The SimpleConnect Light Beacon's are both an audible and visual indicator of system status. They have predefined operations that are contained in Concurrent IO (CIO). The concurrent IO logic exists in all YRC1000 welding systems independent of if an light beacon is included at the time of sale or not. This makes addition of a beacon once the system is deployed and in operation easy as ladder programs do not need to be modified. This artical will exclusively focus on the operation and meaning of the various LED indicator colors.
LED Indicator Meaning:
- Purple: Unused by standard SimpleConnect logic but available for customer designated usage. Add logic by modify 78500 rung detailed below.
- Blue: Unused by standard SimpleConnect logic but available for customer designated usage. Add logic by modify 78501 rung detailed below.
- White: Indicates that the robot has sensed a "Collision" via the "Collision detection" software or the hardware-based shock sensor circuit has been broken/opened resulting in a "Shock Sensor Action" alarm
- Red: Indicates an Alarm, Fault, or Error has occurred and needs to be reset either by pressing a reset button or the issue needs to be resolved before resuming operation. In the even of a "Collision Detection" or "Shock Sensor Action" alarm, the white indicator will be illuminated instead!
- Cyan: Indicates that a tip change is required or torch maintenance is needed. This determination is based on the accumulated times found under the "ARC WELD DIAGNOSIS" screen.
- Green: Indicates that the system is in PLAY mode and based on the flashing status, will indicate if the system is "operating" (solid green = operating) or not (not operating = flashing green)
- Amber: Indicates that the system is in "TEACH" mode and awaiting operator from the teaching pendant.
Some important things to know about the operation of the light beacons:
- The IO at the robot is structured so that users can specify any one of eight possible colors.
- If multiple colors are enabled at the same time the color with the highest priority is displayed
- The IO module housed within the beacon itself multiplexes the incoming commands from the robot to generate a 3-bit binary code to display the proper color (hence only 3 outputs to generate 9-colors)
- Reserved IO addresses are made available for users to modify which then will drive individual colors & outputs to the individual devices
- The SimpleConnect logic is intended to drive two beacons at most and the two beacons will operate in unison. There is not separate logic for each beacon.
Reserved CIO Addresses For Individual LED Colors & Flashing Operation:
- 78500 = Purple
- 78501 = Blue
- 78502 = White:
- 78503 = Red
- 78504 = Cyan
- 78505 = Green
- 78506 = Amber
- 78507 = 1/2 second flashing logic
Purple: User Defined Usage Logic (1st/highest priority):
//***************************************
//PURPLE LED - UNUSED - 1ST PRIORITY
//***************************************
//ADD LOGIC HERE!
//OUT #78500 //INTERNAL - PURPLE LED
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78500 //INTERNAL - PURPLE LED
OR #13690 //UNIVERSAL OUTPUT #2945 (PURPLE LED)
AND-STR
OUT #33710 //EXTERNAL OUTPUT FOR TWR#1-PURPLE
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78500 //INTERNAL - PURPLE LED
OR #13730 //UNIVERSAL OUTPUT #2977 (PURPLE LED)
AND-STR
OUT #33750 //EXTERNAL OUTPUT FOR TWR#2-PURPLE
Blue: User Defined Usage Logic (2nd priority):
//***************************************
//BLUE LED - UNUSED - 2ND PRIORITY
//***************************************
//ADD LOGIC HERE!
//OUT #78501 //INTERNAL - BLUE LED
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78501 //INTERNAL - BLUE LED
OR #13691 //UNIVERSAL OUTPUT #2946 (BLUE LED)
AND-STR
OUT #33711 //EXTERNAL OUTPUT FOR TWR#1-BLUE
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78501 //INTERNAL - BLUE LED
OR #13731 //UNIVERSAL OUTPUT #2978 (BLUE LED)
AND-STR
OUT #33751 //EXTERNAL OUTPUT FOR TWR#2-BLUE
White: "Collision/Shock Sensor Action" Logic (3rd priority):
//***************************************
//WHITE LED - COLLISION/SHOCK SENSE - 3RD PRIORITY
//***************************************
//ADD LOGIC HERE!
STR #80170 //R1 COLLISION DETECT
OR #80171 //R2 COLLISION DETECT
OR #80172 //R3 COLLISION DETECT
OR #80173 //R4 COLLISION DETECT
OUT #78502 //INTERNAL - WHITE LED
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78502 //INTERNAL - WHITE LED
STR #13692 //UNIVERSAL OUTPUT #2947 (WHITE LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33712 //EXTERNAL OUTPUT FOR TWR#1-WHITE
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78502 //INTERNAL - WHITE LED
STR #13732 //UNIVERSAL OUTPUT #2979 (WHITE LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33752 //EXTERNAL OUTPUT FOR TWR#2-WHITE
Red: "Alarm or Error Condition" Logic (4th priority):
//***************************************
//RED LED - ALARM OR ERROR - 4TH PRIORITY
//***************************************
//ADD LOGIC HERE!
STR-NOT #78000 //E-STOPS OK
STR #70020 //ALARM OCCUR (MAPPED IN CIO)
OR #50014 //ERROR OCCUR
OR-STR
AND-NOT #78502 //WHITE LIGHT
OUT #78503 //INTERNAL - RED LED
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78503 //INTERNAL - RED LED
STR #13693 //UNIVERSAL OUTPUT #2948 (RED LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33713 //EXTERNAL OUTPUT FOR TWR#1-RED
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78503 //INTERNAL - RED LED
STR #13733 //UNIVERSAL OUTPUT #2980 (RED LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33753 //EXTERNAL OUTPUT FOR TWR#2-RED
Cyan: "Consumable / Tip Maintenance Required" Logic (5th priority):
//***************************************
//CYAN LED - CONSUMABLE / TIP MAINTENANCE REQUIRED - 5TH PRIORITY
//***************************************
//ADD LOGIC HERE!
STR #78630 //TIP REPLACEMENT REQUEST#1,2,3, OR 4 BASED ON HARDWARE CONFIGURATION
OR #78631 //NOZZLE CLEANING REQUEST#1,2,3, OR 4 BASED ON HARDWARE CONFIGURATION
OUT #78504 //LOW CONSUMABLES/TIP MAINTENANCE REQUIRED
//
STR #29507 //UWI INSTALLED AND RUNNING
STR #28507 //WLDR#1 LOW WIRE
OR #28577 //WLDR#2 LOW WIRE
OR #29007 //WLDR#3 LOW WIRE
OR #29257 //WLDR#4 LOW WIRE
AND-STR
OUT #78520 //LOW WIRE ANY WELDER
//
STR #78630 //TIP REPLACEMENT REQUEST#1,2,3, OR 4 BASED ON HARDWARE CONFIGURATION
OUT #79856 //USER MESSAGE# 39 "TIP CLEAN/CHANGE REQUIRED!"
//
STR #78631 //NOZZLE CLEANING REQUEST#1,2,3, OR 4 BASED ON HARDWARE CONFIGURATION
OUT #79857 //USER MESSAGE# 40 "NOZZLE CLEAN/CHANGE REQUIRED!"
//
STR #78520 //LOW WIRE ANY WELDER
OUT #79860 //USER MESSAGE# 41 "WIRE SPOOL/BARREL LOW!"
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78504 //LOW CONSUMABLES/TIP MAINTENANCE REQUIRED
OR #78520 //LOW WIRE
STR #13694 //UNIVERSAL OUTPUT #2949 (CYAN LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33714 //EXTERNAL OUTPUT FOR TWR#1-CYAN
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78504 //LOW CONSUMABLES/TIP MAINTENANCE REQUIRED
OR #78520 //LOW WIRE
STR #13734 //UNIVERSAL OUTPUT #2981 (CYAN LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33754 //EXTERNAL OUTPUT FOR TWR#2-CYAN
Green: "PLAY / Operating" Logic (6th priority):
//***************************************
//GREEN LED - PLAY/OPERATING - 6TH PRIORITY
//***************************************
//ADD LOGIC HERE!
STR #50070 //OPERATING
OR-NOT #50053 //TEACH
OUT #78505 //INTERNAL - GREEN LED
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78505 //INTERNAL - RED LED
STR #13695 //UNIVERSAL OUTPUT #2950 (GREEN LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33715 //EXTERNAL OUTPUT FOR TWR#1-GREEN
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78505 //INTERNAL - RED LED
STR #13735 //UNIVERSAL OUTPUT #2982 (GREEN LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33755 //EXTERNAL OUTPUT FOR TWR#2-GREEN
Yellow/Amber: "TEACH" Logic(7th/lowest priority):
//***************************************
//YELLOW/AMBER LED - TEACH - 7TH PRIORITY
//***************************************
//ADD LOGIC HERE!
STR #50053 //TEACH MODE
AND-NOT #78502 //SHOCK SENSOR
OUT #78506 //INTERNAL - YELLOW/AMBER LED
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78506 //INTERNAL - YELLOW/AMBER LED
STR #13696 //UNIVERSAL OUTPUT #2952 (YELLOW/AMBER LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33716 //EXTERNAL OUTPUT FOR TWR#1-YELLOW/AMBER
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78506 //INTERNAL - YELLOW/AMBER LED
STR #13736 //UNIVERSAL OUTPUT #2983 (YELLOW/AMBER LED)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33756 //EXTERNAL OUTPUT FOR TWR#2-YELLOW/AMBER
"1/2 Sec Flash": Aux Relay# 78507 Logic
//***************************************
//LED 1/2SEC FLASH
//***************************************
STR #78502 //INTERNAL - WHITE LED
OR #78504 //INTERNAL - CYAN LED
OR #78506 //INTERNAL - YELLOW/AMBER LED
STR #78505 //INTERNAL - GREEN LED
AND-NOT #50070 //OPERATING
OR-STR
OUT #78507 //INTERNAL - TWR#* 1/2SEC FLASH
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78507 //INTERNAL - TWR#* 1/2SEC FLASH
STR #13697 //UNIVERSAL OUTPUT #2952 (TWR#1 1/2SEC FLASH)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33717 //EXTERNAL OUTPUT FOR TWR#1 1/2SEC FLASH
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78507 //INTERNAL - TWR#* 1/2SEC FLASH
STR #13737 //UNIVERSAL OUTPUT #2984 (TWR#2 1/2SEC FLASH)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33757 //EXTERNAL OUTPUT FOR TWR#2 1/2SEC FLASH
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