motoman robotics 1200 Operators Manual

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Yasnac MRC Controller

April 24, 1996

MAN

ArcWorld 1200 Operator’s Manual for SK-Series Robot

Part Number 133676-2

TEL: 513-847-6200 FAX: 513-847-6277

24-HOUR SERVICE HOTLINE: 513-847-3200

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

MOTO

805 Liberty Lane

West Carrollton, OH 45449

authorization of Motoman, Inc.

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

notice. YASNAC and MOTOMAN are registered trademarks of YASKAWA Electric Manufacturing.

TABLE OF CONTENTS

Section Page

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

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

1.2 SYSTEM OVERVIEW.......................................................................... 2

1.2.1 System Layout..................................................................... 2

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

1.3 REFERENCE TO OTHER DOCUMENTATION ................................... 3

1.4 CUSTOMER SERVICE INFORMATION ............................................. 3

2.0 SAFETY.......................................................................................................... 4

2.1 STANDARD CONVENTIONS............................................................. 5

2.2 GENERAL SAFEGUARDING TIPS..................................................... 6

2.3 MECHANICAL SAFETY DEVICES ...................................................... 6

2.4 INSTALLATION SAFETY.................................................................... 7

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

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

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

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

3.1 SK-SERIES ROBOT DESCRIPTION................................................ 11

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

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

3.2.2 Mode Select...................................................................... 12

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 Subpanel...................................................... 13

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

3.3.1 Display.............................................................................. 14

3.3.2 Robot Speed Indicators...................................................... 14

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

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

ArcWorld 1200 MRC Operator's Manual page i MOTOMAN

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

3.3.6 Coordinate System Indicators............................................ 15

3.4 MR-500 POSITIONER .................................................................... 15

3.4.1 Welding Ground System..................................................... 16

3.4.2 Hard Stops and Shock Absorbers....................................... 16

3.4.3 Arc Shield......................................................................... 16

3.5 OPERATOR STATION ..................................................................... 16

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

3.5.2 Hold.................................................................................. 17

3.5.3 Cycle Start....................................................................... 17

3.5.4 Station Ready.................................................................... 17

3.5.5 Alarm............................................................................... 17

3.5.6 Servo On.......................................................................... 17

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

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

3.5.9 Operator Station Enable/Disable........................................ 18

3.5.10 Reset................................................................................ 18

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............................................... 20

3.6.6 Circuit Breakers............................................................... 20

3.6.7 AC Receptacles................................................................. 20

3.7 WELDING EQUIPMENT.................................................................. 20

3.7.1 PWF4 Wire Feeder............................................................ 20

3.7.2 Universal Welding Interface (UWI)................................... 20

3.7.3 MIG Torch....................................................................... 21

3.7.4 RAM Breakaway Mount.................................................... 21

3.8 SAFETY EQUIPMENT ..................................................................... 21

3.8.1 Arc Screens...................................................................... 21

3.8.2 Fencing............................................................................. 22

3.8.3 Interlocks......................................................................... 22

3.8.4 Safety Mats...................................................................... 22

3.8.5 Emergency Stops............................................................... 22

4.0 OPERATION................................................................................................ 23

4.1 OPERATION................................................................................... 23

ArcWorld 1200 MRC Operator's Manual page ii MOTOMAN

4.1.1 Startup............................................................................. 24

4.1.2 Fault Recovery.................................................................. 24

4.1.3 Emergency Stop Recovery................................................. 25

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

4.1.5 Shutdown.......................................................................... 26

4.2 ALARMS AND ERRORS.................................................................. 27

4.2.1 Error Messages................................................................ 27

4.2.2 Minor Alarms................................................................... 27

4.2.3 Major Alarms................................................................... 27

ArcWorld 1200 MRC Operator's Manual page iii MOTOMAN

4.3 PROGRAMMING............................................................................ 27

4.3.1 Cube Assignment............................................................... 28

4.3.2 Sweeping Table to Side A................................................... 28

4.3.3 Sweeping Table to Side B................................................... 29

4.3.4 I/O Assignment................................................................. 29

4.4 SAMPLE JOBS................................................................................ 30

4.4.1 Master Job (Concurrent Job)........................................... 30

4.4.2 Sweep to A Job (Concurrent Job)...................................... 31

4.4.3 Sweep to B Job (Concurrent Job)..................................... 31

4.4.4 Master Robot WeldA Job (Concurrent Job)....................... 32

4.4.5 Master Robot WeldB Job (Concurrent Job)....................... 32

5.0 MAINTENANCE ........................................................................................... 33

5.1 PERIODIC MAINTENANCE............................................................ 33

5.2 MAINTENANCE PROCEDURES...................................................... 34

5.2.1 MR-500 Shock Absorber................................................... 34

5.2.2 MR-500 DC Motor Speed Control Unit............................. 34

5.3 SPARE PARTS LIST......................................................................... 35

5.4 FUSE AND CIRCUIT BREAKER PROTECTION............................... 35

RISK ASSESSMENT................................................................................ Appendix A

SYSTEM OUTLINE................................................................................. Appendix B

ELECTRICAL DRAWINGS........................................................................ Appendix C

MECHANICAL DRAWINGS.................................................................... Appendix D

INDEX ............................................................................................................ Index

ArcWorld 1200 MRC Operator's Manual page iv MOTOMAN

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 Station................................................................................ 16

Figure 3-5 Excel-Arc Controls............................................................................. 19

LIST OF TABLES

Table Page

Table 3-1 Positioner Specifications....................................................................... 15

Table 5-1 Periodic Maintenance........................................................................... 33

Table 5-2 Spare Parts......................................................................................... 35

Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers................................... 35

Table 5-4 MRC Cabinet Fuses and Circuit Breakers............................................. 36

Table 5-5 Universal Welding Interface (UWI) Fuses and Circuit Breakers............ 37

Table 5-6 Com-Arc III Fuses and Circuit Breakers.............................................. 37

Table 5-7 MR-500 Positioner Fuses and Circuit Breakers.................................... 37

ArcWorld 1200 MRC Operator's Manual page v 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 Section 2 provides information regarding the safe use and operation of the

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

system. This section includes a table of component specifications. Section 4 provides instructions to operate the ArcWorld system. This section

describes the various operator controls and indicators. It also provides procedures for start-up, loading, normal operation, fault recovery, and shut-down. This section also contains a number of sample robot programs.

Section 5 contains a table listing periodic maintenance requirements for the ArcWorld 1200 system. 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.

ArcWorld 1200 MRC Operator's Manual page 1 MOTOMAN

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 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.

1.2.1 System Layout

Figure 1-1 shows the system layout for the ArcWorld 1200 cell.

Positioner

Welding

Power

Sources

Com-Arcs

Water

Circulators

Operator

Station

Safety Mats

Door

#2

Robot

Sentrol

Unit

Door

Interlock

Transformer

Feeder

Housings

Torch

Assembly

Fencing

#1

Robot

YASNAC MRC

MRC

Cabinet

External

Axis

Cabinet

Programming

Pendant

Figure 1-1 System Layout

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

ArcWorld 1200 MRC Operator's Manual page 2 MOTOMAN

• 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 is standing 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

1.3 REFERENCE TO OTHER DOCUMENTATION

For additional information refer to the following:

• Motoman SK6 Manipulator Manual (Part Number 133680-2)

• Motoman SK16 Manipulator Manual (Part Number 133680-3)

• 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 133677-2)

• Vendor manuals for system components not manufactured by Motoman

1.4 CUSTOMER SERVICE INFORMATION

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

• Robot Type (SK6 or SK16)

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

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

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

ArcWorld 1200 MRC Operator's Manual page 3 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 Safeguarding Tips (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 4 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 5 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 6 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.

ArcWorld 1200 MRC Operator's Manual page 7 MOTOMAN

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 NODE 2 (for ERC controllers) or PART 1 (for MRC controllers) of the controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to NODE 2 or 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 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.

ArcWorld 1200 MRC Operator's Manual page 8 MOTOMAN

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. On ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3; and I/O (Input and Output) modifications. On MRC controllers this includes controller parameters, ladder 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 9 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.

• 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 10 MOTOMAN

3.0 DESCRIPTION OF EQUIPMENT

3.1 SK-SERIES ROBOT DESCRIPTION

The Motoman SK6 and SK16 robots and YASNAC MRC Controller represent state-of-the-art technology in robotics today. The six-axis SK6 Robot has a payload of 6 kg (13.2 lbs). It features a 1,325 mm (52.1 in) reach and has a relative positioning accuracy of ± 0.1 mm (0.004 in.). The six-axis SK16 Robot has a payload of 16 kg (35.2 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 SK-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 (I/O) 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, operates 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 11 MOTOMAN

YASNAC MRC S K6

Main Power Switch

Programming Pendant

Playback Box

SK6

PLAYBACK BOX

PROGRAMMING PENDANT

MAIN POWER

SWITCH

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

INSIDE SUBPANEL

following paragraphs describe the MRC controls.

3.2.1 Servo Power

Figure 3-1 MRC Controller

Figure 3-2 MRC Playback Box

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

3.2.2 Mode Select

The MODE SELECT button 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.

ArcWorld 1200 MRC Operator's Manual page 12 MOTOMAN

3.2.3 Cycle Select

The CYCLE SELECT button 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 Emergency Stop (E.STOP) button is connected to the system emergency stop circuit. Interrupting the emergency stop circuit causes the robot to go into the emergency stop condition. Pressing the E.STOP button immediately cuts servo power and engages the brakes.

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 indictor lamp turns off.

3.2.6 Hold

The HOLD button is a momentarily actuated switch. Pressing the HOLD button stops the operation of the manipulator momentarily. The indicator lamp lights whenever the robot is in a HOLD state. CYCLE START must be pressed to resume operation. Operation will resume at the point in the program where the HOLD state was initiated. 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 Subpanel

The playback box has an internal subpanel that contains additional user controls. Refer to your MRC Operator’s Manual for more information.

ArcWorld 1200 MRC Operator's Manual page 13 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 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

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.

ArcWorld 1200 MRC Operator's Manual page 14 MOTOMAN

3.3.3 Emergency Stop

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

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 for more information.

3.3.5 Servo Power

The SERVO POWER button 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 MR-500 POSITIONER

The MR-500 is a DC motor-driven, turntable positioner. A steel arc screen divides the standard 60-inch (152 cm) 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.

Table 3-1 Positioner Specifications

Capacity

226.8 kg (500 lb.) on each side of the turntable, center of gravity located 10 inches above the table tooling plate surface at a radius of 20 inches.

Temperature Operating Range

4-43°C (40-110˚F)

Humidity (maximum)

Non-condensing 10-90% relative humidity

Shock

Less than 0.5 G

Sweep Speed

Approximately 5 seconds

Electrical Requirements

115 VAC/60 Hz/Single-Phase supplied by the MRC controller

Welding Current Rating

600 amperes at 100% duty cycle

NOTE: In high humidity areas, use surface protection to prevent corrosion of the tooling plate.

ArcWorld 1200 MRC Operator's Manual page 15 MOTOMAN

3.4.1 Welding Ground System

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 which is located on the lower right side of the positioner base as you face 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.

3.4.2 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.

3.4.3 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 OPERATOR STATION

The operator station (OP-station) includes a NEMA enclosure on a stand-alone 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 Station

ArcWorld 1200 MRC Operator's Manual page 16 MOTOMAN

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 emergency stop circuit is interrupted, the robot and the Motoman MR-500 positioner will go into the emergency stop condition. The operator station E.STOP light will come on when the E.STOP button is pressed. Power to the positioner interface is cut and all table motion stops.

3.5.2 Hold

The operator station HOLD button is a normally-closed button connected to the MRC. The robot will 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-tiedown technique for robot input. The anti-tiedown timer is set for 10 seconds. Holding the palm buttons down for more than 10 seconds, causes the system to time out and prevents the CYCLE START input from reaching the robot a second time after the initial start.

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 (safe position). When the robot is in CUBE #1, Output #1 turns on the STATION READY lamp. Refer to your MRC User Functions and Operator’s Manuals for more information about the Cube Function.

3.5.5 Alarm

The ALARM lamp is connected to the robot SERVO ON output. The ALARM lamp turns on when the robot encounters an alarm condition that cuts power to the servos.

3.5.6 Servo On

The SERVO ON button is connected to the robot SERVO ON input. The robot servo motors will turn on when the SERVO ON button is pressed and an emergency stop condition does not exist.

ArcWorld 1200 MRC Operator's Manual page 17 MOTOMAN

3.5.7 Positioner Auto/Manual

The POSITIONER AUTO/MANUAL selector switch is used to select Automatic or Manual Mode for the positioners. 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, but will return the robot to the home position to wait until CYCLE START buttons are pressed. This function is

dependent on the structure of the master job.

3.5.8 Master Job Start

The MASTER JOB START button is connected to the robot external start input. The robot will start the current active job, once the MASTER JOB START is pressed, as long as the robot is in Remote Mode, the servo motors are on, and the remote switch is enabled on the OP-station.

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 OP-station is enabled. Most programming pendant functions are disabled while in REMOTE.

3.5.10 Reset

The RESET button is connected to the robot alarm reset input. A minor alarm or error condition will be cleared when this button is pressed. In addition, the RESET button and the RIGHT CYCLE START buttons 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 after an 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 emergency stop occurs during programming, be sure to reset the table before resuming programming.

ArcWorld 1200 MRC Operator's Manual page 18 MOTOMAN

3.6 WELDING POWER SOURCE

The Excel-Arc power source (Figure 3-5) is a constant-voltage, transformerrectifier, welding power supply. 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.

10 AMPS 10 AMPS

110 V 9A

CIRCUIT BREAKERS

WIRE FEED#1 WIRE FEED#2

REMOTE

CONTROL

INPUT

POWER

V ON OFFIO

LOCAL

REMOTE

CC CV

A V

1 2

1 Main power pilot light 8 Feeder control receptacle panel 2 Welding voltage/amperage control 9 10 A circuit breaker 3 Volt/Amp meter and switch 10 10 A circuit breaker 4 Positive terminal 11 115 V AC receptacle 5 Negative terminal 6 Local/Remote output control selector 7 Input power switch

Figure 3-5 Excel-Arc Controls

3.6.1 Main Power

The Input Power Switch (7, Figure 3-5) 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, Figure 3-5) illuminates when main power is on.

3.6.2 Volt/Amp Settings

The Welding Voltage/Amperes Control (2, Figure 3-5) adjusts the welding output and open circuit voltage. The Volt/Amp Meter and Switch (3, Figure 3-5) display either DC voltage or 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, Figure 3-5) connects

ArcWorld 1200 MRC Operator's Manual page 19 MOTOMAN

positive welding lead (to the wire feeder). The Negative Terminal (5, Figure 3-5) connects to the negative welding lead (to the positioner ground lug).

ArcWorld 1200 MRC Operator's Manual page 20 MOTOMAN

3.6.4 Local/Remote Operation

The Local/Remote Output Control Selector Switch (6, Figure 3-5) 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, Figure 3-5) 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, Figure 3-5). 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, Figure 3-5). 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:

• PWF4 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 600 IPM. An integral gas valve provides fast gas response time. The PWF4 feeder has an inch-forward button to help simplify setup and reduce changeover time. The PWF4 wire feeder uses interchangeable feed rolls to accommodate different types and sizes of wire.

ArcWorld 1200 MRC Operator's Manual page 21 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.

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 ensure accurate realignment 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 assure 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-interlocked 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 22 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 emergency stop and shuts down the entire system.

3.8.4 Safety Mats

The safety mats provided with the ArcWorld 1200 help prevent serious injury to anyone entering the turntable positioner area during the sweeping process. If a person steps on this mat while the positioner is in motion, an emergency 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.STOP). These are operator-actuated devices that, when activated, immediately cause the system to shut down. E.STOP buttons are located on the:

• MRC control panel

• MRC programming pendant

• Turntable positioner operator station

ArcWorld 1200 MRC Operator's Manual page 23 MOTOMAN

4.0 OPERATION

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

• System startup

• Part setup

• Normal operation

• Fault recovery

• System shutdown This section contains several sample programs. The listed programs illustrate the

proper format and instruction sequences for different operations. 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 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 emergency stop.

Following is a typical sequence of operation for the ArcWorld 1200 cell after startup:

1. Load the parts to be welded into the fixture on the operator side of the

positioner.

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. The positioner sweeps, returning the welded part outside the cell.

5. Unload the welded parts from the fixture.

6. Repeat Steps 1 through 5.

ArcWorld 1200 MRC Operator's Manual page 24 MOTOMAN

4.1.1 Startup

To start up the ArcWorld 1200 cell from a Power Off condition:

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. Enable the OP-station.

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

15. 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 upon the nature of the alarm or error. In some cases, simply resetting the robot and restarting the operation is sufficient. In most cases, you must first correct the condition causing the alarm or error. Refer to paragraph 4.2, Alarms and Errors.

ArcWorld 1200 MRC Operator's Manual page 25 MOTOMAN

4.1.3 Emergency Stop Recovery

An emergency 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.

To restart the ArcWorld 1200 cell after an emergency stop condition occurs, follow the procedure below.

1. To clear the emergency stop condition, perform the following 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 emergency 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. Ensure that the OP-station is enabled.

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

The ArcWorld 1200 cell will continue its operation.

ArcWorld 1200 MRC Operator's Manual page 26 MOTOMAN

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 during 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 emergency stop condition.

To override the shock sensor, perform the following:

1. Press F5 (RESET) on the programming pendant or the RESET button on the OP-station

2. Press and hold the OVERRUN RECOVERY button inside the playback box. Continue to hold the OVERRUN RECOVERY button through Step 5.

3. Press the SERVO ON button on the programming pendant, playback box, or OP-station.

4. Press CYCLE START and RESET on the OP-station.

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

6. Release the OVERRUN RECOVERY button.

7. Reattach the sections of the torch breakaway mount if the impact caused them to separate.

To resume operation after clearing the shock sensor condition, proceed as follows:

1. Close the interlocked enclosure doors.

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

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

4. Press the MASTER JOB START button.

4.1.5 Shutdown

To shut down the ArcWorld 1200 cell after operation is complete:

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.

ArcWorld 1200 MRC Operator's Manual page 27 MOTOMAN

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

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

Error messages are caused by 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.

Error messages are cleared by pressing the CANCEL button on the programming pendant.

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:

• RESET button on the operator’s station

• CANCEL button on the programming pendant twice

4.2.3 Major Alarms

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

To clear major 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 or 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.

ArcWorld 1200 MRC Operator's Manual page 28 MOTOMAN

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 robot is prevented from entering the area and vice versa.

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

To assign the SK6 or SK16 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 the possibility that the paths of the robot arms may intersect with fixtures or each other.

NOTE: If the robot moves outside of its assigned cube, the cube 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 emergency stop recovery, press the RESET

button and the right CYCLE START button.

5. Enable the OP-station.

6. Press the MASTER JOB START button on the OP-station.

7. Press the CYCLE START palm buttons.

8. 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.

ArcWorld 1200 MRC Operator's Manual page 29 MOTOMAN

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

ArcWorld 1200 MRC Operator's Manual page 30 MOTOMAN

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 emergency stop recovery, press the RESET

button and the right CYCLE START button.

5. Enable the OP-station.

6. Press the MASTER JOB START button on the OP-station.

7. Press the CYCLE START palm buttons.

8. 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)

ArcWorld 1200 MRC Operator's Manual page 31 MOTOMAN

MRC Dedicated Inputs

• External Emergency Stop

• External Servo On

• External Hold

• Anti-tiedown

• In Cube 1

• In Cube 2

• External Start

• Alarm Reset

• Remote Mode On

MRC Dedicated Outputs

• Servo Power On

• Alarm Occurrence

• 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 in italics are comments added for clarification only and do not appear in the actual program listing.

4.4.1 Master Job (Concurrent Job)

Line Step Function

000 000 NOP 001 CALL JOB:SWEEPTOA IF IN#(04)=ON 002 CALL JOB:SWEEPTOB IF IN#(03)=ON 003 END

ArcWorld 1200 MRC Operator's Manual page 32 MOTOMAN

4.4.2 Sweep to A Job (Concurrent Job)

This job sweeps the positioner to Side A, jumps to job WELDA, and then returns to the Master Job.

Line Step Function

000 000 NOP 001 PSTART JOB:R1R2 SAFE SUB1 002 PWAIT SUB1 003 DOUT OT#(01) ON 004 WAIT IN#(01)=ON 005 DOUT OT#(02) ON 006 WAIT IN#(03)=ON 007 DOUT OT#(02) OFF 008 DOUT OT#(01) OFF 009 CALL JOB:WELDA IF IN IN#(02)=ON 010 END

4.4.3 Sweep to B Job (Concurrent Job)

This job sweeps the positioner to Side B, jumps to job WELDB, and then returns to the Master Job.

Line Step Function

010 END

ArcWorld 1200 MRC Operator's Manual page 33 MOTOMAN

4.4.4 Master Robot WeldA Job (Concurrent Job)

Line Step Function

000 000 NOP 001 PSTART JOB:WELDA R1 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

4.4.5 Master Robot WeldB Job (Concurrent Job)

Line Step Function

000 000 NOP 001 PSTART JOB:WELDB R1 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 34 MOTOMAN

5.0 MAINTENANCE

5.1 PERIODIC MAINTENANCE

For periodic maintenance procedures and schedules for the SK6 robot, the SK16 robot, and the MRC controller, refer to your SK6 MRC Manipulator Manual or SK16 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. Adjust the frequency of maintenance to suit your specific work conditions.

Table 5-1 Periodic Maintenance

Interval Equipment Action Required

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.

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 hours MR-500 Helical Gear Unit Change oil using Shell Omala Oil #220 or

equivalent.

ArcWorld 1200 MRC Operator's Manual page 35 MOTOMAN

10,000 operating hours Bearing on MR-500

Helical Gear Unit

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

CAUTION!

Use only antifreeze 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.

5.2 MAINTENANCE PROCEDURES

The following procedures should be performed only as needed. 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!

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

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 absorber to achieve the desired deceleration rate:

1. Loosen the adjusting ring lock screw.

2. Turn the adjusting ring towards zero for more cushioning, and towards nine for 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.

ArcWorld 1200 MRC Operator's Manual page 36 MOTOMAN

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. In most cases, MRC spare fuses are placed in the accessory bag with the MRC.

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

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.

Abbreviations:

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

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

Designator Rating Part Number Location Purpose

ArcWorld 1200 MRC Operator's Manual page 37 MOTOMAN

Table 5-4 MRC Cabinet Fuses and Circuit Breakers

Designator Rating Part Number Location Purpose

CB (1MCCB) 30 A

15 A

NF30-SS-30

NF30-SS-15

Upper left front SK16

Upper left front SK6

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

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

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

ArcWorld 1200 MRC Operator's Manual page 38 MOTOMAN

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

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

FU2 .25A 125V Wickman

19303K-250A

On interface board Protects shock sensor

circuit

FU3 .5A 125V Wickman

19303K-500A

On interface board Protects 24V circuit

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

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

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 page 39 MOTOMAN

APPENDIX A

RISK ASSESSMENT

ArcWorld 1200 System

Application: Arc Welding Robot Type: SK6 or SK16 Customer: Varies Plant Loc.: Varies

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 ultraviolet radiation from arc

• 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.

• CYCLE START has dual palm buttons, anti-tiedown, positioned for two hand

operation

ArcWorld 1200 MRC Operator's Manual Appendix A MOTOMAN

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 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

• 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

Mechanical/Electrical Failures

• Safety mat supplied with fail-safe circuit

• Redundant door interlocks

• Interlocks designed to fail-safe

ArcWorld 1200 MRC Operator's Manual Appendix A MOTOMAN

• 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

ultraviolet 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

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

ArcWorld 1200 MRC Operator's Manual Appendix A MOTOMAN

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

ArcWorld 1200 MRC Operator's Manual Appendix A MOTOMAN

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 Appendix A MOTOMAN

APPENDIX B

SYSTEM OUTLINE

This section contains the following outline drawings:

Drawing Number Title

Sheet Number

134239 Cell Layout 1 of 15 134239 Bill of Material 2 of 15

ArcWorld 1200 MRC Operator's Manual Appendix B MOTOMAN

APPENDIX C

ELECTRICAL DRAWINGS

This section contains the following electrical drawings:

Drawing Number Title

Sheet Number

134239 Power Distribution 3 of 15 134239 MRC I/O MRY01-3 Board 4 of 15 134239 MRC I/O MEW01 Board 5 of 15 134239 MRC I/O MI004 Board 6 of 15 134239 MRC I/O MI004 Board 7 of 15 134239 Cable Layout 8 of 15 134239 Cable Charts 9 of 15 134239 Ladder Diagram 10 of 15 134239 Ladder Diagram 11 of 15 134239 Ladder Diagram 12 of 15 134239 Ladder Diagram 13 of 15 134239 Ladder Diagram 14 of 15 134239 Ladder Diagram 15 of 15 132209 PLC Controller 1 of 4 132209 PLC Controller 3 of 4 132209 PLC Controller 4 of 4 130161 Connection/Schematic Diagram 6 of 7

ArcWorld 1200 MRC Operator's Manual Appendix C MOTOMAN

APPENDIX D

MECHANICAL DRAWINGS

This section contains the following mechanical drawings:

Drawing Number Title

Sheet Number

132349 MRC Common Base 1 of 1 131069 Positioner with Interface 1 of 1 130174 Positioner, Turntable, 180˚ and Drive 1 of 2 130174 Positioner, Turntable, 180˚ and Drive 2 of 2 130156 Positioner, Turntable, 180˚ 2 of 3 130156 Positioner, Turntable, 180˚ 3 of 3 130101 Common Base 1 of 1 130227 Robot Spanner Base 1 of 1 130157 Safety Mat 5 130158 Interlock, Entry Access 1 of 1 130161 Station, Operator 1 of 7 130161 Station, Operator 2 of 7

ArcWorld 1200 MRC Operator's Manual Appendix D MOTOMAN

INDEX

ArcWorld 1200 MRC Operator's Manual Index MOTOMAN

ABOUT THIS DOCUMENT, 1 AC RECEPTACLES, 20 ALARM/ERROR, 13, 17, 27 ARC SCREENS, 21 ARC SHIELD, 16

CIRCUIT BREAKERS, 20 COORDINATE SYSTEM INDICATORS, 15 CUBE ASSIGNMENT, 28 CUSTOMER SERVICE INFORMATION, 3 CYCLE SELECT, 13 CYCLE START, 17

DESCRIPTION OF EQUIPMENT, 11 DISPLAY, 14

ELECTRICAL DRAWINGS, APPENDIX C EMERGENCY STOP RECOVERY, 25 EMERGENCY STOP, 13 EMERGENCY STOP, 15 EMERGENCY STOP, 17 EMERGENCY STOPS, 22 ERROR MESSAGES, 27

FAULT RECOVERY, 24 FEEDER CONTROL RECEPTACLES, 20 FENCING, 22 FUSE AND CIRCUIT BREAKER PROTECTION, 35

GENERAL SAFEGUARDING TIPS, 6

HARD STOPS AND SHOCK ABSORBERS, 16 HOLD, 13, 17

I/O ASSIGNMENT, 29 INSTALLATION SAFETY, 7 INTERLOCKS, 22 INTRODUCTION, 1

KEYPAD, 15

LOCAL/REMOTE OPERATION, 20

ArcWorld 1200 MRC Operator's Manual Index MOTOMAN

MAIN POWER, 19 MAINTENANCE PROCEDURES, 34 MAINTENANCE SAFETY, 10 MAINTENANCE, 33 MAJOR ALARMS, 27 MASTER JOB (CONCURRENT JOB), 30 MASTER JOB START, 18 MASTER ROBOT WELDA JOB (CONCURRENT JOB), 32 MASTER ROBOT WELDB JOB (CONCURRENT JOB), 32 MECHANICAL DRAWINGS, APPENDIX D MECHANICAL SAFETY DEVICES, 6 MIG TORCH, 21 MINOR ALARMS, 27 MODE SELECT, 12 MR-500 DC MOTOR SPEED CONTROL UNIT, 34 MR-500 POSITIONER, 15 MR-500 SHOCK ABSORBER, 34 MRC CONTROLLER, 11

OPERATION SAFETY, 9 OPERATION, 23 OPERATION, 23 OPERATOR STATION ENABLE/DISABLE, 18 OPERATOR STATION, 16 OPTIONAL EQUIPMENT, 3

PERIODIC MAINTENANCE, 33 PLAYBACK BOX SUBPANEL, 13 POSITIONER AUTO/MANUAL, 18 PROGRAMMING PENDANT, 14 PROGRAMMING SAFETY, 8 PROGRAMMING, 27 PWF4 WIRE FEEDER, 20

RAM BREAKAWAY MOUNT, 21 REFERENCE TO OTHER DOCUMENTATION, 3 RESET, 18 RISK ASSESSMENT, APPENDIX A ROBOT SPEED INDICATORS, 14

SAFETY EQUIPMENT, 21 SAFETY MATS, 22 SAFETY, 4 SAMPLE JOBS, 30 SERVO ON, 17 SERVO POWER, 12 SERVO POWER, 15

ArcWorld 1200 MRC Operator's Manual Index MOTOMAN

SHOCK SENSOR RECOVERY, 26

ArcWorld 1200 MRC Operator's Manual Index MOTOMAN

SHUTDOWN, 26 SK-SERIES ROBOT DESCRIPTION, 11 SPARE PARTS LIST, 35 STANDARD CONVENTIONS, 5 START, 13 STARTUP, 24 STATION READY, 17 SWEEP TO A JOB (CONCURRENT JOB), 31 SWEEP TO B JOB (CONCURRENT JOB), 31 SWEEPING TABLE TO SIDE A, 28 SWEEPING TABLE TO SIDE B, 29 SYSTEM LAYOUT, 2 SYSTEM OUTLINE, APPENDIX B SYSTEM OVERVIEW, 2

TERMINAL CONNECTORS, 19

UNIVERSAL WELDING INTERFACE (UWI), 20

VOLT/AMP SETTINGS, 19

WELDING EQUIPMENT, 20 WELDING GROUND SYSTEM, 16 WELDING POWER SOURCE, 19

ArcWorld 1200 MRC Operator's Manual Index MOTOMAN

motoman robotics 1200 Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual