motoman robotics 6000 Operators Manual

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Yasnac MRC Controller

January 20, 1995

MAN

ArcWorld 6000 Operator's Manual

Part Number 132340-7

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.......................................................................... 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 MRM2-SERIES POSITIONER......................................................... 15

3.4.1 Part / Fixture Rating......................................................... 16

3.4.2 Swing Diameter................................................................. 16

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

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

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

3.4.6 Sweep Speed ..................................................................... 17

3.4.7 Servo Head Stock Speed.................................................... 17

3.4.8 Air Requirements.............................................................. 17

3.4.9 Electrical Requirements..................................................... 17

3.4.10 Welding Current Rating..................................................... 17

3.4.11 Locking Pins...................................................................... 17

3.4.12 Arc Shield......................................................................... 18

3.5 OP-STATION.................................................................................. 18

3.5.1 Emergency Stop................................................................ 18

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

3.5.3 Cycle Start....................................................................... 19

3.5.4 Station Ready.................................................................... 19

3.5.5 Alarm............................................................................... 19

3.5.6 Servo On.......................................................................... 19

3.5.7 Positioner Auto / Manual................................................... 19

3.5.8 Master Job Start .............................................................. 19

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

3.5.10 Reset................................................................................ 20

3.6 WELDING POWER SOURCE........................................................... 20

3.6.1 Main Power...................................................................... 20

3.6.2 Volt / Amp Settings............................................................ 20

3.6.3 Terminal Connectors......................................................... 20

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

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

3.6.6 Circuit Breakers............................................................... 22

3.6.7 AC Receptacles................................................................. 22

3.7 WELDING EQUIPMENT.................................................................. 22

3.7.1 PWF4 Wire Feeder............................................................ 22

3.7.2 Universal Welding Interface (UWI)................................... 22

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

3.7.4 RAM Breakaway Mount.................................................... 23

3.8 SAFETY EQUIPMENT ..................................................................... 23

3.8.1 Arc Screens...................................................................... 23

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

3.8.3 Interlocks......................................................................... 24

3.8.4 Safety Mats...................................................................... 24

3.8.5 Emergency Stops............................................................... 24

4.0 OPERATION................................................................................................ 25

4.1 OPERATION................................................................................... 25

4.1.1 Start Up........................................................................... 25

4.1.2 Loading / Unloading Procedures......................................... 26

4.1.3 Fault Recovery.................................................................. 26

4.1.4 E-STOP Recovery............................................................. 26

4.1.5 Shock Sensor Recovery..................................................... 27

4.1.6 Shut Down........................................................................ 29

4.2 ALARMS AND ERRORS.................................................................. 29

4.2.1 Error Messages................................................................ 29

4.2.2 Minor Alarms................................................................... 29

4.2.3 Major Alarms................................................................... 30

4.3 PROGRAMMING............................................................................ 30

4.3.1 Cube Assignment............................................................... 30

4.3.2 Sweeping Positioner to Side A............................................ 31

4.3.3 Sweeping Positioner to Side B............................................ 31

4.3.4 Rotating Headstock........................................................... 32

4.3.5 Programming.................................................................... 32

4.3.6 I/O Assignment................................................................. 34

4.4 SAMPLE JOBS................................................................................ 35

4.4.1 Master Job (No Group Axes)............................................ 35

4.4.2 Sweep to A Job (R1 + S1).................................................. 36

4.4.3 Sweep to B Job................................................................. 38

4.4.4 Weld Side A Job (Multiple Weld Jobs)................................ 39

4.4.5 Weld Side A Job (Single Weld Job)..................................... 39

4.4.6 Weld Side B Job................................................................ 40

4.4.7 Clean Job (R1 Job)............................................................ 41

5.0 MAINTENANCE ........................................................................................... 42

5.1 PERIODIC MAINTENANCE............................................................ 42

5.2 SPARE PARTS LIST......................................................................... 43

5.3 FUSE AND CIRCUIT BREAKER PROTECTION............................... 44

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)................................................. 18

Figure 3-5 Excel-Arc Controls............................................................................ 21

Figure 4-1 Shock Sensor Override...................................................................... 28

LIST OF TABLES

Table Page

Table 5-1 Periodic Maintenance.......................................................................... 42

Table 5-2 Spare Parts........................................................................................ 43

Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers.................................. 44

Table 5-4 MRC Cabinet Fuses and Circuit Breakers............................................ 44

Table 5-5 Universal Welding Interface (UWI) Fuses and Circuit Breakers........... 46

Table 5-6 COMARC III Fuses and Circuit Breakers............................................ 46

ArcWorld 6000 Operator's Manual Page 1 MOTOMAN

1.0 INTRODUCTION

The ArcWorld 6000 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 6000 features a Motoman arc welding robot and MRC controller with menu-driven arc welding application software, complete welding package, 180˚ reciprocating positioner, operator interface, and total safety environment.

1.1 ABOUT THIS DOCUMENT

This manual provides operation instructions for the ArcWorld 6000 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 6000 system. Section 3 of this manual provides a detailed description of the major components of

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

system. In this section, we describe the various operator controls and indicators. We also provide procedures for start-up, loading, normal operation, fault recovery, and shut-down. Finally, the section contains a number of sample robot programs.

In the Maintenance Section, you will find a table listing periodic maintenance requirements for the ArcWorld 6000 cell. This section includes detailed instructions to perform specific maintenance tasks. 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 6000 provides a complete arc welding solution in a standardized configuration. The system is designed around a Motoman arc welding robot and includes a complete welding package. A dual ferris-wheel positioner allows an

ArcWorld 6000 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.

Assembled

Fence

Robot

Auxiliary

Equipment

Common Base

Operator

Station

Positioner

Gas Bottle

(customer supplied)

Safety Mats

MRC

Cabinet

Water

Circulator

Disconnect

Transformer

Com-Arc

Welding

Power

Source

Torch

Tender

ArcWorld 6000 Operator's Manual Page 3 MOTOMAN

Figure 1-1 System Layout

ArcWorld 6000 Operator's Manual Page 4 MOTOMAN

1.2.1 System Layout

The illustration in Figure 1-1 shows the system layout for the ArcWorld 6000 cell. The ArcWorld 6000 includes the following major components:

• Motoman robot manipulator and MRC controller

• MRM2 series dual ferris-wheel positioner

• Master 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 MRC controller and welding power source share a common base. Additional auxiliary components, such as the COMARC unit and water circulator, can be located on this base as well. 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 6000:

• Torch tender

• Wire cutter

• COMARC III

• Heavy duty positioners

• Stationary tables

ArcWorld 6000 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 6000 Installation Manual (Part Number 132341-7)

• Motoman RM2-250SE2 Manual (Part Number TT-503.8)

• Motoman RM2-500SE2 Manual (Part Number TT-504.2)

• Additional vendor's 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)

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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)

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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 6000 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.

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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 ladder nodes, parts 1 and 2 of the controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to the ladder. 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 6000 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 6000 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 6000 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 6000 Operator's Manual Page 13 MOTOMAN

3.0 DESCRIPTION OF EQUIPMENT

3.1 K-SERIES ROBOT DESCRIPTION

The standard ArcWorld 6000 uses either a Motoman K6 or K10 robot manipulator. The Motoman K6 and K10 robots and YASNAC MRC Controller represent state-of-the-art technology in robotics today. The six-axis K6 robots have a payload of 6 kg (13.2 lbs). They feature a 1,322 mm (52.01 in.) reach and have a relative positioning accuracy of ± 0.1 mm (0.004 in.). The six-axis K10 robots have a payload of 10 kg (22 lbs). They feature a 1,555 mm (61.2 in.) reach and have 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 manipulators, processes input and output signals, controls the operation of the welding power supply, and provides the signals to operate the welding system. It maintains variable data and performs the numeric processing to convert to and from different coordinate systems.

ArcWorld 6000 Operator's Manual Page 14 MOTOMAN

Figure 3-1 MRC Controller

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

Figure 3-2 MRC Playback Box

3.2.1 Servo Power

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

ArcWorld 6000 Operator's Manual Page 15 MOTOMAN

3.2.2 Mode Select

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

3.2.3 Cycle Select

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

3.2.4 Emergency Stop

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

3.2.5 Alarm / Error

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

3.2.6 Hold

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

3.2.7 Start

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

3.2.8 Playback Box Sub-Panel

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

ArcWorld 6000 Operator's Manual Page 16 MOTOMAN

3.3 PROGRAMMING PENDANT

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

Figure 3-3 Programming Pendant

ArcWorld 6000 Operator's Manual Page 17 MOTOMAN

3.3.1 Display

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

3.3.2 Robot Speed Indicators

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

3.3.3 Emergency Stop

3.3.4 Keypad

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

3.3.5 Servo Power

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

3.3.6 Coordinate System Indicators

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

3.4 MRM2-SERIES POSITIONER

The ArcWorld 6000 cell uses one of two different reciprocating positioners: the MRM2-550 or the MRM2-1100. The MRM2-Series positioners are AC servo controlled by the master robot to provide coordinated motion while welding or between welds. The standard distance between the headstock and tailstock faceplates on the MRM2-550 positioner is 2.6 meters (approximately 102"). The standard distance between the headstock and tailstock faceplates on the MRM21100 positioner is 3.0 meters (approximately 118").

The load side of the positioner is fixed for loading and unloading parts. The patented servo motor design of this ferris-wheel type positioner is used to sweep the positioner workstations into and out of the robot envelope.

ArcWorld 6000 Operator's Manual Page 18 MOTOMAN

A fixture frame is typically mounted between the headstock and tailstock faceplates. Fixtures are either mounted on or integrated to these frames for positioning and clamping of production parts. Pneumatic and electrical signals can be run to the fixtures if required. Depending on part size(s) and weight(s), single, multiple, or a combination of parts can be mounted to the fixture frame to provide a highly flexible system.

3.4.1 Part / Fixture Rating

The combined weight of the part(s) and fixture(s) on each side of the MRM2-550 reciprocating positioner is 550 pounds (1100 pounds total). The maximum offset load for the MRM2-550 is 375 pounds. The positioner will not sweep if the load on one side is more than 375 pounds heavier than the load on the other side.

The combined weight of the part(s) and fixture(s) on each side of the MRM2-1100 reciprocating positioner is 1100 pounds (2200 pounds total). The maximum offset load for the MRM2-1100 is 639 pounds. The positioner will not sweep if the load on one side is more than 639 pounds heavier than the load on the other side.

3.4.2 Swing Diameter

The maximum swing diameter for a part on the MRM2-550 positioner is 0.98 meters (approximately 37.4"). The maximum swing diameter for a part on the MRM2-1100 positioner is 1.1 meters (approximately 43.3").

3.4.3 Temperature Operating Range

40 - 110˚ Fahrenheit.

3.4.4 Humidity

Non-condensing 10 - 90% relative humidity.

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

used.

3.4.5 Shock Rating

Less than 0.5 G.

ArcWorld 6000 Operator's Manual Page 19 MOTOMAN

3.4.6 Sweep Speed

Torque Time

MRM2-550 1000 N.m 4 sec MRM2-1100 2000 N.m 5 sec

3.4.7 Servo Head Stock Speed

Torque Speed

MRM2-550 1050 N.m 0 - 16.8 rpm MRM2-1100 1050 N.m 0 - 16.8 rpm

3.4.8 Air Requirements

80 psi minimum.

3.4.9 Electrical Requirements

The MRC controller supplies the electrical power required to operate the 180˚ reciprocating positioners. These requirements consists of a 24 VDC interface circuit, and a 208 VAC, 6.2 amp circuit for the MRM2-550 motor and drive, or a 208 VAC, 9.0 amp circuit for the MRM2-1100 motor and drive.

3.4.10 Welding Current Rating

The MRM2 positioners have a welding current capacity of 700 amperes at 100% duty cycle. The welding ground system consists of a spring loaded copper brush that contacts a large ring mounted behind the surface of the faceplate. The ground cable to the welding power source is connected to the ground stud located on the right side of the positioner base when facing the back of the ArcWorld 6000 cell.

3.4.11 Locking Pins

The MRM2-1100 positioner has sweep lock drive pins and fixture locking pins for positioner Side A and Side B. There are two of each on the MRM2-1100. The sweep lock pins keep the sweep axis from turning while the servo advances and withdraws. The fixture locking pins are spring loaded, so when the servo withdraws, the pins engage. This keeps the headstock from turning when the servo motor retracts.

ArcWorld 6000 Operator's Manual Page 20 MOTOMAN

3.4.12 Arc Shield

The MRM2 positioners are provided with a sheet metal screen for arc radiation protection between the operator loading zone and the welding zone. Do not operate this equipment unless the arc shield is in place.

3.5 OP-STATION

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

ALARM

RESET

ROBOT HOLD

MASTER JOB

START

MOTOMAN

STATION READY

POSITIONER

AUTO/MAN

SERVO ON

ESTOP

OPERATOR STATION

ENABLE/DISABLE

WARNING!

CYCLE START

3.5.1 Emergency Stop

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

The operator station E-STOP, the robot E-STOP, the air pressure switch, the sliding door interlocks, and the ArcWorld 6000 safety mats are connected in series in the Emergency Stop circuit. If the E-Stop circuit is interrupted, the robots and the MRM2 positioner go into the E-Stop condition. The operator station E-STOP light comes on when the E-STOP button is pressed. In the E-Stop condition, power to the positioner interface is removed. This stops the positioner sweep.

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3.5.2 Hold

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

3.5.3 Cycle Start

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

3.5.4 Station Ready

The STATION READY lamp is interlocked with the robot CUBE #1 output. The robot Output #1 turns on the STATION READY lamp.

3.5.5 Alarm

The ALARM lamp is connected to the robot Alarm Occurrence output. The ALARM lamp turns on when one of the robots encounters a major or minor alarm condition. The ALARM lamp also lights when the positioner is not reset.

3.5.6 Servo On

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

3.5.7 Positioner Auto / Manual

The POSITIONER AUTO / MANUAL selector switch is used to select Automatic or Manual Mode for the MRM2 positioner. The selector switch is connected to robot Input #2. When the selector switch is in the Automatic position, the robots process the part after the positioner sweeps. In Manual Mode, the robot does not process the part after the positioner sweeps. This function is dependent on the

structure of the master job.

3.5.8 Master Job Start

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

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3.5.9 Operator Station Enable / Disable

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

3.5.10 Reset

The RESET pushbutton is connected to the robot alarm reset input. Any alarm or error condition will be cleared when this button is pressed. In addition, the RESET pushbutton and the RIGHT CYCLE START pushbuttons are interlocked and, when pressed simultaneously, enable the MRM2 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.

3.6 WELDING POWER SOURCE

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

3.6.1 Main Power

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

3.6.2 Volt / Amp Settings

The Welding Voltage / Amperes Control (2) adjusts the welding output and open circuit voltage. The Volt / Amp Meter and Switch (3) display either DC voltage or DC current depending on the position of the switch. Refer to your Excel-Arc manual for additional information.

3.6.3 Terminal Connectors

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

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3.6.4 Local / Remote Operation

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

Figure 3-5 Excel-Arc Controls

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3.6.5 Feeder Control Receptacles

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

3.6.6 Circuit Breakers

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

3.6.7 AC Receptacles

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

3.7 WELDING EQUIPMENT

In addition to the Excel-Arc power sources, the ArcWorld 6000 system provides a complete complement of arc welding equipment. In its standard configuration, the ArcWorld system includes the following:

• PWF-600 wire feeder

• UWI welding interface

• Either an air cooled or water cooled MIG torch

• Torch breakaway mount

3.7.1 PWF4 Wire Feeder

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

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.

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3.7.3 MIG Torch

The ArcWorld 6000 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 6000 includes a suitable water circulator kit.

3.7.4 RAM Breakaway Mount

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

3.8 SAFETY EQUIPMENT

The ArcWorld 6000 system incorporates a host of safety equipment. When all standard safety precautions are taken, the safety equipment helps to ensure safe operation of the robotic cell. The ANSI/RIA R15.06 Robot Safety Standard

stipulates the user is responsible for safeguarding.

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

The ArcWorld 6000 safety features include the following:

• Arc screens

• Safety fencing

• Dual interlocking cell door

• Interlocked safety mats

• Emergency stop (E-STOP) buttons

3.8.1 Arc Screens

Two separate arc screens are used on the ArcWorld 6000. 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 6000 Operator's Manual Page 26 MOTOMAN

➪

WARNING!

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

3.8.2 Fencing

The safety fencing provided with the ArcWorld 6000 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 operation. The interlocks consist of a pull plug and magnetic door switch. Opening the cell door with the robot in Play causes an E-Stop and shuts down the entire system.

3.8.4 Safety Mats

The safety mat provided with the ArcWorld 6000 helps prevent serious injury to anyone entering the positioner area during the sweeping process. If a person steps on this mat when the positioner is in motion, an E-Stop occurs causing the entire system to shut down.

3.8.5 Emergency Stops

In addition to the interlocking devices described above, the ArcWorld 6000 has strategically placed emergency stops (E-STOPS). These are operator actuated devices that, when activated, immediately cause the system to shut down. The following is a list of their locations:

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

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

• The positioner operator station has one E-STOP button. In addition, the following conditions also cause an emergency stop:

• Opening the cell door while the robot is in Play mode.

• Stepping on the safety mat while the positioner is sweeping.

• Loss of air system pressure.

• Activating the shock sensor.

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4.0 OPERATION

This section provides operation instructions for the ArcWorld 6000 system. Operation procedures include the following:

• System start up

• Part set up

• Normal operation

• Fault recovery

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

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

4.1 OPERATION

The ArcWorld 6000 is a fully integrated robotic MIG welding cell. The robot welds on one side of the 180˚ reciprocating positioner, while the operator loads parts on the opposite side. Once the robot is finished with its process, it return to the safe position. The operator can then initiate the positioner sweep enabling the robot to start welding on the next part.

The safety door interlocks prevent anyone from entering the cell while the robot is in Play Mode. If anyone steps on the safety mats in front of the part loading area during the positioner sweep, an E-Stop occurs.

4.1.1 Start Up

To start up the ArcWorld 6000 from a power off condition, proceed as follows:

1. Turn on the MRC disconnect.

2. Turn on the power source disconnect.

3. Set the INPUT POWER switch on the welding power source to ON. The pilot

light should glow.

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

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

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

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

lamp in the switch should light.

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

lamp in the switch should light.

9. Press the RESET button and the right CYCLE START button on the operator

station at the same time to initialize the positioner. The ALARM lamp goes off.

10. Use the programming pendant to move the robot to the starting position (CUBE 1 position).

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. Set the OPERATOR STATION ENABLE / DISABLE switch to the ENABLE position.

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

15. Wait for the STATION READY indicator to light.

The ArcWorld 6000 Cell is now ready for operation.

4.1.2 Loading / Unloading Procedures

The following is the typical sequence of operations for the ArcWorld 6000 Cell after startup:

1. Load production parts on the fixtures located on the operator side of the MRM2 positioner.

2. Step off the safety mats and wait for the STATION READY indicator to light.

3. Press both CYCLE START palm buttons on the operator station to sweep the positioner. This places the unwelded parts in the robot work envelope.

4. After the positioner sweeps, the robot begins the welding sequence on the parts. Coordinated motion capabilities allow programming to rotate the parts on the positioner, and weld or move the robot between welds at the same time.

5. Unload the welded parts from the fixture on the operator side.

6. Repeat Steps 1 through 5 to continue production.

4.1.3 Fault Recovery

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

4.1.4 E-STOP Recovery

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

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

• 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 MRM2 positioner is sweeping.

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

• Loss of air system pressure.

To restart the ArcWorld 6000 Cell after an E-Stop condition occurs, follow the procedure below.

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

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

pendant, or the MRC playback box.

• Close the sliding door and connect the safety plug.

• Step off the safety mat.

• Clear the Shock Sensor condition (refer to paragraph 4.1.5).

• Restore operating air pressure.

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

➪

CAUTION!

Make sure the robots are in a clear position to continue motion. A crash may occur if the robots cannot clear the part or fixtures when they resume motion.

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

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

The ArcWorld 6000 Cell will continue its operation.

4.1.5 Shock Sensor Recovery

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

To override the shock sensor, do the following:

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

ArcWorld 6000 Operator's Manual Page 30 MOTOMAN

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

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

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

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

Feeder Housing

Shock Sensor Cord

Torch Assembly

Breakaway

Shock Sensor Plug

Shock Sensor Jumper

Figure 4-1 Shock Sensor Override

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

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

➪

CAUTION!

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

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

3. Close the interlocked enclosure doors.

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

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

➪

CAUTION!

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

6. Press the MASTER JOB START button.

4.1.6 Shut Down

Use the following procedure to shut down the ArcWorld 6000 Cell after operation is complete:

1. Make sure the robot is in the starting position (CUBE 1 position).

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 source to the OFF position.

7. Turn off the power source disconnect.

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

The ArcWorld 6000 Cell is now shut down.

4.2 ALARMS AND ERRORS

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

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

4.2.1 Error Messages

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

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Errors like these are cleared by pressing the CANCEL or ENABLE 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:

• RELEASE soft key on the programming pendant

• RESET button on the operator's station

• ENABLE button on the programming pendant twice

4.2.3 Major Alarms

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

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

4.3 PROGRAMMING

The MRM2 positioner with its programmable axis offers a high degree of programming flexibility. The robot can be programmed to weld a part with the headstock stationary, or the robot and headstock can move simultaneously to weld a part while turning.

You can program the robots independently (R1 job), the station axis independently (S1 job), or robot and station axis together (R1 + S1). You must select the axis combination when teaching the job initially. We recommend programming the robot and station axis together (R1 + S1 jobs) to reduce the risk of interference.

➭

WARNING!

The positioner axis operates as another robot axis and has the potential of hazardous motion.

➭

CAUTION

If the robot is working on a part and the headstock is not turning, DO NOT assume that the headstock will not turn. The robot is

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executing programmed steps which could index the headstock at any time.

NOTE: The ArcWorld 6000 robot S-axis is restricted by hard stops on the robot base and internal soft

stops. Do not change.

4.3.1 Cube Assignment

The system uses the Cube #1 Output as an interlock for sweeping. This is a software zone around the tool center point (TCP). It should be defined with the robot clear of the positioner sweep motion. The Cube #1 Output can be viewed in diagnostics under Specified Outputs. To assign the K6 or K10 robot manipulator position to Cube #1, refer to your MRC User Functions and Operator's Manuals.

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4.3.2 Sweeping Positioner to Side A

NOTE: Before sweeping, make sure the weight of parts and fixturing is approximately equal on Sides

A and B of the positioner. (Refer to paragraph 3.4.1.)

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

To sweep the Motoman MRM2 positioner to Side A:

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

2. Make sure that the robot is in Cube #1 with the headstock in sweep position (marks on headstock lined up, refer to your positioner manual).

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

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

5. Press the MASTER JOB START button.

6. Press the CYCLE START palm buttons. The drive unit disengages the headstock and engages the sweep axis.

7. The sweep axis locking pin retracts and the MRC moves the external sweep axis (S1) 180˚ to align Side A.

8. The sweep locking pin engages.

9. The drive unit engages Side A.

When the positioner sweeps into position at Side A, the drive unit engages the headstock. IN #9 turns off. Side B faces towards the operator, and IN #10, FIX. B LOCK ON, turns on.

4.3.3 Sweeping Positioner to Side B

To sweep the Motoman MRM2 positioner to Side B:

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

2. Make sure that the robots are in Cube #1 with the headstock in sweep position (marks on headstock lined up, refer to your positioner manual).

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

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

5. Press the MASTER JOB START button.

6. Press the CYCLE START palm buttons. The drive unit disengages the headstock and engages the sweep axis.

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7. The sweep axis locking pin retracts and the MRC moves the external sweep axis (S1) 180˚ to align Side B.

8. The sweep locking pin engages.

9. The drive unit engages Side B.

When the positioner sweeps into position at Side B, the drive unit engages the headstock. IN #10 turns off. Side A faces towards the operator, and IN #9, FIX. A LOCK ON, turns on.

4.3.4 Rotating Headstock

To rotate the Motoman MRM2 headstock:

1. Enable the programming pendant.

2. Press the GROUP AXES key and make sure the key LED lights.

3. Press the X+ or X- keys to move the headstock. Jog speed is set on the programming pendant.

NOTE: The GROUP AXES key must be turned off to move the robots with the motion keys.

4.3.5 Programming

You can program three types of moves:

• Rotation of the positioner during air cut moves.

• Robot motion with positioner stationary.

• Rotation of the positioner during welding.

The job you create may consist of a combination of the above. The first two types of moves assume a robot plus station group axis specification (R1 + S1). The last type of move is called station synchronous and should be programmed with a station plus robot group axis specification (S1 + R1).

Rotating the Positioner During Air Cut Moves

1. Teach the robot to the desired position.

2. Rotate the positioner to the desired position. a. Press the GROUP AXES button on the programming pendant so LED is

on. b. Press MAN SPEED button to select the desired axis speed while teaching. c. Press the first set of motion keys, +X or -X, to move the axis in the desired

direction.

3. Record the step after designating the motion type and playback speed.

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4. Check the path with the STEP FWD/BWD keys. The position for the robot or positioner may have to be altered to prevent torch interference.

➭

WARNING!

The positioner axis operates as another robot axis and has the potential for hazardous motion.

NOTE: The GROUP AXES button must be turned off to move the robot.

NOTE: Normally, air cut moves are taught at Joint moves. The speed for Joint moves is specified as a

percentage of maximum speed (VJ=.01 - VJ=100.00). The axis which takes the longest time to complete the programmed motion automatically determines the speed of the system. This might be a wrist axis, a major robot axis, or the positioner axis. Cycle times can be reduced by changing wrist orientation, robot position, and headstock position simultaneously between program points rather than making the moves independently. Setting the speed at 100.00 will normally establish the quickest time between steps.

Robot Motion with the Positioner Stationary

1. Program the robot position without moving the positioner axis.

2. Set motion type and speeds in the normal fashion.

Rotation of the Positioner During Welding

The MRC controller can coordinate motion with the external axis. This requires calibration of the headstock and robot at the time of installation. Jobs programmed for coordinated motion must be taught as S1 + R1 jobs.

Move instructions for coordinated motion are registered using the following format:

Coordinated motion instruction

SMOVL=138 Slave side

(manipulator with torch)

MOVL Master side

(positioner with workpiece)

In coordinated motion instructions, an "S" prefixes the instruction to the slave side.

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Converting Programs from Side A to Side B

The positioner uses the external axis to sweep the positioner in addition to driving the headstock. This results in the external axis position being 180˚ offset from the other side. This offset amount can be determined from the difference in the external axis pulse counts at the two sweep positions. Software can be used to modify the position of the external axis in a job copied to run on the opposite side.

1. Determine the pulse count difference of the external axis between Side A and Side B.

2. Set the pulse count offset amount into an EX variable.

3. Make a copy of the original job. Designate the proper side in the original and copied job name.

4. Use the Modify Position (MODPOS) function to change the position of the external axis in the program.

5. Step through the new program to verify the path.

4.3.6 I/O Assignment

The ArcWorld 6000 positioner and 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#9 Fixture A Lock On IN#10 Fixture B Lock On IN#11 Servo Drive Return IN#12 Servo Drive Forward IN#13 In Position (on MRM2-550 only) IN#13 Sweep Lock On (on MRM2-1100 only) IN#14 Sweep Lock Off (on MRM2-1100 only)

MRC User Outputs

OUT#1 Station Ready interlocked with Cube #1 OUT#4 Wire Cutter (optional) OUT#9 Withdraw Servo OUT#10 Advance Servo

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OUT#11 Sweep Lock On (on MRM2-1100 only) OUT#12 Sweep Lock Off (on MRM2-1100 only) In order to sweep the positioner, the robot must be in Cube #1, and OUT#1 of the

master robot must be ON to enable the operator station.

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MRC Dedicated Inputs

• External Emergency Stop

• External Over Travel

• External Servo On

• External Hold

• Anti-Tie Down

• External Start

• Alarm Reset

MRC Dedicated Outputs

• Servo On

• Alarm Occurrence

• Teach Mode

• Cube #1

For more information on the Motoman MRC User and Dedicated I/O, refer to the MRC Controller I/O Structure Manual and MRC Dedicated I/O Guidelines Manual.

4.4 SAMPLE JOBS

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

4.4.1 Master Job (No Group Axes)

Line Step Function

000 000 NOP 001 CALL JOB:SWEEPTOA IF IN#(09)=ON 002 TIMER T=0.20 003 CALL JOB:SWEEPTOB IF IN#(10)=ON 004 END

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4.4.2 Sweep to A Job (R1 + S1)

Lines 009 through 011, and lines 013 and 014 in the job listing below apply to the systems using an MRM2-1100 positioner only.

Line Step Function

000 000 NOP 001 001 MOVJ P050 EX052 VJ=25.00

'Program position with robot at safe position in Cube #1 and headstock in sweep orientation.

002 DOUT OT#(1) ON

'Turn on Station Ready lamp on operator station.

003 WAIT IN#(01)=ON

'Wait for Cycle Start palm buttons.

004 WAIT IN#(09)=ON

'Verify that locking pin on Side A is engaged.

005 DOUT OT#(10) OFF

Turn off ADVANCE SERVO.

006 DOUT OT#(09) ON

'Turn on WITHDRAW SERVO to retract drive unit.

007 WAIT IN#(11)=ON

'Wait for SERVO DRIVE RTN input indicating the drive unit is fully retracted.

008 WAIT IN#(10)=ON

'Wait for FIX B LOCK ON input to verify that the locking pin has engaged the headstock.

009 DOUT OT#(11) OFF

'Turn off SWEEP LOCK ON output.

010 DOUT OT#(12) ON

'Turn on SWEEP LOCK OFF output to retract the locking pin from the sweep axis.

011 WAIT IN#(14)=ON

'Wait for SWEEP LOCK OFF input to verify the sweep locking pin has been retracted.

012 002 MOVJ P050 EX051 VJ=25.00 CONT

'The robot moves the external axis only, until Side A lines up with the drive unit and the sweep locking pins.

013 DOUT OT#(12) OFF

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'Turns off the SWEEP LOCK OFF output.

014 DOUT OT#(11) ON

'Turns on the SWEEP LOCK ON output. This is necessary to keep the sweep axis from turning.

015 WAIT IN#(13)=ON

'Wait for SWEEP LOCK ON input to verify that pin is engaged.

016 DOUT OT#(09) OFF

'Turn off WITHDRAW SERVO output.

017 DOUT OT#(10) ON

'Turn on ADVANCE SERVO output to send the drive unit forward to engage the headstock.

018 WAIT IN#(12)=ON

'Wait for SERVO DRIVE FORWARD input to verify the drive unit is fully forward.

019 WAIT IN#(09)=OFF

'Wait for FIX A LOCK ON input to go off and verify that the headstock locking pins have been retracted.

020 DOUT OT#(1) OFF

'Turn off the STATION READY lamp.

021 JUMP JOB:A-JOBS IF IN#(02)=ON

'Jump to the job for side A. It is important to use a job Jump and not a Call instruction. Use Input #2 as a jump condition. The job will execute only if the operator station

selector switch is set to AUTO. 022 RET 023 END

NOTE: The sweep positions are programmed in position variables. They are factory set and should not

require editing. Care should be taken not to use these variables in other programs. You can edit position variables from the file display.

ArcWorld 6000 Operator's Manual Page 42 MOTOMAN

4.4.3 Sweep to B Job

Lines 008 through 010, and lines 013 and 014 in the job listing below apply to the systems using an MRM2-1100 positioner only.

Line Step Function

000 000 NOP 001 001 MOVJ P050 EX051 VJ=25.00 002 DOUT OT#(1) ON 003 WAIT IN#(01)=ON 004 WAIT IN#(10)=ON 005 DOUT OT#(10) OFF 006 DOUT OT#(09) ON 007 WAIT IN#(11)=ON 008 DOUT OT#(11) OFF 009 DOUT OT#(12) ON 010 WAIT IN#(14)=ON 011 WAIT IN#(09)=ON 012 002 MOVJ P050 EX051 VJ=25.00 013 DOUT OT#(12) OFF 014 DOUT OT#(11) ON 015 WAIT IN#(13)=ON 016 DOUT OT#(09) OFF 017 DOUT OT#(10) ON 018 WAIT IN#(12)=ON 019 WAIT IN#(10)=OFF 020 DOUT OT#(1) OFF 021 CALL JOB:B-JOBS IF IN#(02)=ON 022 RET 023 END

ArcWorld 6000 Operator's Manual Page 43 MOTOMAN

4.4.4 Weld Side A Job (Multiple Weld Jobs)

➪

CAUTION!

Do not attempt to run programs from Side B on Side A.

The headstock position for jobs on Side B will be 180˚ off from programs on Side A. Refer to paragraph 4.3.5, Programming, for information on converting a Side B job to a Side A job.

Line Step Function

000 000 NOP 001 001 MOVJ VJ=100.00 CONT 002 CALL JOB:WELD1-A 003 CALL JOB:WELD2-A 004 CALL JOB:WELD3-A 005 CALL JOB:CLEAN IF B00=6 006 002 MOVJ VJ=100.00 CONT 007 RET 008 END

4.4.5 Weld Side A Job (Single Weld Job)

Line Step Function

000 000 NOP 001 001 MOVJ VJ=100.00 CONT 002 002 MOVJ VJ=100.00 CONT 003 003 MOVJ VJ=100.00 CONT 004 004 MOVC V=93.0 CONT 005 ASF #1 006 005 MOVC V=12.7 CONT 007 006 MOVC V=12.7 CONT 008 007 MOVC V=12.7 CONT 009 AEF #1 010 008 MOVJ VJ=50.00 CONT 011 009 MOVJ VJ=100.00 CONT

ArcWorld 6000 Operator's Manual Page 44 MOTOMAN

012 INC B00 013 RET 014 END

4.4.6 Weld Side B Job

➪

CAUTION!

Do not attempt to run programs from Side B on Side A.

Line Step Function

000 000 NOP 001 001 MOVJ VJ=100.00 CONT 002 CALL JOB:WELD1-B 003 CALL JOB:WELD2-B 004 CALL JOB:WELD3-B 005 CALL JOB:CLEAN IF B00=6 006 002 MOVJ VJ=100.00 CONT 007 RET 008 END

ArcWorld 6000 Operator's Manual Page 45 MOTOMAN

4.4.7 Clean Job (R1 Job)

Line Step Function

000 000 NOP 001 001 MOVJ VJ=100.00 CONT 002 002 MOVJ VJ=100.00 CONT 003 003 MOVJ VJ=100.00 CONT 004 004 MOVL V=187.0 CONT 005 TIMER T=1.50 006 005 MOVL V=187.0 CONT 007 006 MOVL V=187.0 CONT 008 007 MOVL V=187.0 CONT 009 TIMER T=1.00 010 008 MOVL V=187.0 CONT 011 009 MOVL V=166.7 CONT NWAIT 012 PULSE OT#(63 T=0.50 013 010 MOVL V=187.0 CONT 014 PULSE OT#(13 T=0.50 015 011 MOVL V=46.0 CONT 016 012 MOVJ VJ=100.00 CONT 017 SET B00=0 018 RET 019 END

➪

CAUTION!

Robot will operate independently of the external axis. Be sure the robot points are clear of the positioner and fixture.

NOTE: This program will operate on Side A or Side B because there are no external axis positions

NOTE: Steps 11 through 15 are for the optional wire cutter.

ArcWorld 6000 Operator's Manual Page 46 MOTOMAN

5.0 MAINTENANCE

5.1 PERIODIC MAINTENANCE

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

For additional maintenance information regarding the reciprocating positioners, refer to your positioner 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 6000 cell. Keep in mind that the maintenance intervals given serve as guidelines only, you should adjust the frequency of maintenance to suit your specific work conditions.

➪

CAUTION!

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

Table 5-1 Periodic Maintenance

Frequency Component Procedure

Regularly MRM2-550 servo

headstock RV drive unit

Check for proper grease levels and quality. Use Epinoc APO grease (Motoman P/N 132434-1) as required.

Daily Water circulator

(water-cooled torch application only)

Check the fluid in the water circulator. Add fluid as required. Use the approved antifreeze (Motoman P/N 131224-1) and distilled water.

Daily Air system water

trap on the front of MRM2 positioner

Check water trap and empty if required.

ArcWorld 6000 Operator's Manual Page 47 MOTOMAN

Table 5-1 Periodic Maintenance (Continued)

Frequency Component Procedure

Monthly MRM2 weld

grounds

Lubricate with Burndy Penetrox E conductive copper lubricant (part no. PEN-E-8).

500 operating hrs MRM2 drive pins

and locking pins

Spray the drive and locking pins with a molycote BR2 grease or equivalent.

1000 operating hrs MRM2 positioner

gears

Lubricate with Shell 1029 or equivalent.

20,000 operating hrs MRM2-550 servo

headstock RV drive

Change the grease in the drive unit. Use Epinoc APO grease (Motoman P/N 132434-1).

20,000 operating hrs MRM2-1100 servo

headstock Cyclo drive unit

Change the grease in the drive unit. Use Shell Alvania RA.

5.2 SPARE PARTS LIST

Table 5-2 Spare Parts

Description Part No. AW 6000 safety mat kit 130157-5 Positioner interface 4-pole relay, 24 VDC 470108-5 Positioner interface fuse, 2 A 250 V 400647-3 Positioner interface fuse, 1/2 A 250 V 130293-2 Valve, 2-way (FESTO) JMVH-51/8 B

ArcWorld 6000 Operator's Manual Page 48 MOTOMAN

5.3 FUSE AND CIRCUIT BREAKER PROTECTION

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

➪

WARNING!

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

Abbreviations:

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

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

Device

Designator Rating Part Number Location Purpose

CB1 10A

115V

203627-7 Upper rear panel Protect 115V circuit

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

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

circuit

Table 5-4 MRC Cabinet Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

(1MCCB)

50 A

30 A

NF50-SS

NF30-SS

Upper left front K10

Upper left front K6

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

ArcWorld 6000 Operator's Manual Page 49 MOTOMAN

CB (1SV) 15 A

20 A

Under PC servo board (K10)

Lower servo pack edge (K6)

Protects input for servo pack 1SV for S axis

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

Device

Designator Rating Part Number Location Purpose

CB (2SV) 15 A

20 A

Under PC servo board (K10)

Lower servo pack edge (K6)

Protects input for servo pack 2SV for L axis

CB 15 A Under PC servo

board

Protects input for servo pack 3SV for U axis

CB 10 A Under PC servo

board

Protects input for servo pack 4SV for R axis

CB 10 A Under PC servo

board

Protects input for servo pack 5SV for B axis

CB 10 A Under PC servo

board

Protects input for servo pack 6SV for T axis

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

ArcWorld 6000 Operator's Manual Page 50 MOTOMAN

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

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

Device

Designator Rating Part Number Location Purpose

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

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

FU1 3 A SM1101 MBB-02 External voltage

protection - 24V

FU2 3 A SM1101 MBB-02 External voltage

protection - 24V

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

Device

Designator Rating Part Number Location Purpose

F1 8A 250V On KXA motor

speed control

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

FU1 4A 250V Wickman

19374K-4A

On interface board

Protects 115V circuit

FU2 .25A

125V

Wickman 19303K250A

On interface board

Protects shock sensor circuit

FU3 .5A 125V Wickman

19303K500A

On interface board

Protects 24V circuit

ArcWorld 6000 Operator's Manual Page 51 MOTOMAN

Table 5-6 COMARC III Fuses and Circuit Breakers

Device

Designator Rating Part Number Location Purpose

Fuse 1A 250V TD-1 Front of

COMARC box

Protect 200V circuit

ArcWorld 6000 Operator's Manual Appx. A MOTOMAN

APPX. A RISK ASSESSMENT

Risk Assessment Page 1 MOTOMAN ArcWorld 6000

MOTOMAN Risk Assessment

ArcWorld 6000 System

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

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

MOTOMAN's ArcWorld 6000 robot cell.

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

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

SAFEGUARDING PERSONNEL

Safeguarding Plant Personnel

• Barrier around robot work envelope.

• Interlocked gate for access to cell.

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

• Serious hazards are identified by warning labels.

Safeguarding Operator

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

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

defeat.

• Emergency Stop button on operator station.

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

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

activated. Requires reset at operator station to restart.

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

Risk Assessment Page 2 MOTOMAN ArcWorld 6000

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

operation.

Safeguarding Teacher

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

• Clearance of 24" between robot and fencing.

• Emergency Stop button on programming pendant.

• S-axis motion restricted by hardstops.

• TEACH LOCK prevents operation from controller while programming

pendant is enabled.

• Sweeping of positioner from pendant requires deliberate action.

• Continuous stepping is at reduced speed.

Safeguarding Maintenance Personnel

• Robot controls are outside barrier.

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

troubleshoot.

• Electrical energy sources equipped with lockout/tagout.

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

SOURCES OF HAZARDS

Unauthorized Access

• Interlocked barrier.

• Dual interlocks, difficult to defeat by operator.

Human Errors in Judgment

• Safety mat interlocked with positioner.

• Dual palm cycle start.

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

pendant.

Control Errors

• Most Safety features independent of program logic.

Risk Assessment Page 3 MOTOMAN ArcWorld 6000

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

Risk Assessment Page 4 MOTOMAN ArcWorld 6000

Mechanical / Electrical Failures

• Safety mat supplied with fail-safe circuit.

• Redundant door interlocks.

• Interlocks designed to fail-safe.

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

positioning error.

Environmental

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

violet radiation.

• UV curtain helps contain welding sparks.

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

determined and provided by USER.)

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

supplied.)

Installation Defects

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

connected.

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

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

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

Power System Failure or Inadvertent Power Initiation

• Easy recovery from power failure.

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

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

EQUIPMENT PROTECTION

Risk Assessment Page 5 MOTOMAN ArcWorld 6000

Human Errors

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

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

can index.

Power Faults

• Isolation transformer and circuit breaker protect robot from power surges.

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

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

WHAT-IF CONSIDERATIONS

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

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

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

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

ArcWorld 1000 Operator's Manual Appx. B MOTOMAN

APPX. B SYSTEM OUTLINE

This section contains the following outline drawings:

Drawing Number Title Sheet Number

131929 Cell Layout Sheet 1 of 19 131929 Main Bill of Material Sheet 2 of 19 131929 Cell Layout Sheet 17 of 19 131929 Cell Layout Sheet 18 of 19 131929 Cell Layout Sheet 19 of 19

ArcWorld 6000 Operator's Manual Appx. C MOTOMAN

APPX. C ELECTRICAL DRAWINGS

This section contains the following electrical drawings:

Drawing Number Title Sheet Number

131929 Power Distribution Sheet 3 of 19 131929 MRC I/O, MRY01 Board Sheet 4 of 19 131929 MRC I/O, MEW01 Board Sheet 5 of 19 131929 MRC I/O, MI004 Board Sheet 6 of 19 131929 MRC I/O, MI004 Board Sheet 7 of 19 131929 MRC I/O, MI003 Board Sheet 8 of 19 131929 MRC I/O, MI003 Board Sheet 9 of 19 131929 MRC I/O, MI003 Board Sheet 10 of 19 131929 MRC I/O, MI003 Board Sheet 11 of 19 131929 Cable Layout Sheet 12 of 19 131929 Ladder Diagram Sheet 13 of 19 131929 Ladder Diagram Sheet 14 of 19 131929 Ladder Diagram Sheet 15 of 19 131929 Ladder Diagram Sheet 16 of 19 131093 MSV01 to Servopack Sheet 1 of 1 131982 MRC to EXSB Sheet 1 of 1 131438 2.2KW Power Cable Sheet 1 of 1 131437 EXSB to Positioner Sheet 1 of 1 131094 MRC to Positioner Sheet 1 of 1 131413 Encoder Pigtail Cable Sheet 1 of 1 132366 Bill of Materials Sheet 1 of 2 132366 Circuit Diagram Sheet 2 of 2 130161 Connection/Schematic Diagram Sheet 6 of 7

ArcWorld 6000 Operator's Manual Appx. D MOTOMAN

APPX. D MECHANICAL DRAWINGS

This section contains the following mechanical drawings:

Drawing Number Title Sheet Number

130930 AC Servo Drive Sheet 1 of 1 130102 MRC ArcWorld Sheet 2 of 2 130157 Safety Mat Sheet 5 130161 Station, Operator Sheet 1 of 7 130161 Station, Operator Sheet 2 of 7

ArcWorld 6000 Operator's Manual Index 1 MOTOMAN

INDEX

About This Document, 1 AC Receptacles, 22 Air Requirements, 17 Alarm / Error, 13 Alarm, 19 Alarms and Errors, 29 Arc Screens, 23 Arc Shield, 18

Circuit Breakers, 22 Clean Job (R1 Job), 41 Coordinate System Indicators, 15 Cube Assignment, 30 Customer Service Information, 4 Cycle Select, 13 Cycle Start, 19

Description of Equipment, 11 Display, 15

ArcWorld 6000 Operator's Manual Index 2 MOTOMAN

ArcWorld 6000 Operator's Manual Index 3 MOTOMAN

E-Stop Recovery, 26 Electrical Requirements, 17 Emergency Stop, 13, 15, 18 Emergency Stops, 24 Error Messages, 29 Excel-Arc Controls, 21

Fault Recovery, 26 Feeder Control Receptacles, 21 Fencing, 23 Fuse and Circuit breaker Protection, 44

General Safeguarding Tips, 7

Hold, 13, 18 Humidity, 16

I/O Assignment, 34

ArcWorld 6000 Operator's Manual Index 4 MOTOMAN

Installation Safety, 8 Interlocks, 24 Introduction, 1

K-Series Robot Description, 11 Keypad, 15

Loading / Unloading Procedures, 26 Local / Remote Operation, 20 Locking Pins, 17

Main Power, 20 Maintenance, 42 Maintenance Safety, 10 Major Alarms, 30 Master Job (No Group Axes), 35 Master Job Start, 19 Mechanical Safety Devices, 7 MIG Torch, 22 Minor Alarms, 29 Mode Select, 13 MRC Controller, 11, 12

ArcWorld 6000 Operator's Manual Index 5 MOTOMAN

MRC Playback Box, 12 MRM2-Series Positioner, 15

ArcWorld 6000 Operator's Manual Index 6 MOTOMAN

Op-Station, 18 Operation, 25 Operation Safety, 9 Operator Control Panel (Op-Station), 18 Operator Station Enable / Disable, 19 Optional Equipment, 3

Part / Fixture Rating, 16 Periodic Maintenance, 42 Playback Box Sub-Panel, 13 Positioner Auto / Manual, 19 Programming, 30, 32 Programming Pendant, 14 Programming Safety, 8 PWF4 Wire Feeder, 22

RAM Breakaway Mount, 23 Reference to Other Documentation, 4 Reset, 20 Robot Speed Indicators, 15 Rotating Headstock, 32

ArcWorld 6000 Operator's Manual Index 7 MOTOMAN

ArcWorld 6000 Operator's Manual Index 8 MOTOMAN

Safety, 5 Safety Equipment, 23 Safety Mats, 24 Sample Jobs, 35 Servo Head Stock Speed, 17 Servo On, 19 Servo Power, 12, 15 Shock Rating, 16 Shock Sensor Override, 28 Shock Sensor Recovery, 27 Shut Down, 29 Spare Part List, 43 Standard Conventions, 6 Start, 13 Start Up, 25 Station Ready, 19 Sweep Speed, 17 Sweep to A Job (R1 + S1), 36 Sweep to B Job, 38 Sweeping Positioner to Side A, 31 Sweeping Positioner to Side B, 31 Swing Diameter, 16 System Layout, 2, 3 System Overview, 1

ArcWorld 6000 Operator's Manual Index 9 MOTOMAN

ArcWorld 6000 Operator's Manual Index 10 MOTOMAN

Temperature Operating Range, 16 Terminal Connectors, 20

Universal Welding Interface (UWI), 22

Volt / Amp Settings, 20

Weld Side A Job (Multiple Weld Jobs), 39 Weld Side A Job (Single Weld Job), 39 Weld Side B Job, 40 Welding Current Rating, 17 Welding Equipment, 22 Welding Power Source, 20

motoman robotics 6000 Operators Manual

Specifications and Main Features

Frequently Asked Questions

User Manual