YRC1000: ArcWorld 6000 Series System

1 Introduction
    1.1 About This Document
    1.2 System Overview
    1.3 System Layout
        1.3.1 Positioner Assembly
            1.3.1.1 Positioner Assembly Major Components
        1.3.2 Robot Cell Assembly
            1.3.2.1 Robot Cell Major Components
        1.3.3 Robot Controller Base Assembly
            1.3.3.1 The Robot Controller Base Assembly Major Components
        1.3.4 Optional Equipment
    1.4 Theory of Operation and Safe Guarding
        1.4.1 System Overview and Variations:
        1.4.2 Cell Related Safety Functions & Components:
            1.4.2.1 Trunnion Axis Position via “Axis Range Limit” Function:
            1.4.2.2 Safety Logic Circuit:
            1.4.2.3 FSU Functions Controlled by “Safety Logic Circuit”:
            1.4.2.4 Robot Range Limit Files
            1.4.2.5 Tooling Power Outputs Controlled by “Safety Logic Circuit”
            1.4.2.6 External E-Stop & Safety Gate:
            1.4.2.7 System Teaching:
            1.4.2.8 System Operation:
    1.5 Reference Documentation
        1.5.1 Location of Operations in Reference Documentation
    1.6 Customer Support Information
    1.7 Quick Start Guide
2 Equipment Description
    2.1 Robot Description
    2.2 Robot Controller
        2.2.1 Programming Pendant
    2.3 Operator Station
        2.3.1 Operator Station — ALARM/RESET
        2.3.2 Operator Station — SERVO ON
        2.3.3 Operator Station — ROBOT HOLD
        2.3.4 Operator Station — POSITIONER AUTO/MANUAL
        2.3.5 Operator Station — CYCLE START CYCLE LATCHED
        2.3.6 Operator Station — START
        2.3.7 Operator Station — REV/HOME/FWD
        2.3.8 Operator Station — LIGHT CURTAIN RESET
        2.3.9 Operator Station — Emergency Stop
        2.3.10 Operator Station — THUMBWHEEL SWITCH (Option)
    2.4 Positioner
    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
            2.6.2.2 Safety Fencing (Option)
        2.6.3 Safety Light Curtains
            2.6.3.1 Additional Safety Light Curtains (Option)
        2.6.4 E-Stop
        2.6.5 Programming Pendant’s ENABLE Switch
        2.6.6 Emergency Braking System
        2.6.7 Interlocked Work-cell Access Door
3 Installation
    3.1 Required Materials
        3.1.1 Customer-supplied Items
        3.1.2 Recommended List of Hand Tools and Equipment
    3.2 Site Preparation
    3.3 Removal of System Components from Shipping Skids
    3.4 Installation — Positioner
    3.5 Installation — Robot Common Base Assembly
    3.6 Installation — Safety Fence Assembly
    3.7 Installation — Arc Curtains
    3.8 Installation — Safety Light Curtain System
    3.9 Installation — Operator Station
    3.10 Cable Connections
        3.10.1 Connection to Earth Ground
        3.10.2 Connection to Local Electrical Service
            3.10.2.1 Robot Controller
            3.10.2.2 Process Equipment
    3.11 Safety/Operation Check
    3.12 Installation of Tooling and Fixtures
4 Operation
    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
5 Maintenance
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 Spare Parts
    7.1 Manipulator Spare Parts
    7.2 Positioner Spare Parts
    7.3 ArcWorld Interface Spare Parts
Appendix A
    A.1 Checklist
Appendix B
    B.1 Glossary