the shift operation again.
(5) Message
WRONG MECHANISM-tMODIFY
Description
The mechanism a t the current sequence, which was selected to shift, is wrong.
Solution
, perform block operation to the sequence of the manipulator, and
perform the shift operation again.
(6) Message
NO INSTRUCTION POINT.
Description
Tile shift function was selected a t the position of a Task instruction.
Solution
Press ~ I F Y , perform block operation to the sequence of the manipulator, and 0 perform the shift operation again.
(7) Only points that were taught with the same coordinate system as that used to teach
the current sequence a r e shifted. Points taught with other coordinate systems a r e not
shifted.
(8) In addition to a check on the point of each sequence whether its post-shift position is
within the soft limit, OSACOM SUPER 8700 makes a check for the following
instructions whether each point is on the path:
L, LO, C1, C2, C01, C02, HL, HLO, HO, SFO, and SF1
However, because all points on the path a r e not checked, during block operation, the
manipulator may stop due to outside the soft limit even if Shift e r ro r does not occur.
4 - 8 Shi f t
(9) If the following error condition exists, operation cannot be continued when outside
the soft limit occurs during a shift process. Correct the program s o that all positions
can be within the soft limit:
* The system has 2 manipulators.
* The task program contains any Synchronous Motion instruction.
* Outside the soft limit occurred a t a sequence before the shift s t a r t sequence.
(10) When all the following conditions exit, be sure to teach HP instruction a t the first
sequence, o r "DATA ERROR" will occur.
* The system has 2 manipulators.
* The task program contains any Synchronous Motion instruction.
The Shift base coordinate system is any other than the Base coordinate system.
(11) When the conditions described below exist, the movement may change (the wrist may
be upside down) after execution of Shift. Therefore, before running automatic
operation, check the path by block operation.
The system has 2 manipulators.
The instruction of the current sequence is HP.
* The shifted mechanism is the sub mechanism.
(12) Shifting a Task program which is mixed HP and P may cause the unexpected
sequences to shift.
Avoid the shift execution of a Task program which is mixed HP and P as far a s
possible.
If you perform the shift operation of the above Task program unavoidably, be sure to
check the movement by performing a block operation after shifting.
Shift 4 - 9
i
Management
k
Chapter 1 External Storage
This chapter describes the operating procedures for using an
external storage .
Contents
... 1 1 Connecting and Handling the External Storage ......................................................................... 1 - 1
1 . 2 Selecting Exterllal Storage Functions ............................................................................................... 1 - 2
1 . 3 Formatting Floppy Disks ........................................................................................................................... 1 - 4
1.4 Listing Files ........................................................................................................................................................... 1 - 5
1.5 Saving Files from the Controller to the External Storage ...................... ........ 1 - 6
1 5 2 Batch Saving ................................................................................................................................................. 1 - 9 . .
1 5 3 All Saving ......................................................................................................................................................... 1 . 11 . .
1.6 Loading Files from the External Storage to the Controller 1-13
1 . 6 . 1 ~ ~ d i ~ i d ~ ~ l ~ ~ ~ d i ~ ~ ~ 1 - 13
1 .6.2 ~ ~ t ~ h ~ ~ ~ d i ~ ~ 1-16
1 6 3 All Loading 1 - 19 . . 1 . 7 Comparillg Files 1-21
1 Externa l Storage ( tot ransferf i les)
To store (save) various files contained in the controller to floppy disk o r copy (load)
files into the controller, the user needs an external storage and floppy disks. As an
external storage, DAIHEN floppy disk storage (type E5777) is available. Alternatively, a
NEC o r IBM personal computer is configurable. (In this case, a software option PM-8700
and an interface cable are required to use a personal computer a s an external storage) If
you use the floppy disk storage, set "EXT. MEMORY""' to "FDD" in the user parameters
setting for the System Status.
Two floppy disks are required to make a system disk and a user disk. A system floppy
disk is used to store only the system parameters and a user floppy disk is used to store
files except the system parameters. To make these floppy disks, use the Format Floppy
Disk function. Two floppy disk types, 2HD (high density:1.2M) and 2DD (double density:
720K), a re available.
Specify your floppy disk type beforehand by setting "FD FORMAT TYPE"*2 in the user
parameters setting for the System Status.
r - 1) Some external storages may specify 2HD floppy disk. 2) Do not use floppy disks whose type is different from the user parameter
setting (2HD or 2DD). 3) Be sure to use the same type floppy disks. For example, the mixed use of 2HD
for User and 2DD for System is not allowed. 4) If the optional extended memory is equipped (If the storing area of the Task
programs is extended), the number of Task programs you have stored may cause the number of floppy disks which you must prepare to increase. The standard number of floppy disks you must prepare when saving all data which filled with the storing capacity will be one system floppy disk and two user floppy disks in case of 2HD, or three floppy disks in case of 2DD.
* 1, * 2 : Refer to "Setting the System Status", section 2.1 in part 11.
External Storage 1 - 1
1. 1 Connecting and Handling the External Storage For details of the procedure for connecting the floppy disk storage, refer to the
instruction manual "Controller".
( I ) Inserting a floppy disk
Insert a floppy disk with the label facing upward and the metal shutter facing
forward into the slot. When the floppy disk is inserted in place, the storage clicks and
the eject button slightly pops out.
/ Eject button
(2) Removing a floppy disk
To eject the floppy disk from the external storage, press the eject button. As part of
it comes out, take it out. Do not remove the floppy disk when accessing (loading o r
saving). Otherwise, the data on the disk may be erased.
1. 2 Selecting External Storage Functions The following functions are available to use an external storage:
(1) FORMAT Floppy Disk
Makes a floppy disk available for saving and loading with OSACOM SUPER 8700.
(2) LIST Files
Lists the files contained in the external storage.
(3) FILE Transfer
Saves files to floppy disk o r loads files to the controller.
The following three file transfer options are available:
* Individual transfer
Transfers individual files.
Batch transfer
Transfers a group of files.
* Entire transfer
Transfers all the files.
1 - 2 External Storage
(4) COMPARE Files
Checks whether the files stored with the same name in the controller and the external
storage a r e identical.
(5) DELETE Files
Deletes files.
A selection is made by pressing the relevant function key.
Selecting the External Storage function
1. Press [I>j F5 (MEMORY) at
the top layer of Teach Mode. .n)
Screen 1
2. Select the function you want, by
using the relevant key:
F1 ... Lists Files. (See section 1.4.)
F2 . .. Saves Files. (See section 1.5.)
F3 ... Loads Files. (See section 1.6.)
F4 ... Compares Files. (See section 1.7.)
F5 ... Deletes Files. (See section 1.8.) a F1 . . Formats Floppy Disk. (See section 1.3.)
External Storage 1 - 3
1. 3 Formatting Floppy Disks To store files to floppy disk, the operator needs to format a floppy disk. The floppy
disk type must be 2HD (high density: 1.2M) or 2DD (double density: 720K). To specify
you floppy type, set "FD FORMAT TYPE1'* in the user parameters setting for the
System Status.
Formatting allows you to create a user or system floppy disk but causes all the data
on the disk to be erased. Great care is therefore necessary to perform this operation.
Formatt ing a f loppy disk
1. Press, I> F1 (INITIAL) at U screen 1: *
F1 ... Formats a floppy disk into a user floppy disk.
F2 ... Formats a floppy disk into a system floppy disk.
2. Press F1 (USER) or F2
(SYSTEM). +
3. Insert a floppy disk into the
external storage and press F1
(EXECUTE). *
4. Press F1 (YES) to start
formatting.
If you do not want to format,
press F2 (NO) instead.
* : Refer t o "Setting the System Status", section 2.1 in par t I1
1 - 4 External Storage
TEACH
~ E R V O ,& EXT. MEMORY
INITIALIZATION FLOPPY DISK FORMAT SELECT KIND OF FLOPPY DISK
p - z - i - q ~
1. 4 Listing Files The List function allows the operator to list the files contained in the external storage
by type. The list includes file names and creation dates.
Listing Files
1. Press F1 (LIST) a t screen 1.
F1 ... Lists the Task programs.
F2 ... Lists the Welding Condition files.
F3 ... Lists the Weaving Condition files.
F4 . .. Lists the Sequencer files.
F5 ... Lists the Deviation Correction files.
@ ~1 . . Lists the Offset files. (Option)
F2 ... Lists the Laser Sensor files. (Option)
F3 .. . Lists the Search Pattern files. (Option)
2. Select the file type you want to
list, by using the function key. +
3. Insert a user floppy disk into the
external storage and press F1
(EXECUTE). II)
F1 .. . Moves one page up. (The display does not change a t the last page.)
F2 ... Moves one page back. (The display does not
change a t the first page.)
External Storage 1 - 5
1. 5 Saving Files from the Controller to the External Storage The Save function allows the operator to save files contained in the controller to the
external storage. If you use this function, compare the files later to check whether the
data have been accurately stored.
Note If the optional extended memory is equipped, the plural number of user floppy
I disk will might be required when saving Task programs or all data. In this case, give a number to these floppy disks in order. When loading the data, use these floppy disks in saving order.
L
Saving files
Press F2 (SAVE) a t screen 1. * F1 . . . Specifies Individual saving.
(See 1.5.1.) F2 ... Specifies Batch saving.
(See 1.5.2.) F3 ... Specifies All saving.
(See 1.5.3.)
1.5.1 Individual Saving
To save individual files to the external storage, follow the steps below.
Depending on the file type you specify, you may not be able to save files individually.
For details, see "Restrictions on File Transfer" section 1.9
Bill Saving an individual f i l e
Press F1 (SEPA.). * F1 ... Saves a Task Program
file. F2 ... Saves a Welding
Condition file. F3 ... Saves a Weaving
Condition file. F4 ... Saves a Sequencer file. F5 ... Saves a Deviation
Correction file.(Option)
1 - 6 External Storage
F1 ... Saves an Offset file. (Option)
F2 ... Saves a Laser Sensor file. (Option)
F3 .. . Saves a Welding Characteristic Data file
F4 . . . Saves a Search Pattern file. (Option)
2. Select the file type by using the
function key. I)
3. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). 119
If you selected Welding
Condition file or Weaving
Condition file, specify the
Condition file type by using the
function key:
The screen d is~ laved when vou have
selected Welding Condition file
F1 ... Saves an Arc Start Condition file.
F2 ... Saves an Arc End Condition file.
F3 ... Not used. F4 ... Not used.
The screen displayed when you have
selected Weaving Condition file II)
F1 ... Saves a Fixed Pattern Weaving file.
F2 ... Not used. F3 ... Not used. F4 ... Saves an Axis Weaving file. F5 ... Not used.
TEACH
[SERVO OFF/ EXT. MEMORY
External Storage 1 - 7
SAVE CONTROLLER+EXT.MEMORY
ENTER F I L E NUMBER TRANSMITTING A S C --
TEACH
1 sew0 ~ F F I EXT. MEMORY
p - - - F q ~ ~ C J 1 A ~ ~ ]
SAVE CONTROLLER-EXT. MEMORY
ENTER F I L E NUMBER. TRANSMITTING WAX --
p T T - - q J w \ p i l W \ ~ \ ~
4. Type the file number by using
numeric keys. *
5. Press F1 (EXECUTE) to save
the specified file.
If the specified file does not
exists in the controller, a message
" NO FILE." is displayed. *
In this case, press MODIFY to 0 enter the correct file number.
If a file with the same name
already exists in the external
storage, a message "SAME FILE
EXISTS. " is displayed. * In this case, select by the
function key whether you want to
overwrite o r not:
F1 ... Overwrites. F2 ... Does not overwrite
TEACH
]SERVO OFF( EXT. MEMORY
1 - 8 External Storage
SAVE CONTROLLER-.EXT. MEMORY
ENTER F I L E NUMBER TRANSMITTING WAX 0 1
TEACH
SERVO O P F ~
-1
SAVE CONTROLLER-tEXT.MEMORY
ENTER F I L E NUMBER TRANSMITTING PO 0 1
NO F I L E +MOD I FY
1. 5. 2 Batch Saving
To save a batch of files by file type to the external storage, follow the steps below.
Depending on the file type you specify, you may not be able to save a batch of files.
F o r details, see "Restrictions on File Transfer" section 1.9.
0 Notes \
If you want to save the Welding Characteristic files, select batch saving of the
User Parameter files. They will be saved all together. \ 1
H Saving a Batch of Files
Press F2
F1 ...
F2 ..
(ALL). * . Saves all the Task Program files.
. Saves all the Welding Condition files.
F 3 ... Saves all the Weaving Condition files.
F4 ... Saves all the Sequencer files.
F5 ... Saves all the Deviation Correction files. (Option)
@ F1 ... Saves all the Offset files. (Option)
F2 ... Saves all the Laser Sensor files. (Option)
F3 .. . Saves all the User Parameter files.
F4 ... Saves all the System Parameter files.
F5 ... Saves all the Search Pattern files. (Option)
2. Select the file type by using the
function key. * F1 . . . Confirms overwriting
during transfer. F2 ... Enforces overwriting
without confirmation.
External Storage 1 - 9
@ Note
Even if you select batch saving of the User Parameter files, you cannot save the following parameters to the external storage:
The attitude movement The home stop function The work enable area The s tar t enable area The offset adjustment
* The tool parameters If you want to save these parameters, select batch saving of the System Parameter files.
\
3. Select by the function key
whether you want to confirm
overwriting or not when a file
with the same name already exists
in the external storage. * 4. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). * If you selected batch saving of
the System Parameter files a t step 2, insert a system floppy disk instead.
5. Press F1 (EXECUTE) to execute
batch saving of the files you
selected.
If the optional extended memory
is equipped, batch saving will stop
when the user floppy disk will be
full while executing to save Task
programs. *
1 - 1 0 External Storage
AXIS ML4 TEACH
SERVO ON EXT. MEMORY
SAVE CONTROLLER-EXT. MEMORY
SET NEXT USER DISK AND PUSH F 1 KEY.
[ E E i i q
In this case, insert the second user
floppy disk into the external
storage and press F l (execute).
Then, task programs which have
not been saved will be transfered.
6 . I f you pressed F1 (EXECUTE)
a t step 3, then OSACOM SUPER
8700 requests you to confirm
overwriting when a file with the
same name already exists in the
external storage: * F1 ... Overwrites. F2 ... Does not overwrite.
1.5.3 All Saving
To save all the files to the external storage, follow the steps below
) Important 1) Before you save all the files, be sure to format a floppy disk. If you save all
the files to a floppy disk which contains a file o r files, the file o r the files on the disk will remain (without being erased). Besides, if a file with the same name already exists, such file will be enforcedly overwritten without confirmation. That is, after this saving operation, the files in the controller may not match the files on the disk.In this case, error occurs later when you compare the files.
2) If the optional extended memory is equipped, only Task programs are written for the second user floppy disk when saving all data. The files (Welding condition files, o r Sequencer files, etc. except Task programs) written for the user floppy disk are saved for the first user floppy disk altogether.
L
Saving all the files -
1. Press F3 (BACKUP). I.)
External Storage 1 - 1 1
2. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). *
3. Press F1 (EXECUTE) to save
all the files except the System
Parameter files. *
If the optional extended memory
is equipped, all saving will stop
when the user floppy disk will be
full while executing to save Task
programs. * In this case, insert the second user
floppy disk into the external
storage and press Fl (execute).
Then, task programs which have
not been saved will be transfered.
4. Press the RESET key when the 0 transfer of all the files except the
System Parameter files is
complete. * 5. Replace the floppy disk with a
System floppy disk and press F1
(EXECUTE). *
6. Press the RESET key when the 0 transfer of the System Parameter
files is complete.
1 - 1 2 External Storage
1. 6 Loading Files f rom the External Storage to the Controller The Load function allows the operator to load files contained in the external storage to
the controller. If you use the function, compare the files later whether the data have been
accurately transferred.
III Loading Files
1. Press F3 (LOAD) a t screen 1.
F1 . . . Specifies Individual loading.(See 1.5.1.)
F2 ... Specifies Batch loading (See 1.5.2.)
F3 ... Specifies All loading. (See 1.5.3.)
I . 6.1 Individual Loading
To load individual files to the controller, follow the steps below.
As mentioned in the section for Individual Saving, depending on the file type you
specify, you may not be able to load files individually.
TEACH
LSERVU OFFJ EXT. MEMORY
10 Loading a n individual file
LOAD EXT.MEMORY-+CONTROLLER
SELECT F I L E TRANSMISSION WAY
1. Press F1 (SEPA.). * F1 ... Loads a Task
Program file. F2 ... Loads a Welding
Condition file. F3 ... Loads a Weaving
Condition file. F4 ... Loads a Sequencer file. F5 ... Loads a Deviation
Correction file. (Option)
FI ... Loads an Offset file. (Option)
F2 ... Loads a Laser Sensor file. (Option)
F3 ... Loads a Welding Characteristic Data file.
F4 ... Loads a Search Pattern file. (Option)
[mIam
External Storage 1 - 1 3
2. Select the file type by using the
function key. rzl)
3. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). * If you selected Welding
Condition file or Weaving
Condition file, specify the
Condition file type:
The screen displayed when you
selected Welding Condition file * F1 ... Loads an Arc Start
Condition file. F2 .. . Loads an Arc End Condition
file. F3 ... Not used. F4 ... Not used.
The screen displayed when you
TEACH
1 SERVO O.FF( EXT. MEMORY
selected Weaving Condition file * F1 ... Loads a Fixed Pattern
Weaving file. F2 ... Not used. F3 ... Not used. F4 ... Loads a Axis Weaving file. F5 ... Not used.
LOAD EXT.MEMORY-tCONTROLLER
S E T U S E R D I S K AND P U S H F 1 KEY
4. Type the file number by using
pi%GKq
numeric keys. Irrl,
1 - 1 4 External Storage
TEACH
[SERVO OF^ EXT. MEMORY
LOAD EXT. MEMORY-.CONTROLLER
ENTER F I L E NUMBER T R A N S M I T T I N G P O 0 1
JEXECUTEI
5 . Press F1 (EXECUTE) t o load
t he specif ied f i le.
If the specified file does not
exists in the external storage, a
message "NO FILE." is displayed.
.I)
In this case, press m I F Y to 0 enter the correct file number.
If a file with the same name
already exists in the controller,
a message "SAME FILE EXISTS. "
is displayed. +
In this case, select by the
function key whether you want to
overwrite o r not:
F1 ... Overwrites. F2 ... Does not overwrite.
External Storage 1 - 1 5
I . 6.2 Batch Loading
To load a batch of files by type to the controller, follow the steps below.
As mentioned in the section for Batch Saving, depending on the file type you specify,
you may not be able to load a batch of files.
Loading a batch of files
1. Press F2 (ALL) . * F1 ... Loads all the Task
Program files. F2 ... Loads all the Welding
Condition files. F3 ... Loads all the Weaving
Condition files. F4 ... Loads all the Sequencer
files. F5 ... Loads all the Deviation
Correction files. (Option) 1 . Loads all the Offset files.
(Option) F2 ... Loads all the Laser
Sensor files. (Option) F3 . .. Loads all the User
Parameter files. F4 ... Loads all the System
Parameter files. F5 ... Loads all the Search
Pattern files. (Option)
2. Select the file type by using the
function key. + F1 ... Confirms overwriting
during transfer. F2 ... Enforces overwriting
without confirmation.
1 - 1 6 External Storage
Note Even if you select batch loading of the User Parameter files, you cannot load the following parameters to the controller:
* The attitude movement The home stop function
* The work enable a rea - The s t a r t enable a rea The offset adjustment
* The tool parameters If you want to load these parameters, select batch loading of the System Parameter files.
3. Select whether you want to
confirm overwriting or not when
a file with the same name already
exists in the controller. * 4. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). I.)
If you selected batch loading of
the System Parameter files a t step
2, insert a system floppy disk
instead.
5. Press Fl (EXECUTE) to execute
batch loading of the files you
selected.
If the optional extended memory
is equipped, OSACOM SUPER
8700 requests you to confirm
loading the second floppy disk
when finishing the loading files in
first user floppy disk while
executing to load all Task
programs. I)
External Storage 1 - 1 7
In this case, select by function key
whether loading files in the second
user floppy disk o r not.
F1 Loading files in the second user floppy disk.
F2 Ending batch loading.
I f you select Fl(YES), insert the
second user floppy disk into the
external storage, and then operate
the loading.
6 . I f you pressed F1 (EXECUTE)
at step 3, then OSACOM SUPER
8700 requests you to confirm
overwriting when a file with the
same name already exists in the
controller. * F1 ... Overwrites. F2 ... Does not overwrite.
1 - 1 8 External Storage
1.6.3 Al l Loading
To load all the files to the external storage, follows the steps below:
Loadincl all files v
1. Press F3 (BACKUP). .r).
1
i
2. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). I)
3. Press F1 (EXECUTE) to load all
the files except the System
Parameter files. rrrr)
If the optional extended memory
is equipped, OSACOM SUPER
8700 requests you to confirm
loading the second floppy disk
when finishing the loading files in
first user floppy disk while
executing to load all Task
programs. LI)
In this case, select by function key
whether loading files in the second
user floppy disk o r not.
F1 ... Loading files in the second user floppy disk.
F2 Loading system floppy disk.
External Storage 1 - 1 9
F1 (Y ES) is selected
Insert the second user floppy
disk into the external storage,
and then operate the loading.
FZ(N0) is selected
Proceed t o operation 5.
4. Press the RESET key when the 0 transfer of all the files except the
System Parameter files is
complete. * 5. Replace the floppy disk with a
system floppy disk and press F1
(EXECUTE). I>r).
6. Press the RESET key when the 0 transfer of the System Parameter
files is complete.
0 Important \
I If a file with the same name already exists in the controller, such file will be enforcedly overwritten by loading all the files.
1 - 2 0 External Storage
1. 7 Comparing Files The Compare function allows the operator to check whether the files which exist under
the same name in the controller and the external storage a re identical.
When the files do not match, an error message "VERIFIED ERROR." is displayed.
This error may be caused by the following:
(1) You did not compare the files immediately after saving to a floppy disk.
Be sure to compare the files immediately after saving.
(2) Saving was not properly executed due to:
(a) Imperfect connecting condition of the cable
(b) Degradation of the floppy disk
Comparing Files Press F4 (VERIFY) a t screen 1
F1 . . . Specifies Individual comparison. (See 1.5.1.)
F2 ... Specifies Batch comparison (See 1.5.2.)
F3 ... Specifies All comparison. (See 1.5.3.)
1.7. 1 Individual Comparison
To compare individual files, follow the steps below. As mentioned in the section for
Individual saving, depending on the file type you specify, you may not be able to
compare the files.
Comparing individual files
1. Press F1 (SEPA.). r$
F1 ... Compares Task Program files.
F2 ... Compares Welding Condition files.
F3 ... Compares Weaving Condition files.
F4 ... Compares Sequencer files.
F5 ... Compares Deviation Correction files. (Option)
F l ... Compares Offset files. (Option)
External Storage 1 - 2 I
F2 ... Compares Laser Sensor files. (Option)
F3 ... Compares Welding Characteristic Data files.
F4 ... Compares Search Pattern files. (Option)
2. Select the file type by using the
function key. *
3. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). *
If you selected Welding
Condition file o r Weaving
Condition file, specify a Condition
file type.
The screen displayed when you
selected Welding Condition file
F1 ... Compares Arc Star t Condition files.
F2 .. . Compares Arc End Condition files.
F3 ... Not used. F4 ... Not used.
The screen displayed when you
selected Weaving Condition file * F1 ... Compares Fixed Pattern
Weaving files. F2 ... Not used. F3 ... Not used. F4 ... Compares Axis Weaving
files. F5 ... Not used.
1 - 2 2 External Storage
TEACH
~SERVO OFF~ EXT. MEMORY
FILE VERIFY
ENTER FILE NUMBER VERIFYING FILE WAX --
[ ~ P / / W l ~ C l ~ ]
4. Type the file number by using
numeric keys. Ir)
5. Press F1 (EXECUTE) to
compare the specified files.
If the specified files do not
match, a message "VERIFIED
ERROR. " is displayed. Ir)
If only the comment in the Task
program is different, a message
"COMMENT VERIFIED ERROR. "
is displayed. Ilr$
In this case, press ~ I F Y to
enter a file number. 0
External Storage 1 - 2 3
1.7.2 BatchComparison
To compare a batch of files by type, follow the steps below. As mentioned in the
section for Batch Saving, depending on the file type you specify, you may not be able
to compare batch of files.
Comparing a batch of files
1. Press F2 (ALL). * F1 ... Compares all the Task
Program files. F2 ... Compares all the
Welding Condition files.
F3 ... Compares all the Weaving Condition files.
F4 ... Compares all the Sequencer files.
F5 ... Compares all the Deviation Correction files. (Option)
F1 ... Compares all the Offset files. (Option)
F2 ... Compares all the Laser Sensor files. (Option)
F3 ... Compares all the User Parameter files.
F4 ... Compares all the System Parameter files.
F5 .. . Compares all the Search Pattern files. (Option)
2. Select the fi le type by using the
function key. *
1 - 2 4 External Storage
) Note Even if you select batch comparison of the User Parameter files, you cannot
compare the following parameters:
* The attitude movement
* The home stop function
The work enable a rea
The s t a r t enable a rea
* The offset adjustment
* The tool parameters
If you want to compare these parameters, select Batch Comparison of the
System Parameter files.
3. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). II)
If you selected Batch
Comparison of the System
Parameter files a t step 2, insert a
system floppy disk instead.
4. Press F1 (EXECUTE) to execute
batch comparison of the files you
selected.
If the files do not match, a
message "VERIFIED ERROR " is
displayed. rr)
To cancel the comparison,
press the RESET key 0 * To execute the next
comparison, press the m I F Y
key instead. 0
TEACH
SERVO C~FF] EXT. MEMORY
External Storage 1 - 2 5
FILE VERIFY
ALL TASK PROGRAM VERIFY
TEACH
r s ~ a v o OFFI EXT. MEMORY
/-tEiEq
FILE VERIFY
ALL TASK PROGRAM VERIFY VERIFYING FILE PO01
VERIFIED ERROR ->RESET
If the optional extended memory
is equipped, OSACOM SUPER
8700 requests you to confirm
comparing the second floppy disk
when finishing the comparing files
in first user floppy disk while
executing to compare all Task pro
grams. * In this case, select by function key
whether comparing files in the
second user floppy disk o r not.
F1 ... Comparing files in the second user floppy disk.
F2 Ending batch comparison.
I f you select FI(YES), insert the
second user floppy disk into the
external storage, and then operate
the loading.
1 - 2 6 External Storage
1.7.3 All Comparison
To compare all the files, follow the steps below:
III Comparing all the files
1. Press F3 (BACKUP). .I)
2. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). I.)
3. Press F1 (EXECUTE) to
compare all the files except the
System Parameter files. I.)
If the optional extended memory
is equipped, OSACOM SUPER
8700 requests you to confirm
comparing the second floppy disk
when finishing file comparison in
first user floppy disk while
executing to compare all Task
programs. * In this case, select by function key
whether comparing files in the
second user floppy disk o r not.
F1 -.. Comparing files in the second user floppy disk.
F2 Comparing system floppy disk.
External Storage 1 - 2 7
F1 (YES) is selected
Insert the second user floppy
disk into the external storage,
and then operate the file
comparison.
F2 (NO) is selected
Proceed to operation 5.
4. Press the RESET key when the 0 comparison of all the files except
the System Parameter files is
complete. *
5. Replace the floppy disk with a
system floppy disk and press F1
(EXECUTE). +
6. Press the RESET key when the 0 comparison of the System
Parameter files is complete.
If the files do not match, a
message "VERIFIED ERROR" is
displayed. * * To cancel the comparison,
press the RESET key. 0 To execute the next
comparison, press the ~ I F Y 0 key instead.
1 - 2 8 External Storage
1. 8 Deleting Files The Delete function allows the operator to delete a specified file.
OSACOM SUPER 8700 requests you to confirm the deletion before execution.
Deleting Files
1. Press F5 (DEL. ) a t screen 1.
F1 ... Deletes a Task Program file.
F2 . .. Deletes a Welding Condition file.
F3 ... Deletes a Weaving Condition file.
F4 ... Deletes a Sequencer file. F5 ... Deletes a Deviation
Correction file. (option)
F2 .. . Deletes a Laser Sensor file. (Option)
F3 ... Deletes a Search Pattern file. (Option)
2. Select the fi le type by using the
function key. Ilb
3. Insert a user floppy disk into the
external storage and press F1
(CONFIRM). *
If you selected Welding Condition
file or Weaving Condition file,
specify a Condition file type.
TEACH
SERVO UFF( EXT. MEMORY
External Storage 1 - 2 9
FILE DELETION
SPECIFY FILE TYPE
TEACH
LSERVQ OF^ EXT. MEMORY
[-I JWEpExvFDJJWEAVEIISQmm\ >
FILE DELETION
ENTER FILE NUMBER DELETING FILE P --
The screen displayed when you
selected Welding Condition file
F1 ... Deletes an Arc Star t Condition file.
F2 ... Deletes a n Arc End Condition file.
F3 ... Not used. F4 ... Not used.
The screen displayed when you
selected Weaving Condition file +
F1 ... Deletes a Fixed Pattern Weaving file.
F2 ... Not used. F3 ... Not used. F4 ... Deletes a n Axis Weaving file. F5 ... Not used.
4. Type the file number by using
numeric keys. *
5. Press F1 (EXECUTE) to delete the
specified file.
If you want to cancel the deletion,
press the RESET instead. 0
1 - 3 0 External Storage
TEACH
SERVO OF^ EXT. MEMORY
FILE DELETION
ENTER FILE NUMBER DELETING FILE ASC --
j - ' i rFqCJJAmm
1 . 9 Restrictions on File Transfer Depending on the file types, some functions a re not available. For details, see the list
below:
1 File Transfer I I I Verify
File Type
0 : Operable, X : Inoperable
Task program
Welding Condition file Weaving Condition file
Lasor Sensor file
Sequencer file
Offset file
Deviation Correction file Search Pattern file User Parameter file
System Parameter file Welding
* : Represents a figure
0 Note 1
File Name
p * * * ASC* *, AEC* * ASM* *, AEM* * W A X * * , W F P * *
SRF *
SQF *
The files relating to manual speeds and s tar t allocation a r e transferred only when all the files a re transferred. (Neither Individual nor Batch transfer is applicable.) Therefore, even if all the files in the list a re transferred by specifying Batcli transfer, the result is different from that given by All.
External Storage 1 - 3 1
x x o o o 0
List
0
Backup
0
0
0
0
0
0 0
Sepa.
0 0
0
Characteristic file
x o o x x x o o
0
0
All
0 0
0
0 0
0 0
OFS * *
DEV * * *
SF2M * *
USEMAIN etc.
# * * * - * * *
$ WTBD * *
Delete
0
0 0
0 0
0 0
X O O
0 0 0 0 0
Backup
0
0
0
0
0
0 0 0 0
0 0 0 0
x x x o o
Sepa.
0 0 0 0
0 0 0 0
0
0 0 0 0
0 0 0 0
0
0
0
All
0
I. 10 Error Messages fo r External Storage If an error is encountered, follow table 1.1 to take action:
Table 1.1. Error Messages and Solutions
Be sure to overwrite when asked
-
Error Message
WRITTEN DATA ERROR
+MODIFY
+RESET / disconnected, or the / external storage, or set
Description
The data saved to floppy
disk are broken.
UNIT IS NOT READY
1 external storage you use is 1 "EXT MEMORY" in the user
Solution
Press M O D l ~ ~ -+ F2 (END) and 0 save the file again.
The external storage is Press RESET to connect the 0
different from setting of
"EXT MEMORY" in the I
+MODIFY / save any file.
parameters to the enternal
storage you use.
FLOPPY DISK FULL w
place a new floppy disk in the
external storage.
Save files after formatting the
user parameters.
The disk has no space to
1 I floppy disk.
Press -> F2 (END) and
DISK CAN NOT BE USED
+MODIFY
I external storage. I place a floppy disk.
FD IS NOT READY
+MODIFY
The disk type, 2HD or 2DD,
is wrong.
Replace with a 2HD or 2DD type
disk, or change the format type
External storage is OFF, or
no floppy disk is in the
NO FILE
+MODIFY
WRONG FD I The floppy disk in use is 1 Use a floppy disk formatted for
setting in the user parameters.
Press ~ I F Y - -+ F2 (END) and 0 turn on the external storage o r
SAME FILE EXISTS.
+MODIFY
The specified file does not
exist.
1 - 3 2 External Storage
Type a file number again.
A file with the same name
already exists a t destination.
+RESET
Select to overwrite o r not to
overwrite when asked.
wrong. I User (or System).
Error Message
MEMORY OVER
-+MODIFY
READ/WRITE ERROR
-+MODIFY
CANCEL WRITE PROTECT
-MODIFY
FD SYS ERROR (Error NO.)
Description
There is no room in the
memory of controller to
load files.
The floppy disk is broken.
The floppy disk is write
protected.
Error occurred during data
transfer between controller
and external storage.
Solution
Press WIFY -+ F2 (END) and 0 cancel the operation.
Press -+ F2 (END) and w place another floppy disk in the
external storage.
Press WIFY -+ F2 (END) and 0 move the notch to remove write
protection.
When loading, press WIFY +F2
(END) to load again. 0
When saving, refer to the
solutions on the following pages.
External Storage 1 - 3 3
1 . I 1 Others 1.11. 1 Handling Floppy Disks
(1) No matter how often you use floppy disks, be sure to store them in a case.
(2) Use and store floppy disks in a dust free atmosphere.
(3) Touching the magnetic face may cause degradation in performance of the magnetic
medium and the data on the disk to be destroyed. So, do not touch it.
(4) Never place the floppy disk near magnetic devices. Magnetic fields can destroy the
data on the disk.
(5) Bending and dropping the floppy disk, and putting a heavy load on it may damage
the magnetic medium.
(6) Do not expose floppy disks to an abrupt change in the environmental condition.
When the environmental condition has abruptly changed, leave them for several
hours in the new condition before you use.
1 .I 1.2 Notes on External Storage (I) Do not turn on/off the external storage when it contains a floppy disk. Otherwise,
the data on the disk may be destroyed. (Take care also when you turn on the
controller on/off because the receptacle on the side of the controller is interlocked
with the power supply of the controller.)
(2) After saving a program or programs to floppy disk, check whether the data have
been correctly stored. You can make a data check by comparing the file in the
controller and the file on the floppy disk (which is called file comparison). Make a
file comparison immediately after saving a file or files.
(3) The OSACOM SUPER 8700 files are incompatible with OSACOM 6800.
Therefore, implement floppy disk management for each controller.
(4) Task programs stored in the external storage can be used with the PC Editing
System, which is an software option. However, floppy disks formatted by a personal
computer cannot be used with the external storage. If used, a error message
"WRONG FD" is displayed. Be sure to format a floppy disk with the external
storage.
1 - 3 4 External Storage
Chapter 2 Password
To prevent malfunction of the system caused by accidental
nlodifications, access to some specific operations is restricted by a I / password.
1 This chapter describes how to enter a password and how to set a I user defined password.
Contents
2. Password Misoperation in setting system parameters or initializing the memory may make the
system inoperable or causes the data on the disk to be erased. Because the functions
provided for such operations are to be used by the system management and maintenance
personnel, and DAIHEN servicemen, access to them is restricted by a password. A
password must be a number of 4 digits using0 - 9. If the wrong password is entered, these
functions are not available.
2. 1 Entering the Password A password is required:
* To modifying system parameters - To initializing the memory
* To editing a Sequencer file
When you perform these operations, enter your password.
II1 Entering the password
1. When the function which
requires a password is activated,
OSACOM SUPER 8700 waits for the
password to be entered. * 2. Type the password number of 4
digits by using numeric keys.
3. Press RECORD to enter the number. 0 You can press the following keys ins
tead:
~ I F Y to correct the number you 0 entered.
RESET to cancel the password 0 entry
If the wrong password is entered,
a message "WRONG PASSWORD."
is displayed. .r)
Press W I F Y to enter the correct
number. 0
Password 2 - 1
2. 2 Setting the Password The password can be changed to a desired number. The default setting is 0000.
If you change the setting, do not tell anyone except system management and
maintenance personnel. Be sure to remember the password because it cannot be loaded.
There is no way of recovering it.
Setting the password m
1. Press 1 [>I F3 (MANAGE) at the
top layer of Teach mode. *
2. Press F1 (PASWORD).
3. Type the password number by
using numeric keys.
4. Press @ .
You can press the following keys I
before pressing R E C ~ R D . I
0 0
~ I F Y to correct the number you
entered.
RESET to cancel the password 0 setting.
2 - 2 Password
If you set the wrong password, a
Press W I F Y to enter the correct 0
message "WRONG PASSWORD" is
displayed. *
password.
I WRONG PASSWORD. +MOD I FY
5. Type the new password by using
numeric keys.
r'\
6. Press mm~ to change to the new
number. 0
You can press the following keys
before pressing RECORD .
0 0 ~ I F Y to correct the number you
entered.
RESET to cancel the password 0 setting.
Password 2 - 3
Chapter 3 Absolute Of fse t
1 This chapter describes how to adjust a difference between the
1 position of the manipulator and the position detected by the
1 encoders. The operations covered in this chapter must be performed 1 when the manipulator is installed or mechanical parts a re replaced.
Contents
Absolute Of fse t An absolute encoder is fixed to each motor to detect the position of the manipulator.
When the manipulator is assembled, the attitude computed from the values of the encoders
does not coincide with the actual attitude. As the difference between these attitudes varies
from manipulator to manipulator, it must be computed and set as the absolute offset.
This chapter describes the procedures for setting a n absolute offset and also for
resetting the encoders, which is required prior to that operation.
d lVuLe \
Perform the absolute offset setting operation only on the following occasions:
* When the manipulator is installed
* When any of the following errors occurs
A 11102-XXXX A 11103-XXXX A B S M I S M A T C H ABS D A T A O U T
A 10503-XX00 A 50601-XXXX A B S BATTERY ABSO ERROR
When the encoder is replaced o r the connector is disconnected from the encoder
* When the connector is disconnected from the control cable between the controller and the manipulator
\
3. 1 Resetting the Encoders and Setting an Absolute Offset Be sure to reset the encoders before you set a n absolute offset.
Otherwise, "A 11103-0000 (Outside the ABS range.)" occurs.
Resetting the encoders and setting an absolute offset 1. Move the mechanism by manual
manipulation to align the alignment
marks of each axis.
F4 (SYS.SET) at the
top layer of Teach mode. .r)
A X I S ML4 TEACH
SERVO ON
>
Absolute Offset 3 - 1
3. F2 (RESTART), F3 (MASTRNG),
and F4 (CONTROL) a re to be used
by DAIHEN servicemen only.
Therefore, do not use them.
4. Press F1 (ABSO).
5. Press ~1 (ABS RST). +
6. To reset the encoders, press F1
(CONFIRM). The servo power is
then turned off.
If you want to cancel the resetting
operation, press RESET instead. 0 7. When the encoders have been reset,
you cannot perform any operation.
*
8. Turn on the control power again.
Then, "A 50601-0000 (ABSO
ERROR) " occur. 4
Press RESET to clear each Alarm. 0
3 - 2 Absolute Offset
9. Press
10. Press F1 (ABSO). I)
Select the mechanism by the
function key:
F1 ... Sets ABSO for Mechanism 1. F2 . Sets ABSO for Mechanism 2. F3 ... Sets ABSO for Mechanism 3. F4 ... Sets ABSO for Mechanism 4. F5 ... Sets ABSO for Mechanism 5.
11. When you have selected the
mechanism, the screen looks like
the one shown on the right. * Move the selected mechanism by
manual manipulation to align the
alignment marks of each axis.
(See section 3.2.)
12. Press F l (CONFIRM). Then,
OSACOM SUPER 8700 starts
arithmetic operation to compute the
absolute offset. * If you want to cancel the setting
operation, press RESET instead. 0 13. When the arithmetic operation is
complete, the margin of each axis
is displayed. .I)
Each margin is adjusted to be
around 50.
Absolute Offset 3 - 3
AXIS ML4 TEACH
SERVO ON
MARGIN VALUES OF EACH AXIS. MECHA 1 1 4 9 2 5 0 3 5 0 4 5 1 5 5 1 6 5 1
r F - - K - q m j
When each margin is around 50
Push F1 (END) to terminate the
absolute offset setting operation.
When each margin is 100, 200, or
inappropriate value.
As the absolute offset values a r e not
correct, you must set then again.
(1) Push F2 (RETRY). +
(2) Push F1 (CONFIRM). * Select the mechanism by the
function key, and be sure to
perform a n absolute offset setting
operation.
AXIS ML4 TEACH
SERVO ON
Important \
Each margin is adjusted around 50. Be sure to set absolute offset setting again in the following cases.
ABSO OFFSET IS NOT SET. SET ABSO OFFSET AGAIN.
AXIS ML4 TEACH
SERVO ON
When each margin is too fa r from the optimum value: Improper values may have been set.
~~/
ABSO OFFSET SETTING SELECT MECHANISM
* When each margin is 100 o r 200 :
The absolute offset has not been computed. L J
pz?x-q/MECH211NIECH.Im]~5/ >
3 - 4 Absolute Offset
3. 2 Axis Alignment Marks on the Manipulator Axis alignment marks on the manipulator (G series/V series) a re shown below:
Axis alignment
Axis 2 nment marks
Axis 1 alignment marks
Axis ignment
Axis 5 alignment marks
The aligned manipulator The aligned manipulator (Top)
Fig.3.1 Axis alignment marks (ALMEGA G series)
Axis 4 alignment marks ma.
Axis alignment
Axis 3 5 gnment marks marks
. . - Axis 6 Axls Z
alignment marks nment marks
Axis 1 1 I I alignment marks w
Fig.3.2 Axis Alignment Marks (ALMEGA V series)
Absoluteoffset 3 - 5
3. 3 The ABSO Data Check Feature OSACOM SUPER 8700 check a positioning error by making a comparison between the
ABSO data (values of the encoders) given before and after the servo power is turned on.
If the positioning difference exceeds the allowance setting in the user parameters,
OSACOM SUPER 8700 identifies it a s an positioning error and displays ABSO data
error (Failure code: A11102).
This feature is set on/off by changing the setting of "FUNC OF ABSO DATA
CHECK"" in the user parameters for setting the system status.
You can manually move the axes of manipulator which are not equipped with a brake,
when the servo power is OFF. Therefore, if the manipulator is manually moved beyond
the allowance, ABSO data error occurs even if a positioning error is not encountered.
Also, depending on the attitudes of the wrist axes, the manipulator may voluntarily move
when the servo power state is changed from ON to OFF, or if the allowance is too small.
Solutions to recover f rom ABSO data error
(1) Run Task program P999 by block operation to check whether the position
coincides with the absolute offset position.
(2) If these positions coincide, you do not need to take action further.
(3) If not, reset the encoders and set the absolute offset.
0 Note - When the control power is shut off and turned on again, the encoder values may vary, but this is not identified a s an error.
* : Refer to "Setting the System Status" in part 11.
3 - 6 Absolute Offset
Chapter 4 In i t ia l iz ing the System
This chapter describes how to initialize the system parameters and
user parameters, etc.
Note that misoperation of the Initialize function may make the
robot system inoperable.
4. In i t i a l i z ing the System The Initialize function is use to erase various files, such a s Task programs, Welding
Characteristic Data files and user parameters, from the memory medium or restore the
default settings. This function causes the number of Task programs to be 0 and the user
defined settings to be replaced with the default settings. Therefore, it should be used only
by DAIHEN servicemen and the robot maintenance personnel.
The password must be entered to use this function.
The Initialize function is used for the following operations:
(1) Initializing all data
All the stored Task programs and Condition files a re erased to restore the default
settings in the following files which are necessary to operate a single manipulator unit
(floor mounting type):
System Parameter file
Sequencer file
User parameters file
Welding Characteristic Data file
Start allocations
* Manual speed table
* Block operating speed table
* Arc Sensor file (option)
0 Important 1 ) Initialization of all data causes all the Task programs and Condition files to be
erased. Therefore, before you perform this operation, backup all of your files
by using an external storage.
2 ) If initialization of all data is executed, OSACOM SUPER 8700 asks whether you
still want to use the installed option(s) or not. If you a re using any option, be
sure to select "YES". Otherwise, the option(s) will not be available.
3 ) Be sure to set an absolute offset after initialization of all data.
4 ) Even if initialization of all data is executed, any Laser Sensor file is not
initialized. Therefore, if you initialize all data after initialization of the Laser
Sensor file(s), the default settings in the Laser Sensor file are erased. (That is,
your defined settings remain unchanged.) For this reason, initialize the Laser
Sensor file(s) after initializing all data.
Ini t ial izing the System 4 - 1
(2) Formatting
The Format function is used to erase the following files from the controller:
* All files
Files except Task programs
* Task programs
Important >
If you format, OSACOM SUPER 8700 asks whether you still want to use the installed option(s) or not. If you want to use, be sure to select "YES". Otherwise, the option(s) will not be available.
\ J
(3) Initializing the Welding Characteristic Data files
It is possible to create 12 types of Welding Characteristic data*. If you initialize,
CPVAS-350 COz/0.8ma will be automatically set.
@ Important x
Initialization causes the User Welding Characteristic data to be erased. If you do not want to erase the data, store them by using an external storage.
L J
(4) Creating the Sequencer file
A default Sequencer file corresponding to any one of the following starting systems
is created:
* Multi-station system (up to 3 stations)
* Multi-station system (up to 6 stations)
Direct program entry system (BCD code entry)
* Direct program entry system (Binary code entry)
For details of the default Sequencer file, see the instruction manual "Interface with
Jig".
- -
* : Refer to "Setting Welding Characteristic Data ", section 2.7 in part 11.
4 - 2 Init ial izing the System
(5) Creating the System Parameter file
The system parameters necessary for the following single manipulator unit are
created:
If your system consists of the above overhead or wall mounting manipulator, load
the special parameters described in (6) from the external storage.
(6) Loading the special parameters
The data necessary for any system other than those in (5) are created by
transferring from the external storage.
(7) Initialize the User Parameter file
The user parameter settings are replaced with the default settings. For these default
settings, see "User Parameters", chapter 2 in part II.
(8) Setting the calender
The date and time when a file is created are set. To set the date, enter the year with
2 lower digits, month, and day. To set the time, enter the hours (24-hour clock) and
minutes.
(9) Initializing the manual speed table
The speeds for manual manipulation are initialized.
(lo) Initializing the Arc Sensor file
The data necessary to use Arc Sersor are created
61) Initializing the Laser Sensor file
The data necessary to use the laser sensor are created,
(12) Initializing the s tar t allocation
The Task program numbers allocated to stations 1 - 6 are initialized to perform
automatic operation by the multi-station system. The default settings a re the following:
Ini t ial izing the System 4 - 3
Table 4.1. The default settings for s tar t allocation
Station No. / Task Program No
(13) Initializing the block operating speed table
The block operating speeds are initialized.
Init ial izing the system
1. Turn on the control power. *
2. press and at the same
time while screen 1 is displayed for 3
seconds. +
3. Enter the password. * F1 ... Initializes all data. F2 ... Formats. F3 ... Initializes the Welding
Characteristic Data file. F4 ... Initializes the Sequencer
file. F5 ... Initializes the User
Parameter file.
4 - 4 Init ial izing the System
F1 ... Sets the calender. F2 ... Initializes the System
Parameter file. F3 ... Initializes the s tar t
allocation. F4 ... Initializes the manual
speed table. F5 ... Loads the special
parameters.
F1 ... Initializes the Arc Sensor file.
F2 ... Initializes the Laser Sensor file (option).
F3 ... Edits the user parameters.
F4 ... Edits the system parameters. (To make adjustments only. Do not use it.)
F5 ... Upgrades the version. (To make adjustments
only. Do not use it.)
F1 ... Initializes the block operating speed table.
4. Select the file o r files you want to
initialize by the function key.
5. Depending on the initializing
operation you selected, OSACOM
SUPER 8700 asks questions shown
in table 4.2.
After you answer, press F1
(CONFIRM) to execute the
initialization.
Initializing the System 4 - 5
If you select any initializing
operation other than those shown in
table 4.2, you will not be asked.
Table 4.2. Q,uestions of Initialization
I All files
Initializing Operation Selected
Files except Task programs
Task programs only
Question
Files to be erased
F2 (FORMAT) Select the files by the function key.
WTo use the option(s) o r not
Yes
No
Select Yes o r No by the function key.
MStarting system
Multi-station system (up to 3 stations)
Multi-station system (up to 6 stations)
Direct program entry system (BCD code entry)
Direct program entry system (Binary code entry)
Select the starting system by the function key.
F1 (DATE)
F2 (SYSTEM)
mDate and time
Enter the current date and time by numeric keys.
MManipulator type
Select the type by the function key.
All of these 5 questions
F1 (ALL DAT) I / Select each by the function key.
4 - 6 Initializing the System
Chapter 5 Insta l l ing OSACOM SUPER 8700 So f twa re Opt ions
This chapter describes how to install OSACOM SUPER 8700
software options.
Contents
5. Insta l l ing OSACOM SUPER 8700 So f tware Options OSACOM SUPER 8700 software options are provided to use the following functions:
. Synchromotion
External axis shift
- Multi - pass welding
Endless rotation
Super a rc sensor
* Welding monitor
* PC external storage (PM-8700)
* 3-dimensional shift, Mirror image shift, and Size-up/-down shift
Installation of a software option allows the operator to store the files related to the
optional function to the controller. However, these files cannot be saved to floppy disk
from the controller. Care should be taken to handle the option setup floppy disks.
5. 1 Installing Software Options This section describes how to install OSACOM SUPER 8700 software option by using
the option setup floppy disk.
In order to use an optional function, installation of the relevant software option is
necessary. If the robot system including any software option is purchased, installation of
the option is done by DAIHEN before delivery so that the optional function can be
directly used. (The user does not need to install the software option.) On the other hand,
if any software option is individually purchased after installation of the robot system,
the user needs to install it in accordance with the instructions provided here.
A floppy disk (called an option setup floppy disk) is provided for the use of software
option, which contains one software option. The user needs an external storage to install
it.
Option setup floppy disk contains the available software option and the manufacturing
number of controller, and can be used only with the specified controller.
lns ta l l ing OSACOM SUPER 8700 Sof tware Opt ions 5 - 1
Installing the option software
1. Connect the external storage.
F4 (SYS.SET) a t the
top layer of Teach mode. *
4. Press F1 (SET).
5. Place the option setup floppy disk
into the external storage and press
F1 (EXECUTE).
The option cannot be installed if
any of the following operating
errors occurs.
In such event, press RESET to 0 clear the er ror , so you will be able
to continue the installation.
I f you are using the option setup
floppy disk which has been already
used with another controller:
I f the option has been already
installed and you are still using the
option setup disk specified for
another controller: * 2 Installing OSACOM SUPER 8700 Software Options
A X I S MH1 TEACH
SERVO ON
MISMATCHED CONTROLLER+RESET
I f you are using a floppy disk
which is not option setup floppy
disk: .14
5. 2 Listing Installed Software Options This section describes how to list the software option o r options installed in the
controller.
Listing the instal led software option or options
1. Press F4 (SYS.SET) at the
top layer of Teach mode. .$
2. Press F1 (OPTION). *
3. Press F2 (LIST)
Installing OSACOM SUPER 8700 Software Options 5 - 3
5. 3 Deleting Installed Software Options
This section describes how to delete software options installed in the controller.
Deleting the instal led software option
1, Press @ F4 (SYS.SET) at the
top layer of Teach mode. * A X I S MH1 TEACH
SERVO ON
p i ' - F G Y I l R E S T A R T l r n I r n ] >
2. Press F1 (OPTION).
3. Press F5 (DELETE). * The installed software option or
options will be listed.
4. Highlight the software option you
want to delete by a n d [ g l .
and press F1 (EXECUTE).
The highlighted software option
will be deleted.
If you want to cancel the deletion, - press instead.
5 - 4 Installing OSACOM SUPER 8700 Software Options
Chapter 6 Troubleshooting
Contents
6. 1 Symptoms ................................................................................................................................................................. 6 . 15
6.1.1 NotlIing Appears on the Teaching Box ................................................................................... 6-15
6.1.2 ~l~~ ~ i ~ ~ l ~ ~ on the hi^^ B~~ I~ ullsteady ................................................................ 6-16
6.1.3 Initial Diagllosis Is Not Completed 6-17
6 1 . 4 The Servo power Supply Callnot Be Turned ON ............................................................ 6-20
......... 6.1.5 The Servo Power Supply I s Shut OFF Immediately When Turned ON 6-21
6 . 1 . 6 Manual Manipulation Does Not Function ........................................................................... 6-22
6.2 A ~ ~ i l ~ ~ ~ code and A ~ ~ i l ~ ~ ~ ),fessage A~~ ~ i ~ ~ l ~ ~ ~ d 6-23
6.2.1 The Display of A Failure .................................................................................................................... 6-23
6 2 2 Logical Outputs for Failures 6 -26 . .
6.2 3 Shocli Sensor ................................................................................................................................................ 6-27
6 2.4 Servo power Sllutoff 6 -28
6.2.5 Software Limit / Link Software Limit 6-29
6.2.6 Overrun 6 - 31
6.2.7 CommLlnication Failures 6-32
6 . 2 . 8 Data Installation Failures 6-34
6 . 2 . 9 Memory FailLlres ....................................................................................................................................... 6-36
6.2 10 Setting Errors .............................................................................................................................................. 6-37
6 2 11 ABSO Data Failure .................................................................................................................................. 6-39 . .
6.3 Whell Servo Failure Occurred .................................................................................................................. 6-40
6 3.1 'flow To See the Servo Failure Display 6-40
6.3.2 Troubleshooting for Servo Failures 6-46
6. Troubleshoot ing This chapter describes solutions for failures that may occur during operations of the robot.
Failures a r e mainly divided into 3 groups according to the symptoms :
Where the servo power supply cannot be turned on, nothing appears on the teaching
box, etc. (see Table 6.1.)
* Where a failure code and a failure message a re highlighted (See Table 6.2.)
Where a failure message except the above is displayed (See Table 6.3)
These failures a r e listed in Table 6.1 through Table 6.3. When a failure occurred, refer to
them to find a solution. If you need replace par ts such as boards, contact DAIHEN.
Table 6.1. Symptoms
box. I
Symptoms
Nothing appears on the teaching
T h e display on the teaching box I For details, see section 6.1.2.
Solution
For details, see section 6.1.1.
is unsteady. I Initial diagnosis is not completed. 1 For details. see section 6.1.3
The servo power supply is shut For details, see section 6.1.5.
The servo power supply cannot
be turned on. For details, see section 6.1.4
function. I
off immediately when turned on.
Manual manipulation does not
Troubleshooting 6 - 1
For details, see section 6.1.6.
Table 6.2. Failure Codes and Messages
SHOCK-S ERR -.RESET
For details, see section 6.2.4
Solution Pull the Emergency Stop button (or cancel the emergency stop signal) and press SERVO ON button. For details, see section 6.2.3.
Code / Message EA00101-XXXX EMERGENCSTOP -.RELEASE EA00201 -XXXX
the torch interfered.
EA0040 1 -XXXX SERVO DOWN +RESET
Cause The Emergency Stop button o r emergency stop signal was entered. During automatic operation
I) The servo power was shut off due to an unidentified cause.
2) The hand was released from the deadman switch.
NO ASC FILE -. RESET
EA10201 -XXXX WIF TIMEOUT + RESET
EA50101-XXXX
EA50101-XXXX NO AEC FILE -+ RESET EA50102-XXXX NO WFP FILE + RESET EA50102-XXXX NO WAX FILE
RESET EA50103-XXXX NO ASM FILE -. RESET
Communication trouble between Welding Interface and 1 /0 management board during welding. The specified Arc Start
EA50103-XXXX NO AEM FILE -. RESET EA50104-XXXX NO OFS FILE -. RESET
After pressing the RESET key, turn on the SERVO POWER and restart. If not recovered, turn the CONTROL POWER off and on again. Create an Arc Start Condition file.
EA50105-XXXX NO CL PRG. -. RESET
I Condition file does not exist.
The specified Fixed Patterned Weaving
The specified Arc End Condition file does not exist.
Create a Fixed Patterned Weaving Condition file.
Create an Arc End Condition file.
The specified Multi-pass Welding Start file does not
Condition file does not exist. The specified Axis Weaving Condition file does exist.
I exist.
Create an Axis Weaving Condition file.
The specified Multi-pass Welding End file does not exist.
Create a Multi-pass Welding Start file.
Create a Multi-pass Welding End file.
The specified Offset Condition file does not exist
There is no Task program to call.
Create an Offset Condition file.
Create a Task program to call.
Create a Task program to jump to. EA50106-XXXX NO JF PRG. + RESET
6 - 2 Troubleshooting
There is no Task program to jump to.
Code / Message EA50107-XXXX NO PM + RESET EA50110-XXXX C1 TEACH ERR -+ RESET EA50111 -XXXX C2 TEACH ERR -> RESET EA50112-XXXX
COORD.ERROR + RESET
EA50113-XXXX SAME POINT C -, RESET EA50114-XXXX I/O TIMER -+ RESET
EA50120-XXXX CALL NESTING OVER +RESET EA50201 -XXXX S.LIMIT * * * * -, RESET EA50202-XXXX LNKS.LIMITM * -, RESET EA50301-XXXX NO PROGRAM -+ RESET EA50302-XXXX NO PROGRAM -, RESET EA50303-XXXX NO PROGRAM I -+ RESET EA50401-XXXX ON TIME OUT -+ RESET EA50402-XXXX OFF TIME OUT -+ RESET
Cause There is no point mark to jump to.
There is no reference point for the former half of a circular arc. There is no reference point for the latter half of a circular arc. Teaching of the target/ reference points for an circular arc in the different coordinate systems. The target and reference points for a circular arc are the same. The number of time counts exceeded 9.
The nest has overflown due to program calls.
The robot has reached the software limit.
The robot has reached the link software limit.
The Task program assigned to the station does not exist.
The Task program with the number entered does not exist. Task program No. has not been entered into the port specified. No ON input within the specified monitoring time.
No OFF input within the specified monitoring time.
Solution Add a Point Mark instruction.
A circular arc is formed by 3 points. Add a reference point.
A circular arc is formed by 3 points. Add a reference point.
Teach all 3 points in the same coordinate system to form a circular arc.
Teach again to form a circular arc.
The max. number of timers that can count time a t one time during automatic operation is 9. Check the setting time of each instruction of S, R, N, and F. Calling in the call destination program is possible but limited to the maximum 4 layers. Check the the program. For details, see section 6.2.5.
Check the s tar t allocation and assign the correct Task program number.
Enter the correct Task program number.
Enter a Task program number
Check the input status of the external control signals and the teaching data
Troubleshooting 6 - 3
Code / Message ELA50701-XXXX OPTION ERROR -+ RESET EAA50702-XXXS OPTION ERROR -+ RESET EA50704-XXXX OPTION ERROR -. RESET EA50705-XXXX OPTION ERROR -.. RESET EA50706-XXXX OPTION ERROR -+ RESET EA50708-XXXX OPTION ERROR
RESET EA50709-XXXX OPTION ERROR -+ RESET EB00301 -XXXX OVER RUN -+ RESET EB10404-XXXX CALC. IMPOS. -.. RESET
EB10710-00XX DATA ERROR -> RESET EC10206-XXXX COMUCTN ERR +POWER OFF
Cause The software for 3ynchromotion has l o t been installed. The software for Multipass Welding has not been installed. The software for External Axis Shift has not been installed. The software for welding monitor has not been installed. The software for PM8700 has not been installed.
The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. The manipulator overran.
1) A positioning instruction P is taught base on Work or Tool coordinate system in the synchromotion system.
2) The panipulator is unable to move a t a position on the path taught with a Linear o r Circular interpolation instruction.
The Task program contains a damaged instruction.
Communication between boards cannot be made correctly.
Solution
:f you want to use the optional function, ?urchase its optional software. Press the RESET key to continue the
For details, see section 6.2.6.
1) Modify the relevant instruction P to a
synchromotion instruction HP, o r t ry teaching based on the Base o r World coordinate system again.
2) Correct the taught positions(start/end points). If the manipulator is unable to move, correct the position d a t a of the relevant instruction in search mode o r by using the PC editing svstem.
Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, see section 6.2.7.
6 - 4 Troubleshooting
Cause Solution Code / Message EC10208-XXXX COM. ERR +POWER OFF
I/O management board or For details. see section 6.2.7 teaching box failure.
EC10209-XXXX DPRAM ERROR -+ POWER OFF
Main board or I/O management board failure.
EC10210-XXXX COM LSI ERR -> POWER OFF EC10403-XXXX CALC.ERR + POWER OFF
Motion control board failure.
Replace the Motion control board.
Motion control board Replace the Motion control board. failure.
EC10504-XXXX DC24V ERROR -+ POWER OFF
DC24V power supply failure. Replace the DC24V power supply
EC10505-XXXX DC15V ERROR +POWER OFF
1) DC15V power supply failure.
2) Connector (CN24) is disconnected.
1) Replace the DC15V power supply.
2) Check the CN42 connection.
EC10601-XXXX NO FILE +POWER OFF EC10603-XXXX PCB MISMATCH -+ POWER OFF
Data installation can not be performed correctly.
For details, see section 6.2.8.
SCON/PCON Board is not in place.Or, imperfect contact.
Check the SCON/PCON board connection.
ECl0605-XXXX NO SYS FILE -+ POWER OFF EC10801 -XXXX ROM ERROR - POWER OFF
Multi-synchromotion control data is not found or is insufficient. Misplacement of EPROM, o r imperfect contact.
Install the system parameters again If not recoverd, contact DAIHEN.
For details, see section 6.2.9.
EC10802-XXXX RAM ERROR -+ POWER OFF EC11301-XXXX I/O PORT ERR -+ POWER OFF
The identified board or RAM on that board is broken. 1/0 management board failure.
Replace the mother board.
EC11401-XXXX TB LCD ERROR -+ POWER OFF
Teaching box LCD failure. Replace the teaching box.
Troubleshooting 6 - 5
Code / Message EC20101-XXXX MOTOR ERROR 3 POWER OFF
Cause The system parameter setting for motor is wrong, or any setting of the SCON board rotary switches 3-5 is
EC20102-XXXX AXIS SET ERR 3 POWER OFF
SHOCKS ALARM / mode but not during I
Solution For details, see section 6.2.10.
wrong. The system parameter setting for motor is wrong, or the setting of the SCON board rotary switch 6 is
A 00201-XXXX wrong. The torch interfered in Auto
3 RESET A 00301-XXXX OVER RUN 3 RESET
3 RESET / Work or Tool coordinate I teaching based on the Base o r World
For details, see section 6.2.3.
A 10301-XXXX TEMP. ERROR 3 RESET A 10404-XXXX CALC. IMPOS.
1 system in the 1 coordinate system again.
automatic operation. Overrun was detected during initial-diagnosis.
After initial diagnosis is completed, perform manual manipulation while holding down the SERVO ON button to
The temperature in the controller exceeded 60°C
1) A positioning instruction P is taught base on
1 to move a t a position on 1 end points). If the manipulator is
escape from overrun. Turn off the control power supply and leave the robot as it is until the temperature decrease below 60°C 1) Modify the relevant instruction P to a
synchromotion instruction HP, o r try
synchromotion system. 2) The panipulator is unable
) the path taught with a 1 unable to move, correct the position
2) Correct the taught positions(start/
/ Linear o r Circular 1 data of the relevant instruction in
/ interpolat ion instruction. / search mode or by using the PC
A 10502-XXXX CMOS BATTERY + RESET A 10503-XXXX ABS BATTERY + RESET
The voltage of the memory battery dropped below 2.5V.
1) The voltage of the
A 10601-XXXX
6 - 6 Troubleshooting
editing system. Save all the data by using the external storage.
1) Charge the battery, or replace the charging battery dropped.
2) Imperfect connection of
NO FILE + RESET
charging battery. Be sure to perform the absolute offset adjustment.
Connector(CN47). Data installation cannot be performed correctly.
2) Check the CN47 connection. For details, see section 6.2.8.
Code / Message A 10710-XXXX DATA ERROR -+ RESET A 11102-XXXX ABS MISMATCH
RESET A 11103-XXXX ABS DATA OUT 3 RESET
A 30201-XXXX OVER TRCKNG. 3 RESTART
A 30203-XXXX ARC UNSTABLE -3 RESTART
A 30208-XXXX OVER DETECT. -+RESTART
A 30209-XXXX OVER DIST. + RESTART
A 30210-XXXX OVER SRCHNG. -> RESTART
A 30211-XXXX OVER DIST. +RESTART
A 30213-XXXX OVER SRCHNG. -. RESTART
Cause The Task program contains a damaged instruction.
Position deviation has occurred.
The absolute offset data have been destroyed o r absolute encoders have not been reset. During seam tracking by the a r c sensor, the resultant vector length in horizontal and vertical directions exceeded the specified value. During seam tracking by the a r c sensor, the frequency ra te that the average current exceeds the allowance exceeded defined rate. During automatic editing of parameters, arithmetic problem occurred. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the specified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SFl) , the searching distance exceeded the
specified maximum. During patterned search (SF2), the deviation exceeded the specified limit.
Solution Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, section 6.2.1 1.
Reset the encoders and perform the absolute offset adjustment.
See the Arc Sensor instruction manual.
Troubleshooting 6 - 7
Code / Message A 30214-XXXX OVER DIST. -+ RESTART
A 30215-xxxx SF2 CIVID. ERR -. RESTART A 30216-XXXX SF2 PRM.OVER -+ RESTART A 30217-XXXX SF2 PRM.OVER * RESTART A 30218-XXXX SF2 OVERLAP * RESTART A 30220-XXXX TS RANGE ERR -. RESTART A 30221-XXXX A.S.TRNS.ERR -+ RESTART A 40101-XXXX A.S. FAILURE * RESTART
A 40102-XXXX WIRE STICK -+ RESTART A 40103-XXXX OUT O F ARC -. RESTART A 40201-XXXX WPS NOT RDY + RESTART
A 40201-XXXX WPS NOT RDY + RESET
Cause During patterned search search (SF2), the searching distance exceeded the specified maximum. The SF2 file (Search Pattern file) contains an invalid command other than SF2. A SF2 parameter setting is outside the setting range.
A SF2 parameter condition is wrong.
The SF2 s t a r t position and vector specified position a re the same. Teaching of AS o r AE in the touch section.
Communication with the a rc sensor cannot be made.
The a r c was not generated within the set time after a welding s t a r t signal being input. Wire was sticked.
The a r c is out.
The robot dedicated welding power unit or welding interface has not been connected.
Communication trouble between the robot and welding interface o r the robot dedicated welding power unit.
Solution See the Arc Sensor instruction manual.
Press the START button t o restart .
Cut the deposited wire. After that , press the START button to res tar t welding.
Press the START button.
1) Check the connection between the controller and the robot dedicated power unit o r welding interface.
2) Turn the robot dedicated power unit ON.
Turn the CONTROL POWER off and on again.
6 - 8 Troubleshooting
Code / Message A 40202-XXXX WPS ABNORMAL -+ RESTART A 40301-XXXX OUT OF WIRE -+ RESTART A 40302-XXXX LACK OF GAS -> RESTART A 40303-XXXX LACK OF WATR -+ RESTART A 50101-XXXX NO ASC FILE + RESET A 50101-XXXX NO AEC FILE + RESET A 50102-XXXX NO WFP FILE -+ RESET A 50102-XXXX NO WAX FILE + RESET A 50103-XXXX NO ASM FILE -+ RESET A 50103-XXXX NO AEM FILE + RESET A 50104-XXXX NO OFS FILE + RESET A 50105-XXXX NO CL PRG. 3 RESET A 50106-XXXX NO JF PRG. -2 RESET A 50107-XXXX NO PM 3 RESET
Cause Problem of ALMEGA
During automatic operation the wire was broken.
Solution Remove the cause of the problem of
AUTO II or ALMEGA FUZZY AUTO.
Remove the cause. After that, press the START button.
ALMEGA AUTO II or ALMEGA FUZZY AUTO.
The gas pressure is too low. Displayed only if a detector is ~rovided.
Remove the cause. After that , press the START button.
There is no cooling water.
The specified Arc Start Condition file does not exist.
Remove the cause. After that, press the START button.
Create an Arc Start Condition file.
The specified Arc End Condition file does not exist.
Create an Arc End Condition file.
I
The specified Fixed / Create a Fixed Patterned Weaving Patterned Weaving 1 Condition file. Condition file does not exist. 1 The specified Axis Weaving Condition file does exist.
The specified Multi-pass Welding Start file does not exist.
Create an Axis Weaving Condition file.
Create a Multi-pass Welding Start file.
The specified Multi-pass Welding End file does not
There is no Task program to call.
Create a Multi-pass Welding End file. exist. The specified Offset Condition file does not exist.
Create a Task program to call.
Create an Offset Condition file.
I
There is no Task program 1 Create a Task program to jump to. to to jump to.
There is no point mark to jump to.
Add a Point Mark instruction.
Troubleshooting 6 - 9
C2 TEACH ERR / for the latter half of a
Solution A circular a r c is formed by 3 points. Add a reference point.
Code / Message A 50110-XXXX C1 TEACH ERR -+ RESET A 50111-XXXX
Cause There is no reference point for the former half of a
Add a reference point.
circular arc. There is no reference point
+ RESET A 50112-XXXX COORD. ERROR + RESET
Teach all 3 points in the same coordinate system to form a circular arc.
A circular a r c is formed by 3 points.
circular arc. Teaching of the target and reference points for circular a r c in the different
SAME POINT C I points for a circular a rc a re / be made.
coordinate systems. A 50113-XXXX The target and reference Teach again to form a circular a r c can
1/0 TIMER -+ RESET
-+ RESET A 50114-XXXX
exceeded 9. count time a t one time during automatic operation is 9. Check the setting time of each
the same. The number of timer cou~l ts The max. number of timers that can
A 50120-XXXX The nest has overflown due
instruction of S, R, N, and F. Calling in the call destination program
CALL NESTING OVER -+RESET
to program calls.
A 50201-XXXX S.LIMIT * * * *
The robot has reached the software limit.
+ RESET A 50202-XXXX The robot has reached the
LNKS.LIMITM * -. RESET
link software limit.
A 50401-XXXX ON TIME OUT
No ON input within the specified monitoring time.
+ RESET A 50402-XXXX
A 50501-XXXX SERVO OFF -+SERVO ON
No OFF input within the
OFF TIME OUT -. RESET
Servo ON when the mode was changed to AUTO. Or, the servo power supply was
specified monitoring time
1 turned on before automatic / operation o r after
is possible, but limited to the maximum 4 layers.
A 50502-XXXX OUT O F START
Check the program. For details, see section 6.2.5.
completion of the job. Outside the Star t Enable
Area.
Check the input s ta tus of the external control signals and the teaching data.
Turn the servo power supply ON.
Perform manual operation to move the manipulator to within the Star t Enable
6 - 1 0 Troubleshooting
ENABLEAREA I Area.
Code / Message A 50601-XXXX ABSO ERROR -. RESET A 50701-XXXX OPTION ERROR -+ RESET A 50702-XXXX OPTION ERROR -+ RESET A 50704-XXXX OPTION ERROR + RESET A 50705-XXXX OPTION ERROR -. RESET A 50706-XXXX OPTION ERROR -. RESET A 50708-XXXX OPTION ERROR 3 RESET A 50709-XXXX OPTION ERROR -+ RESET I 00201-XXXX SHOCK SENSOR -.RELEASE
I 10208-XXXX COM. ERROR 3 RESET
I 10208-XXXX COM. ERROR + RESTART
I 11202-XXXX LIMIT SPD. -. RESET
Cause After initialization of the memory, ABSO setting has not been performed. The software for Synchromotion has not been installed. The software for Multi-pass Welding has not been installed. The software for External Axis Shift has not been installed. The software for welding monitor has not been installed. The PM8700 software has not been installed.
The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. This occurs during escape from Shock Sensor Error or Shock Sensor Alarm, or when the torch interfered in Teach mode. The user parameter setting of CRT ON/OFF was ON when the CRT power supply was turned off. During automatic operation, trouble occurred in the CRT communication circuit due to some cause. In synchronous Cartesian manual manipulation, the sub mechanism is unable to synchronize with the main the mechanism.
Solution After completion of initial diagnosis, perform the absolute offset adjustment.
If you want to use the optional function, purchase its optional software. Press the RESET key to continue the pera at ion.
For details, see section 6.2.3.
Press the reset key on CRT to switch the display to the teaching box.
Automatic operation will continue.
Increase the speed of manual manipulation.
Troubleshooting 6 - 1 1
Code / Message I 11401-XXXX CRT ABNMAL --, RESTART I 30100-XXXX L. S. TRNS. ERR --, RESET I 30203-XXXX ARC UNSTABLE -. RESEST
I 30204-XXXX WELD SHRTG. + RESET I 30205-XXXX PARA.CALC. -. RESET I 30208-XXXX OVER DETECT. + RESET
I 30209-XXXX OVER DIST. -. RESET
I 30210-XXXX OVER SRCHNG. -+ RESET
I 3021 1-XXXX OVER DIST. + RESET
I 30213-XXXX OVER SRCHNG. --+ RESET I 30214-XXXX OVER DIST. + RESET
I 30221-XXXX A. S. TRNS. ERR -. RESET
Cause Trouble occured in the CRT printed board.
Communictation with laser sensor cannot be made.
During seam tracking by the a rc sensor, the frequency that the average current exceeds the allowance exceeded the defined data . The welding time was not enough during automatic editing of parameters. During automatic editing of parameters, arithmetic problem occured. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the slsecified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SF1 ), the searching distance exceeded the specified maximum. During patterned search (SFZ), the deviation exceeded the slsecified limit. During patterned search search ( SF2) , the searching distance exceeded the specified maximum. Communication with the a r c sensor cannot be made.
Solution Trun off and on the CONTROL POWER.
Connect the laser sensor.
For details, see the Arc Sensor instruction manual.
6 - 1 2 Troubleshooting
Code / Message I 30301-XXXX CRT DISCNNCT -+ RESET I 30302-XXXX CRT INVALID + RESET I 40201-xxxx WPS NOT RDY -+ RESET
I 40301-XXXX OUT O F WIRE + RESET
Cause Communication with CRT can not be made.
The user parameter setting of CRT ON/OFF will be changed t o OFF. 1) The robot dedicated
welding power unit o r welding interface is not connected.
2) The robot dedicated power unit is OFF.
The residual wire is not enough. Displayed if a detector is provided.
Solution To use CRT, turn on CRT first, and then the controller.
Push RESET key.
1) Check the connection between the controller and the welding interface.
2) Turn the robot dedicated power unit ON.
Supply the wire.
Troubleshooting 6 - 1 3
Table 6.3 Failure Messages
Failure Message
I
COM DATA ERR XX-YY
XX: 03 or 85 YY: 01 - 05 SVC error
Cause Failure was detected a t Servo Control board (SCON board). Servo Control board malfunctioned. The servo power supply was shut off due to an unexpected cause. The temperature in the controller has extraordinarily increased. Trouble occurred in the Servo driver unit. Trouble occurred in the Servo Control board. The servo driver unit is unable to be set in the servo ON state. The position deviation exceeded the set value. The commanded speed exceeded the set value. Servo Control board malfunctioned. Trouble occurred when the servo power supply was turned on. Control program failure.
Control program failure.
Solution For details, see section 6.3.2.
Turn off the control power supply and then on again. If this failure recurs, note down the information displayed on the teaching box and contact DAIHEN. Note down the information displayed on the teaching box and contact DAIHEN.
6 - 1 4 Troubleshooting
6. 1 Symptoms
6.1. 1 Nothing Appears on the Teaching Box
Nothing
appears on the
teaching box
and all LEDs
on the
keyboard a re
OFF.
Primary power
supply indicator
lamp OFF.
(ON in the
1 normal state) I
Cooling fan not
rotating t
No primary power
/ LEDs of I constant voltage
power u n i t ( 5 ~ , I- I flickering palely. 1
I 1 LEDs of I Loss of W phase 1 1
-
H constant voltage H (wire 6) of I-' / 1 power unit(5V. I 1 primary power I
Loss of V phase
(wire 5) of
primary power
supply
k15V 24V) are I I o m .
-
All LEDs on
Interlock board
are OFF. (In
normal state,
LEDs 301, 302,
304, 601, 602 and
603 are ON.)
I Action I
Check the voltage of
each phase of the
primary power supply
Imperfect contact
of interlock board
CN41 - constant
voltage power unit
1 C N 4 1 . 1 Check the flat cable
1 connection and connect I it properly.
i_ I Replace the cable.
/ / Interlock board U Replace the interlock 1
Troubleshooting 6 - 1 5
1 failure. 1 board.
Imperfect con tact Check the flat cable
of backplane
board FCll -
interlock board
FCll
connection and connect
1
/ Replace the cable.
Check 24V of interlock
6.1 .2 The Display on the Teaching Box Is Unsteady
I to teaching box.
The display of
the teaching
box is
unsteady and
flickers.
/ board.
I Red LED on
Servo Control
board ON
1 servo driver I / flickering 1
4 Low vo-on Check the voltage on
/ primary power 1 I the primary power I supply (below AC / 150V) I '
6 - 1 6 Troubleshooting
6. I . 3 In i t ia l Diagnosis Is Not Completed
1 Symptom 1
The display
"START
DIAGNOSIS"
stays on the
The teaching
box display
stops a t step1
of initial
"COMUCTN
ERR"
( Communication
error) is
displayed a t the
right top of the
teaching box
screen.
I Action I
4 Refer to 6.2.7 in this art. I
right top of the
teaching box
screen.
Nothing is
displayed a t the
"NO FILE" is
displayed a t the
right top of the
teaching box
screen.
-
connected correctly. +
-
1 Replace the 1/0
Check that I/O
management board is
I/O management
board failure
Nothing is
displayed a t the
right top of the
teaching box
screen.
I management board. I
-
4 Refer to 6.2.8 in this rsart. 1
connected correctly. L -
Replace the 1/0
management board.
Troubleshooting 6 - 1 7
I/O management
board failure
Check that 1/0
management board is
The teaching
box display
stops a t step2
of initial
"NO FILE" is
displayed a t the
right top of the
teaching box
4 Refer to 6.2.8 in this part. 1
6 - 1 8 Troubleshooting
Motion control
board failure - Nothing is
displayed a t the
-
Check that Motion
control board is
right top of the
-
"WPS NOT
RDY" is
displayed a t the
right top of the
teaching box
screen.
connected correctly.
-
Robot dedicated Turn on the robot
welding power dedicated welding
power unit.
correctly.
- Welding interface
o r robot dedicated
welding power unit
not connected.
teaching box
screen.
Check that the welding
interface o r robot
dedicated welding
power unit is connected
Check that 1/0 Nothing is
Replace the Motion
I/O management
control board.
-
The teaching
box display
stops a t step3
of initial
diagnosis.
board failure
"NO FILE" is Refer to 6.2.8 in this part.
displayed a t the
right top of the
teaching box
screen.
right top of the
teaching box
screen.
displayed a t the management board
is connected correctly.
I
Replace the I/O
-
management board.
1 Symptom 1 The teaching
box display
stops a t step4
of initial
I Check Item 1 I Possible Cause I
"NO FILE" is Refer to 6.2.8 in this part.
displayed a t the
right top of the
teaching box
screen.
the right top of
the teaching box
"A.S.TRNS.ERRn
is displayed a t
I screen. I
-
Nothing is
displayed a t the
right top of the
teaching box
I Action (
Arc sensor unit Check that the Arc
not connected. sensor is connected
correctly.
Arc sensor unit Check that Arc sensor
Arc sensor unit Turn on the Arc
1 failure
OFF
1 Replace the Arc sensor /
sensor unit.
Troubleshooting 6 - 1 9
screen. unit.
6.1 .4 The Servo Power Supply Cannot Be Turned ON
The servo
power cannot
be turned on.
I Action I
Electromagnetic -
contactor MS1 contactor MS1
Replace the
electromagnetic
not ON
303 OFF (ON in
the normal
condition) 1
failure
Check the voltage on
the primary power
I
Red LED on
1 contactor MS1.
----
each Servo
Low voltage on
primary power
Control board
- P
ON (only green
-
ON in the
Interlock board
LEDs 203/301/
normal
condition)
LEDs on each
1 Servo driver ON I 1 in the normal I I condition)
/ Motion control 1 / board OFF (ON
1 in the norm-a1 / condition) I
I
LED 303 on
Interlock board
ON (OFF in the
normal
condition)
supply(3-phase 200
V) (Below AC150V) I 'Supply.
-4 Motion control Replace the Motion
6 - 2 0 Troubleshooting
board failure control board.
6.1 .5 The Servo Power Is Shut OFF Immediately When Turned ON
(Symptom ( I Check Item I
1 The servo t power is shut
off while
"SERVO ON"
stays on the
teaching box
screen.
LEDs 101/301/
303(green) on
Interlock board
OFF (ON in the
normal
( Possible Cause (
Check that each board
1 board failure 1 / 1 is in place. , 1 I
Replace faulty board.
I Action I
Main board failure I
1 condition)
LEDs 101/301/
303/ 203 ( green )
on Interlock
board OFF (ON
in the normal)
/ board failure
board failure
Troubleshooting 6 - 2 1
6. 1 .6 Manual Manipulation Does Not Function
1 Symptom 1 Check Item 1 I Possible Cause I ( Action I
of axes 1 - 6
can moves by
1 Only one axis
manual
manipulation.
1 Bad connection of Check the connections
Only axes 4/5/
6 move by
manual
None of axes
1-6 moves by
manual
Able to move
axes 1/2/3 by
manual
CR3A/CR3B
contacts on
Interlock board
OFF (ON in the
normal
condition)
/ motor line of servo driver
connectors CN51-56. ' i 1 motor line
- Disconnection of
Motor failure Replace the motor.
Replace the cable. !
1 No power supply
to axes 4/5/6 servo I- 1 drivers
Check the connections
of servo driver
connectors CN4, CN6,
and CN8.
Replace the cable.
~ i s c o n n e c o f H Replace the control
Check the connection
of control cable 1.
(Manipulator-side CN1)
-
Set the machine lock
motor line
1 function set ON 1 1 function OFF.
Bad connection of
motor line
cable 1 .(Manipulator
6 - 2 2 Troubleshooting
---
-side CN1)
6. 2 Failure Codes and Failure Messages
6.2. 1 The Display o f A Fai lure
If a failure occurred, a failure code and a failure message a r e displayed on the
teaching box.
[Example] Emergency Stop
A failure code is displayed in the following format:
EAOO 1 0 1 - 0 0 0 1
EMERGENCSTOP
+RELEASE
a: Indicates the severity of a failure (Error , Alarm, o r Information).
+Fa i lu recode
+ Failure message
- Error (EA/EB/EC)
The Error class includes failures, such as failures of par ts and internal da ta ,
which cause the operation to be disabled unless the causes a r e removed, o r
which can cause harm to the system and operators if the operation is
continued.
- Alarm (A)
The Alarm class includes failures which can develop to Errors unless measures
a r e taken soon, o r which require a simple operation, check, o r action before
the operation is carried on though they may not cause harm to the system and
operators.
- Iiiformatioii (I)
The Information class includes failures whicli should be told to the operator
and peripheral equipment though they do not cause trouble to continue the
operation, o r which can develop to Alarms later.
Troubleshooting 6 - 2 3
b: Indicates the cause of failure.
- Urgent Failure (0)
This includes failures which cause the system to be stopped as a last resort
when a failure handling action such a s a detection o r stop cannot be taken
due to the occurrence of another failure.
- Control Failure (1)
This includes internal control system failures being detected a t the main board ,
motion control board, 1/0 management board and the teaching box.
- Servo Failure (2)
This includes servo system failures being detected a t servo control boards and
servo drivers.
- Peripheral Equipment Failure (3)
This includes failures relating to peripheral equipment (optional equipment)
such as sensors.
- Welding Failure (4)
This includes welding failures being detected a t the dedicated welding power
unit and the welding interface.
- Operational Failure (5)
This includes failures relating to operations such a s misoperations.
c : Shows the more detailed cause of b.
d: Indicates the unit where the failure occurred (called a unit code) o r detailed
information of the failure.
For unit codes, see Table 6.4.
e: Indicates the mode (called a mode code) o r detailed information of the failure.
For mode codes, see Table 6.5
6 - 2 4 Troubleshooting
Table 6.4. Unit Codes
Note) PCON: Position control board SCON: Servo control board
Table 6.5. Mode Codes
Code
0 0 0 1 0 2 0 3 0 4
0 5 0 6 0 7 0 8 0 9 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8
Code
6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 7 0 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 8 0 8 1 8 2 8 3 8 4 8 5 8 6 9 0 9 1 9 2 9 3
Unit
Main board Motion control board I/O management board Teaching box Welding interface o r ALMEGA AUTO 1T o r ALMEGA FUZZY AUTO Interlock board Backplane board
Analog board External axis board PCON/SCON board 1 PCON/SCON board 2 PCON/SCON board 3 PCON/SCON board 4 PCON/SCON board 5 PCON/SCON board 6 PCON/SCON board 1 Axis 1 PCON/SCON board 1 Axis 2 PCON/SCON board 1 Axis 3 PCON/SCON board 2 Axis 4 PCON/SCON board 2 Axis 5 PCON/SCON board 2 Axis 6 PCON/SCON board 3 Axis 7 PCON/SCON board 3 Axis 8 PCON/SCON board 3 Axis 9 PCON/SCON board 4 Axis 10 PCON/SCON board 4 Axis 11 PCON/SCON board 4 Axis 12 PCON/SCON board 5 Axis 13 PCON/SCON board 5 Axis 14 PCON/SCON board 5 Axis 15 PCON/SCON board 6 Axis 16 PCON/SCON board 6 Axis 17 PCON/SCON board 6 Axis 18
Code
Unit
Axis 1 servo driver Axis 2 servo driver Axis 3 servo driver Axis 4 servo driver Axis 5 servo driver Axis 6 servo driver Axis 7 servo driver Axis 8 servo driver Axis 9 servo driver Axis 10 servo driver Axis 11 servo driver Axis 12 servo driver Axis 13 servo driver Axis 14 servo driver Axis 15 servo driver Axis 16 servo driver Axis 17 servo driver Axis 18 servo driver Personal computer Arc sensor
Laser sensor Main board of CRT unit CRTC board of CRT unit External storage
Printer I/F
Teach
2 0 1 Remote control
1 I
Mode
Diagnosis
Teaching I I
Troubleshooting 6 - 2 5
Function
1 0 Auto
6.2.2 Logical Outputs for Failures
Failure output ports are provided to inform external devices of the cause, severity,
and solution of a failure:
Table 6.6 Logical Outputs for Failures
Name
Urgent Failure
Logical Output Port No.
0 2 0 1
Control Failure
Servo Failure
I
0 2 0 2
0 2 0 3
Peripheral Equipment Failure
Welding Failure
0 2 0 4
0 2 0 5
Operational Failure
Error
Alarm
Information
ABSO Adjust Request
Reset Reauest
For details of these output ports, see the instruction manual "Interface With Jig".
0 2 0 6
0 2 1 1
0 2 1 2
0 2 1 3
0 2 0 8
0 2 0 9
Start Request
Failure Code
6 - 2 6 Troubleshooting
0 2 7 0
0 3 7 0 - 0 3 7 4
6.2 .3 Shock Sensor
Shock Sensor is a failure which occurs when the torch hits a peripheral jig.
Shock Sensor Error (during automatic operation)
/I 1 SHOCK-S ERR I 1 + RESET I
Shock Sensor Alarm (in Auto mode but not during automatic operation)
/ SHOCKS ALARM I / -. RESET I
* Shock Sensor Information (in Teach mode or during an escape from Shock Sensor
Error or Alarm)
1 SHOCK SENSOR 1
Solution
(A) If the torch is equipped with a shook sensor
Perform manual manipulation in the direction which allows Shock Sensor to be
cancelled.
(B) If the torch is not equipped with a shock sensor
Short-circuit pins 4 - 5 of terminal block TB1 on the Interlock board.
Troubleshooting 6 - 2 7
6.2.4 Servo Power Shutoff
This failure occurs when:
A failure occurred and was momentarily removed.
You release the hand from the deadman switch, provided that the teaching box is
equipped with a deadman switch.
The output form of failure varies with the setting of the user parameter
"ABNOMALTY ENCODE" * available for setting the teaching box key status.
1 SERVO DOWN 1 erased after being / (Automatically reset after
Table 6.7 Differences of Output Form according to Special Failure Output ON/OFF
OFF / SERVO DOWN 1 Reset input. / Error (0221)
Output Signal
Failure Code(0374-370)
EA00401-01XX
( ~ e f a u l t ) + RESET 1 1 Reset Request (0209)
Cancellation
Automatically
Setting
ON
1 1 1 Failure Code (0374 - 370)
Display of Failure
EA00401-01XX
output for 2 seconds.
By the RESET key o r
Solution
being output for 2 sec.)
Urgent failure (0201)
0 When the setting is OFF
After being displayed on the teaching box for 2 seconds, the failure is
automatically erased. Then, turn on the servo power supply.
(B) When the setting is ON
After pressing the RESET key, turn on the servo power supply.
In case of this failure, because it is automatically cancelled, you can carry on the
operation you a re doing, o r can restart the automatic operation.
If this failure recurs during automatic operation, the shock sensor may be working.
In this case, correct the path o r attitude to avoid interference with the jig.
* : See "Setting Teaching Box Keys", section 2.2 in Par t I[.
6 - 2 8 Troubleshooting
The "ABNOMLTY ENCODE" ON setting affects the signals being output when the
following failures occur:
Emergency Stop
p6zFEG-l 1 EMERGENCSTOP 1
* Servo OFF
SERVO OFF
If the setting is ON, Urgent Failure (0201)
and Error (0211) a re not output.
If the setting is ON, Operational Failure (0206)
and Alarm (0212) a r e not output.
6.2.5 Software Limit/Link Software L imi t
(1) Software Limit Failure
This failure is detected when the mechanism attempts to move out of the working
area .
Teach mode
S.LIMIT XYZZ
+MANUAL OPE.
Auto mode
S.LIMIT XYZZ
X: Mechanism number
Y: Axis number (Displays the lowest axis number if multiple axes a r e involved)
Z: Axis information (Displays the Soft Limit of each axis as bit information)
Tens' place Unit's place
Troubleshooting 6 - 2 9
(Example] When Software Limit occurs a t Axes 4 and 6
Tens' place Unit's place
In this case, "28" is displayed a t the ZZ.
Solution
(A) Teach mode
Perform manual manipulation in the direction which allows the Software Limit
to be cancelled.
(B) Auto mode
After pressing the RESET key, turn on the servo power supply. Then,
perform manual manipulation in the direction which allows the Software Limit t o
be cancelled.
(2) Link Software Limit
This failure occurs when the mechanisms could interfere with each other.
* Teach mode
LNKS.LIMITM * +MANUAL OPE.
a Auto mode
YY: Axis numbers (For example, if "23" is displayed, this indicates that Link
Software Limit has occurred a t axes 2 and 3.)
Solution
(A) Teach mode
Perform manual manipulation in the direction which allows the Link Software
Limit to be cancelled.
03) Auto mode
After pressing the RESET key, turn on the servo power supply. Then, perform
manual manipulation in the direction which allows the Link Software Limit to
be cancelled.
6 - 3 0 Troubleshooting
6 .2 .6 Overrun
This failure occurs when the robot overruns.
EB0030 1 -XXXX
OVER RUN
-+ RESET
Solution
After pressing the RESET key, perform manual manipulation in the direction
which allows Overrun to be cancelled, while holding the SERVO ON button down.
If this failure occurs though the robot has not overrun, the cause may be the
following :
(A) Any one of JP 601, 602, and 603 on the Interlock board is not short-circuited
+Short-circuit it.
(B) 24V is not supplied to Interlock board.
+Check the connection between CN 41 of the Interlock board and CN41 of
the constant voltage power supply.
(C) The fuse on the Interlock board is blown
->Replace the fuse.
0) Interlock board failure.
-+Replace the Interlock board.
Troubleshooting 6 - 3 1
6.2.7 Communication Fai lures
(1) Board To Board Communication Failure
This failure occurs when communication cannot be performed correctly between
boards.
EC10206-YYXX
COMUCTN ERR
-+ POWER OFF
Y Y : 0 1 -.. Main Board - Motion Control Board Communication Failure
0 2 -.. Main Board - 1/0 Management Board
Communication Failure
0 3 Main Board - Teaching Box Communication Failure
Solution
(A) YY:O1
Make sure that the Motion control board o r EPROM on the Motion control
board is placed correctly.
Make sure that the 1/0 management board o r EPROM on the 1/0 management
board is placed correctly.
(C) YY:03
Make sure that the Main board or EPROM on the Main board is placed
correctly.
(2) Echo Back Communication Failure
This is I/O management board o r Teaching box failure.
EC10208-YYXX
COM. ERR
-+ POWER OFF
Y Y : 0 2 -.. Main Board - 1/0 Management Board.
0 3 Main Board - Teaching Box
6 - 3 2 Troubleshooting
Solution
0 YY:O2
Replace the I/O management board.
63) YY: 0 3
Replace the teaching box.
(3) DPRAM Failure
This is Main board or I/O management board failure.
EC10209-YYXX
/ DPRAM ERROR I I -+ POWER OFF I
Y Y : 0 0 Main board - Motion control board.
0 2 Motion control board - I/O management board
Solution
(A) YY:OO
Replace the Main Board.
63) YY:02
Replace the 1/0 management board.
Troubleshooting 6 - 3 3
6.2.8 Data Installation Failures
This failure is detected when data (files) necessary to operate the robot do not exist.
If this failure is detected, it is necessary to create a required file with the System
Initialize function.
(1) Data Installation Error
EC10601-YYYY
NO FILE
+ POWER OFF
Y Y Y Y : 0 1 0 0 ... Can't find System Parameter file.
0 1 0 1 ... Can't find Manual Operating Speed Table file.
0 1 0 2 ... Can't find Block Operating Speed Table file.
0 2 0 0 -.. Can't find Sequencer file.
Solution
0 YYYY: 0100
If your system consists of a single robot unit, select the "SYSTEM" function
key with the System Initialize function and create a System Parameter file. Then,
set the offset adjusting values and the tool parameters.
If your system consists of multiple mechanisms, select the "SPECIAL" function
key with the System Initialize function and load the system parameters f rom the
external storage.
(B) YYYY: 0101
Select the "MANUAL" function key with the System Initialize function and
create a Manual Operating Speed Table file.
(C) YYYY: 0102
Select the "BLOCK" function key with the System Initialize function and create
a Block Operating Speed Table file.
(D) YYYY: 0200
Select the "SQ" function key with the System Initialize function and create a
Sequencer file.
6 - 3 4 Troubleshooting
(2) Data Installation Alarm
A 10601-YYYY
NO FILE
+POWER OFF
Y Y Y Y : 0 2 0 1 ... Can't find Welding Characteristic Data file.
0 2 0 2 Can't find Welding Control file.
0 2 0 3 ... Can't find Current Conversion Table.
8 1 0 0 ... Can't find Arc Sensor file.
8 4 0 0 Can't find Laser Sensor file.
Solution
Vi) YYYY : 0201, 0202, o r 0203
Select the "WELD" function key with the System Initialize function and
create a file.
(B) YYYY: 8100
Select the "ARC-S" function key with the System Initialize function and
create a Arc Sensor file.
(C) YYYY: 8400
Select the "LASER-S" function key with the System Initialize function and
create a Laser Sensor file.
Troubleshooting 6 - 3 5
6.2.9 Memory Failures
(1) ROM Failure
This failure is detected when the EPROM or board is broken or the wrong EPROM
is inserted
/ ROM ERROR 1 -+POWER OFF
Y Y : 0 0 Main board
0 1 - a . Motion control board
0 2 -.. 1/0 management board
0 3 ... Teaching box
Solution
Replace the EPROM on the identified board or that board itself
(2) RAM Failure
The identified board is failure.
/ RAMERROR I 1 +POWER OFF I Y Y : 0 0 Main board
0 1 Motion control board
0 2 1/0 management board
0 3 ... Teaching box
Solution
Replace the identified board.
6 - 3 6 Troubleshooting
6.2.10 Setting Errors (1) Motor Setting Failure
This failure occurs when the system parameter setting for motor type differs from
the SCON board setting for motor type.
EC20101-XXXX
MOTOR ERROR + POWER OFF
Solution
Turn off the control power supply, set the rotary switches SW 3 - SW 5 on the SCON
boards to the correct values.
The following table shows the SCON board rotary switch setting for each mechanism:
Table 6.8 Rotary Switch Settings fo r Axis Motors of Manipulator
1 SCON for Base Axes 1 ~ C O N ~ Wrist Axes
Manipulator
G01/G03
V40
WO1
Table 6.9 Rotary Switch Settings for Slider Motor
Troubleshooting 6 - 3 7
Axis 1
S W 3
4
SCON not in use for V40
Slider
PSB series
RSR series
Axis 4
S W 3
0
D
Relevant switch setting of SCON SW3 to SW5
4
7
Axis 2
S W 4
4
Axis 3
S W 5
2
Axis 5
S W 4
0
E
Axis 6
S W 5
-
- 0 B 0
Table 6.10 Rotary Switch Settings for Positioner
Axis 1
Relevant switch
(2) Axis Setting Failure
This failure occurs when the SCON board rotary switch setting for the number of
controlled axes is wrong.
Axis 2
Relevant switch
R P H - 2 0 0
R P H - 5 0 0
R P H - 1 0 0 0
R P l S - 1 0 0 0
R P l D - 2 0 0
R P l D - 5 0 0
R P l D - 1 0 0 0
R P 2 T - 5 0 0
EC20102-XXXX
AXIS SET ERR
--+ POWER OFF
Solution
Turn off the control power supply and set the SCON board rotary switch SW 6 to the
setting of SW3 -SW5
4
8
8
8
4
8
8
1 8
correct value.
The following table shows the SCON board SW6 setting for the number of controlled
setting of SW3 -SW5
-
-
-
-
-
-
8
axes :
Table 6.11 SCON Board SW6 Settings for the Number of Controlled Axes
6 - 3 8 Troubleshooting
- -
SW6 Setting
0
Controlled Axes
3
6.2.11 ABSO Data Failure
This failure is detected when the difference is larger than the allowance in
comparison with the encoder value given when the servo power is shut off and that
when turned on. The allowance and check ON/OFF are set in "FUNC OF ABSO DATA
CHECK" *of the user parameters for setting the system status.
A 11102-YYXX
ABS MISMATCH
-+RESET
YY: 11 - 16 ... SCON/PCON board No.1 - No. 6 (See the unit code table.)
Solution
Run Task program P999 used for checking the origin by block operation and check
the marks. If these marks do not align, reset the absolute encoders and perform the
absolute offset adjustment. If the marks align, the absolute offset values a re correct.
* : Refer to "Setting the System Status", section 2.1 in part II
Troubleshooting 6 - 3 9
6. 3 When Servo Failure Occurred
6.3.1 How to see the Servo Failure Display
This section describes how to see the Servo Failure Code. When Servo Failure
occurred, the Teach Pendant displays the abnormal axis and information of the
failure a s shown in Fig.6.1.
Servo Failure can be identified in detail according to:
Failure category No.
Message (not displayed in some cases)
- Failure information codes
SERVO ABN 8
MECHAl AXS2 ENCODER ABN.
UNIT 1 : 0000 0000 0000 0000
UNIT 2 : 0000 0000 0000 0000
UNIT 3 : 0000 0000 0000 0000
UNIT 4 : 0000 0000 0000 0000
UNIT 5 : 0000 0000 0000 0000
6 - 4 0 Troubleshooting
t T f t
Column : a b c d
+-Failure category No.
+-Message
Failure information
codes
Fig.6.1 Example of Servo Failure Display
(1) Failure Category No.
When Servo Failure occurred, the Teach Pendant displays the following:
"SERVO ABN * * "
A number is displayed a t " * * ", by which the detailed failure can be identified
a s shown in Table 6.12:
Table 6.12 Failure Category Nos.
Troubleshooting 6 - 4 1
Meaning
Failure was detected a t Servo Control
Board.
Servo Control Board malfunctioned.
Servo power was shut off due to
unknown cause.
The temperature extremely increased in
the control unit.
Failure occurred in the Servo Driver
Unit
(For details, see Table 6.14 and 6.15)
Failure occurred in the Servo Driver
Unit.
(For details, see Table 6.14 and 6.15)
The Servo Driver cannot be energized.
The position deviation exceeded the set
value.
The commanded speed exceeded the set
value.
The commanded voltage exceeded the
set value.
Failure occurred when the servo power
was turned on.
* *
3
4
6
7
8
9
1 0
1 2
1 3
1 4
9 9
Name of Failure
Servo Control Board error
CPU failure of SCON Board
Servo power shutoff
Overheat in the Control Unit
Servo Driver failure
Position output failure
Abnormal position/speed
loop ON state
Beyond the position deviation
limit
Beyond the speed command
limit
Beyond the current command
limit
Failure a t the servo startup
(2) Message (not displayed in some cases)
For Servo Failure 8 "Servo Driver Unit failure", a message and failure
information codes a re displayed to give more detailed information.(These
information may be also displayed for othe failures.)
The content of a message corresponds to the failure information codes, and is
displayed as shown below. If multiple failure a re detected, only the earliest failure is
displayed.
Mechanism [No. 1 ]Axis [No. 2 1 [Failure information]
[No. 11 indicates the number of the mechanism where failure was detected.
This number corresponds to any of mechanism numbers 1 - 4 of LEDs which a r e
illuminated by selecting the Axis Changeover key "MECHANISM".
fNo.21 indicates the axis number of the mechanism displayed a t [NO. 11.
Note that this number is not a n axis number used in the entire control unit.
[Failure information] shows the information of a detected failure, for example:
- MECHA * * AXS MOTOR 0-HEAT(Motor Overheat a t Mechanism * Axis * - MECHA * * AXS ENCODER ABN.(Encoder Failure a t Mechanism * Axis * ) - MECHA * * AXS POWTR.0-HEAT
(Power Transistor Overheat a t Mechanism * Axis * ) - MECHA * * AXS OVER CURRENT(0ver Current a t Mechanism * Axis * ) - MECHA * * AXS CURRENT ABN.
(Instantaneous Current Limit Over a t Mechanism * Axis * ) - MECHA * * AXS OVER LOAD (Over Load a t Mechanism * Axis * ) - MECHA * * AXS OVER SPEED
(Speed exceeding detectable limit a t Mechanism * Axis * ) - MECHA * * AXS OVER DEVIAT.
(Position Deviation Limit Over a t Mechanism * Axis * ) - UNIT * OVER VOLTAGE(0ver Voltage a t Unit * ) - UNIT * LACK VOLTAGE(Low Voltage a t Unit * ) - UNIT * STOP INVRTR(1nverter Disconnect a t Unit * - UNIT * A/D ABNORMAL(Fai1ure of A/D signal line a t Unit * ) - UNIT * STOP SIGNAL (Stop signal input a t Unit * )
6 - 4 2 Troubleshooting
(3) Failure information codes
The abnormal par t can be identified from Fig.6.1, as shown in Table 6.13:
Table 6.13 Interpretations of Codes
0000 indicates that that part is normal, while any number (displayed in the
hexadecimal notation) except 0000 indicates that that par t is not normal.
Furthermore, the detailed failure can be identified by the number.
Column *
UNIT 1
(Axes 1-3)
UNIT 2
(Axes 4-6)
UNIT 3
(Axes 7-9)
UNIT 4
(Axes 10-12)
UNIT 5
(Axes 13-15)
Troubleshooting 6 - 4 3
a
Failure of P a r t common
to each axis
Failure of Par t common
to each axis
Failure of Par t common
to each axis
Failure of P a r t common
to each axis
Failure of P a r t common
to each axis
b
Failure of
Axis 1
Failure of
Axis 4
Failure of
Axis 7
Failure of
Axis 10
Failure of
Axis 13
c
Failure of
Axis 2
Failure of
Axis 5
Failure of
Axis 8
Failure of
Axis 11
Failure of
Axis 14
d
Failure of
Axis 3
Failure of
Axis 6
Failure of
Axis 9
Failure of
Axis 12
Failure of
Axis 15
a ) Failures Common to Each Axis
When a number, except 0000, is displayed a t column a in Fig.6.1, a failure can be
identified from Table 6.14:
Undervoltage of Main power 0002 1
(Main power off)
Table 6.14 Common Failure Codes
+This bit sometimes
indicates that the
Code
0001
Meaning
Overvoltage of Main power
1 not failure.
0004
0008
0100 1 Input of Stop signal
Disconnection of Inverter signal line servo power is shut
Failure of A/D signal line off, and in that case
Codes in Table 6.14 a re displayed in the hexadecimal notation on the Teach
Pendant.
If multiple failures occur, a sum of these codes is displayed.
KExamplel Meaning of Failure a t column "a" of UNIT 1
0004 : Disconnection of the inverter signal line of the first Servo Control board
+) 0008 : Failure of the A/D signal line of the first Servo Control board
OOOC : Disconnection of the inverter signal line (0004H) and failure of the A/D
signal line (0008H) of the first Servo Control board (0004H + 0008H)
6 - 4 4 Troubleshooting
b ) Failure Codes of Each Axis
When a number, except 0000, is displayed a t column b, c, or d in Fig.6.1, a failure
can be identified from Table 6.15:
0 0 0 1 I Motor overheat
Table 6.15 Failure Codes of Each Axis
0 0 0 2 1 Encoder failure
Code
0 0 0 4 1 Overheat of power transistor
Meaning
0 0 0 8 1 Overcurrent
0 0 1 0 I Over limit of momentary current
0 0 2 0 1 Overload
0 1 0 0 1 Over limit of detectable speed
0 2 0 0 Over limit of position deviation
Codes in Table 6.13 a re displayed in the hexadecimal notation on the Teach
Pendant.
If multiple failures occur a t one time, a sum of these codes is displayed.
1(Examplel Meaning of Failure a t column "c" of UNIT 2
0001 : Overheat of Axis 5 motor
+) 0004 : Overheat of Axis 5 power transistor
0005 : Motor Overheat(0001H) and Power Transistor Overheat(0004H) of Axis 5
(0001H + 0004H)
Troubleshooting 6 - 4 5
6.3.2 Troubleshooting for Servo Failures
I Action (
( Servo Failure F 1 Refer to (3) of section 6.
1 3 / / 1 codes not "0000" 1 3.1 to remove the cause. I SCON board
error ~ l l failure c a d e s H v Take some measures to
Servo Failure u showing "0000"
CPU failure of
SCON board
Servo Failure m
servo system protect from noise.
Check that the Servo -
/ of Servo Control 1 / Control board is in I Red LED ON
and green LED
OFF on Servo
Control board
Servo Control Replace the Servo
1 board.
I / board failure 1 Control board.
/ place.
Problem of system ti Instal1 the system
Take some measures to
parameters parameters again.
Red LED on
Motion control
servo system
board ON
1 protect from noise.
Servo power
shutoff
Make sure that the
1 placement of / 1 Motion control board 1 Motion control I is placed correctly.
Replace the Motion
/ board o r Servo 1 1 control o r Servo 1 Control board
failure
1 Control board. i
6 - 4 6 Troubleshooting
1 Symptom 1
Servo Failure ri
1 Control board 1 I and Servo driver I
Verify the voltage on 1 I / primary power I ( the primary power I
supply (below AC 1 supply
100V outlet
-
Use within the
over 60°C.
Temperature in
the controller I I I
Overheat in
the controller
/ over the allowance
Replace the Backplane 1
allowable temperature.
Replace the cooling unit.
Cooling unit
failure
Troubleshooting 6 - 4 7
-
the controller
under 60°C. / element failure board.
Servo Failure r Servo driver
failure
Display of
Servo Failure
on teaching box r------------------
:SERVO ABN 8 1
1 indicator lamp 1 1 1 (wire 4) of 1 1 each of the primary 1 Power supply
UNITl :- x Loss of U phase Verify the voltage on
/ and 1
"UNIT1 LACK
VOLTAGE " at Q,"0002" a t
UNITl@, and
@ shown
INVRTR" a t , "000C" a t UNITl
@ a , and "0002"
a t UNIT2 @
1 shown
"UNIT1 LACK
VOLTAGE" a t
Q , and "0002"
a t UNITl @ and
I primary power I I side phases before I supply (3 -~hase
Replace the breaker.
of cable connecting
servo driver CN1
for axis shown by
"000C" or "0002"
and Servo Ctrl.
Imperfect co*
/ board CN2, or 1
Make sure that the
cable connecting
servo driver CN2
/ and power unit I
cable connection is
correct.
I Replace the cable.
/ [LED 3 0 1 0 ~ Motion control Replace the Motion
6 - 4 8 Troubleshooting
on relay unit ON I board failure I 1 control board.
4 "UNIT2 LACK 1 "0002" a t UNIT1
@, and UNIT2
I Possible Cause I Action I
Make sure that the
of control cable 2 control cable (manipulator CN2 connection is correct.
and CN7 on Servo
Replace the cable.
4- Make sure that the
of cable connecting
CN6 on Servo
Control board 1
and switch box
CN135
/ cable connection is I correct. + R.enlace the cable.
Replace the Switch box 1 "UNIT1 LACK
VOLTAGE" a t
@, "0002" a t
UNITl@@@ and
UNIT2 @ shown
Imperfect contact
of control cable 3
(manipulator CN3
and CN7 on Servo
---( Make sure that the 1 1 control cable 1 connection is correct. L
1 Control board 2) 1 / Replace the cable.
Imperfect contact
of cable connecting
CN6 on Servo
Control board 2
and switch box CN
136
-4 Make sure that the
1 cable connection is
I correct
Replace the cable. L Replace the Switch box
Troubleshooting 6 - 4 9
/ Possible Cause 1
‘'ME----I 1mper- Make sure that the
I I AXS OVER
"0020" a t any of
UNITl m, and UNIT2 @@ @ shown
I of moter line 1 I control cable
1 connection is correct.
"MECHA10
AXS CURRENT
ABN" a t @ "0010"at any of
UNITl @@$$
and UNIT2
@@$$ shown
P
Disconnection of
motor line
"MECHAI 0 AXS OVER
CURRENT"
current a t @, and "0008" a t
any of UNITl @ @@ ,and UNIT2
shown
Replace the cable. 1
4 Wrong dip switch Check the dip switch
I setting on Servo I / setting and set
I Control board
6 - 5 0 Troubleshooting
1 correctly.
Check the fuse. - -
Fuse blown by
over current flow
to servo driver Replace the fuse
I Symptom (
"MECHA1 OAX
S OVER DEVIA
T." a t @and
"0200" a t any of
UNIT1- ,and
UNIT2
shown
I Possible Cause I I Action I
The origins of Perform absolute
I mechanical stopper I I offset adjustment.
I and software limit I
Replace the encoder
-
--( "UNIT1 STOP h
that axis.
1 encoder cable
INVRTR" a t @ and "0004" a t
UNIT@ shown
Check the encoder
cable connection of
Imperfect contact
of encoder cable
1 cable.
Motor failure Replace the motor.
-
"UNIT2 STOP
INVRTR" a t @ and "0004" a t
UNIT2 @ shown
Disconnection of
motor line -
Imperfect contact Check the flat cable
Replace the cable.
Control board and I of flat cable
connecting Servo
I servo driver
I connection.
Servo Control Make sure that the
-
1 is placed correctly.
Disconnection of
flat cable
1 I board failure
Replace the servo
Replace the flat cable.
/ Servo Control board 1
[ failure 1 I driver.
Troubleshooting 6 - 5 1
"MECHA1 0 AXS
OVERCURRENT'
a t Q. and "0008"
a t any of UNITl
shown 1 Blown fuse on
servo driver or
robot overrun El- Check the fuse. + / Replace the fuse 1
I
1 Cancel the overrun.
"MECHA10
AXS CURRENT
ABN." a t @, and
"0010" a t any of
UNITl @@@ shown
- "MECHA1 0 AXS CURRENT
ABN." a t Q, and
"0010" a t any of
UNIT2 @@@ shown
Wrong flat cable
connection between
Servo Control
board and servo
driver (Base axes)
Wrong encoder
cable connection
(CN7) between
Servo Control
board (Base axes)
and (Wrist axes).
Check the cable
connection and connect
correctly.
Note)
Check the fuse on the
servo driver indicated , because it may be
blown.
Check the encoder
cable connections and
connect correctly.
6 - 5 2 Troubleshooting
Replace the servo
driver.
v 0
--- Servo driver
failure
- All detail codes
showing "0000"
I Symptom I
! Both red and
green LEDs on
Servo Control
board ON
1 Servo system
failure
Only green LED
on Servo Control
board ON
0-HEATVat@,
and "0001" a t
any of - shown
I Action I
Refer to (3) of section 6. 1 1 3.1 to remove the cause.
-
I driving mechanism 1
Defective -
adjustment to the
1 of the machine I
Overload on the
manipulator
Check the machine.
"ENCODER Motor failure Replace the motor.
Reduce the load.
I I ABN"at @ , and I 1 ' I I - I
I 1 "0001" a t any of I H- Check the encoder
I I correctly.
/ - shown of encoder cable
and connect
Replace the encoder
cable connections
I encoder cable. I I cable.
Replace the servo
Troubleshooting 6 - 5 3
ATJ' a t @ , and
"0004" a any of
failure. driver.
I Symptom 1
Servo Failure r12 Beyond the
position
deviation limit
I Check Item I I Possible Cause I
All failure codes Problem of system Re-install the system
I showing "0000" 1
Noise affecting the Take some measures to
-
1 parameters
None of Axesl- 6
operable by
manual
I parameters.
Blown fuse on
Interlock board
system
Failure a t
highspeed
operation
Replace the fuse.
1 protect from noise.
Imperfect contact Check the connections
-4 Too large load Reduce the mechanical
1 of motor line
I load.
of Servo driver
connectors CN5 1 - CN56.
Beyond the
speed
command limit
Re-install the system
parameters.
1 operation I Servo Failure
13
Imperfect contact Check the connection
Failure a t
highspeed
----
1 6 operable by
manual
manipulation
-
/ of motor line / of the motor power
I line.
Problem of system
parameters
-1 Noise affecting H Take some measures to 1
-
I the system I protect from noise.
command limit
Reduce the mechani
cal load.
- Servo Failure
14
Beyond the
I the system / to protect from noise. 1
1 operation
Troubleshooting 6 - 5 5
-
current
Failure when
starting
Noise affecting Take some measures
Too heavy load
Servo Failure I 99
Failure a t the
servo startup
6 - 5 6 Troubleshooting
Perform the same
checks a s those of
Servo Failure 8
according to the
servo failure display on
the teaching box.
Hie ra rch ica l D iag ram o f Funct ion key
1 H ierarchical Diagram of Function key 1 Function keys shown following D are displayed by pressing the Next Candidate key. 0
Even a function of a n option is included.
1. TEACH --IF1 T E A C H ] ( 1 . 1 )
- I F 2 E D I T 1 ( 1 . 2 )
- I F 3 F I L E I ( 1 . 3 )
--IF4 A L L O T I
--IF5 L O C K I
- 1 ~ 1 P A R M T E R ~ ( 1 . 4 )
- IF2 C H E C K 1 ( 1 . 5 )
--IF3 MANAGE 1 ( 1 . 6 )
- I F 4 S Y S . S E T ] ( 1 . 7 )
- IF5 MEMORY ] ( 1 . 8 )
,.....--..-----..... I Function under development
1.1 TEACH I F 1 L I S T F 2 R O L L U P
P R G NO. F 2 R O L L DN
F 1 S E A R C H [ ~ l S Q MARK]
IF2 A S / A E 1
F 3 WS
F 1 RENAME F 4 S T / E T
IF5 P A T H AT] ( F 5 S F * I
R E V E R S E ; t , ( F 2 C L / J F J P I When the number exists
1 " S E A R C H j r 1 F l S Q MARK F 3 T 1
t 1 ~ 2 J U M P 1 t ( F 2 AS/AE 1
IF3 WS 1
F 4 S T / E T I
IF5 P A T H AT1 IF5 S F * I IF1 ASM SET1 JCY IF1 1/0 1
IF3 R E V E R S E ] ( F 2 C L / J F J P ]
IF3 T I
Hierarchical Diagram of Function key 1
[ F 2 H L
I F 3 H C I
I F 5 H C C H G . I
[ E l H L O
I F 2 H O 1
I F 5 H O C H G . I I F 1 M P S I
-12.2 1/0 [ E l S E T I F 2 M P E I
I F 2 R E S E T F 3 E P I
I F 3 I N P O N
I F 4 I N P O F F
I F 1 S N R
F 2 S F R
- I F 3 B R A N C H /-IF1 C L c L O N
F 2 C L O F F
( F 3 C L C N T 1
I F 4 U N C O N D 1
I F 1 J P O N I
I F 2 J P O F F I
I F 3 J P C N T /
F 4 U N C O N D I
--IF3 J F I F 1 J F O N 1 I F 2 J F O F F 1
( F 3 J F C N T \
F 4 U N C O N D /
- 1 ~ 5 C O U N T E R I ~ I ; ; ;;; I
I I
2 Hierarchical Diagram of Function key
--IF4 W E L D [ E l A S N U M . ]
1 ~ 2 A E NUM. I
1 F 3 A S F I L E ]
I F 4 A E F I L E ]
I F 2 A E M
I F 1 I C H
I F 2 R I C
F 3 GS
I [ F l F P NUM.1
I F 2 F P F I L E /
I F 3 A X NUM. I I F 4 A X F I L E ]
F 5 WE 1
I F 1 T I M E R I
When a Sensor selection i s a l ine master.
When a Sensor selection i s a laser sensor.
I F 4 Z O N
IF5 Z O F
- I F 3 E N D L E s s l T I F l R T 1 r . - . . - - - . - . - - - . . - - - - a F 2 R R N .-------..------.-.. r.----...--....----- 88'3 .---.-...-.---...--. R R F
Hierarchical Diagram of Function key 3
1.2 EDIT jF2 E D I T 1 - IF1 T E A C H 1- /~1 L I S T F 1 R O L L U P
[PRG NO. F 2 R O L L DN
F 1 S E A R C H 1 ~ 1 S Q M A R K /
IF2 A S / A E 1
F 3 WS
F 4 S T / E T
LF5 P A T H AT/ [ F 5 S F * 1 1
When the number ex i s t s I F I S Q MARK^ / F Z C L / J F J P ]
- I F 2 J U M P 1122 A S / A E / IF3 T /
- I F 3 S H I F T I I F 3 WS 1
- I F 4 P A T H [ F 4 S T / E T 1
- 1 ~ 5 P A T H AT/ IF5 S F * 1
- I F 3 R E V E R S E ]
F 3 T / When the number dose not ex i s t -------lp 1 M O T I O N / F 1 P
IF2 HL
( F 3 HC 1
IF5 HC CHG.1
[ F I H L O 1
IF2 HO 1
IF5 HO CHG. I
IF1 M P S I
IF2 1/0 $1 S E T IF2 M P E I
IF2 R E S E T F 3 E P 1
I F 3 I N P ON
IF4 I N P O F F
I F 1 S N R
F 2 S F R
4 Hierarchical Diagram of Function key
- I F 1 C L
Ill IF1 C L ON ]
[ F 2 C L O F F 1
IF3 C L CNT ]
F 4 UNCOND /
- I F 2 J P / F I J P ON 1
IF2 J P O F F I
F 3 J P CNT I
L ~ ~ 4 UNCOND /
IF^ J F ON ]
IF2 J F O F F j
IF3 J F CNT /
IF4 UNCOND
T E l D E F
F 2 D E C
1F 2 AE NUM. I
IF3 A S F I L E J
IF4 AE F I L E ]
J IF2 AEM 1
I IF2 R T C 1 I F 3 G S 1 F 4 GE I
- I F 5 WEAVE I l lFl F P NUM. I
[ F 2 E P F I L E )
I F 3 AX NUM. I
IF4 AX F I L E ]
F 5 W E 1
Hierarchical Diagram of Function key 5
-IF2 W S FILE]
-
IF1 F I X E D / iPS...w-iid..P.i-R-i.; ..--..-...--..------- LF.2--.FRE-Q: .--.. j
......-...--.....--.. -[F4 A S F I L E / LF.?--.P-!T-C.H.. ..I
--IF5 A E F I L E / IF4 J O I N T 1
f i en a Sensor selection i s an arc sensor.
1 When a Sensor selection 1s a laser sensor.
(F4 Z O N I
IF5 Z O F i
- 1 ~ 3 E N D L E S S ] .-.....-.......----- ;F-Z.-RRN -.-. -.-- .-..---...-.-------- 1:' :F.?-.RRF R T .....--- I
6 Hierarchical Diagram of Function key
IF3 O F F S E T I
IF4 S Q I-----INO. E N T R Y I IF5 L A S E R - $
F 2 A E M - I F 1 I N P U T Ill / F I R O L L UP]
/ F Z R O L L D N ]
[ F 3 N O P / M A P /
F 4 b i t I
- I F 2 O U T P U T
IF1 R O L L UP]
IF2 R O L L D N ]
F 3 NOP/MAPI
I L ~ F 4 b i t 1
I F O G C T I IF1 R O L L U P ]
IF2 R O L L D N ]
F 5 E N D J
I F 4 spEclALi J [ E l S Q I N ]
I Il IF1 R O L L U P ]
IF5 E N D IF2 R O L L DNI
IF3 NOP/MAP]
F 4 b i t 1
I F 2 s Q O U T ITl / E l R O L L UP]
IF2 R O L L DN]
IF3 N O P / M A P ]
F 4 b i t 1
I F 3 A N L I N [ E l R O L L UP]
[ F 2 R O L L D N /
IF3 NOP/MAP]
I IF1 R O L L UP]
- I F 5 E N D 1 IF2 R O L L D N ]
IF3 N O P / M A P I
F 4 b i t I
Hierarchical Diagram of Function key 7
1.3 FILE / F 3 F I L E 1 - - / E l T E A C H 1 E l R O L L UP
I F 1 S Q MARK1
F 3 WS
E l R E N A M E F 4 S T / E T
--IF2 W E L D I F 1 R O L L UP1 I F 5 P A T H A T ] p 5 S F * I
I F 3 E D I T ] ~ 3 R E V E R S E ]
[ F 4 C O P Y 1
I F 5 D E L
F 3 W E A V E
LF2 R O L L DNI
I F 3 E D I T
I F 4 C O P Y
I F 5 D E L
E l R E N A M E
8 Hierarchical Diagram of Function key
[ F 3 E D I T 1
I F 4 C O P Y 1
I F 5 D E L I
F 1 R E N A M E ]
I F 1 R O L L U P ]
I F 2 R O L L D N ]
I F 3 D I S P 1
[ F 4 C O P Y 1
[ F 5 D E L I
I F 1 R E N A M E ]
- I F 1 O F F S E T J I F 1 R O L L U P ]
$ 2 R O L L DNI
r F 3 E D I T
I F 4 C O P Y
[ F 5 D E L
F 1 R E N A M E
I F 1 R O L L UP]
I F 2 R O L L DN]
I F 3 E D I T
I F 4 C O P Y
F 3 D E L 1
I F 1 R O L L UP1
I F 2 R O L L DNI
F 3 N O P / M A P ]
L / ~ 4 b i t I
- - I F 2 O U T P U T Ill [ F l R O L L UP1
I F 2 R O L L DN]
[ F 3 N O P / M A P ]
F 4 b i t I
- I F 3 I C T I [ E l R O L L U P /
I F 2 R O L L DN]
F 5 E N D I - I F 4 S P E C I A L I F 1 R O L L U P /
f F 2 R O L L DN]
I F 3 N O P / M A P /
F 4 b i t 1
ll I F 2 R O L L DN]
IF^ N O P / M A P /
F 4 b i t 1
- I F 3 A N L I N ]II [ E l R O L L UP1
[ F 2 R O L L DNI
1 ~ 3 N O P / M A P ]
F 4 b i t 1
- I F 4 OUT![
I F 1 R O L L U P ]
[ F 2 R O L L D N ]
I F 3 N O P / M A P ]
F 4 b i t I
Hierarchical Diagram of Function key 9
1.4 PARMTER IF1 S Y S T E M /
IF2 S W I T C H 1
IF3 W E L D 1
IF4 1/0 I
IF5 A U T O I IF1 N O T E I
IF2 ARC-S IF2 S/W-ARC]
IF3 TOUCH-S/ IF3 S-LASER1
IF4 W- CHAR^
1.5 CHECK p 2 C H E C K 1 IF1 D U M P
T I
I L 1 ~ 3 M O T I O N / IF1 M A I N 1
IF 2 1/0 I
p3 M O T I O N I
F 3 M O D I F Y F 1 M A I N I F 2 I/O I
F 3 M O T I O N I
I N P U T IF1 M A I N 1
I
IF3 M O T I O N 1 F 2 O U T P U T IF 1 M A 1 N 1
I IF2 S T A T E I IF3 M O T I O N I
-1,s L G C CHKJ-1~1 PRG. A L
::::IRM1 I 1
1 0 Hierarchical Diagram of Function key
Hierarchical Diagram of Function key 1 1
1.6 MANAGE IF3 MANAGE I
IF1 T E A C H 1
IF2 WELD
IF 3 WEAVE
IF4 S Q
IF5 O F F S E T
I F 3 L A S E R - S
F 1 T E A C H
F 2 WELD
T, F 1 A S C
F 2 A E C J
( ~ 1 W F P 1 - I F 4 S Q F 2 WAX I
89
- I F 5 O F F S E T ]
- I F 1 W-CHARA]
I F 1 S Y S T E M I ..-.-.--..-----.-.--
- : F 3 .------.--------.-.- DEV. CAL: IF2 S W I T C H /
IF3 WELD
IF4 1/0 1
[F5 A U T O I
IF2 TOUCH-S]
F 3 S - D A T A (
I F 1 ASM I
F 2 AEM I
1.7 SYS. SET pi174 S Y S . S E T I - I F 1 M E C H . 1 j
[ F 2 M E C H . 2 I I F 3 M E C H . 3 ]
[ F 4 M E C H . 4 I
I F 5 M E C H . 5 (
- $ z RESTART]-1~1 C O N F I R M I
- I F 3 M S T R I N G ]
- I F 4 c O N T R O L 1 l [
[ F l MU-CRDN]
- [ F 5 M A N U A L I I F 1 R O T A T 11
I F 2 R O T A T 21
F 3 C A R T E . 1
I F 1 S E T I
- 1- I F 2 L I S T 1
F 5 D E L
1 2 Hierarchical Diagram of Function key
1.8 MEMORY [ F 3 MEMORY I------IF1 L I S T I F I P R O G R A M ]
IF2 WELD
IF3 WEAVE
[F4 S Q
[F2 L A S E R - S
F 3 T O U C H - S
F 2 S A V E F 1 S E P A . F 1 PROGRAM
IF2 WELD IF1 A S C
IF2 A E C
[ F 3 ASM
F 4 AEM
[F 3 WEAVE IF1 W F P
.-------------.--.-- : F 2 W C P - - - - - + - . - - - - - - - . - - - -
.----.------...-.--. l F 3 WCF .---..---....-.-.-..
IF4 WAX ..-------.--.....--. : F 5 WVP .----..----.....--..
F 4 TOUCH-SI
F 2 A L L F 1 P R G A L
F 3 B A C K U P F 2 WELD A L
[ F 3 WEAV AL]
IF4 S Q A L 1
IF5 D E V A L I
IF2 L A S R ALI
I F 3 U S E R ALI
F 4 S Y S AL j
[ I F 5 T C H AL /
Hierarchical Diagram of Function key 1 3
- I F 3 LOAD 1 - --IF1 S E P A . [ ~ l P R O G R A M \
IF 2 WELD I F 1 A S C
J F Z A E C
I F 3 ASM
I F 3 WEAVE I F 1 W F P
I F 1 O F F S E T IF4 WAX
F 4 TOUCH-S]
F 2 A L L E l P R G A L
F 3 B A C K U P F 2 WELD A L
I F 3 WEAV ALI
IF4 S Q A L 1
IF5 DEV AL 1
11-2 L A S R A L I
I F 3 U S E R ALI
IF4 S Y S AL I
1 4 Hierarchical Diagram of Function key
F [ F 4 V E R I F Y I---rlFl S E P A . ]--[--IF1 PROGRAM]
I / F 3 WEAVE 1
( F 5 DEV CALI
IF1 O F F S E T I IF2 L A S E R - S J
A L L
[F 3 W-CHARAI
IF4 T O U C H - S /
F 1 P R G AL 1 F 3 B A C K U P F 2 WELD A L
IF3 WEAV ALI
IF4 S Q A L I IF5 DEV A L 1
IF2 L A S R ALI
I F 3 U S E R AL]
IF4 S Y S A L 1
- I F 5 D E L . F 1 PROGRAM F 5 T C H AL I
F 2 WELD
IF3 WEAVE I
IF4 S Q
IF1 O F F S E T
F 1 I N I T I A L --,-El U S E R
t l F 2 A E C 1
t , p 3 ASM
F 4 AEM 1 IF1 W F P I .---..-...-.---..-.. : F 2 .---.-..---.---.---. WCP r . - . - - - - - - . . - . . . - - - - eF 3 WC F
IF4 WAX I r...---.--..--..--.. sF5 WVP
t l F 2 A E C 1
t , IF3 ASM I
F 4 AEM I
[ E l W F P I ----..---.-----..... K.2- - -k'-c-p. -. . -. - .: ..--.---....---....- F-3.. .k'.G-Y- -. -. . . . : IF4 WAX 1 - - - - - - - - -~~ . . . .~~~~ . LF.3 - - -k'-v.p.. . - . - - - :
L [ ~ 2 S Y S T E M ]
Hierarchical Diagram of Function key 1 5
1.9 Function selection key input IF1 C O R D N T E ] ....---......---..--. :F-2- - -HAND- - W.?; IF3 C R D MOVl
IF4 1/0 R S T ]
F 5 L A S E R I
2. AUTO 2.1 Automatic operation Temporary stop (Multi - station)
I F I RESERVE^
[ F 3 S T R T POI-IF1 P O S S E T ]
F 4 R E T R E A T /
2.2 Automatic operation Temporary stop (BCD, Binary) E l P O S S E T ]
1 6 Hierarchical Diagram of Function key
Appendix
Contents
1. Restrictions on the Overlap Process 1
2. The Relation Between a Minimum Circular Diameter and a Setting Speed ---.-.----.--.-.. 4
3, Restrictions on Weaving Frequency ............................................................................................................ 5
4. Tool Parameters 10
Appendix 1. Restrictions on the Overlap Process
Positioning P
(I) Even if Overlap is set ON, the overlap process may not be in effect depending on the
relation between a travel distance and a travel speed.
Speed
F i g . 1 The relation between the overlap effective travel distance and travel speed
(2) Even if Overlap is set on, the overlap process is not in effect in the following
conditions:
When neither one of two consecutive sequences has Positioning instruction (P)
Sequence Instruction
0 0 1 P 0 0 2 / Overlap is in effect
0 0 2 P
0 0 3 P ,
0 0 4 L P
0 0 5 P LK Overlap process not in effect
When Input Wait instructions(N, or F), Timer Time Wait instruction (T), or No
Operation instruction (NOP) is taught between two sequences
Sequence Instruction
0 0 1 P
0 0 2 P 002 / Overlap is in effect
0 0 4 P f
' Overlap is not in effect p , ~ 0 0 1
Appendix 1
Linear I n terpolation L (or Circular Interpolation)
(1) Even if Overlap is set ON, the overlap process may not be in effect depending on the
relation between a travel distance and a travel speed.
Speed rate [ . .
1 Overlar, Drocess not in effect
<
O l5 20 Travel distance per sequence [ mm 1
Fig.l.2. The relation between the overlap effective travel distance and travel speed
(2) Even if Overlap is set on, the overlap process is not in effect in the following
conditions:
* When two consecutive sequences a re taught with different coordinate systems.
When Input Wait instructions(N, o r F), Timer Time Wait instruction (TI, o r No
Operation instruction (NOP) is taught between two sequences.
* When two consecutive sequences are synchronous interpolation instructions (HL, KC)
and single interpolation instructions(L, C) respectively.
(Example]
003 H P 100% WORK LAP:ON M1,2 004 L 100cm WORK LAP:ON MI 005 H L 100cm WORK LAP:ON M1,2 006 H L lOOcm WORK LAP:ON M1
/ Overlap is not in effect
L
2 Appendix
* When the main mechanism is difference between two consecutive sequences.
(Example1
002 H L 100cm WORK LAP:ON M1,2 003 H L 100cm WORK LAP:ON M1,2 (The main mechanism is set mechanism 1) 004 H L 100cm WORK LAP:ON M1,2 (The main mechanism is set mechanism 1) 005 H L 100cm WORK LAP:ON M1,2 (The main mechanism is set mechanism 2)
tL e---Overlap is in effect
Appendix 3
Appendix 2.
The Relation Between a Minimum Circular Diameter and a Setting Speed
The minimum circular diameter varies according to speeds. The relation between a speed
and a diameter is shown below. Note that the usable area varies according to angles of
the wrist axes.
0 1
4
2 Speed (m/min)
Fig.2.l. The relation between a minimum circular diameter and a speed (ALMEGA G01) p\\\\\\yr (md Usable area
k Q) i-'
Q)
5 100 .3
Tb k cd 4
3 2 50 ;;7
0 1 2 3 Speed (m/min)
Fig.2.2. The relation between a minimum circular diameter and a speed (ALMEGA G03)
Speed (m/min) Fig.2.3. The relation between a minimum circular diameter and a speed (ALMEGA V series)
4 Appendix
Appendix 3. Restrictions on Weaving Frequency
Weaving may not be performed in accordance with the weaving frequency setting.
The relation between a frequency setting and an actual frequency varies according to a
combination of mechanisms.
For details, refer to the following table and Fig.3.1 through Fig.3.7
Table 3.1 Classification based on the system configuration
V01 single unit (overhead) I B
System Configuration
V01 single unit
GO1 single unit
V01 single unit (wall mounting) 1 B
System Category
B
A
VOI+ 1-axis s I B
VOI+ z-axis P I D
V01 i- 1-axis P + l-axis S
V01+ z-axis P + l-axis S
GO1 + l-axis S
D
E
GO1 single unit (overhead)
GO1 single unit (wall mounting)
GO1 + l-axis P
A
A
GO1 + Z-axis P
P : a positioner S : a slider
GO1 i- l-axis P + l-axis S
GO1 + Z-axis P + l-axis S
Appendix 5
C
D
The relation between a set frequency and an actual frequency for
Axis weaving and Fixed pattern weaving
6
t Actual frequency 5
2 4 6 8 Frequency setting (Hz 1 4
Fig.3.1. System Category A
Actual t
frequency
2 4 6 8
Frequency setting (Hz I -+
Fig.3.2. System Category B
6 Appendix
2 4 6 8 Frequency setting ( Hz )
Fig.3.3. System Category C
2 4 6 8
Frequency setting ( Hz )
Fig.3.4. System Category D
Appendix 7
2 4 6 8
Frequency setting ( Hz 1 Fig.3.5. System Category E
8 Appendix
2 4 6 8
Frequency setting [ Hz )
Fig.3.7. System Category G
@ Impontaut 1) This relation is based on an assumption that each of center, 1/4, and 3/4
stopping time settings is 0. If these settings are not 0, this relation is not applicable, and the actual frequency is lower than the set frequency.
2) The actual weaving frequency during seam tracking with the arc sensor is further lower.
\
Appendix 9
Appendix 4. Tool Parameters Tool parameters 1 - 6 are available.
1. To use a curved torch or straight torch for ALMEGA V series fixed a t some angle
from the direction perpendicular to the flange face with a bracket (see Fig.4.1, Fig.4.2, and Table 4.1.):
Parameter 1 = P 1 [ml Parameter 2 = P 2 [ml Parameter 3 = P 3 Cmnl Parameter 4 = P 4 [degl Parameter 5 = P 5 = 0 . 0 Cdegl Parameter 6 = 0 . 0 [degl
To use a straight torch fixed a t an angle of 45' from the direction perpendicular to the flange face with a bracket, set parameter 4 a t -45' .
2. To use a straight torch for ALMEGA G series (see Fig.4.2 and Table 4.2): Parameter 1 = P 1 [m] Parameter 2 = P 2 [m] Parameter 3 = P 3 [ml Parameter 4 = P 4 = - 9 0 [degl Parameter 5 = P 5 = - 9 0 [degl Parameter 6 = 0 . 0 [degl
@ Note The value of parameter 6 should be always 0.0.
X A
P 2
Fig.4.1 A curved torch for ALMEGA V series
Fig.4.2. A straight torch for ALMEGA G/V series
Appendix 1 0
Tables 4.1 and 4.2 list DAIHEN torches and their tool parameter settings:
Table 4.1. Tool parameters fo r torches f o r ALMEGA V series
@Curved torch
V series
@Straight torch (fixed a t 45' from the direction perpendicular to the flange face with a bracket)
Tool Pa rame te r
MTXC-3501set
MTXC-3501 (100mm long) s e t
MTCW -5001set
MTCA-2501set
P1
MWP - 18 (w/shock sensor) s e t / 0.0 I 0.0 1 426 1-45.0 1 0.0 I 0.0
0.0
0 .O
0.0
0.0
MTZ-3502set
MWP- 17 (w/shock sensor) se t
P2
0.0
0.0
0.0
0.0
0.0
0.0
MWP- 17 (w/mechanical fuse) se t
MWP - 18 (w/mechanical fuse) s e t
P4 P 3
MTXA-2501set
CTPW -0801 (w/shock sensor) se t
Table 4.2. Tool parameters fo r torches f o r ALMEGA G series
Tool Pa rame te r
300
400
450
400 '
0.0
0.0
0.0
0.0
CTPW -0801 (w/mechanical fuse) se t
CTPW - 1201 (w/mechanical fuse) se t
P5
0.0
0.0
0.0
-45.0
-45.0
-45.0
-45.0
380
426
0.0
0.0
0.0
0.0
G series
0.0
0.0
P1 1 P2 I P3 I P4 I P5 1 0.0
MTX-3502set
MTY - 3502set
MTW -5001set 1 -235.0 1 0.0 1 28.0 1 -90 / -90 1 0.0
0.0
0.0
0.0
0.0
-45.0
-45.0
350
350
0.0
0.0
MTXW - 5002set
MTZ - 3502set
0.0
0.0
0.0
0.0
380
426
-235.0
-261.0
MWP- 18set 1 -235.0 / 0.0 1 43.0 1 -90 1 -90 1 0.0
0.0
0.0
-45.0
-45.0
350
350
-235.0
-285.0
MTXA -2051set
MWP - l7set
CTPW -0801set
0.0
0.0
-45.0
-45.0
0.0
0.0
CTPW - 120lset ( -235 .01 0.0 1 28.0 1 -90 1 -90 1 0.0
0.0
0.0
-45.0
-45.0
0.0
0.0
-280.0
-235.0
Appendix 1 1
0.0
0.0
0.0
0.0
28.0
28.0
0.0
0.0
0.0
0.0
28.0
28.0
0.0
0.0
0.0
0.0
-90
-90
-90
-90
28.0
43.0
- 90
- 90
0.0
0.0
- 90
- 90
-90
-90
0.0
0.0
- 90
- 90
0.0
0.0
Various kinds of weldinu machines are available from DAIHEN. DAIHEN produces and sells every kinds of welding machines.
ITEMS OF MAIN PRODUCTS
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MIG ARC WELDING MACHINES
TIG ARC WELDING MACHINES
SUBMERGED ARC WELDING MACHINES
NO-GAS-SHIELDED ARC WELDING MACHINES
STUD WELDING MACHINES
AIR PLASMA CUTTING MACHINES
ARC WELDING ROBOT
CO, LASER EQUIPMENTS
Printed in Jaoan
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