ESAB Xcellerator Instruction manual

XCellerator

XC1300, XC2000

Instruction manual

Original instructions

0463 623 001 US 20190219

Valid for: serial no. 815-xxx-xxxx

TABLE OF CONTENTS

1

SAFETY ....................................................................................................... 5

1.1 Meaning of symbols ............................................................................... 5

1.2 Safety precautions ................................................................................. 5

1.3 General safety......................................................................................... 7

1.3.1 Standard compliance............................................................................ 8

1.3.2 Requirements of operating personnel .................................................. 8

1.3.3 Personal Protective Equipment ............................................................ 9

1.4 Installation safety................................................................................... 9

1.4.1 Installation of safeguarding .................................................................. 9

1.5 Wiring safety........................................................................................... 10

1.5.1 Protective ground ................................................................................. 10

1.5.2 Equipotential bonding........................................................................... 10

1.6 Releasing a person trapped in or by the machine .............................. 10

1.7 Decommissioning, storage, and disposal ........................................... 10

1.8 Safety layout........................................................................................... 11

1.9 Safety....................................................................................................... 11

1.9.1 Manufacturer ........................................................................................ 11

1.9.2 Health and safety regulations............................................................... 12

1.9.3 Arc safety ............................................................................................. 13

1.9.4 Maintenance......................................................................................... 14

1.9.5 Guarantee ............................................................................................ 14

1.9.6 Installation ............................................................................................ 14

1.9.7 Manual operation.................................................................................. 15

2

INTRODUCTION.......................................................................................... 16

2.1 Intended use ........................................................................................... 16

2.2 Equipment............................................................................................... 16

3

TECHNICAL DATA ...................................................................................... 17

3.1 Functional specifications ...................................................................... 17

3.1.1 Parameter setting ................................................................................. 17

3.1.2 Position................................................................................................. 17

3.2 Technical data......................................................................................... 17

3.3 Calculating offset ................................................................................... 18

4

INSTALLATION............................................................................................ 20

4.1 Lifting instructions................................................................................. 20

4.1.1 Using a forklift....................................................................................... 20

4.2 Mounting ................................................................................................. 21

4.2.1 Rough setting ....................................................................................... 22

4.2.2 Anchoring ............................................................................................. 25

4.2.3 Connecting the exhaust system ........................................................... 26

4.2.4 Connecting ........................................................................................... 26

4.2.5 Mounting optional equipment ............................................................... 27

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TABLE OF CONTENTS

4.3 Wiring ...................................................................................................... 27

4.3.1 Connection to robot controller .............................................................. 27

4.4 Safety components ................................................................................ 29

4.5 Before first start ..................................................................................... 30

4.5.1 Parameter setting ................................................................................. 30

4.5.2 Initial test .............................................................................................. 30

4.6 Ambient conditions................................................................................ 30

4.7 External supply....................................................................................... 31

4.7.1 Voltage ................................................................................................. 31

4.7.2 Pneumatic (Option) .............................................................................. 31

5

OPERATION ................................................................................................ 32

5.1 Measures before start ............................................................................ 32

5.2 Starting the robot on the programming pendant ................................ 33

5.3 Release of persons trapped in the XCellerator ................................... 33

5.4 Positioning safety components ............................................................ 36

5.5 Function safety system ......................................................................... 36

5.6 Stops........................................................................................................ 36

5.7 Emergency stop ..................................................................................... 37

5.8 Safety stop.............................................................................................. 37

5.9 Control panel .......................................................................................... 38

5.10 Programming pendant ........................................................................... 38

6

MAINTENANCE........................................................................................... 41

6.1 General .................................................................................................... 41

6.2 Maintenance............................................................................................ 41

6.2.1 Maintenance schedule for the XCellerator Base .................................. 41

6.2.2 Maintenance positions 0459990668 and 0459990670......................... 42

6.2.3 Maintenance positioner V2TR-500D5 .................................................. 44

6.2.3.1 Check current transfer unit and ground disc ..................................... 45

6.2.3.2 Check tension of timing belt .............................................................. 45

6.3 Servo units.............................................................................................. 46

6.3.1 General................................................................................................. 46

6.3.2 Reduction gear ..................................................................................... 46

6.3.3 AC Servo .............................................................................................. 46

7

TROUBLESHOOTING................................................................................. 47

7.1 Error messages ...................................................................................... 47

7.2 Outline of alarm ...................................................................................... 47

7.3 Service contact information .................................................................. 48

7.3.1 Contact information .............................................................................. 48

8

ORDERING SPARE PARTS ........................................................................ 50

DIMENSIONS....................................................................................................... 51

WORKING AREAS.............................................................................................. 52

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TABLE OF CONTENTS

FIXTURES............................................................................................................ 53

ACCESSORIES ................................................................................................... 54

WEAR PARTS...................................................................................................... 56

Rights reserved to alter specifications without notice.

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1 SAFETY

1 SAFETY

1.1 Meaning of symbols

As used throughout this manual: Means Attention! Be Alert!

DANGER!
Means immediate hazards which, if not avoided, will result in immediate,

serious personal injury or loss of life.

WARNING!
Means potential hazards which could result in personal injury or loss of life.

CAUTION!
Means hazards which could result in minor personal injury.

WARNING!

Before use, read and understand the instruction manual
and follow all labels, employer's safety practices and
Safety Data Sheets (SDSs).

1.2 Safety precautions

Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety
precautions must meet the requirements that apply to this type of equipment. The following
recommendations should be observed, in addition to the standard regulations that apply to
the workplace.

All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations, which
could result in injury to the operator and damage to the equipment.

1. Anyone who uses the equipment must be familiar with:
○ its operation
○ the location of emergency stops
○ its function
○ the relevant safety precautions
○ welding and cutting or other applicable operation of the equipment

2. The operator must ensure that:
○ no unauthorized person is within the working area of the equipment when it is

started up

○ no-one is unprotected when the arc is struck or work is started with the

equipment

3. The workplace must:
○ be suitable for the purpose
○ be free from drafts

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4. Personal safety equipment:
○ Always wear recommended personal safety equipment, such as safety glasses,

flame-proof clothing, safety gloves

○ Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which

could become trapped or cause burns

5. General precautions:
○ Make sure the return cable is connected securely
○ Work on high voltage equipment may only be carried out by a qualified

electrician

○ Appropriate fire extinguishing equipment must be clearly marked and close at

hand

○ Lubrication and maintenance must not be carried out on the equipment during

operation

WARNING!

Arc welding and cutting may cause injury to yourself and others. Take precautions
when welding and cutting.

ELECTRIC SHOCK - Can kill

• Install and ground the unit in accordance with instruction manual.

• Do not touch live electrical parts or electrodes with bare skin, wet gloves,
or wet clothing.

• Insulate yourself from work and ground.

• Ensure your working position is safe

ELECTRIC AND MAGNETIC FIELDS - Pose health risks

• Welders with pacemakers fitted should consult their doctor before welding.
EMF may interfere with some pacemakers.

• Exposure to EMF may have other health effects which are unknown.

• Welders should use the following procedures to minimize exposure to
EMF:

○ Route the electrode and work cables together on the same side of

your body. Secure them with tape when possible. Do not place your
body between the torch and work cables. Never coil the torch or work
cable around your body. Keep the welding power source and cables
as far away from your body as possible.

○ Connect the work cable to the workpiece as close as possible to the

area being welded.

FUMES AND GASES - Can be dangerous to your health

• Keep your head out of the fumes.

• Use ventilation, extraction at the arc, or both, to take fumes and gases
away from your breathing zone and the general area.

ARC RAYS - Can injure eyes and burn skin

• Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.

• Protect bystanders with suitable screens or curtains.

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NOISE - Excessive noise can damage hearing

Protect your ears. Use ear defenders or other hearing protection.

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MOVING PARTS - Can cause injuries

• Keep all doors, panels and covers closed and securely in place. Have only
qualified people remove covers for maintenance and troubleshooting as
necessary. Reinstall panels or covers and close doors when service is
finished and before starting engine.

• Stop engine before installing or connecting unit.

• Keep hands, hair, loose clothing and tools away from moving parts.

FIRE HAZARD

• Sparks (spatter) can cause a fire. Make sure there are no inflammable
materials nearby.

• Do not use on closed containers.

MALFUNCTION - Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

CAUTION!

This product is solely intended for arc welding and allied processes.

CAUTION!

Class A equipment is not intended for use in residential
locations where the electrical power is provided by the
public low-voltage supply system. There may be
potential difficulties in ensuring electromagnetic
compatibility of class A equipment in such locations,
due to conducted as well as radiated disturbances.

NOTE!
Dispose of electronic equipment at a recycling

facility!

To conform with the European Directive 2012/19/EC on
Waste Electrical and Electronic Equipment and its
implementation in accordance with national law,
electrical and/or electronic equipment that has reached
the end of its life must be disposed of at a recycling
facility.

As the person responsible for the equipment, it is your
responsibility to obtain information on approved
collection stations.

For further information contact the nearest ESAB dealer.

ESAB has an assortment of welding accessories and personal protection equipment
for purchase. For ordering information, contact your local ESAB dealer or visit us on
our website.

1.3 General safety

This machinery fulfills all relevant provisions of Directive 2006/42/EC on machinery.

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1 SAFETY

This machinery also fulfills all relevant provisions of Directive 2004/108/EC on
electromagnetic compatibility (EMC).

The "EC-Declaration of conformity" with the subsequent CE-marking attached to this
machinery is only valid if this machinery is installed according to the installation instructions
in this manual.

YASKAWANordicAB's is not responsible for errors or safety risks that may occur with
equipment connected to and/or installed on the machine, nor errors or safety risks that may
occur on the machine caused by equipment connected to and/or installed on the machine.

1.3.1 Standard compliance

This machine is developed and manufactured according to all relevant provisions of the
following harmonized standards:

• EN349:1993+A1:2008 Safety of machinery — Minimum gaps to avoid crushing of parts
of the human body

• EN574:1996+A1:2008 Safety of machinery — Two-hand control devices — Functional
aspects — Principles for design

• EN953:1997+A1:2009 Safety of machinery — Guards — General requirements for the
design and construction of fixed and movable guards

• ENISO13849-1:2008 Safety of machinery — Safety-related parts of control systems
— Part1: General principles for design

• ENISO13849-2:2012 Safety of machinery — Safety-related parts of control systems
— Part2: Validation

• ENISO13855:2010 Safety of machinery — Positioning of safeguards with respect to
the approach speeds of parts of the human body

• EN 1037:1995+A1:2008 Safety of machinery — Prevention of unexpected start-up

• ENISO10218-1:2011 Robot and robotic devices — Safety requirements for industrial
robots — Part1: Robots

• ENISO10218-2:2011 Robot and robotic devices — Safety requirements for industrial
robots — Part2: Robot system and integration

• ENISO12100:2010 Safety of machinery — General principles for design — Risk
assessment and risk reduction

• ENISO13850:2008 Safety of machinery — Emergency stop — Principles for design

• ENISO13857:2008 Safety of machinery — Safety distances to prevent hazard zones
being reached by upper and lower limbs

• EN 60204-1:2006+A1:2009 Safety of machinery — Electrical equipment of machines —
Part1: General requirements

• EN 61000-6-2:2005+AC:2005 Electromagnetic compatibility (EMC) –Part6-2: Generic
standards – Immunity for industrial environments

• EN 61000-6-4:2007+A1:2011 Electromagnetic compatibility (EMC) – Part6-4: Generic
standards – Emission standard for industrial environments

1.3.2 Requirements of operating personnel

The machine must only be operated by specially trained persons.

General

Operating personnel must not be under the influence of alcohol, drugs, or similar substances.
Operating personnel must not have a restricted field of vision or be restricted in any other
way that could lead to risks. Operating personnel must be in a suitable state of health to
operate the system/component (attention must be paid in particular to medical aids, such as
pacemakers, etc.

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Qualified personnel

Persons involved in commissioning, operation, maintenance, and repair of the
system/component must be familiar with the system/component and trained accordingly.
They must have read and understood the operating manuals. Furthermore, they must be
instructed and must be able to avoid possible residual risks to themselves and others while
working on the system/ component or to reduce such risks as much as possible. To maintain
the qualification, the safety instruction must be repeated at least every year.

1.3.3 Personal Protective Equipment

WARNING!

Use Personal Protective Equipment (PPE), such as safety shoes, helmet, goggles,
hearing protection, and gloves, appropriate for the type of operation being carried
out, in order to reduce risk of personal injury.

WARNING!

Use hearing protection to reduce the level of noise exposure when the machine is
running.

1.4 Installation safety

WARNING!

• Install the safeguarding
Failure to observe this warning may result in injury or damage.

• Do not start the machine or turn ON the power before it is firmly anchored.
The machine may overturn and cause injury or damage.

• Do not install or operate a machine that is damaged or lacks parts.
Failure to observe this warning may cause injury or damage.

• Do not start the machine or turn ON the power before the exhaust system is
connected.
Exhaust gases in workshops are a health hazard.

NOTE!
Important

Install the machine in a location so that the installation into which it is incorporated
complies with the regulations of Machinery Directive 2006/42/EC.

Failure to observe this warning may result in injury or damage.

Read

When installing, it is necessary to observe environmental conditions
requirements. See chapter 4.2Mounting.

1.4.1 Installation of safeguarding

Installing the safeguarding ensures safety and prevents unforeseen accidents for personnel
and damage to equipment. The following excerpt is for your information and guidance:

Responsibility for safeguarding (ENISO10218-2:2011)

The user of a machine or complete system shall ensure that safeguarding is provided and
used in accordance with sections 5, 6, and 7 of ENISO10218-2:2011 Robots and robotic
devices - Safety requirements for industrial robots — Part2: Robot systems and integration.
The means and degree of safeguarding, including any redundancies, shall correspond

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directly to the type and level of hazard presented by the machine system consistent with the
application. Safeguarding may include, but not be limited to safeguarding devices, barriers,
interlock barriers, perimeter guarding, awareness barriers, and awareness signals.

1.5 Wiring safety

WARNING!

Before wiring, turn OFF the primary power supply and put up a warning sign. (e.g.
"DO NOT TURN THE POWER ON".) Failure to observe this warning may result in fire
or electric shock.

WARNING!

Wiring must be performed by authorized or certified personnel. Failure to observe this
warning may result in fire or electric shock.

Important

Keep equipotential bonding and protective grounding separated. Equipotential bonding and
protective grounding are two separate circuits.

1.5.1 Protective ground

WARNING!

Protective grounding must be performed following standard EN 60204-1. Failure to do
so may result in severe incidents.

1.5.2 Equipotential bonding

The wire must be chosen according to standard EN60204-1. For equipotential bonding,
connect the wire directly to the frame of the machine.

NOTE!

Never share this line with other ground lines or grounding electrodes for other
electric power, motor power, welding devices, etc.

1.6 Releasing a person trapped in or by the machine

Read

For instructions on "Releasing a person trapped in or by the machine," see section 5.3
Release of persons trapped in the XCellerator.

1.7 Decommissioning, storage, and disposal

Decommissioning must comply with all applicable local and national standards at the time of
decommissioning. The unit must be decommissioned, stored, and disposed of in accordance
with applicable national laws, regulations, and standards.

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1.8 Safety layout

1. Reset emergency stop "MACHINE ON"

5. Door

Air and safe power supply on

2. Control cabinet main switch 6. Safety reset

3. Emergency stop 7. OP-panel

4. Valve air shut-off

1.9 Safety

The machine is designed for arc welding and must work together with a fixture.

YASKAWANordicAB's is not responsible for errors or safety risks that may occur with
equipment connected to and/or installed on the machine, nor errors or safety risks
that may occur on the machine caused by equipment connected to and/or installed on
the machine.

The machine must only be operated by personnel with sufficient knowledge and skills.

It is prohibited for any person to stay inside the safety guarding when the machine is
in operation.

1.9.1 Manufacturer

Address: YASKAWANordicAB

POBox504

0463 623 001

SE-38525Torsås
Verkstadsgatan2

Phone: [phone]

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1 SAFETY

Fax: [phone]
Machine type: See machinery sign
Machine no.: See machinery sign
Year of manufacture: See machinery sign

1.9.2 Health and safety regulations

All machines can be dangerous if they are operated incorrectly. Therefore, it is of utmost
importance that all users of the machine fully read, understand, and observe the following
safety precautions and warnings. Read these instructions periodically.

All safety precautions have been observed in the manufacture of this equipment. However,
all risks cannot be compensated for; otherwise the working capabilities of the machine would
be limited.

All equipment has been assembled and tested by YASKAWANordicAB's personnel. If the
equipment is properly installed and connected, it will work properly. In the unlikely event of a
malfunction, contact our service organization before making any attempt to modify the
machinery.

Basic safety precautions should always be followed to reduce the risk of fire, electric shock,
and personal injury.

WARNING!

Observe and follow local safety regulations.

Unauthorized persons must not operate the machine.

Do not leave the machine unattended during operation. Ensure that all users of the
machine have read and understood the information in this document.

Safe use of the machine involves:

• The operator

• The machine

• The use of the machine

The operator

The operator must be in good physical condition and not under the influence of any
substance that might impair their vision, dexterity, or judgment. Do not use the machine if you
are fatigued, as you may lose control of the machine. Be alert at all times.

Working with any machine can be strenuous if the operator suffers from an illness that might
be aggravated by strenuous work. Check with your doctor before operating your system.

Work clothing

Clothing must be sturdy and well fitting, yet allow complete freedom of movement. Do not
wear loose clothing, loose sleeves or cuffs, scarves, necklaces, rings, or other items that may
become caught in the machine. Long hair should be tied back.

Good footwear is important as a safety precaution. Wear sturdy boots with non-slip soles.
Steel-toe safety boots are recommended.

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1.9.3 Arc safety

Noise

WARNING!

Noise generated by the welding process may exceed limits.

The noise generated by the arc can reach high levels. Prolonged exposure may
damage your hearing. Always wear hearing protection.

YASKAWANordicAB has measured the emission of airborne noise according to the
Machinery directive.

Operation <85dB(A)
Stand by <70dB(A)

Glare

WARNING!

The light created by the arc contains IR and UV radiation. Exposure to IR and UV
radiation damages eyes and skin. The effect of the radiation increases at closer
proximity to the arc.

Use protective shields and curtains to block this radiation. When examining the arc,
always use a welding shield of sufficient strength and protect any exposed skin with
sturdy clothing.

Heat and fire

CAUTION!

Working with an arc will scintillate hot particles. Always wear protective gloves when
handling the workpiece.

Check fire extinguisher regularly.

Use fire extinguisher suitable for textile, inflammable liquids, electricity

Do not store inflammable material or liquids near the machine.

Emission of gases

The machine does not emit gases. Emitted gases are the result of the welding process and
are generated by the protective gas, wire, and material used.

It is the customer's obligation to evacuate any possible gases.

Air pollution

The arc will generate smoke and fumes. Avoid exposure to fumes generated by heating the
material. Sufficient ventilation is required to evacuate any fumes, and a protective mask must
be used when working near the arc.

Material containing any of the following elements may produce unhealthy amounts of
dangerous fumes: lead, cadmium, zinc, chrome, nickel, mercury, or beryllium.

Machine safety

The machine is tested as a separate unit by YASKAWANordicAB's personnel in accordance
with the Essential Health and Safety Requirements.

Warning signs

The following sign is applied to the machine and must be respected. Location, see figure in
chapter 5.1Measures before start.

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WARNING!

There are high-voltage parts in the equipment that present a risk of electric shock,
which may result in death or severe injury.

1.9.4 Maintenance

Do not modify a YASKAWANordicAB machine in any way. Use spare parts from
YASKAWANordicAB or from a supplier expressly approved by YASKAWANordicAB for your
machine. Using parts from other suppliers may affect the safety or functionality of the
machine.

Recommended service is stated in the documentation.

WARNING!

Do not clean, lubricate, or adjust the machine while it is in operation. Turn off the
main power first.

NOTE!

Keep your eyes open — that's your best protection to avoid accidents.

1.9.5 Guarantee

Do not store these operating instructions without having first read them carefully, and insist
that the operators of this machine also read them thoroughly. They are for your own safety!

This information contains operating and safety instructions for this YASKAWANordicAB
machine.

This machine is intended for high-production capacity. Therefore, strict safety regulations
must be observed in order to reduce the risk of accidents and physical damage.
Carelessness or inappropriate use of the machine may result in severe or even fatal
accidents. Avoid unnecessary disturbances by following the guidelines and safety
precautions provided in this manual.

The machine will only operate correctly if the operator follows the information and
instructions provided in the operating manuals.

YASKAWANordicAB provides a guarantee for this machine. The guarantee is valid
according to the signed contract, beginning on the day of installation. The guarantee is only
valid if genuine spare parts from YASKAWANordicAB are used exclusively.

In order to correctly and promptly order spare parts, please provide the following information:

• Machine type

• Machine no.

• Part no.

• Number of parts

• Voltage information, when applicable

See 8Ordering spare parts and optional equipment.

Changes to robot jobs might cause damage to the machine and may only be done by
specially trained personnel.

1.9.6 Installation

Refer to the installation and service manuals for each machine and unit included in this
documentation. Also see 4Installation.

Following installation, a complete check of all safety functions must be performed.

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Pneumatic system

Be careful when connecting the pneumatic system to the main supply, as valves, cylinders,
and tools may move unexpectedly.

1.9.7 Manual operation

When resetting a robot, it is of utmost importance that it be performed accurately. If in doubt,
ask a service engineer or trained personnel.

WARNING!

The highest precautions must be taken when running the machine in TEACH mode.
Passing program steps or setting IN/OUT signals in the robot job may cause loss of
interlocking function, i.e. the fixtures and positioner may lose balance, the fixture
may be released, or the setting may be lost. This may cause severe damage to
machinery as well as personal injuries.

If the robot is set to a physical position other than the position for the actual step in the job,
the robot will move at high speed to the next position when PLAY - START mode is selected.

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2 INTRODUCTION

2 INTRODUCTION

2.1 Intended use

XCellerator is designed to be equipped with fixtures and to be incorporated into machinery
controlled by a robot controller system. The machine is intended to assist welding robots by
shifting workpieces.

2.2 Equipment

XCellerator is supplied with:

• XCellerator Base

• Positioner with two stations

• Wheel kit

• MOTOMAN-MA1440 (XC1300) MA2010 (XC2000) industrial robot

• Assembly kit for robot controller

• Cable set between positioner and robot controller

• Instruction manual

• Declaration of Conformity

Main parts

• Housing

• Rotating table

• MA1440 Robot (only for XC1300)

• MA2010 Robot (only for XC2000)

The positioners can be equipped at different distances between fixture discs.

Optional equipment

• Welding equipment for MIG/MAG welding

• Media transfer (signal, air, current) for the positioner

• Fixed table or 3-axis positioner (depending on the selected type and design)

• Interior door and cabinet located on the opposite side (left or right)

• MotoWeb for remote supervision and administration

• MotoSim with kinematic simulation

• Beacon light

• Machine foot kit

• Signal and air transmission unit for HM/TM modules

• Additional power supply for HM/TM modules

• Retro fit bracket for HM/TM modules

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3 TECHNICAL DATA

3 TECHNICAL DATA

3.1 Functional specifications

Version Note

XC1300 L=1300
XC2000 L=2000

3.1.1 Parameter setting

NOTE!

The positioner's parameter setting is not included in manuals because it is subject to
change. See the positioner's part number for the correct MMS document.

3.1.2 Position

Repetitive position accuracy: ±0.004in (±0.1mm)

3.2 Technical data

Maximum load and capacity

XC1300/XC2000
Centerrotatingaxis

Dynamic torque 1307lb-ft (1772Nm) 868.1lb-ft (1177Nm)
Static torque 1045.1lb-ft (1417Nm) 694lb-ft (941Nm)
Max. capacity load 1102.3lb (500kg)
Max. offset 0.50ft (0.15m)
Motor power 3.0kW 1.3kW
Gear ratio reducer 119:1 165:1
Gear ratio total 119:1 165:1
Efficiency 0.82 0.81
Nominal speed 12.6rpm 9.0rpm
Max. speed 16.8rpm 23.5rpm

Temperature 32to104°F(0to+40°C)*
Humidity 20to80%RH at constant temperature**

Vibration acceleration

4.9m/s2(0.5g) or less

XC1300/XC2000 Tiltingaxis

Main supply See the requirements for the robot controller system in its

installation/instruction manual.
Pneumatic compressed air specification (option)
Working pressure 87psi (0.6MPa)
Minimum pressure 72.5psi (0.5MPa)
Quality According to ISO8573-1, Class 5,4,3
Welding capacity (standard single carbon brush)
Continuous duty 100% 350A
Continuous duty 60% 460A

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3 TECHNICAL DATA

*This option is only available for the XC2000.

**The ambient conditions are general requirements if no specific equipment, such as an IP
kit or similar, allows for certain extreme environments or conditions.

• Free from corrosive gas, liquid, or explosive gas

• Free from exposure to water or oil

• Free from abnormal exposure to dust

• Free from excessive electrical noise (plasma)

• Located indoors

2×rotate, 2×tilt with central turntable axis Rotating axis Tilting axis

Dynamic torque 669lb-ft (907Nm) 1189lb-ft (1612Nm)
Static torque 535.5lb-ft (726Nm) 981lb-ft (1330Nm)
Max. capacity load 1102.3lb (500kg) 1102.3lb (500kg)
Max. offset 0.5ft (0.145m) 0.89ft (0.270m)
Motor power 1.3kW 2.0kW
Gear ratio spur 90/40
Gear ratio reducer 59:1 171:1
Gear ratio total 132.75:1 171:1
Efficiency 0.7 0.82
Nominal speed 11.3rpm 10.6rpm
Max. speed 30rpm 23.4rpm

The machine should not be overloaded to ensure long and safe operation with high
positioner accuracy. Follow the restrictions.

3.3 Calculating offset

Calculating offset

(Max. static torque of axis in Nm)

--------------------------------------------- =X Max. offset of axis in m
(M Max. payload in kg × 9.81)



Maximum x-offset rotating axis HM-500D

Maximum static torque of rotating axis = 941Nm.

M Maximum payload 500kg (incl. fixtures).

X Maximum offset from rotation center at 500kg = 191mm.

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3 TECHNICAL DATA



Maximum x-offset rotating axis V2TR-500D5

Maximum static torque of rotating axis = 726Nm.

M Maximum payload 500kg (incl. fixtures).

X Maximum offset from rotation center at 500kg = 145mm.

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4 INSTALLATION

4 INSTALLATION

4.1 Lifting instructions

Read

Read and understand the contents of chapter1. Safety before handling the
machine.

WARNING!

Crane operation and forklift truck operation must be only performed by authorized
personnel. When handling the positioner:

• Do not place any part of your body under a suspended machine.

• Do not move the machine over another person's body.

Careless handling can result in severe personnel injury.

4.1.1 Using a forklift

CAUTION!

Transport the machine carefully, as the side walls are easily damaged.

NOTE!

The XCellerator cannot be lifted by a crane.

To lift the machine, use a fork lift with its forks in their outer position. Insert the forks in the
beams and lift the machine as shown in the Lifting instructions illustration. Anchor the
machine and transport it slowly with due caution in order to avoid overturning or slippage.

Using the included wheel kit, the machine can be transported using a hand pallet truck with a
lifting capacity of at least 8818.5lb (4metrictons).

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4 INSTALLATION

A. Fixing points during transport M20 D. Wood beam
B. Fixing points during transport M16 E. Plexiglas® door/cover
C. Transport plate

The machine is provided with transport plates C and a wood beam D for protection during
transport.

Use fixing points A and B to secure the machine during transport and make sure the
Plexiglas® doors/covers E are kept at a distance from the surrounding transport method. Do
not use the fixing points for lifting.

4.2 Mounting

Read

Read and understand the contents of chapter1. Safety before handling the
machine.

NOTE!

The forces listed in the Maximum load and capacity table in the "TECHNICAL
DATA" chapter must be considered when constructing and mounting the positioner.

Mount the XCellerator Base on a base or a foundation firm enough to support the cell and
withstand maximum repulsion forces during acceleration and deceleration.

While constructing a solid foundation and furthermore when applying anchoring bolts or
similar, follow the harmonized standards of European Commission Directive89/106/EEC
(Construction Products) and, if necessary, the specific Construction Product's ETA (European
Technical Approval) (e.g. regarding appropriate concrete thickness/quality and the depth of
anchoring bolt attachments).

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4 INSTALLATION

4.2.1 Rough setting

1. Remove the two transport plates A and the wood beam B used for transport
protection.

2. Make sure the surface of the base or foundation is level and even. If necessary, grind
the swell and flatten the surface.

NOTE!

It is important to place foot washers under the adjustment screws.

Make sure the surface of the base or foundation is level and even. If necessary, grind the
swell and flatten the surface. Place foot washers under the adjustment screws.

Foot washer

A. Adjustment screw D. Base or foundation
B. Positioner baseplate E. Anchor bolt
C. Foot washer F. Recommended distance approx. 1in

(25mm)

Footprints

XC1300 XC2000

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4 INSTALLATION

A. Wheel C. Foot washer
B. Castor wheel

Footprint

Place the machine in its final position. Use the Foot washers on point C in the illustration
above.

NOTE!

Keep a distance of 31.5in (800mm) between cells for XC2000.

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4 INSTALLATION

Figure 1. Side panels XC2000 version 0459990670

A. Side panel, right E. Radius bracket
B. Side panel, left F. Angular plate
C. Radius bracket G. Radius bracket
D. Top side cover H. Radius bracket

Reassemble the side panels A, B for XC2000 version 0459990670 if they have been
removed during transport to allow the cell to fit in a container.

• Fasten the radius brackets C, E, G, and H using 6screws (M10).

• Fasten the top side cover D using 5screws (M6).

• Fasten the angular plate F using 5 screws (M6).

Level the machine using the 4adjustment screws and foot washers.

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4 INSTALLATION

Check that the distance between the sensors A and the glare shield B is 1/8in (3mm).
Otherwise, loosen the bolts and adjust accordingly.

CAUTION!

There is a risk of damaging the sensors if the distance is less than 1/8in (3mm).

4.2.2 Anchoring

Attach the baseplate to the floor by tightening the anchoring bolts.

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4 INSTALLATION

4.2.3 Connecting the exhaust system

Exhaust duct dimensions

Attach the exhaust ducts A to the fume hoods.

CAUTION!

Do not begin using the machine without connecting it to an exhaust system.

NOTE!

Use a flexible or a detachable duct when mounting the exhaust device to the fume
hoods in order to be able to remove the fume hoods for maintenance.

4.2.4 Connecting

Connect electric wiring see Safety chapter,"1.5Wiring safety".

A. Optional 230VAC out E. Main power 400VAC, N, P
B. Optional 400VAC out F. Pneumatic connection in Air 1/2" Min.

35.31CFM at 87psi (1000l/min at 6bar)

C. Robot G. Pneumatic connection out
D. Power source

Connect pneumatic connections A to the building's outlet.

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4 INSTALLATION

4.2.5 Mounting optional equipment

NOTE!

All mounting screws must be of at least strength class 12:9 and minimum thread
length 1.5 × D, where D = thread diameter.

Dimension(12:9strength) Tighteningtorque(lb-ft/ Nm)

M10 58.3/79
M12 100.3/136
M14 160.1/217
M16 245.6/333
M18 341.5/463
M20 478.7/649

4.3 Wiring

Read

Read and understand the contents of chapter1. Safety before handling
the machine.

4.3.1 Connection to robot controller

WARNING!

• Install all electrical cables to the positioner, control system, welding
equipment, etc. in such a way that it is impossible to trip over or step on the
cables.

• Do not put any object directly on the cables.

• Do not place the cables along power cables or underneath the welding
power.

The positioner is controlled from the robot controller and the operator's panel.

Installation and connection to the robot controller includes both a hardware and software
installation. These work steps must be carried out by ESAB service technicians. In cases
where the positioner is delivered together with a robot, this installation is already carried out
at the ESAB factory. When delivered together with other equipment, see the separate
diagram for electrical connection included in the order-specific documentation:

Controller cabinet

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4 INSTALLATION

+AK1 Main controller cabinet A Power supply
+AK10 Controller cabinet for safety X1 W1 encoder cable for robot

X2 W2 motor cable for robot

Connections to HM-500D module

Connector Model Drawing no. Position in the "Connections

to HM-500D" MotoMount
illustration

External servo signal HM-500D 348522-xx A
External servo motor and brake HM-500D 348524-xx B

"-xx" stands for a specific cable length.



Connections for V2TR-500D5

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4 INSTALLATION

Connector Drawing no. Position in the "Connections

for V2TR-500D5" illustration

External servo signal 348522-xx A
External servo motor and brake 348524-xx B

"-xx" stands for a specific cable length.

4.4 Safety components

A. Eden non-contact safety sensor switch,

male 0459990679

B. Eden non-contact safety sensor switch,

female 0459990680

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C. Inductive safety sensor IFMGG712S

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4 INSTALLATION

In order to meet safety requirements, it must only be possible to open the door if one of the
two safety sensors (C) is ON when the other sensor is OFF.

4.5 Before first start

Read

Read and understand the contents of chapter1. Safety before handling
the machine.

WARNING!

Check all safety functions such as emergency stop, safety switches and light beams
before first start. Failure to do so could result in severe personal injury.

WARNING!

Never stay inside the safety guard during operation.

CAUTION!

During operation, check that nothing abnormal occurs, such as vibrations, unusual
noise, etc. Should any of these occur, stop the machine immediately by pushing
EMERGENCY STOP and contact ESAB.

4.5.1 Parameter setting

Parameter setting for the positioner is performed by authorized personnel at the factory or
during installation.

4.5.2 Initial test

NOTE!

For initial test and examination of the positioner and its protective measures, see the
instructions for use related to complete integration.

4.6 Ambient conditions

Temperature 32to104°F(0to+40°C)
Humidity 20 to 80%RH at constant temperature
Vibration acceleration

Others Free from corrosive gas, liquid, or explosive

4.9m/s2(0.5g) or less

gas.

Free from exposure to water or oil.

Free from abnormal exposure to dust.

NOTE!

The ambient conditions are general requirements if no specific equipment, such as
an IP kit or similar, allows for certain extreme environments or conditions.

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Free from excessive electrical noise
(plasma).

Located indoors.

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4 INSTALLATION

4.7 External supply

4.7.1 Voltage

Read

See the requirements for the robot controller system in its
installation/instruction manual.

4.7.2 Pneumatic (Option)

The specifications for compressed air are:

Working pressure: 87psi (0.6MPa)
Minimum pressure: 72.5psi (0.5MPa)
Quality: According to ISO8573-1, Class 5,4,3

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5 OPERATION

5 OPERATION

5.1 Measures before start

• Check that the main switches are set to ON (DX controller, power source, cooler, etc.).
The controller performs a self-test.

• Check the position of the welding torch.

• If the machine is in Emergency Stop mode, reset according to Reset emergency stop.

• Check that the selected robot job matches the workpiece to be used in the fixture.

• Check the robot position (home position).

• Reset the service gate. See Reset safety stop.

• Start the robot according to the "Start robot" subsection.

• Loading cycle:

a) Loading.
b) Press the PreReset button.
c) Leave the loading zone.
d) Press START on the operator panel.

The START button flashes green and the door closes.
It is still possible to press the OPEN DOOR button to open the door as long as
the green button is flashing.
When the doors are closed, the green button remains steadily lit and the
machine is ready.

DX controller cabinet and XC1300 or XC2000

A. DX controller cabinets E. Programming pendant
B. Main power switch F. PreReset
C. Control panel G. Machine ON
D. Warning sign

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5 OPERATION

5.2 Starting the robot on the programming pendant

1. Mode selection switch 4. Emergency stop button

2. PLAY mode START 5. Servo on ready

3. PLAY mode HOLD

• Set the machine to PLAY mode using the Mode selection switch (1).

• Activate the servo power using SERVOON READY (5).

• Press START on the programming pendant (2).

• The green light remains lit and the robot is ready.

SERVOON flashes Safety circuit tripped. No servo power to the robot. In TEACH mode,

the safety circuit can be activated via the enable switch.

SERVOON is lit Safety circuit OK. Servo power to the robot is ON.

5.3 Release of persons trapped in the XCellerator

Follow these release instructions in an emergency situation.

Release of persons in a non-maneuverable robot system

If a person needs to be released when the robot system is in a non-maneuverable state, the
robot must be moved by means of an external force.

Loosen the connection between the robot and robot foot

WARNING!

One bolt must remain attached to prevent a fall. This bolt should be located on the
opposite side of the center of gravity in relation to the trapped person.

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5 OPERATION

Loosen the other bolts between the robot and the robot foot to be able to turn the entire robot
away. Loosening the robot from its fixed position will affect all programmed robot jobs, as this
changes the base coordinates.

NOTE!

Loosening the robot from its fixed position will affect all programmed robot jobs, as
this changes the base coordinates.

Tackle, straps, etc.

Tackle, straps, etc. can be used to force a robot movement. Attach one end of the selected
equipment to and around the robot arm as far out on the arm as possible. Attach the other
end of the equipment to a fixed structure to create a force that is as perpendicular as
possible in relation to the robot arm.

CAUTION!

Forced movement of the robot can damage its mechanical components
(brakes/gears/arms, etc.).

Jack

A smaller jack can be used if permitted by the posture of the robot and the fixture/positioner.
In this case, the jack is placed between the robot arm and a firm surface.

Release of persons in a maneuverable robot system

These instructions are to be used in emergency situations during programming where
persons or equipment have been trapped by the robot or by other DX controlled axes.

If a Shock-sensor alarm has been triggered:

• Press RESET on the display.
(If a Servo Tracking Error alarm has been triggered, reset first.)

If the Shock-sensor alarm is triggered again before a maneuver is possible:

• Press ROBOT in the display menu.

• Choose SHOCK-SENSOR LEVEL in the display menu.

• Press SELECT to set the shock-sensor level as INVALID.

• Return to job by going to JOB.

1. Choose the coordinate system JOINT with the COORD button (1).

2. Icon (2) is displayed in the display's icon row.

3. Press SERVO ON READY (3).

4. Decrease the speed to the second-lowest level using the SLOW button (4). (If the

lowest speed is set, press the FAST button.)

5. Press until the speed icon in the display appears as follows (5).

6. Press the enable switch (6).

WARNING!

Observe which direction (+) and (-) is for each different robot axis prior to
maneuvering. See the direction labels on each respective axis.

7. Maneuver the robot away using the respective (+) and (-) buttons for the axes (7).

(S-,L-,U-,R-,B-,T-).

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5 OPERATION

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5 OPERATION

5.4 Positioning safety components

1. Adam non-contact safety sensor

8540242

2. Eva non-contact safety sensor 8540240

3. Inductive safety sensor IFMGG712S

5.5 Function safety system

Entry into the loading zone is permitted when the front doors are open. When the operator is
loading, the robot is working on the other side of the table or is in its home position.

If the service gate is open, the entire machine is set to safety stop. See the "Safety stop"
section.

5.6 Stops

Production stop

If the operator:

• presses the HOLD button on the programming pendant or

• enters the machine via the service gate.

Reset production stop

Reset after being stopped using the HOLD button:

• Press the START button on the programming pendant and the machine starts its cycle
again.

Reset after being stopped after the service gate has been opened:

• See instructions under the "Safety stop" section.

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5 OPERATION

5.7 Emergency stop

When Emergency stop is pressed, the equipment stops and the servo power is turned off.

Reset emergency stop

1. Reset the emergency stop button mechanically by turning the red knob clockwise.

2. Reset after startup/Emergency stop:

○ Press the EQUIPMENT ON button.

The white button is permanently on.

3. Press the SERVO ON READY button on the programming pendant to turn on the

servo power.

4. Press the START button on the programming pendant.

5.8 Safety stop

Safety stop turns off the servo power and the equipment stops. A Safety stop occurs when
service gate opens.

Reset safety stop

Reset safety gate:

1. Leave through the gate.

2. Ensure that no personnel are within the working area, then close the gate.

3. Press RESET GATE.

4. Activate the servo power via SERVO ON READY.

5. Press START on the programming pendant.

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5 OPERATION

5.9 Control panel

Button Function

Emergency stop button.

1. Emergency stop

2. Yellow push button Opens the front doors.

3. White push button Closes the front doors in Teachmode.

4. Green push button Starts production.

Interrupts all equipment motion.

5.10 Programming pendant

The programming pendant is equipped with keys and buttons used to conduct robot teaching
operations and to edit jobs.

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5 OPERATION

1. PLAY mode START 10.Enter key

2. PLAY mode HOLD 11. Numeric key

3. Emergency stop button 12. Motion type key

4. CF slot 13. Enable switch ("Dead man's switch")

5. PAGE key 14.Cursor

6. Select key 15. Display

7. FAST/SLOW keys 16. Top menu key

8. Axis key 17. Mode selection switch

9. Enable switch (option)

Enable switch ("Dead man's switch")

NOTE!

The enable switch is only activated in TEACH mode.

When servo power is turned OFF, the robot/machine will not run.

When safety circuit is tripped (at programming), the robot must be set to TEACH mode in
order to turn the servo power ON. In this mode, the safety control is transferred from the
system to the operator, who activates the servo power using the enable switch.

The three-position enable switch is located on the back of the programming pendant.

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5 OPERATION

A OFF Released No function (circuit open)
B ARCONMiddle position Operation (circuit closed)

C OFF Squeezed tightly No function (circuit open)

To get from the squeezed tightly position to the middle position, you must first completely
release the enable switch. When the safety circuit is OK (all gates closed and reset), the
enable switch has no effect. When safety circuit is tripped (gate open), the servo power can
be activated.

WARNING!

When returning to PLAY mode after the robot has been operated manually, the
operator must be extremely vigilant not to restart the machine in the wrong position.

At Restart, run the robot to the start position or to the "second home position".

Programming capacity

NOTE!

For information regarding programming and capacity in general, see the robot
controller manuals:

Beginners reference

Installation and wiring

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6 MAINTENANCE

6 MAINTENANCE

6.1 General

Positioner maintenance should only be handled by authorized personnel or YASKAWA
service technicians who are thoroughly familiar with the design and construction of the
machine.

For all types of service/maintenance:

1. Turn off and lock the electrical supplies.

2. Turn off and lock the wiring circuit breaker.

WARNING!

Depending on the type of installation, there can be connections between several
machines and consequently between electrical supplies from several power
sources.

Turn off all live circuits before servicing.

To avoid incidents caused by inadvertent use of the machine, display an
informational sign indicating that maintenance is being performed.

Check after maintenance is completed that all covers are remounted and all bolts
are tightened to the required torque. Check that no tools are left in the cell.

6.2 Maintenance

6.2.1 Maintenance schedule for the XCellerator Base

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6 MAINTENANCE

Interval Pos.

Object Method/specification Lubricant/means

no.

Every shift 1 Overall cleaning The machine does not need

any special cleaning beside
normal cleaning (dust, etc.).

Daily 2 Vibrations and noise

in servo unit.

Listen to make sure that
nothing abnormal occurs,
such as vibrations or
unusual noises.

Weekly 3 Check that bolts and

Tighten if necessary. Wrench key
floor anchor bolts are
tight.

- Pneumatic system air
(optional equipment).

Check air supply and air
quality.

Not shown in figure.

4 Rubber door seals Check for wear and

damage.

500hours - Cables and hoses.

Not shown in figure.

Check for wear and
damage. Clean if necessary.

Annually 5 Angular bearing Lubricate using grease gun

in grease nipple.

Dry cloth and
compressed air

Compressed air

ShellGadusS2

6 Insulation resistance

in servomotors

Make sure it is greater than
10Mohm by measuring with
a Megger 500V tester after
disconnected the motor from
the controller.

Repair
replacing

- Reduction gear Contact ESAB

representative.

6.2.2 Maintenance positions 0459990668 and 0459990670

Megger 500V tester

Maintenance positions HM-500D

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6 MAINTENANCE

Maintenance positions TM-1000

Interval Pos.

Object Method/specification Lubricant/means

no.

Every shift 1 Overall cleaning The machine does not need

any special cleaning beside
normal cleaning (dust, etc.).

Daily 2 Vibrations and noise

in servo unit.

Weekly 3 Check screws for

Listen to make sure that
everything is normal.

Tighten if necessary. Wrench key

tightness.
Pneumatic system air

(optional equipment).

Check air supply and air
quality.

Not shown in figure.

500hours 4a Current transfer unit Check the current transfer

4b Ground disc

unit and the ground disc on
the headstock. If the surface
is too worn, bad contact and
bad welding results will
occur.

Cables and hoses.
Not shown in figure.

Check for wear and
damage. Clean if necessary.

Dry cloth and
compressed air

Compressed air

Annually 5 Insulation resistance

in servomotors

6 Bearings Apply grease 2x stroke at

Repair

Reduction gear Contact ESAB

replacing

0463 623 001

Make sure it is greater than
10Mohm by measuring with
a Megger 500V tester after
disconnected the motor from
the controller.

1.3cm³/ or more depending
on environmental conditions

representative

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Megger 500V tester

MicrolubeGL261

© ESAB AB 2019

6 MAINTENANCE

6.2.3 Maintenance positioner V2TR-500D5

Interval Pos.

Object Method/specification Lubricant/means

no.

Every shift 1 Overall cleaning The machine does not need

any special cleaning beside
normal cleaning (dust, etc.).

Daily 2 Vibrations and noise

in servo unit.

Weekly - Pneumatic system air

(optional equipment).

Listen to make sure that
everything is normal.

Check air supply and air
quality.

Not shown in figure.

500hours 3a Current transfer unit Check the current transfer

3b Ground disc

unit and the ground disc on
the headstock. If the surface
is too worn, bad contact and
bad welding results will
occur.

See "Check current transfer
unit and ground disc".

- Cables and hoses.
Not shown in figure.

Check for wear and
damage. Clean if necessary.

Dry cloth and
compressed air

Compressed air

Annually 4 Check tension of

timing belt

5 Insulation resistance

in servomotors

Repair

- Reduction gear Contact

replacing

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See "Check tension of
timing belt"

Make sure it is greater than
10Mohm by measuring with
a Megger 500V tester after
disconnected the motor from
the controller.

YASKAWANordicAB
representative

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Megger 500V tester

© ESAB AB 2019

6 MAINTENANCE

Remove cover plate for maintenance

NOTE!

Keep screws, washers, nuts, and other parts organized to facilitate remounting. All
parts should be fastened properly before start.

A. Cover plate B. Screw, part no. 6002028 C. Washer, part no. 6026006

6.2.3.1 Check current transfer unit and ground disc

1. Loosen the 6 screws B with the washers C, see figure in "Removing cover plate on tilt
unit" chapter.

2. Remove the cover plate A.

3. Check the current transfer unit and the ground disc.

4. Replace if necessary.

5. Remount in reverse order.

6.2.3.2 Check tension of timing belt

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6 MAINTENANCE

1. Loosen the 6 screws B with the washers C, see figure in "Removing cover plate on tilt
unit" chapter.

2. Remove the cover plate A.

3. Check that the span length L is 5.25in (133.5mm) between the timing pulleys.

4. Apply a tensioning force F of 5.4lbf (23.9N) or a tensioning frequency of 298Hz on
the belt, as shown in the picture.

5. Measure the tensioning deflection q.
If q> 5/64in (2.1mm) increase the belt tension.
If q< 5/64in (2.1mm) reduce the belt tension.

6. Remount in reverse order.

6.3 Servo units

6.3.1 General

NOTE!

Dismounting of the servo unit is not recommended.

If the gear is dismounted by personnel without adequate knowledge, the technical
data performance characteristic cannot be fulfilled.

An ESAB representative should be contacted if certain work has to be performed on
the servo units.

Condition at delivery

Reduction gears are properly greased by ESAB when they are delivered mounted on the
positioner.

Considerations when assembling servo units

Motor shafts should be coated with MoS2paste or spray (e.g. Molycote).

Disassemble - reassemble

Disassembly of the reduction unit is not recommended. No attempt should be made to
change the mesh or clearances within the unit. The operating and performance characteristic
cannot be fulfilled if the unit is disassembled by someone other than ESAB personnel.

6.3.2 Reduction gear

Lubrication

Gears are filled with grease when delivered from ESAB.

The gear is lifetime lubricated.

6.3.3 AC Servo

Servo motor

The AC servo motor has no wearing parts (e.g. brushes), therefore a simple daily inspection
is sufficient.

The inspection schedule for the motor is shown in the "Maintenance" section. Do not
disassemble the motor. If disassembly becomes necessary, contact ESAB.

Servopack

The servopack does not require any special maintenance. Remove dust and tighten screws
periodically.

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7 TROUBLESHOOTING

7 TROUBLESHOOTING

The programming pendant's screen displays alarm and error messages, which can be
translated to Remedy - Measure. This chart is enclosed in a separate ALARM LIST
document.

Two types of messages are generated by the system: error messages and alarms.

7.1 Error messages

An error message is shown due to an error caused by an incorrect operation or access
method when using the programming pendant or an external equipment (computer, PLC,
etc.). The error message warns the operator not to continue to the next operation or step.

When an error occurs, confirm the content of the error, then release the error.

To release the error, perform either of the following operations:

• Press [CANCEL] on the programming pendant.

• Input alarm/error reset signal (system input).

NOTE!

An error is different from an alarm, as it does not stop the robot even if it occurred
while the robot was in operation (during playback).

7.2 Outline of alarm

When an alarm level of 0 to 3 (major alarm) occurs, the servo power supply is turned OFF.

Alarm code classification

Alarm
code

0□□□ Level 0 (Majoralarm)

1□□□
to

3□□□

4□□□
to

8□□□
9□□□ Level 9 (Minoralarm)

Alarm level Alarm reset method

It is not possible to reset using "RESET" under the
(Offline alarm: Initial
diagnosis/ Hardware
diagnosis alarm)

Level 1 to 3
(Majoralarm)

Level 9 (Minoralarm)
(I/Oalarm)

(I/Oalarm)

ALARM window or the system input signal (Alarm reset).

Turn OFF the main power supply and correct the cause

of the alarm. Then turn ON the main power supply again.

It is not possible to reset using "RESET" under the

ALARM window or the system input signal (Alarm reset).

Turn OFF the main power supply and correct the cause

of the alarm. Then turn ON the main power supply again.

After correcting the cause, it is possible to reset using

"RESET" under the ALARM window or the system input

signal (Alarm reset).

After correcting the cause of the system input signal for

the system or user alarm request, it is possible to reset

using "RESET" under the ALARM window or the system

input signal (Alarm reset).

Troubleshooting

WARNING!

Turn the power OFF before performing corrective action.

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7 TROUBLESHOOTING

Trouble Cause Remedy

Motor does not
start

Loose connection Tighten connection

Wrong wiring Correct wiring

Overload Reduce load

Unstable operation Wrong wiring Inspect and correct wiring across motor

terminals L1, L2, L3, and PE

Motor overheats Excessive ambient

temperature

Reduce ambient temperature below

104°F(40°C)
Motor surface is dirty Clean motor surface
Overload Reduce load

Unusual noise Motor mounted loosely Tighten foundation bolts

Motor misaligned Realign
Coupling out of balance Balance coupling
Noisy bearing Check alignment, bearing noise, lubrication,

and contact Yaskawa
Vibration of driven

Contact Yaskawa
equipment

7.3 Service contact information

Each XCellerator robot cell includes a 1-year support and service contract covering
the robot and robot cell, including positioning and handling equipment.

For service and support, please contact your nearest Yaskawa office

For your nearest Yaskawa office, please see "7.3.1 Contact information".

ESAB provides support and service on the welding equipment and welding process
only.

For service and Support please contact your nearest ESAB office.

For your nearest ESAB office visit esab.com.

7.3.1 Contact information

Related issue: Robot and robot cell including positioning and handling equipment.



YASKAWANordicAB

POBox504, SE-385 25 Torsås

SWEDEN

Phone [phone]

www.motoman.se



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7 TROUBLESHOOTING

YASKAWANordicAB

AT YASKAWA Europe GmbH

Vienna [phone]

CZ YASKAWA Czech s.r.o.

Rudná u Prahy [phone]

DE YASKAWA Europe GmbH

Allershausen [phone]

ES YASKAWA Iberica S.L.

Gavà [phone]

FI YASKAWA Finland Oy

Turku [phone]

FR YASKAWA France S.A.

Nantes [phone]

IL YASKAWA Europe Technology Ltd

Rosh Ha’ayin [phone]

IT YASKAWA Italia SRL

NL YASKAWA Benelux B.V

Son [phone]

PL YASKAWA Polska Sp. z o.o

Wrocław [phone]

RU YASKAWA Nordic AB

Moscow [phone]

SE YASKAWA Nordic AB

Torsås [phone]

SI YASKAWA Slovenia d.o.o

Ribnica [phone]

SK YASKAWA Europe GmbH, o.z.

Bratislava [phone]

TU YASKAWA Turkey Elektrik Ticaret
Limited Sirketi

Ümraniye-Istanbul [phone]

Bratislava [phone]

UK YASKAWA UK Ltd

Torino [phone]

Banbury [phone]

ZA YASKAWA Southern Africa PTY Ltd

Johannesburg [phone]

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8 ORDERING SPARE PARTS

8 ORDERING SPARE PARTS

CAUTION!

Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.

XC1300 and XC2000 are designed and tested in accordance with the international and
European standards, see section "Standard compliance" in chapter "SAFETY". Upon
completion of service or repair work, it is the responsibility of the person(s) performing the
work to ensure that the product still complies with the requirements of the above standards.

All welding-related equipment such as power source, feeders, and torches can be ordered
through your nearest ESAB dealer. See esab.com. When ordering, please state product
type, serial number, designation and spare part number in accordance with the spare parts
list. This facilitates dispatch and ensures correct delivery.

NOTE!

For robotics-related equipment such as the robot, robot cell, and positioning and
handling equipment, please contact your nearest Yaskawa office.

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DIMENSIONS

DIMENSIONS

Main drawings, dimensions in mm

Width, dimensions in mm

Version Ordering no. S

[mm]S1[mm]H1[mm]W1[mm]

XC1300 RH door

0459990666 4419 2326 574 1194 3061 MA1440

Fixed table
XC1300 LH door

0459990667 4419 2326 574 1194 3061 MA1440

Fixed table
XC1300 RH door

0459990668 4375 2236 605 1180 3373 MA1440

Ø9003-axis
XC1300 LH door

0459990669 4375 2236 605 1180 3373 MA1440

Ø9003-axis
XC2000 RH door

0459990670 5184 2698 612 1533 3459 MA2010

Ø10003-axis
XC2000 LH door

0459990671 5184 2698 612 1533 3459 MA2010

Ø10003-axis

RH = Right Hand
LH = Left Hand

Weight

[kg]

Robot

type

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WORKING AREAS

WORKING AREAS

Working area XC1300 Fixed table

Working area XC1300/XC2000 3-axis

Model L [mm] R [mm] ØD [mm] W2 [mm] S2 [mm]

XC1300 1300 455 910 1200 1057
XC2000 2050 500 1000 1900 1222

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FIXTURES

FIXTURES

Fixtures for HM-500D/1000D, dimensions in mm

Fixtures for TM-1000, dimensions in mm

Fixture disc

This fixture disc is only applicable for XC2000

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ACCESSORIES

ACCESSORIES

Wheel kit

144709-100 Wheel kit (pos. 1)

Complete signal and air kits for tailstock 114954-100

114954-100 Complete signal and air kits for tailstock
137770-201 Complete signal transfer kit containing

A + B air

Air incl. in signal option 3/8” (Ø12)

12-channel bus (215003-101)

El-kit signal (348083-83) (See Electric kit signal
device)

Specify if 1-axis or 2-axis when ordering

137770-202 Complete signal transfer kit containing A + B air

Air incl. in signal option 3/8” (Ø12)

12 active channels (215003-103)

El-kit signal (347894-83) (See Electric kit signal
device)

Specify if 1-axis or 2-axis when ordering

137770-401 Complete signal transfer kit containing

Controlled air (Air 215005 (2xØ8) incl. in 215008)

12-channel bus (215008-101)

El-kit controlled air (347620-81)

El-kit signal (348083-83) (See Electric kit signal
device)

Specify if 1-axis or 2-axis when ordering

137770-404 Complete signal transfer kit containing

Controlled air (Air 215005 (2xØ8) incl. in 215008)

12 active channels (215003-103)

El-kit controlled air (347620-81)

El-kit signal (347894-83) (See Electric kit signal
device)

Specify if 1-axis or 2-axis when ordering

Electric kit signal device

348083-83 Electric kit signal device (12 channel bus)
347894-83 Electric kit signal device (12 channel active)

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ACCESSORIES

Options for Tailstock TM-1000

Ordering no. Yaskawa no. Denomination

0459990676 Air2x3/8" (2x XCellerator1300)
0459990677 Signal kit, 12chI/O+PE, Air2x3/8"

2x3/8” Valve controlled air (pos.1)
2x3/8”Air, 12 channel I/O + PE

(pos.2)
2x3/8”Air , 24 channel direct I/O + PE

(pos.2)
2x3/8”Air, 4 channel I/O + + PE

(Fieldbus) (pos. 2)
2x3/8”Air, 4 channel I/O + + PE

(Profinet) (pos.2)

Retro fit bracket

143073-100 Retro fit adapter headstock (pos. 1)
143074-100 Retro fit adapter tailstock (pos. 2)

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WEAR PARTS

WEAR PARTS

Pos. Qty. Ordering no. Yaskawa no. Part name Note

Additional power supply
1 1 141645-100 Bracket conductor brush
2 1 0459 990 685 140375-100 Conductor brush

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WEAR PARTS

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© ESAB AB 2019

ESAB AB, Lindholmsallén 9, Box 8004, 402 77 Gothenburg, Sweden, Phone [phone]

http://manuals.esab.com

For contact information visit esab.com