Posts by Robatics1278

    Hello all, I am working with a (used) Motoman positioner (the locking pin type) with an NX100 welding robot. Anyway I have this issue that I just can't figure out. I have to keep resetting the home positions for table A and B about every two weeks. This happens when an operator breaks the light curtain. I don't know exactly what they are doing to try to recover from the light beam hold to cause this problem. I have instructed them to switch to teach mode and hold interlock test start until the positioner completes its sweep. I have tested this procedure multiple times and it has always worked. Several times the operator tells me that they use the procedure I described but when the positioner completes its sweep the pins are off and will not engage the table. The pins aren't off a ton just enough to cause a misalignment issue. What would cause this problem of the pins and table alignment being off??? I don't understand how this is possible since the positioner is geared.

    Help would be greatly appreciated.

    Good morning all, I have a question I hope to get some help with. I am trying to parallel shift a job by means of a parallel shift job conversion. We have a positioner with 3 fixtures on A and 3 on B. I want to shift a welding job from position 3 to 2. This is a distance in Y of 736.6mm.

    I am attempting to accomplish to via the calculate shift by teaching method. So, in the parallel shift menu I go to BASE POINT and when I have BASE POINT (SRC) highlighted I go to my first arc on position on fixture location 3 and hit modify / enter. Then I highlight BASE POINT (DEST) and move to my new first arc on on fixture 2 modify / enter. Seems pretty easy but when I execute job and try to walk through it the robot wants to just spin around and go to some random point until it reaches S axis limit.

    Am I misunderstanding what BASE POINT is?

    Also it is an R1+S1 job. When the position sweeps the first thing the job does is flip the table 180*. Could this be confusing the shift function? I am not calling in a s1_180 program in, the table flip is just a taught rotation.

    Any suggestions? Thank You

    Okay, L2 is an error code for invalid configuration of EDM. I look in the SICK manual and it says:

    "If you connect the contact elements to be monitored to the EDM input, then you must activate the option EDM in the CDS (Configuration & Diagnostic Software. If not, the device will show the error L2."

    "If you later deselect the EDM option, pin 6 of the system plug must not remain connected to 24V."

    I believe our light curtains do not have the EDM enabled and that is why I was getting error L2. Wire 6 on the light curtain was hooked to the Safety relay Y2. I removed wire 6 from the relay and the curtains started working.

    Now the problem is that when we try to flip the positioner we get an external e stop error. It sounds stupid but if we shake the relay it goes away and lets us flip. Doing some reading I see that Y1 / Y2 are for a reset button. I am thinking that the Motoman control or light curtains are looking for a handshake that each other is working?? Odd thing is I can look at the Input for light curtain clear while this e stop error is active and it is saying they are clear.

    Also while this e stop error is active both channel lights are on, on the relay.

    I tried to put a jumper in between Y1 & Y2 but no luck.

    Am I right in thinking I need to fool the relay or control into thinking the EDM is working or what?

    Hello all, the company I work for purchased a used NX100 EA1900 weld cell and it arrived about a month ago. We / I have been battling it the whole time from missing cables to getting it to weld. Long story short there were a bunch of jumpers and aftermarket wiring in the cabinet. We received our light curtains the last piece of our puzzle last Friday. We plug them in and we get error code L2 Invalid configuration of External Device Monitoring on the curtain display. These are SICK 4000 light curtains, none of the curtain led's are lit. When we attempt to go to PLAY mode me get an external device prohibiting error. I am assuming the light curtains.

    As I mentioned there some cut wires and aftermarket jumpers in place so I rang out all the wires having to do with the safety circuit leading between the MXT breakout / Safety relay CR4105 and various terminal blocks. The MXT card had the following already jumped.

    9-10 Door Plug

    11-12 Door Plug

    19-20 External E Stop

    21-22 External E Stop

    26-27 Slow Speed

    31-32 External Hold

    33-34 Enable

    35-36 Enable

    So I am I correct in thinking that all the factory safety features are jumped out? I hooked the external e-stop back up to MXT 20-21 to CR4105 relay for safety reasons. These were disconnected from the MXT.

    I see Input003 is light curtain clear that comes from the CR4105 terminal 34 to B4 on the NI001 CN10 B4.

    I also found jumpers on JANCD CN10 that look like they don't belong:




    Then a wire from A16 goes to TB8

    Another wire from MXT 48 to TB8

    I have no idea what the previous owners did with it or what they were trying to accomplish.

    I know this is very confusing but any tips would be greatly appreciated.

    Thank You

    Well if anyone else has this same issue we talked to a Fronius robot tech who is familiar with robots and the ROB5000 and he had us cut wire 13 on JANCD-XEW01_CN03 to ROB5000 plug X8 wire 10. It was sending an ARCOFF signal after ARCON. I have no idea why but it is welding great now.

    So, an update on my progress. I started looking at the wiring in the cabinet and found several wires cut:

    First pair of wires: Both come from Card Box JANCD - XEW01 - Connector CN03: 34P:6 current flow signal out and on other end DIN +++. Other wire from CN03: 34P:30 Honda Stecker and on the other end DIN ---.

    Second pair of wires found in bottom of cabinet coming from Fronius ROB 5000 connector 8: One says ERROR QUIT 10P MOLEX 2X8:5 and the other says CN02-4.

    I'm guessing there's a pretty good chance this is why we are having issues. We tried to see where they go according to the Motoman wiring schematics, but we didn’t have any luck. One more thing is the schematic pictures a voltage sensing wire piggy backed onto the weld negative cable on the positioner. We have no such wire anywhere.

    Hello all, we have taken delivery of a Motoman NX100 weld cell with a Fronius 3200 TransPlus power supply. This is a used cell in great condition. When it got here a few weeks ago it took a while to hunt down some missing cables but we now have it to the point where it will Arc Start but then immediately goes to Arc Failure. Now this Fronius is much different than our Miller supply's were used to. I read the Fronius and Motoman manuals regarding them and understand:

    There are 3 ways to program welding with this setup:

    Local: where everything is controlled through the front panel of the power supply. We set Output 14&15 to on to enable this function and program on front panel on program 0. Same arc fail outcome.

    Program: Uses AON_FR to set welding parameters. Pulls from a pre set list of programs made by Fronius from 0-99 depending on wire diameter and what material you are welding. Set to program 6 which our manual specifies as 0.035" wire for mild steel. Still Arc start fail.

    Job: Uses AON_FRJ to select jobs made by user stored in the power supply. We made up a schedule and went to run it using the AON_FRJ command and still an arc failure.

    At this point I'm fairly confident we have an understanding of what we are doing programming wise. I don't know what else it could be. Once again it will strike an arc and immediately fault.

    We checked wire, gas, tips, nozzles. Is it possible the control is not getting an arc established?

    Any suggestions would be greatly appreciated. We are at a stand still. We had a conversation with Motoman, we tried all their suggestion, still arc failure.

    Thank You

    Hello all, the company I work for just bought a used Motoman NX100 weld cell with Fronius 3200 power supply however when it got here we realized it was missing some cables. They are the cable / cables comes out of the back of the power supply X91port and splits off into a pig tail. One side of the pig tail runs to port CA34 on the NX100 controller, the other runs to a connector at the robot for the vr5000 wire feeder. We have another robot with this cable but I cannot find any ID markings on them. Motoman claims they don't know the P/N since it is a fronius cable. I contacted Fronius and they have been of no help either. We just need that cable to get up and running. I am frantically looking for it. Worse comes to worse I will try to find the backshells and pins and make one but I'd like to keep that for last resort. Can anyone help me out?

    Thank You

    Hello all, I am the welding engineer at my place of employment, we have four Motoman robots, one NX100 , one MRC and two XRC's. We are trying to record our "Green Light" time. Since we started this around a month ago I have been collecting the data at the same time each morning and using System Info/Monitoring Time/Moving Time. I noticed that the moving time only counts when the robots are moving and does not take into account the positioner. I found there to be about a 15% difference between moving time and actual time so I have been adding 15% to my daily time.

    If I go into Playback Time on the NX100 and record the number for Robot 1 it seems to be very close to my added 15% time. That will work great for the NX100 but on the XRC & MRC the playback time seems to count all the time while the switch on the pendant is in playback so it would be useless data.

    Anyway, my question is, is there a way to get a daily number that starts at cycle start and ends when the positioner flips back to the operator? I have searched on this forum but I have only been able to find how to time an individual program. We are looking for total run time from cycle start to cycle end.

    Help is greatly appreciated, Thank You.

    Right, I have cleared the servo alarm but the user alarm 9065 S4 CUBE ALARM is still active and cannot be cleared since the controls for the positioner (well everything) are locked out. I found that the user alarm is triggering SPECIFIED OUTPUT #50013. I'm thinking somehow I have to go into the ladder and turn that off to be able to move the positioner out of the interference cube.

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