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 article will exclusively focus on the operation and meaning of the various audible indicators.
Basic Beacon Audible Indicator Meaning:
- HORN: The "Horn" will sound anytime there an active "Alarm" or "Error" active on the robot controller as long as the "Mute" signal #78517 isn't active. User can add logic by modifying the #78510 rung detailed below.
- 1/2sec "Chirp": The 1/2second "Chirp" of the horn will sound anytime there an active "Collision Detection" or "Shock Sensor" alarm active on the pendant as long as the "Mute" signal #78517 isn't active. User can add logic by modifying the #78511 rung detailed below.
- 2.5sec "Chirp":The 2.5second "Chirp" of the horn will sound anytime there an active welding consumables require attention and as long as the "Mute" signal #78517 isn't active. User can add logic by modifying the #78512 rung detailed below.
Advanced Beacon Audible Indicator Meaning:
- Synthesized HORN: The "Horn" will sound anytime there an active "Alarm" or "Error" active on the robot controller as long as the "Mute" signal #78517 isn't active. User can add logic by modifying the #78510 rung detailed below.
- "ROBOT COLLISION OR SHOCK SENSOR ACTION": The "Robot collision or shock sensor action" message will sound anytime there an active "Collision Detection" or "Shock Sensor" alarm active on the pendant as long as the "Mute" signal #78517 isn't active. User can add logic by modifying the #78511 rung detailed below.
- "WELDING CONSUMABLES LOW OR REQUIRE MAINTENANCE": 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)
- "ROBOT OR POSITIONER MAINTENANCE DUE"): Indicates that the system is in "TEACH" mode and awaiting operator from the teaching pendant.
- "CAUTION: CYCLE STARTING"
- "CAUTION: CYCLE COMPLETE"
- "WARNING: WELDER OR WELD PROCESS FAULT"
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 messages.
- If multiple messages are enabled at the same time the color with the highest priority is played
- 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 message (hence only 3 outputs to generate 9-messages)
- Reserved IO addresses are made available for users to modify which then will drive individual messages & 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:
| Beacon w/Horn: | Beacon w/ Audible Messages: | |
| 78510 | Horn on constantly |
Synthesized Horn |
| 78511 | 1/2s on , 1/2s off | "ROBOT COLLISION OR SHOCK SENSOR ACTION" |
| 78512 | 2.5s on, 2.5s off | "WELDING CONSUMABLES LOW OR REQUIRE MAINTENANCE" |
| 78513 | NA | "ROBOT OR POSITONER MAINTENANCE DUE" |
| 78514 | NA | "CAUTION: CYCLE STARTING" |
| 78515 | NA | "CAUTION: CYCLE COMPLETE" |
| 78516 | NA | "WARNING: WELDER OR WELD PROCESS FAULT" |
| 78517 | MUTE HORN!! | MUTE MESSAGES!! |
HORN Logic (1st/highest priority):
//***************************************
//HORN / AUDIBLE MESSAGE #1 (SYNTHESIZED HORN)
//***************************************
STR #78503 //ALARM/ERROR (INTERNAL RED LED)
AND-NOT #78517 //SILENCE ALARMS/BEACON(S)
OUT #78510 //INTERNAL - HORN
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #03707 //TWR#1 = AUDIBLE
AND-NOT #78502 //COLLISION DETECT/SHOCK SENSE (INTERNAL WHITE LED)
AND-NOT #78516 //WELDER ALARM
OR-NOT #03707 //TWR#1 = AUDIBLE
AND #78510 //INTERNAL - HORN/AUDIBLE MESSAGE #1 (SYNTHESIZED HORN)
STR #13700 //UNIVERSAL OUTPUT #2953 (HORN)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33720 //EXTERNAL OUTPUT FOR TWR#1-HORN
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #03747 //TWR#2 = AUDABLE
AND-NOT #78502 //COLLISION DETECT/SHOCK SENSE (INTERNAL WHITE LED)
AND-NOT #78516 //WELDER ALARM
OR-NOT #03747 //TWR#2 = AUDIBLE
AND #78510 //INTERNAL - HORN/AUDIBLE MESSAGE #1 (SYNTHESIZED HORN)
STR #13740 //UNIVERSAL OUTPUT #2985 (HORN)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33760 //EXTERNAL OUTPUT FOR TWR#2-HORN
1/2sec "Chirp" Logic (2nd priority):
//***************************************
//0.5SEC CHIRP / AUDIBLE MESSAGE #2 (COLLISION DETECT/SHOCK SENSE: "ROBOT COLLISION OR SHOCK SENSOR ACTION")
//***************************************
STR #78502 //COLLISION DETECT/SHOCK SENSE (INTERNAL WHITE LED)
AND-NOT #78517 //SILENCE ALARMS/BEACON(S)
OUT #78511 //INTERNAL - TWR#* 1/2SEC CHIRP
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78511 //INTERNAL - TWR#* 1/2SEC CHIRP/AUDIBLE MESSAGE #2
STR #13701 //UNIVERSAL OUTPUT #2954 (TWR#1 1/2SEC CHIRP)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33721 //EXTERNAL OUTPUT FOR TWR#1 1/2SEC CHIRP
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78511 //INTERNAL - TWR#* 1/2SEC CHIRP/AUDIBLE MESSAGE #2
STR #13741 //UNIVERSAL OUTPUT #2986 (TWR#2 1/2SEC CHIRP)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33761 //EXTERNAL OUTPUT FOR TWR#2 1/2SEC CHIRP
2.5sec "Chirp" / "WELDING CONSUMABLES LOW OR REQUIRE MAINTENANCE" Logic (3rd priority):
//***************************************
//2.5SEC CHIRP / AUDIBLE MESSAGE #3 (LOW CONSUMABLES: "WELDING CONSUMABLES LOW OR REQUIRE MAINTENANCE")
//***************************************
STR #78504 //LOW CONSUMABLES/TIP MAINTENANCE REQUIRED (INTERNAL - CYAN LED)
OR #78520 //LOW WIRE
AND-NOT #78517 //SILENCE ALARMS/BEACON(S)
OUT #78512 //INTERNAL - TWR#* AUDIBLE MESSAGE#3
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78512 //INTERNAL - TWR#* AUDIBLE MESSAGE#3
STR #13702 //UNIVERSAL OUTPUT #2955 (TWR#1 AUDIBLE MESSAGE#3)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33722 //EXTERNAL OUTPUT FOR TWR#1 AUDIBLE MESSAGE#3
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78512 //INTERNAL - TWR#* AUDIBLE MESSAGE#3
STR #13742 //UNIVERSAL OUTPUT #2987 (TWR#2 AUDIBLE MESSAGE#3)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33762 //EXTERNAL OUTPUT FOR TWR#2 AUDIBLE MESSAGE#3
"ROBOT OR POSITIONER MAINTENANCE DUE" Logic (4th priority):
//***************************************
//AUDIBLE MESSAGE #4 (ROBOT/POSITIONER MAINTENANCE: "ROBOT OR POSITONER MAINTENANCE DUE")
//***************************************
//ADD LOGIC HERE!
//AND-NOT #78517 //SILENCE ALARMS/BEACON(S)
//OUT #78513 //INTERNAL - TWR#* AUDIBLE MESSAGE#4
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78513 //INTERNAL - TWR#* AUDIBLE MESSAGE#4
STR #13703 //UNIVERSAL OUTPUT #2956 (TWR#1 AUDIBLE MESSAGE#4)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33723 //EXTERNAL OUTPUT FOR TWR#1 AUDIBLE MESSAGE#4
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78513 //INTERNAL - TWR#* AUDIBLE MESSAGE#4
STR #13743 //UNIVERSAL OUTPUT #2988 (TWR#2 AUDIBLE MESSAGE#4)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33763 //EXTERNAL OUTPUT FOR TWR#2 AUDIBLE MESSAGE#4
"CAUTION: CYCLE STARTING" Logic (5th priority):
//***************************************
//AUDIBLE MESSAGE #5 (CYCLE START: "CAUTION: CYCLE STARTING")
//***************************************
STR #15020 //STA#1 CYCLE STARTING
OR #15022 //STA#2 CYCLE STARTING
AND-NOT #78517 //SILENCE ALARMS/BEACON(S)
OUT #78514 //INTERNAL - TWR#* AUDIBLE MESSAGE#5
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78514 //INTERNAL - TWR#* AUDIBLE MESSAGE#5
STR #13704 //UNIVERSAL OUTPUT #2957 (TWR#1 AUDIBLE MESSAGE#5)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33724 //EXTERNAL OUTPUT FOR TWR#1 AUDIBLE MESSAGE#5
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78514 //INTERNAL - TWR#* AUDIBLE MESSAGE#5
STR #13744 //UNIVERSAL OUTPUT #2989 (TWR#2 AUDIBLE MESSAGE#5)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33764 //EXTERNAL OUTPUT FOR TWR#2 AUDIBLE MESSAGE#5
"CAUTION: CYCLE COMPLETE" Logic (6th priority):
//***************************************
//AUDIBLE MESSAGE #6 (CYCLE COMPLETE: "CAUTION: CYCLE COMPLETE")
//***************************************
STR #15021 //STA#1 CYCLE COMPLETE
OR #15023 //STA#2 CYCLE COMPLETE
AND-NOT #78517 //SILENCE ALARMS/BEACON(S)
OUT #78515 //INTERNAL - TWR#* AUDIBLE MESSAGE#6
//
STR #28340 //TWR#1 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78515 //INTERNAL - TWR#* AUDIBLE MESSAGE#6
STR #13705 //UNIVERSAL OUTPUT #2958 (TWR#1 AUDIBLE MESSAGE#6)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33725 //EXTERNAL OUTPUT FOR TWR#1 AUDIBLE MESSAGE#6
//
STR #28341 //TWR#2 CONFIGURED ON SIMPLECONNECT NETWORK
STR #78515 //INTERNAL - TWR#* AUDIBLE MESSAGE#6
STR #13745 //UNIVERSAL OUTPUT #2990 (TWR#2 AUDIBLE MESSAGE#6)
AND #50053 //TEACH MODE
OR-STR
AND-STR
OUT #33765 //EXTERNAL OUTPUT FOR TWR#2 AUDIBLE MESSAGE#6