motoman robotics 6200 Operators Manual

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MRC Controller

ArcWorld 6200 Two-Controller Operator's Manual

for SK-Series Robots

Part Number 133676-8 Revised 9/13/99

February 27, 1997

MOTOMAN

805 Liberty Lane

West Carrollton, OH 45449

TEL: 937-847-6200 FAX: 937-847-6277

24-HOUR SERVICE HOTLINE: 937-847-3200

The information contained within this document is the proprietary property of Motoman, Inc., and

may not be copied, reproduced or transmitted to other parties without the expressed written

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

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

authorization of Motoman, Inc.

TABLE OF CONTENTS

Section Page

LIST OF FIGURES ................................................................................................. iv

LIST OF TABLES................................................................................................... iv

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

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

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

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

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

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

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 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

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

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

ArcWorld 6200 Two-Controller Operator's Manual Page i MOTOMAN

Section Page

3.4 MRM2-SERIES POSITIONERS.......................................................... 15

3.4.1 Welding Ground System........................................................... 17

3.4.2 Locking Pins............................................................................ 17

3.4.3 Arc Shield............................................................................... 17

3.5 OPERATOR STATION ........................................................................ 18

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

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

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

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

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

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

3.5.7 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............................................................... 21

3.6.4 Local/Remote Operation........................................................... 21

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

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

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

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

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

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

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

3.7.4 Tregaskiss Gun Mount ............................................................ 22

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

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

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

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

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

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

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

4.1 OPERATING PROCEDURES.............................................................. 25

4.1.1 Start-up.................................................................................. 25

ArcWorld 6200 Two-Controller Operator's Manual Page ii MOTOMAN

Section Page

4.1.2 Normal Operating Procedures................................................. 26

4.1.3 Emergency Stop Recovery....................................................... 26

4.1.4 Shock Sensor Recovery........................................................... 27

4.1.5 Fault Recovery........................................................................ 28

4.1.6 Shutdown................................................................................ 28

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

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

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

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

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

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

4.3.2 Sweeping Positioner to Side A.................................................. 30

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

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

4.3.5 Programming Specific Jobs...................................................... 32

4.3.6 Rotating the Positioner During Air Cut Moves ......................... 32

4.3.7 Robot Motion with the Positioner Stationary............................ 33

4.3.8 Rotation of the Positioner During Welding................................ 33

4.3.9 Converting Programs from Side A to

Side B—Master Robot Only............................................... 33

4.3.10 I/O Assignment....................................................................... 34

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

4.4.1 Master Controller—Master Job............................................. 35

4.4.2 Master Controller—Cube Job................................................. 36

4.4.3 Master Controller—SweepToA Job........................................ 36

4.4.4 Master Controller—SweepToB Job........................................ 37

4.4.5 Master Controller—WeldA Job.............................................. 38

4.4.6 Master Controller—WeldB Job.............................................. 39

4.4.7 Slave Controller—Cube Job.................................................... 40

4.4.8 Slave Controller—WeldA Job.................................................. 40

4.4.9 Slave Controller—WeldB Job................................................. 41

5.0 MAINTENANCE.......................................................................................... 43

5.1 PERIODIC MAINTENANCE............................................................... 43

5.2 SPARE PARTS LIST............................................................................ 44

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

APPENDIX — RISK ASSESSMENT ....................................................... Appendix–1

INDEX

ArcWorld 6200 Two-Controller Operator's Manual Page iii MOTOMAN

LIST OF FIGURES

Figure Page

Figure 1-1 System Layout, Top-Down View............................................................ 2

Figure 3-1 MRC Controller................................................................................ 11

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

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

Figure 3-4 Operator Station................................................................................ 18

Figure 3-5 MotoArc Controls............................................................................. 20

LIST OF TABLES

Table Page

Table 3-1 MRM2-550 (RM2-250) Positioner Specifications............................... 16

Table 3-2 MRM2-1100 (RM2-500) Positioner Specifications............................. 16

Table 3-3 MRM2-1650 (RM2-750) Positioner Specifications............................. 17

Table 5-1 Periodic Maintenance......................................................................... 43

Table 5-2 Spare Parts....................................................................................... 44

Table 5-3 MotoArc 450 CV Fuses and Circuit Breakers..................................... 44

Table 5-4 MRC Cabinet Fuses and Circuit Breakers........................................... 45

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

Table 5-6 MRC System Fuses............................................................................ 46

Table 5-7 Com-Arc III Fuses and Circuit Breakers............................................ 46

ArcWorld 6200 Two-Controller Operator's Manual Page iv MOTOMAN

1.0 INTRODUCTION

The ArcWorld 6200 Two-Controller system 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 6200 features two Motoman arc welding robots, two MRC controllers with menu-driven arc welding application software, two complete welding packages, a 180˚ reciprocating positioner, an operator interface, and a total safety environment.

1.1 ABOUT THIS DOCUMENT

This manual provides operation instructions for the ArcWorld 6200 TwoController system. In addition to this introduction, the manual includes the following sections:

• SECTION 2: SAFETY

Provides information regarding the safe use and operation of the ArcWorld 6200 system.

• SECTION 3: DESCRIPTION OF EQUIPMENT

Provides a detailed description of the major components of the ArcWorld system. This section includes a table of component specifications.

• SECTION 4: OPERATION

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 shutdown. This section also contains a number of sample robot programs.

• SECTION 5: MAINTENANCE

Contains a table listing periodic maintenance requirements for the ArcWorld 6200 cell. It also includes a list of recommended spare parts.

• APPENDIX

The Appendix is a Risk Assessment document.

1.2 SYSTEM OVERVIEW

The ArcWorld 6200 Two-Controller system provides a complete arc welding solution in a standardized configuration. The system is designed around two Motoman arc welding robots and two MRC controllers, and includes two complete welding packages. A dual station reciprocating 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.

ArcWorld 6200 Two-Controller Operator's Manual Page 1 MOTOMAN

1.2.1 System Layout

Figure 1-1 shows a top-down view of the system layout for the ArcWorld 6200 Two-Controller cell.

Master Robot

Assembled Safety Fence

T orch T ender

MotoArc Welding Power Source

Disconnect

Master Controller MRC Cabinet

Water Circulator

Slave Controller MRC Cabinet

Cell Door

MotoArc Welding Power Source

Com-Arc III

Auxiliary Equipment Common Base

Slave Robot

T orch T ender

Gas Bottles (customer supplied)

Positioner

Operator Station

Safety Mat

Figure 1-1 System Layout, Top-Down View

The ArcWorld 6200 Two-Controller cell includes the following major components:

• Two Motoman robot manipulators

• Two MRC controllers

• MRM2-series dual station reciprocating positioner

• Master operator station

• Welding equipment, including the following: — Two MotoArc welding power sources — Two torches (water-cooled or air-cooled)

ArcWorld 6200 Two-Controller Operator's Manual Page 2 MOTOMAN

— Two wire feeders — Two universal welding interfaces (UWIs) — Two Tregaskiss gun mounts

• 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. Each MRC controller shares a common base with its welding power source. Additional auxiliary components, such as the water circulator and the Com-Arc III seam tracking unit, can be located on the bases with the controllers.

NOTE: Arc shield on positioner and arc curtains not shown for clarity.

The robotic cell is fully enclosed by safety fencing and is entered only through an interlocking door. Safety mats prevent the positioner from cycling while anyone is standing directly on the mats. All operator controls, including those on the MRC and welding power supply, are accessible from outside of the safety fencing that encloses the robotic cell.

1.2.2 Optional Equipment

The following optional equipment is available for use with the ArcWorld 6200:

• Torch tender

• Wire cutter

• Com-Arc III through-the-arc seam tracking unit

• Heavy duty positioners

• Stationary tables

1.3 REFERENCE TO OTHER DOCUMENTATION

For additional information refer to the following:

• Motoman SK6 Manipulator Manual (P/N 133680-2)

• Motoman SK16 Manipulator Manual (P/N 133680-3)

• Motoman MRC Operator’s Manual for Arc Welding (P/N 132332-1)

• Motoman MRC User Functions Manual (P/N 132331-1)

• Motoman ArcWorld 6200 Installation Manual (P/N 133677-8)

• Motoman MRC Operator’s Manual for Jigless (P/N 132332-3)

• Com-Arc III Instruction Manual (P/N 132753-1)

• Vendor manuals for system components not manufactured by Motoman

ArcWorld 6200 Two-Controller Operator's Manual Page 3 MOTOMAN

1.4 CUSTOMER SERVICE INFORMATION

If you need technical assistance, contact the Motoman service staff at (937) 847-3200. Please 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 (welding)

• Order Numbers (located on back side of robots and MRC controllers)

ArcWorld 6200 Two-Controller Operator's Manual Page 4 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 (Section 2.1)

• General Safeguarding Tips (Section 2.2)

• Mechanical Safety Devices (Section 2.3)

• Installation Safety (Section 2.4)

• Programming Safety (Section 2.5)

• Operation Safety (Section 2.6)

• Maintenance Safety (Section 2.7)

ArcWorld 6200 Two-Controller Operator's Manual Page 5 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 personnel and 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 6200 Two-Controller Operator's Manual Page 6 MOTOMAN

2.2 GENERAL SAFEGUARDING TIPS

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:

• Improper operation can result in personal injury and/or damage to 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 automatic operation. Programmers must have the teach pendant when they enter the robot 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.

• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use lockout/tagout procedures during equipment maintenance. Refer also to Section

1910.147 (29CFR, Part 1910), Occupational Safety and Health Standards for General Industry (OSHA).

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, ANSI/RIA R15.06 safety standards, 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 following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. Installation tips are as follows:

• Be sure that only qualified personnel familiar with national codes, local codes, and ANSI/RIA R15.06 safety standards are permitted to install the equipment.

• 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

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

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

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

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

ArcWorld 6200 Two-Controller Operator's Manual Page 8 MOTOMAN

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

• Be sure that all safeguards are in place.

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

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

• Be sure 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

• Be sure 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.

• 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 automatic operation. Programmers must have the teach pendant when they enter 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. This includes controller parameters, ladder parts 1 and 2, and I/O (Input and Output) modifications. Check and test all changes at slow speed.

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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 automatic operation. Programmers must have the teach pendant when they enter the cell.

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

• Be sure 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 6200 Two-Controller Operator's Manual Page 10 MOTOMAN

3.0 DESCRIPTION OF EQUIPMENT

3.1 SK-SERIES ROBOT DESCRIPTION

The Motoman SK6 and SK16 robots and MRC controller represent state-of-theart 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 replacement life for the lithium battery is approximately three years.

3.2 MRC CONTROLLER

The MRC controller (see Figure 3-1) coordinates the operation of the ArcWorld system. It controls the movement of the manipulator, processes input and output signals, controls the operation of the welding power supply, and provides the signals to operate the welding system. The ArcWorld 6200 Two-Controller system is configured so that each controller directs the action of its respective robot.

PROGRAMMING PENDANT

SERVO POWER

YASNAC MRC

MODE

CYCLE

E.STOP

REMOTETEACHPLAY

1 CYCLE

STEP

AUTO

ALARM/ ERROR

HOLD

PLAYBACK BOX

START

WARNING

480 VOLTS

Figure 3-1 MRC Controller

ArcWorld 6200 Two-Controller Operator's Manual Page 11 MOTOMAN

The Master controller coordinates the operation of the entire cell and directs the action of the Master robot manipulator. The Slave controller directs the action of the Slave robot manipulator. The Master controller delegates tasks to the Slave controller and monitors task completion by sending output to and receiving output from the Slave controller.

The playback box (see Figure 3-2) has the primary system controls for the MRC. Control buttons are grouped on the front panel and the subpanel. The following paragraphs describe the MRC controls.

SERVO

POWER

3.2.1 Servo Power

On each MRC, the SERVO POWER button on the front panel turns on the robot servo power to the robot controlled by that controller. An indicator lamp in the switch lights when servo power is on. The SERVO POWER button on one controller does NOT turn on servo power to the other controller or its robot. Only by pressing the SERVO ON button on the operator station can you turn on servo power of both the Master and Slave controllers at the same time.

SERVO POWER

MODE

BUTTONS

MODE

REMOTETEACHPLAY

CYCLE

BUTTONS

CYCLE

1 CYCLE

AUTO

STEP

ALARM/ ERROR

HOLD

ALARM/ERROR INDICATOR

Figure 3-2 MRC Playback Box

E.STOP

HOLD BUTTON

E-STOP

START

BUTTON

3.2.2 Mode Select

The MODE SELECT buttons (PLAY, TEACH, and REMOTE) set the robot’s mode of operation. Indicator lamps light to show the current mode of operation. Pressing the TEACH or REMOTE button on one controller will also place the other MRC controller into the TEACH or REMOTE mode. The PLAY mode button on the Slave controller has been disabled to allow for a single point of control and added safety; however, pressing the PLAY mode button on the Master controller WILL place the Slave controller into the PLAY mode. Refer to your MRC Operator’s Manual for more information.

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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. These buttons need to be set individually on each MRC controller. In other words, pressing the AUTO switch on one controller does NOT place the other controller into the AUTO cycle mode. These buttons should typically be set the same on both controllers. 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 on EITHER CONTROLLER immediately cuts servo power and engages the brakes on BOTH ROBOTS and the positioner.

3.2.5 Alarm/Error

The ALARM/ERROR indicator lights whenever an alarm or error condition occurs. The indicator also lights when servo power is cut to the system, as in the case of an E-STOP condition. After you reset the alarm or error condition or restore servo power, the indictor lamp turns off.

3.2.6 Hold

Pressing the HOLD button on EITHER CONTROLLER stops the operation of BOTH robot manipulators and the positioner momentarily. The indicator lamps light whenever the robots are in a HOLD state. The RESET button on the operator station must be pressed to clear the HOLD state. Then the MASTER JOB START button on the operator station must be pressed in order to start both robots at the same time. Operation will resume at the point in the program where the HOLD state was initiated. The HOLD button is normally closed. Refer to your MRC Operator’s Manual for more information.

CAUTION!

If instead of pressing the MASTER JOB START button on the operator station, you press the green START button on either playback box, only that robot will start. This could lead to a possible crash with the other robot.

3.2.7 Start

Pressing the START button on one MRC controller causes the manipulator playback operation to start ONLY for that controller. In other words, pressing the START button on the Master controller will NOT cause the Slave controller to start and vice versa. The indicator lamp lights during playback. The MASTER JOB START button on the operator station is used to start both controllers at the same time. This is explained later in the manual.

3.2.8 Playback Box Subpanel

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

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3.3 PROGRAMMING PENDANT

The programming pendant (see 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 the robot a series of motions and perform programming, editing, maintenance, and diagnostic functions. The pendants for both the Master and Slave manipulators can be programmed at the same time, reducing the time needed to teach jobs to the manipulators.

COORDINATE

SYSTEM

INDICATORS

SERVO

POWER ON

COORD

USER

YASNAC MRC

JOINT WLD

CYL TOOL

SERVO POWER ON

DISP EDIT SELECT

GROUP

AXIS

ENABLE

X- X+

Y-

Z-

GROUP

AXIS

MODIFY

CANCEL

MOTION

TYPE

S-

L- L+

U-

RELEASE

DELETE

PLAY

SPD

S+

Y+ Z+

U+

HOLD

TEACH AUTO

HIGH

COORD

SPD

TEST

START

INSERT MODIFY

WEAV ON

WEAV OFF

TIMER

POS

REF PNT

LVL

F4 F5

FUNC

SLW FST

R-

B- B+

T-

BWD

ARC ON FEED

ARC OFF RETRACT

VOLT

STOP

CUSTOMER

MAN SPD

R+

T+

FWD

ENTER

E.STOP

9 6 3

CUR

DISPLAY

MAN SPD

FST

MED

SLW

INCHING

ROBOT

SPEED

INDICATORS

E-STOP

KEYPAD

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 (Manipulator Speed) indicators light to show the speed of the selected robot manipulator. SLW indicates slow speed and FST indicates fast.

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3.3.3 Emergency Stop

The E-STOP button is connected to the system Emergency Stop circuit. Interrupting the Emergency Stop circuit from EITHER PENDANT causes BOTH robots to go into the Emergency Stop condition. Pressing the E-STOP button on EITHER PENDANT immediately cuts servo power and engages the brakes on BOTH robots and on the positioner.

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 button switch turns on the robot servo power. An indicator lamp in the switch lights when servo power is on. The SERVO POWER button on one controller will NOT turn on servo power to the other MRC controller.

NOTE: The SERVO POWER button on the Master controller also turns on servo power to

the positioner.

3.3.6 Coordinate System Indicators

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

3.4 MRM2-SERIES POSITIONERS

The ArcWorld 6200 cell uses one of three different reciprocating positioners: the MRM2-550 (RM2-250), the MRM2-1100 (RM2-500), or the MRM2-1650 (RM2-750). 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 (RM2-250) positioner is 2.6 meters (approximately 102 in.). The standard distance between the headstock and tailstock faceplates on the MRM2-1100 (RM2-500) and MRM2-1650 (RM2-750) positioners is 3.0 meters (approximately 118 in.).

Tables 3-1, 3-2, and 3-3 provide specifications for the MRM2-550, MRM2-1100, and MRM2-1650 positioners, respectively. The load side of the positioner is fixed for loading and unloading parts. The patented servo motor is used to sweep the positioner workstations into and out of the robot envelope, and also to turn the weld side of the positioner during welding.

A fixture frame is typically mounted between the headstock and tailstock faceplates to provide a highly flexible system. 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), you can mount single, multiple, or a combination of parts to the fixture frame.

The ArcWorld 6200 system is capable of synchronized motion between the Master robot and the positioner only; the Master robot and positioner move at the same time to do the welding. The system is also capable of coordinated motion between the Master robot and the positioner only, where the positioner rotates the parts while the Master robot does the welding. The Slave controller is not coordinated with the positioner or with the Master robot.

ArcWorld 6200 Two-Controller Operator's Manual Page 15 MOTOMAN

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

Table 3-1 MRM2-550 (RM2-250) Positioner Specifications

Capacity

Maximum Weight Differential per Side

Swing Diameter Temperature Operating

Range Humidity Shock Rating Sweep Speed

(Torque/Time) Servo Headstock Speed

(Torque/ Speed) Air Requirements Electrical Requirements

Welding Current Rating

249.5 kg (550 lbs) combined part/fixture weight per side 499 kg (1100 lbs) total

190.6 kg (375 lbs)

0.98 m (37.4 in.) 4–43°C (40–110°F)

Non-condensing 10–90% relative humidity Less than 0.5 G 1000 Nm/4 sec.

1050 Nm/0 - 16.8 rpm

80 psi 24 VDC for interface

208 VAC, 6.2 amp Positioner power supplied by the MRC controller

700 amperes at 100% duty cycle

Table 3-2 MRM2-1100 (RM2-500) Positioner Specifications

Capacity

Maximum Weight Differential per Side

Swing Diameter Temperature Operating

Range Humidity Shock Rating Sweep Speed

(Torque/Time) Servo Headstock Speed

(Torque/ Speed) Air Requirements Electrical Requirements

Welding Current Rating

499 kg (1100 lbs) combined part/fixture weight per side 998 kg (2200 lbs) total

289.8 kg (639 lbs)

1.1 m (43.3 in.) 4–43°C (40–110°F)

Non-condensing 10–90% relative humidity Less than 0.5 G 2000 Nm/5 sec.

1050 Nm/0 - 16.8 rpm

80 psi 24 VDC for interface

208 VAC, 9.0 amp Positioner power supplied by the MRC controller

800 amperes at 100% duty cycle

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Table 3-3 MRM2-1650 (RM2-750) Positioner Specifications

Capacity

Swing Diameter Temperature Operating

Range Humidity Shock Rating Sweep Speed

(Torque/Time) Servo Headstock Speed

(Torque/Speed) Air Requirements Electrical Requirements

Welding Current Rating

750 kg (1650 lbs) combined part/fixture weight per side 1500 kg (3300 lbs) total

1.3 m (51.2 in.) 4–43°C (40–110°F)

Non-condensing 10–90% relative humidity Less than 0.5 G 2770 Nm/8 sec.

900–1100 Nm/9 rpm

80 psi 24 VDC for interface

208 VAC, 9.0 amp Positioner power supplied by the MRC controller

800 amperes at 100% duty cycle

3.4.1 Welding Ground System

The welding ground system consists of a spring-loaded copper brush that contacts a 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 as you face the back of the ArcWorld 6200 cell.

CAUTION!

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 Locking Pins

The MRM2-series positioners are equipped with fixture locking pins that prevent the headstock/tailstock faceplates from turning when the servo motor retracts. The fixture locking pins are spring loaded, so when the servo motor withdraws, the pins engage. Each headstock and tailstock faceplate on the RM2-series positioners has one locking pin.

The MRM2-1100 (RM2-500) and MRM2-1650 (RM2-750) positioners are also equipped with a pair of sweep lock drive pins that prevent the sweep axis from turning during the welding and loading cycles. One sweep lock drive pin is located on the headstock drive base and the other is located on the tailstock drive base.

3.4.3 Arc Shield

CAUTION!

Do not operate this system unless the arc shield is in place.

The MRM2-series positioners are provided with a sheet metal screen for arc radiation protection between the operator loading zone and the welding zone.

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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.

CYCLE START

ALARM

RESET

3.5.1 Emergency Stop

ROBOT HOLD

MASTER JOB

START

MOTOMAN

STATION READY

POSITIONER

AUTO/MAN

WARNING!

OPERATOR STATION

ENABLE/DISABLE

ESTOP

SERVO ON

Figure 3-4 Operator Station

CYCLE STAR

The operator station E-STOP, the robot E-STOP, the sliding door interlocks, and the ArcWorld 6200 safety mats are connected in series in the Emergency Stop circuit. If the Emergency Stop circuit is interrupted, the robots and the Motoman MRM2-series positioner will go into the Emergency Stop condition and all table motion stops. The operator station E-STOP light will come on when the E-STOP button is pressed.

3.5.2 Hold

The operator station HOLD button is a normally closed button connected to both MRC controllers. Both robots and the positioner go into the HOLD condition when this 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 on the Master controller only.

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3.5.4 Station Ready

The STATION READY lamp is interlocked with the robot Cube #1 output (safe position). When the robots are in Cube #1, Output #1 in the Master controller 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 Master robot ALARM OCCURRENCE output. The ALARM lamp turns on when EITHER robot encounters a major or minor alarm condition or when power is cut to the servos.

3.5.6 Servo On

The SERVO ON button is connected to the robot SERVO ON input on both controllers. The servo motors on both robots will turn on when all four of these conditions are met:

• The SERVO ON button is pressed

• Air is supplied to the positioner

• An Emergency Stop condition does not exist

• The operator station is enabled

3.5.7 Auto/Manual

The function of this button is dependent on the structure of the Master job.

The selector switch is connected to robot Input #2 on the Master controller only. The AUTO/MANUAL selector switch is used to select AUTOMATIC or MANUAL mode for the positioners. 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. Examples of how to use this switch are shown later in the manual.

3.5.8 Master Job Start

The MASTER JOB START button is connected to the robot external start input on both the Master and Slave controllers. The robots will start the current active job, once the MASTER JOB START is pressed, as long as

• The robots are in PLAY mode

• The operator station is enabled

• The servo motors are on

• All HOLDS and ALARMS are reset

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 operator station. The REMOTE MODE buttons on the MRC playback boxes light when the operator station is enabled. Most programming pendant functions are disabled while in REMOTE.

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3.5.10 Reset

The RESET button is connected to the robot alarm reset input on both controllers. 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 MRM2-series positioner if the robot servo motors are on. The entire robotic cell needs to be enabled at initial power up or after an Emergency Stop or Shock Sensor condition.

3.6 WELDING POWER SOURCE

The MotoArc 450 power source (see Figure 3-5) is a constant-voltage, transformer-rectifier, 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.

The MotoArc 450 is the standard power source configuration for the ArcWorld cell. Other models are available to meet the client company’s needs. These include the MotoArc 350i, MotoArc 500i, and MotoArc 650.

INPUT

POWER

LOCAL

REMOTE

ON OFFIO

WIRE FEED#1 WIRE FEED#2

REMOTE

CONTROL

CIRCUIT BREAKERS

10 AMPS 10 AMPS

110 V 9A

CC CV

1 Main Power Pilot Light 8 Feeder Cont. 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 Select. 7 Input Power Switch

Figure 3-5 MotoArc Controls

3.6.1 Main Power

The INPUT POWER Switch (7, Figure 3-5) turns on the main power. The main power must be on before any other section of the power source can operate. The Main Power Pilot Light (1) illuminates when main power is on.

3.6.2 Volt/Amp Settings

The Welding Voltage/Amperage Control (2, Figure 3-5) 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 MotoArc manual for additional information.

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3.6.3 Terminal Connectors

The two terminals on the front of the MotoArc power source serve as connection points for the welding leads. The Positive Terminal (4, Figure 3-5) connects positive welding lead (to the wire feeder). The Negative Terminal (5) connects to the negative welding lead (to the positioner ground lug).

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 MotoArc 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 MotoArc 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 MotoArc 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 either of these receptacles.

3.7 WELDING EQUIPMENT

In addition to the MotoArc power source, the ArcWorld 6200 system provides a complete complement of arc welding equipment. In its standard configuration, the ArcWorld system includes the following:

• Two PWF4 wire feeders

• Two universal welding interfaces (UWIs)

• A pair of air-cooled or water-cooled MIG torches

• Two Tregaskiss gun mounts

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 inches per minute (IPM) and can achieve a rate of 750 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.

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3.7.2 Universal Welding Interface (UWI)

The universal welding interface (UWI) 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 6200 uses a pair of air-cooled or water-cooled robotic/automatic MIG torches. 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 6200 includes a suitable water circulator kit.

3.7.4 Tregaskiss Gun Mount

A Tregaskiss gun mount protects the robot, workpiece, fixture, and positioner. It provides multidirectional impact detection, including Z-axis collisions. The Tregaskiss gun mount causes the robot to stop immediately upon impact.

3.8 SAFETY EQUIPMENT

The ArcWorld 6200 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.

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

Users are responsible for

The ArcWorld 6200 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

WARNING!

Although arc screens block dangerous arc radiation, you should not look directly at the arc during operation without protective eyewear!

Two separate arc screens are used on the ArcWorld 6200. The first is a metal arc screen on the reciprocating positioner. This screen blocks arc radiation and sparks from the welding operation. The arc curtain material used to cover the safety fencing around the entire robotic cell acts as the second arc screen. This material reduces the amount of ultraviolet radiation that escapes from the robotic cell.

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3.8.2 Fencing

The safety fencing provided with the ArcWorld 6200 encloses the entire robotic cell. It forms a physical barrier to prevent entry into the robot envelopes.

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 mode causes an Emergency Stop and shuts down the entire system.

3.8.4 Safety Mats

The safety mats provided with the ArcWorld 6200 help prevent serious injury to anyone entering the reciprocating positioner area during the sweeping process. If a person steps on one of these mats 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 6200 has strategically placed Emergency Stops (E-STOPs). 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

• Positioner operator station

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NOTES

ArcWorld 6200 Two-Controller Operator's Manual Page 24 MOTOMAN

4.0 OPERATION

This section provides operation instructions for the ArcWorld 6200 system. Operation procedures include the following:

• System start-up

• Normal operation (includes loading, part setup, and unloading)

• System recovery

• System shutdown

This section contains a number of sample programs. These 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 OPERATING PROCEDURES

The ArcWorld 6200 is a fully integrated robotic GMAW welding cell. The robots weld parts on one side of the 180˚ reciprocating positioner while the operator loads parts on the opposite side. Once the robots are finished with the welding process, they return to the home (safe) position. The operator can then initiate the positioner sweep, enabling the robots to start welding on the next part.

The door interlocks prevent anyone from entering the cell while the robots are in PLAY mode. If anyone steps on the safety mats in front of the part loading area during the positioner sweep, an Emergency Stop occurs.

4.1.1 Start-up

To start up the ArcWorld 6200 from a Power Off condition:

1. Turn on the two power source disconnects.

2. Set the MAIN POWER switches on the MRC controllers to ON.

3. Set the INPUT POWER switches on both welding power sources to ON. The indicator lights on the power sources should glow.

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

5. Open the air supply valve on the positioner.

6. Press the TEACH mode button on either MRC playback box. The indicator lamp in the switch should light on both controllers.

7. Enable the operator station by setting the ENABLE/DISABLE switch on the operator station to ENABLE.

8. Press the SERVO POWER button on the operator station. The indicator light in the switch should turn on.

9. Press the RESET button and the RIGHT CYCLE START button on the operator station at the same time to initialize the entire robotic cell. The ALARM light should turn off.

10. Disable the operator station.

11. Use the programming pendants to move the robots to the starting position (Cube #1 position). This should typically be the first Move in the job.

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12. Call up the Master job on each controller using the programming pendants.

13. Make sure that the cell entry door is closed, the safety plug is connected, and that the safety mats are clear.

14. Press the PLAY mode button on the Master MRC playback box, and then press the AUTO CYCLE button on both controllers. The indicator lamps in the switches should light.

15. Enable the operator station.

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

17. Wait for the STATION READY indicator light to turn on.

The ArcWorld 6200 cell is now ready for operation.

4.1.2 Normal Operating Procedures

Following is a typical sequence of normal operation for the ArcWorld 6200 cell after start-up:

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

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

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 robots’ work area.

4. Load more parts to be welded into the fixture on the operator side of the positioner.

5. Press BOTH CYCLE START palm buttons on the operator station. The positioner sweeps, returning the welded part outside the cell and placing the newly loaded, unwelded parts in the robots’ work area.

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

7. Repeat Steps 1 through 6 to continue production.

4.1.3 Emergency Stop Recovery

An Emergency Stop can occur under any 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 MRM2 positioner is sweeping.

• Activation of the Shock Sensor, indicating a robot crash.

• Loss of air system pressure.

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To restart the ArcWorld 6200 cell after an Emergency Stop condition occurs, follow these procedures:

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 Section 4.1.4).

• 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.

NOTE: If an Emergency Stop condition occurs while the positioner is sweeping, the positioner will

continue to move when initialized.

3. Press the RESET button and the RIGHT CYCLE START button on the operator station at the same time to initialize the system.

4. Ensure that the operator station is enabled.

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

The ArcWorld 6200 cell will continue its operation.

4.1.4 Shock Sensor Recovery

The standard ArcWorld welding package includes a Tregaskiss gun 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, which triggers an Emergency Stop condition.

To override the Shock Sensor, perform the following:

1. Press and hold the OVERRUN RECOVERY button inside the playback box. Continue to hold the OVERRUN RECOVERY button through Step 6.

2. Press F5 (RESET) on the programming pendant or the RESET button on the operator station.

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

4. Press the RIGHT CYCLE START and RESET on the operator station.

5. Make sure the operator station is disabled.

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

7. Release the OVERRUN RECOVERY button.

ArcWorld 6200 Two-Controller Operator's Manual Page 27 MOTOMAN

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 the RIGHT CYCLE START buttons on the operator station at the same time. This initializes the positioner.

4. Enable the operator station.

5. Press the MASTER JOB START button.

4.1.5 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 most cases, you must first correct the condition causing the alarm or error. Refer to Section 4.2, Alarms and Errors.

4.1.6 Shutdown

Use the following procedure to shut down the ArcWorld 6200 cell after operation is complete:

1. Make sure both the robots are in the starting positions, that is, in their Cube #1 zones).

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

3. Disable the operator station.

4. Press the TEACH mode button on either MRC playback box.

5. Set the MRC Main Power switch to the OFF position on both controllers.

6. Turn off the MRC disconnect.

7. Set the INPUT POWER switches on the welding power sources to the OFF position.

8. Turn off the two power source disconnects.

9. Close the regulator valves on the welding gas supply.

The ArcWorld 6200 cell is now shutdown.

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 SK6 or SK16 Manipulator Manual (MRC controller version).

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.

ArcWorld 6200 Two-Controller Operator's Manual Page 28 MOTOMAN

To clear error messages, press the RESET button on the operator station or 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, or for a similar programming error.

Clear minor alarms by pressing the RESET button on the operator station or the CANCEL button on the programming pendant

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

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

WARNING!

If the robots are working on a part and the headstock is not turning, DO NOT assume that the headstock will not turn. The robots are executing programmed steps which could index the headstock at any time.

NOTE: The ArcWorld 6200 robot S-axes are restricted by hardstops on the robot bases and internal

soft stops. Do not change.

4.3.1 Cube Assignment

The cube function defines spatial boundaries or software zones around the robots. Cubes are designed to keep the robots clear of the positioner sweep and of each other. An output is produced when the robot is in the assigned cube (that is, within established boundaries). The cube position is factory set to be clear of the table. To redefine the cube position, refer to the MRC User Functions and Operator’s Manuals.

ArcWorld 6200 Two-Controller Operator's Manual Page 29 MOTOMAN

Cube #1: Positioner Sweep—In the ArcWorld 6200 Two-Controller configuration, each robot has its own Cube #1. These cubes are separate and do not intersect. The system uses these cube outputs as an interlock for sweeping. The Master robot must be in its Cube #1 and the Slave robot must be in its Cube #1 before the positioner can sweep. The cubes are software zones around the tool center points (TCPs). Each cube should be defined with the robot clear of the positioner sweep motion. The cube outputs can be viewed in diagnostics under Specified Outputs. To assign the SK6 or SK16 robot manipulator positions to Cube #1, refer to the MRC User Functions and Operator’s Manuals.

NOTE: If the robot moves outside of its assigned cube, the cube output is lost and the positioner will

not sweep.

Cube #2: Robot Motion—The ArcWorld 6200 uses Cube #2 outputs as an interlock for robot motion. Cube #2 is an interference zone, a software zone between the robots in which it is possible for the robot paths to intersect. However, when one robot is operating in Cube #2, the other robot is prevented from entering the area and vice versa.

NOTE: Redefinition of Cube #2 parameters will probably be required after a fixture change.

CAUTION!

Do not change cube positions unless absolutely necessary, as such changes increase the possibility that the paths of the robot arms may intersect with the loading fixtures or with each other.

4.3.2 Sweeping Positioner to Side A

In order for the positioner to sweep, the Master robot must be in Cube #1, the Slave robot must be in Cube #1, and Output #1 of the Master controller must be ON to enable the operator station.

To sweep the positioner to Side A:

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

2. Call the SweepToA job on the Master controller.

3. Enable the positioner. Make sure that the calibration marks on the headstock line up to show that the positioner is in the sweep position.

4. Make sure that both the Master and the Slave robots are in their Cube #1 zones.

5. Master controller Output #1 “STATION READY” must be ON.

6. Press the PLAY mode button on the MRC playback box. The indicator light in the switch should turn on.

7. If this is the first power up, or an Emergency Stop recovery, press the RESET button and RIGHT CYCLE START button at the same time.

8. Select ENABLE on the operator station.

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

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

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

12. The sweep locking pin engages Side A.

13. The drive unit engages.

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

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

Sides A and B of the positioner (refer to Section 3.4.).

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

4.3.3 Sweeping Positioner to Side B

In order for the positioner to sweep, the Master robot must be in Cube #1, the Slave robot must be in Cube#1, and Output #1 of the Master controller must be ON to enable the operator station.

To sweep the positioner to Side B:

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

2. Call the SweepToB job on the Master controller.

3. Enable the positioner. Make sure that the calibration marks on the headstock line up to show that the positioner is in the sweep position.

4. Make sure that both robots are in Cube #1.

5. Master controller Output #1 “STATION READY” must be ON.

6. Press the PLAY mode button on the MRC playback box. The indicator light in the switch should turn on.

7. If this is the first power up, or an Emergency Stop recovery, press the RESET button and RIGHT CYCLE START button at the same time.

8. Select ENABLE on the operator station.

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

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

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

12. The sweep locking pin engages Side B.

13. The drive unit engages.

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

ArcWorld 6200 Two-Controller Operator's Manual Page 31 MOTOMAN

4.3.4 Rotating Headstock

To rotate the positioner headstock:

1. Enable the programming pendant.

2. Press the GROUP AXES key.

NOTE: The Group Axis LED only lights when R1 + S1 is selected and S1 is the Master.

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 Master robot with the motion keys.

4.3.5 Programming Specific Jobs

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 (for example, R1 + S1). The last type of move is called station synchronous and should be programmed with a station plus robot group axis specification (for example, R1 + S1 S1).

CAUTION!

Remember that the robots only know where the Tool Center Points (TCPs) are, and if not programmed carefully, the arms could still intersect.

NOTE: Refer to the Operator’s Manual for Jigless for information on coordinated motion, selecting

synchronization, group axes, and tooling calibration.

4.3.6 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.

NOTE: The Group Axis LED only lights when R1 + S1 is selected and S1 is the Master.

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.

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

ArcWorld 6200 Two-Controller Operator's Manual Page 32 MOTOMAN

WARNING!

)

The positioner axis operates as another robot axis and has the potential for hazardous motion. The Slave robot does when the positioner is moving except in PLAY mode and with proper I/O communication.

NOTE: The GROUP AXES button must be turned off to move the robot. NOTE: Normally, air cut moves are taught as Joint moves. The speed for Joint moves is specified as a

percentage of maximum speed (VJ=0.01 to 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.

4.3.7 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.

not know

4.3.8 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 R1 + S1 jobs.

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

COORDINATED

MOTION

INSTRUCTION

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

SMOVL=138

MOVL

SLAVE SIDE

(MANIPULATOR WITH TORCH)

MASTER SIDE

(POSITIONER WITH WORKPIECE

4.3.9 Converting Programs from Side A to Side B—Master Robot Only

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. This may be of particular importance to the ArcWorld 6200 user, as it facilitates the development of duplicate jobs on opposite sides of the positioner.

1. Determine the pulse count difference of the external axis between Sides A and B. To do this, display the position (POSN) screen.

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.

ArcWorld 6200 Two-Controller Operator's Manual Page 33 MOTOMAN

4. Use the modify position (MODPS) function to change the position of the external axis in the program.

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

4.3.10 I/O Assignment

The ArcWorld 6200 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 both the Master and Slave robots in

their Cube #1 zones 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

For MRM2-550 (RM2-250) Positioner only:

IN#13 In Position On

For MRM2-1100 (RM2-500) Positioner only:

IN#13 Sweep Lock On IN#14 Sweep Lock Off

MRC User Outputs

OUT#1 STATION READY interlocked with both the Master and Slave

robots in Cube #1

ÑMaster Controller Only

ÑMaster Robot Only

OUT#4 Wire Cutter (optional) OUT#9 Withdraw Servo OUT#10 Advance Servo OUT#11 Sweep Lock On (not used on MRM2-550 positioners) OUT#12 Sweep Lock Off (not used on MRM2-550 positioners) In order for the positioner to sweep, the Master robot must be in its Cube #1, the

Slave robot must be in its Cube #1, and OUT#1 of the Master controller must be ON to enable the operator station.

MRC Dedicated Inputs

• External Emergency Stop

• External Over Travel

• External Servo On

• External Hold

• Anti-Tiedown

ÑBoth Master and Slave Controllers

ArcWorld 6200 Two-Controller Operator's Manual Page 34 MOTOMAN

• Master Job Start

• Alarm Reset

• Remote Mode

MRC Dedicated Outputs

• Servo On

• Alarm Occurrence

• Teach Mode

• CUBE #1

• CUBE #2 For more information on the user and dedicated I/O's, refer to the MRC User

Functions Manual (Motoman P/N 132331-1), the MRC Operator’s Manual for Arc Welding (Motoman P/N 132332-1).

4.4 SAMPLE JOBS

The following jobs are based on the MRM2-1100 (RM2-500) and MRM21650 (RM2-750) positioners and 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.

The job structure shown is designed to allow the two robots to work independently. You should not change the structure of the Master Job and Sweep jobs. You can change the A-Side and B-Side jobs to accomplish a particular task or tasks on each side. Refer to the Independent Control instruction manual for more information on programming parallel jobs.

ÑBoth Master and Slave Robots

You must teach all of the jobs listed below as concurrent jobs, except for the actual motion jobs. Specify the concurrent option when you teach a new job. Lines in italics are comments added for clarification only and do not appear in the actual program listing.

4.4.1 Master Controller—Master Job

Line Step Function

000 000 NOP 001 CALL JOB:SWEEPTOA IF IN#(9)=ON

Call the SweepToA job if Fixture A lock is on.

002 CALL JOB:SWEEPTOB IF IN#(10)=ON

Call the SweepToB job if Fixture B lock is on.

003 END

ArcWorld 6200 Two-Controller Operator's Manual Page 35 MOTOMAN

4.4.2 Master Controller—Cube Job

Line Step Function

000 000 NO P 001 001 MOVJ C0000 VJ=25.00

Move to home position in CUBE #1 at a velocity of 25%.

002 END

4.4.3 Master Controller—SweepToA Job

Line Step Function

000 000 NO P 001 001 MOVJ P040 EX042 VJ=100.00

Move to position 40 and execute operation 42 at 100% velocity.

002 DOUT OT#(1) ON

Turn on STATION READY lamp on operator station.

003 WAIT IN#(1)=ON

Wait for CYCLE START palm buttons.

004 WAIT IN#(9)=ON

Verify that locking pin on Side A is engaged.

005 DOUT OT#(10) OFF

Turn off ADVANCE SERVO.

006 DOUT OT#(9) 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 P040 EX041 VJ=100.00

Move to position 40 and execute operation 41 at 100% velocity.

013 DOUT OT#(12) OFF

Turns off the SWEEP LOCK OFF output.

ArcWorld 6200 Two-Controller Operator's Manual Page 36 MOTOMAN

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#(9) 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#(9)=OFF

Turn off WITHDRAW SERVO output.

020 DOUT OT#(1) OFF

Turn off the STATION READY lamp.

021 DOUT OT#(7) ON 022 CALL JOB:WELDA IF IN#(2)=ON

Call the WeldA job if in AUTO mode.

023 RET

Return to the Master job.

024 END

4.4.4 Master Controller—SweepToB Job

Line Step Function

000 000 NO P 001 001 MOVJ P040 EX041 VJ=100.00

Move to position 40 and execute operation 41 at 100% velocity.

002 DOUT OT#(1) ON 003 WAIT IN#(1)=ON 004 WAIT IN#(10)=ON 005 DOUT OT#(10) OFF 006 DOUT OT#(9) ON 007 WAIT IN#(11)=ON 008 DOUT OT#(11) OFF 009 DOUT OT#(12) ON 010 WAIT IN#(14)=ON

ArcWorld 6200 Two-Controller Operator's Manual Page 37 MOTOMAN

Master Controller—SweepToB Job (Continued)

Line Step Function

011 WAIT IN#(9)=ON 012 002 MOVJ P040 EX042 VJ=100.00

Move to position 40 and execute operation 42 at 100% velocity.

013 DOUT OT#(12) OFF 014 DOUT OT#(11) ON 015 WAIT IN#(13)=ON 016 DOUT OT#(9) OFF 017 DOUT OT#(10) ON 018 WAIT IN#(12)=ON 019 WAIT IN#(10)=OFF 020 DOUT OT#(1) OFF 021 DOUT OT#(5) ON 022 CALL JOB:WELDB IF IN#(2)=ON

Call the WeldB job if in AUTO mode.

023 RET

Return to the Master job.

024 END

4.4.5 Master Controller—WeldA Job

NOTE: WeldA and WeldB jobs do not weld. They are for demonstration purposes only.

Line Step Function

000 000 NOP 001 001 MOVJ C0000 VJ=50.00

Move to home position in CUBE #1 at a velocity of 50%.

002 002 MOVJ C0001 VJ=50.00

Move to first point at 50% velocity.

003 003 MOVJ C0002 VJ=6.25

Move to second point at 6.25% velocity.

004 ARCON ASF#(1)

Call the Welding Start file. Refer to the MRC Operator’s Manual for more information about weld condition files.

005 004 MOVL C0003

Move to third point and begin welding.

ArcWorld 6200 Two-Controller Operator's Manual Page 38 MOTOMAN

006 ARCOF AEF#(1)

Call the Arc Off file to end the welding.

007 005 MOVJ C0004 VJ=50.00

Move to fourth point at 50% velocity.

008 006 MOVJ C0005 VJ=50.00

Move to fifth point at 50% velocity.

009 RET

Return to the Master job.

010 END

4.4.6 Master Controller—WeldB Job

Line Step Function

000 000 NOP 001 001 MOVJ C0000 VJ=50.00

Move to home position in CUBE #1 at a velocity of 50%.

002 002 MOVJ C0001 VJ=50.00

Move to first point at 50% velocity.

003 003 MOVJ C0002 VJ=6.25

Move to second point at 6.25% velocity.

004 ARCON ASF#(1)

Call the Welding Start file. Refer to the MRC Operator’s Manual for more information about weld condition files.

005 004 MOVL C0003

Move to third point and begin welding.

006 ARCOF AEF#(1)

Call the Arc Off file to end the welding.

007 005 MOVJ C0004 VJ=50.00

Move to fourth point at 50% velocity.

008 006 MOVJ C0005 VJ=50.00

Move to fifth point at 50% velocity.

009 RET

Return to the Master job.

010 END

ArcWorld 6200 Two-Controller Operator's Manual Page 39 MOTOMAN

4.4.7 Slave Controller—Cube Job

Line Step Function

000 000 NO P 001 001 MOVJ C0000 VJ=0.78

Move to home position in CUBE #1 at .78% velocity.

002 END

4.4.8 Slave Controller—WeldA Job

NOTE: WeldA and WeldB jobs do not weld. They are for demonstration purposes only.

Line Step Function

000 000 NOP 001 001 MOVJ C0000 VJ=25.00

Move to home position in CUBE #1 at a velocity of 25%.

002 002 MOVJ C0001 VJ=25.00

Move to first point at 25% velocity.

003 003 MOVJ C0002 VJ=6.25

Move to second point at 6.25% velocity.

004 ARCON ASF#(1)

Call the Welding Start file. Refer to the MRC Operator’s Manual for more information about weld condition files.

005 004 MOVL C0003

Move to third point and begin welding.

006 ARCOF AEF#(1)

Call the Arc Off file to end the welding.

007 005 MOVJ C0004 VJ=25.00

Move to fourth point at 25% velocity.

008 006 MOVJ C0005 VJ=25.00

Move to fifth point at 25% velocity.

009 RET

Return to the Master job.

010 END

ArcWorld 6200 Two-Controller Operator's Manual Page 40 MOTOMAN

4.4.9 Slave Controller—WeldB Job

Line Step Function

000 000 NOP 001 001 MOVJ C0000 VJ=25.00

Move to home position in CUBE #1 at a velocity of 25%.

002 002 MOVJ C0001 VJ=25.00

Move to first point at 25% velocity.

003 003 MOVJ C0002 VJ=6.25

Move to second point at 6.25% velocity.

004 ARCON ASF#(1)

Call the Welding Start file. Refer to the MRC Operator’s Manual for more information about weld condition files.

005 004 MOVL C0003

Move to third point and begin welding.

006 ARCOF AEF#(1)

Call the Arc Off file to end the welding.

007 005 MOVJ C0004 VJ=25.00

Move to fourth point at 25% velocity.

008 006 MOVJ C0005 VJ=25.00

Move to fifth point at 25% velocity.

009 RET

Return to the Master job.

010 END

ArcWorld 6200 Two-Controller Operator's Manual Page 41 MOTOMAN

NOTES

ArcWorld 6200 Two-Controller Operator's Manual Page 42 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 Manipulator Manual or SK16 Manipulator Manual (MRC controller version).

For additional maintenance information regarding the reciprocating positioners, refer to your positioner manual.

For maintenance information regarding the welding power source, refer to your MotoArc Owner’s Manual.

Table 5-1 provides a list of periodic maintenance to be performed on the ArcWorld 6200 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.

Table 5-1 Periodic Maintenance

INTERVAL EQUIPMENT ACTION REQUIRED

Regularly MRM2-550 (RM2-

250) servo headstock RV drive unit

Daily Water circulator

(water-cooled torch application only)

Daily Air system water trap

on the front of MRM2 positioner

Monthly MRM2 weld grounds Lubricate with Burndy Penetrox E

500 operating hrs MRM2 drive pins and

locking pins

1,000 operating hrs MRM2 positioner

gears

20,000 operating hrs MRM2-550 (RM2-

250) servo headstock RV drive

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

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

Check water trap and empty if required.

conductive copper lubricant (P/N PEN-E-8).

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

Lubricate with Shell 1029 or equivalent.

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

20,000 operating hrs MRM2-1100 (RM2-

500) and MRM2-1650 (RM2-750) servo headstock Cyclo drive unit

ArcWorld 6200 Two-Controller Operator's Manual Page 43 MOTOMAN

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

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 water circulator pump.

5.2 SPARE PARTS LIST

Table 5-2 Spare Parts

DESCRIPTION PART NO.

ArcWorld 6200 safety mat kit 130157-5 Safety mat controller box 131038-1 Positioner interface 4-pole relay, 24V DC 470108-5 Positioner interface fuse, 2A 250V 400647-3 Positioner interface fuse, 1/2A 250V 130293-2 Valve, 4-way, double solenoid 132108-1

5.3 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.

WARNING!

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

Table 5-3 MotoArc 450 CV Fuses and Circuit Breakers

DEVICE

DESIGNATOR RATING

CB1 10A

115V

CB2 10A

24V

F1 0.5A W-11166-11 On contactor box Protects contactor

PART

NUMBER LOCATION PURPOSE

203627-7 Upper rear panel Protects 115V circuit

203627-7 Upper rear panel Protects 24V circuit

circuit

Abbreviations:

CB—Circuit breaker F, FU or 101FU—Fuse

ArcWorld 6200 Two-Controller Operator's Manual Page 44 MOTOMAN

Table 5-4 MRC Cabinet Fuses and Circuit Breakers

DEVICE

DESIGNATOR RATING

CB (1MCCB) 30A

15A

CB (1SV) 30A Lower left side of

CB (2SV) 30A Lower left side of

FU1 5A GDL-5

FU2 5A GDL-5

FU4 4A GP-40 250V MTU-01 Protects robot brake

FU5 4A GP-40 250V MTU-01 Protects robot brake

PART

NUMBER LOCATION PURPOSE

NF30-SS-30

NF30-SS-15

250V

Upper left front SK16

Upper left front SK6

servo pack

MTU-01 Protects CPT10199

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

Protects input for servopack 1SV for S, L, and U axes

Protects input for servopack 2SV for R, B, and T axes

transformer, brake, and fan circuits

circuits

1FU 1A GDL-1 250V Top/left/rear Protects the four fan

FU3 2A GDL-2 125V Top/left/rear Protects the 100V AC

FU1 3A SM1101 MBB-02 External voltage

FU2 3A SM1101 MBB-02 External voltage

Abbreviations:

CB—Circuit breaker F, FU or 101FU—Fuse

circuits of the MRC

supply to the AC receptacle for the floppy disk controller power

protection - 24V

ArcWorld 6200 Two-Controller Operator's Manual Page 45 MOTOMAN

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

DEVICE

DESIGNATOR RATING

F1 8A 250V On KXA motor

FU1 4A 250V Wickman

19374K-4A

FU2 0.25A

125V

Wickman 19303K250A

FU3 0.5A

125V

Wickman 19303K500A

Table 5-6 MRC System Fuses

DEVICE

DESIGNATOR RATING

1FU 1A GDL-1

125V

PART

NUMBER LOCATION PURPOSE

Limits damage from

speed control

shorts or component breakdowns in DC power supply module

On interface board Protects 115V circuit

On interface board Protects Shock Sensor

circuit

On interface board Protects 24V circuit

PART

NUMBER LOCATION PURPOSE

Bottom/left/rear Protects 24V DC

circuit

2FU 1A GDL-1

Bottom/left/rear Protects fan circuit

125V

3FU 2 A MDL-2

Bottom/left/rear Protects safety mat

125V

4FU 2 A MDL-2

Bottom/left/rear Protects safety mat

125V

5FU 2 A MDL-2

Bottom/left/rear Protects safety mat

125V

Table 5-7 Com-Arc III Fuses and Circuit Breakers

DEVICE

DESIGNATOR RATING

Fuse 1A

250V

PART

NUMBER LOCATION PURPOSE

TD-1 Front of Com-Arc

III box

circuit

Protects 200V circuit

ArcWorld 6200 Two-Controller Operator's Manual Page 46 MOTOMAN

APPENDIX — RISK ASSESSMENT

ArcWorld 6200 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 6200 robot cell.

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

It is the user’s responsibility to

• 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.

• CYCLE START has dual palm buttons, anti-tiedown, 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 at reduced speed.

ArcWorld 6200 Two-Controller Operator's Manual Appendix–1 MOTOMAN

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.

• 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 gases. (User

supplied.)

ArcWorld 6200 Two-Controller Operator's Manual Appendix–2 MOTOMAN

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

• Tregaskiss gun mount 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

• The isolation transformer built into the MRC controller and the circuit breaker

protect the robot from power surges (additional surge control may be required at your facility).

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

• Data have 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, and robot controller. Persons working on equipment should have adequate training to identify hazards.

ArcWorld 6200 Two-Controller Operator's Manual Appendix–3 MOTOMAN

NOTES

ArcWorld 6200 Two-Controller Operator's Manual Appendix–4 MOTOMAN

INDEX

ABOUT THIS DOCUMENT, 1 AC RECEPTACLES, 21 ALARM, 19 ALARM/ERROR, 13 ALARMS AND ERRORS, 28 APPENDIX — RISK ASSESSMENT, APPENDIX–1 ARC SCREENS, 22 ARC SHIELD, 17 AUTO/MANUAL, 19

CIRCUIT BREAKERS, 21 CONVERTING PROGRAMS FROM SIDE A TO

SIDE B—MASTER ROBOT ONLY, 33 COORDINATE SYSTEM INDICATORS, 15 CUBE ASSIGNMENT, 29 CUSTOMER SERVICE INFORMATION, 4 CYCLE SELECT, 13 CYCLE START, 18

DESCRIPTION OF EQUIPMENT, 11 DISPLAY, 14

EMERGENCY STOP RECOVERY, 26 EMERGENCY STOP, 13, 15, 18 EMERGENCY STOPS, 23 ERROR MESSAGES, 28

FAULT RECOVERY, 28 FEEDER CONTROL RECEPTACLES, 21 FENCING, 23 FUSE AND CIRCUIT BREAKER PROTECTION, 44

I/O ASSIGNMENT, 34 INSTALLATION SAFETY, 8 INTERLOCKS, 23 INTRODUCTION, 1

KEYPAD, 15

LIST OF FIGURES, IV LIST OF TABLES, IV LOCAL/REMOTE OPERATION, 21 LOCKING PINS, 17

MAIN POWER, 20 MAINTENANCE SAFETY, 10 MAINTENANCE, 43 MAJOR ALARMS, 29 MASTER CONTROLLER—CUBE JOB, 36 MASTER CONTROLLER—MASTER JOB, 35 MASTER CONTROLLER—SWEEPTOA JOB, 36 MASTER CONTROLLER—SWEEPTOB JOB, 37 MASTER CONTROLLER—WELDA JOB, 38 MASTER CONTROLLER—WELDB JOB, 39 MASTER JOB START, 19 MECHANICAL SAFETY DEVICES, 7 MIG TORCH, 22 MINOR ALARMS, 29 MODE SELECT, 12 MRC CONTROLLER, 11 MRM2-SERIES POSITIONERS, 15

NORMAL OPERATING PROCEDURES, 26

GENERAL SAFEGUARDING TIPS, 7

HOLD, 13, 18

ArcWorld 6200 Two-Controller Operator's Manual MOTOMAN

OPERATING PROCEDURES, 25 OPERATION SAFETY, 9 OPERATION, 25 OPERATOR STATION ENABLE/DISABLE, 19 OPERATOR STATION, 18 OPTIONAL EQUIPMENT, 3

PERIODIC MAINTENANCE, 43 PLAYBACK BOX SUBPANEL, 13 PROGRAMMING PENDANT, 14 PROGRAMMING SAFETY, 8 PROGRAMMING SPECIFIC JOBS, 32 PROGRAMMING, 29 PWF4 WIRE FEEDER, 21

REFERENCE TO OTHER DOCUMENTATION, 3 RESET, 20 RISK ASSESSMENT, Appendix-1 ROBOT MOTION WITH THE

POSITIONER STATIONARY, 33 ROBOT SPEED INDICATORS, 14 ROTATING HEADSTOCK, 32 ROTATING THE POSITIONER

DURING AIR CUT MOVES, 32 ROTATION OF THE POSITIONER

DURING WELDING, 33

INDEX

SLAVE CONTROLLER—CUBE JOB, 40 SLAVE CONTROLLER—WELDA JOB, 40 SLAVE CONTROLLER—WELDB JOB, 41 SPARE PARTS LIST, 44 STANDARD CONVENTIONS, 6 START, 13 START-UP, 25 STATION READY, 19 SWEEPING POSITIONER TO SIDE A, 30 SWEEPING POSITIONER TO SIDE B, 31 SYSTEM LAYOUT, 2 SYSTEM OVERVIEW, 1

TERMINAL CONNECTORS, 21 TREGASKISS GUN MOUNT, 22

UNIVERSAL WELDING INTERFACE (UWI), 22

SAFETY EQUIPMENT, 22 SAFETY MATS, 23 SAFETY, 5 SAMPLE JOBS, 35 SERVO ON, 19 SERVO POWER, 12 SERVO POWER, 15 SHOCK SENSOR RECOVERY, 27 SHUTDOWN, 28 SK-SERIES ROBOT DESCRIPTION, 11

VOLT/AMP SETTINGS, 20

WELDING EQUIPMENT, 21 WELDING GROUND SYSTEM, 17 WELDING POWER SOURCE, 20

ArcWorld 6200 Two-Controller Operator's Manual MOTOMAN

motoman robotics 6200 Operators Manual

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