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)