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Summary of Contents for Miller PerformArc PA550H
- Page 1 System Operating Instructions PerformArc PA550H/PA550HW/PA1100HW Version 2.0...
- Page 2 Instructions in this manual are based on the version E mechanical and version H electrical drawings for the PerformArc PA550H system. Verify that your system matches these versions before using this manual as a basis for the operation of your system.
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Page 3: Table Of Contents
Table of Contents Table of Contents 7.4.1 LED Indicators ........32 1. Safety Precautions – Read Before 8. Robot Settings ........33 Using (som 2013-09) ........ 4 8.1 Tool Center Point (TCP) ......33 Symbol Usage ......... 4 8.2 Home Cube ..........34 Arc Welding Hazards ...... -
Page 4: Safety Precautions - Read Before Using (Som 2013-09)
Safety 1. Safety Precautions – Read Before Using (som 2013-09) Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions. 1.1 Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 5 Safety • Keep cords dry, free of oil and grease, and protected from hot metal and sparks. • Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. •...
- Page 6 Safety WELDING can cause fire or explosion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
Safety CYLINDERS can explode if damaged. Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally part of the welding process, be sure to treat them carefully. • Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs. - Page 8 Safety MOVING PARTS can injure. • Keep away from moving parts. • Keep away from pinch points such as drive rolls. WELDING WIRE can injure. • Do not press gun trigger until instructed to do so. • Do not point gun toward any part of the body, other people, or any metal when threading welding wire. BATTERY EXPLOSION can injure.
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Page 9: California Proposition 65 Warnings
Safety 1.4 California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq. This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. -
Page 10: Emf Information
Safety 1.6 EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF fields may interfere with some medical implants, e.g. -
Page 11: Hazard Labels/Warning Stickers
Safety 1.2.1 Hazard Labels/Warning Stickers Indication labels have been placed on the system to announce some of those task hazards to the individual(s) responsible for operation or maintenance. Below are the stickers that have been placed on the system to indicate those hazards. Sticker Description Danger Robot In Use –... -
Page 12: Specifications
Specifications 2. Specifications Dimensions: PA550S (PA122) PA550SW (PA122W) PA1100HW (PA132) Frame length 4,724mm (186”) 5,182mm (204”) 5,410mm (213”) Frame width 2,489mm (98”) 2,997mm (118”) Frame height 2,286mm (90”) 2,286mm (90”) Table rotation diameter 2337mm (92”) 2743mm (108”) Headstock bolt pattern 6 x M12 x 1.75, 250mm dia, 60°... -
Page 13: Pa550H (Pa122) Dimensions
Specifications 2.1 PA550H (PA122) Dimensions 2.1.1 PA550H Front View... -
Page 14: Pa550H Side View
Specifications 2.1.2 PA550H Side View... -
Page 15: Pa550 Top View
Specifications 2.1.3 PA550 Top View... -
Page 16: Pa550Hw (Pa122W) Dimensions
Specifications 2.2 PA550HW (PA122W) Dimensions 2.2.2 PA550HW Front View... -
Page 17: Pa550Hw Side View
Specifications 2.2.2 PA550HW Side View... -
Page 18: Pa550Hw Top View
Specifications 2.2.3 PA550HW Top View... -
Page 19: Pa1100Hw (Pa132) Dimensions
Specifications 2.3 PA1100HW (PA132) Dimensions 2.3.1 PA1100HW Front View... -
Page 20: Pa1100Hw Side View
Specifications 2.3.2 PA1100HW Side View... -
Page 21: Pa1100Hw Top View
Specifications 2.3.3 PA1100HW Top View... -
Page 22: Parts Identification
Parts Identification 3. Parts Identification Spool Holder Robot Manipulator Slave Receiver Light Curtain Main Disconnect (Fuse Box) Auto-Axcess Power Supply Turntable Master Receiver External Axis Light Curtain Brake Release Box Figure 3a – Left Side PLC Cabinet Main Disconnect (Fuse Box) Robot Controller Main Power Transformer... - Page 23 Parts Identification Robot Controller Slave Emitter Light Curtain Master Emitter Light Curtain Figure 3c – Right Side Operator Station Figure 3d – Front...
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Page 24: Moving And Locating
CAUTION! - The PerformArc PA550H system is not designed to be lifted from the side. Lifting from the side may result in damage to the system. Please make all attempts to lift from the provided fork pockets at the front and rear of the system before attempting to lift from either side. -
Page 25: Leveling
Moving and Locating 4.2 Leveling Leveling the system once it is located is recommended if the floor is uneven or has a significant slope. The robot and turntable are servo controlled and will tolerate a few degrees off of flat level but other components on the system such as the sliding doors may or may not operate correctly if the system is not reasonably level –... -
Page 26: Utilities (Power)
Utilities 5. Utilities (Power) Three-phase power is required for the PerformArc PA550H, PA550HW, and PA1100HW systems. Power should be specified at the time the system is ordered so the system can be properly configured to the electrical service to be provided where the system will be used. -
Page 27: Headstock
Refer to the Positioner Unit Operating Instructions (Model No. YA-RJB series) for loading details. Loads offset from the centerline of rotation may reduce the overall weight capacity of the positioner. Contact the Miller Welding Automation Engineering Department if assistance is needed in determining correct loading of the positioner.. -
Page 28: System Safety Devices
7.1 Emergency Stop Buttons Three emergency stop buttons are provided on all PerformArc PA550H, PA550HW, and PA1100HW welding cells. These are latching type switches that stay in the “pressed” position until the button is twisted to release the latch. - Page 29 System Safety Devices 7.1.3 Table Brake Release Emergency Stop The table brake release is mounted to the robot riser at the back of the robot on the left side of the cell. Below is the procedure for braking/releasing the brake on the positioner in case the positioner has accidentally pinched someone during rotation •...
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Page 30: Door Switches
System Safety Devices 7.2 Door Switches Two sliding wire mesh doors provide access to the welding area, one on the left and one on the right side of the system. Each door is equipped with a magnetic key and switch used to identify if the doors are fully closed or fully opened. Keys are attached to the door and slide open and closed with the door;... - Page 31 System Safety Devices 7.3 Table Position Switches Table position safety switches mounted on the top of the arc screen work together with the light curtains to identify the table’s position. Note: - External Emergency Stop - The table position switches work together with the systems light curtains. If the table is in position and the switch is made, the light curtains are ignored and the operator can walk in to load parts.
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Page 32: Light Curtains
System Safety Devices 7.4 Light Curtains The PreformArc PA550H, PA550HW, and PA1100HW are equipped with light curtains that are intended to protect personnel from unexpected table rotation. These light curtains are only active when the table in position switch (section 7.3 Table Position Switches) is not made. -
Page 33: Robot Settings
Robot Settings 8. Robot Settings PerformArc systems have many settings that are configured when the system is assembled and most of these are one- time settings that will never need to be changed. This section is intended to introduce a few key concepts that will make basic operations and troubleshooting much easier to understand. -
Page 34: Home Cube
Robot Settings 8.2 Home Cube Sending the robot to a “home” location is a common operation of the PerformArc systems and is necessary to running the system in auto mode. PerformArc systems use a robot feature called cube monitor to determine if the robot is at the home position. The cube monitor compares the current XYZ position of the tool center point (TCP) with a programmed XYZ range;... -
Page 35: Robot Home Output
Robot Settings 8.2.2 Robot Home Output Home position is indicated on the robot teach pendant as robot output #1. To display the outputs on the teach pendant go View > Display Change > Display I/O Terminal > List (Terminal Name) The robot user inputs and outputs will be displayed on the right side of the teach pendant screen;... -
Page 36: Clear Work Cube
Robot Settings 8.3 Clear Work Cube There is a second cube monitor set up in the robot that defines a much larger cube called “clear of work”. This cube is tied to the HOME selection of the operator station. When the robot TCP is within this cube the robot is considered safe to go directly home. -
Page 37: Inputs & Outputs
Robot Settings 8.4 Inputs & Outputs Robot inputs and outputs are critical to running the PerformArc systems and understanding where to view these and what they mean can make running and troubleshooting the system much easier. To view the inputs and outputs in either auto or teach mode go to the following teach pendant menu selections: View >... -
Page 38: Robot Inputs
Robot Settings 8.4.1 Robot Inputs Input signals from the different buttons and safety devices let the robot know what operation to perform, what side of the turntable is at the robot, and when it is safe for the robot to start moving. The following list covers the basic inputs to the robot (optional equipment inputs are not covered here). -
Page 39: Robot Outputs
Robot Settings 8.4.2 Robot Outputs Robot outputs tell the robot when to run a tip change and activate let the system know when the robot is clear of the work and at the home position. Output # Name Description @ Home Used in cube monitor #1;... -
Page 40: Global Position Variables
P3, etc that are in typical welding programs) is how they are programmed; these points can NOT be changed from within a program. Global variables typically used on PerformArc PA550H, PA550HW, and PA1100HW systems are: • Home – Home position •... - Page 41 Robot Settings 3. Select “Robot position”. 4. A list of robot position variables will be displayed on the screen. • “Valid” indicated the variable is being used. • “Invalid” means the variable is inactive and can be assigned a new position.
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Page 42: Teaching
Teaching 9. Teaching PerformArc systems are shipped with all of the necessary system programs already installed so end users only need to program the welding that they want the robot to perform. This section makes recommendations and outlines the programming structure; this manual is not intended to instruct users on the operation of the robot teach pendant and explain the commands used in robot programs. -
Page 43: Pre-Teaching Checks
9.2.1 Table Checks The PerformArc PA550H, PA550HW, and PA1100HW systems are equipped with a turntable that can present two different work surfaces to the robot. While the robot is welding on one side, an operator can be loading or unloading the other side. -
Page 44: System Programs
Teaching 9.3 System Programs The following programs come pre-installed on the PerformArc system and handle system functions such as sending the robot to Home position, running a tip change routine, and clamping and unclamping the table. In most cases these programs should not be changed. -
Page 45: System Program Structure
Teaching 9.3.1 System Program Structure In Auto Mode, only programs using the “Prog” prefix followed by four digits can be initiated from an outside source (such as a push button or a signal from a PLC). The main operating program in the PerformArc system, Prog0001.rpg, is an example of this. -
Page 46: Putting Programs Into Weld A & Weld B
Teaching 9.3.2 Putting Programs into Weld A & Weld B Once a program is created to weld a part on the side A table that program needs to be inserted into the Weld A.rpg program. 1. Go to the File pull-down menu. If the red box does not appear anywhere along the icon bar at the top of the screen, use the Window change... - Page 47 Teaching If additional program CALL instructions are in the program that is OK – the program can call as many programs as needed to weld and parts that are presented to the robot on that table. Note - See the section on Tip Change later in this manual for changing whether the tip change program runs before or after the welding program.
- Page 48 Teaching 8. The selected program should be listed in the File name blank. Press ENTER or click on the OK box. 9. The new welding program should now be displayed in the CALL statement. 10. Use the Change Window button to switch from the programming window pane to the icon bar at the top of the screen.
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Page 49: Running Multiple Programs On One Side
Teaching 9.3.3 Running Multiple Programs on One Side The robot is not limited to running one welding program on side A or side B. This can be a useful feature if more than one fixture is placed on one side of the table or if different parts running on the same fixture have different welding needs (weld parameters, fewer or more welds, different weld locations, etc.). - Page 50 Teaching 4. Press the Window Change button to make the icon bar at the top of the screen active (a red box should be visible). Go to the Add Command. 5. Roll the thumbwheel down so the red box is on the Flow icon. 6.
- Page 51 Teaching 8. When the program list window appears, find the program that will be added to Weld A. Press ENTER or click on the program and click again to OK the selection. 9. The new program should now appear in the Call program field. Press ENTER or click on the OK box.
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Page 52: Tip Change
Teaching 12. The robot will automatically ask an operator to save any changes that were made to the program. Click the thumbwheel on “Yes” or press the Enter key to save the program changes. Selecting “No” will close the program without saving changes to the program. - Page 53 Teaching Changing the Tip Change Count 1. Go to the Set pull down menu and select Arc Welding. 2. Select the default welder (Typically Welder 1). Note - Some robot/welder configurations may have different menu selection than those shown here. 3.
- Page 54 Teaching 5. Find the Program start count field. This number is how many times the robot will count the TIP CHANGE.rpg program before turning on the output that tells the robot it is time to run to the tip change location. Change this value by rolling down to the field and clicking the thumbwheel.
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Page 55: Tcp Check
Teaching 9.3.5 TCP Check A pointer is mounted inside the system to be used as a quick reference to verify the torch and/or arm alignment. This can be a valuable tool to in determining if something has moved in a “crash” (when the torch or arm collides with something solid in the system such as the tool, the part being welded, or the system frame). -
Page 56: Operation
Operation 10. Operation The PA550H, PA550HW, and PA1100HW systems are operated from the front of the system using the operator station push buttons. In most cases welding operation only requires the operator to load a part to be welded, press the “start” push button, and rotate the table. - Page 57 Operation 10.2 Table Rotation without Welding To rotate the table without welding the steps will be the same as for the Auto Mode start-up with the exception of the MODE SWITCH must be set to SWEEP A/SWEEP B. 1. Check that he table in position switch is made – both visually and by checking the LOAD/UNLOAD indicator light on the operator station.
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Page 58: Home In Auto Mode
Operation 10.3 Home in Auto Mode The robot can be sent to the home position automatically by selecting the HOME selection on the MODE SWITCH. Sending the robot to the home position in auto mode will only work if the robot is in the clear work cube (see section Clear Work Cube). -
Page 59: Troubleshooting
Troubleshooting 11. Troubleshooting This troubleshooting list addresses only potential system problems and does not cover the robot error and alarm codes. For a comprehensive list of robot errors see the robot operations manual. Problem Probable Cause Remedy External Emergency Stop Table not in position (side A at the robot or 1. - Page 60 Troubleshooting Robot will not run the Auto The PLC needs to see 5 conditions met 1. Check the 5 conditions: • program from the operator before it will allow a start. Are the robot outputs ON when station 1. Robot home, viewed from the robot teach 2.
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Page 61: Appendix
Appendix 12. Appendix 12.1 Prog0001.rpg - Main Program During normal production running of the system Prog0001.rpg is the program that is called every time the operator presses the CYCLE START button at the operator station. This program evaluates what side is at the robot and calls the appropriate table index program and welding program. -
Page 62: Prog0200.Rpg - Sweep Table
Appendix 12.2 Prog0200.rpg – Sweep Table Use the SWEEP A/SWEEP B program selection if the table needs to be indexed without running the robot. Turn the selector switch at the operator station to the middle position, labeled “SWEEP A SWEEP B” on the legend plate, and press the CYCLE START button to start this program. -
Page 63: Sweep A To Robot.rpg
Appendix 12.4 Sweep A to Robot.rpg Programs Prog0001.rpg and Prog0200.rpg call this program when it is time to index the table. Modifying this program may cause the table to malfunction; it is strongly recommended that this program remain in its original, as-delivered state. Program Description Begin of Program... -
Page 64: Go Home.rpg
Appendix 12.6 Go Home.rpg The Go Home program sends the robot to the home position. It is good programming practice to send the robot to the home position at the end of each program; calling the Go Home.rpg program or using the home global variable position are good methods of sending the robot to home. -
Page 65: Tcp Check.rpg
• Miller technical support is familiar with the program structure outlined in this manual. While they can help with customer created programs, troubleshooting system problems becomes much more difficult when the main program... -
Page 66: Weld B.rpg
Appendix 12.10 Weld B.rpg The weld B program is called from the main program, Prog0001.rpg, to run the welding program on side B. Program Description Begin of Program Beginning of the program. CALL Demo Call the Demo.rpg program. The test program is a for demonstration –... -
Page 67: Parts List
Parts List 13. Parts List Description Part Number Comments Manufacture 30.5mm Flush head Green with 1 contact Cycle Start Button 800T-A1D1 block Allen-Bradley 22.5 metal operator black wing knob 3 Program Selector Switch 800FM-HM32 position Allen-Bradley 22.5 metal operator 40mm mushroom head E-Stop Button Push-twist release 800FM-MT44 red (E-STOP) -
Page 68: Warranty
Warranty 14. Warranty Miller Welding Automation PerformArc Robotic Welding System Warranty Information Warranty Table: This table consists of the warranty coverage periods for a variety of MWA supplied components. Please consult this table prior to calling the service department or your integration partner with a warranty claim. -
Page 69: Ria Risk Assessment
General Comments: PerformArc systems are manufactured as unapplied systems that may be used for a broad scope of applications. Miller Welidng Automation (MWA) has made an effort to anitcipate the most common uses of the robotic cell and take these into account in this risk assessment. - Page 70 RIA Risk Assessment PA550H PA550HW PA1100HW Risk Assessment Report Reference ANSI/RIA TR306_sac_ballot_draft_20140226.docx Operator task Hazard Solution Risk Reduction Measures Residual Risk Level Process control and Arc flash High Solid metal wall construction Safeguarding, Warning and Low risk of arc flash by monitoring around the robot workspace, Awareness Means,...
- Page 71 RIA Risk Assessment Robot motion (mechanical Medium Solid metal wall construction Elimination, Safeguarding, Negligible Medium risk of finger/hand hazard - pinch/crush) around the robot workspace, Warning and Awareness injury if fingers and hand are wire mesh doors, restricted Means, Administrative extended through openings access to the robot.
- Page 72 RIA Risk Assessment Workpiece loading Table motion (mechanical High Solid metal wall construction Safeguarding, Warning and Negligible Negligible hazard) around the robot workspace, Awareness Means, wire mesh doors, restricted Administrative Controls access to the table (load side access only). Light curtain and table position switch interlock to prevent motion while personnel is inside the load area.
- Page 73 RIA Risk Assessment Programming and verification Robot motion (mechanical Medium Solid metal wall construction Safeguarding, Administrative Negligible Negligible hazard - pinching, impact) around the robot workspace, Controls wire mesh doors, restricted access to the robot. Safety switches on doors to stop automatic motion with doors open (slow speed teach capability only with doors open).
- Page 74 RIA Risk Assessment Brief operator intervention not requiring disassembly Tip change Welding wire/Torch Safe usage procedures outlined Administrative Controls, Negligible Negligible (mechanical - in the operation manual. Personal Protective Equipment puncture/stabbing) Operator training, personal protection equipment. Welding wire/Torch (thermal Safe usage procedures outlined Administrative Controls, Negligible Negligible hazard - hot nozzle/tip)
- Page 75 RIA Risk Assessment Equipment jams Mechanical (stored energy) Medium Solid metal wall construction Safeguarding, Administrative Negligible Negligible around the robot workspace, Controls wire mesh doors, restricted access to the weld area. Operator training. Dropped parts (unapplied Mechanical (impact, cutting) Personal protective equipment Unapplied systems - no tooling system) supplied by MWA...
- Page 76 RIA Risk Assessment Maintenance and repair Electrical hazard (shock, High Troubleshooting to be performed Administrative Controls Negligible Negligible electrocution, burn) only by trained personnel. Electrical panels interlocked with power on (power must be turned off to access the panel). Lock out/Tag out.
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