osacom 8700 teaching (1l4000c-9)

June 1997

Nal L40QOC-9

This insutruction manual describes basic operation of OSACOM SUPER 8700 ROBOT CONTROL UNIT Read and understand the entire contents of this manual, with special emphasis on the safety devices throughout the manual, before installing, operating or maintaining the Manipulator, Robot Control Unit, and its peripheral equipments. These equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Do not allow untrained persons to install, operate, or maintain these equipments. Contact your distributor i f you do not fully understand these instructions. Following Instruction manuals are provided for these equipments. These instruction manuals shall be referred where necessary in accordance with installation, operation and maintenance.

Model GOlS Model VOIS Model VlOS Model V20S Model V40S Model WOlS OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 INDUSTRIAL ROBOT

MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR CONTROLLER TEACH I NG INTERFACE WITH JIG OPTION SAFETY WARNING

I TRAINING COURSES 1 The equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Therefore, DAIHEN Corporation provides various training courses such as the SAFETY, OPERATION, MAINTENANCE and so on.For the details, contact your distributor or DAIHEN Corporation.

I LIMITED WARRANTY I DAIHEN Corporation warrants this equipment against defects in parts and workmanship, which have occurred under the appropriate service and maintenance conditions including the periodic inspection described in the manual, for shorter period of either 14 months after B/L date of shipment f rom Japan, or 2000 hours actual working time from the date of delivery of equipment to the original user. This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the original user. DAIHEN, a t its option, will repair or replace any equipments during the warranty period, which DAIHEN, upon inspection, shall determine to be defective in material and/or workmanship. The foregoing shall constitute the sole remedy any breach of DAIHEN's warranty.

DAIHEN MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN, INCLUDING WITHOUT LIMITATION THEREOF, WARRANTIES AS TO MARKETABILITY, MERCHANTABILITY, FOR A PARTICULAR PURPOSE OF USE, OR AGAINST INFRINGEMENT OF ANY PATENT. IN NO EVENT SHALL DAIHEN BE LIABLE FOR ANY DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF ANY PRODUCT.

~ F E T V WARNING

THE FOLLOWING ROBOTIC SAFETY SHALL BE KEPT STRICTLY.IF NOT, SERIOUS PERSONAL INJURY OR LOSS OF LIFE IS CAUSED.

A. GENERAL INFORMATION AND SAFETY

A.1 General

Information presented in this section and on various labels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.

A.2 Safety

The installation, operation, maintenance, and troubleshooting of arc welding robots require practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with the safety standard which is applied for your country such as ANSI/RIA document, "American National Standard For Industrial Robots Systems - Safety Requirements" and all other safety material found in this Section and throughout the entire manual. In addition, follow all other codes as applicable to the application. See Arc Welding Safety Precautions Sections in the welding power supply Owner's Manual for safety precautions regarding the operation of arc welding power supplies and welding equipment.

B. SAFETY ALERT SYMBOL AND SIGNAL WORDS

The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions.

This safety alert symbol is used with the signal words WARNING and CAUTION to call attention to the safety statements.

WARNING statements identify procedures o r practices which must be followed to avoid serious personal injury or loss of life.

CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.

IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.

C. G E N E R A L S A F E T Y REQUIREMENTS Read, understand and comply with the following safety rules a t robot maintenance.

1 KEEP OUT of robot working envelope when main power is on.

2 STAY ALERT when near robot.

3 KEEP INFORMED about status of robot and general working conditions.

4 HAVE AN EMERGENCY STOP BUTTON IN HAND whenever you are near the robot.

5 UNDERSTAND AND BE FAMILIAR WITH ROBOTIC MOVEMENTS. Robots are unique industrial devices and can present unexpected hazards t o personnel because of their movements.Unpredictable robot motion can occur in even the best designed areas of operation.

6 NEVER STAND with your back toward the robot.

7 NEVER PLACE yourself between robot work stations i f more than one work station is used.

8 THOROUGHLY TRAIN A L L PERSONNEL in robot operation and safety.

9 READ robot safety regulation of the country installed robot and PUT INTO EFFECT it.

10 DO NOT REMOVE, DESTROY, OR COVER the WARNING and CAUTION labels on Robot Control Unit and Manipulator.

SAFETY REOU l REMENTS FOR l NSTALLATlON (Figure D-I) The robot cell requires initial safety conditions that are vital for both personnel and equipment. Make safety provisions part of the basic cell design.lmplement the following during installation:

1 Brightly mark floor with distinctive areas identifying Zones 1 and 2 on Figure D-1.

2 Route all cables and hoses so that they will not be damaged and will not clutter the cell f loor space.

3 Protect welding system components from spatter, slag, heat, and the general welding environment by locating equipment to minimize exposure.

4 I f any welding components must be located in a high-exposure area, provide proper guards o r shields to minimize d i r t and spatter.

5 Consider all necessary jig requirements t o include turntables, sliding trays, etc., that will become a part of the application so that the operator does not have to enter the work envelope(Zone 1 ).

6 l nstall pressure-sensitive floor mats, proximity devices, l imit switches, light curtains, etc., t o suit the application and number of work stations so that Emergency Stop will occur i f there is any instruction o r violation of the robot work envelope.

7 Install chain fences and light batteries around other cell portions that are not t o be violated.

8 Locate Teach Pendant and Operation Box outside robot work envelope.

9 Provide proper Electrostatic Discharge(ESD) protection for electronic components in Robor Control Unit and Teach Pendant.

10 MAINTAIN SAFE INTEGRITY OF CELL A T A L L TIMES.

Zone 1 - Robot Work Envelope(Area) Zone 2 - Operator Work Area Zone 3 - Outer Area of Robotic Cell

IMPORTANT : See Instruction manual "MANIPULATOR" for vertical space requirements of robot.

Figure D-l Layout Considerations for a Typical Robotic Cell

OPERATOR SAFETY REQUIREMENT

Provide proper ventilation for welding areas.Supply fresh air i f required o r use approved breathing device.

Wear approved head and body protection (this includes, but is not limited to, protective headgear, gloves, and safety shoes).

Install approved filter lens into welding helmet to protect eyes f rom arc rays.

Press an EMERGENCY STOP button before entering robot area.

Stay alert for unexpected robot motion o r movement.

Provide arc guard curtains or shields around the welding area so that arc rays do not injure operator o r other personnel.

Keep robotic cell clean, neat, and orderly.

Close and secure all access doors and panels on components.

Unless i t is specifically necessary to enter the working area of robot system, t o avoid accident, no worker including the operator should enter the working area of robot system. When entering the working area of the robot system for teaching the robot, be sure to check the location and condition of the safety devices such as the EMERGENCY STOP button and DEADMAN SWITCH on the Teach Pendant. And place the EMERGENCY STOP button within the operator's reach for the robot should malfunction.

The robot is keeping the safety speed sufficiently during the teaching mode, however, there is a possibility that the operator is caught in the robot by slow speed.To avoid injury, pay attention to the following:

a) Space requirement for the robotic system cell must allow sufficient area to include installing robot system components, movement around the work envelope by one o r more operators into and out of the cell.

b) The operator should always have some predetermined escape place. c) Never block the escape place of the operator by the other person o r something. d) I f the operator o r the other worker realize the operator's danger, press the

EMERGENCY STOP button immediately. e) A t the worst, i t means that i f the operator was caught in the robot, take the

following procedure.

1) Press the Emergency Stop button immediately. 2) Turn of f the primary power switch of the Robot Control Unit. 3) To avoid fall the robot arm, l i f t the 2nd and 3rd axis of robot by wire ropes. 4) Turn on the primary power switch of the Robot Control Unit again.

(DO NOT TURN ON THE SERVO POWER.) 5) To release the brake, connect pin No. 1 and pin No.2 of terminal block on the

Interlock Board by jumping wire. For search the location of pins, see following Figure E-I.

6 ) To escape the person who was caught in the robot, move the robot arm (the Axis 2).

7) Disconnect the jumping wire, after person escaped.

While operating the system in the automatic operation mode, operator should leave the working area of the robot system.

Interlock board

Figure E-1 Location of Brake release pins

IF. SAFETY PROCEDURES DURING TEACHING (PROGRAMMING) Teaching (programming) often requires the operator to enter the robot work envelope. As a result, always do the following during teaching procedures:

1 Move robot slowly (see instruction manual "TEACHING" - Teaching for speed entry information).

2 Always assign and position a watchperson, with an Emergency Stop button in hand, to present and ready during teaching operations.

3 I f jig motion was programmed to operate from external output control, the jig could energize during teaching.Be careful and alert for jig motion.

SAFETY CHECKS AFTER ENTERING A PROGRAM

1 Have all unauthorized persons leave robotic cell.

2 Check the operation of all warning devices, such as lamps o r horns.

3 Check and be sure that the robot moves normally through its program sequences using the block operation mode(either step or continuous).

4 Check movement of all jigs, and be sure their operation is normal.

5 Check fo r proper operation of EMERGENCY STOP buttons.

H. SAFETY PROCEDURES BEFORE AUTOMATIC OPERATION

Before starting automatic robot operation, do the following:

1 Verify the correct program number allocation is assigned to the appropriate Starting Box(es).

2 Have all unauthorized persons leave the robotic cell area.

3 Close and secure all gates and guard doors, and energimlight fences, barriers, and curtains as applicable for the entire specific cell.

4 Place all jigs in their normal, start-work positions.

5 Place the robot in the axes origin or work origin position as required fo r the operation.

6 Remove all tools f rom the robot work envelope.

7 Place welding workpiece(s) into proper position(s).

8 Place all equipment switches in the proper positions.

I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION

During automatic operation, do the following:

1 Turn off main power o r press an EMERGENCY STOP button BEFORE entering the robot work envelope.Entry may be required fo r nozzle, tip, wire, o r gas adjustments o r replacements.

DO NOT ENTER WORK ENVELOPE UNLESS AN EMERGENCY STOP BUTTON IS PRESSED !

2 Be alert fo r jig movement initiated by an external control signal during operation.

3 Do not allow unauthorized persons to operate controls.

4 I f two or more Starting Boxes are used, be sure that the operators ful ly understand all procedures and cooperate with each other.

5 Press an EMERGENCY STOP button if any problem occurs.

6 Since this an arc welding operation, protect operator(s) f rom arc rays, fumes, and hot parts.

7 Be sure that the Automatic mode can only be selected a t a safe location outside the work envelope.

J. SAFETY PROCEDURES AT END OF WORK

1 Place robot welding torch into an area from which movement to axes origin o r work origin positions is possible without striking any objects.This may require manual operation with Teach Pendant.

2 Press an EMERGENCY STOP button to turn of f robot Servo power.

3 Turn off welding power source and all associated equipment. This includes jig power supplies as applicable.

4 Place line disconnect switches fo r Robot Control Unit and welding power supply in the OFF positions.

5 Allow robot and all equipment to cool.

6 Clean robot, jigs, and entire cell area.

7 Install protective covers over all equipment AFTER proper cooling has occurred to reduce dust and d i r t entry.

K. SAFETY PROCEDURES DURING BNSPECT18N, MAINTENANCE, ADJUSTMENT, AND SERVICING PROCEDURES

Since these procedures can involve entering the robot work envelope and may require that the main power and servo power are turned on, be sure to always do the following during any maintenance, adjustment, o r repair procedures:

1 Train all service personnel in the functions, operations, and jig movements of the specific robotic cell.

2 Allow only trained and qualified persons to service the robot.

3 Always assign and position a watchperson, with an EMERGENCY STOP button in hand, t o be present and ready during any servicing or adjustment procedures.

4 Determine in advance i f the procedure(s) requires an energized robot.When power is not required, turn it off.

5 Determine in advance i f the procedure can be done outside the work envelope.Always work outside the robot work envelope whenever possible.

6 Turn of f o r disable all jig(s) and external equipment not required fo r the specific procedure.

7 Provide proper Electrostatic Discharge (ESD) protection for circuit boards in Robot Control Unit and Teach Pendant.

8 When the procedure is finished, always correctly, securely, and carefully reconnect any wires and reinstall necessary hardware, plugs, covers, and panels.

L. ARC WELDING SAFETY PROCEDURES

Read and understand, and comply with all safety rules at beginning of welding power supply manual in addition to the following before beginning arc welding operations.

1 Prevent electric shock as follows:

1) INSTALL AND GROUND all equipment according to national, regional, and local codes.

2) DO NOT TOUCH live electrical parts.

3) WEAR DRY INSULATING GLOVES AND CLOTHING; be sure gloves have no holes.

4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing any equipment.

2 Provide proper protection from fumes and gases as follows:

1) KEEP YOUR HEAD out of the fumes.

2) USE FORCED EXHAUST VENTILATION at the arc.

3) VENTILATE CELL to prevent build-up of fumes and gases.

4) I f ventilation is inadequate, USE APPROVED BREATHING DEVICE.

5) READ AND FOLLOW WARNING LABELS on all containers of welding materials.

6 ) Before use, READ AND UNDERSTAND the manufacture's instructions, Material Safety Data Sheets (MSDSs), and your employer's safety practices.

3 Protect eyes and skin from arc rays ; protect ears from noise as follows:

1) WEAR PROPERLY FITTING WELDING HELMET with proper shade of fi lter lens (See ANSI 249.1 ).

2) INSTALL ARC PROTECTIVE CURTAINS between operator and the arc.

3) WEAR PROPER SAFETY GLASSES in work area a t all times.

4) WEAR PROPER EAR PROTECTION.

5) WEAR PROPER BODY PROTECTION to include woolen clothing, flame-proof apron and gloves, leather leggings, high boots and leather arm and shoulder gauntlets.

4 Prevent f ire and burns cause by hot metal, spatter, slag, and arc sparks as follows:

1) KEEP FLAMMABLE MATERIALS out of the robotic cell.

2) Have operator(s) keep their sleeves, pockets, and collars down and buttoned as applicable. Wear pants without cuffs.

3) WATCH for fire.

4) Have a f ire extinguisher nearby, and know how to use it.

5) Allow equipment and work to cool before handling.

5 Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs as follows:

1) FASTEN CYLINDERS SECURELY so they cannot fall (use insulated chain or equivalent).

2) INSULATE CYLINDERS from mounts so that they are never grounded o r part of an electrical circuit.

3) KEEP CYLINDERS AWAY from the welding arc and other heat sources.

4) LOCATE CYLINDERS AWAY from personnel and vehicle traff ic patterns.

6 Provide impact protection t o all persons in the cell as follows:

1) ALWAYS WEAR PROPER PROTECTIVE HEADGEAR, such as safety helmet, when in the robotic cell.

2) WEAR SHATTER-RESISTANT SAFETY GLASSES a t all times when in the robotic cel I.

7 Since magnetic fields from high currents can affect pacemaker operation, have wearers consult their doctor before going near arc welding operations.

8 TURN OFF robot and welding power source input power before entering work envelope o r working on welding power source.

9 Prevent EMC (Electro-Magnetic Compatibility) noise caused by welding arc as follows:

1) KEEP PRECISION DEVICES AWAY from the welding arc.

2) Supply primary power t o precision devices and welding power supply separately.

M. WARNING LABELS

DO NOT REMOVE, DESTROY, o r COVER the following labels on the Robot Control Unit and Manipulator. I f following labels become d i r ty o r peeled off, order spare ones immediately. The locations of these labels are shown in the instruction manual "MANIPULATOR" and "CONTROLLER".

KEEP OUT OF ROBOT AREA W E N MAIN POWER IS ON.

READ INSTRUCTION MANUAL.

A WARNING I

K e e p o u t of robot a r e a w h e n m a i n power is o n . R e a d Instruct ion M a n u a l .

D o N o t R e m o v e , Destrov, Or C o v e r This Label. 1 --

ARC WELDING can b e haza rdous . * Read and fo l low t f ~ i s label and the lristructton Manua l careful ly

Only quali f ied persons are to install, operate, or service this unit according to al l applicable codes and safety practices. Pacemaker wearers keep away. @ Keep children away.

@ Welding wire and drive parts rnay be a t welding voltage.

ELECTRIC SHOCK can kill. @ A lways wear dry insulating gloves. @ Insulate yourself f r o m the w o r k and the ground. @ D o not touch l ive electr ical parts. F, Disconnect input power before servicing.

Keep al l panels and covers securely in place.

FUMES AND GASES can be hazardous

@ Keep your head out of the fumes. @ Ventilate area, or use a breath ing dev ice . - Read Mater ia l Safety Data Sheets ( M S D S s ) and

1 I manufacturer's instructions for mater ia l used. I

WELDING can cause fire or explosion. @ D o not we ld near flammable material.

W a t c h for fire; keep extinguisher nearby. @ D o not locate unit over combustible surfaces. @ D o not we ld on closed containers.

/ ARC RAYS can burn eyes and skin: NOISE can damage hearing.

@ Wear welding he lmet w i t h correct filter.

@ Wear correct eye, ear, and body protection

label and the lnstrucr~on Manua l carefully.

e Do not touch l lve electrical pans

FUMES AND GASES can be hazardous ARC RAYS can burn eyes and s k ~ n . NOISE can damage hearing.

Do Not Remove, Dest roy , Or Cover This Label.

@ Keep a w a y f rom moving parts.

@ Keep hands, loose clothing, and tools away during operation.

P INCH POINTS can cause injury.

@ Keep away from pinch points during operation. @ Know and understand equipment operation before

use.

ELECTRIC SHOCK can kil l. @ Always wear dry insulating gloves. @ Insulate yourself from the work and the ground. @ Do not touch live electrical parts. '4 Disconnect input power before servicing. o Keep all panels and covers securely in place.

FALLING EQUIPMENT can cause serious parsonal injury and equipment damage. @ Lif t and move this unit only with proper

equtpment and correct procedures. @ Have only qualified persons ~nstall, operate. or

service this unit. Read Instruction Manual.

WARN ELECTR C SHOCK

@Do not touch live electrical parts.

@Disconnect all power before installing or servicing.

@Multiple sources of voltage may exist inside this enclosure.

A WARNING @Keep out of robot area when

main power is on. @#Do not locate this device

in robot work area. I I e Read Instruct ion Manual. I

A WARNING - ELECTRIC S H O C K can k i l l .

D o not touch l ive electrical parts.

Read this label and Instruction Manual carefully.

@ Disconnect all power before installing or servicing.

O n l y qualified persons are to install. operate. or service this equipment according to all codes and employer's safety practices.

.Wear dry insulating gloves and body protection.

s D o not locate over combustible surfaces.

@ Keep al l panels, covers. and guards securely in place.

@For protection against fire hazard. Replace only wi th the same type and rating of fuse.

NC8052

A WARNING @ Read manual for connection procedures.

@ Connect grounding conductor and input

conductors to proper terminals inside

unit-grounding conductor first.

B e sure grounding conductor goes to

a proper earth ground and has less

than 100 ohms of resistance.

Doublecheck grounding conductor,

input voltage, and frequency before I I applying power.

the connectors respectively. Wrong connection may damage the control unit

@Connect CN67, CM68, CN69, GPV-70, CN71 and CN72 of control cable to interlock ~ o a r d as following drawing.

@ Connect CN31, CN32 and CN33 of starting ox to interlock Board as in the .Following

@ CN69 and CN72 are for external axes such as positioner and slider, in case of a single mechanism (one manipulator) system, 6N69 and CN"7 are not connected.

@As for details of each cable connection,

CN33 CN32 CN31

NCDO66

P a r t I Basics

Chapter 1 Hints fo r Using This Manual 1.1 Instruction Manuals "Teaching" and " Options" .................................................................... 1- 1 1.2 The Organization of This Manual ........ 1- 1 1 3 Conventions Used in This Manual 1 - 2 1.4 Terms Used in This Manual .................................................................................................................... 1- 3

Chapter 2 Overview 2. 1 Control power (Controller) ................ 2- 1 2. 2 Operating Panel ................................................................................................................................................ 2- 2

2 . 3 Teaching Box ..................................................................................................................................................... 2- 3 2 . 3 . 1 Outside View of Teaching Box 2- 3 2 . 3 . 2 Teaching Box Keys 2- 4 2. 3 . 3 Function Keys 2- 9

2 3 4 Display Screen ......................................................................................................................................... 2 - 11 . . 2 . 3 . 5 Entering Numeric Values ............................................................................................................... 2 -15

2 4 Modes 2 -16 2 4 1 TEACH Mode .............................................................................................................................................. 2 - 16 . . 2 4 2 AUTO Mode 2 -16 . . 2 4 3 Initial Mode 2 - 16 . . 2 4 4 Mode Change ........................................................................................................................................... 2 - 16 . . 2 4 5 Mode Change Interlock ..................................................................................................................... 2 - 18 . .

Chapter 3 Basic Features and Functions for Operating OSACOM SUPER 8700 3 1 Turning On OSACOM SUPER 8700 ................................................................................................... 3- 1

3.2 ~~~~i~~ on the servo power ................................................................................................................... 3- 2 3.3 Operations for Manual Manipulation 3 - 3

3.3.1 Manual Manipulation 3 - 3

3 3 2 Changing Manual Speeds ................................................................................................................. 3- 3 . . 3.3.3 Switching between the Axis and Cartesian Movements .. 3- 4

3 4 Teaching (Creating Task Programs) 3- 5

3.4.1 Preparation for Teaching ................................................................................................................... 3- 6

3 4 2 Basic Teaching ............................................................................................................................................ 3- 7 . . 3 4 3 Keys Used for Teaching ..................................................................................................................... 3 - 11 . .

3.5 Block Operation 3- 12

3 6 Modifying Task Programs ......................................................................................................................... 3- 13

3 7 Adding and Deleting Instructions ....................................................................................................... 3 - 15 3.7.1 ~ d d i ~ ~ ti^^^ 3-15

3 7 2 Deleting Instructions .............................................................................................................................. 3 - 16 . . 3 8 Start Allocation 3- 17

3.9 Automatic Operation ...................................................................................................................................... 3 - 18

3 10 Shutting Off the Servo power (Emergency Stop) 3- 19 3 . 11 ~~~~i~~ off the control power 3-20

Chapter 4 Manual Manipulation 4.1 operations for ~~~~~l ~ ~ ~ i ~ ~ l ~ t i ~ ~ .... 4- 1

4.1.1 Changing Positions and Attitudes (Manual Manipulation) 4 - 1 4 . 1 . 2 Changing Manual Speed 4- 2

4.1 3 switchillg between coordinate systems 4- 2 4.1.4 Switching Mechanisms

(Not applicable to the Single Manipulator System) 4- 5 4.1.5 hi^^ and ~ ~ t ~ ~ ~ t i ~ ~ the wire ............................................................................................... 4- 5 4.1.6 Resetting External Control Output Signals 4- 6

4.2 ~~~i~~ ~ i ~ ~ ~ t i ~ ~ ~ 4 - 7 4.2 1 ~~i~ ~~~~~~~t 4- 7 4.2 2 cartesian ~~~~~~~t 4- 9

4.3 cartesian ~~~~~~~t N~~~ the singular point . 4-19

Chapter 5 Teaching 5.1 Creating and ~ i ~ ~ i ~ ~ ~~~k programs 5- 1

5 1. 1 Creating Task programs 5 - 1

5.1 2 ~ i ~ t i ~ ~ ~~~k programs ......................................................................................................................... 5 - 7 5.2 Teaching ti^^ Instructions 5- 8

5 2.1 positioning p 5 - 8 5.2 2 Linear Interpolations 5 - 10 5.2 3 Circular Interpolations 5 - 13 5.2.4 wait for ~i~~~ T ~ ~ ~ / N ~ operation 5 - 15

5 2.5 ~ ~ t ~ ~ ~ ~ l program J~~~ ........................................................................................................................ 5 - 7 5 2 6 ~ ~ t ~ ~ ~ ~ l program J~~~ ..................................................................................................................... 5 -24 . . 5.2 7 program Call 5 -27 5.2.8 End ...................................................................................................................................................................... 5 - 29

5 3 Teaching Task Instructions 5 - 30 5 3 1 A~~ start .......................................................................................................................................................... 5 - 30 . . 5 3 2 Arc End 5 - 34 . . 5 . 3 . 3 ~ ~ ~ h i ~ ~ / ~ ~ ~ ~ ~ ~ t i ~ ~ 5-37 5 . 3 . 4 Gas ON/OFF 5 - 38 5.3 5 Weaving Start 5 - 39 5 3.6 Weaving End 5 -46 5 3.7 External Control Input/Output 5-47

5.4 Block Operation .................................................................................................................................................... 5-53 5.4.1 ~ ~ ~ ~ ~ ~ d / ~ ~ ~ k ~ ~ ~ d ~ l ~ ~ k operations .................................................................................... 5-53 5.4.2 ~ l ~ ~ k ti^^^^^ operation 5-55 5.4.3 Block Operating Speeds 5 - 55 5.4.4 &&ing and starting ~ l ~ ~ k operation 5-56 5.4 5 Cancelling the Halted State of Block Operation 5-57 5.4.6 Sequence Jump 5 - 58

5.5 Adding and Deleting Instructions 5 - 59 5 . 5 . 1 Adding Instructions 5 -59 5 5.2 Deleting Instructions 5 -60

5 6 Changing Teaching Data 5 - 61 5 6 1 Changing Motion Instructions 5 - 61 . . 5.6.2 Changing parameters of Motion Instructions 5-62

Chapter 6 Automatic Operation 6.1 Automatic Operation ...................................................................................................................................... 6- 1 6.2 Automatic Operation by the Multi-station System ................................................................ 6- 3

6.2. 1 Start Allocation ........................................................................................................................................ 6- 4 6.2.2 Changing to Auto Mode and Starting Automatic Operation ................................ 6- 5 6.2 3 Start Reserving and Cancelling 6- 6

6.3 Automatic Operation by the Direct Program Entry System ......................................... 6- 8 6 4 Job End 6 - 11 6.5 Halt 6-11 6 6 Restart 6- 13

6.6.1 Restarting from Halted point ...................................................................................................... 6-13 6 6 2 Restarting from A Specified Start Point ............................................................................... 6-14 . . 6 .6. 3 Overlap Restarting 6 - 15

6 . 6 4 Restarting After Block Operation ............................................................................................... 6 - 16

6.6.5 Restarting from Halting during Execution of Task Instruction ....................... 6-17

Chapter 7 Editing Files 7 . 1 Selecting Files ..................................................................................................................................................... 7- 1 7.2 ~ d i t i ~ ~ welding condition ~ i l ~ ~ ........................................................................................................... 7- 3 7.3 Editing Weaving Condition Files .......................................................................................................... 7- 6

Chapter 8 File Operations 8 . 1 Listing Files ........................................................................................................................................................... 8- 1 8.2 Copying Files ........................................................................................................................................................ 8- 4 8.3 Deleting Files ....................................................................................................................................................... 8- 5 8.4 Renaming Files ..................................................................................................................................................... 8- 6 8.5 ~ ~ ~ t ~ i ~ t i ~ ~ on lj'ile operations 8- 7

Chapter 9 Cancelling Emergency Stop and Shock Sensor 9 . 1 Emergency Stop ................................................................................................................................................. 9- 1 9.2 ~ 1 ~ ~ ~ k sensor ........................................................................................................................................................ 9- 2

9.2.1 cancelling the ,-.hock sensor 9- 2

9.2.2 Before Automatic Operation and After Completion of tlie Job ......................... 9- 2 g 2 3 In Teach Mode ............................................................................................................................................ 9- 3 . . 9.2.4 Correcting Taught Positions Where the Shock Sensor Operates ...................... 9- 3

1 P a r t II App l i ca t ion Features and Funct ions

Chapter 1 Application Features and Function Used in Teach Mode 1.1 Application Features and Functions Used for Manual Operations ......................... 1- 1

1.1.1 Displaying Angles and Coordinates (Reading Positions) .. 1- 1 1 1 2 ~h~ H~~~ s top ti^^ ..................................................................................................................... 1 - 4 . . 1 . 1 3 The Work Enable Area 1 -. 5

1.1.4 The Reference Joint Angles a t the Start Enable Area ... 1- 5 1 . 1 . 5 setting ~~~~~l speeds 1 - 7

1.2 ~ ~ ~ l i ~ ~ t i ~ ~ ~~~t~~~~ and $'Unctions used for hi^^ .................................................. 1 - 9 1.2.1 Logical Check on Task Programs 1 - 9

1 . 2 . 2 Confirmation of Terminating Teaching 1 -. 21 1.2.3 setting the way of performing ~ l ~ ~ k operation ............................................................ 1-22

1.2 4 cursor ~ ~ d i ~ ~ t i ~ ~ of the state of ~ l ~ ~ k operation 1-24 1 .2, 5 setting j310ck operating speeds 1-25

1.2.6 Checking and Modifying Condition Files during Block Operation ................... 1-26

Chapter 2 User Parameters 2 . 1 Setting the System Status .......................................................................................................................... 2 - 3

2 . 1 . 1 Setting the Home position ............................................................................................................... 2 - 8 2.1 2 Setting the Work Enable Area (Soft Limit) 2- 10 2 1 3 Setting the Start Enable Area ........................................................................................................ 2-11 . . 2. 1 . 4 Registering Coordinate Systems ................................................................................................. 2-11

.............. 2.1.5 Setting Conditions for 3-dimensional Shift and Mirror Image Shift 2-12 2.1.6 Setting the ABSO Data Check Function 2-13

2.2 settillg the hi^^ B~~ K~~~ 2-14 2.3 setting the welding parameters 2-17

2.4 Setting the Parameters for External Control Signal Inputs/Outputs .................... 2-20 2.5 setting on ti^^ ~ ~ ~ t ~ i ~ t i ~ ~ ~ on ~ ~ t ~ ~ ~ t i ~ operation 2-22 2 6 Setting the Sensor Type 2 - 22 2.7 setting welding characteristic ~~t~ 2 -23

2.7.1 ~ ~ ~ i ~ ~ ~ ~ i ~ ~ welding characteristic ~~t~ ............................................................................. 2-24 2.7 2 ~ ~ d i f ~ i ~ ~ welding characteristic ~~t~ ................................................................................. 2-24

2.7.3 Creating User Welding Characteristic Data (User Registration) .................... 2-27 2 7 4 ~~t~~ to use ALMEGA FUZZY AUTO .................................................................................. 2-29 . . 2.7 5 ~~t~~ to use TIG ill^^ 2-31

Chapter 3 Application Features and Functions Used for Automatic Operation 3 1 Machine -Jock ........................................................................................................................................................ 3 - 1 3.2 D ~ ~ R ~ ~ 3 - 2 3.3 ~ ~ ~ - ~ ~ ~ ~ d ~ ~ t ~ ~ ~ t i ~ operation . 3 - 6

3.4 Checking the Star t Enable Area during Automatic Operation ...................................... 3- 8 3 5 path Function ....................................................................................................................................................... 3- . 8 3 6 Online Modification 3 - 10

3.7 Sequence Display during Automatic Operation ........................................................................ 3-11

Chapter 4 Shift 4. 1 parallel Shift 4 - 1 4.2 Cylindrical Shift 4- 3

....................................................................................................................... 4.3 Error Messages and Notes 4- 7

1 P a r t III Management

Chapter 1 External Storage 1 1 Connecting and Handling the External Storage 1- 1

1 . 2 Selecting External Storage Functions .............................................................................................. 1- 2 1 3 Formatting Floppy Disks 1 - 4

...................................................................................................................... 1 4 Listing Files 1- 5

1.5 Saving Files from the Controller to the External Storage . 1 - 6 1 . 5 1 Individual Saving 1 - 6 1.5.2 Batch Saving 1- 9 1 . 5 . 3 All Saving 1 - 11

1.6 Loading Files from the External Storage to the Controller ........................................... 1 - 13 .................................................................................................................................... 1 . 6 . 1 Individual Loading 1 - 13

1 .6.2 Batch Loading .............................................................................................................................................. 1 - 16 1.6.3 All Loading 1-19

1 7 Comparing Files ................................................................................................................................................. 1 - 21

1 . 7 . 1 Individual Comparison 1 - 2 1 1 . 7.2 ~ ~ t ~ h ~~~~~~i~~~ 1-24

............................................................................................................................................ 1 . 7 . 3 A]] ~~~~~~i~~~ 1 - 27 1.8 Deleting Files ....................................................................................................................................................... 1-29 1 g Restrictions on File Transfer 1 - 31 1 10 E~~~~ M~~~~~~~ for ~ ~ t ~ ~ ~ ~ l storage ........................................................................................... 1-32 1 11 Others ........................................................................................................................................................................ 1 - 34

. 1 . 11 . 1 Handling Floppy Disks 1 - 34 1 . 11 . 2 Notes External Storage 1 - 34

Chapter 2 Password .................................................................................................................................. 2 1 Entering the Password 2- 1

....................................................................................................................................... 2 2 Setting the password 2- 2

Chapter 3 Absolute Offset 3.1 Resetting the Encoders and Setting an Absolute Offset .................................................. 3- 1 3 2 Axis Alignment Marks on the Manipulator .................................................................................. 3- 5 3 3 The ABSO Data Check Feature ............................................................................................................... 3- 6

Chapter 5 Installing OSACOM SUPER 8700 Software Options 5 1 Installing Software Options ....................................................................................................................... 5- 1

5.2 ~ i ~ t i ~ ~ ~ ~ ~ t ~ l l ~ d software options ...................................................................................................... 5- 3

5 3 Deleting Installed Software Options .................................................................................................... 5- 4

Chapter 6 Troubleshooting 6.1 ~~~~t~~~ 6-15

6 . 1 . 1 ~ ~ t h i ~ ~ A~~~~~~ on the hi^^ B~~ 6-15 6.1.2 The Display on the Teaching Box Is Unsteady ............................................................... 6-16 6. 1 3 Initial Diagnosis Is Not Completed ........................................................................................... 6-17

6.1 4 The Servo Power Supply Cannot Be Turned ON 6-20 ......... 6.1.5 The Servo Power Supply Is Shut OFF Immediately When Turned ON 6-21

6. 1 . 6 Manual Manipulation Does Not Function 6-22

6.2 A ~ ~ i l ~ ~ ~ code and A ~ ~ i l ~ ~ ~ M~~~~~~ A~~ l)isplayed 6-23 6.2. 1 The Display of A Failure ................................................................................................................... 6-23 6.2.2 Logical Outputs for Failures .......................................................................................................... 6-26 6.2.3 shock sensor 6-27 6 2.4 Servo Power Shutoff ............................................................................................................................... 6-28 6.2 5 Software Limit / Link Software Limit 6-29 6 2.6 Overrun 6 -31 6 2.7 Communication Failures 6 - 32 6.2.8 Data Installation Failures ................................................................................................................ 6-34 6 .2.9 Memory Failures ..................................................................................................................................... 6-36 6.2. 10 setting E~~~~~ 6-37

6 2. 11 ABSO Data Failure .................................................................................................................................. 6-39 6.3 When Servo Failure Occurred 6 -40

6 3 1 How To See the Servo Failure Display 6-40 . . 6.3.2 Troubleshooting for Servo Failures .......................................................................................... 6-46

Hierarchical Diagram of Function key

Appendix 1 . Restrictions on the Overlap process 1

.................. 2 . The Relation Between a Minimum Circular Diameter and a Setting Speed 4 3. Restrictions on Weaving Frequency ............................................................................................................ 5 4 Tool parameters 10

Basics

L

Chapter 1 H in t s f o r Using Th is M a n u a l

This chapter provides hints for using this manual. including the

I organization. conventions. and terms . I

Contents

1. H i n t s f o r Using This Manual

1. 1 Instruction Manuals "Teaching" and "Options" Two instruction manuals a re provided to use OSACOM SUPER 8700 :

@ Teaching manual

Describes in detail various features and functions of OSACOM SUPER 8700 and

how to use them

Options manual

Describes in detail optional features and functions of OSACOM SUPER 8700 and

how to use them. Note that optional software and hardware a re required to use

them.

1. 2 The Organization of This Manual This manual consists of the following parts:

)II OSACOM SUPER 8700 Basics

This part describes basic features and functions used for operations such as

teaching and automatic operation.

EIll OSACOM SUPER 8700 Applications

This part describes application features and functions such as user parameters

and shift.

llBl OSACOM SUPER 8700 Management

This par t describes features and functions available for system manager to use an

external storage and initialize the system.

Hints for Using This Manual 1 - 1

I . 3 Conventions Used in This Manual

1. Appl icat ion Features and Function Used in Teach Mode 1. 1 Application Features and Functions Used for Manual Operations

1.1.1 Displaying Angles and Coordinates (Reading Positions)

OSACOM SUPER 8700 displays the joint angle of each axis of the manipulator

measured from the reference position and its coordinate value in the currently specified I I coordinate system.

@This feature is useful to modify the start enable area*' of ALMEGA G series or

W01, the home stop position*', and the work enable area".

@ Important 5

For ALMEGA V series, the angles read by this feature cannot be used to set

the s t a r t enable area (because the reference joint angles a t the s tar t enable

area a re different). For details, refer t o "The Reference Joint Angles for the

Start Enable Area", section 1.1.4. L J

Reading Positions

While you a re holding the keys I.)

down, the rotating angle of each d

axis and the coordinate value in the currently specified coordinate system a re displayed on the left and

I right sides of the screen, respectively.

Press F1 (LIST). rr)

F1 ... Displays the next page. F2 ... Display the previous

page. F3 ... Modify the Task

program the cursor indicates.

F4 ... Make a copy of the Task program the cursor indicate?

- Contains detailed explana tions, cautions, and notes about the feature or function. 0 describes for what purpose the feature or function is used.

Starts the explanation of operation.

The arrow indicates "the screen shown on the right appears when you operate in accordance with the operating procedure".

Joint each Coodinato value in the currently q m i f i d coordinate metam

F5 ... Deletes the Task program the cursor indicatesw

D F1 ... Rename the Task program the cursor indicates."

If more than 6 functions are contained in one layer, the following function keys are displayed in this manner.

* indicates a reference. See the bottom for more information.

1 - 2 Hints fo r Using This Manual

1 . 4 Terms Used in This Manual

The following is a list of terms used in this manual:

manipulator ....................

mechanism

teaching

Task program

Motion

instructions

A robot which welds or handles workpieces. Though

manipulator types of ALMEGA V series (V01, V10,

V20, and V40), G series (G01, and G03),

and W01 are available.

.. A mechanically independent unit, such a s a

manipulator, a positioner, and a slider.

To teach movements and welding works to the

manipulator.

A program which describes the sequential

operational procedure of movements and welding

works taught to the manipulator.

Instructions to not only teach movements

(positioning and interpolation) but also store

positions / attitudes to the manipulator.

Task instructions ......................... Instructions to store tasks (such a s welding,

weaving and signal outputs to external devices)

......................... sequence number A number with which the manipulator stores a point.

Sequence numbers are only given to Motion

instructions.

......................... coordinate system The space defined by the X, Y, and Z axes, which is

referenced when the manipulator moves. There a re

BASE, TOOL, WORK, and WORLD coordinate

systems.

top layer of TEACH ......................... Teach mode in which no teaching function or

mode feature has been selected.

function keys ......................... The keys to which the functions and features of

OSACOM SUPER 8700 or options are assigned.

Hints for Using This Manual 1 - 3

Chapter 2 Overview

This chapter describes each of the operating switches/buttons/

keys provided on Controller. Operating Box and Teaching Box. and

Teach mode and Auto mode .

Contents

2. Overview 2. 1 Control Power (Controller)

The control power switch is provided on the front face of controller. Holding the

handle a t the "ON" position causes the control power to be turned on

Turn the handle to the right and hold it a t the "ON"

position to turn on the control power.

Fig.2.1 The outside views of Controller and Control Power Handle

The controller must be operated by a t least two operators.

Ensure that one of the operators is ready to press the EMERGENCY STOP button in

emergency.

Overview 2 - 1

2. 2 Operating Panel

The operating panel is equipped with operating buttons indispensable for controlling

basic operations.

a * A U T O TEACH - - - - - - - - -. - - - - - - - - - , - - - - - - - - -

I I I 1

OSACOM 0

0 EMERGENCY

STOP button

(B) AUTO MODE

button

(C) TEACH MODE

button

(Dl SERVO POWER

button

(El START button

(F) STOP button

Fig.2.2. Operating Panel

Depress it when you want to stop the manipulator in

emergency. When depressed, the button is locked. To unlock

it, turn the button to the arrow.

Press it when you want to switch from Teach to Auto modes.

The lamp illuminates in Auto mode.

Press it when you want to switch from Auto to Teach modes.

The lamp illuminates in Teach mode.

Press it when you want to turn on the servo power.

The lamp illuminates when the servo power is turned on.

Press it when you s tar t automatic operation of a Task

program. Before starting, ensure that all personnel a re clear

off the danger area. The lamp illuminates during automatic

operation.

Press it when you want to halt automatic operation of the

Task program being running.

The lamp illuminates in the stopped state.

2 - 2 Overview

2 . 3 Teaching Box The following section provides general information of functions of the teaching box keys.

2.3. 1 Outside V iew of Teaching Box

ENABLE u READ DELETE RESET 000

( O S A C O M I

Fig.2.3 The operating parts of Teaching Box

Overview 2 - 3

2.3.2 Teaching Box Keys

* Numeric keys and Instruction selector keys

f [ Na KEY )

MODIFY key

WDI FY

* ADD key

RECORD key

RECORD 0 READ key

* DELETE key

DELETE 0

Used to enter numeric values and to select instructions. When a numeric value is entered, the LED lights.

Used to correct selecting or storing operations or clear the ALARM display which appears when misoperation occurs.

Used to add instructions. The LED on the upper left illuminates during adding operation.

Used to store data settings into the controller.

Used to read out data such a s coordinate values.

Used to delete instructions

RESET key

RESET 0 * SPEED SWITCH key

SPEED 0 COORDINATE SWITCH key

l NATES B * MECHANISM SELECTOR key

MECHA

FUNCTION SELECTOR key

FUNC- [L] * I NC/DEC keys

(UP/DOWN)

* LEFT/RIGHT keys

TEACH Mode keys

TEACH LZ]

Used to step one layer of function keys up, reset ERROR/ARARM, or cancel data settings.

Used to switch the speed display between of Manual operating speed and block operating speed.

Used to switch between the Cartesian and Joint movements used for manual manipulation.

Used to select an external axis. The numeric LED of Axis illuminates when the external axis operates. This key is effective only when external axis is connected.

Used to select a coordinate system in the cartesian movement o r to change over the Synchromotion state.

Used to increase/decrease manual/ block operating speeds, a welding current, etc. These keys are also used to select items you want to change or modify.

Used to select items you want to change or modify. These cursor keys are also used to make changes to data settings.

Used to switch from Auto to Teach Modes. The LED illuminates in Teach mode.

Overview 2 - 5

* Function CANDIDATE key

FUNCTION keys

TEACH

ENABLE

* QUICK INCREASE / DECREASE key

BACK LIGHT ON/OFF key

BACK-

Used to display a function o r functions following the 5th function if there are more than 6 functions assigned to the function keys.

Used to select functions displayed a t the bottom on the screen.

Used to perform manual manipulation and block operation.

Used to perform inching / retract a t high speed. This is also used to switch manual operating speed between Low speed (ML) and High speed (MH).

Used to switch ON/OFF the back light of the teaching box display part.

SENSOR rw:]

1/0 CONTROL ON/OFF SWITCH key - Used to change over between ON/OFF

of the external 1/0 control in the Teach mode. The LED a t the upper left illuminates when the external 1/0 control is executed.

* SENSOR ON/OFF SWITCH key

Used to change over between ON/OFF of Sensing performed in automatic operation. This is effective only when a sensor is connected. The LED a t the upper left illuminates when sensing is performed.

2 - 6 Overview

* WEAVE ON/OFF switch key

WELD ON/OFF switch key

* STOP key

Used to switch between weaving on and off. The LED on the upper left illuminates in the ON state.

Used to switch between welding on/off in automatic operation.The LED on the upper left illuminates in ON state.

Used to halt automatic operation. The LED on the upper Ieft illuminates in the stopped state of block or automatic operation.

BLOCK CONTINUE key Used to change over between continuous and single block operations. The LED a t the upper left illuminates in Continuous block operation.

* FORWARD/BACKWARD BLOCK keys

Used for block operation, sequence search, etc.

WIRE INCHING/RETRACT keys Used for inching/retracting the wire.

Overview 2 - 7

* AX1 S keys [rn)

EMERGENCY STOP button )I

LIGHT button ( LIGHT)

Used to turn on the servo power. To cancel overrun, perform manual manipulation by holding it down.

Used to light up when the operator has to check the target point of the welding wire tip in a dark place.

2 - 8 Overview

2.3.3 Function keys

This section describes the functions of the function keys.

(1) The organization of function keys

5 function keys a r e provided below the liquid crystal display. As shown below,

because the function keys a r e hierarchically organized, each time a function key is

pressed, functions assigned in the following lower layer a r e displayed:

When this function in selected

/ When this function in selected I

I When this function in selected

Fig.2.4. The organization of Function Keys

(2) Specifying function keys

The function corresponding to each function key is displayed a t the bottom on the

screen. Press function keys (F1 - F5) to select functions and data .

I Functions is displayed. I

Function Keys

To specify the function you want, press the relevant function key (F1 - F5)provided

below the display.

Overview 2 - 9

Only 5 functions are displayed on the screen a t one time. If the layer contains

more than 6 functions, the ">" is displayed next to the function key label a t the

right end.

allows you to call the function or functions following the 5th

function.

* If you want to step one layer up, press @ key

Even if you have selected a function in a lower layer, pressing key allows you

to return to the top layer of Teach mode. Note that this feature is not available when

you are using a function (such as Search and Sequence Jump) to edit a Task

program or are editing a Condition file.

2 - 1 0 Overview

2.3.4 Display Screen

The display screen shows the operation and information being currently executed.

This section describes each area on the display screen and also how to see various

information on the screen

(B) I

The display screen consist of the following areas:

( A ) Coordinate system display area

Where the movement coordinate system* being currently selected is

displayed:

(1) ~~i~ ~~~~~~~t AXIS

(2) Tool-side Base coordinate system .......... T.MECH

(3) Work-side Base coordinate system ........ W.MECH

(4) work coordinate system WORLD

(5) Tool coordinate system . TOOL

(6) Work coordinate system ............................. WORK

* :Refer to "Switching between Coordinate Systems", section 4.1.3 in part I.

Overview 2 - I 1

(B) Speed display area

Where a manual o r block operating speed is displayed

Manual operating speed MLO ML1 ML2 ML3 ML4 MH1 MH2 MH3 MH4 (Inching)

B-1 B-2 B-3 B-4 Block operating speed < Low High >

Press the key to change over between Manual / Block operating speeds.

(C) Mode display area

Where the mode* ' being currently selected is displayed:

Auto mode ......................... AUTO.

~~~~h mode . TEACH

Machine lock mode* .-.-- MACH LOCK (highlighted)

(D) File name display area

Where the file name which is in use for the operation being currently

performed, such as teaching, editing, or automatic operation is displayed.

(El The number of sequences display area

Where the number of sequences stored in the Task program being currently

executed is displayed:

When editing a new Work program ............... The number of already stored

sequences is displayed.

When modifying the Work program ............... The number of all sequences

stored in the Task program is

displayed.

(F) Servo Power State display area

Where the servo power state is displayed:

Turning on the servo power ..................... SERVO ON

Shutting off the servo power... .................. SERVO OFF (highlighted)

* 1 : Refer to "Modes", section 2.4 in part I.

* 2: Refer to "Machine Lock", section 3.1 in part 11.

2 - 1 2 Overview

( G ) Auxil iary display area

Where the operation being currently performed (such as, adding,

deleting, o r shift operation), information indicating path setting, and a n

error message due to misoperation a r e displayed.

(H) Main display area

Where the following information a r e displayed, depending on the function o r

feature in use:

* The contents of the file being taught o r edited

* Operating instructions t o the operator

* Operation results

(I) Function Keys display area

Where function keys a r e displayed. When more than 6 functions a r e available,

by pressing

" is displayed a t the right end. The rest of the functions a r e displayed

key.

(J) Synchromotion Status Display Area

Where synchromotion s ta tus is displayed "CRDN" is displayed if the

current status is Synchromotion.

Overview 2 - 1 3

(K) Message display area

Where general1 y various

da ta a r e displayed. *

When a n error , Alarm, or

Information occurs, its code,

message and recovery

action a r e highlighted. *

When the e r ro r is cleared,

the original display appears. *

0 0 1 P 6 0 % > 0 0 2 L l O O c m BASE M1

T.MECH ML4 TEACH P l l l SQNa = 2 SERVO ON

0 0 1 P 6 0% BASE MI > 0 0 2 L l O O c m BASE M1

fL SPEED : l O Om LAP :ON I

2 - 1 4 Overview

[ r n ! / I / O J J B R A N C H / J W \ p K E ' ] >

T.MECH ML4 TEACH P l l l SQNa = 2 SERVO ON

-

0 0 1 P 6096 BASE M1 > 0 0 2 L 1 0 0 ~ BASE M1

--.-=-

[iii55K1W/O/IBRANCHIW]I.DJIWEAVEJ >

2.3. 5 Entering Numeric Values

The sign "No. KEY" illuminates when numeric values can be entered.

RAT I ON R BRANCH B

Keep the following points in mind when entering numeric values:

Numerals as pa r t of a name 1 The numeral "0" must not be omitted:

- Program No., etc. 1 (Example) PO01 and ASCOl

- Sequence number

Integers

Time of the timer,etc.

Any integer can be entered as it is:

- Speed, etc

Real numbers

/ the decimal point:

(Example) 60cm + "6" and "0"

To enter real numbers, use numeric keys and

1 (Example) 0.5 sec 4 "0". .", and "5"

/ If the fraction is 0, you can omit the decimal

1 point and "0":

(Example) 10.0 4 "1" and "0"

Overview 2 - 1 5

2. 4 Modes Two modes, TEACH and AUTO modes, are available. The current mode is displayed a t

the Mode display area*' on the teaching box.

2.4.1 TEACH Mode In TEACH mode mainly teaching/editing of Task programs are performed.

Most of the functions and features except those used for automatic operation a re

available in this mode. As described in section 2.3.3, these functions are hierarchically

organized and assigned to the function keys.

For details of the organization, see the list of hierarchically organized function keys

provided a t the end of this manual.

2.4.2 AUTO Mode In AUTO mode automatic operation is performed to execute Task programs

created in Teach mode.

2.4.3 Initial Mode The default mode setting is TEACH, which is the initial mode when the control power

supply is turned on. You can change this setting to AUTO by changing the "INITIAL

MODE" setting*' in the user parameters for setting the system status.

2.4.4 Mode Change In order to execute Task programs by automatic operation, it is necessary to switch

from TEACH to AUTO modes. This switching operation is referred to a s a mode

change.

You can make a mode change only in the following conditions:

(1) Change from TEACH to AUTO modes

OSACOM SUPER 8700 is in the top layer of TEACH mode.

(2) Change from AUTO to TEACH mode

* The robot is ready to perform Automatic operation, or

The robot is in the stopped state of automatic operation, or

The robot has completed the Job.

If you change to TEACH before automatic operation is started, OSACOM SUPER 8700

enters the top layer of TEACH mode. If you change to TEACH in the stopped state, the

robot remains in the stopped state and the current Task program number, sequence

number, and instruction are held.

-

* 1: Refer to "Display Screen", section 2.3.4 in part I.

*2: Refer to "Setting the System Status", section 2.1 in part 2.

2 - 1 6 Overview

II Changing f rom TEACH to AUTO modes

1. Press F5 (LOCK) at the top

layer of TEACH mode. *

2. Press the AUTO MODE button

on the operating panel. * (Or set the AUTO MODE input

terminal ON.)

Now a mode change from

TEACH to AUTO has been

completed.

lIIl Changing f rom AUTO to TEACH modes 1. In the stopped state of

automatic operation, the screen

looks like the one shown on the

right: *

TEACH 2. Press . I

(Or press the TEACH MODE

button on the operating panel,

o r set the TEACH mode input

terminal ON.)

Now a Inode change from AUTO to

TEACH has been completed.

Overview 2 - 1 7

AXIS MH3 AUTO PO01 SQNa =999 SERVO ON HOLDING STN. 1

0 5 1 P 10 0 % BASE M 2 0 5 2 P 90% BASE M1

> 0 5 3 L 2501x1 BASE MI S 0 1 2 DL=O.OS

054 L 150m BASE M1 055 C1 1501x1 BASE MI

pi"Eq WSHI pT-7-q pi%-=] >

2.4. 5 ModeChangelnterlock

The mode change operation varies according to the ON/OFF settings of the Mode

Change Interlock function (Auto mode interlock o r Teach mode interlock).

Though you can make a mode change by simply pressing a button o r key, provided

the condition is met, you can select the Mode Change Interlock function to prevent a

careless mode change.

Table 2.1. Operating a Mode Change

Auto mode interlock I OFF I ON ( Default)

Teach mode

J,

Auto mode

(1) Press the AUTO

MODE button on the

operating panel, o r

(2) Set the Auto mode

input terminal ON

After you press F5

(LOCK) a t the top layer

of Teach mode o r set the

Auto mode interlock input

terminal ON,

(1) Press the AUTO

MODE button on the

operating panel, o r

(2) Set the AUTO Mode

input terminal ON.

Teach mode interlock OFF ( Default)

(1) Press on the w teaching box,

ON

teaching box while

I Or / holding down the

1 (2) Press the TEACH I TEACH MODE button

Auto mode 1 MODE button on the / on the operating panel,

;1

Teach mode

I operating panel, I Or

/ (2) Press on the

/ (3) Set the Teach mode / teachingbox while

input terminal ON. setting the Teach

mode input terminal

ON.

The Mode Change Interlock function can be set on/off in the user parameters for

setting the system status, "AUTO LOCK" and "TEACH LOCK"*.

* : Refer to "Setting the System Status", section 2.1 in par t 11.

2 - 1 8 Overview

Chapter 3 Basic Features and Func t ions f o r Opera t ing OSACOM SUPER 8700

This chapter describes a series of basic operations necessary for

turning on OSACOM SUPER 8700. teaching. automatic operation.

and turning it off . This chapter is intended to allow the user to understand how to

teach and how to s tar t automatic operation .

For detailed information of teaching and automatic operation.

refer to chapter 5 and chapter 6 respectively .

Contents

3 1 Turning On OSACOM SUPER 8700 ................................................................................................

3 2 Turning On the Servo Power .................................................................................................................

3.3 Operations for Manual Manipulation

3.3.1 Manual Manipulation ........................................................................................................................

3 3 2 Changing Manual Speeds ................................................................................................................. . .

3.3.3 Switching between the Axis and Cartesian Movements .......

3.4 Teaching (Creating Task Programs)

3.4.1 Preparation for Teaching

3.4.2 ~~~i~ hi^^ .......................................................................................................................................

3.4 3 Keys Used for Teaching

3.5 Block Operation ............................................................................................................................................

3.6 Modifying Task Programs

3.7 Adding and Deleting Instructions ....................................................................................................

3 7 1 Adding Instructions ............................................................................................................................. . . 3.7.2 Deleting Instructions

3.8 Start Allocation

3.9 Automatic Operation ..................................................................................................................................

3 . 10 Shutting Off the Servo power (Emergency Stop)

3 11 Turning Off the Control power

3. Basic Features and Funct ions f o r Opera t ing OSACOM SUPER 8700

3. 1 Turning On OSACOM SUPER 8700 OSACOM SUPER 8700 is turned on by holding the handle mounted on the front face a t

the "ON" position.

Then, the start-up screen appears on the display.

1. The start-up screen appears on

the display of the teaching box. II)

2. OSACOM SUPER 8700 s tar ts

initial diagnosis. .I)

3. When this operation is completed,

you can perform various operations

by using the teaching box. .I)

Basic Features and Functions fo r Operating OSACOM SUPER 8700 3 - 1

DIAGNOSIS

' 9 3-0 7-1 5 1 1 : 3 2

THANK YOU FOR WAKING ME UP! THIS I S OSACOM 8 7 0 0 CONTROLLER

START DIAGNOSIS 1, 2, 3, 4

3. 2 Tuning On the Servo Power Turn on the servo power to move the manipulator. Each of the operating panel and

teaching box is equipped with a servo power "ON" button. Before turning on the servo

power, ensure that all personnel a re clear off the manipulator working area.

. . I . I:,

Fig.3.1. Operating Panel

3

Fig.3.2. Teaching Box

The servo power is turned on by pressing the servo power ON button (SERVO ON

button). This causes the lamp of the servo power ON button on the operation panel to

light. The display a t the servo power status display area on the teaching box changes

from "SERVO OFF" to "SERVO ON".

3 - 2 Basic Features and Functions for Operating OSACOM SUPER 8700

3. 3 Operations for Manual Manipulation

3.3. 1 Manual Manipulation

Manual manipulation is performed to move the manipulator by using the teaching

box.

1. Press the Axis key while

The manipulator moves in the

direction specified by the AXIS

key you are pressing.

TEACH

ENABLE

2. It stops when the key is released.

MECHAN l SM

3.3.2 Changing Manual Speeds

You can select a speed for manual manipulation from among a total of 9 steps

including 4 low modes (ML1 - ML4) and 4 high modes (MH1 -MH4).

MLO ML1 ML2 ML3 ML4 MH1 MH2 MH3 MH4

Low High

To change a manual speed, use

The current manual speed is

displayed on the teaching box. @

To increase the speed, press

key.

To decrease the speed, press

key. iai

Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 3

3 . 3 . 3 Switching between the Axis and Cartesian Movements

In manual manipulation, two types of movements, Axis and Cartesian movements,

a r e available; the former provides independent movements of each axis(joint) of the

manipulator, and the latter provides movements defined by a specified coordinate

system.

To switch between the Axis and CM)RD-

Cartesian movements, use (INATE,I key

Each time you press this key, you

can switch between AXIS/

CARTESIAN.

The current movement type is

displayed on the teaching box.


3. 4 Teaching (Creating Task Programs)

Teaching is performed to teach (store) the sequence necessary for a job such a s

welding work to the manipulator.

Details of a job which the manipulator should do are stored in a Task program.

To perform teaching, follow the steps below:

I Enter a Task program number. 1

I Enter a number you give to a Task program you want to create.

on/Task instructions.

Teach the manipulator Motion instructions to store positions and

attitudes and Job instructions to store data of a job such a s welding, etc.

The following are most often used instructions:

(Motion Instructions)

* P (Positioning) Instruction to store a position and attitude to the

manipulator

* L (Liner Interpolation) ... Instruction to store a position and attitude

1 to the manipulator and move it on the

linear path

C (Circular Interpolation) ... Instruction to store a position and

attitude to the manipulator and move it

on the circular path

(Task Instructions)

AS (Starts welding) ... Instruction to s tar t welding

* AE (Terminates welding) .-. Instruction to terminate welding

Block Operation (to check the path)

When teaching is completed, check the path of the manipulator by

performing block operation.


3.4. 1 Preparation for Teaching

Before carrying out teaching, enter a Task program number.

1. After initial diagnosis is

completed, turn on the servo

power. *

2. Press F1 (TEACH).

3. Enter a Task program number.

F o r example, enter "0","0","1"

by using numeric keys. *

Now you can s t a r t teaching Task

program P001.

AXIS ML4 TEACH

SERVO ON

[ m I m j m I I m / L O C l >


3.4.2 BasicTeaching

This section describes a basic teaching by using a simple teaching example.

STEP @ STEP 8

/ f e -. . -

/ . --.

/ . . /

. . / .. .

STEP @ / /

STEP a

Fig.3.3. Teaching Example

1. Enter the Task program number.

+

2. Perform manual manipulation to

step @. Teach Positioning

instruction "P".

(1) Press

(2) Set Speed by using numeric

keys.

(3) You can set Overlap ON/OFF

by pressing 10 1 key.

Basic Features and Funct ions f o r Operat ing OSACOM SUPER 8700 3 - 7

(4) Press @.

3. Teach step @ and as same

way as step @.

4. Teach Arc Start instruction "AS"

at Step 0.

AXIS ML4 TEACH I I

(1) Press .

P O 0 1 SQ Na= 1 SERVO ON

(2) Set welding conditions

> 0 0 1 P 1 0 0 % BASE MI

I P SPEED=l 0 D96 LAP :ON I

(current, voltage, and speed) by

using numeric keys and

(3) Press @.

5. Perform manual manipulation

up t o step @.

Teach linear Interpolation

instruction "L".

(1) Press .

(2) Set Speed by using numeric

keys.

The speed set here is a speed

of the manipulator in block

operation.

In automatic operation, the

manipulator moves a t the

welding speed set with "AS".

AXIS ML4 TEACH P O 0 1 SQ No.= 3 SERVO ON


0 0 1 P 1 0 0 % BASE MI 0 0 2 P 1 0 0 % BASE MI

> 0 0 3 P 5 0 % BASE MI

AS f3OA 20,OV. 6Dm I

T. MECH. ML4 TEACH PO 0 1 SQNo.= 3 SERVO ON

/ ]NUU/ j r n l r n I

0 0 1 P 1 0 0 % BASE M1 0 0 2 P 1 0 0 % BASE MI 0 0 3 P 5 0 % BASE M1 > AS 2 0 0 A 22.OV 8 Om

/LSPEED:LO#m .LAP:ON ' 1 r i - G z i - ~ ~ ~ ] ~ ~ ~ \ >

(3) You can set Overlap ON/OFF

by pressing 10) key.

(4) Press @ .


up t o step @. This position is the

middle point of a circle.

Teach Circular Interpolation

instruction "C" .

(1) Press .

(2) Set Speed and Overlap ON/

OFF as set for "L".

(31 Press @ .


up to step @. This position is the

end point of a circle.

Teach Circular Interpolation

instruction "C".

As we taught "C" a t step @,

press w. 8. Teach Arc End instruction "AE"

a t step 0.

(1) Press .

T.MECH.ML4 T E A C H PO 0 l S Q No.= 4 S E R V O O N


0 0 1 P 1 0 0 9 6 B A S E M 1 0 0 2 P 1 0 0 9 6 B A S E M1 0 0 3 P 1 0 0 % B A S E M I

A S 2OOA 22.OV 8Ocm > 0 0 4 * L 60cm B A S E M 1

1~ 2 S P E E D ' : 6 Orar" \ LAY : ON ]

T.MECH. ML4 T E A C H PO 0 1 SQNo,= 6 S E R V O O N

/ l ~ ~ l / ~ ~ /

A S 2 0 0 A 22.OV 8Ocm 0 0 4 * L 6 0 m B A S E M 1 0 0 5 * C 1 6 0 m B A S E M1 0 0 6 * C 2 6 O m B A S E M 1 > A E 1 5 0 c m 2 0 . 0 , 0 . 5 S . O . O S

LAY? 1 8 0 k ZO.~'V, , b . ' & s , ' 0 , 0 9 1

IASNUM.IIAENUMI(1-J

(2) Set welding conditions

(current, voltage, crater time,

and afterflow time) by using

numeric keys and

(3) Press @ .

9. Perform manual

manipulation up to step a. Press a , and set Speed and

Overlap ON/OFF as set for step

10. Perform manual

manipulation up to step @. In

this case, move the manipulator

until the LED of READY onthe

teaching box lights.

Press @

11. Teaching has been completed.

Press @ .

END will be automatically stored

to terminated teaching.

T.MECB. M L 4 TEACH PO01 SQ No.= 7 SERVO ON

004*L 60m BASE M1 005*C1 60m BASE MI 006*C2 60em BASE MI

AE 15Ona 20.0, 0.5s. 0.0s >007 P 7596 BASE MI

(P SPEED:X#0% \tAP:UN

T.MECH. M L 4 TEACH PO01 SQ No.= 8 SERVO ON

3 - 1 0 Basic Features and Functions for Operating OSACOM SUPER 8700

r i " z z x \ ~ ~ ~ l ~

005 *C1 60m BASE M1 006 *C2 60m BASE M1

AE 150m 20.OV 0.5s. 0.0 s. 0 07 P 75% BASE MI

>0 08 P 10096 BASE MI

IP $PEED:'X@O% %,*' LAP:ON 1

T.MPCH. M L 4 TEACH PO01 SQ Na= 9 SERVO ON

/ 7 ~ ~ / ~ ~ \

> 001 P 100% BASE M1 002 P 100% BASE MI 003 P 50% BASE M1

-I[ Jmlmm]>

3.4.3 Keys Used f o r Teaching

(1) @ key

Stores instructions, parameters, etc.

If the same instruction needs to be continuously taught, pressing RECORD key allows 0 you to re-teach the instruction you have just taught. Note that this teaching is

operational only when the last recorded instruction remains on the 7th line. If you

want to modify only parameters (speed, overlap ON/OFF, etc.), press

before you press RECORD . 0

The instruction you have just taught

AXIS ML4 TEACH P O 0 1 SQ No.= 2 SERVO ON

(2) @ key

Corrects entry errors.

0 0 1 P 1 0 0 % BASE M 1 > 0 0 2 P 1 0 0 % BASE M1

~ P E E D ~ I O O ! % .ta~;a~~":~,, 7

* If you press it immediately after you select a n instruction, you can cancel you

m / I I / OnBRANCil,,,,,,l,,,,,l >

selection.

* If you press it when entering a numeric value (e.g., because you have made an

entry error), you can re-enter

If you press it immediately after you press RECORD , the instruction you have just 0 stored is cancelled.

(3) @ key

Automatically enters END instruction, when pressed during a creation of a Task

program, a t the sequence following by the last sequence to terminate teaching.

(You do not need to teach END instruction.)

Then, you can perform block operation.

Basic Features and Functions for Operating OSACOM SUPER 8700 3 - 1 1

3. 5 Block Operation Block operation is performed to check the positions, attitudes, and paths in a Task

program created. This section explains how to perform block operation, using an

example Task program PO01 created in section 3.4.2:

1. When you have finished creating

Task program PO01 (by pressing

@ key), OSACOM SUPER 8700

is ready for block operation. * 2. Press while holding down

Q . w

Then, the manipulator starts to

move to the position of sequence 001.

Continue block operation by

pressing BLOCK

or 1 , I accordingly.

To halt the manipulator, release n @ .

Then. the LED of will light.

To execute instructions continuously, n-

push . n-

Then, the LED of 'g," will light. U The block continuous state is

cancelled when block operation is

halted. /?

To chande block operation speed,

push .

The display a t the Speed display

area will change to the Block

Operating Speed.

Select the speed by pressing


3. 6 Modifying Task Programs This section describes how to modify Task programs by using an example Task

program PO01 created in section 3.4.2.

(Example 11 Modifying positions and attitudes

Let us modify the position/attitude

of step 2 (Sequence 002):

1. Perform block operation up to

sequence 002. rrr)

2. Perform manual manipulation to

move the manipulator to the

position/attitude you want to store.

I'

STEP 2 \

=o

T.MECII. ML 4 TEACH P O 0 1 SQ Na= 9 SERVO ON

'b f )

STEP 3

0 0 1 P 1 0 0 % BASE M 1 > 0 0 2 P 1 0 0 % BASE M 1

0 0 3 P 5 0 % BASE M I AS 2 0 0 4 22.OV. 8 0 m

0 0 4 * L 6 0 w BASE M 1

3. Press @ ,

~ ~ I J ~ ~ I P A T H / ~ ]

Now, the position/attitude of step 2

have been modified. STEP I

/

4' \ \

P \ \

STEP 2

\\\ J P STEP 3


(Example 21 Modifying "P" to "L"

Let us modify the instruction of step


sequence 003, and then press H

I T.MECI1. ML4 1 0 0 1 P 10096 BASE MI I

2. Press @ . Now, the Motion instruction of

step 3cSequence 003) has been

modified to "L".

(Example 3) Modifying welding conditions

Let us modify the welding

conditions of step 4:

1. Move the cursor to "AS" by

performing block operation, and

press . * 2. Set a current/voltage/welding

speed ( to modify).

3. Press @ .

Now, the welding conditions have

been modified.

Similarly, you can modify the

parameters (moving speed/

overlap ON/OFF) of Motion

instructions.

T.MECI-I.ML4 TEACH P O o 1 SQ Na= 9 SERVO ON

3 - 1 4 Basic Features and Functions fo r Operating OSACOM SUPER 8700

002 P 100% BASE M1 003 P 10096 BASE M1 >r AS p 2 0 04*L 6Om BASE M1 005*C1 6Om BASE M1 006*C2 60m BASE M1 m2 0- 0

T.MECH. ML4 TEACH PO01 SQ No.= 9 SERVO ON

j s E l ~ ~ ~ ~ l >

002 P 10 0% BASE M1 003 P 5096 BASE M1

> AS 18OA. 20. OV. 8Ocm 004*L 6 Om BASE M1 005*C1 60ca BASE M1 006*C2 60cm BASE MI

( sEARC/~JUMPj( /m- >

3. 7 Adding and Deleting Instructions 3. 7. 1 Adding Instructions

This section describes how to insert Positioning "P" between steps 002 and 003 in a n

example Task program PO01 created in section 3.4.2.

1. Perform block operation to the instruction (Sequence 002) which should be followed by an instruction you are adding.

2. Press rrr)

Then, the LED on the upper left

3. Move the manipulator to the position/attitude you want to add,

by performing manual manipulation.

4. Press the key of the instruction you want to add ( in this example). Set a speed and overlap ON/OFF

a s set to create a new program.

5. press @ . * Now, a new instruction "P" has been added. Repeating the operations 3 - 5 allows you to add instructions a s many as you want.

If you press immediately

after you press

cancel the instruction you have

just added.

6. To terminate the adding operation, press O@. + Then, the LED on the upper right

will light.

AXIS ML4 TEACH PO 0 1 SQ No.= 9 SERVO ON

0 0 1 P 1 0 0 % BASE M 1 > 0 0 2 P 1 0 0 % BASE M 1

0 0 3 P 5 0 % BASE M 1 AS 2 0 0 h 22.OV. 80cm

0 0 4 + L 6 0 w BASE M 1

AXIS ML4 TEACH PO 0 1 SQ No.= 9 SERVO O N

pxKcqIJUMP/ISHIFT//PATH//l>

0 0 1 P 1 0 0 % BASE M I > 0 0 2 P 1 0 0 % BASE M 1

AXIS ML4 TEACH P O 0 1 SQ No.= 10 SERVO O N


j M o T I O N / j I / O / m I W E L D / / W E A V E / >

0 0 1 P 1 0 0 9 6 BASE M I 0 0 2 P 1 0 0 % BASE M 1

> 0 0 3 P 2 0 9 6 BASE M 1

I P S P E E D = Z O % L A P :ON I

AXIS ML4 TEACH P O 0 1 SQ No,= 10 SERVO ON

jMoTIONIJ//OIIBRANCHI/WELD/rnj >

0 0 1 P 1 0 0 % BASE M 1 0 0 2 P 1 0 0 % BASE M 1

> 0 0 3 P 2 0 % BASE M 1 0 0 4 P 5 0 % BASE M 1

AS 2 0 0 h 22.OV. 8 0 m 0 0 5 * L 6 0 m BASE M I

/ S E A R l m I S H I F T / m / m l >

3. 7 .2 Deleting Instructions

This section describes how to delete step 3 in an example Task program PO01 created

in section 3.4.2.

I . Perform block operation to the

instruction (Sequence 002) which

should be followed by an

instruction you are deleting.

2. press 66;;r) . + w

Then, the area to be deleted will

be highlighted.

* To extend the area, press

To reduce the extended area,

* To cancel your deletion, press

3. Press F1 (EXECUTE). * Now, the highlighted area has

been deleted.

If you press wFY immediately 0 after you delete, your deletion will

be cancelled.

AXIS ML4 TEACH PO01 SQ No.= 9 SERVO ON

001 P 100% BASE M1 >002P 100% BASE MI 003 P 50% BASE M1

AS 200k 22.OV. 80cm 0 04XL 60cm BASE MI

AXIS ML4 TEACH PO 0 1 SQNo.= 9 SERVO ON RANGE FOR DEL.


/ p 7 x q ~ ~ ~ l >

001 P 100% BASE M1 >002 P 100% BASE MI I003 P 509' BASE A -cm 004XL 6Om BASE M1

AXIS ML4 TEACH PO01 SQ No.= 9 SERVO ON

pEiEq

001 P 100% BASE M1 >002 P 100% BASE M1

AS 200k 22.OV. 8Ocm 003*L 6 Om BASE M1 004*C 60m BASE M1

p T E z - i q / ~ j ~ ~ ~ ~ ~ >

3. 8 Start Allocation Before automatic operation is performed, it is necessary to allocate the created Task

programs to the Start button of each station.

This section explains how to do s tar t allocation:

1. Place OSACOM SUPER 8700 in

the top layer of TEACH mode. *

2. Press F4 (ALLOT).

Then, a list of Task programs

allocated to each station will be

displayed.

3. For example, let us allocate

PI23 to station 01.

Enter "1 ", "2", and "3" by

using numeric keys. *

4. Press @. Now, Task program PI23 has

been allocated to station 01.


3. 9 Automatic Operation When you have finished s tar t allocation to each station, you can now star t automatic

operation.


layer of Teach mode. *

2. Press the AUTO MODE button

on the operating panel. Now, the

mode has been switched to

AUTO. * To execute Task program PO01

allocated t o station 1, press the

START button on the operating

panel. +

To halt the manipulator, press the

STOP button on the operating panel

o r on the teaching box. +

To restart the manipulator, press

the START button on the operating

panel.

When the execution of the Task

program terminates (when the

robot completes the Job), the

display on the right appears. *


3.10 Shutting Of f the Servo Power (Emergency Stop)

When the EMERGENCY STOP button is pressed, the servo power is shut off, causing

the manipulator to immediately stop the motion.

Two EMERGENCY STOP buttons are provided; one is on the operating panel, and the

other is on the teaching box. (If you install a starting box or boxes, each starting box

is also equipped with an EMERGENCY STOP button.)

Cancellina the EMERGENCY STOP button

on the operating panel. 0 0

f ~ - & 7

I OK+ Turn to the button to the arrow.

Cancelling the EMERGENCY STOP button

-\1\ 1 on the teaching box

A Warning

To safeguard the operators, ensure that the EMERGENCY STOP button is always ready to be pressed.

Basic Features and Functions fo r Operating OSACOM SUPER 8700 3 - 1 9

3.1 I Turning Off the Control Power To turn off the control power, follow the steps below:

Now, the control power has been turned off.

Press the EMERGENCY STOP button on the operating panel o r teaching box to turn of f the servo power.

Turn the control power handle to the left, and hold it a t the OFF position.


Chapter 4 Manua l Man ipu la t ion

This chapter describes manual manipulation. Manual manipulation is performed to change positions and attitudes of the manipulator by operating the teaching box. This chapter gives detailed explanations of how to switch moving directions and speeds for manual manipulation, in addition to how to change positions and attitudes.

Contents

4 1 Operations for Manual Manipulation 4 - 1

4.1.1 Changing Positions and Attitudes (Manual Manipulation) ........................................ 4 - 1

4 1 2 Changing Manual Speed ...................................................................................................................... 4- 2 . . 4. 1 .3 Switching between Coordinate Systems 4- 2

4.1.4 Switching Mechanisms

(Not applicable to the Single Manipulator System) 4- 5

4 . 1 . 5 Inching and Retracting the Wire 4- 5

4.1.6 'pesetting ~ ~ t ~ ~ ~ ~ l control output signals ........................................................................ 4- 6

4.2 ~~~i~~ ~ i ~ ~ ~ t i ~ ~ ~ 4 - 7

4 2 1 Axis Movement ........................................................................................................................................... 4- 7 . . 4 2.2 Cartesian Movement 4 - 9

4 3 Cartesian Movement Near the Singular point ........................................................................... 4- 19

4. Manua l Man ipu la t ion 4. 1 Operations for Manual Manipulation

Manual manipulation is performed to change positions and attitudes of the

manipulator, slider and positioner by operating the teaching box. Also, operations

for changing coordinate systems and speeds are involved to perform manual

nlanipulation.

Changing positions and attitudes (Manual Manipulation)

* Changing the manual speed

* Switching between coordinate systems

* Switching between mechanisms

Inching and retracting the wire

- Resetting External Control Output Signals

4. 1. 1 Changing Positions and Attitudes (Manual Manipulation)

To perform manual manipulation, in addition to the servo power ON state, the

following conditions must exist:

AUTO mode

The robot is in the halted state or outside the Start Enabe area before automatic

operation is started or after the Job is completed.

TEACH mode

Block operation or absolute offset setting is not being performed.

II Manual Operation

1. Press the Axis key while holding

down 8 . 2. The manipulator moves in the direction

corresponding to the key being pressed.

3. When you release @ key, all axes

stop. w

For moving directions, refer to

"Moving Directions", section 4.2. in part 1.

TEACH ENABLE (I:

MECHAN l SM

Manual Manipulation 4 - 1

4.1.2 Changing the Manual Speed

A speed for manual manipulation can be selected from among 8 steps of 4 low speed

modes and 4 high speed modes, and inching speed (available only for Cartesian

movement). The speed is displayed a t the speed display area on the teaching box.

(Inching) < > Low Low speed mode High speed mode High

The maximum speed in the low speed mode (ML4) is 15m/min.

H Switching between speeds fo r manual manipulation

* TO increase:

Press 1 8 1 . If the speed is ML4, pressing

changes to MH1.

To decrease:

Press [vl. If the speed is MH1, pressing

changes to ML4.

Speed display area

l4

A X I S M L 4

T E A C H

S E R V O ON

4. 1.3 Switching between Coordinate Systems

In principle, two kinds of movements, Axis and Cartesian movements, a re available.

In the Cartesian movement, even if you press the same "AXIS" key, the direction varies

according to the coordinate system you select.

The following coordinate systems are available:

r Axis movement

Cartesian movement Base coordinate system*'

Tool coordinate system*'

Work coordinate s y ~ t e m * ~

World coordinate ~ y s t e m * ~

* 1: Refer to "Moving Directions", section 4.2 in part I.

* 2: Refer to Instruction Manual "Options"

4 - 2 Manual Manipulation

Coordinate systems that can be selected depend on the system configuration using a

single manipulator or multiple mechanisms:

Table 4.1 Coordinates Systems Available According to the System Configulations

Cartesian 1 ~ o o l 1 Q 1 Q I Q

Axis Movement I I I

0 : Available

0 : Can be set, but gives the same results a s the Base coordinate.

A : Can be set, in the case that Simultaneous control and Synchromotion a re mixed in

Single Manipulator System

@ 63 / Base 1 0

Movement

a system.

@

Note - 1) For Slider or Positioner, only the Axis Movement is available. 2) In a Single Manipulator system using an overhead or wall mounting type, the

World coordinate system is also available.

Multiple-Mechanism System

Work

World

- -

There are two ways of changing the coordinate system from Axis Movement to

each Cartesian Movements.

Simultaneous control

@

* The way of changing to registered Cartesian coordinate systems

Synchromotion

0

0

0

* The way of selecting out of 4 Cartesian coordinate systems - (By pressing key)

0

A


63 0

(1) The way of changing - to registed cartesian coordinate systems

Each time you press ,,,,,, key, you can switch in order of Axis -+ m Cartesian coordinate 1 -+ Cartesian coordinate 2 + Axis -...

You can register Cartesian coordinate 1 and 2 in the user parameter for setting the

system status "ENTRY OF COORDINATES".

As the default settings for Cartesian coordinates 1 and 2 are Base coordinate

system and OFF, respectively, the coordinates system is switched in the order of

Axis + Base coordinate system -+ Axis.

(2) The way of selecting out of 4 Cartesian coordinate systems FUNC- By pressing a key, you select a Cartesian coordinate system you want one of 4

Cartesian coordinate systems(Base, Tool, Work, and World coordinate system).

63 Change coordinate systems you often use by above (1) way, and coordinate

system you do not register by above (2) way.

H Switching coordinate systems by key. - Each time you press

switch coordinate systems.

The current coordinate system is

displayed a t the coordinate system

display area on the teaching box.

FUNC- Switching coordinate systems by key.

FUNC- 1. Press in the state of being

able to perform manual operation.


2. Press Fl(C0RDNAT). * F1 ... Base coordinate system F2 ... Tool coordinate system F3 ..- World coordinate system F4 Work coordinate system

3. Select the coordinate system by

using function key.

Now, you can switch coordinate

systems

4.1.4 Switching Mechanisms (Not applicable to the Single Manipulator System)

In the multiple-mechanism system which consist of manipulator and external axes

such a s slider o r positioner, mechanism should be selected by key during manual

operation.

For detail of switching mechanizms, refer to the Instruction Manual " Options",

depend on the control system(Simultaneously or Synchronous control) in use.

4. 1.5 Inching and Retracting the Wire

on the teaching box allows you to inch/retract the wire.

The operation to pull the wire out from the tip is referred to inching, and the operation

to pull it back is referred to a s retracting.

You can specify wire feed rates for inching and retract by setting

"INCH/RETRACT(HIGH) " and "INCH/RETRACT(LOW) " in the welding user

parameters. *

@ Notes 1) If the setting of "APPLICATION" in the user parameters for setting the

system status is "HANDLING", it is not possible to inch/retract the wire. 2) It is not possible to inch/retract the wire during automatic operation.

Perform these operations in Teach mode, or before automatic operation is started, or after the job is completed.

L

* : Refer to "Setting the Welding Parameters" section 2.3 in part I[.


Inching and retracting

(Inching)

Press IF/. * For h i z e e d inching, press [ q w h i l e holding down a

Press IwI . IUI

* For high speed retracting, press while holding down

4.1.6 Resetting External Control Output Signals

You can set a group of External control output ports 0000 - 0099 to OFF

Any output ports 0100 - 0199 will not be changed.

Resetting external control output signals FUNC- . 1. Press In the state of being

able to perform manual operation.

2. Press F4(1/0 RST). * 3. Press Fl(C0NFIRM).

External control output port 0000

- 0099 will be OFF.

Any output ports 0100 - 0199 will not be changed.


4. 2 Moving Directions This section describes how ALMEGA G series (GO1 and G03),WOl and V series (V01,

V10, V20, and V40) move when Axis and Cartesian manual manipulation is performed.

4.2. 1 Axis Movements

The axis corresponding to each Axis key moves independently.

Axis No. I Movement I Teaching Box Key

Upward and downward

Rotation 2 (left/right)

\' \

Rotation 1 (Axis

xis 2)

Torch angle (Axis 5)

Fig.4.1. Moving directions of ALMEGA G series and W01


Axis No

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5

Axis 6

Movement

Rotation (left/right)

Lower a rm (forward/backward)

Upper a rm (upward and downward)

Wrist (swivel)

Wrist (bend)

Wrist (twist)

Bend

Teaching Box Key

Fig.4.2. Moving directions of ALMEGA V series

3)

xis 2)


4.2.2 Cartesian Movement

This section describes the moving directions given in each of the Base and Tool

coordinate systems.

Cartesian movements a re divided into Base axis movements which define the position

of the torch tip and Wrist axis movements which define the torch attitude.

Furthermore, ALMEGA V series has two types of Wrist axis movements; Cartesian

movements by the Eulerian angle system and the R.P.Y. (Roll, Pitch, and Yaw) system.

You can specify either of them by setting "POSTURE MOTION" in the user

parameters for setting the system status.

In the Simultaneously Controlled system, if the manipulator is selected a s the moving

mechanism, the moving directions are the same a s those in the Single Manipulator

system.

For moving directions on the Work and World coordinate systems selected in the

Synchronous Motion Control system, refer to Instruction Manual "Options".


(1) Base coordinate system

I A L M E G A G series (GO1 and G03) and WOll

(a) Base axis movements

Fig.4.3. Moving directions of Base axes in the Base coordinate system

(ALMEGA G series and W01)

4 - 1 0 Manual Manipulation

(b) Wrist axis movements

- Axis 4

The torch rotates around the perpendicular, with the torch tip being fixed.

I Perpendicular

Fig.4.4. Moving directions of Axis 4 in the Base coordinate system

(ALMEGA G series and W01) * Axis 5

The torch rotates on the plane of rotation of Axis 5, with the torch tip being

fixed

Fig.4.5. Moving directions of Axis 5 in the Base coordinate system


Manual Manipulation 4 - 1 1


Fig.4.6. Moving directions of Base axes in the Base coordinate system

(ALMEGA V series)


(b) Wrist axis movements (the Eulerian angle system)

Axis 4

The center line of rotation of Axis 6

rotates around the Z axis, with the

torch tip being fixed.

Direction of Z axis

Fig.4.7. Moving directions of Axis 4

Axis 5

The torch rotates around the torch tip

on the plane formed by the torch line

and the Z axis, with the torch tip

being fixed. \ Torch line

Direction of Z axis "\ Fig.4.8. Moving directions of Axis 5

Axis 6

The torch rotates around the torch line

a t a constant torch attitude, with the '.

torch tip being fixed. \ \ Torch line


Center line of rotation of Axis 6 Direction of Z axis

, I Torch tip

w , - - Horizontal plane Axis / \ ' Torch line

Line of Axis 6 Moving direction of Wrist axes in the Base coordinate

(ALMEGA V series)

system


(c) Wrist axis movements (the Roll/Pitch/Yaw system)

* Axis 4

Axis 4 rotates around the Z axis, with the tool center being fixed.


Axis 5

Axis 5 rotates around the Y axis, with the tool center being fixed.


Axis 6

Axis 6 rotates around the X axis, with the tool center being fixed.



(2) Tool coordinate system

~ALMEGA G series (GO1 and G03) and WO1I


The direction in which the wire is retracted from the torch is defined a s the Z

axis, the angular reference position of Axis 4 (O0 ) is defined a s the Y axis, and

the axis perpendicular to the Z axis on the plane of rotation of Axis 5 is defined

as X axis. The X/Y/Z coordinate system is the right-hand coordinate system.

Since this coordinate system depends on the torch attitude, the direction of each

axis changes when the attitude changes. Z axis

system

Fig.4.15. Moving directions of Base axes in the Tool coordinate system



Fig.4.16. Moving directions of Base axes a t different attitudes


I ALMEGA V series]


I I I x axis

Fig.4.18. Moving directions of Base axes a t different attitudes


(b) Wrist axis movements

* Axis 4

The torch rotates around the Z axis (torch line), with the torch tip being fixed.


Axis 5

The torch rotates around the Y axis, with the torch tip being fixed.


* Axis 6

The same as Axis 4.



4. 3 Cartesian Movements Near the Singular Point If Cartesian manual manipulation or a linear or circular interpolation is performed

near the singular point, an expected axis o r axes may abruptly move. Therefore, for

manual manipulation near the singular point, use Axis movement. Also, be sure that any

linear and circular path do not pass near the singular point. In case a path does, the set

speed and the accuracy of the path a re not guaranteed.

he singular point of ALMEGA G series and ~ 0 1 )

* Position where Axes 2 and 3 are aligned

Fig.4.22 The singular point of ALMEGA G series and W01

/The singular point of ALMEGA V series/

ALMEGA V series has two attitudes called singular points.

The singular point of Axes 4 and 6 (See Fig.4.23.)

The attitude where the rotated axis of Axis 6 meets the extension line of the

rotated center axis of Axis 4.

Fig.4.23. The singular point of Axes 4 and 6


The singular point of Axes 1 and 6 (See Fig.4.24.)

The attitude where the rotated axis of Axis 6 meets the extension line of the

rotated center axis of Axis 1.

Fig.4.24. The singular point of Axes 1 and 6

If a linear o r circular interpolation is performed a t an attitude near the singular

point in Cartesian manual manipulation, or automatic or block operation, this causes

Axes 2 and 3 to rotate a t a high speed. Because such movements are very dangerous,

OSACOM SUPER 8700 is equipped with a device to control them.


When the manipulator moves to the shadowed area, all mechanisms stop their

movements and the following message is displayed on the teaching box:

I S. L I M I T 1 1 2 1 1 -+MANUAL O P E .

* When all mechanisms stop, it is not possible to perform Cartesian manual

manipulation in the direction approaching to the singular point.

When all mechanism stop, it is possible to perform both Cartesian and Axis

manual manipulations in directions away from the singular point.

This message is displayed also when both Axes 1 and 6 move beyond the soft

limit a t the same time. Therefore, when it appears, identify the cause from the

attitude of the manipulator; whether a ) o r b):

a ) The end of the upper a rm entered the area of the singular point.

b ) Both Axes 1 and 6 moved beyond the soft limit a t the same time.

Fig.4.25. The attitude near the singular point


Chapter 5 Teaching

This chapter describes features of Motion instructions and Task

1 instructions. how to teach them. and block operation to check the I / positions and attitudes in a Task program created . 1

Contents

5. Teaching The teaching features are available by pressing the F1 key a t the top layer of Teach

mode, which allow the operator to create, modify, and list Task programs.

5. 1 Creating and Listing Task Programs

5.1.1 Creating Task Programs

This feature is used to create new Task programs. The created Task programs are

stored a s Task program files.

Task programs a re created in accordance with the following procedure:

Enter a Task program number. m ich do you select, Task instruction

Motion or Task inst I

I Motion instruction I 1 I

Set a manual speed accordingly.

I / Set each type of movement and I 1 1 coordinate system accordingly. I

/ Move the manipulator by manual 1 I 1 manipulation. I I I I

/ Store the Motion instruction 1 1 Store the Task instruction. 1

you want to tdrminate t e a c h i n a No

Perform block operation (to check the positions and attitudes)

Fig.5.1 The procedure for creating a Task program

Teaching 5 - 1

(1) Entering a Task program number

I t is necessary to give a number given to a Task program to be created. If you enter

an existing number, you are not creating a program but will modify its program o r

perform block operation. Though Task program numbers ranging from 1 through 999

are available, do not use 990 - 999 which are used for adjustment.

(2) Selecting a Motion or Task instruction

Move the manipulator to the position you want, and select the instruction by pressing

the data selector key on the teaching box (e.g., P to move by Positioning).(See Table 5.1.)

Instructions are divided into two groups:

Motion instructions

These are instructions to move the manipulator (for positioning and interpolation).

Sequence numbers are given to Motion instructions in order by creation.

The maximum of 999 sequences can be stored in one Task program.

Task Instructions

These are Instructions to execute welding, weaving, output signals to external devices,

etc.

The maximum of 9980 instructions can be stored in one Task program.

For details of how to teach each of Motion and Task instructions, refer to "Teaching

Motion Instructions", section 5.2., and "Teaching Task Instructions", section 5.3.

Important It is not possible to teach more than 9 Task instructions a t one time.

Entering a Task program number

1. Press F1 (TEACH) key at the

top layer of Teach mode. *

5 - 2 Teaching

2. Enter the number by using

numeric keys. rr)

You can now create a Task

program.

Teaching 5 - 3

Table 5.1 List of Motion/Task Instructions

L $ I Linear interpolation

Parameter

P $

Speed and Overlap on/off

Description Key

Linear interpolation with speed and Overlap rotation of attitude

Instruction

Positions Speed rate and Overlap on/ off

Center point of .circular interpolation with rotation of the attitude

LX * $

c 1 $

C2 $

End point of circular interpolation with rotation of the attitude

Rotating speed and Overlap on/off

Uniform interpolation

Center point of circular interpolation End point of circular inter polation

Rotating speed and Overlap on/off

Speed rate and Overlap ON/OFF



AS

AE

ICH

RTC

GS

GE

ASM L

AEM *

Starting welding

Terminating welding

Inching the wire

Retracting the wire

Turning gas ON

Turning gas OFF

Starting multi-pass welding

Ending multi-pass welding

Welding s tar t conditions

Crater condition

Inching time

Retracting time

Welding s tar t condition Weaving condition Offset condition

Crator condition Offset condition

WFP

WAX

WE

Starting weavin (Fixed pattern ?

Starting weaving (Axis)

1 Terminates weaving

Weaving conditions

Weaving conditions

Setting external control output Reseting external control output Waiting for external control input ON Waiting for external control input OFF

Output port number and delay time Output port number and delay time Input port number and input wait time Input port number and input wait time

5 - 4 Teaching

T $

BRANCH W

Waiting for time

$

Time

NOP $

PM $

Internal jump (Unconditional)

J P N $ Internal jump (ON condition)

J P F $

Point mark number

No operation

Point mark (Jump destination)

Internal jump (OFF condition)

J P C $

Point mark number and Input port

Point mark number

Internal jump (Counter condition)



JF $

J F N $

Task program number and Input port number

External jump (Unconditional)

JF F $

Task program number

External jump (ON condition)

External jump (OFF condition)


JF C $

$

External jump (Counter condition)

Calling program (Unconditional)

CL N $


Calling program (ON condition)

CL F $

Task program number

Calling program (OFF condition)

CL C $

Task program number and input port number

Calling program (Counter condition)

Task program number and input port number

Task program number and counter number

/ DEF 1 Setting counter value I Counter value

DEC

END

HP * $

Teaching 5 - 5

Decremental operation of counter value

HL * $

Counter value

Ending program

Synchronous positioning motion

Speed rate Overlap on/off

Synchronous linear interpolation

Speed Overlap on/off

Rotating speed Overlap on/off

HLO * $ Synchronous linear interpolation with rotation of attitude

HC * $

HO * $ Rotating speed Overlap on/off

Synchronous circular interpolation

Synchronous circular interpolation with rotation of attitude

HLX * $

ST * ET *

Speed rate Overlap ON/OFF

Speed Overlap on/off

Simultaneous uniform interpolation

Starting tracking

Ending tracking

/ SF1 * $ One-direction search Deviation store number

* $

Pattern search

Calling deviations

Wire extension

Storing deviation number in tracking Starting high speed touch sensing Ending high speed touch sensing Starting multi-pass section

Deviation store number

Ending multi-pass section

Pattern No.,

Deviation store number,

Search/Move Speeds, Reverse

direction on/off, and

Component on/off

Deviation call No.

Deviation store No.

Speed

Repeating times

* : Indicates Optional instructions. $ : Indicates Motion instructions. Instructions without $

are Task instructions.

EP * $

RT * $

5 - 6 Teaching

Specifying executing pass of task instruction Calculating rotated position

Executive condition

Rotational offset value, Axis number

5.1.2 Listing Task Programs

The List function allows the operator to list the created Task programs in order by

number. It is possible to list them in order by date by modifying the setting of "PRG.

LIST DISP." in the user parameters for setting the system status*'.

II Listing Task programs

1. Press F1 (TEACH) at the top

layer of Teach mode. II)

2. Press F1 (LIST). r)

F1 ... Displays the next page. F2 ... Display the previous

page. F3 . . . Modify the Task

program the cursor indicates.

F4 . .. Make a copy of the Task program the cursor indicates. *'

F5 ... Deletes the Task program the cursor indicates. * 3

F1 ... Rename the Task program the cursor indicates. * 4

3. To terminate, press I-ESET . 0 The list operation is terminated,

and you can enter Task program

numbers again.

* 1: Refer to "Setting the System Status", section 2.1 in part II. * 2: Refer to "Copying Files", section 8.2 in part I . * 3: Refer to "Deleting Files", section 8.3 in part I . *4: Refer to "Renaming Files", section 8.4 in part I .

Teaching 5 - 7

5. 2 Teaching Motion Instructions 5.2. 1 Positioning P

This instruction allows the operator to store positions and attitudes of the

manipulator. The manipulator moves to the taught position/attitude from the

immediately preceding stored position/attitude. The moving path of the manipulator

is not linear.

A speed is specified a t a speed rate (which is a rate to the maximum speed; 100 is the

maximum.) When only one axis is operated, it moves a t a specified speed. However,

when multiple axes are operated, the axis whose motion is the largest moves a t a

specified speed, and the other axes s tar t and stop synchronously with it.

As a parameter, Overlap ON/OFF is available. If ON is selected, the rise and fall of

a moving speed are overlapped.

@When you want to reduce a tact time (a time f rom the start of automatic operation

t i l l the completion of a job), select Overlap ON.

Overlap ON Overlap OFF

Fig.5.2 The paths given by setting Overlap ON/OFF

k n - . - L : - - 4 b i l U L I U I 1 \

1) The tact time can be reduced by setting Overlap ON. However, because there is a difference between the path in automatic operation and the path taught, take care to avoid interference with peripheral equipment such a s a jig. Also, because the overlap process is not performed in block operation, the manipulator may interfere with a jig in automatic operation even if this does not happen in block operation. Set Overlap OFF if interference with the jig is possible.

2 ) Even if Overlap OFF is set, this setting may not be effective, depending on the relation between the moving distance and speed, and also taught data.

i /

* : Refer to "Restrictions on Overlap Process", appendix 1 provided a t the end of this manual.

5 - 8 Teaching

II Teaching Positioning P

1. Move the manipulator, by

manual manipulation, to the

position and attitude you want to

teach.

2. Press B. F1 ... Speed 75% and Overlap ON F2 ... Speed 100% and Overlap ON F3 ... Speed 50% and Overlap ON F4 ... Speed 75% and Overlap OFF F5 ... Speed 100% and Overlap

OFF

3. Set a speed by using the function

key o r numeric keys.

4. Set Overlap ON or OFF, i f

necessary.

The default is "ON".

To change to "OFF" :

(2) Press F2 (OFF).

(3) Press @ .

Now, the Positioning instruction

"P" has been stored.

Teaching 5 - 9

5.2.2 Linear Interpolations L and L O

These instructions allow the operator to lineally move the tool tip of the manipulator

to the taught position/attitude from the immediately preceding stored position and

attitude.

(1) L

This instruction causes the tool tip of the manipulator to lineally move with

rotation of the attitude. A speed rate to a moving distance of the tool tip (cm/min)

is set. The entry range of speed is 1 - 999 cm/min. Note that, if a value over 900 cm/

min is set, moving speeds in block operation and automatic operation a re limited to

900 cm/min. If there is a manipulator such a s ALMEGA V40 on the work-side, the

maximum moving speed of work-side manipulator is 600 cm/min.

(2) LO

This instruction causes the attitude of the manipulator to rotate with linear motion

of the tool tip. A speed rate to a moving angle of the tool tip (deg/sec) is set. The

entry range of speed is 1 - 99.9deg/sec.

Note that, if a speed over 45.0deg/sec is set, moving speeds in block operation and

automatic operation are limited to 45 deg/sec.

Torch ----+ Linear movement (L) Rotation of the attitude (LO)

Fig.5.3. Comparison between L and LO

5 - 1 0 Teaching

As a parameter for each of L and LO, Overlap ON/OFF is available. For welding,

usually set overlap "ON". If overlap is set "OFF", th mentarily stop a t

that point during automatic operation.

I Manipulator stops I momentarity a t

the joint

Robot does not stop but takes a small short cut, which causes the path to round a t the joint.

Overlap ON Overlap OFF

Fig.5.4 The paths given by setting Overlap ON/OFF

Normally, to perform welding, set Overlap ON. If you do not want to make joints

around for cutting , set Overlap OFF.

) Important 1) The difference between overlap "ON" and "OFF" appears a t a joint but has no

affect on any other part of the path. 2) Even if Overlap "ON" is set, the setting may not be effective, depending on the

relation between the moving distance and speed, and also taught data. *

3) In the following cases, the manipulator cannot move a t specified speed. * The change of attitude is large compared to the moving distance. * The moving distance is short compared to the specified speed.

* :Refer to "Restiction on the overlap Process", Appendix 1 provided a t the end of

this manual.

Teaching 5 - 1 1

LFI Teaching Linear Interpolation L (LO) 1. Move the manipulator, by


F1 .. . Speed 60cm/min and Overlap ON

F2 ... Speed 100cm/min and Overlap ON

F3 .. . Speed 200cm/min and Overlap ON

F4 ... Speed 300cm/min and Overlap ON

F5 .. . Speed 100cm/min and Overlap OFF

position and attitude you want to teach.

F1 ... Speed 5.0deg/sec and Overlap ON

F2 ... Speed lO.Odeg/sec and Overlap ON



F5 ... Speed lO.Odeg/sec and Overlap OFF

I w~~~~w ~ ~ ~ ~ p i x x i q ~ ~ ~ ~ >

Pressing [> key causes L to 0


key or numeric keys.

2. Press a . ~lr)

I -a. o a ,-

1 5 . / ~ ~ ~ ~ ~ ~ >


change to LO instruction. +

necessary.

For details, see the steps for

Positioning "P" .

5. Press @ . Now, the Linear Interpolation

instruction "L" has been stored.

5 - 1 2 Teaching

5. 2. 3 Ci rcu la r interpolations C1, C2, CO1,and C02

These instructions allow the operator to circularly move the tool tip of the

manipulator to the taught position/attitude from the immediately preceding stored

position and attitude.

A circular a rc is defined by 3 points- a s tar t , middle, and end points.

Start point: any one of P , L, and LO of C1 o r C2

Middle point : C1 o r C03

* End point: C2 or C02

(1) C1

This instruction creates a circular arc by the present point and each taught point

of the immediately preceding and following Motion instructions.

(2) C2

This instruction creates a circular a rc by the present point and each taught point

of the 2 immediately preceding Motion instructions. P

Path of Circular Interpolation (C1) Path of Circular Interpolation (C2)

Fig.5.5 The paths of Circular Interpolations

(3) C01 and C02

The C01 and C02 a re circular interpolation instructions which cause rotation of

the attitude in addition to C1 and C2, respectively.

For setting moving speeds and Overlap ON/OFF, refer to the descriptions for L

and LO, section 5.2.2.

@ Inportant \

1) Teach all of a start , middle and end points to make a circular arc, with the same

type of coordinate system.

2) The diameter of the minimum circular arc varies according to the manipulator

type and the speed setting.* L J

* : Refer to "The Relation between a Minimum Circular Diameter and a Setting Speed"

Appendix 2 provided a t the end of this manual.

Teaching 5 - 1 3

CIII Teaching Linear Circular C (CO) 1. Move the manipulator, by


position and attitude you want to

teach.

2. Press .

F1 ... SpeedGOcm/min and Overlap ON

F2 . .. Speed 100cm/min and Overlap ON



F5 ... Switches between C1 and C2.

key causes C to

change to CO instruction. * F1 . .. Speed5.0deg/sec and Overlap

ON F2 ... Speed lO.Odeg/sec and

Overlap ON F3 ... Speed 15.0deg/sec and

Overlap ON F4 . .. Speed 20.0deg/sec and

Overlap ON F5 ... Switches between C01 and

C02.

LAP : ONA / 6 l [ O N j r ; i 0 0 c m O j S I m m / >

LAP : ON' ' 1 / 5 I d ] p . ' G i q ~ ~ ~ ] >


key and numeric keys.


necessary.

For details, see the steps for

Positioning "P" .

5. Press RECORD . 0 Now, the Circular Interpolation

"C" has been stored.

5 - 1 4 Teaching

5.2 .4 Wait fo r Timer Time T / No Operation NOP (1) Wait for Timer Time

This instruction allows the operator to stop execution of the Task program for a

specified time. Note that weaving and welding are carried on without being stopped.

(2) No Operation

This instruction allows the operator to specify no operation, and is used t o

synchronize between Motion instructions and Task instructions.

Like the case of Wait for Timer Time, weaving and welding a re carried on

without being stopped.

@Use this instruction when you want to teach more than 9 instructions continuously

o r do not want to simultaneously execute a series of external control inputs/

outputs.

II1 Teaching Wait for Timer Time " T " and No Operation "NOP"

1. Press a 2. Press the function key

corresponding to the instruction

you want.

Wait f o r Timer Time "T"

(1) Set a time by using numeric I

keys.

(2) Press RECORD key. 0

IIT TIMER- 2.0 sa. -..I

Now, the Wait Timer Time

instruction "T" has been stored.

Teaching 5 - 1 5

(1) Press F2 (NOP).

(2) Press @ .

Now, the No Operation instruction

"NOP" has been stored.

5 - 1 6 Teaching

5. 2 .5 Internal Program Jump PM(Point Mark), JP(JumP),

DEC (DECrement), and DEF(DEFine)

Though instructions a r e sequentially executed in block o r automatic operation, the

internal program jump functions allows the operator to shift execution to a desired

sequence. Jump conditions include the external control input state, counter, etc.

The following instructions a r e used to execute a n internal program jump:

* Internal Program Jump J P

* Point Mark (jump destination) PM

* Counter conditions for jump DEC and DEF

(1) Internal Program Jump J P

This instruction allows the operator to shift execution of a Task program to a

specified point mark (PM) within the program.

The Positioning instruction "P" is used to move to a point mark (PM). The speed

is the setting of "SPEED TO PM"* in the userparameters for setting the system

status.

Note that in block operation a block operating speed is applied.

The following jump conditions a r e available:

Unconditional jump

Jumps always to a specified point mark (PM).

* Jump according to the external control input s ta te

Jumps to a specified point mark (PM) if the jump condition exists when the

external control input s ta te is checked.

* Jump according to the internal counter

Jumps to a specified point mark when the internal counter reads 0.

(2) Point M a r k (Jump Destination) PM

The point mark is used to indicate the destination to jump within a program.

Up to 9 point marks can be taught in one Task program.

The following parameter is available:

* Point mark number: 1 - 9


Teaching 5 - 1 7

Important 1) As well as Positioning "P" , Point Mark has data of the position/attitude.

If multiple mechanisms a r e configured, this instruction has da ta of the positions/attitudes of all of them. However, these taught positions/attitudes a r e achieved only when the Internal Program Jump instruction is executed to move to the Point Mark.

2) If a point mark with the same number is taught within a Task program, only the point mark taught a t the lower sequence number is valid. In this event, e r ro r is not displayed. However, an er ror is detected when a logical check on Task program* is performed.

'.

(3) Internal Counter DEF and DEC These instructions a r e used to set a counter value and to perform a decremental operation of it.

(A) DEFine a counter value "DEF" This instruction allows the operator to define a counter value used as a

condition for instructions such a s Internal Program Jump/External Program Jump/Call.

The following parameters a r e available: * Counter number: 1 - 9 * Counter value : 1 - 999

Up to 9 counter numbers can be used in one program for automatic operation. One program for automatic operation means a program which is executed throughout the sequences until the job is complete. Therefore, this includes other programs if they a r e activated by the External Program Jump o r Call instructions.

The counter value specified by DEF is set only when the counter reads 0.

(B) DECrement of a counter value, "DEC" This instruction is used to perform a decremental operation of the counter

number by 1. The execution is ignored when the counter value is 0. The following parameter is available: * Counter number: 1 - 9

The counter number changes in the following conditions: When the controller is turned on =3 0 When the counter value is 0 and DEF is executed 3 the value specified by DEF When the counter value is larger than 0 and DEC is executed

=$ the value deducted is executed by 1 by DEC.

The counter value is held until the controller is turned off.

* : Refer to "Logical Check on Task Programs", section 1.2.1 in P a r t 2.

5 - 1 8 Teaching

[Example)

[Teaching data1

0 0 1 P 0 0 2 PM1 0 0 3 P 0 0 4 P 0 0 5 J P PM1 0 0 6 E N D

[Position]

The position of PM of sequence 2 differs

from those of sequences 1 and 3.

[Path] Positioning to sequences 3 and 4 from sequence 1 by performing block or automatic operation.

Positioning to the position of PM when the condition of JP1 is satisfied.

Execution of sequence 3 and the following sequences because PM1 is sequence 2.

Fig. 5.6 Paths by Internal Program Jump using a Point Mark (PM)

Teaching 5 - 1 9

f Example)

(1) When the state of external control input is a jump condition

To make a program, "Check the state of input port 7 before the program is

terminated + Repeat the operation if there is an input. Terminate the program if

no input." ,teach:

Sequence No

0 0 1 PM 1 +Specify point mark (PM) number 1.

0 0 5 J P N 0 0 7 , P M 1 +Jump to PM1 (sequence 001) if there is a n

0 0 6 E N D input a t input port 007.

(2) When the counter is a jump condition

To repeat the operation 5 times and terminate the Task program, teach:

Sequence No.

0 0 1 P

D E F # 2, 0 0 5 +Set counter 2 a t 5.

0 0 2 PMI

D E C # 2 +Decrement 1 to the value of counter 2 by 1.

0 0 5 J P # 2, P M 2 +Jump to PM2 (sequence 007) if counter 2 is 0, and

terminate automatic operation.

0 0 6 J P P M 1 +Jump to PMI (sequence 001) if counter 2 is not 0.

0 0 7 PM2 (Repeat sequences 001 - 005 5 times.)

0 0 8 E N D

When a~l tomat ic operation is performed, the operation from sequence 001 through

005 is repeated 5 times.

5 - 2 0 Teaching

II Teaching Internal Program Jump "JP" m

I . Press .

2. Press the F2 key (JP). 111)

F1 ... Jump when a specified input port is ON.

F2 ... Jump when a specified input port is OFF.

F3 ... Jump when the counter value is 0.

F4 ... Unconditional jump

Jump according to the external control input state

(1) Press the F1 key (JP ON) o r

the F2 key (JP OFF) r9

(2) Set the jump conditions; a

port number and a point mark

number for the destination.

Jump accordinn to the counter

(1) Press the F3 key (JP CNT)..I)


counter number and a point

mark number for the

destination.

Teaching 5 - 2 1

Unconditional iumr, -

(1) Press the F4 (UNCOND).

(2) Set a point mark number for

the destination.

3. Press RECORD key. 0 Now, the Internal Program Jump

" J P " instruction has been stored.

Teaching Point Mark "PM"

1. Press

2. PresstheF4 key (PM). *

3. Set a point mark number.

4. Press RECORD 0 Now, the Point Mark "PM"

instruction has been stored.

5 - 2 2 Teaching

II Teaching DEFine and DECrement a counter value

1. Press

2. Press the F5 key (COUNTER).

.I)

Teaching DEFine a counter value

(1) Press the F1 key (DEF). .9

(2) Set a counter number and a

counter value.

(3) Press @ .

Now, the DEFine counter value

"DEF" instruction has been

stored.

Teaching DECrement a counter value

(1) Press the F2 key (DEC). I 3

(2) Set a counter number.

(3) Press @ .

Now, the DECrement "DEC"


Teaching 5 - 2 3

5.2.6 External Program Jump JF

This instruction is used to shift execution of a Task program to a specified Task

program. This allows the operator to sequentially run a number of Task programs.

The following jump conditions are available.

Unconditional jump

Jumps always to a specified Task program.

* Jump according to the external control input state

Jumps to a specified Task program if the condition is satisfied when the external

control input state is checked.

* Jump according to the internal counter

Jumps to a specified Task program when a specified counter reads 0.

Note \

When the Task program specified by Program Jump is executed and completed, all Task programs will be terminated (i.e., the Job End). Therefore, the instructions following Program Jump are not executed.

\ /

(Example]

Task programs PO01 and PO02 contain the following taught data:

P O 0 1 P - P - L - L - L - P - P - E N D

P O 0 2 P - P - L - L - P - P - E N D PO01 PO02

I' 7 P 4 \ P, EM) END \,,

, \

Y P' 7 1 I

\

I \

The doted lines and full lines indicate paths in the space and on the plane,

respectively, and the arrows indicate the order of execution.

Fig.5.7 The taught data and paths of Task programs PO01 and PO02 5 - 2 4 Teaching

(1) Unconditional Jump to PO02 after executing PO01

Teaching for PO01 :

P - P - L - L - L - P - P - J F P 0 0 2 - E N D

P ; p .--- \ --'--.P; 0, P, END

I END X\, 1

I I \

Y p'; I \ I I

1 p\

Fig. 5.8 Path made by jumping to PO02 after executing PO01

(2) Jump to PO02 after executing sequence 5 in PO01

Teaching for P001:

P - P - L - L - L - J F P O O 2 - P - P - E N D

L n o t executed

Fig.5.9 Path made by Jumping from within PO01

Teaching 5 - 2 5

Teaching Program Jump " JF " by specifying Task program numbers

by the direct entry

1. Press

Press the F2 key (JP). + F1 ... Jump when a specified

input port is ON. F2 . .. Jump when a specified

input port is OFF. F3 ... Jump when the counter

is 0. F4 .. . Unconditional jump

Jump according to the external control input state

(1) Press the F1 key (JF ON) o r

the F2 key (JF OFF). +


port number and a point mark

number for the destination.

Jump according to the counter

(1) Press the F3 key (JF C N T 1 . e


counter number and a point

mark number for the

destination.

Unconditional lump (1) Press the F4 (UNCOND). * (2) Set a point mark number for

the destination.

3. Press RECORD key. 0 Program Jump " JF" instruction

has been stored.

5 - 2 6 Teaching

5.2.7 Programcal l CL

The Call instruction is used to execute another Task program from within the Task

program being currently executed and return control to the original program after the

called program is executed. This allows the operator to sequentially run multiple Task

programs.

The following call conditions are available.

* Unconditional call

Calls always a specified Task program

Call according to the external control input state

Calls a specified Task program if the condition is satisfied when the external control

input state is checked.

Call according to the internal counter

Calls a specified Task program when a specified counter reads 0.

@ Important 1) When a called Task program has been executed, which does not cause Job

End, execution is returned to the instruction next to the Call instruction. However, if the External Program Jump instruction is used in a called Task program, all Task programs terminate (i.e, Job End) when the Task program a t the jump destination is complete.

2) It is possible to use CL in a called Task program, but such call is limited to a maximum of 4 layers. If you try to call over that, an error will occur.

L

(Example]

The following examples are given to explain the Call Program instruction by

using the Task programs used to explain the Program Jump instruction

(1) Executing PO02 by Unconditional Call after PO01

Teaching for P001:

P - P - L - L - L - P - P - C L P O O 2 - E N D

The path is the same as that shown in (Example] (1) for Program Jump.

Teaching 5 -'2 7

(2) Call PO02 after executing sequence 5 in PO01

Teaching for P001:

P - P - L - L - L - C L P O O 2 - P - P - E N D

Fig.5.10 Path made by Calling PO02 from within PO01

Teaching Cal l Program " C L " by specifying a Task program number

by the direct entry

1. Press

5 - 2 8 Teaching

2. Press the F2 key (JP). + [ O N I E r G F l C N T / [ ~ j

F1 ... Call when a specified input port is ON.

F2 ... Call when a specified input port is OFF.

F3 ... Call when the counter value is 0.

F4 ... Unconditional call

CaII according to the external control input state

(1) Press the F1 key (CL ON) o r

the F2 key (CL OFF) * I C L N PORT,. , # ' P R G F P , , ,]

r E - r T q I O F F I / C L C N T / r n j

(2) Set call conditions; a port

number and a Task program

number to be called.

CaII according to the counter

(1) Press the F3 key (CL CNT1.M

(2) Set call conditions; a counter

number and a Task program

number to be called.

Unconditional cal l

(1) Press the F4 (UNCOND).

(2) Set a Task program number

to be called.

3. Press @ key.

Now, the Call Program "CL"


5.2.8 END

The END instruction is used to terminate execution of a Task program. This instruction causes the J o b complete process to be executed. It is possible to create multiple of END instructions in one Task program.

Ell Teaching the END instruction

Press .

2. Press @. Now, the END instruction has

been stored.

Teaching 5 - 2 9

5. 3 Teaching Task Instructions 5.3.1 A r c Start AS

This instruction is used to s tar t welding a t specified welding conditions o r modify

these conditions during a welding operation.

Welding conditions vary according to the type of welding power unit in use, which is * 1 set in advance a s a user parameter .

(1) Individual control type welding power unit

This is a type of welding power unit which individually controls the current

command and the voltage command. Welding conditions to enter include a current, a

voltage, and a welding speed.

(2) Synergic control type welding power unit This is a type of welding power unit which automatically outputs an optimum

voltage when a current command is given. Welding conditions to enter include a

current, a fine adjustment (-100 -+loo%), and a welding speed. Fine adjustment

is an amount of adjustment to be made to a voltage output by the power unit. Set a

fine adjustment to provide an appropriate welding condition. This setting is not

required if ALMEGA FUZZY AUTO is connected and used a s a synergic control type

Fuzzy power supply.

(3) TIG welding power unit

Welding conditions to enter include a welding current, a filler wire feed rate, and a

welding speed.

There a re two way of specifying welding conditions:

Specifying a Welding Condition file*2 which contains welding conditions

Directly entering numeric values

@If there are multiple areas which should be welded at the same welding conditions,

specifying a Welding Condition files allows you to save teaching time and correcting

time.

* 1: Refer to "Setting Welding Characteristic Data", section 2.7 in part I1

* 2: Refer to "Editing Welding Condition Files", section 7.2 in part I .

5 - 3 0 Teaching

0 Important 1) If the setting of "APPLICATION" in the user parameters for setting the system

status is "HANDLING", welding related operations and instructions are not executed.

2) The entry ranges of current, voltage, and filler wire feed sa te a re defined by the ratings set in welding characteristic data. If values larger than rated values a re entered, the rated values will be stored.

3) The preflow is not available for the standard TIG welding power sopply.

)111 Teaching the AS instruction

Setting Arc Start conditions by entering numeric values -

The display on the 7th line a t Individual control type

the main display area depends on

the type of welding power unit IAS 1 6 0 . 4 2 3 . 0 ~ som 1 used. *

The following explanation is

based on an individual control

type welding power unit. Synergic control type

A preflow time is set in

"PREFLOW TIME"' of the

user parameters for welding. TIG

The preflow is not available for 7 i'"" 8 om S ocat ' ---q the standard TIG welding power

2. Set a welding current by

using numeric keys.

If the condition displayed is O.K.,

proceed to operation 3 (setting a

welding voltage).

* : Refer to "Setting Welding Parameters", section 2.3 in part 11.

Teaching 5 - 3 1

3. Setting a welding voltage

The voltage optimum to the

current is automatically set only

if you are using an individual

control type welding power unit .

(2) Enter a value by using

numeric keys.

4. Set a welding speed.

If the condition displayed is O.K.

proceed to operation 5.

(1) Press

(2) Enter a value by numeric keys.

5. Press @ . Now, the Arc Start instruction

"AS" has been stored.

Setting A r c Start conditions by specifying a Welding Condition f i l e

1. Press @ and then F3

(AS FILE) * 2. Enter the file number by

numeric keys. +

Then, press F1 (COND), and the

specified file will be displayed. +

5 - 3 2 Teaching

AXIS MH1 TEACH P777 SQNa= 4 SERVO ON ASCO 1

WELDING CURRENT 1 8 0A WELDING VOLTAGE 2 0.OV WELDING SPEED 1 5 Om

p'.F"FI

If the specified file does not exist,

an Alarm message is displayed. .r)

N°FILEEXllAs r sTs FILE A s c o l > % , 3 *

-1

* F1 ... Displays the contents of another Condition file.

~ I F Y ... Re-enters a file 0 number.

3. Press

Now, the Arc Start instruction has

been stored.

If the specified Condition file does

not exist, an Alarm message is

displayed.

F1 ... Stores the specified Condition file.

F2 ... Displays the contents of another Condition file, if any. The display does not change if there are no other Condition file.

* m I F Y ... Re-enters a file number. 0 @ Important 3

If F1 (EXECUTE) is pressed, be sure to create the Condition file you specified later. Otherwise, Alarm will occur in block operation, and Error in automatic operation.

L /

Teaching 5 - 3 3

5.3.2 Arc End AE

The AE instruction is used to terminate welding with a crater process using the

specified arc end conditions. Crater process is a process to make a bead shape a t the

weld end part neat. Arc end conditions vary according to the type of welding power

unit in use.

(1) Individual control type welding power unit

Conditions to enter include a current, a voltage, a crater time (0.0-9.9sec.1, and an

postflow time (0.0-9.9 sec.). Postflow is a process to prevent oxidization a t the weld

end part by keeping a gas flow for a specified time after welding is completed.

(2) Synergic control type welding power unit

Conditions to enter include a current, a fine adjustment (- 100-+ loo%), a crater

time (0.0-9.9 sec.), and an postflow time (0.0-9.9 sec.).

(3) TIG welding power unit

Conditions to enter include a current, a wire retracting time, a crater time (0.0-9.9

sec.), and an postflow time (0.0-9.9 sec.). The afterfrow is not availlable for the

Standard TIG welding power supply.

1) The entry ranges of current and voltage are defined by the ratings set in

welding characteristic data. If values larger than rated values a re entered, the

rated values will be stored.

2) If you want to set a wire retracting time to use TIG filler, be sure to set

"WIRE RETRACT SPEED" * ' in the welding user parameters.

There are two way of specifying crater (Arc End) conditions:

Specifying a Arc End Condition file*' which contains crater conditions


* 1:Refer to "Setting Welding Parameters", section 2.3 in part I1

* 2: Refer to "Editing Welding Condition Files", section 7.2 in part I

5 - 3 4 Teaching

II Teaching the AE instruction

Setting A rc End conditions by entering numeric values

1. press . IIAE i s o A 9e.tw.bs.-

If the current sequence is a [NUMlIAENUMIJAS-m I welding section, AE will be

displayed.

The display on the 7th line a t Individual control type

the main display area depends on

the type of welding power unit

used. sr) Synergic control type

"6 + * * The following explanation is

based on an individual control TIG

type welding power unit.

2. Enter a current, a voltage, a

crater time, and an afterflow time

by numeric keys.

The voltage is automatically set

only if an individual control type

of welding power unit is used.

For automatic control, see the

description of AS.

3. Press Q

Now, the Arc End instruction "AE"

has been stored.

Teaching 5 - 3 5

Setting Arc End conditions by specifying a f i le - 1. Press and then F4

(AE FILE). +

2. Enter the file number by

numeric keys. Ir+)

3. Then, press F I (COND), and the

specified file will be displayed.

If the specified Condition file does

not exist, an Alarm message is

displayed.

AXIS MHI TEACH P777 SQ Aa= 4 SERVO ON AECO 1

* F1 ... Displays the contents of ,, another Condition file.

WELDING CURRENT 180A WELDING VOLTAGE 20.0V CRATER TIME 1.0 S . POSTFLOW TIME 0.0 s.

... Re-enters a file number.

/NEXT1

4. Press @ .

Now, the Arc End instruction "AE" has been stored.

If the specified Condition file does not exist, an Alarm message is displayed. *

* F1 ... Stores the specified Condition file.

F2 ... Displays the contents of another Condition file, if any. The display does not change if there are no other Condition files.

* ~JNJ~FY ... Re-enters a file number.

*OFILE I STS EXIl IEXECUTEJ pTYT-1

Important -. If F1 (EXECUTE) is pressed, be sure to create the Condition file you specified later. Otherwise, Alarm will occur in block operation, and Error in automatic operation.

5 - 3 6 Teaching

5.3.3 Inching/Retracting ICH/RTC

The ICH/RTC instructions a r e used to inch/retract the wire during automatic

operation.

Set a n inching time and a retracting time (ranging 0.0 - 99.9 sec. in the unit of 0.1 sec.).

The inching/retracting speeds a r e the settings of welding user parameters "INCH/

RETRACT(LOW) ".

) Important

1) During inching/retracting by ICH/RTC, the manipulator does not stop.

Also, welding by AS is not started until inching o r retracting is completed.

2) Incliing/retracing by ICH/RTC a re not executed:

* When is set OFF.

In a welding section, or

* When the operation is halted during inching/retracting and is restarted

(ICH and RTC a r e ignored when restarted.)

gl] Teaching the ICH/RTC instructions

1. Press , and then two

times. *

Inching

(1) Press F1 (ICH) II)

(2) Set an inching time by

numeric keys.

Retract

AXIS MH1 TEACH P7 7 7 SQ Na= 1 SERVO ON

(1) Press F2 (RTC) .r)

> 0 0 1 P 1 0 0 % BASE M1

[ A S ' . 'XSOA 23,OY 5Om 1

(2) Set a retracting time by

numeric keys.

2. Press @ . Now, the Inching/Retract

[ I C H j I R T C I I G I r n >

ins t r~~c t ions "1CHJ'/"RTC" have

been stored.

AXIS MHI TEACH P7 7 7 SQNa= 1 SERVO ON >001 P 10096 BASE M1

~ X C N Tl[ME=99,9sec ,i 1

Teaching 5-3 7

[CHI/RmIm >

AXIS MH1 TEACH P 7 7 7 SQKa= 1 SERVO ON >001 P 100% BASE MI

IBTC:TX,ME=~ ~ , 9 se c,, , , , r I * ,>> *

I I c H ] I R T C [ S I V l >

5.3.4 Gas ON/OFF GS/GE

The GS/GE instructions are used to start and end a preflow during automatic

operation. Preflow is started from the position taught with the Motion instruction

followed by GS. Preflow stops when the operation is halted during preflow and is

carried out again when restarted.

@ Important I Gas ON/OFF by GS/GE are not executed:

I * When is set OFF, or

In a welding section.

Teaching the GS/GE instructions

1. Pressing , and then

two times.

Gas ON

Press F3 (GS).

Gas OFF

Press F4 (GE).

2. Press . w Now, the Gas ON/OFF

instructions " GS"/" GE" have

been stored.

5 - 3 8 Teaching

5.3.5 Weaving Start WFP and WAX

The WFP and WAX are used to start weaving a t specified weaving conditions or

modify these conditions during a weaving operation.

The following two weaving types are available:

Weaving with fixed pattern WFP

* Weaving by axis WAX

There are two way of specifying weaving conditions:

* Specifying a Weaving Condition file* which contains welding conditions


@If there are multiple areas which are weaved a t the same weaving conditions,

specifying a Weaving Condition file allows you to save teaching time and correcting

time.

(1) Weaving with fixed pattern WFP

The WFP is used to perform weaving on the plane to the main path. The weaving

plane is perpendicular to the torch.

Weaving plane

(The perpendicular torch position) (The torch position a t 45' )

Fig.5.11 Weaving planes

* : Refer to "Editing Weaving ConditionsJ', section 7.3 in part I .

Teaching 5 - 3 9

The follo~ving parameters a re available:

Function type linear function o r sine curve

Amplitude(Ha1f cycle: Yl/Y2) 0.0 -- 50.0 mm

Frequency 0.0 - 10.0 Hz

Center stopping time 0.0 - 9.9 sec

1/4 cycle stopping time 0.0 - 9.9 sec

3/4 cycle stopping time 0.0 - 9.9 sec

Linear function Sine curve

1/4 cycle stopping time /

Center stopping time

Main path

. . . Y. . . . . . . . . . . . . . . . . . . . . . . . .

3/4 cycle stopping time

Fig.5.12 Parameters and Weaving path

Important 1) Weaving may not be performed in accordance with a specified frequency*.

2) The manipulator too stops during the period of each stopping time.

Therefore, if stopping time parameters a r e entered, the time required for

block operation o r automatic operation varies according to WEAVE

"ON"/"OFF".(The cycle time a t the "ON" setting becomes longer by the

total stopping time than that a t the "OFF".)

* : Refer to "Restriction on Weaving Frequency", appendix 3 provided a t the end of

this manual.

5 - 4 0 Teaching

(2) Weaving by axis WAX

The WAX is used to perform weaving by single vibration of each axis.

The following parameters a r e available:

Axis No. 1 - 6

Amplitude (Half cycle: Yl/Y2) 0.0 - 9.99 deg

Frequency 0.0 - 10.0 Hz

Center stopping time 0.0 -- 9.9 sec

1/4 cycle stopping time 0.0 -- 9.9 sec

3/4 cycle stopping time 0.0 -- 9.9 sec

I t is possible to set up to 3 axis numbers a t one time. If more than one axis

number is set, the parameter settings except amplitude, which can be set per axis,

a r e common to them.

~ 1 . ~ 2

Fig.5.13. Weaving by Axis 5 of ALMEGA G series

Teaching 5 - 4 1

Teaching the WFP instruction

Setting Weaving conditions by entering numeric values

1. Press .

2. Press F1 (FP NUM). *

3. Move the cursor by pressing

, and set parameters.

(1) Set a function type (linear

function o r sine curve) by the

function key.

(2) Set each half cycle of weaving

amplitude by numeric keys.

(3) Set a weaving frequency by

numeric keys.

(4) Set each stopping time (center,

1/4 cycle, and 3/4 cycle).

4. Press RECORD key 0 Now, the Weaving with Fixed

Pattern instruction "WFP" has been

stored.

5 - 4 2 Teaching

AXIS MH1 TEACH P7 7 7 SQ Ha= 2 SERVO ON

>FUNCTION pmE%q AMPLITUDE Y1 I. Onm AMPLITUDE Y2 1. Oaa FREQUENCY 5. OIE CENTER STOP 0.0 S . 1/4 FREQ STOP 0.0 S .

3/4 FREQ STOP 0.0 s.

[ L I N E A R / W I G /

Setting Weaving conditions by specifying a f i le

1. Press .

2. Press F2 (FP FILE). .I) 1 LWpP FI&E WPP i

/ m m F I L E I / A X p T T q l W E /


numeric keys. +

4. Then, press F1 (COND.), and

the specified file will be displayed.

*

If the specified Condition file does not exist, an Alarm message is displayed. rr)

* F1 ... Displays the contents of another Condition file,

* m l F Y ... Re-enters a file number.

5. Press @ .

AXIS MH1 TEACH P777 SQ Ha= 4 SERVO ON

Now, the Weaving with fixed pattern instruction "WFP" has been stored.

FUNCTION LINEAR AMPLITUDE Y1 I. Onm AMPLITUDE Y2 1.0ma FREQUENCY 5. 01%~ CENTER STOP 0.0 s. 1/4 FREQ STOP 0.0 S.

3/4 FREQ STOP 0.0 s.

piFx-y

dition file. * F2 ... Displays the contents of

another Condition file, if any. The display does not change if there a re no other Condition files.

m l F Y ... Re-enters a file number.

If the specified Condition file does not exist, a n Alarm message is displayed. +

Important \


NOFILE EX I sTs

-1-

Teaching 5 --'4 3

* F1 ... Stores the specified Con

Teaching the WAX instruction

Setting Weaving conditions by entering numeric values

2. Press F3 (AX NUM.).

3. Move the cursor by pressing

and

set parameters.

(1) Set a weaving frequency by

numeric keys.

(2) Set a weaving axis number or

numbers and each amplitude.

Set amplitudes of the non

weaving axes a t 0.

(3) Set each stopping time (center,

1/4 cycle, and 3/4 cycle).

4. Press RECORD key 0 Now, the Weaving by Axis

instruction "WAX" has been stored.

A X I S MH1 TEACH P 7 7 7 SQ Ha= 5 SERVO ON

5 - 4 4 Teaching

FREQUENCY 5.0 l A X I S 4 Y l 0.OOd. Y 2 0.OOd. P A X I S 5 Y 1 O.OOd. Y 2 O.OOd. 3 A X I S 6 Y 1 0.OOd. Y 2 0.OOd. CENTER S T O P 0.0 S, 1/4 FREQ S T O P 0.0 S . 3/4 FREQ STOP 0.0 S .

Setting Weaving conditions by specifying a f i l e - I . Press M .

2. Press F4 (AX FILE). *


numeric keys. rr)

4. Then, press F2 (COND.), and

the specified file will be displayed.

sr)

If the specified Condition file does not exist, an Alarm message is displayed. sl)

F1 ... Displays the contents of another Condition file.

* ~ I F Y ... Re-enters a file number.

A X I S MH1 TEACH P 7 7 7 SQ Na= 5 SERVO ON WAX 0 1

5. Press @

FREQENCY 5.0 1 . A X I S 4 Y 1 0.OOd. Y 2 O.OOd 2 . A X I S 5 Y 1 O.OOd, Y 2 0.OOd 3 .AXIS 6 Y 1 0.OOd. Y 2 O.OOd CENTER S T O P 0.0 s. 1/4 FREQ S T O P 0.0 S . 3/4 FREQ S T O P 0.0 s.

Now, the Weaving by axis instruction "WAX" has been stored.

If the specified Condition file does not exist, an Alarm message is displayed. I)

* F1 ... Stores the specified Condition file.

F2 ... Displays the contents of another Condition file, if any. The display does not change if there are no other Condition.

M ~ D I F Y ... Re-enters a file 0 number.

Teaching 5 - 4 5

Important 3


\ /

5.3.6 Weaving End WE

The WE instruction is used to terminate all weaving operations specified by the

Weaving Start instructions.

Bill Teaching the WE instruction

1. Press and then F5 (WE).

2. Press @.

Now, the Weaving End instruction

"WE" has been stored.

5 - 4 6 Teaching

5.3.7 External Control Input/Output S, R, N, F, PLS, and PLR

External Control Input/Output instructions a re divided into 2 groups:

* External Control Output instructions S and R

* External Control Input Wait instructions N and F

(1) External Control Output instructions

External control output instructions set a specified output port ON/OFF.

* Set an external control output S

Reset an external control output R

The following parameters are available:

* Output port number: 0000 - 0199

- Delay time: 00 - 99.9 sec. (unit of 0.1 sec.)

Setting a delay time allows holding execution of an instruction for the set time

after the immediately preceding Motion instruction is executed.

However, execution of a Task program is not held during the period of this waiting

time. If the operation is halted during the period of a delay time, the output is not

executed later.

Depending on output port numbers, operation varies when the mode is changed:

* Automatically reset output (0000-0099)

Automatically OFF when switching from Teach to Auto modes

* Automatically held output (0100-0199)

Not OFF even if the mode is changed. OFF when external control output OFF (R)

is executed.

You can also set output ports to OFF manually by using a teaching box. *

* : Refer to "Resetting External Control Output Signals", section 4.1.6 in par t I

Teaching 5 - 4 7

(2) External Control Input Wait instructions

These instructions check whether the specified input ports a r e in the specified

conditions o r not. If not, they hold execution of Task programs until the conditions

a r e satisfied.

Wait for an external control input ON N

Wait for a n external control input OFF F

The following parameters a r e available:

Input port number: 1000-1199

* Input waiting time: 0.1-99.9 sec. (unit of 0.1 sec.) and (infinity)

When the specified input port is not in the specified condition even if the specified

waiting time is over, input time out er ror will occur, which causes the operation to be

halted.

If (infinity) is set, execution of the Task program is held until a n input is

received, without monitoring of input waiting time.

(3) Teaching a series of S, N, and R (S, F, and R)

The use of SNR and SFR enables teaching 4 instructions by one time of operation:

SNR * S, N, NOP, R SFR + S, F, NOP, R

Input/output port numbers and input waiting time a r e specified when each of SFR

and SNR is taught. Remember that output port numbers for S and R must be the

same.

For the relation between output numbers and actual output circuits (output

terminals), refer to the instruction manual "Interface with Jig"

5 - 4 8 Teaching

Cautions \

1) All Task instructions taught between two Motion instructions are almost

simultaneously executed when execution of the Motion instruction followed by

them is complete during automatic operation. Especially, care should be taken

to teach external control input/output instructions.

(Example 11 (Example 21 (Example 31

001 P 001 P 001 P

S 0 0 1 S 0 0 1 S 0 0 1

S 0 0 2 S 0 0 2 N 0 0 1

S 0 0 3 R 0 0 1 R 0 0 1

S 0 0 4 S 0 0 3 002 P

002 P 002 P

(Example 1) Output ports 001 - 004 are simultaneously set ON.

(Example 21 Because SO01 and ROO1 are simultaneously executed, output

port 001 is not set. Only 002 and 003 are simultaneously set ON. If you want

to output 001, add a Timer instruction (T) with about 0.2 sec. immediately

before R001.

[Example 31 Like (Example 21 SO01 is not executed. In this case, add NOP

instruction after N001.

2) In a Task program like the following examples. External Control Output I instructions may not be executed: I

(Example 11 [Example 21

004 P Oo4 i r k the same or almost S 0 0 1

005 P same point. 005 N O P

R 0 0 1 R 0 0 1

In such cases, add a Timer instruction (T) with about 0.2 sec. between them.

Teaching 5 - 4 9

Teaching External Control Input/Output instructions

Press m. F1 ... External control output

I p-c--q~INPON/lOFF/ >

SET I 1

FZ ... External control output p-ii-z psFRI

RESET F3 ... External control input ON

WAIT F4 ... External control input

OFF WAIT

I> F1 ... Teaches a series of S, N, ' NOP, and R. FZ ... Teaches a series of S, F,

NOP, and R.

External Control Output instruction S

1. Press F1 (SET). * I 1

2. Enter the output port number by t

numeric keys.

3. Press, and then set the

delay time.

4. Press RECORD 0 Now, the External Control Output

instruction "S" has been stored

External Control Output instruction R

1. Press F2 (RESET). I

2. Set the output port number and

the delay time as set for SET.

3. Press @

Now, the External Control Output

instruction "R" has been stored.

5 - 5 0 Teaching

The Wait for External Control Input instruction N

2. Enter the input port number by

numeric keys.

1. Press F3 (INPON). I)

3. Press, and then set the

input waiting time.

LON PORTLTIMER-o 9. J

~ ~ T I I R E S E T I / ~ ~ ~

4. Press @ . 1 [ON PORT # O It0 TIMER= w 3. J ~~ This setting causes waiting for

ON input for the specified time. When a signal of the specified input port is switched ON o r F1 (ACCEPT) is pressed, the N instruction is stored. Then, the NOP instruction is

automatically stored following "N".

The Wait for External Control l n ~ u t instruction F

1. Press F4 (INP OFF).

2. Set the input port number by

numeric keys as set for N ( I NP

ON).

3. press @. +

This setting causes waiting for O F F input for the specified time. When a signal of the specified input port is switched O F F o r F1 (ACCEPT) is pressed, the F instruction is stored. Then, the NOP instruction is autoinatically stored following "F" .

Teaching 5 - 5 1

Teaching a series of S, N, and R (St F, and R) ,-----?

I . Press .

2. Set the port numbers to be output

(SET RESET) by numeric keys. * [SNK-OUT-I o o i ~ = 'T1ME=ocs

3. press 101, and then set the por t

number to wait fo r ON in the case

of SNR or the port number to wait

fo r OFF in the case of SFR by

numeric keys. * ~ S N R - O U T = I ~ # IN=O~BTIME-*SI

4. ~ r e s s / o ] , and set the input

waiting time.

5. press @ . * (ISNR OUT=I 8 @ INm0 6 0 TIME=~S,

/ACCEPT] This setting causes waiting for ON

(in the case of SNR) or for OFF (in

the case of SFR) for the specified

time. When a signal of the specified

input port is entered o r F1 (ACCEPT)

is pressed, SNR (or SFR) is stored.

5 - 5 2 Teaching

5. 4 Block Operation Block operation allows the operator to check positions/attitude taught in a Task

program by operating the teaching box.

To perform block operation, the following conditions must be satisfied:

* The SERVO is ON state.

* The current mode is TEACH.

Task program has been specified.

* The Search for Instructions feature* is not active.

5.4.1 Forward/Backward Block Operations

(1) Forward block operation

Forward block operation (as well a s automatic operation) allows the operator

to execute instructions in order by sequence number.

The forward operation stops a t END. If carried on further, it is performed from

sequence 1.

(2) Backward block operation

Backward block operation allows the operator to execute instructions in reverse

order by sequence number. The backward operation terminates a t sequence 1.

It is not possible to run back from sequence 1.

) Important 7 1) In block operation unlike automatic operation, some instructions a r e

not executed:

Instructions that are not executed in (forward or backward) block operation AS, AE, I CH, RTC, GS, GE, ST, ET, SF3, SF5, ASM. AEM. TSS, T S E

* Instructions that are not executed in backward block operation T, J P , JF, CL, SFO, SF 1 , SF2

Thus, In weaving sections, weaving can be performed (a t the same conditions a s those in forward block operation) in block operation.

If DEC is executed in backward operation, the counter value is added

Jh : Refer to "Searching for Instructions", section 5.7 in part I .

Teaching 5 - 5 3

2) When you are in a Task program a t the jump destination o r a called

program by performing operation such a s forward block operation,

backward operation allows you to go back up to the first sequence of

that program but no further. Therefore, in backward operation, it is

not possible to return to the original program.

\ /

Ell Operating a block operation

Finish creating a Task program

by pressing RESET or specify a 0 created Task program number.

You can now perform block

operation

2. Press [El (or El) while

holding @ down.

operation causes the halted state

to be entered. You can restart the

BLOCK operation by pressing 1 ,, 1 or

while holding @y

5 - 5 4 Teaching

5.4 .2 Block Continuous Operation

For continuous execution of instructions, specify block continuous operation. n -

BLOCK $4 key with1 ,, lor key shall be functioning instead ,of specifying block -.

continuous operation.

However, in this case, operation stops for a moment a t each instruction, which does

not occur in the case of continuous execution by specifying blocli continuous operation.

H Block continuous operation

The LED on the upper left will

illuminate to indicate the block ,\ : e n

continuous selection. * 2. Press and hold 63 MU , then,

press

If the n = is released during u

block operation, the LED to go

out and block continuous

operation is canceled.

5.4.3 Block Operating Speeds

In block operation, the manipulator operates a t a block operating speed only when it

executes Positioning instructions (P, HP, and PM). When executing other instructions-

Interpolation Instructions (L, LO, C, CO, etc.1-, it operates a t a taught speed like in

automatic operation.

In welding sections, the robot does not move a t a speed taught wit11 the Welding

instruction "AS" but move a t speed settings of L, C, etc. taught in welding sections.

4 step speed are provided for Block operation and can be switched over with the

teaching box.

B-1 B-2 B-3 B-4

Low High

However, it is not possible to change the speed during block operation.

Teaching 5 -.5 5

SPEED 0 1111 Switching between speeds for block operation

1. Press when the block

operation is not running.

The display a t the speed display

area will chande to the block

operating speed.

2. Select the speed by pressing

5.4.. 4 Halting and Starting Block Operation

Halting and restarting block operation during execution of a Weaving, External

Control Input/Output, or Timer instruction results in the following:

(1) Weaving instructions (WFP and WAX)

When block operation is halted in a weaving section, the center stop process being

performed.

Path after restarting

+ Mainpath

Center stop

Fig.5.14 The weaving path a t the time of halting/restarting (block operation)

The center stop means a return to the main ~a th (whe re weaving is not ~erforrned.1

(2) External Control Input/Output instructions (N, F, S, and R)

The input waiting time and delay time are aborted when the operation is halted,

and a re recounted from the beginning when restarted.

(3) Wait for Timer Time instruction (T)

The timer is stopped when the operation is halted, and is recounted from the

beginning when restarted.

5 6 Teaching

5.4 .5 Cancell ing the Halted State o f Block Operation The operator can cancel the halt s tate of block operation by operating the teaching

box.

@This feature allows the operator to add instructions in the halted state of block

operation.

@If the halted instruction, e.g., Timer or External Control Input/Output, has a long

time setting, this feature enables the operator to shit execution to the next

instruction immediately.

Caution 1

If you perform block operation after cancelling the halted state, the

manipulator s t a r t s to move to the next sequence from the stopped point.

Therefore, take care to avoid interference with the jig.

(Examplel When block operation is performed to run the following Task

program:

, , 1 0 0 % . , I r 0

250cm p Halted point -+ -"

250cm (007) I P 100 (012)

Fig.5.15 Movement after cancellation of the halted state of block operation

Block operation (forward) is halted between sequences 009 and 010 (a t the

halted point shown above), and then the halted state is cancelled. ON is

output to output port 100 immediately when the operation (forward block) is

restarted, and the manipulator moves to sequence 011.

II Cancelling ,\ the halted state

~ r e s s " m in the halted state. u

This causes the LED to go out. + r s ~ o p /

Now, the halted state has been

cancelled.

Teaching 5 - 5 7

5.4.6 Sequence Jump

The Sequence Jump allows the operator to move a mechanism to the position of a

specified sequence number.

@This feature is used when you want to run part of a Task program which contains

a number of sequences, by block operation.

Fig.5.16 A path given by Sequence Jump

Performing the Sequence Jump

1. Press F2 (JUMP).

2. Specify a destination sequence

number.

3. Holding 8 down, press

o r .

The mechanism will move to the

specified sequence.

5 - 5 8 Teaching

5. 5 Adding and Deleting lnstructions

5. 5. 1 Adding lnstructions

The Add feature allows the operator to add instructions. It is possible to

continuously add instructions, but not possible to store more than a series of 10 Task

instructions in one Task program.

Adding l nstructions

Here, let us try to add P a t the point after L of sequence number 86: 1. Move the cursor to the

instruction (sequence 086) which should be followed by the

instruction you want to add, by

performing block operation o r

executing the sequence jump. I)

2. Press B . * The LED on the upper left will

light.

3. Move the manipulator t o the position/attitude to be taught, by

manual manipulation.

4. Press the key of the instruction

to be added ( ).

Set a speed and Overlap ON/ OFF in the same manners a s those for creating data.

5. Press @ . * Now, P has been stored. If you want to add more instructions, repeat the above operation.

If you want to cancel the

addition, press ~ I F Y . 0 6. Press again to terminate

the operation.

The LED on the upper left will

light.

T.MECB. ML4 TEACH P 7 7 7 SQNo. =I32 SERVO ON ADDITION

Teaching 5 - 5 9

WE 0 8 4 P 1 0 0 % BASE Ml 0 8 5 L 1 5 0 m BASE M I

> 0 8 6 L 1 5 O m BASE M1

T.MECH.ML4 TEACH P 7 7 7 SQNo.=132 SERVO ON ADDITION

/ M O T m m l m m / >

0 8 4 P 1 0 0 % BASE M1 0 8 5 L 1 5 0 m BASE M1 0 8 6 L 1 5 0 m BASE M I

> 0 8 7 P 1 0 0 9 6 BASE M I

(PSPEED:IOO% L A P Z Q N ~

/MOTION/ I I /OIm] lmmI >

5. 5. 2 Deleting Instructions

The Delete feature alloivs the operator to delete instructions. It is possible to delete

n~ultiple instructions a t one time by specifying a range. However, deletion resulting in a

series of more than 10 Task instructions is not possible.

IIIf Deleting l nstructions

Here, let us t ry to delete L of sequence number 86:

1. Move the cursor to the

instruction (sequence 085) which

should be followed by the

instruction you want to delete,

by performing block operation or

executing the sequence jump. +

2. Press @ . w

The range to be deleted will be

If you want to extend the

T.MECII. ML4 TEACH P 7 7 7 S Q N a - 1 3 2 SERVO ON

BLOCK deletion range, press 1 ,, 1

WE 0 8 4 P 1 0 0 % B A S E M1

> 0 8 5 L 150cm B A S E M1 0 8 6 L 15Ocm B A S E M1 0 8 7 L 100cm B A S E M1 0 8 8 L 100cm B A S E M1

T.MECH. ML4 TEACH P 7 7 7 SQNo.=132 SERVO ON RANGEFOR DEL.

If you want to reduce it, press

* Pressing MOOIFY allows you to 0 cancel the deletion range you

~ j I J ] r z - i T E l ~ l ~ / >

WE 0 8 4 P 1 0 0 % B A S E M1

> 0 8 5 L 150cm B A S E M1 0 8 6 L i " I S 0 c m B A S E MI'^ 0 8 8 L 100cm B A S E M1

specified by pressing DELETE 0

-1

3. Press F3 (EXECUTE). +

Now, L of sequence 086 has been

deleted

If you press MOOIFY immediately 0 af ter deletion, you can cancel the

deletion.

5 - 6 0 Teaching

T.MECII. ML4 TEACH P 7 7 7 SQ No. = I 3 2 SERVO ON

WE 0 8 4 P 1 0 0 % B A S E M1

> 0 8 5 L 1 5 0 m B A S E M1 0 8 6 L 150cm B A S E M1 0 8 7 L 1OOcm B A S E M1 0 8 8 C 2 100cm B A S E M1

J S E A R C H / ) J p T i E / ~ ~ >

5. 6 Changing Teaching Data It is possible to change the following teaching data :

Motion instructions

Parameters of Motion instructions (i.e., speeds and overlap ON/OFF)

Positions/attitudes

Task instructions

Parameters of Task instructions

5. 6. 1 Changing Motion Instructions

It is possible to change P to L, o r L to P , but not a Motion instruction to a Task

instruction. It is not possible to change Motion instructions of the single manipulator

such as P, L, and C to Motion instructions of the multiple-manipulator such as HP, HL,

and HC.

I(( Changing Motion instructions

Here, let us t ry to change "L" of sequence 085 to "P":

1. Movethecursor to the

instruction to be changed

(sequence 085), by performing

block operation.

2. Press

3. Set a speed and Overlap ON/

OFF in the same manners as

those for creating new data.

4. Press @

Now, the change has been

completed.

Teaching 5 - 6 1

5.6. 2 Changing Parameters of Motion instructions

It is possible to change operating speeds and Overlap ON/OFF settings of Motion

instructions.

Changing Motion instructions

Here, let us try to change the parameters of "L" of sequence 085:




block operation.

3. Set a speed and Overlap ON/OFF

in the same manners as those for

creating new data.

4. press Q . +

Now, the change has been completed.

5. 6. 3 Changing Positions/Attitudes

T.MECkI. ML4 TEACH P 7 7 7 SQ Na=13 2 SERVOON

It is possible to change data of the position/attitude which a Motion instruction has.

WE 0 8 4 P 1 0 0 % BASE M 1

> 0 8 5 L l O O m BASE M1 0 8 6 L 1 5 Om BASE M 1 0 8 7 C 1 1 5 0 m BASE M I 0 8 8 C2 1 5 0 m BASE M 1

Changing positions/attitudes

rEEiqlJ[pl~[PATHAT( >




block operation. * 2. Move the manipulator to the

position/attitude you want, by

performing manual manipulation.

3. Press @ .

Now, the position/attitude

indicated by the cursor have been

changed.

T.MECt1. ML 4 TEACH P 7 7 7 SQ No.=132 SERVO ON

5 - 6 2 Teaching

WE 0 8 4 P 1 0 0 % BASE M I

> 0 8 5 L 1 5 0 m BASE M 1 0 8 6 L 1 5 0 m BASE M I 0 8 7 C1 1 5 0 m BASE M 1 0 8 8 C2 1 5 0 m BASE M 1

I T E E E ' q l J J ~ l ~ ~ ] >

5.6 .4 Changing Task Instructions It is possible to change Task instructions, such as Welding, Weaving, and External

Control Input/Output, to other Task instructions, but not Task instructions to Motion

instructions.

Changing Task instructions

Tliis section explains how to change S (SET) to N (ON WAIT):

1. Move thecu rso r t o the instruction to be changed. In this case, S (SET).

2. Press to change to N

3. Press F3 (INP ON) . Ir)

4. Set the port number and the input waiting time in same manners as those fo r creating new data.

5. Press @

T.MECH. ML4 TEACH P I 7 7 SQ N o ~ 1 3 2 SERVO ON


WE 0 8 4 P 1 0 0 % BASE M I

, . ur,=u.u s , , , . .I 0 8 5 L 1 5 0 m BASE M I 0 8 6 L 150cm BASE M I 0 8 7 C 1 150cm BASE M I

T.MEC1-I. ML 4 TEACH P 7 7 7 SQ No71 3 2 SERVO ON

5.6.5 Changing Parameters of Task Instructions I t is possible to change parameters of Task instructions such a s Welding, Weaving, and

External Control Input/Output.

~ ~ p T i F T i q ~ \

WE 0 8 4 P 1 0 0 9 6 BASE M I > N 0 11 WT=m 0 8 5 L 1 5 0 m BASE M I 0 8 6 L 1 5 0 m BASE M I 0 8 7 C1 1 5 O m BASE M I

H Changing Parameters of Task instructions

This section explains how to change an output port number of external control output.

1. Move the cursor to the instruction to be changed (S in this example).

IrnIIJIpE'qIPATHJ/PATHl>

2. Press

3. Change the output port number.

T.MECI1. ML4 TEACH P 7 7 7 SQ Na=13 2 SERVO OFF

4. press @ . *

WE 0 8 4 P 1 0 0 % BASE M I

)I s i l 1 z I)LE.II . IIS ( 0 8 5 L 1 5 0 m BASE M1 0 8 6 L 1 5 Om BASE M I 0 8 7 C1 1 5 0 m BASE M I


ISEARCH/IJ]/SHIFTIIPATHIW]>

Teaching 5 - 6 3

T.MECA. ML4 TEACH P 7 7 7 SQ Na=l3 2 SERVO ON

WE 0 8 4 P 1 0 0 % BASE M1 > S 0 1 0 DL=O.Os 0 8 5 L 1 5 0 m BASE M I 0 8 6 L 1 5 0 m BASE M I 0 8 7 C 1 1 5 0 m BASE M I

p%'KEq/ J r n I P A T H I r n l >

5. 7 Searching fo r Instructions The Search function is used to find a specified instructions in the Task program being

currently edited. This function allows the operator to change da ta such as welding

conditions without moving sequences. It can be used when the servo power is OFF.

Searching for the following instruction is possible:

Arc Star t (AS)/Arc End (AE)

* Weaving Star t (WFP and WAX)

a Tracking Star t (ST)/Tracking End (ET)

* Touch sensor related instructions (SFO, SF2, SF3, and SF51

External Control Input/Output (S, R , N, and F)

Program Jump/Call ( J P , J F , and CL)

Timer Wait (T)

OSACOM SUPER 8700 searches sequences below the cursor position. Therefore, it is

not possible t o search for instructions a t and above the cursor position.

After searching, you can add instructions, o r delete o r change the instruction you

specified. However, note that, if you add a Motion instruction, the position/attitude of

the manipulator where you a r e entering will be stored.

If you change the position/attitude, the position/attitude of the manipulator where

you a r e entering will not be stored. So, you can change only the parameters(i.e., Speed,

o r Lap on/off) of a Motion instruction.

5 - 6 4 Teaching

1(1 Searching fo r Instructions - 1. Press F1 (SEARCH) on the screen

which is displayed when block

operation is ~er formed. * 'Pressing o r allows

you to move sequences forward o r

backward without moving the

manipulator.

F1 ... Terminates the search. The position of the manipulator does not correspond to the current sequence.

F2 ... Searches for Arc Start / End instructions.

F3 ... Searches for Weaving Star t instructions.

F4 . . . Searches for Tracking Start/End instructions.

F5 .. . Searches for touch sensor related instructions.

F1 ... Searches for External Control Input/Output instructions.

F2 . .. Searches for Program Jump and Call instructions.

F3 ... Searches for Timer Time Wait instructions.

2. Select the instruction you want to

search for by using the function key.

In this example, press F2 key

(AS/AE).

OSACOM SUPER 8700 searches

for the specified instruction through

the Task program and displays it as

the current sequence. rQ

Teaching 5 - 6 5

T . M E C H . M L 4 TEACH P7 7 7 SQ NO-132 SERVOON SEARCH

092 P 1 0 0 % BASE M1 a093 L 1 5 0 m BASE MI > AS 180A 20.5s. 1.0s. 094*C1 150m BASE MI 095*C2 150m BASE M1 096*L 150m BASE M1

[ M A R K I I A S / A E I v l J S T / E T I m >

The sequence corresponding to the current position of the manipulator

is marked with @.

If the specified instruction does not exist, a message "NOT EXIST" appears a t the auxiliary display a rea on the current screen. *

This message will disappear af ter 1 second

3. Add, delete, o r change if necessary.

4. Press F1 (SO MARK) o r @ to terminate the search operat~on.

Pressing F1 (SQ MARK) causes the current sequence in the search mode to be treated as the current sequence. + Because the position of the manipulator differs from the data of the current sequence, take care when you perform block operation.

to terminate the

causes OSACOM SUPER 8700 to return to the original sequence. That is, the current sequence corresponds the position of the manipulator. *

T.MECII. M L 4 TEACH P7 7 7 SQ No.=1 3 2 SERVO ON SEARCH NOT^

092 P 100% BASE M1 >093 L 150m BASE M1

AS 180A 20.5V. 301x1

095*C2 150m BASE M1

WE 092 P 100% BASE M1

>093 L 150m BASE M1 AS 18OA 20.5V. 3Om

094*C1 150m BASE M1 095*C2 150m BASE M1

T.MECII .ML4 TEACH P7 7 7 SQNo.=l32 SERVO ON SEARCH

5 - 6 6 Teaching

j p T K i q M A R K / / ~ l ~ ~ ] >

092 P 100% BASE MI 093 L 150m BASE M1

> AS 180A 20.5V. 301x1 094*C1 15Om BASE MI 095*C2 150m BASE M I 096*L 150cm BASE M 1

Chapter 6 Automat ic Operat ion

/ Automatic operation is performed to execute Task programs . I I This chapter descrilies how to s tar t a Task program by I / Multi-station system or Direct program entry system. and how to I halt and restart the automatic operation .

Contents

6.1 Automatic Operation ..................................................................................................................................

6 2 Automatic Operation by the Multi-station System

6 2 1 Start Allocation ....................................................................................................................................... . .

6.2.2 Changing to Auto Mode and Starting Automatic Operation ..............................

6.2.3 Start Reserving and Callcelling ..................................................................................................

6.3 Automatic Operation by the Direct Program Entry System .......

6.4 Job End ...................................................................................................................................................................

6 5 Halt ......................................................................................................................................

6 6 Restart

6.6. 1 Restarting from Halted Point ....................................................................................................

6.6.2 Restarting from A Specified Start point ............................................................................

6 6.3 Overlap Restarting ................................................................................................................................

6.6.4 Restarting After Block Operation

6.6.5 Restarting from Halting during Execution of Task Instruction

6. A u t o m a t i c Operat ion

6. 1 Automatic Operation Automatic Operation is performed to execute Task programs specified from among the

created Task programs. To perform automatic operation, the following conditions must

be satisfied:

* The servo power is ON.

* The current mode is AUTO.

* Any one of Task program numbers 001 - 999 has been specified.

The manipulator exists in the Start Enable Area.

Depending on the attitude of the manipulator, automatic operation sometimes may not

be started. The range of the attitude which enables automatic operation to be started is

referred to as the Start Enable Area.

When the manipulator exists within the Start Enable Area, the LED of "READY" on

the teaching box lights.

The Start Enable Area varies according to the manipulator types.

Fig.6.1. The Start Enable Area of ALMEGA G series and W01

Automatic Operation 6 - 1

Fig.6.2. The Star t Enable Area of ALMEGA V series

The Star t Enable Area can be modified by setting "START ENABLE AREA" in the

user parameters for setting the system status.

* :Refer to "Setting the System Status", sevtion 2.1 in par t I1

6 - 2 Automatic Operation

6. 2 Automatic Operation by the Multi-station System The multi-station system allows the operator to s tar t a Task program and reserve,a

s tar t of another Task program by press the START button on the operating panel (or

starting box) installed a t each station. This feature enables multiple Task programs to

be sequentially started. Note that it is necessary to allocate Task program numbers to be

started in advance to the START button of each station.

Auto mode

In this system automatic operation is performed in accordance with the following

procedure:

Prepare the conditions to perform

automatic operation.

Teach mode

Press the START button. s Automatic operation 1

Perform star t allocation.

Y

Cancel auto mode interlock.

v

I - Start reservation I

-

I - Start cancellation I

Press the AUTO mode button.


- - Start reservation check

6.2. 1 Start Allocation

Storing a Task program number you want to s tar t to each station is referred to a s

Start Allocation. This operation is performed in Teach mode.

The allocated Task program numbers are held even after the control power is turned off.

H Setting start allocation

1. Press F4 (ALLOT) at the top

layer of Teach mode. *

2. Select the station number by I 4-) I

3. Enter the program number you

want t o start, by numeric keys.

4. When you finish the start

allocation, press RECORD key. 0 If you press RESET , YOU can 0

cancel all allocations you have set,

and the previous settings of Task

program numbers will be stored.


6.2.2 Changing to Auto Mode and Starting Automatic Operation

When you have finished the s tar t allocation, then you change to Auto mode and

perform automatic operation. Before changing to Auto, check that the manipulator

exists within the s tar t enable area.

II Changing to Auto mode and starting automatic operation

This step is not required if the

setting of "AUTO LOCK" * in the

user parameters for setting the

system status is OFF.


layer of Teach mode. .I)

2. Press the AUTO button on the

operating panel (or set the auto

mode input of input terminal ON).

Ir)

In this condition, you can perform

AX1 S ML4 TEACH

the following operations:

AUTO MODE INTERLOCK CANCELLED

- -

Switching or W F F ON/OFF

* Changing to TEACH mode

Starting automatic operation

If the conditions to s tar t

automatic operation a re not ready,

error messages appear:

When the servo power is OFF

* Turn the servo power ON.

* : Refer to "Setting the System Status", section 2.1 in part 11, and "ModesJ', in section

2.4 in part I .


When the manipulator is outside

the start enable area * Move the manipulator to within

the start enable area by manual manipulation.

3. Press the START button. + Automatic operation will start .

6.2.3 Start Reservation and Cancellation (1) Making Start Reservations

When automatic operation is running a t another station, pressing the START

button of a station causes the Task program allocated to this station to enter the

reserved state. When pressed, the START button flickers. It is possible to make s ta r t

reservations for multiple stations. Reserved Task programs a r e automatically

started in sequence (in order by reservation) each time automatic operation is

finished a t one station.

The operator can list the reserved Task programs on the teaching box. OSACOM

SUPER 8700 displays station numbers and allocated Task program numbers in order

by reservation.

@ Note I

I It is not possible to reserve a Task program being currently running by automatic operation.

(2) Cancelling Start Reservations

The operator can cancel s tar t reservations of Task programs. Even if one of

multiple reservations is cancelled, the rest are still effective.

(Example)

Task program 001 (referred to as PO01 in the following) is running by automatic

operation, and P002, P003, and PO04 are reserved in this order.

When 003 is cancelled, automatic operation is performed to execute each of the

reserved PO02 and PO04 in this order after PO01 is completed.


II Making and cancelling start reservations

During automatic operation the

screen look like the one shown on

the right. I)

1. When automatic operation is

running a t another station, press

the START button on the

operating panel (or starting box).

The Task program allocated to

the station whose START button

was pressed, will enter the

reserved state.

2. I f you press F1 (RESERVE)

during automatic operation, you

can view the currently reserved

stations and Task program

numbers. @

You can return to the original

screen when tlie Task program

being currently running by

automatic operation is completed,

o r by pressing RESET 0 3. To cancel a start reservation,

press the START button of the

relevant station.

Automatic Operation 6.- 7

3 Automatic Operation by the Direct Program Entry System The direct program entry system allows the operator to s t a r t automatic operation by

directly specifying Task program numbers to specialized logical input ports. Automatic

operation is started when a Star t input signal is entered.

There a re two ways of specifying Task program numbers, for which specialized logical

input ports a r e provided:

BCD code entry

Binary code entry

(1) The BCD code entry

Task program numbers ranging from 001 through 799 a r e available.

The relation between specialized logical input ports and Task program numbers is

shown below:

Specialized logical input port

/ Hundred 1 Ten 1 One 1

(2) The binary code entry

Task programs numbers ranging from 001 through 999 a re available. Because of

binary entry, for example, when only specialized logical input number 3 receives a n

input, the program number is two cubed, 8. If multiple specialized logical input port

numbers, the total of each sum is the program number.

The relation between specialized logical input ports and Task program numbers is

shown below:

(Example)

Task program number

Specialized logical input port

1 1 1

0 1 0

[Example) Task program number


1 0 0 1

0 1 1 0

1 0 0 1 799

0 1 0 1 - 265

In this system automatic operations is performed according to the following procedure:

Cancel auto mode interlock.

Teach mode

Auto mode

- V

Prepare the conditions to

perform automatic operation.

-

Enter a Task program number.

Press the AUTO mode button.

(Auto Mode input ON)

1 Set the s t a r t input ON.

Automatic Operation 1 Changing to Auto mode and starting automatic operation

This step is not required if the setting of "AUTO LOCK" * in the user parameters for setting the system s ta tus is OFF.

1. Press F5 (LOCK) at the top layer

of Teach mode. .Is,


Automat i c Operat ion 6 - 9

AX1 S ML4 TEACH

AUTO MODE INTERLOCK CANCELLED

2. Press the AUTO button on the

operating panel (or set the auto

mode input of input terminal ON).

* In this condition, you can perform

the following operations:

* Inching/retracting

* Changing to Teach mode

* Starting automatic operation

If the conditions to s tar t

automatic operation are not ready,

error messages appear:

When the servo power is OFF * Turn the servo power ON.

When the man i~u la to r is outside

the start enable area * Move the manipulator to within

the start enable area by manual

manipulation.

3. Enter the Task program number

into specialized logical input ports.

4. Set the Start input ON. * Now, automatic operation is

started.

AUTO

SERVO ON

6 - 1 0 Automatic Operation

AUTO. START READY

PUSH START PB.

AUTO PO 0 1 SQ No.=9 9 9 SERVO ON PRESENT 5 3

AUTO RUNNING

6 . 4 Job End The termination of automatic operation of the specified Task program programs

(execution of the END instruction) is referred to a s Job End, which: - Stops the current weaving or welding process.

* Counts the throughput and reports it on the teaching box.

* Starts the next reserved Task program (if specified by the multi-station system).

The display at the time of Job End At the time of Job End the screen

looks like the one shown on the right.

Ir)

The figure on the 7th line a t the main display area shows the throughput. I t is possible to check it also in the operation of s tar t allocation (provided that the multi-station system is employed). The upper limit is 30000.

6. 5 Halt Automatic operation can be halted by a key operation or an external signal input in a

condition which enables continuation restart.

(1) Halt during welding * When the arc is not generated during a welding process

Immediately the welding process being stopped, the automatic operation halts. * During a crater process

After the current crater process being completed, the automatic operation halts. During a welding process except the above

Immediately the process being stopped, the automatic operation halts.

(2) Halt during weaving The center stop process being performed, the automatic operation halts.

Weaving path

\ Halted point

Fig.6.3 Center stop

The center stop means a return to the main path (where weaving is not performed).

Automatic Operation 6 - 1 1

(3) Halt during waiting for Timer time


(4) Halt during an external control input or output

Waiting for external control input


External control output with a delay timer setting


(5) During inching or retracting

Immediately the inching o r retracting being stopped, automatic operation halts.

@ Note \

I Data contained in the logic table' are executed even in the halted state.

--

Halt when the Multi-station system is employed

Press o r the STOP button on u

the operation panel (or starting box).

The halted sequence is indicated on

the screen.

Halt when the Direct Program Entry system is employed

Set a Start input OFF. * The halted sequence is indicated on

the screen.

* : Refer to instruction manual "Interface with Jig"


6. 6 Restart

There a re several ways of restarting automatic operation:

- Restarting from a halted point

* Restarting after performing manual manipulation from a halted point and specifying

a s tar t point.

* Overlap Restarting

Restarting after performing block operation

Important \

1) When a s tar t reservation has been made by the multi-station system, in the halted state, pressing the START button of the reserved station causes the

I reservation to be cancelled.

2) In the Direct Program Entry system, setting the s tar t input ON allows you to restart automatic operation, but, in this case, the halted Task program will be restarted, but not the Task program you specified.

3) If automatic operation is halted when a Task program a t the jump destination o r a called program is running in accordance with the external control input condition in the original Task program, restarting causes the halted Task program to be executed, regardless of the state of the external control input.

6 .6.1 Restarting from A Halted Point

Restarting allows the operator to continue the operation from a halted point.

II1 Restarting when the Multi-station system is employed

Press the START button of the station where the Task program is in the halted state.

The Task program in the halted state will be restarted.

II Restarting when the Direct Program Entry system is employed Set the start input ON. Then, the Task program in the

halted state will be restarted.


6. 6.2 Restarting f rom A Specified Start Point

It is possible to restart automatic operation from another point by performing

manual manipulation from a halted point. In this case, the manipulator moves to the

target point from that point. The movement depends on data contained in the halted

sequence. For example, the manipulator moves by Linear Interpolation if the halted

sequence contains L, o r by Positioning if P.

+---Manipulator stops. (Stopped point) P , AS

Manual manipulation

Path when automatic operation is restarted

Fig. 6.4 Restarting from a specified s tar t point

If a s ta r t point is not specified after manual manipulation is performed, the

manipulator restarts the operation after returning to the stopped point by positioning

movement. The speed is the setting of "SPEED TO PM" in the user parameters for

setting the system status.

EIll Setting a start point

In the halted state, the screen


right. *

1. Press F3 (STRT PO). *

T.MECH. M H 3 AUTO P O 0 1 SQ No.=9 9 9 SERVO ON HOLDING STN 1

2. Move the manipulator by

manual manipulation.

0 5 1 P 1 0 0 % BASE M 1 0 5 2 P 9 0 % BASE M 1

> 0 5 3 L 2 5 0 ~ x 1 BASE M 1 S 0 1 2 D L = O . O s

0 5 4 L 1 5 0 m BASE M 1 0 5 5 C 1 1 5 0 m BASE M 1

T.MECII. M H 3 AUTO P O 0 1 SQ N0.=9 9 9 SERVO ON HOLD I NG STN 1


pzizivq / r s ' i T q P O / / R E T R E A T I I S Q ]

0 5 1 P 1 0 0 % BASE M 1 0 5 2 P 9 0 % BASE M 1

> 0 5 3 L 2 5 0 w BASE M I S 0 1 2 D L = O . O s

0 5 4 L 1 5 0 m BASE M 1 0 5 5 C l 1 5 0 m BASE M 1

PUSH F1 TO SET RESTART POINT.

iposSEi/

3. Press F1 (POS SET) -, the

START button on the operating

panel (or starting box).

The operation will be restarted

from the position you set.

6.6.3 Overlap Restarting

The overlap restarting is a way of restarting the operation after the manipulator is

moved back from a halted point by a given distance. A distance is set in "RESTART

RETRACT" of the user parameters for setting the system status.

This feature is available when the halted sequence contains an Interpolation

instruction, such a s L or C.

@ Important \

The overlap distance is up to the point in the previous sequence, and moving back further is not possible. In the following example, the manipulator travels back only 10mm even if the setting is 15mm.

Overlap restarting t---

-. I f Halted point

~--10mm-+l Moving direction

I Fig.6.5. Overlap Restarting I

Ell Specifying an overlap restarting

In the halted state, the screen looks like the one shown on the right: * 1. Press F4 (RETREAT).

2. Press the START button on the operation box (or starting box).

The operation will be restarted after the manipulator travels back the distance setting.

* : Refer to "Setting the System status", section 2.1 in part 11.


6. 6.4 Restarting After Block Operation

Before restarting the operation, it is possible to perform block operation in the

halted. However, performing a sequence jump is not possible.

Performing block operation in the halted state

In the halted state, the screen


right: *

1. Press F3 (STRT PO). * In this condition, you can do

block operation.

BLOCK 2 Press I or1 1 , while

3. Press F1(POS SET).

When you restart, the

manipulator moves from the point

where you stopped block operation.

If you want to change taught data,

use the Path function*.

@ Important If you want to specify a restart point after halting during execution of an Circular Interpolation instruction (C1 or C2), perform block operation. If you specify a restart point by manual manipulation, the circular path may change a t the time of restarting.

'.

* : Refer to "Path Function", section 3.5 in part II .


6. 6. 5 Restarting when Halting dur ing Execution of Task Instruction

(1) Halting during a welding process

Operations a t the time restarting are listed in the following table:

Table 6.1. Operations a t restating when halting during a welding process

During preflow

Haltinc Timing.

Resetting the preflow time and then performing preflow from the beginning.

Operation a t Restarting.

During wire-slow down by Scratch s tar t During crater Drocess During online modification*

Restarting with the current welding conditions from the halted point. Execution of the next instruction because the crater Drocess has been com~leted before halting. Restarting with the previous welding conditions not the welding conditions being modified

During any other 1 Restarting with the current welding conditions. welding process

(2) Halt during weaving

As the manipulator returns to a position on the main path when halted, it s tar ts

weaving from that position.

/ Weaving path Stop P sr

Center stop

Fig.6.6 Restarting weaving

(3) Halt during execution of Timer o r the waiting time of an external control input

Restarting causes the time to be recounted from the beginning.

(4) Halt during execution of Delay Timer of an external control output

Restarting causes the external control output instruction to be executed after the

manipulator return to the position of a Motion instruction which is taught

immediately before the external control output instruction (S and R)

* : Refer to "Online Modifications", section 3.6 in part I[.


Chap te r 7 Edi t ing Fi les

This chapter explains how to create Welding Condition files and

Weaving Condition files.

Contents

7. Ed i t i ng Fi les Task programs, Welding Condition data, etc. are treated a s files. Files that can be edited

and created are the following:

Table 7.1. Types of files that can be edited and created

Type of File Task program

Seauencer file 1 Instruction Manual "Interfacing with Jig"

Reference for Editing and Creating "Teaching", chapter 5 in part 1

Welding Condition file Weavincr Condition file

User Parameter file I "User Parameters", chapter 2 in part 2

"Editing Welding Condition Files", section 7.2. in this chapter "Editing Weaving Condition Files", section 7.2. in this c h a ~ t e r

Welding Characteristic file I "User Parameters", chapter 2 in part 2 System Parameter file I Not edited

Multi-pass Welding Condition file

Offset file Laser Sensor file

Not used

Instruction Manual "Options"

Welding Task file I Under development

This chapter gives detailed explanations of operations for editing Welding Condition files and Weaving Condition files. Once welding conditions and weaving conditions a re stored in files, you can use them for teaching by simply specifying file numbers, which allows you can save teaching time.

7. 1 Selecting Files Files a re selected by using the function keys to which various types of files have been

assigned.

II Select ing f i l es

1. Press F2 (EDIT) at the top layer

of Teach mode. * 2. Select, by the function key, the [JOB( (OFFSITI(SpiETx1

file type you want to edit. /S]EM/ F1 . . . Creates/corrects Task

programs. F2 .. . Edits Weaving Condition

files. (See section 7.3.) F3 ... Edits Weaving Pattern files.

(Under development) F4 ... Edits Arc Start Condition

files. (See section 7.2.) F5 ... Edits Arc End Condition

files. (See section 7.2.)

Editing Files 7 - 1

F1 ... Edits Welding Task files. (Under development)

F3 ... Edits Offset files. (Option)

F4 . . . Edits Sequencer files. F5 ... Edits Laser Sensor

files. (Option)

[ [ F . . Edits Multi-pass Arc Start Condition files.

(Not used) F2 ... Edits Multi-pass Arc

End Condition files. (Not used)

7 - 2 Editing Files

7. 2 Editing Welding Condition Files There a re 2 types of Welding Condition files:

- Arc Start Condition file(ASC file)

Arc End Condition file(AEC file)

If an existing file number is entered, OSACOM SUPER 8700 displays the contents of

that file.

If a new file number is entered, OSACOM SUPER 8700 displays the default settings.

Edit files accordingly.

numeric keys, and set condition

data.

II Editing Arc Start Condition files

For individual controlled power unit

1. Press F4 (AS FILE). *

(1) Move the cursor to the item you - want to modify, by using

I. 18Jor *

2 . Enter a file number by using

TEACH A S C -

(2) Enter the condition data by

ENTER F I L E NUMBER

using numeric keys.

For Synergic controlled power unit

Set condition data in the same

manner a s that for individually

coiltrolled power unit.

When you place the cursor (>) a t

"VOLT. ADJUST", you can switch

between + and-by pressing F1 (+/--I. Irr)

Editing Files 7 - 3

For TIG power unit

Set condition da ta in the same

manner as that for individually I > WELDING CURRENT 180A TEACH WIRE SPEED 5 Om ASCl 0 WELD SPEED 150m

controlled power unit * I I I

3. Press RECORD key to store the 0 condition data you entered.

If you want to cancel the data you

just entered, press RESET instead. 0 The previous setting will remain

unchanged.

If you press RESET when creating a 0 new file. the file will not be created.

2. Enter a file number by using

Editing Arc End Condition files


1. Press F5 (AE FILE). *

data.

For individually controlled power unit

(1) Move the cursor to the item you

want t o modify, by u s i n g m l o r

TEACH AEC -

(2) Enter the condition data by

ENTER FILE NUMBER

using numeric keys. *

For Synergic controlled power unit

Set condition data in the same

manner as that for individually

controlled power unit.

When you place the cursor (>) at

"VOLT. ADJUST", you can switch

between+and- by pressing F1 (+/-I . *

7 - 4 Editing Files

I I > CRATER CURRENT 180A TEACH AEClO

CRATER VOLTAGE 2 0.OV CRATER TIME 1.0 s. POSTFLOW TIME 0.0 S .

For TIG power unit

Set condition data in the same I

3. Press RECORD key to store the 0

manner as that for individually

.r) controlled power unit.

condition data you entered.

If you want to cancel the da ta you

TEACH A E C l 0

just entered, press RESET instead. 0

> CRATER CURRENT 1 2 0 ~ WIRE RETRACT 1.0 s. CRATER T I M E 1.0 S. POSTFLOW T I M E 0.0 s.

The previous setting will remain

unchanged.

If you press RESET when creating 0 a new file, the file will not be

created.

Editing Files 7 - 5

7. 3 Editing Weaving Condition Files There a re 2 types of Weaving Condition files:

* Fixed Pattern Weaving file (WFP file)

Axis Weaving file (WAX file)

You cannot edit the other type of Weaving Condition file as it is under development. If

an existing file number is entered, OSACOM SUPER 8700 displays the contents of that

file on the Edit screen. If a new file number is entered, OSACOM SUPER 8700 displays

the default settings. Edit files accordingly.

H Editing Fixed Pattern Weaving files

1. Press F2 (WS FILE). *

2. Press F1 (FIXED). I ENTER F I L E NUMBER * I TEACH



data. * (1) Move the cursor to the item you

want t o modify, by using numeric

keys.

(2) Set the condition data.

Setting the type of function

Select linear function o r sine curve

as a weaving function by the function

key.

Setting an amplitude

Set each half cycle of an weaving

amplitude in the unit of O . l m m by using

numeric keys.

1/4 FREQ STOP 3 / 4 FREQ STOP

Setting a frequency

Set a weaving frequency in the unit

of 0.1 Hz by using numeric keys.

Set each stopping time

Set a s t ~ p p i n g time a t each point in

the unit of 0.lsec.

4. Press RECORD t o store the condition 0 data you entered.

If you want to cancel the da ta you

just entered, press RESET instead. 0 The previous setting will remain

unchanged.

If you press RESET when creating a 0 new file, the file will not be created.

H Setting Axis Weaving files

1. Press F2 (WS FILE).

2. Press F4 (JOINT)



data. * (1) Highlight the item you want to --

modify, by using M91c3 m, a n d m ] .

(2) Set the condition data.

Setting a frequency

Set a weaving frequency in the unit

of O.1Hz by using numeric keys.

Edit ing Fi les 7 - 7

TEACH WAX -

ENTER FILE NUMBER

Setting weaving axes and amplitudes

Set the numbers of weaving axes

and amplitudes by using numeric keys.

For n o n - ~ ~ e a ~ i n g axes, set the

aniplitudes a t 0. Note that the unit of

amplitude is a degree.

Setting each stopping time

Set stopping time a t each point in

the unit of 0.lsec.

4. Press flECORD to store the condition 0 data you entered.

If you want to cancel the data you

just entered, RESET instead. 0 The previous setting will remain

unchanged.

If you press RESET when creating a 0 new file, the file will not be created.

7 - 8 Editing Files

Chapter 8 File Operat ions

This chapter explains how to copy. delete. and rename files .

Contents

8. F i le Operat ions Functions used to deal with files include:

Edit (modify) files

* List files

* Copy files - Delete files - Rename files

Operations for editing files have been discussed in chapters 5 and 7. This chapter gives detailed explanations of file operations except editing files.

These functions a re operated from the List screen for each of the following file types: * Task program

Welding Condition file Weaving Condition file

* Sequencer file

Deviation Correction file (option)

* Offset file (option)

* Laser Sensor file (option) - Search Pattern file (option)

8. 1 Listing Files The List function allows the operator to list created files of the same file type. A list

contains, file type, creation dates, and life sizes (only for Task program files), in

addition to file names. Though files are listed in order by number, only Task programs

can be also listed in order by creation date.'

III Listing files

1. Press F3 (FILE) at the top layer

of Teach mode. I)

F1 ... Lists Task programs F2 ... List Welding Condition

files F3 ... List Weaving Condition

files F4 ... List Sequencer files F5 . . . List Deviation Correction

files

1 . List Offset files F2 ... List Laser Sensor files F3 ... List Search Pattern files

* : Refer to "Setting the System Status", section 2.1 in part 11.

File Operations 8 - 1

2. To select the file type you want to

list, press the relevant function key.

When F1 (TEACH) is pressed +

The Task programs a re listed.

When F2 (WELD) is pressed * The ASC files (Arc Star t Condition

files) and AEC files (Arc End Condition files) a re listed in this order.

When F3 (WEAVE) is pressed * The WFP files (Fixed Pattern

Weaving files) and WAX files (Axis Weaving files) a re listed in this order.

When F4 (SO) is pressed

The Sequencer files a r e listed

TEACH

LSERVO

FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE

> pm'q 66 92-04-01 PO02 5 5 92-03-29 PO 0 3 1 3 0 92-03-28

TEACH

L%ERYO OF^

/RoLL[ pixr-x] 1pFT-i-q -1 >

FILE LIST WELDING FILE FILE DATE >= 9 2-0 3-0 3 AECO 1 9 2-0 2-2 8 AECO 2 9 2-0 2-2 9 AECO 3 9 2-0 3-0 1 AECO 7 9 2-0 3-0 7

TEACH

L S E R Y O ~

8 - 2 File Operations

j r i z - i E q ~ I ~ T r n l / D E L / >

FILE LIST WEAVING FILE FILE DATE

>I?N_PPOII 9 2-0 3-0 3 WAX 0 2 9 2-0 3-2 1 WAXO 3 9 2-0 3-1 1

TEACH

SERVO OF^

[RoLL]IROLLDN]IEDm/m(DEL/ >

FILE LIST SQ PRG. FILE FILE DATE > SQFl 9 3-1 1-2 6 SQF 2 93-11-26 SQF 3 9 3-1 1-2 6

p i E K - i q ~ j ~ ~ ~ I >

3. Move the cursor (>) t o the file

you want, by pressing [a or I

, and select the operation you

want to perform, by the function

key.

F1 ... Moves one page forward. (The screen does not change if the last page is shown.)

F2 ... Moves one page back. (The screen does not change if the first page is shown.)

F3 ... Edits files. * F4 ... Copies files.

(See section 8.2.) F5 ... Deletes files.

(See section 8.3.)

a F1 ... Rename files. (See section 8.4.)

* : Refer to "Editing Files", chapter 7 in part I


8. 2 Copying Files Tlie Copy function allows the operator to make copies of specified files.

If the specified file does not exist, a n error occurs. If a file with the same name already

exists, OSACOM SUPER 8700 asks you to confirm overwriting.

Copying f i les

1. Move the cursor (>) to the copy

source file by pressing

*

2. Press F4 (COPY).

TEACH

LSERVO OPF~

3. Enter the name of a file you want

to make, by numeric keys. *

FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE PO01 55 92-03-20 PO02 5 5 92-03-29

>-1 1 3 0 92-03-28 PO04 125 92-05-07 PO07 87 92-04-03

4. Press F1 (EXECUTE) to copy.

If the file name you specified

already exists, a message

"OVERWRITE ? " is displayed. * Select by the Function key:

/ R o L L l / R O L L l ~ l ~ j I D E L j >

F1 ... Overwrites. F2 .. . Specifies a file name

again without overwriting.

TEACH

[SERVO OFEJ

FILE COPY

COPY FILE 1031 TO P -

TEACH

SERVO OFF^

8 - 4 F i l e Operations

FILE COPY

COPY FILE

TO PO o 4

TEACH

LSERVO OFF^

-1

FILE COPY

COPY FILE

TO PO04

SAME FILE EXISTS. OVERWRITE?

/EXECUSEIpmm]

8. 3 Deleting Files The Delete function allows the operator to delete specified files.

Before deleting, OSACOM SUPER 8700 asks you to check the file name you specified.

If the specified file does not exist, a n er ror occurs.

IZI De le t i ng f i l e s

1. Move the cursor (>) to the file

you want to delete, by pressing

r)

2. Press F5 (DELI.

TEACH

SERVO O P F ~

3. Press F1 (EXECUTE). .I)

FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE P O 0 1 5 5 9 2 - 0 3 - 2 0 PO 0 2 5 5 9 2 - 0 3 - 2 9

>I- 1 3 0 9 2 - 0 3 - 2 8 PO 0 4 1 2 5 9 2 - 0 5 - 0 7 PO 0 7 8 7 9 2 - 0 4 - 0 3

4. After you check the file name,

p i F i r i q ~ D N / I E D ~ l ~ I ~ j >

press F1 (CONFIRM) to delete the

file.

If you want to cancel the deletion,

press RESET . 0


TEACH

b ~ ~ ~ o OFFJ

FILE DELETION DELETE FILE Lm]

-1

8. 4 Renaming Files The Rename function allows the operator to rename specified files.

If the specified file does not exist, a n er ror occurs. If a file with the same name already

exists, OSACOM SUPER 8700 asks you to confirm overwriting.

Renaming fi les

1. Move the cursor (>) to the file

you want to rename, by pressing

2 . Press ~1 (RENAME). *

3. Enter the new name you want to

give, by numeric keys.

4. Press F1 (EXECUTE) to rename

the file. * If the file you specified already

exists, a message "OVERWRITE ? "

is displayed.

Select by the Function key:

F1 ... Overwrites. F2 ... Specifies a file name again

without overwriting.

8 - 6 File Operations

TEACH

~ E R V Q ~

FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE P O 0 l 5 5 9 2 - 0 3 - 2 0 P O 0 2 5 5 9 2 - 0 3 - 2 9

>= 1 3 0 9 2 - 0 3 - 2 8 P O 0 4 1 2 5 9 2 - 0 5 - 0 7 P O 0 7 8 7 9 2 - 0 4 - 0 3

TEACH

SERVO OFFJ

/RoLLUP/rROLLDNJIEDrnT//COPYIrnI >

FILE RENAMING ORIGINAL NAME

RENAME TO P O 0 4

SAME FILE EXISTS. OVERWRITE?

-\/NO]

8. 5 Restrictions on File Operations

- If you perform file operations (copy, delete, and rename) from the List screen and

then list files, the file o r files you dealt with may not be correctly listed (e.g., the file o r

files you have deleted may be listed or a copy of the file you have made may not be

listed). In this case, terminate List once and specify again.

* Depending on file types, some functions are not available. For details, see the list below:

0 : Operable, X : Inoperable

File Type

Task program

Welding Condition file Weaving Condition file Laser Sensor file

Sequencer file

Offset file

Deviation Correction file Search Pattern file User Parameter filee System Parameter file Welding Chara- cteristic file

* : Represents a figure.

0 Note Search Pattern file SF2M01-05 can not be deleted.

Table 8.1. Restrictions

File Name

P * * *

ASC* *. AEC* *

W A X * * , W F P * *

SRF *

SQF *

OFS* *

DEV * * *

SF2M * * USEMAIN,

etc.

# * * * - * * *

$ WTBD * *


on file

Edit

0

0

x

x

0

0

0

operations

Copy

0

0

0

x

X

X

X

Delete

0 0 0 0

0 0 0 0

0

0 0 0 0

0

0 0 0 0

0

6

X

X

x

List

0

0

0

0

X

X

x

Rename

0

0

0

0

0

0

0

x

X

X

x

C h a p t e r 9 Cance l l i ng E m e r g e n c y S t o p a n d S h o c k Sensor

1 This chapter explains how to cancel the emergency stop and the shock sensor. I

Contents

9 1 Emergency Stop ................................................................................................................................................. 9-1

9.2 shock sensor ......................................................................................................................................................... g - 2

9.2.1 ~ ~ ~ ~ ~ l l i ~ ~ the shock sensor 9-2

9.2.2 Before Automatic Operation and After Completion of the Job ......................... 9 - 2

g 2 3 In Teach Mode ............................................................................................................................................ g - 3 . .

9.2.4 Correcting Taught Positions Where the Shock Sensor Operates ...................... 9-3

9. Cancel l ing Emergency Stop and Shock Sensor 9. I Emergency Stop

When emergency stop is entered, the servo power is shut off and the manipulator

immediately stops.

Cancel I ing Emergency Stop

1. When emergency stop is entered,

the window shown on the right

appears on the screen. m)

2. Cancel the emergency stop. .I)

3. Turn the servo power on.

* To restart automatic operation,

press the START button.

In Teach mode, manual

manipulation is executable.

AXIS M L 4 TEACH P 7 7 7 SQ No.=132 ISERVO OFF^

Cancelling Emergency Stop and Shock Sensor 9 - 1

WE 0 8 4 P 1 0 0 % EhIERGENCSTOP

> 0 8 5 L 1 5 0 m 0 8 6 L IOOcat BASE M I 0 8 7 C I 1 5 0 m BASE M I 0 8 8 C 2 1 5 O m BASE M I

AXIS M L 4 TEACH P 7 7 7 SQ No.=132

~ B R V D QFFJ

pzEi"lIJlISHIFTJIPATH/JPATH] >

WE 0 8 4 P 1 0 0 % BASE M I

> 0 8 5 L 1 5 0 m BASE M I 0 8 6 L l O O m BASE M I 0 8 7 C I 1 5 0 ~ BASE M I 0 8 8 C 2 1 5 0 m BASE M 1

pziEqI JWISHIFT/IPATH//PATH>

9. 2 Shock Sensor The way of handling and recovering from Shock Sensor depends on the operating

condition of the manipulator a t the time the shock sensor operated.

9.2.1 Cancell ing the shock sensor

During Automatic Operation

1. When the shock sensor operates,

the servo power is shut of f and

the manipulator enters the halted

state. +

2 Press @ and then turn on

the servo power. nrl,

3. Cancel the shock sensor by


*

4. Pressing the START button

allows you to restart the

operation.

9 .2 .2 Before Automatic Operation and Af ter Completion o f the Job

Cancelling the shock sensor

1. Even i f the shock sensor

operates, the servo power is not

shut off. *

AUTO PO 0 1 SQ No.=999 SERVO ON

STN 1

0 5 1 P 100% 052 P 9096 SWOC@SBESOR

> a 5 3 L 250011 S 012 DL=O.Os

054 L 150m BASE MI 055 C1 150m BASE M1

2. Press @.

/p.EEq

AUTO

SERVO ON

IMPOSSIBLE TO AUT SNOCR ALARM

SHOCK SENSOR ON

9 - 2 Cancell ing Emergency Stop and Shock Sensor

AUTO

SERVO ON

IMPOSSIBLE TO AUT SHOCK SENSOR

SHOCK SENSOR ON



II)

9.2.3 In Teach Mode

(I11 Cancelling the shock sensor

1. Even if the shock sensor

operates, the servo power is not

shut off. 119



*

@ Note When the shock sensor operates, block operation cannot be performed.

9.2.4 Correcting Taught Positions Where the Shock Sensor Operates

The shock sensor may operate a t positions you taught. This sectio~l explains how to

correct such positions.

llBl Correcting taught positions where the shock sensor operates


the sequence followed by the

sequence which contains the

position to be corrected. +

2. Press Fl(SEARCI-1)

Cancel l ing Emergency Stop and Shock Sensor 9 - 3

AXIS M H 3 TEACH P 7 7 7 SQ No.=1 3 2 SERVO ON

0 9 2 P 1 0 0 % BASE M 1 0 9 3 P 1 0 0 % BASE M I

> 0 9 4 L l o o m BASE M 1 AS ASCOl

0 9 5 * L 1 0 0 m BASE M I 0 9 6 * L l o o m BASE M I

[TEEGil JJ] rziKFi=/IPATH/ -1 >

3. Move the cursor, by pressing

[, to the sequence to be

corrected. *

4. Press F1 (SO MARK). *

AXIS MH3 TEACH P7 7 7 SQ Na=132 SERVO ON

5. Move the manipulator, by

a094 P 10096 BASE M I AS ASCOl

>095*L l0Ocm BASE M1 096*L 100m BASE M1 097*L 100m BASE MI

AE AECOI

AXIS MH3 TEACH P7 7 7 SQ No.=132 SERVO ON


[ s a M A R X / r n / I S / / S T / E T I I S / >

0 9 4 P 10096 BASE M1 AS ASCOl

>095*L 1 O O w BASE M1 096*L 10 0 m BASE M 1 097*L 1 O O m BASE M1

AE AECOl

position/attitude you want to

I s E A R C H / ~ ] j l / - - F T q ~ >

teach, and press RECORD . 0

9 - 4 Cancell ing Emergency Stop and Shock Sensor

ication Features and Functions b-

Chapter 1 Appl icat ion Fea tu re and Funct ions Used in Teach Mode

1 This chapter describes application features and functions. s u c l ~ as

1 the Read Positions feature and the Home Stop function. used in I Teach mode .

Contents

1.1 Application Features and Functions Used for Manual Operations .........

1 . 1. 1 Displaying Angles and Coordinates (Reading Positions)

1 1 2 The 'Home Stop Function ................................................................................................................... . . 1.1.3 The Work Enable Area

1.1.4 The Reference Joint Angles a t the Star t Enable Area

1 . 1 5 Setting Manual Speeds

1.2 Application Features and Functions Used for Teaching .................................................

1 . 2 . 1 Logical Check on Task Programs

1 2 2 Confirmation of Terminating Teaching ................................................................................ . .

1 2.3 setting the way of performing ~ l ~ ~ k operation ..........................................................

1.2.4 Cursor Indicatioll of the State of Block Operation

1 . 2.5 setting ~ l ~ ~ k operatillg speeds

1.2.6 Checking and Modifying Condition Files during Block Operation ..................

1. App l i ca t ion Features and Funct ion Used in Teach Mode 1. 1 Application Features and Functions Used for Manual Operations

1. 1. 1 Displaying Angles and Coordinates (Reading Positions)

OSACOM SUPER 8700 displays the joint angle of each axis of the manipulator

measured from the reference position and its coordinate value in the currently specified

coordinate system.

O T h i s feature is useful t o modi fy the s tar t enable area*' of A L M E G A G series o r

W01, the home stop position*', and the work enable area*3.

@ Important \

For AIJMEGA V series, the angles read by this feature cannot be used to set

the s t a r t enable a rea (because the reference joint angles a t the s t a r t enable

a rea a r e different). For details, refer to "The Reference Joint Angles for the

Star t Enable Area", section 1.1.4.

Reading Positions

In Teach mode, hold READ down together with 0 While you a r e holding the keys

down, the rotating angle of each

axis and the coordinate value in the

currently specified coordinate

system a r e displayed on the left and

right sides of the screen,

respectively. C o o r d ~ n a t c values in

J o i n t Angle 01 each ax i s the currently specificci

T.MECA. MH4 TEACH

SERVO ON

coord ina te sys tem

ANG IAXS : 3 6.5 COORDX: 9 8 1.7 2AXS:- 7.9 Y: 84.8 3AXS : -7 3.2 Z: 11.5 4AXS: 54.9 a : 18.2 5AXS: 86.4 b : 3.6

C :-180.1

The reference positions to display the angles a r e shown in Fig.l.1 and Fig.l.2.

I I

* 1: Refer to "The Reference Joint Angles a t the Star t Enable Area", section 1.1.4 in

this part .

* 2: Refer to "The Home Stop Function", section 1.1.2 in this par t

* 3: Refer to "The Work Enable Area", section 1.1.3 in this part .

Application Features and Functions Used in Teach Mode 1 - 1

Axis 4 ' 0"

The reference positions of Axes 1, 3, and 4

The reference position of Axis 2

0"


Axis 1: 0" a t the front position

Axis 2: 0" a t the horizontal position

Axis 3: 0" a t the position where Axes 1 and 3 align.


Axis 5: 0" a t the directly downward position.

Fig.l.1. The reference positions of ALMEGA G series and W01

1 - 2 Application Features and Functions Used in Teach Mode


Axis 2

-I-


The perpendicular line




Axis 2: 0" a t the vertical position

Axis 3: 90" a t the angle between the upper and lower a rms

(The angle of Axis 3 is expressed as a n angle between the upper and lower arms.)



Axis 6: 0" a t the front position.

Fig.l.2. The reference positions of ALMEGA V series


1. 1 .2 The Home Stop Function The Home Stop function allows the operator to stop the manipulator during manual

maiiipulatioi~ a t a position which has been stored in advance. The home stop ON/OFF aind position a re set in "SPECIFIED POINT HOLD" of the user parameters for setting the system status*.

There a r e two way of setting the position: * Directly entering numeric values of the joint angles o r Base coordinate values a t

a stopping position to be stored. First , move the manipulator to the stopping position you want to store, by

performing manual manipulation, and read the joint angles o r Base coordinate values by using the read positions feature. Then, enter these values.

* Moving the manipulator to a stopping position to be stored. Move the manipulator to the stopping position you want to store, by manual

nlanipulation, and set that position as the home position. For details of how to set, refer to "Setting the Home Position" section 2.1.1. Axis 5 of ALMEGA G series and W01 has the default setting of the Home Position

(only when Axis movement is specified) shown below:

When Axis 5 positions directly downward, the operation stops. To move the manipulator in the same direction again, release the key once and press it again.

Perpendicular line

Fig.l.3 The Home position of ALMEGA G series and W01

@This feature is useful to f ix the torch attitude.

Note \

If the system has multiple mechanisms, the Home Stop feature is available only to the mechanism being selected.

\ J

* : Refer to "Setting the System Status", section 2.1 in this part .


1.1.3 The Work Enable Area

There is a limitation of the working range of each axis of the manipulator.

The a rea where the manipulator can work is referred to a s the Work Enable Area.

This a rea can be changed by modifying the setting of "MOVABLE AREA" * ' in the

user parameters for setting the system status. However, do not modify the settings of

the axes except Axis 1.

The default setting of Axis 1 is shown below:

Table 1.1. Default settings of the Axis 1 work enable a rea

Manipulator Type 1 Default Setting

1. 1.4 The Reference Joint Angles at the Start Enable Area

The Star t Enable Area can be changed by modifying the setting of "START ENABLE

AREA"*' in the user parameters fo r setting the system status.

In the case of ALMEGA V series, however, it is not possible to directly enter the

joint angles read by using the read posltion feature (but possible for ALMEGA G

series and W01).

The reference joint angles a t the Start Enable Area (ALMEGA V seris) a r e shown in

Fig.l.4.

* 1 and * 2: Refer to "Setting the System Status", section 2.1 in this par t .



Axis 3 0"


The perpendicular line




Axis 2: 0" a t the vertical position

Axis 3: 0" when the upper a rm is parallel to the ground.



Axis 6: 0" a t the front position.

Fig.l.4. The reference positions of ALMEGA V series


1 .1 .5 Setting Manual Speeds

Though a total of 9 step manual speeds including 4 low speed modes (ML1 - ML4), 4

high speed (MH1 - MH4), and inching (MLO) a r e available, it is possible to set a

desired speed a t each step for both Axis and Cartesian movements.

However, do not modify the inching speed (MLO)

Axis manual speed

Set a ra te to the maximum positioning speed.

The setting range is 0.01 - 100.00%.

* Cartesian manual speed

Set a ra te to 100cm/sec.

The setting range is 0.01 - 100.00%

II( Setting manual speeds

1. Press D at the top layer of U Teach mode and then F4

(SYS SET). *

2. Press F5 (MANUAL). +

3. Place the cursor a t "MANUAL

SPEED", and then select the

item by the function key:

F1 ... Sets Axis manual speeds of mechanisms 1 and 2.

F2 ... Sets Axis manual speeds of mechanisms 3 and 4.

F3 ... Sets Cartesian manual speeds.

A X I S MH4 TEACH

SERVO ON

/ q / l / I m l m J >


A X I S MH4 TEACH

SERVO ON

SELECT MODIFYING PARAMETER

> MANUAL S P E E D P I T C H MOTION

/ROTATI//ROTAT2/TEKI

When F1 (ROTAT 1) is pressed

When F2 (ROTAT 2) is pressed

*

A X I S M H 4 T E A C H

SERVO O N

When F3 (CARTE.) is pressed

e

A X I S S P E E D MECHA. l/MECHA 2

ML1: /7 M H 1 : 47.5096 M L 2 : 15.00% M H z : 65.00% M L 3 : 32.50% M H 3 : 82.50% M L 4 : 30.0096 M H 4 : 100.00%

4. Highlight the speed step you

want t o modify, by using. /gl, , !=!, B] and t h R t e r

the speed by numeric keys.

Set Axis manual speed a t a rate

to the maximum positioning speed

o r Cartesian manual speed a t a

r a t e to 100cm/sec.

5. Press @ .

M L l : 1 2 . 6 M H l : 47.50% ML2: 15.00% M H 2 : 65.00%

ML4: 30.00% M H 4 : 100.00%

A X I S M H 4 T E A C H

SERVO ON


A X I S S P E E D MECHA. l/MECHA 2

M L 1 : \m$6 M H 1 : 62.5096 M L 2 : 25.0096 M H 2 : 75.0096 M L 3 : 37.50% M H 3 : 87.5096 M L 4 : 50.00% M H 4 : 100.00%

1. 2 Application Features and Functions Used for Teaching 1 .2 .1 Logical Check on Task Programs

The logical check on Task programs feature allows the operator to easily find

teaching errors in the Task programs. A Task program to check should be selected by

using the diagnostic function in Teach mode. If a teaching error is found, a Alarm

message is displayed. There are three types of Alarms; one still allows you to run

automatic operation, another requires you to correct taught data; otherwise automatic

operation will halt, and the other does not guarantee normal operation. For details of

the logical check items, and the Alarm messages, descriptions and solutions, see the

Alarm list.

0 NOTE 1

1) The range of logical check

A logical check is made on each Task program. Therefore, if a Task program

contains CL or JF instructions, a logical check is made on existence of any call

or jump destination programs but not on the contents.

[Example) PO01

0 0 1 P

AE

0 0 2 END / 0 0 3 END

For P001, Alarm that AE is outside welding section is given. But, for P002,

because the contents of the called program are not checked, Alarm is not given.

2) The checking order of logical check on Task programs

A logical check is made in order by storing of Task programs. Therefore, if a

JP instruction is contained in a Task program, Alarm may be given even if there

a re not any teaching errors.

AE is not executed due to the unconditional jump, and block and automatic

operations can be executed. However, if a logical check is made, Alarm that AE

is outside welding section is given.

(Example)


0 0 1 P 0 0 2 JP #1

AE

0 0 3 PM1 0 0 4 END

Making a logical check on Task programs

at the top layer of

Teach mode. * TEACH

ISERYO OF^

/ r t G i K q ~ ~ ~ ~ l >

2. Press F2 (CHECK). *

3. Press F5 (LGC MON). err),

I f you want to make a logical

check on all Task programs, press

F1 (PRG.AL) I f a desired program,

enter the Task program number by

numeric keys. * 4. Press F1 (EXECUTE).

A logical check on that program

will be started. * F5 . .. Cancels a logical check.

If the specified Task program is

not found, an er ror message will

appear. * In this event, press ~ J ~ F Y to 0

specify a Task program number

again.

TEACH

DIAGNOSIS /SERVO >OFF]

ENTER PROGRAM NUMBER

Plll

TEACH

DIAGNOSIS SERVO D F F ~

1 - 1 0 Application Features and Functions Used in Teach Mode

IpEi-Tq

Plll CHECK

TEACH

DIAGNOSIS SERVO OPEJ

/STOP]

ENTER PROGRAM NUMBER

Plll

NO FILE -.MOD1 FY

-1 *

5. If Alarm occurs, the relevant

sequence number and message a r e

displayed. .r)

Alarms a r e sequentially displayed on the screen, and a logical check stops when the screen is full with Alarms: *

F1 ... Restarts the logical check.

RESET . . . Cancels the logical 0 check.

6. When a logical check on one

Task program is complete, then

you can enter a Task program

number again.

(if you a r e specifying individual

Task programs). * If you make a logical check on

all Task programs, the screen

shown on the right will appear:

*

Press F1 (CONFIRM), so a

logical check on the next program

will be started.

TEACH

DIAGNOSIS ]SERVO OPFI

Application Features and Functions Used in Teach Mode 1 - 1 1

F 1 -. CONTINUATION

p%i'iGq

1 L i s t of A larm Messages (Logical Check on Task Programs) 1

This list contains Alarm messages that may appear during a logical check on Task

programs, descriptions and solutions. If Alarm occurs, refer to this list to change taught

data. Messages are listed alphabetically.

A E IS OUT OF WELDING

Description : AE exists outside a welding section.

Solution : Delete AE or teach AS before AE. If this is intentional and welding

failure does not occur, you do not need to take action.

AS IS IN T RACKING

Description : AS exists within a tracking section (ST - ET section).

Solution : Delete AS or teach AS before the tracking section.

I C 1 CL IS IN WELDING

Description : CL exists within a welding section.

Solution : Do not teach any Branch instruction within a welding section.

If this is intentional and welding failure does not occur, you do not

need to take action.

CL IS IN T RACKING

Description : CL exists within a Tracking section (ST -ET section).

Solution : Do not teach any Branch instruction within a tracking section.



CL IS IN CIRCULAR

Description : CL exists within a circular section.

Solution : Do not teach any Branch instruction within a circular section.

If this is intentional, you do not need to take action.


C L I S I N W E A V I N G

Description : CL exists within a weaving section.

Solution : Do not teach any Branch instruction within a weaving section.


C O I S I N W E L D I N G

Description : CO exists within a welding section.

Solution : Delete CO o r change to C. If this is intentional and welding failure

does not occur, you do not need t o take action.

C O I S I N W E A V I N G

Description : CO exists within a weaving section.

Solution : Delete CO o r change to C.


E N D I S I N W E A V I N G

Description : END exists within a weaving section.

Solution : Delete END o r add WE before END.

E N D I S I N T R A C K I N G

Description : END exists within a tracking section (ST- ET section).

Solution : Delete END or add AE before END. If this is intentional and welding

failure does not occur, you do not need to take action.

E N D I S I N W E L D I N G

Description : END exists within a welding section.

Solution : Delete END o r add AE before END.

E N D I S I N G S - G E

Description : END exists within a Gas ON/OFF section.

Solution : Delete END o r add GE before END.

Appl icat ion Features and Functions Used i n Teach Mode 1 - 1 3

E T I S O U T O F T R A C K I N G

Description : ET exists outside a tracking section (ST - ET section).

Solution : Delete ET o r add ST before ET.

(F11

F I R S T M O T I O N I S N O T H P

Description : The first Motion instruction is not HP in the multiple-mechanism

system.

Solution : Teach the first Motion instruction as HP.

Otherwise, the mechanism may interfere with each other a t first

Motion instruction.

F I R S T M O T I O N I S C P

Description : The first Motion instruction is CP Motion instruction (L, LO, C1, C2,

C01, o r C02).

Solution : Teach the first Motion instruction as P.

[ G I G E I S I N W E L D I N G

Description : GE exists within a welding section.

Solution : Do not teach GE within a welding section.

G E I S O U T O F G S - G E .

Description : GE exists outside a Gas ON/OFF section (GS - GE section).

Solution : Delete GE o r add GS before GE.

G S I S I N W E L D I N G

Description : GS exists within a welding section.

Solution : Do not teach GS within a welding section.

I C H I S I N W E L D I N G

Description : ICH exists within a welding section.

Solution : Do not teach ICH within a welding section.


K J l

J F I S I N W E A V I N G

Description : JF exists within a weaving section.

Solution : Do not teach any Branch instruction within a weaving section.


J F I S I N C I R C U L A R

Description : JF exists between Circular instructions.



J F I S I N T R A C K I N G

Description : J F exists within a tracking section (ST- ET section).




J F I S I N W E L D I N G

Description : JF exists within a welding section.




J P I S I N W E L D I N G

Description : JP exists within a welding section.

Solution : Do not teach ally Branch instruction within a welding section.



J P I S I N W E A V I N G

Description : JP exists within a weaving section.

Solution : Do not teach any Branch instruction within a weaving section



J P I S I N TRACK1 NG

Description : JP exists within a tracking section (ST- ET section)




J P I S I N CIRCULAR

Description : JP exists between Circular instructions.



( L 1

LO IS IN WEAVING

Description : LO exists within a weaving section.

Solution : Delete LO or change to L.



LO IS IN WELDING

Description : LO exists within a welding section.

Solution : Delete LO or change to L.



EM1

MISMATCH OF WELDER TYPE

Description : Different types of power units (Individual, Synergistic, and TIG) were

specified for AS and AE.

Solution : Delete AS and AE whose types of power units are different, and teach

again.


M O T I O N D A T A A R E M I X E D

Description : Both Synchronous Motion instruction (HP, HL, etc) and Single Motion

instructions (P, L, etc) exist.

Solution : Teach with only Synchronus Motion instructions.

Otherwise, the mechanism may interfere with each other in block

operation.

C N 1 N O D E F B E F O R E D E C

Description : There is no DEF before DEC.

Solution : Delete DEC o r add DEF before DEC.

N O R E F . P O I N T O F C 1

Description : There is no reference point of C1.

Solution : Delete C i o r add a Motion instruction before and after C1.

N O R E F . P O I N T O F C 2

Description : There is no reference point of C2.

Solution : Delete C2 o r add a Motion instruction before C2.

N O T S A M E C C O O R D I N A T E S

Description : The coordinate systems for 3 circular point (s tar t , middle and end) do

not match.

Solution : Delete the wrong sequence and teach again.

N O J U M P P O I N T

Description : Point Mark o r Task program does not exist a t the jump destination.

Solution : Delete J P o r JF, o r add a Point Mark o r Task program a t the jump

destination.

N O C O N D I T I O N F I L E

Description : The specified Condition file does not exist.

Solution : Delete AS, AE, WFP, or WAX, o r create a Condition file.


N O P R O G R A M T O C A L L

Description : The Task program to call does not exist.

Solution : Delete CL o r create a Task program to call.

r.P1

P IS IN W E A V I N G

Description : P exists within a weaving section.

Solution : Delete P o r change to L.


P IS IN W E L D I N G

Description : P exists within a welding section.

Solution : Delete P o r change to L.

If this is intentionaI and welding failure does not occur, you do not


P M IS IN W E A V I N G

Description : PM exists within a weaving section.


If this is intentional, you do not need t o take action.

P M IS IN C I R C U L A R

Description : PM exists between Circular instructions.



P M IS R E P E A T E D

Description : A duplicate PM exists .

Solution : Delete a n unnecessary PM.

P M IS IN T R A C K I N G

Description : PM exists within a tracking section (ST - ET section).




P M I S I N W E L D I N G

Description : PM exists within a welding section.



P M I S N O T L I N K E D

Description : There is PM which is not referenced.

Solution : Delete PM o r add J P .

CRI

R T C I S I N W E L D I N G

Description : RTC exists within a welding section.

Solution : Do not teach RTC within a welding section.

KSI

S F 0 I S I N W E A V I N G

Description : SF0 exists within a weaving section.

Solution : Do not teach S F 0 within a weaving section.

S F 0 I S I N W E L D I N G

Description : SF0 exists within a welding section.

Solution : Do not teach SF0 within a welding section.

S F 1 I S I N W E A V I N G

Description : SF1 exists within a weaving section.

Solutioii : Do not teach SF1 within a weaving section.

S F 1 I S I N W E L D I N G

Description : SF1 exists within a welding section.

Solution : Do not teach SF1 within a welding section.

S T I S O U T O F W E L D P A T H

Description : ST exists outside a welding and weaving.

Solution : Teach ST outside a welding and weaving section.


[ W l

WFP IS I N TRACKING

Description : WFP exists within a tracking section (ST - ET section).

Solution : Delete WFP or teach before the tracking section.

WAX IS I N TRACKING

Description : WAX exists within a tracking section (ST - ET section).

Solution : Delete WAX o r teach before the tracking section.

WE IS O U T O F WEAVING

Description : WE exists outside a weaving section (ST -ET section).

Solution : Delete WE o r teach a Weaving Star t instruction before WE.


1.2 .2 Confirmation of Terminating Teaching

This feature allows the operator to prevent termination of the teaching operation

caused by accidentally pressing the Reset key when creating Task programs.

OSACOM SUPER 8700 asks for confirmation to terminate teaching

This feature is set on/off by modifying the setting of "CNFRMNG TEACH END" in

the user parameters for setting the teaching box keys. (The default is OFF.)

(1) Confirmation of terminating teaching OFF

When the Reset key is pressed during teaching to create a new program, END

instruction is automatically inserted a t the last sequence to terminate teaching.

(2) Confirmation of terminating teaching ON

When the Reset key is pressed during teaching to create a new program,

OSACOM SUPER 8700 asks for confirmation of terminating teaching.

When the setting is ON

I f you press RESET when teaching 0 to create a new program, the screen

similar to the one shown on the

r ight appears : I)

F1 . .. Teminates teaching. F2 ... Returns to the Teaching

screen.

* : Refer to "Setting the Teaching Box Keys", section 2.2. in this part .


AXIS MH4 TEACH P 7 7 7 SQ No.= 3 SERVO ON

0 0 1 P 1 0 0 % BASE MI 0 0 2 P 1 0 0 % BASE M1

S 0 1 2 AS 25OA. 25.OV. 25Ocm

> 0 0 3 * L 25Ocm BASE M1

DO YOU WANT TO EXIT TEACHING?

-1/NOj

1.2.3 Setting the Way of Performing Block Operation The way of performing block operation can be set a s a user parameter.

Hold the way of performing block operation ON/OFF (the setting of the way of performing block operation) Continuous Block operation ON/OFF

(1) Hold the way of performing block operation (the setting of the way of performing

block operation)

This feature is set on/off by modifying the setting of "BLOCK OP. HOLD"" in the user parameters for setting the system status. Even if block operation is performed

in the same manner, the movement of the manipulator varies according to the ON

/OFF settings. Movements of the manipulator according to ON/OFF settings are a s follows:

Table 1.1 Key operations and Movements of the manipulator according to Hold

the way of performing block operation ON/OFF

When, without continuous

Key Operation

block operaton specified, 8 and m a r e

pressed.

* The mechanism stops

Hold Way of Performing Block Operation

a t a taught point.

ON

Releasing and

OFF ( Default)

BLOCK re-pressing / ,, I causes the mechanism to move to the next

/ taught point. I

BLOCK . If 1s still

kept pressed when the mechanism reaches a taught point, it moves to the next taught point.

When, with @ held, BLOCK . w

1s released - during forward block operation.

When Halt is operated during continuous

The mechanism stops immidiately .

The continuous state is held.

When continuous block operation is specified The mechanism carries on the continuous block operation.

* When continuous block operation is not specified The mechanism stops a t a taught point.

(Releasing E ~ ~ L E causes 8 the mechanism to

immediately stop.)

a The continuous state is cancelled.

block operation.

* : Refer to "Setting the System Status", section 1.2. in this part.


@ Note For movements in backward operation, refer to the above table.

(2) Continuous Block ON/OFF

This feature is set ON/OFF by modifying the setting of "CONT. BLOCK" in the

user parameter for setting teaching box keys.

The table below shows how the setting of this parameter works on the relation

beween a key operation and block operation:

Table 1.2 Continuos Block Operation ON/OFF

Continous Block O~era t i on ON/ OFF Key operation 1 ON (Default) OFF

When is pressed. 1 The continuous state / The continuous state is - 1 is entered, and the 1 not entered, and the LED

LED of on the

teaching box is illuminates.

of teaching box is not illumintaes.


1 .2 .4 Cursor Indicat ion o f the State of Block Operat ion

This teature allows the operator to judge by the cursor whether the manipulator is

a t a taught point of the current sequence or is moving to the next sequence.

This feature is set on/off by modifying the setting of "SPECIAL CURSOR DISP" *

in the user parameters for setting the teaching box keys.

63111 The Block operating state

If the setting of "SPECIAL

CURSOR DISP" is on, the screen

similar to the one shown on right

appears. 4 A new c u r s o r a is added. which

does not appear if the setting is off.

> : Indicates the current position. This is not displayed during

block operation o r in the

halted state.

: Indicates the target point

during block operation. This

flickers in the halted state.

A combination of these two

cursors allows you to identify the

current s ta te of block operation:

> I P ) ; 1 I State of Block Operation

TOOL M L 4 TEACH P7 7 7 SB No.=lO 0 SERVO ON

ON 1 ON I Halted s ta te (The manipulator is a t the taught ~ o i n t . 1

& 0 0 1 P 1 0 0 % BASE M I 0 0 2 P 8 0 % BASE M 1 0 0 3 L 1 5 0 m BASE M I

pl iE iq/J~~m/PATH>

@ Notes 1

OFF

OFF

1) Even if the user parameter setting is "ON1', the cursor does not appear if the Sequence Search function is selected. However, it becomes active when the Sequence Search function is terminated.

2) In bacliward block operation, the cursor does not indicate a target point.

* : Refer to "Setting the Teaching Box Keys", section 2.2. in this part .

ON

flicker


Block operating state

Halted state (The manipulator is not a t a taught point.)

1.2.5 Setting Block Operating Speeds

It is possible to set block operating speeds.

Speeds a r e set a t a ra te to the maximum Positioning speed in automatic operation

(setting range: 1 - 15%).

111 Setting a block operating speed

1. Press F4 (SYS. SET) at

the top layer of teach mode, and

then

2. Press F2 (BLOCK). II)

3. Set a block operating speed

by using [m] and numeric

keys.

4. Press a. Now, the block operating speed

has been set.

Applicat~on Features and Functions Used in Teach Mode 1 - 2 5

'1.2.6 Checking and Modifying Condition Files during Block Operation

If welding and weaving conditions are specified by using files, it is possible to check

o r modify data contained in a specified file.

Editing Condition files during block operation

1. Place the cursor a t the data in

the Condition file you want to

check. *

2. Press @ .

A X I S MH4 TEACH P 7 7 7 SQ Na=132 SERVO ON

3. Enter a condition by numeric

keys if you want to modify.

WE 0 9 2 P 1 0 0 % BASE MI

> A S A S C O 5 0 9 3 X L 15Om BASE MI 094XC1 1 5 0 m BASE M1 0 9 5 h C 2 1 5 0 m BASE M1

If you do not modify, press RESET . 0

p - c x i z i I J ~ l / P A T ~ / >

OSACOM SUPER 8700 will return

to the block operation screen.

4. If you want to modify, press

RECORD . 0 OSACOM SUPER 8700 will return

to the block operation screen.

1 - 2 6 Application Features and Functions Used i n Teach Mode

C h a p t e r 2 User P a r a m e t e r s

Contents

2 . 1 SettiIlg the System Status ........................................................................................................................... 2 - 3

2.1.1 setting the H~~~ position ................... 2 - 8

2.1.2 Setting the Work Enable Area (sof t Limit) 2 - 10

2 . 1 3 Setting the Start Enable Area ......................................................................................................... 2-11

2 1 4 Registering Coordinate Systems .................................................................................................... 2-11 . .

2.1.5 Setting Conditions for 3-dimensional Shift and Mirror Image Shift ............... 2-12

2 1 6 setting the ABSO ~~t~ check ti^^ ................................................................................... 2-13 . . 2 2 Setting the Teaching Box Keys 2- 14

2.3 setting the welding parameters 2-17

2.4 Setting the Parameters for External Control Signal Inputs/Outputs 2-20

2.5 setting ti^^ ~ ~ ~ t ~ i ~ t i ~ ~ ~ on ~ ~ t ~ ~ ~ t i ~ operation .................................................. 2-22

2.6 Setting the Sensor Type 2-22

2.7 setting welding characteristic ~~t~ .. 2-23

2 7 1 ~ ~ ~ i ~ t ~ ~ i ~ ~ welding characteristic ~~t~ ....................................................................... 2-24 . . 2.7.2 ~ ~ d i f ~ i ~ ~ welding characteristic ~~t~ 2-24

2.7.3 Creating User Welding Characteristic Data (User Registration) .................... 2-27

2 7.4 ~~t~~ to use ALMEGA FUZZY AUTO ................................................................................... 2-29

2.7.5 ~~t~~ to use TIG ill^^ ...................................................................................................................... 2-31

2. U s e r P a r a m e t e r s Setting user parameters allow the user to turn on/off various features and functions

relating to welding and movements.

If a parameter setting is changed, the new setting immediately becomes effective.

Selecting the User Parameters Setting Function 1. You start f rom the top layer of I I

Teach mode.

2. Press and then F1

Press the function key to select

the parameter type you want:

F 1 ... Sets the system status. ~ N S O R ] I p T F q ~ p i z Z E i I [ ~ ] (See section 2.1.)

F2 ... Sets the teaching box keys. (See section 2.2.)

F 3 ... Sets the welding parameters. (See section 2.3.)

F 4 ... Sets the parameters for external control signal inputs/outputs. (See section 2.4.)

F 5 ... Sets the motion restrictions in automatic operation. (See section 2.5.)

F1 . . Sets the sensor. (See section 2.6.)

F 2 ... Sets the arc sensor parameters. *

F 3 ... Sets the touch sensor parameters. *

F 4 ... Sets the welding characteristic data. (See section 2.7.)

F 5 ... Sets the sample data for arc sensor.*

* : Refer to the Arc Sensor instruction manual "Teaching".

User Parameters 2 - 1

11111 Setting User Parameters Any kinds of user parameters should be set in accordance with the following procedure:

/ Selecting a parameter type to set / -

Move the cursor by using [ml . The item indicated by the cursor is your object to set.

1 Moving pages 1 If there a r e multiple pages which contain parameters, OSACOM SUPER 8700 displays a

page number such a s "1/6" on the top right of the screen. The figure on the left of "/"

shows the current page, and the right shows the total number of pages. To move pages,

press F4 (ROLL DN) o r F5 (ROLL UP).

Changing da ta settings

* Alternative selection of "ON/OFF"

The current setting is highlighted. F1 (EDIT) toggles between ON and OFF

Selection from among multiple data settings

When you place the cursor a t the parameter you want to set, da ta settings you can

select a r e assigned to the function keys. Select the setting you want.

Numeric da ta

Enter a numeric value by using numeric keys. If you want to correct the value you

entered, press ~ I F Y key. 0 Storing da ta settings

To s tore the key. The setting you have stored immediately becomes

it is not stored.

Holding the setting item

When you select a user parameter type, the cursor indicates the previously set item

2 - 2 User Parameters

2. 1 Setting the System Status This section describes the parameters by page. [ I contains options, and ( ) contains

the default setting.

* Page 11'6

(1) Initial mode [TEACH/AUTOl (Teach mode)

Define whether the initial mode which is entered when the control power is turned

on should be Teach o r Auto mode.

AXIS ML4 TEACH

SERVO ON

(2) Auto mode interlock [ON/OFFl (ON)

For details of Auto mode interlock, refer to "Modes", section 2.4 in par t I .

SYSTEN 1 /6 >INITIAL MODE

p i ;;To AUTO LOCK TEACH LOCK ON CONTROL METHOD I m J REMOT APPLICATION PRG. LI ST DI SP 1-j DATE

(3) Teach mode interlock [ON/OFF] (OFF)

For details of Teach mode interlock, refer to "Modes", section 2.4 in pa r t I.

pzKi-Eq-1

(4) Control system [LOCAL/REMOTE]

At present, not available.

(5) Application [WELDING/HANDLINGl ((Welding)

Select Welding fo r welding/cutting applications, o r Material Handling for handling

application.

(6) List Task programs [By number/By date1 (By number)

Define how the Task programs should be listed; in order by number o r by creation

date.


* Page 2/6

(1) Interference soft limit check [ON/OFF]


AXIS ML4 TEACH

SERVO ON

(2) Attitude movement (Wrist axis movement) [Eulerian/R.P.Y. 1

SYSTEN 2/6 INTERF. LIMIT OFF

>POSTURE MOTION RESTART RETRACT 0 lorn

SPEED TO PM 6 0% ONLINE AUTO SET OFF

Select Eulerian Angle for welding/cutting applications, or R.P.Y. for handling

application. For details of each movement, refer to "Operating Directions", section

/SETTING/ [piKrz-\/ROLLUP/

4.2 in part I . Note that R.P.Y. is not available for the use of ALMEGA G series and

(3) Overlap distance for restating automatic operation (Omin)

Set a travel back distance for restarting automatic operation.

For details of the overlap restart, see "Overlap Restart" section 6.6.3 in part I.

(4) Travel Speed to Point Mark (60%)

Set a speed a t which a manipulator moves to Point Mark (PM).

The setting is a rate to the maximum positioning speed and affects the following

speeds:

* A speed a t which the manipulator starts to move from the current position to the

sequence specified by using the Path function.

* A speed a t which the manipulator returns to the point where automatic

operation was restarted from the current position specified by performing

manual manipulation after automatic operation was halted.

(5) Automatic storing for online modification [ON/OFFI ~ ~ % >

The ON setting allows the operator to store the conditions updated online when

AE or the updated AS is executed, and the OFF setting does not. However,

regardless of ON or OFF, the updated conditions are stored when the Record key or

F4 (END) is pressed before the next AS or AE is executed.


* Page 3/6

(1) Home position

(ON only for Axis 5 of ALMEGA G series o r W01, and OFF for the others)

The ON setting allows the operator to halt manual manipulation a t a stored

position/attitude. For details of this function, see "The Home Stop function",

section 1.1.2 in this part, and for the setting procedure, see "Setting the Home

Position", section 2.1.1 in this part.

AXIS ML4 TEACH

SERVO ON

(2) Work enable area(Soft Limit)

The work enable area can be changed a s desired. For the default setting of the

work enable area, see "The Work Enable Area", section 1.1.3 in this part , and for the

setting procedure, see "Setting the Work Enable Area (Soft Limit)", section 2.1.2 in

this part.

SYSTEM 3/6 >SPECIFIED POINT HOLD MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER

(3) Start enable area

As well a s the work enable area, the s tar t enable area can be changed as desired.

For details, see "Automatic Operation", section 6.1 in part I , and for the setting

procedure, see "Setting the Start Enable Area", section 2.1.3 in this part.

p-EiKy pEirxq/ROLL/

(4) Moving Axis


(5) Offset Adjustment

Do not modify this setting since OSACOM SUPER 8700 is provided with the preset

values.

(6) Tool parameters

OSACOM SUPER 8700 is provided with the data of a tool (such a s a torch) used.

Do not change the settings, unless you change the tool. When replacing the tool,

see "Tool Parameters", appendix 4. Note that, if the tool is changed, the Task

programs in service are not available.


/6 SELECTED UNITS -1

EXT. MEMORY

(1) ABSO data check function

Set the ABSO data check ON or OFF. If ON, set an allowance. For details of the

function, refer to "ABSO Data Check Function", section 3.3 in part 111, and for the

setting procedure, see "Setting the ABSO DATA Check Function", section 2.1.6 in this

part.

(2) Unit CMetric/Inchl (Metric)

It is possible to switch unit whether Metric or Inch.

(3) Hold the way of performing block operation (OFF)

This setting affects the way of performing block operation.

For details, refer to "Setting the Way of Performing Block Operation", section

1.2.3 in this part.

(4) Floppy disk type [2DD/2HDl C?J-ID)

Set the floppy disk type used for an external storage.

For details, refer to External Storage, chapter 1 in part III.

(5) Version display CON/OFFl (OFF)

This setting defines whether the control program versions a re displayed o r not

after the control power is turned on. Normally, set it OFF because this feature is

used by DAIHEN serviceman.

(6) External storage type [PC/FDDl (FDD)

Set the external storage type used. Select "FDD" for the use of external storage

unit (option, type: E5777), or "PC" for the use of a personal computer. Note that, if

you want to use a personal computer as an external storage, you need optional

software (PM-8700) and interface cable.


* Page 5/6

(1) Check the s t a r t enable area during automatic operation [ON/OFF] ((OFF)

For details of this feature, see "Checking the Star t Enable Area during Automatic

Operation", section 3.4 in this part .

(2) Teaching synchronous motion [ON/OFF]

For details, refer to Instruction manual "Options".

(3) Register of coordinate systems

(Base as Cartesian coordinate system 1, and OFF as 2)

I t is possible to register up to 2 coordinate systems which a r e switched each time - a is pressed. For details, see "Switching between Coordinate Systems" section

4.1.3 in par t I, and for the registering procedure, see "Registering Coordinate

Systems", 2.1.4 in this part.

* Page 6/6

(1) Conditions for 3-dimensional shift and mirror shift

For the default settings and the setting procedure, see "Setting Conditions for

3-dimensional Shift and Mirror Shift", section 2.1.5 in this part .

Note that 3-dimensional shift and mirror image a re options.


2. 1. 1 Setting the Home Position

For details of the Home Stop function, see "The Home Stop Function", section 1.1.2.

in this part .

Setting the Home position

1. Place the cursor at "SPECIFIED

POINT HOLD". I.)

2. Press F1 (SETTING). * Press the function key to select

the way of setting:

F1 ... Sets by entering a joint coordinate value (an angle of each axis).

F2 ... Sets by entering a Base coordinate value.

F3 ... Sets by moving the mechanism, by manual manipulation,to a position you want to store. Note that the angle of each joint is stored.

F4 ... Sets by moving the mechanism, by manual manipulation,to a position you want to store. Note that the Base coordinate value is stored.

When F1 (AX NUM) is pressed

(1) If the system consists of

multiple mechanisms, the

screen looks like the one

shown on the right. e


AXIS ML4 TEACH

SERVO ON

SYSTEM 3/6 >SPECIFIED POINT HOLD MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER

-1 jpcEEi- piKL-E-1

( 2 ) Select the mechanism you

want to set. * (3) Select the joint by pressing [m] , and then press F1

(EDIT) to select ON or OFF.

(4) Enter the angle by numeric

keys.

When F2 (COR NUM) is pressed

(1) If the system consists of

multiple mechanisms, the screen


right. +

(2) Select the mechanism you

want t o set. * (3) Select the coordinate [a

L - ?

component by pressing / fil, and then press F1 (EDIT)

to select ON or OFF.

(4) Enter the coordinate value by

numeric keys.

When F3 (AXIS) o r F4 (CORDNAT) is pressed

(1) The screen similar to the one

shown on the right appears. I)

(2) Move each mechanism t o the

position/attitude you want to

store.

Even i f the system consists

multiple systems, pressing RECORD 0 allows you to store data of all

axes a t one time.

3. I f you want to store the data,

press L&A . If not, press RESET "0


2. '1.2 Setting the Work Enable Area (Soft L imi t )

For details, refer to " The Work Enable Area", section 1.1.3 in this part .

Setting the work enable area

1. Place the cursor a t "MOVABLE

AREA". *

2. Press F1 (SETTING). * If the system consists of

multiple mechanisms, the screen


right.

Select the mechanism you want

to set. *

3. Select the axis by pressing [a] and the upper/lower

limits by pressing [w] .

F1 (+/-) toggles between the

signs.

4. Set the value by numeric keys.

AXIS ML4 TEACH

SERVO ON

5. Press @ .

SYSTEM 3/6 SPECIFIED POINT HOLD

>MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER

2 - 1 0 User Parameters

[ M I /ROLL1mUP/

2. 1.3 Setting the Star t Enable Area For details, refer to "Automatic Operation", section 6.1 in part I, and "The

Reference Joint Angles for the Start Enable Area", section 1.1.4 in this part .

Setting the start enable area

Follow the setting procedure for the Work Enable Area.

2. 1.4 Registering Coordinate Systems It is possible to register up to 2 most often-used coordinate systems.

Once coordinate systems are registered, they are switched in the order of Axis - Coordinate System 1 + Coordinate System 2 + Axis each time

II Registering coordinate systems

1. Place the cursor a t "ENTRY OF

COODINATES" and press F1

(SETTING). * F1 ... The Base coordinate

system F2 . . . The Tool coordinate

system F3 ... The World coordinate

system F4 ... The Work coordinate

system F5 ... The Hand coordinate

system (at present, not available)

F5 . .. OFF

2. Move the cursor by

and select the coordinate system

by the function key.

3. Press @ .

User Parameters 2 - 1 1

2. 1. 5 Setting Conditions for 3-dimensional Shift and M i r r o r Image Shift

In order to execute the 3-dimensional shift o r mirror image shift, it is necessary to

set conditions.

For details of these functions, refer to the instruction manual "Options"

Important \

Remember that a triangle formed a t an extremely small length o r dimension ra te causes degradation of shift accuracy.

L J

Table 2.1. Triangle Dimensional Conditions

Settinn shift conditions - 1. Place the cursor at "SHIFT

CONDITIONS" and press F1

(SETTING). *

Setting Range

10 -- 200

1 -660

Item

Length of the smallest side [ mm 1

Smallest angle [ deg 1

2. Move the cursor by [m]

Default

100

20

and set a value by numeric keys.

Largest angle C deg I Dimensional ra te [ % 1

(See Table 2.1.)

3. Press RECORD 0

140

90


60 -- 180

1 -699

2.1.6 Setting the ABSO Data Check Function

For details of this feature, refer to "The ABSO Data Check Function", section 3.3 in

pa r t III.

Bll Setting the ABSO data check function

1. Place the cursor a t "FUNC OF

ABSO DATA CHECK". *

2. Press F1 (SETTING). Ilr)

F1 ... Selects ON o r OFF.

Changing the allowance.

(1) Place the cursor "SET

CAPACITY ". I.)

(2) Press F1 (SETTING). r)

(3) Select the axis by

(4) Set the value by numeric key.

EXT. MEMORY

3. Press @


2. 2 Setting the Teaching Box Keys

This section describes the parameters by page. [ 1 contains options and (

contains the default setting.

- Page 1/3

(1) External Control Input/Output ON/OFF key [ON/OFFI (OFF)

Not available.

(2) Sensor ON/OFF key [0N/OFFI

Not available.

(3) Weave ON/OFF key [ON/OFFl (ON)

When this setting is ON, weaving ON/OFF is determined by the AND condition

between the WELD ON/OFF state on the teaching box and the logical input state.

(4) Weld ON/OFF key [ON/OFFl

See (3).

(5) Manual welding ON/OFF [ON/OFFI


(6) Teaching box [Standard/Advancedl (Standard)

Do not modify the setting a s it is preset according to the teaching box provided.


* Page 2/3

(1) Continuous Block key [ON/OFFl (ON)

Set the Block continue key on/off. For details of movement, see "Setting the Way of

Performing Block Operation", section 1.2.3 in this part.

(2) Automatic printer output [ON/OFF]


(3) Special error output ON/OFF [ON/OFFl (OFF)

For details of this feature, see "Trouble Shooting", chapter 6 in part E.

(4) Deadman switch [ON/OFFl (OFF)

When you a re using the teaching box equipped with a deadman switch, set this

parameter ON. Note that Deadman switch is an option.

(5) CRT [ON/OFFl (OFF)

If you use CRT, set this parameter ON. Note that CRT is an option.

(6) Confirmation of terminating teaching [ON/OFF] (OFF)

For details of this feature, see "Confirmation of Terminating Teaching", section 1.2.2

in this part.


/3

(1) Sequence display by the special cursor [ON/OFFl (OFF)

For details of this feature, see "Cursor Indication of The Block Operation",

section 1.2.4 in this part .

AXIS ML4 TEACH

SERVO ON

(2) Sequence display during automatic operation [ON/OFF] (OFF)

For details of this feature, see "Sequence Display during Automatic Operation",

section 3.7.

TEACH PENDANT 3 / 3 >SPECIAL CURSOR DISP SEQ DISP. IN AUTO ENDLESS ROTATE

(3) Endless rotation [AUTO/MANUAL/OFFI

This feature is a n option.

/EDITJ p ? z r E i q l m l

2 - I 6 User Parameters

2. 3 Setting the Welding Parameters This section describes parameters contained on each page. [ ] contains options and

( 1 contains the default setting.

* Page 1/4

(1) Wire slowdown ra te (0%)

Set a feed ra te of the wire, which is fed until the a r c s tar ts , a t % of the maximum

current command value. Note that you do not need to set this parameter if your

welding power unit is equipped with the wire slowdown feature.

AXIS ML4 TEACH

SERVO ON

(2) Hot s t a r t r a t e ( 0 % )

The hot s t a r t feature applies a n excessive welding voltage for a given time to

generate the a r c smoothly a t the beginning of welding. Set a ra te to the rated voltage.

Note that you do not need to set this parameter if your welding power unit is equipped

with the hot s t a r t feature.

APPLICATION - - 1 / 4 >WIRE SLOW DOWN 0 % HOT START RATIO = 0 % HOT START TIME = 0.0s BURNBACK TIME = 0.0s BURNBACK VOLT. = 0.OV STRT ERR CHECK TIME= 1.0 S

(3) Hot s t a r t time (0 sec.)

Set a time fo r which hot s t a r t is performed. Note that you do not need to set this

parameter if your welding power unit is equipped with the hot s t a r t feature.

/ROLLDN//ROLLl

(4) Burn back time (0 sec.)

The burn back feature applies a given voltage to prevent the wire from depositing

onto the base metal a t the end of welding. Set a time for which burn back is performed.

Note that you do not need to set this parameter if your welding power unit is equipped

with the burn back feature.

(5) Burn back voltage (OV)

Set a voltage to apply for burn back. Note that you do not need to set this

parameter if your welding power unit is equipped with the burn back feature.

(6) Arc s t a r t failure detecting time (1.3 sec.)

Set a time required for OSACOM SUPER 8700 to detect a r c s t a r t failure. When the

a r c does not s t a r t within the set time, the wire is retracted a s recovery action from a r c

s t a r t failure ( a t a maximum of 3 times) s o that a r c s t a r t can be retried.


* Page 2/4

(1) Arc outage time (0.5 sec.)

Set a time required for OSACOM SUPER 8700 to detect an outage a rc condition

during welding.

A X I S ML4 TEACH

SERVOON

(2) High inching/retracting speeds (100%))

High inching/retracting speeds a re speeds for inching/retracing with holding

d o w n .

A P P L I C A T I O N 2/4 ARC D I S C O N T I N U I T Y = 0 . 5 s I N C W R E T R A C T (HIGH) = 1 0 0 % I N C W R E T R A C T (LOW) = 6% P R E F L O W T I M E

>WIRE S T I C K CHECK tjG WIRE RETRACT S P E E D = Om

Set each a t % of the maximum command value

[EDlTI lROLLDN//ROLL]

(3) Low inching/retracting speeds (6%)

Low inching/retracting speeds a r e speeds for inching/retracting without holding

down

Set each a t % of the maximum command value.

(4) Preflow time (0%)

Set a preflow time which is a flow time before the a rc starts .

(5) Wire stick check ON/OFF

Set wire stick check ON/OFF

(6) Wire retracting speed (Ocm)

This parameter is available only when TIG filler is used.

Set a retracting speed which is applied a t the end of welding.

Important > Be sure to set this parameter if you use TIG filler. Otherwise, the wire will not be retracted because the default is "0".


* Page 3/4

(1) The way of teaching welding conditions [Numeral/File] (Numeral)

Select whether welding conditions are set by directly entering numeric value o r

specifying files.

This parameter is available only a t the first teaching of welding conditions after the

control power is turned on. Thereafter, the information a t the time of teaching is

displayed as the initial setting.

(2) The way of teaching weaving conditions [Numeral/File]


* Page 4/4

(1) WIF time out check [ON/OFFl

Normally set this parameter ON

(2) Arc timing adjustment

Do not change the setting.

(ON)

(0.0 s)

AXIS ML4 TEACH

SERVO ON


APPLICATION >WIX TIMEOUT CHECK ON & ARC TIMING ADJ. = 0.0s

IEDlT] ]--

2. 4 Setting the Parameters for External Control Signal Inputs/0utputs

This section describes the parameters by page. [ ] contains options and ( )


(1) Sequencer file number in use (1 (SQFI))

This parameter is set to display the sequencer file being currently in use.

The sequencer file is automatically set when updated. You cannot change it here.

AXIS ML4 TEACH

SERVO ON

(2) Execution of external control inputs [ON/OFFl (ON)

Define whether execution of external control inputs is enabled or disabled. When the

setting is OFF, any external control input instructions are not executed. Jump and call

instructions such a s JP , JF , and CL conditioned on waiting for inputs result in the

same effects a s those of unconditional jump and call, respectively.

EXT. INPUT/OUTPUT 1/2 SQ PRG. NUMBER 1 EXT. INPUT EXT. CONTROL 1/0 g;g

>INPUT LOGIC NORMAL OUTPUT LOGIC NORMAL NOP AUTO INPUT OFF

(3) Execution of external control outputs [ON/OFFl (ON)

Define whether execution of external control outputs enabled or disable.

When the setting is OFF, any external control output instructions a re not executed.

~ N O R M A L J I I N V E R S E J I O l F j l R O L L m

(4) Input logic [ Normal/Reverse/OFF I (OFF)

Define whether the external control input instructions (N and F ) should be executed

normally a s taught or reversely during backward block operation.

Normal : Executes the external control input instructions as taught.

Reverse : Executes the external control input instructions which a re logically

reverse to those taught.

OFF : Disables execution of the external control input instructions.

0 Important The setting of execution of external control input (2) overrides.


(5) Output logic [ Normal/Reverse/OFF 1 (OFF)

Define whether the external control output instructions (S and R) should be executed

norlnally a s taught or reversely during backward block operation.

Normal : Executes the external control output instructions a s taught.

Reverse : Executes the external control output instructions which a re logically

reverse to those taught.

OFF : Disables execution of the control output instructions.

@ Important I The setting of execution of external control output instructions (3) overrides.

(6) Automatic insertion of NOP [ ON/OFF I (ON)

Define whether or not NOP is automatically inserted when ON Wait instruction (N)

or OFF wait instruction (F) is taught.


2. 5 Setting on Motion Restrictions on Automatic Operation

This section describes the parameters by page. [ 1 contains options and ( )


* Page 1/1

LOW SPEEED AUTO ON LOW SPEEED RATIO ON

(1) Machine lock [ON/OFFl (OFF)

For details, see "Machine Lock", section 3.1 in this part.

(2) Dry run [ON/OFFl (OFF)

For details, see "Dry Run", section 3.2 in this part.

(3) Interpolating speed in the Weld OFF state

At preset, not available.

(4) Low-speed automatic operation [ON/OFFI (OFF)

For details, see "Low-speed Automatic Operation", section 3.3 in this part.

(5) Speed rate of low-speed automatic operation (15%)

Set a speed of (4) a t a rate to the maximum speed (%I.

2. 6 Setting the Sensor Type

Here, set the sensor type you use.

Page 11'1

(1) Sensor type [Not used/Super arc sensor or Weave arc sensor/Laser sensor/

TIG arc sensor] (Not used)

Select your parameter.

AXIS ML4 TEACH

SERVO ON


SETTING OF SENSOR 1/1 >USING SENSOR =

r F i T T E - I / ~ ~ ]

7 Setting Welding Characteristic Data The output current and voltage of a welding power unit are determined by a command

voltage given to the welding power unit. When the welding power unit is used in

combination with a robot, this command voltage is output from a welding interface,

which is equivalent to a terminal voltage of a remote box employed when a welding

power unit is independently used.

Because the relation between an output current, an output voltage, and a command

voltage varies according to types of welding power units, the robot needs information

about "what degree of command voltage should be output from the welding interface in

order to output the welding conditions set by teaching". This information is called

welding characteristic data.

Because welding characteristic data vary depending on each welding power unit and a

welding process, the actual output value may slightly differ from the setting. Also, in

order to use a welding power unit which is not a DAIHEN product, the user needs to

create such data.

The features covered in the following sections are used to modify and create welding

characteristic data.

The standard welding characteristic data are listed below:

Table 2.2. Kinds of Welding Characteristic Data

Wire 1. 0 1. 2 1. 6

Power Unit

The default setting is ; CPVAS-350CO2, wire diameter of 0.8mm.

If you use any welding power units (except ALMEGA FUZZY AUTO") other than the

units listed, create characteristic data (User Characteristic Data).

It is possible to create up to 60 data*2.

* 1: Refer to "Notes to Use ALMEGA FUZZY AUTO", section 2.7.4 in this part.

* 2: Refer to "Creating User Characteristic Data (User Registration)", section 2.7.3 in

this part.


2. 7. 1 Registering Welding Characteristic Data

To use or modify the standard welding characteristic data, be sure to register them

in accordance with the following procedure:

Important \

If you want to use a created Task program after modifying the welding power and wire diameter settings, delete the welding conditions (AS and AE) once and add them again.

\ I

Registering welding characteristic data

(W-CHARA). * 2. Select a welding power unit by

using screen 1

3. Select the wire diameter by

using

4. Press F1 (REGIST).

2.7.2 Modi fy ing Welding Characteristic Data

The welding conditions depend on various elements such a s the length of a primary

power cable and a wire extension. Therefore, the actual output value may slightly

differ from the setting. In this case, modify welding characteristic data to adjust the

output.

In addition, if an individual control type of welding power unit is used, the voltage

controlled by the automatic voltage control feature (which automatically displays the

voltage adjusted to the output current when AS is taught) is calculated based on

welding characteristic data. Therefore, if you want to change the voltage, modify the

welding characteristic data.


Modifying welding characteristic data

To modifying welding characteristic data, follow the steps below. After modifying

data, follow the procedure in section 2.7.1 to register

1. Select the type of welding power

unit a t screen 1 by using

2. Select the wire diameter by

using . <Individual control type >

3. Press F2 (MODIFY). *

<Synergic control type>

4. Select the control type of

welding power unit (Individual,

Synergic, or TIG) by using

5. Move the cursor by

enter the current and the rated

voltage.


6. Press @ . IEl) <Individual control type >

<Synergic control type>

A X I S ML4 TEACH

SERVO ON

7. Modify the data by [/I

D I S P . REF. D I S P REF. 1. 5 0 A 2 . 4 V 3.OV 2.OV 2. l O O A 5.OV 7.OV 4.OV 3. 1 5 0 A 8 .6V 10.OV 7.OV 4. 2 0 0 A 12 .OV 20.OV 10.OV 5. 3 0 0 A 1 4 . 3 V 2 5 . 0 V 12.OV

1 < > 1 and numeric keys.

8. Press @ .

9. When you have finished making

modifications, register the new

data in accordance with the

procedure in section 2.7.1.


2. 7.3 Creating User Welding Characteristic Data (User Registration)

For the use of any welding power unit other than those listed in table 2.2, it is

necessary to create user welding characteristic data. Registering up to 60 da ta is

possible.

Welding characteristic da ta as well a s welding condition files a r e stored in a file.

Though file numbers ranging from 1 through 99 a re provided, use 40 - 99 ( a maximum

of 60 numbers) to create use welding characteristic da ta because 1 - 39 a re dedicated

to the standard welding characteristic data.

This section describes how to create user welding characteristic data based on a n

example of the following welding characteristic data:

Control type of welding power unit: Individual

Rated current 3 5 0 A

Rated voltage 3 6 V

Current command Voltage command Current setting [A] Voltage setting [V]

value [Vl value [V]

Point 1 5 0 .0 0. 5

Point 2 1 0 0 . 0 1. 8

Point 3 1 5 0 .0 3. 5

Point 4 2 0 0 .0 5. 3

Point 5 2 5 0 .0 7 .8

BI Creating user welding characteristic data

1. Place the cursor a t "USER

REGISTER" on screen 1.

2. Enter any number of 40 - 99 by

using numeric keys.

The number you entered is a

register number of the user welding

cl~aracteristic data you a re creating.


AXIS ML3 TEACH

SERVO ON

POWER SOURCE WIRE CPVAS-3 5 0 COr 0.8 1.0 1.2 CPVAS-3 5 OMAG 0.8 1.0 1.2 CPVAS-5 0 0COz 1.0 1.2 1.6 CPVAS-5OOMAG 1.0 1.2 1.6 USER REGISTER

(REGIST//MODIFYI

3. Press F2 (MODIFY).

4. Set "Individual" control type of

welding unit, "350" rated current,

and "36" rated voltage, and press

RECORD . 0 *

The welding characteristic data

of CPVAS-350 COz 0.8mm will be

displayed.

Modify welding characteristic

data of point 1 through point 5 by

using numeric keys.

5. Af ter you modify, press RECORD . 0 Irr)

Now, the user welding

characteristic data have been

created.

To use the created data,

register them.

6. Press F4 (W-CHARA). * 7. Move the cursor to "USER

REGISTER" and enter the number

given to the created user welding

characteristic data.

8. Press F2 (REGIST).

Now, the user welding

characteristic data have been

registered.


AXIS ML4 TEACH

SERVO ON

RATING OF POWER SOURCE $WTBD 1 1

>TYPE SYNER TIG RATING CURRENT 350A RATING VOLT. 36.0V

PUSH RECORD AFTER SETTING

AXIS ML4 TEACH

SERVO ON

- >

DISP. REF. DISP. REF. 1. 50A 2.4V 3.OV 2.OV 2. lOOA 5.OV 7.OV 4.OV 3. 150A 8.6V 10.OV 7.OV 4. 200A 12.OV 20.OV 10.OV 5. 300A 14.3V 25.OV 13.OV

2.7.4 Notes to Use ALMEGA FUZZY AUTO

(1) Setting welding characteristic data

Regardless of the wire diameter and the kind of gas in use (C02/MAG), select

"CPVAS-350C02" or "CPVAS-350 MAGH.Then, select the control type of welding

power unit (Individual or Synergic).

Ensure that the setting of the welding condition control switch on the front panel

(@ if Fig.2.1.) matches the control type of welding power unit you selected.

Table 2.3 Settings for the control type of welding power unit

Setting of the Welding Condition Control Switch

Individual

(2) The front panel of ALMEGA FUZZY AUTO

The outside view of ALMEGA FUZZY AUTO is shown below:

Setting of the Welding Characteristic Data

SEP A

Synergic

Fuzzy synergic

Fig.2.1 The outside view of Front Panel

SYNER

SYNER

@ ... A welding current/voltage setting knob, effective only when the current/voltage

control switch is set a t "Panel".


@ ... A switch which switches between the front panel side and the robot side to

control the welding current and voltage. If you change the setting, turned off

ALMEGA FUZZY AUTO and turn it on again.

When the setting is "Panel", the welding current and voltage set by Arc Start

instruction AS are ignored, and welding is performed a t the welding current

and voltage set a t the panel side.

When the setting is "Robot", the welding current and voltage set a t the panel

side are ignored, and welding is performed a t the welding current and voltage

set by Arc Start instruction AS.

@ ... A switch which sets a welding process and a wire diameter, which are the

following:

Setting on Panel

1

2

3

4

5

6

7

8

Wire Material

Solid wire

Solid wire

Solid wire

Solid wire

Solid wire

Solid wire

Core wire

Core wire

Wire Diameter

0.9m

l.Om

1.2m

0.9m

1. om

1.2m

1.2m

1.4 m

Gas

coz coz C 0 2

MAG MAG MAG C 0 2

C 0 z

@ ... A switch which sets a control type of welding power unit, which includes

Individual, synergic, and Fuzzy synergic:

a. Individual

Sets a welding current and a welding voltage individually.

b. Synergic

Outputs a welding voltage adjusted to a welding current setting.

It is necessary to set a voltage adjustment in order to output an

optimum welding voltage.

c. Fuzzy synergic

Outputs a voltage optimum to the welding condition by simply setting a

welding current.

Be sure that the control type of welding power unit set by this switch

matches the control type setting in the welding characteristic data.

For details of other switches and errors output to ALMEGA FUZZY AUTO, see the

instruction manual for ALMEGA FUZZY AUTO.


2.7. 5 Notes to Use T IG Fi l l e r

For the use of a TIG filler, it is necessary to modify welding characteristic da ta and

set a wire retracting speed.

(1) Modifying Welding characteristic data

Enter a speed setting and a speed command value.

Select the characteristics data of point 1 through point 5 according to the rated

wire feed ra te from the following list:

Table 2.4. Welding characteristic da ta for TIG filler

(2) Setting a wire retracting speed

Set "WIRE RETRACT SPEED1'* in the welding parameters.

Setting (cm/min)

6

* : Refer to "Setting the Welding Parameters", section 2.3. in this part .


Output value ( V )

0. 7

Chapter 3 Appl icat ion Features and Funct ions Used f o r Automat ic Operat ion

This chapter describes application features and functions used for

automatic operation and how to operate them, including Machine

Lock, Dry Run, Low-speed Automatic Operation, and Path Function.

Contents

3.1 Maclline Lock 3- 1

3.2 D~~ R~~ ..................................................................................................................................................................... 3- 2

3 3 Lowespeed Automatic Operation 3- 6

3.4 Checking the Star t Enable Area during Automatic Operation 3- 8

3 5 'path Function 3- 8

3.6 Online Modification ....................................................................................................................................... 3- 10

3.7 Sequellce Display durillg Automatic Operation ......................................................................... 3- 11

3. Appl ica t ion Features and Funct ions Used f o r Au toma t i c Operat ion

3. 1 Machine Lock The Machine Lock function is used to lock all mechanisms connected with OSACOM

SUPER 8700.

This function allows the operator to run Task programs in the actual cycle time

without operating the mechanism or mechanisms in order to check whether external

control input/output instructions were correctly taught in the programs. It can be set

ON/OFF by modifying the setting of "MACHINE LOCK"* in the user parameters for


The ON Setting make each mechanism in the system inoperative.

4 ~ a u t ~ o n s \

1 ) Teach mode In Teach mode all features and functions except those to move each mechanism

are available. However, there are some restrictions, which are: * In ON setting of the machine lock function, any mechanisms do not operate even

if manual manipulation or block operation is performed. If a Motion instruction such a s P, L, or C is taught, the interrally calculated data of the position will be stored, but not the present position, because the controller performs arithmetic operations.

* Though any mechanisms do not operate in block operation, the normal cycle time is required to run the system.

2 ) Auto mode In Auto mode all features and functions except those to move each mechanism are

available. However, there are some restrictions, which are: Because welding and sensor instructions are executed in the inoperative state of the mechanism(s), be sure to set WELD ON/OFF key OFF and SENSOR ON/OFF key OFF. If not, errors occur.

* If the Emergency Stop or Shock Sensor operates during automatic operation and the servo power is shut off, OSACOM SUPER 8700 makes a computation to restart the manipulator from the current position. Therefore, in this event, an additional time is required, compared with the normal cycle time.

L /

* : Refer to "Setting Motion Restrictions on Automatic Operation", section 2.5 in this part.

Application Features and Functions Used for Automatic Operation 3 - 1

The screen display when the machine lock setting is ON

When the machine lock setting is ON,

the status is displayed on the screen

and logical output (0320) is set ON.

rrc)

A X I S MH4 I ~ C H LOCK[

SERVO ON

J T E A C H I ~ J ~ I ~ ~ l >

3. 2 Dry Run The Dry Run function is used to stop execution of features and functions except

movements of the mechanism(s) in automatic operation. This function allows the

operator to check whether the mechanismh) can operate a s taught, without executing

other controls.

In dry run, the following functions are not active:

(1) External control inputs/outputs (OSACOM SUPER 8700 holds data of the

logical output ports.)

(2) Welding

(3) Sensor

(4) Timer

However, because this function is available only in automatic operation, external

control outputs/inputs, timer, etc. are executed in block operation.

The dry run function is set ON/OFF by modifying the setting of "DRY RUN" * in the

user parameters for setting the system status.

* : Refer to "Setting Motion Restrictions on Automatic Operation", section 2.5 in this part.

3 - 2 Application Features and Functions Used for Automatic Operation

When the dry run is set, during automatic operation some instructions a re available and some are not, which are listed below: Execution 0 * Execute

X * * Not execute

Table 3.1. Mechanism control instructions

I I I

L 0 Liner interpolation with rotation of I M o t i o n I attitude 0 / Motion / Uniform interpolation l o

Execution

0

0

Description

Positioning

Liner interpolation

Instruction

P

L

Type

Motion

Motion

C 1

C 2

co 1

co 2

H P

H L

H L O

Motion

Motion

Motion

H C

H O


Motion

Motion

,Motion

H L X

N O P

T

WF P

W A X

WE

R T

Center point of Circular interpolation

End point of Circular interpolation

Center oint of Circular interpolation with roration of attitude End point of Circular interpolation with rotation of attitude

Motion

0

0

0

0

Synchronous positioning motion

Synclironous linear interpolation Synchronous linear interpolation with rotation of attitude

, Motion

Motion

Motion

Task

Task

Task

Task -

0

0

0

Synchronous circular interpolation Synchronous circular interpolation

0

with rotation of attitude Silnultaneous uniform interpolation

No operation

Waiting for Timer time

Starting pattern weaving

Starting axis weaving

Ending weaving

Caluculating rotated position

0

0

6,

x

0

0

0

0

Table 3.2. Program control instructions

-

J F

C L

PM

E N D

Execution

0

D E F

D E C

MP S

Table 3.3. Sensor instructions I I I

Description

Internal program jump

Instruction

J P

Motion

Motion

Motion

Motion

Instruction I Type 1 Description / Execution

Type

Motion

Task

Task

Motion

Motion

External program jump

Calling program

Point mark

Ending program

Ending multi-pass section

Specifying executing pass of task ~nstruction E P

0

0

0

0

Defining counter

Decremental operation of counter value

Starting multi-pass section

0 X Task

-

S F 0

S F 1

0

0

0

S F 2

Motion

Motion

--

S F 3

S F 5

T S E / Task / Ending high speed touch sensor 1 X

Motion

T S S

Table 3.4. Welding control instructions I I I

Detecting Wire extension

One-direction search

S T Task Starting tracking x

Task

Task

Instruction 1 Type / Description I Execution

X

x

Pattern search

E T

I I I

Task

X

Calling deviations

Storing deviation number in tracking

1 Task 1 Inch

Task

x

x

Starting high speed touch sensor

A S

A E

x

Ending tracking

Task

Task

-

R T C

G S

AEM

x

G E

A S M

I Task I Ending multi-pass welding 1

Arc s tar t

Arc end

Task

Task

- -- -- -


X

x

Task

Task

Retract

Turning gas ON

x

x

Turning gas OFF

Starting multi-pass welding

x

x

Table 3.5. External control input/output instructions

N 1 Task 1 Waiting for external control input ON I X

Instruction 1 Type I Description

S

R

F 1 Task 1 Waiting for external control input 04 X

Execution

%Motion means Motion instruction, and Task means Task instruction.

Task

Task

$ Cautions 1 ) If this function is set ON, the mechanisms move in a condition that external

control input/output do not function. Therefore, if external control inputs/outputs

Setting external control output

Reseting external control output

are used to control the jig, etc., take care to avoid interference with peripheral

X

X

equipment. 2 ) The dry run setting is displayed on LCD of teaching box when the Auto mode is

entered. However, because that display disappears once automatic operation is activated, it is not possible to identify later whether the function is effective o r not.

II Display when the dry run is set

When the dry run setting is ON, logical output port (0321) is set on.

When Auto mode is entered, a

message to perform automatic

operation for "DRY RUN" appears

on the teaching box rr)


3. 3 Low-speed Automatic Operation The Low-speed Automatic Operation is used to perform automatic operation a t a

limited speed of positioning movement. This feature allows the operator to check taught

da ta a t a safety speed. A limited speed can be specified a t any rate to the maximum

speed by setting the user parameter.

Note that this function is only available to limit a speed of positioning movement in

automatic operation and not to block operating speed and a speed of interpolating

movement.

The speed of positioning movement is limited a t the following sections:

(1) The travel distance to a point taught with Positioning instruction P or HP

(referred to a s Positioning distance in the following)

(2) The travel distance to a point taught with Point Mark instruction PM used to

execute Internal Program Jump instruction J P

(referred to a s Point Mark distance in the following)

(3) The travel distance to a sequence specified to execute the Path function* ' (referred to a s Travel distance for Path function in the following)

(4) The travel distance to a halting point for restarting

(referred to a s Travel distance for restarting in the following)

This function is set on/off by modifying the setting of "LOW SPEED AUTO" *'.

The speed is set in a parameter "LOW SPEED RATIO".

The normal speed of positioning movement in automatic operation includes the

following :

Table 3.6. Speeds of positioning movement

Positioning

Positioning distance

Speed

Speed taught

Point Mark distance

* 1 : Refer to "Path Function", section 3.5.

* 2 : Refer to "Setting Motion Restrictions in Automatic Operation", section 2.5.

* 3 : Refer to "Setting the System Status", section 2.1.

The setting of "SPEED TO PM""3 in

Travel distance for Path function

Travel distance for restarting


the user parameters for setting the system status

When this function is set on, making a comparison between the above rate and the

low-speed setting, OSACOM SUPER 8700 uses a lower rate.

(Example]

. Speed to point Mark 609,' 0

. Low-speed rate .............................................................. 30 %

Table 3.7. Speeds a t Low-speed Automatic Operation ON/OFF

( * 4) The manipulator moves a t the normal speed rate which is less than the

1 ) P (100%) 2 ) P ( 50%)

3 ) P ( 20%)

4 P ( 10%) 5 ) Point Mark distance

6 ) Travel distance for Path function

7 ) Travel distance for restarting

speed rate of low-speed automatic operation.

Notes

( * 1) The manipulator moves a t the speed rate taught.

( * 2) The manipulator moves a t the speed rate set a s a travel speed to point mark.

( * 3) The manipulator moves a t the speed rate of Low-speed automatic operation which is less than the normal rate.

OFF setting

(normal)

100% ( * 1)

50% ( * 1)

20% ( * 1)

10% ( * 1)

60% ( * 2)

60% ( * 2)

60% ( * 2 )

1) The low-speed automatic operation setting is displayed when the Auto mode is entered. However, because that display disappears once automatic operation is activated, it is not possible to identify later whether the function is effective o r not.

2) Each of the low-speed automatic operation , machine lock, and dry run can be independently set. For example, when machine lock and low-speed automatic operation are set a t the same time, both functions become effective; all mechanisms are locked and the cycle time becomes longer.

ON setting

30% ( * 3)

30% ( * 3 )

20% ( * 4)

10% ( * 4)

30% ( * 3)

30% ( * 3)

30% ( * 3)

llIl Display when the dry run is set

When the low-speed automatic operation setting is ON, logical output port(0317) is set on. When Auto mode is entered, a message to perform low-speed automatic operation appear on the teaching box. *


3. 4 Checking the Start Enable Area during Automatic Operation This feature allows the operator to check "within or outside the s tar t enable area"

during automatic operation. Depending on the attitude of the manipulator, the

specialized logical output (0264) and the LED of START ENABLE on the teaching box

a re switched ON/OFF. This feature is set on/off by modifying the setting of "START

ENABLE IN AUTO " *'.

Important If this feature is set on, movements which continuously change the attitude between within and outside the s tar t enable area may cause these definitions to be reverse. However, this reverse condition is removed when the job is complete o r the operation is halted.

3. 5 Path Function The Path function allows the operator to s tar t automatic operation from a desired

sequence. A sequence is specified in Teach mode. If this function is set to s tar t automatic

operation, a check on the s tar t enable is not made. Therefore, starting automatic

operation from any position is possible. The manipulator moves with Positioning to a

specified sequence. The speed is the setting of "SPEED TO PM"*2 in the user parameter

for setting the system status.

[Examplel)

1 2 3 4 5 6 7 8 -+ Sequence No.

P , P , L , A S , L , L , A E , P , P , E N D

We assume that the manipulator is a t the position of sequence 6 in Teach mode. If

you specify sequence 4 to perform automatic operation using the path function :

(1) The manipulator performs positioning movement from sequence 6 to sequence 4.

(2) If WELD ON, the manipulator starts welding from sequence 4 and moves to

sequence 5 by L.

@ Notes

The path function is automatically cancelled when any one of the following operations is performed:

After entered, Auto mode is changed to Teach mode without automatic operation being started. The function key for s tar t allocation is selected (if the multi-station system is in use). The function key assigned for file operation is selected. Another Task program but not the Task program where the path function is activated.

* A new Task program is created or a Task program is modified by entering a Task program number o r from the List screen. @ or @ is pressed after path is set.

\

* 1, * 2 : Refer to "Setting the System Status", section 2.1 in this part.


Setting the path function

1. In Teach mode, move the cursor to

the sequence you want to start.

F4 ... Sets the s tar t sequence. F5 ... Sets the s tar t sequence and

then enters to the top layer of Teach mode.

2. Press F4 (PATH) or F5

(PATH AT).

The path function is set.

When F4 (PATH) is pressed

.I)

When F5 (PATH AT) is pressed

Irr)

3. Change to AUTO mode.

4. Press the Start button.

Automatic operation will s tar t

from the sequence where you have

set by the path function.


@ Note \

The path function is set by pressing either F4 (PATH) or F5 (PATH AT). The function of F5 , which is in principle the same a s that of F4, simplifies

operations following setting of the path function. i J

3. 6 Online Modification The Online Modification is used to modify welding conditions (current, voltage, and

speed) during automatic operation through the teaching box.

Updated conditions are stored in the following conditions:

(1) When RECORD is pressed 0 In this case, online modification operation can be carried out.

(2) When F4 (END) is pressed

In this case, the online modification terminates.

(3) When the setting of "ONLINE AUTO SET"* in the user parameter for setting the

system status is ON and

The welding section terminates (AE), or

AS is executed to modify welding condition

@ Important If automatic operation is halted, modifications you have made so fa r are not stored.

Clll Performing on-line modification -

1. During automatic operation, when

execution comes to a welding

section, the current welding

conditions a re displayed. * 2. Press F2 (AS ONLN). *

* : Refer to "Setting the System Status", section 2.1 in this part.

3 - 1 0 Application Features and Functions Used for Automatic Operation

3. Select the welding condition

(current, voltage, or speed) you

want t o modify, by the function key.

If you press F4 (END), OSACOM

SUPER 8700 stores the current

welding condition and terminates

the online modification.

4. Press to modify to the

optimum condition.

Pressing a t the same time

when pressing [m causes the

increment/decrement to enlarge.

3. 7 Sequence Display during Automatic Operation This feature is available by setting "SEQ. DISP. IN AUTO1'* in the user parameters for


If this feature is set off, taught conditions are displayed only

* In Welding section and weaving section,

* In Arc sensor tracking section, or

During waiting for external control input or for timer time

If the feature is set on, conditions of all instructions are displayed during automatic

operation a s well a s block operation.

(1(1 The sequence display durin

When the setting of "SEQ. DISP

AUTO" is on, the screen during

automatic operation looks like the

shown on the right:

one

111)

natic o~era t ion

* : Refer to "Setting Teaching Box Keys", section 2.2 in this part.

Application Features and Functions Used for Automatic Operation 3 - 1 1

Chapter 4 Sh i f t

is used to move positions stored in a Task I I program. This chapter describes the parallel shift and the cyli~ldrical 1 / sh i f t For details of other shift functions such as 3-dimensional shift, 1 / refer to the instruction manual "Options". 1

Contents

4. S h i f t The following 6 types of shift functions a re available:

Parallel shift

Cylindrical shift

* External Axis shift (option)

3-dimensional shift (option)

* Mirror shift (option)

* Scale up/-down shift (option)

I t is possible t o shift a limited range of positions by specifying sequence numbers in a

Task program.

There a r e two ways of entering a n amount of shift; Manual entry and Numerical entry:

Manual entry * a Enters an amount by moving the mechanism from the reference

position to a specified position by manual manipulation.

A difference between 2 points is a n amount of shift.

Numerical entry * a Enters a value by numeric keys.

@ Note \

If a value is entered af ter manual manipulation is performed, the travel distance from a taught point is set as a n amount of shift.

L 1

4. 1 Parallel Shift A position is shifted in parallel to the reference coordinate system by a specified

amount. The reference coordinate system is the coordinate system which was used to

teach the current sequence.

Instruction I P P P

[fill

Coordinate System 1 Base World Tool Work

Sequence

When the current sequence is 001, the reference coordinate system is Base.

When the current sequence is 002, the reference coordinate system is World.

When the current sequence is 001! the reference coordinate system is Tool.

When the current sequence is 002, the reference coordinate system is Work.

0 0 1 0 0 2 0 0 3 0 0 4

S h i f t 4 - 1

Teaching path

Fig.4.l Parallel Shift

4 - 2 Shift

4. 2 Cylindrical Shift

This shift causes the manipulator to rotate around Axis 1 by a specified amount.

Teaching path

Fig.4.2. Cylindrical Shift

Shift 4 - 3

Operating the shift function

1. Perform block operation to the

sequence which contains the

reference position. Irr)

2 . Press F3 (SHIFT). rr)

3. Select a shift type by

1-1 . The selected shift type

will be highlighted.

Shift methods, "EXTERNAL"

"3-DIMENTION", "MIRROR

IMAGE" and "MGC/RDCfl, a r e

options. To use them, optional

software needs to be set.

4. Press F1 (EXECUTE). * For shift e r rors and solutions,

refer to section 4.3.

5. To specify a shift range, position

the cursor a t the "SHIFT AREA",

and enter a sequence number of

each of a start point and an end

point by numeric keys.

AXIS MH3 TEACH PI23 SQ No.=1 3 2 SERVOON

WE 092 P 10096 BASE MI

>093 L 150cn1 BASE M1 AS ASCOC

094hC1 150m BASE MI 095hC2 150m BASE M1

AXIS ML4 TEACH P12 3 SQ Na=13 2 SERVO ON SHIFT

4 - 4 Shift

I I C X J j J!m!ml>

SELECT SHIFT METHOD PARAL LE L_I 3-DIMENTION

EXTERNAL MGC/RDC

TOOL MECHA COODINATES. MECHA 1 SHIFT

AXIS M L 4 TEACH P123 SQ No.=13 2 SERVO ON SHIFT

-1

SET SHIFT PARAMETER

>SFT AREA:093 TO 099 SFT VAL. 1-A NUMERAL

SFT MTHD -, PARALLEL TOOL MECHA COODINATES, MECHA 1 SHIFT

-1

If a shift range is not specified,

positions of all sequences are

shifted.

6. Position the cursor a t the "SFT

VAL." .

Specifying an amount by manual entry

(1) Highlight "MANUAL", and then

move the manipulator t o the

position you want.

Cartesian movement is suitable

for the parallel shift, and Axis

movement for the cylindrical shift.

(2) Press F1 (EXECUTE).

Then, shift will be started

S~ecifv ina an amount by numerical entry

(1) Highlight "NUMERAL" by

and then press F1 (EXECUTE).

Parallel shift .I)

Move the cursor by m], and enter an amount of shift (mm)

by numeric keys.


signs.

Shift 4 - 5

AXIS MH3 TEACH P123 SQ Na=132 SERVO ON SHIFT

NUMERAL SHIFT INPUT

> X DIRECT 0.0 ma Y DIRECT 0.0 am Z DIRECT 0.0 ma

/+//xmTq

Cylindrical shift * Enter an amount of shift

(rotating angle) of Axis 1 by

numeric keys.


signs.

(2) Press F2 (EXECUTE).

Then, shift will be started

7. During a shift process, the screen


right * The shift completed sequences is

displayed on the screen.

8. When a shift process for all

sequences is complete, OSACOM

SUPER 8700 returns to the original

screen (block operation).

If you press ~ I F Y immediately 0 after the shift finishes, you can

make the shift invalid. * F1 ... Makes the shift valid.

F2 ... Makes the shift in valid.

AXIS MH3 TEACH PI23 SQ No.=l 3 2 SERVO ON SHIFT

ENTER SHIFT ANGLE

AXIS ML4 TEACH P12 3 SQ % = I 3 2 SERVO ON SHIFT

4 - 6 Shift

]+/-JIEXECUTEI

SHIFTING

COMPLETED SEQUENCE 0 0 8

AXIS ML4 TEACH PI 2 3 SQ No.=l 3 2 SERVO ON SHIFT

P123 SHIFT COMPLETED

r t Y - ' - T I r n l

4. 3 Error Messages and Notes

(1) Message

SOFT LIMIT, SEQUENCE * * * SHIFT IMPOSSIBLE

or ,

LINK LIMIT, SEQUENCE * * * SHIFT IMPOSSIBLE.

Description

The position of sequence * * * shifted beyond the soft limit o r the link soft

limit.

Solution

Pressing F1 allows you to continue the shift process without shifting that

position. Pressing RESET allows you to cancel the shift process. When this e r ro r 0 -

occurs, reduce the amount and shift again.

(2) Message

DATA ERROR, SEQUENCE * * * SHIFT IMPOSSIBLE

Description

To perform the shift in a system consisting of multiple mechanisms, any of the

instructions(such as HP and HL) which have positional da ta of all the mechanisms

is required in the shift range of the program. The error message will appear if the

above condition does not exist.

Solution

After pressing ju;o;;;), place an instruction which has positional da ta of all the w

mechanisms, in the shift range, o r add an ilzstruction such as HP to the shift range,

and t ry the shift operation again.

(3) Message

CALC.ABNO., SEQUENCE * * * SHIFT IMPOSSIBLE.

Description

The position of sequence * * * shifted beyond the work enable area.

Solution

Pressing F1 allows you to continue the shift process without shifting that

position. Pressing RESET allows you to cancel the shift process. When this er ror 0 occurs, reduce the amount and shift again.

Shift 4 - 7

14) Message

SHIFT RANGE ERROR+-MODIFY

Description

The shift range setting is wrong. (e.g. The specified sequence may not exist.)

Solution

, check the shift range, and perform the shift operation again.

(5) Message

WRONG MECHANISM-tMODIFY

Description

The mechanism a t the current sequence, which was selected to shift, is wrong.

Solution

, perform block operation to the sequence of the manipulator, and

perform the shift operation again.

(6) Message

NO INSTRUCTION POINT.

Description

Tile shift function was selected a t the position of a Task instruction.

Solution

Press ~ I F Y , perform block operation to the sequence of the manipulator, and 0 perform the shift operation again.

(7) Only points that were taught with the same coordinate system as that used to teach

the current sequence a r e shifted. Points taught with other coordinate systems a r e not

shifted.

(8) In addition to a check on the point of each sequence whether its post-shift position is

within the soft limit, OSACOM SUPER 8700 makes a check for the following

instructions whether each point is on the path:

L, LO, C1, C2, C01, C02, HL, HLO, HO, SFO, and SF1

However, because all points on the path a r e not checked, during block operation, the

manipulator may stop due to outside the soft limit even if Shift e r ro r does not occur.

4 - 8 Shi f t

(9) If the following error condition exists, operation cannot be continued when outside

the soft limit occurs during a shift process. Correct the program s o that all positions

can be within the soft limit:

* The system has 2 manipulators.

* The task program contains any Synchronous Motion instruction.

* Outside the soft limit occurred a t a sequence before the shift s t a r t sequence.

(10) When all the following conditions exit, be sure to teach HP instruction a t the first

sequence, o r "DATA ERROR" will occur.

* The system has 2 manipulators.

* The task program contains any Synchronous Motion instruction.

The Shift base coordinate system is any other than the Base coordinate system.

(11) When the conditions described below exist, the movement may change (the wrist may

be upside down) after execution of Shift. Therefore, before running automatic

operation, check the path by block operation.

The system has 2 manipulators.

The instruction of the current sequence is HP.

* The shifted mechanism is the sub mechanism.

(12) Shifting a Task program which is mixed HP and P may cause the unexpected

sequences to shift.

Avoid the shift execution of a Task program which is mixed HP and P as far a s

possible.

If you perform the shift operation of the above Task program unavoidably, be sure to

check the movement by performing a block operation after shifting.

Shift 4 - 9

i

Management

k

Chapter 1 External Storage

This chapter describes the operating procedures for using an

external storage .

Contents

... 1 1 Connecting and Handling the External Storage ......................................................................... 1 - 1

1 . 2 Selecting Exterllal Storage Functions ............................................................................................... 1 - 2

1 . 3 Formatting Floppy Disks ........................................................................................................................... 1 - 4

1.4 Listing Files ........................................................................................................................................................... 1 - 5

1.5 Saving Files from the Controller to the External Storage ...................... ........ 1 - 6

1 5 2 Batch Saving ................................................................................................................................................. 1 - 9 . .

1 5 3 All Saving ......................................................................................................................................................... 1 . 11 . .

1.6 Loading Files from the External Storage to the Controller 1-13

1 . 6 . 1 ~ ~ d i ~ i d ~ ~ l ~ ~ ~ d i ~ ~ ~ 1 - 13

1 .6.2 ~ ~ t ~ h ~ ~ ~ d i ~ ~ 1-16

1 6 3 All Loading 1 - 19 . . 1 . 7 Comparillg Files 1-21

1 Externa l Storage ( tot ransferf i les)

To store (save) various files contained in the controller to floppy disk o r copy (load)

files into the controller, the user needs an external storage and floppy disks. As an

external storage, DAIHEN floppy disk storage (type E5777) is available. Alternatively, a

NEC o r IBM personal computer is configurable. (In this case, a software option PM-8700

and an interface cable are required to use a personal computer a s an external storage) If

you use the floppy disk storage, set "EXT. MEMORY""' to "FDD" in the user parameters

setting for the System Status.

Two floppy disks are required to make a system disk and a user disk. A system floppy

disk is used to store only the system parameters and a user floppy disk is used to store

files except the system parameters. To make these floppy disks, use the Format Floppy

Disk function. Two floppy disk types, 2HD (high density:1.2M) and 2DD (double density:

720K), a re available.

Specify your floppy disk type beforehand by setting "FD FORMAT TYPE"*2 in the user

parameters setting for the System Status.

r - 1) Some external storages may specify 2HD floppy disk. 2) Do not use floppy disks whose type is different from the user parameter

setting (2HD or 2DD). 3) Be sure to use the same type floppy disks. For example, the mixed use of 2HD

for User and 2DD for System is not allowed. 4) If the optional extended memory is equipped (If the storing area of the Task

programs is extended), the number of Task programs you have stored may cause the number of floppy disks which you must prepare to increase. The standard number of floppy disks you must prepare when saving all data which filled with the storing capacity will be one system floppy disk and two user floppy disks in case of 2HD, or three floppy disks in case of 2DD.

* 1, * 2 : Refer to "Setting the System Status", section 2.1 in part 11.

External Storage 1 - 1

1. 1 Connecting and Handling the External Storage For details of the procedure for connecting the floppy disk storage, refer to the

instruction manual "Controller".

( I ) Inserting a floppy disk

Insert a floppy disk with the label facing upward and the metal shutter facing

forward into the slot. When the floppy disk is inserted in place, the storage clicks and

the eject button slightly pops out.

/ Eject button

(2) Removing a floppy disk

To eject the floppy disk from the external storage, press the eject button. As part of

it comes out, take it out. Do not remove the floppy disk when accessing (loading o r

saving). Otherwise, the data on the disk may be erased.

1. 2 Selecting External Storage Functions The following functions are available to use an external storage:

(1) FORMAT Floppy Disk

Makes a floppy disk available for saving and loading with OSACOM SUPER 8700.

(2) LIST Files

Lists the files contained in the external storage.

(3) FILE Transfer

Saves files to floppy disk o r loads files to the controller.

The following three file transfer options are available:

* Individual transfer

Transfers individual files.

Batch transfer

Transfers a group of files.

* Entire transfer

Transfers all the files.

1 - 2 External Storage

(4) COMPARE Files

Checks whether the files stored with the same name in the controller and the external

storage a r e identical.

(5) DELETE Files

Deletes files.

A selection is made by pressing the relevant function key.

Selecting the External Storage function

1. Press [I>j F5 (MEMORY) at

the top layer of Teach Mode. .n)

Screen 1

2. Select the function you want, by

using the relevant key:

F1 ... Lists Files. (See section 1.4.)

F2 . .. Saves Files. (See section 1.5.)

F3 ... Loads Files. (See section 1.6.)

F4 ... Compares Files. (See section 1.7.)

F5 ... Deletes Files. (See section 1.8.) a F1 . . Formats Floppy Disk. (See section 1.3.)


1. 3 Formatting Floppy Disks To store files to floppy disk, the operator needs to format a floppy disk. The floppy

disk type must be 2HD (high density: 1.2M) or 2DD (double density: 720K). To specify

you floppy type, set "FD FORMAT TYPE1'* in the user parameters setting for the

System Status.

Formatting allows you to create a user or system floppy disk but causes all the data

on the disk to be erased. Great care is therefore necessary to perform this operation.

Formatt ing a f loppy disk

1. Press, I> F1 (INITIAL) at U screen 1: *

F1 ... Formats a floppy disk into a user floppy disk.

F2 ... Formats a floppy disk into a system floppy disk.

2. Press F1 (USER) or F2

(SYSTEM). +

3. Insert a floppy disk into the

external storage and press F1

(EXECUTE). *

4. Press F1 (YES) to start

formatting.

If you do not want to format,

press F2 (NO) instead.

* : Refer t o "Setting the System Status", section 2.1 in par t I1


TEACH

~ E R V O ,& EXT. MEMORY

INITIALIZATION FLOPPY DISK FORMAT SELECT KIND OF FLOPPY DISK

p - z - i - q ~

1. 4 Listing Files The List function allows the operator to list the files contained in the external storage

by type. The list includes file names and creation dates.

Listing Files

1. Press F1 (LIST) a t screen 1.

F1 ... Lists the Task programs.

F2 ... Lists the Welding Condition files.

F3 ... Lists the Weaving Condition files.

F4 . .. Lists the Sequencer files.

F5 ... Lists the Deviation Correction files.

@ ~1 . . Lists the Offset files. (Option)

F2 ... Lists the Laser Sensor files. (Option)

F3 .. . Lists the Search Pattern files. (Option)

2. Select the file type you want to

list, by using the function key. +

3. Insert a user floppy disk into the


(EXECUTE). II)

F1 .. . Moves one page up. (The display does not change a t the last page.)

F2 ... Moves one page back. (The display does not

change a t the first page.)


1. 5 Saving Files from the Controller to the External Storage The Save function allows the operator to save files contained in the controller to the

external storage. If you use this function, compare the files later to check whether the

data have been accurately stored.

Note If the optional extended memory is equipped, the plural number of user floppy

I disk will might be required when saving Task programs or all data. In this case, give a number to these floppy disks in order. When loading the data, use these floppy disks in saving order.

L

Saving files

Press F2 (SAVE) a t screen 1. * F1 . . . Specifies Individual saving.

(See 1.5.1.) F2 ... Specifies Batch saving.

(See 1.5.2.) F3 ... Specifies All saving.

(See 1.5.3.)

1.5.1 Individual Saving

To save individual files to the external storage, follow the steps below.

Depending on the file type you specify, you may not be able to save files individually.

For details, see "Restrictions on File Transfer" section 1.9

Bill Saving an individual f i l e

Press F1 (SEPA.). * F1 ... Saves a Task Program

file. F2 ... Saves a Welding

Condition file. F3 ... Saves a Weaving

Condition file. F4 ... Saves a Sequencer file. F5 ... Saves a Deviation

Correction file.(Option)


F1 ... Saves an Offset file. (Option)

F2 ... Saves a Laser Sensor file. (Option)

F3 .. . Saves a Welding Characteristic Data file

F4 . . . Saves a Search Pattern file. (Option)

2. Select the file type by using the

function key. I)



(CONFIRM). 119

If you selected Welding

Condition file or Weaving

Condition file, specify the

Condition file type by using the

function key:

The screen d is~ laved when vou have

selected Welding Condition file

F1 ... Saves an Arc Start Condition file.

F2 ... Saves an Arc End Condition file.

F3 ... Not used. F4 ... Not used.

The screen displayed when you have

selected Weaving Condition file II)

F1 ... Saves a Fixed Pattern Weaving file.

F2 ... Not used. F3 ... Not used. F4 ... Saves an Axis Weaving file. F5 ... Not used.

TEACH

[SERVO OFF/ EXT. MEMORY


SAVE CONTROLLER+EXT.MEMORY

ENTER F I L E NUMBER TRANSMITTING A S C --

TEACH

1 sew0 ~ F F I EXT. MEMORY

p - - - F q ~ ~ C J 1 A ~ ~ ]

SAVE CONTROLLER-EXT. MEMORY

ENTER F I L E NUMBER. TRANSMITTING WAX --

p T T - - q J w \ p i l W \ ~ \ ~

4. Type the file number by using

numeric keys. *

5. Press F1 (EXECUTE) to save

the specified file.

If the specified file does not

exists in the controller, a message

" NO FILE." is displayed. *

In this case, press MODIFY to 0 enter the correct file number.

If a file with the same name

already exists in the external

storage, a message "SAME FILE

EXISTS. " is displayed. * In this case, select by the

function key whether you want to

overwrite o r not:

F1 ... Overwrites. F2 ... Does not overwrite

TEACH

]SERVO OFF( EXT. MEMORY


SAVE CONTROLLER-.EXT. MEMORY

ENTER F I L E NUMBER TRANSMITTING WAX 0 1

TEACH

SERVO O P F ~

-1

SAVE CONTROLLER-tEXT.MEMORY

ENTER F I L E NUMBER TRANSMITTING PO 0 1

NO F I L E +MOD I FY

1. 5. 2 Batch Saving

To save a batch of files by file type to the external storage, follow the steps below.

Depending on the file type you specify, you may not be able to save a batch of files.

F o r details, see "Restrictions on File Transfer" section 1.9.

0 Notes \

If you want to save the Welding Characteristic files, select batch saving of the

User Parameter files. They will be saved all together. \ 1

H Saving a Batch of Files

Press F2

F1 ...

F2 ..

(ALL). * . Saves all the Task Program files.

. Saves all the Welding Condition files.

F 3 ... Saves all the Weaving Condition files.

F4 ... Saves all the Sequencer files.

F5 ... Saves all the Deviation Correction files. (Option)

@ F1 ... Saves all the Offset files. (Option)

F2 ... Saves all the Laser Sensor files. (Option)

F3 .. . Saves all the User Parameter files.

F4 ... Saves all the System Parameter files.

F5 ... Saves all the Search Pattern files. (Option)


function key. * F1 . . . Confirms overwriting

during transfer. F2 ... Enforces overwriting

without confirmation.


@ Note

Even if you select batch saving of the User Parameter files, you cannot save the following parameters to the external storage:

The attitude movement The home stop function The work enable area The s tar t enable area The offset adjustment

* The tool parameters If you want to save these parameters, select batch saving of the System Parameter files.

\

3. Select by the function key

whether you want to confirm

overwriting or not when a file

with the same name already exists

in the external storage. * 4. Insert a user floppy disk into the


(CONFIRM). * If you selected batch saving of

the System Parameter files a t step 2, insert a system floppy disk instead.

5. Press F1 (EXECUTE) to execute

batch saving of the files you

selected.

If the optional extended memory

is equipped, batch saving will stop

when the user floppy disk will be

full while executing to save Task

programs. *

1 - 1 0 External Storage

AXIS ML4 TEACH

SERVO ON EXT. MEMORY

SAVE CONTROLLER-EXT. MEMORY

SET NEXT USER DISK AND PUSH F 1 KEY.

[ E E i i q

In this case, insert the second user

floppy disk into the external

storage and press F l (execute).

Then, task programs which have

not been saved will be transfered.

6 . I f you pressed F1 (EXECUTE)

a t step 3, then OSACOM SUPER

8700 requests you to confirm

overwriting when a file with the

same name already exists in the

external storage: * F1 ... Overwrites. F2 ... Does not overwrite.

1.5.3 All Saving

To save all the files to the external storage, follow the steps below

) Important 1) Before you save all the files, be sure to format a floppy disk. If you save all

the files to a floppy disk which contains a file o r files, the file o r the files on the disk will remain (without being erased). Besides, if a file with the same name already exists, such file will be enforcedly overwritten without confirmation. That is, after this saving operation, the files in the controller may not match the files on the disk.In this case, error occurs later when you compare the files.

2) If the optional extended memory is equipped, only Task programs are written for the second user floppy disk when saving all data. The files (Welding condition files, o r Sequencer files, etc. except Task programs) written for the user floppy disk are saved for the first user floppy disk altogether.

L

Saving all the files -

1. Press F3 (BACKUP). I.)

External Storage 1 - 1 1



(CONFIRM). *

3. Press F1 (EXECUTE) to save

all the files except the System

Parameter files. *


is equipped, all saving will stop

when the user floppy disk will be

full while executing to save Task

programs. * In this case, insert the second user

floppy disk into the external

storage and press Fl (execute).

Then, task programs which have

not been saved will be transfered.

4. Press the RESET key when the 0 transfer of all the files except the

System Parameter files is

complete. * 5. Replace the floppy disk with a

System floppy disk and press F1

(EXECUTE). *

6. Press the RESET key when the 0 transfer of the System Parameter

files is complete.


1. 6 Loading Files f rom the External Storage to the Controller The Load function allows the operator to load files contained in the external storage to

the controller. If you use the function, compare the files later whether the data have been

accurately transferred.

III Loading Files

1. Press F3 (LOAD) a t screen 1.

F1 . . . Specifies Individual loading.(See 1.5.1.)

F2 ... Specifies Batch loading (See 1.5.2.)

F3 ... Specifies All loading. (See 1.5.3.)

I . 6.1 Individual Loading

To load individual files to the controller, follow the steps below.

As mentioned in the section for Individual Saving, depending on the file type you

specify, you may not be able to load files individually.

TEACH

LSERVU OFFJ EXT. MEMORY

10 Loading a n individual file

LOAD EXT.MEMORY-+CONTROLLER

SELECT F I L E TRANSMISSION WAY

1. Press F1 (SEPA.). * F1 ... Loads a Task

Program file. F2 ... Loads a Welding

Condition file. F3 ... Loads a Weaving

Condition file. F4 ... Loads a Sequencer file. F5 ... Loads a Deviation

Correction file. (Option)

FI ... Loads an Offset file. (Option)

F2 ... Loads a Laser Sensor file. (Option)

F3 ... Loads a Welding Characteristic Data file.

F4 ... Loads a Search Pattern file. (Option)

[mIam



function key. rzl)



(CONFIRM). * If you selected Welding

Condition file or Weaving

Condition file, specify the

Condition file type:

The screen displayed when you

selected Welding Condition file * F1 ... Loads an Arc Start

Condition file. F2 .. . Loads an Arc End Condition

file. F3 ... Not used. F4 ... Not used.


TEACH

1 SERVO O.FF( EXT. MEMORY

selected Weaving Condition file * F1 ... Loads a Fixed Pattern

Weaving file. F2 ... Not used. F3 ... Not used. F4 ... Loads a Axis Weaving file. F5 ... Not used.

LOAD EXT.MEMORY-tCONTROLLER

S E T U S E R D I S K AND P U S H F 1 KEY


pi%GKq

numeric keys. Irrl,


TEACH

[SERVO OF^ EXT. MEMORY

LOAD EXT. MEMORY-.CONTROLLER

ENTER F I L E NUMBER T R A N S M I T T I N G P O 0 1

JEXECUTEI

5 . Press F1 (EXECUTE) t o load

t he specif ied f i le.

If the specified file does not

exists in the external storage, a

message "NO FILE." is displayed.

.I)

In this case, press m I F Y to 0 enter the correct file number.

If a file with the same name

already exists in the controller,

a message "SAME FILE EXISTS. "

is displayed. +

In this case, select by the

function key whether you want to

overwrite o r not:

F1 ... Overwrites. F2 ... Does not overwrite.


I . 6.2 Batch Loading

To load a batch of files by type to the controller, follow the steps below.

As mentioned in the section for Batch Saving, depending on the file type you specify,

you may not be able to load a batch of files.

Loading a batch of files

1. Press F2 (ALL) . * F1 ... Loads all the Task

Program files. F2 ... Loads all the Welding

Condition files. F3 ... Loads all the Weaving

Condition files. F4 ... Loads all the Sequencer

files. F5 ... Loads all the Deviation

Correction files. (Option) 1 . Loads all the Offset files.

(Option) F2 ... Loads all the Laser

Sensor files. (Option) F3 . .. Loads all the User

Parameter files. F4 ... Loads all the System

Parameter files. F5 ... Loads all the Search

Pattern files. (Option)


function key. + F1 ... Confirms overwriting

during transfer. F2 ... Enforces overwriting

without confirmation.


Note Even if you select batch loading of the User Parameter files, you cannot load the following parameters to the controller:

* The attitude movement The home stop function

* The work enable a rea - The s t a r t enable a rea The offset adjustment

* The tool parameters If you want to load these parameters, select batch loading of the System Parameter files.

3. Select whether you want to

confirm overwriting or not when

a file with the same name already

exists in the controller. * 4. Insert a user floppy disk into the


(CONFIRM). I.)

If you selected batch loading of

the System Parameter files a t step

2, insert a system floppy disk

instead.

5. Press Fl (EXECUTE) to execute

batch loading of the files you

selected.


is equipped, OSACOM SUPER


loading the second floppy disk

when finishing the loading files in

first user floppy disk while

executing to load all Task

programs. I)


In this case, select by function key

whether loading files in the second

user floppy disk o r not.

F1 Loading files in the second user floppy disk.

F2 Ending batch loading.

I f you select Fl(YES), insert the

second user floppy disk into the

external storage, and then operate

the loading.

6 . I f you pressed F1 (EXECUTE)

at step 3, then OSACOM SUPER


overwriting when a file with the

same name already exists in the

controller. * F1 ... Overwrites. F2 ... Does not overwrite.


1.6.3 Al l Loading

To load all the files to the external storage, follows the steps below:

Loadincl all files v

1. Press F3 (BACKUP). .r).

1

i



(CONFIRM). I)

3. Press F1 (EXECUTE) to load all

the files except the System

Parameter files. rrrr)




loading the second floppy disk

when finishing the loading files in


executing to load all Task

programs. LI)

In this case, select by function key

whether loading files in the second

user floppy disk o r not.

F1 ... Loading files in the second user floppy disk.

F2 Loading system floppy disk.


F1 (Y ES) is selected

Insert the second user floppy

disk into the external storage,

and then operate the loading.

FZ(N0) is selected

Proceed t o operation 5.

4. Press the RESET key when the 0 transfer of all the files except the

System Parameter files is

complete. * 5. Replace the floppy disk with a

system floppy disk and press F1

(EXECUTE). I>r).

6. Press the RESET key when the 0 transfer of the System Parameter

files is complete.

0 Important \

I If a file with the same name already exists in the controller, such file will be enforcedly overwritten by loading all the files.


1. 7 Comparing Files The Compare function allows the operator to check whether the files which exist under

the same name in the controller and the external storage a re identical.

When the files do not match, an error message "VERIFIED ERROR." is displayed.

This error may be caused by the following:

(1) You did not compare the files immediately after saving to a floppy disk.

Be sure to compare the files immediately after saving.

(2) Saving was not properly executed due to:

(a) Imperfect connecting condition of the cable

(b) Degradation of the floppy disk

Comparing Files Press F4 (VERIFY) a t screen 1

F1 . . . Specifies Individual comparison. (See 1.5.1.)

F2 ... Specifies Batch comparison (See 1.5.2.)

F3 ... Specifies All comparison. (See 1.5.3.)

1.7. 1 Individual Comparison

To compare individual files, follow the steps below. As mentioned in the section for

Individual saving, depending on the file type you specify, you may not be able to

compare the files.

Comparing individual files

1. Press F1 (SEPA.). r$

F1 ... Compares Task Program files.

F2 ... Compares Welding Condition files.

F3 ... Compares Weaving Condition files.

F4 ... Compares Sequencer files.

F5 ... Compares Deviation Correction files. (Option)

F l ... Compares Offset files. (Option)

External Storage 1 - 2 I

F2 ... Compares Laser Sensor files. (Option)

F3 ... Compares Welding Characteristic Data files.

F4 ... Compares Search Pattern files. (Option)


function key. *



(CONFIRM). *

If you selected Welding

Condition file o r Weaving

Condition file, specify a Condition

file type.



F1 ... Compares Arc Star t Condition files.

F2 .. . Compares Arc End Condition files.



selected Weaving Condition file * F1 ... Compares Fixed Pattern

Weaving files. F2 ... Not used. F3 ... Not used. F4 ... Compares Axis Weaving

files. F5 ... Not used.


TEACH

~SERVO OFF~ EXT. MEMORY

FILE VERIFY

ENTER FILE NUMBER VERIFYING FILE WAX --

[ ~ P / / W l ~ C l ~ ]


numeric keys. Ir)

5. Press F1 (EXECUTE) to

compare the specified files.

If the specified files do not

match, a message "VERIFIED

ERROR. " is displayed. Ir)

If only the comment in the Task

program is different, a message

"COMMENT VERIFIED ERROR. "

is displayed. Ilr$

In this case, press ~ I F Y to

enter a file number. 0


1.7.2 BatchComparison

To compare a batch of files by type, follow the steps below. As mentioned in the

section for Batch Saving, depending on the file type you specify, you may not be able

to compare batch of files.

Comparing a batch of files

1. Press F2 (ALL). * F1 ... Compares all the Task

Program files. F2 ... Compares all the

Welding Condition files.

F3 ... Compares all the Weaving Condition files.

F4 ... Compares all the Sequencer files.

F5 ... Compares all the Deviation Correction files. (Option)

F1 ... Compares all the Offset files. (Option)

F2 ... Compares all the Laser Sensor files. (Option)

F3 ... Compares all the User Parameter files.

F4 ... Compares all the System Parameter files.

F5 .. . Compares all the Search Pattern files. (Option)

2. Select the fi le type by using the

function key. *


) Note Even if you select batch comparison of the User Parameter files, you cannot

compare the following parameters:

* The attitude movement

* The home stop function

The work enable a rea

The s t a r t enable a rea

* The offset adjustment

* The tool parameters

If you want to compare these parameters, select Batch Comparison of the

System Parameter files.



(CONFIRM). II)

If you selected Batch

Comparison of the System

Parameter files a t step 2, insert a

system floppy disk instead.

4. Press F1 (EXECUTE) to execute

batch comparison of the files you

selected.

If the files do not match, a

message "VERIFIED ERROR " is

displayed. rr)

To cancel the comparison,

press the RESET key 0 * To execute the next

comparison, press the m I F Y

key instead. 0

TEACH

SERVO C~FF] EXT. MEMORY


FILE VERIFY

ALL TASK PROGRAM VERIFY

TEACH

r s ~ a v o OFFI EXT. MEMORY

/-tEiEq

FILE VERIFY

ALL TASK PROGRAM VERIFY VERIFYING FILE PO01

VERIFIED ERROR ->RESET




comparing the second floppy disk

when finishing the comparing files

in first user floppy disk while

executing to compare all Task pro

grams. * In this case, select by function key

whether comparing files in the

second user floppy disk o r not.

F1 ... Comparing files in the second user floppy disk.

F2 Ending batch comparison.

I f you select FI(YES), insert the

second user floppy disk into the

external storage, and then operate

the loading.


1.7.3 All Comparison

To compare all the files, follow the steps below:

III Comparing all the files

1. Press F3 (BACKUP). .I)



(CONFIRM). I.)

3. Press F1 (EXECUTE) to

compare all the files except the

System Parameter files. I.)




comparing the second floppy disk

when finishing file comparison in


executing to compare all Task

programs. * In this case, select by function key

whether comparing files in the

second user floppy disk o r not.

F1 -.. Comparing files in the second user floppy disk.

F2 Comparing system floppy disk.


F1 (YES) is selected

Insert the second user floppy

disk into the external storage,

and then operate the file

comparison.

F2 (NO) is selected

Proceed to operation 5.

4. Press the RESET key when the 0 comparison of all the files except

the System Parameter files is

complete. *

5. Replace the floppy disk with a

system floppy disk and press F1

(EXECUTE). +

6. Press the RESET key when the 0 comparison of the System

Parameter files is complete.

If the files do not match, a

message "VERIFIED ERROR" is

displayed. * * To cancel the comparison,

press the RESET key. 0 To execute the next

comparison, press the ~ I F Y 0 key instead.


1. 8 Deleting Files The Delete function allows the operator to delete a specified file.

OSACOM SUPER 8700 requests you to confirm the deletion before execution.

Deleting Files

1. Press F5 (DEL. ) a t screen 1.

F1 ... Deletes a Task Program file.

F2 . .. Deletes a Welding Condition file.

F3 ... Deletes a Weaving Condition file.

F4 ... Deletes a Sequencer file. F5 ... Deletes a Deviation

Correction file. (option)

F2 .. . Deletes a Laser Sensor file. (Option)

F3 ... Deletes a Search Pattern file. (Option)

2. Select the fi le type by using the

function key. Ilb



(CONFIRM). *

If you selected Welding Condition

file or Weaving Condition file,

specify a Condition file type.

TEACH

SERVO UFF( EXT. MEMORY


FILE DELETION

SPECIFY FILE TYPE

TEACH

LSERVQ OF^ EXT. MEMORY

[-I JWEpExvFDJJWEAVEIISQmm\ >

FILE DELETION

ENTER FILE NUMBER DELETING FILE P --



F1 ... Deletes an Arc Star t Condition file.

F2 ... Deletes a n Arc End Condition file.



selected Weaving Condition file +

F1 ... Deletes a Fixed Pattern Weaving file.

F2 ... Not used. F3 ... Not used. F4 ... Deletes a n Axis Weaving file. F5 ... Not used.


numeric keys. *

5. Press F1 (EXECUTE) to delete the

specified file.

If you want to cancel the deletion,

press the RESET instead. 0


TEACH

SERVO OF^ EXT. MEMORY

FILE DELETION

ENTER FILE NUMBER DELETING FILE ASC --

j - ' i rFqCJJAmm

1 . 9 Restrictions on File Transfer Depending on the file types, some functions a re not available. For details, see the list

below:

1 File Transfer I I I Verify

File Type

0 : Operable, X : Inoperable

Task program

Welding Condition file Weaving Condition file

Lasor Sensor file

Sequencer file

Offset file

Deviation Correction file Search Pattern file User Parameter file

System Parameter file Welding

* : Represents a figure

0 Note 1

File Name

p * * * ASC* *, AEC* * ASM* *, AEM* * W A X * * , W F P * *

SRF *

SQF *

The files relating to manual speeds and s tar t allocation a r e transferred only when all the files a re transferred. (Neither Individual nor Batch transfer is applicable.) Therefore, even if all the files in the list a re transferred by specifying Batcli transfer, the result is different from that given by All.


x x o o o 0

List

0

Backup

0

0

0

0

0

0 0

Sepa.

0 0

0

Characteristic file

x o o x x x o o

0

0

All

0 0

0

0 0

0 0

OFS * *

DEV * * *

SF2M * *

USEMAIN etc.

# * * * - * * *

$ WTBD * *

Delete

0

0 0

0 0

0 0

X O O

0 0 0 0 0

Backup

0

0

0

0

0

0 0 0 0

0 0 0 0

x x x o o

Sepa.

0 0 0 0

0 0 0 0

0

0 0 0 0

0 0 0 0

0

0

0

All

0

I. 10 Error Messages fo r External Storage If an error is encountered, follow table 1.1 to take action:

Table 1.1. Error Messages and Solutions

Be sure to overwrite when asked

-

Error Message

WRITTEN DATA ERROR

+MODIFY

+RESET / disconnected, or the / external storage, or set

Description

The data saved to floppy

disk are broken.

UNIT IS NOT READY

1 external storage you use is 1 "EXT MEMORY" in the user

Solution

Press M O D l ~ ~ -+ F2 (END) and 0 save the file again.

The external storage is Press RESET to connect the 0

different from setting of

"EXT MEMORY" in the I

+MODIFY / save any file.

parameters to the enternal

storage you use.

FLOPPY DISK FULL w

place a new floppy disk in the

external storage.

Save files after formatting the

user parameters.

The disk has no space to

1 I floppy disk.

Press -> F2 (END) and

DISK CAN NOT BE USED

+MODIFY

I external storage. I place a floppy disk.

FD IS NOT READY

+MODIFY

The disk type, 2HD or 2DD,

is wrong.

Replace with a 2HD or 2DD type

disk, or change the format type

External storage is OFF, or

no floppy disk is in the

NO FILE

+MODIFY

WRONG FD I The floppy disk in use is 1 Use a floppy disk formatted for

setting in the user parameters.

Press ~ I F Y - -+ F2 (END) and 0 turn on the external storage o r

SAME FILE EXISTS.

+MODIFY

The specified file does not

exist.


Type a file number again.

A file with the same name

already exists a t destination.

+RESET

Select to overwrite o r not to

overwrite when asked.

wrong. I User (or System).

Error Message

MEMORY OVER

-+MODIFY

READ/WRITE ERROR

-+MODIFY

CANCEL WRITE PROTECT

-MODIFY

FD SYS ERROR (Error NO.)

Description

There is no room in the

memory of controller to

load files.

The floppy disk is broken.

The floppy disk is write

protected.

Error occurred during data

transfer between controller

and external storage.

Solution

Press WIFY -+ F2 (END) and 0 cancel the operation.

Press -+ F2 (END) and w place another floppy disk in the

external storage.

Press WIFY -+ F2 (END) and 0 move the notch to remove write

protection.

When loading, press WIFY +F2

(END) to load again. 0

When saving, refer to the

solutions on the following pages.


1 . I 1 Others 1.11. 1 Handling Floppy Disks

(1) No matter how often you use floppy disks, be sure to store them in a case.

(2) Use and store floppy disks in a dust free atmosphere.

(3) Touching the magnetic face may cause degradation in performance of the magnetic

medium and the data on the disk to be destroyed. So, do not touch it.

(4) Never place the floppy disk near magnetic devices. Magnetic fields can destroy the

data on the disk.

(5) Bending and dropping the floppy disk, and putting a heavy load on it may damage

the magnetic medium.

(6) Do not expose floppy disks to an abrupt change in the environmental condition.

When the environmental condition has abruptly changed, leave them for several

hours in the new condition before you use.

1 .I 1.2 Notes on External Storage (I) Do not turn on/off the external storage when it contains a floppy disk. Otherwise,

the data on the disk may be destroyed. (Take care also when you turn on the

controller on/off because the receptacle on the side of the controller is interlocked

with the power supply of the controller.)

(2) After saving a program or programs to floppy disk, check whether the data have

been correctly stored. You can make a data check by comparing the file in the

controller and the file on the floppy disk (which is called file comparison). Make a

file comparison immediately after saving a file or files.

(3) The OSACOM SUPER 8700 files are incompatible with OSACOM 6800.

Therefore, implement floppy disk management for each controller.

(4) Task programs stored in the external storage can be used with the PC Editing

System, which is an software option. However, floppy disks formatted by a personal

computer cannot be used with the external storage. If used, a error message

"WRONG FD" is displayed. Be sure to format a floppy disk with the external

storage.


Chapter 2 Password

To prevent malfunction of the system caused by accidental

nlodifications, access to some specific operations is restricted by a I / password.

1 This chapter describes how to enter a password and how to set a I user defined password.

Contents

2. Password Misoperation in setting system parameters or initializing the memory may make the

system inoperable or causes the data on the disk to be erased. Because the functions

provided for such operations are to be used by the system management and maintenance

personnel, and DAIHEN servicemen, access to them is restricted by a password. A

password must be a number of 4 digits using0 - 9. If the wrong password is entered, these

functions are not available.

2. 1 Entering the Password A password is required:

* To modifying system parameters - To initializing the memory

* To editing a Sequencer file

When you perform these operations, enter your password.

II1 Entering the password

1. When the function which

requires a password is activated,

OSACOM SUPER 8700 waits for the

password to be entered. * 2. Type the password number of 4

digits by using numeric keys.

3. Press RECORD to enter the number. 0 You can press the following keys ins

tead:

~ I F Y to correct the number you 0 entered.

RESET to cancel the password 0 entry

If the wrong password is entered,

a message "WRONG PASSWORD."

is displayed. .r)

Press W I F Y to enter the correct

number. 0

Password 2 - 1

2. 2 Setting the Password The password can be changed to a desired number. The default setting is 0000.

If you change the setting, do not tell anyone except system management and

maintenance personnel. Be sure to remember the password because it cannot be loaded.

There is no way of recovering it.

Setting the password m

1. Press 1 [>I F3 (MANAGE) at the


2. Press F1 (PASWORD).

3. Type the password number by

using numeric keys.

4. Press @ .

You can press the following keys I

before pressing R E C ~ R D . I

0 0

~ I F Y to correct the number you

entered.

RESET to cancel the password 0 setting.

2 - 2 Password

If you set the wrong password, a

Press W I F Y to enter the correct 0

message "WRONG PASSWORD" is

displayed. *

password.

I WRONG PASSWORD. +MOD I FY

5. Type the new password by using

numeric keys.

r'\

6. Press mm~ to change to the new

number. 0

You can press the following keys

before pressing RECORD .

0 0 ~ I F Y to correct the number you

entered.

RESET to cancel the password 0 setting.

Password 2 - 3

Chapter 3 Absolute Of fse t

1 This chapter describes how to adjust a difference between the

1 position of the manipulator and the position detected by the

1 encoders. The operations covered in this chapter must be performed 1 when the manipulator is installed or mechanical parts a re replaced.

Contents

Absolute Of fse t An absolute encoder is fixed to each motor to detect the position of the manipulator.

When the manipulator is assembled, the attitude computed from the values of the encoders

does not coincide with the actual attitude. As the difference between these attitudes varies

from manipulator to manipulator, it must be computed and set as the absolute offset.

This chapter describes the procedures for setting a n absolute offset and also for

resetting the encoders, which is required prior to that operation.

d lVuLe \

Perform the absolute offset setting operation only on the following occasions:

* When the manipulator is installed

* When any of the following errors occurs

A 11102-XXXX A 11103-XXXX A B S M I S M A T C H ABS D A T A O U T

A 10503-XX00 A 50601-XXXX A B S BATTERY ABSO ERROR

When the encoder is replaced o r the connector is disconnected from the encoder

* When the connector is disconnected from the control cable between the controller and the manipulator

\

3. 1 Resetting the Encoders and Setting an Absolute Offset Be sure to reset the encoders before you set a n absolute offset.

Otherwise, "A 11103-0000 (Outside the ABS range.)" occurs.

Resetting the encoders and setting an absolute offset 1. Move the mechanism by manual

manipulation to align the alignment

marks of each axis.

F4 (SYS.SET) at the

top layer of Teach mode. .r)

A X I S ML4 TEACH

SERVO ON

>

Absolute Offset 3 - 1

3. F2 (RESTART), F3 (MASTRNG),

and F4 (CONTROL) a re to be used

by DAIHEN servicemen only.

Therefore, do not use them.

4. Press F1 (ABSO).

5. Press ~1 (ABS RST). +

6. To reset the encoders, press F1

(CONFIRM). The servo power is

then turned off.

If you want to cancel the resetting

operation, press RESET instead. 0 7. When the encoders have been reset,

you cannot perform any operation.

*

8. Turn on the control power again.

Then, "A 50601-0000 (ABSO

ERROR) " occur. 4

Press RESET to clear each Alarm. 0

3 - 2 Absolute Offset

9. Press

10. Press F1 (ABSO). I)

Select the mechanism by the

function key:

F1 ... Sets ABSO for Mechanism 1. F2 . Sets ABSO for Mechanism 2. F3 ... Sets ABSO for Mechanism 3. F4 ... Sets ABSO for Mechanism 4. F5 ... Sets ABSO for Mechanism 5.

11. When you have selected the

mechanism, the screen looks like

the one shown on the right. * Move the selected mechanism by

manual manipulation to align the

alignment marks of each axis.

(See section 3.2.)

12. Press F l (CONFIRM). Then,

OSACOM SUPER 8700 starts

arithmetic operation to compute the

absolute offset. * If you want to cancel the setting

operation, press RESET instead. 0 13. When the arithmetic operation is

complete, the margin of each axis

is displayed. .I)

Each margin is adjusted to be

around 50.

Absolute Offset 3 - 3

AXIS ML4 TEACH

SERVO ON

MARGIN VALUES OF EACH AXIS. MECHA 1 1 4 9 2 5 0 3 5 0 4 5 1 5 5 1 6 5 1

r F - - K - q m j

When each margin is around 50

Push F1 (END) to terminate the

absolute offset setting operation.

When each margin is 100, 200, or

inappropriate value.

As the absolute offset values a r e not

correct, you must set then again.

(1) Push F2 (RETRY). +

(2) Push F1 (CONFIRM). * Select the mechanism by the

function key, and be sure to

perform a n absolute offset setting

operation.

AXIS ML4 TEACH

SERVO ON

Important \

Each margin is adjusted around 50. Be sure to set absolute offset setting again in the following cases.

ABSO OFFSET IS NOT SET. SET ABSO OFFSET AGAIN.

AXIS ML4 TEACH

SERVO ON

When each margin is too fa r from the optimum value: Improper values may have been set.

~~/

ABSO OFFSET SETTING SELECT MECHANISM

* When each margin is 100 o r 200 :

The absolute offset has not been computed. L J

pz?x-q/MECH211NIECH.Im]~5/ >


3. 2 Axis Alignment Marks on the Manipulator Axis alignment marks on the manipulator (G series/V series) a re shown below:

Axis alignment

Axis 2 nment marks

Axis 1 alignment marks

Axis ignment

Axis 5 alignment marks

The aligned manipulator The aligned manipulator (Top)

Fig.3.1 Axis alignment marks (ALMEGA G series)

Axis 4 alignment marks ma.

Axis alignment

Axis 3 5 gnment marks marks

. . - Axis 6 Axls Z

alignment marks nment marks

Axis 1 1 I I alignment marks w

Fig.3.2 Axis Alignment Marks (ALMEGA V series)

Absoluteoffset 3 - 5

3. 3 The ABSO Data Check Feature OSACOM SUPER 8700 check a positioning error by making a comparison between the

ABSO data (values of the encoders) given before and after the servo power is turned on.

If the positioning difference exceeds the allowance setting in the user parameters,

OSACOM SUPER 8700 identifies it a s an positioning error and displays ABSO data

error (Failure code: A11102).

This feature is set on/off by changing the setting of "FUNC OF ABSO DATA

CHECK"" in the user parameters for setting the system status.

You can manually move the axes of manipulator which are not equipped with a brake,

when the servo power is OFF. Therefore, if the manipulator is manually moved beyond

the allowance, ABSO data error occurs even if a positioning error is not encountered.

Also, depending on the attitudes of the wrist axes, the manipulator may voluntarily move

when the servo power state is changed from ON to OFF, or if the allowance is too small.

Solutions to recover f rom ABSO data error

(1) Run Task program P999 by block operation to check whether the position

coincides with the absolute offset position.

(2) If these positions coincide, you do not need to take action further.

(3) If not, reset the encoders and set the absolute offset.

0 Note - When the control power is shut off and turned on again, the encoder values may vary, but this is not identified a s an error.

* : Refer to "Setting the System Status" in part 11.


Chapter 4 In i t ia l iz ing the System

This chapter describes how to initialize the system parameters and

user parameters, etc.

Note that misoperation of the Initialize function may make the

robot system inoperable.

4. In i t i a l i z ing the System The Initialize function is use to erase various files, such a s Task programs, Welding

Characteristic Data files and user parameters, from the memory medium or restore the

default settings. This function causes the number of Task programs to be 0 and the user

defined settings to be replaced with the default settings. Therefore, it should be used only

by DAIHEN servicemen and the robot maintenance personnel.

The password must be entered to use this function.

The Initialize function is used for the following operations:

(1) Initializing all data

All the stored Task programs and Condition files a re erased to restore the default

settings in the following files which are necessary to operate a single manipulator unit

(floor mounting type):

System Parameter file

Sequencer file

User parameters file

Welding Characteristic Data file

Start allocations

* Manual speed table

* Block operating speed table

* Arc Sensor file (option)

0 Important 1 ) Initialization of all data causes all the Task programs and Condition files to be

erased. Therefore, before you perform this operation, backup all of your files

by using an external storage.

2 ) If initialization of all data is executed, OSACOM SUPER 8700 asks whether you

still want to use the installed option(s) or not. If you a re using any option, be

sure to select "YES". Otherwise, the option(s) will not be available.

3 ) Be sure to set an absolute offset after initialization of all data.

4 ) Even if initialization of all data is executed, any Laser Sensor file is not

initialized. Therefore, if you initialize all data after initialization of the Laser

Sensor file(s), the default settings in the Laser Sensor file are erased. (That is,

your defined settings remain unchanged.) For this reason, initialize the Laser

Sensor file(s) after initializing all data.

Ini t ial izing the System 4 - 1

(2) Formatting

The Format function is used to erase the following files from the controller:

* All files

Files except Task programs

* Task programs

Important >

If you format, OSACOM SUPER 8700 asks whether you still want to use the installed option(s) or not. If you want to use, be sure to select "YES". Otherwise, the option(s) will not be available.

\ J

(3) Initializing the Welding Characteristic Data files

It is possible to create 12 types of Welding Characteristic data*. If you initialize,

CPVAS-350 COz/0.8ma will be automatically set.

@ Important x

Initialization causes the User Welding Characteristic data to be erased. If you do not want to erase the data, store them by using an external storage.

L J

(4) Creating the Sequencer file

A default Sequencer file corresponding to any one of the following starting systems

is created:

* Multi-station system (up to 3 stations)

* Multi-station system (up to 6 stations)

Direct program entry system (BCD code entry)

* Direct program entry system (Binary code entry)

For details of the default Sequencer file, see the instruction manual "Interface with

Jig".

- -

* : Refer to "Setting Welding Characteristic Data ", section 2.7 in part 11.

4 - 2 Init ial izing the System

(5) Creating the System Parameter file

The system parameters necessary for the following single manipulator unit are

created:

If your system consists of the above overhead or wall mounting manipulator, load

the special parameters described in (6) from the external storage.

(6) Loading the special parameters

The data necessary for any system other than those in (5) are created by

transferring from the external storage.

(7) Initialize the User Parameter file

The user parameter settings are replaced with the default settings. For these default

settings, see "User Parameters", chapter 2 in part II.

(8) Setting the calender

The date and time when a file is created are set. To set the date, enter the year with

2 lower digits, month, and day. To set the time, enter the hours (24-hour clock) and

minutes.

(9) Initializing the manual speed table

The speeds for manual manipulation are initialized.

(lo) Initializing the Arc Sensor file

The data necessary to use Arc Sersor are created

61) Initializing the Laser Sensor file

The data necessary to use the laser sensor are created,

(12) Initializing the s tar t allocation

The Task program numbers allocated to stations 1 - 6 are initialized to perform

automatic operation by the multi-station system. The default settings a re the following:

Ini t ial izing the System 4 - 3

Table 4.1. The default settings for s tar t allocation

Station No. / Task Program No

(13) Initializing the block operating speed table

The block operating speeds are initialized.

Init ial izing the system

1. Turn on the control power. *

2. press and at the same

time while screen 1 is displayed for 3

seconds. +

3. Enter the password. * F1 ... Initializes all data. F2 ... Formats. F3 ... Initializes the Welding

Characteristic Data file. F4 ... Initializes the Sequencer

file. F5 ... Initializes the User

Parameter file.

4 - 4 Init ial izing the System

F1 ... Sets the calender. F2 ... Initializes the System

Parameter file. F3 ... Initializes the s tar t

allocation. F4 ... Initializes the manual

speed table. F5 ... Loads the special

parameters.

F1 ... Initializes the Arc Sensor file.

F2 ... Initializes the Laser Sensor file (option).

F3 ... Edits the user parameters.

F4 ... Edits the system parameters. (To make adjustments only. Do not use it.)

F5 ... Upgrades the version. (To make adjustments

only. Do not use it.)

F1 ... Initializes the block operating speed table.

4. Select the file o r files you want to

initialize by the function key.

5. Depending on the initializing

operation you selected, OSACOM

SUPER 8700 asks questions shown

in table 4.2.

After you answer, press F1

(CONFIRM) to execute the

initialization.

Initializing the System 4 - 5

If you select any initializing

operation other than those shown in

table 4.2, you will not be asked.

Table 4.2. Q,uestions of Initialization

I All files

Initializing Operation Selected

Files except Task programs

Task programs only

Question

Files to be erased

F2 (FORMAT) Select the files by the function key.

WTo use the option(s) o r not

Yes

No

Select Yes o r No by the function key.

MStarting system

Multi-station system (up to 3 stations)

Multi-station system (up to 6 stations)

Direct program entry system (BCD code entry)

Direct program entry system (Binary code entry)

Select the starting system by the function key.

F1 (DATE)

F2 (SYSTEM)

mDate and time

Enter the current date and time by numeric keys.

MManipulator type

Select the type by the function key.

All of these 5 questions

F1 (ALL DAT) I / Select each by the function key.

4 - 6 Initializing the System

Chapter 5 Insta l l ing OSACOM SUPER 8700 So f twa re Opt ions

This chapter describes how to install OSACOM SUPER 8700

software options.

Contents

5. Insta l l ing OSACOM SUPER 8700 So f tware Options OSACOM SUPER 8700 software options are provided to use the following functions:

. Synchromotion

External axis shift

- Multi - pass welding

Endless rotation

Super a rc sensor

* Welding monitor

* PC external storage (PM-8700)

* 3-dimensional shift, Mirror image shift, and Size-up/-down shift

Installation of a software option allows the operator to store the files related to the

optional function to the controller. However, these files cannot be saved to floppy disk

from the controller. Care should be taken to handle the option setup floppy disks.

5. 1 Installing Software Options This section describes how to install OSACOM SUPER 8700 software option by using

the option setup floppy disk.

In order to use an optional function, installation of the relevant software option is

necessary. If the robot system including any software option is purchased, installation of

the option is done by DAIHEN before delivery so that the optional function can be

directly used. (The user does not need to install the software option.) On the other hand,

if any software option is individually purchased after installation of the robot system,

the user needs to install it in accordance with the instructions provided here.

A floppy disk (called an option setup floppy disk) is provided for the use of software

option, which contains one software option. The user needs an external storage to install

it.

Option setup floppy disk contains the available software option and the manufacturing

number of controller, and can be used only with the specified controller.

lns ta l l ing OSACOM SUPER 8700 Sof tware Opt ions 5 - 1

Installing the option software

1. Connect the external storage.

F4 (SYS.SET) a t the


4. Press F1 (SET).

5. Place the option setup floppy disk

into the external storage and press

F1 (EXECUTE).

The option cannot be installed if

any of the following operating

errors occurs.

In such event, press RESET to 0 clear the er ror , so you will be able

to continue the installation.

I f you are using the option setup

floppy disk which has been already

used with another controller:

I f the option has been already

installed and you are still using the

option setup disk specified for

another controller: * 2 Installing OSACOM SUPER 8700 Software Options

A X I S MH1 TEACH

SERVO ON

MISMATCHED CONTROLLER+RESET

I f you are using a floppy disk

which is not option setup floppy

disk: .14

5. 2 Listing Installed Software Options This section describes how to list the software option o r options installed in the

controller.

Listing the instal led software option or options

1. Press F4 (SYS.SET) at the

top layer of Teach mode. .$

2. Press F1 (OPTION). *

3. Press F2 (LIST)

Installing OSACOM SUPER 8700 Software Options 5 - 3

5. 3 Deleting Installed Software Options

This section describes how to delete software options installed in the controller.

Deleting the instal led software option

1, Press @ F4 (SYS.SET) at the

top layer of Teach mode. * A X I S MH1 TEACH

SERVO ON

p i ' - F G Y I l R E S T A R T l r n I r n ] >

2. Press F1 (OPTION).

3. Press F5 (DELETE). * The installed software option or

options will be listed.

4. Highlight the software option you

want to delete by a n d [ g l .

and press F1 (EXECUTE).

The highlighted software option

will be deleted.

If you want to cancel the deletion, - press instead.

5 - 4 Installing OSACOM SUPER 8700 Software Options

Chapter 6 Troubleshooting

Contents

6. 1 Symptoms ................................................................................................................................................................. 6 . 15

6.1.1 NotlIing Appears on the Teaching Box ................................................................................... 6-15

6.1.2 ~l~~ ~ i ~ ~ l ~ ~ on the hi^^ B~~ I~ ullsteady ................................................................ 6-16

6.1.3 Initial Diagllosis Is Not Completed 6-17

6 1 . 4 The Servo power Supply Callnot Be Turned ON ............................................................ 6-20

......... 6.1.5 The Servo Power Supply I s Shut OFF Immediately When Turned ON 6-21

6 . 1 . 6 Manual Manipulation Does Not Function ........................................................................... 6-22

6.2 A ~ ~ i l ~ ~ ~ code and A ~ ~ i l ~ ~ ~ ),fessage A~~ ~ i ~ ~ l ~ ~ ~ d 6-23

6.2.1 The Display of A Failure .................................................................................................................... 6-23

6 2 2 Logical Outputs for Failures 6 -26 . .

6.2 3 Shocli Sensor ................................................................................................................................................ 6-27

6 2.4 Servo power Sllutoff 6 -28

6.2.5 Software Limit / Link Software Limit 6-29

6.2.6 Overrun 6 - 31

6.2.7 CommLlnication Failures 6-32

6 . 2 . 8 Data Installation Failures 6-34

6 . 2 . 9 Memory FailLlres ....................................................................................................................................... 6-36

6.2 10 Setting Errors .............................................................................................................................................. 6-37

6 2 11 ABSO Data Failure .................................................................................................................................. 6-39 . .

6.3 Whell Servo Failure Occurred .................................................................................................................. 6-40

6 3.1 'flow To See the Servo Failure Display 6-40

6.3.2 Troubleshooting for Servo Failures 6-46

6. Troubleshoot ing This chapter describes solutions for failures that may occur during operations of the robot.

Failures a r e mainly divided into 3 groups according to the symptoms :

Where the servo power supply cannot be turned on, nothing appears on the teaching

box, etc. (see Table 6.1.)

* Where a failure code and a failure message a re highlighted (See Table 6.2.)

Where a failure message except the above is displayed (See Table 6.3)

These failures a r e listed in Table 6.1 through Table 6.3. When a failure occurred, refer to

them to find a solution. If you need replace par ts such as boards, contact DAIHEN.

Table 6.1. Symptoms

box. I

Symptoms

Nothing appears on the teaching

T h e display on the teaching box I For details, see section 6.1.2.

Solution

For details, see section 6.1.1.

is unsteady. I Initial diagnosis is not completed. 1 For details. see section 6.1.3

The servo power supply is shut For details, see section 6.1.5.

The servo power supply cannot

be turned on. For details, see section 6.1.4

function. I

off immediately when turned on.

Manual manipulation does not

Troubleshooting 6 - 1


Table 6.2. Failure Codes and Messages

SHOCK-S ERR -.RESET

For details, see section 6.2.4

Solution Pull the Emergency Stop button (or cancel the emergency stop signal) and press SERVO ON button. For details, see section 6.2.3.

Code / Message EA00101-XXXX EMERGENCSTOP -.RELEASE EA00201 -XXXX

the torch interfered.

EA0040 1 -XXXX SERVO DOWN +RESET

Cause The Emergency Stop button o r emergency stop signal was entered. During automatic operation

I) The servo power was shut off due to an unidentified cause.

2) The hand was released from the deadman switch.

NO ASC FILE -. RESET

EA10201 -XXXX WIF TIMEOUT + RESET

EA50101-XXXX

EA50101-XXXX NO AEC FILE -+ RESET EA50102-XXXX NO WFP FILE + RESET EA50102-XXXX NO WAX FILE

RESET EA50103-XXXX NO ASM FILE -. RESET

Communication trouble between Welding Interface and 1 /0 management board during welding. The specified Arc Start

EA50103-XXXX NO AEM FILE -. RESET EA50104-XXXX NO OFS FILE -. RESET

After pressing the RESET key, turn on the SERVO POWER and restart. If not recovered, turn the CONTROL POWER off and on again. Create an Arc Start Condition file.

EA50105-XXXX NO CL PRG. -. RESET

I Condition file does not exist.

The specified Fixed Patterned Weaving

The specified Arc End Condition file does not exist.

Create a Fixed Patterned Weaving Condition file.

Create an Arc End Condition file.

The specified Multi-pass Welding Start file does not

Condition file does not exist. The specified Axis Weaving Condition file does exist.

I exist.

Create an Axis Weaving Condition file.

The specified Multi-pass Welding End file does not exist.

Create a Multi-pass Welding Start file.

Create a Multi-pass Welding End file.

The specified Offset Condition file does not exist

There is no Task program to call.

Create an Offset Condition file.

Create a Task program to call.

Create a Task program to jump to. EA50106-XXXX NO JF PRG. + RESET

6 - 2 Troubleshooting

There is no Task program to jump to.

Code / Message EA50107-XXXX NO PM + RESET EA50110-XXXX C1 TEACH ERR -+ RESET EA50111 -XXXX C2 TEACH ERR -> RESET EA50112-XXXX

COORD.ERROR + RESET

EA50113-XXXX SAME POINT C -, RESET EA50114-XXXX I/O TIMER -+ RESET

EA50120-XXXX CALL NESTING OVER +RESET EA50201 -XXXX S.LIMIT * * * * -, RESET EA50202-XXXX LNKS.LIMITM * -, RESET EA50301-XXXX NO PROGRAM -+ RESET EA50302-XXXX NO PROGRAM -, RESET EA50303-XXXX NO PROGRAM I -+ RESET EA50401-XXXX ON TIME OUT -+ RESET EA50402-XXXX OFF TIME OUT -+ RESET

Cause There is no point mark to jump to.

There is no reference point for the former half of a circular arc. There is no reference point for the latter half of a circular arc. Teaching of the target/ reference points for an circular arc in the different coordinate systems. The target and reference points for a circular arc are the same. The number of time counts exceeded 9.

The nest has overflown due to program calls.

The robot has reached the software limit.

The robot has reached the link software limit.

The Task program assigned to the station does not exist.

The Task program with the number entered does not exist. Task program No. has not been entered into the port specified. No ON input within the specified monitoring time.

No OFF input within the specified monitoring time.

Solution Add a Point Mark instruction.

A circular arc is formed by 3 points. Add a reference point.

A circular arc is formed by 3 points. Add a reference point.

Teach all 3 points in the same coordinate system to form a circular arc.

Teach again to form a circular arc.

The max. number of timers that can count time a t one time during automatic operation is 9. Check the setting time of each instruction of S, R, N, and F. Calling in the call destination program is possible but limited to the maximum 4 layers. Check the the program. For details, see section 6.2.5.

Check the s tar t allocation and assign the correct Task program number.

Enter the correct Task program number.

Enter a Task program number

Check the input status of the external control signals and the teaching data


Code / Message ELA50701-XXXX OPTION ERROR -+ RESET EAA50702-XXXS OPTION ERROR -+ RESET EA50704-XXXX OPTION ERROR -. RESET EA50705-XXXX OPTION ERROR -.. RESET EA50706-XXXX OPTION ERROR -+ RESET EA50708-XXXX OPTION ERROR

RESET EA50709-XXXX OPTION ERROR -+ RESET EB00301 -XXXX OVER RUN -+ RESET EB10404-XXXX CALC. IMPOS. -.. RESET

EB10710-00XX DATA ERROR -> RESET EC10206-XXXX COMUCTN ERR +POWER OFF

Cause The software for 3ynchromotion has l o t been installed. The software for Multipass Welding has not been installed. The software for External Axis Shift has not been installed. The software for welding monitor has not been installed. The software for PM8700 has not been installed.

The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. The manipulator overran.

1) A positioning instruction P is taught base on Work or Tool coordinate system in the synchromotion system.

2) The panipulator is unable to move a t a position on the path taught with a Linear o r Circular interpolation instruction.

The Task program contains a damaged instruction.

Communication between boards cannot be made correctly.

Solution

:f you want to use the optional function, ?urchase its optional software. Press the RESET key to continue the


1) Modify the relevant instruction P to a

synchromotion instruction HP, o r t ry teaching based on the Base o r World coordinate system again.

2) Correct the taught positions(start/end points). If the manipulator is unable to move, correct the position d a t a of the relevant instruction in search mode o r by using the PC editing svstem.

Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, see section 6.2.7.


Cause Solution Code / Message EC10208-XXXX COM. ERR +POWER OFF

I/O management board or For details. see section 6.2.7 teaching box failure.

EC10209-XXXX DPRAM ERROR -+ POWER OFF

Main board or I/O management board failure.

EC10210-XXXX COM LSI ERR -> POWER OFF EC10403-XXXX CALC.ERR + POWER OFF

Motion control board failure.

Replace the Motion control board.

Motion control board Replace the Motion control board. failure.

EC10504-XXXX DC24V ERROR -+ POWER OFF

DC24V power supply failure. Replace the DC24V power supply

EC10505-XXXX DC15V ERROR +POWER OFF

1) DC15V power supply failure.

2) Connector (CN24) is disconnected.

1) Replace the DC15V power supply.

2) Check the CN42 connection.

EC10601-XXXX NO FILE +POWER OFF EC10603-XXXX PCB MISMATCH -+ POWER OFF

Data installation can not be performed correctly.


SCON/PCON Board is not in place.Or, imperfect contact.

Check the SCON/PCON board connection.

ECl0605-XXXX NO SYS FILE -+ POWER OFF EC10801 -XXXX ROM ERROR - POWER OFF

Multi-synchromotion control data is not found or is insufficient. Misplacement of EPROM, o r imperfect contact.

Install the system parameters again If not recoverd, contact DAIHEN.


EC10802-XXXX RAM ERROR -+ POWER OFF EC11301-XXXX I/O PORT ERR -+ POWER OFF

The identified board or RAM on that board is broken. 1/0 management board failure.

Replace the mother board.

EC11401-XXXX TB LCD ERROR -+ POWER OFF

Teaching box LCD failure. Replace the teaching box.


Code / Message EC20101-XXXX MOTOR ERROR 3 POWER OFF

Cause The system parameter setting for motor is wrong, or any setting of the SCON board rotary switches 3-5 is

EC20102-XXXX AXIS SET ERR 3 POWER OFF

SHOCKS ALARM / mode but not during I

Solution For details, see section 6.2.10.

wrong. The system parameter setting for motor is wrong, or the setting of the SCON board rotary switch 6 is

A 00201-XXXX wrong. The torch interfered in Auto

3 RESET A 00301-XXXX OVER RUN 3 RESET

3 RESET / Work or Tool coordinate I teaching based on the Base o r World


A 10301-XXXX TEMP. ERROR 3 RESET A 10404-XXXX CALC. IMPOS.

1 system in the 1 coordinate system again.

automatic operation. Overrun was detected during initial-diagnosis.

After initial diagnosis is completed, perform manual manipulation while holding down the SERVO ON button to

The temperature in the controller exceeded 60°C

1) A positioning instruction P is taught base on

1 to move a t a position on 1 end points). If the manipulator is

escape from overrun. Turn off the control power supply and leave the robot as it is until the temperature decrease below 60°C 1) Modify the relevant instruction P to a

synchromotion instruction HP, o r try

synchromotion system. 2) The panipulator is unable

) the path taught with a 1 unable to move, correct the position

2) Correct the taught positions(start/

/ Linear o r Circular 1 data of the relevant instruction in

/ interpolat ion instruction. / search mode or by using the PC

A 10502-XXXX CMOS BATTERY + RESET A 10503-XXXX ABS BATTERY + RESET

The voltage of the memory battery dropped below 2.5V.

1) The voltage of the

A 10601-XXXX


editing system. Save all the data by using the external storage.

1) Charge the battery, or replace the charging battery dropped.

2) Imperfect connection of

NO FILE + RESET

charging battery. Be sure to perform the absolute offset adjustment.

Connector(CN47). Data installation cannot be performed correctly.

2) Check the CN47 connection. For details, see section 6.2.8.

Code / Message A 10710-XXXX DATA ERROR -+ RESET A 11102-XXXX ABS MISMATCH

RESET A 11103-XXXX ABS DATA OUT 3 RESET

A 30201-XXXX OVER TRCKNG. 3 RESTART

A 30203-XXXX ARC UNSTABLE -3 RESTART

A 30208-XXXX OVER DETECT. -+RESTART

A 30209-XXXX OVER DIST. + RESTART

A 30210-XXXX OVER SRCHNG. -> RESTART

A 30211-XXXX OVER DIST. +RESTART

A 30213-XXXX OVER SRCHNG. -. RESTART

Cause The Task program contains a damaged instruction.

Position deviation has occurred.

The absolute offset data have been destroyed o r absolute encoders have not been reset. During seam tracking by the a r c sensor, the resultant vector length in horizontal and vertical directions exceeded the specified value. During seam tracking by the a r c sensor, the frequency ra te that the average current exceeds the allowance exceeded defined rate. During automatic editing of parameters, arithmetic problem occurred. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the specified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SFl) , the searching distance exceeded the

specified maximum. During patterned search (SF2), the deviation exceeded the specified limit.

Solution Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, section 6.2.1 1.

Reset the encoders and perform the absolute offset adjustment.

See the Arc Sensor instruction manual.


Code / Message A 30214-XXXX OVER DIST. -+ RESTART

A 30215-xxxx SF2 CIVID. ERR -. RESTART A 30216-XXXX SF2 PRM.OVER -+ RESTART A 30217-XXXX SF2 PRM.OVER * RESTART A 30218-XXXX SF2 OVERLAP * RESTART A 30220-XXXX TS RANGE ERR -. RESTART A 30221-XXXX A.S.TRNS.ERR -+ RESTART A 40101-XXXX A.S. FAILURE * RESTART

A 40102-XXXX WIRE STICK -+ RESTART A 40103-XXXX OUT O F ARC -. RESTART A 40201-XXXX WPS NOT RDY + RESTART

A 40201-XXXX WPS NOT RDY + RESET

Cause During patterned search search (SF2), the searching distance exceeded the specified maximum. The SF2 file (Search Pattern file) contains an invalid command other than SF2. A SF2 parameter setting is outside the setting range.

A SF2 parameter condition is wrong.

The SF2 s t a r t position and vector specified position a re the same. Teaching of AS o r AE in the touch section.

Communication with the a rc sensor cannot be made.

The a r c was not generated within the set time after a welding s t a r t signal being input. Wire was sticked.

The a r c is out.

The robot dedicated welding power unit or welding interface has not been connected.

Communication trouble between the robot and welding interface o r the robot dedicated welding power unit.

Solution See the Arc Sensor instruction manual.

Press the START button t o restart .

Cut the deposited wire. After that , press the START button to res tar t welding.

Press the START button.

1) Check the connection between the controller and the robot dedicated power unit o r welding interface.

2) Turn the robot dedicated power unit ON.

Turn the CONTROL POWER off and on again.


Code / Message A 40202-XXXX WPS ABNORMAL -+ RESTART A 40301-XXXX OUT OF WIRE -+ RESTART A 40302-XXXX LACK OF GAS -> RESTART A 40303-XXXX LACK OF WATR -+ RESTART A 50101-XXXX NO ASC FILE + RESET A 50101-XXXX NO AEC FILE + RESET A 50102-XXXX NO WFP FILE -+ RESET A 50102-XXXX NO WAX FILE + RESET A 50103-XXXX NO ASM FILE -+ RESET A 50103-XXXX NO AEM FILE + RESET A 50104-XXXX NO OFS FILE + RESET A 50105-XXXX NO CL PRG. 3 RESET A 50106-XXXX NO JF PRG. -2 RESET A 50107-XXXX NO PM 3 RESET

Cause Problem of ALMEGA

During automatic operation the wire was broken.

Solution Remove the cause of the problem of

AUTO II or ALMEGA FUZZY AUTO.

Remove the cause. After that, press the START button.

ALMEGA AUTO II or ALMEGA FUZZY AUTO.

The gas pressure is too low. Displayed only if a detector is ~rovided.

Remove the cause. After that , press the START button.

There is no cooling water.

The specified Arc Start Condition file does not exist.

Remove the cause. After that, press the START button.

Create an Arc Start Condition file.

The specified Arc End Condition file does not exist.

Create an Arc End Condition file.

I

The specified Fixed / Create a Fixed Patterned Weaving Patterned Weaving 1 Condition file. Condition file does not exist. 1 The specified Axis Weaving Condition file does exist.

The specified Multi-pass Welding Start file does not exist.

Create an Axis Weaving Condition file.

Create a Multi-pass Welding Start file.

The specified Multi-pass Welding End file does not

There is no Task program to call.

Create a Multi-pass Welding End file. exist. The specified Offset Condition file does not exist.

Create a Task program to call.

Create an Offset Condition file.

I

There is no Task program 1 Create a Task program to jump to. to to jump to.

There is no point mark to jump to.

Add a Point Mark instruction.


C2 TEACH ERR / for the latter half of a

Solution A circular a r c is formed by 3 points. Add a reference point.

Code / Message A 50110-XXXX C1 TEACH ERR -+ RESET A 50111-XXXX

Cause There is no reference point for the former half of a

Add a reference point.

circular arc. There is no reference point

+ RESET A 50112-XXXX COORD. ERROR + RESET

Teach all 3 points in the same coordinate system to form a circular arc.

A circular a r c is formed by 3 points.

circular arc. Teaching of the target and reference points for circular a r c in the different

SAME POINT C I points for a circular a rc a re / be made.

coordinate systems. A 50113-XXXX The target and reference Teach again to form a circular a r c can

1/0 TIMER -+ RESET

-+ RESET A 50114-XXXX

exceeded 9. count time a t one time during automatic operation is 9. Check the setting time of each

the same. The number of timer cou~l ts The max. number of timers that can

A 50120-XXXX The nest has overflown due

instruction of S, R, N, and F. Calling in the call destination program

CALL NESTING OVER -+RESET

to program calls.

A 50201-XXXX S.LIMIT * * * *

The robot has reached the software limit.

+ RESET A 50202-XXXX The robot has reached the

LNKS.LIMITM * -. RESET

link software limit.

A 50401-XXXX ON TIME OUT

No ON input within the specified monitoring time.

+ RESET A 50402-XXXX

A 50501-XXXX SERVO OFF -+SERVO ON

No OFF input within the

OFF TIME OUT -. RESET

Servo ON when the mode was changed to AUTO. Or, the servo power supply was

specified monitoring time

1 turned on before automatic / operation o r after

is possible, but limited to the maximum 4 layers.

A 50502-XXXX OUT O F START

Check the program. For details, see section 6.2.5.

completion of the job. Outside the Star t Enable

Area.

Check the input s ta tus of the external control signals and the teaching data.

Turn the servo power supply ON.

Perform manual operation to move the manipulator to within the Star t Enable

6 - 1 0 Troubleshooting

ENABLEAREA I Area.

Code / Message A 50601-XXXX ABSO ERROR -. RESET A 50701-XXXX OPTION ERROR -+ RESET A 50702-XXXX OPTION ERROR -+ RESET A 50704-XXXX OPTION ERROR + RESET A 50705-XXXX OPTION ERROR -. RESET A 50706-XXXX OPTION ERROR -. RESET A 50708-XXXX OPTION ERROR 3 RESET A 50709-XXXX OPTION ERROR -+ RESET I 00201-XXXX SHOCK SENSOR -.RELEASE

I 10208-XXXX COM. ERROR 3 RESET

I 10208-XXXX COM. ERROR + RESTART

I 11202-XXXX LIMIT SPD. -. RESET

Cause After initialization of the memory, ABSO setting has not been performed. The software for Synchromotion has not been installed. The software for Multi-pass Welding has not been installed. The software for External Axis Shift has not been installed. The software for welding monitor has not been installed. The PM8700 software has not been installed.

The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. This occurs during escape from Shock Sensor Error or Shock Sensor Alarm, or when the torch interfered in Teach mode. The user parameter setting of CRT ON/OFF was ON when the CRT power supply was turned off. During automatic operation, trouble occurred in the CRT communication circuit due to some cause. In synchronous Cartesian manual manipulation, the sub mechanism is unable to synchronize with the main the mechanism.

Solution After completion of initial diagnosis, perform the absolute offset adjustment.

If you want to use the optional function, purchase its optional software. Press the RESET key to continue the pera at ion.


Press the reset key on CRT to switch the display to the teaching box.

Automatic operation will continue.

Increase the speed of manual manipulation.

Troubleshooting 6 - 1 1

Code / Message I 11401-XXXX CRT ABNMAL --, RESTART I 30100-XXXX L. S. TRNS. ERR --, RESET I 30203-XXXX ARC UNSTABLE -. RESEST

I 30204-XXXX WELD SHRTG. + RESET I 30205-XXXX PARA.CALC. -. RESET I 30208-XXXX OVER DETECT. + RESET

I 30209-XXXX OVER DIST. -. RESET

I 30210-XXXX OVER SRCHNG. -+ RESET

I 3021 1-XXXX OVER DIST. + RESET

I 30213-XXXX OVER SRCHNG. --+ RESET I 30214-XXXX OVER DIST. + RESET

I 30221-XXXX A. S. TRNS. ERR -. RESET

Cause Trouble occured in the CRT printed board.

Communictation with laser sensor cannot be made.

During seam tracking by the a rc sensor, the frequency that the average current exceeds the allowance exceeded the defined data . The welding time was not enough during automatic editing of parameters. During automatic editing of parameters, arithmetic problem occured. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the slsecified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SF1 ), the searching distance exceeded the specified maximum. During patterned search (SFZ), the deviation exceeded the slsecified limit. During patterned search search ( SF2) , the searching distance exceeded the specified maximum. Communication with the a r c sensor cannot be made.

Solution Trun off and on the CONTROL POWER.

Connect the laser sensor.

For details, see the Arc Sensor instruction manual.


Code / Message I 30301-XXXX CRT DISCNNCT -+ RESET I 30302-XXXX CRT INVALID + RESET I 40201-xxxx WPS NOT RDY -+ RESET

I 40301-XXXX OUT O F WIRE + RESET

Cause Communication with CRT can not be made.

The user parameter setting of CRT ON/OFF will be changed t o OFF. 1) The robot dedicated

welding power unit o r welding interface is not connected.

2) The robot dedicated power unit is OFF.

The residual wire is not enough. Displayed if a detector is provided.

Solution To use CRT, turn on CRT first, and then the controller.

Push RESET key.

1) Check the connection between the controller and the welding interface.

2) Turn the robot dedicated power unit ON.

Supply the wire.


Table 6.3 Failure Messages

Failure Message

I

COM DATA ERR XX-YY

XX: 03 or 85 YY: 01 - 05 SVC error

Cause Failure was detected a t Servo Control board (SCON board). Servo Control board malfunctioned. The servo power supply was shut off due to an unexpected cause. The temperature in the controller has extraordinarily increased. Trouble occurred in the Servo driver unit. Trouble occurred in the Servo Control board. The servo driver unit is unable to be set in the servo ON state. The position deviation exceeded the set value. The commanded speed exceeded the set value. Servo Control board malfunctioned. Trouble occurred when the servo power supply was turned on. Control program failure.

Control program failure.

Solution For details, see section 6.3.2.

Turn off the control power supply and then on again. If this failure recurs, note down the information displayed on the teaching box and contact DAIHEN. Note down the information displayed on the teaching box and contact DAIHEN.


6. 1 Symptoms

6.1. 1 Nothing Appears on the Teaching Box

Nothing

appears on the

teaching box

and all LEDs

on the

keyboard a re

OFF.

Primary power

supply indicator

lamp OFF.

(ON in the

1 normal state) I

Cooling fan not

rotating t

No primary power

/ LEDs of I constant voltage

power u n i t ( 5 ~ , I- I flickering palely. 1

I 1 LEDs of I Loss of W phase 1 1

-

H constant voltage H (wire 6) of I-' / 1 power unit(5V. I 1 primary power I

Loss of V phase

(wire 5) of

primary power

supply

k15V 24V) are I I o m .

-

All LEDs on

Interlock board

are OFF. (In

normal state,

LEDs 301, 302,

304, 601, 602 and

603 are ON.)

I Action I

Check the voltage of

each phase of the

primary power supply

Imperfect contact

of interlock board

CN41 - constant

voltage power unit

1 C N 4 1 . 1 Check the flat cable

1 connection and connect I it properly.

i_ I Replace the cable.

/ / Interlock board U Replace the interlock 1


1 failure. 1 board.

Imperfect con tact Check the flat cable

of backplane

board FCll -

interlock board

FCll

connection and connect

1

/ Replace the cable.

Check 24V of interlock

6.1 .2 The Display on the Teaching Box Is Unsteady

I to teaching box.

The display of

the teaching

box is

unsteady and

flickers.

/ board.

I Red LED on

Servo Control

board ON

1 servo driver I / flickering 1

4 Low vo-on Check the voltage on

/ primary power 1 I the primary power I supply (below AC / 150V) I '


6. I . 3 In i t ia l Diagnosis Is Not Completed

1 Symptom 1

The display

"START

DIAGNOSIS"

stays on the

The teaching

box display

stops a t step1

of initial

"COMUCTN

ERR"

( Communication

error) is

displayed a t the

right top of the

teaching box

screen.

I Action I

4 Refer to 6.2.7 in this art. I

right top of the

teaching box

screen.

Nothing is

displayed a t the

"NO FILE" is

displayed a t the

right top of the

teaching box

screen.

-

connected correctly. +

-

1 Replace the 1/0

Check that I/O

management board is

I/O management

board failure

Nothing is

displayed a t the

right top of the

teaching box

screen.

I management board. I

-

4 Refer to 6.2.8 in this rsart. 1

connected correctly. L -

Replace the 1/0

management board.


I/O management

board failure

Check that 1/0

management board is

The teaching

box display

stops a t step2

of initial

"NO FILE" is

displayed a t the

right top of the

teaching box

4 Refer to 6.2.8 in this part. 1


Motion control

board failure - Nothing is

displayed a t the

-

Check that Motion

control board is

right top of the

-

"WPS NOT

RDY" is

displayed a t the

right top of the

teaching box

screen.

connected correctly.

-

Robot dedicated Turn on the robot

welding power dedicated welding

power unit.

correctly.

- Welding interface

o r robot dedicated

welding power unit

not connected.

teaching box

screen.

Check that the welding

interface o r robot

dedicated welding

power unit is connected

Check that 1/0 Nothing is

Replace the Motion

I/O management

control board.

-

The teaching

box display

stops a t step3

of initial

diagnosis.

board failure

"NO FILE" is Refer to 6.2.8 in this part.

displayed a t the

right top of the

teaching box

screen.

right top of the

teaching box

screen.

displayed a t the management board

is connected correctly.

I

Replace the I/O

-

management board.

1 Symptom 1 The teaching

box display

stops a t step4

of initial

I Check Item 1 I Possible Cause I

"NO FILE" is Refer to 6.2.8 in this part.

displayed a t the

right top of the

teaching box

screen.

the right top of

the teaching box

"A.S.TRNS.ERRn

is displayed a t

I screen. I

-

Nothing is

displayed a t the

right top of the

teaching box

I Action (

Arc sensor unit Check that the Arc

not connected. sensor is connected

correctly.

Arc sensor unit Check that Arc sensor

Arc sensor unit Turn on the Arc

1 failure

OFF

1 Replace the Arc sensor /

sensor unit.


screen. unit.

6.1 .4 The Servo Power Supply Cannot Be Turned ON

The servo

power cannot

be turned on.

I Action I

Electromagnetic -

contactor MS1 contactor MS1

Replace the

electromagnetic

not ON

303 OFF (ON in

the normal

condition) 1

failure

Check the voltage on

the primary power

I

Red LED on

1 contactor MS1.

----

each Servo

Low voltage on

primary power

Control board

- P

ON (only green

-

ON in the

Interlock board

LEDs 203/301/

normal

condition)

LEDs on each

1 Servo driver ON I 1 in the normal I I condition)

/ Motion control 1 / board OFF (ON

1 in the norm-a1 / condition) I

I

LED 303 on

Interlock board

ON (OFF in the

normal

condition)

supply(3-phase 200

V) (Below AC150V) I 'Supply.

-4 Motion control Replace the Motion


board failure control board.

6.1 .5 The Servo Power Is Shut OFF Immediately When Turned ON

(Symptom ( I Check Item I

1 The servo t power is shut

off while

"SERVO ON"

stays on the

teaching box

screen.

LEDs 101/301/

303(green) on

Interlock board

OFF (ON in the

normal

( Possible Cause (

Check that each board

1 board failure 1 / 1 is in place. , 1 I

Replace faulty board.

I Action I

Main board failure I

1 condition)

LEDs 101/301/

303/ 203 ( green )

on Interlock

board OFF (ON

in the normal)

/ board failure

board failure


6. 1 .6 Manual Manipulation Does Not Function

1 Symptom 1 Check Item 1 I Possible Cause I ( Action I

of axes 1 - 6

can moves by

1 Only one axis

manual

manipulation.

1 Bad connection of Check the connections

Only axes 4/5/

6 move by

manual

None of axes

1-6 moves by

manual

Able to move

axes 1/2/3 by

manual

CR3A/CR3B

contacts on

Interlock board

OFF (ON in the

normal

condition)

/ motor line of servo driver

connectors CN51-56. ' i 1 motor line

- Disconnection of

Motor failure Replace the motor.

Replace the cable. !

1 No power supply

to axes 4/5/6 servo I- 1 drivers

Check the connections

of servo driver

connectors CN4, CN6,

and CN8.

Replace the cable.

~ i s c o n n e c o f H Replace the control

Check the connection

of control cable 1.

(Manipulator-side CN1)

-

Set the machine lock

motor line

1 function set ON 1 1 function OFF.

Bad connection of

motor line

cable 1 .(Manipulator


---

-side CN1)

6. 2 Failure Codes and Failure Messages

6.2. 1 The Display o f A Fai lure

If a failure occurred, a failure code and a failure message a r e displayed on the

teaching box.

[Example] Emergency Stop

A failure code is displayed in the following format:

EAOO 1 0 1 - 0 0 0 1

EMERGENCSTOP

+RELEASE

a: Indicates the severity of a failure (Error , Alarm, o r Information).

+Fa i lu recode

+ Failure message

- Error (EA/EB/EC)

The Error class includes failures, such as failures of par ts and internal da ta ,

which cause the operation to be disabled unless the causes a r e removed, o r

which can cause harm to the system and operators if the operation is

continued.

- Alarm (A)

The Alarm class includes failures which can develop to Errors unless measures

a r e taken soon, o r which require a simple operation, check, o r action before

the operation is carried on though they may not cause harm to the system and

operators.

- Iiiformatioii (I)

The Information class includes failures whicli should be told to the operator

and peripheral equipment though they do not cause trouble to continue the

operation, o r which can develop to Alarms later.


b: Indicates the cause of failure.

- Urgent Failure (0)

This includes failures which cause the system to be stopped as a last resort

when a failure handling action such a s a detection o r stop cannot be taken

due to the occurrence of another failure.

- Control Failure (1)

This includes internal control system failures being detected a t the main board ,

motion control board, 1/0 management board and the teaching box.

- Servo Failure (2)

This includes servo system failures being detected a t servo control boards and

servo drivers.

- Peripheral Equipment Failure (3)

This includes failures relating to peripheral equipment (optional equipment)

such as sensors.

- Welding Failure (4)

This includes welding failures being detected a t the dedicated welding power

unit and the welding interface.

- Operational Failure (5)

This includes failures relating to operations such a s misoperations.

c : Shows the more detailed cause of b.

d: Indicates the unit where the failure occurred (called a unit code) o r detailed

information of the failure.

For unit codes, see Table 6.4.

e: Indicates the mode (called a mode code) o r detailed information of the failure.

For mode codes, see Table 6.5


Table 6.4. Unit Codes

Note) PCON: Position control board SCON: Servo control board

Table 6.5. Mode Codes

Code

0 0 0 1 0 2 0 3 0 4

0 5 0 6 0 7 0 8 0 9 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8

Code

6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 7 0 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 8 0 8 1 8 2 8 3 8 4 8 5 8 6 9 0 9 1 9 2 9 3

Unit

Main board Motion control board I/O management board Teaching box Welding interface o r ALMEGA AUTO 1T o r ALMEGA FUZZY AUTO Interlock board Backplane board

Analog board External axis board PCON/SCON board 1 PCON/SCON board 2 PCON/SCON board 3 PCON/SCON board 4 PCON/SCON board 5 PCON/SCON board 6 PCON/SCON board 1 Axis 1 PCON/SCON board 1 Axis 2 PCON/SCON board 1 Axis 3 PCON/SCON board 2 Axis 4 PCON/SCON board 2 Axis 5 PCON/SCON board 2 Axis 6 PCON/SCON board 3 Axis 7 PCON/SCON board 3 Axis 8 PCON/SCON board 3 Axis 9 PCON/SCON board 4 Axis 10 PCON/SCON board 4 Axis 11 PCON/SCON board 4 Axis 12 PCON/SCON board 5 Axis 13 PCON/SCON board 5 Axis 14 PCON/SCON board 5 Axis 15 PCON/SCON board 6 Axis 16 PCON/SCON board 6 Axis 17 PCON/SCON board 6 Axis 18

Code

Unit

Axis 1 servo driver Axis 2 servo driver Axis 3 servo driver Axis 4 servo driver Axis 5 servo driver Axis 6 servo driver Axis 7 servo driver Axis 8 servo driver Axis 9 servo driver Axis 10 servo driver Axis 11 servo driver Axis 12 servo driver Axis 13 servo driver Axis 14 servo driver Axis 15 servo driver Axis 16 servo driver Axis 17 servo driver Axis 18 servo driver Personal computer Arc sensor

Laser sensor Main board of CRT unit CRTC board of CRT unit External storage

Printer I/F

Teach

2 0 1 Remote control

1 I

Mode

Diagnosis

Teaching I I


Function

1 0 Auto

6.2.2 Logical Outputs for Failures

Failure output ports are provided to inform external devices of the cause, severity,

and solution of a failure:

Table 6.6 Logical Outputs for Failures

Name

Urgent Failure

Logical Output Port No.

0 2 0 1

Control Failure

Servo Failure

I

0 2 0 2

0 2 0 3

Peripheral Equipment Failure

Welding Failure

0 2 0 4

0 2 0 5

Operational Failure

Error

Alarm

Information

ABSO Adjust Request

Reset Reauest

For details of these output ports, see the instruction manual "Interface With Jig".

0 2 0 6

0 2 1 1

0 2 1 2

0 2 1 3

0 2 0 8

0 2 0 9

Start Request

Failure Code


0 2 7 0

0 3 7 0 - 0 3 7 4

6.2 .3 Shock Sensor

Shock Sensor is a failure which occurs when the torch hits a peripheral jig.

Shock Sensor Error (during automatic operation)

/I 1 SHOCK-S ERR I 1 + RESET I

Shock Sensor Alarm (in Auto mode but not during automatic operation)

/ SHOCKS ALARM I / -. RESET I

* Shock Sensor Information (in Teach mode or during an escape from Shock Sensor

Error or Alarm)

1 SHOCK SENSOR 1

Solution

(A) If the torch is equipped with a shook sensor

Perform manual manipulation in the direction which allows Shock Sensor to be

cancelled.

(B) If the torch is not equipped with a shock sensor

Short-circuit pins 4 - 5 of terminal block TB1 on the Interlock board.


6.2.4 Servo Power Shutoff

This failure occurs when:

A failure occurred and was momentarily removed.

You release the hand from the deadman switch, provided that the teaching box is

equipped with a deadman switch.

The output form of failure varies with the setting of the user parameter

"ABNOMALTY ENCODE" * available for setting the teaching box key status.

1 SERVO DOWN 1 erased after being / (Automatically reset after

Table 6.7 Differences of Output Form according to Special Failure Output ON/OFF

OFF / SERVO DOWN 1 Reset input. / Error (0221)

Output Signal

Failure Code(0374-370)

EA00401-01XX

( ~ e f a u l t ) + RESET 1 1 Reset Request (0209)

Cancellation

Automatically

Setting

ON

1 1 1 Failure Code (0374 - 370)

Display of Failure

EA00401-01XX

output for 2 seconds.

By the RESET key o r

Solution

being output for 2 sec.)

Urgent failure (0201)

0 When the setting is OFF

After being displayed on the teaching box for 2 seconds, the failure is

automatically erased. Then, turn on the servo power supply.

(B) When the setting is ON

After pressing the RESET key, turn on the servo power supply.

In case of this failure, because it is automatically cancelled, you can carry on the

operation you a re doing, o r can restart the automatic operation.

If this failure recurs during automatic operation, the shock sensor may be working.

In this case, correct the path o r attitude to avoid interference with the jig.

* : See "Setting Teaching Box Keys", section 2.2 in Par t I[.


The "ABNOMLTY ENCODE" ON setting affects the signals being output when the

following failures occur:

Emergency Stop

p6zFEG-l 1 EMERGENCSTOP 1

* Servo OFF

SERVO OFF

If the setting is ON, Urgent Failure (0201)

and Error (0211) a re not output.

If the setting is ON, Operational Failure (0206)

and Alarm (0212) a r e not output.

6.2.5 Software Limit/Link Software L imi t

(1) Software Limit Failure

This failure is detected when the mechanism attempts to move out of the working

area .

Teach mode

S.LIMIT XYZZ

+MANUAL OPE.

Auto mode

S.LIMIT XYZZ

X: Mechanism number

Y: Axis number (Displays the lowest axis number if multiple axes a r e involved)

Z: Axis information (Displays the Soft Limit of each axis as bit information)

Tens' place Unit's place


(Example] When Software Limit occurs a t Axes 4 and 6

Tens' place Unit's place

In this case, "28" is displayed a t the ZZ.

Solution

(A) Teach mode

Perform manual manipulation in the direction which allows the Software Limit

to be cancelled.

(B) Auto mode

After pressing the RESET key, turn on the servo power supply. Then,

perform manual manipulation in the direction which allows the Software Limit t o

be cancelled.

(2) Link Software Limit

This failure occurs when the mechanisms could interfere with each other.

* Teach mode

LNKS.LIMITM * +MANUAL OPE.

a Auto mode

YY: Axis numbers (For example, if "23" is displayed, this indicates that Link

Software Limit has occurred a t axes 2 and 3.)

Solution

(A) Teach mode

Perform manual manipulation in the direction which allows the Link Software

Limit to be cancelled.

03) Auto mode

After pressing the RESET key, turn on the servo power supply. Then, perform

manual manipulation in the direction which allows the Link Software Limit to

be cancelled.


6 .2 .6 Overrun

This failure occurs when the robot overruns.

EB0030 1 -XXXX

OVER RUN

-+ RESET

Solution

After pressing the RESET key, perform manual manipulation in the direction

which allows Overrun to be cancelled, while holding the SERVO ON button down.

If this failure occurs though the robot has not overrun, the cause may be the

following :

(A) Any one of JP 601, 602, and 603 on the Interlock board is not short-circuited

+Short-circuit it.

(B) 24V is not supplied to Interlock board.

+Check the connection between CN 41 of the Interlock board and CN41 of

the constant voltage power supply.

(C) The fuse on the Interlock board is blown

->Replace the fuse.

0) Interlock board failure.

-+Replace the Interlock board.


6.2.7 Communication Fai lures

(1) Board To Board Communication Failure

This failure occurs when communication cannot be performed correctly between

boards.

EC10206-YYXX

COMUCTN ERR

-+ POWER OFF

Y Y : 0 1 -.. Main Board - Motion Control Board Communication Failure

0 2 -.. Main Board - 1/0 Management Board

Communication Failure

0 3 Main Board - Teaching Box Communication Failure

Solution

(A) YY:O1

Make sure that the Motion control board o r EPROM on the Motion control

board is placed correctly.

Make sure that the 1/0 management board o r EPROM on the 1/0 management

board is placed correctly.

(C) YY:03

Make sure that the Main board or EPROM on the Main board is placed

correctly.

(2) Echo Back Communication Failure

This is I/O management board o r Teaching box failure.

EC10208-YYXX

COM. ERR

-+ POWER OFF

Y Y : 0 2 -.. Main Board - 1/0 Management Board.

0 3 Main Board - Teaching Box


Solution

0 YY:O2

Replace the I/O management board.

63) YY: 0 3

Replace the teaching box.

(3) DPRAM Failure

This is Main board or I/O management board failure.

EC10209-YYXX

/ DPRAM ERROR I I -+ POWER OFF I

Y Y : 0 0 Main board - Motion control board.

0 2 Motion control board - I/O management board

Solution

(A) YY:OO

Replace the Main Board.

63) YY:02

Replace the 1/0 management board.


6.2.8 Data Installation Failures

This failure is detected when data (files) necessary to operate the robot do not exist.

If this failure is detected, it is necessary to create a required file with the System

Initialize function.

(1) Data Installation Error

EC10601-YYYY

NO FILE

+ POWER OFF

Y Y Y Y : 0 1 0 0 ... Can't find System Parameter file.

0 1 0 1 ... Can't find Manual Operating Speed Table file.

0 1 0 2 ... Can't find Block Operating Speed Table file.

0 2 0 0 -.. Can't find Sequencer file.

Solution

0 YYYY: 0100

If your system consists of a single robot unit, select the "SYSTEM" function

key with the System Initialize function and create a System Parameter file. Then,

set the offset adjusting values and the tool parameters.

If your system consists of multiple mechanisms, select the "SPECIAL" function

key with the System Initialize function and load the system parameters f rom the

external storage.

(B) YYYY: 0101

Select the "MANUAL" function key with the System Initialize function and

create a Manual Operating Speed Table file.

(C) YYYY: 0102

Select the "BLOCK" function key with the System Initialize function and create

a Block Operating Speed Table file.

(D) YYYY: 0200

Select the "SQ" function key with the System Initialize function and create a

Sequencer file.


(2) Data Installation Alarm

A 10601-YYYY

NO FILE

+POWER OFF

Y Y Y Y : 0 2 0 1 ... Can't find Welding Characteristic Data file.

0 2 0 2 Can't find Welding Control file.

0 2 0 3 ... Can't find Current Conversion Table.

8 1 0 0 ... Can't find Arc Sensor file.

8 4 0 0 Can't find Laser Sensor file.

Solution

Vi) YYYY : 0201, 0202, o r 0203

Select the "WELD" function key with the System Initialize function and

create a file.

(B) YYYY: 8100

Select the "ARC-S" function key with the System Initialize function and

create a Arc Sensor file.

(C) YYYY: 8400

Select the "LASER-S" function key with the System Initialize function and

create a Laser Sensor file.


6.2.9 Memory Failures

(1) ROM Failure

This failure is detected when the EPROM or board is broken or the wrong EPROM

is inserted

/ ROM ERROR 1 -+POWER OFF

Y Y : 0 0 Main board

0 1 - a . Motion control board

0 2 -.. 1/0 management board

0 3 ... Teaching box

Solution

Replace the EPROM on the identified board or that board itself

(2) RAM Failure

The identified board is failure.

/ RAMERROR I 1 +POWER OFF I Y Y : 0 0 Main board

0 1 Motion control board

0 2 1/0 management board

0 3 ... Teaching box

Solution

Replace the identified board.


6.2.10 Setting Errors (1) Motor Setting Failure

This failure occurs when the system parameter setting for motor type differs from

the SCON board setting for motor type.

EC20101-XXXX

MOTOR ERROR + POWER OFF

Solution

Turn off the control power supply, set the rotary switches SW 3 - SW 5 on the SCON

boards to the correct values.

The following table shows the SCON board rotary switch setting for each mechanism:

Table 6.8 Rotary Switch Settings fo r Axis Motors of Manipulator

1 SCON for Base Axes 1 ~ C O N ~ Wrist Axes

Manipulator

G01/G03

V40

WO1

Table 6.9 Rotary Switch Settings for Slider Motor


Axis 1

S W 3

4

SCON not in use for V40

Slider

PSB series

RSR series

Axis 4

S W 3

0

D

Relevant switch setting of SCON SW3 to SW5

4

7

Axis 2

S W 4

4

Axis 3

S W 5

2

Axis 5

S W 4

0

E

Axis 6

S W 5

-

- 0 B 0

Table 6.10 Rotary Switch Settings for Positioner

Axis 1

Relevant switch

(2) Axis Setting Failure

This failure occurs when the SCON board rotary switch setting for the number of

controlled axes is wrong.

Axis 2

Relevant switch

R P H - 2 0 0

R P H - 5 0 0

R P H - 1 0 0 0

R P l S - 1 0 0 0

R P l D - 2 0 0

R P l D - 5 0 0

R P l D - 1 0 0 0

R P 2 T - 5 0 0

EC20102-XXXX

AXIS SET ERR

--+ POWER OFF

Solution

Turn off the control power supply and set the SCON board rotary switch SW 6 to the

setting of SW3 -SW5

4

8

8

8

4

8

8

1 8

correct value.

The following table shows the SCON board SW6 setting for the number of controlled

setting of SW3 -SW5

-

-

-

-

-

-

8

axes :

Table 6.11 SCON Board SW6 Settings for the Number of Controlled Axes


- -

SW6 Setting

0

Controlled Axes

3

6.2.11 ABSO Data Failure

This failure is detected when the difference is larger than the allowance in

comparison with the encoder value given when the servo power is shut off and that

when turned on. The allowance and check ON/OFF are set in "FUNC OF ABSO DATA

CHECK" *of the user parameters for setting the system status.

A 11102-YYXX

ABS MISMATCH

-+RESET

YY: 11 - 16 ... SCON/PCON board No.1 - No. 6 (See the unit code table.)

Solution

Run Task program P999 used for checking the origin by block operation and check

the marks. If these marks do not align, reset the absolute encoders and perform the

absolute offset adjustment. If the marks align, the absolute offset values a re correct.

* : Refer to "Setting the System Status", section 2.1 in part II


6. 3 When Servo Failure Occurred

6.3.1 How to see the Servo Failure Display

This section describes how to see the Servo Failure Code. When Servo Failure

occurred, the Teach Pendant displays the abnormal axis and information of the

failure a s shown in Fig.6.1.

Servo Failure can be identified in detail according to:

Failure category No.

Message (not displayed in some cases)

- Failure information codes

SERVO ABN 8

MECHAl AXS2 ENCODER ABN.

UNIT 1 : 0000 0000 0000 0000

UNIT 2 : 0000 0000 0000 0000

UNIT 3 : 0000 0000 0000 0000

UNIT 4 : 0000 0000 0000 0000

UNIT 5 : 0000 0000 0000 0000


t T f t

Column : a b c d

+-Failure category No.

+-Message

Failure information

codes

Fig.6.1 Example of Servo Failure Display

(1) Failure Category No.

When Servo Failure occurred, the Teach Pendant displays the following:

"SERVO ABN * * "

A number is displayed a t " * * ", by which the detailed failure can be identified

a s shown in Table 6.12:

Table 6.12 Failure Category Nos.


Meaning

Failure was detected a t Servo Control

Board.

Servo Control Board malfunctioned.

Servo power was shut off due to

unknown cause.

The temperature extremely increased in

the control unit.

Failure occurred in the Servo Driver

Unit

(For details, see Table 6.14 and 6.15)

Failure occurred in the Servo Driver

Unit.

(For details, see Table 6.14 and 6.15)

The Servo Driver cannot be energized.

The position deviation exceeded the set

value.

The commanded speed exceeded the set

value.

The commanded voltage exceeded the

set value.

Failure occurred when the servo power

was turned on.

* *

3

4

6

7

8

9

1 0

1 2

1 3

1 4

9 9

Name of Failure

Servo Control Board error

CPU failure of SCON Board

Servo power shutoff

Overheat in the Control Unit

Servo Driver failure

Position output failure

Abnormal position/speed

loop ON state

Beyond the position deviation

limit

Beyond the speed command

limit

Beyond the current command

limit

Failure a t the servo startup

(2) Message (not displayed in some cases)

For Servo Failure 8 "Servo Driver Unit failure", a message and failure

information codes a re displayed to give more detailed information.(These

information may be also displayed for othe failures.)

The content of a message corresponds to the failure information codes, and is

displayed as shown below. If multiple failure a re detected, only the earliest failure is

displayed.

Mechanism [No. 1 ]Axis [No. 2 1 [Failure information]

[No. 11 indicates the number of the mechanism where failure was detected.

This number corresponds to any of mechanism numbers 1 - 4 of LEDs which a r e

illuminated by selecting the Axis Changeover key "MECHANISM".

fNo.21 indicates the axis number of the mechanism displayed a t [NO. 11.

Note that this number is not a n axis number used in the entire control unit.

[Failure information] shows the information of a detected failure, for example:

- MECHA * * AXS MOTOR 0-HEAT(Motor Overheat a t Mechanism * Axis * - MECHA * * AXS ENCODER ABN.(Encoder Failure a t Mechanism * Axis * ) - MECHA * * AXS POWTR.0-HEAT

(Power Transistor Overheat a t Mechanism * Axis * ) - MECHA * * AXS OVER CURRENT(0ver Current a t Mechanism * Axis * ) - MECHA * * AXS CURRENT ABN.

(Instantaneous Current Limit Over a t Mechanism * Axis * ) - MECHA * * AXS OVER LOAD (Over Load a t Mechanism * Axis * ) - MECHA * * AXS OVER SPEED

(Speed exceeding detectable limit a t Mechanism * Axis * ) - MECHA * * AXS OVER DEVIAT.

(Position Deviation Limit Over a t Mechanism * Axis * ) - UNIT * OVER VOLTAGE(0ver Voltage a t Unit * ) - UNIT * LACK VOLTAGE(Low Voltage a t Unit * ) - UNIT * STOP INVRTR(1nverter Disconnect a t Unit * - UNIT * A/D ABNORMAL(Fai1ure of A/D signal line a t Unit * ) - UNIT * STOP SIGNAL (Stop signal input a t Unit * )


(3) Failure information codes

The abnormal par t can be identified from Fig.6.1, as shown in Table 6.13:

Table 6.13 Interpretations of Codes

0000 indicates that that part is normal, while any number (displayed in the

hexadecimal notation) except 0000 indicates that that par t is not normal.

Furthermore, the detailed failure can be identified by the number.

Column *

UNIT 1

(Axes 1-3)

UNIT 2

(Axes 4-6)

UNIT 3

(Axes 7-9)

UNIT 4

(Axes 10-12)

UNIT 5

(Axes 13-15)


a

Failure of P a r t common

to each axis

Failure of Par t common

to each axis

Failure of Par t common

to each axis


to each axis


to each axis

b

Failure of

Axis 1

Failure of

Axis 4

Failure of

Axis 7

Failure of

Axis 10

Failure of

Axis 13

c

Failure of

Axis 2

Failure of

Axis 5

Failure of

Axis 8

Failure of

Axis 11

Failure of

Axis 14

d

Failure of

Axis 3

Failure of

Axis 6

Failure of

Axis 9

Failure of

Axis 12

Failure of

Axis 15

a ) Failures Common to Each Axis

When a number, except 0000, is displayed a t column a in Fig.6.1, a failure can be

identified from Table 6.14:

Undervoltage of Main power 0002 1

(Main power off)

Table 6.14 Common Failure Codes

+This bit sometimes

indicates that the

Code

0001

Meaning

Overvoltage of Main power

1 not failure.

0004

0008

0100 1 Input of Stop signal

Disconnection of Inverter signal line servo power is shut

Failure of A/D signal line off, and in that case

Codes in Table 6.14 a re displayed in the hexadecimal notation on the Teach

Pendant.

If multiple failures occur, a sum of these codes is displayed.

KExamplel Meaning of Failure a t column "a" of UNIT 1

0004 : Disconnection of the inverter signal line of the first Servo Control board

+) 0008 : Failure of the A/D signal line of the first Servo Control board

OOOC : Disconnection of the inverter signal line (0004H) and failure of the A/D

signal line (0008H) of the first Servo Control board (0004H + 0008H)


b ) Failure Codes of Each Axis

When a number, except 0000, is displayed a t column b, c, or d in Fig.6.1, a failure

can be identified from Table 6.15:

0 0 0 1 I Motor overheat

Table 6.15 Failure Codes of Each Axis

0 0 0 2 1 Encoder failure

Code

0 0 0 4 1 Overheat of power transistor

Meaning

0 0 0 8 1 Overcurrent

0 0 1 0 I Over limit of momentary current

0 0 2 0 1 Overload

0 1 0 0 1 Over limit of detectable speed

0 2 0 0 Over limit of position deviation

Codes in Table 6.13 a re displayed in the hexadecimal notation on the Teach

Pendant.

If multiple failures occur a t one time, a sum of these codes is displayed.

1(Examplel Meaning of Failure a t column "c" of UNIT 2

0001 : Overheat of Axis 5 motor

+) 0004 : Overheat of Axis 5 power transistor

0005 : Motor Overheat(0001H) and Power Transistor Overheat(0004H) of Axis 5

(0001H + 0004H)


6.3.2 Troubleshooting for Servo Failures

I Action (

( Servo Failure F 1 Refer to (3) of section 6.

1 3 / / 1 codes not "0000" 1 3.1 to remove the cause. I SCON board

error ~ l l failure c a d e s H v Take some measures to

Servo Failure u showing "0000"

CPU failure of

SCON board

Servo Failure m

servo system protect from noise.

Check that the Servo -

/ of Servo Control 1 / Control board is in I Red LED ON

and green LED

OFF on Servo

Control board

Servo Control Replace the Servo

1 board.

I / board failure 1 Control board.

/ place.

Problem of system ti Instal1 the system

Take some measures to

parameters parameters again.

Red LED on

Motion control

servo system

board ON

1 protect from noise.

Servo power

shutoff

Make sure that the

1 placement of / 1 Motion control board 1 Motion control I is placed correctly.

Replace the Motion

/ board o r Servo 1 1 control o r Servo 1 Control board

failure

1 Control board. i


1 Symptom 1

Servo Failure ri

1 Control board 1 I and Servo driver I

Verify the voltage on 1 I / primary power I ( the primary power I

supply (below AC 1 supply

100V outlet

-

Use within the

over 60°C.

Temperature in

the controller I I I

Overheat in

the controller

/ over the allowance

Replace the Backplane 1

allowable temperature.

Replace the cooling unit.

Cooling unit

failure


-

the controller

under 60°C. / element failure board.

Servo Failure r Servo driver

failure

Display of

Servo Failure

on teaching box r------------------

:SERVO ABN 8 1

1 indicator lamp 1 1 1 (wire 4) of 1 1 each of the primary 1 Power supply

UNITl :- x Loss of U phase Verify the voltage on

/ and 1

"UNIT1 LACK

VOLTAGE " at Q,"0002" a t

UNITl@, and

@ shown

INVRTR" a t , "000C" a t UNITl

@ a , and "0002"

a t UNIT2 @

1 shown

"UNIT1 LACK

VOLTAGE" a t

Q , and "0002"

a t UNITl @ and

I primary power I I side phases before I supply (3 -~hase

Replace the breaker.

of cable connecting

servo driver CN1

for axis shown by

"000C" or "0002"

and Servo Ctrl.

Imperfect co*

/ board CN2, or 1

Make sure that the

cable connecting

servo driver CN2

/ and power unit I

cable connection is

correct.

I Replace the cable.

/ [LED 3 0 1 0 ~ Motion control Replace the Motion


on relay unit ON I board failure I 1 control board.

4 "UNIT2 LACK 1 "0002" a t UNIT1

@, and UNIT2

I Possible Cause I Action I

Make sure that the

of control cable 2 control cable (manipulator CN2 connection is correct.

and CN7 on Servo

Replace the cable.

4- Make sure that the

of cable connecting

CN6 on Servo

Control board 1

and switch box

CN135

/ cable connection is I correct. + R.enlace the cable.

Replace the Switch box 1 "UNIT1 LACK

VOLTAGE" a t

@, "0002" a t

UNITl@@@ and

UNIT2 @ shown

Imperfect contact

of control cable 3

(manipulator CN3

and CN7 on Servo

---( Make sure that the 1 1 control cable 1 connection is correct. L

1 Control board 2) 1 / Replace the cable.

Imperfect contact

of cable connecting

CN6 on Servo

Control board 2

and switch box CN

136

-4 Make sure that the

1 cable connection is

I correct

Replace the cable. L Replace the Switch box


/ Possible Cause 1

‘'ME----I 1mper- Make sure that the

I I AXS OVER

"0020" a t any of

UNITl m, and UNIT2 @@ @ shown

I of moter line 1 I control cable

1 connection is correct.

"MECHA10

AXS CURRENT

ABN" a t @ "0010"at any of

UNITl @@$$

and UNIT2

@@$$ shown

P

Disconnection of

motor line

"MECHAI 0 AXS OVER

CURRENT"

current a t @, and "0008" a t

any of UNITl @ @@ ,and UNIT2

shown

Replace the cable. 1

4 Wrong dip switch Check the dip switch

I setting on Servo I / setting and set

I Control board


1 correctly.

Check the fuse. - -

Fuse blown by

over current flow

to servo driver Replace the fuse

I Symptom (

"MECHA1 OAX

S OVER DEVIA

T." a t @and

"0200" a t any of

UNIT1- ,and

UNIT2

shown

I Possible Cause I I Action I

The origins of Perform absolute

I mechanical stopper I I offset adjustment.

I and software limit I

Replace the encoder

-

--( "UNIT1 STOP h

that axis.

1 encoder cable

INVRTR" a t @ and "0004" a t

UNIT@ shown

Check the encoder

cable connection of

Imperfect contact

of encoder cable

1 cable.

Motor failure Replace the motor.

-

"UNIT2 STOP

INVRTR" a t @ and "0004" a t

UNIT2 @ shown

Disconnection of

motor line -

Imperfect contact Check the flat cable

Replace the cable.

Control board and I of flat cable

connecting Servo

I servo driver

I connection.

Servo Control Make sure that the

-

1 is placed correctly.

Disconnection of

flat cable

1 I board failure

Replace the servo

Replace the flat cable.

/ Servo Control board 1

[ failure 1 I driver.


"MECHA1 0 AXS

OVERCURRENT'

a t Q. and "0008"

a t any of UNITl

shown 1 Blown fuse on

servo driver or

robot overrun El- Check the fuse. + / Replace the fuse 1

I

1 Cancel the overrun.

"MECHA10

AXS CURRENT

ABN." a t @, and

"0010" a t any of

UNITl @@@ shown

- "MECHA1 0 AXS CURRENT

ABN." a t Q, and

"0010" a t any of

UNIT2 @@@ shown

Wrong flat cable

connection between

Servo Control

board and servo

driver (Base axes)

Wrong encoder

cable connection

(CN7) between

Servo Control

board (Base axes)

and (Wrist axes).

Check the cable

connection and connect

correctly.

Note)

Check the fuse on the

servo driver indicated , because it may be

blown.

Check the encoder

cable connections and

connect correctly.


Replace the servo

driver.

v 0

--- Servo driver

failure

- All detail codes

showing "0000"

I Symptom I

! Both red and

green LEDs on

Servo Control

board ON

1 Servo system

failure

Only green LED

on Servo Control

board ON

0-HEATVat@,

and "0001" a t

any of - shown

I Action I

Refer to (3) of section 6. 1 1 3.1 to remove the cause.

-

I driving mechanism 1

Defective -

adjustment to the

1 of the machine I

Overload on the

manipulator

Check the machine.

"ENCODER Motor failure Replace the motor.

Reduce the load.

I I ABN"at @ , and I 1 ' I I - I

I 1 "0001" a t any of I H- Check the encoder

I I correctly.

/ - shown of encoder cable

and connect

Replace the encoder

cable connections

I encoder cable. I I cable.

Replace the servo


ATJ' a t @ , and

"0004" a any of

failure. driver.

I Symptom 1

Servo Failure r12 Beyond the

position

deviation limit

I Check Item I I Possible Cause I

All failure codes Problem of system Re-install the system

I showing "0000" 1

Noise affecting the Take some measures to

-

1 parameters

None of Axesl- 6

operable by

manual

I parameters.

Blown fuse on

Interlock board

system

Failure a t

highspeed

operation

Replace the fuse.

1 protect from noise.

Imperfect contact Check the connections

-4 Too large load Reduce the mechanical

1 of motor line

I load.

of Servo driver

connectors CN5 1 - CN56.

Beyond the

speed

command limit

Re-install the system

parameters.

1 operation I Servo Failure

13

Imperfect contact Check the connection

Failure a t

highspeed

----

1 6 operable by

manual

manipulation

-

/ of motor line / of the motor power

I line.

Problem of system

parameters

-1 Noise affecting H Take some measures to 1

-

I the system I protect from noise.

command limit

Reduce the mechani

cal load.

- Servo Failure

14

Beyond the

I the system / to protect from noise. 1

1 operation


-

current

Failure when

starting

Noise affecting Take some measures

Too heavy load

Servo Failure I 99

Failure a t the

servo startup


Perform the same

checks a s those of

Servo Failure 8

according to the

servo failure display on

the teaching box.

Hie ra rch ica l D iag ram o f Funct ion key

1 H ierarchical Diagram of Function key 1 Function keys shown following D are displayed by pressing the Next Candidate key. 0

Even a function of a n option is included.

1. TEACH --IF1 T E A C H ] ( 1 . 1 )

- I F 2 E D I T 1 ( 1 . 2 )

- I F 3 F I L E I ( 1 . 3 )

--IF4 A L L O T I

--IF5 L O C K I

- 1 ~ 1 P A R M T E R ~ ( 1 . 4 )

- IF2 C H E C K 1 ( 1 . 5 )

--IF3 MANAGE 1 ( 1 . 6 )

- I F 4 S Y S . S E T ] ( 1 . 7 )

- IF5 MEMORY ] ( 1 . 8 )

,.....--..-----..... I Function under development

1.1 TEACH I F 1 L I S T F 2 R O L L U P

P R G NO. F 2 R O L L DN

F 1 S E A R C H [ ~ l S Q MARK]

IF2 A S / A E 1

F 3 WS

F 1 RENAME F 4 S T / E T

IF5 P A T H AT] ( F 5 S F * I

R E V E R S E ; t , ( F 2 C L / J F J P I When the number exists

1 " S E A R C H j r 1 F l S Q MARK F 3 T 1

t 1 ~ 2 J U M P 1 t ( F 2 AS/AE 1

IF3 WS 1

F 4 S T / E T I

IF5 P A T H AT1 IF5 S F * I IF1 ASM SET1 JCY IF1 1/0 1

IF3 R E V E R S E ] ( F 2 C L / J F J P ]

IF3 T I

Hierarchical Diagram of Function key 1

[ F 2 H L

I F 3 H C I

I F 5 H C C H G . I

[ E l H L O

I F 2 H O 1

I F 5 H O C H G . I I F 1 M P S I

-12.2 1/0 [ E l S E T I F 2 M P E I

I F 2 R E S E T F 3 E P I

I F 3 I N P O N

I F 4 I N P O F F

I F 1 S N R

F 2 S F R

- I F 3 B R A N C H /-IF1 C L c L O N

F 2 C L O F F

( F 3 C L C N T 1

I F 4 U N C O N D 1

I F 1 J P O N I

I F 2 J P O F F I

I F 3 J P C N T /

F 4 U N C O N D I

--IF3 J F I F 1 J F O N 1 I F 2 J F O F F 1

( F 3 J F C N T \

F 4 U N C O N D /

- 1 ~ 5 C O U N T E R I ~ I ; ; ;;; I

I I

2 Hierarchical Diagram of Function key

--IF4 W E L D [ E l A S N U M . ]

1 ~ 2 A E NUM. I

1 F 3 A S F I L E ]

I F 4 A E F I L E ]

I F 2 A E M

I F 1 I C H

I F 2 R I C

F 3 GS

I [ F l F P NUM.1

I F 2 F P F I L E /

I F 3 A X NUM. I I F 4 A X F I L E ]

F 5 WE 1

I F 1 T I M E R I

When a Sensor selection i s a l ine master.

When a Sensor selection i s a laser sensor.

I F 4 Z O N

IF5 Z O F

- I F 3 E N D L E s s l T I F l R T 1 r . - . . - - - . - . - - - . . - - - - a F 2 R R N .-------..------.-.. r.----...--....----- 88'3 .---.-...-.---...--. R R F


1.2 EDIT jF2 E D I T 1 - IF1 T E A C H 1- /~1 L I S T F 1 R O L L U P

[PRG NO. F 2 R O L L DN

F 1 S E A R C H 1 ~ 1 S Q M A R K /

IF2 A S / A E 1

F 3 WS

F 4 S T / E T

LF5 P A T H AT/ [ F 5 S F * 1 1

When the number ex i s t s I F I S Q MARK^ / F Z C L / J F J P ]

- I F 2 J U M P 1122 A S / A E / IF3 T /

- I F 3 S H I F T I I F 3 WS 1

- I F 4 P A T H [ F 4 S T / E T 1

- 1 ~ 5 P A T H AT/ IF5 S F * 1

- I F 3 R E V E R S E ]

F 3 T / When the number dose not ex i s t -------lp 1 M O T I O N / F 1 P

IF2 HL

( F 3 HC 1

IF5 HC CHG.1

[ F I H L O 1

IF2 HO 1

IF5 HO CHG. I

IF1 M P S I

IF2 1/0 $1 S E T IF2 M P E I

IF2 R E S E T F 3 E P 1

I F 3 I N P ON

IF4 I N P O F F

I F 1 S N R

F 2 S F R


- I F 1 C L

Ill IF1 C L ON ]

[ F 2 C L O F F 1

IF3 C L CNT ]

F 4 UNCOND /

- I F 2 J P / F I J P ON 1

IF2 J P O F F I

F 3 J P CNT I

L ~ ~ 4 UNCOND /

IF^ J F ON ]

IF2 J F O F F j

IF3 J F CNT /

IF4 UNCOND

T E l D E F

F 2 D E C

1F 2 AE NUM. I

IF3 A S F I L E J

IF4 AE F I L E ]

J IF2 AEM 1

I IF2 R T C 1 I F 3 G S 1 F 4 GE I

- I F 5 WEAVE I l lFl F P NUM. I

[ F 2 E P F I L E )

I F 3 AX NUM. I

IF4 AX F I L E ]

F 5 W E 1


-IF2 W S FILE]

-

IF1 F I X E D / iPS...w-iid..P.i-R-i.; ..--..-...--..------- LF.2--.FRE-Q: .--.. j

......-...--.....--.. -[F4 A S F I L E / LF.?--.P-!T-C.H.. ..I

--IF5 A E F I L E / IF4 J O I N T 1

f i en a Sensor selection i s an arc sensor.

1 When a Sensor selection 1s a laser sensor.

(F4 Z O N I

IF5 Z O F i

- 1 ~ 3 E N D L E S S ] .-.....-.......----- ;F-Z.-RRN -.-. -.-- .-..---...-.-------- 1:' :F.?-.RRF R T .....--- I


IF3 O F F S E T I

IF4 S Q I-----INO. E N T R Y I IF5 L A S E R - $

F 2 A E M - I F 1 I N P U T Ill / F I R O L L UP]

/ F Z R O L L D N ]

[ F 3 N O P / M A P /

F 4 b i t I

- I F 2 O U T P U T

IF1 R O L L UP]

IF2 R O L L D N ]

F 3 NOP/MAPI

I L ~ F 4 b i t 1

I F O G C T I IF1 R O L L U P ]

IF2 R O L L D N ]

F 5 E N D J

I F 4 spEclALi J [ E l S Q I N ]

I Il IF1 R O L L U P ]

IF5 E N D IF2 R O L L DNI

IF3 NOP/MAP]

F 4 b i t 1

I F 2 s Q O U T ITl / E l R O L L UP]

IF2 R O L L DN]

IF3 N O P / M A P ]

F 4 b i t 1

I F 3 A N L I N [ E l R O L L UP]

[ F 2 R O L L D N /

IF3 NOP/MAP]

I IF1 R O L L UP]

- I F 5 E N D 1 IF2 R O L L D N ]

IF3 N O P / M A P I

F 4 b i t I


1.3 FILE / F 3 F I L E 1 - - / E l T E A C H 1 E l R O L L UP

I F 1 S Q MARK1

F 3 WS

E l R E N A M E F 4 S T / E T

--IF2 W E L D I F 1 R O L L UP1 I F 5 P A T H A T ] p 5 S F * I

I F 3 E D I T ] ~ 3 R E V E R S E ]

[ F 4 C O P Y 1

I F 5 D E L

F 3 W E A V E

LF2 R O L L DNI

I F 3 E D I T

I F 4 C O P Y

I F 5 D E L

E l R E N A M E


[ F 3 E D I T 1

I F 4 C O P Y 1

I F 5 D E L I

F 1 R E N A M E ]

I F 1 R O L L U P ]

I F 2 R O L L D N ]

I F 3 D I S P 1

[ F 4 C O P Y 1

[ F 5 D E L I

I F 1 R E N A M E ]

- I F 1 O F F S E T J I F 1 R O L L U P ]

$ 2 R O L L DNI

r F 3 E D I T

I F 4 C O P Y

[ F 5 D E L

F 1 R E N A M E

I F 1 R O L L UP]

I F 2 R O L L DN]

I F 3 E D I T

I F 4 C O P Y

F 3 D E L 1

I F 1 R O L L UP1

I F 2 R O L L DNI

F 3 N O P / M A P ]

L / ~ 4 b i t I

- - I F 2 O U T P U T Ill [ F l R O L L UP1

I F 2 R O L L DN]

[ F 3 N O P / M A P ]

F 4 b i t I

- I F 3 I C T I [ E l R O L L U P /

I F 2 R O L L DN]

F 5 E N D I - I F 4 S P E C I A L I F 1 R O L L U P /

f F 2 R O L L DN]

I F 3 N O P / M A P /

F 4 b i t 1

ll I F 2 R O L L DN]

IF^ N O P / M A P /

F 4 b i t 1

- I F 3 A N L I N ]II [ E l R O L L UP1

[ F 2 R O L L DNI

1 ~ 3 N O P / M A P ]

F 4 b i t 1

- I F 4 OUT![

I F 1 R O L L U P ]

[ F 2 R O L L D N ]

I F 3 N O P / M A P ]

F 4 b i t I


1.4 PARMTER IF1 S Y S T E M /

IF2 S W I T C H 1

IF3 W E L D 1

IF4 1/0 I

IF5 A U T O I IF1 N O T E I

IF2 ARC-S IF2 S/W-ARC]

IF3 TOUCH-S/ IF3 S-LASER1

IF4 W- CHAR^

1.5 CHECK p 2 C H E C K 1 IF1 D U M P

T I

I L 1 ~ 3 M O T I O N / IF1 M A I N 1

IF 2 1/0 I

p3 M O T I O N I

F 3 M O D I F Y F 1 M A I N I F 2 I/O I

F 3 M O T I O N I

I N P U T IF1 M A I N 1

I

IF3 M O T I O N 1 F 2 O U T P U T IF 1 M A 1 N 1

I IF2 S T A T E I IF3 M O T I O N I

-1,s L G C CHKJ-1~1 PRG. A L

::::IRM1 I 1

1 0 Hierarchical Diagram of Function key

Hierarchical Diagram of Function key 1 1

1.6 MANAGE IF3 MANAGE I

IF1 T E A C H 1

IF2 WELD

IF 3 WEAVE

IF4 S Q

IF5 O F F S E T

I F 3 L A S E R - S

F 1 T E A C H

F 2 WELD

T, F 1 A S C

F 2 A E C J

( ~ 1 W F P 1 - I F 4 S Q F 2 WAX I

89

- I F 5 O F F S E T ]

- I F 1 W-CHARA]

I F 1 S Y S T E M I ..-.-.--..-----.-.--

- : F 3 .------.--------.-.- DEV. CAL: IF2 S W I T C H /

IF3 WELD

IF4 1/0 1

[F5 A U T O I

IF2 TOUCH-S]

F 3 S - D A T A (

I F 1 ASM I

F 2 AEM I

1.7 SYS. SET pi174 S Y S . S E T I - I F 1 M E C H . 1 j

[ F 2 M E C H . 2 I I F 3 M E C H . 3 ]

[ F 4 M E C H . 4 I

I F 5 M E C H . 5 (

- $ z RESTART]-1~1 C O N F I R M I

- I F 3 M S T R I N G ]

- I F 4 c O N T R O L 1 l [

[ F l MU-CRDN]

- [ F 5 M A N U A L I I F 1 R O T A T 11

I F 2 R O T A T 21

F 3 C A R T E . 1

I F 1 S E T I

- 1- I F 2 L I S T 1

F 5 D E L


1.8 MEMORY [ F 3 MEMORY I------IF1 L I S T I F I P R O G R A M ]

IF2 WELD

IF3 WEAVE

[F4 S Q

[F2 L A S E R - S

F 3 T O U C H - S

F 2 S A V E F 1 S E P A . F 1 PROGRAM

IF2 WELD IF1 A S C

IF2 A E C

[ F 3 ASM

F 4 AEM

[F 3 WEAVE IF1 W F P

.-------------.--.-- : F 2 W C P - - - - - + - . - - - - - - - . - - - -

.----.------...-.--. l F 3 WCF .---..---....-.-.-..

IF4 WAX ..-------.--.....--. : F 5 WVP .----..----.....--..

F 4 TOUCH-SI

F 2 A L L F 1 P R G A L

F 3 B A C K U P F 2 WELD A L

[ F 3 WEAV AL]

IF4 S Q A L 1

IF5 D E V A L I

IF2 L A S R ALI

I F 3 U S E R ALI

F 4 S Y S AL j

[ I F 5 T C H AL /


- I F 3 LOAD 1 - --IF1 S E P A . [ ~ l P R O G R A M \

IF 2 WELD I F 1 A S C

J F Z A E C

I F 3 ASM

I F 3 WEAVE I F 1 W F P

I F 1 O F F S E T IF4 WAX

F 4 TOUCH-S]

F 2 A L L E l P R G A L

F 3 B A C K U P F 2 WELD A L

I F 3 WEAV ALI

IF4 S Q A L 1

IF5 DEV AL 1

11-2 L A S R A L I

I F 3 U S E R ALI

IF4 S Y S AL I


F [ F 4 V E R I F Y I---rlFl S E P A . ]--[--IF1 PROGRAM]

I / F 3 WEAVE 1

( F 5 DEV CALI

IF1 O F F S E T I IF2 L A S E R - S J

A L L

[F 3 W-CHARAI

IF4 T O U C H - S /

F 1 P R G AL 1 F 3 B A C K U P F 2 WELD A L

IF3 WEAV ALI

IF4 S Q A L I IF5 DEV A L 1

IF2 L A S R ALI

I F 3 U S E R AL]

IF4 S Y S A L 1

- I F 5 D E L . F 1 PROGRAM F 5 T C H AL I

F 2 WELD

IF3 WEAVE I

IF4 S Q

IF1 O F F S E T

F 1 I N I T I A L --,-El U S E R

t l F 2 A E C 1

t , p 3 ASM

F 4 AEM 1 IF1 W F P I .---..-...-.---..-.. : F 2 .---.-..---.---.---. WCP r . - . - - - - - - . . - . . . - - - - eF 3 WC F

IF4 WAX I r...---.--..--..--.. sF5 WVP

t l F 2 A E C 1

t , IF3 ASM I

F 4 AEM I

[ E l W F P I ----..---.-----..... K.2- - -k'-c-p. -. . -. - .: ..--.---....---....- F-3.. .k'.G-Y- -. -. . . . : IF4 WAX 1 - - - - - - - - -~~ . . . .~~~~ . LF.3 - - -k'-v.p.. . - . - - - :

L [ ~ 2 S Y S T E M ]


1.9 Function selection key input IF1 C O R D N T E ] ....---......---..--. :F-2- - -HAND- - W.?; IF3 C R D MOVl

IF4 1/0 R S T ]

F 5 L A S E R I

2. AUTO 2.1 Automatic operation Temporary stop (Multi - station)

I F I RESERVE^

[ F 3 S T R T POI-IF1 P O S S E T ]

F 4 R E T R E A T /

2.2 Automatic operation Temporary stop (BCD, Binary) E l P O S S E T ]


Appendix

Contents

1. Restrictions on the Overlap Process 1

2. The Relation Between a Minimum Circular Diameter and a Setting Speed ---.-.----.--.-.. 4

3, Restrictions on Weaving Frequency ............................................................................................................ 5

4. Tool Parameters 10

Appendix 1. Restrictions on the Overlap Process

Positioning P

(I) Even if Overlap is set ON, the overlap process may not be in effect depending on the

relation between a travel distance and a travel speed.

Speed

F i g . 1 The relation between the overlap effective travel distance and travel speed

(2) Even if Overlap is set on, the overlap process is not in effect in the following

conditions:

When neither one of two consecutive sequences has Positioning instruction (P)

Sequence Instruction

0 0 1 P 0 0 2 / Overlap is in effect

0 0 2 P

0 0 3 P ,

0 0 4 L P

0 0 5 P LK Overlap process not in effect

When Input Wait instructions(N, or F), Timer Time Wait instruction (T), or No

Operation instruction (NOP) is taught between two sequences

Sequence Instruction

0 0 1 P

0 0 2 P 002 / Overlap is in effect

0 0 4 P f

' Overlap is not in effect p , ~ 0 0 1

Appendix 1

Linear I n terpolation L (or Circular Interpolation)

(1) Even if Overlap is set ON, the overlap process may not be in effect depending on the

relation between a travel distance and a travel speed.

Speed rate [ . .

1 Overlar, Drocess not in effect

<

O l5 20 Travel distance per sequence [ mm 1

Fig.l.2. The relation between the overlap effective travel distance and travel speed

(2) Even if Overlap is set on, the overlap process is not in effect in the following

conditions:

* When two consecutive sequences a re taught with different coordinate systems.

When Input Wait instructions(N, o r F), Timer Time Wait instruction (TI, o r No

Operation instruction (NOP) is taught between two sequences.

* When two consecutive sequences are synchronous interpolation instructions (HL, KC)

and single interpolation instructions(L, C) respectively.

(Example]

003 H P 100% WORK LAP:ON M1,2 004 L 100cm WORK LAP:ON MI 005 H L 100cm WORK LAP:ON M1,2 006 H L lOOcm WORK LAP:ON M1

/ Overlap is not in effect

L

2 Appendix

* When the main mechanism is difference between two consecutive sequences.

(Example1

002 H L 100cm WORK LAP:ON M1,2 003 H L 100cm WORK LAP:ON M1,2 (The main mechanism is set mechanism 1) 004 H L 100cm WORK LAP:ON M1,2 (The main mechanism is set mechanism 1) 005 H L 100cm WORK LAP:ON M1,2 (The main mechanism is set mechanism 2)

tL e---Overlap is in effect

Appendix 3

Appendix 2.

The Relation Between a Minimum Circular Diameter and a Setting Speed

The minimum circular diameter varies according to speeds. The relation between a speed

and a diameter is shown below. Note that the usable area varies according to angles of

the wrist axes.

0 1

4

2 Speed (m/min)

Fig.2.l. The relation between a minimum circular diameter and a speed (ALMEGA G01) p\\\\\\yr (md Usable area

k Q) i-'

Q)

5 100 .3

Tb k cd 4

3 2 50 ;;7

0 1 2 3 Speed (m/min)

Fig.2.2. The relation between a minimum circular diameter and a speed (ALMEGA G03)

Speed (m/min) Fig.2.3. The relation between a minimum circular diameter and a speed (ALMEGA V series)

4 Appendix

Appendix 3. Restrictions on Weaving Frequency

Weaving may not be performed in accordance with the weaving frequency setting.

The relation between a frequency setting and an actual frequency varies according to a

combination of mechanisms.

For details, refer to the following table and Fig.3.1 through Fig.3.7

Table 3.1 Classification based on the system configuration

V01 single unit (overhead) I B

System Configuration

V01 single unit

GO1 single unit

V01 single unit (wall mounting) 1 B

System Category

B

A

VOI+ 1-axis s I B

VOI+ z-axis P I D

V01 i- 1-axis P + l-axis S

V01+ z-axis P + l-axis S

GO1 + l-axis S

D

E

GO1 single unit (overhead)

GO1 single unit (wall mounting)

GO1 + l-axis P

A

A

GO1 + Z-axis P

P : a positioner S : a slider

GO1 i- l-axis P + l-axis S

GO1 + Z-axis P + l-axis S

Appendix 5

C

D

The relation between a set frequency and an actual frequency for

Axis weaving and Fixed pattern weaving

6

t Actual frequency 5

2 4 6 8 Frequency setting (Hz 1 4

Fig.3.1. System Category A

Actual t

frequency

2 4 6 8

Frequency setting (Hz I -+

Fig.3.2. System Category B

6 Appendix

2 4 6 8 Frequency setting ( Hz )

Fig.3.3. System Category C

2 4 6 8

Frequency setting ( Hz )

Fig.3.4. System Category D

Appendix 7

2 4 6 8

Frequency setting ( Hz 1 Fig.3.5. System Category E

8 Appendix

2 4 6 8

Frequency setting [ Hz )

Fig.3.7. System Category G

@ Impontaut 1) This relation is based on an assumption that each of center, 1/4, and 3/4

stopping time settings is 0. If these settings are not 0, this relation is not applicable, and the actual frequency is lower than the set frequency.

2) The actual weaving frequency during seam tracking with the arc sensor is further lower.

\

Appendix 9

Appendix 4. Tool Parameters Tool parameters 1 - 6 are available.

1. To use a curved torch or straight torch for ALMEGA V series fixed a t some angle

from the direction perpendicular to the flange face with a bracket (see Fig.4.1, Fig.4.2, and Table 4.1.):

Parameter 1 = P 1 [ml Parameter 2 = P 2 [ml Parameter 3 = P 3 Cmnl Parameter 4 = P 4 [degl Parameter 5 = P 5 = 0 . 0 Cdegl Parameter 6 = 0 . 0 [degl

To use a straight torch fixed a t an angle of 45' from the direction perpendicular to the flange face with a bracket, set parameter 4 a t -45' .

2. To use a straight torch for ALMEGA G series (see Fig.4.2 and Table 4.2): Parameter 1 = P 1 [m] Parameter 2 = P 2 [m] Parameter 3 = P 3 [ml Parameter 4 = P 4 = - 9 0 [degl Parameter 5 = P 5 = - 9 0 [degl Parameter 6 = 0 . 0 [degl

@ Note The value of parameter 6 should be always 0.0.

X A

P 2

Fig.4.1 A curved torch for ALMEGA V series

Fig.4.2. A straight torch for ALMEGA G/V series

Appendix 1 0

Tables 4.1 and 4.2 list DAIHEN torches and their tool parameter settings:

Table 4.1. Tool parameters fo r torches f o r ALMEGA V series

@Curved torch

V series

@Straight torch (fixed a t 45' from the direction perpendicular to the flange face with a bracket)

Tool Pa rame te r

MTXC-3501set

MTXC-3501 (100mm long) s e t

MTCW -5001set

MTCA-2501set

P1

MWP - 18 (w/shock sensor) s e t / 0.0 I 0.0 1 426 1-45.0 1 0.0 I 0.0

0.0

0 .O

0.0

0.0

MTZ-3502set

MWP- 17 (w/shock sensor) se t

P2

0.0

0.0

0.0

0.0

0.0

0.0

MWP- 17 (w/mechanical fuse) se t

MWP - 18 (w/mechanical fuse) s e t

P4 P 3

MTXA-2501set

CTPW -0801 (w/shock sensor) se t

Table 4.2. Tool parameters fo r torches f o r ALMEGA G series

Tool Pa rame te r

300

400

450

400 '

0.0

0.0

0.0

0.0

CTPW -0801 (w/mechanical fuse) se t

CTPW - 1201 (w/mechanical fuse) se t

P5

0.0

0.0

0.0

-45.0

-45.0

-45.0

-45.0

380

426

0.0

0.0

0.0

0.0

G series

0.0

0.0

P1 1 P2 I P3 I P4 I P5 1 0.0

MTX-3502set

MTY - 3502set

MTW -5001set 1 -235.0 1 0.0 1 28.0 1 -90 / -90 1 0.0

0.0

0.0

0.0

0.0

-45.0

-45.0

350

350

0.0

0.0

MTXW - 5002set

MTZ - 3502set

0.0

0.0

0.0

0.0

380

426

-235.0

-261.0

MWP- 18set 1 -235.0 / 0.0 1 43.0 1 -90 1 -90 1 0.0

0.0

0.0

-45.0

-45.0

350

350

-235.0

-285.0

MTXA -2051set

MWP - l7set

CTPW -0801set

0.0

0.0

-45.0

-45.0

0.0

0.0

CTPW - 120lset ( -235 .01 0.0 1 28.0 1 -90 1 -90 1 0.0

0.0

0.0

-45.0

-45.0

0.0

0.0

-280.0

-235.0

Appendix 1 1

0.0

0.0

0.0

0.0

28.0

28.0

0.0

0.0

0.0

0.0

28.0

28.0

0.0

0.0

0.0

0.0

-90

-90

-90

-90

28.0

43.0

- 90

- 90

0.0

0.0

- 90

- 90

-90

-90

0.0

0.0

- 90

- 90

0.0

0.0

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