Motoman Controller HyperStart User Manual · 2018-12-10 · Motoman, Incorporated 805 Liberty Lane...

Motoman Controller

HyperStart User Manual(MRC-DX100 Controllers)

Part Number: 148375-1CDDocument Version: 5

Motoman, Incorporated 805 Liberty LaneWest Carrollton, OH 45449TEL: (937) 847-6200FAX: (937) 847-627724-Hour Service Hotline: (937) 847-3200

The information contained within this document is the proprietary property of Motoman, Inc., and may not be copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

Inc.

©2005 by MOTOMANAll Rights Reserved

Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

HyperStart148375-1

Abstract

This is the preliminary copy of the HyperStart User Manual.

Document Control Sheet

Table 1 Document Control Sheet

Document Title: User Manual HyperStart

Version: 2

Issue: 1

Edition: English

ID: 148375-1

Status: Final

Created: August 13, 2003

Date: May 24, 2005

Keywords: arc welding, software

Tools DTP System: Adobe FrameMaker Version: 7.0

Layout Template:

Motoman Manual Template Version: V2.0 - 5 July 1999

Authorship Written by: Paula Copeland

Reviewed by: Jason Young, Chris Anderson

Edited by: Paula Copeland

Approved by: Sally Fairchild

Final

User Manual Document Status Sheet

Document Status Sheet

Document Change Record

Table 2 Document Status Sheet

Title: User Manual HyperStart

ID: 148375-1

Version Issue Date Reason for change

2 0 2/9/04 Corrected Appendix

Table 3 Document Change Record (of changes made since version ... )

Title: User Manual HyperStart

ID: 148375-1

Version: 1 Originator: G.Hxxx

Date: 22 April 2003 Approved By: I.Jxxx

Page Paragraph Reason for Change

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Table of Contents

Chapter 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1 HyperStart Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Cycle Time Savings Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.4 Reference to Other Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.5 Customer Service Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 Standard Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 General Safeguarding Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4 Mechanical Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5 Installation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Programming Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.7 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.8 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 3 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.1 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 HyperStart Control Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.3 Related Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.4 HyperStart Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4.1 HyperStart for NX/DX - Static Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.4.2 HyperStart for XRC with Macro Function- Static Start . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.4.3 HyperStart for XRC without Macro Function - Static Start . . . . . . . . . . . . . . . . . . . . . . 19

3.4.4 HyperStart for MRC - Static Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.4.5 HyperStart for NX/DX - Dynamic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.4.6 HyperStart for XRC - Dynamic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.4.7 HyperStart for XRC without Macro Function - Dynamic Start . . . . . . . . . . . . . . . . . . . 23

3.4.8 HyperStart for MRC - Dynamic Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.4.9 HyperStart for NX/DX - Enabling “WLD DONE = RBT MOV” w/ “Static Start” . . 26

3.4.10 HyperStart for NX/DX - Disabling HyperStart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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User Manual Table of Contents

Chapter 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Appendix A I/O Assignments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Chapter 1

Introduction

1.1 HyperStart Overview

Motoman's HyperStart software function offers a variety of benefits, including reduced cycle time, reduction in weld build-up at start of weld, and better detection of missed arc welds. This function allows users to specify parameters critical for controlling the start and end timing of each weld. HyperStart parameters can used globally or changed from weld to weld. HyperStart is available for MRC, XRC, NX100, and DX100 generation controllers and typically functions independent of the welding power supply.

The MRC and earlier XRC versions of HyperStart allow the user to configure five welding parameters (four timers and one counter) for their welding application. These parameters values are set in Teach mode using the I/O registers. Changes to the various parameter values can only be performed in Teach mode. However, once set, these five welding parameters can be toggled On or Off at any point in the robot job.

Later versions of the XRC, and all versions of the NX/DX, allow the welding parameters to be changed using the “R*-Hyper” macro command. This macro command allows the user to change parameter settings at any point within a robot job. Each robot has its own set of HyperStart settings so the parameter settings for Robot 1 can be totally different than those used on Robot 2. This provides additional flexibility as weld length, part fit-up, and weld quality demands change.

The NX/DX uses two aditional parameters to provide easier enabling and disabling of the HyperStart function along with a new feature that ensures that the weld is completed and the arc has been extinguished before the robot is allowed to move away from the ARCOF point.

Features:

• Significant cycle-time savings in applications with numerous welds.

• Single instruction (XRC, NX/DX) or output (MRC) changes all starting and ending parameters.

• “Dynamic Arc-Starting” reduces cycle time and excessive weld build-up at start of weld by keeping the robot moving while starting the arc.

• “Static Arc Starting” provides consistent bead length while still saving cycle time at the end of the weld.

• Robot retry function continues to work when using “Static Arc-Starting” (does not with “Dynamic Arc-Starting”).

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User Manual Chapter 1 Introduction

• Better detection of arc faults with “Arc Outage Time” and “Arc Outage Counter” parameters.

• Independent settings for each robot in multi-robot applications.

• Includes “Weld-In-Teach” feature for program verification.

• NX/DX version “WLD DONE = RBT MOV” parameter, ensures robot does not move until arc is extinguished.

1.2 Cycle Time Savings Analysis

Cycle time savings might vary by a few tenths of a second per weld, depending on a particular power supply's ending routine. HyperStart’s programmable settings can be changed to suit different joint or material types.

The chart below compares approximate cycle time savings on different controllers using various welding power supplies.

* Actual results may vary depending on application.1 HyperStart settings optimized for speed (cycle time), “Dynamic Arc Start”2 HyperStart settings optimized for consistent weld length, “Static Arc Start”3 HyperStart with Fronius CMT or Aluminum should use “wait for weld complete setting”

1.3 System Requirements

Refer to The chart below lists the available versions of HyperStart and defines the inputs/outputs, relays and additional timers required to run the HyperStart software on a specific robot system. Refer to Appendix A for I/O assignments.

Controller Power Source Number of Welds

Standard Cycle Time (sec.)*

HyperStart1 Savings %

HyperStart2 Savings %

DX100 Lincoln 50 90.13 31% 27%

DX100 Fronius CMT 50 115.53 31% 16%

NX100 Kobelco 6 26.55 21% 16%

XRC AutoInvision™ II 15 31.33 28% 26%

XRC MotoWeld™ II 24 44.73 26% 17%

XRC Dual Robot Auto Invision II 24 59.79 31% 27%

MRC MotoArc 8 20.19 29% 17%

Part NumberDX100/NX100

Description Virtual Outputs

Virtual Inputs

Auxiliary Relays

Additional Timers

Additional Counters

DX100 = NANX100 = 148376-9

NX/DX, Single robot, includes weld-in-teach

28 1 9 8 2

DX100 = NANX100 = 148376-10

NX/DX, DR2C, includes weld-in-teach

35 1 18 16 4

DX100 = NANX100 = 148376-11

NX/DX, TR3C, includes weld-in-teach

42 1 27 24 6

148376-1 XRC, Single robot, w/ macro function*, includes weld-in-teach

27 1 9 6 2

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* Requires macro job function available on XRC Version 5.07 or higher.

1.4 Reference to Other Documentation

For additional information refer to the following:

• Motoman Operator's Manual for Arc Welding

• Motoman Concurrent I/O Parameter Manual

• Vendor manuals for system components not manufactured by Motoman

• Motoman Robotic Arc Welding Manual (various welder models)

1.5 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have the following information ready before you call:

• Robot Type (EA1400N, HP20, etc.)

• Application Type (welding)

• System Type (ArcWorld model)

• Software Version (3.74A)

• Robot Serial Number (located on back side of robot arm)

• Robot Sales Order Number (located on controller)

• Power Source (Miller AutoAxcess)

148376-2 XRC, DR2C, w/ macro function*, includes weld-in-teach

32 1 15 12 4

148376-3 XRC, TR3C, w/ macro function*, includes weld-in-teach

37 1 21 18 6

148376-4 XRC, Single robot, w/o macro function, includes weld-in-teach

4 0 10 8 2

148376-5 XRC, DR2C, w/o macro function, includes weld-in-teach

7 0 17 16 4

148376-6 XRC, TR3C, w/o macro function, includes weld-in-teach

10 0 24 24 6

148376-7 MRC, Single robot or Master/ Slave, w/o macro function, includes weld-in-teach

4 0 8 4 1

148376-8 MRC, DR2C, w/o macro function, includes weld-in-teach

7 0 15 8 2

Part NumberDX100/NX100

Description Virtual Outputs

Virtual Inputs

Auxiliary Relays

Additional Timers

Additional Counters

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User Manual Chapter 1 Introduction

Notes

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Chapter 2

Safety

2.1 Introduction

It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries Association by requesting ANSI/RIA R15.06. The address is as follows:

Robotic Industries Association900 Victors WayP.O. Box 3724

Ann Arbor, Michigan 48106TEL: (734) 994-6088FAX: (734) 994-3338

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel who are adequately trained to operate, program, and maintain the robot cell. The robot must not be operated by personnel who have not been trained!

We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system.

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User Manual Chapter 2 Safety

This safety section addresses the following:

• Standard Conventions (Section 2.2)

• General Safeguarding Tips (Section 2.3)

• Mechanical Safety Devices (Section 2.4)

• Installation Safety (Section 2.5)

• Programming Safety (Section 2.6)

• Operation Safety (Section 2.7)

• Maintenance Safety (Section 2.8)

2.2 Standard Conventions

This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words:

DANGER!

WARNING!

CAUTION!

NOTE:

Pay particular attention to the information provided under these headings which are defined below (in descending order of severity).

DANGER!Information appearing under the DANGER caption concerns the protection of personnel from the immediate and imminent hazards that, if not avoided, will result in immediate, serious personal injury or loss of life in addition to equipment damage.

WARNING!Information appearing under the WARNING caption concerns the protection of personnel and equipment from potential hazards that can result in personal injury or loss of life in addition to equipment damage.

CAUTION!Information appearing under the CAUTION caption concerns the protection of personnel and equipment, software, and data from hazards that can result in minor personal injury or equipment damage.

Note: Information appearing in a Note caption provides additional information which is helpful in understanding the item being explained.

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2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows:

• Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the robot cell.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is not in use.

• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use lockout/tagout procedures during equipment maintenance. Refer also to Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, ANSI/RIA R15.06 safety standards, and other local codes that may pertain to the installation and use of industrial equipment. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following safety measures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.

2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations.

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Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R15.06 safety standards are permitted to install the equipment.

• Identify the work envelope of each robot with floor markings, signs, and barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry into the work envelope.

• Eliminate areas where personnel might get trapped between a moving robot and other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching and maintenance procedures.

2.6 Programming Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Programming tips are as follows:

Any modifications to PART 1 of the XRC controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

Some operations require standard passwords and some require special passwords. Special passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these special passwords.

Back up all programs and jobs onto a floppy disk whenever program changes are made. To avoid loss of information, programs, or jobs, a backup must always be made before any service procedures are done and before any changes are made to options, accessories, or equipment.

The concurrent I/O (Input and Output) function allows the customer to modify the internal ladder inputs and outputs for maximum robot performance. Great care must be taken when making these modifications. Double-check all modifications under every mode of robot operation to ensure that you have not created hazards or dangerous situations that may damage the robot or other parts of the system.

• Improper operation can result in personal injury and/or damage to the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to operate the system.

• Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Be sure that all safeguards are in place.

• Check the E-STOP button on the teach pendant for proper operation before programming.

• Carry the teach pendant with you when you enter the workcell.

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• Be sure that only the person holding the teach pendant enters the workcell.

• Test any new or modified program at low speed for at least one full cycle.

2.7 Operation Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Operation tips are as follows:

• Be sure that only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories are permitted to operate this robot system.

• Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

• Inspect the robot and work envelope to ensure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.


• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the cell.


• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

• All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.

2.8 Maintenance Safety

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. Maintenance tips are as follows:

• Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

• Check all safety equipment for proper operation. Repair or replace any non-functioning safety equipment immediately.

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• Back up all your programs and jobs onto a floppy disk whenever program changes are made. A backup must always be made before any servicing or changes are made to options, accessories, or equipment to avoid loss of information, programs, or jobs.

• Do not enter the robot cell while it is in automatic operation. Programmers must have the teach pendant when they enter the cell.


• Be sure all safeguards are in place.

• Use proper replacement parts.

• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

• All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

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Chapter 3

Operation

3.1 Theory of Operation

HyperStart takes advantage of optimized timers in the Concurrent Input/Output (CIO) ladder to save cycle time. New systems with HyperStart and older systems retrofitted with this software have similar functionality, but require different programming.

On newer XRC and NX/DX systems, the HyperStart instruction takes input data and transfers it to M registers used by the ladder program. This is achieved by a “macro job” that is executed when the robot controller performs a HyperStart instruction in the robot program. The arc on and off timing will always use the same M registers. The values set in these registers are changed by the HyperStart instruction. This provides maximum flexibility and allows the user to change any value at any point during the program. Once a value is set in the register, it will remain set until another HyperStart instruction is executed.

Older MRC systems and XRC controllers with software versions below 5.0 do not support the macro job function. For these controllers, a second set of registers are designated with the optimized HyperStart settings. An output is programmed into the robot job to signal the system to use the HyperStart values instead of the original register values. The effect is HyperStart is simply turned on and off in the robot program. The “Dynamic Start Time” value is controlled by a separate output. If additional cycle time savings are desired, and a minor variation in weld length can be tolerated, then the Dynamic Start output can be turned on in addition to the HyperStart output. A “Static Start” (timer value of zero) will be executed if the Dynamic Start output is off. Use Maintenance mode to set register values on the XRC (M0**). For the MRC, set the register values in C variables ($C**).

The HyperStart instruction has R1, R2, and R3 designations for multiple robot controllers. HyperStart has a robot control group designation and has to be executed in a job with the same control group designation, that is, the R1 HyperStart instruction can not be in a concurrent “Master” job with no motion, it has to be in an R1 “Safe” job or R1 “Weld” job. Alarm signals will include references to the robot which faulted. Standard configuration for multiple robot controllers is that all motion tasks stop (and arcs stop) when an alarm condition exists for any individual program.

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User Manual Chapter 3 Operation

3.2 HyperStart Control Parameters

Motoman’s HyperStart function uses five control parameters for the MRC and XRC robot controllers and seven control parameters for the NX/DX. The two additional parameters provide the NX/DX with an improved method for activating each HyperStart function.

• HyperStart On/Off (NX/DX only, either 1 or 0) This parameter turns all HyperStart functions ON or OFF for the associated robot. This is an improvement over the XRC version where the user must manually turn off each parameter to return the robot to a non-HyperStart state. By setting this parameter to a “0” setting, all of the following parameters are desabled along with the two “Arc Outage” alarms. A setting of “0” also disables the “Wld Done=Rbt Mov” function. When HyperStart is disabled, the robot also reverts to using a 200 ms “Wire Stick Check Delay Time” and 300 ms “Wire Stick Check Time”. Setting this value to “1” enables the HyperStart function and allows the following parameters to take effect

• Dynamic Start Time - t1 (set in 0.1 second intervals). Setting this timer to a value greater than zero provides “Dynamic arc starting.” “Dynamic arc starting” produces optimum cycle-time by allowing the robot to begin starting the arc while approaching the workpiece. If the arc does not start within a set time period, the robot will stop and an “R* DYNAMIC STARTING FAULT” alarm appears on the programming pendant. This prevents the robot from making welds that are too short. Customers with critical weld lengths should set this parameter to zero to ensure “static arc-start” or program longer weld lengths. “Static arc start” moves the robot to the programmed arc-on position and waits until an arc has been established before moving the duration of the weld.

• Arc Outage Time - t2 (set in 0.1 second intervals). This timer detects and controls missing arcs, tip failures, and missed sections of welds. Settings specify the duration of time the robot is allowed to move after an arc has been extinguished mid-weld. Once the specified time is reached, an “R* HYPERSTART ARC OUTAGE (TMR)” alarm appears on the programming pendant. An arc outage condition could be due to tip failure, wire feed problem, burn-though, or missing part. This timer also helps prevent long durations of missing welds.

• Arc Outage Counter (set in # of outage times). This counter is based on the “Arc Establish” signal from the welder. Arc outages can occur due to poor arc starts or large gaps. This counter establishes the number of times the arc can go out. When the number of arc outages exceeds the specified value, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm appears on the programming pendant. Arc outages of short duration may not cause weld defects.

• Wld Done = Rbt Mov (NX/DX only, set to either 1 or 0). This function allows the user to specify how the robot reacts at the end of a weld. Setting this parameter to a “0” allows the robot to immediately enter the “Wire Stick Check Delay” at the end of the weld. This ensures faster cycle times but does not ensure that the welder is done with its arc ending routine. Setting this parameter to “1” forces the robot to wait until the welder reports that the welding arc has been extinguished. Once the arc has been extinguished, the robot is then free to execute the programmed “Wire Stick Check Delay Time” and Wire Stick Check Time” commands.

• Wire Stick Check Delay Time - t3 (set in 0.1 second intervals). This timer setting is mainly used in aluminum welding applications and allows the user to specify a duration of time at the end of each weld where the weld puddle can cool and solidify before the program enters the next parameter “Wire Stick Check Time.”

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• Wire Stick Check Time - t4 (set in 0.1 second intervals). This setting controls the amount of time that the robot applies a “Wire Stick Check” voltage to the tip of the welding wire to ensure that the wire is free of the work. Most newer power supplies have built-in burnback and wire stick check circuitry, so setting this timer to zero removes the redundancy of the robot check and provides faster cycle-time.

3.3 Related Alarms

• Missing Arc Generation Confirm. This alarm is not a HyperStart alarm. It occurs when the arc does not come on at the start of the weld. This alarm could occur when using “Static Start.” It will not occur when using “Dynamic Start.” This alarm indicates that there is a feed problem or the welder is not turned on.

• Arc Failure. This alarm is generated by an output from the power source. It may be due to an arc condition or a fault in the power source.

Final page 13


Figure 1 HyperStart Settings and Alarm Conditions

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3.4 HyperStart Setup

Use the HyperStart function to enhance your welding application. HyperStart can be used to set up global default values. The HyperStart instruction can be inserted in a “sweep job” or “safe position” that will be executed every cycle. This will eliminate the need to insert the instruction in individual weld programs. All welds would use these settings. Another method to achieve global settings would be to develop a “reset” job for maintenance staff. Create a job with a single HyperStart instruction. Maintenance staff can run the job in PLAY mode or TEST START the job in TEACH mode. The timer values will remain set even when control power is turned off. These values would be overridden if a HyperStart instruction is executed in a program. The HyperStart instruction must be in a robot group job. Multiple robot cells will require a HyperStart instruction for each robot (R1, R2, etc.).

HyperStart provides excellent program control. The HyperStart instruction can be set for a group of welds or individually. Placing the HyperStart instruction at the top of the program after the NOP instruction would effect all the welds in the entire program. Individual welds or weld segments can be changed by placing the HyperStart instruction prior to the ARCON instruction. This control might be desirable for using default values for the first arc strike on the part or a joint configuration that requires a longer stickout or poor torch angle.

CAUTION!

The HyperStart instruction uses five to seven digits to set the different timers and counters. The instruction updates all values when executed. Make sure the desired values are set for each digit in the program. For example, if the XRC HyperStart instruction is set for Dynamic Start (R1- HYPER 3, 5, 5, 0, 0) and you want to change to Static Start, change the first digit to zero (R1- HYPER 0, 5, 5, 0, 0) and DO NOT zero out the other digits (R1 HYPER 0, 0, 0, 0, 0). Zeroing out the digits would result in constant alarm conditions.

Table 4 provides a quick reference guide for setting up default Dynamic and Static Start values on both XRC and MRC controllers.

Table 4 HyperStart Default Values for MRC/XRC Controller

* Registers for single robot configurations. See additional instructions in this chapter for registers for multiple robot configurations.

XRC Default

MRC Default

Sample Dynamic

Start

Sample Static Start

XRC* M-Register

MRC* Timer

Variable Units

Dynamic Start Time (t1) X X 5 0 M60 C004 0.1 sec

Arc Outage Time (t2) X X 8 8 M62 C005 0.1 sec

Wire Stick Check Delay Time (t3)

2 1 0 0 M66 C006 0.1 sec

Wire Stick Check Time (t4) 3 3 0 0 M67 C007 0.1 sec

Arc Outage Counter X X 5 5 M64 C020 count

Final page 15


Table 5 HyperStart Setup Values for NX100 and DX100

NX/DX Default

Sample Dynamic

StartSample

Static StartNX/DX M-Register

R1/R2/R3 Units

HyperStart ON/OFFN/A 1

(On)1

(On)N/A 1/0

Dynamic Start TimeN/A 8

(.8 sec)0

(Disabled)M200/M190/M180 0.1 sec

Arc Outage TimeN/A 5

(.5 sec)5

(.5 sec)M202/M192/M182 0.1 sec

Arc Outage CountN/A 3

(3 times)3

(3 times)M204/M194/M184 X times

Wld Done = Rbt MovN/A 0

(Off)0

(Off)N/A 1/0

Wire Stick Check Delay Time2

(.2 sec)0

(0 sec)0

(0 sec)M206/M196/M186 0.1 sec

Wire Stick Check Time3

(.3 sec)0

(0 sec)0

(0 sec)M208/M198/M188 0.1 sec

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3.4.1 HyperStart for NX/DX - Static Start

Set up your welding equipment for Static Start as follows:

1. From the INFORM LIST, select MACRO and then select R*-HYPER. Press SELECT twice. The HyperStart Setup screen appears:

2. Set the following values:

• HYPERSTRT ON/OFF = 1. Enables the HyperStart function and enables the following parameters.

• DYNAM START TIME = 0. Disables the “Dynamic Start” function and ensures a “Static Start”.

• ARC OUTAGE TIMER = 5. Set to trigger an alarm if the arc is extinguished for more than .5 seconds.

• ARC OUTAGE COUNT = 3. Set to trigger an alarm if the arc is extinguished more than three times.

• WLD DONE=RBT MOV = 0. Disables robot wait function allowing the robot to pull away at ARCOF.

• STICK CHECK DELA = 0. Eliminates wire stick check delay, saving 0.2 sec per weld vs. HyperStart OFF.

• STICK CHECK TIME = 0. Eliminates wire stick check, saving 0.3 sec. per weld vs. HyperStart OFF.

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3.4.2 HyperStart for XRC with Macro Function- Static Start

XRC with macro function Version 5.0 or greater - set up welding equipment for Static Start as follows:

3. From the INFORM LIST, select MACRO and then select R*-HYPER. Press SELECT twice. The HyperStart Setup screen appears:


• DYNAM START TIME = 0. Setting this parameter to “0” ensures a “Static Start.”

• ARC OUTAGE TIMER = 5. Setting this parameter to “5” allows the robot to move for 0.5 seconds without an arc in the event the “Arc Established” signal from the welder goes out. Once the Arc Established signal is out for 0.5 seconds, an “R* HYPERSTART ARC OUTAGE (TMR)” alarm occurs.

• ARC OUTAGE COUNT = 3. Setting this parameter to “3” allows the robot to move as long as the “Arc Established” signal from the welder does not go out more that 3 times. Once the Arc Established goes out more than 3 times, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm occurs.

• STICK CHECK DELA = 0. Setting this parameter to “0” disables the robot's “wire stick check delay” function saving considerable cycle time.

• STICK CHECK TIME = 0. Setting this parameter to “0” disables the robot's “wire stick check” function and saves cycle time.

5. On the programming pendant, select INFORM LIST and then MACRO. Locate the “R*-HYPER” command in the macro list and insert it into the R* weld job by pressing ENTER. The example below shows a welding job for R1 with HyperStart settings.

NOPR1-HYPER 0,5,3,0,0 Initial HyperStart SettingsMOVJ VJ=50.00MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00R1-HYPER 0,2,2,1,2 Modified HyperStart SettingsMOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00MOVJ VJ=50.00

ARGUMENT SETTING

!

R1 SCL

JOB EDIT DISPLAY UTILITY

R1-HYPER DYNAM START TIMEARC OUTAGE TIMER ARC OUTAGE COUNT STICK CHECK DELA STICK-CHECK TIME

0 (.X sec) 5 (.X sec) 3 (X times) 0 (.X sec) 0 (.X sec)

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3.4.3 HyperStart for XRC without Macro Function - Static Start

If you are using an XRC without macro function, the HyperStart settings are stored in various “M” registers. Two robot outputs control when the HyperStart settings go into effect. One output controls when a “Dynamic Start” is allowed. When DOUT # 186 is ON, Dynamic Start is enabled for R1 (R2 uses DOUT # 178, R3 uses DOUT # 170). The second output controls when the HyperStart Arc Outage Timer, Arc Outage Counter, Wire Stick Check Delay, and Wire Stick Check Time timers/counters go into effect. When DOUT #187 is ON, the HyperStart parameters are enabled for R1 (R2 uses DOUT # 179, R3 uses DOUT # 171). When DOUT #187 is OFF, all HyperStart parameters are disabled and the system uses the standard “wire stick check delay time” and “wire stick time.” When HyperStart is turned OFF, Arc Outage Time and Arc Outage Count are disabled.

“M” register values can be displayed in EDIT mode, but can only be changed in MANAGEMENT mode. To set up “M” registers, proceed as follows:

1. From the TOP MENU, cursor to IN/OUT and press SELECT.

2. Cursor to REGISTER and press SELECT.

3. Cursor to the M-VARIABLE you wish to change and press SELECT. Enter desired value and press ENTER to record.

4. Set each of the following “M” registers to the indicated value:

• M062 = 5 (R1), M052 = 5 (R2), M042 = 5 (R3). Setting this register to 5 allows the robot to move for 0.5 seconds without an arc, in the event the “Arc Established” signal from the welder goes out. Once the Arc Established signal is out for 0.5 seconds an “R* HYPERSTART ARC OUTAGE (TMR)” alarm occurs.

• M064 = 3 (R1), M054 = 3 (R2), M044 = 3 (R3). Setting this register to 3 allows the robot to move as long as the “Arc Established” signal from the welder does not go out more that three times. Once the Arc Established goes out more than three times, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm occurs.

• M066 = 0 (R1), M056 = 0 (R2), M046 = 0 (R3). Setting this register to zero disables the robot’s “wire stick check delay” function, saving considerable cycle time.

• M068 = 0 (R1), M058 = 0 (R2), M048 = 0 (R3). Setting this register to zero disables the robot’s “wire stick check” function, saving considerable cycle time.

5. Insert two DOUT commands in robot weld job to turn HyperStart ON but disable Dynamic Start function:

NOPDOUT OT#187 ON Activates R1 HyperStart SettingsDOUT OT#186 OFF Disables R1 Dynamic StartMOVJ VJ=50.00MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00DOUT OT#187 OFF Cancels R1 HyperStart and enables normal arc start/end timer settings.MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00MOVJ VJ=50.00

Final page 19


3.4.4 HyperStart for MRC - Static Start

If you are using an MRC, the HyperStart settings are stored in various “$C” registers.Two robot outputs control when HyperStart settings go into effect. One output controls “Dynamic Start.” When DOUT#122 is ON, Dynamic Start is enabled for R1 (R2 uses DOUT#114). The second output controls when the HyperStart Arc Outage Timer, Arc Outage Counter, Wire Stick Check Delay, and Wire Stick Check Time timers/counters go into effect. When DOUT #123 is ON, the HyperStart parameters are enabled for R1 (R2 uses DOUT # 115). When DOUT #123 is OFF, all of the HyperStart parameters are disabled and the system uses the standard “wire stick check delay time” and “wire stick time.” When HyperStart is turned off, Arc Outage Time and Arc Outage Count are totally disabled.

To set “$C” registers, follow these steps:

1. From the Main Display [DISP], press the F4 key [VAR].

2. Press the MORE key to view more menus.

3. Press the FS key [$C].

4. Press F1 [SEARCH] and enter the desired register (or use the cursor to scroll up and down to select the desired register).

5. Press the EDIT key and then the MODIFY key. Key in the desired register value. Press ENTER to record.

6. Listed below are the “$C” register settings for Static Start. Be sure to set each register to the indicated value:

• C05 = 5 (R1), C13 = 5 (R2). Setting this register to 5 allows the robot to move for 0.5 seconds without an arc in the event the “Arc Established” signal from the welder goes out. Once the Arc Established signal is out for 0.5 seconds an “R* HYPERSTART ARC OUTAGE (TMR)” alarm will occur.

• C19 = 3 (R1), C27 = 3 (R2). Setting this register to 3 allows the robot to move as long as the “Arc Established” signal from the welder does not go out more that three times. Once the Arc Established goes out more than three times, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm will occur.

• C06 = 0 (R1), C14 = 0 (R2). Setting this register to zero disables the robot’s “wire stick check delay” function, which saves considerable cycle time.

• C07 = 0 (R1), C15 = 0 (R2). Setting this register to zero disables the robot’s “wire stick check” function, which saves considerable cycle time.

7. Insert two DOUT commands into the robot weld job to turn HyperStart ON but disable the Dynamic Start function:

NOPDOUT OT#123 ON Activates R1 HyperStart SettingsDOUT OT#122 OFF Disables R1 Dynamic StartMOVJ VJ=50.00MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00

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3.4.5 HyperStart for NX/DX - Dynamic Start

Set up your welding equipment for Dynamic Start as follows:

1. From the INFORM LIST, select MACRO and then select R*-HYPER. Press SELECT twice. The HyperStart Setup screen appears.



• DYNAM START TIME = 8. Enables the “Dynamic Start” function while saving cycle time.



• WLD DONE=RBT MOV = 0. Disables robot wait function allowing the robot to pull away at ARCOF.



DOUT OT#123 OFF Cancels R1 HyperStart and enables normal arc start/end timer settings.

MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ C00006VJ=50.00MOVJ C00007VJ=50.00

Final page 21


3.4.6 HyperStart for XRC - Dynamic Start

If you have an XRC with macro function (Version 5.0 or greater), set up your welding equipment for Dynamic Start as follows:

1. From the INFORM LIST, select MACRO and then select R*-HYPER. Press SELECT twice and the HyperStart Setup screen will appear:


• DYNAM START TIME = 8. Setting this parameter to “8” allows the robot to travel for 0.8 seconds before checking an “Arc Established.” If no signal is present, an “R* DYNAMIC STARTING FAULT” is displayed. Dynamic Start does disable the “Retry” function.

• ARC OUTAGE TIMER = 5. Setting this parameter to “5” allows the robot to move for 0.5 seconds without an arc in the event the “Arc Established” signal from the welder goes out. Once the Arc Established signal is out for 0.5 seconds an “R* HYPERSTART ARC OUTAGE (TMR)” alarm will occur.

• ARC OUTAGE COUNT = 3. Setting this parameter to “3” allows the robot to move as long as the “Arc Established” signal from the welder does not go out more that three times. Once the Arc Established goes out more than three times, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm will occur.

• STICK CHECK DELA = 0. Setting this parameter to “0” disables the robot's “wire stick check delay” function saving considerable cycle time.

• STICK CHECK TIME = 0. Setting this parameter to “0” disables the robot's “wire stick check” function and saves cycle time.

3. On the programming pendant, select INFORM LIST and then MACRO. Locate the “R*-HYPER” command in the macro list and insert it into the R* weld job by pressing ENTER. The example below shows a welding job for R1 with HyperStart settings.

NOPR1-HYPER 8,5,3,0,0 Initial HyperStart SettingsMOVJ VJ=50.00MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00R1-HYPER 8,2,2,1,2 Modified HyperStart Settings

ARGUMENT SETTING

!

R1 SCL

JOB EDIT DISPLAY UTILITY

R1-HYPER DYNAM START TIMEARC OUTAGE TIMER ARC OUTAGE COUNT STICK CHECK DELA STICK-CHECK TIME

8 (.X sec) 5 (.X sec) 3 (X times) 0 (.X sec) 0 (.X sec)

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3.4.7 HyperStart for XRC without Macro Function - Dynamic Start

If you are using an XRC without macro function, the HyperStart settings are stored in various “M” registers. Two robot outputs then control when that HyperStart settings go into effect. One output controls when a “Dynamic Start” is allowed. When DOUT # 186 is ON, Dynamic Start is enabled for R1 (R2 uses DOUT # 178, R3 uses DOUT # 170). The second output controls when the HyperStart Arc Outage Timer, Arc Outage Counter, Wire Stick Check Delay, and Wire Stick Check Time timers/counters go into effect. When DOUT #187 is ON, the HyperStart parameters are enabled for R1 (R2 uses DOUT # 179, R3 uses DOUT # 171). When DOUT #187 is OFF, all of the HyperStart parameters are disabled and the system uses the standard “wire stick check delay time” and “wire stick time.” When HyperStart is turned off, Arc Outage Time and Arc Outage Count are totally disabled.

“M” register values can be displayed in EDIT mode, but can only be changed in MANAGEMENT mode. To set up “M” registers, follow these steps:

1. From the TOP MENU, cursor to IN/OUT and press SELECT.

2. Cursor to REGISTER and press SELECT.

3. Cursor to the M-VARIABLE you wish to change and press SELECT. Enter desired value and press ENTER to record.

4. Listed below are the “M” register settings for Static Start. Be sure to set each register to the indicated value:

• M060 = 8 (R1), M050 = 8 (R2), M040 = 8 (R3). Setting this register to 8 allows the robot to move for 0.8 seconds before checking for an “Arc Established” signal. If no signal is present, an “R* DYNAMIC STARTING FAULT” is displayed. Dynamic Start does disable the “Retry” function.

• M062 = 5 (R1), M052 = 5 (R2), M042 = 5 (R3). Setting this register to 5 allows the robot to move for 0.5 seconds without an arc in the event the “Arc Established” signal from the welder goes out. Once the Arc Established signal is out for 0.5 seconds, an “R* HYPERSTART ARC OUTAGE (TMR)” alarm will occur.

• M064 = 3 (R1), M054 = 3 (R2), M044 = 3 (R3). Setting this register to “3” allows the robot to move as long as the “Arc Established” signal from the welder does not go out more than three times. Once the Arc Established goes out more than three times, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm will occur.

• M066 = 0 (R1), M056 = 0 (R2), M046 = 0 (R3). Setting this register to zero disables the robot’s “wire stick check delay” function, which saves considerable cycle time.

• M068 = 0 (R1), M058 = 0 (R2), M048 = 0 (R3). Setting this register to zero disables the robot’s “wire stick check” function, which saves considerable cycle time.

MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00MOVJ VJ=50.00

Final page 23



3.4.8 HyperStart for MRC - Dynamic Start

If you are using an MRC, the HyperStart settings are stored in various “$C” registers.Two robot outputs control when HyperStart settings go into effect. One output controls “Dynamic Start.” When DOUT#122 is ON, Dynamic Start is enabled for R1 (R2 uses DOUT#114). The second output controls when the HyperStart Arc Outage Timer, Arc Outage Counter, Wire Stick Check Delay, and Wire Stick Check Time timers/counters go into effect. When DOUT #123 is ON, the HyperStart parameters are enabled for R1 (R2 uses DOUT # 115). When DOUT #123 is OFF, all of the HyperStart parameters are disabled and the system uses the standard “wire stick check delay time” and “wire stick time.” When HyperStart is turned off, Arc Outage Time and Arc Outage Count are totally disabled.

To set “$C” registers, follow these steps:

1. From the Main Display [DISP], press the F4 key [VAR].

2. Press the MORE key to view more menus.

3. Press the FS key [$C].

4. Press F1 [SEARCH] and enter the desired register (or use the cursor to scroll up and down to select the desired register).

5. Press the EDIT key and then the MODIFY key. Key in the desired register value. Press ENTER to record.

6. For “Dynamic Start,” set up the following values in these “$C” registers:

• C04 = 8 (R1), C12 = 8 (R2). Setting this register to 8 allows the robot to move for 0.8 seconds before checking for an “Arc Established”. If no signal is present, a “R* DYNAMIC STARTING FAULT” is displayed. Dynamic start does disable the “Retry” function.

NOPDOUT OT#187 ON Activates R1 HyperStart SettingsDOUT OT#186 ON Enables R1 Dynamic StartMOVJ VJ=50.00MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00DOUT OT#187 OFF Cancels R1 HyperStart, enables normal

arc start/end timer settings, but contin-ues to use Dynamic Start.

MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00MOVJ VJ=50.00

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• C05 = 5 (R1), C13 = 5 (R2). Setting this register to 5 allows the robot to move without an arc in the event the “Arc Established” signal from the welder goes out. Once the Arc Established signal is out for 0.5 seconds, an “R* HYPERSTART ARC OUTAGE (TMR)” alarm will occur.

• C19 = 3 (R1), C27 = 3 (R2). Setting this register to “3” allows the robot to move as long as the “Arc Established” signal from the welder does not go out more that three times. Once the Arc Established goes out more than three times, an “R* HYPERSTART ARC OUTAGE (CNT)” alarm will occur.

• C06 = 0 (R1), C14 = 0 (R2). Setting this register to zero disables the robot’s “wire stick check delay” function, which saves considerable cycle time.

• C07 = 0 (R1), C15 = 0 (R2). Setting this register to zero disables the robot’s “wire stick check” function, which saves considerable cycle time.


NOPDOUT OT#123 ON Activates R1 HyperStart SettingsDOUT OT#122 ON Enables R1 Dynamic StartMOVJ VJ=50.00MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ VJ=50.00DOUT OT#123 OFF Cancels R1 HyperStart, enables normal

arc start/end timer settings, but contin-ues to use Dynamic Start.

MOVJ VJ=50.00ARCON ASF#(1)MOVL V=13.7ARCOFMOVJ C00006VJ=50.00MOVJ C00007VJ=50.00

Final page 25


3.4.9 HyperStart for NX/DX - Enabling “WLD DONE = RBT MOV” w/ “Static Start”

Set up your welding equipment as follows:




• DYNAM START TIME = 0. Disables the “Dynamic Start” function and ensures a “Static Start”.



• WLD DONE=RBT MOV = 1. Enables robot wait function causing robot to wait for arc to extiguish before moving.



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3.4.10 HyperStart for NX/DX - Disabling HyperStart

Set up your welding equipment as follows:



• HYPERSTRT ON/OFF = 0. Disables the HyperStart function and all the following parameters.

• DYNAM START TIME = 0. Once HYPERSTRT ON/OFF =0, this parameter value has no effect.

• ARC OUTAGE TIMER = 5. Once HYPERSTRT ON/OFF =0, this parameter value has no effect.

• ARC OUTAGE COUNT = 3. Once HYPERSTRT ON/OFF =0, this parameter value has no effect.

• WLD DONE=RBT MOV = 1. Once HYPERSTRT ON/OFF =0, this parameter value has no effect.

• STICK CHECK DELA = 0. Once HYPERSTRT ON/OFF =0, this parameter value has no effect.

• STICK CHECK TIME = 0. Once HYPERSTRT ON/OFF =0, this parameter value has no effect.

Final page 27


Notes

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Chapter 4

Maintenance

Table 6 identifies common problems that occur while using the HyperStart function. To troubleshoot your system, identify the type of problem and look for it in the PROBLEM column. Next to this column is a list of PROBABLE CAUSES, followed by possible SOLUTIONS.

Be aware that sometimes more than one problem can occur at the same time. After identifying and resolving a problem, test the system thoroughly to make sure no other problems exist.

Table 6 Troubleshooting

Problem Probable Cause Solution

Excessive “R* HYPER-START STARTING FAIL-URE” errors (this error only occurs when “Dynamic Start” is enabled)

• No “Arc Established” signal from welder at end of the specified time.

• Power source’s internal“preflow” time is too long, and weld power is not applied until after “Dynamic Start Time” is expired.

• For NX100 and XRC with macro function, increase “Dynamic Start Time” parameter/register. Sug-gested value is between 5 (0.5 sec-onds) and 10 (1.0 seconds). For XRC without macro function, adjust registers M060 (R1), M050 (R2), and M040 (R3). For MRC, adjust registers C004 (R1) and C012 (R2).

• Remove or reduce power source’s internal “preflow” time. See manu-facturer’s manual for adjustment of internal “preflow” time.

• If error still occurs, disable the “Dynamic Start” function. Set “Dynam Start Time” to zero. For XRC without macro function, turn outputs #186, #178, and #170 OFF. For MRC, turn outputs #122 and #114 OFF.

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Excessive “R* HYPER-START ARC OUTAGE (TMR)” errors

• The “Arc Outage Time” parameter is set for too short of a time period. This parameter/register must be greater than zero if HyperStart is enabled.

• Investigate power source or wire feeder problem.

• Increase the “Arc Outage Time” parameter/register. Suggested value is between 3 (0.3 seconds) and 10 (1.0 seconds). For XRC without macro function, adjust registers M062 (R1), M052 (R2), and M042 (R3). For MRC, adjust registers C005 (R1) and C013 (R2).

Excessive “R* HYPER-START ARC OUTAGE (CNT)” errors

• The “Arc Establish” signal in the welder is going off and back on more times than the count value set in the “Arc Outage Count” parameter. This parameter/register must to larger than zero if HyperStart is enabled.

• Investigate power source or wire feeder problems.

• Increase the “Arc Outage Count” parameter/register. Suggested value is between 1 (1 outage) and 3 (3 out-ages). For XRC without macro func-tion, adjust registers M064 (R1), M054 (R2), and M044 (R3). For MRC, adjust registers C019 (R1) and C27 (R2). This value largely depends on the welding power source and its arc starting ability. If poor “machine gun” type starts are typical with your power source, this value will need to be set higher.

Excessive weld puddle at the start of every weld

• The robot starts welding, but waits for an “Arc Establish” signal from the welder before moving.

• Set “Pause Time” in Arc Start file to zero.

• Lower wire feed speed/current set-tings in Arc Start file.

• Enable “Dynamic Start.” Set “Dynam Start Time” to a value greater than zero. For XRC without macro function, turn outputs #186, #178, and #170 ON. For MRC, turn outputs #122 and #114 ON.

Poor penetration at start of every weld

• The robot starts welding, but waits for an “Arc Establish” signal from the welder before moving.

• Set “Pause Time” in Arc Start file to a value greater than zero.

• Raise wire feed speed/current set-tings in Arc Start file.

• Disable “Dynamic Start.” Set “Dynam Start Time” to zero. For XRC without macro function, turn outputs #186, #178, and #170 OFF. For MRC, turn outputs #122 and #114 OFF.

Actual weld length is shorter than the programmed weld length

• HyperStart’s “Dynamic Start” func-tion enables the robot to move for a specified time before checking for an “Arc Establish” signal, possibly resulting in shorter -than-programmed weld lengths.




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Missing welds (welding arc never starts)

• If HyperStart’s “Dynamic Start” is enabled and the parameters/registers are set too high, it is possible to miss whole welds.

• Investigate power source or wire feeder problems.

• Lower “Dynamic Start Time” parameter/registers to a value that is less than the shortest weld. Sug-gested value is between 5 (.5 sec-onds) and 10 (1.0 seconds). For XRC without macro function, adjust registers M060 (R1), M050 (R2), and M040 (R3). For MRC, adjust registers C004 (R1) and C012 (R2). This allows sufficient time for the wire feeder to get the welding wire to the work piece.


Missing sections of the weld between “Arc Start” and “Arc End.”

• This is caused by a mid-weld arc fail-ure.

• Lower the “Arc Outage Time” parameter/register to the longest allowable arc outage time. For XRC without macro function, adjust reg-isters M062 (R1), M052 (R2), and M042 (R3). For MRC, adjust regis-ters C005 (R1) and C013 (R2).

Retry function does not work

• When HyperStart’s “Dynamic Start” function is enabled, the retry function will not work.


Servo/Motion alarms occur when welding in twin sync jobs

• HyperStart’s “Dynamic Start” func-tion may cause timing problems when used in twin sync jobs.


Poor arc starts • Power source internal settings (run-in, preflow, start voltage) need adjust-ment.

• “Arc Start” file or conditions need adjustment.

• HyperStart’s “Dynamic Start” func-tion may conflict with the power source’s starting routine.

• Examine and adjust the power source’s internal settings. See manu-facturer’s manual for adjustment of power source settings.

• Adjust “Arc Start” files (Starting Condition) or Weld Condition files.



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User Manual Chapter 4 Maintenance

Frequent wires sticks at end of welds

• Insufficient burn back/SharpStart™, causing wire to contact the work piece once power source has been turned off.

• Excessive wire feeder coast may allow wire to crash into work piece once the power source has been turned off.

• Weld puddle may move onto welding wire once the welder has been shut off, causing the weld puddle to touch the weld wire.

• Robot’s wire stick function is not set up properly.

• Raise burn back/SharpStart™ volt-age level or time on the power source. Refer to the manufacturer’s manual for power source adjust-ments.

• Adjust wire feeder stopping time. See manufacturer’s manual for instructions.

• Set HyperStart’s “Stick Check Delay Time” and “Stick Check Time” parameters to values other than zero. Allow time for weld puddle to cool and then apply wire stick check volt-age. Ensure anti-stick function is properly set up. Adjust robot’s wire stick check function by setting “Stick Check Delay Time” and Stick Check Time” to zero and all regis-ters to 2.

Weld wire fused to contact tip at the completion of weld (tip change required)

• Excessive burn back/SharpStart™ causing wire to melt back to the con-tact tip.

• Wire feeder stopping time is too fast.• Excessive “crater” time or wire feed

speed/current causing weld puddle to raise up until it contacts tip.

• Excessive arc voltage specified at ArcOff.

• Excessive voltage set in “crater” parameters in the ArcEnd file.

• Lower burn back/SharpStart™ voltage level or time on the power source. Refer to the manufacturer’s manual for burn back or SharpStart adjustment.

• Adjust wire feeder stopping time. See manufacturer’s manual for instructions.

• Lower the pause time or wire feed speed in “crater” settings.

• Lower arc voltage prior to ending the weld.

• Lower “crater” voltage in the ArcEnd file.



page 32 Final

HyperStart148375-1

Appendix A

I/O Assignments

Final page 33

DX100 I/O Assignments:Before adding HyperStart:

OUT #1865 R4 HyperStart Updating (12340)OUT #1866 R4 HyperStart On (12341)OUT #1867 R4 Dynamic Start On (12342)OUT #1868 R4 Wait Weld Done (12343)OUT #1869 R3 HyperStart Updating (12344)OUT #1870 R3 HyperStart On (12345)OUT #1871 R3 Dynamic Start On (12346)OUT #1872 R3 Wait Weld Done (12347)OUT #1873 R2 HyperStart Updating (12350)OUT #1874 R2 HyperStart On (12351)OUT #1875 R2 Dynamic Start On (12352)OUT #1876 R2 Wait Weld Done (12353)OUT #1877 R1 HyperStart Updating (12354)OUT #1878 R1 HyperStart On (12355)OUT #1879 R1 Dynamic Start On (12356)OUT #1880 R1 Wait Weld Done (12357)

OUT #1881 HyperStart Bit 0 (12360)

OUT #1882 HyperStart Bit 1 (12361)OUT #1883 HyperStart Bit 2 (12362)OUT #1884 HyperStart Bit 3 (12363)OUT #1885 HyperStart Bit 4 (12364)OUT #1886 HyperStart Bit 5 (12365)OUT #1887 HyperStart Bit 6 (12366)OUT #1888 HyperStart Bit 7 (12367)OUT #1889 HyperStart Bit 8 (12370)OUT #1890 HyperStart Bit 9 (12371)OUT #1891 HyperStart Bit 10 (12372)OUT #1892 HyperStart Bit 11 (12373)OUT #1893 HyperStart Bit 12 (12374)OUT #1894 HyperStart Bit 13 (12375)OUT #1895 HyperStart Bit 14 (12376)OUT #1896 HyperStart Bit 15 (12377)OUT #1897 ArcEstablished Timer Latch (12380)OUT #1898 Arc Shortage Timer Latch (12381)OUT #1899 Arc Shortage Count Latch (12382)OUT #1900 Stick Check Delay Latch (12383)OUT #1901 Stick Check Latch (12384)OUT #1902OUT #1903OUT #1904OUT #1905OUT #1906OUT #1907OUT #1908OUT #1909OUT #1910OUT #1911OUT #1912

… …. ….

OUT #2017OUT #2018OUT #2019OUT #2020 GAS PURGE R4OUT #2021 R4 Arc Shortage Restart Reset (System Created)OUT #2022 R4 Restart Reset Request (System Created)OUT #2023 INCH FORWARD R4OUT #2024 INCH REVERSE R4OUT #2025OUT #2026OUT #2027OUT #2028 GAS PURGE R3OUT #2029 R3 Arc Shortage Restart Reset (System Created)OUT #2030 R3 Restart Reset Request (System Created)OUT #2031 INCH FORWARD R3OUT #2032 INCH REVERSE R3OUT #2033OUT #2034OUT #2035OUT #2036 GAS PURGE R2OUT #2037 R2 Arc Shortage Restart Reset (System Created)OUT #2038 R2 Restart Reset Request (System Created)OUT #2039 INCH FORWARD R2OUT #2040 INCH REVERSE R2OUT #2041OUT #2042OUT #2043OUT #2044 GAS PURGE R1OUT #2045 R1 Arc Shortage Restart Reset (System Created)OUT #2046 R1 Restart Reset Request (System Created)OUT #2047 INCH FORWARD R1OUT #2048 INCH REVERSE R1

R1 Required IOR2 Required IOR3 Required IOR4 Required IOHyperStart Required IO

Gro

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256

Gro

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253

Gro

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238

Gro

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239

Gro

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254

Gro

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255

Gro

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234

Gro

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Gro

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Gro

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Aux. Relays & Timers:HyperStart: (DX100 with Macro)

AUX #79690 R1 HyperStart Dynamic Start EnabledAUX #79691 R1 HyperStart Dynamic Start TimeAUX # 79692 R1 HyperStart Arc OccurredAUX # 79693 R1 Dynamic Arc Starting FaultAUX # 79694 R1 HyperStart Arc Outage Time ExceededAUX # 79695 R1 HyperStart Arc Outage Count ExceededAUX # 79696 R1 Wld Done = Rbt MoveAUX # 79697

M200 R1 HyperStart Dynamic Start Time (set Value)M201 R1 HyperStart Dynamic Start Time (current value)M202 R1 Hyperstart Arc Outage Time (set value)M203 R1 Hyperstart Arc Outage Time (current value)M204 R1 Hyperstart Arc Outage Count (set value)M205 R1 Hyperstart Arc Outage Count (current value)M206 R1 HyperStart Stick Check Delay Time (set value)M207 R1 HyperStart Stick Check Delay Time (current value)M208 R1 HyperStart Stick Check Time (set value)M209 R1 HyperStart Stick Check Time (current value)

AUX #79680 R2 HyperStart Dynamic Start EnabledAUX #79681 R2 Hyperstart Dynamic Start TimeAUX # 79682 R2 HyperStart Arc OccurredAUX # 79683 R2 Dynamic Arc Starting FaultAUX # 79684 R2 HyperStart Arc Outage Time ExceededAUX # 79685 R2 HyperStart Arc Outage Count ExceededAUX # 79686 R2 Wld Done = Rbt MoveAUX # 79687

M190 R2 HyperStart Dynamic Start Time (set value)M191 R2 HyperStart Dynamic Start Time (current Value)M192 R2 HyperStart Arc Outage Time (set value)M193 R2 HyperStart Arc Outage Time (current value)M194 R2 HyperStart Arc Outage Count (set value)M195 R2 HyperStart Arc Outage Count (current value)M196 R2 HyperStart Stick Check Delay Time (set value)M197 R2 HyperStart Stick Check Delay Time (current value)M198 R2 HyperStart Stick Check Time (set value)M199 R2 HyperStart Stick Check Time (current value)

AUX #79670 R3 HyperStart Dynamic Start EnabledAUX #79671 R3 HyperStart Dynamic Start TimeAUX # 79672 R3 HyperStart Arc OccurredAUX # 79673 R3 Dyanmic Arc Starting FaultAUX # 79674 R3 HyperStart Arc Outage Time ExceededAUX # 79675 R3 HyperStart Arc Outage Count ExceededAUX # 79676 R3 Wld Done = Rbt MoveAUX # 79677


AUX #79670 R3 HyperStart Dynamic Start EnabledAUX #79671 R3 HyperStart Dynamic Start TimeAUX # 79672 R3 HyperStart Arc OccurredAUX # 79673 R3 Dyanmic Arc Starting FaultAUX # 79674 R3 HyperStart Arc Outage Time ExceededAUX # 79675 R3 HyperStart Arc Outage Count ExceededAUX # 79676 R4 Wld Done = Rbt MoveAUX # 79677


NX100 I/O Assignments:Before adding HyperStart: HyperStart: (NX100 with Macro)

OUT #953 OUT #953

OUT #954 OUT #954

OUT #955 OUT #955

OUT #956 OUT #956

OUT #957 OUT #957 R3 HyperStart Updating

OUT #958 OUT #958 R3 HyperStart On

OUT #959 OUT #959 R3 Dynamic Start On

OUT #960 OUT #960 R3 Wait Weld Done









OUT #969 OUT #969 HyperStart Bit 0










OUT #979 OUT #979 HyperStart Bit 10OUT #980 OUT #980 HyperStart Bit 11


OUT #982 OUT #982 HyperStart Bit 13OUT #983 OUT #983 HyperStart Bit 14OUT #984 OUT #984 HyperStart Bit 15

OUT #985 OUT #985

OUT #986 OUT #986

OUT #987 OUT #987

OUT #988 OUT #988

OUT #989 OUT #989

OUT #990 OUT #990

OUT #991 OUT #991

OUT #992 OUT #992

OUT #993 OUT #993

OUT #994 OUT #994

OUT #995 OUT #995

OUT #996 OUT #996

OUT #997 OUT #997

OUT #998 OUT #998

OUT #999 OUT #999OUT #1000 OUT #1000

OUT #1001 OUT #1001

OUT #1002 OUT #1002

OUT #1003 OUT #1003OUT #1004 GAS PURGE R3 OUT #1004 GAS PURGE R3OUT #1005 R3 Arc Shortage Restart Reset (System Created) OUT #1005 R3 Arc Shortage Restart Reset (System Created)OUT #1006 R3 Restart Reset Request (System Created) OUT #1006 R3 Restart Reset Request (System Created)OUT #1007 INCH FORWARD R3 OUT #1007 INCH FORWARD R3OUT #1008 INCH REVERSE R3 OUT #1008 INCH REVERSE R3OUT #1009 OUT #1009OUT #1010 OUT #1010OUT #1011 OUT #1011OUT #1012 GAS PURGE R2 OUT #1012 GAS PURGE R2OUT #1013 R2 Arc Shortage Restart Reset (System Created) OUT #1013 R2 Arc Shortage Restart Reset (System Created)OUT #1014 R2 Restart Reset Request (System Created) OUT #1014 R2 Restart Reset Request (System Created)OUT #1015 INCH FORWARD R2 OUT #1015 INCH FORWARD R2OUT #1016 INCH REVERSE R2 OUT #1016 INCH REVERSE R2OUT #1017 OUT #1017OUT #1018 OUT #1018OUT #1019 OUT #1019OUT #1020 GAS PURGE R1 OUT #1020 GAS PURGE R1OUT #1021 R1 Arc Shortage Restart Reset (System Created) OUT #1021 R1 Arc Shortage Restart Reset (System Created)OUT #1022 R1 Restart Reset Request (System Created) OUT #1022 R1 Restart Reset Request (System Created)OUT #1023 INCH FORWARD R1 OUT #1023 INCH FORWARD R1OUT #1024 INCH REVERSE R1 OUT #1024 INCH REVERSE R1

R1 Required IOR2 Required IOR3 Required IOHyperStart Required IO

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Gro

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Gro

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Gro

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Gro

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Gro

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XRC I/O Assignments:Before adding HyperStart: HyperStart: (XRC with Macro) HyperStart: (XRC without Macro)

OUT #144 OUT #144 HyperStart Bit 0 OUT #144
















OUT #161 OUT #161 ALLOWABLE ESTAB LATCH OUT #161

OUT #162 OUT #162 ARC OUTAGE TIME LATCH OUT #162

OUT #163 OUT #163 ARC OUTAGE COUNT LATCH OUT #163

OUT #164 OUT #164 STICK CHECK DELAY LATCH OUT #164

OUT #165 OUT #165 STICK CHECK TIME LATCH OUT #165

OUT #166 OUT #166 OUT #166

OUT #167 OUT #167 OUT #167

OUT #168 OUT #168 OUT #168

OUT #169 OUT #169 OUT #169

OUT #170 OUT #170 R3 HyperStart Dynamic Start Enabled OUT #170 R3 HyperStart Dynamic Start Enabled

OUT #171 OUT #171 R3 HyperStart Updating OUT #171 R3 HyperStart Timers On/OffOUT #172 GAS PURGE R3 OUT #172 GAS PURGE R3 OUT #172 GAS PURGE R3

OUT #173 R3 Arc Shortage Restart Reset (System Created) OUT #173 R3 Arc Shortage Restart Reset (System Created) OUT #173 R3 Arc Shortage Restart Reset (System Created)

OUT #174 R3 Restart Reset Request (System Created) OUT #174 R3 Restart Reset Request (System Created) OUT #174 R3 Restart Reset Request (System Created)OUT #175 INCH FORWARD R3 OUT #175 INCH FORWARD R3 OUT #175 INCH FORWARD R3OUT #176 INCH REVERSE R3 OUT #176 INCH REVERSE R3 OUT #176 INCH REVERSE R3

OUT #177 OUT #177 OUT #177


OUT #179 OUT #179 R2 HyperStart Updating OUT #179 R2 HyperStart Timers On/Off

OUT #180 GAS PURGE R2 OUT #180 GAS PURGE R2 OUT #180 GAS PURGE R2


OUT #182 R2 Restart Reset Request (System Created) OUT #182 R2 Restart Reset Request (System Created) OUT #182 R2 Restart Reset Request (System Created)

OUT #183 INCH FORWARD R2 OUT #183 INCH FORWARD R2 OUT #183 INCH FORWARD R2

OUT #184 INCH REVERSE R2 OUT #184 INCH REVERSE R2 OUT #184 INCH REVERSE R2

OUT #185 WELD IN TEACH OUT #185 WELD IN TEACH OUT #185 WELD IN TEACH


OUT #187 OUT #187 R1 HyperStart Updating OUT #187 R1 HyperStart Timers On/Off

OUT #188 GAS PURGE R1 OUT #188 GAS PURGE R1 OUT #188 GAS PURGE R1


OUT #190 R1 Restart Reset Request (System Created) OUT #190 R1 Restart Reset Request (System Created) OUT #190 R1 Restart Reset Request (System Created)

OUT #191 INCH FORWARD R1 OUT #191 INCH FORWARD R1 OUT #191 INCH FORWARD R1OUT #192 INCH REVERSE R1 OUT #192 INCH REVERSE R1 OUT #192 INCH REVERSE R1G

roup

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40)

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1230

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20)

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1210

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roup

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(11

90)

Gro

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1200

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Aux. Relays & Timers:Before adding HyperStart: HyperStart: (XRC with Macro) HyperStart: (XRC without Macro)

AUX # 7130 WELD IN TEACH Enable AUX # 7130 WELD IN TEACH Enable AUX # 7130 WELD IN TEACH EnableAUX # 7131 WELD IN TEACH Trigger AUX # 7131 WELD IN TEACH Trigger AUX # 7131 WELD IN TEACH TriggerAUX # 7132 WELD IN TEACH Latch AUX # 7132 WELD IN TEACH Latch AUX # 7132 WELD IN TEACH Latch

All Robots Weld In Teach AUX #7140 R1 HyperStart Dynamic Start Enabled AUX #7140 R1 HyperStart Dynamic Start EnabledR1 Required IO AUX #7141 R1 HyperStart Dynamic Start Time AUX #7141 R1 HyperStart Dynamic Start TimeR2 Required IO AUX # 7142 R1 HyperStart Arc Occurred AUX # 7142 R1 HyperStart Arc OccurredR3 Required IO AUX # 7143 R1 Dynamic Arc Starting Fault AUX # 7143 R1 Dynamic Arc Starting FaultHyperStart Required IO AUX # 7144 R1 HyperStart Arc Outage Time Exceeded AUX # 7144 R1 HyperStart Arc Outage Time Exceeded

AUX # 7145 R1 HyperStart Arc Outage Count Exceeded AUX # 7145 R1 HyperStart Arc Outage Count ExceededAUX # 7146 AUX # 7146 R1 HyperStart Timers EnabledAUX # 7147 AUX # 7147

M060 R1 HyperStart Dynamic Start Time (set Value) M060 R1 HyperStart Dynamic Start Time (set Value)M061 R1 HyperStart Dynamic Start Time (current value) M061 R1 HyperStart Dynamic Start Time (current value)M062 R1 Hyperstart Arc Outage Time (set value) M062 R1 Hyperstart Arc Outage Time (set value)M063 R1 Hyperstart Arc Outage Time (current value) M063 R1 Hyperstart Arc Outage Time (current value)M064 R1 Hyperstart Arc Outage Count (set value) M064 R1 Hyperstart Arc Outage Count (set value)M065 R1 Hyperstart Arc Outage Count (current value) M065 R1 Hyperstart Arc Outage Count (current value)M066 R1 HyperStart Stick Check Delay Time (set value) M066 R1 HyperStart Stick Check Delay Time (set value)M092 R1 HyperStart Stick Check Delay Time (current value) M067 R1 HyperStart Stick Check Delay Time (current value)M068 R1 HyperStart Stick Check Time (set value) M068 R1 HyperStart Stick Check Time (set value)M093 R1 HyperStart Stick Check Time (current value) M069 R1 HyperStart Stick Check Time (current value)

AUX #7340 R2 HyperStart Dynamic Start Enabled M122 R1 Standard Stick Check Delay Time (set value)AUX #7341 R2 Hyperstart Dynamic Start Time M092 R1 Standard Stick Check Delay Time (current value)AUX # 7342 R2 HyperStart Arc Occurred M123 R1 Standard Stick Check Time (set value)AUX # 7343 R2 Dynamic Arc Starting Fault M093 R1 Standard Stick Check Time (current value)AUX # 7344 R2 HyperStart Arc Outage Time Exceeded AUX #7340 R2 HyperStart Dynamic Start EnabledAUX # 7345 R2 HyperStart Arc Outage Count Exceeded AUX #7341 R2 Hyperstart Dynamic Start TimeAUX # 7346 AUX # 7342 R2 HyperStart Arc OccurredAUX # 7347 AUX # 7343 R2 Dynamic Arc Starting Fault

M050 R2 HyperStart Dynamic Start Time (set value) AUX # 7344 R2 HyperStart Arc Outage Time ExceededM051 R2 HyperStart Dynamic Start Time (current Value) AUX # 7345 R2 HyperStart Arc Outage Count ExceededM052 R2 HyperStart Arc Outage Time (set value) AUX # 7346 R2 HyperStart Timers EnabledM053 R2 HyperStart Arc Outage Time (current value) AUX # 7347M054 R2 HyperStart Arc Outage Count (set value) M050 R2 HyperStart Dynamic Start Time (set value)M055 R2 HyperStart Arc Outage Count (current value) M051 R2 HyperStart Dynamic Start Time (current Value)M056 R2 HyperStart Stick Check Delay Time (set value) M052 R2 HyperStart Arc Outage Time (set value)M082 R2 HyperStart Stick Check Delay Time (current value) M053 R2 HyperStart Arc Outage Time (current value)M058 R2 HyperStart Stick Check Time (set value) M054 R2 HyperStart Arc Outage Count (set value)M083 R2 HyperStart Stick Check Time (current value) M055 R2 HyperStart Arc Outage Count (current value)

AUX #7540 R3 HyperStart Dynamic Start Enabled M056 R2 HyperStart Stick Check Delay Time (set value)AUX #7541 R3 HyperStart Dynamic Start Time M057 R2 HyperStart Stick Check Delay Time (current value)AUX # 7542 R3 HyperStart Arc Occurred M058 R2 HyperStart Stick Check Time (set value)AUX # 7543 R3 Dyanmic Arc Starting Fault M059 R2 HyperStart Stick Check Time (current value)AUX # 7544 R3 HyperStart Arc Outage Time Exceeded M132 R2 Standard Stick Check Delay Time (set value)AUX # 7545 R3 HyperStart Arc Outage Count Exceeded M082 R2 Standard Stick Check Delay Time (current value)AUX # 7546 M133 R2 Standard Stick Check Time (set value)AUX # 7547 M083 R2 Standard Stick Check Time (current value)

M040 R3 HyperStart Dynamic Start Time (set value) AUX #7540 R3 HyperStart Dynamic Start EnabledM041 R3 HyperStart Dynamic Start Time (current Value) AUX #7541 R3 HyperStart Dynamic Start TimeM042 R3 HyperStart Arc Outage Time (set value) AUX # 7542 R3 HyperStart Arc OccurredM043 R3 HyperStart Arc Outage Time (current value) AUX # 7543 R3 Dyanmic Arc Starting FaultM044 R3 HyperStart Arc Outage Count (set value) AUX # 7544 R3 HyperStart Arc Outage Time ExceededM045 R3 HyperStart Arc Outage Count (current value) AUX # 7545 R3 HyperStart Arc Outage Count ExceededM046 R3 HyperStart Stick Check Delay Time (set value) AUX # 7546 R3 HyperStart Timers EnabledM072 R3 HyperStart Stick Check Delay Time (current value) AUX # 7547M048 R3 HyperStart Stick Check Time (set value) M040 R3 HyperStart Dynamic Start Time (set value)M073 R3 HyperStart Stick Check Time (current value) M041 R3 HyperStart Dynamic Start Time (current Value)

M042 R3 HyperStart Arc Outage Time (set value)M043 R3 HyperStart Arc Outage Time (current value)M044 R3 HyperStart Arc Outage Count (set value)M045 R3 HyperStart Arc Outage Count (current value)M046 R3 HyperStart Stick Check Delay Time (set value)M047 R3 HyperStart Stick Check Delay Time (current value)M048 R3 HyperStart Stick Check Time (set value)M049 R3 HyperStart Stick Check Time (current value)M142 R3 Standard Stick Check Delay Time (set value)M072 R3 Standard Stick Check Delay Time (current value)M143 R3 Standard Stick Check Time (set value)M073 R3 Standard Stick Check Time (current value)

MRC I/O Assignments:HyperStart: (MRC without Macro)

OUT #113 1150

OUT #114 1151 R2 HyperStart Dynamic Start Enabled

OUT #115 1152 R2 HyperStart Timers On/Off

OUT #116 1153 GAS PURGE R2

OUT #117 1154 R2 ARC Shortage Restart Reset (System Created)

OUT #118 1155 R2 Restart Reset Request (System Created)

OUT #119 1156 INCH FORWARD R2

OUT #120 1157 INCH REVERSE R2

OUT #121 1160 WELD IN TEACH

OUT #122 1161 R1 HyperStart Dynamic Start Enabled

OUT #123 1162 R1 HyperStart Timers Enabled

OUT #124 1163 GAS PURGE R1

OUT #125 1164 R1 Arc Shortage Restart Reset (System Created)

OUT #126 1165 R1 Restart Reset Request (System Created)

OUT #127 1166 INCH FORWARD R1

OUT #128 1167 INCH REVERSE R1

Aux. Relays & Timers:WELD IN TEACH Enable

R2 HyperStart Dynamic Start Time

R2 Arc Occurred

6027 (C15) R2 Stick Check Time (set value)

AUX #7140

AUX #7141

AUX # 7142

AUX # 7143

AUX # 7146

AUX # 7144

6026 (C14)

R1 HyperStart Arc Outage Time Exceeded

6043 (C27)

AUX # 7145

6016 (C06)

6017 (C07)

AUX #7150

AUX # 7156

6014 (C04)

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6015 (C05)

AUX #7151

AUX #7147

6033 (C019)

R1 HyperStart Arc Outage Count Exceeded

6024 (C12)

6025 (C13)

R2 HyperStart Timers Enabled

AUX # 7152

AUX # 7153

AUX # 7154

AUX # 7155

R1 HyperStart Stick Check Delay Time (set value)

R2 Allowable Arc Establish Time (set value)

R1 HyperStart Dynamic Start Enabled

R1 HyperStart Dynamic Start Time

R1 HyperStart Arc Occurred

R1 Dynamic Arc Starting Fault

R2 Arc Outage Time (set value)

R2 Stick Check Delay Time (set value)

R1 HyperStart Timers Enabled

R2 HyperStart Arc Outage Count (set value)

R1 HyperStart Allowable Arc Establish Time (set value)R1 HyperStart Arc Outage Time (set value)

R1 HyperStart Arc Outage Count (set value)

R1 HyperStart Stick Check Time (set value)

R2 HyperStart Dynamic Start Enabled

AUX # 7130

AUX # 7157

R2 Dynamic Arc Starting Fault

R2 HyperStart Arc Outage Time Exceeded

R2 HyperStart Arc Outage Count Exceeded

User Manual Appendix A I/O Assignments

page 34 Final

HyperStart148375-1

Final

Index

AAlarms 13ANSI/RIA 5CControl Parameters 12Customer Service 3Cycle Time Savings Analysis 2DDisabling 27Documentation 3Dynamic Start - MRC 24Dynamic Start - NX 21Dynamic Start - XRC 22, 23II/O Assignments 33Installation Safety 7Introduction 1MMaintenance 29Maintenance Safety 9

OOperation 11Operation Safety 9Overview 1PProgramming Safety 8RRobotic Industries Association 5SSafeguarding Tips 7Safety 5Safety Devices 7Setup 15Static Start - MRC 20Static Start - XRC 18, 19Static Start-NX 17System Overview 2TTheory of Operation 11WWLD DONE = RBT MOV 26

Motoman Controller HyperStart User Manual · 2018-12-10 · Motoman, Incorporated 805 Liberty Lane...

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Transcript of Motoman Controller HyperStart User Manual · 2018-12-10 · Motoman, Incorporated 805 Liberty Lane...