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 o r 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 t o install, operate, o r maintain these equipments. Contact your distributor if 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 ING 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 o r DAIHEN Corporation.
LIMITED WARRANTY
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 from Japan, o r 2000 hours actual working time from the date of delivery of equipment t o 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 t o 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. I N NO EVENT SHALL DAIHEN BE LIABLE FOR A N Y DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF A N Y NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF A N Y PRODUCT.
~ F E T WARNING V
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 t o 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 t o 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 t o the application. See A r c 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 t o call attention t o and identify different levels of hazard and special instructions.
This safety alert symbol is used with the signal words WARNING and CAUTION t o call attention t o the safety statements.
WARNING statements identify procedures o r practices which must be followed to
avoid serious personal injury o r loss of life.
CAUTION statements identify procedures or practices which must be followed t o avoid minor personal injury o r damage t o this equipment. IMPORTANT statements identify special instructions necessary f o r the most efficient operation of this equipment.
C.
1
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. 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 H A V E A N EMERGENCY STOP BUTTON I N HAND whenever you are near the robot. 5 UNDERSTAND A N D BE F A M I L I A R 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 if 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 REOUl REMENTS FOR lNSTALLATlON (Figure D-I)

The robot cell requires initial safety conditions that are vital f o r both personnel and equipment. Make safety provisions part of the basic cell design.lmplement the following during installation:
Brightly mark floor with distinctive areas identifying Zones 1 and 2 on Figure D-1. cell floor space.
2 Route all cables and hoses so that they will not be damaged and will not clutter the
3
Protect welding system components from spatter, slag, heat, and the general welding environment by locating equipment t o minimize exposure.
4 I f any welding components must be located in a high-exposure area, provide proper

guards o r shields t o 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 t o enter the work envelope(Zone 1).
l nstall pressure-sensitive floor mats, proximity devices, limit 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
8
Install chain fences and light batteries around other cell portions that are not t o be violated. Locate Teach Pendant and Operation Box outside robot work envelope.
Provide proper Electrostatic Discharge(ESD) protection for electronic components in Robor Control Unit and Teach Pendant.
10 M A I N T A I N 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 f o r welding areas.Supply fresh air if 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 t o protect eyes f r o m arc rays. Press an EMERGENCY STOP button before entering robot area. Stay alert f o r 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 t o 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 f o r teaching the robot, be sure t o 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 f o r 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 t o the following: a) Space requirement f o r the robotic system cell must allow sufficient area t o 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 if the operator was caught in the robot, take the following procedure.
1) Press the Emergency Stop button immediately. 2) Turn off the primary power switch of the Robot Control Unit. 3) To avoid fall the robot arm, lift 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 t o enter the robot work envelope. As a result, always do the following during teaching procedures:
1 Move robot slowly (see instruction manual "TEACHING"

information).
- Teaching f o r
speed entry
2 Always assign and position a watchperson, with an Emergency Stop button in hand, t o present and ready during teaching operations.
I f jig motion was programmed t o operate from external output control, the jig could energize during teaching.Be careful and alert f o r 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 f o 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 t o 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 f o r 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 f o r the operation.
6
Remove all tools f r o m 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 f o r nozzle, tip, wire, o r gas adjustments o r replacements. DO NOT ENTER WORK ENVELOPE UNLESS A N EMERGENCY STOP BUTTON IS PRESSED !
2 Be alert f o r jig movement initiated by an external control signal during operation.
3 Do not allow unauthorized persons t o operate controls.

4
I f t w o o r more Starting Boxes are used, be sure that the operators fully understand all procedures and cooperate with each other. Press an EMERGENCY STOP button if any problem occurs.
6 Since this an arc welding operation, protect operator(s) f r o m 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 t o axes origin o r work
origin positions is possible without striking any objects.This may require manual operation with Teach Pendant.
Press an EMERGENCY STOP button t o turn off 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 f o r Robot Control Unit and welding power supply in the
OFF positions.
5 Allow robot and all equipment t o cool.
6 Clean robot, jigs, and entire cell area.

7
Install protective covers over all equipment AFTER proper cooling has occurred t o 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 t o 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 t o 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, t u r n it off.
5 Determine in advance if the procedure can be done outside the work envelope.Always work outside the robot work envelope whenever possible.
6 Turn off o r disable all jig(s) and external equipment not required f o r the specific procedure.
7 Provide proper Electrostatic Discharge (ESD) protection f o r 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 a t beginning of welding power supply manual in addition t o the following before beginning arc welding operations.
Prevent electric shock as follows:
1) INSTALL A N D GROUND all equipment according t o national, regional, and local

codes. 2) DO NOT TOUCH live electrical parts. 3) WEAR DRY INSULATING GLOVES A N D 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 a t the arc.
3) VENTILATE CELL t o prevent build-up of fumes and gases.
4) I f ventilation is inadequate, USE APPROVED BREATHING DEVICE. 5) READ A N D 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 filter 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 t o include woolen clothing, flame-proof

apron and gloves, leather leggings, high boots and leather arm and shoulder gauntlets. 4 Prevent fire 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 f o r fire.
4) Have a fire extinguisher nearby, and know how t o use it. 5) Allow equipment and work t o 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 o r 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 traffic 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 t y o r peeled off, order spare ones immediately. The locations of these labels are shown in the instruction manual " M A N I P U L A T O R " and "CONTROLLER".
KEEP OUT OF ROBOT AREA W E N MAIN POWER IS ON. READ INSTRUCTION MANUAL.
A WARNING
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 Instruction Manual.
D o N o t R e m o v e , Destrov, O r C o v e r This Label.

--
ARC W E L D I N G can b e h a z a r d o u s .
t f ~ i slabel and the lristructton M a n u a l carefully Only qualified persons are t o install, operate, or service this unit according to all applicable codes and safety practices. @ Keep children a w a y . P a c e m a k e r wearers k e e p away. @ W e l d i n g w i r e and drive parts rnay be a t w e l d i n g voltage.
* Read and f o l l o w
ELECTRIC S H O C K c a n kill.
@
A l w a y s w e a r dry insulating gloves. D o n o t t o u c h live electrical parts. D i s c o n n e c t input p o w e r before servicing. K e e p a l l panels a n d c o v e r s securely in place.
@ Insulate yourself f r o m t h e w o r k a n d t h e ground.

@
F,
FUMES AND GASES can b e hazardous

@
K e e p your head o u t of the fumes. Ventilate area, or use a b r e a t h i n g d e v i c e . Read M a t e r i a l S a f e t y D a t a Sheets ( M S D S s ) a n d manufacturer's instructions for m a t e r i a l used.
WELDING can cause fire or explosion.

@ D o n o t w e l d near
@ @
flammable material. W a t c h for fire; k e e p extinguisher nearby. D o n o t locate unit o v e r combustible surfaces. D o n o t w e l d o n closed containers.
/ A R CSRAYSn can burn hearing. skin: eyes and N O I E c a damage

@ @
W e a r w e l d i n g h e l m e t w i t h c o r r e c t filter. W e a r c o r r e c t eye, ear, and body protection
label and the lnstrucr~onM a n u a l carefully.
e Do not touch
llve electrical p a n s
FUMES AND GASES can be hazardous
ARC RAYS can burn eyes and s k ~ n . NOISE c a n d a m a g e hearing.
Do Not Remove, D e s t r o y , Or Cover This Label.
@
@
Keep a w a y f r o m m o v i n g parts. Keep hands, loose clothing, and tools a w a y during operation.
P I N C H POINTS c a n cause injury.

@ @
Keep a w a y from pinch points during operation. K n o w and understand equipment operation before use.
ELECTRIC S H O C K c a n kill.
Always wear dry insulating gloves. Insulate yourself from the work and the ground. @ D o not touch live electrical parts. 4 Disconnect input power before servicing. ' o Keep all panels and covers securely in place.
@
@
F A L L I N G E Q U I P M E N T c a n cause serious parsonal injury and equipment damage.

@
Lift and m o v e 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. @Disconnectall power before installing or servicing. @Multiple sources of voltage may exist inside this enclosure.
A WARNING
I I
@Keep out of robot area when main power is on. @#Do not locate this device in robot work area. e Read Instruction Manual.
WARNING
ELECTRIC SHOCK can kill.

o not touch live 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 all panels, covers. and guards securely in place. @For protection against fire hazard. Replace only with 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 e a r t h ground and has less

than 100 ohms of resistance.
Doublecheck grounding conductor, input voltage, and frequency before 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 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,
@ CN69
CN33
CN32
CN31
NCDO66
Part I
Chapter 1
Basics
Hints f o r Using This Manual
1.1 1.2 13 1.4
Instruction Manuals "Teaching" and " Options" .................................................................... The Organization of This Manual ........ Conventions Used in This Manual Terms Used in This Manual ....................................................................................................................
Overview
1- 1 1- 1 1- 2 1- 3
Chapter 2
2. 1 Control power (Controller) ................ 2. 2 Operating Panel ................................................................................................................................................ 2. 3 Teaching Box ..................................................................................................................................................... 2. 3. 1 Outside View of Teaching Box 2. 3. 2 Teaching Box Keys 2. 3. 3 Function Keys 2. 3. 4 Display Screen ......................................................................................................................................... 2. 3. 5 Entering Numeric Values ............................................................................................................... 2 4 Modes 2. 4 . 1 TEACH Mode .............................................................................................................................................. 2. 4 . 2 AUTO Mode 2 . 4 . 3 Initial Mode 2. 4 . 4 Mode Change ........................................................................................................................................... 2. 4 . 5 Mode Change Interlock .....................................................................................................................
Chapter 3 Basic Features and Functions f o r Operating OSACOM SUPER 8700 3 1 Turning On OSACOM SUPER 8700 ................................................................................................... power ................................................................................................................... 3.2 ~~~~i~~ on the servo 3.3 Operations for Manual Manipulation 3.3.1 Manual Manipulation 3.3.2 Changing Manual Speeds .................................................................................................................
22-
1 2
2- 3 2- 3 2- 4 2- 9 2 - 11 2 -15 2 -16 2 - 16 2 -16 2 - 16 2 - 16 2 - 18
33333-
1 2 3 3 3
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 Basic Teaching ............................................................................................................................................ 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 ~ d d ti^^^ i ~ ~ 3.7.2 Deleting Instructions .............................................................................................................................. 3 8 Start Allocation 3.9 Automatic Operation ...................................................................................................................................... 3 10 Shutting Off the Servo power (Emergency Stop) 3. 11 ~~~~i~~ offthe control power
3- 4 3- 5 3- 6 3- 7 3 - 11 3- 12 3- 13 3 - 15 3-15 3 - 16 3- 17 3 - 18 3- 19 3-20
Chapter 4
Manual Manipulation
4.1 operations for ~~~~~l ~
i .... ~
4-
4.1.1 Changing Positions and Attitudes (Manual Manipulation) 4 .1.2 Changing Manual Speed 4.1 3 switchillg between coordinate systems 4.1.4 Switching Mechanisms (Not applicable t o the Single Manipulator System) 4.1.5 hi^^ and ~ ~ tthe wire ............................................................................................... ~ ~ ~ t i ~ ~ 4.1.6 Resetting External Control Output Signals 4.2 ~~~i~~ ~ i ~ ~ ~ t i ~ 4.2 1 ~~i~ ~~~~~~~t 4.2 2 cartesian ~~~~~~~t 4.3 cartesian ~~~~~~~t N~~~ the singular point .
Chapter 5 Teaching
4- 1 4- 2 42
4- 5 4- 5 4- 6 4- 7 4- 7 4- 9 4-19
5.1 Creating and ~ i ~~~k ~ programs ~ i ~ ~ 5 1.1 Creating Task programs ~~~k i ~ ~ 5.1 2 ~ i ~ t programs......................................................................................................................... 5.2 Teaching ti^^ Instructions 5 2.1 positioning p 5.2 2 Linear Interpolations 5.2 3 Circular Interpolations 5.2.4 wait for ~i~~~ T ~ ~ operation ~ ~ / N 5 2.5 ~ ~program J~~~........................................................................................................................ t ~ ~ ~ ~ l 5 .2 .6 ~ ~program J~~~ ~ t ..................................................................................................................... ~ ~ ~ l 5.2 7 program Call 5.2.8 End ...................................................................................................................................................................... 5 3 Teaching Task Instructions 5 .3 .1 A~~ start .......................................................................................................................................................... 5 .3 .2 Arc End 5 .3 .3 ~ ~ ~ h i ~ ~ / ~ ~ ~ ~ ~ ~ t 5.3 .4 Gas ON/OFF 5.3 5 Weaving Start 5 3.6 Weaving End 5 3.7 External Control Input/Output 5.4 Block Operation .................................................................................................................................................... 5.4.1 ~ ~ ~ ~~ ~ operations d k l ~ ~ ~ ....................................................................................k / ~ ~ ~ 5.4.2 ~ l ti^^^^^ operation ~ ~ k 5.4.3 Block Operating Speeds 5.4.4 &&ing and starting ~ l operation ~ ~ k 5.4 5 Cancelling the Halted State of Block Operation 5.4.6 Sequence Jump 5.5 Adding and Deleting Instructions 5 .5 . 1 Adding Instructions 5 5.2 Deleting Instructions 5 6 Changing Teaching Data 5 .6 .1 Changing Motion Instructions 5.6.2 Changing parameters of Motion Instructions
5- 1 5- 1 5- 7 5- 8 5- 8 5 - 10 5 - 13 5 - 15 5-7 5 -24 5 -27 5 -29 5 - 30 5 -30 5 - 34 i 5-37 ~ ~ 5 - 38 5 - 39 5 -46 5-47 5-53 ~ ~ 5-53 5-55 5 - 55 5-56 5-57 5 - 58 5 - 59 5 -59 5 -60 5 - 61 5 - 61 5-62
Chapter 6
Automatic Operation
6.1 Automatic Operation ...................................................................................................................................... 6.2 Automatic Operation by the Multi-station System ................................................................ 6.2. 1 Start Allocation ........................................................................................................................................ 6.2.2 Changing t o Auto Mode and Starting Automatic Operation 6.2 3 Start Reserving and Cancelling
................................
66-
1 3
6- 4 6- 5 6- 6 6- 8 6 - 11 6-11 6- 13 6-13 6-14 6 - 15 6 - 16 6-17
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 .......................
Chapter 7
7 .1 Selecting Files ..................................................................................................................................................... 7.2 ~ d i t welding condition ~ i ........................................................................................................... i ~ ~ l ~ ~ 7.3 Editing Weaving Condition Files ..........................................................................................................
File Operations
Editing Files
777-
1 3 6
Chapter 8
8.1 Listing Files ........................................................................................................................................................... 8- 1 8.2 Copying Files ........................................................................................................................................................ 8- 4 8.3 Deleting Files ....................................................................................................................................................... 8- 5 8- 6 8.4 Renaming Files ..................................................................................................................................................... 8.5 ~ ~ ~ on lj'ile operations i ~ ~ t ~ i ~ t 8- 7
Chapter 9 Cancelling Emergency Stop and Shock Sensor
9 .1 Emergency Stop ................................................................................................................................................. 9.2 ~ 1 sensor ~ ........................................................................................................................................................ ~ ~ k 9.2.1 cancelling the hc -ok . , sensor
999-
1 2 2 2 3 3
9.2.2 Before Automatic Operation and After Completion of tlie J o b ......................... 9g .2 .3 In Teach Mode ............................................................................................................................................ 99.2.4 Correcting Taught Positions Where the Shock Sensor Operates
......................
9-
Part
II
A p p l i c a t i o n F e a t u r e s and F u n c t i o n s
Chapter 1 Application 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) .. 1.1.2 ~h~ H~~~ s t o p ti^^ ..................................................................................................................... 1.1 3 The Work Enable Area 1.1.4 The Reference Joint Angles a t the Start Enable Area ... 1.1.5 setting ~~~~~l speeds 1.2 ~ ~ ~ ~~~t~~~~ and $'Unctions ~used for hi^^ .................................................. l i ~ ~ t i ~ 1.2.1 Logical Check on Task Programs 1.2 .2 Confirmation of Terminating Teaching l operation ............................................................ ~ ~ k 1.2.3 setting the way of performing ~ 1.2 4 cursor ~ d iof the ~ t of ~~ ~ operation k ~ ~ state i l ~ ~ 1.2,5 setting j310ck operating speeds 1.2.6 Checking and Modifying Condition Files during Block Operation
Chapter 2 User Parameters
...................
1- 1 1- 1 1-4 1 5
.
1- 5 1-7 1-9 1- 9 1 21 1-22 1-24 1-25

.
1-26
2 .1 Setting the System Status .......................................................................................................................... 2 .1.1 Setting the Home position ............................................................................................................... 2.1 2 Setting the Work Enable Area (Soft Limit) 2 .1.3 Setting the Start Enable Area ........................................................................................................ 2. 1.4 Registering Coordinate Systems ................................................................................................. 2.1.5 Setting Conditions for 3-dimensional Shift and Mirror Image Shift 2.1.6 Setting the ABSO Data Check Function 2.2 settillg the hi^^ B~~ K~~~ 2.3 setting the welding parameters 2.4 2.5 26 2.7
..............
2-3 2-8 2- 10 2-11 2-11 2-12 2-13 2-14 2-17
Setting the Parameters for External Control Signal Inputs/Outputs .................... 2-20 setting on ti^^ ~ ~ ~ on ~~ i~ ~ toperation ~ ~ ~ ~ t t t ~i i ~ 2-22 Setting the Sensor Type 2 - 22 setting welding characteristic ~~t~ 2 -23 ~ welding characteristic i ~~t~ ............................................................................. ~ ~ ~ ~ 2-24 ~ 2.7.1 ~ ~ ~ d i f ~ characteristic ~~t~ ................................................................................. 2-24 welding i ~ ~ 2.7 2
2.7.3 Creating User Welding Characteristic Data (User Registration) .................... 2-27 2-29 2 .7 .4 ~~t~~ to use ALMEGA FUZZY AUTO .................................................................................. 2.7 5 ~~t~~ to use TIG ill^^ 2-31
Chapter 3 Application Features and Functions Used f o r Automatic Operation
3 1 Machine -Jock ........................................................................................................................................................ 3.2 D ~ ~ R ~ ~ 3.3 ~ ~~ ~ ~ toperation ~. ~ ~~ t i~ ~ ~ ~ 3.4 Checking the S t a r t Enable Area during Automatic Operation ...................................... 3 5 path Function ....................................................................................................................................................... 3 6 Online Modification 3.7 Sequence Display during Automatic Operation ........................................................................
3-1 3-2 3d 6 3- 8 3- . 8 3 - 10 3-11
Chapter 4 Shift 4. 1 parallel Shift 4.2 Cylindrical Shift 4.3 Error Messages and Notes
4- 1 4- 3
.......................................................................................................................
4-
Part
III
Management
1- 1 1- 2 1- 4 1- 5 1- 6 1- 6 1- 9 1- 11 1- 13 1- 13 1- 16 1-19 1- 21 1- 2 1 1-24 1-27 1-29 1- 31 1-32 l 1- 34 1- 34 1- 34
Chapter 1 External Storage 1 1 Connecting and Handling the External Storage
1.2 Selecting External Storage Functions .............................................................................................. 1 3 Formatting Floppy Disks 1 4 Listing Files ...................................................................................................................... 1.5 Saving Files from the Controller to the External Storage 1.5 1 Individual Saving 1.5.2 Batch Saving 1.5.3 All Saving
.
1.6 Loading Files from the External Storage to the Controller ........................................... 1.6.1 Individual Loading .................................................................................................................................... 1.6.2 Batch Loading .............................................................................................................................................. 1.6.3 All Loading 1 7 Comparing Files ................................................................................................................................................. 1.7.1 Individual Comparison 1.7.2 ~ ~ ~~~~~~i~~~ h t ~ 1.7.3 A]] ~~~~~~i~~~ ............................................................................................................................................ 1.8 Deleting Files ....................................................................................................................................................... 1 g Restrictions on File Transfer 1 10 E~~~~ M~~~~~~~for ~ ~storage t ........................................................................................... ~ ~ ~ ~ 1 11 Others ........................................................................................................................................................................ 1.11.1 Handling Floppy Disks . 1.11.2 Notes External Storage
Chapter 2 Password 2 1 Entering the Password .................................................................................................................................. 2 2 Setting the password ....................................................................................................................................... Chapter 3 Absolute Offset 3.1 Resetting the Encoders and Setting an Absolute Offset .................................................. 3 2 Axis Alignment Marks on the Manipulator .................................................................................. 3 3 The ABSO Data Check Feature ...............................................................................................................
22-
1 2
3- 1 3- 5 3- 6
Chapter 5 Installing OSACOM SUPER 8700 Software Options 5 1 Installing Software Options .......................................................................................................................
~ t i ~ ~ ~l l ~ d 5.2 ~ i ~ ~ ~ tsoftware options ...................................................................................................... 5 3 Deleting Installed Software Options ....................................................................................................
5- 1 5- 3 5- 4
Chapter 6
Troubleshooting
6.1 ~~~~t~~~
6-15 6-15 6-16 6-17 6-20 6-21 6-22 6-23 6-23 6-26 6-27 6-28 6-29 6 -31 6 -32 6-34 6-36 6-37 6-39 6 -40 6-40 6-46
h i ~ ~ 6 . 1.1 ~ ~ t A~~~~~~ on the hi^^ B~~ 6.1.2 The Display on the Teaching Box Is Unsteady ............................................................... 6. 1 3 Initial Diagnosis Is Not Completed ...........................................................................................
6.1 4 The Servo Power Supply Cannot Be Turned ON 6.1.5 The Servo Power Supply Is Shut OFF Immediately When Turned ON 6. 1.6 Manual Manipulation Does Not Function
.........
~code and A ~ i l ~M~~~~~~A~~l~ ~ i l)isplayed ~ ~ ~ 6.2 A ~ The Display of A Failure ................................................................................................................... 6.2. 1 6.2.2 Logical Outputs for Failures .......................................................................................................... 6.2.3 shock sensor 6 2.4 Servo Power Shutoff ............................................................................................................................... 6.2 5 Software Limit / Link Software Limit 6 2.6 Overrun 6 2.7 Communication Failures 6.2.8 Data Installation Failures ................................................................................................................ 6 .2.9 Memory Failures ..................................................................................................................................... 6.2. 10 setting E~~~~~ 6 2. 11 ABSO Data Failure .................................................................................................................................. 6.3 When Servo Failure Occurred
6 .3 .1 How To See the Servo Failure Display 6.3.2 Troubleshooting for Servo Failures ..........................................................................................
Hierarchical Diagram of Function key Appendix
1. Restrictions on the Overlap process
2 . The Relation Between a Minimum Circular Diameter and a Setting Speed .................. 4 3. Restrictions on Weaving Frequency ............................................................................................................ 5 10 4 Tool parameters
Basics
C h a p t e r 1 H i n t s f o r Using T h i s M a n u a l
This chapter provides hints for using this manual. including the
organization. conventions. and terms .
Contents
1.
H i n t s f o r Using This M a n u a l
Instruction Manuals "Teaching" and "Options"
@ Teaching manual
Describes in detail various features and functions of OSACOM SUPER 8700 and how t o use them
Options manual
1. 1
Two instruction manuals a r e provided to use OSACOM SUPER 8700 :
Describes in detail optional features and functions of OSACOM SUPER 8700 and how t o use them. Note that optional software and hardware a r e required t o use them.
1. 2
The Organization of This Manual

)I OSACOM SUPER 8700 Basics I
This manual consists of the following parts:
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.
lBl OSACOM SUPER 8700 Management

This p a r t describes features and functions available for system manager t o use a n external storage and initialize the system.
1-1
I. 3
1. 1
1.1.1
Conventions Used in This Manual

Application Features and Functions Used f o r Manual Operations Displaying Angles and Coordinates (Reading Positions)
1. Application Features and Function Used in Teach Mode
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.
I I
-Contains detailed
@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
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 start enable area a r e different). For details, refer t o "The Reference Joint Angles for the Start Enable Area", section 1.1.4.
L
explana tions, cautions, and notes about the feature or function. 0describes for what purpose the feature or function is used.
Reading Positions
While you a r e holding the keys I) . 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.
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 v a l u e in the currently q m i f i d coordinate metam
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? F5 ... Deletes the Task program the cursor indicatesw
If more than 6 functions are contained in one layer, the following function keys are displayed in this manner.
F1 ... Rename the Task program the cursor indicates."
* indicates a reference. See the bottom for more information.
-2
H i n t s f o r Using T h i s Manual
1. 4
Terms Used in This Manual

The following is a list of terms used in this manual:
manipulator
....................
A robot which welds o r handles workpieces. Though manipulator types of ALMEGA V series (V01, V10, V20, and V40), G series (G01, and G03), and W01 a r e available.
..
mechanism
A mechanically independent unit, such a s a manipulator, a positioner, and a slider.
teaching
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 program
Motion instructions
Task instructions
Instructions to store tasks (such a s welding, weaving and signal outputs to external devices)
A number with which the manipulator stores a point. Sequence numbers a r e only given to Motion instructions.
sequence number
.........................
coordinate system
.........................
The space defined by the X, Y, and Z axes, which is referenced when the manipulator moves. There a r e BASE, TOOL, WORK, and WORLD coordinate systems. Teach mode in which no teaching function o r feature has been selected. The keys to which the functions and features of OSACOM SUPER 8700 o r options a r e assigned.
top layer of TEACH mode function keys
.........................
............. ............
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
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
2. 1
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 t o 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 - -O ---U-T ---.
I
I 1
-TEACH-, ------I
---------
OSACOM 0
Fig.2.2. Operating Panel
EMERGENCY STOP button
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 t a r t automatic operation of a Task program. Before starting, ensure that all personnel a r e clear off the danger area. The lamp illuminates during automatic operation.
(B) AUTO MODE

button
(C) TEACH MODE
button (Dl SERVO POWER button

(El START button
(F) STOP button
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
Outside View of Teaching Box
The following section provides general information of functions of the teaching box keys.
2.3.1
u
ENABLE
000
READ DELETE RESET
( OSACOM
Fig.2.3 The operating parts of Teaching Box

Overview
2
-3
2.3.2
*
Teaching Box Keys

Used to enter numeric values and to select instructions. When a numeric value is entered, the LED lights.
Numeric keys and Instruction selector keys
[ Na
KEY
MODIFY key
WDI FY
Used to correct selecting o r storing operations o r clear the ALARM display which appears when misoperation occurs. Used to add instructions. The LED on the upper left illuminates during adding operation.
ADD key
RECORD key
READ key
0
RECORD
Used to store data settings into the controller.
Used to read out data such a s coordinate values.
DELETE key
Used to delete instructions
0
DELETE
RESET key
SPEED SWITCH key
COORDINATE SWITCH key
0 0
RESET
SPEED
Used to step one layer of function keys up, reset ERROR/ARARM, o r cancel data settings.
Used t o switch the speed display between of Manual operating speed and block operating speed.
* MECHANISM SELECTOR key
B
l NATES MECHA
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.
FUNCTION SELECTOR key
[L]
FUNC* I NC/DEC
keys (UP/DOWN)
Used to increase/decrease manual/ block operating speeds, a welding current, etc. These keys a r e also used to select items you want to change o r modify.
keys
* LEFT/RIGHT
Used to select items you want to change o r modify. These cursor keys a r e also used to make changes to data settings.
TEACH Mode keys
LZ]
TEACH
Used to switch from Auto to Teach Modes. The LED illuminates in Teach mode.
Overview
2-5
Function CANDIDATE key
Used to display a function o r functions following the 5th function if there a r e more than 6 functions assigned to the function keys.
FUNCTION keys
Used to select functions displayed a t the bottom on the screen.
TEACH
ENABLE
Used to perform manual manipulation and block operation.
QUICK INCREASE / DECREASE key
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).
BACK LIGHT ON/OFF key
BACK-
Used to switch ON/OFF the back light of the teaching box display part.
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. 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.
SENSOR ON/OFF SWITCH key
r] w :
SENSOR
-6
Overview
WEAVE ON/OFF switch key
Used to switch between weaving on and off. The LED on the upper left illuminates in the ON state.
WELD ON/OFF switch key
Used t o switch between welding on/off in automatic operation.The LED on the upper left illuminates in ON state.
*
STOP key
Used to halt automatic operation. The LED on the upper Ieft illuminates in the stopped state of block o r 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
-7
AX1S keys
[rn)
EMERGENCY STOP button
I)
Used to turn on the servo power. To cancel overrun, perform manual manipulation by holding it down.
LIGHT button
( LIGHT)
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
(1)
Function keys
The organization of function keys
This section describes the functions of the 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
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) t o select functions and d a t a . Functions is displayed.
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 right end.
">"is displayed next to the function key label a t the
allows you to call the function or functions following the 5th function.
If you want to step one layer up, press
@ key
key allows you
Even if you have selected a function in a lower layer, pressing
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
(6) Work coordinate system
.
TOOL WORK
.............................
* :Refer to "Switching between Coordinate Systems", section 4.1.3 in part I.

Overview
2
-I
(B)
Speed display area
Where a manual o r block operating speed is displayed

Manual operating speed
Block operating speed
< Low
MLO ML1 ML2 ML3 ML4 MH1 MH2 MH3 MH4 (Inching) B-1 B-2 B-3 B-4 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 ~~~~h mode
.........................
.
AUTO. TEACH LOCK (highlighted)
Machine lock mode*

(D)
.-.-- MACH
File name display area
Where the file name which is in use for the operation being currently performed, such as teaching, editing, o r 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 t o "Modes", section 2.4 in part I.
* 2: Refer t o "Machine Lock", section 3.1 in part 11.

2-1 2
Overview
(G)
Auxiliary display area
Where the operation being currently performed (such as, adding, deleting, o r shift operation), information indicating path setting, and a n e r r o r 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,

" is displayed a t the right end. The rest of the functions a r e displayed
by pressing
key.
(J)
Synchromotion Status Display Area
Where synchromotion s t a t u s is displayed "CRDN"is displayed if the current status is Synchromotion.
Overview
2-1 3
(K)
Message display area
Where general1y various d a t a a r e displayed.
T.MECH ML4 TEACH P l l l SQNa = 2 SERVO ON
001 P >002 L
6 0% lOOcm
BASE BASE
MI M1
fL SPEED : l O O m
LAP :ON
[ r n ! / I / O J J B R A N C H /J W \ p K E ' ] >
When a n e r r o r , Alarm, o r Information occurs, its code, message and recovery action a r e highlighted.
*
T.MECH ML4 TEACH P l l l SQNa = 2 SERVO ON
001 P >002 L
60% lOOcm
BASE
M1
When the e r r o r is cleared, the original display appears.
001 P >002 L
-.= --
BASE 6096 1 0 0 ~ BASE
M1 M1
[iii55K1W/O/IBRANCHIW]I.DJIWEAVEJ
>
2-1 4
Overview
2.3. 5
Entering Numeric Values
The sign "No. KEY" illuminates when numeric values can be entered.
R
RAT ION
B
BRANCH
Keep the following points in mind when entering numeric values: Numerals as p a r t of a name
-
P r o g r a m No., etc. Sequence number
1 1
The numeral "0" must not be omitted: (Example) PO01 and ASCOl
Integers
-
Any integer can be entered as it is: (Example) 60cm

+
Speed, etc
"6" and "0"
Real numbers Time of the timer,etc.
To enter real numbers, use numeric keys a n d the decimal point: (Example) 0.5 sec 4 "0". .", and "5" If the fraction is 0, you can omit the decimal point and "0": (Example) 10.0 4 "1" and "0"
1 /1
Overview
2-1 5
2. 4
Modes
Two modes, TEACH and AUTO modes, a r e 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 a r e performed. Most of the functions and features except those used for automatic operation a r e available in this mode. As described in section 2.3.3, these functions a r e 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, o r
The robot is in the stopped state of automatic operation, o r 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 a r e 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
I Changing f r o m I
TEACH t o AUTO modes
1. Press F5 (LOCK) a t 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.
lI Changing f r o m AUTO t o TEACH modes Il

1. In the stopped state of automatic operation, the screen looks like the one shown on the right:
*
AXIS MH3 AUTO PO01 SQNa =999 SERVO O N HOLDING STN. 1
051 P 052 P >053 L 100% BASE 90% BASE 2501x1 BASE 012 DL=O.OS 1 5 0 m BASE
2.
Press
TEACH
(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.
M 2 M1 MI
M1
S 054 L 055 C 1 1501x1 BASE
MI
pi"Eq
WH pT-7-q SI pi%-=] >
Overview
2-1 7
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 t o prevent a careless mode change. Table 2.1. Operating a Mode Change Auto mode interlock
OFF
ON ( Default) 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 Teach mode
(2) Set the Auto mode

input terminal ON
J,
Auto mode
(1) Press the AUTO

MODE button on the operating panel, o r
(2) Set the AUTO Mode

input terminal ON. Teach mode interlock O F F ( Default) ON
(1) Press
w teaching box,
Or
on the
I1
Auto mode ;1 Teach mode
(2) Press the TEACH

MODE button on the operating panel,
I
/
teaching box while holding down the TEACH MODE button on the operating panel,
Or
/
/
(2) Press
on the
(3) Set the Teach mode

input terminal ON.
teachingbox while 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
2
"Setting the System Status", section 2.1 in p a r t 11.
-18
Overview
Chapter 3
Basic Features and F u n c t i o n s f o r O p e r a t i n g 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 t a r 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 F e a t u r e s and Functions f o r O p e r a t i n g O S A C O M SUPER 8700

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.
3. 1
Then, the start-up screen appears on the display. 1. The start-up screen appears on the display of the teaching box. I) I
2. OSACOM SUPER 8700 s t a r t s initial diagnosis.
.) I
DIAGNOSIS
THANK YOU FOR WAKING ME UP! THIS IS OSACOM 8 7 0 0 CONTROLLER START DIAGNOSIS
1, 2, 3, 4
' 9 3-0 7-1 5

11:32
3. When this operation is completed, you can perform various operations .) I by using the teaching box.
Basic Features and Functions f o r Operating OSACOM SUPER 8700
3-1
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 r e clear off the manipulator working area.
I:,
. . I .
Fig.3.1. Operating Panel
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 f o r 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
MECHAN l SM
The manipulator moves in the direction specified by the AXIS key you a r e pressing.
TEACH ENABLE
2. It stops when the key is released.
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 To change a manual speed, use
High
The current manual speed is displayed on the teaching box.
To increase the speed, press key. To decrease the speed, press key.
iai
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 Cartesian movements, use

CM)RD(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
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 a r e stored in a Task program.
To perform teaching, follow the steps below:
Enter a Task program number.
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 J o b instructions to store data of a job such a s welding, etc. The following a r e most often used instructions:
(Motion Instructions)
*
P (Positioning)
Instruction to store a position and attitude to the manipulator
L (Liner Interpolation)
... Instruction
linear path
to store a position and attitude
to the manipulator and move it on the
C (Circular Interpolation) ... Instruction to store a position and attitude t o the manipulator and move it on the circular path (Task Instructions) AS (Starts welding)
*
AE
... Instruction to s t a r t welding (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.
-5
3.4. 1
Preparation for Teaching
Before carrying out teaching, enter a Task program number.

AXIS ML4
1. After initial diagnosis is
TEACH SERVO ON
completed, turn on the servo power.
[ m I m j m I I m / L O C l >
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.
3 -6
3.4.2
BasicTeaching
This section describes a basic teaching by using a simple teaching example.
STEP @ STEP
f
/ / /
/ /
- .. .--. .. .
STEP @
.. ..
STEP
Fig.3.3. Teaching Example

1. Enter the Task program number.
+
2.
Perform manual manipulation t o step @. Teach Positioning instruction "P".
(1) Press
(2) Set Speed by using numeric

keys.
(3) You can set Overlap ON/OFF

by pressing
1 1 key. 0
Basic Features a n d Functions f o r Operating OSACOM SUPER 8700
-7
(4) Press
@.
AXIS ML4 TEACH

PO01
I
>001 P 100%
I
BASE
MI
SQ N = 1 a SERVO ON
IP
SPEED=l 0 D96
LAP :ON
3.
Teach step @ and way as step @.
as same
4.
Teach Arc Start instruction "AS" at Step
0.
.
AXIS ML4 TEACH
PO01
(1) Press
(2) Set welding conditions

(current, voltage, and speed) by using numeric keys and
SQ N. o= 3 SERVO ON
001 P 002 P >003 P
100% 100% 50% 20,OV.
BASE BASE BASE

6Dm
MI MI MI
I
AS
f3OA
/]NUU/jrnlrnI
(3) Press
@.
5.
Perform manual manipulation up t o step @.
Teach linear Interpolation instruction " L " .
(1) Press
T. MECH. ML4
TEACH
PO 0 1
SQNo.= 3 SERVO ON
>
-
001 P 002 P 003 P
AS
100% 100% 50% 200A
BASE BASE BASE

22.OV
M1
MI M1 8 Om
(2) Set Speed by using numeric

keys.
/LSPEED:LO#m
.LAP:ON
'
1
> ~
~ ]
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".
3-8
(3) You can set Overlap ON/OFF

by pressing
10)
key.
(4) Press
@.
6.
Perform manual manipulation up t o step @. This position is the
middle point of a circle. Teach Circular Interpolation

. instruction "C"
(1) Press
T.MECH.ML4 TEACH PO 0 l S Q N. o= 4 SERVO ON
001 P 002 P 003 P AS >004*L
10096 10096 100% 2OOA 60cm

\
BASE BASE BASE 22.OV BASE
M1 M1 MI 8Ocm M1
(2) Set Speed and Overlap ON/

OFF as set f o r " L " .
1~ 2
/ l
S P E E D ' : 6 Orar"
LAY :ON
(31 Press
@.
7.
Perform manual manipulation up t o step @. This position is the
end point of a circle.

Teach Circular Interpolation instruction "C".
As we taught "C" a t step press
w.
0.
@,
8. Teach A r c End instruction "AE"
a t step
(1) Press
T.MECH. ML4 TEACH PO 0 1 SQNo,= 6 SERVOON
>
AS 004*L 005*C1 006*C2 AE 180k
200A 22.OV 8Ocm M1 60m BASE M1 60m BASE 6Om BASE M1 150cm20.0,0.5S.O.OS
Z O . ~ ' V , ,b . ' & s , ' 0 , 0 9 1
LAY?
IASNUM.IIAENUMI(1-J
3 -9
(2) Set welding conditions

(current, voltage, crater time, and afterflow time) by using numeric keys and
(3) Press
9.
@.
Perform manual manipulation up t o step Press
a.
T.MECB. M L 4
, and set Speed and
TEACH PO01 SQ No.= 7 SERVO ON
004*L 005*C1 006*C2 AE >007 P
60m BASE M1 60m BASE MI 6e 0 m BASE MI 15Ona 2 . , 0.5s. 0.0s 00 79 5 6 BASE MI
Overlap ON/OFF as set f o r step
(P SPEED:X#0%
\tAP:UN
r
10. Perform manual
"
manipulation up t o step @. In
this case, move the manipulator until the LED of
READY onthe
teaching box lights.
Press
T.MECH. M L 4
005 *C1 60m BASE M1 006 *C2 60m BASE M1 AE 150m 20.OV 0.5s. 0 0s . . 007 P 75% BASE MI >0 08 P 10096 BASE MI
IP
/
11. Teaching has been completed.
$PEED:'X@O%
%,*' LAP:ON
1 ~
Press
@.
[I-
T.MPCH. M L 4
TEACH PO01 SQ Na= 9 SERVO ON
>001
002 003
END will be automatically stored

t o terminated teaching.
P P P
100% 100%
50%
BASE BASE BASE
M1 MI M1
Jmlmm]>
3-1 0
3.4.3
(1)
Keys Used f o r Teaching
@ key
Stores instructions, parameters, etc. If the same instruction needs to be continuously taught, pressing
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
0
RECORD
key allows
0
RECORD
AXIS ML4
TEACH
PO01
S Q No.= 2 SERVO ON
001 P 100% >002 P 100%
BASE BASE
M1
M1
~ P E E D ~ I O O .%a ~ ; a ~ ~ " : ~ , , ! t
l , , , , , l , , , , ,/l iCn I , N A R B O
>
The instruction you have just taught
(2)
@ key
Corrects entry errors.
*
If you press it immediately after you select a n instruction, you can cancel you 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 stored is cancelled.
0
RECORD
, the instruction you have just
(3)
@ key
Automatically enters END instruction, when pressed during a creation of a Task (You do not need to teach END instruction.)
program, a t the sequence following by the last sequence to terminate teaching.
Then, you can perform block operation.
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
Then, the manipulator starts to move to the position of sequence 001. Continue block operation by pressing or
BLOCK
Q. w
1, I accordingly.
To halt the manipulator, release
@.
Then. the LED of
n -
will light.
To execute instructions continuously, push
Then, the LED of
', g" Uwillislight. The block continuous state

cancelled when block operation is halted.
To chande block operation speed, push
/?
n -
The display a t the Speed display area will change t o the Block Operating Speed.
Select the speed by pressing
3-1 2
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
1 Modifying 1
positions and attitudes
Let us modify the position/attitude of step 2 (Sequence 002):
1. Perform block operation up t o

sequence 002.
rrr)
T.MECII. ML 4
TEACH
PO01
S Q Na= 9 SERVO ON
001 P >002 P 003 P
AS
004*L
1 0 0 % BASE M1 1 0 0 % BASE M1 50% BASE MI 2 0 0 4 22.OV. 8 0 m 60w BASE M1
2.
Perform manual manipulation t o move the manipulator t o the position/attitude you want t o store.
I'
STEP 2
\
=o
b '
f)
STEP 3
3. Press
Now, the position/attitude of step 2 have been modified.

/
STEP I
4 '
\ \
\
P
\
\\\
STEP 2
J
P
STEP 3
3-1 3
(Example 21 Modifying "P" to "L"
Let us modify the instruction of step
I T.MECI1.
1. Perform block operation up to
sequence 003, and then press
ML4
001 P
10096
BASE
MI
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 t o "AS" by
performing block operation, and press
T.MECI-I.ML4
TEACH P Oo 1 SQ Na= 9 SERVO ON
100% 10096 AS 2 0 04*L 6Om 005*C1 6Om 006*C2 60m m 2 0
>r p BASE M1
BASE BASE M1 M1
002 P 003 P
BASE BASE
M1 M1
0 E l ~ ~ ~
j
2.
Set a current/voltage/welding speed (to modify).
3. Press
@.
T.MECH. ML4
>
Now, the welding conditions have been modified. Similarly, you can modify the parameters (moving speed/ overlap ON/OFF) of Motion instructions.
002 P 10 0% 5096 003 P AS 18OA. 004*L 6 Om 005*C1 60ca 006*C2 60cm
BASE M1 BASE M1 20. OV. 8Ocm BASE M1 BASE M1 BASE MI
(sEARC/~JUMPj(/m-
>
3-1 4
3. 7
Adding and Deleting Instructions

Adding Instructions
This section describes how t o insert Positioning
3. 7. 1
"P"between steps 002 and 003 in a n
example Task program PO01 created in section 3.4.2.
1. Perform block operation t o the

instruction (Sequence 002) which should be followed by an instruction you are adding.
AXIS ML4 TEACH

PO 0 1
SQ N . o= 9 SERVO ON
001 P > 0 0 2 P 003 P
AS
004+L
100% BASE 100% BASE 50% BASE 2 0 0 h 22.OV. 80cm 60w BASE
M1 M1 M1 M1
pxKcqIJUMP/ISHIFT//PATH//l>
2. Press
Then, the
rrr)
AXIS ML4 TEACH
PO 0 1
LED on the upper left
001 P >002 P
100% 100%
BASE BASE
MI M1
SQ N . o= 9 SERVO O N
jMoTION/jI/O/mIWELD//WEAVE/
>
3. Move the manipulator t o the

position/attitude you want t o add, by performing manual manipulation.
4. Press the key of the instruction

in this you want t o add ( example). Set a speed and overlap ON/OFF
a s set t o create a new program.
5. press . Now, a new instruction "P"has been added. Repeating the operations 3 - 5 allows you t o add instructions a s many as you want.
If you press after you press cancel the instruction you have just added.
6.
To terminate the adding operation, press O @ .
AXIS M L 4 TEACH
PO01
001 P 002 P >003 P
10096 100% 2096
BASE BASE BASE
MI M1 M1
S Q N. o= 10 SERVO O N
IP
SPEED=ZO%
L A P :ON
jMoTIONIJ//OIIBRANCHI/WELD/rnj >
immediately
AXIS ML4 TEACH

PO01
S Q No,= 10 SERVO O N
001 002 >003 004
P P P P
AS
005*L
100% BASE 100% BASE 20% BASE 50% BASE 2 0 0 h 22.OV. 8 0 m 60m BASE
M1 M1 M1 M1 MI
Then, the LED on the upper right will light.
/SEARlmISHIFT/m/ml>
3-1 5
3. 7 . 2
Deleting Instructions
This section describes how to delete step 3 in a n example Task program P 0 created O1 in section 3.4.2.
AXIS ML4 TEACH PO01 SQ No.= 9 SERVO ON
I.
Perform block operation to the instruction (Sequence 002) which should be followed by an instruction you are deleting.
M1 001 P 100% BASE >002P 100% BASE MI 50% BASE M1 003 P AS 200k 22.OV. 8 c 0m 0 04XL 6c 0m BASE MI
>
2.
press
66;;r) . w
Then, the a r e a to be deleted will be highlighted.
AXIS ML4 001 P TEACH >002 P PO 0 1 I003 P SQNo.= 9 SERVO ONm c 004XL RANGE FOR DEL.
100% 100% 59 0' 6Om
BASE BASE
BASE
BASE
A
M1
M1 MI
pEiEq
*
To extend the area, press

To reduce the extended area,
To cancel your deletion, press
3.
Press F1 (EXECUTE).
Now, the highlighted a r e a has been deleted. If you press
AXIS ML4 TEACH PO01 SQ No.= 9 SERVO ON
001 P 100% BASE M1 >002 P 100% BASE M1 AS 200k 22.OV. 8 c Om 003*L 6Om BASE M1 60m BASE M1 004*C
after you delete, your deletion will be cancelled.
0
wFY
immediately
~ >
3-1 6
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 t a r 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.
3-1 7
3. 9
Automatic Operation
When you have finished s t a r t allocation to each station, you can now s t a r 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 or 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.
3-1 8
3.10
Shutting O f 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 a r e provided; one is on the operating panel, and the other is on the teaching box. (If you install a starting box o r boxes, each starting box is also equipped with an EMERGENCY STOP button.)
Cancellina the EMERGENCY STOP button on the operating panel.

0 0
I OK+
7&
Turn t o the button t o the arrow.
Cancelling the EMERGENCY STOP button
-\1\
on the teaching box
Warning To safeguard the operators, ensure that the EMERGENCY STOP button is always ready to be pressed.
3-1 9
3.1 I
Turning Off the Control Power
To turn off the control power, follow the steps below:
Press the EMERGENCY STOP button on the operating panel o r teaching box t o turn off the servo power.
Turn the control power handle t o the left, and hold it a t the OFF position.
Now, the control power has been turned off.
3-2 0
Chapter 4
Manual Manipulation
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 t o 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 4.1.4 Switching Mechanisms (Not applicable to the Single Manipulator System) 4 .1.5 Inching and Retracting the Wire ~control to u t p u t ~ signals ~ ........................................................................ ~ ~ l 4.1.6 'pesetting ~ 4.2 ~~~i~~ ~ i ~ ~ ~ t i ~ ~ ~ 4- 5 4- 5 4- 6 4- 7 4- 2
4 .2 .1 Axis Movement ........................................................................................................................................... 4- 7 4 2.2 Cartesian Movement 4 3 Cartesian Movement Near the Singular point 4- 9
........................................................................... 4-
19
4.
Manual Manipulation
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 a r e involved to perform manual nlanipulation. Changing positions and attitudes (Manual Manipulation)
* * *
4. 1
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 o r outside the Start Enabe area before automatic operation is started o r after the Job is completed. TEACH mode Block operation o r absolute offset setting is not being performed.
MECHAN l SM
II
Manual Operation
1. Press the Axis key while holding

down
2.
The manipulator moves in the direction corresponding t o the key being pressed.
(I:
TEACH ENABLE
Manual Manipulation
3.
When you release stop.
@ key, all axes

w
F o r moving directions, refer to "Moving Directions", section 4.2. in part 1.
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 a r e a on the teaching box.
<
(Inching) Low speed mode High speed mode
>
High
Low
The maximum speed in the low speed mode (ML4) is 15m/min.
H Switching between speeds f o r manual manipulation

* TO increase:
Press
1 81 .
Speed display a r e a
l 4
If the speed is ML4, pressing changes to MH1.
AXIS
TEACH
ML4
To decrease:
Press
[vl.
SERVO
ON
If the speed is MH1, pressing changes to ML4.
4. 1.3
Switching between Coordinate Systems
In principle, two kinds of movements, Axis and Cartesian movements, a r e 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 a r e 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 t o "Moving Directions", section 4.2 in part I. * 2: Refer t o Instruction Manual "Options"
4
- 2 Manual Manipulation
Coordinate systems that can be selected depend on the system configuration using a single manipulator o r multiple mechanisms:
Table 4.1 Coordinates Systems Available According to the System Configulations Single Manipulator System Axis Movement Multiple-Mechanism System Simultaneous control
I
Synchromotion
I
1 Cartesian 1 ~ o o l1
/
Base Movement Work World
@ 0
Q 0 0
@
@
0 6 3
Q
0 A
Q
6 3 0
0: Available
0 : Can be set, but
a system.
gives the same results a s the Base coordinate.
A : Can be set, in the case that Simultaneous control and Synchromotion a r e mixed in
Note 1) For Slider o r Positioner, only the Axis Movement is available. 2) In a Single Manipulator system using an overhead o r wall mounting type, the World coordinate system is also available.
-
There a r e two ways of changing the coordinate system from Axis Movement to each Cartesian Movements.
* The way of changing to registered Cartesian coordinate systems
The way of selecting out of 4 Cartesian coordinate systems
(By pressing
key)
Manual Manipulation
-3
(1) The way of changing to registed cartesian coordinate systems

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

+
-+
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 a r e 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

By pressing
FUNC-
key, you select a Cartesian coordinate system you want one of 4
Cartesian coordinate systems(Base, Tool, Work, and World coordinate system).
6 Change coordinate systems you often 3
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 a r e a on the teaching box.
Switching coordinate systems by
FUNC-
key.
1. Press
FUNC-
in the state of being
able t o perform manual operation.
4 -4
Manual Manipulation
2.
Press Fl(C0RDNAT).
F1 F2 F3 F4
... Base coordinate system ... Tool coordinate system ..- World coordinate system
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 key during manual
such a s slider o r positioner, mechanism should be selected by operation.
F o r detail of switching mechanizms, refer to the Instruction Manual
"
Options",
depend on the control system(Simultaneously o r 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) parameters. *
"
and "INCH/RETRACT(LOW)
"
in the welding user
@ 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, o r before automatic operation is started, o r after the job is completed.
L
* : Refer to "Setting the Welding Parameters" section 2.3 in part
I[.
Manual Manipulation 4 - 5
Inching and retracting
(Inching)
Press
*
IF/.
IwI
I U I
For h i z e e d inching, press [ q w h i l e holding down
a
0099 to OFF
Press
*
.
while holding down
For high speed retracting, press
4.1.6
Resetting External Control Output Signals

You can set a group of External control output ports 0000
Any output ports 0100
0199 will not be changed.
Resetting external control output signals
1. Press
FUNC-
In the state of being
able t o 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 will not be changed.
0199
4 -6
Manual Manipulation
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.
Movement
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
Manual Manipulation
4 -7
Axis No Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
Movement Rotation (left/right) Lower a r m (forward/backward) Upper a r m (upward and downward) Wrist (swivel) Wrist (bend) Wrist (twist)
Teaching Box Key
3)
Bend
xis 2)
Fig.4.2. Moving directions of ALMEGA V series
4 -8
Manual Manipulation
4.2.2
Cartesian Movement
This section describes the moving directions given in each of the Base and Tool coordinate systems.
Cartesian movements a r e 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 a r e the same a s those in the Single Manipulator system. F o r moving directions on the Work and World coordinate systems selected in the Synchronous Motion Control system, refer to Instruction Manual "Options".
Manual Manipulation
-9
(1) Base coordinate system
IALMEGA
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
*
Axis 5
(ALMEGA G series and W01)
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 (ALMEGA G series and W01)
Manual Manipulation
4-1 1
Fig.4.6. Moving directions of Base axes in the Base coordinate system (ALMEGA V series)
-1
Manual Manipulation
(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
Fig.4.9. Moving directions of Axis 6 Center line of rotation of Axis 6 Direction of Z axis
,
w
I
,
Torch tip
-
Axis
/\ '
- Horizontal
Torch line
plane
Line of Axis 6 Moving direction of Wrist axes in the Base coordinate system (ALMEGA V series)
Manual Manipulation
4-1 3
(c) Wrist axis movements (the Roll/Pitch/Yaw system)

*
Axis 4 Axis 4 rotates around the Z axis, with the tool center being fixed.
Fig.4.11. Moving directions of Axis 4 Axis 5 Axis 5 rotates around the Y axis, with the tool center being fixed.
Fig.4.12. Moving directions of Axis 5 Axis 6 Axis 6 rotates around the X axis, with the tool center being fixed.
Fig.4.13. Moving directions of Axis 6

4-14 Manual Manipulation
(2) Tool coordinate system
~ALMEGA series (GO1 and G03) and WO1I G

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 (ALMEGA G series and W01)
Manual Manipulation
4-1 5
Fig.4.16. Moving directions of Base axes a t different attitudes
-1
Manual Manipulation
I ALMEGA V series]
x axis
Fig.4.18. Moving directions of Base axes a t different attitudes

Manual Manipulation
4-1 7
(b) Wrist axis movements

*
Axis 4 The torch rotates around the Z axis (torch line), with the torch tip being fixed.
Fig.4.19. Moving directions of Axis 4 Axis 5 The torch rotates around the Y axis, with the torch tip being fixed.

*
Axis 6 The same as Axis 4.

4
-1
Manual Manipulation
4. 3
Cartesian Movements Near the Singular Point

If Cartesian manual manipulation o r a linear o r 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 r e not guaranteed.
he singular point of ALMEGA G series and ~ 0 1 )

*
Position where Axes 2 and 3 a r e 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

Manual Manipulation 4-19
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, o r automatic o r block operation, this causes Axes 2 and 3 to rotate a t a high speed. Because such movements a r e very dangerous, OSACOM SUPER 8700 is equipped with a device to control them.
-2
Manual Manipulation
When the manipulator moves t o 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 -+MANUAL
112 1
OPE.
When all mechanisms stop, it is not possible to perform Cartesian manual manipulation in the direction approaching t o the singular point. When all mechanism stop, it is possible t o 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 r m entered the a r e a 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
Manual Manipulation
-2
Chapter 5 Teaching
1
/
This chapter describes features of Motion instructions and Task instructions. how to teach them. and block operation t o check the positions and attitudes in a Task program created .
I1
Contents
5.
Teaching
The teaching features a r e 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
5.1.1
Creating and Listing Task Programs

Creating Task Programs
This feature is used to create new Task programs. The created Task programs a r e stored a s Task program files. Task programs a r e created in accordance with the following procedure:
m
Enter a Task program number. ich do you select, Motion o r Task inst
I
Task instruction
I
I
Motion instruction
I
1
Set a manual speed accordingly.
I
1
1 coordinate system accordingly. II

/ Set each type of movement and
/ Move the manipulator
1 manipulation.
/ Store
No the
by manual
I
instruction
Motion
1 1 Store the Task instruction. 1
you want to tdrminate t e a c h i n a
Perform block operation (to check the positions and attitudes)
Fig.5.1 The procedure for creating a Task program
Teaching
-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 a n existing number, you a r e not creating a program but will modify its program o r perform block operation. Though Task program numbers ranging from 1 through 999 a r e 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 a r e divided into two groups: Motion instructions These a r e instructions to move the manipulator (for positioning and interpolation). Sequence numbers a r e given to Motion instructions in order by creation. The maximum of 999 sequences can be stored in one Task program.
Task Instructions These a r e Instructions to execute welding, weaving, output signals to external devices, etc. The maximum of 9980 instructions can be stored in one Task program. F o r 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 a t 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
-3
Table 5.1 List of Motion/Task Instructions Key Instruction P

$
Description Positions
Parameter Speed rate and Overlap on/ off Speed and Overlap on/off speed and Overlap Speed rate and Overlap ON/OFF Speed and Overlap on/off
Speed and Overlap on/off
$ Linear interpolation
Linear interpolation with rotation of attitude LX
*$
Uniform interpolation
c1
C2
$ Center point of circular interpolation $ End point of circular inter polation Center point of .circular interpolation with rotation of the attitude
Rotating speed and Overlap on/off Rotating speed and Overlap on/off Welding s t a r t conditions Crater condition Inching time Retracting time
End point of circular interpolation with rotation of the attitude AS AE ICH RTC GS GE ASM AEM WFP WAX WE
L
Starting welding Terminating welding Inching the wire Retracting the wire Turning gas ON Turning gas OFF Starting multi-pass welding
Welding s t a r t condition Weaving condition Offset condition condition Ending multi-pass welding Crator condition Offset Starting weavin (Fixed pattern
Weaving conditions Weaving conditions
Starting weaving (Axis)
1 Terminates weaving
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 NOP
Waiting for time
Time
$ No operation
$
W
BRANCH
PM
Point mark (Jump destination) Internal jump (Unconditional)
Point mark number Point mark number Point mark number and Input port Point mark number and Input port Point mark number and Input port Task program number Task program number and Input port number Task program number and Input port number Task program number and Input port number Task program number Task program number and input port number Task program number and input port number Task program number and counter number
JP N JP F JP C
$ Internal jump (ON condition)

$
Internal jump (OFF condition) Internal jump (Counter condition)
JF
JF N
$ External jump (Unconditional)

$
External jump (ON condition)
JF F JF C
$ External jump (OFF condition) $ External jump (Counter condition) $
Calling program (Unconditional) Calling program (ON condition)
CL N CL F CL C
$ Calling program (OFF condition)

$ Calling program (Counter condition)
/ DEF
DEC END HP HL
1 Setting counter value

Ending program
I Counter value
Speed rate Overlap on/off Speed Overlap on/off
Decremental operation of Counter value counter value
*$
Synchronous positioning motion Synchronous linear interpolation
*$
Teaching
-5
HLO
*$ *$
Rotating speed Synchronous linear interpolation with rotation Overlap on/off of attitude Synchronous circular interpolation Speed Overlap on/off
HC HO
*$ *$ * *
*$
Rotating speed Synchronous circular interpolation with rotation Overlap on/off of attitude Simultaneous uniform interpolation Starting tracking Ending tracking Wire extension One-direction search Pattern search Deviation store number Deviation store number Pattern No., Deviation store number, Search/Move Speeds, Reverse direction on/off, and Component on/off Calling deviations Storing deviation number in tracking Starting high speed touch sensing Ending high speed touch sensing Starting multi-pass section Ending multi-pass section Deviation call No. Deviation store No. Speed rate Overlap ON/OFF
HLX ST ET
SF1
*$
Speed Repeating times Executive condition Rotational offset value, Axis number
EP RT
*$ *
Specifying executing pass of task instruction Calculating rotated $ position
* : Indicates Optional instructions. $ : Indicates Motion instructions. Instructions without $ a r e Task instructions.
5-6
Teaching
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*'.
I Listing Task programs I

1. Press F1 (TEACH) a t the top
I) I
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
The list operation is terminated, and you can enter Task program numbers again.
0
I-ESET
* 1: Refer to "Setting the System Status", section 2.1 in part * 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 .
II.
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 t a r 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 a r e overlapped.
@When you want t o reduce a tact time (a time f r o m the start of automatic operation till the completion of a job), select Overlap ON.
Overlap ON
Overlap OFF
Fig.5.2 The paths given by setting Overlap ON/OFF
4 k
bilULIUI1
n-.-L:--
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

5-8
Teaching
this manual.
I I
Teaching Positioning P
1. Move the manipulator, by

manual manipulation, t o the position and attitude you want t o teach.
2. Press
B.
75% and Overlap ON 100% and Overlap ON 50% and Overlap ON 75% and Overlap OFF 100% and Overlap
F1 F2 F3 F4 F5
... Speed ... Speed ... Speed ... Speed ... Speed OFF
3.
Set a speed by using the function key o r numeric keys.
4. Set Overlap ON or OFF, if

necessary.
The default is "ON". To change t o "OFF" :
(2) Press F2 (OFF).
(3) Press
@.
Now, the Positioning instruction
"P"has been stored.
Teaching
-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 r e limited t o 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 a r e 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. F o r welding, usually set overlap "ON". If overlap is set "OFF", th that point during automatic operation. mentarily stop a t
I I
Manipulator stops momentarity a t the joint
Robot does not stop but takes a small short cut, which causes the path t o 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
LFI
Teaching Linear Interpolation L (LO) 1. Move the manipulator, by manual manipulation, t o the position and attitude you want t o teach.
2. Press
~
~lr)
Iw ~ ~ ~ p i x x i
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 Pressing [> key causes L to change to LO instruction.
a . I5
oa , -
F1 ... Speed 5.0deg/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 ... Speed lO.Odeg/sec and Overlap OFF 3. Set a speed by using the function
key or numeric keys.
4. Set Overlap ON o r OFF, if

necessary.
For details, see the steps for Positioning 5. Press
"P" .
@.
Now, the Linear Interpolation instruction "L" has been stored.

5-1 2
Teaching
5. 2. 3
C i r c u l a 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 r c is defined by 3 points- a s t a r 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 o r 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 r c 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 r e 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 a r c varies according to the manipulator type and the speed setting.*
* : Refer to "The Relation between
a Minimum Circular Diameter and a Setting Speed"

5-1 3
Appendix 2 provided a t the end of this manual.

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

manual manipulation, t o the position and attitude you want t o teach.
2. Press
ONA / 6 l [ O N j r ; i 0 0 c m O j S I m m />
LAP :
F1 ... SpeedGOcm/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 ... Switches between C1 and C2. key causes C to change t o CO instruction.
LAP :ON'
'
/ 5 I d ] p . ' G i q ~ ~ ~ ] >
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 C 0 1 and C02.
3.
Set a speed by using the function key and numeric keys.
4.
Set Overlap ON or OFF, if necessary.
F o r details, see the steps for Positioning " P " .
5. Press
Now, the Circular Interpolation "C" h a s been stored.

5
0
RECORD
-1
Teaching
5.2.4
Wait f o 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 r e carried on without being stopped.
@Use this instruction when you want to teach more than 9 instructions continuously o r do not want t o simultaneously execute a series of external control inputs/ outputs.
II1
Teaching Wait f o r Timer Time " T " and No Operation "NOP"
1. Press
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
keys.
IT
TIMER-
2.0 sa.
I.-
(2) Press
0
RECORD
key.
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 P r o g r a m J u m p PM(Point Mark), J P ( J u m P ) ,

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 t o a desired sequence. J u m p conditions include the external control input state, counter, etc.
The following instructions a r e used t o execute a n internal program jump:

* * *
Internal Program J u m p Point Mark (jump destination) Counter conditions for jump
JP PM DEC and DEF
(1) Internal Program J u m p J P

This instruction allows the operator t o shift execution of a Task program t o a specified point m a r k (PM) within the program. The Positioning instruction " P " is used to move t o 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 J u m p s always t o a specified point mark (PM).
*
J u m p according t o the external control input s t a t e J u m p s to a specified point mark (PM) if the jump condition exists when the external control input s t a t e is checked.
J u m p according t o the internal counter J u m p s 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
: Refer t o "Setting the System Status", section 2.1 in p a r t 11.

Teaching
5-1 7
' .
Important 1) As well as Positioning " P " , Point Mark h a s d a t a of the position/attitude. If multiple mechanisms a r e configured, this instruction h a s d a t a 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 t o move t o 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 r o r is not displayed. However, a n e r r o r is detected when a logical check on Task program* is performed.
(3) Internal Counter DEF and DEC

These instructions a r e used t o set a counter value and t o 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 P r o g r a m 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 f o r 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 J u m p 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.
*
5
: Refer to "Logical Check on Task Programs", section 1.2.1 in P a r t 2.
-1 8
Teaching
[Example) [Teaching data1 0 0 0 0 0 0 0 0 0 0 0 0 1 2 3 4 5 6 [Position] The position of PM of sequence 2 differs from those of sequences 1 and 3.
PM1
P P J P PM1 END
[Path] Positioning to sequences 3 and 4 from sequence 1 by performing block o r 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 J u m p using a Point Mark (PM)

Teaching
5-19
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 a n input. Terminate the program if
no input." ,teach: Sequence No 0 0 1
PM 1
+Specify point mark
(PM) number 1.
0 0 5 0 0 6
JP
END
N 0 0 7,
PM 1
+Jump to PM1 (sequence 001) if there is a n 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
DE
0 0 2
F # 2, PMI
0 0 5
+Set counter 2 a t 5.
DEC 0 0 5
#2
+Decrement 1 to the value of counter 2 by 1.
# 2 , P M 2 +Jump to PM2 (sequence 007) if counter 2 is 0, and

terminate automatic operation.
0 0 6 0 0 7 0 0 8
JP
P M 1 +Jump to PMI (sequence 001) if counter 2 is not 0.

(Repeat sequences 001 - 005 5 times.)
PM2
END
When a ~ l t o m a t i c operation is performed, the operation from sequence 001 through 005 is repeated 5 times.
5 -2 0
Teaching
I I
Teaching Internal Program Jump "JP"

m
I . Press
2.
Press the F2 key (JP).
111)
F1 ... J u m p when a specified input port is ON. F2 ... J u m p when a specified input port is OFF. F3 ... J u m p 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 f o r the destination.
Jump accordinn to the counter

(1) Press the F3 key (JP CNT)..I)
(2) Set the jump conditions; a

counter number and a point mark number f o r the destination.
Teaching
-2
Unconditional iumr,
(1) Press the F4 (UNCOND).

(2) Set a point mark number f o r
the destination.
3.
Press
0
RECORD
key.
Now, the Internal Program Jump

"
J P " instruction has been stored.
Teaching Point M a r k " P M "
1. Press
2.
PresstheF4 key (PM).
3. Set a point mark number.
4.
Press
0
RECORD
Now, the Point Mark "PM" instruction has been stored.
5-2 2
Teaching
I I
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).
(2) Set a counter number.
(3) Press
@.
Now, the DECrement "DEC" instruction has been stored.
Teaching
5-2 3
5.2.6
External Program Jump J F
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 a r e 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 J o b End). Therefore, the instructions following Program Jump a r e not executed.
\
(Example] Task programs PO01 and PO02 contain the following taught data: PO01 PO02 P-P-L-L-L-P-P-END P-P-L-L-P-P-END PO01
I'
PO02
\ P , EM)
P END \,,
4
,
\
P7 '
1
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 t o PO02 after executing PO01

Teaching for PO01 : P-P-L-L-L-P-P-JF P002-END
P;
I
I
Y I
END
.----'--.P;
\
0,
P , END
1
X\,
\ \
p ;'
I
1
p \
Fig. 5.8 Path made by jumping to PO02 after executing PO01
(2) Jump t o PO02 after executing sequence 5 in PO01
Teaching for P001: P-P-L-L-L-JF POO2-P-P-END L n o t executed
Fig.5.9 Path made by Jumping from within PO01

Teaching 5
-2
Teaching Program Jump " J F " 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 ( J F ON) o r the F2 key ( J F OFF).
(2) Set the jump conditions; a port number and a point mark number f o r the destination.
Jump according to the counter

(1) Press the F3 key ( J F C N T 1 . e
(2) Set the jump conditions; a counter number and a point mark number for the destination.
Unconditional lump
(1) Press the F4 (UNCOND).
(2) Set a point mark number f o r the destination.
3.
Press
0
RECORD
key.
Program Jump " J F " instruction has been stored.

5-2 6
Teaching
5.2.7
Programcall
CL
The Call instruction is used to execute another Task program from within the Task program being currently executed and return control t o the original program after the called program is executed. This allows the operator to sequentially run multiple Task programs.
The following call conditions a r e 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 J o b 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, J o b 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 a r e 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-CL POO2-END
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-CL POO2-P-P-END
Fig.5.10 Path made by Calling PO02 from within PO01
Teaching Call Program " C L " by specifying a Task program number by the direct entry
1. Press
2. Press the F2 key (JP).
+
[ONIErGFlCNT/[~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
5-2 8
Teaching
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,. ' ,#
PRGFP,
,]
rE-rTqIOFFI/CLCNT/rnj
(2) Set call conditions; a port

number and a Task program number t o 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 t o be called.
Unconditional call
(1) Press the F4 (UNCOND). (2) Set a Task program number
t o be called.
3.
Press
key.
Now, the Call Program "CL" instruction has been stored.
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 h a s been stored.

Teaching
5-2 9
5. 3
5.3.1
Teaching Task Instructions

A r c Start AS
This instruction is used to s t a r 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 set in advance a s a user parameter * 1 .
(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 a n 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 r e two way of specifying welding conditions: Specifying a Welding Condition file*2which 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 t o save teaching time and correcting time.
* 1: Refer to "Setting Welding Characteristic Data", section 2.7 in part * 2: Refer to "Editing Welding Condition Files", section 7.2 in part I .
5-3 0
Teaching
I 1
0 Important
1) If the setting of "APPLICATION" in the user parameters for setting the system status is "HANDLING", welding related operations and instructions a r e not executed. 2) The entry ranges of current, voltage, and filler wire feed s a t e a r e defined by the ratings set in welding characteristic data. If values larger than rated values a r e entered, the rated values will be stored. 3) The preflow is not available for the standard TIG welding power sopply.
) 1 Teaching the AS instruction 11
Setting A r c Start conditions by entering numeric values

-
The display on the 7th line a t the main display a r e a depends on the type of welding power unit used. The following explanation is based on an individual control type welding power unit. A preflow time is set in "PREFLOW TIME"' of the user parameters for welding. The preflow is not available for the standard TIG welding power
TIG Synergic control type Individual control type
IAS 6 0 . 4 1
2 3 . 0 ~ som
7 i'"" 8 om
S ocat
' ---q
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 t o "Setting Welding Parameters", section 2.3 in part
11.
Teaching 5
-3
3.
Setting a welding voltage
The voltage optimum to the current is automatically set only

if you a r e 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 b y specifying a Welding Condition f i l e

1. Press
@ and then F3
(AS FILE)
*
+ +
AXIS MH1 TEACH
P777 SQNa=
4
2. Enter the file number by

numeric keys.
Then, press F1 (COND), and the specified file will be displayed.
WELDING CURRENT WELDING VOLTAGE WELDING SPEED
1 8 0A 2 0.OV 1 5 Om
SERVO ON ASCO 1
p'.F"FI
-3
Teaching
If the specified file does not exist, a n Alarm message is displayed.

*
NFILEEXllAs r sTs
FILE A s c o l
>
% , 3 *
.) r
1-
F1 ... Displays the contents of another Condition file.
0
~ I F Y
... Re-enters a file 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 a r e no other Condition file.
*
0
mIFY
@ 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.
L
Teaching
-3
5.3.2
Arc End
AE
The AE instruction is used to terminate welding with a crater process using the specified a r c 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 a n postflow time (0.0-9.9 sec.). Postflow is a process to prevent oxidization a t the weld
end part by keeping a g a s 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 a n postflow time (0.0-9.9 Standard TIG welding power supply. sec.). The afterfrow is not availlable for the
1) The entry ranges of current and voltage a r e defined by the ratings set in welding characteristic data. If values larger than rated values a r e 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 a r e two way of specifying crater (Arc End) conditions: Specifying a Arc End Condition file*' which contains crater conditions Directly entering numeric values
* 1:Refer to "Setting Welding Parameters", section 2.3 in part

5-3 4
Teaching
I1
* 2: Refer t o "Editing Welding Condition Files", section 7.2 in part
I I
Teaching the AE instruction
Setting A r c End conditions by entering numeric values

1. press
IIAE i s o A 9 .wb . et . s-
If the current sequence is a welding section, AE will be displayed.
[ U lA N MJ Sm N MI E U I A -
The display on the 7th line a t the main display area depends on the type of welding power unit used.
sr)
Individual control type
* +
"6
*
Synergic control type
The following explanation is based on an individual control type welding power unit. TIG
2. Enter a current, a voltage, a

crater time, and an afterflow time by numeric keys.
The voltage is automatically set only if a n individual control type of welding power unit is used. For automatic control, see the description of AS.
3. Press
Now, the Arc End instruction "AE" has been stored.
Teaching
-3
Setting Arc End conditions by specifying a file
1. Press
(AE FILE).
and then F4
+
Ir+)
2.
Enter the file number by numeric keys.
3. Then, press F I (COND),and the

specified file will be displayed.
AXIS MHI TEACH

P777 SQ Aa=
4
WELDING CURRENT WELDING VOLTAGE CRATER TIME POSTFLOW TIME
180A 20.0V
1.0
S.
0 0 s. .
SERVO ON AECO 1
If the specified Condition file does not exist, an Alarm message is displayed.
*
/NEXT1
F1 ... Displays the contents of another Condition file. ... Re-enters a file number.
, ,
4. Press
@.
Now, the Arc End instruction "AE" has been stored. If the specified Condition file does not exist, a n Alarm message is displayed.
*
*OFILE I STS
lIXE
IEXECUTEJ pTYT-1
F1 ... Stores the specified Condition file. F2 ... Displays the contents of another Condition file, if any. The display does not change if there a r e no other Condition files. * ~JNJ~FY ... Re-enters a file number.
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 r e not executed:
*
When
is set OFF.
In a welding section, o r
*
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
times.
, and then
two
*
I) I
AXIS MH1 TEACH

P7 7 7 SQ Na= 1
SERVO O N
>001
100%
BASE
5Om
M1
[ A S ' . 'XSOA 23,OY
1
>
[ICHjIRTCIIGIrn
Inching
(1) Press F1 (ICH)

(2) Set an inching time by
numeric keys. Retract
AXIS MHI TEACH

P7 7 7 SQNa=
1 >001
SERVO O N
10096
BASE
, i
M1
~XCN Tl[ME=99,9sec
1
>
[ C H/ IR mm I
.) r
(1) Press F2 (RTC)

(2) Set a retracting time b y
numeric keys.
AXIS MH1 TEACH

P777
SQKa=
SERVO ON
>001 P
100%
BASE
,
,
MI
I
IBTC:TX,ME=~ c,,, ~ , se 9
* ,>> *
2.
Press
@.
IIcH]IRTC[SIVl
>
Now, the Inching/Retract instr~~ctions "1CHJ'/"RTC" have been stored.
Teaching
5-3 7
5.3.4
Gas ON/OFF
GS/GE
The GS/GE instructions a r e 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
Gas ON/OFF by GS/GE a r e not executed:

* 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
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 a r e used to start weaving a t specified weaving conditions o r 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 Directly entering numeric values
@If there are multiple areas which are weaved a t the same weaving conditions, specifying a Weaving Condition file allows you t o 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~vingparameters a r e available: Function type Amplitude(Ha1f cycle: Yl/Y2) Frequency Center stopping time 1/4 cycle stopping time 3/4 cycle stopping time linear function o r sine curve 0.0 -- 50.0 mm 0.0 0.0 0.0 0.0
10.0 Hz 9.9 sec
9.9 sec
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 f o r block operation o r automatic operation varies according t o WEAVE "ON"/"OFF".(The cycle time a t the "ON" setting becomes longer by the total stopping time than that a t the "OFF".)
*
5-4 0
Refer t o "Restriction on Weaving Frequency", appendix 3 provided a t the end of this manual.
Teaching
(2) Weaving by axis WAX
The WAX is used t o perform weaving by single vibration of each axis. The following parameters a r e available: Axis No. Amplitude (Half cycle: Yl/Y2) Frequency Center stopping time 1/4 cycle stopping time 3/4 cycle stopping time 1-6 0.0 0.0
9.99 deg 10.0 Hz
0.0 -- 9.9 sec 0.0 -- 9.9 sec 0.0 -- 9.9 sec
I t is possible t o set up t o 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 t o 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).
AXIS MH1 TEACH P7 7 7 SQ Ha= 2 SERVO ON
>FUNCTION AMPLITUDE Y1 AMPLITUDE Y2 FREQUENCY CENTER STOP 1/4 F R E Q STOP 3/4 FREQ STOP
pmE%q
I. Onm
1. Oaa 5 OE . I 0.0 S .
00 S . . 0 0 s. .
3. Move the cursor by pressing

, and set parameters.
[LINEAR/WIG/
(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
0
RECORD
key
Now, the Weaving with Fixed Pattern instruction "WFP" has been stored.
5 -4 2
Teaching
Setting Weaving conditions by specifying a f i l e

1. Press
2.
Press F2 (FP FILE).
.) I
LWpP FI&E
WPP
/mmFILEI/AXpTTqlWE/
3.
Enter the file number by numeric keys.
4.
Then, press F1 (COND.), and the specified file will be displayed.
AXIS MH1 TEACH P777 SQ Ha= 4 SERVO ON
FUNCTION AMPLITUDE Y1 AMPLITUDE Y2 FREQUENCY CENTER STOP 1/4 FREQ STOP 3/4 FREQ STOP
LINEAR I Onm .
1.0ma 5. 01%~
0 0 s. . 0 0 S. . 0 0 s. .
If the specified Condition file does not exist, a n Alarm message is displayed. rr) * F1 ... Displays the contents of another Condition file, * m l F Y ... Re-enters a file number.
piFx-y
5. Press
@.
Now, the Weaving with fixed pattern instruction "WFP" has been stored. If the specified Condition file does not exist, a n Alarm message is displayed. * F1 ... Stores the specified Con dition file. * F2 ... Displays the contents of another Condition file, if any. The display does not change if there a r e no other Condition files. mlFY ... Re-enters a file number.
NOFILE EX I sTs
-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 E r r o r in automatic operation.
Teaching
5 --'4 3
Teaching the WAX instruction
Setting Weaving conditions by entering numeric values
2.
Press F3 (AX NUM.).
A X I S MH1 TEACH P7 7 7 SQ Ha= 5 SERVO ON
3. Move the cursor by pressing

and set parameters.
FREQUENCY l A X I S 4 Y l 0.OOd. P A X I S 5 Y 1 O.OOd. 3 A X I S 6 Y 1 0.OOd. CENTER S T O P 1/4 FREQ S T O P 3/4 FREQ S T O P
5.0 Y 2 0.OOd. Y 2 O.OOd. Y 2 0.OOd. 0.0 S, 0.0 S . 0.0 S .
(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
0
RECORD
key
Now, the Weaving by Axis instruction "WAX" has been stored.
5 -44
Teaching
Setting Weaving conditions b y specifying a f i l e

I . Press
M.
2.
Press F4 (AX FILE).
*
rr)
3. Enter the file number by

numeric keys.
4.
Then, press F2 (COND.), and the specified file will be displayed.
sr)
A X I S MH1 TEACH P777 SQ N= 5 a SERVO ON WAX 0 1
FREQENCY 5.0 1.AXIS 4 Y 1 0.OOd. Y 2 O.OOd 2.AXIS 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.
If the specified Condition file does not exist, an Alarm message is sl) displayed. F1 ... Displays the contents of another Condition file. ~ I F Y ... Re-enters a file number.
5. Press
Now, the Weaving by axis instruction "WAX" has been stored. If the specified Condition file does not exist, an Alarm message is I ) 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.
0
M~DIFY
Teaching
-4 5
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
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 r e divided into 2 groups: External Control Output instructions External Control Input Wait instructions S and R N and F
(1) External Control Output instructions

External control output instructions set a specified output port ON/OFF.
Set a n external control output
Reset a n external control output R
The following parameters a r e 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 a n 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 p a r 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 a n external control input ON Wait f o r a n external control input O F F
N
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 e r r o r will occur, which causes the operation t o 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:
S N R * S, N, NOP, R S F R + 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 f o r S and same.
R must be the
F o r the relation between output numbers and actual output circuits (output terminals), refer t o the instruction manual "Interface with Jig"
5 - 4 8 Teaching
Cautions 1) All Task instructions taught between two Motion instructions a r e 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 001 P S S S S 002 P 11 0 0 0 0 0 0 0 0 1 2 3 4 (Example 001 P S S R 21 0 0 0 0 0 0 0 0 1 2 1 3 (Example 31 001 P S 001 N 001 R 001 002 P
S
002 P
(Example 1) Output ports 001 - 004 a r e simultaneously set ON. (Example 21 Because SO01 and ROO1 a r e simultaneously executed, output port 001 is not set. Only 002 and 003 a r e 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 instructions may not be executed: (Example 11 Oo4 005 [Example 21 004 the same o r almost same point. 0 0 1 P S 001 001
irk
P R
005 N O P
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.
'
I>
2.
3.
F1 ... External control output SET FZ ... External control output RESET F3 ... External control input ON WAIT F4 ... External control input OFF WAIT F1 ... Teaches a series of S, N, NOP, and R. FZ ... Teaches a series of S, F, NOP, and R.
p-c--q~INPON/lOFF/
I
>
1
p-ii-zsFRI p
External Control Output instruction S

1. Press F1 (SET).
* I
1
t
Enter the output port number by numeric keys. Press, delay time. and then set the
4.
Press
0
RECORD
Now, the External Control Output instruction "S"has been stored
External Control Output instruction R

1. Press F2 (RESET).
2.
Set the output port number and the delay time as set f o r 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

1. Press F3 (INPON).
I )
~ ~ T I I R E S E T I / ~ ~ ~
2.
LON
PORTLTIMER-o
9 .
Enter the input port number by numeric keys.
3.
Press,
and then set the
input waiting time.
4.
Press
@.
~~
[ON PORT # O It0 TIMER=
w 3 .
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 f o r External Control l n ~ u instruction F t

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
Teaching a series of S, N, and R (St F, and R)

,-----?
I . Press
2.
Set the port numbers t o be output (SET RESET) by numeric keys. press
[SNK-OUT-Io o i ~ =
'T1ME=ocs
3.
11 then set the p o r t 0, and
number t o wait f o r ON in the case of SNR o r the port number t o wait f o r OFF in the case of SFR by numeric keys.
4.
* *
~SNR-OUT=I~# IN=O~BTIME-*SI
~ r e s s / o ]and set the input , waiting time.
5. press
@.
(ISNR OUT=I 8 @
INm0 6 0 T I M E = ~ S ,
This setting causes waiting for ON (in the case of SNR) o r 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.
/ACCEPT]
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

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.
(1) Forward block operation
(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
1) In block operation unlike automatic operation, some instructions a r e not executed:
Instructions that a r e not executed in (forward o r backward) block operation
AS, AE, I CH, RTC, G S , GE, ST, ET, S F 3 , S F 5 , ASM. AEM. T S S , T S E

*
Instructions that a r e not executed in backward block operation T, J P , JF, CL, S F O , S F 1 , S F 2
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
2) When you a r e 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
created Task program number.
0
RESET
or specify a
You can now perform block operation
2.
Press holding
[ l El) E
(or
while
down.
operation causes the halted state to be entered. You can restart the operation by pressing while holding
@ y
1 ,1 or ,
BLOCK
5-5 4
Teaching
5.4.2
Block Continuous Operation
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.
$4-.
For continuous execution of instructions, specify block continuous operation. key with1
BLOCK
, lor ,
key shall be functioning instead ,of specifying block
H Block continuous operation

The LED on the upper left will illuminate to indicate the block continuous selection.
: n e
\ ,
2.
Press and hold press
63
MU
, then,
If the
block operation, the LED to go out and block continuous operation is canceled.
n = u
is released during
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 instructionsInterpolation 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 a r e provided for Block operation and can be switched over with the teaching box. B-1 Low B-2
B-3
B4 High
However, it is not possible to change the speed during block operation.

Teaching 5 -.5 5
1111
Switching between speeds for block operation

1. Press
operation is not running.
0
SPEED
when the block
The display a t the speed display a r e a 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, o r 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)
weaving is not ~erforrned.1 The center stop means a return to the main ~ a t h ( w h e r e
(2) External Control Input/Output instructions (N, F, S, and R) The input waiting time and delay time a r e aborted when the operation is halted, and a r e recounted from the beginning when restarted.
(3) Wait f o r Timer Time instruction (T)

The timer is stopped when the operation is halted, and is recounted from the beginning when restarted.
56
Teaching
5.4.5
Cancelling the Halted State o f Block Operation
The operator can cancel the halt state of block operation by operating the teaching box.
@This feature allows the operator t o 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 t o shit execution t o the next instruction immediately.
Caution
If you perform block operation after cancelling the halted state, the
manipulator s t a r t s t o 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:
100%
250cm 250cm 100
p
(007)
Halted point
-+
-"
I I
, , .,
r 0
P
(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.
I I
Cancelling the halted state ,\
~ r e s s " m in the halted state.
This causes the LED t o go out. Now, the halted state h a s been cancelled.
rs~op
Teaching
5-5 7
5.4.6
Sequence Jump
The Sequence J u m p allows the operator t o move a mechanism t o the position of a specified sequence number.
@This feature is used when you want t o 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
or
8
.
down, press
The mechanism will move to the specified sequence.
-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 t o the
instruction (sequence 086) which should be followed by the instruction you want t o add, by performing block operation o r executing the sequence jump. I )
2.
Press
T.MECB. ML4
WE
084 P 085 L >086 L 100% 150m 15Om
TEACH
P777
The LED on the upper left will light.

3.
Move the manipulator t o the position/attitude t o be taught, by manual manipulation. Press the key of the instruction t o be added (
).
SQNo.=I32 SERVO ON ADDITION
BASE BASE BASE
Ml
MI
M1
/ M O T m m l m m / >
4.
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.
T.MECH.ML4
TEACH
P777
SQNo.=132 SERVO O N ADDITION
084 P 085 L 086 L > 0 8 7 P
100% 150m 150m 10096
BASE BASE BASE BASE
M1 M1
MI MI
% O I : DE E P S P ( O
L A P Z Q N ~
/MOTION/II/OIm]lmmI >
6.
Press the operation.
again t o terminate
The LED on the upper left will light.
Teaching
5 -5 9
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 r y to delete L of sequence number 86:
1. Move the cursor t o the
instruction (sequence 085) which should be followed by the instruction you want t o delete,
T.MECII. ML4 TEACH P777 SQNa-132 SERVO ON 084 >085 086 087 088 WE P
L L
L
by performing block operation o r executing the sequence jump.
100% 150cm 15Ocm 100cm 100cm
BASE BASE BASE BASE BASE
M1 M1 M1 M1 M1
~ j I J ] r z - i T E l ~ l ~> /
T.MECH. ML4 TEACH P777 SQNo.=132 SERVO ON RANGEFOR DEL. WE 100% 084 P >085 L 150cm 086 L i"IS0cm 088 L 100cm
2.
Press
@. w
The range t o be deleted will be
BASE BASE BASE BASE
M1 M1 M1
MI'^
1If you want to extend the deletion range, press
1,, 1
BLOCK
If you want to reduce it, press
Pressing
cancel the deletion range you specified by pressing
0
MOOIFY
allows you t o
0
DELETE
3.
Press F3 (EXECUTE).
T.MECII. ML4 TEACH P777 SQ No. = I 3 2 SERVO ON
Now, L of sequence 086 has been deleted
084 >085 086 087 088
WE P
L L L
C2
100% 150m 150cm 1OOcm 100cm
M1 M1 M1 M1 M1
J S E A R C H / ) J p T i E / ~ ~ >
If you press
a f t e r deletion, you can cancel the deletion.

5-6 0
Teaching
0
MOOIFY
immediately
5. 6
Changing Teaching Data

Motion instructions Parameters of Motion instructions (i.e., speeds and overlap ON/OFF) Positions/attitudes Task instructions Parameters of Task instructions
It is possible t o change the following teaching d a t a :
5. 6. 1
Changing Motion Instructions
It is possible t o change P to L, o r L to P , but not a Motion instruction t o a Task instruction. It is not possible t o change Motion instructions of the single manipulator such as P, L, and C t o Motion instructions of the multiple-manipulator such as HP, HL, and HC.
I(( Changing Motion instructions
Here, let us t r y t o change "L" of sequence 085 t o "P":

1. M o v e t h e c u r s o r t o t h e
instruction t o be changed (sequence 085), by performing block operation.
2.
Press
3. Set a speed and Overlap ON/

OFF in the same manners as those f o r creating new data.
4.
Press
Now, the change h a s 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:

3.
Set a speed and Overlap ON/OFF in the same manners as those f o r creating new data.
4.
press
Q.
T.MECkI. ML4
WE
084 >085 086 087 088 P
TEACH
P777 SQ Na=13 2
L
L C1
SERVOON
Now, the change has been completed.
C2
100% lOOm 1 5 Om 150m 150m
M1 M1 M1 MI M1
rEEiqlJ[pl~[PATHAT( >
5. 6. 3
Changing Positions/Attitudes
It is possible to change data of the position/attitude which a Motion instruction has.

Changing positions/attitudes

T.MECt1. ML 4
WE
084 >085 086 087 088 P
TEACH
P777 SQ No.=132
SERVO ON
L L C1 C2
100% 150m 150m 150m 150m
MI M1 MI M1 M1
2.
Move the manipulator t o the position/attitude you want, by performing manual manipulation.
I T E E E ' q l J J ~ l ~ > ] ~
3. Press
@.
Now, the position/attitude indicated by the cursor have been changed.

5-6 2 Teaching
5.6.4
Changing Task Instructions
It is possible t o change Task instructions, such as Welding, Weaving, and External Control Input/Output, to other Task instructions, but not Task instructions t o Motion instructions.
Changing Task instructions
Tliis section explains how to change S (SET) to N (ON WAIT):

1. M o v e t h e c u r s o r t o t h e instruction t o be changed. In this case, S (SET). 2.
3.
T.MECH. ML4
WE
084 P 085 L 086 L 0 8 7 C1 100%
,
TEACH
BASE
.
Press
t o change t o N
I) r
PI77 SQ N o ~ 1 3 2
ur,=u.u s
BASE BASE BASE
MI
, ,
,.
.I
SERVO ON
150m 150cm 150cm
MI MI MI
Press F3 (INP ON) . Set the port number and the input waiting time in same manners as those f o r creating new data.
4.
T.MEC1-I. ML 4
WE
TEACH
P777 SQ No71 3 2
>
084
SERVO ON
5. Press
085 L 086 L 0 8 7 C1
10096 0 11 150m 150m 15Om
BASE WT=m BASE BASE BASE
MI MI MI MI
IrnIIJIpE'qIPATHJ/PATHl>
5.6.5
Changing Parameters of Task Instructions
I t is possible t o change parameters of Task instructions such a s Welding, Weaving, and External Control Input/Output.
Changing Parameters of Task instructions
This section explains how t o change an output port number of external control output.
1. Move the cursor t o the instruction t o be changed (S in this example).
2.
3.
T.MECI1. ML4
WE
084 ) I 085 086 087 P
TEACH
P777 SQ Na=13 2 SERVO OFF
s
L L C1
100% il1z 150m 1 5 Om 150m
BASE
I)LE.II.IIS
MI
(
M1 MI MI
BASE BASE BASE
Press Change the output port number. press
ISEARCH/IJ]/SHIFTIIPATHIW]>
T.MECA. ML4
WE
4.
@.
TEACH
P777 SQ Na=l3 2
>
084
SERVO ON
085 L 086 L 087 C1
100% 010 150m 150m 150m
BASE
DL=O.Os
M1 MI MI MI
BASE BASE BASE
p%'KEq/ n I P A T H I r n l > Jr
Teaching
5-6 3
5. 7
Searching f o r Instructions
The Search function is used to find a specified instructions in the Task program being
currently edited. This function allows the operator t o change d a t a 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 S t a r t (AS)/Arc End (AE)

*
a
Weaving S t a r t (WFP and WAX) Tracking S t a r t (ST)/Tracking End (ET) Touch sensor related instructions (SFO, SF2, SF3, and SF51 External Control Input/Output (S, R , N, and F ) P r o g r a m 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 f o r Instructions 1. Press F1 (SEARCH) on the screen

which is displayed when block operation is ~ e r f o r m e d .
'Pressing
or
allows
you t o move sequences forward o r backward without moving the manipulator.
F1 ... Terminates the search. The position of the manipulator does not correspond t o the current sequence. F2 ... Searches for Arc Start/ End instructions. F3 ... Searches for Weaving S t a r 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 t o search f o r 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
T.MECH.ML4
TEACH P7 7 7 SQ NO-132 SERVOON SEARCH
>
092 P a093 L AS 094*C1 095*C2 096*L
100% 150m
180A 150m 150m 150m
BASE BASE 20.5s. BASE BASE BASE
M1 MI 1.0s. MI M1 M1
[MARKIIAS/AEIvlJST/ETIm>
Teaching
5-6 5
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 r e a on the current screen. This message will disappear a f t e r 1 second
T.MECII. M L 4
TEACH
P7 7 7
SQ No.=1 3 2 SERVO ON SEARCH
NOT^
WE 092 P 100% >093 L 150m AS 18OA 094*C1 150m 095*C2 150m
BASE M1 BASE M1 20.5V. 3Om BASE M1 BASE M1
j p T K i q M A R K / / ~ l ~ ~ ] >
3.
4.
Add, delete, o r change if necessary. Press F1 (SO MARK) o r to terminate the search operat~on.
Pressing F1 (SQ MARK) causes the current sequence in the search mode t o be treated as the current sequence. Because the position of the manipulator differs from the d a t a of the current sequence, take care when you perform block operation. t o terminate the causes OSACOM SUPER 8700 t o return t o the original sequence. That is, the current sequence corresponds the position of the manipulator.
T.MECII.ML4
TEACH
P7 7 7
SQNo.=l32 SERVO ON SEARCH
092 P 093 L > AS 094*C1 095*C2 096*L
100% 150m 180A 15Om 150m 150cm
BASE MI BASE M1 20.5V. 301x1 BASE MI BASE M I BASE M 1
092 P >093 L AS
100% 150m 180A 150m
BASE M1 BASE M1 20.5V. 301x1 BASE M1
095*C2
-6
Teaching
Chapter 6
A u t o m a t i c Operation
/I
/
Automatic operation is performed to execute Task programs . This chapter descrilies how to s t a r t a Task program by Multi-station system o r Direct program entry system. and how to halt and restart the automatic operation .
I
I I
Contents
6.1 Automatic Operation
..................................................................................................................................
6 2 Automatic Operation by the Multi-station System 6.2.1 Start Allocation ....................................................................................................................................... 6.2.2 Changing t o 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.
Automatic Operation
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:
6. 1
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 S t a r t Enable Area of ALMEGA V series
The S t a r t Enable Area can be modified by setting "START ENABLE AREA" in the user parameters for setting the system status.
* :Refer to
6 -2
"Setting the System Status", sevtion 2.1 in p a r t I1
Automatic Operation
6. 2
Automatic Operation by the Multi-station System

The multi-station system allows the operator to s t a r t a Task program and reserve,a
s t a r 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.
In this system automatic operation is performed in accordance with the following procedure: Perform s t a r t allocation.
Teach mode
Cancel auto mode interlock.
Press the AUTO mode button.

-
Prepare the conditions to perform automatic operation.
Auto mode
I1 I
Automatic operation
-
s
Press the START button. Start reservation
-
I
-
Start cancellation
Start reservation check
Automatic Operation
6 -3
6.2. 1
Start Allocation
Storing a Task program number you want to s t a r t to each station is referred to a s Start Allocation. This operation is performed in Teach mode. The allocated Task program numbers a r e held even after the control power is turned off.
Setting start allocation
1. Press F4 (ALLOT) a t the top

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
If you press
cancel all allocations you have set, and the previous settings of Task program numbers will be stored.
0 0
RECORD
key.
RESET
, YOU can
-4
Automatic Operation
6.2.2
Changing to Auto Mode and Starting Automatic Operation
When you have finished the s t a r t allocation, then you change to Auto mode and perform automatic operation. Before changing to Auto, check that the manipulator exists within the s t a r t enable area.
I Changing t o I
Auto mode and starting automatic operation

AX1 S ML4 TEACH
.) I

AUTO MODE INTERLOCK CANCELLED
This step is not required if the setting of "AUTO LOCK" * in the user parameters for setting the system status is OFF.
2.
Press the AUTO button on the operating panel ( o r set the auto mode input of input terminal ON).
Ir)
In this condition, you can perform the following operations: Switching

*
W F F
or
ON/OFF
Changing to TEACH mode Starting automatic operation
If the conditions to s t a r t automatic operation a r e 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 .
Automatic Operation 6
-5
When the manipulator is outside the start enable area
Move the manipulator t o 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 t o make s t a 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 It is not possible to reserve a Task program being currently running by automatic operation.
(2) Cancelling Start Reservations The operator can cancel s t a r t reservations of Task programs. Even if one of multiple reservations is cancelled, the rest a r e 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.
6-6
Automatic Operation
I Making and cancelling start I
reservations
During automatic operation the screen look like the one shown on the right.
1. When automatic operation is
running a t another station, press the START button on the operating panel ( o r starting box).
I )
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
0
RESET
3. T o cancel a start reservation,

press the START button of the relevant station.
Automatic Operation
6.- 7
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 t o specialized logical input ports. Automatic operation is started when a S t a r t input signal is entered. There a r e 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
Ten
One
(Example) Task program number
1
0
1 1
1 0
1 0
0 1
0 1
1 0
1 0
0 1
0 0
1 1
799
265
(2) The binary code entry

Task programs numbers ranging from 001 through 999 a r e 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: Specialized logical input port
[Example)
Task program number
6 -8
Automatic Operation
In this system automatic operations is performed according to the following procedure:
Cancel auto mode interlock.
Teach mode Press the AUTO mode button. (Auto Mode input ON)
-
Prepare the conditions t o perform automatic operation.
Enter a Task program number. Auto mode
1
Set the s t a r t input ON.
1
Automatic Operation
Changing to Auto mode and starting automatic operation

1. Press F5 (LOCK) a t the top layer
of Teach mode.
.s I,
AX1 S ML4 TEACH AUTO MODE INTERLOCK CANCELLED
This step is not required if the setting of "AUTO LOCK" * in the user parameters for setting the system s t a t u s is OFF.
: Refer to "Setting the System Status", section 2.1 in p a r t 11.

A u t o m a t i c Operation
6
-9
2.
Press the AUTO button on the operating panel (or set the auto
AUTO. START READY AUTO PUSH START PB. SERVO ON
mode input of input terminal ON).
In this condition, you can perform the following operations:

*
Inching/retracting Starting automatic operation
* Changing to Teach mode

*
If the conditions to s t a r t automatic operation a r e not ready, error messages appear:

When the servo power is OFF
Turn the servo power ON.
When the m a n i ~ u l a t o r outside is the start enable area
Move the manipulator t o 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.
AUTO RUNNING AUTO PO 0 1 SQ No.=9 9 9 SERVO O N PRESENT 5 3
Now, automatic operation is started.
6-1 0
Automatic Operation
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 J o b End, which:
* *
Stops the current weaving o r 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 J o b End the screen looks like the one shown on the right.
Ir)
The figure on the 7th line a t the main display a r e a shows the throughput. I t is possible to check it also in the operation of s t a r 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 o r a n external signal input in a condition which enables continuation restart.
(1) Halt during welding

*
When the a r c 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 Immediately the process being stopped, the automatic operation halts.
(4)
Halt during a n external control input or output Waiting for external control input Immediately the process being stopped, the automatic operation halts. External control output with a delay timer setting Immediately the process being stopped, the automatic operation halts.
(5)
During inching o r retracting Immediately the inching o r retracting being stopped, automatic operation halts.
Note Data contained in the logic table' a r e executed even in the halted state.
--
Halt when the Multi-station system is employed

Press
u
o r the STOP button on
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 t o instruction manual "Interface with Jig"

6
-1
Automatic Operation
6. 6
Restart
There a r e several ways of restarting automatic operation:
* *
Restarting from a halted point Restarting after performing manual manipulation from a halted point and specifying a s t a r t point. Overlap Restarting Restarting after performing block operation
Important 1) When a s t a r t reservation has been made by the multi-station system, in the halted state, pressing the START button of the reserved station causes the reservation to be cancelled.
2) In the Direct Program Entry system, setting the s t a r 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.
I1 Restarting when the Multi-station system is employed I

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.
I Restarting when the Direct Program Entry system is employed I

Set the start input ON. Then, the Task program in the halted state will be restarted.
Automatic Operation
6-1 3
6 . 6.2
Restarting f r o m 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
P , AS
stops. (Stopped point)
Manual manipulation Path when automatic operation is restarted Fig. 6.4 Restarting from a specified s t a r t point
If a s t a 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 looks like the one shown on the right.
T.MECH. M H 3
AUTO
* *
PO01 SQ No.=9 9 9
051 P 052 P >053 L
S
054 L 055 C1
SERVO ON HOLDING STN 1
100% 90% 250~x1 012 150m 150m
BASE BASE BASE

DL=O.Os
M1 M1 M1 M1 M1
BASE BASE
pzizivq
1. Press F3 (STRT PO).
T.MECII. M H 3
/rs'iTqPO//RETREATIISQ]
051 P 100% 052 P 90% >053 L 250w S 012 054 L 150m 055 C l 150m PUSH F1 TO SET M1 M1 MI DL=O.Os BASE M 1 BASE M 1
AUTO
PO01 SQ N0.=9 9 9
BASE BASE BASE
SERVO ON HOLD ING STN 1
RESTART POINT.
iposSEi/
2. Move the manipulator by manual manipulation.
6-1 4
Automatic Operation
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 a n Interpolation instruction, such a s L o r 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~--10mm-+lf Halted point
Moving direction
Fig.6.5. Overlap Restarting
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.

Automatic Operation
-1 5
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 looks like the one shown on the right:
*
*
1. Press F3 (STRT PO).
In this condition, you can do block operation.
Press
or1
BLOCK
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 t o specify a restart point after halting during execution of an Circular Interpolation instruction (C1 o r 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

6-1 6
Automatic Operation
I. I
6. 6. 5
Restarting when Halting during 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 Haltinc Timing. During preflow During wire-slow down by Scratch s t a r t During crater Drocess During online modification* During any other welding process Operation a t Restarting. Resetting the preflow time and then performing preflow from the beginning. Restarting with the current welding conditions from the halted point. Execution of the next instruction because the crater Drocess has been c o m ~ l e t e d before halting. Restarting with the previous welding conditions not the welding conditions being modified Restarting with the current welding conditions.
(2) Halt during weaving

As the manipulator returns to a position on the main path when halted, it s t a r t s 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 a n external control input
Restarting causes the time to be recounted from the beginning.
(4) Halt during execution of Delay Timer of a n 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[.
Automatic Operation
6
-1 7
Chapter 7
Weaving Condition files.
Editing Files
This chapter explains how to create Welding Condition files and
Contents
7.
E d i t i n g Files
Task programs, Welding Condition data, etc. a r e treated a s files. Files that can be edited and created a r e the following: Table 7.1. Types of files that can be edited and created
Type of File Task program Welding Condition file Weavincr Condition file Seauencer file User Parameter file Welding Characteristic file System Parameter file Offset file Laser Sensor file Multi-pass Welding Condition file Welding Task file
1 I
I I
Reference for Editing and Creating "Teaching", chapter 5 in part 1 "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 Instruction Manual "Interfacing with Jig" "User Parameters", chapter 2 in part 2 "User Parameters", chapter 2 in part 2 Not edited Instruction Manual "Options" Not used
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 r e 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 r e selected by using the function keys to which various types of files have been assigned.
I I
Selecting f i l e s
1. Press F2 (EDIT) at the top layer of Teach mode.
2.
*
[ O ( J B
(OFFSITI(SpiETx1
Select, by the function key, the file type you want t o edit.
/ ] M S E /
F1 ... Creates/corrects Task

F2 F3 F4
F5
programs. .. . Edits Weaving Condition files. (See section 7.3.) ... Edits Weaving Pattern files. (Under development) ... Edits Arc Start Condition files. (See section 7.2.) ... Edits Arc End Condition files. (See section 7.2.)
Editing Files
-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 r e 2 types of Welding Condition files:
Arc Start Condition file(ASC file) Arc End Condition file(AEC file)
If a n 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.
I Editing Arc I
Start Condition files
1. Press F4 (AS FILE). 2.
ENTER F I L E NUMBER
TEACH A S C-
Enter a file number b y using numeric keys, and set condition data.
For individual controlled power unit
(1) Move the cursor t o the item you

want t o modify, by using
I .
using numeric keys.
18Jor *
(2) Enter the condition data by
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 d a t a in the same manner as that for individually controlled power unit
3.
Press
TEACH ASCl 0
II
> WELDING
CURRENT WIRE SPEED WELD SPEED
180A 5 Om 150m
condition data you entered.
0
RECORD
key t o store the
If you want t o cancel the d a t a you just entered, press unchanged. If you press The previous setting will remain
RESET
new file. the file will not be created.
0 0
RESET
instead.
when creating a
Editing Arc End Condition files

1. Press F5 (AE FILE).
ENTER F I L E NUMBER TEACH AEC-
2.
Enter a file number by using numeric keys, and set condition data.
For individually controlled power unit

want t o modify, by u s i n g m l o r
I TEACH
AEClO
I>
CRATER CURRENT CRATER VOLTAGE CRATER TIME POSTFLOW TIME
180A
2 0.OV 1 0 s. .
00 S . .
(2) Enter the condition data by

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
For TIG power unit Set condition data in the same

I
manner as that f o r individually controlled power unit.

.) r
TEACH AECl 0
>
CRATER CURRENT WIRE RETRACT CRATER T I M E POSTFLOW T I M E
1 2 0 ~ 1.0 s. 1.0 S. 0.0 s.
3. Press
condition data you entered.
0
RECORD
key t o store the
If you want to cancel the d a t a you just entered, press
The previous setting will remain unchanged. If you press
0
RESET
instead.
a new file, the file will not be created.
0
RESET
when creating
Editing Files
-5
7. 3
Editing Weaving Condition Files

There a r e 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 a n 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
TEACH
I ENTER
F I L E NUMBER
3. Enter a file number by using

numeric keys, and set condition data.
1/4 3/4
FREQ STOP FREQ STOP

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.lmm by using numeric keys.
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
data you entered.
0
RECORD
t o store the condition
If you want t o cancel the d a t a you just entered, press unchanged. The previous setting will remain
If you press
new file, the file will not be created.
0 0
RESET RESET
instead.
when creating a
H Setting Axis Weaving files

1. Press F2 (WS FILE).
2.
Press F4 (JOINT)
TEACH W A X-
ENTER F I L E NUMBER
3. Enter a file number by using

numeric keys, and set condition data.
(1) Highlight the item you want t o
m,
modify, by using
andm].
M 13 9c
--
(2) Set the condition data.

Setting a frequency Set a weaving frequency in the unit of O.1Hz by using numeric keys.
Editing Files
7 -7
Setting weaving axes and amplitudes Set the numbers of weaving axes and amplitudes by using numeric keys.
F o r n o n - ~ ~ e a ~ axes, set the ing 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
data you entered.
0
flECORD
t o store the condition
If you want to cancel the d a t a you

just entered, The previous setting will remain unchanged. If you press
0
RESET
instead.
new file, the file will not be created.
0
RESET
when creating a
-8
Editing Files
Chapter 8
File Operations
This chapter explains how to copy. delete. and rename files .
Contents
8.
File Operations
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 r e 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 a r e listed in order by number, only Task programs can be also listed in order by creation date.'
II I
Listing files
of Teach mode.
I )
1. Press F3 (FILE) a t the top layer
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
TEACH
LSERVO
The Task programs a r e listed.
FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE > pm'q 66 92-04-01 PO02 55 92-03-29 PO 03 130 92-03-28
/RoLL[
pixr-x] 1pFT-i-q
1-
>
When F2 (WELD) is pressed
TEACH L%ERYO
The ASC files (Arc S t a r t Condition files) and AEC files (Arc End Condition files) a r e listed in this order.
>=
OF^
FILE LIST FILE AECO 1 AECO 2 AECO 3 AECO 7
WELDING FILE DATE 92-0 3-0 3 92-0 2-2 8 92-0 2-2 9 9 2-0 3-0 1 9 2-0 3-0 7
j r i z - i E q ~ I ~ T r n l / D E L / >
When F3 (WEAVE) is pressed
TEACH
>I?N_PPOII
WAX 0 2
FILE LIST FILE
The WFP files (Fixed Pattern Weaving files) and WAX files (Axis Weaving files) a r e listed in this order.
L S E R Y O ~ WAXO3
WEAVING FILE DATE 92-0 3-0 3 9 2-0 3-2 1 92-0 3-1 1
[RoLL]IROLLDN]IEDm/m(DEL/ >
When F4 (SO) is pressed
TEACH
The Sequencer files a r e listed
SERVO
p i
OF^
FILE LIST FILE > SQFl SQF 2 SQF 3
SQ PRG. FILE DATE 93-1 1-2 6 93-11-26 93-1 1-2 6
>
8-2
File Operations
3. Move the cursor (>)t o the file

you want, by pressing
I
[a
or
, and select the operation you
want t o 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.) F1 ... Rename files. (See section 8.4.)
Refer to "Editing Files", chapter 7 in part I

File Operations
8-3
8. 2
Copying Files
Tlie Copy function allows the operator t o 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 a s k s you to confirm overwriting.
Copying f i l e s
1. Move the cursor (>)t o the copy
source file by pressing
TEACH FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE PO01 55 92-03-20 PO02 55 92-03-29 O P F ~1 > 130 92-03-28 PO04 125 92-05-07 PO07 87 92-04-03
LSERVO
/ R o L L l / R O L L l ~ l ~ j I D E>L j
2.
Press F4 (COPY).
FILE COPY TEACH COPY FILE
13 01
P-
[SERVO OFEJ
TO
3. Enter the name of a file you want

t o make, by numeric keys.
*
1-
SERVO OFF^
TO
P Oo 4
4.
Press
F1 (EXECUTE) t o copy.
If the file name you specified already exists, a message "OVERWRITE ? " is displayed. Select by the Function key:
LSERVO OFF^
TO
PO04
SAME FILE EXISTS. OVERWRITE?
/EXECUSEIpmm]
F1 ... Overwrites. F2 .. . Specifies a file name again without overwriting.
8-4
F i l e Operations
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 e r r o r occurs.
IZI
Deleting files
TEACH FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE O P F ~ >IPO01 PO 0 2 PO 0 4 PO 0 7 55 55 130 125 87 92-03-20 92-03-29 92-03-28 92-05-07 92-04-03

you want t o delete, by pressing
r)
SERVO
p i F i r i q ~ D N / I E D ~ l ~ I ~ j >
2.
Press F5 (DELI.
TEACH
FILE DELETION DELETE FILE

OFFJ ~
Lm]
13.
Press F1 (EXECUTE).
.) I
4. After you check the file name,

press F1 (CONFIRM) t o delete the file.
If you want t o cancel the deletion,

press
0
RESET
File Operations
8-5
8. 4
Renaming Files
The Rename function allows the operator to rename specified files. If the specified file does not exist, a n e r r o r occurs. If a file with the same name already
exists, OSACOM SUPER 8700 asks you t o confirm overwriting.
Renaming files
you want t o rename, by pressing
TEACH
~ E R V
FILE LIST TASK PROGRAM FILE FILE SEQUENCES DATE
>=P O 0 4 Q ~
PO 0 l PO02
PO 0 7
55 55 130 125 87
92-03-20 92-03-29 92-03-28 92-05-07 92-04-03
/RoLLUP/rROLLDNJIEDrnT//COPYIrnI >
2.
Press
~1 (RENAME).
3.
Enter the new name you want to give, by numeric keys.

FILE RENAMING ORIGINAL NAME RENAME TO
OFFJ
PO 0 4
4.
Press F1 (EXECUTE) t o rename the file.
TEACH
SERVO
SAME FILE EXISTS. OVERWRITE?
If the file you specified already exists, a message "OVERWRITE ? " is displayed. Select by the Function key:
-\/NO]
F1 ... Overwrites. F2 ... Specifies a file name again without overwriting.
8-6
File Operations
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 o r 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 a r e not available. For details, see the list below:
Table 8.1. Restrictions on file operations
File Type
File Name
Edit
Copy Delete List
Rename
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 Characteristic file
***
*.
AEC*
0
0 0
0
0 0
0
0 0
0 0 0 0 0
ASC*
0 0
WAX**,WFP** SRF * SQF * OFS* DEV *
0
0
0
0
0
0
0
0
* **
0
x x
0
0
x
X
0
0
x
X
0 0
X
SF2M *
6
X
X
USEMAIN, etc.
0
0
#***-***
$ WTBD *
x
X :
x
Inoperable
0 : Operable,
* : Represents a figure.
0 Note
Search Pattern file SF2M01-05 can not be deleted.
File Operations
8-7
Chapter 9
Cancelling Emergency S t o p a n d Shock Sensor
This chapter explains how to cancel the emergency stop and the shock sensor.
Contents
9 1 Emergency Stop 9.2 shock 9.2.1 ~
.................................................................................................................................................
9-1 g -2 9-2 9 -2 g -3 9-3
sensor .........................................................................................................................................................
~ ~ shock sensorl the ~ ~ l i ~ ~
9.2.2 Before Automatic Operation and After Completion of the J o b ......................... g .2.3 In Teach Mode ............................................................................................................................................ 9.2.4 Correcting Taught Positions Where the Shock Sensor Operates
......................
9.
9. I
Cancelling Emergency S t o p and Shock Sensor

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.
AXIS M L 4 TEACH WE
084 >085 086 087 088 P777 SQ No.=132
ISERVO OFF^
m)
P L L CI C2
100% 150m IOOcat 150m 15Om
EhIERGENCSTOP
BASE BASE BASE
MI MI MI
pzEi"lIJlISHIFTJIPATH/JPATH]
2.
Cancel the emergency stop.
.) I
084 P777 >085 SQ No.=132 086 ~ B R V DQFFJ 087 088
>
AXIS M L 4 TEACH
WE
P
L
L
CI C2
100% 150m lOOm 1 5 0 ~ 150m
MI MI MI MI M1
pziEqI JWISHIFT/IPATH//PATH>
3.
*
Turn the servo power on.
To restart automatic operation, press the START button.
In Teach mode, manual

manipulation is executable.
Cancelling Emergency Stop and Shock Sensor
9-1
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
Cancelling the shock sensor
During Automatic Operation
1. When the shock sensor operates,

the servo power is shut off and the manipulator enters the halted state.
+
nrl,
AUTO PO 0 1 SQ No.=999 SERVO ON STN 1
051 P 052 P >a53 L S 054 L 055 C1
Press
@ and then turn on
the servo power.
100% 9096 SWOC@SBESOR 250011 012 DL=O.Os 150m BASE MI 150m BASE M1
/p.EEq
3. Cancel the shock sensor by
performing manual manipulation.
4. Pressing the START button

allows you to restart the operation.
9.2.2
Before Automatic Operation and A f t e r Completion o f the Job

IMPOSSIBLE TO AUT AUTO SHOCK SENSOR O N
SNOCR ALARM
Cancelling the shock sensor
1. Even if the shock sensor

operates, the servo power is not shut off.
SERVO ON
2. Press
@.
IMPOSSIBLE TO AUT AUTO SERVO ON SHOCK SENSOR ON SHOCK SENSOR
9-2
3.
Cancel the shock sensor by performing manual manipulation.

I) I
9.2.3
In Teach Mode
(1 Cancelling the shock sensor I1
1. Even if the shock sensor

operates, the servo power is not shut off.
119
2.
Cancel the shock sensor by performing manual manipulation.
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.
lBl
Correcting taught positions where the shock sensor operates

AXIS M H 3 TEACH
P777 SQ No.=1 3 2 SERVO ON
1. Perform block operation up t o

the sequence followed by the sequence which contains the position t o be corrected.
092 P 093 P >094 L 095*L 096*L
100% 100% loom 100m loom
M1 MI M1 MI MI
AS ASCOl
[TEEGilJJ] K i / P T- / r i F = I A 1H z
>
2.
Press Fl(SEARCI-1)
Cancelling Emergency Stop a n d Shock Sensor
9-3
3. Move the cursor, by pressing

[,
t o the sequence t o be
corrected.
* *
AXIS MH3 TEACH P7 77 SQ Na=132 SERVO ON
a094 P AS >095*L 096*L 097*L AE
10096 ASCOl l0Ocm 100m 100m AECOI
BASE BASE BASE BASE
MI
M1 M1 MI
[saMARX/rn/IS//ST/ETIIS/
094 P AXIS MH3 AS TEACH >095*L P7 77 096*L SQ No.=132 097*L SERVO ON AE
>
M1 M1
M1
4.
Press F1 (SO MARK).
10096 ASCOl 1OOw

100m 1OOm
BASE BASE BASE BASE
M1
AECOl
I s E A R C H / ~ ] j l / - - F T>q ~
5.
Move the manipulator, by manual manipulation, t o the position/attitude you want to teach, and press
0
RECORD
-4
ication Features and Functions

b-
Chapter 1
Application Feature and Functions Used in Teach Mode
11
This chapter describes application features and functions. s u c l ~ as the Read Positions feature and the Home Stop function. used in 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 S t a r 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 operatillg speeds ~ ~ k
l operation ~ ~
.......................................................... k
1.2.4 Cursor Indicatioll of the State of Block Operation 1.2.5 setting ~
1.2.6 Checking and Modifying Condition Files during Block Operation
..................
1.
A p p l i c a t i o n Features and Function Used in Teach M o d e

Application Features and Functions Used for Manual Operations
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.
1. 1
1. 1. 1
O T h i s feature is useful t o modify the s t a r t enable area*' of A L M E G A G series o r
W01, the home stop position*', and the w o r k enable area*3.
@ Important
F o r AIJMEGA V series, the angles read by this feature cannot be used to set the s t a r t enable a r e a (because the reference joint angles a t the s t a r t enable a r e a a r e different). F o r details, refer to "The Reference Joint Angles for the S t a r t Enable Area", section 1.1.4.
Reading Positions
In Teach mode, hold
0
READ
down together with

T.MECA. MH4
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.
TEACH SERVO ON
A N G IAXS : 3 6 5 C O O R D X : 9 8 1.7 . 2AXS:- 7.9 Y: 84.8 . Z: 11.5 3AXS : -7 3 2 4AXS: 54.9 a: 18.2 5AXS: 86.4 b: 3.6 C :-180.1
J o i n t Angle 01 each a x i s
Coord~natc values in t h e currently specificci coordinate system
The reference positions t o display the angles a r e shown in Fig.l.1 and Fig.l.2.
* 1: Refer t o
this part.
"The Reference Joint Angles a t the S t a r t Enable Area", section 1.1.4 in
* 2: Refer to * 3: Refer t o
"The Home Stop Function", section 1.1.2 in this p a r t "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
0"
The reference position of Axis 5
The reference position of Axis 2
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 4: 0" a t the position where Axes 3 and 4 align. Axis 5: 0" a t the directly downward position.
Fig.l.1. The reference positions of ALMEGA G series and W01
1 -2
The reference position of Axis 4 The reference position of Axis 1
Axis 2 -I-
The perpendicular line
The reference position of Axis 6 The reference positions of Axes 2, 3, and 5
Axis 1: 0" a t the front position Axis 2: 0" a t the vertical position Axis 3: 90" a t the angle between the upper and lower a r m s (The angle of Axis 3 is expressed as a n angle between the upper and lower arms.) Axis 4 : 0" a t the position where Axes 3 and 4 align. Axis 5: 0" a t the position where Axes 3 and 4 align. Axis 6: 0" a t the front position. Fig.l.2. The reference positions of ALMEGA V series
Application Features and Functions Used in Teach Mode 1
-3
1. 1 . 2
The Home Stop Function
The Home Stop function allows the operator to stop the manipulator during manual maiiipulatioi~ t a position which has been stored in advance. The home stop ON/OFF a aind position a r e 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 t o 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 t o be stored. Move the manipulator to the stopping position you want to store, by manual nlanipulation, and set that position as the home position. F o r 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 t o fix the torch attitude.
Note If the system h a s multiple mechanisms, the Home Stop feature is available only t o the mechanism being selected.
\
*
1-4
: 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 r e a where the manipulator can work is referred to a s the Work Enable Area. This a r e a 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 r e a Manipulator Type
Default Setting
1. 1.4
The Reference Joint Angles at the Start Enable Area
The S t a r t Enable Area can be changed by modifying the setting of "START ENABLE AREA"*' in the user parameters f o 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 f o r 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 p a r t .

1 -5
The reference position of Axis 4 The reference position of Axis 1
Axis 3
0"
The perpendicular line The reference position of Axis 6
The reference positions of Axes 2, 3, and 5
Axis 1: 0" a t the front position Axis 2: 0" a t the vertical position Axis 3: 0" when the upper a r m is parallel to the ground. Axis 4: 0" a t the position where Axes 3 and 4 align. Axis 5: 0" a t the position where Axes 3 and 4 align. Axis 6: 0" a t the front position. Fig.l.4. The reference positions of ALMEGA V series
1-6 Application Features and Functions Used in Teach Mode
1.1.5
Setting Manual Speeds

-
Though a total of 9 step manual speeds including 4 low speed modes (ML1 high speed (MH1
-
ML4), 4
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 r a t e t o the maximum positioning speed. The setting range is 0.01 - 100.00%.
Cartesian manual speed Set a r a t e to 100cm/sec. The setting range is 0.01 - 100.00%
I( Setting manual speeds I
1. Press
Teach mode and then F4 (SYS SET).
D U
a t the top layer of
A X I S MH4 TEACH
*
+
SERVO ON
/q/l/ImlmJ
2. Press F5 (MANUAL).
A X I S MH4 TEACH SERVO ON
>
S E L E C T MODIFYING PARAMETER
> MANUAL
SPEED P I T C H MOTION
/ROTATI//ROTAT2/TEKI
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.
1 -7
When F1 (ROTAT 1) is pressed
AXIS MH4 TEACH SERVO ON
AXIS SPEED ML1: ML2: ML3: ML4:
MECHA. l / M E C H A
MH1 : 47.5096 MHz: 65.00% MH3: 82.50% M H 4 : 100.00%
15.00% 32.50% 30.0096
/7
When F2 (ROTAT 2) is pressed
AXIS MH4 TEACH SERVO
AXIS SPEED ML1: ML2 : ML3: ML4:
MECHA. l/MECHA 2
62.5096 75.0096 MH2 : MH3: 87.5096 M H 4 : 100.00%
\ m 6H 1 : $ M
25.0096 37.50% 50.00%
ON
When F3 (CARTE.) is pressed
MLl : ML2: ML4:
12.6
15.00% 30.00%
MHl : MH2: MH4:
47.50% 65.00% 100.00%
4. Highlight the speed step you

want t o modify, by using.
,
!=!, B]
/gl,
and t h R t e r
the speed by numeric keys.
Set Axis manual speed a t a rate t o the maximum positioning speed o r Cartesian manual speed a t a r a t e t o 100cm/sec.
5. Press
@.
1-8
1. 2
Application Features and Functions Used for Teaching

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 a r e 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. F o r details of the logical check items, and the Alarm messages, descriptions and solutions, see the Alarm list.
1.2.1
0 NOTE
1) The range of logical check
A logical check is made on each Task program. Therefore, if a Task program contains CL o r JF instructions, a logical check is made on existence of any call o r jump destination programs but not on the contents.
[Example)
PO01
001 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 a r e 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 r e not any teaching errors. (Example)
001 P 0 0 2 JP
AE
#1
0 0 3 PM1 0 0 4 END
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.
1 -9
Making a logical check on Task programs a t the top layer of Teach mode.
TEACH ISERYO
OF^
t G i K q ~ ~ ~ ~
/
2.
Press F2 (CHECK).
3.
Press F5 (LGC MON).
err),
I f you want t o 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.
ENTER PROGRAM NUMBER TEACH Plll DIAGNOSIS /SERVO >OFF]
4.
Press F1 (EXECUTE).
IpEi-Tq
TEACH Plll CHECK DIAGNOSIS SERVO D F F ~
A logical check on that program

will be started.
F5 . .. Cancels a logical check.
/STOP]
If the specified Task program is not found, a n e r r o r message will appear. In this event, press ~ J ~ F to Y specify a Task program number again.
ENTER PROGRAM N U M B E R TEACH Plll DIAGNOSIS SERVO OPEJ N O FILE -.MOD1 F Y
*
*
1-
1-1 0
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.
0
RESET
... Cancels the logical
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).
*
TEACH
DIAGNOSIS
If you make a logical check on all Task programs, the screen shown on the right will appear:
]SERVO
OPFI
F1 .
CONTINUATION
p%i'iGq
Press F1 (CONFIRM), so a logical check on the next program will be started.
1-1 1
L i s t of A l a r m Messages (Logical Check on Task Programs)
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 a r e listed alphabetically.
AE
IS O U T O F W E L D I N G
Description : AE exists outside a welding section. Solution
: Delete AE o r teach AS before AE. If this is intentional and welding
failure does not occur, you do not need to take action.
AS
IS
Solution
IN TRACKING
:
Description : AS exists within a tracking section (ST - ET section). Delete AS o r teach AS before the tracking section.
IC1
CL IS
Solution
IN WELDING
: Do not teach any Branch instruction within a welding section.
Description : CL exists within a welding section.
If this is intentional and welding failure does not occur, you do not need t o take action.
CL
IS
Solution
IN TRACKING
: Do not teach any Branch instruction within a tracking section.
Description : CL exists within a Tracking section (ST -ET section).
If this is intentional and welding failure does not occur, you do not need to take action.
CL
IS
Solution
IN CIRCULAR
: Do not teach any Branch instruction within a circular section.
Description : CL exists within a circular section.
If this is intentional, you do not need to take action.
-12
CL
I S
I N
WEAVING
Description : CL exists within a weaving section. Solution

:
Do not teach any Branch instruction within a weaving section.
CO
I S
I N
WELDING
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.
CO
I S
I N
WEAVING
Description : CO exists within a weaving section. Solution

: Delete CO o r change to C.
If this is intentional, you do not need t o take action.
END
I S
I N WEAVING
Description : END exists within a weaving section. Solution

: Delete END o r add WE before END.
END
I S
I N
TRACKING
Description : END exists within a tracking section (ST- ET section). Solution

: Delete END o r add AE before END. If this is intentional and welding
failure does not occur, you do not need t o take action.
END
I S
I N WELDING
Description : END exists within a welding section. Solution

: Delete END o r add AE before END.
END
I S
I N
GS-GE
Description : END exists within a Gas ON/OFF section. Solution

: Delete END o r add GE before END.
Application Features and Functions Used i n Teach Mode
1-1 3
ET
I S
OUT
OF
TRACKING
Description : ET exists outside a tracking section (ST - ET section). Solution

: Delete
ET o r add ST before ET.
(F11
FIRST MOTION I S NOT HP
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.
FIRST
MOTION
I S
CP
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.
[GI
GE I S I N WELDING
Description : GE exists within a welding section. Solution

:
Do not teach GE within a welding section.
GE
I S
OUT
OF
GS-GE.
Description : GE exists outside a Gas ON/OFF section (GS - GE section). Solution

:
Delete GE o r add GS before GE.
GS
I S
I N
WELDING
Description : GS exists within a welding section. Solution

: Do not teach GS within a welding section.
ICH
I S
I N
WELDING
Description : ICH exists within a welding section. Solution

1- 1 4
Do not teach ICH within a welding section.
K Jl
JF
I S I N WEAVING
Description : JF exists within a weaving section. Solution

: Do not teach any Branch instruction within a weaving section.
JF
I S
I N
CIRCULAR
Description : JF exists between Circular instructions. Solution

JF
I S
I N
TRACKING
Description : J F exists within a tracking section (ST- ET section). Solution

: Do not teach a n y Branch instruction within a tracking section.
If this is intentional and welding failure does not occur, you do not
need t o take action.
JF
I S
I N WELDING
Description : JF exists within a welding section. Solution

JP
I S
I N
WELDING
Description : J P exists within a welding section. Solution

: Do not teach ally Branch instruction within a welding section.
JP
I S
I N WEAVING
Description : J P exists within a weaving section. Solution

:
Do not teach any Branch instruction within a weaving section If this is intentional, you do not need to take action.
-1
JP
I S
I N T R A C K 1 NG
:
Description : JP exists within a tracking section (ST- ET section) Solution Do not teach any Branch instruction within a tracking section. If this is intentional and welding failure does not occur, you do not need to take action.
JP
I S
IN CIRCULAR
:
Description : JP exists between Circular instructions. Solution Do not teach any Branch instruction within a circular section. If this is intentional, you do not need to take action.
(L1
LO
IS
Solution
IN W E A V I N G
: Delete LO or change to L.
Description : LO exists within a weaving section.
LO
IS
Solution
IN WELDING
: Delete LO or change to L.
Description : LO exists within a welding section.
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.
-1
MOTION
DATA
ARE
MIXED
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.
CN1
NO DEF BEFORE DEC
Description : There is no DEF before DEC. Solution

: Delete DEC o r add DEF before DEC.
NO
REF. PO I N T
OF
C1
Description : There is no reference point of C1. Solution

: Delete C i o r add a Motion instruction before and after C1.
NO
REF. P O I N T
OF
C2
Description : There is no reference point of C2. Solution

:
Delete C2 o r add a Motion instruction before C2.
NOT
SAME
COORDINATES
Description : The coordinate systems for 3 circular point ( s t a r t , middle and end) d o not match. Solution
: Delete the wrong sequence and teach again.
NO
JUMP
POINT
Description : Point M a r k 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.
NO
CONDITION
F I L E
Description : The specified Condition file does not exist. Solution

: Delete AS, AE, WFP, o r WAX, o r create a Condition file.
1-1 7
NO
PROGRAM TO CALL
Description : The Task program to call does not exist. Solution
:
Delete CL o r create a Task program t o call.
r.P1
IS
IN W E A V I N G
: Delete P o r change t o L.
Description : P exists within a weaving section. Solution
IS
IN W E L D I N G
:
Description : P exists within a welding section. Solution Delete P o r change t o L. If this is intentionaI and welding failure does not occur, you do not need t o take action.
PM
IS
Solution
IN W E A V I N G
Description : PM exists within a weaving section.
PM
IS
Solution
IN C I R C U L A R
Description : PM exists between Circular instructions.
PM
IS R E P E A T E D
Description : A duplicate PM exists . Solution
:
Delete a n unnecessary PM.
PM
IS
Solution
IN T R A C K I N G
-
Description : PM exists within a tracking section (ST

: Do
ET section).
not teach any Branch instruction within a tracking section.

1
-1
PM
I S
I N
WELDING
Description : PM exists within a welding section. Solution

PM
I S
NOT
LINKED
Description : There is PM which is not referenced. Solution

: Delete PM o r add J P .
CRI
RTC I S I N WELDING
Description : RTC exists within a welding section. Solution

: Do not teach RTC within a welding section.
KSI
SF0 I S I N WEAVING
Description : SF0 exists within a weaving section. Solution

:
Do not teach S F 0 within a weaving section.
SF0
I S
I N WELDING
Description : SF0 exists within a welding section. Solution

: Do not teach SF0 within a welding section.
SF1
I S
I N WEAVING
Description : SF1 exists within a weaving section. Solutioii

: Do not teach SF1 within a weaving section.
SF1
I S
I N
WELDING
Description : SF1 exists within a welding section. Solution

:
Do not teach SF1 within a welding section.
ST
I S
OUT
OF
WELD
PATH
Description : ST exists outside a welding and weaving. Solution

:
Teach ST outside a welding and weaving section.

Application Features and Functions Used in Teach Mode 1-1 9
[Wl
WFP
IS
IN TRACKING
: Delete
Description : WFP exists within a tracking section (ST - ET section). Solution
WFP o r teach before the tracking section.
WAX
IS
IN TRACKING
-
Description : WAX exists within a tracking section (ST Solution
ET section).
: Delete WAX o r teach before the tracking section.
WE
IS O U T O F W E A V I N G
Description : WE exists outside a weaving section (ST -ET section). Solution
: Delete WE o r teach a Weaving S t a r t instruction before
WE.
1-2 0
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 O F F

When the Reset key is pressed during teaching t o 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 t o create a new program, OSACOM SUPER 8700 asks for confirmation of terminating teaching.
When the setting is ON I f you press
t o create a new program, the screen similar t o the one shown on the right appears :
I )
0
RESET
when teaching
AXIS MH4 TEACH

P777
001 P 0 0 2 P
SQ No.= SERVO
S AS
>003*L
ON
100% BASE MI 100% BASE M1 012 2 5 O A . 25.OV. 25Ocm 25Ocm BASE M1
DO YOU WANT TO EXIT TEACHING?
-/ O 1N j
F1 . .. Teminates teaching. F2 ... Returns to the Teaching screen.
Refer t o "Setting the Teaching Box Keys", section 2.2. in this part.
1 -2 1
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 a r e a s follows: Table 1.1 Key operations and Movements of the manipulator according t o Hold the way of performing block operation ON/OFF Hold Way of Performing Block Operation Key Operation When, without continuous block operaton specified,
*
ON The mechanism stops a t a taught point. Releasing and re-pressing If
OFF ( Default)
BLOCK
8
.
1 s
still
and m a r e
pressed.
/ ,I ,
BLOCK
/
When, with
causes the mechanism to move to the next taught point. The mechanism stops immidiately .
kept pressed when the mechanism reaches a taught point, it moves to the next taught point.
I
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
during forward block operation.
BLOCK
1 released s
@ held, w
the mechanism to immediately stop.) When Halt is operated during continuous block operation. The continuous state is held.
a
8
E ~ ~ L E
causes
The continuous state is cancelled.
*
1 -2 2
: Refer to "Setting the System Status", section 1.2. in this part.

@ Note
F o r 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 Key operation When
is pressed.
1 11
Continous Block O ~ e r a t i o n ON/ OFF ON (Default) The continuous state is entered, and the LED of on the
/1
OFF The continuous state is not entered, and the LED of teaching box is not illumintaes.
teaching box is illuminates.
1-2 3
1.2.4
Cursor Indication o f the State of Block Operation
This teature allows the operator to judge by the cursor whether the manipulator is a t a taught point of the current sequence o r is moving t o 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 t o 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.
TOOL M L 4 TEACH
P7 7 7 S B No.=lO 0
SERVO
ON
&
001 P 002 P 003 L
1 0 0% 80% 150m
BASE BASE BASE
MI M1 MI
pliEiq/J~~m/PATH>
>
: 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 t a t e of block operation:
>
ON OFF OFF
IP);1I
ON ON flicker
State of Block Operation Halted s t a t e (The manipulator is a t the taught ~ o i n t . 1 Block operating state Halted state (The manipulator is not a t a taught point.)
@ Notes
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. does not indicate a target point. 2) In bacliward block operation, the cursor
*
1
: Refer t o "Setting the Teaching Box Keys", section 2.2. in this part.
-2
1.2.5
Setting Block Operating Speeds
It is possible t o set block operating speeds. Speeds a r e set a t a r a t e t o the maximum Positioning speed in automatic operation (setting range: 1 - 15%).
111
Setting a block operating speed
1. Press
F4 (SYS. SET) a t
the top layer of teach mode, and then
2.
Press F2 (BLOCK).
I) I
3.
Set a block operating speed by using keys. and numeric
[m]
4.
Press
a.
Now, the block operating speed has been set.
Applicat~onFeatures and Functions Used in Teach Mode
-2
'1.2.6
Checking and Modifying Condition Files during Block Operation
If welding and weaving conditions a r e 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.
A X I S MH4 TEACH P777 SQ Na=132 SERVO ON
>
W E 100% 092 P ASASCO5 093XL 15Om 094XC1 1 5 0 m 095hC2 150m
BASE BASE BASE BASE
MI
MI M1 M1
p-cxiziIJ~l/PAT~/>
2.
Press
@.
3. Enter a condition by numeric

keys if you want t o modify.
If you do not modify, press
OSACOM SUPER 8700 will return

t o the block operation screen.
0
RESET
4.
If you want t o modify, press
0.
RECORD
OSACOM SUPER 8700 will return

t o the block operation screen.
1-2 6
Application Features and Functions Used i n Teach Mode
Chapter 2
User Parameters
Contents
2.1 SettiIlg the System Status ........................................................................................................................... 2.1.1 setting the H~~~ position ................... 2.1.2 Setting the Work Enable Area ( s o f t Limit) 2.1 3 Setting the Start Enable Area ......................................................................................................... 2.1.4 Registering Coordinate Systems
....................................................................................................
2-3 2-8 2 - 10 2-11 2-11
2.1.5 Setting Conditions for 3-dimensional Shift and Mirror Image Shift ............... 2-12 2-13 2.1.6 setting the ABSO ~~t~ check ti^^ ................................................................................... 2 2 Setting the Teaching Box Keys 2.3 setting the welding parameters 2- 14 2-17
2.4 Setting the Parameters for External Control Signal Inputs/Outputs 2-20 2.5 setting ti^^ ~ ~ ~ on ~~ i~ ~ toperation ~.................................................. ~ 2-22 t t ~i ~~ ~ t i 2.6 Setting the Sensor Type 2.7 setting welding characteristic ~~t~ 2.7.1 ~ 2.7.2 ~ ~ ~ d ~ welding characteristic ~ i ~ t ~~t~ ~ ....................................................................... i ~ ~ i f ~ characteristic ~~t~ welding i ~ ~
. .
2-22 2-23 2-24 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.
User Parameters
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 from the top layer of
Teach mode.
2. Press
and then F1
Press the function key t o select the parameter type you want:
F 1 ... Sets the system status. (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 f o r 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 a r c 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 a r c sensor.*
~ N S O R ] I p T F q ~ p i z Z E i I [ ~ ]
: 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 t o set /

-
Move the cursor by using
[ml
.
The item indicated by the cursor is your object t o 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. T o move pages, press F4 (ROLL DN) o r F5 (ROLL UP).
Changing d a t a settings
*
Alternative selection of "ON/OFF" The current setting is highlighted. F1 (EDIT) toggles between ON and O F F
Selection from among multiple d a t a settings When you place the cursor a t the parameter you want t o set, d a t a settings you can select a r e assigned t o the function keys. Select the setting you want.
Numeric d a t a Enter a numeric value by using numeric keys. If you want t o correct the value you entered, press
0
~ I F Y
key.
Storing d a t a settings To s t o r e 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. [
contains options, and ( ) contains
the default setting.

*
Page 11'6
AXIS ML4 TEACH SERVO
SYSTEN >INITIAL MODE AUTO LOCK p TEACH LOCK ON ON CONTROL METHOD I m APPLICATION PRG. LI ST DI SP j -1
1/6
i;;To J REMOT
DATE
pzKi-Eq-1
(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. (ON) F o r details of Auto mode interlock, refer t o "Modes", section 2.4 in p a r t I. (OFF) F o r details of Teach mode interlock, refer to "Modes", section 2.4 in p a r t I.
(2) Auto mode interlock [ON/OFFl
(3) Teach mode interlock [ON/OFF]
(4) Control system [LOCAL/REMOTE] At present, not available.
(5) Application [WELDING/HANDLINGl
((Welding) Select Welding f o 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.
User Parameters
-3
Page 2/6
AXIS ML4 TEACH SERVO ON
SYSTEN INTERF. LIMIT >POSTURE MOTION RESTART RETRACT SPEED T O PM ONLINE AUTO SET
2/6
OFF
0 lorn
6 0%
OFF
/SETTING/
(1) Interference soft limit check [ON/OFF]
At present, not available.
[piKrz-\/ROLLUP/
(2) Attitude movement (Wrist axis movement) [Eulerian/R.P.Y. 1

Select Eulerian Angle for welding/cutting applications, o r R.P.Y. for handling application. For details of each movement, refer to "Operating Directions", section 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 o r the updated AS is executed, and the OFF setting does not. However, regardless of ON o r OFF, the updated conditions a r e stored when the Record key o r F4 (END) is pressed before the next AS o r AE is executed.
2 -4
User Parameters
Page 3/6
SYSTEM >SPECIFIED POINT HOLD MOVABLE AREA START ENABLE AREA MOVABLE AX1 S ON OFFSET ADJUSTMENT TOOL PARAMETER
3/6
p-EiKy
(1) Home position
pEirxq/ROLL/
(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.
(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.
(3) Start enable area

As well a s the work enable area, the s t a r t enable area can be changed as desired. F o r 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.
(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 a r e not available.
User P a r a m e t e r s
2-5
Page 4/6
SELECTED UNITS
1 -
EXT. MEMORY
(1) ABSO data check function

Set the ABSO data check ON o r 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 o r Inch.
(3) Hold the way of performing block operation

This setting affects the way of performing block operation.
(OFF)
F o r details, refer to "Setting the Way of Performing Block Operation", section 1.2.3 in this part.
(4) Floppy disk type [2DD/2HDl

Set the floppy disk type used for an external storage. For details, refer to External Storage, chapter 1 in part III.
C?J-ID)
(5) Version display CON/OFFl
(OFF)
This setting defines whether the control program versions a r e 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.
-6
User Parameters
Page 5/6
(1) Check the s t a r t enable a r e a during automatic operation [ON/OFF]

Operation", section 3.4 in this part.
((OFF)
F o r details of this feature, see "Checking the S t a r t Enable Area during Automatic
(2) Teaching synchronous motion [ON/OFF]

F o r details, refer to Instruction manual "Options".
(3) Register of coordinate systems

(Base as Cartesian coordinate system 1, and O F F as 2)
a
*
It is possible to register up t o 2 coordinate systems which a r e switched each time is pressed. F o r details, see "Switching between Coordinate Systems" section
4.1.3 in p a r 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

F o r 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 r e options.
User Parameters
2 -7
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) .
SYSTEM >SPECIFIED POINT HOLD MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER
3/6
12.
Press F1 (SETTING).
jpcEEi- piKL-E-1
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.
-8
User Parameters
( 2 ) Select the mechanism you want t o set.
(3) Select the joint by pressing

, and then press F1
(EDIT) t o select ON or OFF. (4) Enter the angle by numeric keys. When F2 (COR NUM) is pressed (1) If the system consists of
[m]
(2) Select the mechanism you want t o set.
(3) Select the coordinate
[a
L ?
component by pressing and then press F1 (EDIT)
/ fil,
t o select ON o r 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 t o store. Even if the system consists multiple systems, pressing axes a t one time.
allows you t o store data of all
0
RECORD
3. I f you want t o store the data,

press
L&A
.
RESET
If not, press
"0
User Parameters
2 -9
2. '1.2
Setting the Work Enable Area (Soft Limit)

"
F o r details, refer t o
The Work Enable Area", section 1.1.3 in this part.
Setting the work enable area
1 Place the cursor a t "MOVABLE .

AREA".
* *
SYSTEM SPECIFIED POINT HOLD >MOVABLE AREA START ENABLE AREA MOVABLE AX1 S OFFSET ADJUSTMENT TOOL PARAMETER
3/6
[ M I
2.
/ROLL1mUP/
Press F1 (SETTING).
If the system consists of

Select the mechanism you want t o set.
3.
limits by pressing
[a] [w]
Select the axis by pressing and the upper/lower
F1 (+/-) toggles between the signs.
4.
Set the value by numeric keys.
5. Press
@.
-1
User Parameters
2. 1.3
Setting the Start Enable A r e a
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 a r e registered, they a r e switched in the order of Axis Coordinate System 1 Coordinate System 2 Axis each time
+
+
I Registering coordinate systems I

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 t o execute the 3-dimensional shift o r mirror image shift, it is necessary t o set conditions. F o r details of these functions, refer to the instruction manual "Options" Table 2.1. Triangle Dimensional Conditions Item Length of the smallest side [ mm Smallest angle [ deg 1 Largest angle C deg I Dimensional r a t e [ % 1 Default Setting Range
100 20 140 90
10 -- 200
1 -660
60 -- 180
1 -699
Important Remember that a triangle formed a t a n extremely small length o r dimension r a t e causes degradation of shift accuracy.
L
Settinn shift conditions -
1. Place the cursor at "SHIFT

CONDITIONS" and press F1 (SETTING).
2.
Move the cursor by
[m]
and set a value by numeric keys.
(See Table 2.1.)
3. Press
0
RECORD
2-1 2
User Parameters
2.1.6
Setting the ABSO Data Check Function
F o r details of this feature, refer to "The ABSO Data Check Function", section 3.3 in p a r t III.
Bll Setting the ABSO data check function

1.
Place the cursor a t "FUNC OF ABSO D A T A CHECK".
*
EXT. MEMORY
2.
Press F1 (SETTING).
Ir l)
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.
3. Press
User Parameters
-1
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

Not available.
(OFF)
(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.
2-1 4
User Parameters
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 r e 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 a n 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.
User Parameters
2-1 5
Page 3/3
TEACH PENDANT >SPECIAL CURSOR DISP SEQ DISP. IN AUTO ENDLESS ROTATE
3/3
/EDITJ
p?zrEiqlml
(1) Sequence display by the special cursor [ON/OFFl
(OFF)
F o r details of this feature, see "Cursor Indication of The Block Operation", section 1.2.4 in this part.
(2) Sequence display during automatic operation [ON/OFF]
(OFF)
F o r details of this feature, see "Sequence Display during Automatic Operation", section 3.7.
(3) Endless rotation [AUTO/MANUAL/OFFI

This feature is a n option.
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.

AXIS ML4 TEACH SERVO ON APPLICATION >WIRE SLOW DOWN H O T START RATIO = H O T START T I M E = BURNBACK T I M E = BURNBACK VOLT. = STRT ERR CHECK TIME= 0% 0% 0.0s 0.0s 0.OV
1.0
S
P a g e 1/4
1/4
/ROLLDN//ROLLl
(1) Wire slowdown r a t e
(0%)
Set a feed r a t e of the wire, which is fed until the a r c s t a r t s , a t % of the maximum current command value. Note that you do not need t o set this parameter if your welding power unit is equipped with the wire slowdown feature. (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 f o r a given time t o generate the a r c smoothly a t the beginning of welding. Set a r a t e t o the rated voltage. Note t h a t you do not need t o set this parameter if your welding power unit is equipped with the hot s t a r t feature.
(3) Hot s t a r t time
(0 sec.)
Set a time f o r which hot s t a r t is performed. Note that you do not need t o set this parameter if your welding power unit is equipped with the hot s t a r t feature.
(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 t h a t you do not need t o set this parameter if your welding power unit is equipped with the burn back feature.
(5) Burn back voltage
(OV)
Set a voltage t o apply for burn back. Note that you do not need t o 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 t o 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.
User Parameters
2
-1 7
Page 2/4
A X I S ML4 TEACH SERVOON
APPLICATION 2/4 ARC D I S C O N T I N U I T Y = 0.5s 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% PREFLOWTIME >WIRE S T I C K CHECK WIRE RETRACT S P E E D = O m
tjG
[ DT E l I
lROLLDN//ROLL]
(0.5 sec.)
(1) Arc outage time
Set a time required for OSACOM SUPER 8700 t o detect a n outage a r c condition during welding.
(2) High inching/retracting speeds
(100%))
High inching/retracting speeds a r e speeds for inching/retracing with holding down. Set each a t % of the maximum command value
(3) Low inching/retracting speeds

down Set each a t % of the maximum command value.
(6%)
Low inching/retracting speeds a r e speeds for inching/retracting without holding
(4) Preflow time Set a preflow time which is a flow time before the a r c starts.
(0%)
(5) Wire stick check ON/OFF

Set wire stick check ON/OFF
(6) Wire retracting speed

This parameter is available only when TIG filler is used. Set a retracting speed which is applied a t the end of welding.
(Ocm)
Important > Be sure t o set this parameter if you use TIG filler. Otherwise, the wire will not be retracted because the default is "0".
2-18
User Parameters
Page 3/4
(1) The way of teaching welding conditions [Numeral/File]
(Numeral)
Select whether welding conditions a r e 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]

AXIS ML4 TEACH SERVO ON APPLICATION >WIX TIMEOUT CHECK ON ARC TIMING ADJ. = 0.0s
Page 4/4
&
IEDlT]
-- ]
(1) WIF time out check [ON/OFFl

Normally set this parameter ON
(ON)
(2) Arc timing adjustment

Do not change the setting.
(0.0 s)
User P a r a m e t e r s
-19
2. 4
Setting the Parameters f o r External Control Signal Inputs/0utputs

This section describes the parameters by page. [ ] contains options and ( )

AXIS ML4 TEACH
SERVO
EXT. INPUT/OUTPUT SQ PRG. NUMBER EXT. INPUT EXT. CONTROL 1/0 ON >INPUT LOGIC OUTPUT LOGIC NOP AUTO INPUT
1/2 1
NORMAL NORMAL OFF
g;g
~NORMALJIINVERSEJIOlFjlROLLm
(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.
(2) Execution of external control inputs [ON/OFFl
(ON)
Define whether execution of external control inputs is enabled o r disabled. When the setting is OFF, any external control input instructions a r e not executed. Jump and call instructions such a s J P , J F , and CL conditioned on waiting for inputs result in the same effects a s those of unconditional jump and call, respectively.
(3) Execution of external control outputs [ON/OFFl
(ON)
Define whether execution of external control outputs enabled o r disable. When the setting is OFF, any external control output instructions a r e not executed.
(4) Input logic [ Normal/Reverse/OFF
(OFF)
Define whether the external control input instructions (N and F ) should be executed normally a s taught o r reversely during backward block operation. Normal : Executes the external control input instructions as taught. Reverse : Executes the external control input instructions which a r e logically reverse to those taught. OFF
: Disables execution of the external control input instructions.
0Important
The setting of execution of external control input (2) overrides.
2 -2 0
User Parameters
(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 o r reversely during backward block operation. Normal : Executes the external control output instructions a s taught. Reverse : Executes the external control output instructions which a r e logically reverse to those taught. OFF
:
Disables execution of the control output instructions.
Important The setting of execution of external control output instructions (3) overrides.
(6) Automatic insertion of NOP [ ON/OFF
(ON)
Define whether o r not NOP is automatically inserted when ON Wait instruction ( N ) o r OFF wait instruction (F) is taught.
User Parameters
-2
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

For details, see "Machine Lock", section 3.1 in this part.
(OFF)
(2) Dry run [ON/OFFl

F o r details, see "Dry Run", section 3.2 in this part.
(OFF)
(3) Interpolating speed in the Weld OFF state

At preset, not available.
(4) Low-speed automatic operation [ON/OFFI
(OFF)
F o r details, see "Low-speed Automatic Operation", section 3.3 in this part.
(5) Speed rate of low-speed automatic operation

Set a speed of (4) a t a rate to the maximum speed
(15%)
(%I.
2. 6
Setting the Sensor Type

Here, set the sensor type you use. 1 Page 1'
AXIS ML4 TEACH SERVO ON SETTING OF SENSOR >USING SENSOR =
1/1
r F i T T E - I / ~ ~ ]
(1) Sensor type [Not used/Super a r c sensor o r Weave a r c sensor/Laser sensor/

TIG a r c sensor]
Select your parameter.
2-2 2 User Parameters
(Not used)
Setting Welding Characteristic Data
The output current and voltage of a welding power unit a r e 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 a n 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 a r e used to modify and create welding characteristic data. The standard welding characteristic data a r e listed below:
Table 2.2. Kinds of Welding Characteristic Data Wire
1. 0
Power Unit
1. 2
1. 6
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.
User Parameters
2 -2 3
2. 7. 1
Registering Welding Characteristic Data
To use or modify the standard welding characteristic data, be sure t o 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.
\
Registering welding characteristic data
(W-CHARA).
*
screen 1
2.
Select a welding power unit by using
3.
Select the wire diameter by using
4. Press F1 (REGIST).
2.7.2
M o d i f y i n g 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 a n 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.
-2
User Parameters
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
3.
Press F2 (MODIFY).
<Individual control type
>
<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.
User Parameters
2 -2 5
6. Press
@.
IEl)
<Individual control type

A X I S ML4 TEACH SERVO ON 1. 2. 3. 4. 5. DISP. 50A lOOA 150A 2 00A 300A
>
DISP 3.OV 7.OV 10.OV 20.OV 25.0V REF. 2.OV 4.OV 7.OV 10.OV 12.OV
REF. 2.4V 5.OV 8.6V 12.OV 14.3V
<Synergic control type>
7.
1<
Modify the data by
>
1 and numeric keys.

@.
I/[
8.
Press
9. When you have finished making

modifications, register the new data in accordance with the procedure in section 2.7.1.
-2
User Parameters
2. 7.3
Creating User Welding Characteristic Data (User Registration)
F o r 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 t o 60 d a t a is possible. Welding characteristic d a t a as well a s welding condition files a r e stored in a file. Though file numbers ranging from 1 through 99 a r e provided, use 40 - 99 ( a maximum of 60 numbers) t o create use welding characteristic d a t a because 1 - 39 a r e dedicated t o the standard welding characteristic data. This section describes how to create user welding characteristic d a t a based on a n example of the following welding characteristic data:
Control type of welding power unit: Individual Rated current Rated voltage Current setting [A] Point 1 Point 2 Point 3 Point 4 Point 5 5 0.0 1 0 0.0 1 5 0.0 3 5 0A 3 6V
Current command Voltage command Voltage setting [V] value [Vl value [V] 0. 5 1. 8 3. 5 5. 3
2 0 0.0 2 5 0.0
7.8
BI Creating user welding characteristic data

1. Place the cursor a t "USER
REGISTER" on screen 1.
SERVO A X I S ML3 TEACH POWER SOURCE WIRE CPVAS-3 5 0COr 08 . 10 . CPVAS-3 5 OMAG 08 . 10 . CPVAS-5 0 0COz 10 . 12 . CPVAS-5OOMAG 10 . 1.2 USER REGISTER 12 . 12 . 16 . 16 .
ON
(REGIST//MODIFYI
2.
Enter any number of 40 - 99 b y using numeric keys.
The number you entered is a register number of the user welding cl~aracteristic a t a you a r e creating. d
User Parameters
2 -2 7
3. Press F2 (MODIFY).
RATING OF POWER SOURCE $WTBD 1 1 SYNER TIG >TYPE RATING CURRENT 350A RATING VOLT. 36.0V ON PUSH RECORD AFTER SETTING
4.
Set "Individual" control type of welding unit, "350" rated current, and "36" rated voltage, and press
1. 2 .
>
0
RECORD
3 . ON 4. 5 .
DISP. 50A lOOA 150A 200A 300A
DISP. REF. 3.OV 2.4V 7.OV 5.OV 8.6V 10.OV 12.OV 20.OV 14.3V 25.OV
REF. 2.OV 4.OV 7.OV 10.OV 13.OV
The welding characteristic data
.m of CPVAS-350COz0 8 mwill be
displayed.
Modify welding characteristic data of point 1 through point 5 by using numeric keys.
5.
After you modify, press
0
RECORD
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 t o "USER

REGISTER" and enter the number given t o the created user welding characteristic data.
8.
Press F2 (REGIST).
Now, the user welding characteristic data have been registered.
-2
User Parameters
2.7.4
Notes to Use ALMEGA FUZZY AUTO

Regardless of the wire diameter and the kind of gas in use (C02/MAG), select
(1) Setting welding characteristic data
"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 Synergic Fuzzy synergic Setting of the Welding Characteristic Data SEPA SYNER SYNER
(2) The front panel of ALMEGA FUZZY AUTO

The outside view of ALMEGA FUZZY AUTO is shown below:
Fig.2.1 The outside view of Front Panel
@ ... A welding current/voltage setting knob, effective only when the current/voltage
control switch is set a t "Panel".
User Parameters 2 -2 9
@ ... 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 a r e 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 a r e the following:
Setting on Panel Wire Material Solid wire 1
2
Wire Diameter 0.9m l.Om 1.2m 0.9m 1. om 1.2m 1.2m 1.4 m
Gas
Solid wire Solid wire Solid wire Solid wire Solid wire Core wire Core wire
coz coz
C02
3 4
5
6 7 8
MAG MAG MAG C0 2

C0z
@ ... 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 a n 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 -3 0
User Parameters
2.7. 5
Notes to Use T I G Fi l l e r
F o r the use of a TIG filler, it is necessary t o modify welding characteristic d a t a and set a wire retracting speed.
(1) Modifying Welding characteristic data

Enter a speed setting and a speed command value. Select the characteristics d a t a of point 1 through point 5 according t o the rated wire feed r a t e from the following list:
Table 2.4. Welding characteristic d a t a for TIG filler Setting (cm/min)

6
Output value ( V )
0. 7
(2) Setting a wire retracting speed Set "WIRE RETRACT SPEED1'*in the welding parameters.
: Refer t o "Setting the Welding Parameters", section 2.3. in this part.

User Parameters
2 -3 1
Chapter 3
A p p l i c a t i o n Features and F u n c t i o n s Used f o r A u t o m a t i c O p e r a t i o n
This chapter describes application features and functions used for automatic operation and how t o operate them, including Machine Lock, Dry Run, Low-speed Automatic Operation, and Path Function.
Contents
3.1 Maclline Lock 3.2 D~~ R~~ ..................................................................................................................................................................... 3 3 Lowespeed Automatic Operation 3.4 Checking the S t a r t Enable Area during Automatic Operation 3 5 'path Function 3.6 Online Modification
.......................................................................................................................................
33-
1
2
3- 6 3- 8 3- 8 3- 10 3- 11
3.7 Sequellce Display durillg Automatic Operation
.........................................................................
3. A p p l i c a t i o n Features and Functions Used f o r

Automatic Operation
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 setting the system status. The ON Setting make each mechanism in the system inoperative.
4 ~aut~ons
1 ) Teach mode In Teach mode all features and functions except those to move each mechanism a r e available. However, there a r e some restrictions, which are: * In ON setting of the machine lock function, any mechanisms do not operate even if manual manipulation o r block operation is performed. If a Motion instruction such a s P, L,o r 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 t o run the system. 2 ) Auto mode In Auto mode all features and functions except those to move each mechanism a r e available. However, there a r e some restrictions, which are: Because welding and sensor instructions a r e 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 o r 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
-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)
I ~ C H LOCK[
SERVO ON
A X I S MH4
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 a r e not active:
(1) External control inputs/outputs (OSACOM SUPER 8700 holds d a t a 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. a r e 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.
*
3-2
: Refer to "Setting Motion Restrictions on Automatic Operation", section 2.5 in this part.
When the dry run is set, during automatic operation some instructions a r e available and some a r e not, which a r e listed below: * Execute Execution 0 X * * Not execute Table 3.1. Mechanism control instructions Instruction Type Motion
I
Description Positioning
I
Execution
P L L0
Motion
/ Motion /
C1 C2
Motion Motion
IMotion I
Liner interpolation Liner interpolation with rotation of attitude Uniform interpolation 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 Synchronous positioning motion
0 0
I
l o
0 0 0 0 0 0 0 0 0 0
6,
x
co 1 co 2
HP HL HLO HC HO HLX NOP T WF P
Motion
Motion Motion
Synclironous linear interpolation Synchronous ,Motion with rotation linear interpolation of attitude Motion Synchronous circular interpolation Synchronous circular interpolation with rotation of attitude , Motion Silnultaneous uniform interpolation Motion Motion Task Task Task Task
-
No operation Waiting for Timer time Starting pattern weaving Starting axis weaving Ending weaving Caluculating rotated position
WAX WE RT
0 0 0 0
-3
Table 3.2. Program control instructions Instruction

-
Type Motion Motion Motion Motion Motion Task Task Motion Motion
Description Internal program jump External program jump Calling program Point mark Ending program Defining counter Decremental operation of counter value Starting multi-pass section Ending multi-pass section Specifying executing pass of task ~nstruction
Execution
JP
JF
CL
PM END DE F
DEC
MP S
0 0 0 0 0 0 0 0 0
X
EP
Task
Table 3.3. Sensor instructions

I
Instruction
-
Type Motion Motion Motion Task Task Task Task Task
Description Detecting Wire extension One-direction search Pattern search Starting tracking Ending tracking Calling deviations Storing deviation number in tracking Starting high speed touch sensor
Execution
X
SF0 SF1 SF2 ST ET

-
x
X
x
x
SF3 SF5 TSS

I
x
x x
I
T SE
Task
Ending high speed touch sensor
1
I
Table 3.4. Welding control instructions

I
Instruction
Type Task Task
Description
I Execution
X
AS AE
Arc s t a r t
Arc end
1
-
Task Task Task Task Task
Inch Retract Turning gas ON Turning gas OFF Starting multi-pass welding
RTC
GS
x x x x
GE ASM
-
AEM
--
Task
-
Ending multi-pass welding
3-4
Table 3.5. External control input/output instructions Instruction
1 Type I
Task Task
Description Setting external control output Reseting external control output
Execution
X
X
S R
N
1
1
Task Task
1 1
Waiting for external control input ON Waiting for external control input
X X
04
%Motion means Motion instruction, and Task means Task instruction.
$ 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 a r e used to control the jig, etc., take care t o avoid interference with peripheral 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.
I Display when the dry I
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)
3-5
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 t o check taught d a t a 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 o r HP

(referred to a s Positioning distance in the following)
(2) The travel distance to a point taught with Point Mark instruction PM used t o
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 Point Mark distance Travel distance for Path function Travel distance for restarting Speed taught The setting of "SPEED TO PM""3 in the user parameters for setting the system status Speed
* 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.
3-6
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
.Low-speed rate
609,' 0 30%
..............................................................
Table 3.7. Speeds a t Low-speed Automatic Operation ON/OFF OFF setting (normal) 100% ( * 1) 50% ( * 1) 20% ( * 1) 10% ( * 1) 60% ( * 2) 60% ( * 2) 60% ( * 2 ) ON setting
1) 2) 3) 4 5) 6) 7)
( 1) ( 2)
P (100%) P ( 50%) P ( 20%) P ( 10%) Point Mark distance Travel distance for Path function Travel distance for restarting
30% 30% 20% 10% 30% 30% 30%
( 3)
(*3) ( * 4) ( * 4) ( * 3) ( * 3) ( * 3)
* * *
( 3)
( 4)
The manipulator moves a t the speed rate taught. The manipulator moves a t the speed rate set a s a travel speed to point mark. The manipulator moves a t the speed rate of Low-speed automatic operation which is less than the normal rate. The manipulator moves a t the normal speed rate which is less than the speed rate of low-speed automatic operation.
Notes 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 a r e set a t the same time, both functions become effective; all mechanisms a r e locked and the cycle time becomes longer.
lI ll
Display when the d r y 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
-7
3. 4
Checking the Start Enable Area during Automatic Operation
This feature allows the operator to check "within o r outside the s t a r 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 r e 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 t a r 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 t a r t automatic operation from a desired sequence. A sequence is specified in Teach mode. If this function is set to s t a r t automatic operation, a check on the s t a r t enable is not made. Therefore, starting automatic operation from any position is possible. The manipulator moves with Positioning t o a specified sequence. The speed is the setting of "SPEED TO PM"*2in the user parameter for setting the system status. [Examplel) 1 2 3 4 5 6 7
Sequence No.
P,P,L,AS,L,L,AE,P,P,END
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 t o 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 t a r 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 o r 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.

3
-8
Setting the path function

1. In Teach mode, move the cursor t o
the sequence you want t o start.
F4 ... Sets the s t a r t sequence. F5 ... Sets the s t a r t sequence and then enters to the top layer of Teach mode.
2.
Press F4 (PATH) o r F5 (PATH AT).
The path function is set.
When F4 (PATH) is pressed

.) I
When F5 (PATH AT) is pressed

Irr)
3.
Change t o AUTO mode.
4.
Press the Start button.
Automatic operation will s t a r t from the sequence where you have set by the path function.
3-9
Note The path function is set by pressing either F4 (PATH) o r 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.
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 a r e stored in the following conditions:
(1) When
In this case, online modification operation can be carried out. (2) When F4 (END) is pressed In this case, the online modification terminates.
0
RECORD
is pressed
(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), o r AS is executed to modify welding condition
Important If automatic operation is halted, modifications you have made s o f a r a r e not stored.
Clll
Performing on-line modification execution comes t o a welding section, the current welding conditions a r e displayed.
1. During automatic operation, when
2. Press F2 (AS ONLN).
* *
*
3-10
: Refer t o "Setting the System Status", section 2.1 in this part.

3.
Select the welding condition (current, voltage, o r 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 optimum condition.
t o modify t o the
Pressing when pressing
[m
a t the same time 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
setting the system status. If this feature is set off, taught conditions a r e displayed only
* *
In Welding section and weaving section, In Arc sensor tracking section, o r During waiting for external control input o r for timer time
If the feature is set on, conditions of all instructions a r e 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 one shown on the right:
111)
natic o ~ e r a t i o n
Refer to "Setting Teaching Box Keys", section 2.2 in this part.

-1
Chapter 4
Shift
is used to move positions stored in a Task program. This chapter describes the parallel shift and the cyli~ldrical s h i f t F o r details of other shift functions such as 3-dimensional shift, refer t o the instruction manual "Options".
/
/
I1
1
1
Contents
4.
Shift
The following 6 types of shift functions a r e 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 a n amount by moving the mechanism from the reference position t o 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 a f t e r manual manipulation is performed, the travel distance from a taught point is set as a n amount of shift.
L
4. 1
Parallel Shift
A position is shifted in parallel t o the reference coordinate system by a specified
amount. The reference coordinate system is the coordinate system which was used t o teach the current sequence.
[fill
Sequence Instruction Coordinate System 0 0 1 0 0 2 0 0 3 004
I1
P
Base World
P
Tool
P
Work
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.
Shift
4-1
Teaching path
Fig.4.l Parallel Shift
-2
Shift
4. 2
Cylindrical Shift
This shift causes the manipulator t o 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)
AXIS MH3 TEACH PI23 SQ No.=1 3 2 SERVOON
WE 092 P >093 L AS 094hC1 095hC2
10096
150cn1
BASE BASE
MI M1 MI M1
ASCOC 150m BASE 150m BASE
IICXJj
2.
Press F3 (SHIFT).
rr)
J!m!ml>
MGC/RDC
AXIS ML4 TEACH P12 3 SQ Na=13 2 SERVO ON SHIFT
SELECT SHIFT METHOD PARALLEL_I 3-DIMENTION EXTERNAL
TOOL MECHA COODINATES. MECHA 1 SHIFT
13. 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 t o be set.
4.
Press F1 (EXECUTE).
F o r shift e r r o r s and solutions, refer t o section 4.3.
AXIS M L 4 TEACH P123 SQ N . 1 2 o=3 SERVO ON SHIFT
SET SHIFT PARAMETER >SFT AREA:093 TO 099 SFT VAL.- 1 A NUMERAL SFT MTHD - PARALLEL , TOOL MECHA COODINATES,MECHA 1 SHIFT
1-
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.
4 - 4 Shift
If a shift range is not specified,

positions of all sequences a r e shifted.
6. Position the cursor a t the "SFT

VAL.".
Specifying an amount by manual entry
(1) Highlight " M A N U A L " , 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~ecifvina amount by numerical entry an
(1) Highlight "NUMERAL" by

and then press F1 (EXECUTE).
Parallel shift Move the cursor by
m],
.) I
AXIS MH3 TEACH P123

SQ Na=132
NUMERAL SHIFT INPUT
and enter an amount of shift (mm) by numeric keys.
SERVO ON SHIFT
>
X DIRECT Y DIRECT Z DIRECT
0.0 m a 0.0 a m 0.0 m a
/+//xmTq
F1 (+/-) signs.
toggles between the
Shift
-5
Cylindrical shift Enter an amount of shift (rotating angle) of Axis 1 by numeric keys.
AXIS MH3 TEACH PI23 SQ No.=l 3 2 SERVO ON SHIFT
ENTER SHIFT ANGLE
E/EUI J]CT IX E +
F1 (+/-) toggles between the

signs.
(2) Press F2 (EXECUTE).

Then, shift will be started 7. During a shift process, the screen looks like the one shown on the right
AXIS ML4 TEACH P12 3 SQ % = I 3 2 SERVO ON SHIFT
SHIFTING COMPLETED SEQUENCE 0 0 8
The shift completed sequences is displayed on the screen.
8. When a shift process f o r all

sequences is complete, OSACOM SUPER 8700 returns t o the original screen (block operation). If you press
after the shift finishes, you can make the shift invalid.
F1 ... Makes the shift valid.
0
~ I F Y
immediately
AXIS ML4 TEACH PI 2 3 SQ N . l 3 2 o= SERVO ON SHIFT
P123 SHIFT COMPLETED
F2 ... Makes the shift in valid.
rtY-'-TIrnl
-6
Shift
4. 3
E r r o r Messages and Notes

SOFT LIMIT, SEQUENCE or, LINK LIMIT, SEQUENCE
Description
(1) Message
***
SHIFT IMPOSSIBLE
***
***
SHIFT IMPOSSIBLE.
The position of sequence limit.

Solution
shifted beyond the soft limit o r the link soft
Pressing F1 allows you t o continue the shift process without shifting that position. Pressing
occurs, reduce the amount and shift again.
0
RESET
-
allows you t o cancel the shift process. When this e r r o r
(2) Message
DATA ERROR, SEQUENCE
Description
***
SHIFT IMPOSSIBLE
T o perform the shift in a system consisting of multiple mechanisms, any of the instructions(such as HP and HL) which have positional d a t a of all the mechanisms is required in the shift range of the program. The e r r o r message will appear if the above condition does not exist.
Solution
After pressing
ju;o;;;),place a n instruction which has positional d a t a of all the w
mechanisms, in the shift range, o r add a n ilzstruction such as HP to the shift range, and t r y the shift operation again.
(3) Message
CALC.ABNO., SEQUENCE
Description
***
SHIFT IMPOSSIBLE.
The position of sequence

Solution
***
shifted beyond the work enable area.
Pressing F1 allows you to continue the shift process without shifting that position. Pressing
occurs, reduce the amount and shift again.
0
RESET
allows you to cancel the shift process. When this e r r o r
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
perform the shift operation again.
0
~ I F Y
, perform block operation to the sequence of the manipulator, and
(7) Only points that were taught with the same coordinate system as that used t o 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 f o r 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 r o r does not occur.
4 -8
Shift
(9) If the following e r r o r condition exists, operation cannot be continued when outside
the soft limit occurs during a shift process. Correct the program s o t h a t all positions can be within the soft limit:
* The system h a s 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 h a s 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 m a y
be upside down) after execution of Shift. Therefore, before running automatic operation, check the path by block operation. The system h a s 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 t o 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 s u r e t o check the movement by performing a block operation after shifting.
Shift
4 -9
Management
i
Chapter 1
external storage .
External Storage
This chapter describes the operating procedures for using an
Contents
..
1 1 Connecting and Handling the External Storage ......................................................................... 1.2 Selecting Exterllal Storage Functions ............................................................................................... 1.3 Formatting Floppy Disks 1.4 Listing Files
...........................................................................................................................
1-1 1-2 1-4 1-5 1-6
...........................................................................................................................................................
1.5 Saving Files from the Controller to the External Storage
........... ...........
........
1.5.2 Batch Saving ................................................................................................................................................. 1.5 .3 All Saving ......................................................................................................................................................... 1.6 Loading Files from the External Storage to the Controller 1.6 .1 ~ ~ d i ~ i d ~~ ~ l ~ ~ d i ~ ~ 1.6.2 ~ ~~ t ~ ~ h ~ d i ~ ~ ~
1-9 1. 11 1-13 1 - 13 1-16 1- 19 1-21
1.6 .3 All Loading 1.7 Comparillg Files
E x t e r n a l Storage
(totransferfiles)
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 a n 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 a n interface cable a r e 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 a r e 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 r e available. Specify your floppy disk type beforehand by setting "FD FORMAT TYPE"*2in the user parameters setting for the System Status.
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 o r 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 a r e a 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, o r 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.
/
(2) Removing a floppy disk
Eject button
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 a r e 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 a r e 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) a t
. ) n
the top layer of Teach Mode.
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.)
F1 . . Formats Floppy Disk. (See section 1.3.)
External Storage
1-3
1. 3
Formatting Floppy Disks

To store files t o floppy disk, the operator needs t o format a floppy disk. The floppy
disk type must be 2HD (high density: 1.2M) o r 2DD (double density: 720K). T o specify you floppy type, set "FD FORMAT TYPE1'*in the user parameters setting f o r the System Status. Formatting allows you to create a user or system floppy disk but causes all the data on the disk t o be erased. Great care is therefore necessary t o perform this operation.
Formatting a floppy disk

1. Press,
screen 1:
U
I>
F1 (INITIAL) at
TEACH
INITIALIZATION FLOPPY DISK FORMAT SELECT KIND OF FLOPPY DISK
~ E R V O ,&
F1 ... Formats a floppy disk into a user floppy disk. F2 ... Formats a floppy disk into a system floppy disk.
EXT. MEMORY
p - z - i - q ~
2. Press F1 (USER) or F2
(SYSTEM).
3. Insert a floppy disk into the

external storage and press F1 (EXECUTE).
4.
Press F1 (YES) t o start formatting.
If you do not want t o format, press F2 (NO) instead.
*
1 -4
: Refer t o "Setting the System Status", section 2.1 in p a r t I1

External Storage
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 t o

list, by using the function key.
3. Insert a user floppy disk into the

external storage and press F1 (EXECUTE).
I) I
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.)
External Storage
1-5
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.
I
L
Note If the optional extended memory is equipped, the plural number of user floppy disk will might be required when saving Task programs o r 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.
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)
1-6
External Storage
F1 ... Saves a n 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 )

external storage and press F1 (CONFIRM).
119
If you selected Welding Condition file o r Weaving Condition file, specify the Condition file type by using the function key:
The screen d i s ~ l a v e d when vou have selected Welding Condition file

SAVE TEACH ENTER F I L E NUMBER TRANSMITTING CONTROLLER+EXT.MEMORY A S C--
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
I) I
[SERVO OFF/ EXT. MEMORY
p - - - F q ~ ~ C J 1 A ~ ~ ]
F1 ... Saves a Fixed Pattern Weaving file. F2 ... Not used. F3 ... Not used. F4 ... Saves a n Axis Weaving file. F5 ... Not used.
SAVE TEACH
CONTROLLER-EXT.
MEMORY
1s e w 0 ~ F F I
EXT. MEMORY
ENTER F I L E NUMBER. TRANSMITTING
WAX--
p T T - - q J w \ p i l W \ ~ \ ~
External Storage
1-7
4.
Type the file number by using numeric keys.
SAVE
CONTROLLER-.EXT.
MEMORY
TEACH ENTER F I L E NUMBER TRANSMITTING ]SERVO OFF( EXT. MEMORY WAX 0 1
5. Press F1 (EXECUTE) t o save

the specified file.
1-
If the specified file does not exists in the controller, a message

" NO FILE." is displayed.
SAVE TEACH
CONTROLLER-tEXT.MEMORY
PO 0 1
ENTER F I L E NUMBER TRANSMITTING SERVO O P F ~ NO F I L E
+MOD I F Y
In this case, press
enter the correct file number.
0
MODIFY
to
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
1-8
External Storage
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 t o save a batch of files. F o r details, see "Restrictions on File Transfer" section 1.9.
0 Notes
If you want t o save the Welding Characteristic files, select batch saving of the User Parameter files. They will be saved all together.
\
Saving a Batch of Files Press F2 (ALL).
F1 ... Saves all the Task . P r o g r a m files. F2 .. . 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

F2 F3 F4 F5 files. (Option) ... Saves all the Laser Sensor files. (Option) .. . Saves all the User Parameter files. ... Saves all the System Parameter files. ... Saves all the Search Pattern files. (Option)

function key.
F1 ... Confirms overwriting during transfer. F2 ... Enforces overwriting without confirmation.
External Storage
-9
@ 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 t a r 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 b y the function key

whether you want t o confirm overwriting or not when a file with the same name already exists in the external storage.
*
*

external storage and press F1 (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) t o 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.
AXIS ML4 TEACH SERVO ON EXT. MEMORY
SAVE
CONTROLLER-EXT. MEMORY
SET NEXT USER DISK AND P U S H

F 1 KEY.
[EEiiq
-1 0
External Storage
I n 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 t o 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 a r e 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 a r e saved for the first user floppy disk altogether.
L
Saving all the files 1. Press F3 (BACKUP).

I) .
External Storage
1-1 1
2.
Insert a user floppy disk into the external storage and press F1 (CONFIRM).
* *
3.
Press F1 (EXECUTE) to save all the files except the System Parameter files.
If the optional extended memory

is equipped, all saving will stop when the user floppy disk will be full while executing to save Task programs.
I n 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
transfer of all the files except the System Parameter files is complete.
0
RESET
key when the
* *
5. Replace the floppy disk with a

System floppy disk and press F1 (EXECUTE).
6.
Press the
transfer of the System Parameter files is complete.
0
RESET
key when the
1-1 2
External Storage
1. 6
Loading Files from the External Storage t o 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.
II I
Loading Files
LOAD TEACH SELECT F I L E TRANSMISSION WAY EXT.MEMORY-+CONTROLLER
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.)
LSERVU
OFFJ
EXT. MEMORY
[ m a I m
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.
10 Loading a n individual file

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)
External Storage
-1

function key.
rzl)
LOAD TEACH
EXT.MEMORY-tCONTROLLER
1SERVO O.FF(
EXT. MEMORY
S E T U S E R D I S K AND P U S H F 1 KEY
pi%GKq
external storage and press (CONFIRM).
F1
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.
The screen displayed when you 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.
4.

Irrl,
LOAD TEACH [SERVO OF^ EXT. MEMORY
EXT. MEMORY-.CONTROLLER
ENTER F I L E NUMBER PO01 TRANSMITTING
JEXECUTEI
1
-1
External Storage
5 . Press F1 (EXECUTE) t o load

t h e specified file.
If the specified file does not exists in the external storage, a message "NO FILE." is displayed.
.) I
In this case, press
enter the correct file number.
0
mIFY
to
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.
External Storage
1-1 5
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 ( A L L ) .
F ... Loads all the Task 1

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.
F ... Confirms overwriting 1

during transfer.
F2 ... Enforces overwriting

without confirmation.
-1
External Storage
Note Even if you select batch loading of the User Parameter files, you cannot load the following parameters t o the controller: * The attitude movement The home stop function * The work enable a r e a The s t a r t enable a r e a The offset adjustment * The tool parameters If you want t o load these parameters, select batch loading of the System Parameter files.
3.
Select whether you want t o confirm overwriting or not when a file with the same name already exists in the controller.
4.
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) t o execute

batch loading of the files you selected.
If the optional extended memory is equipped, OSACOM SUPER
8700 requests you to confirm

loading the second floppy disk when finishing the loading files in first user floppy disk while executing t o load all Task programs.
I )
External Storage
1-1 7
In this case, select by function key whether loading files in the second user floppy disk o r not.
F1
F2
Loading files in the second user floppy disk. Ending batch loading.
I f you select Fl(YES), insert the second user floppy disk into the external storage, and then operate the loading. I f you pressed F1 (EXECUTE) a t step 3, then OSACOM SUPER
6.

overwriting when a file with the same name already exists in the controller.
F1 ... Overwrites.
F2 ... Does not overwrite.
1-1 8
External Storage
1.6.3
A l l Loading
To load all the files to the external storage, follows the steps below:
Loadincl all files

v
1. Press F3 (BACKUP).
1
.r).
i
2.
I )
3.
Press F1 (EXECUTE) t o load all the files except the System Parameter files.
rrrr)
If the optional extended memory

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.
LI)
I n this case, select by function key whether loading files in the second user floppy disk o r not.
F ... Loading files in the second 1

F2
user floppy disk. Loading system floppy disk.

External Storage
1-1 9
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
transfer of all the files except the System Parameter files is complete.
0
RESET
key when the
*
I>r).
5.
Replace the floppy disk with a system floppy disk and press F1
(EXECUTE).
6.
Press the
transfer of the System Parameter files is complete.
0
RESET
key when the
0Importantwith the same name already exists in the controller, such file will be If a file
enforcedly overwritten by loading all the files.
-2
External Storage
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 r e 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.
3.
If you selected Welding Condition file o r Weaving Condition file, specify a Condition file type.
F1 ... Compares Arc S t a r t Condition files. F2 ... Compares Arc End Condition files. F3 ... Not used. F4 ... Not used.
FILE VERIFY TEACH ENTER FILE NUMBER VERIFYING FILE WAX--
F1 ... Compares Fixed Pattern Weaving files. F2 ... Not used. F3 ... Not used. F4 ... Compares Axis Weaving files. F5 ... Not used.
1 -2 2
External Storage
~ S E R V OO F F ~
EXT. MEMORY
4. Type the file number by using

numeric keys.
Ir)
5.
Press F1 (EXECUTE) t o 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. In this case, press enter a file number.
Ilr$
~ I F Y
to
External Storage
1 -2 3
1.7.2
BatchComparison
To compare a batch of files by type, follow the steps below. As mentioned in the section f o r Batch Saving, depending on the file type you specify, you may not be able t o 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)

function key.
1-2 4
External Storage
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 r e a The s t a r t enable a r e a * The offset adjustment * The tool parameters If you want t o compare these parameters, select Batch Comparison of the System Parameter files.
3.
I) I
F I L E VERIFY TEACH ALL TASK PROGRAM VERIFY
SERVO
EXT. MEMORY
C~FF]
/-tEiEq
If you selected Batch Comparison of the System Parameter files a t step 2, insert a system floppy disk instead.
4.
Press F1 (EXECUTE) t o execute batch comparison of the files you selected.

F I L E VERIFY TEACH ALL TASK PROGRAM VERIFY VERIFYING F I L E PO01 VERIFIED ERROR ->RESET
If the files do not match, a

message "VERIFIED ERROR " is displayed.
rr)
rs~avo OFFI
EXT. MEMORY
To cancel the comparison, press the

*
To execute the next comparison, press the key instead.
0
RESET
key
0
mIFY
External Storage
1-2 5

comparing the second floppy disk when finishing the comparing files in first user floppy disk while executing to compare all Task pro grams.
I n 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. Ending batch comparison.
F2
I f you select FI(YES), insert the second user floppy disk into the external storage, and then operate the loading.
1 -2 6
External Storage
1.7.3
All Comparison
To compare all the files, follow the steps below:
II Comparing all the files I

1. Press F3 (BACKUP).
.) I
2.
I) .
3.
Press
F1 (EXECUTE) t o
I) .
compare all the files except the System Parameter files.

comparing the second floppy disk when finishing file comparison in first user floppy disk while executing to compare all Task programs.
I n 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. Comparing system floppy disk.
External Storage
F2
1-2 7
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 t o operation 5.
4.
Press the
0
RESET
key when the
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
comparison of the System Parameter files is complete.
0
RESET
key when the
If the files do not match, a

message "VERIFIED ERROR" is displayed.
*
T o cancel the comparison, press the
To execute the next comparison, press the key instead.
0
RESET
key.
0
~ I F Y
1 -2 8
External Storage
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.
FILE DELETION TEACH SPECIFY FILE TYPE
SERVO
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)
UFF( EXT. MEMORY
I-[
J E E v DJ E V IS m> \ W p x F JW A EI Q m
F2 ... Deletes a Laser Sensor file. (Option) F3 ... Deletes a Search Pattern file. (Option) 2. Select the file type by using the
function key.
Ib l
3.
Insert a user floppy disk into the external storage and press
FILE DELETION TEACH
F1
(CONFIRM).
LSERVQ
OF^
ENTER FILE NUMBER DELETING FILE P--
EXT. MEMORY
If you selected Welding Condition

file o r Weaving Condition file, specify a Condition file type.
External Storage
1 -2 9
FILE DELETION TEACH
SERVO OF^
EXT. MEMORY
ENTER FILE NUMBER DELETING FILE ASC--
F1 ... Deletes a n Arc S t a r t Condition file. F2 ... Deletes a n Arc End Condition file. F3 ... Not used. F4 ... Not used.
j-'irFqCJJAmm
F1 ... Deletes a Fixed Pattern Weaving file. F2 ... Not used. F3 ... Not used. F4 ... Deletes a n Axis Weaving file. F5 ... Not used.
4.
5.
Press F1 (EXECUTE) t o delete the specified file.
If you want to cancel the deletion,

press the
0
RESET
instead.
1-3 0
External Storage
1. 9
below:
Restrictions on File Transfer
Depending on the file types, some functions a r e not available. F o r details, see the list
1
File Type File Name
File Transfer
I I I
List Delete
Verify
Sepa. All
Backup
Sepa. All
Backup
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 Characteristic file
p*
**
0 0 0 0 0
0 0 0 0 0 0 0 0
o O
0 0 0 0 0 0 0 0
o O
0 0 0 0 0 0 0 0
x
x
0 0 0 0 0 0 0 0
x
x
0 0 0 0 0 0 0 0
x
x
0 0 0 0 0 0 0 0
o
o
0 0 0 0 0 0 0 0
o
o
ASC* *, AEC* * ASM* *, AEM* * WAX**,WFP** SRF * SQF * OFS * DEV *
0 0 0
x X
** *
SF2M *
USEMAIN etc.
#***-***
$ WTBD
**
o
X :
0 : Operable,
Inoperable
: Represents a figure
0 Note
The files relating t o manual speeds and s t a r t allocation a r e transferred only when all the files a r e transferred. (Neither Individual nor Batch transfer is applicable.) Therefore, even if all the files in the list a r e transferred by specifying Batcli transfer, the result is different from that given by All.
External Storage
1 -3 1
I. 10
Error Messages f o r External Storage

If an error is encountered, follow table 1.1 to take action:
Table 1.1. Error Messages and Solutions

-
Error Message WRITTEN DATA ERROR +MODIFY
Description The data saved to floppy disk a r e broken. Press
Solution
save the file again. Be sure to overwrite when asked
0
M O D l ~ ~
UNIT IS NOT READY +RESET
/ disconnected, o r the
The external storage is
1
I
/ external storage, o r set
Press
0
RESET
to connect the
external storage you use is different from setting of "EXT MEMORY" in the user parameters. The disk has no space to save any file.
"EXT MEMORY" in the user parameters t o the enternal storage you use.
FLOPPY DISK FULL +MODIFY
/
1
Press
place a new floppy disk in the external storage. Save files after formatting the
I floppy disk.
is wrong.
DISK CAN NOT BE USED +MODIFY
The disk type, 2HD o r 2DD, Replace with a 2HD o r 2DD type disk, o r change the format type setting in the user parameters.
FD IS NOT READY +MODIFY
External storage is OFF, o r Press no floppy disk is in the
turn on the external storage o r
~ I F -Y -+
I external storage.
NO FILE +MODIFY SAME FILE EXISTS. +MODIFY WRONG FD +RESET The specified file does not exist.
I place a floppy disk.

Type a file number again. Select to overwrite o r not to
A file with the same name
already exists a t destination. overwrite when asked. The floppy disk in use is wrong.
Use a floppy disk formatted for
I User (or System).
1-3 2
External Storage
+>
F2 (END) and
F2 (END) and
F2 (END) and
Error Message MEMORY OVER -+MODIFY
Description There is no room in the memory of controller to load files. Press

WIFY
Solution
cancel the operation.
0
w
WIFY
F2 (END) and
READ/WRITE ERROR -+MODIFY
The floppy disk is broken.
Press
F2 (END) and
place another floppy disk in the external storage.
CANCEL WRITE PROTECT -MODIFY
The floppy disk is write protected.
Press
move the notch to remove write protection.
F2 (END) and
FD SYS ERROR (Error NO.)
Error occurred during data transfer between controller and external storage.
When loading, press (END) to load again.
0
WIFY
+F2
When saving, refer to the solutions on the following pages.
External Storage
-3
1.I 1
Others
Handling Floppy Disks
1.11. 1
(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 o r 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 o r files. (3) The OSACOM SUPER 8700 files a r e 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.
1-3 4
External Storage
Chapter 2
Password
To prevent malfunction of the system caused by accidental nlodifications, access to some specific operations is restricted by a
password. This chapter describes how to enter a password and how to set a user defined password.
I I
Contents
2.
Password
Misoperation in setting system parameters o r initializing the memory may make the system inoperable o r causes the data on the disk t o be erased. Because the functions provided for such operations a r e 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 functions a r e not available.
-
9. If the wrong password is entered, these
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.
I1 Entering the password I

1. When the function which
requires a password is activated, OSACOM SUPER 8700 waits f o r the password t o be entered.
2.
Type the password number of 4 digits by using numeric keys.
3.
Press
0
RECORD
t o enter the number.
You can press the following keys ins tead:
entered.
RESET
entry
0 0
~ I F Y WIFY
to correct the number you
to cancel the password
If the wrong password is entered, a message "WRONG PASSWORD." is displayed. Press number.
.r)
to enter the correct
Password
-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
@.
I
You can press the following keys before pressing
entered.
RESET
setting.
0 0
~ I F Y
to correct the number you
0
REC~RD
-2
Password
If you set the wrong password, a message "WRONG PASSWORD" is displayed. Press
r'\
I WRONG
PASSWORD.
+MOD I FY
password.
0
WIFY
to enter the correct
5. Type the new password by using

numeric keys.
6.
Press mm~ t o change t o the new number.
You can press the following keys before pressing
entered.
RESET
setting.
0 0
~ I F to Y
correct the number you
0
RECORD
Password
-3
Chapter 3 Absolute O f f s e t
11
1
This chapter describes how to adjust a difference between the position of the manipulator and the position detected by the encoders. The operations covered in this chapter must be performed when the manipulator is installed o r mechanical parts a r e replaced.
Contents
Absolute O f f s e t
An absolute encoder is fixed to each motor t o 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 t o 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.
lVuLe
Perform the absolute offset setting operation only on the following occasions:
* *
When the manipulator is installed When a n y of the following e r r o r s occurs
A 11102-XXXX ABS MISMATCH
A 11103-XXXX ABS DATA OUT
A 10503-XX00 ABS BATTERY
A 50601-XXXX 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 s u r e t o reset the encoders before you set a n absolute offset. Otherwise, "A 11103-0000(Outside the ABS range.)" occurs.
Resetting the encoders and setting a n absolute offset

1. Move the mechanism by manual
manipulation t o align the alignment marks of each axis.

F4 (SYS.SET) a t the
A X I S ML4 TEACH
.) r
S E R V O ON
>
Absolute Offset
-1
3. F2 (RESTART), F3 (MASTRNG),
and F4 (CONTROL) a r e 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
0
RESET
instead.
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. Press
0
RESET
to clear each Alarm.
-2
Absolute Offset
9.
Press
10. Press F1 (ABSO).

Select the mechanism by the function key:
I )
F1 F2 F3 F4 F5
... Sets ABSO . Sets ABSO ... Sets ABSO ... Sets ABSO ... Sets ABSO
for for for for for
Mechanism 1. Mechanism 2. Mechanism 3. Mechanism 4. 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 t o compute the absolute offset.
If you want to cancel the setting operation, press
0
RESET
instead.
13. When the arithmetic operation is

complete, the margin of each axis is displayed. Each margin is adjusted to be around 50.
.) I
AXIS ML4 TEACH SERVO O N
MARGIN VALUES O F E A C H AXIS. MECHA 1

1
49 51
2 5
50 51
3 6
50 51
rF--K-qmj
Absolute Offset
-3
When each margin is around 50 Push F1 (END) t o terminate the absolute offset setting operation.
When each margin is 100, 200, o r inappropriate value.
As the absolute offset values a r e not correct, you must set then again.
(1) Push F2 (RETRY).
AXIS ML4 TEACH ABSO OFFSET IS NOT SET. SET ABSO OFFSET AGAIN. SERVO ON
~~/
(2) Push F1 (CONFIRM).
Select the mechanism by the function key, and be sure t o perform a n absolute offset setting operation.
SERVO ON
AXIS ML4 TEACH
ABSO OFFSET SETTING SELECT MECHANISM
pz?x-q/MECH211NIECH.Im]~5/ >
Important Each margin is adjusted around 50. Be sure t o set absolute offset setting again in the following cases. When each margin is too f a r from the optimum value: Improper values may have been set.
*
L
When each margin is 100 o r 200 : The absolute offset h a s not been computed.
J
-4
Absolute Offset
3. 2
Axis Alignment Marks on the Manipulator Axis alignment marks on the manipulator (Gseries/V series) a r e shown below:
Axis 2 nment marks
Axis ignment
Axis 1 alignment marks Axis alignment
Axis 5 alignment marks
The aligned manipulator
The aligned manipulator (Top)
Fig.3.1 Axis alignment marks (ALMEGA G series)
Axis 4 alignment marks Axis 5 alignment marks
ma.
Axis 3 gnment marks
Axls Z nment marks
. . -
w
Absoluteoffset
Fig.3.2 Axis Alignment Marks (ALMEGA V series)
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 a r e 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, o r if the allowance is too small.
Solutions t o recover f r o m ABSO data error
99 (1) Run Task program P 9 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 a n error.
*
3
: Refer to "Setting the System Status" in part 1 . 1

Absolute Offset
-6
Chapter 4
user parameters, etc.
Initializing t h e System
This chapter describes how to initialize the system parameters and
Note that misoperation of the Initialize function may make the robot system inoperable.
4.
I n i t i a l i z i n g t h e 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 o r 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 r e erased to restore the default settings in the following files which a r e 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 a n external storage. 2 ) If initialization of all data is executed, OSACOM SUPER 8700 asks whether you still want to use the installed option(s) o r not. If you a r e 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 a r e erased. (That is, your defined settings remain unchanged.) For this reason, initialize the Laser Sensor file(s) after initializing all data.
Initializing 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) o r not. If you want to use, be sure to select "YES". Otherwise, the option(s) will not be available.
\
>
(3) Initializing the Welding Characteristic Data files

It is possible to create 12 types of Welding Characteristic d a t a * . If you initialize, CPVAS-350 COz/0.8ma will be automatically set.
@
L
Important
Initialization causes the User Welding Characteristic data to be erased. If you do not want to erase the data, store them by using a n external storage.
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".
*
4 -2
: Refer
to "Setting Welding Characteristic Data ", section 2.7 in part 11.
(5) Creating the System Parameter file The system parameters necessary for the following single manipulator unit a r e created:
If your system consists of the above overhead o r wall mounting manipulator, load the special parameters described in (6) from the external storage.
(6) Loading the special parameters

The d a t a necessary for any system other than those in (5) a r e created by transferring from the external storage.
(7) Initialize the User Parameter file

The user parameter settings a r e 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 a r e 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 a r e created
61) Initializing the Laser Sensor file

The data necessary to use the laser sensor a r e created,
(12) Initializing the s t a r t allocation The Task program numbers allocated to stations 1 - 6 a r e initialized to perform automatic operation by the multi-station system. The default settings a r e the following:
4 -3
Table 4.1. The default settings for s t a r t allocation Station No.
Task Program No
(13) Initializing the block operating speed table

The block operating speeds are initialized.
Initializing 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
F1 ... Sets the calender. F2 ... Initializes the System Parameter file. F3 ... Initializes the s t a r 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 t o

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) t o execute the initialization.
-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 Initializing Operation Selected Question Files t o be erased All files Files except Task programs Task programs only 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 t o 3 stations) Multi-station system (up t o 6 stations) Direct program entry system (BCD code entry) Direct program entry system (Binary code entry) Select the starting system by the function key. mDate and time
F2 (FORMAT)
F1 (DATE)
Enter the current date and time by numeric keys. MManipulator type F2 (SYSTEM) Select the type by the function key. All of these 5 questions
F1 (ALL DAT)
I/
Select each by the function key.
-6
Chapter 5
Installing O S A C O M SUPER 8700 Software Options
This chapter describes how to install OSACOM SUPER 8700 software options.
Contents
5.
Installing OSACOM SUPER 8700 S o f t w a r e Options

OSACOM SUPER 8700 software options are provided to use the following functions:
.Synchromotion
* *
*
External axis shift Multi

-
pass welding
Endless rotation Super a r c 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 s o 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 a n external storage t o 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.
l n s t a l l i n g OSACOM S U P E R 8700 S o f t w a r e Options
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 a n y of the following operating e r r o r s occurs. In such event, press
clear the e r r o r , s o you will be able t o continue the installation.
0
RESET
to
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 f o r another controller:
2
A X I S MH1
TEACH SERVO ON MISMATCHED CONTROLLER+RESET
Installing OSACOM SUPER 8700 Software Options
I f you are using a floppy disk which is not option setup floppy disk:
.4 1
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
. $
2.
Press
F1 (OPTION).
3.
Press F2 (LIST)
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
A X I S MH1 TEACH
SERVO ON
pi'-FGYIlRESTARTlrnIrn]>
2.
Press F1 (OPTION).
3. Press F5 (DELETE).
The installed software option or options will be listed.
4.
Highlight the software option you want t o delete by and[gl.
and press F1 (EXECUTE).
The highlighted software option will be deleted.
If you want to cancel the deletion,

press instead.
-4
Chapter 6
Troubleshooting
Contents
6. 1 Symptoms................................................................................................................................................................. 6.1.1 NotlIing Appears on the Teaching Box ................................................................................... i on the ~ hi^^ B~~ I~ ullsteady ~ l ~ 6.1.2 ~l~~ ~ 6.1.3 Initial Diagllosis Is Not Completed 6 1.4 The Servo power Supply Callnot Be Turned ON
................................................................
6. 15 6-15 6-16 6-17
............................................................
.........
6-20 6-21 6-22 ~6-23d 6-23 6 -26 6-27 6 -28 6-29 6 - 31 6-32 6-34 6-36 6-37 6-39 6-40 6-40 6-46
6.1.5 The Servo Power Supply I s Shut O F F Immediately When Turned ON 6.1.6 Manual Manipulation Does Not Function 6.2 A ~
...........................................................................
~c o d e and A ~ i l ~),fessage A~~l~ i ~ i ~ ~ ~~ l~ ~ ~ 6.2.1 The Display of A Failure .................................................................................................................... 6 .2.2 Logical Outputs for Failures 6.2 3 Shocli Sensor ................................................................................................................................................ 6 2.4 Servo power Sllutoff 6.2.5 Software Limit / Link Software Limit 6.2.6 Overrun 6.2.7 CommLlnication Failures 6 .2 .8 Data Installation Failures 6 .2 .9 Memory FailLlres ....................................................................................................................................... 6.2 10 Setting Errors .............................................................................................................................................. 6 .2 .11 ABSO Data Failure
..................................................................................................................................
6.3 Whell Servo Failure Occurred .................................................................................................................. 6 3.1 'flow To See the ServoFailure Display 6.3.2 Troubleshooting for Servo Failures
6.
Troubleshooting
This chapter describes solutions for failures that may occur during operations of the robot. Failures a r e mainly divided into 3 groups according t o 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 r e 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 t o find a solution. If you need replace p a r t s such as boards, contact DAIHEN.
Table 6.1. Symptoms Symptoms Solution
Nothing appears on the teaching F o r details, see section 6.1.1. box. T h e display on the teaching box is unsteady.
I F o r details, see section 6.1.2.

I
1
F o r details, see section 6.1.4 F o r details, see section 6.1.5.
Initial diagnosis is not completed. F o r details. see section 6.1.3 The servo power supply cannot be turned on. The servo power supply is shut off immediately when turned on. Manual manipulation does not function. F o r details, see section 6.1.6.
Troubleshooting
6-1
Table 6.2. Failure Codes and Messages Code / Message EA00101-XXXX EMERGENCSTOP -.RELEASE EA00201-XXXX SHOCK-S ERR -.RESET EA0040 1-XXXX SERVO DOWN +RESET Cause The Emergency Stop button o r emergency stop signal was entered. During automatic operation the torch interfered. I) The servo power was shut off due to an unidentified cause. 2) The hand was released from the deadman switch. Communication trouble between Welding Interface and 1 / 0 management board during welding. The specified Arc Start Condition file does not exist. Solution Pull the Emergency Stop button (or cancel the emergency stop signal) and press SERVO ON button. For details, see section 6.2.3.
For details, see section 6.2.4
EA10201-XXXX WIF TIMEOUT + RESET EA50101-XXXX NO ASC FILE - RESET . EA50101-XXXX NO AEC FILE -+ RESET EA50102-XXXX NO WFP FILE + RESET EA50102-XXXX NO WAX FILE RESET EA50103-XXXX NO ASM FILE - RESET . EA50103-XXXX NO AEM FILE - RESET . EA50104-XXXX NO OFS FILE - RESET . EA50105-XXXX NO CL PRG. - RESET . EA50106-XXXX NO JF PRG. 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.
Create an Arc End Condition file. The specified Arc End Condition file does not exist. Create a Fixed Patterned Weaving The specified Fixed Condition file. Patterned Weaving Condition file does not exist. Create a n Axis Weaving Condition file. The specified Axis Weaving Condition file does exist. The specified Multi-pass Welding Start file does not exist. The specified Multi-pass Welding End file does not exist. The specified Offset Condition file does not exist There is no Task program to call. There is no Task program to jump to. Create a Multi-pass Welding Start file.
Create a Multi-pass Welding End file.
Create an Offset Condition file.
Create a Task program to call.
Create a Task program to jump to.
6-2
Troubleshooting
Code / Message EA50107-XXXX NO PM RESET EA50110-XXXX C1 TEACH ERR RESET EA50111-XXXX C2 TEACH ERR - RESET > EA50112-XXXX COORD.ERROR + 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 a r c in the different coordinate systems. The target and reference points for a circular arc a r e the same. The number of time counts exceeded 9.
Solution Add a Point Mark instruction.
A circular a r c is formed by 3 points. Add a reference point.

A circular a r c 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.
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
+
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. The nest has overflown due Calling in the call destination program is possible but limited to the maximum 4 to program calls. layers. Check the the program. For details, see section 6.2.5. The robot has reached the software limit. The robot has reached the link software limit. The Task program assigned Check the s t a r t allocation and assign to the station does not exist. the correct Task program number. 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. Enter the correct Task program number.
Enter a Task program number
Check the input status of the external control signals and the teaching data
Troubleshooting
-3
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 .
+ + +
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 h a s not been installed. The software for welding monitor h a s not been installed. The software for PM8700 has not been installed. The software f o r Endress Rotation h a s not been installed. The software for Super Arc Sensor h a s not been installed. The manipulator overran.
Solution :f you want to use the optional function, ?urchase its optional software. Press the RESET key t o continue the
For details, see section 6.2.6.
1) A positioning instruction P is taught base on Work o r Tool coordinate system in the synchromotion system.
1) Modify the relevant instruction P t o a synchromotion instruction HP, o r t r y teaching based on the Base o r World coordinate system again.
EB10710-00XX DATA ERROR > RESET EC10206-XXXX COMUCTN ERR +POWER O F F
2) The panipulator is unable 2) Correct the taught positions(start/end points). If the manipulator is unable t o move a t a position on to move, correct the position d a t a of the path taught with a the relevant instruction in search Linear o r Circular mode o r by using the PC editing interpolation instruction. svstem. The Task program contains Delete the damaged instruction and add a n instruction. If the failure recurs, a damaged instruction. delete the Task program. F o r details, see section 6.2.7. Communication between boards cannot be made correctly.
-4
Troubleshooting
Code / Message EC10208-XXXX COM. ERR +POWER OFF EC10209-XXXX DPRAM ERROR POWER OFF EC10210-XXXX COM LSI ERR - POWER OFF > EC10403-XXXX CALC.ERR POWER OFF EC10504-XXXX DC24V ERROR POWER OFF EC10505-XXXX DC15V ERROR +POWER OFF EC10601-XXXX NO FILE +POWER OFF EC10603-XXXX PCB MISMATCH POWER OFF ECl0605-XXXX NO SYS FILE POWER OFF EC10801-XXXX ROM ERROR POWER OFF EC10802-XXXX RAM ERROR POWER OFF EC11301-XXXX I/O PORT ERR POWER OFF EC11401-XXXX TB LCD ERROR POWER OFF
+ +
Cause I/O management board or teaching box failure. Main board o r I/O management board failure. Motion control board failure. Motion control board failure.
Solution For details. see section 6.2.7
+ +
+
+
+ +
Replace the Motion control board.
DC24V power supply failure. Replace the DC24V power supply
1) DC15V power supply 1) Replace the DC15V power supply. failure. 2) Connector (CN24) is 2) Check the CN42 connection. disconnected. Data installation can not be For details, see section 6.2.8. performed correctly. SCON/PCON Board is not in place.Or, imperfect contact. Multi-synchromotion control data is not found o r is insufficient. Misplacement of EPROM, o r imperfect contact. The identified board o r RAM on that board is broken. 1/0 management board failure. Teaching box LCD failure. Check the SCON/PCON board connection. Install the system parameters again If not recoverd, contact DAIHEN. For details, see section 6.2.9.
Replace the mother board.
Replace the teaching box.
Troubleshooting
6 -5
Code / Message EC20101-XXXX MOTOR ERROR 3 POWER OFF
EC20102-XXXX AXIS SET ERR 3 POWER OFF
A 00201-XXXX SHOCKS ALARM 3 RESET A 00301-XXXX OVER RUN 3 RESET A 10301-XXXX TEMP. ERROR 3 RESET A 10404-XXXX CALC. IMPOS. 3 RESET
Cause The system parameter setting for motor is wrong, o r any setting of the SCON board rotary switches 3-5 is wrong. The system parameter setting for motor is wrong, o r the setting of the SCON board rotary switch 6 is wrong. The torch interfered in Auto mode but not during automatic operation. Overrun was detected during initial-diagnosis.
Solution For details, see section 6.2.10.
/ 1
1 ) / /
+
A 10502-XXXX CMOS BATTERY RESET A 10503-XXXX ABS BATTERY RESET
After initial diagnosis is completed, perform manual manipulation while holding down the SERVO ON button to escape from overrun. Turn off the control power supply and The temperature in the leave the robot as it is until the controller exceeded 60C temperature decrease below 60C 1) A positioning instruction 1) Modify the relevant instruction P to a synchromotion instruction HP, o r try P is taught base on Work o r Tool coordinate teaching based on the Base o r World system in the coordinate system again. synchromotion system. 2) The panipulator is unable 2) Correct the taught positions(start/ end points). If the manipulator is to move a t a position on the path taught with a unable to move, correct the position Linear o r Circular data of the relevant instruction in search mode o r by using the PC interpolat ion instruction. editing system. The voltage of the memory Save all the data by using the external battery dropped below 2.5V. storage.
I 1 1 1 1 /
A 10601-XXXX NO FILE RESET

+
1) Charge the battery, o r replace the charging battery. Be sure to perform the absolute offset adjustment. 2) Imperfect connection of 2) Check the CN47 connection. Connector(CN47). Data installation cannot be For details, see section 6.2.8. performed correctly. 1) The voltage of the charging battery dropped.
6-6
Troubleshooting
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
Cause The Task program contains a damaged instruction. Position deviation has occurred.
Solution Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. F o r details, section 6.2.11.
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
-.
Reset the encoders and perform the The absolute offset d a t a absolute offset adjustment. have been destroyed o r absolute encoders have not been reset. See the Arc Sensor instruction manual. 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 r a t e 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 ( S F l ) , the searching distance exceeded the specified maximum. During patterned search (SF2), the deviation exceeded the specified limit.
Troubleshooting
6-7
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
+
Solution Cause See the Arc Sensor instruction manual. During patterned search search (SF2), the searching distance exceeded the specified maximum. The SF2 file (Search Pattern file) contains a n 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 r e the same. Teaching of AS o r AE in the touch section. Communication with the a r c 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. Press the START button t o restart.
A 40102-XXXX WIRE STICK -+ RESTART A 40103-XXXX OUT O F ARC - RESTART . A 40201-XXXX WPS NOT RDY RESTART
Cut the deposited wire. After that, press the START button t o r e s t a r t welding. Press the START button.
6-8
+
+
The a r c is out.
A 40201-XXXX WPS NOT RDY RESET
The robot dedicated welding 1) Check the connection between the controller and the robot dedicated power unit o r welding power unit o r welding interface. interface h a s not been 2) Turn the robot dedicated power unit connected. ON. Turn the CONTROL POWER off and on Communication trouble again. between the robot and welding interface o r the robot dedicated welding power unit.
Troubleshooting
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 I AUTO I o r ALMEGA FUZZY AUTO. During automatic operation the wire was broken.
Solution Remove the cause of the problem of ALMEGA AUTO II o r ALMEGA FUZZY AUTO. Remove the cause. After that, press the START button.
-+
The g a s pressure is too low. Remove the cause. After that, press the Displayed only if a detector START button. is ~ r o v i d e d . There is no cooling water. Remove the cause. After that, press the START button. Create an Arc Start Condition file. The specified Arc Start Condition file does not exist. Create a n Arc End Condition file. The specified Arc End Condition file does not exist.
I
The specified Fixed Create a Fixed Patterned Weaving Patterned Weaving Condition file. Condition file does not exist. 1 Create an Axis Weaving Condition file. The specified Axis Weaving Condition file does exist. The specified Multi-pass Create a Multi-pass Welding Start file. Welding Start file does not exist. The specified Multi-pass Welding End file does not Create a Multi-pass Welding End file. exist. Create an Offset Condition file. The specified Offset Condition file does not exist. There is no Task program to call.
I
/ 1
Create a Task program to call.
There is no Task program to to jump to. There is no point mark to jump to.
1 Create a Task program to jump to.

Add a Point Mark instruction.
Troubleshooting
-9
Code / Message A 50110-XXXX C1 TEACH ERR RESET A 50111-XXXX C2 TEACH ERR RESET A 50112-XXXX COORD. ERROR RESET
+ +
A 50113-XXXX SAME POINT C RESET A 50114-XXXX 1/0 TIMER RESET

+
A 50120-XXXX CALL NESTING OVER -+RESET A 50201-XXXX S.LIMIT * * * * RESET A 50202-XXXX LNKS.LIMITM * - RESET . A 50401-XXXX ON TIME OUT RESET A 50402-XXXX O F F TIME OUT - RESET . A 50501-XXXX SERVO O F F -+SERVO ON
+
+
Solution Cause A circular a r c is formed by 3 points. There is no reference point Add a reference point. for the former half of a circular arc. A circular a r c is formed by 3 points. There is no reference point Add a reference point. for the latter half of a circular arc. Teach all 3 points in the same Teaching of the target and reference points for circular coordinate system t o form a circular arc. a r c in the different coordinate systems. Teach again to form a circular a r c can The target and reference points for a circular a r c a r e be made. the same. The number of timer c o u ~ l t s The max. number of timers that can count time a t one time during automatic exceeded 9. operation is 9. Check the setting time of each instruction of S, R, N, and F . Calling in the call destination program The nest h a s overflown due is possible, but limited t o the maximum t o program calls. 4 layers. Check the program. F o r details, see section 6.2.5. The robot h a s reached the software limit.
The robot h a s reached the link software limit. No ON input within the specified monitoring time. No O F F input within the specified monitoring time Turn the servo power supply ON. Servo ON when the mode was changed to AUTO. Or, the servo power supply was turned on before automatic operation o r after completion of the job. Perform manual operation t o move the Outside the S t a r t Enable manipulator t o within the S t a r t Enable Area. Area. Check the input s t a t u s of the external control signals and the teaching data.
1 /
A 50502-XXXX OUT O F START ENABLEAREA
-10
Troubleshooting
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
+
+
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 o r Shock Sensor Alarm, o r 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 t o 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.
I 10208-XXXX COM. ERROR 3 RESET I 10208-XXXX COM. ERROR + RESTART I 11202-XXXX LIMIT SPD. - RESET .
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 .
Cause Trouble occured in the CRT printed board. Communictation with laser sensor cannot be made.
Solution Trun off and on the CONTROL POWER.
Connect the laser sensor.
6- 1 2
+
+ +
--+
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 .

Troubleshooting
F o r details, see the Arc Sensor During seam tracking by instruction manual. the a r c 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.
Code / Message I 30301-XXXX CRT DISCNNCT RESET I 30302-XXXX CRT INVALID + RESET I 40201-xxxx WPS NOT RDY + 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 T o use CRT, turn on CRT first, and then the controller. Push RESET key.
1) Check the connection between the controller and the welding interface.
I 40301-XXXX OUT O F WIRE + RESET
2) Turn the robot dedicated power unit ON. Supply the wire.
Troubleshooting
-1 3
Table 6.3 Failure Messages Failure Message Solution Cause Failure was detected a t For details, see section 6.3.2. 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. Turn off the control power supply Control program failure. and then on again. If this failure recurs, note down the information displayed on the teaching box and contact DAIHEN. Note down the information Control program failure. displayed on the teaching box and contact DAIHEN.
COM DATA ERR XX-YY XX: 03 o r 85 YY: 01 - 05 SVC error
6-1 4
Troubleshooting
6. 1
Symptoms
Nothing Appears on the Teaching Box
6.1. 1
I
Nothing appears on the teaching box and all LEDs on the keyboard a r e OFF. Primary power supply indicator lamp OFF. (ON in the normal state) Cooling fan not rotating No primary power
Action
Check the voltage of each phase of the primary power supply
t
I-
/ LEDs of
constant power u n i t ( 5 ~ ,
I voltage
Loss of V phase (wire 5) of primary power supply
I flickering palely. 1
H constant / 1 power unit(5V. I 1 primary power
I1
LEDs of
I Loss of W phase 1 voltage H(wire 6) of
II
'-II
k15V 24V) a r e om. All LEDs on Interlock board a r e OFF. (In normal state, LEDs 301, 302, 1C 304, 601, 602 and 603 a r e ON.) Imperfect contact of interlock board CN41 - constant voltage power unit N41.
1i_
1
Check the flat cable connection and connect it properly.
I Replace the cable.
/ Interlock board 1 failure.
UReplace the interlock 1 1 board.
Troubleshooting
6-1 5
Imperfect con tact of backplane board F C l l interlock board FCll
Check the flat cable connection and connect
/ Replace the cable.
I to teaching box.
6.1.2
The Display on the Teaching Box Is Unsteady
Check 24V of interlock board.
The display of the teaching box is unsteady and flickers.
I
/
Red LED on Servo Control board ON
4Low voon -
/ primary power
1 I
/
I1
supply (below AC 150V)
'
Check the voltage on the primary power
1 servo driver
flickering
6-16
Troubleshooting
6. I . 3
I n i t i a l Diagnosis Is Not Completed
1 Symptom 1
The display "START DIAGNOSIS" stays on the "COMUCTN ERR" ( Communication error) is displayed a t the right top of the teaching box screen. Nothing is displayed a t the right top of the teaching box screen.
I
4 Refer to 6.2.7 in this
art.
Action
I/O management board failure
- Check that I/O management board is connected correctly.
+
I management board.
1 Replace the 1/0

1
The teaching box display stops a t step1 of initial
"NO FILE" is displayed a t the right top of the teaching box screen. Nothing is displayed a t the right top of the teaching box screen.
4 Refer to 6.2.8 in this rsart.
- I/O
management board failure
L
Replace the 1/0 management board.
Check that 1/0 management board is connected correctly.
Troubleshooting
6-1 7
"NO FILE" is displayed a t the right top of the teaching box
4 Refer to 6.2.8 in this part.
Nothing is displayed a t the right top of the teaching box screen.
Motion control board failure
- Check that Motion

control board is connected correctly. Replace the Motion control board.
The teaching box display stops a t step3 of initial diagnosis.
"NO FILE" is displayed a t the right top of the teaching box screen.
Refer to 6.2.8 in this part.
"WPS NOT RDY" is displayed a t the right top of the teaching box screen.
Welding interface o r robot dedicated welding power unit not connected.
Check that the welding interface o r robot dedicated welding power unit is connected correctly. Turn on the robot dedicated welding power unit. Check that 1/0 management board is connected correctly.
Robot dedicated welding power
I/O management
board failure
Replace the I/O management board.
-1
Troubleshooting
1 Symptom 1
Check Item
I Possible Cause I
Refer to 6.2.8 in this part.
I Action
"NO FILE" is displayed a t the right top of the teaching box screen. "A.S.TRNS.ERRnis displayed a t the right top of the teaching box I screen. I
Arc sensor unit not connected.
Check that the Arc sensor is connected correctly. Turn on the Arc sensor unit. Check that Arc sensor
Arc sensor unit OFF Arc sensor unit failure
1 Replace the Arc sensor /

unit.
Troubleshooting
6-1 9
6.1.4
The Servo Power Supply Cannot Be Turned ON
I
The servo power cannot be turned on.
-
Action
contactor MS1 not ON

P
Electromagnetic contactor MS1 failure

- Low
- Replace
1
----
the electromagnetic contactor MS1. Check the voltage on the primary power
Interlock board LEDs 203/301/ 303 O F F (ON in the normal condition)

I
voltage on
primary power supply(3-phase 200 V) (Below AC150V)
'Supply.
Red LED on each Servo Control board ON (only green ON in the normal condition)
1 1 in the normal
LEDs on each Servo driver ON
I
I
I condition)
/ Motion control 1
/ board O F F (ON
condition)
I
1 in the norm-a1 /
LED 303 on Interlock board ON (OFF in the normal condition)
I -4
Motion control board failure
6-2 0
Troubleshooting
6.1.5
The Servo Power Is Shut OFF Immediately When T u r n e d ON
(Symptom (
Check Item
( Possible Cause (
Action
I
1
1 The servo
power is off while "SERVO ON" stays on the teaching box screen.
t shut
1
LEDs 101/301/ 303(green) on Interlock board OFF (ON in the normal condition)
1 board failure
1 1 is in place.
Check that each board
Replace faulty board.
/ board failure
Main board failure
LEDs 101/301/ 303/ 203 ( green ) on Interlock board OFF (ON in the normal)
board failure
Troubleshooting
6-2 1
6. 1 . 6
Manual Manipulation Does Not Function

Check Item
1 Symptom 1
1
1
I Possible Cause I
/
Bad connection of motor line
Action
1 Only
one axis of axes 1 - 6 can moves by manual manipulation.
1
Able to move axes 1/2/3 by manual
Disconnection of motor line Motor failure
'i
Replace the cable.
Check the connections of servo driver connectors CN51-56.
Replace the motor.
Only axes 4/5/ 6 move by manual
1 1
-
No power supply to axes 4/5/6 servo drivers
I-
Check the connections of servo driver connectors CN4, CN6, and CN8. Replace the cable.
None of axes 1-6 moves by manual
CR3A/CR3B contacts on Interlock board OFF (ON in the normal condition)
Bad connection of motor line
---
Check the connection of control cable 1. (Manipulator-side CN1)
~ i s c o n n e c o f H Replace the control cable 1.(Manipulator motor line -side CN1) Set the machine lock function OFF.
1 function set ON 1
-2
Troubleshooting
6. 2
Failure Codes and Failure Messages 6.2. 1 The Display o f A Failure

If a failure occurred, a failure code and a failure message a r e displayed on the teaching box.
[Example] Emergency Stop
EAOO 1 0 1 - 0 0 0 1
EMERGENCSTOP +RELEASE
+Failurecode
+
Failure message
A failure code is displayed in the following format:
a: Indicates the severity of a failure ( E r r o r , Alarm, o r Information).
E r r o r (EA/EB/EC) The E r r o r class includes failures, such as failures of p a r t s and internal d a t a , 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 t o E r r o r s unless measures a r e taken soon, o r which require a simple operation, check, o r action before the operation is carried o n though they may not cause h a r m t o 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 t o continue the operation, o r which can develop t o Alarms later.
Troubleshooting
6 -2 3
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 t o 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 t o 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.
F o r unit codes, see Table 6.4.
e: Indicates the mode (called a mode code) o r detailed information of the failure.
F o r mode codes, see Table 6.5
6-2 4
Troubleshooting
Table 6.4. Unit Codes Code 0 0 0 1 02 0 3 0 4 0 0 0 0 0 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 3 3 3 3 3 3 3 3 3 5 6 7 8 9 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 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 PCON/SCON board 1 PCON/SCON board 1 PCON/SCON board 2 PCON/SCON board 2 PCON/SCON board 2 PCON/SCON board 3 PCON/SCON board 3 PCON/SCON board 3 PCON/SCON board 4 PCON/SCON board 4 PCON/SCON board 4 PCON/SCON board 5 PCON/SCON board 5 PCON/SCON board 5 PCON/SCON board 6 PCON/SCON board 6 PCON/SCON board 6 Code 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 9 9 9 9 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 0 1 2 3 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
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 7 Axis 8 Axis 9 Axis 10 Axis 11 Axis 12 Axis 13 Axis 14 Axis 15 Axis 16 Axis 17 Axis 18
Note) PCON: Position control board
SCON: Servo control board
Table 6.5. Mode Codes Code

1
Mode
I
Function Diagnosis
Teach
I
I
Teaching
1 0 2 0
Auto
Remote control
Troubleshooting
-2 5
6.2.2
Logical Outputs f o r Failures

Failure output ports a r e provided to inform external devices of the cause, severity,
and solution of a failure:
Table 6.6 Logical Outputs for Failures Name

I
Logical Output Port No. 0 2 0 1 0 2 0 2 0 2 0 3 0 2 0 4 0 2 0 5 0 2 0 6 0 2 1 1 0 2 1 2 0 2 1 3 0 2 0 8 0 2 0 9 0 2 7 0 0 3 7 0-03 7 4
Urgent Failure Control Failure Servo Failure Peripheral Equipment Failure Welding Failure Operational Failure Error Alarm Information ABSO Adjust Request Reset Reauest Start Request Failure Code
For details of these output ports, see the instruction manual "Interface With Jig".
6-2 6
Troubleshooting
6.2.3
Shock Sensor
Shock Sensor is a failure which occurs when the torch hits a peripheral jig.
/I
1
1
Shock Sensor Error (during automatic operation)
SHOCK-S ERR
+
RESET
II I
I
Error or Alarm)
Shock Sensor Alarm (in Auto mode but not during automatic operation)
/
*
SHOCKS ALARM
/ -. RESET
Shock Sensor Information (in Teach mode o r during an escape from Shock Sensor
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.
Troubleshooting
6 -2 7
6.2.4
Servo Power Shutoff

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.
This failure occurs when:
The output form of failure varies with the setting of the user parameter "ABNOMALTY ENCODE" * available for setting the teaching box key status.
Table 6.7 Differences of Output Form according t o Special Failure Output ON/OFF Setting ON Display of Failure Cancellation Output Signal
EA00401-01XX SERVO DOWN
1
1
Automatically erased after being output for 2 seconds.
Failure Code(0374-370) (Automatically reset after being output f o r 2 sec.)
OFF
/ SERVO DOWN 1 Reset input.

+
EA00401-01XX
By the RESET key o r Urgent failure (0201)
/ E r r o r (0221)
( ~ e f a u l t ) RESET
1 Failure Code (0374
1 Reset Request (0209)

-
370)
Solution
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 c a r r y on the operation you a r e 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 t o avoid interference with the jig.
*
6
: See "Setting Teaching Box Keys", section 2.2 in P a r t I[.
-2 8
Troubleshooting
The "ABNOMLTY ENCODE" ON setting affects the signals being output when the following failures occur:
Emergency Stop
p6zFEG-l
If the setting is ON, Urgent Failure (0201) and Error (0211) a r e not output.
1 EMERGENCSTOP 1
*
Servo OFF If the setting is ON, Operational Failure (0206) SERVO OFF and Alarm (0212) a r e not output.
6.2.5
Software Limit/Link Software L i m i t

This failure is detected when the mechanism attempts t o move out of the working
(1) Software Limit Failure
area.
Teach mode
Auto mode
S.LIMIT XYZZ +MANUAL OPE.
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
Troubleshooting
6 -2 9
(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 t o 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
Auto mode
LNKS.LIMITM
+MANUAL OPE.
YY: Axis numbers (For example, if "23" is displayed, this indicates t h a t Link
Software Limit h a s occurred a t axes 2 and 3.)
Solution
(A)
Teach mode Perform manual manipulation in the direction which allows the Link Software Limit t o 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 t o be cancelled.
6-3 0
Troubleshooting
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 J P 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.
( ) The fuse on the Interlock board is blown C

->Replace the fuse.
0)Interlock board failure.

-+Replace the Interlock board.
Troubleshooting
6 -3 1
6.2.7
Communication Failures
This failure occurs when communication cannot be performed correctly between boards. EC10206-YYXX COMUCTN ERR
+
(1) Board T o Board Communication Failure
POWER OFF
YY : 0 1
02
-.. Main Board - Motion Control Board Communication Failure
-.. Main Board - 1/0 Management Board

Communication Failure Main Board
-
03
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 o r 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
: 0
YY
-.. Main Board - 1/0 Management Board.

Main Board
-
0 3
6 -3 2
Troubleshooting
Teaching Box
Solution
0 YY:O2
Replace the I/O management board.
63) Y Y : 0 3
Replace the teaching box.
(3) DPRAM Failure

This is Main board or I/O management board failure.
/ DPRAM ERROR
I
+
EC10209-YYXX
POWER OFF
II
-
YY : 0 0
0 2
Main board
Motion control board.

-
Motion control board
I/O management board
Solution
(A)
YY:OO
Replace the Main Board.
63) Y Y : 0 2
Replace the 1/0 management board.
Troubleshooting
-3
6.2.8
Data Installation Failures
This failure is detected when d a t a (files) necessary to operate the robot d o not exist. If this failure is detected, it is necessary t o create a required file with the System Initialize function.
(1) Data Installation E r r o r

EC10601-YYYY NO FILE
+
POWER O F F
:
YYY Y
0 10 0 0 10 1 0 10 2 0 2 0 0
... Can't find System Parameter file. ... Can't find Manual Operating Speed Table file. ... Can't find Block Operating Speed Table file.
-.. Can't find Sequencer file.
Solution
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 r o m 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.
( ) YYYY: 0200 D
Select the "SQ" function key with the System Initialize function and create a Sequencer file.
6
-3
Troubleshooting
(2) Data Installation Alarm
A 10601-YYYY
NO FILE
+POWER OFF
YYYY : 0 2 0 1
... Can't find Welding Characteristic Data file.

Can't find Welding Control file.
0202
0 2 0 3 ... Can't find Current Conversion Table.

8 100 8 40 0
... Can't find Arc Sensor file.

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:8 0 10
Select the "ARC-S" function key with the System Initialize function and create a Arc Sensor file.
(C) YYYY:8 0 40
Select the "LASER-S" function key with the System Initialize function and create a Laser Sensor file.
Troubleshooting
6 -3 5
6.2.9
Memory Failures
This failure is detected when the EPROM o r board is broken o r the wrong EPROM
(1) R O M Failure
is inserted
/ ROM ERROR
-+POWER OFF
YY : 0 0
01
02
0 3
- a .
Main board Motion control board
-.. 1 / 0 management board ... Teaching box
Solution
Replace the EPROM on the identified board o r that board itself
(2) RAM Failure
The identified board is failure.
RAMERROR +POWER OFF
YY : 0 0
01 02 03
Main board Motion control board 1/0 management board
...
Teaching box
Solution
Replace the identified board.
6 -3 6
Troubleshooting
(1) M o t o r Setting Failure

This failure occurs when the system parameter setting for motor type differs from the SCON board setting for motor type. EC20101-XXXX
Solution
Turn off the control power supply, set the rotary switches SW 3 - SW 5 on the SCON boards t o the correct values. The following table shows the SCON board r o t a r y switch setting for each mechanism: Table 6.8 Rotary Switch Settings f o r Axis Motors of Manipulator
6.2.10
Setting Errors
MOTOR ERROR POWER O F F
1
Manipulator G01/G03
SCON for Base Axes
1~
0
O Wrist~Axes N
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 SW3 4 SW4 4 SW5 2 SW3 SW4 0 SW5
-
V40 WO1
SCON not in use f o r V40
Table 6.9 Rotary Switch Settings for Slider Motor Slider PSB series RSR series Relevant switch setting of SCON SW3 t o SW5
4
Troubleshooting
-3
Table 6.10 Rotary Switch Settings for Positioner Axis 1 Relevant switch setting of SW3 -SW5 RPH-2 0 0 RPH-5 0 0 RPH-1 0 0 0 RPlS-1000 RPlD-200 RPlD-500 RPlD-1000 RP2T-500
1
Axis 2 Relevant switch setting of SW3 -SW5
8 8 8
4
8 8 8
(2) Axis Setting Failure
This failure occurs when the SCON board rotary switch setting for the number of controlled axes is wrong. 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 correct value. The following table shows the SCON board SW6 setting for the number of controlled axes : Table 6.11 SCON Board SW6 Settings for the Number of Controlled Axes
-
SW6 Setting 0
Controlled Axes
-3 8
Troubleshooting
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 a r e 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 r e correct.
: Refer to "Setting the System Status", section 2.1 in part
II
Troubleshooting 6
-3
6. 3
When Servo Failure Occurred

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.
6.3.1
Message (not displayed in some cases) Failure information codes
SERVO ABN 8 MECHAl UNIT 1 : UNIT 2 : UNIT 3 : UNIT 4 : UNIT 5 :
+-Failure category No. +-Message
AXS2 ENCODER ABN.
0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 0000 Failure information codes
t
Column :
a
T
b
f
c
t
d
Fig.6.1 Example of Servo Failure Display
-4
Troubleshooting
(1) Failure Category No.

When Servo Failure occurred, the Teach Pendant displays the following:
"SERVO ABN
**
"
A number is displayed a t a s shown in Table 6.12:
"
* * ", by which the detailed failure can be identified
Table 6.12 Failure Category Nos.
**
3
4
Name of Failure Servo Control Board error
Meaning Failure was detected a t Servo Control Board.
CPU failure of SCON Board Servo power shutoff
Servo Control Board malfunctioned. Servo power was shut off due to unknown cause.
6 Overheat in the Control Unit 7 Servo Driver failure
The temperature extremely increased in the control unit. Failure occurred in the Servo Driver Unit (For details, see Table 6.14 and 6.15)
Position output failure
Failure occurred in the Servo Driver Unit. (For details, see Table 6.14 and 6.15)
Abnormal position/speed 10 loop ON state
The Servo Driver cannot be energized.
Beyond the position deviation The position deviation exceeded the set 12 limit Beyond the speed command 1 3 limit Beyond the current command 1 4 limit Failure a t the servo startup value. The commanded speed exceeded the set value. The commanded voltage exceeded the set value. Failure occurred when the servo power was turned on.
99
Troubleshooting
-4
(2) Message (not displayed in some cases)

For Servo Failure 8 "Servo Driver Unit failure", a message and failure information codes a r e displayed t o give more detailed information.(These information may be also displayed for othe failures.) The content of a message corresponds t o the failure information codes, and is displayed as shown below. If multiple failure a r e 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 t o 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 * - MECHA *
-
* AXS MOTOR 0-HEAT(Motor
Overheat a t Mechanism * Axis * Failure a t Mechanism * Axis * )
* AXS ENCODER ABN.(Encoder

* AXS POWTR.0-HEAT
MECHA * MECHA *
(Power Transistor Overheat a t Mechanism * Axis * )
* AXS OVER CURRENT(0ver Current a t Mechanism * - MECHA * * AXS CURRENT ABN.

-
Axis * )
(Instantaneous Current Limit Over a t Mechanism * Axis * ) MECHA * MECHA * MECHA *
* AXS OVER LOAD (Over Load a t Mechanism *
Axis * )
* AXS OVER SPEED

(Speed exceeding detectable limit a t Mechanism * Axis * )
* 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 * )
6 -4 2
Troubleshooting
(3) Failure information codes

The abnormal p a r t can be identified from Fig.6.1, as shown in Table 6.13:
Table 6.13 Interpretations of Codes 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 P a r t common
to each axis
b
c Failure of Axis 2 Failure of Axis 5 Failure of Axis 8 Failure of Axis 11 Failure of Axis 14
Failure of Axis 1 Failure of Axis 4 Failure of Axis 7 Failure of Axis 10 Failure of Axis 13
Failure of Axis 3 Failure of Axis 6 Failure of Axis 9 Failure of Axis 12 Failure of Axis 15
Failure of P a r t common t o each axis Failure of P a r t common to each axis Failure of P a r t common t o each axis
0000 indicates that that part is normal, while any number (displayed in the hexadecimal notation) except 0000 indicates that that p a r t is not normal. Furthermore, the detailed failure can be identified by the number.
Troubleshooting
6-4 3
a ) Failures Common t o 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:
Table 6.14 Common Failure Codes Code 0001 0002 0004 0008 Meaning
Overvoltage of Main power Undervoltage of Main power (Main power off) Disconnection of Inverter signal line Failure of A/D signal line +This bit sometimes indicates that the servo power is shut off, and in that case not failure.
1
1
0100
Input of Stop signal
Codes in Table 6.14 a r e 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
O O : Disconnection of the inverter signal line (0004H) and failure of the A/D OC signal line (0008H) of the first Servo Control board (0004H
+ 0008H)
-4
Troubleshooting
b ) Failure Codes of Each Axis When a number, except 0000, is displayed a t column b, c, o r d in Fig.6.1, a failure can be identified from Table 6.15:
Table 6.15 Failure Codes of Each Axis Code 0001 0 00 2 0 0 04 0 0 08 0 0 10 00 2 0 0 10 0 0200 Meaning
I 1
1
Motor overheat Encoder failure Overheat of power transistor Overcurrent Over limit of momentary current Overload Over limit of detectable speed Over limit of position deviation
I 1 1
Codes in Table 6.13 a r e 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)
Troubleshooting
-4 5
6.3.2
Troubleshooting for Servo Failures
I
(
Action
Servo Failure 3 SCON board error
// 1
F codes not "0000"

~ l failure c l showing "0000"
1
d e s H
servo system
1 Refer to (3) of section 6.

3.1 to remove the cause.
v Take some measures to

protect from noise. Check that the Servo Control board is in place.
u
Servo Failure
-
CPU failure of SCON board
Red LED ON and green LED OFF on Servo Control board
/ of Servo Control 1 /
1 board.
Servo Control board failure Problem of system parameters
Replace the Servo Control board.
ti Instal1 the system

parameters again. Take some measures to protect from noise. Make sure that the
servo system
m
Servo Failure Servo power shutoff
Red LED on Motion control board ON
1 placement of
Motion control
/ 1 Motion control board 1
I is placed correctly.
/ board o r Servo
Control board failure
1 1 control o r Servo 1 Control board.
Replace the Motion
1 i
-4
Troubleshooting
1 Symptom 1
1 Control board 1 I / primary power

I and Servo driver I
supply (below AC
Verify the voltage on the primary power supply
100V outlet
r i
Servo Failure
-
Overheat in the controller
Temperature in the controller over 60C.
Cooling unit failure
Replace the cooling unit.
/ over the allowance

the controller under 60C.
Use within the allowable temperature. Replace the Backplane board.
/ element failure
Troubleshooting
-4 7
r
Servo Failure
Servo driver failure Display of Servo Failure on teaching box r-----------------:SERVO ABN 8
x
1
Power supply indicator lamp
Loss of U phase
Verify the voltage on
1 1 1 (wire 4) of
I primary power
supply ( 3 - ~ h a s e
I I side phases before
1 each of the primary
UNITl : and
Replace the breaker. "UNIT1 LACK VOLTAGE " at Q,"0002" a t UNITl@, and o Imperfect*c of cable connecting servo driver CN1 for axis shown by "000C" or "0002" and Servo Ctrl. board CN2, or cable connecting servo driver CN2 and power unit Make sure that the cable connection is correct.
I Replace the cable.
@ shown
/
INVRTR" a t , "000C" a t UNITl @ a , and "0002" a t UNIT2 @
1
I
1 shown
"UNIT1 LACK VOLTAGE" a t Q , and "0002" a t UNITl @ and
[LED 3 0 1 on relay unit ON
0 Motion control ~ board failure
I 1
-4
Troubleshooting
I Possible Cause
Action
4"UNIT2 LACK 1
"0002" a t UNIT1 @, and UNIT2 of control cable 2 (manipulator CN2 and CN7 on Servo
Make sure that the control cable connection is correct. Replace the cable.
-4
of cable connecting CN6 on Servo Control board 1 and switch box CN135
+
/
Make sure that the cable connection is correct. R.enlace the cable.
Replace the Switch box "UNIT1 LACK VOLTAGE" a t @, "0002" a t UNITl@@@ and UNIT2 @ shown Imperfect contact of control cable 3 (manipulator CN3 and CN7 on Servo Control board 2) Imperfect contact of cable connecting CN6 on Servo Control board 2 and switch box CN 136
1
1 1
---( Make sure that the
1 / Replace the cable.
L
connection is correct. Replace the cable.
1 control cable
-4 sure that the Make

1 cable connection is
I correct
L
Replace the Switch box
Troubleshooting
-4
Possible Cause
I I AXS OVER
"0020" a t any of UNITl and UNIT2 @@ @ shown
I- -ME'
1 pr m eof moter line
1 I
1
Make sure that the control cable connection is correct. Replace the cable.
m,
Disconnection of motor line
"MECHA10 AXS CURRENT ABN" a t @ "0010"at any of UNITl @@$$ and UNIT2 @@$$ shown "MECHAI 0 AXS OVER CURRENT" current a t @, and "0008" a t any of UNITl @ @@ ,and UNIT2 shown
4 Wrong dip switch

I Control board
I setting on Servo I / setting and set

1 correctly.
Check the dip switch
- Fuse
blown by over current flow to servo driver
Check the fuse. Replace the fuse
-5
Troubleshooting
ISymptom (
"MECHA1 O A X S OVER DEVIA T." a t @and "0200" a t any of UNIT1,and UNIT2 shown
I Possible Cause I
I
I
Action
I
I
The origins of mechanical stopper and software limit
I I
Perform absolute offset adjustment.
- Imperfect contact of encoder cable
- Check the encoder

cable connection of that axis. Replace the encoder cable. Replace the motor.
1 encoder cable
Motor failure
Disconnection of Replace the cable. motor line -
--(
"UNIT1 STOP INVRTR" a t @ and "0004" a t UNIT@ shown
h Imperfect contact
I
-
of flat cable connecting Servo Control board and servo driver Disconnection of flat cable Servo Control board failure
Check the flat cable connection.
I
Replace the flat cable.
1 I
"UNIT2 STOP INVRTR" a t @ and "0004" a t UNIT2 @ shown
/ 1
1 I
Make sure that the Servo Control board is placed correctly.
[ failure
Replace the servo driver.
Troubleshooting
-5
"MECHA1 0 AXS OVERCURRENT' a t Q. "0008" and a t any of UNITl shown "MECHA10 AXS CURRENT ABN." a t @, and "0010" a t any of UNITl @@@ shown
+ El
Blown fuse on servo driver o r robot overrun Check the fuse.
Replace the fuse

I
1 Cancel the overrun.
Wrong flat cable connection between Servo Control board and servo driver (Base axes)
"MECHA1 0 AXS CURRENT and ABN." a t Q, "0010" a t any of UNIT2 @@@ shown All detail codes showing "0000"
-
,
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.
Servo driver failure
6-5 2
Troubleshooting
ISymptom I
Action
Both red and green LEDs on Servo Control board ON
Servo system failure
Refer to (3) of section 6. 3.1 to remove the cause.
Only green LED on Servo Control board ON
I1
/
II
- Overload
0-HEATVat@, and "0001" a t any of shown
on the manipulator
Reduce the load.
I
1
Defective adjustment to the driving mechanism of the machine Motor failure
Check the machine.
I
I
"ENCODER ABN"at @ , and "0001" a t any of shown
I1
Replace the motor. Check the encoder
IH
'
II
of encoder cable and connect correctly.
cable connections
I encoder cable.
ATJ' a t @ , and "0004" a any of failure.
Replace the encoder
I I cable.
Troubleshooting
-5
I Symptom 1
I
Check Item
I 1 1
-
I Possible Cause I
Problem of system parameters Blown fuse on Interlock board Noise affecting the system
All failure codes showing "0000"
Re-install the system parameters. Replace the fuse.
Take some measures to protect from noise. Check the connections of Servo driver connectors CN5 1- CN56.
r 2 1
Servo Failure Beyond the position deviation limit
None of Axesl- 6 operable by manual
Imperfect contact of motor line
Failure a t highspeed operation Servo Failure 13 Beyond the speed command limit
----
-4 large load Too

- Problem
Reduce the mechanical load.
Failure a t highspeed operation
I
/
I
of system parameters
- Re-install
the system parameters.
1 6 operable by
manual manipulation
Imperfect contact of motor line
Check the connection of the motor power line.
1 1
Noise affecting the system Too heavy load
HTake some measures t o 1

I protect from noise.
Reduce the mechani cal load. Take some measures to protect from noise.
Servo Failure - Failure when starting 14 operation Beyond the current command limit
Noise affecting the system
Troubleshooting
6 -5 5
Servo Failure
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.
6-5 6
Troubleshooting
H i e r a r c h i c a l D i a g r a m o f F u n c t i o n key
1
1.
--IF1 -IF2 -IF3 --IF4 --IF5
Hierarchical Diagram of Function key
Function keys shown following
Even a function of a n option is included.
D 0
a r e displayed by pressing the Next Candidate key.
TEACH
TEACH EDIT FILE ALLOT LOCK
(1. 1) (1. 2) (1. 3)
,.....--..-----.....
I Function under development
1 I I I
1 1
-1~1 PARMTER~ (1. 4)
-IF2 --IF3 -IF4 -IF5
CHECK MANAGE
(1. 5) (1. 6) (1. 7) (1. 8)
SYS. SET] MEMORY ]
1.1
TEACH
IF1 PRG LIST NO. F2 F2 ROLL ROLL UP DN F1 SEARCH [ ~ Sl M A R K ] Q IF2 AS/AE
F 3 WS F1 RENAME IF5 P A T H AT] F4 (F5 ST/ET SF*
When the number exists
"
SEARCH jr1Fl
REVERSE; S Q MARK
t,
(F2 F3
CL/JFJPI T
t 1 ~ 2U M P J
t ( F 2 AS/AE I F 3 WS F4 ST/ET SF*

1/0
1 1 I
IF5 IF1 IF3
PATH ASM
AT1 SET1
IF5
JCY
IF1
I 1 I
REVERSE]
(F2 CL/JFJP] IF3 T
[F2 IF3 IF5 [El IF2 IF5 IF1 -12.2
HL HC HC HLO HO HO MPS MPE EP CHG. CHG.
I
I
I
I I I
1/0
[El IF2 IF3 IF4 IF1 F 2
SET RESET INP INP SNR SFR CL ON OFF
IF2 F 3
-IF3
B R A N C H /-IF1
cL
F 2 CL
ON OFF CNT
(F3 CL IF4 IF1 IF2 IF3 F4 --IF3 J F IF1 IF2
UNCOND J P J P J P ON OFF CNT
1 1 I
I
/
UNCOND J F J F ON OFF CNT
1
1
(F3 J F F 4 - 1 ~ 5
UNCOND
COUNTERI~I;;
;;;
I I
--IF4
WELD
[El
AS
NUM.] NUM.
1 ~ 2 E A 1F3 A S IF4 AE
FILE] FILE]
IF2 IF1 IF2 F 3
AEM ICH RIC
GS
I
[Fl IF2 IF3 IF4 F 5 IF1 FP FP AX AX WE TIMER NUM.1 FILE/ NUM.
I
1 I
FILE]
When a Sensor selection i s a line master.
When a Sensor selection i s a laser sensor.
IF4
ZON ZOF RT
IF5
-IF3
ENDLEsslTIFl
aF2 R R N .-------..------.-..
r.----...--....-----
r.-..---.-.---..----
.---.-...-.---...--. 88'3 R R F
1.2
jF2
EDIT
EDIT
1-
IF1
TEACH
1-/~1
LIST [PRG NO.
F1 F2
ROLL ROLL
UP DN F1 SEARCH 1 ~ 1S Q M A R K / IF2 AS/AE
F 3 WS F4 LF5 PATH
AT/
ST/ET SF*
[F5
1 1
/
When the number exists

-IF2 -IF3 -IF4 JUMP SHIFT PATH
IFI
SQ
MARK^
/
/FZ CL/JFJP] IF3 T
1122 A S / A E
I F 3 WS [F4 IF5 ST/ET SF*
1
1
- 1 ~ 5 P A T H AT/
-IF3
REVERSE] F3 T P
When the number dose not exist ----p ---l 1 MOTION
F1
IF2
HL
( F 3 HC IF5 [FI IF2 IF5 IF1 IF2

1/0 $1
1
CHG.1
HC
HLO
1
1
CHG.
HO HO MPS MPE EP
I
I
SET
RESET INP INP SNR SFR ON OFF
IF2 F3
IF2 IF3 IF4 IF1 F2
-IF1
CL
-IF2
J P
Ill
[F2 IF3 F4
/FI
IF1
CL CL
ON OFF
1
/
CL
CNT ]
UNCOND ON OFF CNT
J P
1 I
IF2 F3 L ~
J P J P
I
/
]
~ NCOND U 4 J F J F J F ON
IF^
IF2 IF3 IF4
OFF j CNT
UNCOND DEF DEC
T
1F 2 A E
IF3 IF4 AS AE NUM.
E l
F2
FILEJ
FILE]
IF2
AEM
J 1
I
IF2 IF3 F4 -IF5 WEAVE IllFl [F2 IF3 IF4 F5
RTC GS GE FP NUM.
1 1
I
I
I
EP
AX AX
WE
FILE) NUM.
FILE]
f i e n a Sensor selection i s an arc sensor.
1
When a Sensor selection 1s a laser sensor.
(F4 Z O N IF5 Z O F - 1 ~ 3 ENDLESS] -IF2 WS FILE] IF1 F I X E D
..--..-...--..------- iPS...w-iid..P.i-R-i.; LF.2--.FRE-Q: j .--..
1:'
;F-Z.-RRN-.-. -.-.-..---...-.-------:F.?-.RRF .....--RT
.-.....-.......-----
-[F4
AS
FILE/
LF.?--.P-!T-C.H.. . I
IF4 J O I N T
......-...--.....--..
--IF5 A E
FILE/
IF3
OFFSET SQ
LASER-$
I
I-----INO. ENTRY
IF4
IF5
F2
AEM
-IF1
INPUT
Ill
F4
IF2
F3
/FI
ROLL
UP] DN]
/FZ R O L L
[F3 NOP/MAP/
bit
I
UP] DN]
IF1 R O L L
ROLL
-IF2
OUTPUT
NOP/MAPI
L~F4 bit
1
UP]
DN]
I F
IF5
TI
IF2
F5
IF1
ROLL
ROLL
END
SQ
J
I N
END
IF4
spEclA
I
IF2
[El
IF2
OUT
Il ITl
F4
/El
IF2 IF3
IF1
ROLL
UP]
DNI
ROLL
IF3 NOP/MAP]
bit
ROLL
UP]
ROLL
DN]
NOP/MAP]
IF3
ANL
-IF5
END
Qs
F4
bit
[El
ROLL
UP] DN/
IN
[F2 R O L L
IF3
NOP/MAP]
IF1 R O L L UP]
IF2
IF3
ROLL
DN]
NOP/MAPI
F4
bit
1.3
FILE
/F3 F I L E
1-
-/El
TEACH
E l
ROLL
UP
IF1
S Q MARK1
F 3 E l --IF2 WELD IF1 RENAME ROLL F4 IF5 P A T H AT] p 5
WS ST/ET SF*
UP1
IF3 [F4 IF5
EDIT COPY DEL
] ~ REVERSE] 3
F 3
WEAVE LF2 IF3 IF4 IF5 E l ROLL EDIT COPY DEL RENAME DNI
[F3 IF4 IF5 F 1 IF1 IF2 IF3 [F4
EDIT COPY DEL
IF1 IF2 F 3
ROLL ROLL
UP1 DNI
1 I
UP] DN]
NOP/MAP]
RENAME ] ROLL ROLL DISP COPY
L / ~ 4 bit
I
UP1 DN]
[F5 DEL IF1 -IF1 OFFSET J IF1 $2 rF3 IF4
1 1 I
UP] DNI
--IF2
OUTPUT
RENAME ] ROLL ROLL EDIT COPY
-IF3
-IF4
TI
Ill
IF2 F 4 [El IF2 F 5
[Fl
ROLL
ROLL
[ F 3 NOP/MAP]
bit
I
UP/ DN]
ROLL ROLL END
I
IF1 ROLL UP/ DN] fF2 ROLL IF3 F4
SPECIAL
NOP/MAP/
[F5 DEL F 1 IF1 IF2 IF3 IF4 RENAME ROLL ROLL EDIT COPY
bit
1
DN]
UP]
DN]
F 3
DEL
-IF3
ANL
IN
]II
[El ROLL [F2 ROLL F 4
ll
IF2
ROLL
IF^
NOP/MAP/
F4
bit
1
UP1 DNI
1 ~ 3 OP/MAP] N
b i t
IF1
ROLL ROLL
UP] DN]
[F2 IF3
NOP/MAP]
-IF4
[ !TO U
F4
bit
1.4 PARMTER
IF1 IF2
SYSTEM SWITCH
IF3 W E L D IF4 IF5
1/0 AUTO
1 I I
IF1
NOTE
IF2 IF3
ARC-S TOUCH-S/
IF2 IF3
S/W-ARC]
S-LASER1
IF4
W- CHAR^
1.5
p 2
CHECK
CHECK
IF1
DUMP
I
F3 MODIFY
I
L 1 ~ 3M O T I O N IF1 M A I N IF 2
/ 1
1/0
I
I
p3 M O T I O N
F1 MAIN F2
I/O
I I
I
F 3 MOTION
INPUT
IF1 M A I N
I
IF3 M O T I O N F2
OUTPUT
IF 1 M A 1 N
1 1
IF2
STATE PRG. A L
IF3 M O T I O N
I I
1
-1,s
L G C CHKJ-1~1
1 M R I : :
1 0
1.6
IF3
MANAGE
MANAGE
I
IF1 IF2 IF 3 IF4 IF5 TEACH WELD WEAVE SQ OFFSET
IF3 F1 F2
LASER-S TEACH WELD
T,
F1 F2
ASC AEC
( ~ WFP 1
-IF4 -IF5
SQ OFFSET ] W-CHARA]
F2
WAX
1 I
89 - I F 1
IF1 ..-.-.--..-----.-.--:F3 .------.--------.-.D E V . CAL: IF2 IF3 IF4 [F5
SYSTEM SWITCH WELD
I
/
1/0
AUTO
IF2 F3 IF1
TOUCH-S] S-DATA ASM
F 2 AEM
1 1
1.7 SYS. SET

pi174
SYS. SETI-
IF1 [F2
MECH. 1 j MECH. 2
I
I
IF3 MECH. 3 ] [F4 IF5 MECH. 4
MECH. 5 (
-$z
-IF3
RESTART]-1~1
MSTRING]
CONFIRMI
[ F l MU-CRDN] -[F5 MANUAL
IF1 IF2
ROTAT ROTAT CARTE. SET LIST DEL
11
21
-IF4
c O N T R O L 1 l [ 3 F IF1
1
I
-- 1
IF2 F5
1 2
1.8
MEMORY
[ F 3 MEMORY I------IF1 LIST
IFI
IF2
PROGRAM] WELD
IF3 WEAVE [F4 SQ
[F2 F3 F2 SAVE F1
LASER-S TOUCH-S SEPA. F1 IF2 PROGRAM WELD IF1 IF2 ASC AEC
[ F 3 ASM F4 [F 3 W E A V E AEM
IF1 W F P .-------------.--.-:F2 WCP

-----+-.-------.----
.----.------...-.--. lF3 WCF .---..---....-.-.-..
IF4 WAX ..-------.--.....--. : F 5 WVP .----..----.....--..
F4 F2 F3 ALL BACKUP F1 F2
TOUCH-SI PRG WELD AL AL
[ F 3 WEAV AL] IF4 IF5 S Q AL DEV AL
1 I
IF2 IF3 F4 [IF5
LASR USER SYS
ALI ALI AL j
T C H AL
1 3
-IF3
LOAD
1-
--IF1
SEPA.
[ ~ PlR O G R A M \
IF 2 W E L D
IF1
ASC
JFZ AEC IF3 ASM
I F 3 WEAVE
IF1 WFP
IF1
OFFSET
IF4
WAX
F4 F2 F3 ALL BACKUP E l F2
TOUCH-S] PRG AL WELD AL
I F 3 WEAV ALI IF4 IF5

S Q AL
DEV
AL
1 1
11-2 IF3 IF4
LASR USER SYS
ALI
ALI AL
1 4
F[F4
V E R I F Y I---rlFl
SEPA.
][I 1 --F
PROGRAM]
t l F 2
AEC ASM AEM
t,
I / F 3 WEAVE
IF3 F4
1 I
I
[El WFP
( F 5 DEV IF1 IF2 [F 3 IF4 ALL F3 BACKUP F1 F2
CALI
K.2-- -k'-c-p..-..: -. ..--.---....---....F-3.. .k'.G-Y- -...: -. .
----..---.-----.....
OFFSET LASER-SJ W-CHARAI TOUCH-S/ PRG WELD AL AL
I F 4 WAX 1 ---------~~....~~~~. LF.3 - - -k'-v.p...- .- - - :
I F 3 WEAV ALI IF4 IF5 S Q AL DEV AL
I 1
IF2 IF3 IF4 -IF5 DEL. F1 F2 PROGRAM WELD t l F 2 F5
LASR USER
ALI AL]
S Y S AL T C H AL
AEC ASM AEM
1 1 I
t,
IF3 WEAVE IF4 SQ
p 3 F4
IF1 W F P .---..-...-.---..-.. .---.-..---.---.---. : F 2 WCP

r.-.------..-...----
eF 3 IF1 OFFSET IF4
WC F
WAX
r...---.--..--..--..
sF5 WVP
F1
I N I T I A L --,-El
USER
L [ ~ 2 SYSTEM ]
1 5
1.9
Function selection key input

IF1 CORDNTE]
....---......---..--. :F-2-- -HAND-W ? - .;

IF3 IF4 F 5 CRD 1/0 MOVl RST]
LASER
2.
2.1
AUTO
Automatic operation Temporary stop (Multi - station)
IFI
RESERVE^
POI-IF1 POS SET] RETREAT/
[F3 S T R T F4
2.2
Automatic operation Temporary stop (BCD, Binary)

El
POS SET]
1 6
Appendix
Contents
1. Restrictions on the Overlap Process
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 0 0 2 0 0 3 0 0 4 0 0 5
002/
Overlap is in effect
P
L P
P
,
LK
Overlap process not in effect
When Input Wait instructions(N, o r F), Timer Time Wait instruction (T), o r No Operation instruction (NOP) is taught between two sequences Sequence Instruction 0 0 1 0 0 2
P P
002
/ Overlap is in effect
0 0 4
'
Overlap is not in effect
p, ~ 01 0
Appendix
Linear Interpolation 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 [
Overlar, Drocess not in effect
<
l5
20
Travel distance per sequence [ mm
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 r e 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 a r e synchronous interpolation instructions (HL, KC) and single interpolation instructions(L, C) respectively.
(Example] 003 004 005 006
HP L HL HL
100% 100cm 100cm lOOcm
WORK WORK WORK WORK
LAP:ON LAP:ON LAP:ON LAP:ON
M1,2 MI M1,2 M1
Overlap is not in effect
Appendix
When the main mechanism is difference between two consecutive sequences. (Example1 002 003 004 005
HL HL HL HL
100cm 100cm 100cm 100cm
WORK WORK WORK WORK
LAP:ON LAP:ON LAP:ON LAP:ON
M1,2 M1,2 (The main mechanism is set mechanism 1) M1,2 (The main mechanism is set mechanism 1) M1,2 (The main mechanism is set mechanism 2)
tL e---Overlap
is in effect
Appendix
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 a r e a varies according to angles of the wrist axes.
Speed (m/min) Fig.2.l. The relation between a minimum circular diameter and a speed (ALMEGA G01)
(md Usable a r e a
k
i-' Q)
p\\\\\\yr
.3
5 100
cd 3
k
Q)
Tb
50
;;7
2 3 Speed (m/min) Fig.2.2. The relation between a minimum circular diameter and a speed (ALMEGA G03) 0
Speed (m/min) Fig.2.3. The relation between a minimum circular diameter and a speed (ALMEGA V series)
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. F o r details, refer to the following table and Fig.3.1 through Fig.3.7
Table 3.1 Classification based on the system configuration System Configuration V01 single unit GO1 single unit V01 single unit (overhead) V01 single unit (wall mounting) System Category
B
A
B B B
VOI+ 1-axis s
VOI+ z-axis P
V01 i- 1-axis P V01+
I I
+ l-axis S z-axis P + l-axis S
D
E
A
A
GO1 single unit (overhead) GO1 single unit (wall mounting)
+ l-axis S GO1 + l-axis P

GO1 GO1
+ Z-axis P
C
D
+ l-axis S GO1 + Z-axis P + l-axis S

GO1 i- l-axis P
P : a positioner
S : a slider
Appendix
The relation between a set frequency and a n actual frequency for Axis weaving and Fixed pattern weaving
t
Actual frequency 5
4 6 8 Frequency setting (Hz 1 4
Fig.3.1. System Category A
t
Actual frequency
4 6 Frequency setting (Hz I -+
Fig.3.2. System Category B
Appendix
6 Frequency setting ( Hz )
Fig.3.3. System Category C
4 6 Frequency setting ( Hz ) Fig.3.4. System Category D
Appendix
6
( Hz
Frequency setting
Fig.3.5. System Category E
Appendix
4
Frequency setting
6
[ 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 a r e 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 a r c sensor is further lower.
\
Appendix
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 [ m l Parameter 2 = P 2 [ m l 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 [ m l 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
P2
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 a n d 4.2 list DAIHEN torches a n d their tool p a r a m e t e r settings:
Table 4.1. Tool p a r a m e t e r s f o r torches f o r ALMEGA V series

V series
Tool P a r a m e t e r P1 0.0 0. O 0.0 0.0 0.0 0.0 P2 0.0 0.0 0.0 0.0 0.0 0.0 P3 300 400 450 400 380 426
'
P4 -45.0 -45.0 -45.0 -45.0 -45.0 -45.0 1-45.0 -45.0 -45.0 -45.0 -45.0 -45.0 -45.0
P5 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0
@Curved t o r c h MTXC-3501set MTXC-3501 (100mm long) s e t MTCW -5001set MTCA-2501set MTZ-3502set MWP- 17 (w/shock sensor) s e t M W P - 18 (w/shock sensor) s e t MWP- 17 (w/mechanical fuse) s e t M W P - 18 (w/mechanical fuse) s e t MTXA-2501set CTPW -0801 (w/shock sensor) s e t CTPW -0801 (w/mechanical fuse) s e t CTPW - 1201 (w/mechanical fuse) s e t
@Straight torch (fixed a t 45' from the direction perpendicular t o the flange face with a bracket)
0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0
426 350 350 380 426 350 350
0.0 0.0 0.0 0.0 0.0 0.0 0.0
0.0 0.0 0.0 0.0 0.0 0.0 0.0
Table 4.2. Tool p a r a m e t e r s f o r torches f o r ALMEGA G series
G series
MTX-3502set MTY - 3502set MTXW - 5002set MTZ - 3502set MTW -5001set MTXA -2051set M W P - l7set MWP- 18set CTPW -0801set CTPW - 120lset
Tool P a r a m e t e r P1 -235.0 -261.0 -235.0 -285.0
P2 0.0 0.0 0.0 0.0
P3 28.0 28.0 28.0 28.0
P4 -90 -90 -90 -90
P5
-
0.0 0.0 0.0 0.0 0.0
90 90
-90 - 90
1
1
-235.0 -280.0 -235.0 -235.0
1
/
0.0 0.0 0.0 0.0 0.0
1 1
1
28.0 28.0 43.0 43.0 28.0
1 1
-90 -90 -90 -90 -90
-90
- 90 - 90
1 1
0.0 0.0 0.0 0.0 0.0
1 1
-90 -90
(-235.01
Appendix
1 1
Various kinds of weldinu machines are available from DAIHEN. DAIHEN produces and sells every kinds of welding machines.
ITEMS OF M A I N PRODUCTS ARC WELDING MACHINES AC ARC WELDING MACHINES DC ARC WELDING MACHINES CO, GAS-SHIELDED ARC WELDING MACHINES MAG ARC WELDING MACHINES MIG ARC WELDING MACHINES TIG ARC WELDING MACHINES SUBMERGED ARC WELDING MACHINES NO-GAS-SHIELDED ARC WELDING MACHINES STUD WELDING MACHINES AIR PLASMA CUTTING MACHINES ARC WELDING ROBOT CO, LASER EQUIPMENTS
Printed in Jaoan
DAl HEN EUROPE GmbH.

Broichhofstrasse 7, 40882 Ratingen 1, F. R. G E R M A N Y Phone : 02102-444007-8 Facs : 02102-472100
DAIHEN ASIA (THAILAND) CO.,LTD.

60/86 M u 19, Navanakorn Industrial Estate Phase 3. Klong Nueng, Kiong Luang, Pathumthani 12120 Phone : 5292130-1,5293335-8 Facs : 5292132

Osacom 8700 Teaching (1l4000c-9)

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Osacom 8700 Teaching (1l4000c-9)

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June 1997

A. GENERAL INFORMATION AND SAFETY

SAFETY ALERT SYMBOL AND SIGNAL WORDS

WARNING statements identify procedures o r practices which must be followed to

avoid serious personal injury o r loss of life.

2 STAY ALERT when near robot.

10 DO NOT REMOVE, DESTROY, OR COVER the WARNING and CAUTION labels on

SAFETY REOUl REMENTS FOR lNSTALLATlON (Figure D-I)

4 I f any welding components must be located in a high-exposure area, provide proper

10 M A I N T A I N SAFE INTEGRITY OF CELL A T A L L TIMES.

OPERATOR SAFETY REQUIREMENT

Location of Brake release pins

SAFETY PROCEDURES DURING TEACHING (PROGRAMMING)

1 Move robot slowly (see instruction manual "TEACHING"

SAFETY CHECKS AFTER ENTERING A PROGRAM

SAFETY PROCEDURES BEFORE AUTOMATIC OPERATION

2 Have all unauthorized persons leave the robotic cell area.

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

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

I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION

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

3 Do not allow unauthorized persons t o operate controls.

J. SAFETY PROCEDURES AT END OF WORK

Press an EMERGENCY STOP button t o turn off robot Servo power.

5 Allow robot and all equipment t o cool.

6 Clean robot, jigs, and entire cell area.

SAFETY PROCEDURES DURING BNSPECT18N, MAINTENANCE,

7 Provide proper Electrostatic Discharge (ESD) protection f o r circuit boards in Robot

ARC WELDING SAFETY PROCEDURES

Prevent electric shock as follows:

1) INSTALL A N D GROUND all equipment according t o national, regional, and local

4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing

1) KEEP YOUR HEAD out of the fumes.

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

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

5) WEAR PROPER BODY PROTECTION t o include woolen clothing, flame-proof

1) KEEP FLAMMABLE MATERIALS out of the robotic cell.

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

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

1) KEEP PRECISION DEVICES AWAY from the welding arc.

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 Instruction Manual.

D o N o t R e m o v e , Destrov, O r C o v e r This Label.

@ Insulate yourself f r o m t h e w o r k a n d t h e ground.

FUMES AND GASES can b e hazardous

WELDING can cause fire or explosion.

/ A R CSRAYSn can burn hearing. skin: eyes and N O I E c a damage

W e a r w e l d i n g h e l m e t w i t h c o r r e c t filter. W e a r c o r r e c t eye, ear, and body protection

label and the lnstrucr~onM a n u a l carefully.

FUMES AND GASES can be hazardous

ARC RAYS can burn eyes and s k ~ n . NOISE c a n d a m a g e hearing.

Do Not Remove, D e s t r o y , Or Cover This Label.

P I N C H POINTS c a n cause injury.

F A L L I N G E Q U I P M E N T c a n cause serious parsonal injury and equipment damage.

ELECTRIC SHOCK can kill.

B e sure grounding conductor goes to a proper e a r t h ground and has less

Hints f o r Using This Manual

1.1 1.2 13 1.4

2- 3 2- 3 2- 4 2- 9 2 - 11 2 -15 2 -16 2 - 16 2 -16 2 - 16 2 - 16 2 - 18

4.1 operations for ~~~~~l ~

6- 4 6- 5 6- 6 6- 8 6 - 11 6-11 6- 13 6-13 6-14 6 - 15 6 - 16 6-17

Chapter 1 Application Features and Function Used in Teach Mode

1- 5 1-7 1-9 1- 9 1 21 1-22 1-24 1-25

2-3 2-8 2- 10 2-11 2-11 2-12 2-13 2-14 2-17