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Part Number:
Release Date:
Document Version:
Document Status:
142719-1
July 25, 2000
1
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
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.
©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.
TABLE OF CONTENTS
Section
1
2
3
MOTOMAN
Page
LIST OF FIGURES...........................................................................................................................iii
LIST OF TABLES ............................................................................................................................iii
INTRODUCTION
1.1 About this Document .................................................................................................... 1-1
1.2 System Overview .......................................................................................................... 1-2
1.2.1 System Layout ................................................................................................ 1-2
1.2.2 Major Components ......................................................................................... 1-2
1.2.3 Optional Equipment ........................................................................................ 1-2
1.3 Reference to Other Documentation................................................................................ 1-4
1.4 Customer Service Information ...................................................................................... 1-4
SAFETY
2.1 Introduction .................................................................................................................. 2-1
2.2 Standard Conventions .................................................................................................. 2-2
2.3 General Safeguarding Tips............................................................................................ 2-3
2.4 Mechanical Safety Devices ........................................................................................... 2-3
2.5 Installation Safety ......................................................................................................... 2-4
2.6 Programming Safety ..................................................................................................... 2-4
2.7 Operation Safety ........................................................................................................... 2-5
2.8 Maintenance Safety....................................................................................................... 2-6
EQUIPMENT DESCRIPTION
3.1 SV3X Robot Description ............................................................................................... 3-1
3.2 XRC Controller ............................................................................................................. 3-1
3.2.1 Playback Panel ............................................................................................... 3-2
3.2.2 Programming Pendant .................................................................................... 3-3
3.2.3 Brake Release ................................................................................................. 3-6
3.3 Operator Station............................................................................................................ 3-6
3.3.1 Cycle Start ...................................................................................................... 3-6
3.3.2 Emergency Stop (E-STOP) .............................................................................. 3-7
3.3.3 Door Status ..................................................................................................... 3-7
3.4 Stationary Weld Table ................................................................................................... 3-7
3.4.1 Arc Shields ..................................................................................................... 3-7
3.5 Welding Equipment ...................................................................................................... 3-8
3.5.1 Power Sources ................................................................................................ 3-8
3.5.2 PWF Wire Feeder ............................................................................................ 3-9
3.5.3 Universal Welding Interface (UWI) .................................................................. 3-9
3.5.4 GMAW Torch .................................................................................................. 3-9
3.5.5 Motoman Torch Mount ................................................................................... 3-9
i
Arc-WorldLite 50 System Manual
EQUIPMENT DESCRIPTION (CONTINUED)
3.6 Safety Features ............................................................................................................. 3-9
3.6.1 Arc Shields ................................................................................................... 3-10
3.6.2 Fencing ......................................................................................................... 3-10
3.6.3 Emergency Stops (E-STOPS) ........................................................................ 3-10
3.6.4 ENABLE Switch ............................................................................................. 3-10
3.6.5 Interlocked Cell Door .................................................................................... 3-10
3.6.6 Interference Cubes ........................................................................................ 3-11
3.6.7 Brake Release Control ................................................................................... 3-11
4 INSTALLATION
4.1 Materials Required........................................................................................................ 4-1
4.1.1 Customer-Supplied Items ............................................................................... 4-1
4.1.2 List of Tools Required ..................................................................................... 4-1
4.2 Site Preparation ............................................................................................................ 4-2
4.3 Installing the Arc-WorldLite 50 Common Base............................................................. 4-2
4.3.1 Removing the Shipping Brackets .................................................................... 4-3
4.4 Leveling and Securing the Cell ..................................................................................... 4-4
4.5 Connecting the Cables.................................................................................................. 4-4
4.5.1 Connecting the Earth Ground .......................................................................... 4-4
4.5.2 Connecting the Water Circulator (Optional) .................................................... 4-5
4.6 Connecting the Gas/Air Services .................................................................................. 4-6
4.7 Connecting the Power................................................................................................... 4-7
4.8 Conducting a Safety/Operation Check .......................................................................... 4-7
4.9 Installation of Tooling and Fixtures............................................................................... 4-7
5 OPERATION
5.1 Programming................................................................................................................ 5-1
5.1.1 I/O Assignment ............................................................................................... 5-1
5.2 Daily Operation ............................................................................................................. 5-2
5.2.1 Start-Up .......................................................................................................... 5-2
5.2.2 Robot Home Position ...................................................................................... 5-3
5.2.3 Starting the Master Job ................................................................................... 5-3
5.2.4 Shutdown ....................................................................................................... 5-3
5.3 System Recovery .......................................................................................................... 5-4
5.3.1 Alarms and Errors ........................................................................................... 5-4
5.3.2 E-STOP Recovery ........................................................................................... 5-4
5.3.3 Shock Sensor Recovery .................................................................................. 5-5
6 MAINTENANCE
6.1 Periodic Maintenance ................................................................................................... 6-1
6.2 Fuse and Circuit Breaker Protection.............................................................................. 6-2
Arc-WorldLite 50 System Manual
ii
MOTOMAN
LIST OF FIGURES
Page
Figure
Figure 1-1
Figure 3-1
Figure 3-2
Figure 3-3
Figure 3-4
Figure 3-5
Figure 3-6
Figure 3-7
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Figure 4-6
System Layout ............................................................................................................. 1-3
XRC Controller ............................................................................................................ 3-1
XRC Playback Panel .................................................................................................... 3-2
Programming Pendant ................................................................................................. 3-3
RS-232C Serial Port .................................................................................................... 3-5
Enable Switch ............................................................................................................... 3-5
Operator Station ........................................................................................................... 3-6
Power Sources ............................................................................................................. 3-8
Area Needed for Installation ......................................................................................... 4-2
Unbolting the Arc-WorldLite 50 Common Base ........................................................... 4-3
Location of Shipping Brackets ..................................................................................... 4-3
Location of Leveling Bolts ........................................................................................... 4-4
Water Circulator Connections ...................................................................................... 4-6
Gas and Air Service Connections ................................................................................. 4-6
LIST OF TABLES
Table
Table 3-1
Table 5-1
Table 5-2
Table 6-1
Table 6-2
Table 6-3
MOTOMAN
Page
Positioner Specifications ............................................................................................ 3-7
XRC User Inputs .......................................................................................................... 5-2
XRC User Outputs ........................................................................................................ 5-2
Periodic Maintenance .................................................................................................. 6-1
Universal Welding Interface (UWI) Fuses ..................................................................... 6-2
MotoArc 450 CV Fuses and Circuit Breaker.................................................................. 6-2
iii
Arc-WorldLite 50 System Manual
NOTES
Arc-WorldLite 50 System Manual
iv
MOTOMAN
SECTION 1
INTRODUCTION
The Arc-WorldLite 50 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 Arc-WorldLite 50 features a Motoman SV3X arc welding robot and XRC
robot controller with menu-driven arc welding application software, complete
welding package, stationary weld table, and a total safety environment.
1.1
About this Document
This manual is intended as an introduction and overview for personnel who have
received operator training from Motoman, and who are familiar with the operation
of this Motoman robot model. For more detailed information, refer to the manuals
listed in Section 1.3. This manual contains the following sections:
SECTION 1 - INTRODUCTION
Provides general information about the Arc-WorldLite 50 and its components, a
list of reference documents, and customer service information.
SECTION 2 - SAFETY
Provides information regarding the safe use and operation of the Arc-WorldLite 50
system.
SECTION 3 - DESCRIPTION OF EQUIPMENT
Provides a detailed description of the major components of the Arc-WorldLite 50
system. This section also includes a table of component specifications.
SECTION 4 - INSTALLATION
Provides instructions for set up and installation of the Arc-WorldLite 50 system.
SECTION 5 - OPERATION
Provides instructions for basic operation of the Arc-WorldLite 50 system. This
section provides procedures for start-up, loading, normal operation, fault recovery,
and shutdown.
SECTION 6 - MAINTENANCE
Contains a table listing periodic maintenance requirements for the components of
the Arc-WorldLite 50 cell.
MOTOMAN
1-1
Arc-WorldLite 50 System Manual
INTRODUCTION
1.2
System Overview
The Arc-WorldLite 50 provides a complete arc welding solution in a standardized
configuration. The system is designed around a Motoman SV3X arc welding robot
with XRC controller, and includes a complete welding package. A stationary weld
table with protective operator door provides easy operator access to parts, and a
safe welding environment. The cell provides a full complement of safety features
designed to protect both personnel and equipment. Figure 1-1 illustrates the system
layout of the Arc-WorldLite 50 cell.
1.2.1
System Layout
The robot manipulator, XRC controller and welding power source, all share a
common base for ease of installation and to help maintain proper alignment
between components. The Arc-WorldLite 50 cell is fully enclosed by sheet metal
and weld curtains to protect the operator. All operator controls are accessible from
outside the enclosure.
1.2.2
Major Components
The Arc-WorldLite 50 includes the following major components:
• Motoman SV3X manipulator and XRC controller
• Stationary weld table
• Operator station
• Welding equipment, including the following:
• Welding power source
• Torch (water-cooled or air-cooled)
• Wire feeder
• Torch mount
• Safety equipment, including the following:
• Protective arc screen
• Customer actuated Emergency Stops
• Software defined Interference Cubes
1.2.3
Optional Equipment
The following optional equipment is available for use with the Arc-WorldLite 50:
• Torch tender
• Wire cutter
• Com-Arc III seam tracking unit
• Water circulator
Arc-WorldLite 50 System Manual
1-2
MOTOMAN
INTRODUCTION
CELL DOOR
XRC CONTROLLER
ROBOT
AC
SN
YA
C
XR
16X
SK
STOP
ENCY
EMERG
MODE
TEACH
ON
SERVO
READY
PLAY
T
STAR
HOLD
ALARM
LOCK
EDIT
(OFF)
E
REMOT
(ON)
PE
N/ROFF
TRI
P
ON
O
POWER SOURCE
POSITIONER
NO
FF
W
O
by R
M LD
O LI
T
O TE
M
A
N
C
RRU
TNE UPNI
T
AC
ELB H
TAE
AW
RET
O
ARC
RET
LA
MRA I
N
ACID
ROT
NO
FF
OC
2
EP
M
TEN
GA OITAR
N
S
OLO
NOF
61Ø
41Ø
RIW
LF
21Ø EPYT E
WO
A
OTU ID ERIW
A
F
ESU
RC
ETA
CR
RRU
CTNE
TAR
V RE
TLO
EGA
O
SAG
RE
RE
TE
LO
MT
AG
LF S
WO
TE
MM
A
V
A
V
RE
_
NO
0
WO
P
AL
A
MR
OC
O TN
FF LORWOP
E
R
OPERATOR STATION
SAFETY FENCE
FRONT VIEW
WIRE FEEDER
WIRE CASSETTE
POWER
DISCONNECT
110 VOLT OUTLET
REAR VIEW
Figure 1-1 System Layout
MOTOMAN
1-3
Arc-WorldLite 50 System Manual
INTRODUCTION
1.3
Reference to Other Documentation
For additional information refer to the following:
• Motoman SV3X Manipulator Manual (P/N 139067-1)
• Motoman Operator's Manual for Arc Welding (P/N 142098-1)
• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)
• Com-Arc III Instruction Manual (P/N 132753-1)
• Vendor manuals for system components not manufactured by Motoman
1.4
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 (SV3X)
• Application Type (welding)
• System Type (Arc-WorldLite 50)
• Software Version (3.74)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of XRC controller)
Arc-WorldLite 50 System Manual
1-4
MOTOMAN
SECTION 2
SAFETY
2.1
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. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: 313/994-6088
FAX: 313/994-3338
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
MOTOMAN
2-1
Arc-WorldLite 50 System Manual
SAFETY
2.2
Standard Conventions
This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
• NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE:
Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.
Arc-WorldLite 50 System Manual
2-2
MOTOMAN
SAFETY
2.3
General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4
Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment will
be operated safely should be reviewed by the user. The user must be aware of the
various national codes, ANSI/RIA R15.06 safety standards, and other local codes
that may pertain to the installation and use of industrial equipment. Additional
safety measures for personnel and equipment may be required depending on
system installation, operation, and/or location. The following safety measures are
available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.
MOTOMAN
2-3
Arc-WorldLite 50 System Manual
SAFETY
2.5
Installation Safety
Safe installation is essential for protection of people and equipment. The 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. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
2.6
Programming Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special
passwords. Special passwords are for Motoman use only. YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
Arc-WorldLite 50 System Manual
2-4
MOTOMAN
SAFETY
•
•
•
•
•
•
2.7
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.
Carry the teach pendant with you when you enter the workcell.
Be sure that only the person holding the teach pendant enters the workcell.
Test any new or modified program at low speed for at least one full cycle.
Operation Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
MOTOMAN
2-5
Arc-WorldLite 50 System Manual
SAFETY
2.8
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:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any nonfunctioning safety equipment immediately.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
Arc-WorldLite 50 System Manual
2-6
MOTOMAN
SECTION 3
EQUIPMENT DESCRIPTION
3.1
SV3X Robot Description
The Motoman SV3X robot and Xtra Robotic Controller (XRC) represent state-ofthe-art technology in robotics today. The six-axis SV3X robot has a payload of 3
kg (6.6 lbs). It features a 1,019 mm (40.1 in.) vertical reach and has a relative
positioning accuracy of ± 0.03 mm (0.001 in.).
The SV3X robot can reach below its own base as well as behind itself. The SV3X
can also be mounted in floor, wall, or ceiling configurations with few hardware
modifications. For more information, refer to the manipulator manual that came
with your system.
3.2
XRC Controller
The XRC robotic controller (see Figure 3-1) coordinates the operation of the ArcWorldLite 50 system. It controls manipulator movement and welding power
supply, processes input and output signals, and provides the signals to operate the
welding system. It maintains variable data and performs numeric processing to
convert to and from different coordinate systems. In addition, the controller
provides the following: main logic functions, servo control, program and constant
data memory, and power distribution. For more information, refer to the
manipulator manual that came with your system.
BRAKE RELEASE
CONTROL
PLAYBACK BOX
YASNAC XRC SV3X
SERVO ON
READY
MODE
PLAY
EMERGENCY STOP
TEACH
EDIT LOCK
ALARM
(OFF)
(ON)
REMOTE
HOLD
START
ON
IP
SET
RE
N/
PE
OFF
TR
O
POWER
DISCONNECT
PROGRAMMING
PENDANT
Figure 3-1 XRC Controller
MOTOMAN
3-1
Arc-WorldLite 50 System Manual
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
BUTTONS
SERVO ON
READY
ALARM/ERROR
INDICATOR
MODE
PLAY
EMERGENCY STOP
E-STOP
TEACH
SERVO ON
READY
EDIT LOCK
ALARM
(OFF)
(ON)
REMOTE
HOLD
START
START
BUTTON
EDIT LOCK
REMOTE
MODE
HOLD
BUTTON
Figure 3-2 XRC Playback Panel
Servo On Ready
The SERVO ON READY push button turns servo power ON. The switch lights
when servo power is on. In TEACH mode, the SERVO ON READY push button
operates only when the TEACH LOCK button on the programming pendant is ON
and the ENABLE switch on the programming pendant is held in.
Mode
The Mode push buttons (PLAY and TEACH) set the robot's mode of operation.
NOTE:
Changing modes from PLAY to TEACH, during playback, will cause the program to cease
execution (similar to HOLD); to resume operation, press PLAY and then START.
Remote
This push button disables the playback panel and enables servo power to be
applied if play mode is set and positioner door is up.
Alarm/Error
The ALARM/ERROR indicator light turns ON whenever an alarm or error
condition occurs.
Emergency Stop (E-STOP)
The E-STOP button on the playback panel is connected in series with the system
Emergency Stop circuit. Pressing E-STOP ceases all system operation.
Start
Pressing the START button while in PLAY mode with servo power on, causes
playback execution of the current job to begin.
Arc-WorldLite 50 System Manual
3-2
MOTOMAN
EQUIPMENT DESCRIPTION
Hold
The HOLD button is a normally closed, momentarily actuated switch. Pressing
HOLD halts operation of the manipulator until another Start signal is sent.
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. By using the pendant, the
operator can teach robot motion, and perform programming, editing, maintenance,
and diagnostic functions. The programming pendant consists of the items
described below. For more information, refer to the manipulator manual that came
with your system.
NOTE:
The programming pendant LCD display goes dark after a few minutes of inactivity. Press any
key to restore screen.
MENU AREA
STATUS AREA
GENERAL PURPOSE
DISPLAY AREA
EMERGENCY
STOP BUTTON
CURSOR
AXIS KEYS
ENTER KEY
ENABLE
SWITCH
NUMERIC KEYPAD
Figure 3-3 Programming Pendant
General Purpose Display Area
The General Purpose Display Area displays the currently selected menu choice.
Menu Area
The Menu Area contains menu selections for the currently selected screen.
Emergency Stop (E-STOP)
The E-STOP button on the programming pendant is connected in series with the
system Emergency Stop circuit. Pressing the E-STOP button interrupts this circuit
and stops all system operation.
Keypad
The user keypad on the programming pendant serves as an input device. The keys
are grouped into different functional sections to simplify operator use.
MOTOMAN
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Arc-WorldLite 50 System Manual
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
u
Joint,
•
World,
Tool, or
User Frame
Manual Speed Setting
M
L
Inching,
•
Cylindrical,
H
Low,
Medium, or
High
Cycle Mode
S Step, C 1-Cycle, or A Auto
•
System Status
E-Stop,
•
S
Stop,
R
Running/Start,
H
Hold, or
A
Alarm
Additional Pages (when applicable)
TOP MENU Key
The TOP MENU key returns the pendant display to the initial start-up menu. The
cursor key can then be used to choose from the following menu icons:
• JOB
This icon accesses job selections including: Master Job, Select Job, Job
Capacity, and Create New Job while in TEACH mode.
•
•
ARC WELDING, GENERAL, HANDLING, and SPOT WELDING
This icon allows you to select the applications available to the controller.
VARIABLE
This icon accesses the display and editing menu for the arithmetic variables
and display of position variables.
•
IN/OUT
This icon accesses DETAIL and SIMPLE displays of all XRC I/O signals. In
EDITING or MAINT. mode, Universal Outputs can be forced ON or OFF.
•
ROBOT
This icon accesses robot information including: CURR.POS, POWER ON/
OFF, POS, COMMAND POS, SECOND HOME POS, OPE ORIGIN POS,
and TOOL and USER COORDINATE.
•
SYSTEM INFO
This icon provides Version information for both hardware and software,
Alarm History, and Monitoring Time.
Area Key
The Area key moves the cursor to the different areas of the display screen.
Cursor Key
The Cursor key is an 8-way, directional key that moves the up, down, left or right
to highlight a desired item that can then be chosen using the SELECT key.
Arc-WorldLite 50 System Manual
3-4
MOTOMAN
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.
RS-232C Serial Port
This 9-pin serial port is used for data communication between the XRC and a
floppy disk controller (FC1 or FC2), FDE (Floppy Disk Emulator) software, or
other form of communication (see Figure 3-4).
RS-232C
SERIAL PORT
Figure 3-4 RS-232C Serial Port
ENABLE Switch
The ENABLE switch (see Figure 3-5) is a three-position switch located on the left
rear of the programming pendant. It is a safety feature that controls servo power
while in TEACH mode. When pressed in, this switch enables servo power to be
turned on. However, should the operator release the switch, or grasp it too tightly,
servo power is immediately disabled, preventing further robot movement.
BACK OF
PROGRAMMING
PENDANT
ENABLE SWITCH
Figure 3-5 Enable Switch
MOTOMAN
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Arc-WorldLite 50 System Manual
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 brakes
on the robot in case of an emergency or robot failure. The Brake Release Control is
mounted on the front of the XRC cabinet (see Figure 3-1).
3.3
Operator Station
The operator station (see Figure 3-6) includes a NEMA enclosure. The following
paragraphs describe the operator station controls.
CYCLE START
LOWER DOOR
E.STOP
RES
ET
ET
ES
RESET
R
Figure 3-6 Operator Station
3.3.1
Cycle Start
WARNING!
The operation of the CYCLE START palm button is dependent on the
structure of the Master job. Altering the Master job could result in
injury to personnel or damage to the equipment.
The CYCLE START push button, located at the top of the operator station,
completes the CYCLE START circuit when the operator presses this button. The
operator door closes and the robot moves to the appropriate station. The following
is an example of typical operation:
The CYCLE START push button is activated, sending a signal to the XRC to close
the operator door. Switches located on the operator door verify the operator door is
closed, applies servo power, starts the job, and enables the robot to enter the work
area and perform the assigned job.
Arc-WorldLite 50 System Manual
3-6
MOTOMAN
EQUIPMENT DESCRIPTION
3.3.2
Emergency Stop (E-STOP)
The operator station E-STOP button is connected in series with the system
Emergency Stop circuit. Pressing the E-STOP button interrupts this circuit and
stops all system operation. Brakes are applied to the robot and all servo power is
removed from the system. All door motion commands are cancelled.
NOTE:
3.3.3
The air operated safety door may continue to move after an E-STOP occurs until cylinder air
pressure equalizes.
Door Status
The lower door push button opens the positioner door when pressed. This allows
the operator to open the positioner door when needed.
3.4
Stationary Weld Table
The Arc-WorldLite 50 features a weld table with a door that protects the operator
from arc radiation, weld splatter, and physical contact with the robot arm. When
the robot is finished working, the door lowers, giving the operator access to unload
and reload parts from the fixture.
.
Table 3-1 Positioner Specifications
Conditions
.NOTE:
3.4.1
Specifications
Part/Fixture Rating
453.6 kg (1,000 lbs)
Temperature Operating Range
4-43°C (40-110˚F)
Humidity (maximum)
Non-condensing 10-90% relative humidity
Door Cycle Speed
3 - 4 seconds (approximate)
Air Pressure Requirements
0.04 cmm at 620.5 kPa (1.5 scfm at 90 psi) typical
Arc Shield
A single vertically actuated sheet metal screen for arc radiation protection between operator and robot area.
Welding Current Rating
600 amperes at 100% duty cycle
In high humidity areas, use surface protection to prevent corrosion of the tooling plate.
Arc Shields
WARNING!
Although the arc curtain blocks dangerous arc radiation, never look
directly at the arc without protective yellower!
Two separate arc screens are used on the Arc-WorldLite 50. The first is the metal
arc screens on the front and sides of the weld table. These screens block arc
radiation and sparks from the welding operation. The material used to cover the
back of the robotic cell acts as the second arc screen. This material reduces the
amount of ultra-violet radiation that escapes from the robotic cell.
MOTOMAN
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Arc-WorldLite 50 System Manual
EQUIPMENT DESCRIPTION
3.5
Welding Equipment
The ArcWorld system provides a complete complement of arc welding equipment.
In its standard configuration, the ArcWorld system includes a power source, wire
feeder, torch, and torch mount. Optional equipment including water circulators,
Com-Arc units, and torch tenders may also be included with your system.
3.5.1
Power Sources
Motoman offers several different power sources for use with the ArcWorld system
depending on your system’s application. The following are some of the more
common power sources used. However, the power source your system uses may be
different. For more specific information, refer to the vendor manual that came with
your system.
ON
ALARM
INDICATOR
OFF
CRATER
CRATER CURRENT CRATER VOLTAGE
ON
CO2
SOLO
OFF
MAG
FON
PENETRATION
AMMETER
VOLTMETER
A
V
GAS
WIRE TYPE
POWER
ALARM
CURRENT
INPUT
CABLE
HEAT
WATER
Ø16
Ø14
Ø12
FUSE
FLOW
AUTO
WIRE DIA
KOBELCO UC350
POWER SOURCE
GAS FLOW
_
ON
0
OFF
CONTROL
POWER
ON
CRATE
R CURR
ENT
OFF
CRATE
R VOLTA
GE
CRAT
ER
ALAR
M
INDIC
ATOR
ON
OFF
AMM
ETE
R
CO
2
PENE
TRAT MAG
ION
VOL
TME
TER
CURR
INPU ENT
T
CABL
HEATE
WATE
R
SOLO
GAS
FON
WIRE
A
Ø16
Ø14
FUSE
TYPE Ø12
FLOW
WIRE
AUTO
DIA
GAS
FLOW
V
POW
ER
ALA
RM
_
ON
0
CONT
ROL
POWE
R
OFF
CIRCUIT BREAKERS
WIRE FEEDER #1
WIRE FEEDER
10 AMP
10 AMP
REMOTE
CONTROL
115 V 9A
5
115 V 9A
6
4
INPUT
POWER
7
3
A
V
2
ON
1
OFF
0
LOCAL
REMOTE
MOTOARC 450
POWER SOURCE
Figure 3-7 Power Sources
Arc-WorldLite 50 System Manual
3-8
MOTOMAN
EQUIPMENT DESCRIPTION
Mobility
The steel base that supports the power source for the Arc-WorldLite 50 system is
mobile. Four casters enable the power source to be wheeled away from the welding
cell for ease of service and installation.
To remove the power source, remove the two bolts that fasten the base to the
welding cell. The cross member that stabilizes the frame must also be removed
before the power source is wheeled out.
3.5.2
PWF Wire Feeder
The wire feeder is located on the back of the equipment frame. 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.
Interchangeable feed rolls are used to accommodate different types and sizes of
wire.
A Shock Sensor Override switch located on the front of the feeder is used to
recover from torch impact.
3.5.3
Universal Welding Interface (UWI)
The UWI provides microprocessor control to the wire feeder and MotoArc series
power source. It scales the signals from the XRC controller to the appropriate
levels required for control of the welding components. It also provides isolation of
the power source analog signals.
NOTE:
3.5.4
Some power sources available with the Arc-WorldLite 50 system do not use the UWI. For more
information specific to your system, refer to the vendor manuals shipped with your system.
GMAW Torch
The ArcWorld system uses either an air-cooled or a water-cooled robotic/automatic
GMAW torch. These are heavy-duty torches designed for quick replacement while
requiring minimum robot reprogramming. The GMAW torch is installed at the end
of the robot wrist. For applications that use the water-cooled torch, the ArcWorld
system includes a suitable water circulator kit.
3.5.5
Motoman Torch Mount
A Motoman Torch Mount protects the robot, workpiece, fixture, and positioner. It
provides multi-directional impact detection, including Z-axis collisions. Torch
impact causes a system E-STOP and immediately stops all system operation.
Servo power is removed from the system and brakes are applied to the robot. All
positioner and door motion is also stopped.
3.6
Safety Features
The Arc-WorldLite 50 incorporates a host of safety equipment. When all standard
safety precautions are taken, the safety equipment helps to ensure safe operation of
the robotic cell. The ANSI/RIA R15.06 Robot Safety Standard stipulates the user
is responsible for safeguarding. Users are responsible for determining whether the
provided safeguards are adequate for plant conditions. Users must also ensure that
safeguards are maintained in working order.
MOTOMAN
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Arc-WorldLite 50 System Manual
EQUIPMENT DESCRIPTION
3.6.1
Arc Shields
WARNING!
Although the arc curtain blocks dangerous arc radiation, never look
directly at the arc without protective eye wear!
Two separate arc screens are used on the Arc-WorldLite 50. The first is the metal
arc screen on the front of the weld table. These screens block arc radiation and
sparks from the welding operation. The material used to cover the back of the
robotic cell acts as the second arc screen. This material reduces the amount of
ultra-violet radiation that escapes from the robotic cell.
3.6.2
Fencing
The safety fencing provided with the Arc-WorldLite 50 system encloses the entire
robotic cell. It forms a physical barrier preventing entry into the robot envelope
during automatic operation.
3.6.3
Emergency Stops (E-STOPS)
In addition to the safety features described above, the Arc-WorldLite 50 has
strategically placed E-STOPS. These are operator actuated devices that, when
activated, immediately stop all system operation. Brakes are applied to the robot
and all servo power is removed from the system. The system E-STOP lights come
on and all positioner motion is stopped. The following is a list of their locations:
• The playback panel on the controller has one E-STOP button.
• The programming pendant has one E-STOP button.
• The operator station has one E-STOP button.
3.6.4
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. For detailed information about the operation of the
ENABLE switch, refer to the XRC section in the manipulator manual that came
with your system.
3.6.5
Interlocked Cell Door
A safety interlock on the cell entrance door prevents entry into the cell during
PLAY mode. Opening the cell door with the robot in PLAY causes an Gate
Interlock Error. Brakes are applied to the robot and all servo power is removed
from the system. The system E-STOP lights come on and all positioner motion is
stopped.
In TEACH mode, power to the table is removed if the cell door is open. In order to
sweep the table in teach, the door must be closed.
Arc-WorldLite 50 System Manual
3-10
MOTOMAN
EQUIPMENT DESCRIPTION
3.6.6
Interference Cubes
Cubic interference zones prevent interference between multiple manipulators or a
manipulator and peripheral devices. The XRC monitors the robot tool center point
(TCP) during operation. If the TCP enters one of the these software-defined
interference zones, an output is turned on in the XRC. These outputs can be used to
interlock the activity of other manipulators or peripheral devices. The XRC has
eight possible cubes available. These cubes are internally tied to Specified Outputs:
R1 = SOUT #081 - 104
Setup of these cubes is done at the factory prior to shipment. However, should any
of these cubes need redefined or modified due to changes in tooling or system
components, refer to your XRC manipulator for basic interference cube setup.
3.6.7
Brake Release Control
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 releases the automatic brakes on
the robot in case of an emergency or robot failure.
MOTOMAN
3-11
Arc-WorldLite 50 System Manual
EQUIPMENT DESCRIPTION
NOTES
Arc-WorldLite 50 System Manual
3-12
MOTOMAN
SECTION 4
INSTALLATION
The Arc-WorldLite 50 system can be installed easily in just a short time by one or
two workers. Follow established safety procedures at all times throughout the
installation process. Failure to use safe work practices can result in damage to the
equipment and injury to the workers.
CAUTION!
Installation of the Arc-WorldLite 50 is not a task for the novice. The
Arc-WorldLite 50 system is not fragile, but it is a highly
sophisticated robotic system. Handle components with care. Rough
handling can damage system electronic components.
4.1
Materials Required
All system hardware necessary for installing the Arc-WorldLite 50 is included
with the system. This section identifies customer-supplied items and tools required
to complete installation.
4.1.1
Customer-Supplied Items
•
•
•
•
•
4.1.2
List of Tools Required
•
•
•
•
•
•
•
MOTOMAN
Gas bottles for the welding torches
Incoming power supply
Two earth ground cables with two earth ground stakes
Weld wire
Incoming air supply: 0.04 cmm at 620.5 kPa (1.5 scfm at 90 psi)
Safety glasses
Face shields
Gloves
Level
Rachet with 3/4-in. socket
Adjustable wrench set
Hammer drill with appropriate
concrete bits
4-1
•
•
•
•
•
•
•
Phillips and flat screwdrivers
Hammer
Socket set
Forklift and/or overhead crane
Air-impact gun with 3/4-in.
socket
Open-end wrench set
Two socket-head (Allen)
•
Wrench sets (standard and metric)
Arc-WorldLite 50 System Manual
INSTALLATION
4.2
Site Preparation
To prepare your site, proceed as follows:
1. Clear the floor space needed for the unit (see Figure 4-1).
NOTE:
An additional 2.43 to 3.05 m (8 to 10 ft.) on all sides of is recommended.
2. Gather all customer-supplied items and required tools listed in Section 4.1.
2000
(6.56 ft)
2438
(8.00 ft)
1524
(5.00 ft)
XRC
Figure 4-1 Area Needed for Installation
4.3
Installing the Arc-WorldLite 50 Common Base
The Arc-WorldLite 50 is shipped completely assembled on a wooden shipping
skid. To install the Arc-WorldLite 50 common base, proceed as follows:
1. Unbolt Arc-WorldLite 50 common base from wooden shipping skid using a
3/4 -in. socket (see Figure 4-2).
WARNING!
The robot/positioner common base weighs 1724 kg (3800 lbs). Be
sure that your crane or forklift is capable of handling this much
weight or damage to the equipment or injury to personnel can result.
2.
3.
4.
5.
NOTE:
Using a forklift, remove Arc-WorldLite 50 common base from the skid.
Place Arc-WorldLite 50 common base in position (see Figure 4-1).
Carefully remove protective plastic wrapping from all system components.
Inspect all system components, for shipping damage.
If damage is found, notify shipper immediately.
Arc-WorldLite 50 System Manual
4-2
MOTOMAN
INSTALLATION
SHIPPING BOLT
LEVELING BOLT
SK1
XRC
YAS
NAC
ON
SERVO
READY
6X
STOP
EMERGENCY
MODE
TEACH
PLAY
START
HOLD
ALARM
LOCK
EDIT
(OFF)
REMOTE
(ON)
PE
OFF
N/R
TRIP
ON
O
NO
FF
W
O
by R
M LD
O LI
T
O TE
M
A
N
C
RRU
TNE UPNI
T
AC
ELB H
TAE
AW
RET
O
ARC
RET
LA
MRA
NO
NI
ACID
ROT
2
OC
GA
S
OLO
NOF
61 Ø
41 Ø
ERIW
LF
21Ø EPYT
WO
A
OTU ID ERIW
A
F
ESU
M
FF
RC
ETA
CR
RRU
CTNE
TAR
V RE
TLO
EGA
O
EP
TEN
TAR
NOI
SAG
RE
RE
TE
LO
MT
TE
MM
A
V
A
AG
LF S
WO
V
RE
_
NO
0
WO
P
AL
A
MR
OC
O TN
FF LORWOP
E
R
Figure 4-2 Unbolting the Arc-WorldLite 50 Common Base
4.3.1
Removing the Shipping Brackets
CAUTION!
Shipping brackets must be removed before operation. Failure to do
so will result in damage to the robot drive mechanisms.
Three yellow brackets (see Figure 4-3) prevent the robot from moving during
shipping. Two rod brackets secure the lower arm assembly to the S-axis housing.
The smaller bracket on the rear of the robot prevents the S-axis housing from
pivoting. After the system is in place, remove all shipping brackets.
YELLOW
SHIPPING
BRACKETS
Figure 4-3 Location of Shipping Brackets
MOTOMAN
4-3
Arc-WorldLite 50 System Manual
INSTALLATION
4.4
Leveling and Securing the Cell
After everything is in position, the equipment should be leveled and then secured
to the floor. The lag bolts are shipped in the accessories box. Refer to your
Motoman Robot manipulator manual for floor loading requirements. To level and
secure the equipment, proceed as follows:
1. Level cell base by adjusting leveling bolts (see Figure 4-4).
2. Insert a 1/2-in. concrete drill bit through center of the leveling bolts and drill
holes for lag bolts.
3. Vacuum concrete dust from holes.
4. Using lag bolts supplied, lag Arc-WorldLite 50 common base to floor.
SK1
XRC
YAS
NAC
6X
STOP
EMERGENCY
MODE
TEACH
PLAY
ON
SERVO
READY
START
HOLD
ALARM
LOCK
EDIT
(OFF)
REMOTE
(ON)
PE
OFF
N/R
TRIP
ON
O
LEVELING BOLT
NO
FF
W
O
by R
M LD
O LI
T
O TE
M
A
N
C
RRU
TNE UPNI
T
AC
ELB H
TAE
AW
RET
O
ARC
RET
LA
MRA
NO
NI
ACID
ROT
2
OC
GA
S
OLO
NOF
61 Ø
41 Ø
ERIW
LF
21Ø EPYT
WO
A
OTU ID ERIW
A
F
ESU
M
FF
RC
ETA
CR
RRU
CTNE
TAR
V RE
TLO
EGA
O
EP
TEN
TAR
NOI
SAG
RE
RE
TE
LO
MT
AG
LF S
WO
TE
MM
A
V
A
V
RE
_
NO
0
WO
P
AL
A
MR
OC
O TN
FF LORWOP
E
R
Figure 4-4 Location of Leveling Bolts
4.5
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.
CAUTION!
Route wires and cables away from hazardous work areas to avoid
wire breakage and unnecessary interruption of cell operation.
4.5.1
Connecting the Earth Ground
The robot and the XRC must each be connected to an earth ground. An earth
ground is a ground in which the equipment is connected to a ground stake driven
into the earth. The ground stake must be driven a minimum of eight feet into the
earth, and the earth must be treated with chemicals in order to reduce resistance to
the ground stake. Deeper ground stakes may be required depending on area soil
conditions. A maximum of 100 ohms ground resistance is recommended. To
ground the robot and the XRC, proceed as follows:
Arc-WorldLite 50 System Manual
4-4
MOTOMAN
INSTALLATION
WARNING!
• If proper earth grounds cannot be provided, do not use the
equipment! Serious injury or death can occur.
• Do not place the MIG system within 50 feet of other sources of
noise (i.e., GTAW arc starters, plasma cutters, induction
furnaces, high-power-resistance spot welders, dielectric
heaters, etc.). Equipment that generates impulse or highfrequency noise can cause unexpected equipment operation and
failure, which can result in serious injury or death.
NOTE:
If the robot and the XRC are within 15 feet of each other, a common earth ground may be used.
Otherwise, separate earth grounds must be used.
1. Connect one end of robot earth ground cable to lug marked EARTH
GROUND on bottom back of robot.
2. Connect other end of robot earth ground cable to earth ground stake.
3. Connect one end of second earth ground cable to common ground bus bar
inside XRC.
4. Connect other end of second earth ground cable to earth ground stake.
4.5.2
Connecting the Water Circulator (Optional)
If your system uses the water cooled welding torch, it is necessary to connect the
Motoman water circulator. To connect the water circulator, proceed as follows:
1. Connect two water hoses form weld torch to connections on water circulator
marked WATER-IN and WATER-OUT (see Figure 4-5).
CAUTION!
• Use only the antifreeze provided by Motoman. Automotive
antifreeze contains stop-leak additives that will clog small torch
water-cooling ports and damage gaskets in pump.
• Do not fill water circulator past fill line. Damage to water
circulator could occur.
2. Fill water circulator tank with antifreeze coolant provided (P/N 131224-1).
Do not fill water circulator past fill line.
3. Plug power cable into electrical outlet on back of power source, or the 110
Volt AC (10 Amp.) outlet.
MOTOMAN
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Arc-WorldLite 50 System Manual
INSTALLATION
WATER OUT
WATER IN
TO POWER SOURCE
Figure 4-5 Water Circulator Connections
4.6
Connecting the Gas/Air Services
The gas and air hoses for the Arc-WorldLite 100 are already connected when the
unit is shipped. Gas and air services must be completed after the cell has been
secured to the floor. The gas and air connections are located in the back of the cell
above the power box (see Figure 4-6).
AIR CONNECTION
AIR
GAS
AIR
GAS
GAS CONNECTION
REAR VIEW
Figure 4-6 Gas and Air Service Connections
Arc-WorldLite 50 System Manual
4-6
MOTOMAN
INSTALLATION
4.7
Connecting the Power
After all of the system components have been properly installed, power must be
connected to the main disconnect.
4.8
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 three yellow shipping brackets have been removed from robot
(see Section 4.3.1).
2. Check that cell door is closed and latched.
3. Check that all cable connections are tight.
4. Check air line connections to optional torch tender and wire cutter.
5. Check that welding power source is set correctly (see welding power source
vendor's manual).
6. Verify that incoming line power matches the input power specified on the
sticker on the front of the XRC.
Your Arc-WorldLite 50 is now ready for power-up. The ArcWorld system should
be operated only by personnel who have received operator training from Motoman
and who are familiar with the operation of this Motoman robot model. Turn the
main power ON, and continue the safety/operation check.
7. Check all system E-STOPS (pendant, operator station, break a ways,
playback panel).
8. Check system Hold buttons.
4.9
Installation of Tooling and Fixtures
Your Arc-WorldLite 50 system is now ready for the installation of tooling and
fixtures for your application. Installation of tooling and fixtures should be
performed by personnel who are familiar with the operation of this system.
Tooling and fixtures are supplied by the customer. After tooling is installed, test the
positioner for proper operation:
• Door goes up and down.
MOTOMAN
4-7
Arc-WorldLite 50 System Manual
INSTALLATION
NOTES
Arc-WorldLite 50 System Manual
4-8
MOTOMAN
SECTION 5
OPERATION
The Arc-WorldLite 50 is a fully integrated robotic GMAW welding cell. After
production parts have been loaded onto the weld table, the operator door closes,
servo power is applied allowing the robot to safely process the parts. The robot
welds the parts and returns to the home position, the operator door opens removing
servo power allowing the operator to safely remove the welded parts and load new
production parts.
This section provides operation instructions for the Arc-WorldLite 50 system.
Operation procedures include the following:
• Programming (Section 5.1)
• Daily Operation (Section 5.2)
• Fault Recovery (Section 5.3)
5.1
Programming
The operation of this system is programming dependent. The operating
instructions included in this section are based on one possible configuration of this
system. Your system configuration and job structure may differ slightly from that
presented here, however basic operation will be the same.
Any changes made to your system configuration and/or job structure will alter the
operation of this cell. Motoman recommends you do not modify the original jobs
and system configuration that came with your system. If modifications need to be
made, they should be made to copies of these jobs and not to the originals.
Modifications should only be performed by personnel who have received operator
training from Motoman, and who are familiar with the operation of this Motoman
system. If you have questions concerning the configuration of your system please
contact the 24 hour Service Hot Line, at (937) 847-3200 (see Section 1.4).
5.1.1
I/O Assignment
The Arc-WorldLite 50 has dedicated input and output capabilities. For more
information on user and dedicated I/O, refer to the XRC Concurrent I/O
Parameters Manual (P/N 142102-1).The Arc-WorldLite 50 has the following user
inputs and outputs (see Table 5-1 and Table 5-2).
MOTOMAN
5-1
Arc-WorldLite 50 System Manual
OPERATION
Table 5-1 XRC User Inputs
Input
Assignment
IN#001
CYCLE START STATION A
IN#002
LOWER DOOR
IN#003
DOOR CLOSED STATION A
IN#004
NOT USED
IN#005
NOT USED
IN#006
NOT USED
IN#007-IN#016
NOT USED
Table 5-2 XRC User Outputs
Input
OUT#001
LOWER DOOR
OUT#002
RAISE DOOR
OUT#003-OUT#016
5.2
Assignment
NOT USED
Daily Operation
The following is the typical sequence of operation for the Arc-WorldLite 50 cell
after start-up:
NOTE:
By default, the operator door rests in the down position to permit parts loading. This condition
occurs only when the robot is in the Home position (Cube 24) and CYCLE START has not been
activated.
1. Load System with production parts.
2. Press CYCLE START button on operator station. Operator door rises, servo
power is applied and robot begins welding.
3. When robot finishes welding, it returns to home position and operator door
lowers, servo power is remover allowing the operator to unload parts.
5.2.1
Start-Up
To start up the cell from a Power-Off condition, proceed as follows:
1. Turn on main power disconnect for cell.
2. Set MAIN POWER switch on XRC to ON.
3. Set INPUT POWER switch on welding power source to ON.
4. Open regulator valve on welding gas supply.
5. Open air supply valve.
6. Press TEACH mode button on XRC playback box.
7. Place robot in home position (Cube 24).
Arc-WorldLite 50 System Manual
5-2
MOTOMAN
OPERATION
5.2.2
Robot Home Position
To move the robot to the homehome position (Cube 24), proceed as follows:
1. Press TEACH mode button on XRC playback box.
2. Press SELECT on programming pendant.
3. Press SEL JOB (F4).
4. Using cursor keys, move cursor to R1home job and press ENTER. R1home
job appears in display screen.
5. Turn servo power on by pressing SERVO ON push button on playback box.
6. Press ENABLE function key on programming pendant.
7. Use TEST START and FWD buttons on programming pendant to jog robot
to home (Cube 24) position.
5.2.3
Starting the Master Job
With the system powered up and in TEACH mode, call up the Master job:
1. Press SELECT key on programming pendant.
2. Press SEL JOB (F4). Job list appears on display screen.
3. Using cursor keys, move cursor to Master job and press ENTER. Master job
appears in display screen.
4. Make sure cursor is at top of the job.
5. Press PLAY mode button on XRC playback box. Job playback operation is
enabled.
6. Press REMOTE button on playback box.
7. Pressing cycle start at the table will close the door and start the welding job.
The Arc-WorldLite 50 cell is now ready for operation.
5.2.4
Shutdown
Use the following procedure to shut down the Arc-WorldLite 50 cell after
operation is complete:
1. Make sure robot is in home position (Cube 24).
2. Turn off robot servo power by pressing E-STOP button on operator station,
programming pendant, or playback box.
3. Press TEACH mode button on playback box.
4. Set controller Main Power switch to OFF position.
5. Set main power disconnect switch to OFF position.
6. Close regulator valve on welding gas supply.
The Arc-WorldLite 50 cell is now shut down.
MOTOMAN
5-3
Arc-WorldLite 50 System Manual
OPERATION
5.3
System Recovery
Under certain conditions you will be required to clear an alarm or error. Clearing
an alarm or error requires different operator actions depending on the type.
Different types of alarms and errors are described below.
5.3.1
Alarms and Errors
Alarms and errors will cause the program to stop. There are three levels of alarms
and errors: Error Messages, Minor Alarms, and Major Alarms. For more detailed
information about alarm recovery, refer to manipulator manual that came with
your system.
Error Messages
These are simple errors such as pressing the START button when the robot is not in
PLAY mode, or enabling the programming pendant without the servo power being
live. Errors like these are cleared by pressing the CANCEL button on the
programming pendant.
Minor Alarms
Minor alarms are usually programming errors. Minor alarms might occur if a circle
has been programmed with fewer than three circular points, etc. These alarms are
cleared by pressing the RESET (F5) soft key on the programming pendant.
Major Alarms
Major alarms are hardware failures. Major alarms might occur because of a servo
tracking error or an abnormal speed and are usually associated with crashes. To
clear these alarms, you must turn off the controller and then turn it on again.
5.3.2
E-STOP Recovery
An E-STOP can occur under any of the following conditions:
• Pressing an E-STOP button on the operator station, programming pendant, or
playback box.
• Actuating the shock sensor on torch mount.
To restart the system after an E-STOP condition occurs, proceed as follows:
1. Clear E-STOP condition by performing any of following actions that apply:
• Release the E-STOP button on the operator station, programming
pendant, or XRC playback box.
• Clear Shock Sensor condition (see Section 5.3.3).
2. Job Continuation
a) If job execution can continue from the last programmed point without
further E-STOPS, PLAY mode and REMOTE mode must be set and then
the operator door must be cycled.
b) If robot must be manually taught to avoid further collisions, depress the
TEACH and SERVO ON push buttons to manually jog the robot to home
position before resuming play mode operation.
The Arc-WorldLite 50 cell is now ready to continue operation.
Arc-WorldLite 50 System Manual
5-4
MOTOMAN
OPERATION
5.3.3
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. To clear the E-STOP condition, you must override the shock sensor and
move the robot clear of the impact. To override the shock sensor, proceed as
follows:
CAUTION!
It is possible to crash the robot with the Shock Sensor Override
Switch left in the “Override” position. Always remember to
reactivate the Shock Sensor before continuing system operation.
1.
2.
3.
4.
5.
NOTE:
Press TOP MENU on programming pendant.
Select ROBOT icon using cursor keys and press SELECT.
Cursor to OVERRUN-S.SENSOR and press SELECT key.
Select RELEASE to release shock sensor.
Turn servo power ON by holding ENABLE switch on the programming
pendant and pressing SERVO ON.
TEACH LOCK must be ON to turn servo power on in TEACH mode.
6. Move manipulator clear of impact position.
The Arc-WorldLite 50 cell is now ready to continue operation.
MOTOMAN
5-5
Arc-WorldLite 50 System Manual
OPERATION
NOTES
Arc-WorldLite 50 System Manual
5-6
MOTOMAN
SECTION 6
MAINTENANCE
6.1
Periodic Maintenance
For periodic maintenance procedures and schedules for the SV3X robot and the
XRC controller, refer to the manipulator manual that came with your system.
Table 6-1 provides a list of periodic maintenance to be performed on the ArcWorldLite 50 cell. Keep in mind that the maintenance intervals given serve as
guidelines only. You should adjust the frequency of maintenance to suit your
specific work conditions.
CAUTION!
Use only the antifreeze provided by Motoman. Automotive
antifreezes contain stop-leak additives that will clog the small torch
water-cooling ports and damage the gaskets in the water circulator
pump.
Table 6-1 Periodic Maintenance
Frequency
Component
Procedure
Daily
Water circulator (watercooled torch application only)
Check the fluid in the water circulator.
Add fluid as required. Use only distilled
water and approved antifreeze (Motoman
P/N 131224-1).
Daily
Air filter/regulator for
water (high-humidity
environments)
Inspect left glass cylinder for water. If
water is present, loosen the valve at the
bottom of the cylinder to expel any moisture.
Positioner Air filter/regulator oil level
Inspect right glass cylinder and transparent neck on the top of the regulator. If oil
falls below half, add oil.
Weekly
MOTOMAN
6-1
Arc-WorldLite 50 System Manual
MAINTENANCE
6.2
Fuse and Circuit Breaker Protection
Tables 6-2 and 6-3 give the locations of fuses and circuit breakers that are
significant to the operation of the total system. In most cases, spare fuses are
placed in the accessory bag with the controller.
WARNING!
Replace fuses with those of the same type and rating. Replacement
with fuses of higher amperage rating or lower voltage will damage
the robot controller and/or auxiliary equipment, necessitating costly
replacement.
Abbreviations:
CB – designates circuit breaker
F, FU, or 101FU – designates fuse
Table 6-2 Universal Welding Interface (UWI) Fuses
Device
Rating
F1
8A 250V
FU1
4A 250V
FU2
FU3
Part#
Location
Purpose
On KXA motor
speed control
Limits damage from
shorts or component
breakdowns in DC
power supply module.
Wickman
19374K-4A
On interface board
Protects 115V circuit.
0.25A
125V
Wickman
19303K-250A
On interface board
Protects shock sensor
circuit.
0.5A 125V
Wickman
19303K-500A
On interface board
Protects 24V circuit.
Table 6-3 MotoArc 450 CV Fuses and Circuit Breaker
Device
Rating
CB1
10A
203627-7
Upper rear panel
Protects 115V circuit.
CB2
10A
203627-7
Upper rear panel
Protects 24V circuit.
F1
0.5 A
W-11166-11
On contactor box
Protects contactor circuit.
Arc-WorldLite 50 System Manual
Part#
6-2
Location
Purpose
MOTOMAN
INDEX
A
G
About this Document, 1-1
Alarm/Error, 3-2
Alarms and Errors, 5-4
ANSI/RIA, 2-1
Arc Shields, 3-7, 3-10
Arc-WorldLite 52 Common Base, Installation, 4-2
Area Key, 3-4
Gas/Air Services, Connecting, 4-6
General Safeguarding Tips, 2-3
GMAW Torch, 3-9
B
I/O Assignment, 5-1
Installation Safety, 2-4
Installation Section, 4-1
Interference Cubes, 3-11
Introduction, 1-1
Introduction, Safety, 2-1
Brake Release, 3-6
Brake Release Control, 3-11
C
Cell Door, 3-10
Circuit Breaker, 6-2
Connecting the Cables, 4-4
Connecting the Earth Ground, 4-4
Connecting the Power, 4-7
Cursor Key, 3-4
Customer Service Information, 1-4
Customer-Supplied Items, 4-1
Cycle Start, 3-6
D
Daily Operation, 5-2
Display, 3-3
Door Cycle Speed, 3-7
Door Status, 3-7
E
Emergency Stop (E-STOP), 3-2, 3-3, 3-7, 3-10
ENABLE Function Key, 3-4, 3-5
ENABLE Switch, 3-5, 3-10
Equipment Description, 3-1
Error Messages, 5-4
E-STOP Recovery, 5-4
F
Fencing, 3-10
Fuse and Circuit Breaker Protection, 6-2
Fuses, 6-2
MOTOMAN
H
Hold, 3-3
I
K
Keypad, 3-3
L
LCD Display, 3-3
Leveling and Securing the Cell, 4-4
M
Maintenance, 6-1
Maintenance Safety, 2-6
Major Alarms, 5-4
Major Components, 1-2
Materials Required, 4-1
Mechanical Safety Devices, 2-3
Menu Area, 3-3
Minor Alarms, 5-4
Mode, 3-2
Mode Select, 3-2
O
Operation Safety, 2-5
Operator Station, 3-6
Optional Equipment, 1-2
P
Part/Fixture Rating, 3-7
Payload, 3-1
Periodic Maintenance, 6-1
Playback Panel, 3-2
Positioner Specifications, 3-7
Arc-WorldLite 50 System Manual
INDEX
P (continued)
S (continued)
Power Sources, 3-8
Mobility, 3-9
Programming, 5-1
Programming Pendant, 3-3
Programming Safety, 2-4
PWF Wire Feeder, 3-9
Reach, Vertical, 3-1
Reference to Other Documentation, 1-4
Relative Positioning Accuracy, 3-1
Remote, 3-2
Robot Description, SKX-Series, 3-1
Robot Language, 3-3
Robot Safe Position, 5-3
Robotic Industries Association, 2-1
RS-232C Serial Port, 3-5
Symbol
Cylindrical, Coordinate System, 3-4
E-Stop, System Status, 3-4
High, Manual Speed, 3-4
Hold, System Status, 3-4
Inching, Manual Speed, 3-4
Joint, Coordinate System, 3-4
Low, Manual Speed, 3-4
Medium, Manual Speed, 3-4
Running/Start, System Status, 3-4
Step, Cycle Mode, 3-4
Stop, System Status, 3-4
Tool, Coordinate System, 3-4
User Frame, Coordinate System, 3-4
World, Coordinate System, 3-4
System Layout, 1-2
System Overview, 1-2
System Recovery, 5-4
S
T
Safety, 2-1
Safety Features, 3-9
Safety/Operation Check, 4-7
Select Key, 3-5
Serial Number, Robot, 1-4
Servo On Ready, 3-2
Servo Power, 3-2
Shipping Brackets, Removing, 4-3
Shock Sensor Override, 3-9
Shock Sensor Recovery, 5-5
Shutdown, 5-3
Site Preparation, 4-2
Software Version, 1-4
Standard Conventions, 2-2
Start, 3-2
Starting the Master Job, 5-3
Start-Up, 5-2
Stationary Weld Table, 3-7
Status Area, 3-4
Symbol
1-Cycle, Cycle Mode, 3-4
Alarm, System Status, 3-4
Auto, Cycle Mode, 3-4
TEACH LOCK Key, 3-5
Tooling and Fixtures, 4-7
Tools Required, 4-1
Top Menu Key, 3-4
ARC WELDING, GENERAL, HANDLING, and SPOT
WELDING, 3-4
IN/OUT, 3-4
JOB, 3-4
ROBOT, 3-4
SYSTEM INFO, 3-4
VARIABLE, 3-4
Torch Mount, 3-9
R
Arc-WorldLite 50 System Manual
U
Universal Welding Interface (UWI), 3-9
Universal Welding Interface (UWI) Fuses, 6-2
W
Water Circulator (Option), Connecting, 4-5
Welding Current Rating, 3-7
Welding Equipment, 3-8
X
XRC User Inputs, 5-2
XRC User Outputs, 5-2
MOTOMAN
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