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Panasonic YA-1W Series - User Manual

Panasonic YA-1W Series
72 pages
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Before operating this product, please read the instructions carefully and save this manual for future use.
Please read the operating instructions of peripheral equipment together with it.
First of all, please read “Safety precautions”.
English version is the original instructions.
2010
Operating Instructions
Model No. YA-1W/YA-1Z/YA-2E/YA-2G Series
TAWERS WGH 450 A Type
- The Arc Welding Robotic System -
Model No.
YA-1WAR61T**
YA-1WAR61Y**
YA-1WAR61E**
YA-1WAR61U**
(TM-1400/TM-1100/TM-1600)
YA-1WAR81T**
YA-1WAR81Y**
YA-1WAR81E**
YA-1WAR81U**
(TM-1800/TM-2000)
YA-1ZAR81T**
YA-1ZAR81Y**
YA-1ZAR81E**
YA-1ZAR81U**
(TL-1800/TL-2000)
YA-2EAR81T**
YA-2EAR81Y**
YA-2EAR81E**
YA-2EAR81U**
(TS-800/TS-950)
YA-2GA261T**
YA-2GA261Y**
YA-2GA261E**
YA-2GA261U**
(LA-1800)
OM1305066E26
Arc Welding Robot Controllers

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Panasonic YA-1W Series and is the answer not in the manual?

Summary

Introduction and Safety Overview

For Your Safety

Safety precautions and guidelines for operating the robot system.

Registered Trade Mark Information

Lists trademarks and their respective owners.

Disclaimer and Liability

Legal disclaimers regarding product use, responsibility, and liability.

Safety Precautions

Signal Words and Safety Symbols

Explanation of signal words (WARNING, CAUTION) and safety symbols used in the manual.

Safe Welding Operation Guidelines

Cautions for safe welding operations, covering power units and electric shock prevention.

Fire, Explosion, and Blowout Prevention

Cautions to prevent fire, explosion, or blowout during operation.

Ventilation and Protective Equipment

Guidelines for proper ventilation and protective gear for welding hazards.

No Disassembly;Modification Warning

Warning against unauthorized disassembly or modification of the product.

Arc Flash, Spatter, and Hearing Safety

Precautions for eye, skin, and hearing protection from welding hazards.

Rotating Parts Safety

Precautions to prevent injury from rotating parts of the equipment.

Welding Wire Handling Safety

Safety measures related to the welding wire tip part.

Insulation Deterioration Precautions

Warnings about insulation deterioration causing fire and maintenance.

Model Number Specifications

Model Group Definitions

Explanation of model group codes and their design policies for different markets.

Manipulator Type Reference

Refers to separate operating instructions for manipulator types.

Technical Data and Structure

Structure and Control Method Details

Specifics on structure, cooling, power, grounding, axes, and speed control.

Controller Dimensions

Visual diagrams showing dimensions for T/Y, E, and U spec controllers.

Input, Output, and Communication Specifications

Digital Welding Specifications

Static Characteristic and Thermal Protection

Explains welding power source static characteristics and thermal protection.

Teach Pendant Specifications

Operation Box Details

Controller Accessories List

Connecting Cable Specifications

Transportation Methods

Installation Guidelines

Choosing an Installation Site

Criteria for selecting a suitable installation environment.

Installation Site Requirements

Details on controller placement relative to work envelope and safety fence.

Installation Method and Fixing

Procedures for physically fixing the controller and installing peripherals.

Controller Connections

Connecting Cable for Manipulator

Step-by-step instructions for connecting the manipulator motor and RE cables.

Cables for Built-in Welding Power Source

How to connect output cables to the welding power source.

Notes on Using Multiple Robots

Precautions when connecting multiple robots to a single workpiece.

Connecting the Teach Pendant

Detailed steps for connecting the teach pendant cable to the controller.

Ground Wire Connection Procedures

Primary Power Source Wiring

Wiring Primary Cables (T*;Y* Specification)

Specific wiring instructions for T/Y specification controllers.

Wiring Primary Cables (E*;U* Specification)

Specific wiring instructions for E/U specification controllers.

Using at 220 VAC (T*;Y* Specification)

How to switch the controller and power source to 220 VAC input.

Built-in Welding Power Source Voltage Change

How to change harness connections for 200 VAC or 220 VAC input.

Door Handle Operation

Lock Switches with Padlock

External Device Connection and Control

Using the Noise Filter Unit

Safety I;O Specifications

About Safety Circuit

General principles for safety circuit design and component selection.

Spare Emergency Stop Input

Configuration for the spare emergency stop input terminal.

External Emergency Stop Input

How to connect an external emergency stop switch.

Door Stop Input Configuration

How to connect a door status input for safety fence interlock.

Protective Stop 1 Input

Function and connection of the protective stop 1 input.

Protective Stop 2 Input

Function and connection of the protective stop 2 input.

External Enabling Input Function

How to use the external enabling input for safety functions.

Safety Circuit Input Overview

Diagram and description of various safety circuit inputs.

Emergency Stop Output Terminals

Details on the four types of emergency stop output terminals.

Emergency Stop Input;Output Relationships

Table showing relationships between stop inputs and output conditions.

Other Safety Input;Output

Other safety related inputs like Safety Holder and Installation.

Safety Holder Input Function

Function of the safety holder input terminals.

Installation Input Usage

How the installation input warns about incomplete safety I/O setup.

External Control Signal Connections

Sequencer Card Terminal Locations

Pinout and function of sequencer card terminals for I/O and status.

Serial Interface Connectors

Details on RS-232C, RS-422, and EX_IO connectors for communication.

I;O Terminal Equivalent Circuits

Explains the equivalent circuits for input and output terminals.

Auto Start Settings

Details on configuring auto start functionality.

Status Inputs Explained

Explains dedicated input terminals for robot status and control.

Status Outputs Explained

Explains dedicated output terminals for robot status signals.

Status I;O Allocation to User Terminals

Information on allocating status I/Os to user terminals.

Flowchart of Status Outputs

Diagrams illustrating status output timing for operating, holding, and mode changes.

Operating and Holding Output Flowchart

Timing chart for operating and holding output signals.

Mode Change (I;O Monitor) Flowchart

Timing chart for mode change signals.

Emergency Stop Flowcharts

Timing charts for emergency stop 1 and 2 outputs.

Error Output Flowchart

Timing chart for the error output signal.

Connecting to Sequencer Card

Procedures for connecting wires to the sequencer card terminals and connectors.

External Interface and Memory

Details on SD memory card slots and USB ports.

SD Memory Card Slot (Teach Pendant)

Information on the SD card slot on the teach pendant.

USB Port Functionality

Details about the USB ports on the teach pendant and compatible devices.

SD Memory Card Slot (Main CPU Card)

Information on SD card slots on the main CPU card.

Welding Voltage;Current Monitor

How to use monitor terminals for welding voltage and current.

Maintenance and Inspection

Inspection Schedule Details

Lists recommended inspection intervals for daily, 500-hour, and yearly checks.

Daily Check Procedures

Detailed checks to perform before turning on the power.

Inspections After Power On

Checks to perform after turning on the servo power.

Periodical Check Schedule

Schedule for periodical checks of components like screws, cables, and consumables.

Withstand Voltage and Insulation Resistance Precautions

Warnings regarding tests on semiconductor components.

Product Disposal Procedures

Repair Parts List

Controller Repair Parts Diagram

Diagrams identifying repairable parts of the controller.

Controller Parts Breakdown

Detailed list of controller parts with part numbers and quantities.

Controller Part Numbers and Fuses

Lists part numbers, repair order numbers, and fuse types for controllers.

Teach Pendant Repair Parts Diagram

Diagrams identifying repairable parts of the teach pendant.

Teach Pendant Parts Breakdown

Detailed list of teach pendant parts with part numbers and quantities.

Operation Box Repair Parts

Lists parts for the operation box, including switches and cables.

Critical Raw Material List

Circuit Diagrams

Controller 1 Circuit Diagram

Detailed circuit diagram for controller 1.

Controller 2 Circuit Diagram

Detailed circuit diagram for controller 2.

Welding Power Source Circuit Diagram

Detailed circuit diagram for the built-in welding power source.

Label Locations

Controller Label Locations Overview

Diagrams showing the placement of various labels on the controller.

U Specification Label Locations

Shows label placement specific to U specifications.

E Specification Label Locations

Shows label placement for E specifications (LA-1800 and other).

Type Label Examples

Examples of type labels for different controller models and specifications.

Grounding, Daily Check, and Caution Labels

Locations of labels related to grounding, daily checks, and caution symbols.

Crane Operation, Fan Warning, and Power Labels

Locations of labels for crane safety, fan warnings, and input power.

Installation, Maintenance, and Hazard Labels

Locations of labels for installation, maintenance, and hazard warnings.

Power Connection and Safety Certification Labels

Locations of labels for power connection, safety warnings, and certifications.

Summary

Introduction and Safety Overview

For Your Safety

Safety precautions and guidelines for operating the robot system.

Registered Trade Mark Information

Lists trademarks and their respective owners.

Disclaimer and Liability

Legal disclaimers regarding product use, responsibility, and liability.

Safety Precautions

Signal Words and Safety Symbols

Explanation of signal words (WARNING, CAUTION) and safety symbols used in the manual.

Safe Welding Operation Guidelines

Cautions for safe welding operations, covering power units and electric shock prevention.

Fire, Explosion, and Blowout Prevention

Cautions to prevent fire, explosion, or blowout during operation.

Ventilation and Protective Equipment

Guidelines for proper ventilation and protective gear for welding hazards.

No Disassembly;Modification Warning

Warning against unauthorized disassembly or modification of the product.

Arc Flash, Spatter, and Hearing Safety

Precautions for eye, skin, and hearing protection from welding hazards.

Rotating Parts Safety

Precautions to prevent injury from rotating parts of the equipment.

Welding Wire Handling Safety

Safety measures related to the welding wire tip part.

Insulation Deterioration Precautions

Warnings about insulation deterioration causing fire and maintenance.

Model Number Specifications

Model Group Definitions

Explanation of model group codes and their design policies for different markets.

Manipulator Type Reference

Refers to separate operating instructions for manipulator types.

Technical Data and Structure

Structure and Control Method Details

Specifics on structure, cooling, power, grounding, axes, and speed control.

Controller Dimensions

Visual diagrams showing dimensions for T/Y, E, and U spec controllers.

Input, Output, and Communication Specifications

Digital Welding Specifications

Static Characteristic and Thermal Protection

Explains welding power source static characteristics and thermal protection.

Teach Pendant Specifications

Operation Box Details

Controller Accessories List

Connecting Cable Specifications

Transportation Methods

Installation Guidelines

Choosing an Installation Site

Criteria for selecting a suitable installation environment.

Installation Site Requirements

Details on controller placement relative to work envelope and safety fence.

Installation Method and Fixing

Procedures for physically fixing the controller and installing peripherals.

Controller Connections

Connecting Cable for Manipulator

Step-by-step instructions for connecting the manipulator motor and RE cables.

Cables for Built-in Welding Power Source

How to connect output cables to the welding power source.

Notes on Using Multiple Robots

Precautions when connecting multiple robots to a single workpiece.

Connecting the Teach Pendant

Detailed steps for connecting the teach pendant cable to the controller.

Ground Wire Connection Procedures

Primary Power Source Wiring

Wiring Primary Cables (T*;Y* Specification)

Specific wiring instructions for T/Y specification controllers.

Wiring Primary Cables (E*;U* Specification)

Specific wiring instructions for E/U specification controllers.

Using at 220 VAC (T*;Y* Specification)

How to switch the controller and power source to 220 VAC input.

Built-in Welding Power Source Voltage Change

How to change harness connections for 200 VAC or 220 VAC input.

Door Handle Operation

Lock Switches with Padlock

External Device Connection and Control

Using the Noise Filter Unit

Safety I;O Specifications

About Safety Circuit

General principles for safety circuit design and component selection.

Spare Emergency Stop Input

Configuration for the spare emergency stop input terminal.

External Emergency Stop Input

How to connect an external emergency stop switch.

Door Stop Input Configuration

How to connect a door status input for safety fence interlock.

Protective Stop 1 Input

Function and connection of the protective stop 1 input.

Protective Stop 2 Input

Function and connection of the protective stop 2 input.

External Enabling Input Function

How to use the external enabling input for safety functions.

Safety Circuit Input Overview

Diagram and description of various safety circuit inputs.

Emergency Stop Output Terminals

Details on the four types of emergency stop output terminals.

Emergency Stop Input;Output Relationships

Table showing relationships between stop inputs and output conditions.

Other Safety Input;Output

Other safety related inputs like Safety Holder and Installation.

Safety Holder Input Function

Function of the safety holder input terminals.

Installation Input Usage

How the installation input warns about incomplete safety I/O setup.

External Control Signal Connections

Sequencer Card Terminal Locations

Pinout and function of sequencer card terminals for I/O and status.

Serial Interface Connectors

Details on RS-232C, RS-422, and EX_IO connectors for communication.

I;O Terminal Equivalent Circuits

Explains the equivalent circuits for input and output terminals.

Auto Start Settings

Details on configuring auto start functionality.

Status Inputs Explained

Explains dedicated input terminals for robot status and control.

Status Outputs Explained

Explains dedicated output terminals for robot status signals.

Status I;O Allocation to User Terminals

Information on allocating status I/Os to user terminals.

Flowchart of Status Outputs

Diagrams illustrating status output timing for operating, holding, and mode changes.

Operating and Holding Output Flowchart

Timing chart for operating and holding output signals.

Mode Change (I;O Monitor) Flowchart

Timing chart for mode change signals.

Emergency Stop Flowcharts

Timing charts for emergency stop 1 and 2 outputs.

Error Output Flowchart

Timing chart for the error output signal.

Connecting to Sequencer Card

Procedures for connecting wires to the sequencer card terminals and connectors.

External Interface and Memory

Details on SD memory card slots and USB ports.

SD Memory Card Slot (Teach Pendant)

Information on the SD card slot on the teach pendant.

USB Port Functionality

Details about the USB ports on the teach pendant and compatible devices.

SD Memory Card Slot (Main CPU Card)

Information on SD card slots on the main CPU card.

Welding Voltage;Current Monitor

How to use monitor terminals for welding voltage and current.

Maintenance and Inspection

Inspection Schedule Details

Lists recommended inspection intervals for daily, 500-hour, and yearly checks.

Daily Check Procedures

Detailed checks to perform before turning on the power.

Inspections After Power On

Checks to perform after turning on the servo power.

Periodical Check Schedule

Schedule for periodical checks of components like screws, cables, and consumables.

Withstand Voltage and Insulation Resistance Precautions

Warnings regarding tests on semiconductor components.

Product Disposal Procedures

Repair Parts List

Controller Repair Parts Diagram

Diagrams identifying repairable parts of the controller.

Controller Parts Breakdown

Detailed list of controller parts with part numbers and quantities.

Controller Part Numbers and Fuses

Lists part numbers, repair order numbers, and fuse types for controllers.

Teach Pendant Repair Parts Diagram

Diagrams identifying repairable parts of the teach pendant.

Teach Pendant Parts Breakdown

Detailed list of teach pendant parts with part numbers and quantities.

Operation Box Repair Parts

Lists parts for the operation box, including switches and cables.

Critical Raw Material List

Circuit Diagrams

Controller 1 Circuit Diagram

Detailed circuit diagram for controller 1.

Controller 2 Circuit Diagram

Detailed circuit diagram for controller 2.

Welding Power Source Circuit Diagram

Detailed circuit diagram for the built-in welding power source.

Label Locations

Controller Label Locations Overview

Diagrams showing the placement of various labels on the controller.

U Specification Label Locations

Shows label placement specific to U specifications.

E Specification Label Locations

Shows label placement for E specifications (LA-1800 and other).

Type Label Examples

Examples of type labels for different controller models and specifications.

Grounding, Daily Check, and Caution Labels

Locations of labels related to grounding, daily checks, and caution symbols.

Crane Operation, Fan Warning, and Power Labels

Locations of labels for crane safety, fan warnings, and input power.

Installation, Maintenance, and Hazard Labels

Locations of labels for installation, maintenance, and hazard warnings.

Power Connection and Safety Certification Labels

Locations of labels for power connection, safety warnings, and certifications.

Panasonic YA-1W Series Specifications

General IconGeneral
BrandPanasonic
ModelYA-1W Series
CategoryIndustrial Equipment
LanguageEnglish

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