YASKAWA Motoman XRC 2001, System Manual

Page 1: ... West Carrollton OH 45449 TEL 937 847 6200 FAX 937 847 6277 24 Hour Service Hotline 937 847 3200 QVQOCP 4 QPVTQNNGT TE9QTNF 5 UVGO CPWCN HQT 72 4QDQV Part Number 147051 1 Release Date August 15 2002 Document Version 2 Document Status Final ...

Page 2: ...eproduced 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 ...

Page 3: ...y 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 3 EQUIPMENT DESCRIPTION 3 1 UP series Robot Description 3 1 3 2 XRC 2001 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 AUTO MANUAL 3 7 3 3 3 Emergency Stop E STOP 3 7 3 4 Barrier...

Page 4: ...6 Leveling and Securing the Equipment 4 5 4 7 Removing the Shipping Brackets Bolts 4 6 4 7 1 Robot Shipping Brackets Removal 4 6 4 7 2 Positioner Shipping Bolts Removal 4 7 4 8 Connecting the Cables 4 8 4 8 1 Connecting the Earth Ground 4 8 4 8 2 Connecting the Robot Cables 4 8 4 8 3 Connecting the Com Arc III and the Wire Cutter Optional 4 9 4 8 4 Connecting Water Circulator Optional 4 9 4 9 Conn...

Page 5: ...4 RS 232C Serial Port 3 5 Figure 3 5 Enable Switch 3 5 Figure 3 6 Operator Station 3 6 Figure 3 7 Available Power Sources 3 10 Figure 4 1 Area Needed for Installation 4 2 Figure 4 2 Remove Shipping Bolts 4 3 Figure 4 3 System Components 4 4 Figure 4 4 Leveling Bolts 4 6 Figure 4 5 Location of Robot Shipping Brackets 4 6 Figure 4 6 Location of Positioner Shipping Bolts 4 7 Figure 4 7 Connecting Rob...

Page 6: ...ArcWorld II 200 System Manual iv MOTOMAN NOTES ...

Page 7: ...eneral information about the ArcWorld II 200 and its components a list of reference documents and customer service information SECTION 2 SAFETY This section provides information regarding the safe use and operation of the ArcWorld II 200 system SECTION 3 DESCRIPTION OF EQUIPMENT This section provides a detailed description of the major components of the ArcWorld II 200 system This section also inc...

Page 8: ...een the three major components robot manipulator and two barrier stations The robotic cell is fully enclosed by safety fencing and an interlocking door The interlocked operator doors allow the operator to load parts on one table while the robot is welding parts on the other table All operator controls including those on the controller and welding power supply are accessible from outside of the rob...

Page 9: ...arrier door Light Curtains 1 2 3 Optional Equipment The following equipment is available for use with the ArcWorld II 200 Torch tender Wire cutter Com Arc III seam tracking unit Water circulator Robot Positioner base Auxiliary equipment base Tabletops for tooling 1 3 Reference to Other Documentation For additional information refer to the following Motoman UP6 Manipulator Manual P N 142104 1 Motom...

Page 10: ...an service staff at 937 847 3200 Please have the following information ready before you call Robot Type UP6 System Type ArcWorld II 200 Software Version access using TOP KEY SYSTEM INFO VERSION SYSTEM on the programming pendant Robot Serial Number located on the back side of the robot arm Robot Sales Order Number located on front side of controller ...

Page 11: ...ram 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 Safeguardi...

Page 12: ...ate 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 CAUTI...

Page 13: ...uts 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 positio...

Page 14: ...ed 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 p...

Page 15: ...uipment for proper operation Repair or replace any non functioning 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 ...

Page 16: ...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...

Page 17: ...h your system 3 2 XRC 2001 Controller The XRC 2001 robotic controller shown in Figure 3 1 coordinates the operation of the ArcWorld II 200 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 sys...

Page 18: ...E 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 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 ...

Page 19: ... NOTE The programming pendant LCD display goes dark after a few minutes of inactivity Press any key to restore screen 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 pen...

Page 20: ...RC 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 I O signals In EDITING or MAINT mode Universal Outputs can be forced ON or OFF ROBOT This icon acce...

Page 21: ...between the controller and a floppy disk controller FC1 or FC2 FDE Floppy Disk Emulator software or other form of communication see Figure 3 4 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 ena...

Page 22: ...cribed in the following paragraphs 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 Play Mode The CYCLE START push button located at the top of the op station completes the CYCLE START circuit when the operator pres...

Page 23: ...is connected to 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 is also stopped 3 4 Barrier Assembly For detailed specifications including parts lists breakdown refer to the Barrier Assembly Manual P N 147500 1 3 4 1 Stationary Weld Tabl...

Page 24: ...This material reduces the amount of ultraviolet radiation that escapes from the robotic cell 3 5 2 Fencing The safety fencing provided with the ArcWorld II 200 system encloses the entire robotic cell It forms a physical barrier preventing entry into the robot envelope during automatic operation 3 5 3 Emergency Stops E STOPS In addition to the safety features described above the ArcWorld II 200 has...

Page 25: ... a signal is sent out to the controller informing it of the robot penetrating the light curtain This output and a signal from the operator door are interlocked with the OK TO WORK output preventing the robot from welding when the operator door is open 3 5 7 Brake Release WARNING Releasing brakes could cause personal injury or machine damage Always support the axis to be released BEFORE you release...

Page 26: ..._ ON OFF ON OFF CO2 MAG FLOW AUTO SOLO FON fl16 fl14 fl12 GASFLOW WIREDIA WIRETYPE GAS PENETRATION CRATER ALARM INDICATOR CURRENT INPUT CABLE HEAT WATER FUSE CRATERVOLTAGE CRATERCURRENT KOBELCO UC350 POWER SOURCE MOTOWELD P350 POWER SOURCE POWER Vp CONTROL Tp Vb Vp ROBOT REMOTE LOCAL VOLTAGE CURRENT ARC CHARACTERISTIC PULSE OFF S PULSE L PULSE CHECK SEARCH MODE DC 300V OUTPUT Vb Vp PULSE WIDTH BAS...

Page 27: ...ents It also provides isolation of the power source analog signals NOTE Some power sources available with the ArcWorld II 200 system do not use the UWI For more information specific to your system refer to the vendor manuals shipped with your system 3 6 4 GMAW Torch The ArcWorld system uses either an air cooled or a water cooled robotic automatic GMAW torch These are heavy duty torches designed fo...

Page 28: ...EQUIPMENT DESCRIPTION ArcWorld II 200 System Manual 3 12 MOTOMAN NOTES ...

Page 29: ...ugh handling can damage system electronic components 4 1 Materials Required All system hardware necessary for installing the ArcWorld system is included with the system This section identifies customer supplied items and tools required to complete installation 4 1 1 Customer Supplied Items Gas bottles for the welding torches Incoming power supply Two earth ground cables with two earth ground stake...

Page 30: ... floor space needed for unit see Figure 4 1 NOTE An additional 2 43 to 3 05 m 8 to 10 ft on all sides is recommended for set up 2 Gather all customer supplied items and required tools listed in Section 4 1 Figure 4 1 Area Needed for Installation 13 07 ft 3985 mm 10 66 ft 3250 mm 2340 mm 7 67 ft 5 94 in 151 mm 5 94 in 151 mm ...

Page 31: ...components loaded onto it weighs 1045 4 kg 2300 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 1 Using a forklift lift the loaded shipping skid and remove it from the hauler 2 Carefully remove protective plastic wrapping from all cell components 3 Inspect all cell components for shipping damage NOTE If da...

Page 32: ...ion 2 Spanner Plate Fencing Divider Controller Cables Guards Welding power source Water circulator optional Torch cleaner optional Figure 4 3 identifies the cell components and their preferred location Figure 4 3 System Components FENCE SLIDING DOOR DOOR OPENS CONTROLLER OPERATOR STATION SPANNER PLATE SHIPPING BOLTS SHIPPING BOLTS SHIPPING BOLTS SHIPPING BOLTS GUARD GUARD DIVIDER LIGHT CURTAIN BAR...

Page 33: ...just as necessary 4 Attach the guards on the outside of each barrier station 5 Install light curtains 6 Install barrier divider 7 Construct the fencing around the cell Stand the fencing up and fasten to outer guards Apply the arc shield to the fencing 8 Remove the four positioner shipping bolts two on each positioner 9 Recheck the location of all components and adjust if necessary 10 Place the con...

Page 34: ... damage to the robot drive mechanisms Three yellow brackets see Figure 4 5 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 robot is in place remove the shipping brackets Figure 4 5 Location of Robot Shipping Brackets LEVELING BOLT BRACK...

Page 35: ...amage to equipment For shipping purposes a yellow capped shipping bolt see Figure 4 6 is inserted through both front posts of each positioner four bolts total and fastened to the counterbalance Each bolt secures the counterbalance and the rest of the chain assembly to prevent the door from opening These four bolts must be remove before operation of the cell Figure 4 6 Location of Positioner Shippi...

Page 36: ... not place the MIG system within 15 24 m 50 ft 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 high frequency noise can cause unexpected equipment operation and failure which can result in serious injury or death NOTE If the robot and the controller are within 4 57 m 15 f...

Page 37: ...roller The wire cutter cable is connected on the right side of the controller The Com Arc III is usually shipped with it s cables connected To connect the wire cutter 1 Unwrap wire cutter cable 2 Plug wire cutter cable into connector on wire cutter unit 3 Connect wire cutter to an air supply set at 85 to 100 psi For detailed installation and operation instructions for the Com Arc III refer to the ...

Page 38: ...ns stop leak additives that will clog the small torch water cooling ports and damage the gaskets in the pump Do not fill the water circulator past its fill line Damage to the water circulator could occur 2 Fill water circulator tank with antifreeze coolant provided P N 131224 1 3 Plug power cable into electrical outlet on back of power source WATER IN WATER OUT TO POWER SOURCE ...

Page 39: ...ing drawings shows the size and type of wire needed 2 Tighten screws to the torque indicated in the engineering drawings Figure 4 9 Incoming Power Connections 3 Install an M5 lug on the incoming ground wire 4 Terminate the ground wire to the frame ground M5 threaded stud with M5 hardware provided NOTE The ArcWorld II 200 is configured for three phase 460 480V AC unless other voltage was requested ...

Page 40: ... input power specified on front of the controller Your ArcWorld II 200 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 playback panel...

Page 41: ...onfiguration 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 The application programs may assign values to memory locations in the controller Consult you system documentation before modifying your system If modifications need to be made they should be made to copies of these jobs a...

Page 42: ...2 IN 010 AUTO MANUAL 2 IN 011 OK TO WORK 2 IN 012 S2 LIGHT CURTAIN CLEAR IN 003 S2 DOOR LOWERED IN 014 S2 BRAKE RELEASED IN 015 thru 016 NOT USED Table 5 2 XRC 2001 User Outputs Output Assignment OUT 001 S1 MOTOR ENABLE OUT 002 S1 RESERVED OUT 003 S1 DOOR DIRECTION 0 DOWN 1 RAISE OUT 004 NOT USED OUT 005 S1 RELEASE BRAKES OUT 006 thru 008 NOT USED OUT 009 S2 MOTOR ENABLE OUT 010 RESERVED OUT 011 S...

Page 43: ...ion To move the robot to the Home position Cube 24 proceed as follows 1 Press TEACH mode button on controller playback panel 2 Press TOP MENU on programming pendant 3 Select JOB icon using cursor keys and press SELECT 4 Cursor to SELECT JOB and press SELECT key 5 Using cursor keys move cursor to Home job and press SELECT Home job appears on display screen 6 Turn servo power ON by pressing SERVO ON...

Page 44: ...hile the robot is welding on Station 2 unload the welded parts from Station 1 and load new parts 8 Activate CYCLE START to raise the operator door and permit the robot to return to Station 1 NOTE The robot will not return to Station 1 until CYCLE START has been activated even if it has completed work at Station 2 If the robot finishes working at Station 2 before Station 1 is reloaded the robot wil...

Page 45: ...s 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 Error Messages Door Time Out Error A time function has been built into the CIO of the controller If the door fails to reach the intended position within the...

Page 46: ...ct RELEASE to release shock sensor 5 Turn servo power ON by holding ENABLE switch on the programming pendant and pressing SERVO ON NOTE TEACH LOCK must be ON to turn servo power on in TEACH mode 6 Move manipulator clear of impact position The ArcWorld II 200 cell is now ready to continue operation 5 3 5 E STOP Recovery An E STOP can occur under any of the following conditions Pressing the E STOP b...

Page 47: ...de adequate support for axis to be released Support should withstand payload of robot and approximate weight of robot Listed below is the weight of each available robot UP6 135 kg 297 lb WARNING Releasing brakes could cause personal injury or machine damage Always support the axis to be released BEFORE you release it 3 Release specific axis brake by pressing and holding corresponding axis button a...

Page 48: ...OPERATION ArcWorld II 200 System Manual 5 8 MOTOMAN NOTES ...

Page 49: ...your ArcWorld II 200 refer to the manipulator and additional manuals that came with your system 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 Refer to vendor s literature for frequency time table Table 6 1 Periodic Maintenance Frequency Com...

Page 50: ...MAINTENANCE ArcWorld II 200 System Manual 6 2 MOTOMAN NOTES ...

Page 51: ...r 5 5 E Emergency Stop E STOP 3 2 3 3 3 7 Emergency Stops E STOPS 3 8 ENABLE Function Key 3 4 3 5 ENABLE Switch 3 5 3 9 Equipment Description 3 1 Error Messages 5 5 E STOP Recovery 5 6 E Stop Symbol System Status 3 4 F Fencing 3 8 G Gas Flow Error 5 5 General Safeguarding Tips 2 3 General Icon 3 4 GMAW Torch 3 11 H Handling Icon 3 4 High Symbol Speed Setting 3 4 Hold 3 2 Hold Symbol System Status ...

Page 52: ...tus 3 4 S Safety 2 1 Safety Features 3 8 Safety Operation Check 4 12 Select Key 3 5 Servo Power 3 2 Shock Sensor Recovery 5 6 Shutdown 5 4 Site Preparation 4 2 Software Version Access 1 4 Spot Welding Icon 3 4 Standard Conventions 2 2 Starting the Master Job 5 3 Start Up 5 3 Status Area 3 4 Step Symbol Cycle Mode 3 4 Stop Symbol System Status 3 4 System Info Icon 3 4 System Layout 1 2 System Overv...