YASKAWA Motoman ArcWorld II-200 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: 147051-1
Release Date: August 15, 2002
Document Version: 2
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 II-200 System Manual
TABLE OF CONTENTS
Section Page
LIST OF FIGURES...........................................................................................................................iii
LIST OF TABLES ............................................................................................................................iii
1 INTRODUCTION
1.1 About this Document....................................................................................................1-1
1.2 System Overview ..........................................................................................................1-2
1.2.1 System Layout ................................................................................................1-2
1.2.2 Major Components .........................................................................................1-3
1.2.3 Optional Equipment ........................................................................................1-3
1.3 Reference to Other Documentation................................................................................1-3
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 XRC 2001 Controller ....................................................................................................3-1
3.2.1 Playback Panel ...............................................................................................3-2
3.2.2 Programming Pendant ....................................................................................3-3
3.2.3 Brake Release .................................................................................................3-6
3.3 Operator Station............................................................................................................3-6
3.3.1 Cycle Start ......................................................................................................3-6
3.3.2 AUTO/MANUAL ..............................................................................................3-7
3.3.3 Emergency Stop (E-STOP) ..............................................................................3-7
3.4 Barrier Assembly ..........................................................................................................3-7
3.4.1 Stationary Weld Tables ...................................................................................3-7
3.5 Safety Features .............................................................................................................3-8
3.5.1 Arc Screens ....................................................................................................3-8
3.5.2 Fencing ...........................................................................................................3-8
3.5.3 Emergency Stops (E-STOPS) ..........................................................................3-8
3.5.4 ENABLE Switch ...............................................................................................3-9
3.5.5 Interlocked Cell Door ......................................................................................3-9
3.5.6 Light Curtains .................................................................................................3-9
3.5.7 Brake Release .................................................................................................3-9

ArcWorld II-200 System Manual ii MOTO MAN
Section Page
3.6 Welding Equipment ......................................................................................................3-9
3.6.1 Power Sources ................................................................................................3-9
3.6.2 PWF4 Wire Feeder ........................................................................................3-11
3.6.3 Universal Welding Interface (UWI) ................................................................3-11
3.6.4 GMAW Torch ................................................................................................3-11
3.6.5 Motoman Torch Mount .................................................................................3-11
4 INSTALLATION
4.1 Materials Required........................................................................................................4-1
4.1.1 Customer-Supplied Items ...............................................................................4-1
4.1.2 List of Tools ....................................................................................................4-1
4.2 Site Preparation............................................................................................................4-2
4.3 Removal from Shipping Skid........................................................................................4-3
4.3.1 Unloading Procedures ....................................................................................4-3
4.4 Cell Components..........................................................................................................4-4
4.4.1 List of Components ........................................................................................4-4
4.5 Assemble Cell Components..........................................................................................4-5
4.5.1 Setting Up the Cell ..........................................................................................4-5
4.6 Leveling and Securing the Equipment...........................................................................4-5
4.7 Removing the Shipping Brackets/Bolts.........................................................................4-6
4.7.1 Robot Shipping Brackets Removal ..................................................................4-6
4.7.2 Positioner Shipping Bolts Removal ................................................................4-7
4.8 Connecting the Cables..................................................................................................4-8
4.8.1 Connecting the Earth Ground ..........................................................................4-8
4.8.2 Connecting the Robot Cables .........................................................................4-8
4.8.3 Connecting the Com-Arc III and the Wire Cutter (Optional) ............................4-9
4.8.4 Connecting Water Circulator (Optional) ..........................................................4-9
4.9 Connecting the Power.................................................................................................4-11
4.10 Conducting a Safety/Operation Check ........................................................................4-12
4.11 Installation of Tooling and Fixtures.............................................................................4-12
5 OPERATION
5.1 Programming................................................................................................................5-1
5.1.1 I/O Assignment ...............................................................................................5-1
5.2 Daily Operation.............................................................................................................5-3
5.2.1 Start-Up ..........................................................................................................5-3
5.2.2 Robot Home (Cube 24) Position .....................................................................5-3
5.2.3 Starting the Master Job ...................................................................................5-3
5.2.4 Perform Operation Cycle .................................................................................5-4
5.2.5 Shutdown .......................................................................................................5-4

MOTO MAN iii ArcWorld II-200 System Manual
Section Page
5.3 System Recovery ..........................................................................................................5-5
5.3.1 Alarms and Errors ...........................................................................................5-5
5.3.2 Error Messages ...............................................................................................5-5
5.3.3 Door Default Settings ......................................................................................5-5
5.3.4 Shock Sensor Recovery ..................................................................................5-6
5.3.5 E-STOP Recovery ...........................................................................................5-6
5.3.6 Using the Brake Release .................................................................................5-7
6 MAINTENANCE
6.1 Periodic Maintenance...................................................................................................6-1
INDEX
LIST OF FIGURES
Figure Page
Figure 1-1 System Layout...........................................................................................................1-2
Figure 3-1 XRC 2001 Controller.................................................................................................3-1
Figure 3-2 Controller Playback Panel.........................................................................................3-2
Figure 3-3 Programming Pendant..............................................................................................3-3
Figure 3-4 RS-232C Serial Port..................................................................................................3-5
Figure 3-5 Enable Switch............................................................................................................3-5
Figure 3-6 Operator Station........................................................................................................3-6
Figure 3-7 Available Power Sources.........................................................................................3-10
Figure 4-1 Area Needed for Installation......................................................................................4-2
Figure 4-2 Remove Shipping Bolts.............................................................................................4-3
Figure 4-3 System Components.................................................................................................4-4
Figure 4-4 Leveling Bolts...........................................................................................................4-6
Figure 4-5 Location of Robot Shipping Brackets........................................................................4-6
Figure 4-6 Location of Positioner Shipping Bolts.......................................................................4-7
Figure 4-7 Connecting Robot to the Controller...........................................................................4-9
Figure 4-8 Water Circulator Connections.................................................................................4-10
Figure 4-9 Incoming Power Connections.................................................................................4-11
LIST OF TABLES
Table Page
Table 3-1 Weld Table Specifications ............................................................................................3-7
Table 5-1 XRC 2001 User Inputs .................................................................................................5-2
Table 5-2 XRC 2001 User Outputs ...............................................................................................5-2
Table 6-1 Periodic Maintenance ..................................................................................................6-1

ArcWorld II-200 System Manual iv MOTO MAN
NOTES

MOTO MAN 1-1 ArcWorldII-200SystemManual
SECTION 1
INTRODUCTION
The ArcWorld II-200 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 II-200 features a Motoman arc welding robot and XRC 2001
controller with menu-driven arc welding application software, complete welding
package, two weld stations, operator interface, and total safety environment.
1.1 About this Document
This manual is intended as an introduction and overview for personnel who have
received operator training from Motoman, and who are familiar with the operation
of this Motoman robot model. For more detailed information, refer to the manuals
listed in Section 1.3. This manual contains the following sections:
SECTION 1 - INTRODUCTION
This section provides general information about the ArcWorld II-200 and its
components, a list of reference documents, and customer service information.
SECTION 2 - SAFETY
This section provides information regarding the safe use and operation of the
ArcWorld II-200 system.
SECTION 3 - DESCRIPTION OF EQUIPMENT
This section provides a detailed description of the major components of the
ArcWorld II-200 system. This section also includes a table of component
specifications.
SECTION 4 - INSTALLATION
This section provides instructions for set up and installation of the ArcWorld II-
200 system.
SECTION 5 - OPERATION
This section provides instructions for basic operation of the ArcWorld II-200
system. This section also provides procedures for start-up, 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 II-200 cell.
For detailed specifications including parts lists breakdown for the Barrier
Assembly, refer to the Barrier Assembly Manual, P/N 147500-1.

INTRODUCTION
ArcWorld II-200 System Manual 1-2 MOTO MAN
1.2 System Overview
The ArcWorld II-200 provides a complete arc welding solution in a standardized
configuration. The system is designed around a Motoman arc welding robot and
XRC 2001 robot controller, and includes a complete welding package. Two
stationary tables allow an operator to prepare and set up parts on one table while
the robot welds on the other table. The cell provides a full complement of safety
features designed to protect both personnel and equipment.
1.2.1 System Layout
All components of the ArcWorld II-200 are mounted to the floor.A spanner plate is
used to help maintain proper alignment between the three major components:
robot manipulator and two barrier stations. The robotic cell is fully enclosed by
safety fencing and an interlocking door. The interlocked operator doors allow the
operator to load parts on one table while the robot is welding parts on the other
table. All operator controls, including those on the controller and welding power
supply, are accessible from outside of the robotic enclosure. Figure 1-1 illustrates
the system layout of the ArcWorld II-200 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.
OPERATOR
STATION
DOOR GUIDE
RAIL SLIDING
DOOR
ROBOT
LIGHT
CURTAIN
GAS
OPERATOR
DOOR
XRC 2001
CONTROLLER
CABINET
OPERATOR
DOOR
WELDING
POWER
SOURCE

INTRODUCTION
MOTO MAN 1-3 ArcWorldII-200SystemManual
1.2.2 Major Components
The ArcWorld II-200 includes the following major components:
• Motoman UP6 manipulator and XRC 2001 controller
• Two stationary work stations
• Common operator stations
• Welding equipment, including the following:
• Welding power source
• Motoman torch (water-cooled or air-cooled)
• Wire feeder
• Torch mount
• Safety equipment, including the following:
• Safety fencing with arc curtains
• Interlocked cell door
• Interlocked barrier door
• Light Curtains
1.2.3 Optional Equipment
The following equipment is available for use with the ArcWorld II-200:
• Torch tender
• Wire cutter
• Com-Arc III seam tracking unit
• Water circulator
• Robot/Positioner base
• Auxiliary equipment base
• Tabletops for tooling
1.3 Reference to Other Documentation
For additional information refer to the following:
• Motoman UP6 Manipulator Manual (P/N 142104-1)
• Motoman XRC 2001 Manual (P/N 145960-1)
• Motoman Operator's Manual for Arc Welding (P/N 142098-1)
• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)
• Barrier Assembly Manual P/N 147500-1.
• Com-Arc Function Manual (P/N 144075-1)
• Vendor manuals for system components not manufactured by Motoman

INTRODUCTION
ArcWorld II-200 System Manual 1-4 MOTO MAN
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)
• System Type (ArcWorld II-200)
• Software Version (access using TOP KEY/SYSTEM INFO/VERSION/
SYSTEM on the programming pendant)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on front side of controller)

MOTO MAN 2-1 ArcWorldII-200SystemManual
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 II-200 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 ArcWorldII-200SystemManual
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 II-200 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.
• 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.

SAFETY
MOTO MAN 2-5 ArcWorldII-200SystemManual
• 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 II-200 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 ArcWorldII-200SystemManual
SECTION 3
EQUIPMENT DESCRIPTION
3.1 UP-series Robot Description
The Motoman UP6 robot and 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 UP6 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 XRC 2001 Controller
The XRC 2001 robotic controller, shown in Figure 3-1, coordinates the operation
of the ArcWorld II-200 system. It controls manipulator movement and welding
power supply, processes input and output signals, and provides the signals to
operate the welding system. It maintains variable data and performs numeric
processing to convert to and from different coordinate systems. In addition, the
controller provides the following: main logic functions, servo control, program and
constant data memory, and power distribution. For more information, refer to the
manipulator manual that came with your system.
Figure 3-1 XRC 2001 Controller
SERVO ON
READY
REMOTE
PLAY
(OFF) (ON)
TEACH
MODE EMERGENCY STOP
EDIT LOCK ALARM
HOLD START
ON
TRIP
O
P
E
N
/
R
E
S
E
T
O
F
F
PLAYBACK BOX
PROGRAMMING
PENDANT
BRAKE RELEASE
CONTROL
POWER
DISCONNECT

EQUIPMENT DESCRIPTION
ArcWorld II-200 System Manual 3-2 MOTO MAN
3.2.1 Playback Panel
The playback panel (see Figure 3-2) contains the primary system controls and
consists of the features described below. For more information, refer to the
manipulator manual that came with your system.
Figure 3-2 Controller Playback Panel
Servo On Ready
The SERVO ON READY pushbutton turns servo power ON. The switch lights
when servo power is on. In TEACH mode, the SERVO ON READY pushbutton
operates only when the TEACH LOCK button on the programming pendant is ON
and the ENABLE switch on the programming pendant is held in.
Mode
The Mode push buttons (PLAY, TEACH and REMOTE) set the robot's mode of
operation.
NOTE: Changing modes from PLAY to TEACH, during playback, will cause the program to cease
execution (similar to HOLD); to resume operation, press PLAY and then START.
Alarm/Error
The ALARM/ERROR indicator light turns ON whenever an alarm or error
condition occurs.
Emergency Stop (E-STOP)
The E-STOP button on the playback panel is connected in series with the system
Emergency Stop circuit. Pressing E-STOP ceases all system operation.
Start
Pressing the START button while in PLAY mode with servo power on, causes
playback execution of the current job to begin.
Hold
The HOLD button is a normally closed, momentarily actuated switch. Pressing
HOLD halts operation of the manipulator until another Start signal is sent.
SERVO ON
READY
REMOTE
PLAY
(OFF) (ON)
TEACH
MODE EMERGENCY STOP
EDIT LOCK ALARM
HOLD START
MODE
BUTTONS
SERVO ON
READY
E-STOP
START
BUTTON
HOLD
BUTTON
REMOTE
MODE
ALARM/ERROR
INDICATOR
EDIT LOCK

EQUIPMENT DESCRIPTION
MOTO MAN 3-3 ArcWorldII-200SystemManual
3.2.2 Programming Pendant
The programming pendant (see Figure 3-3) is the primary user interface for the
system. The pendant has a 4x5-inch 12-line, 40-character LCD display and
keypad. The system uses the INFORM II robot language and a menu-driven
interface to simplify operator interaction with the robot. By using the pendant, the
operator can teach robot motion, and perform programming, editing, maintenance,
and diagnostic functions. The programming pendant consists of the items
described below. For more information, refer to the manipulator manual that came
with your system.
NOTE: The programming pendant LCD display goes dark after a few minutes of inactivity. Press any
key to restore screen.
Figure 3-3 Programming Pendant
General Purpose Display Area
The General Purpose Display Area displays the currently selected menu choice.
Menu Area
The Menu Area contains menu selections for the currently selected screen.
Emergency Stop (E-STOP)
The E-STOP button on the programming pendant is connected in series with the
system Emergency Stop circuit. Pressing the E-STOP button interrupts this circuit
and stops all system operation.
Keypad
The user keypad on the programming pendant serves as an input device. The keys
are grouped into different functional sections to simplify operator use.
GENERAL PURPOSE
DISPLAY AREA
STATUS AREA
MENU AREA
CURSOR
ENABLE
SWITCH
AXIS KEYS
ENTER KEY
NUMERIC KEYPAD
EMERGENCY
STOP BUTTON

EQUIPMENT DESCRIPTION
ArcWorld II-200 System Manual 3-4 MOTOMAN
Status Area
The Status Area shows system status via the following symbols:
•Active Robot, ExternalAxis, or Base Axis
R1, R2, R3; S1, S2, etc.; or B1, B2, etc.
•Coordinate System
Joint, World, Cylindrical, Tool, or User Frame
•Manual Speed Setting
Inching, Low, Medium, or High
•Cycle Mode
Step, 1-Cycle, or Auto
•System Status
E- Stop Running/Start, Hold, or Alarm
•Additional Pages (when applicable)
TOP MENU Key
The TOP MENU key returns the pendant display to the initial start-up menu. The
cursor key can then be used to choose from the following menu icons:
•JOB
This icon accesses job selections including: Master Job, Select Job, Job
Capacity, and Create New Job while in TEACH mode.
•ARC WELDING, GENERAL, HANDLING, and SPOT WELDING
This icon allows you to select the applications available to the controller.
• VARIABLE
This icon accesses the display and editing menu for the arithmetic variables
and display of position variables.
• IN/OUT
This icon accesses DETAIL and SIMPLE displays of all I/O signals. In
EDITING or MAINT. mode, Universal Outputs can be forced ON or OFF.
• ROBOT
This icon accesses robot information including: CURR.POS, POWER ON/
OFF, POS, COMMAND POS, SECOND Home POS, OPE ORIGIN POS,
and TOOL and USER COORDINATE.
• SYSTEM INFO
This icon provides Version information for both hardware and software,
Alarm History, and Monitoring Time.
Area Key
The Area key moves the cursor to the different areas of the display screen.
Cursor Key
The Cursor key is an 8-way, directional key that moves the up, down, left or right
to highlight a desired item that can then be chosen using the SELECT key.
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