YASKAWA ArcWorld 50 System Manual
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YASKAWA ArcWorld 50 System Manual

YASKAWA ArcWorld 50 System Manual

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ArcWorld
50/50S and 52/52S
SYSTEM MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and
retain for future reference.
Part Number:
183574-1CD
Revision:
0
1 of 126

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Summary of Contents for YASKAWA ArcWorld 50

  • Page 1 ® ArcWorld 50/50S and 52/52S SYSTEM MANUAL Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. Part Number: 183574-1CD Revision: 1 of 126...
  • Page 2 YASKAWA customers to assist in the operation of the Motoman robots, related equipment and software This manual is copyrighted property of YASKAWA and may not be sold or redistributed in any way. You are welcome to copy this document to your computer or mobile device for...
  • Page 3 183574-1CD ArcWorld 50/50S and 52/ Safety For Your Safety Safety For Your Safety Robots generally have requirements which are different from other manufacturing equipment, such as larger working areas, high-speed operation, rapid arm movements, etc., which can pose safety hazards.
  • Page 4 The customer is responsible for providing adequately trained personnel to operate, program, and maintain the equipment. We recommend approved YASKAWA training courses for all personnel involved with the operation, programming, or repair of the equipment. This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC rules.
  • Page 5 The drawings and photos in this manual are examples. Differences may exist between them and the delivered product. • YASKAWA may modify this model without notice due to product improvements, modifications, or changes in specifications. If such modification is made, the manual number will also be revised.
  • Page 6 183574-1CD ArcWorld 50/50S and 52/ Safety Notes for Safe Operation Notes for Safe Operation Read this manual carefully before installing, operating, maintaining, or inspecting the system. In this instruction, Safe Operations are classified as “DANGER”, “WARNING”, “CAUTION” or “NOTICE”. Indicates an imminently hazardous...
  • Page 7 183574-1CD ArcWorld 50/50S and 52/ Safety ArcWorld Explanation of Safety Labels ArcWorld Explanation of Safety Labels The following labels are attached to the ArcWorld. Always follow these safety labels. Fig. : ArcWorld Label Locations  Collaborative Motion Label Collaboration is a special type of operation between a person and Robot sharing a common workspace.
  • Page 8 183574-1CD ArcWorld 50/50S and 52/ Safety ArcWorld Explanation of Safety Labels  High Voltage Label This label indicates that hazardous voltages are present and there is a danger of getting electrical shock.  Controller Labels Refer to Controller Documentation for details.
  • Page 9 183574-1CD ArcWorld 50/50S and 52/ Safety ArcWorld Explanation of Safety Labels  Securely Lock Door Latches This label is supplied to remind users to have doors securely latched before applying power.  High Voltage Lockout/Tagout Use a device to ensure that power remains off while repairs or adjustments are being made.
  • Page 10 183574-1CD ArcWorld 50/50S and 52/ Safety Installation and Wiring Safety Installation and Wiring Safety Review the Robot and Controller Instructions for details on installation and wiring. In planning installation, adapt an easy to observe arrangement to ensure safety. Take safety into consideration when planning the installation.
  • Page 11 183574-1CD ArcWorld 50/50S and 52/ Safety Installation and Wiring Safety CAUTION • Make sure all covers and shields are installed correctly before operating. – Some drawings in this manual may have protective covers or shields removed to show details. Not having all covers and shields installed correctly can result in injury.
  • Page 12 183574-1CD ArcWorld 50/50S and 52/ Safety Ensure Safety Ensure Safety DANGER • When the power supplies of the Robot and Controller are turned ON at start-up, be sure to confirm the following: – Safety protection devices such as the E-STOP circuit, door interlocks, etc.
  • Page 13 183574-1CD ArcWorld 50/50S and 52/ Safety Ensure Safety All personnel working with the Robot (safety administration, installation, operation, and maintenance personnel) must always be prepared and “Safety First” minded, to ensure the safety of all personnel. WARNING • In the vicinity of the area where the Robot is installed, avoid any dangerous actions, such as entering the Robot's operating range without due care.
  • Page 14 183574-1CD ArcWorld 50/50S and 52/ Safety Ensure Safety WARNING • Turn OFF servo power before operating. – Press the EMERGENCY STOP button to turn off SERVO POWER. When servo power is OFF, the SERVO ON LED on the Programming Pendant is OFF.
  • Page 15 183574-1CD ArcWorld 50/50S and 52/ Safety Ensure Safety CAUTION • All operators, programmers, maintenance personnel, supervisors, and anyone working near the system must be familiar with the operation of this equipment. – All personnel involved with the operation of the equipment must understand potential dangers of operation.
  • Page 16 183574-1CD ArcWorld 50/50S and 52/ Safety Operation Safety Operation Safety DANGER • Personnel engaged in teaching or inspection, etc. of the Robot must receive special training required by applicable laws and regulations. • While performing inspection and maintenance, wiring, or attaching a tool to the Robot, etc., make sure to turn OFF the power supply of...
  • Page 17 183574-1CD ArcWorld 50/50S and 52/ Safety Operation Safety DANGER • Before operating the Robot, make sure the servo power is turned OFF by performing the following operations. When the servo power is turned OFF, the SERVO ON LED on the Programming Pendant is turned OFF.
  • Page 18 183574-1CD ArcWorld 50/50S and 52/ Safety Operation Safety WARNING • Read “Safety” of the Controller instructions before operating. Not reading and understanding chapter 1 of the Controller instruction can result in death or serious injury. • Read and understand all Warning Labels before operating.
  • Page 19 183574-1CD ArcWorld 50/50S and 52/ Safety Operation Safety CAUTION Robot Cells have Collaborative Motion functionality: Collaboration is a special type of operation between a person and Robot sharing a common workspace. The following are the guidelines for collaborative operation. 1. Used for pre-determined tasks.
  • Page 20 183574-1CD ArcWorld 50/50S and 52/ Safety Maintenance Safety Maintenance Safety WARNING • Make sure equipment has no potentially hazardous conditions. – area is clean and free of water, oil, debris, etc. – all safeguards are in place. – all safety equipment work correctly. Repair or replace any non- functioning safety equipment immediately.
  • Page 21 Notes for Moving and Transferring the Robot CAUTION • Do not modify the Controller. Making modifications without written permission from YASKAWA will void the warranty. • Back up all programs and jobs onto suitable media before program changes are made.
  • Page 22 Safety Definition of Terms Used Often in This Manual Definition of Terms Used Often in This Manual The Robot is the YASKAWA industrial robot product. The Robot usually consists of a Robot, Controller, Programming Pendant, and Robot cables. In this manual, the equipment is designated as follows:...
  • Page 23 183574-1CD ArcWorld 50/50S and 52/ Safety Registered Trademark Start button* Hold button* START HOLD Mode switch* REMOTE Emergency stop button PLAY TEACH Page key Coordinate key Axis keys Shift key Enter key *The button/switch names are denoted as symbols. Numeric keys...
  • Page 24 183574-1CD ArcWorld 50/50S and 52/ Robot Disposal Registered Trademark Robot Disposal WARNING • Take precautionary measures to prevent the Robot from overturning, such as anchoring it firmly, etc., even when temporarily storing it before disposal. Failure to observe this instruction may cause overturning of the Robot, which may result in personal injury.

  • Page 25: Table Of Contents

    183574-1CD ArcWorld 50/50S and 52/ Table of Contents Table of Contents 1 Introduction ............................. 1-1 1.1 About This Document ......................1-1 1.2 System Overview....................... 1-3 1.3 System Layout ........................1-5 1.3.1 Robot Cell Assembly .................... 1-5 1.3.2 Controller Base Assembly ..................1-6 1.3.3 Optional Equipment ....................
  • Page 26 183574-1CD ArcWorld 50/50S and 52/ Table of Contents 2.5 Welding Equipment......................2-7 2.5.1 Welding Power Sources ..................2-7 2.5.2 Wire Feeder ......................2-7 2.5.3 GMAW Torch ......................2-7 2.6 Safety Features........................2-8 2.6.1 Welding Arc Protection ..................2-8 2.6.2 Safety Fencing (Standard)..................2-8 2.6.2.1 Safety Fencing (Option)................
  • Page 27 183574-1CD ArcWorld 50/50S and 52/ Table of Contents 4 Operation ............................4-1 4.1 Programming ........................4-1 4.2 Daily Operation ........................4-2 4.2.1 Start-up Procedure ....................4-2 4.2.2 Robot HOME Position ..................4-2 4.2.3 Control Master Job ....................4-3 4.2.4 Operation Cycle....................4-3 4.2.5 Shutdown ......................

  • Page 28: Introduction

    ArcWorld 50/50S/52/52S Introduction 1.1 About This Document Introduction The ArcWorld is part of the YASKAWA family of standardized arc welding solutions. It is a fully integrated welding system, and is supported from wire to weld by YASKAWA. About This Document This system manual provides a “first look”...
  • Page 29 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.1 About This Document Chapter 7 “Spare Parts” This section gives a list of recommended spare parts. Appendix A This Appendix includes a checklist for start-up and after maintenance. Appendix B This Appendix is a glossary of definitions used in the industry.

  • Page 30: System Overview

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.2 System Overview System Overview The ArcWorld provides a complete arc-welding solution in a standardized configuration (see Fig. 1.3). The system is designed around a Robot, Controller, welding power source, and one or two work stations, Station 1 and/or Station 2.
  • Page 31 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.2 System Overview Each station also includes a heavy duty, motor driven safety barrier located in front of each station to protect the operator from weld flash or other debris and prevents entry into the Robot work area during Robot operation.

  • Page 32: System Layout

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.3 System Layout System Layout The ArcWorld has two main assemblies: the Robot cell assembly and the Controller base assembly. 1.3.1 Robot Cell Assembly The Robot cell assembly is fully enclosed by safety fencing and interlocking doors. The interlocking barrier doors allow the operator to load parts at one station while the Robot is welding at the other station.

  • Page 33: Controller Base Assembly

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.3 System Layout 1.3.2 Controller Base Assembly The Controller Base Assembly includes the Top Hat and Interface, Control Enclosure Assembly, Controller, Accessories/Air Panel, Welding Power Supply, optional Transformer, and a Power Distribution Enclosure. (see Fig. 1.2 for the location of these components).

  • Page 34: Optional Equipment

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.3 System Layout 1.3.3 Optional Equipment The following optional equipment is available for the ArcWorld: Stationary Tables: (AW50 and AW52 Only)  This table provides a place to position parts. Torch Cleaner  This stand-alone device uses a pneumatic motor with a reamer to clean the torch nozzle.
  • Page 35 Exhaust Hood  Ideal solution for capturing fumes before they can spread throughout a facility, and ensuring regulatory compliance. YASKAWA has worked with RoboVent to provide pre-engineered customized hoods that match each ArcWorld. Specific ventilation requirements require discussions with RoboVent. 183574-1CD...

  • Page 36: System Overview And Variations

    • ArcWorld 50, ArcWorld 52 – Each station will be empty or an optional flat table can be added. (The customer will supply their own fixtures in either case.) •...

  • Page 37: System Teaching

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations 1.4.1 System Teaching WARNING • Review the Risk Assessment prior to any interactions with the Work-Cell. Failure to observe this warning may result in death or serious injury. All systems are programmable by entering the interlocked work-cell access doors on either side of the cell or by viewing inside the cell from the exterior, through an open barrier door.

  • Page 38: System Operation

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations 1.4.2 System Operation WARNING • Check all programs, safety functions, and cell interactions before operating in an automatic operation. Failure to observe this warning may result in death or serious injury.
  • Page 39 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations When pressing the [Cycle Start] button, successful door closure latches this station in for queuing of work. The Robot will approach this station immediately if no work is currently being performed.

  • Page 40: Key Safety Devices

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations 1.4.3 Key Safety Devices 1.4.3.1 Controller with a FSU: • Dual channel Programming Pendant EMERGENCY STOP button • Dual channel Programming Pendant “Enable Device” • “TEACH/PLAY” mode input to FSU – Logic mapped from Machine Safety to FSU.

  • Page 41: Safety Logic Implementation (All Cells)

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations 1.4.4 Safety Logic Implementation (all cells): 1.4.4.1 TEACH/PLAY mode Disabling the FSU function can be difficult, especially when the Robot violates a defined Robot range or some other corrective action needs to be taken.

  • Page 42: Play Mode

    TEACH/PLAY conditions and barrier door status. NOTICE Some numeric values in the screen shots that follow may not represent actual values for your system. The general shape and theory of operation remain constant. Consult YASKAWA for specific system configurations. 183574-1CD 1-15...
  • Page 43 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations – Robot Range Settings: • Zone 1 - Teach access allowed. Door position does not matter. Access doors can be open. Positioner can be rotated.. • Zone 2 - Access Allowed when both Station 1 and 2 barrier doors are open.
  • Page 44 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations • Zone 3 - Station 1 Access Allowed when Station 2 barrier door is open. (Station 1 closed). • Zone 4 - Station 2 Access Allowed when Station 1 barrier door is open.
  • Page 45 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations • Zone 5 - Access allowed when Station 1 and 2 are closed. • Axis Speed Monitor (Stop Monitor) Files: (ArcWorld 52S only) – Axis Speed Monitor Files Used (aka Standstill Monitoring): Always enabled.
  • Page 46 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations – Station#1 Stopped: Headstock in Station 1 has motion monitored to 0.2 degrees of motion (allows some variance when installing parts / fixture.) – Station#2 Stopped: Headstock in Station 2 has motion monitored to 0.2 degrees of motion (allows some variance when installing parts /...
  • Page 47 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations • Safety Logic Circuit: – 52S shown • Tooling Power Outputs – The FSU breakout card is configured with logic to control tooling power at Station 1 and Station 2. The tooling power outputs will be energized in these conditions: •...
  • Page 48 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.4 System Overview and Variations – Safety Logic Circuit Signal Display Setup 183574-1CD 1-21 48 of 126...

  • Page 49: Reference Documentation

    ArcWorld 50/50S/52/52S Introduction 1.5 Reference Documentation Reference Documentation For additional information on individual components of the ArcWorld 50/ 50S/52/52S system, refer to the following documentation that is included with the system: • AR1440 Manipulator Manual (P/N 178958-1CD) • AR1440 Manipulator Maintenance Manual (P/N 179319-1CD) •...

  • Page 50: Reference Table

    183574-1CD ArcWorld 50/50S/52/52S Introduction 1.6 Reference Table Reference Table The table below provides location(s) for various operations. Table 1-2: Reference Table Description Manual/Chapter Environmental Information Manipulator &      Controller Chap 3, Positioner Chap 2 Dimensions ArcWorld Chap 3 ...
  • Page 51 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.6 Reference Table Description Manual/Chapter Maintenance and Intended Life ArcWorld Chap 5   Interface Requirements ArcWorld Chap 3   Dynamic Limiting Zones ArcWorld Chap 2 & 4    Risks that Can Not be Eliminated Throughout Manuals ...
  • Page 52 183574-1CD ArcWorld 50/50S/52/52S Introduction 1.6 Reference Table Description Manual/Chapter Stopping Time and Distance Drawings;  Positioner Chap 4 Specifications for Fluids Manipulator Chap 9   Positioner Chap 6 Limits for Range of Motion ArcWorld Chap 2  Relevant Standards Included Outside ...

  • Page 53: Customer Support Information

    ArcWorld 50/50S/52/52S Introduction 1.7 Customer Support Information Customer Support Information If assistance is needed with any aspect of the ArcWorld 50/50S/52/52S system, please contact Customer Support at the following 24-hour telephone number: (937) 847-3200 For routine technical inquiries, Customer Support can be contacted at the following e-mail address: techsupport@motoman.com...

  • Page 54: Quick Start Guide

    □ Controller Inst. Sec 3.2 & 3.3 □ Controller Inst. Sec 4.1 & 4.2 □ Controller Inst. Sec 3.4 to 3.5 □ Application Specific □ Sales Order □ Contact YASKAWA Academy: PREPARATION Sec 2.6, 3, 3.1 □ ArcWorld System Manual □ ArcWorld System Manual □...
  • Page 55 183574-1CD ArcWorld 50/50S/ 1 Introduction 1.8 Quick Start Guide 52/52S SET TO TEACH MODE SET TO TEACH MODE TOGGLE CYCLE START TOGGLE CYCLE START PHASE 6 PHASE 6 STATION 1 STATION 2 (52 OR52S ONLY) Complete □ TEST OPERATION □ ArcWorld System Manual Sec □...

  • Page 56: Equipment Description

    2.1 Robot Description Equipment Description Robot Description The ArcWorld 50/50S/52/52S system includes an AR1440 six-axis Robot. This Robot is specifically designed for arc-welding applications. The Robot has a payload capacity of 12 kg, a horizontal reach of 1430 mm (56.30in.) and a relative positioning accuracy of ±0.06 mm.

  • Page 57: Programming Pendant

    183574-1CD ArcWorld 50/50S/52/52S Equipment Description 2.2 Controller 2.2.1 Programming Pendant The Programming Pendant (see Fig. 2-2) is the primary means for programmer/operator interaction with the ArcWorld. The pendant features ® a Windows CE operating system and displays information on a 640 X 480 pixels color LCD touch-screen.
  • Page 58 183574-1CD ArcWorld 50/50S/52/52S Equipment Description 2.2 Controller NOTICE • The Programming Pendant’s LCD display goes dark after a few minutes of inactivity. Press any key to restore the screen. • Placing the Programming Pendant’s mode switch to REMOTE transfers control of the ArcWorld to the Operator Station.

  • Page 59: Operator Station

    183574-1CD ArcWorld 50/50S/52/52S Equipment Description 2.3 Operator Station Operator Station The Operator Station (see Fig. 2-3) is located on the front right post (AW50/50S) and right and left posts (AW52/52S). See Fig. 1.3 for the location of the Operator Stations in relation to the other components of the ArcWorld.

  • Page 60: Operator Station - Emergency Stop

    183574-1CD ArcWorld 50/50S/52/52S Equipment Description 2.3 Operator Station 2.3.2 Operator Station — EMERGENCY STOP Pressing the Operator Station’s EMERGENCY STOP button initiates an E-STOP condition. Refer to section 2.6.3 for information on the E-STOP condition and the procedures for recovering from it.

  • Page 61: Work Stations

    Equipment Description 2.4 Work Stations Work Stations Each ArcWorld 50 Series work cell comes with support posts for either weld table or MH-series headstock mounting. Table 2-3 shows the optional weld tables and headstocks available for each work cell. YASKAWA does not supply weld tables with any standard cell.

  • Page 62: Welding Equipment

    ArcWorld (refer to section 1.3.3). 2.5.1 Welding Power Sources YASKAWA offers various brands and types of welding power sources. The welding power source supplied with the ArcWorld depends on the customer’s specific application and preference. For information on the...

  • Page 63: Safety Features

    Equipment Description 2.6 Safety Features Safety Features The ArcWorld 50 Series system includes a total safety environment. When all standard safety precautions are taken, the equipment helps to ensure safe operation of the robotic cell. The ANSI/RIA R15.06- 2012 Robot Safety Standard stipulates that the user is responsible for safeguarding.

  • Page 64: Emergency Stop (E-Stop)

    183574-1CD ArcWorld 50/50S/52/52S Equipment Description 2.6 Safety Features 2.6.3 Emergency Stop (E-STOP) E-STOP is a primary safety feature of the ArcWorld. A work-cell access door interlock, Robot welding torch impact (collision) detection circuitry (refer to section 2.5.3), and [EMERGENCY STOP] buttons can trigger an E-STOP condition.

  • Page 65: Installation

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.1 Required Materials Installation CAUTION • Only qualified personnel who are familiar with the installation and setup are to install the ArcWorld. • Handle all system components with care. The ArcWorld is not extremely fragile, but it is a sophisticated system that can be damaged by rough handling.

  • Page 66: Recommended List Of Hand Tools And Equipment

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.1 Required Materials • Special anchor bolts and drill bits (refer to Motoman Lagging Supplement for suggested anchoring.) 3.1.2 Recommended List of Hand Tools and Equipment • Safety glasses • Face shield • Gloves (heavy-duty leather recommended) •...
  • Page 67 183574-1CD ArcWorld 50/50S/52/52S Installation 3.2 Site Preparation Site Preparation WARNING • During installation planning, allow sufficient room for access to the work-cell doors and system components that are exterior to the work cell. Failure to observe this warning could result in injury to personnel during system operation and maintenance.

  • Page 68: Site Preparation

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.2 Site Preparation Fig. 3-1(b): Plan View Front View (AW50 and AW50S) 381.3 1836.5 OPENING 1149 OPENING 2584 13.4 OPT. TABLE Fig. 3-1(c): Plan View P-Point Envelope (AW50 and AW50S) ROBOT ENVELOPE P-POINT 183574-1CD 68 of 126...
  • Page 69 183574-1CD ArcWorld 50/50S/52/52S Installation 3.2 Site Preparation Fig. 3-1(d): Plan View Positioner (AW50S) 4X M12 X 1.75 X 18.0 TOOLING DIA. 200.0 929.3 Fig. 3-2(a): Plan View Overhead View (AW52 and AW52S) 2190 ROBOT ENVELOPE 2996.5 MAX. TOOLING LG. (2X)
  • Page 70 183574-1CD ArcWorld 50/50S/52/52S Installation 3.2 Site Preparation Fig. 3-2(b): Plan View Front View (AW52 and AW52S) 2965.3 2583.4 Fig. 3-2(c): Plan View P-Point Envelope (AW52 and AW52S) ROBOT ENVELOPE P-POINT 183574-1CD 70 of 126...
  • Page 71 183574-1CD ArcWorld 50/50S/52/52S Installation 3.2 Site Preparation Fig. 3-2(d): Plan View Positioner (AW52S) 4X M12 X 1.75 X 18.0 TOOLING DIA. 200.0 929.3 Fig. 3-3: ArcWorld Tables 1300 1650 ARCWORLD 50 ARCWORLD 50S ARCWORLD 52S ARCWORLD 52 183574-1CD 71 of 126...

  • Page 72: Removal Of System Components From Shipping Skids

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.3 Removal of System Components from Shipping Skids Removal of System Components from Shipping Skids The ArcWorld components are attached to wooden shipping skids at the factory, prior to shipment. The customer is responsible for removing the shipping skids and inspecting the components for shipping damage.

  • Page 73: Installing The System Components

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.4 Installing the System Components Installing the System Components WARNING • Make sure handling equipment can lift 340 kg (750 lbs), approximate weight of the Controller Base Assembly. Injury to personnel and damage to equipment can occur if rating of handling equipment is not at least 340 kg (750 lbs).

  • Page 74: Door Latch Alignment

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.4 Installing the System Components 3.4.1 Door Latch Alignment Adjust the location of the door latch as necessary to provide smooth operation of the door assembly. A #14 spanner bit is provided to loosen and adjust the location of the latch assembly. Shims can also be placed beneath the fence posts to make gross adjustments.

  • Page 75: Installing The Arc Curtains

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.4 Installing the System Components 3.4.2 Installing the Arc Curtains WARNING • Do not install the arc curtains until the cell walls are secure. Unsecured cell walls can fall and injure personnel and damage equipment. The arc curtains may be shipped in an accessories box. Unfold arc curtains and install one curtain on inside of each cell wall section.

  • Page 76: Cable Connections

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.5 Cable Connections Cable Connections After components are level and securely in place, the cables should be unwrapped from around the equipment and installed according to the cable diagram included in the system drawing package. Each cable connection is clearly identified for ease of installation.

  • Page 77: Connection To Local Electrical Service

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.5 Cable Connections 2. Connect one end of an earth ground wire to the COMMON GROUND BUS BAR located inside the Controller. Connect the other end of the earth ground wire to the low-resistance earth ground.

  • Page 78: Controller

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.5 Cable Connections 3.5.2.1 Controller For detailed electrical service connection procedures for the Controller, refer to the Controller Manual and ArcWorld drawings and schematics that are included with the system documentation package (see section 1.5). 3.5.2.2...

  • Page 79: Safety/Operation Check

    183574-1CD ArcWorld 50/50S/52/52S Installation 3.6 Safety/Operation Check Safety/Operation Check Before installing the tooling and fixtures for the application, take a few minutes to perform the following safety/operation check: 1. Ensure that all shipping brackets and material are removed from the system.

  • Page 80: Installation Of Tooling And Fixtures

    Installation of Tooling and Fixtures The ArcWorld is now ready for attachment of tooling fixtures to the table(s) or Positioner. YASKAWA recommends assigning this task to personnel who are familiar with the ArcWorld operation and setup. After installation of the tooling and fixtures, test the Positioner for correct operation. Refer...

  • Page 81: Operation

    ArcWorld 50 Series system documentation package (see section 1.5 “Reference Documentation” on page 1-22). The ArcWorld 50 system is a single station welding cell that uses an AR1440 robot to weld parts. When the robot completes the welding process, it returns to HOME (Safe) position.

  • Page 82: Daily Operation

    183574-1CD ArcWorld 50/50S/52/52S Operation 4.2 Daily Operation Daily Operation The procedures below represent the typical operating sequence from power-up to shutdown. The basic operating procedures may vary depending on the situation. • Perform the start-up procedure (see section 4.2.1). • Move the Robot to HOME position (see section 4.2.2).

  • Page 83: Control Master Job

    183574-1CD ArcWorld 50/50S/52/52S Operation 4.2 Daily Operation 4.2.3 Control Master Job With the system powered up and in TEACH mode, call up the Control Master job: 1. Select {JOB} on the Programming Pendant’s touch screen. 2. Select {CTRL MASTER} on the Programming Pendant’s touch screen.

  • Page 84: Shutdown

    183574-1CD ArcWorld 50/50S/52/52S Operation 4.2 Daily Operation 5. When Station 2 is ready, the operator moves to the Operator Station, and presses the [CYCLE START/CYCLE LATCHED] button. The safety barrier door closes, and the robot moves to Station 2 to perform the welding program.

  • Page 85: System Recovery

    183574-1CD ArcWorld 50/50S/52/52S Operation 4.3 System Recovery System Recovery When a system error or alarm occurs, it needs to be cleared in order to return to normal operation. The paragraphs below describe the different types of alarms and errors that might be encountered and how to clear them.

  • Page 86: E-Stop Recovery

    183574-1CD ArcWorld 50/50S/52/52S Operation 4.3 System Recovery 4.3.2 E-STOP Recovery An E-STOP condition is triggered by any of the following: • An EMERGENCY STOP button is activated. • A work-cell access door is opened while the robot is not in TEACH mode.
  • Page 87 183574-1CD ArcWorld 50/50S/52/52S Operation 4.3 System Recovery 6. Move the robot clear of the impact position. The ArcWorld is now ready to continue operation. 183574-1CD 87 of 126...

  • Page 88: Maintenance

    (refer to section 1.5). CAUTION • Use only YASKAWA-specified antifreeze if the system uses a water- cooled torch. Do not use automotive antifreeze. It typically contains additives that can clog the small cooling ports in the torch and damage sealing gaskets in the water circulator pump.

  • Page 89: Alarms And Messages

    183574-1CD ArcWorld 50/50S/52/52S Alarms and Messages 6.1 Alarms Based on Barrier Door Operation Alarms and Messages This section contains information on alarms that are generated by the Controller. Cause and resolution of each alarm are presented to help with troubleshooting. For additional help contact Customer Support.

  • Page 90: Alarms Based On Functional Safety Unit Conditions

    183574-1CD ArcWorld 50/50S/52/52S Alarms and Messages 6.2 Alarms Based on Functional Safety Unit Conditions Alarms Based on Functional Safety Unit Conditions Table 6-2: Functional Safety Unit Alarms Alarm Text Alarm Cause Suggested Resolutions SYS CRITICAL FSU FUNCT The Functional Safety Unit has...

  • Page 91: Cell Messages

    183574-1CD ArcWorld 50/50S/52/52S Alarms and Messages 6.3 Cell Messages Alarm Text Alarm Cause Suggested Resolutions SYS CRITICAL FSU FUNCT In PLAY mode - with both barriers The Functional Safety Unit has DISABLED open, Robot Range Limit File #3 several files which need to be...

  • Page 92: Spare Parts

    Not removing servo power may result in death or serious injury. When a part malfunctions, it is helpful to have replacement parts in stock for quick replacement. YASKAWA recommends the parts in the following sections be kept on hand. Robot Spare Parts Reference the supplied Robot Manual for spare part recommendations.

  • Page 93: Arcworld Door Spare Parts

    183574-1CD ArcWorld 50/50S/52/52S Spare Parts 7.3 ArcWorld Door Spare Parts ArcWorld Door Spare Parts Each ArcWorld is supplied with a interface panel that is mounted within one of the axillary enclosures. Recommended spare parts include: Table 7-4: Recommended Spare Parts for the Electrical Interface...

  • Page 94: Checklist

    183574-1CD ArcWorld 50/50S/52/52S Appendix A A.1 Checklist Appendix A Checklist Since our customer is very important to us we include a checklist to use before start-ups and after maintenance for convenience and safety. Time/Date Checked By BEFORE APPLYING POWER (Refer to System Drawings)
  • Page 95 183574-1CD ArcWorld 50/50S/52/52S Appendix A A.1 Checklist Time/Date Checked By AFTER APPLYING POWER Check Control Switches (Refer to Operator Station, Controller Manual) Check Axis Move and are Restricted (Refer to Basic Specifications, Robot Manual) Check EMERGENCY STOP(s) (Refer to E-STOP in all Manual(s)
  • Page 96 183574-1CD ArcWorld 50/50S/52/52S Appendix A A.1 Checklist Time/Date Checked By DOCUMENTATION INCLUDED System Drawings Modifications Made to Original Protective Equipment End Effector Load Analysis Instructions on Synchronized Motion (More than one piece of moving synchronized equipment) Programmed Limits Collaborative Operation Declaration...
  • Page 97 183574-1CD ArcWorld 50/50S/52/52S Appendix A A.1 Checklist Time/Date Checked By MARKINGS INCLUDED ON EQUIPMENT Business Name, Address, Info Machinery Designation and Type Year Built Explosive Proof Order Number (Serial Number) Other Markings on Equipment (Vendor Machine Designation, Type, Serial No, Version, etc.)

  • Page 98: Glossary

    183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Appendix B Glossary 3D Graphic Display Function The 3D Graphic Display Function (this will be called 3D Display Function) is that, a 3D model of the robot is displayed on the Programming Pendant window, and the current value of the robot can be confirmed.
  • Page 99 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary ANSI/RIA R15.06-2012 American National Standard for Industrial Robots and Robot Systems This standard provides guidelines for the manufacture and integration of Industrial Robots and Robot Systems with emphasis on their safe use, the importance of risk assessment and establishing personnel safety.
  • Page 100 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Base Coordinate System The Base Coordinate System (sometimes referred to as World Coordinate System) defines a common reference point for a cell or application. This is useful when using multiple robots or devices as positions defined in Base Coordinates will be the same for all robots and devices.
  • Page 101 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Category 3 (Cat3) Category 3 (Cat 3) means that the safety related parts of the control system will be designed so that: • Single faults will not prevent the safety function from working correctly.
  • Page 102 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Collaborative Robot Term used to describe a robot system designed to operate in one or more of the four collaborative modes. • "Safety Monitored Stop" • "Hand Guiding" • "Speed and Separation Monitoring"...
  • Page 103 A Coordinate System (or Frame) defines a reference position and orientation from which a robot position can be measured. All robot positions are defined with reference to a Coordinate System. YASKAWA robots utilize the following Coordinate Systems: • "Base Coordinate System"...
  • Page 104 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Cyclo Drive A brand name for a speed reduction device that converts high speed low torque to low speed high torque, usually used on the major (larger) axis. Cylindrical Topology A topology where the arm follows a radius of a horizontal circle, with a prismatic joint to raise or lower the circle.
  • Page 105 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Enable Switch See "Enabling Device". Enabling Device A manually operated device which when continuously activated, permits motion. Releasing the device shall stop robot motion and motion of associated equipment that may present a hazard. (R15.06)
  • Page 106 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Feedback Control A type of system control obtained when information from a Robot or sensor is returned to the Controller in order to obtain a desired robot effect. See "Feedback", "Closed-loop" and"Feedback Sensor".
  • Page 107 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Gantry Robot A robot which has three degrees of freedom along the X, Y and Z coordinate system. Usually consists of a spooling system (used as a crane), which when reeled or unreeled provides the up and down motion along the Z axis.
  • Page 108 Robot, and a Controller that gives detailed movement instructions. INFORM The robot programming language for YASKAWA robots. INFORM language allows the robot user to: instruct the robot to use its basic capabilities to fulfill a defined set of expectations and also to describe to the robot, through a definition of parameters and conditions, what the expectations are in some given situations or scenarios.
  • Page 109 JOB is the YASKAWA name for a robot program created using YASKAWA’s INFORM robot programming language. Typically, a JOB consists of instructions that tell the Controller what to do and data that the program uses when it is running.
  • Page 110 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Joint A part of the Robot system, which allows a rotation and/or translational degree of freedom of a link of end-effector. Joint Interpolated Motion A method of coordinating the movement of the joints, such that all joints arrive at the desired location simultaneously.
  • Page 111 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Linear Interpolated Motion Is a method of path interpolation that commands the movement of the robot by moving each joint in a coordinated motion so that all axis arrive to the position at the same time. The path of the Tool Control Point (TCP) is predictable and will be linear.
  • Page 112 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Mirror Shift Function With the Mirror Shift Function, a job is converted to the job in which the path is symmetrical to that of the original job. This conversion can be performed for the specified coordinate among the X-Y, X-Z or Y-Z coordinate of the robot coordinates and the user coordinates.
  • Page 113 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Operator The person designated to start, monitor and stop the intended productive operation of a robot or robot system. An operator may also interface with a robot for productive purposes. (R15.06) Optical Encoder A detection sensor, which measures linear or rotary motion by detecting the movement of markings past a fixed beam of light.
  • Page 114 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Pendant Teaching The mapping and recording of the position and orientation of a robot and/ or Robot system as the robot is manually moved in increments from an initial state along a path to a final goal state. The position and orientation of each critical point (joints, robot base, etc.) is recorded and stored in a...
  • Page 115 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Playback Operation Playback is the operation by which the taught job is played back. This function is used to decide where to resume the playback on the start operation after suspending the playback and moving the cursor or selecting other jobs.
  • Page 116 See "Inductive Sensor". Pulse Coordinates YASKAWA robots define robot joint axes position in degrees for revolute joints. Pulse is also another way to specify robot joint position, and it does so in robot motor encoder pulse counts.
  • Page 117 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Real-time System A computer system in which the computer is required to perform its tasks within the time restraints of some process simultaneously with the system it is assisting. The computer processes system data (input) from the...
  • Page 118 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Risk Assessment The process of evaluating the intended use of a machine or system for foreseeable hazards and then determining the level of risk involved for the tasks identified. Risk Mitigation A secondary step in the risk assessment process that involves reducing the level of risk for the identified tasks, by applying risk reduction measures in order to eliminate or mitigate the hazards.
  • Page 119 FSU generated signals. The safety logic circuit is programmed via an intuitive user interface that is supported on the YASKAWA Programming Pendant. It enables to set up the logical operations, such as stopping the Robot or outputting a signal if the servos are on.
  • Page 120 The first or second axis of a robot is sometimes referred to as a shoulder axis as it somewhat resembles a human shoulder. This is often used in describing humanoid or dual-arm systems such as the YASKAWA Motoman® SDA10D. See "Safety Integrity Level"...
  • Page 121 Jacobian matrix, which becomes singular (i.e., has no inverse) in these configurations. SLURBT SLURBT are terms that YASKAWA uses to describe each axis of the robot for convenience. The definition of each value is as follows: S – Swing or Swivel L –...
  • Page 122 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary System Integrator See "Integrator" Teach To program a Robot arm by manually guiding it through a series of motions and recording the position in the Controller memory for playback. Teach Lock While the Teach Lock is set, the mode of operation is tied to the TEACH mode and the machines cannot be played back using either [START] or external input.
  • Page 123 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary Tool against tool Interference is checked by using a cylinder that is slightly larger than the arm or tool. A sphere is placed on both ends of the cylinder. If the cylinder and spheres of one Robot have any contact with those of the other while moving, the Robots stop because interference was detected.
  • Page 124 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary User Coordinate System The User Coordinate System is any reference point that a user has defined for their application. This is often attached to an object such as a pallet and allows a user to teach points relative to this object. For...
  • Page 125 183574-1CD ArcWorld 50/50S/52/52S Appendix B B.1 Glossary World Coordinates A reference coordinate system in which the Robot arm moves in linear motions along a set of Cartesian or rectangular axes in X, Y, and Z directions. The shape of the work envelope forms a rectangular figure.
  • Page 126 SYSTEM MANUAL YASKAWA ELECTRIC CORPORATION 2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu, 806-0004, Japan Phone: +81-93-645-7703 Fax: +81-93-645-7802 http://www.yaskawa.co.jp YASKAWA AMERICA, INC. (MOTOMAN ROBOTICS DIVISION) 100 Automation Way, Miamisburg, OH 45342, U.S.A. Phone: +1-937-847-6200 Fax: +1-937-847-6277 http://www.motoman.com YASKAWA EUROPE GmbH (ROBOTICS DIVISION) Yaskawastrasse 1, 85391, Allershausen, Germany Phone: +49-8166-90-100 Fax: +49-8166-90-103 http://www.yaskawa.eu.com...

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