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.

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motoman robotics 1200 Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual