motoman robotics 7000 Operators Manual

Yasnac MRC Controller

May 9, 1995

MAN

ArcWorld 7000
Operator's Manual

Part Number 132340-9

TEL: [phone] FAX: [phone]

24-HOUR SERVICE HOTLINE: [phone]

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

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

MOTO

805 Liberty Lane

West Carrollton, OH 45449

authorization of Motoman, Inc.

©1995 by MOTOMAN

All Rights Reserved

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

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

TABLE OF CONTENTS

Section Page

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

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

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

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

1.2.2 Optional Equipment.............................................................. 4

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.2.4 Emergency Stop (E-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.............................................................................. 15

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

3.3.3 Emergency Stop (E-Stop)................................................... 15

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

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

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

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

3.2.1 Part / Fixture Rating......................................................... 15

3.2.2 Part Center of Gravity...................................................... 16

3.2.3 Temperature Operating Range........................................... 16

3.2.4 Humidity............................................................................ 16

3.2.5 Shock................................................................................ 16

3.2.6 Sweep Speed ..................................................................... 16

3.2.7 Servo Table Speed............................................................. 16

3.2.8 Air Requirements.............................................................. 16

3.2.9 Electrical Requirements..................................................... 16

3.2.10 Welding Current Rating..................................................... 16

3.2.11 Hard Stops........................................................................ 17

3.2.12 Arc Shield......................................................................... 17

3.5 OPERATOR STATION (OP-STATION) ............................................ 17

3.5.1 Emergency Stop (E-Stop)................................................... 17

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.7.3 GMAW Torch................................................................... 22

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

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

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

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

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

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

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

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

4.1 OPERATING INSTRUCTIONS ........................................................ 24

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

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

4.1.3 E-Stop Recovery................................................................ 26

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

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

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

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

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

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

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

4.3.1 I/O Assignment................................................................. 29

4.3.2 Sweeping Table to Side A................................................... 30

4.3.3 Sweeping Table to Side B................................................... 31

4.3.4 Tilting the Servo Table on Side A........................................ 31

4.3.5 Tilting the Servo Table on Side B....................................... 31

4.3.6 Flattening the Servo Table on Side A.................................. 31

4.3.7 Flattening the Servo Table on Side B................................. 32

4.3.8 Rotating the Servo Tables.................................................. 32

4.4 SAMPLE JOBS................................................................................ 32

4.4.1 Master Job....................................................................... 32

4.4.2 SweepA Job...................................................................... 33

4.4.3 SweepB Job...................................................................... 33

4.4.4 TiltA Job........................................................................... 33

4.4.5 TiltB Job........................................................................... 34

4.4.6 Weld-A Job....................................................................... 34

4.4.7 Weld-B Job....................................................................... 35

4.4.8 Clean Job.......................................................................... 36

5.0 MAINTENANCE ........................................................................................... 37

5.1 PERIODIC MAINTENANCE............................................................ 37

5.2 SPARE PARTS LIST......................................................................... 38

5.3 FUSE AND CIRCUIT BREAKER PROTECTION............................... 38

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

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

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

Figure Page

Figure 1-1 System Layout...................................................................................... 3

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

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

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

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

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

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

LIST OF TABLES

Table Page

Table 5-1 Periodic Maintenance.......................................................................... 37

Table 5-2 Spare Parts........................................................................................ 38

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

Table 5-4 MRC Cabinet Fuses and Circuit Breakers............................................ 39

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

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

LIST OF FIGURES

Table 5-5 Universal Welding Interface (UWI) Fuses and Circuit Breakers........... 40

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

ArcWorld 7000 Operator's Manual Page 1 MOTOMAN

1.0 INTRODUCTION

The ArcWorld 7000 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 7000 features a Motoman arc welding robot and MRC controller
with menu-driven arc welding application software, complete welding package,
indexing tilt/rotate positioner, operator interface, and total safety environment.

1.1 ABOUT THIS DOCUMENT

This manual provides operation instructions for the ArcWorld 7000 system. In
addition to this introduction, the manual includes the following sections:

• Section 2: Safety

• Section 3: Description of Equipment

• Section 4: Operation

• Section 5: Maintenance

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

ArcWorld 7000 system.
The Description of Equipment Section of this manual provides a detailed

description of the major components of the ArcWorld system.
The Operation Section provides instructions to operate the ArcWorld system. In

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

The Maintenance Section contains a table listing periodic maintenance requirements
for the ArcWorld 7000 cell. This section also includes a list of recommended spare
parts.

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

ArcWorld 7000 Operator's Manual Page 2 MOTOMAN

1.2 SYSTEM OVERVIEW

The ArcWorld 7000 provides a complete arc welding solution in a standardized
configuration. The system is designed around a Motoman arc welding robot and
includes a complete welding package. A double-ended, tilt/rotate positioner allows
an operator to prepare and set up parts on one side while the robot welds on the
other side. The cell provides a full complement of safety features designed to
protect both personnel and equipment.

1.2.1 System Layout

The illustration in Figure 1-1 shows the system layout for the ArcWorld 7000 cell.
The ArcWorld 7000 includes the following major components:

• Motoman robot manipulator and MRC controller

• 5-axis, double-ended, tilt/rotate positioner

• Master operator station

• Welding equipment, including the following:

• Excel-Arc welding power source

• Torch (water-cooled or air-cooled)

• Wire feeder

• Universal welding interface (UWI)

• Torch breakaway

• Safety equipment, including the following:

• Safety fencing with arc curtains

• Interlocked safety mats

• Interlocked cell door

• Positioner arc screen

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

ArcWorld 7000 Operator's Manual Page 3 MOTOMAN

Operator
Station

MRC
Cabinet

External
Axis Cabinet

Com-Arc

Disconnect

Water
Circulator

Welding
Power
Source

Auxiliary
Equipment
Common Base

Gas Bottle
(customer supplied)

Assembled
Fence

Robot

Torch
Tender

Positioner

Safety
Mats

Door

Transformer

Disconnect

Figure 1-1 System Layout

ArcWorld 7000 Operator's Manual Page 4 MOTOMAN

1.2.2 Optional Equipment

The following optional welding equipment is available for use with the ArcWorld
7000:

• Torch tender

• Wire cutter

• Com-Arc III

1.3 REFERENCE TO OTHER DOCUMENTATION

For additional information refer to the following:

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

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

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

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

• Motoman ArcWorld 7000 Installation Manual (Part Number 132341-9)

• Additional vendors' manuals

1.4 CUSTOMER SERVICE INFORMATION

If you are in need of technical assistance, contact the Motoman service staff at
[phone]. Have the following information ready before you call:

• Robot Type (K3, K6, K10, etc.)

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

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

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

ArcWorld 7000 Operator's Manual Page 5 MOTOMAN

ArcWorld 7000 Operator's Manual Page 6 MOTOMAN

2.0 SAFETY

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

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

Robotic Industries Association

900 Victors Way

P.O. Box 3724

Ann Arbor, Michigan 48106

TEL: [phone]

FAX: [phone]

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

been trained!

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

This safety section addresses the following:

• Standard Conventions (see Section 2.1)

• General Cautions and Warnings (see Section 2.2)

• Mechanical Safety Devices (see Section 2.3)

• Installation Safety (see Section 2.4)

• Programming Safety (see Section 2.5)

• Operation Safety (see Section 2.6)

• Maintenance Safety (see Section 2.7)

ArcWorld 7000 Operator's Manual Page 7 MOTOMAN

2.1 STANDARD CONVENTIONS

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

• DANGER

• WARNING

• CAUTION

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

defined below (in descending order of severity).

➪

DANGER!

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

➪

WARNING!

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

➪

CAUTION!

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

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

understanding the item being explained.

ArcWorld 7000 Operator's Manual Page 8 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 damage the equipment. Only trained personnel familiar
with the operation of this robot, the operator's manuals, the system equipment,
and options and accessories should be permitted to operate this robot system.

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

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

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

2.3 MECHANICAL SAFETY DEVICES

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

• Safety fences and barriers

• Light curtains

• Door interlocks

• Safety mats

• Floor markings

• Warning lights

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

ArcWorld 7000 Operator's Manual Page 9 MOTOMAN

2.4 INSTALLATION SAFETY

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

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

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

• Position all controllers outside the robot work envelope.

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

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

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

2.5 PROGRAMMING SAFETY

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

• Any modifications to NODE 2 (for ERC controllers) or PART 1 (for MRC
controllers) of the controller PLC can cause severe personal injury or death, as
well as damage to the robot! Do not make any modifications to NODE 2 or
PART 1. Making any changes without the written permission of Motoman
will VOID YOUR WARRANTY!

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

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

ArcWorld 7000 Operator's Manual Page 10 MOTOMAN

• The concurrent I/O (Input and Output) function allows the customer to modify
the internal ladder inputs and outputs for maximum robot performance. Great
care must be taken when making these modifications. Double-check all
modifications under every mode of robot operation to ensure that you have not
created hazards or dangerous situations that may damage the robot or other
parts of the system.

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

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

• Ensure that all safeguards are in place.

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

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

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

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

2.6 OPERATION SAFETY

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

• 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.

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

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

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

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

ArcWorld 7000 Operator's Manual Page 11 MOTOMAN

• All modifications made to the controller will change the way the robot operates
and can cause severe personal injury or death, as well as damage the robot. On
ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3;
and I/O (Input and Output) modifications. On MRC controllers this includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.

2.7 MAINTENANCE SAFETY

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

• 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.

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

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

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

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

• Ensure all safeguards are in place.

• Use proper replacement parts.

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

• All modifications made to the controller will change the way the robot operates
and can cause severe personal injury or death, as well as damage the robot. On
ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3;
and I/O (Input and Output) modifications. On MRC controllers this includes
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.

• 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 7000 Operator's Manual Page 12 MOTOMAN

ArcWorld 7000 Operator's Manual Page 13 MOTOMAN

3.0 DESCRIPTION OF EQUIPMENT

3.1 K-SERIES ROBOT DESCRIPTION

The standard ArcWorld 7000 uses either a Motoman K6 or K10 robot
manipulator. The Motoman K6 and K10 robots and YASNAC MRC Controller
represent state-of-the-art technology in robotics today. The six-axis K6 robot has a
payload of 6 kg (13.2 lbs). It features a 1,322 mm (52.0 inch) reach and has a
relative positioning accuracy of ± 0.1 mm (0.004 inch). The six-axis K10 robot
has a payload of 10 kg (22 lbs). It features a 1,555 mm (61.2 inch) reach and has a
relative positioning accuracy of ± 0.1 mm (0.004 inch).

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

3.2 MRC CONTROLLER

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

• User interface

• Main logic functions

• Input / output control

• Servo control

• Numeric processing

• Variable data memory

• Program and constant data memory

• Analog welding command functions

• Welding interface

• Power distribution

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