Title of This Help Project

Title of this help project
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Table of contents
Equipment ........................................................................................................ 6
Overview ...................................................................................................... 6
Footprint ...................................................................................................... 6
Components ................................................................................................. 6
Safety ............................................................................................................... 9
General Safety Rules ...................................................................................... 9
E-Stop ........................................................................................................ 10
Stack light ................................................................................................... 11
Safety zone ................................................................................................. 12
Safety analysis ............................................................................................. 13
Machine Operation ........................................................................................... 14
Equipment start-up ...................................................................................... 14
Reset safety circuit ....................................................................................... 14
Loading / Unloading Parts ............................................................................. 14
Vertical Loading/Unloading ....................................................................... 16
Horizontal Loading/Unloading ................................................................... 17
Automatic mode .......................................................................................... 18
Automatic mode .......................................................................................... 19
Main page ............................................................................................... 19
Jog setting .............................................................................................. 20
Manual mode .............................................................................................. 21
Rotator ................................................................................................... 21
ZoneA/B ................................................................................................. 24
ROBOT BASE .......................................................................................... 25
Equipment shutdown ................................................................................... 26
Robotic programs ........................................................................................ 26
G1_GoHome ........................................................................................... 26
Program goal ...................................................................................... 26
Frequency ........................................................................................... 26
Launched from where, how? ................................................................. 27
Operation ........................................................................................... 27
Safe zone ............................................................................................ 28
G1_GoPark ............................................................................................. 30
Program goal ...................................................................................... 30
Frequency ........................................................................................... 30
Operations .......................................................................................... 30
G1_WireCut ............................................................................................ 30
Program goal ...................................................................................... 31
Frequency ........................................................................................... 31
Operation ........................................................................................... 31
G1_TCPCheck_1 & G1_TCPCheck_16 ........................................................ 32
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Program goal ...................................................................................... 32

Frequency ........................................................................................... 32
G1_TCPCalib_1 & G1_TCPCalib_16 ........................................................... 32
Program goal ...................................................................................... 32
Frequency ........................................................................................... 32
G0_ELV_PSH ........................................................................................... 34
Program goal ...................................................................................... 34
Frequency ........................................................................................... 34
Parameters .......................................................................................... 34
Operation ........................................................................................... 35
G0_AtHome ............................................................................................ 36
Program goal ...................................................................................... 36
Frequency ........................................................................................... 36
Operation ........................................................................................... 36
G0_Init ................................................................................................... 36
Program goal ...................................................................................... 36
Frequency ........................................................................................... 37
Operation ........................................................................................... 37
G0_End .................................................................................................. 38
Program goal ...................................................................................... 38
Frequency ........................................................................................... 38
Operation ........................................................................................... 38
G0_PreWeld ............................................................................................ 38
Program goal ...................................................................................... 38
Frequency ........................................................................................... 39
Operation ........................................................................................... 39
G0_PostWeld ........................................................................................... 40
Program goal ...................................................................................... 40
Frequency ........................................................................................... 40
Operation .......................................................................................... 40
G0_MoveRail ........................................................................................... 40
Program goal ...................................................................................... 40
Frequency ........................................................................................... 41
Operation ........................................................................................... 41
G0_PreTouch .......................................................................................... 42
Program goal ...................................................................................... 42
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Frequency ........................................................................................... 42
Operation ........................................................................................... 42
G0_PostTouch ......................................................................................... 42
Program goal ...................................................................................... 42
Frequency ........................................................................................... 43
Operation ........................................................................................... 43
G0_Rotate ............................................................................................... 44
Program goal ...................................................................................... 44
Frequency ........................................................................................... 44
Parameters .......................................................................................... 44
Operation ROBOT/PLC ......................................................................... 45
AGTʼs Functions ........................................................................................... 45
G0_Verify_Axis ........................................................................................ 45
Program goal ...................................................................................... 45
Frequency ........................................................................................... 45
Parameters ......................................................................................... 46
Operation ........................................................................................... 46
G0_Offset ............................................................................................... 47
Program goal ...................................................................................... 47
Frequency ........................................................................................... 47
Parameters ......................................................................................... 47
Operation ........................................................................................... 47
Calibration .................................................................................................. 47
Rail mastering ............................................................................................. 48
Error management ....................................................................................... 48
JOB Preparator ................................................................................................ 49
Create & Export 3D model ............................................................................ 49
Explanation of the AGT Tools ........................................................................ 49
Welding path generation step ........................................................................ 49
Owe Template ............................................................................................. 50
Generate production program ....................................................................... 51
Maintenance .................................................................................................... 52
Preventive Maintenance ................................................................................ 52
Welding system operation & maintenance ....................................................... 54
Spare Parts List ............................................................................................ 55
Troubleshooting .............................................................................................. 58
Welding ...................................................................................................... 58
Rotators and Robot Carriage ......................................................................... 61
Alarm list .................................................................................................... 61
Training .......................................................................................................... 62
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Welding ...................................................................................................... 62
General instructions ......................................................................................... 63
Welding ...................................................................................................... 63
Jobs export ............................................................................................. 70
Robot archive ...................................................................................... 71
Weld table ........................................................................................... 72
Welding flow chart ............................................................................... 73
Identification of the weld ...................................................................... 73
Workpiece Positioning & Limitations ............................................................... 74
Beam Justification .................................................................................... 74
Beam Height Adjustment .......................................................................... 75
Beam width Adjustment ........................................................................... 76
Accessories Limitations ............................................................................. 77
Beam Weight Capacity .............................................................................. 80
After Market .................................................................................................... 81
Remote support ........................................................................................... 81
Revision History ............................................................................................... 81
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Equipment
1.1
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Overview
The BeamMaster Weld (hereafter referred as BMW) is a generic robotic cell dedicated to the welding
operation of pre-assembled accessories on various kind of beams. The BMW is divided in two zones that
can be used as distinct workstation. Depending on the arrangement used, this specific machine can
produce beams either:
1. 40 feet long in zone A or B;
2. 80 feet long in zones A and B together;
As part of the pre-processing, an assembler is required to position and tack welds the various accessories
on a given beam. On the other hand, the beam welding sequence and robotʼs paths are pre-programmed in
an offline operation with the supplied software letting the operator free to call upon desired program from the
interface.
The BMW is composed of a robot equipped with and welding tool. The robot is mounted on a carriage that
rides along a longitudinal rail. The beam is mounted and constrained to on 2, 3 or 4 rotators. These allow the
rotation and positioning of the beam around its longitudinal axis. The operatorʼs console allows the operator
to interact with the machine for various tasks such as manual control and work order processing. Finally,
the machine is delimited by a safety perimeter that breaks into zones and constraint the robot motion to
ensure proper safety of the surroundings.
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Footprint
For the footprint of the machine, refer to APPENDIX C – MECHANICAL DRAWINGS, supplied with this
manual.
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Components
The following section depicts the main components of the machine:
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Figure 1 : Overview of the Machine
1. Robot Carriage and Rail

2. Beam Rotator
3. Zone Separator Light Curtain
4. Perimeter Fencing
5. Operatorʼs Console
6. Front Separator Light Curtains
Figure 2 : Overview of the Robot Carriage.

1. Carriage
2. Welding Wire Feeder
3. Welder Robot
4. Rail
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5. Welding Source
6. Welding Tool
7. Welding Torch Cleaning Station
Figure 3 : Overview of the Welding Tool
1. Welding Torch
2. Laser Touch Device
3. Tooling Clutch
Figure 4 : Overview of the Operator Console
1. Robot Controller
2. Machine Interface (HMI)
3. Main Control Panel
4. Robot Teach Pendant
5. Status Stack Light
6. Safety Key, Zone A
7. Emergency Stop (ESTOP)
8. Safety Key, Zone B
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Figure 5 : Overview of the Beam Rotator
1. Rotatorʼs Ring
2. Vertical Clamp (Hereafter referred to V-Clamp)
3. H-Clamp Manual Activation Dock
4. Horizontal Clamp (Hereafter referred to H-Clamp)
5. V-Clamp Manual Activation Dock
6. V-Clamp Tilt Lock
7. H-Clamp Shims (2x)
8. Rotatorʼs Control Panel
9. Rotatorʼs Base
10. Beam Height Adjustment Bar
11. Servomotor
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Safety
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General Safety Rules

A summary of the inherent risks is also available on APPENDIX G (TEC-AGT-216-001-R01 - Safety rules for
BM48).
SAFETY
Do not operate this system without receiving a complete training and
fully understanding this manual.
LASER
This cell uses a laser Class 2B relating to the touch finding system. Avoid
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direct exposure
Never look at the laser beam
OPERATION
Operator is responsible for all workers safety. Always assure that there is
nobody in the cell before starting up or running the equipment. Working
around the welding cell can be dangerous; always wear protection
gloves and safety glasses. The cell can project particles.
HOT PARTS AND COMPONENTS
Hot equipment and hot parts result from the welding cell, always wear
heat protection equipment when you inspect or manipulate parts.
SLIPPERY FLOOR
The use of cutting lubricant can cause a slippery floor. Always clean the floor
before entering the production cell and be alert.
SHARP EDGES
Some parts and particles can cause scratches and bodily injuries.
Always wear protection gloves and safety glasses. During intervention
on the production cell, take care of yourself and always pay attention to
potential dangers.
MODIFICATIONS OR MOVING THE EQUIPMENT
For all modifications or moving parts of the equipment, always refer to the
manufacturer for an evaluation of the modifications. The owner of the equipment
is fully responsible of all non-authorized modifications of the machine.
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E-Stop
There are 4 Emergency Stop buttons on the BeamMaster Weld:
One at each extremities of the cell (total of 2);

One at the HMI station;
One on the robot Smart Pad.
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Stack light
There is a stack light on the bottom of the HMI station. That stack light gives quickly information about the
state of the machine:
1. GREEN LIGHT
- Solid: The equipment is producing.
2. ORANGE LIGHT
- Solid: The equipment is ready, but not in production.
3. RED LIGHT
- Solid: Equipment is in alarm (e-stop, robot, light curtain).
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Safety zone
Robot have safety envelope (SafeOperation) :
• Prevents worker to get hit outside of the cell
• Prevent robot to hit the fences
• Prevent robot and worker to work inside of the same zone
Light curtains:
• Front light curtains (ZoneA & ZoneB)
– Prevent worker to go over the robot working space
• Middle light curtains
– Prevent worker to go over the robot working space
– Prevent robot to go over the worker working space
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Safety analysis
A safety analysis was performed during the design of the equipment. See ANNEX G: TEC-ALF-001-000-
R00-Risk Analysis (Safety-Machine). A summary of the inherent risks is also available on ANNEX G (TEC-
AGT-216-001-R02 - Safety rules for BM48)
It is the responsibility of the employer to provide an adequate work environment, which allows safe
maintenance and operation.
All employees must be trained before operating the equipment, in order to perform their work safely.
Adequate training of employees should include:
a. A review of the inherent risks in the operation of the equipment.

b. A review of the inherent risks in the operation of the laser.
c. Familiarization with all equipment components and working tools, which allows minimizing
the risks.
d. Detailed explanation, demonstration and supervision of safety procedures that must be
observed by the user.
e. Instructions on personal safety.
f. Warning on possible effects of unsafe use, to ensure the safety of both the employee and
the others.
g. The importance of cleanliness of the work area, for everyoneʼs safety.
The operator must take all necessary precautions to ensure personal safety:
h. Long hair must be tied, to avoid strangulation near moving parts.

i. Loose clothes, jewelry and other accessories should not be worn near mechanisms, which
may cause a strangulation hazard.
The employer should not allow a non-experienced person to operate equipment or perform
maintenance without adequate safety training.
The employer is responsible for the training of its operators and must inform them of the inherent
risks in the use of the equipment. They should be supervised or assisted during their training.
The employer should refer to the risk analysis grid and general safety rules to understand the risks
surrounding the operation and maintenance of the robotic welding cell.
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Machine Operation
1.1
Equipment start-up
To avoid any start-up problems, please follow the sequence as displayed below:
1. Power ON
a. Main electrical panel
b. Rotators
c. Welder
d. Robot
2. Turn on the air supply
3. Hit the reset button on the HMI (Reset the emergency stop status)
4. Turn on welding gas
5. Put robot controller in “EXT” mode
6. Reset the robot fault by pressing on “RESET ALARMS” on the HMI
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Reset safety circuit

There are 2 different safety circuits:
1. Emergency stop
a. Make sure that all the E-Stops are not pressed
b. Hit the reset button on the operator control panel
2. Fences (Light curtains)
a. Make sure that the zone to be reset is clear
b. Turn the desired Safety key(A or B or Both) to ON
c. Hit Reset
Loading / Unloading Parts

The loading and unloading operations can be performed in two different methods, either vertical (e.g. using a
crane) or horizontal (e.g. using a fork-lift). The procedure for each method is depicted in their respective
section below. Either way, the following safety rules must be applied when loading and unloading a beam
from the machine. Failing to follow these rules may results in surrounding people injury or death and
damage to the machine.
Before transportation of the beam:

A. Ensure the beam is solidly attached to the loading/unloading carrier.
B. Ensure the robot and its carriage is clear from the path of the beam.
C. For all the beamʼs rotators that will be used with the beam, ensure both clamps are completely
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opened and clear the way of the beam.
D. Depending on the method used (vertical or horizontal), ensure the beamʼs rotator is oriented in
its loading/unloading position.
E. Adjust and secure the beam height adjustment bar prior to loading a new beam.
F. Make sure the beam width insert is installed on the H Clamp if required.
G. Ensure the beam weight repartition do not result in exceeding the rotatorʼs capacity (see
section 8.2 for further information about rotatorʼs capacity)
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During transportation of the beam:

H. Stabilize the beam during the whole lifting or moving operation. Moreover when entering or
exiting the beamʼs rotators.
I. When entering or removing the beam from the rotator, do so with care and at slow speed to
minimise impacts and shocks to the rotator.
J. Never load a beam if the gearmotor have been remove or damaged.
K. When putting down the beam in the rotators, ensure the beam sits on every rotator prior to
detach it form the loading carrier
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Vertical Loading/Unloading
To load a beam with the vertical method, follow the steps below:
1) Through the operatorʼs console, select in which zone the beam will be loaded (zone A, zone B or
zones A &B). If zones A & B is selected, both zones must be in the same position prior loading;
2) Make sure the clamps are fully opened. Use a drill or impact driver with a torque limiter to clamp /
unclamp;
3) Enter the zone into which the beam will be loaded and adjust the beam height adjustment bar, if
required;
4) Lift the beam and transport it inside the rotators taking care to respect the safety rules stated
above;
5) When setting down the beam ensure it is justified to the side of the opening where the vertical
clamp is located, such as the picture below.
Figure 6 : Vertical Loading Justification.
6) Once the beam have been put down and detached, clamp the H Clamp and V Clamp of every rotator
using a drill or impact driver with a torque limiter.
7) Check the beam is well clamped by every rotator. A gap of 1/16 to 1/8 of an inch between the beam
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surface and the clamps is normal. Higher noticeable gap is abnormal and the rotators shall not be
used if so.
8) The operator must then make sure the beam is well positioned inside the rotator and clamped
correctly.
To unload a beam with the vertical method, follow these steps:
1) Through the operatorʼs console, select in which zone the beam will be loaded (zone A, zone B or
zones A &B);
2) Press the button “Vertical Loading” if the rotators are not already at the vertical loading position. The
rotators ring shall rotate to the vertical loading position automatically.
unclamp;
4) Lift the beam and transport it outside the machine, taking care to respect the safety rules stated
above;
Horizontal Loading/Unloading
To load a beam with the vertical method, follow the steps below:
1) Through the operatorʼs console, select in which zone the beam will be unloaded (zone A, zone B or
zones A &B);
2) Enter the zone into which the beam will be loaded and adjust the beam height adjustment bar, if
required;
3) Make sure the beam width insert is installed on the H Clamp if required.
4) Press the button “Horizontal Loading”. The rotators ring shall rotate to the horizontal loading position
automatically.
5) Lift the beam and transport it inside the rotators taking care to respect the safety rules stated
above;
6) When setting down the beam ensure it is justified to the beam height adjustment bar, such as the
picture below.
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Figure 7 : Vertical Loading Justification.
7) Once the beam have been put down and detached, clamp the H Clamp and V Clamp of every rotator
using a drill or impact driver with a torque limiter.
8) Go back inside the zone and check the beam is well clamped by every rotator. A gap of 1/16 to 1/8
of an inch between the beam surface and the clamps is normal. Higher noticeable gap is abnormal
and the rotators shall not be used if so.
9) The operator must then make sure the beam is well positioned inside the rotator and clamped
correctly
To unload a beam with the vertical method, follow these steps:
1) Through the operatorʼs console, select in which zone the beam will be unloaded (zone A, zone B or
zones A &B);
unclamp;
3) Press the button “Horizontal Loading”. The rotators ring shall rotate to the horizontal loading position
automatically.
4) Lift the beam and transport it outside the machine, taking care to respect the safety rules stated
above;
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Automatic mode
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1.1
1.2 Automatic mode
1.2.1
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Automatic mode
1.1
1.1.1
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Main page
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1) Button to start the current selected robot program.

2) Button to stop robot program.
3) Display the current production running on the machine
4) Status of the robot: Green = running, Red = Error.
5) Status of the safety ZoneA, Green Ok.
6) Status of the safety ZoneB, Green Ok.
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Jog setting
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1) Button to abort the current production and the program running on the robot.
2) Push button to move Selected Rotators (3) at desired position (12).
3) Clickable space to select with zone to use.
4) Field to enter the desired production to produce.
5) Button to send production to the robot with selected zone (3).
6) Button to move selected Rotators at horizontal loading position.
7) Button to move selected Rotators at vertical loading position.
8) Button to move selected Rotators at 45 Deg.
9) Status of the loading process on the robot.
10) Desired target position.
Manual mode
1.1
1.1.1
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Rotator
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1) Machine State: Emergency Stop, Running, Stopped

2) Push button to select/Show State Automatic Mode
3) Push button to select/Show State Manual Mode
4) Push button to select/Show State Maintenance Mode. This mode is only possible to Logged user.
No movement security in this mode.
5) Destination of the RotateTo request.
6) Push button to move Rotator at desired position.
7) Alarm status.
8) Button to Login/Logout a user.
9) Mastering the position of the Rotator. (Be careful with this) Must be user logged.
10) Button to select the manual operation wanted.
11) Jog speed selection for movement.(Jog or the MoveTo)
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12) Actual position of the Rotator.
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ZoneA/B
1) Button to abort any sequence in progress of the Rotator like clamping, moving.
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24 / 81
ROBOT BASE
1) Status of the robot position – Is at Home position, safe for Rotator movement.
2) Status of the robot position – Is at Park position, safe for Rotator movement.
3) Button to start Mastering Test of the robot calibration. This test is automatically done, if needed, a
first of welding programme.
4) Button to jog left the robot base. Robot must be in External.
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5) Button to jog right the robot base. Robot must be in External.
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Equipment shutdown
1) Turn off the air supply;
2) Turn off the robot controller;
3) Close the HMI under Status screen (SHUTDOWN WINDOWS);
4) Turn off the rotators power;
5) Turn off the welder;
6) Turn off the process gas.
Robotic programs
1.1
1.1.1
software
G1_GoHome
1.1.1
Program goal
Brings the robot to its HOME position (The Home position is a known safe position,
regardless of the position on the rail). This program looks at the current position of the
robot and if this position is considered safe and without risk of collision determined by the
robot according to a position X, Y, Z, then it returns the robot to HOME.
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Frequency
This routine is called before and after each welds to ensure that it is at a known position
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before launching a new sequence. It is also called inside AGT's Programs such as
Wire_cut, Clean_Torch, TCPCalib, etc .
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Launched from where, how?

That program is called through Octopuz or from AGT's Programs.
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Operation
1. Checks if its current position is within a certain range to perform a safe movement to the
HOME;
2. Check if the robot is in Park position (if yes, then this is a known position);
If the position is not safe, jog the robot to a safe position and restart the sequence;
3. If the robot is too close to the fence (ZoneA) or the central light curtain (Zone B), then the
rail is moved to a safe position;
4. Moves to HOME.
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Safe zone
The calculations are done with the TOOL_DATA [0] with respect to the base of the robot
BASE_DATA [0].
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Note that YMIN et YMAX moves along E1. To determine if YACT is in the zone, substract E1.
YACT ʼ = YACT – E1ACT
The program check if :
XMIN <= XACT <= XMAX
YMIN <= YACT ʼ <= YMAX
ZMIN <= ZACT <= ZMAX
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G1_GoPark
1.1.1
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Program goal
Brings the robot to its PARK position (Park position is a known safe position, regardless of
the position on the rail). This position will be used to bring the robot to a position where it
will not interfere with loading and unloading. It will also be used when the operator wants to
perform maintenance on the robot tool (eg change contact tip).
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Frequency
This routine is called at the end of a production by the program G0_End ().

This program is called inside the AGT Program G0_End (this one is called by Octopuz at
the end of a production).
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Operations
1. Program call G1_GoHome;
2. Brings the robot to position "xPark" (position to load a beam) The position xPark is a
"RefPos";
3. Brings the rail to the left end of the rail if the robot is in zone A or right end of the rail if the
robot is in zone B.
G1_WireCut
1.1.1
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30 / 81
Program goal
Cut the wire to do "Touch Sensing" with the wire.
Frequency
This routine is called before each touch sequence (when touching with the wire) or during
the cleaning sequence.
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This program is called through Octopuz or in the cleaning sequence.
Operation
1. Reset the welding source if it is not ready to make sure wire will get out;
2. Moves to the position to cut the wire;
3. Cut the wire to 20mm (Stickout).
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G1_TCPCheck_1 & G1_TCPCheck_16
1.1.1
Program goal
This routine checks if a TCP has changed.
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Frequency
This routine should be launched after a collision or early production to ensure that the TCP is
accurate.

This program is launched through the SmartPad and require the calibration tip for the
TCPCheck of the torch. It is also called in the G0_AtHome when the collision detection device
(Clutch) have been triggered. The position can be mastered by enabling the TCP_Check
reference variable.
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G1_TCPCalib_1 & G1_TCPCalib_16
1.1.1
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Program goal
Execute an automatic calibration of a TCP already taught and which has the possibility of
making "Touch".
Frequency
This routine must be performed when the TCP is no longer accurate following a collision or
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when a TCP is taught manually.
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This program is launched by the operator in T1 or T2 mode via the SmartPad.
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G0_ELV_PSH
1.1.1
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Program goal
This routine is used for welding development and will create a new welding point
regarding the parameters that have been entered.
Frequency
This routine is called only inside a welding development programs.
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You must use this routine for each welding points.
Parameters
Below is the description of each parameter that needs to be put when calling the routine. The order is
very important.
1. Offset on weld direction;
2. Offset from the wall;
3. Offset from the Floor (Normal to the weld direction);
4. Elevation angle;
5. Push Angle;
6. Tool offset;
7. Weld point (Reference point)
8. Weld Frame
The direction of the weld Frame is crucial. Make sur to use the correct Weld Frame.
1. X axis must be in the weld direction
2. Y axis must pointing to the wall
You can create new weld frames by changing the WORKFRAMEs values
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Operation
1. Creates a new “welding point” by converting the “Reference point” with the elevation/push/offsets
that have been passed thru the functionʼs parameters.
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G0_AtHome
1.1.1
Program goal
·The robot is at Home;
·Robot checks for errors;
·Robot resets errors;
·Robot checks the state of its variables and executes the required operations.
Frequency
Every time the robot is at Home.

That program is called through Octopuz after and before each welds.
Operation
1.Checks if there was a collision. If yes, sequences G1_TCPCheck_1 and
G1_TCPCheck_16 are launched;
2.Checks the welding time and launches the nozzle cleaning and wire cutting after a
determined delay;
3.Turn off the TOUCH CORRECTION.
G0_Init
1.1.1
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Program goal
Resets all the required variables during the welding and touch sequences.
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Frequency
In the beginning of Octopuz sequence.

That program is called through Octopuz.
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Operation
1.Starts the Interrupt that checks the operation of the Submit;
2.Calls the MasteringRef sequence (if required);
3.Calls the BrakeTest sequence (if required);
4.Initialize the welding timer;
5.Close the Laser air shield;
6.Start the production Timer.
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G0_End
1.1.1
Program goal
Launch the necessary programs at the end of a production.
Frequency
At the end of a production.

That program is called through Octopuz.
Operation
1. Will call the program G1_GoPark;
2. Resets the variable LOAD_Program;
3. Turn off the laser air shield;
4. Turn off the production Timer.
G0_PreWeld
1.1.1
Program goal
Perform the necessary operations at the beginning of a welding sequence
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Frequency
At every welding sequence.
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Launched automatically in the beginning of a welding sequence through the sub program
ATA_UsrPre_ArcOn.
Operation
1. Closes the laser touch device door;
2. Disable the Wire Brake.
**Will call the programs that are required before welding
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G0_PostWeld
1.1.1
Program goal
Execute the required operation at the end of a welding sequence.
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Frequency
At every welding sequence.
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Launched automatically at the en of a welding sequence through the sub program
ATA_UsrPost_ArcOff.
Operation
1. No operation, but the program does exist for future needs.
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G0_MoveRail
1.1.1
Program goal
To move the rail to the wanted direction. Robot should be at Home or Park position to
allow the displacement.
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Frequency
Every time the robot needs to be displaced on the rail.

Launched through the HMI.
Operation
The robot manages if whether or not it starts the displacement on the rail.
The start-up is managed in the Submit:

· If no program is selected and the robot is not on alarm;
· If one of the buttons to move rail is "ON".
The stop is managed in the Submit:

· If all the buttons state is "OFF".
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G0_PreTouch
1.1.1
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Program goal
Execute the required operation in the beginning of a "Touch" sequence.
Frequency
At every "Touch" sequece.
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Launched automatically in the beginning of a "Touch" sequence through the sub program
TS_USR_PreTouch.
Operation
If touch with laser
· Open laser door
· Check if laser alarms
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G0_PostTouch
1.1.1
Program goal
Execute the required operations at the end of a "Touch" sequence.
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Frequency
At every "Touch" sequence.

Launched automatically at the end of a "Touch" sequence through the sub program
TS_USR_PostSearch.
Operation
1. No operation, but the program does exist for future needs.
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G0_Rotate
1.1.1
Program goal
Send to the PLC the command to rotate the wanted rotators to the required position.
Frequency
That routine is called in the beginning of each welding sub-program to make sure the
beam is in the right rotating position, or angle.
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That program is called through Octopuz
Parameters
Zone
It is required to give as an argument to one of these zones by writing "#" before:
G0_ROTATE(#AB,90) -> OK
G0_ROTATE(#B,180) -> OK
G0_ROTATE(#D,180) -> Sends an error from Kuka saying the argument in parameter is not
valid.
G0_ROTATE("A",180) -> Sends an error from Kuka saying the argument in parameter is not
valid.
G0_ROTATE(A,180) -> Sends an error from Kuka saying the variable A has not been
declared.
Allowed zone selection

G0_ROTATE(#A,x)
G0_ROTATE(#B,x)
G0_ROTATE(#AB,x)
G0_ROTATE(#NONE,x)
Position:
· Should be INT between 0 and 360° ;
· If not between 0 and 360°: Error message.
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Operation ROBOT/PLC
Zone == #AB
1. ROBOT sends the required position to PLC;
2. ROBOT send the Rotator Group to the PLC A=TRUE; B=TRUE; C=FALSE;
NONE=FALSE;
3. ROBOT allows a delay to make sure the PLC received the information;
4. ROBOT sends to the PLC a signal to rotate;
5. PLC changes the state of the rotators (Group inPos=FALSE);
6. PLC rotated to the new position;
7. PLC changes the state of the rotators (Group inPos=TRUE);
8. ROBOT resets the signal of rotating;
9. ROBOT resets the Rotator Group;
10. ROBOT checks that the rotators are at their right location. If not, error message
and the sequence restarts.
Zone == #NONE
1. Same procedure as the other zones on Robot side;
2. However, the PLC will not rotate any rotator but will send a message on the HMI
saying how many degrees it has to rotate. The operator will then need to rotate
the part. The PLC will then wait for the confirmation on the HMI that the beam has
rotated and will update the values sent to the Robot (ActualPos, inPos).
AGTʼs Functions
These Functions have been programmed by AGT and are used inside many programs.
G0_Verify_Axis
1.1.1
Program goal
Validate that the « Robot axis positions » are under the desired tolerance from the
« Reference axis position ».
Frequency
Each time you want to validate that the actual robot axis position is closed to the
Reference axis position.
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Inside AGTʼs programs that needs to validate robot axis position.
Parameters
AR[1] = Robot axis position
AR[2] = Reference axis position
AR[3] = Tolerance
Operation
1. Validate the angle difference for each axis;

2. If one angle difference is higher than the tolerance, RETURN FALSE;
3. If all angles difference are under the tolerance, RETURN TRUE
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G0_Offset
1.1.1
Program goal
Create an offset position (Frame offset).
Frequency
Each time you want to create a “Frame offset”.

Inside AGTʼs programs that needs a “Frame offset”.
Parameters
AR[1] = Reference position
AR[2] = X offset
AR[3] = Y offset
AR[4] = Z offset
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Operation
1. Apply the offset to the reference point;

2. Return the offset position.
Calibration
Run the TCP Calibration programs for each TCP (#1 and #16)
1. G1_TCPCalib_1 (Need the Teach Tip)
2. G1_TCPCalib_16
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Rail mastering
Mastering kit is on the Robot Base (close to the rail). The zero position is on the left side of Zone A.
Rail mastering use the same procedure than robot mastering (with EMD Mastering Set). Please refer to
robotʼs documentation for mastering procedure.
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Error management
Robot errors will appear on the HMI and on the SmartPad. Error codes are specific for each section of the
machine / Robot programs
Description of the error codes:
· 1xxxx : PLC errors
o 100xx : Safety
o 109xx ZoneGeneral
o 11xxx ZoneA
§ 111xx Master Rotator
§ 112xx Slave Rotator
o 12xxx ZoneB
§ 121xx Master Rotator
§ 122xx Slave Rotator
· 2xxxx : Robot programs errors
o 20xxx G0_Programs (not group locked)
§ 2000x G0_Rotate()
§ 2001x G0_MoveRail()
§ 2002x Pre/Post Touch
§ 2003x Open/Close000 Door
§ 2004x Pre/Post Weld
§ 2005x G0_AtHome
o 21xxx G1_Programs (Group#1 is locked)
§ 2100x G1_Gohome
§ 2101x G1_TCPCalib_(1 - 16)
§ 2102x G1_TCPCheck_(1 - 16)
§ 2103x G1_CleanTorch
§ 2104x G1_WireCut
§ 2105x G1_GoPark
§ 2110x General alarms (eg Overtravel)
o 25xxx : Submit (Background logic)
§ 2501x DirLoader
§ 2502x Abort Program
§ 2503x Interrupts
See Appendix “H” for the complete list of error.
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JOB Preparator
1.1
Create & Export 3D model

Many kind of 3D CAD are possible to be load in Octopuz. To check the file format and for importing a
cad use:
· (In the menu bar) File / Import /
· Browse to your file and check if the extension is list in the “Files of type” in the combobox.
Explanation of the AGT Tools
· Erase the current program

o Using this tool will erase all the Sequence and Statement in your current program. You will
need to refresh the program to see the change. (Reselect the robot in the combo box of the
teach tab)
· Adjust the display of the welding trajectory of seam weld

o An interface will show up when you click this button. Different option will be available to let
you control the display of the seam weld.
o Note, when you click on a seam weld, before using this command you could decide if you
want to affect all the seam weld of the program or just the selected one.
· Integrate the part to the equipment

o This enable the integration of the part rapidly an precisely to the correct location in the
rotators.
o Important to measure the part and set the Bar location at the corresponding place, before
doing using this tool.
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Welding path generation step

1. Load the default layout
2. Import the 3D cad in the layout
3. Measure the part to establish the Bar position on the rotator
4. Set the Bar position on the rotator
5. Integrate the part, using the corresponding AGT Tool
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6. Start creating the welding sequence

a. Add the call sequence to correspond to the structure establish at 4.5
b. Add welds to your program
c. Add your approach and retract position
7. Validate the program
a. Enable the Joint Limit Check
b. Configure and set the collision detection
c. Run the simulation at Real Time at maximum of 2.0 step size
d. Correct any collision or joint limit
8. Generate the robot program
a. Create the folder structure to be able to load from the HMI
i. Folder = Name of your part
1. Folder (Zone_x) = Indicate the corresponding zone (A, B, AB)
a. (M_xxxxxx_Z) Save your program by respecting the naming
convention
i. M = Master always there
ii. Xxxxxx = Same name of the first level folder
iii. Z = Indicate the corresponding zone (A, B, AB)
Owe Template
Description:
The owe files are used to save the parameter you set in the Welding Interface of Octopuz. Using the
owe file, will help you to program faster and get the good welding recipe for your seam.
AGT providing a basic package for programming your seam and this one is organized in that way :
· Selecting the welding start and end type

o Select the configuration (Joint T)
§ Select the Interface of your weld (Horizontal or Vertical)
· Select the start and end distance of your weld relate to the floor
o Select the surface finish of your beam (W; SCALE 0 F;
SCALE 0 or W; SCALE 100 F; SCALE 100
§ Select the file corresponding to the location of your weld
· Dimension_SearchStart_MiddleSearch_EndSearc
h_AngleBetweenFloorWall_NbOfPass
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Generate production program
51 / 81
Maintenance
1.1
Preventive Maintenance
The following table specify the operations to be done on the machine and their periodicity, to ensure a
proper preventive maintenance. It is specific to non-commercial components of the machine.
Notice: For maintenance information of the commercial components, such as motors, gearboxes, linear
slides, etc. refer to their respective documentation in the APPENDIX B – TECHNICAL
DATASHEETS.
Periodicity
Maintenance Operation
ily
a
D ly
k
e
W ly
th
n
o
M ly
rte
a
u
Q
Checks:
Beam rotators:
Backlash between the outer gear of the ring and the intermediate gear
Backlash between the intermediate gear and the driving gear
Backlash between the driving gear and the gearing of the tilting mechanism
Tension of the timing belts of the clamping mech.
Condition of the resting rollers in the base
Condition of the tracking rollers in the base
Condition of the outer rolling surface of the ring
Condition of the clamping mechanism raceways
Wearing of the brass plates on the ACME nut guide of the clamping
mechanisms
Wearing of the brass plates on the sides of the clamps
Wearing of the ACME nut & screw of the clamping mechanisms
Functionality of the sensor for overtravel rotation in clockwise direction
Functionality of the sensor for overtravel rotation in counter clockwise

direction
Structural integrity of the beam height adjustment bar
Structural integrity of the beam width insert
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Periodicity
Maintenance Operation
ily
a
D ly
k
e
W ly
th
n
o
M ly
rte
a
u
Q
Level and run-out of the ring
Mastering of the rotational position
Loosen components:
Resting rollers – Base
Tracking rollers – Base
Tracking rollers – Base
Raceways – Clamping Mechanism
Lubrication:
Beam rotator:
Bronze track rollers – Clamping mechanism
Raceways –Clamping mechanism
ACME nut & screw – Clamping mechanism
Lower resting rollers - Base
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software
Welding system operation & maintenance
Robotic welding equipmentʼs are reliable, low maintenance components. Each welding component has its
own manual and maintenance technician should refer to those manuals before operating and performing the
tasks listed below. Most critical items may be covered during system maintenance training.
Description Refer to APPENDIX B

General power source maintenance Fronius manual : « MIGMAG Power source» (p.175)
Perform L/R alignment Refer to section 8.1
RCU functions and programming Fronius manual: «RCU»
Replacing drive rolls Fronius manual: «Robot wire feed unit» (p.13)
General wire feeder maintenance Fronius manual: «Robot wire feed unit» (p.17)
Collision box (clutch) maintenance Abicor Binzel manual: «Robo CAT2»
General cooling unit maintenance Fronius manual: «Cooling unit» (p.34 to 37)
54 / 81
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Spare Parts List

The following table details the spare parts for this particular machine. Note the quantity given is the number
of iteration of that same part number there is in the machine.
Notice: The blue shaded part numbers signify that datasheets have been provided with this manual. Refer
to APPENDIX B – TECHNICAL DATASHEETS for further details.
QTY
Part Number Manufacturer Description (M achine -
w ide )
AXK 2542 SKF Needle thrust bearing 8

WS 81105 SKF Needle thrust bearing washer 8
GS 81105 SKF Needle thrust bearing washer 8
Deep groove ball bearing, ID 17mm, OD 40mm, WD
6203-2RS SKF 24
12mm
E2B-M12KS04-M1-
Omron Proximity sensor M12 NC 8
B2
Phoenix CABLE M12 90 DEG FEMALE 5M FOR Proximity
1668247 8
Contact sensors
BIM-007-01553-DMU AGT ACME nut mount bronze sleeve, vertical clamp 4
BIM-007-01549-DMU AGT ACME nut mount bronze sleeve, horizontal clamp 4
BIM-007-01134-DMU AGT Bronze track rollers 32
BIM-007-01201-DMU AGT Bottom resting rollers, driver kit 8
MCMASTER- Flanged bronze sleeve bearing, ID 20mm, OD 24mm. LG
6659K410 16
CARR 16mm, oiled
MCMASTER-
95072A132 Bronze nut ACME thread 1”-4 8
CARR
BIM-007-01307-DMU AGT ACME threaded rod 1”-4, vertical clamp 4
BIM-007-01316-DMU AGT ACME threaded rod 1”-4, horizontal clamp 4
40x55x8 CRW1 R SKF Nitrile lip seal, 16
400600 SKF V-Ring seal, 60mm nominal 4
400650 SKF V-Ring seal, 65mm nominal 16
Cam follower OD 1.5”, WD 0.875”, Bushing ø7/8”,
CNBE-48-SB CARTER 24
eccentric
CNB-48-SB CARTER Cam follower OD 1.5”, WD 0.875”, Stud ø5/8” 8
MCNBE-72-SBX CARTER Cam follower OD 72mm, WD 29mm, Bushing ø28mm 16
NK 40/30-XL SKF Needle roller bearing ID 40mm, OD 50mm, WD 30mm 24
BIM-007-01206-DMU AGT Spur gear, rotation, intermediate 4
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QTY
w ide )
BIM-007-01211-DMU AGT Spur gear, rotation, driving 4

6207-2RS1 SKF Deep groove ball bearing ID 35mm, OD 72mm, W 17mm 2
PD110-025/KUKA APEX Planetary Gearbox, Double Stage, 25:1, Low Backlash,
1
MG_60_110_30_S0 DYNAMICS 94% Eff.
ATLANTA DRIVE Pinion, Helical Module 2.0, ISO 9409-1 Flange, Hardened
78.20.529 1
SYSTEMS & Ground, DIN 5, d = 61.54 mm
ATLANTA DRIVE Rack, Helical Module 2.0, Induction Hardened, ~AGMA 8,
39.20.100 1
SYSTEMS 1m lg.
ATLANTA DRIVE Rack, Helical Module 2.0, Induction Hardened, ~AGMA 8,
39.20.200 13
SYSTEMS 2m lg.
MCMASTER- High Plastic Compression Spring, 1100 in-lbs Energy
9677K18 4
CARR Capacity
R1605 304 39, 28000 BOSCH
Rail 35mm x 28000mm, w/Plastic Plugs 2
mm REXROTH
BOSCH
R1619 330 22, 75m Cover Strip 35mm x 75m, Standard Snap Fit 2
REXROTH
BOSCH
R1619 339 50 Cover Strip Clamps Set (2 pieces) 35mm 4
REXROTH
BOSCH
R1619 315 30 Expanding Tool 35mm 1
REXROTH
BOSCH
R1619 340 60 Pneumatic Clamping Unit MKS 35mm 1
REXROTH
BOSCH
R1623 394 20 Ball Runner Block SLS 35mm, C0, N, w/o Ball Chain 8
REXROTH
BOSCH
R1619 325 00 Front Lube Unit 35mm, Pre-Filled 4
REXROTH
BOSCH
R1619 320 50 Seal Kit 35mm for Ball Guide Rail w/Cover Strip 4
REXROTH
14 208mm R4-80 Series Assembled Cable Chain, Tube Version w/o
R4-80-10-200-0 IGUS Camber 1
NCST (Contact Manufacturer for Individual Spare Parts)
8031504 FESTO Solenoid Valve VUVG-L14-T32C-MT-G18-1R8L 1

193156 FESTO One-Way Flow Control Valve 2
Refer to APPENDIX A « TEC-ALF-001-002-R00 - Binzel
Welding torch Abicor Binzel -
spare part list.»
Hobart/Elco/Coil
Wire dispensing Refer to APPENDIX A « TEC-ALF-001-003-R00 - Wire
hose -
system dispensing system spare part list»
pneumatics
Welding power
Fronius Refer to manual APPENDIX B «MIGMAG Power source» -
source
Welding wire feeder Fronius Refer to manual APPENDIX B «Robot wire feed unit» -
Remote control Fronius Refer to manual APPENDIX B «RCU» -
56 / 81
QTY
w ide )
RCU5000
Cleaning station Refer to manual APPENDIX B
Fronius -
(Robacta reamer) «Fronius_Robacta_Reamer»
Torch cooling unit Fronius Refer to manual APPENDIX B «Cooling unit» -
Welding ground Refer to APPENDIX A «TEC-MAK-001-005-R00 – Welding
Tweco -
system ground system spare part list»
IL-1500 KEYENCE Controller for “Laser Touch Sensing system “ 1
IL-300 KEYENCE Laser Head for “Laser Touch Sensing System” 1
OP-87058 KEYENCE 10m Cable for IL-300 Laser Head 1
CJ1B4-20U4 SMC Miniature cylinder for laser device door 1
SIEN-M5B-PS-S-L (INDUCTIVE PROX. SENSOR - PNP-
150371 FESTO 1
5MM BODY - M8 CONN.)
BIM-005
-03201-DMU
AGT Housing for “Laser Touch Sensing system” (include cover) 1
-03202-DMU
-03208-DMU
BIM-005-03215-DMU AGT 45deg aluminum connector for laserʼs housing 1
Plastic connector for “Laser Touch Sensing system”
BVND-M202GT-8 PMA 1
conduit
PIST-12B PMA Plastic conduit for “Laser Touch Sensing system” 1
BIM-005-03104-DMU AGT Laser Housing Bracket (Straight) 1
BIM-005-03217-DMU AGT Laser Housing Bracket (90deg) 1
1053370 KUKA External Axis Adjustment Set (Rail) 1
174901 KUKA KUKA smartPAD, 10 meter cable 1
228934 KUKA KRC4 EMD Mastering set 1
243400 KUKA KUKA.Recovery USB v2.2 ( includes 8Gb USB Stick ) 1
138452 KUKA Reference switch module 15m straight 1
127727 KUKA KUKA external axis motor (MG_60_110_30_S0) 1
Robot cables KUKA KUKA robot cables 1
168334 KUKA KUKA SmartPad 10m cable 1
If any other part is required, call AGT.
57 / 81
Troubleshooting
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Welding
Description Refer to APPENDIX B
Power source error list and troubleshooting Fronius manual : « MIGMAG Power source» (p.163 to
174)
Fronius robotic interface error list Fronius manual: « Robot interface» (p.16 to 20)
Wire feeder error list and troubleshooting Fronius manual: «Robot wire feed unit» (p.16)
Cooling unit troubleshooting Fronius manual: «Cooling unit» (p.41 to 42)
Safety clutch
The clutch is a safety device to avoid breakage when a collision with the torch happens. The clutch will
absorb the impact by moving from a spring loaded shaft.
It has four different “rest” positions that the clutch is not trigged. One is set as reference «HOME
POSITION». The box with the light need to be aligned with the torch. It is very important to stay in this
position because the TCPʼs are set in that position.
58 / 81
59 / 81
Weld defect troubleshooting
What is the location of the defect?

Start
Middle
End
Is it recurrent defects?
Is the wire is pointing at the right place in the joint?
Is the TCP of the torch is good?
Is the TCP of the laser is good?
What kind of defect is it?
Undercut
Slow down the speed
Drop the arc length correction
Asymmetric weld
Modify the Yoff
Rollover
Raise the arc length correction
Raise the elevation
Undersize
Slow down the speed
Increase the WFS
60 / 81
Rotators and Robot Carriage

Call IMPACT if any malfunction occurs.
Alarm list
For complete alarm list and their description, please refer to APPENDIX H (TEC-MAK-001-000-R00 – Alarm
description)
61 / 81
Training
Welding
Refer to the Welding training document in APPENDIX I
62 / 81
General instructions
Welding
Each welding component has its own manual; technician should refer to those manuals to have information
about functionalities and before operating. Most critical items may be covered during welding training. Refer
to APPENDIX B for manuals.
Power source AB Ethercat interface
1. High speed touch sensing connection

2. Power (+) socket with bayonnet latch
3. LocalNet connection RCU
4. LocalNet connection RS-232 fronius explorer
5. LocalNet connection wire feeder
6. EtherCAT OUT
7. EtherCAT IN
8. Main power connection
*Note: The localNet connectors (3, 4, 5) are used to connect:

-Wire feeder communication cable
-RCU communication cable
-RS232 cable for Fronius Xplorer communication
Perform L/R calibration: (APPENDIX B: « RCU_42_0426_0021_EN» P.206-207)
Important tips for L/R calibration

· Take in note the last value
· Inching backward the welding wire arround 4ʼʼ
63 / 81
· Release the pressure on the driveroll

· Grind to remove the scale on the zone that the contact tip will touching
· Make sure that the flat end off the contact tip is in contact with part without angle on the torch
Replacing liner
1. Jog the robot to stretch the W500 cable assembly out straight.
2. Remove the liner-retaining nut from the power pin at the back of the W500 cable assembly.
3. Gently feed the correct liner for your current welding process through the cable assembly from the
machine end of the torch until the liner stop feeding, make sure the liner is touching the contact tip.
4. Cut the liner at 15mm of the end of the power pin. Make sure it not has sharp edge, use file if
necessary.
5. Add the liner-retaining nut and make sure itʼs tight well. Note: the liner should exceed around 2mm
at the end of the nut.
64 / 81
Welding software version (difference between power source and RCU)

Fronius power sources are using welding databases that contain different synergic lines corresponding to
the application needed. There are different versions of database.
Power source
· Each power source has a sticker on the top that specifies:

o Serial number
o Technical data
o Software Version
o Welding database version
o Synergic lines numbers
o Others
RCU remote control
65 / 81
· The RCU itself has its own database version.

· When a RCU is connected to the power source, the front panel of the power source is disabled and
the RCU takes over control (RCU software version is used).
66 / 81
Wire feeder gas pressure sensor adjustment

The gas pressure sensor is a safety device to prevent insufficient gas flow and avoid weld defects like
porosity.
1. Turn ON the gas
1. Adjust the gas flowrate at 30CFH with the gas regulator and a portable gas flowmeter
(confirm flowrate at nozzle, not at bottle)
2. Keep the gas ON and adjust the pressure gas sensor (front of the wire feeder) until the
alarm pops on the RCU
67 / 81
3. Adjust the gas flow at the working flow (40CFH)
68 / 81
Performing backup bundle

A backup bundle contains:
ü Fronius RCU backup file (.fbc)
ü Pdf jobs export
ü Robot Archive
ü Excel weld table.
This backup contains all necessary information to link welding programs and welding parameters at any
point in time. This also allows a traceability of any modification to the welding programs. It is recommended
to perform a backup bundle monthly or after any modification of welding parameters.
RCU backup
· Backup with memory card on RCU (Manual « RCU_42_0426_0021_EN» P.197-198)
· Backup with Fronius Xplorer (Manual «Fronius Xplorer» P.23)
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Jobs export
· Export the welding data in excel sheet
1. Select all the jobs stored.
2. Press on «Export» button
3. Press on «Selected jobs»

4. Choice file localisation to save it
70 / 81
Robot archive
1. Plug a USB stick on the teach pendant or cabinet
2.
3. Press on the button :
§ File/Archive/USB (KCP) or USB (cabinet)
4. Press YES
71 / 81
Weld table
Make copy of the last version of the weld table (according to the RCU backup) and save in the same
location of the others files: «RCU backup», « Jobs export» and «Archive».
72 / 81
Weld table
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Welding flow chart

All welds are using three different JOBS allowing better control of the weld quality. The three jobs are
respectively for start, middle and end of the weld.
software
Identification of the weld
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In filtering each field, that will resulting in three unique number corresponding to the start, center and end
parameters require for the joint characterization that need to be fine-tune.
Workpiece Positioning & Limitations

When loading a part in the rotators there are few rules to ensure proper and safe functioning of the machine.
Beam Justification
The beam must be justified to the right corner, i.e. matting with the same 2 edges of the rotatorʼs opening.
The 2 edges correspond to the beamʼs height adjustment bar and the side closer to the vertical clamp. The
picture below illustrate the justification rule
74 / 81
Figure 8 : Beam Positioning inside a Rotator.
Beam Height Adjustment

The beamʼs height adjustment bar has 4 settings allowing to embark beams from 6” to 60” high. The beam
height span between these 4 settings is given in the table below. For reference on each configuration of the
beamʼs height adjustment bar, see picture below the table.
Minimum Beam Maximum Beam

Configuration
Height Height
0 6” 12”
1 12” 24”
2 24” 40”
3 40” 48”
75 / 81
CONFIGURATION “0” CONFIGURATION “1”
CONFIGURATION “2” CONFIGURATION “3”
Figure 9 : Beamʼs Height Adjustment Bar Configurations.
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Beam width Adjustment

If a beam is from 6” to 14” in width, the shim must be installed on the H Clamp. No shim required for beam
from 12” to 20” in width.
76 / 81
Accessories Limitations
Firstly, there is an area surrounding the rotator where no accessories shall be put to prevent them from
coming in interference with the rotator itself during its revolution, i.e. accessories could hit the rotator base
when it rotates. For this reason, no accessories shall be installed on the beam 8 inches on each side the
rotator, from the center plane of the rotatorʼs ring. Failing to respect this no accessories zone may results in
damaging the machine.
Secondly, Depending on the setting of the beamʼs height adjustment bar, the area available to put
accessories on the beam varies. Refer to the pictures below for reference with the accessories capacity.
The blue rectangle refers to the limitation in beamʼs section dimensions, while the green cycle refers to
accessories limitation. Accessories must be inscribed inside the green area to be used with the rotator. It is
the same for the beam section itself and the blue rectangle. A simplified control area i given in the picture to
the right, with orange outline as the simplified area allowed for accessories. The various zones are given
relative to the justified beam corner.
Configuration “0” Configuration “0”
Figure 10 : Beam & Accessories Limited Area, configuration 0.
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Figure 11 : Beam & Accessories Limited Area, configuration 1 & 2.
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Figure 12 : Beam & Accessories Limited Area, configuration 3.
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Beam Weight Capacity

The rotators maximum capacity is limited to 5000 pounds of extra weight each. However, this capacity can
be reduced to a lower value depending on the position of the center of gravity of the assembled beam. There
are 2 factors to considerate when evaluating if a given beam can be manipulated with the rotators:
1) The position of the center of gravity of the assembled beam and the center of rotation of the rotator.
2) The weight distribution of the beam on each rotator.

For the first point, the following chart give the maximum beam weight (once completely assembled) VS the
distance from its center of gravity to the center of gravity of the rotator. The same chart is bolted to each
rotator for operatorʼs quick reference.
The additional weight applied on each the rotator can never be higher that what
stated in this chart.
Figure 13 : Beam Rotator Capacity Chart
80 / 81
After Market
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Remote support
AGT Robotique.
8800 Boul. Parent

Trois-Rivières, QC, Canada
G9A 5E1
parts-service@agt-group.com
Phone: (819) 693-9682

Fax: (819) 639-9028
Reference Number: ALF-001
Revision History
Date Revision Author Description

2016-11-11 Prel. Joé Landry Original creation of manual
2017-02-07 00 Joé Landry First Official Release
81 / 81

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Program goal ...................................................................................... 32

Figure 1 : Overview of the Machine

1. Robot Carriage and Rail

Figure 2 : Overview of the Robot Carriage.

Figure 3 : Overview of the Welding Tool

Figure 4 : Overview of the Operator Console

Figure 5 : Overview of the Beam Rotator

General Safety Rules

One at each extremities of the cell (total of 2);

a. A review of the inherent risks in the operation of the equipment.

h. Long hair must be tied, to avoid strangulation near moving parts.

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Reset safety circuit

Loading / Unloading Parts

Before transportation of the beam:

opened and clear the way of the beam.

During transportation of the beam:

J. Never load a beam if the gearmotor have been remove or damaged.

Figure 6 : Vertical Loading Justification.

To unload a beam with the vertical method, follow these steps:

Figure 7 : Vertical Loading Justification.

To unload a beam with the vertical method, follow these steps:

1.2 Automatic mode

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1) Button to start the current selected robot program.

1) Machine State: Emergency Stop, Running, Stopped

12) Actual position of the Rotator.

4) Button to jog left the robot base. Robot must be in External.

5) Button to jog right the robot base. Robot must be in External.

1) Turn off the air supply;

2) Turn off the robot controller;

3) Close the HMI under Status screen (SHUTDOWN WINDOWS);

4) Turn off the rotators power;

5) Turn off the welder;

6) Turn off the process gas.

Launched from where, how?

YACT ʼ = YACT – E1ACT

The program check if :

XMIN <= XACT <= XMAX

YMIN <= YACT ʼ <= YMAX

ZMIN <= ZACT <= ZMAX

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Launched from where, how?

G1_TCPCheck_1 & G1_TCPCheck_16

Launched from where, how?

G1_TCPCalib_1 & G1_TCPCalib_16

when a TCP is taught manually.

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Launched from where, how?

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Launched from where, how?

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**Will call the programs that are required before welding