YASKAWA Motoman ArcWorld IV-6200 XHD DR2C User guide

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: [phone]
FAX: [phone]
24-Hour Service Hotline: [phone]
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Part Number: 147855-1
Release Date: June 17, 2003
Document Version: 1
Document Status: Final

The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.

MOTO MAN i ArcWorld IV-6200 XHD DR2C System Manual
TABLE OF CONTENTS
Section Page
LIST OF FIGURES...........................................................................................................................iv
LIST OF TABLES .............................................................................................................................v
1 INTRODUCTION
1.1 About this Document ....................................................................................................1-1
1.2 System Overview .......................................................................................................... 1-2
1.2.1 System Layout ................................................................................................ 1-3
1.2.2 Major Components ......................................................................................... 1-3
1.2.3 Optional Equipment ........................................................................................ 1-3
1.3 Reference to Other Documentation................................................................................ 1-4
1.4 Customer Service Information ......................................................................................1-4
2 SAFETY
2.1 Introduction .................................................................................................................. 2-1
2.2 Standard Conventions .................................................................................................. 2-2
2.3 General Safeguarding Tips............................................................................................ 2-3
2.4 Mechanical Safety Devices ...........................................................................................2-3
2.5 Installation Safety ......................................................................................................... 2-4
2.6 Programming Safety ..................................................................................................... 2-4
2.7 Operation Safety ........................................................................................................... 2-5
2.8 Maintenance Safety....................................................................................................... 2-6
3 EQUIPMENT DESCRIPTION
3.1 UP-series Robot Description ........................................................................................3-1
3.2 DR2C XRC 2001 Controllers – R1 and R2.................................................................... 3-1
3.2.1 Top-Mount External Axis Cabinet ...................................................................3-2
3.2.2 Playback Panel ............................................................................................... 3-3
3.2.3 Programming Pendant .................................................................................... 3-4
3.2.4 Brake Release ................................................................................................. 3-7
3.3 Operator Station............................................................................................................ 3-7
3.4 MRM2-750 S3X Positioner ..........................................................................................3-9
3.4.1 Welding Ground System ...............................................................................3-10
3.4.2 Locking Pins ................................................................................................. 3-10
3.4.3 Arc Shield ..................................................................................................... 3-10
3.5 Welding Equipment .................................................................................................... 3-11
3.5.1 Wire Feeder .................................................................................................. 3-11
3.5.2 GMAW Torch ................................................................................................ 3-11
3.5.3 Torch Mount ................................................................................................. 3-11
3.5.4 Power Sources .............................................................................................. 3-12
3.6 Safety Features ........................................................................................................... 3-13
3.6.1 Service Disconnect Switches ........................................................................ 3-13
3.6.2 Arc Screens .................................................................................................. 3-14
3.6.3 Fencing ......................................................................................................... 3-14

ArcWorld IV-6200 XHD DR2C System Manual ii MOTO MAN
Section Page
3.6.4 Safety Light Curtains .................................................................................... 3-14
3.6.5 ENABLE Switch ............................................................................................. 3-14
3.6.6 Interlocked Cell Door ....................................................................................3-15
3.6.7 Interference Cubes ........................................................................................ 3-15
3.6.8 Brake Release ............................................................................................... 3-15
3.6.9 Emergency Stops (E-STOPS) ........................................................................ 3-16
4 INSTALLATION
4.1 Materials Required........................................................................................................ 4-1
4.1.1 Customer-Supplied Items ............................................................................... 4-1
4.1.2 List of Tools .................................................................................................... 4-1
4.1.3 Cell Components ............................................................................................ 4-2
4.2 Site Preparation ............................................................................................................ 4-3
4.3 Shipment Inspection..................................................................................................... 4-4
4.4 Steps for Installation..................................................................................................... 4-4
4.5 Shipping/Leveling Bolts ............................................................................................... 4-4
4.6 Installing the Positioner................................................................................................ 4-5
4.6.1 Unpacking the Positioner ................................................................................ 4-5
4.6.2 Removing the Positioner Shipping Brackets ................................................... 4-5
4.6.3 Positioner Leveling ......................................................................................... 4-6
4.7 Installing the Robot Common Base............................................................................... 4-7
4.7.1 Removing the Robot Shipping Brackets – UP20/UP20-6 ...............................4-9
4.8 Installing the Programming Platforms ........................................................................4-10
4.9 Installing the Auxiliary Equipment Common Base ......................................................4-11
4.10 Connecting the Cables................................................................................................ 4-13
4.10.1 Cable Routing ............................................................................................... 4-13
4.10.2 Connecting the Earth Ground ........................................................................ 4-13
4.10.3 Connecting the Programming Pendant Cable ............................................... 4-14
4.10.4 Connecting the Welding Cables .................................................................... 4-14
4.10.5 Connecting the Positioner Air Line ............................................................... 4-16
4.10.6 Connecting the Robot Cables .......................................................................4-16
4.10.7 Connecting the Positioner Cables ................................................................. 4-18
4.11 Installing the Fence..................................................................................................... 4-19
4.11.1 Unpacking .................................................................................................... 4-19
4.11.2 Fence Wall Identification ............................................................................... 4-19
4.11.3 Locate Special Fence Posts ..........................................................................4-20
4.11.4 Installing Left Side of Fence .......................................................................... 4-20
4.11.5 Anchor Remaining Fence to Floor – Left Side ............................................... 4-24
4.11.6 Installing Right Side of Fence ....................................................................... 4-25
4.11.7 Anchor Remaining Fence to Floor – Right Side ............................................ 4-29
4.12 Installing the Cell Door............................................................................................... 4-29
4.13 Installing the Arc Curtains ..........................................................................................4-30

MOTO MAN iii ArcWorld IV-6200 XHD DR2C System Manual
Section Page
4.14 Installing the Light Curtain System............................................................................. 4-31
4.14.1 Light Curtain Installation .............................................................................. 4-31
4.14.2 Installing the Light Curtain Cable ................................................................. 4-32
4.15 Installing the Operator Station ....................................................................................4-33
4.15.1 Connecting the Operator Station ...................................................................4-33
4.16 Connecting the Power................................................................................................. 4-34
4.17 System Check – Before System Power Up.................................................................. 4-35
4.18 System Power Up .......................................................................................................4-35
4.19 Light Curtain Alignment/Fence Anchoring.................................................................. 4-35
4.19.1 Light Curtain Alignment ................................................................................ 4-35
4.19.2 Anchor Light Curtain Walls ........................................................................... 4-35
4.19.3 Installing the Swingarm Guards .................................................................... 4-36
4.20 System Check – After Power Up ................................................................................. 4-37
4.21 Installing the Tooling and Fixtures.............................................................................. 4-38
5 OPERATION
5.1 Programming................................................................................................................ 5-1
5.1.1 I/O Assignment ............................................................................................... 5-2
5.1.2 Sweeping the Positioner ................................................................................. 5-4
5.1.3 Rotating the Headstock ................................................................................... 5-4
5.1.4 Programming Specific Jobs ............................................................................ 5-5
5.2 Daily Operation............................................................................................................. 5-7
5.2.1 Start-Up .......................................................................................................... 5-7
5.2.2 Safety Circuit Check .......................................................................................5-8
5.2.3 Robot Safe (Cube 23 and Cube 24) Position ..................................................5-8
5.2.4 Selecting Weld Job (Initial Setup Only) ..........................................................5-9
5.2.5 Starting the Master Job ................................................................................... 5-9
5.2.6 Perform Operation Cycle ................................................................................. 5-9
5.2.7 Shutdown ..................................................................................................... 5-10
5.3 System Recovery ........................................................................................................ 5-10
5.3.1 Alarms and Errors ......................................................................................... 5-10
5.3.2 E-STOP Recovery ......................................................................................... 5-11
5.3.3 Shock Sensor Recovery ................................................................................ 5-12
5.3.4 Using the Brake Release ...............................................................................5-13
6 MAINTENANCE
6.1 Maintenance/Troubleshooting ...................................................................................... 6-1
6.1.1 Periodic Maintenance ..................................................................................... 6-1
INDEX

ArcWorld IV-6200 XHD DR2C System Manual iv MOTO MAN
LIST OF FIGURES
Figure Page
Figure 1-1 System Layout........................................................................................................... 1-2
Figure 3-1 DR2C XRC 2001 Controller – R1 and R2.................................................................. 3-1
Figure 3-2 External Axis Cabinet Components ........................................................................... 3-2
Figure 3-3 XRC 2001 Playback Panel.........................................................................................3-3
Figure 3-4 Programming Pendant .............................................................................................. 3-4
Figure 3-5 RS-232C Serial Port.................................................................................................. 3-6
Figure 3-6 Enable Switch............................................................................................................ 3-6
Figure 3-7 Operator Station Control Panel.................................................................................. 3-7
Figure 3-8 Available Power Sources.........................................................................................3-12
Figure 3-9 Service Disconnect Locations ................................................................................. 3-13
Figure 4-1 System Components................................................................................................. 4-2
Figure 4-2 Area Needed for Installation ...................................................................................... 4-3
Figure 4-3 Shipping/Leveling Bolts............................................................................................4-4
Figure 4-4 Floor Anchors ........................................................................................................... 4-5
Figure 4-5 Positioner Shipping Brackets.................................................................................... 4-6
Figure 4-6 Positioner Anchor Locations..................................................................................... 4-6
Figure 4-7 Robot Common Base Installation.............................................................................. 4-7
Figure 4-8 Robot Common Base Leveling Points....................................................................... 4-8
Figure 4-9 Location of Shipping Brackets................................................................................... 4-9
Figure 4-10 Install Programming Platforms................................................................................ 4-10
Figure 4-11 Unbolting Auxiliary Equipment Common (AEC) Base ............................................. 4-11
Figure 4-12 AEC Base Installation Location................................................................................ 4-12
Figure 4-13 Cable Routing ......................................................................................................... 4-13
Figure 4-14 Ground Welding Cable on Positioner......................................................................4-15
Figure 4-15 Positive and Negative Terminals on the Welding Power Source.............................. 4-15
Figure 4-16 Connecting the Controller to the Robot................................................................... 4-17
Figure 4-17 Positioner Interface Panel Installation ..................................................................... 4-18
Figure 4-18 Crated Fencing Skid................................................................................................ 4-19
Figure 4-19 Fence Wall Identification......................................................................................... 4-20
Figure 4-20 Left Side Fence Wall Assembly – Steps A and B..................................................... 4-21
Figure 4-21 Fence/Post Connections – Left Side ....................................................................... 4-21
Figure 4-22 Fence Anchor Points – Left Side............................................................................. 4-22
Figure 4-23 Left Fence Wall Assembly – Steps C through E ...................................................... 4-22
Figure 4-24 Connect Quick-Access Wall – Left Side.................................................................. 4-23
Figure 4-25 Left Fence Wall Assembly – Step F......................................................................... 4-24
Figure 4-26 Right Side Fence Wall Assembly – Steps A and B .................................................. 4-25
Figure 4-27 Fence/Post Connections – Right Side..................................................................... 4-26
Figure 4-28 Fence Anchor Points – Right Side........................................................................... 4-26
Figure 4-29 Right Fence Wall Assembly – Steps C through E.................................................... 4-27
Figure 4-30 Connect Quick-Access Wall – Right Side ............................................................... 4-28
Figure 4-31 Right Fence Wall Assembly – Step F....................................................................... 4-28

MOTO MAN v ArcWorld IV-6200 XHD DR2C System Manual
LIST OF FIGURES (continued)
Figure Page
Figure 4-32 Install Top Door Rail ............................................................................................... 4-29
Figure 4-33 Install Final Door Rail.............................................................................................. 4-30
Figure 4-34 Securing the Arc Curtains ....................................................................................... 4-30
Figure 4-35 Light Curtain Sensor Installation............................................................................. 4-31
Figure 4-36 Light Curtain Alignment/Cable Routing................................................................... 4-32
Figure 4-37 Operation Station Installation.................................................................................. 4-33
Figure 4-38 Anchoring the Light Curtain Fence.......................................................................... 4-36
Figure 4-39 Swingarm Guard Location....................................................................................... 4-36
Figure 4-40 Swingarm Guard Installation................................................................................... 4-37
LIST OF TABLES
Table Page
Table 3-1 Positioner Specifications ............................................................................................. 3-9
Table 4-1 Cable Connections .................................................................................................... 4-17
Table 5-1 XRC 2001 User Inputs ................................................................................................. 5-2
Table 5-2 XRC 2001 User Outputs ...............................................................................................5-3
Table 5-3 User Messages ..........................................................................................................5-11
Table 5-4 Alarm Messages ........................................................................................................5-11
Table 6-1 Periodic Maintenance .................................................................................................. 6-1

ArcWorld IV-6200 XHD DR2C System Manual vi MOTO MAN
NOTES

MOTO MAN 1-1 ArcWorld IV-6200 XHD DR2C System Manual
SECTION 1
INTRODUCTION
The ArcWorld IV-6200 XHD DR2C (Dual Robot, Two Controller) cell is part of
the ArcWorld family of standardized arc welding solutions. It is a fully integrated
welding system, and is supported from wire to weld by Motoman, Inc.
The ArcWorld IV-6200 XHD DR2C cell features two Motoman arc welding
robots, two XRC 2001 controllers with menu-driven arc welding application
software, two complete welding packages, a 180-degree reciprocating plane
positioner with two orbital servo axes, operator interface, and total safety
environment. The DR2C can be reconfigured from the dual robot system into two
separate robotic systems with independent control (see Motoman DR2C
Conversion Instructions, XRC 2001 (P/N146822-1). For more information, please
call the Motoman service staff at [phone].
1.1 About this Document
This manual is intended as an introduction and overview for personnel who have
received operator training from Motoman, and who are familiar with the operation
of these Motoman robot models. For more detailed robot information, refer to the
manuals listed in Section 1.3. This manual contains the following sections:
SECTION 1 - INTRODUCTION
This section provides general information about the ArcWorld IV-6200 XHD
DR2C and its components, a list of reference documents, and customer service
information.
SECTION 2 - SAFETY
This section provides information regarding the safe use and operation of the
ArcWorld IV-6200 XHD DR2C system.
SECTION 3 - EQUIPMENT DESCRIPTION
This section provides a detailed description of the major components of the
ArcWorld IV-6200 XHD DR2C system. This section also includes a table of
component specifications.
SECTION 4 - INSTALLATION
This section provides instructions for setup and installation of the ArcWorld IV-
6200 XHD DR2C system.
SECTION 5 - OPERATION
This section provides instructions for basic operation of the ArcWorld IV-6200
XHD DR2C system. This section also provides procedures for startup, loading,
normal operation, fault recovery, and shutdown.
SECTION 6 - MAINTENANCE
This section contains a table listing periodic maintenance requirements for the
components of the ArcWorld IV-6200 XHD DR2C cell.

INTRODUCTION
ArcWorld IV-6200 XHD DR2C System Manual 1-2 MOTO MAN
1.2 System Overview
The ArcWorld IV-6200 XHD DR2C provides a complete arc welding solution in a
standardized configuration. The system is designed around two Motoman arc
welding robots, two XRC 2001 controllers functioning as one, and includes two
complete welding packages. A dual-station, 180-degree reciprocating positioner
with rotating headstock allows an operator to prepare and set up parts on one side
while the robot welds on the other side. The cell provides a full complement of
safety features designed to protect both personnel and equipment. Figure 1-1
illustrates the system layout of the ArcWorld IV-6200 XHD DR2C cell.
Figure 1-1 System Layout
NOTE: This manual is for a standard Motoman system. If your system is a custom or modified system,
please use the drawing and Bill of Material (BOM) provided with the system for troubleshooting
and spares provisioning.
SAFETY
FENCE
LIGHT
CURTAIN
CELL DOOR
OPERATOR
STATION
POSITIONER
XRC 2001 R1
CONTROLLER
POWER
SOURCE
WELDER 2
POWER
SOURCE
WELDER 1

INTRODUCTION
MOTO MAN 1-3 ArcWorld IV-6200 XHD DR2C System Manual
1.2.1 System Layout
The robotic cell is fully enclosed by safety fencing and an interlocking door. If the
operator stands in the path of the light curtain, the positioner will not cycle. All
operator controls, including those on the XRC 2001 controllers and welding power
supplies, are accessible from outside the robotic enclosure.
The controllers and welding power sources share a common base. Additional
options, such as the water circulator and the Com-Arc seam tracking unit, can also
be located on this same auxiliary equipment common base.
1.2.2 Major Components
The ArcWorld IV-6200 XHD DR2C includes the following major components:
• Motoman UP6, UP20, or UP20-6 manipulators and XRC 2001 controllers
• MRM2-750 S3X dual-station, 180-degree reciprocating positioner, with two
servo-driven, orbital axes
• Master operator station
• Welding equipment, including the following:
• Welding power sources
• Motoman torches (water-cooled or air-cooled)
• Wire feeders
• Torch mounts
• Safety equipment, including the following:
• Safety fencing with arc curtains
• Interlocked light curtains
• Interlocked cell door
• Positioner arc shields
1.2.3 Optional Equipment
The following optional equipment is available for use with the ArcWorld IV-6200
XHD DR2C:
• Torch cleaner
• Com-Arc seam tracking unit
• Water circulator
• 12-channel slip ring kit
• High-volume air supply kit

INTRODUCTION
ArcWorld IV-6200 XHD DR2C System Manual 1-4 MOTO MAN
1.3 Reference to Other Documentation
For additional information refer to the following:
• Motoman UP6 Manipulator Manual (P/N 145960-1)
• Motoman UP20 Manipulator Manual (P/N 145965-1)
• Motoman UP20-6 Manipulator Manual (P/N 145962-1)
• Motoman MRM2-750 S3X Positioner Manual (P/N 147988-1)
• Motoman DR2C Conversion Instructions, XRC 2001 (P/N146822-1)
• Motoman Operator's Manual for Arc Welding (P/N 142098-1)
• Motoman Concurrent I/O Parameter Manual (P/N 147626-1)
• Com-Arc Instruction Manual (P/N 144075-1)
• Independent/Coordinated Motion Manual (P/N 142969-1)
• Vendor manuals for system components not manufactured by Motoman
1.4 Customer Service Information
If you are in need of technical assistance, contact the Motoman service staff at
[phone]. Please have the following information ready before you call:
• Robot Type (UP6, UP20, or UP20-6)
• Application Type (welding)
• System Type (ArcWorld IV-6200 XHD DR2C)
• Software Version (access using TOP MENU/SYSTEM INFO/VERSION/
SYSTEM on the programming pendant)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of controller)

MOTO MAN 2-1 ArcWorld IV-6200 XHD DR2C System Manual
SECTION 2
SAFETY
2.1 Introduction
.
We suggest that you obtain and review a copy of the ANSI/RIA National Safety
Standard for Industrial Robots and Robot Systems. This information can be
obtained from the Robotic Industries Association by requesting ANSI/RIA
R15.06. The address is as follows:
Robotic Industries Association
900 Victors Way
P.O. Box 3724
Ann Arbor, Michigan 48106
TEL: [phone]
FAX: [phone]
Ultimately, the best safeguard is trained personnel. The user is responsible for
providing personnel who are adequately trained to operate, program, and maintain
the robot cell. The robot must not be operated by personnel who have not been
trained!
We recommend that all personnel who intend to operate, program, repair, or use
the robot system be trained in an approved Motoman training course and become
familiar with the proper operation of the system.
This safety section addresses the following:
• Standard Conventions (Section 2.2)
• General Safeguarding Tips (Section 2.3)
• Mechanical Safety Devices (Section 2.4)
• Installation Safety (Section 2.5)
• Programming Safety (Section 2.6)
• Operation Safety (Section 2.7)
• Maintenance Safety (Section 2.8)
It is the purchaser's responsibility to ensure that all local, county,
state, and national codes, regulations, rules, or laws relating to
safety and safe operating conditions for each installation are met
and followed.

SAFETY
ArcWorld IV-6200 XHD DR2C System Manual 2-2 MOTO MAN
2.2 Standard Conventions
This manual includes information essential to the safety of personnel and
equipment. As you read through this manual, be alert to the four signal words:
• DANGER
• WARNING
• CAUTION
•NOTE
Pay particular attention to the information provided under these headings which
are defined below (in descending order of severity).
DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent hazards
that, if not avoided, will result in immediate, serious personal injury
or loss of life in addition to equipment damage.
WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential hazards that
can result in personal injury or loss of life in addition to equipment
damage.
CAUTION!
Information appearing under the CAUTION caption concerns the
protection of personnel and equipment, software, and data from
hazards that can result in minor personal injury or equipment
damage.
NOTE: Information appearing in a NOTE caption provides additional information which is helpful in
understanding the item being explained.

SAFETY
MOTO MAN 2-3 ArcWorld IV-6200 XHD DR2C System Manual
2.3 General Safeguarding Tips
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. General safeguarding
tips are as follows:
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
should be permitted to operate this robot system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the robot cell.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• In accordance with ANSI/RIA R15.06, section 6.13.4 and 6.13.5, use
lockout/tagout procedures during equipment maintenance. Refer also to
Section 1910.147 (29CFR, Part 1910), Occupational Safety and Health
Standards for General Industry (OSHA).
2.4 Mechanical Safety Devices
The safe operation of the robot, positioner, auxiliary equipment, and system is
ultimately the user's responsibility. The conditions under which the equipment
will be operated safely should be reviewed by the user. The user must be aware of
the various national codes, ANSI/RIA R15.06 safety standards, and other local
codes that may pertain to the installation and use of industrial equipment.
Additional safety measures for personnel and equipment may be required
depending on system installation, operation, and/or location. The following safety
measures are available:
• Safety fences and barriers
• Light curtains
• Door interlocks
• Safety mats
• Floor markings
• Warning lights
Check all safety equipment frequently for proper operation. Repair or replace any
non-functioning safety equipment immediately.

SAFETY
ArcWorld IV-6200 XHD DR2C System Manual 2-4 MOTO MAN
2.5 Installation Safety
Safe installation is essential for protection of people and equipment. The
following suggestions are intended to supplement, but not replace, existing federal,
local, and state laws and regulations. Additional safety measures for personnel and
equipment may be required depending on system installation, operation, and/or
location. Installation tips are as follows:
• Be sure that only qualified personnel familiar with national codes, local
codes, and ANSI/RIA R15.06 safety standards are permitted to install the
equipment.
• Identify the work envelope of each robot with floor markings, signs, and
barriers.
• Position all controllers outside the robot work envelope.
• Whenever possible, install safety fences to protect against unauthorized entry
into the work envelope.
• Eliminate areas where personnel might get trapped between a moving robot
and other equipment (pinch points).
• Provide sufficient room inside the workcell to permit safe teaching and
maintenance procedures.
2.6 Programming Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Programming tips are
as follows:
• Any modifications to PART 1 of the controller PLC can cause severe
personal injury or death, as well as damage to the robot! Do not make any
modifications to PART 1. Making any changes without the written
permission of Motoman will VOID YOUR WARRANTY!
• Some operations require standard passwords and some require special
passwords. Special passwords are for Motoman use only. YOUR
WARRANTY WILL BE VOID if you use these special passwords.
• Back up all programs and jobs onto a floppy disk whenever program changes
are made. To avoid loss of information, programs, or jobs, a backup must
always be made before any service procedures are done and before any
changes are made to options, accessories, or equipment.
• The concurrent I/O (Input and Output) function allows the customer to
modify the internal ladder inputs and outputs for maximum robot
performance. Great care must be taken when making these modifications.
Double-check all modifications under every mode of robot operation to
ensure that you have not created hazards or dangerous situations that may
damage the robot or other parts of the system.

SAFETY
MOTO MAN 2-5 ArcWorld IV-6200 XHD DR2C System Manual
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Inspect the robot and work envelope to be sure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Be sure that all safeguards are in place.
• Check the E-STOP button on the teach pendant for proper operation before
programming.
• Carry the teach pendant with you when you enter the workcell.
• Be sure that only the person holding the teach pendant enters the workcell.
• Test any new or modified program at low speed for at least one full cycle.
2.7 Operation Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Operation tips are as
follows:
• Be sure that only trained personnel familiar with the operation of this robot,
the operator's manuals, the system equipment, and options and accessories
are permitted to operate this robot system.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Inspect the robot and work envelope to ensure no potentially hazardous
conditions exist. Be sure the area is clean and free of water, oil, debris, etc.
• Ensure that all safeguards are in place.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.

SAFETY
ArcWorld IV-6200 XHD DR2C System Manual 2-6 MOTO MAN
2.8 Maintenance Safety
All operators, programmers, plant and tooling engineers, maintenance personnel,
supervisors, and anyone working near the robot must become familiar with the
operation of this equipment. All personnel involved with the operation of the
equipment must understand potential dangers of operation. Maintenance tips are
as follows:
• Do not perform any maintenance procedures before reading and
understanding the proper procedures in the appropriate manual.
• Check all safety equipment for proper operation. Repair or replace any non-
functioning safety equipment immediately.
• Improper operation can result in personal injury and/or damage to the
equipment. Only trained personnel familiar with the operation, manuals,
electrical design, and equipment interconnections of this robot should be
permitted to operate the system.
• Back up all your programs and jobs onto a floppy disk whenever program
changes are made. A backup must always be made before any servicing or
changes are made to options, accessories, or equipment to avoid loss of
information, programs, or jobs.
• Do not enter the robot cell while it is in automatic operation. Programmers
must have the teach pendant when they enter the cell.
• The robot must be placed in Emergency Stop (E-STOP) mode whenever it is
not in use.
• Be sure all safeguards are in place.
• Use proper replacement parts.
• This equipment has multiple sources of electrical supply. Electrical
interconnections are made between the controller, external servo box, and
other equipment. Disconnect and lockout/tagout all electrical circuits before
making any modifications or connections.
• All modifications made to the controller will change the way the robot
operates and can cause severe personal injury or death, as well as damage the
robot. This includes controller parameters, ladder parts 1 and 2, and I/O
(Input and Output) modifications. Check and test all changes at slow speed.
• Improper connections can damage the robot. All connections must be made
within the standard voltage and current ratings of the robot I/O (Inputs and
Outputs).

MOTO MAN 3-1 ArcWorld IV-6200 XHD DR2C System Manual
SECTION 3
EQUIPMENT DESCRIPTION
3.1 UP-series Robot Description
The Motoman UP6, UP20, and UP20-6 robots and the XRC 2001 robotic
controller represent state-of-the-art technology in robotics today. The six-axis UP6
robot has a payload of 6 kg (13.2 lbs). It features a 1,373-mm (54.05-inch) reach
and has a relative positioning accuracy of ± 0.08 mm (0.004 inch). The six-axis
UP20 robot has a payload of 20 kg (44.09 lbs). It features a 1658-mm (65.2-inch)
reach and has a relative positioning accuracy of ± 0.06 mm (0.002 inch). The six-
axis UP20-6 robot has a payload of 6 kg (13.2 lbs). It features a 1885-mm (74.21-
inch) reach and has a relative positioning accuracy of ± 0.06 mm (0.0023 inch).
Each robot can reach below its own base as well as behind itself and can be
mounted on the floor, wall, or ceiling with few modifications. However, the S-axis
has been restricted by hardstops for use in this system. For more information, refer
to the manipulator manual that came with your system.
3.2 DR2C XRC 2001 Controllers – R1 and R2
The DR2C (dual robot, two controller) XRC 2001 robotic controllers, shown in
Figure 3-1, features dual-channel safety circuitry. The controller coordinates the
operation of the ArcWorld IV-6200 XHD DR2C system and is configured so that
one controller directs the action of both robots, designated as Robot 1 (R1) and
Robot 2 (R2). The R1 controller coordinates the operation of the entire cell and
delegates tasks to both robots. Both welders (Welder 1 and Welder 2) and positioner
are also controlled by the R1 controller. The R1 controller controls manipulator
movement, processes input and output signals, and provides the signals to operate
the welding system. It maintains variable data and performs numeric processing to
convert to and from different coordinate systems. In addition, the controller
provides the following: main logic functions, servo control, program and constant
data memory, and power distribution. R2 is the slave controller controlled by R1
and has servo amplifier hardware. For more information, refer to the manipulator
manual that came with your system.
Figure 3-1 DR2C XRC 2001 Controller – R1 and R2
SERVO ON
READY
REMOTE
PLAY
(OFF) (ON)
TEACH
MODE EMERGENCYSTOP
EDIT LOCK ALARM
HOLD START
ON
TRIP
O
P
E
N
/
R
E
S
E
T
O
F
F
BRAKE
RELEASE
CONTROL
COMMUNICATIONS
CABLE
R2 R1
ON
TRIP
O
P
E
N
/
R
E
S
E
T
O
F
F
PLAYBACK BOX
TOP-MOUNT
EXTERNAL AXIS
CABINET
PROGRAMMIN
G
PENDANT
BRAKE
RELEASE
CONTROL
POWER
DISCONNECT

EQUIPMENT DESCRIPTION
ArcWorld IV-6200 XHD DR2C System Manual 3-2 MOTO MAN
DR2C Conversion
The DR2C can be reconfigured from the dual robot system, with the Master XRC
2001 controlling system operation, to two separate robotic systems with
independent control (see Motoman DR2C Conversion Instructions, XRC 2001 P/N
146822-1). For more information, please call the Motoman service staff at (937)
847-3200.
3.2.1 Top-Mount External Axis Cabinet
The external axis cabinet on the R1 controller contains the amplifiers and
converters for the servo motors on the positioner. See Figure 3-2 for external axis
cabinet components.
Figure 3-2 External Axis Cabinet Components
SPARE
DIN RAIL
S
SPARE
TERMINALS
POWER
CONVERTERS
3 kW
AMPLIFIER 2 kW AMPLIFIER
SPARE DIN
RAIL
BREAK-OUT BOARD
FOR ENCODER
MOTOR BRAKE
POWER TERMINAL