Page 1 Industrial Robot Standard controller type Built-in welding machine type YA-1NA***/ YA-1PA*** VR2 Series G2/GX Controllers Before operating this product, please read the instructions carefully and save this manual for future use. OM0105045E09 (0105045) 0403...
Page 2 Systems of “Operating Instructions” of Panasonic Robot VR2 series Name Description and remarks Usage Panasonic robots are designed and manufactured Use this document for training Safety manual on the premise that contents of this manual are programs at installation and also conformed to by users.
Page 3 ■ Introduction Thank you for purchasing our Panasonic industrial robot G2/GX controller series. This manual explains basic operation and advanced operation (details of parameters settings and sequene commands) of G2/GX controller series. Operation procedures explained in this document is based on the software version J* .
Page 4 It is also important to ensure that equipment functions correctly at all times. Panasonic robots are designed and manufactured on the premise that contents of this manual are conformed to by users. Personnel who use any other manuals must read and understand the contents of this manual first.
Page 5: Table Of Contents
BASIC OPERATION -Table of Contents- 4-15-8. Auto-edit of Arc start/end commands ..4-25 1. Structure 4-16. Edit files (Basic operation) ......4-26 1-1. Parts identification ..........1-1 4-16-1. Open a file ..........4-26 1-2. Teaching Playback Method.........1-1 4-16-2. Display a file on top of the screen ... 4-26 4-16-3.
Page 6 8-3. Application examples of variables.......8-3 12-3. Language settings ......... 12-4 8-3-1. Byte variable ..........8-3 12-4. Screen saver settings ........12-4 8-3-2. Position variable ..........8-4 12-5. Programming (Teach) Folder settings.... 12-5 8-3-3. Rotary/Shift variable ........8-5 12-6. Favorite commands ........12-6 9.
Page 7 15-4-7. Pilot arc..........15-20 16-5-20. I-PFALL..........16-18 15-5. Changing Analog type welder settings..15-21 16-5-21. I-PRISE..........16-18 16-5-22. ISC............16-19 16. Commands 16-5-23. ISL1 ............ 16-19 16-1. Move commands ..........16-1 16-5-24. ISL2 ............ 16-20 16-1-1. MOVEC ...........16-1 16-5-25. PENET..........16-20 16-1-2. MOVECW ..........16-1 16-5-26.
Page 8 16-9-4. SAVE TIGFC..........16-34 16-15-3. RSTREV ..........16-44 16-9-5. WFACC..........16-35 16-15-4. VELREF..........16-44 16-9-6. WFDCC ..........16-35 16-16. ARC-ON/ARC-OFF sequences ....16-45 16-9-7. WFEED..........16-35 16-16-1. CO2/MAG/MIG welding ...... 16-45 16-9-8. WFSLDN ..........16-35 16-16-2. TIG welding......... 16-46 16-9-9. WFSPEED ..........16-36 16-16-3. Powder plasma welding ...... 16-46 16-9-10.
Page 9 This manual is for both Welding specification and Handling specification. As for “Advanced operation”, please refer to the latter part of this manual. Contents Structure How to use the teach pendant 3. Get assistance while you work (Help) 4. TEACH mode 5.
Page 10: Structure
1. Structure 1-1. Parts identification Teach pendant Robot controller main body Operation box <*> Operation box is standard specification for specified models only, otherwise optional. Axis name Definition RT axis Rotate Turn UA axis Upper Arm FA axis FA axis Front Arm RW axis RW-axis...
Page 11: How To Use The Teach Pendant
2. How to use the teach pendant The teach pendant is used to operate the robot in most cases. Make sure that you understand the functions and how to use each switch on the teach pendant thoroughly before using it. 2-1.
Page 12: Jog Dial And +/- Key
2-1-1. Jog dial and +/- key This dial is used to control movement of the robot arm, the external axis or the cursor on the screen. It is also used to change data or select a choice. key is used to control continuous movement of the robot arm in the same manner as Jog drag opration.
Page 13: How To Work On The Screen
2-2. How to work on the screen The teach pendant provides a variety of icons that identify functions on the screen that can make your work easier. Move the cursor to the icon you want and click the jog dial to display sub-menu icons or to switch windows. Function icons Menu icons Window title bar...
Page 14: User Function Keys
2-4. User function keys Some functions are allocated to the 5 user function keys (F1 to F5) located at the bottom of the TP. Press a user function key to execute the function indicated with the icon. The chage page key is allocated to the F5 key to display different set (page) of functions F1 to F4 keys.
Page 15: Menu Icons
2-5. Menu icons Click on an icon on the menu bar to pull down its sub menu icons. Jog up/down to move the cursor (red frame). Move the cursor Click the jog dial to Click the jog dial up to close the display sub-menu items.
Page 16: List Of Icons
2-5-1. List of icons Main and submenu icons (down to the 3rd level) are listed as follows. (Main) (Main) File Edit (Sub-1) (Sub-1) ...
Page 17 View File list Display Display Display Display Display Accumulate Operate Shift data...
Page 18 Double Position Position Real Position Byte Integer Variable Rotary/Shift (3D) precision inter number (Robot) (Mechanism) ...
Page 19 ■ Icons in TEACH mode Weld/Air-cut Robot (Interpolation Speed (Edit type) (Joint type) type) Speed Robot Joint (Low) Speed Linear Cartesian Change External axis (Middle) ...
Page 20: Input Numerical Values And Characters
2-6. Input numerical values and characters 2-6-1. Input numerical values The number input box appears to input a numerical value. · Use the L-shift key or R-shift key to switch the digit of the value. · Use the jog dial to change the numerical value. · ...
Page 21: Get Assistance While You Work (Help)
3. Get assistance while you work (Help) When you are in the middle of a task and need help, such as you want to know certain operation procedure or you want to know what to do with the alarm or error that occurred, click the Help icon to get the information you need. The Help menu simply rephrases the contents of the manual.
Page 22: Teach Mode
4. TEACH mode When the Mode select switch is in the TEACH position, it is possible to create or edit a robot operation program using the teach pendant. 4-1. How operation procedures are explained This manual explains the procedure to display a setting dialog box of each setting item using icons. Click Click the icon shown to the right of the >>...
Page 23: Turn On Servo Power
4-2. Turn ON Servo Power Prior to turning ON the servo power make sure that no personnel are present Warning within the robot work envelope. 1. Turn ON the power switch of the robot controller main body, then Transferring system data the system data in the controller will be transferred to the teach pendant to enable robot operation from the teach pendant.
Page 24: Manual Operation
4-4. Manual operation Operation to move the robot using the teach pendant. Data of robot movement made in manual operation won’t be saved. In teach mode, the maximum robot travel speed of the tool center point (at the end of the welding torch where the arc generates) is limited to 15 m/min.
Page 25: Switch The Coordinate System
4-5. Switch the coordinate system It is possible to change the direction of the motion of the robot arm by selecting a coordinate system. There are five coordinate systems to choose from Press the L-Shift key to switch the coordinate system. The Robot motion icon switches correspondingly.
Page 26 Cartesian coordinate system Tool coordinate system [Controls the robot movement based on the robot [Controls the robot movement based on the direction of coordinate system] the end tool attached to the manipulator] （Ｗ）（Ｈ）（Ｗ）（Ｈ）（Ｗ）（Ｈ） Switch functions (with L-Shift key) Switch functions (with L-Shift key) （Ｗ）...
Page 27: Teach Program Programming Procedure
4-6. Teach program programming procedure Perform the teaching operation to create a program of teaching data such as robot movement and task procedures. [Operation flow] 1. Create a new file (program) where teaching data will be saved. 2. Perform teaching operation to create a program. 3.
Page 28: Create A New File
4-7. Create a new file Prior to teaching, it is necessary to creat a file in which teaching points data and robot commands will be saved. Click >> >> File [File name] Initially a file name is automatically specified in the file name box.
Page 29: Move Commands For Each Interpolation
4-8-1. Move commands for each interpolation Interpolation types applicable to welding robots and to handling robots Welding robots Handling robots Move command Interpolation type Move command Interpolation type MOVEP MOVEP MOVEL Linear MOVEL Linear MOVEC Circular MOVEC Circular ...
Page 30: Circular Interpolation
4-9. Circular interpolation The robot control point is capable of following circular path. The circular path will be determined by teaching at least three consecutive circular interpolation points (MOVEC). Circular intermediate point MOVEC （Intermediate） Linear interpolation Circular Circular start point end point MOVEC（Start）...
Page 31: What Is Circular Interpolation
4-9-1. What is circular interpolation The robot calculates a circle from three teaching points and moves on the circular pattern. If there are more than one circular intermediate points, the circular pattern of the current point to the next point will be determined from the current point and two consecutive circular teaching points ahead.
Page 32: Teach Weld Section (Welding Spec.)
4-10. Teach weld section (Welding spec.) Welding robots are provided with functions for operation frequently used in welding (welding ON/OFF operation) for easy operation. 4-10-1. Wire/inching Gas check Turn ON the Wire/gas icon lamp in the menu bar, to use the check Function keys for wire/inching gas check.
Page 33: Settings Of Condition Of A Teaching Point
4-10-3. Settings of condition of a teaching point With the Teach setting dialog box, specify the Arc-ON and Arc-OFF program, welding conditions and crater conditions, then the preset conditions will be automatically programmed to the arc-ON or arc-OFF point when it is saved. Click ...
Page 34: Linear Weaving Interpolation
4-10-5. Linear weaving interpolation Teach a weaving start point (MOVELW), two amplitude points (WEAVEP) and weaving end point (MOVELW) to create weaving pattern. Weaving start point Amplitude point 1 At the point you want to start weaving, Next, move the robot to one of the points press the Enter key.
Page 35 Weaving pattern Pattern 1 (Single weaving) Pattern 2 (L shape) Pattern 3 (Triangular) Pattern 4 (U shape) Pattern 5 (Trapezoid) Pattern 6 (High-speed single weaving) Move to the amplitude points with “PTP” motion. ◎ Specify the frequency of the weaving speed on the weaving end point. ◎ ...
Page 36: Circular Weaving Interpolation
4-10-6. Circular weaving interpolation Teach three points to determine a circular line and two amplitude points (WEAVEP) to create circular weaving movement of the robot. Circular weaving start point Weaving amplitude 1 Weaving amplitude 2 Set the interpolation type to Next, move the robot to one of Then, move the robot to the other “Circle-Weaving”.
Page 37: Trace Operation
4-11. Trace operation Trace is used to check the actual position or conditions of taught points which have been saved. With this operation, it is also possible to change teaching point data. 4-11-1. Trace start/end Use the trace icon and the motion function key to trace points. Trace icon Function Start...
Page 38: Change Teaching Points
4-11-3. Change teaching points In trace operation, move the robot to the taught point you want to change. (The cursor moves to the same point in the screen.) You will find the edit type icon used Click >>...
Page 39: Trace Motion After Editing
4-12. Trace motion after editing The following examples show the robot movement of trace forward/backward operation after each editing in trace operation • Stop the robot on the teaching point 4 and then edit the point Manual edit Trace forward Trace backward Original robot motion Manually move the robot...
Page 40: I/O Monitor
• Stop the robot between teaching points (4 and 5) and then edit the point Manual edit Trace forward Trace backward Original robot motion Manually move the robot (Moves the robot manually) Add a point 6 (new) (Add a teaching point (6) between 4 and 5) Change position of a point 3 ...
Page 41: Program Test
4-14. Program test The program is tested in TEACH mode by performing robot motion and actual welding under the safety condition. And the override operation is available from the software “J” and later version. Functions • Actual welding is available to test. •...
Page 42: Override In The Program Test
Available functions in Program Test Function Availability Function Availablity Real time display only “WELD/CUT OFF” key Load factor view (No overduty error) retry, Stick release, Accumulated time No count in Program test. Restart overlap Arc weld information RT and Cube monitor Weld off input/output (No auto restart) Running output...
Page 43: Advanced Settings
4-15. Advanced settings It is settings for advanced functions available. Click >> >> Advanced MORE settings [Weld section shift] A function to shift all points of a welding section according to the shift value of the welding start point automatically. [Wire touch detection in teach] *Available if the “Touch sensor (option)”...
Page 44: Wire Touch Detection In Teach
4-15-2. Wire touch detection in teach It holds the robot operation when the wire at the end of the torch touches the work. The function is also useful to set the robot at the accurate welding position by adjusting the wire projection length. Valid/Invalid] Specifies the validity of the function.
Page 45: Weaving
4-15-6. Weaving In this dialog box, it is also possible to specify weaving direction to be determined based on the vector created by two amplitude points (WEAVP) [Individual weld line] Select to specify the weaving direction settings toward the next teaching point individually.
Page 46: R-Shift Key And Teach Point Settings
4-15-7. R-shift key and teach point settings It specifies how the confirmation dialog box is to be displayed at teach point settings - whether to press both the Enter and R-shift keys or to press only the Enter key, or either way. It also allows you to specify whether to change the menu data together with the teaching point.
Page 47: Edit Files (Basic Operation)
4-16. Edit files (Basic operation) While teaching or tracing, file edit operation make possible editing the current working program with operating keys on the teaching pendant. Turn OFF the icon lamp to edit files on the window of the teach pendant. Robot motion OFF 4-16-1.
Page 48: Add A Sequence Command
4-16-3. Add a sequence command Move the cursor to the line you want to add a sequence command below. You will find the edit type icon used Click >> >> in the preceding edit operation in (Edit type) the menu bar. On the Command menu, click the sequence command you want to add.
Page 49: Setting Welding Conditions (Welding) -"Auto-Edit Of Arc Start/End Commands
4-16-6. Setting welding conditions (Welding) –“Auto-edit of arc start/end commands” Welding robots are provided with commands for operation frequently used in welding (welding start/end sequences) for easy operation. When creating a program: In teaching operation, by entering “Weld point” and “Air-cut point”...
Page 50: File Sort
Slope control for welding conditions The slope control makes smooth transition of welding arc and welding bead. Welding method Command Function CO2/MAG/MIG ARCSLP Slope command for MAG/MIG welding condition Smooth bead transition TIGSLP Slope command for TIIG welding condition WFDSLP Slope command for filler wire feed speed TIG/MIG Force...
Page 51: Save A File
4-17. Save a file You must save the teaching data after teaching or editing in a file. If you closed the file without saving the data, you loose all teaching data or the changes you have. Overwrites data. Click >>...
Page 52: File Transfer
4-19. File transfer It stores files of program etc. in another folder or memory card. • When you make a backup data on a PC card, insert the PC card (with memory card embedded) into the PC card slot at the near side of the TP. (Please refer to the operating instructions of the controller (OM0105037E)) •...
Page 53: File Properties
4-20. File properties 4-20-1. File properties It provides information particular to each file, for example, when it was saved or who create the file. It also provides a place for you to add a comment. Click >> >> >> >>...
Page 54: File Protect
4-20-3. File protect It is a function that allosw you to protect on a file basis. You can also set a file protection using the “Properties” dialog box. (1) Setting procedure using “Protect” dialog box >> >> >> ...
Page 55: Delete Files
4-21. Delete files Files saved can be deleted. Please be advised that it is not possible to undo once deleted Click >> >> File Delete 1. Cick “Controller” in the System window to show the file list. 2. Change the window and select the files you want to delete in the file list.
Page 56: Auto Mode
5. AUTO mode When the Mode select switch is in the AUTO position, it is possible to operate a program created in teach mode. 5-1. Start There are two ways to start operation (run the program); one way is to use the start switch on the teach pendant (which is called “manual start”), and the other way is to send a signal from an external device (which is called “auto start”).
Page 57: Hold And Restart
5-2. Hold and restart Never enter into the safety fenced area. The robot may move suddenly where it is in HOLD state. Warning Make sure that no personnel or any articles to interfere with the robot are present within the robot work envelope prior to restarting the robot. Press the Hold switch, then the robot becomes inactive while keeping the servo power ON.
Page 58: Program Unit
5-5. Program unit A function to specify a scope of continuous operation. Click >> >> Program unit Stops after completion of each step. Step unit Stops after completion of each program. Program unit Performs a preset series of programs and then stops. Continuous 5-6. Cycle time It is to set program(s) to indicate individual cycle time. Click >>...
Page 59: Override
5-7. Override A function to adjust welding conditions (welding voltage, current or speed) while running a program or while welding. Functions • Data changed using the override function is saved automatically. • Override for travel speed is adjustable from –25% to +25% against the original programmed speed. •...
Page 60: End Of Operation
5-8. End of operation To end the current operation, bring the robot in the hold state and then close the file. 5-9. Advanced use of “AUTO” mode 5-9-1. Offline programming A function to edit the running program. Please be advised that the changes are applied the next time you run the program. Click >>...
Page 61: Welding Data Log
5-10. Welding data log < A function available only with the built-in welding power source controller.> This is a function that receives and records actual welding condition data from the welding power source. Such data is useful to control welding quality. The “Welding data log”...
Page 62: Useful File Edit Functions
6. Useful file edit functions icon lamp to operate the cursor in the edit screen. While editing files turn off the Robot motion OFF 6-1. Cut It removes data of the selected line(s) from the file and move to the clipboard. ...
Page 63: Paste
6-3. Paste It inserts the data that has been either Cut or Copy in the clipboard into the file. Move the cursor to the line where you would like to insert the data. (The data will be inserted below the line where the cursor is positioned.) Click >>...
Page 64: Replace
6-5. Replace It replaces the data in the program with other data. Two kinds of deta input method are prepared. Click >> >> Edit Replace Set the select replace range and [Entire program] Replace the entire program. thenspecify the replacing item. [Specified labels] [Use jog dial to select] “Add”...
Page 65: Edit Local Variable
6-7. Edit local variable It is a function to change name and/or comment of a local variable, and also edit the value of a local variable. It also can increase the number of local variables to be registered. Click >>...
Page 66: Global Data
6-8. Global data Global data is common to all programs. This section explains how to teach “Robot” variable and “Position” variable. Click >> >> Global variable Edit settings Robot Robot Mechanism Position Position Robot [Variable name] Specifies name of the global data. [OK]: Register as global data.
Page 67: Conversion
6-9. Option A function for advanced edit such as “Program shift”, “Tool compensation” and so on. The settings in Option are for advanced operation. Click >> >> Edit Option [Conversion] to shift teaching points of the program. [Compensation of tool]: change to compensation of tool setting mode. [Global variable for Adjustment..]: Change to global variable setting mode for tool center point (TCP) adjustment.
Page 68: Tool Compensation
6-9-2. Tool compensation It is a function to be used when a tool is deviated. It calculates the deviation value and then adjusts taught programs that use the tool according to the calculation. The tool compensation value is unique to each tool offset. Therefore, once a tool compensation value is set, the adjust value will be applied to all taught programs using the same tool Deviation...
Page 69: Global Variable Setting For Tcp Adjustment
To check the tool compensation on the screen. Click >> >> >> Tool Robot Astarisk (*) after the tool name in the tool offset dialog box indicates that the tool has applied the tool compensation. Tool compensation is applied 6-9-3.
Page 70: View
7. View This section explains screen displays available from the View menu. The View menu is available in both Teach mode and AUTO mode. Buttons function as per described in the table on the Button Description right unless specified. Close the current active window.
Page 71: Torch Angle
7-2-2. Torch angle < A function available only with the built-in welding power source controller.> It displays torch angle to the weld line. Click >> >> >> >> Display Display Tilt angle torch angle View change position Swept-forward/Swept back angle 7-2-3.
Page 72: Display Shift-On Data
7-2-6. Display SHIFT-ON data It displays the shift amount of the SHIFT-ON command in execution. Click >> >> >> >> Display Shift data SHIFT-ON data View change 7-2-7. Load factor It displays the load factor of each axis at the current robot orientation to the rated value in percentage. Load factor of each axis at the current Click >>...
Page 73: Operate State
7-2-9. Operate state It displays operation state and program schedule. [Running state] Displays state of the Click >> >> >> Display Operate current operation. If the current View change state program calls another program, hierarchical structure is used. [Reserve state] Displays scheduled programs.
Page 74: List Of Open Files
7-4. List of open files It displays the specified program on top of the screen and bring the program to an active state. Specify a program from programs Click >> >> >> currently in operation, teaching or View Window Online edit operation.
Page 75: Arc Weld Information
7-5. Arc weld information A function to display each welding status. Click >> >> >> >> Display Monitoring View change feeder Icon Screen display Current/ Voltage Weld input/output Deviation count TIP CHANGE If a digital controlled wire feeder is applied, it is Monitoring possible monitor status of the wire feed motor.
Page 76 Contents 8. Variable settings 9. Input/Output settings 10. Robot settings 11. Controller settings 12. Teach pendant (TP) settings 13. System information/Back up setting 14. Management tool settings 15. Arc welding machine settings 16. Commands 17. Errors and Alarms 18. Appendix...
Page 77: Variable Settings
See application examples 8. Variable settings Note When you see this sign, you can find application 8-1. Variables example(s) of the item in Chapter 8. • A quantity capable of assuming any of a set of values, whose value can be changed by such actions as substitution, replacement, arithmetic operation, logic operation etc.
Page 78: Global Variable Settings
8-2. Global variable settings It is to specify and register a variable name to be used as a global variable. Icon Description Q’ty Click >> Sets 1-byte integer variable. >> Variable [Range: 0 to 255] Byte Sets 2-byte integer variable. [Range: -32768 to 32767] Integer Sets 4-byte integer variable.
Page 79: Application Examples Of Variables
8-3. Application examples of variables 8-3-1. Byte variable (1) Group input A byte variable that stores a 1-byte (means 8 bits) value. When an 8-bit group input is received by the byte variable, the terminals of the group input are allocated to and stored in ones to 128s of the byte variable as binary number respectively.
Page 80: Position Variable
8-3-2. Position variable (1) How to use the position variables In teaching operation, P1, P2, P3 and so on that are automatically created whenever you register points are local mechanical position variables. As they are variables, it is possible to change values or to reuse them. For example, if you have taught three points P1, P2 and P3, and you would like to go back to the P1 position as the next movement.
Page 81: Rotary/Shift Variable
8-3-3. Rotary/Shift variable (1) Settings Click >> >> >> Variable Rotary/Shift [X] Parallel shift amount in the direction of X axis. [Y] Parallel shift amount in the direction of Y axis. [Z] Parallel shift amount in the direction of Z axis. [Rx] Rotary shift amount with reference to X axis [Ry] Rotary shift amount with reference to Y axis [Rz] Rotary shift amount with reference to Z axis.
Page 82: Input/Output Settings
9. Input/Output settings 9-1. User Input/Output settings Settings of terminals to be connected to other system equipment to receive signals to the robot (Input terminals or “Input”) or send signals from the robot (Output terminals or “Output”). User Input or User output terminals are terminals users can freely connect to external equipment to receive to or send signals from programs.
Page 83: Status In/Out
9-2. Status IN/OUT Dedicated input/output terminals to send signals when the robot is in specified state or to change the robot status according to the signal received. 9-2-1. Status INPUT Dedicated input terminals Status INPUT Description Turn ON to enable servo power ON if the following conditions are all satisfied. Condition 1: Status output signal ‘Ready’...
Page 84: Status Output
9-2-2. Status OUTPUT Dedicated output terminals Status OUTPUT Description • The signal is output when the robot goes into an alarm condition. (At servo power OFF) Alarm output • Unless power is turned OFF, the output signal remains in ON state. •...
Page 85 Status output Description [Valid/Invalid] Specifies the validity of the function. [Output terminal] Specifies the output terminal name to be allocated to Emergency stop the user output terminal. Output [Input terminal] Specifies the input terminal name to be allocated to the user input terminal. The signal is output when the emergency stop is ON.
Page 86 Status output Description [Valid/Invalid] Specifies the validity of the function. Start mode [Output terminal] Specifies the output terminal name to be allocated to output the user output terminal. It closes the running program file when the input is received. It accepts the input while the operation is in hold or emergency stop state. It accepts the input when the start method is set to “AUTO”.
Page 87 Status output Description [Valid/Invalid] Specifies the validity of the function. OPR Hold [Output terminal] Specifies the output terminal name to be allocated to output the user output terminal. It outputs when the robot goes in a hold state (including error stop) while running a program. •...
Page 88: High-Speed Input
9-3. High-speed input * Available when “Touch sensor” option is provided or with a MIG/TIG force system. An input which has priority over other user inputs. The input is useful to use with a device that requires immediate response. Click >>...
Page 89: Robot Settings
10. Robot settings 10-1. User coordinate system settings 10-1-1. What is a User coordinate system It is a coordinate system that can be defined by the user. For example, if you are using a tilted table, you can define a coordinate system based on the table surface and operate the robot in the defined coordinate system.
Page 90: Tool Offset Settings
10-2. Tool offset settings 10-2-1. What is tool offset • Tool offset is the dimension surrounding the tool control point orientation of tool to be attached to the TW flange surface of the robot, such as a welding torch or gripper. •...
Page 91: Definition Of L1 Type Tool Offset
10-2-3. Definition of L1 type tool offset • It uses 4 parameters, L1, L2, L3 and TW, to determine the tool TW rotation offset. center • When the BW axis is at –90 degrees, define the intersection point of RW-axis and TW-axis as “point P” and the plane on Flange which the control point travels by moving only the TW-axis as surface...
Page 92: Standard Tool Settings
10-3. Standard tool settings It specifies the default tool to be used in new teach programs. That is, the tool specified here is that initially will be displayed when you create a new program. Click >> >> >> Standard Robot tool [Standard tool]: Specifies the default tool.
Page 93: Rt Monitor" Setting Procedure
10-4-2. “RT monitor” setting procedure * You can specify two different RT monitor settings (RT01 and RT02). Click >> >> >> >> Area monitor RT monitor Robot [Valid/Invalid] Specifies the validity of the function. [Face/Side] Face: To monitor within the set range. Side: To monitor outside of the set range in the robot work envelope.
Page 94: Cube Monitor" Setting Procedure
10-5-2. “Cube monitor” setting procedure <Note> The specified output goes ON while the Click >> robot is in the preset monitor area regardless of the >> >> >> Cube mode. Area monitor Robot monitor [Valid/Invalid] Specifies the validity of the function. [Auto re-start] Click in the box to restart operation automatically if the input signal goes OFF when the robot is in wait state at the boundary of the specified...
Page 95: And Condition Monitor
*Multi rotation: Click in the box so that the angle from the zero (0) degree point to the current position (not the actual angle of rotation) is used to check whether or not the external axis is in the range. [In case the monitor range is set to “from 0 to 90 degrees”.] 0 °...
Page 96: Soft-Limit Settings
10-6. Soft-limit settings The operable range of each axis can be limited by means of software, this is called “Soft-limit”. Click >> >> >> Soft-limit Robot [RT] Specifies the operating range of the RT-axis [UA] Specifies the operating range of the UA-axis [FA] Specifies the operating range of the FA-axis [RW] Specifies the operating range of the RW-axis [BW] Specifies the operating range of the BW-axis...
Page 97: Tcp Adjust
10-8. TCP adjust 10-8-1. What is TCP adjust It is a function to set the calculated tool offset value by inputing the specific tool positions at the tool cente point (TCP).It is necessary to teach six tool positions (3 positions each for X-Z plane and X-Y plane). <Note>...
Page 98 To identify the data as variable name, fill in the variable name box and the click the OK button. <Position 2> Position 2 Align the directions of the adjustment jig and of the TW axis rotation center. Then move the Y-axis of the tool coordinate system to align the TW axis rotation center...
Page 99: Controller Settings
11. Controller settings 11-1. Program start method settings • To set the start method, the terminal to which the external signal to start the robot operation is transferred to needs to be allocated to the user I/O terminal. • There are two types of start methods; ‘Manual’ and ‘Auto’. In Auto-start method, there are two different selection methods;...
Page 100: Start Method Settings And I/O Allocation
11-1-2. Start method settings and I/O allocation It is a function to specify the start method you want and then allocate user I/O terminals to be used to specify the program number and to start a program. Click >> >> >>...
Page 101: Program Select Method
11-1-3. Program select method • If a program is reserved while running another program, the reserved program will be started automatically after the completion of the current program. • If the result exceeds the set range (from 1 to 999), then the program reservation is disregarded. •...
Page 102: Binary Method
11-1-5. Binary method It calculates the sum of ‘Program reserve input’ numbers having been in ON state when the ‘Input strobe’ is turned ON, and then reserves the corresponding program. Example: Program reserve input Program name Prog0999.prg Prog0550.prg Prog0050.prg Prog0017.prg １...
Page 103: Bcd Method
11-1-6. BCD method • BCD is the abbreviation for binary-coded decimal code. • It specifies each digit of a number as a binary number using program reserve inputs 1, 2, 4 and 8 for the 1st digit, 16, 32, 64 and 128 for the 2nd digit and 256 and 512 for the 3rd digit. It calculates the sum of ‘Program reserve input’ numbers having been in ON state when the ‘Input strobe’...
Page 104: Login And Logout
11-2. Login and Logout This function is to individualize data by programmer (or user ID) and also to limit scope of authority in settings and programming according to the registered user level. Please refer to section “User management settings” for details of the User ID. Click >>...
Page 105: Resume Settings
11-3. Resume settings It is a function to resume the settings active at power loss (power off) when power is regained (power on). Click >> >> >> Resume Controller [Use resume]: Check the box to enable the resume function. [Unconditional]: Check the box to enable the resume function at all times.
Page 106: Speed Limit Settings
11-4. Speed limit settings 11-4-1. Manual/Override speed limit It specifies the maximum robot travel speed in manual operation. It also specifies the override speed limit in AUTO mode separate from the speed in teaching operation. This function is useful in a system the reference speed is set to the external axis. As in such system the robot motion speed is likely set above the override upper speed limit.
Page 107: Smooth Level
11-5. Smooth level The robot moves to the Smooth level =0 Click >> taught point at the corner. >> >> >> Smooth Motion Controller level parameter Teach point Increase the smooth level [Smooth level]: Specifies how smooth the robot turns at a corner.
Page 108: Error Handling
11-7. Error handling Make sure that no personnel are present within the safety fence before turning ON the error handling input. The robot starts the error handling motion immediatelly after the Warning error handling input is turned ON. 11-7-1. What is “Error handling”? ...
Page 109: Setting Procedure
11-7-2. Setting procedure Advance Click >> Controller setting >> >> >> Select “Error Handling”. ]: Select whether or not to enable Valid/Invalid this “Error handling” function. Move distance Sets a distance from the point where the welding error occurred to the point where the robot moves in the tool direction (idle position) ...
Page 110: Operation Procedure
11-7-3. Operation procedure The below shows the operation procedure of the “Error Handling” function using an example when the robot operation is terminated A welding error because of the occurance of a welding error such as no arc or torch occurred.
Page 111 < Relations with other functions > Function Response of this “Error Handling” function The robot performs the overlapping process when the operation is Arc overlapping restarted after the error handling process. Resume If the resume function is turned ON in the process of retraction, the retraction is ignored even thought the preset input is turned on after power has been newly turned on.
Page 112: Hot Edit
11-8. Hot edit 11-8-1. What is “Hot edit”? It is a function to shift the position of a given welding point so that the step makes a parallel translation without stopping the robot operation. As this function is applicable to a running program as well as a program not in operation, it allows you to correct position of teaching points in case of deviation of works or teaching error without stopping the production line.
Page 113: Preliminary Settings
11-8-2. Preliminary settings Please set validity of this Hot Edit function and the maximum shift amount at each shift can be set Advance Click >> Controller setting >> >> >> Select “ Hot Edit ”. [Valid/Invalid]: When the “Invalid” is selected, icon won’t be displayed in Auto mode.
Page 114: Definition Of Shift Coordinate System
Select a desired shift coordinate system to be applied and input shift data. *See the <Definition of the shift coordinate system>. * Only the preset User’s coordinate system numbers are displayed on the screen. [OK] executes the shift processing ...
Page 115 (2) [Tool] [Tool coordinate system] When “Tool” is selected, teaching points are shifted along the X-axis, Y-axis and Z-axis on the tool coordinate system as per shown in the figure on the right. If the tool No. is changed in the program, such change is reflected and applied to the shift.
Page 116: Teach Pendant (Tp) Settings
12. Teach pendant (TP) settings 12-1. Coordinate system settings It is a function to specify a coordinate system to be used when operating the robot with the teach pendant. Click >> >> >> Select coordinate system [Cartesian] Switches motions of the Cartesian coordinate system.
Page 117 List of functions applicable as User function keys in each operation type EDIT （ Robot motion: OFF ） TEACH （ Robot motion: ON ） AUTO (None) (None) (None) … … … Change page Change page Change page Online Trace Override Wire/gas check Program test Arc lock...
Page 118: Robot Move Key
12-2-2. Robot move key It is a function that allows you to change coordinate system of the wrist motion. Click >> >> >> >> Robot move customize Select a wrist motion of a coordinate system you want to change from the list. (Press on the triangle to display the list.) ( *Figure on the left shows when the wrist motion of the Cartesian coordinate system is changed to “Tool”...
Page 119: Language Settings
12-3. Language settings It specifies the language to be used in menus, dialog boxes etc. (Japanese, English etc.) Click >> >> >> Another language [Select language] Specifies the menu language from the list. 12-4. Screen saver settings It is a function to lengthen service-life of the LCD by turning OFF the screen after a specified time duration of no operation. Click >>...
Page 120: Programming (Teach) Folder Settings
12-5. Programming (Teach) Folder settings This function allows the user to define the default folder in which teaching programs will be saved. Click >> >> >> Folder settings Edit folder Default folder (1) To edit a folder Corresponding User function icons appear next to the User function keys F1 to F3.
Page 121: Favorite Commands
12-6. Favorite commands It is a function to register frequently used commands as favorite command group. Click >> >> >> Edit favorite commands To add a command: Click the Add button to display the “Command list” dialog box. Select the command you want to add to the favorite command group, and click the OK button.
Page 122: System Information/Back Up Settings
13. System information/Back up settings 13-1. Error/Alarm history Click >> >> System Displays a history list of errors that have i nformation occurred. Error history Displays a history list of alarms that have Alarm occurred. history Alarm Error history Errors/alarms type: history Displays Input/Output...
Page 123 Saves a backup copy of a specified data in a specified file. Save Specify a desired “Save to” file name and click the OK button. [All data] To make a backup copy of all data in the controller. [Individual data] To specify data to make a backup copy individually. (See below table) Teach program All teach programs (except ArcStart and...
Page 124: Management Tool Settings
14. Management tool settings 14-1. User management settings Attention! Please make sure to remember your User ID and password. Remember the system monitors access. So DO NOT give out your user ID or Password. The robot is designed to administer all robot users individually. Registration of a User ID allows the robot to record data based on the user logged onto the system.
Page 125: Memory Clear
For deletion A message to confirm the action appears. Click the OK button to delete the specified user ID. (2) To set “Auto login” [Auto login Valid/Invalid]： Specifies if you want to Auto login make the function valid or invalid. When Invalid is selected [Display login screen at power on.］：...
Page 126: Date Settings
14-3. Date settings It sets date and time in the robot. Click >> >> >> Management Day/Time tool Errors, Alarms, etc. use this setting when they are an event. Please be sure to set up the appropriate time for your time zone. 14-3...
Page 127: Origin Re-Adjustment
14-4. Origin re-adjustment This function is to adjust the mechanical origin point of each axis of the manipulator to match with the origin of the controller (position of 0 degree). Standard position Use a ngle to adjust the origin of the (Main axis) manipulator.
Page 128: Teaching (Main Or External Axis)
14-4-3. Teaching (Main or External axis) Check the check-box of the axis you would like to adjust, and then click the Next button. Move the manipulator or external axis to the origin with manual operation and press the Enter key to update the values. Teach Teach (G#) (Main axis)
Page 129: System Settings
14-5. System settings The ‘System settings’ are settings that configure all equipment including the robot that comprises the system. You can also check, change or cancel the connection settings among the robot, external axis and optional equipment. Click >> >> >>...
Page 130: Add Optional Functions
14-5-2. Add optional functions It is a function for the settings necessary when you add an optional unit. <System settings screen> Click on the Add button to display the “Add option” dialog box. Specify an item you would like to add, and then click the OK button to register.
Page 131: Mechanism Settings
14-5-4. Mechanism settings What is “Mechanism”? By classifying all equipment including the robot and external axes that comprise the system into groups, it is possible to control each group separately, such as to assign a different task to each group or to isolate a specific group from operation.
Page 132: Auxiliary In/Out And Analog I/O
14-5-5. Auxiliary IN/OUT and Analog I/O With the Auxiliary IN/OUT unit or Analog I/O unit, it is possible to map correspond the Input/Output to optional equipment. With the Auxiliary IN/OUT unit, it is possible to increase the number of Input/Output terminals. With the Analog I/O unit, it is possible to convert the Input/Output signals to analog signals.
Page 133 (2) Changing number of units <System settings screen> On the System settings screen, click the Edit of ‘Auxiliary IN/OUT’ (or ‘Analog I/O’), and then click the OK button to display the ID setting dialog box 1) To change “Expansion IN/OUT” Enter the ID number of the last unit after the change (Last I/D number).
Page 134: Multi-Welders Settings
14-5-6. Multi-welders settings Different welder number is registered in each program. With this function a welder can be changed per program. Note This function is not available in following conditions. (1) The robot controller is GX type, which is the model with a built-in welding power source. (2) The system uses Robot coordinating function, MIG/TIG-FORCE or/and Spin arc sensor.
Page 135: Owner Entry
14-6. Owner entry Information on the robot owner is registered. Registered information will be utilized for field servicing activity. Click >> >> >> Management Owner entry tool 14-7. Log file Log file of robot internal system is made. The log file will be used for servicing purpose. Click >>...
Page 136: Arc Welding Machine Settings
15. Arc welding machine settings The settings available only for welding robots. (1) Controller with Built-in welding power source GX type robot controller has a following initial screen for arc welding settings. Click >> >> Set welder characteristics. Arc welding Rename the welder characteristics.
Page 137: Add A Welder
[Comm. port] Specify the port number the welder is connected to. [Comm. speed] Specify communication speed between the controller and welding machine. · Select 19200 if you use Panasonic welding machine YD-350GB1/YD-350GB2. · Select 9600 for other welding machines. Click the Initial comm. button.
Page 138 ◎ Procedures to add a welder [Select Welder] Specify communication type of the welder. · Select Analog . [Welder I/F card ID] Specify ID number of the welder I/F card. [Welder] Specify type of applied welder (i.e. “Unlisted (MIG)” for MIG welder or “Unlisted (TIG)” for TIG welder.) * Check the check box next to the “...
Page 139: Rename A Welder
15-1-2. Rename a welder Select the welder you would like to change name (or delete) and click the OK button. Click a welder name you want to rename, then a dialog box appear to type a new name. You can rename any defined welders freely. 15-1-3.
Page 140: Weaving Settings
15-1-5. Weaving settings It is to set the initial weaving parameters when a weaving teaching point is added. Weaving Set parameters and click the OK button. Select a Pattern [Weave FRQ] Set the weaving frequency. (Unit: Hz) [Amplitude timer (T1, T2)] Set how long the robot to move parallel to the main trace at each amplitude point.
Page 141: Override Settings
15-1-6. Override settings Single hand and both hand (default setting) are selectable, and increments and decrements of override are registered in the adjusting tables. Override Override settings Adjusting table for CO2/MAG welder Adjusting table for TIG welder Adjusting table for MIG Force (Subordinate) Adjusting table for MIG Force (Independent) Adjusting table for powder plasma (1) Override settings...
Page 142: Welder Data Settings (Co2 /Mag/Mig)
15-2. Welder data settings (CO2 /MAG/MIG) It is to set the parameters of each defined Panasonic welder. Click >> >> >> User specified Arc welding welder name [Over write] Check this item to edit the current settings. [Backup the current Welder and add a new Welder] Check this item to make a copy of the currently defined welder to add another welder.
Page 143: Adjust Value
15-2-2. Adjust value This function allows the user to calibrate the amperage and voltage of the welding machine if needed. [Current] Specify the correction amperage. [Set range: ± 50 A] Adjust value [Voltage] Specify the correction voltage. [Set range: ± 5.0 V] For both current and voltage, the adjust value is [ Input value] –...
Page 144 Start/End: HOTVLT: Specifies the hot voltage adjustment value.[Set range: -50 to +50] Increase the value to smoothen wire feed immediate after the arc start. Decrease the value to restrain the burn-back immediate after the arc start. WIRSLDN: Specifies the wire slow down speed adjustment value. [Set range: -125 to +125] Increase the value to shorten the time to generate arc.
Page 145 Pulse waveform: IP: Specifies the peak current level in pulsed welding. [Set range: -50 to +50] IB: Specifies the base current level in the pulsed welding. [Set range: -50 to +50] PFRQ: Specifies the pulse frequency level. [Set range: -7 to +7] PRISE: Specifies the rise angle level of the pulse wave.
Page 146: Unification/Individual
15-2-4. Unification/Individual It specifies how you want to set welding conditions. [Unification] Adjusts welding automatically according to Unification/ the welding table by setting welding current. Individual [Individual] Sets the welding current and voltage separately. 15-2-5. Weld conditions Welding conditions can be set easily by selecting a set of conditions preset in the weld condition table if the table is previously prepared.
Page 147: Arc Retry
15-2-7. Arc retry It is a function to be used if the welding machine failed to generate an arc at arc start. The robot automatically shifts its position to retry arc start action. [Re-start] Specifies whether to use this function (Valid) or not (Invalid).
Page 148: Restart Overlap
15-2-10. Restart overlap It is to automatically move the robot back a preset distance at restart after a hold state in order to restart welding by overlapping the weld bead. [Overlap length]: Specifies the overlapping length (or how long the robot should move backward) ［ 1 to 50 Restart mm ］...
Page 149: Weld Monitor
15-2-12. Weld monitor It monitors whether the actual welding conditions are within the set ranges or not. This function is useful to maintain and control welding quality. [Current]: Specifies whether to use this function ( Valid ) or not ( Invalid ). If valid, then specify the welding Weld current monitoring range.
Page 150: Flying Start
15-2-15. Flying start This function allows the robot to make a flying start of executing sequence commands for arc start or arc end to reduce tact time. [Flying start]: Specifies whether to use this function ( Valid ) or not ( Invalid ). [Arc start]: Specifies how much time in seconds the robot to execute arc start prior to the assigned time.
Page 151: Welder Data Settings (Tig)
15-3. Welder data settings (TIG) This section explains welder data settings when a Panasonic TIG welding machine is connected. Click >> >> >> User specified Arc welding welder name [Over write] Check this item to edit the current settings. [Backup the current Welder and add a new Welder] Check this item to make a copy of the currently defined welder to add another welder.
Page 152: Adjust Value
15-3-3. Adjust value It specifies the differences between the actual values of welding current and pulse frequency and their set values as the adjustment value respectively. [Current]: Adjustment value of current. [-50 to +50] Adjust value [FRQ]: Adjustment value of frequency [-5.0 to +5.0] 15-3-4.
Page 153: Electrode Contact Detection
15-3-7. Electrode contact detection It is a function to bring the robot to an error stop when the electrode and workpiece are short-circuited. ・ In welding operation, the robot detects “Electrode contact” when the voltage is lowered down to or below the preset Electrode ...
Page 154: Welder Data Settings (Powder Plasma Welding)15-19
15-4. Welder data settings (Powder plasma welding) This section explains welder data settings for Panasonic powder plasma welding machine. Click >> >> >> User specified Arc welding welder name [Over write] Check this item to edit the current settings. [Backup the current Welder and add a new Welder] Check this item to make a copy of the currently defined welder to add another welder.
Page 155: Powder Control
15-4-3. Powder control [Powder]: Feeding powder, (Yes), or no powder, (No). [Delay of motor on]: Time delay for feed motor start, (0.0 - 5.0)s Powder [Delay of main arc off]: Time delay for main power off, control (0.0-5.0)s [Output for powder warning]: Warning signal output terminal for lower powder level.
Page 156: Changing Analog Type Welder Settings
15-5. Changing Analog type welder settings This section explains welder data settings when analog type welding machines are connected. Click >> >> >> User specified Arc welding welder name [Over write] Check this item to edit the current settings. [Backup the current Welder and add a new Welder] Check this item to make a copy of the currently defined welder to add another welder.
Page 157: Commands
16. Commands 16-1. Move commands 16-1-1. MOVEC Format MOVEC [Position name] [Manual speed] Function Circular interpolation. Position name Teaching position type variable Lock condition Robot lock. Manual speed The robot travel speed toward this point. Syntax check None. Example Travel to the teaching point P3 with circular The same command in MOVEC interpolation at speed 7.5 m/min.
Page 158: Movelw
16-1-4. MOVELW Format MOVELW [Position name] [Manual speed] [Pattern No.] [Frequency] ([Timer]) Function Linear weaving interpolation. Position name Teaching position type variable Lock condition Robot lock. Manual speed The robot travel speed toward this point. Syntax check None. Pattern No. Weaving pattern (n).
Page 159: Input/Output Commands
16-2. Input/Output commands 16-2-1. IN Format IN [Variable]=[Terminal type] ([Terminal name]) Function Digital input. Variable The imported terminal value is assigned to (GB, LB). Import and signal status from I/O port to a variable name. Terminal type I/O terminal type (value or variable (GB, LB)) Terminal types I 4#, I 8#, I 16#, O4#, O8# and I 1#....1-bit input...
Page 160: Pulse
16-2-3. PULSE Format PULSE[Terminal type]([Terminal name]) T=[Time] Function Pulse output command. Terminal type Output terminal type (value or variable (GB, LB)). It inverts the port signal for a specified period of 1-bit input time. Terminal name Terminal label or number (value or variable (GB, LB)).
Page 161: Jump
16-3-4. IF Format IF [Factor1][Condition][Factor2] THEN [Execute1] ELSE [Execute2] Function Conditional branching. Factor 1 Comparison operator 1 Branch the next action according to If it is terminal type. It must be [Terminal type] the result of the condition test. + [Terminal No.] Terminal type: I 4#, I 8#, I 16#, O4#, O8# and O16#.
Page 162: Nop
16-3-7. NOP Format Function No operation. Use it to improve the legibility of the program. Condition Standard. Lock condition None. Syntax check None. Example The same command in conventional models 16-3-8. PARACALL Format PARACALL [File] [ON/OFF] Function Parallel execution of files. File Character string.
Page 163: Rem
16-3-10. REM Format REM [comment] Function Comment Comment Comment character string. Use it to add comments in a file for (max. 32 characters) easy understanding of the file. Condition Standard. Lock condition None. Syntax check None. Example Add a comment “Start welding”. REM Start welding 16-3-11.
Page 164: Wait_Ip
16-3-15. WAIT_IP Format WAIT_IP [Input port No.][Condition] [Input value] T=[Value] s I 1# ..1-bit input Function It stops operation until the condition is Input port No. Terminal type: I 4# ..4-bit input satisfied. If a time condition (T=) is I 8# ..
Page 165: Arithmetic Operation Commands
16-4. Arithmetic operation commands 16-4-1. ADD Format ADD [Variable] [Value] Function It adds a value to variable. Variable Variable whose value is to be referred to, and the calculated value is to be assigned to. Condition Standard (GB, LB, GI, LI, GL, LL, GR, LR, GD) Lock condition None Syntax check...
Page 166: Cos
16-4-5. COS Format COS [Variable][Data] Function It calculates a cosine value and Variable Variable the calculated value is to be assigns the result to specified assigned to. variable. (GR, LR) Condition Standard Data Calculation or variable (or the same type) (Unit: degree) Lock condition None...
Page 167: Getpos
16-4-9. GETPOS Format GETPOS [Variable] Function It saves the current robot orientation in position Variable Variable to save position value variable. (GD, GA, GP, P). Condition None. Lock condition None. Syntax check None. Example Save the robot position when the command is executed in GD001. GETPOS GD001 16-4-10.
Page 168: Set
16-4-13. SET Format SET [Variable 1] [Variable 2] Function It assigns a real number or variable to another Variable 1 Target variable variable. (GB,LB,GI,LI,GL,LL,GR,LR,GD,GT) Condition Standard. Variable 2 Assigned value or variable (of the same type). Lock None. condition Syntax check None.
Page 169: Sub
16-4-17. SUB Format SUB [Variable 1] [Variable 2] Function Subtraction of values of two specified variable Variable 1 Variable whose value is to be names. referred to, and the calculated value is to be assigned to. Condition Standard. (GB,LB,GI,LI,GL,LL,GR,LR,GD) Lock condition None.
Page 170: Welding Commands(Gmaw And Common Use)16-14
16-5. Welding commands(GMAW and common use) 16-5-1. ADJRST Format ADJRST Function To reset welding process fine adjustment to default values. Condition Weld package. Lock condition Arc lock (Internal execution). Syntax check None. Example ADJRST The same command in conventional models ADJRST Values to be reset are those changed from their default values using the following sequences.
Page 171: Arc-Set
16-5-5. ARC-SET Format ARC-SET AMP=[Amperage] VOLT=[Voltage] S=[Speed] Function It specifies welding conditions. Amperage Welding current. [1 – 999] A Condition Weld package. Voltage Welding voltage. [0.1 - 99.9] V Lock condition Arc lock (Internal execution, specify values.) Speed Welding speed. [0.01 - 120.00] m/min Syntax check None.
Page 172: Fttlvl
16-5-9. FTTLVL Format FTTLVL [Value] Function It adjusts the FTT voltage level. Value Fine adjustment value which will be added to the system set value. Increase the value to round the end of the wire. [-50 - +50] As a result it reduces chances of the wire stick. Executing +1 adjustment twice Decrease it to sharpen the end of the wire for does not result in +2.
Page 173: Iac
Shorted Time 16-5-14. IB Format IB [Base amperage] Function It adjusts base amperage. Base Panasonic fully digital welding amperage power sources: [-50 - +50] Condition Weld package. Other power sources: [-5 - +5] Lock condition Arc lock (Internal execution). Syntax check None.
Page 174: Init-Ib
INIT-IP +1 16-5-19. IP Format IP [Peak amperage] Function It adjusts peak amperage. Peak Panasonic fully digital welding amperage power sources: [-50 - +50] Condition Weld package. Other power sources: [-5 - +5] Lock condition Arc lock (Internal execution).
Page 175: Isc
16-5-22. ISC Format ISC [Value] Function It adjusts short-circuit amperage slope of the Value Fine adjustment value which will welding current waveform. be added to the system set value. [-3 - +3] Condition Weld package. Lock condition Arc lock (Internal execution). Executing +1 adjustment twice does not result in +2.
Page 176: Isl2
PENET +1 16-5-26. PFALL Format PFALL [Adjustment value] Function It adjusts the pulse fall angle. Value Panasonic fully digital welding power sources: [-50 - +50] Condition Weld package. Other power sources: [-5 - +5] Lock condition Arc lock (Internal execution).
Page 177: P-Hottm
16-5-31. PRISE Format PRISE [Adjustment value] Function It adjusts the pulse rise angle. Value Panasonic fully digital welding power sources: [-50 - +50] Condition Weld package. Other power sources: [-5 - +5] Lock condition Arc lock (Internal execution).
Page 178: Torchsw
16-5-33. TORCHSW Format TORCHSW Function It turns ON or OFF the torch switch. ON/OFF ON: to turn ON the torch switch. Condition Weld package. OFF: to turn OFF the torch switch. Lock condition Arc lock. Syntax check None. Example Turn ON the torch switch. The same command in OUTB OPORT#209=* conventional models...
Page 179: Wfed
16-5-38. WFED Format WFED [Feed rate] Function It sets wire feed rate. Feed rate Wire feed rate. [0.00 - 15.00] m/min Condition Weld package Lock condition Arc lock (Internal execution) Syntax check None Example Set wire feed rate to 10 m/min. The same command in WFED conventional models...
Page 180: Wldchk
16-5-42. WLDCHK Format WLDCHK [ON/OFF] Function It turns ON or OFF the weld check function (check ON/OFF Weld check flag. for abnormal welding). ON: to check. Condition Weld package OFF: no check. Lock Arc lock (Internal execution) condition Syntax None check Example WLDCHK OFF...
Page 181: Weld Commands（Low Pulse Mig
16-6. Weld commands （ Low pulse MIG ） 16-6-1. LPDELAY LPDELAY [Value] Format Function It finely adjusts low pulse start time. Value Fine time adjustment Condition [0.5 - 10.0] Hz Lock condition Arc lock (Internal execution). Syntax check None. Example Set the fine time adjustment to +1.
Page 182: Weld Commands（For Tig Welding
16-7. Weld commands （ For TIG welding ） 16-7-1. ACFRQ Format ACFRQ = [Frequency] Function It sets AC TIG frequency. Frequency Frequency [50 – 400] Hz Condition Lock condition Arc lock (Internal execution). Syntax check None. Set the AC TIG frequency to 70Hz. Example The same command in ACFRQ = 70 ...
Page 183: Ib_Tig = 100
16-7-5. CRATER_TIG Format CRATER_TIG Ib=[Base Amp] Ip=[Peak Amp] WF=[Filler spd] FRQ=[Frequency] T=[Timer] Function It sets crater welding conditions for TIG welding. Base Amp Base amperage. [1 – 999] A Condition Weld package. Peak Amp Peak amperage. [1 – 999] A Lock condition Arc lock (Internal execution, set values).
Page 184: Pduty_Tig
16-7-10. PDUTY_TIG Format PDUTY_TIG [Pulse width] Function It adjusts pulse width for TIG welding. Pulse width Pulse width. [5 - 95] % Condition Weld package. Lock condition Arc lock (Internal execution). Syntax check None. Example Set pulse width to 50%. The same command in PDUTY PDUTY_TIG 50 ％...
Page 185: Wmode_Tig
16-7-14. WMODE_TIG Format WMODE_TIG = [Weld method] [Wave mode] Function It sets welding method and the AC TIG wave Weld method Selection: [AC, DC or MIX] mode. Wave mode] Selection: [STD, Hard or Soft] Condition Lock condition Arc lock (Internal execution). Syntax check None.
Page 186: Weld Commands（Powder Plasma Welding）16-30 16-8-1. Arc-Set_Powd
16-8. Weld commands （ Powder plasma welding ） 16-8-1. ARC-SET_POWD Format ARC-SET_POWD Ib= [Base amp] Ip= [Peak amp] PF= [Powder] FRQ= [Freq] S= [Speed] Function It sets a powder plasma welding condition. Base amp Welding amperage base amperage at pulsed welding [5 - 200] A Condition Lock condition...
Page 187: Ib_Powd 20
16-8-5. IB_POWD Format IB_POWD = [Value] Function It sets base amperage for powder plasma Value Base amperage [5 – 200] A welding application. Condition Lock condition Arc lock (Internal execution). Syntax check None. Example Set the base amperage to 20A. The same command in conventional models IB_POWD 20...
Page 188: Plasmagas
16-8-10. PLASMAGAS Format PLASMAGAS [ON/OFF] Function It turns on or off the plasma gas. ON/OFF Plasma gas control Condition Lock condition Arc lock (Internal execution). Syntax check None. Example Turn on the plasma gas. The same command in conventional models PLASMAGAS ON 16-8-11.
Page 189: Shldgas
16-8-14. SHLDGAS Format SHLDGAS [ON/OFF] Function It turns on or off the shield gas. ON/OFF Shield gas control Condition Lock condition Arc lock (Internal execution). Syntax check None. Example Turn on the shield gas. The same command in conventional models SH LDGAS ON 16-8-15.
Page 190: Weld Commands （Mig､Tig-Force Application
16-9. Weld commands （ MIG ､ TIG-FORCE application ） 16-9-1. ARC-SET_TIGFC Format ARC-SET_TIGFC Ib=[Base Amp] Ip=[Peak Amp] WFb=[Base WFS] WFp=[Peak WFS] FRQ=[Frequency] S=[Speed] Function It specifies welding conditions for TIG Force. Base Amp Base amperage: [1-999] A Condition Using TIG-FORCE. Peak Amp Peak amperage: [1-999] A Lock condition...
Page 191: Wfacc
16-9-5. WFACC Format WFACC [Acceleration] Function It specifies acceleration time of wire feeding. Acceleration Acceleration time: Condition Using TIG-FORCE. [0.10 – 0.99] s Lock condition Arc lock (Internal execution) Syntax check None. Example WFACC 0.5 16-9-6. WFDCC WFDCC [Deceleration] Format Function It specifies deceleration time of wire feeding.
Page 192: Wfspeed
16-9-9. WFSPEED Format WFSPEED [Feed speed] Function It specifies wire feed speed. Feed speed Feed speed: Using MIG,MAG ､ TIG-FORCE. Condition [0.10 – 30.00] m/min Lock condition Arc lock (Internal execution) Syntax check None. Example WFSPEED 2.00 WFEED Forward on 16-9-10.
Page 193: Logic Operation Commands
16-10. Logic operation commands 16-10-1. AND Format AND [Variable] [Data] Function It carries out logical multiplication. Variable Variable whose value is to be referred to, and the calculated value is to be assigned to. Condition Standard. (GB, LB) Lock condition None.
Page 194: Swap
16-10-4. SWAP Format SWAP [Variable 1] [Variable 2] Function It swaps values of two variable names. Variable 1 Variable whose value is to be referred to, and the calculated value is to be assigned to. Condition Standard. (GB, LB, GI, LI, GL, LL, GR, LR, GD) Lock condition None.
Page 195: Tool
16-11-3. TOOL Format TOOL [Tool No.] Function It switches tools. Tool No. Applied tool No. and tool name. Condition Standard. Lock condition None. Syntax check None. Example Change tool to [1:STD]. The same command in TOOL conventional models TOOL 1:STD 16-12.
Page 196: Snssft-Off
16-13-2. SNSSFT-OFF Format SNSSFT-OFF Function It terminates sensor shift Condition Standard. Lock condition None. Syntax check None. Example Terminate sensor shift. The same command in SFTBUF=0 conventional models SNSSFT-OFF 16-13-3. SNSSFT-ON Format SNSSFT-ON Function It starts sensor shift Condition Standard. Lock condition None.
Page 197: Transbase
16-13-7. TRANSBASE TRANSBASE [Number] See application examples Format Function It registers the reference point for the rotary shift Number Reference point [1 – 3] Condition Touch sensor Priority: 1, 2, 3 Lock condition None. Syntax check None. Example Specify a reference point 1. TRANSBASE 1 · ...
Page 198: Snsgn
16-14-3. SNSGN Format SNSGN [Gain 1] [Gain 2] perpendicular Function It adjusts the sensor gain. Gain 1 Sensor gain to direction to both welding Condition Arc sensor and spin arc sensor and torch directions: [ -99 to +99] ％ Lock condition Arc lock (Internal execution) Gain 2 Sensor...
Page 199: Spnrev
16-14-6. SPNREV Format SPNREV [Spinning speed] Function It specifies spinning speed of the sensor. Spinning Selection: speed Condition Spin arc sensor 1:Low: 10Hz Lock condition Arc lock (Internal execution) 2:Middle: 30Hz Syntax check None. 3:High: 50Hz Change the spinning speed to the low. Example SPNREV 3:Low 16-14-7.
Page 200: Rstrev
16-15-3. RSTREV Format RSTREV [Ext axis] Function It adjusts the rotation angle. The value should be Ext axis Name of the external axis (rotary within -180 to +180. type). Condition A rotary type external axis is connected. Lock condition None.
Page 201: Arc-On/Arc-Off Sequences
16-16. ARC-ON/ARC-OFF sequences The following sequence commands are available only for welding robots. 16-16-1. CO2/MAG/MIG welding Welding start programs factory set at shipment ArcStart1 ArcStart2 ArcStart3 ArcStart4 ArcStart5 GASVALVE ON GASVALVE ON GASVALVE ON DELAY 0.10 DELAY 0.10 TORCHSW ON DELAY 0.10 DELAY 0.20 GASVALVE ON...
Page 202: Tig Welding
16.16.2. TIG welding Arc start/arc end sequences for CO2/MAG/MIG welding are factory registered at shipment. It is necessary to change the settings for TIG welding prior to teaching operation of TIG welding. TIG welding without filler Arc start program Arc end program GASVALVE ON TORCHSW OFF...
Page 203: Errors And Alarms
17. Errors and Alarms 17-1. Alarm codes * If the remedy doesn’t reset the error or alarm condition, consult our service office. Alarm Message Probable Cause Remedy code A4000 Over temperature Abnormal temperature rise is Turn OFF the power and allow the detected.
Page 204 Ext.1 IPM error Ext.1 Amp low-volt Error in controller or inclusion of noise. In case of a recurrent error, contact Ext.1 Servo Power error sales distributor or Panasonic A7130 Ext.1 Motor speed over Speed exceeds rated value. representatives. Ext.1 Current detect error Current exceeds rated value Ext.1 Position count over...
Page 205 Drift error occurred. A7240 Ext.2 Servo memory error In case of a recurrent error, contact Error in servo circuit. sales distributor or Panasonic Ext.2 Servo CPU timer error Error occurred between servo and representatives. Ext.2 Servo CPU Comm error main.
Page 206 Alarm Message Probable Cause Remedy code A9020 Sensor communication error Sensor detects receive command Turn off the power and remove the error or interruption error. cause of the error, and then newly turn on the power. A9030 Sensor power failure Sensor detects power failure.
Page 207: Error Codes
17-2. Error codes Error Message Probable Cause Remedy code E1010 Impossible to start Robot does not start. Check if start program is selected. Check if servo power is turned ON. E1020 Weaving parameter error Selected weaving pattern, speed, Correct (speed, frequency or frequency or timer is out of set range.
Page 208 Error Message Probable Cause Remedy code E1210 Overlap is not available Overlap at re-start will bring the robot Move the robot back to the to the preceding teaching point. preceding teaching point in trace operation before re-starting operation. E1220 Overlap failed The robot reached the preceding Turn off the power and then newly teaching point during overlap...
Page 209 Error Message Probable Cause Remedy code E2010 Sensing not possible. The input signal had been ON when Trace backward and then restart. the touch sensor command was Check the program structure. executed. The three reference points for rotary shift calculation have not been ...
Page 210 Error Message Probable Cause Remedy code E2220 Arc sensor: Data Error in controller, or inclusion of noise . Turn off the power, and newly turn communication it on. Power to the arc sensor is OFF. E2230 Arc sensor: Amp. Error Servo driver inside the spin controller Remove the cover of the spin is defective.
Page 211 Error Message Probable Cause Remedy code E4000 Over run The hard-limit switch input is activated With the overrun release mode, due to overrun. move the axis within the range. E4010 Safety-holder working Safety holder is activated due to Remove the cause of interference.
Page 212 Error Message Probable Cause Remedy code E6105 Ethernet Cable Disconnect Ethernet cable connection Check communication cable insufficient. connection. E6106 Ethernet IP address The specified IP address has already Check IP address settings. Duplicate been used to other equipment. E6107 Ethernet TCP Connect Error Unable to connect Ethernet card to Check the destination equipment.
Page 213: Welder Error Codes
17-3. Welder error codes Error codes start with “W” indicates either error occurred in the applied digital communication welding equipment or data communication error between the robot and the applied digital communication welding equipment. Error Message Probable Cause Remedy code ...
Page 214 Error Message Probable Cause Remedy code W0160 Water circuit error Received "Water circuit error" error from welding machine. Check welding machine. W0170 Weld Error: Cooling water Received "Cooling water circuit" circuit error from welding machine. ...
Page 215 Error Message Probable Cause Remedy code W0360 MIG Force buffer over Exceeded the processible number of Review the commands structure. MIG/TIG force commands at a time. Or add “DELAY” command between commands. W0361 TIG Force: Motor stop over Wire feed does not stop within the Check the TIG Force.
Page 216 Error Message Probable Cause Remedy code W0900 Welder comm. Err 0001 Error occurred while communicating Press the Cancel key to clear the error to welding machine. message. If the error occurred in operation Welder comm. Err 0002 Communication to welding machine mode, exit from Operation mode and is interrupted.
Page 217: Supplements
17-4. Supplements 17-4-1. Remedy of E1050 E1050 occurs when the actual axis position and the teaching position data do not match while the actual tool end position and the tool orientation match their teaching data. Probable causes Remedies In trace operation or operation, the robot moves Switch these points to PTP interpolation.
Page 218: E7Xxx (Load Factor Error)
17-4-2. E7XXX (Load factor error) Motor current of each axis of the manipulator is monitored during operation. Over duty (Average) E7000 The robot is stopped when over-current is detected. Excessive load Over duty (Peak) applied to the machinery elements (bearing or reduction gear) is the E7010 Motor over load error probable cause of the error.
Page 219: Overrun Release
17-4-5. Overrun release The robot is provided with software that monitors the operating range and stops the rbot operation when an axis reaches the soft-limit. However, if an arm moves beyond its soft-limit, the robot detects the overrun error of the arm electrically and shut off the servo power for safe operation.
Page 220: Appendix 18-1. Sample Programs
18. Appendix 18-1. Sample programs (1) Repeat a program for a preset times and then turn ON the lamp to end. Preconditions: Applied processing program: Prog0100.prg, Variable to store the program count: GB001, Lamp ON output terminal: Number of the program execution: 10 times.
Page 221 Supplement 1 You can specify the coordinate system the shift will be based on using the argument of the SHIFT-ON command. ROBOT Robot coordinate system TOOL Tool coordinate system USER User coordinate system Supplement 2 There are two ways to change settings of 3-D position global variable. (1) Use the menu: >>...
Page 222 Count the number of production by counting the number of execution of the processing program and a variable. assigned to Preconditions: Variable the production count is to be assigned to: GI001, Processing program: WORK01.prg Production count program ： Prog0001.prg １ CALL WORK01.prg Execute the processing program.
Page 223: Application Examples Of Cnvset
18-2. Application examples of CNVSET 18-2-1. How to add the command The procedure is the same as other sequence commands (starting from the Add command menu). Use the dialog box to add commands. It is in the arithmetic operation commands group. (1) Setting dialog box [Variable 1 or 2]: Select an element from the list.
Page 224 (4) Supplementary explanation Cut, Copy and Paste The following rules are applied when a sequence command which contains local position variable (P) is cut, copied and then pasted. When both programs have a move command of the same teaching point name. If a CNVSET command which contains a move command of the local position variable is cut or copied together with the move command, the local position variable of the CNVSET command changes its variable name when it is pasted in another program.
Page 225: Transbasv
18-3. Application examples of TRANSBASE/TRANSBASV * Both commands can be used when the touch sensor is used. * Use TRANSBASV command in case of using variable to specify the reference point for the rotary shift conversion. 18-3-1. How to add the command The procedure is the same as other sequence commands (starting from the Add command menu).
Page 226 (2) Supplementary explanation • If the triangle [P1’]-[P2’]-[P3’] won’t match its original form (the triangle [P1]-[P2]-[P3]), then the shifted teaching points are corrected with reference to the shifted reference points in ascending order so that the shapes of those two triangles match. (i.e.
Page 227: Teaching For Powder Plasma Welding
18-4. Teaching for powder plasma welding Arc start/arc end programs for CO2/MAG/MIG welding are factory registered at shipment. It is necessary to change those settings for powder plasma welding prior to teaching operation of powder plasma welding. 18-4-1. Teaching welding program The different point in teaching in powder plasma welding from CO2/MAG welding is that in powder plasma welding, it is necessary to ignite the pilot arc prior to starting welding operation.
Page 228: Powder / Gas Flow Check
18-4-2. Powder / Gas flow check Prior to operation, check if powder and gas flow properly. Place the mode select switch in the Teach position, and then turn ON the LED ( User function key). Then the motion function key shows the following icons. It feeds powder while holding it down.
Page 229: Sample Programs Of Palletizing
18-5. Sample programs of palletizing Operation: Pick up unloaded works and put in a pallet one by one in good order. Precondition: This sample program is a program to put the workpiece in a pallet one by one in good order using minimum teaching points. Therefore, the sample program abbreviated a program to pick up unloaded a work with “PICK-UP.prg”...
Page 230 Sample program 1 (Pallet01.prg ) Program Description TOOL 1:TOOL001 Specify a tool JUMP START Jump to START ● MOVEL P1 5.00m/min Specify the shunting point (Before insertion) ● MOVEL P2 5.00m/min Specify the inserting point ● MOVEL P3 5.00m/min Specify the row pitch (P2-P3 distance) ●...
Page 231: Sample 2
18-5-2. Sample 2 In this sample program, teach a user coordinate system Column taking the direction row as “X” and the direction of column Column pitch User coordinate system as “Y”. Specify the row pitch and column pitch with numerical Row pitch Work values.
Page 232: A Program To Calculate Distance Between Points18-13
18-6. A program to calculate distance between points A program to calculate distance between points by calculating differences of X, Y and Z of two points respectively, and then find the distance from the square root of sum of the squares of X, Y and Z. [ Equation: Program (PtoPlen.prg) The following is a program to calculate distance between points (point-1 and point-2) and then add the result to “GR001”.
Page 233: Sample Program Of Tw Seek
18-7. Sample program of TW seek Flow of the program: 1. A handling robot clamps a work and transfers the work to above the work inserting hole. 2. Then the robot stops and rotates the TW axis. 3. While rotating the TW axis, the sensor detect the work-and-hole matching position and send the detect signal to the robot.
Page 234: Eaxs_Sft-Off
18-8. Application example of EAXS_SFT-ON/EAXS_SFT-OFF A command that shifts position of the external axis(axes) between the EAXS_SFT-ON and EAXS_SFT-OFF commands. <Notes> This “External axis shift” command is applicable to a called program within the shift section. This “External axis shift” command is not applicable to a program called by PARACALL command. Make sure to use EAXS_SFT-ON and EAXS_SFT-OFF commands as a set.
Page 235: Application Example 2
18-8-2. Application example 2 A system to weld stiffening ribs to a pipe shape work. Deviation of the rib is measured using the touch sensor and then adjusted by shifting the angle of the positioner. < Notes > - Only the positioner is shifted while sensing the position of the rib.
Page 236: Application Example Of If-Arc
18-9. Application example of IF-ARC It applies different actions depending on whether or not the arc is generated. This command is useful to adjust the arc start timing in a system using a multi-cooperative robot control or two torches. 18-9-1. Application example: In a multi-cooperative robot control system, a program to start a weld start program when either the master robot or slave robot generates the arc.

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Ya-1na series Ya-1pa series

Panasonic VR2 Series Operating Instructions Manual

1 Structure

2 How to Use the Teach Pendant

3 Get Assistance While You Work (Help)

4 TEACH Mode

5 AUTO Mode

6 Useful File Edit Functions

7 View

8 Variable Settings

9 Input/Output Settings

10 Robot Settings

11 Controller Settings

12 Teach Pendant (TP) Settings

13 System Information/Back up Settings

14 Management Tool Settings

15 Arc Welding Machine Settings

Welder Data Settings (TIG)

16 Commands

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Summary of Contents for Panasonic VR2 Series