Yaskawa DX200 User Manual

DX200 OPTIONS

INSTRUCTIONS

FOR ARC SENSOR COMARC FUNCTION

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

MOTOMAN INSTRUCTIONS

MOTOMAN-- INSTRUCTIONS

DX200 INSTRUCTIONS

DX200 OPERATOR’S MANUAL

DX200 MAINTENANCE MANUAL

The DX200 Operator’s manual above corresponds to specific usage.

Be sure to use the appropriate manual.

Part Number: 165557-1CD

Revision: 0

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MANDATORY

•This manual explains the arc sensor COMARC function of the DX200 system and general operations. Read this manual carefully and be sure to understand its contents before handling the DX200.

•General items related to safety are listed in Chapter 1: Safety of the DX200 Instructions. To ensure correct and safe operation, carefully read the DX200 Instructions before reading this manual.

CAUTION

•Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before operating this product.

•The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product.

•YASKAWA may modify this model without notice when necessary due to product improvements, modifications, or changes in specifications.

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

•If your copy of the manual is damaged or lost, contact a YASKAWA representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

•YASKAWA is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product's warranty.

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Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the DX200.

In this manual, the Notes for Safe Operation are classified as “WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury to personnel and damage to equipment. It may also be used to alert against unsafe practices.

MANDATORY

PROHIBITED

Always be sure to follow explicitly the items listed under this heading.

Must never be performed.

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

At any rate, be sure to follow these important items

To ensure safe and efficient operation at all times, be sure to NOTE follow all instructions, even if not designated as "CAUTION"

and "WARNING".

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WARNING

•Before operating the manipulator, check that servo power is turned OFF pressing the emergency stop buttons on the front door of the DX200 and the programming pendant.

When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.

Figure 1: Emergency Stop Button

•Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator. Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Figure 2: Release of Emergency Stop

TURN

•Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator:

–View the manipulator from the front whenever possible.

–Always follow the predetermined operating procedure.

–Keep in mind the emergency response measures against the manipulator’s unexpected motion toward you.

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

Improper or unintended manipulator operation may result in injury.

•Confirm that no person is present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

–Turning ON the power for the DX200.

–Moving the manipulator with the programming pendant.

–Running the system in the check mode.

–Performing automatic operations.

•Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there is a problem.

The emergency stop buttons are located on the right of front door of the DX200 and the programming pendant.

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CAUTION

•Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

–Check for problems in manipulator movement.

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

•Always return the programming pendant to the hook on the cabinet of the DX200 after use.

The programming pendant can be damaged if it is left in the manipulator's work area, on the floor, or near fixtures.

•Read and understand the Explanation of Warning Labels in the DX200 Instructions before operating the manipulator.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows.

Equipment	Manual Designation
DX200 controller	DX200
DX200 programming pendant	Programming pendant
Cable between the manipulator and the	Manipulator cable
controller

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Descriptions of the programming pendant keys, buttons, and displays are shown as follows:

Equipment		Manual Designation
Programming	Character Keys	The keys which have characters or its
Pendant	/Symbol Keys	symbol printed on them are denoted with [ ].
		ex. [ENTER]
	Axis Keys	[Axis Key] and [Numeric Key] are generic
	/Numeric Keys	names for the keys for axis operation and
		number input.
	Keys pressed	When two keys are to be pressed
	simultaneously	simultaneously, the keys are shown with a
		“+” sign between them,
		ex. [SHIFT]+[COORD]
	Displays	The menu displayed in the programming
		pendant is denoted with { }.
		ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • " means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen.

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and TM are omitted.

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			Table of Contents
1	Installation.......................................................................................................................................				1-1
	1.1	Starting Point Detecting Unit..............................................................................................			1-2
	1.2	Current Detecting Unit .......................................................................................................			1-3
2	DX200 Wiring..................................................................................................................................				2-1
	2.1	Connection Diagnosis........................................................................................................			2-4
3	Arc Sensor Function .......................................................................................................................				3-1
	3.1	Basic Understanding of the Arc Sensor.............................................................................			3-1
		3.1.1 Left and Right Path Correction .............................................................................			3-1
		3.1.2 Up and Down Path Correction..............................................................................			3-2
		3.1.3 Applicable Range of the Arc Sensor.....................................................................			3-2
	3.2	Main Operations for the Arc Sensor Function....................................................................			3-3
		3.2.1 Job Preparation for Welding and Adjustment of Welding Conditions ...................			3-3
		3.2.1.1 Registration of Arc Sensing Instructions .................................................			3-4
	3.3	Arc Sensor Function and Weaving Condition ....................................................................			3-5
		3.3.1 Path Correction Direction and Weaving Basis Coordinate System ......................			3-5
		3.3.2 Cases that Require the Registration of Reference Points ....................................			3-7
4	Registration of Instructions .............................................................................................................				4-1
	4.1	COMARCON (Sensing Start Instruction)...........................................................................			4-1
	4.2	COMARCOF (Sensing End Instruction) ............................................................................			4-4
	4.3	COMARCSET (Sensing Condition Change)......................................................................			4-5
	4.4	REFP (Reference Point Registration)................................................................................			4-7
5	Phase Compensation Value ...........................................................................................................				5-1
	5.1	Job Preparation for Measurement of Phase Compensation Value....................................			5-1
	5.2	Measurement and Registration of a Phase Compensation Value .....................................			5-3
6 Measurement and Registration of Sensing Conditions...................................................................					6-1
	6.1	Job for Measuring Sensing Conditions..............................................................................			6-1
	6.2	Measurement of Sensing Conditions.................................................................................			6-3
	6.3	Registration of Sensing Conditions....................................................................................			6-4
	6.4	Adjustment of Sensing Conditions.....................................................................................			6-5
	6.5	Results of Arc Sensing ......................................................................................................			6-6

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Arc Sensor Comarc				Table of Contents
7	COMARC Condition File .................................................................................................................				7-1
	7.1	COMARC Condition File ....................................................................................................			7-1
	7.2	File Operation ....................................................................................................................			7-3
		7.2.1 Display of a File ....................................................................................................			7-3
		7.2.2 Editing of a File .....................................................................................................			7-3
		7.2.2.1 Editing of “CORRECTION SELECT” and “CONDITION” ........................			7-3
		7.2.2.2 Editing of Other Items..............................................................................			7-3
		7.2.3 Initialization of the File ..........................................................................................			7-4
8 Modification of the Settings in COMARC Function .........................................................................					8-1
9	Instruction List.................................................................................................................................				9-1
10	Parameter List.............................................................................................................................				10-1
11	Alarm Message List.....................................................................................................................				11-1

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Arc Sensor Comarc	1 Installation

1 Installation

WARNING

•Since detected voltage (200 V), welding current, and welding voltage are applied to the starting point detecting unit, install the unit securely so that it does not fall.

Failure to observe this warning may result in an electric shock or damage to the unit.

For installation methods of a starting point detecting unit and a current detecting unit, refer to Fig.1-1 Installation of Starting Point Detecting Unit and Fig.1-2 Installation of Current Detecting Unit.

The starting point detecting unit should be installed outside of the manipulator interference area.

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Arc Sensor Comarc		1	Installation
		1.1	Starting Point Detecting Unit

1.1 Starting Point Detecting Unit

The starting point detecting unit should be installed on the side of the welder.

When installing the unit on a welder or other devices, use a fixture to fix the unit with the mounting holes located on both sides of the unit in order to prevent the unit from falling.

Fig. 1-1: Installation of Starting Point Detecting Unit

3	4	5
1NL 1LED		1PEI	Air vent
3
	ON	1FU
1SW	OFF
		1A
	1		2

400

400

Front View

Eyebolt M8 (2 eyebolts)

Air vent

150

(38)

500

Side View

Units: mm

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	1.2		Current Detecting Unit
1.2	Current Detecting Unit

Fig. 1-2: Installation of Current Detecting Unit

18

38

18

21

.5 33

50

100

Front View

80

100

Units: mm

Side View

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2 DX200 Wiring

2 DX200 Wiring

WARNING

•Before connecting the inter-unit cables and the welding cables, be sure to turn OFF the power supply to the DX200 and the welder.

Failure to observe this warning may result in an electric shock.

•Special attention should be paid during starting point detection, since 200 VDC is applied across the wire and the workpiece (welding jig).

Failure to observe this warning may result in an electric shock.

•Do not place any object directly on the cable of the starting point detecting unit.

Failure to observe this warning may result in an injury or damage caused by the disconnection of the cable.

•Attach the cable of the starting point detecting unit for the wire feeder with the wire stand, to protect it from robot movement.

If interference between the cable and the peripheral devices cannot be avoided, cover the cable with a rubber plate or spiral tube, etc.

Failure to observe this warning may result in an electric shock caused by damage to the cable, or an injury or damage caused by malfunction.

•Do not lay the cable of the starting point detecting unit directly on the floor, but install them in a pit or duct, or attach the cable with a protective cover.

Failure to observe this warning may result in an injury or damage to the cable.

•Since a high current flows through the welding cable, separate it from the cables of the control circuit system. If the cables cannot be separated, take preventative measures such as using metallic ducts or tubes on the cables of the control circuit system.

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Arc Sensor Comarc	2 DX200 Wiring

CAUTION

•Insert the inter-unit cable on the starting point detecting unit side, firmly to the connector, and fix it securely by tightening the coupling nut.

•Fix the other cables connected to the terminal stand securely by tightening the terminal screws.

Failure to observe these cautions may result in an electric shock, an injury, or damage caused by malfunctioning.

•After connected, be sure to reinstall the terminal covers of starting point detecting unit and welder.

Failure to observe this caution may result in an electric shock.

Wire the unit in the following manner, referring to Fig.2-1 Configuration

Diagram of Starting Point Detecting Unit and Fig.2-2 Configuration

Diagram of Current Detecting Unit.

Starting Point Detecting Unit

1.Connect the starting point detecting unit to the DX200.

2.Connect the plus terminal of the starting point detecting unit to the plus terminal of the welder.

3.Connect the minus terminal of the starting point detecting unit to the torch power supply unit on the wire feeder.

4.Connect the front terminal of the stand of the starting point detecting unit to the welding voltage detecting terminal on the wire feeder in the case of a floor-standing type, and to the terminal stand in the welder in the case of a welder-side hung type, respectively.

Fig. 2-1: Configuration Diagram of Starting Point Detecting Unit

DX200

Welder

Starting point

Welding cable

detecting unit

Inter-unit cable

1CN

YCP02 board

E

SE1

To the torch

SE2

To the welder

To the workpiece

To the wire feeder

Cable for welding voltage detection

Ground cable

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2 DX200 Wiring

Current Detecting Unit

1.Connect the connection cable of current detecting unit to the DX200.

2.Connect the plus cable of the current detecting unit to the + terminal of the welder.

Connect the other cable to the welding cable from the torch power supply unit on the wire feeder, and tape it with an insulating tape.

Fig. 2-2: Configuration Diagram of Current Detecting Unit

DX200

Welder

Current detecting unit

YCP02 board

To the workpiece To the wire feeder

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Arc Sensor Comarc	2		DX200 Wiring
	2.1		Connection Diagnosis

2.1 Connection Diagnosis

To confirm a connection, perform a diagnosis of the input status to the YCP02 board.

(The YCP02 board is a board for the COMARC.)

Use the following procedure to call the YCP02 I/O status display. 1. Select {IN/OUT} from the main menu.

2. Select {YCP02 I/O}.

– The YCP02 I/O STATUS window appears.

–In this display, confirm the values read-by the YCP02 board’s A/D converter and the general I/O status.

–Eight channels are provided for the A/D converter.

–Four points for input and output respectively are provided for general I/O.

–Use the YCP02 I/O STATUS window for the following purposes;

•Check whether the A/D converter is correctly operating.

•Check whether the cables for the current detecting unit are correctly connected.

For an incorrect	When welding is performed, the A/D
connection	data shows a negative value (-).
For normal status	When welding is performed by
	executing the normal ARCON/ARCOF,
	the A/D data show a positive value (+).
	(Execute a job without using
	COMARCON/COMARCOF.)

	• The YCP02 I/O STATUS window can be called only in
NOTE	"MANAGEMENT MODE".

• When the icon {YCP02 I/O} does not appear, switch the security mode to "MANAGEMENT MODE".

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Arc Sensor Comarc		3	Arc Sensor Function
		3.1	Basic Understanding of the Arc Sensor

3Arc Sensor Function

3.1Basic Understanding of the Arc Sensor

For welding with a power supply that has constant voltage characteristics, the welding current fluctuates as the distance L changes as shown below. Distance L is the distance between the tip and the base metal. The arc sensor function uses these characteristics.

Welding current

High Low

Tip

Consumable
electrode (wire)	L
Arc

Base metal

3.1.1Left and Right Path Correction

During welding with the torch weaving from side to side, an equal amount welding current flows on points  and  if the distance L is the same on both sides (points  and ) due to the aforementioned characteristics.

1 2

Welding current: 1 = 2 , (When the distance between the tip and the base metal is the same on both sides.)

If the distances L are different at points  and , different currents flow at these two points as shown below.

The arc sensor checks the welding currents at points  and  and corrects the path to equalize the values.

	Direction of path	Direction of path
	correction	correction
1	2	1	2

Welding current 1 > 2 (shifted to the left)

Welding current 1 < 2 (shifted to the right)

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Arc Sensor Comarc	3		Arc Sensor Function
	3.1		Basic Understanding of the Arc Sensor

3.1.2 Up and Down Path Correction

During welding with the torch moving up and down, the arc sensor checks the welding currents at any 2 points, an upper point and a lower point, and corrects the path to equalize the values.

Up and down path correction

Up and down path correction

3.1.3Applicable Range of the Arc Sensor

The applicable metal thickness and joint are as follows.

Metal thickness: 3.2 mm or more

Joint: T joint, Lap joint

Speed: 1 m/min or less

NOTE	The arc sensor function can be used except that the droplet
	transfer status is a spray transfer.

SUPPLE-

MENT

•The droplet transfer means that the welded tip of wire (droplet) transfers to the base metal.

•For the status of droplet transfer, there are dip transfer, spray transfer, and etc.

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