C Epops

Kawasak
C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL MPOEPCCP121E
Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and is furnished solely for customer use only. No other uses are authorized or permitted without the express written permission of Kawasaki Robotics (USA), Inc. The contents of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical, electrical, photocopy, facsimile, or electronic data media, without the express written permission of Kawasaki Robotics (USA), Inc. All Rights Reserved. Copyright 2002, Kawasaki Robotics (USA), Inc. Wixom, Michigan 48393
The descriptions and specifications in this manual were in effect when it was submitted for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discontinue specific robot models and associated hardware and software, designs, descriptions, specifications, or performance parameters at any time and without notice, without incurring any obligation whatsoever. This manual presents information specific to the robot model listed on the title page of this document. Before performing maintenance, operation, or programming procedures, all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc. training course. KAWASAKI ROBOTICS (USA), INC. TRAINING Training courses covering operation, programming, electrical maintenance, and mechanical maintenance are available from Kawasaki Robotics (USA), Inc. These courses are conducted at our training facility in Wixom, Michigan, or on-site at the customers location. For additional information contact: Kawasaki Robotics (USA), Inc. Training and Documentation Dept. 28059 Center Oaks Court Wixom, Michigan 48393
Kawasak
REVISION HISTORY
Revision Number -0 Release Date 5/24/02
ROBOT OR CONTROLLER TYPE OF MANUAL
Description of Change Initial PDF release, based on Rev.-1 of print copy
Initials CB/CB
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I.0 I.1 I.1.1 I.2 I.2.1
C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL
INTRODUCTION
INTRODUCTION.................................................................................................. I-2 Mechanical Unit ................................................................................................... I-2 Mechanical Unit Design Specifications ................................................................ I-3 Robot Controller ................................................................................................... I-5 Robot Controller Design Specifications ............................................................... I-6
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I.0 INTRODUCTION
INTRODUCTION
The Explosion-Proof C Controller Operations and Programming Manual is designed to assist the operator whose primary responsibility is to program and operate the robot on a daily basis. This manual provides specific information on safety, basic operation, programming path and auxiliary data, setting the Auxiliary Data screens, and error information. I.1 MECHANICAL UNIT The Kawasaki KE610 and KF121 AC servo driven industrial robots are articulated coordinate-type robots designed for paint and sealing applications. The robot with, its AC servo closed-loop drive system, is built with high rigidity. This design allows it to perform tasks that require high accuracy, speed, and wrist load capacities, while achieving significant energy reduction through the use of high efficiency brushless AC servo motors. The mechanical unit has six or seven axes depending upon the configuration of the robot. The major axes are: JT1 (R-axis) rotary; rotation of the base JT2 (O-axis) out and in; rotation of the lower arm JT3 (D-axis) down and up; rotation of the upper arm
The KF121 minor axes are: JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion JT5 (B-axis) bend; provides pitch/yaw wrist motion JT6 (T-axis) twist; provides rotation of the tool only
The KE610 minor axes are: JT4 (S-axis) swivel; sets orientation of JT5 for pitch/yaw motion JT5 (S-axis) swivel; provides pitch/yaw wrist motion JT6 (S-axis) swivel; provides rotation of the tool only
The auxiliary axis, if so equipped is: JT7 (V-axis) traverse; linear positioning of the mechanical unit
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INTRODUCTION
The Kawasaki robot system supports Cartesian coordinate motion which includes: Base (world) coordinates Tool coordinates
These coordinate systems can be used when manually operating the robot in the teach mode and with various program instructions for shifting program positional data, defining tool center points, and recording positional data. Kawasaki robot systems use the left-hand rule to determine the orientation of the base or tool coordinate system. For additional information about the left-hand rule, refer to section 6.2.1. I.1.1 MECHANICAL UNIT DESIGN SPECIFICATIONS Table I-1 provides the design specifications for the mechanical units that utilize the explosion-proof C controller.
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INTRODUCTION
Table I-1 Robot Specifications

ROBOT MODEL Number of Axes JT1 JT2 JT3 Maximum Velocity JT4 JT5 JT6 JT7 Maximum Linear Tool Tip Speed JT1 JT2 JT3 Work Envelope (Stroke) JT4 JT5 JT6 JT7 Max. Payload (lbs.) JT4 Wrist Rated Torque (ft. lbs.) JT5 JT6 JT4 Wrist Rated Moment of Inertia JT5 JT6 KE610 6 (7)* 145/sec 135/sec 135/sec 420/sec 470/sec 550/sec KF121 6 (7)* 220/sec 120/sec 240/sec 430/sec 430/sec 720/sec
1,200 mm/sec 1,200 mm/sec (47.24) (47.24) 2000 mm/sec 5000 mm/sec (78.74) (196.85) 90 +60/-110 +90/-80 720 720 210 Standard 3000 mm 15 (33) 69.9 Nm (51.55) 50.3 Nm (37.1) 18.4 Nm (13.57)
3.40 kg m s2
160 90 240 270 145 360 Standard 3000 mm 5 (11) 7.8 Nm (5.75) 7.8 Nm (5.75) 2.9 Nm (2.14) .058 kg m s2 (0.42 ) .058 kg m s2 (0.42) .058 kg m s2 (0.42) 0.2 (0.008) 1 kw (1.4) 1 kw (1.4) 0.4 kw (.54) 0.1 kw (.13) 0.1 kw (.13) 0.1 kw (.13) 0.1 kw (.13)
(24.58 )
1.94 kg m s2
(14.03)
0.30 kg m s2
(2.2) 1.0 (0.04) 5.6 kw (7.5) 5.6 kw (7.5) 3 kw (4) 0.75 kw (1) 0.75 kw (1) 0.75 kw (1) 0.75 kw (1)
Repeatability (in.) JT1 JT2 JT3 Drive JT4 Source (hp) JT5 JT6 JT7 Weight (lbs.)
6 810 kg (1782) 130 kg (286) Axes
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I.2 ROBOT CONTROLLER
INTRODUCTION
The Kawasaki explosion-proof C controller consists of printed circuit boards, explosionproof barrier unit, optional interface panel, and servo amplifiers. The explosion-proof C controller is used with an explosion-proof teach pendant and a multi function panel. The C controller model used depends on the mechanical unit. Table I-2 lists the controller type (Cxx) by robot model.
Table I-2 Robot Controller Versions

C Controller Model Robot Model KE610 KF121 N. American Specification C35 C37
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INTRODUCTION
I.2.1 ROBOT CONTROLLER DESIGN SPECIFICATIONS Control System: 32 bit RISC main CPU 32 bit RISC CPU for multi function panel unit 32 bit RISC servo CPU controller (one per three axes) Software controlled AC servo drive system using PWM (pulse width modulation) circuitry. 6 standard; 7th optional Teach mode Joint Base Tool
Number of Axes: Motion Control:
Repeat mode - Joint move Linear move Circular move (optional) Memory: Memory Capacity: CMOS RAM Standard - 1024 KB (approx. 9,000 steps) Optional - 4096 KB (approx. 36,000 steps) Adjustable between 1 mm - 999 mm
Smooth Range: (Accuracy) Speed: Data Editing:
Adjustable between 1 - 100% Step insertion and deletion, and rewriting of auxiliary function and positional data.
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Software Features:
INTRODUCTION
Continuous path motion control - CP ON/OFF Time delays Coordinate modification Process control programs (3) Peripheral equipment control Interrupt signal control Error interrupt control Input of real, string, and integer variables Local variables Subroutine calls with arguments (maximum stack = 20) Servo shutdown timer Auto start function 1GW I/O board 32 inputs/32 outputs (96 maximum) (including dedicated signals) Device Net (option) Outputs Motor power ON Error occurrence Automatic CYCLE_START Teach mode HOME1 HOME2 Power ON RGSO External program select (RPS) enabled External motor power ON, External error reset External cycle start External program select start (JUMP) JUMP_ON JUMP_OFF JUMP_ST External program select start (RPS) RPS_ON RPS_ST Number of RPS code signal First signal number of RPS code Program reset External Hold (EXT_IT) External condition wait (EXT_WAIT) External slow repeat mode I-7
I/O Signals:
Dedicated Signals:
Dedicated Signals:
Inputs -
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Error Messages:
INTRODUCTION
Error code messages, self-diagnosis, error logging, operation logging LCD display Membrane switch panel Three-position enabling devices Teach lock function Emergency stop switch 18 cm (7.2 in) color LCD Touch panel Pen for touch panel PC card insertion section
Explosion-Proof Teach Pendant:
Multi Function Panel:
Supplemental Data Storage:
PC flash RAM Memory Card 8MB, PCMCIA 2.1 Slot Floppy disk drive (option) Personal computer (option) N. American Spec.: 3-phase 400/440/460/480/515/575 VAC Tolerance: +/- 10% Frequency: Rated Load: Ground: 50/60 Hz 10.5 kVA less than 100 ohm ground line separated from welder power ground
Power Requirements:
Dimensions:
N. American Spec.: WxDxH, 850 mm x 500 mm x 1150 mm (inches: 33.5 x 19.7 x 45.3) N. American Spec.: 280 kg (616 lbs)
Weight:
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OVERVIEW 1.0 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.4 1.4.1 1.4.2 1.4.3 1.4.4 1.4.5 1.4.6 1.4.7 1.4.8 1.4.9 1.5 1.6
OVERVIEW ........................................................................................................ 1-2 Major Features of the Robot System.................................................................. 1-2 Major Components of the Robot System ........................................................... 1-3 User Interface Devices ....................................................................................... 1-6 Explosion-Proof Teach Pendant ......................................................................... 1-7 Multi Function Panel ........................................................................................... 1-8 Flash RAM PC Card ........................................................................................... 1-9 Controller Operation Panel ............................................................................... 1-10 Personal Computer .......................................................................................... 1-11 Software Interface Panel .................................................................................. 1-12 Floppy Disk Drive Unit ...................................................................................... 1-13 Robot Controller Main Circuitry Overview ........................................................ 1-14 1HA Board ....................................................................................................... 1-14 1GB Board ....................................................................................................... 1-14 1GC/1GD Boards ............................................................................................. 1-15 1HP Board ....................................................................................................... 1-15 1GW Board ...................................................................................................... 1-15 1GS Serial Interface ......................................................................................... 1-15 1LU Explosion-Proof Barrier ............................................................................ 1-16 1LW Encoder Barrier Module ........................................................................... 1-16 1LT E-Stop Distribution .................................................................................... 1-16 Explosion-Proof C Controller Digital Servo Control Overview .......................... 1-18 Mechanical Unit Overview ................................................................................ 1-20
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OVERVIEW 1.0 OVERVIEW
1.1 MAJOR FEATURES OF THE ROBOT SYSTEM The Kawasaki KE610 and KF121 robot systems consist of a mechanical unit, controller, software, and supporting peripheral equipment. The following major features are supported by the explosion-proof C controller: Joint coordinate movement Linear movement in base and tool coordinate systems Circular movement (optional) Language programming through program instruction menus AS Language programming through the multi function panel keyboard screen User friendly menu system for programming and system configuration Multi-tasking with the capability to run three process control programs Error message display, self diagnosis Error and operation logging Digital input and output interface PC programming Bilingual menus Program editing, storage, and monitoring via personal computer Software controlled AC servo drive system and excellent mechanical unit design provide accurate, repeatable, high speed program playback. High mechanical unit efficiency and smooth arm movement are assured through the use of close tolerance bearings, gears, and speed reducers.
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OVERVIEW
1.2 MAJOR COMPONENTS OF THE ROBOT SYSTEM The two major components of the robot system are the controller and mechanical unit. The explosion-proof C controller is illustrated in figure 1-1. The KE610 and KF121 mechanical units are illustrated in figures 1-2 and 1-3.
Figure 1-1 North American Explosion-Proof C Controller
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OVERVIEW
Figure 1-2 KE610 Mechanical Unit
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OVERVIEW
Figure 1-3 KF121 Mechanical Unit
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OVERVIEW 1.3 USER INTERFACE DEVICES The user interface devices include the following: Explosion-proof teach pendant Multi function panel PC card Controller operation panel
Personal computer using KCMON or KCWIN monitor software (option) Optional interface panel Optional software programmed interface panel on the multi function panel Optional floppy disk drive
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OVERVIEW 1.3.1 EXPLOSION-PROOF TEACH PENDANT
The explosion-proof teach pendant is equipped with keys for manual robot operation, teaching programs, entering data, and editing data (Figure 1-4).
0 SPEED 1 SPRAY . 5 DATA 6 TIMER -
2X=OUT A GUN 7 CALL D
3X=IN B TABLE 8 JUMP E MOVE
4 SMOTH CSENS 9 CONVR F
SHIFT
CLR
END
SUSPND
SET
RT LFT
SERVO
FRNT BCK
ROB ROB TBL
UP DWN
TBL TRV
SWING
RT
SWING LFT
BEND TURN FRNT UP BEND TURN BCK DWN
H M L
L C J
STORE POS
FRAME
EQPMT
RMT MOTION SPEED
CRCT
Three-Position Enabling Device Teach Lock Emergency Stop
SPRAY TEACH ON/OFF LOCK
STEP NEXT
RESET SPRAY 1/2
STEP STEP BACK
FRONT VIEW
BACK VIEW
Figure 1-4 Explosion-Proof Teach Pendant
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OVERVIEW 1.3.2 MULTI FUNCTION PANEL
The multi function panel, shown in figure 1-5, is equipped with a back lit 18 cm (7.2 in) color graphics liquid crystal display (LCD) touch panel, and PC card slot. The multi function panel is used to display and set the system configuration. The program edit screen is used to cut, copy, paste, and delete program steps. The keyboard screen allows the operator to create and edit programs using AS Language program instructions. A flash random access memory (flash RAM) PC card inserted into the multi function panel is used for program and system configuration upload/download or system software download.
Liquid Crystal Display (LCD)
Touch Panel Pen
PC Card Slot
Contrast Control
Figure 1-5 Multi Function Panel
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OVERVIEW 1.3.3 FLASH RAM PC CARD
The flash RAM PC card is used with the multi function panel to upload/download programs and system configuration data, and install AS, multi function panel, explosionproof teach pendant, and servo system software. An eight MB PC card is supplied with the controller. To backup data, download the contents of the PC card onto a floppy disk or hard disk of a personal computer. A four MB flash RAM PC card is shown in figure 1-6.
Figure 1-6 Flash RAM PC Card
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OVERVIEW 1.3.4 CONTROLLER OPERATION PANEL
The controller operation panel, shown in figure 1-7, is composed of switches used to apply motor power, cycle start programs, hold or stop programs, select operation modes, and reset errors. Lamps that indicate an error condition, motor power on, and automatic operation in repeat mode are included. An hour meter, that indicates motor power on time, and a control power lamp are located to the left of the controller door.
Emergency Stop
ERROR MOTOR POWER
Error Lamp
ERROR RESET CYCLE START
Motor Power
Error Reset Lamp

TEACH REPEAT HOLD RUN
Cycle Start
Teach Repeat Switch

REMOTE LOCAL X2
Run Hold
Figure 1-7 North American Controller Operation Panel
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OVERVIEW 1.3.5 PERSONAL COMPUTER
A PC (personal computer) can be linked to the C controller for program upload/download, program editing, and system monitoring. The PC requires the Kawasaki KCMON or KCWIN interface software to communicate with the robot controller.
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OVERVIEW 1.3.6 SOFTWARE INTERFACE PANEL
The optional software interface panels are programmed and displayed using the multi function panel. The software interface panels are designed to interface the robot with peripheral equipment used in the automated process. Figure 1-8 illustrates a software interface panel programmed for a palletizing application.
INTERFACE PANEL (1/2)

AUTO MANU OFF LINE OFF AUTO ENABLE
HOME
PALLET REMOVE MODE MANUAL AUTO MODE OFF OFF-LINE AUTO
WORK KIND
PROGRAM No.
0022
0022
022
022
00
00
Figure 1-8 Software Interface Panel
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OVERVIEW 1.3.7 FLOPPY DISK DRIVE UNIT
The optional floppy disk drive unit (figure 1-9) is a portable disk drive used to upload and download programs to the C controller. The floppy disk drive unit is connected to the host communication port and the AC outlet on the front of the controller door. For more information about program upload and download procedures refer to unit 11.
Figure 1-9 Floppy Disk Drive Unit
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OVERVIEW
1.4 ROBOT CONTROLLER MAIN CIRCUITRY OVERVIEW This section provides general information on the C-series controller main circuitry. For additional information, refer to the C Series Controller Electrical Maintenance Manual unit 6, Printed Circuit Boards. The Kawasaki C-series controller circuit board block diagram shown in figure 1-10 illustrates the major printed circuit boards inside of the controller. 1.4.1 1HA BOARD The 1HA board is the main central processing unit (CPU) board in the C-series controller, and is equipped with a 32 bit reduced instruction set computer (RISC) processor running at 166 MHz. Features include: AS system software and servo system software are stored in flash memory User programs and system configuration data reside in battery backed static random access memory (SRAM) The standard 1 MB SRAM is expandable to 4 MB
A super capacitor on the 1HA board provides approximately 30 minutes of memory backup when the board is removed from the card rack. When the board is reinstalled, the super capacitor is recharged by the 3.6 volt lithium batteries plugged into the 1HZ motherboard. The 1HA board processes the data needed for the execution of the AS software, operation planning, servo position loop operations, coordinate conversions, path planning, and detection of abnormal +5 VDC, 12 VDC and +12 VDC levels. The 1HA board communicates with the 1GB servo board, 1HP power circuit control board, 1GW I/O board(s), 1GS explosion-proof teach pendant interface board, optional boards for vision, or analog input (IP), multi function panel, and any external equipment such as a personal computer, or a floppy disk drive. 1.4.2 1GB BOARD The 1GB board is the servo CPU. The standard 1GB board is equipped with two RISC processors that control six axes. The optional 1GB board is equipped with a third RISC processor to control a seventh robot axis and allow a conveyor input for line tracking. The 1GB board receives path data from the 1HA board, encoder data from the robot axes and conveyor, and current data from the current detect modules, to generate the pulse width modulation (PWM) signals that are sent to the intelligent power modules (IPMs) located on the power block. The IPMs, in turn, allow current to flow through the 1-14 April 8, 2002
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OVERVIEW
three-phase servo motor windings and produce motor rotation. A 1GM board is attached to the 1GB board to provide an interface for the current sensors. In addition, the 1GB board also controls servo motor brake functions, overtravel limit switch signal processing, and servo system error processing. 1.4.3 1GC/1GD BOARDS The 1GC or 1GD board is the servo system power block. The 1GC board is used for robots with payload capacities of 30 kg or more and the 1GD board is used for robots with payload capacities lower than 30 kg. The power block is comprised of two sections: the power unit and the amplifier. The power unit section rectifies and filters three-phase AC power for use by the servo motors, monitors DC voltage levels, controls regenerative voltage levels, and reports voltage level and regenerative resistor circuit errors. The amplifier section receives PWM signals from the 1GB board. The PWM signals are used by the IPMs to control current flow through the servo motor windings. Current detect modules are used to send current level data back to the 1GB board to indicate robot load. The amplifier section also incorporates various protective functions that are monitored by the 1GB board. 1.4.4 1HP BOARD The 1HP board controls the power up sequence of the controller and serial communication for the multi function panel or small teach pendant 1HA and 1GB board. In addition, the 1HP board powers down the controller if an abnormality of the +/-12 VDC, +5 VDC, or 24 VDC levels exists. 1.4.5 1GW BOARD The 1GW board is a parallel I/O board providing 32 input channels and 32 output channels including dedicated signals. An optional 1GW board is available that provides two channels of analog output in addition to the 32 parallel input/output channels. Up to four 1GW boards can be installed in the C controller for a total of 128 inputs and outputs and four channels of analog output. 1.4.6 1GS SERIAL INTERFACE The 1GS board is the EP type TP to 1HA serial interface board. This is an IP board that mounts directly to the 1HA board.
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OVERVIEW
NOTE
The 1LU, 1LW, and 1LT components are located in the EP type C controller explosion-proof unit.
1.4.7 1LU EXPLOSION-PROOF BARRIER The 1LU explosion-proof barrier board, located in the explosion-proof unit, is one of the controllers main explosion-proof components. The 1LU board, in conjunction with the encoder barrier modules on the 1LU board, provides the 1GB board/encoder interface. The JT1 through JT6 encoder barrier modules provide intrinsic safety for the encoder transmit/receive circuit. In addition to encoder data, the 1LU board routes +6 VDC from the encoder power supply to the encoder barrier modules. The encoder barrier modules regulate the +6 VDC to +5 VDC for the encoder logic circuits. The 1LU board relay interlock circuit, through the zener barriers ZB1ZB4, provides the interface for the pressure switches, flow meters, purge valve solenoids, and limit switches. The zener barriers provide the intrinsically safe portion of the interface. The relay interlock circuit controls +24 VDC to the brakes, motor thermal switch circuit, interlock, emergency stop signals to the 1HP board, and the encoder power supply control relay. 1.4.8 1LW ENCODER BARRIER MODULE 1LW board is mounted inside the encoder barrier module. The encoder barrier module is mounted on the 1LU board inside the explosion-proof unit. The barrier is coupled with the explosion-proof encoders to provide intrinsically safe conditions when the internal pressure of the robot arm drops. (Pressurized state is maintained during normal conditions.) 1.4.9 1LT E-STOP DISTRIBUTION 1LT board is mounted on the explosion-proof teach pendant barrier unit box inside the explosion-proof unit. The 1LT board distributes emergency stop signals and relays enabling device status and explosion-proof teach pendant input.
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OVERVIEW
EXPLOSION-PROOF TP CPU BOARD LCD ENABLING DEVICES EMERGENCY STOP
MULTI FUNCTION PANEL 1FT COLOR LCD TOUCH PANEL PC CARD READER
1HA RISC MEMORY MULTI FUNCTION PANEL I/F PATH PLANNING COORDINATE CONVERSION
1GS BOARD
CONTROL PANEL SWITCHES & LAMPS
VOLTAGE MONITORING
AVR +5 VDC 1HZ (VME BUS) +12 VDC -12 VDC +24 VDC 1HP POWER CONTROL VOLTAGE MON. SERIAL COMM. 1GW 1FS (OPTION) OPTION PCBs VISION ARC I/F
REMOTE I/O I/O RELAYS ANALOG OUTPUT CONTROL NET (OPTIONAL)
E-P TP BARRIER UNIT 1LT 1LU JT1 BARRIER UNIT JT2 BARRIER UNIT JT3 BARRIER UNIT JT4 BARRIER UNIT JT5 BARRIER UNIT JT6 BARRIER UNIT ZENER BARRIER ZB1 ZENER BARRIER ZB2 ZENER BARRIER ZB4 EXPLOSION-PROOF UNIT
BRAKE
1GB A JOINTS 1, 2, 3 RISC ENCODER FEEDBACK ENCODER I/F B JOINTS 4, 5, 6 RISC ENCODER I/F C JOINT 7, CONVEYOR RISC ENCODER I/F
BRAKE CONTROL SEQUENCE 1GM
PWM
CURRENT FEEDBACK
1GC (Large Type) or 1GD (Small Type) IPM CURRENT DETECT MODULES 210 VAC POWER UNIT BRAKE ENCODER FEEDBACK
SERVO MOTOR
H20/M21 ENCODER
Figure 1-10 Circuit Board Block Diagram April 8, 2002 1-17
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OVERVIEW
1.5 EXPLOSION-PROOF C CONTROLLER DIGITAL SERVO CONTROL OVERVIEW This section provides general information on the operation of the digital servo drive system. For additional information, refer to the C Series Controller Electrical Maintenance Manual unit 7, Servo System. There are four major components in the C controller servo drive system: Power block assembly 1GB board and servo software AC servo motor assembly Hybrid encoder assembly
The 1GB board receives path data from the 1HA board, encoder data from the robot axes and conveyor, and load data from the current detect modules. The servo software uses these signals to calculate and produce a digital command signal. The command signal is combined with a triangular wave reference signal to determine the sampling rate of the command signal and to generate the PWM (pulse width modulation) signals that are sent to the IPMs (intelligent power modules) located on the power block. A PWM signal is a pulsed signal with a width or duration that is changed proportionally to motor demands. For example, when the motor starts from a stopped condition, the width of the PWM signals are very wide in order to overcome inertia, in comparison to the PWM signals required to sustain motor velocity. The power block is comprised of two sections: the power unit and the amplifier. The power unit receives 210 VAC/60Hz input power from the main transformer assembly. This voltage is filtered and rectified to provide 300 VDC to the IPMs. The amplifier section receives the PWM signals from the 1GB board. The PWM signals are used by the IPMs to control current flow through the servo motor windings. The IPMs use six insulated gate bipolar transistors (IGBTs) arranged in pairs, with each pair connected to a specific motor winding. When the IGBTs are gated by the PWM signals, current flows through the U, V, and W phases of the AC servo motor causing motor rotation. Current detect modules located on the power block provide feedback to indicate the current levels of the U and V phases. Signals from the modules are sent to the 1GB board where they are used to calculate the W phase current, determine torque requirements, and detect overcurrent errors and current limiter conditions that could damage the servo motor and power block.
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OVERVIEW
The hybrid (both absolute and incremental data) encoder assembly is mounted to the end of the servo motor and coupled to the servo motor shaft. Its function is to sense the servo motor shaft position, direction of rotation, and velocity. This data is sent to the 1GB board for phase calculation and processing by the software position and velocity loop amplifiers. Figure 1-11 provides a block diagram of the servo amplifier circuitry.
SERVO MOTOR
CD
CD
IGBT
Control IC
IGBT
IGBT
IPM
IGBT
Control IC
Control IC
Control IC
IGBT
IGBT
DIODE MODULE
AC 210V
VOLTAGE MONITORING
REGENERATION SIGNAL
Control IC
Control IC
+15 VDC
HIC IPM ERR PWM
H20/M21 ENCODER
Figure 1-11 Servo Amplifier Block Diagram April 8, 2002 1-19
TO 1GB BOARD
CURRENT FEEDBACK
ENCODER SIGNAL TO 1GB BOARD VIA EXPLOSION-PROOF BARRIER MODULE
ERROR SIGNAL
+12 VDC
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OVERVIEW 1.6 MECHANICAL UNIT OVERVIEW
The mechanical unit consists of the arms, linkages, and drive components necessary to provide smooth, accurate, and repeatable movement for consistent teaching and program playback. The typical mechanical unit provides six axes of motion and is available in a variety of configurations that are suited for numerous applications under a variety of conditions. Table 1-1 lists the basic drive components of the robot axes.
Table 1-1 Drive Mechanisms

Robot Drive Mechanisms KE610 JT1 Cycloidal Reduction Unit Cycloidal Reduction Unit Cycloidal Reduction Unit Spur Gears Spur Gears KF121 Cycloidal Reduction Unit Cycloidal Reduction Unit Spur Gears Spur Gears Spur Gears, Bevel Gears Spur Gears, Bevel Gears
JT2
JT3 JT4 JT5
JT6
Spur Gears
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SAFETY 2.0 2.1 2.1.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4 2.4 2.5 2.5.1 2.5.2
SAFETY ............................................................................................................. 2-2 Terminology ........................................................................................................ 2-3 Safety Information Contacts ............................................................................... 2-6 Warning and Caution Symbols ........................................................................... 2-8 Safety Categories ............................................................................................... 2-9 Personal Safety .................................................................................................. 2-9 Safety During Operation ................................................................................... 2-11 Safety During Programming ............................................................................. 2-11 Safety During Inspection, Maintenance and Repair ......................................... 2-12 Safety Features ................................................................................................ 2-13 Restricted Space Drawings .............................................................................. 2-14 KF121 .............................................................................................................. 2-14 KE610 .............................................................................................................. 2-15
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SAFETY 2.0 SAFETY
Safety is the most important consideration when using industrial automated and robotic equipment. All operators, teachers, maintenance, and repair personnel must be aware of all automated, peripheral, and robotic equipment that occupy the safeguarded space (refer to section 2.1.1 below), and their associated operational, maintenance, and repair procedures. For this reason it is recommended that all personnel who operate, teach, maintain, and repair Kawasaki industrial robots (hereafter referred to as robots), attend a Kawasaki approved training course that pertains to each employees specific job responsibilities. The information in this unit is intended to enhance existing safety guidelines that are provided by municipal, state, or national governments; it does NOT supersede existing rules, regulations, or guidelines. Because safety is the primary responsibility of the user, owner, and employer, Kawasaki recommends that specific safety guidelines and recommendations be adopted from safety design and implementation professionals. All safety issues and descriptions, presented in written or oral form by a representative of Kawasaki Robotics (USA), Inc., are intended to provide general safety precautions and procedures. These safety precautions and procedures are NOT intended to provide all safety measures necessary for the protection of personnel and equipment in the work environment. Kawasaki robots are safe for use when all safety guidelines are followed. It is the responsibility of the end user to follow robot operation safety guidelines for the protection of personnel and equipment.
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SAFETY 2.1 TERMINOLOGY
The following terms are used in this safety section and throughout Kawasaki Robotics (USA), Inc. documentation. automatic mode Operating mode in which the control system operates in accordance with the task program. automatic operation The state in which the robot is executing its programmed task. continuous path control 1 A type of robot control in which the robot moves according to a replay of closely spaced points, programmed on a constant time base during teaching. The points are first recorded as the robot is taught along a desired path, and the position of each axis is recorded by the control unit on a constant time basis by scanning axis encoders during the robot motion. The replay algorithm attempts to duplicate that motion. 2 Interpolation of a desired path curve between a few taught points. continuous path system A type of robot movement in which the tool performs the task while the motion axes are moving. All motion axes may move simultaneously, each at a different velocity, in order to trace a required path or trajectory. controller The manipulator power supply and control system. The controller contains microprocessors; memory for the operating system, programs, and data; operator and equipment interfaces; communication hardware and software; and servo amplifiers to drive the manipulator servo motors. emergency stop The operation of a circuit that overrides all other robot controls, removes drive power, causes all moving parts to stop, and removes power from other hazardous functions present in the safeguarded space, and does not cause additional hazards. enabling device (formerly known as trigger switch or deadman switch) A manually operated device which, when continuously activated, permits robot motion. hazard a potential source of harm. industrial robot An automatically controlled, multipurpose manipulator, programmable in three or more axes. It may be either fixed in place or mobile for use in industrial automation applications. limit switch (also overtravel limit switch) An electrical switch positioned so that when physical contact with an object occurs, the switch is activated.
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SAFETY
manipulator (also known as mechanical unit) a mechanism, usually consisting of a series of segments or links, jointed or sliding relative to one another, usually in several degrees of freedom. It is remotely operated using a controller. The term refers to the mechanical portion of the robot. operator The person designated to start, monitor, and stop the operation of a robot or robot system. The operator may also interface with a robot for production purposes. path The path traced by the tool center point (TCP) during the execution of a task program. peripheral equipment The equipment used in conjunction with the robot for a complete robotic system. This equipment includes grippers, dispensers, weld guns, conveyors, part positioners, part or material feeders, and any equipment located within the safeguarded space that is not part of the robot. pinch point Any point where it is possible for a part of the body to be injured between the moving or stationary part of a robot and the moving or stationary part of associated equipment, or between the material and moving part of the robot or associated equipment. point-to-point control A robot motion control in which the robot is programmed to move from one position to the next. The intermediate paths between these points cannot be specified. point-to-point system Robot movement in which the robot moves to a numerically defined position and stops, performs an operation, and then moves to another numerically defined position and stops, and so on. restricted space (formerly known as work envelope) The space defined by the maximum reach of the manipulator, including the end-effector and work piece, in all directions, after a limiting device is actuated. safeguarded space (formerly known as work cell) The space defined by the perimeter safeguarding devices. safeguarding device A device that detects or prevents access to a hazard. slow speed control A mode of robot motion control where the speed is limited to 250 mm/sec. This allows the teacher to either withdraw from hazardous motion or stop the robot.
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SAFETY
teach pendant (also multi function panel) A portable hand-held programming device that interfaces with the robot controller. It contains keys (soft or touch keys), switches (e.g., emergency stop, enabling device, teach/automatic mode), indicators, and a display. Used to direct the controller to position the robot, record positional and auxiliary data information, and interface with auxiliary equipment. teach programming A method of entering a control program into the robot controller. The robot is manually moved by an operator using a teach pendant. The teacher records positions and other data which is saved to the robot controller as the robot is moved through the desired path. teacher A person who provides the robot with a set of instructions to perform a task.
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SAFETY 2.1.1 SAFETY INFORMATION CONTACTS
Four recommended sources for national safety laws and regulations are: 1. Occupational Safety and Health Administration (OSHA) U.S. Department of Labor Office of Public Affairs Occupational Safety and Health Administration - Room: 3647 200 Constitution Avenue Washington, DC 20210 Phone: (202) 693-1999 http://www.osha-slc.gov/SLTC/robotics/index.html 2. Mine Safety and Health Administration (MSHA) http://www.msha.gov 3. National Institute for Occupational Safety and Health (NIOSH) Phone: (800) 35-NIOSH {(800) 356-4674} Outside the U.S.: (513) 533-8328 http://www.cdc.gov/niosh/homepage.html 4. American National Standards Institute (ANSI) Headquarters American National Standards Institute 1819 L Street, NW Washington, DC 20036 Phone: (202) 293-8020 Fax: (202) 293-9287 Customer Service: (212) 642-4980 General Inquiries: (212) 642-4900 http://www.ansi.org
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SAFETY
To order the Industrial Robots And Robot Systems - Safety Requirements (ANSI/RIA R15.06-1999): http://webstore.ansi.org/ansidocstore/find.asp In the Standards Search/Lookup: field, enter robot to locate ANSI/RIA R15.06-1999. Customer Service: (212) 642-4900, or E-mail: storemanager@ansi.org
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SAFETY 2.2 WARNING AND CAUTION SYMBOLS
The following symbol and its enclosed text, when presented in Kawasaki Robotics (USA), Inc. documentation, provides EXTREMELY IMPORTANT personnel safety information. The information relates to the text that directly follows the symbol.
WARNING
Warning symbols indicate processes or procedures that, if not followed properly, can result in serious injury or death to personnel.
The following symbol and its enclosed text, when presented in Kawasaki Robotics (USA), Inc. documentation, provides VERY IMPORTANT equipment protection information. The information relates to the text that directly follows the symbol.
CAUTION
Caution symbols indicate processes or procedures that, if not followed properly, can result in equipment damage.
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SAFETY 2.3 SAFETY CATEGORIES
Personnel safety is described in one of the following four categories: Personal safety Safety during operation Safety during programming Safety during inspection, maintenance, and repair.
Each safety category is described in the following sections. 2.3.1 PERSONAL SAFETY All applicable safety procedures must be followed consistently and be an integral part of standard operating procedures. The following are personal safety guidelines: Comply with ALL applicable OSHA, NIOSH, MSHA, local, state, national, and facility safety specifications and procedures. Before operating, teaching, maintaining, or repairing the robot controller or mechanical unit, ensure ALL operating, programming, maintenance, and repair procedures are fully understood. When performing robot controller or mechanical unit maintenance or repair, do not wear loose clothing, scarves, wrist watches, rings, or jewelry. It is also recommended that if a necktie is worn, it be a clip-on (NOT tied) type. When required by facility safety regulations, ALWAYS wear safety glasses or goggles, approved safety shoes, hard hats, and other protective equipment. Know the ENTIRE safeguarded space, including peripheral devices. Know the extent of the ENTIRE mechanical unit restricted space. Know the location of ALL emergency stop (E-stop) switches. AVOID trap points where personnel can become trapped between moving and stationary devices.
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SAFETY
Before initiating robot motion, ensure that ALL personnel are clear of the safeguarded space and know how the robot will perform when motion is initiated. Before operating the robot, ensure the work area is free of tools, lubricants, cleaning equipment, and debris. If unsafe working conditions are observed, IMMEDIATELY report them to the supervisor or facility safety coordinator. ALL robot operators must be able to identify, by name and function, ALL switches, control devices, and signals that initiate robot motion. NEVER defeat, render useless, jumper out, or bypass any mechanical or electrical safety device. To ensure personnel safety, ALL safety devices approved for use in the facility must be properly installed and maintained. During robot operation, NEVER attempt to stop or brake the mechanical unit with a part of your body. Use E-stop switches to stop mechanical unit motion in emergency situations ONLY. During automatic operation, NEVER enter the safeguarded space.
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SAFETY 2.3.2 SAFETY DURING OPERATION
Before operating the robot, know the boundaries of the restricted space. ALWAYS keep the work area clean and free of debris which includes, but is not limited to, oil, water, tools, and electronic test equipment. Because the teach pendant has provisions to protect the operator during teaching operations, the ONLY person allowed in the safeguarded space is the person operating the teach pendant. Teach pendant safety provisions include an E-stop switch and enabling device. Before performing teach operations, ALWAYS have a planned retreat path. NEVER block the operators retreat path. AVOID trap points.
2.3.3 SAFETY DURING PROGRAMMING Before operating the robot, know the boundaries of the restricted space. Because the teach pendant has provisions to protect the operator during teaching operations, the ONLY person allowed in the safeguarded space is the person operating the teach pendant. Teach pendant safety provisions include an E-stop switch and enabling device. AVOID trap points. Before operating the robot in point-to-point mode, the operator must be COMPLETELY clear of the safeguarded space. During point-to-point playback operations, the robot has information about its present location and the next point to which it is programmed to move. If an object lies between these two points, the robot will impact the object. Playback accuracy and speed affect path coordinate geometry. When changing program accuracy or speed, ALWAYS test a program in the point-to-point mode, or at a slow speed, before performing continuous path operation in the repeat mode. For a newly created program, before performing high-speed playback operation in the repeat mode, ALWAYS run the new program in the point-to-point mode, or at a slow speed.
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SAFETY
2.3.4 SAFETY DURING INSPECTION, MAINTENANCE AND REPAIR Before entering the safeguarded space to perform inspection, maintenance, or repair procedures, set the robot controller main disconnect to OFF and tag and lock it out.
WARNING
When the robot controllers main disconnect is set to OFF, the input side may still be energized. Before performing maintenance on the main disconnect, ALWAYS set the source disconnect to OFF and tag and lock it out.
If an axis is not supported when the servo drive motor is removed, the axis will fall. The brake assembly is part of the servo drive motor. If an axis is not supported and the brake release switch is activated, the axis will fall. Before working on pneumatic or high pressure water supplies, turn the supply pressure off, and purge ALL lines to remove residual pressure. Assign ONLY qualified personnel to perform ALL maintenance or repair procedures. Before performing maintenance or repair procedures, review ALL available documentation related to the procedure. Use ONLY Kawasaki Robotics (USA), Inc. approved replacement parts. Robot controller interlock control circuits are identified with yellow wiring. BEFORE adjusting or repairing an interlock control circuit device, locate the disconnect supplying power to the device and set it to OFF. During inspection, maintenance, or repair procedures, if the system is equipped with safety fences and safety plugs, REMOVE and HOLD the safety plug while performing these procedures. In addition to this safety plug procedure, ALL safety procedures described above must be followed.
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SAFETY 2.4 SAFETY FEATURES
To safeguard the user, Kawasaki robot systems are equipped with many safety features, including the following: All E-stops are hard-wired. The teach pendant or multi function panel, small teach pendant, and operation panel are equipped with red mushroom-type E-stop switches. If an optional interface panel is installed, the operation panel E-stop switch is relocated to the optional interface panel. All robot axes are monitored by the robot controller for velocity and deviation errors. If an over-velocity or deviation condition is detected, the robot faults in a velocity or deviation error condition. Teach and check mode velocities are limited to a maximum of 250 mm/sec (9.843 in/sec). All robot axes have software limits. JT1 is equipped with overtravel limit switches. Optional overtravel limit switches are available for JT2 and JT3. KE610 and KF121 mechanical units have overtravel hardstops on the JT1, JT2, JT3, and JT5 axes. All robot axes are equipped with 24 VDC electromechanical brakes that engage when power is removed. If the robot loses power unexpectedly, the mechanical unit arm is held in position by the brakes and does not fall.
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SAFETY 2.5 RESTRICTED SPACE DRAWINGS 2.5.1 KF121
160
160 JT6: 720 Z JT5: 290
JT4: 540
JT3: 480
90
550
1240 JT1: 320
80
R3
02
JT2: 180
R5
50
150 150
off-set 90
Figure 2-1 KF121 Restricted Space
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18
400
R5
50
600
150 R1
1630
90
Kawasak
SAFETY 2.5.2 KE610
(5428)
6028
1558.5
230
149
5339 (4779) 200 715
(4305)
4707
(1040)
(2714) 2371 3014 644
(2065) 2325
Figure 2-2 KE610 Restricted Space
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1143
(2011)
(703)
750
1400 (1100)
2-15
750
1400 (1100)
200
Kawasak
C SERIES CONTROLLER EP TYPE
3.0 C SERIES CONTROLLER EP TYPE ................................................................... 3-2 3.1 Operation Panel .................................................................................................... 3-2
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Kawasak
3.0 C SERIES CONTROLLER EP TYPE
This unit provides information about the switches, indicators and connectors located on the door and the main body of the controller. 3.1 OPERATION PANEL The numbered call outs in figure 3-1 correspond with table 3-1 to identify the functions of the components.
Multi Function Panel
Multi Function Panel Strain Relief Connector Main Disconnect 3 4 6 9
Operation Panel 10 8 7 5 Communication Port
1 2 Explosion-Proof Teach Pendant Explosion-Proof Teach Pendant Connector
Figure 3-1 C Series Controller EP Type 3-2 April 8, 2002
Kawasak
Table 3-1 Operation Panel Switches

No. 1.
HOUR METER
Switch
Function The white CONTROL POWER lamp indicates that the controller power supply is turned ON. The HOUR METER indicates the total ser vo motor power ON time. The red ERROR lamp indicates that an error has occured. Blinking lamp indicates initialization screen is displayed The yellow ERROR RESET switch resets the system and the error lamp is turned OFF. This switch does not clear the error if the error is continuous. The RUN position allows program execution and robot motion; the HOLD position places the robot into a temporar y stop condition. The TEACH REPEAT switch selects the teach or repeat mode of operation (Key Switch). The green CYCLE START switch initiates execution of the selected program. The lamp remains ON during program execution. The orange MOTOR POWER switch turns ser vo motor power ON. The lamp remains ON while motor power is ON. The REMOTE/LOCAL switch selects the cycle star t source. REMOTE: external star t signal is used. LOCAL: CYCLE START switch on the controller is used.
2.
01996
3.
4.
5.
6.
7.
8.
9.
EMERGENCY STOP
10.
The red EMERGENCY STOP switch turns the ser vo motor power OFF, the brakes are applied, and the robot stops. The motor power lamp and cycle star t lamp are turned OFF. Control power is not turned off.
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4.0 4.1 4.1.1 4.1.1.1 4.1.2 4.2 4.2.1 4.2.2 4.3 4.3.1 4.3.2 4.3.3
POWER ON/OFF PROCEDURES
POWER ON/OFF PROCEDURES .................................................................. 4-2 Controller Power On/Off Procedures ............................................................... 4-2 Controller Power On Procedures ..................................................................... 4-2 Opening Screens ............................................................................................. 4-2 Controller Power Off Procedures ..................................................................... 4-4 Servo Motor Power-On Procedures ................................................................. 4-6 Servo Motor Power-On in the Repeat Mode .................................................... 4-6 Servo Motor Power-On in the Teach Mode ...................................................... 4-6 Methods for Stopping the Robot ...................................................................... 4-7 EMERGENCY STOP Switch ........................................................................... 4-7 Hold/Run Switch .............................................................................................. 4-7 Teach/Repeat Switch ....................................................................................... 4-7
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4.0 POWER ON/OFF PROCEDURES
This unit provides the power ON/OFF procedures for the robot controller and servo motors. Refer to figures 4-1 through 4-4 during these procedures. 4.1 CONTROLLER POWER ON/OFF PROCEDURES 4.1.1 CONTROLLER POWER ON PROCEDURES 1. Ensure all personal are clear of the work cell, and all safety devices are in place and operational. Set the HOLD/RUN switch to the HOLD position. Place the controller main disconnect switch in the ON position. At this time the CONTROL POWER indicator lamp illuminates. Check for error conditions and press the ERROR RESET switch to clear the error condition if the ERROR lamp is illuminated.
2. 3.
4.
4.1.1.1 OPENING SCREENS 1. 2. Controller power ON. The version of controller software installed is displayed on the teach pendant screen on power up (figure 4-1, 2). The air purging process is automatically executed and the display below is shown on the teach pendant screen (figure 4-1, 3). Purge time is counted down. The purge time depends on the robot type (figure 4-1, 4). When the purge cycle is complete the pressurizing screen is displayed (figure 4-1, 5).
3.
4.
5.
NOTE The air purging process is executed for pressurized explosion-proof type robots (KE610 and KF121). Steps 3 through 5 are not executed on robot models equipped with explosion-proof motors.
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Robot AS XTP 2.
: KE610H-A001 axes:7 S-No. :98 : 6H600RAJ ... 01/09/04 10:51 : XH610RAE ... 01/09/04 10:04
PLYBK/STATUS
EASY MOVE 330[sec] b
Checking Air Supplied Waiting time 330[sec] 3. PLYBK/STATUS EASY MOVE 236[sec] b
Air Purging !! Waiting time 236[sec] 4. PLYBK/STATUS EASY MOVE 12[sec] b
Waiting Internal Pressure Up Waiting time 12[sec] 5. EASY MOVE PG11 -0 Select a mode
0. TEACH 2. EDIT PROGRAM 4. DATA BANK 6. SET CONDITION 8. MANUAL EXOUT 1. PLAYBACK 3. MANAGE PROGRAM 5. DISPLAY STATUS 7. PRODUCT/HISTORY
6.
Figure 4-1 Opening Screens
6. 7. 8.
When the pressurizing cycle is complete the main menu is displayed (figure 4-1, 6). Set the TEACH/REPEAT switch to TEACH and the HOLD/RUN switch to RUN. Press the motor power switch to activate the motor power circuit. When teach mode is selected, motor power is not engaged until TEACH LOCK is set to ON and one of the enabling devices on the explosion-proof teach pendant is pressed and held. With an enabling device held there is a 0.5 second delay before motor power is engaged and the motor brakes are released.
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4.1.2 CONTROLLER POWER OFF PROCEDURES 1. 2. Turn the HOLD/RUN switch to the HOLD position; the robot decelerates to a stop. Press the EMERGENCY STOP switch. At this time the MOTOR POWER and CYCLE START lamps are extinguished. Place the controller main disconnect switch in the OFF position.
3.
Main Disconnect Error Lamp Error Reset Lamp Teach Repeat Switch
Operation Panel Emergency Stop Motor Power Cycle Start Run Hold
Control Power Lamp
Explosion-Proof Teach Pendant
Figure 4-2 C Series Controller EP Type 4-4 April 8, 2002
Kawasak
Emergency Stop
ERROR MOTOR POWER
Error Lamp
ERROR RESET CYCLE START
Motor Power
Error Reset Lamp

TEACH REPEAT HOLD RUN
Cycle Start
Teach Repeat Switch

REMOTE LOCAL X2
Run Hold
Figure 4-3 C Series Controller EP Type, Operation Panel
SHIFT
CLR
END
SUSPND
SET
RT LFT
SERVO
FRNT BCK
ROB ROB TBL
UP DWN
TBL TRV
SWING
RT
SWING LFT
H M L
L C J
STORE POS
FRAME
EQPMT
RMT MOTION SPEED
CRCT
Three-Position Enabling Device Teach Lock Emergency Stop
STEP NEXT
RESET SPRAY 1/2
STEP STEP BACK
FRONT VIEW
BACK VIEW
Figure 4-4 Explosion-Proof Teach Pendant April 8, 2002 4-5
Kawasak
4.2 SERVO MOTOR POWER-ON PROCEDURES
4.2.1 SERVO MOTOR POWER-ON IN THE REPEAT MODE 1. 2. 3. 4. 5. Place the TEACH/REPEAT switch in the REPEAT position. Place the TEACH LOCK switch in the OFF position. Press the MOTOR POWER switch. The MOTOR POWER lamp illuminates. Place the HOLD/RUN switch in the RUN position. The robot is now ready to execute a program.
4.2.2 SERVO MOTOR POWER-ON IN THE TEACH MODE 1. 2. 3. 4. Place the TEACH/REPEAT switch in the TEACH position. Place the TEACH LOCK switch the ON position. Set the HOLD/RUN switch to RUN. At the teach screen, press and hold one of the enabling devices and press the MOTOR POWER switch. At this time the MOTOR POWER lamp illuminates.
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4.3 METHODS FOR STOPPING THE ROBOT
Three methods can be used to stop robot motion. Each of these methods is described in the following sections. 4.3.1 EMERGENCY STOP SWITCH When the EMERGENCY STOP switch is pressed, motor power is turned off and the brakes are applied stopping the robot immediately. This places very high loads upon the robot and is only recommended for emergency situations. To stop the robot during nonemergency situations refer to section 4.3.2, HOLD/RUN SWITCH. 4.3.2 HOLD/RUN SWITCH When the HOLD/RUN switch is turned to the HOLD position the robot decelerates smoothly to a stop and the brakes are applied. This places the robot into a temporary stop condition. The motor power lamp turns OFF and the CYCLE START lamp remains ON. When the HOLD/RUN switch is again turned to the RUN position the robot continues the motion it had been executing prior to HOLD. To create a permanent stop condition, press the EMERGENCY STOP switch or turn the TEACH/REPEAT switch to the TEACH position (the CYCLE START and MOTOR POWER indicator lamps turn off in either case). 4.3.3 TEACH/REPEAT SWITCH When the TEACH/REPEAT switch is turned to the TEACH position motor power is turned off and the brakes are applied stopping the robot immediately. This places very high loads upon the robot and is only recommended for emergency situations. To stop the robot during non-emergency situations refer to section 4.3.2, HOLD/RUN SWITCH.
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5.0 5.1 5.1.1 5.1.2 5.2 5.2.1 5.2.2 5.2.3 5.2.3.1 5.2.3.2 5.2.3.3 5.2.3.4 5.2.3.5 5.2.3.6 5.2.3.7 5.2.3.8 5.2.3.9 5.2.3.10 5.2.3.11 5.2.3.12 5.2.3.13 5.2.3.14 5.2.3.15 5.2.3.16 5.2.3.17 5.2.3.18 5.2.3.19 5.2.3.20 5.2.3.21
EXPLOSION-PROOF TEACH PENDANT AND MULTI FUNCTION PANEL
EXPLOSION-PROOF TEACH PENDANT AND MULTI FUNCTION PANEL5-2 Explosion-Proof Teach Pendant ................................................................... 5-2 Keys and Switches ....................................................................................... 5-2 Teach Display Screen ................................................................................... 5-7 Multi Function Panel ..................................................................................... 5-8 Multi Function Panel Keys and Switches ...................................................... 5-8 Multi Function Panel Status Screen ........................................................... 5-10 Multi Function Panel Liquid Crystal Display Touch Keys ............................ 5-12 Program and Step Selection/Display Keys ................................................. 5-12 Program Selection Key ............................................................................... 5-13 Step Selection Key ..................................................................................... 5-15 Cursor Movement Keys .............................................................................. 5-16 Figure Input and Cursor Selection ............................................................. 5-17 Character Set Screen ................................................................................. 5-18 Screen Selection Keys ............................................................................... 5-19 Teaching Key .............................................................................................. 5-20 AS Teaching Screen ................................................................................... 5-21 Status Key .................................................................................................. 5-22 Status Screen............................................................................................. 5-23 Program List Screens ................................................................................. 5-25 Monitor Screen ........................................................................................... 5-26 Current Position Screen ............................................................................. 5-27 Spray Status Screen .................................................................................. 5-28 Spray Output Display ................................................................................. 5-30 All Ratio Set Screen ................................................................................... 5-32 Signal Output Screen ................................................................................. 5-33 Menu Key ................................................................................................... 5-34 Function Screen ......................................................................................... 5-35 Multi Function Panel Keyboard Display ...................................................... 5-36
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5.0 EXPLOSION-PROOF TEACH PENDANT AND MULTI FUNCTION PANEL 5.1 EXPLOSION-PROOF TEACH PENDANT 5.1.1 KEYS AND SWITCHES The explosion-proof teach pendant is equipped with keys for manual robot operation, teaching programs, entering data, and editing data. Refer to figure 5-1 and table 5-1 for key location and function descriptions.
SHIFT
CLR
END
SUSPND
SET
RT LFT
SERVO
FRNT BCK
ROB ROB TBL
UP DWN
TBL TRV
SWING
RT
SWING LFT
H M L
L C J
STORE POS
FRAME
EQPMT
RMT MOTION SPEED
CRCT
STEP NEXT
RESET SPRAY 1/2
STEP STEP BACK
Emergency Stop Switch
Figure 5-1 Explosion-Proof Teach Pendant
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Table 5-1 Explosion-Proof Teach Pendant Key Functions

Key
1 SPRAY .
Function Used to enter the numeric value of 1. A decimal point can be entered when pressed with the shift key. Selects 1. SPRAY from the teach instruction menu. Used to enter the numeric value of 2. The numeric value A (hexadecimal) can be entered when pressed with the shift key. Selects 2. EXTERNAL OUTPUT from the teach instruction menu. Used to enter the numeric value of 3. The numeric value B (hexadecimal) can be entered when pressed with the shift key. Selects 3. EXTERNAL INPUT from the teach instruction menu. Used to enter the numeric value of 4. The numeric value C (hexadecimal) can be entered when pressed with the shift key. Selects 4. SMOOTH from the teach instruction menu. Used to enter the numeric value of 5. Selects 5. DATA BANK from the teach instruction menu. Used to enter the numeric value of 6. A minus can be entered when pressed with the shift key. Selects 6. TIMER from the teach instruction menu. Used to enter the numeric value of 7. The numeric value D (hexadecimal) can be entered when pressed with the shift key. Selects 7. CALL from the teach instruction menu. Used to enter the numeric value of 8. The numeric value E (hexadecimal) can be entered when pressed with the shift key. Selects 8. JUMP from the teach instruction menu. Used to enter the numeric value of 9. The numeric value F (hexadecimal) can be entered when pressed with the shift key. Selects 9. CONVEYOR from the teach instruction menu. Used to enter the numeric value of 0. Selects 0. SPEED from the teach instruction menu.
2X=OUT A GUN
3X=IN B TABLE
4 SMOTH CSENS
5 DATA
6 TIMER -
7 CALL D
8 JUMP E MOVE
9 CONVR F
0 SPEED
SHIFT
Used in combination with other keys for additional functions.
Used to move the cursor up on the screen.
SHIFT +
When used with the shift key, moves the display to the previous screen.
Used to move the cursor down on the screen.
SHIFT +
When used with the shift key, moves the display to the next screen.
CLR
Used to cancel the numeric entry and clears the screen.
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Table 5-1 Explosion-Proof Teach Pendant Key Functions (continued)

Key Function Returns to the main menu.
END
SHIFT + END
When pressed with the shift key, forces termination of repeat operation.
SUSPND
Holds the present mode and moves to another mode. The original mode is displayed when this key is pressed again.
Returns to the upper screen.
SET
Moves to the next screen when pressed for confirmation of menu selection or numeric value entry. Moves the robot to the right in the Car tesian coordinate mode or swivels JT1 axis to the right in the joint mode. The table axis rotates in normal (+) direction. Moves the robot to the left in the Car tesian coordinate mode or swivels JT1 axis to the left in the joint mode. The table axis rotates in normal (-) direction. Moves the robot forward in the Car tesian coordinates or rotates JT2 axis forward in the joint mode. Moves the robot backward in the Car tesian coordinates or rotates JT2 axis backward in the joint mode. When pressed with the shift key, moves the robot forward in the gun coordinates (EASY coordinates only). When pressed with the shift key, moves the robot backward in the gun coordinates (EASY coordinates only). Moves the robot upward in the Car tesian coordinates or rotates JT3 axis upward in the joint mode. Moves the robot downward in the Car tesian coordinates or rotates JT3 axis downward in the joint mode. Turns the gun to the right in the Car tesian coordinates or rotates JT4 axis to the right in the joint mode. Turns the gun to the left in the Car tesian coordinates or rotates JT4 axis to the left in the joint mode. Rotates the gun upward in the Car tesian coordinates or rotates JT5 axis to the right in the joint mode.
RT LFT
FRNT BCK
SHIFT + FRNT
SHIFT + BCK
UP DWN
SWING
RT
SWING LFT
BEND FRNT BEND BCK
Rotates the gun downward in the Car tesian coordinates or rotates JT5 axis to the left in the joint mode.
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Key
TURN UP TURN DWN
Function Rotates the gun to the right in the Car tesian coordinates or rotates JT6 axis to the right in the joint mode. Rotates the gun to the left in the Car tesian coordinates or rotates JT6 axis to the left in the joint mode. Used to select the coordinate system during manual operation: EASY Y GUN Y JOINT When pressed with the shift key, selects the coordinate system to change with the coordinate selection key: EASY Y XYZ1 Y XYZ2 Used to select robot and external axis jogging for the axis keys operation. The LEDs indicate the active axis. ROBOT Y TRAVERSE Y TABLE
FRAME
SHIFT + FRAME
ROB TBL
TRV
EQPMT
Note: Device selection is system dependent.
H M L
RMT SPEED
Used to select speed during manual operation. The LEDs indicate the speed selected. HIGH Y MEDIUM Y LOW
L C J
MOTION
Used to select the interpolation mode during teaching operation. The LEDs indicate the interpolation mode selected. LINEAR Y CIRCULAR (MIDDLE Y END) Y JOINT
When pressed with the shift key during linear and circular interpolations, selects between retaining gun posture or retaining wrist axes angles. SHIFT + MOTION Note: When retaining wrist axes angles the L and C LEDs are illuminated and the J LED blinks.
STORE POS
Used to record the present robot location as a program point. Used to select teach and edit mode, command codes. The selected mode is displayed at the top left of the screen. PROHIBIT Y ADD Y MODIFY Y DELETE Y SEARCH When pressed with the shift key, selects teach and edit mode, default command codes. PROHIBIT Y ADD Y MODIFY Y DELETE Y SEARCH Used to reset an error condition.
CRCT
SHIFT + CRCT
RESET
SHIFT + RESET
When pressed with the shift key, resets errors individually when multiple errors occur.
April 8, 2002
5-5
Kawasak

Key
SPRAY ON/OFF
Function Used to select if paint is sprayed or not sprayed. The LED is illuminated when spray is ON.
SPRAY 1/2
Used to output the spray 1 signal while pressed.
SHIFT +
SPRAY 1/2
When pressed with the shift key, outputs the spray 2 signal. Used to actuate the teach mode and prevent accidental repeat operation during teaching. Ensure the TEACH LOCK is ON before entering the safety fence. The LED is illuminated when TEACH LOCK is ON. Used to select the check mode step method. MOVE Y LINE Y CONTINUOUS Y JUMP
TEACH LOCK
STEP
STEP NEXT STEP BACK
Used to step forward through a program during check mode.
Used to step backward through a program during check mode.
SERVO
ROB
TBL
Indicates the robot servo power is ON when the ROB LED is illuminated.
SERVO
ROB
TBL
Indicates the table servo power is ON when the TBL LED is illuminated. Note: LED labeling is system dependent.
EMERGENCY STOP
Used to stop the robot in an emergency situation. Motor power is turned off and the brakes are applied stopping the robot immediately. This places very high loads upon the robot and is only recommended for emergency situations.
Enabling Device
Used to enable or disable robot motion in teach mode.
5-6
April 8, 2002
Kawasak
5.1.2 TEACH DISPLAY SCREEN
The teach display screen and the item descriptions are shown in table 5-2.
Table 5-2 Teach Screen Display Descriptions

1 2 3 4 5
EASY MOVE PG10 -0 TCH/PRHBT Program contents are as follows

1 SPRAY_SPEED 100MM/S 2 DOUT #100, ON 3 SPRAY #1, ON
Item
Description Displays the correction mode (Prohibit/Add/Modify/Delete/Search), selected. The correction modes are sub-modes of the teach mode. Use the
CRCT
key to change sub-mode.
Displays the manual operation coordinate system [Easy (XYZ1 and XYZ2)/Gun/Joint] selected. Use the
FRAME
key to change mode.
Displays the check step (Move/Line/Continuous/Jump) mode selected. 3 Use the Use the 4 5 6
STEP NEXT
STEP
key and the
STEP BACK
key to step through the program.
key to select the mode.
Current program name display. Current program point display. System message display. The sequential numbers indicate program steps. The highlighted step number indicates step commands are completed through this step. In the above example, program step commands are completed through step 3.
April 8, 2002
5-7
Kawasak
5.2 MULTI FUNCTION PANEL
5.2.1 MULTI FUNCTION PANEL KEYS AND SWITCHES The multi function panel is equipped with a 7.2 inch (18 cm) liquid crystal VGA display and a touch pen used for entering and editing data. The multi function display includes touch keys for entering data and performing check operations. Figure 5-2 shows the multi function panel and table 5-3 describes its features.
Touch Panel Pen
PC Card Slot
Contrast Control
Figure 5-2 Multi Function Panel
5-8
April 8, 2002
Kawasak
Table 5-3 Multi Function Panel Features and Descriptions Feature Liquid crystal display (LCD) PC card slot Contrast adjustment knob Touch pen Description The LCD displays keys for robot manual operation, teaching programs, data entry/editing, check operation, system status, teaching data and system data. The PC card slot is used to save/load program and system data to a flash RAM PC card. The contrast adjustment knob is used to adjust the contrast/brightness of the display. The touch pen is used for touch panel operation.
April 8, 2002
5-9
Kawasak
5.2.2 MULTI FUNCTION PANEL STATUS SCREEN Figure 5-3 shows the multi function panel (MFP) status screen display and table 5-4 describes the numbered areas of the display.
PROGRAM pg99
STEP 5
PC
TEACHING
SPEED 10%
97-03-18 17:30
STATUS
MENU
REPT. CONTINUE RPS ON STEP CONTINUE DRYRUN OFF
1 2
Cleared error state ERROR (-1516) Encoder data abnormal jt 7 8 Cleared error state STATUS ERROR HOLD TEACH CYCLE MOTOR E-STOP START POWER
SRV-ON RUN REPEAT
NORMAL RELEASE EXT. HOLD
REPEAT 10%
REPEAT
CONDITION
STEP
FORWARD
RECORD ACCEPT
JT1 -26.248 X 532.690
JT2 -5.518 Y 656.487
JT3 -37.812 Z 1022.774
JT4 71102 O -154.463
JT5 -75.092 A 113.890
JT6 11.449 T 46.616
JT7 5.315
Figure 5-3 Multi Function Panel Status Screen Display
5-10
April 8, 2002
Kawasak
Table 5-4 Multi Function Panel Status Screen Display Area Descriptions
Area 1 2 3 Description System message area: Displays errors and operation information. Title area: Indicates the selected function or display. Auxiliary data area: Displays the present operation status or the teaching status of the current step for teach, clamp, signal output, and OX/WX data. Status information area: Displays the current system status (see examples below).
M-OFF HOLD TEACH
M-ON RUN WAIT
M-ON RUN REPEAT SPRAY ON
M-ON RUN SLOW REP (SLOW REPEAT) SPRAY IN (SPRAY INHIBIT)
April 8, 2002
5-11
Kawasak
5.2.3 MULTI FUNCTION PANEL LIQUID CRYSTAL DISPLAY TOUCH KEYS 5.2.3.1 PROGRAM AND STEP SELECTION/DISPLAY KEYS
PROGRAM pg1
STEP 1
PC
The keys shown above are used to select robot programs, program steps, and to display the selected program name, step number and process control (PC) program(s). The function of these keys is described in table 5-5.
Table 5-5 Function of Program and Step Selection Keys
Key
PROGRAM pg1
Function The PROGRAM key displays the currently selected program. When this key is pressed, the program select screen is displayed and another program can be selected. The STEP key displays the currently selected program step. When this key is pressed, the step selection screen is displayed and another program step can be selected.
STEP 1
PC
The PC key displays the currently selected process control (PC) program(s).
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April 8, 2002
Kawasak
5.2.3.2 PROGRAM SELECTION KEY
The PROGRAM key is used to select programs for playback, editing, deletion, create new program names (teach mode only), and display the selected program name. Use the cursor keys to select the desired program from the list and press RETURN. Figure 5-4 illustrates the use of the PROGRAM key for program selection.
PROGRAM
8
PROGRAM SELECT
pg?? pg10 work1 test
9 7 5 3 1
RETURN
pg1 pg2 pg8
6 4 2
DELETE
EXIT
BS
PROGRAM LIST
CHARACTER

RETURN
Figure 5-4 Program Selection Methods
April 8, 2002
5-13
Kawasak
To delete a program, select the program name with the cursor keys and press the DELETE key. Press ENTER to continue or EXIT to abort the process. The example in figure 5-5 deletes program pg10.
DELETE
pg?? pg1 pg2 test pg10 pg8 work1 OK to delete the program? (ENTER/EXIT) pg10
ENTER
pg?? pg1 pg8 work1 pg2 test pg
Figure 5-5 Program Delete Function 5-14 April 8, 2002
Kawasak
5.2.3.3 STEP SELECTION KEY
The STEP key is used to select steps for program playback or editing. Four methods of step selection are available: FIRST/LAST, BACKWARD, FORWARD, and STEP SELECT. The FIRST/LAST key selects step one of the program when pressed with the BACKWARD key. The FIRST/LAST key selects the last step of the program when pressed with the FORWARD key. The BACKWARD and FORWARD keys decrement and increment the steps respectively. The STEP SELECT key allows selection of a specific step. When a step number greater than the number of steps in a program is entered, the last step is selected in the REPEAT mode and one step beyond the last step is selected in the TEACH mode.
Press the EXIT key to return to the previous mode. Figure 5-6 illustrates the use of the STEP SELECT key.
STEP 1
PROGRAM pg1
STEP 1
PC
FIRST LAST
STEP 3
STEP 3 is Displayed
RETURN
Figure 5-6 Step Selection, Multi Function Panel April 8, 2002 5-15
Kawasak
5.2.3.4 CURSOR MOVEMENT KEYS
The cursor movement keys are used to select items or data entry fields. Figure 5-7 illustrates the use of the cursor keys for program selection.
PROGRAM SELECT
Pg?? pg10 work1 work2 pg1 pg2 work3
PROGRAM SELECT
Pg?? pg10 work1 work2
pg1 pg2 work3
PROGRAM SELECT
PROGRAM SELECT
Pg?? pg10 work1 work2 pg1 pg2 work3
Pg?? pg10 work1 work2
pg1 pg2 work3
Figure 5-7 Cursor Movement Keys
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Kawasak
5.2.3.5 FIGURE INPUT AND CURSOR SELECTION Many screens allow selection by figure input or cursor keys. Program selection, editing, and the AUX menu allow selection by either method. Figure 5-8 illustrates AUX menu selection using both methods.
AUX
2 LOCATION & SPEED DISPLAY 3 DATA TRANSFER 5 KILL PROGRAM 6 MIRROR CONVERSION 9 DATA CONVERSION 10 MEMORY PC CARD 11 PC CARD MEMORY 12 FILE DIRECTORY (FDIRECTORY) 14 PC CARD AUX. FUNCTION 41 ZEROING FUNCTION NUMBER:
F1
F2
F3
F4
PREV. PG NEXT PG
1 4
AUX
2 LOCATION & SPEED DISPLAY 3 DATA TRANSFER 5 KILL PROGRAM 6 MIRROR CONVERSION 9 DATA CONVERSION 10 MEMORY PC CARD 11 PC CARD MEMORY 12 FILE DIRECTORY (FDIRECTORY) 14 PC CARD AUX. FUNCTION 41 ZEROING FUNCTION NUMBER: 14
AUX
2 LOCATION & SPEED DISPLAY 3 DATA TRANSFER 5 KILL PROGRAM 6 MIRROR CONVERSION 9 DATA CONVERSION 10 MEMORY PC CARD 11 PC CARD MEMORY 12 FILE DIRECTORY (FDIRECTORY) 14 PC CARD AUX. FUNCTION 41 ZEROING FUNCTION NUMBER:
F1
F2
F3
F4
F1
F2
F3
F4
PREV. PG NEXT PG
PREV. PG NEXT PG
RETURN
Figure 5-8 Figure Input or Cursor Key Selection April 8, 2002 5-17
Kawasak
5.2.3.6 CHARACTER SET SCREEN
Some screens require data entry through the character set screen. Press the CHARACTER key to access the character set screen as shown in figure 5-9.
Press the
CHARACTER
key.
! 1
Q A Z { [
2
W S X } ]
# 3
E D C
$ 4
R F V
% 5
T G B
& 6
Y H N
` 7
U J M
( 8
I K
) 9
O L
0
P
= ~
@
BS
NEXT MENU
+ ;
? /
< ,
> .
* : | _
CTL+L
NEXT PG
SHIFT ENTER
A Z 1 0 Select the desired characters.
Enter the selected characters with the ENTER key.

ENTER
Figure 5-9 Character Set Screen
5-18
April 8, 2002
Kawasak
5.2.3.7 SCREEN SELECTION KEYS
TEACHING
STATUS
MENU
The keys shown above are used to select drop down menus for teaching screens, robot status screens, auxiliary menus, and the keyboard screen. The drop down menu for each key is shown in figure 5-10.
TEACHING
STATUS
MENU
AS TEACHING
STATUS STATUS
E-STOP
PROGRAM EDIT PROGRAM LIST
FUNCTION
MONITOR
I/F
I/F
CURRENT POSITION
KEYBOARD
SPRAY STATUS
Figure 5-10 Drop Down Menus
April 8, 2002
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Kawasak
5.2.3.8 TEACHING KEY
TEACHING
TEACHING AS TEACHING
PROGRAM EDIT
Pressing the TEACHING key displays a drop down menu with one or two selections depending on settings in AUX 96 Environment Data of Panel. The two selections are AS TEACHING and PROGRAM EDIT. The STATUS and FUNCTION menus are accessible from all TEACHING screens.
5-20
April 8, 2002
Kawasak
5.2.3.9 AS TEACHING SCREEN
Each step of a program can be edited in the AS Language editor using the optional AS TEACHING screen (Figure 5-11). Steps can be inserted, edited or deleted. The variables, instructions and comments can be programmed beforehand as an AS Language character string. For additional information see AUX 133 AS Instruction Definition in unit 11.
PROGRAM STEP PC
SPEED 10% REPT. CONT '97-03-18 17:30 RPS ON
pgsrt01
TEACHING
STATUS
MENU
STEP CONT DRYRUN OFF
M-OFF HOLD TEACH
AS INSTRUCTION TEACHING
CHARACTER
JMOVE
LMOVE
#pick
place
PROGRAM INPUT
,
SPACE
.
SHIFT
TEACH NEW
RECORD
Figure 5-11 AS Teaching Screen
April 8, 2002
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Kawasak
5.2.3.10 STATUS KEY
STATUS
STATUS
STATUS
PROGRAM LIST
MONITOR
CURRENT POSITION
SPRAY STATUS
Pressing the status key reveals a pull down menu with the following screen selection keys: STATUS, PROGRAM LIST, MONITOR, CURRENT POSITION, and SPRAY STATUS. The TEACHING and MENU keys can be accessed from the STATUS screens.
5-22
April 8, 2002
Kawasak
5.2.3.11 STATUS SCREEN
The STATUS screen, shown in figure 5-12, provides basic system information including the current program and step/repeat conditions, time and date, switch status, and robot position. Refer to table 5-6 for more information about the STATUS screen.
PROGRAM pg99
STEP 5
PC
TEACHING
SPEED 10%
97-03-18 17:30
STATUS
MENU
M-ON RUN WAITING
STATUS ERROR
HOLD
TEACH
CYCLE START
MOTOR E-STOP POWER
4
REPEAT 10% REPEAT
CONDITION
1 2
STEP
FORWARD
RECORD ACCEPT
1 2 3 4 JT1 -26.248 X 532.690
SPRAY_JSPEED 15% SMOOTH_RANGE 1mm JMOVE JOINT 0000, 115.21, -2.85, -63.24, 366.3, 84, 124.71 SPRAY #2, ON JT2 -5.518 Y 656.487 JT3 -37.812 Z 1022.774 JT4 71102 O -154.463 JT5 -75.092 A 113.890 JT6 11.449 T 46.616 JT7 5.315
Figure 5-12 Status Screen
April 8, 2002
5-23
Kawasak
Table 5-6 Status Screen Explanation

No. Item Description The REPEAT key selects and displays the current monitor speed. Adjustments to speed are made in 10% increments. The REPEAT CONDITION key selects the step execution method (STEP CONT/ONCE), program execution method (REPEAT CONT/ONCE), DRYRUN mode, and RPS (Random Program Select) mode.
STEP
FORWARD
1.
The STEP FORWARD key appears when STEP ONCE has been selected with the REPEAT CONDITION key, and is used to execute the next step of a program. Displays the steps of the currently selected program. The step that is being executed is displayed in reverse video.
2.
Program Display Area
SPEED 10%
97-03-18 17:30
3.
Displays the settings of the repeat conditions and monitor speed as well as the date and time.
4.
Switch Status
Displays the current setting of the switches located on the interface panel. Push button switches change color to indicate an ON/OFF change, rotary switches turn to indicate the switch position. Displays the setting of the AUX 71 Record Data (PRG CHG) Inhibit function to prohibit or allow the teaching or editing of programs.
5.
6.
Position Display
Displays the current position of the robot as joint angles and Car tesian coordinates with OAT angles.
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April 8, 2002
Kawasak
5.2.3.12 PROGRAM LIST SCREENS
The PROGRAM LIST screens, shown in figure 5-13, display the instructions within each step of the current program. The SCROLL Page Down and SCROLL Page Up keys allow the operator to scroll through the program display, by five lines based on the line with cursor. The step that is being executed is displayed in reverse video. When the program is modified or edited from the explosion-proof teach pendant, the program list screen is not updated instantaneously. If more than four clamps are defined, a third program list screen is available.
PROGRAM LIST (1/2) .PROGRAM pg99() 1 SPRAY_JSPEED 15% 2 SMOOTH_RANGE 1mm 3 JMOVE JOINT 0000, 115.21, -2.85, -63.24, 366.9, 84, 124.71 4 SPRAY #2, ON 5 FLOW_RATE 1 6 PATTERN 4 7 ATOMIZING 1 8 SPRAY_SPEED 800mm/s 9 LMOVE XYZ1 0004, 873.1, 17.4, -485.8, 40.4, 88, 96, -86.89 10 DIN_WAIT #20, ON
SPRAY ON
SCROLL
SCROLL Page Up
NEXT PG
Page Down
Figure 5-13 Program List Screens
April 8, 2002
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Kawasak
5.2.3.13 MONITOR SCREEN
The MONITOR screens, shown in figure 5-14, display the input, output, and internal signal on/off status. Press the INPUT, OUTPUT, and INTERNAL keys at the bottom of the screen to select the type of signal to monitor. Press the NEXT PG and PREV.PG keys to view the next or previous page of signals. Signals that are in an ON state are displayed in reverse video.
MONITOR (OUTPUT SIGNAL) 1 OX1 2 OX2 3 OX3 4 OX4 5 OX5 6 OX6 7 OX7 8 OX8 9 OUT_ENC1 17 GUN1 18 GUN2 19 OX19 20 OX20 21 OX21 22 OX22 23 OX23 24 OX24 25 OX25 26 OX26
SPRAY ON
10 OUT_ENC2 11 OUT_VENT 12 OUT_AIRPURGE4 12 OUT_AIRPURGE5 13 OUT_AIRPURGE6 14 OUT_AIRPURGE7 15 OUT_AIRPURGE8
27 HOME 28 TEACH_MODE 29 CYCLE_START 30 AUTOMATIC 31 ERROR 32 MOTOR_ON
INPUT
INTERNAL
IN/OUT SIGNAL
NEXT PG
INTEGER DATA
PRE PG
NEXT PG
MONITOR (OUTPUT SIGNAL) 33 OX33 34 OX34 35 OX35 36 OX36 37 OX37 38 OX38 39 OX39 40 OX40 41 OX41 42 OX42 43 OX43 44 OX44 45 OX45 46 OX46 47 OX47 48 OX48 49 OX49 50 OX50 51 OX51 52 OX52 53 OX53 54 OX54 55 OX55 56 OX56 57 OX57 58 OX58 59 OX59 60 OX60 61 OX61 62 OX62 63 OX63 64 OX64
SPRAY ON
INPUT
INTERNAL
IN/OUT SIGNAL
PRE PG
NEXT PG
INTEGER DATA
Figure 5-14 Monitor Screens
5-26
April 8, 2002
Kawasak
5.2.3.14 CURRENT POSITION SCREEN
The CURRENT POSITION screen, shown in figure 5-15, displays the current position of the robot in terms of joint angles and Cartesian coordinates. Joint angles represent the degrees of rotation for each joint from the zeroed position. Cartesian coordinates represent the location and orientation of the tool center point relative to the origin of the base coordinate system.
CURRENT POSITION JOINT JT1 -26.248 XYZ X -776.714 Y Z O 154.041 A T JT2 -5.513 JT3 -37.812 JT4 71.103 JT5 -75.090 JT6 11.448
SPRAY ON
1248.775 801.46
69.848 -40.881
Figure 5-15 Current Position Screen
April 8, 2002
5-27
Kawasak
5.2.3.15 SPRAY STATUS SCREEN
The spray status screen is used to display and change the spray data. Figure 5-16 shows the spray status screen and table 5-7 describes the spray status screen display and settings.
Spray Status Display Area
PROGRAM
STEP
PC
SPEED 10%
02-03-18 17:30
pg99
3
TEACHING STATUS
MENU
Normally completed Normally completed Normally completed
SRV-ON RUN REPEAT SPRAY ON
SPRAY STATUS (SPRAY MANUAL OUTPUT)
SPRAY 1 OFF SPRAY 2 OFF Spray Data Display/Set Selection

SPRAY OUTPUT
FLOWRATE 0.0
AIRMOTOR 0.0
FLUSH STA OFF
SIG5
CONVEYOR SPE CONVEYOR POS PRODUCTION N REPEAT TIME
0.00 m/min. 0 mm 0 0.0 sec.
SHAPING AIR
0.0
HIGH VOLT 0.0
THINNER PUSH OUT OFF
ALL RATIO SET
SIGNAL OUTPUT
Figure 5-16 Spray Status Screen
5-28
April 8, 2002
Kawasak
Table 5-7 Spray Status Screen Descriptions

User Definable Spray Output All Ratio Set Signal Output Conveyor Speed Conveyor Position Display Only Description Displays the spray output screen Displays the all ratio set screen Displays the signal output screen Indicates the conveyor speed Indicates the conveyor position
Production Number Indicates the production number Repeat Time Indicates the repeat time
April 8, 2002
5-29
Kawasak
5.2.3.16 SPRAY OUTPUT DISPLAY
The spray output screen displays and allows modification of the manual spray output signal settings. When a key is pressed the numeric keypad screen is displayed for setting the values. The value range, for setting flowrate, shaping air (pattern air), airmotor (atomize air), and high volt, is 0 upper limit (0 10,000). Press the RETURN key to enter the value and return to the previous screen. Figure 5-17 shows the spray output display and table 5-8 describes the display and setting items. Figure 5-19 shows the numeric keypad screen used to set values (SPRAY STATUS ALL RATIO set screen).
SPRAY 1 OFF SPRAY 2 OFF

SPRAY OUTPUT
FLOWRATE 0.0
AIRMOTOR 0.0
FLUSH STA OFF
SIG5
FLOWRATE UPPER 100.0
AIRMOTOR UPPER 100.0
SIG5
SHAPING AIR 0.0
HIGH VOLT 0.0
THINNER PUSH OUT OFF
SHAPING AIR UPPER 100.0
HIGH VOLT UPPER 100.0
SPRAY OUTPUT
Figure 5-17 Spray Output Screen
5-30
April 8, 2002
Kawasak
Table 5-8 Spray Output Screen Descriptions
Item Spray 1 Spray 2 Flow rate
Description Indicates the ON/OFF status of spray 1 Indicates the ON/OFF status of spray 2 Indicates the dedicated signal status of the flow rate. When the key is pressed the numeric keypad screen is displayed for setting the value. Indicates the dedicated signal status of the shaping air (pattern air). When the key is pressed the numeric keypad screen is displayed for setting the value. Indicates the dedicated signal status of the air motor (atomize air). When the key is pressed the numeric keypad screen is displayed for setting the value. Indicates the dedicated signal status of the high voltage. When the key is pressed the numeric keypad screen is displayed for setting the value. Indicates the ON/OFF status of the flushing dedicated signal. Indicates the ON/OFF status of the push thinner dedicated signal. Indicates the upper limit set for the flow rate. When the key is pressed the numeric keypad screen is displayed for setting the value. Indicates the upper limit set for the shaping air (pattern air). When the key is pressed the numeric keypad screen is displayed for setting the value.
Shaping air (Pattern air) Air motor (Atomize air)
High voltage
Flushing Push thinner
Flow rate upper
Shaping air upper (Pattern air upper)
Indicates the upper limit set for the air motor (atomize Air motor upper air). When the key is pressed the numeric keypad (Atomize air upper) screen is displayed for setting the value. Indicates the upper limit set for the high voltage. When High voltage upper the key is pressed the numeric keypad screen is displayed for setting the value.
April 8, 2002
5-31
Kawasak
5.2.3.17 ALL RATIO SET SCREEN
Ratios for the manual spray output signals are set in percentages from the all ratio set screen. When a key is pressed, the numeric keypad screen is displayed for setting the values. The value range is 0 200%. Press the RETURN key to enter the value and return to the previous screen. Figure 5-18 shows the all ratio set screen display. Figure 5-19 shows the numeric keypad screen used to set the values.
FLOWRATE 100%
AIRMOTOR 100%
SIG5
SHAPING AIR 100%
HIGH VOLT 100%
ALL RATIO SET
Figure 5-18 All Ratio Set Screen
PROGRAM
STEP
PC
SPEED 10% TEACH
'97-03-18 17:30
TEACHING FUNCTION
MENU
8
SPRAY STATUS (ALL RATIO)
FLOWRATE 100%
9 7 5 3 1
6 4 2 0
.
CLEAR
EXIT
BS
RETURN
Figure 5-19 All Ratio Set Numeric Keypad Screen
5-32
April 8, 2002
Kawasak
5.2.3.18 SIGNAL OUTPUT SCREEN
The signal output screen allows the operator to set general output signals ON or OFF by pressing the desired key. Dedicated signals cannot be set ON or OFF. The LED on each key indicates ON, red, or OFF, blue. Figure 5-20 shows the signal output screen display.
SIG1
SIG2
SIG3
SIG5 SIG4
SIG5
SIG6
SIG7
SIG8
SIGNAL OUTPUT
Figure 5-20 Signal Output Screen
April 8, 2002
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Kawasak
5.2.3.19 MENU KEY
MENU MENU
STATUS
E-STOP
FUNCTION
I/F
I/F
KEYBOARD
Pressing the MENU key reveals a drop down menu with four screen selection buttons; STATUS, FUNCTION, Interface Panel (I/F) (option, refer to unit 11), and KEYBOARD. The TEACHING screens can be accessed from the STATUS or FUNCTION screens.
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April 8, 2002
Kawasak
5.2.3.20 FUNCTION SCREEN
Auxiliary functions of the robot can be programmed from the FUNCTION screen (Figure 5-21). Auxiliary functions such as welding schedules, teach speeds, system initialization and the optional interface panel can all be programmed from these screens. See unit 9, Auxiliary Functions, for more details.
PROGRAM
STEP
PC
SPEED 10% TEACH
'97-03-18 17:30
TEACHING FUNCTION
MENU
8
AUX
2 LOCATION & SPEED DISPLAY 3 DATA TRANSFER 5 KILL PROGRAM 6 MIRROR CONVERSION 9 DATA CONVERSION 10 MEMORYPC CARD(SAVE) 11 PC CARDMEMORY(LOAD) 12 FILE DIRECTORY(FDIRECTORY) 14 PC CARD AUX. FUNCTION
9 7 5 3 1
6 4 2
.
CLEAR
EXIT
BS
F1
F2
F3
NEXT PG
F4
RETURN
Figure 5-21 Auxiliary Function Screen
April 8, 2002
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Kawasak
5.2.3.21 MULTI FUNCTION PANEL KEYBOARD DISPLAY The keyboard screen allows AS Language programming and operation control of the robot. Figure 5-22 shows the keyboard screen and table 5-9 describes the key functions.
NEXT PG key NEXT MENU key BS key CTL+L key
! 1
Q A Z { [
2
W S X } ]
# 3
E D C
$ 4
R F V
% 5
T G B
& 6
Y H N
` 7
U J M
( 8
I K
) 9
O L
0
P
= ~
@
BS
NEXT MENU
+ ;
? /
< ,
> .
* : | _
CTL+L
NEXT PG
SHIFT ENTER
Space Key
SHIFT key ENTER key
Figure 5-22 Keyboard Screen
5-36
April 8, 2002
Kawasak
Table 5-9 Keyboard Keys Functions

Key Function The BS (backspace) key is used to delete characters one at a time.
BS
NEXT MENU
The NEXT MENU key toggles between the STATUS screen and the keyboard screen.
ENTER
The ENTER key is used to enter AS Language commands for execution.
SHIFT
The SHIFT key selects the upper character of dual character keys. Pressing the 1 key after pressing the SHIFT key inputs the (!) character.
NEXT PG
The NEXT PG key changes the display to the next page.
CTL+L
The CTL+L/CTL+N key brings up the last 10 lines that were entered. When the SHIFT key is pressed, CTL+L changes to CTL+N. The CTL+N key takes you to the next line in the program.
SPACE Key
The SPACE key inputs a blank space into a character string.
April 8, 2002
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Kawasak
6.0 6.1 6.2 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7 6.2.8 6.2.9 6.2.10 6.2.11 6.2.12
JOGGING OPERATION
JOGGING OPERATION ................................................................................... 6-2 Keys Used for Jogging Operation ..................................................................... 6-2 Jogging Operation Procedures ......................................................................... 6-3 Manual Operation Coordinate Systems ............................................................ 6-5 Manual Operation Coordinate System Selection .............................................. 6-7 Manual Speed Selection .................................................................................. 6-8 KE610 Joint Coordinate System ...................................................................... 6-9 KF121 Joint Coordinate System ..................................................................... 6-11 KE610 Cartesian Coordinate System ............................................................. 6-13 KF121 Cartesian Coordinate System ............................................................. 6-15 KE610 Easy Coordinate System .................................................................... 6-17 KF121 Easy Coordinate System .................................................................... 6-19 Gun Coordinate System ................................................................................. 6-21 External Axes Selection ................................................................................. 6-23 Traverse Axis Manual Operation ..................................................................... 6-23
April 8, 2002
6-1
Kawasak
6.0 JOGGING OPERATION
JOGGING OPERATION
This unit provides information for manual robot operation or jogging. Information provided includes the keys required for manual robot operation, movement modes, and an explanation of the coordinate systems. 6.1 KEYS USED FOR JOGGING OPERATION The keys, on the explosion-proof controller teach pendent, used for jogging the robot are shown in figure 6-1. The teach pendant keys used for jogging are yellow.
Shift Key Equipment Key Coordinate Key
SHIFT
CLR
END
SUSPND
SET
RT LFT
SERVO
FRNT BCK
ROB ROB TBL
UP DWN
TBL TRV
SWING
RT
SWING LFT
Axis Keys Enabling Device Manual Speed Key Teach Lock Key
H M L
L C J
STORE POS
FRAME
EQPMT
RMT MOTION SPEED
CRCT
STEP NEXT
RESET SPRAY 1/2
STEP STEP BACK
FRONT VIEW
BACK VIEW
Figure 6-1 Manual Operation Keys
6-2
April 8, 2002
Kawasak
JOGGING OPERATION
The keys used for jogging the robot include the following: TEACH/REPEAT switch for teach mode selection TEACH LOCK key to prevent accidental repeat mode operation Axis keys for joint or directional movement FRAME (coordinate) key for coordinate system selection SHIFT key used with the FRAME key for coordinate system selection MAN.SPEED key for speed selection EQUIPMENT key to select ROBOT, or optional axes, to jog Enabling devices to enable motor power in the TEACH mode
6.2 JOGGING OPERATION PROCEDURES
TEACH LOCK
1.
Ensure all personal are clear of the work cell, and all safety devices are in place and operational. Turn the HOLD/RUN switch in the HOLD position. Place the controller main disconnect switch in the ON position. At this time the CONTROL POWER indicator lamp illuminates. Turn the TEACH/REPEAT switch to the TEACH position. Press the TEACH LOCK key. The LED on the key is illuminated to indicate TEACH LOCK mode is ON. Turn the HOLD/RUN switch to the RUN position. Press and hold one of the enabling devices on the teach pendant and the motor power MOTOR POWER switch on the operation panel. At this time the MOTOR POWER lamp illuminates and motor power is applied to the servo motors for manual operation.
2. 3.
4. 5.
6. 7.
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Kawasak
JOGGING OPERATION
WARNING
Ensure the TEACH LOCK key is engaged, LED is on, before entering the safety fence for teaching operations.
8.
Use the FRAME key to select the desired coordinate system (see section 6.2.1 table 6-1 and section 6.2.2). Use the manual SPEED key to select the desired jogging speed (see section 6.2.3).
9.
10. Use the axis keys to select the desired axis and direction of movement for jogging (see section 6.2.4).
6-4
April 8, 2002
Kawasak
JOGGING OPERATION
6.2.1 MANUAL OPERATION COORDINATE SYSTEMS The robot moves differently according to the selected coordinate system. A good understanding of the coordinate systems is necessary before proceeding with manual operations. Table 6-1 provides an explanation of each coordinate system.
Table 6-1 Coordinate Systems

Coordinate System Explanation Moves the gun parallel to the Car tesian coordinate system in base coordinates. The tool center point (TCP) is moved in a straight line at a constant speed and gun orientation is maintained (see tables 6-4 and 6-5). Moves the gun parallel to the Car tesian coordinate system in base coordinates. Wrist joints (JT4, JT5, and JT6) are used to compensate for a singularity condition. The gun orientation is not necessarily maintained (see tables 6-4 and 6-5). Moves each axis independently (see tables 6-2 and 6-3). Moves the robot parallel to the tool coordinate system based on the gun orientation. The gun is the last gun designated by the gun selection instruction (see table 6-8). This mode provides linear operation in base or tool coordinates (see tables 6-6 and 6-7).
XYZ1
XYZ2
Joint Gun
Easy
April 8, 2002
6-5
Kawasak
JOGGING OPERATION
An easy way to determine the orientation and direction of the base coordinate system is illustrated by the left-hand rule, shown in figure 6-2. When using the left-hand rule, orient your left hand so that your arm represents the cables entering the base of the robot. From this orientation the middle finger, held 90 degrees from the arm points in the positive X direction. The extended index finger points in the positive Y direction and the extended thumb points in the positive Z direction.
+Z
-Z
-Y
+Y
-X
+X
Figure 6-2 Left-Hand Rule
6-6
April 8, 2002
Kawasak
JOGGING OPERATION
6.2.2 MANUAL OPERATION COORDINATE SYSTEM SELECTION

SHIFT + FRAME
FRAME
The desired coordinate system is selected using the FRAME key [EASY (XYZ1, XYZ2) GUN JOINT]. To select XYZ1 or XYZ2 mode, with the EASY coordinate system selected, press the SHIFT key and use the FRAME key to select the desired mode. The selected mode is displayed at the top center of the teach pendant screen as shown in figure 6-3.
Coordinate System Selected EASY MOVE PG10 -0 TCH/PRHBT Program contents are as follows
Figure 6-3 Selected Coordinate System Display
April 8, 2002
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Kawasak
6.2.3 MANUAL SPEED SELECTION
JOGGING OPERATION
H M L
RMT SPEED
The RMT SPEED key is used to select the desired manual speed (HIGH MEDIUM LOW). The illuminated LED indicates the selected speed. The default values are HIGH = 150 mm/s, MEDIUM = 80 mm/s, LOW = 10 mm/s at the gun tip.
6-8
April 8, 2002
Kawasak
6.2.4 KE610 JOINT COORDINATE SYSTEM
JOGGING OPERATION
Figure 6-4 shows the robot movement in the joint mode, during manual operation. Table 6-2 describes the axis keys operation for joint mode movement during manual operation.
JT3 Axis
Up
JT4 Axis Swing Left JT5 Axis
Down
Swing Right Bend Up
Bend Down JT6 Axis Turn Left
JT2 Axis Back Front Left
Turn Right
Right
JT1 Axis
Figure 6-4 KE610 Joint Coordinate System Movement
April 8, 2002
6-9
Kawasak
JOGGING OPERATION
Table 6-2 KE610 Joint Coordinate System Movement
Key
RT
Wrist Motion Swivel, Swivel, Swivel Rotates the JT1 axis
LFT
FRNT
Rotates the JT2 axis

BCK
UP

DWN
SWING
RT
SWING LFT
BEND FRNT BEND BCK

TURN UP TURN DWN
6-10
April 8, 2002
Kawasak
6.2.5 KF121 JOINT COORDINATE SYSTEM
JOGGING OPERATION
Figure 6-5 shows the robot movement in the joint mode, during manual operation. Table 6-3 describes the axis keys operation for joint mode movement during manual operation.
Up
JT3 Axis JT4 Axis Down Swing Left Swing Right JT2 Axis Bend Up JT6 Axis JT5 Axis Bend Down Back Left Front Right JT1 Axis Turn Right Turn Left
Figure 6-5 KF121 Joint Coordinate System Movement
April 8, 2002
6-11
Kawasak
JOGGING OPERATION
Table 6-3 KF121 Joint Coordinate System Movement

Wrist Motion Swivel, Bend, Swivel Rotates the JT1 axis
LFT
Key
RT
FRNT

BCK
UP

DWN
SWING
RT
SWING LFT
BEND FRNT BEND BCK

TURN UP TURN DWN
6-12
April 8, 2002
Kawasak
JOGGING OPERATION
6.2.6 KE610 CARTESIAN COORDINATE SYSTEM Figure 6-6 shows the robot movement in the Cartesian mode, during manual operation in the XYZ1 coordinate system. For wrist axes movement (JT4, JT5, and JT6) in the XYZ2 coordinate system refer to figure 6-4, KE610 Joint Coordinate System Movement. Table 6-4 describes the axis keys operation for Cartesian mode movement during manual operation.
Up
Back
Left
Front Right
Down
Swing left Swing right Bend up Turn left
Bend down
Turn right
Figure 6-6 KE610 Cartesian Coordinate System Movement April 8, 2002 6-13
Kawasak
JOGGING OPERATION
Table 6-4 KE610 Cartesian Coordinate System Movement

Coordinate Motion XYZ2 Key
RT
XYZ1
XYZ2
XYZ1
3S
X-axis
LFT
Movement parallel to the X-axis
FRNT
Y-axis
BCK
Movement parallel to the Y-axis
UP
Z-axis
DWN
Movement parallel to the Z-axis Rotates around the Z-axis (with the gun tip fixed) Rotates around the X-axis (with the gun tip fixed) Rotates around the Y-axis (with the gun tip fixed) Rotates around the JT4 axis (with the gun tip fixed) Rotates around the JT5 axis (with the gun tip fixed) Rotates around the JT6 axis (with the gun tip fixed)
SWING
RT
SWING LFT
Z-axis
NA
BEND FRNT BEND BCK
X-axis
NA
TURN UP TURN DWN
Y-axis
NA
6-14
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Kawasak
JOGGING OPERATION
6.2.7 KF121 CARTESIAN COORDINATE SYSTEM Figure 6-7 shows the robot movement in the Cartesian mode during manual operation in the XYZ1 coordinate system. For wrist axes movement (JT4, JT5, and JT6) in the XYZ2 coordinate system refer to figure 6-5, KF121 Joint Coordinate System Movement. Table 6-5 describes the axis keys operation for Cartesian mode movement during manual operation.
Up
Back Left
Right Front
Down
Swing left Swing right
Bend up Turn left
Bend down
Turn right
Figure 6-7 KF121 Cartesian Coordinate System Movement April 8, 2002 6-15
Kawasak
JOGGING OPERATION
Table 6-5 KF121 Cartesian Coordinate System Movement

Coordinate Motion XYZ2 Key
RT
XYZ1
XYZ2
XYZ1
Wrist SBS
X-axis
LFT
Movement parallel to the X-axis
FRNT
Y-axis
BCK
Movement parallel to the Y-axis
UP
Z-axis
DWN
Movement parallel to the Z-axis Rotates Rotates around the around the Z-axis (with JT4 axis the gun tip (with the gun tip fixed) fixed) Rotates around the X-axis (with the gun tip fixed) Rotates around the Y-axis (with the gun tip fixed) Rotates around the JT5 axis (with the gun tip fixed) Rotates around the JT6 axis (with the gun tip fixed)
SWING
RT
SWING LFT
Z-axis
NA
BEND FRNT BEND BCK
X-axis
NA
TURN UP TURN DWN
Y-axis
NA
6-16
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Kawasak
6.2.8 KE610 EASY COORDINATE SYSTEM
JOGGING OPERATION
Figure 6-8 shows the robot movement in the easy mode during manual operation in the easy coordinate system. Table 6-6 describes the axis keys operation for easy mode movement during manual operation.
Up
Back
Left
Right
Front
Down Shift+back (key)
Bend up Swing right Bend down Turn left Turn right Shift+front (key)
Figure 6-8 KE610 Easy Coordinate System Movement April 8, 2002 6-17
Kawasak
JOGGING OPERATION
Table 6-6 KE610 Easy Coordinate System Movement
Key
RT
Coordinate X-axis
Motion Movement parallel to the X-axis
With Shift Key NA
LFT
FRNT
Y-axis
BCK
Movement parallel Moves in the to the Y-axis gun direction Movement parallel to the Z-axis Swing horizontal (with the gun tip fixed) Swing ver tical (with the gun tip fixed) Rotates around the gun (with the gun tip fixed)
UP
Z-axis
DWN
SWING
NA
RT
SWING LFT
NA
NA
BEND FRNT BEND BCK

TURN UP TURN DWN
NA
NA
NA
NA
6-18
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Kawasak
6.2.9 KF121 EASY COORDINATE SYSTEM
JOGGING OPERATION
Figure 6-9 shows the robot movement in the easy mode during manual operation in the easy coordinate system. Table 6-7 describes the axis keys operation for easy mode movement during manual operation.
Up
Back Left
Right Front
Down
Shift+back (key) Bend up Swing right Swing left
Bend down Turn right Turn left
Shift+front (key)
Figure 6-9 KF121 Easy Coordinate System Movement April 8, 2002 6-19
Kawasak
JOGGING OPERATION
Table 6-7 KF121 Easy Coordinate System Movement
Key
RT
Coordinate X-axis
Motion Movement parallel to the X-axis
With Shift Key NA
LFT
FRNT
Y-axis
BCK
Movement parallel Moves in the to the Y-axis gun direction Movement parallel to the Z-axis Swing horizontal (with the gun tip fixed) Swing ver tical (with the gun tip fixed) Rotates around the gun (with the gun tip fixed)
UP
Z-axis
DWN
SWING
NA
RT
SWING LFT
NA
NA
BEND FRNT BEND BCK
NA
NA
UP
NA
DWN
NA
6-20
April 8, 2002
Kawasak
6.2.10 GUN COORDINATE SYSTEM
JOGGING OPERATION
The gun coordinate system is configured with the Z-axis in the direction of paint application. The gun coordinate configuration is defined in auxiliary function 48, tool dimensions. For more information about tool dimensions see section 9.15. The gun selection instruction determines the gun coordinates used in teach and repeat modes. Gun 1 is selected by default at controller power-up. Figure 6-10 shows gun coordinates system movement. Table 6-8 describes the axis keys operation for gun coordinate system movement, during manual operation.
Shift+back (key) Bend up Swing right Bend down Turn right Swing left Turn left Shift+front (key)
z (Front) Y (Down)
X (Right)
Figure 6-10 Gun Coordinate System Movement
April 8, 2002
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Kawasak
JOGGING OPERATION
Table 6-8 Gun Coordinate System Movement
Key
RT
Coordinate X-axis
Motion Movement parallel to the X-axis of the gun coordinates Movement parallel to the Z-axis of the gun coordinates Movement parallel to the Y-axis of the gun coordinates Rotates around the Y-axis of the gun coordinates (with the gun tip fixed) Rotates around the X-axis of the gun coordinates (with the gun tip fixed) Rotates around the Z-axis of the gun coordinates (with the gun tip fixed)
LFT
FRNT
Z-axis
BCK
UP
Y-axis
DWN
SWING
RT
SWING LFT
Y-axis
BEND FRNT BEND BCK

TURN UP TURN DWN
X-axis
Z-axis
6-22
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Kawasak
6.2.11 EXTERNAL AXES SELECTION
JOGGING OPERATION
ROB TBL
TRV
EQPMT
The equipment key is used to select robot and external axes operation. The LEDs indicate the active axes ROBOT TRAVERSE TABLE. External axes can only be selected if the system is equipped with external axes. With a six axes robot, only the robot can be selected. 6.2.12 TRAVERSE AXIS MANUAL OPERATION When the joint coordinate system is selected, during manual operation of the traverse axis, only the traverse axis moves. When any other coordinate system is selected, the robot axes move with the traverse axis to maintain the gun tip (tool center point) orientation. Table 6-9 describes the axis keys operation when the traverse axis is selected.
Table 6-9 Traverse Axis Manual Operation

Key
RT LFT
Coordinate
Motion
X-axis of Moves the traverse equipment the traverse in the X-axis direction Y-axis of the Moves the traverse equipment traverse in the Y-axis direction Z-axis of Moves the traverse equipment the traverse in the Z-axis direction
FRNT BCK
UP DWN
April 8, 2002
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Kawasak
7.0 7.1 7.1.1 7.1.2 7.1.3 7.1.3.1 7.1.3.2 7.1.3.3 7.1.3.4 7.1.3.5 7.1.3.6 7.2.1 7.2 7.2.1.1 7.2.1.2 7.2.1.3 7.2.1.4 7.2.1.5 7.2.1.6 7.3 7.3.1 7.3.3 7.3.2 7.3.4 7.3.5 7.3.6 7.3.8 7.3.7 7.3.9 7.3.10 7.3.11 7.4 7.4.1 7.4.2 7.4.3 7.4.5 7.4.4 7.4.6 7.4.7 7.4.8 7.5 7.5.1 7.5.1.1 7.6
RECORDING AND EDITING PROGRAMS
RECORDING AND EDITING PROGRAMS ................................................... 7-3 Recording Programs Using the Explosion-Proof Teach Pendant .................... 7-3 Teach Screen Display ..................................................................................... 7-3 Program Number Assignment......................................................................... 7-5 Teaching Procedures ...................................................................................... 7-7 Teaching Program Data .................................................................................. 7-7 Manual Positioning ........................................................................................ 7-27 Teaching Move Instructions .......................................................................... 7-29 Teaching Other Instructions .......................................................................... 7-32 Program Checking Procedure ....................................................................... 7-34 Editing Program Instructions ......................................................................... 7-37 Speed Instructions ........................................................................................ 7-40 Definition of Program Instructions ................................................................. 7-40 0. SPRAY SPEED ......................................................................................... 7-42 1. AIRCUT SPEED ....................................................................................... 7-42 2. SPRAY JSPEED ....................................................................................... 7-42 3. AIRCUT JSPEED...................................................................................... 7-43 4. MOVING TIME .......................................................................................... 7-43 5. PLAYBACK RATE ..................................................................................... 7-43 Spray Instructions ......................................................................................... 7-44 0. SPRAY 1 ................................................................................................... 7-45 Spray Instructions Program Example ........................................................... 7-45 1. SPRAY 2 ................................................................................................... 7-45 2. PRE_SPRAY (distance) ............................................................................ 7-46 3. PRE_SPRAY (time)................................................................................... 7-46 PRE_Spray Instructions Program Example .................................................. 7-46 5. DLY_SPRAY (time) ................................................................................... 7-47 4. DLY_SPRAY (distance) ............................................................................. 7-47 DLY_Spray Instructions Program Example ................................................... 7-48 6. SPRAY 3 ................................................................................................... 7-49 7. SPRAY 4 ................................................................................................... 7-49 External Output Instructions ......................................................................... 7-50 0. GENERAL EX_OUT ................................................................................. 7-50 1. FLOW_RATE ............................................................................................ 7-52 2. SHAPING AIR ........................................................................................... 7-52 4. HIGH VOLTAGE ........................................................................................ 7-53 3. AIR MOTOR .............................................................................................. 7-53 5. FLUSHING ................................................................................................ 7-54 6. PUSH THINNER ....................................................................................... 7-54 7. PAINT_IO RATIO ...................................................................................... 7-55 3. External Input Instructions ........................................................................ 7-60 0. Data Input Wait ......................................................................................... 7-60 1. Mutual Wait (Option) ................................................................................. 7-63 4. SMOOTH Instructions ............................................................................... 7-64 7-1
April 8, 2002
Kawasak
7.6.1 7.6.1.1 7.7 7.8 7.9 7.10 7.10.1 7.10.1.1 7.10.1.2 7.10.1.3 7.10.1.4 7.10.2 7.10.3 7.11 7.11.1 7.12 7.13 7.14 7.15 7.16 7.17 7.17.1 7.18 7.19 7.19.1 7.19.2 7.20 7.20.1 7.20.2 7.20.3 7.20.4 7.20.5 7.20.6 7.20.7 7.21 7.21.1 7.21.2 7.21.3 7.21.4 7.21.5
0. ACCELERATION ..................................................................................... 7-64 1. SMOOTH (RANGE) ................................................................................ 7-64 5. DATA BANK Instruction ........................................................................... 7-70 6. TIMER Instruction .................................................................................... 7-72 7. CALL Instruction ...................................................................................... 7-74 8. JUMP Instruction ..................................................................................... 7-76 0. JUMP ...................................................................................................... 7-77 0. UC_JUMP ............................................................................................... 7-77 1. TRUE_JUMP ........................................................................................... 7-79 2. FALSE_JUMP ......................................................................................... 7-81 3. SET LABEL ............................................................................................. 7-82 1. COMPARE Instruction ............................................................................. 7-84 1. INPUT SIGNAL Instruction ...................................................................... 7-86 2. COUNTER Instruction ............................................................................. 7-88 Counter Reset and Display ......................................................................... 7-90 3. PROGRAM SELECT Instruction ............................................................. 7-91 9. CONVEYOR Instruction .......................................................................... 7-92 A. GUN CONTROL Instruction .................................................................... 7-94 B. Table Instruction (Option) ........................................................................ 7-95 C. Sensing Instruction ................................................................................. 7-96 E. MOVE Instruction .................................................................................... 7-97 MOVE Instruction Display, Multi Function Panel ......................................... 7-98 F. OTHERS Instruction .............................................................................. 7-102 Checking Programs in Repeat Mode ........................................................ 7-107 Selecting Repeat Mode ............................................................................. 7-107 Setting Repeat Conditions ........................................................................ 7-107 Program Edit With the Explosion-Proof Teach Pendant ............................ 7-109 Edit Screen Display ................................................................................... 7-109 Edit Mode Selection .................................................................................. 7-111 Edit Correction Modes .............................................................................. 7-113 Program Instruction Editing ....................................................................... 7-113 Edit Search Mode ..................................................................................... 7-114 Move Instruction Editing ............................................................................ 7-116 Exiting Program Edit Mode ....................................................................... 7-118 Program Edit Screen, Multi Function Panel .............................................. 7-119 How to Cut and Paste Steps Within a Program ......................................... 7-120 How to Copy and Paste Steps Within a Program ...................................... 7-122 How to Copy and Paste Steps to Another Program .................................. 7-124 How to Delete Steps within a Program ..................................................... 7-126 How to Copy Auxiliary Data ...................................................................... 7-128
7-2
April 8, 2002
Kawasak
7.0 RECORDING AND EDITING PROGRAMS
This sections covers teaching and editing programs using the explosion-proof teach pendant and the multi function panel program edit screen. 7.1 RECORDING PROGRAMS USING THE EXPLOSION-PROOF TEACH PENDANT 7.1.1 TEACH SCREEN DISPLAY Figure 7-1 shows the teach screen display areas and the item descriptions are given in table 7-1.
EASY MOVE PG10 -0 TCH/PRHBT Program contents are as follows

Figure 7-1 Teach Screen Display
April 8, 2002
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Kawasak
Table 7-1 Teach Screen Display Descriptions

Item Description Displays the correction mode (Prohibit/Add/Change/Delete/Search), selected. The correction modes are sub-modes of the teach mode. Use the
CRCT
key to change the sub-mode.
Displays the manual operation coordinate system mode [Easy (XYZ1 and XYZ2)/Gun/Joint] selected. Use the
FRAME
key to change modes.
STEP NEXT
STEP
key and the
STEP BACK
Current program name display. Current program point (motion instruction) display. The motion instructions are counted from the top of the program and indicated as a point number. System message display. The sequential numbers indicate program steps. The highlighted step number indicates step commands are completed through this step. In the example in figure 7-1, program step commands are completed through step 3.
7-4
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Kawasak
7.1.2 PROGRAM NUMBER ASSIGNMENT
Follow the procedure in unit 4, Power ON/OFF Procedures, to power-up the controller and display the main menu. Follow the procedure shown below, and in figure 7-2, to assign the desired program number. 1. From the main menu screen select 0. TEACH using the cursor keys or the number keys and press the SET key. At the Enter program No. prompt use the number keys to select the desired program number and press the SET key to accept the program number. The default teach correction mode can be set by selecting PRHBT, ADD, or CHG using the CRCT key. 3. When the program number is assigned the program content screen is displayed as shown in figure 7-2, step 3. In figure 7-2, step 3, program No. 10 is displayed and [PROGRAM END] indicates the end of the program.
2.
NOTE
If the teach mode default is not set to ADD, the operator must select ADD using the CRCT key each time an instruction is added to the program.
April 8, 2002
7-5
Kawasak
EASY MOVE PG11 -0 Select a mode
or
0 SPEED
1.
SET
Move the cursor to 0. TEACH or enter the mode number using the number keys and press the SET key to display the Enter program No. screen.
TCH/PRHBT Enter program No.
EASY MOVE PG10 -0
PROGRAM No. (0~999)
_10 Enter the desired program number and press the SET key to accept the program number. The default teach correction mode can be set at this time by selecting PRHBT, ADD, or CHG using the CRCT key
0 SPEED
9 CONVR F
SET
2.
CRCT
3. TCH/PRHBT EASY MOVE PG10 -0 Program contents are as follows 0 PROGRAM Name = [ PROGRAM END ]
Figure 7-2 Program Number Assignment
7-6
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Kawasak
7.1.3 TEACHING PROCEDURES 7.1.3.1 TEACHING PROGRAM DATA
This section demonstrates building an example program. The example program points are shown in figure 7-3 and the program data is shown in table 7-2.
Start Point End Point
Figure 7-3 Example Program Points Diagram
Table 7-2 Example Program Data

Program Points N/A 1 2 3 4 Program Data Air-cut joint speed 20% (entire program) Spray speed 500 mm/s (entire program) Joint move to point 1. Linear move from point 1 to point 2. Turn spray#1 ON. Linear move from point 2 to point 3, with spray ON. Turn spray#1 OFF. Linear move from point 3 to point 4, end of program.
April 8, 2002
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Kawasak
1. 2.
Determine the program requirements as shown in figure 7-3 and table 7-2. Use a program planning sheet to enter the program commands and instructions needed to meet the program requirements. (Table 7-3).
Table 7-3 Example Program Planning Sheet
Step Point
Command/Instruction Program name = pg10
1 2 3 4 5 6 7 8 9 4 3 1 2
AIRCUT JSPEED 20% SPRAY SPEED 500 mm/s JMOVE (joint move) LMOVE (XYZ1 move) SPRAY #1, ON LMOVE (XYZ1 move) SPRAY #1, OFF LMOVE (XYZ1 move) PROGRAM END
3.
Follow the procedures in unit 4, Power ON/OFF Procedure, to power-up the controller and select teach mode. Ensure the EMERGENCY STOP switch operates properly before entering the safety fence for teach operations.
7-8
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Kawasak
CAUTION
Gun parameters must be entered in AUX 48 Tool Dimensions, prior to teaching program points. These parameters define the tool center point and the direction of the gun mounted on the robot. If the gun parameters are changed after teaching the program the robot WILL not operate as taught.
WARNING
Because the teach pendant has provisions to protect the operator during teaching operations, the ONLY person allowed in the safeguarded space is the person operating the teach pendant. Teach pendant safety provisions include an E-stop switch and enabling device.
4.
With teach mode selected, enter the desired program number as described in section 7.1.2. Use the CRCT key to select teach ADD mode. To set the default teach mode to ADD use the SHIFT + CRCT key combination. Refer to figure 7-4 for steps 5 through 9. Press the SET key to display the instruction selection menu screen. Use the cursor keys, or the number keys, to select 0. SPEED and press the SET key. Use the cursor keys, or the number keys, to select 3. AIRCUT JSPEED and press the SET key. Use the number keys to select the desired aircut joint speed value and press the SET key. When the SET key is pressed the AIRCUT_JSPEED command is entered as step 1 of the program.
5.
6. 7.
8.
9.
April 8, 2002
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Kawasak
TCH/PRHBT EASY MOVE PG10 -0 Program contents are as follows 0 PROGRAM Name = [ PROGRAM END ]
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter AIRCUT JSPEED value SPEED (1~100) _20[%]
5.
SHIFT + CRCT
9.
2X=OUT A GUN 0 SPEED
TCH/ADD EASY MOVE PG10 -0 Set instruction to ADD by SET key 0 PROGRAM Name = [ PROGRAM END ]
SET
TCH/ADD EASY MOVE PG10 -0 Set instruction to ADD by SET key 1 AIRCUT_JSPEED 20% [ PROGRAM END ]
6.
SET
TCH/ADD EASY MOVE PG10 -0 b Set instruction to ADD by SET key

0. SPEED 1. SPRAY 2. EXTERNAL OUTPUT 3. EXTERNAL INPUT 4. SMOOTH 5. DATA BANK 6. TIMER 8. JUMP A. GUN CONTROL C. SENSING E. MOVE 7. CALL 9. CONVEYOR B. TABLE D. F. OTHERS
or
0 SPEED
7.
SET
TCH/ADD/SPEED EASY MOVE PG10 -0 b Select type of SPEED instruction

0. SPRAY SPEED 2. SPRAY JSPEED 4. MOVING TIME 1. AIRCUT SPEED 3. AIRCUT JSPEED 5. PLAYBACK RATE
or
3X=IN B TABLE
8.
SET
Figure 7-4 Selecting Teach ADD and Aircut JSPEED 7-10 April 8, 2002
Kawasak
10. Press the 0 key to return to the instruction selection menu. Refer to figure 7-5 for steps 10 through 12. 11. Use the cursor keys or the number keys to select 0. SPRAY SPEED and press the SET key. 12. Use the number keys to select the desired spray speed value and press the SET key. When the SET key is pressed the SPRAY_SPEED command is entered as step 2 of the program.
April 8, 2002
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Kawasak
TCH/ADD EASY MOVE PG10 -0 Set instruction to ADD by SET key 1 AIRCUT_JSPEED 20% [ PROGRAM END ]
0 SPEED
10.

or
0 SPEED
11.
SET
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter SPRAY SPEED value SPEED (1~9999) _500[mm/s]
12.
5 DATA 0 SPEED 0 SPEED
SET
TCH/ADD EASY MOVE PG10 -0 Set instruction to ADD by SET key 2 SPRAY_SPEED 500mm/s [ PROGRAM END ]
Figure 7-5 Selecting Spray Speed
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13. Select the desired manual speed using the RMT SPEED key. Each time the RMT SPEED key is pressed the manual speed increments through H, M, and L (high, medium, and low). The LEDs indicated the selected manual speed. Refer to figure 7-6 for steps 13 through 17. 14. Use the FRAME key to select the JOINT coordinate system. Each time the FRAME key is pressed the coordinate system increments through EASY, GUN, and JOINT. The selected coordinate system is displayed at the top center of the screen. 15. Use the axis keys to position the robot at point 1 (Start Point) as indicated in figure 7-2. The move to point 1 is recorded as program step 3 as shown in table 7-3. For instructions on manual operation of the robot refer to unit 6, Jogging Operation and unit 7, Recording and Editing Programs, section 7.1.3.2. 16. Use the MOTION key to select JOINT interpolation. Each time the MOTION key is pressed the interpolation increments through L, C, C MID, C END, and JOINT. The LEDs indicate the selected interpolation mode. 17. With the robot positioned at point 1 (Start Point) press the STORE POS (store position) key. The position at point 1 is entered as step 3 and the program point number is displayed at the top right of the screen.
April 8, 2002
7-13
Kawasak
H M L
RMT SPEED
13.
150mm/s 80mm/s 10mm/s 17.
STORE POS
TCH/ADD JNT MOVE PG10 -1 Set instruction to ADD by SET key 3 JMOVE (JOINT) [ PROGRAM END ]
14.
FRAME
TCH/ADD JNT MOVE PG10 -0 Set instruction to ADD by SET key 2 SPRAY_SPEED 500mm/s [ PROGRAM END ]
RT FRNT BCK UP DWN
15.
LFT
16.
L C J
MOTION
Figure 7-6 Teaching Point 1 (Start Point)
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18. Select the desired manual speed using the RMT SPEED key. Each time the RMT SPEED key is pressed the manual speed increments through H, M, and L (high, medium, and low). The LEDs indicated the selected manual speed. Refer to figure 7-7 for steps 18 through 22. 19. Use the FRAME key to select the EASY coordinate system. Each time the FRAME key is pressed the coordinate system increments through EASY, GUN, and JOINT. The selected coordinate system is displayed at the top center of the screen. 20. Use the axis keys to position the robot at point 2, as indicated in figure 7-2. The move to point 2 is recorded as program step 4, as shown in table 7-3. For instructions on manual operation of the robot refer to unit 6, Jogging Operation and unit 7, Recording and Editing Programs, section 7.1.3.2. 21. Use the MOTION key to select LINEAR interpolation. Each time the MOTION key is pressed the interpolation increments through L, C, C MID, C END, and JOINT. The LEDs indicate the selected interpolation mode. 22. With the robot positioned at point 2 press the STORE POS (store position) key. The position at point 2 is entered as step 4 and the program point number is displayed at the top right of the screen.
April 8, 2002
7-15
Kawasak
H M L
RMT SPEED
18.
150mm/s 80mm/s 10mm/s 22.
STORE POS
TCH/ADD EASY MOVE PG10 -2 Set instruction to ADD by SET key 4 LMOVE (XYZ1) [ PROGRAM END ]
19.
FRAME
TCH/ADD EASY MOVE PG10 -1 Set instruction to ADD by SET key 3 JMOVE (JOINT) [ PROGRAM END ]
RT FRNT BCK UP DWN
20.
LFT
21.
L C J
MOTION
TCH/ADD EASY MOVE PG10 -1 Set instruction to ADD by SET key 3 JMOVE (JOINT) [ PROGRAM END ]
Figure 7-7 Teaching Point 2
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23. Press the SET key to return to the instruction selection menu. Refer to figure 7-8 for steps 23 through 26. 24. Use the cursor keys, or the number keys, to select 1. SPRAY and press the SET key. 25. Use the cursor keys, or the number keys, to select 0. SPRAY_1 and press the SET key. 26. Use the cursor keys, or the number keys, to select 1. ON and press the SET key. When the SET key is pressed the SPRAY #1, ON command is entered as step 5 of the program.
April 8, 2002
7-17
Kawasak
TCH/ADD/SPRAY EASY MOVE PG10 -2 Select output of SPRAY 1 0. OFF 1. ON
23.
SET
or
1 SPRAY .

26.
SET
TCH/ADD EASY MOVE PG10 -2 Set instruction to ADD by SET key 5 SPRAY #1,ON [ PROGRAM END ]
or
1 SPRAY .
24.
SET
TCH/ADD/SPRAY EASY MOVE PG10 -2 b Select type of SPRAY instruction

0. SPRAY_1 2. PRE_SPRAY(D) 4. DLY_SPRAY(D) 1. SPRAY_2 3. PRE_SPRAY(T) 5. DLY_SPRAY(T)
or
0 SPEED
25.
SET
Figure 7-8 Teaching Spray ON Command
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27. Select the desired manual speed using the RMT SPEED key. Each time the RMT SPEED key is pressed the manual speed increments through H, M, and L (high, medium, and low). The LEDs indicated the selected manual speed. Refer to figure 7-9 for steps 27 through 31. 28. Use the FRAME key to select the EASY coordinate system. Each time the FRAME key is pressed the coordinate system increments through EASY, GUN, and JOINT. The selected coordinate system is displayed at the top center of the screen. If the EASY coordinate system was previously selected, skip to the next step. 29. Use the axis keys to position the robot at point 3 as indicated in figure 7-2. The move to point 3 is recorded as program step 6 as shown in table 7-3. For instructions on manual operation of the robot refer to unit 6 Jogging Operation and unit 7, Recording and Editing Programs, section 7.1.3.2. 30. Use the MOTION key to select LINEAR interpolation. Each time the MOTION key is pressed the interpolation increments through L, C, C MID, C END, and JOINT. The LEDs indicate the selected interpolation mode. If LINEAR interpolation was previously selected skip to the next step. 31. With the robot positioned at point 3, press the STORE POS (store position) key. The position at point 3 is entered as step 6 and the program point number is displayed at the top right of the screen.
April 8, 2002
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Kawasak
H M L
RMT SPEED
27.
150mm/s 80mm/s 10mm/s 31.
STORE POS
28.
FRAME
RT FRNT BCK UP DWN
29.
LFT
30.
L C J
MOTION
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32. Press the 1 key to return to the spray instruction selection menu. Refer to figure 710 for steps 32 through 34. 33. Use the cursor keys, or the number keys, to select 0. SPRAY_1 and press the SET key. 34. Use the cursor keys, or the number keys, to select 0. OFF and press the SET key. When the SET key is pressed the SPRAY #1, OFF command is entered as step 7 of the program.
April 8, 2002
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Kawasak
32.
1 SPRAY .

0. SPRAY_1 2. PRE_SPRAY(D) 4. DLY_SPRAY(D) 1. SPRAY_2 3. PRE_SPRAY(T) 5. DLY_SPRAY(T)
or
0 SPEED
33.
SET
or
0 SPEED
34.
SET
TCH/ADD EASY MOVE PG10 -3 Set instruction to ADD by SET key 7 SPRAY #1,OFF [ PROGRAM END ]
Figure 7-10 Teaching Spray OFF Command
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35. Select the desired manual speed using the RMT SPEED key. Each time the RMT SPEED key is pressed the manual speed increments through H, M, and L (high, medium, and low). The LEDs indicated the selected manual speed. Refer to figure 7-11 for steps 35 through 39. 36. Use the FRAME key to select the EASY coordinate system. Each time the FRAME key is pressed the coordinate system increments through EASY, GUN, and JOINT. The selected coordinate system is displayed at the top center of the screen. If the EASY coordinate system was previously selected skip to the next step. 37. Use the axis keys to position the robot at point 4, as indicated in figure 7-2. The move to point 4 is recorded as program step 8, as shown in table 7-3. For instructions on manual operation of the robot refer to unit 6 Jogging Operation and unit 7, Recording and Editing Programs, section 7.1.3.2. 38. Use the MOTION key to select LINEAR interpolation. Each time the MOTION key is pressed the interpolation increments through L, C, C MID, C END, and JOINT. The LEDs indicate the selected interpolation mode. If LINEAR interpolation was previously selected skip to the next step. 39. With the robot positioned at point 4, press the STORE POS (store position) key. The position at point 4 is entered as step 8 and the program point number is displayed at the top right of the screen.
April 8, 2002
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H M L
RMT SPEED
35.
150mm/s 80mm/s 10mm/s 39.
STORE POS
36.
FRAME
RT FRNT BCK UP DWN
37.
LFT
38.
L C J
MOTION
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April 8, 2002
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40. To exit the teach mode press the END key or the previous screen key. The teach mode display at the top left of the screen is changed to TCH/END. Refer to figure 712 for steps 40 through 42. 41. With the TCH/END screen displayed press the 0 key for NO, or the 1 key for YES, and press the SET key to accept the command. 42. Teach mode is terminated, the program is stored in memory, and the Enter program No. screen is displayed.
April 8, 2002
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Kawasak
40.
END
or
TCH/END EASY MOVE PG10 -4 Make sure finish teaching program 10 ? END (0:NO 1:YES) YES
1 SPRAY .
SET
or
0 SPEED
41.
SET
TCH/PRHBT Enter program No. 42. PROGRAM No. (0~999) _10 EASY MOVE PG10 -4
Figure 7-12 Exiting Teach Mode
NOTE When the teach mode is terminated using the END key, the main menu screen is displayed.
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7.1.3.2 MANUAL POSITIONING
This section describes the operation of the robot in the manual mode.
WARNING
Because the teach pendant has provisions to protect the operator during teaching operations, the ONLY person allowed in the safeguarded space is the person operating the teach pendant. Teach pendant safety provisions include an E-stop switch and enabling device.
H M L
RMT SPEED
Figure 7-13 RMT Speed Key
The desired manual speed is selected using the RMT SPEED key. Each time the RMT SPEED key is pressed the manual speed increments through H, M, and L (high, medium, and low). The LEDs indicated the selected manual speed (Figure 7-13).
FRAME
SHIFT + FRAME
Figure 7-14 Frame Key
The desired coordinate system is selected using the FRAME key. The selected coordinate system is displayed at the top center of the screen (Figure 7-14). To select XYZ1 or XYZ2 in the EASY coordinate system, use the shift + FRAME keys (Figure 7-14).
April 8, 2002
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Three-Position Enabling Device
BACK VIEW
Figure 7-15 Teach Pendant Enabling Devices
With teach mode selected, teach lock ON, and motor power ON, press and hold one of the enabling devices to engage motor power for manual operation (Figure 7-15).
WARNING
Never force the enabling devices ON by applying adhesives, tape, or by any other method.
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SWING
RT LFT
FRNT BCK
UP DWN
RT
SWING LFT
BEND TURN UP FRNT BEND TURN BCK DWN
Figure 7-16 Axis Keys
The axis keys are used to position the robot at the program points (Figure 7-16). The operation of the axis keys is dependant on the coordinate system selected. For more information on the axis keys operation refer to unit 6, Jogging Operations. 7.1.3.3 TEACHING MOVE INSTRUCTIONS This section describes the procedures for teaching MOVE instructions using the current position as positional data. The interpolation used by the robot to reach a taught point is recorded as part of the move instruction.
L C J
MOTION
Figure 7-17 Motion Key The MOTION key is used to select program step interpolation (Figure 7-17). Each time the MOTION key is pressed the interpolation increments through L (linear), C (circular) [C MID (C intermediate-LED, ON), C END (C end-LED, BLINKS)], and JOINT. The LEDs indicate the selected interpolation mode (see table 7-4). To select XYZ1 or XYZ2, use the SHIFT + MOTION key combination with linear or circular interpolation selected (LED illuminated). When XYZ1 is selected the joint LED is OFF. When XYZ2 is selected the joint LED BLINKS. An XYZ1 or XYZ2 point is used with linear and circular interpolation. A JOINT point is used with JOINT interpolation (see table 7-5).
April 8, 2002
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Table 7-4 Interpolation

Interpolation Key
L C J
MOTION
Comments All joints move to reach total coincidence simultaneously to achieve the recorded robot posture at the taught point. The tool center point (TCP) moves in an arcing motion. Robot joints are coordinated to drive the TCP in a linear motion, at a constant speed, and maintain tool (gun) orientation. When circular intermediate is selected at P2, the robot path draws a circle passing through P1, P2, and P3. When circular end is selected at P3, the robot path draws a circle passing through P1, P2, and P3.
Detail
Joint
Linear
L C J
MOTION
Circular (Intermediate)
L C J
L C J
MOTION
P1
P2
P3
Circular (End)
Blinks
MOTION
P1
P2
P3
Table 7-5 Point Type
Point Type Interpolation Linear M id Circular End Joint O = Used X = Not Used O X O X X O XYZ1 O O XYZ2 JOINT O O X X
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CRCT
Figure 7-18 CRCT (Correct) Mode Key
Use the CRCT key to select the desired teaching edit mode (Figure 7-18). Each time the CRCT key is pressed the teaching edit modes increment through PRHBT (prohibit), ADD (add), CHG (change), DEL (delete), and SCH (search). After each edit is completed the teaching edit mode returns to the default setting. To change the default setting use the SHIFT + CRCT key combination to select the desired default teaching edit mode. In this case, select ADD.
STORE POS
Figure 7-19 STORE POS (Position) Key
Use the STORE POS key with ADD teaching edit mode selected to add a MOVE instruction after the last step of the program (Figure 7-19). The teaching screen display is updated with the new step and the move number at the top right of the screen as shown in figure 7-20.
April 8, 2002
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STORE POS
Figure 7-20 Using the STORE POS (Position) Key
7.1.3.4 TEACHING OTHER INSTRUCTIONS This section describes teaching instructions other than MOVE instructions. These instructions are shown in figure 7-21. At the program content screen, press the number of the desired instruction set or press the SET key to display the menu (see figure 7-21). The teach pendant number keys are labeled to identify the teaching instruction that corresponds with the numbers displayed on the teaching instructions menu screen. Use the cursor keys to display the second and third menu screens. In the example shown in figure 7-21, 0. SPEED is selected from the teaching instruction menu and 0. SPRAY SPEED is selected from the SPEED instruction set.
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TCH/ADD EASY MOVE PG10 -0 Program contents are as follows 0 PROGRAM NAME = [ PROGRAM END ]
SET
1 SPRAY . 0 SPEED 0 SPEED

SET
SET
or
0 SPEED
9 CONVR F

or
0 SPEED
SET
Figure 7-21 Selecting Other Teaching Instructions
April 8, 2002
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7.1.3.5 PROGRAM CHECKING PROCEDURE
When a new program is recorded, the operator should check step through the program in check mode before running the program in repeat mode to ensure proper robot operation. There are four available program check modes. The STEP key is used to increment though the program check modes MOVE, LINE, CONT, and JUMP. The selected check mode is displayed at the top center of the screen (Figure 7-22). Table 7-6 describes program operation for each of the check modes.
EASY MOVE PG10 -0 TCH/ADD Set instruction to ADD by SET key

2 SPRAY_SPEED 100MM/S 3 DOUT #100, ON 4 SPRAY #1, OFF
STEP
EASY CONT PG10 -0 TCH/ADD Set instruction to ADD by SET key

Figure 7-22 Check Mode Selection
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Table 7-6 Check Mode Program Operation

Check Mode Program Operation Press and hold the STEP NEXT key to execute the next move instruction in ascending order. When the robot reaches coincidence at the recorded point the robot stops. To move to the next program point release, press, and hold the STEP NEXT key. If instructions, other than move instructions, are recorded before the move instruction, those instructions are also executed. MOVE Press and hold the STEP BACK key to execute the next move instruction in descending order. When the robot reaches coincidence at the recorded point the robot stops. To move to the next program point release, press, and hold the STEP BACK key. If instructions are recorded before the next move instruction, only the instructions related to trajectory or motion are executed. Press and hold the STEP NEXT key to execute the next instruction in ascending order. When the robot reaches coincidence at the recorded point the robot stops. To move to the next program point release, press, and hold the STEP NEXT key. The LINE check mode executes the program line-by-line for move and non-move instructions. LINE Press and hold the STEP BACK key to execute the next move instruction in descending order. When the robot reaches coincidence at the recorded point the robot stops. To move to the next program point release, press, and hold the STEP BACK key. If instructions are recorded before the next move instruction, only the instructions related to trajectory or motion are executed. When the STEP NEXT key is pressed and held, the program steps are executed in ascending order as long as the STEP NEXT key is held. All move and non-move instructions are executed. CONT When the STEP BACK key is pressed and held, all move instructions are executed in descending order. If instructions are recorded before the next move instruction, only the instructions related to trajectory or motion are executed. The desired program step number is entered using the number keys and the SET key. The program step is selected without using the STEP NEXT or STEP BACK keys.
JUMP
April 8, 2002
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To check the selected program: 1. 2. 3. 4. 5.
Select the desired check mode (MOVE, LINE, CONT, or JUMP). Set the TEACH/REPEAT switch to TEACH. Set the TEACH LOCK switch to ON. Set the HOLD/RUN switch to RUN. Set the MOTOR POWER switch to ON.
Press and hold one of the enabling devices on the back of the teach pendent and use the STEP NEXT or STEP BACK key to move through the steps of the program. The robot stops at the last step of the program. To check through the program again, reset the program to the desired step using the JUMP check mode.
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7.1.3.6 EDITING PROGRAM INSTRUCTIONS
This section describes the procedures used to edit program instructions. Use the procedure described in section 7.1.3.5, program checking procedure, to move the manipulator to the desired step for editing. The step number is highlighted as the steps are executed. Instructions are added after the last highlighted step number. The LINE edit mode executes the program, one line at a time, and can be used to scroll the program to the desired line for editing (Figure 723).
EASY LINE PG10 -0 TCH/ADD Set instruction to ADD by SET key

STEP NEXT
EASY LINE PG10 -0 TCH/ADD Set instruction to ADD by SET key

Figure 7-23 Selecting Program Line
To edit a MOVE instruction: 1. Use the STEP NEXT or STEP BACK key to select the program line containing the MOVE instruction to edit. Use the axis keys to configure the robot in the new position, if position correction is desired. Select ADD, CHANGE, or DELETE edit mode, using the CRCT key. Press the STORE POS key to add or change a position. If delete mode is selected, press the SET key and use the number keys to enter 1:YES and press the SET key again to complete the procedure. The point number at the top right of the screen is updated (Figure 7-24). 7-37
2.
3. 4.
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Table 7-7 describes use of the edit modes.
TCH/DEL EASY MOVE PG10 -1 Make sure delete following instruction ? 5 LMOVE (XYZ1) DELETE (0:NO 1:YES) NO
1 SPRAY .
SET
Point number is updated
Figure 7-24 Step Delete
Table 7-7 Edit Mode Descriptions
Teach Edit Mode PROHIBIT
Usage When prohibit is selected, program editing is not possible. Use the CRCT key to select ADD, CHANGE, or DELETE When ADD is selected, new instructions are added after the last instruction number or step executed. When CHANGE or DELETE is selected, and a move instruction is edited, the current step is changed.
ADD
CHANGE and DELETE
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NOTE
To edit the program name, select 3. MANAGE PROGRAM from the main menu screen. This changes the name displayed in the program. The program number is not changed.
To edit a step with an instruction, other than a MOVE instruction, use the following procedures. To add a step: 1. 2. 3. Use the LINE check step mode, to select the step to add a step after. Select the ADD edit mode with the CRCT key. Use the procedure described in section 7.1.3.4, Teaching Other Instructions, to add steps after the selected step.
To modify (change) a step: 1. 2. 3. Use the LINE check mode to select the step to edit. Select the CHG (change) edit mode with the CRCT key. Use the SET key to select the parameter screen for the instruction in the step selected and use the procedure for adding steps to complete the procedure.
To delete a step: 1. 2. 3. Use the LINE check step mode to select the step to delete. Select the DELETE edit mode with the CRCT key. Press the SET key and use the number keys to enter 1:YES and press the SET key again to complete the procedure. The point number at the top right of the screen is updated (Figure 7-24).
April 8, 2002
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7.2 DEFINITION OF PROGRAM INSTRUCTIONS
This section describes the use and provides an explanation of the explosion-proof C controller (C35/C37), program instructions.
CAUTION
If program instructions are executed for equipment not installed, unexpected robot motion may occur. Do not use program instructions for equipment not installed in the system. For example, do not use program instructions for a table axis if a table axis is not installed.
7.2.1 SPEED INSTRUCTIONS To add speed instructions to a progam, use the following procedure. 1. 2. Select teach mode and enter the program number as described in section 7.1.2. Use the CRCT key to select the teach ADD mode or the SHIFT + CRCT key combination, to select teach ADD as the default teach mode (Figure 7-25). Press the SET key to display the instruction selection menu screen (Figure 7-25). Use the cursor keys or the number keys to select 0. SPEED (Figure 7-25).
3. 4.
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TCH/PRHBT EASY MOVE PG10 -0 Program contents are as follows 0 PROGRAM Name = [ PROGRAM END ]
SHIFT + CRCT
5 DATA 0 SPEED
TCH/ADD EASY MOVE PG10 -0 Set instruction to ADD by SET key 0 PROGRAM Name = [ PROGRAM END ]
SET
SET

or
0 SPEED
SET

or
0 SPEED
SET
Figure 7-25 Selecting Speed Instruction Screens April 8, 2002 7-41
Kawasak
7.2.1.1 0. SPRAY SPEED
SPRAY SPEED, specifies the speed of the gun tip (tool center point) of the selected gun while SPRAY is ON. This instruction is only valid for linear and circular movement. Maximum SPRAY SPEED setting is 9999 mm/s. Actual speed at the tool center point will not exceed the maximum linear speed. 7.2.1.2 1. AIRCUT SPEED
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter AIRCUT SPEED value SPEED (1~9999) 1000[mm/s]
AIRCUT SPEED, specifies the speed of the gun tip (tool center point) of the selected gun while SPRAY is OFF. This instruction is only valid for linear and circular movement. Maximum AIRCUT SPEED setting is 9999 mm/s. Actual speed at the tool center point will not exceed the maximum linear speed. 7.2.1.3 2. SPRAY JSPEED
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter SPRAY JSPEED value SPEED (1~100) _90[%]
SPRAY JSPEED, specifies the joint speed of the robot of the selected gun while SPRAY is ON. This instruction is only valid for joint movement. Maximum SPRAY JSPEED is 100% of the maximum motor rotation speed of each axis.
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7.2.1.4 3. AIRCUT JSPEED
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter AIRCUT JSPEED value SPEED (1~100) _50[%]
AIRCUT JSPEED, specifies the joint speed of the robot of the selected gun while SPRAY is OFF. This instruction is only valid for joint movement. Maximum AIRCUT JSPEED is 100% of the maximum motor rotation speed of each axis. 7.2.1.5 4. MOVING TIME
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter MOVING TIME TIME (0.1~999.9) _2.1[SEC]
MOVING TIME, specifies the time required for moving between two program points. This instruction is valid only for the first MOVE instruction following the MOVING TIME instruction. The maximum MOVING TIME setting is 999.9 seconds. The actual move time may be longer due to speed limitations for each axis. 7.2.1.6 5. PLAYBACK RATE
TCH/ADD/SPEED EASY MOVE PG10 -0 Enter PLYBK RATE PLYBK RATE (1~999) _80[%]
PLAYBACK RATE, specifies the rate of actual playback speed of programs. The maximum PLAYBACK RATE setting is 999%. The actual playback rate (speed) will not exceed the maximum speed of the robot. The BSPEED option must be set up to use PLAYBACK RATE.
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7.3 SPRAY INSTRUCTIONS
From the instruction selection menu screen select 1.SPRAY (Figure 7-26).

or
1 SPRAY .
SET

0. SPRAY_1 2. PRE_SPRAY(D) 4. DLY_SPRAY(D) 6. SPRAY_3 1. SPRAY_2 3. PRE_SPRAY(T) 5. DLY_SPRAY(T) 7. SPRAY_4
Figure 7-26 Selecting Spray Instruction Screens
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7.3.1 0. SPRAY 1
SPRAY 1, sets the output signal for SPRAY 1 to OFF or ON. 7.3.2 1. SPRAY 2
SPRAY 2, sets the output signal for SPRAY 2 to OFF or ON. 7.3.3 SPRAY INSTRUCTIONS PROGRAM EXAMPLE The example shown in figure 7-27 sets the spray signal for SPRAY #1 to ON at point 1 and to OFF at point 2.
Pt3 Pt1 Pt2 X X X Spray ON X Program point Spray ON point Aircut Spray OFF point 0 1 2 3 4 5 PROGRAM_NAME = SPRAY LMOVE (XYZ1) [Pt1] SPRAY #1,ON LMOVE (XYZ1) [Pt2] SPRAY #1,OFF LMOVE (XYZ1) [Pt3]
Figure 7-27 Spray #1 ON and OFF Program Example
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7.3.4 2. PRE_SPRAY (DISTANCE)
TCH/ADD/SPRAY EASY MOVE PG10 -0 Enter PRE_SPRAY value SPRAY No. (1~4) 1 DISTANCE (0~999) _10[mm] SIGNAL (0:OFF 1:ON) ON
PRE_SPRAY (distance), sets the specified spray signal to OFF or ON in advance of the program point by a specified distance. 7.3.5 3. PRE_SPRAY (TIME)
TCH/ADD/SPRAY EASY MOVE PG10 -0 Enter PRE_SPRAY value SPRAY No. (1~4) 2 TIME (0~999) __20[msec] SIGNAL (0:OFF 1:ON) ON
PRE_SPRAY (time), sets the specified spray signal to OFF or ON in advance of the program point by a specified time. 7.3.6 PRE_SPRAY INSTRUCTIONS PROGRAM EXAMPLE The example shown in figure 7-28 sets the spray signal for SPRAY #1 to ON 10 mm before point 1 and to OFF 5 mm before point 2.
Pt1 X
10 mm
Pt2 Pt3 X X
5 mm
X Program point Spray ON point Spray OFF point 0 1 2 3 4 5
Spray ON Aircut
PROGRAM_NAME = PRE_SPRAY LMOVE (XYZ1) [Pt1] PRE_SPRAY #1,10mm,ON LMOVE (XYZ1) [Pt2] PRE_SPRAY #1,5mm,OFF LMOVE (XYZ1) [Pt3]
Figure 7-28 Pre_Spray #1 ON and OFF Program Example
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NOTE
When the distance between Pt1 and Pt2 is less than 5 mm, the spray is turned OFF immediately after passing Pt1.
7.3.7 4. DLY_SPRAY (DISTANCE)
TCH/ADD/SPRAY EASY MOVE PG10 -0 Enter DLY_SPRAY value SPRAY No. (1~4) 2 DISTANCE (0~999) _20[mm] SIGNAL (0:OFF 1:ON) OFF
DLY_SPRAY (distance), sets the specified spray signal to OFF or ON after the program point is reached by a specified distance. 7.3.8 5. DLY_SPRAY (TIME)
TCH/ADD/SPRAY EASY MOVE PG10 -0 Enter DLY_SPRAY value SPRAY No. (1~4) 1 TIME (0~999) 1300[msec] SIGNAL (0:OFF 1:ON) OFF
DLY_SPRAY (time), sets the specified spray signal to OFF or ON after the program point is reached by a specified time.
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7.3.9 DLY_SPRAY INSTRUCTIONS PROGRAM EXAMPLE The example shown in figure 7-29 sets the spray signal for SPRAY #1 to ON 10 mm after point 1 and to OFF 5 mm after point 2.
Pt1 X
10 mm
Pt2 X
5 mm
Pt3 X Spray ON Aircut
X Program point Spray ON point Spray OFF point 0 1 2 3 4 5
PROGRAM_NAME = DLY_SPRAY LMOVE (XYZ1) [Pt1] DLY_SPRAY #1,10mm,ON LMOVE (XYZ1) [Pt2] DLY_SPRAY #1,5mm,OFF LMOVE (XYZ1) [Pt3]
Figure 7-29 Dly_Spray #1 ON and OFF Program Example
NOTE When the distance between Pt1 and Pt2 is less than 10 mm, the spray is turned OFF immediately after passing Pt1.
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7.3.10 6. SPRAY 3
SPRAY 3, sets the output signal for SPRAY 3 to OFF or ON. 7.3.11 7. SPRAY 4
SPRAY 4, sets the output signal for SPRAY 4 to OFF or ON.
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7.4 EXTERNAL OUTPUT INSTRUCTIONS
This section describes setting general external output signals to ON and OFF. From the instruction selection menu screen, select 2. EXTERNAL OUTPUT (Figure 722). 7.4.1 0. GENERAL EX_OUT From the EX_OUT instruction screen, select 0. GENERAL EX-OUT and press the SET key (Figure 7-31). 1. 2. 3. 4. Select the signal number. Select OFF or ON. Enter a delay time (optional) for setting the specified signal to OFF or to ON. Press the SET key.
The screens shown in figure 7-30, show settings with and without a time delay set.
TCH/ADD/EX-OUT EASY LINE PG10 -10 Enter DOUT data

OUTPUT SIGNAL (1~256) SIGNAL (0:OFF 1:ON) DELAY TIME (0~9999) _15 OFF 1200 [msec]
Time delay set

OUTPUT SIGNAL (1~256) SIGNAL (0:OFF 1:ON) DELAY TIME (0~9999) __1 ON __0 [msec]
No time delay set
Figure 7-30 EX-OUT (External Output) Screen
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or
2X=OUT A GUN
SET
TCH/ADD/EX-OUT EASY LINE PG10 -10b Select type of EX_OUT instruction

0. GENERAL EX-OUT 2. SHAPING AIR 4. HIGH VOLTAGE 6. PUSH THINNER 1. FLOW_RATE 3. AIR MOTOR 5. FLUSHING 7. PAINT_IO RATIO
or
0 SPEED
SET

OUTPUT SIGNAL (1~256) SIGNAL (0:OFF 1:ON) DELAY TIME (0~9999) __1 ON __0 [msec]
Figure 7-31 External Output Instructions Selection
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7.4.2 1. FLOW_RATE
TCH/ADD/EX-OUT EASY LINE PG10 -10 Enter FLOW_RATE level

FLOW_RATE LEVEL (0~100) __0
From the EX_OUT instruction screen, select 1. FLOW_RATE and press the SET key (Figure 7-31). FLOW_RATE is used to set the flow rate level of material during the coating process. General output signals are assigned in AUX 112, Dedicated Output Signals, to control flow rate in accordance with the flow rate level setting. 7.4.3 2. SHAPING AIR
TCH/ADD/EX-OUT EASY LINE PG10 -10 Enter SHAPING AIR level

SHAPING AIR LEVEL (0~100) __0
From the EX_OUT instruction screen, select 2. SHAPING AIR and press the SET key (Figure 7-31). SHAPING AIR is used to set the air flow level of air used during the coating process to shape the spray pattern. General output signals are assigned in AUX 112, Dedicated Output Signals, to control air flow in accordance with the shaping air level setting.
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7.4.4 3. AIR MOTOR
TCH/ADD/EX-OUT EASY LINE PG10 -10 Enter AIRMOTOR level

AIRMOTOR LEVEL (0~100) __0
From the EX_OUT instruction screen, select 3. AIR MOTOR and press the SET key (Figure 7-31). AIR MOTOR is used to set the air flow level of air used during the coating process to atomize the sprayed material. General output signals are assigned in AUX 112, Dedicated Output Signals, to control air flow in accordance with the air motor level setting. 7.4.5 4. HIGH VOLTAGE
TCH/ADD/EX-OUT EASY LINE PG10 -10 Enter HIGH VOLTAGE level

HIGH VOLTAGE LEVEL (0~100) __0
From the EX_OUT instruction screen, select 4. HIGH VOLTAGE and press the SET key (Figure 7-31). HIGH VOLTAGE is used to set the high voltage level used during the coating process when a electrostatic gun is used. General output signals are assigned in AUX 112, Dedicated Output Signals, to control air flow in accordance with the high voltage level setting.
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7.4.6 5. FLUSHING
TCH/ADD/EX-OUT EASY LINE PG10 -10 Select OFF/ON of FLUSHING

FLUSHING (0:OFF 1:ON) OFF
From the EX_OUT instruction screen, select 5. FLUSHING and press the SET key (Figure 7-31). FLUSHING is used to flush the gun, for example, at color change. This instruction sets the flushing output signal to OFF or ON. A general output signal is assigned in AUX 112, Dedicated Output Signals, to control the flushing operation (OFF or ON). 7.4.7 6. PUSH THINNER
TCH/ADD/EX-OUT EASY LINE PG10 -10 Select OFF/ON of PUSH THINNER

PUSH THINNER (0:OFF 1:ON) ON
From the EX_OUT instruction screen, select 6. PUSH THINNER and press the SET key (Figure 7-31). PUSH THINNER is used to dispense thinner to the gun during the coating process. This instruction sets the push thinner output signal to OFF or ON. A general output signal is assigned in AUX 112 Dedicated Output Signals, to control the thinner flow (OFF or ON).
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7.4.8 7. PAINT_IO RATIO
From the EX_OUT instruction screen, select 7. PAINT_IO RATIO and press the SET key (Figure 7-31). These instructions are used to change the output values of FLOW_RATE, SHAPING AIR, AIR MOTOR, and HIGH VOLTAGE to the painting equipment at a specified ratio. When a RATIO instruction is executed the current output value set by the output instruction for painting equipment is changed by multiplying the set value by the specified ratio. The setting FLOW_RATE RATIO screen is shown in figure 7-32. The screens for SHAPING AIR, AIR MOTOR, and HIGH VOLTAGE are similar.
TCH/ADD/EX-OUT EASY LINE PG10 -10 Select item to set RATIO

0. FLOW_RATE RATIO 2. AIRMOTOR RATIO 1. SHAPING RATIO 3. H_VOLTAGE RATIO
or
0 SPEED
SET
TCH/ADD/EX-OUT EASY LINE PG10 -10 Enter FLOW_RATE ratio

RATIO (0~200) 100[%]
Figure 7-32 EX-OUT (External Output) FLOW_RATE Ratio Screen
Changes made to the values in these screens change the value of the program GENERAL EX-OUT instructions for the painting equipment. These changes are effective immediately. The default settings are 100%. When exiting teach mode, or after repeat operation of the program is complete, the settings are set to default (100%).
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The output signals to the painting equipment are based on data from the EX-OUT instructions, PAINT_IO RATIO (Figure 7-31), PRDCT PNTIO RATIO (Figure 7-34), DATA BANK upper value limits (Figure 7-35), and the number of output signals (see figure 733).
Output signals = GENERAL EX-OUT instruction x PAINT_IO RATIO instruction x PRDCT PNTIO RATIO function 2y (y = the number of output signals) X Upper limit value setting
Figure 7-33 Painting Equipment Output Signal Formula
When the value exceeds the upper limit of the set signal output, the upper limit value is used to determine the output signals. The upper limit value is set in 4. DATA BANK from the main menu (Figure 7-35), or AUX 176 Data Bank from the multi function panel. The status of output signals can be monitored from 5. DISPLAY STATUS screen from the main menu.
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or
1 SPRAY .
SET
PLYBK
EASY LINE PG10 -10
Select an item
0. SET PLAYBACK No. 1. DISPLAY PLBK STATUS 2. SET PRODUCT RATE 3. PRDCT PNTIO RATIO
or
3X=IN B TABLE
SET
PLYBK/PNTIO_RATIO EASY LINE PG10 -10 Enter PRODUCT PAINT_IO ratio PRDCT FLOW RATIO PRDCT SHAPE RATIO PRDCT AMOT RATIO 100[%] 100[%] 100[%]
PRDCT HV RATIO
100[%]
Figure 7-34 Product Paint IO Ratio Settings
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or
4 SMOTH CSENS
SET
EASY LINE PG10 -10 Select a data bank operation

DBK 0. EDIT DATA BANK 1. LIST (DATA BANK)
or
0 SPEED
SET
DBK/EDIT
EASY LINE PG10 -10
Enter data bank No.

DATA BANK No. (1~500) __1
or
1 SPRAY .
SET
DBK= Enter DATA BANK conditions

DBK/EDIT/INP FLOW_RATE (-1~10000) SHAPING AIR (-1~100) AIRMOTOR (-1~100) HIGH VOLTAGE (-1~100) SPRAY SPEED (-1~9999) SPRAY JSPEED (-1~100)
__-1 __-1 __-1 __-1 __-1[MM/S] _-1[%]
Figure 7-35 Data Bank Maximum Value Settings 7-58 April 8, 2002
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CAUTION
When an EX-OUT signal is the last instruction of the program the signal may not be recognized. The playback operation ends immediately after executing the last step of the program and there is not enough time for the signal to be set to ON before the program playback operation is completed. When using an external output signal as an interlock signal to the master controller or a PLC, the signal may not be recognized. To prevent this condition, a dummy step can be added after the last step of the program, see figure 7-36.
Step No. 8 LMOVE P8 9 EX-OUT #8,ON [PROGRAM END]
Step No. 8 LMOVE P8 9 EX-OUT #8,ON 10 LMOVE P9 (Dummy step) [PROGRAM END]
Note: Program point P8 and P9 are recorded as the same location.
Figure 7-36 Program With a Dummy Step
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7.5 3. EXTERNAL INPUT INSTRUCTIONS
WARNING
When servo power is ON, do not enter the restricted space. The robot and peripheral equipment controlled by the robot controller may be waiting for an input signal to continue operation. The equipment may appear to be stopped, but may start operation when the signal is received.
This section describes setting external input signal instructions to cause a wait condition, until the specified signal state (ON or OFF) is recognized. From the instruction selection menu screen, select 3. EXTERNAL INPUT (Figure 7-37). 7.5.1 0. DATA INPUT WAIT From the EX_IN instruction screen, select 0. INPUT WAIT and press the SET key (Figure 7-37). 1. 2. 3. 4. Select the signal number. Select OFF or ON. Enter a TIMEOUT time (optional) for setting a time-out period and a time-out error. Press the SET key.
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or
3X=IN B TABLE
SET
TCH/ADD/EX-IN EASY LINE PG10 -10b Select type of EX_IN instruction

0. INPUT WAIT 1. MUTUAL_WAIT
or
0 SPEED
SET
TCH/ADD/EX-IN EASY LINE PG10 -10 Enter DIN WAITdata

INPUT SIGNAL (1~256) SIGNAL (0:OFF 1:ON) TIMEOUT (0~99) __1 ON __0 [msec]
Figure 7-37 External Input Instructions Selection
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The screens, in figure 7-38, show settings with a time-out time and a time-out error condition set.
TCH/ADD/EX-IN EASY LINE PG10 -10 Enter DIN WAIT data

INPUT SIGNAL (1~256) SIGNAL (0:OFF 1:ON) TIMEOUT (0~99) _3 ON 15 [sec]
Time-out time set TCH/ADD/EX-IN EASY LINE PG10 -10 Select ERROR class for timeout
0. NON ERROR 1. OUTPUT ERROR
Figure 7-38 EX-IN (External Input) Time-Out Setting
The screen, in figure 7-39, shows settings without a time-out or a time-out error condition set.
TCH/ADD/EX-IN EASY LINE PG10 -10 Enter DIN WAIT data

INPUT SIGNAL (1~256) SIGNAL (0:OFF 1:ON) TIMEOUT (0~99) _3 ON 0 [sec]
No time-out time set
Figure 7-39 EX-IN (External Input) No Time-Out Setting
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7.5.1.1 1. MUTUAL WAIT (OPTION)
The MUTUAL WAIT option is used with two robots connected by Ethernet. One robot waits in standby until the second robot reaches a specified point. From the EX-IN menu select 1. MUTUAL_WAIT and press the SET key, as shown in figure 7-40. To use this command an Ethernet connection setting is required between the two robots. Refer to the Mutual Wait and Gun Relative Distance Check Functions Manual for details on setting and using this function.
TCH/ADD/EX-IN EASY LINE PG10 -10b Select type of EX_IN instruction
0. INPUT WAIT 1. MUTUAL_WAIT
or
1 SPRAY .
SET
TCH/ADD/EX-IN EASY LINE PG10 -10 Enter WAIT-NUMBER.

WAIT-NUMBER (1~9) 1
Figure 7-40 EX-IN (External Input) Mutual Wait Screen
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7.6 4. SMOOTH INSTRUCTIONS
This section describes the use of the SMOOTH instructions. From the instruction selection menu screen select 4. SMOOTH and press the SET key (Figure 7-41). 7.6.1 0. ACCELERATION From the SMOOTH instruction screen, select 0. ACCELERATION and press the SET key (Figure 7-41). ACCELERATION specifies the acceleration rate used for moves to program points. The default setting is 100% or maximum acceleration. 7.6.1.1 1. SMOOTH (RANGE) To specify a range for the SMOOTH instruction select 1. SMOOTH (RANGE) and press the SET key (Figure 7-42). The SMOOTH range specifies the distance from the program points that the robot path changes trajectory. The larger the SMOOTH range value the earlier the robot starts movement to the following program point. When the smooth range value is set high enough, the moves are blended into one smooth transition from one point to the next point. When the smooth range value is set to 1 mm the robot hesitates at the program point, then moves to the next program point. The default setting is 1 mm. The SMOOTH and ACCELERATION instructions are effective until another SMOOTH or ACCELERATION instruction is executed.
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or
4 SMOTH CSENS
SET
TCH/ADD/SMOOTH EASY LINE PG10 -10b Select type of SMOOTH instruction

0. ACCELERATION 1. SMOOTH(RANGE)
or
0 SPEED
SET
TCH/ADD/SMOOTH EASY LINE PG10 -10 Enter ACCELERATION rate

ACCELERATION (1~100) 100 [%]
Figure 7-41 Smooth Instruction Selection
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TCH/ADD/SMOOTH EASY LINE PG10 -10 Enter SMOOTH_RANGE value

RANGE (1~999) _50 [mm]
Taught path Pt1 Path with SMOOTH range of 50 mm

50 mm
Program point Pt2 Path with SMOOTH range of 1 mm
Pt3
Figure 7-42 Smooth Range Instruction
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The program example, shown in figure 7-43, demonstrates moving to program point Pt2 with a smooth range of 50 mm and moving to program points Pt3 and Pt4 with a smooth range of 1 mm.
Taught path Pt1 Path with SMOOTH range of 50 mm Path with SMOOTH range of 1 mm
50 mm
Pt2
Pt3 0 1 2 3 4 5 6 PROGRAM_NAME = SMOOTH LMOVE (XYZ1) [Pt1] SMOOTH_RANGE 50mm LMOVE (XYZ1) [Pt2] SMOOTH_RANGE 1mm LMOVE (XYZ1) [Pt3] LMOVE (XYZ1) [Pt4]
Pt4
Figure 7-43 Smooth Range Program Example
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The program example shown in figure 7-44 demonstrates the smooth instruction used with output signals. When the robot executes a motion step using the SMOOTH instruction and output signal(s), the output signal(s) is set to ON (except SPRAY signal) as the robot reaches the smooth range. The signal OFF instruction is executed when the robot reaches the smooth range of the next program point (Figure 7-44).
Pt1 Output ON
Pt2
Output OFF Pt4 0 1 2 3 4 5 6 7 PROGRAM_NAME = OUTPUT LMOVE (XYZ1) [Pt1] SMOOTH_RANGE 50mm LMOVE (XYZ1) [Pt2] DOUT #5,ON LMOVE (XYZ1) [Pt3] DOUT #5,OFF LMOVE (XYZ1) [Pt4] Pt3
Figure 7-44 Smooth Range Instruction with Output Signal
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The program example shown in figure 7-45 demonstrates the smooth instruction used with SPRAY instructions. When a program uses the smooth instruction and the spray instruction, the spray signal is set to ON as the robot reaches the nearest position to the program point. When PRE_SPRAY and DLY_SPRAY instructions are used, the spray signal ON timing is calculated based on the nearest position to the program point (Figure 7-45).
Pt1 Pre-spray SPRAY signal ON Delay spray
Pt2
SPRAY ON area
Pt3 0 1 2 3 4 5 PROGRAM_NAME = SPRAY LMOVE (XYZ1) [Pt1] SMOOTH_RANGE 50mm LMOVE (XYZ1) [Pt2] SPRAY #1,ON LMOVE (XYZ1) [Pt3]
Figure 7-45 Smooth Range Instruction with Spray Signal
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7.7 5. DATA BANK INSTRUCTION
This section describes the use of the CALL_DBK instruction. From the instruction selection menu screen, select 5. DATA BANK and press the SET key (Figure 7-46). Conditions set in the specified data bank are effective immediately. The data bank instruction is used at the step where condition changes are needed (Figure 7-47).
or
5 DATA
SET
TCH/ADD/DBK EASY LINE PG10 -10 Enter DBK No. to be called

DATA BANK No. (1~500) _10
Figure 7-46 Data Bank Instruction Selection
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Databank 1 used Pt1 X Pt3 Pt2 X X Program point Spray ON point Spray OFF point 0 1 2 3 4 5 6 7 8 9
Databank 2 used Pt5 X Pt4 X Spray ON Aircut
PROGRAM_NAME = DATABANK LMOVE (XYZ1) [Pt1] LMOVE (XYZ1) [Pt2] CALL_DBK 1 SPRAY #1,ON LMOVE (XYZ1) [Pt3] CALL_DBK 2 LMOVE (XYZ1) [Pt4] SPRAY #1,OFF LMOVE (XYZ1) [Pt5]
Figure 7-47 Data Bank Instruction Sample Program
For information on setting data bank parameters see unit 9, Auxiliary Functions, AUX 176 Data Bank and explosion-proof teach pendant auxiliary functions, data bank.
NOTE The data bank parameters must be set in auxiliary functions before using the data bank instruction in a program. If a data bank is called and parameters are not set, error -2106 results. -2106 Specified PAINTING DATA BANK is undefined.
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7.8 6. TIMER INSTRUCTION
This section describes the use of the TIMER instruction. From the instruction selection menu screen select 6. TIMER and press the SET key (Figure 7-48). The TIMER instruction causes the robot to suspend motion for the specified time. This instruction has no effect on following instructions. The maximum time setting is 99,999 msec
WARNING
When servo power is on, do not enter the restricted space. The robot and peripheral equipment controlled by the robot controller may be waiting for a TIMER instruction to continue operation. The equipment may appear to be stopped, but may start operation when the timer instruction time has elapsed.
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or
6 TIMER -
SET
TCH/ADD/TIMER EASY LINE PG10 -10 Enter TIMER WAIT value

TIMER (1~99999) _5760[msec]
Note: 5760 msec = 5.76 sec
Figure 7-48 Timer Instruction Selection
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7.9 7. CALL INSTRUCTION
This section describes the use of the CALL_PGM instruction. From the instruction selection menu screen select 7. CALL and press the SET key (Figure 7-49). The CALL_PGM instruction is used to call a specified program. When execution of the called program is complete, execution returns to the program instruction following the CALL_PGM instruction in the program.
NOTE The called program must be recorded before using the call instruction. If a call instruction is executed for a program that does not exist error -800 results.
-800 Program does not exist. Program nesting is available up to 20 levels. An error results if a call is executed for more than 20 levels
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or
7 CALL D
SET
TCH/ADD/CALL EASY LINE PG10 -10 Enter CALL_PGM No.

PROGRAM No. (0~999) _10
Figure 7-49 Call Instruction Selection
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7.10 8. JUMP INSTRUCTION
This section describes the use of the JUMP instruction. From the instruction selection menu screen select 8. JUMP and press the SET key (Figure 7-50). The JUMP instruction causes program execution to jump to the specified label. The jump instruction has two function choices, LABEL and COUNTER.
or
8 JUMP E MOVE
SET
TCH/ADD/JUMP EASY LINE PG10 -10 Select type of JUMP instruction

0. JUMP 2. COUNTER 1. COMPARE 3. PGM. SELECTION
Figure 7-50 Jump Instruction Selection
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7.10.1 0. JUMP
From the jump instruction selection screen there are four choices UC_JUMP, TRUE_JUMP, FALSE_JUMP, and SET LABEL. 7.10.1.1 0. UC_JUMP From the jump instruction screen select 0. UC_JUMP (unconditional jump) and press the SET key (Figure 7-51). When an unconditional jump instruction is executed in a program the program execution jumps to the specified label regardless of program step order (Figure 7-52).
or
0 SPEED
SET

0. UC_JUMP 2. FALSE_JUMP 1. TRUE_JUMP 3. SET LABEL
or
0 SPEED
SET
TCH/ADD/JUMP EASY LINE PG10 -10 Enter DESTINATION LABEL to jump

UC_JUMP (LABEL) LABEL NAME ____1111
Figure 7-51 Unconditional Jump Instruction April 8, 2002 7-77
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The program example in figure 7-52 demonstrates using the UC_JUMP instruction to cause the program path to bypass Pt4, Pt5, and Pt6 to move from Pt3 directly to Pt7.
Pt1
Pt2
Pt4
Pt3
Pt5
Pt6
Pt8
Pt7
Program path 0 PROGRAM_NAME = UC_JUMP 1 JMOVE (JOINT) [Pt1] 2 LMOVE (XYZ1) [Pt2] 3 LMOVE (XYZ1) [Pt3] 4 UC_JUMP LABEL 1111 5 LMOVE (XYZ1) [Pt4] [Pt5] 6 LMOVE (XYZ1) 7 LMOVE (XYZ1) [Pt6] 8 LABEL 1111 9 LMOVE (XYZ1) [Pt7] 10 LMOVE (XYZ1) [Pt8]
Figure 7-52 Unconditional Jump Instruction Example Program
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7.10.1.2 1. TRUE_JUMP
From the jump instruction screen select 1. TRUE_JUMP and press the SET key (Figure 7-53). When a true jump instruction is executed in a program the program execution jumps to the specified label only when the conditions for the jump instructions are true (Figure 7-54). The conditions are specified using the COMPARE and COUNTER functions. For information on the COMPARE and COUNTER functions see sections 7.10.2 and 7.11 If the conditions are not true execution moves to the step following the true jump instruction.

or
1 SPRAY .
SET

TRUE_JUMP LABEL NAME 12345678
Figure 7-53 True Jump Instruction Selection
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The program example in figure 7-54 demonstrates using the TRUE_JUMP instruction to cause the program path to repeat movement from Pt2 to Pt5 five times (while the compare parameters are true). Dedicated counters are used in this example, but general counters can be used.
Pt1
Pt2
Pt3
Pt5
Pt4
Pt6
Program path 0 PROGRAM_NAME = TRUE_JUMP 1 LOAD SPE_CNT1, 0 2 JMOVE (JOINT) [Pt1] 3 LMOVE (XYZ1) [Pt2] 4 LABEL 12345678 5 ADD SPE_CNT1, 10 6 SPRAY #1,ON 7 LMOVE (XYZ1) [Pt3] 8 LMOVE (XYZ1) [Pt4] [Pt5] 9 LMOVE (XYZ1) 10 SPRAY #1,OFF 11 LESS SPE_CNT1, 50 12 TRUE_JUMP LABEL 12345678 13 LMOVE (XYZ1) [Pt6]
Figure 7-54 True Jump Instruction Program Example
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7.10.1.3 2. FALSE_JUMP
From the jump instruction screen select 2. FALSE_JUMP and press the SET key (Figure 7-55). When a false jump instruction is executed in a program the program execution jumps to the specified label only when the conditions for the jump instructions are false. The conditions are specified using the COMPARE and COUNTER functions. For information on the COMPARE and COUNTER functions see sections 7.10.2 and 7.11. If the conditions are not false execution moves to the step following the false jump instruction.

or
2X=OUT A GUN
SET

FALSE_JUMP LABEL NAME 12345678
Figure 7-55 True Jump Instruction Selection
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7.10.1.4 3. SET LABEL
From the JUMP instruction screen select 3. SET LABEL and press the SET key (Figure 7-56). The SET LABEL instruction is used to specify the label for the destination of a jump instruction in a program (Figure 7-57).

or
3X=IN B TABLE
SET

SET LABEL LABEL NAME ____1111
Figure 7-56 Set Label Instruction Selection
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In the example shown in figure 7-57, a UC_JUMP instruction is placed at step 4 and a LABEL instruction is placed at step 8 to cause the program path to bypass Pt4, Pt5, and Pt6 to move from Pt3 directly to Pt7.
Pt1
Pt2
Pt4
Pt3
Pt5
Pt6
Pt8
Pt7
Program path 0 PROGRAM_NAME = UC_JUMP 1 JMOVE (JOINT) [Pt1] 2 LMOVE (XYZ1) [Pt2] 3 LMOVE (XYZ1) [Pt3] 4 UC_JUMP LABEL 1111 5 LMOVE (XYZ1) [Pt4] [Pt5] 6 LMOVE (XYZ1) 7 LMOVE (XYZ1) [Pt6] 8 LABEL 1111 9 LMOVE (XYZ1) [Pt7] 10 LMOVE (XYZ1) [Pt8]
JUMP instruction Label for JUMP instruction destination
Figure 7-57 Set Label Instruction Program Example
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7.10.2 1. COMPARE INSTRUCTION
From the JUMP instruction screen select 1. COMPARE and press the SET key (Figure 7-58). There are seven COMPARE instruction functions as shown in figure 7-58. Jump instructions are executed to the specified label in a program based on the results of the designated compare function (Figure 7-59). COMPARE functions may be used with general or dedicated counters. For information on counters refer to section 7.11.

or
1 SPRAY .
SET
TCH/ADD/JUMP EASY MOVE PG10 -0 b Set type of COMPARE instruction

0. EQU(=) 2. GREATER(>) 4. GREATER/EQU(>) = 6. INPUT_SIGNAL 1. NOT_EQU( ) 3. LESS(<) < 5. LESS/EQU(=)
Figure 7-58 Compare Instruction Selection
In the program example shown in figure 7-59, the EQU compare instruction is used; the other compare instructions are used in the same manner. In the program example shown in figure 7-59, a general counter is used, but dedicated counters may be used.
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In the program example shown in figure 7-59, an EQU compare instruction and a general counter are used to cause the program path to repeat movement from Pt1 to Pt6 ten times before moving to Pt7.
Pt1
Pt2
Pt3
Pt5
Pt4
Pt7
Program path 0 PROGRAM_NAME = COMPARE 1 LOAD GEN_CNT12, 0 2 LABEL 2 3 JMOVE (JOINT) [Pt1] 4 LMOVE (XYZ1) [Pt2] 5 SPRAY #1,ON 6 LMOVE (XYZ1) [Pt3] 7 SPRAY #1,OFF 8 LMOVE (XYZ1) [Pt4] 9 SPRAY #1,ON [Pt5] 10 LMOVE (XYZ1) 11 SPRAY #1,OFF 12 LMOVE (XYZ1) [Pt6] 13ADD GEN_CNT12, 1 14 EQU GEN_CNT12, 10 15 TRUE_JUMP LABEL 999 16 UC_JUMP LABEL 2 17 LABEL 999 18 LMOVE (XYZ1) [Pt7]
Figure 7-59 Compare Instruction Program Example
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7.10.3 1. INPUT SIGNAL INSTRUCTION
From the compare instruction screen, select 6. INPUT_SIGNAL and press the SET key (Figure 7-60).
TCH/ADD/JUMP EASY MOVE PG10 -0 b Set type of COMPARE instruction
0. EQU(=) 2. GREATER(>) 4. GREATER/EQU(>) = 6. INPUT_SIGNAL 1. NOT_EQU( ) 3. LESS(<) < 5. LESS/EQU(=)
or
6 TIMER -
SET
TCH/ADD/JUMP EASY LINE PG10 -10 Enter conditions to COMPARE (INPUT)

PORT No. (1~256) No. OF BITS (1~16) VALUE (0~65535) __1 _2 ____3
Figure 7-60 Input Signal Instruction Selection
The specified input signals are read as a binary bit pattern and converted to a decimal number value. The PORT No. (signal number) specifies the first bit of the bit pattern. The first bit is also the least significant bit in the bit pattern. The No. OF BITS specifies the number of bits in the bit pattern. In the program example shown in figure 7-61 two bits are used, signal number 1 is the least significant bit, and the decimal value of 3 is specified as in figure 7-60. The program path jumps from Pt3 to Pt6 when the specified bits are ON to generate the decimal value of 3.
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Signal number Signal state Signal binary value Decimal value
1 2 [ON] [ON] 20x1 + 21x1 = 3 (1 + 2) = 3
Pt1
Pt2
Pt4
Pt3
Pt5
Pt6
Pt8
Pt7
Program path 0 PROGRAM_NAME = DIN_JUMP 1 JMOVE (JOINT) [Pt1] 2 LMOVE (XYZ1) [Pt2] 3 LMOVE (XYZ1) [Pt3] 4 DIN_JUMP #1,2PORT, 3 5 TRUE_JUMP LABEL 999 6 LMOVE (XYZ1) [Pt4] [Pt5] 7 LMOVE (XYZ1) 8 LABEL 999 9 LMOVE (XYZ1) [Pt6] [Pt7] 10 LMOVE (XYZ1) 11 LMOVE (XYZ1) [Pt8]
Figure 7-61 Input Signal Instruction Program Example
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7.11 2. COUNTER INSTRUCTION
From the JUMP instruction screen select 2. COUNTER and press the SET key (Figure 7-62). There are three COUNTER instruction functions as shown in figure 7-62. Jump instructions are executed to the specified label in a program based on the results of the designated compare function. To cause the program jump, the COUNTER, COMPARE and LABEL JUMP instructions are used together (Figure 7-63). Compare functions may be used with general or dedicated (special) counters.

or
2X=OUT A GUN
SET
TCH/ADD/JUMP EASY MOVE PG10 -0 Set type of COUNTER instruction

0. LOAD 2. SUBTRACT 1. ADD
or
0 SPEED
SET
TCH/ADD/JUMP EASY MOVE PG10 -0 Enter conditions to LOAD

CNT_TYP (0:GEN 1:SPE) CNT No. (1~32) VALUE (-32768~32767) SPE _1 __110
Figure 7-62 Counter Instruction Selection 7-88 April 8, 2002
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The LOAD instruction is used to enter the counter into the program and set the count value. The ADD and SUBTRACT instructions are used to increment or decrement the counter to achieve the desired count as shown in figure 7-63.
Pt1
Pt2
Pt3
Pt5
Pt4
Pt6
Program path 0 PROGRAM_NAME = TRUE_JUMP 1 LOAD SPE_CNT1, 0 2 JMOVE (JOINT) [Pt1] 3 LMOVE (XYZ1) [Pt2] 4 LABEL 12345678 5 ADD SPE_CNT1, 10 6 SPRAY #1,ON 7 LMOVE (XYZ1) [Pt3] 8 LMOVE (XYZ1) [Pt4] [Pt5] 9 LMOVE (XYZ1) 10 SPRAY #1,OFF 11 LESS SPE_CNT1, 50 12 TRUE_JUMP LABEL 12345678 13 LMOVE (XYZ1) [Pt6]
Figure 7-63 Counter Instruction Program Example
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7.11.1 COUNTER RESET AND DISPLAY
The general and dedicated counters may be manually reset at any time in teach or repeat mode. To reset counter values select 6. SET CONDITION from the main menu screen and 2. CNT_VALUE from the set condition menu. The general and dedicated counters may be monitored from the display status mode. To monitor counters select, 5. DISPLAY STATUS from the main menu screen and 2. COUNTER DISPLAY from the display status menu.
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7.12 3. PROGRAM SELECT INSTRUCTION
From the jump instruction screen select 3. PGM. SELECTION and press the SET key (Figure 7-64).

or
3X=IN B TABLE
SET
TCH/ADD EASY MOVE PG10 -10 Set instruction to ADD by SET key
9 PGM_SELECT [ PROGRAM END ]
Figure 7-64 Program Select Instruction Selection
Program numbers may be selected for repeat operation using the RPS function. To use the RPS function place the PGM_SELECT instruction in the program at the point the program change is desired (usually the end of the program). Using the RPS function requires setting dedicated signals. For information on the RPS function refer to section 11.35 and the C35/37 Explosion-Proof Type Controller External I/O Manual.
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7.13 9. CONVEYOR INSTRUCTION
From the teach instruction screen select 9. CONVEYOR and press the SET key (Figure 7-65). There are three CONVEYOR instruction functions as shown in figure 7-65. Track on synchronizes the robot with the moving conveyor. Track off stops the synchronization with the moving conveyor.

or
9 CONVR F
SET
TCH/ADD/CONVEYOR EASY LINE PG10 -10 Select type of CONVEYOR instruction

0. TRACK ON 2. CONVEYOR WAIT 1. TRACK OFF
Figure 7-65 Conveyor Instruction Selection
NOTE In repeat mode, the robot automatically selects a smooth range of 1 mm when executing move instructions between the TRACK ON and TRACK OFF instructions, regardless of smooth range setting.
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WARNING
When servo power is ON, do not enter the restricted space. The robot and peripheral equipment controlled by the robot controller may be waiting for a CONVEYOR WAIT instruction to continue operation. The equipment may appear to be stopped, but may start operation when the conveyor wait instruction upper limit position is reached.
The CONVEYOR WAIT instruction causes the robot to wait until the conveyor reaches the specified position (Figure 7-66). The upper limit for the conveyor position can be set up to 65,000 mm.
TCH/ADD/CONVEYOR EASY LINE PG10 -10 Select type of CONVEYOR instruction

0. TRACK ON 2. CONVEYOR WAIT 1. TRACK OFF
or
2X=OUT A GUN
SET
TCH/ADD/CONVEYOR EASY LINE PG10 -10 Enter CONVEYOR WAIT data

UPPER LIMIT CV_POS _2000[mm]
Figure 7-66 Conveyor Wait Instruction Selection
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7.14 A. GUN CONTROL INSTRUCTION
From the teach instruction screen select A. GUN CONTROL and press the SET key (Figure 7-67). The gun control instruction screen is used to specify the gun number (Figure 7-67). Gun numbers 1 through 9 are available as defined in AUX 48 Tool Dimensions using the multi function panel. The robot uses the data in AUX 48 Tool Dimensions to determine the tool center point (TCP) of the gun selected. The robot calculates linear moves, to move the TCP in a straight line at a constant speed.
or
SHIFT +
2X=OUT A GUN
SET
TCH/ADD/GUN-CTRL EASY LINE PG10 -10 Enter GUN No.

GUN No. (1~9) 1
Figure 7-67 Gun Control Instruction Selection
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NOTE
In repeat mode, the robot automatically selects a smooth range of 1 mm when executing a move instruction, when the TCP (gun number) is changed by the gun control instruction, regardless of smooth range setting.
CAUTION
The TCP (gun number) is recorded as part of the move instruction by the STORE POS key. If a gun number is not specified, gun 1 is assumed. When more than one gun is used, gun control numbers must be specified in the program when changing the gun used. During program editing, if a different gun is use for a move instruction the gun instruction in the program must be changed also.
7.15 B. TABLE INSTRUCTION (OPTION) This function is used for systems equipped with an external axis such as a servo turntable.
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7.16 C. SENSING INSTRUCTION
From the teach instruction screen select C. SENSING and press the SET key (Figure 768). The SENSING function is used for systems that the robot controller opens/closes doors or compensate for path deviation using a camera. This instruction is only used with systems equipped as described above.

or
SHIFT +
4 SMOTH CSENS
SET
TCH/ADD/SENS EASY LINE PG10 -10 Select type of SENSING instruction

0. DOOR SENS 1. CAMERA_COMPEN
Figure 7-68 Sensing Instructing Selection
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7.17 E. MOVE INSTRUCTION
From the teach instruction screen select E. MOVE and press the SET key (Figure 7-69). The MOVE function is used to enter positional data as numeric values instead of using the STORE POS key.

TCH/ADD/MOVE Enter position data

X Y Z O A T TRAVEL X TRAVEL Y TRAVEL Z
EASY MOVE PG10 -0 b

_1700.[mm] __500.[mm] _1500.[mm] ___50.[deg] __130.[deg] ___50.[deg] __100.[mm] ____0.[mm] ____0.[mm]
or
SHIFT +
8 JUMP E MOVE
TCH/ADD/MOVE Enter position data

CV_POS
SET
EASY LINE PG10 -10
_____0.[mm]
TCH/ADD/MOVE EASY LINE PG10 -10 Select an interpolaiton

0. LINEAR 2. CIRCULAR (Mid) 1. JOINT 3. CIRCULAR (End)
NOTE: Displayed with converyor axis only
TCH/ADD/MOVE Select a point type

0. XYZ1 (OAT) 2. JOINT
EASY LINE PG10 -10

1. XYZ2 (q 4~6)
Figure 7-69 Move Instructing Selection
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When a linear move is selected, robot joints are coordinated to drive the TCP in a linear motion and maintain tool (gun) orientation. When a joint move is selected, robot points move to reach total coincidence simultaneously to achieve the recorded robot posture at the taught point. When a circular (mid) move is selected, the robot path draws a circle passing through the circular intermediate point (three points are required). When a circular (end) move is selected, the robot path draws a circle passing through the circular (mid) point(s) and ends the circle at the circular end point (three points are required).
7.17.1 MOVE INSTRUCTION DISPLAY, MULTI FUNCTION PANEL The multi function panel, move instruction display includes step No., interpolation type, point type, configuration data and positional data for JT1 through JT9 axes (figure 7-70, table 7-8, and table 7-9).
PROGRAM LIST (1/2) .PROGRAM pg99() 1 SPRAY_JSPEED 15% 2 SMOOTH_RANGE 1mm 3 JMOVE JOINT 0000, 115.21, -2.85, -63.24, 366.9, 84, 124.71 4 SPRAY #2, ON 5 FLOW_RATE 1 6 PATTERN 4 7 ATOMIZING 1 8 SPRAY_SPEED 800mm/s 9 LMOVE XYZ1 0004, 873.1, -485.8, 40.4, 88, 96, -86.89 10 DIN_WAIT #20, ON
SPRAY ON
MOVE instructions
SCROLL
SCROLL Page Up
NEXT PG
Page Down
LMOVE XYZ1 0004, 873.1, -485.8, 40.4, 88, 96, -86.89, 0, 0, 0 Positional data JT1~JT6 Configuration data Point type Interpolation (JT7~JT9 If equipped)
Step number
Figure 7-70 Multi Function Panel Move Instruction Display
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Table 7-8 Configuration Data

Configuration Data 0000 0001 0002 0003 0004 0005 0006 0007
Definition of Robot Posture RIGHTY ABOVE DWRIST LEFTY ABOVE DWRIST RIGHTY BELOW DWRIST LEFTY BELOW DWRIST RIGHTY ABOVE UWRIST LEFTY ABOVE UWRIST RIGHTY BELOW UWRIST LEFTY BELOW UWRIST
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Table 7-9 Configuration Descriptions

Configuration Configuration Description Specifies the posture of the robot axes JT1, JT2, and JT3. The robotapproaches a program point using the configuration of a person's right arm. Specifies the posture of the robot axes JT1, JT2, and JT3. The robot approaches a program point using the configuration of a person's left arm. Example
RIGHTY
RIGHTY
LEFTY
LEFTY
ABOVE
Specifies the posture of the robot's JT3 axis. The JT3 posture is turned up.
ABOVE
BELOW
Specifies the posture of the robot's JT3 axis. The JT3 posture is turned down.
BELOW
UWRIST
Specifies the posture of the robot's JT5 angle as positive with the same posture of the tool mounting flange surface.
UWRIST
DWRIST
Specifies the posture of the robot's JT5 angle as negative, with the same posture of the tool mounting flange surface.
DWRIST
CAUTION
When MOVE instructions,configuration data and/or positional data are changed in edit mode, confirm robot motion in check mode before running the program in repeat mode. The new data may cause unexpected robot motion.
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Table 7-10 Point Type
Point Type Interpolation Linear M id Circular End Joint O = Used X = Not Used O X O X X O XYZ1 O O XYZ2 JOINT O O X X
The combination of interpolation and point type must be correct or the data is not accepted. XYZ1: During a XYZ1 move, the TCP is moved in a straight line at a constant speed and gun orientation is maintained. During a XYZ1 move, if JT2 and JT3 align in a straight position, or if JT5 moves to the 0 degree position, a singularity condition may occur. If a singularity condition occurs, the robot stops and an arm configuration or speed error is generated. XYZ2: During a XYZ2 move, wrist joints (JT4, JT5, and JT6) are used to compensate for a singularity condition. During a XYZ2 move, gun orientation is not necessarily maintained. The gun tip configuration (TCP) is maintained during a XYZ1 or a XYZ2 interpolated move. The interpolation and point type selected during teaching is recorded with the positional data. In edit mode, the interpolation and point type are selected from the MOVE instruction screen, as shown in figure 7-69. Attempting to teach positional data for axes not installed generates an error. The format for MOVE instructions is different depending on the number of axes installed, as shown in figure 7-70.
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7.18 F. OTHERS INSTRUCTION
The OTHERS screen is used for AS Language programming. The example shown in figure 7-71 demonstrates entering the AS Language command for a linear move to program point p1 (LMOVE p1). 1. 2 From the teach instruction screen, select F. OTHERS and press the SET key. From the character set screen, use the cursor keys to select the letter L and press the SET key. From the character set screen, use the cursor keys and the SET key to select and enter the remaining characters to complete the AS Language program instruction LMOVE p1. From the character set screen, use the cursor keys to select END and press the SET key. From the program instruction confirmation screen, press the 1 and the SET keys to accept the program instruction and enter it into the program. Press the 1 and the STORE POS keys to accept the program instruction and the current robot position and enter them into the program. The program instruction LMOVE p1 is entered into the program as step 3.
3.
4.
5.
6.
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TCH/ADD/OTHERS EASY LINE PG3 -1 Enter PROGRAM INSTRUCTION

BS END LMOVE P1________ PGM INSTRUCTION
4.
SET
or
SHIFT +
9 CONVR F
TCH/ADD/OTHERS EASY LINE PG3 -1 Enter following instruction?

(STORE POS key stores current location) LMOVE P1 (0:NO 1:YES) YES
1.
SET
5.
1 SPRAY .

!#$%&{}()*+,-./ @ABCDEFGHIJKLMNO PGM INSTRUCTION 0123456789:;<=>? PQRSTUVWXYZ [ l ] ^_ L_______________
SET
or
1 SPRAY .
STORE POS
TCH/ADD EASY LINE PG3 -1 Set instruction to ADD by SET key 6.

3 LMOVE p1 [ PROGRAM END ]
2. +
SET

!#$%&{}()*+,-./ @ABCDEFGHIJKLMNO PGM INSTRUCTION 0123456789:;<=>? PQRSTUVWXYZ [ l ] ^_ LMOVE P1________
3. +
SET
Figure 7-71 Others Instructions Selection
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Table 7-11 Others Instructions Character Descriptions Character a Description Moves the cursor to the left in the character string entry field. Moves the cursor to the right in the character string entry field.
Deletes the character before the BS cursor in the character string (Back Space) entry field. END Accepts the program instruction and displays the program instruction confirmation screen.
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Table 7-12 Keys Used for Character String Entry

Key(s) Character Moves the cursor left in the character set. At the end of a line, moves the cursor to the last position of the previous line.
SHIFT +
Moves the cursor eight characters to the left in the character set.
Moves the cursor right in the character set. At the end of a line, moves the cursor to the first position of the next line. Moves the cursor eight characters to the right in the character set.
SHIFT +
0 SPEED
through
9 CONVR F
Enters the selected number into the character string at the cursor.
SHIFT +
0 SPEED
Enters a space into the character string at the cursor position.
SHIFT +
1 SPRAY .
Enters a decimal point into the character string at the cursor position.
SHIFT +
5 DATA
Enters a comma into the character string at the cursor position. Enters a minus sign into the character string at the cursor position.
SHIFT +
6 TIMER -
2X=OUT A GUN
3X=IN
4 SMOTH
SHIFT +
7 CALL D
, ,
B TABLE 8 JUMP E MOVE
, ,
CSENS 9 CONVR F
An AS Language instruction, 1 through 6, defined in AUX 133, is inser ted into the character string at the cursor. AUX 133 is accessed using the multi function panel.
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Table 7-12 Keys Used for Character String Entry (Continued)

Key(s) Character
CLR
Deletes the entire character string.
SHIFT + CLR
The character before the cursor is delete from the character string.
SHIFT +
SUSPND
Shifts the cursor to the left one character in the character string.
SHIFT +
Shifts the cursor to the right one character in the character string.
SHIFT + SET
Accepts the entry and displays the program instruction confirmation screen.
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7.19 CHECKING PROGRAMS IN REPEAT MODE
This section describes the procedure for checking program operation in repeat mode.
WARNING
Before initiating the repeat mode of operation ensure all personnel are clear of the restricted space.
7.19.1 SELECTING REPEAT MODE 1. Use the procedure described in unit 4, Power ON/OFF Procedures, to power-up the controller. Place the HOLD/RUN switch in the HOLD position. Place the TEACH/REPEAT switch in the REPEAT position. Place the TEACH LOCK switch in the OFF position. Press the MOTOR POWER switch. The MOTOR POWER lamp illuminates. Before placing the HOLD/RUN switch in the RUN position set the REPEAT conditions as described below.
2. 3. 4. 5. 6.
7.19.2 SETTING REPEAT CONDITIONS 1. 2. 3. Press the STATUS key on the multifunction panel to display the STATUS screen. Press the REPEAT CONDITION key to display the REPEAT CONDITION keys. Set the REPEAT SPEED to 10 percent, REPEAT CONT/ONCE to ONCE, STEP CONT/ONCE to CONT, and RPS ON/OFF to OFF. Press the CYCLE START switch, the cycle start lamp illuminates. Place the HOLD/RUN switch in the RUN position. The program is executed in repeat mode once and the cycle start lamp is turned OFF. To run the program again press the CYCLE START switch. 7-107
4. 5.
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NOTE
If motor power does not engage, ensure the teach pendant, controller, and any external emergency stop switches are not engaged.
CAUTION
When a program is executed in repeat mode, the robot moves from its current location to the step of the program selected. To start the program from the first step, use the STEP NEXT key in teach mode to move the cursor to the beginning of the program. If the first step of the program is a linear move, the wrist may rotate to a angle 360 degrees from the taught rotation. This may cause twisting of the painting hoses. If the first step of the program is a joint move, unexpected wrist motion is not a concern. It is recommended the first step of a program be recorded as a joint move.
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7.20 PROGRAM EDIT WITH THE EXPLOSION-PROOF TEACH PENDANT 7.20.1 EDIT SCREEN DISPLAY Figure 7-72 shows the edit screen display areas. The item descriptions are given in table 7-13. EDIT mode is used to edit programs without moving the robot. The edit submodes are PROHIBIT, ADD, CHANGE, DELETE and SEARCH. The PROHIBIT mode disables the editing functions and permits display of program contents only.
EASY MOVE PG10 -0 EDIT/PRHBT Program contents are as follows

Figure 7-72 Edit Screen Display
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Table 7-13 Edit Screen Display Areas

Item Description Displays the correction mode (Prohibit/Add/Change/Delete/Search), selected. The correction modes are sub-modes of the edit mode. Use the
CRCT
key to change sub-mode.
Displays the manual operation coordinate system [Easy (XYZ1 and XYZ2)/Gun/Joint] selected. Use the
FRAME
key to change mode.
STEP NEXT
STEP
key and the
STEP BACK
Current program name display. Current program point (motion instruction) display. The motion instructions are counted from the top of the program and indicated as a point number. System message display. The sequential numbers indicate program steps. The highlighted step number indicates step commands are completed through this step. In the above example, program step commands are completed through step 3.
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7.20.2 EDIT MODE SELECTION
Follow the procedure in unit 4, Power ON/OFF Procedures, to power-up the controller and display the main menu. Follow the procedure shown below and in figure 7-73, to select the desired program and step number to edit. 1. From the main menu screen, select 2. EDIT using the cursor keys or the number keys and press the SET key. At the Enter program No. prompt use the number keys to select the desired program number. With the program number entered use the cursor keys to select the step number entry field. Use the number keys to enter the desired step number and press the SET key to accept the program and step numbers. If a step number greater than the number of steps in the selected program is entered the last step of the program is displayed. The default edit correction mode can be set by selecting PRHBT, ADD, or CHG using the CRCT key. 3. When the program number is entered the program content screen is displayed as shown in figure 7-73. In the example in figure 7-73, program No. 10, step No. 2 is selected.
2.
NOTE
If the edit mode default is not set, the operator must select the desired mode using the CRCT key each time an instruction is added or changed in the program.
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or
2X=OUT A GUN
SET
EDIT/PRHBT Enter program No.
EASY MOVE PG10 -0

_10 __2
PROGRAM No. (0~999) STEP No. (0~999)
0 SPEED 9 CONVR F
SET
CRCT
EDIT/PRHBT EASY MOVE PG10 -0 Program contents are as follows 1 AIRCUT_SPEED 800mm/s 2 AIRCUT_JSPED 100% 3 JMOVE (JOINT)
Figure 7-73 Edit Mode Selection
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7.20.3 EDIT CORRECTION MODES
The edit correction mode is selected using the CRCT key. The default correction mode is selected using SHIFT + CRCT key combination. Each time the CRCT key is pressed the edit mode display scrolls to the next mode, PROHIBIT, ADD, CHANGE, DELETE, and SEARCH. The PROHIBIT mode does not allow program instruction edits. The ADD mode allows program instructions to be inserted after the selected program instruction (step after the cursor position). The CHANGE and DELETE modes are used to change or delete the selected step (step at the cursor position). 7.20.4 PROGRAM INSTRUCTION EDITING In EDIT mode, select the insertion, change, or delete point using the cursor keys. In the example shown in figure 7-74: If ADD mode is selected, the added program instruction is inserted after line 2 AIRCUT_JSPEED. When a program instruction is added, the existing program instructions are renumbered accordingly. If CHANGE mode is selected, line 2, AIRCUT_JSPEED is changed. If DELETE mode is selected, line 2, AIRCUT_JSPEED is deleted, line 3, JMOVE (JOINT) becomes line 2, and the following steps are renumbered accordingly.
Figure 7-74 Edit Mode Screen
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7.20.5 EDIT SEARCH MODE
In edit mode, use the CRCT key to select the EDIT/SEARCH mode. From the search mode instruction selection screen, use the cursor keys, or the number keys, to choose the program instruction to search for in the selected program (Figure 7-75). The search result screen displays all occurrences of the selected program instruction in the program. The cursor keys are used to select the desired step that contains the program instruction to CHANGE or JUMP TO. In the example shown in figure 7-75, a search for the SMOOTH instruction is performed. 1. With the selected program open in the edit mode, use the CRCT key to select the SCH mode. For information on selecting a program in edit mode, see section 7.20.2. At the edit instruction screen, select the desired program instruction to search for in the selected program and press the SET key. In the example shown in figure 7-75 4. SMOOTH is selected The display changes to show the search results. The step number in the program, that contains the first occurrence of the program instruction found, is highlighted by the cursor position. At the search results screen, the cursor keys may be used to move the cursor to the next occurrence of the program instruction. Press the SET key to change the value or jump to the instruction highlighted by the cursor. 4. At the disposal select screen, select 0. CHANGE to change the value of the instruction displayed in the search result screen or 1. JUMP to jump to the step selected with the cursor at the search result screen. In the example shown in figure 7-75, 0. CHANGE is selected. When change is selected the display changes to a screen to edit the program instruction found using the search. Change the value as needed and press the SET key to enter the new value into the program instruction.
2.
3.
5.
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EDIT/SCH EASY MOVE PG10 -0 Program contents are as follows 1 AIRCUT_SPEED 800mm/s 2 AIRCUT_JSPED 100% 3 JMOVE (JOINT)
EDIT/SCH/SMOOTH EASY MOVE PG10 -1 Enter SMOOTH_RANGE value RANGE (1~999) _8[mm]
1.
CRCT
EDIT/SCH EASY MOVE PG3 -1 b Select an instruction to SEARCH

5.
SET
EDIT/SCH/SMOOTH EASY MOVE PG10 -1 Search result of SMOOTH 5 SMOOTH_RANGE 80mm 6 ACCEL 10% 10 SMOOTH_RANGE 1mm
6.
CRCT
or
4 SMOTH CSENS
or
2.
SET
EDIT/SCH/SMOOTH EASY MOVE PG10 -1 Search result of SMOOTH 5 SMOOTH_RANGE 50mm 6 ACCEL 10% 10 SMOOTH_RANGE 1mm
3.
SET
EDIT/SCH/SMOOTH EASY MOVE PG10 -1 Select a disposal to selected line 0. CHANGE 1. JUMP TO
4.
0 SPEED
or
Figure 7-75 Search Mode Example
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7.20.6 MOVE INSTRUCTION EDITING
The robots current positional data cannot be recorded in edit mode. To edit the positional data, numeric values are entered at the Enter position data screen (Figure 7-76). 1. With the selected program open in edit mode, use the CRCT key to select the EDIT/ CHG mode and press the SET key. Use the cursor keys to select the program step with the move instruction to edit. At the edit instruction selection screen, select E. MOVE and press the SET key. At the Enter position data screen use the cursor and number keys to change the positional data as needed.
2. 3. 4.
To add positional data, select EDIT/ADD mode and to delete positional data, select EDIT/DEL mode.
CAUTION
When MOVE instructions and/or positional data are changed in edit mode, confirm robot motion in check mode before running the program in repeat mode. The new data may cause unexpected robot motion.
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EDIT/CHG EASY MOVE PG10 -1 Program contents are as follows 1 AIRCUT_SPEED 800mm/s 2 AIRCUT_JSPED 100% 3 JMOVE (JOINT)
SET
EDIT/CHG EASY MOVE PG10 -0 b Set instruction to ADD by SET key

or
SHIFT +
8 JUMP E MOVE
SET
EDIT/CHG/MOVE Enter position data

AXIS_1 AXIS_2 AXIS_3 AXIS_4 AXIS_5 AXIS_6 TRAVEL X TRAVEL Y TRAVEL Z
EASY MOVE PG10 -1 b

_39.14[deg] -40.70[deg] _43.42[deg] 120.25[deg] -40.13[deg] 153.49[deg] __100.[mm] ____0.[mm] ____0.[mm]
Figure 7-76 Editing Move Positional Data
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7.20.7 EXITING PROGRAM EDIT MODE
When editing is complete use the END key, or the previous screen key, to exit program edit mode (Figure 7-77). When the END key is used to exit program edit mode, the exit mode confirmation screen is displayed. Answer YES to exit to the main menu screen. Answer NO to return to the program edit mode. When the previous screen key is used, the program number input screen is displayed.
END
+ SET
TCH/PRHBT Enter program No.
EASY MOVE PG10 -0
EDIT/END EASY MOVE PG10 -0 Make sure finish teaching program 10 ? END (0:NO 1:YES) YES
PROGRAM No. (0~999)
_10
1 SPRAY .
+ SET

Figure 7-77 Exiting Edit Mode
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7.21 PROGRAM EDIT SCREEN, MULTI FUNCTION PANEL This section covers editing program steps from the multi function panel. The following sections cover how to cut, copy, paste or delete program steps. 1. 2. Press the TEACHING key (Figure 7-78). Press the PROGRAM EDIT key from the drop down TEACHING menu. If the PROGRAM EDIT key is not displayed, access AUX 96 Environment Data of Panel to enable the program edit function. Refer to unit 9 for information on auxiliary functions. 3. Press the PROGRAM key, and select the program to edit.
PROGRAM pg99
STEP 1
PC
TEACHING STATUS
MENU
Cleared error state. Normally completed. Normally completed.

PROGRAM EDIT (TEACH DATA)
AS TEACHING
M-OFF HOLD TEACH SPRY ON
SPRAY_JSPEED 15%
PROGRAM EDIT
DELETE
CANCEL
CUT
PASTE
TEACH GUN DATA SIGNAL
OX WX
LOCATION DATA
COPY
MODE INSERT /
OVERWRITE
AUX SET&DISP
PARTS COPY
RETURN
Figure 7-78 MFP Program Edit Screen
April 8, 2002
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7.21.1 HOW TO CUT AND PASTE STEPS WITHIN A PROGRAM
NOTE This procedure is used to cut and paste individual program steps by omitting steps 7-8 below.
PROGRAM pg99
STEP 1
PC
TEACHING STATUS
MENU
FIRST STEP
STEP SELECT
EXIT
SPRAY_JSPEED 15%
DELETE CANCEL
CUT
PASTE
OX WX
LOCATION DATA
COPY
MODE INSERT /
OVERWRITE
AUX SET&DISP
PARTS COPY
RETURN
Figure 7-79 Step Editing
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1. 2. 3. 4. 5. 6. 7. Set the TEACH LOCK switch to ON. Set the TEACH/REPEAT switch to TEACH. Press the STEP key.
Press the BACKWARD or FORWARD key to scroll to the first step to cut. Press the CUT key. Press the STEP key (the auxiliary data keys change from yellow to magenta). Press the FORWARD key to scroll to the last step to cut (10 steps maximum; the auxiliary data keys change from magenta to yellow). Press the STEP key (the auxiliary data keys change from yellow to magenta). Press the EXIT key.
8. 9.
10. Press the RETURN key (the auxiliary data keys change from magenta to yellow). 11. Press the STEP key (the auxiliary data keys change from yellow to magenta). 12. Press the BACKWARD or FORWARD key to select the insertion point. 13. Press the EXIT key. 14. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion. 15. Press the PASTE key (the auxiliary data keys change from yellow to magenta). 16. Press the RETURN key (the auxiliary data keys change from magenta to yellow; the copied steps are inserted before the program step selected in step 14 above). 17. (Optional) Repeat steps 8-16 above to cut and paste up to 10 more program steps. 18. Exit the PROGRAM EDIT function.
April 8, 2002
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7.21.2 HOW TO COPY AND PASTE STEPS WITHIN A PROGRAM
NOTE This procedure is used to copy and paste individual program steps by omitting steps 12-13 below.
PROGRAM pg99
STEP 1
PC
TEACHING STATUS
MENU
FIRST STEP
STEP SELECT
EXIT
SPRAY_JSPEED 15%
DELETE CANCEL
CUT
PASTE
OX WX
LOCATION DATA
COPY
MODE INSERT /
OVERWRITE
AUX SET&DISP
PARTS COPY
RETURN
1. 2. 3.
Set the TEACH LOCK switch to ON. Set the TEACH/REPEAT switch to TEACH. Select AUX 96 Environment Data of Panel to enable the PROGRAM EDIT function (if not enabled). Press the EXIT key twice. Press the TEACHING key. Press the PROGRAM EDIT key from the drop down TEACHING menu. Press the PROGRAM key, and select the program to edit.
4. 5. 6. 7.
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8. 9. Press the STEP key.
Press the BACKWARD or FORWARD key to scroll to the first step to cut.
10. Press the COPY key. 11. Press the STEP key (the auxiliary data keys change from yellow to magenta). 12. Press the FORWARD key to scroll to the last step to copy (10 steps maximum; the auxiliary data keys change from magenta to yellow). 13. Press the STEP key (the auxiliary data keys change from yellow to magenta). 14. Press the EXIT key. 15. Press the RETURN key (the auxiliary data keys change from magenta to yellow). 16. Press the STEP key (the auxiliary data keys change from yellow to magenta). 17. Press the BACKWARD or FORWARD key to select the insertion point. 18. Press the EXIT key. 19. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion. 20. Press the PASTE key (the auxiliary data keys change from yellow to magenta). 21. Press the RETURN key (the auxiliary data keys change from magenta to yellow; the copied steps are inserted before the program step selected in step 14 above) 22. (Optional) Repeat steps 8-16 above to copy and paste up to 10 more program steps. 23. Exit the PROGRAM EDIT function.
April 8, 2002
7-123
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7.21.3 HOW TO COPY AND PASTE STEPS TO ANOTHER PROGRAM
NOTE
This procedure is used to copy and paste individual program steps by omitting steps 12-13 below.
PROGRAM pg99
STEP 1
PC
TEACHING STATUS
MENU
FIRST STEP
STEP SELECT
EXIT
SPRAY_JSPEED 15%
DELETE CANCEL
CUT
PASTE
OX WX
LOCATION DATA
COPY
MODE INSERT /
OVERWRITE
AUX SET&DISP
PARTS COPY
RETURN
1. 2. 3.
Set the TEACH LOCK switch to ON. Set the TEACH/REPEAT switch to TEACH. Select AUX 96 Environment Data of Panel to enable the PROGRAM EDIT function (if not enabled). Press the EXIT key twice. Press the TEACHING key. Press the PROGRAM EDIT key from the drop down TEACHING menu. Press the PROGRAM key, and select the program to copy lines from.
4. 5. 6. 7.
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10. Press the COPY key. 11. Press the STEP key (the auxiliary data keys change from yellow to magenta). 12. Press the FORWARD key to scroll to the last step to copy (10 steps maximum; the auxiliary data keys change from magenta to yellow). 13. Press the STEP key (the auxiliary data keys change from yellow to magenta). 14. Press the EXIT key. 15. Press the RETURN key (the auxiliary data keys change from magenta to yellow). 16. Press the PROGRAM key, and select the destination program. 17. Press the STEP key. 18. Press the BACKWARD or FORWARD key to select the insertion point. 19. Press the EXIT key. 20. (Optional) Press the INSERT/OVERWRITE key to select the type of insertion. 21. Press the PASTE key (the auxiliary data keys change from yellow to magenta) 22. Press the RETURN key (the auxiliary data keys change from magenta to yellow; the copied steps are inserted before the program step selected in step 18 above) 23. (Optional) Repeat steps 7-22 above to copy and paste up to 10 more program steps. 24. Exit the PROGRAM EDIT function.
April 8, 2002
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7.21.4 HOW TO DELETE STEPS WITHIN A PROGRAM
NOTE This procedure is used to delete individual program steps by omitting steps 12-13 below.
PROGRAM pg99
STEP 1
PC
TEACHING STATUS
MENU
FIRST STEP
STEP SELECT
EXIT
SPRAY_JSPEED 15%
DELETE CANCEL
CUT
PASTE
OX WX
LOCATION DATA
COPY
MODE INSERT /
OVERWRITE
AUX SET&DISP
PARTS COPY
RETURN
1. 2. 3.
Set the TEACH LOCK switch to ON. Set the TEACH/REPEAT switch to TEACH. Select AUX 96 Environment Data of Panel to enable the PROGRAM EDIT function (if not enabled). Press the EXIT key twice. Press the TEACHING key. Press the PROGRAM EDIT key from the drop down TEACHING menu. Press the PROGRAM key, and select the program to edit.
4. 5. 6. 7.
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10. Press the DELETE key. 11. Press the STEP key (the auxiliary data keys change from yellow to magenta). 12. Press the FORWARD key to scroll to the last step to delete (10 steps maximum; the auxiliary data keys change from magenta to yellow). 13. Press the STEP key (the auxiliary data keys change from yellow to magenta). 14. Press the EXIT key. 15. Press the RETURN key (the auxiliary data keys change from magenta to yellow). 16. (Optional) Repeat steps 8-15 above to delete up to 10 more program steps. 17. Exit the PROGRAM EDIT function.
April 8, 2002
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7.21.5 HOW TO COPY AUXILIARY DATA 1.
Follow steps 1 through 8 of section 7.21.1 HOW TO CUT AND PASTE STEPS WITHIN A PROGRAM. Once at the desired step, press the MODE INSERT/OVERWRITE key to display MODE OVERWRITE. Press the PARTS COPY key. Select the auxiliary data to be copied (the auxiliary data key(s) change color from yellow to magenta). Press the RETURN key. Use the BACKWARD or FORWARD key to select a new position for the copied data or select a desired program using the PROGRAM key. Press the PASTE key. Press the RETURN key; the copy steps have now been placed. To exit the PROGRAM EDIT function, exit the step select screen and select another function.
2.
3. 4.
5. 6.
7. 8. 9.
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8.0 8.1 8.1.1 8.2 8.3 8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.5
PROGRAM EXECUTION
PROGRAM EXECUTION .................................................................................. 8-2 Program Execution Preparation ......................................................................... 8-2 Repeat Operation Procedure ............................................................................. 8-3 Stopping Program Execution.............................................................................. 8-7 Suspending and Restarting Program Execution ................................................ 8-7 Repeat Condition Settings ................................................................................. 8-8 Repeat Speed .................................................................................................... 8-8 REPEAT CONT/ONCE ....................................................................................... 8-8 STEP CONT/ONCE ........................................................................................... 8-9 RPS ENABLE/DISABLE .................................................................................... 8-9 DRYRUN ON/OFF .............................................................................................. 8-9 Wait Override ................................................................................................... 8-10
April 8, 2002
8-1
Kawasak
8.0 PROGRAM EXECUTION
PROGRAM EXECUTION
This unit provides information on running programs in REPEAT mode on a daily basis. 8.1 PROGRAM EXECUTION PREPARATION Confirm robot operation in CHECK mode before attempting new or modified program execution in REPEAT mode.
!
1.
WARNING
Ensure all personal are clear of the restricted and safeguarded areas. Ensure all required safety systems are in place and operational.
2.
!
1.
CAUTION
Inspect tooling and peripherals and repair as necessary before program execution in REPEAT mode. Ensure the robot path does not interfere with peripherals. Ensure the robot is in the home or starting position.
2.
3.
8-2
April 8, 2002
Kawasak
8.1.1 REPEAT OPERATION PROCEDURE
PROGRAM EXECUTION
WARNING
When servo power is on, do not enter the restricted space. Setting the TEACH/REPEAT switch to REPEAT causes servo power to engage after a 0.5 second delay. If a program is on the stack, and proper input signals are present, it is possible for robot motion to begin.
To execute a program in repeat mode refer to the following procedure and figures 8-1 through 8-3. 1. 2. Set the HOLD/RUN switch to the HOLD position. Set the controller main disconnect switch to the ON position. The control power lamp illuminates. Set the TEACH LOCK switch on the explosion-proof teach pendant to OFF. Set the REMOTE/LOCAL switch to the desired position. The remote setting requires an external input signal to execute a program. The local setting allows the operator to select and execute a program from the controller. 5. Set the TEACH/REPEAT switch to the REPEAT position.
3. 4.
April 8, 2002
8-3
Kawasak
PROGRAM EXECUTION
Main Disconnect Error Lamp Error Reset Lamp Teach Repeat Switch
Operation Panel Emergency Stop Motor Power Cycle Start Run Hold Remote Local
Control Power Lamp
Explosion-Proof Teach Pendant Teach Lock
Figure 8-1 Explosion-Proof C Controller
8-4
April 8, 2002
Kawasak
6.
PROGRAM EXECUTION
Select the desired program to execute from the program select screen on the multi function panel (Figure 8-2).
PROGRAM
8
PROGRAM SELECT
pg?? pg10 work1 test
9 7 5 3 1
RETURN
pg1 pg2 pg8
6 4 2
DELETE
EXIT
BS
PROGRAM LIST
CHARACTER

RETURN
Figure 8-2 Program Select Screen
April 8, 2002
8-5
Kawasak
7.
PROGRAM EXECUTION
Select the STATUS screen on the multi function panel and press the REPEAT CONDITION key to set the desired repeat conditions. The repeat conditions include: SPEED, REPEAT CONT/ONCE, STEP CONT/ONCE, RPS ENABLE/DISABLE, and DRYRUN ON/OFF. The selected repeat conditions are displayed at the top right of the multi function panel status screen (Figure 8-3). For more information on repeat conditions refer to section 8.4.
PROGRAM pg99
STEP 1
PC
TEACHING
SPEED 10%
97-03-18 17:30
STATUS
MENU
SRV-ON RUN REPEAT

SPRAY ON
REPEAT REPEAT 10% 10%
REPEAT
CONDITION CONDITION
STEP
FORWARD
RECORD ACCEPT
REPEAT CONT
STEP CONT
RPS
DISABLE
DRYRUN
OFF
JT1 -26.248 X 532.690
JT2 -5.518 Y 656.487
JT3 -37.812 Z 1022.774
JT4 71102 O -154.463
JT5 -75.092 A 113.890
JT6 11.449 T 46.616
JT7 5.315
Figure 8-3 Setting Repeat conditions
8. 9.
Set the HOLD/RUN switch to the RUN position. Press the CYCLE START switch. The cycle start lamp illuminates. The selected program executes using the repeat conditions set in step 7.
If the program does not execute as expected set the HOLD/RUN switch in the HOLD position. In an emergency situation use the EMERGENCY STOP switch. Repeat conditions can be reset during program execution in repeat mode.
8-6
April 8, 2002
Kawasak
8.2 STOPPING PROGRAM EXECUTION 1.
PROGRAM EXECUTION
Set the HOLD/RUN switch to the HOLD position. The robot stops and the CYCLE START lamp remains illuminated. Set the TEACH/REPEAT switch to the TEACH position, the CYCLE START and MOTOR POWER lamps are set to OFF. Press the EMERGENCY STOP switch. Set the controller main disconnect to the OFF position.
2.
3. 4.
8.3 SUSPENDING AND RESTARTING PROGRAM EXECUTION 1. Set the HOLD/RUN switch to the HOLD position. The robot stops and the CYCLE START lamp remains illuminated. To restart program execution set the HOLD/RUN switch to the RUN position.
2.
April 8, 2002
8-7
Kawasak
8.4 REPEAT CONDITION SETTINGS
PROGRAM EXECUTION
This section describes the repeat conditions settings. Refer to figures 8-4 and 8-5 during this discussion. 8.4.1 REPEAT SPEED At the multi function panel status screen, press the REPEAT speed key. The speed increase and decrease 10% keys are displayed. Use the speed adjust keys to set the desired program speed. The selected speed is displayed at the top right of the status screen.
PROGRAM pg99
STEP 1
PC
TEACHING
SPEED 10%
97-03-18 17:30
STATUS
MENU
SRV-ON RUN REPEAT

SPRAY ON
REPEAT 10%
REPEAT
CONDITION
STEP
FORWARD
RECORD ACCEPT
10%
JT1 -26.248 X 532.690
10%
JT2 -5.518 Y 656.487 JT3 -37.812 Z 1022.774 JT4 71102 O -154.463 JT5 -75.092 A 113.890 JT6 11.449 T 46.616 JT7 5.315
Figure 8-4 Repeat Speed Setting
8.4.2 REPEAT CONT/ONCE Pressing the REPEAT CONT key toggles the key to REPEAT ONCE. Selecting the CONT option allows the program to run continuously. Selecting ONCE allows the program to run one time.
8-8
April 8, 2002
Kawasak
8.4.3 STEP CONT/ONCE
PROGRAM EXECUTION
Pressing the STEP CONT key toggles the key to STEP ONCE. Selecting the CONT option allows the program to run continuously. Selecting ONCE allows the program to run only one step at a time. When ONCE is selected for this key, an additional STEP FORWARD key is displayed directly above it. Pressing the STEP FORWARD key allows the operator to execute the program one step at a time. 8.4.4 RPS ENABLE/DISABLE The RPS (random program selection) key is used to select programs from a remote source. Pressing the RPS key changes the display from ENABLE to DISABLE. If ENABLE is selected, an input signal to the controller selects the program to run. If DISABLE is selected, programs are selected by the operator. 8.4.5 DRYRUN ON/OFF The DRYRUN key allows the operator to execute programs without any robot motion. Signals are output and program logic is executed, but there is no movement of the robot when dryrun is ON. When dryrun is OFF, programs run with full robot motion.
PROGRAM pg99
STEP 1
PC
TEACHING
SPEED 10%
97-03-18 17:30
STATUS
MENU
SRV-ON RUN REPEAT

SPRAY ON
REPEAT REPEAT 10% 10%
REPEAT
CONDITION CONDITION
STEP
FORWARD
RECORD ACCEPT
REPEAT CONT
STEP CONT
RPS
DISABLE
DRYRUN
OFF
JT1 -26.248 X 532.690
JT2 -5.518 Y 656.487
JT3 -37.812 Z 1022.774
JT4 71102 O -154.463
JT5 -75.092 A 113.890
JT6 11.449 T 46.616
JT7 5.315
Figure 8-5 Setting Repeat conditions
April 8, 2002
8-9
Kawasak
8.5 WAIT OVERRIDE
M-ON RUN WAITING
PROGRAM EXECUTION
The wait override procedure is a method of bypassing an expected input signal when a program is running and a WX (input) signal is not received. When a wait condition occurs, with any teaching or status screen displayed, the status display changes to waiting. The operator can access the wait override screen (see figure 8-6) by pressing the status display area. From this screen, the operator can press the individual WX signal number(s) to select the signal(s) to override, or select ALL to override all WX signals that are not received.
SRV-ON RUN WAITING

SPRAY ON
WAIT
WX 1
WX 2
WX 3
WX 4
ALL
CONDITION
WAIT
OVERRIDE
5 SPRAY #1,ON
Figure 8-6 Wait Override Screen
8-10
April 8, 2002
Kawasak
SPEED 50% WAITING
MENU
PROGRAM EXECUTION
99-07-12 19:43
Figure 8-7 Repeat Condition Wait Display
When a wait condition occurs with a function or interface panel screen displayed, the repeat condition area indicates a wait condition (see figure 8-7). The operator can access the wait override screen by exiting the function, or interface panel screen, and pressing the status display area. When a wait condition occurs with the keyboard screen displayed, a wait condition is not indicated. The operator can access the wait override screen by exiting the keyboard screen and pressing the status display area.
April 8, 2002
8-11
Kawasak
9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.16.1 9.17 9.18 9.19 9.20 9.21 9.22 9.23 9.24 9.24.1 9.24.2 9.24.3 9.24.4 9.24.5 9.24.6 9.24.7 9.24.8 9.24.9 9.24.10 9.24.11 9.24.12 9.24.13 9.24.14 9.24.15 9.24.16 9.24.17 9.24.18
AUXILIARY FUNCTIONS
AUXILIARY FUNCTIONS .............................................................................. 9-5 Auxiliary Function List Multi Function Panel ................................................... 9-6 AUX 2 Location & Speed Display................................................................. 9-11 AUX 3 Data Transfer .................................................................................... 9-13 AUX 5 Kill Program ...................................................................................... 9-14 AUX 10 MemoryPC Card (Save) ............................................................... 9-15 AUX 11 PC CardMemory (Load) ............................................................... 9-17 AUX 12 File Directory .................................................................................. 9-18 AUX 14 PC Card AUX Function ................................................................... 9-19 AUX 41 Zeroing ........................................................................................... 9-20 AUX 42 Pos. Error Range at E-Stop ............................................................ 9-22 AUX 43 Encoder Error Range ...................................................................... 9-23 AUX 44 Zeroing Data Set/Display ................................................................ 9-24 AUX 46 Installation Type .............................................................................. 9-25 AUX 47 Base Coordinate ............................................................................. 9-26 AUX 48 Tool Dimensions.............................................................................. 9-27 AUX 51 Software Limit ................................................................................. 9-28 Overtravel Error Recovery ........................................................................... 9-29 AUX 53 Accuracy ......................................................................................... 9-30 AUX 55 Slow Repeat Mode ......................................................................... 9-33 AUX 56 Check Speed .................................................................................. 9-34 AUX 57 Teach Speed ................................................................................... 9-35 AUX 70 Memory Available ........................................................................... 9-36 AUX 71 Record Data (PRG CHG) Inhibit ..................................................... 9-37 AUX 73 Spray On/Off ................................................................................... 9-38 AUX 75 System Switch ................................................................................ 9-39 Check.Hold Switch ....................................................................................... 9-41 CP (Continuous Path) Switch....................................................................... 9-41 CYCLE.STOP Switch ................................................................................... 9-42 OX.Preout Switch ......................................................................................... 9-43 Prefetch.Sigins Switch ................................................................................. 9-44 QTool Switch ................................................................................................ 9-44 REP_ONCE (Repeat Once) Switch ............................................................. 9-44 RPS (Random Program Selection) Switch .................................................. 9-44 STP_ONCE (Step Once) Switch.................................................................. 9-45 AFTER.WAIT.TIMER Switch ........................................................................ 9-45 SPOT_OP .................................................................................................... 9-45 Messages Switch ......................................................................................... 9-45 Screen Switch .............................................................................................. 9-45 AUTOSTART.PC Switches ........................................................................... 9-46 ERRSTART.PC Switch ................................................................................. 9-46 DISPIO_01 Switch ....................................................................................... 9-46 HOLD.STEP ................................................................................................. 9-46 WS_COMPOFF ........................................................................................... 9-47 9-1
April 8, 2002
Kawasak
9.24.19 9.24.20 9.25 9.26 9.27 9.28 9.29 9.30 9.31 9.32 9.33 9.34 9.35 9.36 9.37 9.38 9.39 9.40 9.41 9.41.1 9.41.2 9.41.3 9.42 9.43 9.44 9.45 9.45.1 9.45.2 9.45.3 9.45.4 9.45.5 9.45.6 9.45.7 9.46 9.46.1 9.46.2 9.46.2.1 9.46.2.2 9.46.3 9.46.3.1 9.46.3. 9.46.3.3 9.46.3.4 9.47 9-2
AUXILIARY FUNCTIONS
WS.ZERO ................................................................................................... 9-47 PLC.CHECK ............................................................................................... 9-47 AUX 76 Home Position ............................................................................... 9-48 AUX 78 Clear Check Sum Error ................................................................. 9-49 AUX 87 Program Parameter/Comment ...................................................... 9-50 AUX 88 Change Program Name ................................................................ 9-51 AUX 90 Software Version Display .............................................................. 9-53 AUX 91 Environment Data ......................................................................... 9-54 AUX 95 Environment Data2 ....................................................................... 9-55 AUX 96 Environment Data of Panel ........................................................... 9-56 AUX 99 CHECK SPEC. (Check Specification) ........................................... 9-57 AUX 100 System Init. (System Initialization) .............................................. 9-58 AUX 101 Battery Error Check .................................................................... 9-59 AUX 103 Touch Panel Short Circuit Check ................................................. 9-60 AUX 110 Time ............................................................................................ 9-61 AUX 111 Dedicated Input Signal ................................................................ 9-62 AUX 112 Dedicated Output Signal ............................................................. 9-63 AUX 113 Dedicated Signal Display ............................................................ 9-64 AUX 114 Gun Specification ........................................................................ 9-65 Gun Specifications ..................................................................................... 9-66 Painting/Sealing Gun Definition.................................................................. 9-67 Gun Relative Distance Check Function ...................................................... 9-68 AUX 120 Error Logging .............................................................................. 9-70 AUX 122 Operation Logging ...................................................................... 9-71 AUX 140 Encoder Rot. Counter Reset ....................................................... 9-72 AUX 142 Program Queue .......................................................................... 9-73 Display ....................................................................................................... 9-75 Register ...................................................................................................... 9-76 Insert .......................................................................................................... 9-77 Delete ......................................................................................................... 9-78 All Delete .................................................................................................... 9-80 Environment Set ......................................................................................... 9-81 Program Queue Registration Sequence .................................................... 9-83 AUX 143 Start Delay .................................................................................. 9-85 Start Delay Common Delay Distance ......................................................... 9-86 Start Delay Individual Delay Distance ........................................................ 9-87 Start Delay Individual Delay Distance Setting ............................................ 9-88 Start Delay Same Delay Distance Setting .................................................. 9-89 Start Delay, Multi Start Delay Distance ...................................................... 9-90 Start Delay, Multi Start Delay Distance Display .......................................... 9-90 2Start Delay, Multi Start Delay Distance Change ....................................... 9-91 Start Delay, Multi Start Delay Distance Delete ........................................... 9-92 Start Delay, Multi Start Delay Distance All Delete ...................................... 9-93 AUX 144 Interrupt Program ........................................................................ 9-94 April 8, 2002
Kawasak
9.48 9.49 9.50 9.50.1 9.50.2 9.51 9.52 9.53 9.54 9.55 9.56 9.57 9.58 9.58.1 9.58.2 9.59 9.60 9.60.1 9.60.2 9.60.3 9.60.4 9.60.5 9.61 9.61.1 9.61.2 9.61.3 9.61.4 9.61.5 9.61.6 9.61.7 9.61.8 9.61.9 9.61.10 9.61.11 9.61.11.1 9.61.12 9.61.13 9.61.14 9.61.15 9.61.16 9.61.17 9.61.18 9.61.19 9.61.20
AUXILIARY FUNCTIONS
AUX 149 Tool Registration ........................................................................ 9-95 AUX 153 Programs in Detail ..................................................................... 9-97 AUX 154 Total Repeat Cycles of Program ................................................ 9-98 Total Repeat Cycles of Program, Display and Modify ............................... 9-99 Total Repeat Cycles of Program, All Clear ............................................... 9-99 Home Position Check Axis Set, AUX 155 ............................................... 9-100 AUX 158 Dout Function Assignment ...................................................... 9-101 AUX 159 History Clear ........................................................................... 9-103 AUX 166 PG Partial Delete .................................................................... 9-104 AUX 167 Singular Point Alarm Range Set .............................................. 9-105 AUX 168 Difference of Work/Air-Cut Speed ........................................... 9-107 AUX 169 Operation Condition Setting .................................................... 9-108 AUX 172 Syscount Display/Setting ......................................................... 9-110 Syscount Display/Setting, Display .......................................................... 9-111 Syscount Display/Setting, General Syscount Setting ............................. 9-111 AUX 173 Moving Area XYZ Limit ............................................................ 9-113 AUX 176 Data Bank ............................................................................... 9-114 Data Bank, List ....................................................................................... 9-115 Data Bank, Edit ...................................................................................... 9-116 Data Bank, Copy .................................................................................... 9-117 Data Bank, Delete .................................................................................. 9-118 Data Bank, Environment Set .................................................................. 9-119 Auxiliary Functions, Explosion-Proof Teach Pendant ............................. 9-120 Auxiliary Functions List, Explosion-Proof Teach Pendant ....................... 9-122 Program Setting, 1-0 .............................................................................. 9-126 Repeat Status Display, 1-1 ..................................................................... 9-127 Production Rate Value Setting, 1-2......................................................... 9-129 Product Paint_IO Ratio Setting, 1-3 ....................................................... 9-130 Program List Display (Detail), 3-0-0 ........................................................ 9-131 Program Number List Display, 3-0-1 ....................................................... 9-132 Available Memory Capacity Display, 3-0-2.............................................. 9-133 Program Name Registration, 3-0-3 ......................................................... 9-134 Program Copy, 3-1 .................................................................................. 9-136 Program Link, 3-2 ................................................................................... 9-137 Program Link, Same Source and Destination Program, 3-2 ................... 9-138 Program Deletion, 3-3 ............................................................................ 9-139 Partial Program Copy, 3-4-0 ................................................................... 9-140 Partial Program Deletion, 3-4-1 .............................................................. 9-142 Parallel Shift, 3-5-0 ................................................................................. 9-144 Gun-Tip Direction Shift, 3-5-1 ................................................................. 9-145 Mirror Image Conversion, 3-5-2 .............................................................. 9-146 Traveler Shift with Gun Tip Fixed, 3-5-3 .................................................. 9-147 Shuttle Right-Left Conversion (Option), 3-5-4 ........................................ 9-148 Data Bank Editing, 4-0 ........................................................................... 9-149 9-3
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9.61.21 9.61.22 9.61.23 9.61.24 9.61.25 9.61.26 9.61.27 9.61.28 9.61.29 9.61.30 9.61.31 9.61.32 9.61.33 9.61.34 9.61.35 9.61.36 9.61.37 9.61.37.1 9.61.37.2 9.61.37.3 9.61.37.4 9.61.37.5 9.61.37.6 9.61.37.7 9.61.38 9.61.39 9.61.40 9.61.41 9.61.42 9.61.43 9.61.43.1 9.61.43.2 9.61.43.3 9.61.43.4 9.61.43.5 9.61.43.6 9.61.43.7
AUXILIARY FUNCTIONS
Data Bank Details Display, 4-1-0 ............................................................. 9-152 Data Bank Number Display, 4-1-1 ........................................................... 9-153 Gun Position and Angle Display, 5-0-0 .................................................... 9-154 Joint Value Display, 5-0-1 ........................................................................ 9-155 Joint Command Value Display, 5-0-2 ....................................................... 9-156 Encoder Value Display, 5-0-3 .................................................................. 9-157 Position Display of Traverse Axes, 5-0-4.................................................. 9-158 Table Position Display (Option), 5-0-5 ..................................................... 9-159 Gun Position and Wrist Angle Display, 5-0-6 ........................................... 9-160 External Output Signal Display, 5-1-0 ...................................................... 9-161 External Input Signal Display, 5-1-1 ........................................................ 9-162 Internal Signals Display, 5-1-2 ................................................................. 9-163 Home Signals, 5-1-3 ................................................................................ 9-164 General Counter Display, 5-2-0 ............................................................... 9-165 Dedicated Counter Display, 5-2-1 ............................................................ 9-166 Shuttle Condition Display (Option), 5-3 ................................................... 9-167 Operation Condition Selection, 6-0 ......................................................... 9-168 Operation Condition Selection: External Output, 6-0-0 ........................... 9-168 Operation Condition Selection: Input Wait, 6-0-1..................................... 9-170 Operation Condition Selection: Conveyor Wait, 6-0-2.............................. 9-171 Operation Condition Selection: Timer Wait, 6-0-3 .................................... 9-172 Operation Condition Selection: Conveyor Track (CV), 6-0-4 .................... 9-173 Operation Condition Selection: Door Sensor Setting, 6-0-5-0 ................. 9-175 Operation Condition Selection: Camera Sensing Setting, 6-0-5-1 .......... 9-176 Current Conveyor Position Setting (CURRENT CV_POS), 6-1 ............... 9-177 Counter Value Setting, 6-2 ...................................................................... 9-178 Location Variables Registration, 6-3 ........................................................ 9-179 Error History Display, 7-0 ......................................................................... 9-181 Total Playback Count Display, 7-1 ........................................................... 9-182 Manual External Output Execution: General Signal, 8-0 ......................... 9-184 Manual External Output Execution: Spray Signals, 8-1 ........................... 9-185 Manual External Output Execution: Flow Rate, 8-2 ................................. 9-186 Manual External Output Execution: Shaping/Pattern Air, 8-3 .................. 9-187 Manual External Output Execution: Air Motor/Atomizing Air, 8-4 ............ 9-188 Manual External Output Execution: High Voltage, 8-5 ............................. 9-189 Manual External Output Execution: Flushing, 8-6 ................................... 9-190 Manual External Output Execution: Push Thinner, 8-7 ............................ 9-191
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9.0 AUXILIARY FUNCTIONS
AUXILIARY FUNCTIONS
The auxiliary functions, accessed through the multi function panel, provide the operator with the ability to view and change numerous settings that affect robot operation. The auxiliary function screens are accessed by pressing the MENU key and selecting the FUNCTION key from the drop down menu. Figure 9-1 shows the first auxiliary screen, additional screens are accessed by pressing the F3 key.
Figure 9-1 Auxiliary Function Screen
NOTE
Some auxiliary functions are optional and must be purchased separately. The optional auxiliary functions are covered in unit 11 of this manual.
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AUXILIARY FUNCTIONS
9.1 AUXILIARY FUNCTION LIST MULTI FUNCTION PANEL All of the auxiliary function numbers, the function names and a brief description of each are identified below in the Auxiliary Function List. A detailed explanation of each function and its use follows the Auxiliary Function List. Auxiliary Function List No. 2 Function Name Location & Speed Display Data Transfer Function Description Displays present position information.
Used to transfer all, or part of, one program to another. Removes the selected program from the stack, does not delete the program. Saves data from the system memory to a flash RAM or SRAM PC card. Loads file data from a flash RAM or SRAM PC card to system memory. Displays a list of files currently on the PC card. Used to format flash RAM or SRAM PC cards and delete files stored on flash RAM or SRAM PC cards. Used to set zeroing data for encoders with a location reference to ensure proper motion of the robot. Displays a deviation range error message after an E-stop. Displays a deviation range error message at controller power-up. Allows the operator to set zeroing data.
Kill Program
10
MemoryPC Card
11
PC CardMemory
12 14
File Directory PC Card AUX Function
41
Zeroing
42
Position Error Range at Emergency Stop Encoder Error Range
43
44
Zeroing Data Set and Display
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AUXILIARY FUNCTIONS
Auxiliary Function List (continued) No. 46 Function Name Installation Type Function Description Used to determine mechanical unit mounting configuration. Allows the operator to set the base coordinate system at a position other than zero. Used to set tool dimensions. Sets the upper and lower ranges for robot motion. Used to set the distances of the four accuracies used in block step programming. Used in conjunction with an input signal to slow down the program execution speed. Sets the robot speeds used in check mode. Used to set the three teach speeds and the three inching distances. Displays the system memory status. Prevents recording data if set to inhibit. Identifies robot application type. Used to set system software switches. Used to set and display robot home positions. Used to clear check sum errors. Allows a comment after the program name.
47
Base Coordinates
48 51 53
Tool Dimensions Software Limit Accuracy
55
Slow Repeat Mode
56 57
Check Speed Teach Speed
70 71 73 75 76 78 87
Memory Available Record Data/Inhibit Spray On/Off System Switch Home Position Clear Check Sum Error Program Parameter/ Comment Change Program Name
88
Used to change the name of an existing program. 9-7
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AUXILIARY FUNCTIONS
Auxiliary Function List (continued) No. 90 Function Name Software Version Display Environment Data Function Description Displays the version numbers of the installed system software. Sets a timer to turn off servo motors and identify installed equipment. Used to identify installed hardware. Used to identify type of operator interface connected. Enables or disables selected program instructions in check mode. Program data is deleted and system is reset to default settings. Enables or disables RAM low battery error checking at power up. When used, detects if a short circuit is present in the multi function panel/type 2 teach pendant touch screen. Used to set the date and time for the controller processor. Used to set dedicated input signals. Used to set dedicated output signals.
91
95 96
Environment Data2 Environment Data of Panel Check Specification
99
100 System Initialization
101 Battery Error Check
103 Touch Panel Short Circuit Check
110 Time
111 Dedicated Input Signal 112 Dedicated Output Signal 113 Dedicated Signal Display
Displays dedicated input and output signals.
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AUXILIARY FUNCTIONS
Auxiliary Function List (continued) No. Function Name Function Description Used to identify clamp data and specifications. Displays a history of error messages. Displays the history of operation activity. Used to reset the encoder values as part of the zeroing process. Used to register interrupt program. Used to display the program list. Used to display, modify and delete blocks for all repeat cycles of a program. Used to set a check of the registered home position data of each axis. Sets the general output function signals as effective or ineffective. Used to clear the history for all stored operations and errors. Used to partially delete a program. Used to display and set the singular point alarm range function. Used to set program execution with differentiating work and air-cut speeds. Used to set operation conditions as effective or ineffective.
114 Clamp Specification 120 Error Logging 122 Operation Logging 140 Encoder Rotation Counter Reset 144 Interrupt Program 153 Program List 154 Program Cycles
155 Home Position Mask
158 General Output Function Assignment 159 History Clear
166 PG Partial Delete 167 Singular Point Alarm Range Set 168 Diff. of Work/Air-Cut Speed 169 Operation Condition Setting
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AUXILIARY FUNCTIONS
Auxiliary Function List (continued) No. Function Name Function Description Used to display and set general and dedicated counter values. Used to set upper and lower limits of robot movement with XYZ area or Cartensian coordinates. Used for editing and managing coating databank data (list, copy, delete, and environment settings).
172 Syscount Display and Setting 173 Moving Area XYZ Limit
176 Data Bank
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9.2 AUX 2 LOCATION & SPEED DISPLAY
AUXILIARY FUNCTIONS
The Location & Speed Display includes six display modes for positional data and robot movement. Function keys F1 to F6 are used to select the type of positional data displayed. Figure 9-2 shows the initial joint angle display when AUX 2 is selected. For information on the optional Extended Location & Speed Display, see unit 11.
ENTER KEY
Figure 9-2 AUX 2 Location & Speed Display Screen
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AUXILIARY FUNCTIONS
The data in the Location & Speed Display screens is continuously updated and scrolls from the bottom of the screen. When the ENTER key is pressed, the screen stops scrolling. When the ENTER key is pressed again, the screen resumes scrolling. Pressing the EXIT key returns the display to the AUX function screen. Table 9-1 provides information about the six different screens accessed from the Location & Speed Display.
Table 9-1 AUX 2 Location and Speed Display

Key F1 F2 F3 F4 J5 J6 Function JOINT ANGLE XYZOAT Description The present angle of each joint. The TCP position in the base coordinate system (XYZ), and angle (OAT). Unit Degrees Millimeters/Degrees Degrees Degrees Bits Degrees/Second
JOINT COMMAND The present commanded position for each joint. JOINT OFFSET ENCODER JOINT SPEED The deviation between the commanded position and the actual position. The encoder count for each joint. The speed of each joint.
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9.3 AUX 3 DATA TRANSFER
AUXILIARY FUNCTIONS
The Data Transfer function allows the operator to copy and paste program steps from one program to a different program or a different location within the same program. Figure 9-3 shows the Data Transfer screen.
AUX 3 DATA TRANSFER

SOURCE PROGRAM SOURCE STEP NUMBER OF STEPS DESTINATION PROGRAM DESTINATION STEP (0:APPEND AT THE LAST STEP)
Pgtest
5 21
Pgtest2
4
F1
PROGRAM
F2
F3
F4
INPUT
Figure 9-3 AUX 3 Data Transfer Screen
The use of the Data Transfer function is outlined in the following procedure: 1. Press the F1 PROGRAM INPUT key to select a source program containing the steps to be copied. A screen showing a list of available programs in the system memory is displayed. Use the cursor keys to select the program containing the steps to copy, and press the ENTER key. Use the numeric key pad to enter the first step and the number of steps to copy. Press the F1 PROGRAM INPUT key to select the program to paste the copied steps into. A screen showing a list of available programs in the system memory is displayed. Use the cursor keys to select the program to paste the copied steps into and press the ENTER key. Use the numeric key pad to enter the step number, in the destination program, to paste the copied steps before. When 0 is entered, the steps are inserted after the last step of the destination program. When program steps are inserted into a program, the existing steps are renumbered.
2. 3.
4.
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9.4 AUX 5 KILL PROGRAM
AUXILIARY FUNCTIONS
The Kill Program function is used to remove the selected program from active status. The Kill Program function does not delete the program from system memory. Figure 9-4 shows the Kill Program screen.
AUX 5 KILL PROGRAM
Are you sure?
F1
F2
F3
F4
YES
NO
Figure 9-4 AUX 5 Kill Program Screen
Press the F1 (YES) key to confirm the Kill Program operation. If the Kill Program selection is made in error, press the F2 (NO) key to return to the AUX function screen.
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9.5 AUX 10 MEMORYPC CARD (SAVE)
AUXILIARY FUNCTIONS
This function is used to save data in the controllers memory to a PC card. The PC card is inserted into the PC card slot in the back of the multi function panel. Figure 9-5 shows the screen display when the save function is selected.
AUX 10 MEMORY -> PC CARD (SAVE)
AUX 10 MEMORY -> PC CARD (SAVE)
1 2 3 4 10 11
ALL DATA PROGRAM AUXILIARY DATA ALL DATA (selected program only) ROBOT DATA ERROR LOGGING
FILE0 FUNCTION NUMBER:
F1
F2
F3
F4
F1
F2
F3
F4
CHARACTER
Figure 9-5 AUX 10 MemoryPC Card (Save) Screen
The MEMORYPC CARD (SAVE) screen has six selections available for storing differ ent types of data. Data is saved on the PC card as ASCII text files. Use the cursor keys or the numeric keypad to select the desired option and press the enter key. Use the numeric keypad to enter a numeric file name and press RETURN. If an alphanumeric file name is desired press the F4 (CHARACTER) key. Select the desired characters for the file name and press the ENTER key. When the file name screen is displayed press the RETURN key to complete the procedure. File names are limited to fifteen characters. Alphanumeric file names must start with an alpha character. File names cannot contain spaces. An under score or period is used as a delimiter.
The options for saving data on a PC card are shown in table 9-2.
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AUXILIARY FUNCTIONS
Table 9-2 Memory to PC Save Option 1 ALL DATA Extension .AS Description Includes all robot, system, auxiliary, program, variable and program data. Saves program data only. System data and variables are not saved. If the saved program calls other programs (subroutines), the called programs are also saved. Includes auxiliary data such as accuracy, timer and teach speed settings, HOME positions, etc. Saves all data for up to five selected programs. This option saves variables, system data and auxiliary data. If subroutines are called they are not saved unless they are identified individually. Includes robot type, number of axes and specific software settings. Saves the data from the error log up to the last 1,000 entries, including the date and time of the entry.
2 PROGRAM
.PG
3 AUXILIARY DATA 4 ALL DATA (SELECTED PROGRAM ONLY) 10 ROBOT DATA 11 ERROR LOGGING
.AU
.AS
.RB
.EL
When data is stored onto a PC card a file number or name must be specified. The display prompts the operator to enter a number for the file identification. The file extension is added to the file name based on the option of the file type selected. If a file is identified with the same file number, or name, as an existing file, a backup file is automatically created. A B is added to the extension of the original file name indicating a backup file (i.e. .BAS). Only one backup file is created, if additional files of the same name are saved the backup file is overwritten.
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9.6 AUX 11 PC CARDMEMORY (LOAD)
AUXILIARY FUNCTIONS
This function is used to load data to the controllers memory from a PC card. The PC card is inserted into the PC card slot in the back of the multi function panel or type 2 teach pendant. Figure 9-6 shows the screen displayed when the load function is selected.
Figure 9-6 AUX 11 PC CardMemory (Load)
Use the cursor keys or the numeric keypad to select the option number for the data to load from the PC card file into the controller memory. If option one is selected, the display prompts the operator to load, or not to load, the robot data. After the response to loading robot data is entered, the remainder of the data in the selected file is loaded. If option two is selected, the operator is prompted whether or not each category of data in the PC card file is to be loaded. If a program is loaded from the PC card with the same program name as a program in controller memory, the program in the controller memory is overwritten.
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9.7 AUX 12 FILE DIRECTORY
AUXILIARY FUNCTIONS
This function allows the operator to view the names of all the files contained on the PC card. The file extensions identify the type of file, see table 9-2 for a description of file extensions. Figure 9-7 shows an example of the FILE DIRECTORY screen.
Figure 9-7 AUX 12 File Directory Screen
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9.8 AUX 14 PC CARD AUX FUNCTION
AUXILIARY FUNCTIONS
This function allows the operator to format a PC card or delete files from a PC card. When a PC card is formatted, any data on the PC card is deleted. When the PC card formatting option is selected, the display prompts the operator to confirm the action. If the file delete option is selected, the display prompts the operator to select files to delete from a list of files on the PC card. Once a file is deleted from the PC card it is not recoverable. Figure 9-8 shows the PC Card AUX Function screen.
Figure 9-8 AUX 14 PC Card AUX Function Screen
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9.9 AUX 41 ZEROING
AUXILIARY FUNCTIONS
AUX 41 Zeroing, is used to set the value of the encoder count to a zero degree reference position. From this screen, the operator can choose to zero a single joint or zero all joints. The zeroing data set from AUX 41 is entered in conjunction with data recorded in AUX 140 to accomplish zeroing of the mechanical unit. Figure 9-9 shows the display screen when AUX 41 is selected.
CAUTION
Operators must be aware of the effect changes made in this function have on the position of programmed locations. Changing this data without following the complete zeroing process may move programmed locations to positions that cause damage to the robot, fixtures, or work.
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The procedure for simple zeroing is as follows: 1. 2.
AUXILIARY FUNCTIONS
Jog all axes to zero, to algin the zeroing scribe marks. Select AUX 140 Encoder Rot. Counter Reset, and enter the joint number to zero. To zero all joints, 0 is entered for the joint number. Set the zero position value from the AUX 41, Zeroing screen, by entering the joint number to zero. To zero all joints, 0 is entered for the joint number. Confirm the new zero position by operating the robot in the check mode on a previously taught program to verify the playback accuracy of locations.
3.
4.
For further information about the zeroing process, reference the C Series Controller Electrical Maintenance Manual, unit 8, Zeroing.
AUX 41 ZEROING
JT1 JT2 JT3 JT4 JT5 JT6
SETTING 268422562 268437254 268421269 268433264 268427274 268428465
CURRENT 268422562 268437254 268421269 268433264 268427274 268428465
JOINT NO. = 0 (0 = all joint)
F1
PRE DATA
F2
F3
F4
Figure 9-9 AUX 41 Zeroing Screen
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9.10 AUX 42 POS. ERROR RANGE AT E-STOP
AUXILIARY FUNCTIONS
The Pos. Error Range at E-Stop function is used to set a comparison range for checking the robots commanded position when an emergency stop is applied, with the position when motor power is reapplied. If the difference between the robots position when motor power is reapplied and when the emergency stop was pressed is greater than the set value, a position offset error is displayed. The position offset error generated from this function cannot be reset and motor power cannot be applied. The error range must be reset to a value that does not cause an error. The purpose of this function is to prevent interference with fixtures, jigs, or work pieces when the robot is restarted after an emergency stop condition. The acceptable range of data for the position error range at emergency stop is from 0.1 degree to 10.0 degrees for axes one to six and from 0.1 mm to 100 mm for a seventh axis. If 0 is entered the error check is not performed. The default setting for this function is 0. The Pos. Error Range at E-Stop function screen is shown in figure 9-10.
Figure 9-10 AUX 42 Position Error Range at E-Stop Screen
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9.11 AUX 43 ENCODER ERROR RANGE
AUXILIARY FUNCTIONS
This function sets the range of encoder deviation allowed before an error is displayed upon applying power to the controller. The encoder value when control power is turned off is compared to the encoder value when control power is turned on. If the difference is larger than the range set, a JT encoder abnormality error is displayed. The range of acceptable data for this function is from 0.1 degree to 10.0 degrees for axes one to six and from 0.1 mm to 100 mm for a seventh axis. The default setting for the Encoder Error Range function is 2.0 degrees. Operators should be aware that if this range is set too low, error messages may be displayed when the system is performing within design performance specifications. The display screen to set the values for the Encoder Error Range function is shown in figure 9-11. The F1, PREV.DATA, key is used to restore the settings if the enter key has not been pressed.
AUX 43 ENCODER ERROR RANGE
JT1 JT2 JT3 JT4 JT5 JT6
2.0deg 2.0deg 2.0deg 2.0deg 2.0deg 2.0deg
RANGE :Rotation 0.1deg -10.0deg Linear 0.1mm - 100.0mm F1

PRE DATA
F2
F3
F4
Figure 9-11 AUX 43 Encoder Error Range Screen
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9.12 AUX 44 ZEROING DATA SET/DISPLAY
AUXILIARY FUNCTIONS
The Zeroing Data Set/Display function allows the operator to set encoder counts and encoder offsets. Figure 9-12 shows the Zeroing Data Set/Display. The first screen shows the current encoder reading and setting. The second screen shows the offset of the encoders.
AUX 44 ZEROING DATA SET/DISPLAY SETTING CURRENT JT1 JT2 JT3 JT4 JT5 JT6 268427264 268427264 268427264 268427264 268427264 268427264 267427264 267427264 267427264 267427264 267427264 267427264
AUX 44 ZEROING DATA SET/DISPLAY OFFSET JT1 JT2 JT3 JT4 JT5 JT6 1 65539 63 31 65532 115
F1
PRE DATA
F2
F3
NEXT PG
F4
F1
PRE DATA
F2
PRE PG
F3
F4
Figure 9-12 AUX 44 Zeroing Data Set/Display Screen
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9.13 AUX 46 INSTALLATION TYPE
AUXILIARY FUNCTIONS
This function allows the operator to define the mechanical units configuration, such as floor, wall, or ceiling installation as shown in figure 9-13.
AUX 46 INSTALLATION TYPE
INSTALLATION POSTURE
(0:FLOOR 1: CEILING 2: WALL 3: WALL2)
F1
PRE DATA
F2
F3
F4
Figure 9-13 AUX 46 Installation Type Screen
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9.14 AUX 47 BASE COORDINATE
AUXILIARY FUNCTIONS
This function allows the operator to redefine the base reference frame by effectively shifting the base transformation values XYZ and OAT. When the machine is first initialized the transformation values of the base coordinate system are all set to a null or zero position. A null base has the transformation values 0,0,0,0,0,0. The Base Coordinate function is used to change the base reference location. Programmers must be aware of the impact shifting the base coordinate origin has on program playback. Shifting the base coordinate origin results in the equivalent shift occurring for all transformation locations stored in the controller memory. Locations recorded as precision points are played back based on the joint angles of the robots six axes and are not affected by a base coordinate shift. The acceptable range for the base coordinate shift function is from -9999.9 mm to 10000 mm in the XYZ directions and from -180 to 180 for angles OAT. The Base Coordinate function screen is shown in figure 9-14.
AUX 47 BASE COORDINATE
BASE COORDINATE SHIFT VALUE X DIRECTION Y DIRECTION Z DIRECTION O ROTATION A ROTATION T ROTATION 0.0mm 0.0mm 0.0mm 0.0deg 0.0deg 0.0deg
F1 F2 RANG: Rotation 0.0deg - F3 10.0deg F4 Traverse 0.0mm - 100.0mm

PRE DATA
Figure 9-14 AUX 47 Base Coordinate Screen
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9.15 AUX 48 TOOL DIMENSIONS
AUXILIARY FUNCTIONS
This function allows the operator to record the unique tool dimensions and orientation. Up to nine separate tools can be defined with this function. Tool dimensions specified from this function are associated with the nine tools identified in block step programs. Tool dimensions are expressed in XYZ tool coordinates in 0.1 mm increments and 0.1 degree increments for the OAT rotation axes. Nine separate screens are available for this function, pressing the F3 key displays the next available screen and the F2 key returns to the previous screen. The weight of the tool and the load it carries can also be entered from the tool dimensions screens. The F1 key can be used to restore previous tool dimensions and weight information, if the enter key has not been pressed to record the new data. Figure 9-15 shows the Tool Dimensions Display screen for TOOL 1.
Figure 9-15 AUX 48 Tool Dimensions Screen
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9.16 AUX 51 SOFTWARE LIMIT
AUXILIARY FUNCTIONS
This function allows the operator to set the upper and lower limits of robot travel as expressed in degrees of axes rotation. The robot cannot travel to locations that are outside of these limits. During jogging operations, an audible beep indicates the robot is approaching a software limit. The frequency of the audible beep increases as the robot moves closer to the limit. When the limit is reached, the robot stops moving in that direction and the audible tone is constant, no error message is generated. The robot can be jogged away from software limits by simply changing direction. If the robot is moved with the brake release to a location beyond the software limits or the software limits are changed, placing the robot outside the software limits, the operator can jog back into the software limits envelope. If the overtravel limit switch is engaged (JT1), the overtravel error recovery procedure (see 9.16.1) must be used. The Software Limit display is shown in figure 9-16. The allowable maximum and minimum settings are displayed along with the current settings. Use the cursor keys and numeric keypad to change the settings. If data is entered that is beyond the allowable settings, an out of range error occurs. The first screen displayed shows the upper limits, the lower limits are displayed by pressing the F3 NEXT PG key. The operator must be aware that the minus sign for the lower limit settings is not assumed and must be included when data for the lower limits is set.
AUX 51 SOFTWARE LIMIT

UPPER SET ABLE UPPER JT1 JT2 JT3 JT4 JT5 JT6 180.000deg 70.000deg 90.000deg 280.000deg 125.000deg 360.000deg SETTING 45.000deg 70.000deg 90.000deg 280.000deg 125.000deg 360.000deg F3
NEXT PG
AUX 51 SOFTWARE LIMIT

LOWER SET ABLE LOWER JT1 JT2 JT3 JT4 JT5 JT6 -180.000deg -65.000deg -119.000deg -280.000deg -125.000deg -360.000deg SETTING -45.000deg -65.000deg -119.000deg -280.000deg -125.000deg -360.000deg
F1
PRE DATA
F2
F3
NEXT PG
F4
F1
PRE DATA
F2
PREV. PG
F3
F4
Figure 9-16 AUX 51 Software Limit Screen
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9.16.1 OVERTRAVEL ERROR RECOVERY
AUXILIARY FUNCTIONS
To recover from an overtravel error, the operator must press and hold the red override switch located on the 1HP board and reset the error by pressing the ERROR RESET switch on the operation panel or multi function panel. With the override switch held, apply servo power and jog the robot off the limit switch. An alternate method is to use the brake release switch for JT1 and manually move the robot.
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9.17 AUX 53 ACCURACY
AUXILIARY FUNCTIONS
When AUX 53 Accuracy, is selected from the auxiliary function menu, the screen shown in figure 9-17 is displayed. From this screen, the operator sets the four accuracies used in block step programming. The acceptable accuracy range for the KE610 is from 0.5 mm to 5000 mm, and for the KF121 from 0.2 mm to 5000 mm. When the robot is in the repeat mode of operation, the playback accuracy is affected by: Distance between the taught points Speed Accel and decel parameters CP switch setting Timers and wait conditions
Default accuracy settings are shown in figure 9-17.
AUX 53 ACCURACY
ACCURACY1 ACCURACY2 ACCURACY3 ACCURACY4
1.0mm 10.0mm 50.0mm 100.0mm
F1
PRE DATA
F2
F3
F4
Figure 9-17 AUX 53 Accuracy Screen
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AUXILIARY FUNCTIONS
The auxiliary function incorporates Motion Type 1 (MT1) and Motion Type 2 (MT2) path planning systems. Both of these systems blend two robot path segments to achieve continuous path motion. When a fine accuracy is used to reach a target point, maximum deceleration and acceleration are used to reach that point. When a large accuracy is used, a continuous path motion is produced. The deceleration of the current step and the acceleration of the next step creates a smooth transition from one point to the next. The MT1 path planning system determines the blending of multiple linear or joint interpolated segments based on the acceleration, deceleration, and the length of the blended segments. Joint interpolated paths are planned using MT1. MT2 was developed for the C controller to improve the repeat mode path accuracy and repeatability. This is accomplished by blending two linear or circular segments based on accuracy (Figure 9-18). MT2 path planning is valid only for Linear and Circular Interpolation motions, generated by AS/Block instructions, i.e., LINEAR, C1MOVE, C2MOVE, FLIN and HMOVE.
ACCURACY RANGE
100 mm 50 mm 25 mm A B
Figure 9-18 Motion Type 2 Path
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AUXILIARY FUNCTIONS
Refer to figure 9-18 during the following explanation. For Motion Type 2 the maximum allowable accuracy is determined by: Maximum allowable accuracy, Amax = MIN ( AB, BC) Where: AB = Half the distance between point A and point B BC = Half the distance between point B and point C MIN = the minimum value of 2 real numbers example : MIN(2, 3) = 2, MIN(8,5) = 5 Accuracy used is determined by: Accuracy defined in the program = Aoperator and accuracy used by the software = Aused IF Aoperator < Amax, THEN Aused = Aoperator IF Aoperator > Amax THEN Aused = Amax If a WAIT, SWAIT, TWAIT, TOOL or WORK instruction follows a motion instruction, MT2 is invalid and MT1 is used. Example: ACCURACY 25 LMOVE B SWAIT 1001 ;The SWAIT instruction causes the software to ignore the 25 mm ;accuracy and decelerate to point B then resume motion to point C.
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9.18 AUX 55 SLOW REPEAT MODE
AUXILIARY FUNCTIONS
When AUX 55 Slow Repeat Mode, is selected from the auxiliary function menu, the screen shown in figure 9-19 is displayed. This function allows the operator to set the slow repeat mode speed of the robot from 1 to 25% of maximum speed. A dedicated input signal must be assigned for the slow repeat mode function. When this signal is ON, the SLOW REPEAT MODE of operation is activated.
Figure 9-19 AUX 55 Slow Repeat Mode Screen
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9.19 AUX 56 CHECK SPEED
AUXILIARY FUNCTIONS
The Check Speed function sets the three speeds available for single step program playback using the STEP NEXT and STEP BACK keys in teach mode. The default check speed settings are shown in figure 9-20.
Figure 9-20 AUX 56 Check Speed Screen
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9.20 AUX 57 TEACH SPEED
AUXILIARY FUNCTIONS
The AUX 57 Teach Speed display screen is shown in figure 9-21. The three jogging speeds and inching distances are set from this screen. The teach speed set from this function corresponds to the speed selected on the teach pendant. The teach speed function can be set up to a maximum of 250.0 mm/sec. The maximum allowable teach speed is defined by ANSI/RIA standards.
AUX 57 TEACH SPEED MANU.SP SPEED. 1 SPEED. 2 SPEED 3 10.0mm/s 80.0mm/s 250.0mm/s
F1
PRE DATA
F2
F3
F4
Figure 9-21 AUX 57 Teach Speed Screen
April 8, 2002
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9.21 AUX 70 MEMORY AVAILABLE
AUXILIARY FUNCTIONS
This function is used to display the amount of memory available for programming. The available memory is displayed in both bytes and percentage of usable memory. Figure 9-22 shows the Memory Available display.
Figure 9-22 AUX 70 Memory Available Screen
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9.22 AUX 71 RECORD DATA (PRG CHG) INHIBIT
AUXILIARY FUNCTIONS
The Record Data function allows the operator to prevent the recording of block step program data by selecting INHIBIT for record. AS Language programs cannot be edited if the PRG CHANGE is set to INHIBIT. If an attempt to change data is made, an error message is displayed. The error message instructs the programmer to set the respective switch to the ACCEPT status. The Record Data (Prg Chg) Inhibit display screen is shown in figure 9-23.
Figure 9-23 AUX 71 Record Data Inhibit Screen
April 8, 2002
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9.23 AUX 73 SPRAY ON/OFF
AUXILIARY FUNCTIONS
This function enables, or disables, trigger signals for a painting or sealing operation. The operator has the option to select spray on or spray off, depending on the robot application. Figure 9-24 shows the display screen for AUX 73, Spray On/Off.
Figure 9-24 AUX 73 Spray On/Off Screen
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9.24 AUX 75 SYSTEM SWITCH
AUXILIARY FUNCTIONS
The System Switch function allows the operator to turn software switches on and off to alter functions of the robot system. It is important to realize that any changes made to the status of these switches are global and affect all programs in the system memory. The AUX 75 System Switch display screens are shown in figure 9-25. The F3 NEXT PG key is used to display the remaining switches.
Figure 9-25 AUX 75 System Switches Screen
April 8, 2002
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AUXILIARY FUNCTIONS
Table 9-3 shows the default settings for the system switches. When the system is initialized, all switches are reset as shown in table 9-3.
Table 9-3 System Switches Default Settings

Sw itch C HEC K.HOLD CP C YC LE.STOP OX.PREOUT SPOT_OP HOLD .STEP WS_C OMPOFF PLC .C HEC K PREFETC H.SIGINS QTOOL REP_ONC E RPS STP_ONC E AFTER.WAIT.TIMER MESSSAGES SC REEN AUTOSTART.PC AUTOSTART2.PC AUTOSTART3.PC ERRSTART.PC D ISPIO_01 FLOWRATE WS_C OMP OFF WS.ZERO PLC .C HEC K Setting OFF ON OFF ON OFF OFF OFF OFF ON ON OFF OFF OFF OFF ON ON OFF OFF OFF OFF OFF OFF ON OF OFF
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9.24.1 CHECK.HOLD SWITCH
AUXILIARY FUNCTIONS
This function affects the AS Language commands EXECUTE, DO, STEP MSTEP and CONTINUE. When the CHECK.HOLD switch is ON these commands are available only if the HOLD/RUN switch is in the HOLD position. The controller accepts these commands with the HOLD/RUN switch in the HOLD position, but robot motion is not initiated until the switch is manually placed in the RUN position. The default setting for this switch is OFF. 9.24.2 CP (CONTINUOUS PATH) SWITCH The CP switch activates the continuous path function. When the CP switch is ON and the accuracy ranges are large enough, the robot makes smooth transitions from point-to-point, as indicated in figure 9-26. When the switch is OFF, the robot decelerates and stops at each recorded point regardless of the accuracy of those points. The default setting for this switch is ON.
Robot path with CP ON Robot path with CP OFF TAUGHT POSITION
ACCURACY RANGE
Figure 9-26 CP Switch
April 8, 2002
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9.24.3 CYCLE.STOP SWITCH
AUXILIARY FUNCTIONS
The CYCLE.STOP switch is used in conjunction with an external input signal used to stop the motion of the robot. With the switch ON, when the input signal is received the robot stops and the CYCLE START light turns off. When the program is started again it starts at the beginning. If the program was called from another program, the program restarts at the beginning of the main program. With the switch OFF, when the input signal is received the robot stops and the CYCLE START light remains ON. The robot is in a hold condition and, when the program is restarted, it continues at the point in the cycle where it stopped. The default setting for this switch is OFF.
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9.24.4 OX.PREOUT SWITCH
AUXILIARY FUNCTIONS
The OX.PREOUT switch affects the timing of output signal generation in block step programs. When the switch is ON, an output programmed for a given point is turned on as soon as the robot begins motion to that point. With the OX.PREOUT switch OFF, an output programmed for a given point is turned on at the accuracy range of the point. Figure 9-27 shows the different effects the OX.PREOUT switch has on signal timing. Clamp signals are not affected by the setting of the switch. The default setting for this switch is ON.
Figure 9-27 OX.PREOUT Switch
April 8, 2002
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9.24.5 PREFETCH.SIGINS SWITCH
AUXILIARY FUNCTIONS
The PREFETCH.SIGINS switch is used in conjunction with AS Language instructions and has the same affect on signal timing that the OX.PREOUT switch has with block step instructions. The AS Language instructions affected are; SWAIT, SIGNAL, PULSE, DLYSIG, RUNMASK, RESET, and BITS. The default setting for this switch is ON. 9.24.6 QTOOL SWITCH This switch allows the operator to identify tools to use in block step or AS Language programming. When the QTOOL switch is ON, the programmer has up to nine tools available to use for programming and jogging. The unique tool dimensions are recorded and assigned a tool number using auxiliary function number 48. When the QTOOL switch is ON, the selected tool dimensions are in effect for jogging and linear playback of block step programs. When the QTOOL switch is OFF, the tool identified with AS Language instructions is utilized. The default setting for this switch is ON. 9.24.7 REP_ONCE (REPEAT ONCE) SWITCH When the REP_ONCE switch is ON, programs run one time. With the switch OFF, programs run continuously. The default setting for this switch is OFF. 9.24.8 RPS (RANDOM PROGRAM SELECTION) SWITCH This switch enables the processor to scan for a binary input from peripheral devices and select which program is executed. The AS Language instructions EXTCALL, JUMP and END combined with the input signal and RPS function determine which program runs. The default setting for this switch OFF.
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9.24.9 STP_ONCE (STEP ONCE) SWITCH
AUXILIARY FUNCTIONS
When the STP_ONCE switch is ON, the repeat condition function of progressing through a program one step at a time becomes active. The step forward key must be used to progress through a program. When the switch is OFF, programs run continuously. The default setting for this switch is OFF. 9.24.10 AFTER.WAIT.TIMER SWITCH When the AFTER.WAIT.TIMER switch is in the ON position, timers begin their timing at a specified step when all wait conditions are satisfied. With the switch in the OFF position, timers begin timing when the robot reaches coincidence of the taught point. The default setting for this switch is OFF. 9.24.11 SPOT_OP This switch allows the robot controller to monitor the time between weld initiate and weld tip closed and adjust the weld initiate signal timing to optimize the program. The default setting for this switch is OFF. 9.24.12 MESSAGES SWITCH The MESSAGES switch allows PRINT and TYPE information, which is part of programs, to be displayed for operator viewing. If the MESSAGES switch is OFF this information is not displayed. The default setting for this switch is ON. 9.24.13 SCREEN SWITCH This switch enables or disables the scrolling of the screen when the amount of information being sent by the processor is larger than the screen can display. With this switch ON, information is scrolled on the screen using the NEXT PG (next page) and PRE PG (previous page) keys. The default setting for this switch is ON April 8, 2002 9-45
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9.24.14 AUTOSTART.PC SWITCHES
AUXILIARY FUNCTIONS
The AUTOSTART.PC, AUTOSTART2.PC, AND AUTOSTART3.PC switches automatically start the associated PC program when control power is applied. For information on PC programs see the C Series Controller AS Language Reference Manual. The default setting for these switches is OFF. 9.24.15 ERRSTART.PC SWITCH When operator specified errors occur a PC program can be started if the ERRSTART.PC switch is in the ON position. The default setting for this switch OFF. 9.24.16 DISPIO_01 SWITCH This switch allows the operator to select the type of display used to view the status of input and output signals. If the switch is ON, 1s and 0s are displayed to identify the signal state of individual signals. A 1 represents a signal that is on, and a 0 represents a signal that is off. If the switch is OFF, xs and os are used to represent the signal states. An o represents a signal that is ON, and an x represents a signal that is OFF. The X and O display also identifies if a signal number has a dedicated function. Dedicated signals are represented by uppercase Xs and Os. The default setting for this switch is OFF. 9.24.17 HOLD.STEP When this switch is ON and the HOLD/RUN switch is placed in the HOLD position, the current logic or motion step is displayed. When the switch is OFF and the HOLD/RUN switch is placed in the HOLD position, the last motion step executed is displayed. The default setting for this switch is OFF.
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9.24.18 WS_COMPOFF
AUXILIARY FUNCTIONS
When this switch is ON, the weld schedule (WS) bits are set low after they are sent rather than when the robot is at the next step of the program. The default setting for this switch is OFF. 9.24.19 WS.ZERO When this switch is ON and weld schedule 0 is selected, the controller waits for the weld complete signal before continuing robot motion. When this switch is OFF and weld schedule 0 is selected, the controller does not wait for the weld complete signal. The default setting for this switch is OFF. 9.24.20 PLC.CHECK This function enables the 1HA boards CPU and the Sharp Sequencer Board CPU watchdog communication. Watchdog communication is an error checking function. The default setting for this switch is OFF.
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9.25 AUX 76 HOME POSITION
AUXILIARY FUNCTIONS
The Home Position function allows the operator to set two home positions for the robot. These home positions can be set to any location within the work envelope. Home positions have two unique characteristics. A dedicated output signal can be assigned to each of the home positions so that whenever the robot is within the range set for that position the signal is generated. Home positions are also recognized in a unique way in AS Language commands, the only code needed to send the robot to the home position is the statement HOME. When this instruction is encountered, the robot performs a joint move to the home position. A second home position is identified by the designation HOME2 and is set from the second screen of function 76. Figure 9-28 shows the screen to set HOME POSITION 1. From this screen the operator can choose to enter the desired home position as expressed in joint angles or the current position of the robot. To enter a HOME position other than the current position, use the cursor keys to highlight KEY-IN and move to the desired joint number. Enter the desired number of degrees for each joint and press ENTER when completed. The range for the home position is also set from this screen. When the robot reaches a point within the specified range, the output signal is generated. The recommended minimum setting for the home position range is between 5 mm and 10 mm to ensure the home position output is generated.
Figure 9-28 AUX 76 Home Position Screen
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9.26 AUX 78 CLEAR CHECK SUM ERROR
AUXILIARY FUNCTIONS
The Clear Check Sum Error function allows the operator to clear error 1019, abnormal check sum. An abnormal check sum error is generated when the processor calculates a difference between data when the controller is powered up compared to data in memory. When this error occurs select AUX 78, and change the setting to EFFECT as shown figure 9-29. When control power is cycled, the error may be cleared and the setting returned to INEFFECT. If the clear check sum error does not clear with the cycling of control power, the second screen shown in figure 9-29 is displayed identifying additional troubleshooting paths.
Figure 9-29 AUX 78 Clear Check Sum Error Screen
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AUXILIARY FUNCTIONS
9.27 AUX 87 PROGRAM PARAMETER/COMMENT The Program Parameter/Comment function is activated in AUX 96 Environment Data of Panel and allows the operator to add a comment to a program name. When the parameter/comment function is activated in AUX 96, it is displayed in the auxiliary function menu. To use the Program Parameter/Comment function, follow the procedure below. 1. 2. Select AUX 87 from the auxiliary function menu. Use the cursor keys to select the desired program and press the RETURN key. The character set keyboard is displayed. At the character set keyboard enter a semicolon followed by the desired comment (up to nineteen characters) and press ENTER. Repeat steps 2 and 3 to add comments to another program name or press EXIT to return to the auxiliary function screen.
3.
4.
Figure 9-30 shows the Program Parameter/Comment display screen after a comment is entered.
AUX 87 PROGRAM ARGUMENT / COMMENT
pg?? test
[Accuracy test prog.]
test
F1 F2 F3 F4
Figure 9-30 AUX 87 Program Parameter/Comment Screen
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9.28 AUX 88 CHANGE PROGRAM NAME
AUXILIARY FUNCTIONS
AUX 88, Change Program Name, allows the operator to change the names of existing programs. To change the name of a program, select AUX 88 from the function screen. The Change Program Name screen is displayed as shown in figure 9-31. Use the following procedure to change the name of a program. 1. Press the F1 PROGRAM INPUT key and the PROGRAM SELECT screen is displayed Scroll to the program name to change and press ENTER. The Change Program Name screen is displayed with the name of the program selected. Use the down cursor key to select the new program name line. Press the F1 PROGRAM INPUT key and the PROGRAM SELECT screen is displayed with pg at the bottom of the window. Press the F4 CHARACTER key. Enter the new program name and press ENTER. The PROGRAM SELECT screen is displayed with the new name at the bottom of the window. Press ENTER. The Change Program Name screen is displayed with the old and the new name.
2. 3.
4. 5.
6. 7. 8.
9.
10. Press ENTER again and the prompt Are you sure? is displayed. 11. Press the YES key to complete the procedure.
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AUXILIARY FUNCTIONS
AUX 88 CHANGE PROGRAM NAME Old program name
New program name
F1
PROGRAM INPUT
PROGRAM SELECT pg?? pg00 test pg02 pg01 pg04 pg07 pg08
F1
PROGRAM INPUT
F2
F3
F4
F1
PROGRAM INPUT
F2
F3
NEXT PG
F4
CHARACTER
AUX 88 CHANGE PROGRAM NAME Old program name test
New program name
F1
PROGRAM INPUT
PROGRAM SELECT pg?? pg00 pg02 pg04 pg08
test pg01 pg07
F4
CHARACTER
F1
PROGRAM INPUT
F2
F3
F4
test F1
PROGRAM INPUT
F2
F3
NEXT PG
F4
CHARACTER
Figure 9-31 AUX 88 Change Program Name Screen
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9.29 AUX 90 SOFTWARE VERSION DISPLAY
AUXILIARY FUNCTIONS
This function displays the version of software that is operating in the controller and multi function panel. Figure 9-32 shows the screen displayed when AUX 90 is selected.
AUX 90 SOFTWARE VERSION DISPLAY

AS Robot Name Software Version Servo Number of signals Clamp number TP Software version : version T00006106...97/05/20 03:43 : : : : : Js005-E001 Num of AXES 6 Serial Num. 1 version 000006106...97/05/15 14:05 SAOAON-UX120-07 1997.01.27 input=32 output=32 internal=256 2
F1
F2
F3
F4
F5
F6
EXIT
Figure 9-32 AUX 90 Software Version Display Screen
April 8, 2002
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9.30 AUX 91 ENVIRONMENT DATA
AUXILIARY FUNCTIONS
The Environment Data function is used to set an auto servo timer and identify if the controller is operating with a teach pendant or multi function panel installed. The AUTO SERVO OFF TIMER sets a time period that motor power remains ON if no movement of the robot has occurred. The auto servo off timer function is designed to save energy by allowing the brakes to maintain robot position as opposed to using electrical power and servo motors. When the robot has not moved and the auto servo off timer has reached its set value, the brakes are applied and power is removed from the servo motors. The motor power light remains ON and the robot begins motion under the same conditions as if the auto off servo timer did not remove power from the motors. The Environment Data function also allows the operator to identify if a teach pendant is installed. The enabling devices and the emergency stop button are hard-wired and a jumper (or a different operator interface) must be installed if the teach pendant is removed. Figure 9-33 shows the screen that is displayed when AUX 91 is selected.
AUX 91 ENVIRONMENT DATA AUTO SERVO OFF TIMER 0 sec (0: Not servo off) TEACH PENDANT CONN./DISCONN.
F1
PREV.DATA
F2
F3
F4
Figure 9-33 AUX Environment Data Screen
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9.31 AUX 95 ENVIRONMENT DATA2
AUXILIARY FUNCTIONS
The Environment Data2 function allows the operator to identify if a multi function panel or terminal is installed. The enabling devices and the emergency stop switches of the multi function panel are hard-wired and a jumper (or a different operator interface) must be installed if the multi function panel is removed. Figure 9-34 shows the Environment Data2 screen.
AUX 95 ENVIRONMENT DATA2 PANEL TERMINAL CONN./DISCONN. CONN./DISCONN.
F1
PREV.DATA
F2
F3
F4
Figure 9-34 AUX 96 Environment Data 2 Screen
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9.32 AUX 96 ENVIRONMENT DATA OF PANEL
AUXILIARY FUNCTIONS
From this function, the AS INSTRUCTION POS. TEACHING, KEYBOARD, PROGRAM EDIT, AS INSTRUCTION TEACHING, CHECK MODE, and 2 PUSH RECORD MODE menu items affect the menus available from the teaching screens of the multi function panel. If ON is selected for these items, they are available when the teaching key is pressed. If OFF is selected, pressing the teaching key does not display the associated function and screen. In the 2 PUSH RECORD MODE, the RECORD key only records a step if the (S) SHIFT key is held down simultaneously with the RECORD key. If the TEACH NEW/OVERWRITE key is pressed and a different mode is selected from the drop down menu (AUX REWRITE, POS REWRITE, INSERT, DELETE, or OVERWRITE/NEW), the 2 PUSH RECORD must be used if enabled. Figure 9-35 shows the Environment Data of Panel screen for the multi function panel .
Figure 9-35 AUX 96 Environment Data of Panel Screen
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AUXILIARY FUNCTIONS
9.33 AUX 99 CHECK SPEC. (CHECK SPECIFICATION) The Check Spec. function is used to select certain AS Language instructions used when programs are run in the check mode. The following commands are set as EFFECT (on), or INEFFECT (off), during check mode operation: CALL, TIMER, JUMP/END, OX, WX and CLAMP. If INEFFECT is selected for any of these commands, when a program is executed using the check mode, the command is not processed as a program instruction and is bypassed. During check mode operation in reverse program order, only the CLAMP and OX instructions are dependent on the settings of AUX 91. The AS Language instructions CALL, TIMER, JUMP/END, and WX are not processed during reverse order check mode operation. Figure 9-36 shows the AUX 99, Check Spec. screen.
Figure 9-36 AUX 99 Check Spec. Screen
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AUXILIARY FUNCTIONS
9.34 AUX 100 SYSTEM INIT. (SYSTEM INITIALIZATION) The System Init. function is used to clear everything from the system memory and reset all default settings. When the system is initialized, all programs, variable data, system switches, and system settings are deleted or returned to default settings. The only data not affected by the initialization process is the error and operation logs. Figure 9-37 shows the screen displayed when AUX 100, System Init. is selected.
CAUTION
Initializing the system erases all program and variable data and reset system data to default settings. If a PC is connected to the controller and the initialization function is selected, care must be taken not to initialize the hard drive of the PC.
ENTER is selected to activate initialization of the system from this screen. If the system is not to be initialized, EXIT is selected returning the screen to the first auxiliary function screen.
AUX 100 SYSTEM INIT. ************** * WARNING * ************** If this function is performed, all data in memory will be deleted. And all system switches will be reset to default setttings. OK to initialize? (ENTER/EXIT)
F1
F2
F3
F4
Figure 9-37 AUX 100 System Initialization Screen
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9.35 AUX 101 BATTERY ERROR CHECK
AUXILIARY FUNCTIONS
If EFFECT is selected from this function, when control power is applied, the batteries that maintain RAM memory are checked for low voltage. If a low voltage is detected, an error message is displayed. If INEFFECT is selected from this function, the batteries are not checked when control power is applied. Figure 9-38 shows the screen for the Battery Error Check.
Figure 9-38 AUX 101 Battery Error Check Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.36 AUX 103 TOUCH PANEL SHORT CIRCUIT CHECK If EFFECT is selected from this function, at controller power-up, an error is generated if there is a short circuit (closed contact) on the multi function panel touch screen. The same error occurs if the operator presses any area of the multi function panel touch screen during controller power-up. Figure 9-39 shows the Touch Panel Short Ckt. Check function screen.
Figure 9-39 AUX 103 Touch Panel Short Circuit CheckScreen
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9.37 AUX 110 TIME
AUXILIARY FUNCTIONS
The Time function is used to set the current year, month, day, and time. The controller automatically displays the day of the week based on the date information. The cursor keys are used to select the data field to be modified. Error and operations logs are date and time stamped based on the information from this function. Figure 9-40 shows the Time function screen.
AUX 110 TIME DATE : 97-5-20 (TUE) TIME : 10:59:46
F1
F2
F3
F4
Figure 9-40 AUX 110 Time Screen
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9.38 AUX 111 DEDICATED INPUT SIGNAL
AUXILIARY FUNCTIONS
The Dedicated Input Signal function allows the operator to identify signal numbers that are assigned specific functions and cannot be used for other purposes. Figure 9-41 shows the screens used to set dedicated input signals.
Figure 9-41 AUX 111 Dedicated Input Signal Screen
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9.39 AUX 112 DEDICATED OUTPUT SIGNAL
AUXILIARY FUNCTIONS
The Dedicated Output Signal function allows the operator to identify signal numbers that are assigned specific functions and cannot be used for other purposes. Figure 9-42 shows the screens used to set dedicated output signals.
AUX 112 DEDICATED OUTPUT SIGNAL

MOTOR_ON SET/RESET SIGNAL NUMBER: 32 ERROR SET/RESET SIGNAL NUMBER: 31 AUTOMATIC SET/RESET SIGNAL NUMBER: 30 Run in panel switch SET/RESET EXT_IT not set to hold SET/RESET Repeat in panel switch SET/RESET Repeat continuous SET/RESET
AUX 112 DEDICATED OUTPUT SIGNAL

TEACH_MODE
F3
NEXT PG
F2
PREV.PG
SET/RESET SIGNAL NUMBER: 0 SET/RESET SIGNAL NUMBER: 0 HOME2 SET/RESET SIGNAL NUMBER: 0 POWER_ON SET/RESET SIGNAL NUMBER: 0 RGSO SET/RESET SIGNAL NUMBER: 0 Ext. Program select (RPS) enabled SET/RESET SIGNAL NUMBER: 0 HOME1
F1
PREV.DATA
F2
F3
NEXT PG
F4
F1
F2
F3
F4
PREV.DATA PREV.PG
Figure 9-42 AUX 112 Dedicated Output Signal Screen
April 8, 2002
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9.40 AUX 113 DEDICATED SIGNAL DISPLAY
AUXILIARY FUNCTIONS
The Dedicated Signal display, function 113, is a screen where the settings of both dedicated input and output signals can be viewed. This function is used to review the status of the dedicated signals and cannot be used to set or release dedicated signals. Figure 9-43 shows the AUX 113 display screens.
AUX 113 DEDICATED SIGNAL DISPLAY
Dedicated signal set at present EXT. MOTOR ON=1032 EXT. ERROR RESET=1031 EXT. CYCLE START=1030 MOTOR ON=32 ERROR=31 AUTOMATIC=30 Condition: Run in panel switch. Condition: Repeat in panel switch. Condition: Repeat continuous. Condition: Step continuous.
F1
F2
F3
NEXT PG
F4
F5
F6
EXIT
F3
NEXT PG
F2
PREV.PG
AUX 113 DEDICATED SIGNAL DISPLAY
CYCLE_START=29 TEACH_MODE=28 HOME1=27
F1
F2
PREV.PG
F3
F4
F5
F6
EXIT
Figure 9-43 AUX 113 Dedicated Signal Display Screen
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9.41 AUX 114 GUN SPECIFICATION
AUXILIARY FUNCTIONS
AUX 114, Gun Specification, displays a menu screen where information for up to four available guns is entered. From this screen additional menu screens can be accessed to define specific types of guns (painting and sealing) and gun definitions. Each menu screen is accessed using the cursor keys or by entering the function number with the number keys. Figure 9-44 shows the first screen of AUX 114 and table 9-4 gives the menu item descriptions.
AUX 114 GUN SPECIFICATIONS 1 GUN APPLICATION 2 GUN CONDITION 20 HANDLING CLAMP DEFINITION 30 PAINTING/SEALING GUN DEFINITION 32 GUN RELATIVE DISTANCE CHECK
FUNCTION NUMBER: F1 F2
F3
F4
Figure 9-44 AUX Gun Specification Screen
Table 9-4 AUX 114 Menu Item Descriptions

Item 1 Gun application 2 Gun condition 20 Handling clamp definition 30 Painting/sealing gun definition 32 Gun relative distance check function Description Sets the application type for the gun signal. Sets the data corresponding to the CC No.entered as teaching data. Sets data relating to the clamp (open/close hands) signal in handling applications. Sets data relating to the gun signal in painting/sealing applications. Sets the approach distance limit and relative position of the par tner robot for gun distance check.
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9.41.1 GUN SPECIFICATIONS
AUXILIARY FUNCTIONS
Used to set the application type for each of the gun signals from gun 1 to gun 4. To set the application type use the cursor keys to select the desired gun number. At the application number prompt enter the application type number and press the RETURN key. The application types are described in table 9-5.
AUX 114 GUN SPECIFICATIONS

1 GUN APPLICATION APPLICATION 3 3 0 0
GUN1 GUN2 GUN3 GUN4
0 : Not used, 2 : Handling, 3 : Sealing
F1
PRE DATA
F2
F3
F4
Figure 9-45 AUX 114-1 Gun Application Screen
Table 9-5 Gun Application Descriptions

Application 0: Not used 2: Handling 3: Sealing Description The gun signal is not used. The gun signal is designated as a handling clamp signal. The gun signal is designated as a painting/sealing signal.
NOTE When application number 3 is selected for a gun, the data specified in AUX 114-2 Gun Conditions and 114-30 Painting/Sealing is applied. When application number 2 is selected for a gun, the data in AUX 114-20 Handling Clamp Data is applied.
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9.41.2 PAINTING/SEALING GUN DEFINITION
AUXILIARY FUNCTIONS
The paint/sealing gun definition screen is used to set the signal number for guns specified as 3: Sealing in AUX 114-2.

30 PAINT/SEALING GUN DEFINITION GUN ON SIG (0:Not used) ONTIMER OFFTIMER GUN1 GUN2 GUN3 GUN4 17 18 0 0 ON ON ON ON 0.00 S 0.00 S 0.00 S 0.00 S OFF OFF OFF OFF 0.00 S 0.00 S 0.00 S 0.00 S
F1
PRE DATA
F2
F3
F4
Figure 9-46 AUX 114 30 Gun Definition Screen
NOTE
The spray 1/2 key is used to output the gun signals in teach and check mode. The gun signal ON/OFF timing set in AUX 114-30 is used with signals output using the spray 1/2 key.
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AUXILIARY FUNCTIONS
9.41.3 GUN RELATIVE DISTANCE CHECK FUNCTION The gun relative distance check function is used to set the distance limit and relative position of the partner robot for gun distance check. If the partner robots get too close together during teaching, an alarm is sounded. The alarm is in three levels according to the distance. The alarm sound is the same as when approaching software limits during jogging operations. If the partner robots get close enough together, in repeat and check modes, an error is generated: -2128 Relative distance between guns is too near. When this error occurs, manually move the robot away from the partner robot to a safe distance. Figure 9-47 shows the screen used to set the parameters for the gun relative distance check function. Table 9-6 gives the gun relative distance check function screen menu item descriptions.

32 GUN RELATIVE DISTANCE CHECK GUN DISTANCE CHECK EFFECT/INEFFECT LOWER LIMNIT DISTANCE 450.0 mm SETTING POSITION OF ANOTHER ROBOT X DIRECTION 0.0 mm Y DIRECTION 0.0 mm Z DIRECTION 0.0 mm O ROTATION 0.0 deg A ROTATION 0.0 deg T ROTATION 0.0 deg
F1
PRE DATA
F2
F3
F4
Figure 9-47 AUX 114-32 Gun Relative Distance Check Screen
9-68
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AUXILIARY FUNCTIONS
Table 9-6 Gun Relative Distance Check Menu Item Descriptions

Item Gun distance check Lower limit distance X Direction Description Sets effective or ineffective. Initially set to ineffective. Sets approach distance limit. Initially set to 450.0mm. Sets shifting distance in X-axis direction of the par tner robot's coordinates based on its own coordinates. Sets shifting distance in Y-axis direction of the par tner robot's coordinates based on its own coordinates. Sets shifting distance in Z-axis direction of the par tner robot's coordinates based on its own coordinates. Sets rotation angle around the Z-axis of the par tner robot's coordinates based on its own coordinates. Sets rotation angle around the Y-axis after the above rotation of the par tner robot's coordinates based on its own coordinates. Sets rotation angle around the Z-axis after the above rotation of the par tner robot's coordinates based on its own coordinates. Setting EFFECT/INEFFECT 0 ~ 9999.9 mm -9999.9 ~ 10000.0 mm -9999.9 ~ 10000.0 mm -9999.9 ~ 10000.0 mm -180.0 ~ 180.0
Relative position of the partner robot
Y Direction Z Direction O Rotation
A Rotation
-90.0 ~ 90.0
T Rotation
-180.0 ~ 180.0
April 8, 2002
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9.42 AUX 120 ERROR LOGGING
AUXILIARY FUNCTIONS
The Error Logging function allows the operator to view a history of the errors that have occurred on an individual controller. Up to 1,000 errors are recorded by this function. The errors are listed in chronological order with the most recent entry first. The date, time, error number, and a description of the error are all listed. Error messages cannot be deleted or edited and remain in memory even after the controller has been initialized. Figure 9-48 shows an example of the Error Logging function screen. Pressing the F3 key displays the next group of errors in the log.
Figure 9-48 AUX 120 Error Logging Screen
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9.43 AUX 122 OPERATION LOGGING
AUXILIARY FUNCTIONS
The Operation Logging function allows the operator to view a history of the operations that have occurred on an individual controller. Up to 100 previously performed operations are recorded by this function. The operations are listed in chronological order with the most recent entry first. The operation logging function also displays the name of the operator interface the operation was performed on, the date, time, and a description of the operation performed. Operation log entries cannot be deleted or edited and remain in memory even after the controller is initialized. Figure 9-49 shows an example of the Operation Logging function screen. Pressing the F3 key moves the display to the next group of operations in the log.
AUX 122 OPERATION LOGGING

1-(TP), 2-(TP), 3-(TP), 4-(TP), 5-(TP), 6-(TP), 7-(TP), 8-(TP), 9-(TP), 10-(TP), 11-(TP), [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 [97/02/25 16:28:21 16:25:14 16:27:03 16:11:51 16:01:36 15:59:41 14:58:08 13:50:12 09:31:21 09:29:17 09:09:35 WHERE 1:6 3,1] SAVE FILE3] list/r] dir] list/r] dir] list/r] edit] WHERE] SAVE FILE2] SAVE FILE1]
F1
F2
F3
NEXT PG
F4
F5
F6
EXIT
Figure 9-49 AUX 122 Operation Logging Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.44 AUX 140 ENCODER ROT. COUNTER RESET The Encoder Rot. (Rotation) Counter Reset function is used in conjunction with AUX 41 Zeroing and AUX 44 Zeroing Data Set Display, as part of the zeroing process. When maintenance is performed that mechanically changes the position of the robot in relation to the encoders or a servo motor is replaced, zeroing is required.
CAUTION
Operators must be aware of the effect changes made in this function have on the position of programmed locations. Changing this data without following the complete zeroing process may move programmed locations to positions that cause damage to the robot, fixtures or work.
AUX 140 provides the operator with the option of selecting a single joint or all joints to the reset encoder rotation count. If a single joint is selected, a set degree angle for that axis may also be entered. When the data for this function is entered, the offset is stored by the 1HA board to provide accurate robot motion. Figure 9-50 shows the Encoder Rot. Counter Reset screen.
AUX 140 ENCODER ROT.COUNTER RESET
SETTING JT1 JT2 JT3 JT4 JT5 JT6 268427264 268427264 268427264 268427264 268427264 268427264
CURRENT 268427264 268427264 268427264 268427264 268427264 268427264
JOINT number = 0 (0=RESET ALL JOINT) SET DEGREE = 0deg F1

PRE DATA
F2
F3
F4
Figure 9-50 AUX 140 Encoder Rot. Counter Reset Screen
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9.45 AUX 142 PROGRAM QUEUE
AUXILIARY FUNCTIONS
The Program Queue is a memory function that stores the program numbers for playback. If the same program is used several times in the process of the robots operation, this function saves the operator the trouble of inputting program numbers before each play back. Storing the robot program repeat patterns in the Program Queue is used when the process and work piece carried in by conveyor is known in advance. Display each setting screen using the cursor keys or selecting the function by number. Figure 9-51 shows the Program Queue display screen and table 9-7 gives the menu item descriptions.
AUX 142 PROGRAM QUEUE 1 2 3 4 5 6 DISPLAY REGIST INSERT DELETE ALL DELETE ENVIRONMENT SET
FUNCTION NUMBER: F1 F2
F3
F4
Figure 9-51 AUX 142 Program Queue Screen
NOTE
100 programs can be registered in Program Queue Unfinished programs can be registered by No. in Program Queue The same program No. can be registered a number of times. The program queue address numbers are played back in numerical order.
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AUXILIARY FUNCTIONS
Table 9-7 Program Queue Menu Item Descriptions

Item 1 DISPLAY 2 REGIST 3 INSERT 4 DELETE 5 ALL DELETE 6 ENVIRONMENT SET Description Displays the PROGRAM QUEUE. Programs cannot be registered. Registers program in PROGRAM QUEUE. Inser ts program into PROGRAM QUEUE. Deletes designated program from PROGRAM QUEUE. Deletes all programs stored in PROGRAM QUEUE. Sets environment for the PROGRAM QUEUE.
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9.45.1 DISPLAY
AUXILIARY FUNCTIONS
The DISPLAY function allows the operator to view the contents that are registered in Program Queue. This is a display only, registration to Program Queue is not possible from this screen (Figure 9-52).
AUX.142 PROGRAM QUEUE 1 DISPLAY
1 [0] 9 [0] 17 [0] 25 [0] 33 [0] F1
2 [0] 10 [0] 18 [0] 26 [0] 34 [0]
3 4 [0] [0] 11 12 [0] [0] 19 20 [0] [0] 27 28 [0] [0] 35 36 [0] [0] F2
5 [0] 13 [0] 21 [0] 29 [0] 37 [0]
6 [0] 14 [0] 22 [0] 30 [0] 38 [0] F3
7 [0] 15 [0] 23 [0] 31 [0] 39 [0]
8 [0] 16 [0] 24 [0] 32 [0] 40 [0] F4

RENEW
NEXT PG
PRE PG
AUX.142 PROGRAM QUEUE 1 DISPLAY
81 [0] 89 [0] 97 [0]
F1
Figure 9-52 AUX 142-1 Program Queue Display Screen
April 8, 2002
F2
. . .
F3
NEXT PG
82 [0] 90 [0] 98 [0] 83 84 [0] [0] 91 92 [0] [0] 99 100 [0] [0] 85 [0] 93 [0] 86 [0] 94 [0]
F2
PRE PG
.
. .
87 [0] 95 [0] 88 [0] 96 [0]
F3
F4
RENEW
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9.45.2 REGISTER
AUXILIARY FUNCTIONS
The REGISTER function allows the operator to register program numbers into the Program Queue (Figure 9-53). When program numbers are changed previous data is overwritten.
AUX.142 PROGRAM QUEUE 2 REGIST
1 [0] 9 [0] 17 [0] 25 [0] 33 [0] F1
2 [0] 10 [0] 18 [0] 26 [0] 34 [0]
3 4 [0] [0] 11 12 [0] [0] 19 20 [0] [0] 27 28 [0] [0] 35 36 [0] [0] F2
5 [0] 13 [0] 21 [0] 29 [0] 37 [0]
6 [0] 14 [0] 22 [0] 30 [0] 38 [0] F3
7 [0] 15 [0] 23 [0] 31 [0] 39 [0]
8 [0] 16 [0] 24 [0] 32 [0] 40 [0] F4
PRE DATA
NEXT PG
PRE PG
AUX.142 PROGRAM QUEUE 2 REGIST
81 [0] 89 [0] 97 [0]
F1
PRE DATA
Figure 9-53 AUX 142-2 Program Queue Register Screen
9-76
F2
. . .
F3
NEXT PG
82 [0] 90 [0] 98 [0] 83 84 [0] [0] 91 92 [0] [0] 99 100 [0] [0] 85 [0] 93 [0] 86 [0] 94 [0]
F2
PRE PG
.
. .
87 [0] 95 [0] 88 [0] 96 [0]
F3
F4
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9.45.3 INSERT
AUXILIARY FUNCTIONS
This function is used to insert programs into the Program Queue (Figure 9-54). When pressing the F4 key at the cursors current position, data following the cursor is shifted one position. The position with the cursor becomes blank and data can be inserted. When the INSERT (F4) key is pressed again without registering data, insert mode is released. The screen displays previously set values. Insert mode must be enabled to register data.
AUX.142 PROGRAM QUEUE 3 INSERT
1 [0] 9 [0] 17 [0] 25 [0] 33 [0] F1
2 [0] 10 [0] 18 [0] 26 [0] 34 [0]
3 4 [0] [0] 11 12 [0] [0] 19 20 [0] [0] 27 28 [0] [0] 35 36 [0] [0] F2
5 [0] 13 [0] 21 [0] 29 [0] 37 [0]
6 [0] 14 [0] 22 [0] 30 [0] 38 [0] F3
7 [0] 15 [0] 23 [0] 31 [0] 39 [0]
8 [0] 16 [0] 24 [0] 32 [0] 40 [0] F4

INSERT
PRE DATA
NEXT PG
PRE PG
AUX.142 PROGRAM QUEUE 3 INSERT
81 [0] 89 [0] 97 [0]
F1
PRE DATA
Figure 9-54 AUX 142-3 Program Queue Insert Screen April 8, 2002 9-77
F2
. . .
F3
NEXT PG
82 [1] 90 [1] 98 [0] 83 84 [1] [0] 91 92 [1] [1] 99 100 [0] [0] 85 [1] 93 [0] 86 [0] 94 [1]
F2
PRE PG
.
. .
87 [0] 95 [0] 88 [0] 96 [0]
F3
F4
INSERT
Kawasak
9.45.4 DELETE
AUXILIARY FUNCTIONS
This function is used to delete the designated program from the Program Queue (Figure 5-55). When the DELETE (F4) key is pressed at the cursor position, the operation confirmation screen is displayed. Press the F1 key (YES) to delete the data. Press the F4 key (NO) to cancel the operation.
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AUXILIARY FUNCTIONS
AUX.142 PROGRAM QUEUE 4 DELETE
1 [1] 9 [0] 17 [0] 25 [0] 33 [0] F1
2 [2] 10 [0] 18 [0] 26 [0] 34 [0]
3 4 [0] [0] 11 12 [0] [0] 19 20 [0] [0] 27 28 [0] [0] 35 36 [0] [0] F2
5 [1] 13 [0] 21 [0] 29 [0] 37 [0]
6 [0] 14 [0] 22 [0] 30 [0] 38 [0] F3
7 [0] 15 [0] 23 [0] 31 [0] 39 [0]
8 [0] 16 [0] 24 [0] 32 [0] 40 [0] F4

DELETE
NEXT PG
PRE PG
AUX.142 PROGRAM QUEUE 4 DELETE
81 [0] 89 [0] 97 [0]
F1
Are you sure?
F1
YES
Figure 9-55 AUX 142-4 Program Queue Delete Screen
April 8, 2002
F2
. . .
F3
NEXT PG
82 [0] 90 [0] 98 [0] 83 84 [0] [0] 91 92 [0] [0] 99 100 [0] [0] 85 [0] 93 [0] 86 [0] 94 [0]
F2
PRE PG
.
. .
87 [0] 95 [0] 88 [0] 96 [0]
F3
F4
DELETE
F4
DELETE
F2 F3 F4
NO
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9.45.5 ALL DELETE
AUXILIARY FUNCTIONS
This function is used to delete all the data stored in the Program Queue (Figure 9-56). Press the F1 key (YES) to delete the data. Press the F4 key (NO) to cancel the operation.
AUX.142 PROGRAM QUEUE 5 ALL DELETE
Are you sure?
F1
YES
F2
F3
F4
NO
Figure 9-56 AUX 142-5 Program Queue All Delete Screen
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9.45.6 ENVIRONMENT SET
AUXILIARY FUNCTIONS
This function is used to set the shift type and shift mode of the Program Queue. Figure 9-57 shows the ENVIRONMENT SET screen, table 9-8 gives the shift type descriptions, and table 9-9 gives the shift mode descriptions. Select the shift type and shift mode to use for the queue table during Program Queue update.
AUX.142 PROGRAM QUEUE 6 ENVIRONMENT SET
PROGRAM QUEUE SHIFT TYPE FIFO/LOOP PROGRAM QUEUE SHIFT MODE INTERNAL/EXTERNAL
F1
PRE DATA
F2
F3
F4
Figure 9-57 AUX 142-6 Program Queue Environment Set Screen
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AUXILIARY FUNCTIONS
Table 9-8 Program Queue Shift Type Descriptions

Shift Type Description When the program is updated, programs are moved forward sequentially. When the last program of the queue is executed, all data is deleted. FIFO type Example: Address 1 2 3 4 Program 10 11 3 5 update Address 1 2 3 4 Program 11 3 5 6
5 6 6 0 5 6 0 0
When the program is updated, the executed porgram is registered at the last position of the queue and looped. Example: Address 1 2 3 4 Program 10 11 3 5 update Address 1 2 3 4 Program 11 3 5 6
LOOP type
5 6 6 0 5 6 10 0
The shift mode selects the method used to shift the program queue. Table 9-9 gives the shift mode descriptions.
Table 9-9 Shift Mode Descriptions

Shift Mode Internal Shift External Shift Description The queue is shifted automatically when the program is updated. The queue is shifted by external signals.
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AUXILIARY FUNCTIONS
9.45.7 PROGRAM QUEUE REGISTRATION SEQUENCE Program registration to the program queue using dedicated signals is accomplished through the RPS function. When the RPS_ON signal is received after entering the program number, the program is registered into the queue table. When the program queue option is ON, program change cannot be executed with the RPS_ON signal. Figure 9-58 shows the program queue registration sequence and figure 9-59 shows the program execution sequence.
Program Number (Input)
RPS_ON (Input) Queue Register
Figure 9-58 Program Queue Registration Sequence
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RPS_ST (Output) Queue Start (Input)
AUXILIARY FUNCTIONS
Program Number (Output)
RPS_OK (Output)
Robot Operation
Queue Shift (Input)
Queue Update (Internal shift Mode)
Queue Update (External shift Mode)
Figure 9-59 Program Queue Execution Sequence
When the program is waiting for RPSEND, RPS_ST is output. If the QUE START input is received in this condition, the program changes to the first program in the queue table. When RPS_ST is not output (RPS_ST waiting), the Queue Start Input cannot be executed. When the SHIFT MODE is set to EXTERNAL, inputting the queue shift is optional. When the PROGRAM QUEUE option is OFF, programs are changed by RPS_ON, not by Queue Start. When the START DELAY option is ON, programs are registered to DELAY QUEUE by program switches. Program can be registered to the DELAY QUEUE regardless of the condition of RPSEND waiting at this time. 9-84 April 8, 2002
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9.46 AUX 143 START DELAY
AUXILIARY FUNCTIONS
This function is used to delay the timing of the robots actual motion start after the start signal is received depending on the conveyor moving distance. The DELAY DISTANCE is set by the COMMON DELAY DISTANCE, and is used in all programs, or by INDIVIDUAL DELAY DISTANCE, a setting used for particular programs. When both are set, the values of both distances are added for determining the delay distance. Figure 9-60 shows the Start Delay menu screen and table 9-10 gives the menu item descriptions.
AUX.143 START DELAY
1 COMMON DELAY DISTANCE 2 INDIVIDUAL DELAY DISTANCE 3 MULTI START DELAY
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 9-60 AUX 143 Start Delay Menu Screen
Table 9-10 Start Delay Menu Descriptions

Delay Type Common delay distance Individual delay distance Multi star t delay Description Used to set the delay distances common to all programs. Used to set the delay distances for each program. Used to display, change, and delete the program number and delay distance of the star t delay queue.
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NOTE
AUXILIARY FUNCTIONS
When the conveyors remaining distance is 0, programs cannot be changed if the executing program is waiting for the RPSEND signal. When attempting to change a program during repeat mode, an error is generated, and the robot stops. Programs not executed remain in queue.
9.46.1 START DELAY COMMON DELAY DISTANCE This function is used to set the delay distance common to all programs (Figure 9-61). The distance value range is 0 through 99999 mm. The default value is 0 mm.
AUX.143 START DELAY 1 COMMON DELAY DISTANCE
START DELAY DISTANCE
0 mm
F1
PRE DATA
F2
F3
F4
Figure 9-61 AUX 143-1 Start Delay, Common Delay Distance Screen
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AUXILIARY FUNCTIONS
9.46.2 START DELAY INDIVIDUAL DELAY DISTANCE This function is used to set a delay distance for each program (Figure 9-62).
AUX.143 START DELAY 2 INDIVIDUAL DELAY DISTANCE 1 SET EACH DIST. 2 SET SAME DIST.
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 9-62 AUX 143-2 Start Delay, Individual Delay Distance Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.46.2.1 START DELAY INDIVIDUAL DELAY DISTANCE SETTING This function is used to set the delay distance in each program individually (Figure 963). For long queues, 4 programs prior to and following the input program (9 total) are displayed.
AUX.143 START DELAY 2 INDIVIDUAL DEL 1 SET EACH DIST.
PROGRAM No.
F1
F2
F3
F4
0
~
9
RETURN
AUX.143 START DELAY 2 INDIVIDUAL DEL 1 SET EACH DIST. PROGRAM No. DELAY DIST.
1 2 3 4 5 6 7 8 9
0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm 0 mm
F1
PRE DATA
F2
F3
F4
PROGRAM NEXT PG SELECT
F4
PROGRAM SELECT
PROGRAM No.:
F3 F4
F1
F2
Figure 9-63 AUX 143-2-1 Start Delay, Individual Delay Distance Setting Screen 9-88 April 8, 2002
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AUXILIARY FUNCTIONS
To access multiple pages use the NEXT PG and PRE PG keys. Press the PROGRAM SELECT (F4) key to display and change program settings. The distance value range is 0 through 99999 mm. The default value is 0 mm. Program number range is 1 - 999. Start delay distance for programs not registered in the program queue can be stored. 9.46.2.2 START DELAY SAME DELAY DISTANCE SETTING This function is used to set the delay distance for each program to the same value (Figure 9-64). The distance value range is 0 through 99999 mm. The default value is 0 mm.
AUX.143 START DELAY 2 INDIVIDUAL DEL 2 SET SAME DIST.
DELAY DIST.
100 mm
F1
PRE DATA
F2
F3
F4
0
~
9
RETURN
Are you sure?
F2 F3 F4
NO
F1
YES
Figure 9-64 AUX 143-2-2 Start Delay, Same Delay Distance Setting Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.46.3 START DELAY, MULTI START DELAY DISTANCE This function is used to display, change, and delete the program number and delay distance for the start delay queue (Figure 9-65). Twenty programs can be registered in the queue.
AUX.143 START DELAY 3 MULTI START DELAY 1 DISPLAY 2 CHANGE 3 DELETE 4 ALL DELETE
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 9-65 AUX 143-3 Start Delay, Multi Start Delay Distance Menu Screen
9.46.3.1 START DELAY, MULTI START DELAY DISTANCE DISPLAY This function allows the operator to view the status of the start delay queue (Figure 966). The sum of the common delay distance + the individual delay distance is displayed. Press the RENEW (F4) key to update the display data.
AUX.143 START DELAY 3 MULTI START DELAY 1 DISPLAY ADDRESS PROGRAM No. REST DIST.
1 2 3 4 5 6 7 8 9
0 0 0 0 0 0 0 0 0
F1
F2
F3
NEXT PG
F4
RENEW
Figure 9-66 AUX 143-3-1 Start Delay, Multi Start Delay Distance Display Screen
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AUXILIARY FUNCTIONS
9.46.3.2 START DELAY, MULTI START DELAY DISTANCE CHANGE This function is used to change the program number and delay distance for the current queue (Figure 9-67). After the changes are entered, press the MODIFY (F4) key to accept the program or delay distance data highlighted by the cursor. Program addresses not registered in the program queue are not accepted.
AUX.143 START DELAY 3 MULTI START DELAY 2 CHANGE ADDRESS PROGRAM No. DELAY DIST.
1 2 3 4 5 6 7 8 9
0 0 0 0 0 0 0 0 0
F1
PRE DATA
F2
F3
NEXT PG
F4
MODIFY
Figure 9-67 AUX 143-3-2Start Delay, Multi Start Delay Distance Change Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.46.3.3 START DELAY, MULTI START DELAY DISTANCE DELETE This function is used to delete registered queue data (Figure 9-68). The program number and delay distance highlighted by the cursor is deleted by pressing the DELETE (F4) key. Program addresses not registered in the program queue are not accepted.
AUX.143 START DELAY 3 MULTI START DELAY 3 DELETE ADDRESS PROGRAM No. DELAY DIST.
1 2 3 4 5 6 7 8 9
0 0 0 0 0 0 0 0 0
F1
F2
F3
NEXT PG
F4
DELETE
F4
DELETE
Are you sure?
F2 F3 F4
NO
F1
YES
Figure 9-68 AUX 143-3-3 Start Delay, Multi Start Delay Distance Delete Screen
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AUXILIARY FUNCTIONS
9.46.3.4 START DELAY, MULTI START DELAY DISTANCE ALL DELETE This function is used to delete all registered queues in blocks (Figure 9-69). Press the F1 (YES) key to delete all queues or F4 (NO) to cancel the operation.
AUX.143 START DELAY 3 MULTI START DELAY 4 ALL DELETE ADDRESS PROGRAM No. REST DIST.
1 2 3 4 5 6 7 8 9 Are you sure?
0 0 0 0 0 0 0 0 0
F1
YES
F2
F3
F4
NO
Figure 9-69 AUX 143-3-4 Start Delay, Multi Start Delay Distance All Delete Screen
April 8, 2002
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9.47 AUX 144 INTERRUPT PROGRAM
AUXILIARY FUNCTIONS
This function is used to designate the program selected and executed when RPS mode is waiting for input at the end of a program (Figure 9-70). When the interrupt dedicated input signals are set, program execution changes to the designated interrupt program. INTERRUPT PROGRAM 1: changes to the interrupt program 1 set in AUX. 144. INTERRUPT PROGRAM 2: changes to the interrupt program 2 set in AUX. 144. INTERRUPT PROGRAM 3: changes to the interrupt program 3 set in AUX. 144.
AUX.144 INTERRUPT PROGRAM
INTERRUPT PROGRAM 1 INTERRUPT PROGRAM 2 INTERRUPT PROGRAM 3
0 0 0
F1
PRE DATA
F2
F3
F4
Figure 9-70 AUX 144 Interrupt Program Screen
CAUTION
When the start signal of interrupt program is input externally during repeat operation, the interrupt program is executed after the current program execution is completed. See the Explosion-Proof External I/O Manual for interrupt start signal information.
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9.48 AUX 149 TOOL REGISTRATION
AUXILIARY FUNCTIONS
This function is used to record tool mass, center of gravity, and inertia moment around X-axis, Y-axis, and Z-axis data. A total of nine tools may be recorded and monitored (Figure 9-71). This function is activated as part of the Collision Detection Function option. Information for each tool is recorded on an individual page, for a total of nine pages. Utilizing the nine pages results in all tool information recorded in one location. The values in AUX 48 Tool Dimensions is updated automatically when tool registration data is changed.
AUX.149 TOOL REGISTRATION TOOL 1
WEIGHT OF LOAD X POSITION OF LOAD Y POSITION OF LOAD Z POSITION OF LOAD INERTIA AROUND X AXIS INERTIA AROUND Y AXIS INERTIA AROUND Z AXIS
15.0 kg 0.0 mm 0.0 mm 0.0 mm 0.00 kgm^2 0.00 kgm^2 0.00 kgm^2
F1
PRE DATA
F2
F3
NEXT PG
F4
Figure 9-71 AUX 149 Tool Registration Screen
Press the F3 (NEXTPG) key to set tools 2-9. Pressing and holding the F3 (NEXT PG) key or the F2 (PRE PG) key advances to the last, or to the first, page, respectively. Table 9-11 gives the tool registration setting values.
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AUXILIARY FUNCTIONS
Table 9-11 Tool Registration Setting Values

Item WEIGHT OF LOAD X POSITION OF LOAD Y POSITION OF LOAD Z POSITION OF LOAD INATIA AROUND X AXIS INATIA AROUND Y AXIS INATIA AROUND Z AXIS Description Load mass installed on the robot(Handling spec; includes the work-piece) Load value, center of gravity on X axis Load value, center of gravity on X axis Y axis Load value, center of gravity on X axis Z axis The value of iner tia moment around X axis The value of iner tia moment around Y axis The value of iner tia moment around Z axis Setting 0 Payload -9999.9 10000.0 mm -9999.9 10000.0 mm -9999.9 10000.0 mm 0 999.99 0 999.99 0 999.99
CAUTION
The correct mass and center of gravity for motion type 2 (option) is registered. Entering wrong values may decrease the life of the mechanical unit components or cause overload/deviation errors.
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9.49 AUX 153 PROGRAMS IN DETAIL
AUXILIARY FUNCTIONS
This function allows the operator to view a listing of the program information: COMMENT, TOTAL STEP NUMBERS, DATE EDITED (Figure 9-72).
AUX 153 PROGRAMS IN DETAIL

PROGRAM pg1 COMMENT STEP NUMBER 2 EDIT DATE 01-08-30 08:35
F1
F2
F3
F4
F5
F6
EXIT
Figure 9-72 AUX 153 Programs in Detail Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.50 AUX 154 TOTAL REPEAT CYCLES OF PROGRAM This function allows the operator to view, modify, or to clear the repeat cycles of program count (Figure 9-73 through 9-75). When a program is executed in dry run mode (program play back with servo power OFF and no robot motion), the number of cycles is not changed. When a program is executed in repeat mode and a program BRANCH instruction (absolute jump, etc.) exists at the end of program, the number of repeat cycles is not changed. When ending a program with forced termination during repeat mode, the number of repeat cycles is not changed. When program execution ends with the repeat cycle screen displayed, the repeat cycle number is not updated (not a live display). The repeat cycle count is maintained by an internal counter and the correct number of cycles is displayed when the operator exits the repeat cycle screen and displays it again. The number of repeat cycles is counted up to 65535, when this number is exceeded the counter value does not change.
AUX.154 TOTAL REPEAT CYCLES OF PROGRAM
1 DISPLAY AND MODIFY 2 ALL CLEAR
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 9-73 Total Repeat Cycles of Program Screen
9-98
April 8, 2002
Kawasak
AUXILIARY FUNCTIONS
9.50.1 TOTAL REPEAT CYCLES OF PROGRAM, DISPLAY AND MODIFY

AUX 154 TOTAL REPEAT CYCLES OF PROGRAM 1 DISPLAY AND MODIFY pg1 0 pg2 0
F1
PRE DATA
F2
F3
F4
Figure 9-74 AUX 154-1 Total Repeat Cycles of Program Display and Modify Screen
9.50.2 TOTAL REPEAT CYCLES OF PROGRAM, ALL CLEAR
AUX 154 TOTAL REPEAT CYCLES OF PROGRAM 2 ALL CLEAR
F1
F2
F3
F4
Figure 9-75 AUX 154-2 Total Repeat Cycles of Program All Clear Screen
April 8, 2002
9-99
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AUXILIARY FUNCTIONS
9.51 HOME POSITION CHECK AXIS SET, AUX 155 This function is used to set a check of the data registered for the home position of each joint axis. If INEFFECT is selected, the home position of a specified axis is not checked (Figure 9-76). The F3 (NEXT PG) and F2 (PRE PG) keys are used to scroll through the screens: HOME POSITION 1 JT1 JT6 (JT7) HOME POSITION 1 JT8 JT12 HOME POSITION 2 JT1 JT6 (JT7) HOME POSITION 2 JT8 JT12
AUX 155 HOME POSITION CHECK AXIS SET
HOME POSITION JT1 JT2 JT3 JT4 JT5 JT6 JT7 EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT
F1
PRE DATA
F2
F3
NEXT PG
F4
PRE PG
AUX 155 HOME POSITION CHECK AXIS SET
HOME POSITION2 JT8 EFFECT/INEFFECT
F1
PRE DATA
Figure 9-76 AUX 155 Home Position Check Axis Set Screens 9-100 April 8, 2002
F2
. . .
F3
NEXT PG
F2
PRE PG
.
. .
F3
F4
Kawasak
9.52 AUX 158 DOUT FUNCTION ASSIGNMENT
AUXILIARY FUNCTIONS
This function is used to set the general output signals (No.1 No.32) to effective (used) or ineffective (not used) and the signal type (Figure 9-77). The signal types are; signal used or not used, signal output condition at hold, signal output condition when program execution is completed, and signal output condition when program execution is started. The message at the bottom of the screen depends on the cursor position as listed below. When the cursor is at a type 1 position, the message reads Output signal function 0:work 1:not work as shown in figure 9-77. When the cursor is at a type 2 position, the message reads Output at program hold 0:OFF 1:ON 2: KEEP. When the cursor is at a type 3 position, the message reads Output at program end 0:OFF 1:ON 2: KEEP. When the cursor is at a type 4 position, the message reads Output at program starting 0:OFF 1:ON 2:KEEP. The default value for all types is 0. Table 9-12 gives the type setting descriptions.
April 8, 2002
9-101
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AUXILIARY FUNCTIONS
AUX.158 DOUT FUNCTIONAL ASSIGNMENT
No. 1 2 3 4 5 6 7 TYPE 1 [0] [0] [0] [0] [0] [0] [0] TYPE 2 [0] [0] [0] [0] [0] [0] [0] TYPE 3 [0] [0] [0] [0] [0] [0] [0] TYPE 4 [0] [0] [0] [0] [0] [0] [0] No. 9 10 11 12 13 14 15 TYPE 1 [0] [0] [0] [0] [0] [0] [0] TYPE 2 [0] [0] [0] [0] [0] [0] [0] TYPE 3 [0] [0] [0] [0] [0] [0] [0] TYPE 4 [0] [0] [0] [0] [0] [0] [0] Output signal function (0:work 1:not work)
8 [0] [0] [0] [0] 16 [0] [0] [0] [0]
F1
PRE DATA
F2
F3
NEXT PG
F4
PRE PG
Figure 9-77 AUX 158 Dout Function Assignment Screen
Table 9-12 Dout Function Assignment, Type Descriptions

Type Setting 0: work 1 1: not work 0: OFF 2 1: ON 2: KEEP 0: OFF 3 1: ON 2: KEEP 0: OFF 4 1: ON 2: KEEP Comment If output signal setting in Aux 169 is "EFFECT", the signal is output. If output signal setting in Aux 169 is "INEFFECT", the signal is not output. The signal is output regardless of setting in AUX 169. At program hold, signal state is set to OFF. At program hold, signal state is set to ON. At program hold, signal state is maintained At program end, signal state is set to OFF. At program end, signal state is set to ON. At program end, signal state is maintained At program star t, signal state is set to OFF. At program star t, signal state is set to ON. At program star t, signal state is maintained
9-102
F2
. . .
F3
NEXT PG
April 8, 2002
Kawasak
9.53 AUX 159 HISTORY CLEAR
AUXILIARY FUNCTIONS
This function is used to clear the logs for operations (AUX 122) and errors (AUX 120). Press the F1 (YES) key to delete all logs or F4 (NO) to cancel the operation (figure 978).
AUX 159 HISTROY CLEAR
Clear operation and error logging. Are you sure?
F1
YES
F2
F3
F4
NO
Figure 9-78 History Clear Screen
April 8, 2002
9-103
Kawasak
9.54 AUX 166 PG PARTIAL DELETE
AUXILIARY FUNCTIONS
This function is used to delete steps (in one or more units) from programs stored in memory (Figure 9-79). If the step designated does not exist (for example, steps 15 20 are designated for a 15 step program), program contents do not change, though the completion message is displayed.
AUX 166 PG PARTIAL DELETE
PROGRAM NAME TOP NUMBER TO DELETE NUMBER OF STEPS TO DELETE ( 0: Deletes to the last step ) 0 0
F1
PROGRAM INPUT
F2
F3
F4
Figure 9-79 AUX 166 PG Partial Delete Screen
9-104
April 8, 2002
Kawasak
AUXILIARY FUNCTIONS
9.55 AUX 167 SINGULAR POINT ALARM RANGE SET This function is used to display and set the singular point alarm function (Figure 9-80). When the controller determines the robot cannot achieve the calculated joint angles for the position and the posture required to satisfy the tool center point (XYZOAT) position, this called a singular point (singularity). The following situations can cause a singularity condition. 1. Multiple combinations of each joint angle that can satisfy the desired tool tip position and posture exist. If all joint angles cannot be determined, the software does not allow the controller processor to make a decision, and the robot is stopped. Desired position and posture of the tool tip cannot be achieved due to structural constraint. For example, a point out of the operating range is designated that the arm cannot reach.
2.
The robot motion is rapid around the singular point and the vicinity of the singular point. When the robot enters the singular point range, the robot is stopped and an error is displayed. This function allows the robot to be stopped before executing unexpected motion, that can cause damage to the robot, robot tooling, or peripheral equipment. The value range for setting the singular point alarm is 0 through 30 degrees. The default setting is 5.0 degrees.
April 8, 2002
9-105
Kawasak
AUXILIARY FUNCTIONS
AUX 167 SINGULAR POINT ALARM RANGE SET
SINGULAR POINT 1 (FRONT) SINGULAR POINT 2 (BACK)
5.0 deg 5.0 deg
RANGE
: 0.0deg30.0deg
F1
PRE DATA
F2
F3
F4
Figure 9-80 AUX 167 Singular Point Alarm Range Set Screen
When the Singular Point 1 occurs, error code -1203 is generated : -2103 Wrist cant be straightened any more (Singular Point 1) When the singular Point 2 occurs, error code -2104 is generated: -2104 Wrist cant be bent any more (Singular Point 2) Or, error may occur from extending beyond operation range or going over speed limit.
9-106
April 8, 2002
Kawasak
AUXILIARY FUNCTIONS
9.56 AUX 168 DIFFERENCE OF WORK/AIR-CUT SPEED This function is used to select execution of painting moves and air-cut moves at different speeds (Figure 9-81). When YES is selected, the robot operates at the painting and air-cut speed according to differences at each painting step and air-cut step, Operation speed, when NO is selected, is described below. The robot operates at the speed indicated by the last SPRAY_SPEED instruction, AIRCUT instruction or SPEED instruction, until the next SPEED instruction is executed regardless of differences in the painting step or air-cut step. Joint operation occurs only when SPR_JSPEED and SPR_AC_JSPEED instructions are executed. Linear operation occurs only when SPR_SPEED and SPR_AC_SPEED instructions are executed. When a SPEED instruction is not executed, the robot operates at the default value (Joint 10%, Linear 100 mm/s). When a SPEED instruction is executed without designating an ALWAYS instruction, only the next step is operated at the specified speed.
AUX 168 DIFF. OF WORK/AIRCUT SPEED
DIFF. OF WORK/AIRCUT SPEED YES/NO
F1
PRE DATA
F2
F3
F4
Figure 9-81 Difference of Work/Air-Cut Speed Screen
April 8, 2002
9-107
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AUXILIARY FUNCTIONS
9.57 AUX 169 OPERATION CONDITION SETTING This function is used to set the following operation conditions (Figure 9-82). CONDITION SIGNAL OUTPUT SIGNAL WAIT CONVEYOR WAIT DELAY TIME DOOR SENSE CAMERA SENSE CONDITION SIGNAL OUTPUT SIGNAL WAIT CONVEYOR WAIT DELAY TIME DOOR SENSE CAMERA SENSE SETTING EFFECTIVE/INEFFECTIVE EFFECTIVE/INEFFECTIVE EFFECTIVE/INEFFECTIVE EFFECTIVE/INEFFECTIVE EFFECTIVE/INEFFECTIVE EFFECTIVE/INEFFECTIVE LANGUAGE INSTRUCTION INS_SIGOUT INS_SIGWAIT INS_CVWAIT INS_DELAY DOOR_SENSE CAMERA_SENSE SETTING ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF ON/OFF
When a condition dedicated signal is set as effective, the operation condition is set to the default value by the input signal. See the Explosion-Proof C Controller External I/O Manual for more information. Table 9-13 gives the signal descriptions and table 9-14 gives signal setting descriptions.
AUX 169 OPERATION CONDITION SETTING
SIGNAL OUTPUT SIGNAL WAIT CONVEYOR WAIT DELAY TIME DOOR SENSE CAMERA SENSE REPEAT STEP RPS DRY RUN
EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT EFFECT/INEFFECT CONT/ONCE CONT/ONCE EFFECT/INEFFECT EFFECT/INEFFECT
F1
PRE DATA
F2
F3
F4
Figure 9-82 AUX 169 Operation Condition Setting Screen
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April 8, 2002
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AUXILIARY FUNCTIONS
Table 9-13 Output and Spray Signal Descriptions

Signal Output Ineffective Signal output command Spray device output commands Spray commands Comment Instruction is not executed in teach, repeat, or manual mode. SIGNAL SPR_FRATE SPR_FRATE_R SPR_FRATE_A SPR_FRATE_U SPR_PATTERN SPR_PATTERN_R SPR_PATTERN_A SPR_PATTERN_U SPR_ATOMIZE SPR_ATOMIZE_R SPR_ATOMIZE_A SPR_ATOMIZE_U SPR_HVOLT SPR_HVOLT_R SPR_FLUSH SPR_HVOLT_A SPR_PTHINNER SPR_HVOLT_U
GUNON and GUNOFF
Table 9-14 Signal Setting Descriptions

Signal Type Signal wait Effective Ineffective Conveyor wait Effective Ineffective Delay time Effective Ineffective Door sense Effective Camera sense XDELTA, XDSTART Not used DELAY Instruction is not executed in teach or repeat mode. CVWAIT Instruction is not executed in teach or repeat mode. DIN_WAIT Instruction is not executed in teach or repeat mode. Setting Ineffective Comment Instruction is not executed in teach or repeat mode.
April 8, 2002
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9.58 AUX 172 SYSCOUNT DISPLAY/SETTING
AUXILIARY FUNCTIONS
This function is used for displaying the condition of system counters and for setting the general/private system counter values (Figure 9-83). There are 32 available general counters and 32 available private counters.
AUX 172 SYSCOUNT DISPLAY/SETTING
1 SYSCOUNT DISPLAY 2 GENERAL SYSCOUNT SETTING 3 PRIVATE SYSCOUNT SETTING
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 9-83 AUX 172 Syscount Display/Setting Screen
NOTE The general/private counters are set to 0 immediately after turning the control power ON. The general counters are cleared to 0 when teach or repeat modes are initiated.
9-110
April 8, 2002
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9.58.1 SYSCOUNT DISPLAY/SETTING, DISPLAY
AUXILIARY FUNCTIONS
This function is used to display the state of the general and private counter values (Figure 9-84).
AUX 172 SYSCOUNT DISPLAY/SETTING

1 SYSCOUNT DISPLAY GENERAL COUNTER No. 1 2 3 4 5 6 7 8 0 No. 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 No. 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 No. 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 32 No. 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 No. 9 0 10 0 11 0 12 0 13 0 14 0 15 0 16 PRIVATE COUNTER No. 0 17 0 18 0 19 0 20 0 21 0 22 0 23 0 24 No. 0 25 0 26 0 27 0 28 0 29 0 30 0 31 0 32 0 0 0 0 0 0 0 0
F1
F2
F3
F4
F5
F6
EXIT
Figure 9-84 AUX 172-1 Syscount Display Screen
9.58.2 SYSCOUNT DISPLAY/SETTING, GENERAL SYSCOUNT SETTING This function is used to set the general system counter values (Figure 9-85).
AUX 172 SYSCOUNT DISPLAY/SETTING 2 GENERAL SYSCOUNT SETTING
No. 1 2 3 4 5 6 7 8
0 0 0 0 0 0 0 0
No. 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 0
No. 17 18 19 20 21 22 23 24
0 0 0 0 0 0 0 0
No. 25 26 27 28 29 30 31 32
0 0 0 0 0 0 0 0
F1
PRE DATA
F2
F3
F4
Figure 9-85 AUX 172-2 General Syscount Setting Screen
April 8, 2002
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AUXILIARY FUNCTIONS
This function is used to set the private system counter values (Figure 9-86).
AUX 172 SYSCOUNT DISPLAY/SETTING 3 PRIVATE SYSCOUNT SETTING
No. 1 2 3 4 5 6 7 8
0 0 0 0 0 0 0 0
No. 9 10 11 12 13 14 15 16
0 0 0 0 0 0 0 0
No. 17 18 19 20 21 22 23 24
0 0 0 0 0 0 0 0
No. 25 26 27 28 29 30 31 32
0 0 0 0 0 0 0 0
F1
PRE DATA
F2
F3
F4
Figure 9-86 AUX 172-3 Private Syscount Setting Screen
9-112
April 8, 2002
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9.59 AUX 173 MOVING AREA XYZ LIMIT
AUXILIARY FUNCTIONS
This function is used to set the upper and lower limits of robot motion within the XYZ world coordinates, including the traverse axis, if installed (Figure 9-87). The upper and lower limits, of the moving range XYZ limit area, are checked during repeat, check, and teaching operation modes. The range is not checked when changing or recording location data. Moving from out of range to within the range is allowed. The value range is -99999.9 through 99999.9.
AUX 173 MOVING AREA XYZ LIMIT
UPPER X DIRECTION Y DIRECTION Z DIRECTION LOWER X DIRECTION Y DIRECTION Z DIRECTION
0 mm 0 mm 0 mm 0 mm 0 mm 0 mm
F1
PRE DATA
F2
F3
F4
Figure 9-87 Moving Area XYZ Limit Screen
NOTE When upper and lower limits are set to the same value, the moving area XYZ limit check is not executed. When the values, for the upper and lower limit are inverted and input, an error is returned.
April 8, 2002
9-113
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9.60 AUX 176 DATA BANK
AUXILIARY FUNCTIONS
The Data Bank is a data base used to enter and store user-specific spray conditions (Figure 9-88 through 9-93). When the spray conditions are entered into the data bank, the conditions are accessed by the program using the CALL_DBK (call data bank) instruction. The five screens used to build and manage the data banks are LIST, EDIT, COPY, DELETE and ENVIRONMENT SET (Figure 9-88).
AUX 176 DATA BANK
1 2 3 4 5
LIST EDIT COPY DELETE ENVIRONMENT SET
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 9-88 AUX 176 Data Bank Menu Screen
9-114
April 8, 2002
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9.60.1 DATA BANK, LIST
AUXILIARY FUNCTIONS
The list screen displays the conditions stored in the selected data bank. The conditions cannot be changed from this screen (Figure 9-89). The data bank conditions displayed are; Num.(number) COMMENT, FRATE (flow rate), SHAPING AIR or PATTERN AIR, AIRMOTOR or ATOMIZING AIR, HIGH VOLTAGE, SPRAY SPEED and SPRAY JOINT SPEED.
AUX 176 DATA BANK

1 LIST Num. Comment FRATE SHAPING AIRMOTOR HVOLT SPEED JSPEED
F1
F2
F3
F4
F5
F6
EXIT
Figure 9-89 AUX 176-1 Data Bank List Screen
April 8, 2002
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9.60.2 DATA BANK, EDIT
AUXILIARY FUNCTIONS
The Data Bank Edit screen is used to create new data banks or edit existing data banks (Figure 9-90). Specify the data bank number (1 500) to create or edit. The acceptable value ranges are given in table 9-15. The data banks are pre-numbered 1 through 500 and the data bank numbers cannot be changed in the edit mode.
AUX 176 DATA BANK 2 EDIT
DATA BANK No.
F1
F2
F3
F4
0
~
9
RETURN
AUX 176 DATA BANK 2 EDIT
DATA BANK No. COMMENT *Following are set to -1 when not in use FLOW RATE SHAPING AIR AIRMOTOR HIGH VOLTAGE SPRAY SPEED SPRAY JSPEED
-1 -1 -1 -1 -1 -1
F1
PRE DATA
F2
F3
F4
CHARACTER
Figure 9-90 AUX 176-2 Data Bank Edit Screen
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April 8, 2002
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AUXILIARY FUNCTIONS
Table 9-15 Data Bank Value Setting Ranges

Item Flow rate Shaping air Airmotor High voltage Spray speed Spray joint speed Setting Range 0 Upper limit value set in Aux 176-5 0 Upper limit value set in Aux 176-5 0 Upper limit value set in Aux 176-5 0 Upper limit value set in Aux 176-5 1 100 (Sets maximum linear spray speed) 0 100
9.60.3 DATA BANK, COPY The Data Bank Copy screen is used to copy the contents of a specified data bank (1 500) into a different data bank (Figure 9-91).
AUX 176 DATA BANK 3 COPY
SOURCE DATA BANK NO. DESTINATION DATA BENK NO.
1 1
Are you sure?
F1
YES
F2
F3
F4
NO
0
~
9
RETURN
Are you sure?
F2 F3 F4
NO
F1
YES
Figure 9-91 AUX 176-3 Data Bank Copy Screen
April 8, 2002
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9.60.4 DATA BANK, DELETE
AUXILIARY FUNCTIONS
The Data Bank Delete screen is used to delete the contents of a specified data bank (1 500) (Figure 9-92).
AUX 176 DATA BANK 4 DELETE
DELETE DATA BANK NO.
Are you sure?
F1
YES
F2
F3
F4
NO
0
~
9
RETURN
Are you sure?
F2 F3 F4
NO
F1
YES
Figure 9-92 AUX 176-4 Data Bank Delete Screen
9-118
April 8, 2002
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9.60.5 DATA BANK, ENVIRONMENT SET
AUXILIARY FUNCTIONS
The Environment Set screen is used to set the upper limit values of the spray device (Figure 9-93). Table 9-16 gives the setting range values and the corresponding language commands.
AUX 176 DATA BANK 5 ENVIRONMENT SET
FLOW RATE UPPER VALUE SHAPING AIR UPPER VALUE AIRMOTOR UPPER VALUE HIGH VOLTAGE UPPER VALUE
10000 10000 10000 10000
F1
PRE DATA
F2
F3
F4
Figure 9-93 AUX 176-5 Data Bank Environment Set Screen
Table 9-16 Environment Set Value Ranges and Corresponding Language Commands
Item Flow rate upper value Shaping air upper value Airmotor upper value High voltage upper value Setting Range 0 10000 0 10000 0 10000 0 10000 Language Command SPR_FRATE_U SPR_PATTERN_U SPR_ATOMIZE_U SPR_HVOLT_U
April 8, 2002
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AUXILIARY FUNCTIONS
9.61 AUXILIARY FUNCTIONS, EXPLOSION-PROOF TEACH PENDANT The auxiliary functions accessed through the explosion-proof teach pendant provide the operator with the ability to view and change numerous settings that affect robot operation. The auxiliary functions are accessed from the main menu, the functions are listed below. 1. PLAYBACK 2. EDIT PROGRAM (see unit 7) 3. MANAGE PROGRAM 4. DATA BANK 5. DISPLAY STATUS 6. SET CONDITION 7. PRODUCT/HISTORY 8. MANUAL EX-OUT
The list of teach pendant auxiliary functions is shown in section 9.61.1 Figure 9-94 shows selecting the DISPLAY STATUS/ROBOT POSITION/JOINT ANGLE screen as an example. The following teach pendant auxiliary function list gives the auxiliary function index numbers and descriptions.
9-120
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AUXILIARY FUNCTIONS
STATUS/POS JNT MOVE Current FEEDBACK values displayed

Joint value 36.937 -32.093 -12.419 22.001 16.894 95.338
or
5 DATA
SET
STATUS
EASY MOVE PG10 -10

1. SIGNAL 3. SHUTTLE STATUS
Select display item

0. ROBOT POSITION 2. CNT_VALUE
or
0 SPEED
SET
STATUS/POS Select display item EASY MOVE

0. GUN_POS/GUN_ANGLE 1. JOINT ANGLE 2. JOINT COMMAND 3. ENCODER VALUE 4. TRAV POSITION 5. TABLE POSITION 6. GUN_POS/WRST_ANGLE
or
1 SPRAY .
SET
Figure 9-94 Teach Pendant Auxiliary Function Selection Example April 8, 2002 9-121
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AUXILIARY FUNCTIONS
9.61.1 AUXILIARY FUNCTIONS LIST, EXPLOSION-PROOF TEACH PENDANT Teach Pendant Auxiliary Function List Index 1-0 Function Name Program Setting Function Description Sets the program numbers for repeat operation. Displays the status of the repeat operation on the screen. Determines the overall repeat operation speed. Changes the output ratio for the overall painting program. Displays program names, step numbers, and production date and time. Shows the list of all available program numbers. Indicates available memory of teach program.
1-1
Repeat Status Display
1-2
Product Rate Value Setting
1-3
Product Paint_IO Ratio
3-0-0
Program List Display (Detail)
3-0-1
Program Number List Display
3-0-2
Available Memory Capacity Display Program Name Registration Program Copy Program Link Program Deletion Partial Program Copy
3-0-3 3-1 3-2 3-3 3-4-0
Adds names or comments to programs. Copies program contents to other programs Adds program contents after another program. Deletes programs. Inserts a part of program into another program. Deletes a part of program contents. Shifts taught position data parallel to the base coordinate. Shifts taught position data toward gun tip direction. April 8, 2002
3-4-1 3-5-0
Partial Program Deletion Parallel Shift
3-5-1 9-122
Gun-Tip Direction Shift
Kawasak
AUXILIARY FUNCTIONS
Teach Pendant Auxiliary Function List (continued) Index 3-5-2 Function Name Mirror Image Conversion Function Description Converts taught position data using Mirror Image. Transfers traverse axis while keeping the guntip position. For Servo shuttle system, converts position data from left to right and vice versa. Displays or edits data bank contents Displays a listing of stored data bank numbers, names, partial contents information. Displays list of stored data bank numbers. Displays current gun position and direction in real time. Displays each axis angle in real time. Displays current command values for each joint angle. Indicates current encoder value. Displays current position of traverse axes.
3-5-3
Traveler Shift With Gun Tip Fixed Shuttle Right-Left Conversion (Option) Data Bank Editing Data Bank Details Display
3-5-4
4-0 4-1-0
4-1-1 5-0-0
Data Bank Number Display Gun Position/Angle
5-0-1 5-0-2
Joint Value Display Joint Command Value Display
5-0-3 5-0-4
Encoder Value Display Position Display Of Traverse Axes Table Position Display (Option) Gun Position/ Wrist Angle Display External Output Signal Display External Input Signal Display Internal Signal Display
5-0-5 5-0-6
Indicates current table axis angle. Displays current gun positions and wrist angles. Displays current status of output signals. Displays current status of input signals. Displays current status of internal signals.
5-1-0 5-1-1 5-1-2
April 8, 2002
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AUXILIARY FUNCTIONS
Teach Pendant Auxiliary Function List (continued) Index 5-1-3 Function Name Home Position Signal Display Function Description Displays current status of home signals and work space output signals (option). Displays current status of General Counter values. Displays current status of Dedicated Counter values. Monitors shuttle systems current operating conditions. Sets ENABLE/DISABLE for External Output.
5-2-0
General Counter Display
5-2-1
Dedicated Counter Display
5-3
Shuttle Condition Display (Option) Operation Condition Selection (Option) Operation Condition Selection (Input Wait) Operation Condition Selection (Conveyor wait) Operation Condition Selection (Time wait) Operation Condition Selection (CV Track Mode)
6-0-0
6-0-1
Sets ENABLE/DISABLE for Input Waiting.
6-0-2
Sets ENABLE/DISABLE for Conveyor waiting.
6-0-3
Sets ENABLE/DISABLE for Time Waiting.
6-0-4
Sets the method, False pulse (Simulation mode) or Real pulse for synchronizing the robot with conveyor. Sets ENABLE/DISABLE for Door Sensor.
6-0-5-0 Operation Condition Selection (Sensor Setting/Door Sensing) 6-0-5-1 Operation Condition Selection (Sensor Setting/ Camera Sensing) 6-1 Current Conveyor Position Setting (Current CV_Pos) Counter Value Setting
Sets ENABLE/DISABLE for Camera Compensation.
Sets current conveyor position.
6-2
Sets General/Special Counter value.
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AUXILIARY FUNCTIONS
Teach Pendant Auxiliary Function List (continued) Index 6-3 Function Name Location Variables Registration Function Description Registers location variable point command from AS monitor instruction. Displays error history. Displays and sets the number of times a program is repeated. Manual On/Off for external signals.
7-0 7-1
Error History Display Total Playback Count Display
8-0
Manual External Output Execution (General Signal) Manual External Output Execution (Spray signals) Manual External Output Execution (Flow Rate) Manual External Output Execution (Shaping/Pattern Air) Manual External Output Execution (Air Motor/Atomizing Air) Manual External Output Execution (High Voltage) Manual External Output Execution (Flushing) Manual External Output Execution (Push Thinner)
8-1
Manual On/Off for spray signals.
8-2
Sets the flow rate manually.
8-3
Sets the level of Shaping/Pattern Air manually.
8-4
Sets Air motor/Atomizing air manually.
8-5
Sets High Voltage level manually.
8-6
ManualOn/Off for the Flushing start. signal Manual On/Off for the thinner spray. signal
8-7
April 8, 2002
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9.61.2 PROGRAM SETTING, 1-0
AUXILIARY FUNCTIONS
This function is used to set the program number to be executed in repeat mode after teaching or editing a program (Figure 9-95). 1. 2. 3. Enter the program number and the desired start step number to begin execution. Verify the data entered, and press the set key. The PLYBK/STATUS screen is displayed.
PLYBK/SET-PGM JNT MOVE Enter program No.and step No.

PROGRAM No. STEP No. (FROM) __1 __0
1.
SET
PLYBK/SET-PGM JNT MOVE Enter program No.and step No.

PROGRAM No. STEP No. (FROM) __1 __0
2.
SET
PLYBK/STATUS JNT MOVE PG1 -0 PLYBK STATUS REPEAT mode 3.

PRDCT RATE =100 % CV_SPEED =0.00 M/M PRDCT CNT 20 CV_POS = 0 mm PLYBKTIME 0.0 sec Instruction REPEAT mode No program step.
Figure 9-95 Program Setting Screen
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9.61.3 REPEAT STATUS DISPLAY, 1-1
AUXILIARY FUNCTIONS
This function is used to display the status of repeat operations (Figure 9-95). The example in figure 9-96, shows Program No. 1 is executing. When the operation status changes, the display in parentheses on the second row changes accordingly. The cursor keys are used to scroll between the screens.
PLYBK/STATUS JNT MOVE PG1 -0 PLYBK STATUS REPEAT mode PRDCT RATE = 100% CV_SPEED = 0.00 M/M PRDCT CNT 20 CV_POS = 0 mm PLYBKTIME 0.0 sec Instruction REPEAT mode No program step.
Figure 9-96 Repeat Status Display Screen
The program number and the current program point are displayed at the top right of the screen. The current repeat condition is displayed in parentheses at the right of the second line and indicates one of the following conditions: Error, Motor Power Off, Teach Mode, Repeat Mode, Cycle Start On, Program Wait. If the repeat conditions change very quickly the display may not show the changes.
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AUXILIARY FUNCTIONS
The remaining lines indicate the current values of the following five items. 1. Production Rate: Ratio determined by the overall repeat speed of all programs is adjusted. Conveyor Speed: Moving speed of the conveyor in m/min. Conveyor Position: Current position of conveyor (amount of displacement after resetting in mm). Product Count: Indicates the number of repetitions for the program being executed. Playback Time: During a repetition, it displays the time elapsed from the program start. At the end of the program execution, it indicates the required repeat operation time (Cycle time). The counter time display limit is 99999 seconds.
2. 3.
4. 5.
The second screen displays the program instruction being executed (Figure 9-95). When playback is not executing, the message No program step is displayed. If the instruction is executed very quickly or the waiting time is very short, the instruction or the wait condition may not be displayed.
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AUXILIARY FUNCTIONS
9.61.4 PRODUCTION RATE VALUE SETTING, 1-2 This function is used to change the repeat operation speed for all programs during execution in repeat mode (Figure 9-97). Enter the desired repeat speed in percentage at the PRODUCT RATE value line and press the SET key
PLYBK/PRDCT-RATE EASY MOVE Enter PRODUCT RATE value

PRODUCT RATE _ 8 0 [%]
Figure 9-97 Production Rate Value Setting Screen
When PRODUCT RATE value is entered, the gun speed during repeat mode operation is determined by the formula shown below. (Actual Gun Speed = Gun Speed x REPEAT RATE value x PRODUCT RATE value) If the PLAYBACK RATE value is set during program execution, the new value is not effective until the next program is executed. The value displayed on the playback status screen is updated immediately. The PRODUCT RATE value can be set up to 999%, but speed limitations on each axis restrict actual speed. When the PLAYBACK RATE value is changed, it affects the check forward and check backward speeds during teach mode. Manual operation (jogging) speed is not affected.
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AUXILIARY FUNCTIONS
9.61.5 PRODUCT PAINT_IO RATIO SETTING, 1-3 This function is used to change the output ratio during repeat mode operation for all programs. The settings also apply to the painting equipment output instructions (FLOW RATIO, SHAPING/PATTEN AIR, AIR MOTOR/ATOMIZING AIR, HIGH VOLTAGE) in manual signal output mode (Figure 9-98). Enter the PRODUCT PAINT_IO ratio values for items that need to be changed.
PLYBK/PNTIO-RATIO EASY MOVE Enter PRODUCT PAINT_IO ratio PRDCT FLOW RATIO 100[%] PRDCT PTRN RATIO _80[%] PRDCT ATOM RATIO _70[%] PRDCT HV RATIO 100[%]
Figure 9-98 Product Paint IO Ratio Setting Screen
NOTE The PRODUCT PAINT_IO ratio data entered during program execution is effective immediately and is reflected in the current output rate.
The PRODUCT PAINT_IO ratio can be set up to 200%. If the ratio is beyond the capability of the output signal for the painting equipment, the allowable maximum limit takes precedence. Refer to section 7.4, External Output Instructions for the relationship between PRODUCT PAINT_IO ratio and the painting equipment output instruction.
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9.61.6 PROGRAM LIST DISPLAY (DETAIL), 3-0-0
AUXILIARY FUNCTIONS
This function displays program information for programs stored in the controller memory. The information includes the program number, name, number of steps, and creation date (Figure 9-99). The cursor keys are used to scroll through the program list. Programs created with non-numerical names are indicated with asterisks.
MNG/LIST No. NAME

pg1 pg3 pg55 PRG_001 INNER
EASY MOVE STEPS DATE-TIME

25 118 34 01-09-03 15:17 01-09-03 15:18 01-09-03 15:15
Figure 9-99 Program List Screen
April 8, 2002
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9.61.7 PROGRAM NUMBER LIST DISPLAY, 3-0-1
AUXILIARY FUNCTIONS
This function displays the numbers of the programs stored in memory. Each row shows up to eight program numbers (use the cursor keys to scroll) (Figure 9-100). Programs created with non-numerical names are indicated with asterisks.
MNG/LIST Next page by
EASY MOVE keys 101 80 3 90 55 98 56
*** ***
58 END 60
1 100 71 72
***
Figure 9-100 Program Number List Display
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AUXILIARY FUNCTIONS
9.61.8 AVAILABLE MEMORY CAPACITY DISPLAY, 3-0-2 This function indicates the available memory for program storage (Figure 9-101). Available Memory/Total Memory capacity is shown in Kbyte form, and its ratio is indicated in %. Storable Memory indicates remaining memory capacity for program instructions and program point location data.
MNG/LIST/CAPACITY EASY MOVE

Available Memory 466/ 512 [Kbytes] 91 [%] Storable Memory approx. 5191 [points]
Figure 9-101 Available Memory Capacity Screen
NOTE
Total memory capacity varies depending on system specifications (equipped RAM capacity). Storable memory points vary with system configuration. The programming method also creates some differences in memory capacity.
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9.61.9 PROGRAM NAME REGISTRATION, 3-0-3
AUXILIARY FUNCTIONS
This function is used to register a new program name or change an existing program name stored in memory. Up to eight (8) characters can be used (Figure 9-102). 1. 2. Enter a program number and press the SET key. Use the cursor keys to select the letters to enter, and press the SET key. When the Shift key and cursor key combination is used the cursor moves 16 characters at a time. For example, when the cursor is at the G on the screen, by pressing the Shift key and the up cursor key, the cursor moves to the W. Place the cursor on the desired letter, and press the SET key to enter the selected character into the program name. 3. Set the cursor at END, and press the SET key.
Ensure the name is correct and select 1 for yes and press the SET key to accept the program name. Select DEL (delete) to clear the last letter entered, if correction is needed.
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AUXILIARY FUNCTIONS
MNG/LIST/NAME EASY MOVE Enter program No. for NAMING PROGRAM No. _ _1
0 SPEED
1.
9 CONVR F
SET
MNG/LIST/NAME EASY MOVE Select characters by keys

! #$%& ()*+,-./ 0 1 2 3 4 5 6 7 8 9:;<=>? @ABCDEFGHIJKLMNO PQRSTUVWXYZ[ ]^_ PROGRAM NAME _ _ _ _ _ _PR
and
2.
or
SHIFT +
and
SET
MNG/LIST/NAME EASY MOVE Select characters by keys

DEL END PROGRAM NAME
_ PRG_001
3. and
SET
MNG/LIST/NAME EASY MOVE Register the following NAME?

PROGRAM NAME (0:NO 1:YES) PRG_001 YES
Figure 9-102 Program Name Registration Screen
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9.61.10 PROGRAM COPY, 3-1
AUXILIARY FUNCTIONS
This function is used to copy programs stored in memory (one program at a time) (Figure 9-103). Enter the source and destination program numbers and 1 for YES to overwrite the destination program. When 1:YES is entered the COPY confirmation screen is displayed, without pressing the SET key. If 0:NO is entered, processing stops and an error is generated. At the confirmation screen enter 1:YES to complete the procedure or 0:NO to abort the procedure and press the SET key.
MNG/COPY EASY MOVE Enter COPY conditions SOURCE PGM No. _ _1 DESTINATION PGM No. _1 0 OVERWRITE (0:NO 1:YES) NO
and
0 SPEED
9 CONVR F
1 SPRAY .
MNG/COPY EASY MOVE Make sure overwrite program 1 --> 10?
COPY (0:NO 1:YES)
YES
1 SPRAY .
SET
Figure 9-103 Program Copy Screen 9-136 April 8, 2002
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9.61.11 PROGRAM LINK, 3-2
AUXILIARY FUNCTIONS
This function is used to link programs stored in memory. Linking programs using this function connects one program to another (figure 9-104 and 9-105). Enter the source program and the destination program numbers. Ensure the program numbers are correct, and press the SET key. The link confirmation screen is displayed. Enter 1:YES to complete the procedure or 0:NO to abort the procedure. If the destination program does not exist, processing is the same as copy. The example in figure 9-104 is described in the schematic drawing in figure 9-105.
MNG/LINK EASY MOVE Enter program No. to LINK

LINK (PGM No.) TO (PGM No.) __2 _11
SET
MNG/LINK EASY MOVE Make sure link program 2 --> 11 ?

LINK (0:NO 1:YES) YES
Figure 9-104 Program Link Screen
Program 11
Program 11 Program 2
Program 2
Link
Figure 9-105 Program Link Example Schematic
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AUXILIARY FUNCTIONS
9.61.11.1 PROGRAM LINK, SAME SOURCE AND DESTINATION PROGRAM, 3-2 Figure 9-106 shows the results, in a schematic diagram, when the same program number is used for the source and the destination programs.
Program 11
Program 11
Program 11
Link
Figure 9-106 Program Link, Same Source and Destination Program
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9.61.12 PROGRAM DELETION, 3-3
AUXILIARY FUNCTIONS
This function is used to delete programs (a program as a unit) stored in memory (Figure 9-107). Enter the number of the program to delete. Ensure the program number is correct and press the SET key. At the confirmation screen enter 1:YES to complete the procedure or 0:NO to abort the procedure. If a program is linked to another program it is not deleted.
MNG/DEL EASY MOVE Enter program No. to DELETE

PROGRAM No. __3
SET
MNG/DEL EASY MOVE Make sure delete program 3 ?

DELETE (0:NO 1:YES) YES
Figure 9-107 Program Deletion Screen
April 8, 2002
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9.61.13 PARTIAL PROGRAM COPY, 3-4-0
AUXILIARY FUNCTIONS
This function is used to make a copy of specific steps from one program and insert the copied steps into another program (figures 9-108 and 109). Enter the number of the source program, start step number (FROM), and the last step number (TO). Ensure the program and step numbers are correct and press the SET key Enter the destination program number and the step number of the copy insertion point. Ensure the program and step numbers are correct and enter 1:YES to complete the procedure or 0:NO to abort the procedure.
MNG/EDIT/COPY EASY MOVE Enter SOURCE data SOURCE PGM No. _ _4 STEP No. (FROM) _ _3 STEP No. ( TO ) _ _5
SET
MNG/EDIT/COPY EASY MOVE Enter DESTINATION data

DESTINATION PGM No. STEP No. (INTO) _ 13 __3
SET
MNG/EDIT/COPY EASY MOVE Make sure copy program 4--> 13 ? STEP No. (FROM) / (TO) 3, 5 STEP No. (INTO) 3 COPY (0:NO 1:YES) YES
Figure 9-108 Partial Program Copy Screen 9-140 April 8, 2002
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AUXILIARY FUNCTIONS
The example in figure 9-108 is described in the schematic drawing in figure 9-109.
Program 4
Program 13
Program 4
2
Partial Copy
3 5 6
3 5
Program 13
2 3
Figure 9-109 Partial Program Copy Example Schematic
NOTE When designating a nonexistent step number in the destination program, i.e., attempting to insert at step 999 when the program has 15 steps, the source program is inserted after the final step (step 16 in this case), ignoring the nonexistent steps.
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9.61.14 PARTIAL PROGRAM DELETION, 3-4-1
AUXILIARY FUNCTIONS
This function, is used to delete specific steps from a program stored in memory (figures 9-110 and 9-111). Enter the program, start step (FROM), and end step (TO) numbers. The start step, end step, and steps between are deleted. Ensure the program, start step, and end step numbers are correct and press the SET key. At the deletion confirmation screen enter 1:YES to complete the procedure or 0:NO to abort the procedure. The example in figure 9-110 is described in the schematic drawing in figure 9-111.
MNG/EDIT/DEL EASY MOVE Enter DELETE data PROGRAM No. _ _5 STEP No. (FROM) _ _2 STEP No. ( TO ) _ _1
SET
MNG/EDIT/DEL EASY MOVE Make sure delete program 5 ?

STEP No. (FROM) / ( TO ) DELETE (0:NO 1:YES) 2, YES 1
Figure 9-110 Partial Program Deletion Screen
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Program 5
AUXILIARY FUNCTIONS
Program 5
2
Partial Delete
Figure 9-111 Partial Program Deletion Example Schematic
NOTE
When nonexistent step numbers are designated, i.e. steps 15-20 are selected for deletion when only 15 steps are available, no change is made in the contents of the program, although the completion message is displayed.
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9.61.15 PARALLEL SHIFT, 3-5-0
AUXILIARY FUNCTIONS
This function is used to shift program points parallel to the X, Y, and Z base coordinates of the robot. Program points may be shifted in the forward/backward, left/right or upward/downward directions (Figure 9-112). The example in figure 9-113 uses parallel shifting to shift data taught in the program by 30 mm to the right (X +) direction. 1. Enter the program, start step (FROM), and end step (TO) numbers. The start step, end step, and steps between are shifted. Ensure the program, start step, and end step numbers are correct and press the SET key. Enter the value for the desired amount of shift in the desired X, Y, or Z direction. If a negative number is entered, the shift is in the -X, -Y, or -Z direction. With the desired shift value and direction entered, press the SET key to complete the procedure.
2.
3.
4.
MNG/CNVRT (SFT) EASY MOVE Enter CONVERT(SHIFT) data

PROGRAM No. STEP No. (FROM) STEP No. (TO) 102 __0 999
SET
MNG/CNVRT (SFT) EASY MOVE Enter PARALLEL SHIFT data

X (RBT) Y (RBT) Z (RBT) _ _ _ _ _ _ 30.0 [mm] _ _ _ _ 0.0000 [mm] _ _ _ _ 0.0000 [mm]
Figure 9-112 Parallel Shift Screen
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9.61.16 GUN-TIP DIRECTION SHIFT, 3-5-1
AUXILIARY FUNCTIONS
This function is used to shift program points in the gun tip direction (spraying direction) for specified steps (Figure 9-113). 1. Enter the program, start step (FROM), and end step (TO) numbers. The start step, end step, and steps between are shifted. Ensure the program, start step, and end step numbers are correct and press the SET key. Enter the desired shift value and press the SET key.
2.
3.
When approaching the work to spray, enter (+) distance (positive number), and if departing from the work, enter () distance (negative number).

SET
MNG/CNVRT (SFT) EASY MOVE Enter GUN SHIFT data

REF. GUN No. GUN SHIFT LENGTH 1 _100.0 [mm]
SET
Figure 9-113 Gun-Tip Direction Shift Screen
April 8, 2002
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9.61.17 MIRROR IMAGE CONVERSION, 3-5-2
AUXILIARY FUNCTIONS
This function is used to create a mirror image of positional data of programs stored in memory. Positional data of program points taught in the X-axis of the base coordinate system are mirrored about the YZ plane. 1. Enter the program, start step (FROM), and end step (TO) numbers. The start step, end step, and steps between are mirrored (Figure 9-114). Ensure the program start step and end step numbers are correct. Press the SET key.
2. 3.
For more information on the mirror function refer to section, 11.3 Mirror Conversion, for the multi function panel.
SET
Figure 9-114 Mirror Image Conversion Screen
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AUXILIARY FUNCTIONS
9.61.18 TRAVELER SHIFT WITH GUN TIP FIXED, 3-5-3 For systems equipped with a manipulator and traverse equipment, this function enables movement on the traverse axes while keeping the gun tip fixed against ground. Enter the program, start step (FROM), and end step (TO) numbers. The start step, end step, and steps between are shifted (Figure 9-115). Ensure the program, start step, and end step numbers are correct and press the SET key. Enter shift values for each traverse axis, and press the SET key.

SET
MNG/CNVRT (SFT) EASY MOVE Enter TRAVELER SHIFT data

X (TRAV) Y (TRAV) Z (TRAV) _ _ _ _500.0[mm] _ _ _ 0.0000[mm] _ _ _ 0.0000[mm]
SET
Figure 9-115 Traveler Shift with Gun-Tip Fixed Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.19 SHUTTLE RIGHT-LEFT CONVERSION (OPTION), 3-5-4 This function automatically converts a program taught using the right shuttle to make it usable for the left shuttle. Conversion is possible in the reverse condition (left-to-right).
NOTE This function is dedicated for use with the servo shuttle system and cannot be used for other systems.
Right-left conversion of the shuttle programs are performed only when the robot configuration has the servo shuttle system. For a description of this function, please refer to Operation Manual for Servo Shuttle Exclusive Functions.
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9.61.20 DATA BANK EDITING, 4-0
AUXILIARY FUNCTIONS
This mode is used to edit the values and conditions stored in the user data banks. Items set as 1 do not change the current settings when executing a CALL_DBK instruction. Figure 9-116 shows the data bank conditional data value entry procedure. Table 9-17 gives the conditional items contents.
CAUTION
1. A Call_DBK instruction can be set multiple times in a single step. If the same condition item is set multiple times in such cases, the last setting becomes applicable (enabled). 2. A Call_DBK instruction is executed even if it is set in the aircut (spray off) section. The conditional items which are effective within the spraying section do not function in the air cut section. 3. Only an existing data bank should be referenced by the Call_DBK instruction in TEACH mode. If the data bank does not exist, an alarm is output. 4. In EDIT mode, the availability of the specified data bank is not checked. If unavailable, there is an error message at execution in TEACH or REPEAT mode. 5. Because many conditional items can be set in a data bank, its setting varies depending on usage.
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1. 2. 3. Enter the desired conditional data values.
AUXILIARY FUNCTIONS
Ensure the values are correct and press the SET key. At the data bank registration confirmation screen enter 1:YES to complete the procedure or 0:NO to abort the procedure.
EASY MOVE DBK/EDIT Enter data bank No.

DATA BANK No. (1 ~ 500) __1
SET
DBK/EDIT/INP DBK= 1 Enter DATA BANK conditions

FLOW_RATE (-1~15) SHAPING AIR (-1~15) AIRMOTOR (-1~15) _ _ _ _1 ___-1 _ _ _ _3
HIGH VOLTAGE (-1~3) ___-1 SPRAY SPEED (-1~9999) _ 500 [mm/s] SPRAY JSPEED (-1~100) 100 [%]
SET
DBK/EDIT/INP DBK= 1 Make sure regist the data in DATA BANK ?

REGISTER (0:NO 1:YES) YES
Figure 9-116 Data Bank Editing Screens
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AUXILIARY FUNCTIONS
The data banks contains conditional items that can be set according to the needs of the user. The following conditional items are available for setting.
Table 9-17 Data Bank Conditional Items Contents

No. Condition Setting Items 1 2 3 4 FLOW_RATE SHAPING AIR AIR MOTOR HIGH VOLTAGE Condition Items FLOW_RATE SHAPING/ PATTERN AIR AIR MOTOR/ ATOMIZING AIR HIGH VOLTAGE Content FLOW_RATE RANGE PATTERN AIR RANGE ATOMIZING AIR RANGE HIGH PRESSURE
SPRAY SPEED (mm/s) Gun tip speed with spray ON 5 APPLYING SPEED SPRAY JSPEED (%) Joint speed with spray ON
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9.61.21 DATA BANK DETAILS DISPLAY, 4-1-0
AUXILIARY FUNCTIONS
The data bank number, name, and created date registered in memory are displayed on the data bank details screen. Each data bank is displayed on a separate row. The cursor keys are used to scroll through the data. Press the SET key to display the editing screen. The data bank names are set using AUX 176 through the multi function panel (Figure 9-117). Pressing the SET key displays the data bank editing screen.
DBK/MNG/LIST No. NAME 1 2 DBK END
EASY MOVE (EDIT by SET key) 1 -1 3 -1 2 -1 2 -1
SET
DBK/EDIT/INP DBK= 1 Enter DATA BANK conditions

FLOW_RATE (-1~15) SHAPING AIR (-1~15) AIRMOTOR (-1~15) _ _ _ _1 ___-1 _ _ _ _3
HIGH VOLTAGE (-1~3) ___-1 SPRAY SPEED (-1~9999) _ 500 [mm/s] SPRAY JSPEED (-1~100) 100 [%]
Figure 9-117 Data Bank Details Display Screen
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9.61.22 DATA BANK NUMBER DISPLAY, 4-1-1
AUXILIARY FUNCTIONS
This function displays only the numbers of data banks stored in memory. Each row displays up to eight numbers (Figure 9-118). The cursor keys are used to scroll through the data on the screen.
EASY MOVE DBK/MNG/LIST Next page by keys

1 2 END
Figure 9-118 Data Bank Number Display Screen
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.23 GUN POSITION AND ANGLE DISPLAY, 5-0-0 This function displays the current values of the gun tip position and angle in the form of a transformation value (Figure 9-119).
STATUS/POS EASY MOVE Current FEEDBACK values displayed

Transformation value 1722.262 -64.923 22.650 90.739 1211.953 -58.892
Figure 9-119 Gun Position Angle Display Screen
NOTE The gun tip position is displayed as a transformation value in X, Y, and Z values in millimeters of the robot coordinate system. Gun tip direction is displayed on the next line as OAT rotation angles in degrees of the robot coordinate system.
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9.61.24 JOINT VALUE DISPLAY, 5-0-1
AUXILIARY FUNCTIONS
This function displays the current value of each joint angle in degrees (Figure 9-120). The plus and minus direction of each joint is shown in figure 9-121.

Joint value 94.096 6.259 -1.272 -30.980 -1.283 15.726
Figure 9-120 Joint Value Display Screen
JT3 Axis
JT4 Axis +
-
JT5 Axis JT6 Axis +
JT2 Axis
+ -
JT1 Axis
Figure 9-121 Joint Axis Plus and Minus Directions
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.25 JOINT COMMAND VALUE DISPLAY, 5-0-2 This function displays a command value for each joint (Figure 9-122). The displayed values may differ from the current values of 5-0-1 Joint Value.

Joint command 94.097 6.264 -1.273 -30.989 -1.282 15.723
Figure 9-122 Joint Command Value Display Screen
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9.61.26 ENCODER VALUE DISPLAY, 5-0-3
AUXILIARY FUNCTIONS
This function displays current robot encoder values for each axis. Figure 9-123 shows the display for a robot system configuration with 6 axes (single robot). Figure 9-124 shows the display for a robot system configuration with 7 axes (single robot + traverse axis).

ENCODER 268693095 268431718 268431593 268429364 268456868 268423936
Figure 9-123 Encoder Value Display Screen, Six Axes

ENCODER 268693095 268431718 268431593 268429364 268456868 268423936 268435456
Figure 9-124 Encoder Value Display Screen, Seven Axes
NOTE The arrangement of encoder values displayed may differ depending on the system configurations. Six joints are located at set positions. Joints 1 through 3 are displayed left-to-right in the first row of encoder data and joints 4 to 6 are displayed on the second row of encoder data. When an X, Y, and Z traverse axis is included in the system configuration, values are displayed on the third row of encoder data.
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.27 POSITION DISPLAY OF TRAVERSE AXES, 5-0-4 This function displays the current positions of X, Y, and Z traverse axes in millimeters (Figure 9-125).

TRAV POSITION [x, y, z] 9.674 0.000 0.000
Figure 9-125 Position Display of Traverse Axes Screen
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AUXILIARY FUNCTIONS
9.61.28 TABLE POSITION DISPLAY (OPTION), 5-0-5 This function displays current angles of the table system. Table angles are displayed on the screen in fixed fields. Values for axes 10 (SYSTEM_1/TABLE_1) and 11 (SYSTEM_1/TABLE_2) are displayed on the third row, and those for axes 12 (SYSTEM_2/TABLE_1) and 13 (SYSTEM_2/TABLE_2) are on the fourth row in order from left-to-right. For those not assigned axes, indications do not change (0.00 is fixed). The data is displayed in degrees. For information on the table system display function of servo shuttle systems, refer to the Operation Manual of Servo Shuttle Exclusive Functions.
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.29 GUN POSITION AND WRIST ANGLE DISPLAY, 5-0-6 This function displays the current gun tip position and wrist angle (Figure 9-126). The gun position is displayed on the first row of positional data as X, Y, and Z values in the robot coordinate system in millimeters. The robot wrist angles are displayed, on the second row of positional data, as joint angles of the robot wrist axes in degrees.

Transformation value / Joint 456 1722.219 -64.959 6.263 -30.987 1212.019 15.720
Figure 9-126 Gun Position and Wrist Angle Display Screen
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AUXILIARY FUNCTIONS
9.61.30 EXTERNAL OUTPUT SIGNAL DISPLAY, 5-1-0 This function displays the status of selected output signals. Enter the desired output signal number and press the SET key, refer to figure 9-127, top screen. Figure 9-127, bottom screen, shows the display when signal number 27 is selected. The status of six consecutive output signals, starting from the selected signal number, is displayed. The example in figure 9-127 shows the state of the following signals as shown below. Signal Signal Signal Signal Signal Signal 27: OFF 28: ON 29: OFF 30: OFF 31: OFF 32: ON
The display uses simulated LEDs. An LED that is OFF indicates a low signal state. An LED that is ON indicates a high signal state. For the signal assignment and meaning of each output signal, refer to the ExplosionProof C Controller External I/ O Signal Manual.
STATUS/EX-OUT EASY MOVE Enter START PORT No. to display

PORT No. (1~32) _ 27
SET
STATUS/EX-OUT
27 29 31 HOME1 CYCLE_START ERROR
EASY MOVE
28 30 32 TEACH_MODE AUTOMATIC MOTOR_ON
Figure 9-127 External Output Signal Display Screen April 8, 2002 9-161
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AUXILIARY FUNCTIONS
9.61.31 EXTERNAL INPUT SIGNAL DISPLAY, 5-1-1 This function displays the status of selected input signals. Enter the desired input signal number and press the SET key, refer to figure 9-128, top screen. Figure 9-128, bottom screen, shows the display when signal number 1 is selected. The status of six consecutive input signals, starting from the selected signal number, is displayed. The example in figure 9-128 shows the state of the following signals as shown below. Signal Signal Signal Signal Signal Signal 01: ON 02: ON 03: OFF 04: ON 05: OFF 06: ON
The display uses simulated LEDs. An LED that is OFFindicates a low signal state. An LED that is ON indicates a high signal state. For the signal assignment and meaning of each input signal, refer to the ExplosionProof C controller External I/ O Signal Manual.
STATUS/EX-IN EASY MOVE Enter START PORT No. to display

PORT No. (1~32) _ _1
1 SPRAY .
SET
STATUS/EX-IN
1 3 5 IN1 IN3 IN5
EASY MOVE
2 4 6 IN2 IN4 IN6
Figure 9-128 External Input Signal Display Screen
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9.61.32 INTERNAL SIGNALS DISPLAY, 5-1-2
AUXILIARY FUNCTIONS
This function displays the status of selected internal signals. Enter the desired internal signal number and press the SET key, refer to figure 9-129, top screen. Figure 9-129, bottom screen, shows the display when signal number 1 is selected. The status of six consecutive internal signals, starting from the selected signal number, is displayed. The example in figure 9-129 shows the state of the following signals as shown below. Signal Signal Signal Signal Signal Signal 01: ON 02: OFF 03: OFF 04: ON 05: OFF 06: ON
The display uses simulated LEDs. An LED that is OFF indicates a low signal state. An LED that is ON indicates a high signal state. For the signal assignment and meaning of each input signal, refer to the ExplosionProof C Controller External I/ O Signal Manual.
STATUS/INTERNAL EASY MOVE Enter START PORT No. to display

PORT No. (1~256) _ _1
1 SPRAY .
SET
STATUS/INTERNAL EASY MOVE

1 3 5 INT1 INT3 INT5 2 4 6 INT2 INT4 INT6
Figure 9-129 Internal Signals Display Screen
April 8, 2002
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9.61.33 HOME SIGNALS, 5-1-3 This function displays the status of home signals.
AUXILIARY FUNCTIONS
The status of home position output signals is displayed with the status of work space output signals. The example in figure 9-130 shows the state of the following signals as shown below. Home position OFF Home position ON Work space output 1: ON Work space output 2: OFF Work space output 3: Unassigned Work space output 4: Unassigned Work space output 5: Unassigned Work space output 6: Unassigned Work space output 7: Unassigned Work space output 8: Unassigned Work space output 9: Unassigned The display uses simulated LEDs. An LED that is OFF indicates the robot posture or gun tip position is located outside the home position range. An LED that is ON indicates the robot posture or gun tip position is located within the home position range. When the output signal is not assigned, - is displayed. For the signal assignment and meaning of each input signal, refer to the ExplosionProof C Controller External I/ O Signal Manual. For setting functions related to the home position and work space, refer to AUX 76 HOME POSITION and AUX 77 WORK SPACE OUTPUT.
STATUS/HOME
HOME POS. 1 2
EASY MOVE
WORK SPACE 1 2_ _ _ _ _ 8 9 3 4 5 6 7 __
Figure 9-130 Home Signals Screen
9-164
April 8, 2002
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9.61.34 GENERAL COUNTER DISPLAY, 5-2-0
AUXILIARY FUNCTIONS
This function displays the status of general counter values. Each row shows the values for four counters (Figure 9-131). Use the cursor keys to scroll through the screens.
STATUS/INTERNAL EASY MOVE Display CNT VAL GEN_CNT

01-04 05-08 09-12 24 0 0 1 0 0 0 0 0 0 0 53 0 0 0 0 0 0 0
1~
0 0 0
Display
13-16 17-20 21-24
CNT VAL
0 0 0
GEN_CNT
13~
0 0 0
Display
25-28 29-32
CNT VAL
0 0
GEN_CNT
25~
0 0
Figure 9-131 General Counter Display Screen
April 8, 2002
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9.61.35 DEDICATED COUNTER DISPLAY, 5-2-1
AUXILIARY FUNCTIONS
This function displays the status of dedicated counter values. Each row shows the values for four counters (Figure 9-132). Use the cursor keys to scroll through the screens.
STATUS/CNT EASY MOVE Display CNT VAL SPE_CNT

01-04 05-08 09-12 24 0 0 1 0 0 0 0 0 0 0 53 0 0 0 0 0 0 0
1~
0 0 0
Display
13-16 17-20 21-24
CNT VAL
0 0 0
SPE_CNT
13~
0 0 0
Display
25-28 29-32
CNT VAL
0 0
SPE_CNT
25~
0 0
Figure 9-132 Dedicated Counter Display Screen
NOTE All General and Dedicated counter values are initialized (set to 0) immediately at controller power-up. General counter values are also initialized (set to 0) when teach or repeat modes are initiated.
9-166
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.36 SHUTTLE CONDITION DISPLAY (OPTION), 5-3 This function monitors the operating condition status of the right and left shuttle movement.
NOTE
This function is designed for servo shuttle system and cannot be used for other system. The shuttle conditions can be monitored only when servo shuttle system is installed in the robots system For a description of this function, refer to the Operation Manual of Servo Shuttle Exclusive Functions.
April 8, 2002
9-167
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AUXILIARY FUNCTIONS
9.61.37 OPERATION CONDITION SELECTION, 6-0 Prior to returning to normal operation, ensure the conditions are set from DISABLE to ENABLE. When the robot controller main power is ON or the mode is switched between teach and repeat on the operation panel, each condition is automatically switched to ENABLE. 9.61.37.1 OPERATION CONDITION SELECTION: EXTERNAL OUTPUT, 6-0-0 This function sets the external output instruction to ENABLE or DISABLE (Figure 9133). When DISABLE is selected, the instructions: External output, Painting equipment output, Output delay and Spray are not executed in teach and repeat modes, and manual signal output is disabled. This function allows the operator to execute a program in repeat mode to check the robot movement without processing the control signals for turning the peripheral external devices ON and OFF. Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same.
9-168
April 8, 2002
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AUXILIARY FUNCTIONS
COND/DOUT EASY MOVE Select DISABLE / ENABLE of DOUT

0. DISABLE 1. ENABLE (SELECT)
SET
Figure 9-133 Operation Condition Selection Screen
CAUTION
When the operating conditions are switched from DISABLE to ENABLE, such as during program playback, signals that were masked may be output at that moment.
April 8, 2002
9-169
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AUXILIARY FUNCTIONS
9.61.37.2 OPERATION CONDITION SELECTION: INPUT WAIT, 6-0-1 This function is used to set ENABLE or DISABLE for DIN WAIT (digital input wait) instructions (Figure 9-134). When DISABLE is selected, DIN WAIT instructions are not executed during teach and repeat modes. When a DIN WAIT instruction is executed in a program, the robot waits the current program step until the DIN WAIT conditions are satisfied. If the peripheral external devices are not ready during program teaching or a test run, the input wait release signal may not be received by the robot. In this case, the robot can be operated by overriding the DIN WAIT. At controller power-up, the condition is automatically switched to ENABLE. Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same.
COND/DIN-WAIT EASY MOVE Select DISABLE/ENABLE of DIN WAIT

SET
Figure 9-134 Operation Condition Selection, Input Wait Screen
CAUTION
If the condition is switched to DISABLE during program playback, the robot held in standby by the DIN WAIT instruction may suddenly restart operation. Extreme care should be exercised when changing the condition during program playback.
9-170
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.37.3 OPERATION CONDITION SELECTION: CONVEYOR WAIT, 6-0-2 This function is used to set ENABLE or DISABLE for CV_WAIT (conveyor wait) instructions (Figure 9-135). When DISABLE is selected, CV_WAIT instructions are not executed during teach and repeat modes. Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same. At controller power-up, the condition is automatically switched to ENABLE.
COND/CV-WAIT EASY MOVE Select DISABLE / ENABLE of CV_WAIT

SET
Figure 9-135 Operation Condition Selection, Conveyor Wait Screen
CAUTION
If the condition is switched to DISABLE during program playback, the robot operation held in standby by the CV_WAIT instruction may suddenly restart. Extreme care should be exercised when changing the condition during program playback.
April 8, 2002
9-171
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AUXILIARY FUNCTIONS
9.61.37.4 OPERATION CONDITION SELECTION: TIMER WAIT, 6-0-3 This function is used to set ENABLE or DISABLE for the TIMER WAIT instruction (Figure 9-136). When DISABLE is selected, the TIMER WAIT instructions are not executed during repeat mode operation. Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same. At controller power-up, the condition is automatically switched to ENABLE.
COND/TIM-WAIT EASY MOVE Select DISABLE/ENABLE of TIMER WAIT

SET
Figure 9-136 Operation Condition Selection, Timer Wait Screen
CAUTION
If the condition is switched to DISABLE during a repeat operation, the robot under the TIMER WAIT instructions may suddenly restart. Extreme care should be exercised when changing the condition during repeat operation.
9-172
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.37.5 OPERATION CONDITION SELECTION: CONVEYOR TRACK (CV), 6-0-4 This function is used to set the method for synchronizing the robot with the conveyor (Figure 9-137). The CV_TRACK MODE function provides 2 modes: REAL PULSE TRACK and FALSE PULSE TRACK (simulation mode). REAL PULSE TRACK synchronizes the robot with the conveyor in an actual run. FALSE PULSE TRACK (simulation mode) checks the robot motion with non-moving conveyor. With the later function, a dummy pulse is generated in the robot controller to synchronize the robot with the conveyor at the pulse rate. It is possible for the robot to start synchronizing at any point by setting an optional start position for CV_TRACK. REAL PULSE TRACK is set as initial status of the function at controller power-up. Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same.
COND/TRCK-MOD EASY MOVE Select CV_TRACK mode.

0. REAL PULSE TRACK 1. FALSE PULSE TRACK (SELECT)
SET
Figure 9-137 Operation Condition Selection Conveyor Track Screen
April 8, 2002
9-173
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AUXILIARY FUNCTIONS
CAUTION
Ensure the proper CV_TRACK MODE is selected before starting repeat mode operation of the conveyortracking program. If a program is played back while the conveyor is actually running and FALSE PULSE TRACK is selected, the robot moves per the false pulse and may collide with the workpiece or peripheral equipment.
9-174
April 8, 2002
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9.61.37.6
AUXILIARY FUNCTIONS
OPERATION CONDITION SELECTION: DOOR SENSOR SETTING, 6-0-5-0
This function is used to set ENABLE or DISABLE for the DOOR SENSING function for detecting doors opened or closed for robot operation (Figure 9-138). Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same.
COND/SENSOR EASY MOVE Select DISABLE/ENABLE of DOOR SENSING

SET
Figure 9-138 Operation Condition Selection, Door Sensor Setting Screen
NOTE
This function should not be used if the system is not equipped with the door sensing function.
April 8, 2002
9-175
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9.61.37.7
AUXILIARY FUNCTIONS
OPERATION CONDITION SELECTION: CAMERA SENSING SETTING, 6-0-5-1
This function is used to set the work location compensation function (camera sensing setting function) as ENABLE or DISABLE (Figure 9-139). Compensation is performed using a camera sensor.
Select 1. ENABLE or 0. DISABLE and press the SET key. The menu number highlighted by the cursor and the menu number currently selected (SELECT) are not necessarily the same.
COND/SENSOR EASY MOVE Select DISABLE/ENABLE of CAMERA SENSING

SET
Figure 9-139 Operation Condition Selection, Camera Sensing Setting Screen
NOTE This function should not be used if the system is not equipped with the camera sensing function.
9-176
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.38 CURRENT CONVEYOR POSITION SETTING (CURRENT CV_POS), 6-1 This function is used to set the current position of the conveyor (Figure 9-140). Enter the current conveyor position. Ensure the correct data is entered and press the SET key. Maximum setting for the current conveyor position value is 65000 mm. The current set conveyor position is displayed as the initial value.
COND/CONVY EASY MOVE Enter CURRENT CV_POS value

CURRENT CV_POS _ _ 100 [mm]
SET
Figure 9-140 Current Conveyor Position Setting Screen
April 8, 2002
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9.61.39 COUNTER VALUE SETTING, 6-2
AUXILIARY FUNCTIONS
This function is used to set the values for GENERAL and SPECIAL counters (Figure 9141). The counter value can be set regardless of current operation mode (teach or repeat). All the counter values are cleared (set to zero) when the controller is powered-up. General counter values are cleared (set to zero) when initiating teach and repeat modes. Up to 32 different counters can be set for each type, GENERAL and SPECIAL. Set desired counter condition. Ensure the correct data is entered and press the SET key. The example in figure 9-140 shows setting a count of 500 to GENERAL counter No. 1. The current set counter values are displayed on the counter status screen in the status display mode.
COND/CNT EASY MOVE Enter conditions to COUNTER

CNT_TYP (0:GEN 1:SPE) CNT No. (1~32) VALUE (-32768~32767) GEN _1 _500
SET
Figure 9-141 Counter Value Setting Screen
9-178
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.40 LOCATION VARIABLES REGISTRATION, 6-3 Location Variables are registered by selecting HERE or POINT command from AS monitor instruction. Refer to the C Series Controller AS Language Reference Manual for information on the HERE and POINT commands. The example in figure 9-142 uses the POINT command. 1. 2. From the COND/POS screen select 2. POINT and press the SET key. Enter the desired variable name after POINT and the variable values in the [ ] using a comma as a delimiter between each value. Move the cursor to END and press the SET key to accept the POINT command and register the location variable.
3.
Refer to section 7.18, Others (Instructions), for entering character strings.
April 8, 2002
9-179
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AUXILIARY FUNCTIONS
COND/POS EASY MOVE Select COMMAND to define location

0. HERE 2. POINT 1. HERE # 3. POINT #
1.
SET
COND/POS EASY MOVE Enter COMMAND strings

!#$%&{}()*+,-./ @ABCDEFGHIJKLMNO COMMAND 0123456789:;<=>? PQRSTUVWXYZ[|]^_ POINT = & [ ] - - - - - -
2.
and
SET

!#$%&{}()*+,-./ 0 1 2 3 4 5 6 7 8 9:;<=>? @ABCDEFGHIJKLMNO PQRSTUVWXYZ[|]^_ COMMAND OINT P2=& [100,7

!#$%&{}()*+,-./ 0 1 2 3 4 5 6 7 8 9:;<=>? @ABCDEFGHIJKLMNO PQRSTUVWXYZ[|]^_ COMMAND 0, 0, 700, 0, 10, 60
<<
<<
<<
3.
SET
<<
Figure 9-142 Location Variables Registration Screen
9-180
April 8, 2002
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9.61.41 ERROR HISTORY DISPLAY, 7-0
AUXILIARY FUNCTIONS
This function is used to display the last 1,000 errors which have occurred (Figure 9143). Errors are stored in order of occurrence with the lower numbers being more recent. The error number and the first few words of each error message are displayed on the error history screen. Three errors are shown on the screen. Use the cursor keys to scroll through the errors. Detail information is displayed by pressing the SET key. Error number, date, and time of occurrence and an error message are shown. Each screen shows the information for one error. Use the cursor keys to scroll through the errors.
ERR-HIST EASY MOVE Display DETAIL HISTORY by SET key

1 2 3 -1516 -1201 -1800 Encoder data abnormal jt 1 Power sequence board not i AC primary power OFF.
SET
ERR-HIST/DETAILS EASY MOVE

1 -1516 01/09/03 17:12:11 Encoder data abnormal jt 1 7 8
Figure 9-143 Error History Display Screen
April 8, 2002
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9.61.42 TOTAL PLAYBACK COUNT DISPLAY, 7-1
AUXILIARY FUNCTIONS
This function displays the repeat counts for a specified program. The repeat count value can be changed. Input the desired program number and press the SET key (Figure 9-144). Input the desired repeat count value. Ensure the correct data is entered and press the SET key. The repeat count value limit is 65535 times. The value remains at the maximum limit if the count exceeds the limit. The count can be set to zero if desired.
TOTAL-PLYBK-CNT EASY MOVE Enter program No. to display

DISP PGM No. __1
SET
TOTAL-PLYBK-CNT EASY MOVE COUNT value can be rewritten

PROGRAM No. 1 _ _ _ 356 times
Figure 9-144 Total Playback Count Display Screen
9-182
April 8, 2002
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NOTE
AUXILIARY FUNCTIONS
For dry-run-repeat (executing a program in repeat mode, without robot motion, with the servo power OFF), the repeat count value is not incremented. When continuously repeating a program that has a JUMP instruction (JUMP_STEP, etc.) at the end, the repeat count value is not incremented. If a program was forced to terminate during repeat, the repeat count value is not incremented. When a repeat-run ends while the repeat count value indicator screen is displayed, the count value does not change. The internal counter continues counting, and the updated count value is displayed on screen the next time it is accessed. The repeat count value is incremented to 65535, if this value is reached, the value remains the same even if the program repeats more than 65535 times.
April 8, 2002
9-183
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AUXILIARY FUNCTIONS
9.61.43 MANUAL EXTERNAL OUTPUT EXECUTION: GENERAL SIGNAL, 8-0 This function is used to execute external output instructions regardless of the robot status (Figure 9-145). Enter the desired output signal number and 0: OFF to set the signal to the OFF state or 1:ON to set the signal to the ON state. Ensure the correct data is entered and press the SET key.
MANUAL-EX-OUT Enter DOUT data
EASY MOVE
_ _1 OFF
OUTPUT SIGNAL (1~32) SIGNAL (0:OFF 1:ON)
SET
Figure 9-145 Manual External Output, General Signal Screen
9-184
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.43.1 MANUAL EXTERNAL OUTPUT EXECUTION: SPRAY SIGNALS, 8-1 This function is used to execute spray instructions regardless of the robot status (Figure 9-146). Enter the desired spray signal number and 0: OFF to set the signal to the OFF state or 1:ON to set the signal to the ON state. Ensure the correct data is entered and press the SET key.
MANUAL-EX-OUT Enter SPRAY data

SPRAY SIGNAL (1~4) SIGNAL (0:OFF 1:ON)
EASY MOVE
1 OFF
SET
Figure 9-146 Manual External Output, Spray Signal Screen
April 8, 2002
9-185
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AUXILIARY FUNCTIONS
9.61.43.2 MANUAL EXTERNAL OUTPUT EXECUTION: FLOW RATE, 8-2 This function is used to execute flow rate instructions (Figure 9-147). Enter the desired condition level. Ensure the correct data is entered and press the SET key.
MANUAL-EX-OUT EASY MOVE Enter FLOW_RATE level

FLOW_RATE LEVEL (0~100) _ _1
SET
Figure 9-147 Manual External Output, Flow Rate Screen
9-186
April 8, 2002
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9.61.43.3
AUXILIARY FUNCTIONS
MANUAL EXTERNAL OUTPUT EXECUTION: SHAPING/PATTERN AIR, 8-3
This function is used to execute shaping/pattern air instructions (Figure 9-148). Enter the desired condition level. Ensure the correct data is entered and press the SET key.
MANUAL-EX-OUT EASY MOVE Enter PATTERN AIR level

PATTERN AIR LEVEL (0~100) __1
SET
Figure 9-148 Manual External Output, Shaping/Pattern Air Screen
April 8, 2002
9-187
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AUXILIARY FUNCTIONS
9.61.43.4 MANUAL EXTERNAL OUTPUT EXECUTION: AIR MOTOR/ATOMIZING AIR, 8-4 This function is used to execute air motor/atomizing air instructions (Figure 9-149). Enter the desired condition level. Ensure the correct data is entered and press the SET key.
MANUAL-EX-OUT EASY MOVE Enter ATOMIZING AIR level

ATOMIZING AIR LEVEL (0~100) _ _1
SET
Figure 9-149 Manual External Output, Air Motor/Atomizing Air Screen
9-188
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.43.5 MANUAL EXTERNAL OUTPUT EXECUTION: HIGH VOLTAGE, 8-5 This function is used to execute high voltage instructions (Figure 9-150). Enter the desired condition level. Ensure the correct data is entered and press the SET key.
MANUAL-EX-OUT EASY MOVE Enter HIGH VOLTAGE level

HIGH VOLTAGE LEVEL (0~100) __1
SET
Figure 9-150 Manual External Output, High Voltage Screen
April 8, 2002
9-189
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AUXILIARY FUNCTIONS
9.61.43.6 MANUAL EXTERNAL OUTPUT EXECUTION: FLUSHING, 8-6 This function is used to execute flushing instructions (Figure 9-151). Enter 0:OFF or 1:ON and press the SET key.
MANUAL-EX-OUT EASY MOVE Select OFF/ON of FLUSHING

FLUSHING (0:OFF 1:ON) ON
SET
Figure 9-151 Manual External Output, Flushing Screen
9-190
April 8, 2002
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AUXILIARY FUNCTIONS
9.61.43.7 MANUAL EXTERNAL OUTPUT EXECUTION: PUSH THINNER, 8-7 This function is used to execute push thinner instructions (Figure 9-152). Enter 0:OFF or 1:ON and press the SET key.
MANUAL-EX-OUT EASY MOVE Select OFF/ON of PUSH THINNER

PUSH THINNER (0:OFF 1:ON) ON
SET
Figure 9-152 Manual External Output, Push Thinner Screen
April 8, 2002
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10.0 10.1 10.2 10.3
ERROR CODES/TROUBLESHOOTING
ERROR CODES/TROUBLESHOOTING .......................................................... 10-2 Error Recovery .................................................................................................. 10-2 Error Codes ....................................................................................................... 10-5 Troubleshooting Flowcharts ............................................................................ 10-97
April 8, 2002
10-1
Kawasak
10.0 ERROR CODES/TROUBLESHOOTING
This unit provides error recovery flowcharts, error code information, and error code troubleshooting flow charts. In addition, typical causes and remedies for the errors are also provided. 10.1 ERROR RECOVERY Figure 10-1 shows troubleshooting processes that may be helpful if the controller becomes unresponsive to commands or an error code has been encountered that cannot be cleared. Troubleshooting should begin with confirmation of basic integrity of the system: ensure that the power supply is on and meeting supply requirements, all cables are correctly attached, all circuit boards are properly installed and fully seated, all peripheral equipment is wired correctly, software is properly configured, etc.
10-2
April 8, 2002
Kawasak
Locate error in the error code table and determine the characteristics and possible causes of the error
Source of error known
Troubleshoot and correct source of error
Run program and continue to monitor
Source of error unknown
Press the yellow reset button on the controller panel
Error cleared and robot runs normally
Error will not clear or machine is in a locked mode Have any changes been made to system? New internal parts, interface components added or removed, signal interface agrees with program, etc. No Error clears and robot runs normally
Yes
Ensure the robot system data and programs are compatible
Cycle the controller power off and on
Error or locked condition cleared
Error still present
With control power on, press the red reset button on the 1GA board
Error or locked condition cleared
Continued on next page
Figure 10-1 Troubleshooting Process
April 8, 2002
10-3
Kawasak
Continued from previous pg
Error or locked Create backup information condition cleared files and initialize the system
Reset system settings not set to defaults after initialization
Error still present
Remove the 1GA board from the rack and allow RAM memory to deplete
Reinstall 1GA board, initialize the system, zero
Error clears and robot runs normally
Begin electrical troubleshooting and repair if qualified; call service technician for further assistance
Figure 10-2 Troubleshooting Process (contd)
10-4
April 8, 2002
Kawasak
10.2 ERROR CODES
This unit provides information about the error codes that are displayed on the multi function panel or other user interfaces that provide display screen information. The error codes are listed in numerical order by code number with the message that is displayed with the associated code. An expanded explanation of the message is provided along with possible methods to clear or prevent the specific error. Troubleshooting information is preceded by a symbol.
NOTE
All error codes not preceded by an minus sign (-) are for C35/C37 controllers only. These error codes are designated by an asterisk (*).
*ERROR CODE 50
Acknowledgment error.
This error occurs when the main CPU board (1HA board) does not respond to the command requested by the explosion-proof teach pendant. Main causes include: 1. Disconnection, short-circuit, or defective harness in the communication line between the explosion-proof teach pendant and the controller. 2. Defective barrier unit for the explosion-proof teach pendant. 3. Defective explosion-proof teach pendant. 4. Defective communication board (1GS board) for the explosion-proof teach pendant. 5. Defective 1LT board. 6. Malfunction due to noise, etc. Check for disconnection or short-circuit in the communication line between the explosion-proof teach pendant an the controller, and repair or replace as necessary. Replace the barrier unit for the teach pendant. Replace the explosion-proof teach pendant. Replace defective 1GS board. Replace defective 1LT board. Repair source of line noise or shield line noise. _____________________________________________________________________
*This error code is for C35/C37 controllers only. Error code with the minus sign (-) follows.
April 8, 2002
10-5
Kawasak
ERROR CODE -50
Warning! Cannot move along straight line in this configuration.
Joint speed may exceed maximum, joints 4 and 6 aligned. Change angle of joint 5, slow the speed, change to joint mode. _____________________________________________________________________ ERROR CODE -57 Set low speed because of exceeding joint max. speed in check.
When joint speed is checked with commanded speed, the difference exceeds acceptable range. Slow the speed. _____________________________________________________________________
*ERROR CODE 81, 82, 83 Receive data error.

This error occurs when the serial communication control IC in the explosion-proof teach pendant detects an overrun error (81), framing error (82), or parity error (83). Main causes include: 1. Disconnection, short-circuit, or defective harness in the communication line between the explosion-proof teach pendant and the controller. 2. Defective barrier unit for the explosion-proof teach pendant. 3. Defective explosion-proof teach pendant. 4. Defective communication board (1GS board) for the explosion-proof teach pendant. 5. Defective 1LT board. 6. Malfunction due to noise, etc. Check for disconnection or short-circuit in the communication line between the explosion-proof teach pendant and the controller, and repair or replace as necessary. Replace the barrier unit for the teach pendant. Replace the explosion-proof teach pendant. Replace defective 1GS board. Replace defective 1LT board. Repair source of line noise or shield line noise. _____________________________________________________________________
10-6
April 8, 2002
Kawasak
ERROR CODE -100
Matrix Calculation Error.
The vector element of the matrix cannot be operated because of 0. Change and recalculate value. _____________________________________________________________________ ERROR CODE -101 Turn off motor power.
Motor power cannot turn on according to command and instruction. Turn motor power OFF and execute command and instruction. _____________________________________________________________________ ERROR CODE -102 Application is changed. Turn OFF & ON the control power.
The robot configuration was changed from spot welding/material handling to a paint/ sealant application using AUX 907. Turn controller power OFF then ON. _____________________________________________________________________ ERROR CODE -103 There is no external axis.
External axis equipment is not installed and cannot operate. Enable option or contact customer service to install desired option. _____________________________________________________________________ ERROR CODE -104 Illegal positioner type.
Equipment is not installed and cannot operate. Enable option or contact customer service to install desired option. _____________________________________________________________________ ERROR CODE -105 Data cannot be overwritten. Delete current data and replace with new data. _____________________________________________________________________ Cannot change data because user data exist.
April 8, 2002
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Kawasak
ERROR CODE -106 Graphic area error.
Unable to display data in designated display area. Select different display area. _____________________________________________________________________ ERROR CODE -107 Option is OFF.
Selected option is OFF or is not installed. Enable option or contact customer service to install desired option. _____________________________________________________________________ ERROR CODE -200 Cannot execute a program because motor power is OFF.
Program will not start because motor power is not on. Turn motor power ON. _____________________________________________________________________
*ERROR CODE 201
Receive error (STX).
This error occurs when a start code (STX) is not detected in the data transmitted to the explosion-proof teach pendant from the controller. Main causes include: 1. Disconnection, short-circuit, or defective harness in the communication line between the explosion-proof teach pendant and the controller. 2. Defective barrier unit for the explosion-proof teach pendant. 3. Defective explosion-proof teach pendant. 4. Defective communication board (1GS board) for the explosion-proof teach pendant. 5. Defective 1LT board. 6. Malfunction due to noise, etc. Check for disconnection or short-circuit in the communication line between the explosion-proof teach pendant and the controller, and repair or replace as necessary. Replace the barrier unit for the teach pendant. Replace the explosion-proof teach pendant. Replace defective 1GS board. Replace defective 1LT board. Repair source of line noise or shield line noise. _____________________________________________________________________
10-8
April 8, 2002
Kawasak
ERROR CODE -201
Cannot execute a program in TEACH mode.
(ERROR CODE 201 see sec. 10.3)
Programs cannot run when in the teach mode of operation. Ensure that the controller is in the REPEAT mode of operation. _____________________________________________________________________
*ERROR CODE 202
Receive error (ETC).
This error occurs when an end code (ETC) is not detected in the data transmitted to the explosion-proof teach pendant from the controller. Main causes include: 1. Disconnection, short-circuit, or defective harness in the communication line between the explosion-proof teach pendant and the controller. 2. Defective barrier unit for the explosion-proof teach pendant. 3. Defective explosion-proof teach pendant. 4. Defective communication board (1GS board) for the explosion-proof teach pendant. 5. Defective 1LT board. 6. Malfunction due to noise, etc. Check for disconnection or short-circuit in the communication line between the explosion-proof teach pendant and the controller, and repair or replace as necessary. Replace the barrier unit for the teach pendant. Replace the explosion-proof teach pendant. Replace defective 1GS board. Replace defective 1LT board. Repair source of line noise or shield line noise. _____________________________________________________________________ ERROR CODE -202 Cannot execute a program because teach lock is ON.
(ERROR CODE 202 see sec. 10.3)
Programs cannot be run with the teach lock in the ON position. Turn the TEACH LOCK switch to OFF and execute the program again in repeat mode. _____________________________________________________________________
April 8, 2002
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Kawasak
*ERROR CODE 203
Receive error (BCC).
This error is displayed when an error occurs in BCC check for the data transmitted to the explosion-proof teach pendant from the controller. Main causes include: 1. Disconnection, short-circuit, or defective harness in the communication line between the explosion-proof teach pendant and the controller. 2. Defective barrier unit for the explosion-proof teach pendant. 3. Defective explosion-proof teach pendant. 4. Defective communication board (1GS board) for the explosion-proof teach pendant. 5. Defective 1LT board. 6. Malfunction due to noise, etc. Check for disconnection or short-circuit in the communication line between the explosion-proof teach pendant and the controller, and repair or replace as necessary. Replace the barrier unit for the teach pendant. Replace the explosion-proof teach pendant. Replace defective 1GS board. Replace defective 1LT board. Repair source of line noise or shield line noise. _____________________________________________________________________ ERROR CODE -207 Turn to HOLD at HOLD/RUN sw.
Occurs when an attempt to perform DO, STEP, MSTEP, CONTINUE, or EXECUTE commands is made with the RUN/HOLD switch in the RUN position. Only applies if the CHECK HOLD system switch is ON. Turn the RUN/HOLD switch to HOLD position. _____________________________________________________________________ ERROR CODE -208 Teach pendant is not connected.
Hardwired switches for teach pendant and multi function panel must be jumpered and equipment configuration identified in environmental data functions. Install teach pendant or configure system accordingly. _____________________________________________________________________
10-10
April 8, 2002
Kawasak
ERROR CODE -211
Cannot edit a program because the TEACH LOCK switch is ON.
Programs cannot be edited if the TEACH LOCK switch is ON. Turn TEACH LOCK switch OFF. _____________________________________________________________________ ERROR CODE -212 Cannot execute because executed by other device.
Occurs when the operator attempts to execute the same command from the KCWIN terminal and the multi function panel or type 2 teach pendant at the same time. Cannot execute commands from two devices at the same time. _____________________________________________________________________ ERROR CODE -213 Cannot execute a program because of EXT-IT.
External hold signal and or external hold reset signal not received. Check dedicated input signals in AUX 111 match signals programed from the PLC in the Slogic program. If the external hold signal is not needed, change the signal setting in AUX 111 from set to reset. _____________________________________________________________________ ERROR CODE -300 Program is already running.
Occurs when an attempt is made to edit or execute a program that is currently running. Stop the robot control program prior to editing or checking. _____________________________________________________________________ ERROR CODE -301 Robot control program is already running.
Occurs when an attempt is made to execute a DO, TOOL, or BASE command when a robot control program is running. Wait for the robot control program to complete execution. Stop the robot control program. _____________________________________________________________________
April 8, 2002
10-11
Kawasak
ERROR CODE -302
Cant continue. Use EXEC.
The CONTINUE command is not permitted because of program selection status. Use the EXECUTE command to start program. _____________________________________________________________________ ERROR CODE -303 Robot is moving now.
Displayed if any of the following commands are entered while a program is running: EXECUTE, CONTINUE, TOOL, BASE, DO. SYSINIT or CYCLE START. Stop the program or confirm the operation to be performed. _____________________________________________________________________ ERROR CODE -304 Cannot execute because in error now. Reset error.
Occurs when attempt is made to start robot motion if an error has not been cleared. Clear any errors and re-enter the command. _____________________________________________________________________ ERROR CODE -306 Cannot execute with DO command.
Displayed when the DO command is entered with an instruction that is not of acceptable format. Execute the instruction from within a program or use acceptable instruction format for DO command. _____________________________________________________________________ ERROR CODE -308 PC program is running.
Occurs when a PC program is running and instructions are entered that are not allowed. Stop the PC program and enter the command. _____________________________________________________________________ ERROR CODE -314 Cannot execute because the program is already used.
Occurs when a program being edited is selected to run by a CALL, ON, ONI or PC program instruction. Stop editing the program or stop the program that is calling the program being edited. _____________________________________________________________________ 10-12 April 8, 2002
Kawasak
ERROR CODE -316
Waiting weld completion.
Displayed when a command to change the step is entered while a welding sequence is in progress. Wait until after the weld sequence is completed or force a weld complete condition. _____________________________________________________________________ ERROR CODE -317 Position offset error at last E-stop JTxx.
The error message is generated when an E-stop is applied and the position of the robot is not within a range of the commanded position. The error deviation range is specified in AUX 42. Before the error is reset, operators must be aware of the robots position within the work envelope. _____________________________________________________________________ ERROR CODE -318 Waiting retract or extend pos. input signal.
One of the following operations were attempted when the robot was processing a spot weld sequence (waiting for the Retract/Extend signal after the weld complete signal had been received). 1. Cycle start (including EXECUTE, CONTINUE command). 2. Program selection or step change. 3. Record. Input the Retract/Extend detection signal to the robot or press the WX key and wait override key on the multi function panel. _____________________________________________________________________ ERROR CODE -319 Spot sequence is running.
Step change, program change, or program execution were attempted while the spot weld sequence was executing (after Retract/Extend input signal and weld complete signal have been received). For example, the robot is executing move delay time after weld complete. Perform step change, program registration or program execution after the spot welding sequence. _____________________________________________________________________
April 8, 2002
10-13
Kawasak
ERROR CODE -320
Cannot operate because teach pendant in operation.
You cannot perform functions on the personal computer while the multi function panel is in use. Perform functions on the PC after the multi function panel has completed operation. _____________________________________________________________________ ERROR CODE -324 Cannot execute with MC instruction.
MC instruction could not be carried out. Use instruction which can be executed by MC instruction. _____________________________________________________________________ ERROR CODE -325 Cannot execute the instruction in robot program.
Command and instruction cannot be used or executed. Rewrite the command or instruction. _____________________________________________________________________ ERROR CODE -326 Cannot delete because used by another command.
Cannot COPY, DELETE or XFER command because current step is being executed. Perform DELETE commands after execution ends. _____________________________________________________________________ ERROR CODE -327 Used in programs.
The variable used with the program was deleted. Confirm the deleted variable. _____________________________________________________________________ ERROR CODE -328 Used in editor.
When the program was used in the editor, the program was deleted. _____________________________________________________________________
10-14
April 8, 2002
Kawasak
ERROR CODE -329
KILL or PCKILL to delete program.
Occurs when an attempt to delete a program is made and that program is still on the stack (selected). Select another program or KILL/PC KILL the program, then delete. _____________________________________________________________________ ERROR CODE -330 Cannot paste.
Occurs when the operator is executing the paste function and no data is stored in the paste buffer or the step(s) cannot be overwritten. Check paste operation and the destination steps. _____________________________________________________________________ ERROR CODE -350 Illegal input data.
Input data from AS Language monitor command is improper for the instruction. Enter data that is within acceptable range. _____________________________________________________________________ ERROR CODE -351 Too many arguments.
Input data from AS Language editor commands exceeds the number of user specified items allowed by the format. Verify input data and format of command. _____________________________________________________________________ ERROR CODE -353 Input data is too big.
Data entered for the POINT or HERE commands exceeds the allowable range. Enter data that is within acceptable range. _____________________________________________________________________ ERROR CODE -360 Illegal WHERE parameter.
Occurs if data entered with the WHERE command is not an integer between 1 and 6. Ensure that data is within acceptable range. _____________________________________________________________________ April 8, 2002 10-15
Kawasak
ERROR CODE -361 Illegal PC number.
Unused _____________________________________________________________________ ERROR CODE -365 Illegal robot number.
Unused _____________________________________________________________________ ERROR CODE -367 Illegal priority.
Priority level designation is wrong. Input a correct priority level. _____________________________________________________________________ ERROR CODE -368 Invalid coordinate value.
Upper limit value is less than value of lower limit. Input the correct upper limit coordinates. _____________________________________________________________________ ERROR CODE -371 External axis type and gun data mismatch.
The servo gun setting does not correspond to the type of external axis (set in AUX 160) and type of gun (set in AUX 114). This error is detected when motion begins for a step with a clamp signal set. Confirm that the external axis and gun type data settings are correct.
ERROR CODE -400
Syntax error.
Occurs when an AS Language command is entered that does not follow the correct format or contains typing or spelling errors. Correct format or spelling of command/instruction. _____________________________________________________________________
10-16
April 8, 2002
Kawasak
ERROR CODE -401 Invalid statement.
Occurs when an AS Language command is entered that has typing errors, incorrect spelling or is in the wrong format. Correct the input data spelling or format. _____________________________________________________________________ ERROR CODE -402 Ambiguous statement.
Displayed when an abbreviation is entered incorrectly or has missing letters. Enter the correct abbreviation or entire command. _____________________________________________________________________ ERROR CODE -403 Cannot use this command or instruction here.
Displayed because a program or monitor command was entered that could not be executed while a program is running. Stop program execution or wait for completion. _____________________________________________________________________ ERROR CODE -404 Cannot execute with DO command.
A program instruction that is not acceptable to use with the DO command was entered. Place the desired instruction within a program or choose an acceptable instruction for use with a DO command at the monitor prompt. _____________________________________________________________________ ERROR CODE -405 Statement cannot be executed.
Occurs when the AS Language instruction entered was not acceptable for the mode of operation. For example: a monitor command was entered in the editor mode. Use instructions and commands that are compatible with the input mode. _____________________________________________________________________
April 8, 2002
10-17
Kawasak
ERROR CODE -406
Not a program instruction.
An instruction was entered into a program that is not a valid program instruction, i.e., a monitor command, editor command, etc. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________ ERROR CODE -407 Too many arguments.
Input data from AS Language editor commands exceeds the number of user specified items allowed by the format. Verify input data and format of command. _____________________________________________________________________ ERROR CODE -408 Missing argument.
Displayed when a DO command is not followed by an acceptable program instruction. Correct the input and re-enter. _____________________________________________________________________ ERROR CODE -410 Illegal expression.
A real number expression must be present for processing DECOMPOSE command(s). Also displayed when incorrect numerical information is entered with arguments. Ensure correct format and numerical expressions are entered. _____________________________________________________________________ ERROR CODE -411 Illegal function.
Occurs when functions are used to assign values to variables but the data is incompatible. For example: assigning XYZ coordinate data to precision points. Ensure function is compatible with variables. _____________________________________________________________________ ERROR CODE -412 Illegal argument of function.
Occurs when function and argument are not in correct format. Use correct format for functions and arguments. _____________________________________________________________________ 10-18 April 8, 2002
Kawasak
ERROR CODE -413
Invalid variable (or program) name.
Displayed when illegal variable or program name is entered from the editor or monitor modes. For example: JM ##a (to many precision symbols) or CALL #a (not an acceptable program name). Define program names and variables correctly. _____________________________________________________________________ ERROR CODE -414 Illegal variable type.
Displayed when illegal variable is entered from editor or monitor modes. For example: b = #a + b (combining location and real variables using an arithmetic operator). Use compatible variable type for commands or instructions. _____________________________________________________________________ ERROR CODE -415 Illegal array index.
Displayed when an attempt is made to use a variable that has previously been defined as an array. May also occur if the order of an array is reversed when editing or entering monitor commands. Enter the correct array variable information. _____________________________________________________________________ ERROR CODE -416 Missing parenthesis.
Occurs when parentheses are not entered as a pair, containing both a left and right parenthesis. Enter parentheses in left and right pairs. _____________________________________________________________________ ERROR CODE -417 Expected to be a binary operator.
A non-binary operator has been entered where a command expected a binary operator. Input a binary operator. _____________________________________________________________________
April 8, 2002
10-19
Kawasak
ERROR CODE -418 Illegal constant.
A variable, or a non constant is used where a constant or integer should be used in a monitor command. Example: WHERE a (Should be WHERE 1 WHERE 6) Use the proper constant or integer with the command. See the C Series Controller AS Language Reference Manual for more information. _____________________________________________________________________ ERROR CODE -419 Illegal qualifier.
Displayed when monitor commands are followed by unexpected qualifiers. For example: LIST W (expected characters would include P, L, and R for program, location, and real variables; W causes error). Use only acceptable qualifiers. _____________________________________________________________________ ERROR CODE -420 Invalid label.
Occurs in the editor mode when a GOTO instruction is combined with a reserved character. For example: GOTO #a (# is a reserved character). Do not use reserved characters in label identification. _____________________________________________________________________ ERROR CODE -421 Invalid name.
Displayed when an unidentified program, file, variable, etc., is used in a command. Use only names that have been defined. _____________________________________________________________________ ERROR CODE -422 Missing expected character.
Occurs when commands or instructions are entered with an incorrect format. For example: TOOL a=b (TOOL a would be correct, =b causes error). Use correct format for commands and instructions. _____________________________________________________________________
10-20
April 8, 2002
Kawasak
ERROR CODE -423 Illegal switch name.
Displayed when a system switch is incorrectly identified. For example: SWITCH light (there is no system switch named light). Use only available switch names. _____________________________________________________________________ ERROR CODE -424 Ambiguous switch name.
Displayed when a switch name has been entered that is not available for the software version that is operating in the controller. Use only system switches that are compatible with the software version that is operating. _____________________________________________________________________ ERROR CODE -425 Illegal format qualifier.
Occurs when the TYPE or PRINT command is not used with an acceptable format portion of the instruction. Use only specified format instructions with TYPE and PRINT commands. _____________________________________________________________________ ERROR CODE -426 Duplicate statement label.
A specific program label name can only be used once per program. Error is displayed if the same label name is entered a second time in the same program. Use label names only once per program. _____________________________________________________________________ ERROR CODE -430 Cannot define as array.
A non-array variable with the same name as the array variable that was attempted to be created, already exists. Use a different name for the new variable. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________
April 8, 2002
10-21
Kawasak
ERROR CODE -431 Dimension exceeds 3.
Attempted to create an array variable with more than 3 dimensions. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________ ERROR CODE -432 Different dimensional array exist.
An array variable with same name but a different number of dimensions already exists. Change the name of the new variable or provide the same number of dimensions as the existing variable. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________ ERROR CODE -433 Array variable exist.
Attempted to create a non-array variable with the same name as an existing array variable. Confirm array variable exists. Select new name for non-array variable or select array variable. _____________________________________________________________________ ERROR CODE -434 Non array variable exist.
Attempted to create an array variable with the same name as an existing non-array variable. Confirm non-array variable exists. Select new name for array variable or select nonarray variable. _____________________________________________________________________ ERROR CODE -435 Array variable expected.
A non-array variable exists with the same name as the array variable that was specified for the decompose instruction. Select a new name for the array variable that was specified for the decompose instruction. _____________________________________________________________________
10-22
April 8, 2002
Kawasak
ERROR CODE -440
Local variable expected.
A subroutine call to a program with a local variable found a program with the same name but without a local variable. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________ ERROR CODE -441 Unexpected suffix.
No data was provided in the brackets of an array variable. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________ ERROR CODE -442 Mismatch of arguments at subroutine call.
The order of the local variable in the called program and the order of the local variable in the actual program are different. Check the order of the local variable in the actual program and modify the subroutine call accordingly. Refer to the AS Language Manual for proper use of AS Language commands. _____________________________________________________________________ ERROR CODE -443 Mismatch of argument type at subroutine call.
The type of argument, i.e. location variable, real variable, is different than the argument in the origin program. Correct the type of the argument in the called program or origin program. _____________________________________________________________________ ERROR CODE -450 Control structure error.
Displayed when an illegal program control flow structure is evaluated. Use correct syntax and components in control flow structures. _____________________________________________________________________
April 8, 2002
10-23
Kawasak
ERROR CODE -451
Step:xxx Wrong END statement.
Occurs when an illegal END statement is entered during editing. Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE -452 Step:xxx Extra END statement.
Occurs when an extra END statement is present and there is no corresponding structure. Use correct syntax and components in control flow structures, check structure of END statements. _____________________________________________________________________ ERROR CODE -453 Step:xxx Cannot terminate DO with END.
This error is displayed when the control flow structure DO.UNTIL is entered with an END statement . Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE -454 Step:xxx No VALUE statement after CASE.
Occurs when the control flow structure CASE OF.END is entered without a value to evaluate. Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE -455 Step:xxx Preceding IF missing.
Displayed when control flow structure does not contain the correct structure for IFTHEN ELSEEND commands. Use correct syntax and components in control flow structures. _____________________________________________________________________
10-24
April 8, 2002
Kawasak
ERROR CODE -456
Step:xxx Preceding CASE missing.
Displayed when control flow structure does not contain the correct structure for CASEof VALUEANYEND commands. Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE -457 Step:xxx Preceding DO missing.
Displayed when control flow structure does not contain the correct structure for DOUNTIL. Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE -458 Step:xxx Cant find END of xxx.
Occurs when control flow structure that requires an END statement does not contain the necessary END. Use correct syntax and components in control flow structures. _____________________________________________________________________ ERROR CODE -459 Step:xxx Too many control structures.
Occurs when 11 layers of control flow structure are exceeded. Limit control flow structure to 11 layers. _____________________________________________________________________ ERROR CODE -460 Variable (or program) already exists.
Displayed when a variable is entered that is already part of the system memory. For example: a location named weld1 is entered when a program named weld1 is already in the memory. Do not use variable names for more than one item. _____________________________________________________________________
April 8, 2002
10-25
Kawasak
ERROR CODE -461
Variable of different type already exists.
Displayed when a variable is entered that is already part of the system memory. For example: a location named weld1 is entered when a program named weld1 is already in the memory. Do not use variable names for more than one item. _____________________________________________________________________ ERROR CODE -464 Internal buffer over.
Attempted to solve a complex mathematical equation in a program. Rewrite to reduce the complexity of the operations required to solve the equation. _____________________________________________________________________ ERROR CODE -465 Undefined Variable (or program).
Attempt call a subroutine or process a variable that does not exist. Verify the variable or program exists. _____________________________________________________________________ ERROR CODE -466 Illegal clock value.
Time or date was entered in the wrong format. Re-enter the values correctly; time - military, date - yy/mm/dd. _____________________________________________________________________ ERROR CODE -470 Expect =.
The argument is missing the necessary =. Check the argument and correct it. _____________________________________________________________________ ERROR CODE -471 Expect ).
The argument is missing the necessary ). Check the argument and correct it. _____________________________________________________________________
10-26
April 8, 2002
Kawasak
ERROR CODE -472 Expect ].
The argument is missing the necessary ]. Check the argument and correct it. _____________________________________________________________________ ERROR CODE -473 Expect TO.
The argument is missing the necessary TO. Check the argument and correct it. _____________________________________________________________________ ERROR CODE -474 Expect BY.
The argument is missing the necessary BY. Check the argument and correct it. _____________________________________________________________________ ERROR CODE -475 Expect :.
The argument is missing the necessary :. Check the argument and correct it. _____________________________________________________________________ ERROR CODE -476 Expect ON/OFF.
An instruction other than ON/OFF was used with a SYSTEM SWITCH. Check the ON/OFF status SYSTEM SWITCH and input it correctly. _____________________________________________________________________ ERROR CODE -490 Program name not specified.
Displayed when no program is on the stack and the EDIT command is entered without specifying a program name. Identify the name of the program to be edited. _____________________________________________________________________
April 8, 2002
10-27
Kawasak
ERROR CODE -494
Program is interlocked by another procedure.
Attempt to edit a running program was made. Stop program execution before editing the program. _____________________________________________________________________ ERROR CODE -499 Invalid statement.
Occurs when the program is executed and instructions are encountered that cannot be processed as AS Language commands. Use correct syntax and components for AS Language commands. _____________________________________________________________________ ERROR CODE -507 Communication error.
When a vision system is incorporated and the transmission of data is interrupted (transmission line problem or stoppage of the program) this error will be displayed. _____________________________________________________________________ ERROR CODE -514 Device is not ready.
Unused _____________________________________________________________________ ERROR CODE -523 Illegal file name.
Unused _____________________________________________________________________ ERROR CODE -525 File already exists.
Occurs when the operator executes the rename command and the designated file name already exists. Change file name or delete existing file. _____________________________________________________________________ ERROR CODE -543 Data read error.
Unused _____________________________________________________________________
10-28
April 8, 2002
Kawasak
ERROR CODE -545
Record inhibited. Set record accept and operate again.
Displayed when an attempt is made to enter data, but RECORD INHIBIT in auxiliary function 71 is set to inhibit. Change the setting of the RECORD INHIBIT in AUX 71. _____________________________________________________________________ ERROR CODE -548 Program change inhibited. Set program change accept and operate again.
Displayed when an attempt is made to enter data, but PROGRAM CHANGE INHIBIT in auxiliary function 71 is set to inhibit. Change the setting of the PROGRAM CHANGE INHIBIT in AUX 71. _____________________________________________________________________ ERROR CODE -551 Cannot open the file.
Unused _____________________________________________________________________ ERROR CODE -565 1FS board is not installed. Ensure the 1FS board is properly installed and operational. _____________________________________________________________________ ERROR CODE -580 Retry error. RI/O board is not installed.
Occurs when there is a problem with the communication link between the controller and a host communication PC. Check the integrity of the controller and host PC link. _____________________________________________________________________ ERROR CODE -581 Stop of process.
(Option: Host communication I correspondence.) Refer to the host communication manual for details. _____________________________________________________________________
April 8, 2002
10-29
Kawasak
ERROR CODE -583
Receive not data after receive request.
ERROR CODE -584 Too long receive data (MAX=255 character).
ERROR CODE -585 Abnormal data (EOT) received in communicating.
ERROR CODE -586 Time out.
ERROR CODE -591 Illegal device number.
Two types of selections are possible for the serial port. This error occurs when port numbers other than the sensor port are specified.
ERROR CODE -596 Cannot attach terminal.
The prompt instruction was executed by two or more programs at the same time. Do not execute the prompt instruction from two or more programs at the same time. _____________________________________________________________________
10-30
April 8, 2002
Kawasak
ERROR CODE -597
Cannot attach communication port.
The RECEIVE instruction and the SEND instruction were executed by two or more programs at the same time. Do not execute these instructions from two or more programs at the same time. _____________________________________________________________________ ERROR CODE -598 Cannot execute on this terminal.
Attempt was made to execute a command that cannot be used at that terminal. Some commands can only be used at the multi function panel and some only at the PC. Use the above command from the proper terminal. _____________________________________________________________________ ERROR CODE -599 Waiting input data for PROMPT. Connect input device.
The input device specified by the prompt command, i.e., PC or MFP, was not connected. Verify that the specified device is connected. _____________________________________________________________________ ERROR CODE -600 Motor power OFF. Displayed whenever an emergency stop is encountered.
Reset emergency stop button and reapply motor power. _____________________________________________________________________ ERROR CODE -605 PLC communication error.
Allen-Bradley (RI/O) PLC communication error between the 1FS board node adapter chip (NAC) and the Allen-Bradley PLC. Occurs when the PLC is not in run mode, the NAC configuration is incorrect, or connection is lost with the PLC. Ensure the PLC is in run mode. Ensure the NAC configuration is correct. Ensure the PLC connection is established. _____________________________________________________________________
April 8, 2002
10-31
Kawasak
ERROR CODE -606
Weld controller #%d not connected.
Occurs when the 1FS board RI/O function is not able to communicate normally with a welder. When the START sequence is executed there is no response from the welder. Ensure the welder connection is established. Ensure the welder is operational. _____________________________________________________________________ ERROR CODE -607 Weld controller #%d no response.
Occurs when the 1FS board RI/O function is not able to communicate normally with a welder. When the NORMAL sequence is executed there is no response from the welder. Ensure the welder connection is established. Ensure the welder and related peripherals are operational. _____________________________________________________________________ ERROR CODE -608 Weld controller #%d response error.
Occurs when the 1FS board RI/O function is not able to communicate normally with a welder. The data received form the welder or the protocol is incorrect. Ensure the welder connection is established. Ensure the welder communication protocol is correct. Ensure the welder and related peripherals are operational. _____________________________________________________________________ ERROR CODE -610 Weld completion time over.
Occurs when a weld complete signal is not received in a specified time period. Override the wait condition, ensure that weld complete signal specifications are correctly identified, check the operation of the weld gun or controller. _____________________________________________________________________ ERROR CODE -611 Illegal extend (retract) output signal.
Occurs when the output signals for the extend and retract operation of a spot welding application are not properly set. Check the setting in AUX 114. _____________________________________________________________________ 10-32 April 8, 2002
Kawasak
ERROR CODE -612 Weld fault input.
Displayed when the controller receives a weld fault signal. Check operation of welding equipment, ensure signal numbers are correctly set. _____________________________________________________________________ ERROR CODE -613 Retract pos. monitor error.
Occurs when the input signal for the retract operation of a spot welding application is not received. Check the operation of welding equipment, check the signal number setting in AUX 114-10. _____________________________________________________________________ ERROR CODE -614 Extend pos. monitor error.
Occurs when the input signal for the extend operation of a spot welding application is not received. Check the operation of welding equipment, check the signal number setting in AUX 114-10. _____________________________________________________________________ ERROR CODE -615 Weld completion signal is already inputted.
Displayed when the weld complete signal has been received before the weld initiate output has not been issued. Check operation of welding equipment, check the signal number setting in AUX 11411. _____________________________________________________________________ ERROR CODE -616 Gun retract position mismatch.
In the check mode, retractable gun output signals are monitored and compared to open/ close data for a specific step. If the data does not compare, an error is displayed. Check settings in clamp conditions, check operation of gun with clamp key. _____________________________________________________________________
April 8, 2002
10-33
Kawasak
ERROR CODE -631
Cannot achieve desired pressure.
The gun does not obtain the set closing pressure within 5 seconds after the gun starts closing. 1. Tip wear measurement is not executed. 2. Incorrect taught point (closing pressure is not defined for the recorded position). 3. Closing pressure is set too high. Perform the tip wear measurement. Reteach the point. Decrease the closing pressure. _____________________________________________________________________ ERROR CODE -632 Gun chip[tip] stick.
Indicates that the tips are stuck. More power is required to open the gun, following a weld, than the stuck detection value, set in AUX 114-41, WELDING DETECTION(0:NO CHK) [kgf]. If the stuck detection value is set below the power level required for normal operation, the gun cannot operate properly and the error is set. If the gun is stuck, release it manually. If the gun is not stuck, verify that the stuck detection value (AUX 114-41, WELDING DETECTION(0:NO CHK) [kgf]) is set correctly. This setting may need to be increased. _____________________________________________________________________ ERROR CODE -633 Copper plate abrasion over the limit. step=*.
The copper backing plate wear exceeds the copper plate wear limit (AUX 114-12). The error is detected when the gun executes a weld. Replace the copper backing plate. _____________________________________________________________________ ERROR CODE -634 Not dedicated encoder and brake power off signal.
The gun separation accept signal is not received during a gun change. From AUX 111 Dedicated Input Signal, set the gun separation accept signal number (encoder brake power supply OFF control signal). _____________________________________________________________________ 10-34 April 8, 2002
Kawasak
ERROR CODE -641
Now servo gun is disconnected or a different gun.
The robot executes a step when a gun is not attached to the tool changer or the gun number in the tool changer is different than the gun number for the program step. Execute the step in manual mode or manually install the correct gun. In the teach or check mode, verify connection of the gun by pressing the connect/separate button. If the correct gun is attached to the tool changer, confirm that the gun signal number (AUX 114-41, GUN CONNECTION SIGNAL) is correct. From the MONITOR (INPUT SIGNAL) screen, confirm that the signal number is received. Inspect the connectivity from the gun to the 1FG board. Temporarily set the gun connect signal number (AUX 114-41, GUN CONNECTION SIGNAL) to 0 (when the gun connect number is set to 0, the error is not detected); ensure that the correct gun is in the tool changer. Repair the gun connection and set the gun connect signal number as soon as possible. _____________________________________________________________________ ERROR CODE -642 Calibration is not completed.
The controller terminates the calibration operation after a gun change. Reset the error and perform a manual gun change. _____________________________________________________________________ ERROR CODE -643 Measure of chip abrasion (stage 1) was not executed.
When the tip wear measurement program stage 2 (reference plate) is attempted, without first performing stage 1. Execute tip wear measurement program stage 1 prior to executing stage 2. _____________________________________________________________________ ERROR CODE -644 Work sensing signal (gun_chip[tip] touch sig) is not established.
A workpiece thickness measurement is attempted, when the gun tip touch signal (set in AUX 114-41) has not been received. Set the gun tip touch signal number (AUX 114-41). _____________________________________________________________________
April 8, 2002
10-35
Kawasak
ERROR CODE -645
Cannot weld because of abnormal thickness.
The thickness of the workpiece is out of tolerance. Probable causes: 1. 2. 3. 4. Defective workpiece. Incorrect positioning of the workpiece A gap between the two panels being welded. Current tip wear (AUX 114-41) and actual tip wear are different.
Inspect the workpiece. Measure the thickness and positioning; replace workpiece and/or correct abnormal positioning. Execute the tip wear measurement program. Manually measure the tip wear; compare these measurements to the current tip wear data (AUX 114-41). _____________________________________________________________________ ERROR CODE -646 Servo welding gun mechanical parameter is not established.
When connecting a new gun, the mechanical parameters are not defined. Define the parameters in AUX 114-12 SPOT WELD GUN DEFINITION and AUX11442 SERVO WELDING MECHANICAL PARA. _____________________________________________________________________ ERROR CODE -653 Illegal DOUBLE OX output.
When Double type signals are used, if either output in the pair is turned ON, the other turns OFF. An instruction to turn both outputs ON or turn both outputs OFF (OX=+1,2 or OX=-1,2) causes this error. Modify using the teaching screen. _____________________________________________________________________ ERROR CODE -654 Cannot use DOUBLE OX.
When Double type signals are used, if either output in the pair is turned ON, the other turns OFF. An instruction (BITS, PULSE, DELSIG, etc.) to change the state of either output causes this error to occur. Modify using the teaching screen. _____________________________________________________________________
10-36
April 8, 2002
Kawasak
ERROR CODE -660
Gun chip abrasion over the limit.
The maximum tip wear limit (AUX 114-41 MAX ABRASION MOVING/FIXED[mm]) is exceeded. Replace the tips. _____________________________________________________________________ ERROR CODE -662 Start point position error for circle.
The robot was stopped after it began executing a circular motion and moved 4 mm or more away from its calculated path (jogging or brake slippage, etc.). Attempting to continue execution of the path from this position will result in this error. Move the robot closer to the calculated path or restart the program a step prior to the circular path. _____________________________________________________________________ ERROR CODE -671 Cannot execute in check back mode.
The program reached an instruction which cannot be executed in check back mode. Execute after selecting a step that can be checked backward. If possible, check forward. _____________________________________________________________________ ERROR CODE -672 Cannot execute in ONE program.
The instructions specified in the ONE program area not valid for this type of program. Refer to the AS Language manual for proper use of the AS Language commands. _____________________________________________________________________ ERROR CODE -673 Angle between JT2 and JT3 is out of range at start location.
Movement from the current position to the start location position would cause JT2 and JT3 to move beyond their limits. Modify the position of the start location of the program. _____________________________________________________________________
April 8, 2002
10-37
Kawasak
ERROR CODE -674
Angle between JT2 and JT3 is out of range at end location.
Movement from the current position to the end location position would cause JT2 and JT3 to move beyond their limits. Modify the position of the end location of the program. _____________________________________________________________________ ERROR CODE -675 Terminal is not connected.
A PRINT, TYPE, or PROMPT command is specified for display on a PC that is not connected. Verify the PC connections or modify the commands for display on the MFP. _____________________________________________________________________ ERROR CODE -676 Cannot input /output to multi function panel.
A PRINT, TYPE, or PROMPT command is specified for display on the MFP, although no MFP connection is present. Verify the MFP connections or modify the commands for display on the PC. _____________________________________________________________________ ERROR CODE -691 Cannot change two or more guns at the same step.
The operator attempts to execute a step with more than one gun change. Edit the program so that there is only one gun change per step. _____________________________________________________________________
10-38
April 8, 2002
Kawasak
ERROR CODE -692
Gun is connected other.
The tool changer attempts to connect to a gun that is already connected to another tool changer or is missing. Select a different gun or disconnect the gun from the other tool changer.
NOTE
The following are conventional robot errors; however, when they occur for the servo gun axis, the following additional causes are possible.
_____________________________________________________________________ ERROR CODE -700 No free memory.
No free memory is available to teach or edit programs. Delete unused programs and variables, or, expand system memory to maintain the required capacity. _____________________________________________________________________ ERROR CODE -800 Program does not exist.
No program is on the stack at the time of cycle start or execution command (without a program being specified). Identify program to be executed. _____________________________________________________________________ ERROR CODE -801 No program step. The step specified for execution does not exist.
Select valid step numbers for execution. _____________________________________________________________________ ERROR CODE -802 Nonexistent label.
Occurs when executing the GOTO command and the destination label is not defined. Ensure valid labels are used within the program. _____________________________________________________________________
April 8, 2002
10-39
Kawasak
ERROR CODE -803
Undefined variable. Variable data for a specific argument in a command is not defined.
Ensure variables are properly defined. _____________________________________________________________________ ERROR CODE -804 Undefined location data.
The location variable for the BASE, TOOL or POINT command is not specified. Also, a named position in a program is not defined in system memory. Define all locations identified in programs. _____________________________________________________________________ ERROR CODE -805 Undefined string variable. String variables that are evaluated by ASC and LEN functions are not defined.
Define the string variables to be evaluated or correct the name of the string variable used for evaluation. _____________________________________________________________________ ERROR CODE -807 Undefined program or label.
The program name or label associated with an ON or ONI command does not exist. Define the program or label used with the ON or ONI command. _____________________________________________________________________ ERROR CODE -808 Illegal value. The numeric value entered exceeds the upper or lower limits of the acceptable range.
Enter data that is within acceptable range. _____________________________________________________________________ ERROR CODE -809 Undefined array suffix.
Attempt to process an array variable with undefined suffixes, i.e., attempting to process A=B[C,D,E], but C, D, E have no values. Rewrite the program to define the array suffix before attempting to process the array. _____________________________________________________________________
10-40
April 8, 2002
Kawasak
ERROR CODE -810 Divided by zero.
Occurs when the system encounters a mathematical evaluation that involves division by 0. Typically associated with the FRAME function and circular interpolation. Check data source for calculations. _____________________________________________________________________ ERROR CODE -811 Floating point overflow.
Occurs when the system encounters a numeric floating point overflow in using arithmetic (+, -, *, /)or logical (AND, OR, etc.) operators. This also occurs when converting a numeric argument to an integer value. Correct the program. Integer values with full precision ranges are from -16,777,216 to 16,777,216. For more information refer to the C Series Controller AS Language Reference Manual. _____________________________________________________________________ ERROR CODE -812 Character string is too long.
Character strings associated with arithmetic or comparative operators or the LEN function are too long. Correct the program. _____________________________________________________________________ ERROR CODE -813 Illegal exponential operation.
Numeric values that have exponents must be positive in value. Correct equations in program. _____________________________________________________________________ ERROR CODE -814 Expression too complicated.
A numeric calculation too complex to be evaluated was encountered. Simplify mathematical equations. _____________________________________________________________________
April 8, 2002
10-41
Kawasak
ERROR CODE -815
No expressions to evaluate.
The type of data in an argument is incompatible with the operation being performed. Correct the program to evaluate compatible expressions. _____________________________________________________________________ ERROR CODE -816 Unexpected error while evaluating expression.
Occurs when the system is evaluating the argument in an expression and the data of the argument is found to be incompatible or missing. Correct the program so that data is compatible with arguments and expressions. _____________________________________________________________________ ERROR CODE -817 SQRT parameter is negative.
In the argument of a SQRT function, a negative number was entered for evaluation. Do not enter negative numbers for evaluation by the SQRT function. _____________________________________________________________________ ERROR CODE -820 Illegal array index.
Occurs when the array subscript number exceeds the acceptable range from 0 to 9999. Ensure the range of array subscripts is acceptable. _____________________________________________________________________ ERROR CODE -821 Illegal argument value.
Displayed when the parameter specified for an command or instruction is illegal. For example: TOOL 2112 (after the TOOL command a defined transformation location or null is expected, 2112 causes error). Use correct argument values. _____________________________________________________________________ ERROR CODE -822 Illegal joint number.
The joint numbered entered does not exist or is in the wrong format. Retype the command using the correct format. _____________________________________________________________________ 10-42 April 8, 2002
Kawasak
ERROR CODE -823 Illegal signal number.
This is displayed when the SIG or BITS command is used and the specified signal number is beyond the range permitted by the system configuration. Use acceptable signal numbers for system configuration. _____________________________________________________________________ ERROR CODE -824 Illegal timer number.
Displayed when a timer was specified that was not within the acceptable range of between 1 and 10. Specify timers in the range between 1 and 10. _____________________________________________________________________ ERROR CODE -825 Illegal signal number.
When the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT commands are used with a signal number that exceeds the range permitted by system configuration, this error is displayed. Check signal number specified in instruction and ensure it is within system configuration. _____________________________________________________________________ ERROR CODE -826 Illegal clamp number.
Displayed when the clamp number entered exceeds the maximum permitted by system configuration. Use only clamp numbers that are supported by system configuration. _____________________________________________________________________ ERROR CODE -827 Illegal time value.
Displayed when a negative number is entered as part of a DELAY or TIMER command. Correct the time setting to a positive number. _____________________________________________________________________
April 8, 2002
10-43
Kawasak
ERROR CODE -828 No value set.
Occurs when an instruction like the BITS command is evaluated and there is no corresponding value set. Correct program code to evaluate existing values. _____________________________________________________________________ ERROR CODE -829 Illegal signal number.
This error is displayed when the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT commands are used with a signal number that exceeds the range permitted by system configuration. Check signal number specified in the instruction and ensure it is within system configuration. _____________________________________________________________________ ERROR CODE -832 Illegal time input data.
Occurs when erroneous data has been entered in the setting of the TIME and DATE function. For example: a date of Feb. 30. Input time and date information correctly, mm/dd/yy. _____________________________________________________________________ ERROR CODE -834 Program name already exists.
When using the RENAME command a new program name must be specified. If an existing name is used to rename a program this error will be displayed. Specify unused program names when renaming programs. _____________________________________________________________________ ERROR CODE -835 Cant KILL because the program is running.
Displayed when an attempt was made to KILL a program that was in the process of executing. Stop program execution with HOLD or ABORT commands before program is removed from the stack with a KILL command. _____________________________________________________________________
10-44
April 8, 2002
Kawasak
ERROR CODE -837
Cannot use dedicated signal.
Occurs when a previously dedicated signal was used as a general purpose signal. Use signals that have not been dedicated for general functions. _____________________________________________________________________ ERROR CODE -838 Not RPS mode.
Occurs when the required input signals are not dedicated at the time an attempt to run an externally selected program is made. If RPS is to be used the necessary signals must be dedicated. _____________________________________________________________________ ERROR CODE -839 Cannot use negative number. Displayed when a negative number has been used in conjunction with the PULSE or ACCURACY commands.
Use only positive numbers in the acceptable range for the PULSE and ACCURACY commands. _____________________________________________________________________ ERROR CODE -840 Too many subroutines.
Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions. Do not exceed 20 nested subroutines. _____________________________________________________________________ ERROR CODE -842 Nonexistent subroutine. Displayed when the program identified by a CALL, ON, or ONI does not exist.
Select only existing programs to be run as subroutines. _____________________________________________________________________ ERROR CODE -846 No program exist.
Pertinent program does not exist in DIRECTORY and LIST commands. Correct program or make program. _____________________________________________________________________
April 8, 2002
10-45
Kawasak
ERROR CODE -850
Out of absolute lower limit.
Displayed when an attempt has been made to set the software lower limits of robot travel to a value that is too low. Set lower software travel limits to an acceptable range. _____________________________________________________________________ ERROR CODE -851 Out of absolute upper limit.
Displayed when an attempt has been made to set the software upper limits of robot travel to a value that is too high. Set upper software travel limits to an acceptable range. _____________________________________________________________________ ERROR CODE -852 Out of user lower limit.
Displayed when an attempt has been made to set the software lower limits of robot travel to a value that is too low. Set lower software travel limits to an acceptable range. _____________________________________________________________________ ERROR CODE -853 Out of user upper limit.
Displayed when an attempt has been made to set the software upper limits of robot travel to a value that is too high. Set upper software travel limits to an acceptable range. _____________________________________________________________________ ERROR CODE -854 Current position of jt x is out of range. Current position of jt x is out of limit. Out of motion limit!! Current JT x
Current position of the relative joint exceeds the upper or lower limit of motion range. In repeat or check mode, the joint value of the current robot position exceeds the motion range set under software limit. Check and reset the software limit. Correct the taught point or position data. _____________________________________________________________________
10-46
April 8, 2002
Kawasak
ERROR CODE -855
Motion start location of jt-x is out of range.
Prior to beginning a program or motion to a step, the software has calculated the location to be outside of the allowable upper or lower software limits. Correct location to within working envelope or expand software limits to accept location. _____________________________________________________________________ ERROR CODE -856 Motion and location of jt-x is out of range.
While executing a motion to a step, the software has calculated the location destination of the specific joint number to be outside of the allowable upper or lower software limits. Correct location to within working envelope or expand software limits to accept location. _____________________________________________________________________ ERROR CODE -857 Destination is out of range.
While executing a motion to a step, the software has calculated the location destination of all joints to be outside of the allowable upper or lower software limits. Correct location to within working envelope or expand software limits to accept location. _____________________________________________________________________ ERROR CODE -858 Illegal configuration for linear motion.
System software has determined that the start and end points of a linear move will cause the robot to exceed the acceptable motion parameters. Change motion interpolation to a joint move; move location to avoid configuration. _____________________________________________________________________ ERROR CODE -871 Illegal joint number.
Occurs when the DRIVE command is used and specifies a joint number that is not part of the robot configuration. Confirm robot configuration before using the DRIVE command. _____________________________________________________________________
April 8, 2002
10-47
Kawasak
ERROR CODE -872
Cannot execute motion instruction in PC program.
A PC program cannot contain instructions that initiate robot motion. If a motion instruction is encountered in a PC program this error will be displayed. Correct the PC program by removing motion instructions. _____________________________________________________________________ ERROR CODE -873 Illegal auxiliary data number.
The value selected for auxiliary data (speed, timer, tool etc.) exceeds allowable range. Correct the value of auxiliary data. _____________________________________________________________________ ERROR CODE -874 No circular location.
Program circular motion instructions must have C1 moves followed by either a C1 or C2 move. Correct program instructions. _____________________________________________________________________ ERROR CODE -875 No C1MOVE(CIR1) ins.
Program circular motion instructions must have C2 moves preceded by a C1 move. Correct program instructions. _____________________________________________________________________ ERROR CODE -876 Cannot create circle.
Circular interpolation moves cannot be processed because the points identified are too narrow or are on a straight path. Correct program instructions. _____________________________________________________________________ ERROR CODE -877 Cannot execute, because of sealing type.
Occurs when a command for a sealing application is evaluated by a controller that is not configured for sealing applications. Correct program instructions to match software configuration. _____________________________________________________________________ 10-48 April 8, 2002
Kawasak
ERROR CODE -879
Cannot execute, because of not sealing type.
Occurs when a GUNON, GUNOFF, GUNONTIME or GUNOFFTIME command for a sealing application is evaluated by a controller that is not configured for sealing applications. Correct program instructions to match software configuration. _____________________________________________________________________ ERROR CODE -896 Option is not set up, cant execute.
Contact customer service for option specifications after confirming the purchase specification. _____________________________________________________________________ ERROR CODE -900 Arc failure.
The signal (current detection: WCR) that indicates the robot is executing the weld did not return from the welder for 1 sec. or more after welding started. Check for insulating debris that prevents welding. Confirm that adequate supply of wire is available. Confirm that wire is not stuck to the welding tip. _____________________________________________________________________ ERROR CODE -901 Wire stuck.
The wire is stuck to the base metal at the weld end. Cut the wire. Change weld conditions if problem occurs frequently. _____________________________________________________________________ ERROR CODE -902 Electric pole stuck.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -909 Watch-Dog Error RS485 Special Communication Board.
Contact KRI Customer Service. _____________________________________________________________________
April 8, 2002
10-49
Kawasak
ERROR CODE -910
Work not detected (Touch sensing)
Occurs when touch sensing does not detect the workpiece within the range of touch sensing distance set in system data or no workpiece is present. The robot stops and error -910 is generated. Reset the workpiece in the proper position. Increase the range of touch sensing distance in system data. _____________________________________________________________________ ERROR CODE -911 Undefined sensing direction. (Touch sensing)
Occurs when the step proceeding the WORK_DETECT instruction is not an air_cut point. The robot stops and error -911 is generated. Insert an air_cut point in the program before the WORK_DETECT instruction. When using step select to chose the start step, select the air_cut point before the WORK_DETECT instruction in the program _____________________________________________________________________ ERROR CODE -912 Insufficient sensing points. (Touch sensing)
Occurs when two point sensing is set up and the following point is other than an air_cut point. The robot stops and error -912 is generated. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 (error occurs at this step) 3. WS LINEAR SPEED9 TIMER0 Step two sets 2 point sensing and step three is a weld start point instead of an air_cut point. Add the required air_cut sensing points. Example: 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 3. AC JOINT SPEED9 ACCU4 TIMER0 4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 5. WS LINEAR SPEED9 TIMER0 _____________________________________________________________________
10-50
April 8, 2002
Kawasak
ERROR CODE -913
Mother or daughter work does not exist. (Touch sensing)
Occurs when a previous work instruction is not completed before another work instruction is executed. The robot stops and error -913 is generated. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 DAUGHTER_WORK2 (error occurs at this step) Add the required steps in the program to complete the first work instruction before another work instruction is executed. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 _____________________________________________________________________ ERROR CODE -914 Number of sensing points exceeded. (Touch sensing)
Occurs when a work instruction is completed and another work instruction is executed without a reset instruction. The robot stops and error -914 is generated. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 3. AC LINEAR SPEED9 ACCU4 TIMER0 4. WS LINEAR SPEED9 TIMER0 5. WE LINEAR WELD_COND0 6. AC LINEAR SPEED9 ACCU4 TIMER0 7. WS LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 (error occurs at this step) Add a reset instruction before the next work instruction. Example: 6. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_RESET 7. WS LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 _____________________________________________________________________
April 8, 2002
10-51
Kawasak
ERROR CODE -915
Illegal work appointment. (Touch sensing)
Occurs when a previous work instruction is not completed before another work instruction is executed. The robot stops and error -915 is generated. Example: 1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET 2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 3. AC LINEAR SPEED9 ACCU4 TIMER0 4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 (error occurs at this step) Add the required steps in the program to complete the first work instruction before another work instruction is executed. Example: 4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 _____________________________________________________________________ ERROR CODE -916 Illegal sensing points appointment. (Touch sensing)
Occurs when points are taught in incorrect order. Example: points should be taught in order A1, B1, A2, B2, A3, B3. Occurs when the distance between two points taught on the same check plane is 20 mm or less or the angle between the sensing direction for a check plane and for the other check plane is out of the 30 to 150 degrees range. Reteach points to comply with parameters described above . _____________________________________________________________________ ERROR CODE -917 Wire check failed. (Touch sensing)
Occurs when: The position of a taught point is recorded too far from the workpiece. The weld wire was not sent due to the welding unit power off. Reteach point at the correct distance. Check the welding machine for power and press CYCLE START to manually feed wire for five seconds. _____________________________________________________________________
10-52
April 8, 2002
Kawasak
ERROR CODE -919
No RS485 Special Communication board.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -920 Illegal welding condition number.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -921 Weld data not set up.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -922 Weld data out of range.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -934 No weld data base.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -935 Cannot change condition.
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -951 No RTPM board. (RTPM)
Occurs when the software option for RTPM is installed but the hardware (1FH board) is not installed. Occurs when the software and hardware (1FH board) are installed but controller power is not cycled OFF and ON after RTPM option is set-up. Ensure the 1FH board is properly installed. Reseat board and connectors. Perform RTPM option set-up procedure and cycle controller power OFF and ON. _____________________________________________________________________
April 8, 2002
10-53
Kawasak
ERROR CODE -960
To many taught points for RTPM. (RTPM)
Occurs when the number of taught points between the weld start point and the weld end point exceeds 127 points Reteach program points not to exceed 127 points. _____________________________________________________________________ ERROR CODE -961 RTPM arc sensor error. (RTPM)
Contact KRI Customer Service. _____________________________________________________________________ ERROR CODE -962 Out of RTPM tracking value. (RTPM)
Occurs when the detection value exceeds the error check value set in RTPM. Ensure the weld start point is taught in the welding groove. Confirm proper welder operation. Ensure the RTPM function is activated. _____________________________________________________________________ ERROR CODE -963 Out of RTPM tracking capacity. (RTPM)
Occurs when the threshold setting in AUX 31 RTPM Errors, exceeds the number of times setting (also set in AUX 131 RTPM Errors). Example: If the threshold is set a 9 mm and the number of times is set at 30, the error occurs after 30 weave cycles and the path has deviated more than 9 mm from the original welding path. Ensure the welding start point is taught in the grove. Starting outside the grove will cause this error. Execute a weld without the RTPM function, to ensure the welding power supply is operation properly. Improve fixturing and/or part to minimize the required correction. Verify the linearization table is correct by comparing the current reading indicated on the welding power supply to the current value set in the weld condition number in AUX 28. Increase the out of tracking capacity values (threshold and number of times). This allows the robot to deviate further from the planned path and could cause the robot to collide with peripherals or the workpiece. _____________________________________________________________________ 10-54 April 8, 2002
Kawasak
ERROR CODE -964
RTPM current deviation error. (RTPM)
Occurs when actual current exceeds commanded current for a time period that exceeds the current deviation error time-out value while using RTPM. Set controller power to OFF and reseat the 1FH board and the 1FH board connectors. Ensure the weld start point is taught in the welding grove. Ensure the welding unit power is ON and in proper operating condition. Ensure the RTPM function is activated. Ensure the welding unit metered current during a continuous bead is the same a the commanded current. _____________________________________________________________________ ERROR CODE -990 No welding interface board.
The welding interface board was not detected at control power on. Turn control power off and confirm that the weld interface board is mounted. Confirm that the weld interface board is not loose. Insert the board firmly. _____________________________________________________________________ ERROR CODE -999 No welding interface board.
The welding interface board was not detected at control power on. Turn control power off and confirm that the weld interface board is mounted. Confirm that the weld interface board is not loose. Insert the board firmly. _____________________________________________________________________
April 8, 2002
10-55
Kawasak
ERROR CODE -1003 Data base error.
The program storage area of the system memory has been damaged and is not linking data correctly. Turn on the 1GA board switch SW2-8 to initialize the memory, do not use AUX100 or SYSINIT command. Reload the teach data. Check that system is properly isolated from electrical noise. Check the memory backup battery. Replace if necessary. Replace the 1GA board if the error re-occurs. _____________________________________________________________________ ERROR CODE -1012 Command position of jt-x has suddenly changed.
Spot welding and material handling In the repeat mode, the commanded position of the joint identified has exceeded 1.3 times the maximum arm speed. In the check mode, the commanded position of the joint identified has exceeded 200 mm/sec. Check for singularity condition during robot motion and reteach to correct. Check for loose or defective servo system encoders, harnesses, and circuit boards. Servo welding gun Occurs when corrections for deflection cause movement of the robot to exceed the range of motion of one or more axes. This condition is not limited to the gun axis; any axis, including the gun axis, can cause this error. Change the posture of the robot. Decrease the speed in the step. Reduce the amount of the deflection correction in the step by using AS Language SGREFLEX command. Reteach the point and change the configuration of the posture of the robot if needed. _____________________________________________________________________
10-56
April 8, 2002
Kawasak
ERROR CODE -1014
Commanded position of jt-x is out range.
Spot welding and material handling The commanded position for the joint identified has exceeded the software limits. Condition is monitored in both the check and repeat modes. Correct taught positions to avoid the software limits. Adjust the software limits to provide the necessary work envelope. Servo welding gun If a taught point is near a servo gun or arm axis range of motion limit, the combination of tip wear and deflection correction can prevent the robot from reaching the taught point. Do not teach points that are near axes range of motion limits. _____________________________________________________________________ ERROR CODE -1017 Angle between JT2 and JT3 is out of range.
The commanded position for JT2 and JT3 cannot be reached due to the nature of the mechanical links that exist between these points for the U-series, EH, and ES robots. This error does not apply to JS-series robots. The main cause of this error is that the taught positions, including positions through which the robot moves, are bad. Change the taught positions. _____________________________________________________________________ ERROR CODE -1019 Check sum error of system data.
The check sum of the system data of the AS software was changed when the system information such as model number, number of axis, and option setting, was downloaded. When the error occurs in situations other than downloading, the error is caused by defective memory back-up, defective 1GA board, or memory error from noise. Use AUX 78 Clear Check Sum Error or CHSUM command to reset the data. When the error cannot be reset using the check sum commands, the command with the abnormality is shown. Rewrite the command and use CHSUM or Aux 78 to clear the error. Check the memory backup battery. Replace if necessary. Replace the 1GA board if the error re-occurs. _____________________________________________________________________
April 8, 2002
10-57
Kawasak
ERROR CODE -1022
RAM battery low voltage <board name>.
When control power is applied or motor power is turned on, a voltage check is performed on the batteries that maintain SRAM memory when power is off. This message is displayed when a voltage of 2.5 VDC or less is detected (normal is 3.6 VDC). Back up system and program data, check and replace batteries as required. Check batteries for defective connections. Repair the defective connection. Defective battery voltage monitoring circuit. Replace the circuit board. _____________________________________________________________________ ERROR CODE -1025 AS Flash memory sum check error.
A check sum error of AS system data in flash memory on 1GA board occurred when the power was turned on. The check sum data is created when the FCHK command is executed and is recorded in flash memory during download. Main causes of the error are: 1. When the AS system was downloaded, the FCHK command was not executed. 2. The addressing of the FCHK command was wrong. 3. The flash memory and 1GA board are defective. 4. The system data in the flash memory is damaged. Confirm the content of the command as_load.cmd file in the IC card if error occurs immediately after downloading the AS system. Download system again. If error continues after download, exchange the 1GA board. _____________________________________________________________________ ERROR CODE -1026 Servo Flash memory sum check error.
A check sum error of the servo system in flash memory on 1GA board occurred when the power was turned on. The check sum data is created when the FCHK command is executed and is recorded in flash memory during download. Main causes of the error are: 1. When the servo system was downloaded, the FCHK command was not executed. 2. The addressing of the FCHK command was wrong. 3. The flash memory and 1GA board are defective. 4. The system data in flash memory is damaged. If the error occurs immediately after download, confirm the content of as_load.cmd in the PC card and download again. If the error persists, change the 1GA board. _____________________________________________________________________
10-58
April 8, 2002
Kawasak
ERROR CODE -1051
Cannot execute in this robot arm.
Unused _____________________________________________________________________ ERROR CODE -1100 CPU Error (Code = ****).
The 1GA board CPU has stopped (detected with the AS software). This error is caused by defective AS or servo software, defective hardware, or noise related malfunction. With a PC connected enter $save/flt filename to save the fault data, and send to KHI. Confirm which board the error occurred on by referring to the message that appears on the PC. This error does not appear on the multi function panel or the small teach pendant. I/O BUS ERROR: error in the address of the 1FR or 1GW board. PSB BUS ERROR: error with the 1FP or 1HP power sequence board. VME BUS ERROR: error in the address of the boards that use the VME bus. If the initialization prompt appears, answer no, then reload software. If the error returns, initialize the system and reload software. If the multi function panel or PC are not functional, system initialization cannot be performed. If this error occurs during certain specific operations it may indicate a defect in the AS system. Replace the 1GA board if the error cannot be reproduced or cleared. _____________________________________________________________________
April 8, 2002
10-59
Kawasak
ERROR CODE -1101 Main CPU BUS error.
On the 1GA board, a bus error (in the VME bus line, data processing was not able to be done normally) has occurred (detected with the AS software). This error is caused by defective AS or servo software, defective 1GA board, or noise related malfunction. With PC connected enter $save/flt filename to save the fault data, and send to KHI. Confirm which board the error occurred on by referring to the message that appears on the PC. This error does not appear on the multi function panel or the small teach pendant. I/O BUS ERROR: error in the address of the 1FR or 1GW board. PSB BUS ERROR: error with the 1FP or 1HP power sequence board. VME BUS ERROR: error in the address of the boards that use the VME bus. If the initialization prompt appears, answer no, then reload software. If the error returns, initialize the system and reload software. If the multi function panel or PC are not functional, system initialization cannot be performed. If this error occurs during certain specific operations it may indicate a defect in the AS system. Replace the 1GA board if the error cannot be reproduced or cleared. _____________________________________________________________________ ERROR CODE -1102 VME BUS error.
This error occurs when the CPU does not receive a response from one of the I/O bus devices within a specific time. This error is caused by defective AS or servo software, defective 1GA board, or noise related malfunction. With a PC connected enter $save/flt filename to save the fault data, and send to KHI. Confirm which board the error occurred on by referring to the message that appears on the PC. This error does not appear on the multi function panel or the small teach pendant. I/O BUS ERROR: error in the address of the 1FR or 1GW board. PSB BUS ERROR: error with the 1FP or 1HP power sequence board. VME BUS ERROR: error in the address of the boards that use the VME bus. If the initialization prompt appears, answer no, then reload software. If the error returns, initialize the system and reload software. If the multi function panel or PC are not functional, system initialization cannot be performed. If this error occurs during certain specific operations it may indicate a defect in the AS system. Replace the 1GA board if the error cannot be reproduced or cleared. _____________________________________________________________________
10-60
April 8, 2002
Kawasak
ERROR CODE -1200
Encoder board is not installed.
Unused _____________________________________________________________________ ERROR CODE -1201 Power sequence board is not installed.
The first address of the No.1 power sequence board (1FP/1HP board) cannot be read when control power is turned ON. Main causes for this error include: 1. The power sequence board (1FP/1HP board) is not installed in the correct card slot. 2. Jumper or dip switch settings of the power sequence board are incorrect. 3. Defect in the power sequence board. Ensure the 1FP/1HP board DSW1 setting is configured as power sequence board No. 1 and is installed in the 1FP/1HP card rack slot. Check and replace the board if necessary. _____________________________________________________________________ ERROR CODE -1202 No2 power sequence board is not installed.
The first address of the No.2 power sequence board (1FP/1HP board) cannot be read when the control power is turned ON. Main causes for this error include: 1. The power sequence board (1FP/1HP board) is not installed in the correct card slot. 2. Jumper or dip switch settings of the power sequence board are incorrect. 3. Defect in the power sequence board. Ensure the 1FP/1HP board DSW1 setting is configured as power sequence board No. 2 and is installed in the 1FP/1HP card rack slot. Check and replace the board if necessary. _____________________________________________________________________
April 8, 2002
10-61
Kawasak
ERROR CODE -1203
No x-M I/O board is not installed.
Cannot read the first addresses of I/O boards (1FR/1GW board, etc.) based on the number of signals that have been set with DO (output point), or DI (input point) of the ZSIGSPEC command, when the control power supply is turned on. This error is not used when a 1FS board is installed. Main causes include: 1. Incorrect value set with the ZSIGSPEC command. 2. Error in board address of I/O board (1FR/1GW board, etc.). 3. Defect of I/O board (1FR/1GW board, etc.). Set the correct number of signals with the ZSIGSPEC command. I/O cards are typically mounted in the card rack from right to left in ascending order. Because of VME buss communication, this is not critical. The robot can run without I/O boards. The maximum number of signals in the software set with the ZIGSPEC command is DO, DI=256, INT=512, but DO and DI are restricted by hardware and other options. Set board address jumpers correctly. Replace the 1FR/1GW board. _____________________________________________________________________ ERROR CODE -1204 Option SIO port is not installed.
The 1GA board sets more than seven axes at control power ON, but the IC (SIO) for serial communications for command line 3 and 4CH communication with the servo board is not installed. This error typically does not occur because SIO is installed on standard 1GA boards but may not be on the prototype boards. Main causes of this error include more than seven axes set with a prototype board with SIO not mounted or a defect in the 1GA board. Replace the 1GA board. _____________________________________________________________________
10-62
April 8, 2002
Kawasak
ERROR CODE -1205
Power sequence board any error.
An error signal, not classified through the error summary, is generated by the 1FP/1HP board and not recognized by the AS software. Main causes include: 1. The error detection function of the power sequence board does not correspond to the error processing function of the AS software. 2. Defect in the power sequence board. 3. Defect in the 1GB board. 4. Defect in the wiring between the 1FP/1HP board and the 1GB board. (XGB-CN1 XHZ-CN4) Replace the power sequence board. Repair/Replace the 1FP/1HP board to the 1GB board wiring harness. Install the correct version of the AS software. _____________________________________________________________________ ERROR CODE -1206 Built-in sequence board is not installed.
Installation of the built-in sequencer board is checked when the control power supply is turned ON. This error occurs when the built-in sequencer board is not installed. Install the built-in sequencer board. _____________________________________________________________________ ERROR CODE -1208 RI/O board is not installed.
This error occurs when the control power supply is turned on and the first address of the RI/O board is not read (1GW, 1FS etc.). 1. The RI/O board is not installed. 2. Defect in the RI/O board. Ensure the RI/O board installed. Replace the RI/O board. _____________________________________________________________________
April 8, 2002
10-63
Kawasak
ERROR CODE -1209
RI/O board initialize error.
This error occurs when the control power supply is turned on and the RI/O board does not successfully initialize (1FS board). 1. Incorrect dip switch settings on the RI/O. 2. Defect in the RI/O board software. Set dip switch correctly on RI/O board. Reinstall the RI/O board software. _____________________________________________________________________ ERROR CODE -1247 Axis setting data incorrect.
The command channel line for the external axis was incorrectly set using AUX 901, External Axis Set. Input the correct value. _____________________________________________________________________ ERROR CODE -1248 Number of Axis Changed! SYSINI.
The number of axis assigned to the robot has changed. Change the number of axes and initialize the system. _____________________________________________________________________ ERROR CODE -1249 Servo parameter Changed! Control power turn OFF & ON.
Servo parameters in system data changed during LOAD. Turn control power supply OFF and ON. _____________________________________________________________________
10-64
April 8, 2002
Kawasak
ERROR CODE -1250
Servo board (X) Initialize error.
The servo software was not successfully loaded from the FLASH memory on the 1GA board to the servo board when control power was turned ON. The contents of (X) is an alphanumeric code as indicated below:
7: Servo program download error 6: Servo parameter download error 4: Trap error (Servo software initialization error)
CPU channel of servo board
Main causes include: 1. Defect in the 1GB servo board. 2. Defect of the harness between power sequence board and servo board. 3. Error in mother board jumper setting. 4. The servo software is not in the flash memory on the 1GA board. (XGB-CN1XHZ-CN4) 5. Malfunction caused by noise, etc. 6. Servo software and AS software versions incompatible. 7. Versions of ROM in servo software and servo board not compatible. Replace the 1GA, servo board, and each harness. Confirm the servo software and the servo board monitor ROM version and install the corresponding servo software again. Confirmation of the version can be confirmed by AUX 90, Software Version Display, or ID command. _____________________________________________________________________
April 8, 2002
10-65
Kawasak
ERROR CODE -1251
Servo board (X) communication error.
Communications in the command line of each CPU of the servo board (1GB board) failed twice consecutively. The command line always communicates every 4 msec. When each CPU of the servo board stops, this error might be detected. Main causes include:
CH A B To Communication First 1GB PC Board A Unit First 1GB PC Board B Unit First 1GB PC Board C Unit or C Second 1GB P Board A Unit or One Axis Amplifier Second 1GB P Board B Unit D or One Axis Amplifier Slave Slave Relay to Power Sequence Board (1FP/1HP PC Board) Master Master
1. 2. 3. 4. 5. 6. 7.
Defect in the 1GA board. Defect in the 1GB servo board. Defect in each communication harness. Encoder defect if JT3 (A) or JT4 (B) are displayed. Noise malfunction. Mismatch of AS and servo software Improper setting of AUX 928; servo type 2.
Ensure software versions are correct. Ensure AUX 928 setting is correct. Replace the 1GA, servo board, and each harness. _____________________________________________________________________
10-66
April 8, 2002
Kawasak
ERROR CODE -1252(A), -1253(B), -1254(C), -1255(D) Servo board (x) hardware error code = xxxx. A hardware error was detected by the 1GB board with no corresponding error in the AS software. The internal error code number that the AS software detected is displayed in xxxx. The unit name of the servo board displayed at x in the error message corresponds to the CH column in the table below.
CH A B
To Communication First 1GB PC Board A Unit First 1GB PC Board B Unit First 1GB PC Board C Unit or
Relay to Power Sequence Board (1FP/1HP PC Board) Master Master
Second 1GB P Board A Unit or One Axis Amplifier Second 1GB P Board B Unit
Slave
or One Axis Amplifier
Slave
Main causes of this problem include the following abnormalities: 1. Defect in the servo software. 2. Noise malfunction. 3. Defect in the harness between servo board and power sequence board. 4. Defect of the servo board. 5. Versions of servo and AS software incompatible. 6. Malfunction in the servo or AS software. Install upgraded versions of servo and AS software. Replace the 1GA board, the servo board, and each harness. When this error occurs, contact KRI to report the details. _____________________________________________________________________
April 8, 2002
10-67
Kawasak
ERROR CODE -1256(A), -1257(B), -1258(C), -1259(D) Servo board (x) software error code = xxxx. A hardware error was detected by the 1GB board with no corresponding error in the AS software. The internal error code number that the AS software detected is displayed in xxxx. The unit name of the servo board displayed at x in the error message corresponds to the CH column in the table below.
CH A B
Slave
Slave
Main causes of this problem include the following abnormalities: 1. Defect in the servo software. 2. Noise malfunction. 3. Defect in the harness between servo board and power sequence board. 4. Defect of the servo board. 5. Versions of servo and AS software incompatible. 6. Malfunction in the servo or AS software. Install upgraded versions of servo and AS software. Replace the 1GA board, the servo board, and each harness. When this error occurs, contact KRI to report the details. _____________________________________________________________________
10-68
April 8, 2002
Kawasak
ERROR CODE -1260
Option changed! SYSINI.
Unused _____________________________________________________________________ ERROR CODE -1261 Servo board (x) parameter setting error.
After a setting was changed with AUX 976 servo parameter, the data sent to the servo board was different than the data received two or more times. The unit name of the servo board displayed at x in the error message corresponds to the CH column in the table below.
CH A B
Slave
Slave
Main causes of this error include: 1. Defect in the 1GA board. 2. Defect in the servo board. 3. Defect of each communication harness. 4. Versions of servo and AS software incompatible. 5. Malfunction by noise. Replace the 1GA board, the servo board and each harness. Install correct versions of AS and servo software. If error cannot be reset, reset data with AUX 976. If error cannot be reset, cycle control power. _____________________________________________________________________
April 8, 2002
10-69
Kawasak
ERROR CODE -1262
EXT AXIS cutting error.
Occurs when a gun disconnect is not normally completed.
Check for errors on the 1HP and 1GB boards. Check the wiring harness between the 1HP and 1GB boards.
ERROR CODE -1263
EXT AXIS connecting error (CODE ).
Occurs when the gun axis connection is not normally completed. Code 0: Code 11: Code 80: Code 81: Code 101: Code 102: Code 103: Code 200: No answer from the servo welding gun. Terminated normally. Channel No. is erroneous or erroneous code. Inexecutable due to RGSO is unkown. Pressure applying force limit value is not yet selected in negative section. Pressure applying force limit value is not yet selected in positive section. Pressure applying force limit value is not yet selected in both sections. Scope of movement restoration after calibration is not terminated.
According to the code number displayed following the error message, perform the following:
Code 0:This error occurs when the servo software does not respond. It may be caused by failure of the 1HP or 1GB board or the harness between the boards. Code 200: After connecting the gun, if the gun cannot be operated within a specified time this error is displayed. If the gun fully opens once and the error is generated:
Verify that the servo guns upper and lower limits are correctly set. Use the gun brake release switch, release the guns brake. Manually move the gun to check for mechanical binding.
If the gun cannot be moved and the error is generated:

The pressure setting may not be enough to move the gun. From the Spot service : Servo welding gun pressure adjustment function, calibrate the clamping pressure. Check the gun for proper mechanical functioning. Check the brake.
10-70
April 8, 2002
Kawasak
ERROR CODE -1267
1JS board is not installed
1JS board is not installed for interface with an incremental-type conveyor encoder. 1. 1JS board not installed. 2. Defective 1JS board 3. Defective 1GW board to which the 1JS board is installed. Replace the 1JS board. Replace the 1JS board and the 1GW board. _____________________________________________________________________ ERROR CODE -1300 Servo CPU-(x) watch dog error.
The watch dog circuit on the 1GB board has detected a software problem. This is caused by a defective servo board or a problem with the servo software. The unit name of the servo board displayed at x in the error message corresponds to the CH column in the table below.
CH A B
Slave
Slave
Replace the servo board. _____________________________________________________________________
April 8, 2002
10-71
Kawasak
ERROR CODE -1306
Servo board command error.
Servo software has returned the error code to the AS software. Main causes include: 1. Malfunction in the servo or AS software. 2. Noise malfunction. 3. Defect in the harness between servo board and power sequence board. 4. Defect of the servo board or the 1GA board. 5. Versions of servo and AS software incompatible. Install correct versions of servo and AS software. Replace the 1GA board, the servo board, and each harness. _____________________________________________________________________ ERROR CODE -1308 Motor power off.
Occurs when software turns motor power on (K1 or K2 contactors on) but there is no signal feedback (MCON) indicating motor power is on. Main causes include: 1. Defect in the power sequence board (1FP/1HP board). 2. Defect in the relay board (1FY/1HY board). 3. Malfunction in the error detection circuit and error processing of each board. 4. Auxiliary contact of magnet contactor (K1, K2) for motor power is defective. 5. Malfunction with the servo software or the AS software. 6. Defect in the harnesses between XHY-CN3 and KI/K2. Replace the power sequence board. Replace the relay board. Replace the magnetic contactor. Repair or replace the harnesses between XHY-CN3 and K1/K2. _____________________________________________________________________ ERROR CODE -1333 Monitor ID of servo board mismatch!
The monitor ROM software version of each unit on the 1GB board is different, caused by a defect of the 1GB board. Replace the 1GB board. _____________________________________________________________________
10-72
April 8, 2002
Kawasak
ERROR CODE -1334
Servo control line error.
Brake open command is not returned within 2 seconds when the servo control on (SVCN) signal is sent from the AS software to the servo board (1GB) through the EPLD register of the power sequence board (1FP/1HP). Main causes include: 1. Defect in the 1FP/1HP power sequence board. 2. Defect in the 1GB servo board. 3. Incorrect 1GB board dip switch settings. 4. Defect in the harness between the two boards. (XGB-CN1XHZ-CN4) 5. Defect in the harness between the 1GC/1GD power block and K3 contactor. (X1SAMS, X1-SAXGC/XGD-CN10/CN12) 6. Defect in the harness between the 1GB servo board and the 1GC power block. (XGB-CN12XGC/XGD-CN8, XGB-CN13XGC/XGD-CN9) 7. Defect in the 1GC/1GD power block. Repair or Replace harnesses as needed. Exchange the power sequence board and the servo board, etc. Check 1GB board dip switch settings. _____________________________________________________________________ ERROR CODE -1336 Safety gate circuit open.
The safety gate branch of the safety circuit is open due to a missing safety plug or defective circuit. Reinsert the safety plug. Repair open circuit. Replace the power sequence board (1FP/1HP). _____________________________________________________________________ ERROR CODE -1337 Two MC lines are not consistent.
A problem has been detected with the MC lines controlling the K1/K2 contactors, due to an open safety circuit, loose connectors or defects of the 1HP, 1HY, or 1HZ boards. Check the safety circuit. Check connections to the 1HP, 1HY, and 1HZ boards. Replace the 1HP, 1HY, or 1HZ boards as necessary. _____________________________________________________________________
April 8, 2002
10-73
Kawasak
ERROR CODE -1338
K1 and/or K2 works wrong.
Feedback from the auxiliary contacts of the K1/K2 contactors was not received within a fixed time, when the contactor was energized. Main causes are safety circuit failures, K1/K2 auxiliary contact fault (welded, etc.), loose connectors or defects of the 1HP, 1HY, or 1HZ boards. (XHP-CN3XHY-CN41HYXHY-CN3K1/K2) Check the safety circuit. Check connections to the 1HP, 1HY, and 1HZ boards. Replace the 1HP, 1HY, or 1HZ boards as necessary. _____________________________________________________________________ ERROR CODE -1401 Amp over current jt x-M.
The feedback current from a current sensor in the power block exceeded 144% of the maximum instantaneous motor current rating. This error can be caused by the following abnormalities: 1. Short in the U, V, W from the power block to motor and ground wire. (power blockX4/X5robot) 2. Defect in the motor. 3. Defect in the power block. 4. Defect in the servo board (1GB board, etc.) Check the connection for the U, V, W and ground line to the power block. Replace the separation harness if necessary. Replace the motor, 1GB board, or power block. _____________________________________________________________________ ERROR CODE -1407 AMP power unit error.
General servo system error. This error indicates that a servo system error has occurred. Main causes include a defect in the connection of the harness between the power sequence board and the servo board. Check the servo error codes that follow this error for additional information. Check the harness connections between the 1HP board and 1GB board. Replace the 1HP board. _____________________________________________________________________
10-74
April 8, 2002
Kawasak
ERROR CODE -1413
Regenerative resistor overheat or disconnect.
Unused _____________________________________________________________________ ERROR CODE -1420 Current detector type (x) mismatch!
When the control power supply is turned ON, the ID code data of the 1GM board and the AS software installed on the 1GB board do not correspond. The unit name of the servo board displayed at x in the error message corresponds to the CH column in the table below.
CH A B
Slave
Slave
Main causes include: 1. 1GM board is not suitable for the AS software (robot model). 2. The AS software does not correspond to the 1GM board. Install the 1GB board equipped with 1GM board. Load the robot system data when this error occurs immediately after initializing. Re-initialize and reload the robot/system data if this error occurred immediately after loading the data. _____________________________________________________________________
April 8, 2002
10-75
Kawasak
ERROR CODE -1500 Motor overload jt-x.
Spot welding and material handling The current feedback from the power block exceeded maximum continuous ratings longer than the time allowed. Main causes include: Mechanical 1. The robot arm has contacted an external item hindering movement. 2. The harness is caught in the robot arm. 3. The decelerator, the gear, or the bearing are damaged. 4. Gear decelerator backlash is too narrow. 5. Payload weight exceeds robot specifications for capacity. 6. Robot motion pattern exceeds ratings of the motor. 7. Motor brake is not released. Electrical1. Motor power line U, V, and W phase are disconnected. (1GCpower blockX4/X5robot) 2. The brake line is disconnected or brake drive circuit is damaged. (T1TB1V1XHY-CN11HYXHY-CN2XGB-CN141GB XGB-CN6X5robot) 3. The power block is damaged. 4. Defect in the 1HY board. 5. Defect in the 1GB servo board. 6. Malfunction of the motor. Check the decelerator, etc. for mechanical failure. Replace as necessary. Re-teach the robot motion as necessary. Check the harness and servo unit for electrical malfunctions and replace if necessary. Servo welding gun 1. Clamping pressure time is excessive. 2. Distance between weld points is short; the motor does not have time to cool sufficiently between welds. 3. Clamping pressure setting exceeds the servo gun motor power capacity. If the weld points are close to each other, set a time delay. This provides a cool-down period for the servo gun motor. Set the clamping force lower (see servo gun manufacturers specifications). _____________________________________________________________________
10-76
April 8, 2002
Kawasak
ERROR CODE -1501
Overheat or motor harness is disconnected (x).
Motor thermal circuit is open due to motor overheat or harness problem. Not all robot models utilize thermal switches in the motors. The unit name of the servo board displayed at x in the error message corresponds to the CH column in the table below.
CH A B
Slave
Slave
Main causes include: 1. Disconnected thermal line. (1GBXGB-CN6XTHX4robot) 2. Defective connection in the separation harness. 3. Defect in the servo board. 4. When the thermal is built-in: The robot rated weight capacity is exceeded. The ambient temperature exceeds limits for use. Constant execution of abrupt high speed direction changes. Defect robot cooling fan or cooling air purge system. Servo system holding the robot arm in high load position for extended periods. Defect in the thermal switch. When the thermal switch opens, error cannot be reset until cooling is complete. Confirm continuity of thermal line. Replace the harness or servo board as necessary. Use the auto servo off function, AUX 91, to prevent the servo system holding a high load arm position for extended periods. _____________________________________________________________________
April 8, 2002
10-77
Kawasak
ERROR CODE -1503 Speed error jt-x.
Joint speed (motor speed) calculated using encoder values exceeds a regulated value. In the Repeat mode: the regulated value is joint speed (motor speed) multiplied by 1.2. In the Teach/Check modes: the regulated value is 250 mm/sec. multiplied 1.5, at the equivalent radius position for a rotating joint or actual command value speed for joints during a linear move. This error is caused by the following abnormalities: 1. Disconnected motor power line U, V, and/or W phase, or defective power block. 2. Wiring error in motor power line and/or encoder line. 3. Disconnected encoder signal line, short circuit in encoder or encoder wiring, and/or defective main body of the encoder. 4. Robot motion program causes a singularity. 5. Defect in the 1GB servo board and/or 1GB power block. 6. Moment of inertia exceeded the motor torque. Check for disconnection, short circuit, and proper wiring. Replace the harness and encoder if necessary. Replace the servo unit. Rewrite program teach data such as speed and position in the case of singularity motion. _____________________________________________________________________
10-78
April 8, 2002
Kawasak
ERROR CODE -1504
Position envelope error jt-x.
Spot welding and material handling The difference between the current value from the encoder and the command value in the AS software exceeded a regulated value which varies by robot model. Main causes include singularity motion or the following abnormalities: Mechanical 1. The robot arm has contacted an external item hindering movement. 2. The harness is caught in the robot arm. 3. The decelerator, the gear, or the bearing are damaged. 4. Gear decelerator backlash is too narrow. 5. Payload weight exceeds robot specifications for capacity. 6. Robot motion pattern exceeds ratings of the motor. 7. Motor brake is not released. Electrical1. Motor power line U, V, and W phase are disconnected. (1GCpower blockX4/X5robot) 2. The brake line is disconnected or brake drive circuit is damaged. (T1TB1V1XHY-CN11HYXHY-CN2XGB-CN141GB XGB-CN6X5robot) 3. The power block is damaged. 4. Defect in the servo board. 5. Malfunction of the motor. Check the decelerator, etc. for mechanical failure. Replace as necessary. Re-teach robot motion as necessary. Check the harness and servo unit for electrical malfunctions and replace if necessary. Correct the teach data in case of singularity motion. Servo welding gun The thickness of the workpiece at the weld point is greater than the thickness when the point was taught. The thickness difference needed to set this error is approximately 10mm, depending on the gun type. Inspect the workpiece; replace it if necessary. _____________________________________________________________________ ERROR CODE -1505 Velocity envelope error jt-x.
The robots current velocity is unable to keep up with the velocity command signal. Refer to Error Code -1504: Position envelope error jt-x _____________________________________________________________________ April 8, 2002 10-79
Kawasak
ERROR CODE -1506
Commanded speed error jt-x.
Unused. _____________________________________________________________________ ERROR CODE -1507 Commanded acceleration error jt-x.
Unused. _____________________________________________________________________ ERROR CODE -1510 Encoder harness broken jt-x.
The encoder signal is lost. 1. The machine signal or separate signal harness is damaged. 2. The +12 VDC or +5 VDC supply is not present at the 1FG board. 3. Defective 1GB or 1FG board Replace damaged machine signal or separate signal harness. Repair cause of +12 VDC or +5 VDC supply not present at the 1FG board. Replace defective 1GB or 1FG board. _____________________________________________________________________ ERROR CODE -1511 Encoder battery voltage low [Servo (A)].
Voltage of the encoder back up battery on the 1FG board decreased to 3.2 volts, or the encoder battery alarm signal (BAL_AL) was disconnected. This error is only detected at control power on or motor power on. This is caused by the following: 1. Discharged batteries. 2. Defective encoder battery board (1FG board). 3. Defective encoder. 4. Short in the harness from the encoder battery backup board to the encoder. 5. Battery discharge. 6. Defective servo board (1GB board). This error is reported by servo board unit A. Exchange the battery. There is a possibility that internal encoder data may be lost. Check the robot zeroing. Check each harness for short circuit. Replace the encoder, the servo board, or the encoder battery backup board, if necessary. _____________________________________________________________________
10-80
April 8, 2002
Kawasak
ERROR CODE -1513
Encoder rotation data abnormal jt-x.
Occurs when there is a difference between the rotation data in the serial encoder data and the calculated rotation data by incremental technique. Check connections at encoder, 1FG board, and separation harness. Check for noise and shield integrity. Check connections, jumpers, and switches on 1GB board. Check for continuity in the machine harness and separation harness. Replace 1FG board. Replace the 1GB board. Replace the encoder. _____________________________________________________________________ ERROR CODE -1516 Encoder data abnormal jt-x.
When control power is switched ON, the current encoder value is compared to the stored encoder value when the power was turned OFF. If the difference is more than the value set by AUX 43 Encoder Error Range, or the ENCCHK_DATA command, this error occurs. Normal occurrence is due to the following: 1. Back up battery failure due to disconnection or discharged battery. 2. Control power was turned off during robot motion by an abnormal power supply, etc., causing the robot to stop in a position other than the last position memorized by the AS software. 3. Motor replacement/encoder replacement. 4. Robot arm or motor operated by force when control power was off. 5. Robot was initialized. Data may have been lost due to backup battery. See error -1511. Exchange the battery. There is a possibility that internal encoder data may be lost. Check the robot zeroing. Check each harness for short circuit. Replace the encoder, the servo board or the encoder battery backup board if necessary. _____________________________________________________________________
April 8, 2002
10-81
Kawasak
ERROR CODE -1517
Cannot read initial data encoder jt-x.
Spot welding and material handling Immediately after control power on, steady encoder data was not able to be read. This error is caused by a disconnected encoder signal line or a short circuit, or a defect in the main body of the encoder. Check for disconnection or short circuit for encoder signal line. Replace the encoder. Replace the servo board (1GB board). Servo welding gun The gun is disconnected from the tool changer, without performing a software disconnect. Connect the gun manually and cycle the controller power (OFF/ON). _____________________________________________________________________ ERROR CODE -1518 Miscount of encoder data jt*.
The servo gun or tool changer harness is defective. Inspect the servo gun and tool changer harnesses; replace if necessary. _____________________________________________________________________ ERROR CODE -1521 Mismatch ABS and INC encoder of jt-x.
Occurs when there is a large difference between the value in the serial encoder data and the data calculated by incremental technique. Replace encoder, replace 1GB board. Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers, and switches on 1GB board. Check for continuity in the machine harness and separation harness. Replace 1FG board. _____________________________________________________________________ ERROR CODE -1524 Encoder line error of jt-x.
Not used. _____________________________________________________________________
10-82
April 8, 2002
Kawasak
ERROR CODE -1550
Encoder initialize error jt-x.
The encoder is not able to fix the absolute position at control power on. The scanning of absolute data is begun immediately after a shift from the state of non-operation or backup operation to normal encoder operation. BUSY=1 is output until the absolute position has been determined. In the case of a conveyor encoder, ensure power-up speed is below 300 RPM. Check connections at encoder, 1FG board, jumpers, and switches on 1GB board. Replace encoder, replace 1GB board, replace 1FG board. Check for continuity in the machine harness and separation harness. _____________________________________________________________________ ERROR CODE -1553 Encoder response error jt-x.
Spot welding and material handling Occurs when the encoder does not respond to data request signal from the 1GB board. Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers, and switches on 1GB board. Replace encoder, replace 1GB board. Check for continuity in the machine harness and separation harness. Replace 1FG board. Check for noise malfunction and shield integrity. Servo welding gun The servo gun or tool changer harness is defective. Inspect the servo gun and tool changer harnesses; replace if necessary. _____________________________________________________________________ ERROR CODE -1554 Encoder communication error jt-x.
Occurs when the encoder serial data is not correctly transmitted according to communication protocol. Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers, and switches on 1GB board. Replace encoder, replace 1GB board. Check for continuity in the machine harness and separation harness. Replace 1FG board. _____________________________________________________________________
April 8, 2002
10-83
Kawasak
ERROR CODE -1555
Encoder data conversion error jt-x.
Occurs when the M-code data from the encoder has an error pattern. Replace encoder, replace 1GB board. Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers and switches on 1GB board. Check for continuity in the machine harness and separation harness. Replace 1FG board. _____________________________________________________________________ ERROR CODE -1556 Encoder ABS-track error jt-x.
The absolute data and the incremental data in the encoder are different. ABSALM=1 is output from the encoder when this error occurs. Defective encoder. Defective 1GB or 1FG boards. Open or short-circuited encoder harness. _____________________________________________________________________ ERROR CODE -1557 Encoder INC-pulse error jt-x.
Occurs when the encoder A and B incremental pulses are abnormal. The encoder INALM bit sent with the serial data=1. Replace encoder, replace 1GB board. Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers, and switches on 1GB board. Check for continuity in the machine harness and separation harness. Replace 1FG board. _____________________________________________________________________ ERROR CODE -1558 Encoder MR-sensor error jt-x.
The state of the MR sensor in the encoder does not match with JT ENCODER in one rotation. Replace the encoder harness. _____________________________________________________________________
10-84
April 8, 2002
Kawasak
ERROR CODE -1559
Power module error jt-x.
An error signal from the IPM module in the power block was detected. This error may be caused by: 1. Defect in the power block. 2. Defect in the servo board. 3. Short-circuit of the motor power line U, V, and W phase. 4. Defective cooling fan in the servo unit. 5. Defect in the harness between the servo board and the power blocks. (XGB-CN12XGC/XGD-CN8, XGB-CN13XGC/XGD-CN9) Replace the servo unit. Check for short circuit in the motor harness and replace if necessary. _____________________________________________________________________ ERROR CODE -1561 Current sensor disconnect [Servo (x)].
The current sensor cable between the servo board and the power blocks is not connected. The x indicates the servo board unit reporting the error. Check the following harnesses as indicated below. Unit A - 1GB-CN9power block CN1, CN2 CN3. Unit B - 1GB-CN10power block CN4, CN5, CN6. Unit C - 1GB-CN11power block CN7. This error may be caused by a defect in the 1GB board. Check connection and continuity in the current sensor cable between the 1GB board and the power block. (XGB-CN9XGB-CN10) Replace the 1GB board if necessary. _____________________________________________________________________ ERROR CODE -1563 Servo unit 12V DC error [Servo (A)].
The +/-12V supply to the 1GB board is below specified limits of +10.75V and -10.4V. This error may be caused by a defect in the harness between the 1GB board (XGBCN8), the mother board (XHZ-CN2) and the AVR, or a defect in the 1GB board. This error is reported by servo board unit A. Check the voltage and replace the 1GB board and the AVR as necessary. _____________________________________________________________________
April 8, 2002
10-85
Kawasak
ERROR CODE -1567
Regenerative resistor error [Servo (A)].
Current was sent to regenerative resistors for six or more consecutive seconds. Main causes include: 1. Abrupt direction changes at high speed. 2. Burned out resistors or defective power block. 3. Defect in the servo board (1GB board). 4. Defective connection or harness between the servo board and the power block (1GB-CN13 power block CN9). 5. Defect in the optional second regenerative resistance unit (when used). This error is reported by servo board unit A. Avoid abrupt high speed direction changes. Change accuracy, speed, add points. Install optional second regenerative resistance unit. _____________________________________________________________________ ERROR CODE -1568 Servo unit P-N low voltage [Servo (A)].
The voltage between P-N supplied to the power block is 60VDC or less at servo on. Main causes include: 1. Defect of K1, K2, K3. 2. Defect in the relay board (1FY/1HY board). 3. Defect in the power sequence board (1FP/1HP board). 4. Defect in the power unit. 5. Defect in the servo board. 6. Defect in the motor power circuit (diode bridge, K3, etc). 7. Defect in Circuit breaker F2 or F2 is in the OFF position. 8. Defect in the harness between the operation unit and the servo units or the connections. Check the motor power circuit and the equipment, replace as necessary. Check the power sequence board, the relay board ,and the servo unit, and replace as necessary. _____________________________________________________________________
10-86
April 8, 2002
Kawasak
ERROR CODE -1569
Servo unit P-N- high voltage [Servo (A)].
The voltage between P-N supplied to the power block exceeded 410 VDC. This error is caused by: 1. Defect in regenerative resistance control circuit, overheat failure of regenerative resistance unit, defect in the voltage monitoring circuit, or defect in the power block. 2. Defect of servo board (1GB board) 3. Defect in the regenerative resistance unit. 4. Defect in the servo board (1GB board). 5. High inertia loads due to tool weight or program data. This error is reported by servo board unit A. Reteach program steps to eliminate sudden high speed direction changes (dynamic shock). Replace the servo unit and the regenerative unit. Add the second regenerative resistor unit. _____________________________________________________________________ ERROR CODE -1570 Regenerative resistor over-heat [Servo (A)] or controller hot.
The thermal switch for the power block regenerative resistor unit, or the optional regenerative resistor unit reached 140 C (284F), or the heat sink thermal switch reached 90C (194F), or the controller cabinet thermal switch reached 70 C (158 F). This error is reported by servo board unit A. Defective cooling fans. Insufficient clearance for air circulation. Power block connecter X5-SA disconnected, or defect in the wiring harness to the controller cabinet thermal switch, or to the optional regenerative resistor unit. High inertia loads. High ambient controller temperature. Defective power block. Defective regenerating resistor unit. Defective 1GB board. Defect in the following harnesses: 1GB-CN13power block CN9, 1GC-CN21optional regenerative resistor unit. _____________________________________________________________________
April 8, 2002
10-87
Kawasak
ERROR CODE -1600
Uncoincidence error jt-x.
During the execution of a program, all joints must reach total coincidence within a given accuracy and time (approx. 5 seconds) This error occurs if the difference between the designated value and current value exceeds the established accuracy. Typical causes are listed below. Mechanical1. Damaged bearings. 2. Insufficient gear backlash. 3. Motor brake not released. 4. Arm movement restricted by harnesses or peripheral devices. Electrical1. Defective servo board (1GB board). 2. Defective power block. 3. Disconnected motor power or brake lines. 4. Defective encoder or encoder harness. Program data1. Wrist positions at the beginning and end of a path that utilize the same XYZ coordinate. Repair mechanical or electrical failures. Check interference from external devices. Modify taught wrist positions as required. _____________________________________________________________________ ERROR CODE -1601 Limit switch of joint-x is ON.
This error occurs when the software can specify the axis that has caused the over travel condition. If the joint number cannot be specified, ERROR CODE 1602 Limit switch is broken, is displayed. Main causes include: 1. Software limits are set incorrectly. 2. Axis was moved using the manual brake release and the limit switch was turned ON. 3. The limit switch was turned ON by overshoot from inertia. Check and exchange the harness and the limit switch. Set the software limits to an appropriate value. Change the installation angle of the axis restriction limit switch to an appropriate value. Replace the power sequence board if necessary. _____________________________________________________________________
10-88
April 8, 2002
Kawasak
ERROR CODE -1602
Limit switch signal line is broken.
This error occurs when the software cannot specify the axis that has caused the over travel condition. If the joint number can be identified, the ERROR CODE 1601 Limit switch of jt-x is ON. Set the software limits to an appropriate value. Change the installation angle of the axis restriction limit switch to an appropriate value. Check harness and limit switch and replace as necessary. Check the power sequence board and replace if necessary. _____________________________________________________________________ ERROR CODE -1610 Torch is interfered.
The limit switch for torch interference detection has been tripped. Move the robot away from the interference to close the limit switch. Inspect the torch for damage. Determine the cause of the interference before continuing operation. _____________________________________________________________________ ERROR CODE -1735 GROUP is not primed.
The GROUP instruction is not programmed before a motion instruction, with external axis system. This error occurs if the program is interrupted after a GROUP instruction and before the motion commands pertaining to the GROUP instruction are complete. When restarting the program prime the program before the GROUP instruction. In check mode, if the GROUP instruction is used, start checking before the GROUP instruction. _____________________________________________________________________
April 8, 2002
10-89
Kawasak
ERROR CODE -1800 AC primary power off.
This error occurs when there is an instantaneous decrease in the primary power to the AVR for control power supply (AC130-145V or less for 20-30 msec from 0 phase). The main causes for this error are: 1. NFB for the control power supply was turned OFF. 2. AC200/220V supplied to AVR for the control power supply caused the instantaneous decrease. 3. Defective AVR for control power supply. 4. Defective NFB for control power supply or NFB tripped. 5. Defect in the primary power supply. 6. Defective power sequence board. 7. Defect in the relay board. It is normal for this error to occur when NFB for control power supply is turned OFF. Check power supply circuit in AVR for the control power supply and NFB. Confirm that primary power is supplied according to specifications. _____________________________________________________________________ ERROR CODE -1801 24VDC power source is low.
24VDC to the power sequence board has dropped below 21.6V. Main causes include the following abnormalities: 1. Defect in the AVR for control power supply. 2. Defect in the power sequence board. 3. Defect in the relay board. 4. Short circuit in the motor power on circuitry, the EMERGENCY STOP switch and axis restriction limit switch circuits. 5. Short in machine valve and sensor circuits. Check the power supply, machine valve, and the sensor circuits for short circuits. Check the AVR, the power sequence board, and the relay board and replace as necessary. _____________________________________________________________________
10-90
April 8, 2002
Kawasak
ERROR CODE -1802
Primary power source is high.
Voltage level of the AVR for the control power supply was too high (AC2667-277V or more for 1-2 sec.). The main causes of this error include a defect in the AVR, the power sequence board, the relay board or the power supply circuit. Verify the power supply to the controller are within ratings. Check power supply circuit to the AVR. Confirm the supply power is within specifications. Confirm transformer tap settings are correct. _____________________________________________________________________ ERROR CODE -1803 Primary power source is low.
Voltage level of the AVR for the control power supply was too low (AC150-158V or less for 1-2 sec.). The main causes of this error include an instantaneous drop in the power supply; a defect in the AVR or NFB, the power sequence board, the relay board or the power supply circuit. Verify the power supply to the controller is within ratings. Check the AVR and NFB. Confirm supply power is within specifications. Confirm transformer tap settings are correct. _____________________________________________________________________
April 8, 2002
10-91
Kawasak
ERROR CODE -1804
5 VDC or 12 VDC is abnormal.
5 VDC or +/-12 VDC supplied to the 1GA board is out of specifications. +5 VDC: less than +4.85 VDC - more than +5.45 VDC +12 VDC: +10.75 VDC or less -12 VDC: -10.4 VDC or more Main causes include: 1. Defective DC power supply. 2. Defective 1GA board. 3. Power supply contacts in the mother board are bad. 4. Defective MFP, small teach pendant, or harness. 5. Defective servo board or power block. 6. Defective 1FG board. 7. Short in the harness between the servo unit and the 1FG board. 8. Short in the optional circuit boards, i.e., vision, etc. 9. Insufficient DC power supply capacity to support optional boards. Replace the AVR and each board for the control power supply. Check for short circuits in the MFP, the operation panel, and separation harness and replace as necessary. _____________________________________________________________________ ERROR CODE -1805 Memory is locked because of AC_FAIL.
The memory was accessed during the controller shut down due to a power supply abnormality (ACFAIL). Cycle the controller power OFF and ON. _____________________________________________________________________ ERROR CODE -2100 Explosion-proof TP is not connected.
A communication board (1GS board) for the explosion-proof teach pendant is not installed on the main CPU board (1HA board). Main causes include: 1. 1GS board not installed. 2. Defective 1GS board. 3. Defective 1HA board. If not installed, install a 1GS board to the 1HA board. Replace the 1GS board (if installed). Replace the 1HA board. _____________________________________________________________________ 10-92 April 8, 2002
Kawasak
ERROR CODE -2170
Internal pressure sensor error.
This error occurs when inner pressure drops after purging cycle is complete. Main causes include: Mechanical: 1. The air hose is disconnected. 2. The air supply is stopped. 3. The pressure inside the pressurized enclosure drops due to air leakage. 4. Defective pressure switch. Electrical: 1. The signal wiring for the pressure switch is disconnected. 2. A harness connector for circuit boards is disconnected. 3. Defective I/O board (1GW board). 4. Defective power sequence board (1HP board). 5. Defective back plane board for inner pressure barrier (1LU board). 6. Defective MTL barrier ZB1, ZB2, ZB3 (MTL4728+). Repair cause of pressure leak in pressurized enclosure. Repair disconnected and or lose connectors. Replace harnesses or connectors as necessary. Replace defective board(s) (1GW, 1HP, 1LU board). _____________________________________________________________________
April 8, 2002
10-93
Kawasak
ERROR CODE -2171 Lacks of air flux.
This error occurs when the flow rate switch is turned OFF due to insufficient flow rate (the flow rate switch monitors flow rate during purging). Main causes include: Mechanical: 1. The air hose is disconnected. 2. The air supply is stopped. 3. The pressure inside the pressurized enclosure drops due to air leakage. 4. Defective flow rate switch. 5. Defective purging valve. 6. Defective purging electromagnetic valve (solenoid valve). Electrical: 1. The flow rate switch is disconnected. 2. A harness connector for circuit boards is disconnected. 3. Defective I/O board (1GW board). 4. Defective power sequence board (1HP board). 5. Defective back plane board for inner pressure barrier (1LU board). 6. Defective MTL barrier ZB1, ZB2, ZB3 (MTL4728+). Repair air hose disconnected. Repair cause of pressure leak in pressurized enclosure. Replace defective flow rate switch, purging valve, or purging solenoid valve. Repair disconnected and or lose connectors. Replace harnesses or connectors as necessary. Replace defective board(s) (1GW, 1HP, 1LU board). _____________________________________________________________________
10-94
April 8, 2002
Kawasak
ERROR CODE -2172 Internal pressure low.
This error occurs when the inner pressure drops during purging. Main causes include: Mechanical: 1. The air hose is disconnected. 2. The air supply is stopped. 3. The pressure inside the pressurized enclosure drops due to air leakage. 4. Defective pressure switch. Electrical: 1. The pressure switch is disconnected. 2. A harness connector for circuit boards is disconnected. 3. Defective I/O board (1GW board). 4. Defective power sequence board (1HP board). 5. Defective back plane board for inner pressure barrier (1LU board). 6. Defective MTL barrier ZB1, ZB2, ZB3 (MTL4728+). Repair air hose disconnected. Repair cause of pressure leak in pressurized enclosure. Replace defective pressure switch. Repair disconnected and or lose connectors. Replace harnesses or connectors as necessary. Replace defective board(s) (1GW, 1HP, 1LU board). _____________________________________________________________________
April 8, 2002
10-95
Kawasak
ERROR CODE -2173
Illegal barrier unit setting.
This error occurs when the jumper pin (JP1) for selecting I/O base board on the back plane board (1LU board) for the inner pressure barrier is set incorrectly. Main causes include: 1. The jumper pin JP1 is set incorrectly on the back plane board (1LU board) for the inner pressure barrier. 2. A harness connector for circuit boards is disconnected (CN3 on the 1GW board). 3. Defective I/O board (1GW board). 4. Defective power sequence board (1HP board). 5. Defective 1GB board. 6. Defective back plane board for inner pressure barrier (1LU board). Repair jumper set incorrectly (set JP1 on the 1LU board correctly, all set at B-C with 1GW board installed). Repair disconnected and or lose connectors. Replace harnesses or connectors as necessary. Replace defective board(s) (1GW, 1HP, 1GB, 1LU board). _____________________________________________________________________ ERROR CODE -2174 Communication board to explosion-proof teach pendant watch-dog error.
This error occurs when the CPU on the communication board (1GS board) for the explosion-proof teach pendant is suspended. Main causes include: 1. Defective communication board (1GS board). 2. Defective main CPU board (1HA board). Replace defective 1GS board. Replace defective 1HA board. _____________________________________________________________________
10-96
April 8, 2002
Kawasak
10.3 TROUBLESHOOTING FLOWCHARTS
The following flowcharts are arranged in the numerical order of the error code. Refer also to the corresponding error code information in section 10.2 during troubleshooting procedures.
April 8, 2002
10-97
Kawasak
Error 1513
Does this error occur just after resetting error 1553, 1554, or 1555?
Yes
Follow troubleshooting flowchart for each error
No Replace encoder Yes Does problem still exist? Yes Replace 1GB board No
END
Does problem still exist? Yes
No
END
Check connections at the encoder connector Check connections on the 1FG board Check connections in the separation harness Check connections, jumpers, and switches on the 1GB board
Figure 10-3 Error 1513 Flowchart (1) 10-98 April 8, 2002
Kawasak
Does problem still exist? Yes Check inside machine harness and separation harness
No
END
Does problem still exist? Yes Replace 1FG board
No
END
Does problem still exist? Yes Service call
No
END
Figure 10-4 Error 1513 Flowchart (2)
April 8, 2002
10-99
Kawasak
Error 1521
Does this error occur just after resetting error 1553, 1554, or 1555?
Yes
Follow troubleshooting flowchart for each error
No Replace encoder Yes Does problem still exist? Yes Replace 1GB board No END
No
END
Kawasak
No
END
No
END
No
END
April 8, 2002
10-101
Kawasak
Error 1550
Does the encoder revolve over 300 RPM? (Case of conveyor encoder) No Check connections at the encoder connector Check connections on the 1FG board Check connections in the separation harness Check connections, jumpers, and switches on the 1GB board
Yes
Reduce conveyor encoder revolution speed under 300 RPM at power-up
END
Does problem still exist? Yes Replace encoder
No
END
Does problem still exist? Yes A
No
END
10-102
April 8, 2002
Kawasak
Replace 1GB board
No
END
Does problem still exist? Yes Check machine harness and separation harness
No
END
No
END
April 8, 2002
10-103
Kawasak
Error 1553
Can you reset the error?
Yes
Retry robot program execution or manual operation carefully
No Check connections at the encoder connector Check connections on the 1FG board Check connections in the separation harness Check connections, jumpers, and switches on the 1GB board Yes Does the error reoccur? No END
No
END
No
END
10-104
April 8, 2002
Kawasak
Replace 1GB board
No
END
No
END
No
END
April 8, 2002
10-105
Kawasak
Error 1554
Yes
No Check connections at the encoder connector Check connections on the 1FG board Check connections in the separation harness Check connections, jumpers, and switches on the 1GB board Yes Does the error reoccur? No END
No
END
No
END
10-106
April 8, 2002
Kawasak
Replace 1GB board
No
END
No
END
No
END
April 8, 2002
10-107
Kawasak
Error 1555
Yes
No Replace encoder Yes No Does problem still exist? Yes Replace 1GB board No END Yes Does the error reoccur?
No
END
Kawasak
No
END
No
END
No
END
April 8, 2002
10-109
Kawasak
Error 1556
Replace encoder
Does problem still exist? Yes Replace 1GB board
No
END
No
END
No
END
Kawasak
Check inside machine harness and separation harness
No
END
No
END
April 8, 2002
10-111
Kawasak
Error 1557
Replace encoder
Does problem still exist? Yes Replace 1GB board
No
END
No
END
No
END
Kawasak
No
END
No
END
No
END
April 8, 2002
10-113
Kawasak
OPTIONAL FUNCTIONS
11.0 OPTIONAL FUNCTIONS ............................................................................ 11-3 11.1 Optional Multi Function Panel Function List ................................................. 11-3 11.2 AUX 2 Extended Location and Speed Display ............................................. 11-6 11.3 AUX 6 Mirror Conversion ............................................................................. 11-7 11.4 AUX 9 Data Conversion ............................................................................... 11-9 11.5 AUX 20 Floppy Disk Drive (FD_SAVE) ...................................................... 11-10 11.6 AUX 21 Floppy Disk Drive (FD_LOAD) ...................................................... 11-12 11.7 AUX 22 File Directory (FD_FDIR) .............................................................. 11-12 11.8 AUX. 23 FDD AUX Function ...................................................................... 11-13 11.9 AUX 40 Auto Tool Set................................................................................. 11-14 11.9.1 Setting Tool Center Point ........................................................................... 11-15 11.9.2 Tool Center Point and OAT Angles ............................................................. 11-16 11.1 Circular Interpolation .................................................................................. 11-17 11.11 Hybrid Interpolation.................................................................................... 11-19 11.12 AUX 45 Fixed Tool Dimensions .................................................................. 11-19 11.13 AUX 49 Work Dimensions .......................................................................... 11-21 11.13.1 Work Dimensions Definition Procedure ..................................................... 11-22 11.14 AUX 64 Flowrate Control ........................................................................... 11-24 11.15 AUX 65 Speed Output ............................................................................... 11-25 11.16 AUX 75 System Switch .............................................................................. 11-31 11.17 AUX 77 Work Space Output ...................................................................... 11-34 11.18 AUX 80 XYZ Shift ...................................................................................... 11-36 11.19 AUX 81 Joint Shift ...................................................................................... 11-37 11.20 AUX 82 Tool Shift ....................................................................................... 11-38 11.21 AUX 83 Work Shift ..................................................................................... 11-39 11.22 AUX 89 Inverse Copy Program .................................................................. 11-40 11.23 AUX 117 OX Specification Set ................................................................... 11-41 11.24 AUX 130 PC Program Run/Stop ................................................................ 11-43 11.25 AUX 131 Interface Panel ............................................................................ 11-45 11.25.1 Programming Interface Panel Switches/Lamps ......................................... 11-45 11.25.2 Programming Interface Panel Switches/Lamps Procedure ........................ 11-47 11.25.3 Push Button Switch Setting ....................................................................... 11-49 11.25.4 Push Button with Lamp .............................................................................. 11-50 11.25.5 Two Notch Selector Switch ........................................................................ 11-50 11.25.6 Three Notch Selector Switch ..................................................................... 11-51 11.25.7 Pilot Lamp .................................................................................................. 11-51 11.25.8 Digital Switch ............................................................................................. 11-52 11.25.9 Digital Display ............................................................................................ 11-53 11.25.10 Text Window ............................................................................................... 11-54 11.25.10.1 Text Window Procedure ........................................................................ 11-54 11.25.11 Software Dedicated Signal ......................................................................... 11-55 11.25.12 I/F Panel Programmed by PC .................................................................... 11-56 11.26 AUX 133 AS Instruction Definition ............................................................. 11-57 11.27 AUX 135 Online Edit .................................................................................. 11-58 April 8, 2002 11-1
Kawasak
11.28 11.29 11.30 11.30.1 11.30.2 11.30.3 11.30.4 11.30.5 11.31 11.32 11.33 11.34 11.35 11.35.1 11.35.2 11.35.3 11.35.4 11.36 11.37 11.38 11.39
OPTIONAL FUNCTIONS
Slogic ......................................................................................................... 11-64 Remote I/O and Slogic Specifications........................................................ 11-67 AUX 180 RI/O Monitor ............................................................................... 11-70 Signal Status .............................................................................................. 11-71 Timer and Counter Status .......................................................................... 11-72 Slogic Monitor ............................................................................................ 11-73 Last Weld Data........................................................................................... 11-74 Slogic Status .............................................................................................. 11-75 AUX 181 RI/O PLC (NAC) Setting ............................................................. 11-75 AUX 182 RI/O Weld Control ....................................................................... 11-76 AUX 183 RI/O Slogic Control ..................................................................... 11-77 AUX 184 RI/O Slogic Forced Output .......................................................... 11-78 Random Program Selection (RPS) ............................................................ 11-79 RPS Commands ........................................................................................ 11-79 RPS Signals ............................................................................................... 11-79 RPS Procedure .......................................................................................... 11-80 RPS Operation ........................................................................................... 11-82 AUX 197 Password Set .............................................................................. 11-84 AUX 198 Auxiliary Function Select ............................................................ 11-85 Direct Speed .............................................................................................. 11-86 Monitor Screen Graph ................................................................................ 11-87
11-2
April 8, 2002
Kawasak
11.0 OPTIONAL FUNCTIONS
OPTIONAL FUNCTIONS
This unit covers information pertaining to the optional functions of the C controller. To install or enable optional functions contact Kawasaki customer service. 11.1 OPTIONAL MULTI FUNCTION PANEL FUNCTION LIST All of the optional function numbers, the function names and a brief description of each are identified below in the Optional Auxiliary Function List. A detailed explanation of each function and its use follows the auxiliary function list. Optional Auxiliary Function List No. 2 Function Name Extended Loction and Speed Display Mirror Conversion Function Description Provides four different positional information menus. Converts programmed locations into locations with mirror symmetry with the Y and Z planes of the base coordinate system. Provides the ability for off-line data to be converted into data for use in an on-line machine. Used to save program data from RAM to an optional floppy disk drive unit. Used to transfer data from the disk to the controllers RAM memory. Displays all files currently in the Floppy Disc Drive directory. Allows four auxiliary functions to be used. Used to automatically dimension tools. Used to set tool center point coordinates relative to a fixed point. Sets a reference frame for the robot other than the base coordinate system.
Data Conversion
20
Floppy Disk Drive (FD_SAVE) Floppy Disk Drive (FD_LOAD) File Directory (FD_FDIR) FDD Aux Fuction Auto Tool Set Fixed Tool Dimensions
21
22
23 40 45
49
Work Dimensions
April 8, 2002
11-3
Kawasak
OPTIONAL FUNCTIONS
Optional Auxiliary Function List (continued) No. 64 Function Name Flowrate Control Function Description Allows the scaling of output voltage from the analog port of the 1GW board. Allows the operator to input a voltage and flowrate based on the specific application to linearize the flow of sealant. Used to set the flowrate switch. The top and the bottom position of the work space are set from this function. Used to shift programmed locations in the base coordinate system. Used to change the joint values for selected programmed points. Used to shift programmed locations in the tool coordinate system. Used to shift programmed locations in a work coordinate system. Allows the operator to transfer program steps from one program to a different program, or a different location within the same program, in reverse order. Sets output signal characteristics. Monitors motor current to detect possible failures.
65
Speed Output
75 77
System Switch Work Space Output
80
XYZ Shift
81
Joint Shift
82
Tool Shift
83
Work Shift
89
Inverse Copy Program
117 OX Specification 124 Motor Torque Information 127 Operation Information 130 PC Program Run/Stop
Stores and displays system operation information. Allows the operator to control PC programs, and monitor the status of the PC programs. April 8, 2002
11-4
Kawasak
OPTIONAL FUNCTIONS
Optional Auxiliary Function List (continued) No. Function Name Function Description Allows the operator to program switches and lamps to control and monitor robot operation and peripherals. Allows the operator to assign program instructions to keys for repeated use during AS programming. Used to edit block step programs. Allows the operator to store one page of any of the graph screens. Monitors motor current to detect a possible collision. Determines weight and position of load on arm. Allows the operator to enable various remote I/O functions. Allows the operator to view and set information about the PLC Node Adapter Chip (NAC) settings. Allows the operator to view information about the weld control settings. Allows the operator to control the Slogic program or function. Allows the operator to force outputs that are used by the RI/O system. Sets a password level for AUX functions. Allows the operator to set the AUX functions to display or hide. 11-5
131 Interface Panel
133 AS Instruction Definition
135 Online Edit 147 Data Storage Function
148 Collision Detection Function 149 Tool Registration 180 RI/O Monitior
181 RI/O PLC (NAC) Setting
182 RI/O Weld Control
183 RI/O Slogic Control
184 RI/O Slogic Forced Output 197 Password Set 198 Auxiliary Function Select April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
11.2 AUX 2 EXTENDED LOCATION AND SPEED DISPLAY There are four different positional information menus available (see figure 11-1) which are accessed by pressing the F6 (Menu Select) key three separate times. Each time the menu key is pressed the function keys F1 through F5 change allowing access to different functions. The F6 key remains the menu key. Each of the four menu screens display specific function keys for accessing graphs. The first menu screen allows graph access for the F1 (Joint Angle), F2 (XYZOAT), and F3 (Joint Command) keys. Press the function keys twice to access the graphs. The second menu screen displays the F1 (Joint) and F5 (Motor Current) keys to access graphs when pressed twice. The third menu screen displays the F1 (Motor Speed) and F4 (Motor Current Command) screens for accessing graphs when pressed twice. The fourth menu screen displays the F1 (TCP) key for accessing a graph when pressed twice. When a graph is accessed from any of the four menu screens, the F6 (Menu) key becomes a (Graph Exit) key allowing the operator to return to the previous menu.
Figure 11-1 AUX 2 Extended Location and Speed Display Screen 11-6 April 8, 2002
Kawasak
11.3 AUX 6 MIRROR CONVERSION
F1
PROGRAM
OPTIONAL FUNCTIONS
INPUT
This function allows the operator to perform mirror imaging of taught location points. This function mirrors data taught in the X-axis of the base coordinate system about the YZ plane. Another application for the Mirror Conversion function is when two robots are directly opposite each other on a line and are performing the same motion. In this case, one program is recorded, transferred, mirrored, and used as a basis for the robot program on the opposite side of the line. Figure 11-2 shows an application of the mirror conversion function. Figure 11-3 shows the Mirror Conversion function screen.
Figure 11-2 AUX 6 Mirror Conversion
April 8, 2002
11-7
Kawasak
OPTIONAL FUNCTIONS
AUX 6 MIRROR CONVERSION

PROGRAM NAME START STEP 0
END STEP(O:START STEP ONLY) 0
F1
PROGRAM
F2
F3
F4
INPUT
Figure 11-3 AUX 6 Mirror Conversion Screen
1.
To enter the name of the program that contains the points to mirror, press the F1 PROGRAM INPUT key to display the PROGRAM SELECT screen. From the PROGRAM SELECT screen, select the program that contains the points to mirror and press the RETURN key. Enter the step number of the first step to mirror as the START STEP. If a 0 is entered for the START STEP, the first step mirrored is step 1. Enter the last step to mirror as the END STEP. If a 0 is entered for the END STEP, the START STEP is the only step mirrored.
2.
3.
4.
11-8
April 8, 2002
Kawasak
11.4 AUX 9 DATA CONVERSION
OPTIONAL FUNCTIONS
The Data Conversion function allows the operator to utilize off-line programming processes to load program data. One advantage of this process is a robot that is in a production operation does not need to be taken off-line for teaching new programs. Programmers can work off-line with computer simulation models to develop and test program scenarios while keeping on-line machines in production. The Data Conversion function screen is shown in figure 11-4.
Figure 11-4 AUX 9 Data Conversion Screen
April 8, 2002
11-9
Kawasak
11.5 AUX 20 FLOPPY DISK DRIVE (FD_SAVE)
OPTIONAL FUNCTIONS
The Floppy Disk Drive (FD_SAVE) function allows the operator to save program data from RAM to an optional floppy disc drive unit. The six save options are: Option 1: ALL DATA-includes robot data, system data, auxiliary data, program data, and variable data. PROGRAM-includes up to five selected programs. AUX DATA-includes data settings from the Data Set menus. ALL DATA (SELECTED PROGRAM ONLY)-includes robot data, system data, auxiliary data, selected program data, and variable data associated with selected programs. ROBOT DATA-includes the robot type, number of axes, robot specific software settings. ERROR LOGGING-includes error data from the error log.
Option 2: Option 3: Option 4:
Option 10:
Option 11:
To access this function press the MENU key on the top tool bar, then press the FUNCTION key from the drop down menu. Use the arrow keys to navigate through the auxiliary functions until AUX 20 is reached and highlighted, or type in the AUX function number, and press the ENTER key. Figure 11-5 shows the AUX 20 display screen.
AUX 20 MEMORY ->FDD (FD_SAVE)
1 2 3 4 10 11
ALL DATA PROGRAM AUX DATA ALL DATA (SELECTED PROGRAM ONLY) ROBOT DATA ERROR LOGGING
F1
F2
F3
F4
Figure 11-5 AUX 20, FDD (FD_SAVE) Screen 11-10 April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
Save options 2 and 4, in AUX 20, have next page displays to allow the operator to save specific programs. With the save option 2 screen displayed press the F3 NEXT PG key. At the second page use the F1 PROGRAM INPUT key to select up to five programs (see figure 11-6). Figure 11-6 shows the save option 2 next page display.
F3
NEXT PG
F2
PREV.PG
Figure 11-6 AUX 20, Save Option 2 Next Page Display Screen
April 8, 2002
11-11
Kawasak
11.6 AUX 21 FLOPPY DISK DRIVE (FD_LOAD)
OPTIONAL FUNCTIONS
Loading data is accomplished through AUX 21: (FD_LOAD). The data on the disk is loaded to the controllers RAM. The two options are: Option 1: Option 2: ALL DATA SELECTED DATA
Figure 11-7 shows the AUX 21 display screen.
AUX 21 FDD ->MEMORY (FD_LOAD)
1 2
ALL DATA SELECTED DATA
F1
F2
F3
F4
Figure 11-7 AUX 21 FDD (FD_LOAD) Screen
11.7 AUX 22 FILE DIRECTORY (FD_FDIR) This function displays all files currently in the floppy disk drive directory.
11-12
April 8, 2002
Kawasak
11.8 AUX. 23 FDD AUX FUNCTION The FDD AUX. Function consists of four options. The four options are: Option 1:
OPTIONAL FUNCTIONS
FDD FORMATTING (FD_FORMAT) - used to format the floppy disk to 1.44 MB or 1.25 MB. FILE DELETE (FD_FDEL) - used to delete files from the directory. FILE RENAME (FD_RENAME) - used to rename files. FDD CONFIG. - used to configure the optional floppy disk drive unit connection and disconnection.
Option 2: Option 3: Option 4:
Figure 11-8 shows the AUX. 23 display screen.
AUX 23 FDD AUX.FUNCTION
1 2 3 4
FDD FORMATTING (FD_FORMAT) FILE DELETE (FD_FDEL) FILE RENAME (FD_RENAME) FDD CONFIG.
F1
F2
F3
F4
Figure 11-8 AUX. 23 FDD AUX Function Screen
April 8, 2002
11-13
Kawasak
11.9 AUX 40 AUTO TOOL SET
OPTIONAL FUNCTIONS
The Auto Tool Set function is used to determine tool dimensions and orientation for tools 1 through 9. Tool dimensions and orientation are referred to as tool coordinates. Correct tool coordinates are important during jogging, in base and tool mode, and during linear moves, in repeat mode, to maintain proper tool orientation. A tool name is entered and the type of conversion (0:XYZ, 1:XYZOAT) is selected. Type 0 sets only the tool center point (TCP), while type 1 sets the TCP and the OAT angles. Refer to sections 11.9.1 and 11.9.2 respectively, for additional information about setting the TCP and OAT angles. Figure 11-9 shows the Auto Tool Set screens.
Figure 11-9 AUX 40 Auto Tool Set Screens 11-14 April 8, 2002
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11.9.1 SETTING TOOL CENTER POINT
OPTIONAL FUNCTIONS
QTOOL switch must be set to on prior to setting tool dimensions (refer to AUX 75 System Switches in unit 9). For more information about tool dimensions refer to AUX 48 in unit 9. To set the tool center point: 1. Enter the tool name (no.) and the tool type as shown in figure 11-9 and press the RETURN key, NEXT PG appears in the F3 key position. Press the F3 key to access the next screen. The keys on the multi function panel change to show the jogging keys. Points A1 through A4 are displayed at this time. Record the individual tool positions as shown in (Figure 11-9).
2.
3.
The joint angles recorded for each point are used by the controllers CPU to calculate the tool center point. Use the scroll keys to select a position to record. Figure 11-10 shows the tool position relative to points A1 through A4. The tool center point must touch the stationary reference point at each position as shown in figure 11-10. The Zaxis of the tool should be 90 degrees from the Z-axis of the fixed pointer for positions A1, A3, and A4. For position A2, the Z-axis of the tool should be parallel to the Z-axis of the stationary reference point as shown in figure 11-10. 4. 5. Once the robot position is at an A point, press the RECORD key. Jog the tool to the next A point to record and repeat the procedure until all four A points are recorded, refer to figure 11-10. Once all points are recorded, press the ENTER key. The new tool points are now recorded and normally completed appears in the message window. Press the NEXT PG. key and then the YES key to complete the recording procedure. Press the EXIT key to access the AUX function menu and select AUX 48 Tool Dimensions. At this screen press the ENTER key to apply the new tool dimensions (the new dimensions are displayed but are not applied until the ENTER key is pressed).
6.
7.
8.
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Z+
OPTIONAL FUNCTIONS
A2
A3 A1
45-90
Y-
X+
45-90 45-90
A4
Y+ XStationary Reference Point
Figure 11-10 Teaching Tool Dimensions
11.9.2 TOOL CENTER POINT AND OAT ANGLES To set the tool center point and OAT angles, select 1 (XYZOAT) as the type from the AUX 40 screen. Use the procedure from section 11.9.1 to set points A1 through A4. Once these points have been established, the OAT angles are set using points B and C as shown in figure 11-11. 1. 2. Jog the tool center point to the position recorded as point A4. See figure 11-10. Jog the tool away (100 mm min.) from point A4 in the base interpolation mode along the X-axis as shown in figure 11-11. Select point B and press REC. This sets the tool X-axis. Return the tool to the position recorded as point A3 shown in figure 11-10. Jog the tool away (100 mm min.) from point A3 in the base interpolation mode along the Y-axis as shown in figure 11-11. Select point C and press REC. This sets the tool Y-axis. When all points are recorded, press the ENTER key.
3. 4.
5.
The new tool points are now recorded, and normally completed displays in the message window. Press the NEXT PG. key and the YES key to complete the recording procedure. Press the EXIT key to access the AUX function menu and select AUX 48 Tool Dimensions. At this screen press the ENTER key to apply the new tool dimensions (the new dimensions are displayed but are not applied until the ENTER key is pressed). 11-16 April 8, 2002
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11.10 CIRCULAR INTERPOLATION
OPTIONAL FUNCTIONS
Circular interpolation allows the operator to program a path in an arcing motion. The controller computes the circular path based on a minimum of three taught points. The first, or starting move, may be any type of move except CIR1 (JOINT, LINEAR or CIR2). The second point must be a CIR1 move. The last point must be a CIR2 move. Figure 11-11 and 11-12 show examples of circular move programing. Multiple CIR1 moves may be used between the starting move and the CIR2 ending move.
Figure 11-11 Circular Interpolation Program Example
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OPTIONAL FUNCTIONS
Figure 11-12 Circular Interpolation Program Examples
11-18
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11.11 HYBRID INTERPOLATION
OPTIONAL FUNCTIONS
The optional linear 2 interpolation provides for hybrid interpolated movement. Hybrid interpolation allows the operator to avoid singularity on axes when linear moves are necessary. The robot maintains the tool center point in a linear move, but adjust tool orientation to drive through the singularity. An error results if the limits are exceeded. 11.12 AUX 45 FIXED TOOL DIMENSIONS The Fixed Tool Dimensions function allows the operator to program moves that are relative to an external fixed point in the work envelope. This type of interpolation is called fixed linear interpolation (FLIN). In a FLIN move the robot path is calculated to maintain a set relationship to a fixed point. Applications for FLIN moves include moving a part around a fixed sealing dispenser or a fixed stud welding gun. The FLIN path enables the programmer to reduce the number of programmed points needed to maintain a fixed distance from the sealing dispenser. Figure 11-13 shows the auxiliary function screen used to enter the dimensions for a fixed tool used with FLIN moves. Figure 11-14 shows how the path of a windshield moved by a robot is differs with linear and FLIN interpolation.
FIXED TOOL1 X DIRECTION Y DIRECTION Z DIRECTION O ROTATION A ROTATION T ROTATION 0.0mm 0.0mm 0.0mm 0.0deg 0.0deg 0.0deg
Figure 11-13 AUX 45 Fixed Tool Dimensions Screen
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11-19
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OPTIONAL FUNCTIONS
Figure 11-14 Fixed Tool Dimensions and FLIN
11-20
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11.13 AUX 49 WORK DIMENSIONS
OPTIONAL FUNCTIONS
The Work Dimensions function is active in the teach mode and allows the operator to jog the robot relative to an alternative coordinate system. Figure 11-15 shows the display used to set work dimensions 1-9.
AUX 49 WORK DIMENSIONS
WORK 1 X DIRECTION Y DIRECTION Z DIRECTION O ROTATION A ROTATION T ROTATION 0.0mm 0.0mm 0.0mm 0.0deg 0.0deg 0.0deg
F1 F2 F3 F4 RANG: Rotation 0.0deg - 10.0deg PREV.DATA NEXT PG Traverse 0.0mm - 100.0mm
Figure 11-15 AUX 49 Work Dimensions Screen
The work dimensions are determined using the AS Language FRAME and POINT commands to define a coordinate system based on the orientation of the work where points are taught. Reference the KRI AS Language Manual for information on the FRAME function and the commands needed to enter work dimensions. Figure 11-16 shows how the orientation of the work dimensions is different from the base coordinate orientation.
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OPTIONAL FUNCTIONS
X
SIO NS
KD
IM
EN
WO R
Y Y
Figure 11-16 Work Dimensions Orientation
11.13.1 WORK DIMENSIONS DEFINITION PROCEDURE 1. Jog the robot to the X, Y, and Z coordinates (Figure 11-27) for the new work dimension frame location. Use the AS Location teaching screen or the keyboard with the HERE command to record the three locations. The X location is recorded as lc3, the Y location is recorded as lc4, and the Z location is recorded as lc2. 2. At the keyboard enter the AS Language POINT command shown below. POINT lc1 = FRAME(lc2,lc3,lc4,lc2) When this command is entered, the location values for lc1 are displayed as shown below. X[mm] -977.125 3. Y[mm] 955.250 Z[mm] 667.542 O[deg] -31.747 A[deg] 180.00 T[deg] -7.240
Round the values to one decimal place and enter the values in AUX 49 as the values for the desired work dimension, screen 1 through 9, as shown in figure 1117. April 8, 2002
11-22
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OPTIONAL FUNCTIONS
Figure 11-17 (A) shows the robot base coordinate system as X, Y, and Z and the desired new base coordinate system as X1 and Y1. Figure 11-17 (B) shows the three points to record (lc2, lc3, and lc4) to establish the new coordinate system. The line POINT lc1= FRAME(lc2,lc3,lc4.lc2) is entered at the keyboard screen (Figure 11-17B), to associate point lc1 to the frame. When this line is entered the resulting component values of lc1 are displayed. The resulting values are rounded to one decimal place and entered as work dimensions in AUX 49 (Figure 11-15). (See note on the following page)
AUX 49
Figure 11-17 Work Dimension Component Values April 8, 2002 11-23
Kawasak
NOTE
OPTIONAL FUNCTIONS
Work 0 remains as the original base coordinate system. When Work 1- 9 dimensions are used to jog the robot and teach locations, there is no affect on block step program motion in repeat mode. If AS Language program steps are executed after work 1-9 are used in a block step program, the AS Language steps may be affected.
11.14 AUX 64 FLOWRATE CONTROL The Flowrate Control function allows the scaling of output voltage (tool tip speed and bead width) from the analog port of the 1GW board. The FLOWGAIN COMMAND range is from 50% to 150%.
AUX 64 FLOWRATE CONTROL 65 SPEED OUTPUT 70 MEMORY AVAILABLE 71 RECORD DATA (PRG CHG) INHIBIT 75 SYSTEM SWITCH 76 HOME POSITION 77 WORK SPACE OUTPUT 78 CLEAR CHECK SUM ERROR 80 XYZ SHIFT 81 JOINT SHIFT FUNCTION NUMBER: F1 F2
PRE PG
AUX 64 FLOWRATE CONTROL FLOWGAIN COMMAND 100.0%
F3
NEXT PG
F4
F1
PRE DATA
F2
F3
F4
Figure 11-18 AUX 64 Flowrate Control Screen
11-24
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11.15 AUX 65 SPEED OUTPUT
OPTIONAL FUNCTIONS
The Speed Output function starts an analog output voltage according to data the linerization table in AUX 65 Speed Output. This voltage is based on the scale voltage of Flowrate (tool tip speed and bead width) from the analog port of the 1GW board. The screen shown below allows the operator to input a voltage and flowrate based on the specific application to linearize the flow of sealant. The flowrate is entered as mm3/sec and the range of the voltage depends on the dispensing equipment.
Figure 11-19 AUX 65 Speed Output Screen
To access flowrate data for flowrate Nos. eight to twenty one, use the NEXT PG. key.
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OPTIONAL FUNCTIONS
In addition to the OUTPUT SPEED settings, the operator must program the AS Language instructions described below. 1. SETOUTSPEED time time, maxspeed, maxvolt, minvolt Analog output anticipation time. Unit is 0.01 second. Range 0 ~ 10 seconds. Default = 0. Tool tip speed at maximum voltage Range 0 ~ 10,000 mm/sec. Default = 2000 (Only effective when FLOWRATE switch is OFF) Voltage is based on the setting of sw1 or sw2 on the 1GW board. Maximum voltage = +10 if 0 ~ 10 or 10 is selected Maximum voltage = +15 if 0 ~ 15 is selected. Voltage is based on the setting of sw1 or sw2 on the 1GW board. Minimum voltage = 0 if 0 ~ 10 or 0 ~ 15 is selected. Minimum voltage = -10 if 10 is selected. lsb, bits, logic Least significant bit of the analog card. 3000 for 1GW board analog channel 1 or 3001 for 1GW board analog channel 2. 8 bits If 0 ~ 10 or 0 ~ 15 is selected, Negative Theory 0. If 10 is selected, Positive Theory 1. The 1GW board is equipped with a D/A converter with 8 bit signals. The least significant bit (lsb) is 3000 for channel 1 and 3001 for channel 2. 0 volt = 255 and 10 volts = 0 if 0 ~ 10 volts is selected. 0 volt = 255 and 15 volts = 0 if 0 ~ 15 volts is selected. -10 volts = 0 and +10 volts = 255 if 10 volts is selected. 3. OUTSPEED Starts analog output dependent on the scaled voltage of the tool tip speed from the analog port of the 1GW board. Stops the analog output signal.
maxspeed
maxvolt
minvolt
2. SETOUTSIG lsb
bits logic
4. OUTSPEED 0
11-26
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5. OUTSPEED(time)
OPTIONAL FUNCTIONS
Return the tool tip speed after the designated time. Unit is mm/second. Real value: time: seconds >=0 Programing example vel = OUTSPEED(0.3) if VEL >2000 THEN vel = 2000 END output = 255*vel/2000 BITS 33,8 = 255 - output
6. OUTLOC(time)
Return the transformation after the designated time. Real value: time: seconds >=0 Programing example TIMER 1 = 0 POINT last = OUTLOC(0) 10 IF TIMER(1) <0.1 GOTO 10 period = TIMER(1) TIMER 1 = 0 POINT new = OUTLOC dist = DISTANCE (new, last) POINT last = new vel = dist/period IF vel >2000 THEN vel = 2000 END output = 255*vel/2000 BITS 33,8 = 255 - output GOTO 10
7. BEAD dia
Diameter (Default 6) Bead diameter width. Unit is 0.1 mm. Range is 0 ~ 50 mm FLOWRATE is calculated from this bead size and tool tip speed. Volume (default 5000) Determines the volume of sealer dispensed. Unit is 1 mm3/ sec. Range is 0 ~ 200000
8. QBEAD
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9. FLOWGAIN % % (Default 100)
OPTIONAL FUNCTIONS
Adjusts the bead width diameter. Range 0 ~ 150%. ON/OFF ON = FLOWRATE mode OFF = OUTSPEED mode Volt (Default -15) Constant voltage output for purging. Unit is 0.1 volt. Range is -15 ~ +15 volts. Gain (Default 0) Increases the output voltage according to the difference of TCP speed. Causes a break in the program until the current motion command is complete. Programming Example ACCURACY 1000 ALWAYS LMOVE #A LMOVE #B LMOVE #C MBREAK SIGNAL 2 LMOVE #D
10. FLOWRATE ON OFF 11. GUNPURGE volt
12. ACCFLOW gain
13. MBREAK
This program causes signal 2 output at #C and remains on until #D is reached. 14. Conversion of Flow Rate The following is the conversion formula from inch-pound units to metric units. Wn [lbs.]: D [lbs./in3]: Actual weight of material during t sec flow from the nozzle at the n volt analog output (n = 0 ~ 10 volts). Specific gravity (Density)
Flow Rate [mm3/sec.] = 25.43 * (Wn / t) / D = 16387 * Wn / t * D 11-28 April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
To get the flow rate by cc/sec. (cubic centimeter), use the following formula to convert for the OUTSPEED linearize table data in AUX 65. Flow Rate [mm3/sec.] = 1000 * [cc/sec.] 15. Bead Width as Auxiliary Data Set up the bead width matrix from AUX 114-2 Clamp Condition (CC) Code, BEAD. The available range is from 0 to 50 mm. A 0 indicates to use previous data, or the bead remains the same width. Use the F3 NEXT PG key to access codes 1~9.
AUX

1 2 13 14 20 30 GUN APPLICATION GUN CONDITION CLEAR SPOT OPTIMIZE DATA SPOT GUN PRESS ADJUST HANDLING CLAMP DEFINITION PAINTING/SEALING GUN DEFINITION
100 101 103 110 111 112 113 114 120 122
SYSTEM INITIALIZE BATTERY ERROR CHECK TOUCH PANEL SHORT CIRCUIT CHECK TIME DEDICATED INPUT SIGNALS DEDICATED OUTPUT SIGNALS DEDICATED SIGNALS DISPLAY GUN SPECIFICATIONS ERROR LOGGING OPERATION LOGGING
FUNCTION NUMBER:
FUNCTION NUMBER:
F1
F2
PRE PG
F3
NEXT PG
F4
F1
F2
F3
F4

2 GUN CONDITION CODE1
GUN SUBROUTINE 1 (0 : Effect, 1: Ineffect) GUN SUBROUTINE NO. pg 90 (Valid only when enabled) BEAD (0:Unchanged) 50.0 FLOWGAIN 100.0 % OUTSPEED (1:Effect, 0:Ineffect) 0
F1
PRE DATA
F2
F3
NEXT PG
F4
Figure 11-20 Bead Width as Auxiliary Data
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OPTIONAL FUNCTIONS
16. Analog output timing is controlled by the AS Language command SETOUTSPEED or AUX 65-2 Enivronment Set.
Figure 11-21 AUX 65-2 Environment Set Screen 11-30 April 8, 2002
Kawasak
11.16 AUX 75 SYSTEM SWITCH
OPTIONAL FUNCTIONS
Function 75 shown below has a flowrate switch. When this switch is ON, the SPEED OUTPUT AUX 65 table is used. When this switch is OFF, a proportional analog output voltage is calculated based on the tool tip speed and the AUX 65 Speed Output table is not used.
AUX 75 SYSTEM SWITCH ERRSTART.PC DISPIO_01 HOLD.STEP WS_COMP OFF WS.ZERO PLC.CHECK FLOWRATE OFF OFF OFF ON OFF OFF OFF
F1
PREV.DATA
F2
F3
NEXT PG
F4
ON/OFF
Figure 11-22 AUX 75 System Switch Screen
Sample mainline and block step programs for sealing applications are provided on the following pages.
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Sample Mainline Program .PROGRAM pg00() FLOWRATE ON SETOUTSPEED 0,500,13,0 SETOUTSIG 33,8,0 FLOWGAIN 100 OUTSPEED ; 100 HOME SIGNAL 1,2,3 WAIT BITS(1021,4) pg = Bits(1021,4) CASE pg OF VALUE 11: CALL pg11 VALUE 10: CALL pg 10: END IF NOT SIG(1001) GOTO 100 SIGNAL -1,-2,-3 pg = BITS(1021,4) CASE pg OF VALUE 1: CALL pg01 VALUE 2: CALL pg02 VALUE 3: CALL pg03 .END
OPTIONAL FUNCTIONS
RESET ; Clear to xfer and to clamp ; Wait for program selection ; Load program code (4 bits) into pg
; Manual purge program ; Auto purge program
; Sealing operation program 1 ; Sealing operation program 2 ; Sealing operation program 3
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Sample Program including Bead Width
OPTIONAL FUNCTIONS
.PROGRAM pg01() JOINT SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX= LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX= BEAD 3.5 LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX=10 LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX=10 LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX= LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX= BEAD 2.5 LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX=10 LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX=10 LINEAR SPEED9 ACCU1 TIMER0 TOOL1 WORK0 CLAMP1 (OFF,0,0,O) 2 (OFF,0,0,O) 3 (OFF,0,0,O) 4 (OFF0,0,O) WX= OX= .END April 8, 2002 11-33
Kawasak
11.17 AUX 77 WORK SPACE OUTPUT
OPTIONAL FUNCTIONS
When the TCP is within the space defined by the Work Space Output function, the assigned signal is on. Jog the robot to the UPPER and LOWER locations and record the X, Y, and Z positional information for input into AUX 77. Whenever the TCP is within the three dimensional space defined by the Work Space Output function an output signal is on. The work space output signal is set in AUX 112 dedicated outputs. Figure 11-23 shows the display to set the UPPER and LOWER X, Y, and Z dimensions. Figure 11-24 shows an example of how the dimensions are determined.
AUX 77 WORK SPACE OUTPUT WORK SPACE 1 UPPER X DIRECTION Y DIRECTION Z DIRECTION LOWER X DIRECTION Y DIRECTION Z DIRECTION OUTPUT SIGNAL 0mm 0mm 0mm 0mm 0mm 0mm 16
F1
PREV.DATA
F2
F3
NEXT PG
F4
Figure 11-23 AUX 77 Work Space Output Screen
11-34
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OPTIONAL FUNCTIONS
UPPER XYZ LOCATION

WO RK S DIM PACE EN SIO OUTP NS UT
LOWER XYZ LOCATION
Y
Figure 11-24 Work Space Output Dimensions
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11.18 AUX 80 XYZ SHIFT
OPTIONAL FUNCTIONS
The XYZ Shift function is used in conjunction with block step programs and shifts programmed locations in the base coordinate system. The display screen used to set the shift information is shown in figure 11-25.
Figure 11-25 AUX 80 XYZ Shift Screen
The use of the XYZ Shift function is outlined in the following steps: 1. Press the F1 PROGRAM INPUT key to select the name of the program that contains the points to shift. The PROGRAM SELECT screen is displayed. Select the program name that contains the locations to shift. Enter the number of the first step to shift as the START STEP. If a 0 is entered for the START STEP the first step shifted is step 1. The END STEP is the last step shifted in the program. If a 0 is entered for the END STEP only the START STEP is shifted.
2.
3.
The distance and direction of shifting in the base coordinate system is entered in the X,Y,Z section of the screen. The value of the shift in each coordinate direction is entered in mm. In the teach mode of operation the shift value is in the range of 500mm; in the repeat mode of operation the shift value is in the range of 10mm.
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11.19 AUX 81 JOINT SHIFT
OPTIONAL FUNCTIONS
The Joint Shift function is used in conjunction with block step programs and shifts programmed locations based on joint angle information. The display screen used to set the information is shown in figure 11-26.
Figure 11-26 AUX 81 Joint Shift Screen
The use of the Joint Shift function is outlined in the following steps: 1. Press the F1 PROGRAM INPUT key to select the name of the program that contains the points to shift. The PROGRAM SELECT screen is displayed. Select the program name that contains the locations to shift. Enter the number of the first step to shift as the START STEP. If a 0 is entered for the START STEP the first step shifted is step 1. The END STEP is the last step shifted in the program. If a 0 is entered for the END STEP only the START STEP is shifted. Enter the distance (in degrees) and joint to shift in the JT1 to JT6 sections of the screen.
2.
3.
4.
In the teach mode the shift value is in the range of 10, in the repeat mode the shift value is in the range of 1
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11.20 AUX 82 TOOL SHIFT
OPTIONAL FUNCTIONS
The Tool Shift function is used in conjunction with block step programs and shifts programmed locations in the tool coordinate system. The display screen used to set the tool shift information is shown in figure 11-27.
Figure 11-27 AUX 82 Tool Shift Screen
The use of the Tool Shift function is outlined in the following steps: 1. Press the F1 PROGRAM INPUT key to select the name of the program that contains the points to shift. The PROGRAM SELECT screen is displayed. Select the program name that contains the locations to shift. Enter the number of the first step to shift as the START STEP. If a 0 is entered for the START STEP the first step shifted is step 1. The END STEP is the last step shifted in the program. If a 0 is entered for the END STEP only the START STEP is shifted.
2.
3.
Enter the distance and direction of shift in the tool coordinate system in the X,Y,Z section of the screen. Enter the value of the shift in each tool coordinate direction in mm. In the teach mode of operation the shift value is in the range of 500mm, in the repeat mode of operation the shift value is in the range of 10mm.
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11.21 AUX 83 WORK SHIFT
OPTIONAL FUNCTIONS
The Work Shift function is used in conjunction with block step programs and shifts programmed locations in the coordinate system defined as work. The display screen used to set the information is shown in figure 11-28.
Figure 11-28 AUX 83 Work Shift Screen
The use of the Work Shift function is outlined in the following steps: 1. Press the F1 PROGRAM INPUT key to select the name of the program that contains the points to shift. The PROGRAM SELECT screen is displayed. Select the program name that contains the locations to shift. Enter the number of the first step to shift as the START STEP. If a 0 is entered for the START STEP the first step shifted is step 1. The END STEP is the last step shifted in the program. If a 0 is entered for the END STEP only the START STEP is shifted.
2.
3.
Enter the distance and direction of shift in the work coordinate system in the X,Y,Z section of the screen. Enter the value of the shift in each work coordinate direction in mm. In the teach mode of operation the shift value is in the range of 500mm, in the repeat mode of operation the shift value is in the range of 10mm.
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11.22 AUX 89 INVERSE COPY PROGRAM
OPTIONAL FUNCTIONS
The Inverse Copy Program function is used to copy and paste program steps from one program to a different program or a different location within the same program in reverse order. The Inverse Copy Program function works in the same manner as AUX 3 Data Transfer, except program steps are copied in reverse order. Figure 11-29 shows the Inverse Copy Program screen.
AUX 89 INVERSE COPY PROGRAM

SOURCE PROGRAM SOURCE STEP NUMBER OF STEPS DESTINATION PROGRAM DESTINATION STEP (0:APPEND AT THE LAST STEP)
Pgtest
5 21
Pgtest1
4
F1
PROGRAM
F2
F3
F4
INPUT
Figure 11-29 AUX 89 Inverse Copy Program Screen
The use of the Inverse Copy Program function is outlined in the following steps: 1. Press the F1 PROGRAM INPUT key to select a source program for steps to copy. A screen showing a list of programs available in the system memory is displayed. Use the cursor keys to select the program containing the steps to copy and press the ENTER key. Use the numeric key pad to enter the first step and the number of steps to copy. Press the F1 PROGRAM INPUT key and a screen showing a list of programs available in the system memory is displayed. Use the cursor keys to select the program to paste the copied steps into and press the ENTER key. Use the numeric key pad to enter the first step of the destination program to paste the copied steps into. When 0 is entered the data is inserted after the last step of the destination program. When steps are inserted into a program the existing steps are renumbered.
2. 3.
4.
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11.23 AUX 117 OX SPECIFICATION SET
OPTIONAL FUNCTIONS
The OX Specification Set function allows the operator to set the characteristics of output signals. Four types of signals can be specified, they include the STEP, KEEP, DOUBLE, and PULSE types. The settings of the OX PREOUT and AFTER.WAIT.TMR switches affect signal timing; unit 9 of this manual covers the function of these switches. The STEP type signal is the standard type of signal that is output without the optional OX Specification function. The STEP type signal is turned on at each step of the block step program that identifies the signal number. When the robot moves to a location that does not include the signal number in the auxiliary data, the signal is turned off. A 0 is entered to specify a STEP type of signal from the OX specification table. The KEEP type of signal remains on until it is turned off at a specific step. A 1 is entered to specify a KEEP type of signal from the OX specification table. The DOUBLE type of signal turns one signal on and one off; DOUBLE type signals must be entered in pairs. A 2 is entered to specify DOUBLE types of signals from the OX specification table. The PULSE type of signal remains on for the specified length of the pulse width, in seconds. A 3 is entered to specify a PULSE type of signal from the OX specification table. The length of the pulse is also entered from this screen.
Figure 11-30 shows the OX Specification Set screen used to set the signal characteristics and figure 11-31 is a graph showing the affect of each type of signal on signal timing.
8
AUX 117 OX SPECIFICATION SET
OX No. 1 2 3 4 5 6 7 8
9 7 5 3 1
CLEAR
RETURN
TYPE PULSE WIDTH OX No. TYPE PULSE WIDTH
0 0 0.0 0.0 [sec] 9 10 0 0 0.0 0.0 [sec]
0 0 0 0 0 0 0.0 0.0 0.0 0.0 0.0 0.0 11 12 13 14 15 16 0 0 0 0 0 0 0.0 0.0 0.0 0.0 0.0 0.0
6
4
EXIT
TYPE(0:STEP, 1:KEEP 2:DOUBLE, 3:PULSE
2
F4
BS
F1
PREV.DATA
F2
F3
NEXT PG
Figure 11-30 AUX 117 OX Specification Set Screen
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OPTIONAL FUNCTIONS
Figure 11-31 Output Timing
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11.24 AUX 130 PC PROGRAM RUN/STOP
OPTIONAL FUNCTIONS
AUX 130 enables the operator to control the PC program, as well as determine the status of the program. The process control (PC) program allows the operator to coordinate the robot controller with assembly line or process control. The PC program runs in the background and can monitor I/O, set internal signals, and perform mathematical computations. The PC program can execute I/O commands, perform logic operations and mathematical computations, but cannot execute motion instructions. Figure 11-32 shows the PC Program Run/Stop display screen. Refer to table 11-1 for PC program run/stop Commands
AUX 130 PC PROGRAM RUN/STOP
1 2 3 4 5 6
START ABORT STOP CONTINUE KILL STATUS
(PCEXECUTE) (PCABORT) (PCEND) (PCONTINUE) (PCKILL) (PCSTATUS)
FUNCTION NUMBER:
F1 F2 F3 F4
Figure 11-32 AUX 130 PC Program Run/Stop Screen
April 8, 2002
11-43
Kawasak
OPTIONAL FUNCTIONS
Table 11-1 PC Program Run/Stop Commands

AS LANGUAGE COMMAND PCEXECUTE PCABORT
ITEM
EXPLANATION Executes the designated PC program. The number of execution cycles and the star t step can also be defined. Interrupts the currently executing PC program.
START ABORT STOP
Stops the PC program at the next robot program STOP command, or after the last step PCEND of a robot program is executed. Star ts PC program execution, after interruption by a PCABORT or a PCEND command. Cancels the currently selected PC program. Displays the status of the currently executing PC program. PCCONTINUE PCKILL PCSTATUS
CONTINUE KILL STATUS
11-44
April 8, 2002
Kawasak
11.25 AUX 131 INTERFACE PANEL
OPTIONAL FUNCTIONS
On the C-series controller EP type, the operation (interface) panel, with the switches to operate the robot and peripherals and lamps to monitor the robot and peripherals, can be programed on the multi function panel or type 2 teach pendant. AUX 131 allows the operator to program the same switches and lamps for display and use on the software interface panel (I/F). Figure 11-33 shows an example of the interface panel. The numbered locations (Figure 11-34) correspond to the locations on the first I/F panel (1/2) shown in grey numbers (Figure 11-33). To toggle between the first (1/2) and the second (2/2) I/F panel screen press the I/F key at the top of the screen (Figure 11-33). For the type 2 teach pendant the operator can access the interface panel using the MENU key and select the I/F key from the drop down menu or use the soft interface panel key located to the left of the REC (record) key. The interface panel key is also used to toggle between interface panel screens one and two. 11.25.1 PROGRAMMING INTERFACE PANEL SWITCHES/LAMPS Auxiliary function 131 allows the operator to program specified switches, lamps and text boxes to display on one of two I/F panel screens. There are 32 locations available on each screen. The characteristics of each interface panel function are set by pressing the PARAMETER SET key. Pressing this key displays the PARAMETER SET window for each function. When programming each of the interface panel functions, the operator specifies the following items: label, color, signal number and operate inhibit. See figure 11-35, Push Button Parameters. Switches and lamps may have up to four lines available for labels. Each line may contain up to 10 character spaces. To enter text for a line, use the F4 CHARACTER key to access the character set keyboard. Scrolling to the color specification line, the number keypad keys display colors for input. When RETURN is pressed, the message NORMALLY COMPLETED is displayed. Specify signal numbers according to desired output signals. April 8, 2002 11-45
Kawasak
OPTIONAL FUNCTIONS
PROGRAM pg99
STEP 5
PC
SPEED 10%
97-03-18 17:30
I/F
TEACHING
I/F
NEXT MENU
INTERFACE PANEL (1/2)

AUTO MANU
OFF LINE OFF AUTO
ENABLE
HOME
PALLET REMOVE MODE MANUAL AUTO MODE OFF OFF-LINE AUTO
10
13 14 15 16
17 18 25 26
19 20 21 22 23 24 27 28 29 30 31 32
Figure 11-33 Interface Panel Screen
PROGRAM Test
STEP 1
PC
TEACHING FUNCTION
SPEED 30% TEACH
1-01-23 22:17
MENU
Normally completed. Normally completed.
8 6 4 2 0
9 7 5 3 1
CLEAR
RETURN
AUX 131 INTERFACE PANEL

POSITION (UPPER) SPEC (LOWER) 1 2 3 4 5 6 7 8 [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] 9 10 [ 0] [ 0] 17 18 [ 0] [ 0] 11 [ 0] 19 [ 0] 27 [ 0] 12 13 [ 0] [ 0] 20 21 [ 0] [ 0] 28 29 [ 0] [ 0] 14 15 [ 0] [ 0] 22 23 [ 0] [ 0] 30 31 [ 0] [ 0] 16 [ 0] 24 [ 0] 32 [ 0]
Screen Locations
EXIT
Switch or Lamp Type
25 26 [ 0] [ 0]
BS
F1
PRE DATA
F2
F3
F4
SET
NEXT PG PARAMETER
Figure 11-34 AUX 131 Interface Panel Screen
11-46
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
11.25.2 PROGRAMMING INTERFACE PANEL SWITCHES/LAMPS PROCEDURE 1. 2. From the auxiliary function menu select AUX 131 Interface Panel. Use the cursor keys to select the location for display of the switch/lamp (Figure 1133). Use the F3 NEXT PG key to select locations 33-64 (interface panel 2/2). Use the cursor keys to select the switch/lamp type below the location number. The types of switches/lamps are displayed on the number keypad keys (Figure 11-35). Use the cursor keys to select the desired type of switch/lamp and press RETURN. Press the F4 PARAMETER SET key. The screen displayed depends on the type of switch/lamp selected (figures 11-36 through 11-43). As an example procedure the push-button with lamp is used (Figure 11-38). 6. Use the cursor keys to select a line (1-4) for labeling the bush button with lamp. With the desired label line selected press the F4 CHARACTER key, to display the character set keyboard. At the character set keyboard enter the desired label and press the ENTER key. Repeat this step for lines 1-4 if desired. 7. Use the cursor keys to select COLOR (ON)/(OFF). When COLOR (ON)/(OFF) is selected the available colors are displayed on number keypad keys 0 through 8 (Figure 11-36). Press the desired color key and press RETURN. Use the cursor keys to select the SIGNAL NUMBER (SWITCH). Use the number keypad to select the desired 1GA board output signal number (figure 11-32 Robot Signal Numbers). Ensure the signal number selected is not used as a dedicated output signal in AUX 112 (unless the button is used to actuate the function) or used in a program. Press RETURN and normally completed is displayed in the message area. Use the cursor keys to select the SIGNAL NUMBER (LAMP). Use the number keypad to select the desired 1HA board input signal number (figure 11-32 Robot Signal Numbers). Ensure the signal number selected is not used as a dedicated input signal in AUX 111 (unless the lamp is used to indicate the function) or used in a program. Press RETURN and normally completed is displayed in the message area.
3.
4. 5.
8.
9.
10. Edit the Slogic program to assign the signals used above as needed (refer to section 11.28). April 8, 2002 11-47
Kawasak
PROGRAM Test
OPTIONAL FUNCTIONS
STEP 1
PC
TEACHING FUNCTION
SPEED 30% TEACH
1-01-23 22:17
MENU
Normally completed. Normally completed.
8
TEXT WINDOW

POSITION (UPPER) SPEC (LOWER) 1 2 3 4 5 6 7 8 [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] [ 0] 9 10 [ 0] [ 0] 17 18 [ 0] [ 0] 25 26 [ 0] [ 0] 11 [ 0] 19 [ 0] 27 [ 0] 12 13 [ 0] [ 0] 20 21 [ 0] [ 0] 28 29 [ 0] [ 0] 14 15 [ 0] [ 0] 22 23 [ 0] [ 0] 30 31 [ 0] [ 0] 16 [ 0] 24 [ 0] 32 [ 0]
6
DIGITAL SWITCH
7
DIGITAL DISPLAY
4
S-NOTCH SELECTOR
5
LAMP
EXIT
2
PUSHBUTTON WITH LAMP
3
2-NOTCH SELECTOR
BS
F1
PRE DATA
F2
F3
F4
SET
0
NOT USED
1
PUSH BUTTON
CLEAR
RETURN
NEXT PG PARAMETER
Figure 11-35 AUX 131 Switch/Lamp Type Select Screen
PROGRAM Test
STEP 1
PC
TEACHING FUNCTION
SPEED 30% TEACH
1-01-23 28:46
MENU
Normally completed.
8
PINK
9
BISQUE

POSITION LABEL 1 2 3 4 COLOR 1 PUSH BUTTON WITH LAMP
6
YELLOW
7
WHITE
4
0 0 0 0
GREEN
5
LIGHT BLUE
(ON) (OFF) SIGNAL NUMBER (SWITCH) (LAMP)
EXIT
2
RED
3
ORANGE
BS
F1
PRE DATA
F2
F3
F4
CHARACTER
0
GRAY
1
BLUE
CLEAR
RETURN
Figure 11-36 AUX 131 Switch Lamp Color Select Screen
11-48
April 8, 2002
Kawasak
11.25.3 PUSH BUTTON SWITCH SETTING
OPTIONAL FUNCTIONS
Push button switches are set to activate signals. The switch is labeled with up to four lines of characters. Specify the desired color for signal status on and off. Assign the desired output signal to the switch in the SIGNAL NUMBER field. When the push button is pressed on the multi function panel or type 2 teach pendant, the specified signal is generated. Figure 11-37 shows an example of a push button switch.

POSITION 1 PUSH BUTTON LABEL 1 2 HOME 3 4 COLOR (ON) 2 (OFF) 1 SIGNAL NUMBER(SWITCH) 10
HOME
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-37 AUX 131 Push Button Parameters Screen
April 8, 2002
11-49
Kawasak
11.25.4 PUSH BUTTON WITH LAMP
OPTIONAL FUNCTIONS
A push button with a lamp is set similarly to a push button. Different signals are specified for the lamp and the switch. Figure 11-38 shows the parameters for a pallet remove switch.

POSITION 2 PUSH BUTTON WITH LAMP LABEL 1 2 PALLET 3 REMOVE 4 COLOR (ON) 2 (OFF) 1 SIGNAL NUMBER(SWITCH) 11 (LAMP) 1002
PALLET REMOVE
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-38 AUX 131 Push Button with Lamp Screen
11.25.5 TWO NOTCH SELECTOR SWITCH Auxiliary function 131 provides set for a two notch selector switch. Colors are specified for each position of the switch. Enter the appropriate signals numbers for each. Figure 11-39 shows the set up of an AUTO/MAN switch.

POSITION 32-NOTCH SELECTOR SWITCH
LABEL
MODE MANUAL AUTO
1 MANU AUTO 2 3 4 COLOR (LEFT) (UP) 6 (RIGHT) (DOWN) 2 SIGNAL No. (LEFT) (UP) 11 (RIGHT) (DOWN) 12 DISPLAY TYPE UP DOWN/ ROTARY
AUTO MANU
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-39 AUX 131 Two Notch Selector Switch Screen 11-50 April 8, 2002
Kawasak
11.25.6 THREE NOTCH SELECTOR SWITCH
OPTIONAL FUNCTIONS
Switches with three notches are set up similar to two notch switches. Colors and signals are set for all three positions. The three notch switch can also be set as a rotary switch, or a linear up and down switch. Figure 11-40 shows the set up for a mode selector switch.

POSITION 43-NOTCH SELECTOR SWITCH
LABEL
1 2 3 4
OFF LINE OFF AUTO
MODE OFF OFF-LINE AUTO
COLOR
(LEFT) (UP) 6 (MIDDLE) 2 (RIGHT)(DOWN) 1 SIGNAL No. (LEFT) (UP) 11 (MIDDLE) 12 (RIGHT)(DOWN) 13 DISPLAY TYPE UP DOWN/ ROTARY
OFF LINE OFF AUTO
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-40 AUX 131 Three Notch Switch Screen
11.25.7 PILOT LAMP Pilot lamps are set up to display the status of a specific signal. The color specified for ON indicates the activation of the signal specified. Figure 11-41 shows the set up for a pilot lamp.

POSITION 5 PILOT LAMP LABEL 1 2 3 4 COLOR (ON) (OFF) SIGNAL NUMBER(LAMP) ENABLE
ENABLE
6 1 1002
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-41 AUX 131 Pilot Lamp Screen April 8, 2002 11-51
Kawasak
11.25.8 DIGITAL SWITCH
OPTIONAL FUNCTIONS
A digital switch can be created to generate digital output signals. The outputs are based on the number displayed on the switch. The programmer can dictate the outputs by setting the number on the switch. The signals from the switch can be set as binary or decimal. Table 11-2 shows the parameters used to set a digital switch. Figure 11-42 shows the digital switch display screen.
Table 11-2 Digital Switch Input
Digital Switch Figures
Parameter Specifies the number of digits displayed This digital signal indicates which outputs are on or off. Digital input data can be directly entered with the numeric keys or the value increased by one each time the switch is pressed, it returns to the minimum value when the maximum value is exceeded. The range of the input data can be limited (YES) or not limited (NO). Specifies first number of the signal defined for a digital switch (Internal signal number or output signal number). Specifies the channel numbers of signals used as a digital switch. Outputs correspond to either a binary or decimal number. BCD: Decimal number BINARY: Binary Number Specify the maximum/minimum value which can be set.
Input Data
Limit Data Top Signal No. Number of Signals to Use Signal Type Upper Limit Lower Limit
11-52
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS

POSITION 7 DIGITAL SWITCH LABEL 1 WORK 2 KIND FIGURES(1~ 4) 4 INPUT DATA TEN KEYS/PUSH SWITCH LIMIT DATA YES/NO TOP SIGNAL NO. 8 NUMBER OF SIGNALS TO USE 16 SIGNAL TYPE BCD/BINARY UPPER LIMIT 9999 LOWER LIMIT 0
WORK KIND
0022
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-42 AUX 131 Digital Switch Screen
11.25.9 DIGITAL DISPLAY Set up of a digital display is similar to the digital switch in the previous section.

POSITION 8 DIGITAL DISPAY LABEL 1 PROGRAM 2 NUMBER FIGURES(1~ 4) 4 TOP SIGNAL NO. 1008 NUMBER OF SIGNALS TO USE 6 SIGNAL TYPE BCD/BINARY
PROGRAM No.
0022
F1
PREV.DATA
F2
F3
F4
CHARACTER
Figure 11-43 AUX 131 Digital Display Screen
April 8, 2002
11-53
Kawasak
11.25.10 TEXT WINDOW
OPTIONAL FUNCTIONS
A TEXT WINDOW is used in conjunction with an AS Language command to print a message in a designated area of the interface panel. Four text windows are available.
POSITION 1 TEXT WINDOW Window Number 1 Window Size 4 Default Back Ground Color 6
F1
PREV.DATA
F2
F3
F4
Figure 11-44 AUX 131 Text Window Parameters Screen
11.25.10.1 TEXT WINDOW PROCEDURE 1. Enter a number from 1-4 in the Window Number field. The window number corresponds to one of the four windows specified. Enter a number, 1-4, in the Window Size field according to the desired size of the window. The window size corresponds to the size of the display area for the message. An area up to 4 times the sizes of a standard I/F display area can be specified. Select the background color of the text window display. When this field is selected a color palette is displayed to specify the desired color. Enter the AS Language command IFPWPRINT in the program to display the text window message in the TEXT WINDOW. The format for the IFPWPRINT command is: IFPWPRINT window number (1 to 4), line number to display message (1 to 4), number of spaces from the left of the TEXT WINDOW the first character is displayed, the background color of the TEXT WINDOW = the message. Example: IFPWPRINT 1,1,2,6 = Part is not in place. 11-54 April 8, 2002
2.
3.
4.
Kawasak
11.25.11 SOFTWARE DEDICATED SIGNAL
OPTIONAL FUNCTIONS
The interface panel can be automatically displayed by using external input signals. External input signals can be set by DEFSIG INPUT command or Auxiliary 111. I/F panel, One page selection. I/F panel, Two page selection. There are two software dedicated signals. The interface panel changes to the pertinent page when the signal changes from OFF to ON at software dedicated signal.
April 8, 2002
11-55
Kawasak
11.25.12 I/F PANEL PROGRAMMED BY PC
OPTIONAL FUNCTIONS
The interface panel can also be programed from a personal computer. Specify switch type and position as follows when the file is loaded or is saved (xxxxxx is file name). LOAD xxxxxx. if when file with the data is loaded in memory. SAVE/if xxxxxx when saving to disk file. The following example shows set up of the interface panel using a personal computer. .INTER_PANEL 1,1, ,HOME, , ,1,2,1,0 2,2, PALLET,REMOVE, , ,2,3,2,2,0 3,3, AUTOMANU, , , ,3,4,3,4,0,-1 4,4, OFFLINE,OFF AUTO, , ,4,5,6,5,6,7,0,0 5,5, ENABLE, , , ,5,6,1 7,6, WORK, KIND,4,-1,0,8,8,0,999,0,0 8,7, PROGRAM, No.,4,8,8,0 11,3, MODE, MANUAL, AUTO, ,3,4,3,4,-1,-1 12,4, MODO, OFF, OFFLINE, AUTO,4,5,6,5,6,7,-1,0 15,6, , ,3,-1,0,8,8,0,999,0,0 16,7, , ,3,8,8,0 23,6, , ,2,-1,0,8,8,0,999,0,0 24,7, , ,2,8,8,0 31,6, , ,1,-1,0,8,8,0,999,0,0 32,7, , ,1,8,8,0 .END * Specify the data in the following order. The parameter of display position (1-64), type code (0-7), the detailed data (the same order as setting screen), and the selection item shows that the following is selected. 0 : The right side. -1 : The left side.
11-56
April 8, 2002
Kawasak
11.26 AUX 133 AS INSTRUCTION DEFINITION
OPTIONAL FUNCTIONS
AUX 133 allows the operator to assign program instructions to keys for repeated use during AS programming. The operator may define up to 32 variables, instructions, or commands and assign them to corresponding buttons (Figure 11-45).
AUX 133 AS INSTRUCTION DEFINITION
1 2 3 4 5 6 7 8
JMOVE LMOVE #pick place
9 10 11 12 13 14 15 16
F1
PRE DATA
F2
F3
F4
NEXT PG CHARACTER
PROGRAM
STEP
PC
SPEED 10% REPT. CONT
'97-03-18 17:30 RPS ON
pg01
TEACHING
STATUS
MENU
STEP CONT DRYRUN OFF
M-OFF HOLD TEACH
AS INSTRUCTION TEACHING
DEFINED INSTRUCTION BUTTONS
?JMOVE ?
CHARACTER
JMOVE
LMOVE
#pick
place
PROGRAM INPUT
,
SPACE
.
SHIFT
TEACH NEW
RECORD
Figure 11-45 AUX 133 AS Instruction Definition Screen
Instructions 17 through 32 are accessed by pressing the NEXT PG (F3) key. Character strings are defined with up to 8 characters. The character string is defined only when Record Accept is set by AUX 71 Record (PRGCHG) Inhibit. Press the F4 CHARACTER key to access the keyboard for definition string input or editing.
April 8, 2002
11-57
Kawasak
OPTIONAL FUNCTIONS
Once the instructions are defined, pressing the corresponding key inserts the instruction into the AS program as shown in the lower screen of figure 11-45. 11.27 AUX 135 ONLINE EDIT Block step programs can be edited using the multi function panel or type 2 teach pendant in the teach and repeat modes. Online program data includes auxiliary data (SPEED, ACCURACY, TIMER, TOOL, WORK, J/E, and COMMENT), clamps, guns and OX/WX signals. This online data can be edited using AUX 135 Online Edit. Figures 11-46 and 11-47 show the AUX 135 Online Edit display screens.
AUX 135 ONLINE EDIT
PROGRAM NAME
test
STEP NUMBER (0 : FIRST STEP)
10
F1
PROGRAM INPUT
F2
F3
F4
Figure 11-46 AUX 135 Online Edit Screen
11-58
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
AUX.135 ONLINE EDIT pg1

1 2 3 4 5 6 JOINT LINEAR CIR1 CIR2 FLIN FCIR1 9( 100.0%) 4( 50.0%) 4( 50.0%) 4( 50.0%) 9( 100.0%) 9( 100.0%) 1( 1.0) 2( 10.0) 3( 100.0) 3( 100.0) 1( 1.0) 1( 1.0) 0(0.0) 0(0.0) 0(0.0) 0(0.0) 1(0.1) 2(0.2) 1 1 1 1 2 2 0 0 0 0 0 0 ;START
JUMP
. (SET+)
(SET-)
BS
EXIT
RETURN
PRE PG
NEXT PG
SCREEN
SCREEN
AUX.135 ONLINE EDIT pg1
CHARACTER
PRE DATA
STEP SELECT
EXIT
RETURN
Figure 11-47 AUX 135 Online Edit Screen
April 8, 2002
11-59
Kawasak
OPTIONAL FUNCTIONS
With the S key activated, the operator can scroll to the next and previous pages as well as CLAMP DATA, OX/WX and other function screens. Select the desired screen, deactivate the S key and use the arrow keys to move the cursor to the item to change. Use the SET + and SET - keys to change the data.
PRE PG
NEXT PG
SCREEN
SCREEN
The screen display the PRE PG and NEXT PG buttons for programs that have more than seven steps. Use PRE PG and NEXT PG to scroll up and down the steps. The SCREEN buttons select the next screen containing data for other functions.
Pressing the SCREEN key takes you to the following screens: The clamp data (gun data) screen allows the operator to edit clamp signals for each individual step. Figure 11-48 shows a spot welding/handling application and a painting/ sealing application.
Figure 11-48 AUX 135 Clamp Data Screens
11-60
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
Use SET+ and SET- to program OX and WX signals on or off for various steps. The OX signals are edited from the next screen (Figure 11-49). From this screen each OX signal is programmed on or off at each individual step of the program. Scrolling to the next screen reveals OX signals 32 and higher.
AUX.135 ONLINE EDIT pg1 OX 01 05 10 15 1 2 3 4 5 6 7
20
25
30
:ON
SCREEN
SCREEN
Use the SCREEN keys to show more signals.
AUX.135 ONLINE EDIT pg1 OX 35 40 45 1 2 3 4 5 6 7
50
55
60
:ON
Figure 11-49 AUX 135 OX Edit Screen
Use the SCREEN keys to scroll to the WX Edit Screen (Figure 11-50). WX signals are edited the same as OX signals shown above. SET+ and SET- are used to change signal status from on to off.
April 8, 2002
11-61
Kawasak
OPTIONAL FUNCTIONS
AUX.135 ONLINE EDIT pg1 WX 01 05 10 15 1 2 3 4 5 6 7
20
25
30
:ON
SCREEN
SCREEN
Use the SCREEN keys to show more signals.
AUX.135 ONLINE EDIT pg1 WX 35 40 45 1 2 3 4 5 6 7
50
55
60
:ON
Figure 11-50 AUX 135 WX Edit Screen
11-62
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
The robot location can be edited and configured from the location edit screen. Use the SCREEN keys to scroll to the screen. This screen allows the operator to change the numeric joint angle value for each individual joint at each step (Figure 11-51). Use the arrow keys to scroll to the joint position to change and enter the desired numeric value with the number keys. Joint angle data cannot be changed if the online edit program is executing.
Figure 11-51 AUX 135 Joint Location Edit Screen
April 8, 2002
11-63
Kawasak
11.28 SLOGIC
OPTIONAL FUNCTIONS
Relay circuitry for the robot interface is reduced by replacing it with the Slogic software function. Slogic is similar to ladder logic, used with programmable controllers (table 113). Making signal assignments using Slogic is much easier than making changes on hard-wired systems. For hard-wired systems, changes are made by physically making connections. Using Slogic, changes are made by simply making changes to programs. Slogic program instructions are used to specify outputs, timers, and counters. Slogic program instructions are edited on the 1GA board (main CPU) via the multi function panel and then transferred to the 1FS (R I/O) board, which executes the Slogic program. The remote input/output (R I/O) function is performed by the optional 1FS board. The RI/O system provides Allen-Bradley (A-B) programmable logic controller (PLC) serial communication, weld control serial communication, and Slogic execution. The R I/O function provides the status of all signals, including A-B PLC and weld control serial signals. Internal Slogic signals can be displayed via the multi function panel. The R I/O system performs the following functions: A-B PLC serial communication is performed by the A-B node adapter chip (NAC). Robot controllers are daisy chained through the NAC, enabling communication with the line PLC system. A maximum of 128 I/O channels are available. Weld control serial communication is performed by the 1FS board serial I/O function, which is capable of controlling a maximum of four weld controllers. A maximum of 16 I/O channels are available for each weld controller. The Slogic function is similar to a PLC instruction which uses Slogic instructions for outputs, timers, and counters. The Slogic instructions are edited on the robot controller through the 1GA board (main CPU), and then transferred to the 1FS board for execution of Slogic programs.
11-64
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
Table 11-3 Slogic
April 8, 2002
11-65
Kawasak
OPTIONAL FUNCTIONS
The following is an example of the process used to edit the Slogic programs using the keyboard screen. Keyboard Screen SLOGIC Stop S Upload - Upload Slogic from the 1FS board to the 1GA board to edit the program SPG. Program SPG can now be edited.
$SS $SU $EDI SPG
1 SOUT 301 = 101 1? 2 SOUT 302 = 101 and 102 2? 3 SOUT 303 = 101 or 102 3? 4 SOUT 304 = (-101 and -102) or -103 4? 5 SOUT 305 = (101 or 103) and (102 or -104) 5? 6 STIM 2601 = 101, 5.0 6? 7 SOUT 306 = 2601 7? 8 SCNT 2701 = 101, 110, 102, 10 8? 9 SOUT 307 = 2701 9? 10?E Exit $SD S Download - Download the program from the 1GA board to the 1FS board to execute the program. Password 4989 (same for all controllers) $$SR SLOGIC Run Editing SLOGIC S STEP# I D O E The step number to be edited Insert lines before the current step. Delete the program step. Places the cursor on the current step for editing (overwrite) Exits from the editor to the monitor mode. Note: Output may be used only once.
11-66
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
11.29 REMOTE I/O AND SLOGIC SPECIFICATIONS The following are specifications for remote I/O and Slogic functions: Control method: Program size: Note: 1. Stored program (Slogic) Approximately 1,500 steps (max. 72,000 characters)
The following example Slogic instruction is considered two steps: SOUT XXXX=YYYY + 80 comment characters = 96 total characters
2.
The following example Slogic instruction is considered three steps:
SOUT XXXX=YYYY AND ZZZZ + 119 comment characters = 144 total characters Execution cycle time: 1-300 steps 301-900 steps 901-1500 steps 5ms 10ms 15ms
Number of parallel signals: Standard signals (one 1GW board): 32 I/O channels 24 VDC, 100mA
Optional signals:
64 I/O channels (one additional 1GW board) 96 I/O channels (two additional 1GW boards) 128 I/O channels (three additional 1GW boards)
Number of internal signals: Non-retentive relay Retentive relay Timer Counter Message display Slogic status 128 16 16 (range: 0.1 to 999.9 seconds) 16 (range: 1 to 9999 counts) 64 16
April 8, 2002
11-67
Kawasak
OPTIONAL FUNCTIONS
Robot CPU (1GA) Robot Output 1 ~ 256 Robot Input 1001 ~ 1256 Robot Internal 2001 ~ 2256
OX signals = Robot Output signals 1-64 WX signals = Robot Input signals 1001-1064
PLC Serial Input Allen-Bradley PLC
1001 ~ 1256
1 ~ 256
1501 ~ 1564
1FS Board
*SLOGIC Functions (Internal Signals)
1601 ~ 1632
Weld Serial Input Weld Controllers (maximum 8)
PLC Serial Output
501 ~ 564
601 ~ 632 Weld Serial Output
1301~1428 301~428
I/O Boards (1GW, maximum 4, optional) *SLOGIC Functions (Internal Signals) Relays: Non-Retentive Relays: Retentive Relays: Timers Relays: Counters SLOGIC Status Signals W/C #1 Not Connected W/C #2 Communication Error NAC Communication Error Battery Error W/C #2 Not Connected W/C #2 Communication Error Spare Message Display 2301 ~ 2428 2501 ~ 2516 2601 ~ 2616 2701 ~ 2716 2801 ~ 2816 2801 2802 2803 2804 2805 2806 2807 ~ 2816 2901 ~ 2964
An additional magnetic relay output "SRUN" signal is available. This signal indicates that SLOGIC is running. It does not have a signal number.
SLOGIC messages must be named $w2901 ~ $w2964. Refer to AS Language manual for steps to create string variables (e.g., $w2901 = "message"). Signal for Last Weld Current 2965
Figure 11-52 Robot Signal Numbers (1FS board) 11-68 April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
Robot CPU (1GA) Robot Output 1 ~ 256 Robot Input 1001 ~ 1256 Robot Internal 2001 ~ 2256
OX signals = Robot Output signals 1-64 WX signals = Robot Input signals 1001-1064
PLC Serial Input Mitsubishi PLC With CC Link
1001 ~ 1256
1 ~ 256
1501 ~ 1596 1701 ~ 1732
1HS Board
*SLOGIC Functions (Internal Signals)
1601 ~ 1664
Weld Serial Input Weld Controllers (maximum 4)
501 ~ 596 PLC 701 ~ 732 Serial Output
601 ~ 664 Weld Serial Output
1301~1428 301~428
I/O Boards (1GW, maximum 4, optional) *SLOGIC Functions (Internal Signals) Relays: Non-Retentive Relays: Retentive Relays: Timers Relays: Counters SLOGIC Status Signals W/C #1 Not Connected W/C #2 Communication Error NAC Communication Error Battery Error W/C #2 Not Connected W/C #2 Communication Error Spare Message Display 2301 ~ 2428 2501 ~ 2516 2601 ~ 2616 2701 ~ 2716 2801 ~ 2816 2801 2802 2803 2804 2805 2806 2807 ~ 2816 2901 ~ 2964
An additional magnetic relay output "SRUN" signal is available. This signal indicates that SLOGIC is running. It does not have a signal number.
SLOGIC messages must be named $w2901 ~ $w2964. Refer to AS Language manual for steps to create string variables (e.g., $w2901 = "message"). Signal for Last Weld Current 2965
Figure 11-53 Robot Signal Numbers (1HS Board) April 8, 2002 11-69
Kawasak
11.30 AUX 180 RI/O MONITOR
OPTIONAL FUNCTIONS
This optional function allows the operator to access functions regarding the remote I/O functions (Figure 11-54).
Figure 11-54 AUX 180 RI/O Monitor Screen
11-70
April 8, 2002
Kawasak
11.30.1 SIGNAL STATUS
OPTIONAL FUNCTIONS
The signal status screens, shown in figure 11-55, allow the operator to view the status of all remote I/O and robot signals. Figure 11-55 shows two of five signal status screens. Use the NEXT PG keys to scroll to the remaining screens
Figure 11-55 AUX 180 RI/O Signal Status Screens
April 8, 2002
11-71
Kawasak
11.30.2 TIMER AND COUNTER STATUS
OPTIONAL FUNCTIONS
The Timer and Counter Status function allows the operator to view the timer or counter values (Figure 11-56). The elapsed time or number of counts is also displayed. The first screen shows the status of timers and the second screen shows the status of counters. Navigate between the screens using the PRE PG and NEXT PG keys.
Figure 11-56 AUX 180 Timer and Counter Status Screens
11-72
April 8, 2002
Kawasak
11.30.3 SLOGIC MONITOR
OPTIONAL FUNCTIONS
The SLOGIC MONITOR screen (Figure 11-57) allows the operator to monitor output signals used by the Slogic program. It also displays the status of the signal. When this function is accessed, key in the desired output signal at the prompt and press the ENTER key on the multi function panel.
Figure 11-57 AUX 180 Slogic Monitor Screen
April 8, 2002
11-73
Kawasak
11.30.4 LAST WELD DATA
OPTIONAL FUNCTIONS
The LAST WELD DATA screen displays the weld sequence parameters. Use the NEXT PG and PRE PG keys to scroll between the three available screens. Figure 11-58 shows two of the three available screens.
Figure 11-58 AUX 180 Last Weld Data Screens
11-74
April 8, 2002
Kawasak
11.30.5 SLOGIC STATUS
OPTIONAL FUNCTIONS
The SLOGIC STATUS screen allows the operator to view the status of the Slogic program (Figure 11-59). It displays the status of Slogic programs as active (RUN) or inactive (STOP). It also indicates how many steps are used in the Slogic program, the number of bytes free in the memory, and the date and time the Slogic program was downloaded.
Figure 11-59 AUX 180 Slogic Status Screen
11.31 AUX 181 RI/O PLC (NAC) SETTING AUX 181 allows the operator to view and set parameters for the PLC Node Adapter Chip (NAC) settings (Figure 11-60).
Figure 11-60 AUX 181 RI/O PLC(NAC) Setting Screen
April 8, 2002
11-75
Kawasak
11.32 AUX 182 RI/O WELD CONTROL
OPTIONAL FUNCTIONS
AUX 182 allows the operator to view information about the weld control settings. The operator can select the number of weld controllers that are used for the application. Changes to other options cannot be made, it is used only for displaying the current settings.
Figure 11-61 AUX 182 RI/O Weld Control Setting Screen
11-76
April 8, 2002
Kawasak
11.33 AUX 183 RI/O SLOGIC CONTROL
OPTIONAL FUNCTIONS
The RI/O SLOGIC CONTROL screen allows the operator to control the Slogic program or function. The operator can activate (run) or deactivate (stop) the Slogic program by selecting SLOGIC RUN or SLOGIC STOP respectively. To edit the Slogic program: Select SLOGIC STOP to deactivate the Slogic program. Load the Slogic program into the 1GA board memory by selecting SLOGIC UPLOAD. Edit the Slogic program as needed using the keyboard screen (see section 11.28). Select SLOGIC DOWNLOAD to load the edited Slogic program to the 1FS board memory. Enter the password when prompted (see section 11.28). Select SLOGIC RUN to activate the Slogic program.
Slogic programs can also be started and stopped from the keyboard screen using AS Language commands (see section 11.28). Figure 11-62 shows the Slogic Control display screen.
AUX.183 RI/O SLOGIC CONTROL

1 SLOGIC RUN 2 SLOGIC STOP 3 SLOGIC DOWNLOAD 4 SLOGIC UPLOAD (SRUN) (SSTOP) (SDOWNLOAD) (SUPLOAD)
FUNCTION NUMBER:
F1
F2
F3
F4
Figure 11-62 AUX 183 Slogic Control Screen
April 8, 2002
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11.34 AUX 184 RI/O SLOGIC FORCED OUTPUT
OPTIONAL FUNCTIONS
AUX 184 allows the operator to force outputs that are used by the RI/O system. This function cannot be used when Slogic is in the active (run) state.
AUX.184 RI/O SLOGIC FORCED OUTPUT
SIGNAL NUMBER
F1
F2
F3
F4
Figure 11-63 AUX 184 Slogic Forced Output Screen
11-78
April 8, 2002
Kawasak
11.35 RANDOM PROGRAM SELECTION (RPS)
OPTIONAL FUNCTIONS
Random program selection allows the operator to select robot motion programs through a programmable logic controller (PLC). The following commands, signals, and procedures are used to set up and operate the RPS function. 11.35.1 RPS COMMANDS JUMP Is used to jump to another program and return to the step following the jump command based on RPS signal states. Is used to call another program, at the end of a program, based on RPS signal states. If the RPS signals are not changed, the same program repeats.
END
11.35.2 RPS SIGNALS RPS_ON RPS_ST Is used to activate the RPS function by a PLC output signal. Is used by the PLC to monitor the RPS function status by a robot controller output signal. Is used to allow a jump to another program and return to the step following the jump command after the jump program is completed. JUMP ON is a PLC output signal. The RPS function must be active and the jump signal in the ON state. The jump program is determined by the state of the RPS program selection signals. JUMP_OFF Is used to disable the jump function. The END command is executed independent of JUMP ON/OFF signals. JUMP OFF is a PLC output signal. JUMP_ST Is used by the PLC to monitor the JUMP function status by a robot controller output signal. Is a binary or binary coded decimal signal used by the controller to determine program selection. The RPS code signals are PLC output signals. April 8, 2002 11-79
JUMP_ON
RPS code
Kawasak
11.35.3 RPS PROCEDURE 1.
OPTIONAL FUNCTIONS
Programs are named pg0 pgxx and must contain END commands as the last step. JUMP commands are optional. I/O signals are set in AUX 111. See figure 11-64 for example of signal settings.
2.
Figure 11-64 AUX 111 RPS Signals Example
3.
Signals selected in AUX 111 must be hard wired with a 1GW board (discrete I/O) or programed through the Slogic program with a 1FS board. An example Slogic program, to use the signals selected above, is shown in figure 11-65.
1 SOUT 1010 = 1307 1? 2 SOUT 1011 = 1308 2? 3 SOUT 1012 = 1301 3? 4 SOUT 1013 = 1302 4? 5 SOUT 1014 = 1303 5? 6 SOUT 1015 = 1304 6? 7 SOUT 1016 = 1305 7? 8 SOUT 301 = 15 8? 9 SOUT 302 = 16 9?
Figure 11-65 RPS Slogic Program Example 11-80 April 8, 2002
Kawasak
4.
OPTIONAL FUNCTIONS
Set the RPS system switch in AUX 75 to ON and press RETURN (Figure 11-66). For the RPS switch to remain ON, RPS signals in AUX 111 must be entered and accepted.
Figure 11-66 AUX 75 RPS System Switch Screen
5.
From the STATUS screen select REPEAT CONDITION and RPS ENABLE (Figure 11-67).
Figure 11-67 RPS Enable
April 8, 2002
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11.35.4 RPS OPERATION
OPTIONAL FUNCTIONS
For more information on the RPS function refer to the C Series Controller I/O Interface Manual. RPS program names are assigned binary values using a maximum of sixteen bits (Tables 11-4 and 11-5).
Table 11-4 RPS Codes Table

MSB PROGRAM pg0 pg1 pg2 pg3
. . . .
RPS CODE SIGNALS RPS8 (1016) OFF OFF OFF OFF RPS4 (1015) OFF OFF OFF OFF RPS2 (1014) OFF OFF ON ON
LSB RPS1 (1013) OFF ON OFF ON
RPS64 RPS32 RPS16 (1019) (1018) (1017) OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
pg15 pg16
. . . .
OFF OFF
OFF OFF
OFF ON
ON OFF
ON OFF
ON OFF
ON OFF
pg99
ON
ON
OFF
OFF
OFF
ON
ON
7-Bit Binary RPS Code Examples
11-82
April 8, 2002
Kawasak
OPTIONAL FUNCTIONS
Table 11-5 RPS Binary Coded Decimal (BCD) Codes Table

MSB PROGRAM pg0 pg1 pg2 pg3
. . . .
RPS CODE SIGNALS RPS4 (1019) OFF OFF OFF OFF RPS2 (1018) OFF OFF OFF OFF RPS1 (1017) OFF OFF OFF OFF RPS8 (1016) OFF OFF OFF OFF RPS4 (1015) OFF OFF OFF OFF RPS2 (1014) OFF OFF ON ON
LSB RPS1 (1013) OFF ON OFF ON
RPS8 (1020) OFF OFF OFF OFF
pg15 pg16
. . . .
OFF OFF
OFF OFF
OFF OFF
ON ON
OFF OFF
ON ON
OFF ON
ON OFF
pg99
ON
OFF
OFF
ON
ON
OFF
OFF
ON
8-Bit Binary Coded Decimal RPS Code Examples
If BCD is selected, four bits allows up to nine programs, five bits allows up to nineteen programs, and six bits allows up to thirty nine programs (sixteen bits maximum). If no RPS signals are present and RPS is enabled, the controller is in a wait condition until RPS signals are received. If JUMP ON and JUMP OFF signals are received at the same time an error occurs.
April 8, 2002
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11.36 AUX 197 PASSWORD SET
OPTIONAL FUNCTIONS
AUX 197 is used to set a password level for AUX functions. The password corresponds to the level entered for each auxiliary function in AUX 198. The password level entered corresponds to which auxiliary functions are displayed in the function screen. Functions assigned to levels 2 and 3 do not appear in the function screen when a password level 1 is entered.
Figure 11-68 AUX 197 Password Level Screen
11-84
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Kawasak
11.37 AUX 198 AUXILIARY FUNCTION SELECT
OPTIONAL FUNCTIONS
Auxiliary functions can be set to display or be hidden from the auxiliary function menu. By setting password levels for functions, functions are only displayed in the menu when the password level is set to the corresponding level or higher. Auxiliary functions assigned levels 2 and 3 are not displayed in the menu when the password level is 1.
Figure 11-69 AUX 198 Auxiliary Function Select Screen
April 8, 2002
11-85
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11.38 DIRECT SPEED
OPTIONAL FUNCTIONS
The optional Direct Speed function allows the operator to select the absolute speed for joint or linear moves in seconds or millimeters per second respectively. The function is accessible to the operator during the teach mode of operation for the current program. Use the following procedure to set direct speed. 1. Select the interpolation for the current step of the program from the block teaching screen. Select speed 10 from the teach data speed key. Press the teach data speed and the AUX SET and DISP keys simultaneously. The Direct Speed screen is displayed as shown in figure 11-70.
2.
8
DIRECT SPEED
INTERP. SPEED
9 7 5 3 1
RETURN
6 4 2 0
EXIT
BS
Figure 11-70 Direct Speed Display Screen
3.
The INTERP. and SPEED keys, in the upper left corner of the screen, display the interpolation selected from the block teaching screen and the speed selected by the operator from the numeric keypad. Press the RETURN key to complete the procedure and return to the block teaching screen.
4.
11-86
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11.39 MONITOR SCREEN GRAPH
OPTIONAL FUNCTIONS
The monitor screen graph for input, output, and internal signals is an optional function that, when enabled, allows the operator to view a graph of the selected signal type. The accessibility of this function is shown in figure 11-71 and 11-72. Figure 11-72 specifically shows the enabled graph screen.
Figure 11-71 Monitor Screen
April 8, 2002
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OPTIONAL FUNCTIONS
Pressing the graph button displays the first 16 signals of the current signal screen. To view the next 16 signals of the selected 32, press the GRAPH button again. To stop and restart the graph update, press GRAPH STOP/GRAPH START. A vertical line is placed at the point where the graph starts. GRAPH EXIT returns to the previous monitor display.
MONITOR (OUTPUT SIGNAL) 1 OX1 2 OX2 3 OX3 4 OX4 5 OX5 6 OX6 7 OX7 8 OX8 9 OX9 17 WC1-WS1 18 WC1-WS2 19 WC1-WS4 20 WC1-WS8 21 OX21~ 22 CLAMP1_ON 23 OX23 24 CLAMP2_ON 25 OX25 26 OX26 27 HOME 28 TEACH_MODE 29 CYCLE_START 30 AUTOMATIC 31 ERROR 32 MOTOR_ON
10 OX10 11 OX11 12 OX12 12 OX13 13 OX13 14 OX14 15 OX15
INPUT
INTERNAL
NEXT PG
GRAPH
GRAPH EXIT
GRAPH
MONITOR (OUTPUT SIGNAL) OX 1 OX 2 OX 3 OX 4 OX 5 OX 6 OX 7 OX 8 OX 9 OX 10 OX 11 OX 12 OX 13 OX 14 OX 15 OX 16
INPUT
INTERNAL
PREV.PG
GRAPH
GRAPH STOP
GRAPH EXIT
GRAPH START
Figure 11-72 Monitor Screen and Graph
11-88
April 8, 2002
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APPENDIX
A.0 APPENDIX ........................................................................................................... A-2 A.1 Setting of Tool Dimensions ................................................................................... A-2 A.2 Programming Sheets ............................................................................................ A-5
April 8, 2002
A-1
Kawasak
APPENDIX A.0 APPENDIX A.1 SETTING OF TOOL DIMENSIONS
AUX 48 Tool Dimensions, shown in figure A-1, allows the operator to set and store tool dimensions and coordinate system orientation parameters, for one to nine different end effectors. Changes in the X, Y, and Z directions are measured in millimeters. The range is from 10,000 mm to +10,000 mm, and is measured in tenths of a millimeter (0.1 mm). Changes in the O, A, and T tool coordinate rotation angles are measured in degrees. The range is from 180 to +180, and is measured in tenths of a degree (0.1).
AUX 48 TOOL DIMENSIONS
TOOL 1 X DIRECTION Y DIRECTION Z DIRECTION O ROTATION A ROTATION T ROTATION WEIGHT OF LOAD X POSITION OF LOAD Y POSITION OF LOAD Z POSITION OF LOAD F1 F2 F3
PRE DATA
0.0mm 0.0mm 0.0mm 0.0deg 0.0deg 0.0deg 120.0kg 0.0mm 0.0mm 0.0mm F4
NEXT PG
Figure A-1 AUX 48 Tool Dimensions Screen
A-2
April 8, 2002
Kawasak
APPENDIX
The base and tool coordinate systems shown in figure A-2 show the standard orientation and origin of each coordinate system. The tool coordinate system has been rotated, through system software, from the base coordinate orientation by using the O, A, and T angles of +90, +90, and 90 respectively. For this reason, the robot location is shown as having O, A, and T angles of +90, +90, and 90 when the wrist is in a straight, or zero position, and the tool dimension is set with O, A, and T angles of 0, 0, and 0. The tool coordinate system can be rotated into other orientations by defining the proper O, A, and T angles. Typically this is done so that the "Z" tool coordinate axis is aligned in the direction of the tool.
X Y Tool Coordinate System X, Y, Z, O, A, T = 0, 0, 0, 0, 0, 0
Y Base Coordinate System X, Y, Z, O, A, T = 0, 0, 0, 0, 0, 0
Figure A-2 Robot Coordinate Systems
April 8, 2002
A-3
Kawasak
APPENDIX
Figure A-3 shows the rotation of the tool coordinate system in its standard orientation from the base coordinate system orientation, with the values O = +90, A = +90, and T = 90. This standard orientation is displayed as O = 0, A = 0, and T = 0 on the tool dimension setup screens (AUX 48). To properly specify the OAT angles, the tool coordinate system axes must be rotated in the correct order, beginning with the O angle, then the A angle, and finally the T angle. O Turning angle around the Z-axis A Turning angle around the Y-axis after O has been specified T Turning angle around the Z-axis after O and A have been specified
Defining O=90 Z
Defining A=90 Z Y
Defining T=-90
X Z
X X O - Defined Z Y Y A - Defined T - Defined
X X Y
Figure A-3 Orientation of XYZ and OAT
A-4
April 8, 2002
Kawasak
APPENDIX A.2 PROGRAMMING SHEETS
The following pages contain examples of painting program, programming sheets. Programming sheets are aids used when programs are written and to track changes to production programs. They are particularly helpful in tracking input and output signal numbers and their assigned functions.
April 8, 2002
A-5
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APPENDIX
Step Point
Command/Instruction
A-6
April 8, 2002
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APPENDIX
Step Point
Command/Instruction
April 8, 2002
A-7
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GLOSSARY
GLOSSARY ................................................................................................................ G-2
April 8, 2002
G-1
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GLOSSARY
This glossary contains definitions of terms used by operators, programmers, and maintenance personnel who work with Kawasaki robots. The definitions are listed in alphabetical order.
A
ACCELERATE To speed up a process. ACCURACY A measure of the difference between the commanded robot arm position and the actual position. Also identifies how well an indicated value conforms to a true value (i.e., an actual or accepted standard value). ACRONYM A word formed from the initial letters of words in a name or phrase. For example, ASCII is an acronym for American Standard Code for Information Interchange. ADDRESS A number that identifies a specific location in the computers or processors memory. Means of identifying a location or data in a control system. ADDRESSING Computer operations store data in specific memory locations or addresses. The largest memory location determines the amount of data that can be stored. The larger the number, the larger the possible program. AIR CUT Moving a weld gun into position but without generating an arc. ALGORITHM A finite set of well-defined rules or procedures for solving a problem step-by-step. ALPHANUMERIC Pertaining to a set of symbols that contain both letters and numbers, either individually or in combination. AMBIENT TEMPERATURE The temperature of air or liquid that surrounds a device. AMPERE (AMP) A unit of electrical current flow that is equivalent to one (1) coulomb per second. One (1) volt across one (1) ohm of resistance causes a current flow that is equivalent to one (1) amp. April 8, 2002
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Kawasak
GLOSSARY
ANALOG A continuously changing electrical voltage signal. In robot systems, the magnitude or value of the signal represents commanded robot axis motion. ANALOG DATA Information that is represented by a characteristic of the value or magnitude of an electrical signal, such as the amplitude, phase, or frequency of the voltage, the amplitude or duration of a pulse, the angular position of a shaft, or the pressure of a fluid number. ANTI-FRICTION BEARING A rolling element which is used to support a rotating shaft. ARC SENSOR A sensor that detects weld lines utilizing arc characteristics. ARGUMENT A value applied to a procedure; data used by a function or other command. For instance, in the AS command JMOVE flange, 2. The variable, flange, and the clamp number 2 are the arguments of the function JMOVE. ARRAY An ordered set of addresses or their values. Elements of an array can be referenced individually or collectively. Array elements all have the same type of data, for instance, integer or character, and are usually presented in rows and columns. ARTICULATED To join together permanently or semi-permanently by means of a pivot connection for operating separate segments as a unit. ARTICULATED ROBOT A robot arm which contains at least two consecutive revolute joints, acting around parallel axes, resembling human arm motion. The work envelope is formed by partial cylinders or spheres. The two basic types of articulated robots, vertical and horizontal, are sometimes called anthropomorphic because of the resemblance to the motions of the human arm. ASCII An acronym for American Standard Code for Information Interchange. This standard 8-bit code is used by many devices, such as keyboards and printers. AS LANGUAGE Kawasaki robot language used to communicate commands and instructions from a keyboard to the CPU. G-3
April 8, 2002
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GLOSSARY
ASSIGNMENT An instruction used to express a sequence of operations, or used to assign operands to specified variables, or symbols, or both. ASYNCHRONOUS A means of data communication where the data is sent a character at a time preceded by a start bit and followed by a stop bit. No direct timing signal links the transmitter and receiver. AUXILIARY DATA Information about a point, other than the positional data, such as speed, accuracy, weld schedule and clamp condition. AXIS A straight line about which sections of the mechanical unit rotate (e.g., joints JT1, JT2, JT3 etc.).
B
BACKLASH The clearance, slack, or play between adjacent gears, or the jar or reaction often caused by such clearance when the parts are suddenly put in action or are in irregular action. BASE COORDINATE A fixed coordinate system having an origin at the intersection of the X, Y, and Z axes. BAUD RATE Determines the number of bits per second (bps) or characters transmitted between devices. BCD An abbreviation for binary coded decimal. The BCD 8-4-2-1 code expresses each decimal digit by its own 4-bit binary equivalent. The 8-4-2-1 code is identical to binary through the decimal number 9. Above the decimal number 9 each decimal digit is represented by its own 4-bit binary equivalent. For example, using the 8-4-21 binary-coded system, the number 10 is interpreted as 0001 0000. BINARY CODE A system in which characters are represented by a group of binary digits, that have the value of either 0 or 1, true or false, on or off.
G-4
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GLOSSARY
BIT Acronym for binary digit, having one of two values: 0 or 1. BOOT The method by which computers are brought from a non-operating to an operating state. During this sequence, the computer memory is usually reset. This is often performed to restart the computer after a crash, to bring it on-line. BUFFER A temporary memory storage area in a computer or electronic device. BUG A problem in a software or hardware element of a system. BUS The primary communication path in the controller along which internal signals are sent among processors and memories.
C
CABLE CARRIER A device which carries cables and hoses (including power sources) from a stationary location to a linear moving device. CARTESIAN COORDINATE A location in space defined by three axes at right angles to each other, commonly labeled X, Y, Z. cc Abbreviation for cubic centimeter. CELL A manufacturing unit consisting of two or more work stations or machines, and the material transport mechanisms and storage buffers that interconnect them. CENTER OF GRAVITY The point at which the entire weight of a body may be considered as concentrated, so that if supported at this point the body would remain in equilibrium in any position. CHARACTER A term that describes all numbers, letters, and other symbols typically found on a computer keyboard.
April 8, 2002
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GLOSSARY
CHECK MODE A procedure that allows the user to check positional data and auxiliary data while in the teach mode with the Kawasaki robot . This procedure is in many ways analogous to reverse point and forward point operations in other robot models. CHECKSUM A method by which the contents of data or a transmission are verified to be accurate. This method sums all the characters and translates them into a number which is appended to the data. CHEMICAL ANCHOR A threaded rod installed in a structure (e.g., a concrete floor) and secured by epoxy, for the purpose of securing hardware. CIRCULAR INTERPOLATION A path taken by the robot that connects at least three points with an arching motion. The CPU will calculate a path that places the taught points on a section of a circle. CLOSED-LOOP SYSTEM A system in which a command value is output and a feedback value is returned. The resulting error, the difference between the command and the feedback, is used to correct the signal. In a robot system, the command signal is output by the controller, causing the robot arm to move, and the feedback signal is produced by the encoder, which reads the current position of the arm. CODE A set of rules for expressing information in a language that is understood and processed by a control system. Also, a term for instructions in a computer program. Code performs a process, and data is the information that is processed.
COMMAND An analog signal, or group of signals or pulses, which cause a specified function to be performed. An instruction or request in a computer program that performs a particular action. Commands that are needed to run the operating system are called a command language. COMMENT Optional, non-executing remarks added to a program to explain various aspects of the program.
G-6
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GLOSSARY
COMPILER A system task that translates a program written in source code, into binary code that can be understood by the processor. COMPOUND TRANSFORMATION A location in the Cartesian coordinate system that is defined relative to another Cartesian coordinate location. CONTIGUOUS FILE A file that is stored in continuously adjacent areas of memory, in contrast to a file which is scattered to make more efficient use of disk space. CONTINUOUS PATH CONTROL A type of robot control in which the robot moves according to a replay of closely spaced points programmed on a constant time base during teaching. CONTROL ERROR CODE A code which identifies system problems whenever an alarm condition occurs. CONTROLLED AXIS A robot axis that is operated by electrical or hydraulic power. CONTROLLER An electronic device, with processing capabilities and software, which controls the robot actions and functions. CONVEYER TRACKING Used to make the robot follow a part on a conveyor, without the use of a traverse axis. COORDINATE A set of numbers that locate a point in space. CPU Abbreviation for central processing unit. A collection of hardware in a computer which performs all calculations, handles I/O, and executes programmed tasks. CRASH A situation where the computer fails to operate, due to a software or hardware problem. CRT Abbreviation for cathode ray tube. A CRT is a charge storage tube in which the information is written by means of the cathode ray beam. G-7
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GLOSSARY
CURRENT LOOP A circuit in which a portion of the output is returned to modify the control circuit output. This circuit may be used as a limiting device, for safety protection. CURSOR A pointer or indicator on a computer screen, that identifies the current position on the screen. CYCLE A complete path of projectory performed by the robot for a specific application. CYCLOIDAL DRIVE A mechanical gear reduction unit that reduces the speed of the input and increases the torque capacity. The cycloidal unit consists of an internal arrangement of discs and pins that are driven by an eccentric drive cam. This type of gear reduction offers low gear train backlash and the capability to achieve high reduction ratios from a single contained unit.
D
DATA A term given to information, instructions, words or symbols that are usually transmitted, processed, or stored as a group. DETENT A part of a mechanism that locks or unlocks a movement. DISCONNECT A switch that isolates a circuit or one or more pieces of electrical apparatus after the current has been interrupted by other means. DEVIATION ERROR In all mechanical devices, the actual position of the mechanical unit will lag behind the electrical command of the controller. An allowable limit is assigned for this difference. However, if the controller detects a condition where the difference between this mechanical value and the desired electrical position is larger than the established value limit, the robot controller will generate a deviation error. This error is sometimes referred to as a FOLLOWING ERROR in the robot industry. DEBUG The process by which an operators program is checked for mistakes and then corrected.
G-8
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GLOSSARY
DECIMAL NUMBER Numbers in the base-10 numbering system, which uses the numerals 0 - 9. DEDICATED A term used to describe a system resource, such as an I/O device or terminal, which is used for only one purpose, or assigned a single function. DEDICATED SIGNAL A term used to describe a signal which is used for only one purpose, or assigned a single function. Both inputs and outputs can be dedicated. DEFAULT A value or operation that is automatically entered by the system, if the operator does not specify one. Typically, the default is the standard or expected response. DELETE A command which will eliminate unwanted data. DELIMITER A character which separates a group of items or a character string, from other groups, or which terminates a task. DEVICE Any peripheral hardware connected to the processor and capable of receiving, sorting, or transmitting data. DIAGNOSTICS Function performed by the processor to identify and check for error conditions in the robot arm and peripheral devices. DIP SWITCH DIP is an acronym for dual in-line package. A set of small switches on circuit boards that can be set for different configurations. DIRECTORY A logical structure that organizes a group of similar files. DISK A high-speed, random-access memory device. DISK-BASED SYSTEM System in which programs and files are stored on the hard disk and are read into memory when requested by the user.
April 8, 2002
G-9
Kawasak
GLOSSARY
DISK PACK A device which is used to store additional data in a computer system, and is usually removable.
E
ECHO Process in which characters that are typed on a keyboard are also displayed on the screen or are sent to the printer. EDITOR An aid for entering information into the computer system and modifying existing text. EMERGENCY STOP (E-Stop) An immediate stop of robot motion, selected by the operator with a switch. ENCODER An electromechanical device that is connected to a shaft to produce a series of pulses that indicate the position of the shaft. EPROM Acronym for erasable programmable read-only memory. The contents of this memory (computer chip) are retained, even when power to the system is turned off. Usually stores executive programs and critical system variables. ERROR LOG A report which contains a sequential list of system error messages. ERROR MESSAGE Messages displayed on the plasma screen of the robot controller, when the action requested by the operator could not be completed. Error messages can occur when components malfunction or if an incorrect command is typed by the operator. EXPRESSION A combination of real-valued variables and functions, and mathematical and logical operators. When evaluated, this combination yields a numeric value.
F
FEEDBACK The transmission of a signal from a measuring device (e.g., encoder, transducer) to the device which issued the command signal within a closed-loop system. See CLOSED-LOOP SYSTEM. April 8, 2002
G-10
Kawasak
GLOSSARY
FIELD SIGNALS All electrical signals that exit or enter an electrical panel. FILE A set of related records or data elements, which are stored using one name and are arranged in a structure that can be used by a program. FILESPEC Includes the name, creation date and size of the specified file. FIXED DISK An electromagnetic mass storage device which is not removable. Hard disks have much higher storage capacity than floppy disks. FLOPPY DISK An electromagnetic mass storage device which can be removed and exchanged. FORM FEED Process which causes a printer to advance the paper to the top of the next page. FUNCTION A formula or routine for evaluating an expression.
G
GAIN A proportional increase in power or signal value relative to a control signal. The ratios of voltage, power, or current as related to a reference or control signal input. GLOBAL Refers to a function or process that affects the entire system or file. GRAY CODE A positional binary number notation in which any two numbers whose difference is one are represented by expressions that are the same except in one place or column and differ by only one unit in that place or column.
H
HALF-DUPLEX COMMUNICATION Data transmission between two devices, where the signal is sent in only one direction at a time.
April 8, 2002
G-11
Kawasak
GLOSSARY
HANDSHAKING PROTOCOL Communication rules used for data transmissions between devices. Each device must recognize the same protocol in order to communicate. HANG A term which refers to the state of a computer system that seems to be inoperative when processing should be taking place. HARDSTOP A mechanical constraint or limit on motion. HARDWARE Physical equipment and devices such as computer hard disk, cables, printer, etc. HAZARDOUS SIDE The unsafe side of a component or panel, such as the inside of the control panel when power is applied and functions are being performed. HOLD When an external or an internal input is available for a hold condition, the robot will stop its motion and servo drive power will be removed from the robot. When an external hold reset is performed, the servo drive power will be energized. HOME POSITION Refers to the starting or resting position of the robot. HYBRID ENCODER On the Kawasaki robot a hybrid encoder is used to generate positional data, and is composed of an incremental encoder that generates incremental pulses, and an absolute encoder that generates gray code binary data.
I
ID Abbreviation for Identification. INCHING A value that is used during the jogging process that allows the user to position the robot in small minute increments.
G-12
April 8, 2002
Kawasak
GLOSSARY
INCREMENTAL CODE A digital closed loop feedback code that provides digital feedback pulses to the robot controller for the purpose of providing positional information. These incremental pulses are generated by an encoder through the use of an optical disk with alternating opaque and transparent bars or lines around the periphery of the disk. On one side of the disk a light source is mounted, and on the opposite side a phototransistor When the disk rotates, the phototransistor is alternately forced into saturation and cutoff, producing the digital signal. INPUT Transmission of an external signal into a control system. INTEGRATED CIRCUIT (IC) A combination of interconnected circuit elements which are within a continuous substrate. INTERACTIVE SYSTEM System where the user and the operating system communicate directly; the user through the keyboard, and the operating system via the display screen. INTERLOCK An arrangement whereby the operation of one part or mechanism automatically brings about or prevents the operation of another. INTERPRETER A program that changes English-like commands into machine language. An interpreter translates and executes one command at a time. INSTRUCTIONS Discrete steps in a computer program that are commands or statements that tell a computer to do something or identify data. INTEGER A whole number, a number without a fractional part such as 7, -318, or 19. INTERFACE The circuitry that fits between a system and a peripheral device to provide compatible coupling between the two pieces of equipment. INTERPOLATION The mathematical process that the CPU utilizes to plot a path for the robot to travel from one position to another. A mathematical process that evaluates a number of dependent and independent variables for the purpose of comparison and prediction.
April 8, 2002
G-13
Kawasak
GLOSSARY
INTERRUPT An external signal that halts program execution so that the computer can service the needs of some peripheral device or subsystem. INTRINSIC SAFETY BARRIER (ISB) An electronic device used in robot controllers to restrict current and voltage to a safe level. INVERTER A circuit which switches a positive signal to a negative signal, and vice versa. I/O Abbreviation for Input/Output. The interconnections through which the computer and its peripheral devices communicate. IPM Abbreviation for Intelligent Power Module
J
JOG A term used to describe the process in which the user moves the mechanical unit through interaction with the robot controller and the teach pendant. Sometimes referred to as slewing. JOINT 1. A term used to describe the individual axes of a robot. 2. A term used to describe the jogging process in which the robot is jogged one axis at a time. JOINT MOVE A mode of operation in which the robot moves from one point to the next with an arching path. All axes motors (required for the move) begin and end their rotation at the same time. The tool center point does not follow a linear path to reach the taught position.
L
LABEL An identifier for a program command line. To identify an instruction, memory location, or part of a program.
G-14
April 8, 2002
Kawasak
GLOSSARY
LAN An acronym for local area network. A group of computer terminals interconnected by cables, allowing communication of information via the network. LCD Abbreviation for liquid crystal display. This type of display is made of material whose reflectance or transmittance of light changes when an electric field is applied. LIMIT SWITCH An electrical switch positioned to be switched when a motion limit occurs, thereby deactivating the actuator that caused the motion. LINEAR MOVE An operation where the rate and direction of relative movement of the robot arm are continuously under computer control. LINE PRINTER A high-speed output device that prints a line at a time. LINE TURN-AROUND Changing the source of transmission in half-duplex communications. LOGICAL OPERATION Any of several operations that manipulate information according to the rules of logic (e.g., AND, OR, NOT, and exclusive OR). LM Abbreviation for linear motion. LOAD The weight applied to the end of the robot arm. LOCKOUT Serving to prevent operation of a device or part of it. LSB Abbreviation for least significant bit.
April 8, 2002
G-15
Kawasak
GLOSSARY
M
MANIPULATOR Another term for the mechanical portion of the robot system. MACHINE LANGUAGE A low-level computer language, usually written in binary code. MASS-STORAGE DEVICE An input/output device that retains data input to it. Examples include: hard disk drives, magnetic tapes, floppy diskettes, and disk packs. MECHANICAL UNIT robot (excluding controller) MEMORY An area of the computer which stores data, either permanently or temporarily. When a program is requested, it is first loaded into memory so it can be accessed quickly by the processor. MHz Abbreviation for megahertz. One million cycles per second. MIRROR IMAGE A process which converts the positive and negative values of a taught path from a right-handed robot to a left-handed robot, or vice versa. The actions of the opposing robots are then coordinated and synchronized. mm Abbreviation for millimeter. MNEMONIC A term used to help the operator remember a large string of words or commands. MODEM A signal conversion device that modulates and demodulates data into an audio signal for transmission. MOMENT OF INERTIA Used to calculate end of arm tooling and handling weights. The sum of the products formed by multiplying the mass of the load by the square of the distance from the tool mounting flange.
G-16
April 8, 2002
Kawasak
GLOSSARY
MONITOR PROGRAM An administrative computer program that oversees operation of a system. The AS monitor accepts user input and initiates the appropriate response, follows instructions from user programs to direct the robot, and performs the computations necessary to control the robot. MSB Abbreviation for most significant bit. MSEC Abbreviation for millisecond (0.001 seconds).
N
NOISE Any unwanted disturbance within a dynamic, mechanical, or electrical system. NULLED An electrical zero state.
O
OCTAL NUMBER A numeral in the base-8 numbering system, which uses the numerals 0 - 7. OFF LINE A state in which communications between two devices cannot occur (e.g., between a printer and a computer, if the printer is off line). ON LINE A state in which communication between two devices can occur. OPERATING SYSTEM A set of system tasks and commands that are entered by the operator and interpreted and performed by the system. OPEN LOOP A control which does not use feedback to determine its output.
April 8, 2002
G-17
Kawasak
GLOSSARY
OPERATOR Any mathematical action or function. The arithmetic operators are: add, subtract, multiply, divide, modulo, and exponentiate. The relational operators are: greater than, less than, equal to, and their combinations. The logical operators are: AND, OR, exclusive OR, negate. The binary logical operators are AND, OR, exclusive OR, ones complement. OPTO An optical isolator or level converter. OVERFLOW When a value or buffer exceeds a predefined limit. OVERTRAVEL An error condition that exists when the robot exceeds its normal software limit values, and then actuates an overtravel limit switch. OVERVELOCITY When an axis exceeds a preset value for velocity. OX (OUTPUT EXTERNAL) Information transferred from the robot controller through output modules to control output devices.
P
PARITY Method by which errors are detected. In this method the combined binary values of a byte are flagged as 1 or 0. PARSE To break a command string into individual elements, so it can be interpreted. PASSWORD A code, entered by the user, to permit access to protected information. PAYLOAD The maximum weight that a robot can handle satisfactorily during its normal operations and extensions. PC PROGRAM PC is an abbreviation for process control. A PC program cannot contain any step that causes robot motion. PC programs are used to evaluate logic and variables and execute program CALL and GOTO commands April 8, 2002
G-18
Kawasak
GLOSSARY
PERIPHERAL DEVICE Hardware equipment which is external to the CPU, but that transmits and/or receives I/O from the processor. Examples include: printer, CRT screen, or disk. PHASE The angular relationship between current and voltage in alternating current circuits. In a waveform or period function, the fraction of the period that has elapsed, as measured from a reference point. Phase angle is determined by multiplying the phase by 360 degrees. PINCH POINT Any point where it is possible for a part of the body to be injured between the moving or stationary parts of a robot and the moving or stationary parts of associated equipment, or between the material and moving parts of the robot or associated equipment. PLA Abbreviation for programmable logic array. Used in many servo drive circuits. PLAYBACK An operation where a taught path is run for evaluation purposes. PLC Abbreviation for programmable logic controller. Usually referred to as the cell module controller. POINT-TO-POINT A robot motion control in which the robot can be programmed by a user to move from one position to the next. The intermediate paths between these points cannot be specified. POLARITY KEYS These teach pendant or multi function panel keys allow the user to jog or slew the robot in the Joint, Base (XYZ), or Tool coordinates system. PORT The connection point of an opening or passage that is usually located outside the housing of a device. POSITIONAL DATA The location in space of the robot manipulator.
April 8, 2002
G-19
Kawasak
GLOSSARY
POUNCE POSITION A positional location at a point near the workpiece, clear of the transfer mechanism and part, from which the robot is ready to begin production. PRINTED CIRCUIT An assembly of electronic elements that provide a complete path of electrical current through conductive material deposited between terminals on an insulated surface. PRECISION POINT The play back of robot location based on the angular position of the six axes, joint angles PRINTING A process in which characters are stamped on a surface, usually paper. PROGRAM A predefined, step-by-step set of instructions that are entered into a computer so a specific process can be performed repeatedly without reentering all the steps. Robot paths are stored and run as part of programs. PROGRAM EDIT Modification of an existing program. PROCESSOR Generally, any hardware or software system for carrying out programs and acting on data. PULSE WIDTH MODULATION (PWM) A modulation process in which the instantaneous sampling of the modulating wave is caused to modulate the duration of the pulse. This type of modulation is also referred to as pulse duration modulation (PDM), or pulse length modulation (PLM).
R
RAM Acronym for random access memory. An area used by the CPU for processing and temporarily loading programs so they can be accessed quickly. The contents of RAM are lost when the computer is powered down, unless battery backup is provided. REAL NUMBER A number with a fractional part, such as 1.75, -31.89, .5, -4.00, etc.
G-20
April 8, 2002
Kawasak
GLOSSARY
REAL-TIME The actual time during which the computer analyzes and processes data: information is usually processed as it is received. REAL VARIABLE AS language term for a variable that has had a real value assigned to it. REPEAT MODE A mode of operation that allows the user to check positional and auxiliary information at a selected speed value, in a continuous or a step by step type of movement of the mechanical unit. REPEATABILITY The measurement of the closeness of agreement among repeated measurements of the same variable under the same conditions. REWRITE MODE A mode of operation which allows the user to rewrite positional, or auxiliary data, and to insert or delete step address locations. RISC Acronym for reduced instruction set computer. ROM (read-only memory) A memory device which is programmed at the factory and whose contents thereafter cannot be altered.
RS-232C An ASCII specification for connections and communication between serial devices. RUN A mode of operation that allows the user to select servo motor power to provide drive energy to the robot, allowing it to perform such modes of operation as teach, check, repeat, and rewrite.
S
SAFETY PLUG A device used with safety fencing to interlock the opening of the fence with the removal of power to the robot.
April 8, 2002
G-21
Kawasak
GLOSSARY
SCROLL When more information exists than can be displayed on one screen, the operator can move up and down through the data to view it. When data is scrolled to the screen, the information previously viewed moves up off the screen, and new information enters the screen from the bottom. SENSOR A device used to detect various conditions: proximity, heat, pressure, etc. An electrical signal from the sensor can be used to communicate information to a robot program. SERIAL A method of transmitting data by which only one bit is sent or received at any one point in time. SEQUENTIAL ACCESS A method used by many computers whereby data is read in the order in which it is physically stored. SINGULARITY POSITION When the robot is processing a linear or circular move and two or more joints are in alignment. The CPU can not process the ambiguity of a singularity configuration and an error is generated. SOFTWARE LIMITS Programmed values that are included in a program at the point before a mechanical device hits an overtravel limit switch or a hard limit. SOFTWARE A set of written programs and instructions that are executed by a computer system. SOURCE CODE A program that contains the actual software instructions entered by the user, in contrast to object code which is source code that has been translated into a language which can be interpreted by the computer. STRING A series of characters that have been entered in a distinct sequence that can be interpreted as a valid statement or command. STROKE The movement in either direction of a mechanical part having a reciprocating motion. The entire distance passed through in such a movement.
G-22
April 8, 2002
Kawasak
GLOSSARY
SUBSCRIPT A set of numbers that identifies an element of an array. SUBROUTINE A set of instructions that is run by another routine. SYMBOL A character or design that has a distinct meaning and/or is associated with something. SYNTAX The proper way in which commands and phrases should be typed in order to be understood by the control system. If the operator incorrectly types a command (i.e., misspelled or invalid characters), a syntax error message will be displayed. SYSTEM DATA Data that is specific to a individual robot. Zeroing data, upper and lower software limits, and software switch settings are all examples of system data. SYSTEM SWITCH Software switches that are set to determine various configurations and characteristics of the robot system performance.
T
TEACH MODE A mode selected on the operator panel, during which robot arm axes positions can be taught by the operator and are recorded by the robot. TEACH PENDANT A hand-held, portable device used by the operator during teach and jogging operations. TOOL COORDINATES A Cartesian coordinate system in which the origin point is at the face plate of the robot and the orientation of the tool can be expressed in terms of a 3-dimensional space representation of X, Y, and Z projections. TOOL MODE A mode of operation in which all motions are calculated to maintain the orientation of the tool in space.
April 8, 2002
G-23
Kawasak
GLOSSARY
TORQUE Something which produces or tends to produce rotation or torsion and whose effectiveness is measured by the product of the force and the perpendicular distance from the line of action of the force to the axis of rotation. TRANSFORMER A device to convert the current of a primary circuit into variations of voltage and current used in secondary circuits. TRANSFORMATION A mathematical description of a location that defines the position and orientation of the location without regard for the configuration of the robot when it is at that location. TRAP POINT See PINCH POINT. TTL Abbreviation for transistor-transistor logic. TWOS COMPLEMENT A means of representing a negative number as one more than the binary complement of the absolute value of the number. TRIANGULAR WAVEFORM A waveform that has the shape of a triangle and is used in determining sampling values for servo drive circuits that utilize pulse width modulation.
U
UHF Abbreviation for ultra-high frequency.
V
VARIABLE The name of a memory location or stored value. A variable can refer to a scalar or an array. VELOCITY COMMAND This analog signal is directly proportional to motor speed, and provides the initial signal that is processed by the servo drive system to drive a servo motor.
G-24
April 8, 2002
Kawasak
GLOSSARY
VELOCITY ERROR When the robot controller detects an axis that has exceeded a preset value for velocity, the robot controller will E-stop the robot. VOLT A unit of electrical potential difference and electromotive force. One volt is equivalent to the force required to produce one amp of current through one ohm of resistance.
W
WORK ENVELOPE The effective range or reach of a robots axes. WORLD COORDINATES A Cartesian coordinate system in which the origin point is near the base of the robot, and robot movement can be expressed in terms of a 3-dimensional space representation of X, Y, and Z projections. WRITE In computer systems, a process in which information is output to and stored by a device or area in memory. WS (WELD SCHEDULE) Data that is stored in the weld controller and provides the specific current, clamp pressures, etc. for spot welding applications. WX (WAIT EXTERNAL) The wait external signal is one of many inputs that are processed by the robot controller. When the robot encounters a wait external condition, the robot will cease motion and the servo power will be removed.
Z
ZEROING This procedure provides the robot controller with encoder data that is referenced from a known mechanical position (zeroing witness marks, in simple zeroing, or inclinometer values in precision zeroing) and then establishes an encoder value for this known position. Two methods can be used, simple and precision zeroing. Some robot manufacturers call this procedure mastering or calibration.
April 8, 2002
G-25
Kawasak
INDEX INDEX
......................................................................................................................IN-2
April 8, 2002
IN-1
Kawasak
INDEX Symbols
1 and 0 Display, 9-46 1FS Board, 11-64, 11-68 1GA Board, 11-64 1GB Board, 1-14, 1-18 1GC Board, 1-15 1GD Board, 1-15 1GM Board, 1-15 1GS Board, 1-14 1GW Board, 1-14, 1-15 1HA Board, 1-14 1HP Board, 1-14, 1-15 1HS Board, 11-69 1HZ Motherboard, 1-14 1LT E-Stop Distribution, 1-16 1LU Explosion-Proof Barrier, 1-16 1LW Encoder Barrier Module, 1-16 3 Notch Selector Switch, 11-51
A
Abnormal Check Sum, 9-49 ACCELERATION, 7-64 ACCFLOW, 11-28 Accuracy, I-6, 2-11, 9-30 ADD Mode, 7-9 After Wait Timer Switch, 9-45 AIR MOTOR, 7-53 Air Motor/Atomizing Air, 9-188 Air Purging Process, 4-2 AIRCUT JSPEED, 7-9, 7-43 AIRCUT SPEED, 7-42 All Ratio Set, 5-32 All Ratio Set Screen, 5-32 Allen-Bradley, 11-64 American National Standards Institute (ANSI), 2-6 Amplifier, 1-18 ANSI, 2-6 ANSI/RIA Standards, 9-35 AS Instruction Definition, 11-57 AS Teaching Screen, 5-21 Auto Servo Timer, 9-54 Auto Tool Set, 11-14 Autostart.PC Switches, 9-46 Aux 181, 11-75 Aux 198, 11-85 Aux 48 Tool Dimensions, A-2 Aux 64, 11-24 Aux 65, 11-25 Auxiliary Axis, I-2 Auxiliary Function List, 9-6, 11-3 Auxiliary Function List Multi Function Panel, 9-6 Auxiliary Function Screens, 9-5
IN-2
April 8, 2002
Kawasak
INDEX
Auxiliary Function Select, 11-85 Auxiliary Functions, 5-35 Auxiliary Functions, Explosion-Proof Teach Pendant, 9-120 Auxiliary Functions List, Explosion-Proof Teach Pendant, 9-122 Available Memory Capacity, 9-133 Axis Keys, 6-4
B
B-Axis, I-2 Backup File, 9-16 Base, I-6 Base Coordinate, 9-26 Base Coordinate Shift, 9-26 Base Coordinate System, A-3 Base Coordinates, I-3 Batteries, Lithium, 1-14 Battery Error Check, 9-59 BEAD, 11-27 Bead Width, 11-29, 11-33 Brake Assembly, 2-12 Brakes, 2-13
C
C Controller Models, I-5 C Series Controller EP Type, Operation Panel, 4-5 CALL Instruction, 7-74 CALL_PGM Instruction, 7-74 Camera Sensing, 9-176 Cartesian Coordinate, I-3 Caution Symbol, 2-8 Central Processing Unit (CPU), 1-14 Character Set Screen, 5-18 Character String Entry, 7-105, 7-106 Check Mode, 2-13, 7-35 Check Mode Selection, 7-34 Check Specification, 9-57 Check Speed, 9-34 Check Sum Error, 9-49 Checking Programs, 7-107 Circuit Board Block Diagram, 1-17 Circular Interpolation, 11-17 Circular Move, I-6 Clamp Specifications, 9-65 Clear Check Sum Error, 9-49 CMOS RAM, I-6 COMPARE Instruction, 7-84 Compare Instruction, 7-85 Computer Simulation Models, 11-9 Configuration Data, 7-99 Configuration Descriptions, 7-100 Continuous Path, 2-11 Control Power Lamp, 3-3
April 8, 2002
IN-3
Kawasak
INDEX
Controller Design Specifications, I-6 Controller Dimensions, I-8 Controller Operation Panel, 1-10 Controller Power Off Procedures, 4-4 Controller Weight, I-8 Conversion of Flow Rate, 11-28 Conveyor Instruction, 7-92 Conveyor Track, 9-173 Conveyor Wait, 9-171 Conveyor Wait Instruction, 7-93 Coordinate System, 6-7 Coordinate System, BASE, A-3 Coordinate System Selection, 6-7 Coordinate System, TOOL, A-3 Coordinate Systems, 6-5 Copy and Paste, 7-122, 7-124 Copy Auxiliary Data, 7-128 COUNTER Instruction, 7-88 Counter Instruction, 7-89 Counter Reset, 7-90 Counter Value Setting, 9-178 CP Switch, 9-41 CPU, Main, 1-14 CRCT Key, 7-9 Current Conveyor Position Setting, 9-177 Current Detect Modules, 1-18 Current Position Screen, 5-27 Cursor Movement Keys, 5-16 Cut and Paste, 7-120 CYCLE START Lamp, 4-4, 8-7 Cycle Start Switch, 3-3
D
D-Axis, I-2 Data Bank, 7-58, 7-70, 9-114 Data Bank Conditional Items, 9-151 Data Bank, Copy, 9-117 Data Bank, Delete, 9-118 Data Bank Details, 9-152 Data Bank, EDIT, 9-116 Data Bank Editing, 9-149 Data Bank, Environment Set, 9-119 DATA BANK Instruction, 7-70, 7-71 Data Bank, List, 9-115 Data Bank Number, 9-153 Data Conversion, 11-9 Data Editing, I-6 Data Input Wait, 7-60 Data Storage, I-8 Data Transfer, 9-13 Dedicated Counter Display, 9-166 Dedicated Input Signals, 9-62
IN-4
April 8, 2002
Kawasak
INDEX
Dedicated Output Signals, 9-63 Dedicated Signal Display, 9-64 Dedicated Signals, I-7 Default Settings, 9-30 Delete, 7-126 Deviation Error, 2-13 Difference of Work/Air-Cut Speed, 9-107 Digital Command Signal, 1-18 Digital Display, 11-53 Digital Switch, 11-52 Direct Speed, 11-86 Display Inputs/Outputs, 9-46 Dly_Spray #1, 7-48 DLY_SPRAY Distance, 7-47 DLY_SPRAY Time, 7-47 Door Sensor, 9-175 Double Type Output Signal, 11-41 Dout Function Assignment, 9-101, 9-102 Drive Mechanisms, 1-20 Drop Down Menus, 5-19 Dry Run, 8-9 DRYRUN ON/OFF, 8-6, 8-9 Dummy Step, 7-59
E
E-stop Switch, 2-9, 2-10, 2-11, 2-13 Easy Mode, 6-7 Edit Correction Modes, 7-113 Edit Mode, 7-111, 7-112 Edit Mode Descriptions, 7-38 Edit Screen, 7-109 Edit Screen Display, 7-110 Edit Search Mode, 7-114 Editing Move Positional Data, 7-117 Editing Program Instructions, 7-37 Emergency Stop Switch, 3-3, 4-4, 4-7, 7-8, 8-7 Enabling Device, 2-11 Encoder Abnormality Error, 9-23 Encoder Deviation, 9-23 Encoder Rotation Counter Reset, 9-72 Encoder Value Display, 9-157 END Command, 11-79 Environmental Data, 9-54 Environmental Data2, 9-55 Equipment Key, 6-23 Error Codes/Troubleshooting, 10-2 Error History, 9-181 Error Lamp, 3-3, 4-2 Error Logging, 9-70 Error Messages, I-8 Error Recovery, 10-2 Error Reset Switch, 3-3, 4-2
April 8, 2002
IN-5
Kawasak
INDEX
Error Start.PC Switch, 9-46 Exiting Program Edit Mode, 7-118 Exiting Teach Mode, 7-26 Explosion Proof C Controller, 3-2 Explosion-Proof C Controller, I-5, 1-3, 4-4, 8-4 Explosion-Proof Teach Pendant, I-8, 1-6, 1-7, 4-5, 5-2 Explosion-Proof Teach Pendant Key Functions, 5-3, 5-4, 5-5, 5-6 External Axes Selection, 6-23 External Fixed Point, 11-19 External Input, 7-60, 7-61 External Input Signal Display, 9-162 External Output, 9-168 External Output Instructions, 7-50, 7-51 External Output Signal Display, 9-161
F
FALSE_JUMP, 7-77, 7-81 Features, 1-2 Figure Input and Cursor Selection, 5-17 File Extension, 9-16, 9-18 Fixed Linear Interpolation (FLIN), 11-19 Fixed Tool Dimensions, 11-19 Flash Memory, 1-14 Floppy Disk Drive Unit, 1-13 Flow Rate, 9-186 FLOW_RATE, 7-52 Flowgain, 11-28 Flowrate Control, 11-24 Flowrate Switch, 11-31 Flushing, 7-54, 9-190 Frame Key, 6-4, 7-13, 7-19, 7-23, 7-27 Function Screen, 5-35
G
General Counter Display, 9-165 GENERAL EX_OUT, 7-50 General Signal, 9-184 General Syscount Setting, 9-111 Global Changes, 9-39 Goggles, 2-9 Graph Access, 11-6 Graph Screens, 11-88 GUN CONTROL Instruction, 7-94 Gun Coordinate System, 6-21, 6-22 Gun Position and Angle, 9-154 Gun Position and Wrist Angle Display, 9-160 Gun-Tip Configuration, 7-101 Gun-Tip Direction Shift, 9-145
H
Hard Hat, 2-9 Hardstop, 2-13
IN-6
April 8, 2002
Kawasak
INDEX
HIGH VOLTAGE, 7-53 High Voltage, 9-189 High-Speed Playback, 2-11 History Clear, 9-103 HOLD/RUN Switch, 3-3, 4-2, 4-3, 4-4, 4-6, 4-7, 8-3, 8-7 Home Position, 9-48 Home Position Check Axis Set, 9-100 Home Signals, 9-164 Hour Meter, 3-3 Hybrid Encoder, 1-18, 1-19 Hybrid Interpolation, 11-19
I
I/O Channels, 11-64, 11-67 I/O Signals, I-7 Initialization, 9-58 INPUT SIGNAL Instruction, 7-86, 7-87 Input Wait, 9-170 INPUT_SIGNAL, 7-86 Inputs, I-7 Intelligent Power Modules, 1-14 Interface Devices, 1-6 Interface Panel, Optional, 2-13 Interlock Control Circuit, 2-12 Internal Signals Display, 9-163 Interpolation, 7-30 Interrupt Program, 9-94 IPM, 1-15
J
Jogging Operation Procedures, 6-3 Joint, I-6 Joint Command Value Display, 9-156 Joint Move, I-6 Joint Shift, 11-37 Joint Value Display, 9-155 JT1, I-2 JT2, I-2 JT3, I-2 JT4, I-2 JT5, I-2 JT6, I-2 JT7, I-2 JUMP, 7-77 JUMP Command, 11-79 JUMP Instruction, 7-76 JUMP_OFF, 11-79 JUMP_ON, 11-79 JUMP_ST, 11-79
K
KCMON, 1-6
April 8, 2002
IN-7
Kawasak
INDEX
KCWIN, 1-6 KE610, I-2 KE610 Cartesian Coordinate System, 6-13, 6-14 KE610 Easy Coordinate System, 6-17, 6-18 KE610 Joint Coordinate System, 6-9, 6-10 KE610 Mechanical Unit, 1-4 KE610 Restricted Space, 2-15 Keep Type Output Signal, 11-41 Keys and Switches, 5-2 KF121, I-2 KF121 Joint Coordinate System, 6-11 KF121 Cartesian Coordinate System, 6-15, 6-16 KF121 Easy Coordinate System, 6-19, 6-20 KF121 Joint Coordinate, 6-11 KF121 Joint Coordinate System, 6-12 KF121 Mechanical Unit, 1-5 KF121 Restricted Space, 2-14 Kill Program, 9-14
L
Ladder Logic, 11-64 Last Weld Data, 11-74 Left-Hand Rule, I-3 Limit Switch, 2-13 Linear Move, I-6 Lithium Batteries, 1-14 Location & Speed Display, Aux 2, 9-11 Location Display, 9-12 Location Variables Registration, 9-179 Lock Out, 2-12 Lower Limits, 9-28
M
Main Disconnect, 2-12 Major Components, 1-3 Manual External Output Execution, Air Motor/Atomizing Air, 9-188 Manual External Output Execution, Flow Rate, 9-186 Manual External Output Execution, Flushing, 9-190 Manual External Output Execution, General Signal, 9-184 Manual External Output Execution, High Voltage, 9-189 Manual External Output Execution, Push Thinner, 9-191 Manual External Output Execution, Shaping/Pattern, 9-187 Manual External Output Execution, Spray Signals, 9-185 Manual Operation, 6-5, 6-7 Manual Operation Keys, 6-2 Manual Positioning, 7-27 Manual Speed, 7-13 Manual Speed Key, 6-4 Manual Speed Selection, 6-8 MBREAK, 11-28 Mechanical Unit, 1-20 Mechanical Unit Design Specifications, I-3
IN-8
April 8, 2002
Kawasak
INDEX
Memory, I-6 Memory Available, 9-36 Memory Capacity, I-6 Memory, Flash, 1-14 Memory Load, 9-17 Memory PC Card Save, 9-15 Memory Saving, 9-15 Menu Key, 5-34 Messages Switch, 9-45 Mine Safety and Health Administration (MSHA), 2-6 Mirror Image Conversion, 9-146 Monitor Screens, 5-26 MOTOR POWER Lamp, 8-7 MOTOR POWER Switch, 3-3, 4-6 Motor Power-On in the Repeat Mode, 4-6 Motor Power-On in the Teach Mode, 4-6 MOVE Instruction, 7-97 Move Instruction Editing, 7-116 Moving Area XYZ Limit, 9-113 MOVING TIME, 7-43 MSHA, 2-6, 2-9 Multi Function Panel, I-6, I-8, 1-6, 1-8, 1-14, 2-13, 5-2, 5-8, 11-64 Multi Function Panel Display Area Descriptions, 5-11 Multi Function Panel Features, 5-9 Multi Function Panel Keyboard, 5-36 Multi Function Panel Keys and Switches, 5-8 Multi Function Panel Status Screen, 5-10, 5-11 Mutual Wait, 7-63
N
NIOSH, 2-6, 2-9 Node Adapter Chip (NAC), 11-64 Null, 9-26 Numeric Keypad, 5-32
O
O-Axis, I-2 OAT Angles, A-4 Off Line Programming, 11-9 Online Edit, 11-58 Opening Screens, 4-2 Operation Condition Selection, 9-168 Operation Condition Selection: Camera Sensing, 9-176 Operation Condition Selection: Conveyor Track, 9-173 Operation Condition Selection: Conveyor Wait, 9-171 Operation Condition Selection: Door Sensor Setting, 9-175 Operation Condition Selection: External Output, 9-168 Operation Condition Selection: Input Wait, 9-170 Operation Condition Selection: Timer Wait, 9-172 Operation Condition Setting, 9-108 Operation Logging, 9-71 Operation Panel, 2-13, 3-2
April 8, 2002
IN-9
Kawasak
INDEX
Operation Panel Switches, 3-3 Optional Functions, 11-3 OSHA, 2-6, 2-9 OTHERS Instruction, 7-102, 7-103, 7-104 OUTLOC, 11-27 Output and Spray Signal Descriptions, 9-109 Outputs, I-7 OUTSPEED, 11-26 Overtravel Error Recovery, 9-29 OX Preout Switch, 9-43 OX Specification Function, 11-41
P
Paint IO Ratio Settings, 7-57 PAINT_IO RATIO, 7-55 Parallel I/O, 1-15 Parallel Shift, 9-144 Partial Program Copy, 9-140 Partial Program Deletion, 9-142 Parts, Replacement, 2-12 Password Level, 11-84 PC Card, 1-6, 1-8, 1-9, 9-15 Peripheral Device, 2-9 Personal Computer, 1-11 Personal Safety, 2-9 PG Partial Delete, 9-104 Playback Accuracy, 9-30 PLAYBACK RATE, 7-43 PLC(NAC), 11-75 Pneumatic, 2-12 Point Type, 7-30 Point-to-Point Mode, 2-11 Position Display of Traverse Axes, 9-158 Position Error Range, 9-22 Power Block, 1-15, 1-18 Power On Procedures, 4-2 Power ON/OFF Procedures, 4-2 Power Requirements, I-8 Power Unit, 1-18 Power Up Sequence, 1-15 PRE_SPRAY, 7-46 PRE_SPRAY Distance, 7-46 Pressurizing Cycle, 4-3 Privat Syscount Setting, 9-112 Process Control Program, 5-12 Product Paint_IO Ratio Setting, 9-130 Production Rate Value Setting, 9-129 Program Checking Procedure, 7-34 Program Copy, 9-136 Program Data, 7-7 Program Delete Function, 5-14 Program Deletion, 9-139
IN-10
April 8, 2002
Kawasak
INDEX
Program Edit, 7-109 Program Edit Screen, 7-119 Program Execution, 8-2 Program Instruction Editing, 7-113 Program Instructions, 7-40 Program Link, 9-137 Program Link, Same Source and Destination, 9-138 Program List Display, 9-131 Program List Screen, 5-25 Program Name Registration, 9-134 Program Number, 7-5, 7-6 Program Number List Display, 9-132 Program Parameter/Comment, Aux 87, 9-50 Program Planning Sheet, 7-8 Program Points, 7-7 Program Queue, 9-73 Program Queue All Delete, 9-80 Program Queue Delete, 9-79 Program Queue Display, 9-75 Program Queue Environment Set, 9-81 Program Queue Insert, 9-77 Program Queue Menu Item Descriptions, 9-74 Program Queue Register, 9-76 Program Queue Registration Sequence, 9-83 Program Queue Shift Type Descriptions, 9-82 Program Select Instruction, 7-91 Program Select Screen, 8-5 Program Selection, 5-12 Program Selection Key, 5-13 Program Selection Methods, 5-13 Program Setting, 9-126 Programmable Logic Controller (PLC), 11-64 Programming Sheets, A-5 Programs in Detail, 9-97 Pulse Type Output Signal, 11-41 Pulse Width Modulation, 1-14 Purge Cycle, 4-2 Purge Time, 4-2 PUSH THINNER, 7-54, 9-191 PWM, 1-18
Q
QBEAD, 11-27 QTOOL Switch, 9-44
R
R-Axis, I-2 Random Program Selection, 9-44 Recording and Editing Programs, 7-3 Recording Programs, 7-3 Remote I/O, 11-67 REMOTE/LOCAL Switch, 8-3
April 8, 2002
IN-11
Kawasak
INDEX
Repeat Condition, 8-8 REPEAT CONDITION Key, 8-6 Repeat Condition Wait, 8-11 Repeat Conditions, 7-107 REPEAT CONT/ONCE, 8-6, 8-8 Repeat Mode, I-6, 2-11, 7-107 Repeat Once, 8-8 Repeat Once Switch, 9-44 Repeat Operation Procedure, 8-3 Repeat Speed, 8-8 Repeat Status Display, 9-127 Replacement Parts, 2-12 Restricted Space, 2-9, 2-11, 2-14 Retreat Path, 2-11 RI/O PLC (NAC) Setting,, 11-75 RI/O Signal Status, 11-71 RISC Processor, 1-14 RMT Speed Key, 6-8, 7-27 Robot Controller, I-5 Robot Controller Versions, I-5 Robot Specifications, I-4 RPS Code, 11-79 RPS Codes, 11-82 RPS Enable, 11-81 RPS ENABLE/DISABLE, 8-6, 8-9 RPS Operation, 11-82 RPS Procedure, 11-80 RPS Random Program Selection, 8-9 RPS Slogic Program Example, 11-80 RPS System Switch, 11-81 RPS_ON, 11-79 RPS_ST, 11-79
S
S-Axis, I-2 Safeguarded Space, 2-2, 2-9, 2-10, 2-11, 2-12 Safety Categories, 2-9 Safety Coordinator, 2-10 Safety Device, 2-10 Safety During Inspection and Maintenance, 2-12 Safety During Operation, 2-11 Safety During Programming, 2-11 Safety Features, 2-13 Safety Fence, 2-12 Safety Glasses, 2-9 Safety Plug, 2-12 Safety Shoes, 2-9 Safety Terminology, 2-3 Sample Mainline Program, 11-32 Save Screen, 9-15 Screen Selection Keys, 5-19 Screen Switch, 9-45
IN-12
April 8, 2002
Kawasak
INDEX
Search Mode, 7-115 Selecting Other Teaching Instructions, 7-33 Selecting Speed Instructions, 7-41 Selecting Spray Speed, 7-12 Selecting Teach ADD, 7-10 Sensing Instruction, 7-96 Serial Communication, 1-15, 11-64 Servo Amplifier Block Diagram, 1-19 Servo CPU, 1-14 Servo Drive Motor, 2-12 Servo Motor, 1-18 Servo Software, 1-18 SET LABEL, 7-77, 7-82 Set Label Instruction, 7-83 SETOUTSIG, 11-26 SETOUTSPEED, 11-26 SHAPING AIR, 7-52 Shaping/Pattern Air, 9-187 Shuttle Condition Display, 9-167 Shuttle Right-Left Conversion, 9-148 Signal Output Screen, 5-33 Signal Timing, 9-43 Singular Point Alarm Range Set, 9-105, 9-106 Singularity, 11-19 Slogic, 11-64, 11-66, 11-67 Slogic Editing, 11-66 Slogic Forced Output, 11-78 Slogic Program, 11-66 Slogic Status Screen, 11-75 Slow Repeat Mode, 9-33 Small Teach Pendant, 2-13 Smooth Instruction, 7-65 SMOOTH Instructions, 7-64 SMOOTH RANGE, 7-64 Smooth Range, 7-66, 7-67, 7-68, 7-69 Software Features, I-7 Software Interface, 1-12 Software Limit, 2-13 Software Switches, 9-39 Software Version, 9-53 Speed, I-6, 2-11, 7-9 Speed Display, 9-12 Speed Instruction, 7-32 Speed Instructions, 7-40 Speed Output, 11-25 SPRAY 1, 7-45 SPRAY 2, 7-45 SPRAY 3, 7-49 SPRAY 4, 7-49 Spray Instruction Selection, 7-21 Spray Instructions, 7-44, 7-45, 7-46, 7-48 SPRAY JSPEED, 7-42 Spray On/Off, 9-38
April 8, 2002
IN-13
Kawasak
INDEX
Spray Output Display, 5-30 Spray Output Screen, 5-30 Spray Output Screen Descriptions, 5-31 Spray Signals, 9-185 SPRAY SPEED, 7-11 Spray Status Screen, 5-28 Spray Status Screen Descriptions, 5-29 SPRAY_1, 7-17 SRAM Memory, 1-14 Start Dealy Menu, 9-85 Start Delay, 9-85 Start Delay Common Delay Distance, 9-86 Start Delay Individual Delay Distance, 9-87, 9-88 Start Delay, Multi Start Delay, 9-90 Start Delay, Multi Start Delay Distance All Delete, 9-93 Start Delay, Multi Start Delay Distance Change, 9-91 Start Delay, Multi Start Delay Distance Delete, 9-92 Start Delay Same Delay Distance, 9-89 Status Key, 5-22 Status Screen, 5-23, 5-24 STEP CONT/ONCE, 8-6, 8-9 Step Delete, 7-38 Step Once, 8-9 Step Once Switch, 9-45 Step Selection, 5-12 Step Selection, Multi Function Panel, 5-15 Step Type Signal, 11-41 Stopping Program, 8-7 Stopping the Robot, 4-7 Store Pos Key, 7-19, 7-23, 7-31 Suspending and Restarting Program, 8-7 Syscount Display/Setting, 9-110, 9-111 System Initialization, 9-58 System Switch, 9-39
T
T-Axis, I-2 Table Instruction, 7-95 Table Position Display, 9-159 Tag Out, 2-12 Teach Add, 7-31 Teach Display Screen, 5-7 Teach End, 7-25 Teach Lock, 4-3 Teach Lock Key, 6-4 Teach Lock Switch, 4-6, 8-3 Teach Mode, I-3, I-6, 2-13 Teach Pendant, 2-11, 2-13 Teach Repeat Switch, 3-3 Teach Screen, 7-3 Teach Screen Display, 7-3 Teach Screen Display Descriptions, 5-7, 7-4 TEACH/REPEAT Switch, 4-3, 4-6, 4-7, 8-3, 8-7
IN-14
April 8, 2002
Kawasak
INDEX
Teaching Instruction Menu, 7-32 Teaching Key, 5-20 Teaching Move Instructions, 7-29 Teaching Other Instructions, 7-32 Teaching Procedures, 7-7 Teaching Program Data, 7-7 Teaching Spray OFF, 7-22 Teaching Spray ON, 7-18 Text Window, 11-54 Time Function, 9-61 TIMEOUT, 7-60 TIMER, 7-72 Timer and Counter Status Screens, 11-72 Timer Instruction, 7-73 Timer Wait, 9-172 Tool, I-6 Tool Coordinate System, A-3 Tool Coordinates, I-3 Tool Dimensions, 9-27, 9-44, A-2 Tool Registration, 9-95 Tool Registration Setting Values, 9-96 Tool Shift, 11-38 Total Playback Count, 9-182 Total Repeat Cycles of Program, 9-98, 9-99 Trap Point, 2-11, 2-9 Traveler Shift with Gun Tip Fixed, 9-147 Traverse Axis Manual Operation, 6-23 Troubleshooting Flowcharts, 10-97 TRUE_JUMP, 7-77, 7-79
U
UC_JUMP, 7-77 Upper Limits, 9-28 User Interface, 1-6
V
Velocity Error, 2-13
W
Wait Override, 8-10 Wait Override Screen, 8-10 Warning Symbol, 2-8 Water, High Pressure, 2-12 Weld Control, 11-64 Weld Control Setting, 11-76 Work Envelope, 8-10 Work Shift, 11-39
X
X and O Display, 9-46 XYZ Shift, 11-36
April 8, 2002
IN-15
Kawasak
INDEX
XYZ1, 7-101 XYZ1 Mode, 6-7, 7-29 XYZ2, 7-101 XYZ2 Mode, 6-7, 7-29
Z
Zeroing, 9-6, 9-9, 9-20, 9-21, 9-24, 9-72 Zeroing Data, 9-72 Zeroing Data Set Display, 9-24
IN-16
April 8, 2002

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C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL MPOEPCCP121E

ROBOT OR CONTROLLER TYPE OF MANUAL

Description of Change Initial PDF release, based on Rev.-1 of print copy

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Table I-1 Robot Specifications

6 810 kg (1782) 130 kg (286) Axes

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Table I-2 Robot Controller Versions

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Number of Axes: Motion Control:

Smooth Range: (Accuracy) Speed: Data Editing:

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Explosion-Proof Teach Pendant:

Multi Function Panel:

Supplemental Data Storage:

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Figure 1-1 North American Explosion-Proof C Controller

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Figure 1-2 KE610 Mechanical Unit

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Figure 1-3 KF121 Mechanical Unit

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

0 SPEED 1 SPRAY . 5 DATA 6 TIMER -

2X=OUT A GUN 7 CALL D

3X=IN B TABLE 8 JUMP E MOVE

4 SMOTH CSENS 9 CONVR F

BEND TURN FRNT UP BEND TURN BCK DWN

RMT MOTION SPEED

Three-Position Enabling Device Teach Lock Emergency Stop

SPRAY TEACH ON/OFF LOCK

RESET SPRAY 1/2

STEP STEP BACK

Figure 1-4 Explosion-Proof Teach Pendant

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Liquid Crystal Display (LCD)

Touch Panel Pen

Figure 1-5 Multi Function Panel

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Figure 1-6 Flash RAM PC Card

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Error Reset Lamp

Teach Repeat Switch

Figure 1-7 North American Controller Operation Panel

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

INTERFACE PANEL (1/2)

PALLET REMOVE MODE MANUAL AUTO MODE OFF OFF-LINE AUTO

Figure 1-8 Software Interface Panel

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

Figure 1-9 Floppy Disk Drive Unit

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL

C SERIES CONTROLLER EP TYPE OPERATIONS AND PROGRAMMING MANUAL