YASKAWA YRC1000 User manual

MANUAL NO.

HW1484216 2

YRC1000 OPTIONS

INSTRUCTIONS

FOR WELDCOM FUNCTION:

ARC WELDING/DIGITAL I/F FUNCTION

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and

retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN- INSTRUCTIONS

YRC1000 INSTRUCTIONS

YRC1000 OPERATOR’S MANUAL (GENERAL) (SUBJECT SPECIFIC)

YRC1000 MAINTENANCE MANUAL

YRC1000 ALARM CODES (MAJOR ALARMS) (MINOR ALARMS)

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DANGER

• This manual explains the endless function of the YRC1000 system.

Read this manual carefully and be sure to understand its contents

before handling the YRC1000. Any matter, including operation,

usage, measures, and an item to use, not described in this manual

must be regarded as "prohibited" or "improper".

• General information related to safety are described in "Chapter 1.

Safety". To ensure correct and safe operation, carefully read

"Chapter 1. Safety".

CAUTION

• In some drawings in this manual, protective covers or shields are

removed to show details. Make sure that all the covers or shields

are installed in place before operating this product.

• YASKAWA is not responsible for incidents arising from

unauthorized modification of its products. Unauthorized

modification voids the product warranty.

NOTICE

• YASKAWA may modify this model without notice when necessary

due to product improvements, modifications, or changes in

specifications.

• If such modification is made, the manual number will also be

revised.

• If your copy of the manual is damaged or lost, contact a YASKAWA

representative to order a new copy. The representatives are listed

on the back cover. Be sure to tell the representative the manual

number listed on the front cover.

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NOTES FOR SAFE OPERATION

Read this manual carefully before installation, operation, maintenance, or

inspection of the YRC1000.

In this manual, the Notes for Safe Operation are classified as “DANGER”,

“WARNING”, “CAUTION”, or “NOTICE”.

Even items described as “CAUTION” may result in a serious accident in

some situations.

At any rate, be sure to follow these important items.

DANGER

Indicates an imminently hazardous

situation which, if not avoided, will

result in death or serious injury.

Safety Signs identified by the signal

word DANGER should be used

sparingly and only for those

situations presenting the most

serious hazards.

WARNING

Indicates a potentially hazardous

situation which, if not avoided, will

result in death or serious injury.

Hazards identified by the signal

word WARNING present a lesser

degree of risk of injury or death than

those identified by the signal word

DANGER.

CAUTION

Indicates a hazardous situation,

which if not avoided, could result in

minor or moderate injury. It may

also be used without the safety alert

symbol as an alternative to

“NOTICE”.

NOTICE

NOTICE is the preferred signal word

to address practices not related to

personal injury. The safety alert

symbol should not be used with this

signal word. As an alternative to

“NOTICE”, the word “CAUTION”

without the safety alert symbol may

be used to indicate a message not

related to personal injury.

NOTE

To ensure safe and efficient operation at all times, be sure

to follow all instructions, even if not designated as “DAN-

GER”, “WARNING” and “CAUTION".

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DANGER

• Before operating the manipulator, make sure the servo power is

turned OFF by performing the following operations. When the servo

power is turned OFF, the SERVO ON LED on the programming

pendant is turned OFF.

– Press the emergency stop buttons on the front door of the

YRC1000, on the programming pendant, on the external control

device, etc.

– Disconnect the safety plug of the safety fence.

(when in the play mode and the remote mode)

If operation of the manipulator cannot be stopped in an emergency,

personal injury and/or equipment damage may result.

Fig. : Emergency Stop Button

• Before releasing the emergency stop, make sure to remove the

obstacle or error caused the emergency stop, if any, and then turn

the servo power ON.

Failure to observe this instruction may result in personal injury caused

by unintended manipulator movement.

Fig. : Release of Emergency Stop

TURN

• Observe the following precautions when performing a teaching

operation within the P-point maximum envelope of the manipulator:

– Be sure to perform lockout by putting a lockout device on the

safety fence when going into the area enclosed by the safety

fence. In addition, the operator of the teaching operation must

display the sign that the operation is being performed so that no

other person closes the safety fence.

– View the manipulator from the front whenever possible.

– Always follow the predetermined operating procedure.

– Always keep in mind emergency response measures against the

manipulator’s unexpected movement toward a person.

– Ensure a safe place to retreat in case of emergency.

Failure to observe this instruction may result in personal injury caused

by improper or unintended manipulator movement.

• Confirm that no person is present in the P-point maximum envelope

of the manipulator and that the operator is in a safe location before:

– Turning ON the YRC1000 power

– Moving the manipulator by using the programming pendant

– Running the system in the check mode

– Performing automatic operations

Injury may result if any person should enter the P-point maximum

envelope of the manipulator during operation. Immediately press an

emergency stop button whenever there is a problem. The emergency

stop buttons are located on the front panel of the YRC1000 and on the

right of the programming pendant.

• Read and understand the Explanation of the Warning Labels before

operating the manipulator.

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Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the

programming pendant, and supply cables.

In this manual, the equipment is designated as follows.

WARNING

• Perform the following inspection procedures prior to conducting

manipulator teaching. If there is any problem, immediately take

necessary steps to solve it, such as maintenance and repair.

– Check for a problem in manipulator movement.

– Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the hook on the

YRC1000 cabinet after use.

If the programming pendant is left unattented on the manipulator, on a

fixture, or on the floor, the Enable Switch may be activated due to

surface irregularities of where it is left, and the servo power may be

turned ON. In addition, in case the operation of the manipulator starts,

the manipulator or the tool may hit the programming pendant left

unattended, which may result in personal injury and/or equipment

damage.

Equipment Manual Designation

YRC1000 controller YRC1000

YRC1000 programming pendant Programming pendant

Cable between the manipulator and the

controller

Manipulator cable

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Descriptions of the programming pendant keys, buttons, and displays are

shown as follows:

Equipment Manual Designation

Programming

Pendant

Character Keys

/Symbol Keys

The keys which have characters or symbols

printed on them are denoted with [ ].

e.g. [ENTER]

Axis Keys

/Numeric Keys

[Axis Key] and [Numeric Key] are generic

names for the keys for axis operation and

number input.

Keys pressed

simultaneously

When two keys are to be pressed

simultaneously, the keys are shown with a “+”

sign between them, e.g. [SHIFT]+[COORD].

Mode Switch Mode Switch can select three kinds of modes

that are denoted as follows: REMOTE, PLAY or

TEACH.

(The switch names are denoted as symbols)

Button The three buttons on the upper side of the

programming pendant are denoted as follows:

START, HOLD, or EMERGENCY STOP.

(The button names are denoted as symbols)

Displays The menu displayed in the programming

pendant is denoted with { }.

e.g. {JOB}

Numeric keys

Axis keys

Enter key

Mode switch*

Start button* Hold button*

Emergency stop button

Shift key

Page key

Coordinate key

PLAY

REMOTE

TEACH

START

*The button/switch names

are denoted as symbols.

HOLD

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Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • "

means that the cursor is moved to the object item and [SELECT] is

pressed, or that the item is directly selected by touching the screen.

Registered Trademark

In this manual, names of companies, corporations, or products are

trademarks, registered trademarks, or brand names for each company or

corporation. The indications of (R) and TM are omitted.

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Contents

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1 Functional Overview........................................................................................................................ 1-1

1.1 Overview ............................................................................................................................ 1-1

2 Setup............................................................................................................................................... 2-1

2.1 Setup Flow ......................................................................................................................... 2-1

2.2 Upgrading YRC1000 System Software.............................................................................. 2-1

2.2.1 Individual Data Backup ......................................................................................... 2-1

2.2.2 Upgrading System Software ................................................................................. 2-1

2.3 Setting and Confirmation of Hardware Configuration ........................................................ 2-2

2.3.1 Removing Unnecessary EW Board ...................................................................... 2-2

2.3.2 Station Number when EW Board is Left ............................................................... 2-2

2.4 Connection of Welding Power Source and YRC1000........................................................ 2-3

2.4.1 Standard Connection (When connecting one welding power source of

digital interface to YRC1000)................................................................................ 2-3

2.4.2 When Connecting to YRC1000 the Multiple Welding Power Sources of

Digital Interfaces and also Other Devices with Data Transmission Function

using Ethernet Function........................................................................................ 2-4

2.5 System Configuration......................................................................................................... 2-5

2.5.1 I/O Module Setting Check after Changing EW Board Station Number Setting..... 2-6

2.5.2 Setting of Optional Function “Network Function” .................................................. 2-7

2.5.3 Setting of Optional Function “WELDCOM Function” ............................................ 2-9

2.5.4 Detailed Setting of Welding Power Source......................................................... 2-11

2.5.5 I/O Module Setting Check after Adding Virtual EW Module................................ 2-13

2.5.6 Setting of Optional Function "MotoPlus Function"

(When Welder is FroniusTPSi) ........................................................................... 2-15

2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)....................... 2-16

2.5.8 Setting of Parameter (When Welder is MOTOWELD)........................................ 2-17

2.5.9 Setting of Parameter (When Welder is FroniusTPS) .......................................... 2-19

2.5.10 Setting of Parameter (When Welder is FroniusTPSi) ....................................... 2-21

2.5.11 Optional Parameters for Fronius TPS............................................................... 2-24

2.5.12 Optional Parameter for FroniusTPSi................................................................. 2-24

3 Operation of Welding Condition File Edit Window .......................................................................... 3-1

3.1 Overview ............................................................................................................................ 3-1

3.2 Display of Welding Condition File Edit Window ................................................................. 3-1

3.3 MOTOWELD Type: Operation of Top Window .................................................................. 3-2

3.4 MOTOWELD Type: Operation of Weld type Window ........................................................ 3-3

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3.5 MOTOWELD Type: Operation of Customize Window ....................................................... 3-4

3.6 MOTOWELD Type: Operation of Maintenance Window ................................................... 3-7

3.7 MOTOWELD Type: Operation of Welder Parameter Window........................................... 3-8

3.8 FroniusTPS Type: Operation of Top Window .................................................................... 3-9

3.9 FroniusTPS Type: Operation of Program No. setting Window ........................................ 3-10

3.10 FroniusTPS Type: Operation of Param. setting Window ............................................... 3-11

3.11 FroniusTPSi Type: Operation of Top Window ............................................................... 3-12

3.12 FroniusTPSi Type: Operation of Select Synergic Window ............................................ 3-13

3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window ............................... 3-13

4 Job Preparation for Welding ........................................................................................................... 4-1

4.1 Job Preparation for Welding .............................................................................................. 4-1

5 Synchro-welding Function [Compatible Welder : MOTOWELD-X350] ........................................... 5-1

5.1 Setting of “Synchro-welding”..............................................................................................5-2

6 Alarm and Error............................................................................................................................... 6-1

6.1 Alarm ................................................................................................................................. 6-1

6.2 Error................................................................................................................................. 6-24

6.3 Message .......................................................................................................................... 6-24

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1 Functional Overview

1.1 Overview

1-1

HW1484216

1 Functional Overview

1.1 Overview

The WELDCOM function serves as a digital interface that communicates

via Ethernet with an arc welding power source. The function provides high

data rate transmission between YRC1000 and the welding power source,

enables the welding power source parameter to be set from the

programming pendant, and monitors graphically welding current and

voltage during welding.

The WELDCOM function can use either of the following four welding

power sources for connection.

MOTOWELD-EL350-AJ2E (manufactured by YASKAWA

ELECTRIC CORPORATION)

(AJ2E indicates that an Ethernet interface is incorporated.)

MOTOWELD-RP500 (manufactured by YASKAWA ELECTRIC

CORPORATION)

(In the case of digital communication mode)

MOTOWELD-RL350 (manufactured by YASKAWA ELECTRIC

CORPORATION)

(In the case of digital communication mode)

MOTOWELD-X350 (manufactured by YASKAWA ELECTRIC

CORPORATION)

MOTOWELD-X500 (manufactured by YASKAWA ELECTRIC

CORPORATION)

MOTOWELD-RD350S/S-AC (manufactured by YASKAWA

ELECTRIC CORPORATION)

MOTOWELD-RD500S (manufactured by YASKAWA ELECTRIC

CORPORATION)

( , , System version: YAS2.03.00(□)-00 or later)

TPS4000 CMT (manufactured by Fronius International GMBH)

(Only the model that incorporates the WeldCom interface)

TPSi (manufactured by Fronius International GMBH)

(System version: YAS1.34.00(□)-00 or later)

(Only the model that incorporates the WeldCom interface)

Programming a job is available using general arc welding

commands.

ARCSET ASF#( ),

ARCON ASF#( ),

ARCOF AEF#( )

Welding conditions are set in a welding start condition file or a

welding end condition file specified in an arc welding command.

The welding start condition file or welding end condition file has the

edit window that provides the setting window for a digital interface,

enabling users to check or edit parameters to be set in welding

power source.

The parameter to be set in the edit window of the welding condition

file is saved in the dedicated condition file, "Welding type file" and

"Digital welder condition file", where the data can be loaded and

saved with the external memory function.

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