MANUAL NO.

0
161646-1CD
YASKAWA ELECTRIC CORPORATION
Part Number: 161646-1CD
Revision: 0
DX100 OPTIONS
INSTRUCTIONS
FOR ERROR RECOVERY FUNCTI ON
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.

DX100
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MANDATORY
This manual explains the error recovery function. Read this manual
carefully and be sure to understand its contents before operation.
General items related to safety are listed in Section 1: Safety, in the
DX100 Instructions. To ensure correct and safe operation, carefully
read the DX100 Instructions before reading this manual.
For detailed instructions regarding additional equipment including
the HyperStart, DX100 controller, manipulator, or other
components, refer to the specific equipment manuals included with
your documentation package.
CAUTION
Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product's warranty.
Software described in this manual is supplied against licensee only,
with permission to use or copy under the conditions stated in the
license. No part of this manual may be copied or reproduced in any
form without written consent of YASKAWA.
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Not es f or Saf e Oper at i on
Before using this product, read this manual and all the other related
documents carefully to ensure knowledge about the product and safety,
including all the cautions.
In this manual, the Notes for Safe Operation are classified as
WARNING, CAUTION, MANDATORY, or PROHIBITED.
Even items described as CAUTION may result in a serious accident in
some situations.
At any rate, be sure to follow these important items.
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury to
personnel.
CAUTION
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury to
personnel and damage to equipment.
It may also be used to alert against
unsafe practices.
MANDATORY
Always be sure to follow explicitly the
items listed under this heading.
PROHIBITED
Must never be performed.
NOTE
To ensure safe and efficient operation at all times, be sure to
follow all instructions, even if not designated as "CAUTION"
and "WARNING".
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WARNING
Before operating the manipulator, check that servo power is turned
OFF pressing the emergency stop buttons on the front door of the
DX100 and the programming pendant.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button
Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN
Observe the following precautions when performing teaching
operations within the P-point maximum envelope of the
manipulator:
View the manipulator from the front whenever possible.
Always follow the predetermined operating procedure.
Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
Turning on the power for the DX100 .
Moving the manipulator with the programming pendant.
Running the system in the check mode.
Performing automatic operations.
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of front door of the
DX100 and the programming pendant.
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Not at i on f or Menus and But t ons
Descriptions of the programming pendant, buttons, and displays are
shown as follows:
Desc r i pt i on of t he Oper at i on Pr oc edur e
In the explanation of the operation procedure, the expression "Select "
means the cursor is moved to the object item and the SELECT key is
pressed, or that the item is directly selected by touching the screen.
Regi st er ed Tr ademar k
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.
CAUTION
Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately,
and be sure that all other necessary processing has been
performed.
Check for problems in manipulator movement.
Check for damage to insulation and sheathing of external wires.
Always return the programming pendant to the hook on the cabinet
of the DX100 after use.
The programming pendant can be damaged if it is left in the
manipulator's work area, on the floor, or near fixtures.
Read and understand the Explanation of Warning Labels in the
DX100 Instructions before operating the manipulator:
Item Manual Designation
Menu The menus displayed on screen are
denoted with { }. ex. {TOOL}.
Button The buttons, check boxes, radio
buttons displayed on screen are
denoted with [ ].
ex. [Close]; [Sync] check box; [Fast]
radio button.
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1 Introduction ..................................................................................................................................... 1-1
1.1 Overview............................................................................................................................ 1-1
1.2 Applications........................................................................................................................ 1-2
2 Setup and Configuration ................................................................................................................. 2-1
2.1 Required Functions and Parameters ................................................................................. 2-1
2.2 Required Jobs.................................................................................................................... 2-3
2.3 System Job Configuration.................................................................................................. 2-4
2.4 Variables............................................................................................................................ 2-5
2.4.1 Byte (B) Variables................................................................................................. 2-5
2.4.2 Integer (I) Variables .............................................................................................. 2-5
2.4.3 Double (D) Variables ............................................................................................ 2-6
2.4.4 Position (P) Variables ........................................................................................... 2-6
2.4.5 Register (M) Variables.......................................................................................... 2-6
2.5 I/O...................................................................................................................................... 2-7
2.5.1 Universal Outputs ................................................................................................. 2-7
2.5.2 Universal Inputs.................................................................................................... 2-7
2.6 Interrupt Job Setup ............................................................................................................ 2-8
2.7 Arc Auxiliary Condition File Setup...................................................................................... 2-9
2.7.1 Restart Function Set ........................................................................................... 2-10
2.8 Weld Job Setup................................................................................................................ 2-10
2.8.1 ERR-MNGR Macro Job ...................................................................................... 2-11
2.8.2 R*-EXIT Macro Job............................................................................................. 2-14
2.8.3 R*-PATHS Macro Job......................................................................................... 2-15
2.8.4 Escape Route Programming Requirements ....................................................... 2-17
3 Monitoring Status: ........................................................................................................................... 3-1
1 Introduction
DX100 1.1 Overview
1-1
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1 Introduction
1.1 Overview
The YASKAWA Motoman DX100 Error Recovery function is part of the
YASKAWA family of standardized solutions. The function is designed to
automatically remove the weld torch from the part after an alarm condition.
The robot moves the torch to a pre-defined service location, ideally
outside the robot work envelope, for inspection and repair by maintenance
personnel. Moving the torch outside the work envelope, eliminates the
need for maintenance personnel to enter the work cell, and enables cell
operators to safely perform simple tip replacement and repair. Once the
repair has been made and all alarms cleared, pressing the [Start] button
moves the robot back to the fault location at the part and restarts the
welding process. Optional lap welding can also be performed at this time if
configured.
The DX100 Error Recovery function can be used with single and double
robot cells with or without external axis positioners. When using the
DX100 Error Recovery function with multiple robots, the alarm trigger can
be configured to stop the non-faulted robot immediately or the faulted
robot can be paused while the non-faulted robot completes its current
weld. The faulted robot follows one of 255 user programmed paths to
move safely to the service location.
The robot moves the torch to the service location and the alarm
occurrence is recorded in the alarm history. Once all repairs have been
made and all alarms cleared, the operator presses the [Start] button and
the robot moves back to the fault location following the same user
programmed path, and restarts the welding process. Optional lap welding
can be performed at this time if configured.
Once properly setup, the DX100 Error Recovery function works with very
little input from the user. However, the DX100 Error Recovery function
makes use of several additional DX100 features and functions. Each of
these additional functions must be setup properly for the DX100 Error
Recovery to operate correctly. These additional DX100 Error Recovery
functions include:
Ladder Logic - monitors welder and robot status for generated
alarms.
Interrupt Job Function - pauses the currently running job and starts
the correct error recovery job.
Collision Detect Function - monitors servo motor feedback for
indications of a collision during movement into and out of the robot
work area.
Macro Jobs - allow ease of setup for determining which alarm
triggers the function and which user programmed escape path is to
be used.
1 Introduction
DX100 1.2 Applications
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1.2 Applications
While the DX100 Error Recovery function can be used with all basic
arc-welding applications, some applications are better suited than others.
When used with YASKAWA Motoman ArcWorld type cells, the DX100
Error Recovery function provides a high degree of functionality as there is
typically more space available for programming escape routes. Also, the
robot can more easily reach a service window located in the safety
fencing. While it may not be possible to reach a service window in a very
large system, the DX100 Error Recovery function can still speed up
recovery time, by safely extracting the torch from the work area. The torch
can be automatically removed from the work area and positioned for easy
inspection and repair by maintenance personnel.
2 Setup and Configuration
DX100 2.1 Required Functions and Parameters
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2 Setup and Configuration
This chapter provides detailed setup procedures for the DX100 Error
Recovery function. Setup of the DX100 Error Recovery function should be
performed by personel familiar with arc welding application setup and
configuration. Read this chapter thoroughly before beginning setup and
configuration of the DX100 Error Recovery function.
2.1 Required Functions and Parameters
The following functions and parameters must be installed and operating
on the DX100 for the Error Recovery function to work properly. Please
contact your YASKAWA Motoman representative for information on
purchasing and enabling these functions and parameters.
Interrupt Job Function
The interrupt job function is included with purchase of DX100 Error
Recovery function.
This function monitors a specified input. When the input actuates, the
currently executing job is stopped and the specified "interrupt job" begins.
Macro Job Function
The Macro Job function is included with purchase of DX100 Error
Recovery function.
Provides a customizable user interface screens with user defined
parameters and text. This acts as the interface for the "Error Recovery"
function.
System Job Function:
Used to clear and reset I/O status in the event that error recovery is
aborted mid-process.
CAUTION
The customer is responsible for providing trained operators to run
the equipment. The customer is also responsible for making sure
that the equipment is operated in accordance with the ANSI/RIA
R15.06-1999 Robot Safety standard, as well as any other local or
state standards.
2 Setup and Configuration
DX100 2.1 Required Functions and Parameters
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S4C242 Parameter = Step Number to Register
This parameter must be set to equal (255) to report the current step
number to the M-register.
The DX100 Error Recovery function reports the location of the cursor for
each of the various operating sub-tasks:
S2C446 Parameter = MOVC Motion Following Error Recovery
0 = Executes a linear path to the next programmed point following
error recovery during a circular motion.
1 = (DEFAULT) Continue to execute a circular move (if specified)
following error recovery.
Sub#0 = M690 Sub#5 = M695
Sub#1 = M691 Sub#6 = M696
Sub#2 = M692 Sub#7 = M697
Sub#3 = M693 Sub#8 = M698
Sub#4 = M694
2 Setup and Configuration
DX100 2.2 Required Jobs
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2.2 Required Jobs
The following jobs must be installed on the DX100 controller for the Error
Recovery function to work properly.
Table 2-1: Required Jobs
Required Jobs User
Modification
Single
Robot
Dual
Robot
Description
ERR_MNGR.JBI No-
requires setup
in weld job
X X R* Macro Job:
Allows the user to specify what alarm triggers the
function and how the robot(s) resume welding.
CANCERR1 No X R1 Robot Job:
Used to acknowledge an arc failure.
R1-EXIT.JBI No-
requires setup
in weld job
X X R1 Macro Job:
Used in R1 weld jobs to define torch extraction distance,
escape route #, and sub-task number.
R1-PATHS.JBI Yes-
user must
program escape
path
X X R1 Robot Job:
Defines basic structure (template) for programming
escape paths. This is the job executed when an error
occurs.
R1-RCVRY.JBI No-
requires use in
R1-PATHS.JBI
X X R1 Macro Job:
Contains the logic for performing the error recovery and
posting robot status messages.
RECOVERY-
RESET.JBI
No X System Job:
Clears and resets I/O based on signals generated by
ladder.
CANCERR2 No X R2 Robot Job:
Used to acknowledge an arc failure.
R2-EXIT.JBI No-
requires setup
in weld job
N/A X R2 Macro Job:
Used in R2 weld jobs to define torch extraction distance,
escape route #, and sub-task number.
R2-PATHS.JBI N/A X R2 Robot Job:
Defines basic structure (template) for programming
escape paths. This is the job executed when an error
occurs.
R2-RCVRY.JBI N/A X R2 Macro Job:
Contains the logic for performing the error recovery and
posting robot status messages.
R3-EXIT.JBI No-
requires setup
in weld job
N/A X R3 Macro Job:
Used in R3 weld jobs to define torch extraction distance,
escape route #, and sub-task number.
R3-PATHS.JBI N/A X R3 Robot Job:
Defines basic structure (template) for programming
escape paths. This is the job executed when an error
occurs.
R3-RCVRY.JBI N/A X R3 Macro Job:
Contains the logic for performing the error recovery and
posting robot status messages.
2 Setup and Configuration
DX100 2.3 System Job Configuration
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2.3 System Job Configuration
The Error Recovery function utilizes a system job called "Recovery-
Reset.jbi" which constantly operates in the background monitoring I/O
status. Modification of the system job is not required and set-up should be
performed prior to shipment. However verification of operation can be
made from management mode. Press the "Job" button, then select "Cntrl
System Job". From within the system job screen, the "Recovery-Reset.jbi"
should be selected, set for "Auto" startup, and when executing, the line
number field should be changing rapidly.
Fig. 2-1: System Job Screen
2 Setup and Configuration
DX100 2.4 Variables
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2.4 Variables
2.4.1 Byte (B) Variables
2.4.2 Integer (I) Variables
Table 2-2: Byte (B) Variables
Variable Description
B090 R1 currently specified escape route number (set by R1-ERROR.jbi)
B091 R2 currently specified escape route number (set by R2-ERROR.jbi)
B093 R1 extract point calculated
B094 R1 extracted
B095 R2 extract point calculated
B096 R2 extracted
Table 2-3: Integer (I) Variables
Variable Description
I080 R1 Tool X Extract Distance (mm)
I081 R1 Tool Y Extract Distance (mm)
I082 R1 Tool Z Extract Distance (mm)
I083 R2 Tool X Extract Distance (mm)
I084 R2 Tool Y Extract Distance (mm)
I085 R2 Tool Z Extract Distance (mm)
I090 R1 currently specified M-register to get the step # based on
sub-task# (set by R1-ERROR.jbi)
I091 First step # of R1 escape route (captured in R1-PATHS.jbi)
I092 Last step # of R1 escape route (captured in R1-PATHS.jbi)
I093 R2 currently specified M-register to get the step # based on
sub-task# (set by R2-ERROR.jbi)
I094 First step # of R2 escape route (captured in R2-PATHS.jbi)
I095 Last step # of R2 escape route (captured in R2-PATHS.jbi)
2 Setup and Configuration
DX100 2.4 Variables
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2.4.3 Double (D) Variables
2.4.4 Position (P) Variables
2.4.5 Register (M) Variables
Table 2-4: Double (D) Variables
Variable Description
D090 R1 User specified Tool X extraction distance * 1000
(set by R1-ERROR.jbi)
D091 R1 User specified Tool Y extraction distance * 1000
(set by R1-ERROR.jbi)
D092 R1 User specified Tool Z extraction distance * 1000
(set by R1-ERROR.jbi)
D093 R2 User specified Tool X extraction distance * 1000
(set by R2-ERROR.jbi)
D094 R2 User specified Tool Y extraction distance * 1000
(set by R2-ERROR.jbi)
D095 R2 User specified Tool Z extraction distance * 1000
(set by R2-ERROR.jbi)
Table 2-5: Position (P) Variables
Variable Description
P090 R1 position at time of error / return position (pulse)
(captured in R1-RCVRY.jbi)
P091 R1 calculated extraction location (pulse) (captured in R1-RCVRY.jbi)
P092 R2 position at time of error / return position (pulse)
(captured in R2-RCVRY.jbi)
P093 R2 calculated extraction location (pulse) (captured in R2-RCVRY.jbi)
Table 2-6: Register (M) Variables
Variable Description
M215 Contains data indicating what errors the function responds to how
(lap / no lap) (set by ERR-MNGR.jbi)
M690 Contains the step # of the cursor while executing Master job
M691 Contains the step # of the cursor while executing sub-task #1
M692 Contains the step # of the cursor while executing sub-task #2
M693 Contains the step # of the cursor while executing sub-task #3
M694 Contains the step # of the cursor while executing sub-task #4
M695 Contains the step # of the cursor while executing sub-task #5
M696 Contains the step # of the cursor while executing sub-task #6
M697 Contains the step # of the cursor while executing sub-task #7
2 Setup and Configuration
DX100 2.5 I/O
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2.5 I/O
2.5.1 Universal Outputs
2.5.2 Universal Inputs
Table 2-7: Universal Outputs
Output Description
OUT#993 (#11250) R1 error recovery function enabled
OUT#994 (#11251) R1 error recovery in-process (interrupt job executing)
OUT#995 (#11252) R1 at service location, service required
OUT#996 (#11253) R1 arc failure simulate, (Can be triggered from IF-Panel
while in play mode)
OUT#997 (#11254) R2 error recovery function enabled
OUT#998 (#11255) R2 error recovery in-process (interrupt job executing)
OUT#999 (#11256) R2 at service location, service required
OUT#1000 (#11257) R2 arc failure simulate, (Can be triggered from IF-Panel
while in play mode)
OUT#1004 (#11263) R1 satisfy work start via I/O
OUT#1005 (#11264) R2 satisfy work start via I/O
Table 2-8: Universal Inputs
Output Description
IN#993 (#01250) R1 arc fault active, error recovery required
(trigger for interrupt job R1-PATHS.jbi)
IN#994 (#01251) R1 Restarting (latched until complete or abort)
IN#995 (#01252) R1 Error in-process but aborted via job change
IN#996 (#01253) R1 Simulate Arc Failure (generated from IF-Panel)
IN#997 (#01254) R2 error recovery required (trigger for interrupt job
R2-PATHS.jbi)
IN#998 (#01255) R2 Restarting (latched until complete or abort)
IN#999 (#01256) R2 error recovery in process but aborted via job change
IN#1000 (#01257) R1 Simulate Arc Failure (generated from IF-Panel
2 Setup and Configuration
DX100 2.6 Interrupt Job Setup
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2.6 Interrupt Job Setup
The YASKAWA Motoman Interrupt Job Function is shipped
pre-configured for operation with the Error Recovery function. However, in
the event of a re-initialization of the controller, the function must be
reconfigured as follows:
1. Select {JOB} under the main menu. The sub menu appears.
2. Select {INTERRUPT JOB} from the sub menu.
Depending on the system configuration, there can be up to 8 tables
depending on if "Independent Coordinated Control" is required for the
system. For each of the possible interrupt tables, the following settings
should be made:
Fig. 2-2: Interrupt Job
2 Setup and Configuration
DX100 2.7 Arc Auxiliary Condition File Setup
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2.7 Arc Auxiliary Condition File Setup
The Arc Auxiliary Condition File contains important settings effecting many
arc-related functions including; Arc Retry, Arc Restart, and Automatic
Wire-stick Release. These condition files are referred to by the ARCON/
ARCOF instructions or in arc start/end condition files. For more
information, refer to the Operators Manual for Arc Welding.
Configuration of the Arc Auxilliary Condition file is critical for proper
operation of the DX100 Error Recovery Function. The settings contained
in the "Arc Aux" file influences the operation by allowing the overlap
distance to be specified and executed as desired. Other settings not
related to the DX100 Error Recovery function are detailed in the
"Operators Manual for Arc Welding" (155490-1CD). Below, the setting
requirements for proper operation of the DX100 function are highlighted.
1. Select {ARC WELDING} from the main menu.
2. Select {ARC AUX COND}. The setting window appears.
Fig. 2-3(a): Arc Auxiliary Condition File
Fig. 2-3(b): Arc Auxiliary Condition File
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-10
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2.7.1 Restart Function Set
NO. Set to a value of 1 or more if before going to service an
automatic restart attempt is desired. Setting to a value of zero will
result in the robot traveling to service at the time of the arc failure.
LAP DISTANCE: Specifies the distance the robot reverses from the
point where the arc fault occurs.
SPEED: Determines the speed at which the manipulator reverses for
the above specified distance.
CURRENT: Specifies the welding current/WFS which is applied while
the robot executes its lap. At completion of the specified lap
distance, the robot reapplies its main weld condition settings.
VOLTAGE: Specifies the welding voltage/trim which is applied while
the robot executes its lap. At completion of the specified lap
distance, the robot reapplies its main weld condition settings.
Restart Mode
1. ARC FAILURE
Must be set to "Auto Restart" to prevent the stoppage at the failure
point.
Can be set to "Semi-Automatic." This causes a pause in system
operation at the time of the arc failure. The user would be required to
press the "Start"
button again before the robot travels to the service location.
2. GAS FAILURE
Not used with the DX100 Error Recovery function.
3. WIRE FAILURE
Not used with the DX100 Error Recovery function.
2.8 Weld Job Setup
The DX100 Error Recovery function is intended to have a minimal impact
on the programming experience of the user. Commands and instructions
operate the same with the recovery function as they do without. There are,
however, several commands that must be added to the weld job to set-up,
enable, and execute the DX100 Error Recovery function. Below are the
needed commands that are required to properly setup and execute the
DX100 Error Recovery function from within a weld job.
2 Setup and Configuration
DX100 2.8 Weld Job Setup
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2.8.1 ERR-MNGR Macro Job
The ERR-MNGR macro job allows the user to specify which welding
related alarms trigger the DX100 Error Recovery function and how the
robot resumes welding. The macro can be added to any non-group job (ie.
master job) or R* weld job as it is not associated with any specific control
group. The settings specified in ERR-MNGR macro job affect all robots
and can not be individually tailored for a specific robot. Settings specified
affect operation of all available robots.
Fig. 2-4: ERR-MNGR Macro
Hyper dynam strt
Specifies how the robot responds to the "R* DYNAMIC ARC START
FAULT". The "Dynamic Arc Start" function is enabled and disabled with
the "R*-Hyper" command. When enabled, an "R* DYNAMIC ARC START
FAULT" occurance causes the settings specified in the first parameter of
the ERR-MNGR macro setting to take affect.
0 = Alarm at Fault Location: A setting of 0 (zero) results in the robot
faulting at the end of the dynamic time. No error recovery takes
place.
1 = Go to service, return without overlap: The faulted robot executes
its error recovery path by exiting the part, proceeding to the specified
service location, alarming at the service location, and then returning
to the fault location and resuming welding without executing a over-
lap distance.
2 = Go to service, return with overlap: The faulted robot executes its
error recovery path by exiting the part, proceeding to the specified
service location, alarming at the service location, and then returning
to the fault location, backing-up the distance specified in the Arc Aux
file (or to the start point of the weld) and resumes welding.
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-12
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Hyper arc fault
Specifies how the robot responds to a "R* HYPER ARC FAULT (CNT or
TMR)". If while welding, the Arc Established input from the welder goes
out for longer then specified or more times than specified in the
R*-HYPER command, the following will occur.
0 = Alarm at Fault Location: A setting of 0 (zero) results in the robot
faulting at the location of the HyperStart related arc fault. No error
recovery takes place.
1 = Go to service, return without overlap: The faulted robot executes
its error recovery path by exiting the part, proceeding to the specified
service location, alarming at the service location, and then returning
to the fault location and resumes welding without executing an
overlap distance.
2 = Go to service, return with overlap: The faulted robot executes its
error recovery path by exiting the part, proceeding to the specified
service location, alarming at the service location, and then returning
to the fault location, backing-up the distance specified in the Arc Aux
file (or to the start point of the weld) and resumes welding.
Missing arc gen
Specifies how the robot responds to a "MISSING ARC START CONFIRM"
or "MISSING ARC GENERATION" alarm. If the robot does not receive an
Arc Established signal after one second, the robot will respond per the
following setting:
0 = Alarm at Fault Location: A setting of 0 (zero) results in the robot
faulting at the start location. No error recovery takes place.
1 = Go to service, return without overlap: The robot which failed to
start executes its error recovery path by exiting the part, proceeding
to the specified service location, alarming at the service location, and
then returning to the fault location and resumes welding without exe-
cuting a overlap distance.
Arc Failure
Specifies how the robot responds to an Arc Failure signal generated either
internally or generated by the welding power supply. Various power
supplies generate the Arc Failure signal based on various conditions.
Consult the power supply documentation to ensure that error recovery
function is desired. The power supply fault may not require torch
maintenance so it may not be desirable to enable arc recovery for this
alarm input.
0 = Alarm at Fault Location: A setting of 0 (zero) results in the robot
faulting at the location of the arc fault. No error recovery takes place.
1 = Go to service, return without overlap: The robot which faulted
executes its error recovery path by exiting the part, proceeding to the
specified service location, alarming at the service location, and then
returning to the fault location and resumes welding without
executing an overlap distance.
2 = Go to service, return with overlap: The robot which faulted
executes its error recovery path by exiting the part, proceeding to the
specified service location, alarming at the service location, and then
returning to the fault location, backing-up the distance specified in
the Arc Aux file (or to the start point of the weld) and resumes
welding.
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-13
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Tip chng=service
Specifies if the robot travels to its service location when the tip change
time specified in the Arc Diag file has been exceeded. This is checked
both at the beginning and end of every weld while the R* ERROR RCVY
ON output (R1 = out 993, and R2 = out 997) is ON.
0 = Disabled: A setting of 0 (zero) results in the robot continuing to
weld independent of the tip change time setting. No error recovery
takes place.
1 = Go to service when time exceeded: At the start and end of every
weld while R* ERROR RCVY ON is on, the system checks to see if
the tip change time has been exceed. If the time has been
exceeded, the robot travels to the service location, alarms, and
returns to the start or end location before continuing on the
programmed path.
Noz chng=service
Specifies if the robot travels to its service location when the Nozzle
change time specified in the Arc Diag file has been exceeded. This is
checked both at the beginning and end of every weld while the R* ERROR
RCVY ON output (R1 = out 993 and R2 = out 997) is ON.
0 = Disabled: A setting of 0 (zero) results in the robot continuing to
weld independent of the nozzle change time setting. No error
recovery takes place.
1 = Go to service when time exceeded: At the start and end of every
weld while R* ERROR RCVY ON is on, the system checks to see if
the tip change time has been exceed. If the time has been
exceeded, the robot travels to the service location, alarms, and
returns to start or end location before continuing on the programmed
path.
Alarm after wlds:
Only has an effect in multi-robot systems (no effect on single robot
system). In the case of a multi-robot system, this setting specifies how the
non-faulted robot responds to a fault condition on the other robot(s)
* 0 = When an alarm occurs on any robot in the system the faulted robot
executes it's recovery path and generates the appropriate alarm
independant of what the other robots in the system are in-process of
doing. In the case of a multi-robot system, if both robots are welding and
one robot faults, the faulted robot will extract itself and travel to service.
Once at service it will alarm causing the other robot to stop welding
mid-weld.
* 1= When an alarm occurs, the faulted robot enters a "Sequence Wait"
state until the other robots completes their current weld. At the completion
of the non-faulted robot's weld, the non-faulted robot enters a "Sequence
Wait"s state while the faulted robot travels to the specified service location
and alarms. This ensures that non-faulted robots can complete their welds
without mid-weld interruptions caused by other robots in the system. (A
setting of 1 should not be used if coordinated motion between the two
robots are required)
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-14
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2.8.2 R*-EXIT Macro Job
The R*-EXIT macro enables and configures the DX100 Error Recovery
function for the specified robot. In application, it can be used to change the
exiting parameters mid-weld to change exit routes or extraction distances
based on close proximity obstructions. This is the enabling function call
that allows error signals to be handled as specified by the ERR-MNGR
command. Once this command is issued, the DX100 Error Recovery
function is enabled and active. Any subsequent R*-EXIT commands
change how the robot responds to alarms. To disable the function once a
R*-EXIT command is issued, the user must disable the output (R1 = out
993, and R2 = out 997) from the inform job.
Fig. 2-5: R*-EXIT
Tool X
Specifies the distance (valid settings: +1000mm to -1000mm) in tool
coordinate systems X direction that the robot moves when an error occurs
and the robot is directed to travel to its service location.
Tool Y
Specifies the distance (valid settings: +1000mm to -1000mm) in tool
coordinate systems Y direction that the robot moves when an error occurs
and the robot is directed to travel to its service location.
Tool Z
Specifies the distance (valid settings: +1000mm to -1000mm) in tool
coordinate systems Z direction that the robot moves when an error occurs
and the robot is directed to travel to its service location.
Exit Route #
This setting specifies which of the possible 255 exit routes (valid settings:
0 to 255) the robot follows once torch extraction has occurred. The exit
routes are programmed in the R*-Paths job where a label within the job
corresponds to the route number specified above. For more information
regarding the job structure of the R*-Paths job, refer to bottom. If it is
desirable to have the robot simply extract the torch from the part and not
travel to a service location, this setting can be set to 0 (zero). This setting
results in a torch extraction followed by the appropriate alarm.
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-15
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Sub Task #
This setting specifies what sub-task number (valid settings: 0 to 7) the
current job is being run as. This setting is critical for proper operation of
the function. If a sub-task is changed in a upper-level job, the sub-task
number also needs to be updated in all child jobs where a R*-EXIT
command exists. A setting of 0 (zero) indicates that no independent or
coordinated task is being executed (true for most single robot systems).
2.8.3 R*-PATHS Macro Job
Contained within the R*-PATHS job are all of the possible escape paths
that the robot can follow when traveling to the service location. These
paths consist of only the programmed points required to get the robot to
the service location following arc fault as specified in the ERR-MNGR
macro job. The path required to get the robot back to the part and
reinserted into the part is calculated using the same path that was traveled
to get to the service location. Therefore, the user only needs to program
the escape path. There are however some restrictions that must be
adhered to for proper operation of the function. Those restrictions include
the following:
No CALL or JUMP instructions can be issued from within an escape
path
Inform instructions other than motion are only executed on the
escape path not on the return path.
All escape paths must be programmed using joint motion ONLY.
Robot will reverse its path using the coordinate system that was cho-
sen for the escape path. Verify moves to assure collisions will not
occur. Programming escape routes using joint motion ensures that
the same path is followed when returning to the fault location.
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-16
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Fig. 2-6: R*-PATHS
Directs operation to the
specified route number
specified in the last
R*-EXIT macro command.
If set to "0" no route
is requested.
DO NOT MODIFY!
Escape Route #1
Escape Route #2
Escape Route #3
Once at the service
location, this portion of
the job reverses the
escape route to generate
the return route.
DO NOT MODIFY!
2 Setup and Configuration
DX100 2.8 Weld Job Setup
2-17
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2.8.4 Escape Route Programming Requirements
The following requirements for individual route programming are critical to
proper operation of the DX100 Error Recovery function.
Fig. 2-7: Route Programming Requirements
These steps are required
for all escape routes to
calculate the current
position within the job and
extract the torch from the
part as specified by the
R*-ERROR macro.
These steps are required
for all escape routes to
calculate the current
position within the job and
trigger the welding
related alarm before
returning to the start of the
return path.
These steps are the user
programmed escape route.
These steps can be
modified and added to as
required based on system
configuration.
3 Monitoring Status:
DX100
3-1
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3 Monitoring Status:
Fig. 3-8: I/F Panel
R* ARCON COMMAND:
Indicates the state of the welder as directed from the robot. When on, the
welder is commanded on and should be welding. When off, the welder is
in an idle state.
R* ARC ESTABLISHED:
Indicates the status of the welder's arc established signal. When on, the
welder is welding and the robot free to move. When off the welder is idle.
WLDER#* FAULT:
Indicates the status of the input generated by the welder indicating if a
fault is active. When on, the welder is generating a fault condition. When
off, the welder is not in a fault state.
R* ERROR REVRY ON:
Indicates that status of the error recovery function for the particular robot.
When on the robot will respond to alarms as indicated by "Err-Mngr".
When off, the robot will fault at the fault location. Enabled with "R*-EXIT"
macro call.
R* EXTRACT TOOL X:
Indicates the extraction distance (in mm) that the robot will extract in tool
coordinate system, X direction. Specified in "R*-EXIT" macro.
R* EXTRACT TOOL Y:
Indicates the extraction distance (in mm) that the robot will extract in tool
coordinate system, Y direction. Specified in "R*-EXIT" macro.
R* EXTRACT TOOL Z:
Indicates the extraction distance (in mm) that the robot will extract in tool
coordinate system, Z direction. Specified in "R*-EXIT" macro.
3 Monitoring Status:
DX100
3-2
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R* ERROR ROUTE#:
Shows the currently specified escape route to be used in the event of an
alarm. Specified in "R*-EXIT" macro.
R* SIMULATE ARC FAULT:
Button acts as a momentary push button allowing simulation of an power
source generated arc fault. When pressed the specified escape path is
executed. (Requires "Operation" switch be located in the "permit" location)
R* WIRE INCH:
Button acts as a momentary push button causing wire to inch forward
from the feeder. (Requires "Operation" switch be located in the "permit"
location)
0
161646-1CD
MANUAL NO.
Specifications are subject to change without notice
for ongoing product modifications and improvements.
YASKAWA ELECTRIC CORPORATION
DX100 OPTIONS
INSTRUCTIONS
FOR ERROR RECOVERY FUNCTI ON