Motoman XRC Series - User Manual

Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
Motoman XRC Controller
Spot Welding
Manual
for Medar
TM
Integrated
Weld Control
Part Number: 147296-1CD
Revision: 0

Motoman XRC Series Specifications

General

Programming Language	INFORM III
Communication Ports	Ethernet
Power Requirements	200-220 VAC single phase, 50/60 Hz, 1.5 kVA
Mounting	Floor mount
Operating Temperature	0°C to 45°C
Humidity	20% to 80% (non-condensing)
Storage Temperature	-20°C to 60°C

Summary

Introduction to Spot Welding Systems

1.2 System Configuration

Details the components and layout of the spot welding system.

1.3 System Components

1.3.1 XRC 2001 Controller

1.3.2 Robot

1.3.3 Servo Robot Gun

1.3.4 Medar Integrated Weld Control

1.4 Equipment and Component Specifications

Safety Guidelines for Robotic Welding

2.3 General Safeguarding Tips

Provides essential tips for safe operation and personnel awareness.

2.4 Mechanical Safety Devices

2.5 Installation Safety

2.6 Programming Safety

2.7 Operation Safety

Details essential safety tips for operating the robotic system.

2.8 Maintenance Safety

Outlines crucial safety precautions for performing maintenance tasks.

Theory of Resistance Welding

3.2 The Weld Cycle

3.3 Critical Factors in Resistance Welding

Explains essential factors influencing resistance welding performance.

3.3.1 Current in Welding

Details the significance of current in spot welding and transformer function.

3.3.2 Voltage in Welding

3.3.3 Ohms Law Application

3.3.5 Reactance, Resistance, and Power Factor

3.4 AC Welding Process

3.5 DC Welding Process

3.6 Spot Welding Theory Basics

3.6.1 Steppers in Welding

3.7 Current Control Methods

Details different methods for controlling welding current.

3.7.1 Automatic Power Factor

Explains how automatic power factor correction prevents half-cycling.

3.7.2 Automatic Voltage Compensation Mode

Describes AVC mode and its voltage-based current regulation.

3.7.3 Constant Current Mode

Explains Constant Current mode for precise current regulation.

Setup and Operation Procedures

4.1 Setting Up Parameters

Guides on setting Medar Timer parameters for system configuration.

4.2 Set Up Procedures

4.3 Simple Weld Condition Files

4.4 Enhanced Weld Schedules

4.5 Stepper Condition Files

4.6 Monitoring Weld Results

Troubleshooting Guide

5.1 Medar Alarms and Errors

Identifies common Medar alarms and their potential causes.

5.2 XRC Alarms and Errors

Lists common XRC alarms and error types for diagnosis.

5.3 Troubleshooting Welding Problems

Provides a chart of common welding problems and their probable causes.

5.4 Tips for Producing Quality Welds

5.5 Troubleshooting Dual Port RAM I;O

Guides on troubleshooting communication issues using I/O definitions.