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.

ArcWorld 7000 Operator's Manual Page 14 MOTOMAN

Figure 3-1 MRC Controller

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

Figure 3-2 MRC Playback Box

3.2.1 Servo Power

ArcWorld 7000 Operator's Manual Page 15 MOTOMAN

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

3.2.2 Mode Select

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

3.2.3 Cycle Select

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

3.2.4 Emergency Stop (E-Stop)

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

3.2.5 Alarm / Error

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

3.2.6 Hold

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

3.2.7 Start

Pressing the START button causes the manipulator playback operation to start.
The indicator lamp lights during playback. Pressing the START button also
releases a Hold state.

3.2.8 Playback Box Subpanel

The playback box has an inside subpanel that contains additional user controls.
Refer to your MRC Operator's Manual for Arc Welding more information.

ArcWorld 7000 Operator's Manual Page 16 MOTOMAN

3.3 PROGRAMMING PENDANT

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

ArcWorld 7000 Operator's Manual Page 17 MOTOMAN

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 Arc Welding for more information.

3.3.2 Robot Speed Indicators

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

3.3.3 Emergency Stop (E-Stop)

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

3.3.4 Keypad

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

3.3.5 Servo Power

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

3.3.6 Coordinate System Indicators

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

3.4 POSITIONER

The ArcWorld 7000 cell uses a five-axis modular positioner. This positioner
provides a central axis that reciprocates 180 degrees per cycle. An air motor drives
the central axis. The positioner has a servo driven rotating table mounted at each
end. Each servo table also has an air cylinder actuated tilt axis.

ArcWorld 7000 Operator's Manual Page 18 MOTOMAN

3.4.1 Part / Fixture Rating

The maximum combined weight of the part and fixture on each side of the unit is
500 pounds.

3.4.2 Part Center of Gravity

Each of the tilt tables is rated for a 500-pound load with a center of gravity located 6
inches above and 6 inches from the center of each table.

3.4.3 Temperature Operating Range

The temperature operating range is 40 to 110˚ Fahrenheit.

3.4.4 Humidity

Noncondensing 10 to 90% relative humidity is acceptable.

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

be used.

3.4.5 Shock

The positioner can accept shocks less than 0.5 G.

3.4.6 Sweep Speed

Sweep speed is typically 3 to 5 seconds with a full load of 500 pounds on each
side.

3.4.7 Servo Table Speed

The servo table speed is 0 to 5 RPM.

3.2.8 Air Requirements

Input required to operate the unit is 90 SCFM at 80 PSIG.

3.4.9 Electrical Requirements

ArcWorld 7000 Operator's Manual Page 19 MOTOMAN

All electrical power required to operate the unit is supplied from the MRC
controller and consists of a 115 VAC, 60 Hz, single phase circuit that provides
power for the solenoids, brake, and interface. The servo tables operate by external
MRC servo motors.

3.4.10 Welding Current Rating

The positioner has a welding current capacity of 600 amperes at 100% duty cycle.

3.4.11 Hard Stops

The positioner has hard stops for variable positioning of the tilt axis.

3.4.12 Arc Shield

The positioner has a sheet metal screen for welding arc radiation protection between
the operator loading zone and the welding zone. Do not operate this equipment
unless the arc shield is in place.

3.5 OPERATOR STATION (OP-STATION)

The op-station (Figure 3-4) includes a NEMA enclosure on a stand-alone pedestal.
The following sections describe each of the op-station controls.

ALARM

RESET

ROBOT HOLD

MASTER JOB

START

MOTOMAN

STATION READY

POSITIONER

AUTO/MAN

SERVO ON

ESTOP

WARNING!

DO NOT ENTER

ROBOT WORK AREA

CYCLE START

CYCLE START

ArcWorld 7000 Operator's Manual Page 20 MOTOMAN

Figure 3-4 Operator Station (Op-Station)

3.5.1 Emergency Stop (E-Stop)

The operator station E-Stop, the robot E-Stop, the sliding door interlocks, and the
ArcWorld 7000 safety mats are connected in series in the Emergency Stop circuit.
If the E-Stop circuit is interrupted, the robot and the Motoman positioner will go
into the E-Stop condition. The operator station E-Stop light will come on when the
E-Stop button is pressed. In the E-Stop condition, power to the Motoman
positioner interface is removed. This stops the table sweep.

3.5.2 Hold

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

3.5.3 Cycle Start

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

3.5.4 Station Ready

The STATION READY lamp is interlocked with the robot CUBE #1 output. The
robot Output #11 turns on the STATION READY lamp.

3.5.5 Alarm

The ALARM lamp is connected to the robot Alarm Occurrence output. The
ALARM lamp turns on when the robot encounters a major or minor alarm
condition.

3.5.6 Servo On

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

3.5.7 Positioner Auto / Manual

ArcWorld 7000 Operator's Manual Page 21 MOTOMAN

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

the structure of the master job.

3.5.8 Master Job Start

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

3.5.9 Operator Station Enable / Disable

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

3.5.10 Reset

The RESET pushbutton is connected to the robot alarm reset input. Any alarm or
error condition will be cleared when this button is pressed. In addition, the RESET
pushbutton and the RIGHT CYCLE START pushbuttons are interlocked and,
when pressed simultaneously, enable the positioner if the robot servo motors are
on. The positioner needs to be enabled at initial power up or emergency stop or
shock sensor condition.

NOTE: Resetting the positioner may cause some motion of the positioner. Do not reset the positioner

with the robot near the tooling. If E-Stop occurs during programming, be sure to reset the
positioner before resuming programming.

3.6 WELDING POWER SOURCE

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

3.6.1 Main Power

ArcWorld 7000 Operator's Manual Page 22 MOTOMAN

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

3.6.2 Volt / Amp Settings

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

3.6.3 Terminal Connectors

The two terminals on the front of the Excel-Arc power source serve as connection
points for the welding leads. In its standard configuration, the ArcWorld 7000 is
set up for reverse polarity. The Positive Terminal (4) connects to the positive
welding lead (to the wire feeder). The Negative Terminal (5) connects to the
negative welding lead (to the workpiece).

ArcWorld 7000 Operator's Manual Page 23 MOTOMAN

Figure 3-5 Excel-Arc Controls

3.6.4 Local / Remote Operation

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

ArcWorld 7000 Operator's Manual Page 24 MOTOMAN

3.6.5 Feeder Control Receptacles

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

3.6.6 Circuit Breakers

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

3.6.7 AC Receptacles

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

3.7 WELDING EQUIPMENT

In addition to the Excel-Arc power source, the ArcWorld 7000 system provides a
complete complement of arc welding equipment. In its standard configuration, the
ArcWorld system includes the following:

• PWF-600 wire feeder

• UWI welding interface

• Either an air-cooled or water-cooled GMAW torch

• Torch breakaway mount

3.7.1 PWF4 Wire Feeder

The PWF4 wire feeder mounts on the robot arm. This 4-roll wire feeder provides
reliable wire feeding at rates up to 600 IPM. An integral gas valve provides fast
gas response time. The PWF4 feeder has an inch forward button to help simplify
set-up and reduce change-over time. The PWF4 wire feeder uses interchangeable
feed rolls to accommodate different types and sizes of wire.

3.7.2 Universal Welding Interface (UWI)

The UWI interface provides microprocessor control to the wire feeder and power
source. It scales the signals from the MRC to the appropriate levels required for
control of the welding components. It also provides isolation of the power source
analog signals.

ArcWorld 7000 Operator's Manual Page 25 MOTOMAN

3.7.3 GMAW Torch

The ArcWorld 7000 uses either an air-cooled or water-cooled robotic/automatic
GMAW torch. These are heavy-duty torches designed for quick replacement while
requiring minimum robot reprogramming. The GMAW torch mounts on the end
of the robot wrist. For applications that use the water-cooled torch, the ArcWorld
7000 includes a suitable water circulator kit.

3.7.4 RAM Breakaway Mount

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

3.8 SAFETY EQUIPMENT

The ArcWorld 7000 system incorporates a host of safety equipment. When all
standard safety precautions are taken, the safety equipment helps to ensure safe
operation of the robotic cell. The ANSI/RIA R15.06 Robot Safety Standard

stipulates the user is responsible for safeguarding.

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

The ArcWorld 7000 safety features include the following:

• Arc screens

• Safety fencing

• Dual interlocking cell door

• Interlocked safety mats

• Emergency stop (E-Stop) buttons

3.8.1 Arc Screens

Two separate arc screens are used on the ArcWorld 7000. The first is a metal arc
screen on the turntable positioner. This screen blocks arc radiation and sparks from
the welding operation. The material used to cover the safety fencing of the entire
robotic cell acts as the second arc screen. This material reduces the amount of ultra­violet radiation that is emitted from the robotic cell.

ArcWorld 7000 Operator's Manual Page 26 MOTOMAN

➪

WARNING!

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

3.8.2 Fencing

The safety fencing provided with the ArcWorld 7000 encloses and defines the
robotic cell. This helps ensure that all robotic activity occurs without anyone
entering the robot's path during operation.

➪

WARNING!

The strip of fencing that runs across and under the positioner is
intended to define the cell boundary. This boundary is not to be
crossed during cell operation.

3.8.3 Interlocks

Dual safety interlocks on the cell entrance door prevent entry into the cell during
Play mode. Opening the cell door with the robot in Play causes an E-Stop and
shuts down the entire system.

3.8.4 Safety Mats

The safety mat provided with the ArcWorld 7000 helps prevent serious injury to
anyone entering the turntable positioner area during the sweeping process. If a
person steps on this mat when the positioner is in motion, an E-Stop occurs
causing the entire system to shut down.

3.8.5 Emergency Stops (E-Stops)

In addition to the interlocking devices described above, the ArcWorld 7000 has
strategically placed emergency stops (E-Stops). These are operator actuated
devices that, when activated, immediately cause the system to shut down. The
following is a list of their locations:

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

ArcWorld 7000 Operator's Manual Page 27 MOTOMAN

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

• The turntable positioner operator station has one E-Stop button.

ArcWorld 7000 Operator's Manual Page 28 MOTOMAN

4.0 OPERATION

This section provides operation instructions for the ArcWorld 7000 system.
Operation procedures include the following:

• System start up

• Part set up

• Normal operation

• Fault recovery

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

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

4.1 OPERATING INSTRUCTIONS

The ArcWorld 7000 is a fully integrated robotic GMAW welding cell. The robot
welds on one side of the positioner while the operator loads parts on the opposite
side. Once the robot is finished with its process, it returns to the home position.
The operator sweeps the positioner enabling the robot to start welding on the next
part.

The safety entrance door interlocks prevent anyone from entering the cell while the
robot is in Play mode. Stepping on the safety mat in front of the positioner during
sweeping causes an E-Stop. If anyone crosses the cell boundary fence section in
front of the positioner, an E-Stop occurs.

The following is the typical sequence of operations for the ArcWorld 7000 Cell
after start-up:

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

welded.

2. Wait for the STATION READY indicator to light.

3. Press both CYCLE START palm buttons on the operator station. The

positioner sweeps to the other side and places the unwelded parts in the robot
work area. The robot begins welding the unwelded parts.

4. Unload the welded parts from the fixture on the other side of the positioner.

5. Repeat steps 1 through 4.

ArcWorld 7000 Operator's Manual Page 29 MOTOMAN

4.1.1 Start-Up

To start up the ArcWorld 7000 Cell from a Power Off condition, proceed as
follows:

1. Make sure that the disconnect from the transformer to the MRC is ON.

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

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

indicator light on the power source should glow.

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

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

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

lamp in the switch should light.

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

lamp in the switch should light.

8. Enable the operator station.

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

station at the same time to initialize the positioner.

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

11. Make sure the positioner servo tables are in flat position.

12. Make sure the positioner servo tables' rotational axes are in the home position.

13. Call up the master job.

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

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

16. Wait for the STATION READY indicator to light.

The ArcWorld 7000 cell is now ready for operation.

4.1.2 Fault Recovery

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

ArcWorld 7000 Operator's Manual Page 30 MOTOMAN

4.1.3 E-Stop Recovery

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

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

• Opening the sliding door on the robot enclosure or removing the safety plug
when the robot is not in Teach Mode.

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

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

To restart the ArcWorld 7000 Cell after an E-Stop condition occurs, follow the
procedure below.

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

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

pendant, or the MRC playback box.

• Close the sliding door and connect the safety plug.

• Step off the safety mat.

• Clear the Shock Sensor condition (refer to Section 4.1.4).

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

➪

CAUTION!

If an E-Stop condition occurs while the positioner is sweeping,
the positioner will continue the sweep when initialized.

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

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

The ArcWorld 7000 Cell will continue its operation.

4.1.4 Shock Sensor Recovery

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

To override the shock sensor, do the following:

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

ArcWorld 7000 Operator's Manual Page 31 MOTOMAN

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

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

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

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

Feeder
Housing

Shock Sensor
Cord

Torch
Assembly

Breakaway

Shock
Sensor Plug

Shock Sensor
Jumper

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

Figure 4-1 Shock Sensor Override

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

➪

CAUTION!

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

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

3. Close the interlocked enclosure doors.

ArcWorld 7000 Operator's Manual Page 32 MOTOMAN

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

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

➪

CAUTION!

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

6. Press the MASTER JOB START button.

4.1.5 Shutdown

Use the following procedure to shut down the ArcWorld 7000 Cell after operation
is complete.

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

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

3. Press the TEACH MODE button on the MRC playback box.

4. Set the MRC Main Power switch to the OFF position.

5. Set the INPUT POWER switch on the welding power source to the OFF
position.

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

The ArcWorld 7000 Cell is now shut down.

4.2 ALARMS AND ERRORS

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

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

4.2.1 Error Messages

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

ArcWorld 7000 Operator's Manual Page 33 MOTOMAN

Errors like these are cleared by pressing the CANCEL or ENABLE button on the
programming pendant.

4.2.2 Minor Alarms

Minor alarms are usually programming errors. Minor alarms might occur if a
circle has been programmed with fewer than three circular points, etc.

These alarms are cleared by pressing one of the following:

• RELEASE soft key on the programming pendant

• RESET button on the operator's station

• ENABLE button on the programming pendant twice

4.2.3 Major Alarms

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

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

4.3 PROGRAMMING

4.3.1 I/O Assignment

The ArcWorld 7000 positioner and ArcWorld operator station use the following
MRC user and dedicated inputs and outputs.

MRC User Inputs

• IN #1 Cycle Start Interlocked with CUBE #1

• IN #2 Auto/Manual Selector Switch

• IN #9 At Side A

• IN #10 At Side B

• IN #11 Side A Flat

• IN #12 Side A Tilt

• IN #13 Side B Flat

• IN #14 Side B Tilt

ArcWorld 7000 Operator's Manual Page 34 MOTOMAN

MRC User Outputs

• OUT #1 Station Ready Interlocked with CUBE#1

• OUT #9 Sweep to A Interlocked with CUBE#1 and OUT #15

• OUT #10 Sweep to B Interlocked with CUBE#1 and OUT #15

• OUT #11 Slow 1

• OUT #12 Slow 2

• OUT #13 Slow 3

• OUT #14 Tilt A / Flat A (1 = Tilt)

• OUT #15 Tilt B / Flat B (1 = Tilt)

NOTE: The K-series robot must be in CUBE #1 before the ArcWorld 7000 system can sweep the

positioner.

MRC Dedicated Inputs

• External Emergency Stop

• External Servo On

• External Hold

• Anti-Tie-Down

• External Start

• Alarm Reset

• Remote Mode On

MRC Dedicated Outputs

• Servo On

• Alarm Occurrence

• Teach Mode

• Cube 1

4.3.2 Sweeping Table to Side A

To sweep the positioner to Side A:

• The servo tables must both be in the flat position.

ArcWorld 7000 Operator's Manual Page 35 MOTOMAN

• The robot servo power must be on.

• Both external axes must be in the home position.

• The positioner must be enabled.

• The robot must be in CUBE #1.

• The robot Output #1 must be on.

• The robot Output #9 must be on.

When the table sweeps into position at Side A, the positioner provides an input to
IN #9 "AT SIDE A." When this input turns on, robot Output #9 should be off.

4.3.3 Sweeping Table to Side B

To sweep the positioner to Side B:

• The servo tables must both be in the flat position.

• The robot servo power must be on.

• The external axes must both be in the home position.

• The positioner must be enabled.

• The robot must be in CUBE #1.

• The robot Output #1 must be on.

• The robot Output #10 must be on.

When the table sweeps into position at Side B, the positioner provides an input to
IN #10 "AT SIDE B". When this input turns on, robot Output #10 should be off.

4.3.4 Tilting the Servo Table on Side A

• The robot servo power must be on.

• The positioner must be enabled.

• The robot must be in CUBE #1.

• The robot Output #14 must be on.

4.3.5 Tilting the Servo Table on Side B

• The robot servo power must be on.

• The positioner must be enabled.

• The robot must be in CUBE #1.

• The robot Output #15 must be on.

4.3.6 Flattening the Servo Table on Side A

ArcWorld 7000 Operator's Manual Page 36 MOTOMAN

• The robot servo power must be on.

• The positioner must be enabled.

• The robot must be in CUBE #1.

• The robot Output #14 must be off.

4.3.7 Flattening the Servo Table on Side B

• The robot servo power must be on.

• The positioner must be enabled.

• The robot must be in CUBE #1.

• The robot Output #15 must be off.

4.3.8 Rotating the Servo Tables

The MRC external axis function controls the rotation axes of the positioner. The
motion points for the external axes are taught and recorded in the program in the
same manner as any of the robot axes. The MRC controls the speed and position.

The external axis motion is interlocked with the positioner Side A and Side B
inputs (Input #9 and Input #10). Only the axis on the robot side can be moved in
Teach or Play modes.

4.4 SAMPLE JOBS

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

4.4.1 Master Job

Line Step Function

000 000 NOP
001 WAIT IN#(02)=ON
002 WAIT IN#(01)=ON
003 CALL JOB:SWEEPA
004 CALL JOB:WLDFLATA

'Weld job
005 CALL JOB:TILTA
006 CALL JOB:WLDTILTA

ArcWorld 7000 Operator's Manual Page 37 MOTOMAN

'Weld job
007 WAIT IN#(02)=ON
008 WAIT IN#(01)=ON
009 CALL JOB:SWEEPB
010 CALL JOB:WLDFLATB

'Weld job
011 CALL JOB:TILTB
012 CALL JOB:WLDTILTB

'Weld job
013 END

4.4.2 SweepA Job

Line Step Function

000 000 NOP
001 CALL JOB:CUBE1
002 DOUT OT#(01) ON
003 DOUT OT#(09) ON
004 WAIT IN#(09)=ON
005 DOUT OT#(09) OFF
006 DOUT OT#(01) OFF
007 END

4.4.3 SweepB Job

Line Step Function

000 000 NOP
001 CALL JOB:CUBE1
002 DOUT OT#(01) ON
003 DOUT OT#(10) ON
004 WAIT IN#(10)=ON
005 DOUT OT#(10) OFF
006 DOUT OT#(01) OFF
007 END

ArcWorld 7000 Operator's Manual Page 38 MOTOMAN

4.4.4 TiltA Job

Line Step Function

000 000 NOP
001 CALL JOB:CUBE1
002 DOUT OT#(14) ON
003 WAIT IN#(12)=OFF
004 WAIT IN#(11)=ON
005 DOUT OT#(14) OFF
006 END

4.4.5 TiltB Job

Line Step Function

000 000 NOP
001 CALL JOB:CUBE1
002 DOUT OT#(15) ON
003 WAIT IN#(14)=OFF
004 WAIT IN#(13)=ON
005 DOUT OT#(15) OFF
006 END

4.4.6 Weld-A Job

Line Step Function

000 000 NOP

'Ret to Master job if not at A
001 RET IF IN#(09)=OFF
002 001 MOVJ VJ=25.00

'Move to first point at 25%
003 002 MOVJ VJ=50.00

'Move to second point at 50%
004 003 MOVJ VJ=50.00

'Move to third point at 50%
005 ARCON ASF#(1)

'Call the welding start file

ArcWorld 7000 Operator's Manual Page 39 MOTOMAN

006 004 MOVL V=80

'Move to the next point
007 ARCOF AEF#(1)

'Call the welding end file
008 005 MOVJ VJ=25.00

'Move away from the weld end
009 006 MOVJ VJ=50.00

'Move to the next point at 50%
010 INC B00

'Counter for nozzle cleaner
011 RET
012 END

4.4.7 Weld-B Job

Line Step Function

000 000 NOP
001 RET IF IN#(10)=OFF

'Ret to Master job if not at B
002 001 MOVJ VJ=25.00

'Move to first point at 25%
003 002 MOVJ VJ=50.00

'Move to second point at 50%
004 003 MOVJ VJ=50.00

'Move to third point at 50%
005 ARCON ASF#(1)

'Call the welding start file
006 004 MOVL V=80

'Move to the next point
007 ARCOF AEF#(1)

'Call the welding end file
008 005 MOVJ VJ=25.00

'Move away from the weld end
009 006 MOVJ VJ=50.00

ArcWorld 7000 Operator's Manual Page 40 MOTOMAN

'Move to the next point at 50%
010 INC B00

'Counter for nozzle cleaner
011 RET
012 END

4.4.8 Clean Job

Line Step Function

000 000 NOP
001 RET IF IN#(02)=OFF
002 SET B00=0
003 001 MOVJ VJ=100.00

etc.

NOTE: Add "INC B00" instruction in EACH of the welding jobs.

ArcWorld 7000 Operator's Manual Page 41 MOTOMAN

5.0 MAINTENANCE

5.1 PERIODIC MAINTENANCE

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

For additional maintenance information regarding the 5-axis servo positioner, refer
to your positioner manual.

For maintenance information regarding the welding power source, refer to your
Excel-Arc Owner's Manual.

Table 5-1 provides a list of periodic maintenance to be performed on the ArcWorld
7000 cell. Keep in mind that the maintenance intervals given serve as guidelines
only. You should adjust the frequency of maintenance to suit your specific work
conditions.

➪

CAUTION!

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

Table 5-1 Periodic Maintenance

Frequency Component Procedure

Daily Water circulator

(water-cooled torch
application only)

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

ArcWorld 7000 Operator's Manual Page 42 MOTOMAN

5.2 SPARE PARTS LIST

Table 5-2 Spare Parts

Description Part No.
Valve, 2-Way Parker: 12F23C2148ACFSB05
Valve, 4-Way MAC: 6531A311PM11D
Limit Switch Square D: 9007,c68110
Limit Switch Arm, 1.5" Square D: MA-1
Harmonic Drive Assembly Aronson: 9945-2072-00

5.3 FUSE AND CIRCUIT BREAKER PROTECTION

Tables 5-3 through 5-6 give the locations of fuses and circuit breakers that are
significant to the operation of the total system. In most cases, MRC spare fuses are
placed in the accessory bag with the MRC.

➪

WARNING!

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

Abbreviations:

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

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

Device

Designator Rating Part Number Location Purpose

CB1 10A

115V

203627-7 Upper rear panel Protects 115V circuit

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

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

circuit

ArcWorld 7000 Operator's Manual Page 43 MOTOMAN

Table 5-4 MRC Cabinet Fuses and Circuit Breakers

Device

Designator Rating

Part

Number Location Purpose

CB
(1MCCB)

50 A

30 A

NF50-SS

NF30-SS

Upper left front
K10

Upper left front
K6

Main circuit breaker for
incoming 200 VAC, 3­phase for MRC cabinet

CB (1SV) 30 A Lower left side

of servo pack

Protects input for servo pack
1SV for S, L, and U axes

CB (2SV) 30 A Lower left side

of servo pack

Protects input for servo pack
2SV for R, B, and T axes

FU1 5 A GDL-5

250V

MTU-01 Protects CPT10199

transformer, brake, and fan
circuits

FU2 5 A GDL-5

250V

MTU-01 Protects CPT10199

transformer, brake, and fan
circuits

FU4 4 A GP-40

250V

MTU-01 Protects robot brake circuits

FU5 4 A GP-40

250V

MTU-01 Protects robot brake circuits

1FU 1 A GDL-1

250V

Top/left/rear Protects the four fan circuits

of the MRC

FU3 2 A GDL-2

125V

Top/left/rear Protects the 100 VAC

supply to the AC receptacle
for the floppy disk controller
power

FU1 3 A SM1101 MBB-02 External voltage protection -

24V

FU2 3 A SM1101 MBB-02 External voltage protection -

24V

ArcWorld 7000 Operator's Manual Page 44 MOTOMAN

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

Device

Designator Rating Part Number Location Purpose

F1 8A 250V On KXA motor

speed control

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

FU1 4A 250V Wickman

19374K-4A

On interface
board

Protects 115V circuit

FU2 0.25A

125V

Wickman
19303K­250A

On interface
board

Protects shock
sensor circuit

FU3 0.5A

125V

Wickman
19303K­500A

On interface
board

Protects 24V circuit

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

Device

Designator Rating Part Number Location Purpose

Fuse 1A 250V TD-1 Front of Com-

Arc III box

Protects 200V circuit

ArcWorld 7000 Operator's Manual Appx. A MOTOMAN

APPX. A RISK ASSESSMENT

Risk Assessment Appx. A MOTOMAN
ArcWorld 7000

MOTOMAN Risk Assessment

ArcWorld 7000 System

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

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

MOTOMAN's ArcWorld 7000 robot cell.

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

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

SAFEGUARDING PERSONNEL

Safeguarding Plant Personnel

• Barrier around robot work envelope.

• Interlocked gate for access to cell.

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

• Serious hazards are identified by warning labels.

Safeguarding Operator

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

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

defeat.

• Emergency Stop button on operator station.

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

• Safety mats are interlocked to stop positioner motion when activated. Requires

reset at operator station to restart.

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

Risk Assessment Appx. A MOTOMAN
ArcWorld 7000

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

operation.

Safeguarding Teacher

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

• Clearance of 24" between robot and fencing.

• Emergency Stop button on programming pendant.

• S-axis motion restricted by hardstops.

• TEACH LOCK prevents operation from controller while programming

pendant is enabled.

• Sweeping of positioner from pendant requires deliberate action.

• Continuous stepping is at reduced speed.

• Safety mats are provided inside cell to provide redundant protection against

operator entry, and to prohibit sweep during teach mode.

Safeguarding Maintenance Personnel

• Robot controls are outside barrier.

• Electrical energy sources equipped with lockout/tagout.

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

SOURCES OF HAZARDS

Unauthorized Access

• Interlocked barrier.

• Dual interlocks, difficult to defeat by operator.

Human Errors in Judgment

• Safety mat interlocked with positioner.

• Dual palm cycle start.

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

pendant.

Control Errors

• Most Safety features independent of program logic.

Risk Assessment Appx. A MOTOMAN
ArcWorld 7000

• 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 ultra-

violet radiation.

• UV curtain helps contain welding sparks.

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

determined and provided by USER.)

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

supplied.)

Installation Defects

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

connected.

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

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

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

Power System Failure or
Inadvertent Power Initiation

• Easy recovery from power failure.

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

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

Risk Assessment Appx. A MOTOMAN
ArcWorld 7000

EQUIPMENT PROTECTION

Human Errors

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

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

can index.

Power Faults

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

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

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

WHAT-IF CONSIDERATIONS

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

Redundant safety mats and fence extensions help prevent pinch points.

What if personnel step over the cell fencing into the positioner path?

Redundant safety mats are provided that prevent positioner from sweeping in play
mode when activated.

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

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

ArcWorld 7000 Operator's Manual Appx. B MOTOMAN

APPX. B SYSTEM OUTLINE

This section contains the following outline drawings:

Drawing Number Title Sheet Number

131931 Cell Layout Sheet 1 of 17
131931 Main Bill of Material Sheet 2 of 17

ArcWorld 7000 Operator's Manual Appx. C MOTOMAN

APPX. C ELECTRICAL DRAWINGS

This section contains the following electrical drawings:

Drawing Number Title Sheet Number

131931 Power Distribution Sheet 3 of 17
131931 MRC I/O, MRY01 Board Sheet 4 of 17
131931 MRC I/O, MEW01 Board Sheet 5 of 17
131931 MRC I/O, MI004 Board Sheet 6 of 17
131931 MRC I/O, MI004 Board Sheet 7 of 17
131931 MRC I/O, MI003 Board Sheet 8 of 17
131931 MRC I/O, MI003 Board Sheet 9 of 17
131931 MRC I/O, MI003 Board Sheet 10 of 17
131931 MRC I/O, MI003 Board Sheet 11 of 17
131931 Cable Layout Sheet 12 of 17
131931 Cable Charts Sheet 13 of 17
131931 Ladder Diagram Sheet 14 of 17
131931 Ladder Diagram Sheet 15 of 17
131931 Ladder Diagram Sheet 16 of 17
131931 Ladder Diagram Sheet 17 of 17
130784 MRC to EXSB - Dual Axis
130785 MRC to EXSB
131144 Junction Box to Motor
131145 Junction Box to Encoder
132367 Bill of Materials Sheet 1 of 3
132367 Power Diagram Sheet 2 of 3
132367 Panel Layout Sheet 3 of 3
130161 Connection/Schematic Diagram Sheet 6 of 7

ArcWorld 7000 Operator's Manual Appx. D MOTOMAN

APPX. D MECHANICAL DRAWINGS

This section contains the following mechanical drawings:

Drawing Number Title Sheet Number

131460 External Axis and Cables Sheet 6 of 6
131279 5-Axis Unit Tilt / Rotate Sheet 1 of 2
130128 5-Axis Unit Tilt / Rotate Sheet 1 of 5
132349 MRC Common Base
130157 AW7000 Safety Mat Sheet 6
131177 AW7000 Common Base
130161 Station, Operator Sheet 1 of 7
130161 Station, Operator Sheet 2 of 7

ArcWorld 7000 Operator's Manual Index 1 MOTOMAN

INDEX

A

About this Document, 1
AC Receptacles, 21
Air Requirements, 16
Alarm / Error, 13
Alarm, 18
Alarms and Errors, 28
Arc Screens, 22
Arc Shield, 17

C

Circuit Breakers, 21
Clean Job, 36
Com-Arc III Fuses and Circuit Breakers, Table 5-6, 40
Coordinate System Indicators, 15
Customer Service Information, 4
Cycle Select, 13
Cycle Start, 18

D

Description of Equipment, 11
Display, 15

E

E-Stop Recovery, 26
Electrical Drawings, Appendix C
Electrical Requirements, 16
Emergency Stop (E-Stop), 13
Emergency Stop (E-Stop), 15
Emergency Stop (E-Stop), 17
Emergency Stops, 23
Error Messages, 28
Excel-Arc 6045 CV Fuses and Circuit Breakers, Table 5-3, 38

ArcWorld 7000 Operator's Manual Index 2 MOTOMAN

Excel-Arc Controls, Figure 3-5, 20

F

Fault Recovery, 25
Feeder Control Receptacles, 21
Fencing, 23
Flattening the Servo Table on Side A, 31
Flattening the Servo Table on Side B, 32
Fuse and Circuit Breaker Protection, 38

G

General Safeguarding Tips, 7
GMAW Torch, 22

H

Hard Stops, 17
Hold, 13
Hold, 18
Humidity, 16

I

I/O Assignment, 29
Installation Safety, 8
Interlocks, 23
Introduction, 1

K

K-Series Robot Description, 11
Keypad, 15

L

Local / Remote Operation, 20

M

Main Power, 19
Maintenance, 37
Maintenance Safety, 10
Major Alarms, 29

ArcWorld 7000 Operator's Manual Index 3 MOTOMAN

Master Job, 32
Master Job Start, 18
Mechanical Drawings, Appendix D
Mechanical Safety Devices, 7
Minor Alarms, 29
Mode Select, 13
MRC Cabinet Fuses and Circuit Breakers, Table 5-4, 39
MRC Controller, 11
MRC Controller, Figure 3-1, 12
MRC Playback Box, Figure 3-2, 12

O

Operating Instructions, 24
Operation, 24
Operation Safety, 9
Operator Station (Op-Station), Figure 3-4, 17
Operator Station (Op-Station), 17
Operator Station Enable / Disable, 19
Optional Equipment, 4

P

Part / Fixture Rating, 15
Part Center Of Gravity, 16
Periodic Maintenance, 37
Periodic Maintenance, Table 5-1, 37
Playback Box Subpanel, 13
Positioner, 15
Positioner Auto / Manual, 18
Programming, 29
Programming Pendant, 14
Programming Pendant, Figure 3-3, 14
Programming Safety, 8
PWF4 Wire Feeder, 21

R

Ram Breakaway Mount, 22
Reference to Other Documentation, 4

ArcWorld 7000 Operator's Manual Index 4 MOTOMAN

Reset, 19
Risk Assessment, Appendix A
Robot Speed Indicators, 15
Rotating the Servo Tables, 32

S

Safety, 5
Safety Equipment, 22
Safety Mats, 23
Sample Jobs, 32
Servo On, 18
Servo Power, 12
Servo Power, 15
Servo Table Speed, 16
Shock, 16
Shock Sensor Override, Figure 4-1, 27
Shock Sensor Recovery, 26
Shut Down, 28
Spare Parts List, 38
Spare Parts, Table 5-2, 38
Standard Conventions, 6
Start, 13
Start Up, 25
Station Ready, 18
Sweep Speed, 16
SweepA Job, 33
SweepB Job, 33
Sweeping Table to Side A, 30
Sweeping Table to Side B, 31
System Layout, 2
System Layout, Figure 1-1, 3
System Outline, Appendix B
System Overview, 2

T

Temperature Operating Range, 16
Terminal Connectors, 19

ArcWorld 7000 Operator's Manual Index 5 MOTOMAN

TiltA Job, 33
TiltB Job, 34
Tilting the Servo Table on Side A, 31
Tilting the Servo Table on Side B, 31

U

Universal Welding Interface (UWI), 21
Universal Welding Interface (UWI) Fuses and Circuit Breakers, Table 5-5, 40

V

Volt / Amp Settings, 19

W

Weld-A Job, 34
Weld-B Job, 35
Welding Current Rating, 16
Welding Equipment, 21
Welding Power Source, 19