Yasnac MRC Controller
FabWorld
Operator's Manual
Part Number 132342-1
Revised 7/15/96
June 21, 1995
MOTOMAN
805 Liberty Lane
West Carrollton, OH 45449
TEL: 513-847-6200
FAX: 513-847-6277
24-HOUR SERVICE HOTLINE: 513-847-3200
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.
©1995 by MOTOMAN
Because we are constantly improving our products, we reserve the right to change specifications without
notice. YASNAC and MOTOMAN are registered trademarks of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section
Page
LIST OF FIGURES................................................................................................. iv
LIST OF TABLES ................................................................................................... iv
1.0 INTRODUCTION............................................................................................ 1
1.1
ABOUT THIS DOCUMENT............................................................... 1
1.2
SYSTEM OVERVIEW..........................................................................2
1.2.1
1.2.2
System Layout.....................................................................2
Optional Equipment..............................................................4
1.3
REFERENCE TO OTHER DOCUMENTATION ...................................5
1.4
CUSTOMER SERVICE INFORMATION.............................................5
2.0 SAFETY ..........................................................................................................7
3.0
2.1
STANDARD CONVENTIONS.............................................................8
2.2
GENERAL SAFEGUARDING TIPS.....................................................9
2.3
MECHANICAL SAFETY DEVICES......................................................9
2.4
INSTALLATION SAFETY.................................................................. 10
2.5
PROGRAMMING SAFETY .............................................................. 10
2.6
OPERATION SAFETY...................................................................... 11
2.7
MAINTENANCE SAFETY................................................................. 12
DESCRIPTION OF EQUIPMENT ................................................................. 13
3.1
K-SERIES ROBOT DESCRIPTION .................................................. 13
3.2
MRC CONTROLLER ........................................................................ 13
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
3.3
Servo Power..................................................................... 14
Mode Select...................................................................... 15
Cycle Select...................................................................... 15
Emergency Stop (E-Stop)................................................... 15
Alarm / Error.................................................................... 15
Hold.................................................................................. 15
Start................................................................................. 15
Playback Box Subpanel...................................................... 15
PROGRAMMING PENDANT.......................................................... 16
3.3.1
FabWorld Operator's Manual
Display.............................................................................. 17
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MOTOMAN
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.4
ROTARY PLANE POSITIONER MODULE........................................ 17
3.4.1
3.4.2
3.4.3
3.4.4
3.4.5
3.5
Part/Fixture Rating ...........................................................20
Dimensions .......................................................................20
Welding Current Range .....................................................20
OPERATOR STATIONS (OP-STATIONS)........................................ 21
3.8.1
3.8.2
3.8.3
3.8.4
3.8.5
3.8.6
3.8.7
3.8.8
3.8.9
3.8.10
3.9
Specifications .................................................................... 19
Temperature Operating Range........................................... 19
Humidity............................................................................ 19
Air Requirements ..............................................................20
Electrical Requirements.....................................................20
Welding Current Rating.....................................................20
Hardstops.........................................................................20
STATIONARY TACK-WELDING TABLE...........................................20
3.7.1
3.7.2
3.7.3
3.8
Part/Fixture Rating ........................................................... 18
Dimensions ....................................................................... 18
Welding Current Rating..................................................... 19
MULTI-PLANE POSITIONER MODULE.......................................... 19
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
3.6.6
3.6.7
3.7
Specifications .................................................................... 17
Temperature Operating Range........................................... 18
Humidity............................................................................ 18
Electrical Requirements..................................................... 18
Welding Current Rating..................................................... 18
STATIONARY FLAT PLANE MODULE............................................. 18
3.5.1
3.5.2
3.5.3
3.6
Robot Speed Indicators...................................................... 17
Emergency Stop(E-Stop).................................................... 17
Keypad.............................................................................. 17
Servo Power..................................................................... 17
Coordinate System Indicators............................................ 17
Emergency Stop (E-Stop)...................................................22
Hold..................................................................................22
Cycle Start .......................................................................22
Station Ready....................................................................22
Alarm ...............................................................................22
Servo On ..........................................................................22
Positioner Auto / Manual...................................................23
Master Job Start..............................................................23
Operator Station Enable / Disable......................................23
Reset................................................................................23
WELDING POWER SOURCE ...........................................................23
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MOTOMAN
3.9.1
3.9.2
3.9.3
3.9.4
3.9.5
3.9.6
3.9.7
3.10
WELDING EQUIPMENT.................................................................. 26
3.10.1
3.10.2
3.10.3
3.10.4
3.11
Main Power......................................................................24
Volt / Amp Settings............................................................25
Terminal Connectors.........................................................25
Local / Remote Operation...................................................25
Feeder Control Receptacles...............................................25
Circuit Breakers ...............................................................25
AC Receptacles.................................................................25
PWF4-600 Wire Feeder.....................................................26
Universal Welding Interface..............................................26
GMAW Torch ...................................................................26
RAM Torch Breakaway Mount..........................................26
SAFETY EQUIPMENT .....................................................................27
3.11.1
3.11.2
3.11.3
3.11.4
3.11.5
3.11.6
Arc Curtains .....................................................................27
Fencing.............................................................................27
Safety Mats ......................................................................27
Photo Eyes........................................................................28
Zone Ring Monitor............................................................28
Emergency Stops (E-Stops) ...............................................28
4.0 OPERATION ................................................................................................29
4.1
NORMAL OPERATION ...................................................................29
4.1.1
4.1.2
4.1.3
4.1.4
4.1.5
4.2
Start-Up...........................................................................29
Fault Recovery..................................................................30
E-Stop Recovery................................................................30
Shock Sensor Recovery..................................................... 31
Shutdown..........................................................................32
ALARMS AND ERRORS ..................................................................33
4.2.1
4.2.2
4.2.3
Error Messages................................................................33
Minor Alarms ...................................................................33
Major Alarms ...................................................................33
4.3
I/O ASSIGNMENT...........................................................................34
4.4
PROGRAMMING THE MULTI-PLANE POSITIONER .....................36
4.4.1
4.4.2
4.4.3
Tilting the Positioner.........................................................36
Flattening the Positioner...................................................36
Rotating the Positioner......................................................37
4.5
PROGRAMMING THE ROTARY PLANE POSITIONER...................37
4.6
SAMPLE JOBS................................................................................37
4.6.1
FabWorld Operator's Manual
Master Job.......................................................................37
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MOTOMAN
4.6.2
4.6.3
4.6.4
4.6.5
4.6.6
4.6.7
Weld-A Job .......................................................................38
Weld-B Job.......................................................................39
Weld-C Job .......................................................................39
Tilt Job (for tilt and rotate tables only)..............................39
Flat Job ............................................................................39
Clean Job..........................................................................40
5.0 MAINTENANCE...........................................................................................43
5.1
PERIODIC MAINTENANCE............................................................44
5.2
SPARE PARTS LIST.........................................................................45
5.3
FUSE AND CIRCUIT BREAKER PROTECTION...............................45
APPENDIX A - ELECTRICAL DRAWINGS...............................................Appendix A
APPENDIX B - MECHANICAL DRAWINGS .......................................... Appendix B
LIST OF FIGURES
Figure
Page
Figure 1-1 FabWorld System Layout.......................................................................3
Figure 3-1 MRC Controller ................................................................................. 14
Figure 3-2 MRC Playback Box ............................................................................ 14
Figure 3-3 Programming Pendant........................................................................ 16
Figure 3-4 Operator Station (Op-Station) ........................................................... 21
Figure 3-5 Excel-Arc Controls ............................................................................24
Figure 4-1 Shock Sensor Override ....................................................................... 31
LIST OF TABLES
Table
Page
Table 1-1 FabWorld Configuration Chart ...............................................................4
Table 5-1 Periodic Maintenance..........................................................................44
Table 5-2 Spare Parts........................................................................................45
Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers ..................................46
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MOTOMAN
Table 5-4 Universal Welding Interface (UWI) Fuses and Circuit Breakers...........46
Table 5-5 Com-Arc III Fuses and Circuit Breakers .............................................46
Table 5-6 MRC Cabinet Fuses and Circuit Breakers............................................47
Table 5-7 MRC System Fuses.............................................................................48
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MOTOMAN
1.0 INTRODUCTION
FabWorld systems feature a modular, flexible approach to configuring robotic arc
welding systems. A FabWorld system can be tailored to meet ever-changing
production needs because the modular design allows for the addition of positioners
and operator stations at a later date for increased versatility. FabWorld systems are
designed especially for low and medium volume production.
A FabWorld system consists of a K6 or a K10 robot, an MRC robot controller,
and one, two, or three positioners. You can use different types of positioners,
either singly or in combination, to meet your specific needs. Available positioner
options include a multi-plane (tilt/rotate) positioner, a rotary plane (headstock/
tailstock) positioner, and a stationary flat table. A stationary tack-welding table is
also an option.
Standard FabWorld systems have either one or two stations (zones). By adding
optional equipment, a FabWorld cell can be configured with up to three stations.
Each station includes a positioner, an operator station, safety fencing, photo eyes,
arc screens, and safety mats. Many different FabWorld system configurations are
possible due to the different modules that are available.
1.1
ABOUT THIS DOCUMENT
This manual provides operation instructions for the FabWorld system. In addition
to this introduction, the manual includes the following sections:
•
Section 2: Safety
•
Section 3: Description of Equipment
•
Section 4: Operation
•
Section 5: Maintenance
•
Appendices
The Safety Section provides information regarding the safe use and operation of the
FabWorld system.
The Description of Equipment Section provides a detailed description of the major
components of the FabWorld system. This section also includes a table of
component specifications.
The Operation Section of the manual provides instructions to operate the FabWorld
system. This section describes the various operator controls and indicators, and
provides procedures for start-up, loading, normal operation, fault recovery, and
shutdown. Finally, the section contains a number of sample robot programs.
The Maintenance Section includes a table listing periodic maintenance requirements
for the FabWorld cell. This section includes detailed instructions to perform
specific maintenance tasks. It also includes a list of recommended spare parts.
FabWorld Operator's Manual
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MOTOMAN
The appendices contain a full set of reference drawings and supporting
documentation.
1.2
SYSTEM OVERVIEW
FabWorld provides complete arc welding solutions in modular packages. The
basic system is designed around a Motoman arc welding robot and includes a
complete welding package. Standard FabWorld systems have one or two stations.
Each station includes a positioner, operator station, safety mats, and photo eyes. At
each station, an operator can set up or unload parts while the robot either stands
ready or welds parts at another station. The cell also provides a full complement of
safety features designed to protect both personnel and equipment.
By adding auxiliary equipment to one of the standard platforms in building block
fashion, you can design a system tailored to meet your specific requirements. All
equipment in a FabWorld system is designed to work together. The result is an
optimized, integrated system.
1.2.1
System Layout
The illustration in Figure 1-1 shows a typical FabWorld system layout. The chart
shown in Table 1-1 lists the standard configurations of the FabWorld line.
The main components of a FabWorld system are:
•
Motoman robot manipulator and MRC controller
•
Positioner(s)
•
Operator station(s)
•
Welding equipment, including the following:
•
•
Excel-Arc welding power source
•
Torch (water-cooled or air-cooled)
•
Wire feeder
•
Universal welding interface (UWI)
•
Torch breakaway
Safety equipment, including the following:
•
Safety fencing with arc curtains
•
Photo eyes
•
Zone ring monitors
•
Interlocked safety mats
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MOTOMAN
Figure 1-1
FabWorld Operator's Manual
Page 3
FabWorld System Layout
MOTOMAN
Slave
Operator
Station
Assembled
Fence
Slave
Operator
Station
Safety
Mat
Tack
Table
Safety
Mat
Shredded
Arc Curtain
Robot
External
Axis
Cabinet
Safety
Mat
Fence
MRC
Positioner
Torch
Tender
Water
Circulator
Com-Arc
Disconnect
Transformer
Positioner
Gas Bottle
(Customer
Supplied)
Welding
Power
Source
Master
Operator
Station
Table 1-1 FabWorld Configuration Chart
Robot Manipulator
w/ MRC Controller
1.2.2
K10
Torch
(Choice)
AirWaterCooled Cooled
Rotary
Plane
Model
K6
K6/R
✓
✓
✓
K6/F
✓
✓
✓
K6/M
✓
✓
✓
K6/RF
✓
✓
✓
K6/MF
✓
✓
✓
K6/2R
✓
✓
✓
K6/2M
✓
✓
✓
K6/MR
✓
✓
✓
✓
✓
K10/R
✓
✓
✓
K10/F
✓
✓
✓
K10/M
✓
✓
✓
K10/RF
✓
✓
✓
K10/MF
✓
✓
✓
K10/2R
✓
✓
✓
K10/2M
✓
✓
✓
K10/MR
✓
✓
✓
Power
Source
Positioner
Flat
Plane
Multi- Excel-Arc
Plane
6045
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
2
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
✓
2
✓
✓
✓
2
✓
✓
2
✓
✓
✓
Optional Equipment
The following optional equipment is available for use with the FabWorld system:
•
Torch tender
•
Wire cutter
•
Com-Arc III
•
Stationary tack-welding table
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MOTOMAN
1.3
REFERENCE TO OTHER DOCUMENTATION
For additional information refer to the following:
1.4
•
Motoman K10 MRC Manipulator Manual (Part Number 132330-7)
•
Motoman K6 MRC Manipulator Manual (Part Number 132330-4)
•
Motoman MRC Operator's Manual for Arc Welding (Part Number 132332-1)
•
Motoman MRC User Functions Manual (Part Number 132331-1)
•
Motoman FabWorld Installation Manual (Part Number 132343-1)
•
Vendor manuals for system components not manufactured by Motoman
CUSTOMER SERVICE INFORMATION
If you need technical assistance, contact the Motoman service staff at
(513) 847-3200. Please have the following information ready before you call:
•
Robot Type (K3, K6, K10, etc.)
•
Robot Serial Number (located on the back side of the robot arm)
•
Application Type (palletizing, welding, handling, etc.)
•
Robot Sales Order Number (located on back side of robot and MRC controller)
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MOTOMAN
NOTES
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MOTOMAN
2.0 SAFETY
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 (see Section 2.1)
•
General Safeguarding Tips (see Section 2.2)
•
Mechanical Safety Devices (see Section 2.3)
•
Installation Safety (see Section 2.4)
•
Programming Safety (see Section 2.5)
•
Operation Safety (see Section 2.6)
•
Maintenance Safety (see Section 2.7)
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MOTOMAN
2.1
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 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.
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MOTOMAN
2.2
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:
2.3
•
Improper operation can damage 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 operation. Place the robot in
Emergency Stop (E.STOP) mode and ensure that all motion has stopped
before entering the 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.
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, RIA safety recommendations, 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.
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MOTOMAN
2.4
INSTALLATION SAFETY
Safe installation is essential for protection of people and equipment. The user must
be aware of the various national codes, RIA safety recommendations, 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
suggestions are intended to supplement, but not replace, existing federal, local, and
state laws and regulations.
2.5
•
Ensure 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.
•
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.
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 safety
tips are as follows:
•
Any modifications to NODE 2 (for ERC controllers) or PART 1 (for MRC
controllers) of the controller PLC can cause severe personal injury or death, as
well as damage to the robot! Do not make any modifications to NODE 2 or
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
FabWorld Operator's Manual
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MOTOMAN
created hazards or dangerous situations that may damage the robot or other
parts of the system.
2.6
•
Improper operation can damage 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.
•
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.
•
Check the E.STOP button on the teach pendant for proper operation before
programming.
•
Keep the teach pendant with you when you enter the workcell.
•
Ensure 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 safety tips
are as follows:
•
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 damage 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 operation. Place the robot in
Emergency Stop (E.STOP) mode and ensure that all motion has stopped
before entering 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. On
ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3;
and I/O (Input and Output) modifications. On MRC controllers this includes
FabWorld Operator's Manual
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MOTOMAN
controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.
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MOTOMAN
2.7
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 safety 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 damage 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 operation. Place the robot in
Emergency Stop (E.STOP) mode and ensure that all motion has stopped
before entering the cell.
•
The robot must be placed in Emergency Stop (E.STOP) mode whenever it is
not in use.
•
Ensure 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. On
ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3;
and I/O (Input and Output) modifications. On MRC controllers 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).
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MOTOMAN
3.0 DESCRIPTION OF EQUIPMENT
3.1
K-SERIES ROBOT DESCRIPTION
The Motoman K6 and K10 robots and YASNAC MRC Controller represent stateof-the-art technology in robotics today. The six-axis K6 Robot has a payload of 6
kg (13.2 lbs). It features a 1,322 mm (52.0 inch) reach and has a relative
positioning accuracy of ± 0.1 mm (0.004 inch). The six-axis K10 Robot has a
payload of 10 kg (22 lbs). It features a 1,555 mm (61.2 inch) reach and has a
relative positioning accuracy of ± 0.1 mm (0.004 inch).
Each robot can reach below its own base as well as behind itself. These robots can
also be mounted in floor, wall, or ceiling configurations with few hardware
modifications. The Motoman K-Series robots have been constructed for ease of
maintenance utilizing brushless AC servo motors with absolute positioning
encoders. All motors are readily accessible. A combination of capacitance and
lithium batteries in both the robot encoder assemblies and in the Motoman
YASNAC MRC controller protects program position data for up to one year. The
replacement life for the lithium battery is approximately three years.
3.2
MRC CONTROLLER
The MRC controller (Figure 3-1) coordinates the operation of the FabWorld
system. It provides the following control functions:
•
User interface
•
Main logic functions
•
Input / output control
•
Servo control
•
Numeric processing
•
Variable data memory
•
Program and constant data memory
•
Analog welding command functions
•
Welding interface
•
Power distribution
The MRC controls the movement of the manipulator, processes input and output
signals, controls the operation of the welding power supply, and provides the
signals to operate the welding system. It maintains variable data and performs the
numeric processing to convert to and from different coordinate systems.
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MOTOMAN
Figure 3-1 MRC Controller
The playback box (Figure 3-2) on the MRC has the primary system controls. The
following Sections describe the MRC controls.
Figure 3-2 MRC Playback Box
3.2.1
Servo Power
The SERVO POWER pushbutton switch turns on the robot servo power. An
indicator lamp in the switch lights when servo power is on.
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3.2.2
Mode Select
The Mode Select pushbutton switches (PLAY, TEACH, and REMOTE) set the
robot's mode of operation. Indicator lamps in the Mode Select switches light to
show the current mode of operation. Refer to your MRC Operator's Manual for
Arc Welding for more information.
3.2.3
Cycle Select
The Cycle Select pushbutton switches (AUTO, 1-CYCLE, and STEP) set the
operating method for playback operations. Indicator lamps in the Cycle Select
switches light to show the selected playback method. Refer to your MRC
Operator's Manual for Arc Welding for more information.
3.2.4
Emergency Stop (E-Stop)
The E-Stop button is connected to the system emergency stop circuit. Interrupting
the E-Stop circuit causes the robot to go into the E-Stop condition. Pressing the EStop pushbutton immediately turns off servo power.
3.2.5
Alarm / Error
The ALARM / ERROR indicator lights whenever an alarm or error condition
occurs. After you reset the alarm or error condition, the indictor lamp goes off.
3.2.6
Hold
The HOLD button is a momentarily actuated switch. Pressing the HOLD button
stops the operation of the manipulator momentarily. The Hold state is active only
while the switch is held down. The indicator lamp lights whenever the robot is in a
Hold state. Refer to your MRC Operator's Manual for Arc Welding for more
information.
3.2.7
Start
Pressing the START button causes the manipulator playback operation to start.
The indicator lamp lights during playback.
3.2.8
Playback Box Subpanel
The playback box has an inside subpanel that contains additional user controls.
Refer to your MRC Operator's Manual for Arc Welding for more information.
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MOTOMAN
3.3
PROGRAMMING PENDANT
A programming pendant (Figure 3-3) provides the primary user interface with the
system. The pendant has a 12-line LCD display and a 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, and diagnostic functions.
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MOTOMAN
Figure 3-3 Programming Pendant
3.3.1
Display
The programming pendant has a 12-line LCD display. The display provides status
information, system messages and prompts, and a graphic work area. Refer to
your MRC Operator's Manual for Arc Welding for more information.
3.3.2
Robot Speed Indicators
The MAN SPD indicators light to show the selected robot manipulator speed.
3.3.3
Emergency Stop (E-Stop)
The E-Stop button is connected to the system emergency stop circuit. Interrupting
the E-Stop circuit causes the robot to go into the E-Stop condition. Pressing the EStop pushbutton immediately turns off servo power.
3.3.4
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. For more
information, refer to your MRC Operator's Manual for Arc Welding.
3.3.5
Servo Power
The SERVO POWER pushbutton switch turns on the robot servo power. An
indicator lamp in the switch lights when servo power is on.
3.3.6
Coordinate System Indicators
The COORD indicators light to show the currently active coordinate system.
3.4
ROTARY PLANE POSITIONER MODULE
The rotary plane positioner module consists of a headstock and tailstock mounted
on a common bed that provides for a maximum of 76 inches between mounting
plates. The unit includes an operator station, safety mats and photo eyes, and an
external axis cabinet capable of holding up to four external axes.
3.4.1
Specifications
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Capacity: Each mounting plate has a capacity of 500 lbs. The center of gravity of
the load must be located within 6 inches of the centerline of the mounting plate.
The center of gravity of the load must be within 6 inches of the face of the
mounting plate. The combined headstock/tailstock has a capacity of 1,000 lbs. The
center of gravity of the load must be within 3 inches of the headstock/tailstock axis.
Rotation: The positioner turns at zero to 10 RPM and produces 3,000 lb-in
torque. The variable-speed servo motor is direct-coupled to a harmonic drive that is
direct-coupled to the table. The motor equipped with an internal brake. The
tailstock is freewheeling.
Table: The table (RT18 ) has a diameter of 18 inches, a thickness of 1 inch, and a
pilot hole that is 2.000 inches in diameter and 1/2 inch deep. The surface of the
table is machined.
Chassis: The height of the chassis is fixed with the axis of rotation at 27-3/4
inches above floor.
3.4.2
Temperature Operating Range
The temperature operating range is 40-110˚ Fahrenheit.
3.4.3
Humidity
Noncondensing 10 to 90% relative humidity is acceptable.
NOTE:
In high-humidity areas, the table tooling plate may rust or corrode. Surface protection should
be used.
3.4.4
Electrical Requirements
The servo tables are operated by external MRC servo motors.
3.4.5
Welding Current Rating
The positioner has a welding current capacity of 600 amperes at 100% duty cycle.
3.5
STATIONARY FLAT PLANE MODULE
The stationary flat plane module is a steel table with a 1/2-inch blanchard-ground
steel top. The unit includes an operator station, safety mats, and dual photo eyes.
3.5.1
Part/Fixture Rating
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MOTOMAN
The maximum capacity of the table is 2,000 lbs.
3.5.2
Dimensions
The dimensions of the stationary flat table are 1/2 inch thick by 24 inches wide by
92 inches long by 34 inches high.
3.5.3
Welding Current Rating
The positioner has a welding current capacity of 600 amperes at 100% duty cycle.
3.6
MULTI-PLANE POSITIONER MODULE
The multi-plane module is a rotary positioner with a pneumatically powered tilt
module. The unit includes an operator station, safety mats and photo eyes, and an
external axis cabinet capable of holding up to four external axes.
An optional tailstock unit is also available for use with the multi-plane positioner.
The tailstock is a non-powered, freewheeling support device. It includes a common
bed that ties the headstock to the tailstock and provides for a maximum of 76
inches between mounting plates.
3.6.1
Specifications
Capacity: The mounting plate has a capacity of 500 lbs. The center of gravity of
the load must be located within 6 inches of the centerline of the mounting plate.
The center of gravity of the load must be within 6 inches of the face of the
mounting plate.
Rotation: The positioner turns at zero to 10 RPM and produces 3,000 lb-in
torque. The variable-speed servo motor is direct-coupled to a harmonic drive that is
direct-coupled to the table. The motor equipped with an internal brake.
Table: The table (RT18 ) has a diameter of 18 inches, a thickness of 1 inch, and a
pilot hole that is 2.000 inches in diameter and 1/2 inch deep. The surface of the
table is machined.
Chassis: The height of the chassis is fixed with the axis of rotation at 27-3/4
inches above floor.
Tilt Module: The tilt axis is powered by a pneumatic cylinder. The table motion
is limited by hardstops at the 0° and 90° positions. The capacity and rotation are as
specified above.
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3.6.2
Temperature Operating Range
The temperature operating range is 40 to 110˚ Fahrenheit.
3.6.3
Humidity
Noncondensing 10 to 90% relative humidity is acceptable.
NOTE:
In high-humidity areas, the table tooling plate may rust or corrode. Surface protection should
be used.
3.6.4
Air Requirements
Clean dry air 15 SCFM at 90 PSIG is required.
3.6.5
Electrical Requirements
All electrical power required to operate the unit is supplied from the MRC
controller and consists of a 110-volt circuit to provide power for the solenoids and
interface. The servo tables are operated by external MRC servo motors. The
external axis cabinet provides 208 volts for servos.
3.6.6
Welding Current Rating
The positioner has a welding current capacity of 600 amperes at 100% duty cycle.
3.6.7
Hardstops
The tilt axis is equipped with hardstops at the 0° and 90° positions.
3.7
STATIONARY TACK-WELDING TABLE
The stationary tack-welding table is a steel table with a 1/2-inch blanchard ground
steel top. The unit includes an operator station, safety mats, and dual photo eyes.
3.7.1
Part/Fixture Rating
The maximum capacity of the table is 500 lbs.
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MOTOMAN
3.7.2
Dimensions
The dimensions of the stationary tack-welding table are 1/2 inch thick by 24 inches
wide by 31-1/4 inches long by 34 inches high.
3.7.3
Welding Current Range
The positioner has a welding current capacity of 600 amperes at 100% duty cycle.
3.8
OPERATOR STATIONS (OP-STATIONS)
The FabWorld system uses two types of op-stations: a master op-station (Figure
3-4) and a slave op-station. The master op-station is located at the primary station.
Slave stations are located at secondary or optional stations. Each op-station
includes a NEMA enclosure on a stand-alone pedestal. Both types of op-station
have the following controls:
•
Emergency Stop
•
Robot Hold
•
Station Ready
•
Alarm
•
Master Job Start
•
Cycle Start
•
Reset
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MOTOMAN
CYCLE START
CYCLE START
MOTOMAN
ALARM
ROBOT HOLD
STATION READY
RESET
MASTER JOB
START
POSITIONER
AUTO/MAN
OPERATOR STATION
ENABLE/DISABLE
ESTOP
SERVO ON
WARNING:
WARNING:
WARNING!
NOT
ENTER
DODO
NOT
ENTER
ROBOT WORK
ROBOT
WORKAREA
AREA
Figure 3-4
Operator Station (Op-Station)
In addition to the controls listed above, the master op-station also has the
following controls:
•
Servo On
•
Positioner Auto / Manual
•
Op-Station Enable / Disable
The following sections describe each of the op-station controls.
3.8.1
Emergency Stop (E-Stop)
The operator station E-Stop, the robot E-Stop, the photo eyes, zone ring monitor,
and the FabWorld safety mats are connected in series in the E-Stop circuit. If the
E-Stop circuit is interrupted, the robot and positioner go into the E-Stop condition.
The operator station E-Stop light comes on when the E-Stop button is pressed.
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3.8.2
Hold
The op-station HOLD button is a normally closed pushbutton and is connected to
the MRC to cause the robot to go into the Hold condition when the button is
pressed.
3.8.3
Cycle Start
The CYCLE START palm buttons located on both ends of the op-station use an
anti-tiedown technique for robot input. The anti-tiedown timer is set for 10
seconds. Holding the palm buttons down for more than 10 seconds causes the
timer to time out and prevents the input from reaching the robot. The CYCLE
START buttons are connected to robot Input #1.
3.8.4
Station Ready
The STATION READY lamp is interlocked with the robot CUBE #1 output. The
robot Outputs #1, 2, and 3 turn on the STATION READY lamp.
3.8.5
Alarm
The ALARM lamp is connected to the robot Alarm Occurrence output. The
ALARM lamp turns on when the robot encounters a major or minor alarm
condition.
3.8.6
Servo On
The SERVO ON pushbutton is connected to the robot Servo On input. The robot
servo motors will turn on when the SERVO ON pushbutton is pressed and an EStop condition does not exist.
3.8.7
Positioner Auto / Manual
The POSITIONER AUTO / MANUAL selector switch is used to select Automatic
or Manual Mode for the positioners. The selector switch is connected to robot
Input #2. When the selector switch is in the Automatic position, the robot will
process the part after the positioner sweeps. In Manual Mode, the robot will not
process the part after the positioner sweeps. This function is dependent on the
structure of the master job.
3.8.8
Master Job Start
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MOTOMAN
The MASTER JOB START pushbutton is connected to the robot external start
input. The robot will start the currently active job when this pushbutton is pressed
if the robot is in Play Mode and the servo motors are on.
3.8.9
Operator Station Enable / Disable
The OPERATOR STATION ENABLE / DISABLE selector switch is used to
transfer primary control of the FabWorld cell from the MRC to the Op-Station.
The REMOTE MODE button on the MRC playback box lights when the opstation is enabled. Most programming pendant functions are disabled.
3.8.10
Reset
The RESET pushbutton is connected to the robot alarm reset input. Any alarm or
error condition will be cleared when this button is pressed. In addition, the RESET
pushbutton and the right CYCLE START palm button are interlocked. When
pressed simultaneously, thes two pushbuttons enable the positioners if the robot
servo motors are on. The positioner needs to be enabled at initial power up or at
emergency stop or shock sensor condition.
NOTE:
When resetting the multi-plane positioner, some table motion may occur. Do not reset the
positioner with the robot close to tooling. If an E-Stop occurs during programming, be sure to
reset the table before resuming programming. This will ensure that the table is in the same
position as before the E-Stop.
3.9
WELDING POWER SOURCE
The Excel-Arc power source (Figure 3-5) is a constant voltage transformer-rectifier
type welding machine. It provides volt-current characteristic curves that are
essentially flat. This power source can be used with most GMAW (MIG)
applications from thin sheet metal to heavy-gauge plate.
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MOTOMAN
Figure 3-5 Excel-Arc Controls
3.9.1
Main Power
The Input Power switch (7) turns on the main power to the Excel-Arc unit. The
main power must be on before any other section of the power source can operate.
The indicator light (1) illuminates when main power is on.
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3.9.2
Volt / Amp Settings
The Welding Voltage / Amperes Control (2) adjusts the welding output and open
circuit voltage. The Volt / Amp Meter and Switch (3) display either DC voltage or
DC current depending on the position of the switch. Refer to your Excel-Arc
manual for additional information.
3.9.3
Terminal Connectors
The two terminals on the front of the Excel-Arc power source serve as connection
points for the welding leads. The Positive Terminal (4) connects to the positive
welding lead (to the wire feeder). The Negative Terminal (5) connects to the
negative welding lead (to the workpiece).
3.9.4
Local / Remote Operation
The Local / Remote Output Control Selector Switch (6) sets the mode of operation
for the power source. For FabWorld applications, this switch should be set to
REMOTE. Refer to your Excel-Arc manual for additional information.
3.9.5
Feeder Control Receptacles
The Feeder Control Receptacle Panel (8) located in the back of the power source
provides connectors for use with remote voltage control applications. For
FabWorld applications, the MRC connects to the 19-pin connector.
3.9.6
Circuit Breakers
The Excel-Arc power source uses two 10-amp circuit breakers (9 and 10). One
circuit breaker protects the 24 volt circuit; the other protects the 115 volt circuit.
3.9.7
AC Receptacles
The Excel-Arc unit has two standard 115-VAC Receptacles (11). These provide
auxiliary power at a maximum current of 10 amps. For applications using the
water-cooled torch, the water circulator plugs into one of these receptacles.
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3.10
WELDING EQUIPMENT
In addition to the Excel-Arc power source, the FabWorld system provides a
complete complement of arc welding equipment. In its standard configuration, the
FabWorld system includes the following:
•
PWF4-600 wire feeder
•
Universal welding interface (UWI)
•
Either an air-cooled or water-cooled GMAW torch
•
RAM torch breakaway mount
The following sections briefly describe each of the listed devices. Refer to your
Motoman Robotic Arc Welding Manual for more detailed information.
3.10.1
PWF4-600 Wire Feeder
The PWF4-600 wire feeder mounts on the robot arm. The 4-roll wire feeder
provides reliable wire feeding at rates up to 600 IPM. An integral gas valve
provides fast gas response time. The wire feeder has an inch forward button to
help simplify setup and reduce change-over time. The PWF4-600 wire feeder uses
interchangeable feed rolls to accommodate different types and sizes of wire.
3.10.2
Universal Welding Interface
The universal welding interface (UWI) provides microprocessor control to the wire
feeder and power source. It scales the signals from the MRC to the appropriate
levels required for control of the welding components. It also provides isolation of
the power source analog signals.
3.10.3
GMAW Torch
The FabWorld uses either an air-cooled or water-cooled robotic/automatic GMAW
torch. These are heavy-duty torches designed for quick replacement while
requiring minimum robot reprogramming. The GMAW torch mounts on the end
of the robot wrist. For applications that use the water-cooled torch, the FabWorld
includes a suitable water circulator kit.
3.10.4
RAM Torch Breakaway Mount
A Motoman RAM torch breakaway mount protects the robot, workpiece, fixture,
and positioner. It provides multi-directional impact detection, including Z-axis
collisions. The torch breakaway causes the robot to stop immediately upon impact.
Keyed joints ensure accurate realignment of components.
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MOTOMAN
3.11
SAFETY EQUIPMENT
The FabWorld system 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.
The FabWorld safety features include the following:
3.11.1
•
Arc curtains
•
Safety fencing
•
Interlocked safety mats
•
Photo eyes
•
Zone ring monitor
•
Emergency stop (E-Stop) buttons
Arc Curtains
WARNING!
Although the arc screens block dangerous arc radiation, you
should not look directly at the arc during operation without
protective eyewear!
The FabWorld cell uses two different arc screens. The first set covers the safety
fencing of the robotic cell. The second set mounts on posts located at the sides of
each station. The cell has no fencing or arc screen at the openings of the separate
stations (where the operator loads and unloads parts). Motoman recommends that
the user provide portable arc screens that can be put in place to protect workers in
the area against arc radiation.
3.11.2
Fencing
The safety fencing provided with the FabWorld system encloses and defines the
robotic cell. It forms a physical barrier to prevent entry into the robot envelope.
3.11.3
Safety Mats
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MOTOMAN
The safety mats provided with the FabWorld helps prevent serious injury to anyone
entering the active welding station. Stepping on a mat while the robot is in Play
mode and in the same zone causes an E-Stop.
3.11.4
Photo Eyes
The through-beam photoelectric switch consists of two devices: a light sender and
a light receiver. The separate construction permits scanning across large distances
with a corresponding reserve capacity. Breaking the photo beam while the robot is
in Play mode and in the same zone causes an E-Stop.
3.11.5
Zone Ring Monitor
The zone ring monitor is a monitoring control that allows the operator to load and
unload parts in any zone other than the active welding zone. The zone monitor
works in conjunction with the safety mats and the photo eyes of the system.
Entering the active welding zone while the robot is in Play mode causes an E-Stop
condition to occur.
3.11.6
Emergency Stops
In addition to the interlocking devices described above, the FabWorld cell has
several strategically placed emergency stops (E-Stops). These are operator actuated
devices that, when activated, immediately cause the system to shut down. The
following is a list of their locations:
•
The MRC control panel has one E-Stop button.
•
The MRC programming pendant has one E-Stop button.
•
Each positioner operator station has one E-Stop button.
The following actions also cause an E-Stop when the robot is in Play mode:
•
Breaking the photo eye light beams in an active zone.
•
Stepping on the safety mats in an active welding zone.
•
Insufficient air pressure in the multi-plane (tilt/rotate) positioner.
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4.0 OPERATION
This section provides operation instructions for the FabWorld system. Operation
procedures include the following:
•
System start-up
•
Part setup
•
Normal operation
•
Fault recovery
•
System shutdown
This section also includes several sample programs that demonstrate the proper
format and instruction sequences for different operations. You can use these
programs as guidelines when creating programs for your specific applications.
4.1
NORMAL OPERATION
The FabWorld system is a fully integrated robotic GMAW welding cell. The robot
welds parts at the active station while the operator loads or unloads parts at any of
the remaining stations.
The following is the normal sequence of operations for FabWorld after start-up:
1. Load parts into the fixture at Station A.
2. Press the right and left CYCLE START palm buttons simultaneously on the
operator station. The robot begins welding.
3. Repeat Steps 1 and 2 for each remaining station.
4. Unload the welded parts.
5. Repeat Steps 1 through 4.
NOTE:
Pressing the CYCLE START palm buttons latches the input signal. If all operator stations are
latched, the master job controls the order in which the jobs actually run.
4.1.1
Start-Up
To start up the FabWorld from a power-off condition, follow these steps:
1. Turn on all power disconnects.
2. Set the main power switch on the MRC to ON.
3. Set the INPUT POWER switch on the welding power source to ON. The pilot
light on the power source should glow.
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MOTOMAN
4. Turn on the welding gas.
5. Turn on the air supply to the positioner (if required).
6. Press the TEACH MODE button on the MRC playback box. The indicator
lamp in the switch should light.
7. Press the SERVO POWER button on the MRC playback box. The indicator
lamp in the switch should light.
8. Call up the master job.
9. Press the PLAY MODE button on the MRC playback box, and then press the
AUTO CYCLE button. The indicator lamps in the switches should light.
10. Initialize the positioner by pressing the RESET button and the right CYCLE
START button on the master operator station simultaneously.
11. Press the MASTER JOB START button on the master operator station.
12. Wait for the STATION READY light to turn on.
The FabWorld system is now ready for operation.
4.1.2
Fault Recovery
Under varying conditions, an alarm or error can occur. Clearing an alarm or error
condition may require different operator intervention depending on the nature of the
alarm or error. In some cases, simply resetting the robot and restarting the
operation is sufficient. In other instances, you must first remedy the condition
causing the alarm or error. Refer to Section 4.2, Alarms and Errors.
4.1.3
E-Stop Recovery
An E-Stop can occur under one of the following conditions:
•
Pressing the E-Stop button on the operator station, the teach pendant, or the
MRC playback box.
•
Stepping on the safety mat or breaking the photo eyes light beam when the
robot is in the same zone and in play mode.
•
Lack of air pressure on the multi-plane positioner.
•
Activation of the shock sensor, indicating a robot crash.
To restart the FabWorld Cell after an E-Stop condition occurs, follow the procedure
below.
1. Clear the cause of the E-Stop condition.
•
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Release the E-Stop button on the operator station, the teach pendant, or the
MRC playback box.
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MOTOMAN
•
Step off the safety mat or clear the path of the photo eyes.
•
Turn on the air supply (if required).
•
Clear the shock sensor condition (see Section 4.1.4).
2. Press the SERVO POWER button on the MRC playback box or programming
pendant, or the SERVO ON button on the operator station.
3. Press the RESET button and the right CYCLE START button on the operator
station simultaneously to initialize the system.
4. Press the MASTER JOB START button on the operator station.
The FabWorld Cell will continue its operation.
4.1.4
Shock Sensor Recovery
The ArcWorld welding package includes a RAM breakaway torch 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 error. A more severe crash
separates the torch mount from the robot arm. The SHOCK SENSOR error is
factory set to an E-Stop condition.
To override the shock sensor, do the following:
1. Disconnect the shock sensor plug from the connector at the front of the wire
feeder (see Figure 4-1).
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MOTOMAN
Shock Sensor
Jumper
Feeder
Housing
Shock
Sensor Plug
Shock Sensor
Cord
Breakaway
Torch
Assembly
Figure 4-1 Shock Sensor Override
2. Connect the shock sensor jumper (Motoman Part Number 132601-1) to the
connector at the front of the wire feeder.
3. Press the RESET and right CYCLE START buttons on the operator's station at
the same time.
4. Use the programming pendant to operate the manipulator out of the impact
position.
5. Reattach the sections of the torch breakaway mount if the impact caused them
to separate.
To resume operation after clearing the shock sensor condition, proceed as follows:
1. Disconnect the shock sensor jumper from the connector at the front of the wire
feeder (see Figure 4-1).
CAUTION!
You must remove the shock sensor jumper during normal
operation. Failure to do so can result in equipment damage.
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MOTOMAN
2. Connect the shock sensor plug to the connector at the front of the wire feeder.
3. Close the interlocked enclosure doors.
4. Press the SERVO ON button on the MRC or programming pendant.
5. Press the RESET and right CYCLE START buttons on the operator's station at
the same time. This initializes the positioner.
CAUTION!
You may need to move the robot to recover from a crash. To avoid
another crash, make sure that the robot has a clear path to the
next step.
6. Press the MASTER JOB START button.
4.1.5
Shutdown
To shut down the FabWorld system after operation is complete, use the
following procedure:
1. Make sure that the robot is in the starting position.
2. Turn off the robot servo motors by pressing the E-Stop button on either the
operator station, the programming pendant, or the MRC playback box.
3. Press the TEACH MODE button on the MRC playback box.
4. Set the MRC main power switch to the OFF position.
5. Set the INPUT POWER switch on the welding power source to OFF.
6. Close the regulator valve on the welding gas supply.
7. Turn off air supply to positioner.
8. Turn off the power disconnects.
The FabWorld system is now shut down.
4.2
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 your Motoman MRC
Manipulator Manual.
4.2.1
Error Messages
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MOTOMAN
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 or ENABLE button on the
programming pendant.
4.2.2
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 one of the following:
4.2.3
•
RELEASE soft key on the programming pendant
•
RESET button on the operator's station
•
ENABLE button on the programming pendant twice
Major Alarms
Major alarms are hardware failures. Major alarms might occur because of a servo
tracking error or an abnormal speed associated with crashes.
To clear these alarms, you must turn off the controller and then turn it on again.
FabWorld Operator's Manual
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MOTOMAN
4.3
I/O ASSIGNMENT
MRC User Inputs
IN#1
Cycle Start 1
IN#2
Auto/Manual Selector Switch
IN#3
Cycle Start 2
IN#4
Cycle Start 3
IN#5
Zone 1 Active
IN#6
Zone 2 Active
IN#7
Zone 3 Active
MRC User Outputs
OUT#1
Station #1 Ready
OUT#2
Station #2 Ready
OUT#3
Station #3 Ready
OUT#4
Wire Cutter (optional)
OUT#9
Tilt Pos. (first Multi-Plane Positioner Only)
OUT#10
Flat Pos. (first Multi-Plane Positioner Only)
OUT#110
Unlatch Zone 1
OUT#111
Unlatch Zone 2
OUT#112
Unlatch Zone 3
OUT#124
Gas Purge
OUT#127
Inch Forward (Wire)
OUT#128
Inch Reverse (Wire)
FabWorld Operator's Manual
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MOTOMAN
MRC Dedicated Inputs
•
Servo ON
•
Start
•
Hold
•
Alarm Reset
•
Cube #1 Intrf. Prohibit
•
Cube #2 Intrf. Prohibit
•
Arc Occurrence Prohibit
•
Arc On Response
•
Arc Occurrence Check
•
Arc Shortage
•
Gas Shortage
•
Water Shortage
•
Panel Operation Prohibit
•
Teach
•
Play and Auto
•
In-Guard Safety Drive Inst.
MRC Dedicated Outputs
•
Control Power Off
•
External Emergency Stop
•
Servo Power On
•
Emergency Stop OK
•
Play and Auto Mode
•
Teaching
•
Holding
•
Battery Low Power
•
Working In Intrf. Cube #1
•
Working In Intrf. Cube #2
•
Operating
FabWorld Operator's Manual
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MOTOMAN
•
Alarm Occurrence
•
Operation Ready
•
In-Guard Safety Drive Inst.
•
Gas On
•
Inch Reverse
•
Power Source On
•
Wire Feeder On
•
Gas Low (Optional)
•
Water Low (Optional)
For more information on the user and dedicated I/Os, refer to the MRC User
Functions Manual (Motoman Part Number 132331-1) and the MRC Operator's
Manual for Arc Welding (Motoman Part Number 132332-1) and the electrical
drawings in Appendix A.
4.4
PROGRAMMING THE MULTI-PLANE POSITIONER
4.4.1
Tilting the Positioner
To manually tilt the multi-plane positioner in the teach mode, follow these steps:
1. Ensure that robot servo power is on.
2. Ensure that the positioner is enabled.
3. Ensure that the robot is in CUBE #1.
4. Ensure that Robot Output #10 is off.
5. Ensure that Robot Output #9 is on.
6. Wait for Input #6 to come on.
7. Turn Input #9 off.
NOTE:
If a second tilt/rotate positioner is included, different outputs will be used.
4.4.2
Flattening the Positioner
To manually flatten the multi-plane positioner in the teach mode, follow these steps:
1. Ensure that robot servo power is on.
2. Ensure that the positioner is enabled.
3. Ensure that the robot is in CUBE #1.
4. Ensure that Robot Output #9 is off.
FabWorld Operator's Manual
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MOTOMAN
5. Ensure that Robot Output #10 is on.
6. Wait for Input #5 to come on.
7. Turn Input #10 off.
NOTE:
If a second tilt/rotate positioner is included, different outputs will be used.
4.4.3
Rotating the Positioner
The rotation axes of the positioner are controlled by the MRC external axis
function. The motion points for the external axes are taught and recorded in the
program in the same manner as any of the robot axes. The speed and position are
controlled by the MRC. Pressing the EXT AXIS button on the teach pendant
changes the blue motion keys from robot axis keys to positioner axis keys.
4.5
PROGRAMMING THE ROTARY PLANE POSITIONER
The rotation axes of the positioner(s) are controlled by the MRC external axis
function. The motion points for the external axes are taught and recorded in the
program in the same manner as any of the robot axes. The speed and position are
controlled by the MRC. Pressing the EXT AXIS button on the teach pendant
changes the blue keys from robot axis keys to positioner axis keys.
4.6
SAMPLE JOBS
The following jobs are shown as examples only. Your system may have other
features and/or options requiring program changes. Double-check your system
before running these jobs.
4.6.1
Master Job
Line
Step
Function
000
000
NOP
001
001
MOVJ VJ=100.00 CONT
002
CALL JOB:WELD-A IF IN#(01)=ON
003
CALL JOB:WELD-B IF IN#(03)=ON
004
CALL JOB:WELD-C IF IN#(04)=ON
005
CALL JOB:CLEAN IF I00>=5
006
END
FabWorld Operator's Manual
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MOTOMAN
4.6.2
Weld-A Job
Station A looks for Input #1. Station A will perform whatever job has been
programmed to take place in Station A. Output #110 must be pulsed at the
beginning of each weld A job to unlatch the operator station. This prevents the
robot from repeating weld jobs.
Output #1 must be turned on in the beginning of weld job A. Output #1 controls
the station ready light on the operator station.
Line
Step
Function
000
000
NOP
001
DOUT OT#(01) 1
002
WAIT IN#(01)=1
003
DOUT OT#(01) 0
004
PULSE OT#(110) T=0.25
005
001
MOVJ EX VJ=100.00 CONT
006
002
MOVJ EX VJ=100.00 CONT
007
003
MOVJ EX VJ=25.00 CONT
008
ARCON ASF#(2)
'Call the welding start file
009
004
MOVL EX V=76 CONT
010
005
MOVL EX V=76 CONT
011
006
MOVL EX V=76 CONT
012
ARCOF AEF#(2)
'Call the welding end file
013
007
MOVJ EX VJ=50.00 CONT
014
008
MOVJ EX VJ=100.00 CONT
FabWorld Operator's Manual
Page 41
MOTOMAN
015
4.6.3
009
MOVJ EX VJ=100.00 CONT
016
RET
017
END
Weld-B Job
Station B looks for Input #3. Station B will perform whatever job has been
programmed to take place in Station B. Output #111 must be turned on at the
beginning of each weld B job to unlatch the operator station. This prevents the
robot from repeating weld jobs. Output #2 must be turned on in the beginning of
weld job B. Output #2 controls the station ready light on the operator station.
4.6.4
Weld-C Job
Station C looks for Input #4. Station C will perform whatever job has been
programmed to take place in Station C. Output #112 must be turned on at the
beginning of each weld C job to unlatch the operator station. This prevents the
robot from repeating weld jobs. Output #3 must be turned on in the beginning of
weld job C. Output #3 controls the station ready light on the operator station.
4.6.5
4.6.6
Tilt Job (for tilt and rotate tables only)
Line
Step
Function
000
000
NOP
001
DOUT OT#(10) OFF
002
DOUT OT#(09) ON
003
WAIT IN#(05)=OFF
004
WAIT IN#(06)=ON
005
DOUT OT#(09) OFF
006
RET
007
END
Flat Job
FabWorld Operator's Manual
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MOTOMAN
4.6.7
Line
Step
Function
000
000
NOP
001
DOUT OT#(09) OFF
002
DOUT OT#(10) ON
003
WAIT IN#(06)=OFF
004
WAIT IN#(05)=ON
005
DOUT OT#(10) OFF
006
RET
007
END
Clean Job
CAUTION!
Robot will operate independently of the external axis. Be sure
the robot points are clear of the positioner and fixture.
NOTE:
Nozzle cleaning jobs should be programmed with Position (P) variables on systems that have
external axes. This allows the robot to make motions through a clean job while any external
axis movement is inhibited. For information about P variables, refer to your MRC User
Functions Manual.
NOTE:
P variables other than those used on the above example may be used. The number of steps
may also vary.
Line
Step
Function
000
000
NOP
001
001
MOVJ P000 VJ=100.00 CONT
002
002
MOVJ P001 VJ=100.00 CONT
003
003
MOVJ P002 VJ=50.00 CONT
004
004
MOVL P003 V=150.0 CONT
'@ Air Hammer/Cleaner
005
TIMER T=1.00
006
005
MOVL P002 V=150.0 CONT
007
006
MOVL P004 V=150.0 CONT
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MOTOMAN
'@Anti-Spatter Spray
008
TIMER T=1.00
009
007
MOVL P005 V=150.0 CONT
010
008
MOVL P006 V=150.0 CONT
011
009
MOVJ P007 VJ=50.00 CONT
012
010
MOVL P008 V=150.0 CONT
013
011
MOVL P009 V=150.0 CONT
014
PULSE OT#(127) T=0.50
'Inch Forward
015
012
MOVL P008 V=150.0 CONT
016
013
MOVL P010 V=150.0 CONT
017
PULSE OT#(4) T=0.50
'Wire Cut
018
014
MOVL P011 V=150.0 CONT
019
015
MOVJ P000 VJ=100.00 CONT
020
SET I00=0
'Reset Counter
021
RET
022
END
NOTE:
The program will operate on Side A or Side B because there are no external axis positions.
NOTE:
Lines 15 through 17 are for the optional wire cutter.
FabWorld Operator's Manual
Page 44
MOTOMAN
NOTES
FabWorld Operator's Manual
Page 45
MOTOMAN
5.0 MAINTENANCE
5.1
PERIODIC MAINTENANCE
For periodic maintenance procedures and schedules for the K6 robot, the K10
robot, and the MRC controller, refer to your K6 MRC Manipulator Manual or K10
MRC Manipulator Manual.
For maintenance information regarding the multi-plane and rotary plane
positioners, refer to your Aronson Manual.
For maintenance information regarding the welding power source, refer to your
Excel-Arc Owner's Manual.
Table 5-1 provides a list of periodic maintenance to be performed on the FabWorld
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.
WARNING!
Do not use automotive antifreezes in the water circulator.
Automotive antifreeze has stop leak additives that will clog the
small GMAW torch water cooling ports. The additives will
damage gaskets in the pump. Use Dynaflux Inc. Defense DF929 or
equivalent Ethylene Glycol with fungus inhibitors and emulsion
lubrication.
CAUTION!
Before performing maintenance on the wire cutter, be sure to turn
off the air supply.
FabWorld Operator's Manual
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MOTOMAN
Table 5-1 Periodic Maintenance
Frequency
Component
Procedure
As Required
Torch Tender
(optional)
Refill anti-spatter container.
Regularly
Photo Eyes
Clean the photo eye lenses with a
soft clean cloth and nonsolvent
cleaner.
Regularly
Safety Mats
Sweep the tops and underneath the
safety mats to remove debris.
Make sure that the mats lay flat.
Anything under the mats can cause
them to actuate.
Check the mats for tears, gouges,
buckling, etc. Replace the mats if
necessary.
Daily
Water Circulator Kit Check the fluid in the water
(optional)
circulator. Add fluid as required.
Use only distilled water and
approved antifreeze (Motoman
Part Number 131224-1).
Weekly
Wire Cutter
(optional)
Clean the unit with detergent
machine cleaner.
Apply grease to the wire cutting
mechanism through the grease
zerk provided.
6 Months
PWF4 Pancake
Wire Feeder
Annually
Water Circulator Kit Flush the system completely.
(optional)
Refill as needed.
FabWorld Operator's Manual
Page 47
Clean feed roll grooves with
industrial machine cleaner.
Replace feed rolls as required.
MOTOMAN
5.2
SPARE PARTS LIST
Table 5-2 Spare Parts
Description
5.3
Part No.
FabWorld Safety Mats (36" by 60")
130157-10
FabWorld Safety Mats (30" by 72")
130157-9
Safety Mat Control Box
131038-1
Positioner Interface 4 Pole Relay, 24 VDC
470108-5
Omni-Beam Emitter Sensor
131632-1
Omni-Beam Receiver Sensor
131633-1
Receiver Power Block Receptacle
131634-1
Emitter Power Block Receptacle
131635-1
Conductor Cables
130130-X
FUSE AND CIRCUIT BREAKER PROTECTION
Tables 5-3 through 5-7 give the locations of fuses and circuit breakers that are
significant to the operation of the total system. In most cases, MRC spare fuses are
placed in the accessory bag with the MRC.
WARNING!
Replace fuses with the same type and rating. Replacement of
fuses with 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
FabWorld Operator's Manual
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MOTOMAN
Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers
Device
Designator
Rating
Part Number
Location
Purpose
CB1
10A
115V
203627-7
Upper rear panel Protects 115V circuit
CB2
10A 24V
203627-7
Upper rear panel Protects 24V circuit
1A
W-11166-11 On contactor box Protects contactor
circuit
F1
Table 5-4 Universal Welding Interface (UWI) Fuses and Circuit Breakers
Device
Designator
Rating
F1
8A 250V
FU1
4A 250V
FU2
FU3
Part Number
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
19303K250A
On interface
board
Protects shock
sensor circuit
0.5A
125V
Wickman
19303K500A
On interface
board
Protects 24V circuit
Table 5-5 Com-Arc III Fuses and Circuit Breakers
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MOTOMAN
Device
Designator
Rating
Fuse
1A 250V
Part Number
TD-1
Location
Front of ComArc III box
Purpose
Protects 200V circuit
Table 5-6 MRC Cabinet Fuses and Circuit Breakers
Device
Designator Rating
CB
(1MCCB)
50 A
30 A
Part
Number
Location
Purpose
NF50-SS Upper left front Main circuit breaker for
incoming 200-VAC, 3K10
phase for MRC cabinet
NF30-SS Upper left front
K6
CB (1SV)
30 A
Lower left side Protects input for servo pack
of servo pack
1SV for S, L, and U axes
CB (2SV)
30 A
Lower left side Protects input for servo pack
of servo pack
2SV for R, B, and T axes
FU1
5A
GDL-5
250V
MTU-01
Protects CPT10199
transformer, brake, and fan
circuits
FU2
5A
GDL-5
250V
MTU-01
Protects CPT10199
transformer, brake, and fan
circuits
FU4
4A
GP-40
250V
MTU-01
Protects robot brake circuits
FU5
4A
GP-40
250V
MTU-01
Protects robot brake circuits
1FU
1A
GDL-1
250V
Top/left/rear
Protects the four fan circuits
of the MRC
FabWorld Operator's Manual
Page 50
MOTOMAN
FU3
2A
GDL-2
125V
Top/left/rear
Protects the 100-VAC
supply to the AC receptacle
for the floppy disk controller
power
FU1
3A
SM1101
MBB-02
External voltage protection 24V
FU2
3A
SM1101
MBB-02
External voltage protection 24V
Table 5-7 MRC System Fuses
Device
Designator Rating
Part
Number
Location
Purpose
1FU
1A
GDL-1
125V
Bottom/left/rear Protects 24-VDC circuit
2FU
1A
GDL-1
125V
Bottom/left/rear Protects fan circuit
3FU
2A
MDL-2
125V
Bottom/left/rear Protects safety mat circuit
4FU
2A
MDL-2
125V
Bottom/left/rear Protects safety mat circuit
5FU
2A
MDL-2
125V
Bottom/left/rear Protects safety mat circuit
FabWorld Operator's Manual
Page 51
MOTOMAN
APPENDIX A - ELECTRICAL DRAWINGS
This section contains the following electrical drawings:
Drawing Number
Title
Sheet Number
130804
MRC I/O MRY01 Board
Sheet 4 of 19
130804
MRC I/O MEW02 Board
Sheet 5 of 19
130804
MRC I/O MI004 Board
Sheet 6 of 19
130804
MRC I/O MI004 Board
Sheet 7 of 19
130804
MRC I/O MI003 Board
Sheet 8 of 19
130804
MRC I/O MI003 Board
Sheet 9 of 19
130804
MRC I/O MI003 Board
Sheet 10 of 19
130804
MRC I/O MI003 Board
Sheet 11 of 19
130804
E-Stop Circuit
Sheet 12 of 19
130804
Cable Layout
Sheet 13 of 19
130804
Power Distribution
Sheet 14 of 19
130804
Ladder Diagram
Sheet 16 of 19
130804
Ladder Diagram
Sheet 17 of 19
130804
Ladder Diagram
Sheet 18 of 19
130804
Ladder Diagram
Sheet 19 of 19
130805
MRC I/O MRY01 Board
Sheet 4 of 19
130805
MRC I/O MEW02 Board
Sheet 5 of 19
130805
MRC I/O MI004 Board
Sheet 6 of 19
130805
MRC I/O MI004 Board
Sheet 7 of 19
130805
MRC I/O MI003 Board
Sheet 8 of 19
130805
MRC I/O MI003 Board
Sheet 9 of 19
130805
MRC I/O MI003 Board
Sheet 10 of 19
130805
MRC I/O MI003 Board
Sheet 11 of 19
130805
E-Stop Circuit
Sheet 12 of 19
130805
Cable Layout
Sheet 13 of 19
130805
Power Distribution
Sheet 14 of 19
FabWorld Operator's Manual
Appendix A
MOTOMAN
Drawing Number
Title
Sheet Number
130805
Ladder Diagram
Sheet 16 of 19
130805
Ladder Diagram
Sheet 17 of 19
130805
Ladder Diagram
Sheet 18 of 19
130805
Ladder Diagram
Sheet 19 of 19
130806
MRC I/O MRY01 Board
Sheet 4 of 19
130806
MRC I/O MEW02 Board
Sheet 5 of 19
130806
MRC I/O MI004 Board
Sheet 6 of 19
130806
MRC I/O MI004 Board
Sheet 7 of 19
130806
MRC I/O MI003 Board
Sheet 8 of 19
130806
MRC I/O MI003 Board
Sheet 9 of 19
130806
MRC I/O MI003 Board
Sheet 10 of 19
130806
MRC I/O MI003 Board
Sheet 11 of 19
130806
E-Stop Circuit
Sheet 12 of 19
130806
Cable Layout
Sheet 13 of 19
130806
Power Distribution
Sheet 14 of 19
130806
Ladder Diagram
Sheet 16 of 19
130806
Ladder Diagram
Sheet 17 of 19
130806
Ladder Diagram
Sheet 18 of 19
130806
Ladder Diagram
Sheet 19 of 19
131982
MRC to EXSB
Sheet 1 of 1
131981
MRC to EXSB
Sheet 1 of 1
132347
MRC FabWorld External Axis
Sheet 1 of 3
132347
MRC FabWorld External Axis
Sheet 2 of 3
132347
MRC FabWorld External Axis
Sheet 3 of 3
130161
Connection/Schematic Diagram
Sheet 3 of 7
130161
Connection/Schematic Diagram
Sheet 6 of 7
FabWorld Operator's Manual
Appendix A
MOTOMAN
APPENDIX B - MECHANICAL DRAWINGS
This section contains the following mechanical drawings:
Drawing Number
Title
Sheet Number
131716
Servo Rotate Positioner
Sheet 1 of 1
131717
Pneumatic Tilt Positioner
Sheet 1 of 1
131723
Flat Table Positioner
Sheet 1 of 1
131711
Rotary Positioner
Sheet 1 of 2
131712
Pneumatic Tilt Positioner
Sheet 1 of 1
131512
Headstock Positioner
Sheet 1 of 7
131549
Pneumatic Tilt/Rotate Positioner
Sheet 1 of 1
131503
Tailstock Positioner
Sheet 1 of 7
130161
Station, Operator
Sheet 1 of 19
130161
Station, Operator
Sheet 2 of 19
130157
Safety Mat
Sheet 7
130157
Safety Mat
Sheet 9
131784
K6 Zone Ring Assembly
Sheet 1 of 3
131784
K10 Zone Ring Assembly
Sheet 2 of 3
131784
Zone Ring
Sheet 3 of 3
131142
Mounting Bracket
Sheet 1 of 1
FabWorld Operator's Manual
Appendix B
MOTOMAN
INDEX
HUMIDITY, 18, 19
A
ABOUT THIS DOCUMENT, 1
AC RECEPTACLES, 25
AIR REQUIREMENTS, 20
ALARMS AND ERRORS, 15, 33
ALARM, 22
ARC CURTAINS, 27
I
I/O ASSIGNMENT, 34
INSTALLATION SAFETY, 10
INTRODUCTION, 1
K
C
CIRCUIT BREAKERS, 25
CLEAN JOB, 40
COM-ARC III FUSES AND CIRCUIT BREAKERS, 46
COORDINATE SYSTEM INDICATORS, 17
CUSTOMER SERVICE INFORMATION, 5
CYCLE SELECT, 15
CYCLE START, 22
K-SERIES ROBOT DESCRIPTION, 13
KEYPAD, 17
L
LOCAL / REMOTE OPERATION, 25
M
E-STOP RECOVERY, 30
ELECTRICAL DRAWINGS, APPENDIX A
ELECTRICAL REQUIREMENTS, 18, 20
EMERGENCY STOP (E-STOP), 15, 17, 22, 28
ERROR MESSAGES, 33
EXCEL-ARC 6045 CV FUSES AND CIRCUIT BREAKERS, 46
EXCEL-ARC CONTROLS, 24
MAIN POWER, 24
MAINTENANCE SAFETY, 12
MAINTENANCE, 43
MAJOR ALARMS, 33
MASTER JOB START, 23
MASTER JOB, 37
MECHANICAL DRAWINGS, APPENDIX B
MECHANICAL SAFETY DEVICES, 9
MINOR ALARMS, 33
MODE SELECT, 15
MRC CABINET FUSES AND CIRCUIT BREAKERS, 47
MRC CONTROLLER, 13, 14
MRC PLAYBACK BOX, 14
MRC SYSTEM FUSES, 48
MULTI-PLANE POSITIONER MODULE, 19
F
N
FABWORLD CONFIGURATION CHART, 4
FABWORLD SYSTEM LAYOUT, 3
FAULT RECOVERY, 30
FEEDER CONTROL RECEPTACLES, 25
FENCING, 27
FLAT JOB, 39
FLATTENING THE POSITIONER, 36
FUSE AND CIRCUIT BREAKER PROTECTION, 45
NORMAL OPERATION, 29
OPERATION SAFETY, 11
OPERATION, 29
OPERATOR STATION (OP-STATION), 21
OPERATOR STATION ENABLE / DISABLE, 23
OPTIONAL EQUIPMENT, 4
G
P
GENERAL SAFEGUARDING TIPS, 9
GMAW TORCH, 26
PART/FIXTURE RATING, 18, 20
PERIODIC MAINTENANCE, 43, 44
PHOTO EYES, 28
PLAYBACK BOX SUBPANEL, 15
POSITIONER AUTO / MANUAL, 23
PROGRAMMING PENDANT, 16
D
DESCRIPTION OF EQUIPMENT, 13
DIMENSIONS, 18, 19
DISPLAY, 17
E
H
HARDSTOPS, 20
HOLD, 15, 22
FabWorld Operator's Manual
O
MOTOMAN
INDEX
PROGRAMMING SAFETY, 10
PROGRAMMING THE MULTI-PLANE POSITIONER, 36
PROGRAMMING THE ROTARY PLANE POSITIONER, 37
PWF4-600 WIRE FEEDER, 26
R
RAM TORCH BREAKAWAY MOUNT, 26
REFERENCE TO OTHER DOCUMENTATION, 5
RESET, 23
ROBOT SPEED INDICATORS, 17
ROTARY PLANE POSITIONER MODULE, 17
ROTATING THE POSITIONER, 37
S
SAFETY EQUIPMENT, 27
SAFETY MATS, 27
SAFETY, 7
SAMPLE JOBS, 37
SERVO ON, 22
SERVO POWER, 14, 17
SHOCK SENSOR OVERRIDE, 31
SHOCK SENSOR RECOVERY, 31
SHUTDOWN, 32
SPARE PARTS LIST, 45
SPECIFICATIONS, 17, 19
STANDARD CONVENTIONS, 8
START, 15
START-UP, 29
STATION READY, 22
STATIONARY FLAT PLANE MODULE, 18
STATIONARY TACK-WELDING TABLE, 20
SYSTEM LAYOUT, 2
SYSTEM OVERVIEW, 2
T
TEMPERATURE OPERATING RANGE, 18, 19
TERMINAL CONNECTORS, 25
TILT JOB (FOR TILT AND ROTATE TABLES ONLY), 39
TILTING THE POSITIONER, 36
U
UNIVERSAL WELDING INTERFACE FUSES AND
CIRCUIT BREAKERS, 46
UNIVERSAL WELDING INTERFACE, 26
V
VOLT / AMP SETTINGS, 25
W
WELD-A JOB, 38
WELD-B JOB, 39
WELD-C JOB, 39
WELDING CURRENT RANGE, 20
WELDING CURRENT RATING, 18, 19, 20
WELDING EQUIPMENT, 26
WELDING POWER SOURCE, 23
Z
ZONE RING MONITOR, 28
FabWorld Operator's Manual
MOTOMAN