Do not submit this electronic data to the customer.

Transcription

1 YASKAWA YASNAC XRC Cocurret I/O Parameter Upo receipt of the product ad prior to iitial operatio, read these istructios thoroughly, ad retai for future referece. MOTOMAN INSTRUCTIONS MOTOMAN SETUP MANUAL MOTOMAN- INSTRUCTIONS YASNAC XRC INSTRUCTIONS YASNAC XRC OPERATOR S MANUAL YASNAC XRC OPERATOR S MANUAL for BEGINNERS The YASNAC XRC operator s mauals above correspod to specific usage. Be sure to use the appropriate maual. Do ot submit this electroic data to the customer. THIS MATERIAL IS FOR STUDY PURPOSE ONLY. YOU MUST READ THE MANUAL WHICH ENCLOSED WITH A ROBOT. YASKAWA MANUAL NO. RE-CKI-A41 2

2 MANDATORY This maual explais the various compoets of the YASNAC XRC system ad geeral operatios. Read this maual carefully ad be sure to uderstad its cotets before hadlig the YASNAC XRC. Geeral items related to safety are listed i Sectio 1: Safety of the Setup Maual. To esure correct ad safe operatio, carefully read the Setup Maual before readig this maual. CAUTION Some drawigs i this maual are show with the protective covers or shields removed for clarity. Be sure all covers ad shields are replaced before operatig this product. The drawigs ad photos i this maual are represetative examples ad differeces may exist betwee them ad the delivered product. YASKAWA may modify this model without otice whe ecessary due to product improvemets, modificatios, or chages i specificatios. If such modificatio is made, the maual umber will also be revised. If your copy of the maual is damaged or lost, cotact a YASKAWA represetative to order a ew copy. The represetatives are listed o the back cover. Be sure to tell the represetative the maual umber listed o the frot cover. YASKAWA is ot resposible for icidets arisig from uauthorized modificatio of its products. Uauthorized modificatio voids your product s warraty. ii

3 NOTES FOR SAFE OPERATION Read this maual carefully before istallatio, operatio, maiteace, or ispectio of the YASNAC XRC. I this maual, the Notes for Safe Operatio are classified as WARNING, CAUTION, MANDATORY,or PROHIBITED. WARNING CAUTION Idicates a potetially hazardous situatio which, if ot avoided, could result i death or serious ijury to persoel. Idicates a potetially hazardous situatio which, if ot avoided, could result i mior or moderate ijury to persoel ad damage to equipmet. It may also be used to alert agaist usafe practices. MANDATORY Always be sure to follow explicitly the items listed uder this headig. PROHIBITED Must ever be performed. Eve items described as CAUTION may result i a serious accidet i some situatios. At ay rate, be sure to follow these importat items. NOTE To esure safe ad efficiet operatio at all times, be sure to follow all istructios, eve if ot desigated as CAUTION ad WARNING. iii

4 WARNING Before operatig the maipulator, check that servo power is tured off whe the emergecy stop buttos o the playback pael or programmig pedat are pressed. Whe the servo power is tured off, the SERVO ON READY lamp o the playback pael ad the SERVO ON LED o the programmig pedat are tured off. Ijury or damage to machiery may result if the emergecy stop circuit caot stop the maipulator durig a emergecy. The maipulator should ot be used if the emergecy stop buttos do ot fuctio. Emergecy Stop Butto E.STOP Oce the emergecy stop butto is released, clear the cell of all items which could iterfere with the operatio of the maipulator. The tur the servo power ON Ijury may result from uitetioal or uexpected maipulator motio. TURN Release of Emergecy Stop Always set the Teach Lock before eterig the robot work evelope to teach a job. Operator ijury ca occur if the Teach Lock is ot set ad the maipulator is started from the playback pael. Observe the followig precautios whe performig teachig operatios withi the workig evelope of the maipulator : - View the maipulator from the frot wheever possible. - Always follow the predetermied operatig procedure. - Esure that you have a safe place to retreat i case of emergecy. Improper or uiteded maipulator operatio may result i ijury. Cofirm that o persos are preset i the maipulator s work evelope ad that you are i a safe locatio before: - Turig o the YASNAC XRC power - Movig the maipulator with the programmig pedat - Ruig check operatios - Performig automatic operatios Ijury may result if ayoe eters the workig evelope of the maipulator durig operatio. Always press a emergecy stop butto immediately if there are problems.the emergecy stop butto is located o the right side of both the YASNAC XRC playback pael ad programmig pedat. iv

5 CAUTION Perform the followig ispectio procedures prior to coductig maipulator teachig. If problems are foud, repair them immediately, ad be sure that all other ecessary processig has bee performed. -Check for problems i maipulator movemet. -Check for damage to isulatio ad sheathig of exteral wires. Always retur the programmig pedat to the hook o the XRC cabiet after use. The programmig pedat ca be damaged if it is left i the maipulator s work area, o the floor, or ear fixtures. Read ad uderstad the Explaatio of the Alarm Display i the setup maual before operatig the maipulator. Defiitio of Terms Used Ofte i This Maual The MOTOMAN maipulator is the YASKAWA idustrial robot product. The maipulator usually cosists of the cotroller, the playback pael, the programmig pedat, ad supply cables. I this maual, the equipmet is desigated as follows. Equipmet Maual Desigatio YASNAC XRC Cotroller YASNAC XRC Playback Pael YASNAC XRC Programmig Pedat XRC Playback Pael Programmig Pedat v

6 Descriptios of the programmig pedat ad playback pael keys, buttos, ad displays are show as follows: Equipmet Maual Desigatio Programmig Pedat Character Keys Symbol Keys Axis Keys Number Keys Keys pressed simultaeously Displays The keys which have characters prited o them are deoted with [ ] ex. [ENTER] The keys which have a symbol prited o them are ot deoted with [ ] but depicted with a small picture. ex. page key The cursor key is a exceptio, ad a picture is ot show. Axis Keys ad Number Keys are geeric ames for the keys for axis operatio ad umber iput. Whe two keys are to be pressed simultaeously, the keys are show with a + sig betwee them, ex. [SHIFT]+[COORD] The meu displayed i the programmig pedat is deoted with { }. ex. {JOB} Playback Pael Buttos Playback pael buttos are eclosed i brackets. ex. [TEACH] o the playback pael Descriptio of the Operatio Procedure I the explaatio of the operatio procedure, the expressio "Select " meas that the cursor is moved to the object item ad the SELECT key is pressed. vi

7 1 Cocurret I/O 1.1 Features of Cocurret I/O Costructio ad Specificatios of the Cocurret I/O Classificatio of I/O Sigals Iput Sigal Meaig of Number Register Geeral Register System Register Aalog Output Register Numeric Data Cofiguratio of I/O Sigals Arc Weldig Hadlig, Spot Weldig, Geeral-Purpose Applicatios Specific Iput Sigals (4xxx) Commo for All Applicatios Arc Weldig Hadlig Spot Weldig Geeral-Purpose Applicatios Displayig Alarms Ad Messages : System Alarm Request : User Alarm Request : System Message Request : User Message Request : Alarm Reset Selectig Mode/Cycle ad Callig Master Job to 441: Selectio of Mode , 456, 457: Selectio of Operatig Modes to 452: Selectio of Cycles : Master Job Callig Exteral Servo O : Exteral Servo O to 487: Exteral Servo Off : Exteral Start : Exteral Hold Operatig Istructios : I-Guard Safe Operatig Istructio : Check Operatio : Weavig Prohibitio to 47: 1-Step Back Operatig Istructio to 471: Sequece Wait , 474, 484: Work Home Positio Retur Request Idepedet Cotrol Sigals (Optioal) , 412, 413, 414, 415: SUB1, 2, 3, 4, 5 ALM REQ vii

8 491, 492, 493, 494, 495: SUB1, 2, 3, 4, 5 MASTER CALL Applicatio Sigals , 421, 425: WORK START RESPONSE , 4215, 4255: RETRY REQUEST , 4216, 4256: RETRY RETURN REQUEST , 4211, 4251: WORK END RESPONSE , 4217, 4257: AUTOMATIC ANTI-STICKING REQUEST , 4212, 4252: WORK TIME MEASURE , 4213, 4253: TIP REPLACEMENT COMPLETED , 4214, 4254: NOZZLE CLEANING COMPLETED , 422, 426: RESTART REQUEST (ARC SHORTAGE) , 4221, 4261: RESTART REQUEST (GAS SHORTAGE) , 4222, 4262: RESTART REQUEST (WIRE SHORTAGE) , 4223, 4263: RESTART RESET PROCESS , 4224, 4264: RETRY TIMES CLEAR , 4225, 4264: ARC SHORTAGE RESTART TIMES CLEAR , 4226, 4265: AUTOMATIC ANTI-STICKING TIMES CLEAR , 424, 428: SENSING PROHIBIT Hadlig , 421, 425: WORK START RESPONSE , 4211, 4251: WORK END RESPONSE , 4212, 4252: WORK TIME MEASURE , 4187, 422, 4227, 4263, 4264: SENSOR INPUT Spot Weldig , 4212, 4252: WORK TIME MEASURE , 4217, 4257: WELDING STOP Geeral-Purpose Applicatios , 421, 425: WORK START RESPONSE , 4211, 4251: WORK END RESPONSE , 4212, 4252: WORK TIME MEASURE Specific Output Sigals (5xxx) Commo For All Applicatios ARC WELDING Hadlig Spot Weldig Geeral-Purpose Applicatios Displayig Alarms ad Messages to 514: ALARM/ERROR OCCURRENCE , 516: BATTERY WEAK : COOLING FAN ERROR Settig of Mode / Cycle ad Particular Play Operatio to 552: CYCLE SETTING to 554: MODE SETTING viii

9 555: COMMAND REMOTE SETTING : TEACH LOCK SETTING : IN-GUARD SAFE OPERATION SETTING : DRY-RUN SETTING : MACHINE LOCK SETTING : SOFT LIMIT RELEASE SETTING : CHECK OPERATION SETTING Idicatio of Start/Stop ad Status to 518: SERVO ON STATUS : POSITION CHECK COMPLETED : OPERATING : HOLDING : SERVO ON : JOB EDITING OPERATION INDICATION : JOG OPERATION INDICATION , 597, 517: PERMISSIBLE WORK OPERATING ,59,51: SEQUENCE WAITING , 591, 511: SEQUENCE CONTINUING , 593, 513: SEARCH START : HEAD OF MASTER JOB , 595, 515: WORK RESTART PROHIBIT , 596, 516: LOCUS DEVIATION Iterferece Sigals to 5137: IN-CUBE , 5141, 515, 5151, 5161, 5162: S-AXIS INTERFERENCE AREA , 5154, 5164, 5146, 5156, 5166, 5147, 5157, 5167: MOVING SPHERE INTERFERENCE AREA Arithmetic Istructio Sigal , 5261, 5262: Arithmetic Flag Sigals Durig Operatio ad for Jog Offset Juctio (Optioal) , 522, 523, 524, 525: TOP SUB1, 1, 2, 3, 4, 5 MASTER , 5155, 5165: CRD WORKING , 5142, 5143, 5144, 5155: SUB ALM OCCUR , 5153, 5154, 5155, 5156: SUB HELD Sigals for Servo Float Fuctio (Optio) , 694, 514: Servo Float ON Arc Weldig , 531, 535: WORK START INSTRUCTION , 5311, 5351: WORK END INSTRUCTION , 5312, 5352: WORK CONTINUING PROHIBIT INSTRUCTION , 5313, 5353: TIP REPLACEMENT REQUEST , 5314, 5354: NOZZLE CLEANING REQUEST , 5315, 5355: INCHING , 5316, 5356: RETRACT ,5317,5357: RETRY RETURN PROCESSING ix

10 528, 532, 536: RESTART PROCESSING (ARC SHORTAGE) , 5321, 5361: RESTART PROCESSING (GAS SHORTAGE) , 5322, 5362: RESTART PROCESSING (W IRE SHORTAGE) , 5323, 5363: RESTART RETURN PROCESSING , 5324, 5364: RETRY SETTING TIME EXCEEDED , 5325, 5365: ARC SHORTAGE RESTART SETTING TIMES EXCEEDED , 5326, 5366: AUTOMATIC ANTI-STICKING SETTING TIMES EXCEEDED , 5327, 5367: RETRY REPLAY MODE Hadlig , 5316, 5356: SHOCK SENSOR FUNCTION SELECT , 5317, 5357: SHOCK SENSOR INPUT to 5287, 532 to 5327, 536 to 5367: TOOL VALVE OUTPUT Spot Weldig , 5314, 5354: WEAR DETECTION ERROR (Motor Gu) , 5315, 5355: CHANGE TIP ALM (Motor Gu) , 5316, 5356: SVSPOT EXECUTE (Motor Gu) , 5317, 5357: WELDING ON/OFF Geeral-Purpose Applicatios , 531, 535: WORK START INSTRUCTION , 5311, 5351: WORK END INSTRUCTION , 5312, 5352: WORK CONTINUING PROHIBIT INSTRUCTION Iteral Sigal Used i Stadard Ladder (7xxx) Arc Weldig Hadlig Spot Weldig Geeral-Purpose Applicatios Iteral Cotrol Status Sigals (8xx) Iteral Cotrol Status Sigals Iteral Cotrol Status Sigal (Moitor) : EDITING PROHIBITION to 813: MODE SELECTION : *PLAYBACK PANEL HOLD : OPERATION START : SERVO POWER ON : 24VOK : *SAFETY PLUG INPUT : *XCP1 CPU Error : *EXTERNAL EMERGENCY STOP : *PROGRAMMING PENDANT EMERGENCY : * PLAYBACK PANEL EMERGENCY STOP x

11 831: SERVO ON CONDITION : FORCED RELEASE INPUT : SERVO ON CONDITION : DEADMAN SWITCH INPUT : *EXTERNAL HOLD : EXTERNAL SERVO ON INPUT : SAFE SPEED : SAFE SPEED , 855, 861, 865, 871, 875, 881, 885, 891, 895, 811, 815: CONFIRMATION OF SERVO POWER ON , 856, 862, 866, 872, 876, 882, 886, 892, 896, 812, 816: CONFIRMATION OF BRAKE RELEASE , 857, 863, 867, 873, 877, 883, 887, 893, 897, 813, 817: POWER ON UNIT SIGNAL ALARM to 8113: DIRECT IN 1 to : *SHOCK SENSOR OPERATION HOLD : *SERVO ON ENABLED : *BRAKE FUSE BLOWOUT : *SERVO CPU ERROR : *SHOCK SENSOR OPERATION EMERGENCY STOP : *EXTERNAL AXIS OVERTRAVEL : *OVERTRAVEL Pseudo Iput Sigals (82xx) Pseudo Iput Sigals to 8216: REMOTE FUNCTION SELECTION to 8224: SIGNAL SELECT STATUS (SPOT WELDING) Network Iput Sigals (9xxx) I/O Except Cocurret I/O Hardware Specific Iput EXESP: FOR EXTERNAL EMERGENCY STOP EXHOLD: FOR EXTERNAL HOLD SAF_F: FOR SAFETY PLUG EXSVON: FOR EXTERNAL SERVO ON DIN1 to 4: FOR DIRECT IN INPUT SIGNAL FORCE: FORCED RELEASE INPUT SIGNAL Register Commo Usage Arc Weldig Hadlig Spot Weldig Geeral-Purpose Applicatios Stadard Ladder Program List of Usable Istructios Istructio Descriptio STR Istructio STR-NOT Istructio xi

12 AND Istructio AND-NOT Istructio OR Istructio OR-NOT Istructio AND-STR Istructio OR-STR Istructio OUT Istructio PART Istructio END Istructio TMR Istructio CNT Istructio GSTR Istructio / GOUT Istructio PLS Istructio PLF Istructio ADD Istructio SUB Istructio MUL Istructio DIV Istructio MOD Istructio BIN Istructio BCD Istructio MOV Istructio WAND Istructio WOR Istructio WXOR Istructio WNOT Istructio SHL Istructio SHR Istructio ROL Istructio ROR Istructio Arithmetic Flag Flag Type Flag Trasitio uder Scaig Arc Weldig Ladder Program List I/O Alarm I/O Message USER OPEN SIGNALS Hadlig LADDER PROGRAM LIST I/O ALARM I/O Message Spot Weldig Ladder Program List I/O Alarm I/O Message Geeral-Purpose Applicatios LADDER PROGRAM LIST I/O ALARM I/O MESSAGE xii

13 1.14 Editig Ladder Programs Flow of Data By Ladder Programs Basic Operatio Editig Operatio Isertig Istructio CHANGING INSTRUCTIONS DELETE INSTRUCTIONS EDITING OPERANDS CANCELLING EDITING Compile Search TOP LINE, END LINE SEARCH FOR LINE NO. AND BLOCK NO SEARCH FOR RELAY NO. AND REGISTER NO How to Moitor Sigals I/O Display I/O STATUS DISPLAY Pseudo Iput Sigal Display Register Display Servo Power Status Display Aalog Output Display I/O Messages ad I/O Alarms Registerig the User Sectio Parameter 2.1 Parameter Cofiguratio System Coform Parameters S1CxG Parameter S1CxG: IN-GUARD SAFE OPERATION MAX. SPEED.2-2 S1CxG1: DRY-RUN SPEED S1CxG2 to S1CxG9: JOINT SPEED FOR REGISTRATION S1CxG1 to S1CxG17: LINEAR SPEED FOR REGISTRATION S1CxG18 to S1CxG25: POSITION ANGLE SPEED S1CxG26 to S1CxG29: JOG OPERATION ABSOLUTE VALUE SPEED S1CxG3 to S1CxG32: INCHING MOVE AMOUNT S1CxG33 to S1CxG36: POSITIONING ZONE S1CxG44: LOW-SPEED START S1CxG45 to S1CxG48: JOG OPERATION LINK SPEED.2-5 S1CxG49 to S1CxG51: YAG LASER SMALL CIRCLE CUTTING S1CxG52 to S1CxG53: YAG LASER SMALL CIRCLE CUTTING DIRECTION LIMIT VALUE xiii

14 S1CxG54 to S1CxG55: YAG LASER SMALL CIRCLE CUTTING OVERLAP VALUE S1CxG56: WORK HOME POSITION RETURN SPEED S1CxG57: SEARCH MAX. SPEED S1CxG63, S1CxG64: PATTERN CUTTING DIMENSION 2-5 S1CxG65: MIRROR SHIFT SIGN INVERSION S1CxG7 to S1CxG85: PULSE SOFT LIMIT S1CxG86 to S1CxG93: ALLOWABLE MOVE AMOUNT AT STARTING S2C PARAMETERS S2C1: CUBE SOFT LIMIT CHECK S2C2: S-AXIS INTERFERENCE CHECK S2C3 to S2C26: CUBE INTERFERENCE CHECK S2C27 to S2C74: CUBE USING METHOD S2C75: SECURITY MODE WHEN CONTROL POWER SUPPLY IS TURNED ON S2C76: SELECTION OF PERPENDICULAR/CYLINDRICAL S2C77: COORDINATE SWITCHING S2C78: EXECUTION UNITS AT FORWARD OPERATION S2C79: INSTRUCTION (EXCEPT FOR MOVE) EXECUTION AT FORWARD OPERATION S2C81: POSTURE CONTROL AT PERPENDICULAR OPERATION OF JOG S2C82: OPERATION IN USER COORDINATE SYSTEM (WHEN EXTERNAL REFERENCE POINT CONTROL FUNCTION USED) S2C83: STEP ONLY CHANGING S2C84: MANUAL SPEED STORING FOR EACH COORDINATE S2C86: ADDITIONAL STEP POSITION S2C87: MASTER JOB CHANGING OPERATION S2C88: CHECK AND MACHINE-LOCK KEY OPERATION IN PLAY MODE S2C89: RESERVED WORK JOB CHANGING OPERATION S2C9: MASTER CALL OPERATION IN PLAY MODE S2C91: LANGUAGE LEVEL S2C92: +MOV INSTRUCTION SPEED INPUT S2C93: +MOV INSTRUCTION INTERPOLATION INPUT 2-17 S2C94: INSTRUCTION INPUT LEARNING FUNCTION S2C95: ADDRESS SETTING WHEN CONTROL POWER IS TURNED ON S2C96: JOB LIST DISPLAY METHOD AT JOB SELECTION S2C97: INITIAL OPERATION OF MANIPULATOR S2C98: PLAYBACK EXECUTION AT CYCLE MODE 1- STEP S2C99: EXTERNAL START S2C1: PLAYBACK PANEL START xiv

15 S2C11: SPEED DATA INPUT FORM S2C12: RESERVED START S2C14: JOB SELECTION AT REMOTE FUNCTION (PLAY MODE) S2C15: EXTERNAL MODE SWITCH S2C16: MODE SWITCHING FROM PLAYBACK PANEL.2-19 S2C17: EXTERNAL CYCLE SWITCHING S2C18: PROGRAMMING PENDANT CYCLE SWITCHING S2C19: SERVO ON PROHIBITION S2C11: PLAYBACK PANEL AND PROGRAMMING PENDANT OPERATION WHEN IO IS SELECTED FOR REMOTE MODE S2C111: OPERATION METHOD AT FWD/BWD OPERATION OR TEST RUN BY INDEPENDENT CONTROL S2C112: JOB AT CALLING MASTER OF SUBTASK 1, 2, 3, 4, 5 BY INDEPENDENT CONTROL S2C114: STEP EDITION AT TOOL NO. CHANGE S2C115: GENERAL OUTPUT RELAY WHEN CONTROL POWER IS ON S2C117 to S2C119: PARITY OF GENERAL INPUT GROUPS S2C122 to S2C124: PARITY OF GENERAL OUPUT GROUPS S2C127 to S2C129: DATA OF GENERAL INPUT GROUPS S2C132 to S2C134: DATA OF GENERAL OUTPUT GROUPS S2C139: REMOTE FIRST CYCLE MODE S2C14: LOCAL FIRST CYCLE MODE S2C141: GENERAL OUTPUT NO. WHEN ROBOT DROP ALLOWABLE RANGE ERROR OCCURS S2C143 to S2C145: GENERAL OUTPUT GROUP TO BE INITIALIZED AT SWITCHING MODE S2C158: POWER ON FIRST CYCLE MODE S2C159: TEACH MODE FIRST CYCLE MODE S2C16: PLAY MODE FIRST CYCLE MODE S2C161: ALARM CODE SPECIFIC OUTPUT DATA S2C162: START CONDITION AFTER ABSOLUTE DATA ALLOWABLE RANGE ERROR OCCURS S2C166: CONTROLLED GROUP JOB TEACHING POSITION CHANGE S2C167: COOLING FAN ALARM DETECTION S2C168, S2C169: COOLING FAN ALARM 1 OPERATION S2C17, S2C171: COOLING FAN ALARM 2 OPERATION S2C172, S2C173: COOLING FAN ALARM 3 OPERATION S2C213 to S2C228: SETTING OF OPERATING RELAY NO xv

16 S2C229 to S2C244: OPERATING METHOD OF RELAYS 2-28 S2C245 to S2C249: TIME RESET S2C25: POSTURE CONTROL OF SYNCHRONIZED MANIPULATOR (Whe Twi Sychroous Fuctio Used) S2C251: POSTURE CONTROL OF MANIPULATOR IN MULTI- JOB (Whe Twi Sychroous Fuctio Used) S2C252, S2C253: OPERATION AFTER RESET FROM LOCUS DEVIATION S2C254: DEVIATED POSITION S2C257 to S2C259: ROBOT INTERFERENCE CHECK S2C26: RELATIVE JOB OPERATION METHOD S2C261: TOOL NO. SWITCHING S2C263: POSITION TEACHING BUZZER S2C264: JOB LINKING DESIGNATION (Whe Twi Sychroous Fuctio Used) S3C Parameter S3C412: WORK HOME POSITION CUBE S3C413 to S3C415: POSITION CORRECTING FUNCTION DURING PLAYBACK S3C416: MAXIMUM DEVIATION ANGLE OF CURRENT STATION POSITION (Whe Twi Sychroous Fuctio Used) S3C426 to S3C449: ANALOG OUTPUT FILTER CONSTANT (Whe aalog output correspodig to speed fuctio is used) S3C45: CUT WIDTH CORRECTION VALUE (Whe form cuttig fuctio is used) S4C Parameter S4C15: CURSOR ADVANCE CONTROL FUNCTION S4C16: CURSOR ADVANCE CONTROL FUNCTION CONT PROCESS COMPLETION POSITION S4C17: CURSOR ADVANCE CONTROL FUNCTION WORK START INSTRUCTION STEP MOTION COMPLETION DELAY TIME S4C4 to S4C45: TWIN DRIVE UNIVERSAL INPUT NO. DESIGNATION (WHEN TWIN DRIVE FUNCTION USED) 2-35 S4C49: OPERATION OF JOB WITHOUT CONTROL GROUP SPECIFICATION S4C5: EXECUTION OF BWD OPERATION S4C52: PERMISSION TO CHANGE NON-MOVE INSTRUCTION TO MOVE INSTRUCTION S4C53: STATION AXIS CURRENT VALUE DISPLAY FUNCTION S4C54 to S4C59: STATION DISPLAYED UNIT S4C6: BASE AXIS OPERATION KEY ALLOCATION SETTING TRANSMISSION PARAMETERS RS: COMMUNICATION PROTOCOL Basic Protocol RS3: NUMBER OF DATA BITS xvi

17 RS31: NUMBER OF STOP BITS RS32: PARITY RS33: TRANSMISSION SPEED RS34: RESPONSE WAITING TIMER (TIMER A) RS35: TEXT TERMINATION MONITORING TIMER (TIMER B) RS36: NUMBER OF ENQ RE-TRANSMISSION RETRIES RS37: NUMBER OF DATA RE-TRANSMISSION RETRIES RS38: BLOCK CHECK METHOD FC1 Protocol RS5: NUMBER OF DATA BITS RS51: NUMBER OF STOP BITS RS52: PARITY RS53: TRANSMISSION SPEED RS54: RESPONSE WAITING TIMER (TIMER A) RS55: TEST TERMINATION MONITORING TIMER (TIMER B) RS56: NUMBER OF ENQ RE-TRANSMISSION RETRIES RS57: NUMBER OF DATA RE-TRANSMISSION RETRIES RS58: FC2 FORMAT SPECIFICATION RS59: EXTERNAL MEMORY FILE OVERWRITE SPECIFICATION Applicatio Parameters Arc Weldig AxP: APPLICATION AxP3: WELDING ASSIGNMENT OF WELDING START CONDITION FILE AxP4: WELDING ASSIGNMENT OF WELDING END CONDITION FILES AxP5: WELDING SPEED PRIORITY AxP9: WORK CONTINUING AxP1: WELDING INSTRUCTION OUTPUT AxP11, AxP12: MANUAL WIRE OPERATION SPEED AxP13, AxP14: WELDING CONTROL TIME AxP15 to AxP17: NUMBER OF WELDING CONTROL.2-41 AxP26 to AxP29: TOOL ON/OFF GENERAL OUTPUT NO. (Jigless system) Hadlig Applicatio AxP2, AxP4: f1 KEY FUNCTION AxP3, AxP5: f2 KEY FUNCTION Spot Weldig AxP3: MAXIMUM NUMBERS OF CONNECTED WELDERS AxP4: GUN FULL OPEN STROKE ON/OFF SIGNAL AxP5: STROKE CHANGE ANSWER TIME LIMIT xvii

18 AxP6: PARITY SPECIFICATION FOR WELDING CONDITIONS AxP7: ANTICIPATE TIME AxP15: WELDING ERROR RESET OUTPUT TIME AxP16, AxP17: ELECTRODE WEAR AMOUNT ALARM VALUE Geeral-purpose Applicatio AxP9: WORK CONTINUE PROHIBIT Parameter List S1CxG Parameter S2C Parameter S3C Parameter S4C Parameter Trasmissio Parameters AP (Arc Weldig) Parameters AP (Hadlig) Parameters AP (Spot Weldig) Parameters AP (Geeral-Purpose Applicatios) Parameters xviii

19 1.1 Features of Cocurret I/O 1 Cocurret I/O Cocurret I/O cotrol is a I/O cotrol fuctio that processes cotrols relative to the XRC I/O idepedet of the maipulator operatio (i parallel with maipulator operatio). 1.1 Features of Cocurret I/O Termials ad coectors to which I/O sigals are coected ca be used effectively. Termials ad coectors are provided for coectig I/O sigals. Although the umber of coectios are limited, the termials ca be used effectively because oly the ecessary sigals ca be selected ad coected to the desired termial. Istructios relative to the I/O (Robot Laguage: INFORM II) ca be simplified for smooth maipulator operatio. Fixed procedures relative to the I/O ca be registered as idepedet ladder programs, thus eablig simplificatio of I/O istructios of the job (operatio program) ad reducig iterruptios. Reserved sigals ca be accepted while the maipulator is operatig. Reserved sigals ca be accepted durig operatio sice maipulator operatio processig ad I/O processig ca be executed at the same time. 1.2 Costructio ad Specificatios of the Cocurret I/O The Cocurret I/O cosists of the followig two blocks. SYSTEM LADDER SECTION (PART 1) USER LADDER SECTION (PART 2) Costructio of Cocurret I/O Ladder Program 1-1

20 1.2 Costructio ad Specificatios of the Cocurret I/O System Ladder Sectio User Ladder Sectio A stadard ladder selected for your applicatios is prepared at the factory. For more iformatio, see 1.13 Stadard Ladder Program The ladder program caot be edited. Specificatio of sigal coectios ad iterface sigal with system ladder are prepared at the factory. The ladder program ca be edited icludig these sigals. Cocurret I/O Specificatios Item Cotets Cotrol Method Programmig Sca Time Memory Capacity Number of Istructios Geeral Iput Port Geeral Output Port Specific Iput Port Specific Output Port Hardware Status Sigal Poits Auxiliary Relays Exteral Iputs Exteral Outputs Register (Numeric Data) Pseudo Iput Sigal Poits Power Failure Protective Fuctio Sca cotrol by stored program Relay ladder program symbology 1 msec 15 steps (Optio:Max. 3 step) 33 types 192 poits (Cocurret I/O à Maipulator Cotrol Sectio) 192 poits (Cocurret I/O ß Maipulator Cotrol Sectio) 224 poits icludig uspecified sigals (Cocurret I/O à Maipulator Cotrol Sectio) 34 poits icludig uspecified sigals (Cocurret I/O ß Maipulator Cotrol Sectio) 96 poits (Cocurret I/O à Maipulator Cotrol Sectio) 74 poits 256 poits 256 poits Geeral Register 1 poits (-65535) System Register 5 poits (-65535) Aalog output register 12 poits (-65535) 32 poits (Cocurret I/O ß System Parameter) Ladder Program (Battery Back-Up) Output status is reset. 1-2

21 1.3 Classificatio of I/O Sigals Cocurret I/O Specificatios Item Diagostic Fuctios Moitor Fuctioi Cotets Error Detectio of CPU, system program ad ladder programs. Ladder programmig error detectio as follows: Double Use of Output Relay No END Istructio Circuit Error Format Error Exceeded Program Capacity Moitor each sigal status i cocurret I/O o CRT display. 1.3 Classificatio of I/O Sigals Classificatio of I/O sigals Logic Name Classificatio Descriptio Rage xxx 1 xxx 2 xxx 3 xxx 4 xxx 5 xxx 7 xxx 8 xxx 81 xxx 82 xxx 9 xxx M xxx Geeral Iput Refereced with iput istructio of the job (192 sigals) Geeral Output Refereced with output istructio of the job (192 sigals) Exteral Iput Sigal No. correspodig to the iput termial (256 sigals) Exteral Output Sigal No. correspodig to the output termial (256 sigals) Specific Iput Specific Output Sigal to chage the operatig coditio of the robot Sigal otifyig the operatig coditio of the robot (224 sigals) (34 sigals) Auxiliary Relay Auxiliary relay i the cocurret I/O (74 sigals) Cotrol Status Pseudo Iput Moitorig of the hardware sigal status of the robot cotrol sectio Pseudo iput relay readig from the system parameter (96 sigals) (32 sigals) Network Iput Iput sigal from the etwork device (256 sigals) Register 1 word data (16 bits) Geeral Register: M - M99 System Register: M1 - M149 Aalog output register: M15 - M161 M - M161 (162 sigals) 1-3

22 1.3 Classificatio of I/O Sigals Iput Sigal Meaig of Number The I/O processig part ad the maipulator operatio processig part are coected by "Logical I/O". However, for the fuctio, they are separated as a quite idepedet fuctio. How to hadle each sigal is also differet from the maipulator operatio processig part. I ladder programmig, to specify each sigal uitedly, the umber is set to as follows. "Relay umber" is specified by the umerical value of four digits. This umerical value is composed of the followig three iformatio. 2 3 Specified Block Number This is divided ito the followig block. (c)relay No. i Specified Chael (b) Specified Chael No. (a) Specified Block No. [] Geeral Iput [1] Geeral Output Physical I/O [2] Iput Termial [3] Output Termial Logic I/O [4] Specified Iput [5] Specified Output [8(2)] Pseudo Iput [9] Network Iput [7] Auxiliary Relay (Iteral Relay) [8(/1)] Cotrol Iput I/O Iteral Processig Hard Sigal Moitor 1-4

23 1.3 Classificatio of I/O Sigals Specified Chael Number Eight sigals are defied as oe chael. [1] Last eight sigals [] Last eight sigals Refer to the udermetioed table for cocrete chael umber. Relay Number i Specified Chael Oe of eight sigals is specified by umerical value (-7). Chael No Bit No. (Relay No.) m As for each block, a miimum digit is specified by the umerical value to -7 for a relay umber as uderstood from the table. I a word, it is a serial umber which omits 8 ad 9. Moreover, the first relay umber of each block starts from xx1 because chael umber eters betwee digits of 1 ad 1. The relay umber will be specified by the umerical value of the fourth digit i the frame. Block Number: Relay Number: m : Chael1 19 Chael2 29 Chael3 39 Chael4 49 Chael5 59 Chael There is o relay which correspods to this umber. (This umber caot be used.) NOTE The relay is occasioally treated by the uits (8 bits) of the byte (chael) or the uits (16bits) of the word. 1-5

24 1.3 Classificatio of I/O Sigals Register The register is data of each every word (16 bits). Geeral register (M - M99) ad aalog output register (M15 - M161) are readable ad writable. System register is readable oly, ad the data is set by the system. NOTE The register is treated by the uit of oe word (16 bits). Therefore, it is ot possible to hadle it by the bit specificatio istructio (STR, AND, OR, ad OUT, etc.) ad the PLS istructios, etc. Geeral Register This is composed of oe word (16 bits). System Register This is composed of oe word (16 bits). Bit M M1 : : M99 Bit M1 M11 : : M149 Aalog Output Register This is composed of oe word (16 bits). The aalog output registers (M15 - M161) correpod to the aalog outputs 1 to 12. Sice a aalog output board with differet degital resolutio (D/A circuit) is used i commo with the aalog output register, the data below the resolutio is cut off at output. Aalog output AOUT1 AOUT2 Bit M15 M151 : : : AOUT12 M

25 1.3 Classificatio of I/O Sigals 8-bit resolutio: Bit 8 to Bit 15 are valid data. 12-bit resolutio: Bit 4 to Bit 15 are valid data. 16-bit resolutio: Bit to Bit 15 are valid data. Resolutio Bit bit 12-bit 16-bit Regardless of the resolutio, the register value per 1 V is: 1 (V) = (7fffH)/14(V) = 234(924H) Output voltage +14V 8H ffffh H 7fffH Register value (hexadecimal) -14V SUPPLE- MENT Aalog output board (JANCD-XEW1- ) uses a 12-bit resolutio D/A circuit. 1-7

26 1.3 Classificatio of I/O Sigals Numeric Data Biary umber is the oe that the umeric data was expressed by 1(ON) ad (OFF). Iteral data of a usual computer is expressed by the biary umber. O the other had, BCD(Biary Code Decimal) makes oe digit of the decimal umber by usig four bits of the biary umber, that is, four digits, combies these, ad shows the decimal umber. The equipmet coected with XRC occasioally uses BCD as a iput ad a output sigal. Whe trasferig the data betwee these, it is ecessary to covert BCD ito the biary umber whe XRC receives the data, ad it is ecessary to covert the biary umber ito BCD whe outputtig the data to the equipmet. It is possible to covert the data by BIN ad the BCD istructio i the cocurret I/O fuctio. Biary Number Bit BCD Digit of 1 Digit of 1 Digit of 1 Digit of 1 Bit Biary umber ad BCD expressio of the decimal umber Decimal Number Biary BCD

27 1.4 Cofiguratio of I/O Sigals 1.4 Cofiguratio of I/O Sigals Arc Weldig YASNAC XRC CONTROL (HARDWARE) STATUS PROCESSING SECTION OPERATING STATUS / CONDITION PROCESSING SECTION INSTRUCTION PROCESSING SECTION (JOB) NETWORK PROCESSING SECTION JANCD-XCP1 CONTROL STATUS SIGNAL AREA SPECIFIC I/O AREA GENERAL I/O AREA SYSTEM PARAMETER AREA NETWORK INPUT AREA REGISTER AREA 8XX 81XX 5XXX 4XXX 1XXX XXX 82XX 9XXX MXXX CONCURRENT I/O LADDER PROGRAM SERVO ON EMERGENCY STOP OK CONTROL POWER ON EMERGENCY STOP DATA FOR ANALOG VOLTAGE 3XXX 2XXX 3XXX 2XXX SPECIFIC I/O BOARD JANCD-XIO1 WELDER I/F BOARD JANCD-XEW GENERAL I/O BOARD JANCD-XIO OPTION I/O BOARD How to Moitor Sigal Status To moitor a sigal, verify the sigal status of the sigal logic umber i the C. I/O moitor display. 1-9

28 1.4 Cofiguratio of I/O Sigals Hadlig, Spot Weldig, Geeral-Purpose Applicatios YASNAC XRC CONTROL (HARDWARE) STATUS PROCESSING SECTION OPERATING STATUS / CONDITION PROCESSING SECTION INSTRUCTION PROCESSING SECTION (JOB) NETWORK PROCESSING SECTION JANCD-XCP1 CONTROL STATUS SIGNAL AREA SPECIFIC I/O AREA GENERAL I/O AREA SYSTEM PARAMETER AREA NETWORK INPUT AREA REGISTER AREA 8XX 81XX 5XXX 4XXX 1XXX XXX 82XX 9XXX MXXX CONCURRENT I/O LADDER PROGRAM SERVO ON EMERGENCY STOP OK CONTROL POWER ON EMERGENCY STOP DATA FOR ANALOG VOLTAGE 3XXX 2XXX 3XXX 2XXX SPECIFIC I/O BOARD JANCD-XIO1 WELDER I/F BOARD JANCD-XEW GENERAL I/O BOARD JANCD-XIO OPTION I/O BOARD How to Moitor Sigal Status To moitor a sigal, verify the sigal status of the sigal logic umber i the C. I/O moitor display. 1-1

29 1.5 Specific Iput Sigals (4xxx) 1.5 Specific Iput Sigals (4xxx) Commo for All Applicatios Safety Speed Alarm Reset User Msg Req User Alm Req System Msg Req System Alm Req User Alarm Code (Biary) System Alarm Code (Biary) d2 d1 d d4 d3 d2 d1 d User Message Code (Biary) System Message Code (Biary) d2 d1 d d4 d3 d2 d1 d INHB Weavig Check Ru Ext Servo O Ext Start CMD Remote Sel Play Mode Sel Teach Mode Sel Ihibit I/O Ihibit PP. PPael Cot Cycle Sel 1 Cycle Sel Step Cycle Sel Ext Hold Op Org Ret R1 Wait Job Seq R1J Step Back R1J Ext Servo Off 1 Ope Org Ret R2 Wait Job Seq R2J Step Back R2J Ext Servo Off 2 Ope Org Ret R3 Wait Job Seq R3J Step Back R3J Sub Master Job5 Call Sub Master Job4 Call Sub Master Job3 Call Sub Master Job2 Call Sub Master Job1 Call Master Job Call 1-11

30 1.5 Specific Iput Sigals (4xxx) Sub Task 5Alarm Request Sub Task 4Alarm Request Sub Task 3Alarm Request Sub Task 2Alarm Request Sub Task 1Alarm Request

31 1.5 Specific Iput Sigals (4xxx) Arc Weldig Device Ati-Stick Retry Ret Retry Nozzle Tip Time Work Ed Work Req Req Req Cleaed Chaged Measure As Start As Clr At- Stk No Clr Restart No Clr Retry No Restart Reset Restart/ Wire Restart/ Gas Restart/ Arc Ihb Sesig Device Ati-Stick Retry Ret Retry Nozzle Tip Time Work Ed Work Req Req Req Cleaed Chaged Measure As Start As Clr At- Stk No Clr Restart No Clr Retry No Restart Reset Restart/ Wire Restart/ Gas Restart/ Arc Ihb Sesig 1-13

32 1.5 Specific Iput Sigals (4xxx) Device Ati-Stick Retry Retry Nozzle Tip Time Work Ed Work Req Ret Req Req Cleaed Chaged Measure As Start As Clr At- Stk No Clr Restart No Clr Retry No Restart Reset Restart/ Wire Restart/ Gas Restart/ Arc Ihb Sesig 1-14

33 1.5 Specific Iput Sigals (4xxx) Hadlig Device Time Measure Work Ed As Work Start As Sesor Sesor Sesor Sesor Sesor Sesor Sesor Sesor Iput 8 Iput 7 Iput 6 Iput 5 Iput 4 Iput 3 Iput 2 Iput Device Time Measure Work Ed As Work Start As Sesor Sesor Sesor Sesor Sesor Sesor Sesor Sesor Iput 8 Iput 7 Iput 6 Iput 5 Iput 4 Iput 3 Iput 2 Iput

34 1.5 Specific Iput Sigals (4xxx) Device Time Measure Work Ed As Work Start As Sesor Sesor Sesor Sesor Sesor Sesor Sesor Sesor Iput 8 Iput 7 Iput 6 Iput 5 Iput 4 Iput 3 Iput 2 Iput

35 1.5 Specific Iput Sigals (4xxx) Spot Weldig Device Weldig Stop Time Measure Device Weldig Stop Time Measure

36 1.5 Specific Iput Sigals (4xxx) Device Weldig Stop Time Measure