Note: Always refer to your specific Yaskawa controller manual (FS100, DX100, DX200, YRC1000, YRC1000micro) as commands and menu structures vary between models.

Yaskawa Arc Welding Robot - Sample Program & Setup

Sample INFORM III Program

/JOB
//NAME ARCWELD_SAMPLE
//POS
///NPOS 5,0,0,0,0,0
///TOOL 1
///POSTYPE PULSE
///RECTAN
///RCONF 0,0,0,0,0,0,0,0
P00000={ 0.000, 0.000, 0.000, 0.000, 0.000, 0.000}
P00001={ 500.000, 200.000, 600.000, 0.000, 90.000, 0.000}
P00002={ 500.000, 200.000, 450.000, 0.000, 90.000, 0.000}
P00003={ 500.000, 400.000, 450.000, 0.000, 90.000, 0.000}
P00004={ 500.000, 600.000, 450.000, 0.000, 90.000, 0.000}
P00005={ 500.000, 600.000, 600.000, 0.000, 90.000, 0.000}
//INST
///DATE 2025/11/29 00:00
///ATTR SC,RW
///GROUP1 RB1
NOP
'--- MOVE TO HOME POSITION ---
MOVJ C00000 VJ=25.00
'--- APPROACH WELD START ---
MOVJ C00001 VJ=50.00
MOVL C00002 V=100.0
'--- START WELDING SEQUENCE ---
ARCON ASF#(1) AC=100 AV=240
TIMER T=0.10
'--- WELD LINEAR SEAM ---
MOVL C00003 V=50.0 AC=100 AV=240
MOVL C00004 V=50.0 AC=100 AV=240
'--- CRATER FILL ---
TIMER T=0.20
'--- ARC OFF ---
ARCOF
'--- RETRACT ---
MOVL C00005 V=100.0
'--- RETURN HOME ---
MOVJ C00000 VJ=50.00
END

Setup Instructions

1. System Configuration

A. Wire Feeder Communication Setup

1. Navigate to: SETUP → I/O → WELD I/O
2. Configure communication type:
   • DeviceNet: Set node address
   • Analog: Configure voltage/current signals
   • Digital: Assign I/O points

B. Arc Start Sensor (ASS) Configuration

1. Go to: SETUP → WELD → ASS
2. Set parameters:

 ASS USE: VALID
 SENSOR: OT-3000 (or your sensor model)
 RETRACT DISTANCE: 5.0 mm
 SEARCH SPEED: 10 mm/s
 APPROACH SPEED: 50 mm/s

2. Welding Condition Files

Creating Arc Start Files (ASF)

1. Press: SETUP → WELD → ARC START FILE
2. Create new file (e.g., ASF#1):

 FILE NUMBER: 1
 CURRENT: 180 A
 VOLTAGE: 22 V
 WIRE FEED SPEED: 6.0 m/min
 PRE-GAS TIME: 0.5 sec
 POST-GAS TIME: 0.5 sec
 ARC-ON DELAY: 0.1 sec
 BURN-BACK TIME: 0.05 sec

Creating Arc Condition Files (ACF)

1. Press: SETUP → WELD → ARC CONDITION
2. Create conditions for different materials/thicknesses

3. Tool Center Point (TCP) Setup

Torch TCP Calibration

1. Manual Method:
   • Navigate to: TOOL → TOOL FILE
   • Select Tool #1
   • Enter torch tip offset values (X, Y, Z)
2. Auto-Calibration Method:
   • Use calibration jig
   • Press: TOOL → CALIBRATE
   • Touch jig from 5 different orientations
   • System calculates TCP automatically

4. Digital I/O Assignment

Standard Welding I/O

OUTPUT SIGNALS:
OT#10001 - Gas Solenoid
OT#10002 - Arc On
OT#10003 - Wire Feed Start
OT#10004 - Torch Collision

INPUT SIGNALS:
IN#10001 - Welding Ready
IN#10002 - Wire Feed Ready
IN#10003 - Gas Flow OK
IN#10004 - Torch Collision Detected
IN#10005 - Emergency Stop

Configuration path: SETUP → I/O → GENERAL PURPOSE

5. Touch Sensing Setup

Enable Touch Sensing Feature

1. Navigate to: SETUP → WELD → TOUCH SENSING
2. Configure parameters:

 SENSING CURRENT: 15-25 A
 SENSING VOLTAGE: 10-15 V
 RETRACT DISTANCE: 2.0 mm
 APPROACH SPEED: 10 mm/s

3. Use in program:

 'Touch sensing example
 SFTCHON
 MOVL C00010 V=10.0 UNTIL IN#10010=ON
 SFTSTOF
 GETS P00020 $POSC

6. Weaving Pattern Setup

Configure Weave Patterns

1. Navigate to: SETUP → WELD → WEAVE
2. Create weave file (e.g., WV#1):

 TYPE: TRIANGLE / SINE / SQUARE
 WIDTH: 10.0 mm
 FREQUENCY: 2.0 Hz
 LEFT DWELL: 0.1 sec
 RIGHT DWELL: 0.1 sec

3. Use in program:

 WVON WV#(1)
 MOVL C00100 V=50.0 AC=100 AV=240
 WVOF

7. Multi-Layer Welding Program

'--- MULTI-PASS WELD EXAMPLE ---
*LAYER_LOOP
SET I000 1 'Layer counter
*PASS_START
'Start arc
ARCON ASF#(1) AC=100 AV=240
TIMER T=0.10
'Weld pass
MOVL C00100 V=50.0 AC=100 AV=240
'End arc
TIMER T=0.20
ARCOF
'Increment layer
ADD I000 I000 1
'Check if complete
JUMP *LAYER_LOOP IF I000<=3

8. Safety Setup

Interference Zones

1. Navigate to: SAFETY → INTERFERENCE
2. Define zones:
   • Work envelope limits
   • Fixture collision zones
   • Operator zones

Speed Limits

1. Navigate to: SAFETY → SPEED
2. Set limits:

 TEACH MODE: 250 mm/s
 PLAY MODE: 750 mm/s (max)

9. Program Testing Procedure

1. Dry Run (no arc):
   • Set mode to TEACH
   • Hold DEADMAN switch
   • Press START
   • Verify motion path
2. Air Cut (arc on, no workpiece):
   • Reduce to 25% speed
   • Enable arc
   • Verify parameters
3. Production Run:
   • Set to PLAY/AUTO mode
   • Run at full speed
   • Monitor weld quality

10. Common Commands Reference

Troubleshooting Tips

Arc Won't Start

• Check gas flow sensor (IN#10003)
• Verify wire feed ready (IN#10002)
• Check ASF parameters
• Inspect torch contact tip

Poor Weld Quality

• Adjust travel speed
• Check welding current/voltage
• Verify gas flow rate (15-20 L/min)
• Check wire stick-out (10-15 mm)

Robot Communication Errors

• Check DeviceNet/fieldbus cable
• Verify baud rate settings
• Check node address configuration
• Reset wire feeder communication

Additional Features

Ethernet/IP Integration

For modern Yaskawa DX200/YRC1000 controllers:

• Configure Ethernet/IP adapter
• Add welder as device
• Map I/O through network

Vision Integration

• Add Yaskawa SmartPendant with camera
• Configure seam tracking
• Enable real-time path correction

sample program 

/JOB//NAME ARCWELD_SAMPLE//POS///NPOS 5,0,0,0,0,0///TOOL 1///POSTYPE PULSE///RECTAN///RCONF 0,0,0,0,0,0,0,0P00000={    0.000,    0.000,    0.000,    0.000,    0.000,    0.000}P00001={  500.000,  200.000,  600.000,    0.000,   90.000,    0.000}P00002={  500.000,  200.000,  450.000,    0.000,   90.000,    0.000}P00003={  500.000,  400.000,  450.000,    0.000,   90.000,    0.000}P00004={  500.000,  600.000,  450.000,    0.000,   90.000,    0.000}P00005={  500.000,  600.000,  600.000,    0.000,   90.000,    0.000}//INST///DATE 2025/11/29 00:00///ATTR SC,RW///GROUP1 RB1NOP'--- MOVE TO HOME POSITION ---MOVJ C00000 VJ=25.00'--- APPROACH WELD START ---MOVJ C00001 VJ=50.00MOVL C00002 V=100.0'--- START WELDING SEQUENCE ---ARCON ASF#(1) AC=100 AV=240TIMER T=0.10'--- WELD LINEAR SEAM ---MOVL C00003 V=50.0 AC=100 AV=240MOVL C00004 V=50.0 AC=100 AV=240'--- CRATER FILL ---TIMER T=0.20'--- ARC OFF ---ARCOF'--- RETRACT ---MOVL C00005 V=100.0'--- RETURN HOME ---MOVJ C00000 VJ=50.00END