System Operating Instructions
PerformArc 750 S
Version 2.0
Introduction
♦ Introduction
Thank you for purchasing our Miller PerformArc PA750S/PA750SW robotic welding system. This manual
explains the safety, installation, teaching, and operation of the PerformArc PA750S and PA750SW system.
Instructions in this manual are based on the PerformArc PA750S revision E mechanical and revision K
electrical specifications. Verify the system being worked on is built to these revisions before making any
changes. Contact Miller Welding Automation for questions about determining the mechanical or electrical
version information.
PA750S Operations
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Table of Contents

Table of Contents
1.1 Symbol Usage ............................................... 4
1.2 Arc Welding Hazards .................................... 4
1.3 Additional Symbols For Installation,
Operation, And Maintenance ............................. 7
1.4 California Proposition 65 Warnings ............ 9
1.5 Principal Safety Standards .......................... 9
1.6 EMF Information .......................................... 10
1.7 Hazard Labels/Warning Stickers ............... 11
8.2.1 Home - Cube Monitor 1 ......................... 32
8.2.2 Robot Home Output............................... 32
8.3 Clear Work Cube ........................................ 33
8.4 Inputs & Outputs ........................................ 34
8.4.1 Robot Inputs .......................................... 35
8.4.2 Robot Outputs ....................................... 36
8.5 Global Position Variables .......................... 37
8.5.1 Changing a Global Position by Teaching
........................................................................ 37
2. Specifications .................................... 12
9. Teaching ............................................ 39
1. Safety Precautions .............................. 4
9.1 Teach Mode................................................. 39
9.2 Pre-Teaching Checks ................................. 40
9.2.1 Table Checks ......................................... 40
9.2.2 Robot Checks ........................................ 40
9.3 System Programs ....................................... 41
9.3.1 System Program Structure .................... 42
9.3.2 Putting Programs into Weld A & Weld B 43
9.3.3 Running Multiple Programs on One Side
........................................................................ 46
9.3.4 Tip Change ............................................ 49
9.3.5 TCP Check ............................................ 52
2.1 Dimensions .................................................. 13
2.1.1 PA750S Front View ................................ 13
2.1.2 PA750S Side View ................................. 14
2.1.3 PA750S Top View .................................. 14
2.2.1 PA750SW Front View............................. 15
2.2.2 PA750SW Side View .............................. 16
2.2.3 PA750SW Top View ............................... 16
3. Parts Identification ............................ 17
4. Moving and Locating ......................... 19
4.1 Lifting With a Forklift .................................. 19
4.1.1 Front Fork Pockets ................................. 19
4.1.2 Rear Fork Pockets .................................. 19
4.2 Leveling ........................................................ 20
4.2.1 Lag Bolts................................................. 20
10. Operation ......................................... 54
10.1 Auto Mode Start-up .................................. 54
10.2 Table Rotation without Welding ............. 55
10.3 Home in Auto Mode ................................. 56
5. Utilities (Power) ................................. 21
11. Troubleshooting .............................. 57
12. Appendix .......................................... 59
5.1 Main Power Input ........................................ 21
6. Work Table ......................................... 22
7. System Safety Devices...................... 23
12.1 Prog0001.rpg - Main Program ................. 59
12.2 Prog0200.rpg – Sweep Table .................. 60
12.3 Prog0100.rpg – Home .............................. 60
12.4 SWEEP A TO ROBOT.rpg ........................ 61
12.5 SWEEP B TO ROBOT.rpg ........................ 61
12.6 Go Home.rpg............................................. 62
12.7 Tip Change.rpg ......................................... 62
12.8 TCP Check.rpg ......................................... 63
12.9 Weld A.rpg ................................................ 63
12.10 Weld B.rpg .............................................. 64
7.1 Emergency Stop Buttons ........................... 23
7.1.1 Operator Station Emergency Stop ......... 23
7.1.2 Teach Pendant Emergency Stop ........... 23
7.1.3 Table Brake Release Emergency Stop .. 24
7.2 Door Switches ............................................. 25
7.3 Table Position Switches ............................. 27
7.4 Light Curtains .............................................. 28
7.4.1 LED Indicators ........................................ 28
7.5 Awareness Barrier ...................................... 29
13. Parts List .......................................... 65
14. Warranty........................................... 67
15. RIA Risk Assessment ..................... 68
8. Robot Settings ................................... 30
8.1 Tool Center Point (TCP) ............................. 30
8.2 Home Cube .................................................. 31
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Safety
1. Safety Precautions – Read Before Using (som 2013-09)
Protect yourself and others from injury – read, follow and save these important safety precautions and operating instructions.
1.1 Symbol Usage
DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are
shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
 Indicates special instructions.
This group of symbols means: Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT
PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1.2 Arc Welding Hazards
The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is
only a summary of the more complete safety information found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or severe burns. The electrode and work circuit is electrically live whenever
the output is on. The input power circuit and machine internal circuits are also live when power is on. In semiautomatic or automatic
wire welding, the wire, wire reel, drive roll housing, and all metal parts touching the welding wire are electrically live. Incorrectly
installed or improperly grounded equipment is a hazard.
•
Do not touch live electrical parts.
•
Wear dry, hole-free insulating gloves and body protection.
•
Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact
with the work or ground.
•
Do not use AC output in damp areas, if movement is confined, or if there is a danger of falling.
•
Use AC output ONLY if required for the welding process.
•
If AC output is required, use remote output control if present on unit.
•
Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such as floors, gratings, or scaffolds; when in cramped
positions such as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the work
piece or ground. For these conditions, use the following equipment in order presented: 1) a semiautomatic DC constant
voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most
situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone!
•
Disconnect input power or stop engine before installing or servicing this equipment. Lockout/tagout input power according
to OSHA 29 CFR 1910.147 (see Safety Standards).
•
Properly install, ground, and operate this equipment according to its Owner’s Manual and national, state, and local codes.
•
Always verify the supply ground − check and be sure that input power cord ground wire is properly connected to ground
terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet.
•
When making input connections, attach proper grounding conductor first − double-check connections.
•
Keep cords dry, free of oil and grease, and protected from hot metal and sparks.
•
Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged –
bare wiring can kill.
•
Turn off all equipment when not in use.
•
Do not use worn, damaged, undersized, or repaired cables.
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Safety
•
•
•
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Do not drape cables over your body.
If earth grounding of the workpiece is required, ground it directly with a separate cable.
Do not touch electrode if you are in contact with the work, ground, or another electrode from a different machine.
Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will
be present.
Use only well-maintained equipment. Repair or replace damaged parts at once. Maintain unit according to manual.
Wear a safety harness if working above floor level.
Keep all panels and covers securely in place.
Clamp work cable with good metal-to-metal contact to workpiece or worktable as near the weld as practical.
Insulate work clamp when not connected to workpiece to prevent contact with any metal object.
Do not connect more than one electrode or work cable to any single weld output terminal. Disconnect cable for process
not in use.
Use GFCI protection when operating auxiliary equipment in damp or wet locations.
•
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•
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SIGNIFICANT DC VOLTAGE exists in inverter welding power sources AFTER removal of input power.
•
Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
•
•
•
Do not touch hot parts bare handed.
Allow cooling period before working on equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health.
•
Keep your head out of the fumes. Do not breathe the fumes.
•
If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. The
recommended way to determine adequate ventilation is to sample for the composition and quantity of fumes and gases to
which personnel are exposed.
•
If ventilation is poor, wear an approved air-supplied respirator.
•
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings,
cleaners, consumables, coolants, degreasers, fluxes, and metals.
•
Work in a confined space only if it is well ventilated, or while wearing an air-supplied respirator. Always have a trained
watch-person nearby. Welding fumes and gases can displace air and lower the oxygen level causing injury or death. Be
sure the breathing air is safe.
•
Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with
vapors to form highly toxic and irritating gases.
•
Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the
weld area, the area is well ventilated, and while wearing an air-supplied respirator. The coatings and any metals
containing these elements can give off toxic fumes if welded.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin.
Sparks fly off from the weld.
•
Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays
and sparks when welding or watching (see ANSI Z49.1 and Z87.1 listed in Safety Standards).
•
Wear approved safety glasses with side shields under your helmet.
•
Use protective screens or barriers to protect others from flash,glare and sparks; warn others not to watch the arc.
•
Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
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Safety
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc.
The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects
can cause sparks, explosion, overheating, or fire. Check and be sure the area is safe before doing any welding.
•
Remove all flammables within 35 ft (10.7 m) of the welding arc. If this is not possible, tightly cover them with approved
covers.
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Do not weld where flying sparks can strike flammable material.
•
Protect yourself and others from flying sparks and hot metal.
Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent
•
areas.
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Watch for fire, and keep a fire extinguisher nearby.
Be aware that welding on a ceiling, floor, bulkhead, or partition can cause fire on the hidden side.
•
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Do not weld on containers that have held combustibles, or on closed containers such as tanks, drums, or pipes unless
they are properly prepared according to AWS F4.1 and AWS A6.0 (see Safety Standards).
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Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline).
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Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long,
possibly unknown paths and causing electric shock, sparks, and fire hazards.
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Do not use welder to thaw frozen pipes.
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Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Wear body protection made from durable, flame−resistant material (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
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Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding.
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After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames.
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Use only correct fuses or circuit breakers. Do not oversize or bypass them.
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Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B for hot work and have a fire watcher and extinguisher
nearby.
FLYING METAL or DIRT can injure eyes.
Read and understand the Safety Data Sheets (SDSs) and the manufacturer’s instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
•
Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, they can throw off slag.
•
Wear approved safety glasses with side shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
•
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Shut off compressed gas supply when not in use.
Always ventilate confined spaces or use approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices.
•
•
Wearers of Pacemakers and other Implanted Medical Devices should keep away.
Implanted Medical Device wearers should consult their doctor and the device manufacturer before going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating operations.
NOISE can damage hearing.
•
•
Noise from some processes or equipment can damage hearing.
Wear approved ear protection if noise level is high.
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Safety
CYLINDERS can explode if damaged.
Compressed gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas cylinders are normally
part of the welding process, be sure to treat them carefully.
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•
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Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks,
and arcs.
Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder − explosion will result.
Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain
them and associated parts in good condition.
Turn face away from valve outlet when opening cylinder valve. Do not stand in front of or behind the regulator when
opening the valve.
Keep protective cap in place over valve except when cylinder is in use or connected for use.
Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
Read and follow instructions on compressed gas cylinders, associated equipment, and Compressed Gas Association
(CGA) publication P-1 listed in Safety Standards.
1.3 Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
•
•
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Do not install or place unit on, over, or near combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
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Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories.
Use equipment of adequate capacity to lift and support unit.
If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when
manually lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
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•
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Allow cooling period; follow rated duty cycle.
Reduce current or reduce duty cycle before starting to weld again.
Do not block or filter airflow to unit.
FLYING SPARKS can injure.
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Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body
protection.
Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
•
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Put on grounded wrist strap BEFORE handling boards or parts.
Use proper static-proof bags and boxes to store, move, or ship PC boards.
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Safety
MOVING PARTS can injure.
•
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Keep away from moving parts.
Keep away from pinch points such as drive rolls.
WELDING WIRE can injure.
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Do not press gun trigger until instructed to do so.
Do not point gun toward any part of the body, other people, or any metal when threading welding wire.
BATTERY EXPLOSION can injure.
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Do not use welder to charge batteries or jump start vehicles unless it has a battery charging feature designed for this
purpose.
MOVING PARTS can injure.
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Keep away from moving parts such as fans.
Keep all doors, panels, covers, and guards closed and securely in place.
Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when maintenance is finished and before reconnecting input power.
READ INSTRUCTIONS.
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•
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Read and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety
information at the beginning of the manual and in each section.
Use only genuine replacement parts from the manufacturer.
Perform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local
codes.
H.F. RADIATION can cause interference.
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High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment.
Have only qualified persons familiar with electronic equipment perform this installation.
The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the equipmentat once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep spark gaps at correct setting, and use grounding and
shielding to minimize the possibility of interference.
ARC WELDING can cause interference.
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Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer-driven
equipment such as robots.
Be sure all equipment in the welding area is electromagneticallycompatible.
To reduce possible interference, keep weld cables as short as possible, close together, and down low, such as on the
floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded according to this manual.
If interference still occurs, the user must take extra measures such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
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Safety
1.4 California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects
and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive
harm. Wash hands after use.
1.5 Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1, from Global
Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Combustibles, American Welding Society Standard AWS A6.0, from Global
EngineeringDocuments (phone: 1-877-413-5184, website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas Association, 14501 George Carter Way, Suite 103,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 5060 Spectrum
Way, Suite 100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website: www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 25
West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot Work, NFPA Standard 51B, from National Fire Protection Association, Quincy,
MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q, and
Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954 (phone:
1-866-512-1800) (there are 10 OSHA Regional Offices— phone for Region 5, Chicago, is 312-353-2220, website: www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600 Clifton Rd,
Atlanta, GA 30333 (phone: 1-800-232-4636, website: www.cdc.gov/NIOSH).
American National Standard for Industrial Robots and Robot Systems – Safety Requirements, ANSI/RIA R15.06-2012, Robotic Industries
Association, 900 Victors Way, Suite 140, Ann Arbor, Michigan, 48108, USA (phone: 734-994-6088, web-site: www.robotics.org).
Robotic Industries Association Technical Report – supplement to ANSI/RIA R15.06-2012, RIA TR 15.406-2014, Robotic Industries Association, 900
Victors Way, Suite 140, Ann Arbor, Michigan, 48108, USA (phone: 734-994-6088, web-site: www.robotics.org).
Electrical Standard for Industrial Machinery, NFPA Standard 79, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-7703000, web-site: www.nfpa.org).
Safety Standard for Robots and Robotic Equipment, UL 1740, Underwriters Laboratory (UL), (phone: 1-888-595-9844, web-site:
www.ulstandards.ul.com). Panasonic UL certification (TETZ.E173188) can be found here: http://database.ul.com/cgibin/XYV/template/LISEXT/1FRAME/showpage.html?name=TETZ.E173188&ccnshorttitle=Robots+and+Robotic+Equipment&objid=1075388022&cf
gid=1073741824&version=versionless&parent_id=1073993560&sequence=1#PAGEBOTTOM.
Industrial robots and robot systems, CAN/CSA-Z434, Canadian Standards Association (CSA), Toronto, ON, Canada M9W 1R3 (phone: 800-4636727, web-site: www.csa.ca).
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Safety
1.6 EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting, and induction heating operations) creates an EMF field around the welding circuit. EMF
fields may interfere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For
example, restrict access for passers−by or conduct individual risk assessment for welders. All welders should use the following procedures in order
to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a cable cover.
2. Do not place your body between welding cables. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recommended.
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Safety
1.7 Hazard Labels/Warning Stickers
Indication labels have been placed on the system to announce some of those task hazards to the individual(s)
responsible for operation or maintenance. Below are the stickers that have been placed on the system to indicate
those hazards.
Sticker
DANGER
ROBOT IN USE
DANGER
DO NOT WATCH
ARC OF WELDER
WITHOUT PROPER
EYE PROTECTION
CAUTION
DO NOT SIT OR STAND
ON ANY WORCELL
COMPONENTS
DANGER
HIGH VOLTAGE
TURN OFF POWER BEFORE SERVICING
Main Disconnect
_________
3 phase
Description
Danger Robot In Use
DANGER! Motion of the robot can cause serious injury. Panasonic robots are
equipped collision detection capabilities that will stop the arm when it collides with
another object but there is still the possibility of an injury. This includes both teach
and auto operation.
Danger Do Not Watch the Arc of Welder Without Proper Eye Protection
Yellow door curtains are intended only to prevent arc flash to people working
around the system and are NOT adequate protection for direct viewing of the
welding arc. Use appropriate eye and skin protection if watching the robot during
normal welding operation.
Caution Do Not Sit Or Stand On Any Workcell Components
Sheet metal barriers and other system structures are intended to prevent operators
from entering areas around the robot that may become unsafe while the robot is in
motion. Sitting or standing on these components may either pose a hazard to
personnel or damage the system.
Danger High Voltage, Danger 120VAC Inside Panel
DANGER! Electric shock can kill! All PerformArc systems use high voltage
electricity to operate. High voltage power can kill or severely injure personnel. Only
trained personnel should service the system. Turn off all power to the PerformArc
system and lock out the electrical service before servicing any equipment.
DANGER
HIGH VOLTAGE
DISCONNECT POWER
BEFORE SERVICING
DANGER
120VAC
INSIDE
PANEL
DANGER
PINCH POINT.
KEEP FINGERS &
HANDS CLEAR OF
WIRE MESH WHEN
ROBOT IS IN
OPERATION.
Danger Pinch Point Keep Fingers & Hands Clear of Wire Mesh Doors
DANGER! Do not stick fingers or hands into or near the wire mesh doors while the
robot is in operation, injury to fingers or the hand can occur from collision with the
torch or welding wire. During normal operation the robot will follow a programmed
path; robots should be programmed to stay a safe distance from the door during
operation.
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Specifications
2. Specifications
Dimensions:
Frame length
Frame width
Frame height
Table rotation diameter
Table bolt pattern
Table load height (from floor)
Table payload per side
Table index method
Maximum fixture/part height (above
platen)
1
Machine weight
PA750S (PA112)
4,724mm (186”)
2,604mm (102.5”)
PA750SW (PA112W)
5130mm (202”)
3010mm (118.5”)
2,285mm (90”)
2743mm (108”)
2,337mm (92”)
30" x 20" at 14" from table centerline
786mm 30.95”
750lbs (159kg)
Robot Controlled Servo Power
12192mm (40”)
6800lbs (3091kg)
7200lbs (3273kg)
Electrical:
Please refer to system electrical documentation for input power requirements and recommended input fuse
size
Compressed Air: Optional Add-On
Optional nozzle cleaner
90-120 PSI, dried and lubricated compressed air
Notes:
1. Machine weight is approximate and may vary depending on the configuration and optional equipment.
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Specifications
2.1 Dimensions
2.1.1 PA750S Front View
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Specifications
2.1.2 PA750S Side View
2.1.3 PA750S Top View
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Specifications
2.2.1 PA750SW Front View
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Parts and Identification
2.2.2 PA750SW Side View
2.2.3 PA750SW Top View
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Parts and Identification
3. Parts Identification
Robot Manipulator
Main Disconnect
(Fuse Box)
Slave Receiver
Light Curtain
Spool Holder
Auto-Axcess
Power Supply
External Axis
Brake Release Box
Figure 3a – Left Side
Turntable
Master Receiver
Light Curtain
PLC Cabinet
Main Disconnect
(Fuse Box)
Robot Controller
Main Power
Transformer
Figure 3b – Back View
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Parts and Identification
Slave Emitter
Light Curtain
Master Emitter
Light Curtain
Robot Controller
Figure 3c – Right Side
Operator Station
Figure 3d – Front
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Moving and Locating
4. Moving and Locating
The PerformArc PA750S and PA750SW systems are constructed as single frame structures capable of being
moved as a single unit. This not only makes moving the system easy, it also means a quick startup time once the
machine is placed. Power, air, welding wire, and welding gas are generally all that are required to have the
system ready to program and run production.
A 12,000 pound (5455 kg) capacity fork truck is recommended for safely moving and lifting the PA750S system
due to the system weight being offset from either end of the system.
A 14,000-15,000 pound capacity fork truck is recommended for moving the PA750SW systems (heavier, longer
frame).
4.1 Lifting With a Forklift
Fork pockets are provided on the front and the rear of the system. The pockets are rectangular tube with inside
dimensions of 7.25” wide x 3.25” high and run the full length of the system. If shipping the system by open flatbed
trailer, it is recommended that chains be passed through these tubes and secured to the trailer at both ends.
WARNING:
The PerformArc 750S/750SW system is not designed to be lifted from the side. Lifting from the
side may result in damage to the system. Lift from the provided fork pockets at the front and rear
of the system before attempting to lift from either side. If side lifting is unavoidable, verify the
forks can safety support the system across both main support tubes (shown as the fork pockets
in the following illustrations).
4.1.1 Front Fork Pockets
At the front of the system, the pockets are seen as two
rectangular openings at the base of the system. Take care to
avoid running the forklift mast into the circular awareness barrier
around the work table.
4.1.2 Rear Fork Pockets
The same fork openings seen at the front of the system are at
the base of the rear of the system. The pockets/openings run
the length of the system.
Note:
In some system configurations cables such as the torch (+)
cable and/or cooling water hoses may extend beyond the
system base. Use care to avoid hitting or pinching these cables
and/or hoses when lifting with a forklift.
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Moving and Locating
4.2 Leveling
Leveling the system once it is located is recommended if the floor is uneven or has a significant slope. The robot
will tolerate a few degrees off of flat level but system components like the doors could tend to slide open or closed
if the system is not level. Six leveling brackets are provided on the system with holes for lag bolts. See the
diagram below for bracket locations.
Figure 4.2 Leveling Brackets
4.2.1 Lag Bolts
For minimal vibration during robot movement it is recommended that the system be lag bolted to the floor. Bolt
the system to the floor using the six leveling brackets shown in figure 4.2. A 5/8” hole is already drilled through
the leveling bracket; select a lag bolt that will fit through the 5/8” thru hole on the system and use shims as
needed under the leveling brackets.
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Utilities
5. Utilities (Power)
Three-phase power is needed for PerformArc systems. The preferred input power should be specified at the time
the system is ordered so the system can be properly configured to the electrical service to be provided where the
system will be used.
5.1 Main Power Input
Each system is equipped with a main power disconnect/fuse box that is properly sized for that specific system’s
electrical configuration. Transformers are provided with the system when necessary to bring the supplied voltage
within the specifications required by the robot and other system components.
Connect 3-phase power to the system at the disconnect/fuse box located on the back of the system. Figure 5.1
shows the location of the disconnect/fuse box.
The robot system is not phase dependent (meaning the incoming power phases do not need to be ordered
correctly for the system to operate).
See the system heavy electrical documentation for power requirements.
.
Figure 5.1 – Main Power
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Work Table
6. Work Table
A flat plate is provided on the A and B sides of the system turn table for a welding tool, fixture, or jig to be bolted
to. Four holes come pre-drilled and tapped for M12x1.75 bolts. Holes are spaced as shown in Figure 6.
Flat head screws or a similar tapered style head fastener is recommended to help locate tools and fixtures in the
same location every time the tool is installed. Dowel pins are recommended, two 12 mm holes have been
provided for dowel pins (see Figure 6).
Note:
Each side is rated for a maximum of 750 lbs combined weight of tooling and parts. Do not exceed the rated
capacity of the table.
Figure 6 – Work Table Dimensions
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System Safety Devices
7. System Safety Devices
Several safety devices have been installed in the system to protect both personnel working around the system
and the robotic equipment in the system. It is strongly recommended that personnel check for proper operation of
the safety devices on a regular basis.
7.1 Emergency Stop Buttons
Three emergency stop buttons are provided on all PerformArc PA750S welding cells. These are latching type
switches that stay in the “pressed” position until the button is twisted to release the latch.
7.1.1 Operator Station Emergency Stop
At the top of the operator station is a large mushroom type E-stop push
button.
• Press the E-stop button in to stop all robot functions and turn off robot
servo power.
• Twist the red portion of the button clockwise to release the emergency
stop condition and allow servo power to be turned back on. The button
should “pop” out when the button is turned.
Note:
Spare Emergency Stop - This message will typically appear on the robot
teach pendant screen when the operator station E-stop button is pressed.
The message can be cleared from the pendant screen by pressing the Enter
or Cancel buttons on the teach pendant but the emergency stop will remain
active and prevent servo operation until the emergency stop button is
released.
Figure 7.1.1 - Operator
Station E-Stop
7.1.2 Teach Pendant Emergency Stop
The robot teach pendant has an emergency stop push
button in the upper right corner of the pendant.
• Press the E-stop button in to stop all robot functions
and turn off robot servo power.
• Twist the red portion of the button clockwise to
release the emergency stop condition and allow servo
power to be turned back on. The button should “pop”
out when the button is turned.
Note:
TP Emergency Stop – This message will appear on the
robot teach pendant screen when the teach pendant
emergency stop button is pressed. The message can be
cleared from the pendant screen by pressing Enter or
Cancel but the emergency stop will remain active and
prevent servo operation until the emergency stop button is
released.
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Figure 7.1.2 – Teach Pendant E-Stop
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System Safety Devices
7.1.3 Table Brake Release Emergency Stop
The table brake release is mounted to the robot riser at
the back of the robot on the left side of the cell. Below is
the procedure for braking/releasing the brake on the
positioner in case the positioner has accidentally
pinched someone during rotation
• Press the E-stop button in to stop all robot
functions and turn off robot servo power.
• Twist the red portion of the button clockwise to
release the emergency stop condition and allow
servo power to be turned back on. The button
should “pop” out when the button is turned.
Note:
Panel Emergency Stop – This message will appear on
the robot teach pendant screen when the teach pendant
emergency stop button is pressed. The message can
be cleared from the pendant screen by pressing Enter or
Cancel but the emergency stop will remain active and
prevent servo operation until the emergency stop button is
released.
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Figure 7.1.3 – Table Brake Release E-Stop
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System Safety Devices
7.2 Door Switches
The PA750S/PA750SW systems come equipped with two sliding wire mesh doors, one on the left and one on the
right side of the system. Each door is equipped with a magnetic key used to identify if the doors are fully closed or
fully opened.
Left Door
Right Door
Figure 7.2a – Sliding Doors
Figure 7.2b – Magnetic Key Switch (door)
Note:
Inputs 13, 14, and 15 relate to door position status based on switch contact. See section 8.4.1 Robot Inputs for
further details regarding door open/closed inputs.
DANGER
Closing the doors while inside the system with power on can
create a potentially dangerous situation.
Use the LOCK OUT/TAG OUT whenever
entering the robot system. Holes to insert
a lock out lock are provided at both
doors, look for the LOCK OUT/TAG OUT
sticker next to the lock out location.
LOCK OUT/
TAG OUT
INSTALL
LOCK HERE
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System Safety Devices
The sliding wire mesh doors on the left and right sides of the PerformArc system are tied into the robot safety
circuit using keyed magnetic switches. The “switches” are mounted to the frame of the system and remain
stationary. The key that actuates the switch is mounted to the sliding door and moves with the door.
• In Auto Mode, both doors must be closed and the key must align within a few millimeters or the switch to
properly engage the switch and allow robot servo power.
• A RED LED indicates that the switch is too far from the key or not properly aligned.
• A GREEN LED indicates the switch and key are correctly aligned and close enough together to complete
the safety circuit.
• In teach mode, the message "Dead man switch stop, Please grip the dead man switch again." will appear
if the doors are not both fully open with the door switches made. Ensure that doors are fully open and switch
is made
• In auto mode, operate mode confirm (auto button on the operator station) will not occur until both doors a
closed with the door closed switches made.
Fully closed door
Door Closed Switches
Door Open Switches
Figure 7.2c – Door Closed/Open Switches
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System Safety Devices
7.3 Table Position Switches
Table position safety switches mounted on the top of the arc screen work together with the light curtains to
identify the table’s position.
Note:
External Emergency Stop - The table position switches work together with the systems light curtains. If the table is
in position and the switch is made, the light curtains are ignored and the operator can walk in to load parts. If the
table is out of position and no connection is made on the table position switch, the light curtains are active and
walking through the curtains will cause an external emergency stop.
Side A Switch
(indicates side A is at
the robot).
Side B Switch (indicates
side B is at the robot).
Figure 7.3 – Table Position Switches
Note:
Picture shows the optional "Tool Safe" configuration which provides separate A and B switches. A standard
system will only have one table in position switch.
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Robot Settings
7.4 Light Curtains
The PA750S is equipped with light curtains that are intended to protect personnel from unexpected table rotation.
These light curtains are only active when the table in position switch (see above) is not made.
7.4.1 LED Indicators
The light curtain unit is equipped with LED indicators to show power on and the current state. Refer to the
Tapeswitch Guardstar B technical manual for troubleshooting details.
All Light Curtain Units:
• Orange/Amber = power to the sticks is “ON.”; all sticks.
Master Receiver:
• Green = lights are clear and aligned
• Red Steady = light curtain obstructed or not aligned
• Diagnostic Display = shows the beam number that is obstructed
Master Emitter:
• Red Steady = test outputs open (refer to the electrical drawings for
the system)
•
Red Blinking = error state; light curtain faulty
Slave Emitter
Slave Receiver
Master Receiver
Master Emitter
Figure 7.4a – Left Light Curtains (emitter)
Figure 7.4b – Right Light Curtains (receiver)
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Robot Settings
7.5 Awareness Barrier
The awareness barrier (yellow hoop, figure 7.5) inside the cell represents the sweep area of the table. This is for
both machine safety and for personnel safety:
•
•
Robot should be clear of this area whenever the table sweeps from one side to the other,
People should not enter the area inside the awareness barrier when robot power is on.
DANGER
Sitting or standing inside the awareness barrier with robot servo
power on can be dangerous!
Sitting on or standing inside the awareness barrier creates a pinch
point between the barrier and the table. If the table moves
unexpectedly it can pinch, crush, or trap a person.
It is strongly recommended that the awareness barrier remain in
place, but if programming cannot be effectively completed from
outside the barrier it is better to remove it than to stand inside.
Figure 7.5 – Awareness Barrier
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Robot Settings
8. Robot Settings
PerformArc systems have many settings that are configured when the system is assembled and most of these are
one-time settings that will never need to be changed. This section is intended to introduce a few key concepts
that will make basic operations and troubleshooting much easier to understand. This is not a comprehensive list
of all of the settings that each system may have.
8.1 Tool Center Point (TCP)
The tool center point (TCP) definition tells the robot where the end of the torch is - the point where welding occurs
(at least under ideal conditions). These values are not only critical to good path accuracy of the robot but are also
used in determining when the robot is in a “cube monitor”. Cube monitors are explained in the next two sections
so it is important to have a general understanding of the robot’s TCP before continuing on to the home cube and
clear work cubes.
Standard torches from manufacturers such as
®
®
Tregaskiss and Binzel typically have dimensions
that are close to the standard Panasonic torch TCP
values. If the exact torch dimensions are not know,
start with the default Panasonic values (select the
“Default” box in the tool menu).
To view the TCP values go to:
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Robot Settings
8.2 Home Cube
“Home” is a position the robot moves to that is clear of the part, tooling, and rotation of the table. PerformArc
systems use a robot feature called cube monitor to determine if the robot is at the home position. The cube
monitor compares the current XYZ position of the tool center point (TCP) with a programmed XYZ range; when
the current position is within the programmed monitoring range the cube monitor can turn on a robot output that
lets the system know the robot is at the home position.
Figure 8.2a is an example of a home cube: when the
TCP is within the cube, represented by the red box, a
robot output turns on telling the system the robot is at
the home location.
Figure 8.2a
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Robot Settings
8.2.1 Home - Cube Monitor 1
It is highly recommended that users do not change the factory settings for cube monitor 1 but it may be necessary
to view those settings when a torch with a different tool center point (TCP) definition is installed. In some cases, a
torch that is significantly longer or shorter than the original equipment torch may have a TCP that falls outside the
factory set cube 1 monitor.
To view the cube monitor settings go to:
Set > Advanced > Area Monitor > Cube Monitor
IMPORTANT:
The home cube (cube monitor #1) must be defined
as a space that will keep the robot clear of the
table during the table index. If the cube needs to
be modified for any reason follow the guidelines
below:
• Verify that the robot position will clear the
main sweep arc screen.
• Add ±25mm to each X position value and
±50mm to each Y and Z value to get a
range to enter into the table.
Figure 8.2.1 – Home Cube
8.2.2 Robot Home Output
Home position is indicated on the robot teach pendant as robot output #1. To display the outputs on the teach
pendant go to:
View > Display Change > Display I/O Terminal
> List (Terminal Name)
The robot user inputs and outputs will be displayed on
the right side of the teach pendant screen; Home will
be the first output listed. When there is a green box
next to the output, that output is ON.
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Robot Settings
8.3 Clear Work Cube
There is a second cube monitor set up in the robot that defines a much larger cube called “clear of work”. This
cube is tied to the HOME selection of the operator station. When the robot TCP is within this cube the robot is
considered safe to go directly home.
Settings for the clear work cube, cube monitor #2, are much more flexible than the home cube monitor and may
need to be changed based on the size of the fixture/part presented to the robot.
Caution:
When modifying this cube keep in mind
that this cube represents an area above
or behind the fixture/tool that is safe for
the robot to move at high speed back to
the home position.
Figure 8.3a Clear Work Cube
To view or change the clear work cube settings (cube monitor #2) go to:
Set > Advanced > Area Monitor > Cube
Monitor
IMPORTANT:
The values shown in figure 8.3b are the factory
settings. As stated earlier in this section, the
values for P1 and P2 may need to be modified if
the part or fixture on the either side of the table
extends into the cube area – this could create an
unsafe condition for the manipulator.
Figure 8.3b Cube Monitor 2
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Robot Settings
8.4 Inputs & Outputs
Robot inputs and outputs are critical to running the PerformArc 750 S system and understanding where to view
these and what they mean can make running and
troubleshooting the system much easier.
To view the inputs and outputs in either auto or teach mode
go to the following teach pendant menu selections:
View > Display Change > Display I/O Terminal
> List (Terminal Name)
In teach mode there is also an I/O monitor that can be used to view the same information. To use the I/O
monitor find the icon at the top of the teach pendant screen and click the thumbwheel on it. The “Display I/O
terminal” window should open on the right side of the screen.
Figure 8.4b – I/O Monitor
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Robot Settings
8.4.1 Robot Inputs
Input signals from the different buttons and safety devices let the robot know what operation to perform, what side
of the turntable is at the robot, and when it is safe for the robot to start moving. The following list covers the basic
inputs to the robot (optional equipment inputs are not covered here).
Input #
1
2
3
4
5
6
Name
Strobe
Master
Home
Sweep
I1#0005
Tip Chg
7
Rsv Cnl
8-12
13
Drs Open
14
LDrClsd
15
RDrClsd
16
A@Robot
Description
Signal needed to read in auto operation program inputs (Auto, Home, Sweep)
Program select for program Prog0001.rpg - main program for auto operation
Program select for program Prog0100.rpg - send the robot home program
Program select for program Prog0200.rpg - rotate the table program
Spare (used with the optional BCD selector)
Tip change reset: this resets the tip change counter in the welder setup and is
wired from robot output #4. Output #4 is triggered "ON" by program logic in the Tip
change.rpg program.
Program reserve cancel is turned on when the operator enters the light curtain.
This input only affects pending programs and not the currently running program.
Not used with the standard system configuration
Both Doors Open. Right and left doors must be fully open for this indicator to turn
on. Both doors must be open to enable servo power in teach mode.
Left Door Closed - Left from the operator load/unload position. This input will turn
on when the left door is fully closed and the magnetic switch & key are aligned.
Right Door Closed - Right from the operator load/unload position. Similar to the
Left Door Closed, the right door must be closed with the magnetic switch & key
aligned to turn this input ON.
Side A at robot. The table position switch indicating side A of the main sweep is at
the robot is on (this is the magnetic key mounted to the top of the table arc
screen). If the A@Robot or B@robot switch does not align with a table position
key, the robot will stop when the light curtain is obstructed (external emergency
stop).
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Robot Settings
8.4.2 Robot Outputs
Robot outputs tell the robot when to run a tip change and activate let the system know when the robot is clear of
the work and at the home position.
Output #
1
Name
@ Home
2
ClrWork
3
Tip Chng
Description
Used in cube monitor #1; this output turns on when the TCP is inside cube #1.
The robot is Home when this output is ON.
Used in cube monitor #2; this output turns on when the TCP is inside cube #2.
The robot is Clear of Work and safe to use the HOME selection on the
operator station when this output is ON.
Tip Change required; this output is set in the Set > Arc Welding > Default
welder > Tip Change function and turns on when a specified count, time, or arc
start count is reached (default is 5 cycles in auto).
Set > Arc Welding > Welder 1 > OK
> Tip Change
4
Tip Rst
5
OPR Hold
6
A@Robot
7
B@Robot
Tip change reset output; this output resets the counter or timer in the tip
change function. This is turned on in the Tip Change program.
Operational hold output; this hold turns on when the robot stops during auto
operation due to a HOLD input or a robot error. A restart signal is needed to
resume operation.
Turns ON when the A side table is in the robot welding area of the system.
This output is tied to the E-axis range monitor (see the robot operations
manual for function details). The robot monitors the position of the G4 axis
table and turns on the output when the table is within the specified range for A
side at the robot (typically -0.03° to +0.03°).
Turns ON when the B side table is in the robot welding area of the system.
This output is tied to the E-axis range monitor (see the robot operations
manual for function details). The robot monitors the position of the G4 axis
table and turns on the output when the table is within the specified range for B
side at the robot (typically -179.97° to +180.03°).
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Robot Settings
8.5 Global Position Variables
A global position is a programmed point that can be used in any program. This makes a global position variable
very useful for sending the robot to points that are used frequently like sending the robot home, to the tip check
position, and to the tip change position. The biggest difference between these global position variables and a
local point (like the P1, P2, P3, etc that are in typical welding programs) is how they are programmed; these
points can NOT be changed from within a program.
Global variables typically used on PerformArc PA750S and PA750SW systems are:
•
•
•
Home – Home position
TCP Chk – Tool Center point check position
Tip Chg – Tip change position
8.5.1 Changing a Global Position by Teaching
Adding or changing a global position by moving the robot manipulator and storing the location can be done
through the EDIT pull-down menu. The robot must be in Teach mode but changing a global position can be done
while a program is open.
1. Go to the “Edit” pull-down menu.
2. Select “Global variable settings”.
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Robot Settings
3. Select “Robot position”.
4. A list of robot position variables will be displayed on the
screen.
• “Valid” indicated the variable is being used.
• “Invalid” means the variable is inactive and can be
assigned a new position.
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Teaching
9. Teaching
PerformArc systems are shipped with all of the necessary system programs already installed so end users only
need to program the welding that they want the robot to perform. This section makes recommendations and
outlines the programming structure; this manual is not intended to instruct users on the operation of the robot
teach pendant and explain the commands used in robot programs. Please refer to the robot operations manual
for specific information on using the teach pendant.
NOTICE:
It is strongly recommended that new robot users attend a robot basic operations training class
before attempting to create or modify programs on the PerformArc 750 S system. The robot can
potentially injure personnel or damage itself if not programmed properly.
Hold
9.1 Teach Mode
To teach new programs the robot must be in “Teach Mode”.
This means the key switch on the robot teach pendant needs
to be set to “Teach”.
It is recommended that the teach pendant Auto/Teach key
switch not be switched while the robot is actively running a
program. If you wish to interrupt auto mode operation, press
the HOLD button first, then turn the key switch to Teach.
Both doors must be fully opened when teaching the robot.
DANGER:
Failure to open both doors during teaching creates a potential pinch point between the
robot and the system door. Personnel may become trapped if the robot moves
unexpectedly and both doors are not open.
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Teaching
9.2 Pre-Teaching Checks
Teaching a robot to move around a part and do a little welding in the process is not really that difficult but there
are some things to keep in mind that will make the process easier.
9.2.1 Table Checks
The PerformArc PA750S and PA750SW systems are equipped with a turntable that can present two different
work surfaces to the robot. While the robot is welding on one side, an operator can be loading or unloading the
other side. This is a benefit for production but does introduce a few things to be checked before beginning a new
program or before touching up an existing program:
• Check the side of table currently facing the robot. Does the table side match the program?
• Verify the table is at the zero (A at robot) or 180 degree (B at robot) position before teaching or touch-up.
• Both sides of the table should be loaded as if the system was running production. This is typically not a
critical check but having the maximum 750 lbs on one side and no weight on the opposite side may cause a
slight deflection in the table surface that would not be present if both sides were loaded equally. Sitting on
the table could affect the amount of table deflection and the part location relative to the robot.
9.2.2 Robot Checks
Any time the an operator or programmer has an opportunity to stop the robot and enter the system is a good time
to look for normal wear that may need to be addressed, this is even more critical when a programmer is entering
the system to correct a weld or begin creating a new program. Failure to check the robot hardware before
touching up points could result in lost time.
• Robot torch alignment. Crashes happen and many times no adjustment is needed but it is good
programming practice to check the robot torch position against a fixed reference point to see if anything has
moved since the last time the robot was programmed. If it has, maybe correcting the hardware misalignment
will solve any welding problems.
• Safety holder/safety clutch condition. Spring loaded devices like a safety holder or a safety clutch save
torches and end effectors from damage but do wear out over time. Replacement is needed when the safety
holder no longer repeats back to the same position after deflecting. (This does not apply to robots using solid
mount torch holders.)
• Cables – the torch cable (whip), power cables, and liners sometimes get caught up on equipment inside
the system or against the walls of the system itself. Twisted cables cause short circuits or broken wires.
Welding wire liners forced to bend in a very small radius can keep wire from passing freely through the liner.
Replace or service any cable or liner that is visibly damaged or has reached the end of its useful service life.
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Teaching
9.3 System Programs
The following programs come pre-installed on the PerformArc system and handle system functions such as
sending the robot to Home position, running a tip change routine, and clamping and unclamping the table. In
most cases these programs should not be changed. With the exception of the programs “Weld A” and Weld B”,
modifying or deleting the system programs may make the system inoperable.
Examples of these programs are listed in the Appendix.
1
Program
Prog0001.rpg
2
Prog0100.rpg
3
Prog0200.rpg
5
6
7
Sweep A to Robot.rpg
Sweep B to Robot.rpg
Sweep Table.rpg
8
9
10
11
12
Go Home.rpg
Tip Change.rpg
TCP Check.rpg
Weld A.rpg
Weld B.rpg
Description
Main program called when the Mode Switch is set to “AUTO” and the
cycle start button is pressed. Calls the Sweep Table program and the
Weld A or Weld B program.
Home program called when the Mode Switch is set to “HOME” and the
cycle start button is pressed. Calls the Go Home program.
Sweep Table program called when the Mode Switch is set to “SWEEP
A/SWEEP B” and the cycle start button is pressed. Calls the Sweep
table program.
Sweeps side A to the robot.
Sweeps side B to the robot.
This is a generic sweep and will sweep the table 180° from the current
position. Calls Sweep A to Robot or Sweep B to Robot programs.
Sends the robot to the home position.
Sends the robot to the tip change position.
Sends the robot to the TCP pointer.
Calls the welding program for the part on table A.
Calls the welding program for the part on table B.
Table 8.3 – System Programs
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Teaching
9.3.1 System Program Structure
In Auto Mode, only programs using the “Prog” prefix followed by four digits can be initiated from an outside source
(such as a push button or a signal from a PLC). The main operating program in the PerformArc 750 S system,
Prog0001.rpg, is an example of this. It is possible to put every command needed to run, weld, clean the torch,
etc. into one of these programs but that would make programming the robot very complicated in some cases. By
breaking the program structure down into smaller, more manageable subprograms, teaching the robot is made
much easier as well as safer.
There are three programs that follow the
“ProgXXXX” pattern: Prog0001.rpg,
Prog0080.rpg, and Prog0100.rpg. These are
the only programs that can be started in Auto
Mode by pressing the cycle start button.
Selecting which of these programs is started
is done using the 3-position mode switch.
Note:
Programs with an “x” next to them are
protected and cannot be deleted or modified.
See the robot operations manual for
instructions on protecting and un-protecting
files.
Figure 9.3.1a – System Programs
When AUTO is selected on the Mode Switch and the cycle start button is pressed, the program “Prog0001.rpg” is
started. This program evaluates what side is at the robot and selects the appropriate sequence of subprograms.
Figure 9.3.1b shows the main program Prog0001.rpg.
CALL Weld A.rpg – The Weld A program is
where the welding program(s) for side A will
be inserted.
CALL Weld B.rpg – The Weld B program is
where the welding program(s) for side B will
be inserted.
Figure 9.3.1b – Prog0001.rpg
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Teaching
9.3.2 Putting Programs into Weld A & Weld B
Once a program is created to weld a part on the side A table that program needs to be inserted into the Weld
A.rpg program.
1. Go to the File pull-down menu.
If the red box does not appear anywhere along the icon
bar at the top of the screen, use the Window change
button to change the active area of the screen. It may be
necessary to press the button more than once.
2. Select Open > Program Files
3. Highlight the Weld A.rpg (or Weld B.rpg) program and
press ENTER or OK.
4. When the Weld A.rpg (or Weld B.rpg) opens there
should be at least two instructions: one CALL Tip
Change.rpg and one calls a welding program (or a demo
program in this case).
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Teaching
If additional program CALL instructions are in the program that is OK – the program can call as many programs
as needed to weld and parts that are presented to the robot on that table.
Note:
See the section on Tip Change later in this manual for changing whether the tip change program runs before or
after the welding program.
5. Highlight the CALL instruction that calls the test program
(or old welding program), make sure the
pendant is set to CHANGE the
instruction, and press the ENTER
button.
6. Use the “Browse” box to open a list of available
programs.
7. Select the welding file that will be running on that side
and press ENTER (or click OK).
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Teaching
8. The selected program should be listed in the File name
blank. Press ENTER or click on the OK box.
9. The new welding program should now be displayed in
the CALL statement.
10. Use the Change Window button to switch from the
programming window pane to the icon bar at the top of the
screen.
Go to File > Close.
11. Select “Yes” to save the changes.
The new welding program is now inserted into the Weld
A.rpg and should be ready to run production.
Selecting “No” will close the program without saving the
changes.
Selecting “Cancel” will cancel the closing of the program.
The program will remain open with all of the changes still
there.
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Teaching
9.3.3 Running Multiple Programs on One Side
The robot is not limited to running one welding program on side A or side B. This can be a useful feature if more
than one fixture is placed on one side of the table or if different parts running on the same fixture have different
welding needs (weld parameters, fewer or more welds, different weld locations, etc.).
1. Go to the File pull-down menu at the top of the screen
(use the Window Change button if you don’t see the red
box in the icon bar at the top of the screen).
Select Open > Program Files
2. Highlight the Weld A.rpg (or Weld B.rpg) program and
press ENTER or OK.
3. There should already be a couple of CALL instructions
listed in the program: a tip change program and a welding
program (or demo program). Programs will run in the order
they are called and adding commands to the Weld A/Weld
B happens AFTER the highlighted line, keep this in mind
when adding CALL instructions.
Before going to the next step, highlight the instruction line
that the new CALL instruction will come after.
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Teaching
4. Press the Window Change button to make the icon bar
at the top of the screen active (a red box should be visible).
Go to the Add Command.
5. Roll the thumbwheel down so the red box is on the Flow
icon.
6. A window should pop-up listing all of the flow control
commands. Select CALL and press ENTER or click on the
OK box.
7. When the CALL pop-up appears, go to the Browse box
and click the thumbwheel.
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Teaching
8. When the program list window appears, find the program
that will be added to Weld A. Press ENTER or click on the
program and click again to OK the selection.
9. The new program should now appear in the Call program
field. Press ENTER or click on the OK box.
10. There should now be an additional call statement in the
program that calls the program selected in the step 7 of the
above procedure.
At this point additional programs can be added (go back to
step 4) or the program can be closed and saved (go on to
the next step).
11. Go to the File pull-down menu and roll down to Close.
Select the Close icon by clicking the thumbwheel.
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Teaching
12. The robot will automatically ask an operator to save any
changes that were made to the program. Click the
thumbwheel on “Yes” or press the Enter key to save the
program changes.
Selecting “No” will close the program without saving
changes to the program.
Selecting “Cancel” will cancel the close and the program will
remain open with any changes/additions still in place.
Note:
Changes to the program can also be saved by selecting the Save icon in the File pull-down before closing the
program. Selecting Save manually saves all of the same information saved by going to Close, then saving at the
automatic prompt.
9.3.4 Tip Change
Programs Weld A and Weld B both have a program call for Tip Change.rpg. This program runs every time Weld
A or Weld B runs but the program instructions that move the robot to the tip change location are executed only
after the specified count has been reached.
The tip change program uses a built-in
function under the Arc Welding menu called
Tip Change that counts the number of times
the tip change program runs and notifies the
robot when the preset count has been
reached.
The factory setting for tip change is to run the
tip change program every 5 times the Tip
Change.rpg program is called – or every five
cycles with the factory programming.
Figure 9.3.4 – Tip Change Program Call
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Teaching
Changing the Tip Change Count
1. Go to the Set pull down menu and select Arc Welding.
2. Select the default welder (Typically Welder 1).
Note:
Some robot/welder configurations may have different menu
selection than those shown here.
3. The “Change method” window will appear. No changes
are needed here – do not change the default settings.
Select OK or press the Enter button.
4. Select Tip change.
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Teaching
5. Find the Program start count field. This number is how
many times the robot will count the Tip Change.rpg
program before turning on the output that tells the robot it
is time to run to the tip change location.
Change this value by rolling down to the field and clicking
the thumbwheel. A pop-up window
for number entry will appear.
Change the number and press the
Enter button.
Enter
6. Close out of the Arc Welding menus to return to the initial screen.
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Operation
9.3.5 TCP Check
A reference point and/or pointer is provided inside the system and can be used as a quick reference to verify the
torch and/or arm alignment. This can be a valuable tool to in determining if something has moved in a “crash”
(when the torch or arm collides with something solid in the system such as the tool, the part being welded, or the
system frame).
•
•
All systems will have a TCP check “hole” on the front of the TM/TL robots UA axis (TA robots did not have
this option).
System with the optional nozzle cleaner will have the TCP check hole on the robot and will also have
TCP Check on Robot UA Axis
TCP Check on Wire Cutter/Nozzle
Cleaner
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Operation
UA Axis TCP
All systems with TM or TL robots will have a TCP check location on the front of the UA axis of the robot. There
will be a small machined block with a hole attached to the robot casting as shown in the picture below.
To check the TCP:
1. Install a new contact tip on the torch.
2. Check the welding wire stick-out length (typically 1215mm) and straightness of the wire. Consistency is
more important than how straight the wire is; a natural
“cast” or bend to the wire is acceptable as long as the
bend is consistent.
3. Open the TIP Check program (this may be called the
TCP Check Robot program on some systems).
4. Trace forward through the program to the step before
the TCP Chk point.
5. From this point forward be prepared to stop tracing if
the torch or wire looks like it will collide with the TCP
pointer.
6. Trace forward to the TCP Chk point.
7. If the wire aligns with the pointer all is good with the
robot and torch.
8. If the wire does not align with the pointer the torch may need straightening or adjustment, or it is possible
that the robot origin position is no longer correct.
9. If the wire aligns with the pointer but the part program is still not tracing or running correctly the tool or
parts to be welded may not be repeating correctly.
Nozzle Cleaner TCP
On systems equipped with the optional Tregaskiss nozzle cleaner,
the tool center point (TCP) pointer will be mounted on top of the
nozzle cleaner.
Use the same procedure to check this TCP pointer as the TCP
check on the robot, systems with both check locations will typically
have two TCP check programs:
• TCP Check or TCP Check Reamer – this will be the
program for the TCP check location on the nozzle cleaner.
• TCP Check Robot – this should be the
program for the TCP “hole” on the robot UA
axis.
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Operation
10. Operation
The PA750S and PA750SW systems are operated from the front of the system using the operator station push
buttons. In most cases welding operation only requires the operator to load a part to be welded, press the “start”
push button, and rotate the table.
IMPORTANT:
All personnel that will be operating the system must be familiar with the safety features of
the system and know how to stop the robot in the case of an emergency.
10.1 Auto Mode Start-up
Once the weld programs are set to run in the Weld A and Weld B programs (section 9.3.2) follow the steps below
to run the robot automatically.
1. Check that he table in position switch is made – both visually and by checking the LOAD/UNLOAD
indicator light on the operator station. When table switch contact is made, the LOAD/UNLOAD indicator
should be illuminated.
2. Close both doors.
3. Turn the teach pendant key switch to Auto.
4. Press the AUTO MODE pushbutton on the operator station (the auto mode light should
turn on).
5. Press the SERVO ON pushbutton on the operator station (the servo on light should
turn on).
Step 4
6. Turn the MODE SWITCH to AUTO.
(ROBOT HOME should already be lit from step #1)
Step 5
7. Load and secure the part for welding.
8. Press the CYCLE START push button. This will reserve the next cycle.
Step 6
9. The table will automatically rotate 180° and begin welding.
The operator can "reserve" the next cycle while the robot is running/welding - this means the
operator does not need to wait for the robot to finish running before pressing the cycle start
button. When robot finishes its current task, it will automatically sweep the table and start
welding the next part.
Step 8
Note:
The reserved cycle will cancel if the operator re-enters the light curtain.
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Operation
10.2 Table Rotation without Welding
To rotate the table without welding the steps will be the same as for the Auto Mode start-up with the exception of
the MODE SWITCH must be set to SWEEP A/SWEEP B.
1. Check that he table in position switch is made – both visually and by checking the LOAD/UNLOAD
indicator light on the operator station. When table switch contact is made, the LOAD/UNLOAD indicator
should be illuminated.
1. Close both doors.
Auto.
2. Turn the teach pendant key switch to
3. Press the AUTO MODE pushbutton on the operator station (the auto mode light should
turn on).
4. Press the SERVO ON pushbutton on the operator station (the servo on light should turn
on).
5. Turn the MODE SWITCH to SWEEP A/SWEEP B.
Step 4
(ROBOT HOME should already be lit from step #1)
6. Press the CYCLE START push button.
Step 5
7. The table will automatically rotate 180° and begin welding.
Step 6
Note:
The table will stop if the light curtain is entered during a sweep, and the recovery procedure if the
table stops during a sweep is to clear the light curtain, press the SERVO ON button, and press
the CYCLE START button.
Step 7
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Operation
10.3 Home in Auto Mode
The robot can be sent to the home position automatically by selecting the HOME selection on the MODE
SWITCH. Sending the robot to the home position in auto mode will only work if the robot is in the clear work cube
(see section 8.3 Clear Work Cube).
1. Verify the robot is clear of the part and fixture
inside the cell. It is recommended to check
both visually and by checking the Clr Work
indicator on the teach pendant I/O Terminal
display.
To display the I/O Terminal display:
View > Display Change > Display I/O Terminal
> List (Terminal Name)
Figure 10.2.1 – Clr Work Output
2. Close both doors.
3. Turn the teach pendant key switch to Auto.
Step 4
4. Press the AUTO MODE pushbutton on the operator station (the auto mode light should
turn on).
Step 5
5. Press the SERVO ON pushbutton on the operator station (the servo on light should turn
on).
Step 6
6. Turn the MODE SWITCH to HOME.
7. Press the CYCLE START push button.
8. The robot should automatically move to the HOME position.
Step 7
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Trouble Shooting
11. Troubleshooting
This troubleshooting list addresses only potential system problems and does not cover the robot error and alarm
codes. For a comprehensive list of robot errors see the robot operations manual.
Problem
External Emergency
Stop
Probable Cause
Table not in position (side A at the robot
or side B at the robot) AND the robot is
not at the HOME position.
Remedy
1. Move the table so that side A or
side B is completely toward the robot.
It may be necessary to run Sweep A
or Sweep B program in program test
mode.
2. Chek the table position safety
switches (roller switches).
Door Stop (only occurs
in Auto Mode)
One or both of the swing doors is not
closed.
Panel Emergency Stop
Operator station emergency stop push
button is pressed.
The robot is not in Auto Mode
Auto Mode pushbutton
will not light green when
pressed
Servo On pushbutton
will not light green when
pressed
Robot servo power is not turned on
Table Load/Unload
indicator at the operator
station is not lit
Turntable is not in position; the
magnetic key on the arc screen is not
aligned with the magnetic switch.
Robot will not run the
HOME program from the
operator station.
Robot is not in the Clear Work Cube
3. Check the robot HOME safety
switch (magnetic switch mounted to
the RT axis of the robot).
Check the door switches. Switch and
key need to be aligned and the LED
on the switch should be lit green
when the door is closed.
Twist the emergency stop button at
the operator station to release it.
Check the key switch on the robot
teach pendant. Set the key to AUTO.
1. Make sure the robot is in AUTO
mode and there are no error or
emergency stop messages on the
robot teach pendant screen.
2. Try pressing the servo ON button
on the robot teach pendant. If servo
power can be turned on here, verify
the program start method is set to
“Auto”.
1. Open and trace the Sweep A or
Sweep B program in the robot teach
pendant.
1. Change the teach pendant display
to show user inputs and outputs and
verify that output #2 Clr Work has a
green box next to it (go to “View” >
“Display Change” > “Display In/Out
terminal”).
If the robot is not in the clear work
cube either manually move the robot
up and away from the part/fixture or
open the Go Home program and trace
the robot home.
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Trouble Shooting
Robot will not run the
Sweep Table program
from the operator station
Robot is not HOME
Robot will not run the
Auto program from the
operator station
The PLC needs to see 5 conditions met
before it will allow a start.
1.
2.
3.
4.
5.
Robot home,
Robot in auto,
Robot servo power ON,
Light curtains OK, and
Table in position.
Weld A/Weld B program(s) are not
setup correctly
Run the “HOME” program from the
operator station or trace the Go Home
program. The green Home indicator
on the teach pendant I/O display
should be ON.
1. Check the 5 conditions:
•
•
•
•
•
Are the robot outputs ON
when viewed from the robot
teach pendant?
Are the green lights on the
operator station?
Light curtain LEDs OK?
Table position switch LEDs
OK?
Check the PLC to verify the
inputs are seen at the PLC:
o Home = X1
o Auto = X3
o Servo = X4
o Light Curtain = X6
o Table = X7
2. If the table turns but the robot
never moves – make sure Weld A.rpg
and Weld B.rpg have a welding
program called from them.
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Appendix
12. Appendix
12.1 Prog0001.rpg - Main Program
During normal production running of the system Prog0001.rpg is the program that is called every time the
operator presses the CYCLE START button at the operator station. This program evaluates what side is at the
robot and calls the appropriate table index program and welding program.
1
2
3
4
Program
Begin of Program
TOOL = 1:TOOL01
GETPOS GP#(3:Cur Pos)
CNVSET GI#(1:G4 Pos) =
GP.G4#(3:Cur Pos)
5
IF GI#(1:G4 Pos) = 0 THEN JUMP RSV
B ELSE NOP
6
IF GI#(1:G4 Pos) = 180 THEN JUMP
RSV A ELSE JUMP END
7
:RSV A
8
CALL Sweep A To Robot
9
RSV_PROG WELD A
10
JUMP END
11
:RSV B
12
CALL Sweep B To Robot
13
RSV_PROG Weld B
14
15
:END
End of Program
Description
Beginning of the program
Defines the tool TCP data that will be used for this program.
Read in the position of the G4 axis (turntable).
Convert the G4 position data to an integer value.
If the G4 position is 0°, then jump to label “RSV B” (line 11 in
this example), if position does not equal 0° then execute “no
operation” and continue to the next instruction (line 6).
If the G4 position is 180° then jump to label “RSV A” (line 7 in
this example), if the position does not equal 180° then jump to
the end of the program (label END).
Label “Reserve A Side”.
Open and run the “SWEEP A TO ROBOT” program; the main
program Prog0001 remains open in the background and when
“SWEEP A TO ROBOT” is done Prog0001 will resume running
and execute the next line.
Reserve the “Weld A” program; this means the Weld A
program goes into a queue that will wait until Prog0001 has
completed before running the next program, in this case, the
Weld A program.
Jump to the “END” label; jump over lines 11 thru 13 and go
directly to the end of the program. Lines 11, 12, and 13 are
ignored.
Label “Reserve B Side”.
Open and run program “SWEEP B TO ROBOT”; Prog0001
remains open in the background and will resume running when
SWEEP B TO ROBOT has completed.
Reserve the “Weld B” program; Weld B goes into a queue that
will begin running when Prog0001 has completed.
Label “END”.
End of the program.
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12.2 Prog0200.rpg – Sweep Table
Use the SWEEP A/SWEEP B program selection if the table needs to be indexed without running the robot. Turn
the selector switch at the operator station to the middle position, or SWEEP A SWEEP B, and press the CYCLE
START button to start this program.
Once started, program Prog0100.rpg will remain open and running until the table is rotated 180 degrees and
locked into the ready position. Notice that the program instructions are an abbreviated version of the
Prog0001.rpg program.
1
2
3
Program
Begin of Program
GETPOS GP#(3:Cur Pos)
CNVSET GI#(1:G4 Pos) =
GP.G4#(3:Cur Pos)
4
IF GI#(1:G4 Pos) = 0 THEN JUMP RSV
B ELSE NOP
5
IF GI#(1:G4 Pos) = 180 THEN JUMP
RSV A ELSE JUMP END
6
:RSV A
7
CALL Sweep A To Robot
10
JUMP END
11
:RSV B
12
CALL Sweep B To Robot
14
15
:END
End of Program
Description
Beginning of the program
Read in the position of the G4 axis (turntable).
Convert the G4 position data to an integer value.
If the G4 position is 0°, then jump to label “RSV B” (line 11 in
this example), if position does not equal 0° then execute “no
operation” and continue to the next instruction (line 6).
If the G4 position is 180° then jump to label “RSV A” (line 7 in
this example), if the position does not equal 180° then jump to
the end of the program (label END).
Label “Reserve A Side”.
Open and run the “SWEEP A TO ROBOT” program; the main
program Prog0001 remains open in the background and when
“SWEEP A TO ROBOT” is done Prog0001 will resume running
and execute the next line.
Jump to the “END” label; jump over lines 11 thru 13 and go
directly to the end of the program. Lines 11, 12, and 13 are
ignored.
Label “Reserve B Side”.
Open and run program “SWEEP B TO ROBOT”; Prog0001
remains open in the background and will resume running when
SWEEP B TO ROBOT has completed.
Label “END”.
End of the program.
12.3 Prog0100.rpg – Home
When the robot is in the Clear Work cube (cube monitor #2) the HOME selection on the operator station can be
used to send the robot to home position. “Home” position is programmed as a global position variable and can be
used in any robot motion program.
1
2
3
Program
Begin of Program
CALL Go Home
End of Program
Description
Beginning of the program.
Call the Go Home program.
End of the program.
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Appendix
12.4 SWEEP A TO ROBOT.rpg
Programs Prog0001.rpg and Prog0200.rpg call this program when it is time to index the table. Modifying this
program may cause the table to malfunction; it is strongly recommended that this program remain in its original,
as-delivered state.
1
2
3
4
Program
Begin of Program
CALL Go Home
MOVE GP#(1:A@Robot) 100.0%
DELAY 0.25s
5
End of Program
Description
Beginning of the program.
Call the Go Home program.
Move the table from 180° to 0°.
Delay for 0.25 seconds before ending the program. This delay
is used to keep the robot from moving out of the home cube
before the table position magnetic key has time to align with
the table at A switch.
End of the program
12.5 SWEEP B TO ROBOT.rpg
Programs Prog0001.rpg and Prog0200.rpg call this program when it is time to index the table. Modifying this
program may cause the table to malfunction; it is strongly recommended that this program remain in its original,
as-delivered state.
1
2
3
4
Program
Begin of Program
CALL Go Home
MOVEP GP#(2:B@Robot) 100.0%
DELAY 0.25 s
21
End of Program
Description
Beginning of the program.
Call the Go Home program.
Move the table from 0° to 180°.
Delay for 0.25 seconds before ending the program. This delay
is used to keep the robot from moving out of the home cube
before the table position magnetic key has time to align with
the table at A switch.
End of the program
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Appendix
12.6 Go Home.rpg
The Go Home program sends the robot to the home position. It is good programming practice to send the robot
to the home position at the end of each program; calling the Go Home.rpg program or using the home global
variable position are good methods of sending the robot to home.
Use the “CALL Go Home.rpg” instruction to send the robot home only after programming the
robot to move to a location that is clear of obstructions. The robot will take the shortest path to
CAUTION:
the home position when the Go Home program is called and will not move around fixtures or
parts that may be in the way.
1
2
Program
Begin of Program
TOOL = 1:TOOL01
3
4
MOVEP GA#(1:Home) 10.00m/min
End of Program
Description
Beginning of the program.
Tells the robot what tool center point definition to use. This will
vary depending on the torch make and model.
Move to the global robot position #1 at 10.00 m/min.
End of the program.
12.7 Tip Change.rpg
1
2
Program
Begin of Program
TOOL = 1:TOOL01
3
IF o1#(3:Tip Chng) = OFF THEN JUMP
END ELSE NOP
4
5
MOVEP GA#(2:Tip Change)
10.00m/min
HOLD Tip Change
6
MOVEP GA#(1:Home) 10.00m/min
7
PULSE o1#(4:Tip Rst) T=0.50 s
8
9
:END
End of Program
Description
Beginning of the program.
Tells the robot what tool center point definition to use. This will
vary depending on the torch make and model.
Evaluate robot output #3: if the tip change counter has not
reached its preset count and the output is OFF then jump to
the label “END” (line 9 of the program), if the tip change
counter has reached its count and the output is ON then run
through the tip change routine (line 4 of the program).
Move to the global position variable for the tip change location
at 25.00m/min.
Hold all robot operations and display the message “TIP CHG”
on the teach pendant screen. (Robot waits for a restart signal
– press CYCLE START to restart)
Move to the global position variable for home position at
25.00m/min.
Turn on output #4 for 0.50 seconds then turn it off. The robot
will continue with the next step of the program while the 0.50
seconds is counted and the output is turned off.
Label “END”
End of the program.
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Appendix
12.8 TCP Check.rpg
1
2
Program
Begin of Program
TOOL = 1:TOOL01
3
4
5
6
MOVEP GA#(1:Home) 25.00m/min
MOVEP P001(0) 25.00m/min
HOLD Remove TCP Cover
MOVEL GA#(2:TCP Check) 3.00m/min
7
8
9
MOVEP P001(0) 25.00m/min
MOVEP GA#(1:Home) 25.00m/min
End of Program
Description
Beginning of the program.
Tells the robot what tool center point definition to use. This will
vary depending on the torch make and model.
Move to the global position variable for home position.
Move to the TCP Check approach point.
Move from home position toward the TCP pointer.
Move to the global position variable for the TCP Check
location.
Move to the TCP Check approach point.
Move to the global position variable for home position.
End of the program.
12.9 Weld A.rpg
The weld A program is called from the main program, Prog0001.rpg, to run the welding program on side A.
1
2
Program
Begin of Program
CALL DEMO
Description
Beginning of the program.
Call the DEMO program. The test program is for a
demonstration – replace this program with the welding
program that will be used in production.
If more than one program needs to run to complete a part, add
separate CALL instructions to call those additional programs.
3
CALL Tip Change
4
End of Program
Call the Tip Change.rpg program. This program is called every
cycle but has an internal counter built into it that will only
execute the tip change movement when the preset count has
been reached.
End of the program.
Note:
Some have asked if the Weld A program (and Weld B program) is necessary and why can they not just insert the
CALL statements from the Weld A program directly into the main program, Prog0001.rpg. Yes, that will work and
the system will run correctly with the welding program called directly from the main program, but this is not
recommended.
• Modifying the main program to run without the Weld A program creates more chances to accidentally
change or delete instructions from the main program which could result in the system not functioning
correctly.
• Miller technical support is familiar with the program structure outlined in this manual. While they can help
with customer created programs, troubleshooting system problems becomes much more difficult when the
main program structure is vastly different than a standard system.
PA750S Operations
Ver. 2.0
63
Appendix
12.10 Weld B.rpg
The weld B program is called from the main program, Prog0001.rpg, to run the welding program on side B.
1
2
Program
Begin of Program
CALL DEMO
Description
Beginning of the program.
Call the TEST.rpg program. The test program is for a
demonstration – replace this program with the welding
program that will be used in production.
If more than one program needs to run to complete a part, add
separate CALL instructions to call those additional programs.
3
CALL Tip Change
5
End of Program
Call the Tip Change.rpg program. This program is called every
cycle but has an internal counter built into it that will only
execute the tip change movement when the preset count has
been reached.
End of the program.
Note:
See section 12.9 Weld A.rpg for important notes regarding the weld B program.
PA750S Operations
Ver. 2.0
64
Parts List
13. Parts List
Item
1
Qty
1
Unit
Ea
2
1
Ea
3
1
Ea
4
5
Ea
5
3
Ea
6
2
Ea
7
1
Ea
8
3
Ea
9
4
Ea
10
11
1
1
Ea
Ea
12
2
Ea
13
1
Ea
14
15
16
1
0
3
Ea
Ea
Ea
17
18
19
2
2
5
Ea
Ea
Ea
20
4
Ea
21
22
1
2
Ea
Ea
23
24
7
2
Ea
Ea
25
1
Ea
26
1
Ea
Description
Cycle Start
Button
Program Selector
Switch
E-Stop Button
Push-twist
release
2 Across
mounting latch
N.C. Contact
block (2 across
only)
Auto Mode-Servo
On PB (green)
2 across
mounting
latch/24dc light
2 across
mounting
latch/24dc LED
N.O. Contact
block (2 across
only)
PLC DL05
Power Supply
24vdc
Center Jumper
10ea set
120vac Main
Input Fuse
250V, 2A FUSE
250V, 10A FUSE
MAIN FUSES 60
AMP
Relay Socket
Relays, 4 Pole
Magnetic Limit
Switch
Magnetic Limit
Switch Key
Safety Relay
Welding Curtains,
Yellow
Plastic Caps 3"
Door Handles
Doors &
Hardware
24" Master Light
Curtain
Part Number
800T-A1D1
800FMHM32
800FM-MT44
800F-ALM
Comments
30.5mm Flush head Green with 1
contact block
22.5 metal operator black wing
knob 3 position
22.5 metal operator 40mm
mushroom head red (E-STOP)
E-Stop, Auto Mode, Servo On,
Mode Switch and Load/Unload
Contact Block for 2 across N.C.
800F-X01
800FM-LF3
22.5 metal operator green flush
mount push button/Light
22.5 metal Pilot Light Load/Unload
800FM-P3
Manufacture
Allen-Bradley
Allen-Bradley
Allen-Bradley
Allen-Bradley
Allen-Bradley
Allen-Bradley
Allen-Bradley
800F-N3G
Mounting latch (Servo On) LED
Type
Allen-Bradley
800F-X10
Contact N.0. For servo on,auto
mode and Mode Switch
Allen-Bradley
D0-05DR
ML50.100
PLC 8 DC Inputs & 6 Relay Outputs
24vdc 2.15amp (AB#1606-XLP50E)
Auto Direct
Pulz
17627705
For wire terminals
Entrelec
CCMR015
13/32" x 1.5" 15amp Cartridge
Fuse, FU4
250V, 2A Fuse, Glass Tube, FU5
250V, 10A Fuse, Glass Tube, FU6
Main Fuses for Input H
Little Fuse
Little Fuse
Little Fuse
Little Fuse
Panasonic Safety PCB
Panasonic Safety PCB
Door & Table Switch
Omron
Omron
Mechan
Door & Table Switch
Mechan
Safety Relay for Table Limit Switch
53" x 83" Door Curtains, See
Drawing PDC001A
Cap inserts for 3" tubes
For WireCrafters Doors, Paint Grey
Banner
A. B. Kelly
312 002
314 010
FLSR 60
ID/600 VIND
PYF14A
MY4N-24DC
SS-R-2110M
SS-R-ACT
ES-FA-9AA
PDC001A
SQR-80MM
17135A41
PA-102SWCM
#0921M
PA750S Operations
Side Wire Doors & Hardware
Any
McMaster
Carr
WireCrafters
Mounted Horizontal
Tapeswitch
Ver. 2.0
65
Parts List
27
1
Ea
28
29
1
1
Ea
Ea
30
8
Ea
56" Slave Light
Curtain
Emitter Cable 30'
Receiver Cable
30'
Swivel Brackets
Mounted Vertical
#0925S
Tapeswitch
#0973
#0975
Tapeswitch
Tapeswitch
10401
Tapeswitch
PA750S Operations
Ver. 2.0
66
Warranty
14. Warranty
Miller Welding Automation
PerformArc Robotic Welding System
Warranty Information
Warranty Table:
This table consists of the warranty coverage periods for a variety of MWA supplied components.
Please consult this table prior to calling the service department or your integration partner with a warranty
claim.
Warranty Coverage Periods (Effective 1/1/2012)
1 year
3 Years
90 Days
Mig Inverter Welding Power Supplies
X
Mig Conventional Welding Power Supplies
X
X
Tig Welding Power Supplies
Robotic Wire Feeder
X
Robotic Torches
X
Wire Feeder Extension Cable
X
Remote Pendent
X
Remote Pendent Extension Cable
X
Ground Cable w/ Clamp
X
Gas Regulators
X
Dinse Connector
X
Ground Cable w/ Clamp
X
Panasonic Robots and Optional Hardware (i.e. Seam
X
Tracker)
Panasonic Welders built into Robot Controller (WG)
X
PerformArc Systems Components - Non Panasonic
Mfg.
warranty
terms and
conditions
PerformArc Systems Components - Customer
N/A
Supplied
*PerformArc systems warranty coverage begins
Warranty Registration Effective From 1/01/2012
from ship date to the MWA customer.
Revised 2/21/2012
*Robot warranty coverage begins from the ship
date to the MWA customer.
NOTE: Warranty terms and conditions are subject to change without notice.
PA750S Operations
Ver. 2.0
67
RIA Risk Assessment
15. RIA Risk Assessment
RISK ASSESSMENT REPORT
Company:
Location:
Date:
Miller Welding Automation
Carol Stream, IL
9/16/2015
Robot/Cell Identification:
Accomplished by:
PerformArc PA750S/PA750SW line of pre-engineered weld cells
MWA Engineering Department
Robot Manufacturer and Model Number:
Date of Manufacture:
Panasonic Robot: TA, TB, TM model arms with G3 controller
For PerformArc systems manufactured Jan2015 to present
Approved by:
Date:
Review/revision dates:
Eric North (MWA Engineer)
9/16/2015
Revision 1/reviewed 9/16/2015
General description of application (Narrative):
This is a risk assessment report for the PerformArc model PA750S and PA750SW robotic welding cells.
PerformArc PA750S/PA750SW cells have been designed for the safe opertaion of a Panasonic robot in a
production environment. The system has a single operator station and a single robot workspace. Production
personnel load unprocessed materials onto a rotation table that indexes the materials into the robot workspace.
The robot performs production tasks on the materials and indexes the task completed parts out to the original
load position for unloading by production personnel. During normal production tasks, there is no direct
interaction between the robot and operator. In cases where direct interaction is needed, for programming or
maintenance tasks, the robot can only operate under direct control from personnel using the robot teach
pendant; motor power cannot be turned on without personnel using the robot teach pendant.
General Comments:
PerformArc systems are manufactured as unapplied systems that may be used for a broad scope of applications.
Miller Welidng Automation (MWA) has made an effort to anitcipate the most common uses of the robotic cell
and take these into account in this risk assessment.
Important: Tooling, fixtures, and other equipment added to the robotic cell after delivery may change the type
and number of hazards present in and around the PerformArc system. A review of the safety and another risk
assessment should be made after installation of any additional equipment to the robotic cell.
The Panasonic robots used in PerformArc sysetms are manufactured to UL/CSA standards; UL certification
TETZ.E173188. Click here to go to the UL website.
All standards and codes applicable to RIA standards were used in this risk assessment including:
1. RIA Technical Report, tr306_sac_ballot_draft20140226
2. ANSI/RIA R15.06-2012
3. NFPA 79
4. NEC (National Electric Code)
5. ANSI B
PA750S Operations
Ver. 2.0
68
RIA Risk Assessment
PA750S/PA750SW Risk Assessment Report
Exposure (E1,E2)
Avoidance (A1,A2,A3)
Risk Category
Exposure (E1,E2)
Avoidance (A1,A2,A3)
Severity (S1,S2, S3)
Risk Category
A
Severity (S1,S2, S3)
Sequence No.
Reference ANSI/RIA TR306_sac_ballot_draft_20140226.docx
Arc flash
S2
E2
A2
High
Solid metal wall construction
around the robot workspace,
colored vinyl door curtains on
wire mesh doors. Warning
stickers and hazard outlines in
operation manual.
Safeguarding, Warning and
Awareness Means,
Administrative Controls
E1
A2
S2
Low
Welding fumes/smoke
S1
E2
A1
Low
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace. Operation manual
warning.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Unexpected table and/or robot
motion (mechanical hazard crush, impact, stabbing)
S3
E1
A2
High
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace.
Safeguarding, Warning and
Awareness Means,
Administrative Controls
E1
A2
S3
Medium
Medium risk of finger/hand
injury if fingers are extended
through the wire mesh doors
into the robot work area and the
programmed robot path does
not leave adequate clearance for
fingers between the door.
Table motion (mechanical
hazard - crush)
S3
E2
A1
High
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the table (load side
access only). Light curtain and
table position switch interlock to
prevent motion while personnel
is inside the load area. Warning
signs installed. Safe usage
procedures outlined in the
operation manual.
Safeguarding, Warning and
Awareness Means,
Administrative Controls
E1
A1
S3
Low
Operator task
Process control and
monitoring
Cycle start (initiate automatic
operation sequence)
Hazard
Solution
PA750S Operations
Risk Reduction Measures
Residual Risk Level
Low risk of arc flash by
intentional, long term viewing of
the welding arc through the vinyl
door curtains.
Low.
Ver. 2.0
69
RIA Risk Assessment
Elimination, Safeguarding,
Warning and Awareness
Means, Administrative
Controls
E1
A1
S2
Negligible
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area.
Turntable delivers parts to the
robot workspace instead of
direct operator/robot
interaction. Safe usage
procedures outlined in the
operation manual. PPE
Elimination, Safeguarding,
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Neglible
High
Solid metal wall construction
around the robot workspace,
turntable delivers parts to the
robot workspace instead of
direct operator/robot
interaction, colored vinyl door
curtains on wire mesh doors. PPE
Elimination, Safeguarding,
Warning and Awareness
Means, Administrative
Controls, Personal Protective
Equipment
E1
A1
S1
Negligible
Negligible
Low
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safe
usage procedures outlined in the
operation manual.
Elimination, Safeguarding,
Administrative Controls
E1
A1
S2
Medium
Medium risk of finger/hand
injury if fingers and hand are
extended through openings
around the arc screen and table
into the robot work area into the
robot programmed path. This is
considered an intentional misuse
of the system and safety devices.
Medium Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the robot. Turntable
delivers parts to the robot
workspace instead of direct
operator/robot interaction.
Safety switches on doors to stop
automatic motion with doors
open (slow speed teach
capability only with doors open).
Warning signs installed. Safe
usage procedures outlined in the
operation manual.
Robot motion (mechanical
hazard - pinch/crush)
S2
E2
A1
Arc welding (thermal hazard)
S1
E2
A1
Low
Arc welding (radiation hazard arc flash)
S2
E2
A2
Welding wire/Torch
(mechanical puncture/stabbing)
S1
E2
A1
PA750S Operations
Medium risk of finger/hand
injury if fingers and hand are
extended through openings
around the arc screen and table
into the robot work area into the
robot programmed path. This is
considered an intentional misuse
of the system and safety devices.
Ver. 2.0
70
RIA Risk Assessment
B
Workpiece loading
Workpiece unloading
Welding fumes/smoke
S1
E2
A1
Low
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Table motion (mechanical
hazard)
S3
E2
A1
High
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the table (load side
access only). Light curtain and
table position switch interlock to
prevent motion while personnel
is inside the load area. Warning
signs installed. Safe usage
procedures outlined in the
operation manual.
Safeguarding, Warning and
Awareness Means,
Administrative Controls
E1
A1
S1
Negligible
Negligible
Welding fumes/smoke
S1
E2
A1
Low
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Table motion (mechanical
hazard)
S3
E2
A1
High
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the table (load side
access only). Light curtain and
table position switch interlock to
prevent motion while personnel
is inside the load area. Warning
signs installed. Safe usage
procedures outlined in the
operation manual.
Safeguarding, Warning and
Awareness Means,
Administrative Controls
E1
A1
S1
Neglible
Negligible
Hot parts (thermal hazard)
S1
E2
A2
Low
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safe
usage procedures outlined in the
operation manual.
Safeguarding, Administrative
Controls, Personal Protective
Equipment
E2
A1
S1
Negligible
Negligible
Welding fumes/smoke
S1
E2
A1
Low
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
PA750S Operations
Ver. 2.0
71
RIA Risk Assessment
C
Programming and verification
Medium Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the robot. Safety
switches on doors to stop
automatic motion with doors
open (slow speed teach
capability only with doors open).
Warning signs installed. Safe
usage procedures outlined in the
operation manual.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Low
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safe
usage procedures outlined in the
operation manual. Operator
training.
Safeguarding, Administrative
Controls, Personal Protective
Equipment
E1
A1
S1
Negligible
Negligible
A2
High
Solid metal wall construction
around the robot workspace,
colored vinyl door curtains on
wire mesh doors. Safe usage
procedures outlined in the
operation manual. Operator
training.
Safeguarding, Administrative
Controls, Personal Protective
Equipment
E2
A2
S1
Low
E1
A1
Low
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safe
usage procedures outlined in the
operation manual. Operator
training.
Safeguarding, Administrative
Controls, Personal Protective
Equipment
E1
A1
S1
Negligible
Negligible
S3
E1
A1
High
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the table (awareness
barrier/safety ring). Warning
signs installed. Safe usage
procedures outlined in the
operation manual.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
S1
E1
A1
Neglible
E1
A1
S1
Negligible
Negligible
Robot motion (mechanical
hazard - pinching, impact)
S2
E1
A1
Arc welding (thermal hazard)
S1
E1
A1
Arc welding (radiation hazard arc flash)
S2
E1
Welding wire/Torch
(mechanical puncture/stabbing)
S1
External axis motion
(mechanical - pinch/crush)
Tripping hazard
PA750S Operations
Low risk to a programmer, while
welding in test mode around the
robot and workpiece.
Ver. 2.0
72
RIA Risk Assessment
D
Brief operator intervention
not requiring disassembly
d1
Tip change
d2
d3
d4
Tungsten change
Nozzle cleaning
Wire change
E
Set-up (eg. Fixture changes,
tool changes)
F
Troubleshooting
Welding wire/Torch
(mechanical puncture/stabbing)
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training, personal
protection equipment.
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Negligible
Negligible
Welding wire/Torch (thermal
hazard - hot nozzle/tip)
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training.
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Negligible
Negligible
Mechanical hazard puncture/stabbing
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training.
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Negligible
Negligible
Thermal hazard - hot torch
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training.
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Negligible
Negligible
Welding wire/Torch
(mechanical puncture/stabbing)
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training.
Administrative Controls
E1
A1
S1
Negligible
Negligible
Welding wire/Torch (thermal
hazard - hot nozzle/tip)
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training.
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Negligible
Negligible
Welding wire/Torch
(mechanical puncture/stabbing)
S1
E2
A1
Low
Safe usage procedures outlined
in the operation manual.
Operator training.
Administrative Controls,
Personal Protective Equipment
E1
A1
S1
Negligible
Negligible
Mechanical hazard (tripping)
S1
E1
A1
Neglible
E1
A1
S1
Negligible
Negligible
Unapplied systems -no tooling
sold by MWA
Electrical hazard (shock,
electrocution, burn)
S3
E1
High
Troubleshooting to be performed
only by trained personnel.
Electrical panels locked out with
power on.
Safeguarding, Administrative
Controls, Personal Protective
Equipment
E1
A1
S1
Negligible
Negligible
Unexpected table and/or robot
motion (mechanical hazard crush, impact, stabbing)
S3
E1
High
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace. Interlocked doors to
enter workspace.
Troubleshooting to be performed
only by trained personnel.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Mechanical hazard (tripping)
S1
E1
E1
A1
S1
Negligible
Negligible
A1
Neglible
PA750S Operations
Ver. 2.0
73
RIA Risk Assessment
G
H
Correction of malfunction(s)
Equipment jams
Mechanical (stored energy)
S2
E1
Medium Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area.
Operator training.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Personal protective equipment
Negligible
Dropped parts (unapplied
system)
Mechanical (impact, cutting)
Event recovery (wire stick, no
arc, etc.)
Mechanical (crushing, stabbing,
cutting)
S2
E2
A2
High
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safety
interlock on doors. Operator
training.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Abnormal condition (process
issues - part burn thru)
Thermal hazard (burn)
S1
E1
A2
Low
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safety
interlock on doors. Operator
training. PPE.
Safeguarding, Administrative
Controls, Personal Protective
Equipment
E1
A1
S1
Negligible
Negligible
Nozzle clean jam
Stored energy/unexpected
motion
S2
E1
A2
Medium Solid metal wall construction
Safeguarding, Administrative
around the robot workspace,
Controls, Personal Protective
wire mesh doors, restricted
Equipment
access to the weld area. Safety
interlock on doors. Operator
training. Air filter/regulator shutoff valve. PPE.
E1
A1
S1
Negligible
Negligible
Control of hazardous energy
(including fixtures, clamps,
turntables and other
equipment)
Drive power
S3
E2
A2
High
Solid metal wall construction
around the robot workspace,
wire mesh doors, restricted
access to the weld area. Safety
interlock on doors. Operator
training.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Compressed air
S1
E2
A2
Low
Air filter/regulator shut-off valve.
Safeguarding
E1
A1
S1
Negligible
Negligible
Unintended motion
S3
E1
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace.
Safeguarding, Warnings and
Awarness Means
E1
A1
S1
Negligible
Negligible
High
PA750S Operations
Unapplied systems - no tooling
supplied by MWA
Ver. 2.0
74
RIA Risk Assessment
I
J
Maintenance and repair
Equipment cleaning
Electrical hazard (shock,
electrocution, burn)
S3
E1
High
Troubleshooting to be performed
only by trained personnel.
Electrical panels interlocked with
power on (power must be turned
off to access the panel). Lock
out/Tag out.
Administrative Controls
E1
A1
S1
Negligible
Negligible
Unexpected table and/or robot
motion (mechanical hazard crush, impact, stabbing)
S3
E1
High
Solid metal wall construction
around the robot workspace,
restricted access to the
workspace. Interlocked doors to
enter workspace. Lock out/Tag
out. Troubleshooting to be
performed only by trained
personnel.
Safeguarding, Administrative
Controls
E1
A1
S1
Negligible
Negligible
Mechanical hazard (tripping)
Ergonomic hazards (difficult
access)
S1
S1
E1
E1
A1
A1
Neglible
Neglible
E1
E1
A1
A1
S1
S1
Negligible
Negligible
Negligible
Negligible
Environmental hazards (dirt,
oil)
S1
E1
A1
Neglible
E1
A1
S1
Negligible
Negligible
Negligible
Negligible
Negligible
Mechanical hazard (tripping)
Ergonomic hazards (difficult
access)
S1
S1
E1
E1
A1
A1
Neglible
Neglible
E1
E1
A1
A1
S1
S1
Negligible
Negligible
Negligible
Environmental hazards (dirt,
oil)
S1
E1
A1
Neglible
E1
A1
S1
Negligible
PA750S Operations
Ver. 2.0
75
Warranty
PA750S Operations
Ver. 2.0
76