Cyan Light Beacon (Torch Consumable Reset Required)

General Overview:

If your Simple Connect light beacon illuminates with a flashing cyan color (see image below) and remains cyan during normal operation of the system, the system is indicating that your arc welding consumables are past-due for exchange or your arc welding consumable settings need adjusted. The following will detail the implementation of the welding consumables monitoring into the light beacon’s operation, how you adjust and reset the setting ultimately clearing the cyan light indicator on the Simple Connect light beacon.

Arc Welding Consumable Monitor Function:

Yaskawa robots have for many generations have had a “Arc Weld Diagnosis” screen where users can specify the frequency with which they want torch consumables to be examined or exchanged. This function is intended for welding contact tips and for nozzles. When setup, the robot controller will increase the accumulated welding time from when the timers were last cleared. Once the accumulated welding time reaches the setting/specified time, a system output will come on indicating that the set time has been exceeded. Yaskawa suggests taking advantage of this functionality to ensure proper torch consumable life and ultimately weld quality. Please set these settings according to your application & weld process requirements. Accessing these settings is possible from Management mode by pressing “ARC WELD” -> “ARC WELD DIAG.” (pressing the “PAGE” key will allow access to various robot settings)

Associated IO signals with Tip & Nozzle Monitor Function:

Implementation within Simple Connect:

Within Simple Connect, the Specific Outputs (SOUT#s) listed above are monitored via the robot’s ladder program and used to trigger a blinking cyan light on the light beacon when any of the robot outputs become active.

Resetting of Arc Welding Consumable Monitor Function:

Initial versions of Simple Connect required “Manual reset” meaning Maintenance personnel to clear the “ACCUM” (accumulated) timer values within the “ARC WELD DIAG.” screen itself once they reached the set limit or the end user would have to add logic that would pulse the Specific Inputs (SIN#s) associated with each robot and function listed above.

Later versions of Simple Connect logic implemented “Automatic reset” which would trigger the Specific Inputs (SIN#s) whenever the following occurs:

• Nozzle Clean Reset -> When robot is sent to torch cleaner and “RMR START/CLEAN” output is triggered
• Tip Change/Replace Reset -> When the robot is sent to a “Tip Change Box” (TCB) and “Tip Change Complete” is pressed

Determining if your robot system has “Manual” or “Automatic” reset:

The revision # of the concurrent IO /Ladder is contained in M-Register 435. To determine which type of reset is available on your system, navigate to M-Register 435 via “INPUT/OUTPUT” -> “REGISTER” then “PAGE” down to register 435.

Value within M435:

• If 435=122 or less: Your system has “Manual” reset
• If 435 = 123 or higher (Dec. 2022): Your system has “Automatic” reset

Performing a “Manual Reset” (M435 = 122 or less):

Explanation of “Automatic Reset” (M435 = 123 or greater):

As stated above “Automatic reset” will trigger the Specific Inputs (SIN#s) whenever the following occurs:

• Nozzle Clean Reset -> When robot is sent to torch cleaner and “RMR START/CLEAN” output is triggered
• Tip Change/Replace Reset -> When the robot is sent to a “Tip Change Box” (TCB) and “Tip Change Complete” is pressed.