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Troubleshooting
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Summary of Contents for Motoman XRC Series
- Page 1 Motoman XRC Controller Spot Welding Manual for Medar Integrated Weld Control Part Number: 147296-1CD Revision: 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 COMPLETE OUR ONLINE SURVEY Motoman is committed to total customer satisfaction! Please give us your feedback on the technical manuals you received with your Motoman robotic solution. To participate, go to the following website: http://www.motoman.com/forms/techpubs.asp 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 authorization of Motoman, Inc.
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Page 3: Table Of Contents
TABLE OF CONTENTS Section Page INTRODUCTION About this Document ....................1-1 System Configuration ....................1-2 System Components..................... 1-4 1.3.1 XRC 2001 Controller ..................1-4 1.3.2 Robot ......................1-4 1.3.3 Servo Robot Gun .................... 1-5 1.3.4 Medar Integrated Weld Control ............... 1-5 1.3.5 Water Cooling System .................. - Page 4 Current Control Methods .................... 3-10 3.7.1 Automatic Power Factor ................3-10 3.7.2 Automatic Voltage Compensation Mode ............3-10 3.7.3 Constant Current Mode ................3-11 SETUP AND OPERATION Setting Up Parameters ....................4-1 Set Up........................... 4-4 Simple Weld Condition Files ..................4-5 Enhanced Weld Schedules....................
- Page 5 LIST OF TABLES Table Page Table 1-1 Equipment and Component Specifications ..............1-6 Table 4-1 Medar Timer Parameter List ..................4-1 Table 5-1 Medar Application Errors ..................... 5-1 Table 5-2 XRC Alarms and Errors ....................5-3 Table 5-3 Welding Troubleshooting Chart ................... 5-4 Table 5-4 XRC Outputs to Medar Board ..................
- Page 6 NOTES SpotWelding Manual for Medar MOTO MAN...
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Page 7: Introduction
SECTION 1 INTRODUCTION About this Document This manual provides both general and specific information about Motoman’s spot welding system using a Medar integrated weld control. This manual is divided into the following sections: SECTION 1 - INTRODUCTION This section provides general information regarding this manual, descriptions of the integrated weld control and its components, technical specifications,... -
Page 8: System Configuration
XRC TO MEDAR OUTGOING POWER INTERFACE CABLE TO TRANSGUN Figure 1-1 XRC and Medar Integrated Weld Control • Motoman robot manipulator and XRC 2001 controller • 3-Slot CPU rack • Medar integrated welding board • Welding equipment, including the following: •... -
Page 9: Figure 1-2 Xrc/Medar Board Interface
INTRODUCTION The robot moves the spot welding gun and supply lines through a series of programmed steps. The XRC controls the speed, direction, and position of the robot as it moves from point to point. The XRC also controls the actuation of the spot gun. -
Page 10: System Components
These robots can be floor-, wall-, or ceiling-mounted. Motoman robots use brushless AC servo motors with absolute position encoders. A combination of capacitance and lithium batteries in both robot and controller assemblies protects program positional data for up to a year. -
Page 11: Servo Robot Gun
1.3.3 Servo Robot Gun The Motoman servo gun, when provided with the integrated welding package, improves productivity and provides high quality welds. The servo motor variable controls allow operators to program an exact force and ensure that force is accurate and repeatable for every weld. -
Page 12: Water Cooling System
INTRODUCTION 1.3.5 Water Cooling System The water cooling system circulates water through both the spot weld controller and the weld gun. It is important that the water temperature not exceed 86° F, as inadequate cooling could damage the servo weld gun and transformer. The Medar board supports thermal overload sensors from the transformer and Medar SCR. -
Page 13: Reference To Other Documentation
• Vendor manuals for system components not manufactured by Motoman 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, ES165, etc.) •... - Page 14 INTRODUCTION NOTES SpotWelding Manual for Medar MOTO MAN...
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Page 15: Safety
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: •... -
Page 16: 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 17: 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 18: Installation Safety
Any modifications to the controller PLC can cause severe personal injury or death, as well as damage to the robot! Do not make any modifications to the PLC. Making any changes without the written permission of Motoman will VOID YOUR WARRANTY! •... -
Page 19: 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 20: 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 21: Theory Of Operation
SECTION 3 THEORY OF OPERATION In resistance (spot) welding, current is generated by a transformer, and is fired through electrodes, which hold the metal pieces in place. These electrodes also apply force to the metal pieces, usually before, during, and after the firing of the electric current. -
Page 22: The Weld Cycle
A transformer consists of two coils of wire, called the primary and the secondary, wound around an iron core. See Figure 3-2. Power is transferred from primary to secondary via the magnetic properties of the iron. The factor by which the current Spot Welding Manual for Medar MOTOMAN... -
Page 23: Voltage
Ohm’s Law expresses the relationship between voltage, current, and resistance. The relationship is expressed as voltage equals current times resistance (E = I x R). • E – Electromagnetic Force (voltage) • I – Current (pure current) • R – Resistance (pure resistance) MOTOMAN Spot Welding Manual for Medar... -
Page 24: Secondary Resistance
Because the weld control calculates power factor and resistance for you, you can calculate impedance without knowing the reactance of the secondary circuit. A large drop in power factor can indicate poor connections that require maintenance. Spot Welding Manual for Medar MOTOMAN... -
Page 25: Primary Current
Figure 3-4 AC Welding Current is regulated by enabling the SCR of different sine wave angles, as illustrated in Figure 3-5. More current is delivered as more of the sine wave is allowed to conduct. MOTOMAN Spot Welding Manual for Medar... -
Page 26: Dc Welding
This will result in metal loss as expulsion. Too much pressure can cause severe indentation at the weld point, because the electrodes continue to press together as the metal liquefies. Spot Welding Manual for Medar MOTOMAN... -
Page 27: Figure 3-6 Welding Circuit With Heat Loss
Figure 3-6 shows what happens to the heat when resistance is high in places other than the part contact area. In this simple circuit, only 40 percent of the current is used for welding. 50µΩ 100µΩ 200µΩ Part 50µΩ 100µΩ Figure 3-6 Welding Circuit with Heat Loss MOTOMAN Spot Welding Manual for Medar... -
Page 28: Figure 3-7 Shunting
This happens because the force at the contact point is distributed over a larger area. Resistance depends in part on the pressure of an electrode against the part. Mushroomed caps result in less pressure at the weld point. Spot Welding Manual for Medar MOTOMAN... -
Page 29: Steppers
During each stepper step, current will gradually increase from the first weld to the last weld in that step. Figure 3-10 illustrates a stepper program with five steps. Figure 3-10 Stepper Program MOTOMAN Spot Welding Manual for Medar... -
Page 30: Current Control Methods
If the line voltage changes (and it does), then the weld control will alter the firing angle to ensure that the heat output is the same regardless of the fluctuating line voltage. See Figure 3-12. Spot Welding Manual for Medar 3-10 MOTOMAN... -
Page 31: Constant Current Mode
Constant Current regulation monitors the current delivered and dynamically adjusts the SCR firing angle to ensure that the desired amount of current is delivered, regardless of the available current. NOTE: Available current must be greater than the current being delivered. MOTOMAN 3-11 Spot Welding Manual for Medar... -
Page 32: Figure 3-13 Avc Mode (Top) Vs. Constant Current Mode
Constant current control will always deliver the requested current as long as the tool capacity allows it. While AVC current drops over time due to increased secondary resistance, Constant current doesn’t have this problem. Spot Welding Manual for Medar 3-12 MOTOMAN... -
Page 33: Setup And Operation
* On a new system, do not change this parameter to “1” until after initial system startup. To set up parameters S2C370, S2C371, and S2C373, enter Management mode and follow these instructions: 1. From the XRC Main Menu, select PARAMETER. 2. The following screen appears. Select S2C. S1CxG MOTOMAN Spot Welding Manual for Medar... - Page 34 7. Restart the system and verify that the setting for MAXIMUM PRIMARY CURRENT still has the same value. 8. Repeat steps 4 - 6 to change the current maximum back to its original value. Spot Welding Manual for Medar MOTOMAN...
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Page 35: Set Up
(The expected current is the base current - programmed in the weld function - plus the current boost that the stepper is providing). MOTOMAN Spot Welding Manual for Medar... -
Page 36: Simple Weld Condition Files
Press SHIFT plus the ARROW key to return to previous schedules. Figure 4-1 depicts this particular simple weld condition file. DATA EDIT DISPLAY UTILITY WELD CONDITION FILE DOWNLOAD: DONE/NOT DONE FILE NO. SQUEEZE TIME WELD TIME 9000 WELD CURRENT HOLD TIME Spot Welding Manual for Medar MOTOMAN... -
Page 37: Enhanced Weld Schedules
WELD2 IMPULSE HEAT TIME : WELD2 IMPULSE COOL TIME : DATA EDIT DISPLAY UTILITY WELD CONDITION FILE WELD2 IMPULSE COUNT WELD2 CURRENT 9000 WELD2 COOL TIME WELD3 POSTHEAT TIME 4000 WELD3 CURRENT HOLD TIME MOTOMAN Spot Welding Manual for Medar... -
Page 38: Stepper Condition Files
(Refer to paragraph 3.5.1.) For example, during the first step, current will be incremented 7 amps for each weld. STEPPER CONDITION STEPPER#1, GROUP#0 DOWNLOAD: DONE/NOT DONE AMPS WELDS ST#1 : ST#2 : ST#3 : ST#4 : ST#5 : < > STEPPER STATUS Spot Welding Manual for Medar MOTOMAN... -
Page 39: Monitoring Weld Results
AVG DC BUS (VOLTAGE) : AVG SEC. CURRENT : 9000 AVG SEC. CURRENT 9000 AVG POWER FACTOR AVG POWER FACTOR AVG %I USED AVG %I USED STEP NUMBER STEP NUMBER RESET FAULTS RESET FAULTS MOTOMAN Spot Welding Manual for Medar... - Page 40 SETUP AND OPERATION NOTES Spot Welding Manual for Medar MOTOMAN...
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Page 41: Troubleshooting
Extend Weld Medar - Isolation Contactor Isolation Contactor Off When Nee Error MFDC Inverter ISO CNTR Off Medar - Welding Bus Voltage AC/MFDC No Zero Crossing Sync MFDC DC Bus Over Voltage MFDC Inverter Bus MOTOMAN Spot Welding Manual for Medar... - Page 42 Medar - Internal Timer Error AC/MFDC RAM Checksum AC/MFDC ROM Checksum AC/MFDC Hardware/Software Incompatibility MFDC Inverter Serial Comm Medar - Inverter Fault MFDC Capacitor Discharge MFDC Capacitor Charge MFDC Hard OverCurrent MFDC Driver Low Voltage Spot Welding Manual for Medar MOTOMAN...
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Page 43: Xrc Alarms And Errors
S2C (373) error S2C (371) error S2C (372) error Medar Stepper Transmit Error Stepper data Receive Timeout MEDLAN Response Header Character error MEDLAN Response Command Code error MEDLAN Response Checksum error MEDLAN Response NAK MOTOMAN Spot Welding Manual for Medar... -
Page 44: Troubleshooting Welding Problems
Weld force too low, weld current too high, or weld time too long. Electrode face too small. Fit up is poor. Weld is too close to edge of part. Material is dirty. Squeeze time is too short. Follow up is poor Spot Welding Manual for Medar MOTOMAN... -
Page 45: Tips For Producing Quality Welds
Always use electrode holders with adjustable internal water cooling tubes. When switching to a different tip length, adjust the holder’s internal water cooling tube to the appropriate height. • Do not use holders that have leaky or deformed tapers. MOTOMAN Spot Welding Manual for Medar... -
Page 46: Troubleshooting Dual Port Ram I/O
Control Stop 0 = Active 7121 Isolation Contactor Status 0 = Closed 7122 Fault Reset 1 = Active 7123 No Weld 0 = No Weld 7124 Weld Initiate 1 = Initiate 7125 - 7127 Reserved Spot Welding Manual for Medar MOTOMAN... -
Page 47: Table 5-5 Xrc Inputs From Medar Board
MFDC Charge Request 1 = Charge Request Status 3 M006 Low Byte 7240 - 7246 Application Specific 7247 MFDC Timer 1 = MFDC; 0 = AC Status 4 M007 High Byte 7270 - 7277 Application Specific MOTOMAN Spot Welding Manual for Medar... - Page 48 TROUBLESHOOTING NOTES Spot Welding Manual for Medar MOTOMAN...
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Page 49: Robot I/O
1237 7107 Reset to Step 1 1240 7130 Reset to Step 2 1241 3261 1242 3262 Upload Dynamic Data 1243 3263 Welding Error Reset 1244 4014 Initiate Weld 1245 7124 1246 3266 1247 3267 MOTOMAN Spot Welding Manual for Medar... - Page 50 0240 Stepper at Max 7606 0241 Reset to Step 2 (from OUT 186) 1241 0242 Upload Dynamic Data from OUT 188 1243 0243 2264 0244 Robot at Ready 5137 0245 2266 0246 2267 0247 Spot Welding Manual for Medar MOTOMAN...
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