90210-1277DEA - Arc Welding Thick Plate Option Operation Manual (E Series)

Kawasaki Robot Controller
E Series
Arc Welding
Thick Plate Option
OPERATION MANUAL
(Option)
Kawasaki Heavy Industries, Ltd.
90210－1277DEA
E Series Controller
Kawasaki Robot Arc Welding Thick Plate Option Operation Manual
PREFACE
This manual describes operating instructions for arc welding thick plate option of Kawasaki
Robot Controller E series.
Read the following manual together with this manual: Arc Welding Operation Manual,
Operation Manual, Arc Welding AS Language Reference Manual, and AS Language
Reference Manual. Also read the Safety Manuals and the relevant manuals such as
Installation and Connection Manuals (for arm and for controller) and Installation and
Connection Manuals (Arc Welding Specification) for arc welding robot controlled by the E
series controller. Thoroughly comprehend the contents of these manuals before actually
operating the robot.
！ CAUTION
The option described in this manual is an independent option respectively.

It will not equip all the options in the robot which the customer uses.
This manual provides as much detailed information as possible on the standard operating methods
for arc welding specification of the Kawasaki robot. However, not every possible operation,
condition or situation that should be avoided can be described in full. Therefore, should any
unexplained questions or problems arise during robot operation, contact Kawasaki. Refer to the
contact information listed on the rear cover of this manual for the nearest Kawasaki.
The explanations in this manual include information on optional functions, but depending on the
specification of each unit, not every optional function detailed here may be included with the
robot. Also, note that figures given here may differ partially from actual screens.
1. This manual does not constitute a guarantee of the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damage, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the right to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different side or sold off to a different use, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
All rights reserved. Copyright © 2011 by Kawasaki Heavy Industries Ltd.
i
E Series Controller
SYMBOLS
The items that require special attention in this manual are designated with the following
symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
！ DANGER
Failure to comply with indicated matters can result in

imminent injury or death.
！ WARNING
Failure to comply with indicated matters may possibly

lead to injury or death.
！ CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,

handling, teaching, operation and maintenance.
！ WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute
certainty. Should any unexplained questions or problems arise, please
contact Kawasaki Machine Systems.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.
ii
E Series Controller
INTRODUCTORY NOTES
1. HARDWARE KEYS AND SWITCHES (BUTTON)
E series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms “key” or “switch” which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by “+” as shown in the example below.
EXAMPLES
ENTER: expresses the hardware key “ENTER”.
TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.
A+MENU: indicates pressing and holding down A then pressing MENU.
2. SOFTWARE KEYS AND SWITCHES
E series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this
manual, the names of software keys and switches are enclosed by “< >” parentheses. The terms
“key” or “switch” which should follow the relevant names are sometimes omitted for simpler
expression.
EXAMPLES
<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.
3. SELECTION ITEMS
Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].
EXAMPLES
[Auxiliary Function]: Expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the ↵ key. For
detailed description, this procedure should be described every time, but
“select [XXX] item” will be used instead for simpler expression.
iii
E Series Controller
CONTENTS
1.0 RTPM Function (Option) ................................................................................. 1-1

1.1 Outline of RTPM (Real Time Path Modulation) Function .............................. 1-1
1.2 Principle Of RTPM Function ........................................................................... 1-2
1.3 Applicable Scope Of RTPM Function ............................................................. 1-3
1.4 Caution When Using RTPM Function ............................................................. 1-5
1.5 Teaching of RTPM Function............................................................................ 1-6
1.5.1 Teaching by Simplified Operation ................................................................... 1-6
1.5.2 Making of Teach Program By As Language.................................................... 1-9
1.5.3 Bias Setting of RTPM Function ..................................................................... 1-10
1.5.3.1 Setting Method by Simplified Operation ....................................................... 1-10
1.5.3.2 Setting Method by As Language .................................................................... 1-12
1.5.4 Continuing and Terminating RTPM Function ............................................... 1-13
1.5.4.1 Teaching Examples by Simplified Operation ................................................ 1-13
1.5.4.2 Teaching Examples by As Language Programming ...................................... 1-15
1.6 Data Setting Screen ........................................................................................ 1-17
1.6.1 Operating Method of Data Setting Screen ..................................................... 1-17
1.6.2 Example of Setting Screen And Parameter Explanation................................ 1-18
1.7 Displaying Various RTPM Data (As Language Specification
Only) .............................................................................................................. 1-22
1.7.1 Displaying Current Reference, Current Actual, Current Wall
And Current Floor Of Present Welding Current............................................ 1-22
1.7.2 Displaying Modification Value According To Present Current
Value .............................................................................................................. 1-22
1.7.3 Displaying Current Reference, Current Actual, Current Wall
And Current Floor Of Logged Welding Current ........................................... 1-23
1.7.4 Displaying Modification Value According To Logged Current
Value .............................................................................................................. 1-23
1.8 RTPM Function Errors ................................................................................... 1-24
1.8.1 Error Message List ......................................................................................... 1-24
1.8.2 Error Handling................................................................................................ 1-24
2.0 Start Point Sensing Function (Option) ............................................................. 2-1

2.1 Outline of Start Point Sensing Function........................................................... 2-1
2.1.1 Outline of Function .......................................................................................... 2-1
2.1.2 Robot Motion Example in the Repeat Mode.................................................... 2-2
2.2 Teaching Start Point Sensing Function ............................................................ 2-4
iv
E Series Controller
2.2.1 Teaching by Simplified Operation ................................................................... 2-4

2.2.2 Programming Using AS Language .................................................................. 2-7
2.3 Registration of Start Point Sensing Parameter ................................................. 2-8
2.3.1 Registration of Start Point Sensing System Parameter .................................... 2-8
2.3.1.1 Basic Parameter ................................................................................................ 2-9
2.3.1.2 Special Groove Shape .................................................................................... 2-10
2.3.1.3 Standard Groove Shape .................................................................................. 2-11
2.3.2 Motion Patterns with Various Grooves .......................................................... 2-12
2.3.3 Setting Start Point Sensing Pattern in Welding Condition Setting Function . 2-13
2.4 Start Point Sensing Function Errors ............................................................... 2-14
2.4.1 Error Message List ......................................................................................... 2-14
2.4.2 Error Handling................................................................................................ 2-14
3.0 Thick Plate Database Function (Option) .......................................................... 3-1

3.1 Outline of Thick Plate Arc Welding Database ................................................. 3-1
3.2 Thick Plate Arc Welding Database Parameters ............................................... 3-2
3.2.1 Calling Up Arc Welding Database ................................................................... 3-2
3.2.2 Screen for Arc Welding Database Function ..................................................... 3-3
3.2.3 Additional Parameters for Thick Plate Database ............................................. 3-4
3.2.4 Parameters Common with Standard Database ................................................. 3-7
3.3 Registration of Thick Plate Arc Database ........................................................ 3-8
3.3.1 Overwriting (Modifying) Pass Data ................................................................. 3-8
3.3.2 Registering New Pass Data Continuously........................................................ 3-9
3.3.3 Inserting Pass .................................................................................................. 3-10
3.3.4 Deleting Pass .................................................................................................. 3-11
3.4 How to Use Thick Plate Arc Welding Database ............................................ 3-12
3.4.1 Auto Setting of Welding Condition ............................................................... 3-12
3.4.2 Arc Weld Condition Modification Function .................................................. 3-13
3.5 Thick Plate Database Function Errors ............................................................ 3-15
4.0 Multi-layer Expansion Function (Option) ....................................................... 4-1

4.1 Outline of Multi-layer Expansion Function .................................................... 4-1
4.2 Using Method of Multi-layer Expansion Function ......................................... 4-2
4.3 Explanation of Parameters .............................................................................. 4-6
4.4 Multi-layer Expansion Errors ........................................................................ 4-11
4.5 Relation Between Multi-layer Expansion Function and Other Thick
Plate Options ................................................................................................. 4-12
4.6 Precautions for Multi-layer Expansion ......................................................... 4-13
v
E Series Controller
Appendix. 1 RTPM Board (1TH Board) Jumber and Dip Switch Setting ................. A-1
Appendix. 2 Summary of Thick Plate Arc Welding Teaching................................... A-3
vi
E Series Controller 1. RTPM Function (Option)
1.0 RTPM FUNCTION (OPTION)
1.1 OUTLINE OF RTPM (REAL TIME PATH MODULATION) FUNCTION
Robot welding requires precise positioning of workpiece and high workpiece accuracy.
However, the conditions in the actual production site may not always allow precise positioning
and accurate manufacturing of workpieces. With this RTPM function, the weaving motion of
the welder makes it possible for the welder to detect the change in the arc current and to track the
weld line of the workpiece in real time even when the positioning and shape of the workpiece is
not very accurate, thus realizing a high accuracy welding. In the arc welding specification, the
RTPM function is actualized as an optional function by using an arc sensor.
The arc sensor uses the fluctuation phenomenon of the arc length caused by weaving welding.
Robot detects deviation from a weld line or a groove width and corrects the welding torch in a
horizontal direction. Also, welding torch is adjusted vertically so that the averaged wire
extension length is kept constant to uniform weld beads.
1-1
1.2 PRINCIPLE OF RTPM FUNCTION
The weld current value of welding source with constant-voltage characteristics used for robot
welding becomes less when the arc length becomes long. The arc sensor compensation using
this feature realizes the function to correct the motion of robot which automatically tracks the
weld line by taking the actual weld current during weaving weld into the robot controller. Take
the flat fillet welding as an example to consider the principle of arc sensor.
Right and
left deviation
Robot corrects the trajectory so that

deviations in vertical and horizontal
directions are eliminated.
Up and down
deviation
Command weld current value

Averaged real weld current value
Real weld current value
= Adjustment in horizontal direction =

When the center line of the torch tip is off to the right of the weld line, the weld current value on
the right side becomes larger than the value on the left side as shown above. With the arc sensor,
robot compares difference of the current values (area between 1 and 2 in the above figure), and
adjusts the torch tip to the left so as to eliminate the difference.
= Adjustment in vertical direction =
When the torch tip position is off to upper side of the weld line, the averaged weld current value
becomes smaller than the command weld current value. With the arc sensor, robot adjusts the
torch tip to a downward direction to eliminate the difference between the command weld current
value and the averaged real weld current value.
1-2
1.3 APPLICABLE SCOPE OF RTPM FUNCTION
Applicable scope of RTPM function is described below.
 Welding method (gas) : CO2 and MAG

Consult Kawasaki separately for
 Diameter of wire : φ1.2: Solid wire.
specifications other than described here.
 Wire extension : 20.0mm
1. Condition of welding data base

 Welding posture / Joint shape : Horizontal fillet, Flat fillet, Bevel Groove, V Groove, Flat
Bevel Groove, Horizontal Bevel groove
 Leg length / Board thickness : 6 mm or more
 Route gap : 2 mm
 Groove angle : 90 degrees or less
The length from the

Groove angle leg length should be
2 mm or more.
Wire
extension
Leg length /
Board
Leg
length
Route gap
2. Welding condition
 Welding current : 200A or more
 Welding speed : 60cm/min or less
 The shortest welding length : 70mm
Consult Kawasaki separately
3. Weaving condition for specifications other than
Weaving amplitude : 3 - 5mm described here.
Weaving frequency : 2 - 4Hz
Weaving shape : Single vibration weaving (PN=0)
！ CAUTION
The applicable scope of RTPM function varies depending on welding methods.

Consult Kawasaki separately, except for the scope described above.
1-3
4. RTPM tracking performance
The RTPM function can make adjustment of the welding line in real time by using the principle
of the arc sensor. In this case, the RTPM function adjusts welding position once per weaving
cycle. In a word, the tracking performance to follow the welding line is proportional to the
weaving frequency and in inverse proportion to the welding speed.
Tracking performance when using welding database

Horizontal fillet : Weld speed = 33cm/min,
Weaving frequency = 2Hz  Tracking performance 4.5%
Flat fillet : Welding speed = 55cm/min,
Weaving frequency = 4Hz  Tracking performance 5.5%
Thus, the RTPM tracking performance demonstrates the Enable for the installation error of
workpiece which cannot be prevented even if it devises jig, and for the error due to the heat warp
of workpiece during the welding.
Rough standard of the RTPM tracking performance calculated according to database conditions
etc. is shown below.
(The value of each column is a tracking performance (%))

Weaving frequency
Welding
（Hz） 1 2 3 4
speed (cm/min)
20 3.75 7.5 11.25 15.0
25 3.0 6.0 9.0 12.0
30 2.5 5.0 7.5 10.0
33 2.27 4.54 6.81 9.08
40 1.88 3.76 5.64 7.52
50 1.5 3.0 4.5 6.0
55 1.36 2.72 4.08 5.44
60 1.25 2.5 3.75 5.0
Consult Kawasaki separately, except for the scope of application described above.
1-4
1.4 CAUTION WHEN USING RTPM FUNCTION
Check followings thoroughly before using the RTPM function.
！ CAUTION
1. Are values of built-in linearizer table/ offset gain correct?
With workpiece fixed, confirm that a weld current/voltage satisfy
taught welding conditions. If not satisfy, adjust the value of
linearizer table/offset gain.
2. Are registered values of robot’s installation posture, tool dimensions,
and base coordinates correct?
3. As for welding passes using the RTPM function, are rules of welding
instruction satisfied?
In the welding instruction, rules are applied including;
･ Starting the welding pass : Weld start point.
･ Ending the welding pass : Weld end point.
･ Between the weld start point and the weld end point, only the weld
continue point can be taught.
The RTPM function is only enabled only when being in repeat mode,
weld ON and step continuously. Note a welding error may be caused
by the RTPM function when the welding pass does not satisfy the rules
of the welding instructions.
4. Set taught points within 127 (from weld start point to weld end point)
in one pass.
1-5
1.5 TEACHING OF RTPM FUNCTION
1.5.1 TEACHING BY SIMPLIFIED OPERATION
This section describes teaching procedures of the RTPM function by simplified operations using
Teach Pendant. Refer to Arc Welding Operation Manual for basic teaching method in arc
welding specifications.
Example of teaching:
Assume that a horizontal fillet workpiece

shown in the left figure is welded using
RTPM function.
Teaching of Point A
1. Move the robot to point A by +/- and set the auxiliary data, the instruction to AC (Air Cut).
2. Press RECORD to teach the pose and the auxiliary data to point A.
1-6
Teaching of Point B
1. After moving the torch tip to a weld start point (Point B) by +/-, teach start point sensing and
RTPM functions.
2. Set the auxiliary data, the instruction to WS.
3. Move cursor to [Option Switch] by A+←. The following option switch screen is displayed.
Select [Enable] for [RTPM] and press ↵.
4. Press RECORD to teach the pose and the auxiliary data including the option switch
condition to point B.
1-7
Teaching of Point C
1. After moving torch tip to weld end point (point C)
by +/-, teach whether to continue RTPM function
or to end RTPM function.
2. Set the auxiliary data, the instruction to WE.
Set the welding condition. Assume that the
welding condition is set 0 (zero).
[ NOTE ]
If the weaving is not set in a welding condition, the
RTPM function does not become Enable.
For details, see 1.5.3 Bias Setting of RTPM Function and “Arc Welding Operation Manual”
3. Move cursor to [Option Switch] by → and press ENTER. The following option switch
screen is displayed. Using A+←/→, select either [Enable] or [Disable] for [RTPM
Continue] on the option screen and press ↵. For details, see 1.5.4 Continuing and
Terminating RTPM Function.
4. Press RECORD to teach the pose and the auxiliary data including option switch condition to
point C.
Teaching of Point D
1. Move the torch tip to the escape point (point D) after completing welding by +/-, and set the
auxiliary data, the instruction to AC (Air Cut) on Teach screen.
2. Press RECORD to teach the pose and the auxiliary data to point D.
1-8
1.5.2 MAKING OF TEACH PROGRAM BY AS LANGUAGE
This section describes procedures of preparing programs taught with RTPM function with AS
language. An example of programming in welding with the RTPM function is shown below.
W1SET 1=33 , 250 , 27 , 3 , 2 ................. Sets welding conditions.

W2SET 1=1.3 , 170 , 22.5........................ Sets crater conditions.
RTPM OFF ............................................... Initializes (OFF) RTPM function.
JMOVE a0
RTPM ON ................................................. Changes the RTPM function to “Enable”.
LWS a1 .................................................. Executes the RTPM tracking at weld start point
taught with a name of a1. and, executes welding.
LWC a2 , 1 ............................................. With the welding condition No.1, executes
welding up to weld continue point taught with a
name of a2, executing the RTPM tracking.
LWE a3 , 1 , 1 ....................................... With the welding condition No.1, executes
welding up to the weld end point taught with a
name of a3, executing the RTPM tracking.
After arriving at a3, process crater with the crater
condition No.1.
RTPM OFF ............................................... Change the RTPM function to Disable
(terminate).
JMOVE b0
In the AS language, the RTPM function becomes enabled by RTPM ON command and becomes
disabled by RTPM OFF command.
[ NOTE ]
If the weaving is not set in the
welding condition, the RTPM
function does not become
Enable.
b0
Escape point (air cut point)
a0
Work starting
point a2
(weld continue) a3
a1
(weld start) (weld end)
1-9
1.5.3 BIAS SETTING OF RTPM FUNCTION
The bias of the RTPM function is a parameter used for welding with uneven thickness of bead
including horizontal fillets when keeping right and left current values constant (Bias: 0) and is
used to keep even welding in a horizontal direction.

Adjusting right
and left bias.
Right and left bias: 0 Right and left bias: χ

Bead biased to vertical wall side Right and left even welding
1.5.3.1 SETTING METHOD BY SIMPLIFIED OPERATION
Set in “Welding condition”.
1. Display pull-down menu by activating B area and pressing MENU, or by pressing the B area
window directly, and select [Aux Function].
2. Input auxiliary function number 14 by NUMBER and press ↵, or move cursor to

[14. Arc Weld] and press ENTER.
1-10
3. Select [1. Arc Weld Condition].
4. Input desired weld condition number by NUMBER and press ↵.
5. Move cursor to each item and input required data by NUMBER. If the setting is correct,
press ↵. Press <Next Page> and <Prev Page> to display the setting screens for weld
condition No. 0 to 99. Pressing <Auto Set> displays the screen to reference the arc weld
condition database.
1-11
The bias can be set per step like the weld condition.
[ NOTE ]
[Weaving Data], [Pole Ratio] and [Start Sensing Pattern] are
displayed only when Option is installed.
Direction of bias
Input a plus (+) value Input a minus (-) value
Vertical
bias Direction of Direction of
uplifting torch lowering torch
Input a plus (+) value Input a minus (-) value
To the floor
Lateral direction To the wall
bias direction
1.5.3.2 SETTING METHOD BY AS LANGUAGE
1. RTBIAS instruction
Refer to “Arc Welding AS Language Reference Manual” for details.
2. Setting with the setting screen.
Refer to 1.6.2 Example of Setting Screen and Parameter Explanation for details.
1-12
1.5.4 CONTINUING AND TERMINATING RTPM FUNCTION
1.5.4.1 TEACHING EXAMPLES BY SIMPLIFIED OPERATION
1. When continuing modification of RTPM function
When robot moves from a seam to another seam with position modified by the RTPM function
during welding shown above, it is called RTPM Continue Enable.
Program list
Specify “RTPM Enable” 1 AC
at the weld start point. 2 WS RTPM YES
3 WE RTPM=CNT This shows the
4 AC RTPM Continue
5 WS RTPM YES Enable.
Welding of seam 1 6 WE
7 AC
Specify RTPM ................. Keep the position modification.

Continue Enable at the
weld end point.
Specify “RTPM Enable”

at the weld start point.
Welding of seam 2
Specify “RTPM Continue

Disable” at the weld end
point.
Thus, when a weld end point of seam welded with “RTPM Enable” and the next seam’s weld
start point are on the same workpiece, the deviation of RTPM is reflected even if there is a
deviation between the taught position and the actual position at repeat operation if “RTPM
Continue Enable” is specified. Robot can start welding at the next weld start point without
sensing.
1-13
2. When terminating modification of RTPM function
The robot terminates the position modification by the RTPM function once when completing the
welding of a certain seam, and moves to the next seam as shown in the above figure, which is
called “RTPM Continue Disable”.
Program list
Specify “RTPM Enable” 1 AC
at the weld start point. 2 WS RTPM YES
3 WE It is not displayed
4 AC when the RTPM
5 WS RTPM YES Continue is set to
Welding of seam 1 6 WE
7 AC Disable.

Disable” at the weld end ... The position modification is terminated once.
point.
Specify “RTPM Enable”

at the weld start point.
Welding of seam 2

Disable” at the weld end
point.
！ CAUTION
Teach “RTPM Continue Disable” at the end point of the final seam
welded by the RTPM function without fail. Note the deviation of
RTPM is reflected to the next workpiece when teaching “RTPM
Continue Enable”, and the weld start point deviates.
1-14
1.5.4.2 TEACHING EXAMPLES BY AS LANGUAGE PROGRAMMING
This section describes teaching examples by RTPM instructions; the case when continuing
modification of the RTPM function and the case when not continuing modification of the RTPM
function in seams. In the AS language programming, RTPM Continue becomes Enable with
RTCONT ON and becomes Disable with RTCONT OFF.
1. When continuing modification of RTPM function
RTCONT OFF ............... Initializes.

JMOVE #a1
RTPM ON
RTCONT ON ................. Enables the RTPM Continue.
LWS a2
LWE a3 , 1, 1
RTPM OFF
JMOVE a4 Welds seams ((5) - (6)), keeping the position
RTPM ON modification.
LWS a5 Calculates deviation at (3) and welds the next
LWE a6 , 1 , 1 seam while modificating RTPM.
RTPM OFF
RTCONT OFF ............... Disables the RTPM Continue.
JMOVE a7
1-15
When not continuing modification of RTPM function
RTPM OFF ............... Initializes.

JMOVE #a1
RTPM ON
RTCONT OFF ............... Disables the RTPM Continue.
LWS a2
LWE a3 , 1 , 1
RTPM OFF
JMOVE a4
Does not keep the position modification
RTPM ON
by the previous RTPM. Restarts
LWS a5
executing RTPM.
LWE a6 , 1 , 1
RTPM OFF
JMOVE a7
！ CAUTION
1. RTPM ON/OFF of AS language is equivalent to the RTPM
Enable/Disable by simplified operation.
2. RTCONT ON/OFF of AS language is equivalent to the RTPM
Continue Enable/Disable by simplified operation. Refer to
“Arc Welding AS Language Reference Manual” for detail.
1-16
1.6 DATA SETTING SCREEN
1.6.1 OPERATING METHOD OF DATA SETTING SCREEN
This section describes a method of registering the parameter for the RTPM function.
1. Move cursor to [1404. Arc Weld Setting] in the auxiliary function screen to display auxiliary
function list as shown in the figure below.
2. Input “12” using the NUMBER keys and press ↵, or move cursor to [12. RTPM] and press
ENTER to display.
3. Select each setting screen on this screen and set each parameter.
1-17
1.6.2 EXAMPLE OF SETTING SCREEN AND PARAMETER EXPLANATION
1. Tracking Gain/Bias
Move cursor to each item and input required data* by NUMBER (0-9), and press ↵.
Note* The parameter registered here is a standard parameter of Kawasaki.
Item Explanation Setting range
Vertical
GAIN** Value of tracking gain.
-1.00 - 1.00
Vertical Robot moves fleetly when setting a large value and
Lateral
Lateral moves smoothly when setting a small value.
-1.00 - 1.00
Limiter** Limiter value of travel distance calculated by gain.
Every Robot puts the limiter so that the calculated travel 0.00 - 9.99
Weaving distance should not become too large.
Used to change the target position by RTPM Vertical
Bias
function. Enable only when used in AS language. -100.0 - 100.0
Vertical
Refer to 1.5.3 Bias Setting of RTPM Function Lateral
Lateral
when using this bias by simplified operation. -100.0 - 100.0
Note** The gain and the limiter are values per weaving.
Input plus(+) value Input minus (-) value
Vertical
Bias Direction to
Direction to
uplifting torch lowering torch
Input plus(+) value Input minus (-) value
To direction of
Lateral To direction of
the floor
Bias the wall
1-18
2. Tracking Data
Input required data* by NUMBER, and press ↵.


No Tracking
Time to omit unstable data in welding
Time After 0.0 -10.0
immediately after arc ON.
Welding Start
1-19
3. Limiter/Filter
Move cursor to each item and input required data* by NUMBER (0-9), and press ↵.
Setting
Item Explanation
range
Filter value to eliminate elements with large
Filter for change among noise elements in current value
Averaging after input current filtering. 0 - 1000
Current Used with Limiter for error of current.
Filter OFF when inputting 0 (zero).
Limiter value to eliminate elements with large
Limiter for
change among noise elements in current after
Error of 0.0 - 100.0
input current filtering.
Current
Used with Filter for averaging current.
Filter for Filter value to eliminate noise elements in input
Input current. 0 - 1000
Current Filter OFF when entering 0 (zero).
1-20
4. Error
Move cursor to each item and input required data* by NUMBER, and press ↵.

Out of Tracking Sets the detection threshold of the error
Value “E6537 RTPM tracking value is out of 0.0 - 1000.0
Threshold range”.
Sets the frequency when robot detects the
error “E6537 RTPM tracking value is out
Out of Tracking
of range” ( weaving). If
Value 0 - 100
above-mentioned abnormality is detected
Number of Times
more than the frequency continuously, it
becomes an error.
Out of Tracking Sets the detection threshold of the error
Capacity “E6538 Beyond RTPM tracking ability”. 0.0 - 1000.0
Threshold
Sets the data to compare with when
detecting the error “E6538 Beyond RTPM
tracking ability” ( weaving). It
Out of Tracking
becomes an error when there is a larger
Capacity 0 - 100
difference than the amount of tracking
Number of Times
ability over detection between this
frequency and the frequency for set time
before.
Current Deviation Sets the detection threshold of the error
“E6536 RTPM current deviation error”. 0.0 - 1000.0
Error Threshold
Sets the time to detect the error “E6536
Current Deviation RTPM current deviation error”. It
Error becomes an error when the 0 - 100
Time above-mentioned abnormality is detected
more than this time continuously.
1-21
1.7 DISPLAYING VARIOUS RTPM DATA (AS LANGUAGE SPECIFICATION ONLY)
This section describes commands to display various RTPM statuses. Refer to “Arc Welding AS
Language Reference Manual” for details on the following commands.
1.7.1 DISPLAYING CURRENT REFERENCE, CURRENT ACTUAL, CURRENT

WALL AND CURRENT FLOOR OF PRESENT WELDING CURRENT
Data is displayed as follows by inputting MONITOR command “RTMON 1”.

>rtmon 1
Cur.Ref. (A) Cur.Act.(A) Cur.Wall(A) Cur.Floor (A)
[ 1] 250.00 246.60 247.70 245.50
[ 2] 250.00 243.85 247.70 240.00
[ 3] 250.00 243.85 247.70 240.00
[ 4] 250.00 245.10 250.20 240.00
[ 5] 250.00 245.25 250.20 240.30
[ 6] 250.00 244.95 249.60 240.30
[ 7] 250.00 251.70 249.60 253.80
[ 8] 250.00 248.20 242.60 253.80
[ 9] 250.00 248.20 242.60 253.80
[ 10] 250.00 245.20 242.60 247.80
－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－
Ave. Cur.Ref. (A) Cur.Act.(A) Cur.Wall(A) Cur.Floor (A)
250.00 246.61 247.49 245.74
1.7.2 DISPLAYING MODIFICATION VALUE ACCORDING TO PRESENT CURRENT

VALUE
Data is displayed as follows by the input of MONITOR command “RTMON 2”.

>rtmon 2
Current(A) Tool Delta(mm) Total Modif.(mm)
Ref.-Act Fl.-Wal. Tool-Z Tool-Y Base-X Base-Y Base=Z
(Up =+) (Floor =+)
[ 1] 5.70 -6.20 -0.57 0.62 0.21 5.36 3.36
[ 2] 4.75 -4.30 -0.48 0.43 0.24 5.38 2.70
[ 3] 0.80 -12.20 -0.08 0.90 0.24 5.38 2.70
[ 4] 3.65 -17.90 -0.37 0.90 0.29 5.82 1.73
[ 5] 11.50 -2.20 -0.90 0.22 0.29 5.82 1.73
[ 6] 11.50 -2.20 -0.90 0.22 0.29 5.82 1.73
[ 7] 3.35 14.10 -0.34 -0.90 0.25 4.99 2.11
[ 8] 0.10 7.60 -0.01 -0.76 0.25 4.99 2.11
[ 9] 0.85 6.10 -0.09 -0.61 0.22 4.51 2.47
[ 10] 1.00 6.40 -0.10 -0.64 0.22 4.51 2.47
－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－
Ave Ref.-Act Fl.-Wal. Tool-Z Tool-Y Base-X Base-Y Base=Z
(Up =+) (Floor =+)
3.43 0.83 -0.30 -0.12 0.24 5.09 2.40
1-22
1.7.3 DISPLAYING CURRENT REFERENCE, CURRENT ACTUAL, CURRENT

WALL AND CURRENT FLOOR OF LOGGED WELDING CURRENT
Data is displayed as follows by inputting specified MONITOR “RTMON 3”. (To use
RTMON3, it is necessary to RTLOG ON before welding.)
>rtmon 3
Cur.Ref.(A) Cur.Act (A) Cur.Wall(A) Cur.Floor(A)
[ 1] 250.00 246.60 247.70 245.50
[ 2] 250.00 243.85 247.70 240.00
[ 3] 250.00 243.85 247.70 240.00
[ 4] 250.00 245.10 250.20 240.00
[ 5] 250.00 245.25 250.20 240.30
[ 6] 250.00 244.95 249.60 240.30
[ 7] 250.00 251.70 249.60 253.80
[ 8] 250.00 248.20 242.60 253.80
[ 9] 250.00 248.20 242.60 253.80
[ 10] 250.00 245.20 242.60 247.80
－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－
Ave. Cur.Ref.(A) Cur.Act (A) Cur.Wall(A) Cur.Floor(A)
250.00 246.61 247.49 245.74
1.7.4 DISPLAYING MODIFICATION VALUE ACCORDING TO LOGGED CURRENT

VALUE
Data is displayed as follows by inputting MONITOR command “RTMON 4”. (To use
RTMON4, it is necessary to RTLOG ON before welding.)
>rtmon 4
Ref.-Act Fl.-Wal. Tool-Z Tool-Y Base-X Base-Y Base=Z
(Up =+) (Floor =+)
[ 1] 5.70 -6.20 -0.57 0.62 0.21 5.36 3.36
[ 2] 4.75 -4.30 -0.48 0.43 0.24 5.38 2.70
[ 3] 0.80 -12.20 -0.08 0.90 0.24 5.38 2.70
[ 4] 3.65 -17.90 -0.37 0.90 0.29 5.82 1.73
[ 5] 11.50 -2.20 -0.90 0.22 0.29 5.82 1.73
[ 6] 11.50 -2.20 -0.90 0.22 0.29 5.82 1.73
[ 7] 3.35 14.10 -0.34 -0.90 0.25 4.99 2.11
[ 8] 0.10 7.60 -0.01 -0.76 0.25 4.99 2.11
[ 9] 0.85 6.10 -0.09 -0.61 0.22 4.51 2.47
[ 10] 1.00 6.40 -0.10 -0.64 0.22 4.51 2.47
－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－－
Ave. Ref.-Act Fl.-Wal. Tool-Z Tool-Y Base-X Base-Y Base=Z
(Up =+) (Floor =+)
3.43 0.83 -0.30 -0.12 0.24 5.09 2.40
1-23
1.8 RTPM FUNCTION ERRORS
This section describes errors and their countermeasures for the errors that occur during RTPM
function operation.
1.8.1 ERROR MESSAGE LIST

Error code Error message Main cause
E6533 No RTPM board. Hardware (board) for the RTPM option is not mounted.
Too many taught Num. of points taught RTPM within 1 pass (weld start to
E6534 weld end) exceeds 127 points.
points for RTPM.
RTPM tracking The tracking shift amount used as criterion for
E6537 value is out of determining error output was exceeded continuously
range. more than the num. of times allowed
The difference between the current tracking amount and
Beyond RTPM the tracking amount detected previously per preset num.
E6538
tracking ability. of times exceeds the RTPM tracking ability/criterion
amount used as threshold for this error.
During execution of RTPM, state of
|Command current – Feedback current| > Criterion
RTPM current
E6536 current, specified as the threshold for detecting an
deviation error.
over-current deviation, continued longer than the time
allowed.
1.8.2 ERROR HANDLING
If the program taught with the RTPM function suffers an error while it is running, execute the
recovery procedures detailed here and on the following pages.
1. E6533: No RTPM board.
The robot suspends its motion and stops at the step where this error occurs.
Main causes:
1. Though software option is added, hardware (1TH board) is not installed at controller power
ON.
2. Though the board is mounted, controller power was not turned OFF then ON after setting
optional function.
Countermeasures:
1. Turn OFF “Controller power” once, and check if the board for RTPM (1TH board: analog
1-24
input board) is mounted on power sequence board in the controller. See Appendix 1.
2. If correctly mounted, check if the jumpers, etc. are properly set.
3. If correctly mounted, insert the board firmly as connectors, etc. may be loose.
4. After setting optional function, turn the controller power OFF then ON.
2. E6534: Too many taught points for RTPM.
Main cause:
Num. of taught points within 1 pass (weld start to weld end) exceeds 127 points when using
RTPM function.
Countermeasure:
Correct the num. of taught points in 1 pass to be 127 points or less.
3. E6537: RTPM tracking value is out of range.
Main cause:
Tracking shift amount for determining error output
WS WE
Planning (teaching)
The tracking shift amount used as criterion for determining error output has exceeded
continuously from in the above figure for more than the num. of times allowed.
Countermeasures:
When weld line is far from the groove;
1. Check if weld start point is in the groove as error occurs when it is far from the groove.
2. Weld with RTPM disabled, and check for defects in the weld machine as the weld machine
itself may be broken.
When weld line is being tracked normally;
1. Make the criterion amount used for error check larger as it is too small.
1-25
4. E6538: Beyond RTPM tracking ability.
Main cause:
Tracking shift amount for

determining error output
Plan line (teaching)
Num. of tracking shift
The difference between the current tracking amount and the tracking amount detected previously
per preset num. of times exceeds the RTPM tracking ability/criterion amount used as threshold
for this error.
Countermeasures:
When weld line is far from the groove;
1. Check if weld start point is in the groove as an error occurs when it is far from the groove.
When weld line is being tracked normally;
1. The error occurs when settings for neither Linearizer nor Offset/gain are correct. Check if
the command current and welder meter instruction current are the same with a plate bead ON.
2. Set a greater value for the shift amount for error detection. However, by doing this, the
robot may not be able to stop immediately even when it conducts an unexpected tracking
motion.
1-26
5. E6536: RTPM current deviation error.
Main cause:
During execution of RTPM, the state of |Command current – Feedback current| > Criterion
current, specified as the threshold for detecting over-current deviation, continued longer than the
time allowed.
When this error occurs, robot holds detection of the workpiece and stops at the place the error
occurred.
Countermeasures:
1. Turn OFF control power once to check wiring and connectors as loosening of connector on
the front panel of RTPM board, etc. may cause the error.
2. Check if weld start point is in the groove as the error occurs when it is far from the groove.
3. Check if the power of the weld machine is ON as the error occurs when the power is OFF.
5. The error occurs when neither Linearizer nor Offset/gain are correct. Check if the command
current and welder meter instruction current are the same with a plate bead ON.
1-27
1-28
E Series Controller 2. Start Point Sensing Function (Option)
2.0 START POINT SENSING FUNCTION (OPTION)
2.1 OUTLINE OF START POINT SENSING FUNCTION
2.1.1 OUTLINE OF FUNCTION
Start point sensing function is a function to find a weld start point according to the shapes of
grooves even if the weld start point deviates from taught points.
As a general usage, robot detects the weld start point by start point sensing and welds tracking
a welding line by RTPM.
！ CAUTION
When workpiece detection function is

Torch
working, a constant voltage (DC15V
Weld
machine standard, DC400V as Option) is
Voltage Workpiece
applied between torch and base
+ -
Insulating material as shown on the left so that
sheet Set table/Base material
the contact position can be detected
Working table
the instant a touch has been made.
Thus, beware the following items:
1 . Avoid touching the base material or wire during workpiece detection.
2. Do not fail to connect the workpiece to be touched and the set table to the earth
side. Furthermore, take the touch sensing point on a processed surface
without deviation. Execute the touch sensing on a firmly fixed set table.
2-1
2.1.2 ROBOT MOTION EXAMPLE IN THE REPEAT MODE
At the weld start point, robot moves in a following order shown in figures below when setting
the start point sensing to Enable.
(1) Torch tip moves to a point away for

“Approach distance” from the taught point in
Tool -Z direction.
(2) The torch tip moves for “Sensing distance

in groove” at the maximum from the taught
point in the direction of Tool, and executes
workpiece sensing.
(3) Upon completion of the workpiece sensing,

the torch tip moves for “Depart distance
after detecting” in the Tool -Z direction.
For details on “Approach distance”,
“Sensing distance in groove”, and “Depart
distance after detecting”, refer to 2.3
Registration of Start Point Sensing
Parameter.

in groove”, and executes a wall sensing.
2-2
(5) Torch tip moves to a point set for “Depart

distance after detecting” after executing
workpiece sensing.

in groove”, and executes workpiece sensing
on floor again.
(7) The torch tip moves to the middle point

between the sensing points in (4) and (6).
(8) The torch tip moves to the weld start point

calculated by the sensing points.
[ NOTE ]
1. When the robot is restarted due to
HOLD/RUN, Emergency stop, and controller
power OFF/ON, etc. while sensing procedures
(1) through (8) above are conducted, the robot
executes sensing again from (1).
2. Robot does not execute starting point sensing in
check mode or when “STEP ONCE” is selected
in repeat mode.
2-3
2.2 TEACHING START POINT SENSING FUNCTION
2.2.1 TEACHING BY SIMPLIFIED OPERATION
This section describes procedures for teaching start point sensing and RTPM functions by
simplified operation using the teach pendant. For basic teaching methods in arc welding
specifications, refer to the “Arc Welding Operation Manual”.
In the example below, a horizontal fillet

workpiece shown in the left figure is welded
using start point sensing and RTPM
functions.
Assume that weaving condition is set
properly by welding condition settings.
[ NOTE ]
1. RTPM does not function unless the weaving is set in welding conditions.
(For details on RTPM, refer to 1.0 RTPM Function.)
2. Start point sensing does not function unless the start point sensing pattern
is set in the welding conditions.
(Refer to 2.3 Registration of Start Point Sensing Parameter about a
setting method of the start point sensing pattern.)
Teaching of Point A
1. Move the robot to point A by +/- and set the auxiliary data, the instruction to AC (Air
Cut).
2. Press RECORD to teach the pose and the auxiliary data to point A.
2-4
Teaching of point B
1. After moving the torch tip to a weld start point (point B) by +/-, teach start point sensing
and RTPM functions.
2. Set the auxiliary data, the instruction to WS.
3. Move cursor to [Option Switch] by → and press ENTER. The following option
switch screen is displayed. Select [Enable] for both [Start (point) Sens(ing)] and
[RTPM] by A+← and press ↵.
[ NOTE ]
The start point sensing pattern is taught at the next C
point together with the welding conditions.
condition to B point.
2-5
Teaching of point C
After moving torch tip to weld end point (point

C) by +/-, teach whether to continue RTPM or
to end RTPM function.
1. Set the auxiliary data, the instruction to WE.

2. Set the welding condition. The pattern of the start point sensing at point C is registered
in the welding condition. For details, see 2.3.3 Setting Start Point Sensing Pattern in
Welding Condition Setting Function and “Arc Welding Operation Manual”.
3. Move cursor to [Option Switch] by → and press ENTER. The following option switch
screen is displayed. On the option screen, select either [Enable] or [Disable] for [RTPM
Continue] by A+←/→ and press ↵. For details, see 1.5.4 Continuing and Terminating
RTPM function.
condition to point C.
Teaching of Point D
Move the torch tip to the escape point (point D)

after completing welding
1. Move the torch tip to the escape point (point D) after completing welding by +/-, and set
the auxiliary data, the instruction to AC (Air Cut) on Teach screen.
2. Press RECORD to teach the pose and the auxiliary data to point D.
2-6
2.2.2 PROGRAMMING USING AS LANGUAGE
This section describes program creation for start point sensing and RTPM functions using AS
language. An sample welding program using start point sensing and RTPM functions is
shown below.
W1SET 1=33 , 250 , 27 , 3 , 2 .. Sets welding conditions.

W2SET 1=1.3 , 170 , 22.5 ....... Sets crater conditions.
RTPM OFF
JMOVE a0
SSENSPTN 101 ........................... Sets start point sensing pattern.

(For details, refer to Arc Welding AS Language
Reference Manual.)
SSENSING ON............................ Changes the start point sensing function to “ON”.

RTPM ON
LWS a1 Executes the starting point sensing based on

taught point a1 and welding from the sensed weld
start point.
LWC a2 , 1......................... Executes welding by applying RTPM.
LWE a3 , 1 , 1 .................... Executes welding by applying RTPM.
RTPM OFF
SSENSING OFF .......................... To change the start point sensing function “OFF”.
JMOVE b0
b0
Escape point
(air cut point)
a0
a3
Work starting
point
a2
a1
(weld start)
2-7
2.3 REGISTRATION OF START POINT SENSING PARAMETER
This section describes the data settings for start point sensing.
2.3.1 REGISTRATION OF START POINT SENSING SYSTEM PARAMETER
Selecting [1404. Arc Weld Setting] - [14. Start Point Sensing] displays the following screen.
Call up each setting screen from this screen, and set the data.
Next section describes each parameter on the setting screen.
2-8
2.3.1.1 BASIC PARAMETER
The registered parameter is a standard parameter of Kawasaki.

Approach Distance from the taught point to the point of
0 - 999
distance start point sensing. (1) in figure below.
Depart distance Distance from the sensing point to escaping
0 - 999
after detecting position after sensing. (2) in figure below.
Sensing Upper limit of the torch’s travel distance in
distance in workpiece sensing. (3) in figure below. 0 - 999
groove
Escaping position after sensing
[ NOTE ]
The first sensing limit is the point approach distance away from the
taught point. Other sensing limits are the points that are away from
the sensing start position by the distance set for sensing distance in
groove.
2-9
2.3.1.2 SPECIAL GROOVE SHAPE
The shape of workpiece with a special groove shape except for a standard groove (horizontal
fillet, flat fillet, V groove, flat bevel groove, bevel groove, and horizontal bevel groove) is
registered. Five patterns (No.1 to No.5) can be set.
No parameter of the special groove shape is registered at shipment.

Lower plate angle Figure belowα -180 to 180
Groove angle Figure belowβ 0 to 360
Groove depth Figure below L 0 to 999
Root gap Figure below R 0 to 999
Root gap angle Figure belowγ 0 to 360
2-10
2.3.1.3 STANDARD GROOVE SHAPE
This screen displays grooves registered as standard grooves; system data cannot be input in
this screen.
Numbers on the left of displayed items show start point sensing pattern numbers of the
corresponding groove.
2-11
2.3.2 MOTION PATTERNS WITH VARIOUS GROOVES
1 - 5:Special groove shape
Numbers on the left of groove names show a start point sensing number of the groove.
2-12
2.3.3 SETTING START POINT SENSING PATTERN IN WELDING CONDITION

SETTING FUNCTION
When using start point sensing option, items for the start point sensing pattern will be appear
on the screen called up from teaching screen and auxiliary function. (Refer to figure below.)
Input shape of the groove (1 to 5) or the shape of a standard groove (101 to 106) suitable for
the workpiece for start sensing pattern when using the starting point sensing function.
Screen below is an example of Aux. 1401 Arc Weld Condition.
For the special groove shape and the standard groove shape, refer to 2.3.1.2 Special Groove
Shape and 2.3.1.3 Standard Groove Shape.
The start point sensing pattern can be also input from the following screens.
(1) Aux. 1403. Arc Weld Condition Database
(2) Aux. 1406. Arc Weld Condition Modify
[ NOTE ]
1. Weaving Data, Pole Ratio and RTPM Bias are displayed only when the
starting point sensing option is installed.
2. Start point sensing does not function if “0” is set for the starting point sensing
pattern.
3. When inputting a pattern number (1 to 5) of a special groove shape with no
shaping data, it becomes an error – “E6518 No weld data set”.
2-13
2.4 START P O I N T SENSING FUNCTION ERRORS
This section describes errors and their countermeasures for the errors that occur during start
point sensing function operation.
2.4.1 ERROR MESSAGE LIST
Error code Error message Main cause

Workpiece was not detected after sensing the
E6509 No work detected.
specified distance.
Since the robot understood the direction of
E6510 Undefined sensing direction. the welding at the sensing, cannot have done
the sensing.
2.4.2 ERROR HANDLING
If the program taught with the start point sensing function suffers an error while it is running,
execute the recovery procedures detailed here and on the following pages.
1. E6509: No Work detected.
Main causes:
This error occurs when workpiece was not detected after sensing the specified distance.
1. Workpiece was not set.
2. Workpiece was set far from the designated position.
3. Taught point for sensing start was too far from the workpiece.
occurred.
Countermeasures:
1. When workpiece is not set, set the workpiece.
2. When workpiece is set far from a designated position, reset the workpiece to its
designated position.
3. When taught point for sensing start is too far from the workpiece;
 Change values of “start distance” and “touch sensing distance”.
 Move taught points closer to the workpiece.
2-14
2. E6510: Undefined sensing direction.
Main causes:
This error occurs when robot cannot execute sensing because the welding direction is not
specified in start point sensing. The following cases can be thought as causes of the error.
1. There are no WC and WE taught after WS with the start point sensing is enabled.
2. WS with the start point sensing enabled is taught at the same point as WC and WE.
occurred.
Countermeasures:
1. When there are no WC and WE taught after WS with the start point sensing enabled,
teach WC and WE.
2. When WS with the start point sensing enabled is taught at the same point as WC and WE,
teach WC and WE at points other than the taught point of WS.
2-15
2-16
E Series Controller 3. Thick Plate Database Function (Option)
3.0 THICK PLATE DATABASE FUNCTION (OPTION)
3.1 OUTLINE OF THICK PLATE ARC WELDING DATABASE
Thick plate welding database is a database that includes parameters exclusive for the thick
plate welding in addition to the standard welding database. With this database, welding
condition (speed, current, voltage, etc.) for several passes can be set per leg length/board
thickness, and the data can be added / changed / deleted. Moreover, the database can be
reached from the setting screens for simplified teaching and the database can be referred to
while setting the welding conditions.
Items added by the thick plate welding database is mainly used for the multi-layer expansion
function. To use the multi-layer expansion function, the parameter of this thick plate
welding database must be set properly. Refer to “Arc Welding Operation Manual” on the
welding condition setting function by the simplified teaching and 4.0 Multi Layer Expansion
Function for details on the multi-layer expansion function.
Standard database
One welding condition for a groove shape
Horizontal fillet of 6 mm First pass
Welding speed 1200m/ min

Welding current 230 A
Welding voltage 26.0 V
:
:
Thick plate database
Horizontal fillet of 6 mm First pass

Several welding conditions for a groove shape
Weld speed 33 cm/min Second pass
Weld current 250 A Third pass
Weld voltage 27.0 V
:
:
：
：
：
3-1
3.2 THICK PLATE ARC WELDING DATABASE PARAMETERS
This section describes how to call up the welding database from other functions so it can be
used in weld database registration, weld condition settings, etc..
3.2.1 CALLING UP ARC WELDING DATABASE
This section describes the procedure for registering data in database via Aux. 1403 Arc Weld
Condition Database.
Selecting [Aux. 1403 Arc Weld Condition Database] on auxiliary function screen displays the
screens below. As shown below, move the cursor to [Big Category] to display big category
items and to [Small Category] to display small category items which correspond to the
selected big category items. Select the desired item for each category by NUMBER (0-9).
Big category items Small category items
Pressing <Display> displays the weld condition data for the selected big/small category items
on the right half of the screen.
Database is selected in combination of a groove kind and leg length/board thickness.
3-2
3.2.2 SCREEN FOR ARC WELDING DATABASE FUNCTION
Pressing <Display> in Aux. 1403 Arc Weld Condition Database displays the screen below.
To change data, input required data and press ↵ to display the setting screen above. Move
cursor to each item and input required data by NUMBER. Press ↵ to determine.
[ NOTE ]
Weaving pattern, polarity ratio, RTPM bias, and start point
sensing pattern are displayed only when Option is installed.
3-3
3.2.3 ADDITIONAL PARAMETERS FOR THICK PLATE DATABASE
Pressing <Next Page> displays the screen below.
The following parameters are parameters added for the thick plate database.
1. Pass
Pass means individual beads in multi-layer expansion. Though multi-layer expansion is
formed by each bead, it is necessary to number the pass and define the welding order.
This parameter is automatically updated whenever registering data in the welding
database. The display with “END” at the end of the pass No. means the final pass.
(Example Pass: 6 END Layer : 3)
3-4
2. Layer
The multi-layer welding is composed of plural layers. In the thick plate database, each
layer is numbered and distinguished. This parameter is used in the multi-layer
expansion function, and reflects the amount of cascade in the multi-layer expansion.
Refer to 4.0 Multi-layer expansion function for the multi-layer expansion.
(1) - (6): Pass No.
First layer
(6) Second layer
(3) Third layer

(5)
(1)
(2) (4)
3. RTPM Bias (option)

Used to adjust the torch aimed position when using RTPM function. This is displayed
only when the RTPM option is mounted. Refer to 1.0 RTPM Function for details.
4. Start Sensing Pattern (option)
The groove shape of workpiece can be registered as a pattern number, which is subject to
start point sensing. This item is displayed only when the RTPM option is mounted.
Refer to 2.0 Start Point Sensing Function for details of the RTPM function.
5. DELTA Y (Shift length to Y direction), DELTA Z (Shift length to Y direction),
DELTA THETA (Angle for torch inclination)
These are used for the multi-layer expansion function.
Delta Y: Shift length in the Y direction from the taught aiming position.
Delta Z: Shift length in the Z direction from the taught aiming position.
Delta theta: Angle of torch inclination when welding the first layer first pass.
(See the figure below) Unit for Delta Y and Delta Z: mm, Delta theta: degree. Refer
to 4.0 Multi-layer Expansion Function for details.
-Delta theta
+ Delta Y
+Delta theta
Taught point +Delta Z

3-5
6. GAMMA (Amount of forward angle/Amount of backward angle)

This sets the angle of the torch in respect to the welding advance direction. (See the
figure below.) Used only when settings of the multi-layer expansion function is enabled.
At this time, the robot automatically sets the torch angle in the teach data to the value
Gamma. Unit: degree. Refer to 4.0 Multi-layer Expansion Function for details.
Welding advance direction Welding advance direction Welding advance direction
GAMMA GAMMA
Torch posture Torch posture Torch posture

Backward angle Vertical Forward angle
Gamma : Negative value Gamma : 0 Gamma : Positive value
3-6
3.2.4 PARAMETERS COMMON WITH STANDARD DATABASE
The following parameters are the same with those used in a standard welding database.
1. Weld speed
Specifies motion speed in welding. (Unit: cm/min)
2. Weld current
Specifies weld current. (Unit: Ampere (A))
3. Weld voltage
Specifies weld voltage. (Unit: Volt (V))
4. Weaving width
Specifies amplitude in weaving. (Unit: mm). Set 0 (zero) when executing weaving.
5. Weaving frequency
Specifies frequency in weaving. (Unit: Hertz (Hz)). Set 0 (zero) when executing weaving.
6. Weaving pattern (option)

Specifies pattern in weaving. When option is not mounted, only simple harmonic
motion is available and parameter is not displayed. * Refer to Arc Welding Operation
Manual for details.
7. Crater time
Specifies stopping time in crater treatment. (Unit: second (s)). Set 0 (zero) when not
executing crater treatment.
8. Crater current
Specifies crater current in crater treatment. (Unit: Ampere (A)). Set 0 (zero) when not
9. Crater voltage
Specifies crater voltage in crater treatment. (Unit: Volt (V)). Set 0 (zero) when not
10. Polarity ratio (option)

Specifies ratio of negative-positive polarity energizing. (16 steps of 0 –15) When the
option is not mounted, this parameter is not displayed.
3-7
3.3 REGISTRATION OF THICK PLATE ARC DATABASE
3.3.1 OVERWRITING (MODIFYING) PASS DATA
This section describes a procedure for overwriting pass data.
1. Selects a database to be modified on Arc Weld Condition Database screen and a pass to
be modified. Selecting a new pass No., a new pass is created. Selecting an existing
pass No., the pass is overwritten. (Procedures for creating a new pass and inserting a
new pass are the same for the following steps.)
2. Confirm that “O(ver) Write” is displayed on a key in the screen. Press the key until
“Overwrite” is displayed if not displayed. The display changes “O. Write” → “Insert”
→ “Delete” → “New” → “O. Write” each time the key is pressed.
3. Move cursor to each item, input required data by NUMBER.
4. Press ↵ to register the pass with the new data.
3-8
3.3.2 REGISTERING NEW PASS DATA CONTINUOUSLY
This section describes a method of continuous registration of new pass data.
be modified.
2. Confirm that “New” is displayed on a key in the screen. Press the key until “New” is
displayed if not displayed. The display changes “O. Write” → “Insert” → “Delete” →
“New” → “O. Write” each time the key is pressed.
3. Move cursor to each item, input required data by NUMBER (0-9).
4. Press ↵ to register the pass with the new data. After the pass is registered, another pass
can be registered continuously. As for weld condition, the weld condition of the
registered pass is copied.
5. Modify data of only desired items and press ↵. Passes can be registered continuously
until END key is pressed.
3-9
3.3.3 INSERTING PASS
This section describes how to insert a pass.
[ NOTE ]
About the insertion of the pass:
When selecting the second pass and insert a pass, the second pass becomes
the third pass and newly registered pass becomes the second pass.
be modified.
2. Confirm that “Insert” is displayed on a key in the screen. Press the key until “Insert” is
displayed if not displayed. The display changes “O. Write” → “Insert” → “Delete” →
“New” → “O. Write” each time the key is pressed.
3. Move cursor to each item, input required data by NUMBER.
3-10
3.3.4 DELETING PASS
This section describes how to delete a pass.
be modified.
2. Confirm that “Delete” is displayed on a key in the screen. Press the key until “Delete”
is displayed if not displayed. The display changes “O. Write” → “Insert” → “Delete”
→ “New” → “O. Write” each time the key is pressed.
3. Press ↵ to delete the pass.
！ CAUTION
As a pass cannot be recovered once deleted, delete the
pass carefully.
3-11
3.4 HOW TO USE THICK PLATE ARC WELDING DATABASE
3.4.1 AUTO SETTING OF WELDING CONDITION
Thick plate arc welding database can be reached from the Teach screen or [1401. Arc Weld
Condition] same as a standard welding database. Refer to “Arc Welding Operation Manual”
for details.
Pressing <Auto Set> displays the screen below. Select 1 (H FILLET) for Big Category and
3 (10 mm) for Small Category and press <Display>.
The difference points from the welding condition set function of the standard are:
1. “Reference Database” for the multi-layer expansion has been added on the top of screen.
2. There are <Prev Pass> and <Next Pass>.
Groove type number and Leg length/board thickness number when referring to the database
are inserted in “Reference Database”.
(Example) When referring to database of Horizontal fillet (1) and 10 mm (3):
1-3 H FILLET 10 mm
The welding condition of the selected pass is set in each item of the welding condition. The
welding condition can be also input directly by NUMBER after referencing the database by
pressing <Auto Set>. In this case, however, [Reference Database] is cleared and is not
displayed. Refer to 4.0 Multi-layer Expansion Function on the multi-layer expansion and
3.2 Parameter Explanation of Thick Plate Arc Welding Database on each item of the welding
condition.
3-12
[ NOTE ]
1. [Weaving Data] and [Pole Ratio] are displayed only when Option is installed.
2. With the weld continue instruction, the items of the crater condition are not displayed.
3.4.2 ARC WELD CONDITION MODIFICATION FUNCTION
The thick plate welding database is referred to from Aux. 1406 Arc Weld Condition Modify as
well as a usual welding database. Refer to the “Arc Welding Operation Manual” for details
of the arc weld condition modification function.
1. Move cursor to [Program Name] and set the desired program name.
2. Input required data, and press ↵.
3. Condition setting screen as shown above is displayed. Move cursor to each item and
input required data by NUMBER and press ↵.
3-13
Press <Auto Set> to refer to the arc weld condition database screen.
[Pole Ratio], [Weaving Data-Pattern], [Start Sensing Patten] and [RTPM Bias] are displayed
only when Option is installed.
The differences from the standard welding condition setting function are:
1. Item of “Reference Database” for the multi-layer expansion has added.

2. There are <Prev Pass> and <Next Pass>.
Groove type number and Leg length/board thickness number when referring to the database
are inserted in “Reference Database”.
(Example) When referring to the database of Horizontal fillet (1) and 10mm (3),
“REFERENCE DATABASE 1-3” is displayed on the screen.
The welding condition of the selected pass is set in each item of the welding condition. The
welding condition can be also input directly by NUMBER (1-9) after referencing the database
by pressing <Auto Set>. In this case, however, [Reference Database] is cleared and is not
displayed. Refer to 4.0 Multi-layer Expansion Function on the multi-layer expansion and
3.2 Parameter Explanation of Thick Plate Arc Welding Database on each item of the welding
condition.
3-14
3.5 THICK PLATE DATABASE FUNCTION ERRORS
This section describes errors and their countermeasures for the errors that occur during thick
plate database operation.
1. P6502: No weld database.
Main cause:
No data of passes was registered in the selected database.
Countermeasure:
Set the arc weld condition database specified by the program.
2. P1031: No free memory.
Main causes:
1. Not enough free user memory.
2. In arc welding, attempted to register too many passes, total passes in database cannot
exceed 900.
Countermeasures:
1. When there is not enough free memory, delete unnecessary programs and variables.
2. When total passes in database exceed 900 passes in whole database, delete unnecessary
passes.
3-15
3-16
E Series Controller 4. Multi-layer Expansion Function (Option)
4.0 MULTI-LAYER EXPANSION FUNCTION (OPTION)
4.1 OUTLINE OF MULTI-LAYER EXPANSION FUNCTION
The multi-layer expansion function converts a program for a taught pass into a program with
the most suitable welding condition according to the joint shape, based on the welding data
set in the welding condition. The multi-layer expansion function is conducted based on the
thick plate welding database which includes the aiming position of the torch for all passes and
the welding condition, etc., necessary in multi-layer welding. Therefore, no expertise in the
multi-layer welding is not required. Refer to 3.0 Thick Plate Database Function for the thick
plate database and refer to Arc Welding Operation Manual for teaching.
Procedure 1. With workpiece which needs multi-layer welding
Teach only the first layer.
Procedure 2. Using the multi-layer expansion function
1. AC Air cut 1. AC Air cut
2. WS Weld start The first layer 2. WS Weld start The first layer
3. WE Weld end 3. WE Weld end
4. AC Air cut 4. WS Weld start The second layer

5. WE Weld end
Thick plate database 6. WS Weld start The third layer

7. WE Weld end
8. AC Air cut
Procedure 3. Executing the program Generate the program of the

multi-layer welding.
Achieve the multi-layer welding.
4-1
4.2 USING METHOD OF MULTI-LAYER EXPANSION FUNCTION
This section describes the multi-layer expansion of programs PG1001 shown below.
Pass(1) : Torch tip moves from work start point (P0) to weld start point (P1).
Pass(2) : The arc is generated at P1 point.
Pass(3) : The robot welds from the P1 point to the P2 point with the multi-layer welding.
(Welding data base: Groove number 1, Leg length / Board thickness number 3)
Pass(4) : The robot terminates welding at P2 point, and processes the crater.
Pass(5) : The torch tip moves to P3 point.
Pass(6) : The torch tip moves to work start point (P0).
[ NOTE ]
1. To use the multi-layer expansion function, set the welding
condition with Auto Set. The purpose of this is to determine the
referred data base.
See 3.4.1 AutoSetting of Welding Condition.
2. Program name must be PG1000 or more. This purpose is not to
confuse the source expansion program (in this case, PG1001) and
the expansion destination program.
Refer to the “Arc Welding Operation Manual” and 3.0 Thick Plate Database Function for the
setting method of the welding condition.
4-2
Source expansion program PG1001
1 AC JOINT SPEED9 ACCU4 TIMER0 OX= WX=

#[0, -25.093, 63.611, 9.8942, 60.634, 0] ;
2 WS LINEAR SPEED9 TIMER0 START_SENSING RTPMYES OX= WX=

#[0, -24.862, 80.454, 12.362, 44.33, -4.0215] ;
3 WE LINEAR WELD_COND SP=33 A=250 V=27 WEAVING WV=3 f=2 CRATER Ct=0 CA=0 CV=0
SSENS=101 DB=1-1 OX= WX= #[-38.842, -45.781, 46.325, -13.768, 58.564, 45.46] ;
4 AC LINEAR SPEED9 ACCU4 TIMER0 OX= WX=

#[-38.841, -51.571, 16.422, -11.828, 82.099, 39.812] ;

#[0.0033236, -25.09, 63.616, 9.8942, 60.632, -0.0012242] ;
Weld part
In this example the welding condition is taught “directly”.
Database used (Groove number 1, Thick plate number 1)
Here, it is assumed that all the data up to the third pass are included in this database.
4-3
1. Move cursor to [1408. Multi-Layer Expansion] in the auxiliary function screen to display
the screen below.
2. Input program name for [Source Program] and [Destination Program]. In this example,
PG1 and PG1001 are specified for [Source Program] and [Destination Program],
respectively. For other parameters, refer to 4.3 Explanation of Parameter.
3. Press ↵ to execute the multi-layer expansion. “Multi-layer expansion completed” is
displayed when it is completed properly.
[ NOTE ]
To avoid mistaking the names of the source program and the
destination program, the source program should be named with
PG1000 or up. The destination program should be named by
taking away 1000 from the source program name.
Example: When source program is PG1001, then destination

program name is PG1.
4-4
Destination expansion program (result) PG1
1 ; *** Multi-layer Expanded from pg1001
#[0, -25.093, 63.611, 9.8942, 60.634, 0] ;
3 WS LINEAR SPEED9 TIMER0 START_SENSING RTPMYES PASS=1 OX= WX=
#[1.366e-05, -24.733, 80.644, 12.375, 44.271, -4.0402]
4 WE LINEAR WELD_COND SP=33 A=250 V=27 WEAVING WV=3 f=2 CRATER Ct=1.3 CA=170
CV=22.5 SSENS=101 DB=1-3 PASS=1 OX= WX=
#[-38.898, -45.639, 46.577, -13.815, 58.47, 45.554]
5 WS LINEAR SPEED9 TIMER0 PASS=-2 OX= WX=
#[-38.834, -44.843, 47.986, -13.871, 57.86, 45.654]
CV=23.5 SSENS=101 DB=1-3 PASS=-2 OX= WX=
#[-0.38399, -24.347, 81.21,12.145, 44.016, -3.5758]
7 WS LINEAR SPEED9 TIMER0 PASS=3 OX= WX=
#[-0.3817, -24.594, 80.254, 11.995, 44.71, -3.367]
CV=23.5 SSENS=101 DB=1-3 PASS=3 OX= WX=
#[-38.666, -45.233, 46.723, -13.648, 58.668, 45.218]
9 AC LINEAR SPEED9 ACCU4 TIMER0 OX= WX=
#[-38.841, -51.571, 16.422, -11.828, 82.099, 39.812] ;

#[0.0033236, -25.09, 63.616, 9.8942, 60.632, -0.0012242] ;
3rd pass welding
2nd pass welding
1st pass welding
4-5
4.3 EXPLANATION OF PARAMETERS
Following parameters are necessary for the multi-layer expansion function.
(1) Source Program

Input source program name of the program that uses the multi-layer expansion function.
Pressing <Program> switches to Specify Program screen. Specify the AS program taught
with one pass. Specify program name of PG1000 or more.
(2) Dest.(ination) Program

Specify the program name of the program output after executing the multi-layer expansion
function. Pressing <Program> switches to Specify Program screen. Though there is no
restriction in program name, a program name of PG999 or less is recommended to distinguish
between Source expansion program and Destination expansion program.
4-6
(3) Air Cut On/Off

Air Cut On ············ The torch tip moves to the next pass in the multi-layer welding with the arc
OFF. The initial setting is Air Cut On.
Air Cut Off ··········· The torch tip moves to the next pass in the multi-layer welding with the arc
ON. This cannot be selected when One Way Expansion is set to Enable.
When moving from P2 to P3 and from P4 to P5 in the above figures;

Air Cut On: Arc is OFF
Air Cut Off: Arc is ON
(4) One Way Expansion Enable/Disable

One Way Expansion Disable ··················· Robot executes the multi-layer welding as
shown in the figure below. Initial setting is
set to Disable.
One Way Expansion Enable Robot executes the welding as shown in the
figure below. (Welding in one direction)
[ NOTE ]
1. One Way Expansion Enable cannot be selected with Air Cut Off.
2. When converting the program with One Way Expansion Enable, the
Air Cut step is written as weld current/voltage 0. Changing the
weld current/ voltage in the converted program will cause the welder
to actually weld, so do not change the weld current/ voltage.
4-7
(5) Gamma Expansion Enable/Disable

Gamma Expansion Enable The robot reflects parameter Gamma (Forward angle
amount/Backward angle amount) of the thick plate
database to the multi-layer expansion.
Gamma Expansion Disable The robot does not reflect parameter Gamma of the
thick plate database to the multi-layer expansion.
The initial setting is set to [Disable].
Gamma (Forward angle amount/Backward angle amount)
This parameter is an angle of the torch to its advance direction of welding. (See figure below.)
Unit: degree
Welding advance Welding advance Welding advance Welding advance

direction direction direction direction
GAMMA GAMMA GAMMA
Torch posture Torch posture Torch posture Torch posture

Remains in teaching Backward angle Vertical Forward angle
Gamma: negative value Gamma: 0 Gamma: positive value
Setting of Gamma: Setting of Gamma:

Disable Enable
The error in teaching can be eliminated and the torch posture in teaching can be kept constant
by enabling the setting of gamma.
4-8
(6) Cascade
When specifying a “positive value” for Cascade start point, the WS (weld start) point for
second layer and on shifts to the direction where the weld line shortens by the layer number of
“Database” specified with WE (weld end) point. When specifying a “negative value”, on
the other hand, the position shifts to the direction where the weld line becomes long. The
initial value is 5 mm.
When specifying a “positive value” for Cascade end point, the WE (weld end) point for
second layer and on shifts to the direction where the weld line shortens by the layer number of
“Database” specified with WE (weld end) point. When specifying a “negative value”, on
the other hand, the position shifts to the direction where the weld line becomes long. The
initial value is –5 mm.
Setting range : -99 - 99 [mm].

The figures below show the relation between of the length of the weld line and the layer.
Source expansion
2nd layer after expansion
3rd layer after expansion
ds : [ Specified cascade (start point) amount ]

ds ds de de
de : [ Specified cascade (end point) amount ]
When [Specified cascade (start point) amount] is “positive value”

and [Specified cascade (end point) amount] is “negative value”
Source expansion
ds : [ Specified cascade (start point) amount ]

ds ds de de
When [Specified cascade (start point) amount] is “negative value”

and [Specified cascade (end point) amount] is “positive value”
4-9
Source expansion
ds ds ds : [ Specified cascade (start point) amount ] de de

When [Specified cascade (start point) amount] is “positive value”

and [Specified cascade (end point) amount] is “positive value”
Source expansion
ds ds ds : [ Specified cascade (start point) amount ] de de

When [Specified cascade (start point) amount] is “negative value”

and [Specified cascade (end point) amount] is “negative value”
(7) Reverse Speed

Decides moving velocity of the torch with arc OFF when One Way Expansion is Enable.
This is not used when One Way Expansion is Disable. The initial value is 100 cm/min.
Input range : 1 - 999 cm/min
4-10
4.4 MULTI-LAYER EXPANSION ERRORS
During the multi-layer expansion, the expansion sometimes cannot be completed successfully
and the following error messages are displayed. Below are some possible causes of the
errors. Remove the cause and restart the expansion.
(1) “Database is not selected.”

 This error occurs when the parameter is not registered or there is no specified database.
Set the database correctly.
(2) “No free memory.”
 This error occurs when there is no space of user memory capacity. Delete unnecessary
programs and restart the expansion.
(3) “Illegal source program’s name.”
 This error occurs when there is no specified source program or the source program is not
PG1000 or more. Check if the source expansion program is correct.
(4) “Names of source and destination program are same.”
 This error occurs when the names of the source expansion program and destination
expansion program are the same. Change the destination expansion program name.
(5) “Source program is already expanded.”
 This error occurs when restarting the expansion of expanded program. Check if the
source expansion program is correct.
(6) “Cannot expand because circular 1 is taught continuously”
 This error occurs when expanding program where circular 1 instruction is taught
consecutively. Modify the program so that the circular trajectory ends with circular 2.
(7) “Too much rotation of torch angle.”
 This error occurs when the welding
direction reverses. (See the figure on the
right). Reteach or change the database.
(8) “Destination is out of motion range.”
 This error occurs when the active First pass
position exceeds the motion range of the Second pass
robot after the expansion. Reteach or
Third pass
change the database.
When errors (1) to (6) above occurs, the destination expansion program will not be expanded.
When errors (7) and (8) above occurs, it is expanded up to the step where the error occurred.
4-11
4.5 RELATION BETWEEN MULTI-LAYER EXPANSION FUNCTION AND OTHER

THICK PLATE OPTIONS
In general, the multi-layer function is often used with other thick plate options. This section
describes how each option works respectively at this time.
Using of RTPM and start point sensing together
Air cut
Weld start Start point sensing RTPM Enable
Weld continue Welding condition Referring data base 1-3
Weld end Welding condition Referring data base 1-3
Air cut
As shown in the above program, when expanding a welding program with the RTPM function
and the start point sensing function which are the options of thick plate, the following
programs are made.
;***Multi-layer Expanded from pg1001
Air cut
Weld start Start point sensing RTPM Enable
Weld continue Welding condition The first layer (the first pass)
Weld end Welding condition
Weld start
Weld continue Welding condition PASS=-2 The second pass
Weld end Welding condition PASS=-2
Weld start
Weld continue Welding condition PASS=3 The third pass
Weld end Welding condition PASS=3
Air cut
When executing this program;
(1) The robot executes the start point sensing at the weld start point only in the first layer
(first pass).
(2) The RTPM function is executed only in welding of the first layer (first pass).
(3) In the welding from the second pass, the welding is executed while correcting with
RTPM tracking amount taught at each taught point in the first layer.
Even if the work
deviates
･Start point sensing

･RTPM
the teaching of the
first layer
+
Multi-layer expansion
Achievement of multi-layer welding
4-12
4.6 PRECAUTIONS FOR MULTI-LAYER EXPANSION
Concerning the motion from the weld end point in the destination programs.
If the number of expanded layers are multiple of twos and One Way Expansion is disabled,
then be careful with the motion after the weld end point. The sample program below is
converted using multi-layer expansion function.
Path 5 is the motion after the weld end point. It is the path for the motion moving to P3 after
ending welding at P2.
When this program is

・expanded in three layers (or more odd number of layers)
・and expanded with One Way Expansion Enable, then the welding ends near P2 which is the
weld end point for the destination program. In this case the next motion will be a motion
similar to the motion in path 5.
On the other hand, if the same program is expanded into a program with two layers (or more
even layers) with One Way Expansion Disable, the welding ends near P1 which is the weld
start point of the source program. In this case, the robot will start its next motion from near
P1 which is the weld start point instead of starting from P2, the weld end point of the source
program, as shown in the next figure. Be careful so that the robot does not interfere with the
workpiece, etc.
4-13
Motion after welding
[ NOTE ]
Interference may occur in the destination program even if it does not occur in
the source program. Please operate the robot carefully after program
expansion.
4-14
E Series Controller Appendix.1 RTPM Board (1TH Board) Jumper and Dip switch Setting
APPENDIX.1 RTPM BOARD (1TH BOARD) JUMPER AND DIP SWITCH SETTING
CN3
J2
2 10
1 9
2 10
1 9
J3
Set J2 (jumper switch 3) as shown in the figure above (to 5-6, 7-8, 9-10 side). Incorrect setting
may cause damage to externally connected equipments.
[ NOTE ]
Incorrect setting may cause damage to externally connected equipments.
After setting the jumpers as shown above, follow the below instructions:
RTPM board (1TH board: analog input board) is mounted at the position in the controller as
shown in the figure on next page (inside the card rack, left to 1 TR board:CN3, CN4).
[ NOTE ]
When using only 1TH board, connecting either to CN3 or CN4 both are
recognized as RTPM board.
When using two 1TH boards, the one connected to CN3 is recognized as
RTPM board.
A-1
E Series Controller Appendix.2 Summary of Thick Plate Arc Welding Teaching
1TR board
1TH board
CN3 connector
on 1TR board
CN4 connector on
1TR board
Left side view of 1TR board
A-2
APPENDIX 2 SUMMARY OF THICK PLATE ARC WELDING TEACHING
This section summarizes the kinds of taught points, auxiliary data, etc. used in teaching thick
plate arc welding.
Kinds of taught points and auxiliary data

Next step
Kinds of Selected
Explanati selected
taught auxiliary Changeable auxiliary data
on automaticall
point data
y
Air cut Point not Interpolation mode (Joint, Linear), Air cut Air cut point
AC
point welded speed, Accuracy, Timer, OX, and WX.
Weld Point for Interpolation mode (Joint, Linear), Air cut Weld
WS
start starting speed, Timer, OX, and WX continue
point welding Start point sensing Enable/Disable point
RTPM Enable/Disable
Weld Middle Interpolation mode (Linear, CIR1 and CIR2) Weld
WC
continue point of Weld condition continue
point welding (Speed, Current, Voltage, *Polarity ratio point
*start point sensing pattern,
*RTPM bias)
Weaving condition
(Amplitude, Frequency, *Pattern)
OX
Weld Point for Interpolation mode (Linear, CIR1 and CIR2) Air cut point
WE
end point ending Welding condition
welding (Speed, Current, Voltage, *Polarity ratio
*start point sensing pattern,
*RTPM bias)
Weaving condition
(Amplitude, Frequency, *Pattern)
Crater condition
(Suspending time, Current, and Voltage)
OX
RTPM continue Enable/Disable
Arc spot Point for Interpolation mode (Joint, Linear), Air cut point
AS
point arc spot Air cut speed, Accuracy, Timer
welding Arc spot condition
(Suspending time, Current, Voltage,
*Polarity ratio)
OX, WX
Note* Those auxiliary data are options.
A-3
A-4
KAWASAKI ROBOT Controller E Series
Arc Welding Thick Plate Option
OPERATION MANUAL
(Option)
November 2011 : 1st Edition
Publication : KAWASAKI HEAVY INDUSTRIES, LTD.

ROBOT DIVISION
90210-1277DEA
All rights reserved. Copyright  2011 KAWASAKI HEAVY INDUSTRIES, LTD.

90210-1277DEA - Arc Welding Thick Plate Option Operation Manual (E Series)

Uploaded by

Copyright:

Available Formats

90210-1277DEA - Arc Welding Thick Plate Option Operation Manual (E Series)

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

90210-1277DEA - Arc Welding Thick Plate Option Operation Manual (E Series)

Uploaded by

Copyright:

Available Formats

What is the manual describing?

What is the manual describing?

What safety precautions should be taken?

What safety precautions should be taken?

Kawasaki Robot Controller

Kawasaki Heavy Industries, Ltd.

The option described in this manual is an independent option respectively.

Failure to comply with indicated matters can result in

Failure to comply with indicated matters may possibly

Denotes precautions regarding robot specification,

1. The accuracy and effectiveness of the diagrams, procedures, and detail

1. HARDWARE KEYS AND SWITCHES (BUTTON)

2. SOFTWARE KEYS AND SWITCHES

1.0 RTPM Function (Option) ................................................................................. 1-1

2.0 Start Point Sensing Function (Option) ............................................................. 2-1

2.2.1 Teaching by Simplified Operation ................................................................... 2-4

3.0 Thick Plate Database Function (Option) .......................................................... 3-1

4.0 Multi-layer Expansion Function (Option) ....................................................... 4-1

1.0 RTPM FUNCTION (OPTION)

1.1 OUTLINE OF RTPM (REAL TIME PATH MODULATION) FUNCTION

1.2 PRINCIPLE OF RTPM FUNCTION

Robot corrects the trajectory so that

Command weld current value

= Adjustment in horizontal direction =

1.3 APPLICABLE SCOPE OF RTPM FUNCTION

Applicable scope of RTPM function is described below.

 Welding method (gas) : CO2 and MAG

1. Condition of welding data base

The length from the

The applicable scope of RTPM function varies depending on welding methods.

4. RTPM tracking performance

Tracking performance when using welding database

(The value of each column is a tracking performance (%))

20 3.75 7.5 11.25 15.0

25 3.0 6.0 9.0 12.0

30 2.5 5.0 7.5 10.0

33 2.27 4.54 6.81 9.08

40 1.88 3.76 5.64 7.52

50 1.5 3.0 4.5 6.0

55 1.36 2.72 4.08 5.44

60 1.25 2.5 3.75 5.0

1.4 CAUTION WHEN USING RTPM FUNCTION

Check followings thoroughly before using the RTPM function.

1.5 TEACHING OF RTPM FUNCTION

1.5.1 TEACHING BY SIMPLIFIED OPERATION

Assume that a horizontal fillet workpiece

1.5.2 MAKING OF TEACH PROGRAM BY AS LANGUAGE

W1SET 1=33 , 250 , 27 , 3 , 2 ................. Sets welding conditions.

1.5.3 BIAS SETTING OF RTPM FUNCTION

Right and left bias: 0 Right and left bias: χ

1.5.3.1 SETTING METHOD BY SIMPLIFIED OPERATION

Set in “Welding condition”.

2. Input auxiliary function number 14 by NUMBER and press ↵, or move cursor to

3. Select [1. Arc Weld Condition].

4. Input desired weld condition number by NUMBER and press ↵.

Input a plus (+) value Input a minus (-) value

Input a plus (+) value Input a minus (-) value

1.5.3.2 SETTING METHOD BY AS LANGUAGE

1.5.4 CONTINUING AND TERMINATING RTPM FUNCTION