5-420 ROBOT MAINTENANCE AND TROUBLESHOOTING REFERENCE MANUAL This publication contains proprietary information of the GMFanuc Robotics Corporation fur...
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5-420 ROBOT MAINTENANCE AND TROUBLESHOOTING REFERENCE MANUAL
This publication contains proprietary information of the GMFanuc Robotics Corporation furnished for customer use only. No other uses are authorized without the express written permission of the GMFanuc Robotics Corporation.
GMF Robotics Corporation 2000 South Adams Road Auburn Hills, Michigan 48057-2090
The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing, GMFanuc Robotics Corporation, hereinafter referred to as GMF Robotics or GMF, reserves the right to discontinue models at any time or change specifications or design without notice and without incurring obligation. GMF Robotics recommends that only those persons who have received training from GMF perform the procedures contained herein, GMF TRAINING
GMF Robotics conducts training courses on GMF products on a regularly scheduled basis at our facilities in Auburn Hills, Michigan,
For additional information, contact: Training & Documentation Department GMF Robotics 2000 South Adams Road Auburn Hills, Michigan 48057-2090 (313) 377-7000 The information illustrated or contained herein may not be reproduced, copied, used, or transmitted in whole or in part in any way without the prior written consent of GMF Robotics, All Rights Reserved. Copyright 1988, GMFanuc Robotics Corporation.
INFORMATION
List of error messages
-----
DETAILS
Include error message number message following error message number any numbers following error message
--
List of diagnostic LEDs
Note the PCB where the LED is located and the LED name or designation.
History of problem
Description of events leading up to problem.
---
Application software
List
--
---
any application software running on the system the line number where the program halted a description of what is happening on that line
TABLE OF CONTENTS I
.
OVERVIEW AND CONTROLLER MAINTENANCE
...................................................... 1-1 ....................................................... 1-2 ....................... 1-2 .................................... 1-2 ........................... 1-3 .......*........................1-3 2 . SAFETY ............................................................. 1-4 2.1 Personnel Safety Considerations ................................. 1-4 2.1.1 General precautions ....................,..........*......... 1-4 Operator safety precautions ................................. 1-5 2.1.2 INTRODUCTION
1.
1.1 Structure 1.2 Problem Conditions and Determining Causes Making preliminary check 1.2.1 1.2.2 Locating the cause of the problem Checking the mechanical unit 1.2.3
.................................. 1-5 1-5 ................. ........ 1-6 ..................................... 1-6 1-6 ...................................... .*................................... 1-6 ...........................*........... 1-6 .............................*.......1-7 1-6 ...................................... .............................. 1-7 ..................................... 1-7 ...................................... 1-7 3. CONTROLLER DESCRIPTIONS ......................................... 1-8 3.1 General Description .................................*...........1-8 External Components ............................................. 1-18 3.2 Internal Components ............................................. 1-22 3.3 Controller Components Specifications ................*...........1-24 3.4 4. PREVENTIVE MAINTENANCE ............................................. 1-27 4.1 Daily Checks ............................................... . 1-27 Teacher safety precautions 2.1.3 2.1.4 Maintenance personnel safety considerations Machine Tool and Peripheral Device Safety Considerations 2.2 Programming precautions 2.2.1 2.2.2 Mechanical precautions 2.3 Robot Safety Considerations Operating precautions 2.3.1 Programming precautions 2.3.2 2.3.3 Mechanical precautions 2.4 End Effector Safety Considerations Programming precautions 2.4.1 Mechanical precautions 2.4.2
4.2 4.3 4.4 4.5 4.6
5
.
............... 1-28 ................................................ 1-29 ............................................... 1-29 ........................................... 1-29 ...............................*...............1-30
Monthly Checks (Determined by hours of operation) Quarterly Checks Semiannual Checks Periodic Repl.acement Maintenance Tools
.................................................... ................................................. .......................................
TROUBLESHOOTING 5.1 Introduction 5.2 Power Cannot be Turned On 5.3 Troubleshooting Using Error Codes 5.3.1 Error code 4001 DEADMAN switch 5.3.2 Error code 4002 emergency stop 5.3.3 Error code 4003 pneumatic pressure alarm .................... 5.3.4 Error code 4004 hand breakage detection 5.3.5 Error code 4005 robot overtravel ............................ 5.3.6 Error code 4006 relay welding detection ..................... 5.3.7 Error code 4008 TGLS alarm .................................. 5.3.8 Error codes 4009 - 4014 .....................................
............................... .............................. .............................. .....................
....................... 1-38 1.-38 ................ 1-41 ................................. 1-42 .....................................
5.3.9 Error code 4020 ve1oci.t~ready is off 5.3.10 Error code 4022 overload 5.3.11 Error. code 4024 fuse alarm in brake circuits 5.4 Troubleshooting Servo Amplifier
....................................
6
.
BACKPLANE PCB (A20B-1002-0860) 6.1 Theory of Operation 6.2 Block Diagram 6.3 Connector/Signal Identification 6.4 Jumper Settings 6.5 Fuse 6.6 Test Points 6.7 ~emoval/~eplacement ...........................................
.............................................. ................................................... ................................. ............................................... ....................................................... ......................................................
.7.1POWER SUPPLY UNIT (A2OB-1000-0770) ................................. Theory of Operation ............................................ 7.2 Block Diagram ................................................... 7.3 Connector/Signal Identification ................................. 7.4 Variable Resistors .............................................. 7.5 Fuses ...........................................*............... 7.6 Test Points ..................................................... 7.7 Removal/~eplacement............................................. 8. MAIN CPU BOARD (A16B.1211.0040. 0041) .............................. 1-67 8.1 Theory of Operation ........................................ 1-67 8.2 Block Diagram .............................................. 1-67 8.3 Connector/Signal Identification ................................. 1-67 8.4 LEDs ............................................................ 1-70 8.5 Test Points ..................................................... 1-71 8.6 Removal/Replacement ............................................ 1-72 .................................... 9 . PATH CPU BOARD (A16B.1211.00.30) 9.1 Theory of Operation ............................................ 9.2 Block Diagram ................................................... 9.3 Connector/Signal Identification ................................. 9.4 LEDs ............................................................ 9.5 Jumper Settings ................................................. 9.6 Variable Capacitor ............................................... 9.7 Test Points ..................................................... 7
............................................. 10. SHARED RAM BOARD (A16B-1211-0860) ................................. 1-80 10.1 Theory of Operation ...................,....................... . 1-80 9.8
Removal/Replacement
................................................ 1-80 ............................. 1-81 ........................................................... 1-85 .................................................... 1-86
10.2 10.3 10.4 10.5 10.6
Block Diagram Connector/Signal Identification LEDs Test Points Removal/Replacernent
11.4 11.5
Jumper and Switch Settings Test Points
............................................ 1-87 11- BUBBLE MEMORY BOARD (A16B.1211.0090. 0091. 0092) .................. 1-88 11.1 Theory of Operation ............................................ 1-88 11.2 Block Diagram .................................................. 1-88 11.3 Connector/Signal Identification ................................ 1-88 ..................................... 1-90 .................................................... 1-91
.
......................... 1-93 ..................................--..... 1-93 .................................................. 1-94 ................................ 1-95
12 AXIS CONTROL BOARD (A16B.1211.0060. 0062) 12.1 Theory of Operation 12.2 Block Diagram 12.3 Connector/Signal Identification 12.4 LEDs 12.5 Jumper Settings 12.6 Test Points 12.7 Removal/Replacement
.......................................................... 1-102 ............................................... 1-102 .................................................... 1-103 ............................................ 1-103
.................................... 1-104 ............................................ 1-104 .................................................. 1-104 ................................ 1-105 ........................,... 1-106 ............................ 1-106 ......................................... 1-107
13. REMOTE CRTIKB (A13B-0144-B001) 13.1 Theory of Operation 13.2 Block Diagram 13.3 ConnectorISignal Identification 13.4 CRTIKB Control PCB (A16B-1211-0760) 13.4.1 Connectorlsignal identification 13.4.2 Variable resistors 13.4.3 Jumper settings 13.4.4 Test points Removal/replacement 13.4.5 13.5 Keyboard PCB (A86L-0001-0149) 13.5.1 Connectorlsignal identification 13.5.2 Removal/replacement 13.6 CRT Monitor (A61L-0001-0088) 13.6.1 Connectorlsignal identification
............................................ 1-109 1-108 ................................................ ........................................ 1-110 .................................. 1-111 ............................ 1-111 ........................................ 1-111 ................................... 1-112 ............................ 1-112 C102) ............................ 1-113 14. BUILT-IN CRTIKB (AOSB.2051.ClOl. 14.1 Theory of Operation ............................................ 1-113 14.2 Block Diagram ..................................................1-113 14.3 ConnectorISignal Identification ................................ 1-113 14.4 CRT/KB Control PCB (A20B-1003-0340) ............................ 1-114 14.4.1 Connectorlsignal identification ............................ 1-114 14.4.2 Variable resistors ......................................... 1-116 14.4.3 Jumper setting ........................................... 1-116 14.4.4 Test points ................................................ 1-117 ........................................ 1-117 .................................. 1-118 ............................ 1-118 ........................................ 1-118 ......................... 1-119 ............................1-119 ........................................ 1-119
14.4.5 Removal/replacement 14.5 Keyboard PCB (A86L-0001-0149) 14.5.1 Connectorlsignal identification 14.5.2 ~emoval/replacement 14.6 Software Keyboard PCB (A20B-1000-0844) 14.6.1 Connectorlsignal identification 14.6.2 Removal/replacement 14.7 CRT Monitor (A13B-0056-C001) 14.7.1 Connector/signal identification 14.7.2 Adjustment routine 14.7.3 Special adjustment 14.7.4 Troubleshooting flow chart Removal/replacernent 14.7.5
.................................... 1-120 ............................ 1-120 ......................,................. . 1-121 .................................... . . 1-122
................................. 1-124 ........................................ 1-125 15 . f/O BASE UNIT (A03B-0801-C012) .................................... 1-126 15.1 Theory of Operation ......................................... 1-126 15.2 15.3 15.4
Block Diagram ................................................. 1-126 Connector/Signal Identification ............................... 1-126 ............................................ 1-128 Rem~valjRe~lacement
............................. ............................................ ..................................................
16. ROBOT CONTROL MODIJLE (AO3B-0801-C462) 16.1 Theory of Operation 16.2 Block Diagram 16.3 Connector/Signal Identification 16.4 LEDs 16.5 Jumper Settings 16.6 Test Points 16.7 RemovaI./Replacement
................................ ........................................................... ..........................................,...... ...............................-..........*..........
............................................ 17. D I MODULE ..............*.......................................... 1-139 17.1 Theory of Operation ...*................l...............**...... 1-139 17.2 Block Diagram .................................................. 1-140 17.3 Connector/Signal Identification ......................,...*..... 1-140
...........................*............................... 1-142 ............................................ 1-143 1 8. DO MODULE ........................*................................1-144 18.1 Theory of Operation ...................................*........ 1-144 17.4 17.5
LEDs Removal/Replacement
.................................................. 1-145 ................................ 1-145 ........................................................... 1-147 ...................*...*.................................. 1-148 ..................................*.........1-153 1 9. ANALOG INPUT MODULE (A03B-0801-C41O) .............................. 1-154 1 9 - 1 Theory of Operation ............................................ 1-154 19.2 Block Diagram .......*........................................... 1-154 19.3 Connector/Signal Identification ................................ 1-155 19.4 Variable Resistors .............................*............... 1-156 19.5 Test Points .....................*..............................1-156 19.6 Removal/Replacement .......................*.................... 1-158 1-159 19.7 Calibration Procedure ................................*..*...... 20 . ANALOG OUTPUT MODULE (A03B-08014411) ............................. 20.1 Theory of Operation ............................................ 20.2 Block Diagram ................................*................. 20.3 Connector/Signal Identification ................................ 18.2 18.3 18.4 18.5 18.6
Block Diagram Connector/Signal Identification LEDs Fuses Removal/Replacement
.....................................*....... ......................................*..*...... ..........................................*....*.... ............................................ ........................*................. 21 . FIXED 1/0 BOARI) (A16B-1211-0750) .................................. 1-168 21.1 Theory of Operation ............................................ 1-168 20.4 20.5 20.6 20.7 20.8
Variable Resistors Jumper Settings Test Points Removal/~e~lacement Calibration Procedure
21.2 21.3 21.4 21.5
Block Diagram Connector/Signal Identification Jumper Settings Removal/Replacement
..................................................1-168 ................................ 1-169 ................................................ 1-171 ............................................ 1-172 .................................... ............................................ ................................................ ................................. ............................
22 . TEACH PENDANT (AOSB-2051-C142) 22.1 Theory of Operation 22-2 Block Diagram 22.3 Teach Pendant (A05B-2051-Cl42) 22.3.1 Connector/signal identification
1-173 1-173 1-173 1-174 1-174
........ ............................ ......................................... ............................................ ............................................. ...........
Removal/replacement of teach pendant and components 22.3.2 22.4 Teach Pendant Control PCB (A20~-1002-0980) 22.4.1 Connector/signal identification 22.4.2 Variable resistors 22.4.3 Jumper settings 22.4.4 Test points ~emoval/replacementof teach pendant conarol PCB 22.4.5 22.5 Keyboard PCB (A20B-1002-0970) 22.5.1 ~onnector/signalidentification 22.5.2 Removal/replacement of keyboard PCB 22.6 LCD Module (A61L-0001-0109) 22.6.1 Connector/signal identification 22.6.2 Removal/replacement of LCD module 22.7 LCD Control PCB (A61L-0001-0100 #CB1053RP) 22.7.1 Connector/signal identification Removal/replacement of LCD control. PCB 22.7.2
.....................
.................................. ............................ ........................ .................................... ............................
.......................... ..................... ............................ ..................... 23. POWER INPUT UNIT .................................................. 1-184
............................................ 1-184 .................................................. 1-185 ............................................... 1-187 ................................................... 1-189 ........................................ 1-189 .......................... 1-190 ............................ 1-190 ............................. 1-195 ....................................................... 1-197 ................................................... 1-198 .............................................. 1-199
23.1 Theory of Operation 23.2 Block Diagram 23.3 Power Input Unit 23.3.1 Fuses 23.3.2 Removal/replacement 23.4 Power Input Unit PCB (A16B-1310-0530) 23.4 1 Connector/signal identification 23.4.2 ~un&er/shorting strip settings =EDs 23.4.3 23.4.4 Fuses 23.4.5 Test points Removal/replacement 23.4.6
........................................ 1-200 24. TRANSFORMERS ...................................................... 1-201 24.1 Fuses .......................................................... 1-201 24.2 Settings ....................................................... 1-203 25 . HOUR METER ...................................................... . 1-204 25.1 Connector/Signal Identification ................................ 1-204 25.2 Rernoval/Replacement ....................l....................... 1-204 26 . SERVO AMPLIFIER ................................................... 26.1 One-Axis Servo Amplifier for S-420F ............................ 26.1.1 Theory of operation ................................. ..............................................
26.1.2 Block diagram 26.1.3 Connector/signal identification 26.1.4 LEDs 26.1.5 Test points 26.1.6 3umper settings 26.1.7 Removal/replacement 26.2 One-Axis Servo Amplifier for S-420A 26.2.1 Theory of operation 26.2.2 Block diagram 26.2.3 Connector/signal identification 26.2.4 LEDs 26.2.5 Fuse .............................................. 26.2.6 Test points
........................,-. ....................................................... .....................-.................... ............................................ .....................-..-................. ............................ ........................................
..............................--............... ............................ ....................................................... ................................................
.......................................... 1-223 ........................................ 1-224 ................... 1-225 ................................. 1-225 ............................................. 1-225
26.2.7 Jumper settings Removal/replacement 26.2.8 26.3 Dynamic Brake Resistor Unit (A05B-2046-C452) 26.3.1 Theory of operation 26.3.2 Block diagram 26.3.3 Connections 26.3.4 Rernoval/replacement
.
............................................. 1-225 ........................................ 1-225 PANEL .................................................. 1-226
27 OPERATOR'S 27.1 Connector/Signal Identification 27.2 Removal/Replacement
................................ 1-227 ........................................... 1-231 28. BATTERY UNIT ...................*..................................1-232 28.1 Connector/Signal Identification ................................ 1-232 28.2 Removal./Replacement ........................................ 1-232 29. OUTLET UNIT AND GROUND CONNECTED LAMP ............................. 1-233
........................................................... 1-233 ........................................................... 1-233 ........................................... 1-233 30. SERVO-ON RELAY UNIT AND SERVO-ON LAMP ............................. 1-234 30.1 Connector/Signal Identification ................................ 1-234 30.2 Lamp ........................................................... 1-234 30.3 Removal/Replacement ......................................... 1-235 31 . FAN UNIT .......................................................... 1-236 31.1 Operation of the Heat Exchange System .......................... 1-236 1-237 31.2 Removal/Replacement .......................................... 32. ABSOLUTE PULSE CODER .............................................. 32.1 Theory of Operation ............................................ 32.2 Block Diagram .................................................. 32.3 Connector/Signal Identification ................................ 32.4 Variable Resistors ............................................. 32.5 Test Points ..................................................... 32.6 Removal/Replacement ............................................ 32.6.1 Replacing pulse coder ....................................... 32.6.2 Replacing batteries ........................................ 29.1 29.2 29.3
.
Lamp Fuse Remova.l/Replacement
.................................................... 1-249 ..................................... 1-249 ............................................ 1-249
33 DISCHARGE UNIT 33.1 Location of Discharge Unit 33.2 Removal/Repl.acement 11
. 1.
S-420F MECHANICAL UNIT MAINTENANCE
...................................................... 2-1 ....................,.-................. . 2-1 .....................................-.. 2-2 ......................................,. 2-2 .......................................... 2-3
CONFIGURATION 1.1 8-axis Drive Mechanism 1.2 ll/W- axis Drive Mechanism 1.3 a/B-.axis Drive Mechanism 1.4 y-axis Drive Mechanism 1.5 Major Component Specifications
2. LUBRICATING CONDITION CHECK
.................................. 2-3 ........................................ 2-5
2.1 2.2 2.3
3
................................................ 2-5 ............................................ 2-5 .............................................. 2-7
Quarterly Checks Replacing Oil/Grease Greasing Procedure
....................................................2-10 ......................................................... 2-10 ............................................. 2-10
.
TROUBLESHOOTING 3.1 General 3.2 Problems and Causes 3.3 Replacing P a r t s and Performing Adjustments
...................... 2-12 4 . ADJUSTMENTS ........................................................ 4.1 Adjusting L i m i t Switches and Dogs ................................ 4.2 0-axis Stroke Modification ...................................... 4.3 Mastering Procedure .............................................
............................................. ......................................... ........................................ ......................... 5 . REPLACING MECHANICAL PARTS ......................................... 2-24 5.1 Replacing Battery ............................................... 2-24 5.2 Replacing 9-axis Motor and Reducer .............................. 2-25 5.3 Replacing UiW-axis Motor and Reducer ............................ 2-28 5.4 Replacing a/B/y-axis Motor and y-axis Reducer ................... 2-30 5.5 Replacing Wrist Unit ......................*................... 2-32 6 . PIPING AND WIRING .................................................. 2-33 6, 1 Piping Diagram .................................................. 2-33 6.2 Wiring Diagram .................................................. 2-34 6.3 Limit Switch I n s t a l l a t i o n Diagram .....................*......... 2-35 6.4 Mechanical Unit Cable I n s t a l l a t i o n Diagram ...................... 2-35 7 . REPLACING ELECTRIC CABLES .......................................... 2-36 7.1 Clamping Cables ................................................. 2-36 7.2 Replacing Cables ................................................ 2-38 4.3.1 4.3.2 4.3.3 4.3.4
7.3
.
111
Replacing Limit Switches
........................................ 2-42
S-420A MECHANICAL UNIT MAINTENANCE
.
1
Introduction Mastering procedure Zero-degree p o s i t i o n Mastering using a mastering f i x t u r e
...................................................... 3-1 .......................................... 3-2 ........................................ 3-2 ........................................ 3-2 .......................................... 3-2
CONFIGURATION 1.1 0-axis Drive Mechanism 1.2 U/W-axis Drive Mechanism 1.3 a/B-axis Drive Mechanism 1.4 y-axis Drive Mechanism 1.5 Major Component S p e c i f i c a t i o n s
.................................. 3-2 2 . LUBRICATING CONDITION CHECK ........................................ 3-4 2.1 Quarterly Checks ..............................-............. 3-4 2.2 Replacing Oi.l/Grease .......................................... 3-4
............................................. 3 . TROUBLESHOOTING ................................................. 4 . ADJUSTMENTS ........................................................ 5 . REPLACING MECHANICAL PARTS ......................................... 2.3
Greasing Procedure
3-6
3-9 3-9 3-9
6
.
.................................................. .................................................. ..................................................
PIPING AND WIRING Piping Diagram Wiring Diagram Limit Switch Installation Diagram Mechanical Unit Cable Installation Diagram
6.1 6.2 6.3 6.4
............................... ...................... 7 . REPLACING ELECTRIC CABLES ........................................ 7.1 7.2 7.3
................................................. ................................................ ........................................
Clamping Cables Replacing Cables Replacing Limit Switches
. CONNECTIONS 1 . GENERAL ............................................................ 4-1 1.1 Block Diagram ................................................... 4-1
IV
SAFETY PRECAUTIONS . ..................e............e............. General Safety Precautions
2.
4-2 ......................................................... 4-2 .............................................. 4-2 3 . CONTROLLER CONNECTIONS AND SIGNALS ...............*................. 4-5 3.1 Connection Diagram .............................................. 4-5 3.1.1 Cable clamp ................................................. 4-5 3.2 Connections ..................................................... 4-6 Input power connection ...................................... 4-6 3.2.1 3.2.2 Connection for external. on-off control of power supply ...... 4-7 3.2.3 Connection to 1/0 devices ................................... 4-8 Connection to pulse encoder for line tracking ............... 4-10 3.2.4 3.2.5 Controller and peripheral device connections ................ 4-13 3.2.6 Connection for emergency stop control ....................... 4-27 3.2.7 Connection to computer ...................................... 4-29 Connection to remote CRT/KB ................................. 4-31 3.2.8 3.3 Setting USAT .................................................... 4-32 1/0 Module Specifications ....................................... 4-40 3.4 3.5 Fixed I/O Board Specifications ...*..............................4-58 4 . MECHANICAL UNIT .................................................... 2.1 2.2
4.1 4.2
......... ................................................ ................................................. .......... ........................ ...........................................
Connection between the Control Unit and Mechanical Unit Connections and Signals between Mechanical Unit and End Effector 4.2.1 Connections 4.2.2 DI/DO standards for end effector control interface 4.2.3 End effector control interface cable 4.2.4 Noise suppressors 4.3 S-420F Mechanical Interface 4.. 3.1 Robot interference area 4.3.2 Mechanical coupling of the end effector to the wrist 4.3.3 Location and dimensions of equipment mounting holes 4.3.4 Air-pressure supply 4.4 S-420A Mechanical Interface 4.4.1 Robot interference area Mechanical coupling of the end effector to the wrist 4.4.2 4.4.3 Location and dimensions of equipment mounting holes 4.4.4 Air-pressure supply
..................................... ........................*............ ........ .........
......................................... .............................. .....................................
........ ......... ...............................-..
INSTALLATION
V.
.......... ......................................... . 5-1 ................................. 5-1 .............................................. 5-1 ................................................ 5-1 ............................................ 5-4
.
1
S-420F ROBOT 1.1 Transportation and Installation 1.1.1 Transportation 1.1.2 Installation 1.1.3 Maintenance area 1.2 Assembly During Installation
.................................... 5-4 ........................................ . . . . . 5-6 ................................ . . . 5-7 ................................. 5-8 2 . S-420A ...................................... ~ . . . . . . . . . 5-9. 2.1 Transportation and Installation ................................. 5-9 2.1.1 Transportation .............................................. 5-9 2.1.2 1nstal.lation................................................ 5-9 2.1.3 Maintenance area ............................................ 5-12 2.2 Assembly During Installation .................................... 5-13 3. ADJUSTMENTS AND CHECKS DURING INSTALLATION ......................... 5-14 3.1 Items to be Checked ...............................*............. 5-14 4 . INITIAL START ZTP ................................................... 5-22 4.1 Description of Initial Start Up ................................. 5-22 4.2 Recovery from Alarm Conditions .................................. 5-23 General error recovery ...................................... 5-24 4.2.1 4.2.2 Overtravel ................................................ 5-25 4.2.3 Emergency stop .............................................. 5-25 Vf . APPENDIXES APPENDIX 1. INTERNAL CONNECTIONS ...................................... 6-1 1-1 S-420~/A .........................................................6-1 1.2 Power Input Unit Connection Diagram ............................. 6-16 1.2.1 1.2.2 1.2.3
Robot cables Air piping 1nstall.ation specifications
...................................... 6-20 PREVENTIVE MAINTENANCE SCHEDULES .......................... 6-24 Preventive Maintenance Schedules ................................ 6-24
. APPENDIX 3 . APPENDIX 2 3.1 3-2
CABLE SPECIFICATIONS
Preventive Maintenance Check List
...............................
................ 6-27 .................................
. SYSTEM IY;APHABETICAL DESCfiIPTIONS 4 1 SystemVariab1e Descri.ptions
APPENDIX 4
6-25
I. OVERVIEW AND CONTROLLER MAINTENANCE
1. INTRODUCTION T h i s manual p r e s e n t s a d e s c r i p t i o n of t h e S-420F and S-420A r o b o t s and a l s o a c o n t r o l l e r and each of i t s components, i n c l u d i n g d e s c r i p t i o n of t h e R-H component setting, adjustment and replacement procedures. Preventive maintenance and t r o u b l e s h o o t i n g methods a r e a l s o d e s c r i b e d . The c o n t r o l l e r and mechanical u n i t s p e c i f i c a t i o n s are: Mechanical u n i t
Control.ler.
S-420F
High-speed a a x i s High-torque a a x i s
A05B-1302-B201 A05B- 1302-B202
A05B-2052-BOO1
S-420A
High-speed a a x i s High-torque a axis
A05B-1302-B231 A05B-1302-B232
A05B-2052-BOO1
The s p e c i f i c a t i o n number can be found on t h e MFG p l a t e as shown i n Fig.
p l a t e
Fig. 1 Position of MFG plate
1.
1.I Structure F i g . 1.1 shows t h e c o n f i g u r a t i o n of t h e robot.
CRT/KH panel
Opcraior's panel
Teach pendant
Control u n i t
Mechanical u n i t Fig. 1.1
Configuration
The S-420F/A is a n a r t i c u l a t e d r o b o t w i t h a i x a x e s as shown i.n Fig. mechanical u n i t i s provided w i t h 8 a x i s (base r o t a t i o n ) , W axis r o t a t i o n ) , U axis (elbow r o t a t i o n ) , y a x i s ( w r i s t end r o t a t i o n ) and B bending) , and a axis ( w r i s t r o t a t i o n ) . The c o n t r o l uni.t i s comprised of t h e o p e r a t o r ' s p a n e l , t h e CRT/KB and pendant.
1.1. The (shoul.der axis(wrist t h e teach
1.2 Problem Conditions and Determining Causes To c o r r e c t l y i d e n t i f y t h e c a u s e o f problem, i t is necessary t o a n a l y z e t h e problem c o n d i t i o n s a c c u r a t e l y , To minimize t h e downtime caused by t h e s e problems, p e r f o m t h e f o l l o w i n g checks: F i r s t make a preliminary check of items (a) t h r u (c). Second, make s u r e t h a t t h e problem has n o t been caused by T h i r d , f i n d o u t whether t h e i n c o r r e c t o p e r a t i o n o r e r r o r s i n programming. malfunction is i n t h e c o n t r o l u n i t o r t h e mechanical u n i t ,
a
12.1 Making preliminary check
a ) Is t h e r o b o t b e i n g o p e r a t e d normal.ly? (Check emergency s t o p , t e a c h pendant DISABLE/ENABLE switch, hold.) b) Is an e r r o r message d i s p l a y e d ? c ) I h e n and i n what l o c a t i o n d i d t h e problem o c c u r ? What i s i t s frequency? Note t h e following: . Mechanical p o s i t i o n where t h e problem occurred . E r r o r message d i s p l a y e d . Problem frequency . Amount of p o s i t i o n i n g e r r o r Display of t h e program p o s i t i o n where t h e problem occurred . Software s e r i e s and e d i t i o n nunber d i s p l a y e d o n t h e CRT when the power i s turned on.
System variables Compare the values set in system variables to the standard values for system variables set in the control unit, . Results of interface signal check by using the diagnostic system. In what part of program did the problem occur? (program name, line number, 'etc.) Is the problem related to the movement of a controlled axis?
.
1.2.2
Locating the cause of the problem
Identify an abnormal symptom by using the analysis of the above items, and determine a probable cause of the problem from the following: a) Error in operation or programming Operate the robot correctly and note any difference. b) A problem in a peripheral device, remote control panel, or another externally connected unit. Check the interface signals between the system and error messages. If necessary, change the externally connected unit to agree with the interface diagram. c) Control unit check Check to see if any of the LEDs used on the PCBs in the control unit are lighted indicating the cause of an alarm. If an alarm related to the servo system has occurred, check the LEDs in the servo amplifier to determine the axis which is the cause ;of the problem. Check whether this LED is lighted before turning off the power supply. 1 2 3 Checking the mechanical unit
Check the following: a) External damage Check the mechanical unit for damage due to foreign substances in the unit or contact with peripheral devices or other external equipment. b) Excessive load or external force Is the force required for the movement of the workpiece within the limit conditions set for the robot? Has excessive external force been applied? c) Cables and hose Are cable connectors securely connected? Are moving cables and internal cables free of damages, sharp bends, or other defects? Are there any air leaks? d) Smooth movement Is the servo amplifier functioning normally? Do the axes decelerate smoothly without any shock when the robot stops? Are there any abnormal noises or vibrations during movement?
2. SAFETY GMF Robotics C o r p o r a t i o n i s concerned with t h e s a f e t y and w e l f a r e of i t s c u s t o m e r s , t h e i r employees, and t h e i r equipment. However GMF does n o t design o r i n s t a l l s a f e t y r e l a t e d equipment and consequently cannot be r e s p o n s i b l e f o r e n s u r i n g t h e s a f e t y of t h e v a r i o u s u s e r personnel. GMF e x p r e s s l y d i s c l a i m s any such r e s p o n s i b i l i t y . S a f e t y s h o u l d , however, b e g i v e n t h e h i g h e s t p r i o r i t y i n d e s i g n i n g and u s i n g a r o b o t system. Although t h e u s e r must comply w i t h a l l f e d e r a l , s t a t e , and municipal laws, r e g u l a t i o n s , o r g u i d e l i n e s p e r t a i n i n g t o s a f e t y , t h e u s e r must a l s o t a k e such s t e p s a s may b e n e c e s s a r y t o e n s u r e t h e s a f e t y of a l l personnel.
2.1 Personnel Safety Considerations 2.1 .I General precautions While GMF cannot b e r e s p o n s i b l e f o r t h e s a f e t y o f t h e r o b o t system d e s i g n , GMF s t r o n g l y recommends t h a t t h e f o l l o w i n g s t e p s be t a k e n t o promote t h e s a f e t y of u s e r personnel. These s u g g e s t i o n s a r e intended t o supplement and n o t r e p l a c e any f e d e r a l , state, o r l o c a l laws, r e g u l a t i o n s , o r g u i d e l i n e s , T r a i n a l l i n d i v i d u a l s a s s o c i a t e d w i t h t h e r o b o t system i n a n approved GEfF t r a i n i n g course. Equip t h e system w i t h a f l a s h i n g l i g h t o r other v i s u a l o r audPb*le warning d e v i c e t o i n d i c a t e when t h e r o b o t i s o p e r a t i n g (i.e. power is a p p l i e d t o t h e robot's servo drive units). P r o v i d e an i n t e r l o c k e d b a r r i e r guard, such a s t h a t shown i n Fig. 2.1.1, which c u t s d r i v e power t o t h e s e r v o s when a b a r r i e r g a t e is opened.
. .
.
Fig..2.1.1
. Ensure . -
Use of a fence to secure work area
t h a t a l l . p e r i p h e r a l . d e v i c e s a r e p r o p e r l y grounded t o minimize t h e e f f e c t s of e l e c t r o m a g n e t i c i n t e r f e r e n c e (EMI) and radio-frequency i n t e r f e r e n c e (RFI ) Locate a l l c o n t r o l s o u t s i d e t h e r o b o t mechanical u n i t ' s work envel.ope. C l e z r l y i d e n t i f y t h e work envelope of t h e r o b o t w i t h s i g n s , l i n e s on t h e f l o o r , and s p e c i a l . b a r r i e r s .
.
. Use
.
presence-sensing devices such as light curtains, mats, capacitance systems, proximity-sensing devices, and vision systems to enhance safety. Make provisions for power lockout/tagout.
2.1 -2 Operator safety precautions
Implement the following measures to safeguard the operator. Use anti-tie-down logic to prevent the operator from bypassing safety measures. Install a lockout device using an "access code" to prevent unauthorized persons from operating the robot. Mount EMERGENCY STOP switches within easy reach of the operator and at critical points in and around the work cell. , Where possible, install safety fences, shown in Fig. 2.1.1, to protect against unauthorized entry into the work envelope, , Install special guarding to prevent the operator from reaching into restricted areas of the work envelope.
. .
.
2.1.3 Teacher safety precautions
Implement the fol.lowing safety measures to safeguard the program teacher. ,-Before teaching, make a visual inspection of the robot and work envelope to ensure no potentially hazardous conditions exist, , Before entering the york envelope, confirm that all safeguards are in place. When teaching positional data, the teacher must have sole control of the robot, , When data is being taught, isolate the robot from all remote control signals that can cause motion. , Any program being run for the first time should \ e tested in the following manner :
.
WARNING: The user should remain clear of the robot's work envelope at a11 times when a program is being run. I, Using a low motion speed, test run the program in the single step mode for at least one full cycle, 2, Using a low motion speed, test run the brogram in the continuous mode for at least one full cycle. 3. Using a higher motion speed, test run the program in the continuous mode for at least one full cycle. 4. If the program operates correctly for each of the above tests, install. all safety measures and run the program in automatic mode.
. work Do not begin an automatic mode of operation until the teacher is clear of the envelope. 2.1.4
Maintenance personnel safety considerations
Implement the following safety measures to safeguard maintenance personnel. , Where possible, perform maintenance with the power off. Implement lockout/tagout procedures and release or block all stored energy (air, etc.). Before entering the work envelope, make a visual inspection of the robot system to ensure that no potentially hazardous conditions or malfunctions exist. Functionally test the teach pendant for proper operation before entering the work envelope. . When maintenance must be performed inside the work envelope with power applied, those inside the work envelope must have sole control of the robot. Isolate the robot from all remote control signals,
-
. .
Do not place t h e robot i n t o automatic mode u n l e s s a l l personnel a r e c l e a r of the work envelope, Place t h e robot arm i n a 1ocati.on t h a t w i l l ensure t h a t personnel w i l l n o t be exposed t o a t r a p p o i n t - An escape p a t h should always be provided. Use d e v i c e s such a s b l o c k s , mechanical s t o p s , and p i n s t o prevent hazardous movement of t h e r o b o t . Care must be taken t o ensure t h a t such d e v i c e s do not g e n e r a t e t r a p p o i n t s f o r personnel, For some procedures, a second person should be positioned a t t h e o p e r a t o r ' s panel. This person must have proper understanding of t h e robot system and knowledge of t h e a s s o c i a t e d p o t e n t i a l hazards.
2.2 Machine Tool and Peripheral Device Safety Considerations 22.1 Programming precautions
Implement t h e f o l l o w i n g programming s a f e t y measures t o prevent damage t o t h e machine t o o l and o t h e r p e r i p h e r a l devices. Back-check any 1.i.mit s w i t c h e s used i n t h e work c e l l t o i d e n t i f y f a i l u r e b e f o r e any component of t h e work c e l l can b e damaged. Implement " f a i l u r e r o u t i n e s " i n r o b o t programs t h a t are designed t o p r o v i d e a p p r o p r i a t e r o b o t a c t i o n s i n t h e event t h a t a p e r i p h e r a l device o r a n o t h e r robot i n t h e work c e l l f a i l s . Use "handshakingt' p r o t o c o l t o e n s u r e t h a t t h e o p e r a t i o n s of t h e r o b o t and t h e p e r i p h e r a l d e v i c e are synchroni.zed, , Program t h e r o b o t t o check t h e c o n d i t i o n of a l l p e r i p h e r a l d e v i c e s d u r i n g a n o p e r a t i n g cycle.
.
222 Mechanical precautions Implement t h e f o l l o w i n g mechanical s a f e t y measures t o prevent damage t o t h e machine t o o l and o t h e r p e r i p h e r a l devices. Ensure t h a t t h e work c e l l i s c l e a n and f r e e of o i l , water, o r d e b r i s o f any kind. Limit t h e work envelope of t h e robot through t h e u s e of l i m i t s w i t c h e s (software l i m i t s ) and mechanical s t o p s t o avoid unnecessary movement o f t h e robot i n t o t h e work area of t h e machine t o o l and peripheral. devices.
. .
2.3 Robot Safety Considerations 2.3.1 Operating precautions
Implement t h e f o l l o w i n g o p e r a t i n g s a f e t y measures t o prevent damage t o t h e robot. When jogging t h e r o b o t , u s e a low speed o v e r r i d e t o o b t a i n g r e a t e r c o n t r o l of t h e mechanical u n i t . Before p r e s s i n g any of t h e manual jog keys on t h e teach pendant, t h i n k of t h e robot motions t h a t w i l l r e s u l t .
. .
.
2..3.2Programming precautions
Implement t h e f o l l o w i n g programming s a f e t y measures t o prevent damage t o t h e robot. When two o r more r o b o t s must s h a r e t h e same work a r e a , e s t a b l i s h " i n t e r f e r e n c e zones" t o provide o t h e r robot c o n t r o l l e r s and peripheral. d e v i c e s with information r e g a r d i n g t h e l o c a t i o n of t h e robot mechanical u n i t d u r i n g operation. . Ensure t h a t t h e r o b o t program ends with t h e mechanical u n i t n e a r t h e c a l i b r a t i o n point.
-
2.3-3 Mechanical precautions
Implement the following safety measures to prevent damage to the robot. . Ensure that the work envelope of the robot is clean and free of oil, water, or debris of any kind. Use circuit breakers to guard against electrical overload,
.
2.4 End Effector Safety Considerations 2.4.1
Programming precautions
The following programming safety measures should be implemented to prevent damage to the end effector. Provide an "open-gripper" command just prior to picking up the workpi.ece. Provide a time delay to allow any actuator (pneumatic, hydraulic, or electrical) sufficient time to operate after the appropriate inputloutput command has been given. Use output signals from limit switches in the end effector to verify that the end effector is operating properly (i.e. a part-in-gripper limit switch). , Program a reduced deceleration rate as the robot approaches a "pick-up point" or workpiece to prevent an overshoot of the programmed poht.
. . .
2.4.2 Mechanical precautions
Implement the following mechanical safety measures to prevent damage to the end effector Use a safety joint to protect and end-of-am tooling. Design sufficient compliance into the end effector to allow for small variations in the orientation of the workpiece, Install sensors on the end effector (i,e., photoelectric, cats-whisker limit switch) to detect when the end-of-arm tooling is approaching an obstruction. , Use a vision system to ensure that the robot mechanical unit and end effector are oriented properly to pick up the workpiece, , Use additional hardware to ensure that the workpiece is oriented properly so that the robot mechanical unit end effector picks up the part correctly.
. . .
.
3. CONTROLLER DESCRIPTIONS 3.1 General Description The c o n t r o l l e r c o n t r o l s s e r v o motors provided f o r each a x i s of t h e robot. It a l s o c o n t r o l s t h e end e f f e c t o r and i n t e r f a c e s i g n a l s between t h e c o n t r o l l e r and a s s o c i a t e d p e r i p h e r a l devices. The c o n t r o l l e r contains t h e following components: 1) Basic c o n t r o l u n i t ( i n c l u d i n g backplane, power supply u n i t , and c o n t r o l PCBs) 2) 1/O u n i t , Fixed 110 board 3) Battery u n i t 4) Circui.t breaker, Disconnect switch 5) Power i n p u t u n i t 6) Servo a m p l i f i e r 7) Operator's panel 8) Remote CRT/KB u n i t o r B u i l t - i n CRT/KB panel 9) Teach pendant 10) Transformers 11) Fan u n i t s 12)- Outlet u n i t 13) Servo-on r e l a y u n i t (g). The connection of each u n i t i s shown i.n Fig. 4.1 (a) The f u n c t i o n of each u n i t i.s shown i n Table 3.1.
-
L
r_
7
) Modular 1"
unit
Power input unit
c ~ - - - - - - - -
---------
--Operator's
panel
Pulseencoder
Servo arnplif~en
CN1 Amp. 1 TI
CN1 Amp. 2 TI OI1 A m p 3
CNBA?' U
7
1 )
Battery unit
Fig.. 3..1(a) Connection diagram (Controller with modular 1/0 unit)
}
Backplane CNPZ
IS_CNPZ
CNP3 -A0
110 base unit rnA1
OJA.
]Ti ----I
cop4
Robot control module
CNB CNC
If----------0
, 4 ~ q ,fzLzzzq~
mA3
CNA4
1fxzEzqi#
-5
6
a- f3
--
4-{I
Fig. 3.1
(b) Connection diagram (Modular 1/0 unit)
Backplane CNP3
Shared RAM board COP2 Power input unit CNI Robot mechanical unit
C I
CNPZ
--- - - ~
CNP3
PSUl
CNPI
CNB
VE1
CNA
1
Power supply unit
Power input unit
Vision engine 1
-----------
CNB CNA
VE2
Vision engine 2
f
'
I
Future option
Vision OlPOB CPU board
CNB CNA
b
J
CNPI l)---
1- b- u
Shared 01P04 RAM board
CNA
Q----
CNOP 'OP2
operator\ pane,
CD4
~ o scomputer t
Backplane CNA
WUbD
I
I
I
CNA
R~~CPU 01P02 board
CNA
Bubble memory 01P08 board
Pulse encoder
for line tracking
I Robot mechanical
. unit CNA
board for customer use
Servo amplifiers Axis OIP05 control board
CNA
CN1 Amp.2 T1 CN1 Amp.3 T1 CN1 Amp.4 T1 Axis 02P05 control board
CNA
CV21
-
CNBA'T U
'7
)
Battcry unit
I
Fig. 3..1(c) Connection diagram (Controller with fixed 110 board)
Operator's panel
--
Customer's logic
Remote CRTjKB
,,, 0--
Shared RAM
E-STOP button
Robot control
I
Power input unit
1
Fig. 3.1 (d) Connection diagram of the controller (Remote CRT/KB, operator's panel, power input unit, circuit breaker
Operator's panel
Customer's logic
1 -
Shared RAM board
RS-232C 110 device
E-STOP button
Fig. 3.1 (e) Connection diagram of the controller (Remote CRTIKB, operator's panel, power input unit, disconnect switch
Built-in CR'TIKB
control PCB
monitor
Operator's panel
EMGl EMG2
CN3 Shared RAM board
-
4[ 0 4 5
')
-- Customer's logic
RS-232C ]
RS-2324 110 device
-
ESTOP button w
Cricuit
,
Control transformer
Robot mechanical unit
I
Power input unit
I
Fig, 3.1 (f) Connection diagram of the controller (Built-in CRTIKB, operator's panel,
power input unit, circuit breaker)
Built-in CRT'IKB
Operator's panel
CN3 Shared RAM
board
[
EMGl EMG2 " m-232C
1-n
Customer's logic
RS-2324 110 device
ESTOP button
Servo transformer
Disconnect AC input+\
3
Fan unit Input transformer Power
CP14 Control transfbrmer Robot control module CNB Shared RAM board CNPI
---.------I
[n---
[ CNl Robot mechanical unit
CN2
Power input unit
Fig. 3.1 (9) Connection diagram of the controller (Built-in CRTIKB, operator's panel, power input unit, disconnect switch)
Table 3.1 Component function
--
S l o t No. o r modu l e No.
Function
Name
Remarks
I
Provides t h e bus connection f o r t h e c o n t r o l PCBs,
Backplane
-----
-PCBs mounted on the backplane
-
Power supply unit
Supplies t h e DC v o l t a g e t o b a s i c c o n t r o l u n i t and t h e I / O u n i t
Main CPU board
. Co-processor
. Main
. .
P a t h CPU board
Shared RAM board
Bubble memory board
CPU
PSUl
01P09
interface DRAM, 1 MB o r 2 MB Battery-backed RAM, 64 kB
. Path CPU . Co-processor i n t e r f a c e . DRAM, 256 kB . Calendar c l o c k
01P02
. Tracking c o u n t e r . RAM, 64 kB . Optical l i n k . RS-422 f o r t e a c h pendant . RS-232-C f o r h o s t computer RS-2324 f o r CRT/KB .. RS-232-C f o r 110 d e v i c e s . Operator's panel i n t e r f a c e . vSat or iraebs l esystem software, system s and K a r e l
01P04
01P08
a p p l i c a t i o n programs 1.5 MB o r 2 MB
. 1 MB, Axis c o n t r o l board
1/0 u n i t
I/O b a s e u n i t
.PCB mounted i n 1/0 base u n i t
Robo t control module
. D i g i t a l servo c o n t r o l . D i gi t a l servo c o n t r o l
( 4 axes) (2 a x e s )
01P05 02P05
Bus connection between t h e v a r i o u s 1 / 0 modules i n c l u d i n g t h e r o b o t control. module, D I / D O modules, and analog 1/0 modules
. I n t e r f a c e between b a s i c c o n t r o l u n i t and IjO u n i t . Robot mechanical u n i t interface . Power i n p u t u n i t i n t e r f a c e
RCOlC
--
S l o t No. o r modu l e No.
Function
Name
D I module
(Cont'd)
Input f o r p e r i p h e r a l device control (Various types a r e prepared f o r i n p u t c o n t r o l . Details a r e d e s c r i b e d i n s e c t i o n 17.)
Remarks
ID08Cy ID16C, ID08D, ID16D, IA08E o r
IA16E DO module
Output f o r p e r i p h e r a l d e v i c e control (Various t y p e s are prepared f o r output c o n t r o l . Details a r e d e s c r i b e d i n s e c t i o n 18,)
,
Analog i n p u t module
Analog i n p u t f o r p e r i p h e r a l device c o n t r o l (Details are d e s c r i b e d i n s e c t i o n 19.)
AD04A
Analog output module
Analog o u t p u t s f o r p e r i p h e r a l device c o n t r o l ( D e t a i l s are dezcri'bed i n s e c t i o n 20.)
DA02A
Fixed 1/0 board
, Robot
. Power i n p u t u n i t
-
Input u n i t PCB
. Power ON/OFF c o n t r o l c i r c u i t . Magnetic c o n t a c t o r . Fuses . .
ON/OFF c o n t r o l Relay c i r c u i t f o r emergency stop control Motor brake c o n t r o l c i r c u i t
-
Servo amp1 i f i e r 1
mechanical u n i t interface Power i n p u t u n i t i n t e r f a c e
B a t t e r i e s f o r RAM are mounted.
Battery u n i t
PCB mounted i n power input u n i t
OD08B, 0D16By 0D08Cy OD16C, OD08G, 0D16Gy OA08D, OA16D, OA08E o r 0 %6~ ~
Unit t o amplify t h e PWM s i g n a l s and d r i v e t h e s e r v o motors
-
--
J
-
7 -
I
Name
1 1 Slot No. I Function ( or mod- / I
Operator's panel
. Lamps and switches to operate the robot . Connector panel for RS-232-C
1 Remarks
ule No.
. Connector panel for the CRTIKB . Hour meter (option on vertical operator's panel, large size cabinet) Teach pendant
Transfo m e r
Servo transformer Input transformer Control transformer
. 40 x 8 characters LCD 40 keys and DEADMAN switch . EMERGENCY STOP button . AC power drive source for the . 200 VAC for the power unit ,
. User transformer Fan units
TF1
servo amplifiers
Outputs 100 VAC for MCC contacts in servo amplifier and motor brakes. For S-420A, provides 18 VAC for servo amplifiers.
. Provides 115 VAC for the user,
TF4 TF3
TF5
. Fans are provided to cool inside the main or connecting cabinet. , Fans are provided to circulate air inside the main cabinet.
Outlet unit
. 115 VAC output terminal for maintenance
r
-1
Servo-on relay unit
Relay circuit that outputs the servo on status to external equipment.
3.2 External Components Various external components are provided for the R-H controller. teach pendant, operator's panel and CRTIKB.
They are the
I
+
Fig.
RISER (OrnON)
3.2 (a) External view of controller (S-420 controller breaker handle)
RISER (OPTION)
Fig..3.2 (b) External view of controller (S-420 controller disconnect switch)
1- 19
P I
--TEACH PENDANT EIUBLED
PANEL ENABLE0
IN CYCLE
NOT CALIBRATED
POWER ON
(3 \ 4
@
o
i
In
@
CrFLElrqRT
W
c3 E
63
T'-==R .T
D U E FAULT
NOT WlBRITEO
CYCLE
CbUaBCLTE
HEU)
lLJl
FAULT
@
@
@
c3
OVERTRAVEL
OVERTRAVEL
FAULT RESET
FAULT R E S T
l o
ol
(For built-in CRTJKB)
(For remote CRT/KB)
Fig. 3 2 (c) External view of vertical type operator's panel (Large size cabinet)
Fig. 3.2 (d) External view of built-in CRTIKB (20" angled)
1-20
Fig. 3.2 (e)
External view of built-in CRTIKB (40" angled)
370
Fig..3.,2 (f)
External view of remote CR'f/KB
HI
ri
I Ili
Fig. 3.2 (g) External view of the teach pendant
3.3 Internal Components Various components are mounted in the controller. They are the basic control unit, 1/0 unit, servo amplifiers and so on. For the internal components location diagram, refer to Fig. 3.3.
Servo amp. 2
\\
servo amp. 1
Servo tmnsforrner
Fig.. 3..3 internal components iocation (S-420 controller)
1-23
3.4 Controller Components Specifications A05B-205 1-BOO 1
Unit
P a r t number
Controller
A05B-2052-BOO1
Basic c o n t r o l u n i t Backplane Power supply u n i t -Main CPU board Path CPU board Shared RAM board Bubble memory board 1 / 0 board Axis c o n t r o l board
A20B-1002-0860 A20B-1000-0770 A16B-1211-0040 A16B-1211-0041 A16B-1211-0030 A16B-1211-0860 A16B-1211-0090 A16B-1211-0091 A16B-1211-0092 A16B-1211-0750 A16B-1211-0060 A16B-1211-0062
7
t L
-
,.,.. 01P09 2MB DRAM ,.... 01009 1MB DRAM ,.... 01P02 ..... OlP04 ..... OlP08 2MB ..,.. 01P08 1,5MB ,,... 01P08 1MB .,... 01P05 4-axis
,.... 02P05 2-axis
I/O unit
I -7 1 / 0 base u n i t L ~ backplane / ~ PCB Robot c o n t r o l module Analog i n p u t module Analog o u t p u t module D I module
DO module
B u i l t - i n CRT/KB u n i t (20 degree angled) (40 degree angled) -CRT monitor Control PCB - Keyboard PCB Software keyboard PCB
AO3B-0801-C012 A20B-1002-0450 A03B-0801-C462 - A03B-0801-C410 A03B-0801-C411 A03B-0801-C420 A03B-0801-C421 A03B-0801-C422 A03B-0801-C423 A03B-0801-C424 A03B-0801-C425 A03B-0801-C440 A03B-0801-C441 A03B-0801-C442 A03B-0801-C443 A03B-0801-C444 A03B-0801-C445 A03B-0801-C446 AO3B-0801-C447 AO3B-0801-C448 -A03B-0801-C449
.. . .,.,. AD04A ..... DA02A .,... ID08C ...,. ID16C ,,... ID08D ,.,.. ID16D .,... IA08E ,.... IA16E ,,,.. OD08B ...,. OD16B ,.... OD08C ,.... OD16C ,.... OA08D ..... OA16D ,.... OA08E , , RCOlC
..... OA16E
..... OD08H ...,. OD16H
-
Unit
Part number
Remote CRT/KB unit CRT monitor Control PCB Keyboard PCB Fan unit
A13B-0144-BOO1 A61L-0001-0088 A16B-1211-0760 A86L-0001-0149 A13B-0144-CQ01
Battery unit Battery case Battery
A98L-0004-0096 A98L-0031-0005 (3 units are necessary)
Operator's panel (Vertical type) (Vertical type)
A05B-2051-C122 (for Remote CRT/KB) A05B-2051-C121 (for Built-in CRT/KB)
t
Outlet unit (Large size cabinet) Servo-on lamp (Large size cabinet) Servo-on relay Lamp switch
t
L~arnp
Power disconnect switch Teach pendant Control PCB Keyboard PCB LCD module LCD control board Fan unit
Fan Fan Fan Fan Fan Fan Fan
1 2 3 4 5
6 7
Transformer Servo transformer TF1 Input transformer TF4 -User transformer TF5 Control transformer TF3
E
Servo amplifier (S-420F) -- B axis (20) -W axis (20F) -U axis (20F) -a axis (10) - 8 axis (10) -y axis (10)
-
Part number
Unit
Servo a m p l i f i e r (S-420A) 8 a s i x (30F) W a x i s (20F) -U a x i s (30F) - a a x i s (10) B a x i s (10) y a x i s (10) (Note) The numbers i n parentheses r e f e r t o t h e motor type. Discharge u n i t
A06B-6050-H050
C i r c u i t breaker (220/240 VAC input) (380-550 VAC i n p u t ) (575 VAC input) C i r c u i t breaker with l e a k d e t e c t o r (220/240 VAC i n p u t ) (380-550 VAC input) Power input u n i t (220/240 VAC i n p u t , breaker) Power i n p u t u n i t PCB Contactor
A60L-0001-0116fDA A60L-0001-0116fBA A14B-0076-B323 A16B-1310-0530 A60L-0001-0042#JG1-30 A58L-0001-0094#200V1AlB
Power input u n i t (380-550 VAC i n p u t , breaker) Power i n p u t u n i t PCB Contactor Power input u n i t A14B-0076-B325 (220/240 VAC i n p u t , disconnect switch) Power i n p u t u n i t PCB A16B-1310-0530 Fuse (FL1-3) A60L-0001-00428JGZ-50 Fuse (F7-9) A60L-0001-0042#JG1-30 Contactor A58L-0001-0094#200V1A1B Power input u n i t A1 4B-0076-B324 (380-575 VAC i n p u t , disconnect switch) Power input u n i t PCB A16B-1310-0530 -Fuse (FL1-3) A60L-0001-0042fJGl-30 Fuse (F7-9) A60L-0001-00428JGlF-15 Contactor A58L-0001-0094?"200VlA1B
E
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PREVENTIVE MAINTENANCE Preventive maintenance i s based upon the amount of hours of operation of t h e robot. Some a p p l i c a t i o n s r e q u i r e a robot t o be o p e r a t i o n a l f o r 24 hours a day, I f the robot is t o operate continually, a l l while o t h e r s r e q u i r e l e s s on-time. check items should be maintained accordingly. The following c h a r t should be used a s a quick r e f e r e n c e guide f o r preventive maintenance. This c h a r t i s based upon hours of o p e r a t i o n and n o t calendar time. Some i t e m s should be checked a s Quality of t h e work accomplished by t h e robot a d a i l y r o u t i n e by t h e operator. Use t h e c h a r t t o should be checked t o determine t h e need f o r mai.ntenance. i n d i c a t e minimum preventive maintenance requirements. Hot, dusty, d i r t y o r o t h e r poor environment w i l l a c c e l e r a t e t h e frequency of maintenance. 4.
Note) Appendix 3 c o n t a i n s a r e f e r e n c e m a t r i x of preventive maintenance schedules and a maintenance check list.
4.1 Daily Checks Clean each p a r t , and v i s u a l l y check t h e o v e r a l l system and component p a r t s f o r damage b e f o r e d a i l y system operation. Check t h e following items as t h e occasion demands, 1) Before automatic o p e r a t i o n check i t e m s one through e i g h t , l i s t e d i n Table 4.1 2) After automatic operation, r e t u r n t h e robot t o t h e z e r o p o s i t i o n and t u r n o f f t h e power. Continue t h e maintenance checks by checking items n i n e through 11 i n Table 4.1, Table 4.3 Daily preventive maintenance checks t
Item
Check i t e m s
Check p o i n t s
Air p r e s s u r e
Check a i r p r e s s u r e using t h e p r e s s u r e gauge on t h e a i r r e g u l a t o r . I f i t does n o t m e e t t h e s p e c i f i e d pressure of 5-7 kg/cm2 (standard 5 kg/cm2), a d j u s t i t u s i n g t h e r e g u l a t o r pressure s e t t i n g handle. See Fig. 4.1.
2
Oiler oil mist quantity
Check t h e drop q u a n t i t y during wrist o r If i t does not m e e t t h e hand motion. s p e c i f i e d v a l u e (1 drop/10-20 s e c ) , a d j u s t i t using t h e o i l e r c o n t r o l knob. Under normal usage t h e o i l e r becomes empty i n about 10 t o 20 days under normal o p e r a t i o n .
3
Oiler oil level
Check t o s e e t h a t t h e o i l e r l e v e l i s w i t h i n t h e s p e c i f i e d l e v e l shown i n Fig. 4.1,
4
Leakage from hose
Check t h e j o i n t s , hoses, e t c . f o r leaks. Repair l e a k s , o r r e p l a c e p a r t s , a s required.
1
When a i r c o n t r o l s e t i s combined
-
-
-
7
5
Visual check of c a b l e s
-
'Refer r o 11-6.2 (S-420A).
--
(S-420F) and 111-6.2
Item
Check items
Check points
6
Vibration, abnormal noises, and motor heating
Check to see that each axis moves smoothly
7
Changing repeatability
Check to see that the stop position of the robot has not deviated from previous stop posi.tions
.
~
Peripheral devices for proper operation
8
-
.
Check whether the peripheral devices operate properly according to commands from robot.
-9
Operating condition of brake
Check for excessive drop (visual inspection only).
10
Cleaning and checking of each part
Clean each part (remove chips, etc.) and check component parts for cracks and flaws.
11
Ventilation portion of control If the ventilation portion of the control unit is dusty, turn off power unit and clean the unit.
Oil inlet
amount check
/ Filter
/
hes®auge
Regulator pressure setting handle Fig. 4.1 Air control set
4.2 Monthly Checks (Determined by hours of operation)
Check the following items monthly. Additional inspection areas and times should be added to the table according to the robot's working conditions, environment, etc. Table 4 2 Monthly preventive maintenance checks (or 500 hours)
Item
I
Check items Check each part for play and looseness
I
Check points
I
4.3 Quarterly Checks Check the following i t e m s once every t h r e e months (or 1000 hours). Table 4.3 Quarterly preventive maintenance checks
Check i t e m s
Item
I
Check l u b r i c a t i o n of w r i s t
Check p o i n t s Refer t o 11-2 (S-420F) (S-420A).
and 111-2
L
4.4 Semiannual Checks Check t h e following i t e m s once every 6 months ( o r 2000 hours). Table 4.4 Semiannual periodic maintenance checks
Check i t e m s
Item
1
DC power v o l t a g e check
Check p o i n t s Check t h e +5 V, +15 V, +24 V, and -15 V power s u p p l i e s of t h e power u n i t and t h e i-24 V, +15 V, and -15 V power s u p p l i e s of t h e s e r v o un5.t f o r t h e s p e c i f i e d values. .i
4.5 Periodic Replacement Replace t h e f o l l o w i n g p a r t s when needed.
1
Replace
Replaced p a r t s
Item
Greasing b e a r i n g of b a l a n c e r
Refer t o 11-2 (S-420F)
and 111-2
(S-42OA). 2
Moved c a b l e s
Refer t o 11-7 (S-420F) (S-420A).
and 111-7
3
~ r e a s i n g / o i l i n gt h e reducer of each a x i s Greasing r o l l e r b e a r i n g and balancer
Refer t o 11-2 (S-420F) (S-420A).
and 111-2
F i l t e r cover on c o n t r o l u n i t
Replace once every two y e a r s i f needed.
1-L
-
-J
Maintenance Tools The following instruments and t o o l s a r e required f o r t h e maintenance procedures contained i n t h i s manual. 1) Measuri.ng instruments
4.6
Accuracy/Tolerance
Instruments
Applications
-
AC v o l t m e t e r
DC v o l t m e t e r
AC power v o l t a g e measurement. Tolerance: Less than +2%
AC power v o l t a g e measurement
Maximum s c a l e 10 V, 30 V Tolerance: Less than +2% (A d i g i t a l voltmeter required 20,000 ohmlvolt)
DC power v o l t a g e measurement
is
Oscilloscope
Frequency bandwidth: DC t o g r e a t e r than 5 MHz, 2 channels
Item
Check items
D i a l gauge
1/100 mm
Slide calipers
150 mm
Push/pull tension gauge
10 kg
Check p o i n t s Measurement of p o s i t i o n i n g and backlash.
I
Bolt t e n s i o n Measurement of p o s i t i o n i n g and backlash
2) Tools Tool Cross-point (-Iscrewdrivers .) Conventional (-) screwdrivers Hexagonal wrench key sets ( m e t r i . ~ ) Adj ustab1.e wrenches Pliers Cutting p l i e r s Grease gun P l i e r s f o r C-retaining r i n g D i a l i n d i c a t o r and s t a n d Socket wrench s e t Torque wrench
Size Large, medium, and s m a l l s i z e s Large, medium, and small sizes M3 - M16 Medium and s m a l l s i z e s Adjustable, l o n g nose Diagonal With o u t p u t p i p e and f i t t i n g I n t e r n a l and e x t e r n a l 0-10 mm range
5.
TROUBLESHOOTING
5.1 Introduction This s e c t i o n c o n t a i n s information f o r troubleshooting t h e system, The m a t e r i a l included h e r e d e s c r i b e s t h e a l a r m s t h a t a r e involved with hardwired c i r c u i . t s . Refer t o t h e KAREL System Reference Manual f o r a d e s c r i p t i o n of a l l of t h e e r r o r codes. 5.2 Power Cannot be Turned On Item
1
Cause of t r o u b l e Input power supply i s n o t connected
Checking procedure
Corrective action
1) Check whether t h e c i r c u i t b r e a k e r o r disconnect switch i s turned on. 2) Check t o see t h a t t h e p i l o t lamp PIL (green LED) i s l i t i n t h e power i n p u t u n i t , (Refer t o 23-4.2)
3) When PIL is OFF, make s u r e t h a t i n p u t power i s supplied connection t e r m i n a l f o r 200R and 200s on t h e power i n p u t unit, -
4) When power is n o t supplied t o t h e power i n p u t u n i t a t 200R and 200S, f u s e F1 on t h e i n p u t transformer TF4 may b e blown,
5) When power i s s u p p l i e d t o power i n p u t u n i t and PIL is OFF, r e f e r t o 23.3.3. Fuses F l y F2, o r F3, on t h e power i n p u t u n i t may be blown, 2
A l a r m lamp i s ON
3
Cable connection
1) Make s u r e t h a t t h e c a b l e s a r e c o r r e c t l y connected a s shown i n Fig. 5.2.
4
POWER OFF s w i t c h on o p e r a t o r ' s panel i s f a u l t y
1) V e r i f y t h a t t h e POWER OFF b u t t o n c o n t a c t i s closed.
-
-
Remove c a u s e s of blown f u s e and r e p l a c e t h e fuse.
Remove c a u s e s of blown f u s e s and replace fuses.
Make s u r e 1) Refer t o 23.4.2. t h a t lamp ALM (red LED) i s OFF. I f i.t i s ON, remove t h e cause. P r e s s POWER OFF button once, and t h e n p r e s s POWER ON b u t t o n t o t u r n power on.
Replace POWER OFF switch,
3
Item
Cause of t r o u b l e
Checking procedure
Corrective a c t i o n
4
POWER OFF s w i t c h on o p e r a t o r ' s panel is f a u l t y
2) V e r i f y t h a t two p i n s "OFF" on t h e power i n p u t u n i t PCB of t h e power i n p u t u n i t a r e shorted. (Refer t o 23.4.1)
5
POWER OFF c o n t a c t of e x t e r n a l power supply ON/OFF
1) Make s u r e t h a t OFF and COM a r e s h o r t e d a t TPl t e r m i n a l on t h e power i n p u t u n i t PCB o f t h e i n p u t u n i t . (Refer t o 23.4.2)
If not shorted, s h o r t them by using a shorting strip,
6
POWER ON s w i t c h on o p e r a t o r ' s panel is f a u l t y
1) V e r i f y t h a t t h e c o n t a c t is c l o s e d when t h e POWER ON b u t t o n is p r e s s e d .
Replace POWER ON switch.
2) Make s u r e t h a t two p i n s "ON" on t h e i n p u t u n i t PCB o f t h e power i n p u t u n i t are s h o r t e d when t h e POWER ON b u t t o n i s pressed. ( R e f e r t o 23.4.2)
OFF
4-, ,
Note External power ONIOFF' switches
11
Power ONIOF'F
Power input unit
Note) A jumper w i r e i s necessary between OFF and COM when e x t e r n a l power ON/OFF s w i t c h e s a r e not a v a i l a b l e . Fig,.5..2Power ONIOFF control
5.3 Troubleshooting Using Error Codes The 4000 e r r o r c o d e s i n d i c a t e problems i n s e r v o c o n t r o l . w i t h t h e e r r o r message i s i n t e r p r e t e d a s follows: 008: 004: 002: 001: 080: 040: 5.3.1
error error error error error error
on on on on on on
1st 2nd 3rd 4th 5th 6th
The number i n c l u d e d
axis axis axis axis axis axis
Error code 4001 DEADMAN switch
T h i s s i g n a l i n d i c a t e s t h a t t h e t e a c h pendant i s enabled and n e i t h e r deadman s w i t c h is b e i n g h e l d . Its f u n c t i o n is t o i n d i c a t e a breakage i n t h e c i r c u i t s t r i n g between t h e t e a c h pendant a n d c o n t r o l l e r . When t h e s w i t c h is h e l d i n , R e l e a s i n g t h e switch, o r breaking t h e c a b l e , w i l l t h e s i g n a l is n o t a c t i v e . Power t o t h e s e r v o a m p l i f i e r i s removed, r e s u l t i n t h e alarm b e i n g d i s p l a y e d . and t h e r o b o t is p l a c e d i n a n emergency s t o p c o n d i t i o n .
Note)
FNl and FN2 are connected Remove connector if safety fence is used. Fig..5.3.1
Error code 4001 DEADMAN switch
5..3.2 Error code 4002 emergency stop
The emergency s t o p a l a r m i n d i c a t e d t h a t o n e o f t h e E-stop b u t t o n s h a s been EFIERGENCY STOP b u t t o n s a r e p r e s s e d or. t h a t t h e E-stop w i r i n g i s d e f e c t i v e . l o c a t e d on t h e t e a c h pendant and on t h e o p e r a t o r ' s p a n e l . Additional buttons may b e connected t o t h e e x t e r n a l emergency s t o p c i r c u i t .
-&jN o m l l y open contact Normally c l d o o n m
L
110 base unit
Fig. 5.3.2 Error code 4002 emergency stop
5.3.3 Error code 4003 pneumatic pressure alarm T h i s alarm i n d i c a t e s t h a t t h e pneumatic p r e s s u r e u s e d i n t h e end e f f e c t o r i s abnormal. Check t h e pneumatic p r e s s u r e a n d / o r p n e u m a t i c p r e s s u r e i n p u t *PPABN t o t h e S e e S e c t i o n 4.2 f o r t h e controller. The c o n t a c t *PPABN i s n o r m a l l y c l o s e d , connecti.on of t h i s c o n t a c t . Robot conrrol n ~ o d u l e
Robot mcchsnical unit
32-34
Kcccivcr
G b l c K9 1
.-
4
Norrmny open contact
110 base unit
-.o-O Normally c l o d c o n m
Fig.. 5.3.4
5.3.5
I
Error code 4004/4005 hand breakage detection and robot overtravel
Error code 4005 robot overtravel
Robot o v e r t r a v e l i n d i c a t e s t h a t a n a x i s h a s exceeded i t s l i m i t s and h a s a c t i v a t e d a l i m i t switch. AI.1 a x e s employ l i m i t s w i t c h e s t h a t are mounted a t t h e p o s i t i v e and n e g a t i v e extremes of t h e motion range and a r e wired i n series. Robot o v e r t r a v e l a l a r m s i n d i c a t e t h a t an opening i n t h e s e r i e s s t r i n g h a s occurred, When t h i s alarm o c c u r s , t h e power i s removed from t h e d r i v e s and brakes a r e applied. The r o b o t a x i s must be moved, u n t i l t h e s w i t c h r e l e a s e s , before r e s e t t i n g is possible. R e f e r t o Fig, 5 . 3 - 4 . 5.3..6 Error code 4006 relay welding detection
T h i s e r r o r i n d i c a t e s t h e c o n t a c t s of t h e emergency s t o p r e l a y (RL2) on t h e power I f t h i s a l a r m cannot be r e s e t , r e p l a c e RL2. i n p u t u n i t PCB a r e welded t o g e t h e r , Note)
For e r r o r c o d e 4007, r e f e r t o s e c t i o n 5 - 3 - 1 0 .
5,.3..7 Error code 4008 TGLS alarm The f u n c t i o n of t h e TGLS alarm i s t o i n d i c a t e a problem i n t h e feedback system. If a Each a x i s p u l s e e n c o d e r ' s i n f o r m a t i o n i s monitored i n t h e c o n t r o l l e r . Refer t o s i g n a l . i s l o s t , t h e a l a r m i s s e n t , and t h e r o b o t motion i s t e r m i n a t e d . t h e following figures,
I1 Robot mechanical unit
1 Axis control board A16B-1211-0060
CF91 W servo motor pulse coder connectors
CF92 U 01P05
cF93 To a,p,7axis servo motor pulse coder connectors
6
+. P2 Axis control board
Fig. 5.3.7 (a)
Error code 4008 TGLS alarm
Fig. 5.3.7 (b) Error code 4008 TGLS alarm
5..3..8 Error codes 4009 - 4034
Error codes 4009 - 4014 i n d i c a t e a problem on the servo a m p l i f i e r . s e c t i o n 5.4 "Troubleshooting Servo Amplifier".
Refer t o
5.3..9 Error code 4020 velocity ready i s off
The DRDY s i g n a l , i n d i c a t i n g t h e servo a m p l i f i e r i s on, h a s n o t been received a f t e r . *MCON s i g n a l is s e n t t o t h e servo a m p l i f i e r PCB. V e r i f y t h a t RYLl i s o p e r a t i n g properly and t h a t 100 V (100 A) is present, Power Amp NFB3 NFB2 ; I
-
MCC
i
-
NFBl TI
I Servo Amp PCB
ALl
-
r
'A L3
'ACLR
DR~YL MCONM
MCONL
C N I L ~ 1 2 13
1
7DRDYM
1213
71
I 17
1
1
1 2 13
1 1 1 2 1 3
7
I
17
1
I
Axis Control PCB
An overheat alarm i n d i c a t e s t h a t a thermal, sensor i n t h e c o n t r o l l e r h a s d e t e c t e d an overload ( o r a thermal s e n s o r has gone bad). Sensors are l o c a t e d i n t h e servo a m p l i f i e r s , s e r v o transformer, and t h e motors. T h i s c o n d i t i o n i s u s u a l l y caused by a n a x i s exceeding i t s c a p a c i t y o r duty cycle. A l l of t h e s e n s o r s are s e l f r e s e t t i n g a f t e r they c o o l s u f f i c i e n t l y . When t h e alarm o c c u r s , power. is removed from t h e s e r v o d r i v e s , and robot motion i s stopped. ( I f t h e alarm i s received a f t e r t h e motors have cooled, check and replace any d e f e c t i v e thermal sensors. Refer t o Fig. 5.3.10 (a,b).
Fig. 5.3.10 (a) Error code 4022 overload (S420F)
Servo transformer
m
ml Discharge
Fig. 5.3.10 (b) Error code 4022 overload (S-420A)
5..3..11 Error code 4024 fuse alarm in brake circuits The f u s e a l a r m i n d i c a t e s t h a t one o r more f u s e s on t h e power i n p u t u n i t PCB h a s blown. Each f u s e c o n t a i n s a n i n t e r n a l s w i t c h which t r i g g e r s t h e a l a r m when t h e f u s e blows. A blown f u s e might have been caused by an o v e r l o a d c o n d i t i o n o r a s h o r t c i r c u i t i n t h e brake wiring. By observing which f u s e i s blown, t h e problem a r e a may be narrowed t o a group of d r i v e s .
Fig. 5.3.11 [a) Error code 4024 fuse alarm on power input unit PCB
5.4 'Troubleshooting Servo Amplifier 1) Protection and e r r o r d e t e c t i o n f u n c t i o n s The servo a m p l i f i e r has t h e following f u n c t i o n s designed t o p r o t e c t the motor from overload and t o d e t e c t an error. i n servo loop c i r c u i t s . No.
Kinds of f u n c t i o n s
Indications
Description
1
Overload
Overload alarm I f t h e temperature of t h e r a d i a t i o n f i n on t h e servo a m p l i f i e r or of t h e i s indicated for the s e r v o transformer exceeds a set control unit v a l u e , t h i s overload alarm i s generated,
2
C i r c u i t breaker (No-fuse breaker)
Circuit breaker i s tripped
3
High voltage alarm
LED EV l i g h t s
I f t h e DC v o l t a g e of the main power supply is abnormally high, t h e motor i s stopped by dynamic braking and t h e HV lamp l i g h t s .
4
Low voltage alarm
LED LV l i g h t s
If c o n t r o l v o l t a g e is abnormally low, t h e motor i s stopped by dynamic b r a k i n g and t h e LV lamp l i g h t s .
5
Circuit f a u l t detection
LED HC l i g h t s
I f a n abnormally high c u r r e n t flows t o t h e main c i r c u i t , t h e motor is stopped by dynamic braking and t h e HC lamp l i g h t s ,
-
-
If an abnormal c u r r e n t exceeding t h e r a t e d l i m i t of t h e b r e a k e r i s a p p l i e d t o t h e motor, t h i s NFB o p e r a t e s , c a u s i n g t h e motor t o b e stopped by dynamic braking.
d e c e l e r a t i o n r a t e i s t o o high, t h e motor i s stopped by dynamic braking and t h e DC lamp l i g h t s .
2) Troubleshooting Troubleshooting and fault recovery are discussed in this section. a) Overload alarm
Item
Check procedures
Causes of problems
Check if S1 of PCB is set as specified.
1
PCB setting failure
2
Thermostat of the servo Remove the wires connected to transformer terminals 51 transformer is open. and 54 and measure the resistance across them. The normal value is 10 ohms or less, if the circuit is open (more than 100 kilo-ohms), the thermostat is open. If the thermostat is open and the surface temperature of the transformer is 80 to 90°C, check , the motor current. ' If the surface temperature is 60" or less, the transformer is defective.
3
Radiation fins of the unit are overheated.
4
Thermostat of the servo Check the motor current. Check to see if the motor is open. friction in the robot mechanical part is excessively large.
Check the motor current.
Corrective action Set Sl properly. Check the friction torque. Replace the transformer.
Reduce the load. Reduce the load on the motor.
A
b) Circuit breaker is tripped Item
1
Causes of problems Circuit breaker is tripped.
u
Check procedures
Corrective action
The operating condition of the breaker is as illustrated below. This button pops out when the circuit breaker is tripped. Depress this button after turning off the power supply to reset the circuit breaker.
Reset the breaker after turning off the power supply. (If the breaker cannot be reset immediately, wait for about 10 minutes before resetting it.)
-
i
I
I
T
i
e
Check procedures
s of problems
Diode module DS o r o t h e r p a r t s a r e defecti v e i n servo a m p l i f i e r .
k t
Mechanical u n i t
Corrective a c t i o n
The c i r c u i t b r e a k e r i s t r i p p e d j u s t when turning on t h e power supply a f t e r the corrective action i n I t e m I i s taken,
Replace diode module DS or servo amplifier.
Observe t h e s e r v o a m p l i f i e r PCB using an oscil.1oscope t o determine i f t h e load c u r r e n t of t h e motor exceeds t h e r a t e d c u r r e n t during r a p i d movement. Refer t o s e c t i o n 2 6 .
Remove t h e overload.
c ) HV alarm Check procedures
Item
Causes of problems
I.
Input AC power v o l t a g e is higher than specified.
Check i f t h e s e r v o transformer t a p s are properly connected.
2
Servo motor i s defective,
Check i f t h e i n s u l a t i o n r e s i s t a n c e i s normal between t h e motor armature (power l i n e ) and t h e body.
I
1
PCB i s d e f e c t i v e .
defective.
Repair t a p connection.
7 Replace motor.
Increase t h e acceleration/ d e c e l e r a t i o n time constant.
Load i n e r t i a i s
4
---ICorrective a c t i o n
I f HV alarm occurs without any d e f e c t i n i t e m s 1, 2, 3, t h e PCB i s d e f e c t i v e .
Replace t h e PCB.
i f t h e discharge c i r c u i t i s d e f e c t i v e and t h a t t h e wiring i s properly
Replace t h e PCB, discharge transistor, or discharge unit.
d) LV alarm t
Item
Causes of problems
Check procedures
1
Input AC power voltage is lower than specified.
Check if the input AC power voltage and tap connection of servo transformer are correct.
Correct the tap connection.
2
Connection failure between the control transformer and CN2 on the PCB. (S-420A)
Check if +24 V, +15 V, and +5 V of PCB are zormal.
Correct connections,
+5 V supply circuit is
Check if +5 V is normal,
Replace the PCB,
If LV alarm occurs and items 1, 2 and 3 are not defective, the PCB is defective.
Replace the PCB.
3
defective, 4
Corrective action
Check if the transformer and PCB are connected properly.
(S-420A)
PCB is defective.
e) HC alarm Item
Causes of problems
Check procedures
Corrective action
1
Wrong connection of motor power line
HC alarm does not occur when the power supply is turned on after the motor power line has been disconnected, (Since the gravity axis may drop in this case, support it or disconnect the drive cable of gravity axis brake.)
2
Transistor module is defective.
Replace transistor Check if HC alarm occurs module, when the power supply is turned on after disA-06B-6058-H005, connecting the power line E006, H007, HOll Check resistance according to item 1. Turn between Ci-Ei off the power supply, (i=l-6) remove PCB, and check the See Fig. 5.4 right terminal of the transistors module with a circuit tester. The transistor module is defective if the resistance between terminals is several ohms (within 10 ohms).
Reconnect the motor power line correctly,
0
Item
Causes of problems
3
Internal short-circuit failure of motor windings
Check motor windings for normal insulation.
Replace motor,
4
PCB is defective,
If HC alarm occurs and items 1, 2, 3 are not defective, the PCB is defective,
Replace PCB.
Check procedures
Corrective action
J
Els E2 E2, E4, E6
@
: E3* C4
Fig. 5.4 Layout and urarit diagram of transistor module
f) Machine vibrates Check procedures
Corrective action
Item
Causes of problems
1
Position loop gain is not set correctly.
Check the related system variable.
2
Pulse coder signal is defective,
Replace the pulse Check whether the pulse coder signal cable (Cl, C2, coder signal C4 and C8) is disconnected, cable,
Set the system variable properly.
,
6.. 8ACKPL.ANE PCB (A20B-1002-0860) 6.1 Theory of Operation The backplane PCB i s used t o i n t e r c o n n e c t t h e power supply u n i t and t h e c o n t r o l PCBs by means of t h e backplane bus. Connector CNPl is dedicated f o r t h e power supply u n i t ; t h e o t h e r s a r e f o r c o n t r o l PCBs, Control PCBs a r e connected by means of e l e c t r i c a l buses on t h e backplane PCB. The t h r e e types of buses and t h e i r use a r e a s follows:
-
Bus
Connector
Use
System bus
CNAO-CNAlO
For t h e main system PCBs such a s Main CPU, Path CPU, Axis c o n t r o l and o t h e r s
CNB 10 CNBV1-CNBV2
I n t e r f a c e f o r v i s i o n CPU and Vision engine 1 and 2
CNAVI-CNAV2
Local bus f o r Vision engine 1 and 2
- Vision
engine interface
- Vision
engine interconnection
The backplane PCB has s e v e r a l connectors o t h e r than t h e 96-pTn=connectors. The connectors CNP2 and CNP3 are used t o provide v o l t a g e t o p e r i p h e r a l u n i t s such as Connector CA27 i s used f o r t h e b a t t e r y i n p u t . Connector t h e modular 1/0 u n i t . CNP4 and t h e test p o i n t s (HI, TEST, LO) are used only a t production test. The backplane PCB a l s o has r e s i s t o r s and r e s i s t o r modules, The z ; . s i s t o r s are u s e d w i t h i n t h e c i r c u i t r y f o r c l o c k s and serial d a t a transfer, The r e s i s t o r modules are used t o p u l l up t h e tri-state s i g n a l s on each bus.
6.2 Block Diagram Vision interface
\ VoPage for battery back-up
Voltage source
r----------For power supply unit
/
System bus
i
Vision interconnection
6..3Connector/Signal ldentif ication
CNAO (System-bus
, CCU*) AM0
-
GAOl GDOO
2
-
-
: Address modifier #O f2 23: Global address -.bus- #l #23 15: Global d a t a bus °#e' #15
*GAS R/W *GUDS *GLDS *GDTACK *GBR *BGIN *BGOUT *GBERR *GBBSY *SYSTMR *ITP *ITPL *IDSTB SYSCLK2 SUBCLKl *SYSCLR *SY SFAIL *SYSEMG SDO SDI *PF VBAT
: Global a d d r e s s s t r o b e : Read/Write : Global d a t a s t r o b e h i g h b y t e : Global d a t a s t r o b e low b y t e : Global d a t a acknowledge : Global bus r e q u e s t : Bus ground i n : Bus ground o u t : Global bus e r r o r : Global bus busy : System t i m e r : Interpolation start : Interpolation lock : I D strobe : System c l o s k (16.384 MHz)
: : : : : : : :
Subsidiary c l o c k #1 System c l e a r System f a i l System emergency Serial data out Serial data i n Power o f f i n t e r r u p t B a t t e r y power
: Power enabled *EN "*EN" i s a r e v e r s e l o g i c s i g n a l of "EN".
0 V +5 V
: Reference f o r supply v o l t a g e : +.5 VDC power supply f o r
i-24 V
: +24 VDC power supply f o r 1 / 0
d i g i t a l logic c i r c u i t interface
*CCU: Central Control Unit
+15 VDC power supply f o r
-15 V
memory backup
CNAI
-
10 (System bus) AM0 - 2 : Address modifier f O - #2 GAOl - 2 3 : Global a d d r e s s bus # l - 623 GDOO - 15: Global d a t a bus #O - #15 *GAS : Global a d d r e s s s t r o b e R/W : Read/Write *GUDS : ~lobad l a t a s t r o b e high b y t e *GLDS : Global d a t a s t r o b e low b y t e *GDTACK : Global d a t a acknowledge *GBR : Blobal bus r e q u e s t *BG I N : Bus ground i n *BGOUT : Bus ground o u t *GBERR : Global bus e r r o r *GBBSY : Global bus busy *SYSTMR : System timer *ITP : I n t e r p o l a t i o n start *ITPL : Interpolation lock *IDSTB : I D strobe *USED : S l o t used : System cl=G (16,384 MHz) SYSCLK SUBCLKl : S u b s i d i a r y c l o c k #l *SYSCLR : System clear *SYSFAIL : System f a i l *SYSEMG : System emergency SDO : serial d a t a o u t SDI : Serial data i n VBAT : B a t t e r y power *EN : Power enabled : Reference f o r supply v o l t a g e 0 V : +5 VDC power supply f o r +5 V digital logic circuit : +24 VDC power supply f o r 1/0 +24 V interface +15 VDC power supply f o r
CNAV1, 2 (Vision engine interconnection
6MCLK
: Clock (6 MHz)
B i t map window (External d i s p l a y timing) (External V sync.) (External H sync.) Display timing V sync. H sync. Character overlay Output window Runleng t h *mom : X a d d r e s s over *YAOVR : Y a d d r e s s over BNRC : Binary output *LDxDCT : Load X down counter *DCTDN : Count down X RDBRAM : Read b u f f e r RAM WTBRAM : Write b u f f e r RAMACNTBF : Address count enabl6 f o r BRAM APSBF : Address p r e s e t f o r BRAM *WD08 : Write DO 8 *WD02 : Write DO 2 *CTEYO : Count e n a b l e YO *BLOE : BRAM o u t p u t l a t c h enable *QADC : Clock (12 MHz) Clock (12 MHz) QA DO-7 : 8-bit d a t a bus f o r i n t e r engine BMWD
(EXDISP) : (EXVSYN) : (EXHSYN) : *DSPTM : VSYNC : HSYNC : CHRD : OUTWD : RUNLNG :
*McD21
Modal command s t r o b e 2-3 : : (Strobe f o r f u t u r e o p t i o n ) : Master access enable : Runlength enable *IUm : Runlength window ISSYN : ISP sync. ISASL : ISP a d d r e s s s e l e c t *MCDS : Modal command s t r o b e 5 ISACO : ISP a d d r e s s c o n t r o l 0 ISACl : ISP a d d r e s s c o n t r o l I ISPCKE : ISP c l o c k enable IDBOA-7A: Image d a t a bus A IDBOB-7B: 1.mage d a t a bus B +5 v : .t5 V power 0 v 0 V *MCD3 (*STRB) MSABE *RUNLE
S i g n a l s i n parentheses a r e n o t used.
CNBVl,
2; C N B l O (Vision engine i n t e r f a c e )
*C12MM
: Clock (12 MHz) *C24MM : Clock (24 MHz) MAB1 - 17: Address b u s
READ PPUDS MPLDS *FMRDU *FMRDL
*FMWU *FMWL
: Read/Write : Upper b y t e d a t a s t r o b e
: Lower b y t e d a t a s t r o b e : Read frame memory upper byte : Read frame memory lower byte
: Write frame memory upper b y t e : Write frame memory lower byte *IRDRAW : I n t e r r u p t from ACRTC *SDBE : System d a t a bus e n a b l e for ACRTC : I n p u t / o u t p u t select IOSEL CRTR/W : Read/Write f o r ACRTC RS : R e g i s t e r s e l e c t f o r ACRTC *DTDRAW : DATACK from ACRTC *FMRDY : Ready from frame memory *INIIM : Access inMbit t o MPU *POW : Power on reset *CSCRT : Chip s e l e c t for ACRTC *WEDO : Write e n a b l e f o r DO REREQ : R e f r e s h r e q u e s t t o frame memory MDBO 15: 16-bit d a t a bus
-
For t e s t ( f o r v a r i a t i o n of +5 V)
+lo% i n -
COM
*
*PF EN
: Power f a i l u r e : Enable
*PF: Power o f f i n t e r r u p t EN : Power enabled
+5 V : +5 VDC power s o u r c e 0 V : 0 V (Ground) +24 V: +24 VDC power source
: For test ( f o r v a r i a t i o n of 210% i n +5 V)
LO
VBAT: B a t t e r y power
6.4 Jumper Settings
Standard setting
Jumpers
Uses
-
P2
Jumpers P1 - P9 correspond t o CNAl .- 9. I f a PCB i s i n t h e s l o t n, t h e jumper Pn i s set t o 0 s i d e , i f n o t i.c i s set t o V s i d e . (n = 1 -. 9) (0 i s Occupied and V i s Vacant.)
P3
For. example, t h e r e a r e PCBs on CNAO, 1, 2, 3, 8 and 9. The jumper s e t t i n g s a r e as f o l l o w s :
P1
P4
P5 P6
P7 P8 P9
TEST
0
n I
FUK
O
O
O
O
O
O
O
O
O
Location of jumpers
,
6.5 Fuse
HI TEST LO
I
Fuse
Causes and corrective a c t i o n s f o r blown fuses. The basic c o n t r o l u n i t is provided with a f u s e a t t h e b a t t e r y i n p u t end a s shown The following d e s c r i p t i o n covers t h e causes o f h Eilown fuse. i n Fig. 6.5. The blown f u s e shows a white f a i l u r e d i s p l a y i n t h e i n d i c a t o r a s shown i n t h e f i g u r e a t t h e r i g h t , a ) A p a r t insi.de t h e Backplane PCB may be shorted. b) A p a r t i n s i d e t".: Main CPU PCB may be shorted, c ) A p a r t i n s i d e t h e Path CPU PCB may be shorted,
Indicator
Specification number of fuse: A60L-0001-0046#0,32 Replace t h e f u s e with one having t h e same s p e c i f i c a t i o n number.
I I
I l0lb
-
I I
-
11
Battery _'
Fig. 6.5
II t
.
I I
Fuse a t battery input
6..6 Test Points
I
Test points
I
I
I
Contents F o r v a r i a t i o n of
+lo% i n -
-t.5 V.
TEST
s h o r t HI TEST -: +lo% TEST -LO : -10%
LO
Note) These are u s e d o n l y a t production t e s t ,
6.7 Removal/Repiacement 1) P r o c e d u r e 1 Remove a l l b o a r d s o n t h e b a c k p l a n e . 2 Detach t h e cables.
8
@ Remove t h e b a c k p l a n e by l o o s e n i n g f o u r s c r e w s ,
@
F o r mounting a new b a c k p l a n e , r e v e r s e t h e above procedure.
1-56
I
7.
POWER SUPPLY UNI'T (A20B-7000-0770)
7.1 Theory of Operation The power supply u n i t produces DC v o l t a g e s f o r d i s t r i b u t i o n and use throughout t h e c o n t r o l l e r . A l l DC v o l t a g e s f o r t h e b a s i c control u n i t and t h e modular I/O u n i t a r e supplied from t h i s u n i t . Additional DC voltages a r e supplied by o t h e r PCBs f o r s p e c i f i c purposes. An input voltage of 200 VAC i s r e c t i f i e d , f i l t e r e d , and regulated f o r t h e IIC v o l t a g e l e v e l s of +5 V, +15 V, -15 V, and $24 V. The power supply u n i t i s p r o t e c t e d from an overcurrent of AC i n p u t by two f u s e s located on t h e u n i t . These f u s e s have an i n t e r n a l switch t h a t t r i p s t o f l a g t h e alarm t o t h e i n p u t u n i t when t h e device i s blown. One o t h e r f u s e e x i s t s on t h e power supply u n i t . This f u s e i s connected t o t h e +24 v o l t l i n e l a b e l l e d +24 E t h a t s u p p l i e s t h e following c i r c u i t s :
. I/O . overtravel . emergency s t o p . hand breakage . o t h e r +24 v o l t c i r c u i t s
Overcurrent l i m i t i n g c h a r a c t e r i s t i c s of t h e r e g u l a t o r p r o t e c t t h e power supply from overload o r s h o r t c i r c u i t . When t h e v o l t a g e monitor b G t h e power supply d e t e c t s a drop i n output v o l t a g e , excluding +24 E, it f l a g s a n alarm t o t h e c o n t r o l l e r . There are no LEDs o r v a r i a b l e r e s i s t o r s f o r t h e u s e r t o monitor o r adjust. A l l v o l t a g e l e v e l s a r e passed through smoothing c i r c u i t s t h a t ensure o u t p u t s a r e of t h e proper l e v e l f o r l o g i c c i r c u i t s .
CP13 (Input unit PCB)
CP12
06 05 04 03 02 01
ALD ALC
PF PFH PFL : Alarm output
ALC PF
: Power failure
PFL CP14 (I/O unit)
CPll (Input unit PCB)
G 200S 200R
}
: Ground : 200 VAC input
+.5 V, +15 V, -15 V, +24 E, 0 V: DC output TH
COM TL *PF
EN VNR
1
: For test (for variation of +lo% in +5 V) : Power failure : Enable : Not used
7.4 Variable Resistors This power supply unit contains no adjusting or setting points that require adjusting routinely. The reference voltage A10 (=10,00 V) has already been adjusted during tests of this unit. Always check reference voltage A10 whenever the power supply unit is replaced. The location of VRll and A10 is shown in Fig, 7.4. If A10 voltage is deviated, adjust it to 10.00 V by turning VR11. (Use a digital voltmeter.) The voltage increases when turning VRll clockwise.
Fig..7..4 Power supply unit external view
7.5 Fuses Refer t o Fig. 7.4 f o r t h e p o s i t i o n of t h e f u s e s . The power supply u n i t i s provided w i t h f u s e s F11 t o El2 a t t h e i n p u t end, and F14 a t +24 E output terminal. The following d e s c r i p t i o n covers causes and a c t i o n s t o be taken when t h e s e f u s e s a r e blown, @ Cause and remedies of a blown F11 o r El2 f u s e a ) S h o r t - c i r c u i t of diode s t a c k DSll b) S h o r t - c i r c u i t between C-E of s w i t c h i n g t r a n s i s t o r s 414, 415 c ) S h o r t - c i r c u i t of diodes D24, D25 d ) S h o r t - c i r c u i t between C-E of t r a n s i s t o r i n a u x i l i a r y power s u p p l y c i r c u i t MI 1 Replace with t h e s p a r e power supply u n i t , i f t h e p a r t s d e s c r i b e d i n (a) (d) a r e found t o b e shorted. S p e c i f i c a t i o n number of F11 t o F12: A60L-0001-0101#P475H Replace with f u s e s having t h e same s p e c i f i c a t i o n number. @ Causes and remedies of a blown F14 fuse. a ) The f 2 4 E power c a b l e t o 1/0 b a s e u n i t o r a p a r t i n s i d e t h e 1/0 u n i t may be shorted. b) The f 2 4 E power l i n e may b e i n c o n t a c t w i t h t h e o t h e r power l i n e o r cause a ground f a u l t by t h e r o b o t mechanical u n i t s i d e wiring. Remove CP14, and check them c a r e f u l l y . S p e c i f i c a t i o n number of F14: A60L-0001-0046#2.0 Replace w i t h a f u s e having t h e same s p e c i f i c a t i o n number.
Fig..7..5Position of components on the power supply unit (The unit cover is removed in the above figure)
7.6 'Test Points The meanings of t h e t e s t p o i n t s on the power supply u n i t a r e a s follows. Fig. 7.6)
'
T
points
( Symbol-
(See
---4
Contents
Wavef o m
Pre-driver s i g n a l of
+5 V r e g u l a t o r
i-5 V c o n t r o l
CP16
TNE
When "INH" is shorted t o 0 V, overcurrent alarm of +5 VDC output i s neglected. This t e r m i n a l i s used f o r t e s t i n g only. Reference v o l t a g e a d j u s t a b l e by v a r i a b l e r e s i s t o r VRl1, Shut down c o n t r o l s i g n a l . When t h e power is turned o f f , +24 V o u t p u t is c u t o f f by t h i s s i g n a l .
+15 V c o n t r o l
-
10.000
-
1
10.007 VDC
7
T e s t points
F
Contents
Symbol
-
Wavef o m
Triangle wave
-0v
H 5-75
PC
-
- 6 S rscc
+5 V control
1 -A-:: 11.5
A, B
-
Terminals for the current measurement of +24 V and +24 E output.
4
- 13-0rcseC.
+24V
7+24<11
:-' C:7-
1-
- ~ 2 * 1- L-J OV
3
C, D
-
A
--Terminals for the current measurement of +5 V output.
--
+sv
----!
a
--I Ti I
'-J-ETD
OV
---J
C
-
J
Fig. 7..6 Location of test points on the power supply unit (The unit cover is removed in the above figure)
Backplane
1 ) Procedure
8
1 Disconnect cables of connectors CPl1, CP13 and CP14, 2 Detach the power supply unit by removing four screws. The power supply unit is connected to the backplane PCB of the basic control unit by the connector shown by a dotted line in the figure. @ For mounting new power supply unit, reverse the above procedure. Caution) Always check reference voltage A10 whenever the power supply unit is replaced.
8.
MAIN
CPU BOARD (A16B-1211-0040,0047)
8.1 Theory of Operation The main CPU board processes t h e KAREL language system, f i l e o p e r a t i o n s , and system I / O . The board c o n t a i n s t h e l o c a l memory f o r a microprocessor, The memory i s organized by f o u r (-0041) o r e i g h t (-0040) DRAM modules, t h e t o t a l c a p a c i t y i s I MB (-0041) o r 2 MB (-0040); The system s o f t w a r e i s loaded i n t o t h e DRAM from bubble memory. I n a d d i t i o n t o t h e DRAM, t h e r e is a 64 kB battery-backed RAM. The board can b e equipped w i t h a f l o a t i n g - p o i n t coprocessor c h i p a s a n o p t i o n a l f e a t u r e . The system bus i n t e r f a c e a l l o w s t h e microprocessor t o access t h e shared r e s o u r c e s on t h e system bus.
8.2 Block Diagram To backplane f CNA Battery voltage
1MB or 2MB
64 kB RAM
1
C
L
I
1
CNl
1
For development purposes only
8.3 ConnectorfSignal Identification
CNA (Main CPU)
I
321
-19 18 17
- ---
--
0 V 0 V -15 V
GA02 GAOl *GAS
GAOl GDOO
1
GAl5 ( GA14 I *GDTACK
-
11 1 *BGIN 10 1 *BGOUT 09
08 07 06 05
I*GBBSY
GD07 GD06 GDO5 GD04
1 1
O V 0 V I SDI ( *IDSTB I OV I OV I *USED
*ITP *ITPL SDO 1 GD15 1 GD14 1 GD13 1 GD12
1
1 1
O V O V I VBAT
I Of
GDOO
: Address modifier #O - f 2 23: Global a d d r e s s bus 91 - f23 - 15: Global d a t a bus 80 - #15 *GAS : Global address s t r o b e R/W : Read/Write *GUDS : Global d a t a s t r o b e high byte *GLDS : Global d a t a s t r o b e low b y t e *GDTACK : Global d a t e acknowledge *GBR : Global bus r e q u e s t *BGIN : Bus ground i n *BGOUT : Bus ground o u t *GBERR : Global bus e r r o r *GBBSY : Global bus busy *SYSTMR : System timer *ITP : Interpolation s t a r t *ITPL : Interpolation lock *IDSTB : I D strobe *USED : S l o t used : System c l o c k (16.384 MHz) SYSCLK SUBCLKl : S u b s i d i a r y c l o c k #1 *SYSCLR : System c l e a r *SYSFAIL : System f a i l *SYSEMG : System emergency SDO : S e r i a l data out SDI : Serial data i n VBAT : B a t t e r y power *EN : Power enabled 0 V : Reference f o r supply v o l t a g e +5 V : +5 VDC power supp1.y f o r digital logic circuit +24 V : +24 VDC power supp1.y f o r I / O interface +15 VDC power supply f o r
AM0
a I SYSCLK 1 + 5 V
GDlO GDO9 I GD08
J
-
2
-
CN1 (Test PCB)
This connector is nor used.
8.4
I
LEDs
-LED I.
,,,A
,1
B
Meanings "stem
Status ON f i r s t d u r i n g Power Up; ON d u r i n g normal o p e r a t i o n
running
ON second w h i l e i n i t i a l i z i n g KAREL; ON d u r i n g normal o p e r a t i o n
System running
( Green )
/
C
ree en)
D
I
System running
7
I
ON second w h i l e i n i t i a l i z i n g KAREL; ON d u r i n g normal o p e r a t i o n
Not used
LED 2
Meanings
Status
A (Red)
DRAM p a r i t y alarm
P a r i t y alarm o c c u r s , a c c e s s i n g dynamic-RAM on main CPU PCB.
B
SRAM p a r i t y alarm
P a r i t y alarm o c c u r s , a c c e s s i n g static-RAM main CPU PCB,
(Red) C
-------------D
Not used
8.5 Test Points
Test points
0 V (ground)
G
TEST
Contents
,'
This t e r m i n a l i s used i n software debugging
I
OlP09
Backplane PCB
a
I) Procedure 1 Detach PCB by loosening the screws @ 2 Mount new PCB, 2) Cauti.on If t h e PCB being replaced has t h e optional I C , check that the I C mounted on t h e new PCB has the same s p e c i f i c a t i o n ,
8
.
Optional IC
9.
PATH CPU BOARD (A16B-1211-0030)
9.1 Theory of Operation The path CPU board calculates path information and provides it to the servo system. The board contains the local memory for a microprocessor. The memory size is 256 kB, organized by DRAMS. The executive software is loaded into the DRAM from bubble memory after power UP* The board can be equipped with a floating-point coprocessor chip and a line tracking counter as optional features. The board has an overheat sensor and a battery-operated calendar clock, which provides the R-H controller with an absolute date and time base. The overheat sensor detects abnormal temperature rise and si.gnals it to the path CPU via a digital input. The critical temperature is 65°C. The global bus interface allows the microprocessor to access the shared resources on the system bus. 9.2 Block Diagram To backplane
I 256 kB
I
4).
System bus interface
Overheat
DRAM
I
CNA
sensor
1
i
1
L \
F Microprocessor
1
calendar Clock
12w-b
i) CN1
]
For development purposes only
FPCP , mtedace
clock
' G ~ ~ ~ counter
I1
-
CA2 (
From pulse en( for line trackin
CNA (Path CPU)
-
-
2 : Address modifier #0 f2 GAO1 23: Global address bus #1 $23 GD00 15: Global d a t a bus 110 f15 *GAS : Global a d d r e s s s t r o b e R/W : ReadIWrite *GUDS : Global d a t a s t r o b e h i g h b y t e *GLDS : Global d a t a s t r o b e low b y t e *GDTACK : Global d a t a acknowledge *GBR : Global bus r e q u e s t *BGIN : Bus ground i n *BGOUT : Bus ground o u t *GBERR : Global bus e r r o r *GBBSY : Global bus busy *SYSTMR : System timer *ITP : I n t e r p o l a t i o n start *ITPL : Interpolation lock *IDSTB : I D strobe : S l o t used USED SYSCLK : System clock (16.384 MHz) SUBCLKl : Subsi.diary clock f 1 *SYSCLR : System c l e a r *SYSFAIL : System f a i l *SYSEMG : System emergency SDO : S e r i a l d a t a out SDI : Serial data in VBAT : Battery power *EN : Power enabled 0 V : Reference f o r supply v o l t a g e +5 V : +5 VDC power supply f o r d i g i t a l logic c i r c u i t +24 V : +24 VDC power supply f o r 1 / 0 interface +15 VDC power supply f o r -15 V memory backup
AM0
CA2 (Position coder)
*PC2 *PCA
PCB}
*PCB
: Z-phase of Position Coder
: A-phase of Position Coder : B-phase of Position Coder
CN1 (Test PCB) This connector is not used.
9.4
LEDs
-. Pleaning
LED 1 A
(Green) B (Grsen)
System running
-
D
Oh' f i r s t during Power Up; ON i.n normal operation.
-
System running
ON second while i n i t i a l i z i n g KAREL; ON i n normal operation.
Systern running
ON second while i n i t i a l i z i n g KAREL; ON i n normal operation.
---
C (Green)
Status
-
Not used
-
--
-.
LED LED2 (Red)
Meaning DRAM p a r i t y alarm
Status
-
P a r i t y alarm occurs, accessing dynamic-RAM on path CPU PCB.
LED
9.5 Jumper Settings
Jumper
Standard setting
Uses
-
1
Pulse width adjustment of t h e 16.384 MHz clock. Change t h e s e t t i n g s o t h a t t h e waveform a t t e s t p o i n t C 1 6 i s a s shown i n s e c t i o n 9 . 7 . (The s e t t i n g P1 was a d j u s t e d b e f o r e shipping,)
9.6 Variable Capacitor The v a r i a b l e c a p a c i t o r CK4 i s used f o r minute adjustment of t h e frequency f o r RTC ( R e a l Time C o n t r o l l e r ; M6242). The frequency i s measured a t 64 Hz using a (Refer t o s e c t i o n 9.7 f o r frequency counter. CK4 was a d j u s t e d b e f o r e shipping. t h e l o c a t i o n of t h e RTC t e s t p o i n t ) . I f CK4 r e q u i r e s adjustment: 1 Connect frequency counter t o test p o i n t RTC. 2 Adjust CK4 u n t i l frequency e q u a l s 64 Hz.
8
9.7 Test Points
Test p o i n t s
Contents
Waveform
G
0 V (ground)
0 V
0 V (ground)
+5 V
Supply v o l t a g e f o r l o g i c
+5 VDC
+15 V
Supply v o l t a g e
+15 VDC
-15 V
Supply v o l t a g e
-15 VDC
+24 V
Supply v o l t a g e
+24 VDC
C16M
Clock f o r main system (16.384 MHz)
TEST
This t e r m i n a l is used i n software debugging.
RTC
R e a l Time Control This t e r m i n a l is used i n minute adjustment of t h e frequency f o r RTC (M6242).
--
-
-
1
RTC 0
G 0
+5v0 ov 0
G 0 d
TEST 0OG
Z U
4
Location of t e s t p o i n t s
--
Backplane PCB
Procedure 1 Detach PCB by loosening the screws @, 2 Mount new PCB, Caution If the PCB.being replaced has the optional IC, check that the IC mounted the new PCB has the same specification,
8
Optional IC
10.. SHARED R A M BOARD (A76B-727 1-0860) 70.1 Theory of Operation The shared M I board i s an e s s e n t i a l module i n che R-H c o n t r o l l e r , f u n c t i o n i n g a s a c e n t r a l c o n t r o l module f o r t h e System BUS. It provides a system clock, c l e a r , timer, and o t h e r important s i g n a l s . Four s e r i a l p o r t s a r e a v a i l a b l e ; Direct Memory Access (DMA) d a t a t r a n s f e r c a p a b i l i t y i s supported f o r some, The shared RAM is used not only by t h e p r o c e s s o r s on t h e The s h a r e d ROM c o n t a i n s a bus b u t a l s o by a n o p t i c a l l i n k f o r t h e I / O u n i t . d i a g n o s t i c program and an i n i t i a l program loader. P r o c e s s o r s are designed t o r u n w i t h t h i s ROM f i r s t a f t e r power up. The board a l s o c o n t a i n s d r i v e r s and r e c e i v e r s t o d r i v e LED d i s p l a y s and t o r e c e i v e push b u t t o n s t a t u s s i g n a l s from t h e o p e r a t o r p a n e l and t o send and r e c e i v e s i g n a l s from t h e teach pendant, RS-2324 i n t e r f a c e and t h e power i n p u t u n i t i n t e r f a c e . Four. LEDs are l o c a t e d on t h e shared RAM PCB. The LEDs i n d i c a t e system e r r o r s . Note) The system can be operated without t h e t e a c h pendant by plugging a t e a c h pendant bypass plug i n t o CNTP.
102 Block Diagram
RAM &Is
ROM
control
Modular
40
i CNPI Power input unit interface
Tea& pendant
RS-232.C device
Operator p a d
10.3 ConnectorISignal ldentif ication
CNA
-
-
AM0 2 : Address m o d i f i e r #O 82 GAOl 23: Global a d d r e s s bus #1 #23 GDOO 15: Global d a t a bus $0 815 *GAS : Global a d d r e s s s t r o b e R/W : Read/Write *GUDS : Global d a t a s t r o b e h i g h b y t e *GLDS : Global d a t a s t r o b e low b y t e *GDTACK : Global d a t a acknowledge *GBR : Global bus r e q u e s t *BGIN : Bus ground i n *BGOUT : Bus ground o u t *GBERR : Global bus e r r o r *GBBSY : Global bus busy *SYSTMR : System t i m e r ITP : I n t e r p o l a t i o n start *ITPL : Interpolation lock *IDSTB : I D strobe
-
-
*
SYSCLK1} SYSCLK2 SUBCLKl *SYSCLR *SYSFAIL *SYSEMG SDO SDI *PF VBAT
EN *EN
}
: System c l o c k (16.384 MHz)
S u b s i d i a r y c l o c k /I1 System c l e a r System f a i l System emergency S e r i a l data out : Serial data i n : Power o f f i n t e r r u p t : B a t t e r y power : : : : :
: Power enabled
"*ENw is a r e v e r s e l o g i c s i g n a l of "EN". 0V : Reference f o r supply v o l t a g e +5 V : +5 VDC power supply f o r d i g i t a l logic circuit +24 V : +24 VDC power supply f o r 1 / 0 interface i-15 VDC power supply f o r
CD4A RS-232-C
port A
RDA SDA RSA CSA DRA ERA $24 VR
Receiving data Sending data Request to send Clear to send Data set ready Data terminal ready : +24 VDC power supply for RS-232-C port 0v
CNTP RS-422 for teach pendant Receiving data from teach "*RDTPW is a reverse logic signal of "RDTp"
SDTP *SDTP TPI
}
: Sending data to teach pendant : Status signal,of EMERGENCY
STOP button and DEADMAN switch TP2
: Status signal of EMERGENCY
EMG
STOP button and DISABLE/ENABLE switch : Common line signal for TP1 and TP2 : Extra E-stop contact output
TP4 +24 F 0
v
: 4-24 VDC power supply for teach
pendant :
ov
CNOP RS-232-C
p o r t s and D I / D O f o r o p e r a t o r ' s panel TPENBL: TEACH PENDANT ENABLED LED PENBL : PANEL ENABLED LED INCYC : I N CYCLE LED NOTCAL: NOT CALIBRATED LED ULEDl : User LED # l ULED2 : User LED #2 FAULT : FAULT LED HELD : HELD LED CSTART: CYCLE START b u t t o n CALIB : CALIBRATE b u t t o n UPBl : User panel b u t t o n I1 UPB2 : User panel. b u t t o n #2 FRESET: FAULT RESET b u t t o n HOLD : HOLD button OTREL : OVERTRAVEL RnEASE b u t t o n Contact of t h e POWER ON b u t t o n : (normally open) Contact of t h e POWER OFF b u t t o n : (normally c l o s e d ) REMOTE: REMOTE switch ESTOP : EMERGENCY STOP b u t t o n RDB : Receiving d a t a SDB : Sending d a t a RSB : Request t o send : Clear t o send CSB DRB : Data set ready ERB : Data terminal ready The s i x s i g n a l s l i s t e d above are f o r t h e RS-232-C i n t e r f a c e . RDC : Receiving d a t a : Sending d a t a SDC RSC : Request t o send CSC : Clear t o send DRC : Data s e t ready ERC : Data terminal ready Above 6 s i g n a l s a r e c o n t a c t of CRT/KB interface.
}
gi:}
1
: Extra E-stop c o n t a c t output Tp3 TP4 +24 F : +24 VDC power connection f o r RS-232-C i n t e r f a c e +24 VDC power connection f o r operator's panel
i2: '1:
Input unit interface OTREL
: OVERTRAVEL RELEASE
button Contact of the POWER ON button O ON2 N'} : (normally open) Contact of the POWER O F F button : (normally closed) TP 1 : Status signal of EMERGENCY STOP button and D W A N switch TP2 : Status signal of EMERGENCY STOP button and ENABLE O N I O F F switch i-24 VDC power connection for -o v F F~} ~: power input unit interface
}
OPTIN
: Optical input signal from
modul.ar 110 unit OPTOUT : Optical output signal to modular 110 unit
LEDs
Status
Meanings
A (Red)
System fail
This indicates that at least one module is malfunctioning. This signal is asserted illuminating the LED when the main CPU PCB or sub CPU PCB is malfunctioning.
B (Red)
System emergency
This indicates a system emergency. The causes are as follows: AC power failure , The watch-dog timer timeout Error in serial data communication
.
.
C
D (Red)
Not used
One of the following battery problems,
Battery alarm
This indicates , The battery for shared RAM PCB is not connected. Fuse on the backplane PCB is blown. , The voltage of the battery becomes less than 3.6 VDC,
.
10.5 Test Points
-Test p o i n t s
Contents
--
Waveform
G
0 V (ground)
+5 V
Supply voltage for l o g i c
+5 VDC
i12 V
Supply voltage f o r RS-232-C and RS-422 d r i v e r
+12 VDC
-12 V
Supply v o l t a g e f o r RS-232-C and RS-422 d r i v e r
-12 VDC
*C8M.c
Clock f o r bus c o n t r o l l e r (8.192 MHz)
-
_/iT 122 nsu:
C16M
ov
f u r
Clock f o r main system (16.384 MHz)
/-
C32M
4
35v
61 nsec
-4
31 nsec
4
Clock source f o r C8M and C16M (32.768 Mhz)
TEST
This terminal is used i n software debugging
*RES
This t e r m i n a l i s used i n software debugging,
:t..I +I% -12v
0 TEST
V
Backplane PC13
1) Procedure Disconnect c a b l e s from the PCB. Detach PCB by loosening the screws @, For mounting new PCB, reverse the above procedure.
17.
BUBBLE MEMORY BOARD (A76B-1211~~0090,0091,0092)
17.1 Theory of Operation The bubble memory board i s a non v o l a t i l e mass-storage d e v i c e used f o r s t o r i n g t h e system s o f t w a r e , system v a r i a b l e s , and KAREL a p p l i c a t i o n programs. There a r e t h r e e t y p e s of bubble memory boards.
A16B-1211-0090: 2 FIB Al6B-1211-0091: 1.5 PIB A1 6B- 1211-0092 : 1 MB The bubble memory d e v i c e s are c o n t r o l l e d by t h e c o n t r o l l e r LSI c i r c u i t on t h e b o a r d ; d a t a is t r a n s f e r r e d between t h e bubble memory board and t h e o t h e r boards by t h e system bus. S i n c e t h e DMA ( D i r e c t Memory Access) f u n c t i o n is s u p p o r t e d , t h e d a t a t r a n s f e r o p e r a t i o n is done by hardware once i t h a s been i n i t i a t e d by software. A factory-programmed EPROM s t o r e s t h e d e f e c t i v e l o o p i n f o r m a t i o n f o r a l l bubble memory d e v i c e s on t h e board, I f m u l t i p l e b u b b l e memory b o a r d s a r e i n s t a l l e d , t h e y must b e p l a c e d i n a d j a c e n t s l o t s . 11.2 Block Diagram To backplane
f Bubble memory devices
CNA
1
System bus interface
0 DVmV
EPROM
I
11.3 Connector/Signal Identification
DMA controller
1
CNA (Bubble memory) AM0 .- 2 : Address m o d i f i e r fO - #2 GAOl - 23: Global a d d r e s s bus $1 - 823 GDOO - 15: Global d a t a bus #O - /I15 *GAS : Global a d d r e s s s t r o b e R /W : Read/Write *GUDS : Global d a t a s t r o b e high b y t e *GLDS : Global d a t a s t r o b e low b y t e *GDTACK : Global d a t a acknowl.edge *GBR : Global bus r e q u e s t *BGIN : Bus ground i n *BGOUT : Bus ground o u t *GBERR : Global bus e r r o r *GBBSY : d l o b a l bus busy *SYSTMR : System t i m e r ITP : Interpolation s t a r t *ITPL : Interpolation lock *IDSTB : I D strobe USED : S l o t used SYSCLK : System c l o c k (16.384 MHz) SUBCLKl : Subsidiary c l o c k #1 *SYSCLR : System c l e a r *SYSFAIL : System f a i l *SYSEMG : System emergency SDO : Serial data out SDI : Serial data i n VBAT : Battery power *EN : Power enabled 0 V : Reference f o r supply v o l t a g e +5 V : +5 VDC power supply f o r digital logic circuit +24 V : +24 VDC power supply f o r 1/0 i n t e r £ace k1.5 VDC power supply f o r +15 V} ' memory backup -15 V
*
.
11.4 Jumper and Switch Settings
I
jumperS
/
Standard setting
Uses
B s i d e s e t t i n g i s s e l e c t e d i n s o f t w a r e debugging only. I n normal u s e , a l l must b e s e t t o A s i d e .
Switch
Standard setting
SW1
OFF
Uses ON : Bubble-free mode t o i n i t i a l i z e t h e b u b b l e memory. OFF: Normal mode
Location of jumpers
Location of s w i t c h
1 7 -5 Test Points I
Contents
Test p o i n t s
G
0 V
HB1
These test p o i n t s are used f o r e r a s i n g the bubble memory devices. If "ERASEri and *'HBnWare short-circuited, t h e corresponding d e v i c e MBMn w i l l be erased, (n = 1 -- 4 )
HB2
HB 3 HB4 ERASE
Waveform
I
T e s t point HB1 ERASE .ERASE HB2 ERASE HB3 ERASE HB4
--
: : : :
Device MBMl MBM2 MBM3 MBM4
Location o f test p o i n t s
1) Procedure
8
1 Detach PCB by loosening the screws 2 Mount new PCB.
@.
12.
AX tS CONTROL BOARD (A16B-1211-0060, 0062)
12.1 Theory of Operation The axis control board receives the motion commands from the path CPU and moves the robot's axes. There are two types of axis control boards.
A16B-1211-0060: 4-axis control A16B-1211-0062: Z-axis control For every two axes, one high-speed microprocessor provides full digital servo control based on modern digital control theory. The microprocessor has 16 kB RAM. The software is loaded into RAM by the main CPU via the system bus. The servo interface contains a custom LSI circuit, A/D converter and some glue (misce1,laneous) logic. For each axis, two connectors are located on the front end of the board, One is a position feedback from the pulse encoder on the motor. The other is a connector to the servo amplifier, which generates the motor power proportional to the torque command from the axis control board, The board has a feedback loss detect circuit that indicates an error when the pulse encoder cable is disconnected. If the servo amplifier detects an error, the board receives the information via a digital input.
Block Diagram To backplane
r
r
I
1
Servo " s interface
Servo M interface A
A
Servo interface
s Servo interface
A
A
\7
77
DYW
DUD0 A
i
i
r
i To servo amplifiers
(a722 1 1C~9 2
-I
From puke encoders
12.3 Connector/Siganl ldentif ication The r e l a t i o n s h i p between t h e a x i s numbers, a x i s names, and t h e connectors on t h e a x i s c o n t r o l PCB, robot mechanical u n i t , and servo a m p l i f i e r s i s shown i n Table 12.3. Table 12.3 S-420 FIA
--
Axis Feedback Connect- Axis Velocity Servo Axis Axis ConAxis c o n t r o l connect- amp. hardware woftware c o n t r o l connect- o r on nector name PCB PCB or No. or robot number number
W
1
2
U
2
3
8
3
1
a
4
6
3
5
5
Y
6
4
1 (01P05)
2 (02~05)
CF91
P1
CF92
P1
CF93
P1
CF94
P2
CF91
P2
cF92
P2
1 (OlPO5)
2 (02P05)
CV21
1
CN 1
CV22
2
CN 1
cv23
3
CN1
CV24
4
CN 1
CV21
5
CNl
CV22
6
CNl
Connector position (Side view of PCB)
CNA (Axis control)
AM0 - 2 : Address modifier #O -. 62 GAOl - 23: Global a d d r e s s bus 81 - !I23 GDOO - 15: Global d a t a bus b0 - /I15 *GAS R/ W *GUDS *GLDS *GDTACK *GBR *BGIN *BGOUT *GBERR *GBBSY *SYSTMR *ITP *ITPL *IDSTB USED SYSCLK SUBCLKI *SYSCLR *SYSFAIL *SYSEMG SDO SDI VBAT *EN 0 V +5 V
4-24 V
: Global a d d r e s s s t r o b e : Read/Write : Global d a t a s t r o b e high byte : Global d a t a s t r o b e low byte : Global d a t a acknowledge : Global bus r e q u e s t : Bus ground i n : Bus ground o u t : Global bus e r r o r : ~ l o b a bus l busy : System t i m e r
: I n t e r p o l a t i o n start : I n t e r p o l a t i o n lock : I D strobe : S l o t used : System c l o c k (16.384 MHz) : Subsidiary c l o c k fl : System c l e a r : System f a i l : System emergency : S e r i a l data out : Serial data i n : B a t t e r y power : Power enabled : Reference f o r supply v o l t a g e : +5 VDC power supply f o r digital logic circuit : +24 VDC power supply f o r 1 / 0 interface 4-15 VDC power supply f o r backup
For 1 s t a x i s CF91, W
OH1} OH2
: Motor overheat
: Gray code from pulse coder
C1
For 2nd a x i s CF92, U
} } *PCA PCB } *PCB *PC2
REQ
: 2-phase
of p u l s e coder
: A-phase of p u l s e coder : B-phase of p u l s e coder : Request s i g n a l f o r abso3.ute
p u l s e coder A6 r e p r e s e n t s t h e a x i s S u f f i x A1 number 1 - 6.
-
For 3rd a x i s CF93, 8
For 4th a x i s CF94, a
For 5 t h a x i s CF91, B
(CF91 of t h e second a x i s c o n t r o l board 02P05)
For 6 t h a x i s CF92, y
(CF92 of t h e second axis c o n t r o l board 02P05)
For 1st a x i s CV21, W CV21
-
*PWMD
CV24 Pulse width modulator (Note 2)
*PWME *PWMF COMB COMC
: Common s i g n a l s f o r PWM
COME GDR
: Feedback c u r r e n t of
GDS
: Feedback c u r r e n t of
R-p hase For 2nd a x i s CV22, U
S-phase : Ground f o r feedback current Note 1) S u f f i x A1 A6 r e p r e s e n t s t h e a x i s number 1 6. Note 2) PWM s i g n a l p i n s a r e used b i d i r e c t i o n a l l y , Normally they a r e outputs. When t h e servo a m p l i f i e r is alarming, they become inputs. Names i n parentheses a r e alarm s i g n a l s i n such a case.
GND
-
-
For 3 r d axis CV23, 8
For 4th a x i s CV24, a
For 5th a x i s CV21, B
(CV21 of the second a x i s control board 02P05)
For 6 t h a x i s CV21, y
(CV21 of the second a x i s c o n t r o l board 02P05)
12.4 LEDs
-
.--
SALM
Status
Meani.ngs
LED
1. P a r i t y alarm occurs, a c c e s s i n g static-RAM on t h e a x i s c o n t r o l PCB. 2, Watch dog time out,
Servo a l a r m
L
12.5 Jumper Settings
Jumper
Standard setting
Uses
A: T h i s PCB i s used in "I$-H" system, B: T h i s PCB is used i n "R-G1' system,
P1 w
-
I n t h i s system, i t must be s e t t o A s i d e .
0
-
S1 S 0 U
FIG] A
PI B
< z v
,3,
Q ' N
>>
P) N
U U
12.6 Test Points
Test points
Contents
7
G
0 V (ground)
Location of test points
Backplane PCB
1) Procedure 1 Disconnect cables from the PCB. 2 Detach PCB by loosening the screws @. 3 For mounting new PCB, reverse the above procedure. 2) Caution When connecting cables, be careful to match cables and connectors on PCB.
8
13.
REMOTE CRTIKB (Al3B-0144-B001)
13.1 Theory of Operation The remote CRT/KB i s a p o r t a b l e t e r m i n a l which c o n t a i n s a 12" CRT d i s p l a y and a f u l l ASCII keyboard. The remote CRT/KB i s connected t o t h e R-H c o n t r o l l e r a t i t s RS-232.-C p o r t acd i s used a s a user i n t e r f a c e . The u n i t i s composed of a 12" monochrome CRT, a membrane keyboard, a f a n u n i t and a c o n t r o l board. The c o n t r o l board h a s a microprocessor t h a t p r o c e s s e s serial communication, key-scanning and CRT d i s p l a y information. The CRT c o n t r o l c i r c u i t g e n e r a t e s a v i d e o s i g n a l based on t h e d a t a i n t h e v i d e o RAM. The 4-24 V A l l DC power used i n t h e u n i t is s u p p l i e d from t h e R-H c o n t r o l l e r . p r o v i d e d v i a RS-232-C c a b l e i s a s o u r c e f o r t h e DC-DC c o n v e r t e r . 13.2 Block Diagram
12" CRT Microprocessor
control -
I
Keyboard
interface
Control board
'
U
R-H contro1Ier
13.3 Connector/Signal Identification
Remote CRT/KB side
FG
RD
: Frame ground : ~eceiveddata : Transmitted data : Request to send : Data terminal ready : Signal ground
Controller side
} }
RS-2324 data signal SD RS RS-232-C control signal ER SG +24 V: +24 VDC power source for the remote CRT/KB
73.4 CRT/KB Control PCB (A16B-1211-0760) 13..4..1 Connector/signal identification
I
CNl
CAS
CD4
CN2
I
Front view of the CRTjKB control PCB
+12 VDC power source f o r t h e
0 V
*VIDEO : Video s i g n a l f o r CRT *INCINT: Increased i n t e n s i t y HSYNC : Rorizontal synchronous control s i g n a l VSYNC : V e r t i c a l synchronous control s i g n a l 0 V : 0 V (ground l e v e l )
RS SG 4-24 V
!
: Refer t o Sec. 13.3
signal
*COMO
-
*KEY0
-
*LED2
+24 V GND
9: Common of t h e key switch (from t h e CRT/KB c o n t r o l PCB) 7: Input s i g n a l of key switch s t a t u s ( t o t h e CRTjKB c o n t r o l PCB) Input s i g n a l of LED s t a t u s : (from t h e CRT/KB c o n t r o l PCB)
: +24 VDC power source f o r t h e fan u n i t : O V
13.42 Variable resiston
Adj u s tment
Name
Function
VR1
Adjustment of t h e +5 V v o l t a g e
Adjust t h e VR1 s o t h a t t h e v o l t a g e a t "+5 V" is w i t h i n a range of 5 V + 0.1 V,
VR2
Adjustment of t h e +12 V v o l t a g e
Adjust t h e VR2 s o t h a t t h e v o l t a g e a t "+I2 V" is w i t h i n a range of 12 V + 0.1 V,
.
-
-
0 +5V (Test point)
0 0 +12V (I'est point)
Locati.on of v a r i a b l e r e s i s t o r s
13..4.3 Jumper settings
Jumpers
Standard setting
Uses b
to
--
Not used (all B s i d e )
Location of jumpers
13.4.4
Test points
Test points
Symbol
CLK9M
-
Contents
IJavef o m
System clock for the cRT/KB control PCB
J7A-'2: -4 k
CLRTV
-
108 nsec
J 1 IfJ*:' -
Character clock for the CRT/KB control PCB
37Onsec
*DOTCLK
-
- >24v
Dot clock for the CRT/KB control PCB 46nsec I
*CLR
-
+24 V
-
$12 V
-
-12 V
-
+5
v
GND
-
-
Power on signal f o r the CRT/KB control PCB
>2.4 VDC
Power source for t h i s unit
+22
Supply voltage f o r CRT f 1 2 unit and RS-232-C driver
- +24 VI)C
VDC
+ 0.1
Supply voltage f o r RS-232-C driver
-12 VDC -+. 0.1
Supply voltage f o r the control circuit
+5 VDC
0
+ 0.1 -
v
0 +5v 0 GND o+24V
0 -12V
0 CLKg'V
0 CLK9M 0 *DOT'CLK+24V0
0 +12v
CL.R 0
- -
Location of t e s t points 1-109
V
vV
1
OV
7 3.4.5 Removal/replacement
1 ) Procedure @ Remove t h e top cover by loosening four screws.
@ Remove t h e PCB by loosening two screws.
8 3 4
Disconnect c a b l e s from t h e PCB. For mounting a new PCB, r e v e r s e t$e above procedure.
'13.5 Keyborad PCB (A86L-0001-0'149) 13..5.1 Connectorfsignal identification
*LED 1 *LED2
: Refer t o Sec. 13.4.1
13.52 Removal/replacement
1) Procedure @ Remove t h e keyboard panel by loosening f o u r screws.
Panel
8 2 3
Disconnect t h e connector. Remove the keyboard by loosening s i x nuts.
, Panel
Backside of' h e keyboard
@
For mounting a new keyboard, reverse t h e above procedure.
13.6 CRT Monitor (A61L-0001-0088) 13..6..1 Connector/signat identification
CN2
Front
Rear
CRT monitor PCB
View of t h e part-mounting s i d e CN1 *VIDEO HSYNC VSYNC INCINT
'* 0
: Refer t o 13.4.1
v
t12 V
: Refer to Sec. 13.4.1
14.1 Theory of Operation
The built-in CRT/KB is a console which contains a 9" CRT display and a full ASCII keyboard. The built-in CRT/KB is connected to the shared RAM board at its RS-2.32-C port and is used as a user .interface. The unit is composed of a 9" monochrome CRT, a membrane keyboard, a software keyboard and a control board. The control board has a microprocessor that processes serial communication, key-scanning and CRT display information. The CRT control circuit generates a video signal based on the data in the video RAM. All DC power used in the unit is converted from the +24 V provided via RS-232-C cable. 14.2 Block Diagram
9" CRT
Software keyboard
Keyboard
b--+
b-
P-<
Shared
RAM
CRT conaol
1 'I
board
Processor
EPROM
Keyboard interface
RAM
I
Control booard
14.3 Connector/Signal ldentification
(Rear side view)
CD4
RD SD RS ER
: Received data : Transmitted data
1
RS-232-C signal data Request to send RS-232-C control signal Data terminal ready SG : Signal ground +24 V: +24 VDC power. source for the remote CRT/KB : :
I
74.4 CRTIKB Control PCB (A20B-1003-0340) 14.4.1 Connector/signal identification
Front view of the CRT/KB control PCB
2 ::
V
V)
+24 VDC power source for : the CBT unit
*VIDEO : Video signal for CRT *INCINT: Increased intensity HSPNC : Bori.zonta1 sync~ronous CRT control signal control VSYNC : Vertical synchronous signal control signal 0 V : 0 V (ground level)
SD RD RS ER
: Transmitted data : Received data : Request to send : Data terminal
} 1
J
RS-232-C data signal RS-232-C control signal
ready SG : Signal. ground +24 V: +24 VDC power source for the remote CRT/lU3
*COMO
-
*KEY0
-
LED2
7: Common of t h e key switch (from t h e CRTIKB c o n t r o l PCB) 9: I n p u t s i g n a l of key s w i t c h s t a t u s ( t o t h e CRT/KB c o n t r o l PCB) Input s i g n a l of LED s t a t u s : (from t h e CRTIKB c o n t r o l PCB)
*SCOM : Common of t h e s o f t k e y s w i t c h *KY1 - 7 : Input s i g n a l of s o f t k e y switch s t a t u s (from t h e CRT/KB c o n t r o l PCB)
F]
14.42 Variable resistors
F
'
I
I
Adjustment of the
+5 V voltage
X
I
~
Ad,ju;ment
Adjust the VR1 so that the voltage a t "+5 V" i s within a range of 5 V + 0.1 V.
0ml 0 *sv
('Test point)
Location of variable resistors 14.4.3 Jumper setting
I
I
Standard Juqer setting ST 1 A
m
B
-1
Uses Character generator selection: Select A side: KANB + AT.,PHA N7JMERIC Select B side: ALPHA NUMERIC
Location of jumpers
14.4.4
Test points
Test p o i n t s
---
CLK9M
CLKTV
Symbol
-
-
Contents
Wavef o m
System clock f o r t h e CRT/KB c o n t r o l PCB
'
Character clock f o r t h e CRT/KB c o n t r o l PCB
I 108 nsec
[
2:
i\_i-"4v 1 OV
370-
*DOTCLK
-
Dot c l o c k f o r t h e CRT/KB c o n t r o l PCB
J7-r
b-46n~ec 4
*CLR
-
Power on s i g n a l f o r t h e CRT/KB c o n t r o l PCB
>2.4 VDC
+24 V
-
Power s o u r c e f o r t h i s unit
+22
+12 V
-
Supply v o l t a g e f o r CRT u n i t and RS-232-C driver
+12 VDC
+ 0.1
V
-12 V
-
Supply v o l t a g e f o r RS-232-C d r i v e r
-12 VDC
+ 0.1
V
Supply v o l t a g e f o r t h e circuit
+5 VDC
- control
0
- +24
VDC
+ 0.1
V
v
Screws (M3)
AZOB-I 003-0340
1) Procedure 1 Disconnect c a b l e s from t h e CRT/RB c o n t r o l PCB. Detach t h e CRT/KB c o n t r o l PCB by l o o s e n i n g t h e f o u r screws. 3 For mounting t h e PCB, r e v e r s e t h e above p r o c e d u r e .
Q
> 2.4V
ov
14.5 Keyboard PCB (A86L-0001-0149) 14.5..1 Conneetor/signa! identification
*LED 1 *LED2
a
1
: R e f e r t o Sec. 13.4-1
1 Remove t h e CRTfKB control. PCB, a c c o r d i n g t o Sec. 14.4.5. 2 Disconnect c a b l e s from t h e keyboard PCB. 3 Remove t h e n u t s @ from t h e keyboard mounting p l a t e , and d e t a c h t h e keyboard PCB a l o n g w i t h t h e mounting p l a t e . (The mounting p l a t e and PCB a r e attached.) @ Remove t h e key s h e e t from t h e keyboard mounting p l a t e , (The key s h e e t a d h e r e s t o t h e keyboard mounting p l a t e , ) @ For mounting t h e PCB, r e v e r s e t h e above procedure.
14.6 Software Keyboard PCB (A20B-1000-0844) 14..6.,1 Connector/signal identification
*COMOO *KYDl
Front view of CRT/KB panel
8 8 I
2
3 4
-
: Common of key switch 7: Input s i g n a l of key switch status
Rear view of t h e CRT escutcheon
Disconnect t h e f l a t cable f o r software keyboard from t h e PCB, Remove f o u r screws @ f i x i n g t h e CRT escutcheon, and detach t h e software keyboard PCB along with t h e CRT escutcheon, Detach t h e so£tware keyboard PCB by loosening t h e two screws For mounting t h e PCB, reverse t h e above procedure.
a.
14.'7 CRT Monitor ( A 1 3 B - 0 0 5 6 - C 0 0 1 ) 14.'7.1 Connector/signal identification
Rear view of the CRT monitor
i2;v}
:
VIDEO HSPNC VSYNC HIGH VIDEO
Supply voltage for CRT monitor
: Video signal : Horizontal sync. signal. : Vertical sync. signal : High brightness video
signal
H VIDEO RET.: 0 V for "HIGH VIDEO" 0
v
:
ov
14.72 Adjustment routine
The CRT c h a r a c t e r d i s p l a y c o n t r o l s a r e set a t t h e f a c t o r y and g e n e r a l l y w i l l n o t r e q u i r e major adjustment. To a d j u s t b r i g h t n e s s (BRIGHT) and c o n t r a s t (CONT), t u r n t h e c o r r e s p o n d i n g v a r i a b l e r e s i s t o r s mounted on t h e s i d e of t h e CRT d i s p l a y u n i t (Fig. 14.7.2). Caution) Keep f i n g e r s and t o o l s away from t h e d i s p l a y u n i t when f i r s t t u r n i n g t h e power on, because an extremely h i g h i n i t i a l v o l t a g e , between 10 and 11 kV, i s p r e s e n t . Note) I f a s i g n a l c a b l e i s d i s c o n n e c t e d , t h e e n t i r e CRT s c r e e n w i l l go blank. 1) A d j u s t i n g B r i g h t n e s s ( v a r i a b l e r e s i s t o r BRIGHT) T h i s c o n t r o l knob ( v a r i a b l e r e s i s t o r BRIGHT) c o n t r o l s t h e o v e r a l l b r i g h t n e s s of t h e CRT s c r e e n . a ) Adjust t h e b r i g h t n e s s c o n t r o l knob ( v a r i a b l e r e s i s t o r BRIGHT) t o t h e b r i g h t e s t l e v e l p o s s i b l e b e f o r e t h e r a s t e r (scanning l i n e ) a p p e a r s on t h e screen. b ) I f t h e raster a p p e a r s d u r i n g t h e c o n t r a s t ( v a r i a b l e r e s i s t o r CONT) o r o t h e r screen adjustment, u s e t h e b r i g h t n e s s c o n t r o l ( v a r i a b l e r e s i s t o r BRIGHT) t o e l i m i n a t e i t . 2) A d j u s t i n g C o n t r a s t ( v a r i a b l e r e s i s t o r CONT) The c o n t r a s t knob c o n t r o l s t h e d i f f e r e n c e between t h e b r i g h t e s t and d a r k e s t p i c t u r e elements. a) A d j u s t t h e c o n t r a s t c o n t r o l knob ( v a r i a b l e r e s i s t o r CONT) u n t i l d i s p l a y c h a r a c t e r s a c h i e v e an easy-to-read b r i g h t n e s s level, b ) Do n o t a p p l y t o o much c o n t r a s t , as t h i s can d i s t o r t t h e c h a r a c t e r s and make them d i f f i c u l t t o read.
New type (Matsushita)
New type (Totoku)
Note) We CRT display unit includes the regulator unit.. Fig. 14.7.2
Adjustment position (Rear view of display unit)
14.7..3 Special adjustment
I f t h e CRT p i c t u r e i s d i s t o r e d o r t i l t e d , t h e a d j u s t i n g magnets l o c a t e d on t h e CRT d i s p l a y u n i t (Fig. 14.7.3 ( a ) ) w i l l c o r r e c t t h e s e problems, Bringing t h e magnets c l o s e r t o o r f a r t h e r from t h e cathode r a y d e f l e c t s t h e s c a n n i n g beam t o t h e d e s i r e d r e s u l t , G e n e r a l l y , a d j u s t m e n t s a r e n o t r e q u i r e d u n l e s s a CRT component, s u c h a s a CRT d e f l e c t i o n c o i l , h a s been newly i n s t a l l e d . 1) P i c t u r e d i s t o r t i o n and p o s i t i o n a d j u s t m e n t s are made u s i n g t h e d e f l e c t i o n c o i l . d i s t o r t i o n a d j u s t i n g magnets, c e n t e r i n g magnet, and d e f l e c t i o n c o i l s e t screw, To avoid an e l e c t r i c shock, a d j u s t them a f t e r t u r n i n g t h e power o f f . Magnet for adjusting the distortion at the upper left of the CRT ween By removing the retaining spring, this magnet can be rotated to adjust the picture..
Magnet for adjusting the distortion at upper right of the CRT screen
Centering magnet The picture moves verticaty and i a t d y when the two entering magnets are turned at the same time.
I
%
Magnet for adjusting the right lower distortion
Mamet for m o v i m dist-ortion at the 1oG1 k f t of the CRT sawn
\ Deflection coil setscrew By loosening this screw, the deflection coil can be rotated, and the parallelism of the picture can be adjusted.
Fig. 14-73(a) Adjustment position (Rear view of
CRT)
2) Adjustments for synchronization (vertical and horizontal), focus, linearity, width and height are made by using the variable resistors and adjustable coil located on the PCB in the CRT display unit. See Fig. 14.7.2, :
WIDTH
Changes the horizontal picture size
(H-SIZE) : :
FOCUS &HOLD
Sharpens characters Stops the picture from shifting horizontally (Horizontal synchronization) V.LIN : Equalizes character sizes vertically in the upper and lower parts of the screen (Vertical amplitude) HEIGHT : Changes vertical picture size (V-SIZE) (Vertical amplitude) V-HOLD : Stops the picture from rolling vertically (Vertical synchronization) 3) Fuse CRT display unit power fuse 1.6 A, 125 V. (Surge protection type)
CRT unit Al3B-OO56C001
6 4 rs
i--i
1.5
-*
"'A ,YNC 18 ms
-
HSYNC
VSY NC VIDEO
H VSYNC
1rnrt-C-
:. :.
-
t
CRT display unit
Regulator unit
I
VIDEO HYIDEO
N
-
-ii+ Brightness
Contrast
----------------24V -,12V Regulator
CRT/KB control PCB A20B-1003-0340
Fig. 14.7.3 (b) CRT unit block diagram
Fig.. 14..7..3(c) CRT unit block diagram
1-123
\
-
Edge connector
14.7.4
Troubleshooting flow chart
I ) No d i s p l a y
r 7 urn off CRT 3 minutes aftcr turning on the
Is I2 VDC voltage present between OV and CRT display unit fuw?
No
power supply. Is the picture bright white at OFF?
Yes
Yes
i
Dces the piaure become white when brightness is at maximum?
Yes
N~
-
Disconnect the edge connector which connects CRT display unit reguttor. Does t& resistance value (500kR)change between connector terminals B-D and also between conneaor termids C-D when turning the (B)bri@tnen VR (.See Note 1) (Fig. 14.7.3 (a))
-
Is 24WC applied t o remrIator wit? (Fig.. 14.7.3 (c)) CNS (1.2 = 2 4 V CNS (3.4 = O W CNS (5.6 = N.O (See Note 2)
Yes ).-
Yes
No
No
Does a waveform appear at VDO3 terminaI of CRT/KE? control PCB
MOB-100M340
No
Yes
Disconnect the edge connector whiQ connects CRT diiptay unit and regulator. Does waveform appear a a o n OV (termhi A) and VIDEO ( J ) (Fig. 17.9.3 (b))
Yes
*
No
C-
A20B-1003-0340 01 control circuit is defective.
CRT d i p t y unit
Regulator unit is defective.
CRT/KB control PCB
-
control unit..
" CRT display unit Al3B6056C001
Note 1) VR: Variable resistor Note 2) Check cable connector pins after disconnecting the connector.
2 ) Picture s h i f t s Start
I Docs a normal waveform appear at check tcrmlnal of CRTlKB
control PCB (Fig 14 7 3 (c))? HSYNC (Horizontal sync signal) Cyde : About 64irsec Width : About 15pwc VSYNC [ V e r t i ~ sync l signal) Cycle : About 18mwc Width : About lmwc
, y
Disconnect the edge connector Fig- 14 7 (b)) which connects CRT &play unit and the W u h t o r unit Docs a HSYNC waveform
Yes
Does the picture stop moving when V HOLD and H.HOLD (Fig.14 7 3 @)) of dbphy unit arc turned?
(Fig 14.7.3 (b)) appear at edge connector terminal F? Docs VSYNC waveform a p p u r zt edge connector tcrrninll K?
No
No
No
t
r
CRTD control PCB is
t
I
Regulator unit is defeaivc
defective
A20B-1003-0340
.
L
14.7.5
CRT display unit
is d d e a i n .
+
.
.
CRT display unit A13B-0056C001
Removal/replacement
Remove four screws holding t h e CRT monitor, and detach t h e CRT monitor.
CRT monitor
/
15.. 1/O BASE UNIT (A03B-0801-CO12) 15.1 Theory of Operation The 1/0 base unit serves as the bus connection between the various 1/0 moduies including the robot control module, the DI module, the DO module, the analog input module, and the analog output module.
75.2 Block Diagram
DC power
I
II
110 bus
15.3 Connector/SigmaI Identification CNA8 CNA7 CNA6 CNAS CNA4 CNA3 CNA2 CNAl CNAO
O O n O lO n O O ~ ~ DC power supply from the basic
GND EN N. C
+24V +24
: control unit : DC voltage output enable :
signal No connection
DC power supply from the power
GND
E is +24 VDC for robot control module. 1-24
CNAO AO- 2
: Address bus f o r the 110
D 0- 7 DP R/W
: Data bus f o r the 1/0 modules : p a r i t y b i t of t h e d a t a bus : Readlwrite c o n t r o l s i g n a l f o r
*DS
: Data s t r o b e s i g n a l f o r t h e 110
modules
t h e 1 / 0 modules modules : Bus enable s i g n a l f o r t h e 110 modules *POR : Power-on reset s i g n a l : Ready s i g n a l from t h e 110 RDY modules *ERR0 : E r r o r s i g n a l detected i n t h e robot c o n t r o l module *ERR1 : E r r o r s i g n a l detected i n t h e I/o modules : S i g n a l t o synchronize ITPS t h e interp&lation *RID : Read s t r o b e f o r I D code of t h e I / O modules ST : Start signal *CS1-10 : Card select f o r t h e 110 module ( s i o t I- 10) *SAO-3 : S l o t a d d r e s s f o r e x t e r n a l 110 bus AOR-A2R : Address bus f o r e x t e r n a l 1 / 0 bus *DOR-D7R: D a t a bus f o r e x t e r n a l 110 bus *DPR : P a r i t y b i t of t h e e x t e r n a l d a t a bus RCKl-3 : S e l e c t i n g si.gnal of a d d i t i o n a l I / O base u n i t (not used) RWR : R e a d k i t e signal f o r external 1 / 0 bus *EXRDY : Ready s i g n a l from a d d i t i o n a l 110 base u n i t (not used) : Data s t r o b e s i g n a l f o r e x t e r n a l 1 / 0 bus *DSR *ERROR : E r r o r s i g n a l d e t e c t e d i n t h e r o b o t c o n t r o l module *IOCRDY : I n t e r f a c e module ready f o r e x t e r n a l 110 bus : Bus e n a b l e s i g n a l f o r e x t e r n a l 1 / 0 bus *BER *ERRIR : Error s i g n a l d e t e c t e d i n a d d i t i o n a l 1 / 0 base u n i t (not used) *EXRCK : A d d i t i o n a l I / O b a s e u n i t e x i s t i n g s i g n a l : Read s t r o b e f o r I D code of 110 modules on a d d i t i o n a l 1 / 0 base u n i t *RIDR (not used) : Ready s i g n a l from a d d i t i o n a l I / O base u n i t (not used) RDYR : DC v o l t a g e output e n a b l e s i g n a l from t h e power u n i t EN t24 V *BE
-24
El
+I5 -15 +5
(
GND
v
!
: DC v o l t a g e i n p u t s
CNA 1- 8
Connector CNA1-8 a r e used f o r t h e connection w i t h 1 / 0 modules. "CNAI" corresponds with s l o t 1 and "CNA2" with s l o t 2 , and s o on. The s i g n a l meanings a r e d e s c r i b e d i n t h e "CNAO" expl.anat ion.
1) Procedure Remove the 1 / 0 modules i n t h e I / O base u n i t according t o Sec. 16-20. Disconnect a l l c a b l e s @ from t h e 1 / 0 base u n i t . Disconnect t h e ground w i r e @. The 1 / 0 base u n i t can be removed by loosening f o u r screws @. For mounting new 1 / 0 base u n i t , r e v e r s e t h e above procedure.
110 h3sc unit
16.
ROBOT' CONTROL MODULE (A03B-0801-C462)
The external view of the robot control module is shown
the following figure,
Note
Note) "RCOlC" means the robot control module. 16.1 Theory of Operation
The robot control module is connected to the L/O base unit, The robot control module serves as an interface between the shared RAM board and the I/O base unit through fiber optic communications. Information is received from and transmitted to the cables, other 1/0 modules, or circuitry. LEDs indicate circuit performance, A section of 8/16 converter converts 16 bits data bus width of shared RAM PCB to 8 bits data bus width. RAM is used on this module to store address translation data, 1/0 modules are mapped on the memory area of the main processor according to the contents of the RAM. The mapping arrangement is independent of the physical arrangement of the modules. Robot control module also serves as an interface for data transfer from the robot and the operator's panel. Eight input and eight output lines are wired to the robot for customer selected interfacing. Along with these lines on the CNC connector are lines for signals such as hand breakage, overtravel, near zero, and other robot indicators. Connector CNB is the internal connection of the controller. A voltage of +24 VDC for the input or output signals of this module is connected to the power input unit through CNB. Information from relays such as the fuse alarm, relay welding, and other inputs is fed to this module. The robot control module also drives the brake on/off control signals.
16.2 Block Diagram To 110 base unit
16.3 ConnectorISignal ldentification
CNA
AO-2
: Address bus f o r t h e 1 / 0
DO-7 DP R/W
: Data bus f o r t h e 1/0 modules : P a r i t y b i t of t h e d a t a bus : Readlwrite c o n t r o l s i g n a l f o r
*DS
: Data s t r o b e s i g n a l f o r t h e 1 / 0
modules
t h e 1/0 modules
*BE *POR
RDY *ERR0 *ERR1
ITPS *RID ST *CS1-10 *CSll-15
gi:?
modules : Bus enable s i g n a l f o r t h e 1/0 modules : Power-on r e s e t s i g n a l : Ready s i g n a l from t h e 1 / 0 modules : Error s i g n a l d e t e c t e d i n t h e robot c o n t r o l module : Error s i g n a l d e t e c t e d i n t h e 110 modules : S i g n a l t o synchronize the interpolation : Read s t r o b e f o r ID code of t h e 110 modules : Start signal : Card select f o r t h e 1 / 0 module ( s l o t 1- 10)
1
: Not used *OPTOFF *IOCON *SAO-3 : Slot address f o r e x t e r n a l 1 / 0 bus AOR-A2R : Address bus f o r e x t e r n a l 1 / 0 bus *DOR-D7R: Data bus f o r e x t e r n a l 1 / 0 bus *DPR : P a r i t y b i t of t h e e x t e r n a l d a t a bus RCKl-3 : S e l e c t i n g s i g n a l of a d d i t i o n a l 110 b a s e u n i t (not used) RWR : Read/write s i g n a l f o r e x t e r n a l 1 / 0 bus *EXRDY : Ready s i g n a l . from a d d i t i o n a l 1 / 0 b a s e u n i t (not used) *DSR : Data s t r o b e s i g n a l f o r e x t e r n a l 1 / 0 bus *ERROR : E r r o r s i g n a l d e t e c t e d i n t h e robot c o n t r o l module *IOCRDY : I n t e r f a c e module ready f o r e x t e r n a l 1 / 0 bus *BER : Bus e n a b l e s i g n a l f o r e x t e r n a l . 110 bus *ERRIR : E r r o r s i g n a l d e t e c t e d i n a d d i t i o n a l 1 / 0 base u n i t (not used) *EXRCK : Additional 1 / 0 b a s e u n i t e x i s t i n g s i g n a l *RIDR : Read s t r o b e f o r I D code of 1/0 modules on a d d i t i o n a l 1 / 0 base u n i t (not used 1 RDYR : Ready s i g n a l from a d d i t i o n a l 1 / 0 b a s e u n i t (not used) EN : DC v o l t a g e output e n a b l e s i g n a l from t h e power supply u n i t
i5 "1 GND j
: DC v o l t a g e
*ROT RLWD
: Robot o v e r t r a v e l s i g n a l : Relay welding s i g n a l detected
i n t h e power input u n i t : Fuse alarm of t h e brake
control circuit : Emergency s t o p s i g n a l from
t h e t e a c h pendant Contact s i g n a l of t h e brake release Contact s i g n a l of t h e brake release Contact s i g n a l of t h e breakage d e t e c t i o n : Brake r e l e a s e enable Contact s i g n a l of t h e brake release
2nd 3rd hand 1st
: DC v o l t a g e
CNC The connector "CNC" i s used f o r t h e i n t e r f a c e w i t h t h e mechanical u n i t . RDIl-8 : General purpose D I s Rb01-8 : General purpose DOs *ROT : Robot o v e r t r a v e l s i g n a l *IIBKD : Hand breakage d e t e c t i o n ALML : DO f o r t h e alarm lamp OPRL : DO f o r t h e o p e r a t i o n lamp
32 +24 E 1 2 1 ALML 33 +24 E ( 22 +24 E 34 +24 E 1
10 11 12
OE 0 E OE
NZ6 NZ1-5 +24 0 E
OPTIN
OPTOUT
: Not used : Near z e r o s i g- n a l s : DC v o l t a g e f o r DI & DO'S
: O p t i c a l i n p u t s i g n a l from t h e s h a r e d RAM PCB : O p t i c a l output s i g n a l t o t h e s h a r e d RAM PCB
.
16.4 LEDs E r r o r i n d i c a t o r LEDs a r e mounted on t h e f r o n t p a n e l o f t h e r o b o t c o n t r o l module (RCOlC) t o i n d i c a t e an e r r o r which may o c c u r d u r i n g d a t a t r a n s f e r between b a s i c c o n t r o l u n i t and RCOlC o r between RCOlC and 1 / 0 module. 1/0 module means r o b o t c o n t r o l module, D I module, DO module, a n a l o g i n p u t module o r a n a l o g o u t p u t module. E r r o r i n d i c a t o r LEDs
Error indimtor (red)
t
Error module indicazor &enow)
LThese LEDs are used to locate a parity error.
Error contents Error display TOUT ER3 ER2 ERI
-
-
-
-
Normal o p e r a t i o n
t
-
o
o
o
CLOCK STOP
-
o
o
-
CARRIER STOP
-
o
-
o
0
-
0
-
-
-
o
OVERRUN ERROR
-
o
-
ERROR WORD
o
TIME OUT ERROR
o
PARITY ERROR
-
- -
1. O p t i c a l c a b l e is disconnected. 2. O p t i c a l conn e c t o r i s not sufficiently connected. 3. O p t i c a l connector t i p is dirty. 4. RCOlC i s defective. 5. Shared RAM board i s defe&ive,
A p a r i t y e r r o r was detected during data t r a n s f e r between RCOlC and 1/0 module, o r a p a r i t y e r r o r occurred i n RAM o f RCOlC, I n t h i s case, t h e mounting b a s e number o f t h e d a t a t r a n s f e r module i n t r o u b l e and t h e s l o t number are d i s p l a y e d i n SA3-SAO and BAI-0, SA3-SAO: S l o t number (binary display) BA1, BAO: Base number (binary display)
1. I / O module i s defective, 2. RCOlC i s defective,
--
o
Example) Base 81, s l o t #5 Sk3 SA2 SA1 SAO BA1 BAO O l O l O l
--
S l o t #5
-d
Base f 1
0 : Goes o u t
1: L i g h t s I f b o t h s l o t number and b a s e number a r e "O", there is a pariry error of RAM i n RCOlC.
o: Lamp lighrs -: Lamp goes out
Causes
An e r r o r o c c u r r e d during d a t a t r a n s f e r between RCOlC and t h e s h a r e d RAM board,
FORMAT ERROR
-.
-
--
,
SIGNALFORM ERROR $
-
Error c o n t e n t s
--
-
I
Name of e r r o r
16.5 Jumper Settings
r
7
Jumpers
Standard setting
PI
ik&l P2
Uses Selecting common voltage for RDI: When P I is set to A side, a pneumatic pressure alarm will occur.
OV common
Short-circuit *HBKD input. 'HBKD is effective
L
Location of jumpers
(The plastic cover is removed in the above figure) Refer to Sec. 16.7 for the plastic case disassembly method.
+2JV common
el
'HBKD is
short-circuited
76.6 Test Points The meanings of t h e t e s t p o i n t s on t h e robot c o n t r o l module a r e a s fol.lows.
Test p o i n t s
Contents
TDIS
When TP3 is connected t o GND, t h e t i m e o u t e r r o r detected i n r o b o t c o n t r o l module i s disabled. T h i s t e s t p o i n t is used f o r development.
+5 VDC
+5 V
CLK
Waveform
n
8 MHz c l o c k
35v ov
I__---!
125 nsec
DVO
DVO i n d i c a t e s t h a t the r e s e t i s i n i t i a t e d by t h e s o f t w a r e ,
GND
0V
.
Location of t e s t p o i n t s Note)
111 t h e above f i g u r e , t h e p l a s t i c cover. is removed, t h e p l a s t i c c a s e disassembly method.
R e f e r t o Sec.
16.7 f o r
76.7 Removal/Repiacement I ) Removing robot c o n t r o l module from 1/0 base u n i t Slot 0
a) Procedure 1 Disconnect t h e c a b l e from t h e robot c o n t r o l module (RCOlC). 2 Detach RCOlC by loosening two screws @, 3 For mounting t h e new RCOlC, reverse t h e above procedure. b) S e t t i n g Set t h e new RCOlC c o r r e c t l y using t h e o r i g i n a l RCOlC a s a r e f e r e n c e , 2) P l a s t i c case disassembly method
8
Case
Panel
'.
Cover
I
tiif=@ @
Using both thumbs push t h e p o s i t i o n s @ on the cover i n t h e d i r e c t i o n of t h e arrows. S l i d e t h e cover o f f . The panel car. be detached by pushing t h e c e n t e r of t h e panel from d i r e c t i o n @ u n t i l i t is curved.
8 3
3) Detaching t h e PC]; from the p l a s t i c case
.
1 Remove PCB mounting screws @ Draw the PCB out of the case in the direction
8 2
@.
'17. Dl MODULE The e x t e r n a l view of t h e D I module i s shown i n t h e f o l l o w i n g f i g u r e .
Note) The code marked o n t h e u p p e r s i d e of t h e f r o n t p a n e l i n d i c a t e s t h e t y p e o f D I module. ID08C Indicates Indicates Indicates Indicates
D I module DC o r AC power The numbers of p o i n t s (08 o r 16) t h e t y p e (C, D o r E)
The DI module h a s t h e f o l l o w i n g s p e c i f i c a t i o n numbers:
17.1 Theory of Operation The D I module p r o v i d e s t h e u s e r w i t h t h e means of i n t e r f a c i n g p e r i . p h e r a 1 equipment i c p u t s t o t h e c o n t r o l l e r . AC o r DC t y p e n o d u l e s are a v a i l a b l e f o r t h i s purpose. The D I module c o n n e c t s t o t h e I / O base u n i t through t h e CNA connector. I n t e r f a c i n g i s completed by c o n n e c t i n g i n p u t l i n e s t o t h e CNT t e r m i n a l s t r i p s . E i g h t and s i x t e e n c h a n n e l i n p u t modules can be s e l e c t e d f o r i n t e r f a c i n g . The D I nodule a l s o a c t s a s a l e v e l c o n v e r t e r because AC and DC i n p u t s may b e accessing the controller, A l l i n t e r f z c e s i g n a l s a r e c o n v e r t e d t o l o g i c - l e v e l +5 v o l t s b e f o r e being p l a c e d o n t h e If0 bus. LEDs a r e mounted on t h e module t o monitor each i n p u t l i n e . These LEDs l i g h t when a n i n p u t i s r e c e i v e d on t h e module.
To user's interface
7 7.3 Connector/Signal ldentification
CNA
Card s e l e c t Address signal Data bus Parity b i t of the data bus : R e a d k i t e control s i g n a l : Data strobe s i g n a l : Bus enable s i g n a l : Error si.gna1 detected in the DI module : Read strobe f o r I D code : : : :
: DC voltage
CNT Refer to IV-3.2.5
f o r terminal CNT.
17.4 LEDs The DI module is provided with LEDs f o r indicating the o n j o f f conditions of each input signal.
IAOBE. IA16E
IDOBC. ID16C IWBD. ID16D
Yellow LED
LED: :
Lights
. . . - . -- -- -- input Inputturnson. - - -turns - off:
Goes out turns off
YeUow LED
1) Procedure @ Disconnect cables from Dl module, Disconnect the terminal board by loosening the two screws @ shown in the following figure and, while holding its upper and lower ends, pulling out the entire terminal board, For disconnecting the wiring, open the nameplate. The nameplate is opened by pulling it out, while holding it at @ shown in the following figure. Terminal board
Detach DI module by loosening the screws @. For mounting new DI module, reverse the above procedure, replacing the terminal board on the new DI module with the original terminal board. 2) Cautions Mount rhe terminal board removed from the replacement DI module on the old DI module before returning the'module for repair.
78. DOMODULE The e x t e r n a l view of t h e DO module i s shown i n t h e f o l l o w i n g f i g u r e .
Note
Note) The code marked on t h e u p p e r s i d e of t h e f r o n t p a n e l i n d i c a t e s t h e t y p e of DO module.
OD083 Indicates Indicates Indicates Indicates
DO module
DC o r A C power T h e number of p o i . n t s (08 o r 16) t h e t y p e (B, C, D, E or H)
The DO module has t h e f o l l o w i n g s p e c i f i c a t i o n numbers:
18.1 Theory of Operation The DO module p r o v i d e s o u t p u t s t o t h e u s e r f o r i n t e r f a c i n g . AC o r DC t y p e o u t p u t s a r e a v a i l a b l e and c o v e r a range of o u t p u t c u r r e n t c a p a c i t i e s . Eight and s i x t e e n channel output modules a r e a v a i l a b l e . Data is t a k e n from t h e 1/0 b a s e u n i t through t h e CNA connector and conditioned The DO module provides t h e t o be o u t p u t by means of t h e CNT t e r m i n a l s t r i p s , l e v e l conversion from l o g i c l e v e l t o t h e s i g n a l l e v e l s p e c i f i e d by t h e module. LEDs monitor each c u t p u t a s t h e o u t p u t i s f i r e d by t h e c o n t r o l l e r . Fuses on each module p r o t e c t t h e equipment from o v e r c u r r e n t c o n d i t i o n s .
18.2 Block Diagram
18.3 Connector/SignaI Identification
Card s e l e c t Address s i g n a l Data bus P a r i t y b i t of the data bus Readjwrite control s i g n a l Data strobe signal Bus enable s i g n a l Power-on r e s e t Error s i g n a l detected i n t h e 110 interface module Error s i g n a l detected i n t h e DZ: module Read stro6e f o r I D code
DC v o l t a g e
cm Refer t o IV-3.2.5
f o r terminal CNT.
78.4 LEDs The DO module is provided with LEDs for indicating the on/off conditions of each output signal. OW8B. 0 0 1 6 8 OWSC. OD16C
OAOSD. OA16D Y eilow LED
LED : Lights : Goer out
OW8H. OD16H
OA08E. OA16E
lYdOW
LED
... .. Output turns on. ..... . Ourput rums off..
llow LED
18.5 Fuses The DO module is provi.ded w i t h a b u i l t - i n f u s e f o r every common. I f t h e s e f u s e s are blown, t h e f u s e - a l a r m i n d i c a t o r LED of t h e corresponding module l i g h t s t o indicate the fuse f a i l u r e . The f o l l o w i n g f i g u r e s shown t h e mounting p o s i t i . o n s o f t h e fuse-alarm i n d i c a t o r LEDs of e a c h module and t h e mounting p o s i t i o n s o f fusesI n t h e f i g u r e t h e p l a s t i c c o v e r i s removed. Refer t o Sec. 16.7 f o r t h e p l a s t i c c a s e disassembly method.
f
OD08B, OD16B
Nodule name Mounting p o s i t i o n s o f fusealarm indicator LEDs and mounting p o s i t i o n s of fuses
0
I
Fuse alarm LED (red) Indicator
I f o n e of f o u r t h e above f u s e The blown f u s e display i n the Correspondence between f u s e s and output terminals
Fuse number Output number
--
-
f u s e s FU1 FU4 i s blown, a l a r m LED l i g h t s . shows a w h i t e f a i l u r e i n d i c a t o r shown a t t h e r i g h t .
mTl
01
-
FU3
FU2 04
05
-
08
09
-
FU4 12
13
-
16
OD08C, OD16C
Module name Mounting posit i o n s of fusealarm i n d i c a t o r LEDs and mounting p o s i t i o n s of fuses
Inditor
Fuse alarm LED (red)
-
I f one of e i g h t f u s e s F1 F8 is blown, t h e above f u s e alarm LED l i g h t s . The blown f u s e shows a whi.te f a i l u r e d i s p l a y i n t h e i n d i c a t o r shown at t h e r i g h t . Correspondence between f u s e s and output terminals
t
i
1
0
Fuse number
F1
F2
F3
F4
F5
F6
F7
F8
Output number
01 02
03 04
05 06
07 08
09 10
11 12
13 14
16
15
Procedure @ Disconnect cables from DO module. Disconnect t h e terminal board by loosening t h e two screws @ shown i n t h e following f i g u r e and, w h i l e holding i t s upper and lower ends, pulling out t h e e n t i r e terminal board. For disconnecting t h e wiring, open t h e nameplate. The nameplate i s opened by p u l l i n g it o u t , while holding i t a t @ shown i n the following figure. Tmninal board
.
Detach DO module by loosening t h e screws @ For mounting new DO module, reverse t h e above procedure replacing the terminal board on the new DO module by t h e o r i g i n a l termi.na1 board. 2) Cautions Mount the terminal board removed from the replacement DO module on the old DO module before returning t h e module f o r r e p a i r ,
8 2
3
19.
ANALOG INPUT MODULE (AO3B-0801-C410)
The external view of the analog input module is shown in the following figure.
1) 1 I
Note) 'AD04A' means the analog input module.
19.1 Theory of Operation The analog input module provides the user with a means for interfacing peripheral equipment analog inputs to the controller. This device connects to the I / O base unit through the CNA connector, Interfacing is completed by connecting input lines to the CNT terminal strips, A four channel input module is available, For interfacing, the analog input module also acts as an A/D converter because analog inputs may be accessing the controller, All interface signals are converted to the digital value before being placed on the I / O bus. 19.2 Biock Diagram To 110 base unit
I
CNA
1
1I
Buffer
8 MIiz clock
I
19.3 ConnectorJSignalIdentification
CNA
CNT
CNA *CS AO-3 DO-7 DP R/W *BE *POR *ERR1
.
: Card s e l e c t : Address signal : Data bus : Parity b i t of"tEie data bus : ~ e a d / w r i t econtrol signal : Bus enable signal : Power-on reset : Error signal detected is
the analog input module *RID : Read strobe f o r I D code 4-15 V ) -I5 +5
CWT Refer to IV-3.2.5
for terminal CNT.
v
} : DC voltage
19.4 Variable Resistors Ten variable resistor's are located on the analog input module (AD04A). Refer to Sec, 19.7 for the adjusting method. The variable resistors VR3 and VR4 are used for the gain adjustment of the operation-amplifiers. The variable resistor VR5 is used for the balance adjustment between two operation-amplifiers. The variable resistor VR6 is used for the gain adjustment of the operation-amplifiers. The variable resistor VR12 is used for the offset adjustment of the A/D converter, The variable resistor VRll is used for the gain adjustment of the A/D converter. The variable resistors VR7, VR8, VR9 and VRlO are used for the adjustment of the input resistance.
19.5 Test Points The meanings of the test points on the analog input module are as follows. Test points Symbol TP1
-
TP2
-
TP3
-
Contents
Waveform (voltage)
Used for test. Input common selected by multiplexer.
Common for TP3
Output of the operation-amplifiers whose input is "TP1".
Common for TP4
Used for test, Analog input selected by multiplexer
-10 V
- 4-10V
(Reference is TP1)
Output of the operation-amplifiers whose input is "TP3".
-10 V
- +10 V
(Reference is TP2)
Differential voltage between TP4 and TP2.
-10 V
- +10 V
Input to the A/D converter.
-10 V
- +10 V
.
TP4
-
TP 5
-
TP 6
-
TP7
+15 V
+15 VDC power
+15 VDC
TP8
-15 V
-15 VDC power
-15 VDC
TPlO
4-5 V
+5 VDC power
+5 VDC
TP9 TPl l
0V
I
Test points TP12
Symbol
Contents
INH
Used for test. By connecting TP12 to T P l l (GND), all the analog input is neglected (disconnected) to the A/D converter input.
-10 +SV
Waveform (voltage)
Note) In the left figure the plastic conr is removed. Refer to sec. 16.7 for the pksbc case dtcambly method..
TP11 GND
~4
0
CNT16 CNT17
TP6
0
VR1l
0 0
VR12
M I 8
CNT19
f CNT~O CNl-21
Fig. 19.5 Location of test points and variable resistors on the analog input module
1) Procedure
@ Disconnect cables from the analog input module. Disconnect the terminal board by loosening the two screws @ shown in the following figure and, while holding its upper and lower ends, pulling out the entire terminal board, For disconnecting the wiring, open the nameplate, The nameplate is opened by pulling it out, while holding it at @ shown in the following figure. Termid board
Detach analog input module by loosening the screws @. For mounting new analog input module, reverse the above procedure. 2) Adjusting 3) Cautiorls Mount the terminal board removed from the replacement nodule on rhe old module before returning the module for repair.
8 2
3
79.7 Calibration Procedure Obtain the following equipment: Voltage source (resolution 1 mV) Voltage meter (resolution 0.1 mV) , Resistance meter (resolution 0.01 ohm)
.
Calibrate as follows. 1, Input 0.000 V to TP1 and TP3. 2, Adjust VR3 until the voltage at TP5 becomes 0.0 mV. 3, Adjust VR4 until the voltage at TP6 becomes 0.0 mV.
4, Input +5 V to TP1 and TP3, 5 , Adjust VR.5 until the voltage at TP5 becomes 0.0 mV.
6, Input 0,000 V to TP1 and input +10.000 V to TP3.
7. Adjust VR6 until the voltage at TP6 becomes 3-9.768 V, 8, Input 0.000 V to TP1 and input -10.000 V to TP3. 9 , Adjust VR12 until the display for analog inputs on the KAREL controller A10
screen (Note) becomes F830 (hex), 10. Input 0.000 V to TP1 and input +10.000 V to TP3. 11, Adjust VR12 until the display for analog inputs on the KAREL controller A10 screen becomes 07D0 (hex). 12, Input 0.000 V to TPI and TP3. 13, Confirm that the display for analog inputs on the KAREL controller A10 screen is 0000. 14, Repeat steps 8 through 13 until all conditions are net.
15, Adjust VR7 until the resistance between CNT(2) ohms.
and CNT(3)
becomes 250.0
16. Adjust VR8 unti.1 the resistance between CNT(6) ohms
and CNT(7)
becomes 250.0
17. Adjust VR9 until the resistance between CNT(10) ohms
and CNT(11) becomes 250.0
18. Adjust VRlO until the resistance between CNT(14) ohms.
and CNT(15) becomes 250.0
. .
Note) The KAREL controller A10 screen can be displayed on the CRT/KB by pressing STATUS (F2) on the POWER UP screen, followed by 1 / O (F3) on the STATUS screen, and A10 (F4) on the I/O screen.
20.
ANALOG OUTPUT MODULE (AO3B-0807-C417)
The e x t e r n a l view of the analog output module i s shown i n the following figure,
Note) 'DAOZA' means the analog output module.
20.1 Theory of Operation The analog output module provides analog o u t p u t s t o t h e u s e r f o r i n t e r f a c i n g , A two channel output module is a v a i l a b l e , Data i s taken from t h e I / O base u n i t through t h e CNA connector and conditioned t o be output through t h e CNT terminal s t r i p s . This module a l s o provides D/A conversion from t h e d i g i t a l value. 20.2 Block Diagram To I10 base unit
20.3 Connector/Signal Identification
CNA *CS AO-2 DO-7 DP R/W *BE *DS *BE *POR *ERR0
*ERU
*RID
: Card s e l e c t : Address s i g n a l : Data bus : P a r i t y b i t of t h e d a t a bus : R e a d k i t e control signal : Bus enable s i g n a l : Data s t r o b e s i g n a l : Bus enable s i g n a l : Power-on r e s e t : Error s i g n a l detected i n t h e 1/0 i n t e r f a c e module : Error s i g n a l detected i n t h e analog output module : Read s t r o b e f o r I D code : DC voltage
-15 V 0v
CNT Refer to ZV-3.2.5
for terminal CNT.
20.4 Variable Resistors Twelve v a r i a b l e r e s i s t o r s a r e l o c a t e d on t h e a n a l o g output module (DA02A). Refer t o Sec. 20.8 f o r t h e a d j u s t i n g method. The v a r i a b l e r e s i s t o r s VRAl and VRBl a r e used f o r t h e o f f s e t adjustment of t h e D ~ converter, A V M l i s provided f o r channel 1 o u t p u t and VRB1 is f o r channel 2 output. The v a r i a b l e r e s i . s t o r s VRA2 and VRB2 are used f o r t h e o f f s e t adjustment of t h e voltage amplifiers, VRA2 i s provided f o r channel 1 output and VRB2 is f o r channel 2 output. The v a r i a b l e r e s i s t o r s VRA5 and VRB5 are used f o r t h e g a i n zdjustment of t h e v o l t a g e amplifi.ers. VRAS is f o r channel 1 and VRBS i s f o r c h a m e l 2. The v a r i a b l e r e s i s t o r s VRA3 and VRB3 are used f o r t h e o f f s e t adjustment of t h e V / I conversion c i r c u i t , VRA3 is f o r channel 1 and VRB3 i s f o r channel 2. The v a r i a b l e r e s i s t o r s , VRA4 and VRB4 are used f o r t h e balance adjustment of t h e V / I conversion c i r c u i t , VRA4 i.s f o r channel 1 and VRB4 i s f o r channel 2. The v a r i a b l e r e s i s t o r s VRA6 and VRB6 are used f o r t h e g a i n adjustment of t h e V / I conversion c i r c u i . t . VRA6 is f o r channel 1 and VRB6 is f o r channel 2. 20.5 Jumper Settings 1
Standard setting
S1
;q
S2 >
2 +
Uses This jumper is used only f o r t h e o f f s e t and balance adjustment of t h e V/I conversion c i r c u i t f o r channel 1. Refer t o Sec,'20,8 f o r t h e s e t t i n g method. The standard s e t t i n g is always open. This jumper is used only f o r t h e o f f s e t and balance adjustment of t h e V / I conversion c i r c u i t f o r channel 2, Refer t o Sec, 20.8 f o r t h e s e t t i n g method. The standard s e t t i n g is always open.
20.6 Test Points The meanings of the test points on the analog output module are as follows.
Contents
Symbol
Test points
Wavefo m (voltage)
-.
PA1
Output of the D/A converter of channel 1
PA2
Output of the voltage amplifier of channel 1 -
-
Used for the offset and balance adjustment of the V/I conversion circuit of channel I, Refer to Sec. 20.8 for details.
I I
Output of the D/A converter of channel 2 Output of the voltage amplifier of channel 2 Used for the offset and balance adjustment of the V/I conversion circuit of channel 1, Refer to ~ec.20.8 for details.
+15 VDC power
+15 VDC
-15 V
-15 VDC power
-15 VDC
GND
0 V
+5 V
+5 VDC power
+5 VDC
3-24 V
+24 VDC power
+24 VDC
+12 V
,+.I2VDC power
+12 VDC
-12 VDC power
-12 VDC
-5 VDC power
-5 VDC
-5 V
Fig. 20.6 Location of test points and variable resistors on the analog output module
The plastic cover is removed i n the above figure, p l a s t i c case disassembly method.
Refer t o Sec, 16.7
f o r the
Procedure @ Disconnect cables from above analog output module (DA02A). Disconnect the terminal board by loosening the two screws @ shown in the following figure and, while holding its upper and lower ends, pulling out the entire terminal board. For disconnecting the wiring, open the nameplate. The nameplate is opened by pulling it out, while holding it at @ shown in the following figure. Terminal board
2 Detach analog input module by loosening the screws @. 3 For mounting new DA02A, reverse the above procedure. 2) Adjusting Adjust the PCB correctly after replacement. 3) Setting Set new DA02A correctly using the original DA02A as a reference. 4) Cautions Mount the terminal board renoved from the replacement module on the old module before returning it for repair.
8
20.8 Calibration Procedure Obtain the following equipment: Voltage meter (resolution 0.1 mV) Current meter (resolution I u A )
. .
Calibrate the Analog output channel 1 as fo1,lows: 1. From the KCL> prompt, type in the following: SET PORT AOUTCn] = 0 where n is the port number. This command will force a 0 V output.
2. Adjust VRAl until 0 V is measured at PA1.
3. Adjust VRA2 until 0 V is measured at PA2. 4, From the KCL> prompt, type in the foll.owing: SET PORT AOUTCnl = 2000 where n is the port number. This command will force a +10 V output.
5, Adjust VRAS until 10 V i.smeasured at PA2,
6, From the KCL> prompt, type in the following: SET PORT AOUTCnl = -2000 where n is the port number, This command will force a -10 V output.
7, Confirm that -10 V is measured at PA2. 8, From the KCL> prompt, type in the following: SET PORT AOUTCnl = 0 where n is the port number.
9. Set the jumper S1 to 0 V side (or connect PA4 to 0 V), 10, Turn VRA3 clockwise until it stops: then turn it again counterclockwise until 0 V is measured at PA2, Stop immediately when the voltage at PA2 reaches 0 V, otherwise the offset of the V/I converter cannot be adjusted correctly, 11. Set the jumper S1 to i-12 V side (or connect PA4 to +12 V). 12, Adjust VRA4 until the voltage between PA3 and PA4 becomes 0 V.
13. Remove the jumper S1 (PA4 should be open). 14, Connect a current meter between CNT(3) and CNT(4). 15. From the KCL> prompt, type in the following: SET PORT AOUT [n] = 1000 where n is the port number. This command will force a 20 mA output. 16. Adjust VRA6 until 20 mA is measured.
Calibrate the Analog output channel 2 as follows: I . From the KCL> prompt, type in the following:
SET PORT AOUTCn] = 0 where n is the port number, This command will force a 0 V output. 2. Adjust VRBl until 0 V is measured at PBl.
3. Adjust VRB2 until 0 V is measured at PB2. 4. From the KCL> prompt, type in the following: SET PORT AOUTCnl = 2000 where n is the port number, This command will force a +10 V output. 5. Adjust VRB5 until 10 V is measured at PB2.
6, From the KCL> prompt, type in the following: SET PORT AOUTCnl = -2000 where n is the port number. This command will force a -10 V output.
7. Confirm that -10 V is measured at PB2. 8. From the KCL> prompt, type in the following: SET PORT AOUTfnl = 0 where n is the port number, 9 - Set the jumper S 1 to 0 V side -(or connect PB4 to 0 V).
10, Turn VRB.3 clockwise until it stops, then turn it again counterclockwise until 0 V is measured at PB2. Stop immediately when the voltage at PB2 reaches 0 V, otherwise the offset of the V/Z conveter cannot be adjusted correctly. 11. Set the jumper S1 to +12 V side (or connect PB4 to +12 V).
12, Adjust VRB4 until the voltage between PB3 and PB4 becomes 0 V. 13. Remove the jumper Sl (PB4 should be open).
14, Connect a current meter between CNT(3)
and CNT(4).
15, From the KCL> prompt, type in the following: SET PORT AOUT[n] = 1000 where n is the port number. This command will force a 20 mA output. 16. Adjust VRB6 until 20 mA is measured.
21.
FIXED 110 BOARD (A168-1217-0750)
21.1 Theory of Operation The f i x e d I / O board i s a s i n g l e I / O board, which i s i n s t a l l e d i n t h e c o n t r o l l e r backplane. The board p r o v i d e s a n i n t e r f a c e t o t h e robot mechanical u n i t and u s e r system. S i g n a l l i n e s a r e connected t o t h e a p p r o p r i a t e connector from t h e f i x e d 1 / 0 board, CNC i.s used f o r connection t o t h e mechanical u n i t , and CNB i s used f o r connection t o t h e power i n p u t u n i t . CNI and CN2 a r e used f o r u s e r I/O. The f i x e d 1 / 0 board i s connected t o t h e shared RAM board v i a a s e r i a l l i n k , which i s i d e n t i c a l t o t h e o p t i c a l l i n k system used i n t h e modular I/O u n i t . The 1/0 c o n t r o l l e r (IOC) r e c e i v e s a s e r i a l d a t a s i g n a l , converts i t t o p a r a l l e l d a t a , and provides t h e d a t a t o t h e d r i v e r s DV. The i n p u t s from C N l , CN2, CNB and CNC a r e received by t h e r e c e i v e r s RV, and t h e I O C converts them i n t o a s e r i a l d a t a stream.
21.2 Block Diagram To Backplane
I
CNA
To robot xncchanical unit
I
To power input unit
T user devices
To user devices
21-3 Connector/Signal Identification
CNA
I
: Bus ground i n Wired t o g e t h e r i n t h e board : Bus ground out : S e r i a l data i n : S e r i a l data out : Reverse l o g i c s i g n a l o f power enable *SYSCLR: System clear 0 v
*BGIN *BGOUT SDI SDO *EN
+15 V -15 V
UDIl
UDOl 0 E
-
32: User D I 24: User DO : Common of U D l s and UDOs
CNB
BKR22 BKR32 HBKD2 *BKRE BKR 12
0
v
: Robot o v e r t r a v e l s i g n a l : Relay welding s i g n a l d e t e c t e d i n the input u n i t : Fuse alarm of t h e brake control circuit : Emergency s t o p s i g n a l from t h e teach pendant Contact s i g n a l of t h e 2nd brake r e l e a s e Contact s i g n a l of t h e 3rd brake r e l e a s e Contact s i g n a l of t h e hand breakage d e t e c t i o n : Brake r e l e a s e enable Contact s i g n a l of t h e 1 s t brake r e l e a s e : DC voltage
The connector "CNC" i s used f o r t h e i n t e r f a c e w i t h t h e mechanical u n i t . RDIl 8: General purpose D I s RDOl 8: General purpose D O s *ROT : Robot o v e r t r a v e l s i g n a l *HBKD : Hand breakage d e t e c t i o n ALML : DO f o r t h e alarm lamp OPRL : DO f o r the o p e r a t i o n lamp
-
*ppABN) : Not used
HZ6 NZl
-
C24 0
v
5 : Near zero s i g n a l s : DC v o l t a g e f o r D I and DO'S
21.4 Jumper Settings Standard setting
PI
IS] P2
Uses S e l e c t i n g common v o l t a g e f o r When P1 i s set t o A s i d e , a pneumatic p r e s s u r e alarm w i l l occur.
RDI:
S h o r t - c i r c u i t *HBKD i n p u t .
OV common
El
OHBKI) i s effaive
Location of jumpers
+2JV common
*HBKDis shon-circuited
1) Procedure Disconnect cables from the fixed 1/0 board. Detach PCB by loosening two screws @. For mounting new PCB, reverse the above procedure.
22.
TEACH PENDANT (A05B-2051-C742)
22.1 Theory of Operation The teach pendant p r o v i d e s a means of i n p u t t i n g j o g commands through a keyboard. It a l s o d i s p l a y s messages from t h e r o b o t c o n t r o l l e r t o t h e user. The t e a c h pendant i s cabled t o t h e c o n n e c t o r CNTP o f t h e s h a r e d RAM board. CNTP i s a n RS-422 s e r i a l p o r t connector. Data is t r a n s m i t t e d and r e c e i v e d between t h e main The power source i s +24 WC, CPU and t h e t e a c h pendant via t h i s s e r i a l p o r t . which i s s u p p l i e d by t h e c o n t r o l l e r v i a t h e same c a b l e . The t e a c h pendant c o n t r o l PCB c o v e r t s +24 V t o +5 V, -5 V, and 4-3.4 V, The -l-5 V i s used f o r t h e l o g i c on t h e PCB a n d t h e l i q u i d c r y s t a l d i s p l a y (LCD) c o n t r o l . The -5 V (VEE) and +3,4 V (VO) are used t o d r i v e t h e LCD. The LCD module h a s a back l i g h t , which throws l i g h t on t h e b a c k of t h e LCD panel. The back l i g h t is d r i v e n by t h e +24 V power, One microprocessor is used f o r communication w i t h t h e c o n t r o l l e r , r e a d i n g keyed i n f o r m a t i o n and d i s p l a y i n g t h e i n f o r m a t i o n on t h e LCD. One ROM i s r e s p o n s i b l e f o r supporting system o p e r a t i n g s o f t w a r e t o t h e t e a c h pendant. An EMERGENCY STOP b u t t o n a n d a DEADMAN s w i t c h are provided f o r t h e u s e r ' s safety. An ENABLE ONfOFF s w i t c h is p r o v i d e d f o r c o n t r o l of t h e DEADMAN s w i t c h and s e l e c t e d software functions.
Note) The system c a n b e o p e r a t e d w i t h o u t t h e t e a c h pendant by plugging t h e t e a c h pendant b y p a s s p l u g i n t o t h e CNTP.
222 Block Diagram To shared RAM board CNTP CNl I
- I
+24V +24V Power source
-
EMERGENC STOP
CN6 -I . . I
9.2 16MH.z clock
CPU
I + I +5v -5v +3.4v
- LCD
0 DEADMAN
Buffe
switch
- PCB
r
A
1
'
9
,
Key address detector
CN3
Keyboard PCB
h LCD module with back light
J
-
~20B-1002-0980
22.3 Teach Pendant 1A05B-2051-C142) 22.3.7 Connector/signal identification
EMERGENCY STOP
button
/
Connector to the shared RAM board
DEADMAN switch
: Sending data *SD "*SDW is a reverse logic signal of "SD". : Receiving data
EMG
DEADMAN
;
EMG
5
TP3
-
TP4
-
TPI
ENBLE TP1
"*RDW is a reverse logic signal of "RD". Note) Above signals are RS-422 interface. EMG : EMERGENCY STOP +24 VDC which comes from the controller TP1 : Status signal of EMERGENCY STOP button and DEADMAN switch TP2 : Status signal of EMERGENCY STOP button and ENABLE ON/OFF switch TP3,TP4: Extra contact output of EMERGENCY STOP button +24 V : i-24 VDC for logic circuit 0 V : Signal ground FG : Frame ground
22.32 Removal/replacernent of teach pendant and components
1) Unit (Teach pendant)
a) Procedure 1 Disconnect the cable. 2 Replace the teach pendant with a new one, and connect the cable,
8
2) Component (EMERGENCY STOP button) a) Procedure 1 Disconnect the cable. 2 Remove the back-cover by loosening six screws , 3 Disconnect the cable 3 , 4 Remove the EMERGENCY STOP button by loosening part @. @ For mounting a new button, reverse the above procedure.
8 8
8
3) Component (ENABLE ON/OFF switch) a) Procedure 1 Disconnect t h e cable. 2 Remove t h e back cover by l o o s e n i n g s i x screws @. 3 Disconnect c a b l e @. 4 Remove t h e ENABLE ON/OFF switch. @ For mounting a new switch, r e v e r s e t h e above procedure.
8 8
22.4 Teach Pendant Control PCB (A20B-1002-0980) 22.4.1 Connector/signal identification
Refer t o Sec. 22.3.1 f o r t h e s i g n a l names
.
:0 v : 4-5 VDC power supply : Power s o u r c e t o d r i v e LCD : R e s i s t o r s e l e c t t o LCD controller RW : Read/write c o n t r o l t o LCD controller E : Read enable t o LCD controller DBO 7 : Data bus tojfrom LCD controller *CS : Chip select t o LCD controller *RES : Reset s i g n a l t o LCD controller VEE(-5 V) : Power s o u r c e t o d r i v e LCD
VSS (0 V) VDD(+5 V) VO(i3.4 V) RS
-
*KEY00
- 07:
*KCOM0
-
*LED1 4-5 V
-
Output s i g n a l of keyswitch s t a t u s t o t h e teach pendant c o n t r o l PCB 5 : Common of t h e keyswitch from t h e t e a c h pendant c o n t r o l PCB 7 : Drive s i g n a l of LED d i s p l a y : Common of LEDs
EMGL, 2 : The s t a t u s of t h e EMERGENCY STOP button (normally c l o s e d ) EMG3, 4 : The s t a t u s o f t h e EMERGENCY STOP button (normally open)
EFIGS, 6: The s t a t u s of t h e EMERGENCY STOP button (normally closed) used f o r TP3/TP4 *24 0
: Power source f o r LCD back l i g h t
v
ENBl, 2: The s t a t u s of t h e ENABLE ON/OFF s w i t c h (closed i n "ENABLE") ENB3, 4: The s t a t u s of t h e ENABLE ON/OFF s w i t c h (open i n "ENABLE") 2242 Variable resiston
Function
Adjustment
VRl
+5 V adjustment
Adjust VRl u n t i l f 5 V i s observed a t test p o i n t i-5 v.
VR2
VO adjustment
Adjust VR2 u n t i l +3.4 V i s observed a t t e s t p o i n t VO.
Symbol
b
C9M
*RES
0
0
CLWD S1
0
OoV 0+5v
l.ol 0
0
0" 0
0s2
+5L -5L
lol
:Om VR2 VRI 0
+24V
! Fig.. 22.4..2 Location of variable resistors, jumpers and test points
22.4.3 Jumper settings
Jumpers
Standard setting
S1
m
Used for production testing only
m
Not used
Uses
Short
S2
Open
See Fig. 22-4.2 for 1ocati.onof S1 and S2. 22.4.4
Test points
The meanings of the test points on the teach pendant control PCB are as follows. Test points Symbol *RES
-
CLWD
-
C 9M
-
Contents
Waveform
Used for emulation of power on reset: When *RES is connected to G terminal, the circuit is reset as though it were powered up. This is used for software debugging only, Short-circuit of watch dog alarm detection: When CLWD is connected to G terminal, the watch dog alarm detection is disabled. This is used for software debugging only. Clock for MPU of the teach pendant.
r3-1:
I-\ 108.5 nsec
+24 V
+24 VDC voltage +5 VDC voltage
Test p o i n t s +5 L
-5 L
VO See Fig, 22.4.2
Symbol
-
-
Contents Voltage supplied t o t h e LCD module
f o r l o c a t i o n of t e s t p o i n t s ,
22.4.5 Removalfreplacement of teach pendant control PCB
1) Procedure 1 Disconnect t h e cable. 2 Remove t h e back cover by loosening s i x screws @. @ Disconnect t h e c a b l e s from t h e teach pendant c o n t r o l PCB. @ Detach t h e teach pendant c o n t r o l PCB by loosening six screws @ @ Detach t h e LCD c o n t r o l PCB according t o Sec. 22.7.2. @ For mounting t h e new t e a c h pendant c o n t r o l PCB, r e v e r s e t h e above procedure. 2) S e t t i n g S e t t h e new teach pendant c o n t r o l PCB c o r r e c t l y using t h e o r i g i n a l PCB as a reference, 3) Adjustment Adjust t h e teach pendant c o n t r o l PCB c o r r e c t l y a f t e r replacement. 4) Cautions Check t h e ROM No. and e d i t i o n number between t h e o l d and t h e new PCBs.
8
.
Waveform +4.85
-
-4.85
- -5.15
+3.4 VDC
+5.15
VDC (Equals $5 V)
VDC
't
22.5 Keyboard PCB (A20B-1002-0970) 22.5.1 ConneaorJsignal identification
Connector to the teach pendant control PCB CN3 '\ (mounted on the back side)
Top view
*KEY00
- 07:
*KCOM0
-
*LED1 +5 V
22.52 Removal/repiacement of keyboard PCB
1) Procedure @ Remove t h e cover and t h e t e a c h pendant c o n t r o l PCB according t o Sec. 22.4.5. 2 Remove t h e screws and s p a c e r s @. 3 Detach t h e keyboard PCB by loosening two screws @. @ For mounting a new PCB, r e v e r s e t h e above procedure.
8
-
Output s i g n a l of keyswitch s t a t u s t o t h e t e a c h pendant c o n t r o l PCB 5 : Common of t h e keyswitch from t h e teach pendant c o n t r o l PCB 7 : Drive s i g n a l of LED d i s p l a y : Common of LEDs
22.6 LCD Module (A61L-0001-0109) 22.6..1 Connectorfsignal identification
/
2
CNl D l , D2 CLl, -2
FLM
]
Rear view
: z r o l signals t o drive
M
VDD (4-5 V) ) VSS(o
VEE(-5 V)
}
: Power source t o d r i v e LCD
, Power *
2 2 6 2 Removal/replacement of LCD module 1) Procedure @ Remove t h e cover and t h e teach pendant c o n t r o l PCB according t o Sec. 22.4.5. 2 Disconnect c a b l e @, 3 Detach t h e LCD module by loosening four screws @ @ For mounting a new module, r e v e r s e the above procedure,
8
.
source t o d r i v e t h e LCD back l i g h t
22.7
LCD Control PCB (A611-0001-0700 $CB1053RP)
22.7.1 Connector/signal identification
,--------- -----.-L
---..,---.-----
--J
Top view
CN2 7
CNI
Dl, D2
1
CLl, CL 2 FLM M vDD(+5 V) 1 VSS'O V ) VEE(-5 V) (
Control s i g n a l s t o d r i v e :LCD
: Power s o u r c e t o d r i v e LCD
v s s ( 0 V) : 0 v VDD(I-5 V) : 4-5 VDC power supply V0(+3,4 V): Power s o u r c e t o d r i v e LCD RS : R e s i s t o r select t o LCD conzroller R W : Readlwrite c o n t r o l t o LCD controller E : Read e n a b l e t o LCD controller DBO 7 : Data bus to/from LCD controller *CS : Chip select t o LCD controller *RES : Reset s i g n a l t o LCD controller VEE(-5 V) : Power s o u r c e t o d r i v e LCD
-
22.7.2 Removal/replacement of LCD control PCB
I ) Procedure @ Remove t h e cover and t h e t e a c h pendant c o n t r o l PCB according t o Sec. 22.4.5. 2 Disconnect t h e cable @. 3 Detach t h e LCD c o n t r o l PCB by loosening f o u r screws @, @ For. mounting a new PCB, r e v e r s e t h e above procedure.
8
23. POWER INPUT U N I T Described i n t h i s s e c t i o n are: The theory of o p e r a t i o n of AC power c o n t r o l The block diagram of AC power c o n t r o l The power input u n i t excluding PCB The power input u n i t PCB
(23.1) (23- 2) (23.3) (23.4)
23.1 Theory of Operation AC power i s supplied t o t h e c o n t r o l l e r by t h e power input u n i t . The power i n p u t u n i t b r i n g s i.n t h r e e phase power from t h e main supply through t h e c i r c u i t breaker o r t h e disconnect s w i t c h w i t h f u s e s and d i s t r i b u t e s t h e power t o t h e servo transformer and t h e power i n p u t u n i t PCB, The power input u n i t c o n s i s t s of t h e l i n e c o n t a c t o r (LC3), f u s e s F7 F9, and t h e power i n p u t u n i t PCB. When t h e c o n t r o l l e r i s equipped w i t h a c i r c u i t breaker, t h r e e phase AC i n p u t s are connected t o t h e c i r c u i t breaker. Their o u t p u t s are connected t o t h e s e r v o transformer through t h e l i n e c o n t a c t o r (LC3) and f u s e s F7 F9. LC3 is energized from t h e power i n p u t u n i t PCB (A16B-1311-0530) s t a r t up c i r c u i t r y , This suppl.ies t h r e e phase power t o t h e servo transformer. The servo t r a n s f o r m e r o u t p u t s 200 VAC f o r s e r v o d r i v e power. The power i n p u t u n i t PCB a l s o s u p p l i e s 200 VAC t o t h e c o n t r o l transformer (TF3), which s u p p l i e s 100 VAC back t o t h e power input u n i t PCB, When t h e c o n t r o l l e r is equipped w i t h a power disconnect switch i n s t e a d of a c i r c u i t breaker, f u s e s FLl FL3 are mounted on t h e power i n p u t u n i t . Three phase AC i n p u t s are connected t o t h e power disconnect switch, and i t s outputs a r e connected t o t h e s e r v o t r a n s f o r m e r through t h e f u s e s FLl FL3, t h e l i n e c o n t a c t o r (LC3), and f u s e s F7 F9. The remaining c i r c u i t r y is as described above, The power i n p u t u n i t PCB r e c e i v e s 200 VAC from t h e i n p u t transformer (TF4). Primary power f o r TF4 comes from t h e c i r c u i t b r e a k e r o r power disconnect switch through f u s e F1. The power i n p u t u n i t PCB c o n t r o l s t h e start up sequence. Once t h e s t a r t up sequence h a s been completed, t h e power i n p u t u n i t PCB c o n t r o l s 100 VAC f o r t h e o v e r t r a v e l and emergency s t o p c i r c u i t r y , t h e brake c i r c u i t s , t h e o p t i o n a l hour meter and t h e magnetic c o n t a c t o r c o n t r o l (MCC) on t h e servo amplifier, The power i n p u t u n i t PCB a l s o c o n t r o l s t h e 200 VAC t h a t s u p p l i e s power t o t h e fan, t h e DC power s u p p l y u n i t , and t h e c o n t r o l transformer (TF3). Eight LEDs (PIL, ALM, BK1, BK2, BK3, S,ON, FALM and FALM2) are on t h e power i n p u t u n i t PCB. PIL i n d i c a t e s t h a t power i s supplied. ALM i n d i c a t e s t h a t an alarm s i g n a l has been received. BK1, BK2, and BK3 i n d i c a t e brake ON/OFF s t a t u s . S.ON i n d i c a t e s 100 VAC ONIOFF s t a t u s t o t h e servos. FALM and FALM2 i n d i c a t e a f u s e blown alarm.
-
-
-
-
-
23.2 Block Diagram
Control tranfbrrner
Power supply unit
Fig. 23.2 (a)
Block diagram of power input unit (Circuit breaker)
fwoucrrnpur untt
Disc-onncctsu rrsh
Scrvo trans
TFl
Input trans TF4
-
To sc.r\o amplilicr
I
Power supply unit 0 1 3 ALC1AL.D
Power supply unit
ALAlALB Extaaai
ONIOFF ONLW -
0
E-STOP EMGINll2lCOM FNllFN2 'ROT. HBIIl), PPABN
BRKE BKR RLUD
I
I
A14B-00763324.B325
Fig. 23.2 (b) Block diagram of pwoer input unit (Disconnect switch)
23.3 Power Input Unit There are four types of power input units, The one used is based on the AC input voltage, and the power disconnection device,
Specification t
AC input voltage
220/240 VAC
Power disconnect device
380/415/460/480 500/550/575 VAC
Circuit breaker including leak detector
A14B-0076-B323
A14B-0076-B322
Disconnect switch
A14B-0076-B325
A14B-0076-B324
Differences in internal configurations among these power input units are shown in the block diagrams Fig, 23-2 (a) and (b), Differences due to the AC input voltage selection are the wire color of AC lines and the capacity of the fuses, The location of the components is shown in Fig. 23-3 (a). Main-components are: : Power input unit PCB PCB : Line contactor LC3 F7 9 : Fuses for servo transformer FLl 3: Fuses for AC input power TF3 : Control transformer
-
. From
disconnect switch From circuit breaker and to input transformer
To servo transformer
Fig. 23.3 (a) Location of power input unit components
To input transformer
To scrvo transformer
Power input unit A14B Q076-B3?2.B323
F7
LC3
1
+
input
T o suvo transformer
- I- I
200 575 VAC -
F9
I 1
I To fan unit
from control tramformer
(100VAO
-t
LZgg gu.a
ggg asg
CI
I
.-
C
N
a.3
zO zo so so szoo
5 %
z2
P o w a input unit PCB
A16&~13104530 A
k
Fig. 23.3 (b) Power input unit circuitry (Circuit breaker)
Power input unit
A14B-007-324.
B32S
-
200 575 VAC input
. T o fan unit
--1
I
Power input unit PCB
A16tL~l3104530
Fig.. 23.3 (c) Power input unit circuitry (Disconnect switch)
From control transformer
23..3..1 fuses
The fuse specifications are shown below. Power input unit specification A14B-0076- Cr]
B325
B323 AC input voltage
F7-9 Fuse
-
220/240 VAC
B322
nUIZ] B 324
380/415/460/480/500/ 550/575 VAC
A60L-0001-0042 A60L-0001-0042 A60L-0001-0042 IfJG1-30 #JGl-15 fJG1-30
A60L-0001-0042 fJG1-15
A60L-0001-0042 #JG2-50
A60L-0001-0042 fJG1-30
FL1-3
Refer to Fig. 23.3 (a) for location of fuses, 23.3.2 Removaiheplacement
1) Power input unit a) Procedure Disconnect all cables from the power input unit PCB. Disconnect all cables @ from the power input unit. The power input unit can be removed by loosening four screws @. For mounting new power input unit, reverse the above procedure.
Front view of power input unit
2 ) Line contactor (LC3)
a) Procedure Disconnect all cables @ from the line contactor. The line contactor can be removed by loosening two screws @. For mounting new line contactor, reverse the above procedure.
Line contactor
Front view of the power input unit 23.4 Power Input Unit PCB (A16B-1310-0530) 23.4.7
Connector/signal identification
Fig..23.4.7
Location of terminals and connectors on the power input unit PCB
EMGIN1
/
i 1 I 1
EMGOUT1 EWGOUTC EMGOUT2 OP1 OP2 EMGIN 1 ENGINC ENGIN2 lOOOUTl 1000~~2 BW1 BICM1 BW2 BICMZ BKP3 BI(M3 ON
EMGIN2 Emergency stop control outputs for external EMGOUT2
BPM2 BKM3
: 2nd brake control output : 3rd brake control output
BKP is a positive side output, and B:M is a negative side output. Input of the emergency stop on the OP2 operator's panel Input of the gate switch of the protective
FN2 ON
Connection terninals for external ON/OFF : control switches (Note)
COM FN2
: equipment : 1st brake control output
OFF FN1
Emergency stop control inputs from external
100 OUT2 : 100 VDC power output (for servo amp.) looOm']
Note) Refer to Sec, 23.4.2 for the connection information. The relationship between the signals is as fo3 Lows. 100 VAC output for t h e s e r v o
100 VAC output for t h e motor
amplifiers
brake
Normal (Note) (Robot can be operated)
100 VAC
EWGINI-EMGINC (open)
OFF
ON
Contact betveen
Contact between =GOUT2
100 VAC ON
Closed
OFf I
EWGIBC-EMGIN2 (open)
OFF
OFF
Closed
OFF
OFF
open
ON
OFF
Closed
emergency s t o p
f "ROT" o r "MG" I of TP.. E-STOP b u t t o n is pressed
-
E-STOP b u t t o n is released but RESET h a s not been pressed
P
-
h'ote) Xormal status means that "EMGINlt' and ' EMGINC" are shorted, "EMGINC" and "EIGFN2" are shorted, and any other el lergency srop conditions have not occurred.
PFLl ;FJ ALC
: Power ON/OFF l e a d i n g s i g n a l
These c o n t a c t s i g n a l s a r e output t o t h e power supply u n i t b e f o r e power i s normally turned on o r normally turned o f f by t h e ON/OFF b u t t o n provided on t h e o p e r a t o r ' s panel or an e x t e r n a l ON/OFF button. As shown i n t h e diagram, PFL/PF a r e connected p r i o r t o t h e AC i n p u t u n i t coming on a f t e r t h e ON b u t t o n has been pressed, PF/PFH are connected a t l e a s t 150 m s a f t e r t h e OFF b u t t o n is pressed. Loss of t h e P??L s i g n a l i n d i c a t e s t o t h e power supply u n i t t h a t power is going o f f , Power s ~ p p l yunit
Power input unit
-
OFF button
ON button
"",OFF IMmg signal
RY 1 relay operation
\
AC input ON
ALD
: Alarm s i g n a l d e t e c t e d by t h e power supply u n i t
This c o n t a c t s i g n a l is given from t h e power supply u n i t when t h e EN s i g n a l o f t h e power supply u n i t goes low, The EN s i g n a l goes low when t h e DC output v o l t a g e s , being monitored by a v o l t a g e monitoring c i r c u i t on t h e power supply u n i t , f a l l o u t s i d e of t h e s p e c i f i e d range, When t h i s s i g n a l i s g i v e n , t h e AL r e l a y i n t h e power i n p u t u n i t e n e r g i z e s and l a t c h e s i n t o t u r n o f f t h e AC i n p u t power. Power supply unit ry12
4Aq: power input unit
ALD 0
Open normally Closed when an alarm occurs
The alarm LED l i g h t s , The power o f f burton must be pressed t o r e l e a s e t h e l a t c h e d AL r e l a y i n o r d e r t o recover from t h i s alarm.
200A} 200B GND
: 200 VAC power source f o r t h e power suppl,y u n i t : 0 V (ground)
CP3 and CP4: These connectors a r e not used.
+24 E: +24 V (External u s e from power supply u n i t ) 0 V: Ground +24 V: +24 V from power supply u n i t
+24 F: +24 V ( v i a f u s e F10) 0 V: Ground
CNl OTREL *ROT RLWD
: Overtravel release s i g n a l from t h e o p e r a t o r ' s p a n e l through t h e robot c o n t r o l module : Robot o v e r t r a v e l s i g n a l from t h e mechanical u n i t through t h e robot c o n t r o l module : Relay welding s i g n a l t o t h e robot c o n t r o l module : Fuse alarm of t h e brake control c i r c u i t : Emergency s t o p s i g n a l of t h e t e a c h pendant : +24 VDC t o t h e r o b o t c o n t r o l module Contact s i g n a l of t h e 1st brake r e l e a s e Contact s i g n a i of t h e 2nd brake release Contact s i g n a l of t h e 3rd * brake r e l e a s e Contact s i g n a l of t h e hand breakage d e t e c t i o n : Brake r e l e a s e enable
.
+24 F : +24 V to CNPI on shared RAE1 board
CN2 is connected to CNPI on the shared RAM board.
OTREL: Overtravel release signal from the operator panel through CNPI on the shared RAM board TP1 : Status signal of EMERGENCY STOP button and DEADMAN switch on the teach pendant TP2 : Status signal of EMERGENCY STOP button and DISABLE/ENABLE switch on the teach pendant
1
.
ON2 Connection with ON/OFT switch OFF1 ' provided on'the operator's panel OFF2 ON1 0 V : Ground CONNECTION TERMINALS 200B
1"
: 200 VAC power output to the control transformer
Control signal output of the line contactor (LC3) for the servo transformer
LCS
-
*}FNS
: 200 VAC power output for fan units
200s
: 200 VAC power input for the power input unit PCB
loOIN1\ : 100 VAC power (output of control transformer) 100IN2
1000mi} : 100 VAC power output (same as TPI, 9 and 10) 1000UT2 ALB DIL2 -i-24 F
0V
: Connecti.on terminals for an external alarm
Connection terminals of the door interlock switch When these are not used, these should beshorted. : +24 V fuse line : Ground : These terminals are not used.
23..4.2 Jumper/shorting strip settings
When t h e t e r m i n a l s "EMGINL", "EMGINC", and "EMGIN2" on TP1 are n o t used, t h e t e r m i n a l s should be shorted, The s e t t i n g method is as follows. When t h e t e r m i n a l s "EMGIN1" and . "EMGINC" are used, remove t h e s h o r t i n g s t r i p @ , And when "EMGINC" and "EMGIN2" are used, remove @
.
'*OFFw and "COM" of t e r m i n a l TP1 should b e shorted when t h e e x t e r n a l ONIOFF c o n t r o l i s n o t used. When t h e e x t e r n a l ON/OFF c o n t r o l i s used, t h e connection is shown below.
External emergency stop or limit switches
BKMI BKP2
BKM 2
"FNI" and "FN2" of t e r m i n a l TP1 should be shorted when t h e g a t e switch of t h e p r o t e c t i v e fence i s n o t used, When t h e g a t e switch of t h e p r o t e c t i v e fence i s not used, t h e connection i s shown below.
BKP3 BKM3 ON OFF COM I 31 FN2 ON/OFF switch externally furnished for ONOFF control
Remove this shorting strip when the external power supply ON/OFF switch is uscd .
r LED
Meaning
Status
S-ON (amber )
Servo on
100 VAC i s supplied t o t h e servo a m p l i f i e r , when t h i s LED l i g h t s .
BKl (amber)
1st brake is released
When t h i s LED l i g h t s , t h e brakes of t h e W and U axes are re1 eased.
BK2 (amber)
2nd brake is released
When t h i s LED l i g h t s , t h e brake of t h e 8 a x i s i s r e l e a s e d .
BK3 (abmer)
3rd brake is When t h i s LED l i g h t s , t h e brakes of t h e a, 8 , and y a x e s released a r e released.
FALM (red)
Fuse alarm of t h e brake circuit
PIL (amber)
P i l o t lamp
PIL l i g h t s while t h e power i s supplied t o t h e t e r m i n a l TPl "200R" and "200S" i f F3 i s n o t blown,
ALM
A l a r m lamp
ALM l i g h t s when t h e power
- F6
i n p u t u n i t PCB r e c e i v e s an alarm s i g n a l from t h e power u n i t . (Note)
(red)
FALM2 (red)
I f one of t h r e e f u s e s F4
i s blown, t h i s LED l i g h t s .
Fuse alarm of t h e 4-24 F SUPPLY
I f f u s e F10 i s blown, t h i s LED lights,
Note) When ALM l i g h t s , t h e l i n e c o n t a c t o r s LC1, LC2 and LC3 t u r n o f f , LC1 and LC2 a r e i n s t a l l e d on t h e power input u n i t PCB, and LC3 i s o n , . t h e power input unit. The c o n t r o l l e r power cannot be turned on under t h i s c o n d i t i o n , t o r e s e t t h i s c o n d i t i o n , t h e power supply must be turned o f f , o r t h e POWER OFF b u t t o n ( e i t h e r t h e c o n t r o l l . e r POWER OFF button o r e x t e r n a l POWER OFF button) must be pressed. Caution) Even when t h e c o n t r o l l e r power has been turned o f f , power is s t i l l a p p l i e d r o t h e i n p u ~u n i t and t h e amber PIL LED w i l l be l i t . Before touching any p a r t of t h e i n p u t uni.t be s u r e t h a t t h e PIL i s o f f and t h e c i r c u i t breaker/disconnect switch i s o f f .
TP1 Remove this shorting strip (M3 terminals) when the gate switch of the protective fence is used..u
Gate switch of the protective fence.
ALA and ALB terminals should be left open when an external alarm is not used. When an external alarm is used, the connection is as follows.
Alarm switch
Faston terminal
"DIL1" and "DIL2" terminals are not used in the power input unit PCB. these terminals are open, the controller cannot be turned on.
When
23-43 LEDs
Eight LEDs (S-ON, BK1, BK2, BK3, FA&, power input unit PCB.
PIL, ALM and FBLM2) are provided with the
Fuses Seven f u s e s a r e i n s t a l l e d i n t h e power input u n i t PCB. F1, F2 Input f u s e s of 200 VAC l i n e F3 Input f u s e of t h e c o n t r o l c i r c u i t F4, F5, F6 Fuses of t h e brake c o n t r o l l i n e F10 Input f u s e of 24 VDC l i n e Each f u s e s p e c i f i c a t i o n i s as follows. 23.4.4
.,... ,.... ..... ..,..
Specification
Fuse number
F1, F2
A60L-0001-0101#P4100H
F3
~60L-0001-0172#DMO3
F4, F5, F6
A60L-0001-004662.0
F10
A60L-0001-0046#5,0
.
d
-
I f one <;f t h e t h r e e f u s e s F4 F6 is blown t h e FALM LED l i g h t s . I f F10 is blown t h e FALM.2 LED l i g h t s , The blown f u s e shows a white f a i l u r e d i s p l a y i n t h e i n d i c a t o r shown below,
0
Indicator
D ~3 l3El
m
u
FlO
I Fig. 23.4.4
TPl
I
Location of fuses on power input unit PCB
23..4.5 Test points
Test points
Contents
Symbol
C
-
B
-
E
-
0 V
-
Waveform (voltage)
Output of the diode bridge t o convert AC t o DC v o l t a g e
about 25 VDC
Cathode of t h e Zener diode (ZDl)
about 22 VDC
DC power v o l t a g e of the input u n i t PCB circuit
21 t o 22 VDC
0 V reference f o r output o f bridge
0 V
i
Fig. 23.4.5
Location of test points on power input unit PCB
23.4.6
Removal/replacement
1) Power i n p u t u n i t PCB a) Procedure
Disconnect c a b l e s from t h e power input u n i t PCB. Detach t h e PCB by loosening t h e f i v e screws @, For mounting t h e PCB, r e v e r s e t h e above procedure.
Fig. 23.4.6 (a) Left tide view of power input unit PCB
2) Component (relay)
/+;b
Relay removal diction
Relay removal direction
Spring removal direction
m y
mn; Securing
Securing spring Relayq c3Spring removd direction Socket
Socket Fig. 23.4.6 (b) Relays LCI, LC2, RL1,
Fig. 23.4.6 (c) Relay R S l
R L2, RL7, RL8, RS2
Remove t h e s p r i n g t h a t clamps the r e l a y t o i t s s o c k e t by p u l l i n g i t i n t h e shown above. Then remove t h e r e l a y by d i r e c t i o n i n d i c a t e d by t h e arrow ( 0 ) ) shown above. pulling it i n the direction (
24. TRANSFORMERS Four transformers (servo, input, control, and user) are installed in the controller, Servo transformer : Provides power for servo amplifiers Input transformer : Provides 200 VAC for power supply unit, fan units, control. transformer and power input unit. Control transformer: Provides 100 VAC for servo amplifiers and motor brakes. The control transformer for the S-420A also provides 18 VAC for the servo amplifiers, User transformer : Provides 115 VAC for user (option). Specifications of transformers are as follows. S-420F
S-420A
Servo transformer TFI
A80L-0026-0001
A80L-0001-0517
Input transformer TF4
A80L-0012-0010
A80L-0012-0010
Control transformer TF3
A80L-0001-0017
A80L-0001-0498
User transformer TF5
A80L-0001-0520
A80L-0001-0520
24.1 Fuses 1) Servo transformer TF1 F1 F3: Fuses for 200 VAC output. (30 A)
-
A60L-0001-00428JGl-30
Front view
2) Input transformer TF4 F1: Input fuse
A60L-0001-0193#FH-32F
3) Control gransfomer TF3 F1, F2: Input fuses of control transformer TF3 A60L-0001-0101#P450H F3, F2: Output fuses of control transformer TF3 A60L-0001-0101#P450H FLA F6A, F1B F6B : Output fuses of control transformer TF3 A60L-0001-010l#P420H
-
-
4) User transformer F1: Input fuse of user transformer TF5 A60L-0001-0042BJG1- 10 F2: Output fuse of user transformer TF5 A60L-0001-0042/\JG1-20
115 VAC. 9..6A
24.2 Settings 1) Servo transformer TF1 Connect the jumpers as follows. Power supply voltage
I
220 240 380 4 15 440 460 480 500 550 575
Connection of primary tap Connecting style U
V
W
7 6 7
15 14 15
23 22 23
6
14
22
5 4 3 2
13 12 11 10 9
21 20 19 18 17
1
Jumper 8-15 8-14
8-16
1
1
16-23 16-22
1 1
24-7 24-6
16-24
Delta A
Star
2) Input transformer TF4 Select the correct tap so that the power supply voltage is within +.lo% to -15% of the tap voltage. 3) User transformer Select the correct tap so that the power supply voltage is within + l o % to -15% of the tap vol.tage.
25.
HOUR METER
25.1 Connector/Signal identification
LJ-
, ,e*
Terminals: 100 VAC input terminals for hour meter
(Rear view of the hour meter)
25.2 Removal/Replacernent 1) Procedure Di.sconnect cables @ from the hour meter. The hour meter can be removed by loosening two nuts @. mounting new hour meter, reverse the above procedure.
or
(Rear side of the operator's panel)
26. SERVO AMPLIFIER For each of W, U, 8, a, 8 , and y axes, a one-axis type servo amplifier is used. Note that the amplifi.ex-sused in the floor-mount S-420 are different from those in the wall-mount S-420. The difference is the AC input voltage of the servo amplifier, which is 200 VAC for the floor mount S-420 and 185 VAC for the wall mount S-420. These two types of amplifiers are incompatible with each other. 26.1 One-axisServo Amplifier for S-420F The part numbers of the amplifiers used in the S-420F robot controller are as follows. The numbers in parentheses show motor types,
W axis (20F) U axis (20F)
A06B-6058-ROO6 A06B-6058-H006 A06B-6058-H006/J016 A06B-6058-I3005 A06B-6058-8005 A06B-6058-H005
8 axis (20)
a axis (10) 6 axis (10) y axis (10)
The relationship between the axis hardware and software numbers, axis names, and the connectors of the axis control PCB, robot mechanical unit, and servo amplifiers is shown in Table 26.1. Table 26.1 Axis hardware No.
Axis Axis Connector Axis Servo Servo Servo softFeedback control control on amp. amp. Axis ware connector connector board robot board No. connector No.
1
2
W
2
3
U
CF91 CF92
P1
1
CV21
1
CNl
CV22
2
CNI
1
3
1
8
CF93
CV23
3
CN1
4
6
a
CF94
CV24
4
CN 1
5
5
B
CV21
5
CN 1
CV22
6
CN 1
CF91 2
6 26.7.1
4
Y
P2 2
CF92
Theory of operation
The servo amplifier drives an AC servo motor. It consists of two parts, the power amplifier (unit base) and the servo amplifier PCB. The power amplifier employs three-phase power supply for the main circuit and single phase 100 VAC for the braking contact. An input voltage of three-phase power is rectified and filtered by the diode bridge and the capacitor for the DC voltage power supply. The DC voltage is converted to three-phase current by the three-phase transistor bridge which is driven by the pulse width modulation (PWM) signals from the servo amplifier PCB through CN3 and CN4, The current of the motor is detected by the current detecting resistors and transmitted to the servo amplifier PCB through CN3, Then it is sent to the axis control board via CN1. The regenerative discharge circuit is in the power amplifier to absorb =he energy from the motor,
x l e servo a m p l i f i e r PCB a l s o has the alarm c i r c u i t f o r the p r o t e c t i o n of t h e s e r v o c o n t r o l system. The LEDs on the servo amp1i.fi e r PCB i n d i c a t e the alarm c o n d i t i o n wher. the alarm c i r c u i t operates. 26.7 2 Block diagram
I 200 VAC
3@ a V A C
I:
T o axis
Servo ampW1er PCB A20B-1003-0090
contro1 board
To servo transformer overheat sensor,
-
z V
L
2
0
/
Receiver
-
*
1
-
-+
Driver
I"
To power circuit
r
Alarm detect I
+SV,+24V +ISV. -1SV
i-tJ
Power supply
0
I
1
A
Block diagram of the servo a m p l i f i e r PCB
26.1 -3 Connectorlsignal identification
0
0
1T.1 r
A2051 003-0090
D
Ir.l
a41
I -
1
TI
n
n
R, S, T : 200 VAC three phase IOOA, 100B: 100 VAC single phase U, V, W : Three phase output for motor 6 : Ground terminal
pi
LCG HCA
: Collector of transistor Q1 : DC main power supply
HCA
TOH1, TOH2: Transformer overheat input
IR, GDR IS, GDS *MCON
*DRDY GND *PWMA(*ALM~),COMA *PWMB (*ALM2) ,COMB *PWMC (*ALm),COMC *PWMD (*ALM8) ,COMD *PWME, COME *PWMF, COMF
: Phase-R current : Phase-S current : MCC control : Servo ready : Ground : PWM signals and
their commons
*PWMA, *PWMB, *PmfC and *PWMD are bidirectional. When an alarm is signalled to the axis control board, these lines become outputs and they are referred to as *ALMl, *ALM2, *ALM4 and *ALP18, respectively.
DB : Base signal for transistor D FB : Base signal for transistor F VL : Emitter signal for transistor B, D, F, G THl, TH2 : Overheat of heatsink RLY : Precharge control relay : 20 VDC for precharge control relay 20V ITLK : Interlock of contactor LOOA, 100B: 100 VAC MCC : Magnetic contactor control CDIJ1, CDU2: Current detect of U phase CDV1, CDV2: Current detect of V phase
: Collector signal for transistor G : Base signal for transistor G
VDS, PDT: 200 VAC for DC power supply : Frame ground : Current detect of DC link : Positive voltage of DC link Base signal for transistor A : Emitter signal for transistor A . : Base signal for transistor C : Emitter signal for transistor C : Base signal for transistor E : Emitter signal for transistor E : Base signal for transistor B ':
LEI)
HV (R)
Conditions
Function
High voltage The DC voltage of the main power supply is higher than 450 V. alarm a. AC power supply is higher than the specified range, b, The regenerative energy discharge circuit becomes defective, which includes the PCB, the transistor Ql, and discharge resistor or the separately mounted discharge unit. c. Servo motor or the power cable for motor insulation is defective, d. Load inertia is excessive. -
HC (R)
High current The DC current through the main DC power supply is too high. alarm a, Transistor module is defective. b. Short-circuit failure in the motor or the cable, c, PCB is defective,
LV
Low voltage alarm
Regulated power supply +1S V or +5 V on PCB is abnormally low. a, AC input power supply is lower than specified. b, PCB is defective, . .
Discharge circuit alarm
On time of the discharge transistor Q1 is too long (over several seconds) or its capacity to discharge is overloaded, a, Transistor Q1 or PCB is defective. b, ~ccelerationfdecelerationfrequency is too high. c, The setting of jumper S2 is improper. Refer to 26-1.6 for proper settings.
(R)
DC (R)
A thermostat in the controller has operated. a. The thermostat at the heat-sink on servo amplifier. b. The thermostat in the servo transformer, c, The thermostat in the regenerative discharge unit, MCC turns on and motor is energized.
5 volts present
Alttl
IWj-$090
f 8% 0 +5V
(GREEN)
a 1
El
Location of LEDs on A20B-1003-0090
26.1.5 Test points
CH7
IR
R--phase c u r r e n t (Note)
CH8
IS
S,-phase c u r r e n t (Note)
0 V (Ground) 4-5 VDC
--Note)
Conversion factor (Ampsjvolt):
[ a 1
1
El
1
Location of test p o i n t s on A20B-1003-0090
26..1..6 Jumper settings
I I Servo Anp. Jumpers S1
1
2
L
L
1
I
f
Meaning
3
4
5
6
H
H
H
H
TOH s e t t i n g Idhen t h e overheat s i g n a l i s n o t p r o v i d e d t o T4, t h e Sf s e t t i n g s h o u l d be H s i d e .
L
DC alarm s e t t i n g When t h e d i s c h a r g e u n i t i s n o t added, t h e S2 s e t t i n g should b e L s i d e .
-
S2 I -
--H
H
H
L
L
--
'
L o c a t i o n of jumper s e t t i n g s
1) Unit a) Remove the cables connected to the connector CN1 and termina1.s T1, 1'2 and
T4. Unclamp connectors are follows: CN 1 Squeeze the clamp release to remove the connector.
a
b) Loosen two mounting screws at the bottom. c) Remove two mounting screws at the top and remove the unit.
Clamp @ release
Mounting screws, top
Mounting screws, bottom
2) Component a) PCB I Release six PCB holders. 2 Pull. up PCB from connectors CN3, C N 4 .
Push to release
8
PCB holder
26.2 One-axis Servo Amplifier for S-420A The p a r t numbers of t h e a m p l i f i e r s used i n t h e S-420A follows. The numbers i n parentheses show motor types.
robot c o n t r o l l e r a r e a s
A06B-6057-H006 A06B-6057-H007 A06B-605 7-H007 A06B-605 7-H005 A06B-6057-HOOS A06B-6057-H005
W a x i s (20F)
U a x i s (30F) 9 a x i s (30) a a x i s (10) 13 a x i s (10) y a x i s (10)
The r e l a t i o n s h i p between t h e a x i s hardware and software numbers, a x i s names, and t h e connectors of t h e a x i s c o n t r o l PCB, r o b o t mechanical u n i t , and s e r v o a m p l i f i e r s i s shown i n Table 26.2. Table 26.1 Axis hardware No.
Axis Connector Axis Servo Servo softFeedback Servo Axis control on control amp. amp. ware connector connect o r robot board board connector No. No.
1
2
W
2
3
U
CF91 CF92
P1
1
CV21
1
CNI
CV22
2
CN 1
1
3
1
8
CF93
CV23
3
CN1
4
6
a
CF94
CV24
4
CNl
CV21
5
CN 1
CV22
6
CN 1
P2 2
26.21 Theory of operation
The servo a m p l i f i e r d r i v e s an AC servo motor. It c o n s i s t s of two p a r t s , t h e power a m p l i f i e r ( u n i t base) and t h e servo a m p l i f i e r PCB. The power a m p l i f i e r employs three-phase power supply f o r t h e main c i r c u i t and A n i n p u t v o l t a g e of three-phase s i n g l e phase 100 VAC f o r t h e braking contact. power is r e c t i f i e d and f i l t e r e d by t h e diode b r i d g e and t h e c a p a c i t o r f o r t h e DC v o l t a g e power supply. The DC v o l t a g e i s converted t o three-phase c u r r e n t by t h e three-phase t r a n s i s t o r bridge which i s d r i v e n by t h e p u l s e k d t h modul.ation (PWM) s i g n a l s from t h e servo a m p l i f i e r PCB through CN3 and CN4. The c u r r e n t of t h e motor i s d e t e c t e d by t h e c u r r e n t d e t e c t i n g r e s i s t o r s and t r a n s m i t t e d t o t h e s e r v o a m p l i f i e r PCB through CN3. Then i t i s s e n t t o t h e a x i s c o n t r o l board v i a CN1. The r e g e n e r a t i v e d i s c h a r g e c i r c u i t i s i n t h e power a m p l i f i e r t o absorb t h e energy from t h e motor. An input voltage of 18 VAC supplied through CN2 i s r e c r i f i e d , f i l t e r e d f o r +24 VDC and r e g u l a t e d f o r l e v e l s of +5 V, +15 V, and -15 V. The v o l t a g e s a r e used i n the PCB, The servo a m p l i f i e r PCB a l s o h a s the alarm c i r c u i t f o r t h e p r o t e c t i o n of t h e s e r v o c o n t r o l system. The LEDs on t h e servo a m p l i f i e r PCB i n d i c a t e t h e alarm c o n d i t i o n when t h e alarm c i r c u i t operates.
26..2..2 Block diagram
1
190 VAC 3@ 1
100vAc 1@ I1
_--Servo amplifier PCB ~16B-12004670
To axis control board
To servo transformer overheat sensor ' TO control transformer I8 VAC
1
I
I L
Receiver
Driver
-
0
To power circuit
2'
~ l a n ndetect
TOHI, TOH2 IS vAc
I
DRDY HV HC
LV
DC
OH
r V
I
Block diagram of the servo amplifier PCB
26..2..3 Connector/signaI identification
T : 190 VAC t h r e e phase 100.4, lOOB: 100 VAC s i n g l e phase U, V, W : Three phase o u t p u t f o r motor I : Ground t e r m i n a l R, S,
Fl
: Collector of t r a n s i s t o r Q1 : DC main power s u p p l y
LCG HCA
HCA
102
1
COMA
109
1
GDR
1 15 1
COMD
I
1
COME
I
1 0 4 1 COMB
1111 GDS 1 1 7
1 0 6 1 COMC
113
07
*DRDY
1
GND
1;: 1
Corn
1
IR, GDR I S , GDS *MCON *DRDY GND *PWMA(*ALMl),COMA *PWMB(*ALM2),COMB *PWMC (*ALM4), COMC *PWMD(*UM8),COMD * P W , COME *PWMF, COMF
: : : : : :
1
Phase-R c u r r e n t Phase-S c u r r e n t MCC c o n t r o l Servo r e a d y Ground PWM s i g n a l s and t h e i r commons *PWMA, *PWMB *PW'C and *PWMD a r e b i d i r e c t i o n a l , When a n alarm is - s i g n a l l e d t o t h e axis c o n t r o l board, t h e s e l i n e s become o u t p u t s and t h e y are r e f e r r e d t o as *ALMI, *ALM2, *AM4 and *ALM8, respectively.
-1
18A
2
CT
3
18B
4
TOHl
5
TOH2
18A
: 18 VAC
CT
:
18B
: 18 VAC
Center Tap
TOHl, ROH2 : Transformer overheat input
6 ---A
LCG : Col.lector signal for discharge circuit : Base signal for discharge circuit LBG : Emitter signal for discharge circuit LEG CDH1 : Current detect of DC link DIC : DC power supply CDVl, CDV2 : Current detect of V phase CDU1, CDU2 : Current detect of U phase '?HI, TH2 : Overheat of heat sink INTLl,INTL2: Interlock of contactor 1OOA : 100 VAC NCC : Contactor control
HCA LBA LEA LBB LEB HCC LBC LEC LBD LED HCE LBE LEE LBF LEF
: Collector signal for transistor : Base signal. for transistor A : Emitter signal for. transistor A : Base signal for transistor B : Emitter signal for transistor B : Collector signal for transistor C : Base signal for transistor C : Emitter signal for transistor C : Base signal for transistor D : Emitter signal for transistor D : Collector signal for transistor E : Base signal for transistor E : Emitter signal for transistor E : Base signal for transistor F :
Emitter signal for transistor F
26..2.4 LEDs
LED HV (R)
HC (R)
Function
Conditions
-
High voltage The DC voltage of the main power supply is higher than alarm 440 V. a. AC power supply is higher than the specified range. b. The regenerative energy discharge circuit becomes defective, which includes the PCB, the transistor QI, and discharge resistor or the separately mounted discharge unit. c. Servo motor or the power cable for motor insulation is defective. d. Load inertia is exces.sive. High current The DC current through the main DC power supply is too alarm high. a, Transistor module is defective, b, Short-circuit failure in the motor or the cable. c, PCB is defective, Low voltage alarm
Regulated power supply +15 V or +5 V on PCB is abnormally low, a. AC input power supply is lower than specified. b. Fuse F1 on PCB for +5 V supply is blown. c. PCB is defect'ive.
(R)
Discharge circuit alarm
On time of the discharge transistor Q1 is too long (over several seconds) or its capacity to discharge is overloaded. a. Transistor Ql or PCB is defective. b. Acceleration/deceleration frequency is too high. c. The setting of jumper S2 is improper, Refer to 26.2.7 for proper settings,
OH (R)
Overheat alarm
Some thermostat in the controller has operated, a. The thermostat at the heat-sink on servo amplifier. b. The thermostat in the servo transformer. c. The thermostat in the regenerative discharge unit,
LV (R)
DC
DRDY Servo amp. ready (G)
MCC turns on and motor is energized,
I Al6B-12004670
Ii
DRDY 0 HV
DC OH CNl
CN2
Location of LEDs on A16B-1200-0670 26.2.5 Fuse
Specification of fuse F1: A60L-0001-0172fDM20
Fig.. 26.2.5
Location of fuse
26..2,6'Test points
Test p o i n t s
Contents
Symbol
CH 1
*PWMA
A-phase PIJM s i g n a l
CH2
*PWMB
B-phase PIJM s i g n a l
CH3
*PkXC
C-phase Plnl s i g n a l
CH4
+WMD
D-phase PWM s i g n a l
CH5
*PWME
--
CH6
*PW
F-phase PWM s i g n a l
Waveform
--
-
--
-
E-phase PWM s i g n a l
.-
CH7
IR
R-phase c u r r e n t (Note)
CH8
IS
S-phase c u r r e n t (Note)
CH9
0 V
0 V (Ground)
CHlO
i-5v
+5mc
--
I
CH11
4-15 V
i-15 VDC
CH12
-15 V
-15 VI)C
CH13
+24 V
4-24 VDC Note)
Conversion f a c t o r (Amps/volt) : A06B-605 7-H005 : 10.0 A06B-6057-H006 : 20.0 AO6B-60.57-H007 : 25.0
Location of t e s t p o i n t s on A20R-1200-0670
26.2..7 Jumper settings
Axis Jumpers
S1
Meaning W
U
B
a
f
3
y
L
H
H
H
H
H
TOH s e t t i n g When t h e overheat s i g n a l i s not provided t o CN2, t h e S1 s e t t i n g should be H s i d e ,
H
H
L
L
L
DC alarm s e t t i n g When t h e discharge u n i t i s n o t added, t h e S2 s e t t i n g should be L s i d e .
I S2
H
J
-
Location of jumpers
1) Unit a) Remove the cables connected to the connectors CN1 and CN2, and terminals T1 and T2. Unclamp connectors are follows: . CN1, CN2 Claxnp @ release @ Squeeze the clamp release to remove the connector,
b) 1,oosen two mounting screws at the bottom. c) Remove two mounting screws at the top and remove the unit.
Mounting screws, top
Mounting saews, bottom
2) Component a) PCB 1 Release six PCB holders. 2 Pull up PCB from connectors CN3, C N 4 .
Push to release
8
PCB holder
26.3 Dynamic Brake Resistor Unit (A05B-2046-C452) 26.3.7 Theory of operation
When t h e EMERGENCY STOP b u t t o n i s p r e s s e d d u r i n g robot motion, t h e MCC b-contact i s closed and t h e dynamic b r a k e works t o s t o p t h e robot motion. The motor energy w i l l b e d i s s i p a t e d by c u r r e n t flow between t h e motor l e a d s v i a t h e MCC b-contact and t h e motor w i l l b e q u i c k l y stopped. When t h i s dynamic b r a k e i s t o o e f f e c t i v e c a u s i n g t o o much mechanical stress, t h e dynamic b r a k e r e s i s t o r (DBR) T h i s u n i t r e d u c e s t h e shock caused by t h e dynamic b r a k e by u n i t i s added. p u t t i n g a r e s i s t o r between t h e l e a d s of t h e motor t o l i m i t t h e c u r r e n t flow. The DBR is connected t o t h e s e r v o a m p l i f i e r s of t h e W, U and 8 axes. 26.3.2 Block diagram
AC servo motor
26.3.3 Connections Dynamic b r a k e r e s i s t o r u n i t
A05B-2046-C452 DBR unit
To servo amp 1 26..3.4 Removai/replacement
8 1 2
Remove w i r i n g s t o t h e component. Remove mounting screws.
27. OPERATOR'S PANEL There a r e two types of o p e r a t o r ' s p a n e l s . - V e r t i c a l type o p e r a t o r ' s p a n e l f o r remote CRT/KB T h i s type i s used i n t h e c o n t r o l l . e r s w i t h o u t a b u i l t - i n CRT/KB u n i t . An RS-232.-C s e r i a l p o r t c o n n e c t o r named CRT/KB is on t h e p a n e l and i s used t o connect t h e remote CRT/KB u n i t . See Fig. 3 . 2 ( e ) . - V e r t i c a l type o p e r a t o r ' s p a n e l f o r b u i l t - i n CRTIKB T h i s t y p e i s used i n t h e c o n t r o l l e r s w i t h a b u i l t - i n CRTIKB u n i t , Since t h e R S - 2 3 2 4 p o r t c a b l e is routed i n s i d e t h e cabinet, t h e connector f o r CRTIKB is not a v a i l a b l e on the panel. See Fig. 3.2 ( e ) .
2'7.1 Connector/Signal ldentif ication I ) Vertical type operator's panel for remote CRT/KB (A05B-2051-.C122)
(Front view)
OIEILmm
UYI
-
wow2
0
0
--
>
- -ti
a-m-c
Connector for remote CRTJKB "
_I
arm
LU
I
Hour meter (option)
\
Connector.for RS-232Cinterfke L-1
(Rear view)
- EMERGENCY STOP button
L-J
0
0
Operator's panel PCB A20B-1003-0040 Connection of thc hour meter
0
0
\
Connection of the
Connector for shared RAM interface
EMERGENCY STOP button
(Note)
-
Note) For customer use, a contact output is available at this terminal. Contacts of EMERGENCY STOP buttons on the operator's panel and the teach pendant are connected in series and appear at this terminal.
2) Verti.ca1 type operator's panel for built-in CRT/KB (A05B-2051-C121) (Front view)
rn
Hour metex (option)
I](!$ EMERGENCY STOP button
0
0
(Rear v i e w )
Operator's panel PCB
A20B-1003-0041 0
Connection o f the hour meter
\ Connection of'the E:MERGENCY STOP button
0
r \
/ /
Connector for built-in CRTIKB interface
Connector for shared RAM interface
Note) For customer use, a contact output is available at this terminal. Contacts of EMERGENCY STOP buttons on the operator's panel and the teach pendant are connected series and appear at this terminal.
CN5 (connector f o r shared RAM i n t e r f a c e ) TPENBL PENBL INCYC NOTCAL ULEDl ULED2 Fault HELD CSTART CALIB UPBl UPB2 FRESET HOLD OTRn
: TEACH PENDANT ENABLED LED
: PANEL ENABLED LED : I N CYCLE LED : NOT CALIBRATED
} ]:", CN3 ( b u i l t - i n CRT/KB i n t e r f a c e )
LED
USER LED # l USER LED 82 FAULT LED HELD LED CYCLE START b u t t o n CALIBRATE b u t t o n USER PB # I USER PB f 2 FAULT RESET b u t t o n HOLD button : OVERTRAVEL RELEASE b u t t o n Contact of t h e POWER ON b u t t o n : (normally open) Contact of t h e POWER OFF b u t t o n : (normally closed) REMOTE : REMOTE switch ESTOP : EMERGENCY STOP switch RDB : Receiving d a t a SDB : Sending d a t a RSB : Request t o send CSB : Clear t o send DR3 : Data s e t ready ERB : Data t e r m i n a l ready The s i x s i g n a l s l i s t e d above a r e f o r t h e RS-232-C i n t e r f a c e RDC : Receiving d a t a : Sending d a t a SDC RSC : Request t o send : Clear t o send CSC DRC : Data s e t ready ERC : Data terminal ready The s i x s i g n a l s l i s t e d above a r e f o r t h e CRT/KB i n t e r f a c e TP3) : Extra emergency s t o p output TP4 +24 VDC powe; connection f o r : RS-2324 i n t e r f a c e +24 VDC power connection f o r o p e r a t o r ' s panel : : : : : : : : : :
i 2}
-
Contact output of emergency stop Contact output of emergency stop buttons
[Op.panel
Teach pendant
-EMG2
Connection of emergency stop Emergency stop contact which is used to interrupt 100 VAC for servo amp's.
Connecti.onof the hour meter 100 VAC which is available when there are no emergency stop conditions.
Connector for RS-232-C interface
,
1 FG 2 SDB 3 RDB 4 RSB 5 CSB 6 I DRB 7 O E 8 9 10 11 12 13,
1 14 1 I 15 I 16 1
1
17 ( 18 / 19 1 20 ERB 121 1 22 23 24 25 +24 R
a~ : Receiving data SDB : Sending data RSB : ~equestto send CSB : Clear to send DRB : Data set ready ERB : Data terminal ready FG : Frame ground +24 R: +24 V power supply for RS-232-C drive OE :OV
Connector for CRT/KB interface 1 FG 2 SDC 3 RDC 4 RSC 5 CSC 6 7
DRC O V
8
,
9 10 11 12 13
--
RDC : Receiving data SDC : Sending data RSC : Request to send CSC : Clear to send DRC : Data set ready ERC : Data terminal ready : Frame ground FG +24 V: +24 V power supply for CRTjKB drive
14 15
16 17 18 19 20 -. ERC 21 22 23 1 24 25 +24 V I
ov : o v 2
27.2 Removaf/Replacement I ) Unit a ) Procedure Disconnect a l l cables from the o p e r a t o r ' s panel. Remove t h e o p e r a t o r ' s panel by loosening s i x screws @. For mounting new u n i t , reverse t h e above procedure,
Vertical. type
2) Component (lamps and switches) a ) Procedure Disconnect t h e soldered wire from lamp o r switch. Remove t h e lamp o r switch by loosening t h e nuts. For mounting new lamp o r switch, r e v e r s e t h e above procedure. 3) Component (EMERGENCY STOP button) a) Procedure Disconnect al.1 cables @ from t h e EMERGENCY STOP button. Remove t h e top of button by loosening a screw @ Remove t h e button by loosening a r i n g For mounting new button, reverse t h e above procedure.
a.
.
28.
B A n E R Y UNIT
28.7 Connector/Signal Identification Basic control u n i t s i d e VR: Battery (+ s i d e ) OV: Battery (- s i d e )
Battery caw
Basic control uait side
28.2 Removaf/Replacement Various data of t h e u s e r program i.s saved i n t h e RAM by back-up b a t t e r i e s , These b a t t e r i e s should be replaced with new ones annually. When t h e voltage of t h e b a t t e r i e s becomes t o o low, CRT d i s p l a y shows "low Battery Alarm." Change them according t o following procedure: 1) Procedure 1 Keep t h e c o n t r o l l e r power on. 2 Open t h e f r o n t door of t h e c o n t r o l l e r . 3 Remove t h e b a t t e r y case cap, 4 Take out old b a t t e r i e s from t h e b a t t e r y case, 5 S e t t h e new b a t t e r i e s i n t o t h e b a t t e r y case. Pay a t t e n t i o n t o t h e d i r e c t i o n of b a t t e r i e s , @ Put t h e case cap on t h e b a t t e r y case.
1
29.
OUTLET UNIT AND GROUND CONNECTED
LAMP
29.11 Lamp A lamp c a l l e d Ground Connected Lamp i s i n s t a l l e d under t h e h a n d l e of
t h e main cabinet. Its l i g h t i n g i n d i c a t e s t h a t t h e one t e r m i n a l (L2) of t h e o u t l e t i s connected t o t h e ground and 115 VAC i s o u t p u t t o t h e secondary s i d e of t h e u s e r When i t i s transformer, When t h i s lamp i s pressed i n halfway, i t goes o u t . p r e s s e d i n a l l t h e way, t h e lamp l i g h t s a g a i n . Its l i g h t i n g i n d i c a t e s t h a t 115 VAC is o u t p u t t o t h e secondary s i d e of u s e r transformer.
29.2 Fuse T h i s f u s e i s provided f o r t h e o u t p u t One f u s e i s i n s t a l l e d i n t h e o u t l e t u n i t . of t h e o u t l e t terminals. Fuse s p e c i f i c a t i o n A60L-0001-0101#PL475L
.....
Locati.on of f u s e on t h e o u t l e t u n i t
29.3 Removal/Replacement 1) Unit (Ground Connected lamp) a ) Procedure 1 Remove t h e r i n g @ from t h e Ground Connected lamp. 2 The Ground Connected lamp can b e removed w i t h attached. 3 Disconnect a l l c a b l e s from t h e lamp. 4 For mounting new lamp, reverse t h e above procedure.
8 8
connection
cables
F r o n t view of t h e lamp 2) Component (lamp) a ) Procedure @ Remove t h e Ground Connected lamp, a c c o r d i n g t o t h e above p r o c e d u r e
Remove t h e cap of t h e lamp. new lamp, r e v e r s e t h e above procedure.
30.
SERVO-ON RELAY UNIT AND SERVO-ON LAMP
30.1 Connector/Signal Identification
0 SVON1
~looAI OOB SVONl
@
@
SVON2
S V O N 2 2 SVONC
100 VAC input f o r servo-on relay unit Relay output t e r m i n a l s : SVONl - SVbNC; Normally open SVONC SVON2; Normally closed
-
-
1 OOA 1OOB
0 >
30.2 Lamp A lamp c a l l e d t h e servo-on lamp is i n s t a l l e d under t h e ground connected lamp of t h e main cabinet. Its l i g h t i n g i n d i c a t e s t h a t 100 VAC is supplied t o the s e r v o amplifiers. When t h i s lamp i s p r e s s e d in halfway, i t goes out. When i t i s pressed i n a l l t h e way, t h e lamp l i g h t s again, Its l i g h t i n g i n d i c a t e s t h a t 100 VAC i s a v a i l a b l e i n t h e c o n t r o l l e r .
Ground c 0 ~ e c t e dlamp
. Servo-on lamp
30.3 Removal/Replacement 1) Unit (servo-on r e l a y u n i t ) a ) Procedure Disconnect a l l c a b l e s @ from t h e servo-on r e l a y u n i t . The servo-on r e l a y u n i t can be removed by loosening two screws For mounting new u n i t , r e v e r s e t h e above procedure.
a.
2 ) Component ( r e l a y ) Remove t h e s p r i n g t h a t clamps t h e r e l a y t o i t s socket by p u l l i n g i t i.n t h e ) shown above. Then remove t h e r e l a y d i r e c t i o n i n d i c a t e d by t h e arrow ( ) shown above. by p u l l i n g it i n t h e d i r e c t i o n ( Relay removal direction
Relay RL8 3) Unit (servo-on lamp) a ) Procedure 1 Remove t h e r i n g @ from t h e servo-on lamp. 2 The servo-on lamp c a n be removed w i t h connection c a b l e s a t t a c h e d . 3 Disconnect a l l c a b l e s from t h e l a p . 4 For.mounting new l,amp, r e v e r s e t h e above procedure,
W
4) Component (lamp ) a ) Procedure Remove t h e servo-on lamp, a c c o r d i n g t o t h e above procedure Remove t h e cap of t h e lamp. For mounting new lamp, r e v e r s e t h e above procedure.
@,
0.
31. FAN UNIT 31.I Operation of the Heat Exchange System
Location of fan units The electrical The controller utilizes an air-to-air heat exchange system. components are isolated from outside air except for the bottom segment of the side cabinet where the servo transformer and discharge units are installed. Air flow direction is shown in Fig. 31.1.
Main cabinet
Side cabinet Fig. 31.1 Air flow
.2 Removal/Repalcement Fan 1 a ) Specification
A05B-2051-C901 (fan u n i t ) A90L-0001-0043 ( f a n motor) b ) Procedure @ Disconnect t h e c a b l e s from t h e fan u n i t , @ Remove t h e u n i t by loosening f o u r screws @ @) Disconnect t h e c a b l e s from t h e f a n motors. @ Remove t h e f a n motor from the p l a t e by loosening f o u r screws @, @ Remove t h e f i n g e r guard from t h e f a n motor by loosening For mounting f o u r screws @ a new f a n motor, r e v e r s e t h e above procedure.
.
.
Fan 2 a ) Specification A05B-2051-C902 (fan u n i t ) A90L-0001-0213fiA (fan motor) b ) Procedure Disconnect t h e c a b l e s from t h e fan u n i t . @ Remove t h e u n i t by loosening f o u r screws @ - For mounting a new f a n u n i t , r e v e r s e t h e above procedure.
a
3) Fan 3 a) Specification A05B-2051-C905 (fan unit) A90L-0001-0043 (fan motor) b) Procedure @ Disconnect the cables from the fan unit. @ Remove the unit by loosening four screws @ @ Disconnect the cable from the fan motor, @ Remove the fan motor from the plate by loosening four screws @. @ Remove the finger guard from the fan motor by loosening four screws @ For mounting a new fan motor, reverse the above procedure.
.
.
4) Fan 4 a) Specification A05B-2051-C903 (fan unit) A90L-0001-0213/iA (fan motor) b) Procedure @ Disconnect the cables from the fan unit, @ Remove the unit by loosening four screws @ , For mounting a new fan unit, reverse the above procedure, 5 ) Fan 5
a) Specification A05B-2051-C902 (fan unit) A90L-0001-0213#A (fan motor) b) Procedure Same as the Fan 2. 6) Fan 6 a) Specification A05B-2051-C905 (fan unit) A90L-0001-0043 (fan motor) 2) Procedure Same as the Fan 3.
7) Fan 7 a) Specification A05B-2051-C904 (fan unit) A90L-0001-0213tA (fan motor) b) Procedure @ Disconnect the cables from the fan unit. @ Remove the unit by loosening For mounting four screws @ a new fan unit, reverse the above procedure,
.
32. ABSOLUTE PULSE CODER
32.1 Theory of Operation The Absolute Pulse Coder is made up of a rotating mechanism, an LED, a code disk, photo cells, and a signal processing circuit. The code disk contains several slits. As the disk rotates on a shaft the sli.ts in the disk alternately block and permit light to the photo cells. The photo cells receive the interrupted light beams which the signal processing circuit converts to digital electrical signals. The signals are amplified and transformed into a square wave-form of C-MOS level as PA and PB in Hybrid IC 1. Signals PA and PB are applied to the Feedback Pulse Detector and the Output Selector contained in the LSI chip. The Feedback Pulse Detector generates plus and minus pulses according to the rotary direction of the code disk, A 28-bit counter increments the plus pulses and decrements the minus pulses. The REQ Signal Receiver is a level converter to C-MOS level. The absolute pulse coder receives the data request signal, REQ. The Data Converter translates the 32 bits of data, 28 bits of counter data and 4 bi.ts of alarm data into serial data. At the same time, the Output Selector selects signals from the Data Converter, and the serial data is transmitted to the controller through two pairs of phase signals as A, *A, B, and *B. Following the data transmission, the Output Selector selects signals PA and PB and position control operation is available. The Absolute Pulse Coder also has a Power Selector in Hybrid IC 1, When +5 volts is not applied to the pulse coder from the power supply, the power select circuit obtains power from the battery unit,
32.2 Block Diagram
32.3 Connector/Signal identification
\
-
Battery
Standard type S i g n a l (MS3102A 22-14P) A, *A, B y *B : Count s i g n a l Z, * Z : Reference s i g n a l C l , C2, C4, C8: Phase c o n t r o l s i g n a l f o r AC servo motor +SV, OV : Power supply from c o n t r o l l e r OEl, 032 : Over h e a t s i g n a l of servo motor REQ : Data r e q u e s t s i g n a l +6V, OVA : Power supply from b a t t e r y u n i t
B a t t e r y (MS3102A 1 0 ~ ~ - 4 ~ )
I A 1 +6VB 1 B I OVB
I
+6VBy OVB
: Power supply from b a t t e r y u n i t
Signal
I
Wire c o l o r
1 Black I Blue
I Signal1
I Signal I I OV I
I Gray
I *B
I Oranee 1 RE0 Red/White Gra /White Red ( t h i c k ) +6B Gray ( t h i c k ) OVB
Green Purple /White Red
Wire c o l o r
1 *A
+5
I
32.4 Variable Resistors V.R.
Standard s e t t i n g
VRl
-
-
(A) VR2
-
(B) VR3
-
( 21
Remarks Adjustment of t h e duty of A or *A (Pulse coder o u t p u t s ) Duty = 50:50 Adjustment of t h e duty of B o r *B (Pulse coder o u t p u t s ) Duty = 50:50 Adjustment of t h e l e v e l of Z and ZR (Photo diodes o u t p u t s )
Note
=;*.
f;l Vl,
3 15 m V
z R
VR4 (V) VR 5 (c)
-
Adjustment of t h e v o l t a g e of T1 T I v o l t a g e = 4 i-O.04V (When +6A o r +65 are s u p p l i e d 6V, and +5V i s o f f ) Adjustment of CS l e v e l which i s t h e comparison l e v e l of C1, C2, C4, C8 (Photo diode o u t p u t s ) .
C1-a
T2
Note) VR3 i s used f o r t h e adjustment of t h e both *Z and C2, C4, C 8 s i g n a l s . Trimmer c a p a c i t o r s V.R.
Standard s e t t i n g
TC 1
-
(F)
Remarks Adjustment of t h e frequency of CLK F = 10 kHz (When +6A o r +6B a r e supplied 6V, and +5V i s o f f )
---
TC2 (W)
1
-
Adjustment of t h e low l e v e l width of CLK Low l e v e l width = 600 n s (When +6A o r +6B a r e s u p p l i e d 6V, and +5V i s o f f )
32.5 Test Points 1) When "+6A1' or "+6Bn are supplied 6 V, and "+5V1' is off.
( Test points
I
ON
I
Specifications --
-
-
-
Voltage
3.96 V
Voltage
1.5 V
-
I Voltage
23.93
v
Voltage
23.93 V
Voltage
50.05 V
2.5 V
I --
T-zl-
Waveform
CLK
4.04 V
580 XIS
5 TL
98pSST
620 XIS
G 102d
1
I Waveform ..... Inverse waveform of "CLKtf 2) When "+5"
5s supplied SV, and "+6AW and "+6Bt1
are off.
Specifications
Test points
T1
Voltage
24.7 V
TO
Voltage
1.5 V
ON
Voltage
24.7 V
BT
Voltage
50.05 V
CT
Voltage
24.7 V
CLK
Frequency
1.1 MHz
AM
Voltage
24.7 V
XREQ
Duty
24.5 V (When "REQ1' is supplied 0 V. ) 50.4 V (When "REQ" is supplied 10 V.)
PA
Duty
45:S.S
-
5 5 : 4 5 (When the shaft is rotating.)
PB
Duty
45:55
-
5 5 : 4 5 (When the shaft is rotating.)
-.
-
2.5 V
-
1.9 MHz
--
-
3 ) Output waveform a) Count signal
0.45.T 6 Aw, Bw 6 0.55 T 0.14-T 6 a, b, c, d
'H' h 2.4 volt 'L' B 0.4 volt
Upper drawing shows the'waveform with CW rotation, When the shaft is rotated in CCW direction (viewed from shaft end), signals "A" and "*A" are interchanged with B and *B respectively,
b) Reference signal
'H' h 2.4 volt 'L' 5 0.4 volt
c)
P t ~ a s cc o n t r o l signa! f o r XC s e r v o motor
v T
H * h 2.4 v o l t L 1 I 0.4 v o l t
The drawing above shows t h e waveform wi,th CW r o t a t i o n . When t h e s h a f t i s r o t a t e d i n CCW d i r e c t i o n , s i g n a l "C8" has an i n v e r t e d waveform.
326.1 Replacing pulse coder
1) Replacing p u l s e c o d e r The method w r i t t e n h e r e i s a p p l i c a b l e t o AC servo motor models 0, 5, 10, 20, 20H 30, 30Hand 30R. It is i m p o s s i b l e t o remove t h e pulse coder from t h e o t h e r motor 1-Q, 3-0, 4-0, 5-O), because, f o r t h o s e types, t h e p u l s e coder models (2-0, i t s e l f is d i r e c t l y assembled o n t o the motor s h a f t . a) Remove t h e d e f e c t i v e p u l s e coder. 1 Remove rubber cap. 2 Unfasten b o l t @. 3 Unfasten s c r e w @ 4 Remove p u l s e c o d e r (+attachments) from t h e motor s h a f t . b) Pfount new (good) p u l s e coder. @ Mount p u l s e c o d e r (+attachments) on t h e motor s h a f t , Notice t h a t both a t o o t h (of c o u p l i n g ) and a groove (of p u l s e coder) a r e j u s t f i t t e d together. Care should be taken, f o r f i t t i n g l e n g t h is s h o r t . 2 Connect both s h a f t s by b o l t @. 3 Adjust marking-off l i n e between attachments of p u l s e coder and motor housing @ Fasten screw @.
W
8
.
-
\
Motor housing
2) Checking t h e phase-relationship The method w r i t t e n h e r e i s a p p l i c a b l e t o a l l models of FANUC AC servo motors. Connect V and W of motor power line, Excite motor a t r a t e d DC c u r r e n t from U t o V and W, (U: +, V and W: -) Correct Supply 5 VDC t o t h e pulse coder, and check s i g n a l s of Cl - C8. p a t t e r n is as follows. C1 1 or 1
C2 1 1
C4 1 1
C8
1 0 (Note)
(1: HIGH,
0 : LOW)
Note) C 8 is "0" f o r CCW r o t a t i o n Rated DC c u r r e n t a t t h e check of phase r e l a t i o n s h i p is a s follows: tfOTOR MODEL. 3-0, 4-0: 1 . 2 A 1-0,2-0: 4A 0.5 : 9 A
32.6..2 Replacing batteries
Caution) Be s u r e t h a t t h e power s o u r c e from t h e c o n t r o l l e r is on b e f o r e removing I f t h e r e i s no power t o t h e a b s o l u t e p u l s e o r replaci.ng b a t t e r i e s . c o d e r s , r e m a s t e r i n g of t h e mechanical u n i t w i l l be r e q u i r e d . 1) Removing dead b a t t e r i e s 1 U n f a s t e n two s c r e w s @ and remove t h e l i d . 2 Remove dead b a t t e r i e s , 2) Mounting new b a t t e r i e s @ Mount f o u r new a l k a l i n e manganese d i o x i d e b a t t e r i e s , p o l a r i t y t o e n s u r e t h e y are i n s t a l l e d c o r r e c t l y . @ F a s t e n two s c r e w s @ t o a t t a c h t h e l i d .
8
Banay case for absolute puke coda
Check
their
33. DISCHARGE UNIT 33.1 Location of Discharge Unit
33.2 RemovaI/Repfacement I) Specifi.cation
0-
A06B-6050-H050 2) Procedure Disconnect cables from the discharge unit. @ Remove the unit by loosening two screws @. 3 ) Caution When discharge units have been replaced, check that units are correctly oriented.
a
TOP
I I.
S-420F MECHANICAL UN tT MAINTENANCE
1..
CONFIGURATION
The configuration of the mechanical unit is shown in Fig. I . y-asis AC scrvo motor &-axis AC scrvo motor
y-axis unit
/
Wrist (alo-axis unit)
Fig. 1 Mechanical unit (S420F)
1.1 6-axis Drive Mechanism Fig, 1.1 shows the 9-axis drive mechanism. Rotation of the AC servo motor i s input t o the reducer, and the reduced rotation rotates the table. The table i s held t o the post with the cross r o l l e r bearing.
AC servo motor
Cross roller
base
Fig.. 1..1 0-axis drive mechanism
1.2 UIW-axis
Drive Mechanism
Fig. 1.2 shows the U/W-axis drive mechanism. Rotation of the U-axis motor is directly fed to the reducer. The reducer output is coupled to U-axis ].ink 1 and moves the U-axis arm via U-axis link 2. Likewise, the W-axis is driven by the W-axis motor.
U.-axislink
U-axis
I W-axis motor W-axis reducer Model 20F: S-420F (Model 30F: W2OA)
The mechanical operation is the same for both the W axis and U axis. Fig. 1.2 U/W-axis drive mechanism
1.3 alp-axis Drive Mechanism Fig. 1.3 shows the a/8-axis drive mechanism of the wrist. Rotation of the motor (Model 10) is reduced by the gear and transmitted to the wrist through the drive shaft. In the 8 axis, the drive shaft rotation is fed to the 8-axis reducer through the bevel gear, and the reducer output directly rotates the B axis. In the a axis, the drive shaft rotation is transmitted to the a-axis reducer through the bevel gear and helical gear, and the reducer output rotates the a-axis output flange.
Helical gear
a-asismotor
a-axis shaft
Helical gcar
cr-axis reduccr
Drive shaft
- -. A.
&axis reducer
@-axismotor
~~~~lgear
Fig. 1.3 alp-axis drive mechanism
1.4 7-axis Drive Mechanism Fig. 1.4 shows t h e y-axis d r i v e mechanism. Rotation of t h e y-axis motor (Model 10) i s t r a n s m i t t e d t o t h e reducer through t h e g e a r , and t h e reducer output d i r e c t l y r o t a t e s t h e y-axis.
Wrist
Fig. 1.4 y-axis drive mechanism
A non-excited brake i s i n c o r p o r a t e d i n t h e motors f o r a l l a x e s (8, W, U, and y axes) and i s a c t u a t e d a t power o f f o r i.n a n emergency.
1.5 Major Component Specifications 1) Motor
-
Specifications
-
8
A06B-0502-B75 1 A06B-0352-B731
W, U
--
A06B-0501-B75 1
Axis
-
a, 8, Y
a, B
2) Reducer Specifications
I
Axis
3) Wrist unit f
Specifications
L
Axis
A290-7302-V501
High-speed type
A290-7302-V511
High-torque type
2..
LUBRICATING CONDITION CHECK
2..1 Quarterly Checks Check t h e foll.owing items q u a r t e r l y .
Item
Check item
---
-
Check procedure
1
Lubricating condition of w r i s t gear box
D i r e c t t h e w r i s t f l a n g e s u r f a c e downwards, and check t o s e e i f t h e o i l gauge f i l l s , i n d i c a t i n g t h e r e is s u f f i c i e n t oil, and whether t h e o i l h a s become extremely t u r b i d .
2
Lubricating c o n d i t i o n of U-axis gear box
Check w i t h a n o i l gauge t o s e e i f t h e o i l l e v e l i s normal and whether t h e o i l h a s become extremely t u r b i d .
2.2 Replacing OiIlGrease Replace t h e g r e a s e of t h e r e d u c e r s of 8, W and U a x e s and t h e o i l of t h e U-axis g e a r box and t h e wrist uni.t every t h r e e y e a r s o r 20,000 hours i n t h e following procedure: 1) Replacing t h e g r e a s e of t h e 8-axis r e d u c e r Remove t h e @-axis b a s e f r o h t cover, @ Remove t h e p l u g (PT1/8) and t h e g r e a s e n i p p l e shown i n Fig. 2.2 (a). Blow a i r i n t o t h e h o l e from which t h e p l u g w a s removed, s o t h a t a l l t h e g r e a s e i n s i d e comes o u t a n o t h e r hole. Take c a r e n o t t o i n c r e a s e t h e a i r 2 p r e s s u r e over 0.3 kg/cm , @ Attach t h e g r e a s e n i p p l e t o t h e g r e a s e i n l e t , and supply a new grease. I n s e r t t h e plug. 2) Replacing t h e g r e a s e of t h e W/U-axis r e d u c e r Remove t h e plug (PT1/8) and t h e g r e a s e n i p p l e shown i n Fig. 2.2 (a). @ Blow a i r i n t o t h e h o l e from which t h e p l u g was removed, s o t h a t a l l t h e g r e a s e i n s i d e comes ou another hole, Take c a r e n o t t o i n c r e a s e t h e a i r p r e s s u r e over 0 . 3 kg/cm @ Attach t h e g r e a s e n i p p l e t o t h e g r e a s e i n l e t , and supply a new grease. @ I n s e r t t h e plug.
a a
a a
tr.
C
t
ocer
Fig. 2.2 (a) Replacing grease of B/W/U-axis reducer
@
o i l of t h e U-axis gear box t h e o i l i n l e t plug and t h e o i l o u t l e t plug shown i n Fig. 2.2 (b). a l l o i l , and t h e n i n s e r t t h e plug, t h e o i l shown i n Table 2.2 (a). The l e v e l of o i l should be between H- and L-marks of t h e o i l gauge a t t h e condition t h a t U-axis (The amount of o i l is about 5.1 l i t t e r s . ) angle is horizontal, I n s e r t t h e o i l i n l e t plug. Oil inlet plug
\
Fig.. 2.2 (b) Replacing oil of U-axis gear box
2-6
4 ) R e p l a c i n g o i l of t h e w r i s t @ S e t t h e I1 and Y a s e s t o a t t i t u d e s of 0".
Remove b o t h p l u g s shown i n F i g .
8'" 2
3
@
D r a i n a l l o i l , and t h e n i n s e r t t h e p l u g i n t o t h e o i l o u t l e t Supply t h e o i l shown i n T a b l e 2.2 ( a ) . The l e v e l o f oil s h o u l d b e a b o u r t h e c e n t e r of t h e o i l gauge a t t h e c o n d i t i o n t h a t t h e mounting f a c e o f t h e w r i s t f l a n g e p l a c e s downward. I n s e r t t h e plug i n t o t h e o i l i n l e t . Oil gauge
/
Fig. 2 2 (c) Replacing oil of wrist Table 2.2 (a) Grease and oil for 3-year periodical replacement
Grease
Oil
0-axis reducer W-axis
reducer
U-axis
reducer
900 c c EPNOC APO (NIPPON OIL)
Wrist
1600 cc 1800 c c
U-axis g e a r box
L
Q' t y
-
GEARLUB SP90 o r GEAROIL TS80W90 (NIPPON OIL)
5.1 l i t e r s
2.0 liters
GEAROIL TS80W90 is s p e c i a l o i l f o r RV r e d u c t i o n g e a r , a n d i t h a s good s t a r t i n g c h a r a c t e r i s t i c s u n d e r low t e m p e r a t u r e . W e recommend GEAROIL TS8090 when t h e a t m o s p h e r i c t e m p e r a t u r e i s l o w e r t h a n 5C. T h e r e i s n o t r o u b l e i f you mix GEAROIL TS80W90 a n d GEAEU.UB SP90.
2.3 Greasing Procedure 1) Greasing Supply g r e a s e t o t h e s p h e r i c a l b e a r i n g o f t h e b a l a n c e r a n n u a l l y . Supply grease t o the other p a r t s a t every t h r e e years. Supply g r e a s e t o t h e o t h e r p a r t s every t h r e e y e a r s . F o r t h e p a r t s a n d t h e g r e a s i n g methods, r e f e r t o F i g . 2 . 3 and T a b l e 2 - 3 ( a ) . 2-7
Table 2.3 (a) Greasing points
Item 1
Positions 8-axis c r o s s r o l l e r bearing
--.
2
Grease
Amount
SHELL ALVANIA N0.2
40 cc f o r each (2 l o c a t i o n s )
-
W r i s t y-axis bearing
4
Balancer spheri c a l bearing (both ends)
5
Balancer
Supply t o the grease nipple.
20 c c f o r each (2 l o c a t i o n s )
W/U-axis j o i n t bearing
3
Method
-
40 c c
5 c c f o r each (4 l o c a t i o n s )
Remove t h e plug, a t t a c h the grease n i p p l e , and supply t o t h e grease nipple. (Prepare t h e PT 1/8 of g r e a s e n i p p l e by t h e customer.) Supply t o t h e g r e a s e nipple.
10 cc f o r each (2 l o c a t i o n s ) i
1
Table 2.3 (b) Recommended grease
Grease Mobil O i l
M o b i l i t h AW2
Esso Standard
VICON No.2
Shell O i l
S h e l l Alvania No.2
Mitsubishi
Diamond Multi-purpose Grease No.2
Nippon O i l
EPNOC No. 2
Idemitsu Kohsan
DAPHNE Colonex Grease No.2
Plaruzen O i l
LIMAX No. 2
W/U
arm
j o i n t
bearing
a r ing
Fig. 2.3 Greasing points
3,
TROUBLESHOOTING
3.1 General The sources of mechanical u n i t problems may be d i f f i c u l t t o l o c a t e because of overlapping causes. Problems may become f u r t h e r complicated i f they a r e n o t c o r r e c t e d properly. Therefore, i t i.s necessary t o keep a n a c c u r a t e record of problems and t o take proper c o r r e c t i v e acti.ons.
3.2 Problems and Causes Major problems i n t h e mechanical u n i t and t h e i r probable causes and c o r r e c t i v e measures a r e l i s t e d below. I) Position e r r o r a ) (Cause) Robot s t r u c k an o b s t a c l e . (Measure) Revise t h e teaching p o i n t s . b ) (Cause) System v a r i a b l e s a r e not standard. (Refer t o t h e (Measure) Change t h e system v a r i a b l e s t o s t a n d a r d s e t t i n g s . KAREL System Reference Manual) A c a b l e is disconnected o r broken. (Pulse coder cable, i n c ) (Cause) particular ) (Refer t o 7.2) (Measure) Confirm t h e connection o r r e p l a c e t h e cable, d ) (Cause) APC abnormal, (Refer t o 5.2 5.4) (Measure) Replace t h e motor. e ) (Cause) Excessive backlash. (Measure) See below. f ) (Cause) Robot o r p e r i p h e r a l machine i s n o t f i r m l y mounted. (Measure) Mount f i r m l y , 2) The robot v i b r a t e s The r o b o t i s n o t b o l t e d s e c u r e l y on t h e f l o o r . a ) (Cause) (Measure) Tighten t h e b o l t s firmly. b) (Cause) The f l o o r i t s e l f v i b r a t e s . ( E s p e c i a l l y when t h e robot i s i n s t a l l e d on t h e second f l o o r and higher.) (Measure) Change t h e robot mounting p l a c e , A c a b l e is broken. The power s i g n a l ground l i n e i s c ) (Cause) disconnected. The p u l s e coder c a b l e C1, C2, C4, o r C8 i s disconnected o r open. (Refer t o 7.2) (Measure) Replace t h e cable. d ) (Cause) Not grounded. (Measure) Ground t h e robot. e ) (Cause) The motor o r reducer i s f a u l t y . (Refer t o 5.2 - 5.4) (Measure) Replace t h e motor o r reducer, f ) (Cause) The adjustment of t h e s e r v o c o n s t a n t s is f a u l t y ; system v a r i a b l e s a r e not standard. (Measure) Change t h e system v a r i a b l e s f o r t h e s e r v o c o n s t a n t s t o s t a n d a r d settings. The time constant i s s e t t o too low a value. g) (Cause) (Measure) Revise time c o n s t a n t . (Refer t o t h e KAREL System Reference Flanual) , h ) (Cause) Excessive backlash(Measure) See below. 3 ) Excessive backlash a ) (Cause) Screws a r e loose. (Measure) Tighten screws. Coat t h e s p e c i f i.ed a r e a w i t h LOCTITE. b ) (Cause) The reducer i s f a u l t y . (Measure) Replace the reducer. (Refer t o 5.2 - 5.4)
-
c) (Cause) The adjustment of t h e gear b a c k l a s h i s f a u l t y . (Measure) A d j u s t t h e g e a r backlash. d) (Cause) A g e a r i s worn, (Measure) Replace t h e g e a r . e ) (Cause) A b e a r i n g i s worn. (Measure) Replace t h e b e a r i n g . A c a s i n g o r arm, f o r example, i.s broken. f ) (Cause) (Measure) Replace t h e broken p a r t s . However, b a c k l a s h l e s s t h a n t h e amounts shown i n t h e f o l l o w i n g t a b l e i s n o t abnormal.
Angle c o n v e r s i o n
(deg)
Displacement conversion (mm)
0
W
U
Y
I3
a
1.5
-
1.5
1.5
1. 5
1.5
1.5
0.4 (900)
0.6 (1300)
0.2 (500)
0.2 (500)
0.1 (300)
1.0 (2350)
-.
Note) The d i s p l a c e m e n t conversion v a l u e s show b a c k l a s h i n t h e r o t a t i n g d i r e c t i o n a t t h e d i s t a n c e from t h e a x i s c e n t e r shown i n p a r e n t h e s e s . 4) Abnormal n o i s e a ) (Cause) Grease/oil t o t h e gear o r reducer i s insufficient. (Measure) Greasing. (Refer t o 2 (3)) b) (Cause) Dust i s i n t h e g e a r o r reducer. (Refer t o 2 (3)) (Measure) F l a s h i n g and t h e n g r e a s i n g . c) (Cause) The pre-load t o t h e b e a r i n g i s e x c e s s i v e . (Measure) A d j u s t t h e pre-load. R e f e r t o t h e S-420 P a r t s Manual. d) (Cause) A r e d u c e r is f a u l t y . 5.4) (Measure) Replace t h e r e d u c e r . (Refer t o 5.2 e ) (Cause) The a d j u s t m e n t of t h e g e a r b a c k l a s h i s f a u l t y . (Measure) A d j u s t t h e backlash. (Consult GMFanuc) f ) (Cause) A g e a r i s exhausted. (Consult GMFanuc) (Measure) Replace t h e g e a r . g) (Cause) A b e a r i n g is exhausted. (Consu1.t GWanuc) (Measure) Replace t h e b e a r i n g . h ) (Cause) The c a b l e t r a c k i s broken. (Measure) Replace t h e c a b l e t r a c k . (Refer t o 7) i ) (Cause) The a d j u s t m e n t of s e r v o c o n s t a n t s i s f a u l t y ; system v a r i a b l e s are n o t s t a n d a r d . (Measure) Change t h e system v a r i a b l e s f o r t h e s e r v o c o n s t a n t s t o s t a n d a r d settings. 5) Abnormal h e a t Grease/oil t o the gear o r reducer is insufficient. a ) (Cause) (Measure) Greasing. (Refer t o 2 ( 3 ) ) b) (Cause) Non-specified g r e a s e / o i l i s used. (Measure) Replace t h e g r e a s e / o i l . (Refer t o 2 ( 3 ) ) c ) (Cause) The pre-load t o t h e b e a r i n g i s e x c e s s i v e . (Heasure) A d j u s t t h e pre-load. R e f e r t o t h e S-420 P a r t s Manuald) (Cause) Overload. (Measure) Decrease t h e l o a d o r e a s e t h e moving c o n d i t i o n s . e ) (Cause) The adjustment of t h e g e a r b a c k l a s h i s f a u l t y . (Measure) A d j u s t t h e backlash. (Consult GMFanuc)
-
f ) (Cause) The time constant i s s e t t o too low a value. (Measure) Revise time constant, (Refer t o t h e KAREL System Reference Manua 1) 6 ) Drop of an a x i s when the power i s turned o f f , a ) (Cause) Brake gap i s noticeable. (Measure) Replace the motor. (Refer t o 5.2 .- 5.4) b) (Cause) Brake d r i v e r e l a y i s d e f e c t i v e , (Measure) Replace t h e r e l a y . 6 mm drop of t h e W o r U a x i s when power is i n t e r r u p t e d when t h e robot was not moving o r when an emergency s t o p i s made i s normal. 7) Leakage of g r e a s e / o i l a ) (Cause) O-ring, o i l s e a l , o r packing i s broken. (Measure) Replace t h e broken p a r t s . b) (Cause) Casing i s broken. (Consult GMFanuc) (Measure) Replace t h e broken p a r t s . c ) (Cause) Screws a r e loose. (Measure) Tighten screws. Coat t h e s p e c i f i e d p o i n t w i t h LOCTITE.
3.3 Replacing Parts and Performing Adjustments A f t e r r e p l a c i n g a p a r t , an adjustment i s u s u a l l y r e q u i r e d . r e q u i r e d replacement and adjustments.
Table 3 . 3 shows t h e
Table 3.3 Required adjustments after part replacement
Replacement p a r t o r f u n c t i o n t o be changed
Ad.justment
Motor
(a) Mastering
Cable
(a) Routing and s e c u r i n g c a b l e (b) L i m i t s w i t c h (c) Mastering
Limit switch
(a) L5mit switch and dog
W r i s t unit
(a) Quantity of o i l (b) Mastering
$-axis s t r o k e
(a) Limit switch and dog (b) Stop mounting p o s i t i o n (c) System v a r i a b l e s ($LOWERLIMS[11 and $UPPERLIMS[17)
Batteries (Replace annually)
Replace while keeping c o n t r o l l e r power on. No adjustment i s needed,
4. ADJUSTMENTS Each p a r t of t h e mechanical u n i t i s c a r e f u l l y a d j u s t e d a t t h e f a c t o r y b e f o r e shipment. T h e r e f o r e i t i s u s u a l l y unnecessary f o r t h e customer t o make a d j u s t m e n t s a t t h e time of d e l i v e r y . However', a f t e r f o r a long p e r i o d of u s e o r a f t e r p a r t s a r e r e p l a c e d , a d j u s t m e n t s may b e required. 4.1 Adjusting Limit Switches and Dogs 1) Zero p o s i t i o n and motion l i m i t The motion r a n g e s of t h e 8, W, U, and B axes a r e r e s t r i c t e d by s o f t w a r e l i m i t s and mechanically by means of h a r d s t o p s . O v e r t r a v e l (OT) s w i t c h e s on t h e 8, W, and U a x e s are used t o p r e v e n t t h e a x i s from exceeding i t s motion l i m i t and h i t t i n g t h e h a r d s t o p s . When a n o v e r t r a v e l s w i t c h h a s been t r i p p e d the a x i s is i n a n o v e r t r a v e l condition. Note t h a t t h e a and y axes are n o t r e s t r i c t e d by h a r d s t o p s o r o v e r t r a v e l switches. a and y a x e s a r e r e s t r i c t e d o n l y by t h e s o f t w a r e . They can have as many as 27 t u r n s . The d e f a u l t s e t t i n g i s 5360". O v e r t r a v e l i s d e t e c t e d at b o t h ends of e a c h of t h e t h r e e major a x e s (6, W, U). The r o b o t cannot exceed t h e motion r a n g e u n l e s s t h e r e i.s a f a i l u r e of t h e system. (d) show t h e z e r o p o s i . t i o n and motion l i m i t of each a x i s . Fig. 4.1 (a)
-
stops
Fig. 4.1 (a) B-axis rotation (6 300~)
Fig..4..7 (b) W-axis rotation
Restricted by s o f l w a r r
-50"< ( W -
a x i s) <30" angle
Mechanical
Rcstriettd by software
+35" 2 W a x i s 2+65"
(
ingle) Fig. 4.1 (c) U-axis rotation
+30°< W a x i s <+35'
(
ingle)
Mechanical stopper
Mechanical stopper
Note) OT is not provided in the B-axis. Fig. 4.1 (d) Faxis wrist swing
4.2 8 -axis Stroke Modification The @-axis stroke can be restricted according to available work area of the By changing the dog robot. The stroke can be changed as shown in Fig. 4.2 (a). position, the stroke is changed corresponding to the OT stroke, The mechanical stop can also be changed corresponding to the stroke. (Normally it is better to change the mechanical stop when the stroke has changed.) If you change the hardware limits you must also change the software limits. The default settings for the 0-axis are: $UPPERLIMS[ll=2.61799387799149 (150") $LOWERLIMSCl]=-2.61788387799149 (-150")
4
Note) Standard stroke -150" to +150° Front
Stroke change +IS0 j +30° +45 " +60° +75" , +90° +105" +120° .i-135" +150°
-15"
/
+150°
-15" -30" -45" -60" -75" -90" -105" - 120" -135" -150"
-1 50"
Fig.. 4.2 ( a ) Modifying 6-axis stroke
1) Changing t h e dog p o s i t i o n Change t h e dog p o s i t i o n a s shown i n Fig. stroke position.
4.2
(b) t o match w i t h a d e s i r e d
2) Changing t h e mechanical s t o p Change t h e s t o p p o s i t i o n of t h e @-axis b a s e a s shown i n Fig. 4.2 ( c ) . 3) Changing s o f t w a r e l i m i t s f o r t h e 8-axis @ Determine how many degrees t h e r o b o t w i l l t r a v e l from i t s zero-degree p o s i t i o n t o t h e d e s i r e d motion l i m i t , Convert t h i s number of degrees t o r a d i a n s u s i n g t h e f o l l o w i n g formula: 2 x pi Radians = No. of degrees x -. 360
a
@ Power up t h e c o n t r o l l e r . @ A t t h e POWER UP s c r e e n , p r e s s t h e KCL s o f t k e y .
@ A t t h e KCL prompt t y p e KCL > SET VAR SUPPERLIMSCl] P r e s s ENTER. A t t h e NEW VALUE prompt t y p e i n t h e v a l u e f o r t h e u p p e r motion l i m i t t h a t you c a l c u l a t e d i n s t e p @ and p r e s s ENTER. @ Repeat s t e p s 5 - 7 f o r $LOWERLIMS[l]. ~ tt h-e KCL prompt t y p e KCL > SSAVE SYS STANDARD 10 P r e s s ENTER. 11 Power down t h e c o n t r o l l e r and a f t e r 15 seconds power i t up again.
8 6 7
8
-
Front Standard
t
Standard
--
Note) 8-axis b a s e t o p view. F i g . 4.2 (b) Dog locations
4.3 Mastering Procedure 4.3.1 lntroduction
T h i s procedure d e s c r i b e s t h e m a s t e r i n g procedure f o r a r o b o t w i t h a n a b s o l u t e p u l s e c o d e r system. No o p e r a t i o n is r e q u i r e d f o r c a l i b r a t i o n w i t h t h i s system. The r o b o t is a u t o m a t i c a l l y c a l i b r a t e d when power i s turned on and t h e system becomes ready. M a s t e r i n g i s t h e e s t a b l i s h m e n t of a n a b s o l u t e r e f e r e n c e p o i n t ( o r known l o c a t i o n ) as t h e m a s t e r i n g p o s i t i o n of t h e robot. The known l o c a t i o n c a n b e t h e z e r o p o s i t i o n (determined by a l i g n i n g t h e z e r o w i t n e s s marks on a p a r t i c u l a r a x i s o r by making p r e c i s e measurements a c c o r d i n g t o s p e c i f i e d d i s t a n c e s ) o r a l o c a t i o n determined by moving t h e a x i s i n t o a - m a s t e r i n g f i x t u r e . The method used f o r d e t e r m i n i n g t h e known l o c a t i o n i s depehdent on t h e r o b o t model and i s d e s c r i b e d i n d e t a i l i n S e c t i o n s 4.4.3 and 4.4.4. Using a m a s t e r i n g f i x t u r e i s t h e most a c c u r a t e and recommended m a s t e r i n g procedure. Note t h a t t h e same m a s t e r i n g f i x t u r e should b e used f o r a l l r o b o t s i n a system. Mastering i s done a t t h e f a c t o r y and g e n e r a l l y i s n o t r e q u i r e d a s p a r t of t h e d a i l y o p e r a t i o n . Mastering w i l l need t o be done when a mechanical p a r t h a s been r e p l a c e d o r a l t e r e d , i f t h e system v a r i a b l e s .dealing w i t h m a s t e r i n g have been l o s t o r changed, o r i f t h e p o s i t i o n a l 2nformation from t h e a b s o l u t e p u l s e c o d e r s h a s been i o s t .
4..3..2 Mastering procedure
There a r e two procedures used f o r mastering depending on whether o r not bubble memory has been i n i t i a l i z e d :
the
-.. When bubble memory has been i n i t i a l i z e d
1 , Power up t h e c o n t r o l l e r . 2. Turn REMOTE ON/OFF switch t o ON. 3. Using t h e CRT/KB, c a l l up t h e KCL d i s p l a y screen.
4. A t t h e KCL> prompt, e n t e r UTIL,
.At
t h e UTIL> prompt, e n t e r SINIT, This d i s p l a y s menu-driven prompts description.
that
request
the
mechanical
unit
6 , Follow t h e menu and e n t e r t h e system s t a n d a r d values,
-
7, When t h e KCL> prompt reappears, e n t e r SSAVE SYS STANDARD. 8, Power down and up. 9. Using t h e teach pendant, j o g t h e mechanical u n i t t o t h e mastering p o s i t i o n described i n Section 4 - 4 . 3 . 10, Using t h e CRT/KB (with REMOTE ON/OFF s w i t c h turned t o ON), response t o t h e KCL> prompt,
11, I n response t o t h e UTIL> prompt, e n t e r MASTER, 12, Enter Y i n response t o t h e displayed q u e s t i o n "Are you sure?" 13, A t t h e prompt "Mastering at 0 degrees Y/N?" e n t e r : Y i f you are mastering a t t h e zero-degree p o s i t i o n o r N i f you a r e mastering u s i n g a mastering f i x t u r e . 14. P r e s s ENTER twice,
e n t e r UTIL i n
-
When bubble memory has not been i n i t i a l i z e d 1, Power up t h e c o n t r o l l e r ,
2 . Turn REMOTE ON/OFF switch ON.
3, Using t h e CRT/KB, call up t h e KCL d i s p l a y screen, 4. Enter DISMOUNT BM: i n response t o t h e KCL> prompt.
5 . Enter MOUNT BM: i n response t o t h e KCL> prompt.
6. Enter KCL>DEL F I DYNMSTR.DY i n response t o t h e KCL> prompt. 7. Using t h e t e a c h pendant, jog t h e mechanical u n i t t o t h e m a s t e r i n g p o s i t i o n described i n S e c t i o n 4 . 3 . 3 . 8. Using t h e CRT/KB (with REMOTE switch turned t o ON) e n t e r UTIL i n response t o t h e KCL> prompt.
9. I n response t o t h e UTIL> prompt e n t e r MASTER. 10. E n t e r Y i n response t o t h e displayed q u e s t i o n "Are yuu sure?" 11. A t t h e prompt "Mastering a t 0 degrees Y/N?" e n t e r : Y i f you are mastering a t t h e zero-degree posi.tion o r N i f you are mastering using a mastering f i x t u r e , 1 2 , P r e s s ENTER twice. When mastering h a s been completed a dynamic mastering f i l e h a s been c r e a t e d .
4.3..3 Zero-degree position
The zero-degree p o s i t i . o n of t h e S-420F r o b o t i s shown i n Fig. 4.3.3. f i . 0 ~ 1ZCIC) ~ dcgrcc mark
U-axis zero degree mark
W-axiszero degree mark
Fig. 4.3.3
4.3.4
Zero degree mark of each axis
Mastering using a mastering fixture
When a major p a r t of t h e r o b o t mechanical u n i t i s r e p l a c e d and t h e a c t u a l p o s i t i o n of each a x i s i s n o t t h e same as t h e c u r r e n t v a l u e s t o r e d through an a b s o l u t e p u l s e c o d e r (APC), m a s t e r i n g i s r e q u i r e d t o e s t a b l i s h t h e a c t u a l p o s i t i o n of t h e r o b o t . When mastering t h e r o b o t , meet t h e f o l l o w i n g c o n d i t i o n s : Level t h e robot mounting base. It s h o u l d n o t d e v i a t e from t h e h o r i z o n t a l by more than 1 mm. Remove t h e hand and o t h e r p a r t s from t h e w r i s t . Make s u r e t h a t n o t h i n g i s l e a n i n g on o r pushing a g a i n s t t h e robot.
. . .
Note) Since t h e a x i s s t r o k e i s n o t l i m i t e d d u r i n g m a s t e r i n g , be c a r e f u l around equipment t h a t is normal1.y p r o t e c t e d by t h e motion l i m i t s .
1) Mastering procedure a ) Mount t h e mastering j i . g i ) Mount t h e d i a l j i g Adjust t h e d i a l . gauge t o 3.00 mm u s i n g t h e c a l i b r a t i o n block, and (Do n o t t i g h t e n t i g h t e n i t w i t h M5 b o l t as shown i n Fig. 4 . 3 . 4 ( a ) , t h e b o l t t o o s t r o n g l y . The d i a l gauge may b e broken.)
\
Calibration block
Fig. 4.3.4 (a) Mounting the gauge
i i ) Assembling t h e j i g b a s e Assemble t h e j i g b a s e as shown i n Fig. 4 . 3 . 4
Plat
Fig..4..3,.4(b) Assembling jig base
(b).
i i i ) Mounting the j i g on the robot body Mount the j i g on the 8-axis base using bolts and p i n s as shown in Fig. 4 . 3 . 4 (c). Mi2.u 35 bolt
016 pin
/
&axisbase Fig. 4.3.4 (c)
Mountingjig on robot body
iv) Mounting the jig to the wrist Jig the robot wrist to the position where the a, 8, and y zero degree witness marks line up. Mount the jig to the a-axis flange as shown in Fig. 4.3.4 (dl. 1
3 Fig., 4..3..4(d) Mounting jig to wrist
b ) Mastering procedure
i ) Jog t h e robot w r i s t t o t h e p o s i t i o n c l o s e t o t h e master5ng j i g . (See Fig. 4 . 3 . 4 ( e l ) Take c a r e n o t t o h i t t h e w r i s t on t h e m a s t e r i n g j i g . i i ) Adjust each a x i s t o t h e m a s t e r i n g j i g p o s i t i o n by l o g g i n g . To prevent an e r r o r caused by a b a c k l a s h , a d j u s t t h e d i a l gauge p o i n t e r s o t h a t when t h e a x i s i s moved t h e d i a l gauge v a l u e s w i l l d e c r e a s e . I f i t i s adjusted i n the reverse d i r e c t i o n , r e p e a t t h e adjustment. @ Move t h e robot g r a d u a l l y s o t h a t t h e t i p of t h e d i a l gauge shown i n Fig. 4.3.4 ( c ) c o n t a c t s t h e j i g a t t h e p a r t of a r r o w A-F shown i n Fig. 4 . 3 . 4 ( d ) . @ Move t h e a a x i s s o t h a t t h e d i a l gauges A and B i n d i c a t e t h e same value. @ Move t h e 0 and y a x e s s o t h a t t h e d i a l gauges D a n d E i n d i c a t e t h e same v a l u e , and t h e d i a l gauge C i n d i c a t e s 3 . 0 0 mm. I f the r e a d i n g s of d i a l gauges A and B are d i f f e r e n t a t t h i s time, a d j u s t t h e a x e s t o o b t a i n t h e same v a l u e . @ Move W, U and B a x e s s o t h a t t h e d i a l gauges A, D and F i n d i c a t e 3.00 mm. @ A f t e r t h e above o p e r a t i o n , v e r i f y t h a t al.1 t h e d i a l gauges i n d i c a t e 3.00 mm. i i i ) Perform t h e mastering procedure d e s c r i b e d i n S e c t i o n 4 . 3 . 2 , s t a r t i n g a t Step @.
w-axis
y-axis 0" craxis 0"
p-axis Fig. 4.3.4 (e) Mastering attitude
5,. REPLACING MECHANICAL PARTS 5.1 Replacing Battery The z e r o p o s i t i o n d a t a of each a x i s is preserved by t h e backup b a t t e r y . The b a t t e r y needs t o be p e r i o d i c a l l y r e p l a c e d every year. Replace t h e b a t t e r y u s i n g t h e f o l l o w i n g procedure: @ Keep t h e power. on, Caution) If you do n o t power up t h e c o n t r o l l e r b e f o r e removing t h e b a t t e r i e s t h e p o s i t i o n d a t a w i l l b e l o s t and you w i l l need t o r e m a s t e r t h e robot.
@ P r e s s t h e EMERGENCY STOP b u t t o n t o p r o h i b i t t h e r o b o t motion. a Remove t h e b a t t e r y case cap. @ Take o u t t h e o l d b a t t e r y from t h e b a t t e r y case. @ I n s e r t a new b a t t e r y i n t o t h e b a t t e r y c a s e .
Pay a t t e n t i o n t o t h e d i r e c t i o n
of b a t t e r i e s , @ Close t h e b a t t e r y c a s e cap.
B a t t e r y s p e c i f i c a t i o n : A98L-0031-.000.5 x 4 UM1, 1.5 V Fig..5.1 Replacing battery
5.2 Replacing $-axis Motor and Reducer 1 ) Replacing t h e @-axis motor 1 Turn t h e power o f f . 2 Remove t h e r e a r cover from t h e W-axis b a s e and then t h e 0-axis motor connectors. @ Remove t h e motor mounting b o l t s , and then remove t h e motor through t h e W-axis r e a r window. @ Remove t h e C-ring, i n p u t g e a r and c o u p l i n g i n t h a t o r d e r . Remove t h e draw b o l t , and then t h e i n p u t s p l i n e . @ Replace t h e motor, and remount a new motor r e v e r s i n g t h e above procedure. Apply LOCTITE No. 242 t o t h e t h r e a d of t h e draw b o l t . @ Perform t h e mastering procedure. ( R e f e r t o 4 . 3 . 2 - 4 . 3 . 4 )
8
Draw bolt .-
Fig.. 5..2 fa) Replacing 8-axis motor
2 ) Replacing 0-axis r e d u c e r Turn t h e power o f f .
0 @
Remove t h e robot c o n n e c t i n g c a b l e a n d t h e a i r hose from t h e 0-axis connector panel. 4 Remove t h e r e a r c o v e r from t h e W-axis base. 5 Remove t h e mechanical u n i t c a b l e except t h e b a t t e r y c a b l e . (Refer t o 7.2) @ Remove t h e b a t t e r y c a b l e c o n n e c t o r of 0 a x i s motor. (Do n o t remove t h e o t h e r b a t t e r y c a b l e connector t h a n 0 a x i s . ) @ Remove t h e b o l t s and s p r i n g p i n , mounting t h e W-axis b a s e t o t h e 8 - a x i s table. @ L i f t up t h e W/U-axis u n i t b e i n g c a r e f u l o f t h e c a b l e , and s e p a r a t e i t from t h e 0-axis a n i t . Remove t h e b o l t s mounting t h e 8-axis motor, and then remove t h e motor. Remove t h e b o l t s mounting t h e mounting r i n g of t h e c r o s s r o l l e r b e a r i n g , Remove t h e b o l t s and t a p e r p i n mounting t h e t a b l e t o t h e reducer. Remove t h e t a b l e t o g e t h e r w i t h t h e r i n g and t h e c r o s s r o l l e r b e a r i n g , and t h e n t h e O-ring 2, Remove t h e b o l t s a n d t a p e r p i n mounting t h e reducer t o t h e 0-axis base. 4 Remove and r e p l a c e t h e r e d u c e r , Mount a new r e d u c e r r e v e r s i n g t h e above procedure. P o l i s h t h e reducer mounting s u r f a c e and t h e motor f l a n g e mounting s u r f a c e u s i n g an o i l s t o n e , Apply Apply LOCTITE No.262 t o t h e b o l t s removed i n s t e p s 11 and 13 LOCTITE No.242 t o t h e t a p e r p i n s removed i n s t e p s 11 and 13 , and B e s u r e t o mount t h e O-ring. Apply a i n s e r t t h e p i n s after reaming, s e a l a n t (Threebond No.1121) t o t h e p a r t s i n d i c a t e d i n Fig. 5.2 (b), Reform t h e c a b l e . (Refer t o 7.1) Apply g r e a s e t o t h e r e d u c e r , (Refer t o 2) Perform t h e m a s t e r i n g procedure. 4.3.4) (Refer t o 4.3.2
8
8
.
-
IV-asis base mounting bolts
I I
W-axis base
@12x35
Table mountig bolts M12x8O (Floor) aper pin 610x40 (S420F) 610x35 (S420A)
Ring mounting bolts
8,
I .
' BJ
Cross rolier bearing
I
1
.
/
'J
--
Ring
/
, Ring mounting bolts
Reducer mounting bolts M16x130 (S.420F) M16~140(S420A)
l . ,
-.
Taper pin 616x60 (S420F) 620x70 (S-42OA)
I
Apply s e a l a n t (Threebond No.1121)
t o surface indicated.
Fig.. 5..2 (b) Replacing 6-axis reducer
5..3 Replacing U/W-axis Motor and Reducer 1 ) Replacing t h e U/W-axis motor Turn t h e power o f f . Remove t h e c a b l e from t h e r e p l a c i n g motor. Remove t h e mounting b o l t s of t h e motor. Draw t h e motor a b o u t 3 mm o u t , and t u r n t h e motor t o t h e p o s i t i o n f o r p r e v e n t i n g i t from f a l l i n g . When t h e a x i s c o n t a c t s the stopper, then s t o p turning. 4 Rem~vet h e motor. 5 Remove t h e C-ring, t h e i n p u t g e a r and t h e c o u p l i n g i n t h a t o r d e r . Remove t h e draw b o l t , and then t h e i n p u t s p l i n e . @ Replace t h e motor, and remount a new motor by @ , @ procedure. Replace t h e O-ring too. Apply LOCTITE (No.242) t o t h e t h r e a d of t h e draw bolt. 7 Apply g r e a s e . 8 P e r f o m t h e m a s t e r i n g procedure. (Refer t o 4.3.2 4.3.4)
8
8
--
U/W-axis motor
1 Fig 5 3 (a) Replacing U/W-axis motor
2 ) Replacing t h e U/W-axis r e d u c e r 1 Turn t h e power o f f . 2 Hang t h e f r o n t and back p a r t s of U-axis arm with balanced f o r c e , When r e p l a c i n g t h e U-axis r e d u c e r , hang t h e U-axis l i n k too. 3 Remove t h e motor mounting b o l t s , and t h e n t h e motor. 4 Remove t h e b o l t s and t a p e r p i n mounting t h e b r a c k e t t o t h e r e d u c e r , and remove t h e b r a c k e t and O-ring. Remove t h e b o l t s and t a p e r p i n mounting t h e reducer. Remove and r e p l a c e t h e reducer. P o l i s h t h e reducer Mount a new r e d u c e r r e v e r s i n g t h e above procedure. mounting s u r f a c e and t h e motor f l a n g e mounting s u r f a c e u s i n g a n o i l s t o n e . Apply LOCTITE No.262 t o t h e b o l t s removed i n t h e s t e p s @ and ~ p p l yLOCTITE NO. 242 t o t h e t a p e r p i n s removed i n t h e s t e p s @ and , and i n s e r t t h e p i n s a f t e r reaming. Be c a r e f u l t o r e p l a c e t h e O-ring a t the specified position. 8 Apply g r e a s e t o t h e r e d u c e r . ( R e f e r t o 2) 9 Perform t h e m a s t e r i n g procedure. ( R e f e r t o 4.3.2 4.3.4)
8 8
8.
8
-
U-axis arm
Rephcing the UIW-axis
Fig..5.3 (b) Position for replacing U/W-axis reducer
Reducer Mountins bolts h116x150 (U ot S4201 ,W,U of S-420A) h4 1 6 ~ 1 4 0(W of S-4201;) Bracket mounting bolts M 12x70 (W, U of S-420F ;
U of S-420A) #20x80 (W of S420A)
U of W 2 0 A ) #lox35 (W of S-420A)
Fig. 5 2 (c) Replacing U M a x i s reducer
5.4 Replacing crlBl7-axis Motor and 7-axis Reducer 1) Replacing a/B/y-axis motor @ Move t h e a, f3 and y axes t o t h e p o s i t i o n where t h e e x t e r n a l f o r c e is n o t applied, (Refer t o 2) Drain t h e o i l from t h e gear box, Remove t h e motor mounting b o l t s (M12x40) and then t h e motor. Remove t h e n u t and then t h e gear. Replace t h e motor, and remount a new motor r e v e r s i n g t h e above procedure. (Refer t o 2) F i l l t h e g e a r box w i t h o i l . (Refer t o 4.3.2 4.3.4) Perform t h e mastering procedure.
-
a-axis
rnolor
\
L
f
i3elical g a r
9
O-ring
rn
I
y-axis motor H C U gear ~ ~
paxis motor
i
I
'
1
-
tn w
IF bar box
O-ring
\
Helical gear Motor mounting bolts M12x40 Fig. 5.4 (a) Replacing cr/plrsxis motor
2) Replacing t h e y-axis reducer @ Move t h e a, f3 and y axes t o t h e p o s i t i o n where t h e e x t e r n a l force i s n o t applied. 2 Drain t h e o i l from t h e gear box. (Refer t o 2 ) 3 Remove t h e s l e e v e mounting b o l t s (M12x40) and then t h e U-axis sleeve. 4 Remove t h e b o l t s (M10x85, M8x5.5) and t a p e r p i n s (d10x30, d80x30) t h e from reducer. 5 Remove and r e p l a c e t h e reducer, 6 Remount a new reducer r e v e r s i n g t h e above procedure. Polish t h e reducer mounting s u r f a c e and t h e motor f l a n g e mounting s u r f a c e using an oilstone. Apply LOCTITE No.262 t o t h e b o l t s removed i n t h e s t e p @ Apply LOCTITE No.242 t o t h e t a p e r p i n s removed i n t h e s t e p 0 , and i n s e r t t h e p i n s a f t e r reaming, Be c a r e f u l t o r e p l a c e t h e O-ring a t the s p e c i f i e d position. 7 F i l l t h e gear box with o i l . (Refer t o 2) 8 Perform t h e mastering procedure. (Refer t o 4-3.2 - 4 i 3 . 4 )
8 8
8
.
Reducer mounting bolts
U-axis unit
'Taper pin 910x30
bolts
Fig. 5.4 (b) Replacing y-axis reducer
Replacing Wrist Unit Remove t h e hand, workpiece, and any o t h e r equipment from t h e w r i s t , (Refer t o 2) Drain t h e o i l from t h e w r i s t u n i t . Remove t h e wrist u n i t mounting b o l t (M10x30) and then t h e w r i s t u n i t , Replace t h e w r i s t u n i t , and remount a new w r i s t u n i t r e v e r s i n g t h e above procedure. F i l l t h e w r i s t u n i t with o i l . (Refer t o 2) (Refer t o 4-3.2 - 4.3.4) Perform t h e mastering procedure. Wrist unit
\
Wrist unit mounting bolts
M10x30
Fig..5.5
Replacing wrist unit
6.
PIPING AND WIRING
6.1 Piping Digrarn Fig. 6.1 i s a d i a g r a m of t h e p i p i n g i n t h e m e c h a n i c a l u n i t . Panel u n i o n PT3\/8 f e m a l e
i r h o s e 010
Pane PT3/
Fig. 6.1 Piping diagram
.
6.2 Wiring Diagram Fig 6.2 shows the wiring diagram of the mechanical unit.
Fig..6..2 Wiring diagram in mechanical unit
2-34
6.3 Limit Switch Installation Diagram
Fig. 6 . 3 shows the mechanical. unit limit switch installation diagram.
Fig. 6.3 Limit switch installation diagram
6.4 Mechanical Unit Cable lnstallation Diagram Fig. 6.4 shows the mechanical unit cable installation diagram.
Movable part
f i g . . 6..4Mechanical unit cable installation diagram
2-35
'7. REPLACING ELECTRIC CABLES Replace t h e c a b l e every two years. When t h e c a b l e i s broken o r damaged, r e p l a c e it following t h e instructi.ons i n t h i s chapter. Pay a t t e n t i o n t o t h e f o l l o w i n g two p o i n t s , Otherwise, t h e c u r r e n t p o s i t i o n i s l o s t and r e m a s t e r i n g i s necessary. 1) Do n o t r e p l a c e t h e p u l s e coder c a b l e s (K104 and K105) and t h e b a t t e r y c a b l e s (K106, K107, K108 and K109) a t t h e same t i m e . 2) Replace t h e b a t t e r y c a b l e s w i t h t h e c o n t r o l l e r power t u r n e d on. P r e c a u t i o n s on h a n d l i n g t h e b a t t e r y c a b l e The b a t t e r y c a b l e connector i s g i v e n t h e marking t a g shown below t o p r e v e n t c a r e l e s s d i s c o n n e c t i o n d u r i n g t r a n s p o r t a t i o n , i n s t a l l a t i o n o r maintenance, If t h e c o n n e c t o r with t h e marking t a g i s disconnected w i t h t h e c o n t r o l l e r power o f f , m a s t e r i n g must b e executed again.
BATIERY
Dl SCONNECT
Marking t a g
7.1 Clamping Cables Fig. 7.1 shows When r e p l a c i n g u s i n g a clamp p u l l e d causing
t h e cab1.e clamp p o s i t i o n . c a b l e s , clamp t h e c a b l e a t t h e p o s i t i o n s p e c i f i e d i n Table 7.1, o r a t i e wrap. Otherwise, c a b l e s can b e loosened o r f o r c e d l y t h e i r disconnection.
Fig. 7..1 Cable clamp position
2-36
Table 7..1 Cable clamp position
7.2 Replacing Cables The procedure of t h e periodic replacement of a l l t h e mechanical u n i t c a b l e s i s d e s c r i b e d here. I n t h i s case, r e p l a c e o t h e r mechanical u n i t c a b l e s than t h e b a t t e r y c a b l e s a t f i r s t . Turn t h e power on, p r e s s t h e EMERGENCY STOP b u t t o n , and then r e p l a c e t h e b a t t e r y cable, I f not powering up t h e c o n t r o l l e r b e f o r e removing t h e b a t t e r y c a b l e s , t h e p o s i t i o n d a t a w i l l be l o s t and i t w i l l need t o be mastered. For r e p l a c i n g one of mechanical u n i t cables, perform t h e replacing procedure r e f e r r i n g t o t h e d e s c r i p t i o n i n t h i s section. If b o t h of t h e p u l s e coder and b a t t e r y c a b l e s a r e broken a t a time, t h e p o s i t i o n d a t a of the a x i s w i l l be l o s t , and then i t w i l l need t o be remastered. @ Turn t h e power o f f , and remove a l l t h e connectors except t h e b a t t e r y c a b l e connector from t h e connector panels and motors. 2 Cut off t h e nylon band of t h e U-axis casing p l a t e . 3 Remove t h e p l a t e mounting b o l t s . Pull o u t t h e c a b l e from t h e space between U and W axes t o t h e f r o n t . (Fig. 7.2 (b)) @ Remove t h e p l a t e on t h e f r o n t s i d e of t h e W-axis arm. Remove t h e clamp mounting b o l t s , 5 Remove t h e p l a t e a t t h e r e a r of t h e W-axis base. 6 P u l l out clamps 1 and 2, and s e p a r a t e them by removing t h e b o l t , (Fig, 7.2 (c) @ P u l l out t h e c a b l e from t h e punched h o l e l o c a t e d a t t h e lower p a r t of t h e W - a x i s arm, and i n s e r t it i n t o t h e W-axis b a s e from t h e r e a r s i d e of t h e W-axis base. (Fig, 7.2 (d)) 8 Remove t h e p l a t e a t t h e f r o n t of t h e W a x i s , and remove t h e connector panel. 9 Remove t h e 8-axis base s i d e cover and then t h e p l a t e mounting b o l t s . 0 Remove t h e 8-axis connector p a n e l mounting b o l t s , and p u l l out t h e connector p a n e l halfway. Remove t h e guide mounting b o l t s , and then t h e guide, Remove t h e p i n mounting b o l t s , and then t h e pin. Remove t h e connector panel t o g e t h e r with t h e c a b l e t r a c k , (Fig. 7.2 (e)) Cut o f f t h e nylon band and remove t h e clamp mounting b o l t s , Open t h e c a b l e t r a c k s i d e cover w i t h a screwdriver, and p u l l o u t t h e cable. (Fig. 7.2 ( f ) ) Replace t h e c a b l e s except t h e b a t t e r y cable and reform the c a b l e of 0-axis @ p a r t , and t h e n reconnect new c a b l e s t o t h e motor connector through t h e c a b l e r o u t e . Apply LOCTITE No.262 t o t h e b o l t s removed i n s t e p s 9 and 12 Connect a l l c a b l e s t o t h e connector panels and motors, P r e s s t h e EMERGENCY STOP b u t t o n t o t u r n t h e power on. 9 Remove and r e p l a c e t h e b a t t e r y cable, 0 Confirm t h e connection of a l l c a b l e s , and then reform a l l cables.
8
8
>
8
Q
.
" 6P
ky@y -
Fig. 7 2 (a)
Replacing cable
Nylon band
Fig. 7.2 (b) Replacing cable 6-420)
2-3 9
Fig 7.2 (c) Replacing cable
+ To W-axis arm
Fig.. 7.2 (d) Replacing cable
Plate
Fig. 7 2 (e) Replacing cable
Tap the part shown by with a plastic hammer..:
axis connector panel
&axis connector panel
Fig. 7.2 ( f ) Replacing cable
7.3 Replacing Limit Switches 0-axis limit switch the switch cover and then the limit switch from the plate. the nylon band, and replace the limit switch, the OT switch. Adjust the limit switch step allowance to about 3 m.
kiT--.
Step alIowance approx. 3 mm
Limit switch
Secure with a nylon
Fig. 7.3 (a) 8-axis limit switch mounting diagram
e ,
Cover
Fig..7..3 (b) Replacing 8-axis limit switch
2-42
2) Replacing W/U-axis limit switch 1 Remove the W-axis base rear cover, 2 Remove the limit switch mounting plate, 3 Remove the limit switch from the plate, and replace the limit switch cable ( K 1 1 1 ) with a new one. 4 Remount the new limit switch reversing above procedures. 5 Adjust the OT switch so that the limit switch step al3.owance will be about 3 mm.
8
8
Fig. 73 (c) WfU-axis limit switch mounting diagram
3) Replacing U/W-axis l i m i t switch @ Remove t h e f r o n t p l a t e from t h e W-axis arm and then t h e l i m i t switch connector. 2 Remove t h e cover, nylon c l i p and then l i m i t switch mounting p l a t e 3 Replace t h e l i m i t switch c a b l e (K112) w i t h a new one. 4 Remount t h e new 1 . i m i t switch c a b l e r e v e r s i n g above procedures. 5 Adjust t h e OT s w i t c h s o t h a t t h e l i m i t switch s t e p allowance w i l l about 2 mm,
W
Connector Fig. 7.3 (d) U/W-axis limit switch mounting diagram
111.
S420A MECHANICAL UNIT MAINTENANCE
1. CONFIGURATION I - A X l S
Fig. 1 (a) S-420A mechanical unit configuration (with pull balancers) (mount angle: from 0 to 29 degrees)
Fig.. 1 (b) S-420A mechanical unit configuration (with pull push balancers) (mount angle: from 30 to 72 degrees)
3- 1
)-axts AC s e r v o m o t o r
G e a r box
11-21 1 1
Wl
IS1
(a/#-ax~s
a x i s AC s e r v o m o t o r
Fig. 1 (c) S420A mechanical unit configuration (with push balancers) (mount angle: from 73 to 90 degrees)
1.1 8-axis Drive Mechanism Refer t o Section 11-1.1. 1.2 U/W-axis Drive Mechanism Refer to Section 11-1.2.
1.3 alp-axis Drive Mechanism Refer t o Section 11-1.3.
1.4 y-axis Drive Mechanism Refer t o Section 11-1-4.
1.5 Major Component Specifications I) Motor Axis
Specifications
A06B-0353-B83 1
0, W
A06B-0352-B731 -A06B-0501-B751
U
--
a, 8, Y
-
u n l ! )
2) Reducer
I
Specifications
-
Axis
-
3) W r i s t u n i t
Specifications
---
Axis
A290-7302-V501
High-speed t y p e
A290-7302-V511
High-torque type
2.
LUBRICATING CONDITION CHECK
2.1 Quarterly Checks Check t h e following items quarter3.y.
Check item
Check procedure
Lubricating c o n d i t i o n of w r i s t gear box
D i r e c t t h e w r i s t f l a n g e s u r f a c e downwards, and check t o s e e i f t h e o i l gauge f i l l s , i n d i c a t i n g t h e r e i s s u f f i c i e n t o i l , and whether t h e o i l has become extremely t u r b i d . >
Lubricating c o n d i t i o n of U-axis g e a r box
Check w i t h an o i l gauge t o see i f t h e o i l l e v e l is normal and whether t h e o i l has become extremely t u r b i d .
2.2 Replacing OilIGrease Replace t h e grease of t h e reducers of 0 , W and U axes and t h e o i l of t h e U-axis g e a r box and t h e wrist u n i t every t h r e e y e a r s o r 20,000 hours i n t h e following procedure: 1) Replacing t h e g r e a s e of t h e 8-axis r e d u c e r Remove t h e + a x i s base f r o n t cover. @ Remove t h e plug (PT1/8) and t h e g r e a s e n i p p l e shown i n Fig. 2.2 (a). @ Blow a i r i n t o t h e h o l e from which t h e plug was removed, so t h a t a l l t h e g r e a s e i n s i d e comes o u t a n o t h e r h o l e , Take c a r e n o t t o i n c r e a s e t h e a i r 2 p r e s s u r e over 0.3 kg/cm 4 Attach t h e g r e a s e n i p p l e t o t h e g r e a s e i n l e t , and supply a new grease. I n s e r t t h e plug, 2) Replacing t h e g r e a s e of t h e W/U-axis reducer 1 Remove t h e plug (PT1/8) and t h e g r e a s e n i p p l e shown i n Fig. 2.2 (a). 2 Blow a i r i n t o t h e h o l e from which t h e plug w a s removed, s o t h a t a l l t h e g r e a s e i n s i d e comes ou another hole. Take c a r e n o t t o i n c r e a s e t h e air p r e s s u r e over 0.3 kg/cm , @ Attach t h e g r e a s e n i p p l e t o t h e g r e a s e i n l e t , and supply a new grease. @ I n s e r t t h e plug,
a
8
8
.
5
Fig. 2.2 (a) Replacing grease of B/W/U-axis reducer (S-420A)
3) Replacing o i l of t h e U-axis gear box 1 Remove t h e o i l i n l e t plug and t h e o i l o u t l e t plug shown i n Fig. 2.2 (b),
8 2
3
@
Drain a l l o i l , and then i n s e r t t h e plug. Supply t h e o i l shown i n Table 2.2 (a). The l e v e l of o i l should be between H- and L-marks of t h e o i l gauge a t t h e condition t h a t U-axis arm i s h o r i z o n t a l o r t h e gauge should be f i l l e d a t t h e condition t h a t U-axis arm i s v e r t i c a l , ( t h e amount of o i l is about 5.1 l i t t e r s . ) I n s e r t t h e o i l i n l e t plug,
Oil inlet plug
Oil gauge
Fig.. 2.2 (b) Replacing oil of U-axis gear box
3-5
4 ) R e p l a c i n g o i l of t h e w r i s t @ S e t t h e y a x i s t o a t t i t u d e of 0'.
Remove b o t h p l u g s shown i n Fig.
2.2
8 2
3
@
D r a i n a l l o i l , and t h e n i n s e r t t h e p l u g i n t o t h e o i l o u t l e t . The l e v e l of o i l should be about Supply t h e o i l shown i n Table 2.2 ( a ) . t h e c e n t e r of t h e o i l gauge a t t h e c o n d i t i o n t h a t t h e mounting f a c e of w r i s t f l a n g e i s downward. I n s e r t t h e plug i n t o t h e o i l i n l e t . Oil gauge
Oil inlet plug
O i l outlet plug
Fig. 2.2 (c) Repiacing oil of wrist Table 2.2 (a) Grease and oil for 3-year periodical replacement
Grease
0i.l
1 4 0 0 cc
8-axis reducer W-axis r e d u c e r
EPNOC APO (NIPPON OIL)
Wrist
-
1700 cc 1800 cc
U-axis r e d u c e r U-axis g e a r box
Q'ty
GEARLUB SP90 o r GEAROIL TS80W90(NIPPON OIL)
5.1 l i t e r s 2.0 l i t e r s
Notice) GEAROlL TS80W90 i s s p e c i a l o i l f o r RV r e d u c t i o n g e a r , a n d i t h a s good s t a r t i n g c h a r a c t e r i s t i c s under low t e m p e r a t u r e . W e recommend GEAROIL TS80W90 when t h e atmospheric t e m p e r a t u r e i s lower t h a n 5C. T h e r e i s n o t r o u b l e i f you mix GEAROIL TS80W90 and GEARLUB SP90. 2.3 Greasing Procedure I ) Creasing Supply Supply g r e a s e t o t h e s p h e r i c a l b e a r i n g o f t h e b a l a n c e r a n n u a l l y . F o r t h e p a r t s and t h e g r e a s e t o the o t h e r p a r t s a t every t h r e e y e a r s . g r e a s i n g methods, r e f e r t o Fig. 2 - 3 and T a b l e 2.3 ( a ) 3-6
Table 2..3(a) Greading points (S-420A)
Positions
Grease
Amount
1
@-axis c r o s s r o l l e r bearing
SHELL ALVANIA NO, 2
40 c c f o r each (2 l o c a t i o n s )
2
W/U-axis bearing
3
W r i s t y-axis bearing
4
Balancer spheri c a l bearing ( b o t h ends)
It cnl
5
Method Supply t o t h e g r e a s e nipple.
20 c c f o r each (2 l o c a t i o n s )
joint
40 c c
Remove t h e plug, a t t a c h t h e grease n i p p l e , and supply t o t h e grease nipple. ( P l e a s e p r e p a r e PT 1/8 of g r e a s e n i p p l e by t h e customer.)
5 c c f o r each
Supply t o t h e g r e a s e
(4 l o c a t i o n s f o r n i p p l e . p u l l balancers) (4 l o c a t i o n s f o r push b a l a n c e r s )
Balancer
-
10 c c f o r each (2 l o c a t i o n s f o r p u l l balancers) (2 l o c a t i o n s f o r push b a l a n c e r s )
i
Table 2.3 (b)
Recommended grease (S420A)
Grease
/
Mobil. O i l
M o b i l i t h AW2
Esso S t a n d a r d
VICON No. 2
Shell O i l
S h e l l Alvania No.2
M i tsubishi
Diamond Multi-purpose
Nippon O i l
EPNOC No. 2
Idemi t s u Kohsan
DAPHNE Colonex Grease No. 2
Elaruzen O i l
I
LIMAX No.2
Grease No.2
I
Fig.
2.3 Greasing points (S-420A)
3. TROUBLESHOOTING Refer to Section 11-3.
4. ADJUSTMENTS Refer to Section 11-4.
5. REPL.ACING MECHANICAL PARTS Refer to Section 11-5. 6.
PIPING AND WIRING
6.1 Piping Diagram Refer to Section 11-6.
6.2 Wiring Diagram Fig. 6.2 shows the w i r i n g diagram of the m e c h a n i c a l u n i t .
Fig..6.2 Wiring diagram of mechanical unit (S-420A)
3-10
6..3 Limit Switch Installation Diagram Fig. 6 . 3 shows the mechanical unit limit switch installation diagram.
WOT 1 imi t UOT 1 imi t
Fig. 6.3 Limit switch installation diagram (S-420A)
6.4 Mechanical Unit Cable Installation Diagram Fig. 6.4 shows the mechanical unit cable install.ation diagram.
Fig..6..4 Mechanical unit cable installation diagram (S-420A)
'7. REPLACING ELECTRIC CABLES Replace the cable every two years. When the cable is broken or damaged, replace it following the instructions in this chapter. Pay attention to the following two points. Otherwise, the current position is lost and remasrering is necessary. 1) Do not replace the pulse coder cables (K104 and K105) and the battery cables (K161, K107, K108 and K109) at the same time. 2) Replace the battery cables with the controller power turned on. Precautions on handling the battery cable The battery cable connector is given the marking tag shown below to prevent careless disconnection during transportation, installation or maintenance. If the connector with the marking tag is disconnected with the controller power off, mastering must be executed again.
BATTERY BACKUP
DISCONNECT
Marking tag
7.1 Clamping Cables Fig. 7.1 shows the cable clamp position. When replacing cables, clamp the cable at the position specified in Table 7.1, using a clamp or a tie wrap. Otherwise, cables can be loosened or forcedly pulled causing their disconnection.
Clamp position
Fig..7.1 Cable clamp position
3-12
Table 7..1 Cable clamp position
Ccb!e
clamp
Stamp
posiion
Clamp p a s
I t
Cable N o
ion
OM
K151
WM
K152
UM
K153
aM
Kl03
aBK BM BBK 7M 7 BK
WP
K104
UP 8P aP
K 105
BP 7P
aB
Kt09
BB 7B
UWOT K I I I
7.2 Replacing Cables Refer to Section 11-7.2. 7.3 Replacing Limit Switches 1 ) Replacing +axis limit switch Refer to Section 11-7.3.
2) Replacing W/U-axis limit switch @ Remove the W-axis base rear cover. 2 Remove the limit switch mounting plate. 3 Remove the limit switch from the plate, and replace the limit switch cable (K111) with a new one, @ Mount the new limit switch reversing the above procedures. @ Adjust the OT switch so that the limit switch step allowance will be about 3 mm.
8
Liit switch mounting plate WOT) Plate
I
Limit switch cable (K111)
connector
3) Replacing U/W-axis limit switch Refer to Section 11-7.3.
IV. CONNECTIONS
1.
GENERAL
This section describes the connections between the mechanical and electrical interfaces in the robot mechanical unit and control unit and instructions for installing the robot.
1.1 Block Diagram The block diagram of the robot connections is shown in Fig. 1.1.
I
Controuer
I
L
Pneumatic pressure source
unit (a)
Teach pendant (c)
t---i
I
Remote CRT/KB (d)
1 110 devices (e)
Computer (f)
t
Pulse encoder for line mcking (g) Input power source (h)
1 --- --
mechanical connection electrical connection
Fig. 1.1 Block diagram of the robot connection
1) Controller The controller interfaces electrically with the following devices: a) Robot mechanical unit b) Peripheral devices c) Teach pendant d) Remote CRT/KB e) 110 devices f) Computer g) Pulse encoder for line tracking h) Input power source 2) Mechanical unit a) End effecror This is a mechanical mounting face used for mounting the end effector of hand, etc, to the robor wrist, It also supplies pneumatic pressure and electrical signals for controlling the end effector. b) Installation holes There are holes in the base of the mechanical unit for mounting it to the floor or the wall. For details refer to V - 1.1.2 and 2.1.2.
2.. SAFETY PRECAU'TlONS 2.1 General Care should be taken t o p r o t e c t workers and machines ( r o b o t and p e r i p h e r a l d e v i c e s ) when o p e r a t i n g a system which combines t h e r o b o t w i t h p e r i p h e r a l devices. I t should b e noted t h a t t h e robot may move suddenly when i t r e c e i v e s a moti,on command s i g n a l . F i r s t ensure workers' s a f e t y and, then, s a f e o p e r a t i o n of t h e p e r i p h e r a l d e v i c e s and t h e robot. Fig. 2.1 shows t h e p r i o r i t y of s a f e t y measures. 3
Worker
Peripheral devices
Robot
Fig. 2.1 Priority of safety measures
2.2 Safety Precautions 1) Worker's s a f e t y Worker's s a f e t y must b e ensured d u r i n g t h e o p e r a t i o n of a machining c e l l , It i s v e r y dangerous t o e n t e r t h e o p e r a t i n g space of t h e r o b o t d u r i n g o p e r a t i o n of t h e system. I f i t i s necessary t o do t h i s , follow t h e p r o t e c t i v e measures given below, If i t i s necessary f o r any reason t o e n t e r t h e robot a r e a , s t o p t h e robot u s i n g t h e following procedures: I f power i s not r e q u i r e d , t u r n o f f t h e c o n t r o l u n i t power source. I f a i r pressure i s n o t r e q u i r e d , t u r n o f f t h e pneumatic system a i r p r e s s u r e . I f i t i s necessary t o i n s p e c t r o b o t motion, check i t , w h i l e monitoring t h e robot motion, and p l a c e t h e EMERGENCY STOP b u t t o n where i t can b e pressed quickly i f necessary. I f e n t r y i n t o t h e o p e r a t i n g space of t h e robot i s going t o be n e c e s s a r y , t a k e t h e following precautions: a ) Construct a p r o t e c t i v e fence around t h e system (Fig, 2.2 ( a ) ) , Provide a s a f e t y gate. Its o p e r a t i o n should be such t h a t no one can e n t e r t h e operating space without opening t h e g a t e .
.
Provide a limit switcll uhich operates \\hen the gate is opened
Fig. 2.2 (a) Protective fence
P r o v i d e a l i m i t s w i t c h which o p e r a t e s when t h e g a t e i s opened, and connect i t t o t h e power i n p u t u n i t a c c o r d i n g t o Fig, 2.2 (b), The c o n t a c t of t h e l i m i t s w i t c h shou1.d b e "ON" when t h e g a t e i s c l o s e d ; it should b e "OFF" when t h e g a t e i s opened. The r a t i n g o f t h e c o n t a c t should b e more t h a n 0.3 A a t 24 VDC,
/-
FNl 1
The contact is "ON" when the gate is ciosed..
I t
Power input unit
I
Fig. 2.2 (b) Connection of the gate limit switch
b) Mount a m a t s w i t c h o r p h o t o e l e c t r i c s w i t c h on t h e f l o o r t o i s s u e a n alarm by means of a b u z z e r , l i g h t , e t c , , i f a worker e n t e r s t h e o p e r a t i n g space. I f i t i s n e c e s s a r y , s t o p t h e r o b o t o p e r a t i o n u s i n g t h e same switch. c ) Mount a l i m i t s w i t c h w i t h a t a c t i l e b a r on t h e r o b o t t o s t o p i t i f i t comes i n c o n t a c t w i t h something. 2) Machine s a f e t y Take t h e f o l l o w i n g p r e c a u t i o n s t o p r e v e n t damage t o t h e p e r i p h e r a l d e v i c e s and t h e robot. a ) S e t t i n g t h e motion r a n g e I f t h e system s e r v i c e range is narrower t h a n t h e motion r a n g e of t h e r o b o t , t h e system v a r i a b l e s which c o n t r o l t h e motion range of t h e robot c a n be s e t from t h e CRT/KB s o t h a t t h e motion range of t h e r o b o t does n o t exceed t h e s e r v i c e range. b) Using r o b o t i n t e r l o c k s i g n a l s The r o b o t h a s s e v e r a l k i n d s of t e r m i n a l s f o r r e c e i v i n g e x t e r n a l i n t e r l o c k s i g n a l s . The r o b o t can b e h e l d o r stopped by t h e s e s i g n a l s . To u s e them, s e t up c o n t r o l c i r c u i t s on t h e p e r i p h e r a l d e v i c e s t h a t w i l l be a c t i v a t e d when t h e r e i s a p o s s i b i l i t y of damage t o t h e equipment. c ) Use a l i m i t s w i t c h w i t h a t a c t i l e b a r I n o r d e r t o p r e v e n t i n j u r y t o a worker o r damage t o t h e r o b o t , a l i m i t s w i t c h w i t h t a c t i l e b a r can be used.
3) The limit switch with a tactile bar When using a limit switch with a tactile bar, use one which provides a The rating circuit with normally closed contacts as shown in Fig. 2.2 (c). of the contact should be more than 4 A at 100 VAC.
NC3 NCI
Fig. 2.2 (c) ~ x a r n ~of l ea limit switch
The electrical. connection of limit switches with tactile bars is shown in Fig. 2.2 (d), Controller
Ll
LZ
Normally closed contacts
"::ZG\ EMGI Power input unit 0 INC
1
Normally closed contacts
Dl module in the 110 unit
oCOM
Fig. 2.2 (d) Example of connections
The normally closed contacts when several limit switches are used should be connected in series to the power input unit of the controller. The other normally closed contacts should be connected in series to the DI module in the 1/0 unit of the controller.
3.
CONTROLLER CONNECTIONS A N D SIGNALS
3.1 Connection Diagram Fig. 3.1 shows the connections of the controller with the exception of those between the controller and the mechanical unit. They are described in CONNECTIONS section 4.1.
Controller Modular I/Ounit or fured 110
*1
K57
Shared RAM board CNTP
Teach pendant
K70
Built-in operator's panel connection for CRTJKB Built-in operator's panel connector for RS-2324 -j Shared RAM board
CD4
]lf
Path CPU board
CAR
]D
Circuit breaker U,V,W,G 0
EON
Peripheral devices
'
*1
u
3
Computer
*1
*1
i
Note) Cables marked with *1 are provided by the customer.
Fig, 3.1 Connection diagram
3.1.1 Cable clamp
Cables led into this controller should be clamped by the method shown below. This cable clamp treatment is not only for cable support but also for shield-treatment. It is very important for the stable operation of this robot system that this be performed. Peel the sheath partially as shown below and expose the shield. Push the cable and clamp it by the cable clamp. The cable clamp is attached to the control unit. The ground board is prepared at the bottom of the cabinet.
Fig.. 3.1..1 Cable ciamp
3.2 Connections 3.2..1 lnput power connection
Cover
the cover after cabling. Fig. 32.1 (a) lnput power connection (Circuit breaker or circuit breaker with leak detector) Disconnect switch
Note) Mount t h e cover after cabling. Fig.. 3..2..1(b) lnput power connection (Disconnect switch)
3.2.2 Connection for external on-off control o f power supply
thlG
UC'J'I L?fG
-7
OUTC EMG Our? UP 1
OP? 'Ehll.
IS1 EMG INC
'y IN
A$?, ~
SYOS
100
OLT2 BXY1 tlKR1
BKM I BKPZ BhK2
mh12
M4 terminals
BRP3 B h R 3 FUSE. BKM3~~\11
ox OI:r
PI1 A1.M
COY FNf
FX2 FLTE
ALSI2/
0 Remove this shorting strip when the external power supply ON/OFF switch is used. Fig.
3.2.2 Power input unit TP1 terminal
On/Off Control by Alarm Circuitry To control power externally, a relay can be connected across the ALA and ALB terminals on the input unit PCB. Note that these terminals are not on the connector (TP1) but on the PCB itself. This should be a normally closed but held open switch. Shorting these two terminals together causes controller operating power to be lost. Recovery can be achieved by first pressing the OFF button on the controller.
Normally closed held open
1
Power input unit PCB ALA
3..2.3 Connection t o I /Odevices
When the controller is used with a built-in operator's panel, I/O devices which have RS-232-C interface can be connected to the connector provided on the built-in operator's panel.
Connollcr
25p D-subminiature connector (Female) i
Built-in operator's panel connector
RS-232C
110 devices (RS-232-C)
] I
i
Note) Pin 25 has +24 V for power supply to offline storage devices. It cannot be used for If0 devices,
Regarding the meaning of t h e signals, refer t o t h e figure shown below. 7
SD (send data)
RD (receive data)
---f
RS (request to send) RS-232-C interface
CS (clear to send)
Connect RS to CS when CS is not used -.---I
ER (data terminal ready)
---
DR (data set ready)
1 -- ,-J
7 when Connect ER DR DR is not used.
--7
--,-,
CD (carrier detect)
to
I
\
Connect ER to CD, ahvays
SG (signal ground)
\Connect to signal ground of 110 device FG (fiame ground)
Signals ON/OFF voltage levels are given in the following table. h
Less than Function Signal condition
-3
OFF Marking
V
More than +3 V ON Spacing
Cable connections between the controller and the 1/0 device should be as follows:
I
\
110 device
Cable: 20 s 0 18 mmz with unified shield
3..2..4 Connection to pulse encoder for line tracking
Fig. 3.2.4
Connection to pulse encoder for line tracking
/
1-
Path CPU board
CA2 (MRE-2OKMA) Pulse encoder inputs
(Male)
CA2
'
Pulse encoder for line tracking
Driver should be SN75 1I 3 (producr of TI) or equivalent
Consumption of +5V should be kss than 0 3A
Pulse encoder
\
8 pairs of'unifed shield cable (cable material: 0..3mm2 cable length should be less than 50 m.
Peel the sheath of cable and attach the cable t o the ground board of controller cabinet by means of the cable clamp metal fixture.
the
Pulse input signals Phase A and phase B signals are used for pulse input. between both signals should be 90 degrees,
1
Phase B
i
1
!
Phase A
I
The difference of phase
Normal rotation
I
Phase A
Phase B
Inverse rotation
Phase A, B and requirements,
r
reference detection signals shou1.d satisfy the following
r
Phase A
1
Reference detection td21~s
tpllO8u tw:more than tp
32.5 Controller and peripheral device connections The R-H controller has two 1/0 options for communication with peripheral devices
-- a fixed 1/0 board or a modular 1/0 system. The fixed 1/0 board is a single board system installed in the backplane. The modular 1/0 system hardware includes the I/O rack and 1/0 modules. Various types of modules can be added to the modular I/O. Modular Input/Output System The modular 1/0 structure provides a hardware interface to the 110 system. Signal lines are connected to the 110 modules, which reside in the controller 110 rack. Differing types of 1/0 modules can be used to connect various types of electrical signals, The 110 rack communi.cates 110 status information to the controller through an internal serial data link. The connections for the modular 110 system are shown in Fig, 3.2.5 (a), One I/O rack shown in Fig. 3.2.5 (b) , (c) , is provided with the KAREL modular I/O system. The 1/0 rack has a capacity of nine 1/0 modules. One slot on the 110 rack, Slot 0, is reserved for the robot control module, The remaining eight slots on the 110 rack are available for user-defined 110 modules,
I
110 base unit
I
Robot control module
p p qqc C&P4
I To shared RAM board To robot To power input unit
User 110 slots CNP3
CNC
Fig.. 3.25(a) Modular 1/0 structure
4-13
Fig. 32.5
(b) Location of modular I/O unit
The modular 110 system s u p p o r t s t h e following number of s i g n a l s :
- Number
of DI./DO A maximum of 64 u s e r d i g i t a l i n p u t s i g n a l s and 64 u s e r output s i g n a l s a r e available. These can b e used a s Group T.nputs/Outputs, Analog I n p u t s / Outputs, o r Hand S i g n a l s .
- Number
of group i n p u t s / o u t p u t s A maximum of f i v e group i n p u t s and f i v e group o u t p u t s a r e a v a i l a b l e .
-
Number of a n a l o g i n p u t s / o u t p u t s A maximum of f i v e analog i n p u t s and f i v e analog o u t p u t s a r e a v a i l a b l e .
-
Hand s i g n a l s A maximum of f o u r hand s i g n a l s a r e a v a i l a b l e .
-
Robot d e d i c a t e d 1 / 0 (RDI/RDO) The robot c o n t r o l module has e i g h t i n p u t l i n e s (RDIs) and e i g h t output l i n e s (RDOs) which a r e a v a i l a b l e a t t h e base of t h e robot. I n t h e S-420F/A f i v e R D I and RDO l i n e s a r e wired t o t h e w r i s t .
Fixed Lnput/Output System The f i x e d I / O system i s a s i n g l e 110 board which i s i n s t a l l e d i n t h e c o n t r o l l e r backplane. S i g n a l l i n e s a r e connected t o one of f o u r c o n n e c t o r s :
-
CN1: 50 p i n male, f o r a p p l . i c a t i o n D I / D O
-
CN2.: 20 p i n female, f o r a p p l i c a t i o n D I / D O o r UOP i n t e r f a c e i f t h e system has a user operator panel
-
CNB: 20 p i n male, f o r b r a k e c o n t r o l CNC: 34 p i n male, f o r RDI/RDO s i g n a l s and r o b o t s t a t u s s i g n a l s
(c), The connections f o r t h e f i x e d 1/0 system a r e shown i n Fig. 3.2.5 S i g n a l l i n e s a r e connected t o t h e a p p r o p r i a t e connector from t h i s board. f i x e d I / O board does n o t s u p p o r t a n a l o g i n p u t s o r outputs.
Backplane A20B-1002-0860
1-
CNA4 -
TOrobot
To power 0-- input unit
1
User 110
CNB
CN I
CNC
Fig..3..2..5(c)
Fixed 1/0structure
4- 15
(d). The
r - 3
r - a r-
. Fixed I/O board
Fig. 3.2.5 (d) ~ocation'of fixed I/O board
With no u s e r o p e r a t o r panel, capabilities:
-
t h e f i x e d 110 system h a s t h e following u s e r I / O
U s e r D I : 32 b i t t o t a l DC 24 V non-isolated r e c e i v e r ( i n t e r n a l l y p u l l e d up t o +24 V w i t h r e s i s t o r s ) Response t i m e of 20 ms. Three ground commons.
- User
DO: 24 b i t t o t a l Open c o l l e c t o r NPN t r a n s i s t o r , non-isolated d r i v e r 24 V 200 mA c u r r e n t s i n k . DC power o u t p u t n o t provided. S i x ground commons.
-
RDI/RDO Eight i n p u t s and e i g h t o u t p u t s a r e provided, l o c a t e d on connector CNC. Five R D I l i n e s The RDI and RDO l i n e s a r e wired t o t h e b a s e of t h e robot. and s i x RDO l i n e s a r e wired t o t h e w r i s t i n t h e S-420F/A robot.
A user o p e r a t o r p a n e l i n t h e robot system w i l l u s e e i g h t D I N S and e i g h t DOUTs.
Input/Output Signal Types User-defined signals are mapped in the User Signal Assignment Table (USAT), represented by the' system variable $USAT. You have access to user-defined signal types through the following predefined port arrays:
- DIN (digital input) - DOUT (digital output) - GIN (group input)
- GOUT - AOUT
(group output)
- AIN (analog input)
(analog output)
Each element of a port array corresponds to a user-defined signal, You also have access to a special set of robot hand control signals through the KAREL language HAND statements, rather than through port arrays. Discrete 110 (DIN and DOUT) The DIN and DOUT signal types are interpreted as one-bit ON/OFF signals in KAREL, The KAREL program has access to these signals as BOOLEAN values. You can define the polarity of the signals (in eight-bit groups) through $USAT as either active-high (ON when voltage i s applied) or active-low (ON when voltage is not applied). Either AC or DC 1/0 modules can be used for DIN and DOUT signals. GIN and GOUT Signal Types The GIN and GOUT signal types provide access to a group of input or output lines interpreted as an INTEGER in a KAREL program, A group can have a size of I to 16 bits, with each bit corresponding to an input or output line, and can start at any place within the 110 slot. If the group size is defined as less than 16 bits the unused bits are interpreted as binary zeros, Either AC or DC 110 modules can be used for GIN and GOUT signals, AIN and AOUT Signal.Types The AIN and AOUT signal types provide access to data in the form of an analog electrical signal. The analog data is digitized by the system and passed to the KAREL program as a 16 bit binary number, of which 12 bits or 8 bits are significant depending on the analog module. The program treats the data as an INTEGER data type, Table 3.2-5 (a) shows the correspondence between the actual signal voltage and the value assigned to the AIN or AOUT, These are available with the modular 1/0 system,
Table 3..2.5(a) Analog signal value/voltage r
110 module in 1/0 rack
AIN value Input volt. (12 significant bits)
AOUT value Output volt. (12 significant bits)
v
+2000
;(+20 mA)
+~1000
+2000
+10
+loo0
+5
0
0
v
(0 mA)
6
-1000
-5
v
(-20 mA)
-1000
-2000
-10
v
-2000
+10 +5
v
;(+20 mA)
. . 0v
(0 mA)
-5
v
(-20 mA)
-10
v
Either voltage or current range can be selected: -10 V +10 V (voltage input) -20 mA +20 mA (current input)
..,. ..,
HAND Signal Type The HAND signal type provides a KAREL program with access to two output lines that work in a coordinated manner to control the tool, The lines are designated as the open line and the close line, Either AC or DC digital output modules can be used for RAND signals. They can also be mapped as RDI/RDO signals. The system can support up to four HAND signals. The following KAREL language statements are provided for controlling the signal, where "n" is the signal number defined in $USAT:
OPEN HANDCnl CLOSE HAND[n] RELAX HANDCnl Four modes of operation, which allow you to control different types of tools, are available:
- Mode - Mode
0: Single Line Mode 1: Dual Line Mode .- Modes 2 and 3: Dual.Line Pulsed Modes
UOP Signal Type The user operator panel (UOP) is any user-supplied device that connects ro the UOP signals. UOP signals have functions resembling those of the operator panel buttons, switches, and indicator lights on the front of the controller cabinet. UOP signals also allow you to execute predefined command files from the UOP, UOP control signals connect indirectly via AC or DC I/O modules in the 1/0 rack UOP signals are distinguished from other system(or via the fixed 110 board). defined signal types by their mapping in $USAT, UOP signals are used primarily for system control and status reporting. The modular 110 system supports 32 UOP control signals. The fixed 110 board supports 16, Special consideration must be given to safety because the UOP can cause robot motion through its input signals. Thirty-two UOP control signals are connected through two 110 modules in the modular 110 system. Any type of digital 110 modules can be used, placed as you desire, in the I10 rack, For the fixed 110 system the 16 UOP signals are attached to connector CN2. UOP control signals must be mapped as such in the UOP input table and UOP output table of the USAT, For the modular 110 system, sixteen of the UOP control signals are input signals to the controll.er. The other 16 signals are outputs, All 16 input signals and 11 of the output signals are implemented in the current version of KAREL software. The remaining output signals are reserved by GMF for use in future software versions. Tables 3.2-5 (b) and 3.2.5 (c) list the UOP input and output control signals for the modular 110 system, Next to the signal name (in parentheses) is the name of the operator panel button, switch, or indicator light that has a function similar to the signal, (Refer to the KAREL operations manual for your controller model for information on operator panel functions.) Table 32.5 (b) Modular 110 UOP input control signals
Number 1
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
UOP name (Operator panel function) *ESTOP (EMERGENCY STOP button) *HOLD (HOLD button) RESET (FAULT RESET button) CALIB (CALIBRATE button) CSTRT (CYCLE START button) CSTOP (CYCLE STOP button) HOME (HOME button) MPROT (MEMORY PROTECT keyswitch) executes KCP UOP1,CF executes KCP-UOP~,CF executes KCP-UOP~ CF executes KCP-UOP~ CF executes KCP-UOPS CF executes KCP-UOPG CF executes KCP-UOP~ CF executes KCP-UOP~ CF
. . . . . .
I
Input signals 9 through 16 activate the command files that are indicated by name ir. Table 3.2.5 (b). Connection of these UOP input signals is shown in Fig. 3.2.5 (e).
Internal address
Input module
Peripheral device
Fig. 3..2.5(e) UOP input connections
The system v a r i a b l e SUDIN ENBL e n a b l e s t h e upper e i g h t b i t s of t h e UOP i n p u t I f i t i s FALSE, t h e upper e i g h t b i t s of t h e i n p u t module can be used module. f o r o t h e r user-defined i n p u t s i g n a l s . SUDIN ENBL must b e s e t t o TRUE i n o r d e r f o r t h e p r e d e f i n e d command p r o c e d u r e s t o be executed. Table 3.2.5 ( c ) Modular I/O UOP output control signals 1
Number
1 2 3 4 5
6 7
8
9 10 11 12 13 14 15 16
UOP name (Operator p a n e l f u n c t i o n ) CMDENBL SYSRDY PAUSED PROGRUN UNCAL LOCKED HELD FAULT TPEN UPENBL CSTOP reserved reserved reserved reserved reserved
-----
(UOP only motion c o n t r o l ) (SYSTEM READY l i g h t ) program paused) (UOP only program running) (UOP only (NOT CALIBRATED l i g h t ) (UOP only LOCK param ON) (ROBOT HE'LD l i g h t ) (ROBOT FAULT l i g h t ) (TEACH PENDANT ENABLED l i g h t ) (PANEL ENABLED l i g h t ) (CYCLE STOP l i g h t ) f o r future use f o r future use for future use f o r future use f o r future use
The system v a r i a b l e $FULL RMT'OUT e n a b l e s t b e u p p e r e i g h t b i t s of t h e UOP o u t p u t module. I f it i s FALSE,ihe upper e i g h t b i t s o f t h e o u t p u t module can b e used f o r o t h e r user-defined o u t p u t s i g n a l s . Connection of t h e s e UOP output s i g n a l s is shown i n Fig. 3.2.5 (f).
Output module
-PROGRUN
Reserved fbr
09 - 16 are not mounted on OD08C. Fig. 3.2.5 (f)
UOP output connections
For the fixed 1/0 system, eight of the UOP control signals are inputs, and ti:e other eight are outputs. The UOP signals are available on the CN2 connector on the fixed 1/0 board, Tables 3.2.5 (d) and 3 - 2 . 5 (e) list the COT iuput and output control signals for the fixed 110 system. Table 3.2.5 (d) Fixed 110 UOP input control signals r
UOP name (Operator panel function)
Number
*ESTOP *HOLD RESET CALIB CSTRT CSTOP HOME MPROT
1 2
3 4 5
6 7 8
Table 32.5
(EMERGENCY STOP button) (HOLD button) (FAULT RESET button) (CALIBRATE button) (CYCLE START button) (CYCLE STOP button) (HOME button) (MEMORY PROTECT keyswitch)
(el Fixed I10 UOP output control signals I
UOP name (Operator panel function)
Number I 9
L
3 4 5 6 7 8
CMDENBL (UOP only -- motion control) SYSRDY (SYSTEM READY light) PAUSED .(UOP only - program paused) PROGRUN (UOP only -- program running) UNCAL (NOT CALIBRATED 1i.ght) (UOP only LOCK param ON) LOCKED HELD (ROBOT HELD.light) FAULT (ROBOT FAULT light)
--
C
UOP Signal Interaction This section describes the interaction of UOP interface signals relative to each other and to the state of the controller, The timing diagrams are used for il.lustrative purposes only and do not represent the actual time difference between state changes. The diagrams represent steady-state mode input signals, Reaction to the input occurs after a new state has been maintained for 200 milliseconds. Input and output signals are distinguished in the diagrams by an (I) or (0) following the name. UOP Motion Control The following UOP control signals are capable of invoking commands or ccmazd procedures that cause motion: CALIB (CALIBRATE) CSTRT (CYCLE START) HOME KCP.-.UOPl through KCP-UOP8
As with any motion command, the device from which the command is issued must have motion control or the command is not executed. The UOP has motion control under the following conditions:
-
The following UOP output signals have the indicated values: FAULTY = OFF (No fault conditions exist.) SYSRDY = ON (The system is ready.) PROGRUN = OFF (No program is being executed,) TPEN = OFF (Teach pendant is not enabled.) UPENBL = ON (The UOP is enabled.)
- The
operator panel REMOTE keyswitch (on the controller cabinet) is set to
ON,
- The REMOTE parameter
must be set to UOP. REMOTE UOP command to accomplish this.
You can use the KCL>SET PARAM
The UOP must be programmed to check to ensure that it has motion control (CMDENBL = ON) before issuing motion commands, The controller does not respond to UOP motion commands while the UOP is not the motion control device. CLIB Signal. The CALIB signal invokes the calibration sequence. CAL1.B is a motion command; do not issue it unless the UOP output CMDENBL = ON (act5ve). When the execution of the calibration sequence is complete, the UOP output UNCAL is turned OFF. (See Fig. 3.2.5 (g),)
-
UNCAL (0)
0
.
Calibration complete - --
--
-
--
-
Fig. 3.2.5 (9) CALIB timing diagram
CSTRT Signal The effects of activating CSTRT depend on the controller state and the value of user-set system variables. In all cases, CSTRT causes the UOP outputs CSTOP, HELD, and PAUSED to turn OFF. (See Fig. 3.2.5 ( h ) . ) If CSTRT is invoked while execution of a KAREL program is paused (UOP output PAUSED is ON) program execution is resumed (and PAUSED turns OFF). In all other cases (PAUSED OFF when command issued), CSTRT executes a user-defined KCL command file, specified by the system variable $CYCLE-STRT. If a file has not been specified, no commands are executed. CSTRT is a motion command; do not issue it unless the UOP output CMDENBL is ON. Status of the UOP outputs can be affected by the commands issued by the KCL command file.
-- -.------- -1 --- . -
I
HELD (0)
Fig. 3.2.5 (h) CSTRT timing diagram
HOME Signal
If a file by The HOME signal executes the predefined command file KCP-HOME.CF. that name does not exist, the HOME button executes the KCL> MOVETO $HOME command using JOINT motion. The system variable $HOME stores a position that you can define to be the home position for the robot. A similar system variable, SAUXHOME stores an auxpos, which you can define as the home position for auxiliary axes. You can then create a command procedure, using the predefined name KCP-HOME.CF, to move both the robot and the auxiliary axes to their respective home positions. HOME is a motion command; do not issue it unless the UOP output CMDENBL is ON. *HOLD Signal The *HOLD signal pauses program execution and thus stops motion. *HOLD is ON when the voltage is zero. Activating *HOLD causes the UOP outputs HELD and PAUSED to turn ON, and PROGRUN to turn OFF. (See Fig, 3.2.5 (i) )
.
HELD ( 0 ) PAUSED ( 0 )
PROGRUN (0) (formerlyIN,-.CYCLE)
Fig, 3.2.5 ( i )
1 I
1
----
*HOLD timing diagram
You can clear the HOLD condition by issuing any motion command, but you can
clear the PAUSED condition only by executing a KAREL program (for example, by issuing the KCL> RUN or RESUME commands or pressing the CYCLE-START button.)
CSTOP S i g n a l The e f f e c t of a c t i v a t i n g t h e CSTOP s i g n a l depends on t h e s t a t u s o f t h e liOP o u t p u t UPENBL and t h e system v a r i a b l e $C STOP ENBL. In t h i s I f UOP o u t p u t UPENBL i s OFF t h e c o n t r o l T e r w i l l n o t respond t o CSTOP. c a s e CSTOP h a s no e f f e c t on c o n t r o l l e r operation. I f UPENBL i s ON, t h e CSTOP i n p u t s i g n a l s e t s t h e system v a r i a b l e $C STOP t o TRUE and t u r n s on t h e UOP (See Fig. 3.2.5 (j) .)o u t p u t s i g n a l CSTOP. I n a d d i t i o n , i f t h e system v a r i a b l e $C STOP ENBL is FALSE, t h e CSTOP i n p u t s i g n a l acts i d e n t i c a l l y t o t h e UOP i n p u t s i g n a l *HOLD, pausing a n e x e c u t i n g program and h o l d i n g motion. I f $C STOP ENBL i s TRUE, t h e CSTOP i n p u t s i g n a l does n o t pause t h e program automaticaEy. The KAREL language C STOP f u n c t i o n can b e used i n a program t o test t h e v a l u e of $C-STOP and pause a-program i f $C STOP i s TRUE.
-
t
If $C- STOP- ENBL is FALSE:
HELD (0)
---
t
---
PAUSED (0) 0
Fig. 3;2.5 (j)
CSTOP timing diagram
RESET S i g n a l The e f f e c t of t h e RESET i n p u t depends on t h e c u r r e n t s t a t u s of t h e c o n t r o l l e r I f a n e r r o r c o n d i t i o n e x i s t s (FAULT o u t p u t ON) and t h e cause of t h e e r r o r h a s If a n e r r o r c o n d i t i o n does n o t been removed, RESET r e s e t s t h e e r r o r c o n d i t i o n . e x i s t (FAULT o u t p u t OFF), RESET clears t h e message l i n e on t h e CRT/KB d i s p l a y (See F5g. 3.2.5 (k),)
I
With Error Condition in effect:
I z Z = FAULT (0)Z 3 3 { . RESET (I)
=
I
I ------ I
Z
=
=
------
SYSRDY (0)I
Fig., 3..2.5(k)
RESET timing diagram
3..2..6 Connection for emergency stop control
The connections described in this section are made at the power input unit, the location of which is shown in Fig. 3 . 2 . 6 . Safety Fence This input causes an emergency stop. This emergency stop differs from the ElviERGENCY STOP button on the operator panel only in the error message. This is a normally open contact held closed by a gate on a safety fence that should be connected across the terminals FN1 and FN2 on terminal TP1 on the power input unit PCB.
Tzm
Normally open held closed
Power input unit
External Emergency Stop Terminals EMGIN1, EMGI.NC, and DIGIN2 allow for connection o£ external emergency stops. Both place the robot in an emergency stop condition, however the status of the emergency stop output differs.
EMGIN 1 EMGINC
Power input ..it
EMGIN2
Note) Short when not used. Emergency Stop Outputs Emergency stops outputs are provided as shown in the following diagram. Controller Power input
1
EMGOUTI
I
EMGOUTC E,MGOUT2
When the emergency stop occurs in the controller or from an emergency stop from EMGINl - EMGINC, the contact between EMGOUTl and EMGOUTC will be open and the contact between EMGOUTC and EMGOUT2 will be shorted. The contact specifications are as follows. The minimum load is 5 VDC and 10 rnADC. The maximum voltage of the contact is 380 VAC or 125 VDC, The maximum current of the contact is 5 A. The controller also provides the interface of emergency stop inputs which do not affect the contacts of EMGOUT1, EMGOUTC, and EMGOUT2, They are called EMGINC and EMGIN2. When this contact is open, the robot is stopped by the emergency stop, but the contacts "EMGOUT1, EMGOUTC, and EMGOUT2" do not change, allowing the continued operation of the external equipment.
I
I
l
1
I
II
I
0
(rpi) \
EMG OLT1 EMG
OUTC
Externally furnished emergency stop button or limit switch..
EMG OLT2 OP1
.-
OPZ EYG IN I EMG 1NC EYG
Remove these jumpers when the external emergency stop function is used.
SYON loo OUT2 BKPl BKRl
BKMl BKP2 B I R 2 BKM? BKP3 BKRB SECu3 FUSE ! . ' L A I ON
Externally furnished gate switch
nL
OFF ALM COM
FH1 FNZ FLSE Am2
.. Remove this shorting strip when the gate switch for the protective fence is used.
0 I
3..2..7 Connection to computer
The RS-232-C controller.
interface is provided for the conneciion to the conputer in tho
RAM
Fig. 3.2.7
/
R*M board
Connection to computer
Regarding the meaning of the signals, refer to che figure shown below.
-4
SD (send data) R D (receive data)
---4
- - - 7 Connect RS to CS
RS (request to send)
KS-2 3 2-C interface
I when CS is not used
---A
ER (data terminal ready)
- -1I -- -J
-'
DR (data set ready)
d SG
Connect ER to DR when DR is not used
(signal ground)
\Connect to signal ground of' computer..
Note) +24 V cannot be used for computer. ON/OFF voltage levels are given in the following table.
Less than -3 V
More than +3 V
OFF
ON
Function
Spacing
Marking
Signal condition &
Cable connection between the controller and the computer should be as follows: Controller
Computer SDo
- *.
; .;
I
;
! I
DRO
t
f
! !
1
1
I
I I
I
I
I
I
<
- - - - - - - - - - - - - - - - -w
\
\ Cable: 20 x 0.J8 mm' with unified shield
Peel the sheath of cable and attach the cable ro the ground board of the controller cabinet by means of the cable clamp metal fixture.
3.2.8
Connection to remote CRTIKB
When the controller is used with the built-in operator's panel, the renote CRTfKB can be connected to the connector provided on ckle built-in operator's panel.
Operator's panel
Operator's panel CO;;";;~
15P I)-subminiature iernsle
7
CRT/KB
3.3 Setting USA7 The User S i g n a l Assignment Table (USAT), a mapping of t h e p h y s i c a l s i g n a l s t o t h e system s o f t w a r e , d e s c r i b e s t h e u s e r 1 / 0 hardware c o n f i g u r a t i o n t o t h e LlOP and HAND s i g n a l s a r e a l s o mapped i n t h e USAT. The t a b l e i s controller. s t o r e d i n the system v a r i a b l e $USAT, The USAT c o n s i s t s of n i n e b l o c k s of t a b l e s , one f o r each 1 / 0 s i g n a l type. Each b l o c k c o n t a i n s a t a b l e f o r each 1 / 0 s i g n a l of t h e corresponding type. These t a b l e s c o n t a i n m u l t i p l e b y t e s of d a t a t h a t d e s c r i b e d e t a i l s of t h e I/O hardware. The s t r u c t u r e of t h e b l o c k s and t h e t a b l e s w i t h i n each b l o c k vaxy w i t h t h e t y p e of 1 / 0 s i g n a l . (See Table 3 . 3 (a)) A f t e r you have s e l e c t e d t h e hardware c o n f i g u r a t i o n and 1/0 t y p e s , e n t e r t h e a p p r o p r i a t e d a t a i n t o t h e t a b l e , making i t a v a i l a b l e f o r u s e by t h e c o n t r o l l e r . I f you a r e not u s i n g t h e KAREL System Software U t i l i t y Package a v a i l a b l e from GMF, perform t h e f o l l o w i n g s t e p s f o r each e n t r y : I . Determine t h e a p p r o p r i a t e numbers f o r each of t h e d a t a f i e l d s .
2. Convert each number t o b i n a r y format u s i n g t h e number of b i n a r y b i t s s p e c i f i e d f o r t h e s i g n a l type. 3. Configure t h e d a t a i n t o t h e a p p r o p r i a t e e i g h t - b i t b i n a r y words.
4. Convert t h e b i n a r y words t o decimal format, $USAT is a system v a r i a b l e ARRAY w i t h each element mapping a group of 1/0 signals. To change $USAT ARRAY element number 9 t o a v a l u e of t h r e e , e n t e r KCL> SET VAR USA AT[^^= 3. (See Table 3 . 3 (a);) L i k e o t h e r system v a r i a b l e s , $USAT i s s t o r e d i n t h e f i l e SYS STANDARD.SV (through u s e of t h e KCL> SSAVE command). Each t i m e you power up t h F c o n t r o l l e r i t r e a d s t h e s e v a r i a b l e s and u s e s t h e d a t a from $USAT t o understand t h e 1/0 c o n f i g u r a t i o n you have s e l e c t e d .
Table 3..3(a) USAT structure
Element number [ n l
Table number
S i g n a l number Cnl
size i n bytes
D I N Tables USATCll USATC33 USATC.51 USATC 71
US AT^^^
USATC11I USAT[131 USAT[ 153
DIN DIN DIN DIN DIN DIN DIN DIN
f1 82 f.3 84 f5 f6
Table Table Table Table Table Table Table Tab1.e
87 f8
DINCl] DINC93 DINC171 D I N [25] DINC331 DINC411 DLNC493 DINC571
2 bytes 2 bytes 2 bytes 2 bytes 2 bytes 2 bytes 2 bytes 2 bytes
DOUT Tables DOUT DOUT DOUT DOUT DOUT DOUT DOUT DOUT
Table Table Table Table Table Table Table Table
2 2 2 2 2 2 2 2
f1 12 #3 #4 15
f6
87 f8
bytes bytes bytes bytes bytes bytes bytes bytes
G I N Tables G I N Table G I N Table G I N Table G I N Table G I N Table (unused)
#l 112 #3 1'14 f5
GINCl] GINC21
GINC31 GINC4I GINC.51
3 3 3 3
bytes bytes byres bytes 3 bytes
GOUT Tables GOUT Table GOUT Table GOUT Table GOUT Table GOUT Table (unused)
#1 #2 #3 #4 115
GOUT[ 11 GOUTC21
GOUTC~] GOUT [ 4 3 GOUTC.51
3 3 3 3 3
bytes bytes bytes bytes bytes
2 2 2 2 2
bytes bytes bytes bytes bytes
AIN Tables AIN AIN AIN AIN AIN
Table Table Table Table Table
%1 f2 1'13 #4
85
AINC 1I AINC2 j AINC 3 1 A I N C ~1 A I N [ ~1
Element number Cnl
size in bytes
S i g n a l number Cnl
Table number
AOUT T a b l e s AOUT AOUT AOUT AOUT AOUT
Table Table Table Table Table
AOUTC 11 AOUTC 21 AOUT C31 AOUTC41 AOUT [5 1
dl #2 #3 #4 115
2 2 2 2 2
bytes bytes bytes bytes bytes
UOP I n p u t Table I n p u t Table
1 byte
UOP I n p u t s UOP Output Table
Output Table
1 byte
UOP Outputs
HAM> S i g n a l Tables HAND Table # I
3 3 3 3
HANDL-11 IiANDL-23 HAND C31 - HANDC43
HAND Table #2 HAND Table #3 HAND Table #4
bytes bytes bytes bytes
D i g i t a l I n p u t and Output T a b l e s The two b l o c k s f o r d i g i t a l i n p u t and d i g i t a l o u t p u t e a c h c o n t a i n e i g h t t a b l e s (DIN Table 81 D I N Table $8 and DOUT Table f l DOUT Table P8 i n Table 3.3 ( a >1. Each t a b l e c o n s i s t s of two b y t e s f o r c o n f i g u r i n g t h e DINS and DOUTs and d e s c r i b e s e i g h t s i g n a l s , o r d e r e d by s i g n a l number (DIN T a b l e # l is f o r D I N C 1 1 DINC83, D I N Table f 2 i s f o r DINC93 DINE167, and s o on). For t h e modular 1 / 0 s y s t e m d a t a w i t h i n e a c h t a b l e d e f i n e s t h e l o c a t i o n of t h e I / O module f o r t h e a s s o c i a t e d s i g n a l s . For t h e f i x e d 1 / 0 system d a t a w i t h i n each t a b l e determines which s i g n a l s are a s s o c i a t e d w i t h t h e d e d i c a t e d 1 / 0 l i n e s on t h e ..fixed 1 / 0 board. Table 3 . 3 (b) shows t h e format of t h e d a t a i n t h e D I N and DOUT t a b l e s .
-
-
-
-
Table 3.3 (b) DINjDOUT table format
I
L--
Rack
(4 b i t s )
I
Base s i g n a l 1 ( 7 b i t s )
-
-
--
-
Slot # (4 b i t s ) Polarity (I b i t )
1
F i r s t byte Second b y t e
o Rack -- 1/0 r a c k number i n which t h e 1/0 module i s mounted, r a c k number must b e 1,
For f i x e d 1 / 0
o S l o t -- S l o t number (on t h e 1/0 r a c k ) i n which t h e I/o module is mounted. For f i x e d 110 s l o t number must b e 1.
o Base S i g n a l
--
-
Modular I/O: S i g n a l number on t h e I/O module t h a t c o r r e s p o n d s t o t h e f i r s t DIN or. DOUT i n t h e t a b l e (1 o r 9 f o r s t a n d a r d a p p l i c a t i o n s ) .
-
Fixed I/O: S i n c e t h e f i x e d 1/0 system h a s d e d i c a t e d 1/0 l i n e s and modules t h e b a s e s i g n a l does not have t h e same meaning a s f o r modular 110. Consider t h e f i x e d 1/0 card a s an i n p u t module w i t h s i g n a l s and a n o u t p u t module with 24 s i g n a l s . The numbering of s i g n a l s i s a s follows:
OUTPUTS
INPUTS S i g n a l name
Number
S i g n a l name
RDIl RDT2 RDI.3 RDI4 RDI5 RDI6 RDI7 RDI8
RDO1 RD02 RD03 RD04 RD05 RD06 RD07 RD08
UDIl UDI2 UDI3 UD14 UDI5 UDI6 UD17 UDI8 UDI9 UDIlO UDI11 UDI12 UDI13 UDI14 UDI15 UDI16 UDI.17 UDI18 UDI19 UDI20 UDI21 UDI22 UDI23 UDI24 UDI25 CD126 UDI27 UD128 UDI29 UDI30 L'D131 UDI32
UDOl UD02 UD03
UD04 UD0.5 UD06 UD07 UD08 UD09 UDOlO UDOl 1 UD012 UD013 UD014 UD015 UD016 UD017 UD018 UD019 UD020 UD021 UD022 UD023 UD024
Number
not the
32 the
The U D I / U D O number i s always 64 more t h a n t h e s i g n a l name. The numbers l i s t e d i n t h e t a b l e a r e v a l i d a s t h e b a s e s i g n a l number when s e t t i n g t h e USAT f o r t h e f i x e d 1 / 0 system. A s a n example, t o a s s i g n UDI9 - UDI16 t o be D I N C ~ -~ DINC83, t h e b a s e s i g n a l i n $USAT[21 would be 73.
-
P o l a r i t y -- The p o l a r i t y of t h e s i g n a l : 0 f o r a c t i v e h i g h (ON when v o l t a g e i s a p p l i e d ) , 1 f o r a c t i v e low (ON when v o l t a g e i s n o t a p p l i e d ) .
Group Input and Output T a b l e s The two b l o c k s f o r group i n p u t and group o u t p u t e a c h c o n t a i n f i v e t a b l e s ( G I N Table #1 - G I N Table #5 and GOUT Table #1 GOUT T a b l e it5 i n Table 3 . 3 ( a ) ) . Each t a b l e c o n s i s t s of t h r e e b y t e s f o r c o n f i g u r i n g t h e GINS and GOUTS and d e s c r i b e s one s i g n a l , o r d e r e d by s i g n a l number (GIN T a b l e # 1 i s f o r GINL'17, G I N Table 82 i s f o r GINC21, and s o on). Data w i t h i n each t a b l e defi.nes t h e l o c a t i o n of t h e 1 / 0 module f o r t h e a s s o c i a t e d s i g n a l . Table 3 . 3 ( c ) shows t h e forinat o f t h e d a t a i n t h e G I N and GOUT t a b l e s .
-
Table 3.3 (c) GINBOUT table format
Fir-st b y t e Base s i g n a l # (8 b i t s )
Second b y t e Third b y t e
o Rack -- 1 / 0 r a c k number i n which t h e 1 / 0 module i s mounted. r a c k number must b e 1.
For f i x e d 1 / 0
o S l o t -- S l o t number (on t h e I / O r a c k ) i n which t h e 1 / 0 module i s mounted. For f i x e d 1 / 0 s l o t number must b e 1. o Base S i g n a l
-
--
Modular I/O: S i g n a l number on t h e I f 0 module t h a t corresponds t o t h e f i r s t D I N o r DOUT i n t h e t a b l e ( 1 o r 9 f o r s t a n d a r d a p p l i c a t i o n s ) . Fixed I / O : S i n c e t h e f i x e d 1 / 0 system h a s d e d i c a t e d I / O l i n e s and not t h e b a s e s i g n a l d o e s n o t have t h e s a m e meaning as f o r t h e Consider t h e f i x e d 1/0 b o a r d as a n i n p u t module w i t h 32 modular I / O . s i g n a l s and a n o u t p u t module w i t h 24 s i g n a l s . The numbering of t h e s i g n a l s is a s follows:
. modules
INPUTS S i g n a l name RDI 1 RDI2 RD13 KDI4 RD15 WI6 RDT 7 RDI8
Number
1 2 3 4 5 6 7 8
Signal
OUTPUTS name
RDO 1 RD02 RD03 RD04 RD05 RD06 RD07 RD08
Number
INPUTS S i g n a l name
OUTPUTS Number
S i g n a l name
Number
UDO 1
UDI 1 UDI2
UD02
UDI3
UD03
UDI4
UD04 UDO5 UD06 UD07 UD08 UD09 uD010 UDO11 UD012 UD013 UD014 UD015 UD016 UDO17 UD018 UD019 UD020 UD021 UD022 UD023 UD024
UDI 5 IJDI6 UD17 UD18 UDI9 UDI10 UDIll UDI12 U D I 13 UDI14 UDI15 UDI16 UDI17 UD118 UDI19 UDI20 UDI21 UDI22 UDI23 UDI24 UDI25 UDI26 UDI27 UDI28 UDI29 UDI3O UDI31 UDI32
The numbers The UDI/UDO number i s always 64 more t h a n t h e s i g n a l name. l i s t e d i n t h e t a b l e a r e v a l i d a s t h e b a s e s i g n a l number when s e t t i n g t h e UDI16 t o USAT f o r t h e f i x e d 1/0 system. As a n example, t o a s s i g n UDI9 be DINClI - DINC81, t h e b a s e s i g n a l i n SUSATC21 would b e 73.
-
o Group S i z e -- Number of b i n a r y b i t s i n t h e group ( t h e number of connected t o t h e 110 module always w i t h i n t h e range of 1 t o 16).
--
lines
Analog I n p u t and Output T a b l e s Analog i n p u t s and o u t p u t s a r e a v a i l a b l e w i t h t h e modular 110 system. The two blocks f o r a n a l o g i n p u t and analog o u t p u t each c o n t a i n f i v e t a b l e s (AIN Table # i - A I N Table P5 and AOUT Table ill AOUT Table # 5 i n Table 3.3 ( a ) ) . Each t a b l e c o n s i s t s o f two b y t e s f o r c o n f i g u r i n g t h e A I N s and AOUTs and d e s c r i b e s one s i g n a l , o r d e r e d by s i g n a l number (AIN Table !I1 i s f o r AINC 11, AIK Table 92 i s f o r AINC23, and s o on). Data w i t h i n e a c h t a b l e d e f i n e s t h e l o c a t i o n of t h e 110 module f o r t h e a s s o c i a t e d s i g n a l . Table 3 . 3 (d) shows t h e format of t h e d a t a i n t h e A I N and AOUT t a b l e s -
-
Table 3.3 (dl AIN/AOUT table format
F i r s t byte Channel i/ (8 b i t s ) o Rack
--
Second byte
110 rack number i n which t h e 1 / 0 module i s mounted.
o S l o t -.- S l o t number (on t h e I / O rack) i n which t h e 110 module i.s mounted. o Channel -- D i g i t a l f h a l o g (or Analog/Digital) channel number on t h e I f 0 module which corresponds t o t h e A1.N o r AOUT f o r t h i s t a b l e . UOP Input and Output Table The UOP i n p u t and UOP o u t p u t each have one block c o n t a i n i n g a l l of t h e UOP i n p u t o r output s i g n a l s . Each t a b l e c o n s i s t s of one b y t e f o r configuring t h e UOP i n p u t s and outputs. No s i g n a l number i s r e q u i r e d f o r UOP s i g n a l s , Data w i t h i n each t a b l e d e f i n e s t h e l o c a t i o n of t h e 110 module f o r t h e - a s s o c i a t e d s i g n a l , Table 3.3 (e) shows t h e format of t h e d a t a i n t h e UOP t a b l k s . Table 3.3 (el UOP input/output table format
I
Rack # ( 4 b i t s )
S l o t # (4 b i t s )
F i r s t byte
--
o Rack 1 / 0 r a c k number i n which t h e 1 / 0 module i s mounted. rack number must b e 1.
For f i x e d 110
--
S l o t number (on t h e I f 0 rack) i n which t h e I f 0 module i s mounted. o Slot For f i x e d 1 / 0 s l o t number must be 1. Hand Control S i g n a l Tables
-
The one block f o r HAND c o n t r o l s i g n a l s c o n t a i n s f o u r t a b l e s (HAND Table $1 HAND Table #4 i n Table 3.3 ( a ) ) . Each t a b l e c o n s i s t s of t h r e e b y t e s f o r configuring t h e HAND c o n t r o l s i g n a l s and d e s c r i b e s one s i g n a l , ordered by s i g n a l number (HAND Table # l i s f o r KANI>Cl], HAND Table !I2 is f o r HANDC23, and so on). Data w i t h i n each t a b l e d e f i n e s t h e l o c a t i o n of t h e output module (or t h e number of t h e f i x e d I f 0 s i g n a l ) f o r t h e a s s o c i a t e d s i g n a l and t h e mode of o p e r a t i o n f o r the s i g n a l l i n e s . Table 3 . 3 ( f ) shows t h e format of t h e d a t a i n t h e HAND tables. Table 3.3 (f) HAND signal table format
I
Operation mode # (8 b i t s ) Rack # ( 4 b i t s )
S l o t # (4 b i t s )
Open l i n e F (8 b i t s )
(
F i r s t byte Second b y t e Third byte
o Operation Mode
--
Operation mode number is defined as follows:
- Mode 0 : Single line mode - Mode 1: Dual line mode .- Mode 2 : Dual line pulsed mode, 200 msec pulses - Mode 3: Dual line pulsed mode, 400 msec pulses (Refer to the KAREL System Reference Manual for a detailed description of each mode,) o Rack .-- 110 rack number in which the output module is mounted. 110 rack number must be 1.
For fixed
o Slot -- Slot number (on the I/O rack) in which the output module i.s mounted. For fixed I/O slot number must be I , o Open Line -- Signal number that corresponds to the open line. signal is the close line.
The next
Setting Unassigned Signals Unused I/O signals should be left unassigned in the USAT. Use a value of zero for the rack and slot numbers in the corresponding assignment table.
3..41/0 Module Specifications
Fig. 3.4 (a) Typical output module
Various 1/0 modules are prepared to connect with peripheral devices. DI/DO modules are mounted in slot No. 1, 2, 3, 4, 5, 6, 7, 8 or 9 in 1/0 unit. For For analog the types of DI/DO modules, refer to Tables 3.4 (a) through (d). input/output modules, refer to Tables 3.4 (h) through (i). For noise suppressors, refer to Sec. 4.2.4. Table 3.4 (a) Variety of Dl modules
---
* Module Rated voltage name
Input current
Response time
-
Lou level High level Number of '"Put input inputs (=ax) (mid
ID16C
24 VDC
9 mA
20 ms
8 V
15 V
16
ID08C
24 VDC
9 mA
20 ms
8V
15 V
8
External LED connection display terminal block (H3) ditto
Number o f
commons
YES
NO
YES
NO
4
2 I
ID16D
24 VDC
9 mA
2 ms
8 V
15 V
16
ditto
YES
NO
4
IDO8D
24 VDC
9 mA
2 ms
8 V
15 V
8
ditto
YES
NO
2
IA16E
120 VAC
9 mA
50 ms
20 VAC
70 VAC
16
ditto
YES
NO
50 m s
20 VAC
70 VAC
8
ditto
YES
NO
--
m0
9 mA
vAc
For the connections diagram see Fig. 3.4 (b), (c). Fig. 3.4 (b): ID16C, ID08C, ID16D, ID08D. Fig. 3.4 (c) : IA16E, IA08E. For the specifications, refer to Table 3.4 (b), (c). Table 3.4 (b): DC input specifications ID16C, ID08C, ID16D, ID08D. Table 3.4 ( c ) : AC input specifications IA16E, IA08E.
4
---
2
1ntc:nsl
lddros o f m < d u l cear
lerrzurt~ll o r M.) scrcus
09
Fig. 3..4 (b)
.-
16 are not saountcd on
ID08C.08D
Dl module lD16C,ID08C,1016D,10080
Table 3..4 (b) DC input specifications
---
I
Module
ID08C
l - 2 ,
Item
Point s/module
--
-
16
16
---
30 VDC
--
--
ON
15 V o r more
OFF
8 V o r less
ON
4.5 aA o r more
-
2 mA o r less
Input c u r r e n t
9 mA t y p i c a l (24 VDC)
I n p u t impedance
2.5 kQ approx. OFF
--ON
-
--
OFF
Response time (Note 2)
8
24 VDC
Maximum i n p u t v o l t a g e
Operation c u r r e n t (Note 1)
ID 16D
ID08D
8
Rated i n p u t v o l t a g e
Operation v o l t a g e (Note 1)
I D 16C
-t
-t
ON
OFF
20 m s max.
2 m s max.
20 ms max.
2 m s max.
i
Operation d i s p l a y
LED l i g h t s when i n p u t i s ON
E x t e r n a l connection method
Terminal board connection (M3)
Common p o i n t s (Note 3)
1 common per 4 p o i n t s i n p u t
Dielectric strength
1 minute under 1000 VAC
Note 1) When t h e v o l t a g e between t h e i n p u t terminal and common t e r m i n a l i s 15 V o r more, o r when t h e c u r r e n t flowing i n t o t h e i n p u t terminal is 4.5 mA o r more, t h e i n p u t s i g n a l ( c o n t a c t p o i n t ) i s regarded a s ON. When t h e i n p u t t e r m i n a l v o l t a g e i s 8 V o r less, o r when t h e i n p u t c u r r e n t is 2 mA o r l e s s , t h e i n p u t s i g n a l ( c o n t a c t p o i n t ) i s regarded a s OFF. When u s i n g proximity switches o r p h o t o - e l e c t r i c switches, be c a r e f u l of c u r r e n t leakage when the c o n t a c t p o i n t i s o f f . I f t h e c u r r e n t leakage i s 2 mA o r more, i t w i l l not be regarded a s OFF, Note 2) The response t i m e shown h e r e i s t h e delay time from module input t o o u t p u t . The a c t u a l response t i m e i s t h i s v a l u e p l u s t h e scanning time which i s d i f f e r e n t f o r each system c o n f i g u r a t i o n . Note 3) The commons a r e n o t connected t o each o t h e r i n t h e module.
Inrern~l~ddrcS2 rntrdute u r d
,tf
09
- 16 are not mounted on iA08E.
Fig. 3.4 (c)
Dl module 1A16E, iA08E
Table 3.4 (c) AC input specifications
-Item
\
Module
---___--
IA08E
IA16E
8
Points/module
-
120 VAC, 50/60 Hz
Rated i n p u t v o l t a g e
100
Maximum i n p u t v o l t a g e
140 VDC
Operation v o l t a g e (Note 1)
Operation c u r r e n t (Note 1)
16
-
ON
70 V o r more
OFF
20 V o r l e s s
ON
5 mA o r more
OFF
2 mA. o r l e s s
-
Input c u r r e n t
9 mA type (100 VAC)
I n p u t impedance
Approx. 12.5 kQ
Response t i m e (Note 2)
OFF -+ ON
50 m s max.
OFF
50 m s max.
ON
-+
Common p o i n t s (Note 3)
Dielectric s t r e n g t h
-
LED l i g h t s when i n p u t i s ON
Operation d i s p l a y E x t e r n a l connection method
.-
-
Terminal board (M3)
1 common p e r 4 p o i n t s i n p u t
I 1 minute
under 1000 VAC
I
Note 1) When t h e v o l t a g e a t t h e i n p u t t e r m i n a l i s 70 V o r more, o r when t h e c u r r e n t flowing i.nto t h e i n p u t terminal i s 5 mA o r more, t h e i n p u t When t h e i n p u t t e r m i n a l s i g n a l ( c o n t a c t p o i n t ) i s regarded a s ON. - v o l t a g e i s 20 V o r less, or. when t h e i n p u t c u r r e n t i s 2 mA o r less, t h e i n p u t s i g n a l ( c o n t a c t p o i n t ) i s regarded as OFF. When u s i n g proximity switches o r p h o t o - e l e c t r i c switches, be c a r e f u l of c u r r e n t l e a k a g e when t h e c o n t a c t p o i n t is o f f , I f t h e c u r r e n t leakage i s 2 mA o r more, i t w i l l n o t be regarded a s OFF. Note 2) The response t i m e i s t h e delay time from module i n p u t t o o u t p u t . The a c t u a l time is t h i s value p l u s t h e scanning time which i s d i f f e r e n t f o r each system c o n f i g u r a t i o n . Note 3) The commons a r e not connected t o each o t h e r i n t h e module.
Table 3..4 (d) Variety of DO modules
OFF s t a t e
Rated current
Module name
Rated voltage
OD168
26-48 VDC
0.5
OD08B
21-48 VDC
0.5 A
2 A
4 A
OD16C
26-48 VDC
2 A
4 A
16A
24-48 VDC
2 A
I20 VAC
1.6 A
120 VAC
1.6 A
260 VAC
1.6 A
240 VAC
1.6 A
24-48 VDC
2 A
0D08C OA16D
OA08D
OAI6E
OA08E
ODl6H
ON s t a t e
leak current
bch A
0 1 mA
8 A
2 A
drop
Numln-r o f outputs
1 0 V
I6
E x t e r t ~ ~ l i FI) conlrectlon d i s p l a y terrnittal hlock 043)
YbS
Fuse
YES
Number o f commons 1
i Remarks LK sink output
0.1 mA
1 0 V
8
ditto
YES
YES
2
ditto
0.5aA
l..OV
16
ditto
YES
YES
4
ditto
0.5mA
1.0V
8
ditto
YES
YES
2
ditto
16
ditto
YES
YFS
4
ditto
YES
YES
2
YES
YES
6
YES , YES
2
4 A
8 A
-----
3.2
A
12.8 A
1.5 mA
1.5 V
3.2
A
6.4
A
1.5
mA
1.5 V
8
3.2
A
12.8 A
3 mA
1.5 V
16
ditto
---3.2 A
6.4 A
3 mA
1.5 V
8
ditto
4 A
16A
0.5mA
1.OV
16
ditto
YES
YES
4
DC source output
8
ditto
VM:
For the connections di.agrams see Fig, 3 . 4 (d) - ( h ) . Fig. 3 . 4 (d): OD16B, OD08B. Fig. 3 . 4 (e): OD16C, OD08C. Fig. 3 . 4 (f): OA16D, OA08D. Fig. 3 . 4 (g): OA16E, OA08E. Fig. 3 . 4 (h) : OD16H, OD08H. For the specifications, refer to Table 3 . 4 (e) - (i). Table 3 . 4 (e): DC output specifications OD16B, OD08B. Table 3 . 4 (f): DC output specifications OD16C, OD08C. Table 3 . 4 (g): AC output specifications OA16D, OA08D. Table 3 . 4 (h): AC output specifications OA16E, OA08E. Table 3 . 4 (i): DC output specifications OD16H, OD08H.
YES
-
YES
2
ditto
t
-
09
-
16 arc not s~~onrrtcd OII ODOXH
Fig. 3.4 (d)
DO module OD16B. OD086
24-48 VDC Power Source
Table 3.4 (el
------_
-Cq-
-
Item
-
DC output specifications
Module
01) 16B
ODO8B
----
16
8
Pointsjmodule
-
48 VDC
Rated input voltage
24
Output voltage range
50 VDC or less (Note 1)
-
Max. output current
Per output
0.5
Per common
2 A
Total
4 A
A
8 A
-
Surge-on current Output voltage drop at ON
1 V max. (Note 6)
Current leakage at OFF
0.1 mA max.
Response time (Note 2)
--.
-
ON
0.3 ms max. (resistance load)
ON + OFF
0.3 ms max. (resistance load)
OFF
-+
Operation display
LED lights when output is ON
External connection method
Terminal board (M3)
Common points (Note 3)
1 common per 4 points input
Fuse (Note 4)
3.2 A/common 7
Polarity Dielectric strength
Exists (the common is the
"-"
side)
1 minute under 1000 VAC
Note 1) Thexe is no lower limit in output voltage for the output operation, but the operation display LED of the modules with operation display will dim if the output voltage is 24 VDC or less. Note 2) Response time shown here is the delay time from module input to output. The actual response time is this value plus the scanning time which is different for each system configuration. Note 3) The commons are mutually connected to the modules, but the load current cannot be sent in the internal pattern. The common must: a i m i y s be connected to the minus side ( 0 V) of the load current. Note 4) Fuses are inserted in each common. The red LED at the bottom of the module front will light if any of the fuses break.
Note 5 ) When c o n n e c t i n g i n d u c t i v e l o a d s ( l i k e r e l a y s ) t o t h e o u t p u t , a l w a y s When c o n n e c t i n g a lamp l o a d , i n s e r t connect a diode a c r o s s t h e load. dimmer r e s i s t o r s a c r o s s che o u t p u t t e r m i n a l s t o d e c r e a s e c u r r e n t f l o w t o within the standard l i m i t . Note 6) Output v o l t a g e d r o p a t ON depends o n t h e l o a d c u r r e n t and i.s e x p r e s s e d as f a l l o ~ ~ sVsat : = 2 x I 2 ( V s a t : O u t p u t v o l t a t g e d r o p , IL: l o a d c u r r e n t )
13 14
15 16
09
-.
24-48 VDC Power Sourc
16 arc not ~nountcdo n 0L)OdC.
--
Fig. 3..4 (e)
DO module OD16C. OD08C
Table 3..4 (f) DC output specifications
Modu 1e
---.\-
Item
ODO8C
\-
Point~/module
8
--
Rated input voltage
-
--
-
24
16
- 48 VDC
50 VDC or less (Note 1)
Output voltage range
Max. output current
OD 16C
Per output
2A
Per common
4 A (Note 5)
Total
8A
--
16 A
-
Surge-on current
--
Output voltage drop at ON
1.0 V max. (Note 7)
Current leakage at OFF
0.5 mA max.
Response time (Note 2)
OFF
-t
ON + OFF
---
n . L *s max. (resistance load)
0.4 ms max. (resistance load) LED lights when output is ON
Operation display External connection method
-
Terminal board connectors (M3)
Common points (Note 3)
1 common per 4 points output
Fuse (Note 4)
3 . 2 A x 2/common
Polarity
Exists (the common is the
Dielectric strength
-
"-.If
side)
1 minute under 1000 VAC
Kote 1) There is no lower limit in output voltage for the output operation, but the operation display LED will dim if the output voltage is 24 VDC or less. Note 2) Response time shown here is the delay time from module input to output. The actual response time is this value plus the scanning time which is different for each system configuration. Note 3) The commons are mutually connected to the modules, but the load current cannot be sent in the internal pattern. The common must always be connected to the minus side (0 V) of the load current. Note 4) A fuse is inserted between the following two points of outputs. (00,01) (02,03) (04,051 (06,071 (10,ll) (12,131 (14,151 (16,17) Xote 5 ) The output current is limited to 2 A per fuse (group of two pincs).
Note 6) When connecting inductive loads (like relays) to the output, always connect a diode across the load. When connecting a lamp load, insert dimmer resistors across the output terminals to decrease current flow to within the standard limit. Note 7) Output voltage drop at ON depends on the load current and is expressed as follows: Vsat = 2 x IR (Vsat: Output voltatge drop, 12: load current).
V
-
09 16 are not mounted on OA08E.. Fig. 3.4 (f)
100 - 120 VAC,+lo%, -15%
DO module OAl6D,0A08D
Table 3..4(g) AC output specifications ('100 VAC t y p e )
Module
-
I OA08D
P o i n t s /module
8 outputs
Rated i n p u t v o l t a g e
100
1
I Output v01,tage range Max. o u t p u t c u r r e n t
I Surge-on
16 o u t p u t s
120 VAC, 50160 Hz ---
85
-
132 VAC
Per o u t p u t
1.6 A
Per common
3.2 A (Note 5)
-
r
-
OA16D
Total
-
1 1
current
-
6.4 A
-
1
12.8A
10 A ( 1 c y c l e ) (Note 6)
1
Output v o l t a g e drop a t ON
1.5 V max. (peak)
Current l e a k a g e a t OFF
1.5 mA max.
Response time (Note 1)
OFF + nN ON
1
-t
0.2 m s max.
-
1/2 m s max.
OFF
Operation d i s p l a y
/
E x t e r n a l c o n n e c t i o n system
I Terminal board
No. of common p o i n t s (Note 2)
I
LED l i g h t s when o u t p u t i s t u r n e d
- -
c o n n e c t o r s (M3)
-
1 common14 o u t p u t s
Fuse (Note 3)
6 . 3 A/common
Polarity
None
Dielectric strength
1 minute under 1500 VAC
Note 1) The r e s p o n s e time shows a d e l a y t i m e from an i n p u t t o an o u t p u t of t h e module. Actual response t i m e i s o b t a i n e d by adding t h e scan time determined by t h e system c o n f i g u r a t i o n t o t h e v a l u e shown i n t h e above table. Note 2) The common l i n e s a r e i n t e r c o n n e c t e d i n s i d e t h e module. However, no load c u r r e n t i s a p p l i c a b l e t o i n t e r n a l p a t t e r n s . Always connect each conxon t o or?e end of t h e l o a d power supp1.y. Note 3) A f u s e i.s i n s e r t e d i n every common l i n e . I f one of t h e s e f u s e s i s blown t h e r e d LED l i g h t s a t t h e bottom p a r t of t h e f r o n t p a n e l of t h e module. Note 4) Mount a s u r g e s u p p r e s s o r a c r o s s t h e l o a d i f an i n d u c t i v e load l i k e a r e l a y i s connected t o t h e o u t p u t . When connecting a lamp load i n s e r t a dimmer r e s i s t o r a c r o s s outpue t e r m i n a l s t o reduce t h e rush c u r r e n t . Use t h e lamp load w i t h i n t h e s p e c i f i e d v a l u e .
I I
Note 5) I n a d d i t i o n t o t h e above l i m i t a t i o n , t h e output c u r r e n t i s l i m i t e d t o 1.6 A f o r every 2-output group shown below. (00.01) (02,03) (04,OS) (06,07) . i l 0 ; 11) (12,1,3) (14,151 (16,1'7) For example, no load c u r r e n t can b e f e d t o o u t p u t "Ol", w h i l e a 1.6 A load c u r r e n t i s b e i n g f e d t o o u t p u t "00". Note 6) Surge-on c u r r e n t means t h e maximum s u r g e c u r r e n t which can b e s e n t t o one fuse. When two l o a d s o r more a r e ON s i m u l t a n e o u s l y , t h e t o t a l v a l u e of t h e surge c u r r e n t which i s set t o one f u s e must b e w i t h i n t h e above <
lue
.
-
,
Internal address of module card
M3 ~crminal
200 - 240 V.AC, +lo%,..1.5%
-
09 16 Ire not
---
Fig.. 3.4 (g)
'DOmodule OA16E. OA08E
Item
'Table 3..4 (h)
--
AC output specifications (200 VAC type) I
?lodule
-
--.
P o i n t s /module
OA16E
8
--
Rated i n p u t v o l t a g e
200
-
Output v o l t a g e r a n g e
160
- 264 VAC
Max. o u t p u t c u r r e n t
16
240 VAC, 50/60 Hz
Per output
1.6 A
P e r common
3.2 A (Note 5 )
Total
6.4 A
12.8 A
Surge-on c u r r e n t
10 A ( 1 c y c l e ) (Note 6)
Output v o l t a g e d r o p a t ON
1.5 V max. (peak)
Leak c u r r e n t a t OFF
3 mA max.
Response t i m e (Note 1)
-
O F F + ON
ON
I
OA08E
+
OFF
0.2 m s max.
1 / 2 c y c l e max.
Operation d i s p l a y
LED l i g h t s when o u t p u t i s t u r n e d on
E x t e r n a l c o n n e c t i o n system
Terminal b o a r d c o n n e c t o r s (M3)
No. of common o u t p u t s (Note 2)
1 comrnon/4 o u t p u t s
Fuse (Note 3)
3.2 A x 2 pcs/common
Polarity
None
Dielectric strength
1 minute under 1500 VAC
-
Note 1) The r e s p o n s e time shows a d e l a y t i m e from a n i n p u t t o a n o u t p u t of t h e module, A c t u a l r e s p o n s e time i s o b t a i n e d by adding t h e s c a n t i m e determined by t h e system c o n f i g u r a t i o n t o t h e v a l u e shown i n t h e above table. Note 2) The common l i n e s a r e i n t e r c o n n e c t e d i n s i d e t h e module. However, no l o a d current is applicable t o internal patterns, Always connect each common t o one end o f t h e l o a d power supply. Note 3) Two f u s e s are i n s e r t e d i n every common l i n e . One r e d LED i s mounted f o r every two f u s e s . A c o r r e s p o n d i n g LED l i g h t s , i f a f u s e i s blown. Note 4) Mount a s u r g e s u p p r e s s o r a c r o s s t h e l o a d , i f a n i n d u c t i v e load Like a r e l a y i s connected t o t h e o u t p - ~ t . When c o n n e c t i n g a lamp load i n s e r t a dimmer r e s i s t o r a c r o s s o u t p u t t e r m i n a l s t o reduce t h e r u s h c u r r e n t . Use the lamp l o a d w i t h i n t h e s p e c i f i e d v a l u e .
Note 5 ) I n a d d i t i o n t o t h e above limitation, t h e o u t p u t c u r r e n c is l i m i t e d t o 1 - 6 A f o r e v e r y 2-output g r o u p shown below, (00,Ol) (02,03) (04,05) (06,07) ( 1 0 , l L) (12,13) (14,15) (16,17) For example, no l o a d c u r r e n t c a n b e f e d t o o u t p u t " O l " , w h i l e a 1.6 A l o a d c u r r e n t i s b e i n g f e d t o o u t p u t "00". Note 6) Surge-on c u r r e n t means t h e maximum s u r g e c u r r e n t which c a n b e s e n t t o o n e f u s e . When two l o a d s or more are ON s i m u l t a n e o u s l y , t h e t o t a l v a l u e o f t h e s u r g e c u r r e n t which i s s e n t t o o n e f u s e must b e w i t h i n t h e above lue
.
24-48 VDC Power S o u r c e
24-48 VDC Power S o u r c e
Fig.. 3..4 (h) 00 module 0076H. OD08H
-
Table 3.4 ti) DC output specifications
Item Points/module Rated input voltage Output voltage range Max. output current
Module
Suf ge-on
current Output voltage drop at ON Current leakage at OFF Response time (Note 2)
OFF ON
Operation display External connection method Common points (Note 3) Fuse (Note 4) Polarity Dielectric strength
8
1 / Per output Per common Total
ON OFF
+
-t
OD16H
OD08H
-
24 - 48 VDC 50 VDC or less (Note 1) 12 A 4 A (Note 5) 8A I 16 A
16
--
1.0 0.5 0.4 0.4
V m a ~ . (Note -7) mA max.
ms max. (resistance load) ms max. (resistance load) LED lights when output is ON Terminal board connectors (M3) 1 common per 4 points output 3.2 A x 2lcommon Exists (the common is the If-" side) 1 minute under 1000.VAC
Note 1) There is no lower limit in output voltage for the output operation, but the operation display LED will dim if the output voltage i.s 24 VDC or less. Note 2) The response time shown here is the delay time from module input to output. The actual response time is this value plus the scanning time which is different for each system configuration. Note 3) The commons are not connected to each other in the module. Each common must always be connected to the minus side (0 V) of the load current. Note 4) A fuse is inserted between the following two points of outputs. (00,Ol) (02,03) (04,05) (06,07) (10,ll) (12,131 (14,151 (16,171 The red LED at the bottom of the module fronr will light if any of the fuses break. Note 5) The output current is limited to 2 A per fuse (group of two points). Note 6) When connecting inductive Loads (like relays) to the output, always connect a di.ode across the load. When connecting a lamp load, insert dimmer resistors across the output terminals to decrease current flow to within the standard limit. Note 7) Output voltage drop at ON depends on the load current and is expressed as follows: Vsat = 0.5 x IR (Vsat: Output voltage drop, 12: Load current)
Table 3..4 (j)
Analog input module
Piax
Module name ADO4A
Input points 4 points/ module
Resolution
Analog i n p u t s -10 - +10 VDC (Input r e s i s t o r 1 Ma) -20 - +20 IOADC (Input r e s i s t o r 250 52) can be selected.
Note I : Shielded twist pair cables (2 cores) are required as the conyctlng a b l e The shield o f the ~ b k should be connected to thc g o u n d board of the controller b> nlwns of the o b l c cbmp
5mV 20 PA
Accuracy
+0.5%or less
input voltage/ current
External connection
t15V +40 mA
Termina 1 block (M3)
VP1
I Fig., 3..4 (i)
Analog input module connection
Table 3..4(k) Analog ourput module
--Module name
--
DA02A
Output points
Analog o u t p u t s
2 points/ module
-10 - +10 VDC (External load r e s i s t a n c e more t h a n
Resolution overall accuracy
--
5 mV w i t h i n 1 20 PA 0.5%
Isolated
,,
1
Not isolateti
1 KQ)
0 - +20 mA DC (External load r e s i s t a n c e 0 - 500 9) can be selected. DAOZA
Current output
converter
1 -
ZL
-- - - - - - ---.
soon
or krc
T
L -,--
10 b a d impcdana
5 soon
11
)
b
Note 1: A 2-pair shielded wble must be used as connection a b l e The shield must be connected to ground at the load side
Fig 3..4(j) Analog output module connection
txternal ;on n e s t i o n
Terminal board (113)
3..5 Fixed 1/0 Board Specifications Table 3.5 (a) Fixed I/O board - input
VALUE/DESCRIPTION
FEATURE/CAPABILITY
Digital Input Signal Standards
t
Type Rated Input Voltage
Grounding type voltage receiver
+20 to 28 VDC (logic 1 "closed") 0 to +4 VDC (logic 0 "open")
--
I
Maximum Input Voltage
-
+28 VDC
-
Input Impedance
About 3.3 kSZ
Response Time
5 to 20 ms
-
Attachment Side Contact Standards
-
Rated Contact Capacity
30 VIIC, 16A or over
Input Signal Width
More than 200 ms (ON and OFF)
-
Shorter than 5 ms
Chattering Time Closed Circuit Resistance -
-
-
--
Lower than 100 kQ
-
Open Circuit Resistance [Robot side3
Higher than 100 kQ 1Robot side] +24
3..3KT2
I
Level conversion drcuit (Signal)
Level conversion circuit
For UDI
k'
(Signal)
b-f-----b-t-----;t71
Robot reccivcr ourput signal (Chattcrins: L.css th2n Sms) Pcripheral dcviccs con tact signal
Table 3..5(b) Fixed 110 board - output
VALUE/DESCRIPTION
FEATURE/CAPABILITY
-
Rated Voltage
-
-
24 VDC
Maximum Applied Voltage
30 VDC
Maximum Load Current
0.2 A
Transistor Type
NPN
Output Pulse Width
200 ms +8 ms
Saturation Voltage at Turn-On Time
About 1.0 V
--
--
---
-
Damper Diode Rated peak reverse dielectric strength Higher than 1OO.V Rated effective forward current Higher than 1 A If a relay, solenoid, or other inductive device is used as a load, you must connect a reverse-biased diode in parallel with the load to prevent the generation of a high counter electromotive voltage across the output when the output is switched off.
-
Dimmer Resistor If an incandescent lamp is uded as a load, you must connect a protective resistor across the output terminals to prevent a destructive load current surge when the output is switched on. [Robot side]
Damper diode
[Robot side]
Protective (Dimmer) resistor
OV
4.. MECHANICAL UNIT
4.1 Connection between t h e Control Unit and Mechanical Unit
Axis .- . control board
(W) 01P05 CF9l
(U) 01P05 CF92
I
bw I
krl
---ad
K92
1 P1
Signal to pulse encoder for servo motor (W,U, 8)
(el O ~ P ~O ~~ 9 3 (a) OlP05 CF94
(8) 02P05 -91
P2 Signal encoder tofbr pulse servo motor (a,& 7 )
(7)02P05 CF92
Power and-" brake to . servo motor Servo amplifier
BKPl , Power input unit
BKP2,
--+'d
Robot control module or Fixed 110 board
K9 1
Kg9
Chound board Controller
$
1 -, Mechanical unit
Note) The s h i e l d of t h e c a b l e s h o u l d b e c o n n e c t e d t o t h e ground b o a r d of t h e c o n t r o l l e r by means o f a c a b l e clamp. Fig..4.1 (a) Interconnection between the control unit and the mechanical unit by means of robot connection cables
Fig.. 4..1 (b) Pin assignment of connectors in mechanical unit
board
Note) Cable Kg1 is connected to the robot control module for modular 1/0 or to the fixed I/O board for fixed 110Fig..4..1 (c) Connection diagram for the robot connection cables
4.2 Connections and Signais between Mechanical Unit and End Effector 4..2..1 Connections
N o t e ) Connecting c a b l e s are customer provided.
4..2.2 DI/DO standards for end effector control interface
Table 4..2.2 (a) DO signal standards
DI/DO
Type -
DO
Nonpolarity noncontact DC output
Signal s t a n d a r d s
Connection type
Rated voltage: 24 48 VDC Output v o l t a g e range: 50 VDC o r l e s s Max. output c u r r e n t : 0.25 A Output v o l t a g e drop a t ON: 1.5 V max. Current leakage a t OFF: 0.1 mA max. Response time: 0.2 m s max.
[Robot s i d e 1
-
Spark suppxcssion diodt:
I
-
When u s i n g a +24 VDC output s i g n a l , t h e robot s i d e +24 V power source can b e used w i t h i n +24 VDC +7%, 0.7 A. This power source i.s r e q u i r e d f o r %iving t h e small s o l e n o i d v a l v e i n the end e f f e c t o r o r o t h e r devices, w i t h i n t h e c a p a c i t y of t h e power supply. Spark suppression d,iode Rated peak i n v e r s e v o l t a g e Rated e f f e c t i v e forward
........ G100 reater VDC c u r r e n t ... Greater
than
than 1 A I f a r e l a y o r s o l e n o i d i s d i r e c t l y connected a s a load, connect a spark suppression diode p a r a l l e l w i t h t h e load.
Protective r e s i s t o r When a lamp i s used, connect a dimmer r e s i s t o r t o prevent a rush c u r r e n t when i t i s turned on.
-
----
Signal RDOl RD0 6
-
Table 4.2.2 (b) Dl signal standards
DI/DO
Type
DI
Receiver contact input
Connection type
-
[Robot side1
Signal Signal standards @ Digital input signal RDOl RDIS standards *PPABN
$2-f3 kn
Lcvei convanon circuit
use +24 V from the robot as an input volt-
"HBKD : Type voltage Grounding receiver type Rated input voltage: +20 - 28 VDC (logic "1" closed) 0 -. +4 v (logic "0" open) Max. input voltage: +28 VDC Input impedance: Approx. 3.3 kQ Response cime: 5 - 20 uisec
@ End effector side contact standards Rated contact capacity: 30 VDC, 16 A or over Chattering time: Shorter than 5 msec Closed circuit resistance: Less than 100 Q Open circuit resistance: Greater than 100 kQ
PcriphersI device connct signal
Robot receiver output sisnat
(Chattermg: Less than 5 mscc)
--
4..2..3 End effector control interface cable
I ) Cable connector specifications
The wrist connector shown in Fig. 4.2.3 interface.
is attached to the end effector
C : 37"s D: 9.6 15..0 (inner dhmercr) E.: e33
-
F: 11..2 G : 24.7
0 0 0 0 0 0 0 0 0 0 0
f mm>
JMSP2524M (made by Daiichi Denshi Kogyo Co.) Fig. 4.2.3
Specification of wrist connector
2) Wire specification for the recommended cable Table 4-2.3 shows an example of recommended wires unshielded cabtyre cable using ETFE (ethylene-tetraf luoroethylene) as an insulator, con£orming to the specifications shown in this table. The cable should be long enough to allow the wrist to operate over its full range without interfering with the end effector. Table 4.2.3 Cables
A66L-0001-0143
A66L-0001-0144
6 cores
20 cores
Diameter
41.1 m
41.1 mm
No, and types
40j0.08
40/0,08
Thickness of sheath
1 mm
1 mm
Outer diameter
d5.3 mm
d8.6 mm
91 n/km
91 Q/km
3.7 A
2.3 A
Specifications No. of cores Conductors
Conductor resistance Allowable current
-
4..2..4 Noise suppressors
All relays, solenoids, and motors to be used in a machine or on peripheral devices connected to the controller unit must be provided with noise suppressors. These suppressors are used also to protect the relay contacts. Fig. 4.2.4 (a) shows examples of noise suppressors. 3 phase motor
DC relay +24VDC DC relay
motor
22OVAC
3 phase
Diode V06C (HITACHI)
AC relay lOOVAC Spark suppressor 52-A
AC relay. soienoid or motor
(FUJrnU)
Spark suppressor S1 - B
(FUJITSU)
Fig. 42.4 (a) Noise suppressor examples
1) Dimensions and specifications for DCR2-50D100B Capacitance 0.5pF
Toler- Rated voltage ance
+lo%
Resistor
1000VDC 22051 210% 2W
Piastic case (black)
-u----i,
1..25 mma Heat resiainz vinyl wire
2) Dimensions and specifications for DCR4-60A55 Capacitance 0.2uF for each of three leads
Toler- Rated voltage ance
+lo%
550VDC
Resistor 22051 +lo% 2W
1
0.75 mm' Vinyl
wlrt
......'--.......-." ....-. .... .---.--.
Tin plate u w : P
^.P
4.-:
4.3 S-420FMechanical Interface 4..3.7 Robot interference area
Fig. 4.3.1 shows t h e e x t e r n a l dimensions of t h e r o b o t . When i n s t a l l i , n g d e v i c e s , be c a r e f u l t o c l e a r away any o b j e c t s t h a t a r e i n t h e r o b o t ' s motion p a t h i n normal o p e r a t i o n .
Fig..4..3..1 Dimensions of S-420F
4.3..2 Mechanical coupling of the end effector to the wrist
1 ) Mechanical coupling of end effector to wrist Fig. 4.3.2 (a) shows the end effector mounting face of the wrist. Locate the end effector center using the d60H7 engagement tool; position the end
effector using the 2-Q10H7 reamed holes; and mount it using the 6-MI0 holes. Select the M10 bolts and positioning pins so that they do not extend beyond the tap depth (20 nun) of ,the robot. (Fig. 4 . 3 . 2 (a) is a standard layout of the end effector.) 6-MI 0 tap depth 20, equally spaced o n @90 circumference
2-@10H7 reamer depth 20, equallyspacedon 690 circumference
Fig. 4.3.2 (a) End effector mounting face
2) Wrist load specifications Table 4 . 3 . 2 shows the wrist load specifications. The end effector to be mounted to the wrist should conform to the conditions specified in Table 4.3.2. Table 4.3.2
Wrist load specifications of S420F
I
II
11 High-torque u axis
*+ I
Allowable moment of a-axis ass'y Ma (kg-m)
2
Allowable inertia of a-axis ass'y Ja (kg*cm0s )
High-speed ci axis
36
50
110
212
120
-. 120
.. Allowable moment of 6-axis ass'y MB (kg-m)
2
Allowable inertia of B-axis ass'y J B (kg*cm*s )
Allowable inertia of y-axis ass'y My (kgom)
Allowable inertia of y-axis --ass'y Jy (kg-cm-s )
Maxinum load weight (kg)
Fig. 4.3.2 (b) Wrist
-
Fig. 4.3.2 (c) (5) show w r i s t load condi.tions. l o a d i s w i t h i n t h e range shown i n these graphs.
Operate t h e robot s o t h a t t h e
Fig. 4.3.2 (c) a-axis load condition (High-torque cz axis) Lead
(kg)
1 20'
80-
I
I
f
20
30
40
50 crn
Distance from the a-axis rotational centcr to the center of gravity for load..
Fig,. 4.3.2 (d) a..axis load condition (high-speed a: axis)
Load (kg)
1
Distance from the p-axis rotational center (B-point) to the center of gravity for load..
Fig. 4.3.2 (e) paxis load condition
-Distance from the y-axis rotational center (C-point) to the center of gravity for load.
Fig. 4.3.2 (f) cr-axis load condition
4..33 Location and dimensions of equipment mounting holes
On t h e upper f a c e o f t h e U-axis arm, h o l e s ( f o u r M 8 t a p s ) f o r mounting equipment ( c a b l e h o l d e r , e t c . ) a r e d r i l l e d a s shown i n Fig. 4 . 3 . 3 . The b o l t l e n g t h should be l e s s than 10 mm. On t h e s i d e f a c e of t h e N.-axis arm and t h e s i d e and back f a c e s of t h e W-axis b a s e , h o l e s (twenty M12 t a p s ) f o r mounting equipment ( t r a n s f o r m e r b r a c k e t , c a b l e Fig. 4 . 3 . 3 . h o l d e r , e t c . ) a r e d r i l l e d a s shown
Fig.. 4..3..3 Location and dimensions of equipment mounting holes (S-420F)
4 . 3 4 Air-pressure supply
The T h e r e i s a n a i r - p r e s s u r e s u p p l y o p e n i n g on t h e f r o n t of t h e y - a x i s u n i t . c o n n e c t o r is a PT 3/8 female. As c o u p l i n g s a r e n o t s u p p l i e d , i t w i l l b e n e c e s s a r y t o p r e p a r e c o u p l i n g s s u i t a b l e t o t h e hose s i z e .
Air supply conncction (PT3/8)
Fig. 4.3.4
Air-pressure supply connection
4.4 4.4.1
S-420A Mechanical Interface Robot interference area
Fig. 4.4.1 shows the external dimensions of the robot. When i n s t a l l i n g d e v i c e s , be c a r e f u l t o c l e a r away any objeccs that a r e i n t h e robot's motion path i n normal operation.
4..4-2 Mechanical coupling of tf~ecnd effecxor ro thc wrist
Refer t o scceion 4 - 3 - 2 4.4.3
Location and dimensions of equipment mounting holcs
a r m , b o l e s ( f o u r tlS t a p s ) for m o u n r i ~ l gcquiptuez;~ ( c a b l e h o l d e r , e r c - ) a r c d r i l l e d as shown i n F i g - 4 - 3 - 3 The b o l t l e n g t h eo be u s e d t o mount should b e less rilan 10 aOn c h e s i d e f a c e o f che W ~ a x i sarm a n d t i l e s i d e a n d b a c k face of c h e U - a s i s base. holes ( ~ e n t yEL12 caps) f o r mounting equipment ( t r a n s f o r m e r b r a c k e t . c a b l e h o l d e r , e t c - ) are d r i l l e d as s h o w i n F i g . 4 - 4 - 3 , On r b e u p p e r f a c e o f r h e U-axis
Fig.. 4.4...3 Oimensionsof equipment mounting face { s - 4 2 0 ~ ) 4..4..4 Air-pressure supply
Refer eo s e c t i o n 4 . . 3 . 4 -
V. INSTALLATION
7..
7.1
S-420F ROBOT Transportarion and installation
1..1..7 Transportation
WARNlNG Do not transport the robot by attaching ropes t o eye bolts that are screwed into nuts welded o n t o the forklift brackets of the robot. Doing this could result in serious injury t o either personnel or equipment. 1) Transportation using a crane The robot can be transported by lifting it using a crane. Mount a support plate to prevent rotation while the robot is being transported. Remove the forklift bracket and mount four M20 eyebolts on the taps provided for installing the forklift brackets. Attach ropes to the eyebolts for lifting the robot. (See Fig. l.l.la) 2) Transportation using a forklift The robot can also be transported by using a forklift. (See Fig. 1.l.lb)
Fig. l.l.la
Transporting using a crane
~ e & dof using eye bolts
Fig. 1.1.1 Transporting using a forklift or a crane
1.1.2
Installation
Mount t h e r o b o t t o t h e f o u n d a t i o n prepared by t h e customer u s i n g anchor b o l t s . Fig. 1.1.2 ( a ) shows t h e i n s t a l l a t i o n dimensions of t h e r o b o t b a s e . Fig. 1.1.2 (b) shows t h e b a s e diagram, and Fig. 1.1.2 ( c ) , t h e f o u n d a t i o n i n s t a l l a t i o n diagram. O r i e n t t h e s u r f a c e i n d i c a t e d by "xxxx" t o t h e d e s i r e d d i r e c t i o n . 2nd b o l t the robot t o t h e foundation. Do n o t i n s t a l l a n y t h i n g on f a c e @ , a s i t w i l l be used t o mount t h e m a s t e r i a g jig.
Fig. 1-19(a) Installation hole dimensions of the robot base (S-420F)
Fig. 1..1..2(b) Base diagram
5--2
Epoxyed anchors:M20 S t r e n g t h c 1 a c i f i c a " t i o n 4.8 Tightening t o r q u e l g k g m
\
N o t e ) Embed
the floor plate Fig.. 1.1.2 (c)
in c o o c r e t e
Foundation instalfation diagram
I f t h e p a t h t a u g h t t o one r o b o t - must be t r a n s f e r r e d t o t h e new u n i t when t h e r o b o t mechanical u n i t s a r e exchanged, p r e p a r e a n i n s t a l l a t i o n p l a t e s u c h a s t h a t shown i n Fig. 1.1.2 (d). Robot base mor
1
a
Fig. 1.1.2 (dl Instaflationplate
Note 1) P a r t s t o be provided by t h e customer: Robot mounting b o l t s : N20 x 50 ( s t r e n g t h c l a s s i f i c a t i o n 12.9, I S 0 R898 Plaximum s t r e s s = 120 kg, Yield s t r e s s = 902 o f maximum s t r e s s ) x 8 : H20 ( s t r e n g t h c l a s s i f i c a t i o n 4.8, I S 0 R898 Epoxyed a n c h o r s H a x i m u m s t r e s s = 40 kg, Yield s t r e s s = 802 o f maximum s t r e s s ) x 8 Base p l a t e s : t h i c k n e s s 32 t x 4 Floor p l a t e : t h i c k n e s s 32 t x 1 Note 2) I n s t a l l a t i o n work ( w e l d i n g , anchoring, e t c . ) i s performed by t h e cus torner
.
1..1..3 Maintenance area
Fig. 1.1.3
( a ) shows t h e maintenance area of t h e mechanical u n i t . Maintenance lrca
Fig. 1.1.3 (a) Maintenance area of the rnecfianical unit (S--420)
Locate t h e maintenance a r e a t o e n s u r e t h e a t t i t u d e f o r mastering p o s i t i o n s of 0 = 0 ° , -90° o r 90° as shown i n Fig. 1 . 1 . 3 (b).
In-line w r i s t Fig. 1.1.3 (b) Attitude for mastering (S-420F)
at
the
Fig. 1.1.3 (c) Maintenance area of the controller
1.2 Assembly During lnstatlation Cable ducts, etc. are to be provided by the customer, when the control and mechanical units are connected. Connect cables to the 0-axis connector panel as When connecting take care not to damage the cables. The shown in Fig. 1.2. mechanical unit is shipped with connecting cables disconnected, but they are connected to the control unit.
Air supply conneciion PT 318
Fig.. 1.2 Connector panel on mechanical unit (S420F)
1.2.7
Robot cables
Remarks
No.
Specification
KlOl
A660-4002-T851
K102
A660--4002-T852 W/U
power, brake
8
power, b r a k e
--
power, brake
K103
A660-4002-T853
a/B/y
K104
A660-8006-T868
%/W/U p u l s e coder
K105
A660-8006-T869
-
a/B/y p u l s e coder -.
K106
A660-8006-T870
8 battery
K107
A660-8006-T87 1
W battery
K108
A660-8006-T872
TJ
K109
A660-8006-T873
a/B/y b a t t e r y
Kl 10
6660-8006-T874
DIIDO
Klll
A05B-1302-DO02
W/U
OT l i m i t s w i t c h
K112
AOSB-1302-DO03
W/U
OT E m i t s w i t c h
K113
A660-2003-T318
DI/DO (end e f f e c t o r ) (option)
battery
--.
K169
A05B-1032-DO01
8
-
OT l i m i t s w i t c h
1.2..2 Air piping F i g . 1.2.2 ( a ) shows how t o c o n n e c t a i r hose t o t h e r o b o t .
I f the a i r control s e t i s s p e c i f i e d a s a n o p t i o n , t h e a i r hose between t h e m e c h a n i c a l u n i t and t h e a i r c o n t r o l s e t i s provided. Mount t h e a i r c o n t r o l s e t u s i n g t h e i n f o r m a t i o n in F i g - 1.2.2 (b).
Fig. 12.2 (a) Air piping (S-420F/~)
-
Use t u r b i n e o i l 890 f140 of t h e a i r c o n t r o l set, a n d f i l l t o t h e s p e c i f i e d l e v e l , Mounting b o l t s are p r o v i d e d by t h e customer.
Fig.. 1..2..2(b) Air control set (s-420F/A)
1..2..3 l nstallation specifications
Table 1.2.3
shows t h e i n s t a l l a t i o n s p e c i f i c a t i o n s . Table 1..2..3 1nstallation specifications
I terns A i r pressure ,
Specifications
-
2 2 7 kg/cm G (Set p r e s s u r e 5 kgfcm G)
Pressure
5
A i r . flow
Max, peak 150 Nll/min.
-
Weight .--
-
Mechanical u n i t : Control u n i t :
-
-
7
(Note 1)
Approx. Approx.
1600 kg 550 kg
-
----
Allowable ambient temperature
0
Allowable ambient humidi.ty
Less than 75% RH. (Less t h a n 95% w i t h i n I month) Condensation f r e e
45°C
---
Atmosphere F r e e of c o r r o s i v e gases (Note 2) 1 -
I
Note 1) I % i s value i n d i c a t e s t h e maximum c a p a c i t y of t h e a i r c o n t r o l set. Adjust t h e a i r flow t o be less than t h i s value. Note 2) Contact t h e s e r v i c e r e p r e s e n t a t i v e i f t h e r o b o t i s t o be used i n an environment o r a p l a c e s u b j e c t e d t o s e v e r e v i b r a t i o n s , heavy d u s t , c u t t i n g o i l s p l a s h and o r o t h e r f o r e i g n substances.
2.1 Transportation and installation 2.7.1 Transportation
Refer to section 1- 1.1. 2..1.2 Installation
Mount the robot to the foundation prepared by the customer. Fig. 2.1.2 (a) shows the installation dimensions of the robot base. Fig. 2.1.2 (b) shows the base diagram, and the foundation installation diagram. Orient the surface indicated by "xxxxt' to the desired direction and bolt the robot to the foundation. Do not install. anything on face @ , as it wi.l.1be used to mount the mastering jig. When installing the robot on the wall, provide the support required by the weight of the robot.
@Anchor bolt through hole
ii
8-024
through depth
038 c ' b o r e
5
8-!423
I h ro u g h 1ran:por 1 ~ n g m z r e r ~ a l or eye bolt)
(10:
Fig 2..1.2 (a) Installationdimensions of the robot base (S-420A)
Detail
of
positioning
plate
Fig..21.2 (c) Foundation instaffation diagram
Note) The l e v e l i n g p l a t e and a n c h o r b o l t s a r e provided by t h e customer. The f o u n d a t i o n depth is determined by t h e s i z e of t h e b o l t s .
If t h e p a t h t a u g h t t o one r o b o t must be t r a n s f e r r e d t o t h e new u n i t when t h e r o b o t mechanical, u n i t s a r e exchanged, p r e p a r e a n i n s t a l l a t i o n p l a t e such a s t h a t shown i n Fig. 2.1.2 (d).
Note 1 ) P a r t s t o be provided by t h e customer: Robot mounting b o l t s : M20 x 50 ( s t r e n g t h c l a s s i . f i c a t i o n s
Note 1) P a r t s t o be provided by t h e customer: Robot mounting b o l t s : M20 x 50 ( s t r e n g t h c l a s s i f i c a t i o n 12.9, IS0 R898 Maxislum s t r e s s = 120 kg, Yield stress = 90% of maximum s t r e s s ) x 8 Wall mounting b e l t s : M20 x 90 ( s t r e n g t h c l a s s i f i c a t i o n 12.9, IS0 R898 Maximum s t r e s s = 120 kg, Yield stress = 90% of maximum s t r e s s ) x 8 Floor p l a t e : thickness 50t x 1 Note 2) 1 n s t a l l . a t i o n work (welding, anchoring, e t c . ) i s performed by t h e customer.
2..1..3
Fig.
Fig.
2.1.3 (a) Maintenance area (S-420A)
Locate t h e maintenance a r e a t o ensure t h e atti.tude for mastering p o s i t i o n s of % = 0°, +90° a s shown i n Fig. 5.3 (b).
at
the
0 ' a-ax i s 0 ' 7-axis
Fig.. 2.13 (b) Attitude for mastering (S-420A)
Fig.. 2.1.3 (c) Maintenance area of the controller
2.2
Assembly During Installation
Refer t o section 1.2. 2.2.1 Robot c a b l e s
2..2.2 Refer 2.2.3 Refer
K107
A660-8006-T871
U battery
K108
AG60-8006-T872
U battery
K109
~660-8006-~873
o 6 y battery
KllO
AOSB-8007-T87G
DI/DO
Kl 11
AOSB-1302-DO02
WU
K112
AOSB-1302-~003
W/U OT limit switch
K113
A660-2003-T818
DI/DO end effector (option)
K169
A05B-1031-DO05
0
-
Air piping t o s e c t i o n 1.2.2 Installation specifications t o s e c t i o n 1.2.3
OT limit switch
OT limit switch
ADJUS'T'MENTS AND CHECKS DURING INSTAL.LATION For c o n n e c t i n g c a b l e s between t h e c o n t r o l u n i t and t h e mechanjcal u n i t of t h e Check t h a t t h e s e c a b l e s a r e connected p r o p e r l y t o t h e r o b o t , r e f e r t o IV-4.1. c o r r e c t a x i s and t h a t t h e p o l a r i t y is c o r r e c t .
3.
3.1 Items to be Checked T h i s procedure d e s c r i b e s t h e a d j u s t m e n t procedures t o be followed d u r i n g i n s t a l l a t i o n of t h e c o n t r o l l e r . Adjust t h e r o b o t i n t h e sequence i n which t h e i t e m s a r e l i s t e d below. For. d e t a i l s , refer t o t h e p a r a g r a p h s shown i n t h e "Remarks" column i.n t h e f oll.owing t a b l e .
-Description
Item
Remarks
--
V i s u a l l y i n s p e c t t h e i n t e r i o r and e x t e r i o r appeara n c e s of t h e c o n t r o l u n i t and t h e mechanical u n i t .
Refer t o 3.1 (1)
2
V e r i f y t h a t screws on t h e t e r m i n a l s are t i g h t .
Refer t o 3.1 (2)
3
V e r i f y t h a t t h e c o n n e c t o r s and PCBs are p r o p e r l y mounted.
Refer t o 3.1 (3)
4
Check t h e foll.owing: Transformer t a p s e t t i n g and f u s e s i z e
Refer t o 3.1 ( 4 )
5
Connect t h e c a b l e s t o t h e c o n t r o l and mechanical units.
Refer t o 3.1 (5)
V e r i f y t h a t t h e c i r c u i t b r e a k e r is o f f . t h e power i n p u t c a b l e .
Refer t o 3.1 (6)
1
-
-
-
6
-
Connect
-
7
Make s u r e t h a t t h e o u t p u t v o l t a g e s a r e n o t grounded.
Refer t o 3.1 (7)
8
Check t h e i n p u t v o l t a g e .
Refer t o 3.1 (8)
9
P r e s s t h e EMERGENCY STOP b u t t o n on t h e o p e r a t o r ' s p a n e l . Turn on t h e power s u p p l y , and check t h e power supply v o l t a g e s .
Refer t o 3.1 (9)
10
Check t h e i n t e r f a c e s i g n a l s from t h e c o n t r o l u n i t t o t h e mechanical u n i t .
Refer t o 3.1 (10)
11
Check system v a r i a b l e s .
Refer t o 3.1 (11)
-.
--
12
Change i f n e c e s s a r y .
Turn on t h e power s u p p l y , v e r i f y t h a t t h e EMERGENCY It i s n o t , r e l e a s e i t .
Refer t o 3.1
(12)
Check t h e movement of each a x i s when i t is manually jogged.
Refer t o 3.1 (13)
Check t h e i n t e r f a c e s i g n a l s t o t h e w r i s t and end
Refer t o 3.1 ( 1 4 )
Check t h e p e r i p h e r a l d e v i c e c o n n e c t i o n i n t e r f a c e signals.
Refer t o 3.1 (15)
STOP b u t t o n i s r e l e a s e d . 13
-
1) Check the condition of the control unit and the mechanical unit as follows.
Item -
-
-
Check for dirt or damage on the outside of CRT/KB panel, operator's panel, or the teach pendant. Check for loose items inside the cabinet such as PCBs, the power unit, the input unit, or. the servo amplifiers.
-
Check for any damage to the cables and conduits, etc.
(Cover strippings, etc.)
Remove any brackets or. braces used to secure the robot axes during shipping, 2) Check that the following terminals are secure1.y connected: -
-
-
-
-
Item (200R, 200S, 200A, 200B, 100IN1, 100IN2, 1000UT1, Terminals on the input unit 1000UT2, EMGINI, EMGINC, EMGIN2, EMGOUTI, EMGOUTC, EMGOUT2, ON, OFF, COM, ALA, ALB, OP1, OP2, FN1, FN2, BKPl, MI, P2, M2, P3, M3)
--
Terminals on the fuse holders Terminals on thk 1/0 modules Terminals on the fan unit Terminals on the servo amplifier Terminals on the ser-votransformer TFl (Primary side, secondary side)
( Tewina1.s on the input transformer TF4
(Primary side, secondary side)
--
Terminals on the discharge units Check that terminals are covered, if required.
-
I
--
3) Verify that all connectors and PCBs are properly mounted.
Itern
Are clamp screws in the HONDA connectors tight? Are nail type fixtures fitted with black connector for power source?
--
Are nail type fixtures fitted with brown connector for power source? Are nail type fixtures fitted with white connector for power source? Are PCB mounting screws for the control PCB tight?
Basic control unit
Mounting screws
Are PCB mounting screws for the 1/0 PCB tight?
I
Are ROMs mounted in the IC sockets on PCB of 01P04, and 01P08?
6) Check settings of the transformers and fuse size
The location of the power transformers is shown in "T. CONTROLLER FUINTENANCE 3.3 Internal Components"
OVERVIEW AND
-Item
-
Tap setting on the servo transformer (TF1)
Check the transformer primary tap connection to see if the power voltage is within +lo% to -15% of the tap voltage. If the voltage does not satisfy this condition, select the correct tap. Primary side
i
Fig. 3.1 (a) The servo transformer TFI tap selection (input voltage: 480 VAC)
Table 3.1 (a) The servo transformer T F l primary tap selection
Connection of primary tap W Jumper 1 2 3 8 - 1 5 1 1 6 - 23 1 24 1 22 16 - 22 1 24 23 22 21 20 8 -- 16 19 18 17
5 -
Power supply voltage 220 V 240 V 380 V 415 V 460 V 480 V
--
U
1
7 6 7 6 5 4 3
- 2
1
V 15 14 15 14 13 12 11 10 9
I
-
-
7 6
Item Tap setting on the input transformer' (TF4) Check the transformer primary tap connection to see if the power voltage is within +lo% to -15% of the tap voltage. If the voltage does not satisfy this condition, select the correct tap. Primary side
Fig. 3.1 (b) The input transformer TF4 tap selection (input voltage: 480 VAC)
Item Tap setting on the user transformer (TF5) Check the transformer primary tap corrections to see if the power voltage within +lo% to -15% of the tap voltage. If the voltage does not satisfy this condition, select the correct tap.
llSVAC.96A
Fig.. 3.1 (c) The user transformer TF5 tap selection (input voltage: 480 VAC)
Note 1) Turn off the input power supply to the control unit selecting transformer taps. Note 2) U, V, and W in the figure correspond to input power terminals U, V, W.
-
Item
Fuse s i z e f o r AC v o l t a g e i n p u t types (Refer t o I. OVERVIEW AND CONTROLLER FIAINTENANCE 23.3.1)
5 ) Connect t h e c a b l e s between t h e c o n t r o l u n i t and t h e mechanical u n i t -
-
Item
--
Connect t h e AC motor power c a b l e and brake c a b l e f o r each a x i s Connect t h e p u l s e coder c a b l e f o r each a x i s
--
Connect t h e robot i n p u t / o u t p u t c a b l e -
- --
-
-
--
--
__I
Connect t h e t e a c h pendant c a b l e
I
6 ) Connecti.ng t h e power i n p u t c a b l e Turn t h e c i r c u i t breaker/disconnect switch o f f and then connect t h e power i n p u t cable. The power c a b l e should be brought i n t o t h e c a b i n e t through t h e bottom of t h e c a b i n e t and connected t o t h e U, V and W t e r m i n a l s on t h e c i r c u i t b r e a k e r / disconnect switch. (See IV-3.2.1) 7 ) Confirm t h a t t h e f o l l o w i n g output v o l t a g e s a r e not grounded. Item -
-
- -
--
-
--
Check t h a t t h e power u n i t output +5 V i s n o t s h o r t e d t o 0 V (GND). Check t h a t t h e power u n i t output +24 V is n o t s h o r t e d t o 0 V (GND).
I Check t h a t -
F
/
t h e power u n i t o u t p u t +24 V (+24 E) i s not s h o r t e d t o 0 V (GND). --
--
-
--
--
-
--
k t h a t t h e power u n i t output + 1 5 V i.s n o t s h o r t e d t o 0 V (GND). C h e c k t h a t t h e power u n i t o u t p u t -15 V i s not s h o r t e d t o 0 V (GND).
8) Confirm t h a t t h e i n p u t power source v o l t a g e and frequency a r e c o r r e c t . Ttem
-
-
The input power s o u r c e v o l t a g e i s a p p l i e d a s follows. 220/240/380/415/460/480/500/550/575 VAC +lo%/-15% 50/60 Hz +1 Hz, 3d
-
The input power s o u r c e c a p a c i t y should be s u f f i c i e n t t o power t h e c o n t r o l u n i t
1
9) Output v o l t a g e check P r e s s t h e EMERGENCY STOP b u t t o n on t h e o p e r a t o r ' s panel. s u p p l y , and check t h e o u t p u t v o l t a g e .
Turn on t h e power
-Item
-
Check t h a t a l l f a n s i n t h e c a b i n e t a r e working normally. t h a t each power o u t p u t i s w i t h i n t h e s p e c i f i e d range a t t h e t e r m i n a l s on t h e Path CPU board. (See I. OVERVIEW AND CONTROLLER MAINTENANCE 9 . 7 . )
r
Check t h e each power o u t p u t i s w i t h i n t h e s p e c i . f i e d range a t t h e t e r m i n a l s on t h e s e r v o a m p l i f i e r PCB. (See I. OVERVIEW AND CONTROLLER MAINTENANCE 26.1.5, 26.2.5, 26.3.5.)
i
Reset t h e EMERGENCY STOP b u t t o n on t h e o p e r a t o r panel. P r e s s t h e EMERGENCY STOP b u t t o n on t h e t e a c h pendant and v e r i f y t h e d i s p l a y , which should i n d i c a t e a t e a c h pendant emergency s t o p .
--
10) Check t h e i n t e r f a c e s i g n a l s o f t h e c o n t r o l u n i t and mechanical u n i t of robot. P r e s s t h e EMERGENCY STOP b u t t o n and check t h e i n t e r f a c e s i g n a l s . Item
-
Check t h e f u n c t i o n i n g of t h e +, o v e r t r a v e l l i m i t s w i t c h e s f o r a l l a x e s by manually t r i p p i n g them, and u s i n g d i a g n o s t i c s . Check t o s e e i f t h e p o s i t i o n e r r o r v a l u e is changed by t h e feedback s i g n a l of t h e p u l s e coder on t h e AXISTAT s c r e e n of t h e d i a g n o s t i c s , when t h e motor i s r o t a t e d using an e x t e r n a l force. 11) Check and set v a r i o u s system v a r i a b l e s . P r e s s t h e EMERGENCY STOP b u t t o n and check and set t h e system v a r i a b l e s t h a t , f o r your system, may r e q u i r e d i f f e r e n t v a l u e s t h a n t h e d e f a u l t v a l u e s .
12) Release t h e EMERGENCY STOP b u t t o n .
Item
L
If an alarm i s produced, c o r r e c t t h e problem r e f e r r i n g t o t h e e r r o r code tables.
1 3 ) Check t h e movement of each a x i s when i t is manually jogged. Refer t o s e c t i o n 4 f o r i n i t i a l . s t a r t - u p procedures.
r
Item
a x i s u s i n g incremental jog, and s e e i f t h e a x i s movement of t h e robot f o l l o w s c o r r e c t l y .
-
-
Whi1.e manually jogging each a x i s a t low o v e r r i d e , operate any e x t e r n a l l y mounted EMERGENCY STOP b u t t o n and s e e i f t h e a x i s s t o p s and a l s o check t h a t t h e a x i s s t o p s when an o v e r t r a v e l switch i s tripped.
L
Manually jog each a x i s a t v a r i o u s o v e r r i d e speeds t o make s u r e t h a t t h e r e i s no v i b r a t i o n o r overshoot.
J
14) Check t h e o p e r a t i o n o f i n t e r f a c e s i g n a l s of t h e end e f f e c t o r .
I Item
Check t h e o p e r a t i o n of t h e r o b o t end e f f e c t o r by d i a g n o s t i c s and executing t h e commands from t h e t e a c h pendant. -
--
15) Check t h e o p e r a t i o n of p e r i p h e r a l d e v i c e connection i n t e r f a c e s i g n a l s . Item Check t h e o p e r a t i o n of t h e p e r i p h e r a l d e v i c e by d i a g n o s t i c s and executing t h e commands from t h e t e a c h pendant.
4. INITIAL START UP The robot i s shipped w i t h one o r more a x e s p l a c e d on hard s t o p s . c o n d i t i o n p l a c e s those axes i n an o v e r t r a v e l . c o n d i t i o n . Prior to up, t h e EMERGENCY STOP b u t t o n should be p r e s s e d . After i n i t i a l must r e s e t t h e EMERGENCY STOP b u t t o n t o remove t h e emergency s t o p move t h e mechanical u n i t o u t of t h e o v e r t r a v e l c o n d i t i o n .
This shipping i n i t i a l start s t a r t up, you condi.tion and
4.1 Description of Initial Start Up When power i s a p p l i e d t o t h e robot t h e s y s t e m s o f t w a r e w i l l b e loaded a u t o m a t i c a l l y from bubble memory t o t h e DRAM i n t h e c o n t r o l PCBs. When this h a s been completed t h e c o n t r o l l e r w i l l be i n i t i a l i z e d and t h e KAREL power up d i s p l a y w i l l appear on t h e CRT. The s t a r t up procedures a r e :
1. P r e s s t h e EMERGENCY STOP b u t t o n . 2. Turn c i r c u i t b r e a k e r h a n d l e t o t h e ON p o s i t i o n .
3. P r e s s t h e ON b u t t o n on t h e o p e r a t o r p a n e l . The d i s p l a y shown i n Fig. 4.1 (a) w i l l a p p e a r .
em Mom Mom Mom Vorr: Morn
siot
M O ~ U ~ C
0 Shored r e s 2 Servo c v l 5 PATH CPU 6 7
M a i n CPU B u b b l e mem
C l e a r t n g DROM m e m o r t e s
ID 4 5
2 9 8
OP 0 1 - 0 2 1 0 3 0 0
ax
....
Sysrem l o s t sowed 18..Mor-1987 B o o t l n q MPlIN Bcotlng Porh B o o t ~ n g&XIS B o o t t n q SRVO
FC 3
10:00:22
p r o c o s s o r / m o d u l c . . 768K b y t e s f r o m BMO: processor/module. 135K b g r e s f r o m BMO: p r o c e s s o r ~ / m o d u l e . 53K b g t e s f r o m BMO: processor/modulc. 17K b y t e s f r o m BMO:
IKAC?EL..HH IKAREL-Ri4 IKAREL-RH IKAREL-HH
II
Fig. 4.1 (a) Software booting display
During t h i s time t h e c o n t r o l l e r s o f t w a r e r e p o r t s t h e l o c a t i o n of e a c h board i n t h e c o n t r o l l e r backplane and i n d i c a t e s t h a t t h e s o f t w a r e i s b o o t i n g from bubble memory t o t h e v a r i o u s DRAMS on t h e boards. When t h i s o p e r a t i o n i s complete, t h e d i s p l a y shown i n Fig. 4.1 (b) a p p e a r s .
Fig. 4.1 (b) KAREL initializing display
A f t e r t h e i n i t i a l i z a t i o n i s completed, t h e d i s p l a y i n Fig. 4.1
II
14011 Teach pendent connected Program: Progrom Status: RECIDY
1-Jan-1988 15:48:26 Lane Number:
GMF R O ~ O ~ ~ C S
II
Copgrlght (c)1985.1986.1987 GMF Robouc~ A11 R~ghtsReserved
KAREL Contr-ol.ler-
(c) appears.
-
I/
I1
1i
Sof trere Vers~on: V1..40P Hordxare Model: S-420
.
I
fFI1rF71IF3Df61mT-F811-F91KCL
STATUS POSN
Fig. 4.1 (c) KAREL POWER-UP screen
4.2 Recovery from Alarm Conditions If a u s e r o r system e r r o r o c c u r s d u r i n g o p e r a t i o n of t h e r o b o t , an e r r o r message w i l l be d i s p l a y e d on t h e CRT d i s p l a y and t h e t e a c h pendant LCD screen. If the e r r o r o c c u r s when t h e t e a c h pendant i s e n a b l e d , t h e LCD s c r e e n on t h e t e a c h Error pendant a u t o m a t i c a l l y d i s p l a y s t h e RESET menu, shown i n Fig. 4.2. recovery p r o c e d u r e s a r e d e s c r i b e d below.
STAT:
ERROR MENU:
RESET JOG:
JOINT
RESET
F3
FJ
Fig. 4.2 Teach pendant RESET menu 42.1 General error recovery
1) Correct t h e c o n d i t i o n t h a t caused t h e e r r o r message t o b e displayed. 2) To recover from t h e e r r o r and resume o p e r a t i o n , p r e s s t h e RESET f u n c t i o n key (F3) on t h e t e a c h pendant, shown i n Fig, 4.2, o r t h e FAULT RESET b u t t o n on t h e o p e r a t o r ' s panel, shown i n Fig. 4.2.1.
FAULT RESET button
FAut.1
b FAULT R E S 3
RS-p2-C
CRTIm
EYERCEYCY STOP
k--Fig.. 4..2.1 Operator's panel fault reset control
42.2
Overtrave1
When a r o b o t a x i s o v e r e x t e n d s i t s motian l i m i t and t r i p s one of t h e a x i s o v e r t r a v e l l i . m i t s w i t c h e s , s e r v o power i s s h u t o f f by a hard wired r e l a y c i r c u i t and t h e f o l l o w i n g o v e r t r a v e l e r r o r message i s displayed: 4005 WARN ROBOT OVERTRAVEL
To r e c o v e r from t h e o v e r t r a v e l perform t h e f o l l o w i n g procedure:
1. S e t t h e REMOTE keyswitch on t h e o p e r a t o r ' s p a n e l t o OFF. 2. P r e s s t h e OVERTRAVEL RELEASE b u t t o n on t h e o p e r a t o r ' s p a n e l . This w i l l engage a bypass c i r c u i t t o supply power t o t h e s e r v o u n i t w h i l e t h e o v e r t r a v e l l i m i t switch is pressed.
3. Check t h a t t h e t e a c h pendant i s enabled.
4. T h i s a l a r m can o n l y be r e s e t from t h e t e a c h pendant. P r e s s t h e RESET f u n c t i o n key (F3) on t h e t e a c h pendant, shown i n Fig. 4.2, w h i l e h o l d i n g t h e DEADMAN switch. Servo power i s a p p l i e d t o t h e mechanical u n i t a s long as a DEADMAN s w i t c h i s pressed.
5. J o g t h e a x i s i n t h e o v e r t r a v e l c o n d i t i o n away from i t s motion l i m i t . 42.3 Emergency stop When t h e emergency s t o p i s e x e c u t e d , s e r v o power i s s h u t o f f and the f o l l o w i n g emergency s t o p e r r o r message i s d i s p l a y e d on t h e CRT: 4002 WARN EMERGENCY STOP XXX
where "XXXr' i n d i c a t e s t h e s o u r c e of t h e emergency s t o p as follows: XXX = 100 operator panel 200 u s e r o p e r a t o r p a n e l ( i f equipped) 400 s a f e g u a r d f e n c e ( i f equipped) 800 t e a c h pendant
...
... ... ...
To r e c o v e r from a n emergency s t o p from t h e o p e r a t o r panel:
1, Release t h e o p e r a t o r p a n e l EMERGENCY STOP b u t t o n by t u r n i n g t h e b u t t o n clockwise allowing i t t o unlatch. 2. P r e s s t h e FAULT RESET b u t t o n t o r e s e t s e r v o power. To r e c o v e r from a n emergency s t o p from t h e t e a c h pendant: 1. Release t h e t e a c h pendant EMERGENCY STOP b u t t o n by p r e s s i n g t h e b u t t o n again.
2. Reset s e r v o power by p r e s s i n g t h e RESET s o f t k e y . (Teach pendant m u s t be enabled and s e r v o power must be t u r n e d on by holding t h e D E A D M switch. To r e c o v e r from an emergency s t o p from a user-designed d e v i c e , recominended o p e r a t i n g p r o c e d u r e s f o r t h e p a r t i c u l a r i n s t a l l a t i o n .
check
rhe
PANEL ENAELEO
e3!il
USER LEDW
1 0
POWER ON
USER
EMERGENCY STOP button
Operator's panel
EMERGENCY STOP button
Teach pendant Fig. 4.2.3 Emergency stop controls
VI. APPENDIXES
APPENDIX 1
INTERNAL CONNECTIONS
Fig. 1..1(a) lnternaf connection diagram (S-420F/A, circuit breaker)
1
OISCONNECI SWITCH
I
POWER INPUT UNIT A14B-0076-B324/B325
I
SERVO
/
AC POWER SUPPLY
460/480 500/550 574
--
INPUT TRANSFORMER
- '
( -
('
''I lSIl
C.
200R
CONTROL PCB AI6B-1310-0930
I
.
< t 200s
P
TI??NSFORMER
~ 8 0 ~ - 0 0 2 6 - 0 0 6 '?(FOR S-420F I ABOL-0001-0517 (FOR S-420AI
P .'0 I
Fig. 1.1 (c) internal connection diagram (S-420FlA)
6-3
Fig. 3.7 (d) Internal connection diagram
6-4
(S-420F)
SERVO TRANSFORMER t F I A80L-0001-0517
6-AXIS
CONTROCLER FOR
S-420A ANWE MOUJT PROWCTION U N I T
I
BRAKE I O U I L I - I W I
I
SYMBOL
I
SPECIFICATION
I
SYMBOL
I
SPECIFICATION
I
DRAKE
IBUIL1-111)
BRAKE
IB'V:LT. IN1
CONNECTION BOARD A20B-1003-0041
FLOPPY CASSETTE ADAPTER
POWER INPUT UNIT A14B-0076-8322-8325
CONTROL PCB Al6B-1310-0530
PERIPHERAL EMERGENCY STOP EFFECTEO ON EMGOUT
TO ROBOT.Ol
--------PERIPHERAL EMERGENCY STOP NOT EFFECTEO FROM EMGOUT
TO BRAKE OF ROBOT POWER SUPPLY
EXTERNAL 0 N
*
WHEN THESE CONTROC TERMINALS ARE NOT USEO. THEY SHOULD BE SHORTEO.
RS-232-C(CHA) CONNECTION BOARD A208-1003-0040
FLOPPY C A S S E l l t AOAPTER
POWER INPUT U N I T Al48-0076-0322-8329
CONTROL PCB A168-1310-0530
Q\
I w
11: 0
m
3 3
TO ROBOT . O l
----- - )
(YTPUT OF EMERGENCY CONLIITION Kl6
n
PERIPHERAL EMERGENCY STOP EFFECTEO ON EPGOUT
PERIPHERAL
\
.>
EMERGENCY NOT EFFECTEO STOP FROM EMGOllT
TO BRAKE OF ROBOT EXTERVAL
WHEN THESE CONTROL TERMINALS ARE NOT USED, THEY SHMRO BE SHORTED.
Fig. 1.1 (h) Internal connection diagram (S420FIA)
6-8
fig.. 1.1
ti)
Internal connection diagram (S420FIAl
BACKPLANE
I
1208- 1002-0860
C
C
C
I-,,.,"
3$a U
3U
U
CNTP
CNPI
CPI I
C
c
$a$a$a
ZZ
gObncxa
In
zdYdYd BE RE RE 050805 CUCUCU
CNOP
gg U)
2, 2,
2
P e
Fig. ?..I (k) Internal connection diagram (S-420F/A)
6-1 1
BACKPLANE
T
CNB
CNC
;
A20B-1002-0860
I
Fig 1
n
Mechanical unit connection diagram (S-420F)
Fig.. I .. 1
(0)
Mechanical unit connection diagram (S-420A)
I
I
I
I
l
I
6
l
F 3
0
p 3
p 0
s
E 0
r - * - 7
,
w
$
u f
N
w
w
Z -
.-
a % -
#
;
,
-
o
,
o
N ~
,
~
I
LI
:
I
!
i
l
!
l
l
!
l
!
Z
U
6
O
U
-
0 ~ e
f
I
L
)
~:
-.oL
e
4
l
-
:
-
N
:
l
!
!
ij ;I Il ; j I
~ r-7 in. ,nnnn
~L
Z
1 1
L
g
CJ
z
- N N m n Z k Z - m S a s P I O L O z z L
i r
#P J.,
1 1
I
i-
U
"
0 - - 0 . : : 0 - 0 - : : = : t t = : t : = : =
6
c 3 0
n Wz H W W
l znooo l
I
2 2
8
0 2 0 m
INIOOI
ZN1001
GOO2 VOOZ
-
N
~
+ "'
---< + mi ---< + SNA -----<
+
--<+ z l r r o o o t
- ---< + +
6
1.2 Power Input Unit Connection Diagram
--
- Ill
--
Fig,, 1..2(a) Power input unit connection diagram
a
I
I
I
z
< C3
n z ~3
o
0 m
0 0 (U
A
f??? CUr)g
-
aaa UUV
A
ycum I I CUMW aaa OUU
A
--CUMW aaa UUU
m 0
cu
0
V)
0 0
CU
-I
0
1
cr v
Z
n m
0
CU bY W
mx
A
~+++~
41
0
m
0
CT
Cu
0 0
m
a
o> cooof 0-u7 #
V)
a
og 9
am
cn a
cum m 0
MIO -0
00
a
,,-,g
000
o so>
cuo
+ V)
>-
I I I
0 1
a
-
-m ,,
>
0:
a
<
<
Z
r)
LD
S
x y 2 r m
a
J L L L L L L
a
r "
Fig 1.2 (b) Power input unit PCB circuit diagram
@
J
m
n
IOOIN2
-
@
8
RL6
C N I -6.7
'+2LE tlBKD I IPI ?P2
r-1
04
CP7-6
RL6
CNI-14
>C N 2 - 6 >C N 2 - 1 9
01
lOOAl IOOBI
1
CNI
9
- 15
(OdAl) (04AI)
~b4-P
ROT
EMGOUT l EMGOUTC
OTREL OTREi.
CNI-I
1X CN2-5
-
I I
1
6x1 7
IX
1
EMGOUT2
Fig.. 7.2 (d) Power input unit PCB circuit diagram
6- 19
APPENDIX 2 '
-
CABLE SPEClFtCATlONS
---
Cable No.
Specifications
KO3
~ 6 6 0 8006-T9 15/iLlR303
CB
KO4
~660-8006-T922/iL2R503
PIU
-
TFI
KO6
A660--8006-T924/IL 1R503
TF4
-
PIU
KO3
A660-8006-T9 14#LlR303
CB
KO4
A660-8006-T92 1/IL3R303
PIU
-
TF1
KO6
B660-8006-T923fLlR503
TF4
-
PIU
KO3
A660-8006-T916#LlR303
CB
KO4
A660-8006-T921fL3R303
PIU
KO6
B660-8006-T923fLlR503
TF4
KO3
A660-8006-T918ZLlR303
CB
KO4
A660-8006-.T922ZL3R303
-
-
---
.--
-
Power i n p u t 1A (Breaker ) (2201240 V)
PIU
-
PIU
-
-
Power i n p u t 1B (Breaker) (380 - 550 V)
PIU
-
TF1
Remarks
-
Power i n p u t 1C (Breaker) (575 V)
PIU
PIU
Power i n p u t 2A (Circuit breaker with leak detector (220/240 V) Power i n p u t 2B (Circuit breaker with leak detector (2201240 V)
KO3
A660-8006-T917fLlR303
- TF1 TF4 - PIU CB - PIU
KO4
A660-8006-T921FL3R003
PIU
-
TFI
KO6
3660.-8006-T923#LlR503
TF4
-
PIU
KO3
A6 60-8006-T920ZL600RO
DSW
-
PIU
KO4
A660.-8006-T922fL3RO03
TF1
KO6
B660-8006-T924#LlR003
KO3
A660-8006-T919fL600RO
TF4 DSW -
KO4
A660-8006-T92 1 f L2R203
PIU
-
TF1
KO6
B660-8006-T923#LlR003
TF4
-
PIU
Power i n p u t 3A (Disconnect switch) (380 - 550 V)
-
FAN
AC power c o n n e c t i o n
KO6
B660-8006-T924/ILlR503
----
-
-
--
PIU
PIU
PIU PIU
Power i n p u t 3A (Disconnect switch) (220/240 V)
J
K12
A660-8006-T998
PIU
KG9
A660-8006-T927#L2K203
TF3 - PIU
KO7
A660-8006-T926/t1,250R3
TF4 - TfS-1
A660-8006-T925#L250R3
TF4
-
TF5
A660-8006-T928
PIU
-
SVO
K19
--
A
Servo-on r e l a y
User transformer
Cable No. -
Specifications
Remarks
K20
A660-8006-T92 91jL3R703
PIU
-
HPI
Hour meter
K21
A660-8006-T930//L800RO
TF1
-
AMP
Servo amplifier cocnection
K22
A660-8006-T9488LlR303
TF1
- AMP
K23
A660-8006-T949
PIU
- AMP
K25
A660-8006-T936
TF3
(S-42GA)
K26
A660-4002-T8648L9OORO
TF3
- AElP - AMP
K27
A660-8006-T990
AMP
- DCU
(S-42OA)
AMP
- DCU 01P0.5 - AMP OlP05 - AMP 01P05 - AMP - 01P05 - ANP 01P05 - AMP 01P05 - AMP
(S-420A)
Robot connection cable (7 m)
-
-..
-
A660-8007-TI00
-
K7 1
A660-2003-T230#L2R003NA
K72
A660-2003-~T230fL1R8030A
K73
A660-2003-T230#L2R303PA
K74
A660-2003-T230#LlR903QA
K75
A660-2003-T2309LlR803RA
K76
A660-2003-T23OfLlR603SA
K31
A660-8006-Tg53fL7R503
AMP-WM
K32
A660-8006-T954fL7R503
AMP
-
UM
K33
A660-8006-T955#L7R503
AMP
-
OM
K35
A660-8006-T956#L7R503
AMP
-
M1
Kg1
A660-2002-.T946#L9R203CC
IOU
- D1
-
(S-420A)
Cable No.
Specifications
Remarks
.--
A660-8006-T953ML14R53
AMP
K32
~660-8006-Tg54ML14R53
AMP
K33
~660-8006-T955#L14R53
K35
~660-8006-T956!IL14R53
AMP
- VPI - UM - OM - M1
Kg1
A660-2002-T946fL16R23CC
IOU
- Dl
Kg2
A660-4002-T803#L15RO3A
01P05
K93
A660-4002-T804#L15RO3A
02P05
Kg9
A660-8006-T910#L14R53
GROUND
K57
A660-2003-T329//LIORO3A
01P04
-
TP
10 m
Teach pendant
A660.-2003-T329fL20R03A
01P04
- TP
20 m
L
-
-.--
-.--
---
-
APE'
- P1 - P2
K15
A660-8006-T659//L3R803
K52
A660-2003-T271#L2R503B
K56
A660-2003-T216#L2R503C
K10
A660-2003-T3318LlR803
- PIU 01P04 - OP OlP04 - PIU PIU - PSU
K4 6
A660-2002-T945fLIR303
PIU
-
K47
A660-2002-T9498LIR303
PIU
- PSU
K70
A660-2002-T523#L500ROA
OP
A660-8006-T003#L3R003
-
Robot connection c a b l e (14 m)
OP
--
Operator's panel
Power s u p p l y u n i t
PSU
-
OP
- CRT - CRT
Remote ( 3 m)
A660-8006-T003/IL7R003
OP
-
CRT
Remote (7 m)
K50
A660-8005-T927#L500ROA
BAT
BP
Battery u n i t
--
K48
A660.-2002-T945fLlRO03A
BP
-
IOU
K49
A660-2002-T949VLlR003B
BP
-
IOU
K4 1
A66L-~6001-0005ML2RO03
01P04 - IOU
K53
A660-2003-T233#L800ROC
IOU
-
-
-
t
--
K31
-
-
PIU
Built-in
I/O u n i t
CRT /KB
Cable No.
Specif j cations
K18
Connected by customer
-
Remarks
-
SVO
Servo-on output
KO 1
- CB
AC power input
K55
-
External power on/off
K60
- PIU
Fence
- PIU
Peripheral emergency stop
K61
-
Line tracking
K62
- OP
K16
--
PIU
01P02
RS-232-C
Symbols used in the table : Servo amplifier BAT : Battery unit : Backplane BP CB : Circuit breaker CRT : CRTIKB unit DSW : Disconnect switch IOU : Modular I/O unit OP : Operator's panel PIU : Power input unit PSU : Power supply unit SVO : Servo-on relay unit TF1 : Servo transformer TF3 : Control transformer : Input transformer TF4 TF5 : User transformer TP : Teach pendant 01P02 : Path CPU board OlP04 : Shared RAM board 01P05 : Axis control board for 4-axis 02P05 : Axis control board for 2-axis WM, UM, OM, M1, Dl, PI, P2 : Connector in robot mechanical unit
AMP
APPENDIX 3
PREVENTIVE MAINTENANCE SCHEDULES
3.1 Preventive Maintenance Schedules R e f e r t o t h e maintenance replacement/adjustment s e c t i o n s f o r e x a c t i n f o r m a t i o n p e r t a i n i n g t o t h e s e procedures. 350 hours
Check items Overall system
500 hours
1000 hours
*
-
*
Greasing bearings / balancer Repeatability
-
As required
Special purpose
2000 hours
Replace anually
--
*
* After repair
Visual check
*
Mist o i l Cables
* Visual check
Ventilation system Backlash
Brakes
*
k
I -
Replace
k
Clean o r repair
Access doors
*
* Check
.
* Ob-
serve dropping Voltage (DC)
Batteries
* Check
-
A f t e r replacement
3.2 Preventive Maintenance Check List
-Item
Schedule
-
-
Air control set: Air pressure Oiler oil mist Oiler oil 1eve1 Hose leakage
Data checked (other than daily)
Daily
7
Cables (visual check)
Daily
Vibration
Daily
Repeatability
Daily
Peripheral devices
Daily
Each part (clean and check)
Daily
-
---
--
Ventilation
Daily
Lubrication
Monthly (500 hrs)
Each part (for play and looseness)
Monthly (500 hrs)
Connectors (for looseness)
Monthly (500 hrs)
Greasing bearings
Semianually (2000 hrs)
-
-
---
---Control PCB offset voltage
Semianually (2000 hrs)
Lubrication oil
Semianually (1000 hrs)
BackLash
Semianually (2000 hrs)
L --
A
I tern
Schedule
DC power voltage
Anually (4000 hrs)
RAM backup batteries (replacement)
Anually (4000 hrs)
(replacement)
Bi-ennually (8000 hrs)
Data checked (other than d a i l y )
SYSTEM VARIABLE DESCRIPTIONS
APPENDIX 4 SYSTEM VARIABLE ALPHABETICAL DESCRIPTIONS
System variables are variables that are decIared as part of the KAREL system software. Permanently defined variable names, which begin with a dollar sign ($), identify system variables. Some system variables are robot specific, meaning their values depend on the type of robot that is attacl~edto the system. Other variables reflect the current status of the system and are constantly being updated. Still others allow you to define operating parameters for a particular application. This appendix lists all the system variables available in the KAREL system. Section 4.2 in this appendix lists the default values for the S-420A and S420F robot dependant system variables. Variable names followed by a "*" are for software version 2.1 and up. '
4.1 System Variable Descriptions
This section describes each system variable in alphabetical order. Each description includes a list with the following information: Data CI'Ype: MinimumlMaximum: ProgdKCL: Default: e
Power Up: Saved:
Backed Up:
"Data Type7' indicates the type of value associated with the system variable. If the type is ARRAY, the length also is included. "MinimumlMaximum" lists minimum and maximum values when they differ from the standard values for each data type.
Software Version 2.0 and Up 6 - 27
SYSTEM VARIABLE DESCRIPTIONS $ACCLE,OVRD System Variable
"Program/KCL" shows access rights for use in KAREL programs and for all other uses (KCL). "Power Up" indicates whether or not changes to the value take effect only at power up. "Saved" indicates whether or not the value is saved by the KCL> SAVE command.
e
"Backed Up" indicates whether or not the value is restored by the power fail recovery procedure. "Default" indicates the default value for the variable.
e
The function and any additional details of the system variable are described following this list. Unauthorized modification of system variables identified as "reserved for GMF internal use only" could affect the performance of the KAREL system adversely. The names, values, and effects of GMF internal system variables are subject to change without notice. -
-
$ACCEL-OVRD (acceleration override) * Data Type: INTEGER
Power Up: No Default: 0 Backed Up: Yes
Saved: Yes
ProgramKCL: RWmW MinimumlMaximum: 0/255
$ACCEL-OVRD scales the acceleration time if $USERELACCEL = TRUE and if the acceleration option is installed (optional feature). Acceleration time is defined as: new-accel-time =def ault-accel-time
VRD * $ACCEL-0 100
If $ACCEL-OVRD = 0 it is treated as if it were 100. If RELACCEL is defined as
INTEGER user-defined associated data, $USERELACCEL = TRUE and the relaccel option is installed, then the acceleration time is defined as: new-accel-time =defhult-accel-time *$ACCEL-0 VRD *
Software Version 2.0 and Up 6 - 28
RELACCEL
loo00
SYSTEM VARIABLE DESCRIPTIONS $ACCEL-TIME1 System Variable
-
-
--
$ACCEL.-TIME1 (acceleration time 1) Power Up: Yes Saved: Yes Backed Up: No
Data Type: INTEGER ARRAY[9] Minimum/Maximum: 112560* ProgramlKCL: NoPW Default: 320
$ACCEL-TIME1 is an array of times, one per axis, for the first stage of the second order acceleration/deceleration algorithm for joint motion. The value is in milliseconds (msec). $ACCEL-TIME1 is set by the KCL> UTIIXI"Y SINIT command, and should not be changed. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program. *The maximum value for $ACCEL--TIME1 is limited by the maximum value for each system (usually 500 msec).
$ACCEL_TlME2 (acceleration time 2 ) Power Up: Yes Saved: Yes Backed Up: No
Data Type: INTEGER ARRAY[9] Minimum/Maxirnum: 112560* Program/KCL: NolPW Default: 160
$ACCEL-TIh4E2 is an array of times, one per axis, for the second stage of the second order acceleration/deceleration algorithm for joint motion. The value is in milliseconds (msec). $ACCEL-lTME2 is set by the KCL> UTILITY SINIT command, and should not be changed. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup P~ogram. *The maximum value for $ACCEL-TIME2 is limited by the maximum value for each system (usually 5500 rnsec).
$ACCURACYNUM (accuracy number) Data Type: INTEGER MinimumIMaximum: 015 ProgramIKCL: RWIRW Default: 0
-- .
* Power IJp: No Saved: Yes Backed Up: Yes
Software Version 2.0 and Up 6 - 29
SYSTEM VARIABLE DESCRIPTIONS $ACCURACYNUM System Variable $ACCURACYNUM determines which local accuracy area will be used for subsequent motion (optional feature). The local accuracy area must have been defined and set by the GMF ACCUSIGHT High Accuracy Option Package. This option is currently supported only by the A-600 robot. When $ACCURACYNUM = 0, the use of the local accuracy area data is disabled.
$AFRAMENUMl (auxiliary frame number 1) Data Type: INTEGER MinimumlMaximum: 013 ProgramiKCL: RW/RO Default: 0
Power Up: No Saved: No Backed Up: Yes
$AFRAMENUMl is used to connect an auxiliary axis tracking frame (defined using the KAREL language built-in DEFAUXFRAME) to a motion statement for auxiIiary axis tracking (optional feature). A value of 0, the default value, indicates a stationary frame. Values of 1,2, or 3 indicate defined auxiliary axis tracking frames. $AFRAMENUMl is set to 0 each time a program is executed.
$AFRAMENUM2 (auxiliary frame number 2) Data Type: INTEGER Minimum/Maximum: 013 Program/KCL: RWIRO Default: 0
Power Up: No Saved: No Backed Up: Yes
$AFRAMENUM2 is used to connect an auxiliary axis tracking frame (defined using the KAREL language built-in DEFAUXFRAME) to a motion statement for auxiliary axis tracking (optional feature). The default value indicates a stationary frame. Values of 1,2, or 3 indicate defined auxiliary axis tracking frames. $AFRAMENUM2 is set to 0 each time a program is executed.
$ALL-SYSVARS (all system variables) Data Type: BOOLEAN Saved: Yes Program/KCL: NOIRW
Software Ve~sion2.0 and Up 6 - 30
Backed Up: Yes Power Up: No Default: FALSE
SYSTEM VARIABLE DESCRIPTIONS $AFRAMENUM2 System Variable $ALL-SYSVARS is accessed using the Non-Positional Data screen on the CRT and the teach pendant to determine whether a partial or complete list of available system variables is displayed. If $ALL-SYSVARS is FALSE only comrnonIy used system variables are displayed. If $ALL-SYSVARS is TRUE all available system variables are displayed. The following is a list of commonly used system variables. This list cannot be modified.
$APC--DONE (absolute pulse coder done) Data Type: BOOLEAN ProgramlKCL: NOIPW Power Up: No Default: FALSE
Power Up: No Saved: No Backed Up: No
$APC-DONE indicates the successful completion of absolute pulse coder (APC) communication for robots with APC motors when it is TRUE. FALSE indicates communication has not been successfully completed. The value of $APC,DONE is set and updated automatically.
$APC-SYSTEM (absolute pulse coder system) Data Type: BOOLEAN PIogramlKCL: NOIPW Default: TRUE
Power Up: Yes Saved: Yes Backed Up: No
$APC-SYSTEM indicates the robot has absolute pulse coder (APC) system hardware for calibration when it is TRUE. Otherwise, it is FALSE and the robot has incremental calibration hardware. The value of $APC-SYSTEM is set by the KCL> UTILITY SINIT command and should not be changed..
Software Version 2.0 and Up 6-31
SYSTEM VARIABLE DESCRIPTIONS $APPROACHTOL System Variable
$APPROACHTOL (approach vector tolerance) Data Type: REAL ProgradKCL: RWIRW Default: 0.0003046096 (1 degree)
Power Up: No Saved: Yes Backed Up: No
$APPROACHTOL is used when comparing the z-axis (approach yector) of two positions. $APPROACHTOL, along with $LOCTOL, $ORIEN'ITOL, and $CHECKCONFIG, is used in conjunction with the relational operator "> =<" to compare two positions. If $APPROACHTOL is negative, no comparison is made and the approach vectors of the two positions are "nearly" identical. When $APPROACHTOL is 0.0 (1 degree), the approach vectors must be identical in order for the relational operator to return a TRUE result.
When $APPROACHTOL is greater than 0 the following test is made: approach1 = approach(pos1); approach;! = approach0pos2); If (ABS(approachl[l] - approach2[l] <= $APPROACH"rOL) and (ABS(approachl[2] - approach2[2] <= $APPROACHTOL) and (ABSfapproachl[3] - approach2131 <= $APPROACHTOL) then the approach vectors of the two positions are "nearly7' identical.
$ARM-TYPE (arm type) Data Type: INTEGER Minimum,Maximum: 015 ProgramlKCL: NOIPW Default: Robot Specific
Power Up: No Saved: Yes Backed Up: No
$ARM-TYPE defines the robot arm type using the integer values 0-5. The meanings associated with these values depend on which robot is being described. The value of $AM-TYPE is set by the KCL> UTILITY SINIT command and should not be changed.
$ATPERCH (at perch) Data Type: BOOLEAN ProgradKCL: ROIRO Power Up: No
Software Ve~sion2.0and Up 6 - 32
Saved: No Backed Up: No Default: FALSE
SYSTEM VARIABLE DESCRIPTIONS $ARM-TYPE System Variable
$ATPERCH returns TRUE if the robot is at the specified perch position. The variable will return FALSE if the robot is not at the perch position. See Also:
$PERCH and $PERCHTOL system variables for more information on setting the perch position.
$AUXEXTREMEl (auxiliary axis extreme 1) Data Type: REAL Program/KCL: RWIRO Default: UninitiaIized
Power Up: No Saved: No Backed Up: Yes
$AUXEXTREMEl can be used to indicate the extreme auxiliary axis position of a path for auxiliary axis tracking (optional feature). $AUXEXTREMEl is set uninitialized each time a program is executed, meaning extreme checking will not be performed. You can enable it by assigning a value less than 10,000,000 to $AUXEXTREMEl. The assigned value will be used for extreme checking. Assigning a value greater than 10,000,000 will discontinue extreme checking.
$AUXEXTREME2 (auxiliary axis extreme 2) Data Type: REAL Program/KCL: RW/RO Default: Uninitialized
Power Up: No Saved: No Backed Up: Yes
$AUXEXTREME2 can be used to indicate the extreme auxiliary axis position of a path for auxiliary axis tracking (optional feature). $AUXEXTREME2 is set uninitialiied each time a program is executed, meaning extreme checking will not be performed. You can enable it by assigning a value less than 10,000,000 to $AUXEXTREME2. The assigned value will be used for extreme checking. Assigning a value greater than 10,000,000 will discontinue extreme checking.
$AUXHOME (auxiliary axes home position) Data Type: AUXPOS ProgradKCL: RW/PW Power Up: No
Saved: Yes Backed Up: Yes Default: uninitialized
$AUXHOME is a user-definable home position for auxiliary axes.
Softwase Version 2.0 and UP 6 - 33
SYSTEM VARIABLE DESCRIPTIONS $AUXHOME System Variable You can include a KCL> MOVETO $AUXHOME command in the predefined command file KCP,,HOME.CF, which is executed by the UOP HOME signal. This command moves the auxiliary axes to their home position. You can assign a value that defines a home position for auxiliary axes. The system variable
$HOMErepresents a use~definabIehome position for the robot. See Also:
Chapter 12, KAREL Reference Manual for more information on KCP-HOME.CF
$AUXSPEED (auxiliary axis speed) Data Type: REAL ProgrardKCL: RWIRW Default: 25.0
Power Up: No Saved: No Backed Up: Yes
$AUXSPEED is used to compute segment times for auxiliary axis motion in conjunction with $JNTVELL,IM. The value of $AUXSPEED is expressed as a percentage between 0 and 100.
$AUX-OFFSET (auxiliary axis offset) Data Type: VECTOR ProgrardKCL: RWIRW Default: 0, 0, 0
Power Up: No Backed Up: No
$AUX-OFFSET is the X, Y, Z location of the integrated auxiliary axes at the position to be tested by tile KAREL built-in functions INRANGE or TINRANGE. See Also:
Chapter 8, KAREL Reference Mmanual for more information on integrated auxiliary axes.
$AUX-ZROSHFT (auxiliary axis zero shift) Data Type: REAL ProgrardKCL: RWIRW Power Up: No
Saved: No Backed Up: No Default: 0.0
$AUX-ZROSHFT performs a function for auxiliary axis positions similar to that performed by $UFRAME for the TCP position. It affects the auxiliary axis whose number is specified by $TRK-AXSNUM. Tile zero reference point of that auxiliary axis is shifted using the value of $AUX-ZROSHFT. $AUX-ZROSHFT is mainly for teaching auxiliary axis positions for auxiliary axis tracking applications (optional feature).
Sofm7ar.e Version 2.0 and Up 6 - 34
SYSTEM VARIABLE DESCRIPTIONS $AXISORDER System Variable
$AXISORDER (axis order) Data Type: INTEGER ARRAY [I21 Minimum/Maximum: 019 ProgramlKCL: NOPW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$AXISORDER is a mapping array from software axis index to servo hardware registers. It indicates which axis is controlled by a particular servo motor. For example, $AXlSORDER[i] = j, where axis index j is connected to servo register i. (Axis j is controlled by servo motor i.) $AXISORDER[i] = 0 indicates tbat servo register i is not used. ?he value of $AXISORDER is set by the KCL> UTILITY SMIT command and should not be changed. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program..
$BELT-ENABLE (belt alarm enable) Data Type: BOOLEAN P r o m C L : NOIPW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$BELT-ENABLE enables the belt breakage detection feature. If it is TRUE, the controller will generate an error message if a drive belt breaks. Only the A-200 and A-510 robot models are equipped with belt-driven axes. For these,
$BELT-ENABLEshould be TRUE. For all other robots, $BELT-ENABLE should be set to FALSE. If your system is equipped with belt-driven auxiliary axes, you can set $BELT-ENABLE to TRUE to enable belt breakage detection on the auxiliary axes.
$BK-TLINE (Basic KAREL testing line) * Data Type: INTEGER ProgrdKCL: RW/RW Default: -1
Power Up: No Backed Up: No
$BK-TLINE contains the line number used by a Basic KAREL program to start execution. This variable is set at the teach pendant Test Run menu and is used by Basic KAREL run time programs, This system variable has been added to be used for Basic KAREL testing..
Software Version 2.0 and Up 6 - 35
SYSTEM VARIABLE DESCRIF'TIONS $BRK,-ON-HOLD System Variable
--
-
$BRK-ON-HOLD (brake on hold) Data Type: BOOLEAN ProgrdKCL: NOPW Default: TRUE
Power Up: Yes Backed Up: No
If $BRK,ON-HOLD
is enabled, all holds generated by the hardware (by pressing the HOLD button on the operator panel or UOP or by pressing the IIOLDISTEP key on teach pendant) shut the servo power off after the robot ann decelerates and stops its motion. Software-generated holds (KAREL HOLD statement, HOLD action, or KCL> HOLD command) are not affected by this feature. When the servo power is shut off, the error message "4039 Brake on H o l d is displayed on the CRT. Use the RESET button or the KCL> RESET command to reset the servo power. aftel shut down. If the HOLD input is active neither the RESET button or the KCL> RESET command will reset the servo power. This causes the error "2053 HOLD active" to be displayed. To inactivate the HOLD condition, release the HOLD button on the operator panel or the HOLD key on the teach pendant. Next, push the FAULT RESET button to turn on the servos.
$BRK-OUTPUT (brake output) Data Type: BOOLEAN ARRAY [9] ProgrdKCL: NOIPW Power Up: No
Saved: No Backed Up: No Default: FALSE
$RRK-OUTPUT is an array that you can use to set the brake output bits manually if $BRK-.OUTENB is TRUE. Note that the elements in this array do not correspond to individual axes. Several brakes might be released by a single brake output. See Also:
Enhanced KAREL Operations Manual for robot brake information
$BRK_OUT-ENB (brake output enable) Data Type: BOOLEAN ProgradKCL: NOPW Power Up: No
Saved: No Backed Up: No Default: FALSE
$BRK-OUT-ENB indicates whether or not manual setting of brake outputs is allowed. If it is TRUE brakes can be set or. released manually as specified by the value of $BRK-OUTPUT. If it is FALSE brakes cannot be set or released manually.
Software Version 2.0 and Up 6 - 36
-
--
SYSTEM VARIABLE DESCRIPTIONS $BRK-OUT-ENB System Variable
By default, the value of $BRK-OUT-ENR is set to FALSE. $BRK-OUT-ENB is also set to FALSE when an emergency stop, overtravel condition, or DEADMAN switch error occurs.
$CAL (calibrated) Data Type: BOOLEAN Program/KCL: NOIPW Power Up: No
Saved: No Backed Up: No Default: FALSE
$CAL indicates whether or not the robot has been calibrated. If it is TRUE, the robot is calibrated. Otherwise, it is FALSE and the robot has not been calibrated or an error that caused the robot to lose calibration has occurred. The value of $CAL is set and updated automatically by the system.
$CALIB-POS (calibration position) Data Type: REAL ARRAY [9] Program/KCL: NOIPW Default: Robot Specific
Power Up: No Saved: Yes Backed Up: No
$CALIJ-POS defines the calibration position of each axis for robots that require incremental calibration procedures. During calibration, the robot moves to this position, which is often called the zero return position, although this position is not necessarily at zero. The value of $CALTI3,POSis set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program.
$CALSIGN (calibration sign) Data Type: BOOLEAN ARRAY [93 ProgradKCL: NOJRW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$CALSIGN indicates the direction of axis motor rotation during calibration for incremental encoders. The system uses $CALSIGN to determine the direction it should move to find the calibration index puIse. The value of $CALSIGN is set by the KCL> UTILITY SINIT command and should not* be changed for robot axes. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program.
Software Version 2.0 and UP 6 - 37
SYSTEM VARIABLE DESCRIPTIONS $CALVELHIGH System Variable
-
$CALVELHIGH (calibration velocity high) Power Up: No Saved: Yes Backed Up: Yes
Data Type: REAL ARRAY [9] ProgramIKCL: NOlRW Default: Robot Specific
$CALVELHIGH indicates the dog-search approach speed for each axis during calibration of robots with incremental encoders. The vdue is in millimeters or radians per second depending on whether the axis is a linear motion axis or a rotational axis. The value of $CALVELEIIGH is set by the KCL> UTILITY SMIT command and should not be changed for robot axes. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program.
$CALVELLQW (calibration velocity low) Data Type: REAL ARRAY [9] Prograrn/KCL: NOJRW Default: Robot Specific
Power Up: No Saved. Yes Backed Up: Yes
$CALVELLOW indicates the index pulse search speed for each axis during calibration of robots with incremental encoders. The value is in millimeters or radians per second depending on whether the axis is a linear motion axis or a rotational axis. The value of $CALVELLOW is set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For auxiliaq axes, you are responsible for setting this variable using the Motion Hardware Setup Program.
$CART-ACCELI
(Cartesian acceleration time 1)
Data Type: INTEGER MinimudMaximum: 0/2560* PrograrnlKCL: NO/PW Defauit: 224
Power Up: Yes Saved: Yes Backed Up: No
$CART-ACCELI is the length, in ms, of the first stage of the second order acceieration/deceleration filters for Cartesian motion. The total acceleration/decelerationtime for either linear or circular Cartesian motion (except where speed override is used) is the sum of $CART-ACCEL1 and $CART-ACCEL2.
Software Version 2..0and Up 6 - 38
-.
SYSTEM VARIABLE DESCRIPTIONS $CART-ACCEL1 System Variable The value of $CART-ACCELI is set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program.
*The maximum value for $CART-ACCEL1 is limited by the maximum value for each system (usually 500 msec)
$CART_ACCEL2 (Cartesian acceleration time 2) Data Type: INTEGER Minimum/Maximum: 0/2560* ProgramlKCL: NOIPW Default: 128
Power Up: Yes Saved. Yes Backed Up: No
$CART-ACCEL2 is the length in msec of the second stage of the second order accelerationfdeceleration algorithm for Cartesian motion. The total accelerationldeceleration time for either linear or circular Cartesian motion (except where speed override is used) is the sum of $CART-ACCEL1 and $CART_ACCEL2. The value of $CART-ACCEL2 is set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For'auxiliary axes, you are responsible for setting this variable using the Motion IIardware Setup Program.
*The &ximum value for $CARTTACCEL2is limited by the maximum value for each system (usually 500 msec).
$CART-AXIS (Cartesian axis) Data Type: INTEGER MinirnumlMaxirnurn: 01987 ProgradKCL: NOIPW Default: 0
Power Up: No Saved: Yes Backed Up: No
$CART-AXIS indicates which auxiliary axes, if any, are to be integrated into the Cartesian ca1cuIations for the position of the TCP. Integrated motion of robot and auxiliary axes is turned on by setting $CART-AXIS to a value other than 0. A value of 0 means that no auxiliary axes will be integrated. The value of $CART-AXIS is a three-digit decimal number that associates the x, y, and z components of the world coordinate system with the auxiliary axis numbers for integration. See Also:
Chapter 8, KAREL Reference Manual
Software Version 2.0 and Up 6-39
SYSTEM VARIABLE DESCRIPTIONS $CHECKCONFIG System Variable
$CHECKCONFIG (check configuration) Data Type: BOOLEAN ProgramfKCL: RWIRW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$CHECKCONFIG is used to determine if the position configurations should be compared. $CHECKCONFIG, along with $APPROACHTOL, $LOCTOL, and $ORIEN'I'TOL are used in conjunction with the relational operator ">= <" to compare two positions. If $CMECKCONFIG is FALSE, the configurations are not compared and the relational operator treats the configurations as being "nearly" identical. If $CHECKCONFIG is TRUE,the configurations are compared by the relational operator.
$CHK-JNT-SPD
(check joint speed)
Data Type:BOOLEAN ProgramIKCL: NOIPW Power Up: No
Saved: Yes Backed Up: No Default: TRUE
$CHK-JNT-SPD indicates whether or not joint speed is checked against the system variable $JNTVELLIM during Cartesian motion, If it is TRUE, the speed of each joint is checked against the corresponding joint speed limit and if a limit is exceeded, all joint speeds are reduced at the same ratio. Please note that the motor speed limits ($MOT-SPD-LIM) always are checked regardless of this variable. See Also:
Chapter 8,KAREL Reference ManuaZ for more information on speed limits
$CMR (command multiplier ratios) Data Type: INTEGER ARRAY [9] Minimum/Maximum: 1132767 ProgradKCL: NOIPW Default: 1
Software Version 2-0 and Up 6 - 40
Power Up: Yes Saved: Yes Backed Up: No
SYSTEM VARIABLE DESCRIPTIONS $CMR System Variable $CMR defines command multiplier ratios, one per axis. The values of $CMR and $DMR are used as follows:
motor
N R
1
r Motor
-----
-
Encoder 1
Detected Pulses
DMR
-z
Encoder pulses
The product of commanded pulses muitiplied by $CMR is compared with the detected pulses to drive the error counter either up or dowm. The resultant error register drives the motor through a gain constant. $DMR (detector multiplier ratio) multiplies the encoder pulses to produce detected pulses. Many system variables are tolerances or other parameters specified in detector pulses. The value of $CMR is set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For auxiliary axes, you are responsible for setting this variable using the Motion Hardware Setup Program. See Also:
$KV1000 System Variable in this appendix
$CNSTNT-PATH (constant path) Data Type: BOOLEAN ProgramIKCL: RWIRW Power Up: No
Saved: No Backed Up: Yes Default: TRUE
If $CNSTNT-PATH is TRUE the acceleration/deceleration time is adjusted for the current speed override vaIue ($GENOVERRIDE and $PRGOVERRIDE) so that the path of the motion will be the same regardless of the speed override value. ?%is adjustment only applies to the program motions. The acceleration/decelerationtime for jogging or for "MOVE TO" commands, issued by KCL or the teach pendant, will not change.
If it is FAISE, the filter length is not adjusted, meaning the path taken will vary with the speed override value. See Also:
Chapter 8, KAREL Refe?ence Manual
Software Version 2.0 and UP 6 - 41
SYSTEM VAFZIABLE DESCRIPTIONS $COARSETOL System Variable
$COARSETO1 (coarse tolerance) Data Type: INTEGER ARRAY [9] Minimum/Maximnm: 0132767 ProgramKCL: NOIRW Default: 300
Power Up: No Saved: Yes Backed Up: No
$COARSETOL is an array of in-position tolerances used to determine when the robot is in position when $TERMTYPE = COARSE. The value is in units of detector pulses (as explained under $CMR). The tolerance in radians or millimeters is computed as follows: $COARSETOL coarse angle =
$CMR * SENCSCALE
The value of SCOARSETOL is set by the KCL> UTILITY SINIT command and should not be changed.
$COND-TIME (condition handler scan time) Data Type: INTEGER Minimum/Maximum: 11128 Program/KCL: NOIPW Default: 32
Power Up: Yes Saved: Yes Backed Up: Yes
$COND-TIME is used to specify the time between scans in a condition handler. The value, in rnilIiseconds, is rounded to the next lowest multiple of 8 msec. $COND-TIME is the default scanning time. The actual scanning time is the value you specify in $SCAN_TIME multiplied by $COND-TIME. See Also:
$SCAN-TIME Condition Handler QuaIifier in this appendix Wll'H Clause, Appendix A, KilREL Reference Mama1 for more information on using $COND-TIME and $SCAN-TIME
Software Version 2.0 and Up 6 - 42
-
SYSTEM VARIABLE DESCRIPTIONS $CONFIG-MASK System Variable
$CONFIG-MASK
(configuration mask)
Data Type: INTEGER ProgramIKCL: ROIPW Default: Robot Specific
Power Up: No Saved. Yes Backed Up: No
$CONFIG-MASK indicates which configuration bits are tested in the solution programs. The value depends on robot type. $CONFIG,MASK also indicates when multiple-turn joints are used. $CONFIG,MASK affects the input and display of the configuration sing when you specify or display positions. The value of $CONFIG,MASK is set by the KCL> UTILITY SINIT command and should not be changed. This variable is set up on the characteristics of each rnodel robot. Each bit is defined as follows: high we
low byte
not usec]
Software Version 2.0 and Up 6 - 4.3
SYSTEM VARIABLE DESCRIPTIONS $CONFIG,-MASK System Variable
The labels in the bit masks have the following meanings: LABET,
noflip-flip right-lcft up-down turns-4 turns-5
turns-6 cfg-right
MEANING 1 :no noflip-flip ocnfiguration
0 :has noflip-flip contigumtion 1 :no right-left configuration 0 :has right-lcft configmation I : no up-down configuration 0 :has up-down configuration 1 :RO multiple tum for 4th p i n t 0 :has multiple turn for 4th joint I :no multiple turn for 5th joint 0 :has multiplc turn for 5111 joint I :no multiple turn for 6th joint 0 :has multiple turn for 6th joint 1 :dcfault configmation right 0 :defadt configuration Icft
See Also:
E~thancedKAREL Operations Manual for specific robot configuration
information. $CONTAXISNUM (continuous axis number) Data Type: INTEGER Minimum/Maximum: 0/9 ProgamlKCL: NOIPW Default: 0
Power Up: Yes Saved: Yes Backed Up: No
$CON'TAXISNUM indicates which axis operates in continuous turn mode (optional feature) and enables continuous ttlrn for that axis. The only valid values for $CONTAXISNUM are the highest robot axis number or an auxiliary axis number.
The default value indicates that no axis will operate in continuous mode (all axes operate normally.)
Software Version 2.0 and Up 6 - 44
-
-
SYSTEM VARIABLE DESCRIPTIONS $CONTAXISVEL System Variable
$CONTAXJSVEL (continuous axis velocity) Data Type: REAL ProgradKCL: RW/RO Power Up: No
Saved: No Backed Up: Yes Default: 0.0
$CONTAXISVEL indicates the velocity of continuous turn motion, including both magnitude and direction. $CONTAXISVEL can have values between -100.0 and + 100.0. The magnitude is a percentage of maximum joint speed expressed as a REAL value and a positive or negative direction is indicated by the + or - sign. If $CONTAXISNUM has a value other than 0, the specified axis begins continuous turn motion with the next motion statement after the value is assigned to $CONTAXISVEL. The velocity of the continuous turn motion is determined by the value of $CONTAXISVEL. The motion terminates during or at the completion of the next motion statement after $CONTAXZSVEL is set back to 0. The default is set each time a program is run. This means you must assign a value within a program if you want to use continuous turn mode (optional feature). See Also: Continuous Turn Manual for more information
$CUR-CRFRAME
(current circular reference frame)
Data Type: POSITION ProgramIKCL: RWfRW Power Up: No
Saved: No Backed Up: No
$CUR,CRFRAME is effective only for circular moves in the Path Relative Frame (optional feature). $CUR-CRFRAME is updated by the system, which indicates the current circular reference frame defined by the arc of the motion. It is used in conjunction with $CUR-PRFRAME and $PFR_RESUME to resume a stopped motion smoothly for moves in the Path Relative Frame. See Also: $TTOOLNUM System Variable in this appendix
$CUR-PRFRAME Data Type: POSITION Program/KCL: RW/RW Power Up: No
(current path relative frame) Saved: No Backed Up: No
$CUR-PRFRAME is effective only for linear moves in Path Relative Frame (optional feature). $CUR,PRFRAME indicates the current Path Relative Frame with respect to the World Coordinate Frame and is updated by the system. It is used in conjunction with $CUR-CRFRAME and $PFR.-RESUME to resume a stopped motion for moves in the Path Relative Frame
Software Version 2.0 and Up 6 - 45
-
SYSTEM VARIABLE DESCRIPTIONS $CUR-PRFRAME System Variable
$CYCLE-STRT (cycle start) Data Type: STRING Program/KCE: NO/RW Power Up: No
Saved: Yes Backed Up: Yes Default: ' ' (blank)
$CYCLE.-STRT specifies the KCL command proceduse that is executed when the operator panel CYCLE START button is pressed. If the command procedure is not found, the system will searcb for a pcode file of the same name as specified in $CYCLE,START. If found in RAM, this file will be executed. If it is found in bubble memory, the file will be loaded before execution. The command procedure is executed only if a KAREL program is not running or paused. You are responsible for setting the value of $CYCLE-STRT if you want the CYCLE START button to execute a command procedure. See Also:
Enlmced KAREL Operations Manual for more information on setting
$CYCLE-STRT.
$C-STOP (cycle stop) Data Type: BOOLEAN ProgramMCL: NO/RO Power Up: No
Saved: No Backed Up: No Default: FALSE
$C-STOP indicates whether or not the UOP CYCLE STOP signal has been activated. The value of $C-STOP automatically is set to TRUE after CYCLE STOP is activated. It is set to FALSE after CYCLE START is activated.
$C-STOP-ENBL
(cycle stop enable)
Data Twe: BOOLEAN PrograrnlKCL: NO/RW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$C-STOP-ENBL controls the function of the UOP CYCLE STOP signal. If it is FALSE, CYCLE STOP performs the same function as HOLD. If you set $C-STOP-ENBL to TRUE, the CYCLE STOP button will not pause the program automatically. You can use the KAREL language C-STOP function in a program to test the value of $C-STOP and pause a program if $C-STOP is TRUE.
Version 2..0and Up -Software --
6 - 46
-
SYSTEM VARIABLE DESCRIPTIONS $C-STOP-ENBI, System Variable
$DDCMP- PAR AM (DDCMP parameter) Data Type: INTEGER ARRAY [2] ProgramlKCL: NOIP W Power Up: No
Saved: Yes Backed Up: No
$DDCMP-PARAM is an ARRAY which specifies the DDCMP communications parameters. ?'he array elements represent the following parameterr: $DDCMP-PARAMfl]indicates the maximum number (between 0 and 3) of simultaneous DDCMP connections. $DDCMPMPPARAM[2] currently is not used. See Also: &4REL-MAP InstuZIution and M~intenanceManual
$DECELTOL (deceleration tolerance) Data Type: INTEGER MinimumlMaximum: 1/99 ProgmmKCL: RW/RW Default: 50
Power Up: No Saved: No Backed Up: Yes
$DECELTOL specifies the percent of deceleration distance that must be covered before a motion is considered finished and the next segment is permitted to start. It is used with the VARDECEL termination type. Setting $DECELTOL to 1makes VARDECEL nearly equivalent to the NODECEL termination type. Setting $DECELTOL to 99 makes VARDECEL nearly equivalent to NOSETTLE. See AIso:
Chapter 8, KAREL Reference Manual for more information on termination types.
Software Version 2.0 and Up 6-47
SYSTEM VARIABLE DESCRIPTIONS $DELTAFRAME System Vax iable
$DELTAFRAME (delta frame) Power Up: No Saved: No Backed Up: No
Data Type: POSITION ProgradKCL: RW/RO Default: $NILP
$DELTAFRAME represents the positional data needed to integrate the robot motion with an external sensor. 13e value of $DELTAFRAME is used to provide dynamic path modification by incorpoxating it into path planning to change the nominal path. $DELTAFRAME can be set based on externaI sensor data, internal auxiliary axes positions (table coordinates), a generated vector (for weaving appIications), or by some other method. Its value can be with respect to the world coordinate system or the user frame, based on the application and on the value of $TFRAMENUM.
$DELTAFRAME location location + orientation location location + orientation
$TFRAMENUM
-1 --2 -3 -4
Coordinate Frame World World User Frame User Frame
$TFRAMENUM can be set in a KAREL program to determine, in conjunction with $DELTAFRAME, the desired coordinate system. See Also:
$TFRAMENUM System Variable in this appendix
$DELTATOOL (delta tool) Data Type: POSITION PrograrnJKCI,: RWIRO Power Up: No
Saved. No Backed Up: No
$DELTATOOL represents the position change with respect to the tool frame based on external sensor data. The value of $DELTATOOL, is incorporated into path planning to change the noininal path dynamically. Its value can be used with respect to the tool coordinate system or the path relative coordinate system attached to the path trajectory depending on the value of $TTOOLNUM..
Software Version 2..0and Up 6 - 48
-
SYSTEM VARIABLE DESCRIPTIONS $DELTATOOL System Variable
$DELTATOOL location location + orientation disabled location + orientation location -1 location + orientation location -3 location + orientation
$TTOOLNUM 1 2 0 0 Path Relative Frame -2 Path Relative Frame -4
Coordinate System Tool Tool Path Relative Frame Path Relative Frame Path Relative Frame
$TTOOLNUM can be set in a KAREL program to determine the desired coordinate system. See Alw:
$TTOOLNUM System Variable in this appendix
$DFLT-PROG (default program) Data Type: STRING ProgramJKCL: NO/RO Power Up: No
Saved: No Backed Up: Yes Default: ' ' (blank)
$DFLT-PROG identifies the default program name that is used by KCL commands and the teach pendaat when you do not specify a program name.
You set the value of $DFLT-PROG using the KCL> DEFAULT command.
$DISPLAY-ON (display on) Data Type: BOOLEAN Program/KCL: NOIRW Power Up: No
Saved: Yes Backed Up: Yes Default: TRUE
$DISPLAY-ON indicates whether or not a program will be displayed on the CRTIKB as it is being translated. If the value is TRUE the program is displayed. If you set it to FALSE, only header information indicating which file is being translated is displayed.. If a translation error occuIr, it will also be displayed. Translation will proceed faster if $DISPLAY-ON is FALSE.
The value of $DISPLAY-ON can be ovemdden wing the IDISPLAY or MODISPLAY options with the KCL> TRANSLATE command.
Software Version 2.0 and Up 6 - 49
SYSTEM VARIABLE DESCRIPTIONS $DMR System Variable
$DMR (detector multiplier ratio) Data Type: INTEGER ARRAY [9] Minimum/Maximum: O n ProgramIKCL: NOIPW Default: Robot Specific
Power Up: Yes Saved. Yes Backed Up: No
$DMR multiplies encoder pulses to produce detected pulses. $~hiR is encoded as follows:
The value of $DMR is set by the KCL> UTILITY SINI'r command and should not be changed for robot axes. For auxiliary axes, set this variable using only the Motion Hardware Setup Program. See Also:
$CMR System Variable in this appendix
$DO-RECOVER
(do recover)
Data Type: BOOLEAN ProgramlKCL: NOIRW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$DO-RECOVER indicates whether or not the power fail recovery (optional feature) is enabled. At power up, the system loads $DO-RECOVER from bubble memory. If the value of $DO-RECOVER is TRUE,the system tries to recover. I f $DO-RECOVER is FALSE, the system will not attempt to recover.. Also, if the SYSVARS.SV file is not present, the value of $DO-RECOVER is set to FALSE automatically and the system will not recover. You are responsible for setting the value of $DO-RECOVER to indicate whether or not you want the power. fail recovery procedure to be executed. See Also:
Power Fail Recovep R-HController Manrml for more information
Software Version 2.0 and Up 6 - 50
SYSTEM VARIABLE DESCRIF'TIONS $DRY-RUN System Variable
$DRY-RUN (dry run) Saved: No Backed Up: No Default: FALSE
Data Type: BOOLEAN ProgramKCL: NOIRO Power Up: No
$DRY-RUN indicates whether or not a program is being run with servo power off and the robot locked. The valrre of $DRY-RUN is set and cleared automatically when the machine LOCK pasameter is set by a KCL command or by the teach pendant. -
-
$DYNAMICFLTR (dynamic filter) Power Up: No Saved: Yes Backed Up: No
Data Type: BOOLEAN ProgramtKCL: NOPW Default: FALSE
When $DYNAMICFLTR is set to FALSE, the default accelerationldeceleration time constants at power up are used. When $DYNAMICFLTR is TRUE, the acceleration/deceleration time constants of the axes are computed dynamically based on the inertia of the robot at the start and destination positions. Hence, the acceleration/decelesation time is equal to or shorter than the default case in order to improve the cycle time.
NOTE Currently this featura is implemented only on the first joint (0 axis) of the S420 robot.
$ENBL-OVRD (enable override) Data Type: BOOLEAN ProgramlKCL: RWIRN Power Up: No
Saved: No Backed Up: Yes Default: FALSE
$ENRI.-QVRD enables the setting of the general override from the teach pendant while the teach pendant is disabled. If $ENBL-OVRD is FALSE, the OVERRTDE fJP and DOWN keys on the teach pendant only function when the teach pendant is enabled in order to prevent inadvertent changes to the robot motion during production.
If $ENBL-OVRD is TRUE,the OVERRIDE keys will work at a11 times.
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Softwase Version 2.0 and Up 6-51
SYSTEM VARIABLE DESCRIPTIONS $ENCOFFSTS System Variable $ENBL-OVRD is program accessible so that KAREL program-driven "teaching programs" can pernlit an operator to change the override while the teaching program is running.
$ENCOFFSTS (encoder off sets) Saved: Yes Backed IJp: No
Data Type: INTEGER ARRAY [9] Program/KCL: NO/PW Power Up: Yes
$ENCOFFSTS indicates encoder offsets, one per axis, in command pulses. The formula for conversion from joint angles to command pulses is: command pulses Cil = $ENCOFFSTS [i] -t. ($ENCSCAtES [i]
*
joint-angle [i])
The value of $ENCOFFSTS is set internally and should not be changed. See Also:
$CMR and $ENCSCALES System Variables in this appendix $ENC%ALES
(encoder scale factor)
Data Type: REAL ARRAY [9] Program/KCL: NO/PW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$ENCSCALES defines a scaling factor, in countdunit, used to convert from units to pulses. It is used in the formula defined for $ENCOFFSTS. The value of $ENCSCALES is set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For auxiliary axes, set this variable using the Motion Hardware Setup Program.
$FB-MON-ENB (feed back monitor enable) Data Type: BOOLEAN ARRAY [9] ProgradKCL: NO/PW Power Up: Yes
Saved: Yes Backed Up: No Default: TRUE
$FB-MON-ENB indicates whether or not feedback monitor alarm checking is enabled for each axis. --
Sofhvare Version 2.0 and Up6 - 52
SYSTEM VARIABLE DESCRIPTIONS $FINETOL Systenl Variable
-.
$FINETOL (fine tolerance) Data Type: INTEGER ARRAY [9] MinimumlMaximum: 0132767 ProgramKCL: NO/RW Default: Robot Specific
Power Up: No Saved: Yes Backed Up: No
$FINETOL is an array of in-position tolerances used to determine when the robot is in position when $TERMTYPE = FINE. The value is in units of detector pulses (as explained under $CMR). The value of' $FINETOL is set by the KCL> UTILITY SINIT command and should not be changed. For auxiliary axes, set this variable using the Motion EIar'dware Setup Program. See Also:
$COARSETOL System Variable in this appendix to compute the tolerance in radians or millimeters.
$FUL-RMT-OUT
(full remote output)
Data Type: BOOLEAN ProgramIKCL: NOIPW Power Up: No Default: FALSE
Power Up: No Saved: Yes Backed Up: No
$FUL-RMT-OUT determines whether 8 or 16 outputs are available for remote interface. If it is FALSE, only the lower 8 bits are used. If it is TRUE,ail 16 bits are used for remote interface. See Also:
Chapter 13, KAREL Reference Manual
Software Version 2.0 and Up 6 - 53
SYSTEM VARIABLE DESCRIPTIONS $GAINS System Variable
$GAINS (gains) Data Type: INTEGER ARRAY [9] MinimumlMaximum: 1/50 ProgradKCL: NO/PW Default: 20
Power Up: Yes Saved: Yes Backed Up: No
$GAINS defines an array of gains of the servo system. The value of $GAINS is set by the KCL> UTILITY SINIT command and should not be changed. For auxiliary axes, set this variable using the Motion Hardware Setup Program.
$GENOVERRlDE (general override) Data Type: MTEGER Minimum/Maximum: 11100 Program/KCL: R O / W Default: 10
Power Up: No Saved: No Backed Up: No
$GENOVERRIDE, a scaling factor, is expressed as a percentage of the motion speed. For all programmed motion $GENOVERRIDE is multiplied with $PRGOVERRIDE to obtain a total override value, which is then multiplied by the motion speed. As a safety feature, the value of $GENOVERRIDE automaticaIly is set to 10 if yor~do not wnfvm the setting before jogging the robot. You can set the value of $GENOVERRIDE using the teach pendant 0VER-RJ.DE UP and DOWN keys or KCL commands.
$GRID (grid) Data T p :MTEGER ARRAY (91 MinimumlMaximum: 119 ProgradKCL: NO/PW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$GRIDdefines the number of detector pulses per revolution of the encoder. The word "grid refers to the repeating pattern of lines or pulses produced by an incremental encoder with each revolution.
The grid is in units of detector pulses. For example, if the actual encoder has 2000 grid Iines per revolution, and a DMR of 4 is used, the detector grid size is 8000 pulses.
Software Version 2..0and Up 6 - 54
SYSTEM VARIABLE DESCRIPTIONS $GRID System Variable $GRID is encoded as foIlows:
+
gridsize = ($GRID I) * 1000 $GRID = 7 : g r i d size = 8000 $GRID = 3 : grid size = 4000 <$GRID = 6 o r 8 is an i n d . i d value.)
Formula: Example:
The value of $GRID is set by the KCL> UTILITY S I N E command and should not be changed. For auxiliary axes, set this variable using only the Motion Hardware Setup Program.
See Also: $DMR System Variable in this appendix
$GRIDSHIFTS (grid shifts) Data Type: INTEGER ARRAY 19) Minimum~Maximum:-32768132767 ProgramlKCL: NOIPW Default: 0
Power Up: Yes Saved: Yes Backed Up: No
$GRIDSHIFTS is an array of grid shifts for incremental encoders, one per axis, used to shift the location of the detected encoder index pulse relative to the actual index pulse. This allow the servo system to be used to adjust tl~eapparent position of the encoder on its shaft without performing a physical adjustment. You might need to change the default value following a dog check. Use the KCL> DOGCHECK command to adjust the value of $GRLDSHIFTS. See Also: DOGCHECK command, Appendix B, KAREL Reference Manual
$HOLD (hold) Data Type: BOOLEAN ProgradKCL: NO/RW Power Up: No
Saved: No Backed Up: No Default: FALSE
$HOLD causes robot motion to be held.. While $HOLD is TRUE, interpolation of the motion is suspended; the robot decelerates to a stop and remains stopped until $HOLDis FALSE. Pressing the operator panel HOLD button or teach pendant HOLD key sets the value of $HOLD to TRUE To set $HOLD to FALSE, use the KCL> RESUME command.
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Software Version 2.0 and UP 6 - 55
SYSTEM VARIABLE DESCRIPTIONS $HOME System Variable
$HOME (llorne position) Data Type: POSITION Progxam/KCL: RW/PW Power Up: No
Saved: Yes Backed Up: Yes Default: Uninitialized
$HOME is a userdefinable home position for the robot. Activating the UOP HOME signal moves the robot to this position unless a predefined command file, KCP-HOME.CF, exists, in which case tile command file is executed. You can also use the KCL> MOVETO command to move the robot to the HOME position. -
$INC,DEC-DIS
-
(incremental deceleration distance)
Data Type: INTEGER ARRAY [9] MinimumlMaximurn: -32768132767 ProgrdKCL: NOIPW
Power Up: No Saved: Yes Backed Up: No
$INC-DEC-DIS indicates the distance for approaching the dog for each axis on robots with incremental encoders. It is usually expressed in units of negative pulse counts. For auxiliary axes, you are responsible for setting the value of' $INC_DEC-DIS to correctly define the calibration sequences using the Motion Hardware Setup Program.
$INC-F WD-DIS (incremental forward distance) Data Type: INTEGER ARRAY [9] MinimumlMaximurn: -32768132767 ProgramlKCL: NOIPW
Power Up: No Saved: Yes Backed Up: No
$INC-FWD-DIS indicates the distance for moving away from the dog, for each axis on robots with incremental encoders. It is expressed in units of' positive pulse counts. For auxiiiary axes, you are responsible for setting the value of $MC-FWD-DIS to correctly define the calibration sequences using the Motion Hardware Setup Program.
$INC-OFFSET (incremental offset) Data Type: REAL ARRAY [9] ProgrdKCL: NO/PW Power Up: No
Software Version 2..0 and Up 6 - 56
Saved: Yes Backed Up: No Default: 0.0
SYSTEM VARIABLE DESCRLPTIONS $INC-OFFSET System Variable The value of $TNC-OFFSET is determined automatically by the mastering procedure. It is the positive or negative difference in radians (or millimeters in prismatic joints) between the onerevolution index pulse and the actual calibration position for each axis on robots with incremental encoders. When the mastering data has been altered (for example, by replacing a motor), the index position of the robot will not corsespond to the calibration position. By moving the robot to the mastering position this error can be determined. $INC-OFFSET represents this value.
$INC-.RVS-DIS (incremental reverse distance) Power Up: No Saved: Yes Backed Up: No
Data Type: INTEGER ARRAY [93 Minimum/Maximurn: -32768132767 frogram/KCL: NO/PW
$INC,RVS-DIS indicates the distance for approaching close to the onerevolution index pulse for each axis on robots with incremental encoders. It is expressed in units of negative pulse counts. For auxiliary axes, you are responsible for setting the value of $INC,RVS-DIS to correctly define the calibration sequences using the Motion Hardware Setup Program.
$INPOSITION (in position) Saved: No Backed Up: No Default: FALSE
Data Type: BOOLEAN ARRAY [9] ProgrdKCL: NOIRO Power Up: No
$INPOSITION is an array of flags indicating the axes that are in position. At the beginning of a segment the flags are automatically set to FALSE. By the end of the segment all of the flags are TRUE,indicating each axis is within tolerance for the specified position. The value of $INPOSITION is set and updated automatically.
$INTP-.STATUS (interpreter status) Data Type: INTEGER Minirnum/Maximum: -111 Program/KCL: NOIRO
Power Up: No Saved: No Backed Up: No
Software Version 2.0 and UP 6 - 57
SYSTEM VARIABLE DESCRIPTIONS $INTESTATUS System Variable $INTP-STATUS indicates the current status of the program interpreter using the following values: -1 = running
0 = paused
+1 = aborted $INTF',.STATUS is set and updated automatically.
$IN-USERMENU (in usermenu) Data Type: BOOLEAN ProgramlKCL: RO/RO Power Up: No
Saved: No Backed Up: Yes Default: FALSE
$ININUSERMENUindicates USERMENU is displayed on the teach pendant. It is used in conjunction with $LOCK-TPMENU to tell a program when the teach pendant menu has been locked to the USERMENU. $IN-USERMENU automatically is set to TRUE whenever USERMENU is displayed on the teach pendant.
$10-Tf MEOUT (input/output time-out) Data Type: INTEGER Minimum: 0 ProgradKCL: RWIRW Default: 0
Power Up: No Saved: Yes Backed Up: Yes
$10-TIMEOUT indicates the timeout value in milliseconds. It is used on KAREL language READ and WRITE statements. An $10-TIMEOUT value of 0 indicates an infinite time-out value.
$JNTCALSEQ (joint caIibration sequence) Data Type: INTEGER ARRAY [9] MinimundMaximum: 0/9 ProgradKCL: NO/PW Default: Robot Specific
Power Up: No Saved: Yes Backed Up: No
$JNTCALSEQ indicates the sequence in which each axis moves to the calibration position for incremental calibration.
Software Version 2.0 and Up
6-58
SYSTEM VARIABLE DESCRIPTIONS $JNTCALSEQ System Variable The value of $JNTCALSEQ is set by the KCL> UTILITY SINIT command and should not be changed. For auxiliary axes, you are responsible for setting the value of $JNTCALSEQ to correctly define the calibration sequences using the Motion Hardware Setup Program.
$JNTFOLERR (joint following error) Data Type: INTEGER ARRAY [9] ProgramlKCL: NO/RO Power Up: No
Saved: No Backed Up: No Default: 0
$JNTFOLERR indicates the joint following error. The units are detector pulses. The value of $JNTFOLERR is set and updated automatically.
$JNNELLIM (joint velocity limit) Data Type:REAL ARRAY [93 ProgramlKCL: NO/R W Default: Robot Specific
Power Up: No Saved: Yes Backed Up: Yes
$JNTVELLIM defines joint speed limits in units of radians per second or millimeters per second for each robot joint. It is used to calculate the speed of all joint interpolated motion. If motion speed of' any joint exceeds the value of $JNTVELLIM during linear or circular motion, the robot speed will slow down so that the joint velocity becomes within its limit, and the warning message, "Joint speed limit used," will be displayed. Since the accuracy of motion is not guaranteed in this case, this condition should be avoided by reteaching the positions. The value of $JNTVELLIM is set by the K C D UTILITY SINlT command and should not be increased beyond the default values for robot axes. For auxiliary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program. See Also:
Chapter 8, KAREL Re@rence Manual
$JOGFRAME (jogging frame) Data Type: POSITION ProgramlKCL: RWIRW Power Up: No
-
Saved: Yes Backed Up: Yes Default: $NILP
Software Version 2.0 and Up 6 - 59
SYSTEM VARIABLE DESCRIPTIONS $JOGFRAME System Variable $JOGFRAME is used as the frame of reference for jogging when "JOGFRAME is selected on the teach pendant. For most cases, it is convenient to set it to the same value as $UFRAME. It will allow you to jog the robot along the x,y,z direction defined by $UFRAME. For some cases you may want to set $JOGFRAME to a different value than $UFRAME. This will allow you to jog the robot independently of $UFRAME and still permit you to RECORD positions in refesence to $UFRAME. See Also:
$JOG-COORD System Variable in this appendix Enlraizced Karel Operations Manual
$JOGLOCK (jog Iock) * Saved: No Backed Up: Yes Default: FALSE
Data ?'ype: BOOLEAN ProgdKCL: RWINO Power Up: No
$JOGI.OCK, together with $JOGLOCK-EN, d o w the =[I keys on the teach pendant to be locked in the pressed position., This eliminates having to manually hold them down while jogging the robot. There are two methods you can use to lock the
keys:
Press both I=/ keys on the teach pendant when the teach pendant is enabled and the system variable $JOGLOCK-EN = TRUE. 0
The
Set $JOGLOCK = TRUE from a running KAREL program while the teach pendant is enabled and $JOGLOCK,EN = TRUE. keys cannot be locked in place if $JOGLOCK-EN = FALSE.
When the SHIFT keys are locked, an "L"will replace the "95" sign on the top right comer of the teach pendant screen.
$JOGLOCK,EN will be set to FALSE automatically if you are rompted to enter an INTEGER or REAL value from the teach pendant when the e SHIFT lkeys are locked in place. When this occurs, the "L" will change to a "%".
WARNlNG If a KAREL RELEASE statement is executed in the program, the teach pendant will have motion control. Therefore, $JOGLOCK-EN will not be reset and the robot will begin jogging if the f E ] keys are locked and you press a numeric/jog key in response to a prompt which asks for an INTEGER or REAL value.
Software Version 2.0 and Up 6 - 60
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SYSTEM VARIABLE DESCRIPTIONS $JOGLOCK System Variable See Also:
$JOGLOCK,EN System Variable Enhanced KAREL Operations Manual for more information on jogging
and teaching.
$JOGLOCK--EN (jog lock enable)
* Saved: Yes Backed,Up: No Default: FALSE
Data Type: BOOLEAN ProgramIKCL: NOJRW Power Up: No
keys on the teach pendant $JOGLOCK, together with $JOGLOCK,EN, allow the to be locked in the pressed position. This eliminates having to hold them down while 'ng the robot. Both $JOGLOCK,EN and $JOGLOCK must be TRUE to lock the SIIFT keys in place..
B
$JOGLOCK-EN cannot be set from within a KAREL program. See Also:
$JOGI,OCK System Variable Enhan~edKAREL Operations Manual for more information on jogging and teaching.
$JOGWRISTJNT (jog orientation method) Saved: No Backed Up: Yes Default: FALSE
Data Type: BOOLEAN ProgxmnKCL: RWIRW Power Up: No
$JOGWRISTJNT indicates the currently selected orientational method for the teach pendant. The following values are used:
TRUE = Two angle orientation FALSE = Wrist joint orientation $JOGWRISTJNTis set automatically dis lay the Setup screen, selecting the ~3 UJOG function key.
d'
the teach pendant by selecting the SETUP key to SETFRAME function key and then selecting the
$JOG-COO RD (jog coordinate system) Data Type: INTEGER Minimum/Maximum: 014 ProgrdKCL: RWIRW
Power Up: No Saved: No Backed Up: Yes
Software Version 2.0 and UP 6-61
SYSTEM VARIABLE DESCRIPTIONS $JOG-COORD System Variable $JOG-COORD indicates the currently selected jog coordinate system for the teach pendant, using the following values: 0 = JOINT 1 = JOGFRAME 2 = WORLDFRAME 3 = TOOLFRAME 4 = AUX AXIS $JOG,COORD is automatically set by the teach pendant COORD key on the teach pendant.
$KEPTMIRLIM (KEPT Motion Instruction Record LIMits) Data Type: INTEGE,R ProgradKCL: NOIPW Power Up: No
Saved: Yes Backed Up: No Default: 0
$KEPTMIRLIM is the number of motion instruction records kept in the path planning system during motion. Adjusting this value makes it possible to recover all interrupted motions after a servo error (for example, EMERGENCY STOP). The range of $KEPTMIRLIM is from 0-9 but must be less than or equal to ($NUM,MIR 3).
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See Also:
$NUM,MIR System Variable in this appendix
Data Type: BOOLEAN ProgradKCL: RW/RO Power Up: No
Saved: No Backed Up: Yes Default: FALSE
$KL-USERSTAT indicates whether the KAREL system or application program has control of the KAREL screen status line on the CRTIKB. If $KL-USERSTAT is set to TRUE and a KAREL program is running or paused the system stops updating the status line, giving control to the program. The predefined constant CRTSTANS can be used to write to the status line when $KL-USERSTAT is TRUE.
If $KL-USERSTAT is set to FALSE the system automatically updates the status line. By default, $KL-USERSTAT is set to FALSE each time a program is executed. It automatically resets to FALSE when program execution ends or the program is aborted.
Software Version 2.0 and Up 6 - 62
SYSTEM VARIABLE DESCRIPTIONS $KL-USERSTAT System Variable
See Also:
Eizhanced KAREL Operations Manual for more information
on CRTIKB screens.
$KG P-PAR AM
(KNCP parameter) Saved: Yes Backed Up: No
Data Type: INTEGER ARRAY [8] ProgrdKCL: NOIPW Power Up: No
$KNCP-PARAM is an array which specifies NCP communications parameters. The array elements represent the following parameters: $KNCP-PARAM111 is the number of copies of NCP running DDCMP connections. By default, the value is set to 1. $KNCP,PARAM[2] is the number of copies of NCP running MAP connections. By default, the value is set to 1.
NOTE KAREL can run a maximum of 2 copies of NCP. Therefore, the sum of $KNCP,PARAM[l] and $KNCP-PARAM[2] cannot exceed 2. $KNCP,PARAM[3] indicates which severity category of error codes is reported. You can specify no category, a particular category, or all categories. By default, the value is set to 0,meaning no errors are reported. $KNCP_PARAM[4] is a coded value indicating which "facility" or KAREL subsystem reports errors. By default, the value is set to 0, meaning no errors are reported. $KNCP-PARAM[4] enables Subsystems 19-17. r,
$KNCP,PARAM[.S] is a coded value indicating which "facility" or KAREL subsystem reports errors. By default, the value is set to 0, meaning no errors are reported. $KNCP,PARAM[5] enables Subsystems 16-1. $KNCPPPARAM[6] currently is not used. $KNCP-PARAM[7] currently is not used. $KNCP-PARAMI81 currently is not used.
Values are assigned to $KNCP-PARAM by default. EIowever, you might need to change these values to tailor the system for specific communication applications, See Also:
SERIAL Commrcnication Reference Manual for more information on setting $KNCP-PARAM
Software Version 2.0 and UQ 6 63
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SYSTEM VARIABLE DESCRIPTIONS $LINK-LEN-1 System Variable
$LINK-LEN,-1 (link length 1) Data Type: REAL ProgramIKCL: NOIPW Default: Robot Specific
Power Up: No Saved: Yes Backed Up: No
$LINK-LEN-1 has a meaning that is robot specific. It is intended primarily to support multiple versions of a given robot model, where the differences are only in link lengths. It can also be used in some cases to support multiple versions with other minor differences in kinematic parameters. The value of $LINK-LEN-1 is set by the KCL> UTILITY SINIT command and should not be changed.
$LINK-LEN-;!
(link length 2)
Data Type: REAL ProgramlKCL: NOIPW Default: Robot Specific
Power Up: No Backed Up: No
$LINK,LEN.-2 has a meaning that is robot specific. The value of' $LINK_LEN-2 is set by the KCL> UTILITY SINIT command and should not be changed. See Also:
$LINK-LEN-1 System Variable in this appendix to compute the tolerance in radians or millimeters.
$LIST-ON (list on) Data Type: BOO1.EAN ProgradKCL: NOIRW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$LIST-ON indicates whether or not the language translator will generate a listing file when a source file is translated. To conserve space, the same file specification, LiSSING.LS, is used for all listing files. If you set the value to TRUE,a listing file is generated. If you set it to FALSE, a listing file is not generated and tile translation procedure is faster. The value of $LIST-ON can be overridden using the /LISTING or /NOLISTING options with the KCL> TRANSLATE command.
Software Version 2.0 and Up 6 - 64
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SYSTEM VARIABLE DESCRIPTIONS $LOCK-KLMENU System Variable
$LOCK-KLMENU (lock KAREL menu) * Power Up: No Backed Up: Yes Saved: No
Data Type: BOOLEAN ProgradKCL: RW/PW Default: FALSE
$LOCK-KLMENU provides KAREL programs with the ability to lock any KAREL screen or menu displayed on the CRT while a program is running. When a KAREL screen or menu is locked, all function keys are accessible by the program, however, they will be blank unless the program writes to them. Setting $LOCK-KLMENU = TRUE wil lock the display of the current KAREL screen or menu.
m,
While the CRT screen is locked, the function key, will not be active. Therefore, the program has controI over which menu is being displayed. The DISPLAYPG built-in must be used within the program to force a KAREL screen or menu to be displayed. If $LOCK,KLMENU is FALSE, all system defined function keys will be displayed and active.
$LOCK-TPMENU (lock teach pendant menu) Data Type: BOOLEAN ProgramIKCL: R W/PW Power Up: No
Saved: No Backed Up: Yes Default: FALSE
$LOCK-TPMENU is a program accessible variable intended for use in "teaching programs" to prevent novice operators from "escaping" the control of the KAREL program. KCL cornnland access is also permitted to allow start-up command files to lock the menu.
If $LOCK-TFMENU is TRUE, the teach pendant is locked at the USERMENU display. $LOCK-TFMENU can ody be used if a program is running. If USERMENU is not being displayed when $LOCK-TPMENU is first set to TRITE, the lock function does not take effect until the user selects the USERMENU on the teach pendant. (The value of $IN,USERMENU indicates whether or.not the USERMENU is has been selected.)
$LOCTOL (location vector tolerance) Data Type: REAL ProgramIKCL: RWJRW Power Up: No
Saved: Yes Backed Up: No Default: 3.0 -
Software Version 2.0 and UR 6 - 65
SYSTEM VARTABLE DESCRIPTIONS SLOCTOL System Variable $LOCTOL is used when comparing the location vector of two positions. $IaOCTOL, aIong with $APPROACIITOL, $OUNTTOL, and $CHECKCONFIG is used in conjunction with the relational operator "> =<" to compare two positions.
If $LOCTOL is negative, no comparison is made and the location vectors of the two positions are "nearly" identical. When $LOCTOL is 0, the location vectors must be identical in order for the relational operator to return TRUE, When $LOCTOL is greater than 0 the following test is made: locl = LOC(pos1); loc2 = LOC(pos2); If (ABS(lacl[l] - loc2[l] <= $LOCTOL) and (ABS(loc1[2] - loc2[2] <= $LOCTOL) and (ABS(locl[3] - loc2[3] <= $LOCTOL) then the location vectors of the two positions are "nearly" identical.
$LOWERLIMS (lower joint limits) Data Type: REAL ARRAY [9] Program/KCL: NO/PW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$LOWERLIMS defines the lower joint limits in radians or millimeters. The value of $LOWERI-IMS is set by the KCL> UTILITY SINIT command and should not be changed for robot axes. For auxiliary axes, you are responsible for setting the value correctiy using the Motion Hardware Setup Program.
$MO-KNAME (MAPO node name) Data Type:STRING[@] ProgramKCL: RWIPW Power Up: No
Saved: Yes Backed Up: Yes
$MO,KNAME specifies the port name (application process title) of the specific KAREL controller for which it is defined. The name must be unique on the MAP network. It is required to receive connections on the MAPO channel. You are responsible for setting the value of $MO-KNAME before any associations are attempted on the MAP0 channel. See Also:
KAREL-MAP, Installation and Maintenance
Software Version 2.0 and UP 6 - 66
SYSTEM VARIABLE DESCRIPTIONS $MI-FNAME System Variable
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$Mi-FNAME (Wlforeign node name) Saved: Yes Backed Up: Yes
Data Type: STRING[64] Fkogram/KCL: RWIPW Power Up: No
$MI,FNAME specifies the port name of the foreign application process title to which the KAREL controller is to be connected when requesting an association on the MAPl channel. You are responsible for setting the value of $MI-FNAbefore any associations are requested on the MAPl channel. See Also:
KAREL-MAP, Installation and Maintenance
$MI-KNAME (MAP1 node name) Data Type: STRING[64] Program/KCL: RW/PW Power Up: No
Saved: Yes Backed Up: Yes
$Ml,,KNAME specifies the port name (application process title) of the specific KAREL controller on which it is defined. The name must be unique on the MAP network. It is required to initiate connections on the MAPl channel. You are responsible for setting the value of $MI-KNAME before any associations are attempted on the MAPl channel. See Also: KARELMAP, Installation and Maintenance -
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$MANLIM (manual motion speed limit) Dab Type: INTEGER MinimudMaximum: 01100 Program/KCL: NO/PW Default: 25
Power Up: No Saved: Yes Backed Up: No
$MANLIM, a scaling factor, is expressed as a percentage of the maximum speed for jogging. For joint motion the maximum speed is $JNTVELIM, and for Cartesian motion it is $SPEEDLIM..$MANI,IM is used to calculate the speed of joint and Cartesian jog motions as well as the default value of $SPEED. See Also:
Chapter 8, KAREL Refe~enceManual
Software Version 2.0 and Up 6 - 67
SYSTEM VARIABLE DESCRIPTIONS $MAEPARAM System Variable
$MAP-PAR AM (MAP parameter) Data Type: INTEGER ARRAY [a] ProgradKCL: NOIPW Power Up: No
Saved: Yes Backed Up: No
$MAP-PARAM is an array that specifies MAP communications parameters. The array elements represent the following parameters: 0
$MAP-.PARAM[I] is the data rate of the CIM to MI serial link. It is effective when $MAP-PARAM = 0. By default, the value is set to 8 which represents 56K bits'sec. (Maximum value = 9). $MAP-PARAM[?] is the time-out vaIue on KARELMAIN service associations and releases. By default, the value is set to 60 seconds, the minimum allowable. $MAP,-PARAMI31 indicates whether an internal or external clock is used on the MAP card. ]By default, the value is set to 0 (internal clock). A value of 1represents the external clock. $MAP-PARAMI41 is the MG-400 response time-out value. By defauIt, the value is set to 15 (1.5 seconds). $MAP-PARAMIS] disables MMFS syntax checking (Default: 0 = enable, 1 = disable). $MAP-PARAMI61 indicates the MAP/TBI restart time in seconds (Default: 0 = 60 seconds). $MAP-PARAM[7] is reserved for future use. $MAP-PARAM[8] is reserved for future use.
Values are assigned to $MAP-PARAM by default. However, you might need to change these values to tailor the system for speciftc communication applications. See Also:
KAREL-MAP. Installation and Maintenance
$MASTER-DONE (master done) Data Type: BOOLEAN ProgramJKCL: NO/PW Power Up: No
Saved: Yes Backed CJp: No Default: FALSE
$MASTER-DONE indicates whether or not the mastering procedure has been performed. If it is TRUE, mastering has been done. Currently, $MASTER-DONE is implemented only for APC systems. The value of $MASTER-DONE is set and updated automatically.
Software Version 2.0 and Up 6 - 68
SYSTEM VARIABLE DESCRIPTIONS $MASTER,POS System Variable
$MASTER-POS (master position) Data Type: REAL ARRAY [9] ProgrdKCL: NOIPW Default: Robot Specific
Saved: Yes Backed Up: No
$MASTER-POS defines the mastering position of the robot as determined by the mastering fixture. The value of $MASTER-POS is in radians for rotary axes and millimeters for linear axes. $MASTER-POS is set by the KCL> UTILITY SINIT command and should not be changed. For auxiIiary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program.
$MAXDATAPGMS (maximum data programs) Data Type: INTEGER MinimundMaximum: 21500 ProgramlKCL: NOtRW Default: 21
Power Up: Yes Saved: Yes Backed Up: No
$MAXDATAPGMSspecifies the maximum number of programs for which static variables can be defined. System variables are counted as one static variable program. The maximum number of programs available is $MAXDATAPGMS 1.
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$MAXROUTINES (maximum routines) Data Type: INTEGER MinimundMaximum: 5011000 ProgramfKCL: NO/RW Default: 300
Power Up: Yes Saved: Yes
Backed Up: No
$MAXROUTINES specifies the maximum number of routines that can be declared in all of the programs that are loaded in RAM. Each Ioaded program is also counted as a routine. Each program 01. routine is counted only once.
$6~-ACCTIME (minimum acceleration time) Data Type: INTEGER ARRAY[9] Minimum/Maximum: 112560* ProgradKCL: NO/PW Default: 160
Power Up: Yes Saved: Yes Backed Up: No
Software Version 2.0 and Up 6 69
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SYSTEM VARIABLE DESCRIPTIONS $MIN_ACCTIME System Variable $MIN-ACCTIME defines the minimum acceIerationldeceleration time in milliseconds while the short motion speed up algorithm is used. It is the sum of the first and second stages. The value of $MM-ACCTIME is set by the KCL> UTILITY SINIT command and should not be changed. For auxiliary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program. *The maximum value for $MIN,ACCI1ME is limited by the maximum value for each system (usually 500 msec.)
$MIRRORPLANE (mirror xz-plane) Data Type: POSITION ProgradKCL: ROfRW Default: $NILP
Power Up: No Saved: Ye
Backed Up: Yes
$MIRRORPLANE indicates a position whose xz-plane is used as the mirroring plane in the KCL> MLliROR command, which is part of the optional Mirror Image feature. When $MIRRORPLANE and $UFRAME are set to nil, data is mirrored about the xzplane of the world coordinate system. This is the normal case for mirroring across assembly lines where the mirrored &ta is used on a robot that is also rotated by 180 degrees. You can set the value of $MIRRORPLANE for the optional Mirror Image feature using either KCL commands or the teach pendant.
$MODEL-ID (model identifier) Data Type:STRING Program/KCL: NOIRO Power Up: No
Saved: No Backed Up: No Default: Robot Specific
$MODEL-IDdefines the robot model identifier (name). The string value appears on the POWER UP screen of the CRTIKB. $MODEL-IDis set by the system and cannot be changed.
$MOSIGN (motion sign) Data Type: BOOLEAN ARRAY [9] Prog am/KCL: NOIRW Default: Robot Specific
Software Version 2.0 and Up 6 - 70
Power Up: No Saved: Yes Backed Up: No
SYSTEM VARIABLE DESCRIPTIONS $MOSIGN System Variable $MOSIGN defines the direction of axis motor rotation for each axis during calibration of robots with absolute encoders. The value of $MOSIGN is set by the KCL> UTILITY SINlT command and should not be changed for robot axes. For auxiliary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program.
$MOTYPE (motion type) Power f ~ No~ : Saved: No Backed Up: Yes
Data Type: INTEGER Minimt~m/Maximum:618 ProgramIKCL: RWIRW Default: 6
$MOTYPE defines the type of motion interpolation used for motion statements using the following values:
6 = JOINT 7 = LINEAR
8 = CIRCULAR The value of $MOTYPE can be overridden in a path by setting the SEGMOTYPE field in the standard associated data. The default value is set each time a program is executed.
$MOT-SPD-LIM
(motor speed limit)
Data Type: INTEGER ARRAY [9] Minimurn/Maximum: 0132767 ProgramKCL: NOIPW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$MOT-SPD-LIM defines an array of motor speed limits, one per motor, in units of RPM. The value of $MOT-SPD-LIM is set by the KCL> UTILITY SINIT command and should not be changed.
$MOVEDIST (move distance) Saved: No Backed Up: No
Data Type: REAL ProgramIKCL: ROIRO Power Up: No
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Software Version 2.0 and UP 6-71
SYSTEM VARIABLE DESCRIPTIONS $MOVEDIST System Variable $MOVEDIST indicates the Cartesian distance the robot has traveled since the beginning of the current intervai. It is only valid for Cartesian moves. Joint interpolated segments are treated as zero length segments. The value of $MOVEDIST is automatically set to zero at the beginning of an interval. It is updated at the Cartesian interpolation rate appropriate for the segment being interpolated. The final value of SMOVEDIST remains valid until the next interval begins.
$MOVERRLIM (move error limit) Data Type: INTEGER ARRAY [9] MinimumlMaximurn: 0/32767 ProgramlKCL: NOIPW Default: Robot Specific
Power Up: Yes Saved: Yes Backed IJp: No
$MOVERRI,IM defines a motion following the error limit during motion for each axis, in units of detector pulses. If the following error exceeds its limit while the robot is in motion, servo power shuts off and the system displays the message "Move error excess." The value of $MOVERRLIM is set by the KCL> UTILrrY SINIT command and should not be changed. For auxiliary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program. .
$MSTUSE-RST (must use reset) Data Type: BOOLEAN ProgradKCL: NO/PW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$MSTUSE-RST indicates whether or not pressing the DEADMAN switch while the teach pendant is enabled will activate servo power automatically. If it is TRUE, the servo power can be activated only by issuing a RESET using the operator panel RESET button, the teach pendant RESET softkey, or the KCL> RESET command. If it is FALSE, servo power is activated automatically by pressing the DEADMAN switch on the enabled teach pendant. A value of FAJSE aIIows you to use the DEADMAN switch to control servo power.
$MSTUSE-STRT (must use start) Data Type: BOOLEAN ProgramIKCL: NO/PW Power Up: No
Software Version 2.0 and Up 6 - 72
Saved: Yes Backed Up: No Default: TRUE
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SYSTEM VARIABLE DESCRIPmONS $MSTUSE-SmT System Variable
$MSTUSE,STRT indicates whether or not the START button on the teach pendant must be held down in order for a program to continue running during a test run. If it is TRUE, the program continues to run only as long as the START button is held down. If it is FALSE, the program continues to run even when the START button is released. As a safety consideration it should remain TRUE except in cases where the application demands that the user have a free hand during test runs. --
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$NILP (nil position) Data Type: POSITION PsogradKCL: ROIRO Power Up: No
Saved: No Backed Up: Yes Default: 0,0,0,0,0,0,'N7
$NILP defines a nil or zero position, which is useful in program assignment statements. For example, the statement $UTOOL = $NILP assigns a nil position to $UTOOL. -
$NLOG-CHAN (network log channel) Data Type: INTEGER Program/KCL: NOfPW Power Up: No
Saved: Yes Backed Up: No Default: 0
$NLQG-CHAN identifies the communication channel to which alarm conditions are to be reported using the following values:
0 = no device I = co: 4 = c3:
8 =MO: 16 = MI: See Also:
KAREL-MAP, Installation and Maintenance -
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$NUM-AUX-AXS
(number of auxiliary axes)
Data Type: INTEGER MinimumlMaximum: 019 ProgramIKCL: ROIPW Default: 0
Power Up: Yes Saved: Yes Backed Up: No
$NUM-AUX-AXS defines the number of' auxiliary axes used in the system. Its value is used to determine the size of AUXPOS data types,
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Software Version 2.0 and UP 6 - 73
SYSTEM VARIABLE DESCRIPTIONS $NUM-AUX-AXS System Vaziabie The sum of the values of $NUM-AUX.-AXS and $NUM,ROB-AXS cannot exceed nine. The vaiue will be adjusted at power up and the message "2132 $NUM-AUX-AXS adjusted to n" will appear if the sum of the two variables is greater than nine. The new value of $NUM,AUX-.AXS is 9 - $NUXROB,AXS. If the system has auxiliary axis control (optional feature), the value of $NUM.-AUX-AXS must be set and saved as part of the initial setup procedure using the Motion Hardware Setup Program..
$NUM-MIR (number of motion instruction records) Data Type: INTEGER ProgramlKCL: NOIPW MinimtldMaximum: 3/20 Default: 10
Power Up: Yes Saved: Yes Backed Up: No
$NUM-MIR is the number of motion instruction records (internal data structure) to be created in the system. It affects the maximum number of STOPSto be executed in a row and the memory size available to the user.
$NUM-ROB-AXS
(number of robot axes)
Data Type: INTEGER MinimumlMaximum: 019 Program/KCL: ROIPW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$NUM-ROB-AXS defines the number of robot axes for the robot. The value of $NUM-ROB-AXS is set by the KCL> UTILITY SINIT command and should not be changed.
Software Version 2.0 and Up 6 - 74
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SYSTEM VARIABLE DESCRIPTIONS $ORIENT-TYPE System Variable
$ORIENT-TYPE (orientation type) Power Up: No Saved: No Backed Up: Yes
Data T,ype: MTEGER Minimum/Maximum: 113 ProgsadKCL: RWRW Default: 1 (RSWORLD)
$ORIENT-TYPE indicates the type of orientation control to be used when $MOTYPE is set to LINEAR motion. Tlie following values are used: 1 = RSWORLD, two angle orientation control
2
=
AESWORLD, three angle orientation control
3 = WRISTJOINT, wrist-joint orientation control For CIRCULAR motion, three angle orientation planning is used regardless of the value of $ORIENT-TY PE. The default value of $ORIENTNT'I'YPEis set each time a program is executed. See A h :
Chapter 8, KAREL Reference Manual for more information on orientation types.
$ORIENTTOL (orient vector tolerance) Data Type: REAL ProgramJKCL: RWIRW Power Up: No
Saved: Yes Backed Up: No Default: 0.003046096 (1 degree)
$ORIENTTOL is used when comparing the y-axis (orient vector) of two positions. $ORIENTTOL, along with $APPROACHTOL, $LOCTOL, and $CHECKCONFIG, is used in conjunction with tile relational operator ">=<" to compare two positions If $ORIEN?TOL is negative, no comparison is made and the orient vectors are "nearly" identical. When $ORLEN'ITOL is 0 the orient vectors must be identical in order for the relational operator to return TRUE. When $ORIENTI'OL is greater than 0 the following test is made:
orient1 = orient(pos1); orient2 = orient(pos2); If (ABS(orientl[l] - orient2[1] <= $ORIENTTOL) and (ABS(orientl[2] - orient2[2] <= $ O R E N O L ) and (ABS(orientll3l - orient2[3] <= $ORIEN'ITOL) then the orient vectors of the two positions are "nearly" identical.
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Software Version 2.0 and Up 6 - 75
SYSTEM VARIABLE DESCRIPTIONS $OT-MINUS System Variable
$OT-MINUS (overtravel minus) Data Type: BOOLEAN ARRAY [9] ProgramlKCL: NOIPW Power Up: No
Saved: No Backed Up: No Default: FAISE
$OT,MMUS is an array with each element representing the overtravel condition for the respective axis. If an element is set TRUE,the corresponding axis has a minus overtravel condition and can be jogged only in the positive direction. When an overtravel does not exist, all of the array elements are reset to FALSE. The appropriate array elements in $OT,MINUS are automatically set to TRUE when an overtravel occurs in the minus direction, and automatically set back to FALSE when the condition is corrected. This variable is saved to the DYNMSTR.DY system file automatically every time its value is changed and is automatically loaded into the system at power up.
Data Type: BOOLEAN ARRAY [9] ProgramlKCL: NO/PW Power Up: No
Saved: No Backed Up: No Default: FALSE
$OT-PLUS is an array with each element representing the overtravel condition for the respective axis. If an element is set TRUE, the corresponding axis has a plus overtravel condition and can be jogged only in the negative direction. When an overtravel does not exist, all of the array elements are FALSE. The appropriate array elements in $OT-PLUS are automatically set to TRUE when an overtravel occurs in the plus direction, and automatically set back to FALSE when the condition is corrected. This variable is saved to the DYNMSTR-DY system file automaticaliy every time its value is changed and is automatically loaded into the system at power up.
$PATH.-NODE (path node) Data Type: INTEGER Minimum/Maximurn: 1/32767 Program/KCL: ROIRO
Software Version 2.0 and Up 6 - 76
Power Up: No Saved: No Backed Up: No
SYSTEM VARIABLE DESCRIPTIONS $PATH-NODE System Variable $PATILNODE indicates the path node to which the robot is moving or has most recently moved. After an error, KAREL programs can test to determine the node toward which the robot is or was most recently moving when the error occurred. For emergency stops or errors that cause brakes to be applied and drive power to the servo system to be shut off, $PATH,NODE might be ahead of the robot's actual position. The value of $PATH-NODE is set and updated automatically.
$PATHREFPOS (path reference position of path relative frame) * Data Type: POSITION ProgWKCL: RW/RO Power Up: No
Saved: No Backed Up: Yes Default: Uninitialized
$PATHREFPOS is a userdefinable position to establish the desired Path Relative Frame (optional feature).
$PCODR-REF (pulse coder reference) Data Type: MTEGER ARRAY [9] Program/KCL: NOIPW Power Up: No
Saved: Yes Backed Up: No Default: Robot Specific
For APC systems, $PCODR,REF is the APC counter value of each axis at the reference position. It is part of the mastering data and is saved into the DYNMSTR-DY file automatically every time the KC- MASTER command is executed or. the remastering procedure takes place.
$PENDMOCOUNT (pending motion count) Data Type: INTEGER ProgramlKCL: RO/RO Power Up: No
Saved: No Backed Up: No Default: 0
$PENDMOCOUNT keeps track of how many motions have been issued but have not yet been completed.. It is automatically incremented each time the program interpreter issues a motion and decremented each time the motion interpolator finishes a motion.
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SYSTEM VARIABLE DESCRIPTIONS $PERCH System Variable
$PERCH (perch) Data Type: ARRAY[9] of REAL ProgramlKCL: No/RW Backed Up: No
Power Up: Yes Saved: Yes Default: 0.00
$PERCH is used to set the perch position. The $ATPERCH system variable can be used to determine if the current position of the robot is the same position as specified by $PERCH. For robot axes, $PERCH[i] is in degrees or millimeters depending on the value of $ROTARY-AXIS.. For auxiliary axes, $PERCH[i] is in the coordinates determined by $ENCSCALES. $PERCH is set using the $SETPERCH built-in procedure, See Also:
$ATPERCH and $PERCHTOL System Variables in this appendix SETPERCIi Built-In Procedure, Appendix A, KAREL Reference Manual
$PERCHTOL (perch tolerance) Data Type: ARRAY[9] of REAL ProgradKCL: NoIRW Backed Up: No
Power Up: Yes Saved: Yes Default: -1.0
$PERCHTOL is used to define the tolerance used when the robot position is checked using $PERCH. For robot axes, $PERCHTOL[i] is in degrees or millimeters depending on the value of $ROTARY-AXIS. For auxiliary axes, $PERCHTOL[i] is in the coordinates determined by $ENSCALES. If $PERCHTOL[i] is negative, perch checking is turned off for axis i. $PERCHTOL is normally set using the built-in function SETPERCII. See Also:
$ATPERCH and $PERCH System Variables in this appendix SETPERCH Built-In Procedure, Appendix A, KARLZ Rcfere~tceManual
$PPABN,-ENABL (pneumatic pressure abnormal enable) Data Type: BOOLEAN ProgradKCL: NOIRW Power Up: No
Software Version 2.0 and Up 6 - 78
Saved: Yes Backed Up: No Default: FALSE
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SYSTEM VARIABLE DESCRIPTIONS $PPABN.-ENABL System Variable $PPABN-ENABL indicates whether or not digital input that indicates abnormal pneumatic pressure is enabled. If it is TRUE, sensing of low line-pressure input on the robot control module (for systems with modular YO) or the fixed YO board is enabled. See Also: Chapter 13, KAREL Reference Manual
$PRF-RESUME (path relative frame resume) Data Type: BOOLEAN ProgramlKCL: RWLRW Power Up: No
Saved: No ~ a c k e dUp: ' No Default: FALSE
$PRF-RESUME is effective only for linear moves in Path Relative Frame. If the robot stops during motion, the user can set $PRF,RESUME to TRUE in order for the motion to continue without any loss of continuity. Once the motion is resumed, $PRF_RESUME is reset to FALSE by the system. See A h :
$CUR-PRFXAME and $CUR-CRFRAME System Variables in this appendix $TTOOLNUM System Variable in this appendix for more information on Path Relative Frame
$PRGOVERRIDE (program override) Data Type: INTEGER MinimumfMaximum: 11100 ProgramlKCL: RWIRO Default: 100
Power Up: No Saved: No Backed Up: No
$PRGOVERRIDE, a scaling factor, is expressed as a percentage of the motion speed. For all programmed motion, $PRGOVERRIDE is multiplied by $GENOVERRIDE to obtain a total override value, which is then multiplied by the motion speed. $PRGOVERRIDE has no effect for motions other than program motion. You can assign a value to $PRGOVERRIDE from a program or from the teach pendant.
$PRIORITY can be used only in a condition handIer statement WITI3 clause. This condition handler qualifier is not a normal system variable. It has write only (WO) access by programs and cannot be accessed by KCL (NO).
Software Version 2.0 and Up 6 - 79
SYSTEM VARIABLE DESCRIPTlONS $PRIORITY Condition Handler Qualifier $PRIORITY is used to specify the priority of execution for the indicated routine. An interrupt routine with a low priority will not be executed until control is returned to the program from a higher-priority routine. Therefore, the actual priority value specified is not important; only that one must be larger than the other. Where $PRIORITY is not specified, a default value of 0 is assumed. Two interrupt routines that have the same priority value, or default values of 0, can interrupt each other. See Also:
Chapter 6, M R .Reference Manual WITH Clause, Appendix A, KAREL Reference Manual
Saved: No Backed Up: No Default: 'R-H'
Data Type: STRMG[12] ProgramtKCL: ROIRO Power Up: No
$PRODUCT-ID allows KAREL programs to determine which controller is being used. This allows the program to access controller-specific system variables and functions (for example, 80 columns of the CRT on the R-H controller as opposed to 40 columns on the R-F controller).
$FROG-BASE (program base) Data Type: STRING[12] ProgradKCL: RWIRW Power Up: No
" Saved: Yes Backed Up: No Default: 'prog'
$PROG-BASE allows Basic and Enhanced KAREL users to select programs by number from the teach pendant. An ASCII number is appended to $PROG,BASE to form the program name. When you select PRGM # from the teach pendant you are prompted to input the program number. For example, if you type "1" in answer to this prompt, you will be selecting "PROG~O1" as the default program name. The program "PROG-01" must already exist as a program in order for you to select it as the default program. Two characters are reserved for the program number. This allows for programs to be listed in order through program #99. $PROG-BASE is Limited to a maximum of 10 characters.
Software Version 2.0 and Up 6 - 80
SYSTEM VARIABLE DESCRIPTIONS $PTH-MODEL System Variable
$PTH-MO DEL (path model) Data Type: STRING ProgramKCL: N O R 0 Default: Robot Specific
Power Up: No Saved: No Backed Up: No
$PTH_MODEL defines the robot model identifier. The value of $PTH_MODEL matches the value of' $MODEL-.ID and is set and used internally. It cannot be changed.
$PTH-VERSION (path version) Data Type: STRING ProgmdKCL: NO/RO Default: Robot Specific
Power Up: No Saved: No Backed Up: No
$PT.€i-VERSION identifies the KAREL software version currently in use. The value of $PTH.-VERSION matches the value of $VERSION-ID and is set and used internally. It cannot be changed.
$PWR-FAIL (power fail) Data Type: STRING Program/KCL: NO/RW Power Up: Yes
Saved: Yes Backed Up: No Default: ' '(blank)
$PWR_FAIL specifies the name of the KCL command file that is executed if the system is in a recoverable state at power up. If no name is specified, a KCL command procedure is not executed. You are responsible for setting the value of $PWR,FAIL if you want a command procedure to be executed at power up when the system is in a recoverable state. If you assign a command procedure name to $PWR,FAIL the message "Running Power Fail File file-name" is displayed on the CRTKB at power up, while the procedure is being executed, where file-name is the command file name. See AIso:
$RECOVERABLE System Variable
Software Version 2.0 and UP 6-81
SYSTEM VARIABLE DESCRIPTIONS $PWR-NORMAL System Variable
$PWR-NORMAL (power normal) Data Type: STRING ProgradKCL: NO/RW Power Up: Yes
Saved: Yes Backed Up: No Default: ' ' (blank)
$PWR,NORMAL specifies the name of the KCL command file that is executed if the system is not in a recoverable state at power up and the conditions for using the $PWR-RESTART command file are not met. If no name is spebified, a KCL command procedure is not executed. You are responsible for setting the value of $PWR,NORMAL if you want a command procedure to be executed at power up when the system is not in a recoverable state.
If you assign a command procedure name to $PWR-NORMAL the message "Running Power Up File lile-name" is displayed on the CRTIKB at pourer up, while the procedure is being executed, where file-name is the command file name. See Also:
$RECOVERABLE System Variable
$RECOVERABLE (recoverable) Data Type: INTEGER ProgramtKCL: NOIRO Power Up: No
"
Saved: No Backed Up: Yes Default: 0
$RECOVERABLE indicates whether or not the system is in a recoverable state for the power fail recovery procedure (optional feature). If it is zero, then the system is in a recoverable state ($PWR-FAIL is executed). Othe~wise,it is a nonzero value and the system is not recoverable ($PWR-NORMAL is executed). The value of $RECOVERABLE is set automatical1y as part of the power fail recovery procedure.
$REMOTE (remote) Data Type: BOOLEAN ProgramlKCL: NOIRO Power Up: No
Software Version 2.0 and UD 6 - 82
Saved: No Backed Up: No Default: TRUE
SYSTEM VARIABLE DESCRIPTIONS $REMOTE System Variable $REMOTE indicates tbe operator panel REMOTE keyswitch setting. It is TRUE when tile key is set to ON and a remote device has motion control. It is FALSE when tbe key is set to OFF and the operator panel has motion control. The value of $REMOTE is set and updated automatically.
$I? ESULT (result) Data Type: INTEGER PIogramlKCL: RWIRN Power Up: No
Saved: No 33a~ked.u~: Yes
The function of $RESULT depends on how it is used within a program. It allows the programmer to assign an integer value to a system variable. The value of $RESULT can be set by the RESULT condition handler action as p a t of a WHEN or. UNTIL clause. See Also:
Chapter 6, KAREL Reference Manual
$ROTARY-AXIS (rotary axis) Data Type: BOOLEAN ARRAY [9] ProgramlKCL: NOIPW Default: Robot Specific
Power Up: No Saved: Yes Backed Up: No
$ROTARY-AXIS is an array, with one element for each axis, indicating whether the axis is rotary or linear. A value of TRUE indicates a rotary axis and FALSE indicates a linear axis. The value of $ROTARY-AXIS is set by the KCL> UTILITY SINIT. command and should not be changed. For auxiliary axes, the default value is TRUE.
$ROTSPEED (rotational speed) Data Type: REAL ProgramlKCL: R W/RO Default: Uninitialized
Power Up: No Saved: No Backed Up: Yes
$ROTSPEED controls how fast the robot is allowed to rotate the tool center. point (TCP) approach vector for programmed Cartesian motion (linear, circular.) The value is expressed in radians per second.
-.
Software Version 2.0 and UP 6 - 83
SYSTEM VARIABLE DESCRIPTIONS $ROTSPEED System Variable
By default, the value of $ROTSPEED is set to an uninitialized value each time a program is executed. If you do not assign a value to $ROTSPEED in the program and the speed of the programmed motion is higher than the value of $ROTSPEEDLIM, the warning message "ROTATION SPEED LIMITS USED" is displayed. The robot speed will then slow down so that the rotation speed is less than $ROTSPEEDLIM See Also:
$ROTSPEEDLIM, $SPINSPEED, $SPINSPEEDLIM System Variables in this appendix Chapter 8, KAREL Reference Manual
$ROTSPEEDLIM (rotational speed limit) Data Type: REAL Program/KCL: RO/RW Power Up: No
Saved: Yes Backed Up: Yes Default: 1.5
$ROTSPEEDL.IM is the maximum value for the rotational speed of the TCP approach vector in programmed Cartesian motion. The value is expressed in radians per second. The default value may be reset to a higher value to increase the speed of the robot. If the new value is too large, the error message, "Joint velocity Limit ($JNTVELLIM)" will be displayed.
$RUNWITHERR (run with error) Data Type: BOOLEAN Program/KCL: NOPW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$RUNWITHERR, when set to TRUE, allows KCL> RUN and KCL> RESUME to execute while an error is pending. If $RUNWITHERR is FALSE, the error must be cleared before the K C W RUN or KCL> RESUME commands will execute. Note that the program will not be able to issue a motion if an error is pending.
$SCAN-TIM E (scan time condition handler qualifier) Program/KCL: WO/NO Minimum/Maximum: 11.512 Default: 1 $SCAN-TIME can only be used in a condition handler statement WITI3 clause.. This condition handler qualifier is not a normal system variable. It cannot be accessed by KCL (NO) and has write only (WO) access by programs.
Software Version 2.0 and Up 6 - 84
SYSTEM VARIABLE DESCRIPTIONS $SCAN-TIME Condition Handier Qualifier
$SCAN-TIME is used to specify the time in milliseconds between scans in a condition handler. The syntax for $SCAN-?UIE = time-in-ms where time-in--ms is an INTEGER expression. Actual time-in-ms values will be one of the following: 1, 2, 4, 8, 16,32, 64, 128,256, 512, times the value of the $COND-TIhE system variable. Any value less than $COND-TIME will default to the value of $COND-TIME. Any value greater than (512 * $COND-TIME) ms will default to (512 * $COND-TIME). Any value between one of the above intervals will default to the next lower value. See Also:
$COND,TIME System Variable
$SCN-HLD-NBL
(screen hold enable)
Data Type: BOOLEAN Program/KCL: NO/RW Power Up: No
Saved: Yes Backed Up: No Default: TRUE
$SCN-HLD-NBL indicates whether or not the CRT/KB HOLD SCREEN key, which stops the screen display from scrolling, is enabled. By default, $SCN-HLD-NBL is
TRUE.
$SCREEN-.HELD (screen held) Data Type: BOOLEAN ProgradKCL: NOIRO Power Up: No
Saved: No Backed Up: No Default: FALSE
$SCREEN-HELD indicates that scrolling onthe CRT screen is currently being held by the CRTIKB HOLD SCREEN key. $SCREEN--HELD is updated automatically each time you press the HOLD SCREEN key.
$SEGFRACTION (segment fraction) Data Type: REAL ProgramfKCL: ROIRO Power Up: No
Saved: No Backed Up: No Default: 0.0
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Software Version 2.0 and UP 6 - 85
SYSTEM VARIABLE DESCRIPTIONS $SEGFRACTION System Variable $SEGFRACTION indicates what fraction of the current segment has been interpolated. For example:
0.0 means interpolation is just beginning. 0.5 means interpolation is half done.
1.0 means interpolation is complete, and robot is starting to decelerate toward the destination Note that when the value is 1.0, the robot will not be exactly at the indicated position because of the digital filters. The robot still needs to decelerate. $SEGFRACTION is set and updated automatically.
--$S EGLENGTH (segment length) Data Type: REAL Prograrn/KCL: RO/RO Power Up: No
Saved: No Backed Up: No Default: 0.0
$SEGLENGTH indicates the current Cartesian length of a straight line segment or the arc length of a circular segment as computed by the motion planner for the segment currently being executed by the motion environment. Joint interpolated segments are treated as zero length segments. $SEGLENGTH is set and updated automatically.
$SEGTERMTYPE (segment termination type) Data Type: INTEGER MinimudMaximum: 115 ProgramlKCL: RWIRW Default: 4 (NODECEL)
Power Up: No Saved: No Backed Up: Yes
$SEGTERMTYPE indicates the default termination type for intermediate path nodes (all but the last node in a path), using the following values: l=FINE 2 = COARSE 3 = NOSETTLE 4 = NODECEL 5 = VARDECEL If the SEGTERMmPE associated data field is set to anything other than one of these values, then SEGTERMTYPE associated data overrides the $SEGTERMTYPE system variable value. If the SEGTERMTYPE field is left to the default then the type specified by the value of $SEGTERMTYPE is used
Software Version 2.0 and Up
6-86
SYSTEM VARIABLE DESCRIPTIONS $SEGTERMTYPE System Variable
$SEGJIME
(segment time)
Data Type: INTEGER ProgramKCL: RWIRO Power Up: No
Saved: No Backed IJp: Yes Default: 0
$SEG_TIME indicates the time required for a motion segment. E3y specifying a value for $SEG-TIME, you are specifying the time it will take to complete the segment. The speed will vary depending on the distance (as opposed to $SPEED in wliich the speed remains constant and the time varies). Motion statements are executed using $SEG,TIME as long as $SEG-TIME has a value that is greater than 0. $SEG-TIME is set to 0 each time a program is executed. The segment time is specified in units of milliseconds as an INTEGER value greater than or equal to 0. A value of 0 indicates $SPEED will be used instead of a segment time.
$SERVO-READY (servo ready) Data Type: BOOLEAN ProgramlKCL: ROIRO Power Up: No
Saved: No Backed Up: No Default,: FALSE
$SERVO-.READY indicates whether or not servo power is active. The value of $SERVO-READY is set and updated automatically.
$SIMUL-CAL (simultaneous calibration) Data Type: BOOLEAN ProgramlKCL: NO/RW Power Up: No
Saved: Yes Backed Up: No Default: TRUE
$SIMUL-CAL controls whether or not the axes move simcdtaneously during incremental calibration. If it is TRUE the axes (or groups of axes) move simultaneously. If'it is FALSE the axes move one at a time. $SIMULCAL has no meaning on robots with an APC system.
$SPEED (speed) Data Type: REAL ProgramIKCL: RWIRO Power Up: No
Saved: No Backed Up: Yes Default: 375*
Software Version 2.0 and UP 6 - 87
SYSTEM VARIABLE DESCRIPTIONS $SPEED System Variable $SPEED is the TCP translation speed of the programmed motions, expressed in rnmlsec. It is used to calculate the speed of all programmed motion.
*By default, the value of $SPEED is set to the product of $MANLIMI100 multiplied by $SPEEDLIM each time a program is executed. You can assign a new value within the
program. See Also:
Chapter 8 , KAREL Reference Manual
$SPEEDLIM (speed limit) Data Type: REAL Program/KCL,: RORW Power Up: No
Saved: Yes Backed Up: Yes Default: 1500
$SPEEDLIM is the motion translation speed limit, expressed in mrnlsec. It is the maximum value that can be assigned to $SPEED for Cartesian motion. It is also used in calculating the speed of Cartesian jog motion. The default value may be reset as long as it is a valid value specified by the robot specifications or the error message, "Joint speed limits used" will be displayed. See Also:
Chapter 8, KAREL Reference Manual
$SPEEDLIMJNT (speed limit joint) Data Type: REAL ProgramlKCL: RORW Power Up: No
Saved: Yes Backed Up: Yes Default: 1500
$SPEEDLM.iNT is the maximum value of $SPEED for programmed, joint interpolated motion. It is used to calculate the motion speed of each joint. See Also:
Chapter 8 , KAREL Reference Manual
$SPINSPEED (spin speed) Data Type: REAL ProgradKCL: RWIRO Defauit: Uninitiaiized
Software Version 2.0 and Up
6 - 88
Power Up: No Saved: No Backed Up: Yes
--
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SYSTEM VARIABLE D E S C R m N S $SPINSPEED System Variable
$SPINSPEED controls how fast the robot is allowed to spin about the tool center point (TCP) approach vector for programmed Cartesian motion (linear, circular). The value is expressed in radians per second. By default, the value of $SPINSPEED is set to an uninitialized value each time a program is executed. If you do not assign a value to $SPINSPEED in the program, and if the spin speed of the programmed motion is larger than the value of $SPINSPEEDLIM, the warning error message "ROTATION SPEED LIMITS USED" is displayed. The robot will then slow down so that the spin speed is within $SPINSPEEDLIM. See Also:
$ROTSPEED, $ROTSPEEDLIM, $SPINSPEEDLM System Variables in this appendix Chapter 8, KAREL Rcfirence Manual
$SPINSPEEDLM (spin speed limit) Saved: Yes Backed Up: Yes Default: 1.5
Data Type:REAL ProgramIKCL: ROmW Power Up: No
$SPINSPEEDLM is the maximum value for the spin speed about the TCP approach vector in programmed Cartesian motion. The value is expressed in radians per second. The default value may be reset to a higher value to increase the speed of the robot. If the new value is too large, the error message, "Joint velocity Limit ($JNTVELLIh4)" will be displayed.
$SPIN-CTRL (spin control) Saved: Yes Backed tJp: No Default: FALSE
Data Type: BOOLEAN Program/KCL: NO/PW Power Up: Yes
$SPIN-CTRL indicates which type of'control is used for 5-axis robots. If it is FALSE, approach vector contr.ol is used. If it is TRUE, spin control is used.
$SRVO,-BLOCK1 Reserved for GMF internal use only. $SRVO_BLOCK2 Reserved for GMF internal use only. ---
--
---
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-
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$SRVQBLOCK3 Reserved for GMF internal use onIy.
Software Version 2.0 and UP 6 - 89
SYSTEM VARIABLE DESCRIPTIONS $SRVO,RLOCK4 System Variable
-
-
-
-
$SRVO_BLOCK4 Reserved for GMF internal use only. $SRVO-BLOCK5 Reserved for GMF internal use only. -
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$SRVO-BLOCK6 Resewed for GMF internal use only. $SRV-CODE-ID
(servo code identification)
Data Type: STRING ProgradKCL: NOfRO Default: Robot Specific
Power Up: No Saved: No Backed Up: No
$SRV-CODE-ID is the revision level of the digital servo code. It is set internally and cannot be changed. -
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--- -
--
$SRV-PARM-ID
--
-
(servo parameters identification)
Data Type: STRING Prograrn/KCL: NOIRO Default: Robot Specific
Power Up: No Saved: No Backed Up: No
$SRV-PARM-ID is the revision level of the default digital servo parameters. It is set internally and cannot be changed. If $SRV-PARAM-ID is blank or uninitidked at power up, the user will be prompted to enter the Servo Parameter Setting Program disk. This will copy the file KSSP.CF and execute it. Power down and power up the controller to continue.
$STOPERLIM (stop error limit) Data Type: INTEGER ARRAY [9] Minimum/Maximum: 0132767 Program/KCL: NO/PW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$STOPERLIM defines an array of the servo following error tolerances while stopping for each axis. It is expressed in units of detector pulses. The value of $STOPERLIM is set by the KCL> UTILITY SINIT command and should not be changed. For auxiliary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program. Software Ve~sion2 0 and Up 6 - 90
SYSTEM VARIABLE DESCRIPTIONS $STOP-ON-ERR System Variable
(stop on error)
$STOP-ON-ERR
Saved: Yes Backed Up: No Default: FALSE
Data Type: BOOLEAN PsogramKCL: NOIRW Power Up: No
$STOP-ON-ERR inclicates whether or not the system stops on a KCL command file error. If'TRUE, execution of the command procedure stops if any error condition is found. You can set and clear $STOP-ON-ERR within a command procedure to control the execution of command files depending on desired response to errors. Note that $STOP-ON-ERR applies only to errors that can be detected by the KCL command interpreter. For example, a KCL> MOVETO command can cause a solution error that prevents the motion from proceeding, but the KCI, command interpreter will continue because the motion command itself has succeeded.
$SV-OFF-ENB
(servo off enable)
Data Type:BOOLEAN ARRAY [9] Program/KCL: NO/PW Power Up: Yes
Saved: Yes Backed Up: No Default: FALSE
$SV-OFF-ENB controls whether or not each servo motor uses a timed servo shutdown feature. It is used with $SV-OFF-TIME to shut off servo motors after motion has been completed. This feature is used primarily for energy saving purposes. The value of $SV-OFF-ENB is set by the KCL> UTILITY SINIT command and should not be changed.
$SV-OFF-TIME
(servo off time)
Data Type: INTEGER ProgradKCL: NO/PW Power Up: Yes
Saved: Yes Backed Up: No Default: loo00
$SV-OFF-TIME defines the time interval, in milliseconds, after which the servo motors are shut down. The value of $SV-OFF-??ME not be changed.
is set by tbe KCL> UTILITY SINIT command and should
Software Version 2.0 and Up 6 - 91
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SYSTEM VARIABLE DESCRIPTIONS $SV-OFF-TIME System Variable See Also:
$SV-OFF-ENB System Variable in this appendix
$SYNC-GAIN
(synchronous compensation gain)
Data Type: INTEGER MinimuxdMaximum: 0/127 ProgramIKCL: NO/PW &fault: 20
Power Up: Yes Saved: Yes Backed Up: No
$SYNCGAIN defines the compensation gain for robot models with dual drive (synchronous) control. The value of $SYNC-GAIN is set by the KCL> UTILITY SINIT command and should not be changed.
$SYNC-M-AX1 S (synchronous master axis) Data Type: INTEGER MinimudMaximum: 019 ProgramlKCL: NO/PW
Power Up: Yes Saved: Yes Backed Up: No
Default: 0 $SYNC-M-AXIS indicates which robot axis motor has been designated as the master axis for robot models with dual drive (synchronous) control. The value of $SYNC-M-AXIS is set by the KCL> UTILITY SINIT command and should not be changed.
$SYNC-OFFSET (synchronous compensation offset) Data Type: INTEGER MinimudMaximum: 0/32767 Program/KCL: NOIPW Default: 150
Power Up: Yes Saved: Yes Backed Up: No
$SYNC-OFFSET defines the compensation offset for robot models with dual drive (synchronous) control.. The value of $SYNC-OFFSET is set by the KCL> UTILITY SMIT command and should not be changed.
Software Version 2.0 and Up 6 - 92
SYSTEM VARIABLE DESCRIPTIONS $SYNC-S-AXIS System Variable
$SYNC-S-AXIS
(synchronousslave axis)
Data m e : INTEGER Minimum/Maximum: 019 Pr ogamlKCL: NOIPW Default: 0
Power Up: No Saved: Yes Ebcked Up: No
$SYNC,S,AXIS indicates which robot axis motor has been designated as the slave axis for robot models with dual drive, or synchronous, control. The value of $SYNC-S-AXIS is set by the KCL> UTILITY SINIT command and should not be changed.
$SYN-AD J-MOD (synchronous adjust mode) Saved: No Backed Up: No Default: FALSE
Data Type: BOOLEAN ProgradKCL: NO/PW Power Up: No
For robot models with dual drive (synchronous) control, $SYN,ADJ-MOD whether or not the synchronous adjust mode is enabled.
indicates
If it is TRUE, synchronous adjust mode is enabled and you can jog only the master or only the slave motor. You cannot move any of the other axes while synchronous adjust mode is enabled. If it is FALSE, you cannot jog the master and slave motors independently.
$SYN,ADJ-MOD shotlid remain FALSE for all normal operation. If it is set to TRUE, the robot loses its calibration and must be recalibrated after $SYN,ADJ--MOD is set back to FALSE. -
- -
- - --
-- -
$SYN_ADJ-SEL (synchronous adjust selection) Data Type: BOOLEAN Program/KCL: NOIPW Power Up: No
Saved: No Backed Up: No Default: FALSE
For robot models with dual drive (synchronous) control, $SYN,ADJ-SEL indicates ~vhich axis, either master or slave, is selected for synchronous adjust mode. If it is TRUE, the slave axis is selected. If it is FALSE, the master axis is selected. If you want to adjust the slave axis, you must set $SYN-ADJ-SEL to TRUE.
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Software Version 2.0 and UP 6 - 93
SYSTEM VARIABLE DESCRIPTIONS $SYN-ERR-CNT System Variable
$SYN-ERR-CNT (synchronous error counter) Data Type: INTEGER ProgramIKCL: NOfRO Power Up: No
Saved: No Backed Up: No Default: 0
$SYN,ERR-CNT is the value of the error counter for robot models with dud drive (synchronous) control.
$SYN-,ERR-LIM (synchronous error limit) Data Type: INTEGER Minimum/Maximurn: 0132767 Program/KCL: NOIPW Default: 1000
Power Up: Yes Saved: Yes Backed Up: No
$SYN,ERR-LIM defines the error h i t for robot models with dud drive (synchronous) control. The value of $SYN-ERR-LIM is set by the KCL> UTILITY SINIT command and should not be changed.
$TCPEXTREME (tool center point extreme) Data Type: POSITION ProgramlKCL: R W/RO Default: Uninitialized
Power Up: No Saved: No Backed Up: Yes
$TCPEXTREME can be used to indicate the x-extreme position of a path for rail tracking (optional feature). $TCPEXTREME is used to ensure that a path is not executed until this extreme enters the lower boundary. $TCPEXTREME is set uninitialized each time a program is executed. Extreme checking is performed only if $TFRAMENUM is greater than 1.
Software Version 2.0 and UP 6 94
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SYSTEM VARIABLE DESCRIPTIONS $TERMTYPE System Variable
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$TERMTYPE (motion termination type) Data Type: IN'TEGER Minimum/Maximum: 115 ProgramlKCL: RWIRW Default: 2 (COARSE)
Power Up: No Saved: No Backed Up: Yes
$TERMTYPE defines the type of motion termination at the end of an interval using the following values: 1 = FINE 2 = COARSE 3 = NQSETTTdE 4 = NODECEL 5 = VARDECEL The default value of $TERMTYPE is set each time a program is executed. See Also: Chapter 8, KAREL Reference Manual -
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--
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$TFRAMENUM (tracking frame npmkr) Data Type: MTEGER MinimudMaximum: -413 ProgramfKCL: R W/RO Default: 0
Power Up: No Saved: No Backed Up: Yes
$TFRAMENUM is used by the motion environment to determine which tracking frame to use for line tracking and dynamic path modification. If it is 0, $UFRAME is used for all motions. The values 1, 2, and 3 specify tracking frames 1,2, and 3. When used in conjunction with dynamic path modification, the values determine the coordinate fiame of reference as Iisted in the following table: $TFRAMENUM -1 -2
-3 -4
-
$DELTAFRAME location location + orientation location location + orientation
Coordinate Frame World World User Frame User Frame
$TFRAMENUM is used only for molions caused by the KAREL interpreter. All KCL or teach pendant motions are always relative to $UFRAME.
See Also: $DELTAFRAME System Variable in this appendix
Software Version 2.0 and UP 6 - 95
SYSTEM VARIABLE DESCRIP'TlONS $TP_USERSTATSystem Variable
$TP-USERSTAT (teach pendant user status line) Data Type: BOOLEAN ProgramlKCL: RWRO Power Up: No
Saved: No Backed Up: Yes Default: FALSE
$TP-USERSTAT indicates whether the KAREL system or the application program has control of the teach pendant status line.
If $TP_USERSTAT is set to TRUE and a KAREI, program is running or paused. the system stops updating the status line, giving control to the program. The predefined constant TPSTATUS can be used to write to the status line when $TP_USERSTAT is TRUE. If $TP_USERSTATis set to FALSE the system automatically updates the status line. By default, $TP,USEKSTAT is set to FALSE each time a program is executed. It automaticdly resets to FALSE when program execution ends or the program is aborted.
$Y RK-AXSNUM (tracking auxiliary axis number) Data Type: INTEGER ARRAY [Z] ProgramlKCL: NOmW Power Up: No
Saved: Yes Backed Up: No Default: 0
$TRK-AXSNUM is used mainly for teaching positions for auxiliary axis tracking applications (optional feature). Each element of $TRY,AXSNUM can be assigned an auxiliary axis number. Then $AUX-ZROSHFT will be appIied to the specified axis.
$TSPEED (TCP speed) Dab Type: INTEGER Program/KCL: ROlRO Power Up: No
Saved: No Backed Up: No Default: 0
$TSPEED is the tool center point (TCP) speed estimate. It is derived from the following equation: $TSPEED =$TSPEEDSCALE *estimmtcpPspeed+$TSPEEDOFST
(If$TSPEEDSCALE = 1.0 and $TSPEEDOFST = 0 then $TSPEED is in mmlsec.)
Software Version 2.0 and tlD 6-96
SYSTEM VARIABLE DESCRIPTIONS $TSPEED System Variable The value of $TSPEED is set by the interpolator at the Cartesian update rate for the current segment. The estimate is passed through the acceleration/deceleration algorithm, so it will have approximately the same accelerationldeceleration profile as the joints. See Aiso:
$TSPEEDENBI, System Variable in this appendix ---
-
$TSPEEDENBL (TCP speed enable) Data Type: BOOLEAN PrograrnIKCL: RWIRW Power Up: No
Saved: No Backed Up: No Default: FALSE
$TSF'EEDENBL enables the TCP speed estimation. H it is FALSE,$ W E E D is 0.
By default, the value of $TSPEEDENBL is set to FALSE. See Also:
$ W E E D System Variable in this appendix
$TSPEEDOFST (TCP speed offset) Data Type: INTEGER ProgramlKCL: RWIRW Power Up: No
Saved: No Backed Up: No Default: 0
$TSPEEDOFST is used in calculating the value of $TSPEED when you want $TSPEED to have a value other than zero when the robot is not moving. You are responsible for setting the value of $TSPEEDOFST. See Also:
$TSPEED System Variable in this appendix
$TSPEEDSCALE (TCP speed s d e ) Data Type: REAL ProgramKCL: RWIRW Power Up: No
Saved: No Backed Up: No Default: 1.0
$TSPEEDSCALE, a scaling factor, is used in calculating the value of $TSPEED. It is used to scale the value of $TSPEED if mmlsec is not the desired unit. You are responsible for setting the value of $TSPEEDSCALE. See Also:
$TSPEED System Variable in this appendix
---
Software Version 2.0 and UP 6 - 97
SYSTEM VARIABLE DESCRIPTIONS $TTOOLNUM System Variable
$TTOOLNUM (tracking tool frame number) Data Type: INTEGER MinimumlMaximum: --4/2 PrograrnIKCL: RW/RO Default: 0
Power Up: No Saved: No Backed Up: Yes
$TTOOLNUM is used to indicate how $DELTATOOL is to be applied. Its value determines whether $DELTATOOL will be with respect to the tdol coordinate system or the path relative coordinate system (attached to the path trajectory). $?TOOLNUM can be set in a KAREL program. The values for $TTOOLNUM, $DELTATOOL, and the coordinate systems used are listed in the following table:
$a"L'OoLNUM
I
$DELTATOOL location location + orientation none location location + orientation location location + orientation
1 2
0 -1 -2
-3 -4
Coordinate System Tool Tool Path Relative Frame Path Relative Frame Path Relative Frame Path Relative Frame
See Also:
$DELTATOOL System Variable in this appendix
$UDIN-ENBL (user definable input enable) Data Type: BOOLEAN ProgramtKCL: NOIPW Power Up: No
Saved: Yes Backed Up: No Default: FALSE
$UDM-ENBL enables the upper eight bits of the UOP (user operator panel) input module for user-definable input. If it is FALSE, the upper eight bits of the input module can be used for other user-defined input signals. $IJDIN_ENBL must be set to TRUE in order for the predefined command procedures KCP-UOPl through KCP-UOP8 to be executed.
Software Version 2.0 and UP 6 - 98
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SYSTEM VARIABLE DESCRIPTIONS $UFRAME System Variable
--
$UFRAME (user frame) Data Type: POSITION ProgramlKCL: RWIRW Default: $NILP
Power Up: No Saved: Yes Backed Up: Yes
$UFRAME is the position of a user frame of reference. A11 programmed positions are defined with respect to $UFRAME. Any value you assign to $UFRAME is defined with respect to the world coordinate system. By default, $UFRAME is identical to the world coordinate system, meaning $UFRAME = $NILP. Chapter 8, "Motion" -
--
$UO-POLARITY (user operator panel polarity) Data Type: INTEGER ProgramIKCL: NOIPW Power Up: No
Saved: Yes Backed Up: No Default: 0
$UO-POLARITY indicates the polarity of user operator panel (UOP) signals. When the decimal INTEGER is converted to a binary number, each bit of the $UO-POLARITY value corresponds to a bit in the UOP output value. If a bit is set to 0, the polarity of the signal is not changed.. If a bit is set to 1, the polarity is inverted.
$UPPERLIMS (upper joint limits) Data Type: REAL ARRAY [9] ProgramIKCL: NOIPW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$UPPERLIMS defines the upper joint limits, in radians or millimeters. The value of $UPPERLIMS is set by the KCL> UTILITY SINIT command and shotlld not be changed.. For auxiliary axes, you are responsible for setting the value correctly using the Motion Hardware Setup Program.
Software Version 2.0 a n d m 6 - 99
SYSTEM VARIABLE DESCRIPTIONS $USAT System Variable
$USAT (user signal assignment table) Data Type: INTEGER ARRAY 1981 ProgramIKCL: NOfPW Power Up: Yes
Saved: Yes Backed Up: No Default: 0
$USAT is an array that corresponds to the User Signal Assignment Table (USAT). You are responsible for setting the value of $USAT if you want to use user-definable input and output. See Also:
Chapter 13, KAREL Reference Manual for more information on the USAT
$USE-CAL (use calibration procedure) Data Type: BOOLEAN ProgrdKCL: NOIRW Power Up: No
Saved: Yes Backed Up: No Default: TRUE
$USE-CAL enables or disables automatic-calibration. If it is TRUE, automatic calibration is executed when the operator panel CALIBRATE button is pressed. If $USE-CAL is FALSE, the current position of the robot is taken as the zero position for
all axes and the register values are returned to zero when you press the CALIBRATE button. In this case, the normal calibration procedures are not used.
$USE-CARTACC (use Cartesian acceleration) * Data Type: BOOLEAN Saved: No ProgramIKCL: NOfRW
Power Up: Yes Default: FALSE Backed Up: No
By setting the system variable $USE-CARTACC, path accuracy can be improved for both position and speed for Cartesian acceleration (optional feature). The improvement becomes more noticable as speed increases. However, at very high speeds, the motion will not be as smooth.
When $USE,CARTACC is TRUE, about 60% of the acceleration is performed in Cartesian space (for example, in the direction of a line for linear motion or along the circle for circular motion). $USE-CARTACC is set to FALSE every time a program is executed. The motion clause, WITH $USE-CARTACC = TRUE or WITH $USE-CARTACC = FALSE, applies only to that particular motion. --
Software Version 2.0 and Uo 6 - 100
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--
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SYSTEM VARIABLE DESCRIPTIONS $ USE-CONFIG System Variable
$USE-CONFIG (use configuration) Data Type: BOOLEAN ProgradKCL: RWIRW Power Up: No
Saved: No Backed Up: Yes Default: FALSE
$USE-CONFIG indicates how the system handles Cartesian moves where the configuration is inconsistent from one position to the next. For example, configurations having flip and nofiip configuration are inconsistent with one another. If the value of $USE-CONFIG is TRUE the inconsistency causes an error that pauses the program. If the value is FALSE, the motion is carried out, using the joint placement of the beginning position. For example, if $USE-CONFIG is FALSE and a move is from a position with a noflip joint placement to one with a flip joint placement, noflip is used. Configuration not only includes joint placement (flip, noflip) but also turn number. If $USE-CONFIG is set to TRUE the turn number from the taught point will be applied to determine the destination position. If $USE-CONFIG is set to FALSE the turn number from the taught point will be ignored.. See Also:
Chapter 8, KAREL Reference Manual
$USEMAXACCEL (use maximum acceleration) Data Type: BOOLEAN Program/KCL: RWIRW Power Up: No
Saved: No Backed Up: No Default: FALSE
$USEMAXACCEI, enables or disables the fast acceleration/deceleration feature. If it is TRUE the required acceleration time is linearly reduced to improve fast acceleration and deceleration, reduce the percentage of corner rounding, and improve the cycle time. If it is FALSE, the normal acceleration time is applied..
By default, $USEMAXACCEL is set to FALSE each time a program is executed.
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Software Version 2.0 and UP 6 101
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SYSTEM VARIABLE DESCRIPTIONS $ USERELACCEL System Variable
$USERELACCEL (use relative acceleration) Data Type: BOOLEAN Saved: ProgramIKCL:
Power Up: Default: Backed Up:
If $USERELACCEL is True, the desired motion will use the $ACCEL,OVRD and RELACCEL values (optional feature). If $USERELACCEL is False, the acceleration time defined in $ACCEL,OVRD will be ignored.
$USER-ALARM (user aIarm) Data Type: BOOLEAN Saved: No Program/KCL: NOIRW
Power Up: No Default: FALSE Backed Up: No
$USER-ALARM can be used to turn off servo power while switching the multiplex auxiliary axes. If $USERALARM is TRUE, the servo alarm error message, 4037 "User servo alarm," will be displayed, the servo power wiI1 be dropped and the program will pause. You must set $USER-ALARM to FALSE,and press the ieset button or use the RESET KCL command to reset the servo power. The user alarm is generated by the software and will not affect the emergency stop contact status.
Software Version 2.0 and Up 6 - 102
SYSTEM VARIABLE DESCRIPTIONS $USER-PB1 System Variable
$USER-PB1 (user pushbutton 1) * Saved: Yes Backed Up: No Default: ' ' (blank)
Data Type: STRING[12] ProgramlKCL: RO/RW Power Up: No
$USER-PB1 specifies the KCL command procedure that is executed when the operator panel USER PBI button is pressed. If the command procedure is not found, the system will search for a pcode file of the same name as specified in $USER-PBI. If found in RAM, this file will be executed. If it is found in bubble memory, the file will be loaded before execution. The command procedure is executed whether 01.not a KAREL program is running. You are responsible for setting the value of $USER-PBI if you want the USER PBI button to execute a command procedure. See Also:
Enhanced K A m Operations Manual for more information on setting $USERPBl.
$USER--PB2 (user pushbutton 2) Data Type: STRING[12] ProgramlKCL: RO/RW Power Up: No
* Saved: Yes Backed Up: No Default: ' ' (blank)
$USER-PI32 specifies the KCL command procedure that is executed when the operator panel USER PI32 button is pressed. If the command procedure is not found, the system will search for a pcode file of the same name as specified in $USER,PB2. If found in RAM, this file will be executed. If it is found in bubble memory, the file will be loaded before execution. The command procedure is executed whether or not a KAREL program is running. You are responsible for setting the value of $USER_PB2 if you want the USER PB2 button to execute a command procedure. See Also:
Enltcutced KAREL Operations Manual for more information on setting $USER_PB2.
$UTOOL (user tool) Data Type: POSITION ProgradKCL: RW/RW Power Up: No
Saved: Yes Backed Up: Yes Default: $NILP
Software Version 2.0 and UP 6 - 103
SYSTEM VARIABLE DESCRIPTIONS $UTOOL System Variable $UTOOL defines the location and orientation of the tool that is attached to the faceplate. The position in $UTOOL is defined with respect to a fured coordinate system on the robot faceplate and is the origin of the TOOL FRAME. By default, the value of $UTOOL is set to $NILP, which means the position of the TCP is identical to the location and orientation of the faceplate coordinate system. You must change the value of $UTOOL to define the specific tool you are using. See Also:
Chapter 8, KAREL Reference Manual
$VERSION-ID
(version identifier)
Data Type: STRING ProgradKCL: NOIRO Default: Software Specific
Power Up: No Saved: No Backed Up: No
$VERSION-ID identifies the KAREL software version currently in use. The $VERSIONNU)string appears on the POWER UP screen of the CRT. The value of $VERSION-ID is set internally.
$WRIST-TYPE (wrist type) Data Type: INTEGER MinimumlMaximum: 019 Program/KCL: NO/PW Default: Robot Specific
Power Up: Yes Saved: Yes Backed Up: No
$WRIST-TYPEdefines the type of wrist and the number of robot axes used with that wrist. The meanings associated with the values 0 through 9 depend on which robot is being described. The value of $WRIST-TYPE is set by the KCL> UTILITY SINIT command and should not be changed.
Software Version 2.0 and Up 6 - 104
SYSTEM VARIABLE DESCRIPTIONS S420 SYSTEM VARIABLE DEFAULT VALUES
4.2 S-420 System Variable Default Values
Table 4.2. S-420System Variable Default Values
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S420*
$ACCEL-TIMEl[l] $ACCEL_TIMElr2] $ACCEL-TIME1[3] $ACCEL-TIMEl[4] $ACCEL-TIMElrS] $ACCEL-TIME1 [G] $ACCEL-TME2[1] $ACCEL-TIME2[2] $ACCEL-TIME2[3] $ACCEL-TIME2[4] $ACCEL-TIME2[5] $ACCEL-TIME2[6] $APC,SYSTEM $-TYPE $ARM,TYPE $AXISORDER[l] $AXISORDER[Z; $AXISORDER[3: $AXISORDER[4] $AXISORDER[5] $AXISORDER[6] $BELT-ENABLE $BRK-ON-HOLD $CART-ACCEL1 $CART-ACCEU $CMR[l] k [ 2 ]
Default Value
1
I
I I 1 1
512 416 384 384 384 384 288 192 192 192 192 192 TRUE 4 5 2 3 1 6 5 4 FALSE FALSE 320 160 1 1
Notes
-.
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Floor mount Angle mount W
U 0
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ar
p Y
Command multiplier ratio = 1 Command multipliex ratio = 1
*Wall and Angle Mount have the same values..
Software Version 2..0and UD
SYSTEM VARIABLE DESCRIPTIONS S-420 SYSTEM VARIABLE DEFAUL,T VALUES
Table 4.2. S-420 System Variable Default Values (Continued) Default Value
M20* $CMR[3] $CMR[4] $CMR[S] $CMR[6] $COARSETOL[l] 1 $COARSETOL[2] $COARSETOL[3] -..$COARSETOL[4] $COARSETOL[51 $COARSETOL[6] $CONFIG,MASK* $DMR[l] $DMR[2] $D-[3] $DMR[4] $DMR[5] $DMR[6] $DYNAMICFLTR $ENCSCALES[l] $ENCSCALES[2] $ENCSCALES[l] $ENCSCALES[2] $ENCSCALES[3] $ENCSCALES[4] $ENCSCALES[5] $ENCSCALES[6] $ENCSCALES[q $FB-MON-ENB[l] $FB_MON_EN3[2] $FBJVlON-ENB[3] $FB-MON-ENB[4]
1
'
Notes
1 Command multiplier ratio = 1 1 Command multiplier ratio = 1 1 Command multiplier ratio = 1 1 Command multiplier ratio = 1 300 1 ---. 300 300 300 300 300 11010110 1OOOOOOO -10624 7 Detector multiplier ratio = 4 7 Detector multiplier ratio = 4 7 Detector multiplie~ratio = 4 7 Detector multiplier ratio = 4 7 Detector multiplier ratio = 4 7 Detector multiplier ratio = 4 FALSE 164247.9013 Floor mount, 516000/ countdrad 164247.9013 Floor Mount, 5160001 countdrad 245007.6667 Angle Mount, 53880001~countdrad 245007.6667 Angle Mount, 5388000/~countdrad 164247.9013 516000l~rcountdrad 126050.7149 396000/7~wunts/rad 123589.1185 In-Line Wrist, 4000*1456/(15~r)countslrad 122886.9076 Standard Speed Wrist, 4000*3185/33n countdrad 75622.71235 High Speed Wrist, 4000*1960/33~icountslrad TRUE -
TRUE TRUE TRUE
*Wall and Angle Mount have the same values. **Refer to $CONFIG-MASK in the System Variable Alphabetical Description of this handout for definition of the $CONFIG-MASK bits.. a
Software Version 2.0 and Up 6-106
I
SYSTEM VARIABLE DESCRIPTIONS S420 SYSTEM VARIABLE DEFAULT VALUES
TabIe 4.2. S-420 System Variable Default Values (Continued) Default Value
S-420* $FB_MON-ENB[5] $FB-MON-ENB[6] $FB_MON,ENB[7l $FILMON-ENB[8] $FB-MON-ENl3[9] $FINETOL[l] $FINETOQ2] $FINETOL[3] $FINETOL[4] $FINETOQ5] $FINETOyq $GAINS[l] $GAINS[2] $GAINS[3] $GAINS[4] $GAINS[S] $GAINS[6] $GRID[l] $GRID121 $GRID[3] $GRID[4] $GRID[S] $GRfDI6] $JNTVELLIM[l] $JNTVELLIM[2] $JNTVELLIM[l] $JNTVELLIM[2] $JNTVELLIM[3] $JNTVELLIM[4] $JNTVELLIM[5] $JNTVELLIM[6] $JNTVELLIM[6]
Notes
TRUE
1
TRUE TRUE TRUE TRUE 150 150 150 150 150 150 16 20 20 20 20 20 7 7 7 7 7 7 1.57079632679489 1.57079632679489 1.047197551 1.047197551 1.57079632679489 2.09439510239319 2.09439510239319 2.09439510239319 3.141592654
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means 4 means 4 means 4 means4 means4 means 4 Floor Mount, 90 dedsec Floor Mount, 90 deglsec Angle Mount, 60 degtsec Angle Mount, 60 deg/sec 90 deglsec 120 deglsec 120 dedsec Standard Speed Wrist,l20 deg/sec High Speed WIist, 180 dedsec
*Wall and Angle Mount have the same values.
Software Version 2.0 and Up 6 - 107
SYSTEM VARIABLE DESCRIPTIONS S420 S Y S E M VARIABLE DEFAULT VALUES
Table 4.2. S-420 System Variable Default Values (Continued) W20*
Default Value
$LINI(-LEN-1 $LINK-LEN-2 $LOW E R L W l ] $LOWERLIMS[2] $LOWERLIMS[3] $LOWERLIMS[4] $LOWERLIMS[5] $LOWERLIMS[61 $MASTER-POS[1: $MASTERRPOg21 $MASTERRPOS[3] $MASTERRPOS[4] $MASTERRF'OS[5] $MASTER-POS[6] $MASTERRPOS[l] $MASTERRPOS[2j $MASTERRPOS:3] $MASTERRPOS:4] $MASTERRPOS[5] $MASTER_POS[63 $MR\T_ACCTIME[l] $MIN_ACCTUIE[Z] $MIN_ACCTIME[3] $MINRACCTIME[4] $MIN-ACCTIME[5]
0.0 0.0 -2.617993877799149 -0.872664626 -1.745329252 -4.188790205 -2.09439510239320 -4.71238898 0.0 0.610865238 -1.745329252 0.0 -1.396263402 0.0 0.0 0.59428461 -1.718712981 0.0 -1.422879673 0.0 256 - 256 256 256 256 256 256 256 256 1935 1935 1925 1925
$MIN_ACCTIME[7] $MIN_ACCTIME[8] $MIN_ACCTIME[9] $MOT-SPDDLIM[l] $MOT-SPDDLIM[2] $MOT-SPD-LIM[l] $MOTRSPDDLIM[21
*Wall and Angle Mount have the same values
Software Version 2.0 and Up 6 - 108
Notes
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-150 deg -50 deg -100 deg -240 deg -120 deg -270 deg Floor Mount, 0 deg Roo1 Mount, 35 deg Floor Mount, -100 deg Floor Mount, 0 deg moor Mount, -80 deg Floor Mount, 0 deg Angle Mount, 0 deg Angle Mount, 34.05 deg Angle Mount, -98.475 deg Angle Mount, 0 deg Angle Mount, -81.525 deg Angle Mount, 0 deg
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Floor Mount Floor Mount Angle Mount Angle Mount
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SYSTEM VARIABLE DESCRIPTIONS S-420 SYSTEM VARIABLE DEFAULT VALUES
Table 4.2. S-420 System Variable Default Values (Continued) r
Notes
Default Value
S-420' $MOT_SPD,LIM[3] $MOT,SPD,LIM[4] $MOT-SPD,LIM[S] $MOT-SPD,LIM[6] $MOT-SPD-LIh4[6] $MOVERRLIM[l]
1935 1980 1942 1931 1782 20156
$MOVERRLUI[l]
32250
$MOVERRLIM[Z] $MOVERRLIM[lJ
16125 20053
$ROTARY_AXIS[6] j $SPIN_CTRL $STOPERLIM[l] I $STOPERLIM[2] $STOPERLIM[3] $STOPERLIM[4] $STOPERLIM[5] I $STOPERLIM[6]
I
I
1
In-Line Wrist Standaxd Speed Wrist High Speed Wrist Floor Mount, max 1935 rpm, Pgain = 16, for DSP I axis control board Floor Mount, max 1935 rpm, Pgain = 10, for DSP II axis control board Floor Mount, max 1935 rpm, Pgain = 20 Angle Mount, max 1925 rpm, Pgain = 16
1 1
Detector pulses Detector pulses Detector pulses Detector pulses Detector pulses Detect01 pulses
TRUE FALSE 1200 -1200 1000 800 800 800
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1
'Wall and Angle Mount have the same values.
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Software Version 2.0 and Up 6 - 109
SYSTEM VARIABLE DESCRIPTIONS 5420 SYSTEM VARIABLE DEFAULT VALUES
Table 4.2. S-420System VariabIe Default Values (Continued) I
Notes
Default Value
S-420*
FALSE $SV-OFF-ENB[l] $SV-0FFFFENB[2] FALSE $SV_OFF_ENB[3] f FALSE FALSE I $SV_OFF_ENB[4] FALSE $SV-OFF_ENB[S] $SV-OFF_ENB[6] FALSE $SV-OFFFFloo00 2.61799387799149 150 deg $UPPERLIMS[l] $UPPERLIMS[2] 1.134464014 65 deg -.$UPPERLIMSP] 0.523598775598299 f 30 deg 4.188790205 240 deg $WPERLIMS[4] $ uPPERLIMS[5] 2.09439510239320 1 120 deg --$uPPERLIMS[q I 4.71238898 270 deg 10 In-Line Smdard Speed Wrist $Wrist-TYPE 12 1 In-Line EHgh Speed Wrist 1 1 $Wrist-TYPE
2
1
1
!
I I
1 1 1
1 1 1
*Wall and Angie Mount have the same values.
Software Version 2.0 and UD 6 - 110
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