ArcWorld 1000 SERIES WITH SIGMA-7 POSITIONERS SYSTEM MANUAL (R1)

November 09, 2026 21:43
Updated

1.1 About This Document

1.2 System Overview

1.3 System Layout

1.3.1 Cell Assembly

1.3.1.1 Common Base Assembly

1.3.1.2 Positioner Assembly

1.3.1.3 Robot Cell Assembly

1.3.2 Robot Controller Base Assembly

1.3.2.1 The Robot Controller Base Assembly Major Components

1.3.3 Optional Equipment

1.4 Theory of Operation and Safe Guarding

1.4.1 System Overview and Variations:

1.4.2 Sequenced Time-Limited Reset Function

1.4.2.1 TEACH Mode

1.4.2.2 PLAY Mode

1.4.3 Cell Related Safety Functions & Components:

1.4.3.1 Side A/Side B Determination via “Axis Range Limit” Function:

1.4.3.2 Safety Logic Circuit:

1.4.3.3 Tooling Power Outputs Controlled by “Safety Logic Circuit”

1.4.3.4 External E-STOP & Safety Gate:

1.4.3.5 System Teaching:

1.4.3.6 System Operation:

1.4.3.7 Inner-cell PRE-RESET

1.5 Reference Documentation

1.5.1 Location of Operations in Reference Documentation

1.6 YASKAWA Representative Information

1.7 Quick Start Guide

2 Equipment Description

2.2.1 Programming Pendant

2.3 Operator Station

2.3.1 Operator Station — CYCLE START CYCLE LATCHED

2.3.2 Operator Station — POSITIONER AUTO/MANUAL

2.3.3 Operator Station — SYSTEM RESET

2.3.4 Operator Station — EMERGENCY STOP Button

2.5 Welding Equipment

2.5.1 Welding Power Sources

2.5.2 Wire Feeder

2.5.3 GMAW Torch

2.6 Safety Features

2.6.1 Welding Arc Protection

2.6.2 Safety Fencing (Standard)

2.6.2.1 Safety Fencing Based on Tooling Diameter

2.6.3 Safety Light Curtains

2.6.4 Emergency Stop (E-STOP)

2.6.5 Programming Pendant’s ENABLE Switch

2.6.6 Emergency Braking System

2.6.7 Interlocked Work-cell Access Doors

3.1 Required Materials

3.1.1 Customer-supplied Items

3.1.2 Recommended List of Tools and Equipment

3.2 Site Preparation

3.3 Removal of System Components from Shipping Skids

3.4 Securing ArcWorld in Position

3.5 Installation — Safety Light Curtain System

3.6 Installation — Operator Station

3.7 Cable Connections

3.7.1 Connection to Earth Ground

3.7.2 Ground Rod Connection (Optional)

3.7.3 Connection to Local Electrical Service

3.7.4 Connection to Local Air Service

3.8 Safety/Operation Check

3.9 Installation of Tooling and Fixtures

4.1 Programming

4.2 Sweeping the Positioner

4.3 Daily Operation

4.3.1 Start-up Procedure

4.3.2 Robot HOME Position

4.3.3 Master Job

4.3.4 Operation Cycle

4.3.5 Shutdown Procedure

4.4 System Recovery

4.4.1 Alarms and Errors

4.4.1.1 Error Messages

4.4.1.2 Minor Alarms

4.4.1.3 Major Alarms

4.4.2 E-STOP Recovery

4.4.3 Shock Sensor Recovery

6 Alarms and Messages

6.1 Alarms Based on Robot Position

6.2 Alarms Based on Functional Safety Unit Conditions

6.3 Cell Messages

7.1 Robot Spare Parts

7.2 Positioner Spare Parts

7.3 ArcWorld Interface Spare Parts

8 Lockout/Tagout Labels

8.1 Example Labels

8.2 Standard Lockout Hierarchy

8.2.1 Electrical Disconnect - E1

8.2.2 Pneumatic Disconnect - P1

8.2.3 Gate Entrance - G*

8.2.4 Water Lockout - W*

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