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The Lincoln Electric Company System 10 rev 10.21

TABLE OF CONTENTS

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ROBOTIC MENU
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SYSTEM 10

Table of Contents

Safety

Technical Specifications......................................................................................................................................6

Setup and Installation

Handling ..............................................................................................................................................................7Unpacking & Inspecting......................................................................................................................................9Lagging to Floor ................................................................................................................................................10Required Utilities...............................................................................................................................................11Table Surface / Mounting Tooling..................................................................................................................... 12

System Mastering

System 10 Special Quick Mastering Procedure................................................................................................. 13Mastering Procedure..........................................................................................................................................14RIA Operating Space.........................................................................................................................................15Layout................................................................................................................................................................16

Setup of the Tool Center Point

Tool Center Point...............................................................................................................................................17

System Operation and Programming

System 10 Operation..........................................................................................................................................23Sample Programs...............................................................................................................................................25Safety Network ..................................................................................................................................................26

Maintenance

Maintenance.......................................................................................................................................................28Common Error Codes........................................................................................................................................ 30

Torchmate and Collision Guard Options

Torchmate Appendix .........................................................................................................................................33Robot Payload and Collision Guard .................................................................................................................. 38


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ROBOTIC MENU
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Technical Specifications

Power Wave 455M/STT or 455M - Recommended Input Wire and Fuse Sizes for Maximum

Rated Output

Input VoltageFrequency

Type 75C CopperWire in ConduitAWG[IEC] sizes

(MM2)

Type 75C GroundWire in Conduit

AWG [IEC] sizes(MM

2)

Type 75C(Super Lag) orBreaker Size

(Amps)

208/60Hz 4(25) 6(16) 110

230/60Hz 4(25) 6(16) 100

460/60Hz 8(10) 10(6) 50

575/60Hz 10(6) 10(6) 40

Robot Controller Fanuc ArcMate R-30iA - Recommended Input Wire and Fuse Sizes


+10% -15%V1Hz

Type 75C CopperWire in ConduitAWG[IEC] sizes

(MM2)


AWG [IEC] sizes(MM

2)


(Amps)

460/60Hz 12(4) 10(6) 20

575/60Hz 12(4) 12(4) 15

Robot Controller Fanuc ArcMate R-30iA with PW355i - Recommended Input Wire andFuse Sizes


+10% -15%V1Hz

Type 75C CopperWire in Conduit

AWG[IEC] Sizes(MM2)


AWG [IEC] Sizes(MM2)


(Amps)

460/60Hz 6(14) 8(10) 60

575/60Hz 8(10) 10(6) 50

System Pneumatic Requirements: Turntables, Flash Screens, or any Peripheral device

Clean and Dry shop air 80psi minimum, 75 cfm

Recommended fuse sizes are based on the National Electric Code. Specifications are providedfor reference only. The end user is responsible for meeting all electrical codes and certifications.


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Handling

The System 10 is designed to be handled by forklift. Note fork locations below. Do not attempt to

lift the system by any other means.

FORK LOCATION

FORK LOCATION

FORK LOCATION


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Care should be taken when unloading from truck. Because the System 10 is an integrated systemwith minimal end-user set-up, components such as light towers and control buttons are mounted onthe outside of the cell and may be exposed and unprotected.

A typical System 10 weighs approximately 2550 lbs. See figure below for approximate systemcenter of gravity. Be sure to use forklift with appropriate capacity.

These figures assume the system is shipped with a Power Wave 455.

APPROXIMATE CG


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Unpacking & Inspecting

Before setting up and programming robot, be sure to unpack and identify all items. Be sure youhave received all items on the order. Any questions can be referred to your LECO Sales

Representative or Automation Project Manger.

Before receiving, make sure to inspect the system and all components for damage.


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Required Utilities

Below are the typical locations of the components that need utilities. Because these componentsmay vary between systems, be sure to reference the individual component utility requirements.

WELDING WIRE AND GAS

INPUT POWER

INPUT AIR


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Table Surface / Mounting Tooling

The System 10 table surface is shown below. The surface is 1/4 sheet with 2 x 2 structural tubingfor support. Although the table surface is reasonably flat and rigid, it is not a machined surface.

Additional support can be added by means of a customer supplied base plate. No pre-drilled holepatterns exist. If many tooling changes are expected, it is recommended that a common base platewith tapped holes and dowel holes be used (fixed to table tops) to facilitate in tooling changes.Lincoln Electric Automation can assist in a robot reach analysis to determine appropriate placementof parts and fixtures to maximize robot operating space. Before fixing tooling to table, it isrecommended that the customer verify that the robot can reach all welds.


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System 10 Special Quick Mastering Procedure

With a normal position of the robot in the System 10, the robots J1 zero position will be at zerodegrees. This ensures that the torch will not collide with any System 10 fencing or peripherals.

Follow the procedure on the next page. If the robot has been mounted in a non-traditional position,then the zero mastering position of the robot may be different from zero degrees. See the graphicbelow for illustration:


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Mastering Procedure

System 10 Quick Mastering Procedure

Software Version 6.40-1 and above

This procedure assumes the robot has been mastered and is in operational condition

with no faults.

This procedure assumes the operator is familiar with robot operation.

1. Create a program called Zero.2. To Create the modified zero point:

a. Record a point anywhere in space.b. Cursor to the [1] in the single line program you just created.c.

Press F5 (position).d. Press F5 again (repre) to change the representation of the point to joint.e. Key in the following values:

J1 = 0J2 = 0J3 = 0J4 = 0J5 = 0J6 = 0

3. Press F4 (done) when finished.4. While facing the front of the robot, carefully jog the robot to the left or right so that J1 is approximately 0 degrees.5.

At 10% speed, run the Zero program.6.

Menu.7. #0 (next page).8. #6 (system).9. F1 (type).

10.

#3 (master cal) - If master cal does not appear:a. menub. #0 (next page)c. #6 (system)d. F1 (type)e. #2 (variable)f. Cursor to Master_Enbg. Change the 0 to a 1h. Return to step 6 and continue

11. Select #5 (set quick master ref) then press enter.12. F4 (yes).13. Place a scribe on the robot pedestal casting that corresponds to the existing scribe on the rotating portion of J1.

14.The procedure is complete.


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RIA Operating Space

The System 10 is an RIA compliant cell as shipped from LECO. To maintain compliance, it is theend-users responsibility to train all operators, maintenance personnel, and all other personnel

involved with the system. Special attention should be given to pinch points. In order to complywith RIA regulations regarding pinch points, the System 10 can be taught in the T1 or T2 mode. Itis also imperative that the maintenance door be closed during teaching and Automatic PlaybackVerification (i.e. APV). You can teach with the pneumatic screens down; however torch and robotclearance must be verified prior to running in automatic production mode.


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Layout

EXTERIOR POP-UP ( DOWN )

PF10 ROBOTIC WIRE FEEDER

ROBOT CONTROLLER

PW455

SWING DOOR FOR MAINTENANCE

AM100IB/6S ROBOTINDICATING LIGHT TOWER SIREN

INTEGRATED OPERATOR PALM STATION

WORK TABLE

EXTERIOR POP-UP ( UP )

TORCHMATE /REAMER STAND


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Tool Center Point

Tool Center Point Six Point Method

Procedure 4.2 Setting Up Tool Frame Using the Six Point Method

Steps

1Press MENUS.2Select SETUP.3Press F1, [TYPE].4Select Frames.5To choose the motion group for the frame you are setting up in systems with multiple motion groups press F3,[OTHER], and select the group you want: Group 1, Group 2, Group 3, Group 4, or Group 5. The default motion groupis Group 1.6If tool frames are not displayed,press F3, [OTHER], and select Tool Frame. If F3, [OTHER], is not displayed,press PREV.7To display the settings for all the frames,press PREV repeatedly until you see a screen similar to the following.

NOTE: The maximum number of tool frames is set in the system variable $SCR.$MAXNUMUTOOL. Refer to

the FANUC Robotics SYSTEM R-J3 Controller Software Reference Manualfor more information.

8To set the numerical values to zero,move the cursor to the frame number and press F4, CLEAR.9Press F2, DETAIL.


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10To select a frame,

aPress F3, FRAME.

bType the desired frame number.

cPress ENTER.

11Press F2, [METHOD].12Select Six Point. You will see a screen similar to the following.

13To add a comment:

aMove the cursor to the comment line and press ENTER.

bSelect a method of naming the comment.

cPress the appropriate function keys to enter the comment.

dWhen you are finished, press ENTER.

NOTE Record the three approach points with the tool tip touching the same point from three differentapproach directions. The Tool frame will be inaccurate if the approach points face each other.

14Record the first approach point and the Orient Origin point:


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aMove the cursor to Approach point 1.

bJog the robot, in the WORLD coordinate system, so that the tool tip touches a reference point. The tool isaligned with the WORLD coordinate frame.

cPress and hold the SHIFT key and press F5, RECORD.

dMove the cursor to Orient Origin Point. ePress and hold the SHIFT key and press F5, RECORD.

15Define the +X Direction Point:

aMove the cursor to X Direction Point.

bChange the jog coordinate system to WORLD.

cJog the robot so that the tool moves in the +x direction by at least 250 mm.

16Define the +Z Direction Point:

aMove the cursor to Orient Origin Point.

bPress and hold the SHIFT key and press F4, MOVE_TO, to move the robot to the Orient Origin Point.

cMove the cursor to Z Direction Point.

dJog the robot in the +z (world) direction.

ePress and hold the SHIFT key and press F5, RECORD.

17Record the second approach point:



cJog the robot in the WORLD coordinate system +Z direction approximately 50 mm.

dMove the cursor to Approach point 2.

eRotate axis 6 (faceplate) in the JOINT coordinate system at least 90(but no more than 180) around the zaxis of the tool coordinates.


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fJog the robot in the WORLD coordinate system so that the tool tip touches the reference point used in Step14.

gPress and hold the SHIFT key and press F5, RECORD.

hJog the robot in the WORLD coordinate system +Z direction approximately 50 mm.

18Record the third approach point:



cJog the robot so that the tool moves in the +x direction by at least 250 mm.

dMove the cursor to Approach point 3.

eRotate axis 4 and axis 5 in JOINT coordinate system (no more than 90) about either the x or y axis of thetool coordinates.

fJog the robot in the WORLD coordinate system so that the tool tip touches the reference point used in Step14.

gPress and hold the SHIFT key and press F5, RECORD.

hJog the robot in the WORLD coordinate system +Z direction approximately 50 mm.

Figure 4-4 . Defining the Orientation of the Origin

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19To select the tool frame to use;press F5, SETIND. Type the number of the tool frame you want, and pressENTER. If the F5, SETIND softkey is not visible on your teach pendant, press PREV until it is visible.

-OR-

You can also select the frame by pressing and holding the SHIFT key and pressing the COORD key to displaythe Jog Menu.

NOTE You can also use the Jog Menu to select the number of the tool frame you want to use. Refer to

Section 2.3.7, Jog Menu, for more information.

20To move to a recorded position,press and hold the SHIFT key and press F4, MOVE_TO.

21Jog the robot in the frame you just taught.

If the TCP is correct, it will remain stationary during rotational moves. Go to Step 24.

If the TCP is not correct, it will not remain stationary during rotational moves. If the TCP is not correct, youneed to review your recorded positions. Go to Step 19.

22To move to a recorded position, move the cursor to the desired position, press and hold the SHIFT key and pressF4, MOVE_TO.

Checking the Tool Frame

23To check that the tool frame has been properly defined:

aMove the cursor to Orient Origin Point.

bPress and hold the SHIFT key and press F4, MOVE_TO, to move the robot to the orient origin point.

cPress COORD until Tool is displayed.

dRotate the TCP around the +x, -x, +y, -y, +z, and -z axes and visually verify that the TCP remains close to

the reference point. eIf the TCP does not remain close to the reference point, repeat Procedure 4-2 .

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Saving Frame Configuration

24To save the frames and related system variables to a file on the default device,

aPress MENUS.

bSelect FILE.

cPress F1, [TYPE].

dSelect File.

ePress F5, [UTIL].

fSelect Set Device.

gMove the cursor to the device you want and press ENTER.

hDisplay the tool frame screen.

iPress FCTN.

jSelect SAVE. This will save the frame positions and comments for all frames to the file, FRAMEVAR.SV,on the default device.

Display the SYSTEM Variables menu,

aPress MENUS. bSelect SYSTEM.

cPress F1, [TYPE].

dSelect Variables.

ePress FCTN.

f Select SAVE to save the tool frame positions and system variables.


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System 10 Operation

The System 10 is a standard robotic welding cell that incorporates two weld zones of operation.The two-zone design provides a flexible base for automating small and medium sized parts. The

compact, fully integrated cell features a comparatively large work area ready to receive a varietyof parts. System design features two, large metal pneumatic pop-up shields positioned on eitherside of the ArcMate100iB/6S robot for maximum ergonomic efficiency as an operator loads andunloads parts in the two separate work areas. The System 10 has been designed to meetANSI/RIA 15.06-99 specifications for workcell safety. The workcell enclosure provides acomplete cell barrier with a solid sheet metal weld flash barrier. This cell is configured with anintegrated palm station complete with operator controls and status indicating pilot lights.

Modes of Operation

The System 10 has two modes of operation that the operator will use to interface with the robot.These modes consist of a Program Mode and an Auto ( Production ) Mode. Refer to Table 1 toverify each condition that must be set in order to achieve a certain mode of operation. Refer toFigures 1 through 4 on page-24 to view pictures of the items discussed in Table 1.

Program Mode - The mode that a programmer will use to create or touch-up welding programsand program system peripheral devices. This mode will also be used for system start-up andvarious maintenance procedures.

Auto Mode - The mode used for production via the two front access doors for loading andunloading parts. Auto Mode is disabled when the maintenance door is open.

Table 1 Mode Conditions to Satisfy

Mode Robot Key MaintenanceDoor

Zone

Shields

Teach

Pendant

E-Stops Robot Position

Program T1 or T2 Closed N/A On Reset Any

Auto Auto Closed Closed Off Reset Home or at Opposite Station

WARNING: PRIOR TO OPERATION OF ANY PALM STATION PUSHBUTTON, VERIFY

CELL IS CLEAR. ROBOT MOTION CAN OCCUR.

Program Mode

To operate in Program Mode, the conditions must be met that have been established in Table 1.Prior to programming, verify that a Tool Center Point (TCP) has been established; refer to the"Start-Up and Installation" section of the manual. This mode will be used to program all partsand peripheral devices, as well as touch up existing programs. Review sample programs forprogramming examples and sequence.


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Auto (Production) Mode

To operate in the Auto Mode, the conditions must be met that have been established in Table 1.This will be the normal operating mode of the system. After all parts are programmed and welds

have been examined to meet specifications, the welding cell can be setup for continuous operationof the production cycle.

For example, after a part is loaded into Station 1, press and release the cycle start pushbutton.The zone shield will close. The robot will begin the welding sequence. While the robot is weldingthe part at Station 1, the zone shield at Station 2 will open indicated by the green light and partscan be loaded into Station 2. Press and release the cycle start pushbutton for Station 2 and thezone shield will close. When the welding cycle at Station 1 is complete, the robot will start thewelding cycle at Station 2. The amber light at Station 2 will be on, and the green light at Station 1will be on. Unload and reload Station 1 and the process continues. If the robot faults duringwelding, simply turn the fault reset switch to the reset position and wait for the fault to clear, then

press and release the cycle start push button. The robot will resume the program from the point offault.

Figures 1, 2, 3, 4: Palm Station, Robot Key Switch, Pendent E-Stop and On/Off, Door Switches showing adjustment slots.


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Sample Programs

During assembly of the System 10 five basic programs are written for use during production. Thefive programs are as follows; with actual robot teach pendant screen prints.

1. HOME :Safe point for robot2. RSR0001 :Designated program3. RSR0002 :Designated program

4. ZONE 1 :Program for Zone 15. ZONE 2 :Program for Zone 2

The HOME program is a one-line program that positions the robot at the center of the J1 axis, andback on the J2 axis in a safe position, indicated by both green lights being on. This is a safecondition, and the access doors may be opened.

HOME LINE 0 T2 JOINT 10%

1: J P[1] 100% FINE[END]

POINT ARCSTRT WELD_PT ARCEND TOUCHUP>

Robot Service Request (RSR) is a request for service from an external device (palm station orPLC). That request is a dedicated input to the robot. RSR0001 is referenced to Station 1 andRSR0002 is referenced to Station 2.

RSR0001 LINE 0 T2 JOINT 10%

1: CALL ZONE 1[END]



1: CALL ZONE 2[END]

POINT ARCSTRT WELD PT ARCEND TOUCHUP>

The RSR's will call a sub program, ZONE 1 or ZONE 2 respectfully. After a part program isdeveloped it must be inserted in the ZONE 1 or ZONE 2 programs. This is illustrated in thefollowing fields.

ZONE 2LINE 0 T2 JOINT 10%

1: CALL HOME2: CALL "CUSTOMER PROGRAM"3: CALL HOME[END]


ZONE 1LINE 0 T2 JOINT 10%

1: CALL HOME2: CALL "CUSTOMER PROGRAM"3: CALL HOME[END]



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Safety Network

Safety features have been integrated into the design of this system. Any attempt to defeat, modify,or change those features could result in injury.

The System 10 has a detailed safety circuit that is always active in the Auto (production) mode.There are five basic components to the safety fence circuit: the Front Access Zone ShieldSwitches, Station 1 Limit Switch, Station 2 Limit Switch, the Maintenance Door Switch, andRobot Home Switch. The purpose of the fence circuit is to protect the operator from injury causedby robot movement.

The operator may access a zone to load or unload parts only when the robot is at the oppositestation or in the home position, otherwise a fault condition will occur and the robot motion willstop. When the safety network is faulted, the system can be reset with the fault reset switch.Refer to the Error Recovery section for a complete description.

Error Recovery

Lowering a zone shield while the robot is at that station will cause a fault condition to occurindicated by the red indicator light. To recover; raise the shield via the teach pendant and activatethe fault reset switch.

To recover from an error during production, first determine the fault and correct if necessary.Once the fault is corrected, verify all conditions are satisfied for the AUTO mode, activate theFAULT RESET switch on the palm station, wait for the red light to go out on the light tower, andthen press and release the cycle start pushbutton. The robot will continue from its current position

to the next programmed point.

VERIFY PROGRAM IS AT PROPER LINE.

For example: A fault occurs during a welding routine and the operator identifies the fault on theTeach Pendant as an ARC START FAILURE. The following steps must be followed to recover:

1. Actuate the FAULT RESET Switch on the palm station.2. Wait for the alarm to clear and the red light to go out.3. Press and release the CYCLE START pushbutton.4. Observe robot recover and restart welding routine.5. Return to normal operation.

Indicator Status

The System 10 has integrated light towers above the operator palm stations to provide necessarystatus lights to the operator. The towers are necessary because the operator may not have a clearview into the cell, so the towers act as an external interface. Refer to Table 2 and Figure 5 for adescription of the light tower.


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Table 2 Light Tower Status

Color On Off

RED System Fault No Fault

AMBER System in Motion at Lighted Station No Motion

BLUE Swing Door Open Swing Door ClosedGREEN System ready at Lighted Station System not ready robot not at home

Figure 5 Light Tower Key


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Maintenance

This section provides maintenance guidelines for the system as a whole; however, it does notprovide maintenance guidelines for the systems individual components. Be sure to follow the

appropriate maintenance procedures for the different components in your system (robot, powersource, reaming station, etc.).

System 10 Specific Maintenance:

The zone shields on the System 10 should be inspected daily. The shield is guided by a linearbearing. If the shield does not open and close smoothly, it may be necessary to lubricate thebearings (use linear bearing grease).

Recommended Maintenance Schedule:

Daily Check cell and remove any object not required for safe operation.Check any exposed cables for defect.Check for loose connections or improper operation of cell function.Check welding torch for tip, nozzle, or cable wear. (May depend on application)

Weekly Verify the proper operation of all safety components.Test peripheral devices for proper operation.Clean robot, power source, operating cell, and all peripheral devices.

Monthly Inspect welding torch body and components.Inspect teach pendant cable.

Clean feeder assembly.

Six Months Change D-cell encoder batteries (with robot power on).


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Recommended Maintenance Schedule (Cont.)

Yearly Change CPU Lithium battery (with robot power on).

Every 3 Years Grease robot mechanical unit.

For detailed instructions on changing the batteries and greasing the robot, refer to the suppliedelectronic document robot manual CD-ROM. This CD contains all procedures and recommendedtechniques for robot maintenance and proper upkeep.


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Common Error Codes

The following error codes are commonly seen during the startup of new robotic systems. Refer tothe designated error code and remedy to clear any faults.

SYST-042 PAUSE DEADMAN defeatedCause:The mode switch was changed from T1 or T2 mode to AUTO mode and the DEADMAN wasalready pressed. The DEADMAN must be released when switching to AUTO mode.Remedy:Release the DEADMAN and press RESET.

SYST-043 PAUSE TP disabled in T1/T2 modeCause:The mode selector is in T1 or T2 and the TP ON/OFF switch is in the OFF position.

Remedy:Turn the TP ON/OFF switch to ON. Press RESET.

SRVO-001 SERVO Operator panel E-stopCause:The operator panel emergency stop push button is pressed.Remedy:Twist the operator panel emergency stop push button clockwise to release. Press reset.

SRVO-230 SERVO Chain 1 (+24v) abnormalCause:

Single chain 1 (+24V) failure occurred.Remedy:Menus, Alarm, F4 (res_ch1), F4 (yes) then press reset. Check all safety switches such as doorswitches, safety mats, and light curtains for proper operation. If this does not work, repair thecircuit of the chain 1 (+24V) on hardware.

SRVO-231 SERVO Chain 2 (0v) abnormalCause:Single chain 2 (0V) failure occurred.Remedy:Menus, Alarm, F4 (res_ch1), F4 (yes) then press reset. Check all safety switches such as door

switches, safety mats, and light curtains for proper operation. If this does not work, repair thecircuit of the chain 2 (0V) on hardware.

SRVO-232 SERVO NTED inputCause:Cell door switch is not in proper position to allow teach pendant operation.Remedy:

Check to make sure safety doors are in proper position. Refer to Table One.


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SRVO-233 SERVO TP OFF in T1,T2/Door openCause:Teach Pendant is disabled when mode switch is T1 or T2

Remedy:Change the TP Enable/Disable switch to ON then reset.

SRVO-234 WARN Deadman switch releasedCause:The teach pendant deadman switch is released.Remedy:This is just a notification.

SRVO-005 SERVO Robot overtravelCause:

Fuse FS2 on the amplifier control board has blown.Remedy:Check cell/robot wiring for any possible short circuit between 24VDC and ground and replacefuse.

SRVO-206 SYSTEM Deadman switch (SVEMG abnormal)Cause:The teach pendant deadman switch is released while the teach pendant is enabled and incorrectwiring on SVEMG is detected. However, the most likely cause for this problem is a bad teachpendant cable causing a blown fuse.Remedy:

Power off. Replace the teach pendant cable and check fuse FS1 on the amplifier control board.

SYST-005 WARN UOP is the master deviceCause:The attempted operation could not be done because the User Operator Panel is enabled.Remedy:Menus, 0 (next), system, F1 (type), Config, remote/local setup = remote.

SYST-003 WARN TP is enabledCause:The attempted operation could not be done because the teach pendant is enabled.

Remedy:Disable the teach pendant and try the same operation again.

SYST-012 WARN Not in remoteCause:Remote condition is not satisfied.Remedy:Menus, 0 (next), system, F1 (type), Config, remote/local setup = remote.


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SYST-015 WARN Robot Service Request failedCause:

RSR operation has failed by some reason. The most likely cause is an improper mode on thecontroller key switch. A missing, or incorrectly labeled program could also be at fault.Remedy:Refer to the error cause code. Use MENU to display the Alarm Log screen.

Power Wave Related Faults

ARC-045 Weld EQ Device is OFFLINECause:The PW455 has not yet established communication with the robot or there is a communicationproblem.

Remedy:If this fault can not be reset after a few moments pause between powering up the system, checkfor proper connection of the Arclink cable connected between the robot Devicenet board andPW455 Arclink connector. There are two wires in the Arclink cable; one white and one black.There should be continuity between pin A on the PW455 amphenol connector and the black wireon the Devicenet board and pin B on the PW455 amphenol and the white wire on the Devicenetboard. If connections are sound, the Devicenet board may be faulty. Also, check the status lightand note the error code that is being flashed. When calling for assistance, this code will be usefulin diagnosing the problem.

Welding Wire Will Not Inch

Cause:Most likely the water cooler is not turned on or supplying proper flow.Remedy:

Check the water cooler and make sure it is on. If a water flow sensor is used, confirm connectionsto contacts 9 & 11 of the terminal strip located on the outside front of the PW455. As atroubleshooting aid, you can jumper pins 9,10, and 11 of the terminal strip (located on the lowerfront of Power Wave) and check to see if machine operates normally (please see PW manual forterminal strip pin functions).


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Torchmate Appendix

The Torchmate option provides a cost effective, easy-to-use solution for automatic adjustment ofthe Tool Center Point (TCP). Torchmate automatically compensates for bent torch barrels and worn

contact tips to reduce weld defects and increase system productivity.

When you use Torchmate, you start with a system that is fully functional and has a properly definedTCP. Then, you set up Torchmate and master the TCP. After it is mastered, Torchmate can be usedat any time to check and adjust the TCP to compensate for problems such as a bent torch body.Since Torchmate is an executable program, it can be called either automatically (for example, every50 production parts) or manually, whenever desired.

When setting up Torchmate, the following procedures must be accomplished for proper option use.

1. Install the touch block on a stationary object in the robot workcell.

2.

Set up Torchmate tool frame.3. Calibrate the Torchmate TCP.4. Add Torchmate information to a program.

Touch Block Installation

1. Install the touch block on a flat, level surface well within the workcell. Allow space within thework envelope for a 250mm "edge search" along the robot WORLD x and y direction, andwithin the robot workcell.

2. Align the touch plant so that the edges are parallel to the robot WORLD frame. The touch placex, y, and z axes should be parallel to the robot x, y, and z axes.

a.

Loosen the M5 bolts until the touch plate moves freely.b. On the teach pendant, press the COORD key until you have selected the WORLD

coordinate system.c. Adjust the touch plate until its edges are parallel to the robot WORLD frame. Jog the

robot along the edges to check the alignment of the touch plate. It should be parallel tothe WORLD frame to within 0.5 mm from end to end.

d. Tighten the M5 bolts to secure the touch plate.e. Verify the alignment of the touch plate. It should be parallel to the WORLD frame

within 0.5 mm from end to end.

Set up of Tool Frame (TCP)

1. Refer to the TCP sectionof this manual for a detailed procedure to enter the TCP.2. For the System 10, the torch head must be configured such that the right side of the torch faces

towards the rear of the cell. Use the following robot angles as a general guideline.

J1 = 90 J2 = 45 J3 = -55

J4 = 60 J5 = -60 J6 = 0


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Torchmate Calibration

After you have defined the Torchmate tool frame, you must calibrate the tool center point (TCP).

You must do this to establish the Torchmate master TCP.

You do not always need to recalibrate the TCP when you replace a worn-out torch with anidentically new one. If the new torch is nested in the mount exactly like the original torch, thenrecalibration is not necessary.

1. Select the Torchmate tool frame and move to the origin.a. Press MENU.b.

Select SETUP.c. Press F1, [TYPE].d. Select Frames.

e.

If tool frames are not displayed, press F3, [OTHER], and select Tool Frame. If F3,[OTHER], is not displayed, press PREV. You will see a screen similar to the following.

SETUP Frames JOINT 10%

Tool Frame Setup/ Six PointX Y Z Comment

1: 5.6 -2.7 350.1 Tool Frame 12: 0.8 -3.3 350.9 Tool Frame 23: 1.0 -3.1 349.1 Tool Frame 34: 0 0 0 ***********5: 0 0 0 ***********

Active TOOL $MNUTOOLNUM[1] = 1[TYPE] DETAIL [OTHER] CLEAR SETIND

f. To select a tool frame to use, press F5 SETIND. Type the number of the tool frame thatcorresponds to the Torchmate tool frame, and press ENTER.

g. Press F2, DETAIL. You will see a screen similar to the following.

SETUP Frames JOINT 10% Tool Frame Setup/ Six Point

Frame Number 3X: 1.0 Y: -3.1 Z: 349.1W: 180.0 P: -45.0 R: 90.0

Comment: TOOL FRAME 3Approach point 1: USEDApproach point 2: USEDApproach point 3: USEDOrient Origin Point: USEDX Direction Point: USEDZ Direction Point: USEDActive TOOL $MNUTOOLNUM[1] = 1[TYPE] [METHOD] FRAME MOVE_TO RECORD


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h. Move the cursor to Orient Origin Point.i. Press and hold in the DEADMAN switch and turn the teach pendant ON/OFF switch to

ON.

WARNING: In step 1j, DO NOT press SHIFT and FWD. Otherwise, the robot will execute thecurrently selected program, causing unexpected results and movement.

j. Press and hold the SHIFT key and press F4, MOVE_TO. The TCP should be lined upwith the touch block pointer.

2. Select the Torchmate SETUP screen:a. Press MENU.b. Press SETUP.c. Press F1 [TYPE].

d.

Select Torchmate. You will see a screen similar to the following.

Torchmate Setup JOINT 10%1/14

1. Tool Number: 12. Input Signal: DI [26]3. Output Signal: DO [27]4.

X Y offset limit: 20 mm5. Z compensation: DISABLED6. Z offset limit: 5 mm7. Search speed: 15 mm/sec8. Search Start: 25 mm9.

Search start z: 36 mm10. Wire advance time: .150 sec11.

Wire retract time: .150 sec12. Wire speed: 250 IPM13. Starting PR [ ] number: 114. Reference position: RECORDED15. Error recovery method: PROMPT16.

Error output signal: DO [0]17. Touchup monitor: 0.00 hrs18. Collision monitor: DISABLED

[TYPE] MASTER ADVWIRE RETWIRE HELP

3. The values displayed are default values. If you want to change any of the values, move the

cursor to each item and set as desired. Either select an option from the displayed list of options,or type the appropriate number and press ENTER.4. To record the Reference Position, move the cursor down to Reference Position. Function keys

F3 and F4 will change to MOVE_TO and RECORD respectfully. Press and hold the SHIFT keyand press F4, RECORD.

5. To test wire advance, move the cursor up or down until function key F3 MOVE_TO, changes toADVWIRE. Move the robot away from the pointer and press F3, ADVWIRE.


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6. To test wire retract, move the cursor up or down until function key F4 RECORD, changes toRETWIRE. Press F4, RETWIRE.

7. Move the cursor back to Reference Position. Press and hold the SHIFT key and press F3,MOVE_TO, to move the robot to the reference position.

NOTE: Before mastering, the welding wire must be at nominal stickout. Typically, this is 1/2" -3/4" from the contact tip. You should use a new contact tip and verify the tool frame.

CAUTION: Make sure that the robot is at 100% jog speed; otherwise, an error will be displayed.

WARNING: In the next step, the robot will move. Make sure that unnecessary personnel andequipment are out of the workcell before continuing. Otherwise, you could injurepersonnel or damage equipment.

8. To find the master TCP, press and hold the SHIFT key and press F2, MASTER. The robot will

find the master positions and then move back to the reference position.

Programming Torchmate

Performing Torchmate adjustments can be accomplished by either of the two methods describedbelow:

Manually, by running the TM_ADJST macro. Automatically, by incorporating the Torchmate adjustment instruction into a teach pendant

program.

Manual operation1. Confirm that the welding torch is causing the problem.2. Select the Torchmate adjustment program, TM_ADJST.

a. Press SELECT.b. Press F1, [TYPE].c. Select All or Macro Programs.d. Move the cursor to TM_ADJST and press ENTER.

3. Verify that the robot has a clear path to the touch block.4. Place the robot in 100% override.5.

Press and hold the SHIFT and FWD keys while the robot runs the adjust routine.

Automatic operationTorchmate can be configured to operate within a production program or auto operation connected tothe User 1 pushbutton on the control panel. Torchmate instructions included in production programswill add time to production cycles and possibly over use the Torchmate option. It is recommendedto run Torchmate after any torch maintenance or collision. It will be helpful to run the option at thebeginning of any shift change as well. This will confirm accuracy of the system prior to the creationof production parts.


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To link the operation of Torchmate to either of the User pushbuttons on the control panel, followthe instructions below.1. Press MENUS.2. Select SETUP.

3.

Press F1 [TYPE].4. Select MACRO. Cursor to line 69 and you will see a screen similar to the following.

Macro Command JOINT 10% Instruction Name Program Assign69. [TorchMate Adjust] [TM_ADJST] SP [04]70. [ ] [ ] - - [ ]71. [ ] [ ] - - [ ]72. [ ] [ ] - - [ ]73. [ ] [ ] - - [ ]74. [ ] [ ] - - [ ]75. [ ] [ ] - - [ ]

[TYPE] CLEAR CHOICE

5. Place cursor on ASSIGN dashes and press F4, CHOICE.6. Select SP from the pop-up menu.7. Cursor to the empty number slot and type in number 4 for User PB #1, or 5 for User PB #2.

The robot will now execute Torchmate Adjust from the control panel when the associated User PBis depressed.

WARNING: Verify the robot has a clear path to the touch block or add additional programmed

points to clear any obstruction.

Insert the following instructions into a production program for the automatic execution ofTorchmate during production.


1: CALL HOME2: CALL ZONE_13: CALL HOME4: R[2]=R[2]+15: IF R[2]>=10, JMP LBL[1]

6: JMP LBL[2]7: LBL[1]8: TORCHMATE ADJUST9: R[2]=010: CALL HOME11: LBL[2][END]

POINT ARCSTRT WELD PT ARCEND TOUCHUP>


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Robot Payload and Collision Guard

1. Before setting up the payload of a robot for use with the Collision Guard option, using the

automatic method, the Payload ID option must first be installed in the robot. Payload ID canbe installed using one of two methods:

A. Install the Torch Guard option which includes the Torchmate, Collision Guard, andPayload ID options.

B. Install the Collision Guard and Payload ID options as two separate options.

2. Obtain the Fanuc factory test and inspection sheets which ship with the robot. Note at thebottom of first sheet is a section labeled Torque Margin Data. There are four system variablefiles shown in this section. Make note of two of these files:

$PLCL_GRP[ 1 ] . TRQ_MGN[ 5 ]$PLCL_GRP[ 1 ] . TRQ_MGN[ 6 ]

There will be a value after each of these two files. This value will be keyed into theappropriate system variable in the next step.

3. Power up the robot in the standard manner. Press Menus key, 0-next page, cursor to line 6System, Enter. Press F1-Type, cursor to line Variables, Enter. Cursor to line $PLCL_GRP,approximately line 270, see screen below:

With cursor on line $PLCL_GRP, press Enter. Screen below now appears:

SYSTEM\Variables 270/458

266 $PG_DEFSPD PG_DEFSPD_T267 $PG_MAX_SPED [5] of PGMAXSPD_T268 $PING_CTRL PING_T269 $PIPE_CONFIG PIPE_CFG_T270 $PLCL_GRP [5]\of\PLCL_GRP_T271 $PLID_GRP [5] of PLID_GRP_T272 $PLID_KNOW_M FALSE

[ TYPE ]

SYSTEM\Variables$PLCL_GRP 1/5

1 [1] PLCL_GRP_T2 [2] PLCL_GRP_T3 [3] PLCL_GRP_T4 [4] PLCL_GRP_T5 [5] PLCL_GRP_T

[ TYPE ]


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With cursor on line 1 press Enter. Screen below now appears:

Cursor to line 2: $TRQ_MGN [ 9 ] of REAL press Enter. Screen below appears:

Cursor to line 5 and key in the value that was attached to file $PLCL_GRP[ 1 ]TRQ_MGN[5 ], as noted on the Fanuc factory test and inspection sheet.

Cursor to line 6 and key in the value that was attached to file $PLCL_GRP[ 1 ] .TRQ_MGN[ 6 ], as noted on the Fanuc factory test and inspection sheet.

Press PREV key one time, move cursor to line 1 $CALIB_STAT and set its value to 1.

SYSTEM\Variables$PLCL_GRP[1] 1/2

1 $CALIB_STAT 02 $TRQ_MGN [9] of REAL

SYSTEM\Variables$PLCL_GRP[1].$TRQ_MGN 1/9

1 [1] 1.0002 [2] 1.0003 [3] 1.0004 [4] 1.0005 [5] 1.004

6 [6] .9417 [7] 1.0008 [8] 1.0009 [9] 1.000

4. Press the F1-Type key, cursor to line Motion, Enter. Screen below now appears, listing 10different payloads that can be setup:

MOTION\PERFORMANCEGroup1 1/10

No. PAYLOAD[kg] Comment1 6.00 [ ]2 1.86 [ ]3 6.00 [ ]4 6.00 [ ]5 6.00 [ ]6 6.00 [ ]7 6.00 [ ]8 6.00 [ ]9 6.00 [ ]10 6.00 [ ]Active PAYLOAD number = 2[ TYPE ] GROUP DETAIL ARMLOAD SETIND >


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Activate desired payload number, typically1, by pressing the F5-SETIND key, key in desirednumber, Enter. Note cursor is now on that payload line and at bottom of screen notes thatpayload number is active.

5. Armload must be set up before the payload can be set up. Press the F4-Armload key. Screenbelow appears:

MOTION/ARMLOAD\SET 2/2Group 1

1 ARM LOAD AXIS #1 [kg] 0.002 ARM LOAD AXIS #3 [kg] 12.00

[ TYPE ] GROUP DEFAULT HELP

Cursor to line 2 Arm Load Axis # 3 and key in the weight of the wire drive unit, approximately10.5 kg. A prompt will appear at the bottom of the screen noting path and change to the cycletime. Press the F4-YES key. Next, a prompt appears at the bottom of the screen to powerdown and up. Turn off robot, then turn back on. After power up, return to the payload set upscreen by pressing the Menus key, 0-next page, cursor to line Motion, Enter. Place cursor ondesired payload line.

6. Press the NEXT key, then press the F2-IDENT key. Screen below now appears:

MOTION/PAYLOAD\ID1/4

Group 1Schedule No[ 2]: [****************]

1 PAYLOAD\ESTIMATION *****Previous Estimated value (Maximum)Payload [Kg] : 1.86 ( 6.00)Axis Moment [Nm]J4: 7.78E+00 ( 1.57E+01)J5: 7.78E+00 ( 9.80E+00)J6: 4.73E+00 ( 5.88E+00)Axis Inertia [Kg cm^2]J4: 3.40E+03 ( 6.27E+03)J5: 3.40E+03 ( 2.16E+03)J6: 1.26E+03 ( 6.08E+02)

2 MASS IS KNOWN [NO ] 6.000[Kg]

3 CALIBRATION MODE [OFF]4 CALIBRATION\STATUS DONE

[ TYPE ] GROUP NUMBER EXEC APPLY >


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Line 1 Payload Estimation will be ******Line 2 Mass Is Known set to NOLine 3 Calibration Mode set to OFF

Line 4 Calibration Status set to DONE

7. Place robot arm in a typical home position. Turn off the teach pendant. Place AUTO/TEACHswitch in the AUTO position. Set speed to 100 % and verify Step mode is Off.

Cursor to line 4 Calibration Status and press F4-EXEC key. A new prompt appears at bottomof screen as shown below:

CAUTION: In the next step, Axis 5 and 6 on the robot arm now begin a slow rotation toa position 180 degrees from where they started and then they slowly return

to their original positions. Then they will repeat the same motion at a muchhigher speed.

The prompt notes robot will be moving, are you ready? ; press F4-YES key, motion begins.

MOTION/PAYLOAD\ID 4/4J5: 7.26E+00 ( 9.80E+00)J6: 4.22E+00 ( 5.88E+00)Axis Inertia [Kg cm^2]J4: 4.08E+03 ( 6.27E+03)J5: 4.08E+03 ( 2.16E+03)J6: 1.37E+03 ( 6.08E+02)



Robot moves and estimates. Ready?

YES NO

8. After the high speed movement has finished, press the F5-Apply key. A new prompt appearsat bottom of screen as shown below:




Path and Cycletime will change. Set it?

YES NO


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The new prompt notes that the Path and Cycle time will change; press F4-YES key.

A new prompt appears at bottom of screen noting load is over spec, as shown below:

Press F4-YES key to accept.




Load is OVER spec! Accept?YES NO

9. To view details of how the robot has automatically set up the payload, press PREV key andwith cursor on desired payload line, press the F2-Detail key. Following screen appears:

MOTION/PAYLOAD\SET 2/8Group 1

1 Schedule No[ 2]:[****************]2 PAYLOAD [kg] 1.49

3 PAYLOAD CENTER X [cm] 29.634 PAYLOAD CENTER Y [cm] -5.465 PAYLOAD CENTER Z [cm] 31.036 PAYLOAD INERTIA X [kgfcms^2] 0.007 PAYLOAD INERTIA Y [kgfcms^2] 0.008 PAYLOAD INERTIA Z [kgfcms^2] 0.00

[ TYPE ] GROUP NUMBER DEFAULT HELP

If it is necessary to repeat this procedure, first press the F4-Default key, then the F4-YES key toreturn the payload to original factory set payload settings.

10.

After the payload is calculated the robot must be cold started to lock in new settings. Powerdown the robot then power back up while holding in the SHIFT and RESET keys on theteach pendant.

11.After the Payload ID and Collision Guard has been set and if a dummy safety mount is beingused on the end of the robot arm, disable the Hand Broken signal by pressing Menus key, 0-next page, cursor to line System, Enter. Press F1-Type, cursor to line Config, Enter. Cursor toapprox. line 36 Hand Broken, onto the word Groups and press Enter. Set to disable bypressing the F-key for disable.


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Collision Guard

The Collision Guard option provides a highly sensitive method to detect that the robot hascollided with an object and then stops the robot immediately. This helps to minimize the potential

for damage to the end-of-arm tooling and robot.

Collision Guard also helps to prevent damage during teaching.

The ability to disable the option selectively allows you to use it when some disturbances areapplied to the robot, as long as you can predict in your program when these disturbances willoccur.

Collision Guard is in effect both during jogging motion and programmed motion whenever it isenabled.

There are several ways to configure and adjust Collision Guard:

The Collision Guard Setup screen allows you to enable and disable Collision Guard globally,for both programmed motion and jogging motion.

In addition, you can use this screen to adjust the sensitivity of collision detection forprogrammed motion.

Collision Guard automatically uses more sensitive limits for jogging motion. These limits can

not be adjusted. You can still disable Collision Guard for jogging motion, using the CollisionGuard SETUP screen.

Within a teach pendant program, you can disable Collision Guard locally through the use ofspecial teach pendant instructions, COL DETECT OFF and COL DETECT ON.

Collision Guard Adjust Macro

You can use the Collision Guard Adjust macro program, CG_ADJST, to set the Collision Guardsensitivity during program execution. You must use the CG_ADJST macro program with thesensitivity macro register, usually register 1.

The sensitivity macro register is a register that contains the Collision Guard setting value. Thesensitivity value is a value from 1% to 200%, where 1 is the least sensitive.

Adjusting Collision Guard within a Program

To adjust Collision Guard sensitivity within a program, do the following:

1. Verify that CG_ADJST macro is added to the macro table. Software default loads the macrointo the table as item 97.

2. Verify that the sensitivity macro register number has been set. Factory set to register 1.


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Add the following instructions to your program each time you want to set the Collision Guardsensitivity.

A register assignment instruction- to assign the sensitivity value you want to the sensitivity

macro register that is specified in the setup screen (usually register 1). A macro instruction - CG_ADJST, to run the Collision Guard macro program.

TEST_PRG JOINT 10%

7: R[1] = 1258: CG_ADJST

Use the following steps to enter line seven into your program:

1.

Press NEXT.2.

Press F1 for INST.3. Select REGISTERS.4. Select = 5. Key in 1 for the register number.6. Select constant then enter the value that is desired for sensitivity.

Use the following steps to enter line eight into your program:1. Press NEXT.2. Press F1 for INST.3. Select Macro, press enter.

4.

Select CG_ADJST, press enter.

NOTE: It is recommended to use the CG_ADJST macro only after motion instructions that usethe FINE termination type.

Manual Adjusting of Collision Guard

Collision Guard can be manually adjusted by setting the sensitivity value on the Collision Guardsetup screen. A nominal value can be determined to satisfy both air and welding movements toprotect the torch and torch brackets.

CG_ADJST JOINT 10%COL\GUARD\SETUP

Collision guard status ENABLEDSensitivity 130%Sensitivity Macro Reg R [ 1 ]

Documents

System 10