Page 1 of 7

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MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

1.0 SCOPE and PURPOSE

1.1 This document defines the standard procedure for the installation of the MedWeld 6000
pendant application with Ethernet IP I/O Interface.

2.0 MATERIALS
2.1 256MB Compact Flash card (Part # 144650-2) or compatible
2.2 Medar serial programming pendant DEP-100S

3.0 SOFTWARE REQUIREMENTS

3.1 Download the latest version software from:
http://inet.motoman.com/ssg/WORLDJOBS/XXXX/index.htm
.
4.0 SOFTWARE PREPERATION
4.1 Prepare a DX software upgrade card (You do not need to change robot software but
you do need to use an upgrade CF card for this process)

4.2 Make a ‘PP_APP’ folder on the root of the CF card

4.3 Copy the contents of the MedWeld zip file into the ‘PP_APP’ folder
4.4 Insert CF card into the pendant

5.0 SOFTWARE INSTALLATION PROCEDURE

5.1.1 Load Application Software
5.1.1.1 Reboot the controller while holding [INTERLOCK + 8 + SELECT]
5.1.1.2 Select Application VersionUp
5.1.1.3 Touch the blank area under the Operation column
5.1.1.4 Select Add from the dropdown box next to the MedWeld listing
5.1.1.5 Select the Execute button and allow the process to finish
5.1.1.6 Select the Option button
5.1.1.7 From the ‘Auto Run Application’ drop down select MedWeld
5.1.1.8 From the ‘One Touch Run Application’ drop down select MedWeld
5.1.1.9 Select the Return button
5.1.1.10 Select the Execute button and allow the process to finish

5.1.2 Parameter Setup:

5.1.2.1 Enter Yaskawa security mode
5.1.2.2 Select Parameters from the top menu

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 Page 2 of 7
Work
MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

5.1.2.3 Set parameter FD188 = 9

5.1.2.4 Reboot the controller

6.0 ROBOT EIP SETUP

6.1 CARD INSTALLATION
6.1.1 Follow ESD Control Procedure MFGP-023
6.1.2 Remove PCI card from the static shield bag.
6.1.3 Insert the card in the DX100’s CPU rack slot ID: PCI Slot 1
6.1.4 Secure the card with a M3 x 10 screw.

6.2 EIP SETUP PROCEDURE

6.2.1 Reboot in maintenance mode
6.2.2 Login as Management.
6.2.3 Go to System -> Setup Menu
6.2.4 Select Option Board
6.2.5 Make sure the Ethernet/IP card is detected as PCU-ETHIO
6.2.6 Highlight Device Information List: Detail and press ‘Select’
6.2.7 Select a blank slot and press ‘Select’
6.2.8 Enter a registration name of ‘Medar’
6.2.9 Set the following default settings:
 RPI Connection - 50
 Input Size – 2
 Output Size – 2
 Configuration Size – 0
 Input Instance – 100
 Output Instance – 150
 Configuration Instance – 128

6.2.10 Press ‘Enter’

6.2.11 Modify: Yes
6.2.12 Highlight PCU-ETHIO(1CH): DETAIL and press SELECT.
6.2.13 Set PCU-ETHIO to USED.
6.2.14 Set IO SIZE (IN/OUT) to 2 bytes.
6.2.15 Select ETHERNET DETAIL and press SELECT.

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 Page 3 of 7
Work
MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

6.2.16 At the NETWORK screen select HOST SETUP: DETAIL.

6.2.17 Set the IP ADDRESS to 192.168.0.99
6.2.18 Set the subnet mask to 255.255.255.0
6.2.19 Press the ENTER key to go to the NETWORK screen.
6.2.20 Press ENTER again to return to the “PCU-ETHIO” screen.
6.2.21 Select SCANNER and press ENTER.
6.2.22 Select ‘MEDAR’
6.2.23 Set the IP Address of each Medar Scanner as follows:
 Unit 1: 192.168.0.250
 Unit 2: 192.168.0.251
 Unit 3: 192.168.0.252
 Unit 4: 192.168.0.253
6.2.24 Press ENTER again to return to the “PCU-ETHIO” screen. Press ENTER a
final time to receive the Modify prompt. Select Yes.

6.2.25 After the beep the “OPTION BOARD” menu is again displayed.
6.2.26 Press ENTER to receive another Modify prompt. Press yes.
6.2.27 Cycle power to the controller to restart normally.

7.0 MEDAR 6000 TIMER SETUP

7.1 Connect DEP-100S to timer serial port. Wait for the status display.
7.2 Select Program mode on the DEP 100S
7.3 Press F5 - *
7.4 Press F5 - *
7.5 Press F1 - EIP Mapping
7.6 Press 2 - Map Inputs
7.7 Set input name assignments per Ethernet IP I/O list at the end of this document
7.8 Press F3 - Download
7.9 Press F4 - Exit
7.10 Select 3 - Map Outputs
7.11 Set input name assignments per Ethernet IP I/O list at the end of this document
7.12 Press F3 - Download
7.13 Press F4 - Exit

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 Page 4 of 7
Work
MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

7.14 Select 4 - EIP Configuration

7.14.1 Set IP Address
 Timer 1: 192.168.0.250
 Timer 2: 192.168.0.251
 Timer 3: 192.168.0.252
 Timer 4: 192.168.0.253
 All Timers - Set Subnet Mask: 255.255.255.0

7.15 F3 - Download
7.16 F4 - Exit
7.17 Select Program mode from DEP 100S
7.18 Press F5 - *
7.19 Press F4 - Fieldbus Mapping
7.20 Press 4 – IP Configuration
7.20.1 Set IP Address:
 Timer 1 – 10.0.0.10
 Timer 2 – 10.0.0.11
 Timer 3 – 10.0.0.12
 Timer 4 – 10.0.0.13

7.21 F3 - Download
7.22 F4 – Exit
7.23 Press 2 - Map Fieldbus Inputs
7.24 Set inputs to ‘none’
7.25 Press F3 – Download
7.26 Press F4 – Exit
7.27 Press 3 - Map Fieldbus Outputs
7.28 Set outputs to ‘none’
7.29 Press F3 – Download
7.30 Press F4 – Exit
7.31 Cycle Power to the timer
7.32 Verify timer setup

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 Page 5 of 7
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MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

8.0 Verify The Install

8.1 Verify that the application starts when the controller re-booted.
8.2 If you do not have the Medar weld timer connected and configured, the application will fail
at startup. Close the application

8.3 Verify that the ‘MedWeld’ button is available under the 'PP Application' button and the
program launches. Close the application

8.4 Verify that the MedWeld shortcut button is available and the program launches. Close the
application

8.5 The installation procedure is complete.

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MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

Typical Ethernet/Ethernet IP Connection

Robot

Original Robot
Pendant Pendant
Connection (Windows CE)
IP: 10.0.0.2
IP: 10.0.0.4
Ethernet IP Card
IP: 192.168.0.99
255.255.255.000

Ethernet Switch

EIP Port
IP: 192.168.0.250
255.255.255.000

Medar Timer 1

Ethernet Port
(Half Duplex)
IP: 10.0.0.10
255.255.255.000

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 Page 7 of 7
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MOTOMAN Robotics Doc. Number: SSGW-297
Instruction
Date: 06/30/2010
Subject: MedWeld 6000 DX with EIP DCR# 7092
FOR INTERNAL MOTOMAN USE ONLY

Ethernet IP I/O List (Robout Outputs)

Robot Timer Number Name Description
Active high is Weld Mode, active low is No
Output Input 1 Weld / No Weld Weld Mode.
Output Input 2 Fault Reset Resets faults in timer weld control.
Output Input 3 Weld Fault Acknowledge Acknowledges a weld error.
Initiates a weld schedule based upon Binary
Output Input 4 Initiate Weld Select.
Output Input 5 Stepper Reset Resets all steppers to zero.
Output Input 6 Isolation Contactor Saver Enable Isolation Contactor Saver Enable bit
Output Input 7 Control Stop Control Stop
Output Input 8 Tips Dressed Tips have been dressed
Output Input 9 Binary Select #1 Binary Schedule Select #1
Output Input 10 Binary Select #2 Binary Schedule Select #2
Output Input 11 Binary Select #4 Binary Schedule Select #4
Output Input 12 Binary Select #8 Binary Schedule Select #8
Output Input 13 Binary Select #16 Binary Schedule Select #16
Output Input 14 Binary Select #32 Binary Schedule Select #32
Output Input 15 Binary Select #64 Binary Schedule Select #64
Output Input 16 Binary Select #128 Binary Schedule Select #128

Ethenet IP I/O List (Robot Inputs)

Robot Timer Number Name Description
Input Output 1 Weld Enable Weld Mode On
Input Output 2 No Fault No Faults Exist
Input Output 3 No Alert No Alerts Exist.
Input Output 4 Weld Fault Indicates that a weld fault error code is set
Input Output 5 Weld Complete Initiates a weld schedule has completed.
Input Output 6 Weld in Progress Indicates that a weld is currently in progress.
Input Output 7 Steppers are Reset Indicates that all steppers are reset.
Input Output 8 Stepper Approaching Max Stepper has entered last step.
Input Output 9 End of Stepper The last weld in the last step of the programmed
stepper was reached.
Input Output 10 Ready to Weld The control is ready to begin welding.
Input Output 11 Tip Dress Request The weld control is requesting a tip dress.
Input Output 12 Weld Error Bit 1 Binary Bit for weld error code 1
Input Output 13 Weld Error Bit 2 Binary Bit for weld error code 2
Input Output 14 Weld Error Bit 4 Binary Bit for weld error code 4
Input Output 15 Weld Error Bit 8 Binary Bit for weld error code 8
Input Output 16 Weld Error Bit 16 Binary Bit for weld error code 16

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