ADVANCED WELDING &

ROBOTIC SYSTEMS

ADVANCED
PROGRAMMING
BASIC OPERATIONS

1
Frequently used terms

Frequently used terms

Explained below, for the benefit of those individuals who will be operating the robot for the first time, are the basic
terms which are frequently used in this manual.

Table 1.3.1 Frequently used terms

Terms Explanation
Teach pendant This is used to perform the manual robot operations, teaching, etc.
Enable switch This is a safety device for ensuring that the robot will not operate unexpectedly
due to incorrect operations. The Enable switch is located on the rear panel of the
teach pendant. Manual robot operations and check go/back operations are only
permitted when the Enable switch is held down.
Teach mode This mode is mainly used for creating programs.
Playback mode This mode is used to automatically execute the created programs.
Motor Power This denotes the status of power to the robot, that is to say, whether it is on or off.
At motor power ON, power is supplied to the robot, and at motor power OFF, the
robot is set to emergency stop.
Teaching This refers to teaching the robot how to move and how to do welding work. What
is taught is successively recorded in the programs.
Program This is a file in which the robot movements, welding work and other execution
procedures are recorded.
Movement Command These commands cause the robot to move.
These commands are used to perform auxiliary jobs during robot operations, such
Function Command
as welding, program branching, and external I/O control.
When movement or function commands are taught, their successive numbers are
Step
written in the program. These numbers are known as steps.
Accuracy The robot reproduces the taught positions accurately but in some cases these
positions need not be accurate. The “accuracy” function specifies how precisely
the robot is to operate.
Coordinate System The robot has coordinates. Normally, they are known as robot coordinates. As
viewed from the front of the robot, the back and forth movement is represented by
X, the left and right movement by Y and the up and down movement by Z, thus
forming three orthogonal coordinates. These coordinates serve as a reference for
calculating operations such as manual operations or shift operations etc. In
addition, there are tool coordinates which are referenced to the tool installation
surface (flange surface).
Axis The robot is controlled by a multiple number of motors. The parts controlled by
these motors are called axes. A robot which is controlled by six motors is called a
6-axis robot.
AUX. Axis Axes other than those of the robot (such as positioners or sliders) are generally
called auxiliary axes.
An alternative term is “external axes.”
Check go/check back This function slowly runs the created programs on a step by step basis to check
the teach positions. It operates in two directions, step forward (check go) and step
backward (check back).
Start Start refers to the playback of a program which has been created.
Automatic operation Both “automatic operation” and “playback” mean the playback of a program in the
/ Playback playback mode.
Stop Stop refers to stopping the robot in the start status (playback).
Emergency stop Emergency stop refers to stopping the robot (or system) in an emergency.
Generally, a multiple number of buttons for initiating emergency stop are provided
in the system, and emergency stop can be applied to the system immediately by
pressing one of these buttons.

2
 Frequently used terms

Table 1.3.1 Frequently used terms

Terms Explanation
Error If an error occurs during a playback operation, the robot is
If an error in set to the stop status, and the servo power (motor power)
operation or is turned off immediately.
teaching or trouble in
Alarm the robot itself has If an alarm occurs during a playback operation, the robot is
been detected set to the stop status. The servo power (motor power) is
during a teaching or not turned off. This type of trouble is less serious than an
playback operation, error.
the operator is
Information alerted to the error or If information occurs, the robot remains in the start status
trouble concerned. even during a playback operation. It includes alarms or
errors that have the potential to develop in the future.

Mechanism A mechanism refers to a unit such as a “manipulator”, “positioner”, “servo gun” or

“servo travel” device that configures a control group and cannot be broken down
any further.
A “multi-mechanism” refers to a configuration where, for instance, a servo gun has
been added to a manipulator. For the multi-mechanism, it is necessary to select
which mechanism will be manually operated.
Unit This refers to the increments in which a program is created.
On some occasions, only one mechanism configures the unit; on other occasions,
multiple mechanisms (multi-mechanism) are involved.
When the “Multi-unit” option is set, multiple units can be operated at the same
time. In other cases, only 1 unit is used overall, so there is no need to be
concerned with the unit.

3
Basic concepts applying to the robot

Basic concepts applying to the robot

This section describes an overview of operations that you should know before reading chapter 2 and subsequent
chapters.

Robot system
A robot system normally denotes a combination of a robot, a teach pendant, and peripheral
devices which are all connected to one controller.

D
C

A: Robot body
B: Teach pendant
C: Controller
D: Control box

Fig. 1.4.1 Diagram of basic configuration for robot (When the control box is connected)

B
A: Robot body
B: Teach pendant
C: Controller
D: Operation panel

Fig. 1.4.2 Diagram of basic configuration for robot (When the operating panel is equipped)

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 Basic concepts applying to the robot

Overview: from teaching to auto operation

Proceed as follows to continuously operate the robot.

Creating the program (teaching)

The program is created in the sequence shown below. The entire process is known as
the "teaching work." It refers to creating the program and modifying it into the optimal
form.

Turning on the power,

selecting the program
Preparation
(teach or playback mode)

Manual operations:
Record recording the program

(teach mode)

Playing back the program

Operation check
(teach or playback mode)

YES
OK? End
NO
Modifying,
adding, deleting Modifying, adding or deleting
movement commands
Recording, modifying or
deleting function command

(teach mode)
Auto operation

After the creation of the program has been completed, automatic operation is performed.
When automatic operation is performed, the selected program is repeatedly played back.

Preparation Turning on the power,

starting up the
peripheral devices

Program selection

Start

Auto operation

5
Basic concepts applying to the robot

Manual operation
“Manual operation” refers to moving the robot with the use of the teach pendant. Move the robot to
the position recorded using the “manual operation”.

For manual operation, there is a mode in which each axis of the “robot” is operated separately,
and the mode in which the robot tip is moved in a straight line.

Fig. 1.4.3 Operating the axes separately (independent axis operation)

Fig. 1.4.4 Moving the robot tip in a straight line (robot coordinate operation)

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 Basic concepts applying to the robot

Teaching
Teach the robot positions to which it is to be moved and the numerical sequence of these
positions ahead of time.
This job is called “teaching,” and it is performed in the following sequence.

1 Select the teach mode.

Teaching is performed in the teach mode.

2 Select the program number.

Select the number of the program to be used.

Successively record the operation positions to which the robot is to move and the
3
robot's postures.
•Move the robot to the recorded position and posture using manual
operation.
•Press [O.WRITE/REC] key to record the step.
•Repeatedly press this key to record the steps in succession.

Step 1
Current Step 5
position (Last step)

Step 2

Step 4

Step 3

4 If necessary, record the function commands.

Record the function commands in the appropriate steps. When the function
commands are recorded, signals can be output to an external source or the
robot can be placed in the standby mode, for instance.
See 1-10 ”1.4.5 Function Command (Function)”.

Record the end command (function command END) that indicates the end of
5
operation.
Record the END command (function command END) in the step that ends
the movement.

6 Check what has been taught and modify it if necessary.

This completes the sequence of the teaching session, and a program is created as a result.

The teaching system outlined above is called the “teaching playback system.”
Alternative systems include the “robot language system” and “off-line teaching system.”
The robot supports all of these systems but only the “teaching playback system” is
explained in this instruction manual.

7
Basic concepts applying to the robot

Function Command (Function)

In order to operate the hand or gun attached to the robot wrist or capture signals that check the
work, function commands (functions) are recorded at the appropriate positions in the program.

Furthermore, in order to perform complicated work, other programs may be called or, depending
on the status of the external signals, operation may jump to other programs. These are also
recorded as function commands.

Typical function commands

The function commands are expressed using a format based on SLIM (Standard Language for
Industrial Manipulators) that is a robot language.
Alternatively, function commands can be specified using the “FN***” format where a 1 to 3 digit
number is input into the *** part (which is called a function number).

Some typical function commands are listed below.

Table 1.4.1 Typical function commands

Function
Function
Command Title Description of function
number
(SLIM)
The specified output signal is set to
SET FN32 Output signal ON
ON.
The specified output signal is set to
RESET FN34 Output signal OFF
OFF.
Operation stands by for the specified
DELAY FN50 Timer
time.
Another program which has been
CALLP FN80 Program call
specified is called.
Conditional When the specified signal is ON,
CALLPI FN81
program call another program is called.
The execution of the program is
END FN92 END
ended.

Teaching example

Step 8
Step 9 END (FN92)
Step 1
Step 5
Step 6 DELAY [2] (FN50)
Step 2 Step 7 RESET [1] (FN34)
Step 3 DELAY [1] (FN50) The s quare brackets [ ] following an
Step 4 SET [1] (FN32) function command indicate the
parameter which has been set.

In the case of the teaching example above, the robot operates in the following way.

(1) After the robot has moved to the position in step 2

Step 3 DELAY [1] (FN50) ..........Operation stands by for 1 second.
Step 4 SET [1] (FN32) ...............Output signal “1” is set to ON.
(2) After the robot has moved to the position in step 5
Step 6 DELAY [2] (FN50) .......... Operation stands by for 2 second.
Step 7 RESET [1] (FN34) ...........Output signal “1” is set to OFF.

8
 Basic concepts applying to the robot

Auto operation
The following steps are taken to automatically run the program which has been created.

1 Select the playback mode.

One of the following playback methods may be selected.
Step: The program is executed step by step.
Cycle: The program is executed once from start to end.
Continuous: The program is executed continuously.
“Cycle” or “step” playback is selected to check what has been taught or
perform a trial run for auto operation. (The program can be stopped on a
step by step basis in these modes.)
“Continuous” playback is used for actual operations.

2 Proceed with playback.

The robot starts to move from its current position to step 1. (It is also
possible to specify the start step.)

Step 1

Current
Last step position

With one-time playback (cycle),

the robot moves from the current position to step 1 and subsequent steps,
and its movement ends with the last step.

For the second and subsequent times: the robot moves from the step 1
and subsequent steps, and its movement ends with the last step.

Current position

Step 1 Last step

End

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 Controller

Controller

When the operation box is connected

The circuit breaker is provided on the front side of the FD11 controller, and the teach pendent and
operation box are connected here as well.

OPERATION BOX

CIRCUIT BREAKER

TEACH PENDANT

Fig. 2.1.1 FD11 Controller (OPERATION Box Specifications)

Circuit breaker
This turns the power of the controller ON and OFF.

Teach pendant
The teach pendant has the keys and buttons to perform teaching, file operation, various
condition settings, etc.

Operation Box
Buttons for performing the minimum required operations such as motor power ON,
automatic operation start and stop, emergency stop, and switching between the teach and
playback modes are provided.

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 operation box

operation box
The operation box is provided with the minimum buttons required to exercise basic control over the robot, such
as motor power on, starting and stopping automatic operation, emergency stop, and switching between modes.

ST2 ST3 ST4

(E)
非 常 停 止
EMERGENCY STOP

(A) (D)
運転準備 教示 再生
MOTOR ON TEACH PLAYBACK

(B) (C)

起 動 停 止
START STOP

Fig. 2.2.1 Operation box

Table 2.2.1 Functions of buttons and switches on the operation box

Indication used in this manual Description of function

This is used to set the motor power to ON. When it is set to ON, the robot is
(A) [MOTOR ON BUTTON]
readied for operation.

(B) [START BUTTON] In the playback mode, this starts the program which has been specified.

(C) [STOP BUTTON] In the playback mode, this stops the program which is in the start status.
This is used to select the mode. The teach or playback mode can be selected.
(D) [MODE SELECT SWITCH] This switch is used in combination with the teach pendent “TP selector
switch.”
When this is pressed, the robot is set to emergency stop. Emergency stop is
[EMERGENCY STOP performed by pressing the switch on the control box or on the teach pendant.
(E)
BUTTON] To release emergency stop, turn the button clockwise. (The button will then
return to its original position.)

POINT When a control box is connected, an operation panel cannot be installed.

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 Teach pendant

Teach pendant

External appearance of teach pendant

The teach pendent is provided with operation keys, buttons, switches and jog dials etc. for
creating programs and performing various settings.
You can allocate move commands to number keys [7~9] by pressing the [ENABLE] key at the
same time as a number key [7~9], and allocate often used function commands (function groups)
by pressing the [ENABLE] key and a number key [4~6]. Functions can also be allocated to the
[JOG DIAL] .

Be sure to follow the cautions below for the USB port (see fig. 2.4.2).

 Only connect USB memory while operating files.

 When file operations have finished, always remove the USB memory and
close the USB cap.
 Continuing use with the USB memory connected, or failing to close the
USB cap may hinder the dust protection, waterproofing, and anti-spatter
CAUTION properties, which may lead to failure.
 The USB cap is a consumable part. If the USB cap becomes loose, or is
damaged or lost, quickly replace it with a new one. In the time until a new
one is procured, use tape etc. to block up the USB port.

TP Selector Emergency
switch stop button

Touch panel
LCD screen

Jog dial

Operation
keys

Fig. 2.4.1 Teach pendant (Front)

INFO. The design of the operation keys shown in Fig. 2.4.1 may be slightly different to
those on the actual teach pendant.

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Teach pendant

USB Cap

Enable switch
USB Port

Fig. 2.4.2 Teach pendant (rear)

LED Functions
LEDs are arranged above each teach pendent operation key, and operate as shown below.

(B)

(C)
(A)

Fig. 2.4.3 Teach pendent LED

Table 2.4.1 LED Functions

LED Functions
Color
Flashes during preparation of motor power ON, and lights when motor power is ON
(A) Green (servo ON). It is the same as the green “Motor power ON button” lamp on the
operation panel and control box.
Flashes after the power to the controller is switched on, and lights when the teach
(B) Orange
pendent system starts. At all other times it remains lit.
Lights when a hardware malfunction occurs in the teach pendent.
(C) Red
Normally this remains off.

INFO. Directly after power to the controller is switched on, all of the LEDs light for
approximately 0.5 seconds to check they are operating normally, and then switch
off. After this, they operate as shown in Table 2.4.1.

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 Teach pendant

Functions of buttons and switches

The buttons and switches on the teach pendant have the following functions.

Table 2.4.2 Functions of buttons and switches

External Indication used in this
Function
appearance manual
This is used to switch between the teach mode and
the playback mode in combination with the [MODE
SELECT SWITCH] on the operation panel or control
[TP SELECTOR SWITCH]
box.
For further details, refer to “3.2 Mode selection” in
Chapter 3.
When this is pressed, the robot is set to emergency
stop.
[EMERGENCY STOP To release emergency stop, turn the button in the
BUTTON] direction of the arrow.
(The button will then return to its original position.)
Used to manually operate the robot in teach mode.
Normally, it is provided on the left side only. There
may be two buttons, one at the left and the other at
the right as an option.

When the enable switch is grasped, power is

supplied to the robot (Motor power ON (servo ON)).
[Enable switch] The robot can be operated manually only while the
switch is grasped.
If an impending danger is sensed, either release the
enable switch or grasp it tightly until a clicking sound
is heard. The robot is set to emergency stop.
For details on how to operate the enable switch, refer
to “3.3 Turning the motor power to ON” in Chapter 3.
The [JOG DIAL] has two operations, a longitudinal
dial rotation operation and a latitudinal push button
operation.
The dial rotation operations move the cursor and
[JOG DIAL] scrolls through screens, and the push button
operation selects items and enters inputs.
Also, a wide range of operations such as frequently
used key operations can be allocated to the dial
rotation operation and push button operation. For
details, see “2.4.8 [JOG DIAL].”

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Teach pendant

Functions of operation keys

The operation keys provided on the teach pendant have the following functions.

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
The functions are executed by pressing this key
together with other keys.
[ENABLE] Also, various functions can be executed by rotating
or pushing the [JOG DIAL] while holding down this
key.
The functions are executed by pressing this key
together with other keys.
[SHIFT] Also, various functions can be executed by rotating
or pushing the [JOG DIAL] while holding down this
key.

The motor power is set to ON by pressing this key

[MOTOR POWER ON]
together with the [ENABLE] key.

PRESSED ON ITS OWN

MECHANISM SELECTION
When a multiple number of mechanisms are
connected to the system, the mechanism to be
[UNIT/MECHANISM] operated manually is selected.
WITH [ENABLE]
UNIT SELECTION
When a multiple number of units are defined in the
system, the unit to be operated is selected.
This key is used by a system in which a multiple
number of mechanisms are connected, and it has
the following functions.
PRESSED ON ITS OWN
SYNCHRO MOTION ON/OFF
It selects or releases synchronized (cooperative)
[SYNCHRONIZE] manual operation.
WITH [ENABLE]
SYNCHRO MOTION ON/OFF
When synchronized (cooperative) operation is
specified for a move command, “H” appears before
the step number.
PRESSED ON ITS OWN
COORDINATE SYSTEM SELECTION
During manual operation, the coordinate system that
serves as the reference for operation is selected.
Each time it is pressed, the axis independent,
orthogonal coordinates (or user coordinates) or tool
[INTERP/COORD] coordinates are selected and displayed on the LCD
screen.
WITH [ENABLE]
INTERPOLATION TYPE SELECTION
This switches the interpolation type (joint
interpolation, linear interpolation or circular
interpolation) of the recording status.

15
 Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
PRESSED ON ITS OWN
MANUAL SPEED CHANGE
The operating speed of the robot during manual
operation is selected. Each time it is pressed, one of
the 1 to 5 operating speeds is selected (the higher
the number, the faster the speed).
Furthermore, the following function is provided as
well.
<<Operating mode S>>
The playback speed recorded in the steps is also
[CHECK SPD/TEACH determined by the manual speed which has been
SPEED] selected by this key.
This function is set by selecting [Constant
INFO.
Setting] →[5 Operation Constants] →
[4 Record speed] →[Value of recording
method — Decision method].
WITH [ENABLE]
CHECK SPEED CHANGE
The speed during a check go or check back
operation is selected. Each time it is pressed, one of
the 1 to 5 operating speeds is selected (the higher
the number, the faster the speed).
PRESSED ON ITS OWN
CONTINUOUS / NON-CONTINUOUS
Continuous or non-continuous during a check go or
check back operation is selected.
When continuous operation is selected, the
[STOP/CONTINUOUS] operation of the robot does not stop at each step.
WITH [ENABLE]
PLAYBACK STOP
The program being played back is stopped. (This
has the same function as the stop button.)
PRESSED ON ITS OWN

If a multiple number of monitor screens are

[CLOSE/SELECT displayed, the screen targeted for operation is
SCREEN] selected.
WITH [ENABLE]

The selected monitor screen is closed.

PRESSED ON ITS OWN
No function
WITH [ENABLE SWITCH]
[Axis operating keys] AXIS OPERATION
The robot is moved manually. If an auxiliary axis to
be moved, the operation target is selected ahead of
time using [UNIT/MECHANISM].

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Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
PRESSED ON ITS OWN
No function
WITH [ENABLE SWITCH]
CHECK GO / BACK
When these are pressed together with the [ENABLE
[CHECK GO] SWITCH], the check go or check back operation is
[CHECK BACK] performed.
Normally, the robot is stopped at each recorded
position (step). It is also possible to move the robot
continuously.
Use [STOP/CONTINUOUS] to select step or
continuous.
PRESSED ON ITS OWN
RECORDING A MOVEMENT COMMAND
During teaching, the movement command is
recorded. This can be used only when the last step
in the task program has been selected.
WITH [ENABLE]
OVERWRITING THE MOVEMENT COMMAND
The already recorded movement command is
overwritten by the current recording statuses
(position, speed, interpolation type, and accuracy).
However, the command can be overwritten only
when changes are made to what is recorded for the
movement commands. A movement command
cannot be overwritten by a function command;
neither can a function command be overwritten by
another function command.
[O.WRITE / REC] <<Operating mode A>>
The recording position of a recorded movement
command can be revised using [MOD Position].
<<Operating mode S>>
The recording position, speed and accuracy of a
recorded movement command can each be revised
using [MOD Position], [SPEED] and [ACC],
respectively.
INFO.

The [SPEED] and [ACC] key functions are

set by selecting [Constant Setting] →[5
Operation Constants] → [1 Operation
condition] →[5 Usage of SPD key] or [6
Usage of ACC key].

17
 Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
PRESSED ON ITS OWN
No function
WITH [ENABLE]
INSERTION OF A MOVEMENT COMMAND
<<Operating mode A>>
The movement command is inserted “After” the
current step.
<<Operating mode S>>
[INS] The movement command is inserted “Before” the
current step.
INFO.

“Before” can be changed to “After” or vice

versa by selecting [Constant Setting] →
[5 Operation Constants] →[1 Operation
condition] →[7 Step insertion position].
This key functions in a different way depending on
the application concerned.

When the arc welding application is used

PRESSED ON ITS OWN
EASY SELECTION OF A COMMAND
Frequently used function commands such as the
movement command, welding start and stop
commands and weaving commands are displayed in
the f key, and can be input.
WITH [ENABLE]
No function
[CLAMP ARC] When the spot welding application is used
PRESSED ON ITS OWN
SPOT WELDING COMMAND
It is used to set the spot welding command.
Each time the key is pressed, the ON or OFF is
selected for the recording status.
WITH [ENABLE]
MANUAL PRESS
The spot welding gun is manually pressurized.
Other functions can also be allocated. For details,
see “4.13 Clamp/Arc Key Settings” in the “SETUP” of
the instruction manual.
PRESSED ON ITS OWN
No function

[MOD Position] WITH [ENABLE]

STEP POSITION MODIFICATION
The position stored in the movement command now
selected is changed to the current robot position.
Press this for help concerning an operation or
[HELP] function.
The built-in tutorial function (help function) is called.
PRESSED ON ITS OWN
No function

[DEL] WITH [ENABLE]

STEP DELETION
The step now selected (movement command or
function command) is deleted.
This clears the input or returns the setting screen to
its original status. It also enables R codes (short-cut
[RESET/R]
codes) to be input. The function that is to be used
can be called immediately by inputting an R code.

18
Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
PRESSED ON ITS OWN
STEP SELECTION
This is used to call a step specified in the program.
[PROG/STEP]
WITH [ENABLE]
PROGRAM SELECTION
The specified program is called.
This enters the menu or numerical input contents.
INFO.

[Enter] Determination operation of numerical input

can also be performed with arrow keys by
<Constant Setting> - [7F-key] – [7 Numerical
input] and switching to “Cursol” under
[Decision method of numerical input].
PRESSED ON ITS OWN
CURSOR MOVEMENT
When these keys are pressed on their own, the
cursor moves.
WITH [ENABLE]
PAGE UP/DOWN , SETTING MODIFICATION
 On a screen where the settings are configured on
Cursor keys a multiple number of pages, the page is moved.
 Lines are moved in units of multiple lines in the
work program editing screen etc.
 On a service or constant setting screen, for
instance, the selection items arranged horizontally
(radio buttons) are selected.
 On a teach or playback mode screen, the number
of the current step is changed.
PRESSED ON ITS OWN
SHORTCUT FOR SETM function
During teaching, this short-cut calls the output signal
[OUT] command (SETM <FN105> function command).
WITH [ENABLE]
MANUAL SIGNAL OUTPUT
The external signals are set to ON or OFF manually.
During teaching, this short-cut calls the input signal
[IN] wait “positive logic” command (WAITI <FN525>
function command).
<<Operating mode A>>
This is used to set the speed of movement
commands.
(The setting is reflected in the recording status.)
<<Operating mode S>>
This is used to revise the speed of recorded
[SPD] movement commands.
INFO.

This function is set by selecting [Constant

Setting] →[5 Operation Constants] →
[1 Operation condition] →[5 Usage of SPD
key].

19
 Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
<<Operating mode A>>
This is used to set the accuracy of a movement
command which is to be recorded. (What has been
set is reflected in the recording status.)
<<Operating mode S>>
This is used to revise the accuracy of a recorded
[ACC] movement command.
INFO.

This function is set by selecting [Constant

Setting] →[5 Operation Constants] →
[1 Operation condition] →[6 Usage of ACC
key].
PRESSED ON ITS OWN
SHORTCUT FOR DELAY function
During teaching, this short-cut records the timer
command (DELAY <FN50> function command)
［END／TIMER］
WITH [ENABLE]
SHORTCUT FOR END function
During teaching, this short-cut records the end
command (END <FN92> function command).

20
Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
PRESSED ON ITS OWN
Numerical input
Numbers (0 to 9, decimal point) are input.
WITH [ENABLE]
JOINT INTERPOLATION (with [7] )
A shortcut for a "JOINT" move command
WITH [ENABLE]
LINEAR INTERPOLATION (with [8] )
A shortcut for a "LIN" move command
WITH [ENABLE]
CIRCULAR INTERPOLATION (with [9] )
A shortcut for a "CIR" move command
For arc welding uses
WITH [ENABLE]
APPLICATION FUNCTION 1 (with [4] )
During teaching, commands for arc welding are
displayed on the f keys (f1~f12).
WITH [ENABLE]
APPLICATION FUNCTION 2 (with [5] )
During teaching, commands for weaving are
displayed on the f keys (f1~f12).
WITH [ENABLE]
APPLICATION FUNCTION 3 (with [6] )
During teaching, commands for sensors are
displayed on the f keys (f1~f12).
For uses other than arc welding
Numeric keys/ WITH [ENABLE]
[0] to [9] / [.]
APPLICATION FUNCTION 1 (with [4] )
APPLICATION FUNCTION 2 (with [5] )
APPLICATION FUNCTION 3 (with [6] )
Application functions 1~3 can be allocated to the
desired functions. For details, see “7.7 Customizing
Hard Keys”.
WITH [ENABLE]
"ON" (with [1])
On a setting screen, for instance, a check mark is
placed inside the check box.
WITH [ENABLE]
"OFF" (with [2])
On a setting screen, for instance, the check mark
inside the check box is removed.
WITH [ENABLE]
"REDO" (with [3])
This re-does the operation which was restored by
clearing (undo) the operation immediately before. It
is effective only while creating a new or editing an
existing program.
WITH [ENABLE]
"+" (with [0])
“+” is input.
WITH [ENABLE]
"-" (with [.])
“-” is input.

21
 Teach pendant

Table 2.4.3 Functions of operation keys

External Indication used in this
Function
appearance manual
PRESSED ON ITS OWN
Deletion of a number or character
The number or character before the cursor position
is deleted. The key is also used to release a
selection during file operations.
[BS] WITH [ENABLE]
UNDO
The operation performed immediately before is
cleared, and the status prior to the change is
restored.
It is effective only while creating a new or editing an
existing program.

This is used when selecting the function

[FN] (Function)
commands.

Opens the program editing screen.

[EDIT] In the program editing screen, mainly function
commands are changed, added or deleted, and the
parameters of move commands are changed.

[I/F] (Interface) Opens the interface panel window.

22
Teach pendant

Configuration of display screen

Indicated on the display screens are the program and settings used for the current operation and
the icons (f keys) for selecting the various functions.

1 2 3 4 5
6
10
7

9
Fig. 2.4.4 Configuration of display screen

1 Mode display area

The selected mode (teach, playback or high-speed teach) is displayed here. (The
highspeed teach mode is optional.)
The motor power, operation underway and emergency stopped statuses are also
displayed.

Table 2.4.4 Status display

Playback
Status Teach mode
mode
Motor power OFF

Motor power ON, servo power OFF, now

saving energy (playback mode)

Motor power ON, servo power ON

Motors energized, check GO/BACK

operation underway (teach mode), now
operating (playback mode)
Emergency stopped

2 Program number display area

The number of the selected program is displayed.

23
 Teach pendant

3 Step number display area

The number of the step selected in the program is displayed here.

4 Date & time display area

The current date and time are displayed here.

5 Mechanism display area

The mechanism targeted for manual operation is displayed here.
With a multi-unit specifications robot, the numbers of the units involved in the teaching
are also displayed.

6 Coordinate system display area

The selected coordinate is displayed here.

Table 2.4.5 Coordinate system display

Types of coordinate systems Display
Axis coordinate system

Machine coordinate system

Tool coordinate system

(The number on the left of the icon is the tool number.)
Work coordinate system

Absolute coordinate system (world coordinate system)

Cylindrical coordinate system

User coordinate system

(The number on the left of the icon is the coordinate number.)
Welding line coordinate System

7 Speed display area

The manual operation speed is displayed here. When [ENABLE] is pressed, the check
speed is displayed.

Table 2.4.6 Speed display

Speed Display
Manual speed

Check speed

8 Monitor display area

The contents of the program are displayed here (in the case of the initial settings).

9 f key display area

By touching a display area, called f key, selectable functions are displayed. The six keys
on the left correspond to f1 to f6; the six keys on the right correspond to f7 to f12.
See 2-19 “2.4.6 Concerning the operation of the f keys”.

10 Variable status display area

Various status displays such as “Input wait (I wait)” and “External start selected” appear
as the icons shown in Table 2.4.7 in this area. When this status ends, the icon is cleared.

24
 Checking what has been taught

Checking what has been taught

After the program has been created, be absolutely sure to check what has been taught.
This checking work is called the check operation. When the check operation is performed, the robot can be
made to stop at each step so that its position and posture at each step, and the path of its movement between
steps can be checked. If necessary, modifications can be made.
Use [CHECK GO] and [CHECK BACK] on the teach pendant for the check operation. “Check go” refers to
moving the robot step by step starting with the lowest step number; “check back” refers to operating the robot
starting with the highest step number.
The robot can also be moved through all the steps continuously.

Checking the step sequence [CHECK GO]

The operation of the program created in the previous section will be checked here.
The screen that appears when teaching is completed should be the one shown below.

If the created program has not been selected, select it using the method described in “4.2
Preparations prior to teaching” (Page 4-2).

1 Press [PROG/STEP] in order to call the step which is to be checked first.

>> The [Step Selection] screen now appears.

2 Input [0] in “Designated step”, and press [Enter].

>> The cursor moves to step 0 ([START]).

POINT To check from the start of the program, specify “0” as the Designated
step.

3 To specify the speed to be used during the check operation, press [CHECK
＋ SPD/TEACH SPEED] while holding down [ENABLE]. Here, select “3” to ensure
safety.
>> Each time the [CHECK SPD/TEACH SPEED] key is pressed, the speed changes in
sequence to the next of the 5 settings.
“1” is the slowest speed, and “5” is the fastest.

25
Checking what has been taught

INFO. The check operation speed can be changed by grasping the [ENABLE
SWITCH], and rotating the [JOG DIAL] while holding down [Enable].

4 Press [CHECK GO] while grasping the [ENABLE SWITCH].

>> While [CHECK GO] is pressed, the robot starts moving toward step 1, and when it
＋ reaches step 1, it stops.

When the step is

reached, the display
turns yellow.

When [CHECK GO] is released while the robot is moving, the robot stops.
The robot also stops when the enable switch is released during operation. However,
in this case, the servo power is turned off immediately without the acceleration or
deceleration applying a heavy load to the mechanisms. Before releasing the enable
switch, try to remember to release [CHECK GO] and wait for the robot to come to a
standstill.

5 To move to step 2, first release [CHECK GO] and then press it again.
Check up to the final step by repeating these operations.
When the final step is reached, the robot operates again from step 1.

Checking the steps in the reverse order [CHECK BACK]

The robot can also be operated in the reverse order of the steps.

1 Press [CHECK BACK] while grasping the [ENABLE SWITCH].

>> The robot now moves in the reverse order of the steps.
＋ When step 1 is reached by [CHECK BACK], the robot operates no further. (Check
back cannot be performed to the final step.)

2 The operation method after the speed has been switched or robot has stopped at a step,
etc. are the same as for Check Go.
The robot also stops when the enable switch is released during operation. However, in
this case, the servo power is turned off immediately without the acceleration or
deceleration applying a heavy load to the mechanisms. Before releasing the enable
switch, try to remember to release [CHECK BACK] and wait for the robot to come to a
standstill.

Checking the steps continuously

The robot can be operated continuously step by step by holding down [CHECK GO] or [CHECK
BACK].
When the continuous mode is specified, the robot passes along an arc on the inside of the
recorded points, reflecting the accuracy levels taught at each step.

1 Press [STOP/CONT].
>> “CONT” is displayed in the [Step number display area].

2 Perform the Check Go/Check Back operation. Hold down the [CHECK GO] or
[CHECK
＋ BACK] key.
>> The robot operates continuously step by step.

3 To release the continuous mode, press [STOP/CONT] again.

26
 Checking what has been taught

Switching the continuous/step mode during Check Go operation

The continuous mode can be switched to the step mode and vice versa by pressing down [Shift]
while pressing [CHECK GO].
While pressing the [Shift], the display is shown to switch from the continuous mode to the step
mode and conversely, therefore Check Go is operated following the mode which is switched.

When the continuous mode

1 Press the [STOP/CONT].
>> “CONT” is displayed in the [Step number display area].

2 Perform the Check Go operation. Press down the [CHECK GO].

>> The robot operates continuously step by step.
＋

3 Pressing down the [Shift] while Check Go operation, switching from the
＋ continuous mode into the step mode.
>> During this time, the display changes from "[CONT]” to “[step].”
While this “step” is displayed, Check Go is considered as the completion when the
current step has been completed as the same Check Go of “BREAK” mode.
When Check Go is completed, the display returns from “[step]” to “[CONT].”

4 To release the step mode, release the [Shift].

Or release the [CHECK GO].
>> When the mode release is completed, the display returns from “[step]” to “[CONT].”

When the step mode

1 Press [Stop/Cont].
>> Nothing has been displayed in the [Step number display area].

2 Perform the Check Go operation. Pressing down the [CHECK GO].

>> The robot operates step toward the next step.
＋

3 Pressing down the [Shift] while playback, switching from the step mode into the
＋ continuous mode.
>> During this time, the display changes from “ ” (no display) to "[CONT].”
While this “CONT” is displayed, Check Go is considered as the completion when the
final step has been completed, and the robot operates continuously step by step as
the same Check Go of the continuously mode.
When Check Go is completed, the display returns from “[CONT]” to “ ” (no display).

4 To release the continuous mode, release the [Shift].

Or release the [CHECK GO].
>> When the mode release is completed, the display returns from “[CONT]” to “ ” (no
display).

27
Checking what has been taught

Jump to the Specified Step [Step Jump]

When you want to move to a specified step, press [PROG/STEP] and specify the number of the
step to which you want to move.
However, when you move the robot using [CHECK GO] operation after specifying the step,
always be sure to specify a move command step. You can specify an function command step and
only move the cursor, but an error will occur when you do [CHECK GO].

1 Press [PROG/STEP].
>> [Step Selection] screen appears.

2 When designating the number of the step, input the number of the step in
Number “Designated step”, and press [Enter].
>> The cursor moves to the step which has been designated.

3 When you move relatively from the current step, without specifying a step
number, specify the jump destination in the “Edit” column.
>> The cursor moves to the step which has been designated.

You can select from among the following items.

Movement destination Movements of the cursor

Next Move Step Move from the current step to the next move step (skip function
command steps).
Prev. Move Step Move from the current step to the previous move step (skip
function command steps).
Last Move Step Move to the last move step in the program.
Bottom Move to the last step in the program.
Copy Call the step copy function.
This is the same as selecting <Service Utilities> — [9 Program
Conversion] — [2 Step copy].

4 “Select Interpolation” specifies the operation method when moving to a step.

＋ Before inputting a step number, you can switch using [LEFT/RIGHT] while holding
down [ENABLE].

Movement format Movements of the robot

depend on step At the time of a check operation to the specified
step, operation is done according to the
interpolation classification of the target step. For
example, when the target step is “LIN”, movement
is done using linear interpolation.
Joint At the time of check operation to the specified
step, movement is done using joint interpolation.

5 While grasping the [ENABLE SWITCH], press [CHECK GO].

>> The robot moves as far as the designated step.
＋

28
UTILIZING SHORT-CUTS

29
 Using short-cuts

Using short-cuts
The controller comes with a short-cut function for selecting functions quickly.
Normally, even with operations where one menu is opened from another, a target operation can be quickly
accessed simply by inputting a short-cut code (a number with up to 3 digits). It is a good idea to learn frequently
used short-cut codes to memory.

For details on the short-cut codes that can be used, refer to the Help function contained in the robot controller.

Using short-cuts
1 On the teach or playback mode top screen, press the [RESET/R] key.
>> The [Shortcut R code Entry] screen now appears.

2 If the number of the target function is not known, press the [up or down] key.
>> The list of codes in the center of the screen is scrolled, and the usable short-cut
codes (R codes) are displayed.

3 Align the cursor with the desired short-cut code, and press the [Enter] key.
If the number is already known, input the code number directly into the edit box
at the bottom of the screen, and press the [Enter] key.

4 This completes the selection procedure.

The short-cut which has been input is now executed.
If, for instance, R17 (display program file list) has been input, a list of the programs of
the current unit picked out from among the files stored in the internal memory is
displayed.

31
Monitoring various information of the robot

Monitoring various information of the robot

With this controller, various information from the robot can be monitored and displayed on the teach pendant.
Monitors 1 to 4 (maximum of 4) can be started and their information can be displayed simultaneously on the
teach pendant. The program display screen is one of these monitors, and this is set at the factory as monitor 1.

The monitor updating cycle is approximately 100 [msec].

The next screen shows an example where all four monitors were started simultaneously. Programs are
monitored on monitor 1, general-purpose input signals are monitored on monitor 2, general-purpose output
signals are monitored on monitor 3, and errors are monitored on monitor 4.

Starting a multiple number of monitors

As an example, the steps taken to allocate the display of the general-purpose input signals to
monitor 2 and the display of the general-purpose output signals to monitor 3 will be described.

Starting a multiple number of monitors

1 The signals can easily be displayed on monitor 2 by operating an f key.
Press <Monitor 2>.
>> The monitor 2 setting screen now appears.

32
 Monitoring various information of the robot

2 Align the cursor with “7 User Inputs”, and press [Enter].

>> Monitor 2 now starts.

3 Monitor 3 is set from the service menu. Press <Service Utilities>.

(All four monitors 1 to 4 can be set from the service menu.)
>> The service screen now appears.

4 Select “5 Monitor 3”, and press [Enter].

>> The monitor 3 setting screen now appears.

5 Align the cursor with “8 User Outputs”, and press [Enter].

>> Monitor 3 now starts.

33
Monitoring various information of the robot

Switching and closing the monitors

Any one of a multiple number of monitors started can be selected to be operated or closed.

Switching and closing the monitors

1 To select a monitor to be operated from among a multiple number of monitors,
press [CLOSE/SELECT SCREEN].
>> Each time [CLOSE/SELECT SCREEN] is pressed; the monitor which can be
operated is switched.
The monitor which can be operated has a deep blue title bar.
Monitors that cannot be operated have light blue title bars.

In the case of the screen shown below, monitor 1 can be operated.

When deep blue:

The monitor can be operated.

When light blue:

The monitor cannot be operated.
(The information is updated.)

2 To close a monitor, select the monitor to be closed, and while holding down
＋ [ENABLE], press [CLOSE/SELECT SCREEN].
>> The monitor now selected is closed.

34
 Monitoring various information of the robot

Operating the Use Inputs and Outputs monitors

When a general-purpose input or output monitor is started, the ON/OFF statuses of the
general-purpose signal attributes can be viewed.

Using the general-purpose output monitor as an example, how to read the information and
perform the operations on the monitor screen will be described below.

Operating the User Inputs and Outputs monitors

1 By performing the steps on page 7-2, select “8 User Outputs”.
>> The statuses of general-purpose output signals 0001 to 2048 are now displayed.

Cursor When the cursor is

aligned here, a
description of the signal
is displayed.

A yellow background The bold and italic numbers

signifies “ON” whereas a signify the robot status signals.
gray background signifies The other numbers signify the
“OFF”. general-purpose signals.

2 There is a limit on the number of signals which can be displayed on one screen.
To view the statuses of other signals, move the cursor using the up and down
keys.
＋ When the up or down key is pressed while holding down [ENABLE], one page of
information can be scrolled on the screen.

3 Output signals can be turned on and off manually with the general-purpose
output monitor. (You cannot turn input signals on and off with the
generalpurpose input monitor.)

To set the signal to ON, press [1] while holding down [ENABLE] (or press
＋ [Enter]).
>> The specified signal is now set to ON.

To set the signal to OFF, press [2] while holding down [ENABLE].
＋ >> The specified signal is now set to OFF.

35
Setting the output signals ON or OFF manually

Setting the output signals ON or OFF manually

The output signals can be set to ON or OFF manually. (Each signal to be set to ON or OFF is specified using an
output signal number.)
This function can be used in the teach mode or playback mode (step by step).

Setting the output signals to ON or OFF manually

1 While holding down [ENABLE], press [OUT].
＋ >> The [Manual output signal] screen now appears.

2 Input the output signal number.

3 To set the signal to ON, press [1] while holding down [ENABLE] (or press
＋ [Enter]).
>> The specified signal is now set to ON.
or

To set the signal to OFF, press [2] while holding down [ENABLE].
＋ >> The specified signal is now set to OFF.

36
 Using help for information on functions

Using help for information on functions

This controller comes with a help function (built-in tutorial function).

For information on functions to be known or to be checked out, press [HELP]. The help function can be called
not only during teaching but also during playback.

Calling the help top page

The best way to browse carefully through the help information from the beginning is to call the top
page.
In order to call the top page, make sure that none of the functions has been selected, and press
the [HELP] key.

Calling the help top page

1 While making sure that none of the functions has been selected, press the
[HELP] key.
>> The help top page now appears.

This is the table of contents for help

● Select the desired item using [Up/Down], and press
[Enter].
● The information for the selected item appears in the
window on the right.
● If the contents window is partially covered, press
[Left/Right].

The current mode,

program number
and step number
are displayed here.

This is the help text.

● Once the item in the table of contents has
been selected, press [CLOSE/Select screen] to
set the window to active.
● The window can be scrolled using [Up/Down].
● Pages can be scrolled using [ENABLE] and
[Up/Down].

37
Using help for information on functions

2 Select the item to be viewed using the [Up/Down] key, and press [Enter].
>> The selected item now appears on the right.
For instance, select “Frequently used terms” under Basic Operations Manual to
obtain the following.

3 To manipulate the window showing the text information, press [CLOSE/

Select screen].
>> The text window is set to active.
To return to the table of contents window, press [CLOSE/Select screen] again

4 To scroll up or down, press [Up/Down].

The text can be scrolled quickly by press [Up/Down] together with [ENABLE].
or

5 To close help, either press [RESET/R] or press [ENABLE] and [CLOSE/Select

screen].
or

38
 Using help for information on functions

Directly calling a function to be checked out

For information on the constants menu, service menu, function commands or shortcuts, select the
menu, and then press the [HELP] key. The help text concerned is displayed straight away.

Directly calling a function to be checked out

1 Align the cursor bar with the menu.

When the constants menu or service menu has been selected

Align the cursor bar with the menu to be checked out. (The screen shown appears
when the service menu is selected.)

When a function command has been selected

First press [FN] on the top screen of the teach/playback mode, and then align the
cursor bar with the function command which is to be checked out.

39
Using help for information on functions

When a shortcut has been selected

First press [RESET/R] on the top screen of the teach/playback mode, and then
align the cursor bar with the function command which is to be checked out.

2 Press [HELP].
>> The help information on the selected menu item appears on the right.
For instance, when [HELP] is pressed with the “FN21: Step call” function command
selected, the help information on the step call command (FN21) is displayed.

3 To close help, either press [RESET/R] or press [ENABLE] and [CLOSE/Select

screen].
or

40
 Using help for information on functions

Searches using keywords

Help information can also be searched using the index prepared in advance or any keyword.

Searching using a keyword

1 Press [HELP].
>> This calls help.

2 While holding down [ENABLE], press [Right], and select the “Index” tab.
＋ >> The index tab appears.

3 In the Index tab, select the term using [Up/Down] and press [Enter].
>> The help information contained the selected word now appears

When inputting a keyword (term) to initiate a search, press [EDIT] in the “Type in the
keyword to find:” field. A soft keyboard appears so that the desired keyword can now
be input using its keys.
If, however, the input keyword is not included in the index, the search will not be
successful. Searches can be conducted only using the keywords which have been
registered in the index.

Take the following steps to search for all the help information using a particular
keyword.

4 While holding down [ENABLE], press [Right], and select the “Search” tab.
＋ >> The search tab appears.

41
Using help for information on functions

5 Align the cursor with the “Type in the keyword to find:” field, and press
[EDIT].
>> The soft keyboard now appears.

6 Use the keys on the soft keyboard to input the desired keyword, and press
f12 <Complete>.
>> The help topics containing the keyword are now displayed.

7 While holding down [ENABLE], press [Up/Down], and move to the “Select
＋ Topic to display:” field.
>> Check that the blue cursor bar is displayed.

42
 Using help for information on functions

8 Select the help topic to be displayed using [Up/Down], and press [Enter].
>> The help is now displayed.

43
Displaying T/P Key Help

Displaying T/P Key Help

The name, position, and design of each operating key on the monitor screen can be checked. By displaying "68
T/P Key Help” on the monitor screen, the content can be checked when using either the teach mode or playback
mode.

Displaying the T/P Key Help

Display the T/P key help on the monitor screen.

Selecting from the monitor menu

1 Press <Monitor 2>
>> A list of monitor functions that can be displayed is shown.

2 Select “68 T/P Key help,” and press [Enter]. Alternatively, enter the numbers [6]
[8] directly into the edit box at the bottom, and press [Enter].
>> The T/P key help is displayed on the monitor screen.

Selecting from the shortcut function

1 Press the [RESET/R] key in the top screen of Teach/Playback mode.
>> The “Shortcut R Code Entry” screen is displayed.

2 Select "T/P Key help” with the [Up/Down] keys, and press the [Enter] key.
Alternatively, enter the number [9] directly into the edit box at the bottom, and
press the [Enter] key.

44
 Displaying T/P Key Help

Operating T/P Key Help

This section explains the operations of the T/P key help. The structure of the T/P key help screen
is as shown below. Here, T/P key help is displayed in monitor 2.

２
１

1 Operation key list

Displays a list of operation keys. Selected operation keys are reverse highlighted
in blue.
2 Operation key arrangement
Displays the arrangement of the operation keys. Selected operation keys are
encircled by a blue line.
3 Key names
Displays the key name of the operation key selected in the operation key list or
operation key arrangement.

Searching for the operation key position and design from the name
Perform the following operations to search for the position and design of an operation key from
the name of the operation key.

1 Press the [Up/Down] key, and select the name of the operation key that you want
to search for from the “Operation Key List” on the left side of the monitor.
Alternatively, touch the key name in the “Operation Key List.”
>> The selected operation key is displayed in the “Operation Key Arrangement” on the
right of the monitor with a blue border.

45
Displaying T/P Key Help

Searching for the operation key name from the position or design
Select the key name from the operation key arrangement.

1 Use [ENABLE] + cursor keys to scroll up, down, left, and right the "Operation
Key Arrangement” on the right side of the monitor screen, and display the
operation key that you want to research.
＋
>> The “Operation Key Arrangement” is scrolled up, down, left and right.

Use [ENABLE] + [Up/Down] to scroll vertically, and [ENABLE] + [Left/Right]

to scroll horizontally.

2 Touch the operation key that you want to research from the “Operation Key
Arrangement” on the right side of the monitor screen.
>> The name of the touched operation key is displayed in "Key Name” at the top of the
monitor screen.
Also, the same name also becomes selected in the “Operation Key List” on the left
of the monitor screen.

Moving the display area

When multiple monitors are running, part of the T/P key help screen may be hidden. In this
situation, the following operations can be used to display the hidden parts of the display area.

1 Press the [Left/Right] keys to scroll the T/P key help screen itself horizontally.

For example, if the “Operation Key Arrangement” is hidden press [Right], or if

the “Operation Key List” is hidden press [Left] to scroll the monitor screen itself.

INFO. If this operation is performed when no parts are hidden, the screen does not
scroll.

46
Concerning the file operation menu

Concerning the file operation menu

Selecting the file operation menu enables operations for not only programs but also constant files, etc. to be
performed.

This menu has the following functions which can be selected in either the teach mode or playback mode.

Table 6.2.1 Functions of file operation menu

Operation menu Details
This is for copying files.
File Copy Files can be copied not only between internal memories, but also from an
internal memory to an external storage device using a USB memory (stored), or
from an external storage device to an internal memory (read).
This is for displaying a list of the files stored in the internal memory or external
Directory
storage device.
This is for deleting the files stored in the internal memory or external storage
File Delete
device.
This is for setting protection for the files stored in the internal memory or
File Protect
external storage device.
This is for verifying whether the contents match between two files or between all
Verify
the files on different storage media match.
Format IC card/Floppy This is for initializing the USB memory. Initialization can only be executed by
disk “RC External Storage.”
File Backup This stores all the files in an external storage device.
This is for restoring all the backed up files in the controller.
Backup restore An operator must have the qualifications class of EXPERT or above to use the
backup restore function.
This is for automatically backing up the files under the specified conditions. An
Automatic backup operator must have the qualifications class of EXPERT or above to use this
function.

File operation menu selection and common operations

This section describes how to select the file operation menu and how to perform operations after
its functions have been selected.

Selecting the file operation menu

1 Press f4 <File>.
If this soft key is not provided, the menu can be opened from the service menu.
In this case, select “7 File Manager” from the service menu, and press [Enter].
>> The file operation menu such as the one shown below is now opened.

2 When a function is selected and [Enter] is pressed, the function concerned is

selected.

47
 Concerning the file operation menu

Common operation using file operation menu

This section describes the common operations performed after the functions have been selected
on the file operation menu.

1 When copy is selected, for instance, the screen shown below appears.

1 2 3 5

2 Move through fields 1 to 8, and set the items required.

To move through each field (1 to 8), use the left and right keys.
To select the items displayed in the fields, use the up and down keys.

1 Device selection field (for details, refer to page 6-6 “6.2.2 Types of usable storage
media”)
Select the device containing the file targeted for operation.
To copy a file, select the copy source device in field 1 and the copy destination
device in field 6.
2 Program input field
To specify a program to be copied or deleted, input its number in this field
(program files in ¥WORK¥PROGRAM can be specified). To display a list of files and
select one or more of these files, specify “PROGRAM” in field 4.
3 File type selection field (for details, refer to page 6-7 “6.2.3 Operable files”)
Select the file type. Select the type here when performing file operation by type of
file such as program file or constant file.
4 older selection field (for details, refer to page 6 6-8 “6.2.4 Folder structure of internal
memory”)
To search the file targeted for operation, specify the folder that contains the file.
5 File directory
If a folder is specified in 4, a list of files is displayed in 5. To select an individual file
or files and perform file operations, select the files here.
6 Device selection field (when copying only)
Select the copy destination device.
7 Program input field (when copying only)
Input the number of the program to be copied.
8 Folder selection field (when copying only)
Specify the copy destination folder.

48
Concerning the file operation menu

3 If a folder is specified in 4, a list of files is displayed in 5. In this case, the

sequence in which the files are arranged can be switched using f7 <Name> or f8
<Ascending>.

4 Upon completion of the necessary settings, press f12 <Execute>.

>> The file operation is now executed.

To stop the processing during a file operation, press f11 <Quit>.

>> A confirmation message now appears.

Processing is aborted by pressing any key.

5 To exit the operation, press [RESET/R].

>> Operation returns to the file operation menu.

Types of usable storage media

This controller is equipped with a USB port for external storage devices, and USB memory can be
used as storage media. Data can be stored in an external storage device, or conversely, data can
be read from an external storage device.
USB ports for external storage devices are equipped to both the controller and the teach pendent.
To access the external storage device, it is necessary to select the target beforehand.
See table 6.2.2.

Table 6.2.2 Usable storage media

External storage device
Details
(media)
This accesses the USB memory connected to the USB port on the
RC External memory 1
controller.
This accesses the USB memory connected to the USB port on the
TP External memory
teach pendant.

Before files are stored in an external storage device, the storage media must have been
initialized.
See page 6-27 “6.9 Initializing the USB memory ”.

Do not connect any other type of USB device other than USB memory to the
USB port.
CAUTION

There are two RC external memory USB ports. Do not use them at the same
time.
IMPORTANT

49
 Concerning the file operation menu

Operable files
The files that can be operated using the file operation menu are listed below.

Table 6.2.3 Operable files

File Description of file
This kind of file contains the created programs.
Program file
[Example] SH166.**** (**** denotes numbers)
This kind of file is for the position data used in the robot language.
Pose file
[Example] SH166_P.**** (**** denotes numbers)
This is a program file which is described in the robot language.
Language file It is a text file.
[Example] SH166_A.**** (**** denotes numbers)
This kind of file contains the values inherent to the robots and
various settings.
Constant file It is an INI format text file.
[Examples] MECHANISM.CON (mechanism definition file)
TOOTOL01.C01 (tool constants file)
This kind of file contains error histories, welding histories etc.
Log file It is an INI format text file.
[Example] LG-ERR001.LOG (Error history file 001)

PLC program This is a PLC program (ladder program) used by the software PLC.
(Ladder program) [Example] ********.stf (******** denotes any name)

These are the arc start/end condition files which are used with arc
Arc welding condition welding.
files [Example] AS###ARCW.*** (### denotes the type of welder and
*** denotes number)
These are the weaving start/end condition files used when weaving
with arc welding.
Weaving condition files
[Examples] WFP.*** (*** denotes number)
WAX.*** (*** denotes number)

50
Concerning the file operation menu

Folder structure of internal memory

The internal memory of the controller is structured in the following way.
The operator must be familiar with the folder structure when performing operations for files stored
in the internal memory
Internal Memory

CONVERT (1)

INI (2)

A_APPLICATION (2.1)

EU (2.1.1)

JPN (2.1.2)

SETUP (2.1.3)

USA (2.1.4)

APPLICATION (2.2)

AUTOCAL (2.3)

ERROR (2.4)

HELP (3)

PLCENGINE (4)

WORK (5)

A_APPLICATION (5.1)

AE (5.1.1)

AS (5.1.2)

OFFSET (5.1.3)

SENS (5.1.4)

WELD (5.1.5)

WS (5.1.6)

AUTOCAL (5.2)

LOG (5.3)

PLC (5.4)

PROGRAM (5.5)

TRACE (5.6)

UNDO (5.7)

UNIT (5.8)

USERERROR (5.9)

PRGFLD (5.10)
Fig. 6.2.1 Folder structure of internal memory

51
 Inserting the USB Memory

Inserting the USB Memory

This controller is equipped with USB ports as a standard feature.
To prepare to back up the data, plug a USB memory into the USB port.

Backing up the data on a frequent base is advised.

POINT If, by any chance, the data is accidentally lost by an incorrect operation, the data
can be restored from the backup.

Do not connect any other type of USB device other than USB memory to the
USB port.
CAUTION

Types of USB memory that can be used

For details on the types of USB memory that can be used and for precautions for use, see the
“Controller Maintenance” section of the instruction manual.

Inserting the USB Memory

To save files onto the USB memory, plug the USB memory into the USB port of the controller or
teach pendant in advance.
If there are two storage devices available which USB memories are inserted into, it is advisable to
use them as shown in table 6.3.1 below.

Table 6.3.1 USB memory uses

External Storage Device

Use
(Media)
Suitable for transferring large files, such as for backup
RC External memory 1 etc. Use this when the USB memory is always connected
for automatic backup.
Suitable for transferring small files, such as for copying
TP External memory
files etc.

52
Inserting the USB Memory

Inserting USB memory into the robot controller (RC External Memory)

Only insert and remove the USB memory when the robot controller power is
switched off.
Inserting or removing the USB memory when the power is on may corrupt the
WARNING data saved on the USB memory.

1 Turn off the power of the robot controller, and open the door.
Insert the USB memory into “CNUSB2” or “CNUSB3” on the CPU board.
The CPU board is installed in the rack unit.
Insert the USB memory in the correct orientation. It cannot be inserted in the
wrong orientation.

Front (Internal)
正面図（内部） Enlarged rack unit diagram
ラックユニット拡大図
Rack unit
ラックユニット CPU CPU
Board
基板
CNUSB3
CNUSB2

USBメモリ
USB Memory

There are 2 USB ports in the CPU board. The USB memory will work
irrespective of which USB port it is connected to. However, do not connect 2
IMPORTANT USB memories at the same time.

2 Close the door of the controller, and turn the power on.

3 Perform backup and other tasks.

4 The USB memory can be used continually when connected.

Before removing the USB memory, always be sure to turn off the controller
power.

53
 Inserting the USB Memory

Inserting USB memory into the teach pendant (TP External Memory)

During LED of the USB memory has been flashing, please don't remove the
USB memory from the USB port. Data may break.
IMPORTANT

1 Remove the USB cap from the back of the teach pendant.

USB Cap

2 Insert the USB memory.

>> Insert the USB memory in the correct orientation. It cannot be inserted in the wrong
orientation.

3 Perform file copying and other tasks.

4 When the tasks are complete, remove the USB memory.

When the USB memory is removed, firmly close the USB cap on the back of the
teach pendant.

Only connect USB memory to the USB port when operating files. When the TP
external storage memory is not being used, always close the USB cap on the
back of the teach pendant.
Leaving the USB cap open for long periods may hinder the dust protection and
CAUTION waterproofing properties, which may lead to failure.

54
Copying files

Copying files
When files are copied, files with the same contents can be created in the internal memory or stored in an
external storage device. The files that can be copied are listed below.

• Program file
• Pose file
• Language file
• Constant file
• Log file
• All files (all of the above files)

Opening the copy screen

1 Select “1 File Copy” on the file operation menu, and press [Enter].
>> The [File Copy] screen is now opened.

2 It is on the above screen that the files are copied.

To move through each field, use the [left or right] keys.
To select the items displayed in the fields, use the [up or down] keys.

Specify a file and copy it.

As an example, the steps taken to copy program “1” stored in the internal memory as program
“10” in the internal memory will be described.

1 Select “Memory” in the copy source device selection field.

2 After moving to the program input field, input “1” and press [Enter].
>> The program “1” in “¥WORK¥PROGRAM" is selected for copying.

When you copy a program by specifying the program number, the program
copied will always be in a folder with the same name as the original folder, no
matter what folder is specified or displayed. In this case, the folder is
POINT “¥WORK¥PROGRAM”.
If there is no folder that has the same name, a new folder is made.
Concerning the details of the file types and the folder names and their structure,
refer to “6.2.4 Folder structure of internal memory”.

55
 Copying files

3 Move to the file type selection field, and select “Program”.

4 Move to the copy destination device selection field, and select “Memory”.

5 Move to the program input field, and input “10”.

If the initial value for the copy location program number is not changed, the
program is copied as number 0. Be careful.

6 Press f12 <Execute>.

>> Copying now starts.

Specifying and copying a multiple number of files

As an example, the steps taken to select a multiple number of programs stored in the internal
memory and copy them onto a USB memory stick will be described.

1 Select “Memory” in the copy source device selection field.

2 Move to the file type selection field, and select “Program”.

3 Move to the folder selection field, and select “PROGRAM”.

>> A list of the programs now appears.

Any settings may be used for the program input field and file type selection field.
(The selection made from the file list takes precedence over the program input field
and file type selection field settings.)

56
Copying files

4 Select a file using the up or down key, and press [Enter]. The selected file is
highlighted in blue.
A multiple number of files can be selected by repeating these steps.

To release the selected status, select the file to be released, and press [BS].

5 Move to the copy destination device selection field, and select “RC ExMem1.”

6 Move to the folder selection field, and select the destination folder.

7 Press f12 <Execute>.

>> Copying now starts.

Copying all the files

As an example, the steps taken to copy all the programs stored in the Memory onto a USB
memory stick will be described.

1 Select “Memory” in the copy source device selection field.

2 Move to the file type selection field, and select “All programs”.

3 Move to the copy destination device selection field, and select “RC ExMem1.”

4 Move to the folder selection field, and select the copy destination folder.

5 Press f12 <Execute>.

>> This now completes the copying.

57
Deleting files

Deleting files
The files stored in the internal memory or external storage device can be deleted.
The files that can be deleted are as follows.

• Program files (deleted individually or altogether)

• Pose files (deleted individually or altogether)
• Language files (deleted individually or altogether)
• Log file (deleted altogether)

Opening the deletion screen

1 Select “3 File delete” on the file operation menu, and press [Enter].
>> The [File delete] screen is now opened.

2 Files are deleted on this screen.

To move through each field, use the left and right keys.
To select the items displayed in the fields, use the up and down keys.

Specifying one file and deleting it

As an example, the steps taken to delete program “1” stored in the Memory will be described.

1 In the device selection field, select “Memory”.

2 Move to the file type selection field, and select “Program”.

3 After moving to the program input field, input “1” and press [Enter].

4 Press f12 <Execute>.

>> This completes the file deletion.

58
 Deleting files

Specifying a multiple number of files and deleting them

As an example, the steps taken to select a multiple number of programs stored in the internal
memory and delete them will be described.

1 In the device selection field, select “Memory”.

2 Move to the file type selection field, and select “Program”.

3 Move to the folder selection field, and select “PROGRAM”.

>> A list of the programs now appears.

Any settings may be used for the program input field and file type selection field.
(The selection made from the file list takes precedence over the program input field
and file type selection field settings.)

4 Select a file using the up or down key, and press [Enter]. The selected file is
highlighted in blue.
A multiple number of files can be selected by repeating these steps.

To release the selected status, select the file to be released, and press [BS].

5 Press f12 <Execute>.

>> This completes the file deletion.

59
 Setting protection for files

Setting protection for files

Protection settings are used for files in order to prohibit them from being changed or deleted.
There are three types of protection: complete protection, partial protection and playback protection. When these
settings are used, files can no longer be deleted or changed, as shown below.

Table 6.7.1 Protection types and functions

All protect Partial protect
(Either complete or partial protection Playback protect
only can be selected.)
Display mark (highlighting in red) 1 2 P
Modification of position data × ◎ ◎
Modification of all other data × ◎
File Delete × ◎
Playback or step go from step 0,
◎ ×
CHECK GO
Playback, check go after step 1
◎ ◎

◎：Possible
×：Cannot be performed (= protected)

・ When opening a program for which protection has been set, the protection status is
displayed.

・ Complete protection (or partial protection) and playback protection can be used
simultaneously.(With a combination of “O” and “×”, “×” takes precedence.)
In this case, The display mark that indicates the protection status of the file is a
combination of the two display marks.
・ For constant files, partial protection has the same significance as complete
protection. Playback protection cannot be set for these files.
・ When files are copied, the protection information is also copied.

60
Setting protection for files

Opening the protection setting screen

1 Select “4 File Protect” on the file operation menu, and press [Enter].
>> The [File Protect] screen is now opened.

2 The protection is set on this screen.

To move through each field, use the left and right keys.
To select the items displayed in the fields, use the up and down keys.

Select a file, and set the type of protection for it.

As an example, the steps taken to set “All protect” for program “1” stored in the internal memory
will be described.

1 In the device selection field, select “Memory”.

2 Move to the protection type field, and select “All protect”.

3 Move to the file type selection field, and select “Program”.

4 Move to the program input field, and input [1].

5 Press f12 <Execute>.

>> The protection setting is now completed.

61
 Setting protection for files

Setting protection for all files

As an example, the steps taken to set “All protect” and “Playback protect” for all the programs
stored in the internal memory will be described.

1 In the device selection field, select “Memory”.

2 Move to the protection type field, and select “Playback protect”.

3 Move to the file type selection field, and select “All programs”.

4 Move to the folder selection field, and select “PROGRAM”.

>> A list of the programs now appears.

5 Press f12 <Execute>.

>> This sets “Playback protect” for the files. (“P” appears in the attribute field.)

“P” appears in the attribute field.

6 Move to the protection type field, and select “All protect”.

7 Press f12 <Execute>.

>> This sets “All protect” for the files. (“1P” appears in the attribute field.)

“1P” appears in the attribute field.

62
 Initializing the USB memory

Initializing the USB memory

To save data onto an external storage device, the USB memory needs to be initialized in advance.
Initialization is only required the first time the USB memory is connected to the controller. (If initialization is
done once, these steps are no longer required).
Also, initialization is performed to erase all of the contents of the media.

 When the USB memory is initialized, all of the data stored on it is

deleted. Be careful when initializing the memory.
IMPORTANT  Connect the USB memory to be used to the CPU board in this controller
to initialize it. When initializing USB memories using an external device such
as a personal computer, initialize it to “FAT32” format.
 Do not remove the USB memory, and switch off the power while the
USB memory is initialized.

Initializing the USB Memory

1 Select "6. Format IC card/Floppy disk" on the file operation menu, and press
[Enter].
>> The [Format IC card/Floppy disk] screen now appears.

2 In the device selection field, select the USB memory to be initialized.

3 Press f12 <Execute>.

>> Initializing now starts.

63
Backing up files

Backing up files
All the files stored in the internal memory can be backed up and saved.
Differences with file copying are as follows.
 There is no need to select which files to copy.
 Important parameters such as option protection information that is not copied when “Specify and copy all files”
is used are also copied.
Either the internal memory or external storage device may be used as the storage media.
Backup does not include copying the system (operating system and the software itself).

The name of the backup folder is given automatically using the following format.

INFO. NRA2011-2011-11-06-0932
Date Time

The external storage device is recommended for the backup destination device.
POINT
If the backup destination to the internal memory, please make sure you have enough free
space in internal memory
(Only as a guide. requires at free space of 10MB after the backup).

Opening the backup screen

1 Select “10 File Backup” on the file operation menu, and press [Enter].
>> The [File Backup] screen is now opened.

2 Files are backed up on this screen.

To move through each field, use the left and right keys.
To select the items displayed in the fields, use the up and down keys.

64
 Backing up files

Creating folders in the storage media

To back up and store the files of a multiple number of robots in a single storage media, create
folders under the kind of names that will enable the robots to be identified.

1 Press f9 <Make Folder>, and input the folder name.

The soft keyboard starts up. Input the folder name.
For details on how to input text, see “2.5 To input characters”.

2 Press f12 <Complete>.

>> A folder is now created in the storage media.

Setting the file verification

For this setting, it is necessary to switch operator class to EXPERT or above.

1 Press f-key <File Verify Setting>.

>> The setting screen shown as below appears.

2 Set the each setting.

3 After completion of the all settings, press f12 <Complete>

>> File verification will be done using the settings on this screen when executing backup
process.

Table 6.10.1 File Verify Settings for Backup

Default
Parameter Input range Description
setting

Enabled / Set the file verification Enabled/Disabled when

Verify Disabled
Disabled executing the backup.
Discontinuance / Select the procces to be executed when an error
Abnormal Retry
Retry occurs while the file verification.

65
Backing up files

Backing up the folders

1 In the device selection field, select “RC ExMem1” for instance.

2 Move to the folder selection field, select the backup destination folder, and press
[Enter].

3 Press f12 <Execute>.

>> Backup now starts.

66
 Restoring all files from backup

Restoring all files from backup

The steps taken to restore all the files using the stored backup data in order to restore normal operation after
trouble has occurred or on other such occasions will be described.
When restoration has been performed, all the files including the constant files, program files and history files (all
the files in 6.2.4 Folder structure of internal memory) inside the internal memory are destroyed and replaced with
the backup data files.
Restoration should be done by an operator with the qualifications class of EXPERT or above.
For details on switching operator qualifications, see the instruction manual "SETUP MANUAL".

1) Do not execute backup restoration so lightly except when upgrading accompanied

with replacement of the system CF or restoring after a trouble occurred.

2) At the shutdown after backup restoration and at the power restoration, the status
restoration processing of the auto resume function (restoration of the manual status,
playback and others) cannot be executed. This is one of the safety measures
against the mismatch in the system configuration before and after the restoration
operation.
CAUTION 3) Follow the directions described in the instruction manual for the endless rotation
function to execute the backup restoration operation when the endless rotation
function is used.

4) When restoring the backup, it is necessary to change the settings of the system
memory maintenance function. For details, see the “Controller Maintenance” section
of the instruction manual.

Opening the File Restore screen

1 Select “11 File Restore” on the file operation menu, and press [Enter].
>> The [File Restore] screen now appears.

2 To move through each field, use the [Left/Right] keys.

To select the items displayed in the fields, use the [Up/Down] keys.

67
Restoring all files from backup

Setting the file verification

For this setting, it is necessary to switch to operator class EXPERT or above.

1 Press f-key <File Verify Setting>.

>> The setting screen shown as below appears.

2 Set the each setting.

3 After completion of the all settings, press f12 <Complete>.

>> File verification will be done using the settings on this screen when executing
restoring process.

Table 6.11.1 File Verify Settings for File Restore

Default
Parameter Input range Description
setting

Enabled / Set the file verification Enabled/Disabled when

Verify Disabled
Disabled executing the file restore.
Discontinuance / Select the process to be executed when an error
Abnormal Retry
Retry occurs while the file verification.

68
 Restoring all files from backup

Restoring all files from the backup

1 Stop the robot, and set the motor power to OFF.
Backup data cannot be restored while the robot is operating.
Before proceeding, the robot must be stopped and the motor power set to OFF.

2 Select “11 File Restore” on the file operation menu, and press [Enter].
>> The [File Restore] screen now appears.

3 In the device (source) selection field, select the device on which the backup data
to be restored is saved.
For example, if backup data is saved to the USB memory and the USB memory is
inserted in the controller, select “RC ExMem1.”

4 Move to the folder selection field, select the folder containing the backup data to
be restored, and press [Enter].

The folder in which the backup data is stored must have “read-only”
attributes. (Backup folders are automatically given “read-only” attributes
when data is backed up manually or automatically.)
If the USB memory is accessed by a PC or other devices and the attributes
IMPORTANT of the backup folder are changed to an attribute other than “read-only,”
the folder cannot be selected because it is not recognized as a backup
source folder.

5 Press f12 <Execute>.

>> Backup restoration now starts.

6 The following message is displayed. Press a key to shutdown.

Do not switch off the power during shutdown.

69
Performing automatic backup

Performing automatic backup

This function is used to back up all the files contained in the NRA2011¥WORK folder at the predetermined time,
day of the week and date in order to store a history of the robot’s operation statuses at regular intervals. These
files can also be automatically backed up when the power is turned on or when the mode is switched.
By utilizing this function, the robot’s operation statuses can be accurately grasped so that restoration can be
initiated promptly when trouble has occurred, for example.
An operator must have the qualifications class of EXPERT or above to use this function.
For details on switching operator qualifications, see the instruction manual "SETUP MANUAL".

Automatic backup procedure

1 Select “12 Automatic Backup” on the file operation menu, and press [Enter].
>> The “Automatic Backup” screen is opened.

2 Set the conditions listed on Table 6.12.1, and press f12 <Execute>.
>> Automatic backup starts when the set conditions are met.

Table 6.12.1 Automatic backup settings

Initial
Parameter Input range Description of function
setting
Dev. Internal Internal This is for selecting the media that is stored backup files.
memory memory/ "TP external memory" cannot be used in automatic
RC External backup.
memory 1/
Host 1/
Host 2
Max. backup 0 0 to 10 This is for setting the maximum number of backup folders.
number Up to 10 folders can be created.
Folders are given names as follows on the basis of their
dates and times.
(Folder name) NRA2011-2011-09-26-1834
If automatic backup is performed when the maximum
number of backup folders already exists, the backup
folders will be deleted one by one starting with the oldest
one.
Verify Enable Enable/Disable This is for setting file verification when backup files are
created.
Abnormal Disconti Discontinuance/ This is for selecting the processing to be performed when
nuance Retry trouble has occurred during file verification.
Power on Disable Enable/Disable This is for setting whether automatic backup is to be
performed when the control power is turned on.

70
 Performing automatic backup

Initial
Parameter Input range Description of function
setting
Mode change Disable Enable/Disable This is for setting whether automatic backup is to be
performed when the mode has been switched (from
teaching to playback or vice versa).
Frequency Disable Disable/ This is for setting the automatic backup frequency.
Every day/
Every week/
Every month
Day Sunday Monday - This is for setting the day of the week on which the data is
Sunday to be backed up when “Every week” has been selected as
the backup frequency.
Date 1 1 to 31 This is for setting the day of the month on which the data is
to be backed up when “Every month” has been selected as
the backup frequency.
If 29, 30 or 31 has been set as the day of the month but the
day concerned does not exist, backup will be performed at
the end of the month.
Time 00:00 00:00 to 24:00 This is for setting the time at which the data is to be
backed up when “Every month,” “Every week” or “Every
day” has been selected as the backup frequency.
Automatic backup is not performed when 00:00 has been
set as the time. To start backup at 00:00 AM, set “24:00.”

If the “Dev.” is set to “Host 1” or “Host 2”, the backup folder is generated on the
INFO. FTP server that is set in the FTP client function. In this case, the backup folder in
generated on the initial folder that is set in the FTP client function. For the details
of the FTP client function, refer to the instruction manual of “Ethernet function”.

Displays during automatic backup

Automatic backup is commenced when the backup execution conditions which were set on the
“Automatic backup” menu are met.
When automatic backup is started, an icon is displayed in the variable status display area.
The progress made during automatic backup is indicated as a percentage.
Upon completion of the automatic backup, the icon vanishes.

If the destination device is set to "Host 1" or "Host 2", the attribute of the backup
folder that will be created on the FTP server is "Read Only". And, the attribute of
the initial folder on the FTP server is "Read Only"; the backup folder cannot be
IMPORTANT created. Therefore, remove the "Read Only" attribute from the initial folder on
the FTP server in advance.

71
 Program Conversion AXC to AII

1. In AX controller select what unit you will be converting

2. Press enable and Service utilities, then select Program conversion

73
3. Select Language

4. Select SRC “Memory”, Conversion Type “Source{--exe”, Output “Language

(MOVEX-X), select what program you wish to convert/copy, select (dest) “IC
Card”, then press execute.

74
 5. Move CF card to AII controller and do steps 1-3 then step 6.

6. To copy to the AII controller select Src “IC card”, Conversion Type
“Source--}exe”, Output “PoseType(Encoder)”, select what program you wish
to load, select dest “Memory”, then press Execute.

• Please note that only the unit you are in on your TP screen will appear for
conversion selection so when doing multiple units copy all of like units then move
to the next unit.
• You must copy the programs from the AX control using steps 1-4, you cannot use
a backup or standard program copy.

75
ARC WELDING

1
Connect digital welding power supplies

Connect digital welding power supplies

Electric shock may cause serious injury or death.

Wiring work should be done after turning off the primary power supply and circuit breaker
on the robot controller and welding power supply.
WARNING

This section describes the connection procedures to perform the arc welding by combining a robot and a digital
welding power supply.

(f) Gas hose

(a) Control cable 5
(c) Wire feeding unit
Welding power supply

(e) Torch side welding cable

(b) Control cable 4

(d) Workpiece side

welding cable

(g) Voltage detecting cable

(Workpiece) (Workpiece side)
(Required by some
welding power sources)

Fig. 1.2.1 Connect a digital welding power supply

Do the connecting work, referring to Table 1.2.1 on the following page.

78
 Registering the welding power supply

Registering the welding power supply

This section describes the procedure for setting the welding power supply which is to be used. The welding
power supply which is to be actually connected must be registered without fail.

The registered welding power supply can be given any name (composed of up to 10
INFO. halfsize characters or 5 full-size characters).
The name given here is displayed at times when, for instance, teaching is performed or the
welding constants are set. Especially when a number of welding power supplies are to be
connected, giving each one a different name makes it easier to identify for which welding
power supply the operation or settings is to be performed, thereby preventing errors in
operation or mistakes in settings.

Registering the welding power supply

Before proceeding, switch the operator qualification level to EXPERT or above.

1 In teach mode, select f5 <Arc Constant> - [1 Registration of welder].

>> The registration of welder screen appears.

2 When only one welder is to be used, proceed with the registration for the “Welder
1” line.
When [Enter] is pressed, the selection choices appear. Select the welder using
[up] or [down].

Table 2.3.1 Selection Choice List

Welding
Welding power unit used power Region
supply
Welbee Inverter M350L (Japan specifications)
Welbee Inverter M350L (CCC specifications) WBML Japan
Welbee Inverter M350L（Asia specifications）
Welbee Inverter M350 (Japan specifications）
WBM Japan
Welbee Inverter M350（Asia specifications）
Welbee Inverter M500 (Japan specifications） WBM Japan
DM350 (Japan specifications) DM Japan
DM350 (U.S. specifications) DM U.S.
DM350 (Europe specifications) DM Europe
DM350 (Asia specifications) DM Japan
DM500 (Japan specifications) DM Japan
DM500 (U.S. specifications) DM U.S.
DM500 (Asia specifications) DM Japan
DP350 (Japan specifications) DP Japan
DP350 (Taiwan specifications) DP Japan
DP400 (U.S. specifications) DP U.S.

79
Registering the welding power supply

Table 2.3.1 Selection Choice List

Welding
Welding power unit used power Region
supply
DP400 (Europe specifications) DP Europe
DP400 (CCC specifications) DP Europe
DP500 (Japan specifications) DP Japan
DP500 (U.S. specifications) DP U.S.
DP500 (Europe specifications) DP Europe
DP500 (Taiwan specifications) DP Japan
DP400R (Japan specifications) DPR Japan
DP400R (U.S. specifications) DPR U.S.
DP400R (CCC specifications) DPR Japan
DA300P (Japan specifications) DA Japan
DA300P (Europe specifications) DA Europe
DR350 (Japan specifications) DR Japan
DR350 (Taiwan specifications) DR Japan
DL350 (Japan specifications) DL Japan
DL350 (U.S. specifications) DL U.S.
DW300+(PLUS) (Japan specifications) DW Japan
DW300+(PLUS) (U.S. specifications) DW U.S.
DW300+(PLUS) (Europe specifications) DW Europe
DM-350(S-2) (Japan specifications) DM(S-2) Japan
Digital inverter DL-350(S-2) (Japan specifications) DL(S-2) Japan
Welding interface (Standard) WIF －
Welding interface (4-channel specifications) WIF(4ch) －
Welder connected by input/output signals WPS(I/O) －

3 When [Enter] is pressed after moving to “Area,” a list of options appears. Select
the area which matches the welder using [up] and [down].

4 To give a name to a welder, first move to “Name,” and then press [EDIT] while
＋ holding down [ENABLE].
>> The soft keyboard now starts up.

5 Input the desired name, and exit the soft keyboard.

6 When a multiple number of welding power supplies are to be connected, follow the
same steps to register “Welder2” and so on.

7 When the settings are completed, press f12 <Complete>.

>> This completes the registration of the welder or welders.

When the welder has been re-registered, the welding characteristic data may be
initialized.
IMPORTANT Back up this data before re-registering the welding power supply.

POINT When two or more welding power supplies are connected, continuously register in order
starting from “Welder1”.

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 Settings relating to how to operate the welding power supply

Settings relating to how to operate the welding power

supply
Set the robot to which the welding power supply is to be connected and the connection type.
When a robot system with the multi-unit specifications is to be used, these settings must be performed for each
unit.

Settings relating to how to operate the welding power supply

Before proceeding, switch the operator qualification level to EXPERT or above.

1 In teach mode, select f5 <Arc Constant> - [2 Setting of welder].

>> The welding power supply setting screen now appears.

2 In the “Mechanism” field, set the robot to which the welding power supply is to be
connected.
When [Enter] is pressed, the selection choices appear. Select one of them.

Table 2.4.1 Mechanism Selection Choice

Selection choice Description
Manipulator Name Manipulator connected to the user’s robot system. If a multiple
(Example: NV6-02) number of manipulators are connected, select one of them.
This is selected when the welding power supply is not going to be
Not used
used.
This is selected in the case of special usage where, rather than
Stationary connecting the welding power supply to the manipulator, the torch
is permanently installed in a fixed position, for example.

3 In the “Connection type” field, set the connection type of the welding power
supply.
When [Enter] is pressed, the selection choices appear. Select one of them.

Table 2.4.2 Connection Type Selection Choices

Selection choice Description
Independent This is selected when none of the applications below apply.
This is set when two welding power supplies are connected to one
TwinTorch1
manipulator and twin-torch welding is performed. Up to two sets of
twin torches can be connected to the system: the first one is set as
TwinTorch2 “TwinTorch1” and the second as “TwinTorch2.”
Tandem 1 This is set to use the tandem GMA welding function. Up to two sets
of tandem GMA welding power supplies can be connected to the
Tandem 2 system: the first one is set as “Tandem 1” and the second as
“Tandem 2.”
This is set when the tool changer at the end of the manipulator is to
be used to replace two or more welding power supplies in the same
ToolChange
unit with a single welding power supply which is then to be
connected to the manipulator.

4 For multi-unit specification robot systems, press <f10 <Next unit> to set the
second and subsequent units.

5 When the settings are completed, press f12 <Complete>.

>> This completes the registration of the welder or welders.

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Registering the welding characteristic data and wire feed characteristic data

Registering the welding characteristic data and wire

feed characteristic data

What is the welding characteristic data?

In order to proceed with arc welding using the robot, the welding characteristic data must be
registered ahead of time.

The welding characteristic data defines the welding process, wire material, wire diameter, gas
type and the correspondence table (welding characteristic curve) for welding current/voltage
setting value (value taught to the task program) and command values (actual values instructed to
the welding power supply that correspond to the setting values).Depending on the operating
environment such as the wire extension length or welding power supply secondary cable length, if
the setting value and actual welding power supply output do not match, the welding characteristic
data can be corrected.

Robot Dedicated Welding Power Supply

[A] [V]
Each point is connected with a straight
Command current
Command voltage

line to give an approximation of a welding

characteristic curve. The set values and
the command values are determined by
the proportionality between each pair of
points.

Set current [A] or set voltage [V]

Fig. 2.5 1 Welding characteristic curve

What is the wire feed characteristic data?

When the robot dedicated welding power supply is used, the wire feed characteristic data must be
registered alongside the welding characteristic data. (It need not be registered with a welding
power supply which does not use a robot dedicated welding power supply.)

Wire characteristic data defies the maximum rated feed speed for the wire feeder and type of wire
feeder. The robot dedicated welding power supply controls the wire feeder based on this data.

Performing the registration operation

The welding characteristic data and wire feed characteristic data of the robot dedicated welding
power supplies are contained inside the robot as standard data. This means that if the applicable
data suited to the welding power supply to be used and the environment (wire diameter, wire
material, shielding gas, etc.) is registered, the welding can be performed immediately.
If the robot does not contain this information as standard data, operators must first prepare the
characteristic data (user characteristic data) themselves ( Page 2-41 “2.7 Preparing the user
characteristic data”) and then register it by performing the following steps.

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 Registering the welding characteristic data and wire feed characteristic data

Registering the welding characteristic data and wire feed characteristic data
Before proceeding, switch the operator qualification level to EXPERT or above.

1 In teach mode, select f5 <Arc Constant> - [4 Setting of weld data].

>> The screen for setting the characteristic data now appears.

The DP-350 is shown as the example given on the screen shown above, and up to
10 sets of characteristic data (characteristic 1 to 10) can be registered (The display
screen and maximum number of registrations differ depending on the type of welding
power supply connected.).

Table 2.5.1 Characteristic Data Registration Quantity

Maximum number of
registrations
Model Format
Welding Wire
characteristic characteristics
Welbee Inverter M350L WB-M350L 10 10

Welbee Inverter M350/500 WB-M350/500 10 10

DM-350/500 DM-350/-500 ２ ２

DM-350(S-2) DM-350(S-2) ２ ２

DP350/400/500 DP-350/400/500 10 10

DP400R DP-400R 10 10
0
DA-300 DA-300 １
(unnecessary)
DR-350 DR-350 10 10

DW300+(PLUS) DW-300 10 10

DL350 DL-350 10 10

DL350(S-2) DL-350(S-2) 10 10
Semi-automatic welder other than
the above
－－－ １ ０
(When equipped with a welding
interface)

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Registering the welding characteristic data and wire feed characteristic data

To weld while switching among multiple welding methods,

INFO. The multiple sets of welding characteristic data which have been
registered are displayed as the welding methods, one of which can be
selected when the arc welding start command (AS) and arc welding end
command (AE) are set.
Therefore, when welding while switching among multiple welding
methods, register the welding characteristic data that corresponds to all of
the welding modes here.

2 When a multiple number of welding power supplies have been registered by the
operations on page 2-3 “2.3 Registering the welding power supply”, press [Enter]
in the “welder” field, and select the welding power supply which is the target of
the settings.
This operation need not be performed when only one welding power supply has been
registered.
3 Use [Up] and [Down] to the target section, and press f8 <Select>.
>> A list of the characteristic data now appears.

[Welding characteristic data display]

[Wire feed characteristic data display]

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 Registering the welding characteristic data and wire feed characteristic data

4 While reading the comments, select the desired characteristic data, and press
[Enter].
>> The characteristic data is now selected. Repeat these steps for as many times as
necessary.

5 Lastly, press the f12 <Complete>.

>> This completes the registration of the characteristic data.

When registering multiple sets of characteristic data, register the sets starting from
characteristic data 1.
IMPORTANT

85
 Registering the welding characteristic data and wire feed characteristic data

Standard internal wire feed characteristic data

The robot contains the following wire feed characteristic data serving as the standard welding
characteristic data for using the wire feeder.

Table 2.5.29 Standard internal wire feed characteristic data

Wire feed
Wire feeder Welding application,
characteristic Comment
model description
data number
L-7437 Steel type (CO2, MAG) L-7437/7594：
$WFCD001
L-7594 4-roll with encoder, 18 m CO2/MAG 4 roll Encoder
L-6699 Steel type (CO2, MAG) L-6699/7431：
$WFCD002
L-7431 2-roll, 15m CO2/MAG 2roll
L-6702 Steel type (CO2, MAG)
$WFCD003 L-6702/7432：CO2/MAG 4 roll
L-7432 4-roll, 15m
L-7433 Steel type (CO2, MAG)
$WFCD004 L-7433/7613：CO2/MAG 4 roll
L-7613 4-roll, 18m
Steel type (CO2, MAG) L-7590：
$WFCD005 L-7590
4-roll, 32m CO2/MAG 4 roll AC-Servo
L-7438 Aluminum type (MIG) L-7438/7524：
$WFCD006
L-7524 4-roll with encoder, 18 m MIG(Al) 4 roll Encoder
L-7434 Aluminum type (MIG)
$WFCD007 L-7434/7611： MIG(Al) 4 roll
L-7611 4-roll, 18m
Aluminum type (MIG) L-7591：
$WFCD008 L-7591
4-roll, 32m MIG(Al) 4 roll AC-Servo
L-6701
Steel, aluminum type (TIG)
$WFCD009 L-7435 L-6701/7435/7436： TIG 2 roll
2-roll, 3 m
L-7436
L-7142
L-7143 Steel, aluminum type (TIG) L-7142/7143/7601/7602：
$WFCD010
L-7601 4-roll AC servo, 15 m TIG AC-Servo
L-7602
Wire feeder for D-series /
Welbee Inverter series of AF***-#0##:
$WFCD011 AF***-****
welding power supplies Rated Max Speed 22m
feed speed 22 m specifications
Wire feeder for D-series of
welding power supplies TIG
specifications AF***-#2##:
$WFCD012 AF***-****
Max Speed 5m TIG
Rated feed speed, TIG
specifications
Wire feeder for D-series of
welding power supplies, AC AF**S-41##:
$WFCD013 AF***-**** servo Max Speed 25mAC-Servo(Push)
Rated feed speed 25m (push)
Wire feeder for D-series of
welding power supplies, AC AF*PS-41##:
$WFCD014 AF***-**** servo Max Speed 31mAC-Servo(Pull)
Rated feed speed 31m (pull)
Wire feeder for D-series /
Welbee Inverter series of
welding power supplies, AC AF*PS-23##:
$WFCD015 AF***-****
servo Max Speed 30mAC-Servo(Pull)
Rated feed speed 30m (pull)

86
Registering the welding characteristic data and wire feed characteristic data

When the welding mode or voltage adjustment method was changed

When the following changes are made in the welding characteristic data, either correct the arc
start command, arc end command, and welding condition file recorded for the completed task
programs, or delete all of these and redo teaching. However, it is not necessary to correct the arc
start command, arc end command and welding condition files for welding characteristic data that
has not been used yet.
 When registered welding characteristic data is changed to welding characteristic data for
a different welding mode
(Example) "DC" is registered in the welding characteristic data for characteristic 1,
and this is changed to the "DC pulse" welding characteristic data.
 When the voltage adjustment method in the welding characteristic data is changed
 When the welding mode in the user characteristic data is changed
If these steps are not taken, the robot may stop abnormally or the welding quality may deteriorate
significantly.

When the welding power supply type had been changed

When the type of welding power supply is changed during operation, perform the following actions
(1), (2) and (3) in order.
If these steps are not taken, the robot may stop abnormally or the welding quality may deteriorate
significantly.

(1) Refer to "Chapter 8 Useful Functions", and check that the welding power supply supports
"File conversion required by the change of welding power supply". This function can be used
to convert program files, welding characteristic data files, and welding condition files. Also,
the steps after (2) are not required.
(2) If step (1) is not performed, the welding characteristic data of the current welding power
supply is re-registered.
(3) The new data will be added and the arc start command and arc end command stored in the
already prepared task program will be deleted.

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 Revising the welding characteristic data

Revising the welding characteristic data

The welding characteristic data is revised in the following situations.

・When the setting values taught by the welding conditions in the task program and actual output values are
different
The welding conditions are affected by a number of factors including the length of the secondary side
cable and length of the protruding wire. As a result, there may be slight discrepancies between the
settings which were established at the teaching stage and what is actually output. In this type of situation,
adjustments are performed by correcting the welding characteristic data.

・To adjust the “automatic voltage adjustment function”:

The voltage of the “automatic voltage adjustment function” (where the voltage that has been aligned with
the current is automatically displayed when the arc start command is taught) while the individual
adjustment welding power supply is being used is calculated on the basis of the welding characteristic
data. When this voltage is to be changed, adjustment is made by revising the welding characteristic data.

・When switching the voltage adjustment method

There are two types of voltage adjustment method, namely "individual control" and "synergetic control",
and they can be switched by revising the welding characteristic data.
When the voltage adjustment method has been switched, the already taught arc start and arc end
commands cannot be used. See "2.5.7 When the welding mode or voltage adjustment method was
changed" and perform the correct steps.

Revising the welding characteristic data

Before proceeding, switch the operator qualification level to EXPERT or above.

1 In teach mode, select f5 <Arc Constant> - [5 Weld data].

>> The characteristic data preparation screen now appears.

2 Place the cursor in the "Data number" field, and press f8 <Select>.
>> A table of the welding characteristic data now appears.
If the number of the data to be revised (the “***” part of $WTBD***) is already
known, this number may also be input directly.

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Revising the welding characteristic data

3 Align the cursor with the welding characteristic data to be revised using [up or
down], and press [Enter].
>> The data stored in the selected welding characteristic data is called.

The screen shown above contains both data that can and cannot be revised. Any attempt
to change data cannot be revised, these changes will not be accepted.

4 To edit the comment, align the cursor with the "Comment" field, and press
f11 <Comment>.
>> The comment can now be revised.
The soft keyboard starts up when [ENABLE] and [EDIT] are pressed together so
make the changes to the characters.

5 For revising the data that can be changed.

＋
Use [ENABLE] + [left or right] to revise the data.

6 To revise the welding characteristics, press f10 <Scroll page>.

>> The welding characteristic editing screen now appears.

7 Move the cursor to each point, and then input the value and press [Enter].

8 Lastly, press the f12<Complete>.

>> This completes the revision of the characteristic data.

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Teaching using the movement commands

Teaching using the movement commands

Details on recording movement commands are described in "Teaching" in chapter 4 of the Basic Operation
manual.
This section provides additional information that is required for arc welding.

Interpolation type
The operation methods used as far as the specified position and posture are called interpolation
types, namely, joint interpolation, linear interpolation and circular interpolation. Select an
interpolation type when recording a movement command.

Table 3.2.1 Interpolation type

Interpolation
Path of tool nose movement
type
If the target step involves joint
interpolation, the robot moves to
the target step in such a way JOINT
General
that the movement amount JOINT JOINT
description
between each joint is at the
Joint minimum. The path of the tool
interpolation tip is not controlled.
(JOINT) Joint interpolation is recorded at a location where there is no
need to weld. For instance, this location may be the section that
Application the robot approaches the welding start point, or the section
between the robot completed welding and return to the home
point.
Speed Specify the ratio (0 to 100%) to the maximum speed.

If the target step involves linear Moves in a LIN

General interpolation, the tool tip moves straight line

Linear description in a straight line that connects

JOINT JOINT
interpolation the steps.
(LIN) Record it at the location where welding along a straight line is
Application
required.
Speed Specify the movement speed (1 to 9999 cm/min.)
If the target step involves
circular interpolation, the tool tip
moves along an arc.The CIR1
and CIR2 arcs are different.
(1)JOINT
CIR1 (5)CIR2
(3)CIR2
An arc that connects the 3
points of the "current step",
"target step" and "step after the (4)CIR1
target step". (2)CIR1
In the figure on the right, if the
General current step is (3) and the target
Circular description step is (4), it is the arc that
interpolation connects (3)-(4)-(5).
(6)JOINT
(CIR) CIR2 (10)CIR2
(8)CIR2
An arc that connects the 3
points of the "step before the
current position step", "current (9)CIR2
position step" and "target step". (7)CIR1
In the figure on the right, if the
current step is (8) and the target
step is (9), it is the arc that
connects (7)-(8)-(9).
Application Record this at a position where circular welding is required.
Speed Specify the movement speed (1 to 9999 cm/min.) as the speed.

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 Teaching using the movement commands

Record a movement command in a welding section with a linear

POINT interpolation or circular interpolation
Record a movement command in a welding section with a linear interpolation
(LIN) or circular interpolation (CIR1, CIR2).
During automatic operation (playback), the movement speed of the robot in
the welding section is not the speed specified with the movement command,
but rather the welding speed specified with the arc start command. However,
when the movement command is a joint interpolation (JOINT), the robot
operates with the speed specified with the movement command.

When recording a circular interpolation (CIR) movement command, CIR1 or

INFO. CIR2 is recorded automatically according to the previous movement command.
If the previous movement command is CIR1, the interpolation type of the
recorded movement command is CIR2. In other cases, it is CIR1.

Revising the interpolation type of recorded movement commands

The interpolation type of a movement command that has already been recorded can be changed.
When circular interpolation is set as the interpolation type of the movement command, CIR2 can
be revised to CIR1.

1 As an example, the procedure for changing CIR2 to CIR1 is described below.

Select the screen editing function, and move the cursor to the interpolation type
(CIR2 here) of the movement command to be revised.

The interpolation type identifiers and input values are as follows.

Table 3.2.2 Interpolation type

Step identifier Guide message identifier Input value
JOINT OFF 0
LIN Linear 1
CIR1 Circular (Middle) 2
CIR2 Circular (End) 3

2 Input the value in response the guide message that appears at the bottom of the
screen.
Since circular (Middle) is displayed for CIR1, input “2” and press [Enter].
>> CIR2 is changed to CIR1, and the status in which the interpolation stationery
specification is to be input is established.

3 Input “0” that signifies the standard, and press [Enter].

>> CIR2 has now been changed to CIR1.

Stationary “1” is selected only when the torch has been defined as a “stationary tool”.
Since a “stationary tool” is one which is used for special applications, standard “0” is
set normally.
This is the same as when revising to linear interpolation (LIN).

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Teaching using the movement commands

Accuracy
This refers to the degree by which the path along Inside arc
which the tool tip travels as it passes through the amount Recorded point
recorded point of each step is distanced from the A1 Small
recorded point, thereby describing an arc on the
：
inside of these points. It is specified with a level from ：
A1 to A8. When A1 is specified, the tool tip will pass ：
through the recorded point. When A2 or above is
specified, the playback time is reduced depending on A8 Large
how far the tool tip passes along an arc on the inside
of the recorded points. Set a strict level (low) at
welding points and a light level (high) at air cut
portions.
This controller describes an inside arc even for
successive steps whose interpolation types are
different.
The operation control of robots related to the accuracy level differs depending on the application
that is used.

When A1 to A8 is specified, the speed lapping ratio is

set that varies in steps in a range of 0 to 100%. Accuracy level
Even if the accuracy level remains the same, the path of Level Speed lapping ratio
the robot is changed by the recording speed. (The A1 0%
higher the recording speed, the further inside the arc A2 5%
which is described.) A3 10 %
Even when the playback speed is changed, the inside A4 15 %
arc path is calculated so it will not affect the path. A5 25 %
However, the actual inside arc amount may vary due to A6 50 %
machine deflection or delays in servo control. A7 75 %
“When the playback speed is changed” is the speed A8 100 %
change when using the speed override or low safety
speed functions.

INFO. "Accuracy" is equivalent to "Overlap" of the DAIHEN robots in the EX-C

series and earlier. "With overlap" can be used as A8 and "Without overlap"
can be used as A1.

When preparing arc welding programs, the key points for setting accuracy are as follows.

 Increase the level for air cut portions where there is no fear of running into peripheral jigs.
 When moving in small areas where the robot could run into peripheral jigs, or in cases such
as moving the torch to the torch cleaner, lower the level.
 When there are multiple straight line or circular arc steps in a welding section, increase the
accuracy level at those points. This is because decreasing the level causes the speed to be
reduced at each step, so it affects the welding quality. If the accuracy level is raised, then the
robot will move smoothly without reducing speed at each step, so there is no affect on
welding quality.

POINT If the higher positioning accuracy at the recorded point is needed, use “A1P”
(‘P’ means “Pause”).

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 Teaching using the movement commands

Torch posture during welding

To obtain good welding results, teaching must be performed not only with the welding conditions
to be set, but also with the appropriate torch posture and target position.

Torch angle
The torch angle is the angle between the vertical plate and welding torch. The torch angle
and the target position in the case of horizontal fillet welds are classified into the following
two kinds depending on the difference in their leg length.To obtain beads with equal leg
lengths at high current, set the torch angle and tool center point as shown on the right in the
figure below.

Fig. 3.2.1 Torch angle

Push and drag angles

Welding when the torch tilts in the opposite direction to the forward direction of welding is
known as the push method, and the torch angle in this situation is known as the push angle.
Conversely, welding when the torch tilts in the same direction as the welding direction is
known as the drag method, and the angle in this situation is known as the drag angle.

Fig. 3.2.2 Push and drag angles

Wire extension length

The wire extension length is the length from the contact tip to the tip of the welding wire.
Although it differs depending on the level of the welding current which is set and the
diameter of welding wire which is used, adjust it to 15 mm as a rough guide.

94
Teaching arc welding start/end commands

Teaching arc welding start/end commands

This section describes the arc welding commands and the conditions set with these commands.
For details on the teaching and operation methods for arc welding, refer to "Chapter 9 Basic arc welding
operations" in the Basic Operation manual.
The following arc welding start and end commands are provided.

Table 3.3.1 Arc welding start/end command list

Command
SLIM Description
Name FN code
identifier
This command starts the arc welding. Even if the welding
condition is changed during welding, this command is
AS FN414 recorded in the changed position.
The condition described in "3.3.1 Arc welding start
Arc welding start conditions" is set for this command.
commands In the same way as the AS command, this command starts
the arc welding or changes the conditions during welding.
ASV FN665 The arc welding start condition is set by this command
using the method described in "3.3.9 Designating a variable
for the condition file number".
This command ends the arc welding. The condition
AE FN415 described in "3.3.2 Arc welding end conditions" is set for
this command.
Arc welding end
In the same way as the AE command, this command ends
commands
the arc welding. The arc welding end condition is set by this
AEV FN666
command using the method described in "3.3.9
Designating a variable for the condition file number".

POINT About the arc welding start/end (variable) (ASV/AEV)

ASV and AEV are mainly used when changing the welding conditions with an
external signal or for complex teaching using robot language.
When performing other types of welding, use AS and AE.

POINT Changing conditions in a welding section

Even while in a welding section, if you record the arc welding start command
(AS<FN414> or ASV<FN665>) in the position where you want to change the
welding condition, the condition will be changed during welding.

Arc welding start conditions

The arc welding start conditions specified with the arc start command include special setting
items provided for individual welding power supply models, and setting items common to multiple
models.
This section describes typical setting items common to multiple models. For details on items
special to individual welding power supply models, see the chapters shown in Table 3.3.2.

Table 3.3.2 Locations of detailed descriptions of welding conditions

Description
Welding power supply used
location
Welbee Inverter series welding power supply Chapter 4
D-series welding power supply Chapter 5
All other welding power supplies (such as welding
Chapter 6
power supply interface)

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 Teaching arc welding start/end commands

Table 3.3.3 Arc start control conditions

Setting item Description
This is used to specify the target welding power supply when multiple welding power
Welder supplies are connected. This need not be set if only one welding power supply is to
be used.
This is used to specify the welding condition file number to use in the arc start
command.
Condition file ID 0 :
The welding conditions are set directly with the
arc start command.
AS Cond. file
A welding condition file is not used.
Condition file ID 1 to 999 : The welding condition file of the specified
number is used.
”3.3.3 How to set the arc welding conditions”
This is used to set the retry operations if an arc is not generated at the start of
welding.
Retry No. 0 : The standard internal arc retry operation is
Retry No. performed.
Retry No. 1 to 99 : The arc retry operation is performed using the retry
condition file of the specified number.
“3.3.6 Arc retry”
This is used to set the restart (retry) operation if arc outage occurs during welding.
Restart No. 0 : A restart operation is not performed.
Restart No. Restart No. 1 to 99 : The arc restart operation is performed using the
retry condition file of the specified number.
“3.3.7 Arc restart”
This is used to select the welding method to use. The welding methods registered as
Welding process
welding characteristic data are displayed as selection choices.
Welding speed This is the movement speed of the torch in the welding section.
This is used to select whether to specify the welding conditions with current or the
Current cond.
wire feed speed.
This is used to select the setting method for the slope control performed at the start of
welding. Select whether to specify the slope control range with time (time
Slope cond. specification) or distance (distance specification).
“3.3.5 Slope control”
Normally, fixed to "Standard". This condition can be set when optional software such
Welding control
as "Synchro MIG" is installed.
This is used to set the operation method for RS control.
This condition can be set when the "RS control" optional software is installed
RS control and the "RS control" welding constant is set to "Enabled".
OFF : RS control is not performed.
ON : RS control is performed using the wire feeder.
This is used to specify the condition file number for RS control.
RS No. RS No. 0 : The standard internal RS condition is used.
RS No. 1 to 999 : The RS condition file of the specified number is used.
This is used to set the operation method for robot RS control.
This condition can be set when the "Robot RS control" optional software is installed
and the "Robot RS control" welding constant is set to "Enabled".
Robot RS control OFF :
RS control is not performed.
Robot RS No. :
RS control is performed with the robot using the robot
RS condition file of the specified number. It is
necessary to create the robot RS condition file in
advance.
Robot RS cond. no. This is used to set the robot RS condition file number to use in robot RS control.
This is used to specify the robot move condition at the start of welding and in the
welding section with a file number.
Move cond. no. Details about the robot move condition number are described in "Chapter 7 Arc
welding-related settings".
Normally, “0” is set.

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Table 3.3.3 Arc start control conditions

Setting item Description
This condition can be set when the "Gas flow control unit" of arc constant is set to
"ON". For details, see the separate instruction manual for option [Gas saver GFC].
Gas flow control
setting Disabled : The gas flow rate that is set in the welding characteristic data
or welding constant is used.
Enabled : The gas flow rate is set in the arc start condition.

Table 3.3.4 Arc start conditions

Item name Setting range Unit
Welding current (when current is the current condition) 1 to rating A
Wire speed (when wire speed is the current condition) 1 to rating cm/min.
Welding voltage (with separate adjustments) 0.1 to rating V
Arc length tun. (with individual adjustment) -100 ～ 100 －
Welding speed 1 ～ 999 cm/min.
Arc character. -100 ～ 100 －
Gas flow rate *1 See below *1 L/min.
Slow down 100 to rating cm/min.
Slope time (when time is the slope condition) 0.0 ～ 9.9 sec.
Slope distance (when distance is the slope condition) 0 ～ 99 mm
Initial current (when current is the current condition) 1 to rating A
Ini. wire speed (when wire feed speed is the current
1 to rating cm/min.
condition)
Initial voltage (with individual control) 0.1 to rating V
Initial arc length fine adjustment (with synergetic control) -100～100 －
*1: For details on the gas flow rate and the input range for the gas flow rate, see the separate
instruction manual for option [Gas saver GFC].

Arc welding end conditions

The arc welding end conditions specified with the arc end command include special setting items
provided for individual welding power supply models, and setting items common to multiple
models.
This section describes setting items common to multiple models. For details on items special to
individual welding power supply models, see the chapters shown in Table 3.3.2.
Table 3.3.5 Arc end control conditions
Item name Setting range
This is used to specify the target welding power supply when multiple welding power
Welder supplies are connected. This need not be set if only one welding power supply is to
be used.
This is used to specify the welding condition file number to use in the arc end
command.
Welding condition file No. 0 : The welding conditions are set directly
with the arc end command. A welding
AS Cond. file condition file is not used.
Welding condition file No. 1 to : The welding condition file of the specified
999 number is used.
“3.3.3 How to set the arc welding conditions”
This is used to set which welding method to use for welding. The items displayed
Welding process
here are the welding methods registered as welding characteristic data.
This is used to select whether to specify the welding conditions with current or the
Current cond.
wire feed speed.
This is used to select the setting method for the slope control performed at the end of
welding. Select whether to specify the slope control range with time (time
Slope cond. specification) or distance (distance specification).
“3.3.5 Slope control”

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 Teaching arc welding start/end commands

Table 3.3.6 Arc end conditions

Item name Setting range Unit

Welding current (when current is the current condition) 1 to rating A
Wire speed (when wire speed is the current condition) 1 to rating cm/min.
Welding voltage (with individual control) 0.1 to rating V
Arc length tun. (with synergetic control) -100 ～ +100 －
Crater time 0.0 ～ 9.9 sec.
Post-flow time 0.0 ～ 9.9 sec.
Arc characteristics -100 ～ +100 －
Slope time (when time is the slope condition) 0.0～9.9 sec.
Slope distance (when distance is the slope condition) 0～99 mm
Robot stop time 0.0～9.9 sec.

How to set the arc welding conditions

The arc start commands and arc end commands have the following three methods available for
setting the welding conditions.
Method by which the welding conditions are specified directly using numerical values
In this method, numerical values for the welding conditions are input directly into the arc start
command and arc end command. In this case, specify "0" in "Condition file ID". This setting
method is known as "direct input".
This can only be used in arc start command (AS <FN414>) and arc end command (AE
<FN415>).
Method by which the number of the file storing the welding conditions is specified directly
In this method, the welding conditions are stored in a file in advance, and the number of this
file is input directly into the arc start command and arc end command. In this case, specify
the number of the condition file to be used in "AS Cond. file ". This setting method is known
as "file designation".
Method by which the number of the file storing the welding conditions is specified with a
variable
In this method, the welding conditions are stored in a file in advance, and the number of the
condition file to use is input indirectly by using a variable in the arc start command and arc
end command. This setting method is known as "variable designation".
This can only be used in arc start command (ASV <FN665>) and arc end command (AEV
<FN666>).
“3.3.9 Designating a variable for the condition file number”

Table 3.3.7 Arc welding start/end commands and welding condition setting methods
Command Welding condition setting methods
SLIM File Variable
Name FN code Direct input
identifier designation designation
Arc welding start AS FN414 ○ ○ ×
commands ASV FN665 × ○ ○
Arc welding end AE FN415 ○ ○ ×
commands AEV FN666 × ○ ○
○ Can be used
× Cannot be used

INFO. When welding multiple locations with the same welding conditions, it is useful to
specify the welding conditions with a file number. By revising the contents of a
welding condition file, you can change the welding conditions of all the arc start
commands and arc end commands that specify this file number.

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Teaching arc welding start/end commands

Creating new condition files and revising existing ones during teaching
When a number other than “0” is input in the “AS cond. file” field during arc welding command
teaching, the conditions stored in the corresponding condition file that has already been created
are called. If the number input corresponds to a file which has not yet been created, the initial
conditions are called.
The condition file can be created or edited with f6<Arc Condition>, as described in "Chapter 9
Basic arc welding operations" in the Basic Operation manual. However, the called conditions can
be immediately revised. When the revisions are made and then written, the revised conditions are
reflected in the file concerned. If a new file is to be created, the new file is created and stored in
the internal memory.

INFO. This operation is common to commands that specify conditions with a file, such
as the arc start command, arc end command and weaving start command.

This section describes the method used to call and revise condition file “1” during teaching, using
the arc start command (AS) as an example. (The same description applies when a new condition
file “1” is created.)

1 Input “1” in the “AS Cond. file” field, and press [Enter].
>> The conditions stored in condition file “1” are called. (If a new file is created, the initial
conditions are called.) At the same time, the f key for [Input Value] is displayed in f11.

2 To revise the conditions, press f11 <Input Value>.

>> The status in which the conditions can be revised is now established.

3 Revise the conditions, and after finishing press f12 <Complete>.

>> The revised conditions are reflected in the file concerned. If a new file is to be
created, the new file is created and stored in the internal memory.

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 Teaching arc welding start/end commands

Arc welding condition guide function

The welding condition guide function uses the welding condition database to automatically set
welding conditions suitable for the joint.
The welding conditions can be set automatically using the welding condition guide function if the
welding condition database for the welding power supply and wire diameters being used is
installed in the controller.
The welding condition guide function has the welding condition database shown in Table 3.3.8
loaded internally as standard. If any of Table 3.3.8 applies as the operating environment, the
welding condition guide function can be used straight away.
If they do not apply, creating a new welding condition database will enable the welding condition
guide function to be used. For details on creating a welding condition database, refer to “Chapter
7 Arc welding-related settings”.

Table 3.3.8 Standard internal welding condition database

Wire
Welding power units Welding method Gas Joint shape
Material Diameter
Solid mild
DC CO2
steel
DC MAG
Solid mild
DC pulsed (80%Ar,
steel
DC wave pulsed 20%CO2) Φ0.8
DC Φ0.9
MIG Stainless Φ1.0
DC pulsed (98%Ar, steel Φ1.2
DC wave pulsed 2%O2) solid
DC MAG
1
DC pulsed (90%Ar, Ferrite*
Welbee Inverter series Horizontal
/D-series welding power DC wave pulsed 10%CO2) fillet weld
supply Mild steel Φ1.0 Lap fillet weld
DC CO2
cored Φ1.2
Stainless
Φ0.9
DC CO2 steel
Φ1.2
cored
DC
MIG Φ1.2
DC pulsed Soft aluminum
(100%Ar) Φ1.6
DC wave pulsed
DC Φ1.0
MIG Hard
DC pulsed Φ1.2
(100%Ar) aluminum
DC wave pulsed Φ1.6
*1 A “Ferrite” indicates a ferritic stainless steel solid wire.

In some cases, it is not possible to use the above standard internal welding condition
database as is.
The standard internal welding condition database in Table 3.3.8 contains values
IMPORTANT obtained under the test environment inherent to the manufacturer. Depending on the
user’s operating environment, it may not be possible to use these values as is. In a case
like this, revise the data in the welding condition database before operation.

INFO. When using WB-M350L/WB-M350/WB-M500 with characteristic data where the

application in "Table 2.5.2.", “Table2.5.3.” and “Table2.5.4.” is "automatic machine", use a
welding condition database.

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Teaching arc welding start/end commands

Setting the conditions using the welding condition guide function

1 Open the welding conditions editing screen.
>> If a welding power supply is registered that can use the welding condition guide
function, f7 <Welding DB> appears on the pages with welding current items.
The following screen shows the display for the DP-350.

2 Press f7 <Welding DB>.

>> The following screen now appears.

If the following message is displayed, it means that there is no built-in welding condition
database that corresponds to the welding method (welding characteristics data) to be
used. If the welding condition guide function is to be used, it is necessary to create the
welding condition database.

3 Move the cursor to “Plate,” and then press [Enter] to specify the plate thickness of
the workpiece.

4 Move the cursor to “Joint,” and then select the type of joint using [ENABLE] +
＋ [LEFT/RIGHT].

5 To change the calculated welding speed or leg length, input the desired value.

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 Teaching arc welding start/end commands

6 Press f12 <Complete>.

>> The welding conditions are input automatically.

Slope control of arc welding conditions

Slope control changes the conditions (welding current, welding voltage) in a sloping form
(gradually), instead of immediately changing welding conditions to the specified values. Slope
control reduces abnormalities such as spatter and welding defects when starting welding or
changing conditions. Slope control can be used at the start of welding, when changing conditions,
and at the end of welding.

Slope control at the start of welding

As shown in the figure below, slope control is performed from the set initial welding conditions to
the regular welding conditions.
You can specify the section in which to perform slope control using either distance or time.

Fig. 3.3.1 Slope control sequence at the start of welding

Slope control when changing conditions

When changing conditions, slope control is performed from the conditions before the change to
the conditions after the change.
The current and voltage are changed gradually from the conditions before the change to the
conditions after the change. The initial current and initial voltage settings are not used when
changing the conditions.

Fig. 3.3.2 Slope control sequence when changing conditions

POINT If a welding command is executed again during slope control

If the arc end command is taught immediately after starting to weld, or
welding conditions are changed at a short distance, the arc start command or
end command will be executed during slope control. If this happens, slope
control stops at the moment that the command is executed.

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Slope control at the end of welding

At the end of welding, slope control is performed from the regular welding conditions to the crater
conditions.
As shown in the figure below, slope control is performed of the welding current and welding
voltage for the "Slope distance or time" + "Robot stop time".

Fig. 3.3.3 Slope control sequence at the end of welding

POINT Before performing the slope process, be sure to set the crater conditions
At the end of welding, slope control is performed from the regular welding
conditions to the crater conditions. This means that even if the crater
treatment is not required, the crater conditions (crater current, crater voltage)
must be input in order to perform slope control.

About restrictions to the slope process at the end of welding

If the robot reaches the arc end point during slope control, the slope control
stops and the crater treatment is entered.
This is because, although the maximum input value for the slope time (or
distance) is 9.9 sec. (or 99 mm), during robot control, the movement time (or
distance) from the step before the welding end to the welding end step is
recognized as the maximum slope time (or distance).

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 Teaching arc welding start/end commands

Arc retry
Arc retry is an operation that tries arc start again after arc start fails. The following two methods
are available for arc retry.

Table 3.3.9 Arc retry methods

Type Specification method Description
Standard Specify 0 in the "Retry No." of The retry operation available internally as
internal the arc start command. standard is performed.
If arc start fails, you can perform various retry
Specify the retry condition file
methods, such as changing the arc start position
User number (1 to 99) in the "Retry
or changing the retry operation with each retry.
defined No." of the arc start
The retry method is defined in the retry condition
command.
file (RETRYARCW file).

This section describes the standard internal arc retry. For details on the user defined arc retries,
refer to “7.4 Defining arc start” in “Chapter 7 Arc welding-related settings”.

In the standard internal arc retry operation, the robot initiates wire retract and slowdown at the
corresponding position (arc start point). "Slowdown" is feeding the wire at a lower speed than the
feed speed during welding while applying the voltage for generating the arc. If the arc is not
generated even after repeating this operation the number of times set with the welding constant,
the robot stops because of an arc start failure.
The welding constants related to the standard internal arc retry when using a robot-dedicated
welding power supply are shown in the table below.

Table 3.3.10 Arc welding constants related to standard internal arc retry
(robot-dedicated welding power supply)

Constant name Setting range Default Significance

This is used to set the time taken to
determine that arc start has failed.
Arc start failure 1.3 The wire is slowed down from the start of the
0.0 ～ 9.9
detection time sec. arc start process to the specified time. If arc
start fails to be performed in the specified
time, the arc retry process is performed.
3 This sets how many retries are to be initiated
Arc start retry number 0 ～ 9
times if arc start was not successful.
This sets the wire retract time. This
0.5 parameter is used to make the adjustment if
Wire retract time 0.00 ～ 0.99
sec. the wire has been retracted too far or too
little.

POINT Adjust the retract amount during arc retry using the arc welding constants
The retract amount during arc retry varies slightly depending on factors such
as the feeder used and the feed path length. If the retract amount during arc
retry is not appropriate for the inching amount at arc start, adjust the value of
the welding constant [Wire retract time], for instance.

Arc retry does not work with scratch starts

The arc retry function does not work when scratch start has been set.

No need to create retry condition file 0

When “0” is specified as the number of the retry condition file, the standard
internal arc retry is initiated. This means that there is no need to create a retry
condition file with the number “0.”

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Arc restart
Arc restart is the operation that retries arc start to restart welding after an arc outage has occurred
during welding for some reason or other. Using this function prevents the robot from being
stopped by an arc outage.
For the welding restart method of the arc restart operation, the same definition and same
conditions as user defined arc retry conditions are used. Also, the three specification methods
shown in the table below are available for arc restart.

Table 3.3.11 Arc restart specification methods

Setting type Specification method Description
Specify 0 in the "Restart No." of the arc
start command, and specify 0 in the A restart operation is not
Not used
"Arc restart number for arc outage" of performed.
the welding constant.
Restart operations are performed
with the specified restart
For individual Specify the retry condition file number (1
conditions for each individual
welding to 99) in the "Restart No." of the arc
welding section. This has priority
sections start command.
over the “For all welding sections”
setting.
Specify the retry condition file number (1
For all welding A common restart operation is
to 99) in the "Arc restart number for arc
sections performed for all welding sections.
outage" welding constant.

For details on arc restart, refer to “7.5 Specifying arc restart” in “Chapter 7 Arc welding-related
settings”.

Robot movement condition file

These conditions are provided for optimizing the robot movement to suit the arc welding
conditions. The parameters shown in Table 3.3.12 can be specified as the parameters of the AS
commands.
For details, refer to “7.5 Robot movement condition file” in “Chapter 7 Arc welding-related
settings”.

Table 3.3.12 Type of robot movement condition

Motion condition Description
Chasing Level (0 to 3) This parameter is used to enhance the ability of the
robot to track commands values.
Smooth Level (0 to 3) This parameter is used to make the robot
operations smoother.
Accel Level (0 to 3) This parameter is used to make the robot operation
speeds smoother.
Smooth Level before AS (0 to 3) This parameter is used to reduce the vibrations of
the robot at arc start.

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 Teaching the weaving command

Teaching the weaving command

Weaving is used when there are gaps in the work piece or the leg length is to be shortened. Details on the
teaching and operation methods for weaving are described in "Chapter 9 Basic arc welding operations" in the
Basic Operation manual. This section describes the weaving commands and the conditions set with these
commands.

To set up the robot for weaving, record the weaving start command where weaving is to start and the weaving
end command where it is to end. The following weaving start and end commands are available.

Table 3.4.1 Weaving command list

Command
SLIM Description
Name FN code
identifier
This is the command for weaving using the NV6 and
other 6-axis robots.
Fixed pattern weaving
WFP FN440 Weaving can be performed to match the groove shape
start command
by specifying the inclination angles, crosswise angles
and other conditions.
This is the fixed pattern weaving start command. The
weaving condition can be specified by a weaving
Fixed pattern weaving
WFPV FN667 condition file. There are alternatives whether to specify
start command (variable)
the condition file number directly by a number or to
specify by a variable.
Joint weaving start This performs weaving using the simple harmonic
WAX FN441
command motion of the axes.
This is the joint weaving start command. The weaving
Joint weaving start condition can be specified by a weaving condition file.
command WAXV FN668 There are alternatives whether to specify the condition
(variable) file number directly by a number or to specify by a
variable.
This is the command for starting the weaving using the
pattern which was taught in advance in accordance
Taught weaving start with the groove shape.
WSF FN442
command However, taught weaving is an option and, as such, it
is not described in this chapter. Refer to the separate
instruction manual for option “Taught Weaving.”
Weaving end command WE FN443 This is the command for ending the weaving.

POINT Changing the conditions in a weaving section

To change the conditions during weaving, record a weaving start command of
the same type again in the position where you want to change the conditions.
If the weaving command is of the same type, the phase direction is continued
even if a condition is changed. (It is not continued if the weaving command is
of a different type.)

Advance direction
WFP start

WFP change

Fig. 3.4.1 Continuation of phase when conditions are changed

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Teaching the weaving command

Fixed pattern weaving

This command is used to start weaving using a predetermined pattern in accordance with the
specified amplitude and frequency.
The following conditions are set.

Table 3.4.2 Fixed pattern weaving conditions

Item Setting range Default Unit
Frequency 0.0 ～ 20.0 5.0 Hz
Linear function Linear
Function type －
/ Sine wave / Circle function
Amplitude (right amplitude, left
amplitude)
* When the linear function or trigonometric 0.0 ～ 50.0 1.0 mm
function has been set as the operation
pattern
Radius (right radius, left radius)
* When the arc has been set as the operation 0.0 ～ 50.0 1.0 mm
pattern
Stopping time (center, 1/4 period, 3/4
0.0 ～ 9.9 0.0 sec.
period)
Move at stop time ON / OFF ON －
Keep weaving time Yes / no No －
Weaving start direction Right / Left Right －
Weaving Angle (right angle of
-180 ～ 180 0.0 deg
inclination, left angle of inclination)
Torch Angle (right angle of inclination,
-180 ～ 180 0.0 deg
left angle of inclination)
Push Angle (right crosswise angle, left
crosswise angle)
* When the linear function or trigonometric -180 ～ 180 0.0 deg
function has been set as the operation
pattern
Circle ratio (front roundness ratio, back
roundness ratio)
1 ～ 100 100 %
* When the arc has been set as the operation
pattern

Frequency
This is the weaving frequency (number of waveforms per second).

Function type
One of the following can be selected as the weaving operation pattern (waveform).

Linear function Sine wave Circle

Fig. 3.4.2 Weaving operation patterns

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 Teaching the weaving command

Amplitude and radius

This condition is for setting the weaving amplitude when the linear function or trigonometric
function has been set as the operation pattern. Both the left and right amplitudes relative to the
advance direction can be set.
The radius from the center of the circle is set when the circle has been set as the operation pattern.
Both the left and right radius relative to the advance direction can be set.

Left
amplitude Left radius

Right Right radius Advance direction

amplitude Advance direction

When the linear function or trigonometric When the circle is set

function is set
Fig. 3.4.3 Amplitude

Stopping time
The center stop time, 1/4 period stop time and 3/4 period stop time are set.

3/4 period stop time

Advance direction
Left amplitude
Main
path
Right amplitude
Center stop time

1/4 period stop time

Fig. 3.4.4 Stopping time

Move at stop time

This condition is for selecting whether the robot is to move forward in the advance direction or
stop during the weaving stop time when weaving stop time has been set. The default setting is
“ON”.

When the advance at stop time has been set to When the advance at stop time has been set to
"Not Exist" "Exist"

Fig. 3.4.5 Forward movement during stop time

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Teaching the weaving command

Keep weaving time

The condition is for setting whether the actual welding time is to be maintained even when the
weaving stop time has been set.
If the weaving stop time is not set, the condition will not have any function.

・Setting the Keep weaving time to ‘Keep’, the movement speed of the robot
becomes larger than the welding speed taught in advance according to the
IMPORTANT setting of the weaving stop time.
・When setting the weaving ON/OFF to ‘OFF’, the weaving control is not
executed, however the movement speed of the robot is the same as the case
with the weaving set to ‘ON’.

Weaving start direction

This condition is for setting whether the weaving is to start on the right or left relative to the
advance direction. Right is the default setting, and weaving starts from the right side relative to the
advance direction.

Left Advance
Left Start point
amplitude direction
amplitude

Right Right
amplitude Advance amplitude Start point
direction

When oscillation start is on the right side When oscillation start is on the left side
Fig. 3.4.6 Phase when started (oscillation start direction of weaving)

Weaving angle
This condition is for setting angle of the weaving from the main path. It can be set for both the left
and right amplitude. The initial value is 0 degrees, and the weaving plane is perpendicular to the
torch.

Right angle of (+) (+) Left angle of

R ig ht L eft inclination Right Left inclination
a mpl itu de a mp li tud e amplitude amplitude
0゜ 0゜

(-) ( -)

Weaving at an angle of inclination of Weaving when there is an angle of inclination

0 degrees
Fig. 3.4.7 Weaving angle

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 Teaching the weaving command

Torch angle
When the angle of inclination of the torch is set, this condition makes it possible to determine the
welding posture in respect of the work piece surface at the weaving end point.

Torch left angle － 0°

of inclination
＋

＋
0°
－

Torch right angle of

inclination

The rear plane direction from the front paper plane is

the welding direction.

Fig. 3.4.8 Torch angle

Crosswise angle
When the crosswise angle is set, this enables a change into a waveform such as the one shown in
the figure below.
However, when the crosswise angle is set, the amplitude is tilted in the advance direction and is
thus shortened. If, for instance, the angle is set to -45 degrees, the amplitude will be about 70% of
what it would be if the angle were 0 degrees.

Fig. 3.4.9 Crosswise angle

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Teaching the weaving command

Circle center ratio

The roundness ratio is set when arc has been set as the operation pattern. This ratio is for
determining the percentage of the advance direction components to be reflected in the arc radius
(for determining to what extent the arc is to be distorted).

The circle will be completely round if, for instance, it is assumed that the circle in Fig. 3.4.10 has:
• A left radius and right radius of the same length
• A front roundness and back roundness of 100%
(Perfect circles are formed in cases where weaving is performed immediately. Normally, they are
not formed since the speed component of the advance direction is added.)

The center circle ratio is what determines the extent to which the arcs are to be distorted in the
advance direction.
The circle shown in Fig. 3.4.11 will be formed if 50% is set as the front roundness ratio and 75%
as the back roundness ratio.

Weld line Weld line

Waveform when Waveform when
both the front the front
Front roundness ratio roundness ratio is
and the back Front
roundness 50% and the back
roundness ratio are roundnes
ratio roundness ratio is
100% s ratio
= 100% 75%
= 50%
Back
Back
roundnes
s ratio
roundnes
= 100% s ratio
= 75%

Left radius Right radius Left radius Right radius

= 10 mm = 10 mm

Fig. 3.4.10 When the front roundness ratio and Fig. 3.4.11 When the front roundness ratio is
back roundness ratio are 100% 50% and the back roundness ratio is 75%

Joint weaving
This command is used to start weaving using the simple harmonic motion of the axes.
The following conditions are set.

Table 3.4.3 Joint weaving conditions

Item Setting range Unit

Frequency 0.0 ～ 20.0 Hz
Stopping time (center, 1/4 period, 3/4 period) 0.0 ～ 9.9 sec.
Move at stop time ON/OFF －
Keep weaving time Yes/no －
Axis number 1 ～ 6 －
Amplitude (right amplitude, left amplitude) 0.0 ～ 9.99° deg

Axis number
This condition specifies the number of the axis which will be used to conduct the weaving.

Other items
Refer to "3.4.1 Fixed pattern weaving".

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 Teaching the weaving command

Weaving end command

This command is used to end the weaving while it is being executed.
Operation returns to the main path if it is midway through a weaving waveform.

Returns to the main path

at the end position.

Main path

Fig. 3.4.12 Weaving end

How to set the weaving conditions

With the weaving start command, “the conditions under which weaving is to be performed in the
section concerned” are set. These conditions are known as the weaving conditions.
The following methods of setting the weaving conditions are provided.

Method by which the weaving conditions are specified directly using numerical values
In this method, numerical values for the weaving conditions are input directly into the weaving
start command. In this case, specify "0" in "Weaving condition file ID". This setting method is
known as "direct input".

Method by which a file specifying the weaving conditions is created beforehand and its number is
specified
In this method, the weaving conditions are stored in a file in advance, and the number of this file
is input directly into the weaving start command. In this case, specify the number of this file in
"Condition file ID". This setting method is known as "file designation".

Method by which the number of the file specifying the weaving conditions is specified with a
variable
In this method, the weaving conditions are stored in a file in advance, and the number is
specified indirectly by using a variable as the number of this file in the weaving start command.
This setting method is known as "variable designation".
This can only be used for fixed pattern weaving start command (WFPV<FN667>) and the joint
weaving start command (WAXV<FN668>).
Table 3.4.4 Weaving start commands and weaving condition setting methods
Command How to set the weaving conditions
SLIM Direct File Variable
Name FN code
identifier input designation designation
WFP FN440 ○ ○ ×
Fixed pattern weaving
WFPV FN667 × ○ ○
WAX FN441 ○ ○ ×
Joint weaving
WAXV FN668 × ○ ○
Taught weaving*1 WSF FN442 *1 *1 *1
○ Can be used
× Cannot be used
*1 Refer to the separate instruction manual for option “Taught Weaving.”

 When welding multiple locations with the same weaving conditions, it is useful
INFO. to specify the weaving conditions with a file number. By revising the contents
of a weaving condition file, you can change the weaving conditions of all the
weaving start commands that specify this file number.
 In the same way as arc welding commands, you can create new condition files
and revise existing ones during the teaching of a weaving start command. For
details, refer to "3.3.1 Arc welding start conditions" in "Chapter 3 Preparing arc
welding programs".

113
 Teaching other arc welding commands

Teaching other arc welding commands

In addition to the arc start command and arc end command, the following arc welding commands are also
available.

Table 3.5.1 Arc welding start/end command list

Command
SLIM Description
Name FN code
identifier
This is used to inch (forward feed) the welding wire.
Inching command ICH FN410
“3.5.1 Inching command/retract command”
This is used to retract (reverse feed) the welding wire.
Retract command RTC FN411
“3.5.1 Inching command/retract command”
This is used to discharge the shielding gas.
Gas ON command GS FN412
“3.5.2 Gas ON command/gas OFF command”
This is used to stop the discharging of the shielding gas.
Gas OFF command GE FN413
“3.5.2 Gas ON command/gas OFF command”

Inching command/retract command

The inching command (ICH command) and retract command (RTC command) are used for
inching and retracting the wire during automatic operation.
The following conditions are set for both these commands.

Table 3.5.2 Setting conditions for the inching and retract

commands
Condition to set Setting range Unit
Time 0.0 ～ 9.9 sec.
Wire feed speed 1 ～ 9999 cm/min.

About the inching and retract amounts

POINT
The inching and retract amounts are determined by the relationship between the
time and speed described above.

A robot does not stop while executing inching or retract.

The movement of the robot does not stop while an inching or retract command
is being executed.
Also, if an arc start command is taught immediately after an inching or retract
command is executed, the welding starts after the inching or retract is
completed.

Sometimes inching or retract may not be executed

In the following cases, inching and retract commands are not executed.

・ When welding ON/OFF is set to OFF

・ When in a welding section *1
・ When operation was temporarily stopped and restarted while inching or
retract was being executed
*1: The retract command for the filler wire in DA-300P is executed even when in
the welding section.

115
Teaching other arc welding commands

Gas ON command/gas OFF command

Gas ON command
The gas can be output by recording the gas ON command (GS command). This is useful for
situations such as when you want to start the welding gas pre-flow at a time of your own choosing.
If automatic operation is temporarily stopped while gas is being output due to the gas ON
command, the gas output is stopped, but when the operation is restarted, the gas output is also
executed again.

Gas OFF command

The gas can be stopped by recording the gas OFF command (GE command). This is useful for
situations such as when you want to stop the gas output with the gas ON command, or when you
want to stop the welding gas post-flow at a time of your own choosing.

POINT Sometimes gas output may not be executed

In the following cases, gas output is not executed.
・ When welding ON/OFF is set to OFF
・ When in a welding section

Continuing the gas output even after an END command

To continue the gas output even after an END command, in [Arc constant] - [3
Constant of Weld], set [Stop welder at END] to "OFF".
At this time, you can use the operations described in Table 3.5.3 to continue the
gas output even after the END command.
Table 3.5.3 Gas output after END command
Setti method Description
Stops the gas output after the execution of the
post-flow of the arc end command.
It continues until the time specified in [Arc
Arc end command
constant] - [3 Constant of Weld] - [Gas off
(AE command)
delay time].
The gas output is not stopped with the END
command.
The gas output is not stopped automatically.
The gas output continues until the following.
Gas ON command
 Gas OFF command (GE command)
(GS command)
 AS command is executed
 Emergency stop

116
 Useful function commands

Useful function commands

This section gives a simple description of the function commands in Table 3.6.1, which are useful when
preparing arc welding programs. For details on function commands not described in this section, refer to the
internal help of the robot controller.

Table 3.6.1 Useful function commands

Identifying Function Reference
Classification Name Function
abbreviation number page
This attaches a comment inside a
Comment Comment REM FN99 3-30
program.
Operation stands by for the specified
Timer Timer DELAY FN50 3-30
time.
The specified output signal is set to
Output signal ON SET FN32 3-32
ON.
This sets the specified output signal
Output signal OFF RESET FN34 3-32
to OFF.
Output signal This sets the specified output signal
SETM FN105 3-33
ON/OFF to ON or OFF.
This sets the specified output signal
External Output signal to ON for a specific period of time
SETMD FN35 3-33
input/ output (pulsed, with delay) only. The delay time can also be
specified.
This sets all the output signals to
All output signals clear ALLCLR FN0 3-34
OFF.
Input signal wait This waits for the specified input
WAITI FN525 3-34
(positive logic) signal to be set to ON.
Input signal wait This waits for the specified input
WAITJ FN526 3-35
(negative logic) signal to be set to OFF.
Step jump JMP FN20 This jumps to the specified step. 3-36
Program Step jump This jumps to the specified step if the
JMPI FN23 3-37
branch (conditional) input signal is ON.
inside
This jumps to the specified step after
program Step jump
JMPN FN26 the command has been executed for 3-38
(with count condition)
the specified count.
Program call CALLP FN80 This calls other programs. 3-39
Program call This calls the specified program if
CALLPI FN81 3-40
(conditional) the input signal is ON.
Program call
This calls the specified program after
Program call
CALLPN FN82 the command has been executed for 3-41
(with count condition)
the specified count.

Including the above function commands, all the function commands relevant to
I/O signals cannot use the signals allocated to the dedicated I/O signals.
If the signals allocated to the dedicated I/O signals are to be placed as the
IMPORTANT condition for the branch command or signal wait command, it lapses into the
conditional failures without exception.

117
Useful function commands

Comment - [REM<FN99>] -
Function This command is used to write a comment inside the program.

Alphanumerics, symbols, hiragana, katakana and kanji can be input using the software
keyboard. (Hiragana, katakana and kanji can be input only when the Japanese language
specifications are provided.)
Up to 199 half-size (or 99 full-size) characters can be input.

Selection [FN] → [9] [9] → [Enter]

method

Parameters Any character string (with up to 199 half-size or 99 full-size characters)

Point (1) A comment written at the head (step 1) of a task program is treated specially as the
“program name”, and it appears on the program list display using short-cut R17 or
status window at the top of the screen.

[Example] Comment displayed on status window

A comment attached to the head

(step 0) of a work program is
displayed here as the “program
name”. Up to 38 characters (half
size) can be displayed from the start
of the comment that is input with the
REM function command.

(2) Comments may be recorded at any position in task programs. In addition, any number
of comments may be recorded.

Timer - [DELAY<FN50>] -
Function Operation stands by immediately for the time specified by the robot. During standby, the
robot remains stationary at the position recorded immediately before the timer command.

Selection [FN] → [5] [0] → [Enter]

method

Parameters Standby time (0 to 60 sec.)

Point The timer command can be used in the following ways.

118
 Useful function commands

Torch cleaning
When the torch is to be cleaned, teach this command so that the robot will stand by for the time
required by cleaning after the torch has moved by linear interpolation as far as the inside of the
cleaner.

Torch

1 4

Cleaner

2
3 DELAY

Fig. 3.6.1 Example of teaching the timer command for torch cleaning

Tack welding
When tack welding is to be performed, teach the timer command so that it is sandwiched between
the arc start and arc end commands.

1
6 11

Work-
piece
2 7
3 AS 8 AS
4 DELAY 9 DELAY
5 AE 10 AE

Fig. 3.6.2 Example of teaching the timer command for tack welding

Weaving during timer time

If there are places where deep penetration is desired while thick sheets are being welded, teach
the timer command so that welding is executed immediately while weaving is conducted for the
specified time. In this case, the following must be taught to determine the operation direction of
the weaving.

To determine the weaving direction, teach the

movement command (linear interpolation) for
the direction to the welding location. It doesn’t
matter if the distance is short.

Fig. 3.6.3 Example of teaching the timer command during weaving within timer time

119
Useful function commands

Output signal ON - [SET<FN32>] -

Function This command is used to set any one of the general-purpose output signals (O1 to O2048)
to ON.
However, it cannot be used to set a status signal (a gun signal, starting signal or other
signal whose application has been pre-allocated) to ON.

Selection [FN] → [3] [2] → [Enter]

method * The command can be selected by a single action if the [Output] key on the teach pendant
is used.

Parameters Output signal number (1 to 2048)

Point As in steps 2 and 3 in the figure below, the signal is output as soon as the inside arc is
started if the accuracy level (inside arc) has been specified using a movement command
immediately before this function command.
If the timing at which the signal is to be output must be exactly at the position (step 2),
where the movement command is recorded, the command must be taught in such a way
that the accuracy level is set to A1 or positioning is to be performed so that the tool will not
describe an inside arc.

Output signal OFF - [RESET<FN34>] -

Function This command is used to set any one of the general-purpose output signals (O1 to O2048)
to OFF.
However, it cannot be used to set a status signal (a gun signal, starting signal or other
signal whose application has been pre-allocated) to OFF.

Selection [FN] → [3] [4] → [Enter]

method

Parameters Output signal number (1 to 2048)

Point Same as for output signal ON (SET <FN32>).

120
 Useful function commands

Output signal ON/OFF - [SETM<FN105>] -

Function This command is used to set any one of the general-purpose output signals (O1 to O2048)
to ON and OFF.
However, it cannot be used to set a status signal (a gun signal, starting signal or other
signal whose application has been pre-allocated) to ON.

Selection [FN] → [1] [0] [5] → [Enter]

method

Parameters (1) Output signal number (1 to 2048)

(2) ON/OFF (1/0)

Point Same as for output signal ON (SET <FN32>).

Output signal ON/OFF (pulsed, with delay) - [SETMD<FN35>] -

Function This command is used to set any one of the general-purpose output signals (O1 to O2048)
to ON or OFF. It can also specify a pulsed output, advance output or delayed output.
However, it cannot be used to set a status signal (a gun signal, starting signal or other
signal whose application has been pre-allocated) to ON and OFF

Selection [FN] → [3] [5] → [Enter]

method

Parameters (1) Output signal number (1 to 2048)

(2) ON/OFF (1/0)
(3) Delay time (–10.0 to 10.0 [sec.])
If “0.0” is specified as the time, the command is executed at the timing which coincides
with the recorded position. If a minus value is specified, the command is output ahead
of the original execution timing by the amount equivalent to the delay time setting.
Conversely, if a plus value is specified, it is output after the timing by the amount
equivalent to the delay time setting.
(4) Pulse time (0.0 to 10.0 [sec.])
This is set when the output signal is to be output as a pulse signal. It is used to specify
the width of the pulse signal. When “0.0” is specified as the time, a level signal is
output.

Point When advance output or delayed output has been specified, it can be output astride the
immediately preceding movement command (step 1 in the figure below) or immediately
subsequent movement command (step 4 in the figure below).

121
Useful function commands

All output signals clear - [ALLCLR<FN0>] -

Function This command is used to set all the general-purpose output signals (O1 to O2048) to OFF.
However, it cannot be used to set a status signal (a gun signal, starting signal or other
signal whose application has been pre-allocated) to OFF.
Whether it has been allocated to a status signal can be ascertained on the monitor screen.
Signals whose numbers are in bold italics are status signals, and so the command sets all
other signals to OFF.

Selection [FN] → [0] → [Enter]

method

Parameters OFF

Point Same as for output signal ON (SET <FN32>).

Input signal wait (positive logic) - [WAITI<FN525>] -

Function This command is used to cause the robot to stand by until one of the specified
general-purpose input signals is set to ON.

It is not possible to wait for a status signal (a signal such as the welding finish signal and
start signal whose application has already been assigned). Whether it has been allocated
to a status signal can be ascertained on the monitor screen. Signals whose numbers are
displayed in the bold italics are status signals so any of the other signals can be awaited.

Selection [FN] → [5] [2] [5] → [Enter]

method * The command can be selected by a single action if the [Input] key on the teach pendant
is used.

Parameters Input signal number (1 to 2048)

Point When the inside arc has been set by the movement command immediately before this
function command, the input of the signal is checked at the timing at which the inside arc is
started.
If the signal has been input, the robot describes the inside arc straight away with no
deceleration.
If the signal has not been input, the robot moves to the position where the movement
command is recorded, and then the signal input is checked.

122
 Useful function commands

Input signal wait (negative logic) - [WAITJ<FN526>] -

Function This command is used to cause the robot to stand by until one of the specified
general-purpose input signals is set to OFF.

It is not possible to wait for a status signal (a signal such as the welding finish signal and
start signal whose application has already been assigned).

Selection [FN] → [5] [2] [5] → [Enter]

method

Parameters Input signal number (1 to 2048)

Point Same as for input signal wait (positive logic).

123
Useful function commands

Step jump - [JMP<FN20>] -

Function This command is used to jump unconditionally to a step which has been specified in the
same program.
It makes no difference whether the jump destination step is a movement command or
function command. However, bear in mind that if the jump destination step is a function
command, the function command at the jump destination will be executed as soon as the
step jump command is executed.
Use JMPI <FN23> to jump in accordance with the input signal status, and use JMPN
<FN26> to jump after the command has been executed for the specified count.

Selection [FN] → [2] [0] → [Enter]

method

Parameters Step number (1 to 9999)

Point (1) Teach as follows when a program is to be repeatedly played back using the step jump
command.
Jump
destination step

Repeated
until it stops.

Jump to step 1

(2) When the step jump command is taught midway through a program as below, the
subsequent steps will not be executed. In the case of the figure below, steps 5 and 6
will not be executed.
Step 4
JMP: Step jump (FN20)
Step No. = 7

１ ２ ３ ５

● ● ● ●

９ ８ ７ ６
● ● ● ●

(3) If the jump destination step is a function command, the function command at the jump
destination will be executed as soon as the step jump command is executed.
Step 4
JMP: Step jump (FN20)
Step No. = 7

１ ２ ３ ５

● ● ● ●

１０ ９ ８ ６
● ● ● ●
Step 7: Output command
Step 7: After the output
command is executed in this
position, moves to step 8

(4) Even when the jump destination step has shifted because a command was added or
deleted, the jump destination step number specified by the step jump command will
be followed. (If the jump destination step prior to a revision was 2 but it then became
1 due to a deletion, the number of the jump destination step number will change from
2 to 1.)

124
 Useful function commands

Step jump (conditional) - [JMPI<FN23>] -

Function This command is used to jump to a step which was specified in the same program in
accordance with the input signal status.
If the specified input signal is ON, the robot jumps; conversely, if it is OFF, the robot does
not jump, and it passes the command.
It makes no difference whether the jump destination step is a movement command or
function command. However, bear in mind that if the jump destination step is a function
command, the function command at the jump destination will be executed as soon as the
step jump command is executed.

Selection [FN] → [2] [3] → [Enter]

method

Parameters (1) Step number (1 to 9999)

(2) Input signal number (1 to 2048)

Point (1) Teach as follows when a program is to be repeatedly played back using the step jump
command. In the example given below, the robot jumps if input signal “1” is ON; if it is
OFF, it ends the playback.

Jumps if input Jump destination step

signal “1” is ON.
If it is OFF,
executes the
command (END)
and ends the Jumps to step 1 in
playback. accordance with the
input signal status

(2) In the example shown in the figure below, if input signal “1” has been input, the robot
jumps to step 7; if it has not been input, it advances to step 5.

Step 4
JMPI: Conditional step jump (FN23)
Step No. = 7
Input signal = I1
１ ２ ３ ５

● ● ● ●
When the I1 When the I1
signal is input signal is not input

９ ８ ７ ６
● ● ● ●

If the accuracy level (inside arc) has been specified by a movement command
immediately before this function command, the input of the signal is checked at the
timing at which the inside arc is started.
If the signal has been input, the robot describes the inside arc straight away with no
deceleration.
If the signal has not been input, the robot moves to the position where the movement
command is recorded, and then the signal input is checked.

(3) Even when the jump destination step has shifted because a command was added or
deleted, the jump destination step number specified by the step jump command will
be followed. (If the jump destination step prior to a revision was 2 but it then became
1 due to a deletion, the number of the jump destination step number will change from
2 to 1.)

125
Useful function commands

Step jump (with count condition) - [JMPN<FN26>] -

Function This command is used to jump to the step specified in the same program in accordance
with the pass count.
The robot passes for the specified count, and the jump is executed the next time
(specified count + 1). (For instance, if the specified count is “2”, the robot passes twice
and on the third occasion the jump is executed.)
It makes no difference whether the jump destination step is a movement command or
function command. However, bear in mind that if the jump destination step is a function
command, the function command at the jump destination will be executed as soon as the
step jump command is executed.

Selection [FN] → [2] [6] → [Enter]

method

Parameters (1) Step number (1 to 9999)

(2) Variable number (1 to 200)
(3) Frequency (0 to 10000)

Point (1) Teach as follows if a program is to be repeated five times using the step jump
command and then its playback is to be ended.

Jump destination: Step 11,

Counter: 1 (V1%),
Execution count: 5 times

After executing
for the specified
count, jumps to
After executing 5 step 11
times, jumps to
step 11 (END) and
ends the playback. Returns to the
start each time
after finishing the
work cycle

(2) If the accuracy level (inside arc) has been specified by a movement command
immediately before this function command, the robot jumps at the timing at which the
inside arc is started.

(3) Even when the jump destination step has shifted because a command was added or
deleted, the jump destination step number specified by the step jump command will
be followed. (If the jump destination step prior to a revision was 2 but it then became
1 due to a deletion, the number of the jump destination step number will change from
2 to 1.)

126
 Useful function commands

Program call - [CALLP<FN80>] -

Function This command is used to call the specified program unconditionally.

When the playback of the program at the call destination finishes (when the END
command is executed), operation returns to the step following the call command in the call
source program.

Use CALLPI <FN81> to call in accordance with the input signal status, and use CALLPN
<FN82> to call after the command has been executed for the specified count.

Selection [FN] → [8] [0] → [Enter]

method

Parameters Program number (1 to 9999)

Point (1) The following operations are performed when another program is called midway
through a program.

Step 4
Program 1
CALLP; Program call (FN80)
Program number = 2

１ ２ ３ ５ ６
● ● ● ● ●
7: End (FN92)

Program 2
１
5: End (FN92) ●４ ●

● ●
３ ２

(2) The program call can be executed again in the call destination program. Up to 8 layers
of calls can be executed. If calls exceeding 8 layers are executed, the “A2138 Wrong
call command setting” alarm is detected during playback, and the robot stops.

127
Useful function commands

Program call (conditional) - [CALLPI<FN81>] -

Function This command is used to call the specified program in accordance with the input signal
status.
If the specified input signal is ON, the program is called; conversely, if it is OFF, the
program is not called, and the robot passes.
When the playback of the program at the call destination finishes (when the END
command is executed), operation returns to the step following the call command in the call
source program.

Selection [FN] → [8] [1] → [Enter]

method

Parameters (1) Program number (1 to 9999)

(2) Input signal number (1 to 2048)

Point (1) The following operations are performed when another program is called conditionally
midway through a program.
Step 4
Program 1
CALLPI; Conditional program call (FN81)
Program number = 2
Input signal = I1

１ ２ ３ ５ ６
● ● ● ● ●
7: End (FN92)
When the I1
signal is input When the I1
signal is not input
Program 2

5: End (FN92)
●４ ●
１

● ●
３ ２

If the accuracy level (inside arc) has been specified by a movement command
immediately before this function command, the input of the signal is checked at the
timing at which the inside arc is started.
If the signal has been input, the robot describes the inside arc straight away with no
deceleration.
If the signal has not been input, the robot moves to the position where the movement
command is recorded, and then the signal input is checked.

(2) The program call can be executed again in the call destination program. Up to 8 layers
of calls can be executed. If calls exceeding 8 layers are executed, the “A2138 Wrong
call command setting” alarm is detected during playback, and the robot stops.

128
 Useful function commands

Program call (with count condition) - [CALLPN<FN82>] -

Function This command is used to call a program in accordance with the pass count.
The robot passes for the specified count, and the call is executed the next time (specified
count + 1). (For instance, if the specified count is “2”, the robot passes twice and on the
third occasion the call is executed.)

When the playback of the program at the call destination finishes (when the END
command is executed), operation returns to the step following the call command in the call
source program.

Selection [FN] → [8] [2] → [Enter]

method

Parameters (1) Program number (1 to 9999)

(2) Variable number (1 to 200)
(3) Frequency (0 to 10000)

Point If the accuracy level (inside arc) has been specified by a movement command immediately
before this function command, the program is called at the timing at which the inside arc is
started.

129
Operations during check GO or BACK

Operations during check GO or BACK

This section describes the items required in the check operations of task programs that perform arc welding.
After the task program has been created, check what has been taught with a check operation (check GO/BACK).
For detail on operating check GO/BACK , refer to the “Chapter 4 Teaching” in the “BASIC OPERATION
MANUAL”.
During the check operations for task programs that perform arc welding, also check the following.
 Target position check
Check whether what has been taught ensures that the wire tip will move along the weld line. If it is
off the weld line, revise the already recorded positions and/or add new ones.
 Torch posture check
Check for problems in the torch posture, push angle, drag angle, etc. If necessary, correct the
robot’s posture at the recorded positions.
 Weaving check
First, set weaving ON/OFF to OFF, and check whether what has been taught ensures that the wire
tip will move along the center of the groove.
Now set weaving ON/OFF to ON, and check whether the weaving follows the shape of the groove.
If necessary, revise the amplitude and other conditions.

Operations in the arc welding section

In the check operation, the robot does not perform arc welding regardless of the following setting
statuses. In the same way, the output and stopping of the shielding gas with the function
commands and the inching and retract of the welding wire are not performed either.
 [Service] - [1 Teach/Playback Condition] -[9 Function playback during checking]
 Welding ON/OFF
Also, the movement speed in the welding section during the check operation is the check speed,
and not the welding speed specified in the arc start command.

INFO. Arc welding can also be performed in the check operation.

For details, see "8.3 Welding during check operations (check welding)" in
"Chapter 8 Useful functions".

131
 Operations during check GO or BACK

Weaving operation
The robot performs the following operations when check GO or BACK is initiated for the weaving
section.

Table 3.7.1 Operation when check GO or BACK is initiated

Description Robot operation
When check GO is Weaving is performed in the weaving section.
initiated However, weaving is not performed if weaving ON/OFF is set to OFF.
When check BACK
Weaving is not performed even in the weaving section.
is initiated
The robot returns to the main path and stops. When check GO is
then resumed, weaving starts from current position.

C enter stop

If operation has Main

been temporarily path
stopped during
check GO
Temporary Path after restarting
stop

“Center stop” refers to returning to the main path (or to the path when
no weaving is performed).

132
Operations in automatic operation (playback)

Operations in automatic operation (playback)

This section describes the items required for checking the robot operations and welding results in automatic
operation.

Temporary stopping and restarting operations during arc welding

If operation has been temporarily stopped and restarted during welding, the robot operates as
follows.

(1) When operation was temporarily stopped and restarted during pre-flow
Temporary stop The pre-flow is suspended, and the robot stops.
Restart The pre-flow time which elapsed up until the operation was temporarily
stopped is canceled, and pre-flow is performed from the start.

(2) When operation was temporarily stopped and restarted during welding
Temporary stop Welding is stopped immediately and post-flow is performed. The crater
treatment is not executed.
Restart Welding is started under the welding conditions which were
established prior to the temporary stop.

(3) When operation was temporarily stopped and restarted during crater treatment
Temporary stop The crater treatment is stopped immediately and post-flow is
performed.
Restart The crater time which elapsed up until the operation was temporarily
stopped is canceled, and the crater treatment is performed from the
start.

(4) When operation was temporarily stopped and restarted during inching or retract
Temporary stop The inching or retract is suspended immediately.
Restart Operation is restarted with the command of the current step without
inching or retract.

(5) When operation was temporarily stopped and restarted during arc retry
Temporary stop Arc retry is suspended immediately.
Restart The robot returns to the arc retry start point (original arc start point),
and regular arc start is initiated.
If no arc was generated at this time, arc retry is initiated again.

(6) When operation was temporarily stopped and restarted during arc restart
Temporary stop Arc restart is suspended immediately.
Restart The robot returns to the arc restart start point (arc outage detection
point), and regular arc start is initiated.
If an arc was not generated at this time, arc restart is not initiated.
(However, arc retry is initiated if the arc retry setting is valid.)

(7) When operation was temporarily stopped and restarted during on-line changes
Temporary stop Welding is stopped immediately and post-flow is performed. The crater
treatment is not executed. Whatever has been changed so far is not
stored in the memory.
Restart Operation is restarted under the welding conditions existing prior to the
changes.

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 Operations in automatic operation (playback)

Temporary stopping and restarting operations during weaving

If operation has been temporarily stopped and restarted during weaving, the robot operates as
follows.

Temporary stop The torch tip returns to the main path, and the robot stops.
Restart The robot returns to the weaving path where it stopped, and the
weaving waveform is continued. However, the weaving waveform is
not continued if lap start or a mode change was initiated after the robot
stopped.

Returns to the main path Returns to the

Weaving path (Center stop) path where the
robot stopped

Fig. 3.8.1 Temporary stop during weaving Fig. 3.8.2 Weaving during restart

Various restart methods

This section uses the following terms in its descriptions.

Table 3.8.1 Terminology in this section

Term Description
Stopped The position where the robot stopped temporarily during automatic
position operation.
The current position of the robot.
In most cases, the current position and the stopped position are the same
Current
position. However, if the teaching mode is selected after temporarily
position
stopping and the robot is moved with a manual operation, the current
position and the stopped position will be different.
Recorded This is the position recorded in the movement command step of the task
position program.
Lapped This is the position after returning a fixed distance from the position where
position the robot stopped temporarily.
As shown below, this is the step indicated by the green band in the task
program.

Current step

Program example
：
4 JOINT
5 AS
6 LINE
7 LINE
： Current
position

7 LINE

4 JOINT Lapped Stopped

5 AS Recorded position
position position
6 LINE
Fig. 3.8.3 Relationship between the position of each term

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Operations in automatic operation (playback)

The methods in Table 3.8.2 are available for restarting automatic operation after it has been
temporarily stopped.

Table 3.8.2 Restarting methods

Restarting method Description
This can be set only in the case of multi-station startup.
Each time the mode is changed from the teach mode to
the playback mode, the program enters the
Returning the program to non-selected status.
(1) non-selected status before
restarting When restarting, the program corresponding to the
multi-station start button is started up from the
beginning.
“3.8.4 Restart settings”
Restarting from the stopped The robot is returned to the stopped position before
position restarting automatic operation.
Example: A temporary stop is performed during
automatic operation, and the robot is moved
Current position
with a manual operation in teach mode. The
position to which the robot was moved is the
(2) current position.
When restarting, the robot returns from the
7 LINE
current position to the stopped position before
Stopped Recorded position welding restarts.
position 6 LINE
“3.8.5 Restarting after returning to the position at
which the robot stopped”
Restarting from the current The automatic operation restarts from the current
position position.
Example: A temporary stop is performed during
automatic operation, and the robot is moved
Current position with a manual operation in teach mode. The
position to which the robot was moved is the
(3) current position.
When restarting, the welding restarts from the
7 LINE
current position.
Stopped Recorded position
“3.8.6 Restarting from a position after manual
position 6 LINE operation”
“3.8.8 Restarting operation after changing the
current step”
Restarting from the The robot moves with a joint interpolation operation to
recorded position the recorded position before automatic operation
restarts.
Example: A temporary stop is performed during
Current position automatic operation, and the current step is
moved from the step when the robot was
(4) stopped to another step.
When restarting, the robot moves with joint
7 LINE interpolation to the recorded position of the
Stopped Recorded position
current step and the automatic operation
position 6 LINE restarts.
“3.8.8 Restarting operation after changing the
current step”
Restarting welding from
This function is enabled only when a temporary stop is
the lapped position
performed during welding.
(5) When restarting, the robot reverses from the stopped
7 LINE
position to the lapped position before welding restarts.
Lapped
position
Stopped
position
Recorded position
6 LINE
“3.8.7 Restarting after reversing a fixed distance ”

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 Operations in automatic operation (playback)

Selectable restarting methods and settings from the current status

Check the restarting methods and settings that are selectable from the current status by following
the flowchart in Fig. 3.8.4 and checking the corresponding item from (A) to (C) in Table 3.8.3.

Fig. 3.8.4 Restarting method flowchart

Table 3.8.3 Restarting methods

f keys on 2nd page of playback mode
Flowchart
Restarting method f3 <Restart method in f4 <Recover to f5 <Recover pos.
Play Mode> stopped position> after step set>
(1) Returning the program
to a non-selected
(A) * *
status when playback
mode is selected <Step Clear>

(2) Restarting from the

*
stopped position
<Specified> <Stopped position>

(3) Restarting from the

(B) *
current position
<Specified> <Current position>
(5) Restarting welding
from the lapped *
position <Lapped position>
<Specified>

(3) Restarting from the

*
current position
<Specified> <Current position>
(C)
(4) Restarting from the
*
recorded position
<Specified> <Recorded position>
*: Will not affect the restarting method no matter what is set.

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Operations in automatic operation (playback)

Restart settings
After a stop, you need to set the restart method using the f keys or service utilities menu in order
to restart the robot with the methods described in Table 3.8.2. If the functions in Table 3.8.4 are
not allocated to the f keys, refer to "Chapter 7 Useful functions" in the Basic Operation manual and
allocate the functions.
This section explains the operations involved in setting the restart method, and is based on a
condition where the initial allocations have not been changed. Also, the f keys in the operation
descriptions are explained with their positions on the screen.

Table 3.8.4 Function names and commands

Function Code Initial allocation Position on screen
f6
f18
(teach mode 2nd page)
Restart method in Play Mode 2211
f3
f15
(playback mode 2nd page)
Recover to stopped position 2212 f4
f16
(playback mode 2nd page)
Recover pos. after step set 2213 f5
f17
(playback mode 2nd page)

Setting the path recovery method

1 In the teach mode, press f1 <Change Key>.

2 Press f6 <Step Clear>.

>> The [f6] display changes to <Specified>.

For internal start and external start

For internal start and external start, this operation is not needed because the setting is
always <Specified>.

Table 3.8.5 Setting the path recovery method

f3 Significance of the displays
<Step Clear> is set. This setting can be selected only in the case of
multi-station startup. For internal start and external start, it is fixed to
<Specified>.
If <Step Clear> is set, when the mode is changed from the teach mode to the
playback mode, the program will be a non-selected.
To set the restart method, press f3 and change to <Specified>.
<Specified> is set. With this setting, restarting is performed according to the
restart method set with f4 <Recover to stopped position> or f5 <Recover pos.
after step set>.

POINT For multi-station startup, in the default setting, < Restart method in Play Mode
> is set to <Step Clear>.

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 Operations in automatic operation (playback)

Setting the restart method

Change the operator qualification to EXPERT or higher in advance.

1 In the playback mode, press f1 <Change Key>.

>> The f keys used to determine the restart method are displayed in [f3] to [f5].

2 Check f3 < Restart method in Play Mode >.

>> If <Step Clear> is set, press f3 to set <Specified>.

POINT In playback mode, <Specified> cannot be changed to <Step Clear>. To return

to <Step Clear>, select the theach mode, and change with an f3<Restart
method in Play Mode> key operation or select "Step Clear" in [Service] -
[Teach/Playback Condition] - [19 Restart method in Play Mode].

3 Press f4 < Recover to stopped position >.

>> Every time you press f4, the setting will switch in order among the following 3 states.
Select the recovery position if the current step will not be changed. The recovery
position is for determining “where the robot should return to before resuming
operations” when restarting the robot.

Table 3.8.6 Stopped position recovery in playback mode

f4 Significance of the displays
<Stopped Position> is set. In this setting, the robot returns from the current
position to the stopped position with joint interpolation before restarting.
Select this setting to restart the robot after you have moved the robot in teach
mode from the position at which it stopped to a safe place and want to return it
to the position at which it stopped before restarting it.
Example: If the robot was stopped in the welding section and is then restarted,
it restarts welding from the stopped position.
“3.8.5 Restarting after returning to the position at which the robot
stopped”
<Current position> is set. In this setting, the robot restarts from the current
position, going towards the step that was the target when the robot stopped.
Example: If the robot was stopped in the welding section and is then restarted,
it restarts welding from the current position.
“3.8.6 Restarting from a position after manual operation”
<Lapped welding> is set. This setting is enabled only in the welding section.
Example: If the robot was stopped in the welding section and is then restarted,
the robot reverses a fixed distance before restarting welding from the
lapped position.
“3.8.7 Restarting after reversing a fixed distance ”

138
Operations in automatic operation (playback)

POINT  The default setting is <Stopped position>.

 If the display does not change even after pressing f4, change
[Teach/Playback Condition] - [20 Recover to stopped position] to "Enabled".

4 Pres f5 <Recover pos. after step set>.

>> Every time you press f5, the setting will switch in order among the following 2 states.
Select the recovery position for when the current step is different from the step at the
time of the temporary stop.

Table 3.8.7 Start position after step setting

f5 Significance of the displays
<Recorded position> is set. In this setting, the robot returns to the recorded
position of the current step with joint interpolation before restarting.
Example: If the robot was stopped in the welding section and is then restarted,
it moves to the recorded position of the current step before restarting
welding.
“3.8.8 Restarting operation after changing the current step”
<Current position> is set. In this setting, the robot restarts from the current
position according to the interpolation type of the current step.
Example: If the robot was stopped in the welding section and is then restarted,
it restarts welding from the current position.
“3.8.8 Restarting operation after changing the current step”

 f4 <Recover to stopped position> and f5 <Recover pos. after step set> are
POINT different functions. The f5 setting does not affect the f4 setting (and vice
versa).
"Restarting if the current step will not be changed" is set with f4, and
"Restarting if the current step is changed" is set with f5.

 The following operations correspond to the operations when the "current step
is changed".
・ Press [PROG/STEP] and select the step.
・ Play back the steps using check GO and check BACK.
・ Select the step using [ENABLE] + [up or down].
・ Select the step using [ENABLE] + [Jog Dial].

 If the display does not change even after pressing f5, change
[Teach/Playback Condition] - [20 Recover to stopped position] to "Enabled".

5 This now completes the settings.

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 Operations in automatic operation (playback)

Restarting after returning to the position at which the robot stopped

This section describes the operation for returning the robot automatically to the stopped position
after a manual operation, and then restarting automatic operation.
This section is based on "3.8.4 Restart settings" with the settings shown in Table 3.8.8.

Table 3.8.8 Restarting after returning to the position at which

the robot stopped
f3 f4
Restart method in Play Mode Recover to stopped position

<Specified> <Stopped position>

In this setting, after the robot is operated manually, the robot will return to the position at which it
stopped using joint interpolation and then resume operations. If the stopped position is within the
welding section, the robot will begin welding after it returns to that position.
This is useful, for example, when moving the robot to a safe place to replace a chip or cut wires
after a welding failure has occurred.

 In the default settings, the robot moves to the stopped position with joint
POINT interpolation. At this time, the movement speed is 60%.
The interpolation classification and movement speed can be changed with
"Position Resume at Restart" in [Constant Settings] — [Machine Constants]
- [10 Position Resume Setting].
 If an operation is performed to change the current step before the operation
is restarted, the function in this section cannot be used. Restart the
operation using the method in "3.8.8 Restarting operation after changing the
current step".

4 100% JOINT ① Stop here

①ここ で一時停止
5 ASＳ
Ｐ，Ａ
Ｌ6 300cm/m LINE
7 AS
③ When
③再始動 restarted after
するとロボッ the operation,
トは位置決め 動作で the robot
② Change ②手動運転で移動
to teaching
returns
一時 to the stopped position
停止点に戻り、停止前の 動作を継続withするa joint
mode and move to a interpolation operation, and continues the
safe place manually operation from before the stop.

Fig. 3.8.5 Restarting after returning to the position at which the robot stopped

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Operations in automatic operation (playback)

Restarting from a position after manual operation

This section describes the operation for restarting automatic operation from a position after a
manual operation (current position).
This section is based on "3.8.4 Restart settings" with the settings shown in Table 3.8.9.

Table 3.8.9 Restarting from a position after manual operation

f3 f4
Restart method in Play Mode Recover to stopped position

<Specified> <Current position>

In this setting, when you restart the robot, it operates according to the interpolation classification
and speed of the current step (safety speed restrictions do not apply for this restart method).

6 LINE
Point y
5 LINE ③
Point x ②
① ④
6 LINE

① During automatic operation, the ③ Do Check GO operation up to point y,

shock sensor is triggered at point x. near point x, and end teaching
② After clearing the shock sensor, corrections.
change to Teach mode and correct ④ When you change to Playback Mode and
the position in Step 6. startup the robot, resume operations from
point y.

Fig. 3.8.6 Restarting from a position after manual operation/from a revised position (current
position)

Restarting after reversing a fixed distance (lap welding function)

This function used to be known as the lap welding function (lap start). The robot reverses a fixed
distance on the weld line and restarts from the lapped position. This is useful if a welding failure
such as arc outage occurs.
This section is based on "3.8.4 Restart settings" with the settings shown in Table 3.8.10.

Table 3.8.10 Restarting from a position after manual operation

f3 f4
Restart method in Play Mode Recover to stopped position

<Specified> <Lapped position>

To use this function, set the welding constants in Table 3.8.11.

Table 3.8.11 Welding constants

Item name Setting range Default
Restart retract distance 0 to 99 [mm] 0

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 Operations in automatic operation (playback)

 Reversal beyond the current step cannot be implemented. In following case, even
when the retract distance is set to 15 mm, the robot reverses by 10 mm only.
IMPORTANT
15 mm (set retract distance)
Because there is a
teach point within the
set retract distance, the 10mm Weld line
robot can only reverse
Advance
to this position. T3 direction
T2 Temporary stop ：Teach point at
T1 point T ：lap start

 The lap welding function works only when the stop timing is inside a welding section
regardless of the welding ON/OFF status. The lap welding function does not work,
even if it has been set, when the stop timing is outside a welding section.

 When the robot is stopped again during lap welding (from the lapped position to the
stopped position), the start position of lap welding serves as the first lapped position.

 The lap welding function does not work, even if it has been set, in an arc sensor copy
section (between ST and ET).

 The lap welding function does not work, even when it has been set, in a laser sensor
copy section (between ZT and ZN and ZE or between ZT and ZE).

Restarting operation after changing the current step

This section describes the method for “operating after changing the current step”.
This section is based on "3.8.4 Restart settings" with the settings shown in Table 3.8.12.

Table 3.8.12 Restarting after changing the current step

f3 f5
Restart method in Play Mode Recover pos. after step set

(a)
<Recorded position>

<Specified>
(b)
<Current position>

POINT Restarting from the recorded position

In the default settings, the robot moves to the stopped position with joint
interpolation. At this time, the movement speed is 60%.
The interpolation classification and movement speed can be changed with "
Position Resume at Restart " in [Constant Settings] — [Machine Constants] -
[10 Position Resume Setting].

There are 2 ways of doing this method.

(a) Restart operations after moving the robot from the current position to the changed current
step using joint interpolation.
This operation is the same as "3.8.5 Restarting after returning to the position at which the
robot stopped".
(b) Immediately restart operations from the current position towards the changed current step.
This operation is the same as "3.8.6 Restarting from a position after manual operation".

The current step can be changed in both the teach and playback modes.

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 Robot movement condition file

Robot movement condition file

The robot movement conditions are provided for optimally tailoring the robot operations to suit the arc welding
conditions. See the parameters shown in Table 7.6.1.
For how to set the robot movement conditions in the arc welding condition, refer to "Chapter 3 Preparation of Arc
Welding Programs and Automatic Operation".

Table 7.6.1 Type of robot movement condition

Motion condition Description/Explanation
Chasing Level (0 to 3) This parameter is used to enhance the ability of the
robot to track commands values.
Smooth Level (0 to 3) This parameter is used to make the robot operations
smoother.
Accel Level (0 to 3) This parameter is used to make the robot operation
speeds smoother.
Smooth Level before AS (0 to 3) This parameter is used to reduce the vibrations of the
robot at arc start.

Creating the robot movement condition files

Creating the robot movement condition files

１ Select f6 <Retry condition file> - [11 Robot move condition].

>> The robot movement condition screen appears.

２ Set the condition file ID and parameters and press f12 <Complete>.
>> The robot movement condition file of the specified ID is created.

INFO. It is possible to edit the robot movement conditions in the arc welding start
condition editing screen. Select "Move cond. no." in the arc welding start
conditions and press [Enable] + f8 <Edit>.

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Robot movement condition file

Parameters of robot movement condition

This section explains each parameter in detail.

Chasing level
When level 1 or above is recorded, the accuracy of the robot path within the welding section is
improved.
It can be used effectively when the target position of the wire tip is inadvertently changed with
welding performed while the torch posture changes significantly.

INFO. The higher the level, the greater the improvement in the path accuracy but the
longer the operating time.

 Do not change the level for arc start command (AS command) changing the
conditions. The robot may slow down its speed depending on the recorded
robot movement conditions.
 With check go, the robot operates at a path accuracy commensurate with
the tracking level. With check back, however, it operates using a tracking
level of zero.
 When level 1 or above is recorded, the corner areas may become more
IMPORTANT rounded.
 When level 1 or above is recorded, the smoothness level and
acceleration/deceleration level cannot be specified.
 When level 1 or above is recorded, the smoothness and acceleration
specifications recorded in each step within the welding section are rendered
invalid.

Smooth level
When level 1 or above is recorded, the path accuracy when the robot starts off and when it stops
is improved.
Smoothness is a function for adjusting the smoothness by changing the jerk of each of the robot’s
axes. This parameter is used to specify the smoothness of all the steps within the welding section
together. It is used effectively if the target position of the wire tip is inadvertently changed when
high-speed welding starts off.

INFO. If the level is increased, the path accuracy at start-off is improved, but the
operation time is increased.

 Do not change the level for arc start command (AS command) changing the
conditions. The robot may slow down its speed depending on the recorded
robot movement conditions.
 When level 1 or above is recorded, the corner areas may become more
IMPORTANT rounded.
 When level 1 or above is recorded, the smoothness specification recorded in
each step within the welding section are rendered invalid.

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 Robot movement condition file

Accel level
When level 1 or above is recorded, the path accuracy when the robot starts off and when it stops
is improved.
Acceleration is a function for adjusting the smoothness by adjusting the acceleration of the robot
operation. This parameter is used to specify the acceleration of all the movement commands
within the welding section together. It is used effectively if the target position of the wire tip is
inadvertently changed when high-speed welding starts off.

INFO. If the level is increased, the path accuracy at start-off is improved, but the
operation time is increased.

 Do not change the level for arc start command (AS command) changing the
conditions. The robot may slow down its speed depending on the recorded
robot movement conditions.
 When level 1 or above is recorded, the corner areas may become more
IMPORTANT rounded.
 When level 1 or above is recorded, the “acceleration” specification recorded
in each step within the welding section are rendered invalid.

Smooth Level before AS

This parameter is used to reduce the vibration in the positioning operation immediately before arc
start command (AS command).
It is used effectively when the robot approaches the arc start point in an extended forward-tilting
posture and there is significant vibration when it stops.

INFO. As the level is increased, the vibration during arc start can be reduced, but the
operation time is increased.

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 Monitoring the welding conditions (Arc Monitor)

Monitoring the welding conditions (Arc Monitor)

Arc Monitor is a function to monitor the teaching conditions of the arc welding start command and the actual
welding conditions that are being output (such as current and voltage). Arc Monitor has the functions shown in
Table 8.1.1.

Fig 8.1.1 Arc Monitor

screens

Table 8.1.1 Arc Monitor functions

Function Description/Explanation
It can monitor actual welding conditions and teaching conditions
Arc Monitor in real time.
“8.1.3 Arc Monitor”
Monitoring items for the actual welding conditions can be
Arc Monitor customizing changed.
“8.1.4 Arc Monitor customizing”
Welding and weaving conditions can be modified in real time
The online modification
during welding.
function
“8.1.5 The online modification function”
Feeder I/F adjustment 0 adjustment of Feeder I/F can be performed.
function “8.1.6 0 adjustment of Feeder I/F”

Actual welding conditions that can be monitored

The actual welding conditions that can be monitored by Arc Monitor (hereafter referred to as
'monitoring items') depend on the welding power supply. The monitoring items for each welding
power supply are shown in Table 8.1.2.

Table 8.1.2 Actual welding conditions that can be monitored

Welding power EN Reduction Feed Feed

Welding method Current Voltage
supply ratio rate load * speed *
WB-M350L All ● ● － ● ● ○
WB-M350/500 All ● ● － － ● ○
DM-350/500
All ● ● － － ● －
DM-350(S-2）
DP-350/400/500
All ● ● － － ● －
DP-400R
DA-300P All ● ● － － ● －
DR-350 All ● ● － － ● －
DL-350
All ● ● － ● ● －
DL-350(S-2)
AC pulsed
● ● ● － ● －
AC wave pulsed
DW-300+ (Plus)
DC pulsed
● ● － － ● －
DC wave pulsed
●：Monitoring possible (Initial value for the Arc Monitor customizing）
○：Monitoring possible (Necessary to set the Arc Monitor customizing)）
－：Monitoring impossible
*：Handling monitoring outside the welding section.

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Monitoring the welding conditions (Arc Monitor)

If the AC Servo wire feeder controller is used, the following combinations make
"Feed Load" monitoring possible.
 AC Servo type wire feeder controller L21588
 Robot I/F L21030C
IMPORTANT
However, when the Welbee Inverter series and DP-400R welding power supply are
used, regardless of the above combinations, it is possible to monitor "Feed Load".

The current value is also displayed when the current condition type is wire
INFO. feed speed
The actual current value is always displayed on the monitor, even if the current
condition types in the welding conditions are specified by wire feed speed.
The voltage value is displayed when synergetic control is the voltage
adjustment method.
The actual voltage value is always displayed on the monitor when the welding
method is under synergetic control.
What is the feed load?
The feed load shows the load current as a percentage of the wire feeder's rated
current. With normal wire feed, it ranges from around 40% to 60%.
What is the reduction rate?
The reduction rate indicates the necking detection status in the form of a
percentage. It ranges from 90 % to 100% when necking is detected properly. For
details, refer to "Chapter 4 Welding Conditions for Welbee Inverter Series
Welding power supplies" or "Chapter 5 Welding Conditions for D Series Welding
power supplies".
Optional monitoring conditions that can be added
In addition to the items in Table 8.1.2, it may be possible to add monitoring items
depending on optional functions. Please refer to the relevant instruction manuals
for details.
About the section to monitor the actual welding conditions:
 The actual welding conditions are monitored in the section between the AS
command and the AE command.
 The feed load and feed speed can also be monitored at times other than
during welding. For details, see “7.1.4 Monitoring Other Than During Welding”.
Actual welding conditions cannot be monitored for some welding power
supplies
Actual welding conditions are not displayed in the case of welding interface or
WPS (I/O). Only teaching conditions are displayed.

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 Monitoring the welding conditions (Arc Monitor)

Settings relating to Arc Monitor

The settings relating to Arc Monitor can be set with <Arc Constant> - [3 Constant of weld].
Please refer to "7.1 Setting the welding constants" in "Chapter 7 Arc welding-related settings" with
regard to the constants.

Table 8.1.3 Constants settings relating to Arc Monitor

Constant name
*
Arc monitor sampling cycle Welding voltage failure limit (Rate) *
Arc monitor sample data num Welding voltage failure time*
Arc Monitor display cycle* Wire feed load fail action
*
Arc Monitor display type Wire feed load fail rate
*
Arc Monitor output cycle type Welding wire feed speed failure
time*
Welding curr./volt. fail. act. Disregard time of Arc start*
*
Welding current failure limit type Disregard time of Arc change*
Welding current failure limit (inc.) Feeder I/F*
Welding current failure limit (Rate) * Feeder I/F Adj.*
Welding current failure time* Arc monitor customizing
Welding voltage failure limit type* Gas flow control unit
Welding voltage failure limit (inc.)
*: Change not available in DM series.

Table 8.1.4 Constants settings related to Arc Monitor (Welbee inverter series welding
power supply only)
Constant name
Abnormal speed of wire judgment Detection time at abnormal speed
Abnormal speed of wire(inc.) Action at abnormal speed of wire
Abnormal speed of wire(Rate)

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Monitoring the welding conditions (Arc Monitor)

Arc Monitor
This chapter explains the basic operations of Arc Monitor

Starting up Arc Monitor

１ Press f4 <Arc Monitor> in playback mode.
>> “Arc Monitor” starts up in monitor 2.
The following information appears if welding is in progress.

Taught welding
conditions

(Upper section)
Actual welding
conditions
(Lower section)
Minimum
values/maximum
values

２ Do one of the following operations to switch which welding power supply is

shown on the monitor. These operations are only available when multiple welding
power supplies are connected.
 Press the number key corresponding to the W.P.S No. of the monitoring target.
For instance, to monitor welding power supply 2, press the number key [2].

 Press the number key “0”.

Every time you press the key, the W.P.S No. switches in turn.
The welder being shown on the monitor will be displayed in the title bar.

Welder number
and model

POINT It cannot be changed using the f keys

The <Select arc welder> f keys are used to change the welding
power supply that is to be operated manually. They cannot be
used to change the welding power supply that is to be monitored.

How to switch weaving conditions

Weaving conditions and tracking conditions are switched to mechanism
conditions for the currently selected welding power supply.

３ To close Arc Monitor, press [ENABLE] + [CLOSE/SELECT SCREEN].

＋
>> Arc Monitor now closes.

150
 Monitoring the welding conditions (Arc Monitor)

４ Press [CLOSE/SELECT SCREEN] when Arc Monitor has not been selected for an
active monitor.
>> Each time [CLOSE/SELECT SCREEN] is pressed, the active monitor is switched
through.
The monitor which can be operated has a deep blue title bar.
The monitors which cannot be operated have gray title bars.

Depending on the monitor layout, not all the items may be displayed on the
POINT screen. In that case, you can view all the items by scrolling up and down the
screen using the cursor keys.

Displaying Arc Monitor outside the welding sections

１ Press [ENABLE] + [1] in Arc Monitor.
＋
>> The monitoring items are displayed.
When the Welbee Inverter series welding power supply is used

When the D series welding power supply is used

２ Press [ENABLE] + [2] for non-display of feed load.

＋

 Select <Service Utilities> - [4 Monitor 2] - [35 Arc welding] to display Arc

INFO.
Monitor in teach mode.
 It will not be on monitors outside the welding section after the welding has been
completed, and will always be in non-display status.

151
Monitoring the welding conditions (Arc Monitor)

Arc Monitor customizing

It is possible to change the Table8.1.5 items by using the Arc Monitor customizing function.

Table8.1.5 Arc Monitor customizing settings

Setting
Item name Description/Explanation Default
range

Arc Monitor Set any monitoring items. Monitoring items See See
Display items can be set at the top/bottom of Sequences 1 to Table 8.1.2 Table 8.1.2
4.
The size of the monitoring items can be set
from "Large" to "Small".
Max./Min.
Arc Monitor Item Size
display Large/Small Large
Display item size
Large Default ON
Half the size
Small OFF
of "Large"
The display of weaving conditions can be
Weaving changed between ON/OFF in Arc Monitor. Enable /
Enable
conditions display Weaving conditions must be set as ON in Disable
order to change them online.
The display of tracking conditions can be
Tracking changed between ON/OFF in Arc Monitor. Enable /
Enable
conditions display Tracking conditions must be set as ON in order Disable
to change them online.

INFO. By changing the "Arc Monitor display items", it is possible to display the Welbee
Inverter series wire feed speed or additional optional monitoring items.

152
 Monitoring the welding conditions (Arc Monitor)

Changing the monitoring item

１ Select f5 <Arc Constant> - [3 Constant of weld] in teach mode, and then select
"ON" in [Arc Monitor customizing].
>> f11 <Refer> is displayed.

２ Press f11 <Refer>.

>> The setting screen for arc monitor customizing appears.

153
Monitoring the welding conditions (Arc Monitor)

３ Set monitoring items.

>>Set monitoring items and the size of monitoring item by row. Press the [Enter] key
and the selectable items are displayed. Please refer to Table 8.1.2 for the
selectable items.

Allocation sample of monitoring item

The arc monitor display item 1, 2, 3, and 4 respectively corresponds to each column
from the left. A maximum of 2 lines x 4 columns can be displayed.

Upper monitor
display

Lower monitor
display

154
 Monitoring the welding conditions (Arc Monitor)

４ Specify the size of the monitoring item.

＋
>> Specify the size of the monitoring item. Press [ENABLE] + [LEFT/RIGHT] to switch
between Large/Small.

Example of “Large” display

Example of “Small” display

Example of “Large” and ”Small” combination display

INFO.
Indication of “Min/Max” appears when the display size is “Large”.

155
Monitoring the welding conditions (Arc Monitor)

５ Set the weaving conditions and tracking conditions.

>> Press [ENABLE] + [LEFT/RIGHT] to switch the weaving conditions and tracking
conditions Enable/Disable.

The weaving conditions and tracking conditions are displayed as below. Tracking
conditions appear only when the type of sensor is “Arc sensor”, “TIG-AVC” and
“Manual-Tracking”.

Weaving conditions Tracking conditions

The weaving condition items to be displayed are as shown below depending on the
weaving command.
Table 8.1.6 Weaving condition display items
Right
Weaving command Frequency Left amplitude
amplitude
WFP(Fixed pattern) ● ● ●
WAX(Axis) ● ● ●
WSF(Taught) － － －
(●: Displayed －: Not displayed)
The tracking condition items to be displayed are as shown below depending on the
type of sensor.
Table 8.1.7 Tracking condition display items
Offset Offset Tracking Tracking
Type of sensor Up/Down Left/Right Up/Down Left/Right
Arc sensor ● ● － －
TIG-AVC ● － － ●
Manual-Tracking － － ● ●
(●: Displayed －: Not displayed)

156
 Monitoring the welding conditions (Arc Monitor)

６ Press f12 <Complete>.

>> The setting for Arc Monitor customizing is stored.

７ Press f12 <Complete> again.

>> The setting for Arc Monitor customizing is stored as “ON”.

157
Monitoring the welding conditions (Arc Monitor)

Performing online modifications

１ Press f4 <Arc Monitor> in playback mode during welding.
>> "Arc Monitor" starts up in Monitor 2.

２ Activate Arc Monitor, and press [EDIT].

>> During welding, it will switch to the screen editor (It won’t switch if it is not during
welding).
At this time, online modification is available.

３ Align the cursor with the condition to be changed.

４ The condition to be modified can be changed by operations ５～７ below.

５ Modify the welding conditions/weaving conditions.

>> To increase/decrease at low speed, press f8 <Low Inc.> or f9 <Low Dec.>.
To increase/decrease at high speed, press f8 <High Inc.> or f9 <High Dec.>.

Alternatively, modify by turning the jog dial while holding down [ENABLE].
＋

POINT Simultaneous modification for the arc characteristics

In using WB-M350L or WB-M350/500, it is available to execute online
modification to change the “Arc char.1 (Short)” and “Arc char.2 (Arc)” at the
same time. For the setting of “Simultaneous” and “ Individual”, use the f6
key.

158
 Monitoring the welding conditions (Arc Monitor)

６ Switch the weaving condition to be modified.

>> Modification method can be switched by using f6 <Synchro> or <Individual>.

⇔
Or

<Synchro>
Right and Left amplitude is modified in synchro.

<Individual>
Right and Left amplitude is modified individually.

７ Modify the tracking conditions.

>> To make adjustments in the vertical direction, press f2 <Vert. Inc.> or
f3 <Vert. Dec.>. To make adjustments in the horizontal direction, press f8 <Hori.
Inc.> or f9 <Hori. Dec.>.

POINT
Online modification order
The order of modification at low speed is the minimum unit of the target x 1.
In the case of high-speed modification, the default setting is the minimum
unit x 5. The order of modification done at high speed can be altered with the
setting in Table 8.1.11.

Table 8.1.11 High-speed modification order settings

Item name Setting points
<Arc Constant> - "Online modification cycle" in [3
Welding conditions
Constant of weld].
<Arc Constant> - "Modification order" in [12 Weaving
Weaving amplitude
Condi ion].
Manual tracking <Service Utilities> - [29 Sensor application] - "Adjust
input pitch" in [11 Online Correct. of Seam Track.].

159
Monitoring the welding conditions (Arc Monitor)

８ At this point the conditions have only been temporarily modified.

The changes are not reflected in the task program (or in each condition file).

To save the modifications, perform the following operations.

Table8.1.12 Save operations

Operation Description/Explanation
Press f12 <Complete>
The welding conditions after making changes
are saved.
Press [EDIT] The online modification is finished.

Press [WRITE/REC] The modified welding conditions are saved.

The online modification is continued.

They are automatically saved when the following commands are executed. The
timing is different for the automatic storing of welding and weaving conditions.

Table8.1.13 Automatic storage timing

Command Description/Explanation
Arc start command (AS The modifications are saved when the welding
command) conditions are modified by arc start command.
The modifications to the welding conditions are
Arc end command (AE command) saved when the welding section currently being
run is finished by arc end command.
The modifications are saved when the weaving
Weaving start command
conditions are modified by weaving start
(WFP/WAX command)
command.
The modifications to the weaving conditions are
Weaving end command (WE
saved when the weaving section currently being
command)
run is finished by weaving end command.

POINT To disable automatic storage of online modifications

If you do not wish to automatically store the online modifications, you can
disable automatic storage with the items in Table 8.1.14.

Table 8.1.14 Automatic storage settings

Item name Setting points
<Arc Constant> - [3 Constant of weld]. Set "Auto.
Wel ing conditions
storing for online mod.” to "OFF".
To enable/disable automatic storage, <Arc
Constant> - [12 Weaving operation condition
Weaving conditions
settings]. Set "Auto. storing for online mod." to
"OFF".

９ Press f11 <Cancel> or [RESET/R] if the changes are not to be saved.

>>This will exit online modification without saving the changed welding conditions.
or

160
Welding during check operations (check welding)

Welding during check operations (check welding)

The check welding function runs arc welding executed step by step when the Check Go operation is performed
for arc welding sections in teach mode. (Arc welding is not executed with check back operations.) For further
information about check operations, please refer to both "Chapter 4 Teaching" in the “BASIC OPERATIONS
MANUAL”, and to "Chapter 3 Preparation and Automatic Operation of Arc Welding Programs" in this manual.
By using this function, arc welding can be done without performing automatic operations. This simplifies
operations such as setting conditions, performing tack welding and reworking sections where the welding is
incomplete.

 This function cannot be used for a tandem pulse GMA robot system.
 This function does not support the multi-pass welding system.
IMPORTANT

Preparing for check welding (allocation in f key)

Check welding is enabled or disabled using an f key. If it is set to ON, welding is performed during
Check Go. No welding is done if it is set to OFF.
However, the f key used to set Check Welding to ON or OFF is not allocated as an initial setting
when the system is shipped. To use the Check Welding function, refer to "Chapter 7 Useful
Function" in the “BASIC OPERATIONS MANUAL”, and allocate the function in Table 8.3.1.

Table 8.3.1Function name and code

Function Code
Check Welding ON/OFF setting 2217

Please do not allocate the "Check welding ON/OFF" f key to the following
locations.
 f1, f13, f25 (keys allocated to <soft key selection>)
IMPORTANT  [ENABLE] + f1 to f36

161
 Welding during check operations (check welding)

Switching check welding between ON and OFF

Check Welding can be switched ON/OFF using the <Check Weld> assigned to an f key.
The current status can be checked by the <Check Weld> f key display. A beep is sounded while
Check Welding is ON.

Table8.3.2 Check welding setting statuses

Setting Description
status
Check welding is OFF. No welding is executed even when the Check Go
operation is performed for the welding section.

Check welding is ON. While check welding is ON, a continuous beep is

sounded to remind the operator to proceed with caution. Welding is executed
when the Check Go operation is performed for the welding section in this
status.
The setting is automatically set to OFF when any of the following operations
has been performed.
• When an operation for selecting a welding power supply has been
performed
• When an operation for changing a mode has been performed
• When f1 <Switch keys> has been pressed
• When any one of the menus has been displayed by operating an f key
• When [ENABLE] has been pressed
• When [RESET/R] has been pressed
Check Welding cannot be enabled (one of the following statuses applies).
・The operator has the qualifications level of USER or BEGINNER.
・"Function playback during check" in <Service Utilities> - [1
(Shaded) Teach/Playback condition] hasn’t been set as "All".
・The teach mode is not the currently established mode.
・Arc welding is not the currently selected application.
・The welding power supply has not been registered.
・The current unit is the control unit (when the multi-unit specifications
apply).
・The welding power supply currently selected is not registered to the
current unit.

Switching check welding between ON and OFF

Set the operator qualifications level to EXPERT or above beforehand.

１ Set <Welding ON/OFF> to ON.

２ Press <Check Weld>.

>> The f key displays changes, and a continuous beep is sounded.

３ Welding is now performed in the welding sections if the Check Go operation is

performed in this status.

The welding ON/OFF status always takes precedence.

The status must be "Welding ON" for the check welding function to be
IMPORTANT performed.

162
 Shift welding section collectively

Executing the collective shift of a welding section

The collective shift of a welding section is performed by the following operation.

Performing the collective shift of a welding section

１ Select the program to shift, and perform the check operation to get the welding
section to shift.

２ Press <XYZ shift>.

>>The following screen will be displayed. At that time, the "Source program No." and
"Start/end Steps" of the currently selected welding section will automatically be
entered.

Welding section is automatically set to shift object step

POINT
If the parallel shift function is selected when the current step is in the
welding section, the default value of the shift condition’s shift start/end
step is the arc start point/arc end point step.
However, if the current step is outside the welding section, the default
value of the shift condition’s shift start/end step is the first/last step of
the program.

163
Shift welding section collectively

３ When the amount of shift is specified by "numerical value input".

Each amount of shift is entered as a numerical value.

When the amount of shift is specified by "storage location value".

The amount of shift is set by operations ４～６ below.

４ Press f8 <Pre-conversion reference>.

>> The current position is set as the pre-conversion reference.

５ The robot is moved for the amount of the shift from the location in ４ by a manual
operation.
６ Press f11 <Post-conversion reference>.
>>The amount of movement from ４ to ６ is set as the amount of shift.

f11 <Select> is displayed instead of f11 <Post-conversion reference>

While "origin program" or "destination program" is selected, f11
IMPORTANT <Post-conversion reference> becomes f11 <Select>. If you set the amount of
shift with the "storage location value", please do so with items that exclude
these selected.

Shift amount input range

If the amount of movement in ５ exceeds the shift amount input range, the
upper and lower limits of the amount of shift are set.
The input range of the shift amount can be changed by <Constant Setting> -
[3 Machine constants] - [6 Shift Amount Limit].

７ Press f12 <Execute>.

>>Parallel shift will be executed.

164
Displaying the torch angles
This section explains the function to display torch angles on the axis monitor (hereafter referred to as the torch
angle display function).
Monitoring the torch angles with this function makes it possible to teach while checking the push/drag angles
with respect to the welding direction (torch advance direction), which serves as a welding condition, and while
checking the work angles.

The torch angle is displayed based on the following coordinate system.

Fig. 8.8.1 Push/drag angle Fig. 8.8.2 Work angle

The “reference plane” must be set so that the work angle is 0 degrees. The “reference plane” is set in the torch
angle display by setting the “Base coord of work ang” and the “Base plane of work ang”. For example, the XY
plane of the machine coordinate system can be set as the “reference plane” by setting the “Base coord of work
ang” as the machine coordinate system and the “Base plane of work ang” as the XY plane.

Setting the torch angle display

To enable the torch angle display, switch the function to enabled using the constant setting.
For this procedure, the operator must be qualified as EXPERT or above.

Setting the torch angle display to enabled

１ In teach mode, press <Constant Setting> - [5 Operation Constants] - [5 Coordinate
registration].
>> The setting screen on which to register the orthogonal coordinate system is
displayed.

165
 Displaying the torch angles

２ Bring the cursor to "8 Torch angle monitor", press [ENABLE] + [Right] and select
＋ "Enable".
>> The setting items for the torch angle display are now displayed.

３ Select "Base coord of work ang" and press [ENTER].

>> The coordinate system is selected from the following items.

Table 8.8.1 Work angle reference coordinate system

Item
Description
name
During a
The selected manual operation coordinate system becomes the
manual
"Base coord of work ang".
operation
Current Simultaneous The machine coordinate system becomes the
During an (without H) "Base coord of work ang".
automatic
operation Cooperative The work coordinate system becomes the
(with H) "Base coord of work ang".
Machine
User
The selected coordinate system becomes the "Base coord of work ang".
Absolute
Work

４ Select "Base plane of work ang" and press [ENTER].

>> The reference plane is selected from the following items.

Table 8.8.2 Work angle reference plane

Item
Description
name
XY
The coordinate system plane selected in the "Base coord of work ang"
YZ becomes the "Base plane of work ang".
ZX

５ Press f12 <Complete>.

>> The torch angle display is now enabled, and the work angle reference plane is set.

166
Displaying the torch angles

Axis monitor display

Displaying the axis monitor

１ Press <Service Utilities> - [Monitors 1 to 4] - [2 Axis Position].
>> The axis monitor starts up, and the torch angles are displayed.

When the torch angle display is enabled

Push/drag angle

Work angle

(1) Under the following conditions, the torch angles are not displayed, and "---" will
appear instead.
・When the program has not been selected
・ When the positions defining the direction of movement are the same points

IMPORTANT

(2) The direction of movement is defined using the teach point positions. It is not
affected by compensation provided by the sensor commands or shift
commands.

167

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1
 What the multi-unit function does

Introduction

What the multi-unit function does

The multi-unit function divides up all the mechanisms connected to a control unit into a number of groups called
“units” and controls the robot on a unit-by-unit basis.
The units are preset prior to shipment from the factory or prior to delivery in accordance with what the user has
specified.

What is a unit?

Unit 1 With the multi-unit function, all the mechanisms connected Unit 2
are divided up into a number of groups called “units.”
In this group, the Normally, the initial settings for the units are performed prior In this group, the
manipulator to shipment from the factory or prior to delivery in manipulator
exercises accordance with the user’s specifications. Two units are exercises
synchromotion defined in this example, but other units can also be divided synchromotion
control for positioner up into other groups. It is also possible to divide up the units control for positioner
A. into an “only manipulators” or “only positioners” group. B.

Unit 1 Unit 2

Manipulator

Positioner B
Positioner A

The task program is created by each of the units.

Unit 1 Unit 2

Program in which the manipulator Program in which the manipulator

exercises synchromotion control exercises synchromotion control
for positioner A for positioner B

It is possible not only for the programs

(units) to be started up individually but
also to provide a main program and
then switch between the units while
operation is in progress by calling a
program of each unit from the main
program.

Fig. 1.1.1 Thinking behind the multi-unit (with multi-cooperation robots)

169
 Switching between units

Basic Operations

Switching between units

Before proceeding with teaching or manual operation, the units to be operated must first be selected. Motor
power may be either on or off.

Switching between units

1 The currently selected unit and the mechanism defined for it are displayed on the teach
pendant.
Confirm the current unit selection by checking the display of the teach pendant.

Number of unit being selected

Mechanisms included in the

currently selected unit

Number and name of

mechanism being selected

2 Press [UNIT/MECHANISM] while holding down [ENABLE].

＋ >>The unit selection screen is displayed while [ENABLE] is held down.

3 The units are switched in sequence by pressing [UNIT/MECHANISM] while

[ENABLE] is held down so switch to the desired unit.

4 When the managing unit has been defined, it is selected by performing the same
operations.
The managing unit can be distinguished by the icon displayed below.
(Shown below is an example that the managing unit has been defined for the unit
4.)

This icon indicates

the managing unit.

170
Switching between mechanisms

Switching between mechanisms

If a multiple number of mechanisms are connected to the units, select the mechanism to be manually
operated.
Motor power may be either on or off.

When selecting the mechanism to be manually operated, be absolutely sure to switch to the unit
which belongs to the mechanism in question. Mechanisms which are not defined for the units
cannot be operated manually.
For instance, it is assumed that the current unit is unit 1 and that NV6 is the only mechanism
defined. In this case, mechanisms other than NV6 cannot be operated manually while unit 1 is
selected.
In addition, when the managing unit has been defined, any mechanism cannot be operated
manually since the managing unit does not have mechanisms.

Switching between mechanisms

1 The mechanism selected for manual operation is displayed on the teach pendant.

The currently selected

mechanism is displayed in
color.

2 To switch the mechanism, press [UNIT/MECHANISM].

>>The selected mechanism changes (and the display of the teach pendant changes).
An example of switching in a unit comprising a manipulator and a positioner is shown
below.

Manipulator name Positioner name

Mechanism number Mechanism number

3 After switching the mechanism, manual operation using the newly selected
mechanism is possible.
While holding the deadman switches, press the axis keys to operate the mechanism.

171
 Preparing the program s for each unit

Preparing the program s for each unit

In the case of a multi-unit function robot, the task program is created for each unit. (The teaching is targeted at
the currently selected units.) For instance, when number “100” for a new program is specified while “UNIT1” is
selected, program “100” will be created as belonging to “UNIT1.”
When a prepared program is opened, operation is automatically switched to the unit to which that program
belongs.
For instance, if a program belonging to unit 1 is opened while unit 2 is selected, operation is automatically
switched to unit 1.

After a program has been prepared, the filename is as follows.

Filename of task program

Program name. ****

Program name: Prior to delivery, the system was set up using names which will easily identify
programs.
For instance, when the system was set up with “UNIT1” as the unit name and
“NV6” as the program name, then if new program number “100” is specified while
“UNIT1” is selected, the program will be stored inside the internal memory under
the name of “NV6.100.”
****: This denotes the program number.
Program numbers range from 0 to 9999, and they are used in common by all the
defined units.

The filename (UNIT1.001, etc.) of a program appears on the teach pendant when a list of the
programs is displayed or when file copy or other operations are performed.
In the case of a multi-unit function robot, there will be one program name for each unit.
Therefore, unless the operator knows under what names the prepared programs have been
stored, there may be some confusion when a list of the programs is displayed or when file
operations are performed. The operator must remember the filenames correctly by preparing
programs on a test basis immediately after the robot is delivered or by taking some other such
step.

Preparing the programs for each unit

1 Switch to the unit targeted for teaching by performing the operations described on
Page 3-1 "3.1 Switching between units".

2 Press [PROG/STEP] while holding down [ENABLE], and input the program
＋ number.
>>A new program is now prepared.

3 No further special steps need to be taken. Proceed with teaching as usual.

172
Preparing the program s for each unit

Preparing the managing program using the managing unit

1 Switch to the managing unit by performing the operations described on
Page 3-1 "3.1 Switching between units".

2 Press [PROG/STEP] while holding down [ENABLE], and input the program
＋ number.
>>A new program is now prepared.

3 The “managing unit” refers to a special unit which has no defined mechanism and
welder, and which exists solely to start the other units, call the programs, and
control the input/output signals.

Therefore, the following restrictions apply compared to other units.

• Manual operation of mechanisms is not possible. (However, the inching/retract and gas
check operations for welders are possible.)
• Teaching of movement commands is not possible.
• Teaching of function commands regarding welding and sensors is not possible.
• Teaching of function commands controlling movement of mechanisms is not possible.

173
Other functions

Copying programs between units

Copying files using shortcut R115 (program copy) or by selecting [1 File Copy] from <File> is
limited to copying between identical units.

When copying programs prepared with one unit to another unit, follow the steps for “Copying
programs between units” in order to reduce the number of teaching steps. (The operator must
have the qualifications level of EXPERT or above.)

However, programs can be copied only when the number of axes and configuration are exactly
the same. One example is copying a program prepared with unit 1 which is a separate NV6 unit to
unit 2 which is another separate NV6 unit. Programs cannot be copied if the units have a different
number of axes or if the type and number of their mechanism differ even though they have the
same number of axes.

(1) Examples where programs can be copied

If the copy source and copy destination units have exactly the same number of axes and
configuration, programs can be copied between these units.
However, if the configuration includes a multiple number of mechanisms, the numerical sequence
of the mechanisms must be the same for both the copy source and copy destination units.

Copying from a single unit of a Unit 2

Unit 1 mechanism to a single unit of a
mechanism
(But only when the number of axes is the
same)

OK!

Unit 1 Unit 2
Copying to a unit with the same
mechanism configuration and same
installation relationship
(But only when the total number of
axes and numerical order of the
mechanisms are the same)

OK!

Fig. 3.4.1 Example where programs can be copied

174
 (2) Examples where programs can be copied but changes must be made
When, as shown below, units such as ones capable of switching positioners A and B which are
subject to cooperative control have been defined, programs can be copied between the unit.
However, major changes must be made to the positions.
For instance, the program for unit 1 below contains the jobs recorded for the work installed on
positioner A. If this program is copied into unit 2, the recorded positions for positioner A will be
transferred as is in the copied program: in other words, these positions will not serve as the
recorded positions for positioner B. Therefore, after a program has been copied, the positions in
all the steps must be changed (or shift operation performed) so that the jobs will be done for the
work installed on positioner B.
Please see Angle Shift or Mirror Shift for possible shift operations.

Unit 1 Unit 2
Programs can be copied (if the total
number of axes and the sequence of
the mechanisms are the same).
After a program has been copied, what
has been taught must be changed.

OK

A B A B

Fig. 3.4.2 Example where major changes must be made to a program

(3) Examples where programs cannot be copied

When the copy source and copy destination units have a different number of axes or configuration,
programs cannot be copied between these units.

Unit 1 Unit 3

Copying to a unit with a different

mechanism configuration

NG!

Fig. 3.4.3 Examples where programs cannot be copied between units

Even when programs are copied between units, the function commands are not
converted.
In other words, if information relating to the units has been recorded in the
parameters of the function commands, that information will not be converted.
After copying the programs, the function commands must be changed.
An instance will now be considered where welder 1 is defined as unit 1 and welder
2 as unit 2 and where the arc start command (AS) has been recorded in the
Important program for each of these units.
Since, in a case like this, the function command will not be converted even when
the unit 1 program is copied into unit 2, the arc start command (AS) in the copied
program will be the command for welder 1. Consequently, this command must be
changed after copying the program.

175
Copying programs between units
1 After pressing <File>, select [7 Program copy between units].
Alternatively, select <Service Utilities> – [7 File] – [7 Program copy between units].
>>The following screen now appears.

2 Select the copy source unit. Press [Enter] in the “Unit” field, and select the unit
using the [UP/DOWN] key.
>>The program belonging to the selected unit is displayed.
At the same time, if the unit to serve as the copy destination is present, this unit can
be selected in the combo box.
If the unit to serve as the copy destination is not present, only the same unit as the
copy source is displayed. In this case, the same operation as simple program copying
is performed.

3 Specify the copy source program.

Input the number of the copy source program in the “Program” field or press
[Enter] on the program list to select it. By pressing [Enter] on other programs on
the list one after another, a multiple number of programs can be selected.

4 Select the copy destination unit.

5 Input the number of the copy destination program.

6 Press f12 <Execute>.

>>The programs are now copied from one unit to another.

176
177
178
Other functions

Locking the unit to be displayed on the program monitor

It is possible to lock the program monitor to display the data of only the specified unit.
With the initial settings, the program monitor displays the data on the “current unit.” The “current
unit” refers to the unit now selected. When steps are taken to switch to another unit, this setting
ensures that details of the programs previously selected by the current unit will be displayed.

In the case of a robot with the multi-unit function, in order to enable a multiple number of units to
be started simultaneously, the operator may want to check which step of the program is being
executed by the current unit especially during automatic operation and at other such times. At
times like this, the program monitor is set to display the data of the specified unit.

Recording, adding, overwriting and deleting instructions, specifying steps and performing other
such teach operations are performed only for the current unit. For all other units (the monitor is set
up to display only the specified unit), modifications can be made after starting up the screen editor.
(Editing tasks with the exception of modifying the position data can be performed.)

Locking the unit to be displayed on the program monitor

1 If the unit now selected is unit 1, the “” and “UNIT1” characters are displayed at the top
right of the program monitor screen. “*” indicates that the setting to display the current
unit is established.

2 As an example, the method used to switch the teach pendant display to two
246 screens by having the display of unit 2 fixed on monitor 2 will be described.
After pressing [RESET/R], input “246”, and press [Enter].
(The same can be achieved by selecting [4 Monitor 2] from [Service Utilities].)

3 Select [1 Robot program], and press [Enter].

>>The program monitor setting screen now appears.

4 Use the [UP/DOWN] key to select “Unit 2,” and press [Enter].
>>The unit 2 program appears on monitor 2.

5 The teach operations are performed for the programs of unit 1 which is the
current unit.
Modifications cannot be made even when the active window has been switched to
monitor 2.
However, after the active window has been switched, modifications can be made
if the screen editor has been started up. (Editing tasks with the exception of
modifying the position data can be performed.)

179
 FORK <FN450> －Unit external start－

Function Command

FORK <FN450> －Unit external start－

Outline
This command starts the task programs in the other units.

Example of operation
The specified task program is started up alongside the task program now being played back.
When the FORK command has been taught, teach the FORKWAIT command, which is for awaiting the
completion of the FORK command, at the appropriate position whenever this is possible.
The FORK and FORKWAIT commands do not always need to be taught as a pair, but it is safer to do so in
order to avoid contention for resources and duplicated execution of the FORK command.

Unit1.001
001 100% JOINT
002 FORK [002,0] Unit2.002
003 600cm/m LIN 001 100% JOINT
004 600cm/m LIN 002 600cm/m LIN
005 600cm/m LIN 003 600cm/m LIN
006 FORKWAIT 004 600cm/m LIN
007 100% JOINT 005 600cm/m LIN
008 100% JOINT 006 END
009 END

：The shaded areas indicate operations

performed in parallel.

2：FORK 002,0 6：FORKWAIT

1 3 4 5 7 8 9：END
Unit1.001

1 2 3 4 5
Unit2.002 6：END

 Parameter
Parameter Data Details Setting
range
First parameter Number of task This is used to specify the number of 1 to 9999
program the program to be started.
Second Resource contention In a case where the mechanism used ∞ (-1)、
parameter wait time inside the program to be started may be 0 to 100
played back by another unit, this
parameter is used to specify in seconds
how long to wait for that mechanism to
be released.
If the mechanism is released within the
specified time, the specified program
starts. If it is not released, an error
results.

180
FORKI <FN451> －Unit external start (with input condition)－

FORKI <FN451> －Unit external start (with input

condition)－

Outline
This command enables a task program of another unit to be started up when its signal is input. If its signal is
not input, the task program is not started up.

Example of operation
The specified task program is started up alongside the task program now being played back.
When the FORKI command has been taught, teach the FORKWAIT command, which is for awaiting the
completion of the FORKI command, at the appropriate position whenever this is possible.
The FORKI and FORKWAIT commands do not always need to be taught as a pair, but it is safer to do so in
order to avoid contention for resources and duplicated execution of the FORKI command.

Unit1.001
001 100% JOINT
002 FORKI [002,0,3] Unit2.002
003 600cm/m LIN 001 100% JOINT
004 600cm/m LIN 002 600cm/m LIN
005 600cm/m LIN 003 600cm/m LIN
006 FORKWAIT 004 600cm/m LIN
007 100% JOINT 005 600cm/m LIN
008 100% JOINT 006 END
009 END

：The shaded areas indicate operations

performed in parallel.

2：FORKI [002,0,3] 6：FORKWAIT

1 3 4 5 7 8 9：END
Unit1.001

1 2 3 4 5
Unit2.002 6：END

 Parameter
Parameter Data Details Setting
range
First parameter Number of task This is used to specify the number of the 1 to 9999
program program to be started.
Second Resource In a case where the mechanism used ∞ (-1) 、
parameter contention wait inside the program to be started may be 0 to 100
time played back by another unit, this parameter
is used to specify in seconds how long to
wait for that mechanism to be released.
If the mechanism is released within the
specified time, the specified program
starts. If it is not released, an error results.
Third parameter Number of input This is used to specify the number of the 1 to 2048、
signal input signal which decides whether the 5001 to
program is to be started up. 5064

181
 FORKN <FN452> －Unit external start (with count condition)－

FORKN <FN452> －Unit external start (with count

condition)－

Outline
This command enables a task program of another unit to be started up when the counter exceeds the
specified value. If the counter shows a figure below the specified value, the task program is not started up.

Example of operation
The specified task program is started up alongside the task program now being played back.
When the FORKN command has been taught, teach the FORKWAIT command, which is for awaiting the
completion of the FORKN command, at the appropriate position whenever this is possible.
The FORKN and FORKWAIT commands do not always need to be taught as a pair, but it is safer to do so in
order to avoid contention for resources and duplicated execution of the FORKN command.

Unit1.001
001 100% JOINT
002 FORKN [002,0,1,3] Unit2.002
003 600cm/m LIN 001 100% JOINT
004 600cm/m LIN 002 600cm/m LIN
005 600cm/m LIN 003 600cm/m LIN
006 FORKWAIT 004 600cm/m LIN
007 100% JOINT 005 600cm/m LIN
008 100% JOINT 006 END
009 END

：The shaded areas indicate

operations performed in parallel.

2：FORKN [002,0,1,3] 6：FORKWAIT

1 3 4 5 7 8 9：END
Unit1.001

1 2 3 4 5
Unit2.002 6：END

 Parameter
Parameter Data Details Setting
range
First parameter Number of task This is used to specify the number of the 1 to 9999
program program to be started.
Second Resource contention In a case where the mechanism used ∞、0 to 100
parameter wait time inside the program to be started may be
played back by another unit, this
parameter is used to specify in seconds
how long to wait for that mechanism to
be released.
If the mechanism is released within the
specified time, the specified program
starts. If it is not released, an error
results.
Third parameter Register number This is used to specify the number of the 0 to 100
count register.
Fourth Count This is used to specify the number of 0 to 10000
parameter times (count) for comparing the
specified value with the counter value.

182
FORKWAIT <FN453> －Fork completion wait－

FORKWAIT <FN453> －Fork completion wait－

Outline
This command leads the robot to await the completion of the task program of the other unit which was started
up by the FORK, FORKI or FORKN command.

Example of operation
When the task program specified by the FORK, FORKI or FORKN command has started up, the completion of
all the programs being started is awaited.

：The shaded areas indicate operations

Unit1.001 performed in parallel.
001 100% JOINT
002 FORK [002,0] Unit2.002
003 FORK [003,0] 001 100% JOINT Unit2.003
004 600cm/m LIN 002 600cm/m LIN 001 100% JOINT
005 600cm/m LIN 003 600cm/m LIN 002 600cm/m LIN
006 FORKWAIT 004 600cm/m LIN 003 600cm/m LIN
007 100% JOINT 005 600cm/m LIN 004 600cm/m LIN
008 END 006 END 005 600cm/m LIN
006 END

2：FORK [002,0]
3：FORK [003,0] 6：FORKWAIT
Unit1.001 1 4 5 7 8：END

Unit2.002 1 2 3 4 5 6：END

Unit3.003 1 2 3 4 5 6：END

183
 CALLFAR <FN454> －Unit external call－

CALLFAR <FN454> －Unit external call－

Outline
This command calls a task program of another unit.
When it is called, the execution of the existing program is suspended, and it is not resumed until the execution
of the called program is completed.
Another unit external call cannot be executed by the call destination program. However, programs can be
called inside the unit using the CALLP or other such commands in the call destination program (up to 8 levels).

 Parameter
Parameter Data Details Setting
range
First parameter Number of task This is used to specify the number of 1 to 9999
program the program to be called.
Second Resource contention In a case where the mechanism used ∞ (-1)、
parameter wait time inside the program to be called may be 0 to 100
played back up by another unit, this
parameter is used to specify in seconds
how long to wait for that mechanism to
be released.
If the mechanism is released within the
specified time, the specified program is
called. If it is not released, an error
results.

184
CALLFARI <FN455> －Unit external call(with input condition)－

CALLFARI <FN455> －Unit external call(with input

condition)－

Outline
This command calls a task program of another unit when its signal is input.
When it is called, the execution of the existing program is suspended, and it is not resumed until the execution
of the called program is completed.
Another unit external call cannot be executed by the call destination program. However, programs can be
called inside the unit using the CALLP or other such commands in the call destination program (up to 8 levels).

 Parameter
Parameter Data Details Setting
range
First parameter Number of task This is used to specify the number of the 1 to 9999
program program to be called.
Second Resource contention In a case where the mechanism used ∞ (-1)、
parameter wait time inside the program to be called may be 0 to 100
played back up by another unit, this
parameter is used to specify in seconds
how long to wait for that mechanism to
be released.
If the mechanism is released within the
specified time, the specified program is
called. If it is not released, an error
results.
Third parameter Number of input signal This is used to specify the number of the 1 to 2048、
input signal which determines whether 5001 to
the program is to be called. 5064

185
 CALLFARN <FN456> －Unit external call (with count condition)－

CALLFARN <FN456> －Unit external call (with count

condition)－

Outline
This command calls a task program of another unit when the counter shows a figure above the specified value.
If the counter shows a figure below the specified value, the task program is not started up.
When it is called, the execution of the existing program is suspended, and it is not resumed until the execution
of the called program is completed.
Another unit external call cannot be executed by the call destination program. However, programs can be
called inside the unit using the CALLP or other such commands in the call destination program (up to 8 levels).

 Parameter
Parameter Data Details Setting
range
First parameter Number of task This is used to specify the number of the 1 to 9999
program program to be called.
Second Resource contention In a case where the mechanism used ∞(-1)、
parameter wait time inside the program to be called may be 0 to 100
played back up by another unit, this
parameter is used to specify in seconds
how long to wait for that mechanism to
be released.
If the mechanism is released within the
specified time, the specified program is
called. If it is not released, an error
results.
Third parameter Register number This is used to specify the number of the 0 to 100
count register.
Fourth Count This is used to specify the number of 0 to 10000
parameter times (count) for comparing the
specified value with the counter value.

186
Start status displays and start release

Start status displays and start release

Checking the start status of programs

If programs have been started in parallel using the program start commands (FORK, FORKI or
FORKN) and unit external call commands (CALLFAR, CALLFARI and CALL FARN) described in
Chapter 4, it is possible to check (1) which unit is the start source (call source) and (2) which unit
is now running by monitoring the display on the teach pendant.

(1) is displayed in the status area of the teach pendant.

When Multi Task Monitor is started, both statuses (1) and (2) can be checked.

Checking the start status of programs

1 If one of the units has been started by a FORK or CALLFAR command, the
following icons will appear on the teach pendant.

This shows that a CALLFAR command is

being executed.
The numeral indicates the number of the call
source unit.

This shows that a FORK command is being

executed.
The numeral indicates the number of the call
source unit.

This display remains on the teach pendant even when the playback is stopped or when
operation has been transferred to the teach mode.

2 An alternative method is to start the Multi Task Monitor.

As an example, the method used to switch the teach pendant display to two
screens by having the display of unit 2 fixed on monitor 2 will be described.

After pressing [Reset/R], input “246,” and press [Enter].

(The same result is obtained also by selecting [4 Monitor 2] from <Service Utilities>.）
246

187
3 Select [51 Multi Task], and press [Enter].
>>The unit selection screen now appears.

4 Select the unit to be monitored.

It is a good idea to select the unit whose icon is displayed on screen 1.
>>The start statuses of the units are now displayed.

188
Start status displays and start release

Releasing the start statuses of the programs

Once playback has stopped, the program may be played back again from its start. Perform the
following steps in a situation like this.

Releasing the start statuses the programs

When releasing all the starts using a FORK or CALLFAR command
1 Perform the unit switching operation to switch to the “call source unit.”
＋ The call source unit is displayed on the operation 1 screen on page 5-4.

2 Press [RESET/R], [0] and [Enter] in this sequence.

(Execute shortcut R0 which executes reset and return to step 0.)
>>The start statuses of all the programs executed by the FORK or CALLFAR command
are released (all multi-task starts are released).
At the same time, the start status icons are cleared.
The fact that the programs have not yet been started is also shown on the multi-task
monitor.

When playing back only the FORK or CALLFAR destination program from the start while the
start statuses remain unchanged
1 Perform the unit switching operation to switch to the “called unit.”
＋

2 Press [RESET/R], [0] and [Enter] in this sequence.

(Execute shortcut R0 which resets the step counter.）
>>The step of the selected unit is reset to “0.” (The start status established by the FORK
or CALLFAR command remains unchanged so the program is executed from the
start when it is started next.)

Concerning automatic release of the start status

If either of the following steps is taken in the stopped status after another program has started up
from the parent program (control program) serving as the start source, the start status will be
released.

(A)When the number of a step in the parent program (control program) serving as the start source
has been changed
(B)When an attempt has been made to open a program which is different from the parent program
(control program) serving as the start source

A confirmation message giving the option of either proceeding with the release or canceling it now
appears.

1 When either of the above steps is taken, the following message appears.

2 If YES is selected, the operation during which the attempt was made to release the
start continues.
If NO is selected, the operation is canceled, and the display returns to the original
screen.

189
 What is multi-cooperation?

For operators using the

multi-cooperation

What is multi-cooperation?
The multi-cooperation enables playback to be performed while the positioners serving as the target of
cooperative control are switched.
If, for instance, a system consists of a manipulator and positioners A and B, cooperative control can be
exercised on some occasions for the manipulator and positioner A and on other occasions for the manipulator
and positioner B.

Unit Unit 2

Manipulator

Positioner B
Positioner A

Fig. 6.1.1 Example of multi-cooperation robot configuration

190
Key points for teaching

Key points for teaching

With multi-cooperation robots, the simplest procedure is to prepare the main program with one of the units and
then teach so that the programs of the units will be called by this main program.

Unit 1

Start Call Unit 2

Start button
Unit 1 Unit 1
External start
signal U1

Unit 1
Call

Unit 2
Unit 2

Fig. 6.2.1 Example of multi-cooperation robot startup

In the case of the diagram above, a main program prepared with unit 1 is started up, and then programs of unit 1
and unit 2 are called.

Program to be called (unit 1)

Main program (unit 1)

Program to be called (unit 2)

The following function commands are used to call a

program of the same unit.
・CALLP ：Program call (No condition)
・CALLPI ：Program call (Input signal condition)
・CALLPN ：Program call (Frequency condition)

The following function commands are used to call a

program of another unit.
・CALLFAR ：Call for program (No condition)
・CALLFARI ：Call for program (Input signal condition)
・CALLFARN：Call for program (Frequency condition)

191
 What is multi task?

For operators using the multi task

What is multi task?

For robots with the multi-unit function, a multiple number of units can be started up in parallel from the managing
unit. The “managing unit” refers to a special unit which has no defined mechanism, and which exists solely to
start the other units, call the programs, and control the input/output signals. It is defined prior to shipment from
the factory or prior to delivery in accordance with the user’s specifications.

By using the multi-tasks in conjunction with multi-cooperation robots, it is possible to switch dynamically
between the parallel or separate tasks and the cooperative tasks, as shown below.

The nozzle cleaning undertaken by

Unit 1
the manipulator and the operations
conducted by positioners A and B
for initiating the loading and
unloading of the work are each
performed by independent
operations
Unit 2 Unit 3

Unit 4 Unit 5

Unit 3 Unit 2

The manipulator performs the welding task using The manipulator performs the welding task using
synchromotion control with positioner A. synchromotion control with positioner B.
Positioner B operates on its own independently of Positioner A operates on its own independently of
the welding task, and it adopts the postures for the welding task, and it adopts the postures for
loading and unloading the work. loading and unloading the work.

Fig. 7.1.1 Example of multi-task configuration

192
Key points for teaching

Key points for teaching

To facilitate the multi task, prepare the managing program using the managing unit, and teach in such a way that
the units will be started up from the managing program.

Start Start
Start button
Managing unit Unit 1

Parallel start
External start
(Unit 6) Unit 2 Unit 1
signal

Unit 3

Start Unit 4 Unit 5

Parallel start
Unit 4

Unit 3

Start
Unit 2 Unit 3

Parallel start
Unit 5

Unit 2 Unit 6 = Managing unit

Fig. 7.2.1 Example of startup from managing program

Units 1, 2 and 3 are started up simultaneously.

Management program (unit 6)

Units 3 and 4 are started up simultaneously.

Units 2 and 5 are started up simultaneously.

The following function commands are used to start a program

of another unit from the managing unit.
・FORK ：Fork program
・FORKI ：Fork program（Input signal condition）
・FORKN ：Fork program（Frequency condition）

Fig. 7.2.2 Teaching example

193

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INSTRUCTION MANUAL 




SYNCHROMOTION
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SYNCHROMOTION
SIMULTANEOUS


CONTROL

1
 Control processes

Control processes
This controller is equipped with the functions outlined below. They allow the controller to control multiple
mechanisms connected with it simultaneously, thereby permitting the robot system to operate more efficiently
overall and producing high-quality welding results. Each of your robots is configured for one of the following
control processes. They are also optimally configured and fine tuned for their specific applications and modes of
use.

• Simultaneous Control
• Synchromotion control (cooperative control)
• Multi-unit control

Multi-mechanism

Single unit Multi unit

Simultaneous control Cooperative control Cooperative control, simultaneous control, or single mechanism
control for individual units

Multiple mechanisms start out simultaneously toward At some times, multiple units start operating in parallel and each works
their target step and reach it simultaneously independently (multi task)

Control of the position, Control of the position, Cooperative operation at some times
posture, and speed of posture, and speed of Dynamic switching of targets of cooperative control (multi-cooperation)
tools relative to the ground tools relative to the work Manipulator grips work (jig-less cooperation)
Two manipulators weld simultaneously (twin cooperation)
Multiple manipulators work in cooperation (collaboration)

Cooperative control and simultaneous control setup Example of switching between independent, parallel operation and
example cooperative operation

Cooperative control of Cooperative control of

positioners positioners and sliders

Simultaneous control of Simultaneous control of

positioners sliders

Examples of the application of cooperative control

Twin cooperation Multi-cooperation

Jig-less cooperation Collaboration

195
Control processes

Synchromotion control
Synchromotion control is a control process in which multiple mechanisms (manipulators, auxiliary
axes, etc.) operate simultaneously and the position, posture, and speed of the tools is controlled
relative to the work. It is also sometimes referred to as cooperative control.
For example, in an arc welding system configured as shown below, the manipulator could
maintain at all times the optimal torch posture and speed, relative to the work mounted on the
positioner.

Fig. 1.3.1 Arc welding using synchromotion control

Simultaneous control
Simultaneous control is a control process in which multiple mechanisms (manipulators, auxiliary
axes, etc.) operate simultaneously.
Multiple mechanisms begin to move toward their target step at the same time and they stop
moving at the same time. Cooperative control allows control over position, posture, and speed
relative to the work. Simultaneous control permits control the position, posture, and speed of tools
relative to the ground.
Simultaneous control is sufficient for applications such as the following.

• Cases where it is possible for the manipulators to maintain an optimal posture at all times
relative to the work mounted on the positioner
• Controlling sliders on which manipulators are conveyed

196
 Control processes

Multi-unit control
The multi-unit control divides up all the mechanisms connected to a control unit into a number of
groups called “units” and controls the robot on a unit-by-unit basis.
The units are preset prior to shipment from the factory or prior to delivery in accordance with what
the user has specified.

What is a unit?

Unit 1 With the multi-unit function, all the mechanisms Unit 2

connected are divided up into a number of groups called
In this group, the “units.” Normally, the initial settings for the units are In this group, the
manipulator performed prior to shipment from the factory or prior to manipulator
exercises delivery in accordance with the user's specifications. exercises
synchromotion Two units are defined in this example, but other units synchromotion
control for positioner can also be divided up into other groups. It is also control for positioner
A. possible to divide up the units into an “only manipulators” B.
or “only positioners” group.

Unit 1 Unit 2

Manipulator

Positioner B
Positioner A

The task program is created by each of the units.

Unit 1 Unit 2

Program in which the Program in which the

manipulator exercises manipulator exercises
synchromotion control for synchromotion control for
positioner A positioner B
It is possible not only for the programs
(units) to be started up individually but
also to provide a main program and
then switch between the units while
operation is in progress by calling a
program of each unit from the main
program.

Fig. 1.3.2 Thinking behind the multi-unit (with multi-cooperation robots)

This figure shows a simple outline the concept of the multi-unit. Note that it is only one example.
By using a multi-unit, you can operate the robots more flexibly and efficiently.
For details, see the instruction manual “Multi-unit”.

197
 Before performing teaching or manual operation

Before performing teaching or manual operation

If multiple mechanisms are connected to the system, it is necessary to switch among units or mechanisms when
performing teaching or manual operation.

Switching between units

If the system has multiple units defined (multi-unit specification), it is necessary to first select the
unit to be the target for teaching or manual operation. Motor power may be either on or off.
This operation is unnecessary if multiple units are not defined. (No switching takes place even if
the unit switching operation is performed.)

Switching between units

1 The currently selected unit and the mechanism defined for it are displayed on the
teach pendant.
Confirm the current unit selection by checking the display of the teach pendant.
Number of unit being
selected

Mechanisms included in
the currently selected unit

Number and name of

mechanism being
selected

UNIT 2 While holding down [ENABLE], press [UNIT/MECHANISM].

ENABLE ＋ MECHA-
>> The unit selection screen is displayed while [ENABLE] is held down.
NISM

3 The units are switched in sequence by pressing [UNIT/MECHANISM] while

[ENABLE] is held down so switch to the desired unit.

198
Before performing teaching or manual operation

Switching between mechanisms

After switching the unit, select the mechanism to be used for manual operation. Motor power may
be either on or off.

POINT
When selecting the mechanism to be manually operated, be absolutely sure to switch to the unit
to which the mechanism in question belongs. Mechanisms which are not defined for the units
cannot be operated manually.
For instance, it is assumed that the current unit is unit 1 and that NV6 is the only mechanism
defined. In this case, mechanisms other than NV6 cannot be operated manually while unit 1 is
selected.
In addition, when the managing unit has been defined, any mechanism cannot be operated
manually since the managing unit does not have mechanisms.

Switching between mechanisms

1 The mechanism selected for manual operation is displayed on the teach pendant.

The currently selected

mechanism is displayed
in color.

UNIT 2 To switch the selected mechanism, press [UNIT/MECHANISM].

MECHA-
NISM >>The selected mechanism changes (and the display of the teach pendant changes).
An example of switching in a unit comprising a manipulator and a positioner is shown
below.

Manipulator name Positioner name

Mechanism number Mechanism number

3 After switching the mechanism, manual operation using the newly selected
mechanism is possible.
While holding the deadman switches, press the axis keys to operate the mechanism.

199
 Coordinates

Coordinates
The coordinates used for manual operation of a manipulator are generally axis coordinates and robot
coordinates (machine coordinates).
If the unit supports cooperative control, manual operation using “work coordinates” is also possible.
In addition, if multiple mechanisms are connected to the system, “world coordinates (absolute coordinates)” that
are unique to the system as a whole may be selected.

Axis coordinates

Decalt coordinate system Robot coordinates (machine coordinates)

Tool coordinates

Work coordinates

World coordinates (absolute coordinates)

Work coordinates
Work coordinates can be selected for units supporting cooperative control. One example would
be a case in which cooperative control is used for a manipulator and an auxiliary axis (such as a
positioner). Work coordinates cannot be selected for simultaneous control of the manipulator and
auxiliary axis, or for the unit with the single manipulator or single auxiliary axis.
Work coordinates have a starting point and axis directions fixed at the mechanism on the work
side (such as a positioner). If the mechanism on the work side moves, the starting point and axis
directions of the work coordinates move with it.

Tool side

Tool side

Z
Z

Work side Y

X Y

Work side

Work coordinates for starting point at positioner Work coordinates after movement of positioner

Fig. 2.2.1 Work coordinates

As shown in the illustration at right above, moving the mechanism on the work side causes the
work coordinates to move to match.
When performing manual operation in a case such as this, with work coordinates selected, the
manipulator must follow the work coordinates (X, Y, and Z directions) after they have moved. It is
quite useful when performing teaching for cooperative operation.
The rotation of the wrist axis performs the same action as the robot coordinates (machine
coordinates), relative to the work coordinates after they have moved.

200
Coordinates

World coordinates (absolute coordinates)

World coordinates are fixed at a specified position. Unlike tool coordinates or work coordinates,
the starting point and axis directions of world coordinates do not change to match the posture of
individual mechanisms.
If, for example, multiple manipulators are connected, world coordinates can be used for tasks
such as having all the manipulators move in the same direction.

Fig. 2.2.2 World Coordinate

In a typical system, the starting point and axis directions of the world coordinates are the same as
those of the machine coordinates for the first manipulator. In cases where multiple robots are
operating on a production line, the world coordinates can be set to a specified position with
absolute coordinates, as per the customer’s specifications.

201
 Coordinates

Registering coordinates
Under the default factory settings, each time the [INTERP/COORD] key is pressed, the setting
changes in the following sequence: “axis coordinates” → “robot coordinates” → “tool
coordinates”.
This is the case because under the factory settings robot coordinates (machine coordinates) and
tool coordinates are registered as rectangular coordinates to be used. (Axis coordinates can be
selected even if they have not been registered.)
This controller allows a maximum of three sets of rectangular coordinates to be registered.
In order to use work coordinates or world coordinates for manual operation, the desired
coordinates must first be registered using the following procedure.
Note, however, that an operator qualification of Expert or above is necessary in order to register
coordinates.

Registering coordinates
1 After pressing <Constant Setting>, select [5 Operation Constants] — [5 Coordinate
registration].
>> The coordinate registration menu is displayed.

Under the default factory settings, “robot coordinates (machine coordinates)” is set as
coordinate set 1 and “tool coordinates” is set as coordinate set 2.

2 The example below shows the procedure for registering work coordinates as
coordinate set 3.
Use [Up] or [Down] key to move the cursor to “Coord.3”.

3 While holding down [ENABLE], press [Left] or [Right] to select “Work”.

＋

4 Press f12 <Complete>.

>> The new settings are saved to memory and the previous menu is redisplayed.

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Cooperative manual operation

Cooperative manual operation

Cooperative manual operation is a function that causes the additional mechanisms to move to match if one
among two or more mechanisms that have been defined in the unit as enabled for cooperative control is moved
using manual operation. This function is used when teaching movement commands for cooperative operation
and when making position or posture corrections.

If a manipulator and positioner are under cooperative control

When the positioner is moved, the manipulator moves so as to maintain the same position and posture relative
to the work mounted on the positioner. When the manipulator is moved it operates independently; the positioner
does not move.

Fig 2.3.1 Cooperative manual operation when positioner is moved

If a manipulator and slider are under cooperative control

When the slider is moved, the manipulator moves so as to keep the tip of the tool at the same spot. When the
manipulator is moved it operates independently; the slider does not move.

Fig 2.3.2 Cooperative manual operation when slider is moved

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 &ooperative manual operation

If two manipulators are under cooperative control

When one of the manipulators is moved the other manipulator moves to match.
For example, moving a manipulator holding the work causes the manipulator holding the tool to move so as to
maintain the relative positions and postures of the tool and the work. The same thing happens in the reverse
case.
Either axis coordinates or rectangular coordinates may be used to perform manual operations.

Fig 2.3.3 Cooperative manual operation by two manipulators

204
Cooperative manual operation

Performing cooperative manual operation

Cooperative manual operation is not possible under all circumstances.
In order for it to be possible, the following conditions must all be met.

• The unit on which cooperative manual operation is to be performed must be selected.

• The unit’s manipulator and auxiliary axis (positioner or slider) must be enabled for cooperative
control, or two of the unit’s manipulators must be enabled for cooperative control.
• In the case of a manipulator and auxiliary axis, the auxiliary axis must be the target for manual
operation.
(In the case of two manipulators, either may be the target for manual operation.)

1 In this example a manipulator and auxiliary axis are under cooperative control.
Confirm that a unit for which cooperative control is enabled has been selected.

2 Press [UNIT/MECHANISM] to select the auxiliary axis as the target for manual
operation.
>> When the auxiliary axis is selected the coordinate set switches automatically to “axis
coordinates”.

3 Press [SYNCHRONIZE] at the position where you wish to perform cooperative

manual operation.
>> The display changes each time [SYNCHRONIZE] is pressed, as shown below.

→ → →

Cooperative manual operation is possible if “POS/POSE” or “POS” is displayed.

If neither of these is displayed the system operates in the normal way (each axis
operating independently).

POINT
There are two ways to perform cooperative manual operation. Select the one that is most
appropriate for the teaching position or the work configuration.

• Position and posture cooperation The relative positions and posture of the tool
and work are maintained.
• Position cooperation Only the relative positions of the tool and work
are maintained.

Position
cooperation

Position and
Manual
posture
operation
cooperation

205
 Teaching with cooperative control and simultaneous control

Teaching with cooperative control and simultaneous control

Even if the unit has multiple mechanisms defined, the series of operations involved in teaching—moving the
mechanism and recording its position—is the same as when working with a unit with only a single manipulator.
The difference is that recording a movement command causes the position of all of the mechanisms to be
recorded at once. (It is not possible to record the position of only one particular mechanism.)
For units with cooperative control enabled, you can specify whether or not to use cooperative control when
recording movement commands. If no specification is made simultaneous control is used automatically.
In addition, if multiple mechanisms with different speed standard are defined, you can specify which speed
standard will be used.

Recording movement commands

1 For a multi-unit specification system, hold down [ENABLE] and then press
＋ [UNIT/MECHANISM] to select the unit to be the target for teaching.

This step is unnecessary if there is only one unit.

2 Hold down [ENABLE] and then press [PROG/STEP] to input the number of the
program to be created.

3 Using [UNIT/MECHANISM] to switch among the mechanisms as necessary, use

manual operation to move all of the mechanisms to the position to be recorded.

4 To have the mechanisms move from the preceding position to the present position
＋ under cooperative control, hold down [ENABLE] and then press [SYNCHRONIZE].
>> The indication “H” appears as the recording status.
This indication means that the mechanisms will move to that position under cooperative
control.

Use ENABLE and SYNCHRO-

NIZE
to toggle between cooperative control (“H” displayed)
and simultaneous control (“H” not displayed).

If the “H” indication does not appear even when [SYNCHRONIZE] is pressed while holding
down [ENABLE], cooperative control is not possible for the current unit.

5 The next step, 6, is where the speed will be set. Before that, however, it is necessary
to specify for which mechanism teaching of the speed will be performed.
This mechanism is called the speed standard mechanism. Switching among the
mechanisms is accomplished using the <Change Speed Standard Mechanism> f key.

The number (B*) of the mechanism to be

used as the speed standard is displayed
here.
Depending on the system settings, there
may be nothing displayed in some cases.
(There is no need to make a setting if there
is no display.)

However, in most cases there is no need to be aware of the speed standard mechanism.
This step is therefore unnecessary and we can continue with step 6.

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Teaching with cooperative control and simultaneous control

What is the speed standard mechanism?

ヒント
HINT
The speed standard mechanism is the mechanism that sets the standard for cases
where multiple mechanisms move at the same time. During playback the other
mechanisms move at the same speed as the speed standard mechanism.
For example, if the unit comprises a manipulator and an auxiliary axis (such as a
positioner) and the manipulator is set as the speed standard, the procedure described in
step 6 below is used to teach the operating speed of the manipulator. During playback
the positioner moves in synchronization with the movement speed of the manipulator. It
also begins and ends movements at the same time as the manipulator.
Conversely, if the positioner is the speed standard, the step below will teach the
operating speed for the positioner. During playback the manipulator moves in
synchronization with the movement speed of the positioner. It also begins and ends
movements at the same time as the positioner.

Based on the above, we can see that it is best to be aware of the speed standard
mechanism in cases such as the following.

When performing linear or circular interpolation when the manipulator and positioner are
under simultaneous control (“H” not displayed)
If the position is rotated without moving the manipulator much in order to perform arc
welding, or the like, teaching is easier if one is aware of the speed of the positioner. In a
case such as this the positioner should probably be selected as the speed standard
mechanism.

When performing straight line or arc interpolation when two or more manipulators are
under cooperative control (“H” displayed)
If two or more manipulators are under cooperative control, it is probably best to select
the speed standard mechanism based on which of the manipulators is doing the majority
of the movement.

6 Set the necessary parameters, such as interpolation type, speed, and accuracy.

7 Press [O.WRITE/REC] to record the settings.

>> When step is recorded while the “H” indication is displayed, movement commands
corresponding to cooperative control are recorded. (“H” is displayed after the step No.)

If the “H” indication is not displayed when the settings are recorded, the result is
simultaneous control.

Operation during playback is as described below, depending on whether or not the “H”
indication is displayed and the interpolation type setting.

Interpolation “H” Operation during playback

type indication
Joint “H” All of the mechanisms in the unit move from the preceding
interpolation displayed recorded position to the present position using joint
(JOINT) interpolation.
“H” not Same as when “H” is displayed.
displayed In other words, the same movements take place regardless of
whether or not the “H” indication is displayed when joint
interpolation is used.
Linear “H” All of the mechanisms in the unit move from the preceding
interpolation displayed recorded position to the present position simultaneously.
(LIN) or The manipulators move on the work coordinates using linear
Circular or circular interpolation, so the position, posture, and speed
interpolation are maintained relative to the work.
(CIR) “H” not All of the mechanisms in the unit move from the preceding
displayed recorded position to the present position simultaneously.
The manipulators move using linear or circular interpolation,
but they move independently and without regard to the work
coordinates; position, posture, and speed are not maintained
relative to the work.

207
 Twin cooperation

Twin cooperation
This function enables multiple manipulators to perform cooperative control of one work item.
Specifically, this function could be employed to have two manipulators perform arc welding on both ends of a
long piece of work held by a double support positioner at the same time. This enables two different points to be
welded simultaneously, thus enabling the work efficiency to be improved.

Fig. 3.1.1 Example of twin cooperation configuration

● Multiple manipulators cannot execute search operation commands simultaneously

when a touch sensor or laser search is being used during twin cooperation. Each
manipulator executes a search operation command one at a time in the taught
sequence.
Search operation commands refer to the following.
Touch sensor:
Wire length detection (SF0), unidirectional search (SF1), pattern search (SF2)
Laser search:
Unidirectional search (ZF1), pattern search (ZF2), acquisition of beveling data (ZG1)
● Twin cooperation drift acquisition (SF3) can be performed by means of a cooperative
operation by multiple manipulators.
IMPORTANT ● For the method of teaching using a touch sensor or a laser search, refer to “Touch
sensor” or “Laser search” in the instruction manual.
● An arc sensor or laser sensor cannot be used in twin cooperation.
● An arc retry function cannot be used on the user settings in twin cooperation.
● A check welding which is enabled cannot be set simultaneously as multiple welders in
twin cooperation.
● An on-line change cannot be used simultaneously as multiple welders in twin
cooperation.

208
Preparations for using twin cooperation

Preparations for using twin cooperation

In order to perform twin cooperation, it is necessary to set up the welder and also set up the input and output
signals exclusive to arc welding.

Setup relating to welder

Perform the setup relating to the welder. For this procedure, an operator qualification of Expert or
above is necessary.

When the robot and welder have been purchased at the same time, the setup is normally done
prior to shipment, and so it need not be done by the user.
The setup must be done if operators aim to do the setup themselves or if the welder is to be
changed after the robot was delivered. For further details, refer to the “Application Manual (Arc
Welding)”.
Here, a description of the points to note concerning setup for twin cooperation operation is given.

Settings relating to how to operate the welder

Set the robot to which the welder is to be connected and the connection type.
When a robot system with the multi-unit specifications is to be used, these settings must be
performed for each unit.

ポイント
POINT
● Multiple welders connected to the unit are used for twin cooperation.

The following is an example of setup for the case where twin cooperation is performed by
assigning a welder to each of the two manipulators in unit 1.

1 In the teach mode, press f5 <Arc Constant>, and then select [2 Setting of welder].
>> The welder setting screen is displayed.

Set Welder 1 as “Mechanism 1”, and Welder 2 as “Mechanism 5”, in the “Mechanism”
box.
Set “Independent” for both “Welder 1” and “Welder 2” in the “Connection type” box.

209
 Preparations for using twin cooperation

Section welding OFF【W1 to W4】

Initial allocation No. 0
Meaning of the signal The operation is underway in the “Section welding OFF” status.
When a welding trouble (arc outage or arc start failure) occurred while
section OFF was set as the operation that takes place after an arc start
Operation when turned ON
failure or an arc outage, by the Abnorm. sect. OFF input signal (page
3-5).
 All the action for the welding section concerned is completed. or
Operation when turned OFF  When the section weld OFF status was canceled by the Section weld
OFF status cancel input signal (page 3-5)
Remarks
Operator qualifications User or above

Setup for the screen edit display mode

Under the twin cooperation system, it is available to use two or more manipulators at the same
time and individually teach a different interpolation type to each manipulator. Therefore, it is
necessary to set to the mode in advance, allowing to edit the command by each manipulator on
screen editing.

Changing the screen edit display mode

1 Press f5 <Constant Setting> in the Teach mode, select [2 Screen Constants] - [4
Menu Selection].
≫ Next screen appears.

2 In the “Screen Editor”, select [Form2] or [All].

＋

3 Lastly, press f12<Complete>.

≫ Thus, the screen edit display mode has been changed.

210
Preparations for using twin cooperation

Concerning the screen edit display mode

ヒント
HINT
The screen edit display mode has 2 kinds of screen by each
mechanism.
-Standard screen : Displaying the data such as the interpolation type,
Speed, Accuracy, etc…
-Second screen : Displaying the joint angle or coordinate value of
each axis.

The details for the screen edit display mode are as follows.
From1 Mechanism1 : Standard screen + Second screen
Mechanism2~ : Second screen
Form2 All mechanism : Standard screen only
All All mechanism : Standard screen + second screen

For the unit where two or more manipulators are set, it is necessary to
set the interpolation type by each manipulator. Please select [Form2] or
[All].

211
 Teaching of twin cooperation

Switching over the welders and mechanisms to be operated

The twin cooperative system consists of multiple mechanisms. Multiple welders are connected to the system.
For this reason, it is necessary to specify the welder to be operated when welding is to be performed manually
for inching or retracting the wire, for example.
Also, it is necessary to specify which mechanisms are to be turned ON/OFF when turning weaving ON/OFF.

Switching over the welder to be operated

It is necessary to select the welder to be operated when performing one of the following
operations.

・ Wire inching/retraction
・ Gas check

Switching over the welder to be operated manually.

1 Teach mode f key

>> It is possible to judge which of the welders has been selected for operation by
observing the “W1” indication at bottom left of f10 <Inching>, f11 <Retract> and f12
<Gas>.
This is an example in which welder 1 has been selected for operation.
2 While pressing [ENABLE], press f2 <Select Arc>.
＋ >> The number of the welder selected for operation that is displayed at bottom left of f10
<Inching>, f11 <Retract> and f12 <Gas> changes over to the number of the next
welder registered in the system.
3 It is possible to inch the welder selected for operation at low speed, by pressing
f10 <Inching>.
To inch the welder at high speed, press f10 <Inching> while pressing [ENABLE].
It is possible to retract the welder selected for operation at low speed, by pressing
f11 <Retract>.
To retract the welder at high speed, press f11 <Retract> while pressing [ENABLE].
It is possible to perform a gas check of the welder selected for operation, by pressing f12
<Gas>.

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Teaching of twin cooperation

Switchover between welding ON/OFF consists of individual switchover in which a single welder is
switched ON/OFF, and ganged switchover in which all welders registered in the system are
switched ON/OFF together.

Switching each welder ON/OFF individually

1 Teach mode f key

>> Confirm that the welder number of the selected welder (“W1” in this case) is
displayed at bottom left of f2 <Weld ON/OFF>. In this status, it is possible to turn
each welder ON/OFF individually.

2 While pressing [ENABLE], press f2 <Select Arc>.

＋ >> The number indicating the welder selected for operation displayed at bottom left of f2
<Weld ON/OFF> switches over to the number of the next welder registered in the
system.

3 It is possible to change the ON/OFF status of the welder selected for operation, by
pressing f2 <Weld ON/OFF>.
Indicates that the welder selected for operation is ON.

Indicates that the welder selected for operation is OFF.

Indicates that the welding ON/OFF status of the welder selected for
operation switches over according to the status of the “Weld ON/OFF” input
signal.
In this example, the “Weld ON/OFF” input signal is OFF, and welding is
OFF.

213
 Teaching of twin cooperation

Switching over all welders ON/OFF together

1 Press f6 <Arc Condition> in the teach mode, then select [1. Arc
Teach/Playback Condition].
>> The arc teach and playback condition setting screen is displayed.

2 Move the cursor to “Weld On/Off”, then switch the radio buttons (horizontal
＋ row of selector buttons) to “To all” using the [ENABLE] + [Left/right cursor]
keys.
3 Upon completion of the settings, press f12 <Complete>.
The settings are saved in the file, and so their statuses are retained even when
the power is turned off.
4 When the display returns to the top screen of the teach mode, “To all” appears
at bottom left of f2 <Weld ON/OFF>.
It is possible to change the welding ON/OFF status of all welders registered in the
system, by pressing f2 <Weld ON/OFF>.
Indicates that all welders are ON.

Indicates that all welders are OFF.

Indicates that the welding ON/OFF status of all welders switches over
according to the status of the “Weld ON/OFF” input signal.
The ON/OFF status of each welder differs according to the status of
each “Weld ON/OFF” input signal.
The ON/OFF status displayed at f2 <Weld ON/OFF> indicates the status
of the welder selected by f2 <Select Arc> which is displayed when
[ENABLE] is pressed.

Method of easily switching between “To each” and “To all”

5 On the teach or playback mode top screen, press the [RESET/R] key.
>> The [Shortcut R code Entry] screen is displayed.

6 Press the [Up/Down] key to move the cursor to [R380: Change the arc welder
selection], or enter “380” in the edit box directly below and press the [Enter]
key.
>> The display switches between “To each” and “To all” of Weld On/Off.

214
Teaching of twin cooperation

Switching over mechanism selected for a weaving ON/OFF operation

There are two types of switchover between weaving ON/OFF: Individual switchover of weaving
ON/OFF of one mechanism, and ganged switchover of weaving ON/OFF of all mechanisms
(manipulators or module robots) registered in the system that can perform weaving.

Individual switchover of weaving ON/OFF

1 Teach mode f key

>> Confirm that the applicable mechanism number (“M1” in this case) is diaplayed at
bottom left of f3 <Weaving ON/OFF>. It is possible to perform individual weaving
ON/OFF in this status.

2 While pressing [ENABLE], press f3 <Select Robot>.

＋
>> The number indicating the mechanism selected for operation displayed at bottom left
of f3 <Weaving ON/OFF> switches over to the number of the next welder
mechanism (manipulator or module robot) registered in the system that can perform
weaving.

3 It is possible to change the weaving ON/OFF status of the mechanism selected for
operation, by pressing f3 <Weaving ON/OFF>.
Indicates that the mechanism selected for operation is in a weaving ON
status.
Indicates that the mechanism selected for operation is in a weaving OFF
status.
Indicates that the weaving ON/OFF status of the mechanism selected for
operation is switched over according to the status of the “Weaving ON/OFF”
input signal. In this example, the “Weaving ON/OFF” input signal is OFF, and
weaving is OFF.

215
 Teaching of twin cooperation

Switching over all weaving ON/OFF together

1 Press f6 <Arc Condition> in the teach mode, then select [1. Arc
Teach/Playback Condition].
>> The arc teach and playback condition setting screen is displayed.

2 Move the cursor to “Weav On/Off”, then set the radio buttons (horizontal row
＋ of selector buttons) to “To all” using the [ENABLE] + [Left/right cursor] keys.
3 Upon completion of the settings, press f12 <Complete>.
The settings are saved in the file, and so their statuses are retained even when
the power is turned off.
4 When the display returns to the top screen of the teach mode, “To all” appears
at bottom left of f3 <Weaving ON/OFF>.
It is possible to change the weaving ON/OFF status of all mechanisms
registered in the system that can perform weaving, by pressing f3 <Weaving
ON/ OFF>.
Indicates that all mechanisms that can perform weaving are in a weaving
ON status.
Indicates that all mechanisms that can perform weaving are in a
weaving OFF status.
Indicates that all mechanisms that can perform weaving are
switched over between “Weaving ON and OFF” by the “Weaving
ON/OFF” input signal.
The ON/OFF status of each mechanism differs according to the
status of each “Weaving ON/OFF” input signal.
The ON/OFF status indicated by f3 <Weaving ON/OFF> indicates
the status of the mechanism selected by f3 <Select Robot> which
appears when [ENABLE] is pressed.

Method of easily switching between “To each” and “To all”

5 On the teach or playback mode top screen, press the [RESET/R] key.
>> The [Shortcut R code Entry] screen is displayed.

6 Press the [Up/Down] key to move the cursor to [R381: Change the weaving
mecha. selection], or enter “381” in the edit box directly below and press the
[Enter] key.
>> The display switches between “To each” and “To all” of Weav On/Off.

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Teaching of twin cooperation

Teaching of twin cooperation

The twin cooperative system consists of multiple mechanisms. Multiple welders are connected to the system.
For teaching the MOVE commands, it is necessary to set the interpolation type by manipulator. For details, see
the instruction manual “Basic Operation”.
And, it is necessary to specify the object of teaching when teaching welding commands and weaving commands.
(For example, in the case of a welding start command, specify which welder a command is intended for during
teaching.)
For details of the method of teaching welding commands, refer to the “Application Manual (Arc Welding)” in the
instruction manual.

Teaching the MOVE Command

In the twin cooperation, the interpolation action is performed by two manipulators. It is available
to set up the interpolation (Positioning, Linear interpolation, Circular interpolation) by each
manipulator. When the manipulator 1 is in the linear interpolation, the manipulator 2 could be in
the circular interpolation for example.
However a motion speed follows the standard mechanism, be sure to give attention to the
interpolation motion of the mechanism other than the standard one.

Concerning the motion speed

A motion speed of the standard mechanism is a taught speed. Meanwhile, a motion
speed of the mechanism other than the standard one is calculated on the basis of the
IMPORTANT time of motion of standard mechanism by each sequence.
If the amount of motion is extremely large comparing with one of the standard
mechanism, the manipulator may operate at unexpected high speed.

The explanation is given below with the twin cooperation unit including all the following
mechanisms.
Mechanism 1 : Manipulator
Mechanism 4 : Positioner
Mechanism 5 : Manipulator

Teaching the MOVE command (Normal)

1 Move the positioner to the teaching position.

Switch the mechanism to Mechanism4. (The interpolation type of positioner is fixed at
JOINT.)
Move the positioner by manual operation to the teaching point.

2 Move the manipulator of Mechanism1 to the teaching position.

Switch the mechanism to Mechanism1, and select a desired interpolation type.
Move the manipulator by manual operation to the teaching point.

3 Move the manipulator of Mechanism5 to the teaching position.

Switch the mechanism to Mechanism5, and select a desired interpolation type.
Move the manipulator by manual operation to the teaching point.

4 Set up the speed, accuracy, acceleration, and smoothness, and press <Record>.

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 Teaching of twin cooperation

Teaching the MOVE command (Simple teaching)

1 Press [CLAMP/ARC] key.

≫ The commands frequently used for f key are now displayed.

2 Move all the mechanisms to the teaching point, and select either [f7 Joint P], [f8
Line L], or [f9 Circle C] depending on the interpolation type.
≫ Then, the next screen appears.
or

or

Item Detail
Speed Sets up the motion speed of main mechanism.
Mechanisms other than the main mechanism operate at a
speed consistent with the time of operation of main mechanism
in each step.
The speed can be set either by the Line Speed (cm/min), Ability
(%), or Time (sec).
Main This is the mechanism to be a standard for speed.
Mechanism
Movement Simultaneous/Synchronize
Overlap Enable/Disable or Numerical input
Mechanism The interpolation type (JOINT, LINE, CIRCLE) can be set for
each mechanism.
Interp.
The auxiliary axis such as positioner and slider is fixed at
“JOINT”.
Tool The tool number can be set for each mechanism.
This is available only for manipulator.

218
Teaching of twin cooperation

3 For detailed settings such as the specified value of accuracy and the acceleration,
use the ”DETAILS” tab.
To switch the tab, press [CLOSE/Move screen].

4 On completion of setting all the conditions, press f12<Complete>.

When teaching the MOVE command in the twin cooperation, be sure to confirm the
interpolation type in all mechanisms. Even if changing the interpolation type in
IMPORTANT Mechanism1 for example, that of the other mechanisms remains the same.

ヒント
HINT
The interpolation type in each mechanism can be changed on the screen edit mode for
the teaching data already created or the wrong sequence.
However, it is necessary to set the screen edit display mode to “Form2” or “All” in
advance.
3.2.3 Setup for the screen edit display mode

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 Teaching of twin cooperation

Specifying the object welder of a welding command

This section describes the method of specifying the welder to be made the object of welding
commands during teaching of welding start and welding end commands.
The description given here is based on the welding start command as an example. It is possible to
specify a welder as the object of a welding end command, using the same method.

Specifying a welder when teaching welding commands

1 Press f7 <AS>.
Alternatively, after pressing [CLAMP/ARC], press f2 <AS>.
>> The screen for setting the arc welding start conditions is displayed.
or

2 Press [Enter] in the “Welder” box.

>> A list of welders connected to the unit currently being taught is displayed.

3 Press the [Up/Down] key to select a welder, and then press the [Enter] key.
>> The “Welder” box display switches over.

The welder that is the object of the welding start command has now been specified.
Enter the parameters of the welding start command, and press f12 <Complete> to end
teaching.

4 “W2” and the object welder are displayed alongside the welding start command
on the program monitor.

220
Teaching of twin cooperation

Specifying the mechanism that is the object of a weaving start command

This section describes the method of specifying the mechanism to be the object of weaving during
teaching of a weaving start command.
Here, the description is given based on fixed pattern weaving as an example. It is also possible to
use the same method to specify a mechanism as the object of another weaving start command.

Specifying a mechanism when teaching a weaving start command

1 Press f8 <WS>.
Alternatively, after pressing [CLAMP/ARC], press f4 <WFP>.
>> The screen for setting the fixed pattern weaving conditions is displayed.
or

2 Press [Enter] in the “Mechanism No.” box.

>> A list of mechanisms contained in the unit currently being taught that can perform
weaving is displayed.

3 Press the [Up/Down] key to select a mechanism, and then press the [Enter] key.
>> The display in the “Mechanism No.” box switches over.

The mechanism that is the object of the weaving start command has now been
specified.
Enter the parameters of the weaving start command, then press f12 <Complete> to end
teaching.

4 “5” and the object mechanism are displayed alongside the weaving start
command on the program monitor.

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 Teaching of twin cooperation

Specifying the mechanism that is the object of a weaving end command

This section describes the method of specifying the mechanism to be the object of weaving during
teaching of a weaving end command.

Specifying a mechanism when teaching a weaving end command

1 While pressing [ENABLE], press f8 <WE>.

＋ Alternatively, after pressing [CLAMP/ARC], press f5 <WE>.
>> The functions are displayed, and the mechanism ID can now be input by [FN443
or Weaving end].

2 Enter the mechanism ID and press the [Enter] key.

>> The mechanism that is the object of the weaving end command has now been
specified, thus ending teaching of the weaving end command.

3 “5” and the object mechanism are displayed alongside the weaving end command
on the program monitor.

222
Automatic operation of the twin cooperative system

Automatic operation of the twin cooperative system

The twin cooperative system permits simultaneous welding of multiple points (multi-pass welding) using multiple
welders.
Automatic operation of arc welding is programmed to stop the motion of the robot during normal welding
start/end in order to prevent an arc start failure or the formation of craters. However, during multi-pass welding,
trouble will occur if the motion of the robot stops while an arc is generated by one welder. For this reason, a
special function is provided for multi-path welding.
For a general description of automatic operation, refer to “Basic Operation” in the instruction manual.

Welding start
It is possible to select the method of welding start processing when a welding start command is
issued to multiple welders simultaneously.
・ Scratch start
Even if an arc is not generated, the system deems that the welding start command has
been executed.
If all of the welders have scratch-started, the robot will start even if an arc is not
generated. It is possible to make a setting that prevents the robot on which arcing
started normally from stopping in the event of an abnormality, such as an arc start failure,
in one welder.
・ Normal arc start
The system confirms that an arc has been generated, and deems that the welding start
command has been executed.
The system confirms that an arc has been generated, and the robot starts operating.
Used for tack welding, and similar cases.
・ Twin arc start (Arc start → Scratch start)
Initially, the system performs normal arc start processing, and then waits until an arc is
generated. It deems that a welding start command has been executed when an arc has
been generated by another welder, even if an arc has not been emitted from the
selected welder.

For a description of welding start processing when the welding section has shifted, refer to “3.5.3
Processing by the welder and robot in the welding section”.

Select the welding start method

To start welding using scratch starting, turn ON the “Scratch start signal” (page 3-4).

To start welding using a twin arc start, turn ON the “WCR input twin AS signal” (page 3-5).

To start welding using a normal arc start, turn OFF both of the above signals.

● To select the welding start method, set “Scratch start” to “OFF” according to “Setting
various constants related to arc welding” in “3.2.1 Setup relating to welder”. When
“Scratch start” is set to “ON”, welding always starts by scratch starting.
● To start welding using a twin arc start, turn ON the “WCR input twin AS signal” for
all of the welders that are to be started by twin arc start. If even one welder is OFF,
IMPORTANT the robot will not start to operate until the system has confirmed that the arc has
been generated.
● When both the “Scratch start signal” and the “WCR input twin AS signal” are
turned ON, the “Scratch start signal” has priority.

223
 Automatic operation of the twin cooperative system

Welding end
When multiple welders execute welding end commands simultaneously, the welding end
processing stops the motion of the robot in the conventional way, and processing of craters and
after-flow takes place according to the teaching conditions of the welding end command.

For a description of welding end processing when the welding section has shifted, see “3.5.3
Processing by the welder and robot in the welding section”.

Processing by the welder and robot in the welding section

For multi-path welding, it is possible to teach welding command to each welder, so it is also
possible to shift the welding section. There are several points that differ from the standard
specifications in order to ensure that welding work is not impeded when the welding section has
shifted.

100% JOINT A8 T1 Welder 1 Welder 2

1 AS [W1, OFF, 00, 150 A, 18.0 V, 60 cm/m, →] Welding start
200 cm/m LIN A8 T1 ↓
2 AS [W2, OFF, 00, 150 A, 18.0 V, 60 cm/m →] ↓ Welding start
200 cm/m LIN A8 T1 ↓ ↓
3 AE [W2, OFF, M, 150 A, 18.0 V, 0.5 s, 0.5 s, →] ↓ Welding end
200 cm/m LIN A8 T1 ↓
4 AE [W1, OFF, M, 150 A, 18.0 V, 0.5 s, 0.5 s, →] Welding end
100% JOINT A8 T1

(1) Welding start when all of the welders are in non-welding sections
AS command processing (when scratch start was enabled)
Preflow
Robot motion stop
Arc start processing
Robot motion start

(2) Welding start when another welder is in the welding section

AS command processing (when scratch start was enabled)
Preflow
Arc start processing
(The motion of the robot does not stop.)

(3) Welding end when another welder is in the welding section

AE command processing
Anti-stick processing
Welding check processing
Postflow
(The motion of the robot does not stop.)

(4) Welding end when another welder is already in a non-welding section

AE command processing
Robot motion stop
Crater processing
Anti-stick processing
Welding check processing
Postflow
Robot motion start

224
Automatic operation of the twin cooperative system

Speed of motion in the welding section

A movement command in the welding section causes the robot to move, not at the speed taught
by the movement command, but at the welding speed taught by the welding start command. The
robot moves at the welding speed determined by the welding start command that was taught
immediately prior to the movement command.

Speed of motion under the MOVE

Non-welding section
command
100% JOINT A8 T1 Moves at the taught speed
1 AS [W1, OFF, 00, 120 A, 18.0 V, 50 cm/m, →] Welder 1 Welding start
200 cm/m LIN A8 T1 Moves at the welding speed of 1.
2 AS [W1, OFF, 00, 150 A, 18.0 V, 60 cm/m, →] Welder 1 Change of condition
200 cm/m LIN A8 T1 Moves at the welding speed of 2.
3 AS [W2, OFF, 00, 140 A, 18.0 V, 70 cm/m →] Welder 2 Welding start
200 cm/m LIN A8 T1 Moves at the welding speed of 3.
4 AS [W1, OFF, 00, 150 A, 18.0 V, 70 cm/m →] Welder 1 Change of condition
5 AS [W2, OFF, 00, 150 A, 18.0 V, 60 cm/m, →] Welder 2 Change of condition
200 cm/m LIN A8 T1 Moves at the welding speed of 5.
AE [W2, OFF, M, 150 A, 18.0 V, 0.5 s, 0.5 s, →] Welder 2 Welding end
200 cm/m LIN A8 T1 Moves at the welding speed of 5.
AE [W1, OFF, M, 150 A, 18.0 V, 0.5 s, 0.5 s, →] Welder 1 Welding end
100% JOINT A8 T1 Moves at the taught speed

ポイント
POINT ● The movement command in the welding section causes the robot to move at the
welding speed determined by the welding start command taught immediately prior to
the movement command, regardless of the mechanism that is connected to the
welder.
● In the above example, welder 1 is still in the welding section when welding of the
welding section in which welder 2 is located has ended. The movement command at
this time causes the robot to move, not at the welding speed determined by the
welding start command of welder 1, but at the welding speed determined by the
welding start command of welder 2. This is because the welding start command
taught immediately prior to the movement command is the welding start command (5)
of welder 2.

225
 Automatic operation of the twin cooperative system

Multi weaving
The following precautions must be observed when weaving simultaneously using multiple
mechanisms.

When “Move at Stop Time” is set to “Not Exist” by the weaving command

To set “Move at Stop Time” to “Not Exist”, it is necessary to set the parameters so that multiple
weaving mechanisms stop simultaneously and also remain stopped for an equal length of time.
Concretely, perform teaching as indicated below.
・ Make the value of “Frequency” the same for all mechanisms.
・ Make the parts (1/4, center, 3/4) for setting “Stopping Time” the same for all mechanisms.
・ Make “Stopping Time” the same for all mechanisms.
・ Make the setting for “Keep weaving time” the same for all mechanisms.

If these conditions are mismatched, preventing weaving from being performed, an abnormality
(“E4102 It is weaving condition disagreement.”) will occur.

Pause and restart

If the restart variation is set so that “after welding is paused, the robot returns exactly a fixed
distance, and then restarts welding” (“lap start” of the conventional Daihen model), when the robot
restarts after pausing during operation, it first returns exactly the specified distance with respect to
the weld line, and then restarts welding. In this case, the distance through which the robot returns
is set by the welding constant setting for each welder. It is the longest distance among the settings
of the welders in the welding section.

ポイント
POINT The welding constant setting that “causes the welder that was paused during
welding to return exactly a fixed distance, and then resume operation” is “the
method of reversing when restarting” and also the “Reversing distance during
restarting”/“Correction time during restarting”.

226
 EXTERNAL AXIS SHIFT
1R /)(


 series

INSTRUCTION MANUAL

EXTERNAL AXIS SHIFT

‫ ع‬Read and follow these instructions and all safety blocks carefully.
‫ ع‬Have only trained and qualified persons install, operate, or service this unit.

‫ ع‬Give this manual to the operator.

‫ ع‬For help, call your distributor.

1
 What is external axis shift function

1. What is external axis shift function

In a system where a slider or positioner is connected to the manipulator, the positions of the slider, positioner
or servo gun may be shifted (moved) in the task program. This function is called "external axis shift." This
function can shift these positions either using cooperative control or simultaneous control as the control system.
This function can shift the positions in any task program which has already been prepared. (A program can be
shifted itself or stored under a different number.)
It is also possible to shift any ranges in the task programs by specifying the step numbers.

1.1 Specifying the shift amount

With external axis shift, the shift amount is determined by manually operating the external axis
as far as the position where the shift is to be made. The shift amount cannot be specified using
numerical values. (Positions can be shifted by inputting numerical values by selecting <Service
Utilities> – [9 Program Conversion] – [3 Angle].)

1.2 Example of shifting a slider

When the position of a slider is to be shifted, what has been taught can be moved as is in the
motion direction of the slider.

Fig. 1.1 Example where the taught position of a slider has been shifted

1.3 Example of shifting a positioner

When the position of a positioner is to be shifted, what has been taught can be moved as is in
the rotational direction of the positioner.

Work B Work A

Work A Work B

Fig. 1.2 Example where the taught position of a positioner has been shifted

229
External axis shift operations

2. External axis shift operations

External axis shift is implemented by selecting <Service Utilities> - [9 Program Conversion] - [11 External Axis
Shift].
The shift amount is specified by manually operating the mechanism. The simplest method is first to move to
the standard position (any step with a movement instruction) by initiating a check operation and then to move
the mechanism to the position to which the mechanism is to be shifted. The movement amount resulting from
the manual operation is set as the shift amount.

Implementing external axis shift

1 External axis shift is accompanied by manual operations so the teach mode is
selected.
(It cannot be implemented in the playback mode.)

2 Open the program in which the shifts are to be made, and advance to the shift
standard position (any step with a movement instruction) by initiating a check
operation.

3 After pressing <Service Utilities>, select [9 Program Conversion] – [11 External

Axis Shift].
>>The screen shown below appears.

4 If there is a multiple number of external axes, select the mechanism to be shifted

＋ using [ENABLE] and [UP/DOWN].

5 Input the "Source program No.," "Destination program No." and "Start/end Steps."

6 Since the shift amount is specified by performing manual operations, switch the
target of the manual operations to the mechanism to be shifted.

7 If the operator neglected to specify the shift standard position in step 2 or if the
standard position is to be changed, press f8 <Renew Std. Posi.>. The current
mechanism position is set as the standard position.
Normally, the position that applies when external axis shift is selected is automatically
set as the standard position.

8 Manually operate the mechanism as far as the position resulting from the shift.

9 Press f12 <Execute>.

>>External axis shift is executed. Open the program which reflects the shift, conduct a
check operation, and check the position and posture.

230
 1R /*(


POSITIONER ENDLESS
ROTATION FUNCTION
 series

INSTRUCTION MANUAL
POSITIONER ENDLESS
ROTATION FUNCTION

‫ ع‬Read and follow these instructions and all safety blocks carefully.
‫ ع‬Have only trained and qualified persons install, operate, or service this unit.

‫ ع‬Give this manual to the operator.

‫ ع‬For help, call your distributor.

1
 1. Endless rotation function

1. Endless rotation function

When the positioner is rotated one turn, it returns to the original position. However, because the amount of
rotation is stored, there is a difference between the positional data before and after rotation.
Therefore, during continuous Automatic operation, the positioner must be rotated one turn in the reverse
direction to return to the start position whenever the Program is started.
The Endless Rotation function lets a positioner rotate in the shortest direction. In other words, useless
rotation from the end position to the start position can be excluded. Therefore, the positioner always rotates in
the shortest direction, resulting in the improvement of cycle time.

● When the power failure detection function is invalidated, the endless rotation function
cannot be used.

● When you execute the restoration operation of the backup, or the copy operation of the
constant file, the following pop-up window opens, asking whether to maintain the
endless rotation data.

！
CAUTION

Select “No” if the system configuration before and after the restoration (copy) is
different. Then, reset the encoder of the endless axis and execute the encoder
compensation.
See page3 ”2.3 Encoder reset of endless axis”

232
2. Setup

2. Setup
The following setup work is necessary to use the endless rotation function.

2.1 Setting up the optional software

The endless rotation function is an optional software. The optional software was already set up
at the shipment from the factory or installation stage so no further steps need to be taken by the
user.

2.2 Enabling Endless Rotation function

After setting the optional software, set the control method and the reduction ratio of target
positioner for the endless control.
Note that Specialist or higher operator qualification is required for this work.

How to enable the endless rotation function

1 Press <Constant Setting> key and select [3 Machine Constants] - [23 Endless Axis
Information].
≫ The target axis information for the endless control appears. (The screen below
shows the case when the 1-axis positioner 1PB250 is in connection.)

2 Select the target axis for the endless control and move to the “Control method”.
Press [Enter] key and select “Position”.

3 Move to “Reduction ratio” and set the reduction ratio of endless axis.
Input a numerator and a denominator, respectively by an integral number, of the
total reduction ratio from the motor axis to the mechanism axis.

● Now that checking the specifications of reduction device, exactly input a

numerator and a denominator of the total reduction ratio with an integral
IMPORTANT number, respectively.
● If the setting of total reduction ratio disagrees with the specifications of
reduction device, the position deviation occurs.

4 Lastly, press f12 <Complete> key.

233
 2. Setup

2.3 Encoder reset of endless axis

After resetting the encoder of endless axis, be sure to compensate the encoder of endless axis
in the standard posture. (Perform the encoder compensation according to the position record.)

If inputting the encoder compensation at shipment by numerical values or not compensating the
encoder, positional deviation may occur in the endless axis.

With the endless axis, the motor angle in the standard posture does not always come to the
same position. therefore, positional deviation may occur if just using the encoder compensation
value at shipment.

234
3. Teaching and playback

3. Teaching and playback

3.1 Teaching
How to teach the endless axis is the same as that for the regular axis. However, the endless
axis always rotates in the direction, taking a shorter distance from the current position to the
destination. Considering this feature, it is recommended to teach the amount of rotation smaller
than ±180 [deg].
Even if teaching it larger than ±180 [deg], the endless axis rotates in the direction of shorter
distance.

3.2 Motion during check go/back or automatic operation

During Check operation or Automatic operation, any endless axis always rotates in the direction
of less than 180 [deg]. For example, if rotated 200 [deg] and taught at that position, the endless
axis or axes will rotate 160 [deg] in the reverse direction during Check operation or Automatic
operation.

0 [deg] 0 [deg]

160 [deg]

200 [deg]

Taught point During Check operation/Automatic operation

Fig. 3.1 Difference in Endless Axis Motion (1)

If rotated 400 [deg] and taught at that position, the endless axis or axes will rotate only 40 [deg].

0 [deg] 0 [deg]
400 [deg] 40 [deg]

Taught point During Check operation/Automatic operation

Fig. 3.2 Difference in Endless Axis Motion (2)

235
 3. Teaching and playback

3.3 Modification of positioner rotation angle on screen edit

Press [EDIT] key on Teach pendant to start the screen edit function and modify the task
programs currently displayed.

Also, the record position of the endless axis can be modified in the same way as the regular
axis using the screen edit function. However, note that it must be within the range of ±180 [deg],
otherwise the position cannot be recorded.

236
 MACHINE
ADJUSTMENT
PROCEDURE
 Machine Adjustment Procedure

Machine Adjustment Procedure

The machine adjustments using the AX21 control unit (ABSO settings, mastering, etc.) are performed in the
sequence below.
Before the machine adjustments can be undertaken, the settings set forth in "Chapter 1 System Installation and
Memory Formatting" must have already been performed.

Encoder reset and encoder correction Page 3-2 3.2 Performing Encoder Reset and Encoder Correction

"Encoder correction" is the same as what was previously called the "ABSO setting," and it refers to
the task that determines the home positions of the axes.
In this way, the "encoder correction values" are obtained.

Discrete mastering Page 3-6 3.3 Performing Discrete Mastering

Since an adequate interpolation accuracy is not achieved with the encoder correction alone, it is
calibrated by the "mastering."
Upon completion of the mastering, the "encoder correction values" are adjusted further. The
"post-mastering encoder correction values" may be thought of as identical to what has been called
the "main unit adjustment amounts" in the past.

Tool-related settings Page 3-9 3.4 Setting Tool Constants

The "tool length" and "tool angle" are input. These settings are the identical to what has been
conventionally referred to as the "tool parameters".
Since the tool parameters are already known for a DAIHEN standard torch, all that needs to be done
is input their values.
The tool parameters for hands or spot guns, etc. are not known. They are set using the automatic
setting function.
V series -AP type manipulators are not available for mounting the torch gauge. Fine-adjust the “tool
length” according to the actual torch tip position using the “Tool length automatic setting function”. If
changing the tool shape, retain the task program that contains the previous tool tip position before
change so that the tool length can be easily adjusted with the two-point tool length setting function.

Installation posture settings Page 3-31 3.5 Setting the Installation Posture

If a discrete manipulator is mounted on the wall or ceiling or if an external axis is provided, the
installation posture is set in order to determine in what kind of position and posture the manipulator or
external axis is installed.
In the case of a cooperative system, the values obtained as a result of the cross mastering are input
here.
Incidentally, no settings are required if a discrete manipulator is mounted on the floor.

Cross mastering Page 3-34 3.6 Performing Cross Mastering

Cross mastering is performed in order to obtain the necessary cooperative accuracy.

The values obtained as a result of the cross mastering are input as the "installation posture of the
external axis."

There are both ”former system” and ”new system” for the cross mastering. This instruction manual
describes ”former system”.
For details of “new system”, see the instruction manual ”Cross mastering (No.1L9341L-J)”.

238
Performing Encoder Reset and Encoder Correction

Performing Encoder Reset and Encoder Correction

Encoder reset and encoder correction (previously referred to as the ABSO setting) are performed in order to
adjust the home positions of the robot's axes.
These tasks must be carried out when the robot is shipped from the factory and whenever a motor is replaced
(including when a mechanism main unit is replaced).
Upon completion of the encoder correction, the basic posture check program is prepared. This program
corresponds to the conventional P999 or P9999. Prepare the program using the same number of 9999 for the
AX21 control unit as well.

In some robots and servo guns that apply the servo motors, encoder reset cannot be
executed on Teach pendant. With these models, special operation is required to
execute encoder reset.
For the details on how to execute encoder reset, refer to each instruction manual.
CAUTION

< Relevant models >

・Servo guns driven by Panasonic MS152Q2D and MS252Q2D

Moving to the basic posture and selecting the menu items

1 Select the teach mode.

2 Turn on the servo power supply.

3 Perform manual operations in such a way that all the robot's axes are aligned with
the mark-off lines on the castings.
* The encoder reset and encoder correction positions are not index mark
positions. (Index marks have been discontinued with the AX control unit.)
If an index mark is adhered at the home position of an axis, peel it off (and
adhere it elsewhere) to reveal the mark-off lines underneath, and then proceed
with the manual operations.

4 Press <Constant Setting>, and select [3 Machine Constants] and [4 Encoder

Correction].
≫ This has the effect of selecting the encoder correction & reset screen.
Now proceed with the encoder reset and encoder correction operations. (These are
described on the next and subsequent pages.)
The screen that appears when the menu is selected is the screen on which the
encoder correction is performed. The encoder correction or encoder reset operation is
selected on this screen.

239
 Performing Encoder Reset and Encoder Correction

Resetting the encoder

1 To reset the encoder, press f9 <Encoder Reset>.
≫ The encoder reset screen is selected.

2 To reset all the axes at once, press f8 <All Select>.

≫ All the axes are selected, and check marks appear for them.
The selected status can be released by pressing f8 <All Release>.

ON 3 To reset a specific axis only for replacing a motor, for instance, select the axis, and
ENABLE ＋ press [ENABLE] + [1].
1
≫ A check mark appears for the selected axis.

To release the selected axis, press [ENABLE] + [2].

4 When the axis to be reset is selected, press f12 <Execute>.

If the robot axes are not equipped with a brake, press f12 <Execute> while keeping
the servo power on. (If all the axes of the robot are equipped with a brake, this
operation may be performed with the servo power off.)

(Action to be taken 5 After resetting the encoder, move the robot so that its margin becomes 50.
soon after the motor At this time, the robot is not supposed to pass through “00”. Aligning the margin
replacement) at 50, line it up with the triangular mark.

240
Performing Encoder Reset and Encoder Correction

Correcting the encoder

1 Upon completion of the encoder resetting, proceed with the encoder correction.
Press f9 <Encoder Correct>.
≫ The screen which appeared immediately after [3 Machine Constants] and [4 Encoder
Correction] were selected is restored.
2 Either "Data Input" or "Position Record" can be used as the method for encoder
correction.
"Position Record" is normally used.

Compensation
Details
method

Position Select this method at a production process or when a motor or

Record mechanism is to be replaced.
Be absolutely sure to perform the operations with the robot placed in
a posture where the mark-off lines are aligned.
The correction value is input by pressing
[Enter] followed by [REC]. (These values
are input for each axis.)

Angle (deg.) of each axis

Encoder value (in hexadecimal

notation) after correction

Data Input Use this method when the encoder correction values are already
known.
An "encoder correction value which is already known" is a
post-mastering encoder correction value which is provided inside
the control unit when the robot is shipped from the factory. It
corresponds to what was referred to as the "manipulator adjustment
value" in the past.
Therefore, the times when the encoder correction values are input
after shipment are as follows:
• When the encoder battery has been replaced
• After the memory has been formatted
When these values are input, it is acceptable for the robot to be in
any position and any posture.
The encoder correction value is
input (in decimal notation) here.

Angle (deg.) of each axis

Encoder value (in decimal

notation) after correction

241
 Performing Encoder Reset and Encoder Correction

3 The "Position Record" method is described here.

Press f8 <Record Position>.
≫ The screen now changes.

4 Align the cursor with the axis whose encoder is to be corrected, and press [Enter]
Enter O.WRITE
followed by [REC].
REC
If the robot axes are not equipped with a brake, press [REC] while keeping the
servo power on. (If all the axes of the robot are equipped with a brake, this
operation may be performed with the servo power off.)
* Encoder correction cannot be implemented for all the axes together so repeat these
operations for each axis in turn.

5 At this stage, the encoder correction values are still not saved in the memory.
To save them, first turn the motor power OFF (by pressing emergency stop).
Then press f12 <Complete>.

242
 Axis 4 Matchmarks Axis 1 Matchmarks

Axis 3 Matchmarks Axis 6 Matchmarks

Axis 2 Matchmarks
Axis 5 Matchmarks

Fig. 4.3.5 Origin Adjusting Match-mark Positions (NV6/NV6L/NV20)

A Pose to insert the zeroing pin (J1,J2 and J3 axis of SRA166-01)

243
Performing Discrete Mastering

Performing Discrete Mastering

Mastering is performed to achieve the interpolation accuracy.
There are two kinds of mastering: discrete mastering which achieves the accuracy for the manipulator unit, and
cross mastering which achieves the accuracy when cooperative control is performed. Discrete mastering is
described here. For a description of cross mastering, refer to page 3-34 3.6 Performing Cross Mastering.

The AX21 control unit provides a choice between two ways of achieving discrete accuracy. One of these ways
must be used without fail. When the "tool length and axis constant adjustments" are performed on an already
mastered robot, the positions in the programs already prepared will be offset. The reverse is also true.

Table 3.3.1 Method used to achieve discrete accuracy

Method used to achieve
Details
discrete accuracy
Mastering This method is the same as conventional mastering. Use this method with
a DAIHEN manipulator.

Tool length and axis constant This is the adjustment method used by NACHI in the past. Use this
adjustments method with a NACHI manipulator.
It is usually helpful to use it when the tool parameters are not known
(when a hand or spot gun has been attached).
When it is used, the settings of the tool parameters and discrete
mastering can be completed altogether.
When using this method to perform the adjustments, follow the steps
outlined on page 3-16 3.4.2 Setting tool length of unkown tool. As the
setting type, select "Tool length & axis constant."

Performing discrete mastering

1 Perform the steps listed below.

■ In the case of production processes

① Attach the mastering gauge to the robot.
② Input the tool parameters (see 3.4 Setting Tool Constants in page 3-9 of the
mastering gauge in "Tool 1" by following the steps on page 3-9 3.4 Setting Tool
Constants.
③ Copy the mastering program, which was prepared in advance for production
processes, into the AX21 control unit. Use [File] - [Copy] to copy the program
from the CF card into ¥Work¥Program.
④ Open the mastering program and perform CHECK/GO.
⑤ Position the mastering stand in such a way that its tip is aligned with the torch tip
position in the first step.
⑥ Perform CHECK/GO at the next step. If the torch tip is offset from the tip of the
mastering stand, correct the teaching (position correction) so that the two tips are
aligned.
⑦ Perform step ⑥ at all the steps in which the linear interpolation instruction (LIN)
was taught.

■ When a motor or other part has been replaced after shipment

① Attach the tip gauge.
② Create a new mastering program.
Teach at least 20 or so steps for various angles for one fixed point (at any
position) inside the operating range of the robot.

Tool tip

Sharp tip
secured to
ground

244
 Performing Discrete Mastering

2 Press <Constant Setting>, and select [3 Machine Constants] and [21 Mastering].
≫ The following screen now appears.

3 Select the number of the tool to be adjusted using f10 <Next>.

This is "Tool 1" in almost all cases.

4 Align the cursor with "Correction type," and select "Interpolation."

"Absolute" is selected when the absolute accuracy is to be corrected. However, a special
jig is required for this, and it is a task which is carried out only by the Quality
Management Section at the request of the user. Normally, do not select it.
It is usually sufficient to select only "Interpolation." (Conventional mastering also involved
the correction of only the interpolation accuracy.)

5 Align the cursor with "Program Number," input the number of the mastering
Number Enter program, and press [Enter].

6 Press f12 <Execute>.

≫ An error (encoder pulse value) is displayed for each axis.

245
Performing Discrete Mastering

O.WRITE 7 Select the axis for which the calculation result is to be reflected, and press [REC].
REC ≫ The result is reflected in the encoder correction value. (The correction value obtained
after the encoder correction is further corrected.)

8 The post-mastering encoder correction values correspond to the "main unit

adjustment amounts" used in the past.
Save these values as the data for the production processes.

9 At this stage, the encoder correction values are still not saved in the memory.
To save the data, press f12 <Complete>.

246
 Setting Tool Constants

Setting Tool Constants

The “tool constants” refer to a set of parameters including the length, angle, center of gravity, weight and
moment of inertia of the installed tool. These parameters are extremely important for ensuring precise linear
operations and appropriate acceleration/deceleration control. Before moving the robot, read carefully through
the instructions in this section and take the steps described without fail. Tool constants for up to 32 tools can
be stored in the AX21 controller’s memory. If an application involves the use of a multiple number of tools,
perform the settings for all the tools concerned.

Continued use under the wrong settings for the center of gravity, weight and tool’s
moment of inertia may fatally damage the machine. Perform the settings set forth in
this section without fail.
The settings must be performed even for small and/or lightweight tools. The theory
CAUTION “The greater embraces the less” does not apply.

When using the welding torch, be sure to use the values of tool length, angle, center
of gravity, and moment of inertia described in the page 3-10 3.4.1 Tool constants of
DAIHEN arc welding torch. Use of the automatic setting function of the tool center of
CAUTION gravity and moment of inertia may occasionally bring inaccurate values depending on
the arrangement of conduit or cables. And then, this will cause improper
acceleration/deceleration control of the robot.

The new software shock sensor function requires the accurate tool setting data
(Weight, Center of gravity). Inaccurate setting of these values may cause misdetection
on the interference.
CAUTION

Table 3.4.1 Tool Constants

Tool
Explanation Usage
Constants

If tool names are provided when

A name can be set for each of the tools. A tool name a multiple number of torches are
Tool Name may consist of not more than 16 alphanumerics and selected by a tool changer, etc.
symbols.(Japanese characters cannot be used.) for use, it will be easier to
identify the tools.

 The "tool length" and "tool

This constant is the length up to the tool tip in the TCP angle" together correspond to
coordinate system (X, Y and Z components of the tool what used to be referred to as
tip). It is absolutely necessary in order to ensure the "tool parameters" with
precise linear movements. DAIHEN's conventional
When the tool length automatic setting function is models.
Length  When the DAIHEN standard
used, the tool length can be ascertained automatically
using the already created program. welding torch is to be used,
With the tool shape changed, use the two-point tool input the values which match
length setting function so that the tool length after its the torch to be used.
shape’s change can be easily calculated.  Use the "simple setting
function" to perform the

247
 settings when using a tool
This constant is for setting the inclination of the tool tip such as a hand or spot gun for
in the TCP coordinate system using the X, Y and Z axis which the parameters are not
rotation components. It proves useful since, when known.
Angle teaching, the tool can be operated manually in the  With the V series -AP type
direction in which it is pointing. manipulators, use the “Tool
When the tool angle simple setting function is used, length automatic setting
the tool angle can be set easily. function” to fine-tune the tool
length.

This constant is for setting the tool's center of gravity  These constants correspond to
position in the TCP coordinate system and its weight. It the "transfer conditions for
is required in order to ensure appropriate optimum acceleration/
C of G acceleration/deceleration control. deceleration control" with
DAIHEN's conventional
The constant is set using the tool center of gravity
models.
(COG) and weight automatic setting function. (The
weight of a tool cannot be input manually.)  When using a welding torch or
other such tool, input the
values which match the torch
to be used.
 Use the "simple setting
This constant is for setting the moment of inertia function" to adjust to the
around the center of gravity in the TCP coordinate optimum values when using a
system using the X, Y and Z components. It must be tool such as a hand or spot
set if the moment of inertia has exceeded the allowable gun for which the parameters
Inertia value. are not known.
When the tool moment of inertia simple setting
function is used, the moment of inertia can be set
easily by designating the tool shape.

This constant is the max. radius of the tool. It is used to Set this parameter when setting
Max. radius
check the territory, etc. the interference area.

Tool constants of DAIHEN arc welding torch

When an arc welding torch made by DAIHEN is used, use the following tool constant values.
The values “Moment of inertia” and ”Max. rotation diameter” are negligible for the welding torch.
They should be set to ”0.0”.

To use the welding torch, be sure to apply the values introduced below for the tool length,
angle, tool center of gravity and moment of inertia. Especially about the center of
gravity and moment of inertia, follow the table below.
CAUTION

248
 Setting Tool Constants

CO2/MAG Torch
Table 3.4.2 Daihen arc welding torch tool constant(New torch)
For N series Referential
Length Angle Center of gravity Weight Moment of inertia Radius
V type drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
RT3500S 127.0 2.1
118.0 0.050 0.030
RT5000S 128.0 2.2
140.0 0.0 385.0 180.0 0.0 0.0 0.0 0.090 Fig. 3.4.1
RTW5000S 119.0 129.0 2.3
0.060 0.040
RZ3500S 118.0 126.0 2.2
RT3500H 140.0
2.3 0.070 0.100
RT5000H 107.0
0.0 0.0 400.0 180.0 -45.0 0.0 0.0 142.0 0.030 0.0 Fig. 3.4.2
RTW5000H 2.4 0.080
0.110
RZ3500H 111.0 141.0 2.3 0.070
RT3500L 148.0
119.0 2.4 0.120 0.040
RT5000L 149.0
0.0 0.0 400.0 180.0 -45.0 0.0 0.0 0.080 Fig. 3.4.3
RTW5000L 121.0 146.0 2.6
0.130 0.050
RZ3500L 126.0 142.0 2.5
For N series Referential
Length Angle Center of gravity Weight Moment of inertia Radius
B type drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 Kgm^2 mm
RT3500H -10.0 74.0 1.9
310.0 0.030 0.030 Fig. 3.4.4
RT5000H -135.5 -11.0 76.0 2.0
0.0 180.0 -45.0 0.0 0.0 0.0 0.0
RTW5000H 320.0 85.0 2.1 0.040 Fig. 3.4.5
-12.0 0.040
RZ3500H -140.5 315.0 79.0 2.0 0.030 Fig. 3.4.6
RT3500L -5.0 69.0
310.0 1.9 0.030 0.030 Fig. 3.4.7
RT5000L -90.5 70.0
0.0 180.0 -31.0 0.0 -6.0 0.0 0.0 0.0
RTW5000L 82.0 0.040 0.040 Fig. 3.4.8
330.0 2.0
RZ3500L -95.5 -7.0 78.0 0.030 0.030 Fig. 3.4.9

Fig. 3.4.1 Fig. 3.4.2 Fig. 3.4.3 Fig. 3.4.4

Fig. 3.4.5 Fig. 3.4.6 Fig. 3.4.7 Fig. 3.4.8 Fig. 3.4.9

249
Setting Tool Constants

CO2/MIG/MAG Torch(Past Torch)

Table 3.4.3 Daihen arc welding torch tool constant (Past Torch)
Referential
For V series Length Angle Center of gravity Weight Moment of inertia Radius
drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
MTXC-3531 2.0
MTXCB-3531 2.1
MTXCB-5031 2.3
MTXC-5031 0.0 0.0 400.0 180.0 -45.0 0.0 109.0 0.0 123.0 2.1 Fig 3.4.1
MTXCW-5031 2.2
MTXCA-2531 2.1
MTXCAW-5031 2.2
MTX-3531 1.9
MTXB-3531 2.0
MTX-5031 2.0
MTXB-5031 140.0 0.0 385.0 180.0 0.0 0.0 116.0 0.0 107.0 2.2 0.0 0.0 0.0 0.0 Fig 3.4.2
MTXW-5031 2.1
MTXA-2531 2.0
MTXAW-5031 2.1
MTX-3531 1.9
MTXB-3531 2.0
MTX-5031 2.0
MTXB-5031 0.0 0.0 350.0 180.0 -45.0 0.0 143.0 0.0 195.0 2.2 Fig 3.4.3
MTXW-5031 2.2
MTXA-2531 1.9
MTXAW-5031 2.2

Fig 3.4.1 Fig 3.4.2 Fig 3.4.3

250
 Setting Tool Constants

TIG Torch
Table 3.4.4 Daihen arc welding torch tool constant (TIG Torch)
Referential
For V series Length Angle Center of gravity Weight Moment of inertia Radius
drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
MWXC-2001 90.0 0.0 151.0 2.2
0.0 0.0 360.0 180.0 -45.0 0.0 Fig 3.4.4
MWXC-3501 90.0 0.0 148.0 2.1
0.0 0.0 0.0 0.0
MWX-2001 114.0 0.0 148.0 2.2
170.0 0.0 385.0 180.0 0.0 0.0 Fig 3.4.5
MWX-3501 111.0 0.0 146.0 2.1

Fig 3.4.4 Fig 3.4.5

Pull type servo torch (4 roll specifications) CO2/MIG/MAG

Table 3.4.5 Tool constants of DAIHEN pull type servo torch (4 roll specifications)
Referentia
For V series Length Angle Center of gravity Weight Moment of inertia Radius
l drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
MTXC-3534P 5.4
MTXCB-3534P 0.0 0.0 445.0 5.5 Fig 3.4.6
MTXC-5034P 180.0 -45.0 0.0 107.0 0.0 212.0 5.4 0.0 0.0 0.0 0.0
MTXCW-5034P 5.6 Fig 3.4.7
MTXCA-2534P 0.0 0.0 465.0 5.6 Fig 3.4.8
MTXCAW-5034P 5.7 Fig 3.4.9

Fig 3.4.6 Fig 3.4.7 Fig 3.4.8 Fig 3.4.9

251
Setting Tool Constants

Pull type servo torch (2 roll specifications) Aluminum MIG

Table 3.4.6 Tool constants of DAIHEN pull type servo torch (2 roll specifications)
For N series Referentia
Length Angle Center of gravity Weight Moment of inertia Radius
V type l drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
MTXC-3541PS
0.0 0.0 375.0 3.3 Fig.3.4.10
MTXCA-3041PS
180.0 -45.0 0.0 110.0 0.0 80.0 0.0 0.0 0.0 0.0
MTXCW-5041PS 3.4
0.0 0.0 385.0 Fig.3.4.11
MTXCAW-4041PS 3.3
For N series Referentia
Length Angle Center of gravity Weight Moment of inertia Radius
B type l drawing
X Y Z Rx Ry Rz Gx Gy Gz Mass Ix Iy Iz r
[mm] [mm] [mm] [deg] [deg] [deg] [mm] [mm] [mm] [kg] kgm^2 kgm^2 kgm^2 mm
MTXC-3541PS
-137.0 0.0 440 3.2 Fig.3.4.12
MTXCA-3041PS
180.0 -45.0 0.0 -11.0 0.0 150.0 0.0 0.0 0.0 0.0
MTXCW-5041PS -127.0 0.0 460.0 3.3 Fig.3.4.13

MTXCAW-4041PS -123.0 0.0 455.0 3.2 Fig.3.4.14

Fig.3.4.10 Fig.3.4.11 Fig.3.4.12 Fig.3.4.13 Fig.3.4.14

Mastering Gauge

The mastering adapter (No.Y2861X08) is necessary to mount the mastering gauge of

V/B common type (No. Y1886W70) to the B series manipulator.
CAUTION

Table 3.4.7 Tool constants of DAIHEN's Mastering Gauge

Mastering Gauge Length Angle C of G Weight Inertia Radius
V/B common type
Y1886W70 -350.0 0.0 150.0 0.0 0.0 0.0
For V series
V/B common type
Y1886W70 -350.0 0.0 165.0 0.0 0.0 0.0
For B series
For B series
-135.0 0.0 310.0 0.0 0.0 0.0
Y3087S11A
For H03/S03 -200.0 0.0 122.0 0.0 0.0 0.0
For G series
0.0 -285.0 29.5 -90.0 0.0 0.0
(MTX-3531)

252
3. Installing and Adjusting Procedure of Welding Torch
3.1 Mounting of Welding Torch on AII-V6 Type Manipulator
3.1.1 Mounting of shock sensor and mounting bracket

Torch mounting bracket ASSY

(L10620B)

Output flange
Insulating bracket
（L10620B02）
Mount
（L6300B01）

Hexagon socket head cap screw

（4-M6X12）
L bracket
（L10620B03）

Hexagon socket head cap screw

（2-M8X25）
Shock sensor
Hexagon socket head cap screw
（SSV）
（2-M8X20）

Hexagon socket head cap screw

(4-M5X15） Tightening Torque：7.0N･m

Hexagon socket head cap screw

（M5X20） Tightening Torque：8.0N･m

Welding torch Tip gauge

(L317X)[RT3500]
(L317Z)[RT5000]
(L10319H)[RTW5000]
(L10669D)[RZ3500]
(Note: Purchase the torch mounting bracket ASSY separately.)
Fig. 3.1 Mounting of torch and shock sensor (for 45° curved / straight torch)

(1) Assemble the mount (L6300B01) onto the output flange of manipulator using 4 pieces of hexagon socket
head cap screws (M6×12).

(2) Mount the L-bracket (L10620B03) to the mount that has assembled in the procedure (1) with 2 pieces of
hexagon socket head cap screws (M8×25).

(3) Mount the insulating bracket (L10620B02) to the L-bracket that has mounted in the procedure (2) with 2
pieces of hexagon socket head cap screws (M8×20).

(4) Mount the shock sensor onto the insulating bracket with 4 pieces of hexagon socket head cap screws
(M5×15).

(5) Loosen the hexagon socket head cap screw (M5×20) of shock sensor to insert the torch. Fix it by
tightening the screw.

－8－
253
 Torch mounting bracket ASSY
(L10620C):[RT3500L/RT5000L]
(L10620D):[RTW5000L/RZ3500L]

Output flange

Insulating bracket
Mount
（L10620B02）
（L6300B01）

Hexagon socket head cap screw

（4-M6X12）

For 31° torch L bracket

（L10620C01）:[RT3500L/RT5000L]
(L10620D01):[RTW5000L/RZ3500L]

Hexagon socket head cap screw

（2-M8X25）

Hexagon socket head cap screw

（2-M8X20）

Shock sensor
（SSV） Hexagon socket head cap screw
(4-M5X15） Tightening Torque7.0N･m

Hexagon socket head cap screw

（M5X20） Tightening Torque：8.0N･m

Welding torch
Tip gauge
RT3500L (L317X)[RT3500]
RT5000L (L317Z)[RT5000]
RTW5000L (L10319H)[RTW5000]
RZ3500L (L10669D)[RZ3500]

(Note: Purchase the torch mounting bracket ASSY separately.)

Fig. 3.2 Mounting of torch and shock sensor (for 31° curved torch)

(1) Assemble the mount (L6300B01) onto the output flange of manipulator using 4 pieces of hexagon socket
head cap screws (M6×12).

(2) Mount the L-bracket (L10620B01 or L10620D01) to the mount that has assembled in the procedure (1)
with 2 pieces of hexagon socket head cap screws (M8×25).
Choose an L bracket according to the type of the welding torch. (For detail, refer to Fig. 3.2)

(3) Mount the insulating bracket (L10620B02) to the L-bracket that has mounted in the procedure (2) with 2
pieces of hexagon socket head cap screws (M8×20).

(4) Mount the shock sensor onto the insulating bracket with 4 pieces of hexagon socket head cap screws
(M5×15).

(5) Loosen the hexagon socket head cap screw (M5×20) of shock sensor to insert the torch. Fix it by
tightening the screw.

－9－
254
3.1.2 Mounting the torch gauge
L317Z L10319H
L317X L10669D
500A 500A
350A トーチ用 RZ トーチ用
空冷トーチ用 水冷トーチ用
for 350A torch for RZ torch
for 500A torch for 500A torch
エクステンション エクステンション エクステンション エクステンション
Extension Extension Extension Extension
15mm 20mm 20mm 15mm
Hexagon socket
head cap screw
（2-M5X30）
15
15

Torch gauge ASSY

Reference point （L6300E）

RT3500S RT5000S RTW5000S RZ3500S

RT3500H RT5000H RTW5000H RZ3500H
RT3500L RT5000L RTW5000L RZ3500L

Detail drawing

Fig. 3.3 Mounting the torch gauge (for straight torch)

Hexagon socket
head cap screw
（2-M5X30）
Hexagon socket
head cap screw
（2-M5X30） Torch gauge ASSY
Reference point （L10620E）
Reference point
Torch gauge ASSY
(L6300C）

Detail drawing Detail drawing

Fig. 3.4 Mounting the torch gauge (for 45° curved torch) Fig. 3.5 Mounting the torch gauge (for 31° curved torch)
(Note: Purchase the torch gauge ASSY separately.)

(1) As for the RT series dismount the nozzle and the contact tip from the torch. As for the RZ series dismount the nozzle
and the tip holder from the torch.
(2) Mount the tip gauge firmly to the torch. (The gauge is an attached component of the torch mount.)
(3) Mount the torch gauge ASSY with 2 pieces of hexagon socket head cap screws (M5x30). (The screws are
attached components of the torch gauge Assy.)
(4) Make sure that the reference point of torch gauge matches with the tip gauge end. If not, make adjustments
for the reference point to align with it.
In addition, about each part to use at the time of torch installation to the V6 type manipulator, confirm it in
Table 3.1.

－10－
255
Table 3.1 Type of Torch mounting bracket ASSY / Torch gauge ASSY / Tip gauge
Torch mounting
Torch model Torch gauge ASSY Tip gauge
bracket ASSY
RT3500S
L6300E

L10620B
RT3500H
L6300C L317X

RT3500L
L10620C L10620E

RT5000S
L6300E

L10620B
RT5000H
L6300C L317Z

RT5000L
L10620C L10620E

RTW5000S
L6300E

L10620B
RTW5000H
L6300C L10319H

RTW5000L
L10620D L10620E

RZ3500S
L6300E

L10620B
RZ3500H
L6300C L10669D

RZ3500L
L10620D L10620E

－11－
256
 3.1.3 Adjusting procedure of the torch
L-bracket
（L10620B03）

Insulating bracket
（L10620B02）

Loosen the screw that fixes the Nozzle holder ASSY,

and adjust the torch right and left so that the point of
tip gauge can align with the reference point.
Mount
（L6300B01）

Upward

Loosen the screw (2 pieces) that fixes the

Downward mount, and adjust the torch back and
Nozzle holder Assy forth so that the point of tip gauge can
（L10602C） align with the reference point.

Feeding cable
(L10601D) Loosen the screw (2 pieces) that fixes the insulating
bracket, and adjust the torch up and down so that the
point of tip gauge can align with the reference point.
Left Right

Backward Forward

Hood
(L10602B02)
Tip gauge Reference point

Fig. 3.6 Adjusting procedure of the torch

(1) If the tip gauge end slips out of the reference point of torch gauge in the upward or downward direction,
loosen the 2 pieces of hexagon socket head cap screws (M8×20) that fix the insulating bracket
(L10620B02) onto the L-bracket (L10620B03). Correct the position, moving the insulating bracket
upward or downward, and then fix it firmly by tightening the screws.
(2) If the tip gauge end slips out of the reference point of torch gauge in the frontward or rearward
direction, loosen the 2 hexagon socket head cap screws (M8×25) that fix the mount (L6300B01) onto
the L-bracket (L10620B03). Correct the position, moving the mount frontward or rearward, and then fix
it firmly by tightening the screws.

－12－
257
 (3) If the tip gauge point is out of alignment in the horizontal direction to the reference point of the touch
gauge, make alignment adjustment following the procedure shown below.
1. Dismount the hood (L10602B02).
2. Disconnect the power cable (L10601D) from the nozzle holder assembly (L10602C),
unfasten the hexagon socket head cap screws (M5×20) that fix the nozzle holder to rotate it
to the direction of misalignment (or to the left or right), and then make adjustment.
3. Securely fix the nozzle holder and power supply cable, and then mount the hood.

The bolt to fix nozzle holder

Dismount the hood (L10602B02) Dismount the bolt to fix feeding cable
comes out.

Hood

Nozzle holder ASSY

Fig. 3.7 Right and left direction adjusting procedure of the torch

(4) In case that the torch tip is not correctly positioned even after making adjustments as shown in (1) - (3),
it is possible that there is a distortion in the L-bracket or the nozzle assembly. Follow the procedures
(1) - (3) once again, and if it remains uncorrected, please contact to your nearest sales distributor of
our company.
(5) Dismount the torch gauge when the adjusting procedure of torch is finished. Note that you need to
create the origin position checking program before removing the tip gauge and mounting the nozzle
and the contact tip onto the torch.

－13－
258
 3.2 Mounting of Welding Torch on AII-B4 Type Manipulator
3.2.1 Mounting of curved torch Insulating case
（L10601B07）

No displacement or
misalignment of insulating case

Shock sensor cable

Coaxial power cable Welding torch

Insulating plate
Hole for insulating knock pin （L10601B08）
Power cable cover
Tab of Hood
Tumor of cover
Hood

Cable tie
(SKB-2MC<B>)
Insulating case
（L10601B07）

Insulating bushing
Insulating plate （L10601B09）
（L10601B08）

Power cable cover

（L10601B13）
Shock sensor unit
（L10601B）

Spacer
（L10601B11）

Nozzle holder assy

（L10601C）
Hexagon socket head cap screw
（4-M5X20）
Tightening Torque：7.0N･m

Hexagon socket head cap screw Output flange

（M5X20）
Welding torch
Tightening Torque：8.0N･m

Insulating dowel pin

Hood
（L10601B10）

Fig. 3.8 Mounting of torch and shock sensor

(1) Drive the two insulating dowel pins onto the output flange of manipulator from underneath. (The pins
are attached to the shock sensor unit (L10601B).)
(2) Make sure that the insulating case (L10601B07) and the insulating plate（L10601B08）are fixed
properly.
(3) Insert the shock sensor unit into the output flange of manipulator from underneath. Position correctly
the holes for insulating dowel pin of shock sensor to the insulating dowel pins.
(4) Mount the insulating bushing (L10601B09) and the spacer (L10601B11) onto the shock sensor unit
from underneath, using 4 pieces of hexagon socket head cap screws （M5×20）. (The screws are
attached to the shock sensor unit.)
(5) Unfasten the hexagon socket head bolt (M5×20) that fixes the shock sensor, and then insert and fix
the welding torch.
(6) Attach the power cable cover (L10601B13) from above, and the hood (L10601B10) from underneath.
(Refer to the top view in fig.3.8 for the installation direction.)
To fix the power cable cover, use the cable ties that come with the shock sensor. (Fix the cover at the
top and bottom.)
－14－
259
3.2.2 Reference point teaching procedure (Creation of home position confirmation program)
(1) On the RT series, dismount the nozzle and the contact tip from the torch. On the RZ series,
dismount the nozzle and the tip holder from the torch.
(2) Secure the tip gauge to the torch.
(3) To set a reference point, prepare a sharp-pointed object fixed to the ground (e.g. tip gauge)
(hereinafter referred to as the “reference gauge”).
(4) Align the point of the tip gauge on tip of the reference gauge, and then teach such point as the
reference point 2 (point teaching). Use this reference point 2 to confirm the mechanical deviation of
the torch.

L317X L317Z L10319H L10669D

for 350A torch for 500A torch for 500A torch for RZ torch

Extension Extension Extension Extension

15mm 20mm 20mm 15mm
15
15

RT3500S RT5000S RTW5000S RZ3500S

RT3500H RT5000H RTW5000H RZ3500H
RT3500L RT5000L RTW5000L RZ3500L

Fig.3.9 Tip gauge

Tip Gauge

Fig.3.10 Teaching of reference point

－15－
260
3.2.3 Mounting of gauge ASSY (option)

(1) Dismount the nozzle and the contact tip from the torch to the RT series. Dismount the nozzle
and the tip holder from the torch to the RZ series.
(2) Secure the tip gauge (L317X, L317Z, L10319H or L10669D01) to the torch.
(3) Dismount the hood from the shock sensor. Mount the gauge ASSY (L10618B) with the two
hexagon socket head cap bolts (M5×16) that comes with the gauge ASSY.
(4) To set a reference point, prepare a sharp-pointed object fixed to the ground (e.g. tip gauge
(L317X)) (hereinafter referred to as the “reference gauge”).

Note) This gauge is designed to confirm the current position of the robot. (Unlike the conventional torch gauges, it is
not designed to make measurement of positional accuracy of the torch.) For the adjustment procedure, refer
to information in Section 3.2.4.

Hexagon socket head cap screw

（2-M5×16）

Gauge ASSY(Option)
（L10618B）

Tip gauge
(L317X)[RT3500]
(L317Z)[RT5000]
(L10319H)[RTW5000]
(L10669D)［RZ3500］

Fig.3.11 Mounting of gauge ASSY

－16－
261
 Setting Tool Constants

Setting Tool Constants

1 Select the teach mode.

2 Select <Constants>, and select [3 Machine constants] -> [1 Tool constants].

>>The tool constant input screen resembling the one shown below now appears.

3 To change the tool number, press the page up or down key.

4 Following the common operating procedure outlined above: Align the cursor
ENABLE ＋
EDIT with the tool name field, and press [ENABLE] + [EDIT].
>>The character input screen (Soft Keyboard) shown below now appears. Input a tool
name consisting of up to 16 characters using alphanumerics and symbols.

With an application which involves the use of a multiple number of tools, the
parameters become more comprehensible if the welding gun or torch name and
model, for instance, are registered here first.
It is not required to set the tool name. The initial setting may be used as is. (Initial
setting: TOOL where “” is the tool number)
The tool name does not appear on the programs display screen.

5 Upon completion of the character input, press f12 <Complete>.

>>Operation returns to the above tool constant setting screen.

6 Enter the tool constants of a welding torch or a mastering gauge.

7 Upon completion of the settings, press f12 <Complete>. The settings are now
saved in the constant file.
>>Operation returns to the machine constant menu screen.

262
Tool constant settings

Setting the tool length automatically

Although one program for calculating the tool length must be taught, the tool length can then be set
automatically simply by taking this preparatory step.
It does not matter whether the tool angle has already been set or not.

1 First, the programs for setting the tool length automatically must be taught.
Teach the kind of programs where the tip of the installed tool (install a tool with
a sharp tip here as well) is aimed in a number of different postures at a sharp
tip which has been secured to the ground. The required number of steps is at
least 10.

Tool tip

Sharp tip fixed on

the ground

Ensure that the posture of the robot varies significantly with each of the steps, and
that its aim is as accurate as possible. This holds the key for ensuring a high
accuracy.
Record all the steps with linear interpolation ON. (Although it has nothing to do with
calculating the tool length, this comes in handy in when checking the results in 7.)

2 On the tool constant setting screen for the desired tool number, press the
<Easy Setting> key.
>>The tool length automatic setting screen such as the one shown below now
appears.

3 If any other screen has appeared, press the <Length Set> key.

4 Select the setting type. Select "Axis Constants & Length" or "Length only"
＋ using the [ENABLE] and [Left/right cursor] keys.
Normally, "Length only" is selected.
Select "Axis Constants & Length" only when more accurate length setting is required.
In this case, the axis constants of J2, J3, J4 and J5 axes are corrected automatically.
(The axis constants of all the other axes remain unaffected.)
(The axis to be compensated differs depending on the mechanism type.)

5 Align the cursor with the program No., input the program No. (such as 1) that
was created previously in 1, and press the [Enter] key.

6 Press the <Execute> key.

263
 Tool constant settings

7 The tool length is calculated, and the results appear as follows a few moments
later.
>>The maximum error expresses the accuracy of the tool length which has been
calculated. The lower the value here, the higher the resulting accuracy of the tool
length which has been calculated.
The errors at each step up to a maximum of 10 steps are displayed simultaneously.
If the results in 9 below are not satisfactory, simply proceed to modify the position in
sequence starting with the step with the highest value.

If satisfactory results have been obtained, select [Yes] on the pop-up window,
and press [Enter] key.
>>At this stage, only the display is updated, and the data is not yet stored in the
constant file.

8 Upon completion of the settings, press the <Complete> key. The settings are
now saved in the constant file.
>>Operation returns to the machine constant menu screen.

9 Upon completion of the settings, check them.

Exit the constant menu and try check go/back of program taught in 1.

＋
Tool tip

Sharp tip fixed on

the ground

If, unlike the movements which resulted when the program was first taught, the tool
tip hardly moves at all from the sharp tip secured to the ground even during
operations between the steps, then the tool length has been set successfully.

When pressing <Complete> key, following message will appear. If programs are already
taught and these are not to be modified, please select [NO].

CAUTION

264
 Service Utilities menu
■Transform existing program/Tool transform

This function enables already prepared task programs to be easily converted so that, even when a tool (such as a gun, hand
or torch) has been deformed, the tool center point position and target angle will remain unchanged from their statuses prior to
the deformation.A multiple number of programs can be converted at one time (the steps to be converted cannot be specified).
Steps with function commands are not changed by this conversion.

However, the reference point program taught by the tool prior to its deformation is required in order to use this function.
Immediately after the robot is delivered, create the reference point program in which are recorded the steps where the tool
center point position and target angle are clearly defined.
The program specified for a reference point before and after conversion is not converted.

●Display and setting items

Item name Initial value Setting range
Mechanism The manipulator that becomes an object
from all manipulators registered to the
system is selected.
Tool The tool number to be converted is 1 to 32
specified.
Reference for This is for specifying the number of the 0 to 9999
original tool program in which the pre-conversion
position / reference points have been taught.
orientation
Program No.
Reference for This is for specifying the number of the 1 to 9999
original tool step in which are stored the reference
position / points of the program in which the pre-
orientation conversion reference points have been
Step No. taught.
Reference for This is for specifying the number of the 0 to 9999
new tool program in which the destination reference
position / points have been taught.
orientation
Program No.
Reference for This is for specifying the number of the 1 to 9999
new tool step in which are stored the reference
position / points of the program in which the post-
orientation conversion reference points have been
Step No. taught.
Transform Specify the program number to be shifted. 0 to 9999
existing programs
Limit of revise This is for setting a value close to the 1 to 999 mm

265
 deformation amount of the tool as the 1 to 180 deg.
compensation amount limit width.It
prevents errors from being made in
conversion by extremely large amounts
due to an erroneous wrong program
number, etc.

After changes have been made to a program,

the operation check must be performed at the
CAUTION low speed without fail.Changes in operation
may cause the robot to interfere with the
peripheral devices.

266
 No. 1L22151L-E-1

series

INSTRUCTION MANUAL

CROSS MASTERING

CROSS MASTERING
■ Read and follow these instructions and all safety blocks carefully.
■ Have only trained and qualified persons install, operate, or service this unit.

■ Give this manual to the operator.

■ For help, call your distributor.

1
 1．What the mastering among mechanisms is

1. What the mastering among mechanisms is

In order to execute cooperative motions at a high level of accuracy in a synchromotion system, there must be a
precise match between the correlation of the actual positions of the mechanisms that configure the system and
the settings which are contained inside the controller. However, the installation of the mechanisms is a job which
is done on-site, and it is extremely difficult to install the mechanisms very precisely.
As a result, it is necessary to match the parameters inside the controller with the actually installed mechanisms.
This job is referred to as "mastering among mechanisms".
Using the task program, this function compensates the parameters by calculating the positions between the
mechanisms and the torsion information.

In order to use this function, the operator must have the qualifications level of EXPERT or above.

269
Prior to starting the mastering among mechanisms

2. Prior to starting the mastering among mechanisms

2.1 The accuracy of a single robot

The TCP calibration must be conducted in advance for each single robot in order to use the function of the
mastering among mechanisms, because the installation information among the mechanisms is to be calculated
automatically, based on the position information given in the task program for mastering.

*1 Confirm that the accuracy of each robot is within a 3mm diameter sphere in terms of
POINT TCP before teaching the task program for the mastering among mechanisms.
→Make the “Tool length auto setting” as necessary.
*2 Be sure to record, in the task program for mastering among mechanisms, the number
of the tool with which the accuracy of a single robot has been adjusted to be within
3mm in diameter.

2.2 Mechanism configuration

The function of the mastering among mechanisms can be utilized in the certain mechanism configurations
described in Table 2.1. As for other mechanism configurations, the mechanism installation posture must be
calculated manually and then entered from Teach Pendant.

Regarding the case of a mechanism installation upon other mechanism, the function of the
POINT mastering among mechanisms can be used only for the installation relation of “the ground
→one-axis slider→robot”. For other installation relations, the installation posture must be
calculated manually.

Table 2.1 Mechanism configurations that enable the function of the mastering among mechanisms
Mechanism configuration Image of installation relation among mechanisms
Robot＋One axis slider
Robot
Robot 1-axis slider
1-axis slider
Ground
Ground
Robot＋Positioner (*1)
Robot 1-axis positioner Robot 2-axis positioner

Ground Ground
Robot＋Robot
Robot Robot

Ground
Robot ＋ One axis slider ＋
Positioner (*1) Robot Robot

1-axis slider 1-axis positioner 1-axis slider 2-axis positioner

Ground Ground
Robot＋Robot＋Positioner (*1)
Robot positioner Robot

Ground
(*1) The function of the mastering among mechanisms is available for 1-axis positioner (Table type or Tilted
type) and 2-axis positioner (Tilted axis＋Table axis).

270
 2. Prior to starting the mastering among mechanisms

2.3 Installation relation among mechanisms

When conducting the mastering, the current installation place of each mechanism must be set up in advance.
Confirm the setting details of <Constant > - [12 Format and configuration] - [9 Mechanism relation].

The following Fig. 2.1 shows the settings of the installation relation in a system composed of three mechanisms: a
robot (installed on a one-axis slider), a 1-axis slider (installed on the ground) and a 2-axis positioner (installed on
the ground).

Composition of mechanism
Settings of installation relation among mechanisms
installations

NV6

1SR29 2PF300

Ground

Fig. 2.1 Installation relation among mechanisms

2.4 Notes for a system composed of three or more mechanisms

In the function of the mastering among mechanisms, the installation posture of one mechanism is set up through
one operation. Therefore, a system composed of three or more mechanisms requires multiple operations of the
mastering among mechanisms, according to each type of combination of mechanisms that are under
synchronous control.

Be sure to teach the task program for the mastering among mechanisms for a unit that
POINT includes a robot whose mechanism number is the smallest and a mechanism on which the
installation posture needs to be set up.

To conduct the mastering among mechanisms for a system with two positioners
For a system that has two positioners, conduct twice the operation of the mastering between mechanisms in
order to set up the installation posture of each positioner. When two sliders are installed instead of two
positioners, conduct twice the mastering between mechanisms as well in order to set up the installation postures
of both the sliders.

1 Mastering between M1 Robot and M2 Positioner

Create the task program for the mastering among mechanisms for the unit including
M1 and M2. Conduct the mastering between the two mechanisms, using the created
task program, and the installation posture of M2 will be set up.

M2 M1 M4
Positioner Robot Positioner

Ground

2 Mastering between M1 Robot and M4 Positioner

Create the task program for the mastering among mechanisms for the unit including
M1 and M4. Conduct the mastering between the two mechanisms, using the created
task program, and the installation posture of M4 will be set up.

M2 M1 M4
Positioner Robot Positioner

Ground

271
2．Prior to using the mastering among mechanisms

To conduct the mastering among mechanisms for a system with a robot installed
upon a slider.
First, conduct the mastering between a robot and a 1-axis slider in order to set up the installation posture of the
robot. Then, conduct the mastering between the robot and the positioner in order to set up the installation posture
of the positioner.

POINT Be sure to firstly conduct the mastering among for the robot and the slider for a system
where a robot has been installed upon a slider.

1 Mastering between M1 Robot and M3 1-axis slider

Create the task program for the mastering among mechanisms for the unit including
M1 and M3. Conduct the mastering between the two mechanisms, using the created
task program, and the installation posture of M3 will be set up.

M1
Robot

M3 M4
1-axis slider Positioner

Ground
2 Mastering between M1 Robot and M4 Positioner

Create the task program for the mastering among mechanisms for the unit including
M1, M3 and M4. Conduct the mastering among the three mechanisms, using the
created task program, and the installation posture of M4 will be set up.

M1
Robot

M3 M4
1-axis slider Positioner

Ground

272
 2. Prior to starting the mastering among mechanisms

To conduct the mastering among mechanisms for a twin synchronization system

First, conduct the mastering between the robot and the positioner in order to set up the installation posture of the
positioner. Then, conduct the mastering between the two robots in order to set up the installation posture of M2
Robot.

1 Mastering between M1 Robot and M4 Positioner

Create the task program for the mastering among mechanisms for the unit including
M1 and M4. Conduct the mastering between the two mechanisms, using the created
task program, and the installation posture of M4 will be set up.

M1 M4 M2
Robot Positioner Robot

Ground
2 Mastering between M1 Robot and M2 Robot

Create the task program for the mastering among mechanisms for the unit including
M1 and M2. Conduct the mastering between the two mechanisms, using the created
task program, and the installation posture of M2 will be set up.

M1 M4 M2
Robot Positioner Robot

Ground

273
3．Preparing the task program

3. Preparing the task program

The mastering among mechanisms first prepares the task program used for the mastering among mechanisms, and it
calculates the mechanism installation information using this task program.

In the case of a robot with the multi unit specifications, the task program for the mastering
POINT among mechanisms is prepared by the units that exercise cooperative motion control.
(Teaching is not required with units which do not exercise cooperative motion control or
units of discrete mechanisms.)

3.1 Preparing the task program for a table-type 1-axis positioner

1 Provide a point serving as a reference on the surface of the positioner's face

plate.(This point will henceforth be referred to as the "fixed point".)
Ensure that the fixed point remains fixed and motionless on the face plate of the
positioner even when the positioner is moved.

2 Select an appropriate task program number, and display the screen on which
the task programs are prepared.

3 Align the robot TCP with the fixed point, and store the position in the memory.
(Point A) *
It does not matter whether the format is joint, linear or circular for the teach points
which are recorded from this time on. Neither do the speed and accuracy level matter.

4 Move the positioner so that its angle differs from the angle obtained in step 3,
align the robot TCP with the fixed point, and store the position in the memory.
(Point B) *
Move the positioner counterclockwise as seen facing the face plate through at least
90 degrees.

5 Move the positioner so that its angle differs from the angles obtained in step 3
and 4, align the robot TCP with the fixed point, and store the position in the
memory. (Point C) *
Move the positioner counterclockwise as seen facing the face plate through at least 90
degrees.

This now completes the preparation of the task program.

* Concerning the sequence for preparing the teach points

・ When the teach points are to be prepared, proceed in the
counterclockwise direction as seen facing the face plate of the positioner.
(Sequence as shown in figure below: [1st point: A] → [2nd point: B] →
[3rd point: C])
・ Three teach points must be provided without fail. An error results if not
enough teach points are provided. If there are too many teach points, an
error does not result, and the three teach points starting with the step
having the lowest number are used for the calculation.

274
 3．Preparing the task program

Ｂ Ａ

Fig 3.1 Position (table-type 1-axis positioner) recorded in task program for mastering among mechanisms

3.2 Preparing the task program for a tilted 1-axis positioner

1 Provide a point serving as a reference on the surface of the positioner's face

plate. (This point will henceforth be referred to as the "fixed point".)
Ensure that this point remains fixed and motionless on the face plate of the positioner
even when the positioner is moved.

2 Select an appropriate task program number, and display the screen on which
the task programs are prepared.

3 Align the robot TCP with the fixed point, and store the position in the memory.
(Point A) *
It does not matter whether the format is joint, linear or circular for the teach points
which are recorded from this time on. Neither do the speed and accuracy level matter.

4 Move the positioner so that its angle differs from the angle obtained in step 3,
align the robot TCP with the fixed point, and store the position in the memory.
(Point B) *
Move the positioner counterclockwise as seen facing the face plate through at least 90
degrees.

5 Move the positioner so that its angle differs from the angles obtained in steps 3
and 4, align the robot TCP with the fixed point, and store the position in the
memory.(Point C) *
Move the positioner counterclockwise as seen facing the face plate through at least
90 degrees.

This now completes the preparation of the task program.

* Concerning the sequence for preparing the teach points

・ Prepare the teach points by proceeding in the counterclockwise direction
as seen facing the face plate of the positioner.
(Sequence as shown in figure below: [1st point: A] → [2nd point: B] →
[3rd point: C])
・ Three teach points must be provided without fail. An error results if not
enough teach points are provided. If there are too many teach points, an
error does not result, and the three teach points starting with the step
having the lowest number are used for the calculation.

275
3．Preparing the task program

Fig 3.2 Position (tilted 1-axis positioner) recorded in task program for mastering among mechanisms

3.3 Preparing the task program for a 2-axis positioner

1 Provide a point serving as a reference on the surface of the positioner's face

plate. (This point will henceforth be referred to as the "fixed point".)
Ensure that this point remains fixed and motionless on the face plate of the positioner
even when the positioner is moved.

2 Select an appropriate task program number, and display the screen on which
the task programs are prepared.

3 Set J2 (table axis) to 0.0 deg. *3

4 Align the robot TCP with the fixed point, and store the position in the memory.
(Point A) *1
It does not matter whether the format is joint, linear or circular for the teach points
which are recorded from this time on. Neither do the speed and accuracy level matter.

5 Move positioner J1 (tilted axis) so that its angle differs from the angle obtained
in step 4, align the robot TCP with the fixed point, and store the position in the
memory. (Point B) *1
Move the positioner away from the robot by at least 30 degrees.

6 Move positioner J1 (tilted axis) so that its angle differs from the angles obtained
in steps 4 and 5, align the robot TCP with the fixed point, and store the position
in the memory. (Point C) *1
Move the positioner away from the robot by at least 30 degrees.

7 Set J1 (tilted axis) to 0.0 deg. *3

8 Align the robot TCP with the fixed point, and store the position in the memory.
(Point D) *2

9 Move the positioner so that its angle differs from the angle obtained in step 8,
align the robot TCP with the fixed point, and store the position in the memory.
(Point E) *2
Move the positioner counterclockwise as seen facing the face plate through at least 90
degrees.

10 Move the positioner so that its angle differs from the angles obtained in steps 8
and 9, align the robot TCP with the fixed point, and store the position
in the memory. (Point F) *2
Move the positioner counterclockwise as seen facing the face plate through at least 90
degrees.

276
 3．Preparing the task program

This now completes the preparation of the task program.

*1 Concerning the sequence for preparing the teach points for J1 (tilted axis)
・ Prepare the teach points in sequence in the direction away from the robot.
(Sequence as shown in figure below: [1st point: A] → [2nd point: B] →
[3rd point: C])
*2 Concerning the sequence for preparing the teach points for J2 (table axis)
・ Prepare the teach points in sequence in the counterclockwise direction as
seen facing the face plate of the positioner. (Sequence as shown in figure
below: [1st point: D] → [2nd point: E] → [3rd point: F])
*3 When the joint angle is to be set to 0.0, use the home stop function. In the case of a
2-axis positioner, teach a total of six points.
・ If points A to F have not been recorded in the sequence described above,
the calculation will not be performed properly.

Ｄ
Ｂ Ｆ

Ａ Ｃ

Fig 3.3 Position (2-axis positioner) recorded in task program for mastering among mechanisms

277
3．Preparing the task program

3.4 Preparing the task program for a slider

1 Provide a fixed point which will serve as the reference on the ground.
(Select a fixed point which will remain motionless even when the slider moves.)

2 Select an appropriate task program number, and display the screen on which
the task programs are prepared.

3 Align the robot TCP with the fixed point, and store the position in the memory.
(Point A) *

4 Move the slider, set it to a position (angle) which differs from the position
obtained in step 3, align the robot TCP with the fixed point, and store the
position in the memory. (Point B) *
Now move the slider in the "+" direction, and teach.

This now completes the preparation of the task program.

* Concerning the sequence for preparing the teach points

・ Move the slider in the "+" direction, and teach the teach points.
・ Two teach points must be provided without fail.
An error results if not enough teach points are provided.
If there are too many teach points, an error does not result, and the two
teach points starting with the step having the lowest number are used for
the calculation.

Ａ Ｂ
＋
Fig 3.4 Position (slider) recorded in task program for mastering among mechanisms

278
 3．Preparing the task program

3.5 Preparing the task program for two robots

1 Provide a point that will serve as the reference (hereafter referred to as the
"reference point") for the tool TCP of each of the two robots.
Adjust the discrete accuracy of the robots to less than 3 mm diameter sphere at each
reference point.
(Use the numbers of the tools at the teaching stage for which the above accuracy has
been confirmed.)

2 Select an appropriate task program number, and display the screen on which
the task programs are prepared.

3 At the appropriate position, align the reference points of the two robots, and
record the positions. (Point A) *

4 Move the robots to positions which differ from the ones in step 3, align the
reference points of the two robots, and record the positions. (Point B) *
Now increase the movement amount as much as possible.

5 Move the robots to positions which differ from the ones in steps 3 and 4, align
the reference points of the two robots, and record the positions. (Point C) *
Now increase the movement amount as much as possible.

This now completes the preparation of the task program.

* Precautions when preparing the teach points

・ Ensure that points A, B and C do not form a straight line.
・ Prepare points A, B and C in such a way that they will be on a surface
which is horizontal to the ground. (This may be done by sight.)
・ Prepare the teach points in such a way that the area of the triangle formed
with points A, B and C is as great as possible. The greater the area of the
triangle formed with the three points, the better the accuracy between the
mechanisms.

Fig 3.5 Positions (of the 2 robots) recorded in task program for mastering among mechanisms

279
4．Performing mastering among mechanism

4. Performing mastering among mechanism

Using the task programs created by following the procedure in "3. Preparing the task program," the information on the
installation between the mechanisms is calculated.
Before proceeding with mastering among mechanisms, check whether the discrete accuracy of each of the
mechanisms has been obtained.

Performing mastering among mechanism

1 Select <Constant Setting> – [3 Machine Constants] – [25 Cross Mastering].

>>The following screen now appears.

2 Input the program number.

If the program number is already known, input it using the number keys.

If the program number is not known, press f8 <Program List> to display a list of the
programs, and then select the desired program.

When the program is selected, the program comment, unit number, unit name and list
of mechanisms are displayed.

If there is a multiple number of mechanisms such as a robot, positioner and slider

units, select the mechanisms targeted for mastering among mechanisms. The robot
and only one mechanism can be selected as the mechanisms.

280
 4. Performing mastering among mechanism

3 Press f11 <Execute>.

>>Based on the teach points recorded in the designated program, the mastering
among mechanisms is automatically executed, and the pre-calculation settings and
post-calculation settings are displayed.

The values thus obtained are the positions and poses of the mechanisms as
expressed in terms of the worked coordinates.

4 To save the post-calculation settings, press f12 <Complete>.

>>The settings are now saved in the constant file.

5 The values obtained by the mastering among mechanisms are stored in the
robot as the data which is set in "Installation Angle".

To check the installation poses, select <Constant Setting> – [12 Format and
Configuration] – [5 Installation Angle]. In order to do this, the operator must have the
qualifications level of EXPERT or above.

Adjustment between mechanism Installation angle

Ｘ X coordinates of the installation position
Ｙ Y coordinates of the installation position
Ｚ Z coordinates of the installation position
Ａ X axis rotation
Ｂ Y axis rotation
Ｃ Z axis rotation

Settings regarding “The present direction is hold.”

POINT
Normally, select “Disabled”.
However, under all of the following conditions, select “Enabled”.
・The mastering object, between machines, is robot + positioner.
・It is a re-adjusting operation for the mastering between machines which
improves the synchro motion’s accuracy of robot + positioner.
・The interchangeability of the task program’s position data is necessary
after the re-adjustment operation of the mastering, and when the task
program, taught before re-adjustment, exists.

281
USER COORDINATE
 Service Menu
■ User coordinate

Teaching is facilitated by setting the original coordinate system for the jigs, the work pieces, etc. installed
around the robot.
Up to a hundred coordinates can be registered.

User coordinates can be specified in a program in which 3-point positions have been recorded. The program is created ahead
of time, and its number is specified on the following setting screen.

Menu Explanation

User coordinates are specified in a program in

Program
which 3-point positions have been recorded.
The number of the already taught program is input

284
 here.
Order of Step The method used to specify the above 3 points
may differ depending on the shape of the
peripheral device. One of the following three
variations is specified.
OXY: S1＝starting point, S2＝X direction, S3＝Y
direction
OZX: S1＝starting point, S2＝Z direction, S3＝X
direction
OYX: S1＝starting point, S2＝Y direction, S3＝X
direction

Furthermore, using the operation method shown below, a special user coordinate system can be defined.

The user coordinates are also used to register the settled installation tool tip location for stationary tool interpolation as well. In
this case, only the home point of the user coordinates is referenced.

285
HOME POSITION
REGISTRATION
Home position registration

Home position registration

When a multiple number of robots are to be started up together from the host controller unless start is instructed
after it has been verified that the robots are at their prescribed positions (home positions), they may, in a worst
case scenario, interfere with one another.
To solve this problem, whether the robots are at their prescribed positions can be verified by means of an output
signal by registering the home positions of the robots.
In checking the home positions, the positions of each robot axis are directly monitored so that the operator can
know for sure that a robot is at its home position by the output signal.

Range in which work home

position is registered

While the robot is in this range, the

home position output signal is set to
ON; when it is outside this range, it
is automatically set to OFF.

Fig. 7.3.1 Home position

Up to 32 home positions can be registered per unit (the unit in which the task program is configured).
Some methods are provided for registering. First, the usual registration method is described.

Home position registration by referencing the program

1 First, teach the position that is to serve as the home position using the robot.
Select any program, and record the actual position as a step.
Any interpolation type, speed or tool number is acceptable.
>>Normally, this step should be the first step (move command) in the program which
is to be started from the work home position. Any program and any step with any
number will do. Make a note of them.

2 Select the teach mode.

3 Select <Constant Setting> - [9 Territory Definition] - [1 Home Position].

>>A screen such as the one shown below now appears.

288
 Home position registration

4 Align the cursor with "Area Definition," and press[ENABLE] and left or right
＋ cursor keys together to set the radio button to "Defined."
>>The home position setting screen such as the one shown below now appears.

5 Leave the "Position" setting as "Program" and the "Range" setting as "TCP."

6 Align the cursor with "Program No.," input the number of the program
prepared in 1, and press [Enter] key.
In the same way, align the cursor with "Step No.," input the step number, and
press [Enter] key. A step No. indicating a move command—not a comment or
other function command—must be input without fail.
>>The data recorded in the program and step which were input is now called, and the
positions recorded for the axes are displayed in the center.

7 Align the cursor with "TCP," input the home position range here, and press
[Enter] key. The diameter of a spherical shape that can be visualized is input
here. The home position signal is output when the tool tip is inside this
spherical shape.
Normally, about 20 mm is recommended.
>>The size of the spherical shape is broken down into the angles of the axes, and a
range is now displayed at the positions recorded for the axes in the center.

8 Press the <Complete> f key.

This now completes the settings.

If the position of the program and step which were input in 6 has been modified or if
interim steps have been deleted or inserted at any point after this, the setting for the
step number of the home position will be automatically updated in tandem with this
change.
By having the step in the registered program serve as the first step in the program
which is started, no further attention need be paid to the home position registration
even when the position in that step has been modified by teaching after home
position registration.
(However, in the event that the registered step itself has been deleted, the home
position registration will be deleted in tandem with this deletion.)

289
Home position registration

Registering a multiple number of work home positions

9 A multiple number of home positions can be recorded. (Up to 32 positions per

unit) To switch the screen, press [Prev No] or [Next No] key.
Alternatively, align the cursor with the "Territory No." in the edit box, input the
home position number directly, and press [Enter] key.

Basic output signal is allocated to only “Territory No.1” when shipped. To use No.2 and
up, basic output signals must be allocated for each of it.
Output signal number currently assigned is displayed at the bottom of the screen.

Specifying the range on an axis by axis basis

10 The range of the home position can be specified directly for each of the axes.
Set "Range" to "Angle" rather than to "TCP."
>>The range input field changes as shown below. Input the range directly in degrees
into the range field of each axis (the edit box on the right of + –).

When auxiliary mechanisms are present

11 If an auxiliary mechanism such as servo gun or travel unit is being used, "Aux.
mechanisms," which is a new item, is displayed. Depending on the
characteristics of the mechanism concerned, the home position may or may not
be monitored.
Select one or the other. In the case of a servo gun, select "Ignored."

When “Ignored” is selected,

setting item for auxiliary
axis disappears.

290
 Home position registration

Home position registration by manual recording

This method is used to record the home position directly without referencing the program. Operate the robot
to set it.
The home position registration is not changed in tandem with any modifications made by teaching, and the
absolute position is now registered. Unlike the program reference system, a programs need not be provided
ahead of time.

Only the differences from the program reference system will be described below.

1 Set "Position" to "Manual."

>>The setting screen changes as shown below.

2 Turn on the motor power (servo power), and move the robot by manual
operations to the position which is to serve as the home position.
Once the position has been determined, release the enable switch.
(Alternatively, turn off the motor power.)

3 Press the <Current Record Posi.> f key.

>>The current position is read from the robot encoder, and the position data of each
axis is displayed in the center.

4 Set the "TCP" in the same way as with referencing the program. (The next steps
are the same.)

291
Home position registration

Home position registration by numeric input

This method is used to record the home position directly without referencing the program. Key in the position
data directly from the teach pendant.
The home position registration is not changed in tandem with any modifications made by teaching, and the
absolute position is now registered. Unlike the program reference system, a programs need not be provided
ahead of time.

Only the differences from the program reference system will be described below.

1 Set "Position" to "Numerical."

>>The setting screen changes as shown below.

2 Move the cursor to the "Territory" field, input the position of each of the axes
directly in degrees, and press the [Enter] key.
>>It is possible to input positions that significantly exceed the software limits
(operating ranges) of the axes. Some axes which have been excluded from being
the target of inspection for their home positions can be supported by setting a high
value.

The same result can be achieved by proceeding as follows: after "Position" has been
set to "Program," the program and step have been specified and the position data has
been read, switch the "Position" setting to "Numerical," and modify the position of each
axis.

3 Set the "TCP" in the same way as with referencing the program. (The next steps
are the same.)

292
  series

SOFTWARE PLC,I/O
INSTRUCTION MANUAL

Software PLC,I/O

‫ ع‬Read and follow these instructions and all safety blocks carefully.
‫ ع‬Have only trained and qualified persons install, operate, or service this unit.

‫ ع‬Give this manual to the operator.

‫ ع‬For help, call your distributor.

1
 General description of the software PLC

General description of the software PLC

General description of the software PLC

The PLC (Programmable Logic Controller) is a device that controls various devices by incorporating input
signals and previously created programs to switch contacts within output circuits ON/OFF.
The software PLC is software incorporated into the robot controller that has all of the functions of the PLC, and
can be programmed using the teach pendant. In this way, the need to provide a special external PLC is obviated,
thereby helping to reduce costs.

Hardware PLC used

to control peripherals
Upper level

Peripherals can be controlled

with a software PLC
Hardware PLC This
Controller

Peripheral Peripheral Manipulator Peripheral Peripheral

Fig. 1.1.1 Utilizing the software PLC

As in Fig. 1.1.2, the software PLC occupies a position between the inside and outside of the robot controller. The
physical signals to and from the devices outside the controller connected by the parallel I/O, field buses, etc. are
connected to the logical signals through the PLC programs.

Controller

Status Output signal

signal
Status
signal Input signal Output signal
Logical signals

Logical signals

Software
PLC
Input signal
Output signal
General-
purpose
signals
Input signal

Fig. 1.1.2 Flow of input/output signals through software PLC

295
l description of the software PLC

Software PLC Factory Settings

POINT The factory settings for the software PLC differ depending on the operation mode.
The current operating mode can be checked on the system environment screen displayed
with shortcut code "286". For details, see “Basic Operations Chapter 1 Introduction” in the
Instruction Manual.

Irrespective of the operation mode, both cases are directly connected with logical signals
and physical signals.

Operation mode A: Shipped in the <startup> state using the software PLC.
Logical and physical signals are connected directly by the
PLC program "Default.stf" installed in the factory.
Operation mode S: Shipped in the disconnected state, not using the software
PLC.
In the disconnected state, logical and physical signals are
directly connected.

PLC programs are scanned normally irrespective of the work program. Use of the
software PLC can be switched on and off in <Constant settings> - [1 Control Environment]
– [4 Built-in PLC].

296
 Input/output relays

Input/output relays
The input/output relays and internal relays are described here. Relays are called “variables” as far as the
software PLC is concerned. The ON/OFF coil contacts and those with integer data are all treated equally.

Controller

Status Output signal

signal
Input signal
Software Output signal

Logical signals
Logical signals
PLC Outside
General- Output signal Input signal
purpose
signals Input signal

Board internal

Normal
32 fixed inputs X0032-X0063
Logical input
BOOL variablesB0000-B1499 variables
2048
2000 signals
32 fixed outputs Y0032-Y0063
B1500-B1999 I/O board
I0000-I2047
or Real variables 32 standard inputsX0000-X0031
100 signals R0000-R0099
I0001-I2048
DINT variables 32 standard inputs Y0000-Y0031
500 signals D0000-D0499 Retained
64 additional
Logical SINT variables variables inputs X0064-X0127
output 2048 100 signals DB000-DB099 64 additional
outputs Y0064-Y0127
Timer variables
o0000-o2047 500 signals TM000-TM499
32 additional
or Character variables inputs X0096-X0127
o0001-o2048 10 signals ST000-ST009
32 additional
outputs Y0096-Y0127

Arc I/F board

8 additional
inputs X0128-X0135
8 additional
outputs Y0128-Y0135

Field bus
Field bus inputs
2048 signals X1000-X3047
Field bus outputs
2048 signals Y1000-Y3047

Fig. 1.2.1 Input/output relays & internal relays

297
 Creating programs

Creating programs

Starting the ladder editor

Use the ladder editor to create new PLC programs or editing programs which have already been taught. The
ladder (LD language) displays appear on the teach pendant, enabling direct editing. Either the teach or playback
mode may be established.
Any number of PLC programs can be recorded in the memory in the form of display image files.

1 Select <Service Utilities> - [14 PLC Program Edit], and select [1 PLC program
edit] from the menu items displayed.
>> A list of the ladder programs (display image files) is now displayed as follows.
Depending on the factory settings, Default.stf may be incorporated. For details,
see “Chapter 1 Overview”.

A new ladder programs can be edited regardless of whether the scanning of a ladder
program is in progress.
The programs listed here on the display are display image files which have been
recorded in the memory, and they are not the files which are actually being scanned
by the run time engine.

2 The first step which must be taken when a new program is created is to decide
＋ on the filename of the ladder program.
Align the cursor with the filename field, and press [ENABLE] + [EDIT].
>> The soft keyboard screen is now displayed so register the filename using this
keyboard.
Hiragana, Katakana and Kanji can be used as well as alphanumerics for the file
name.

After inputting the filename, press f12 [Complete]. →4

3 If the ladder programs have already been recorded, use the up or down cursor
key to select the file to be edited, and press f12 [Execute].

Ladder programs (display image files) have the "stf" extension. A list of all the stf files
already stored in the memory now appears on the display.

298
Creating programs

4 When the file to be edited is entered, the ladder editor starts up, and a ladder-
editing screen such as the one shown below appears.

When a ladder program (display image file) already stored in the memory has been
selected, the head of this program is displayed.

The "Insert" status is

always established for
ladder editing. No data
is overwritten.

Ladder editing
［Up/Down］
Or

Function key
menu
［Jog Dial］ Guide message
Scrolling upward and input range
downward can be done
using.

There are f keys for

two screens: select the
applicable menu items
using f1 <Change
Menu> to switch
between the two
screens, and edit the
ladder program.
Fig. 2.1.1 Ladder program editing screen

299
 Creating programs

Inputting a new rung

The "rung" is a closed circuit. Input a new rung according to the procedure shown below.

1 Select the f keys with f1 <Operation Menu>, and then press [Enable] + f10
＋ <Insert Rung> in a blank area.
>> A new closed circuit (1 rung) is inserted and displayed as shown below.
The closed circuit (1 rung) can be also inserted by pressing [Enable] + [Enter].

The area with a blue background represents the cursor position (area subject to
editing).
A rung comment (i.e., a comment describable in units of closed circuits) is displayed
inside (* *), while the rung number (i.e., the serial closed circuit number starting from
"1") is displayed inside [ ].

2 To input the contact number, put the cursor on the contact, and then press
[Enter].

>> The f keys are now switched to the parameter selection menu as shown below.

1st Page 2nd Page

Function Name Input Function Name Input
example/Description example/Description
f1<Variable switch> Switches parameter f1<Variable switch> Switches parameter
candidates. candidates.
f2<TRUE> Insertion of TRUE
constant (always ON)
f3<FALSE> Insertion of FALSE
constant (always OFF)
f4<SINT variable> E.g: DB123
Specify the bit number
as the relay number + “.”
+ bit number 0~7.
f5<DINT variable> E.g: D1234
Specify the bit number
as the relay number + “.”
+ bit number 0~31.
f6
f7
f8<Logic input> E.g: l1234 f8<String variable> E.g: ST123
f9<Logic output> E.g: O1234 f9<Time variable> E.g:TM123
f10<Physical input> E.g: X1234 f10<Real variable> E.g: R1234
f11<Physical output> E.g: Y1234
f12<BOOL variable> E.g: B1234

300
 3 To input the logical input I0000, press [Enable] + f8 <Logical Input>, and then
＋ [0] [Enter].
>> "I0000" is displayed above the contact symbol.

The f keys return to the original menu placement..

4 Now try to change the contact type. Press f6 <Switch type> once.
>>The contact type is changed to the "B".

Every time f6 [Switch type] is pressed, the contact type is changed as shown below.

"A" contact

／ "B"contact

Ｐ Rising edge

Ｎ Rising edge

5 Now try to insert the OR circuit. Press [Enable] + f9 <Insert OR>.

＋ >> The symbol is inserted as shown below.

Input the contract number that was inserted according to the same procedure
as those in the Steps 2 to 3.

6 Now try to insert the relay contact to the right.

＋ Press [Enable] + f8 <Insert a relay to the right of the cursor>.
>> The symbol is inserted as shown below.

Input the contract number that was inserted according to the same procedure
as those in the Steps 2 to 3.

301
 Creating programs

7 Then, input the coil number.

As in the case of inputting the contact number, put the cursor on the coil,
and then press [Enter].

>> The f keys are switched to the Parameter Selection screen as shown below.

8 According to the same procedure as that for inputting the contact number,
＋ input the coil number. (Example for physical output Y0005)

9 Now try to change the coil type. Press f6 <Switch type> once.
>> The coil type is changed to the reverse coil as shown below.

Every time f6 <Switch type> is pressed, the coil type is changed as shown below.

Coil

／ Reverse coil

Ｓ Set coil

Ｒ Reset coil

Coil with rising

Ｐ edge detection

Ｎ Coil with falling

edge detection

10 To output multiple coils, put the cursor on the coils respectively, and then
press f2 <Coil>.
>> The coil number is input one after another in the same manner.

302
Saving program in editing process
Save the finished PLC program in the memory in the form of display image.

INFO. Compiling and download of the created PLC program can also be done from the
ladder editor. Operations are the same as “3.2 From compile to download”.

1 Press [Enable] + f12 <Save>, wherever the cursor is positioned.

＋ >> The ladder program (display image file) on display is saved in the memory.

Make sure the display image file with a name that was specified before the editing
was initiated is still on the List.

2 Press f12 <Complete>.

>>The following pop-up message is displayed.

3 To continue editing without checking and transferring the program, use

[Right/Left] to select [NO], and then press [Enter].
Selecting [YES] makes it possible to check and transfer the program.
For details on program checking and transfer, see Chapter 3 “Program Check”.

303
Exiting editor
Exit the ladder editor.

1 Press [Reset/R] at any cursor position.

>> If the ladder program has been changed, the message shown below is
displayed.

If the ladder program has not been changed, the editor is exited without displaying
the message.

2 To exit the editor without saving the ladder program, use [Right/Left] to select
[NO], and then press [Enter].
Selecting [YES] makes it possible to save the ladder program in the editing process
sand then exit the editor.
Selecting [Cancel] does not exit the editor.

304
 From compiling to downloading

From compiling to downloading

This section describes the operations involved in selecting ladder programs (display image files) stored in the
internal memory, compiling them while specifying the running sequence, and downloading.

1 Select <Service Utilities> - [14 PLC Program Edit], and select [3 PLC program
check] from the menu items displayed.
>> A list of the ladder programs (display image files) is now displayed as follows.

2 Select the ladder program to be compiled using [Up/Down], and press [Enter].
>> The selected ladder program is highlighted in blue, and the figure "1" appears on
its right. This indicates that when a multiple number of ladder programs are to be
linked together and run, this file is the ladder program which will be run first.

3 Select the next ladder program to be compiled using [Up/Down], and press
[Enter].
>> The selected ladder program is highlighted in blue, and the figure "2" appears on
its right. This indicates that when a multiple number of ladder programs are to be
linked together and run, this file is the ladder program which will be run second.

In this way, the ladder programs are selected in the sequence in which they will be
run.
If only one executable file is sufficient, select just the one file.

4 If a mistake was made in specifying the execution sequence, move the cursor
to the ladder program concerned, and press [BS].
>>The display of the ladder program number in the execution sequence is now
cleared.

305
From compiling to downloading

5 After all the ladder programs have been selected, press f12 <Execute>.
>>The programs are compiled in sequence starting with execution sequence number
1. Upon completion of the compiling, the results are displayed as shown below.

In the example given here, file ABC456.stf is error-free but one compilation error was
found in file ABC123.stf.

6 If one or more compilation errors have been found, use [Reset/R] to exit the
program check menu.
Start the ladder editor using [1 PLC program edit], resume compiling, pinpoint
the error locations and make corrections.

7 If there are no compilation errors, the message shown below appears.

8 Select "Yes" using [Right/Left], and press [Enter].

>> The multiple number of ladder programs which have been compiled are linked
together into a single program and downloaded to the run time engine. When the
file downloading is completed properly, the message shown below appears.

The program has now been transferred to the run time engine.
If the PLC (run time engine) is already started, it stops scanning temporarily, and after
the program has been downloaded, resumes scanning.

9 Exit the menu using [Reset/R].

>> If PLC (run time engine) is not started, set it to start using the procedure in “3.3
Program start, stop, and disconnect”.

306
Program start, stop and disconnect
This section describes the procedures for starting and stopping the scanning of the ladder program
downloaded from the run time engine. This operation is done from the constant menu.
Normally, if the PLC status setting is set to “Running”, it need not be changed later. Scanning is started by
turning on the power of the controller.
Furthermore, it is possible for the software PLC not to be used (=disconnected) temporarily depending on the
connection status of the peripheral devices etc.

The PLC status setting has the following three status settings.

Table 3.3.1 Program start, stop and disconnect

Setting choice Explanation
Isolation
The built-in PLC is not used.
In other words, the logical inputs/outputs and physical inputs/outputs are connected
on a one-on-one basis in this status.
The PLC (run time engine) does not scan the downloaded programs.
Stop
The built-in PLC is used.
However, since the PLC (run time engine) does not scan downloaded programs, no
further changes occur in the physical I/O statuses.
Start
The built-in PLC is used.
The PLC (run time engine) scans the downloaded programs.
<Start> is not established automatically even when the downloading is initiated in the
program check. The status must be changed to <Start> without fail using this menu.

1 In the teach mode, select f 5 <Constant Setting> - [1 Control Constants], and

select [6 Built-in PLC] from the menu items displayed.
>> The setting menu related to the built-in PLC now appears as shown below.

2 Select “Disconnect/Stop/Run” by pressing [ENABLE] + [Right/Left] together.

＋

3 Press f12 [Complete].

>> Operation is immediately transferred to the “Disconnect/Stop/Run” control
status.

If the PLC status setting is changed to "Running", the PLC program input/output signal
status also changes accordingly. It is extremely dangerous to perform this operation while
work piece is gripped or while there is interference with any of the peripheral devices. Take
DANGER sufficient care when performing this operation.

307
 Ladder monitor

Ladder monitor
The program now being run by the PLC can be monitored on the display in the ladder display status.

Displaying the ladder monitor

1 Select [3 Ladder monitor] from the monitor menu items.

>> The monitor screen such as the one shown below appears. (The figure below
shows the whole screen display.)
The program now being run by the PLC is displayed from its start.
The area with the white background is the cursor position. Move across the display
using [Cursor keys].

Linking and executing multiple programs

1 program (display image file; ***.stf) can be displayed for 1 ladder monitor.
If multiple programs are being linked and executed, a dialog box for
selecting the program for monitor display appears. Select the programs to
be displayed.
Up to 4 monitors can be displayed (opened) simultaneously. To monitor
multiple programs at the same time, display the ladder monitor in a
different monitor window, and select a different program in that window.

The contact and coil ON/OFF, timer and other current values are displayed as
shown below.

When the A (normally open) contact is set to the ON status, a red display in bold lines
appears.

OFF ON

When the B (normally open) contact is set to the OFF status, a red display in bold
lines appears.

OFF ON

When the coil is set to the ON status, a red display in bold lines appears.

OFF ON

308
 Logical input/output relays

Logical input/output relays

Board internal
32 fixed inputs X0032-X0063

variables
Normal
B0000-B1499
Logical input BOOL variables
2048 signals 2000 signals
32 fixed outputs Y0032-Y0063
B1500-B1999
I/O board
I0000-I2047 Real variables
R0000-R0099 32 standard inputs X0000-X0031

Retained variables
or 100 signals
I0001-I2048 DINT variables
32 standard outputs Y0000-Y0031
500 signals
D0000-D0499
32 additional inputs X0064-X0127
Logical output SINT variables
100 signals
DB000-DB09
2048 signals
9 32 additional outputs Y0064-Y0127
Timer variables
o0000-o2047 500 signals
TM000-TM499
or 32 additional inputs X1000-X3047
Character variables
o0001-o2048 10 signals
ST000-ST009 32 additional outputs
Y1000-Y3047
Arc I/F board
8 additional inputs X0128-X0135
8 additional outputs Y0128-Y0135

Field bus
Field bus input 2048 signals
X1000-X3047
Field bus output 2048 signals
Y1000-Y3047

Fig. 6.1.1 Logical input/output relays

The logical input/output signals are the input/output signals of this controller as seen from the software PLC.
The logical input/output relays are identified using a code starting with I (input) or O (output) so that their
identification is consistent with the input/output signals which are actually recorded in the programs.

309
Logical input/output relays

Relay numbers
This function enables the settings of logical input/output relay numbers with the Constant menu.
Select the numbers from the two types listed in Table 6.1.1. The factory setting is made to the range of "0 to
2047".

Table 6.1.1 Logical input and output

Selection range Description
0 - 2047 Used to make settings of relay numbers in the range of 0 to 2047.
Signal numbers are assigned in the range of 1 to 2048. Consequently,
"Logical input relay number = Logical input signal number - 1"
"Logical output relay number = Logical output signal number - 1"

1 - 2048 Used to make settings of relay numbers in the range of 1 to 2048, like the signal
numbers.
"Logical input relay number = Logical input signal number"
"Logical output relay number = Logical output signal number"

1 While in teach mode, select f5 <Constant Setting> - [1 Control Constants] and

[4 Built-in PLC] from the menu on display.
>> The setting menu related to the built-in PLC is as shown below. Move the cursor to
the PLC logical input/output.

2 Press [Enable] + [Right/Left] at a time to select either 0-2047 or 1-2048.

＋

3 Press f12 <Complete>.

>> If the PLC status is set to "Start", the message shown below is displayed.

Pressing [Enter] exits the Setting screen. At this time, the PLC status is set to "Stop".
Be sure to execute checking according to information in Chapter 3 "Program check".

310
 Physical input/output relays

Physical input/output relays

Board internal

variables
32 fixed inputs X0032-X0063

Normal
BOOL variables
B0000-B1499
2000 signals 32 fixed outputs Y0032-Y0063
Logical input B1500-B1999
2048 signals
I/O board
Real variables R0000-R0099

Retained variables
I0000-I2047 100 signals 32 standard inputs X0000-X0031
or DINT variables
D0000-D0499 32 standard outputs Y0000-Y0031
I0001-I2048 500 signals

Logical output
SINT variables
DB000-DB099 32 additional inputs X0064-X0127
100 signals
2048 signals
Timer variables
32 additional outputs Y0064-Y0127
TM000-TM499
o0000-o2047 500 signals
32 additional inputs
or Character variables
ST000-ST009 X0096-X0127
o0001-o2048 10 signals 32 additional outputs
Y0096-Y0127
Arc I/F board
8 additional inputs X0128-X0135
8 additional outputs Y0128-Y0135
Field bus
Field bus input 2048 signals
X1000-X3047
Field bus output 2048 signals
Y1000-Y3047

Fig. 6.2.1 Physical input/output relays

Fixed input/output
These are the servo ON/OFF and other input/output signals which are used to control the operations inside the
controller.
The fixed input/output signals can only be referenced by the software PLC. An error results during compiling if a
program calling for signals to be output to the settled input/output signals is created.

Table 6.2.1 List of settled input/output relay numbers

Relay Relay
Settled input signal name Settled output signal name
number number
0 Motors-ON X0032 0 Motors-ON lamp Y0032
1 G-STOP X0033 1 Motors-ON request Y0033
2 Start 1 X0034 2 Start lamp 1 Y0034
3 Start 2 X0035 3 Start lamp 2 Y0035
4 Start 3 X0036 4 Start lamp 3 Y0036
5 Start 4 X0037 5 Start lamp 4 Y0037
6 Stop X0038 6 Stop lamp Y0038
7 Playback mode X0039 7 TP enable release Y0039
8 Mat switch X0040 8 Motors-ON enable Y0040
9 － X0041 9 Magnet-ON enable Y0041
10 High-speed Teach X0042 10 Internal/External Y0042
11 P1 correct X0043 11 WPS E-STOP ctrl Y0043
12 Ext Emergency stop X0044 12 CPU failure Y0044
13 Emergency stop X0045 13 TP mode Y0045
14 Safety plug X0046 14 Ext motors-ON Y0046
15 Confirm motors-ON X0047 15 Motors-ON lamp Y0047
16 TP Emergency stop X0048 － － －
17 Teach mode X0049 － － －
18 － X0050 － － －

311
Physical input/output relays

19 TP enable SW X0051 － － －
20 － X0052 － － －
21 CR ON X0053 － － －
22 Servo-ON X0054 － － －
23 Servo enable X0055 － － －
24 － X0056 － － －
25 － X0057 － － －
26 － X0058 － － －
27 Magnet-ON X0059 － － －
28 － X0060 － － －
29 Weld detection X0061 － － －
30 Inconsistency X0062 － － －
31 － X0063 － － －
32 Inconsist(GSTOP) － － － －
33 Inconsist(mode) － － － －
34 Inconsist(MAT-SW) － － － －
35 Inconsist(HI-SP) － － － －
36 Inconsist(Ext ES) － － － －
37 Inconsist(E.S.) － － － －
38 Inconsist(S.plug) － － － －
39 Inconsist(TP-ES) － － － －
40 Inconsist(ENB-SW) － － － －
41 Inconsist(CRON) － － － －
42 － － － － －
43 － － － － －
44 － － － － －
45 － － － － －
46 － － － － －
47 － － － － －

Standard inputs/outputs
These are the input/output signals for the CNIN (input) and CNOUT (output) connectors of the I/O PCB provided
as an optional accessory.
IPM Drive unit CPU Board Sequence Board
Multi-power unit I/O Board
rd
(3 board)
I/O Board
(2nd board)

I/O Board
st
(1 board)

<Front view (internal)> <Rack unit magnified view>

Fig. 6.2.2 Positions of standard input/output signal connectors

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Signal specifications of Optional Physical I/O board

Signal specifications of Optional Physical I/O board

This section explains the physical I/O signal specifications for the Arc I/F board, Relay Unit + I/O board, and
I/O board. Refer to Table 3.9.1, and refer to the correct explanation for your board.

Table 3.9.1 Reference Explanations for Each Board

Board name Reference

Common items Individual
Arc I/F board page 3-48 Refer to the section 3.9.2.
Refer to the
Relay unit + I/O board This page page 3-53 Refer to the section 3.9.3.
section 3.9.1.
I/O board page 3-59 Refer to the section 3.9.4.

Common items
DC24V supplying procedure
The capacity for the DC24V that can be supplied by the internal DC24V is 0.8A.
If the input/output current for the used external device exceeds this value, you need to prepare
an external DC24V power supply.
In case of supplying the internal DC24V to the external device, the Relay Unit cannot be
combined due to the capacity limitation of the internal DC24V.

Electrical specifications of physical input

Table 3.9.2 shows the power specifications for 1 input signal point. This is the same for all
boards.

Table 3.9.2 Electrical specifications of physical input

Items Specifications
Input impedance Approx. 3 kΩ
Input voltage DC+24 V ±10 %
Input current 8 mA (typ.)

Table 3.9.3 and Fig. 3.9.1 show the input load (customer prepared) specifications.

Table 3.9.3 Specifications of the load for input circuit (prepared by customer)

Input load (Customer prepared) Specifications Remarks

Minimum applicable load should be
Relay contact
DC24V, 5 mA The input signals needs to be
Leakage current should be 1 mA or closed for 150ms or longer.
Open collector device
less.

Fig. 3.9.1 Specifications of the load for input circuit (prepared by customer)

INFO. A transistor (PNP) type can be selected for the relay unit.
page 3-57, Refer to “Fig. 3.9.8 Signal connection with external jigs”.

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 Signal specifications of Optional Physical I/O board

Electrical specifications of physical output

Table 3.9.4 and Table 3.9.5 show the power specifications for 1 output signal point for each
board.
Prepare the output load that conforms to the used physical output signal.

Electrical specifications of physical output (Arc I/F board, Relay unit + I/O board)

Table 3.9.4 Electrical specifications of physical output (Arc I/F board, Relay unit + I/O board)
Items Specifications
Output method Relay contact
Rated voltage AC 100 V or DC 30 V
Rated current 1A
Minimum applicable load DC24V 5mA
5
Min. 10 (1A,100 V AC, 1A,30 V DC, resistive load, at 20
Electrical expected life
times/min.)

・Be absolutely sure to use a surge killer for the load.

・Since the value of minimum applicable load depends on the switching frequency,
environment conditions, and expected reliable level, be sure to check with the actual
CAUTION load condition before operation.
・Electrical expected value is a reference value in case of using under the conditions
described in parentheses. The value depends on the environmental conditions.

Electrical specifications of physical output (I/O board)

Table 3.9.5 Electrical specifications of physical output (I/O board)

Items Specifications
Rated voltage DC+24 V ±3 V
Rated current 0.1 A

・Be absolutely sure to use a surge killer for the load.

・Do not use power with the wrong polarity.
CAUTION

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Signal specifications of Optional Physical I/O board

I/O signal specifications of Arc I/F board

3.9.2.1 I/O signal specifications of Arc I/F board
Table 3.9.6 and Table 3.9.7 show the input signal specifications and output signal specifications
for the Arc I/F board terminal block.

Table 3.9.6 Input terminal block TBIN of Arc I/F board

Pin No. Signal name Signal (I*) Descriptions
Internal power source 0V
14 M1 Internal 0V
(to drive relays)
13 M1 Internal 0V Internal power source 0V
Internal power source DC24V
12 P1 Internal 24V
(to drive relays)
11 P1 Internal 24V Internal power source DC24V

9 10 11 12 13 14
10 INCOM102 COMMON Common for IN101～IN104
9 IN104 I104
8 IN103 I103
General input signals
7 IN102 I102

8
6 IN101 I101

7
6
5 INCOM101 COMMON Common for IN97～IN100

5
4
4 IN100 I100

3
3 IN99 I99

2
General input signals

1
2 IN98 I98
1 IN97 I97

Table 3.9.7 Output terminal block TBOUT of Arc I/F board

9 10 11 12
Pin No. Signal name Signal (O*) Descriptions
12 OUTCOM102 COMMON Common for OUT101～OUT104

8
11 OUT104 O104

7
6
10 OUT103 O103
General output signals

5
9 OUT102 O102

4
3
8 OUT101 O101

2
7 OUTCOM101 COMMON Common for OUT97～OUT100

1
6 OUT100 O100
5 OUT99 O99 Terminal
General output signals blocks
4 OUT98 O98
TBIN /
3 OUT97 O97
TBOUT
2 HP- HP- Warning lamp signal -
1 HP+ HP+ Warning lamp signal +

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 Signal specifications of Optional Physical I/O board

I/O signal specifications of Relay unit with I/O board

I/O signal specifications of relay unit
This section shows the input signal specifications and output signal specifications for the relay
unit terminal blocks.
References for the explanations of each terminal block are shown in Table 3.9.8.

Table 3.9.8 Relay Unit Terminal Block Input Signal Specifications and Output Signal Specifications (Factory Settings)

I/O type Terminal block No. Reference

Terminal block TBIN1 page 3-54 Refer to Table 3.9.9.
Input
Terminal block TBIN2 page 3-54 Refer to Table 3.9.10.
Terminal block TBOUT1 page 3-55 Refer to Table 3.9.11.
Output
Terminal blockTBIOUT2 page 3-55 Refer to Table 3.9.12.

For general signals, logical signals used as status signals can be assigned freely.
Table 3.9.9 to Table 3.9.12 show the factory setting assignments.
For details on the assignment method, see “4.6 Signal attribute settings”.

INFO.
Initial settings of signal allocations depend on the application type.

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Signal specifications of Optional Physical I/O board

Table 3.9.9 List of input signals(TBIN1)

Terminal block Signal
Signal name Pin description
pin No. (I*)
1 IN1 I1 General-purpose input signals
2 IN2 I2 General-purpose input signals
3 IN3 I3 General-purpose input signals
4 IN4 I4 General-purpose input signals
5 IN COM1 COMMON Common for pins 1 to 4 (IN1～IN4)
6 IN5 I5 General-purpose input signals
7 IN6 I6 General-purpose input signals
8 IN7 I7 General-purpose input signals
9 IN8 I8 General-purpose input signals
10 IN COM2 COMMON Common for pins 6 to 9 (IN5～IN8)
11 IN9 I9 General-purpose input signals
12 IN10 I10 General-purpose input signals
13 IN11 I11 General-purpose input signals
14 IN12 I12 General-purpose input signals
15 IN COM3 COMMON Common for pins 11 to 14 (IN9～IN12)
16 IN13 I13 General-purpose input signals
17 IN14 I14 General-purpose input signals
18 IN15 I15 General-purpose input signals
19 IN16 I16 General-purpose input signals
20 IN COM4 COMMON Common for pins 16 to 19 (IN13～IN16)
21 24V Internal 24V 24V internal power supply
22 EX 24VA Input 24V External power supply input (24V)
23 EX 24VB Output 24V External power supply output (24V)

Table 3.9.10 List of input signals(TBIN2)

Terminal block Signal
Signal name Pin description
pin No. (I*)
1 EX 0VB Output 0V External power supply output (0V)
2 EX 0VA Input 0V External power supply input (0V)
3 0V Internal 0V 0V internal power supply
4 IN17 I17 Program selection bit 1
5 IN18 I18 Program selection bit 2
6 IN19 I19 Program selection bit 3
7 IN20 I20 Program selection bit 4
8 IN COM5 COMMON Common for pins 4 to 8 (IN21～IN24)
9 IN21 I21 Program selection bit 5
10 IN22 I22 Program selection bit 6
11 IN23 I23 Program selection bit 7
12 IN24 I24 Program selection bit 8
13 IN COM6 COMMON Common for pins 9 to 12 (IN21～IN24)
14 IN25 I25 Program strobe U1
15 IN26 I26 General-purpose input signals
16 IN27 I27 General-purpose input signals
17 IN28 I28 Welding ON/OFF
18 IN COM7 COMMON Common for pins 14 to 17 (IN25～IN28)
19 IN29 I29 General-purpose input signals
20 IN30 I30 Ext. play start.
External stop (keep an input signal supplied here
21 IN31 I31
when this pin is not used.)
22 IN32 I32 External motor power OFF
23 IN COM8 COMMON Common for pins 19 to 22 (IN29～IN32)

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Table 3.9.11 List of output signals (TBOUT1)

Terminal block Signal
Signal name Pin description
pin No. (O*)
1 OUT1 O1 General-purpose output signals
2 OUT2 O2 General-purpose output signals
3 OUT3 O3 General-purpose output signals
4 OUT4 O4 General-purpose output signals
5 OUT COM1 COMMON Common for pins 1 to 4 (OUT1～OUT4)
6 OUT5 O5 General-purpose output signals
7 OUT6 O6 General-purpose output signals
8 OUT7 O7 General-purpose output signals
9 OUT8 O8 General-purpose output signals
10 OUT COM2 COMMON Common for pins 6 to 9 (OUT5～OUT8)
11 OUT9 O9 General-purpose output signals
12 OUT10 O10 General-purpose output signals
13 OUT11 O11 General-purpose output signals
14 OUT12 O12 General-purpose output signals
15 OUT COM3 COMMON Common for pins 11 to 14 (OUT9～OUT12)
16 OUT13 O13 General-purpose output signals
17 OUT14 O14 General-purpose output signals
18 OUT15 O15 General-purpose output signals
19 OUT16 O16 General-purpose output signals
20 OUT COM4 COMMON Common for pins 16 to 19 (OUT13～OUT16)

Table 3.9.12 List of output signals(TBOUT2)

Terminal block Signal
Signal name Pin description
pin No. (O*)
1 OUT17 O17 Wire stick check
2 OUT18 O18 Weld failure
3 OUT19 O19 Unit READY U1
4 OUT20 O20 Program end U1
5 OUT COM5 COMMON Common for pins 4 to 8 (OUT17～OUT20)
6 OUT21 O21 Error U1
7 OUT22 O22 Interlock alarm U1
8 OUT23 O23 Alarm U1
9 OUT24 O24 Emergency stopped
10 OUT COM6 COMMON Common for pins 9 to 12 (OUT21～OUT24)
11 OUT25 O25 In teach mode
12 OUT26 O26 Robot running U1
13 OUT27 O27 Ext. prg. sel enable
14 OUT28 O28 Ext. start enable
15 OUT COM7 COMMON Common for pins 14 to 17 (OUT25～OUT28)
16 OUT29 O29 Motors energized
17 OUT30 O30 Status output 1
18 OUT31 O31 Work home position 1 U1
19 OUT32 O32 Information U1
20 OUT COM8 COMMON Common for pins 19 to 22 (OUT29～OUT32)

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Signal specifications of Optional Physical I/O board

Connections to Relay Unit Input Signals

INFO. For details on the electrical specifications for the input signals, see “section 3.9.1.2 Electrical
specifications of physical input” on page 3-46.

A connection example to relay unit input signals is shown below.

Both type of NPN and PNP power suppies can be selected by switchig CNSW.

Fig. 3.9.7 Input circuit of relay unit

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 Signal specifications of Optional Physical I/O board

Signal connection with external jigs

To input the relay unit, connect the output of relay dry contact or transistor as the diagram below.

Connection of relay dry contact Connection of transistor output Transistor (PNP) Output connections
(NPN). (Sink type (-) Common) (Sink type：(+) common)
Fig. 3.9.8 Signal connection with external jigs

Procedure to supply DC 24 V by external power source

Fig. 3.9.9 Procedure to supply DC 24 V by external power source

1 Check that shorting cables are connected to TBIN1 and TBIN2.

2 Disconnect the two TBIN1 and TBIN2 shorting cables.

3 Connect the external power supply input (24 V) and (0 V) pins to the pins shown in 3.

4 When a multiple number of relay units are used or 24 V is to be supplied elsewhere,

connect the 24 V output pin to the pin shown in 4.

320