DX200 OPTIONS

OPERATOR’S MANUAL
FOR WELDCOM FUNCTION:
ARC WELDING/DIGITAL I/F FUNCTION

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.

MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
DX200 INSTRUCTIONS
DX200 OPERATOR’S MANUAL (for each purpose)
DX200 MAINTENANCE MANUAL
The DX200 operator’s manuals above correspond to specific usage. Be sure to use the appropriate manual.

Part Number: 169861-1CD

Revision: 2

MANUAL NO.

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Weldcom Function: Arc

Welding Digital I/F

Copyright © 2017, 2016, 2014 YASKAWA America, Inc.

Terms of Use and Copyright Notice

All rights reserved. This manual is freely available as a service to
YASKAWA customers to assist in the operation of Motoman robots,
related equipment and software This manual is copyrighted property of
YASKAWA and may not be sold or redistributed in any way. You are
welcome to copy this document to your computer or mobile device for
easy access but you may not copy the PDF files to another website, blog,
cloud storage site or any other means of storing or distributing online
content.

Printed in the United States of America

First Printing, 2014

YASKAWA America, Inc.

Motoman Robotics Division
100 Automation Way
Miamisburg, OH 45342
Phone: 937-847-6200

www.motoman.com

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Weldcom Function: Arc
Welding Digital I/F

MANDATORY
• This manual explains the various components of the DX200 system
and general operations. Read this manual carefully and be sure to
understand its contents before handling the DX200.
• General items related to safety are listed in the Chapter 1: Safety of
the DX200 Instructions. To ensure correct and safe operation,
carefully read the DX200 Instructions before reading this manual.

CAUTION
• Some drawings in this manual are shown with the protective covers
or shields removed for clarity. Be sure all covers and shields are
replaced before operating this product.
• The drawings and photos in this manual are representative
examples and differences may exist between them and the
delivered product.
• YASKAWA may modify this model without notice when necessary
due to product improvements, modifications, or changes in
specifications. If such modification is made, the manual number will
also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA
representative to order a new copy. The representatives are listed
on the back cover. Be sure to tell the representative the manual
number listed on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized
modification of its products. Unauthorized modification voids your
product’s warranty.

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We suggest that you obtain and review a copy of the ANSI/RIA National
Safety Standard for Industrial Robots and Robot Systems (ANSI/RIA
R15.06-2012). You can obtain this document from the Robotic Industries
Association (RIA) at the following address:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: (734) 994-6088
FAX: (734) 994-3338
www.roboticsonline.com
Ultimately, well-trained personnel are the best safeguard against
accidents and damage that can result from improper operation of the
equipment. The customer is responsible for providing adequately trained
personnel to operate, program, and maintain the equipment. NEVER
ALLOW UNTRAINED PERSONNEL TO OPERATE, PROGRAM, OR
REPAIR THE EQUIPMENT!
We recommend approved YASKAWA training courses for all personnel
involved with the operation, programming, or repair of the equipment.
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC rules. These limits
are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio
frequency energy and, if not installed and used in accordance with the
instruction manual, may cause harmful interference to radio
communications.

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Weldcom Function: Arc Notes for Safe Operation
Welding Digital I/F

Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or
inspection of the DX200.
In this manual, the Notes for Safe Operation are classified as “DANGER”,
“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.
Indicates a imminent hazardous
DANGER situation which, if not avoided,
could result in death or serious
injury to personnel.
Indicates a potentially hazardous
WARNING situation which, if not avoided,
could result in death or serious
injury to personnel.
Indicates a potentially hazardous
CAUTION situation which, if not avoided,
could result in minor or moderate
injury to personnel and damage to
equipment. It may also be used to
alert against unsafe practices.
Always be sure to follow explicitly
MANDATORY the items listed under this
heading.

PROHIBITED Must never be performed.

Even items described as “CAUTION” may result in a serious accident in

some situations.
At any rate, be sure to follow these important items

To ensure safe and efficient operation at all times, be sure

NOTE to follow all instructions, even if not designated as
“DANGER”, “WARNING” and “CAUTION”.

DANGER
• Maintenance and inspection must be performed by specified
personnel.
Failure to observe this caution may result in electric shock or injury.
• For disassembly or repair, contact your YASKAWA representative.
• Do not remove the motor, and do not release the brake.
Failure to observe these safety precautions may result in death or
serious injury from unexpected turning of the manipulator's arm.

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Weldcom Function: Arc Notes for Safe Operation

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WARNING
• Before operating the manipulator, check that servo power is turned
OFF when the emergency stop buttons on the front door of the
DX200 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the
programming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit
cannot stop the manipulator during an emergency. The manipulator
should not be used if the emergency stop buttons do not function.
Fig. : Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all
items which could interfere with the operation of the manipulator.
Then turn the servo power ON
Injury may result from unintentional or unexpected manipulator motion.
Fig. : Release of Emergency Stop
TURN

• Observe the following precautions when performing teaching

operations within the P-point maximum envelope of the
manipulator:
– Be sure to use a lockout device to the safeguarding when going
inside. Also, display the sign that the operation is being
performed inside the safeguarding and make sure no one closes
the safeguarding.
– View the manipulator from the front whenever possible.
– Always follow the predetermined operating procedure.
– Keep in mind the emergency response measures against the
manipulator’s unexpected motion toward you.
– Ensure that you have a safe place to retreat in case of
emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no person is present in the P-point maximum envelope
of the manipulator and that you are in a safe location before:
– Turning ON the DX200 power
– Moving the manipulator with the programming pendant
– Running the system in the check mode
– Performing automatic operations
Injury may result if anyone enters the P-point maximum envelope of the
manipulator during operation. Always press an emergency stop button
immediately if there is a problem.
The emergency stop buttons are located on the right of the front door of
the DX200 and the programming pendant.

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Weldcom Function: Arc Definition of Terms Used Often in This Manual
Welding Digital I/F

CAUTION
• Perform the following inspection procedures prior to conducting
manipulator teaching. If problems are found, repair them
immediately, and be sure that all other necessary processing has
been performed.
– Check for problems in manipulator movement.
– Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the DX200
cabinet after use.
The programming pendant can be damaged if it is left in the
manipulator’s work area, on the floor, or near fixtures.
• Read and understand the Explanation of the Warning Labels in the
DX200 Instructions before operating the manipulator.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.
The MOTOMAN usually consists of the manipulator, the controller, the
programming pendant, and supply cables.
In this manual, the equipment is designated as follows:

Equipment Manual Designation

DX200 Controller DX200
DX200 Programming Pendant Programming Pendant
Cable between the manipulator and the Manipulator Cable
controller

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Weldcom Function: Arc Description of the Operation Procedure

Welding Digital I/F

Descriptions of the programming pendant keys, buttons, and displays are

shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters printed on
Pendant them are denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them
are not denoted with [ ] but depicted with a
small picture.
GO BACK

ex. page key PAGE

The cursor key is an exception, and a picture
is not shown.
Axis Keys “Axis Keys” and “Numeric Keys” are generic
Numeric Keys names for the keys for axis operation and
number input.
Keys pressed When two keys are to be pressed
simultaneously simultaneously, the keys are shown with a “+”
sign between them, ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming
pendant is denoted with { }.
ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression “Select • • • “
means that the cursor is moved to the object item and [SELECT] is
pressed.

Registered Trademark
In this manual, names of companies, corporations, or products are
trademarks, registered trademarks, or brand names for each company or
corporation. The indications of (R) and TM are omitted.

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Weldcom Function: Arc Safeguarding Tips
Welding Digital I/F

Safeguarding Tips
All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General
safeguarding tips are as follows:
• Improper operation can result in personal injury and/or damage to
the equipment. Only trained personnel familiar with the operation of
this equipment, the operator's manuals, the system equipment, and
options and accessories should be permitted to operate this
equipment.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.
• The system must be placed in Emergency Stop (E-Stop) mode
whenever it is not in use.
• In accordance with ANSI/RIA R15.06-2012, section 4.2.5, Sources of
Energy, use lockout/tagout procedures during equipment
maintenance. Refer also to Section 1910.147 (29CFR, Part 1910),
Occupational Safety and Health Standards for General Industry
(OSHA).

Mechanical Safety Devices

The safe operation of this equipment is ultimately the users responsibility.
The conditions under which the equipment will be operated safely should
be reviewed by the user. The user must be aware of the various national
codes, ANSI/RIA R15.06-2012 safety standards, and other local codes
that may pertain to the installation and use of this equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following
safety equipment is provided as standard:
• Safety barriers
• Door interlocks
• Emergency stop palm buttons located on operator station
Check all safety equipment frequently for proper operation. Repair or
replace any non-functioning safety equipment immediately.

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Weldcom Function: Arc Programming, Operation, and Maintenance Safety

Welding Digital I/F

Programming, Operation, and Maintenance Safety

All operators, programmers, maintenance personnel, supervisors, and
anyone working near the system must become familiar with the operation
of this equipment. Improper operation can result in personal injury and/or
damage to the equipment. Only trained personnel familiar with the
operation, manuals, electrical design, and equipment interconnections of
this equipment should be permitted to program, or maintain the system.
All personnel involved with the operation of the equipment must
understand potential dangers of operation.
• Inspect the equipment to be sure no potentially hazardous conditions
exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place. Check all safety equipment
for proper operation. Repair or replace any non-functioning safety
equipment immediately.
• Check the E-Stop button on the operator station for proper operation
before programming. The equipment must be placed in Emergency
Stop (E-Stop) mode whenever it is not in use.
• Back up all programs and jobs onto suitable media before program
changes are made. To avoid loss of information, programs, or jobs, a
backup must always be made before any service procedures are
done and before any changes are made to options, accessories, or
equipment.
• Any modifications to the controller unit can cause severe personal
injury or death, as well as damage to the robot! Do not make any
modifications to the controller unit. Making any changes without the
written permission from YASKAWA will void the warranty.
• Some operations require a standard passwords and some require
special passwords.
• The equipment allows modifications of the software for maximum
performance. Care must be taken when making these modifications.
All modifications made to the software will change the way the
equipment operates and can cause severe personal injury or death,
as well as damage parts of the system. Double check all
modifications under every mode of operation to ensure that the
changes have not created hazards or dangerous situations.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller and other
equipment. Disconnect and lockout/tagout all electrical circuits
before making any modifications or connections.
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Use proper replacement parts.
• Improper connections can damage the equipment. All connections
must be made within the standard voltage and current ratings of the
equipment.

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Weldcom Function: Arc Maintenance Safety
Welding Digital I/F

Maintenance Safety
Turn the power OFF and disconnect and lockout/tagout all electrical
circuits before making any modifications or connections.
Perform only the maintenance described in this manual. Maintenance
other than specified in this manual should be performed only by
YASKAWA-trained, qualified personnel.

Summary of Warning Information

This manual is provided to help users establish safe conditions for
operating the equipment. Specific considerations and precautions are also
described in the manual, but appear in the form of Dangers, Warnings,
Cautions, and Notes.
It is important that users operate the equipment in accordance with this
instruction manual and any additional information which may be provided
by YASKAWA. Address any questions regarding the safe and proper
operation of the equipment to YASKAWA Customer Support.

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Weldcom Function: Arc Customer Support Information

Welding Digital I/F

Customer Support Information

If you need assistance with any aspect of your Weldcom Function: Arc
Welding Digital I/F system, please contact YASKAWA Customer Support
at the following 24-hour telephone number:

(937) 847-3200

For routine technical inquiries, you can also contact YASKAWA Customer
Support at the following e-mail address:

[email protected]

When using e-mail to contact YASKAWA Customer Support, please

provide a detailed description of your issue, along with complete contact
information. Please allow approximately 24 to 36 hours for a response to
your inquiry.

Please use e-mail for routine inquiries only. If you have an

NOTE urgent or emergency need for service, replacement parts,
or information, you must contact YASKAWA Customer
Support at the telephone number shown above.

Please have the following information ready before you call Customer
Support:

• System Weldcom Function: Arc Welding

Digital I/F

• Primary Application ___________________________

• Controller DX200

• Software Version Access this information on the

Programming Pendant’s LCD
display screen by selecting {MAIN
MENU} - {SYSTEM INFO} -
{VERSION}

• Robot Serial Number Located on the robot data plate

• Robot Sales Order Number Located on the DX200 controller

data plate

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Weldcom Function: Arc Table of Contents
Welding Digital I/F

Table of Contents

1 Functional Overview ....................................................................................................................... 1-1

1.1 Overview............................................................................................................................ 1-1

2 Setup .............................................................................................................................................. 2-1

2.1 Setup Flow......................................................................................................................... 2-1

2.2 DX200 System Software Upgrade..................................................................................... 2-1

2.2.1 Individual Data Backup......................................................................................... 2-1

2.2.2 System Upgrade................................................................................................... 2-1

2.3 Setting and Confirmation of Hardware Configuration ........................................................ 2-2

2.3.1 Removing Unnecessary EW Board ...................................................................... 2-2

2.3.2 Station Number when EW Board is Left ............................................................... 2-2

2.4 Connection of Welding Power Source and DX200 ............................................................ 2-3

2.4.1 Standard Connection............................................................................................ 2-3

2.4.2 When Connecting to DX200 the Multiple Welding Power Sources

of Digital Interfaces and also Other Devices with
Data Transmission Function using Ethernet Function.......................................... 2-4

2.5 System Configuration ........................................................................................................ 2-5

2.5.1 I/O Module Setting Check after Changing EW Board Station Number Setting .... 2-6

2.5.2 Setting of Optional Function “Network Function”.................................................. 2-6

2.5.3 Setting of Optional Function “WELDCOM Function” ............................................ 2-7

2.5.4 Detailed Setting of Welding Power Source........................................................... 2-9

2.5.5 I/O Module Setting Check after Adding Virtual EW Module ............................... 2-11

2.5.6 Setting of Optional Function “MotoPlus Function”

(When Welder is FroniusTPSi) ........................................................................... 2-12

2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)....................... 2-13

2.5.8 Setting of Parameter (When Welder is FroniusTPSi) ......................................... 2-14

2.5.9 Optional Parameters for FroniusTPS ................................................................. 2-15

2.5.10 Optional Parameter for FroniusTPSi ................................................................ 2-16

3 Operation of Welding Condition File Edit Window .......................................................................... 3-1

3.1 Overview............................................................................................................................ 3-1

3.2 Display of Welding Condition File Edit Window ................................................................. 3-1

3.3 MOTOWELD Type: Operation of Top Window.................................................................. 3-2

3.4 MOTOWELD Type: Operation of Weld type Window ........................................................ 3-3

3.5 MOTOWELD Type: Operation of Customize Window ....................................................... 3-4

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3.6 MOTOWELD Type: Operation of Maintenance Window.................................................... 3-7

3.7 MOTOWELD Type: Operation of Welder Parameter Window ........................................... 3-8

3.8 FroniusTPS Type: Operation of Top Window .................................................................... 3-9

3.9 FroniusTPS Type: Operation of Program No. setting Window ........................................ 3-10

3.10 FroniusTPS Type: Operation of Param. setting Window ............................................... 3-11

3.11 FroniusTPSi Type: Operation of Top Window ............................................................... 3-12

3.12 FroniusTPSi Type: Operation of Select Synergic Window............................................. 3-13

3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window ............................... 3-14

4 Job Preparation for Welding............................................................................................................ 4-1

4.1 Job Preparation for Welding .............................................................................................. 4-1

5 Alarm and Error............................................................................................................................... 5-1

5.1 Alarm.................................................................................................................................. 5-1

5.2 Error ................................................................................................................................. 5-24

5.3 Message .......................................................................................................................... 5-24

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Weldcom Function: Arc 1 Functional Overview
Welding Digital I/F 1.1 Overview

1 Functional Overview

1.1 Overview
The WELDCOM function serves as a digital interface that communicates
via Ethernet with an arc welding power source. The function provides high
data rate transmission between DX200 and the welding power source,
enables the welding power source parameter to be set from the
programming pendant, and monitors graphically welding current and
voltage during welding.

 The WELDCOM function can use either of the following four welding
power sources for connection.
MOTOWELD-EL350-AJ2E (manufactured by YASKAWA
ELECTRIC CORPORATION)
(AJ2E indicates that an Ethernet interface is incorporated.)
MOTOWELD-RP500 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(System version: DN1.00.00(□)-00 or newer)
(In the case of digital communication mode)
MOTOWELD-RL350 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(System version: DN1.00.00(□)-00 or newer)
(In the case of digital communication mode)
MOTOWELD-X350 (manufactured by YASKAWA ELECTRIC
CORPORATION)
(System version: DN2.10.00(□)-00 or newer)
(In the case of digital communication mode)
TPS4000 CMT (manufactured by Fronius International GMBH)
(Only the model that incorporates the WeldCom interface)
6 TPSi (manufactured by Fronius International GMBH)
(System version: DN1.90.01(□)-78, DN1.91.00(□)-78, and
DN2.15.00(□)-00 or newer)
(Only the model that incorporates the WeldCom interface)

 Programming a job is available using general arc welding commands.

ARCSET ASF#( ),
ARCON ASF#( ),
ARCOF AEF#( )
 Welding conditions are set in a welding start condition file or a
welding end condition file specified in an arc welding command.

 The welding start condition file or welding end condition file has the
edit window that provides the setting window for a digital interface,
enabling users to check or edit parameters to be set in welding
power source.

 The parameter to be set in the edit window of the welding condition

file is saved in the dedicated condition file, “Welding type file” and
“Digital welder condition file”, where the data can be loaded and
saved with the external memory function.

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Weldcom Function: Arc 1 Functional Overview

Welding Digital I/F 1.1 Overview

 TCP Speed Function

This is the function only for TPS4000 CMT (Not available for MOTOWELD
EL350-AJ2E), welding with bead leg length kept constant by changing the
feeding rate according to the welding speed.
(NOTE)
• When using TCP Speed, you must add the ARATION and ARATIOF
commands to the welding section for the welding speed to be output in
analog.
Ex. ARATION BV 7.00 SPD 512
• To use TCP Speed, special software must be installed on TPS4000 CMT.
• TCP Speed cannot be used with the TPS of the US specification.

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.1 Setup Flow

2 Setup

2.1 Setup Flow

Setup the DX200 with the following procedure.

DX100 system software upgrade

DX200

Setting and confirmation of hardware configuration

Connection of welding power source and DX200

DX100

System configuration

2.2 DX200 System Software Upgrade

The WELDCOM function is incorporated into the system software version,
DN1.00.00()-00 or later. If DX200 has a version of earlier than DN1.00
installed, upgrade the version by following the procedure below. DX200
with DN1.00.00()-00 or later does not need to be upgraded.
MOTOWELD-X350 is available for the version DN2.10.00()-00 or newer.
FroniusTPSi is available for the version DN1.90.01()-78,
DN1.91.00()-78, and DN2.15.00()-00 or newer. Also, it needs the
MotoPlus function .

2.2.1 Individual Data Backup

Save all the individual data including job and condition files to initialize the
system after the upgrade. Also, save the system configuration file in the
maintenance mode.

2.2.2 System Upgrade

Upgrade the version to DN1.00.00()-00 or later. (For detailed
information of the system software upgrade procedure, see “DX200
Upgrade Procedure” 165560-1CD).

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.3 Setting and Confirmation of Hardware Configuration

2.3 Setting and Confirmation of Hardware Configuration

2.3.1 Removing Unnecessary EW Board

The WELDCOM is connected to the welding power source using the
digital interface via Ethernet communication. This does not require the EW
board (YEW01, XEW02, etc.) for an analog interface, so remove the EW
board.

In multiple robot systems, if some welding power source uses

SUPPLE- digital interface and some uses analog interface, leave as
MENT
many EW boards as the necessary analog interfaces.

2.3.2 Station Number when EW Board is Left

A digital interface requires a virtual EW module, not an actual EW board.
The virtual EW module also has a station number. If leaving an EW board
unremoved for other welding power sources, set the actual EW board
station number so that it does not duplicate the virtual EW module station
number.
(Setting Example)

 Replacing welding power source of analog interface with that of

digital interface
 Remove the actual EW board, which will be unnecessary. (The station
number of the virtual EW module is set at the time of configuration.)
X100
DX200

YEW01
Welder1

Station Number: 01 Digital I/F

Power Source

YCP21
YCP01
Station Number: 01 Virtual
EW

 When connecting welding power source of digital interface as

Welder 1, and analog interface as Welder 2
 Because the virtual EW module station number is set to the smallest
number at the time of configuration, set the EW board station number
to the second or later number.
DX200

Welder1
YEW01
Digital I/F

Station Number: 02
Power Source

Welder2
YCP21 Analog I/F
Station Number: 01 Virtual
EW Power Source

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.4 Connection of Welding Power Source and DX200

 When applying digital interface to welder and using EW board as

general analog output board
 Because the EW board is automatically set as welding application due
to the configuration restrictions, set the arc application to Arc + Arc.
Specifically, set as follows:
• Set the application setting of [Initialization] to “Arc + Arc”, and set Arc
2 as not for use.
• In [OPTION FUNCTION - WELDCOM FUNC.], set Arc 1 to digital
interface.

2.4 Connection of Welding Power Source and DX200

2.4.1 Standard Connection

(When connecting one welding power source of digital interface to DX200)
• Connect a LAN cable to YCP01 for LAN (CN104).

CAUTION
• Use the LAN cable that comes with our arc welding robot package
MOTOPAC. (The system may not properly work with a LAN cable
other than this, and we are not responsible for any problems that
may occur.)

When preparing a LAN cable other than the cable above

SUPPLE-
MENT • You can use either cross cable or straight cable.
• Use a cable with the connector that has a metal cover for
noise suppression and with the cable shield grounded to
the metal cover.

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.4 Connection of Welding Power Source and DX200

2.4.2 When Connecting to DX200 the Multiple Welding Power Sources of

Digital Interfaces and also Other Devices with Data Transmission
Function using Ethernet Function
As shown in the following figure, connect the LAN cable to YCP21 for LAN
(CN104) using a switching hub.
DX200

Welder1
Digital I/F
YCP21
Power Source
CN104
for LAN Welder2
Digital I/F
Power Source

Welder3
Digital I/F
Power Source
HUB

(You can use either cross cable or straight cable.)

CAUTION
• Use the industrial switching hub that we recommend. (The system
may not properly work with a hub other than this, and we are not
responsible for any problems that may occur.)
• Our recommended switching hub: Model EDS-205 (manufactured
by MOXA)

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.5 System Configuration

2.5 System Configuration

The following figure illustrates the configuration procedure outline. The
following and later pages explain the detailed procedure of each setting.
Note that the initialization processing after system upgrade is omitted.

Start

Did you upgrade

NO
system software?

YES

[Initialization] entry [SETUP] entry

Language, model, I/O module, ... [2.5.1] I/O Module Setting Check
Initialization processing of each items after Changing EW Board
: Station Number Setting

[SETUP] entry

For Fronius welding power source,

change the "ARC WELDING" setting
from "STANDARD" to "ENHANCED"

[2.5.2] Setting of Optional Function

"Network Function"

[2.5.3] Setting of Optional Function

"WELDCOM Function"

[2.5.4] Detailed Setting of

Welding Power Source

[2.5.5] I/O Module Setting Check

after Adding Virtual EW Module

* When the welder is FroniusTPSi;

[2.5.6] Setting of Optional

Function "MotoPlus Function"

[2.5.7] Loading of Dedicated

MotoPlus Application

[2.5.8] Setting of Parameter

End

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.5 System Configuration

2.5.1 I/O Module Setting Check after Changing EW Board Station Number
Setting
The EW board removal and station number change performed in the
section 2.3 “Setting and Confirmation of Hardware Configuration”
changes the I/O module setting. The setting changes must be recognized
with [Setting] in the maintenance mode.
1. Start the DX200 while pressing [MAIN MENU]
– Start the DX200 in maintenance mode.
2. Select {SYSTEM} → {SECURITY} → “MANAGEMENT MODE”.
– A password must be entered after selecting “MANAGEMENT
MODE”.
3. Select {SYSTEM} → {SETUP} → “IO MODULE”.

4. Press the [ENTER] to check the I/O module connection status.

– If no EW board is connected, the board column displays “NONE” as
follows.

5. A confirmation dialog box appears. Select {YES}.

2.5.2 Setting of Optional Function “Network Function”

The WELDCOM function uses the network function (optional function).
Set the network function by following the procedure below.

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.5 System Configuration

1. Select {SYSTEM} → {SETUP} → {OPTION FUNCTION}, and then

“DETAIL” of “NETWORK”.

2. Change the setting of “DEVICE” from “NOT USED” to “Ethernet”, and

select “DETAIL” of “HOST SETUP”.
– Set the Network (Ethernet) function to enable.

3. After setting “IP ADDRESS SETTING” to “MANUAL SETTING”,

change “IP ADDRESS” to “192.168.255.200”.

• Set “SUBNET MASK” to “255.255.255.0”.

• Set “DEFAULT GATEWAY” to “0.0.0.0”.

4. After the setting above is completed, press the [ENTER]. When a

confirmation dialog appears, select {Yes} to confirm the setting.

2.5.3 Setting of Optional Function “WELDCOM Function”

Set the WELDCOM function by following the procedure below.
1. Select {SYSTEM} → {SETUP} → {OPTION FUNCTION}, and then
“DETAIL” of “WELDCOM FUNC. (ARC DIGITAL I/F)”.

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.5 System Configuration

* If “WELDCOM FUNC. (...)” is not displayed, the system software version

may be old (earlier than DN1.00.00-00) or the function parameter may be
disabled. Contact your YASKAWA representative.

2. The WELDER SETUP window appears.

When multiple applications (welders) are set, you can navigate among
welder numbers with the upper or lower cursor.
– When the application setting is arc and no actual EW board exists,
only one line is displayed with *** for the items.

<Explanation of each item>

• The window displays as many lines as the number of applications.
• ST#: The station number of EW module corresponding to the
welders
• TYPE: Kind of EW module (EX: XEW02, XEW01-1, etc..)
• <Second board>: Displayed when two EW boards are used in the
enhanced mode.
• DIGITAL I/F TYPE: Displays the type of welding power source
connected. (Either MOTOWELD, Fronius TPS,
or Fronius TPSi)
3. On the number of welder where you want to set a digital interface,
press the [SELECT] to select a digital interface type.

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.5 System Configuration

4. After specifying the digital interface above, pressing the [ENTER]

displays the confirmation dialog for initializing the related files. Select
{Yes} to confirm the initialization.

2.5.4 Detailed Setting of Welding Power Source

After setting the digital interface in the WELDER SETUP window and
initializing the related files, “Type” shows VEW01, indicating that the
virtual EW module for the digital interface has been assigned. Perform
detailed setting for each welding power source by following the procedure
below.
Set the each welding power source by following the procedure below.
1. VEW01 (Virtual EW module) has been assigned. Move the cursor to
the “DETAIL” in the far right, and press the [SELECT].
– VEW01 for the digital interface has been assigned.

2. The WELDCOM function works with the default detailed settings. You
do not especially need to make settings. Press the [ENTER] to confirm
the setting.
To see the welding currents and voltages obtained and the error codes
in the concurrent IO ladder, specify the M register address of output
destination accordingly.
• Selecting “DETAIL” displays the following DETAILED SETUP
window.
• The DETAILED SETUP window varies depending on a welding
power source type.
<MOTOWELD type>

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.5 System Configuration

<Fronius TPS type>

<Fronius TPSi type>

*HTTP POWER SOURCE IP ADDRESS:

– Set the IP address to be used to obtain the welding type database
from TPSi. (For the IP address for HTTP communication, check at
the TPSi side.)

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.5 System Configuration

3. A confirmation dialog box appears. Select {YES}.

2.5.5 I/O Module Setting Check after Adding Virtual EW Module

Once the digital interface setting is confirmed, the virtual EW module
VEW01 is added as an I/O module.
The following explains the final checking process, not the setting
procedure, to add VEW01 as an I/O module at the time of completion of
the WELDCOM function setting.
1. In the WELDER SETUP and the DETAILED SETUP window, when the
settings are completed, the IO MODULE setting window automatically
appears.
– The virtual EW module, VEW01, is displayed.

2. Press [ENTER].
A confirmation dialog box appears. Select {YES}.

3. Select {AUTO} or {MANUAL} in the ALLOCATION MODE

A confirmation dialog box appears. Select {YES}.

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.5 System Configuration

4. The window goes back to OPTION FUNCTION window.

The DX200 setup is now completed.

Turn OFF the main power and restart the system in normal mode.

2.5.6 Setting of Optional Function “MotoPlus Function”

(When Welder is FroniusTPSi)
When the welder is FroniusTPSi, use the MotoPlus function (optional
function). Set the MotoPlus function to enable by following the procedure
below.
1. In the maintenance mode, select {SYSTEM} → {SETUP} → {OPTION
FUNCTION} to display “MotoPlus FUNC.”, and then set to “USED”.

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.5 System Configuration

2. Press [ENTER] to confirm the setting.

A confirmation dialog box appears. Select {YES}.

2.5.7 Loading of MotoPlus Application (When Welder is FroniusTPSi)

Load FroniusTPSi and a MotoPlus application for communication.
1. Select {MotoPlus APL.} → {LOAD(USER APPLICATION)}.
At this time, select a device and a folder in which the execution file of
MotoPlus application (FroniusXML.out) is saved.

2. Select “FroniusXML.out” in the displayed folder(s). (When selected,

is added at the left of it.)

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.5 System Configuration

Press [ENTER] to confirm the setting.

A confirmation dialog box appears. Select {YES}.

2.5.8 Setting of Parameter (When Welder is FroniusTPSi)

When the welder is FroniusTPSi, the following parameters should be set.
Parameter Initial value Name
AxP92 160 Status flag input register

The register number to be set allows to check the welder status.

Bit0:Heartbeat Powersource
Bit1:Power source ready
Bit2:Arc stable
Bit3:Current flow
Bit4:Main current signal
Bit5:Torch collision protection
Bit6:Wire stick control
Bit7:Wire available
Bit8:Touched
Bit9:Torchbody connected
Bit10:Command value out of range
Bit11:Correction out of range
Bit12:Process active
Bit13~15:Reserved (Do not change.)
Parameter Initial value Name
AxP93 161 Control flag input register

The register number to be set allows to operate the signals to the welder.
Bit7:Welding simulation
Bit8:Touch sensing
Bit9:Reserved
Bit10:SFI ON
Bit11:Synchropulse ON
Bit12:WireBreake
Bit13:Torch XChange
Bit14:TeachMode
Bit15:Reserved (Do not change.)

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Weldcom Function: Arc 2 Setup
Welding Digital I/F 2.5 System Configuration

Parameter Initial value Name

AxP103 0
AxP104 0 TPSi IP address for HTTP
AxP105 0 communication
AxP106 0

Set the IP address to be used to obtain the welding type database from
TPSi. (For the IP address for HTTP communication, check at the TPSi
side.)

Example: When the IP address is “192.168.255.211”;

AxP103=192, AxP104=168, AxP105=255, AxP106=211

2.5.9 Optional Parameters for FroniusTPS

Parameter Name
-AxP91 RCU5000i Use Mode
0: It can set Job numbers from 0 to 99. (Initial setting)
1: It can set Job numbers from 0 to 999. (Only when RCU5000i is used.)

Parameter Name
-AxP92 Status flag input register

The register number to be set allows to check the welder status.

Bit0:Communication ready
Bit1:Power source ready
Bit2:Arc stable
Bit3:Process active
Bit4:Main current signal
Bit5:Torch collision protection
Bit6:Wire stick control
Bit7:Wire available

Parameter Name
-AxP93 Control flag input register

The register number to be set allows to operate the signals to the welder.
Bit7:Welding simulation
Bit9:Master selection Twin
Bit10~15 reserved (Do not change.)

Parameter Name
-AxP96 TPS panel type forcible designation

It can change the “Select Synergic” window.

0: auto (Initial setting)
1: Standard
2: CMT
3: US
5: CMT-L

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Weldcom Function: Arc 2 Setup

Welding Digital I/F 2.5 System Configuration

Parameter Name
-RS380 Timeout lifecycle of welder
Unit:10 ms
Range: 5 (50 ms) - 30 (300 ms)
If it is out of range, 100 ms will be set (initial setting).

2.5.10 Optional Parameter for FroniusTPSi

Parameter Name
-AxP107 Designation of switching TPSi working mode

It can change the switching rule for TPSi working mode

0: Switch to the mode selected by welding condition (Initial setting)
1: Switch the mode with following rule.
Executing a job → Switch to the mode selected by welding condition
NOT Executing a job → “INTERNAL” mode (fixed)

Parameter Name
-RS380 Timeout lifecycle of welder

Unit: 10 ms
Range: 5 (50 ms) - 30 (300 ms)
If it is out of range, 100 ms will be set (initial setting).

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.1 Overview

3 Operation of Welding Condition File Edit Window

3.1 Overview
The WELDCOM function can set and obtain the parameter of the welding
power source in the edit window of an arc start condition file or an arc end
condition file.

3.2 Display of Welding Condition File Edit Window

1. Select {ARC WELDING} under the Main Menu.
2. Select {ARC START COND.} or {ARC END COND.}.
Fig. 3-1: E.g.) Edit window for arc start condition

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.3 MOTOWELD Type: Operation of Top Window

3.3 MOTOWELD Type: Operation of Top Window

1. Display {OTHER} tab of the welding condition file to specify the
number of a weld user file to be used.

2. Display {OTHER} tab of the welding condition file, and press {Welder
setting}.

3. Move the cursor to the weld user file number specified in 1.

– Select weld user file.

4. Select {Weld type}.

– Register a welding type in the weld user file selected.
→Go to Weld type window.
5. Select {Customize}.
– Change the parameter of the weld user file selected.
→Go to Customize window.
6. Select {Maintenance}.
– Perform maintenance. →Go to Maintenance window.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.4 MOTOWELD Type: Operation of Weld type Window

3.4 MOTOWELD Type: Operation of Weld type Window

1. At the top window, select a weld user file, and select {Weld type}.

2. Select welding condition.

– Select a value for “Wire type, Diameter, Shield Gas, and Pulse”.
3. Select a welding type to be used, and press {SAVE}.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.5 MOTOWELD Type: Operation of Customize Window

3.5 MOTOWELD Type: Operation of Customize Window

1. At the top window, select {Customize}.
– Change the parameter of the weld user file selected.
2. Select {Start/End}.
– Change the parameter. For details on the parameters, see the user
manual of the welding power source.

3. Select {Short} or {Pulse}.

– Change the parameter. For details on the parameters, see the user
manual of the welding power source.
【Case : Selected weld type is “Short”.】

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.5 MOTOWELD Type: Operation of Customize Window

–【Case : Selected weld type is “Pulse”.】

4. Select {End}.
– Change the parameter. For details on the parameters, see the user
manual of the welding power source.

5. Select {Curr. Character}.

– Change the parameter. For details on the parameters, see the user
manual of the welding power source.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.5 MOTOWELD Type: Operation of Customize Window

6. Select {HAWC}.
– Change the parameter. For details on the parameters, see the user
manual of the welding power source.

7. Select {SAVE}.
– Apply the parameters changed.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.6 MOTOWELD Type: Operation of Maintenance Window

3.6 MOTOWELD Type: Operation of Maintenance Window

1. At the top window, select {Maintenance} button.
2. Select {Maintenance}.

(1) “Welder update”

: Update Welder’s data.
Select “Data type” and “Device” in which welder’s data is put.
Select {Upload starting} and send update data to the welding
power source
(2) {All write(Controller->welder)}: Send the parameters at a time to
the welding power source.
(3) {All read(welder->Controller)}: Receive the parameters at a time
from the welding power source.
(4) “CPU ver.,DSP ver.,DB ver”: The versions of software and
database in the welding power
source are displayed.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.7 MOTOWELD Type: Operation of Welder Parameter Window

3.7 MOTOWELD Type: Operation of Welder Parameter

Window
1. At the top window, select {Welder prm.}.
2. Select {Gas/Wire}.
– Change the common parameter (C parameter).
• For details on the C parameters, see the user manual of the welding
power source.

3. Select {Other}.
– Change the common parameter (C parameter).
• For details on the C parameters, see the user manual of the welding
power source.

4. Select {Other2}.
– Change the common parameter (C parameter).
• For details on the C parameters, see the user manual of the welding
power source.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.8 FroniusTPS Type: Operation of Top Window

3.8 FroniusTPS Type: Operation of Top Window

1. Display {OTHER} tab of the welding condition file to specify the
number of a weld user file to be used.

2. Display {OTHER} tab of the welding condition file, and press

{Welder setting}.

3. Select weld user file.

4. Select {Program No. setting}.

– Set a welding program in the weld user file selected.
→Go to the [Program No. setting] window.
5. Select {Param. setting}.
– Change the parameter setting of the weld user file selected.
→Go to the [Param. setting] window.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.9 FroniusTPS Type: Operation of Program No. setting Window

3.9 FroniusTPS Type: Operation of Program No. setting

Window
1. At the top window, select a weld user file, and select {Program No.
setting}.

2. Select welding condition.

– Select a value for “Diameter, Wire (Gas), and Operating mode”.
3. Press {SAVE}.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.10 FroniusTPS Type: Operation of Param. setting Window

3.10 FroniusTPS Type: Operation of Param. setting Window

1. At the top window, select {Param. setting}.
– Change the parameter of the weld user file selected.
2. Select {Gas/Wire}.

(1) Gas preflow: Pre-flow that the robot performs as approaching the
welding start point.
(2) Gas postflow: Specify the time period of gas release performed at
the end of the welding.
(3) SFI: Select from “AUTO”, “MANUAL”, or “OFF”. Feeding rate
when the wire is approaching the
base material at the touch start.
3. Select {Synchropulse}.
– Change the welding parameters for changing the feeding rate or arc
length in low-cycle pulses at the time of welding. For details, see the
user manual of the welding power source.

4. Select {SAVE}.
– Apply the parameters changed.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.11 FroniusTPSi Type: Operation of Top Window

3.11 FroniusTPSi Type: Operation of Top Window

1. Display {OTHER} tab of the welding condition file, and then press
{Welder setting}.
– When the welding type database is not obtained yet, obtain the
database from the welder.
Open the Weld Parameter Setting window.

(When using Job mode of Fronius power source, put a check mark
in the check box of Job mode.)
2. Select a weld user file.

{Type:ISO/AWS}: Switches the display of materials.

{Unit:mm/inch}: Switches the unit of wire diameter.
{Refresh DataBase}:
Obtains the welding type database from the welder again.
3. Select {Select Synergic}.
– The welding type can be set to the selected weld user file.
→ Go to Select Synergic window.
4. Select {Set Parameter}.
– The parameter setting of the selected weld user file can be changed.
→ Go to Weld Parameter Setting window.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.12 FroniusTPSi Type: Operation of Select Synergic Window

3.12 FroniusTPSi Type: Operation of Select Synergic Window

1. At the top window, select a weld user file, and then select {Select Synergic}.

2. Select the welding condition.

– Select a value for “Mode”, “Material type”, “Diameter”, and “Gas Type”.
3. Select a welding program to be used, and then press {OK}.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window

Welding Digital I/F 3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window

3.13 FroniusTPSi Type: Operation of Weld Parameter Setting

Window
1. At the top window, select {Set Parameter}.
– The parameter of the selected weld user file can be changed.
2. Select {Weld Parameter}.
Penetration stabilizer: Sets the allowable value of speed fluctuation in
fluctuating the wire feeding speed in order to stabilize the welding current.
It is available only when the welding mode is PMC or LSC.
Arc length stabilizer: Stabilizes welding even the amount of wire sticking
out for short circuiting arc varies or there is interference from the outside.
It is available only when the welding mode is PMC.
For details, see the user manual of the welding power source.

3. Select {Gas/Wire}.
Gas preflow: Pre-flow that the robot performs as approaching the
welding start point.
Gas postflow: Specify the time period of gas release performed at the
end of the welding.

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Weldcom Function: Arc 3 Operation of Welding Condition File Edit Window
Welding Digital I/F 3.13 FroniusTPSi Type: Operation of Weld Parameter Setting Window

Inching speed: Wire feeding speed in perform inching manually by the

operator.

4. Select {Synchro Pulse}.

Changes the welding parameters for changing the feeding rate or arc
length in low-cycle pulses at the time of welding. For details, see the
user manual of the welding power source.

5. Select {OK}.
– The changed parameters are reflected.

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Weldcom Function: Arc 4 Job Preparation for Welding

Welding Digital I/F 4.1 Job Preparation for Welding

4 Job Preparation for Welding

4.1 Job Preparation for Welding

1. Select {Job} under the main menu to create a job.
2. Select {INFORM} → {DEVICE}, and then select {ARCON}, {ARCSET},
and {ARCOF}.
– For the ARCON and ARCSET instructions, specify a welding start
condition file in the tag.
– For the ARCOF instruction, specify a welding end condition file in
the tag.

An example of a simple welding job

NOP
MOVJ VJ=30.00
MOVJ VJ=5.00
ARCON ASF#(1)
MOVL
ARCSET ASF#(10) ACOND=1
MOVL
ARCOF AEF#(5)
MOVJ VJ=50.00
MOVJ VJ=50.00
END

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Weldcom Function: Arc 4 Job Preparation for Welding
Welding Digital I/F 4.1 Job Preparation for Welding

3. When using a FroniusTPS-type welding power source, edit the

welding condition file so that the conditions are specified by using the
following physical quantity, not by welding current instruction or
welding voltage instruction.
• V1 (WFS): Wire feeding amount (m/min)
The range varies depending on a welding type.
• V2 (Arc Length): Arc length correction (%)
Set the value in the -30% to +30% range.
• V3 (CORR2): Correction 2
Set the value in the -5.0% to +5.0% range.
• V4 (CORR3): Correction 3
Set the value in the -0.2% to +0.2% range.

V2 (Arc Length): Arc length correction (%)

Controls the arc length.
+: Long arc-length, -: Short arc-length

V3 (CORR2): Correction 2
Parameter for the heat input control.
This varies depending on a welding type.
When the material is iron and the operating mode is CMT,
+: Small heat-input, -: Large heat-input
For details, see the user manual of the welding power source.

V4 (CORR3): Correction 3
This varies depending on a welding type.
– When TPS4000CMT is used for the welding power source,
This is a parameter for correction of burning-up.
– When CMTL is used for the welding power source, and
• the operating mode is CMT + P;
This is a parameter for changing the welding type ratio.
• the operating mode is one of the others;
This is a parameter for correction of burning-up.

Correction of burning-up
+: Increases burning-up time, -: Decreases burning-up time
Welding type ratio
+: Increases pulse ratio, -: Decreases pulse ratio

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Weldcom Function: Arc 4 Job Preparation for Welding

Welding Digital I/F 4.1 Job Preparation for Welding

4. When using a FroniusTPSi-type welding power source, edit the

welding condition file so that the conditions are specified by using the
following physical quantity, not by welding current instruction or
welding voltage instruction.
• V1: Wire feeding speed (m/min)
The range varies depending on the welding type.
• V2: Arc Length
Set the value between -10.0% and +10.0%.
• V3: Pulse/Dynamic
Set the value between -10.0% and +10.0%.
• V4: Wire retraction
Set the value between 0.00 and 10.00.

V2: Arc Length

Controls the arc length.
+: Long arc-length, -: Short arc-length

V3: Pulse/Dynamic
For details, see the user manual of the welding power source.

V4: Wire retraction

For details, see the user manual of the welding power source.

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Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

5 Alarm and Error

5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
1 no Prg Select a pre-programmed program
Sub code[1**] shows the error code of Confirm the Fronius's manual
Fronius power source
1 :main error code
** :sub error code

2 ts1 Allow the machine to cool

Sub code[2**] shows the error code of Confirm the Fronius's manual
Fronius power source
2 :main error code
** :sub error code

3 ts2 Allow the machine to cool

Sub code[3**] shows the error code of Confirm the Fronius's manual
Fronius power source
3 :main error code
** :sub error code

4 ts3 Allow the machine to cool

Sub code[4**] shows the error code of Confirm the Fronius's manual
Fronius power source
4 :main error code
** :sub error code
TPS:
4290
ERROR 5 tp1 Allow the machine to cool
Sub code[5**] shows the error code of Confirm the Fronius's manual
Fronius power source
5 :main error code
** :sub error code

6 tp2 Allow the machine to cool

Sub code[6**] shows the error code of Confirm the Fronius's manual
Fronius power source
6 :main error code
** :sub error code

7 tp3 Allow the machine to cool

Sub code[7**] shows the error code of Confirm the Fronius's manual
Fronius power source
7 :main error code
** :sub error code

8 tp4 Allow the machine to cool

Sub code[8**] shows the error code of Confirm the Fronius's manual
Fronius power source
8 :main error code
** :sub error code

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Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
9 tp5 Allow the machine to cool
Sub code[9**] shows the error code of Confirm the Fronius's manual
Fronius power source
9 :main error code
** :sub error code

10 tp6 Allow the machine to cool

Sub code[10**] shows the error code of Confirm the Fronius's manual
Fronius power source
10 :main error code
** :sub error code

11 Errtf1 Change the thermo sensor on the

Sub code[11**] shows the error code of sec. side
Fronius power source Confirm the Fronius's manual
11 :main error code
** :sub error code

12 Errtf2 Change the thermo sensor on the

Sub code[12**] shows the error code of prim. side
Fronius power source Confirm the Fronius's manual
12 :main error code
** :sub error code

13 Errtf3 Check cable tree of temperature

Sub code[13**] shows the error code of sensors
TPS: Fronius power source Confirm the Fronius's manual
4290
ERROR 13 :main error code
** :sub error code

14 Errtf4 Only for Magic Wave power source

Sub code[14**] shows the error code of Confirm the Fronius's manual
Fronius power source
14 :main error code
** :sub error code

15 Errtf5 Check cable tree of temperature

Sub code[15**] shows the error code of sensors
Fronius power source Confirm the Fronius's manual
15 :main error code
** :sub error code

16 Errtf6 Change BPS PC-board

Sub code[16**] shows the error code of Confirm the Fronius's manual
Fronius power source
16 :main error code
** :sub error code

17 DSPE05 Update firmware, otherwise change

Sub code[17**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
17 :main error code
** :sub error code

5-2 HW1482771 52 of 75
169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
18 ErrbPS Update firmware, otherwise change
Sub code[18**] shows the error code of the UST board or otherwise change
Fronius power source the BPS board
18 :main error code Confirm the Fronius's manual
** :sub error code

19 Err IP Change the BPS board

Sub code[19**] shows the error code of Change the secondary diode
Fronius power source Change the welding transformer
19 :main error code Confirm the Fronius's manual
** :sub error code

20 DSPAxx Update firmware, otherwise change

Sub code[20**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
20 :main error code
** :sub error code

21 DSPExx Update firmware, otherwise change

Sub code[21**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
21 :main error code
** :sub error code
TPS:
4290
ERROR 22 ErrEPF Update firmware, otherwise change
Sub code[22**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
22 :main error code
** :sub error code

23 Err23.x Update firmware, otherwise change

Sub code[23**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
23 :main error code
** :sub error code

24 Err24.x Update firmware, otherwise change

Sub code[24**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
24 :main error code
** :sub error code

25 Err25.x Update firmware, otherwise change

Sub code[25**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
25 :main error code
** :sub error code

5-3 HW1482771 53 of 75
 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
26 Err26.x Check whether the CfgMem has
Sub code[26**] shows the error code of good contact to the connecting
Fronius power source cables and in the plug.
26 :main error code Re-crimp if necessary.
** :sub error code If this does not help, remove and
send to Fronius Austria, together
with details of the series number of
the machine.
Confirm the Fronius's manual

27 Err027 Measure the +24VDC of NT 24

Sub code[27**] shows the error code of Confirm the Fronius's manual
Fronius power source
27 :main error code
** :sub error code

28 Err028 Change the cooling-unit temperature

Sub code[28**] shows the error code of sensor
Fronius power source Confirm the Fronius's manual
28 :main error code
** :sub error code

29 DSPC Update firmware, otherwise change

Sub code[29**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
29 :main error code
TPS: ** :sub error code
4290
ERROR

30 EFd Check wire feed system.

Sub code[30**] shows the error code of Confirm the Fronius's manual
Fronius power source
30 :main error code
** :sub error code

31 Err31 Update firmware, otherwise change

Sub code[31**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
31 :main error code
** :sub error code

32 EcF Install correct primary BPS power

Sub code[32**] shows the error code of module
Fronius power source Confirm the Fronius's manual
32 :main error code
** :sub error code

33 tSt Allow the machine to cool

Sub code[33**] shows the error code of Confirm the Fronius's manual
Fronius power source
33 :main error code
** :sub error code

5-4 HW1482771 54 of 75
169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
34 Errtf7 Change the UST board
Sub code[34**] shows the error code of Confirm the Fronius's manual
Fronius power source
34 :main error code
** :sub error code

35 DSP KL Update firmware, otherwise change

Sub code[35**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
35 :main error code
** :sub error code

36 DSPnSy Update firmware, otherwise change

Sub code[36**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
36 :main error code
** :sub error code

37 US POL Change over the polarity of the two

Sub code[37**] shows the error code of cables otherwise change the UST
Fronius power source board
37 :main error code Confirm the Fronius's manual
** :sub error code

38 -Stop- Deactivate the -Stop- by input -

Sub code[38**] shows the error code of RobotReady- and activate briefly -
Fronius power source SourceErrorReset-
TPS: 38 :main error code Confirm the Fronius's manual
4290 ** :sub error code
ERROR

39 NoH2O Check the coolant level and (if

Sub code[39**] shows the error code of appropriate) the coolant return-flow
Fronius power source rate
39 :main error code If necessary, clean the coolant filter.
** :sub error code Rate-of-flow watchdog may be
defective
Confirm the Fronius's manual

40 ErrLic Confirm the Fronius's manual

Sub code[40**] shows the error code of
Fronius power source
40 :main error code
** :sub error code

41 unknown OR NOT IN USE

Sub code[41**] shows the error code of Confirm the Fronius's manual
Fronius power source
41 :main error code
** :sub error code

42 unknown OR NOT IN USE

Sub code[42**] shows the error code of Confirm the Fronius's manual
Fronius power source
42 :main error code
** :sub error code

5-5 HW1482771 55 of 75
 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
43 unknown OR NOT IN USE
Sub code[43**] shows the error code of Confirm the Fronius's manual
Fronius power source
43 :main error code
** :sub error code

44 unknown OR NOT IN USE

Sub code[44**] shows the error code of Confirm the Fronius's manual
Fronius power source
44 :main error code
** :sub error code

45 unknown OR NOT IN USE

Sub code[45**] shows the error code of Confirm the Fronius's manual
Fronius power source
45 :main error code
** :sub error code

46 unknown OR NOT IN USE

Sub code[46**] shows the error code of Confirm the Fronius's manual
Fronius power source
46 :main error code
** :sub error code

47 unknown OR NOT IN USE

Sub code[47**] shows the error code of Confirm the Fronius's manual
TPS: Fronius power source
4290
ERROR 47 :main error code
** :sub error code

48 unknown OR NOT IN USE

Sub code[48**] shows the error code of Confirm the Fronius's manual
Fronius power source
48 :main error code
** :sub error code

49 Err049 Check the mains power supply

Sub code[49**] shows the error code of Check all 3 phases
Fronius power source Confirm the Fronius's manual
49 :main error code
** :sub error code

50 Err050 Disconnect NT60 or change/check

Sub code[50**] shows the error code of NT24/UST/BPS/intermediate circuit
Fronius power source capacitors
50 :main error code Confirm the Fronius's manual
** :sub error code

51 Err051 Mains voltage too low or NT 24

Sub code[51**] shows the error code of defective
Fronius power source Confirm the Fronius's manual
51 :main error code
** :sub error code

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169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
52 Err052 Mains voltage too high or NT 24
Sub code[52**] shows the error code of defective
Fronius power source Confirm the Fronius's manual
52 :main error code
** :sub error code

53 ErrPE Low-resistance connection between

Sub code[53**] shows the error code of secondary and machine housing find
Fronius power source out the cause
53 :main error code Confirm the Fronius's manual
** :sub error code

54 Err054 Increase the bbc (burn-back control)

Sub code[54**] shows the error code of Switch off “Wire stick” in the set-up
Fronius power source menu
54 :main error code After the end of welding, make sure
** :sub error code that the wire does not collide with the
workpiece when the torch is
retracted.
Confirm the Fronius's manual

55 NoIGn Set a lower Ito value

Sub code[55**] shows the error code of Keep the torch stand-off distance
Fronius power source smaller before ignition.
55 :main error code Confirm the Fronius's manual
TPS: ** :sub error code
4290
ERROR

56 Err056 Check how much wire is left on the

Sub code[56**] shows the error code of spool
Fronius power source If necessary, change the spool
56 :main error code Confirm the Fronius's manual
** :sub error code

57 NoGAS Check what volume of gas is still

Sub code[57**] shows the error code of available
Fronius power source Confirm the Fronius's manual
57 :main error code
** :sub error code

58 NoArc Check the seam

Sub code[58**] shows the error code of Confirm the Fronius's manual
Fronius power source
58 :main error code
** :sub error code

59 Err059 Confirm the Fronius's manual

Sub code[59**] shows the error code of
Fronius power source
59 :main error code
** :sub error code

5-7 HW1482771 57 of 75
 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
60 Err060 Confirm the Fronius's manual
Sub code[60**] shows the error code of
Fronius power source
60 :main error code
** :sub error code

61 ErrArc Confirm the Fronius's manual

Sub code[61**] shows the error code of
Fronius power source
61 :main error code
** :sub error code

62 Err062 Allow the machine to cool

Sub code[62**] shows the error code of Confirm the Fronius's manual
Fronius power source
62 :main error code
** :sub error code

63 EIF Check interface configuration

Sub code[63**] shows the error code of Confirm the Fronius's manual
Fronius power source
63 :main error code
** :sub error code

64 Errtf8 Change the thermo sensor of the

Sub code[64**] shows the error code of cooling unit
TPS: Fronius power source Confirm the Fronius's manual
4290
ERROR 64 :main error code
** :sub error code

65 hotH2O Cool down the cooling liquid

Sub code[65**] shows the error code of Confirm the Fronius's manual
Fronius power source
65 :main error code
** :sub error code

66 tJo Allow the JobMaster torch to cool

Sub code[66**] shows the error code of Confirm the Fronius's manual
Fronius power source
66 :main error code
** :sub error code

67 ErrtJo Change JobMaster PC-board

Sub code[67**] shows the error code of Confirm the Fronius's manual
Fronius power source
67 :main error code
** :sub error code

68 Err068 Confirm the Fronius's manual

Sub code[68**] shows the error code of
Fronius power source
68 :main error code
** :sub error code

5-8 HW1482771 58 of 75
169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
69 Err069 New welding start
Sub code[69**] shows the error code of Confirm the Fronius's manual
Fronius power source
69 :main error code
** :sub error code

70 Err70 Check gas

Sub code[70**] shows the error code of Confirm the Fronius's manual
Fronius power source
70 :main error code
** :sub error code

71 Err71 Check the welding seam

Sub code[71**] shows the error code of Confirm the Fronius's manual
Fronius power source
71 :main error code
** :sub error code

72 ErrCfg Check LHSB connection

Sub code[72**] shows the error code of Confirm the Fronius's manual
Fronius power source
72 :main error code
** :sub error code

73 noHost Check the connection between UST

Sub code[73**] shows the error code of and RCU and the firmware
TPS: Fronius power source Confirm the Fronius's manual
4290
ERROR 73 :main error code
** :sub error code

74 Touch Touch sensing mode activated - no

Sub code[74**] shows the error code of error
Fronius power source Confirm the Fronius's manual
74 :main error code
** :sub error code

75 Err75 Confirm the Fronius's manual

Sub code[75**] shows the error code of
Fronius power source
75 :main error code
** :sub error code

76 unknown OR NOT IN USE

Sub code[76**] shows the error code of Confirm the Fronius's manual
Fronius power source
76 :main error code
** :sub error code

77 Err77 Check the wire feeding alignment if it

Sub code[77**] shows the error code of is smooth
Fronius power source Confirm the Fronius's manual
77 :main error code
** :sub error code

5-9 HW1482771 59 of 75
 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
78 E-Stop Close the Safety circuit and activate
Sub code[78**] shows the error code of the Error reset
Fronius power source Confirm the Fronius's manual
78 :main error code
** :sub error code

79 ErrU0 Confirm the Fronius's manual

Sub code[79**] shows the error code of
Fronius power source
79 :main error code
** :sub error code

80 Err080 Check the connection hose pack

Sub code[80**] shows the error code of between power source and wire
Fronius power source feeder
80 :main error code Confirm the Fronius's manual
** :sub error code

81 tP7hot Allow the machine to cool

Sub code[81**] shows the error code of Confirm the Fronius's manual
Fronius power source
81 :main error code
** :sub error code

82 ErrEHF Allow the external HF to cool down

Sub code[82**] shows the error code of Confirm the Fronius's manual
TPS: Fronius power source
4290
ERROR 82 :main error code
** :sub error code

83 PHASE Check the mains supply cable of the

Sub code[83**] shows the error code of power source
Fronius power source Confirm the Fronius's manual
83 :main error code
** :sub error code

84 unknown OR NOT IN USE

Sub code[84**] shows the error code of Confirm the Fronius's manual
Fronius power source
84 :main error code
** :sub error code

85 unknown OR NOT IN USE

Sub code[85**] shows the error code of Confirm the Fronius's manual
Fronius power source
85 :main error code
** :sub error code

86 unknown OR NOT IN USE

Sub code[86**] shows the error code of Confirm the Fronius's manual
Fronius power source
86 :main error code
** :sub error code

5-10 HW1482771 60 of 75
169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
87 unknown OR NOT IN USE
Sub code[87**] shows the error code of Confirm the Fronius's manual
Fronius power source
87 :main error code
** :sub error code

88 unknown OR NOT IN USE

Sub code[88**] shows the error code of Confirm the Fronius's manual
Fronius power source
88 :main error code
** :sub error code

89 unknown OR NOT IN USE

Sub code[89**] shows the error code of Confirm the Fronius's manual
Fronius power source
89 :main error code
** :sub error code

90 unknown OR NOT IN USE

Sub code[90**] shows the error code of Confirm the Fronius's manual
Fronius power source
90 :main error code
** :sub error code

91 unknown OR NOT IN USE

Sub code[91**] shows the error code of Confirm the Fronius's manual
TPS: Fronius power source
4290
ERROR 91 :main error code
** :sub error code

92 unknown OR NOT IN USE

Sub code[92**] shows the error code of Confirm the Fronius's manual
Fronius power source
92 :main error code
** :sub error code

93 unknown OR NOT IN USE

Sub code[93**] shows the error code of Confirm the Fronius's manual
Fronius power source
93 :main error code
** :sub error code

94 unknown OR NOT IN USE

Sub code[94**] shows the error code of Confirm the Fronius's manual
Fronius power source
94 :main error code
** :sub error code

95 unknown OR NOT IN USE

Sub code[95*] shows the error code of Confirm the Fronius's manual
Fronius power source
95 :main error code
** :sub error code

5-11 HW1482771 61 of 75
 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
96 unknown OR NOT IN USE
Sub code[96**] shows the error code of Confirm the Fronius's manual
Fronius power source
96 :main error code
** :sub error code

97 unknown OR NOT IN USE

Sub code[97**] shows the error code of Confirm the Fronius's manual
Fronius power source
97 :main error code
** :sub error code

98 unknown OR NOT IN USE

Sub code[98**] shows the error code of Confirm the Fronius's manual
Fronius power source
98 :main error code
** :sub error code

99 unknown OR NOT IN USE

Sub code[99**] shows the error code of Confirm the Fronius's manual
Fronius power source
99 :main error code
** :sub error code

100 UndOpc Update firmware, otherwise change

Sub code[100**] shows the error code of the UST board
TPS: Fronius power source Confirm the Fronius's manual
4290
ERROR 100 :main error code
** :sub error code

101 PrtFlt Update firmware, otherwise change

Sub code[101**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
101 :main error code
** :sub error code

102 IllOpa Update firmware, otherwise change

Sub code[102**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
102 :main error code
** :sub error code

103 IllIna Update firmware, otherwise change

Sub code[103**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
103 :main error code
** :sub error code

104 IllBus Update firmware, otherwise change

Sub code[104**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
104 :main error code
** :sub error code

5-12 HW1482771 62 of 75
169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
105 Err105 Update firmware, otherwise change
Sub code[105**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
105 :main error code
** :sub error code

106 STKOVL Update firmware, otherwise change

Sub code[106**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
106 :main error code
** :sub error code

107 STKUVL Update firmware, otherwise change

Sub code[107**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
107 :main error code
** :sub error code

108 ErrDog Update firmware, otherwise change

Sub code[108**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
108 :main error code
** :sub error code

109 ASSErt Update firmware, otherwise change

Sub code[109**] shows the error code of the UST board
TPS: Fronius power source Confirm the Fronius's manual
4290
ERROR 109 :main error code
** :sub error code

110 EDg 1 Update firmware, otherwise change

Sub code[110**] shows the error code of the UST board
Fronius power source Confirm the Fronius's manual
110 :main error code
** :sub error code

111 unknown OR NOT IN USE

to Sub code[111**] shows the error code of Confirm the Fronius's manual
149 Fronius power source
111 :main error code
** :sub error code

150 Err150 Check the power supply of the power

Sub code[150**] shows the error code of source
Fronius power source Confirm the Fronius's manual
150 :main error code
** :sub error code

151 unknown OR NOT IN USE

to Sub code[151**] shows the error code of Confirm the Fronius's manual
200 Fronius power source
151 :main error code
** :sub error code

5-13 HW1482771 63 of 75
 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4241 MOTOWELD 302 Sub Code: MOTOWELD's Err Code. When finish system reset, Shut
SYSTEM down the welding power source.
RESET
4242 MOTOWELD 107 Sub Code: MOTOWELD's Err Code. (1)Check if the output cable is short-
INPUT OVER- circuited or grounded.
CURRENT (2) The power circuit may be
broken . Contact your YASKAWA
representative.

4243 MOTOWELD 701 Sub Code: MOTOWELD's Err Code. Confirm the following content.
OUTPUT (1) Check that the torch cable or
OVER- power cable is not grounded?
CURRENT (2)Check that the contact tip does
not contact the welding work piece?
(3)Check that the encoder cable is
not damaged?
(4)Check if the screws of the
connector terminal block are
securely fastened. If the encoder
cable is disconnected or the screws
are loosened, the wire feeding speed
becomes excessively fast and an
error occurs in the wire feeding
amount. Replace the encoder cable
or fasten the screws of the connector
terminal block.
4244 MOTOWELD 001 Sub Code: MOTOWELD's Err Code. Confirm the input voltage.
INPUT OVER-
VOLTAGE
4245 MOTOWELD 102 Sub Code: MOTOWELD's Err Code. (1)Check the ambient temperature
EXCESSIVE (40 degrees centigrade or less) and
TEMPERAT- operational ratio (60%).
URE (2) Check if there are dust, dirt, and
clogging on the dust protective filter.
Clean or replace the dust protective
filter if necessary.
(3)In case of RL350, Check the
thermal guard of primary side (Item
No.410).
In case of X350, Check the
thermal guard of primary side (Item
No.410).

5-14 HW1482771 64 of 75
169861-1CD
Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
103 Sub Code: MOTOWELD's Err Code. (1)Check the ambient temperature
(40 degrees centigrade or less) and
operational ratio (60%).
(2) Check if there are dust, dirt, and
clogging on the dust protective filter.
Clean or replace the dust protective
filter if necessary.
(3)In case of RL350, Check the
thermal guard (Item No.318).

105 Sub Code: MOTOWELD's Err Code. (1)Check the ambient temperature
(40 degrees centigrade or less) and
operational ratio (60%).
MOTOWELD (2) Check if there are dust, dirt, and
EXCESSIVE clogging on the dust protective filter.
4245 Clean or replace the dust protective
TEMPERAT-
URE filter if necessary.
(3)In case of RL350, Check the
thermal guard of DCL2 (Item
No.312).

340 Sub Code: MOTOWELD's Err Code. (1)Check the ambient temperature
(40 degrees centigrade or less) and
operational ratio (60%).
(2) Check if there are dust, dirt, and
clogging on the dust protective filter.
Clean or replace the dust protective
filter if necessary.
(3)Replace the Main board Pr (MB)-
030(Item No. 504).

4246 MOTOWELD 002 Sub Code: MOTOWELD's Err Code. Confirm the input voltage.
INPUT
UNDER-
VOLTAGE
4247 MOTOWELD 703 Sub Code: MOTOWELD's Err Code. (1)Fill up the cooling water.
WATER (2)Check the circuit of cooling water.
UNDER-
FLOW
4248 MOTOWELD 401 Sub Code: MOTOWELD's Err Code. Confirm the following content.
DIGITAL I/F (1) The LAN cable has not
WDG.ERROR damaged.
(2) The Ethernet protocol address
setting is correct. (Check that C
parameter of the welding power
source and RS parameter of the
robot controller.)
(3) Welding power source is turn on.
(4) Please confirm the Ethernet
setting (Ethernet function is effective
and sets an IP address (RS
parameter, AxP parameter)) of the
robot control unit.
4249 MOTOWELD 402 Sub Code: MOTOWELD's Err Code. Check the Node of the each welder
DIGITAL I/F power sources and robot controller.
NODE
ERROR

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 169861-1CD

Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4250 MOTOWELD 403 Sub Code: MOTOWELD's Err Code. Confirm the following content.
DIGITAL I/F (1) LAN cable is not damaged.
ERROR (2) Protocol type of the VEW01 is
correct. (is MOTOWELD type?)
4251 MOTOWELD 404 Sub Code: MOTOWELD's Err Code. Set the user file number 1...16.
DIGITAL I/F
FILE# ERROR
4252 MOTOWELD 405 Sub Code: MOTOWELD's Err Code. Replace the main board {Pr (MB) -
DIGITAL I/F 024}. Contact your Yaskawa
CHIP ERROR representative.
4253 MOTOWELD 304 Sub Code: MOTOWELD's Err Code. The setting of hardware or software
MACHINE may be not performed correctly.
TYP.ERROR1 Contact your YASKAWA
representative.
4254 MOTOWELD 305 Sub Code: MOTOWELD's Err Code. The setting of hardware or software
MACHINE may be not performed correctly.
TYP.ERROR2 Contact your YASKAWA
representative.
4255 MOTOWELD 306 Sub Code: MOTOWELD's Err Code. The setting of hardware or software
MACHINE may be not performed correctly.
TYP.ERROR3 Contact your YASKAWA
representative.
4256 MOTOWELD 307 Sub Code: MOTOWELD's Err Code. The setting of hardware or software
MACHINE may be not performed correctly.
TYP.ERROR4 Contact your YASKAWA
representative.
4257 MOTOWELD 303 Sub Code: MOTOWELD's Err Code. (1) Check the DIP switch setting of
PANEL SW EL350:PR(CR) -008/RP500:WK-
SETTING 7036 board.
ERROR (2) EL350:PR(CR) -008/RP500:WK-
7036 board may be broken. Contact
your YASKAWA representative.

4258 MOTOWELD 501 Sub Code: MOTOWELD's Err Code. Confirm the following content.
FEEDER (1)The encoder cable be not
ERROR damaged?
(2)Isn't there loosening of the screw
of the encoder cable connection
terminal block?
When there are a disconnection of
the encoder cable or loosening of the
screw, the wire feeding speed
quickens abnormally, and it becomes
an abnormal amount of feeding.
Replace the encoder cable or fasten
the screw of the terminal block.
(3)Check if the wire load becomes
heavy. Make sure that the torch
cable and conduit cable are not bent
excessively.
331 Sub Code: MOTOWELD's Err Code. (1)Confirm the feeder motor type.
(2)Check the C parameter for feeder
motor is correct.
(3)Check the dip switch SW700 on
the Main board (Service parts code:
UNIT-Pr (MB)-030).

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Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4259 MOTOWELD 502 Sub Code: MOTOWELD's Err Code. Check if the wire load becomes
MOTOR heavy. Make sure that the torch
OVER- cable and conduit cable are not bent
CURRENT excessively.
4260 MOTOWELD 203 Sub Code: MOTOWELD's Err Code. The board may be broken. Contact
CPU ERROR1 your YASKAWA representative.

4261 MOTOWELD 204 Sub Code: MOTOWELD's Err Code. The board may be broken. Contact
CPU ERROR2 your YASKAWA representative.

4262 MOTOWELD 205 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR1 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset")
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.
4263 MOTOWELD 215 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR2 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset”)
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.
4264 MOTOWELD 206 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR3 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset”)
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.
4265 MOTOWELD 207 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR4 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset”)
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.

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Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4266 MOTOWELD 208 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR5 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset”)
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.
4267 MOTOWELD 209 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR6 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset”)
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.
4268 MOTOWELD 210 Sub Code: MOTOWELD's Err Code. The data may not have been
MEMORY correctly saved when the welding
ERROR7 conditions are recorded because of
a power failure, etc. Reset the
system after saving the changed
parameters. (See the manual of
MOTOWELD section 4.2.10 “System
Reset”)
If the error occurs again, the board
may be broken. Contact your
YASKAWA representative.
4269 MOTOWELD 601 Sub Code: MOTOWELD's Err Code. Check again the operation timing or
STARTING signal cable connections. The same
SIGNAL error may occur at momentary power
ERROR failure.
4270 MOTOWELD 602 Sub Code: MOTOWELD's Err Code. Select a correct welding process in
NO WELDING the using the welding user file.
TYPE

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Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4271 MOTOWELD 702 Sub Code: MOTOWELD's Err Code. (1)Check if the voltage detection wire
VOLT.DETEC is connected. Check to confirm that
T WIRE the welding voltage sensing cable
ERROR select switch is set to “Base Metal”.
The use of MOTOWELD-RP500:
Check to confirm that the voltage
sensing cable is connected between
the base metal and the terminal
block TB2 7.
The use of MOTOWELD-RL350/
X350:
Check to confirm that the base
metal-side welding voltage sensing
cable connects between the base
metal and the welding power source
via wire feeder cable.
(2)Check to confirm that the contact
chip and the welding work are not in
contact. Cancel the contact if any,
and weld them.
(3)Temporary power failure may
have occurred.
(4) When the welding voltage
sensing cable is used, please
connect the welding voltage sensing
cable to the base metal.
(5) When the AC unit used, a
weldingpower source output cable,
please?confirm whether the output
cable of the wiring of the AC unit is
not a mistake.
(6) When the AC unit used, please
make sure that the power of the AC
unit is turned on.
4272 MOTOWELD 101 Sub Code: MOTOWELD's Err Code. Contact your YASKAWA
SAFTY- representative.
CIRCUIT
ERROR
4273 MOTOWELD 104 Sub Code: MOTOWELD's Err Code. Replace the IGBT device (Part code
IGBT SHORT AJ0EL3870). Contact your
CIRCUIT YASKAWA representative.
4274 MOTOWELD 110 Sub Code: MOTOWELD's Err Code. Contact your YASKAWA
VOLTAGE representative.
DETECTOR
ERROR
4275 MOTOWELD 111 Sub Code: MOTOWELD's Err Code. The board may be broken. Contact
AUX. your YASKAWA representative.
CIRCUIT OV.
CURRENT
4276 MOTOWELD 119 Sub Code: MOTOWELD's Err Code. Contact your YASKAWA
DSP ADC representative.
ERROR

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Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4277 MOTOWELD 790 Sub Code: MOTOWELD's Err Code. (1)Check if the selection of motor is
OUTSIDE OF correct, or confirm the settings of C
CURR.SETTI parameter C09.
NG(H) (2)Check that the welding wire does
not slip, or the wire is fed as
instructed by the feeding command.
(3)Check that the wire stick out is not
excessively short or long.
(4)Check that the range set in C
parameter C29 is not too narrow.
(5)Check if the wire, shielding, etc.
are correctly set.
4278 MOTOWELD 791 Sub Code: MOTOWELD's Err Code. (1)Check if the selection of motor is
OUTSIDE OF correct, or confirm the settings of C
CURR.SETTI- parameter C09.
NG(L) (2)Check that the welding wire does
not slip, or the wire is fed as
instructed by the feeding command.
(3)Check that the wire stick out is not
excessively short or long.
(4)Check that the range set in C
parameter C29 is not too narrow.
(5)Check if the wire, shielding, etc.
are correctly set.
4279 MOTOWELD 108 Sub Code: MOTOWELD's Err Code. (1)Check that short-circuit or the
MOMENTARY earth grounded of the output cable.
OVER-CURR (2)May be power circuit broken.
Contact your YASKAWA
representative.

4280 MOTOWELD 109 Sub Code: MOTOWELD's Err Code. Contact your YASKAWA
OVER- representative.
VOLTAGE
4281 MOTOWELD 704 Sub Code: MOTOWELD's Err Code. The use of MOTOWELD-RP500:
+15V POWER Replace the switching power supply
SUPPLY unit (Service parts
ERROR code:35015612200) or the Main
board (Service parts
code:AJ0RP3024). Or, please
change two of them.
The use of MOTOWELD-RL350:
Replace the Interface board (Service
parts code: UNIT-Pr (IF)-008B) or
the Main board (Service parts code:
UNIT-Pr (MB)-030). Or, please
change two of them.
4282 MOTOWELD 705 Sub Code: MOTOWELD's Err Code. The use of MOTOWELD-RP500:
POWER Replace the switching power supply
SUPPLY unit (Service parts
ERROR code:35015612200) or the Main
board (Service parts
code:AJ0RP3024). Or, please
change two of them.
The use of MOTOWELD-RL350:
Replace the Interface board (Service
parts code: UNIT-Pr (IF)-008B) or
the Main board (Service parts code:
UNIT-Pr (MB)-030). Or, please
change two of them.

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Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4283 MOTOWELD 406 A wrong welding process is set in the Confirm the welding process setting
ILLEGAL welding user file. in the welding user file.
WELD TYPE
407 A welding type is not set in a user file of Set a welding type to user file of
the MOTOWELD. MOTOWELD. The user file can
setup in the editor screen for ARC
START CONDITION FILE or ARC
END CONDITION FILE of the robot
controller.
4284 MOTOWELD 310 The version of the data base is not Load the suitable database.
SOFTWARE suitable for the software of the welding
MULFUNCT- power source.
ION 311 The version information of the PLD on Replace the main board (Service
the main board Pr(MB) is wrong. parts code: UNIT-Pr (MB)-030).
Contact your YASKAWA
representative.
312 The version of the firmware of front Replace the main board (Service
panel is not suitable for the software of parts code: UNIT-Pr (MB)-030).
the main board Pr(MB). Contact your YASKAWA
representative.
316 The check sum of the PLD on the main Replace the main board (Service
board Pr(MB) is wrong. parts code: UNIT-Pr (MB)-030).
Contact your YASKAWA
representative.
317 The program or data base was load by Reboot the power source.
the ethernet.
318 The check sum error of loading data. (1)Do not turn off the power source
and reload the data.
(2)In case of turn off and reboot was
OK, reload the data.
(3)In case of turn off and reboot was
NG, load the data by special loading
tool.
(4)Other case of step 1,2,3, replace
the main board Pr (MB)-030.

400 Watch dog error of the PLD. (1)Movement abnormality of PLD

occurred, and a welding power
supply rebooted.
(2)Replace the main board {Pr (MB)
-030}.
Contact your YASKAWA
representative.

4285 MOTOWELD 320 The machine type is wrong. (1)Check the connection between
MACHINE front panel and main board.
SETTING (2)Check the status of dip switch
ERROR （SW301）on the front panel.
(3)Replace the front panel.
(4)Replace the main board.
4286 MOTOWELD 330 The current class 350A / 500A setting is (1)Confirm the power source class
CURRENT wrong. which of 350A or 500A.
CLASS (2)Switch a status of dip switch
ERROR SW600 which of 350A or 500A.
(3)Change the software which for
correct current class.

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Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4287 SHORTCIRUI 795 The count of short circuit is largely (1) Check that setting current is not
T COUNT decreased.(The bead NG). too high.
OVER (BEAD (2) Check that range set in C
NG) parameter C62 is not too narrow.
(3) Check that the wire stick out is
not excessively short.
4288 AC-UNIT 126 AC unit temperature anomaly (1) Check the ambient
ERROR temperature(45 degrees or below)
and the usage rate(60%)
(2) Check for no dirt or clogging in
the dust-proof filter. Check or replace
as needed.
(3) Make sure thermal guard of AC
unit is not broken.
129 AC unit over-voltage (1) Check the usage rate (60%)
(2) Check the length of the power
cable is round-trip less than 20m.
(3) Check a power cable does not
wind up a coil.

623 AC welding method setting error It can not AC welding for the AC unit
is not connected.

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Weldcom Function: Arc 5 Alarm and Error
Welding Digital I/F 5.1 Alarm

Alarm Alarm Sub Meaning Remedy

No. Name Code
4289 SERVO PACK 530 SERVO PACK ALARM (EAGL) (1) A.720: Overload (maximum
ALARM continuous)
(EAGL) Check to that the wire is not strike
the material.
Check to whether the feed
resistance is not excessive.
There is a possibility of servo pack
failure. Please replace the servo
pack.
(2) A.C90: Encoder communication
error
There is a connection possibility of
failure of the Encoder cable.
There is a bad connection possibility
of the Encoder cable. Check whether
each connector is connected.
There is a possibility of Encoder
cable disconnection. Please replace
the encoder cable.
There is a possibility of servo motor
main circuit cable failure. Please
replace the servo motor main circuit
cable.
There is a possibility of servo pack
failure. Please replace the servo
pack.
(3) A.b33: Current detection
abnormality
There is a bad connection possibility
of the servo motor main circuit cable.
Check the connection of each
connector.
There is a possibility of
disconnection of the servo motor
main circuit cable.Please replace the
servo motor main circuit cable.
There is a possibility of servo pack
failure. Please replace the servo
pack.
4) A.100: Overcurrent detection
There is a bad connection possibility
of the servo motor main circuit cable.
Please replace the servo motor main
circuit cable.
There is a possibility of life of the
servo motor. Please replace the
servo motor.
There is a possibility of servo pack
failure. Please replace the servo
pack.

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Weldcom Function: Arc 5 Alarm and Error

Welding Digital I/F 5.2 Error

5.2 Error
Error No. Message Cause Remedy
1110 TPS: SELECTED A welding program unprepared for Select again a welding program.
UNREGISTERED the welding power source was
PROGRAM selected.
1111 TPS: FEEDING A wire was clogged or so in the The most problems automatically
SYSTEM FAILURE feeding system, leading to improper solve when inching retract is
feeding. performed on the wire for a short
For the CMT welding power source, time at the time of error reset.
the possibilities are high that the If the problem persists, try to
wire buckled in the wire buffer and perform manual wire inching or
this caused a problem with the wire retract.
sensor in the buffer. Adjust manually the sensor of the
wire buffer to the proper position.
If the problem frequently occurs,
first check the feeding system for
abnormally high feeding load, and
replace parts as needed.
1112 TPS: ABNORMAL The water flow sensor was Check if water flows. If water flows
WATER FLOW activated. and the error still occurs, replace
the sensor because the sensor
possibly has failed.

5.3 Message
Message Cause Remedy
TPS: TOUCH SENSOR The touch sensor was activated and This is only a notification. It does not
IN OPERATION the status flag bit turned ON. indicate any problem.
TPS: ARC IGNITION When welding started, timeout Remove the slag or other objects at the
FAILURE occurred while waiting for arc to be wire tip or in the base material. For CO2
generated that produces current flow. welding especially, because slag tends to
An insulator such as slag prevented prevent conduction, take some action
current from flowing, thus arc was not whenever possible so that welding starts
generated. Or the wire took long time from other than welding bead edge. Adjust
to contact the base material, being the crater conditions for welding ending
determined as arc ignition failure. time so that some short length of wire
comes out from the chip (so that the wire
can immediately contact the base
material).
TPS: ROBOT NOT The welding power source received Check if the digital interface type of
READY the notification that the "Robot ready" VEW01 is FroniusTPS.
bit turned OFF, which was sent from
the robot side, and issued the error.
WELDING POWER The Ethernet communication was Check if the LAN cable is connected. If
SOURCE: Ethernet disconnected. using a HUB, check if the HUB is turned
COMMUNICATION ON.
ERROR
TPS: WELDING The welding power source notified This phenomenon may temporarily occur
POWER SOURCE NOT that it is not ready for welding. when the welding power source is turned
READY ON or OFF, but it has no problem.
However, if the error persists, restart the
welding power source.
TPS: OUTSIDE THE Welding is performed with the feeding When welding with the TCP speed
RANGE OF FEEDING amount exceeding the maximum function, decrease the welding rate to
AMOUNT value set for welding programs. reduce the feeding amount.

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DX200 OPTIONS
OPERATOR’S MANUAL
FOR WELDCOM FUNCTION:
ARC WELDING/DIGITAL I/F FUNCTION

HEAD OFFICE
2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004, Japan
Phone +81-93-645-7703 Fax +81-93-645-7802

YASKAWA America Inc. (Motoman Robotics Division)

100 Automation Way, Miamisburg, OH 45342, U.S.A.
Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Europe GmbH Robotics Divsion )

Yaskawastrasse 1, 85391 Allershausen, Germany
Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Nordic AB
Verkstadsgatan 2, Box 504 ,SE-385 25 Torsas, Sweden
Phone +46-480-417-800 Fax +46-486-414-10

YASKAWA Electric (China) Co., Ltd.

22F, One Corporate Avenue, No.222, Hubin Road, Huangpu District, Shanghai 200021, China
Phone +86-21-5385-2200 Fax 㸩86-21-5385-3299
YASKAWA SHOUGANG ROBOT Co. Ltd.
No7 Yongchang North Road, Beijing E&T Development AreaChina 100176
Phone +86-10-6788-2858 Fax +86-10-6788-2878

YASKAWA India Private Ltd. (Robotics Division)

#426, Udyog Vihar, Phase- IV,Gurgaon, Haryana, India
Phone +91-124-475-8500 Fax +91-124-475-8542

YASKAWA Electric Korea Corporation

35F, Three IFC, 10 Gukjegeumyung-ro, Yeongdeungpo-gu, Seoul, Korea 07326
Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric Taiwan Corporation

12F, No.207, Sec. 3, Beishin Rd., Shindian District, New Taipei City 23143, Taiwan
Phone +886-2-8913-1333 Fax +886-2-8913-1513

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741
Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

59,1st-5th Floor, Flourish Building, Soi Ratchadapisek 18,Ratchadapisek Road,
Huaykwang, Bangkok 10310, THAILAND
Phone +66-2-017-0099 Fax +66-2-017-0199

PT. YASKAWA Electric Indonesia

Secure Building-Gedung B Lantai Dasar & Lantai 1 JI. Raya Protokol Halim Perdanakusuma,
Jakarta 13610, Indonesia
Phone +62-21-2982-6470 Fax +62-21-2982-6741

Specifications are subject to change without notice

for ongoing product modifications and improvements.

MANUAL NO.

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