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#TE9QTNF ++
5[UVGO /CPWCN
HQT 72 4QDQV
Part Number:
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Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
147051-1
August 15, 2002
2
Final
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Table of Contents
Related Manuals for YASKAWA Motoman ArcWorld II-200
Summary of Contents for YASKAWA Motoman ArcWorld II-200
- Page 1 /QVQOCP :4% %QPVTQNNGT #TE9QTNF ++ 5[UVGO /CPWCN HQT 72 4QDQV Part Number: 147051-1 Release Date: August 15, 2002 Document Version: Document Status: Final Motoman, Incorporated 805 Liberty Lane West Carrollton, OH 45449 TEL: (937) 847-6200 FAX: (937) 847-6277 24-Hour Service Hotline: (937) 847-3200...
- Page 2 Motoman, Inc. ©2003 by MOTOMAN All Rights Reserved Because we are constantly improving our products, we reserve the right to change specifications without notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
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Page 3: Table Of Contents
TABLE OF CONTENTS Section Page LIST OF FIGURES...........................iii LIST OF TABLES ..........................iii INTRODUCTION About this Document ....................1-1 System Overview ......................1-2 1.2.1 System Layout ....................1-2 1.2.2 Major Components ..................1-3 1.2.3 Optional Equipment ..................1-3 Reference to Other Documentation................1-3 Customer Service Information .................. - Page 4 Section Page Welding Equipment ...................... 3-9 3.6.1 Power Sources ....................3-9 3.6.2 PWF4 Wire Feeder ..................3-11 3.6.3 Universal Welding Interface (UWI) ..............3-11 3.6.4 GMAW Torch ....................3-11 3.6.5 Motoman Torch Mount ................. 3-11 INSTALLATION Materials Required......................4-1 4.1.1 Customer-Supplied Items ................
- Page 5 Section Page System Recovery ......................5-5 5.3.1 Alarms and Errors ................... 5-5 5.3.2 Error Messages ....................5-5 5.3.3 Door Default Settings ..................5-5 5.3.4 Shock Sensor Recovery .................. 5-6 5.3.5 E-STOP Recovery ................... 5-6 5.3.6 Using the Brake Release ................. 5-7 MAINTENANCE Periodic Maintenance ....................
- Page 6 NOTES ArcWorld II-200 System Manual MOTO MAN...
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Page 7: Introduction
SECTION 1 INTRODUCTION The ArcWorld II-200 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 II-200 features a Motoman arc welding robot and XRC 2001 controller with menu-driven arc welding application software, complete welding package, two weld stations, operator interface, and total safety environment. -
Page 8: System Overview
INTRODUCTION System Overview The ArcWorld II-200 provides a complete arc welding solution in a standardized configuration. The system is designed around a Motoman arc welding robot and XRC 2001 robot controller, and includes a complete welding package. Two stationary tables allow an operator to prepare and set up parts on one table while the robot welds on the other table. -
Page 9: Major Components
INTRODUCTION 1.2.2 Major Components The ArcWorld II-200 includes the following major components: • Motoman UP6 manipulator and XRC 2001 controller • Two stationary work stations • Common operator stations • Welding equipment, including the following: • Welding power source • Motoman torch (water-cooled or air-cooled) •... -
Page 10: Customer Service Information
INTRODUCTION Customer Service Information If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200. Please have the following information ready before you call: • Robot Type (UP6) • System Type (ArcWorld II-200) • Software Version (access using TOP KEY/SYSTEM INFO/VERSION/ SYSTEM on the programming pendant) •... -
Page 11: Safety
SECTION 2 SAFETY Introduction 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. -
Page 12: Standard Conventions
SAFETY 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). -
Page 13: General Safeguarding Tips
SAFETY 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: •... -
Page 14: Installation Safety
SAFETY Installation Safety Safe installation is essential for protection of people and equipment. following suggestions are intended to supplement, but not replace, existing federal, local, and state laws and regulations. Additional safety measures for personnel and equipment may be required depending on system installation, operation, and/or location. -
Page 15: Operation Safety
SAFETY • Inspect the robot and work envelope to be sure no potentially hazardous conditions exist. Be sure the area is clean and free of water, oil, debris, etc. • Be sure that all safeguards are in place. • Check the E-STOP button on the teach pendant for proper operation before programming. -
Page 16: Maintenance Safety
SAFETY 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. Maintenance tips are as follows: •... -
Page 17: Equipment Description
SECTION 3 EQUIPMENT DESCRIPTION UP-series Robot Description The Motoman UP6 robot and XRC 2001 robotic controller represent state-of-the- art technology in robotics today. The six-axis UP6 robot has a payload of 6 kg (13.2 lbs). It features a 1,373 mm (54.05 inch) reach and has a relative positioning accuracy of ±... -
Page 18: Playback Panel
EQUIPMENT DESCRIPTION 3.2.1 Playback Panel The playback panel (see Figure 3-2) contains the primary system controls and consists of the features described below. For more information, refer to the manipulator manual that came with your system. MODE ALARM/ERROR BUTTONS INDICATOR E-STOP SERVO ON MODE... -
Page 19: Programming Pendant
EQUIPMENT DESCRIPTION 3.2.2 Programming Pendant The programming pendant (see Figure 3-3) is the primary user interface for the system. The pendant has a 4x5-inch 12-line, 40-character LCD display and keypad. The system uses the INFORM II robot language and a menu-driven interface to simplify operator interaction with the robot. - Page 20 EQUIPMENT DESCRIPTION Status Area The Status Area shows system status via the following symbols: • Active Robot, External Axis, or Base Axis R1, R2, R3; S1, S2, etc.; or B1, B2, etc. • Coordinate System Joint, World, Cylindrical, Tool, or User Frame •...
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Page 21: Figure 3-4 Rs-232C Serial Port
EQUIPMENT DESCRIPTION SELECT Key The SELECT key is used to choose the item currently highlighted by the cursor. TEACH LOCK Key The TEACH LOCK key locks operation of the robot with the programming pendant. Operation is not possible from the playback panel or operator station. Servo power can not be applied in TEACH mode unless TEACH LOCK is ON. -
Page 22: Brake Release
EQUIPMENT DESCRIPTION 3.2.3 Brake Release WARNING! Releasing brakes could cause personal injury or machine damage. Always support the axis to be released BEFORE you release it. The Brake Release Control is a safety feature that allows you to release the automatic brakes on the robot in case of an emergency or robot failure. -
Page 23: Auto/Manual
EQUIPMENT DESCRIPTION Teach Mode Depressing the CYCLE START push button will cause the door to go from open to close or close to open depending on the door status. 3.3.2 AUTO/MANUAL The AUTO/MANUAL button changes the function of the CYCLE START button. •... -
Page 24: Safety Features
EQUIPMENT DESCRIPTION Table 3-1 Weld Table Specifications - continued Conditions Specifications Electrical Requirements 24V DC, 3 amps for the interface is supplied by the controller. Welding Current Rating 600 amperes at 100% duty cycle Arc Shield The arc screen protects from radiation between the operator and robot areas. -
Page 25: Enable Switch
EQUIPMENT DESCRIPTION 3.5.4 ENABLE Switch The ENABLE switch is a safety feature which controls servo power while in TEACH mode. When pressed in, this switch allows the operator to turn servo power ON and initializes the system. However, should the operator release the switch or grasp it too tightly, servo power is immediately disabled, preventing further robot movement. -
Page 26: Figure 3-7 Available Power Sources
EQUIPMENT DESCRIPTION CURRENT INPUT ALARM CABLE INDICATOR HEAT WATER FUSE CRATER fl16 SOLO FLOW CRATER CURRENT CRATER VOLTAGE fl14 AUTO fl12 PENETRATION WIRE TYPE WIRE DIA GAS FLOW AMMETER VOLTMETER POWER ALARM CONTROL POWER VOLT INP UT ICA TOR ATIO fl16 fl14 PENDANT... -
Page 27: Pwf4 Wire Feeder
EQUIPMENT DESCRIPTION 3.6.2 PWF4 Wire Feeder The PWF4 wire feeder mounts on the robot arm. This 4-roll wire feeder provides reliable wire feeding at rates up to 750 inches per minute (IPM). An integral gas valve provides fast gas response time. The wire feeder has an inch forward button to help simplify set-up and reduce change-over time. - Page 28 EQUIPMENT DESCRIPTION NOTES ArcWorld II-200 System Manual 3-12 MOTOMAN...
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Page 29: Installation
SECTION 4 INSTALLATION The ArcWorld system can be installed easily in just a short time by three workers. The more people involved (within reason), the more quickly installation can be completed. Follow established safety procedures at all times throughout the installation process. -
Page 30: Site Preparation
INSTALLATION Site Preparation To prepare your site, proceed as follows: 1. Clear floor space needed for unit (see Figure 4-1). NOTE: An additional 2.43 to 3.05 m (8 to 10 ft) on all sides is recommended for set up. 2. Gather all customer-supplied items and required tools listed in Section 4.1. 2340 mm 7.67 ft 3250 mm... -
Page 31: Removal From Shipping Skid
INSTALLATION Removal from Shipping Skid Cell components are placed onto a large shipping skid and then shipped to the customer. The customer is responsible for safely removing the components from the skid and inspecting them for damage. NOTE: If damage is found, notify shipper immediately. 4.3.1 Unloading Procedures To successfully unload the shipping skid, proceed as follows:... -
Page 32: Cell Components
INSTALLATION Cell Components 4.4.1 List of Components Once the cell components have removed from the shipping skid, account for each item with the following list: • Robot • Barrier - station 1 • Barrier - station 2 • Spanner Plate •... -
Page 33: Assemble Cell Components
INSTALLATION Assemble Cell Components To make sure the cell is complete and to verify floor space efficiency, Motoman recommends that all cell components be set in place together prior to anchoring to the floor. Assemble the cell component in the order they appear below. Use Figure 4-3 and the system drawings to identify cell component locations. -
Page 34: Removing The Shipping Brackets/Bolts
INSTALLATION LEVELING BOLT Figure 4-4 Leveling Bolts Removing the Shipping Brackets/Bolts 4.7.1 Robot Shipping Brackets Removal CAUTION! Failure to remove shipping brackets from robot before operating the ArcWorld II-200 may result in damage to the robot drive mechanisms. Three yellow brackets (see Figure 4-5) prevent the robot from moving during shipping. -
Page 35: Positioner Shipping Bolts Removal
INSTALLATION 4.7.2 Positioner Shipping Bolts Removal CAUTION! Failure to remove the positioner shipping bolts from before operating the ArcWorld II-200 will result in a blown fuse and possible damage to equipment. For shipping purposes, a yellow-capped shipping bolt (see Figure 4-6) is inserted through both front posts of each positioner (four bolts total), and fastened to the counterbalance. -
Page 36: Connecting The Cables
INSTALLATION Connecting the Cables After components are level and securely in place, the cables should be unwrapped from around the equipment and laid out according to the cable diagram included in the system drawing package. Each cable connection is clearly identified for ease of installation. -
Page 37: Connecting The Com-Arc Iii And The Wire Cutter (Optional)
INSTALLATION 2. Unpack two large black manipulator cables, connected to the controller, and route to back of robot. 3. Carefully engaging connectors, connect three cables (labeled 1BC, 2BC, and 3BC) to 1BC, 2BC, and 3BC connections on back of robot (see Figure 4-7). FROM CONTROLLER Figure 4-7 Connecting Robot to the Controller... -
Page 38: Figure 4-8 Water Circulator Connections
INSTALLATION WATER OUT WATER IN TO POWER SOURCE Figure 4-8 Water Circulator Connections CAUTION! • Use only the antifreeze provided by Motoman. Automotive anti- freeze contains stop-leak additives that will clog the small torch water-cooling ports and damage the gaskets in the pump. •... -
Page 39: Connecting The Power
INSTALLATION Connecting the Power After all of the system components have been properly installed, connect the power to the ArcWorld II-200. To connect incoming power to the ArcWorld II-200, proceed as follows: DANGER! Power should be connected only by a qualified electrician. Electrical and grounding connections must comply with applicable portions of the national electrical code and/or local electrical codes. -
Page 40: Conducting A Safety/Operation Check
INSTALLATION 4.10 Conducting a Safety/Operation Check Before installing the tooling and fixtures for your application, take a few minutes to perform a safety/operation check. To conduct a safety/operation check, proceed as follows: 1. Check that all shipping brackets and bolts have been removed from robot and positioners (see Section 4.7). -
Page 41: Operation
SECTION 5 OPERATION The ArcWorld II-200 is a fully integrated robotic GMAW welding cell. The robot welds on one station while the operator loads the other station with parts. Once the robot is finished welding, it returns to the safe position (Cube 24), the operator doors cycle, and the robot begins welding on the other station. -
Page 42: Table 5-1 Xrc 2001 User Inputs
OPERATION Table 5-1 XRC 2001 User Inputs Input Assignment IN#001 CYCLE START INPUT S1 IN#002 AUTO/MANUAL 1 IN#003 OK TO WORK 1 IN#004 S1 LIGHT CURTAIN CLEAR IN#005 S1 DOOR LOWERED IN#006 S1 BRAKE RELEASED IN#007 thru 008 NOT USED IN#009 CYCLE START INPUT IN#010... -
Page 43: Daily Operation
OPERATION Daily Operation The procedures below represent the typical operating sequence from power up to shutdown. Your basic operating procedures may vary depending on your situation. • Perform Start-up Procedures (see Section 5.2.1). • Move Robot to Home Position (see Section 5.2.2). •... -
Page 44: Perform Operation Cycle
OPERATION 7. Press SERVO ON button on playback panel. 8. Press START button on playback panel. The ArcWorld II-200 cell is now ready for operation. 5.2.4 Perform Operation Cycle Perform the operation cycle as follows: 1. Load Station 1 (station on the right) with production parts. 2. -
Page 45: System Recovery
OPERATION System Recovery Under certain conditions you will be required to clear an alarm or error. The paragraphs below describe the different types of alarms and errors you may encounter and how to remedy them when you do. 5.3.1 Alarms and Errors Alarms and errors will cause the program to stop. -
Page 46: Shock Sensor Recovery
OPERATION 5.3.4 Shock Sensor Recovery The ArcWorld welding package includes a Motoman gun 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 message, which triggers an E-STOP condition. -
Page 47: Using The Brake Release
OPERATION 5.3.6 Using the Brake Release Robot The brake release control panel is located on front of the controller. Each axis brake is controlled by an individual axis buttons. Simultaneously pressing the ENABLE button and one of these axis buttons releases the indicated axis. To release the brakes, proceed as follows: 1. - Page 48 OPERATION NOTES ArcWorld II-200 System Manual MOTOMAN...
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Page 49: Maintenance
SECTION 6 MAINTENANCE Periodic Maintenance For detailed specifications including parts lists breakdown for the Barrier Assembly, refer to the Barrier Assembly Manual, P/N 147500-1. Table 6-1 provides periodic maintenance items and intervals for the ArcWorld II- 200 cell. Keep in mind that the maintenance intervals serve as guidelines only. You should adjust the frequency of maintenance to suit your specific work conditions. - Page 50 MAINTENANCE NOTES ArcWorld II-200 System Manual MOTOMAN...
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Page 51: Index
INDEX Numerics 1-Cycle Symbol, Cycle Mode Fencing About this Document Gas Flow Error Alarm Symbol, System Status General Safeguarding Tips Alarm/Error General, Icon Alarms and Errors GMAW Torch 3-11 ANSI/RIA Arc Screens Handling, Icon Arc Welding, Icon High Symbol, Speed Setting Area Key Hold Auto Symbol, Cycle Mode... - Page 52 INDEX Software Version, Access Spot Welding, Icon Operation Standard Conventions Operation Safety Starting the Master Job Operator Station Start-Up Cycle Start Status Area Emergency Stop (E-STOP) Optional Equipment Step Symbol, Cycle Mode Stop Symbol, System Status System Info, Icon Periodic Maintenance System Layout Playback Panel System Overview...