130787-1 - FabWorld Op ERC

FabWorld
Operator's Manual
Part Number 130787-1
March 14, 1994
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.
©1994 by MOTOMAN
All Rights Reserved
TABLE OF CONTENTS
Section Page
1.0 INTRODUCTION............................................................................................ 1
1.1 GENERAL DESCRIPTION OF THE FABWORLD SYSTEM ................. 1
1.2 REFERENCE TO OTHER DOCUMENTATION ...................................2
2.0 SAFETY ..........................................................................................................3
2.1 STANDARD CONVENTIONS.............................................................3
2.2 CAUTIONS AND DANGERS .............................................................4
3.0 DETAILED DESCRIPTION OF EQUIPMENT.................................................7
3.1 K6 AND K10 ROBOTS ......................................................................7
3.2 ERC CONTROLLER............................................................................7
3.3 WELDING POWER SOURCES ...........................................................8
3.4 MULTI-PLANE (TILT/ROTATE) POSITIONER...................................8
3.4.1 Specifications ......................................................................8
3.4.2 Temperature Operating Range.............................................8
3.4.3 Humidity..............................................................................8
3.4.4 Air Requirements ................................................................9
3.4.5 Electrical Requirements.......................................................9
3.4.6 Welding Current Rating.......................................................9
3.4.7 Hard Stops..........................................................................9
3.5 ROTARY PLANE (HEADSTOCK/TAILSTOCK)....................................9
3.5.1 Specifications ......................................................................9
3.5.2 Temperature Operating Range........................................... 10
3.5.3 Humidity............................................................................ 10
3.5.4 Electrical Requirements..................................................... 10
3.5.5 Welding Current Rating..................................................... 10
3.6 STATIONARY FLAT TABLE ............................................................. 10
3.6.1 Part/Fixture Rating ........................................................... 10
3.6.2 Dimensions ....................................................................... 11
3.6.3 Welding Current Rating..................................................... 11
3.7 STATIONARY TACK/WELDING TABLE ........................................... 11
3.7.1 Part/Fixture Rating ........................................................... 11
3.7.2 Dimensions ....................................................................... 11
3.7.3 Welding Current Range ..................................................... 11
3.8 OPERATOR STATIONS................................................................... 11
3.8.1 Emergency Stop ................................................................ 12
3.8.2 Robot Hold........................................................................ 12
3.8.3 Cycle Start ....................................................................... 12
3.8.4 Station Ready.................................................................... 12
3.8.5 Alarm ............................................................................... 12
3.8.6 Servo On .......................................................................... 12
3.8.7 Positioner Auto/Manual..................................................... 12
3.8.8 Master Job Start.............................................................. 13
3.8.9 Reset................................................................................ 13
3.9 SAFETY EQUIPMENT ..................................................................... 13
3.9.1 Safety Mats ...................................................................... 13
3.9.2 Photo Eyes........................................................................ 13
3.9.3 Zone Ring Monitor............................................................ 13
3.9.4 Emergency Stops............................................................... 14
3.9.5 Arc Curtains ..................................................................... 14
3.9.6 Fencing............................................................................. 14
3.10 OPTIONAL EQUIPMENT................................................................ 15
3.10.1 Torch Cleaning and Prep Station ....................................... 15
3.10.2 Com-Arc II Seam Tracking With Touch Sense Seam Finder. 15
3.10.3 Automatic Wire Cutter....................................................... 15
3.10.4 Bulk DeReeler .................................................................. 15
3.10.5 Water-Cooled Weld Package .............................................. 16
4.0 THEORY OF OPERATIONS......................................................................... 17
4.1 SEQUENCE OF OPERATIONS ........................................................ 17
4.1.1 Startup ............................................................................. 17
4.1.2 E-Stop Occurrence............................................................ 18
4.1.3 E-Stop Recovery................................................................ 18
4.1.4 Alarm Recovery ................................................................ 18
4.1.5 Shutdown.......................................................................... 18
4.2 PROGRAMMING THE MULTI-PLANE POSITIONER ..................... 19
4.2.1 Tilting the Positioner......................................................... 19
4.2.2 Flattening the Positioner................................................... 19
4.2.3 Rotating the Positioner......................................................20
4.3 PROGRAMMING THE ROTARY PLANE POSITIONER...................20
4.3.1 Rotating the Positioner......................................................20
4.4 I/O ASSIGNMENT...........................................................................20
4.5 SAMPLE JOBS................................................................................23
4.5.1 Master Job.......................................................................23
4.5.2 Weld-A Job .......................................................................23
4.5.3 Weld-B Job.......................................................................23
4.5.4 Weld-C Job .......................................................................23
4.5.5 Tilt Job .............................................................................24
4.5.6 Flat Job ............................................................................24
4.5.7 Clean Job..........................................................................24
4.5.8 ARC-ON1 Job...................................................................26
4.5.9 ARC-OFF1 Job..................................................................26
5.0 MAINTENANCE...........................................................................................27
5.1 PERIODIC MAINTENANCE............................................................27
5.1.1 Photo Eyes........................................................................27
5.1.2 Safety Mats ......................................................................27
5.1.3 Torch Tender (Optional)....................................................27
5.1.4 Wire Cutter (Optional) ......................................................27
5.1.5 Water Circulator Kit (Optional) .........................................28
5.1.6 UWI Pancake Feeder.........................................................28
5.1.7 Side Mount Package ..........................................................28
5.2 SPARE PARTS LIST.........................................................................28
5.3 FUSE AND CIRCUIT BREAKER PROTECTION...............................29
5.3.1 Welding Power Sources.....................................................29
5.3.2 ERC Cabinet Robot Protection...........................................29
5.3.3 External Axis Cabinet ....................................................... 31
5.3.4 Motoman Welding Interface (On ERC Door)......................32
5.3.5 Com-Arc II Fuse (If Com-Arc II Option Is Furnished)........32
5.4 LIST OF DRAWINGS.......................................................................33
5.4.1 FabWorld System Outline Drawings (Appendix A)..............33
5.4.2 Mechanical Drawings (Appendix B)...................................33
5.4.3 Electrical Drawings (Appendix C)......................................34
5.4.4 Ladder Drawings (Appendix D)..........................................34
5.5 SERVICE TELEPHONE NUMBER....................................................35
6.0 TROUBLESHOOTING.................................................................................36
6.1 GENERAL TROUBLESHOOTING INFORMATION..........................36
6.1.1 TW-5 Torch and TA-4 Torch .............................................36
6.1.2 External E-Stop Condition .................................................36
6.1.3 Torch Tender....................................................................37
6.1.4 Wire Cutter.......................................................................37
6.1.5 Water Circulator...............................................................37
6.1.6 Operator Stations .............................................................37
6.1.7 Side Mount Package ..........................................................37
6.1.8 UWI Pancake Feeder.........................................................37
APPENDIX A - FABWORLD SYSTEM OUTLINE DRAWINGS............................ A-1
APPENDIX B - FABWORLD MECHANICAL DRAWINGS.................................. B-1
APPENDIX C - FABWORLD ELECTRICAL DRAWINGS ..................................... C-1
APPENDIX D - LADDER DRAWINGS................................................................ D-1
APPENDIX E - ARONSON MANUAL..................................................................E-1

1.0 INTRODUCTION
1.1 GENERAL DESCRIPTION OF THE FABWORLD SYSTEM

FabWorld systems feature a modular, flexible approach to configuring robotic arc
welding systems. A FabWorld system can be tailored to meet ever-changing
production needs because the modular design allows for the addition of positioners
and operator stations at a later date for increased versatility. FabWorld systems are
designed especially for low- to medium-volume production.
A FabWorld system consists of a K6 or a K10 robot, an ERC robot controller, and

one, two, or three positioners. The three positioner options are the multi-plane
(tilt/rotate) positioner, the rotary plane (headstock/tailstock) positioner, and the
stationary flat table. A stationary tack/welding table is also an option.
A FabWorld system will have either one, two, or three stations (zones). Each
station includes a positioner, an operator station, safety fencing, photo eyes, arc
screens, and safety mats. Many different FabWorld system configurations are
possible due to the different modules that are available.
Motoman's growing family of standard systems reduce cost, and lower the risk
involved with custom-designed robotic welding systems. Additionally,
standardized components offer benefits in safety, spare parts, service, and
reliability.
All of the equipment in a FabWorld system is designed to work together. The

result is an optimized, integrated system.
The main components of a FabWorld system are:

• K6 or K10 Robot
• ERC Robot Controller
• Welding Power Source
• Positioner(s)
• Operator Station(s)
• Safety Equipment
NOTE: Refer to Appendix A (FabWorld System Outline Drawings) for examples of FabWorld
Systems.
FabWorld Operator's Manual Page 1 MOTOMAN

1.2 REFERENCE TO OTHER DOCUMENTATION
For additional information, refer to the following:
• Motoman K10S Robot Manipulator Manual (Part Number 479951-4)
• Motoman K6S Robot Manipulator Manual (Part Number 479951-2)
• Motoman K6SB1 Robot Manipulator Manual (Part Number 479951-14)
• Motoman ERC Programming Manual (Part Number 479950-3)
• Motoman ERC OP2 Key Function Manual (Part Number 479950-4)
• Motoman Robotic Welding Manual (Part Number 479950-6)
• Hobart Owner's Manual for Arc-Master 500 (OM-815)
• Hobart Owner's Manual for FabStar 4030 (OM-849)
• Hobart Owner's Manual for Excel-Arc 6045 (OM-826)
• ERC Controller I/O Structure Manual (Motoman Part Number 479236-4)
• ERC Dedicated I/O Guidelines Manual (Motoman Part Number 479236-14)

2.0 SAFETY
It is the purchaser's responsibility to insure 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. The last page of this section is
an order form for the safety standard and other safety material from RIA. This
information can also 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 shall not be operated by personnel who have not been
trained.
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, and NOTE. Pay particular attention to the
information provided under these headings which are defined below (in descending
order of severity). Also read the Risk Assessment information located in
Appendix A of this manual.
➪ DANGER!
Information appearing under the DANGER caption concerns the
protection of personnel from the immediate and imminent
hazards which, if not avoided, will result in immediate, serious
personal injury or loss of life in addition to equipment damage.
Examples are: Exposed high voltage, open fans, or pinch points.

➪ WARNING!
Information appearing under the WARNING caption concerns the
protection of personnel and equipment from potential
hazards,which can result in personal injury or loss of life in
addition to equipment damage. Examples are: Incorrect body
position, insufficient ventilation, etc.
➪ CAUTION!
Information appearing under the CAUTION caption concerns the
protection of equipment, software, and data from hazards which
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 CAUTIONS AND DANGERS

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 have a good knowledge of its safe operation, working range and
potential dangers of operation. All personnel must read and thoroughly understand
the manuals and all DANGERs, WARNINGs, CAUTIONs, and the conditions
under which they may occur. Plant safety personnel must conduct a risk analysis
of the completed system and working conditions prior to its operation.
➪ CAUTION!
System operation may differ due to product improvements,
options, equipment, accessories, and programming technique!
Additional guarding, barriers, interlocked access, pressure mats, and other means
of operator and area protection may be required depending on system installation or
location and system operation. 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 safely operated 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.

Refer to the ANSI / RIA publication R15.06-1986, "Safety Requirements for
Industrial Robots" and other industry publications for additional safety guidelines.

➪ DANGER!
Improper wiring can cause severe personal injury or death and
can damage the equipment! Only trained personnel familiar with
the robot manuals, electrical design and equipment
interconnections should be permitted to connect or modify the
system.
➪ DANGER!
High voltage can kill! DO NOT touch electrically live parts.
Disconnect and LOCKOUT / TAGOUT all electrical connections to
equipment before making electrical connections.
➪ DANGER!
Check all safety equipment frequently for proper operation!
Repair any non-functioning safety equipment immediately.
➪ DANGER!
This equipment has multiple sources of electrical supply!
Electrical interconnections are made between the ERC controller,
external axis cabinet, and other equipment. Disconnect and
Lockout all electrical circuits before making modifications
and/or connections.
The ERC Controller allows the customer to modify its internal logic for maximum
robot performance. Considerable care must be taken when making these
modifications. Double check all modifications under every mode of operation to
insure that you have not created hazardous or dangerous situations that may cause
personal injury or damage the robot or other parts of the system.
➪ DANGER!
All modifications made to the ERC Controller will change the way
the robot operates and can cause severe personal injury or death

and can damage the robot! This includes ERC parameters; LADDER
NODES 1, 2, or 3; and I/O modifications. Recheck and test all
changes at slow speed.

➪ DANGER!
Any person in the robot cell during teaching must have the robot
teach pendant in their hand!
➪ DANGER!
Improper operation can damage equipment! Only trained
personnel familiar with the operation of this Motoman robot, the
operator's manuals, the system equipment, options, and
accessories should be permitted to operate this robot system.
Read and understand the following messages and the other messages used throughout this manual.
➪ CAUTION!
Improper connections can damage the robot! All connections
must be made within the standard voltage and current ratings of
the robot I/O.
➪ CAUTION!
The robot must be placed into E-STOP mode whenever it is NOT in
use!
NOTE: 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.

3.0 DETAILED DESCRIPTION OF EQUIPMENT
3.1 K6 AND K10 ROBOTS

The Motoman K6S and K10S robots, and the YASNAC ERC controller represent
state-of-the-art technology in robotics today (see Motoman K10S Robot
Manipulator Manual Part Number 479951-4, Motoman K6S Robot Manipulator
Manual Part Number 479951-2, Motoman K6SB1 Robot Manipulator Manul (Part
Number 479951-14), and Motoman ERC Programming Manual Part Number
479950-3).
The six-axis K6S robot has a payload of 6 kg. or 13.2 pounds. It features a 1,322
mm (52.01") reach and has a relative positioning accuracy of + 0.1 mm or + .004
inches.
The six-axis K10S robot has a payload of 10 kg. or 22 pounds. It features a 1,555
mm (61.2") reach and has a relative positioning accuracy of + 0.1 mm or + .004
inches.
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. Motoman K-Series robots have been constructed for ease of
maintenance, utilizing brushless AC servo motors with absolute position encoders.
All motors are readily accessible. A combination of capacitance and lithium
batteries in both the robot encoder assemblies and in the Motoman YASNAC ERC
controller protects program positional data for up to one year. The replacement life
expectancy for the lithium battery is approximately three years.
A teach pendant is used to program all robot motions. Standard software features
include point-to-point, linear, and circular interpolation. A 9-inch CRT display and
menu programming are supplied as a standard feature. This feature facilitates initial
programming, editing, and maintenance functions, as large blocks of program or
maintenance information can be readily displayed. The teach pendant has its own
eight-character LED display. In addition to controlling robot motion, the teach
pendant allows for program scrolling and verification.
3.2 ERC CONTROLLER

For detailed information regarding the ERC controller (including ERC setting of
absolute welding values, refer to the Motoman ERC Programming Manual (Part
Number 479950-3).

3.3 WELDING POWER SOURCES
The purpose of a power source is to provide electric power of the proper current
and voltage to maintain a welding arc. The FabWorld system can use a number of
different welding power sources. For detailed information regarding specific MIG
welding power sources, refer to the following manuals:
3.4 MULTI-PLANE (TILT/ROTATE) POSITIONER
3.4.1 Specifications
Capacity: 500-lb. load, center of gravity, 6" overhang, 6" off center
Rotation: 10 to 0 RPM variable speed @ 3,000 lbs.-in. torque; servo motor is

direct-coupled to harmonic drive, which is direct coupled to table. Motor is
equipped with internal brake.
Table: RT18 Table - 18" diameter x 1" thick, machined surface, 2.000 id x 1/2"
deep pilot hole.
Chassis: Fixed height. Rotation axis at 27-3/4" above floor.
Tilt Module: Equipped with rotational axis same as above. Tilt axis is powered
by pneumatic cylinder to one positioner (0° to 90°) set by hard stops. 500-lb.
capacity, eccentric 6" overhang, 6" off center.
Includes: Operator station with safety mats and photo eyes, external axis cabinet
capable of holding up to four external axes, and common bed. The tailstock is an
option for the multi-plane positioner.
3.4.2 Temperature Operating Range

40-110 º Fahrenheit.
3.4.3 Humidity
Non-condensing 10-90% relative humidity.

NOTE: In high-humidity areas, the table tooling plate may rust or corrode. Surface protection should
be used.

3.4.4 Air Requirements
Clean dry air 15 scfm @ 90 psig.
3.4.5 Electrical Requirements

All electrical power required to operate the unit is supplied from the ERC controller
and consists of a 24 VDC circuit to provide power for the solenoids and interface.
The servo tables are operated by external ERC servo motors.
The external axis cabinet provides 200 volts for servos.
3.4.6 Welding Current Rating

The positioner has a welding current capacity of 600 amperes at 100% duty cycle.
3.4.7 Hard Stops

The tilt axis is equipped with hard stops.
3.5 ROTARY PLANE (HEADSTOCK/TAILSTOCK)

POSITIONER)
3.5.1 Specifications
Capacity: 500-lb. load, center of gravity, 6" overhang, 6" off center. Combined
HS/TS capacity 1,000 lbs., 3" of center of gravity.
Rotation: 10 to zero RPM variable speed @ 3,000 lbs.-in. torque; servo motor is
direct-coupled to harmonic drive which is direct coupled to table. Motor equipped
with internal brake.
deep pilot hole.
Chassis: Fixed height. Rotation axis at 27-3/4" above floor.
capable of holding up to four external axes, and common bed (ties headstock to
tailstock), which provides for a maximum of 76" between mounting plates.

There is also a heavy-duty model of the rotary plane positioner. Its specifications
are as follows:
Capacity: 1,000 lbs load, center of gravity, 6" overhang, 6" off center.
Rotation: 10 to zero RPM variable speed @ 6,000 lbs.-in. torque; servo motor is
direct-coupled to harmonic drive which is direct coupled to table. Motor equipped
with internal brake.
deep pilot hole.
Chassis: Fixed height. Rotation axis at 33" above floor.
capable of holding up to four external axes, and common bed (ties headstock to
tailstock), which provides for a maximum of 76" between mounting plates.
3.5.2 Temperature Operating Range

40-110 º Fahrenheit.
3.5.3 Humidity
Non-condensing 10-90% relative humidity.
NOTE: In high-humidity areas, the table tooling plate may rust or corrode. Surface protection should
be used.
3.5.4 Electrical Requirements

The servo tables are operated by external ERC servo motors.

3.6 STATIONARY FLAT TABLE
3.6.1 Part/Fixture Rating

1500 lbs.

3.6.2 Dimensions
The dimensions of the stationary flat table are: 1/2" thick by 24" wide by 92" long
by 34" high.

3.7 STATIONARY TACK/WELDING TABLE
3.7.1 Part/Fixture Rating

1500 lbs.
3.7.2 Dimensions
The dimensions of the stationary tack/welding table are 1/2" thick by 24" wide by
31.25" long by 34" high.
3.7.3 Welding Current Range

3.8 OPERATOR STATIONS

There are two types of operator stations: the master operator station and the slave
operator station. The slave operator station has the following controls:
• Emergency Stop
• Robot Hold
• Station Ready
• Alarm
• Master Job Start
• Cycle Start
The master operator station has the above controls and it also has the following
additional controls:
• Reset

• Servo On
• Positioner Auto /Manual

The master and slave operator station controls are described in the following
paragraphs.
3.8.1 Emergency Stop

The operator station E-Stop, the robot E-Stop, the safety mats, and the photo eyes
are connected in series in the emergency stop circuit. If the E-Stop circuit is
interrupted, the robot and the positioner will go into the E-Stop condition. The
operator station E-Stop light will come on when the E-Stop pushbutton is pressed.
In the E-Stop condition, power to the positioner and robot is removed.
3.8.2 Robot Hold

The operator station HOLD button is a normally closed pushbutton and is
connected to the ERC to cause the robot to stop its program when the button is
pressed.
3.8.3 Cycle Start

The palm buttons in the operator station use an anti-tie-down technique for robot
input. The anti-tie-down timer is set for 10 seconds. If the palm buttons are held
down for more than 10 seconds, the timer will time out and prevent the input from
reaching the robot. The CYCLE START buttons are connected to robot Input #1.
3.8.4 Station Ready

The STATION READY indicates when the positioner is ready to move..
3.8.5 Alarm
The ALARM lamp is connected to the robot alarm occurrence output. The
ALARM lamp turns on when the robot encounters a major or minor alarm
condition.
3.8.6 Servo On
The SERVO ON pushbutton is connected to the robot servo on input. The robot
servo motors will turn on when the SERVO ON pushbutton is pressed and an E-
Stop condition does not exist.
3.8.7 Positioner Auto/Manual

The POSITIONER AUTO/MANUAL selector switch is used to select
automatic or manual mode for the unit. The selector switch is connected to robot
Input #2. When the selector switch is in the automatic position, the robot will

process the part when the cycle is initiated. In manual mode, the robot will not
process the part after the cycle is initiated. This function is dependent on the
structure of the master job.

3.8.8 Master Job Start
The MASTER JOB START pushbutton is connected to the robot external start
input. The robot will start the current active job when pressed if the robot is in play
mode and the servo motors are on.
3.8.9 Reset
The RESET pushbutton is connected to the robot alarm reset input. Any alarm or
error condition will be cleared when this button is pressed. In addition, the RESET
and the right CYCLE START pushbuttons (which are located on the master
operator station only) are interlocked. When pressed simultaneously, they enable
the positioner if the robot servo motors are on.
3.9 SAFETY EQUIPMENT

The FabWorld system has a host of safety equipment. The safety equipment is
provided to ensure safe operation of this robotic cell providing all standard safety
precautions are taken. The ANSI/RIA RIS.06 Robot Safety Standard stipulates that
the user is responsible for safeguarding. Users are responsible for determining
if the provided safeguards are adequate for plant conditions. Users must also
ensure that safeguards are maintained in working order.
3.9.1 Safety Mats

The safety mats provided with the FabWorld System are used to prevent anyone
from entering the positioner area while the robot is operating in that zone. In play
mode, if someone steps on the safety mat when the robot is in the same zone, the
entire system will E-Stop.
3.9.2 Photo Eyes

The through-beam photoelectric switch consists of two devices: a light sender and
a light receiver . The separate construction permits large scanning distances with a
corresponding reserve capacity. In play mode, if someone breaks the photo beam
when the robot is in the same zone, the entire system will E-Stop.
3.9.3 Zone Ring Monitor

The zone ring monitor is a monitoring control that allows the operator to load and
unload parts in any zone other than the active welding zone. The zone monitor
works in conjunction with the safety mats and the photo eyes of the system. In
play mode, if an operator enters the active welding zone, an E-stop condition will
occur.

3.9.4 Emergency Stops
The FabWorld System has several strategically placed E-Stop buttons. The
following is a list of E-stop button locations:
1. The ERC control panel has one E-STOP button.
2. The ERC teach pendant has one E-STOP button.
3. Each positioner operator station has one E-STOP button.
The following actions will also cause an E-stop in play mode:

4. Breaking the photo eyes light beam in an active zone
5. Stepping on the safety mats in an active welding zone
6. Lack of air pressure in the multi-plane (tilt/rotate) positioner.
3.9.5 Arc Curtains
➪ WARNING!
Although this curtain is used to block dangerous arc radiation, it
is not recommended that you look directly at the arc during
operation without protective eyewear!
There are two sets of arc curtains. One set is used to cover the safety fencing of the
robotic cell. The second set is mounted on posts that are located between the robot
and the positioner(s). No fencing or arc curtain is provided at the opening of the
separate work stations (where the operator is loading and unloading the parts).
Motoman recommends that the customer provide portable arc curtains that can be
moved in place to protect workers in the areas against any arc flash.
NOTE: If the FabWorld system contains a stationary tack/welding table, arc strip curtains will be
provided.
3.9.6 Fencing
The safety fencing provided with the FabWorld system is used to enclose and
define the robotic cell.

3.10 OPTIONAL EQUIPMENT
3.10.1 Torch Cleaning and Prep Station

This device uses compressed air to drive a nozzle-vibrating device and to blow anti-
spatter compound into the torch nozzle.
3.10.2 Com-Arc II Seam Tracking With Touch Sense Seam Finder

The Com-Arc II seam tracking function with touch sensing (Part No. 479194-1)
includes:
• Com-Arc II Seam Tracker. The Com-Arc II Seam Tracker functions by

weaving the welding wire in the joint (i.e., Fillet Weld, "T", Lap and Single
"V" Groove Weld) and sensing the current at each stroke of the weaving
motion. If the detected current at each stroke is not the same, the robot will
correct its path in a direction required to make the current the same.
Correction can be either left, right, up, or down as determined by the robot
controller and Com-Arc II unit. Seam tracking can be performed in either
short-circuiting, globular, or spray arc welding modes. The usable
amperage range is from 90-460 amps.
• MOTOMAN Touch Sensing Function (200-Volt System). The

Motoman Touch Sensing Function enables the robot to find the welding
joint. The 200-volt system allows use of touch sense seam finding even
with coated or dirty parts. The robot is programmmed to “touch” the part
in one, two, or three dimensions, using the welding wire. The programmed
path is then parallel shifted to the new location. Motoman automatic wire
cutter is recommended.
NOTE: The Com-Arc II Seam Tracking and Touch Sensing Functions can be used together or
separately.
3.10.3 Automatic Wire Cutter

The Motoman automatic wire cutter automatically cuts welding wire to a desired
length. A programmed path brings the welding wire into the cutter jaw. Using a
robot output signal, the pneumatic device will shear off the wire, leaving a clean
edge at the programmed stick-out length. A specific length of wire is used for
touch sensing on the robot system. The unit can cut up to 1.6 mm (0.062")
diameter solid wire. Working pressure is 85-140 psi.
3.10.4 Bulk DeReeler

For information regarding bulk dereelers, contact your local Motoman sales
representative.

3.10.5 Water-Cooled Weld Package
The water-cooled package includes a Hobart TW-5 water-cooled torch and a self-
contained water circulator with a 3-gallon capacity. This water-cooled MIG torch is
rated at 550 amps - 100% duty cycle using mixed gases.

4.0 THEORY OF OPERATIONS
4.1 SEQUENCE OF OPERATIONS

The sequence of operations for FabWorld after startup is:
1. Load parts into the fixture for Station A.
2. Press the right and left CYCLE START palm buttons on the operator station.
The robot will begin welding the unwelded parts.
3. Repeat Steps 1 through 3 for all additional stations.
4. Unload the welded parts.
NOTE: Once the cycle start palm buttons are pushed, the input siganl is latched. If all operator
stations are latched, the master job controls the order in which the jobs are actually run.
4.1.1 Startup
To start up the FabWorld from a power-off condition, follow these steps:
1. Turn on all power disconnects.
2. Turn on the external axis cabinet.
3. Turn on the ERC.
4. Turn on the welding power source.
5. Turn on the welding gas.
6. Turn on air supply to positioner.
7. Place the robot in TEACH mode.
8. Turn on the robot servo motors.
9. Call up the master job.
10. Place the robot in PLAY/AUTO mode.
11. Initialize the positioner by pressing the RESET button and the right CYCLE
START button on the master operator station simultaneously.
12. Press the MASTER JOB START button on the master operator station.
13. Wait for the STATION READY light to turn on.
The FabWorld system is now ready for operation.

4.1.2 E-Stop Occurrence
There are three different ways an E-Stop condition can occur:
1. Pressing the E-STOP button on the operator station, the teach pendant, or the
ERC terminal.
2. Stepping on the safety mat or breaking the photo eyes light beam when the
robot is in the same zone and in play mode.
3. Lack of air pressure on the multi-plane positioner.
4.1.3 E-Stop Recovery

To restart the FabWorld system from an E-Stop condition occurring during
operation, use the following procedure:
1. Clear the cause of the E-Stop condition:
a. Release the E-STOP button on the operator station, the teach pendant, or
the ERC terminal.
b. Step off of the safety mat or clear the path of the photo eyes.
c. Turn on the air supply (if required).

2. Turn on the robot servo motors.
3. Initialize the system by pressing the RESET button and the right CYCLE
START buttons on the master operator station simultaneously.
4. Press the MASTER JOB START button on the master operator station.
The FabWorld system will continue its operation.
4.1.4 Alarm Recovery

For detailed information about alarm recovery, refer to the Motoman K6S Robot
Manipulator Manual (Part Number 479951-2) for the K6 robot, and to the
Motoman K10S Robot Manipulator Manual (Part Number 479951-4) for the
K10S robot.
4.1.5 Shutdown
To shut down the FabWorld system after operation is complete, use the following
procedure:
1. Ensure that the robot is in the starting position.
2. Turn off the robot servo motors by pressing the E-STOP button on either the
operator station, the teach pendant, or the ERC terminal.

3. Place the robot in teach mode.
4. Turn off the ERC.

5. Turn off the welding power source.
6. Turn off the welding gas.
7. Turn off air supply to positioner.
8. Turn off the power disconnects.
9. Turn off external axis cabinet.
The FabWorld system is now shut down.
4.2 PROGRAMMING THE MULTI-PLANE POSITIONER
4.2.1 Tilting the Positioner

To manually tilt the multi-plane positioner in the teach mode, follow these steps:
• Ensure that robot servo power is on.
• Ensure that the positioner is enabled.
• Ensure that the robot is in CUBE #1.
• Ensure that Robot Output #10 is off.
• Ensure that Robot Output #9 is on.
• Wait for Input #6 to come on.
• Turn Input #9 off.
NOTE: If a second tilt/rotate positioner is included, different outputs will be used.
4.2.2 Flattening the Positioner

To manually flatten the multi-plane positioner in the teach mode, follow these steps:
• Ensure that robot servo power is on.
• Ensure that the positioner is enabled.
• Ensure that the robot is in CUBE #1.
• Ensure that Robot Output #9 is off.
• Ensure that Robot Output #10 is on.
• Wait for Input #5 to come on.
• Turn Input #10 off.
NOTE: If a second tilt/rotate positioner is included, different outputs will be used.

4.2.3 Rotating the Positioner
The rotation axes of the positioner are controlled by the ERC external axis function.
The motion points for the external axes are taught and recorded in the program in
the same manner as any of the robot axis. The speed and position are controlled by
the ERC. Pressing the EXT AXIS button on the teach pendant changes the blue
motion keys from robot axis keys to positioner axis keys.
4.3 PROGRAMMING THE ROTARY PLANE POSITIONER
4.3.1 Rotating the Positioner

The rotation axes of the positioner(s) are controlled by the ERC external axis
function. The motion points for the external axes are taught and recorded in the
program in the same manner as any of the robot axis. The speed and position are
controlled by the ERC. Pressing the EXT AXIS button on the teach pendant
changes the blue keys from robot axis keys to positioner axis keys.
4.4 I/O ASSIGNMENT
ERC User Inputs

IN#1 Cycle Start 1
IN#2 Auto/Manual Selector Switch
IN#3 Cycle Start 2
IN#4 Cycle Start 3
IN#5 Flat Pos. (1st Multi-Plane Positioner Only)
IN#6 Tilt Pos. (1st Multi-Plane Positioner Only)
IN#17 Zone 1 Active
IN#18 Zone 2 Active
IN#19 Zone 3 Active

ERC User Outputs
OUT#3 Inch Reverse (Wire)
OUT#4 Gas Purge
OUT#6 Station #1 Ready
OUT#9 Tilt Pos. (1st Multi-Plane Positioner Only)
OUT#10 Flat Pos. (1st Multi-Plane Positioner Only)
OUT#11 Wire Cutter
OUT#16 Touch Sense Enable
OUT#44 Unlatch Zone 1
OUT#63 Inch Forward (Wire)
ERC Dedicated Inputs

• Servo ON
• Start
• Hold
• Alarm Reset
• Cube #1 Intrf. Prohibit
• Cube #2 Intrf. Prohibit
• Arc Occurrence Prohibit
• Arc On Response
• Arc Occurrence Check
• Arc Shortage
• Gas Shortage
• Water Shortage
• Panel Operation Prohibit
• Teach
• Play and Auto

• In-Guard Safety Drive Inst.
ERC Dedicated Outputs

• Control Power Off
• External Emergency Stop
• Servo Power On
• Emergency Stop Ok
• Play And Auto Mode
• Teaching
• Holding
• Battery Low Power
• Working In Intrf. Cube #1
• Working In Intrf. Cube #2
• Operating
• Alarm Occurrence
• Operation Ready
• In-Guard Safety Drive Inst.
• Gas On
• Inch Reverse
• Power Source On
• Wire Feeder On
• Gas Low (Optional)
• Water Low (Optional)
For more information on the Motoman ERC User and Dedicated I/Os, refer to the
ERC Controller I/O Structure Manual (Motoman Part Number 479236-4) and the
ERC Dedicated I/O Guidelines Manual (Motoman Part Number 479236-14).

4.5 SAMPLE JOBS
4.5.1 Master Job

Line Step Function
000 000 NOP
001 001 MOVJ C000 E000 VJ=100.00 CONT
002 CALL JOB:WELD JOB A IF INPUT#1 = 1
003 CALL JOB:WELD JOB B IF INPUT#3 = 1
004 CALL JOB:WELD JOB C IF INPUT#4 = 1
005 END
4.5.2 Weld-A Job

Station A looks for Input #1. Station A will perform whatever job has been
programmed to take place in Station A. Output #44 must be turned on at the
beginning of each weld A job to unlatch the operator station. This prevents the
robot from repeating weld jobs.
Output #6 must be turned on in the beginning of weld job A. Output #6 controls

the station ready light on the operator station.
4.5.3 Weld-B Job

Station B looks for Input #3. Station B will perform whatever job has been
programmed to take place in Station B. Output #45 must be turned on at the
beginning of each weld B job to unlatch the operator station. This prevents the
Output #7 must be turned on in the beginning of weld job B. Output #7 controls

4.5.4 Weld-C Job

Station C looks for Input #4. Station C will perform whatever job has been
programmed to take place in Station C. Output #46 must be turned on at the
beginning of each weld C job to unlatch the operator station. This prevents the
Output #8 must be turned on in the beginning of weld job B. Output #8 controls


4.5.5 Tilt Job
Line Step Function
000 000 NOP
001 DOUT OT#10 0
002 DOUT OT#09 1
003 WAIT IN#05=0
004 WAIT IN#06=1
005 DOUT OT#09 0
006 RET
007 END
4.5.6 Flat Job

Line Step Function
000 000 NOP
001 DOUT OT#09 0
002 DOUT OT#10 1
003 WAIT IN#06=0
004 WAIT IN#05=1
005 DOUT OT#10 0
006 RET
007 END
4.5.7 Clean Job
➪ CAUTION!
Robot will operate independently of the external axis. Be sure
the robot points are clear of the positioner and fixture.

NOTE: Clean jobs should be programmed with Position P variables on systems that have external
axes. This allows the robot to make motions through a clean job while any external axis
movement is inhibited. For information about P variables, see the Motoman ERC Programming
Manual (Part Number 479950-3).
NOTE: P variables other than those used on the above example may be used. The number of steps
may also vary.
Line Step Function

000 000 NOP
001 001 MOVJ P040 VJ=100.00 CONT
002 002 MOVJ P041 VJ=100.00 CONT
003 003 MOVJ P042 VJ=100.00 CONT
004 004 MOVL P043 V=187.0 CONT
005 TIMER T=1.50
006 005 MOVL P042 V=187.0 CONT
007 006 MOVL P044 V=187.0 CONT
008 007 MOVL P045 V=187.0 CONT
009 TIMER T=1.00
010 008 MOVL P044 V=187.0 CONT
011 009 MOVL P046 V=166.7 CONT NWAIT
012 PULSE OT#63 T=0.50
013 010 MOVL P047 V=187.0 CONT
014 PULSE OT#13 T=0.50
015 011 MOVL P048 V=46.0 CONT
016 012 MOVJ P040 VJ=100.00 CONT
017 SET B00=0
018 RET
019 END
NOTE: The program will operate on Side A or Side B because there are no external axis positions.
NOTE: Lines 11 through 15 are for the optional wire cutter.

4.5.8 ARC-ON1 Job
Line Step Function
000 000 NOP
001 VWELD 6.82
002 AWELD 10.00
003 ARCON
004 TIMER T=0.30
005 RET
006 END
4.5.9 ARC-OFF1 Job

Line Step Function
000 000 NOP
001 VWELD 4.80
002 AWELD 5.50
003 TIMER T=0.30
004 ARCOF
005 RET
006 END
NOTE: Several arc-on and arc-off files can be used if different starting and ending AWELD and VWELD
values are needed.
NOTE: The ABSVOL and ABSCUR instructions can be substituted for AWELD and VWELD. Refer to
the ERC Setting of Absolute Welding Values Manual (479236-23).
NOTE: Arc on/off files can vary greatly for different applications. The above are basic examples and
are for reference only.

5.0 MAINTENANCE
5.1 PERIODIC MAINTENANCE

For periodic maintenance procedures and schedules for the K6S robot, the K10S
robot, and the ERC controller, refer to the Motoman K6SB Robot Manipulator
Manual (Part Number 479951-2), the Motoman K10S Robot Manipulator Manual
(Part Number 479951-4), and the Motoman K6SB1 Manipulator Man
ual (Part Number 479951-14).
For maintenance information regarding the multi-plane and rotary plane
positioners, refer to the Aronson Manual (see Appendix D of this manual).
For maintenance information regarding the TW-5 torch, and the TA-4 torch, refer
to the Motoman Robotic Welding Manual (Part Number 479950-6).
5.1.1 Photo Eyes

When dust accumulates on photo eyes, clean with a soft clean cloth and nonsolvent
cleaner. How often the photo eyes will need to be cleaned depends on the welding
environment in which they are located.
5.1.2 Safety Mats

Ensure that safety mats stay clear of debris by sweeping them periodically. It is
important to sweep both the tops of the mats and underneath the mats.
Ensure that mats lay flat. Anything under the mats may cause them to trip.
Check mats for tears, gouges, buckling, etc. Replace mats if necessary.
5.1.3 Torch Tender (Optional)

Refill anti-spatter container as needed.
5.1.4 Wire Cutter (Optional)
➪ CAUTION!
Turn off air supply.
The following maintenance procedures should be done weekly:

• Apply grease to the wire cutting mechanism through the grease zerk provided.
• Clean the unit with detergent machine cleaner.

5.1.5 Water Circulator Kit (Optional)
➪ WARNING!
Do not use automotive antifreezes. Automotive antifreeze has
stop leak additives that will clog the small GMAW torch water
cooling ports. The additives will damage gaskets in the pump.
Use Dynaflux Inc. Defense DF929"or equivalent Ethelene Glycol
with fungus inhibitors and emulsion lubrication.
Check liquid levels daily. Refill as needed. Flush the system completely once a
year.
5.1.6 UWI Pancake Feeder

Clean feed roll grooves with industrial machine cleaner every 6 months. Replace
feed rolls as required.
5.1.7 Side Mount Package

Whenever wire spool is changed, use low-pressure air to remove dirt and dust
from input wire liner. Replace liner if visible signs of wear are present or if liner is
clogged.
5.2 SPARE PARTS LIST

The major components of the FabWorld system are listed on Sheet 3 of System
Drawing 131468 in Appendix B of this manual. Other recommended spare parts
are as follows:
PART MFR MFR #
1. FabWorld Safety Mats (5' by 3') 130157-10

2.FabWorld Safety Mats (6' by 36") 130157-9
3. Safety Mat Control Box 131038-1
4. Positioner Interface 4 Pole Relay, 24 VDC 470108-5
5. Omni-Beam Emitter Sensor 131632-1
6. Omni-Beam Receiver Sensor 131633-1
7. Emitter Power Block Receptacle 131634-1

8. Emitter Power Block Receptacle 131635-1
9. Conductor Cables 130130-X

5.3 FUSE AND CIRCUIT BREAKER PROTECTION
The following are the locations of fuse and circuit breakers that are significant to the
operation of the total system. In most cases, ERC spare fuses are placed in the
accessory bag with the ERC.
➪ WARNING!
Replace fuses with the same type. 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
5.3.1 Welding Power Sources

For welding power source information, refer to the following manuals:
5.3.2 ERC Cabinet Robot Protection
NOTE: The circuit breaker for the K6S servo packs is on the two servo packs and not individually
protected as the K10S is below. All other fuses and protection in the ERC remain the same.
DEVICE AMP MFG # MOTOMAN# LOCATION
CB(1MCCB) 50 NF50–SS Upper left front - K10S

CB(1MCCB) 30 NF30-SS Upper left front - K6S
Purpose: This is the main circuit breaker for incoming 200-volt AC, 3-phase for ERC cabinet.

DEVICE AMP MFG # MOTOMAN# LOCATION (Cont.)
CB(1SV) K10S 15 Under PC servo board

CB(1SV) K6S 20 Lower servo pack edge
Purpose: Protects input for servo pack 1SV for S Axis. If this breaker trips, you will get ALARM
0222, SERVO PACK FAILURE with the axis affected highlighted on the CRT. The red LED on
the servo pack will display #2. The same ALARM will be displayed for the other axes.
CB(2SV) K10S 15 Under PC servo board

CB(2SV) K6S 20 Lower servo pack edge
Purpose: Protects input for servo pack 2SV for L Axis.
CB 15 Under PC servo board
Purpose: Protects input for servo pack 3SV for U Axis.
Purpose: Protects input for servo pack 4SV for R Axis.
Purpose: Protects input for servo pack 5SV for B Axis.
Purpose: Protects input for servo pack 6SV for T Axis.
Fuse(FU2) 1/2 AGC–1/2 I/O–03 PC board
Purpose: Protects I/O–03 power to the transistors outputs and inputs. If this fuse blows, the
ALARM 1170 will be displayed and will indicate "DC 24 V POWER SUPPLY FAILURE." The
red LED on the HOLD button will be lit.
Fuse(1FU) 1 GDL–1 Top left rear
Purpose: Protects the four fan circuits of the ERC.

Purpose: Protects the control transformer and fan (above computer rack) in the ERC.
Purpose: Protects the control transformer and fan (above computer rack) in the ERC.
Purpose: Protects the 100 volt AC supply to the AC receptacle (under the latching cover below the
CRT) for floppy disk controller power.
Fuse(FU1) 3.2 GP-32 Top of I/O–03
Purpose: Protects the robot brake circuits. If the fuse blows, ALARM 0212 "Overload S axis"
and/or ALARM 0222 "Servo pack failure S-axis" will be displayed on the CRT. This is caused by
the servo motor trying to drive against the brake which did not release. The S-axis is usually the
first to be overloaded, but other manipulator or external axis may cause the same type alarm.
Fuse (FU3) 3.2 GP–32 Top of I/O–03
Purpose: Protects the robot brake circuits.
5.3.3 External Axis Cabinet

CB 15 Upper right of cabinet
Purpose: Protects incoming power.
Fuse (1FU) 0.5 MDL-05 Upper left of cabinet
Purpose: Protects servo pack power.
Purpose: Protects servo pack power..
Purpose: Protects contactor (external from ERC).

Purpose: Protects fan power.
Purpose: Protects fan power.
5.3.4 Motoman Welding Interface (On ERC Door)

Fuse 2 MDL–2 On din rail end
Purpose: Protects 24 volt control transformer and feeder circuit.
Fuse 1/4 AGC–1/4 On din rail end
Purpose: Protects 24 volt DC computer circuit if impact sensor leads short to robot or ground.
Fuse 8 ABC–8 On motor controller
Purpose: Protects motor controller if output/transistors short.
Fuse 1/2 AGX–1/2 On logic relay board
Purpose: Protects 24 volt DC regulated power supply on relay logic board when used.
5.3.5 Com-Arc II Fuse (If Com-Arc II Option Is Furnished)

Fuse 1 TD–1 On front of
250 volt Com-Arc box
Purpose: Protects 200-volt circuit in Com-Arc II.

5.4 LIST OF DRAWINGS
The FabWorld drawing package is as follows:
5.4.1 FabWorld System Outline Drawings (Appendix A)

131468 (Sheet 1 of 14) K6R System Outline
131468 (Sheet 2 of 14) K10R System Outline
131468 (Sheet 3 of 14) Bill of Material
131468 (Sheet 9 of 14) Rotary System Outline
131468 (Sheet 11 of 14) Fence Configurations
131469 (Sheet 1 of 14) K6M System Outline
131469 (Sheet 3 of 14) K-M System Outline
131470 (Sheet 1 of 14) K6F System Outline
131470 (Sheet 2 of 14) K10F System Outline
131470 (Sheet 3 of 14) K-F System Outline
131470 (Sheet 9 of 14) Flat Table System Outline
5.4.2 Mechanical Drawings (Appendix B)

131475 (Sheet 1 of 1) FabWorld Sub-Tack Table
131498 (Sheet 1 of 2) Common Bed Plate
131503 (Sheet 1 of 6) Tailstock Positioner
131512 (Sheet 1 of 6) Headstock Positioner
131621 (Sheet 1 of 1) FabWorld Weld Table
131716 (Sheet 1 of 1) Servo Rotate Positioner
9939-7402-00 (Sheet 1 of 1) R/T2, Air Tilt/Servo Rotate Module E/A
9939-7401-01 (Sheet 1 of 1) Air Tilt/Servo Rotate "B" Module E/A

9939-7401-00 (Sheet 1 of 1) Air Tilt/Servo Rotate "A" Module E/A
5.4.3 Electrical Drawings (Appendix C)

131647 (Sheets 1-4 of 4) External Axis Kit
5.4.4 Ladder Drawings (Appendix D)

131468 (Sheet 12 of 14) Single Node Ladder Diagram

5.5 SERVICE TELEPHONE NUMBER

If you are in need of technical assistance, call the Motoman technical
service staff at (513)-847-3200.

6.0 TROUBLESHOOTING
6.1 GENERAL TROUBLESHOOTING INFORMATION

For troubleshooting information about the K6S robot, the K10S robot, and the
ERC controller, refer to the Motoman K6S Robot Manipulator Manual (Part
Number 479951-2), the Motoman K10S Robot Manipulator Manual (Part Number
479951-4), and the Motoman K6SB1 Manipulator Manual (Part Number 479951-
14).
For troubleshooting information regarding the multi-plane and rotary plane
positioners, refer to the Aronson Manual (see Appendix D of this manual).
For troubleshooting information regarding the UWI interface assembly and the
UWI Pancake Feeder, refer to the Motoman Robotic Welding Manual (Part
Number 479950-6).
6.1.1 TW-5 Torch and TA-4 Torch
Problem: Wire feed stoppages/wire not feeding correctly.
Possible Cause Solution

Clogged contact tube Clean or replace the contact
tube.
Clogged conduit in welding gun assembly Cleaning conduit with

compressed air, or replace
conduit.
Sharps bends or kinks in wire feed conduit Straighten or replace

wire feed conduit.
Excessive pressure on wire feed rolls (can Reduce pressure on wire feed
cause breakage of wire) rolls.
Inadequate pressure on wire feed rolls Increase pressure on wire feed

rolls in order to provide
adequate driving force.
Spool of wire clamped too tightly to the Reduce clamping pressure on

wire reel support spool of wire.
6.1.2 External E-Stop Condition

Ensure that all safety mat control boxes are active (green light indicates active; red
light indicates E-Stop). Ensure that photo eyes are aligned correctly (indicator light
on indicates that photo eyes are receiving signal).

6.1.3 Torch Tender
Refer to the Automation Peripherals Torch Tender Installation and Operation
Instructions Manual.
6.1.4 Wire Cutter

If a no-air condition occurs, ensure that air lines are connected properly.
If wire cutter will not operate, check wiring cable for cuts, crimps, breaks, etc.
6.1.5 Water Circulator

If unit will not operate, ensure that unit is plugged in.
If a no or low water condition occurs, check water lines for cuts, crimps, breaks,
etc. Straighten or replace lines. Replace water as required.
Check for leaks around the fittings. Tighten fittings.
6.1.6 Operator Stations

If indicator lights are not operational, replace lights.
6.1.7 Side Mount Package

If erratic wire speed occurs or wire tangles on spool, remove dust cover and adjust
tension by using a wrench to tighten or loosen bolt. Erratic wire speed is an
indication of tension that is too tight; wire tangling on the spool indicates tension
that is too loose.
6.1.8 UWI Pancake Feeder

If unstable wire feed occurs, check for wear of gear teeth. If gear teeth are worn,
replace entire feed roll assembly.
If arcing or overheating occurs, clean the brass current gun connections. Replace
brass pin if cleaning the connections does not solve the problem.
If erratic wire feed occurs, or if wire shavings are present, check the center guide
and output guides for wear. Replace guides if they are worn.
If gross porosity is present, check for loose hose on gas collar. Tighten hose
connection.

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FabWorld

March 14, 1994

APPENDIX B - FABWORLD MECHANICAL DRAWINGS.................................. B-1

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

APPENDIX D - LADDER DRAWINGS................................................................ D-1

APPENDIX E - ARONSON MANUAL..................................................................E-1

1.1 GENERAL DESCRIPTION OF THE FABWORLD SYSTEM

A FabWorld system consists of a K6 or a K10 robot, an ERC robot controller, and

All of the equipment in a FabWorld system is designed to work together. The

The main components of a FabWorld system are:

FabWorld Operator's Manual Page 1 MOTOMAN

FabWorld Operator's Manual Page 2 MOTOMAN

Robotic Industries Association

2.1 STANDARD CONVENTIONS

FabWorld Operator's Manual Page 3 MOTOMAN

2.2 CAUTIONS AND DANGERS

FabWorld Operator's Manual Page 4 MOTOMAN

FabWorld Operator's Manual Page 5 MOTOMAN

FabWorld Operator's Manual Page 6 MOTOMAN

FabWorld Operator's Manual Page 7 MOTOMAN

FabWorld Operator's Manual Page 8 MOTOMAN

3.1 K6 AND K10 ROBOTS

3.2 ERC CONTROLLER

FabWorld Operator's Manual Page 9 MOTOMAN

3.4 MULTI-PLANE (TILT/ROTATE) POSITIONER

Rotation: 10 to 0 RPM variable speed @ 3,000 lbs.-in. torque; servo motor is

Chassis: Fixed height. Rotation axis at 27-3/4" above floor.

3.4.2 Temperature Operating Range

FabWorld Operator's Manual Page 10 MOTOMAN

FabWorld Operator's Manual Page 11 MOTOMAN

3.4.5 Electrical Requirements

The external axis cabinet provides 200 volts for servos.

3.4.6 Welding Current Rating

3.4.7 Hard Stops

3.5 ROTARY PLANE (HEADSTOCK/TAILSTOCK)

Chassis: Fixed height. Rotation axis at 27-3/4" above floor.

FabWorld Operator's Manual Page 12 MOTOMAN

Chassis: Fixed height. Rotation axis at 33" above floor.

3.5.2 Temperature Operating Range

3.5.4 Electrical Requirements

3.5.5 Welding Current Rating

3.6 STATIONARY FLAT TABLE

3.6.1 Part/Fixture Rating

FabWorld Operator's Manual Page 13 MOTOMAN

3.6.3 Welding Current Rating

3.7 STATIONARY TACK/WELDING TABLE

3.7.1 Part/Fixture Rating

3.7.3 Welding Current Range

3.8 OPERATOR STATIONS

FabWorld Operator's Manual Page 14 MOTOMAN

FabWorld Operator's Manual Page 15 MOTOMAN

3.8.1 Emergency Stop

3.8.2 Robot Hold

3.8.3 Cycle Start

3.8.4 Station Ready

3.8.7 Positioner Auto/Manual

FabWorld Operator's Manual Page 16 MOTOMAN

FabWorld Operator's Manual Page 17 MOTOMAN

3.9 SAFETY EQUIPMENT

3.9.1 Safety Mats

3.9.2 Photo Eyes

3.9.3 Zone Ring Monitor

FabWorld Operator's Manual Page 18 MOTOMAN

The following actions will also cause an E-stop in play mode: