YASKAWA Motoman WorldLite-50 User guide

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: [phone]
FAX: [phone]
24-Hour Service Hotline: [phone]
/QVQOCP:4%%QPVTQNNGT
#TE9QTNF.KVG
5[UVGO/CPWCN
HQT58:4QDQV
Part Number: 142719-1
Release Date: July 25, 2000
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 Arc-WorldLite 50 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 ......................................................................................... 1-2
1.2.3 Optional Equipment ........................................................................................ 1-2
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 SV3X Robot Description ...............................................................................................3-1
3.2 XRC 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 Emergency Stop (E-STOP) .............................................................................. 3-7
3.3.3 Door Status ..................................................................................................... 3-7
3.4 Stationary Weld Table................................................................................................... 3-7
3.4.1 Arc Shields ..................................................................................................... 3-7
3.5 Welding Equipment ...................................................................................................... 3-8
3.5.1 Power Sources ................................................................................................ 3-8
3.5.2 PWF Wire Feeder ............................................................................................3-9
3.5.3 Universal Welding Interface (UWI) .................................................................. 3-9
3.5.4 GMAW Torch .................................................................................................. 3-9
3.5.5 Motoman Torch Mount ................................................................................... 3-9

Arc-WorldLite 50 System Manual ii MOTO MAN
EQUIPMENT DESCRIPTION (CONTINUED)
3.6 Safety Features ............................................................................................................. 3-9
3.6.1 Arc Shields ................................................................................................... 3-10
3.6.2 Fencing ......................................................................................................... 3-10
3.6.3 Emergency Stops (E-STOPS) ........................................................................ 3-10
3.6.4 ENABLE Switch ............................................................................................. 3-10
3.6.5 Interlocked Cell Door .................................................................................... 3-10
3.6.6 Interference Cubes ........................................................................................ 3-11
3.6.7 Brake Release Control ................................................................................... 3-11
4 INSTALLATION
4.1 Materials Required........................................................................................................ 4-1
4.1.1 Customer-Supplied Items ............................................................................... 4-1
4.1.2 List of Tools Required ..................................................................................... 4-1
4.2 Site Preparation ............................................................................................................ 4-2
4.3 Installing the Arc-WorldLite 50 Common Base.............................................................4-2
4.3.1 Removing the Shipping Brackets .................................................................... 4-3
4.4 Leveling and Securing the Cell ..................................................................................... 4-4
4.5 Connecting the Cables.................................................................................................. 4-4
4.5.1 Connecting the Earth Ground .......................................................................... 4-4
4.5.2 Connecting the Water Circulator (Optional) .................................................... 4-5
4.6 Connecting the Gas/Air Services ..................................................................................4-6
4.7 Connecting the Power................................................................................................... 4-7
4.8 Conducting a Safety/Operation Check ..........................................................................4-7
4.9 Installation of Tooling and Fixtures............................................................................... 4-7
5 OPERATION
5.1 Programming................................................................................................................ 5-1
5.1.1 I/O Assignment ............................................................................................... 5-1
5.2 Daily Operation............................................................................................................. 5-2
5.2.1 Start-Up .......................................................................................................... 5-2
5.2.2 Robot Home Position ...................................................................................... 5-3
5.2.3 Starting the Master Job ................................................................................... 5-3
5.2.4 Shutdown ....................................................................................................... 5-3
5.3 System Recovery .......................................................................................................... 5-4
5.3.1 Alarms and Errors ........................................................................................... 5-4
5.3.2 E-STOP Recovery ........................................................................................... 5-4
5.3.3 Shock Sensor Recovery .................................................................................. 5-5
6 MAINTENANCE
6.1 Periodic Maintenance ................................................................................................... 6-1
6.2 Fuse and Circuit Breaker Protection.............................................................................. 6-2

MOTO MAN iii Arc-WorldLite 50 System Manual
LIST OF FIGURES
Figure Page
Figure 1-1 System Layout ............................................................................................................. 1-3
Figure 3-1 XRC Controller ............................................................................................................ 3-1
Figure 3-2 XRC 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 Power Sources .............................................................................................................3-8
Figure 4-1 Area Needed for Installation .........................................................................................4-2
Figure 4-2 Unbolting the Arc-WorldLite 50 Common Base ........................................................... 4-3
Figure 4-3 Location of Shipping Brackets ..................................................................................... 4-3
Figure 4-4 Location of Leveling Bolts ........................................................................................... 4-4
Figure 4-5 Water Circulator Connections ...................................................................................... 4-6
Figure 4-6 Gas and Air Service Connections .................................................................................4-6
LIST OF TABLES
Table Page
Table 3-1 Positioner Specifications ............................................................................................ 3-7
Table 5-1 XRC User Inputs .......................................................................................................... 5-2
Table 5-2 XRC User Outputs ........................................................................................................5-2
Table 6-1 Periodic Maintenance .................................................................................................. 6-1
Table 6-2 Universal Welding Interface (UWI) Fuses .....................................................................6-2
Table 6-3 MotoArc 450 CV Fuses and Circuit Breaker.................................................................. 6-2

Arc-WorldLite 50 System Manual iv MOTO MAN
NOTES

MOTO MAN 1-1 Arc-WorldLite 50 System Manual
SECTION 1
INTRODUCTION
The Arc-WorldLite 50 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 Arc-WorldLite 50 features a Motoman SV3X arc welding robot and XRC
robot controller with menu-driven arc welding application software, complete
welding package, stationary weld table, and a 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
Provides general information about the Arc-WorldLite 50 and its components, a
list of reference documents, and customer service information.
SECTION 2 - SAFETY
Provides information regarding the safe use and operation of the Arc-WorldLite 50
system.
SECTION 3 - DESCRIPTION OF EQUIPMENT
Provides a detailed description of the major components of the Arc-WorldLite 50
system. This section also includes a table of component specifications.
SECTION 4 - INSTALLATION
Provides instructions for set up and installation of the Arc-WorldLite 50 system.
SECTION 5 - OPERATION
Provides instructions for basic operation of the Arc-WorldLite 50 system. This
section provides procedures for start-up, loading, normal operation, fault recovery,
and shutdown.
SECTION 6 - MAINTENANCE
Contains a table listing periodic maintenance requirements for the components of
the Arc-WorldLite 50 cell.

INTRODUCTION
Arc-WorldLite 50 System Manual 1-2 MOTO MAN
1.2 System Overview
The Arc-WorldLite 50 provides a complete arc welding solution in a standardized
configuration. The system is designed around a Motoman SV3X arc welding robot
with XRC controller, and includes a complete welding package. A stationary weld
table with protective operator door provides easy operator access to parts, and a
safe welding environment. 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 Arc-WorldLite 50 cell.
1.2.1 System Layout
The robot manipulator, XRC controller and welding power source, all share a
common base for ease of installation and to help maintain proper alignment
between components. The Arc-WorldLite 50 cell is fully enclosed by sheet metal
and weld curtains to protect the operator. All operator controls are accessible from
outside the enclosure.
1.2.2 Major Components
The Arc-WorldLite 50 includes the following major components:
• Motoman SV3X manipulator and XRC controller
• Stationary weld table
• Operator station
• Welding equipment, including the following:
• Welding power source
• Torch (water-cooled or air-cooled)
• Wire feeder
• Torch mount
• Safety equipment, including the following:
• Protective arc screen
• Customer actuated Emergency Stops
• Software defined Interference Cubes
1.2.3 Optional Equipment
The following optional equipment is available for use with the Arc-WorldLite 50:
• Torch tender
• Wire cutter
• Com-Arc III seam tracking unit
• Water circulator

INTRODUCTION
MOTO MAN 1-3 Arc-WorldLite 50 System Manual
Figure 1-1 System Layout
AV
POWER
ALARM
ON
OFF
CONTROL
POWER
AMMETERVOLTMETER
0
_
ON
OFF
ON
OFF
CO
2
MAG
FLOW
AUTO
SOLO
FON
Ø16
Ø14
Ø12
GASFLOWWIREDIA
WIRETYPE
GAS
PENETRATION
CRATER
ALARM
INDICATOR
CURRENT
INPUT
CABLE
HEAT
WATER FUSE
CRATERVOLTAGE
CRATERCURRENT
SERVO ON
READY
REMOTE
PLAY
(OFF)(ON)
TEACH
MODE EMERGENCY STOP
EDIT LOCK ALARM
HOLDSTART
YASNACXRCSK16X
ON
TRIP
O
P
E
N
/
R
O
F
F
WORLDLITE
by MOTOMAN
REAR VIEW
FRONT VIEW
XRC CONTROLLER
POWER SOURCE
SAFETY FENCE
ROBOT
CELL DOOR
POSITIONER
OPERATOR STATION
110 VOLT OUTLET
WIRE FEEDER
WIRE CASSETTE
POWER
DISCONNECT

INTRODUCTION
Arc-WorldLite 50 System Manual 1-4 MOTO MAN
1.3 Reference to Other Documentation
For additional information refer to the following:
• Motoman SV3X Manipulator Manual (P/N 139067-1)
• Motoman Operator's Manual for Arc Welding (P/N 142098-1)
• Motoman Concurrent I/O Parameter Manual (P/N 142102-1)
• Com-Arc III Instruction Manual (P/N 132753-1)
• 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 (SV3X)
• Application Type (welding)
• System Type (Arc-WorldLite 50)
• Software Version (3.74)
• Robot Serial Number (located on the back side of the robot arm)
• Robot Sales Order Number (located on back side of XRC controller)