motoman robotics 1200 Operator Manual

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Part Number: 132340-2 Release Date: February 17, 1995 Document Version: 1 Document Status: Final

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Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200

The information contained within this document is the proprietary property of Motoman, Inc., and may not be

copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,

Because we are constantly improving our products, we reserve the right to change specifications without

notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

Inc.

TABLE OF CONTENTS

Section Page

1.0 INTRODUCTION............................................................................................ 1

1.1 ABOUT THIS DOCUMENT............................................................... 1

1.2 SYSTEM OVERVIEW.......................................................................... 1

1.2.1 System Layout..................................................................... 3

1.2.2 Optional Equipment.............................................................. 3

1.3 REFERENCE TO OTHER DOCUMENTATION ................................... 4

1.4 CUSTOMER SERVICE INFORMATION ............................................. 4

2.0 SAFETY.......................................................................................................... 5

2.1 STANDARD CONVENTIONS............................................................. 6

2.2 GENERAL SAFEGUARDING TIPS..................................................... 7

2.3 MECHANICAL SAFETY DEVICES ...................................................... 7

2.4 INSTALLATION SAFETY.................................................................... 8

2.5 PROGRAMMING SAFETY ................................................................ 8

2.6 OPERATION SAFETY ........................................................................ 9

2.7 MAINTENANCE SAFETY................................................................. 10

3.0 DESCRIPTION OF EQUIPMENT................................................................. 11

3.1 K-SERIES ROBOT DESCRIPTION.................................................. 11

3.2 MRC CONTROLLER........................................................................ 11

3.2.1 Servo Power..................................................................... 12

3.2.2 Mode Select...................................................................... 13

3.2.3 Cycle Select...................................................................... 13

3.2.4 Emergency Stop................................................................ 13

3.2.5 Alarm / Error.................................................................... 13

3.2.6 Hold.................................................................................. 13

3.2.7 Start................................................................................. 13

3.2.8 Playback Box Sub-Panel.................................................... 13

3.3 PROGRAMMING PENDANT.......................................................... 14

3.3.1 Display.............................................................................. 15

3.3.2 Robot Speed Indicators...................................................... 15

3.3.3 Emergency Stop................................................................ 15

3.3.4 Keypad.............................................................................. 15

3.3.5 Servo Power..................................................................... 15

3.4 POSITIONER.................................................................................. 15

3.4.1 Part / Fixture Rating......................................................... 15

3.4.2 Part Center of Gravity...................................................... 16

3.4.3 Temperature Operating Range........................................... 16

3.4.4 Humidity............................................................................ 16

3.4.5 Shock................................................................................ 16

3.4.6 Sweep Speed ..................................................................... 16

3.4.7 Electrical Requirements..................................................... 16

3.4.8 Welding Current Rating..................................................... 16

3.4.9 Hard Stops and Shock Absorbers....................................... 17

3.4.10 Arc Shield......................................................................... 17

3.5 OP-STATION.................................................................................. 17

3.5.1 Emergency Stop................................................................ 17

3.5.2 Hold.................................................................................. 18

3.5.3 Cycle Start....................................................................... 18

3.5.4 Station Ready.................................................................... 18

3.5.5 Alarm............................................................................... 18

3.5.6 Servo On.......................................................................... 18

3.5.7 Positioner Auto / Manual................................................... 18

3.5.8 Master Job Start .............................................................. 18

3.5.9 Operator Station Enable / Disable...................................... 19

3.5.10 Reset................................................................................ 19

3.6 WELDING POWER SOURCE........................................................... 19

3.6.1 Main Power...................................................................... 19

3.6.2 Volt / Amp Settings............................................................ 19

3.6.3 Terminal Connectors......................................................... 19

3.6.4 Local / Remote Operation................................................... 20

3.6.5 Feeder Control Receptacles............................................... 21

3.6.6 Circuit Breakers............................................................... 21

3.6.7 AC Receptacles................................................................. 21

3.7 WELDING EQUIPMENT.................................................................. 21

3.7.1 PWF4 Wire Feeder............................................................ 21

3.7.2 Universal Welding Interface (UWI)................................... 21

3.7.3 MIG Torch....................................................................... 22

3.7.4 RAM Breakaway Mount.................................................... 22

3.8 SAFETY EQUIPMENT ..................................................................... 22

3.8.1 Arc Screens...................................................................... 22

3.8.2 Fencing............................................................................. 23

3.8.3 Interlocks......................................................................... 23

3.8.4 Safety Mats...................................................................... 23

3.8.5 Emergency Stops............................................................... 23

4.0 OPERATION................................................................................................ 24

4.1 OPERATION................................................................................... 24

4.1.1 Start Up........................................................................... 24

4.1.2 Fault Recovery.................................................................. 25

4.1.3 E-STOP Recovery............................................................. 25

4.1.4 Shock Sensor Recovery..................................................... 26

4.1.5 Shut Down........................................................................ 28

4.2 ALARMS AND ERRORS.................................................................. 28

4.2.1 Error Messages................................................................ 28

4.2.2 Minor Alarms................................................................... 28

4.2.3 Major Alarms................................................................... 29

4.3 PROGRAMMING............................................................................ 29

4.3.1 Cube Assignment............................................................... 29

4.3.2 Sweeping Table to Side A................................................... 29

4.3.3 Sweeping Table to Side B................................................... 30

4.3.4 I/O Assignment................................................................. 30

4.4 SAMPLE JOBS................................................................................ 31

4.4.1 Master Job (Concurrent Job)........................................... 32

4.4.2 Sweep to A Job (Concurrent Job)...................................... 32

4.4.3 Sweep to B Job (Concurrent Job)..................................... 33

4.4.4 Master Robot WeldA Job (Concurrent Job)....................... 33

4.4.5 Master Robot WeldB Job (Concurrent Job)....................... 34

5.0 MAINTENANCE ........................................................................................... 35

5.1 PERIODIC MAINTENANCE............................................................ 35

5.2 MAINTENANCE PROCEDURES...................................................... 36

5.2.1 MR-500 Shock Absorber................................................... 37

5.2.2 MR-500 DC Motor Speed Control Unit............................. 37

5.3 SPARE PARTS LIST......................................................................... 37

5.4 FUSE AND CIRCUIT BREAKER PROTECTION............................... 37

APPX. A RISK ASSESSMENT.......................................................................... A-1

APPX. B SYSTEM OUTLINE ............................................................................ B-1

APPX. C ELECTRICAL DRAWINGS.................................................................. C-1

APPX. D MECHANICAL DRAWINGS.............................................................. D-1

INDEX ......................................................................................................... Index 1

LIST OF FIGURES

Figure Page

Figure 1-1 System Layout...................................................................................... 2

Figure 3-1 MRC Controller................................................................................. 12

Figure 3-2 MRC Playback Box............................................................................ 12

Figure 3-3 Programming Pendant........................................................................ 14

Figure 3-4 Operator Control Panel (Op-Station)................................................. 17

Figure 3-5 Excel-Arc Controls............................................................................ 20

Figure 4-1 Shock Sensor Override...................................................................... 27

LIST OF TABLES

Table Page

Table 5-1 Periodic Maintenance.......................................................................... 35

Table 5-2 Spare Parts........................................................................................ 37

Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers.................................. 38

Table 5-4 MRC Cabinet Fuses and Circuit Breakers............................................ 38

Table 5-5 Universal Welding Interface (UWI) Fuses and Circuit Breakers........... 39

Table 5-6 Com-Arc III Fuses and Circuit Breakers............................................. 40

Table 5-7 MR-500 Positioner Fuses and Circuit Breakers................................... 40

ArcWorld 1200 MRC Operator's Manual Page 1 MOTOMAN

1.0 INTRODUCTION

The ArcWorld 1200 is part of the ArcWorld family of standardized arc welding solutions. It is a fully integrated welding system, and is supported from wire to weld by Motoman, Inc.

The ArcWorld 1200 features two Motoman arc welding robots and MRC controller with menu-driven arc welding application software, complete welding package, indexing rotary positioner, operator interface, and total safety environment.

1.1 ABOUT THIS DOCUMENT

This manual provides operation instructions for the ArcWorld 1200 system. In addition to this introduction, the manual includes the following sections:

• Section 2: Safety

• Section 3: Description of Equipment

• Section 4: Operation

• Section 5: Maintenance

• Appendices The Safety Section of the manual provides information regarding the safe use and

operation of the ArcWorld 1200 system. Section 3 of this manual provides a detailed description of the major components of

the ArcWorld system. The Operation Section of the manual provides instructions to operate the ArcWorld

system. In this section, we provide procedures for start-up, loading, normal operation, fault recovery, and shut-down. The section also contains a number of sample robot programs.

In the Maintenance Section, you will find a table listing periodic maintenance requirements for the ArcWorld 1200 cell. It also includes a list of recommended spare parts.

Appendix A is a Risk Assessment document. The remaining appendices to this manual contain a full set of reference drawings.

1.2 SYSTEM OVERVIEW

The ArcWorld 1200 provides a complete arc welding solution in a standardized configuration. The system is designed around two Motoman arc welding robots and includes a complete welding package. An indexing rotary positioner allows an

ArcWorld 1200 MRC Operator's Manual Page 2 MOTOMAN

operator to prepare and set up parts on one side while the robots weld on the other side. The cell provides a full complement of safety features designed to protect both personnel and equipment.

ArcWorld 1200 MRC Operator's Manual Page 3 MOTOMAN

Positioner

Welding

Power

Sources

Com-Arcs

Water

Circulators

Operator

Station

Safety Mats

Door

#2

Robot

Sentrol

Unit

Door

Interlock

Programming

Pendant

Transformer

Feeder

Housings

Torch

Assembly

Fencing

#1

Robot

YASNAC MRC

MRC

Cabinet

External

Axis

Cabinet

Figure 1-1 System Layout

ArcWorld 1200 MRC Operator's Manual Page 4 MOTOMAN

1.2.1 System Layout

The illustration in Figure 1-1 shows the system layout for the ArcWorld 1200 cell. The ArcWorld 1200 includes the following major components:

• Motoman robot manipulators and MRC controller

• MR series indexing rotary positioner

• Operator station

• Welding equipment, including the following:

• Excel-Arc welding power source

• Torch (water-cooled or air-cooled)

• Wire feeder

• Welding interface

• Torch breakaway

• Safety equipment, including the following:

• Safety fencing with arc curtains

• Interlocked safety mats

• Interlocked cell door

• Positioner arc screen

The robot manipulators and positioner share a common base for ease of installation and to help maintain proper alignment between these components. The MRC controller and welding power sources also share a common base. The robotic cell is fully enclosed by safety fencing and an interlocking door. Safety mats prevent positioner cycling while anyone stands in front of the positioner. All operator controls, including those on the MRC and welding power supply, are accessible from outside of the robotic enclosure.

1.2.2 Optional Equipment

The following optional equipment is available for use with the ArcWorld 1200:

• Torch tender

• Wire cutter

• Com-Arc III

• Heavy duty positioner

• Stationary tables

ArcWorld 1200 MRC Operator's Manual Page 5 MOTOMAN

1.3 REFERENCE TO OTHER DOCUMENTATION

For additional information refer to the following:

• Motoman K10 MRC Manipulator Manual (Part Number 132330-7)

• Motoman K6 MRC Manipulator Manual (Part Number 132330-4)

• Motoman MRC Operator's Manual for Arc Welding (Part Number 132332-1)

• Motoman MRC User Functions Manual (Part Number 132331-1)

• Motoman ArcWorld 1200 Installation Manual (Part Number 132341-2)

• Additional vendors' manuals

1.4 CUSTOMER SERVICE INFORMATION

If you are in need of technical assistance, contact the Motoman service staff at (513) 847-3200. Have the following information ready before you call:

• Robot Type (K3, K6, K10, etc.)

• Robot Serial Number (located on the back side of the robot arm)

• Application Type (palletizing, welding, handling, etc.)

• Robot Sales Order Number (located on back side of robot and MRC controller)

ArcWorld 1200 MRC Operator's Manual Page 6 MOTOMAN

2.0 SAFETY

It is the purchaser's responsibility to ensure that all local, county, state, and national codes, regulations, rules, or laws relating to safety and safe operating conditions for each installation are met and followed.

We suggest that you obtain and review a copy of the ANSI/RIA National Safety Standard for Industrial Robots and Robot Systems. This information can be obtained from the Robotic Industries Association by requesting ANSI/RIA R15.06. The address is as follows:

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: 313/994-6088

FAX: 313/994-3338

Ultimately, the best safeguard is trained personnel. The user is responsible for providing personnel who are adequately trained to operate, program, and maintain the robot cell. The robot must not be operated by personnel who have not

been trained!

We recommend that all personnel who intend to operate, program, repair, or use the robot system be trained in an approved Motoman training course and become familiar with the proper operation of the system.

This safety section addresses the following:

• Standard Conventions (see Section 2.1)

• General Cautions and Warnings (see Section 2.2)

• Mechanical Safety Devices (see Section 2.3)

• Installation Safety (see Section 2.4)

• Programming Safety (see Section 2.5)

• Operation Safety (see Section 2.6)

• Maintenance Safety (see Section 2.7)

ArcWorld 1200 MRC Operator's Manual Page 7 MOTOMAN

2.1 STANDARD CONVENTIONS

This manual includes information essential to the safety of personnel and equipment. As you read through this manual, be alert to the four signal words:

• DANGER

• WARNING

• CAUTION

• NOTE Pay particular attention to the information provided under these headings which are

defined below (in descending order of severity).

➪

DANGER!

Information appearing under the DANGER caption concerns the protection of personnel from the immediate and imminent hazards that, if not avoided, will result in immediate, serious personal injury or loss of life in addition to equipment damage.

➪

WARNING!

Information appearing under the WARNING caption concerns the protection of personnel and equipment from potential hazards that can result in personal injury or loss of life in addition to equipment damage.

➪

CAUTION!

Information appearing under the CAUTION caption concerns the protection of equipment, software, and data from hazards that can result in minor personal injury or equipment damage.

NOTE: Information appearing in a NOTE caption provides additional information which is helpful in

understanding the item being explained.

ArcWorld 1200 MRC Operator's Manual Page 8 MOTOMAN

2.2 GENERAL SAFEGUARDING TIPS

operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows:

• Improper operation can damage the equipment. Only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories should be permitted to operate this robot system.

• Do not enter the robot cell while it is in operation. Place the robot in Emergency Stop (E-Stop) mode and ensure that all motion has stopped before entering the cell.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

• The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

2.3 MECHANICAL SAFETY DEVICES

The safe operation of the robot, positioner, auxiliary equipment, and system is ultimately the user's responsibility. The conditions under which the equipment will be operated safely should be reviewed by the user. The user must be aware of the various national codes, RIA safety recommendations, and other local codes that may pertain to the installation and use of industrial equipment. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following safety measures are available:

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

Check all safety equipment frequently for proper operation. Repair or replace any non-functioning safety equipment immediately.

ArcWorld 1200 MRC Operator's Manual Page 9 MOTOMAN

2.4 INSTALLATION SAFETY

Safe installation is essential for protection of people and equipment. The user must be aware of the various national codes, RIA safety recommendations, and other local codes that may pertain to the installation and use of industrial equipment. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. The following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations.

• Ensure that only trained personnel familiar with the operation of this robot, the operator's manuals, the system equipment, and options and accessories are permitted to operate this robot system.

• Identify the work envelope of each robot with floor markings, signs, and barriers.

• Position all controllers outside the robot work envelope.

• Whenever possible, install safety fences to protect against unauthorized entry into the work envelope.

• Eliminate areas where personnel might get trapped between a moving robot and other equipment (pinch points).

• Provide sufficient room inside the workcell to permit safe teaching and maintenance procedures.

2.5 PROGRAMMING SAFETY

All operators, programmers, plant and tooling engineers, maintenance personnel, supervisors, and anyone working near the robot must become familiar with the operation of this equipment. All personnel involved with the operation of the equipment must understand potential dangers of operation. General safeguarding tips are as follows:

• Any modifications to PART 1 of the controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to PART 1. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY!

• Some operations require standard passwords and some require special passwords. Special passwords are for Motoman use only. YOUR WARRANTY WILL BE VOID if you use these special passwords.

• Back up all programs and jobs onto a floppy disk whenever program changes are made. To avoid loss of information, programs, or jobs, a backup must always be made before any service procedures are done and before any changes are made to options, accessories, or equipment.

• The concurrent I/O (Input and Output) function allows the customer to modify the internal ladder inputs and outputs for maximum robot performance. Great

ArcWorld 1200 MRC Operator's Manual Page 10 MOTOMAN

care must be taken when making these modifications. Double-check all modifications under every mode of robot operation to ensure that you have not created hazards or dangerous situations that may damage the robot or other parts of the system.

• Improper operation can damage the equipment. Only trained personnel familiar with the operation, manuals, electrical design, and equipment interconnections of this robot should be permitted to operate the system.

• Inspect the robot and work envelope to ensure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.

• Check the E-STOP button on the teach pendant for proper operation before programming.

• Keep the teach pendant with you when you enter the workcell.

• Ensure that only the person holding the teach pendant enters the workcell.

• Test any new or modified program at low speed for at least one full cycle.

2.6 OPERATION SAFETY

• Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.

• Inspect the robot and work envelope to ensure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc.

• Ensure that all safeguards are in place.

• Do not enter the robot cell while it is in operation. Place the robot in Emergency Stop (E-Stop) mode and ensure that all motion has stopped before entering the cell.

• The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

• This equipment has multiple sources of electrical supply. Electrical interconnections are made between the controller, external servo box, and other equipment. Disconnect and lockout/tagout all electrical circuits before making any modifications or connections.

• All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot.

ArcWorld 1200 MRC Operator's Manual Page 11 MOTOMAN

This includes controller parameters; ladder nodes, parts 1 and 2; and I/O (Input and Output) modifications. Check and test all changes at slow speed.

ArcWorld 1200 MRC Operator's Manual Page 12 MOTOMAN

2.7 MAINTENANCE SAFETY

• Do not perform any maintenance procedures before reading and understanding the proper procedures in the appropriate manual.

• Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.

• Back up all your programs and jobs onto a floppy disk whenever program changes are made. A backup must always be made before any servicing or changes are made to options, accessories, or equipment to avoid loss of information, programs, or jobs.

• Do not enter the robot cell while it is in operation. Place the robot in Emergency Stop (E-Stop) mode and ensure that all motion has stopped before entering the cell.

• The robot must be placed in Emergency Stop (E-Stop) mode whenever it is not in use.

• Ensure all safeguards are in place.

• Use proper replacement parts.

• All modifications made to the controller will change the way the robot operates and can cause severe personal injury or death, as well as damage the robot. This includes controller parameters; ladder nodes, parts 1 and 2; and I/O (Input and Output) modifications. Check and test all changes at slow speed.

• Improper connections can damage the robot. All connections must be made within the standard voltage and current ratings of the robot I/O (Inputs and Outputs).

ArcWorld 1200 MRC Operator's Manual Page 13 MOTOMAN

3.0 DESCRIPTION OF EQUIPMENT

3.1 K-SERIES ROBOT DESCRIPTION

The standard ArcWorld 1200 uses either two Motoman K6 or two K10 robot manipulators. The Motoman K6 and K10 robots and YASNAC MRC Controller represent state-of-the-art technology in robotics today. The six-axis K6 robot has a payload of 6 kg (13.2 lbs). It features a 1,322 mm (52.01 in) reach and has a relative positioning accuracy of ± 0.1 mm (0.004 in.). The six-axis K10 robot has a payload of 10 kg (22 lbs). It features a 1,555 mm (61.2 in) reach and has a relative positioning accuracy of ± 0.1 mm (0.004 in.).

Each robot can reach below its own base as well as behind itself. These robots can also be mounted in floor, wall, or ceiling configurations with few hardware modifications. The Motoman K-Series robots have been constructed for ease of maintenance, utilizing brushless AC servo motors with absolute positioning encoders. All motors are readily accessible. A combination of capacitance and lithium batteries in both the robot encoder assemblies and in the Motoman YASNAC MRC controller protects program position data for up to one year. The replacement life for the lithium battery is approximately three years.

3.2 MRC CONTROLLER

The MRC controller (Figure 3-1) coordinates the operation of the ArcWorld system. It provides the following control functions:

• User interface

• Main logic functions

• Input / output control

• Servo control

• Numeric processing

• Variable data memory

• Program and constant data memory

• Analog welding command functions

• Welding interface

• Power distribution

The MRC controls the movement of the manipulator, processes input and output signals, controls the operation of the welding power supply, and provides the signals to operate the welding system. It maintains variable data and performs the numeric processing to convert to and from different coordinate systems.

ArcWorld 1200 MRC Operator's Manual Page 14 MOTOMAN

Figure 3-1 MRC Controller

The playback box (Figure 3-2) on the MRC has the primary system controls. The following paragraphs describe the MRC controls.

Figure 3-2 MRC Playback Box

3.2.1 Servo Power

The SERVO POWER pushbutton switch turns on the robot servo power. An indicator lamp in the switch lights when servo power is on.

ArcWorld 1200 MRC Operator's Manual Page 15 MOTOMAN

3.2.2 Mode Select

The Mode Select pushbutton switches (PLAY, TEACH and REMOTE) set the robot's mode of operation. Indicator lamps in the Mode Select switches light to show the current mode of operation. Refer to your MRC Operator's Manual for more information.

3.2.3 Cycle Select

The Cycle Select pushbutton switches (AUTO, 1-CYCLE, and STEP) set the operating method for playback operations. Indicator lamps in the Cycle Select switches light to show the selected playback method. Refer to your MRC Operator's Manual for more information.

3.2.4 Emergency Stop

The E. STOP button is connected to the system emergency stop circuit. Interrupting the E-Stop circuit causes the robot to go into the E-Stop condition. Pressing the E. STOP pushbutton immediately turns off servo power.

3.2.5 Alarm / Error

The ALARM / ERROR indicator lights whenever an alarm or error condition occurs. After you reset the alarm or error condition, the indicator lamp goes off.

3.2.6 Hold

The HOLD button is a normally closed, momentarily actuated switch. Pressing the HOLD button stops the operation of the manipulator. The Hold state is active only while the switch is held down. The indicator lamp lights whenever the robot is in a Hold state. Refer to your MRC Operator's Manual for more information.

3.2.7 Start

Pressing the START button causes the manipulator playback operation to start. The indicator lamp lights during playback.

3.2.8 Playback Box Sub-Panel

The playback box has an inside sub-panel that contains additional user controls. Refer to your MRC Operator's Manual for more information.

ArcWorld 1200 MRC Operator's Manual Page 16 MOTOMAN

3.3 PROGRAMMING PENDANT

A programming pendant (Figure 3-3) provides the primary user interface with the system. The pendant has a 12-line LCD display and keypad. The system uses the INFORM II robot language and a menu driven interface to simplify operator interaction with the robot. By using the pendant, the operator can teach robot motion, and perform programming, editing, maintenance, and diagnostic functions.

Figure 3-3 Programming Pendant

ArcWorld 1200 MRC Operator's Manual Page 17 MOTOMAN

3.3.1 Display

The programming pendant has a 12-line LCD display. The display provides status information, system messages and prompts, and a graphic work area. Refer to your MRC Operator's Manual for more information.

3.3.2 Robot Speed Indicators

The MAN SPD indicators light to show the selected robot manipulator speed.

3.3.3 Emergency Stop

3.3.4 Keypad

The user keypad on the programming pendant serves as an input device. The keys are grouped into different functional sections to simplify operator use. For more information, refer to your MRC Operator's Manual.

3.3.5 Servo Power

The SERVO POWER pushbutton switch turns on the robot servo power. An indicator lamp in the switch lights when servo power is on.

3.3.6 Coordinate System Indicators

The COORD indicators light to show the currently active coordinate system.

3.4 POSITIONER

The MR-500 is a DC motor-driven, turntable positioner. A steel arc screen divides the standard 60-inch diameter table in half, providing two work stations. The rotary table sweeps back and forth between two positions; one located inside the robot cell, the other outside. Hard stops and shock absorbers built into the positioner ensure accurate and repeatable parts positioning.

3.4.1 Part / Fixture Rating

This is the combined weight of part and fixture - 500 pounds on each side of the Motoman MR-500 Positioner.

ArcWorld 1200 MRC Operator's Manual Page 18 MOTOMAN

3.4.2 Part Center of Gravity

The Motoman MR-500 Positioner is rated for a maximum load with a center of gravity of 500 pounds located 10 inches above the table tooling plate surface at a radius of 20 inches.

3.4.3 Temperature Operating Range

40 - 110˚ Fahrenheit.

3.4.4 Humidity

Non-condensing 10 - 90% relative humidity.

NOTE: In high humidity areas, the table tooling plate may rust or corrode. Surface protection should

be used.

3.4.5 Shock

Less than 0.5 G.

3.4.6 Sweep Speed

Typically 5 seconds.

3.4.7 Electrical Requirements

All electrical power required to operate the Motoman MR-500 is supplied from the MRC controller and consists of a 115 VAC / 60 Hz / Single-Phase circuit to provide power for the drive system and interface.

3.4.8 Welding Current Rating

The Motoman MR-500 Positioner has a welding current capacity of 600 amperes at 100% duty cycle. The welding ground system consists of a spring loaded copper brush that contacts a large ring mounted below the surface of the table. The ground cable to the welding power source is connected to the insulated ground lug located on the lower right side of the positioner base when facing the front of the ArcWorld 1200 cell.

NOTE: The ground cable connection to the insulated stud must be tight. If the connection is loose,

arcing can occur and cause the insulator to melt.

ArcWorld 1200 MRC Operator's Manual Page 19 MOTOMAN

3.4.9 Hard Stops and Shock Absorbers

The Motoman MR-500 positioner is equipped with two hard stops and two shock absorbers. The hard stops and shock absorbers are located on the right side of the positioner base beneath the table top. The hard stops and the shock absorbers are adjustable for Side A and Side B.

3.4.10 Arc Shield

The Motoman MR-500 positioner is provided with a sheet metal screen for arc radiation protection between the operator loading zone and the welding zone. Do not operate this equipment unless the arc shield is in place.

3.5 OP-STATION

The operator control station (Figure 3-4) includes a NEMA enclosure on a standalone pedestal. The following paragraphs describe each of the Op-station controls.

ALARM

RESET

ROBOT HOLD

MASTER JOB

START

MOTOMAN

STATION READY

POSITIONER

AUTO/MAN

SERVO ON

ESTOP

OPERATOR STATION

ENABLE/DISABLE

WARNING!

CYCLE START

Figure 3-4 Operator Control Panel (Op-Station)

3.5.1 Emergency Stop

The operator station E-STOP, the robot E-STOP, the sliding door interlocks, and the ArcWorld 1200 safety mats are connected in series in the Emergency Stop circuit. If the E-Stop circuit is interrupted, the robot and the Motoman MR-500 positioner will go into the E-Stop condition. The operator station E-STOP light

ArcWorld 1200 MRC Operator's Manual Page 20 MOTOMAN

will come on when the E-STOP button is pressed. In the E-Stop condition, power to the Motoman MR-500 positioner interface is removed. This stops the table sweep.

3.5.2 Hold

The operator station HOLD button is a normally closed pushbutton and is connected to the MRC to cause the robots to go into the Hold condition when the button is pressed.

3.5.3 Cycle Start

The palm buttons in the operator station use an anti tie-down technique for robot input. The anti tie-down timer is set for 10 seconds. Holding the palm buttons down for more than 10 seconds, causes the timer to time out and prevents the input from reaching the robot. The CYCLE START buttons are connected to robot Input #1.

3.5.4 Station Ready

The STATION READY lamp is interlocked with the robot CUBE #1 output. The robots' Output #1 in conjunction with the Cube 1 relay turns on the STATION READY lamp.

3.5.5 Alarm

The ALARM lamp is connected to the robot Alarm Occurrence output. The ALARM lamp turns on when the robot encounters a major or minor alarm condition.

3.5.6 Servo On

The SERVO ON pushbutton is connected to the robot Servo On input. The robot servo motors will turn on when the SERVO ON pushbutton is pressed and an EStop condition does not exist.

3.5.7 Positioner Auto / Manual

The POSITIONER AUTO / MANUAL selector switch is used to select Automatic or Manual Mode for the Motoman MR-500 positioner. The selector switch is connected to robot Input #2. When the selector switch is in the Automatic position, the robot will process the part after the positioner sweeps. In Manual Mode, the robot will not process the part after the positioner sweeps. This function is

dependent on the structure of the master job.

ArcWorld 1200 MRC Operator's Manual Page 21 MOTOMAN

3.5.8 Master Job Start

The MASTER JOB START pushbutton is connected to the robot external start input. The robot will start the current active job when pressed if the robot is in Play Mode and the servo motors are on.

3.5.9 Operator Station Enable / Disable

The OPERATOR STATION ENABLE / DISABLE selector switch is used to transfer primary control of the ArcWorld cell from the MRC to the Op-Station. The REMOTE MODE button on the MRC playback box lights when the opstation is enabled. Most programming pendant functions are disabled.

3.5.10 Reset

The RESET pushbutton is connected to the robot alarm reset input. Any alarm or error condition will be cleared when this button is pressed. In addition, the RESET pushbutton and the RIGHT CYCLE START pushbuttons are interlocked and, when pressed simultaneously, enable the MR-500 positioner if the robot servo motors are on. The positioner needs to be enabled at initial power up or emergency stop or shock sensor condition.

NOTE: Resetting the positioner may cause some table motion. You must be careful when you reset

the positioner with the robot close to tooling. If an E-Stop occurs during programming, be sure to reset the table before resuming programming.

3.6 WELDING POWER SOURCE

The Excel-Arc power source (Figure 3-5) is a constant voltage transformer-rectifier type welding machine. It provides volt-current characteristic curves that are essentially flat. This power source can be used with most MIG applications from thin sheet metal to heavy gauge plate.

3.6.1 Main Power

The Input Power switch (7) turns on the main power to the Excel-Arc unit. The main power must be on before any other section of the power source can operate. The pilot light (1) illuminates when main power is on.

3.6.2 Volt / Amp Settings

The Welding Voltage / Amperes Control (2) adjusts the welding output and open circuit voltage. The Volt / Amp Meter and Switch (3) display either DC voltage or

ArcWorld 1200 MRC Operator's Manual Page 22 MOTOMAN

DC current depending on the position of the switch. Refer to your Excel-Arc manual for additional information.

3.6.3 Terminal Connectors

The two terminals on the front of the Excel-Arc power source serve as connection points for the welding leads. The Positive Terminal (4) connects positive welding lead (to the wire feeder). The Negative Terminal (5) connects to the negative welding lead (to the workpiece).

ArcWorld 1200 MRC Operator's Manual Page 23 MOTOMAN

Figure 3-5 Excel-Arc Controls

3.6.4 Local / Remote Operation

The Local / Remote Output Control Selector Switch (6) sets the mode of operation for the power source. For ArcWorld applications this switch should be set to REMOTE. Refer to your Excel-Arc manual for additional information.

3.6.5 Feeder Control Receptacles

The Feeder Control Receptacle Panel (8) located in the back of the power source provides connectors for use with remote voltage control applications. For ArcWorld applications, the MRC connects to the 19-pin connector.

3.6.6 Circuit Breakers

The Excel-Arc power source uses two 10 amp circuit breakers (9 and 10). One circuit breaker protects the 24 volt circuit, the other protects the 115 volt circuit.

3.6.7 AC Receptacles

The Excel-Arc unit has two standard 115 V AC Receptacles (11). These provide auxiliary power at a maximum current of 10 amps. For applications using the water-cooled torch, the water circulator plugs into one of these receptacles.

3.7 WELDING EQUIPMENT

In addition to the Excel-Arc power source, the ArcWorld 1200 system provides a complete complement of arc welding equipment. In its standard configuration, the ArcWorld system includes the following:

• PWF-600 wire feeder

• UWI welding interface

• Either an air cooled or water cooled MIG torch

• Torch breakaway mount

3.7.1 PWF4 Wire Feeder

The PWF4 wire feeder mounts on the robot arm. This 4-roll wire feeder provides reliable wire feeding at rates up to 750 IPM. An integral gas valve provides fast gas response time. The PWF4 feeder has an inch forward button to help simplify set-up and reduce change-over time. The PWF4 wire feeder uses interchangeable feed rolls to accommodate different types and sizes of wire.

ArcWorld 1200 MRC Operator's Manual Page 24 MOTOMAN

3.7.2 Universal Welding Interface (UWI)

The UWI interface provides microprocessor control to the wire feeder and power source. It scales the signals from the MRC to the appropriate levels required for control of the welding components. It also provides isolation of the power source analog signals.

ArcWorld 1200 MRC Operator's Manual Page 25 MOTOMAN

3.7.3 MIG Torch

The ArcWorld 1200 uses either an air-cooled or water-cooled robotic/automatic MIG torch. These are heavy-duty torches designed for quick replacement while requiring minimum robot reprogramming. The MIG torch mounts on the end of the robot wrist. For applications that use the water-cooled torch, the ArcWorld 1200 includes a suitable water circulator kit.

3.7.4 RAM Breakaway Mount

A Motoman RAM torch breakaway mount protects the robot, workpiece, fixture, and positioner. It provides multi-directional impact detection, including Z-axis collisions. The torch breakaway causes the robot to stop immediately upon impact. Keyed joints assure accurate re-alignment of components.

3.8 SAFETY EQUIPMENT

The ArcWorld 1200 system incorporates a host of safety equipment. When all standard safety precautions are taken, the safety equipment helps to ensure safe operation of the robotic cell. The ANSI/RIA R15.06 Robot Safety Standard

stipulates the user is responsible for safeguarding.

Users are responsible for determining whether the provided safeguards are adequate for plant conditions. Users must also ensure that safeguards are maintained in working order.

The ArcWorld 1200 safety features include the following:

• Arc screens

• Safety fencing

• Dual interlocking cell door

• Interlocked safety mats

• Emergency stop (E-STOP) buttons

3.8.1 Arc Screens

Two separate arc screens are used on the ArcWorld 1200. The first is a metal arc screen on the turntable positioner. This screen blocks arc radiation and sparks from the welding operation. The material used to cover the safety fencing of the entire robotic cell acts as the second arc screen. This material reduces the amount of ultraviolet radiation that escapes from the robotic cell.

ArcWorld 1200 MRC Operator's Manual Page 26 MOTOMAN

➪

WARNING!

Although this screen blocks dangerous arc radiation, you should not look directly at the arc during operation without protective eyewear!

3.8.2 Fencing

The safety fencing provided with the ArcWorld 1200 encloses the entire robotic cell. It forms a physical barrier to prevent entry into the robot envelope.

3.8.3 Interlocks

Dual safety interlocks on the cell entrance door prevent entry into the cell during Play mode. Opening the cell door with the robot in Play causes an E-Stop and shuts down the entire system.

3.8.4 Safety Mats

The safety mat provided with the ArcWorld 1200 helps prevent serious injury to anyone entering the turntable positioner area during the sweeping process. If a person steps on this mat when the positioner is in motion, an E-Stop occurs causing the entire system to shut down.

3.8.5 Emergency Stops

In addition to the interlocking devices described above, the ArcWorld 1200 has strategically placed emergency stops (E-STOPS). These are operator actuated devices that, when activated, immediately cause the system to shut down. The following is a list of their locations:

• The MRC control panel has one E-STOP button.

• The MRC programming pendant has one E-STOP button.

• The turntable positioner operator station has one E-STOP button.

ArcWorld 1200 MRC Operator's Manual Page 27 MOTOMAN

4.0 OPERATION

This section provides operation instructions for the ArcWorld 1200 system. Operation procedures include the following:

• System start up

• Part set up

• Normal operation

• Fault recovery

• System shut down We have included several sample programs. The listed programs demonstrate the

proper format and instruction sequences for different operations. You can use these programs as guidelines when creating programs for your specific applications.

4.1 OPERATION

The ArcWorld 1200 is a fully integrated robotic MIG welding cell. The robots weld on one side of the turntable positioner while the operator loads the opposite side with parts. Once the robots are finished with their process, they return to the home position. The operator sweeps the turntable enabling the robots to start welding on the next part.

The safety entrance door interlocks prevent anyone from entering the cell while the robot is in Play mode. Stepping on the safety mat in front of the turntable positioner during sweeping causes an E-stop.

The following is the typical sequence of operations for the ArcWorld 1200 Cell after startup:

1. Load the fixture on the operator side of the positioner with the parts to be

welded.

2. Wait for the STATION READY indicator to light.

3. Press both CYCLE START palm buttons on the operator station. The

positioner sweeps to the other side and places the unwelded parts in the robot work area. The robots then begin welding the unwelded parts.

4. Unload the welded parts from the fixture.

5. Repeat Steps 1 through 4.

4.1.1 Start Up

To start up the ArcWorld 1200 Cell from a Power Off condition, proceed as follows:

ArcWorld 1200 MRC Operator's Manual Page 28 MOTOMAN

1. Make sure that the disconnect from the transformer to the MRC is ON.

2. Turn on the two power source disconnects.

3. Set the Main Power switch on the MRC to ON.

4. Set the INPUT POWER switches on the welding power sources to ON. The

pilot lights on the power sources should glow.

5. Make sure that the enclosure door is closed, and the safety plug is connected.

6. Open the regulator valve on the welding gas supply.

7. Press the TEACH MODE button on the MRC playback box. The indicator

lamp in the switch should light.

8. Press the SERVO POWER button on the MRC playback box. The indicator

lamp in the switch should light.

9. Make sure the robots are in the starting positions (R1 in CUBE #1 and R2 in

CUBE #2).

10. Press the RESET button and the right CYCLE START button on the operator station at the same time to initialize the positioner.

11. Call up the master job.

12. Press the PLAY MODE button on the MRC playback box, and then press the AUTO CYCLE button. The indicator lamps in the switches should light.

13. Press the MASTER JOB START button on the operator station.

14. Wait for the STATION READY indicator to light.

The ArcWorld 1200 Cell is now ready for operation.

4.1.2 Fault Recovery

Under varying conditions an alarm or error can occur. Clearing an alarm or error condition may require different operator intervention depending on the nature of the alarm or error. In some cases, simply resetting the robot and restarting the operation is sufficient. In other instances, you must first remedy the condition causing the alarm or error. Refer to paragraph 4.2, Alarms and Errors.

4.1.3 E-STOP Recovery

An E-Stop can occur under one of the following conditions:

• Pressing the E-STOP button on the operator station, the programming pendant, or the MRC playback box.

• Opening the sliding door on the robot enclosure or removing the safety plug when the robot is not in Teach Mode.

• Stepping on the safety mat when the MR-500 positioner is sweeping.

• Activation of the shock sensor, indicating a robot crash.

ArcWorld 1200 MRC Operator's Manual Page 29 MOTOMAN

To restart the ArcWorld 1200 Cell after an E-Stop condition occurs, follow the procedure below.

ArcWorld 1200 MRC Operator's Manual Page 30 MOTOMAN

1. To clear the E-Stop condition, do any of the following actions that apply:

• Release the E-STOP button on the operator station, the programming

pendant, or the MRC playback box.

• Close the sliding door and connect the safety plug.

• Step off the safety mat.

• Clear the Shock Sensor condition (refer to paragraph 4.1.4).

2. Press the SERVO ON button on operator station.

➪

CAUTION!

If an E-STOP condition occurs while the positioner is sweeping, the positioner will continue the sweep when initialized.

3. Press the RESET button and the right CYCLE START button on the operator station to initialize the system.

4. Press the MASTER JOB START button on the operator station.

The ArcWorld 1200 Cell will continue its operation.

4.1.4 Shock Sensor Recovery

The ArcWorld welding package includes a RAM breakaway torch mount. This mount is designed to protect the torch from damage in case of a crash. A slight deflection of the torch activates a SHOCK SENSOR error. A more severe crash separates the torch mount from the robot arm. The SHOCK SENSOR error is factory set to an E-Stop condition.

To override the shock sensor, do the following:

1. Disconnect the shock sensor plug from the connector at the front of the wire feeder (see Figure 4-1).

2. Connect the shock sensor jumper (Motoman P/N 132601-1) to the connector at the front of the wire feeder.

3. Press the RESET and right CYCLE START buttons on the operator's station at the same time.

4. Use the programming pendant to operate the manipulator out of the impact position.

5. Re-attach the sections of the torch breakaway mount if the impact caused them to separate.

ArcWorld 1200 MRC Operator's Manual Page 31 MOTOMAN

Feeder Housing

Shock Sensor Cord

Torch Assembly

Breakaway

Shock Sensor Plug

Shock Sensor Jumper

Figure 4-1 Shock Sensor Override

To resume operation after clearing the Shock Sensor condition, proceed as follows:

1. Disconnect the shock sensor jumper from the connector at the front of the wire feeder (see Figure 4-1).

➪

CAUTION!

You must remove the shock sensor jumper during normal operation. Failure to do so can result in equipment damage.

2. Connect the shock sensor plug to the connector at the front of the wire feeder.

3. Close the interlocked enclosure doors.

4. Press the SERVO ON button on the MRC or programming pendant.

5. Press the RESET and right CYCLE START buttons on the operator's station at the same time. This initializes the positioner.

ArcWorld 1200 MRC Operator's Manual Page 32 MOTOMAN

➪

CAUTION!

You may need to move the robot to recover from a crash. To avoid another crash, make sure that the robot has a clear path to the next step.

6. Press the MASTER JOB START button.

4.1.5 Shut Down

To shut down the ArcWorld 1200 Cell after operation is complete, do the following:

1. Make sure the robots are in the starting positions (R1 in CUBE #1 and R2 in CUBE #2).

2. To turn off the robot servo motors, press the E-STOP button on either the operator station, programming pendant, or MRC playback box.

3. Press the TEACH MODE button on the MRC playback box.

4. Set the MRC Main Power switch to the OFF position.

5. Turn off the MRC disconnect.

6. Set the INPUT POWER switch on the welding power sources to the OFF position.

7. Turn off the two power source disconnects.

8. Close the regulator valve on the welding gas supply.

The ArcWorld 1200 Cell is now shut down.

4.2 ALARMS AND ERRORS

Alarms and errors will cause the program to stop. There are three levels of alarms and errors: Error Messages, Minor Alarms, and Major Alarms.

For more detailed information about alarm recovery, refer to your Motoman MRC Manipulator Manual.

4.2.1 Error Messages

These are simple errors such as pressing the START button when the robot is not in Play mode, or enabling the programming pendant without the servo power being live.

Errors like these are cleared by pressing the CANCEL or ENABLE button on the programming pendant.

ArcWorld 1200 MRC Operator's Manual Page 33 MOTOMAN

4.2.2 Minor Alarms

Minor alarms are usually programming errors. Minor alarms might occur if a circle has been programmed with fewer than three circular points, etc.

These alarms are cleared by pressing one of the following:

• RELEASE soft key on the programming pendant

• RESET button on the operator's station

• ENABLE button on the programming pendant twice

4.2.3 Major Alarms

Major alarms are hardware failures. Major alarms might occur because of a servo tracking error or an abnormal speed associated with crashes.

To clear these alarms, you must turn off the controller and then turn it on again.

4.3 PROGRAMMING

The robots may be programmed to execute synchronous jobs, simultaneous mirror opposite jobs, both robots may be programmed to weld different seams on the same part, or each robot may be programmed to execute a completely different job at the same time.

NOTE: The ArcWorld 1200 robot S-axes are restricted by hard stops on the robot bases and internal

soft stops. Do not change.

4.3.1 Cube Assignment

The system uses the Cube #1 and Cube #2 Outputs as interlocks for sweeping. These are software zones around the tool center points (TCP). They should be defined with the robots clear of the positioner sweep motion. The Cube #1 and Cube #2 Outputs can be viewed in the diagnostics under Specified Outputs.

The ArcWorld 1200 uses the Cube #3 Output as an interlock for robot motion. This is a software zone between the robots in which it is possible for the robot paths to intersect. However, when one robot is operating in this cube, the other is prohibited from entry and vice versa.

NOTE: Redefinition of Cube #3 parameters will probably be required after a fixture change.

To assign the K6 or K10 robot manipulator positions to Cube #1, Cube #2, or Cube #3, refer to your MRC User Functions and Operator's Manuals.

Do not

change cube positions unless absolutely necessary, as such changes increase

ArcWorld 1200 MRC Operator's Manual Page 34 MOTOMAN

the possibility that the paths of the robot arms may intersect with fixtures or each other.

NOTE: If the robot moves outside of the cube, the output is lost and the positioner will not sweep.

4.3.2 Sweeping Table to Side A

To sweep the Motoman MR-500 positioner to Side A:

1. Press the SERVO ON button on the operator station.

2. Make sure that robot R1 is in Cube #1 and robot R2 is in Cube #2.

3. Press the PLAY MODE button on the MRC playback box. The indicator lamp in the switch should light.

4. If this is the first power up, or an E-Stop recovery, press the RESET button and the right CYCLE START button.

5. Press the MASTER JOB START button.

6. Press the CYCLE START palm buttons.

7. The robot Output #2 must be on.

When the table sweeps into position at Side A, the positioner provides an input to IN #3 "AT SIDE A". When this input turns on, robot Output #2 turns off.

NOTE: Before sweeping, make sure the weight of the part and fixturing on each side of the positioner

is approximately equal.

NOTE: Before sweeping at first power up, make sure the correct job has been loaded.

4.3.3 Sweeping Table to Side B

To sweep the Motoman MR-500 positioner to Side B:

1. Press the SERVO ON button on the operator station.

2. Make sure that robot R1 is in Cube #1 and robot R2 is in Cube #2.

3. Press the PLAY MODE button on the MRC playback box. The indicator lamp in the switch should light.

4. If this is the first power up, or an E-Stop recovery, press the RESET button and the right CYCLE START button.

5. Press the MASTER JOB START button.

6. Press the CYCLE START palm buttons.

ArcWorld 1200 MRC Operator's Manual Page 35 MOTOMAN

7. The robot Output #3 must be on.

When the table sweeps into position at Side B, the positioner provides an input to IN #4 "AT SIDE B". When this input turns on, robot Output #3 turns off.

4.3.4 I/O Assignment

The ArcWorld 1200 positioner and the ArcWorld operator station use the following Motoman MRC user and dedicated inputs and outputs:

MRC User Inputs

• IN#1 Cycle Start Interlocked with CUBE #1

• IN#2 Auto/Manual Selector Switch

• IN#3 At Side A

• IN#4 At Side B

MRC User Outputs

• OUT#1 Station Ready Interlocked with CUBE #1

• OUT#2 Sweep to A Interlocked with CUBE #1 and CUBE #2

• OUT#3 Sweep to B Interlocked with CUBE #1 and CUBE #2

• OUT#4 Wire Cutter (optional)

MRC Dedicated Inputs

• External Emergency Stop

• External Servo On

• External Hold

• Anti-Tie Down

• In Cube 1

• In Cube 2

• External Start

• Alarm Reset

• Remote Mode On

MRC Dedicated Outputs

• Servo Power On

• Alarm Occurrence

ArcWorld 1200 MRC Operator's Manual Page 36 MOTOMAN

• Teach Mode

• Cube 1

• Cube 2

4.4 SAMPLE JOBS

The following jobs are shown as examples only. Your system may have other features and / or options requiring program changes. Double-check your system before running these jobs. Lines that begin with an apostrophe (') are comments added for clarification only and do not appear in the actual program listing.

ArcWorld 1200 MRC Operator's Manual Page 37 MOTOMAN

4.4.1 Master Job (Concurrent Job)

Line Step Function

000 000 NOP 001 001 MOVJ P001 VJ=100.00 002 CALL JOB:SWEEPA IF IN#(04)=ON 003 CALL JOB:SWEEPB IF IN#(03)=ON 004 END

4.4.2 Sweep to A Job (Concurrent Job)

Line Step Function

000 000 NOP 001 PSTART JOB:HOME1 SUB1 002 PSTART JOB:HOME2 SUB2 003 PWAIT SUB1 004 PWAIT SUB2 005 DOUT OT#(01) ON 006 WAIT IN#(01)=ON 007 DOUT OT#(02) ON 008 WAIT IN#(03)=ON 009 DOUT OT#(02) OFF 010 DOUT OT#(01) OFF 011 CALL JOB:WELDA IF IN IN#(02)=ON 012 RET 013 END

Sweeps positioner to Side A, jumps to job WELDA, then returns to Master Job.

ArcWorld 1200 MRC Operator's Manual Page 38 MOTOMAN

4.4.3 Sweep to B Job (Concurrent Job)

Line Step Function

Sweeps positioner to Side B, jumps to job WELDB, then returns to Master Job.

4.4.4 Master Robot WeldA Job (Concurrent Job)

Line Step Function

000 000 NOP 001 PSTART JOB:WELDA SUB1

'WeldA subroutine for robot R1

002 PSTART JOB:WELDAR2 SUB2

'WeldA subroutine for robot R2 003 PWAIT SUB1 004 PWAIT SUB2 005 RET 006 END

ArcWorld 1200 MRC Operator's Manual Page 39 MOTOMAN

4.4.5 Master Robot WeldB Job (Concurrent Job)

Line Step Function

000 000 NOP 001 PSTART JOB:WELDB SUB1

'WeldB subroutine for robot R1 002 PSTART JOB:WELDBR2 SUB2

'WeldB subroutine for robot R2 003 PWAIT SUB1 004 PWAIT SUB2 005 RET 006 END

ArcWorld 1200 MRC Operator's Manual Page 40 MOTOMAN

5.0 MAINTENANCE

5.1 PERIODIC MAINTENANCE

For periodic maintenance procedures and schedules for the K6 robot, the K10 robot, and the MRC controller, refer to your K6 MRC Manipulator Manual or K10 MRC Manipulator Manual.

For maintenance information regarding the welding power source, refer to your Excel-Arc Owner's Manual.

Table 5-1 provides a list of periodic maintenance to be performed on the ArcWorld 1200 cell. Keep in mind that the maintenance intervals given serve as guidelines only, you should adjust the frequency of maintenance to suit your specific work conditions.

➪

CAUTION!

Use only the anti-freeze provided by Motoman. Automotive antifreeze contains stop-leak additives that will clog the small torch water-cooling ports, and damage the gaskets in the circulator pump.

Table 5-1 Periodic Maintenance

Frequency Component Procedure

Daily Water circulator

(water-cooled torch application only)

Check the fluid in the water circulator. Add fluid as required. Use only distilled water and approved antifreeze (Motoman part number 131224-1).

Weekly MR-500 Brake Make sure positioner stops

properly at end of sweep. Adjust brake per instruction label on brake assembly if required.

Monthly MR-500 Turntable

Nylon Ground Insulator

Check ground insulator for signs of electrical breakdown (melting). Replace the insulator as required.

ArcWorld 1200 MRC Operator's Manual Page 41 MOTOMAN

Table 5-1 Periodic Maintenance (Continued)

Frequency Component Procedure

Monthly MR-500 Turntable

Welding Ground

There is an insulated lug at the base of the positioner for a welding ground. This lug is connected to carbon brushes located under the table top. Check the brushes for proper lubrication and signs of wear. Excessive heat buildup in the brushes indicates uneven wear or the lack of grease. Keep the contact area lubricated with Burndy Penetrox E conductive copper lubricant (part no. PEN-E-8).

3 - 6 months MR-500 Flexible

Coupling

Make sure that the flange bolts are tight. Torque to 40 ft-lbs

Regularly (based on usage)

MR-500 Helical Gear Unit

Check oil level and quality. Add or change oil as required using Shell Omala Oil #220 or equivalent.

10,000 operating hrs MR-500 Helical

Gear Unit

Change oil using Shell Omala Oil #220 or equivalent.

10,000 operating hrs Bearing on MR-500

Helical Gear Unit

Clean the bearing and then grease with Shell Alvania Grease #R3.

5.2 MAINTENANCE PROCEDURES

The following procedures should be performed only as required. Read through the instructions completely before performing any maintenance procedure. Be sure that you understand the procedure, have the proper tools, and observe all applicable safety precautions.

➪

WARNING!

Make sure that servo power is off before performing the following procedures. Observe standard lockout/tagout practices.

ArcWorld 1200 MRC Operator's Manual Page 42 MOTOMAN

5.2.1 MR-500 Shock Absorber

Proper adjustment of the shock absorber is important to achieve efficient operation. All units are preset at the factory for maximum performance before shipping. If deceleration becomes a problem, adjust the shock to achieve the desired declaration rate:

1. Loosen the adjusting ring lock screw.

2. Turn the adjusting ring towards zero to achieve more cushioning and towards nine to achieve less cushioning.

3. Tighten the adjusting ring lock screw.

5.2.2 MR-500 DC Motor Speed Control Unit

The DC Motor Speed Control Unit is factory set and serviceable by Motoman ONLY! Opening the DC Motor Speed Controller will VOID YOUR

WARRANTY.

5.3 SPARE PARTS LIST

Table 5-2 Spare Parts

Description Part No. AW1000 Safety Mat Kit 130157-2 MR-500 Positioner Table Shock Absorber 130592-3 Positioner Table Interface 2 Pole Relay, 24 VAC 130134-6 Positioner Table Interface 4 Pole Relay, 120 VAC 130134-5

5.4 FUSE AND CIRCUIT BREAKER PROTECTION

Tables 5-3 through 5-7 give the locations of fuses and circuit breakers that are significant to the operation of the total system. In most cases, MRC spare fuses are placed in the accessory bag with the MRC.

➪

WARNING!

Replace fuses with the same type and rating. Replacement of fuses with higher amperage rating or lower voltage will damage the robot controller and/or auxiliary equipment necessitating costly replacement.

ArcWorld 1200 MRC Operator's Manual Page 43 MOTOMAN

Abbreviations:

CB – designates circuit breaker F, FU or 101FU – designates fuse

Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

CB1 10A

115V

203627-7 Upper rear panel Protect 115V circuit

CB2 10A 24V 203627-7 Upper rear panel Protect 24V circuit

F1 .5 A W-11166-11 On contactor box Protect contactor

circuit

Table 5-4 MRC Cabinet Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

CB (1MCCB)

50 A

30 A

NF50-SS

NF30-SS

Upper left front K10

Upper left front K6

Main circuit breaker for incoming 200 V AC, 3 phase for MRC cabinet

CB (1SV) 30 A Lower left side

of servo pack

Protects input for servo pack 1SV for S, L, and U axes

CB (2SV) 30 A Lower left side

of servo pack

Protects input for servo pack 2SV for R, B, and T axes

FU1 5 A GDL-5 MTU-01 Protects CPT10199

transformer, brake, and fan circuits

FU2 5 A GDL-5 MTU-01 Protects CPT10199

transformer, brake, and fan circuits

FU4 4 A GP-40 MTU-01 Protects robot brake

circuits

FU5 4 A GP-40 MTU-01 Protects robot brake

circuits

ArcWorld 1200 MRC Operator's Manual Page 44 MOTOMAN

1FU 1 A GDL-1 Top/left/rear Protects the four fan

circuits of the MRC

2FU 1 A GDL-1 Top/left/rear Protects the control

transformer and fan (above computer rack) in the MRC

Table 5-4 MRC Cabinet Fuses and Circuit Breakers (Continued)

Device

Designator Rating Part Number Location Purpose

3FU 1 A GDL-1 Top/left/rear Protects the control

transformer and fan (above computer rack) in the MRC

4FU 1 A GDL-1 Top/left/rear Protects the 100 V

AC supply to the AC receptacle for the floppy disk controller power

FU1 3 A SM1101 MBB-02 External voltage

protection - 24V

FU2 3 A SM1101 MBB-02 External voltage

protection - 24V

Table 5-5 Universal Welding Interface (UWI) Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

F1 8A 250V On KXA motor

speed control

Limits damage from shorts or component breakdowns in DC power supply module

FU1 4A 250V Wickman

19374K-4A

On interface board

Protects 115V circuit

ArcWorld 1200 MRC Operator's Manual Page 45 MOTOMAN

FU2 .25A

125V

Wickman 19303K250A

On interface board

Protects shock sensor circuit

FU3 .5A 125V Wickman

19303K500A

On interface board

Protects 24V circuit

ArcWorld 1200 MRC Operator's Manual Page 46 MOTOMAN

Table 5-6 Com-Arc III Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

Fuse 1A 250V TD-1 Front of

Com-Arc box

Protect 200V circuit

Table 5-7 MR-500 Positioner Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

Fuse 30A

600V

Amptrap ATM-30

Top of ratiotrol under table

Protects input line to ratiotrol

ArcWorld 1200 MRC Operator's Manual Appx. A MOTOMAN

APPX. A RISK ASSESSMENT

Risk Assessment Page 1 MOTOMAN ArcWorld 1200 MRC

MOTOMAN Risk Assessment

ArcWorld 1200 System

Application: Arc Welding Robot Type: K6 or K10 Customer: Varies Plant Loc.: Varies

See cell layout This document was prepared to explain the rationale behind the safeguarding of

MOTOMAN's ArcWorld 1200 robot cell.

It is the User's responsibility to review this document and verify that the safeguards are adequate for their plant conditions. This review should include the current revision of ANSI/RIA

R15.06 American National Standard for Industrial Robot Systems - Safety Requirements. The User must also ensure that safeguards are used and maintained.

SAFEGUARDING PERSONNEL

Safeguarding Plant Personnel

• Barrier around robot work envelope.

• Interlocked gate for access to cell.

• Curtain around cell blocks ultra-violet radiation from arc.

• Serious hazards are identified by warning labels.

Safeguarding Operator

• Interlocked gates stop robot motion if opened in PLAY mode.

• Dual sensors on interlocked gate make safeguards difficult for operator to

defeat.

• Emergency Stop button on operator station.

• Two station positioner keeps operator out of robot work envelope.

• Extended length safety mats are interlocked to stop positioner motion when

activated. Requires reset at operator station to restart.

• Robot program will wait for Cycle Start buttons before sweeping positioner.

Risk Assessment Page 2 MOTOMAN ArcWorld 1200 MRC

• Cycle Start has dual palm buttons, anti-tie down, positioned for two hand

operation.

Safeguarding Teacher

• Interlocked gate: Active in PLAY mode; Inactive in TEACH mode.

• Clearance of 24" between robot and fencing.

• Emergency Stop button on programming pendant.

• S-axis motion restricted by hardstops.

• TEACH LOCK prevents operation from controller while programming

pendant is enabled.

• Continuous stepping is at reduced speed.

Safeguarding Maintenance Personnel

• Robot controls are outside barrier.

• Positioner controls are inside cell, but do not require robot drive power to

troubleshoot.

• Electrical energy sources equipped with lockout/tagout.

• Programming pendant displays I/O status and other diagnostic functions.

SOURCES OF HAZARDS

Unauthorized Access

• Interlocked barrier.

• Dual interlocks, difficult to defeat by operator.

Human Errors in Judgment

• Safety mat interlocked with positioner.

• Dual palm cycle start.

• Emergency Stops on operator station, robot controller, and programming

pendant.

Control Errors

• Most Safety features independent of program logic.

• Program must have instructions to wait for palm buttons to sweep.

Risk Assessment Page 3 MOTOMAN ArcWorld 1200 MRC

Mechanical / Electrical Failures

• Safety mat supplied with fail-safe circuit.

• Redundant door interlocks.

• Interlocks designed to fail-safe.

• Robot has sophisticated control loop designed to remove drive power in case of

positioning error.

Environmental

• Sheet metal partition and UV curtain to help prevent eye damage from ultra-

violet radiation.

• UV curtain helps contain welding sparks.

NOTE: Fume ventilation may be required depending on application and plant conditions. (To be

determined and provided by USER.)

NOTE: Care must be used when handling and securing compressed and combustible gasses. (User

supplied.)

Installation Defects

• Safeguards will place the robot in Emergency Stop unless they are correctly

connected.

• Safety fence is self supporting when fully erected (fencing should be lagged).

• Equipment is shipped on bases to ease installation and provide a secure

mounting surface (robot base needs to be leveled and lagged).

Power System Failure or Inadvertent Power Initiation

• Easy recovery from power failure.

• Different levels of power up; primary power on, controller power on, servo

power on, and robot start. Difficult to inadvertently start.

Risk Assessment Page 4 MOTOMAN ArcWorld 1200 MRC

EQUIPMENT PROTECTION

Human Errors

• Torch breakaway protects robot and torch in the case of a torch crash.

• Cube #1 interlock requires the robot to be in a "safe" position before the

positioner can index.

• Cube #2 output is used as an interlock for robot motion. This is a software

zone between the robots in which it would be possible for the paths of the robots to intersect. When one robot is operating in this cube, the other is prohibited from entry, and vice versa.

Power Faults

• Isolation transformer and circuit breaker protect robot from power surges

(additional surge control may be required at your facility).

• Robot "remembers" its position and place in program at power down.

• Data has battery backup and can be saved on optional floppy disk drive.

WHAT-IF CONSIDERATIONS

What if personnel reach over safety mat and pinch an arm on moving parts?

Extended length mats are provided to help prevent inadvertent access to moving parts.

What if there is a hazard not covered by a warning label?

Labels are provided on positioner, robot, power source, feeder, transformer, and robot controller. Persons working on equipment should have adequate training to identify hazards.

ArcWorld 1200 MRC Operator's Manual Appx. B MOTOMAN

APPX. B SYSTEM OUTLINE

This section contains the following outline drawings:

Drawing Number Title Sheet Number

131927 Cell Layout Sheet 1 of 15 131927 Bill of Material Sheet 2 of 15

ArcWorld 1200 MRC Operator's Manual Appx. C MOTOMAN

APPX. C ELECTRICAL DRAWINGS

This section contains the following electrical drawings:

Drawing Number Title Sheet Number

131927 Power Distribution Sheet 3 of 15 131927 MRC I/O MRY01-3 Board Sheet 4 of 15 131927 MRC I/O MEW01 Board Sheet 5 of 15 131927 MRC I/O MI004 Board Sheet 6 of 15 131927 MRC I/O MI004 Board Sheet 7 of 15 131927 Cable Layout Sheet 8 of 15 131927 Cable Charts Sheet 9 of 15 131927 Ladder Diagram Sheet 10 of 15 131927 Ladder Diagram Sheet 11 of 15 131927 Ladder Diagram Sheet 12 of 15 131927 Ladder Diagram Sheet 13 of 15 131927 Ladder Diagram Sheet 14 of 15 131927 Ladder Diagram Sheet 15 of 15 132209 PLC Controller Sheet 1 of 4 132209 PLC Controller Sheet 3 of 4 132209 PLC Controller Sheet 4 of 4 130161 Connection/Schematic Diagram Sheet 6 of 7

ArcWorld 1200 MRC Operator's Manual Appx. D MOTOMAN

APPX. D MECHANICAL DRAWINGS

This section contains the following mechanical drawings:

Drawing Number Title Sheet Number

132349 MRC Common Base Sheet 1 of 1 131069 Positioner with Interface Sheet 1 of 1 130174 Positioner, Turntable, 180˚ Sheet 1 of 2

and Drive

130174 Positioner, Turntable, 180˚ Sheet 2 of 2

and Drive 130156 Positioner, Turntable, 180˚ Sheet 2 of 3 130156 Positioner, Turntable, 180˚ Sheet 3 of 3 130101 Common Base Sheet 1 of 1 130227 Robot Spanner Base Sheet 1 of 1 130157 Safety Mat Sheet 2 130158 Interlock, Entry Access Sheet 1 of 1 130161 Station, Operator Sheet 1 of 7 130161 Station, Operator Sheet 2 of 7

ArcWorld 1200 MRC Operator's Manual Index 1 MOTOMAN

INDEX

About This Document, 1 AC Receptacles, 21 Alarm / Error, 13 Alarm, 18 Alarms and Errors, 28 Arc Screens, 22 Arc Shield, 17

Circuit Breakers, 21 Coordinate System Indicators, 15 Cube Assignment, 29 Customer Service Information, 4 Cycle Select, 13 Cycle Start, 18

Description of Equipment, 11 Display, 15

E-Stop Recovery, 25 Electrical Requirements, 16 Emergency Stop, 13, 15, 17 Emergency Stops, 23 Error Messages, 28 Excel-Arc Controls, 20

Fault Recovery, 25 Feeder Control Receptacles, 21 Fencing, 23

ArcWorld 1200 MRC Operator's Manual Index 2 MOTOMAN

Fuse and Circuit Breaker Protection, 37

General Safeguarding Tips, 7

Hard Stops and Shock Absorbers, 17 Hold, 13, 18 Humidity, 16

I/O Assignment, 30 Installation Safety, 8 Interlocks, 23 Introduction, 1

K-Series Robot Description, 11 Keypad, 15

Local / Remote Operation, 20

Main Power, 19 Maintenance Procedures, 36 Maintenance Safety, 10 Maintenance, 35 Major Alarms, 29 Master Job (Concurrent Job), 32 Master Job Start, 18 Master Robot WeldA Job (Concurrent Job), 33 Master Robot WeldB Job (Concurrent Job), 34 Mechanical Safety Devices, 7 MIG Torch, 22 Minor Alarms, 28 Mode Select, 13

ArcWorld 1200 MRC Operator's Manual Index 3 MOTOMAN

MR-500 DC Motor Speed Control Unit, 37 MR-500 Shock Absorber, 37 MRC Controller, 11, 12 MRC Playback Box, 12

ArcWorld 1200 MRC Operator's Manual Index 4 MOTOMAN

Op-Station, 17 Operation Safety, 9 Operation, 24 Operator Control Panel (Op-Station), 17 Operator Station Enable / Disable, 19 Optional Equipment, 3

Part / Fixture Rating, 15 Part Center of Gravity, 16 Periodic Maintenance, 35 Playback Box Sub-Panel, 13 Positioner Auto / Manual, 18 Positioner, 15 Programming Pendant, 14 Programming Safety, 8 Programming, 29 PWF4 Wire Feeder, 21

RAM Breakaway Mount, 22 Reference to Other Documentation, 4 Reset, 19 Robot Speed Indicators, 15

Safety Equipment, 22 Safety Mats, 23 Safety, 5 Sample Jobs, 31 Servo On, 18 Servo Power, 12, 15 Shock Sensor Override, 27 Shock Sensor Recovery, 26 Shock, 16

ArcWorld 1200 MRC Operator's Manual Index 5 MOTOMAN

Shut Down, 28 Spare Parts List, 37 Standard Conventions, 6 Start Up, 24 Start, 13 Station Ready, 18 Sweep Speed, 16 Sweep to A Job (Concurrent Job), 32 Sweep to B Job (Concurrent Job), 33 Sweeping Table to Side A, 29 Sweeping Table to Side B, 30 System Layout, 2, 3 System Overview, 1

Temperature Operating Range, 16 Terminal Connectors, 19

Universal Welding Interface (UWI), 21

Volt / Amp Settings, 19

Welding Current Rating, 16 Welding Equipment, 21 Welding Power Source, 19

motoman robotics 1200 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual