1323408

Yasnac MRC Controller
ArcWorld 6200
Operator's Manual
Part Number 132340-8
Revised 7/25/96
July 24, 1995
MOTOMAN
805 Liberty Lane
West Carrollton, OH 45449
TEL: 513-847-6200 FAX: 513-847-6277
24-HOUR SERVICE HOTLINE: 513-847-3200
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.
©1995 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. YASNAC and MOTOMAN are registered trademarks of YASKAWA Electric Manufacturing.
TABLE OF CONTENTS
Section Page
LIST OF FIGURES................................................................................................. iv
LIST OF TABLES ................................................................................................... iv
1.0 INTRODUCTION............................................................................................ 1
1.1 ABOUT THIS DOCUMENT............................................................... 1
1.2 SYSTEM OVERVIEW.......................................................................... 1
1.2.1 System Layout.....................................................................2
1.2.2 Optional Equipment..............................................................4
1.3 REFERENCE TO OTHER DOCUMENTATION ...................................4
1.4 CUSTOMER SERVICE INFORMATION.............................................4
2.0 SAFETY ..........................................................................................................5
2.1 STANDARD CONVENTIONS.............................................................6
2.2 GENERAL SAFEGUARDING TIPS.....................................................7
2.3 MECHANICAL SAFETY DEVICES......................................................7
2.4 INSTALLATION SAFETY....................................................................8
2.5 PROGRAMMING SAFETY ................................................................8
2.6 OPERATION SAFETY........................................................................9
2.7 MAINTENANCE SAFETY................................................................. 10
3.0 DESCRIPTION OF EQUIPMENT ................................................................. 11
3.1 K-SERIES ROBOT DESCRIPTION .................................................. 11
3.2 MRC CONTROLLER ........................................................................ 11
3.2.1 Servo Power.......................................................................8
3.2.2 Mode Select........................................................................8
3.2.3 Cycle Select........................................................................8
3.2.4 Emergency Stop (E-Stop).....................................................8
3.2.5 Alarm / Error......................................................................8
3.2.6 Hold....................................................................................8
3.2.7 Start...................................................................................8
3.2.8 Playback Box Subpanel........................................................8
3.3 PROGRAMMING PENDANT............................................................9
3.3.1 Display................................................................................9
ArcWorld 6200 Operator's Manual Page i MOTOMAN

3.3.2 Robot Speed Indicators........................................................9
3.3.3 Emergency Stop (E-Stop).....................................................9
3.3.4 Keypad................................................................................9
3.3.5 Servo Power.......................................................................9

3.3.6 Coordinate System Indicators..............................................9
3.4 MRM2-SERIES POSITIONER ......................................................... 16
3.4.1 Part / Fixture Rating ......................................................... 16
3.4.2 Swing Diameter................................................................. 16
3.4.3 Temperature Operating Range........................................... 16
3.4.4 Humidity............................................................................ 16
3.4.5 Shock Rating..................................................................... 17
3.4.6 Sweep Speed ..................................................................... 17
3.4.7 Servo Headstock Speed...................................................... 17
3.4.8 Air Requirements .............................................................. 17
3.4.9 Electrical Requirements..................................................... 17
3.4.10 Welding Current Rating..................................................... 17
3.4.11 Locking Pins...................................................................... 17
3.4.12 Arc Shield......................................................................... 18
3.5 OPERATOR STATION (OP-STATION)............................................ 18
3.5.1 Emergency Stop (E-Stop)................................................... 18
3.5.2 Hold.................................................................................. 18
3.5.3 Cycle Start ....................................................................... 18
3.5.4 Station Ready.................................................................... 18
3.5.5 Alarm ............................................................................... 18
3.5.6 Servo On .......................................................................... 18
3.5.7 Positioner Auto / Manual................................................... 19
3.5.8 Master Job Start.............................................................. 19
3.5.9 Operator Station Enable / Disable...................................... 19
3.5.10 Reset................................................................................20
3.6 WELDING POWER SOURCE ...........................................................20
3.6.1 Main Power......................................................................20
3.6.2 Volt / Amp Settings............................................................20
3.6.3 Terminal Connectors.........................................................20
3.6.4 Local / Remote Operation...................................................20
3.6.5 Feeder Control Receptacles...............................................20
3.6.6 Circuit Breakers ...............................................................20
3.6.7 AC Receptacles................................................................. 21
3.7 WELDING EQUIPMENT.................................................................. 22
3.7.1 PWF4-600 Wire Feeder.....................................................22
ArcWorld 6200 Operator's Manual Page ii MOTOMAN

3.7.2 Universal Welding Interface (UWI) ...................................22
3.7.3 GMAW Torch ...................................................................22
3.7.4 RAM Torch Breakaway Mount..........................................22
3.8 SAFETY EQUIPMENT .....................................................................22
3.8.1 Arc Screens......................................................................23
3.8.2 Fencing.............................................................................23
3.8.3 Interlocks .........................................................................23
3.8.4 Safety Mats ......................................................................23
3.8.5 Emergency Stops (E-Stops) ...............................................24
4.0 OPERATION ................................................................................................25
4.1 OPERATING PROCEDURES...........................................................25
4.1.1 Start-Up...........................................................................25
4.1.2 Loading / Unloading Procedures .........................................26
4.1.3 E-Stop Recovery................................................................26
4.1.4 Shock Sensor Recovery.....................................................27
4.1.5 Shutdown..........................................................................28
4.1.6 Fault Recovery..................................................................28
4.2 ALARMS AND ERRORS ..................................................................28
4.2.1 Error Messages................................................................28
4.2.2 Minor Alarms ...................................................................29
4.2.3 Major Alarms ...................................................................29
4.3 PROGRAMMING............................................................................29
4.3.1 Cube Assignment...............................................................30
4.3.2 Sweeping Positioner to Side A............................................30
4.3.3 Sweeping Positioner to Side B............................................ 31
4.3.4 Rotating Headstock ........................................................... 31
4.3.5 Programming ....................................................................32
4.3.6 I/O Assignment.................................................................34
4.4 SAMPLE JOBS................................................................................35
4.4.1 Master Job.......................................................................36
4.4.2 SweeptoA Job ...................................................................36
4.4.3 SweeptoB Job...................................................................37
4.4.4 R1R2Safe Job ...................................................................38
4.4.5 S1-A Job...........................................................................38
4.4.6 S1-B Job...........................................................................38
4.4.7 A-Side Job.........................................................................38
4.4.8 Demo-1 Job.......................................................................38
4.4.9 B-Side Job ........................................................................39
5.0 MAINTENANCE........................................................................................... 41
ArcWorld 6200 Operator's Manual Page iii MOTOMAN

5.1 PERIODIC MAINTENANCE............................................................ 41
5.2 SPARE PARTS LIST.........................................................................42
5.3 FUSE AND CIRCUIT BREAKER PROTECTION...............................42
APPENDIX A - RISK ASSESSMENT .................................................................. A-1
APPENDIX B - SYSTEM OUTLINE DRAWINGS................................................ B-1
APPENDIX C - ELECTRICAL DRAWINGS.......................................................... C-1
APPENDIX D - MECHANICAL DRAWINGS ...................................................... D-1
ArcWorld 6200 Operator's Manual Page iv MOTOMAN

LIST OF FIGURES
Figure Page
Figure 1-1 System Layout......................................................................................2
Figure 3-1 MRC Controller ................................................................................. 12
Figure 3-2 MRC Playback Box ............................................................................ 12
Figure 3-3 Programming Pendant........................................................................ 14
Figure 3-4 Operator Station (Op-Station) ........................................................... 18
Figure 3-5 Excel-Arc Controls ............................................................................20
LIST OF TABLES
Table Page
Table 5-1 Periodic Maintenance..........................................................................40
Table 5-2 Spare Parts........................................................................................ 41
Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers ..................................42
Table 5-4 Universal Welding Interface (UWI) Fuses and Circuit Breakers...........44
Table 5-5 MRC Cabinet Fuses and Circuit Breakers............................................42
Table 5-6 MRC System Fuses.............................................................................42
Table 5-7 Com-Arc III Fuses and Circuit Breakers .............................................44
ArcWorld 6200 Operator's Manual Page v MOTOMAN

1.0 INTRODUCTION
The ArcWorld 6200 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 6200 features two Motoman arc welding robots, an MRC
controller, menu-driven arc welding application software, a complete welding
package, a 180˚ reciprocating positioner, an operator interface, and a total safety
environment.
1.1 ABOUT THIS DOCUMENT

This manual provides operation instructions for the ArcWorld 6200 system. In
addition to this introduction, the manual includes the following sections:
• Section 2: Safety
• Section 3: Description of Equipment
• Section 4: Operation
• Section 5: Maintenance
• Appendices
The Safety Section of the manual provides information regarding the safe use and
operation of the ArcWorld 6200 system.
The Description of Equipment Section provides a detailed description of the major

components of the ArcWorld system.
The Operation Section gives instructions to operate the ArcWorld system. This
section contains procedures for start-up, loading, normal operation, fault recovery,
and shutdown. The section also contains a number of sample robot programs.
The Maintenance Section includes a table of periodic maintenance requirements for

the ArcWorld 6200 cell. This section includes detailed instructions to perform
specific maintenance tasks. It also includes a list of recommended spare parts.
Appendix A is a Risk Assessment document. The remaining appendices contain a

full set of reference drawings.
1.2 SYSTEM OVERVIEW

The ArcWorld 6200 provides a complete arc welding solution in a standardized
configuration. The system is designed around dual Motoman arc welding robots
and includes a complete welding package. A dual station reciprocating positioner
allows an operator to prepare and set up parts on one side while the robots weld on
ArcWorld 6200 Operator's Manual Page 1 MOTOMAN

the other side. The cell provides a full complement of safety features designed to
protect both personnel and equipment.
1.2.1 System Layout

The illustration in Figure 1-1 shows the system layout for the ArcWorld 6200 cell.
The ArcWorld 6200 includes the following major components:
• Motoman robot manipulators and MRC controller
• MRM2 series dual station reciprocating positioner
• Operator station
• Welding equipment, including the following:
• Excel-Arc welding power source
• Torch (water-cooled or air-cooled)
• Wire feeder
• Welding interface
• Torch breakaway
• Safety equipment, including the following:
• Safety fencing with arc curtains
• Interlocked safety mats
• Interlocked cell door
The MRC controller and welding power source share a common base. Additional
auxiliary components, such as the Com-Arc III unit and water circulator, can be
located on this base as well. The robotic cell is fully enclosed by safety fencing and
an interlocking door. Safety mats prevent positioner cycling while anyone stands in
front of the positioner. All operator controls, including those on the MRC and
welding power supply, are accessible from outside of the robotic enclosure.

External
Axis Cabinet Com-Arcs Welding
MRC
Power
Cabinet Water Disconnect Sources
Circulators
Disconnects
Auxiliary
Equipment
Common Base
Transformer
Assembled
ArcWorld 6200 Operator's Manual

Fence
Gas Bottles
(customer
supplied)
#1
Robot
Figure 1-1
#2
Page 3
Robot
NOTE: Arc shield not shown for clarity.

Torch Torch
Tender Tender
System Layout
Positioner
Operator
Station Safety Mats
MOTOMAN
1.2.2 Optional Equipment
The following optional equipment is available for use with the ArcWorld 6200:
• Torch tender
• Wire cutter
• Com-Arc III
• Heavy-duty positioners
1.3 REFERENCE TO OTHER DOCUMENTATION

For additional information refer to the following:
• Motoman K10 MRC Manipulator Manual (Part Number 132330-7)
• Motoman K6 MRC Manipulator Manual (Part Number 132330-4)
• Motoman MRC Operator's Manual for Arc Welding (Part Number 132332-1)
• Motoman MRC User Functions Manual (Part Number 132331-1)
• Motoman MRC Operator's Manual for Jigless (Part Number 132332-3)
• Motoman ArcWorld 6200 Installation Manual (Part Number 132341-8)
• 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
(513) 847-3200. Please have the following information ready before you call:
• Robot Type (K3, K6, K10, etc.)
• System Number (located on the cover page of this manual)
• Robot Serial Number (located on the back side of the robot arm)
• Application Type (palletizing, welding, handling, etc.)

2.0 SAFETY
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.
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: 313/994-6088
FAX: 313/994-3338
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 (see Section 2.1)
• General Safeguarding Tips (see Section 2.2)
• Mechanical Safety Devices (see Section 2.3)
• Installation Safety (see Section 2.4)
• Programming Safety (see Section 2.5)
• Operation Safety (see Section 2.6)
• Maintenance Safety (see Section 2.7)

2.1 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 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.

2.2 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 damage 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 operation. Place the robot in
Emergency Stop (E.STOP) mode and ensure that all motion has stopped
before entering the 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.
2.3 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, RIA safety recommendations, 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.

2.4 INSTALLATION SAFETY
Safe installation is essential for protection of people and equipment. The user must
be aware of the various national codes, RIA safety recommendations, 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
suggestions are intended to supplement, but not replace, existing federal, local, and
state laws and regulations.
• Ensure 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.
• 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.
2.5 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 safety
tips are as follows:
• Any modifications to NODE 2 (for ERC controllers) or PART 1 (for MRC
controllers) of the controller PLC can cause severe personal injury or death, as
well as damage to the robot! Do not make any modifications to NODE 2 or
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. Y O U R
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.
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 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.
• Check the E.STOP button on the teach pendant for proper operation before
programming.
• Keep the teach pendant with you when you enter the workcell.
• Ensure 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.
2.6 OPERATION SAFETY

equipment must understand potential dangers of operation. Operation safety tips
are as follows:
• 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.
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. On
ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3;
and I/O (Input and Output) modifications. On MRC controllers this includes

controller parameters, ladder parts 1 and 2, and I/O (Input and Output)
modifications. Check and test all changes at slow speed.

2.7 MAINTENANCE SAFETY
equipment must understand potential dangers of operation. Maintenance safety 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.
• 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.
not in use.
• Ensure 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. On
ERC controllers this includes controller parameters; ladder nodes 1, 2, or 3;
and I/O (Input and Output) modifications. On MRC controllers 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).

3.0 DESCRIPTION OF EQUIPMENT
3.1 K-SERIES ROBOT DESCRIPTION

The standard ArcWorld 6200 uses two Motoman K-Series robot manipulators
operating in a master/slave configuration. The Motoman K6 and K10 robots and
YASNAC MRC controller represent state-of-the-art technology in robotics today.
The six-axis K6 robots have a payload of 6 kg (13.2 lbs). They feature a 1,322
mm (52.0 inch) reach and have a relative positioning accuracy of ± 0.1 mm (0.004
inch). The six-axis K10 robots have a payload of 10 kg (22 lbs). They feature a
1,555 mm (61.2 inch) reach and have a relative positioning accuracy of ± 0.1 mm
(0.004 inch).
Each robot can reach below its own base as well as behind itself. These robots can
also be mounted in floor, wall, or ceiling configurations with few hardware
modifications. The Motoman K-Series robots have been constructed for ease of
maintenance, utilizing brushless AC servo motors with absolute positioning
encoders. All motors are readily accessible. A combination of capacitance and
lithium batteries in both the robot encoder assemblies and in the MRC controller
protects program position data for up to one year. The replacement life for the
lithium battery is approximately three years.
3.2 MRC CONTROLLER

The MRC controller (see Figure 3-1) coordinates the operation of the ArcWorld
system. It provides the following control functions:
• User interface
• Main logic functions
• Input / output control
• Servo control
• Numeric processing
• Variable data memory
• Program and constant data memory
• Analog welding command functions
• Welding interface
• Power distribution
The MRC controls the movement of the manipulators, processes input and output
signals, controls the operation of the welding power supply, and provides the
signals to operate the welding system. It maintains variable data and performs the
numeric processing to convert to and from different coordinate systems.

Figure 3-1 MRC Controller
The playback box (see Figure 3-2) on the MRC has the primary system controls.
The following paragraphs describe the MRC controls.
Figure 3-2 MRC Playback Box

3.2.1 Servo Power
The SERVO POWER pushbutton switch (see Figure 3-2) turns on the robot servo
power. An indicator light in the switch turns on when the servo power is on.
3.2.2 Mode Select

The Mode Select pushbutton switches (PLAY, TEACH, and REMOTE) set the
robot's mode of operation. Indicator lights in the Mode Select switches turn on to
show the current mode of operation. Refer to the MRC Operator's Manual for Arc
Welding more information.
3.2.3 Cycle Select

The Cycle Select pushbutton switches (AUTO, 1-CYCLE, and STEP) set the
operating method for playback operations. Indicator lights in the Cycle Select
switches turn on to show the selected playback method. Refer to your MRC
Operator's Manual for Arc Welding more information.
3.2.4 Emergency Stop (E-Stop)

The E-Stop button on the playback box is connected to the E-Stop circuit. Also
included in the E-Stop circuit is the op-station E-Stop button, the pendant E-Stop
button, the air pressure switch, the sliding door interlocks, and the safety mats. All
these components are connected in series. Interrupting the E-Stop circuit causes the
robot to go into the E-Stop condition, which immediately turns off the servo power
and removes power from the positioner interface. This stops the positioner sweep.
Pressing any one of the E-Stop buttons also stops the movement of both robots
and removes the electrical power from the welding torch.
3.2.5 Alarm / Error

The ALARM / ERROR indicator light turns on whenever an alarm or error
condition occurs. After you reset the alarm or error condition, the indicator light
turns off.
3.2.6 Hold
The HOLD button is a normally closed, momentarily actuated switch. Pressing the
HOLD button stops the operation of the manipulator. The hold state is active only
while the switch is held down. The indicator light turns on whenever the robot is in
a hold state. Refer to your MRC Operator's Manual for Arc Welding for more
information.
3.2.7 Start
Pressing the START button causes the manipulator playback operation to start.
The indicator light turns on during playback.

3.2.8 Playback Box Subpanel
The playback box has an inside subpanel that contains additional user controls.
Refer to your MRC Operator's Manual for Arc Welding for more information.
3.3 PROGRAMMING PENDANT

A programming pendant (see Figure 3-3) provides the primary user interface with
the system. The pendant has a 12-line 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.
3.3.1 Display
The programming pendant has a 12-line LCD display. The display provides status
information, system messages and prompts, and a graphic work area. Refer to
your MRC Operator's Manual for Arc Welding for more information.
3.3.2 Robot Speed Indicators

When in Teach Mode, the MAN SPD indicators turn on to show the selected robot
manipulator speed.

The E-Stop button on the pendant is connected to the E-Stop circuit. Interrupting
the E-Stop circuit causes the robot to go into the E-Stop condition, which
immediately turns off the servo power and removes power from the positioner
interface. This stops the positioner sweep. Pressing any one of the E-Stop buttons
also stops the movement of both robots and removes the electrical power from the
welding torch.
3.3.4 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. For more
information, refer to your MRC Operator's Manual for Arc Welding.
3.3.5 Servo Power

The SERVO POWER pushbutton switch turns on the robot servo power. An
indicator light in the switch turns on when servo power is on.
3.3.6 Coordinate System Indicators

The COORD indicator lights turn on to show the currently active coordinate
system.

Figure 3-3 Programming Pendant

3.4 MRM2-SERIES POSITIONER
The ArcWorld 6200 cell uses one of two different reciprocating positioners: the
MRM2-550 or the MRM2-1100. The MRM2-Series positioners are AC servo
controlled by the master robot to provide coordinated motion while welding or
between welds. The standard distance between the headstock and tailstock
faceplates on the MRM2-550 positioner is 2.6 meters (approximately 102 inches).
The standard distance between the headstock and tailstock faceplates on the
MRM2-1100 positioner is 3.0 meters (approximately 118 inches).
The load side of the positioner is fixed for loading and unloading parts. The
patented servo motor is used to sweep the positioner workstations into and out of
the robot envelope, and also to turn the weld side of the positioner during welding.
A fixture frame is typically mounted between the headstock and tailstock faceplates
to provide a highly flexible system. Fixtures are either mounted on or integrated to
these frames for positioning and clamping of production parts. Pneumatic and
electrical signals can be run to the fixtures if required. Depending on part size(s)
and weight(s) you can mount single, multiple, or a combination of parts to the
fixture frame.
The ArcWorld 6200 system is capable of synchronized motion where the
positioner holds the parts stationary and both robots move at the same time to do
the welding. The system is also capable of coordinated motion where the
positioner rotates the parts while the robots do the welding.
3.4.1 Part / Fixture Rating

The combined weight of the part(s) and fixture(s) on each side of the MRM2-550
reciprocating positioner is 550 pounds (1,100 pounds total). The maximum offset
load for the MRM2-550 is 375 pounds. The positioner will not sweep if the load
on one side is more than 375 pounds heavier than the load on the other side.
The combined weight of the part(s) and fixture(s) on each side of the MRM2-1100
reciprocating positioner is 1,100 pounds (2,200 pounds total). The maximum
offset load for the MRM2-1100 is 639 pounds. The positioner will not sweep if
the load on one side is more than 639 pounds heavier than the load on the other
side.
3.4.2 Swing Diameter

The maximum swing diameter for a part on the MRM2-550 positioner is 0.98
meters (approximately 37.4 inches). The maximum swing diameter for a part on
the MRM2-1100 positioner is 1.10 meters (approximately 43.3 inches).
3.4.3 Temperature Operating Range

The temperature operating range is 40 - 110˚ Fahrenheit.
3.4.4 Humidity

Non condensing 10 to 90 percent relative humidity is acceptable.
NOTE: In high humidity areas, the table tooling plate may rust or corrode. Surface protection should
be used.
3.4.5 Shock Rating

The positioner can accept shocks of less than 0.5 G.
3.4.6 Sweep Speed

Torque Time
MRM2-550 600 N.m 5.5 - 7.0 seconds
MRM2-1100 1,500 N.m 10 seconds
3.4.7 Servo Headstock Speed

Torque Speed
MRM2-550 550 N.m 0 - 13.0 rpm
MRM2-1100 785 N.m 0 - 13.4 rpm
3.4.8 Air Requirements

A minimum air supply of 80 PSIG is required to operate the positioner.
3.4.9 Electrical Requirements

The MRC controller supplies the electrical power required to operate the 180˚
reciprocating positioners. These requirements consists of a 24-VDC interface
circuit, and a 208-VAC, 6.2-amp circuit for the MRM2-550 motor and drive, or a
208-VAC, 9.0-amp circuit for the MRM2-1100 motor and drive.
3.4.10 Welding Current Rating

The MRM2 positioners have a welding current capacity of 600 amperes at 100%
duty cycle. The welding ground system consists of a spring loaded copper brush
that contacts a large ring mounted behind the surface of the faceplate. The ground
cable to the welding power source is connected to the ground stud located on the
right side of the positioner base when facing the back of the ArcWorld 6200 cell.
3.4.11 Locking Pins

The MRM2 positioners are equipped with fixture locking pins that prevent the
headstock/tailstock face plates from turning when the servo motor retracts. The

fixture locking pins are spring loaded, so when the servo motor withdraws, the pins
engage. Each headstock faceplate on the MRM2-550 positioner has one locking
pin. Each headstock faceplate on the MRM2-1100 positioner has two locking pins.
The MRM2-1100 positioner is also equipped with a pair of sweep lock drive pins
that prevent the sweep axis from turning during the welding and loading cycles.
One sweep lock drive pin is located on the headstock drive base and the other is
located on the tailstock drive base.
3.4.12 Arc Shield

The MRM2 positioners are provided with a sheet metal screen for arc radiation
protection between the operator loading zone and the welding zone. Do not operate
this equipment unless the arc shield is in place.
3.5 OPERATOR STATION (OP-STATION)

The op-station (see Figure 3-4) includes a NEMA enclosure on a stand-alone
pedestal. The following paragraphs describe each of the controls.

The E-Stop button on the op-station is connected to the E-Stop circuit. Interrupting
the E-Stop circuit causes the robot to go into the E-Stop condition, which
immediately turns off the servo power and removes power from the positioner
interface. This stops the positioner sweep. Pressing any one of the E-Stop buttons
also stops the movement of both robots and removes the electrical power from the
welding torch.
3.5.2 Hold
The op-station HOLD button is a normally closed pushbutton and is connected to
the MRC to cause the robots to go into the Hold condition when the button is
pressed.
3.5.3 Cycle Start

The CYCLE START palm buttons, located on both sides of the op-station, use an
anti-tiedown technique for robot input. The anti-tiedown timer is set for 10
seconds. Holding a palm button down for more than 10 seconds causes the timer
to time out and prevents the input from reaching the robot. The CYCLE START
buttons are connected to robot Input #1. Press both CYCLE START buttons at the
same time to let the positioner sweep.
3.5.4 Station Ready

The STATION READY light is interlocked with the robot Cube 1 output. The
robot Output #1 turns on the STATION READY light.

3.5.5 Alarm
The ALARM light is connected to the robot Alarm Occurrence output. The
ALARM light turns on when one of the robots encounters a major or minor alarm
condition. The ALARM light also turns on when the positioner is not reset.
3.5.6 Servo On
The SERVO ON pushbutton is connected to the robot Servo On input. When the
SERVO ON pushbutton is pressed, servo power is applied to the servo motors,
but only if an E-Stop condition does not exist.
CYCLE START CYCLE START
MOTOMAN
OPERATOR STATION
ALARM ROBOT HOLD STATION READY ENABLE/DISABLE
ESTOP
MASTER JOB POSITIONER

RESET SERVO ON
START AUTO/MAN
WARNING:
WARNING:
DODO NOT
NOT ENTER
WARNING!
ENTER
ROBOT WORKAREA
ROBOT WORK AREA
Figure 3-4 Operator Station (Op-Station)
3.5.7 Positioner Auto / Manual

The POSITIONER AUTO / MANUAL selector switch is used to select Automatic
or Manual Mode for the MRM2 positioner. The selector switch is connected to
robot Input #2. When the selector switch is in the Automatic position, the robots
process the part after the positioner sweeps. In Manual Mode, the robot does not
process the part after the positioner sweeps.
NOTE: This function is dependent on the structure of the master job.
3.5.8 Master Job Start

The MASTER JOB START pushbutton is connected to the robot external start
input. The robot will start the job that is currently active when this pushbutton is
pressed if the robot is in Play Mode and the servo motors are on.
3.5.9 Operator Station Enable / Disable

The OPERATOR STATION ENABLE / DISABLE selector switch is used to
transfer primary control of the ArcWorld cell from the MRC to the op-station.
When the op-station is enabled, the light in the REMOTE MODE button on the
MRC playback box turns on and most of the programming pendant functions are
disabled.
3.5.10 Reset
The RESET pushbutton is connected to the robot alarm reset input. Most alarms
or error conditions will be cleared when this button is pressed. In addition, the
RESET pushbutton and the right CYCLE START palm button are interlocked.
When pressed simultaneously, these two buttons enable the positioner if the robot
servo motors are on. The positioner needs to be enabled at initial power up, or after
an E-Stop or shock sensor condition.
3.6 WELDING POWER SOURCE

The Excel-Arc power source (see Figure 3-5) is a constant voltage transformer-
rectifier-type welding machine. It provides volt-current characteristic curves that
are essentially flat. This power source can be used with most GMAW applications
from thin sheet metal to heavy-gauge plate.
3.6.1 Main Power

The Input Power Switch (7) turns on the main power to the Excel-Arc unit. The
main power must be on before any other section of the power source can operate.
The indicator light (1) turns on when main power is on.
3.6.2 Volt / Amp Settings

The Welding Voltage Control (2) adjusts the welding output voltage. The Volt /
Amp Meter (3) displays either DC voltage or DC current depending on the position
of the switch below the meter. Refer to your Excel-Arc Manual for additional
information.
3.6.3 Terminal Connectors

The two terminals on the front of the Excel-Arc power source serve as connection
points for the welding leads. The positive welding lead should be connected
between the Positive Terminal (4) and the wire feeder. The negative welding lead
should be connected between the Negative Terminal (5) and the positioner.

3.6.4 Local / Remote Operation
The Local / Remote Output Control Selector Switch (6) sets the mode of operation
for the power source. For ArcWorld applications, this switch should be set to
REMOTE. Refer to your Excel-Arc manual for additional information.
3.6.5 Feeder Control Receptacles

The Feeder Control Receptacle Panel (8) located in the back of the power source
provides connectors for use with remote voltage control applications. For
ArcWorld applications, the MRC connects to the 19-pin connector.
3.6.6 Circuit Breakers

The Excel-Arc power source uses two 10-amp circuit breakers (9 and 10). One
circuit breaker protects the 24-volt circuit; the other protects the 115-volt circuit.

Figure 3-5 Excel-Arc Controls
3.6.7 AC Receptacles
The Excel-Arc unit has two standard 115 VAC Receptacles (11). These provide
auxiliary power at a maximum current of 10 amps. For applications using the
water-cooled torch, the water circulator plugs into one of these receptacles.

3.7 WELDING EQUIPMENT
In addition to the Excel-Arc power sources, the ArcWorld 6200 system provides a
complete complement of arc welding equipment. In its standard configuration, the
ArcWorld system includes the following:
• PWF4-600 wire feeder
• Universal welding interface
• Either an air-cooled or water-cooled GMAW torch
• RAM torch breakaway mount
3.7.1 PWF4 -600 Wire Feeder

The PWF4-600 wire feeder mounts on the robot arm. This 4-roll wire feeder
provides reliable wire feeding at rates up to 600 IPM. An integral gas valve
provides fast gas response time. The wire feeder has an inch forward button to
help simplify setup and reduce change-over time. The wire feeder uses
interchangeable feed rolls to accommodate different types and sizes of wire.
3.7.2 Universal Welding Interface (UWI)

The UWI provides microprocessor control to the wire feeder and power source. It
scales the signals from the MRC to the appropriate levels required for control of the
welding components. It also provides isolation of the power source analog signals.
3.7.3 GMAW Torch

The ArcWorld 6200 uses either an air-cooled or water-cooled robotic/automatic
GMAW torch. These are heavy-duty torches designed for quick replacement while
requiring minimum robot reprogramming. The GMAW torch attaches to the
RAM torch breakaway mount that is connected to the end of the robot wrist. For
applications that use the water-cooled torch, the ArcWorld 6200 includes a suitable
water circulator kit.
3.7.4 RAM Torch Breakaway Mount

A Motoman RAM torch breakaway mount protects the robot, workpiece, fixture,
and positioner. It provides multi-directional impact detection, including Z-axis
collisions. The mount causes the robot to stop immediately upon impact. The
joints are match-marked to ensure accurate realignment of components.
3.8 SAFETY EQUIPMENT

The ArcWorld 6200 system incorporates a host of safety equipment. When all
standard safety precautions are taken, the safety equipment helps to ensure safe
operation of the robotic cell. The ANSI/RIA R15.06 Robot Safety Standard

stipulates the user is responsible for safeguarding. Users are responsible for
determining whether the provided safeguards are adequate for plant
conditions. Users must also ensure that safeguards are maintained in
working order.
The ArcWorld 6200 safety features include the following:

• Arc screens
• Safety fencing
• Dual interlocking cell door
• Interlocked safety mats
• Emergency stop (E-Stop) buttons
3.8.1 Arc Screens

Two separate arc screens are used on the ArcWorld 6200. The first is a metal arc
screen on the turntable positioner. This screen blocks arc radiation and sparks from
the welding operation. The material used to cover the safety fencing of the entire
robotic cell acts as the second arc screen. This material reduces the amount of ultra-
violet radiation that escapes from the robotic cell.
WARNING!
Although this screen blocks dangerous arc radiation, you should
not look directly at the arc during operation without protective
eyewear!
3.8.2 Fencing
The safety fencing provided with the ArcWorld 6200 encloses the entire robotic
cell. It forms a physical barrier to prevent entry into the robot envelope.
3.8.3 Interlocks
Dual safety interlocks on the cell entrance door prevent entry into the cell during
operation. The interlocks consist of a pull plug and magnetic door switch.
Opening the cell door with the robot in Play causes an E-Stop and shuts down the
entire system.
3.8.4 Safety Mats

The safety mat provided with the ArcWorld 6200 helps prevent serious injury to
anyone entering the positioner area during the sweeping process. If a person steps
on this mat when the positioner is in motion, an E-Stop occurs causing the entire
system to shut down.

3.8.5 Emergency Stops (E-Stops)
In addition to the interlocking devices described above, the ArcWorld 6200 has
strategically placed E-Stop buttons. The E-Stop buttons immediately cause the
system to shut down, and are located as follows:
• On the playback box on the MRC controller
• On the MRC programming pendant
• On the op-station
In addition, the following conditions also cause an E-Stop:
• Opening the cell door while the robot is in Play mode
• Stepping on the safety mat while the positioner is sweeping
• Loss of air system pressure
• Activating the shock sensor

4.0 OPERATION
This section provides operation instructions for the ArcWorld 6200 system.
Operation procedures include the following:
• System start-up
• Part setup
• Normal operation
• Fault recovery
• System shutdown
Several sample programs are included in this section. The listed programs
demonstrate the proper format and instruction sequences for different operations.
You can use these programs as guidelines when creating programs for your
specific applications.
4.1 OPERATING PROCEDURES

The ArcWorld 6200 is a fully integrated robotic GMAW welding cell. The robots
weld parts on one side of the 180˚ reciprocating positioner, while the operator loads
parts on the opposite side. Once the robots are finished with their process, they
return to the safe position. The operator can then initiate the positioner sweep,
enabling the robots to start welding on the next part.
The safety door interlocks prevent anyone from entering the cell while the robots
are in Play Mode. If anyone steps on the safety mats in front of the part loading
area during the positioner sweep, an E-Stop occurs.
4.1.1 Start-Up
To start up the ArcWorld 6200 from a power-off condition, proceed as follows:
1. Turn on the MRC disconnect.
2. Turn on the two power source disconnects.
3. Set the INPUT POWER switch on both welding power sources to ON. The
indicator light should turn on.
4. Set the main power switch on the MRC to ON.
5. Open the regulator valve on the welding gas supply.
6. Press the TEACH MODE button on the MRC playback box. The indicator
light in the switch should turn on.
7. Press the SERVO POWER button on the MRC playback box. The indicator
light in the switch should turn on.

8. Press the RESET button and the right CYCLE START button on the op-station
at the same time to initialize the positioner. The ALARM light should turn off.
9. Use the programming pendant to move the Robot 1 to Cube 1 and Robot 2 to
Cube 2.
10. Call up the master job.
11. Make sure that the cell entry door is closed and the safety plug is connected.
12. Press the PLAY MODE button on the MRC playback box, and then press the
AUTO CYCLE button. The indicator lights in the switches should turn on.
13. Set the OPERATOR STATION ENABLE / DISABLE switch to the
ENABLE position.
14. Press the MASTER JOB START button on the op-station.
15. Wait for the STATION READY indicator light to turn on.
The ArcWorld 6200 Cell is now ready for operation.
4.1.2 Loading / Unloading Procedures

The following is the typical sequence of operations for the ArcWorld 6200 Cell
after startup:
1. Load production parts on the fixtures located on the operator side of the MRM2
positioner.
2. Step off the safety mats and wait for the STATION READY indicator light to
turn on.
3. Press both CYCLE START palm buttons on the op-station to sweep the
positioner. This places the parts to be welded in the robot work envelope.
4. After the positioner sweeps, the robots begin the welding sequence on the parts.
The coordinated motion capability of the system allows rotation of the weld
side of the positioner during the welding cycle, but the positioner will not sweep
and the operator side of the positioner will not move.
5. Unload the welded parts from the fixture on the operator side.
6. Repeat Steps 1 through 5 to continue production.
4.1.3 E-Stop Recovery

An E-Stop can occur under any one of the following conditions:
• Pressing the E-Stop button on the op-station, the programming pendant, or the
MRC playback box
• Opening the sliding door on the robot enclosure or removing the safety plug
when the robot is not in Teach Mode
• Stepping on the safety mat when the MRM2 positioner is sweeping
• Activation of the shock sensor, indicating a robot crash

• Loss of air system pressure
To restart the ArcWorld 6200 Cell after an E-Stop condition occurs, follow the
procedure below.
1. To clear the E-Stop condition, do any of the following actions that apply:
• Release the E-Stop button on the op-station, the programming pendant, or
the MRC playback box.
• Close the sliding door and connect the safety plug.
• Step off the safety mat.
• Clear the Shock Sensor condition (refer to Section 4.1.4).
• Restore operating air pressure.
2. Press the SERVO ON button on the op-station.
CAUTION!
Make sure the robots are in a clear position to continue motion.
A crash may occur if the robots cannot clear the part or fixtures
when they resume motion.
CAUTION!
If an E-Stop condition occurs while the positioner is sweeping,
the positioner will continue to move when initialized.
3. Press the RESET button and the right CYCLE START button on the op-station
at the same time to initialize the system.
4. Press the MASTER JOB START button on the op-station.
The ArcWorld 6200 Cell will continue its operation.
4.1.4 Shock Sensor Recovery

The ArcWorld welding package includes a RAM breakaway torch mount. This
mount is designed to protect the torch from damage in case of a crash. A slight
deflection of the torch activates a SHOCK SENSOR error. A more severe crash
separates the torch mount from the robot arm. The SHOCK SENSOR error is
factory set to an E-Stop condition.
To override the shock sensor, do the following:

1. Press and hold the overrun recovery button located on the subpanel of the
playback on the controller. This is a momentarily activated switch.

2. With the shock sensor in override, you can energize the robot by pressing the
SERVO ON button.
3. While pressing the shock sensor override button, use the programming pendant
to operate the manipulator.
To resume operation after clearing the Shock Sensor condition, proceed as follows:
1. Press the RESET and right CYCLE START buttons on the operator's station at
the same time. This initializes the positioner.
CAUTION!
You may need to move the robot to recover from a crash. To
avoid another crash, make sure that the robot has a clear path to
the next step.
2. Press the MASTER JOB START button.
4.1.5 Shutdown
Use the following procedure to shut down the ArcWorld 6200 Cell after operation
is complete:
1. Make sure that Robot 1 is in Cube 1 and Robot 2 is in Cube 2.
2. To turn off the robot servo motors, press the E-Stop button on either the op-
station, programming pendant, or MRC playback box.
3. Press the TEACH MODE button on the MRC playback box.
4. Set the MRC Main Power switch to the OFF position.
5. Turn off the MRC disconnect.
6. Set the INPUT POWER switch on the welding power source to the OFF
position.
7. Turn off the two power source disconnects.
8. Close the regulator valve on the welding gas supply.
The ArcWorld 6200 Cell is now shut down.
4.1.6 Fault Recovery

Under varying conditions, an alarm or error can occur. Clearing an alarm or error
condition may require different operator intervention depending on the nature of the
alarm or error. In some cases, simply resetting the robot and restarting the
operation is sufficient. In other instances, you must first remedy the condition
causing the alarm or error. Refer to Section 4.2, Alarms and Errors.

4.2 ALARMS AND ERRORS
Alarms and errors will cause the program to stop. There are three levels of alarms
and errors: Error Messages, Minor Alarms, and Major Alarms.
For more detailed information about alarm recovery, refer to your Motoman MRC
Operator's Manual for Arc Welding.
4.2.1 Error Messages

These are simple errors such as pressing the START button when the robot is not
in PLAY mode, or enabling the programming pendant without the servo power
being live.
Errors like these are cleared by pressing the CANCEL or ENABLE button on the
programming pendant.
4.2.2 Minor Alarms

Minor alarms are usually programming errors. Minor alarms might occur if a
circle has been programmed with fewer than three circular points, etc.
These alarms are cleared by pressing one of the following:

• RELEASE soft key on the programming pendant
• RESET button on the op-station
• ENABLE button on the programming pendant
4.2.3 Major Alarms

Major alarms are hardware failures. Major alarms might occur because of a servo
tracking error or an abnormal speed associated with crashes. To clear these alarms,
you must turn off the controller and then turn it on again.
4.3 PROGRAMMING
The MRM2 positioner with its programmable axis offers a high degree of
programming flexibility. The robots can be programmed to weld a part with the
headstock stationary, or the robots and headstock can move simultaneously to weld
a part while turning. Further, the robots may be programmed to execute
synchronous jobs, simultaneous mirror opposite jobs, both robots may be
programmed to weld different seams on the same part, or each robot may be
programmed to execute a completely different job at the same time.
You can program the robots independently (R1 or R2 jobs), the station axis
independently (S1 job), or master robot and station axis together (R1 + S1 job
combinations). You must select the axis combination when teaching the job

initially. We recommend programming the robot and station axis together
(R1 + S1 S1 jobs) to reduce the risk of interference.
WARNING!
The positioner axis operates as another robot axis and has the
potential of hazardous motion.
CAUTION!
If the robots are working on a part and the headstock is not
turning, DO NOT assume that the headstock will not turn. The
robots are executing programmed steps which could index the
headstock at any time.
NOTE: The ArcWorld 6200 robot S-axes are restricted by hardstops on the robot base and internal
soft stops. Do not change.
4.3.1 Cube Assignment

The system uses the cube outputs as an interlock for sweeping. Robot 1 must be in
Cube 1 and Robot 2 must be in Cube 2 before the positioner can sweep. The cubes
are software zones around the tool center points (TCP). Each cube should be
defined with the robot clear of the positioner sweep motion. The cube outputs can
be viewed in diagnostics under Specified Outputs.
The ArcWorld 6200 uses the Cube 3 output as an interlock for robot motion. This
is a software zone between the robots in which it is possible for the robot paths to
intersect. However, when one robot is operating in this cube, the other is prohibited
from entry and vice versa.
NOTE: Redefinition of Cube 3 parameters will probably be required after a fixture change.
CAUTION!
Do not change cube positions unless absolutely necessary, as
such changes increase the possibility that the paths of the robot
arms may intersect with fixtures or each other.
To assign the K6 or K10 robot manipulator positions to Cube 1 or Cube 2, refer to

your MRC User Functions Manuals.

NOTE: If the robot moves outside of the cube, the output is lost and the positioner will not sweep.
4.3.2 Sweeping Positioner to Side A

To sweep the positioner to Side A:
2. Make sure that Robot 1 is in Cube 1 and Robot 2 is in Cube 2. Make sure that
the calibration marks on the headstock line up to show that the positioner is in
the sweep position.
3. Press the PLAY MODE button on the MRC playback box. The indicator light
in the switch should turn on.
4. If this is the first power up, or an E-Stop recovery, press the RESET button
and right CYCLE START button at the same time.
6. Press the CYCLE START palm buttons. The drive unit disengages the
headstock and engages the sweep axis.
7. The sweep axis locking pin retracts and the MRC moves the external sweep
axis (S1) 180˚ to align Side A.
8. The sweep locking pin engages Side A.

9. The drive unit engages.
When the positioner sweeps into position at Side A, the drive unit engages the
headstock. IN #9 turns off. Side B faces towards the operator, and IN #10, LOCK
FIX. B ON, turns on.
NOTE: Before sweeping, make sure the weight of parts and fixturing is approximately equal on Sides
A and B of the positioner. (Refer to Section 3.4.1.)
NOTE: Before sweeping at first power up, make sure the correct job has been loaded.
4.3.3 Sweeping Positioner to Side B

To sweep the positioner to Side B:
2. Make sure that Robot 1 is in Cube 1 and Robot 2 is in Cube 2. Make sure that
the calibration marks on the headstock line up to show that the positioner is in
the sweep position.
3. Press the PLAY MODE button on the MRC playback box. The indicator light
in the switch should turn on.
4. If this is the first power up, or an E-Stop recovery, press the RESET button
and right CYCLE START button at the same time.

6. Press the CYCLE START palm buttons. The drive unit disengages the
headstock and engages the sweep axis.
7. The sweep axis locking pin retracts and the MRC moves the external sweep
axis (S1) 180˚ to align Side B.
8. The sweep locking pin engages.
9. The drive unit engages Side B.
When the positioner sweeps into position at Side B, the drive unit engages the
headstock. IN #10 turns off. Side A faces towards the operator, and IN #9, LOCK
FIX. A ON, turns on.
4.3.4 Rotating Headstock

To rotate the positioner headstock:
1. Enable the programming pendant.
2. Press the GROUP AXES key and make sure the key LED turns on.
3. Press the X+ or X- keys to move the headstock. Jog speed is set on the
programming pendant.
NOTE: The GROUP AXES key must be turned off to move the robots with the motion keys.

4.3.5 Programming
You can program three types of moves:
• Rotation of the positioner during air cut moves
• Robot motion with positioner stationary
• Rotation of the positioner during welding
The job you create may consist of a combination of the above. The first two types
of moves assume a robot plus station group axis specification (for example,
R1 + S1). The last type of move is called station synchronous and should be
programmed with a station plus robot(s) group axis specification (for example,
R1 + S1 S1).
CAUTION!
Remember that the robots only know where the Tool Center
Points (TCPs) are, and if not programmed carefully, the arms
could still intersect.
NOTE: Refer to the Operator's Manual for Jigless for information on coordinated motion, selecting
synchronization, group axes, and tooling calibration.
Rotating the Positioner During Air Cut Moves

1. Teach the robot to the desired position.
2. Rotate the positioner to the desired position.
a. Press the GROUP AXES button on the programming pendant. The LED
will turn on.
b. Press MAN SPEED button to select the desired axis speed while teaching.
c. Press the first set of motion keys, +X or -X, to move the axis in the desired
direction.
3. Record the step after designating the motion type and playback speed.
4. Check the path with the step FWD or step BWD keys. The position for the
robot or positioner may have to be altered to prevent torch interference.
WARNING!
The positioner axis operates as another robot axis and has the
potential for hazardous motion. The slave robot does not know
when the positioner is moving except in PLAY MODE and with
proper I/O communication.
NOTE: The GROUP AXES button must be turned off to move the robot.
NOTE: Normally, air cut moves are taught as Joint moves. The speed for Joint moves is specified as a
percentage of maximum speed (VJ=0.01 to 100.00). The axis which takes the longest time to
complete the programmed motion automatically determines the speed of the system. This
might be a wrist axis, a major robot axis, or the positioner axis. Cycle times can be reduced by
changing wrist orientation, robot position, and headstock position simultaneously between
program points rather than making the moves independently. Setting the speed at 100.00 will
normally establish the quickest time between steps.
Robot Motion with the Positioner Stationary

1. Program the robot position without moving the positioner axis.
2. Set motion type and speeds in the normal fashion.
Rotation of the Positioner During Welding

The MRC controller can coordinate motion with the external axis. This requires
calibration of the headstock and robot at the time of installation. Jobs programmed
for coordinated motion must be taught as S1 + R1 jobs.
Move instructions for coordinated motion are registered using the following
format:
Slave side
{
SMOVL=138 (manipulator with
Coordinated torch)
motion
instruction Master side
MOVL (positioner with
workpiece)
In coordinated motion instructions, an "S" prefixes the instruction to the slave side.
Converting Programs from Side A to Side B - Master Robot Only

The positioner uses the external axis to sweep the positioner in addition to driving
the headstock. This results in the external axis position being 180˚ offset from the
other side. This offset amount can be determined from the difference in the
external axis pulse counts at the two sweep positions. Software can be used to

modify the position of the external axis in a job copied to run on the opposite side.
This may be of particular importance to the ArcWorld 6200 user, as it facilitates the
development of duplicate jobs on opposite sides of the positioner.
1. Determine the pulse count difference of the external axis between Sides A
and B. To do this, display the position (POSN) screen.
2. Set the pulse count offset amount into an EX variable.
3. Make a copy of the original job. Designate the proper side in the original and
copied job name.
4. Use the modify position (MODPS) function to change the position of the
external axis in the program.
5. Step through the new program to verify the path.
4.3.6 I/O Assignment

The ArcWorld 6200 positioner and ArcWorld op-station use the following
Motoman MRC user and dedicated inputs and outputs:
MRC User Inputs

IN#1 Cycle Start interlocked with Robot 1/Cube 1 and Robot 2/Cube 2
IN#2 Auto/Manual Selector Switch
IN#9 Fixture A Lock On
IN#10 Fixture B Lock On
IN#11 Servo Drive Return
IN#12 Servo Drive Forward
For MRM2-550 Positioner only:
IN#13 In Position On
For MRM2-1100 Positioner only:
IN#13 Sweep Lock On
IN#14 Sweep Lock Off
MRC User Outputs

OUT#1 Station Ready interlocked with Robot 1/Cube 1 and Robot 2/Cube 2
OUT#4 Wire Cutter (optional)
OUT#9 Withdraw Servo
OUT#10 Advance Servo

OUT#11 Sweep Lock On (not used on MRM2-550 positioners)
OUT#12 Sweep Lock Off (not used on MRM2-550 positioners)
OUT#16 Search (optional)
In order for the positioner to sweep Robot 1 must be in Cube 1, Robot 2 must be in
Cube 2, and OUT#1 of the master robot must be ON to enable the op-station.
MRC Dedicated Inputs

• External Emergency Stop
• External Over Travel
• External Servo On
• External Hold
• Anti-Tiedown
• Master Job Start
• Alarm Reset
• Remote Mode
MRC Dedicated Outputs

• Servo On
• Alarm Occurrence
• Teach Mode
• Cube 1
• Cube 2
For more information on the user and dedicated I/Os, refer to the MRC User
Functions Manual (Motoman Part Number 132331-1), the MRC Operator's
Manual for Arc Welding (Motoman Part Number 132332-1), or the electrical
drawings in Appendix C.
4.4 SAMPLE JOBS

The following jobs are shown as examples only. Your system may have other
features and / or options requiring program changes. Double-check your system
before running these jobs.
The job structure shown is designed to allow the two robots to work independently.
The PSTART (ParallelStart) instruction accomplished this. You should not change

the structure of the Master job and Sweep jobs. You can change the A-Side and B-
Side jobs to accomplish a particular task or tasks on each side. Refer to the
Independent Control instruction manual for more information on programming
parallel jobs.
In the samples below, instructions highlighted in bold are critical for safe operation
of the system. Instructions highlighted in italics can be changed by the user. You
must teach all of the jobs listed below as concurrent jobs, except for the actual
motion jobs. Specify the concurrent option when you teach a new job.

4.4.1 Master Job
Line Step Function
000 000 NOP
001 CALL JOB:SWEEPTOA IF IN#(10)=OFF
002 CALL JOB:SWEEPTOB IF IN#(9)=OFF
003 END
4.4.2 SweeptoA Job
NOTE: This must be set up as a concurrent job.
Line Step Function

000 000 NOP
001 PAUSE IF IN#(10)=ON
002 PSTART JOB:R1R2SAFE SUB1
003 PSTART JOB:S1-B SUB2
004 PWAIT SUB1
005 PWAIT SUB2
006 DOUT OT#(1) ON
007 WAIT IN#(1)=ON
008 WAIT IN#(9)=ON
009 DOUT OT#(10) OFF
010 DOUT OT#(9) ON
011 WAIT IN#(11)=ON
012 WAIT IN#(10)=ON
014 DOUT OT#(14) ON
015 WAIT IN#(14)=ON
016 PSTART JOB:S1-A SUB1
017 PWAIT SUB1
018 DOUT OT#(9) OFF
019 DOUT OT#(10) ON
020 WAIT IN#(12)=ON
021 WAIT IN#(9)=OFF

023 DOUT OT#(13) ON
024 WAIT IN#(13)=ON
025 DOUT OT#(1) OFF
026 JUMP JOB:A-SIDE IF IN#(2)=ON
027 END
4.4.3 SweeptoB Job

Line Step Function
000 000 NOP
001 PSTART JOB:R1R2SAFE SUB1
002 PSTART JOB:S1-A SUB2
003 PWAIT SUB1
004 PWAIT SUB2
005 DOUT OT#(1) ON
006 WAIT IN#(1)=ON
007 WAIT IN#(10)=ON
009 DOUT OT#(9) ON
010 WAIT IN#(11)=ON
011 WAIT IN#(9)=ON
013 DOUT OT#(14) ON
014 WAIT IN#(14)=ON
015 PSTART JOB:S1-B SUB1
016 PWAIT SUB1
017 DOUT OT#(9) OFF
018 DOUT OT#(10) ON
019 WAIT IN#(12)=ON
020 WAIT IN#(10)=OFF
022 DOUT OT#(13) ON

023 WAIT IN#(13)=ON
024 DOUT OT#(1) OFF
025 JUMP JOB:B-SIDE IF IN#(2)=ON
026 END
4.4.4 R1R2Safe Job

Line Step Function
000 000 NOP
001 001 MOVJ VJ=100.00 +MOVJ VJ=100.00
002 END
4.4.5 S1-A Job

Line Step Function
000 000 NOP
001 001 MOVJ VJ=100.00
002 END
4.4.6 S1-B Job

Line Step Function
000 000 NOP
001 001 MOVJ VJ=100.00
002 END
4.4.7 A-Side Job
Line Step Function

000 000 NOP
001 PSTART JOB:R1-11 SUB1
003 PWAIT SUB1
004 PWAIT SUB2
005 END

4.4.8 Demo-1 Job
Line Step Function

000 000 NOP
003 PWAIT SUB1
004 PWAIT SUB2
007 PWAIT SUB1
008 PWAIT SUB2
011 PWAIT SUB1
012 PWAIT SUB2
013 PSTART JOB:CAR1-S SUB1
014 PSTART JOB:CAR2-S SUB2
015 PWAIT SUB1
016 PWAIT SUB2
017 END
4.4.9 B-Side Job
Line Step Function

000 000 NOP
003 PWAIT SUB1
004 PWAIT SUB2
005 END

NOTES

5.0 MAINTENANCE
5.1 PERIODIC MAINTENANCE

For periodic maintenance procedures and schedules for the K6 robot, the K10
robot, and the MRC controller, refer to your K6 MRC Manipulator Manual or K10
MRC Manipulator Manual.
For additional maintenance information regarding the reciprocating positioners,

refer to your positioner manual.
For maintenance information regarding the welding power source, refer to your
Excel-Arc Owner's Manual.
Table 5-1 provides a list of periodic maintenance to be performed on the ArcWorld

6200 cell. Keep in mind that the maintenance intervals given serve as guidelines
only, you should adjust the frequency of maintenance to suit your specific work
conditions.
CAUTION!
Use only the antifreeze provided by Motoman. Automotive
antifreeze contains stop-leak additives that will clog the small
torch water-cooling ports, and damage the gaskets in the water
circulator pump.
Table 5-1 Periodic Maintenance
Frequency Component Procedure
Regularly MRM2-550 servo Check for proper grease levels and

headstock RV drive quality. Use Epinoc APO grease
unit (Motoman Part Number 132434-
1) as required.
Daily Water circulator Check the fluid in the water

(water-cooled torch circulator. Add fluid as required.
application only) Use only distilled water and
approved antifreeze (Motoman
Part Number 131224-1).
Daily Air system water Check water trap and empty if

trap on the front of required.
MRM2 positioner

Table 5-1 Periodic Maintenance (Continued)
Frequency Component Procedure
Monthly MRM2 weld Lubricate with Burndy Penetrox E

grounds conductive copper lubricant (Part
Number PEN-E-8).
500 operating hrs MRM2 drive pins Spray the drive and locking pins
and locking pins with a Molykote BR2 grease or
equivalent.
1,000 operating hrs MRM2 positioner Lubricate with Shell 1029 or

gears equivalent.
20,000 operating hrs MRM2-550 servo Change the grease in the drive unit.
headstock RV drive Use Epinoc APO grease
(Motoman Part Number 132434-
1).
20,000 operating hrs MRM2-1100 servo Change the grease in the drive unit.
headstock Cyclo Use Shell Alvania RA.
drive unit
5.2 SPARE PARTS LIST

Table 5-2 Spare Parts
Description Part No.
ArcWorld 6200 safety mat kit 130157-5
Safety mat controller box 131038-1
Positioner interface 4-pole relay, 24 VDC 470108-5
Positioner interface fuse, 2 A 250 V 400647-3
Positioner interface fuse, 1/2 A 250 V 130293-2
Valve, 4-way, double solenoid 132108-1
5.3 FUSE AND CIRCUIT BREAKER PROTECTION

Tables 5-3 through 5-7 give the locations of fuses and circuit breakers that are
significant to the operation of the total system. In most cases, MRC spare fuses are
placed in the accessory bag with the MRC.
WARNING!
Replace fuses with the same type and rating. Replacement of
fuses with higher amperage rating or lower voltage will damage
the robot controller and/or auxiliary equipment necessitating
costly replacement.
Abbreviations:
CB – designates circuit breaker
F, FU or 101FU – designates fuse
Table 5-3 Excel-Arc 6045 CV Fuses and Circuit Breakers
Device
Designator Rating Part Number Location Purpose
CB1 10A 203627-7 Upper rear panel Protect 115V circuit

115V
CB2 10A 24V 203627-7 Upper rear panel Protect 24V circuit
F1 0.5 A W-11166-11 On contactor box Protect contactor

circuit
Table 5-4 Universal Welding Interface (UWI) Fuses and Circuit Breakers
Device
F1 8A 250V On KXA motor Limits damage from

speed control shorts or component
breakdowns in DC
power supply
module
FU1 4A 250V Wickman On interface Protects 115V circuit

19374K-4A board

FU2 0.25A Wickman On interface Protects shock
125V 19303K- board sensor circuit
250A
FU3 0.5A Wickman On interface Protects 24V circuit

125V 19303K- board
500A
Table 5-5 MRC Cabinet Fuses and Circuit Breakers
Device Part
Designator Rating Number Location Purpose
CB 50 A NF50-SS Upper left front Main circuit breaker for

(1MCCB) K10 incoming 200 VAC, 3-
phase for MRC cabinet
30 A NF30-SS Upper left front
K6
CB (1SV) 30 A Lower left side Protects input for servo pack
of servo pack 1SV for S, L, and U axes
CB (2SV) 30 A Lower left side Protects input for servo pack

of servo pack 2SV for R, B, and T axes
FU1 5A GDL-5 MTU-01 Protects CPT10199

250V transformer, brake, and fan
circuits
FU2 5A GDL-5 MTU-01 Protects CPT10199

250V transformer, brake, and fan
circuits
FU4 4A GP-40 MTU-01 Protects robot brake circuits

250V
FU5 4A GP-40 MTU-01 Protects robot brake circuits

250V
1FU 1A GDL-1 Top/left/rear Protects the four fan circuits

250V of the MRC
FU3 2A GDL-2 Top/left/rear Protects the 100 VAC

125V supply to the AC receptacle
for the floppy disk controller
power

FU1 3A SM1101 MBB-02 External voltage protection -
24V
FU2 3A SM1101 MBB-02 External voltage protection -

24V
Table 5-6 MRC System Fuses
Device Part
Designator Rating Number Location Purpose
1FU 1A GDL-1 Bottom/left/rear Protects 24-VDC circuit

125V
2FU 1A GDL-1 Bottom/left/rear Protects fan circuit

125V
3FU 2A MDL-2 Bottom/left/rear Protects safety mat circuit

125V

125V

125V
Table 5-7 Com-Arc III Fuses and Circuit Breakers
Device
Fuse 1A 250V TD-1 Front of Com- Protect 200V circuit

Arc III box

NOTES

APPENDIX A - RISK ASSESSMENT
MOTOMAN Risk Assessment
ArcWorld 6200 System
Application: Arc Welding Robot Type: K6 or K10
Customer: Varies Plant Loc.: Varies
See cell layout
This document was prepared to explain the rationale behind the safeguarding of
Motoman's ArcWorld 6200 robot cell. It is the User's responsibility to review
this document and verify that the safeguards are adequate for their plant
conditions. This review should include the current revision of ANSI/RIA R15.06
American National Standard for Industrial Robot Systems - Safety Requirements.
The User must also ensure that safeguards are used and maintained.
SAFEGUARDING PERSONNEL
Safeguarding Plant Personnel

• Barrier around robot work envelope.
• Interlocked gate for access to cell.
• Curtain around cell blocks ultra-violet radiation from arc.
• Serious hazards are identified by warning labels.
Safeguarding Operator
• Interlocked gates stop robot motion if opened in PLAY mode.
• Dual sensors on interlocked gates make safeguards difficult for operator
to defeat.
• Emergency Stop button on op-station.
• Two-station positioner keeps operator out of robot work envelope.
• Extended length safety mats are interlocked to stop positioner motion when
activated. Requires reset at op-station to restart.
ArcWorld 6200 Operator's Manual A-1 MOTOMAN

• Robot program will wait for Cycle Start buttons before sweeping positioner.
• Cycle Start has dual palm buttons, anti-tiedown, positioned for two-hand
operation.
Safeguarding Teacher
• Interlocked gate: Active in PLAY mode; inactive in TEACH mode.
• Clearance of 24 inches between robot and fencing.
• E-Stop (Emergency Stop) button on programming pendant.
• S-axis motion is restricted by hardstops.
• TEACH LOCK prevents operation from controller while programming
pendant is enabled.
• Sweeping of positioner from pendant requires deliberate action.
• Continuous stepping is at reduced speed.
Safeguarding Maintenance Personnel

• Robot controls are outside barrier.
• Positioner controls are inside cell, but do not require robot drive power to
troubleshoot.
• Electrical energy sources equipped with lockout/tagout.
• Programming pendant displays I/O status and other diagnostic functions.
SOURCES OF HAZARDS
Unauthorized Access
• Interlocked barrier.
• Dual interlocks, difficult to defeat by operator.
Human Errors in Judgment

• Safety mat interlocked with positioner.
• Dual palm cycle start.
• Emergency Stops on op-station, robot controller, and programming pendant.
Control Errors
• Most Safety features independent of program logic.

• Program must have instructions to wait for palm buttons to sweep.
Mechanical / Electrical Failures

• Safety mat supplied with fail-safe circuit.
• Redundant door interlocks.
• Interlocks designed to fail-safe.
• Robot has sophisticated control loop designed to remove drive power in case of
positioning error.
Environmental
• Sheet metal partition and UV curtain to help prevent eye damage from ultra-
violet radiation.
• UV curtain helps contain welding sparks.
NOTE: Fume ventilation may be required depending on application and plant conditions. (To be
determined and provided by USER.)
NOTE: Care must be used when handling and securing compressed and combustible gases. (User
supplied.)
Installation Defects
• Safeguards will place the robot in Emergency Stop unless they are correctly
connected.
• Safety fence is self supporting when fully erected (fencing should be lagged).
• Equipment is shipped on bases to ease installation and provide a secure
mounting surface (robot base needs to be leveled and lagged).
Power System Failure or

Inadvertent Power Initiation
• Easy recovery from power failure.
• Different levels of power up: primary power on, controller power on, servo
power on, and robot start. Difficult to inadvertently start.

EQUIPMENT PROTECTION
Human Errors
• Torch breakaway protects robot and torch in the case of a torch crash.
• Cube interlock requires the robot to be in a (user defined) "safe" position before
the positioner can index.
• Cube 2 Output is used as an interlock for robot motion. This is a software zone
between the robots in which it would be possible for the paths of the robots to
intersect. When the Master robot is operating in the cube, the Slave is
prohibited from entry.
Power Faults
• Isolation transformer and circuit breaker protect robot from power surges
(additional surge protection may be necessary at your facility).
• Robot "remembers" its position and place in program at power down.
• Data has battery backup and can be saved on optional floppy disk drive.
WHAT-IF CONSIDERATIONS
What if personnel reach over safety mat and pinch an arm on moving parts?
Extended length mats are provided to help prevent inadvertent access to moving
parts.
What if there is a hazard not covered by a warning label?
Labels are provided on positioner, robot, power source, feeder, transformer, and
robot controller. Persons working on equipment should have adequate training to
identify hazards.

APPENDIX B - SYSTEM OUTLINE DRAWINGS
This section contains the following outline drawings:
Drawing Number Title Sheet Number
131930 Cell Layout Sheet 1 of 23
131930 Main Bill of Material Sheet 2 of 23
ArcWorld 6200 Operator's Manual B-1 MOTOMAN

NOTES
ArcWorld 6200 Operator's Manual B-2 MOTOMAN

APPENDIX C - ELECTRICAL DRAWINGS
This section contains the following electrical drawings:

131930 Power Distribution Sheet 3 of 23
131930 MRC I/O, MRY01 Board Sheet 4 of 23
131930 MRC I/O, MEW01 Board Sheet 5 of 23
131930 MRC I/O, MI004 Board Sheet 6 of 23
131930 MRC I/O, MEW01 Board Sheet 12 of 23
131930 Cable Layout Sheet 13 of 23
131930 Cable Chart Sheet 14 of 23
131930 Ladder Diagram Sheet 15 of 23
131093 MSV01 to Servo Pack
131982 MRC to EXSB
131438 2.2KW Power Cable
131437 EXSB to Positioner
131094 MRC to Positioner
131413 Encoder Pigtail Cable
132366 Bill of Materials Sheet 1 of 2
132366 Circuit Diagram Sheet 2 of 2
130161 Connection/Schematic Diagram Sheet 6 of 7
ArcWorld 6200 Operator's Manual C-1 MOTOMAN

NOTES
ArcWorld 6200 Operator's Manual C-2 MOTOMAN

APPENDIX D - MECHANICAL DRAWINGS
This section contains the following mechanical drawings:
130930 AC Servo Drive
132349 MRC Common Base
130157 Safety Mat Sheet 5
130161 Station, Operator Sheet 1 of 7
130161 Station, Operator Sheet 2 of 7
ArcWorld 6200 Operator's Manual D-1 MOTOMAN

NOTES
ArcWorld 6200 Operator's Manual D-2 MOTOMAN

INDEX
A
A-SIDE JOB, 38
ABOUT THIS DOCUMENT, 1 I
AC RECEPTACLES, 21 I/O ASSIGNMENT, 34
AIR REQUIREMENTS, 17 INSTALLATION SAFETY, 8
ALARM / ERROR, 13 INTERLOCKS, 23
ALARM, 18 INTRODUCTION, 1
ALARMS AND ERRORS, 28
ARC SCREENS, 23 K
ARC SHIELD, 18 K-SERIES ROBOT DESCRIPTION, 11
KEYPAD, 14
B
B-SIDE JOB, 39 L
LOADING / UNLOADING PROCEDURES, 26
C LOCAL / REMOTE OPERATION, 20
CIRCUIT BREAKERS, 20 LOCKING PINS, 17
COORDINATE SYSTEM INDICATORS, 14
CUBE ASSIGNMENT, 30 M
CUSTOMER SERVICE INFORMATION, 4 MAIN POWER, 20
CYCLE SELECT, 13 MAINTENANCE, 41
CYCLE START, 18 MAINTENANCE SAFETY, 10
MAJOR ALARMS, 29
D MASTER JOB, 36
DEMO-1 JOB, 38 MASTER JOB START, 19
DESCRIPTION OF EQUIPMENT, 11 MECHANICAL SAFETY DEVICES, 7
DISPLAY, 14 MINOR ALARMS, 29
MODE SELECT, 13
E MRC CONTROLLER, 11
E-STOP RECOVERY, 26 MRM2-SERIES POSITIONER, 16
ELECTRICAL REQUIREMENTS, 17
EMERGENCY STOP (E-STOP), 13, 14, 18, 24 O
ERROR MESSAGES, 28 OPERATING PROCEDURES, 25
OPERATION, 25
F OPERATION SAFETY, 9
FAULT RECOVERY, 28 OPERATOR STATION (OP-STATION), 18
FEEDER CONTROL RECEPTACLES, 20 OPERATOR STATION ENABLE / DISABLE, 19
FENCING, 23 OPTIONAL EQUIPMENT, 4
FUSE AND CIRCUIT BREAKER PROTECTION, 42
P
G PART / FIXTURE RATING, 16
GENERAL SAFEGUARDING TIPS, 7 PERIODIC MAINTENANCE, 41
GMAW TORCH, 22 PLAYBACK BOX SUBPANEL, 13
POSITIONER AUTO / MANUAL, 19
H PROGRAMMING, 29, 32
HOLD, 13, 18 PROGRAMMING PENDANT, 14
HUMIDITY, 16 PROGRAMMING SAFETY, 8
PWF4-600 WIRE FEEDER, 22
ArcWorld 6200 Operator's Manual MOTOMAN

INDEX
R
R1R2SAFE JOB, 38
RAM TORCH BREAKAWAY MOUNT, 22
REFERENCE TO OTHER DOCUMENTATION, 4
RESET, 20
ROBOT SPEED INDICATORS, 14 SWEEPING POSITIONER TO SIDE A, 30
ROTATING HEADSTOCK, 31 SWEEPING POSITIONER TO SIDE B, 31
SWEEPTOA JOB, 36
S SWEEPTOB JOB, 37
S1-A JOB, 38 SWING DIAMETER, 16
S1-B JOB, 38 SYSTEM LAYOUT, 2
SAFETY, 5 SYSTEM OVERVIEW, 2
SAFETY EQUIPMENT, 22
SAFETY MATS, 23 T
SAMPLE JOBS, 35 TEMPERATURE OPERATING RANGE, 16
SERVO HEADSTOCK SPEED, 17 TERMINAL CONNECTORS, 20
SERVO ON, 18
SERVO POWER, 13, 14 U
SHOCK RATING, 17 UNIVERSAL WELDING INTERFACE (UWI), 22
SHOCK SENSOR RECOVERY, 27
SHUTDOWN, 28 V
SPARE PARTS LIST, 42 VOLT / AMP SETTINGS, 20
STANDARD CONVENTIONS, 6
START, 13 W
START-UP, 26 WELDING CURRENT RATING, 17
STATION READY, 18 WELDING EQUIPMENT, 22
SWEEP SPEED, 17 WELDING POWER SOURCE, 20
ArcWorld 6200 Operator's Manual MOTOMAN

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Yasnac MRC Controller

July 24, 1995

LIST OF TABLES ................................................................................................... iv

ArcWorld 6200 Operator's Manual Page i MOTOMAN

3.3.5 Servo Power.......................................................................9

ArcWorld 6200 Operator's Manual Page ii MOTOMAN

ArcWorld 6200 Operator's Manual Page iii MOTOMAN

APPENDIX B - SYSTEM OUTLINE DRAWINGS................................................ B-1

APPENDIX C - ELECTRICAL DRAWINGS.......................................................... C-1

APPENDIX D - MECHANICAL DRAWINGS ...................................................... D-1

ArcWorld 6200 Operator's Manual Page iv MOTOMAN

ArcWorld 6200 Operator's Manual Page v MOTOMAN

1.1 ABOUT THIS DOCUMENT

The Description of Equipment Section provides a detailed description of the major

The Maintenance Section includes a table of periodic maintenance requirements for

Appendix A is a Risk Assessment document. The remaining appendices contain a

1.2 SYSTEM OVERVIEW

ArcWorld 6200 Operator's Manual Page 1 MOTOMAN

1.2.1 System Layout

ArcWorld 6200 Operator's Manual Page 2 MOTOMAN

ArcWorld 6200 Operator's Manual

NOTE: Arc shield not shown for clarity.

1.3 REFERENCE TO OTHER DOCUMENTATION

1.4 CUSTOMER SERVICE INFORMATION

ArcWorld 6200 Operator's Manual Page 4 MOTOMAN

Robotic Industries Association

This safety section addresses the following:

ArcWorld 6200 Operator's Manual Page 5 MOTOMAN

ArcWorld 6200 Operator's Manual Page 6 MOTOMAN

2.3 MECHANICAL SAFETY DEVICES

ArcWorld 6200 Operator's Manual Page 7 MOTOMAN

2.5 PROGRAMMING SAFETY

ArcWorld 6200 Operator's Manual Page 8 MOTOMAN

2.6 OPERATION SAFETY

ArcWorld 6200 Operator's Manual Page 9 MOTOMAN

ArcWorld 6200 Operator's Manual Page 10 MOTOMAN

ArcWorld 6200 Operator's Manual Page 11 MOTOMAN

3.1 K-SERIES ROBOT DESCRIPTION

3.2 MRC CONTROLLER

ArcWorld 6200 Operator's Manual Page 12 MOTOMAN

Figure 3-2 MRC Playback Box

ArcWorld 6200 Operator's Manual Page 13 MOTOMAN

3.2.2 Mode Select

3.2.3 Cycle Select

3.2.4 Emergency Stop (E-Stop)

3.2.5 Alarm / Error

ArcWorld 6200 Operator's Manual Page 14 MOTOMAN

3.3 PROGRAMMING PENDANT

3.3.2 Robot Speed Indicators

3.3.3 Emergency Stop (E-Stop)

3.3.5 Servo Power

3.3.6 Coordinate System Indicators

ArcWorld 6200 Operator's Manual Page 15 MOTOMAN

ArcWorld 6200 Operator's Manual Page 17 MOTOMAN

3.4.1 Part / Fixture Rating

3.4.2 Swing Diameter

3.4.3 Temperature Operating Range

ArcWorld 6200 Operator's Manual Page 18 MOTOMAN

3.4.5 Shock Rating

3.4.6 Sweep Speed