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Part Number: 144075-1

Release Date: December 31, 2000
Document Version: 2
Document Status: Final
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section Page
1 INTRODUCTION
1.1 About this Document .....................................................................................1-1
1.2 Reference to Other Documentation................................................................1-1
1.3 Customer Service Information .......................................................................1-1
2 SAFETY
2.1 Introduction ...................................................................................................2-1
2.2 Standard Conventions....................................................................................2-2
2.3 General Safeguarding Tips.............................................................................2-4
2.4 Mechanical Safety Devices.............................................................................2-4
2.5 Installation Safety ..........................................................................................2-5
2.6 Programming Safety......................................................................................2-5
2.7 Operation Safety ............................................................................................2-6
2.8 Maintenance Safety........................................................................................2-7
3 COMARC FUNCTION
1 Installation ....................................................................................................1-1
2 Wiring............................................................................................................2-1
3 Arc Sensor Function ......................................................................................3-1
4 Registration of Instructions ...........................................................................4-1
5 Measurement and Registration of Sensing Conditions ..................................5-1
6 ComArc Condition File ...................................................................................6-1
7 Modification of the Settings in ComArc Function...........................................7-1
8 Phase Compensation Value ...........................................................................8-1
9 Instruction List ..............................................................................................9-1
10 Parameter List .............................................................................................10-1
11 Alarm Message List .....................................................................................11-1
APPENDIX A COMARC III SUPPLEMENT
MOTOMAN i ComArc Function

NOTES
ComArc Function ii MOTOMAN

SECTION 1
INTRODUCTION
1.1 About this Document
This manual provides instructions for ComArc Function and contains the
following sections:
SECTION 1 – INTRODUCTION
General information about this manual, a list of reference documents, and
customer service information.
SECTION 2 – SAFETY
Provides information for the safe use and operation of Motoman products.
SECTION 3 – COMARC FUNCTION
Provides detailed instructions to utilize the ComArc Function.
APPENDIX A – COMARC III SUPPLEMENT
Provides set-up parameters and instructions for programming a dual ComArc
configuration.
1.2 Reference to Other Documentation

For additional information refer to the following:
• Concurrent I/O Parameters Manual (P/N 142102-1)
• Operator’s Manual for General Purpose (P/N 142099-1)
• Operator’s Manual for Handling (P/N 142100-1)
• Operator’s Manual for Spot Welding (P/N 142101-1)
• Operator’s Manual for Arc Welding (P/N 142098-1)
• Motoman UP6, XRC Manipulator Manual (P/N 142104-1)
1.3 Customer Service Information

If you are in need of technical assistance, contact the Motoman service staff at
(937) 847-3200. Please have the following information ready before you call:
• Robot Type (UP6, SK16X, etc.)
• Application Type (welding, handling, etc.)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of XRC controller)
MOTOMAN 1-1 ComArc Function

INTRODUCTION
NOTES
ComArc Function 1-2 MOTOMAN

SECTION 2
SAFETY
2.1 Introduction
.
It is the purchaser's responsibility to ensure that all local, county,

state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
MOTOMAN 2-1 Comarc Function

SAFETY
2.2 Standard Conventions

This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
• NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE: Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.
Comarc Function 2-2 MOTOMAN

SAFETY
2.3 General Safeguarding Tips

All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4 Mechanical Safety Devices

The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware of
the various national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following safety
measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.

SAFETY
2.5 Installation Safety

Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing federal,
local, and state laws and regulations. Additional safety measures for personnel and
equipment may be required depending on system installation, operation, and/or
location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
2.6 Programming Safety

equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the MRC controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special
passwords. Special passwords are for Motoman use only. YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.

SAFETY
• Inspect the robot and work envelope to be sure no potentially hazardous

conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.
2.7 Operation Safety

equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
must have the teach pendant when they enter the cell.
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.

SAFETY
2.8 Maintenance Safety

equipment must understand potential dangers of operation. Maintenance tips are
as follows:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
must have the teach pendant when they enter the cell.
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).

YASKAWA
YASNAC XRC OPTIONS

INSTRUCTIONS
FOR ARC SENSOR COMARC FUNCTION
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN SETUP MANUAL
MOTOMAN-!!! INSTRUCTIONS
YASNAC XRC INSTRUCTIONS
YASNAC XRC OPERATOR’S MANUAL
YASNAC XRC OPERATOR’S MANUAL for BEGINNERS
The YASNAC XRC operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
YASKAWA MANUAL NO. HW9482786 1

MANDATORY
• This manual explains the arc sensor COMARC function of the YASNAC
XRC system and general operations. Read this manual carefully and be
sure to understand its contents before handling the YASNAC XRC.
• General items related to safety are listed in Section 1: Safety of the

Setup Manual. To ensure correct and safe operation, carefully read the
Setup Manual before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.
ii
NOTES FOR SAFE OPERATION
Read this manual carefully before installation, operation, maintenance, or inspection of the
YASNAC XRC.
In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”
“MANDATORY,” or ”PROHIBITED.”
Indicates a potentially hazardous situation which, if not avoided,

WARNING could result in death or serious injury to personnel.
Indicates a potentially hazardous situation which, if not avoided,

CAUTION could result in minor or moderate injury to personnel and dam-
age to equipment. It may also be used to alert against unsafe
practices.
Always be sure to follow explicitly the items listed under this

M A N D A T O R Y heading.
PROHIBITED Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
N OT E To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING”.
iii
WARNING
• Before operating the manipulator, check that servo power is turned off
when the emergency stop buttons on the playback panel or program-
ming pendant are pressed.
When the servo power is turned off, the SERVO ON READY lamp on the
playback panel and the SERVO ON LED on the programming pendant are
turned off.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
the servo power ON
Injury may result from unintentional or unexpected manipulator motion.

TURN
Release of Emergency Sto
• Always set the Teach Lock before entering the robot work envelope to
teach a job.
Operator injury can occur if the Teach Lock is not set and the manipulator is started from
the playback panel.
• Observe the following precautions when performing teaching operations

within the working envelope of the manipulator:
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the manipulator’s work envelope

and that you are in a safe location before:
- Turning on the YASNAC XRC power
- Moving the manipulator with the programming pendant
- Running check operations
- Performing automatic operations
Injury may result if anyone enters the working envelope of the manipulator during opera-
tion. Always press an emergency stop button immediately if there are problems.The
emergency stop button is located on the right side of both the YASNAC XRC playback
panel and programming pendant.
iv
WARNING
• Since detected voltage (200V), welding current, and welding voltage are
applied to the starting point detecting unit, install the unit securely so
that it does not fall.
Failure to observe this warning may result in an electric shock or damage to the unit.
• Before connecting the inter-unit cables and the welding cables, be sure
to turn OFF the power supply to the XRC and the welder.
Failure to observe this warning may result in an electric shock.
• Special attention should be paid during starting point detection, since

200 VDC is applied across the wire and the workpiece (welding jig).
• Do not place any object directly on the cable of the starting point
detecting unit.
Failure to observe this warning may result in an injury or damage caused by the discon-
nection of the cable.
• Attach the cable of the starting point detecting unit for the wire feeder
with the wire stand, to protect it from robot movement. If interference
between the cable and the peripheral devices can not be avoided, cover
the cable with a rubber plate or spiral tube, etc.
Failure to observe this warning may result in an electric shock, an injury, or damage to the
cable.
• Do not lay the cable of the starting point detecting unit directly on the
floor, but install them in a pit or duct or attach the cable with a protec-
tive cover.
Failure to observe this warning may result in an injury or damage to the cable.
• Since a high current flows through the welding cable, separate it from
the cables of the control circuit system. If the cables can not be sepa-
rated, take preventative measures such as using metallic ducts or tubes
on the cables of the control circuit system.
v
CAUTION
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the XRC cabinet
after use.
The programming pendant can be damaged if it is left in the manipulator’s work area, on
the floor, or near fixtures.
• Correctly fix the connector at the starting point detecting unit end of
the inter-unit cable by fully pushing it into position and tightening the
coupling nut.
• The other cables are connected to the terminal stand. Fully tighten the
terminal screws to correctly fasten the cables.
Failure to observe this caution may result in an injury, damage, or an electric shock.
• After connecting the cables, correctly attach the terminal covers on the
starting point detecting unit and welder.
Failure to observe this caution may result in an electric shock.
• Read and understand the Explanation of the Alarm Display in the setup
manual before operating the manipulator.
Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the playback panel, the programming pen-
dant, and supply cables.
The MOTOMAN manipulator is the YASKAWA industrial robot product.
In this manual, the equipment is designated as follows.
Equipment Manual Designation
YASNAC XRC Controller XRC
YASNAC XRC Playback Panel Playback Panel
YASNAC XRC Programming Pendant Programming Pendant
vi
Descriptions of the programming pendant and playback panel keys, buttons, and displays are
shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters printed on them are
Pendant denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them are
not denoted with [ ] but depicted with a small picture.
ex. page ke
The cursor key is an exception, and a picture is not
shown.
Axis Keys “Axis Keys” and “Number Keys” are generic names
Number Keys for the keys for axis operation and number input.
Keys pressed When two keys are to be pressed simultaneously,

simultaneously the keys are shown with a “+” sign between them,
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming pendant is

denoted with { }.
ex. {JOB}
Playback Panel Buttons Playback panel buttons are enclosed in brackets.

ex. [TEACH] on the playback panel
Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • " means that the
cursor is moved to the object item and the SELECT key is pressed.
vii
viii
1 Installation
1.1 Floor-mounted Standard Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.2 Floor-mounted Slim Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Side-by-side Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Current Detecting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2 Wiring
2.1 Connection Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3 Arc Sensor Function

3.1 Basic Understanding of the Arc Sensor . . . . . . . . . . . . . . . . . . . . .3-1
3.1.1 Left and Right Path Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.1.2 Up and Down Path Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.3 Applicable Range of the Arc Sensor . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.2 Main Operations for the Arc Sensor Function . . . . . . . . . . . . . . .3-3
" Job Preparation for Welding and Adjustment of
Welding Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
" Registration of Arc Sensing Instructions . . . . . . . . . . . . . . . . . . . .3-3
4 Registration of Instructions
4.1 COMARCON (Sensing Start Instruction) . . . . . . . . . . . . . . . . . . . .4-1
4.2 COMARCOF (Sensing End Instruction) . . . . . . . . . . . . . . . . . . . . .4-3
4.3 COMARCSET (Sensing Condition Change) . . . . . . . . . . . . . . . .4-4
5 Measurement and Registration of Sensing Conditions

5.1 Job for Measuring Sensing Conditions . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Measurement of Sensing Conditions . . . . . . . . . . . . . . . . . . . . . . . .5-2
5.3 Registration of Sensing Conditions . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.4 Adjustment of Sensing Conditions . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5.5 Results of Arc Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
6 COMARC Condition File

6.1 COMARC Condition File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 File Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.1 Display of a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.2 Editing of a File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
" Editing of “CORRECTION SELECT” and “CONDITION” . . . . . . .6-3
" Editing of Other Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.3 Initialization of the File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
ix
7 Modification of the Settings in COMARC Function
8 Phase Compensation Value
8.1 Job Preparation for Measurement of Phase
Compensation Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2 Measurement and Registration of a Phase
Compensation Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
9 Instruction List
10 Parameter List
11 Alarm Message List
x
1 Installation
WARNING
• Since detected voltage (200 V), welding current, and welding voltage
are applied to the starting point detecting unit, install the unit securely
so that it does not fall.
Failure to observe this warning may result in an electric shock or damage to the unit.
The starting point detecting unit should be installed outside of the manipulator interference
area.
For installation methods of a starting point detecting unit and a current detecting unit, refer to
the diagrams of each type.
1-1
1.1 Floor-mounted Standard Type
1.1 Floor-mounted Standard Type
The floor-mounted standard type should be installed on the side of the welder.
When installing a floor-mounted standard type on a welder or another device, attach the unit
securely with a fixing jig to the 4-M6 tapped mounting holes on the side of unit to prevent the
unit from falling.
350
35)
400
Side view of starting point detecting unit

450
4-M6 tapped holes

300 75
20
Fig. 1 Floor-mounted Standard Type Installation (Dimensions in mm)
1-2
1.2 Floor-mounted Slim Type
1.2 Floor-mounted Slim Type
To prevent the unit from falling, weld the bracket at the bottom of the starting point detecting
unit to the common base, or drill holes on the bracket to attach the unit with anchor bolts.
170 370
600
Anchor bolts Fix by welding or bolting
Fig. 2 Floor-mounted Slim Type Installation (Dimensions in mm)
1.3 Side-by-side Type
The starting point detecting unit should be attached to a welder with eyebolts on the top of the
welder.
Eyebolt
300
15
150
D=350
Fig. 3 Side-by-side Type Installation (Dimensions in mm)
1-3
1.4 Current Detecting Unit
1.4 Current Detecting Unit
Attach the unit securely to the mounting holes (4-φ5).
200
130
230
250
100 150
4- 5
+ cable
Current detecting cable
1-4
2 Wiring
WARNING
• Before connecting the inter-unit cables and the welding cables, be sure
to turn OFF the power supply to the XRC and the welder.
• Special attention should be paid during starting point detection, since

200 VDC is applied across the wire and the workpiece (welding jig).
• Do not place any object directly on the cable of the starting point
detecting unit.
Failure to observe this warning may result in an injury or damage caused by the discon-
nection of the cable.
• Attach the cable of the starting point detecting unit for the wire feeder
with the wire stand, to protect it from robot movement. If interference
between the cable and the peripheral devices can not be avoided, cover
the cable with a rubber plate or spiral tube, etc.
Failure to observe this warning may result in an electric shock, an injury, or damage to the
cable.
• Do not lay the cable of the starting point detecting unit directly on the
floor, but install them in a pit or duct or attach the cable with a protec-
tive cover.
Failure to observe this warning may result in an injury or damage to the cable.
• Since a high current flows through the welding cable, separate it from
the cables of the control circuit system. If the cables can not be sepa-
rated, take preventative measures such as using metallic ducts or tubes
on the cables of the control circuit system.
2-1
CAUTION
• Insert the inter-unit cable on the starting point detecting unit side,
firmly to the connector, and fix it securely by tightening the coupling
nut.
• Fix the other cables connected to the terminal stand securely by tight-
ening the terminal screws.
Failure to observe this caution may result in an electric shock, an injury or damage
caused by malfunctioning.
• After connected, be sure to reinstall the terminal covers of starting

point detecting unit and welder.
Failure to observe this caution may result in an electric shock.
Wire the unit in the following manner, referring to Figs. 4 and 5.
Starting Point Detecting Unit

1. Connect the starting point detecting unit to the XRC.
2. Connect the plus terminal of the starting point detecting unit to the plus terminal of the
welder.
3. Connect the minus terminal of the starting point detecting unit to the torch power sup-
ply unit on the wire feeder.
4. For the floor-mounted standard type and the floor-mounted slim type, connect the front
terminal stand of the starting point detecting unit to the welding voltage detecting termi-
nal on the wire feeder.
For the side-by-side type, connect the front terminal stand of the starting point detect-
ing unit to the terminal stand inside the welder.
2-2
• Floor-mounted type (standard and slim types)
XRC
Welder
Starting point
detecting unit
Welding cable
Inter-unit cable
1CN XCP02 board
SE1
To the torch
E SE2 To the welder
To the workpiece side To the wire
feeder Cable for welding voltage detection
Ground cable
• Side-by-side type
XRC
Welding cable
Starting point
Welder detecting unit
Inter-unit cable between
the unit and the XRC
1CN XCP02 board
To the wire feeder

To the workpiece side
Inter-unit cable between

the welder and the unit
Fig 4 Diagram of Start Point Detecting Unit
Side-by-side type start point detecting unit

SUPPLE
-MENT
DAIHEN: CPVY-350
NASTOA: Inverter Ace 350Y
MATSUSHITA: YD-350RFG10, YD-200RFG10
2-3
Current Detecting Unit
1. Connect the connection cable of current detecting unit to the XRC.
2. Connect the plus cable of the current detecting unit to the + terminal of the welder.
Connect the other cable to the welding cable from the torch power supply unit on the
wire feeder.
• Current detecting unit

XRC
Welder
Current detecting unit
XCP02 bpard
To the workpiece To the wire feeder

side
Fig 5 Diagram of Current Detecting Unit
2-4
2.1 Connection Diagnosis
To confirm a connection, perform a diagnosis of the input status to the XCP02 board. (The
XCP02 board is a board for the COMARC.)
Use the following procedure to call the XCP02 I/O status display.
Operation
Select {IN/OUT} from the top menu Select {XCP02 I/O}
DATA EDIT DISPLAY UTILITY

L
XCPO2 I/O STATUS R1 C S
NO. A/D (IN) (OUT)
01 4
02 0
03 0
04 0
05 0
06 0
07 0
08 0
!
In this display, confirm the values read-by the XCP02 board’s A/D converter and the general I/
O status.
Eight channels are provided for the A/D converter, and four points are provided for general I/
O.
Use the XCP02 I/O status display for the following purposes.
1. Check whether the A/D converter is correctly operating
2. Check whether the cables for the current detecting unit are correctly connected.
For an incorrect connection: When welding is performed, the A/D data shows a negative
value (- value).
For normal status: When welding is performed, the A/D data shows a positive
value (+ value). (Execute a job without using COMARCON
and COMARCOF.)
N OT E The XCP02 I/O status display can be called only in “MANAGEMENT MODE”. When the
icon {XCP02 I/O} does not appear, switch the security mode to “MANAGEMENT MODE”.
2-5
2-6
3.1 Basic Understanding of the Arc Sensor
3 Arc Sensor Function
For welding with a power supply that has constant voltage characteristics, the welding current
fluctuates as the distance L changes as shown below. Distance L is the distance between the
tip and the base metal. The arc sensor function uses these characteristics.
Welding current
High Low
Tip
Consumable
electrode
L
(wire)
Arc
Base
metal
3.1.1 Left and Right Path Correctio

During welding with the torch weaving from side to side, an equal amount welding current
flows on points # and $ if the distance L is the same on both sides (points # and $) due to
the aforementioned characteristics.
#% $%
Welding current:#% = $%, (When the distance

between the tip and the base metal is the
same on both sides.)
3-1
If the distances L are different at points # and $, different currents flow at these two points as
shown below. The arc sensor checks the welding currents at points # and $ and corrects
the path to equalize the values.
Direction of path Direction of path

correction correction
Welding current #%> $%(shifted to the left) Welding current #%< $%(shifted to the right)
3.1.2 Up and Down Path Correction

During welding with the torch moving up and down, the arc sensor checks the welding cur-
rents at any 2 points, an upper point and a lower point, and corrects the path to equalize the
values.
Up and down path

correction
Up and down path

correction
3.1.3 Applicable Range of the Arc Sensor

The applicable metal thickness and joint are as follows.
Metal thickness: 3.2 mm or more

Joint: T joint, Lap joint
Speed: 1 m/min or less
N OT E The arc sensor function can be used except in a spray transfer.
3-2
3.2 Main Operations for the Arc Sensor Function
" Job Preparation for Welding and Adjustment of Welding Conditions

Prepare a job for welding and adjust the welding conditions.
.
JOB EDIT DISPLAY UTILITY

L
JOB CONTENT R1 C S
J: TEST S:000 R1 TOOL:0
0000 NOP
0001 MOVJ VJ=50.00
0002 MOVJ VJ=50.00
0003 ARCON AC=200 AVP=100 T=0.30 Prepare a job for welding. Set and
0004 MOVL V=80 adjust the welding conditions.
0005 MOVL V=80
0006 MOVL V=80
0007 ARCOF
!
" Registration of Arc Sensing Instructions

Register a COMARCON/COMARCOF instructions in the section where arc sensing is to be
performed.
Set the same value as the value of the current setting in the ARCON instruction as the UP/
DOWN correction condition (U/D). Set “0” as the LEFT/RIGHT correction conditions (L/R).
When adjustment of the targeted position is required after seeing the results of the welding
done with the arc sensor, adjust the UP/DOWN correction conditions (U/D) or the LEFT/
RIGHT correction conditions (L/R). For details on how to adjust the UP/DOWN and LEFT/
RIGHT correction conditions, refer to “5.4 Adjustment of Sensing Conditions”.

L
JOB CONTENT R1 C S
J:TEST S:003 R1 TOOL:*
0002 MOVJ VJ=50.00
0003 ARCON AC=200 AVP=100 T=0.30
0004 M O V L V = 8 0 Register a COMARCON/
0005 COMARCON AMP=2.0 FREQ=3.0 U/D=200 COMARCOF instruction in
0006 MOVL V=80 the arc sensing section.
0007 COMARCOF
0008 MOVL V=80
0009 ARCOF
!
3-3
• Depending on the welding current range to be used, the current value set with ARCON
N OT E instruction may differ from the current value actually output from the welder. In this case,
measure the sensing conditions when registering the COMARCON instruction.
For details on how to measure a sensing condition, refer to “5 Measurement and Registra-
tion of Sensing Condition”.
When an actual workpiece cannot be used to measure a sensing condition, use a test
piece. Then, for the UP/DOWN and LEFT/RIGHT correction conditions (U/D and L/R) for
the COMARCON instruction in the actual work job, enter the values based on those mea-
surements using the number keys.
• When using welders other than the MOTOWELD-S350, measure the phase compensation
value. For details on how to measure the phase compensation value, refer to “8 Phase
Compensation Value”.
3-4
4.1 COMARCON (Sensing Start Instruction)
4 Registration of Instructions
The COMARCON instruction starts the arc sensing and weaving.

There are three types of settings for the COMARCON instruction: weaving conditions, sensor
correction conditions (UP/DOWN, RIGH/LEFT), and the COMARC condition file No. specifica-
tions.
< > indicates numerical or alphabetical data.
Function Starts arc sensing and weaving.
Instruc- Settings Data input range Unit

tion
items Weaving conditions* 1
AMP = <Weaving amplitude> AMP: 0.1 to 99.9 0.1 mm
FREQ = <Weaving frequency> FREQ: 1.0 to 5.0 0.1 Hz
ANGL=<Weaving angle> ANGL: 0.0 to 180.0 0.1 deg.
WEV# (<Weaving file No.>) 1 to 16 -
DIR=<Weaving direction> 0 or 1 -
Correction conditions
COMARCON U/D = <Correcting the up and U/D: 1 to 999 1A
down path)
L/R = <Correcting the left and L/R: -255.0 to 255.0 0.1 A
right path>
COMARC condition file No.

CAF# (<COMARC condition file 1 to 16 -
No.>)
Exam- COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R=0.0

ples COMARCON WEV#(1) U/D=200 L/R=0.0
COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R=0.0 CAF#(1)
COMARCON WEV#(1) U/D=200 L/R=0.0 CAF#(1)
*1 Two setting methods are available: setting by AMP and FREQ or setting by WEV#.
When weaving conditions are set by AMP and FREQ, the weaving mode is “single
oscillation.” When ANGL is set to UNUSED, weaving angle is set to 45 deg.
Do not use DIR normally. DIR specifies the weaving direction changing. DIR=0 equals
to UNUSED.
4-1
• Be sure to register the COMARCON instruction after the ARCON instruction.

N OT E Register the COMARCON/COMARCOF instruction and the ARCON/ARCOF instruction
in the same job.
• For setting and adjusting sensor correction conditions, refer to “5 Measurement and Reg-
istration of Sensing Conditions”.
• When a COMARC condition file is not specified for the COMARCON instruction, perform
sensing under the following conditions in the COMARC condition file display.
• “CORRECTION SELECT” (direction of path correction): U/D & L/R (all directions)
• “CONDITION” (operation after pass-over): NOT MONITOR
For details on the COMARC condition file, refer to “6 COMARC Condition File”.
Operation
Move the cursor to the address area Press [INFORM LIST] Select “SENSOR”* 1
Select “COMARCON” Press [SELECT], and set the conditions in the detail edit
display* 2 Press [ENTER] twice * 3
Explanation
*1 The instruction appears with the previously registered additional items in the input
buffer line.

L
JOB CONTENT R1 C S
J:TEST S:008 R1 TOOL:0
0017 MOVJ VJ=50.00 ..
0018 MOVJ VJ=50.00 COMARCON
0019 ARCON AC=200 AVP=100 COMARCOF
COMARCSET
0020 MOVL V=80
0021 MOVL V=80
0022 ARCOF
0023 MOVJ VJ=100.00
= >C O M A R C O N A M P = 2 . 0 F R E Q = 3 . 0 U / D = 2 0 0 L / R
!
*2 Move the cursor to the item to be set, and press [SELECT]. Enter each condition using
the number keys, and then press [ENTER].
The following two methods are available to set weaving conditions.
• When a weaving condition is set by additional items

DETAIL EDIT
COMARCON
AMPLITUDE AMP= 2.0
FREQUENCY FREQ= 3.0
ANGLE UNUSED
DIRECTION UNUSED
UP/DOWN U/D= 200
LEFT/RIGHT L/R= 0.0
COMARC COND UNUSED
=> COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R
!
4-2
4.2 COMARCOF (Sensing End Instruction)
• When a weaving condition is specified by the file

DETAIL EDIT
COMARCON
WEAVING COND WEV#() 1
DIRECTION UNUSED
UP/DOWN U/D= 200
LEFT/RIGHT L/R= 0.0
COMARC COND UNUSED
=> COMARCON WEV#(1) U/D=200 L/R=0.0

!
*3 Press [ENTER] to display the setting details in the input buffer line. Press [ENTER]
again to register the setting details in the job.
4.2 COMARCOF (Sensing End Instruction)
The COMARCOF instruction ends arc sensing and weaving.
Function Ends arc sensing and weaving.
Instruction -
COMARCOF
item
Example COMARCOF
Be sure to register the COMARCOF instruction before the ARCOF instruction.

N OT E Register the COMARCON/COMARCOF instruction and the ARCON/ARCOF instruction in
the same job.
Operation
Select “COMARCOF” Press [ENTER]
Explanation
*1 The instruction appears in the input buffer line.

L
JOB CONTENT R1 C S
0018 MOVJ VJ=50.00 ..
0019 ARCON AC=200 AVP=100 COMARCON
COMARCOF
0020 COMARCON AMP=2.0 FREQ=3. C O M A R C S E T
0021 MOVL V=80
0022 MOVL V=80
0023 ARCOF
0024 MOVJ VJ=50.00
=> COMARCOF
!
4-3
4.3 COMARCSET (Sensing Condition Change)
The COMARCSET instruction changes the arc sensing conditions and the weaving condi-
tions.
There are three types of settings for the COMARCSET instruction: weaving conditions (weav-
ing amplitude, weaving angle), sensor correction conditions (correcting the up and down
direction, correcting the left and right direction), and the COMARC condition file No. specifica-
tions.
<> indicates numerical or alphabetical data.
Function Changes the sensing conditions and the weaving condition.

tion
items Weaving conditions
AMP = <Weaving amplitude> AMP: 0.1 to 99.9 0.1 mm
ANGL=<Weaving angle> ANGL: 0.0 to 180.0 0.1 deg.
U/D = <correcting the up and U/D: 1 to 999 1A
down path>
COMARCSET* 1 L/R = <correcting the left and L/R: -255.0 to 255.0 0.1 A
right path>

No.>)
Exam- COMARCSET AMP=2.5 U/D=210 L/R=0.0 CAF#(2)

ples COMARCSET AMP=2.5
COMARCSET U/D=210
COMARCSET L/R=1.0
COMARCSET CAF#(2)
*1 For the COMARCSET instruction, only the items to be changed can be set.
• The conditions registered with the COMARCSET instruction are validated when execut-
N OT E ing the move instruction after the COMARCSET instruction.
• For setting and adjusting sensor correction conditions, refer to “5 Measurement and Reg-
istration of Sensing Conditions”.
• For details on the COMARC condition file, refer to “6 COMARC Condition File”.
4-4
Operation
Select “COMARCSET” Press [SELECT], and set the conditions in the detail edit
display* 2 Press [ENTER] twice * 3
Explanation
*1 The instruction appears with the previously registered additional items in the input
buffer line.

L
JOB CONTENT R1 C S
0018 MOVJ VJ=50.00 ..
0019 ARCON AC=200 AVP=100 COMARCON
COMARCOF
0020 COMARCON AMP=2.0 FREQ=3. C O M A R C S E T
0021 MOVL V=80
0022 MOVL V=80
0023 COMARCOF
0024 ARCOF
=> COMARCSET
!
*2 Move the cursor to the item to be set, and press [SELECT]. Enter each condition by
using the number keys, and then press [ENTER].

D E TAIL EDIT
COMARCSET
A MPLITUDE AMP=2.0
ANGLE UNUSED
UP/DOWN U/D=200
LEFT/RIGHT L/R=0.0
COMARC COND CAF#( ) 1
=>COMARCSET AMP=2.0 U/D=200 L/R=0.0 CAF

!
4-5
4-6
5.1 Job for Measuring Sensing Conditions
5 Measurement and Registration of

Sensing Conditions
5.1 Job for Measuring Sensing Conditions
Play back the measuring job in the sensing condition measurement mode to automatically
measure the data of the sensing conditions (correction conditions in the up/ down/left/right
directions).
The following shows an example of a measuring job.
<Example>
Job for measuring sensing conditions
0000 NOP
0001 MOVJ VJ=50.00 Stand-by position
0002 MOVJ VJ=50.00
0003 MOVJ VJ=30.00 Welding start position
0004 ARCON AC=200 AVP=100
0005 COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R=0.0 Sensing starts (measures a condition)
0006 MOVL V=80 Welding end position
0007 COMARCOF Sensing completed
0008 ARCOF
0009 MOVJ VJ=30.00
0010 MOVJ VJ=50.00 Stand-by position
0011 END
6
1
5
2
3
1 to 6: Taught steps
5-1
5.2 Measurement of Sensing Conditions
Before measuring a condition, make sure that the workpiece is not dislocated. If the work-
N OT E piece is dislocated, correct the dislocation or correct the taught position for the measure-
ment job.
Measure the sensing conditions in a single section within the same job. Do not set more
than one sensing section in the same job.
<Wrong Setting Example>

MOVJ VJ=30.00
ARCON AC=200 AVP=100
COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R=0.0
MOVL V=80
COMARCOF
MOVL V=80
COMARCOF
ARCOF
MOVJ VJ=30.00
5.2 Measurement of Sensing Conditions
Operation
Select {UTILITY} in the job content display in the play mode Select {SPECIAL PLAY}
* 1 * 2
from the selection dialog box Set “VALID” as the “COMARC MEASURE MODE”
Execute the job
Explanation
*1 The special play display appears.

L
SPECIAL PLAY R1 C S
LOW SPEED START INVALID
SPEED LIMIT INVALID
DRY-RUN SPEED INVALID
MACHINE LOCK INVALID
CHECK-RUN INVALID
WEAV PROHIBIT IN CHK-RUN INVALID
COMARC MEASURE MODE INVALID
COMPLETE
*2 Move the cursor to “COMARC MEASURE MODE”, and press [SELECT] to set the
mode to “VALID”. “COMARC MEASURE MODE “ appears in the message line.
N OT E Be sure to reset “INVALID” as the “COMARC MEASURE MODE” after measuring the
sensing conditions.
5-2
5.3 Registration of Sensing Conditions
5.3 Registration of Sensing Conditions
Operation
Select {UTILITY} in the job content display in the teach mode Select {COMARC COND
* 1 * 2
MODIFY Select “MODIFY COMARC COND” from the {DATA} selection dialog box
Explanation
*1 The modify COMARC condition modify display appears.

L
C O M A R C C O N D . M O D I F Y R1 C S
JOB NAME:TEST
STEP CURRENT OFFSET-CURRENT
04 200 2.0
*2 The sensing conditions are registered in the job.

L
M O D I F Y C O M A R C C O N D R1 C S
JOB NAME:TEST
STEP CURRENT OFFSET-CURRENT
04 200 2.0
When registration is complete, the job content display reappears.
5-3
5.4 Adjustment of Sensing Conditions
5.4 Adjustment of Sensing Conditions
Operation
Move the cursor to the instruction area of the COMARCON instruction or the COMARCSET
instruction Press [SELECT] twice Select either “UP/DOWN” or “LEFT/RIGHT” in
* 1
the detail edit display
Explanation
*1 Enter a value using the number keys.
JOB EDIT DISPLY UTILITY
L
DETAIL EDIT R1 C S
COMARCSET
AMPLITUDE UNUSED
UP/DOWN U/D= 200
RIGHT/LEFT L/R= 5.0
COMARC COND UNUSED
=> COMARCSET U/D=200 L/R=5.0

!
The following is the relation between the settings of the correction conditions and the cor-
N OT E rection direction.
To define the direction along the wall and horizontally, refer to “9 Weaving Condition File”
of YASNAC XRC OPERATOR’S MANUAL.
• To lengthen a wire extension, decrease the UP/DOWN (U/D) correction condition in units
of 10 A.
• To shorten a wire extension, increase the UP/DOWN (U/D) correction condition in units of
10 A.
• To move the targeted position toward the wall, decrease the LEFT/RIGHT (L/R) correction
condition in units of 5 A.
• To move the targeted position toward the horizontal direction, increase the LEFT/RIGHT
(L/R) correction condition in units of 5 A.
Wall direction L E F T UP
DOWN RIGHT
Horizontal direction
5-4
5.5 Results of Arc Sensing
After arc sensing has been performed, the history of the correction amount in each step can
be viewed.
Operation
Select {ARC WELDING} from the top menu Select {COMARC CORRECT}* 1
Explanation
*1 The correction amount in each step appears.

L
CORRECTING LIST R1 C S
NO. OF STEPS : 6 STEP
STEP VAR-U VAR-D VAR-L VAR-R
005 0.0 0.0 0.0 0.0
006 0.0 0.0 0.0 0.0
007 0.0 0.0 0.0 0.0
008 0.0 0.0 0.0 0.0
009 0.0 0.0 0.0 0.0
010 0.0 0.0 0.0 0.0
The correcting list display only appears when sensing has been performed.
N OT E Therefore, the icon “COMARC CORRECT” does not appear when turning the power ON or
before performing sensing.
5-5
5-6
6.1 COMARC Condition File
6 COMARC Condition File
Set the following two items in the COMARC condition files.

• Direction of path correction by sensing
• Pass-over monitoring condition

L
COMARC R1 C S
# COND NO. :1
$ CORRECTION SELECT :U/D & L/R
<PASS OVER MONITOR>
& CONDITION : ALARM
' VERTICAL MONITOR : 0.0 mm
( HORIZONAL MONITOR : 0.0 mm
) NO. : 1 times
#COND NO. (1 to 16)

Displays the file No.
$CORRECTION SELECT (direction of path correction) (U/D & L/R, U/D, L/R,
NO CORRECTION)
Specifies the direction to be corrected. When “NO CORRECTION” is selected, a correction
by sensing is not performed.
U/D & /L/R Corrects the path in the up, down, left, and right directions.
L/R Corrects the path in the left and right directions (the up and down directions are
not corrected).
U/D Corrects the path in the up and down directions (the left and right directions are
not corrected).
&CONDITION (operation after pass-over) (ALARM, TEACHING POSITION,

CORRECTION RETAIN, NOT MONITOR)
Specifies the operation to be done when a pass-over occurs.
6-1
ALARM: An alarm occurs, and the manipulator stops.

Pass-over occurred,
and the manipulator
stops. Actual welding line
Pass-over
monitor value
: Taught
Taught line
position
TEACHING POSITION: Sensing stops, and the manipulator returns to the taught position
and continues welding.
Pass-over occurred Restarts sensing from the taught position
Sensing stops, and the manipulator returns to the taught

position.
CORRECTION RETAIN: The taught position just after the occurrence of pass-over. The
manipulator restarts welding from a position adjusted for the amount of shift from the taught
position just before the occurrence of the pass-over.
Sensing restarts at a new, adjusted position.
The distance between this new position and the
taught position is equal to the amount of drift
Pass-over from the taught position just before the pass-
occurred over.
Amount of shift from

the taught position
Taught position just before Taught position just after

the occurrence of pass-over the occurrence of pass-over
NOT MONITOR: The pass-over is not monitored.
'VERTICAL MONITOR (the pass-over monitor value in the up and down

directions)(0.0 to 25.5 mm)
Sets the pass-over monitor value in the up and down directions. When set to 0.0, the up
and down directions are not monitored.
(HORIZONTAL MONITOR (the pass-over monitor value in the left and right
directions) (0.0 to 25.5 mm)
Sets the pass-over monitor value in the left and right directions. When set to 0.0, the left
and right directions are not monitored.
6-2
6.2 File Operation
)NO. (the number of pass-overs) (1 to 10)

When the number of pass-over exceeds this set value, the manipulator moves as described
in &.
The pass-over monitor function monitors whether the manipulator is in the rectangular range
SUPPLE
-MENT
specified by the vertical monitor value and horizontal monitor value with the taught path as
its center line. When the manipulator moves out of the specified range more than the set
number of times, the manipulator moves as described in &.
6.2 File Operation
6.2.1 Display of a File

Operation
Select {ARC WELDING} from the top menu Select {COMARC COND.} Display a
* 1
desired file No.
Explanation
*1 Press the page key to call the next file No.
Press [SHIFT] + the page key to call back the previous file No.
6.2.2 Editing of a File

" Editing of “CORRECTION SELECT” and “CONDITION”
Operation
Select either “CORRECTION SELECT” or “CONDITION” Select the item to be set fro
the selection dialog box

L
COMARC R1 C S
COND NO. :1
CORRECTION SELECT : U/D & L/R
< P A S S O V EARL AMROMN I T O R >
CONDITIONT E A C H I N G P O S :ALARM
ITION
VERTICAL C O R R E C T I O N R E:0.0
MONITOR TAINmm
HORIZONAL N OMONITOR
T M O N I T O R :0.0 mm
NO. :1 times
6-3
6.2 File Operation
" Editing of Other Items

Operation
Move the cursor to the item to be set, and then press [SELECT] Enter a value to be set
using the number keys Press [ENTER]
6.2.3 Initialization of the File

The COMARC condition file can be initialized in the maintenance mode.
To initialize the COMARC condition file, change the security mode to “MANAGEMENT
N OT E MODE”.
(When the security mode is set to “OPERATION MODE” or “EDITING MODE”, a file cannot
be initialized.)
Operation
While pressing [TOP MENU], turn ON the power Change the security mode (“SECU-
RITY”) to “MANAGEMENT MODE” Select {FILE} from the top menu Select {INI-
TIALIZE} Select “FILE/GENERAL DATA”* 1 Select “COMARC COND FILE” * 2
Press [ENTER]* 3 Select “YES” * 4

Turn ON the power again
Explanation
*1 The condition file/general data selection display appears.
INITIALIZE
TOOL DATA TOOL .CND

WEAVING DATA WEAV .CND
USER COORDINATE DATA UFRAME .CND
ARC START COND DATA ARCSRT .CND
ARC END COND DATA ARCEND .CND
ARC AUXILIARY COND DATA ARCSUP .DAT
WELDER CONDITION DATA WELDER .DAT
USR DEF WELDER COND DATA WELDUDEF.DAT
!Maintenanse Mode
6-4
6.2 File Operation
*2 A star “*” appears on the left of the “COMARC COND FILE”.
INITIALIZE
WEAVING DATA WEAV .CND The condition files/data marked

USER COORDINATE DATA UFRAME .CND with " " " cannot be selected.
ARC AUXILIARY COND DATA ARCSUP .DAT
*COMARC COND FILE COMSRT .CND
!Maintenanse Mode
*3 The confirmation dialog box appears.
INITIALIZE
WEAVING DATA WEAV .CND

USER COORDINATE DATA UFRAME .CND
Initialize?
ARC AUXILIARY
Y ECOND
S DATA N O ARCSUP .DAT
*COMARC COND FILE COMSRT .CND
!Maintenanse Mode
*4 The COMARC condition file is initialized.
6-5
6.2 File Operation
6-6
7 Modification of the Settings in
COMARC Function
To validate the COMARC function, mount the JANCD-XCP02 board in the CPU rack (JZNC-
XRK01B- +) with the power OFF.
To invalidate the COMARC function, remove the JANCD-XCP02 board from the CPU rack
(JZNC-XRK01B- +) with the power OFF.
The COMARC function has been set before shipment.

N OT E Do not change the settings for the COMARC function unless it is required to invalidate the
COMARC function.
To validate/invalidate the COMARC function, change the security mode to “MANAGEMENT

SUPPLE
-MENT
MODE”.
When the security mode is set to “OPERATION MODE” or “EDITING MODE”, only the set-
ting status can be referenced.
Operation
While pressing [TOP MENU], turn ON the power Change the security mode (“SECU-
RITY”) to “MANAGEMENT MODE” Select {SYSTEM} from the top menu Select
* 1 * 2 * 3
{SETUP} Select {OPTION BOARD} Press [ENTER] Select “YES”
Turn ON the power again
Explanation
*1 The setup display appears.
SETUP
LANGUAGE
CONTROL GROUP
APPLICATION
IO MODUlE
OPTION BOARD
CMOS MEMORY
DATE/TIME
OPTION FUNCTION
!Maintenanse mode
7-1
*2 The setting status appears.
• When the XCP02 board is mounted, the following display appears.
OPTION BOARD
CP02#1 : COMARC
-
-
CP02#2 : NONE
!Maintenanse Mode
When the XCP02 Board is Mounted
Press [ENTER], and the robot sensor display appears.
ROBOT SENSOR OPTION
CP02#1 R1
SL#1 : COMARC
:-
CP02#2
:-
:-
!Maintenanse Mode
• When the XCP02 board is not mounted, the following display appears.
OPTION BOARD
CP02#1 : NONE
CP02#2 : NONE
!Maintenanse Mode
When the XCP02 Board is not Mounted
7-2
*3 The confirmation dialog box appears.
OPTION BOARD
CP02#1 : NONE
Modify?
C P 0 2 # 2 : N O NYE E S NO
!Maintenanse Mode
7-3
7-4
8 Phase Compensation Value
As explained in “3.1 Basic Understanding of Arc Sensor”, the arc sensing corrects the manip-
ulator path by measuring the welding current values at the peak and bottom of the waves of
weaving motion.
However, in the actual welding, a discrepancy between the weaving cycle and the peak value
of the current variation cycle is generated as shown in the following figure. The phase com-
pensation value compensates for this discrepancy.
Since the phase compensation value differs depending on the welding circumstances. Mea-
sure and register a value for each welder.
Welding current peak value
Welding current wave form
Both ends of weaving motion Weaving motion

A discrepancy between the weaving motion and the welding current peak
value is generated.
8-1
8.1 Job Preparation for Measurement of Phase Compensation Value
8.1 Job Preparation for Measurement of Phase Com-

pensation Value
Prepare a job to measure a phase compensation value.

Refer to the following job example to prepare a job for measurement of a phase compensation
value.
Job Example for Measurement of Phase Compensation Value
NOP
MOVJ VJ=50.00
MOVJ VJ=50.00
ARCON AC=200 AVP=100
MOVL V=80
COMARCOF
ARCOF
MOVL V=800
MOVJ VJ=50.00
END
For measurement of a phase compensation

value, teach the torch positions as if there is a
top plate. (Steps 2 and 3).
Step 4
Step 3 Steps 1 and 5
Step 2
• Execute a job for measurement of phase compensation value under the same welding
N OT E condition (current value, voltage value, torch positions) as a job with an actual workpiece.
• For the weaving conditions, measure the phase compensation values for all the weaving
frequencies used in the actual welding.
8-2
8.2 Measurement and Registration of a Phase Compensation Value
8.2 Measurement and Registration of a Phase Com-

pensation Value
• Measuring and registering a phase compensation value is only possible in “MANAGE-

N OT E MENT MODE”. Change the security mode to “MANAGEMENT MODE”.
• The phase compensation value is registered in the parameter SxE. To measure and reg-
ister phase compensation value, set “1” as the parameter SxE197 first, then proceed the
following operations.
• After the completion of the registration of phase compensation value, be sure to reset “0”
as the parameter SxE197.
Operation
Select the job for measurement of a phase compensation value Select {UTILITY} in
the job content display in play mode Select {SETUP SPECIAL RUN} from the selection
dialog box* 1 Set “VALID” as the “COMARC MEASURE MODE” * 2
Execute the job
Select {UTILITY} in the teach mode Select {COMARC COND MODITY} * 3
Select {PARAMETER} from the top menu Select {SxE} Display the parameter No.
to be changed Register the measured value * 4
Explanation
*1 The special play display appears.

L
SPECIAL PLAY R1 C S
LOW SPEED START INVALID
SPEED LIMIT INVALID
DRY-RUN SPEED INVALID
MACHINE LOCK INVALID
CHECK-RUN INVALID
WEAV PROHIBIT IN CHK-RUN INVALID
COMARC MEASURE MODE INVALID
COMPLETE
*2 Move the cursor to “COMARC MEASURE MODE”, and press [SELECT] to set “VALID”
as the mode. The message “COMARC MEASURE MODE” appears in the message
line.
8-3
8.2 Measurement and Registration of a Phase Compensation Value
*3 The COMARC phase compensation display appears.

L
COMARC PHASE COMP R1 C S
JOBNAME : TEST
PARAMETER NO. : 200

PHASE COMP : 100 msec
*4 Register the phase compensation value confirmed in the COMARC phase compensa-
tion display as the parameter SxE.
• After measuring the phase compensation value, be sure to reset “INVALID” as the
N OT E “COMARC MEASURE MODE”.
• When the shielding gas is changed, measure and register the phase compensation
value.
• Measure and register phase compensation values for all the frequencies used in the
actual welding.
Depending on the frequency for which a phase compensation value is measured, the val-
ues may be registered in same parameter No. In this case, register the average value of
several measured phase compensation values.
<Example>
The phase compensation values for the weaving frequencies 4.0 Hz and 5.0 Hz are regis-
tered in SxE060.
In this case, the average value of the phase compensation values for the weaving frequen-
cies 4.0 Hz and 5.0 Hz is registered in SxE060.
8-4
9 Instruction List
< > indicates numerical or alphabetical data.
Function Starts arc sensing and weaving.

tion
item Weaving conditions* 1
AMP = <Weaving amplitude> AMP: 0.1 to 99.9 0.1mm
FREQ = <Weaving frequency> FREQ: 1.0 to 5.0 0.1Hz
ANGL=<Weaving angle> ANGLE: 0.0 to 180.0 0.1deg.
WEV# (<Weaving file No.>) 1 to 16 -
DIR=<Weaving direction> 0 or 1 -
COMARCON U/D = <Correcting the up and U/D: 1 to 999 1A
down path)
L/R = <Correcting the left and L/R: -255.0 to 255.0 0.1A
right path>

No.>)
Exam- COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R=0.0

ples COMARCON WEV#(1) U/D=200 L/R=0.0
COMARCON AMP=2.0 FREQ=3.0 U/D=200 L/R=0.0 CAF#(1)
Function Ends arc sensing and weaving.
Instruct- -
COMARCOF
tion item
Example COMARCOF
9-1
Function Changes sensing condition and weaving condition.

tion
item Weaving condition
AMP = <Weaving amplitude> AMP: 0.1 to 99.9 0.1mm
ANGL=<Weaving angle> ANGL: 0.0 to 180.0 0.1deg
Correction condition
U/D = <Correcting the up and U/D: 1 to 999 1A
down path>
COMARCSET* 2 L/R = <Correcting the left and L/R: -255.0 to 255.0 0.1A
right path>

No.>)
Exam- COMARCSET AMP=2.5 U/D=210 L/R=5.0 CAF#(2)

ples COMARCSET AMP=2.5
COMARCSET U/D=210
COMARCSET L/R=5.0
COMARCSET CAF#(2)
*1 Two setting methods are available: setting by AMP and FREQ, or setting by WEV#.
When weaving conditions are set by AMP and FREQ, the weaving mode is “single
oscillation.” When ANGLE is set to UNUSED, weaving angle is set to 45 deg.
Do not use DIR normally. DIR specifies the weaving direction changing. DIR=0 equals
to UNUSED.
*2 For the COMARCSET instruction, only the items to be changed can be set.
The data in < > can be set by using constants or user variables.
N OT E To use user variables, pay attention to the unit of set data.
<Example>
COMARCSET AMP=B000
The unit for the weaving amplitude settings is “0.1 mm”. To set 2.5 mm as the amplitude,
set “25” as the B000.
9-2
9-3
9-4
10 Parameter List
SxE Parameters
Parameter Initial Setting

Contents Unit
No. Value Range
0 Application designation - - -
Analog signal input channel SL1: 1 1 to 8

20 - SL2: 2
SL3: 1
Compensation value for conversion of [%] 100 0 to 100

21
an AD value to a current value
Number of times that correction was - 4 0 to 10000

22
prohibited at COMARCON
Correction prohibited minimum cur- [0.1A] 500 0 to 10000

24
rent
Correction prohibited maximum cur- [0.1A] 10000 0 to 10000

25
rent
27 Dead zone U/D [0.1A] 50 0 to 10000
28 Dead zone L/R [0.1A] 50 0 to 10000
Correction amount Y+ [µm] 150 0 to 10000

30 (Weaving frequency less than 2.0
[Hz])
Correction amount Y- [µm] 150 0 to 10000

[Hz])
Correction amount Z+ [µm] 150 0 to 10000

[Hz])
Correction amount Z- [µm] 150 0 to 10000

[Hz])

34 (Weaving frequency 2.0 [Hz] or more,
less than 3.0 [Hz])

less than 3.0 [Hz])

less than 3.0 [Hz])
10-1
SxE Parameters
Parameter Initial Setting

Contents Unit
No. Value Range

less than 3.0 [Hz])

less than 4.0 [Hz])

less than 4.0 [Hz])

less than 4.0 [Hz])

less than 4.0 [Hz])

42
(Weaving frequency 4.0 [Hz] or more)

43

44

45
50 Sampling interval [msec] 2 1 to 10
10-2
11 Alarm Message List
Alarm
Message Cause Remedy
Number
TWO STEPS The weaving base point was the Reset the alarm.
4410 SAME POSI- same as the wall point. Reteach the 3 different
TION (WEAV) points.
PASS OVER The path went outside the desig- Remove the cause of
[Decimal data] nated pass-over monitoring area. the pass-over
4486 Set the pass-over radius
inside the permitted
range.
DEFECTIVE 1: Weaving start point and end Check the start point,
TAUGHT POINT point were the same. the end point, and the
(WEAV) If not using hover weaving, the reference point. Teach
weaving start point and end point again.
will be the same point, or the
weaving start point and the refer-
4494
ence point will be the same point.
If using hover weaving, the weav-
ing start point and the reference
point will be the same point.
2: Weaving targeted point outer
product error
ROM ERROR Checksum error in the ROM Replace the XCP02

1003
(XCP02) (memory) of the sensor program. board.
ANALOG INPUT The analog input value of XCP02 Check the cable con-
ERROR board can not be read properly. nection.
5010 (XCP02) The decimal data indicates the Replace the XCP02
[Decimal data] channel where an input fault board.
occurs.
TRANSMISSION An error occurs in serial transmis- Check the parameters

ERROR sion on the XCP02 board. for the sending and
(XCP02) The decimal data indicates the receiving side.
[Decimal data] contents of error. Check the transmission
0: Receiving FIFO error cable.
1: Framing error
5011
2: Parity error
3: Overrun error
4: Checksum error
5: NAK receiving error
6: Sending time over
7: Receiving time over
SYSTEM An error occurs in the system of Needs investigation.

ERROR the sensor in the COMARC func- Contact your Yaskawa
(COMARC) tion. representative. State
5012
[Decimal data] The decimal data indicates the any observations, the
contents of error. alarm No. and data dis-
played.
11-1
Alarm
Message Cause Remedy
Number
COMARC An error occurs when processing Needs investigation.

ERROR the sensor in the COMARC func- Contact your Yaskawa
[Decimal data] tion. representative. State
5013
The decimal data indicates the any observations, the
contents of error. alarm No. and data dis-
played.
11-2
YASNAC XRC OPTIONS
INSTRUCTIONS
FOR ARC SENSOR COMARC FUNCTION
TOKYO OFFICE
New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo 105-6891, Japan
Phone 81-3-5402-4511 Fax 81-3-5402-4580
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
MOTOMAN INC. TROY FACILITY
1050 S. Dorset, Troy, OH 45373, U.S.A.
Phone 1-937-440-2600 Fax 1-937-440-2626
YASKAWA MOTOMAN CANADA LTD.
2280 ARGENTIA ROAD, MISSISSAUGA, ONTARIO, L5N 6H8, CANADA.
Phone 1-905-813-5901 Fax 1-905-813-5911
YASKAWA ELECTRIC EUROPE GmbH
Am Kronberger Hang 2, 65824 Schwalbach,Gemany.
Phone 49-6196-569-300 Fax 49-6196-888-301
Motoman Robotics AB
Box 504 S38525 Torsås, Sweden
Phone 46-486-48800 Fax 46-486-41410
Motoman Robotec GmbH
Kammerfeldstraβe1,85391 Allershausen, Germany
Phone 49-8166-900 Fax 49-8166-9039
YASKAWA ELECTRIC KOREA CORPORATION
Kfpa Bldg #1201, 35-4 Youido-dong, Yeongdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park Singapore 556741, Singapore
Phone 65-282-3003 Fax 65-289-3003
YATEC ENGINEERING CORPORATION
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
BEIJING OFFIC
Room No. 301 Office Building of Beijing Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
Phone 86-10-6532-1850 Fax 86-10-6532-1851
SHANGHAI OFFICE
27 Hui He Road Shanghai 200437 China
Phone 86-21-6553-6600 Fax 86-21-6531-4242
YASKAWA JASON (HK) COMPANY LIMITED
Rm. 2909-10, Hong Kong Plaza, 186-191 Connaught Road West, Hong Kong
Phone 852-2803-2385 Fax 852-2547-5773
TAIPEI OFFICE
Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road,Taipei, Taiwan
Phone 886-2-2563-0010 Fax 886-2-2567-4677
BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD.
30 Xue Yuan Road, Haidian, B eijing P.R. China Post Code: 100083
Phone 86-10-6233-2782 Fax 86-10-6232-1536
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Street, Beijing Economic Technological Investment & Development Area,
Beijing 100076, P.R. China
Phone 86-10-6788-0551 Fax 86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice MANUAL NO. HW9482786 1

for ongoing product modifications and improvements. C Printed in Japan December 2000 99-8
-4
APPENDIX A
COMARC III SUPPLEMENT
A.1 Overview
ComArc III Seam Tracking is based on the concept that on a constant voltage
welding machine (CV), the current will vary depending on the distance of the
contact tip from the work piece, or contact tip to work distance (CTWD). Weaving
is required so that a variation in welding current can be observed, and then
reproduced, by the XRC controller. For a fillet weld, the current is a function of
the distance from the contact tip to the walls of the fillet joint. As the robot moves
through the weld joint, it monitors the welding current and corrects the path as it
travels by moving into or away from the joint, depending on the current feedback
that it receives.
If ComArc III Seam Tracking is purchased, hardware must be installed, including
additional boards, chips, and the actual ComArc box, and software must also be
installed and/or enabled. Normally these installations are completed at
MOTOMAN by MOTOMAN technicians, but field retrofits are possible.
Once ComArc III is installed, it is necessary to collect data to verify the correct
operation of the seam tracking system. There are a couple steps that must be
followed to gather the correct information.
A.2 Setting Up ComArc

Phase Compensation or "PC" data allows the user to "synchronize" the power
source with the ComArc system. The PC data is used to define the time lag
between the position of the robot in its weave and the welding current. This data
varies with different robot types, welding power sources, shielding gases, electrode
diameters, weave frequencies, and welding cable lengths. Large changes in
welding current may require re-measurement of PC data. For example, if you
measure PC data with a weld current of 200 amps, then need to do other welds at
350 amps, you will need to collect new data to use on those other welds.
To properly collect the PC data, use the weld path defined in the steps below with
the weld parameters properly set for the joint you wish to track. Develop a good,
stable arc and an acceptable weld bead. Use about a 45° work angle and a push-
travel angle of around 10-20°. Sound welding conditions should provide weave
conditions such that the arc is on the leading edge of the weld pool, with no
undercutting.
MOTOMAN A-1 ComArc Function

1. Set up the following job structure for good weaving and welding conditions:
MOVJ
MOVJ
ARCON ASF#(4)
WVON WEV#(2)
MOVL V=90
WVOF
ARCOF AEF#(3)
MOVJ
2. Replace the WVON command in the job with the COMARCON command
(specify the weave file the COMARCON command should reference).
NOTE: These instructions can be found in the Inform List under SENSOR.
3. Replace the WVOF command with the COMARCOF command.
Next, measure current and offset current as follows:
1. Set up a complete fillet joint, with upper and lower leg.
2. In PLAY mode, select UTILITY ‡ SETUP SPECIAL RUN ‡ COMARC
MEASUREMENT MODE = VALID.
3. START (commence welding).
4. Once welding is completed, select TEACH mode.
5. Select UTILITY ‡ COMARC CONDITION MODIFY. This will give you
the correct U/D and L/R data to be inserted into the COMARCON
instruction. Selecting DATA - COMARC CONDITION MODIFY will
insert the U/D and L/R data into the last COMARCON instruction that was
executed during job playback.
6. From job display, select UTILITY ‡ SETUP SPECIAL RUN ‡ COMARC
MEASURE MODE = INVALID.
7. The job structure for normal ComArc operation is now set up:
MOVJ
MOVJ
ARCON ASF#(4)
If ComArc does not track the joint, will need to record phase compensation (PC)
data as outlined below.
1. Set parameter S1E197 (S3E197 for R2) to 1. This makes phase
compensation (PC data) measurement mode possible.
2. Set up a weld plate with no upper leg.
3. Select PLAY mode.
4. From the job display screen, select: UTILITY ‡ SETUP SPECIAL RUN ‡
COMARC MEASURE MODE = VALID.
5. START (commence welding) on the plate.
ComArc Function A-2 MOTOMAN

NOTE: Observe the current range while making this weld. The highest current will be when
the weave is toward the bottom or horizontal leg. The average current will be when
the weave is passing through what was the center of the joint when both legs were
intact. The lowest current will be seen when the weave is at the position that would
normally be the upper or vertical leg of the leg. In this joint, which is missing the
upper leg, the electrical stick out is the longest, which produces a lower current.
This is a constant voltage welding power source, so the voltage should remain
relatively constant.
6. Phase compensation data is now recorded.
7. Once welding is complete, select TEACH mode.
8. UTILITY ‡ COMARC CONDITION MODIFY ‡ Set the given parameter
number for S1E(S3E for R2) parameter shown to the given value (example:
245 msec.)
9. Set parameter S1E197 (S3E197 for R2) to 0.
10. Arrange a fillet weld joint with an upper and lower leg.
11. Select PLAY mode.
12. START (commence welding).
13. Once welding is complete, select TEACH mode.
14. Select UTILITY ‡ COMARC CONDITION MODIFY ‡ DATA ‡ COMARC
CONDITION MODIFY.
15. From the job display screen, select: UTILITY ‡ SETUP SPECIAL RUN ‡
COMARC MEASURE MODE = INVALID.
A.3 ComArc Files and Pass Over Monitor

A.3.1 ComArc Condition File
A ComArc File (CAF#(x)) can be referenced in the COMARCON command. This
specifies correction directions and Pass Over Monitor. Because direct opening the
COMARCON instruction produces the Weave File screen, the only way to access
the ComArc file is from TOP MENU ‡ ARC WELDING ‡ COMARC COND.
The correction direction has four options for adjusting the robot path. These are:
U/D and L/R
U/D only
L/R only
No Correction

A.3.2 Pass Over Monitor

The ComArc file also specifies Pass Over Monitor. First, create a window that
describes a maximum vertical and maximum horizontal distance the robot path can
be altered. Pass Over Monitor allows the user to define the number of times the
manipulator can go out of the specified zone. If this zone is exceeded as many as
or more times than specified, the user can set a condition, which determines what
occurs. Possible actions once the robot path moves outside the PASS OVER
envelope the specified number of times are:
ALARM – Stop welding, halt robot motion, and send a Pass Over Alarm
TAUGHT POSITION – revert to taught path
CORRECTION RETAIN – maintain corrected amount, but do not deviate
further
NOT MONITOR
A.3.3 ComArc Correction Screen
The ComArc Correction screen is only visible if seam tracking has taken place. It
is accessed from TOP MENU ‡ ARC WELDING ‡ COMARC CORRECT. This
displays the magnitude of correction (in millimeters) for each step that ComArc
tracked. The correction amounts are described by UP, DOWN, LEFT and RIGHT
directions.
A.4 Additional Parameters

A.4.1 Dead Zone
The Dead Zone, like the COMARCON / COMARCSET commands, refers to UP/
DOWN and LEFT/RIGHT directions. If minor current fluctuations occur (i.e. a
tack weld) in the axial direction of the torch, a set amperage value can be
registered for UP/DOWN sensitivity. Variations within this range will be ignored.
If the variations are likely to occur in the weave plane, the measured value would
be registered for LEFT/RIGHT. As the robot welds over tacks, the raised area of
the tack weld causes a shorter CTWD, which raises the current. If seam tracking
this joint, the robot would correct away from the tack, then once past it, track back
into the joint. This often causes small nuisance voids in the welds. With the use of
Dead Zones, these minor variations would be ignored and no corrections would
take place. Adjustment of the Dead Zone is found in the S1E(S3E) parameter list.
A.4.2 Correction Amount
Other parameters that can be found in the parameter list are Correction Data,
Correction Prohibition Current, and Sampling Interval. Correction data are
parameters which control the amount of correction (step size, in millimeters) the
robot will make. For small variations in the programmed path use small values
(100 to 150) while large variations in part fit-up may require large steps to track the
part. Listed below are the default values, which are based on the weaving
frequency range.

Table A-1 ComArc Parameter Listing (S1E, S3E)
S1E/S3E Item Range Units Default

20 Analog Signal Input Channel SL1/SL3=1, 1
SL2=2
21 A-->D Current Conversion Compensa- 0 to 100 % 100

tion
22 Correction Prohibition Count (Pass 0 to 10000 4

Over)
24 Min. Correction Prohibition Current 0 to 10000 0.1 A 500
25 Max. Correction Prohibition Current 0 to 10000 0.1 A 10000

(Pass Over)
27 Dead Zone: U/D 0 to 10000 0.1 A 50
28 Dead Zone: L/R 0 to 10000 0.1 A 50
30 0 to 10000 0.001mm 150
31 Correction Data 0 to 10000 0.001mm 150
32 (weaving frequency < 2 Hz) 0 to 10000 0.001mm 150
33 0 to 10000 0.001mm 150
34 0 to 10000 0.001mm 150
36 (2 Hz <= weaving frequency < 3 Hz) 0 to 10000 0.001mm 150
37 0 to 10000 0.001mm 150
38 0 to 10000 0.001mm 100
40 (3 Hz <= weaving frequency < 4 Hz) 0 to 10000 0.001mm 100
41 0 to 10000 0.001mm 100
42 0 to 10000 0.001mm 100
44 (weaving frequency >= 4 Hz) 0 to 10000 0.001mm 100
45 0 to 10000 0.001mm 100
50 Sampling Interval 1 to 10 msec 2
NOTE: The correction prohibit current parameters listed above are used when a ComArc file
(CAF) is not referenced by the COMARCON instruction. Also, the S1E parameters
are used for a single robot system. For a dual robot system (R1 and R2) the S3E
parameters are used for R2.

A.5 Coordinated Motion with ComArc

In order to interface ComArc with Master Tool Frame (the Cartesian, X-Y-Z
reference frame used to describe the position of R1 relative to S1) the use of
specific instructions in necessary. Substitute the following instructions when using
coordinated motion:
MOVL/C/S SMOVL/C/S
REF SREF
WVON SWVON
COMARCON SCOMARCON
COMARCSET SCOMARCSET
WFOF SWVOF
COMARCOF SCOMARCOF
A.6 Sample Jobs

Single Robot ComArc:
NOP
MOVJ C00001 VJ=25.00 Approach point
MOVL C00002 V=23.0 Starting Point
ARCON ASF#(1) Arc Start using ArcStart file #1
COMARCON WEV#(1) U/D=200 ComArc Start instruction using Weaving condi-
L/R=10.0 tion file #1 and Up/Down of 200 mm max with
Left/Right correction of10mm max
MOVL C00003 V=11.0 Ending point
COMARCOF Disabling ComArc Function
ARCOF Disabling Welding Arc
MOVL C00004 V=46.0 Retraction point
END

Single Robot with Single Coordinated Axis ComArc:
NOP
MOVJ C00001 VJ=25.00 +MOVJ Approach point
EC00001 VJ=25.00
SMOVC C00002 V=83.3 +MOVJ Synchronized Starting Point
EC00002
SCOMARCON WEV#(1) U/D=234 Synchronized ComArc Start instruction using
L/R=10.0 Weaving condition file #1 and Up/Down of 200
mm max with Left/Right correction of 10mm
max
SMOVC C00003 V=10.0 +MOVJ Synchronized Ending point
EC00003
SCOMARCOF Disabling Synchronized ComArc Function
SMOVC C00004 V=10.0 +MOVJ Retraction point
EC00004
END

Dual Robot with Single Coordinated Axis ComArc:
NOP
MOVJ C00002 VJ=12.50 +MOVJ Approach point
EC00002 VJ=25.00
SMOVC C00004 V=11.0 +MOVJ 1st Synchronized point (Arc Starting point)
EC00004
TSYNC 2
SCOMARCON WEV#(4) U/D=200 Synchronized ComArc Start instruction using
L/R=10.0 Weaving condition file #4 and Up/Down of 200
mm max with Left/Right correction of 10mm
max
SMOVC C00005 V=11.0 +MOVJ 2nd Synchronized point
EC00005
SCOMARCST U/D=237 L/R=12.5 Resetting ComArc Correction amounts "on the
fly"
SMOVC C00006 V=11.0 +MOVJ 3rd Synchronized point
EC00006
SCOMARCST U/D=238 L/R=22.1 Resetting ComArc Correction amounts "on the
fly"
SMOVC C00007 V=11.0 +MOVJ 4th Synchronized point (Arc Ending point)
EC00007
SCOMARCOF Disabling Synchronized ComArc Function
TSYNC 3
END

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Part Number: 144075-1

MOTOMAN i ComArc Function

ComArc Function ii MOTOMAN

1.2 Reference to Other Documentation

1.3 Customer Service Information

MOTOMAN 1-1 ComArc Function

ComArc Function 1-2 MOTOMAN

It is the purchaser's responsibility to ensure that all local, county,

MOTOMAN 2-1 Comarc Function

2.2 Standard Conventions

Comarc Function 2-2 MOTOMAN

2.3 General Safeguarding Tips

2.4 Mechanical Safety Devices

MOTOMAN 2-3 Comarc Function

2.5 Installation Safety

2.6 Programming Safety

Comarc Function 2-4 MOTOMAN

• Inspect the robot and work envelope to be sure no potentially hazardous

2.7 Operation Safety

MOTOMAN 2-5 Comarc Function

2.8 Maintenance Safety

Comarc Function 2-6 MOTOMAN

YASNAC XRC OPTIONS

YASKAWA MANUAL NO. HW9482786 1

• General items related to safety are listed in Section 1: Safety of the

• The drawings and photos in this manual are representative examples

• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

• YASKAWA is not responsible for incidents arising from unauthorized

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Always be sure to follow explicitly the items listed under this

PROHIBITED Must never be performed.

Emergency Stop Button

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Sto

• Observe the following precautions when performing teaching operations

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the manipulator’s work envelope

Failure to observe this warning may result in an electric shock.

• Special attention should be paid during starting point detection, since

Failure to observe this warning may result in an electric shock.

Failure to observe this caution may result in an electric shock.

Definition of Terms Used Often in This Manual

Equipment Manual Designation

YASNAC XRC Controller XRC

YASNAC XRC Playback Panel Playback Panel

YASNAC XRC Programming Pendant Programming Pendant

Equipment Manual Designation

Keys pressed When two keys are to be pressed simultaneously,

Displays The menu displayed in the programming pendant is

Playback Panel Buttons Playback panel buttons are enclosed in brackets.

Description of the Operation Procedure

3 Arc Sensor Function

5 Measurement and Registration of Sensing Conditions

6 COMARC Condition File

1.1 Floor-mounted Standard Type

Side view of starting point detecting unit

4-M6 tapped holes