manual robo kawasaki.pdf

7/27/2019 manual robo kawasaki.pdf

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C Series Controller

Kawasaki Heavy Industries, Ltd.

902031075DEB

Explosion-Proof Type

Operation Manual

Caution

Read this manual carefully before you use the robot

actually and keep it safe, so as to fully bring out the

functions of our Kawasaki Robot for ourself.


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C Series Controller, Explosion-Proof Type For safety

Kawasaki Robot Operation Manual

i

FOR SAFETY

This operation manual and the labels on the products are indicated with the symbols belowfor

proper use and to avoid injuries or property damage.

Read this manual and the related documents thoroughly before installation, operation,

maintenance and inspection.

Identifies procedures that, if not properly followed, can

result in imminent injury or death.

DANGER

Identifies procedures that, if not properly followed, may

possibly lead to injury or death.

WARNING

Identifies procedures that, if not properly followed, may

lead to human and/or mechanical injury.

CAUTION

Denotes easily-misunderstood items regarding product

performance, operation, and maintenance.

[ NOTE ]


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This manual intends to explain the operational procedures as detailed as possible. As not all

operations can be explained in one manual, only the major functions are explained.

Therefore, only the operation of functions specifically described herein can be guaranteed.

PREFACE

This manual describes operational procedures for the Kawasaki C Series Controller,

Explosion-Proof Type.Please read the Safety Manual thoroughly, a separate volume, before reading this manual.

Also, this manual should be read before actual operation of the robot, and be stored for

safe-keeping for later reference.

This manual is written on the following assumptions:

The robot is installed according to the Installation and Connection Manual (for robot arm), a

separate volume.

The controller is installed and connected according to the Installation and Connection Manual

(for robot controller), a separate volume.

The peripheral equipment is connected with the controller according to the External I/O Manual,a separate volume.

Because Kawasaki constantly strives to improve the quality of its products, this manual may

be changed or revised without prior notice.This manual may not, in whole or in part, be reproduced or copied without the prior written

consent of Kawasaki.

Though this manual was prepared to be as thorough and accurate as possible, the authors

apologize should any information be found in error.

The screen examples in this manual may differ depending on software version.

Some functions may not be installed depending on software version.

This manual concerns operating procedures. It is not a guarantee of safety, and Kawasaki

is not responsible for damages by the system or any industrial property troubles related with

patent, as in the event of unforeseen trouble.

MS-DOS is a registered trademark of Microsoft Corporation, USA.

The other company and product names are also registered.

All rights reserved. Copyright @ 2001 by KAWASAKI HEAVY INDUSTRIES, LTD.


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BASIC CONFIGURATION OF THIS MANUAL

This manual describes the fundamental operational procedures for the Kawasaki C Series

Controller, Explosion-Proof Type.

Overview and basic operations that need to be understood first for using Kawasaki RobotController are explained. Operations which are common in every application and are peculiar to

painting application are included and need to be read thoroughly.

Many functions for making full use of the controller are also explained and should be read

depending on the aim of the user.

A glossary is included at the end of the manual as a reference for commonly used language and

keywords regarding robots.

The) indicates a reference. For example, ) A-142 indicates that the auxiliary function 142

should be referenced.


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TEACHING METHODS

The Kawasaki C Series Controller, Explosion-Proof Type can be programmed by a variety of

equipment including the explosion-proof teach pendant.

Select a teaching method that best suits the needs of your application and level of expertise.

Explosion-proof teach pendant:

Multifunction panel:

PC (Option):

Various data can be displayed and set

using the multifunction panel. Its

keyboard screen is used for

programming.

Manual operation and teaching for the

robot can be conducted using the

explosion-proof teach pendant.

Manual operation can be conducted

only by the teach pendant.

It is possible to create an advanced

application program by entering program

instructions on PC. (This is called

general programming.) Robot

Language (AS Language) functions canbe fully used, so that programs using

advanced functions, such as coating

operations, communication, and vision

sensing, are possible.


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SYSTEM STRUCTURE

The system structure of the Kawasaki C Series Controller, Explosion-Proof Type is as follows:

Kawasaki

Robot

C Series

Controller Multifunction Panel

Explosion-Proof

Teach Pendant

PCPeripheral

Equipment

PCControllerMultifunction Panel

Program selection

Displays programs and steps

Monitoring the signals

Setting the repeat conditions

General teaching

Regular operation Instruction entry of AS Language

Keyboard entry of AS Language

programs

Loading/Saving of the programs

into/from disk

PC

(Prepared by the user)

KOSMOS Monitoring

Software [For PC] (Provided

by Kawasaki; Optional)

Multifunction Panel

Monitoring software for PC is

run by the OS such as MS-DOS.

OS needs to be prepared by the

user.

[ NOTE ]

Explosion-Proof Teach Pendant

Program selection

Programs and steps Display

Manual operation of the robot

Monitoring the signals

Setting the repeat conditions

Positional teaching

General teaching

Explosion-Proof Teach Pendant

Explosion-Proof Type

Controller


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C Series Controller, Explosion-Proof Type Contents


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SAFETY1 ENSURING SAFETY.......................................................................................... 2

2 SAFETY IN GENERAL....................................................................................... 23 ROBOT SPEED LIMITATIONS.......................................................................... 34 ROBOT MOTION RANGE ................................................................................. 35 FIVE SAFETY RULES TO BE OBSERVED FOR KHI ROBOTS...................... 46 SAFETY DURING START-UP........................................................................... 77 ENSURING SAFETY DURING TEACHING OPERATIONS............................. 88 DANGER PREVENTION DURING OPERATIONS........................................... 9

SWITCHES AND KEYS

1.1 SWITCHES ON THE CONTROLLER........................................................... 1-21.2 MULTIFUNCTION PANEL ............................................................................ 1-4

1.2.1 SWITCHES ON THE MULTIFUNCTION PANEL ...................................1-41.2.2 LIQUID CRYSTAL DISPLAY................................................................... 1-51.2.3 KEYS ON THE LIQUID CRYSTAL DISPLAY ......................................... 1-61.2.4 KEYBOARD..............................................................................................1-7

1.3 EXPLOSION-PROOF TEACH PENDANT....................................................1-81.3.1 KEYS AND SWITCHES........................................................................... 1-81.3.2 DISPLAY DURING TEACHING.............................................................1-13

PROCEDURES FOR POWER ON/OFF AND STOPPING THE ROBOT

MOTION2.1 TURNING THE POWER ON......................................................................... 2-2

2.2 TURNING THE POWER OFF....................................................................... 2-52.3 STOPPING THE ROBOT MOTION.............................................................. 2-6

BASIC OPERATION OF MULTIFUNCTION PANEL

3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL...............3-23.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION

PANEL ..............................................................................................3-43.1.2 STATUS SCREEN...................................................................................3-53.1.3 OTHERS ..............................................................................................3-63.1.4 STATUS SCREEN...................................................................................3-83.1.5 SPRAY STATUS SCREEN......................................................................3-9

3.1.6 PROGRAM LIST SCREEN.................................................................... 3-133.1.7 MONITOR SCREEN .............................................................................. 3-143.1.8 CURRENT POSITION SCREEN...........................................................3-17

3.2 MOVING CURSORS................................................................................... 3-183.3 SELECTION BY ENTERING NUMERIC VALUES OR USING

CURSOR OPERATION...............................................................................3-193.4 ENTERING CHARACTERS........................................................................ 3-203.5 SELECTING PROGRAMS.......................................................................... 3-213.6 SELECTING STEPS....................................................................................3-23

CONTENTS


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MANUAL OPERATION

4.1 KEYS USED FOR MANUAL OPERATION...................................................4-24.2 PROCEDURES FOR MANUAL OPERATION..............................................4-3

4.2.1 TYPES OF THE MANUAL OPERATION COORDINATE SYSTEM.......4-54.2.2 SELECTING THE MANUAL OPERATION COORDINATE

SYSTEM ..............................................................................................4-54.2.3 SELECTING THE MANUAL OPERATION SPEED................................4-54.2.4 MANUAL OPERATION ON THE JOINT COORDINATE SYSTEM........4-64.2.5 MANUAL OPERATION ON THE CARTESIAN COORDINATE

SYSTEM ..............................................................................................4-94.2.6 MANUAL OPERATION ON THE EASY COORDINATE SYSTEM ......4-114.2.7 GUN COORDINATE SYSTEM.............................................................. 4-154.2.8 SELECTING THE OPERATION FOR TRAFERSE EQUIPMENT........4-174.2.9 MANUAL OPERATION OF THE TRAVERSE EQUIPMENT................4-17

TEACHING

5.1 OPERATION FOR TEACHING..................................................................... 5-25.1.1 DISPLAY DURING TEACHING............................................................... 5-25.1.2 REGISTERING THE PROGRAM NUMBER...........................................5-35.1.3 TEACHING PROCEDURES.................................................................... 5-45.1.4 MANUAL POSITIONING........................................................................5-185.1.5 TEACHING THE MOVE INSTRUCTIONS............................................5-205.1.6 TEACHING THE OTHER INSTRUCTIONS (ADD)...............................5-225.1.7 THE PROCEDURES FOR CHECKING PROGRAMS (CHECK

OPERATION)......................................................................................... 5-245.1.8 CORRECTING INSTRUCTIONS...........................................................5-25

5.2 EXPLANATION OF INSTRUCTIONS......................................................... 5-295.2.1 SPEED INSTRUCTION .........................................................................5-30

5.2.2 SPRAY INSTRUCTION .........................................................................5-325.2.3 EXTERNAL OUTPUT INSTRUCTION ..................................................5-365.2.4 EXTERNAL INPUT INSTRUCTION ......................................................5-405.2.5 SMOOTH INSTRUCTION...................................................................... 5-425.2.6 CALL DATA BANK INSTRUCTION.......................................................5-465.2.7 TIMER INSTRUCTION ..........................................................................5-485.2.8 CALL PROGRAM INSTRUCTION.........................................................5-495.2.9 JUMP INSTRUCTION............................................................................5-505.2.10 CONVEYOR INSTRUCTION.............................................................. 5-595.2.11 GUN CONTROL INSTRUCTION........................................................5-615.2.12 TABLE INSTRUCTION (OPTION)......................................................5-625.2.13 SENSING INSTRUCTION...................................................................5-63

5.2.14 MOVE INSTRUCTION ........................................................................ 5-645.2.15 OTHER INSTRUCTIONS....................................................................5-67

5.3 REPEAT OPERATION FOR CHECKING ..................................................5-71

PROGRAM EDIT WITH EXPLOSION-PROOF TEACH PENDANT

6.1 DISPLAY DURING EDITING .......................................................................... 6-26.2 STARTING EDIT PROGRAM MODE............................................................. 6-36.3 HOW TO EDIT INSTRUCTION.......................................................................6-5


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6.4 HOW TO SEARCH INSTRUCTIONS............................................................. 6-76.5 EDITING OF MOVE INSTRUCTION ............................................................6-106.6 ENDING EDIT PROGRAM MODE ...............................................................6-11

7 PROGRAM EDITING WITH MULTIFUNCTION PANEL OPTION

7.1 OVERVIEW OF PROGRAM EDITING ........................................................... 7-27.2 PROGRAM EDITING SCREEN......................................................................7-37.3 PROGRAM EDITING PROCEDURES ........................................................... 7-4

7.3.1 EDIT OF AN ENTIRE STEP .................................................................... 7-47.3.2 EDIT OF ALL DATA IN MULTIPLE STEPS ..........................................7-10

8 REPEAT OPERATION PROCEDURES8.1 BEFORE EXECUTING REPEAT OPERATION............................................. 8-28.2 METHOD OF REPEAT OPERATION.............................................................8-38.3 STOP AND RESTART REPEAT OPERATION PROCEDURES................... 8-78.4 REPEAT CONDITION SELECTION............................................................... 8-88.5 WAIT OVERRIDE..........................................................................................8-10

8.6 SLOW REPEAT MODE.................................................................................8-12

9 AUXILIARY FUNCTIONS9.1 AUXILIARY FUNCTION LIST ......................................................................... 9-3

A2 LOCATION & SPEED DISPLAY.........................................................9-6

A3 DATA TRANSFER...............................................................................9-8

A5 KILL PROGRAM..................................................................................9-9

A6 MIRROR CONVERSION (OPTION).................................................9-10

A9 DATA CONVERSION (OPTION)...................................................... 9-12

A10 MEMORYPC CARD (SAVE)...........................................................9-13

A11 PC CARDMEMORY (LOAD)...........................................................9-15

A12 FILE DIRECTORY (FDIRECTORY)...................................................9-16A14 PC CARD AUX. FUNCTION...............................................................9-17

A40 AUTO TOOL SET (OPTION)..............................................................9-18

A41 ZEROING............................................................................................ 9-19

A42 POSITION ERROR RANGE AT EMERGENCY STOP .....................9-20

A43 ENCODER ERROR RANGE..............................................................9-21

A44 ZEROING DATA SET DISPLAY.........................................................9-22

A46 INSTALLATION POSTURE................................................................9-23

A47 BASE COORDINATES.......................................................................9-24

A48 TOOL DIMENSIONS ..........................................................................9-25

A51 SOFTWARE LIMIT..............................................................................9-27A53 ACCURACY ........................................................................................9-28

A55 SLOW REPEAT MODE...................................................................... 9-33

A56 CHECK SPEED ..................................................................................9-34

A57 TEACH SPEED...................................................................................9-35

A70 MEMORY AVAILABLE .......................................................................9-36

A71 RECORD DATA/INHIBIT.................................................................... 9-37

A72 AUTOMATIC PATH GENERATION...................................................9-38


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A73 SPRAY ON/OFF .................................................................................9-47

A75 SYSTEM SWITCH..............................................................................9-48

A76 HOME POSITION............................................................................... 9-51

A77 WORK SPACE OUTPUT (OPTION)..................................................9-52

A78 CLEAR CHECK SUM ERROR........................................................... 9-53

A80 XYZ SHIFT (OPTION).........................................................................9-54

A81 JOINT SHIFT (OPTION).....................................................................9-55

A82 TOOL SHIFT (OPTION)......................................................................9-56

A83 WORK SHIFT (OPTION) .................................................................... 9-57

A87 PROGRAM ARGUMENT/COMMENT (OPTION)..............................9-58

A90 SOFTWARE VERSION DISPLAY......................................................9-60

A91 ENVIRONMENT DATA.......................................................................9-61

A95 ENVIRONMENT DATA ..................................................................9-62

A96 ENVIRONMENT DATA OF PANEL....................................................9-63

A99 CHECK SPECIFICATION...................................................................9-64

A100 SYSTEM INITIALIZATION................................................................9-65A101 BATTERY ERROR CHECK..............................................................9-66

A103 TOUCH PANEL SHORT CIRCUIT CHECK.....................................9-67

A110 TIME ............................................................................................9-68

A111 DEDICATED INPUT SIGNAL...........................................................9-69

A112 DEDICATED OUTPUT SIGNAL.......................................................9-70

A113 DEDICATED SIGNAL DISPLAY ......................................................9-71

A114 GUN SPECIFICATIONS...................................................................9-73

A114-1 GUN APPLICATION...................................................................9-74

A114-20 HANDLING CLAMP DEFINITION...............................................9-75

A

114-30

PAINTING/SEALING GUN DEFINITION....................................9-76A114-32 GUN RELATIVE DISTANCE CHECK.........................................9-77

A120 ERROR LOGGING........................................................................... 9-78

A122 OPERATION LOGGING...................................................................9-79

A124 MOTOR TORQUE INFORMATION (OPTION)................................9-80

A1241 WORNING LOG.............................................................................9-80

A1242 PEAK CURRENT...........................................................................9-80

A127 OPERATION INFORMATION (OPTION).........................................9-81

A130 PC PROGRAM RUN/STOP (OPTION)............................................9-82

A1301 START (PCEXECUTE)...............................................................9-83

A1302 ABORT (PCABORT)...................................................................9-83

A1303 STOP (PCEND)...........................................................................9-84

A1304 CONTINUE (PCCONTINUE)......................................................9-84

A1305 KILL (PCKILL)..............................................................................9-85

A1306 STATUS (PCSTATUS) ...............................................................9-85

A131 INTERFACE PANEL (OPTION) ....................................................... 9-86

A133 AS INSTRUCTION DEFINITION (OPTION) ....................................9-87

A140 ENCODER ROTATION COUNTER RESET....................................9-88

A142 PROGRAM QUEUE (OPTION)........................................................9-89


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A142-1 DISPLAY........................................................................................ 9-90

A142-2 REGIST..........................................................................................9-91

A142-3 INSERT.......................................................................................... 9-92

A142-4 DELETE......................................................................................... 9-93

A142-5 ALL DELETE..................................................................................9-94

A142-6 ENVIRONMENT SET....................................................................9-95

A143 START DELAY (OPTION)................................................................ 9-97

A143-1 COMMON DELAY DISTANCE......................................................9-98

A143-2 INDIVIDUAL DELAY DISTANCE..................................................9-98

A143-2-1 INDIVIDUAL SETTING...............................................................9-99

A143-2-2 SET SAME DIST ...................................................................... 9-100

A143-3 MULTI START DELAY ................................................................ 9-100

A143-3-1 DISPLAY...................................................................................9-101

A143-3-2 CHANGE...................................................................................9-101

A143-3-3 DELETE....................................................................................9-102

A143-3-4 ALL DELETE ............................................................................9-102A144 INTERRUPT PROGRAM................................................................9-103

A149 TOOL REGISTRATION (OPTION).................................................9-104

A153 PROGRAMS IN DETAIL.................................................................9-105

A154 TOTAL REPEAT CYCLES OF PROGRAM...................................9-106

A154-1 DISPLAY AND MODIFY..............................................................9-107

A154-2 ALL CLEAR..................................................................................9-107

A155 HOME POSITION CHECK AXIS SET............................................9-108

A158 DOUT FUNCTION ASSIGNMENT.................................................9-109

A159 HISTORY CLEAR...........................................................................9-110

A

166

PG PARTIAL DELETE....................................................................9-111A167 SINGULAR POINT ALARM RANGE SET...................................... 9-112

A168 DIFF. OF WORK/AIR-CUT SPEED................................................9-113

A169 OPERATION CONDITION SETTING ............................................9-114

A172 SYSCOUNT DISPLAY/SETTING...................................................9-116

A172-1 SYSCOUNT DISPLAY/SETTING................................................9-116

A172-2 GENERAL SYSCOUNT SETTING .............................................9-117

A172-3 PRIVATE SYSCOUNT SETTING ...............................................9-117

A173 MOVING AREA XYZ LIMIT ............................................................ 9-118

A176 DATA BANK....................................................................................9-119

A176-1 LIST ..........................................................................................9-119

A176-2 EDIT ..........................................................................................9-120

A176-3 COPY ..........................................................................................9-121

A176-4 DELETE.......................................................................................9-121

A176-5 ENVIRONMENT SET.................................................................. 9-122

A197 PASSWORD SET (OPTION)..........................................................9-123

A198 AUXILIARY FUNCTION SET (OPTION)........................................9-124


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10 OTHER FUNCTIONS THAN TEACHING BY EXPLOSION-PROOF

TEACH PENDANT10.1 LIST OF OTHER FUNCTIONS BY EXPLOSION-PROOF TEACH

PENDANT.................................................................................................10-41-0 PROGRAM SETTING............................................................................ 10-71-1 REPEAT STATUS DISPLAY................................................................. 10-81-2 PRODUCT RATE VALUE SETTING.....................................................10-91-3 PRODUCT PAINT_IO RATIO..............................................................10-103-0-0 PRORAM LIST DISPLAY (DETAIL) ....................................................10-113-0-1 PROGRAM NUMBER LIST DISPLAY.................................................10-113-0-2 AVAILABLE MEMORY CAPACITY DISPLAY.....................................10-113-0-3 PROGRAM NAME REGISTRATION................................................... 10-123-1 PROGRAM COPY ...............................................................................10-143-2 PTOGRAM LINK .................................................................................. 10-153-3 PROGRAM DELETION........................................................................10-163-4-0 PARTIAL PROGRAM COPY............................................................... 10-17

3-4-1 PARTIAL PROGRAM DELETION.......................................................10-193-5-0 PARALLEL SHIFT................................................................................10-203-5-1 GUN-TIP DIRECTION SHIFT..............................................................10-213-5-2 MIRROR IMAGE CONVERSION ........................................................10-223-5-3 TRAVELLER SHIFT WITH GUN TIP FIXED.......................................10-233-5-4 SHUTTLE RIGHT-LEFT CONVERSION (OPTION) ...........................10-233-5-5 CONVEYOR POSITION SHIFT (OPTION).........................................10-243-6 AUTOMATIC PATH GENERATION.................................................... 10-254-0 DATA BANK EDITING......................................................................... 10-264-1-0 DATA BANK DETAILS DISPLAY........................................................ 10-284-1-1 DATA BANK NUMBER DISPLAY........................................................10-285-0-0 GUN POSITION/ANGLE......................................................................10-29

5-0-1 JOINT VALUE DISPLAY......................................................................10-305-0-2 JOINT COMMAND VALUE DISPLAY.................................................10-315-0-3 ENCODER VALUE DISPLAY..............................................................10-315-0-4 POSITION DISPLAY OF TRAVERSE AXES......................................10-325-0-5 TABLE POSITION DISPLAY (OPTION)..............................................10-325-0-6 GUN POSITION/ WRIST ANGLE DISPLAY .......................................10-325-1-0 EXTERNAL OUTPUT SIGNAL DISPLAY ...........................................10-335-1-1 EXTERNAL INPUT SIGNAL DISPLAY ...............................................10-345-1-2 INTERNAL SIGNAL DISPLAY............................................................. 10-355-1-3 HOME POSITION SIGNAL DISPLAY .................................................10-365-2-0 GENERAL COUNTER DISPLAY.........................................................10-375-2-1 DEDICATED COUNTER DISPLAY.....................................................10-37

6-0-0 OPERATION CONDITION SELECTION (EXTERNAL OUTPUT)......10-386-0-1 OPERATION CONDITION SELECTION (INPUT WAIT) ....................10-396-0-2 OPERATION CONDITION SELECTION (CONVEYOR WAIT)..........10-406-0-3 OPERATION CONDITION SELECTION (TIME WAIT) ......................10-416-0-4 OPERATION CONDITION SELECTION (CV TRACK MODE)...........10-426-0-5-0 OPERATION CONDITION SELECTION (SENSOR SETTING/

DOOR SENSING).............................................................................10-436-0-5-1 OPERATION CONDITION SELECTION (SENSOR SETTING/

CAMERA SENSING)........................................................................10-43


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6-1 CURRENT CONVEYOR POSITION SETTING (CURRENTCV_POS) ..........................................................................................10-44

6-2 COUNTER VALUE SETTING.............................................................. 10-456-3 LOCATION VARIABLES REGISTRATION.........................................10-467-0 ERROR HISTORY DISPLAY...............................................................10-47

7-1 TOTAL PLAYBACK COUNT DISPLAY...............................................10-488-0 MANUAL EXTERNAL OUTPUT EXECUTION (GENERAL

SIGNALS) ..........................................................................................10-498-1 MANUAL EXTERNAL OUTPUT EXECUTION (SPRAY SIGNALS)...10-508-2 MANUAL EXTERNAL OUTPUT EXECUTION (FLOW RATE)...........10-518-3 MANUAL EXTERNAL OUTPUT EXECUTION (SHAPING/

PATTERN AIR).....................................................................................10-528-4 MANUAL EXTERNAL OUTPUT EXECUTION (AIR MOTOR/

ATOMIZING AIR) .................................................................................10-538-5 MANUAL EXTERNAL OUTPUT EXECUTION (HIGH VOLTAGE) ....10-548-6 MANUAL EXTERNAL OUTPUT EXECUTION (FLUSHING) .............10-558-7 MANUAL EXTERNAL OUTPUT EXECUTION (PUSH THINNER) ....10-56

11 AUTOMATIC TOOL REGISTRATION (OPTIONAL)11.1 AUTOMATIC TOOL REGISTRATION FUNCTION - OVERVIEW............11-211.2 REQUIRED DATA FOR AUTOMATIC TOOL REGISTRATION...............11-3

11.2.1 TEACHING TOOL DIMENSIONS FOR 4 BASE POINTS....................11-311.2.2 TEACHING TOOL POSTURE FOR TOOL Z DIRECTION...................11-411.2.3 TACHING TOOL ORIENTATION WHEN DISPLACED IN Y

DIRECTION............................................................................................11-411.3 MEASURING TOOL DIMENSIONS POINTS FOR CAUTION..............11-5

11.3.1 METHOD FOR TEACHING POINTS B, C (EXAMPLE)........................11-611.4 OPERATION METHOD ............................................................................. 11-7

11.4.1 PREPARATIONS FOR AUTOMATIC TOOL REGULATION................11-711.4.2 REGISTERING BASE POSTURE.........................................................11-811.4.3 REGISTERING MEASUREMENT VALUES .........................................11-9

12 CONVEYOR TRACKING (OPTION)12.1 OVERVIEW OF CONVEYOR TRACKING FUNCTION............................12-212.2 OPERATION OF CONVEYOR TRACKING FUNCTION..........................12-3

12.2.1 SELECTING CONVEYOR TRACING ..............................................12-312.2.2 CURRENT POSITION DISPLAY......................................................12-412.2.3 SETTING THE DATA ........................................................................ 12-512.2.4 SETTING ENVIRONMENTAL DATA................................................12-7

12.3 OPERATING THE SIMULATION FUNCTION ........................................12-10

12.3.1 SELECTING.................................................................................... 12-1012.4 TEACHING STANDARDS ....................................................................... 12-1212.4.1 OVERVIEW OF TEACHING OPERATIONS BY CONVEYOR

TRACKING .......................................................................................12-1212.4.2 PREPARATORY OPERATIONS FOR TEACHING.......................12-15

12.5 TEACHING...............................................................................................12-1612.5.1 CAUTIONS TO BE TAKEN DURING TEACHING.........................12-1612.5.2 EXAMPLES OF TEACHING...........................................................12-16

12.6 REPEAT RUN AND PROGRAM CHECKING METHOD........................12-32


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12.6.1 OVERVIEW OF CHECKING OPERATION....................................12-3212.6.2 FLOW OF CHECKING OPERATION AND REPEAT RUN............12-33

12.7 INTERLOCK SIGNALS............................................................................ 12-3712.8 CONVEYOR POSITION SHIFT FUNCTION...........................................12-38

13 INTERFACE PANEL SETTINGS (OPTION)13.1 OVERVIEW OF THE INTERFACE PANEL...............................................13-213.2 PROCESSING SEQUENCE ON INTERFACE PANEL............................13-313.3 SELECTING THE INTERFACE PANEL SCREEN ...................................13-413.4 METHODS FOR SETTING INTERFACE PANEL..................................... 13-5

13.4.1 SWITCH SETUP............................................................................... 13-513.4.2 PUSH BUTTON SETUP ................................................................... 13-613.4.3 PUSH BUTTON WITH LAMP - SWITCH SETUP............................13-713.4.4 2-NOTCH SELECTOR SWITCH - SETUP .....................................13-813.4.5 3-NOTCH SELECTOR SWITCH - SETUP....................................... 13-913.4.6 PILOT LAMP - SETUP.................................................................... 13-1013.4.7 DIGITAL SWITCH - SETUP............................................................13-11

13.4.8 DIGITAL DISPLAY - SETUP...........................................................13-1213.4.9 TEXT WINDOW SETUP (OPTION).............................................13-1313.4.10 SOFTWARE DEDICATED SIGNALS.............................................13-14

14 COUNTER MEASURES FOR ERRORS14.1 SYSTEM INITIALIZATION.........................................................................14-2

14.1.1 CALLING UP INITIALIZATION SCREEN..............................................14-314.1.2 OPERATION PROCEDURES ON THE INITIALIZATION SCREEN....14-4

14.2 NORMAL PROCEDURES WHEN ERRORS OCCUR .............................14-5

APPENDIXAPPENDIX1 PROGRAM SHEET.......................................................................A-2APPENDIX2 EXPLOSION-PROOF TEACH PENDANT MENU

DIRECTORY LIST........................................................................A-5APPENDIX3 MULTI-FUNCTION PANEL MENU DIRECTORY LIST............ A-11APPENDIX4 MULTI-FUNCTION PANEL AUXILIARY FUNCTION LIST....... A-12APPENDIX5 INITIAL DATA SETTINGS......................................................... A-16APPENDIX6 OAT ............................................................................................ A-18

AS LANGUAGE LIST................................................................................................AS-1

ERROR MESSAGE TABLE.........................................................................................E-1

GLOSSARY................................................................................................................. G-1

INDEX............................................................................................................................I-1


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Memo


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This section summarizes safety precautions to be taken prior to operating your Kawasaki Robot.

Also, safety measures and the speed, motion range limitations on the robot are described.

1 ENSURING SAFETY........................................................................................................ 2

2 SAFETY IN GENERAL ..................................................................................................... 2

3 ROBOT SPEED LIMITATIONS........................................................................................ 3

4 ROBOT MOTION RANGE................................................................................................ 3

5 FIVE SAFETY RULES FOR KHI ROBOTS..................................................................... 4

6 SAFETY DURING START-UP......................................................................................... 7

7 ENSURING SAFETY DURING TEACHING OPERATIONS.......................................... 8

8 DANGER PREVENTION DURING OPERATIONS........................................................ 9

SAFETY


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C Series Controller, Explosion-proof Type Safety


2

1 ENSURING SAFETY

In order to ensure safety, all local, regional, municipal and national safety laws and regulations

must be strictly observed.

1. The teaching and maintenance work on the robot must be carried out in accordance with labor

safety laws and regulations.

2. The user should prepare safety regulations for working on the robot itself and observe these

regulations responsibly.

3. In order to ensure safety, the following safety standards should be observed: JIS B8433,

ISO10218, EN775, for robots used in production applications.

4. Safety administrators and full-time personnel should be assigned for work on the robot. In

addition, a safety administrative system should be established as a means of providing

thorough education regarding safety.

2 SAFETY IN GENERAL

1. The plant administrator should create safety and work regulations in consideration of

structure of the line and peripheral equipment so that injuries from the robot are prevented.

Moreover, appropriate steps should be taken so that safety education and work standards are

created for the benefit of the workers.

2. Never use a Kawasaki Robot beyond the standard ability of the robot as set in the

specifications manual. (Including specifications for payload, speed, motion range,

environment, etc.)

3. Prior to starting operation, operators are expected to fully understand operation manuals and

materials relating to the robot usage. And, care must be taken so that no injury occurs as a

result of carelessness during operation.

4. Care must be taken so that none of the electrical components become loose or disconnected

while the robot is energized. (e.g. connectors, circuit boards, etc.)

5. Also, care must be taken so that neither the explosion-proof teach pendant nor the

multifunction panel are dropped or exposed to heavy impact, as they consist of a variety of

precision instruments.

The safety content described here applies only to operations

with the robot unit and is not intended as a safety explanation

for the whole system.

[ Note ]


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3

3 ROBOT SPEED LIMITATIONS

The maximum speed is limited to 250mm/sec. when operating the robot in check orteach mode

from the multifunction panel or the teach pendant.

4 ROBOT MOTION RANGE

A maximum possible motion range has been established for every robot model, unless the robot

is given special specifications at the time of purchase. However, the motion range can be

restricted to support the requirements according to the needs of the application.

1. Motion Range Limits via Software

Motion range limits can also be set for the robot by software.

2. Motion Range Limits via Mechanical Stoppers

When mechanical stoppers are needed refer to the separate volume Installation and

Connection manuals for the robot arm.

WWARNING

Setting only software limits on the robots motion range is

insufficient as a countermeasure for preventing serious or fatal

accidents. Mechanical stoppers as well as a safety fence must

also be established.


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4

5 FIVE SAFETY RULES FOR KHI ROBOTS

1. Without exception, install the robot within a safety fence. Ensure that the robot is not easily

approachable by people.

2. Provide a safety plug mechanism on the door of the safety fence. The safety plug should be

installed so that the door cannot be opened without removing the plug and so that motor

power to the robot will be cut off if the plug is removed during operation.

WARNING

Before operating, the following five basic points must be given

attention in order to use the robot safely. Because the content

here describes only fundamental points regarding safety,

thorough reading of the separate safety manual is highly

recommended.


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5

3a.When performing work inside the safety fence, such as robot teaching or confirming that the

work is complete, the worker must enter only after removing the safety plug. This will

prevent the robot from being switched on to automatic run by another worker.

3b. In addition, during teaching operations an observer must be stationed in front of the

controller and be ready and able to stop the robot at any time in case of an emergency. These

duties can only be assigned to persons who have completed special training and are qualified

to use the robot.

4. While the robot is operating automatically (running) or waiting in stand by mode, never enter

the fenced area.


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6

5. Indicate the current status of the robot clearly and simply so that anyone can understand, for

example with a sign showing automatic operation, teaching, emergency stop, etc.


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7

6 SAFETY DURING START-UP

1. Before switching Motor Power on, make certain that the work cell is empty and that no one

is within the safety fence, also confirm that there are no obstructions in the path of the robot.

When switching Motor Power on, be ready and able to press the Emergency Stop switch in

the event the robot moves abnormally.

2. Before starting operations in repeat mode, confirm that the work cell is empty and that no

one is within the safety fence, also confirm that there are no obstructions in the path of therobot.

When starting up the robot, switch on

the power to the motor and control

panel.

Pay special attention to the items below

to ensure safety during start-up.


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8

7 ENSURING SAFETY DURING TEACHING OPERATIONS

1. When entering the safety fence area, confirm that all safety and indicator devices, as well as

the functions and devices for regulating the motion range of the robot are in good working

order. Moreover, the worker should hold the teach pendant and perform teaching so as to

be able to stop the robot or find cover immediately in the event the robot moves abnormally.

2. The robot must be installed in an area where the entire motion range of the robot can be

overseen by an observer responsible for holding the Emergency Stop switch. When one

worker (teacher) is inside the safety fence, the observer must be stationed outside and be able

to press the Emergency Stop switch immediately if trouble arises. Duties including

observing and working inside the safety fence are limited to those who have completed

special training on robot usage.

3. In order to run at a safe speed during teaching, operate the robot at 10% (or lower) of the

repeat speed when: jogging the robot to the teaching point, and confirming the teaching by

moving either in one step increments or in 1 continuous cycle of steps.

4. During teaching, alert the attention of others so that none of the robotic instruments are

handled carelessly or accidently. Instruments include: controller, multi-function panel,

teach pendant, keyboard, etc.

5. When observer and teacher work together, one person must be designated as supervisor

before the teaching operation can proceed. In addition, any signals used during teaching

and the step order of the teaching must be understood and confirmed in advance.

6. While working within the area of the safety fence the observer and teacher must never take

their eyes off the robot.

Confirm the contents of the teaching

when creating programs or teachingpoint information to the robot.

Pay special attention to the items

below to ensure safety during

teaching.


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9

8 DANGER PREVENTION DURING OPERATIONS

1. During automatic operation, never enter the safety fence area under any circumstances.

2. In automatic operation, the robot may stop motion during timer mode or while waiting for

input signal. Be careful at these times because the robot will restart motion as soon as the

signal conditions are realized or the time count is completed.

3. If the installation of the tool or the grasp of the work is insufficient during automatic

operation, the tool may become disengaged or the work may be ejected from the robot. To

prevent these kinds of accidents, take extra care in checking the conditions of the tool

attachment and the grasping of the work.

Moreover, for applications in which the work is manipulated with a pneumatic device (hand,

end-effector), set up a fail safe structure so that the work is not thrown as a result of an

accidental cut in air or power to the solenoid valve.

4. When the robot stops due to some malfunction during automatic operation, confirm the

contents of the error message shown on the display and perform an appropriate restoration of

the system.

Responsibility for resolving the error code numbers/messages that may arise should be

assigned to teaching, operations and maintenance supervisors in advance. In addition, it is

essential to clearly define the steps to be taken by each supervisor during system trouble.

Typically, the robot is running in a state

of continuous motion during automatic

operation.

In order to prevent any accidents during

automatic operation pay special attention

to the items below.


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10

Memo


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1-1

SWITCHES AND KEYS

This chapter describes the switches and keys for thecontroller, explosion-proof teach pendant, and

multifunction panel.

1.1 SWITCHES ON THE CONTROLLER............................................................. 1-2

1.2 MULTIFUNCTION PANEL ..............................................................................1-4

1.2.1 SWITCHES ON THE MULTIFUNCTION PANEL........................................... 1-4

1.2.2 LIQUID CRYSTAL DISPLAY........................................................................... 1-5

1.2.3 KEYS ON THE LIQUID CRYSTAL DISPLAY................................................. 1-6

1.2.4 KEYBOARD ..................................................................................................... 1-7

1.3 EXPLOSION-PROOF TEACH PENDANT .....................................................1-8

1.3.1 KEYS AND SWITCHES................................................................................... 1-8

1.3.2 DISPLAY DURING TEACHING ....................................................................1-13

1


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C Series Controller, Explosion-Proof Type 1. Switches and Keys


1-2

1.1 SWITCHES ON THE CONTROLLER

This unit provides information about the switches located on the C Series Controller,

Explosion-Proof Type.

Control power switch (breaker):

Switch to ON to turn on the control power of the controller.

Switch to OFF to turn off the control power of the controller.

Multifunction Panel

Multifunction

panel connector

Control power switch

(circuit breaker)

Backside of the controller

Operation panel

10

8

7

5

3

4

1

2

Explosion-proof

teach pendant

Connector for

the explosion-

proof teach

pendant

Communication

port

6

9


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1-3

These switches are mainly for the regular repeat operation.

No. Switch or light Function

1Illuminates when the control power of the controller is

ON.

2 Hour meter Indicates the total motor power ON time.

3Illuminates when errors occur. Blinks when the

initialization screen appears.

4

An error is reset when pressed. The error light is

turned off after the error is reset properly. (Sequential

errors cannot be reset.)

5Switches the robot condition between operable (RUN)

and temporary stop (HOLD).

6Switches modes between TEACH and REPEAT. (This

needs the attached keys.)

7Repeat operation starts when pushed. This light

illuminates when repeat operation starts properly.

8Motor power is turned on when pushed. This light

illuminates when motor power is applied properly.

9

Switches the method to start repeat operation.

REMOTE: From the external start signal.LOCAL: From the Cycle Start button on the controller.

10

Emergency

Stop The motor power is shut off and the robot stops when

pushed. Motor Power light and Cycle Start light are

turned off at the same time. (Control power is not shut

off).

Teach mode: A mode for teaching by the remote control box forteaching (called explosion-proof teach pendant).

Repeat operation is not possible in this mode.

Repeat mode: A mode for starting repeat operation.

Repeat operation: A robot condition in which taught operations are

automatically repeated.

Terms


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1-4

1.2 MULTIFUNCTION PANEL

1.2.1 SWITCHES ON THE MULTIFUNCTION PANEL

Multifunction panel uses a large-sized color liquid crystal VGA display equipped with touch

panel function. Keys are easily operated just by touching lightly on the liquid crystal display.These keys are for entering and editing various data.

No. Switch or light Function

1Liquid crystal

display

Provides keys for entering and editing various data on

robots. Also displays status, teaching and various data.

2 PC card slotFor inserting a PC card.

See A 14 PC card

3

Contrast

adjustment

knob

Adjusts the shading (brightness) of the display.

4Touch panel

penUsed for touch panel operation.

2

1

3

4


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1-5

1.2.2 LIQUID CRYSTAL DISPLAY

The liquid crystal display contains the following areas:

(The actual display may be different in some parts.)

1. System message area:

Errors are indicated.

2. Title area:

Displays the title of the selected status or function.

3. Auxiliary data area:

Displays the present status and the teaching status of the present step.

4. Status information area:

Displays status information.For example:

Slow repeat

Inhibit

Repeat

Accept

{M-ON

{RUN

{REPEAT

{

{M-OFF

{HOLD

{TEACH

{

3

2

14


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1-6

1.2.3 KEYS ON THE LIQUID CRYSTAL DISPLAY

Keys associated with programs and steps:

Key Function

PROGRAMDisplays the program name that is currently selected.

The program selection screen appears when pushed.

Displays the current step number.

The step selection screen appears when pushed.

Displays the PC program name that is currently selected.

Keys for selecting screen:

Key Function

Used for teaching programs. Screens for teaching appear when pushed:

AS TEACHING (option), PROGRAM INPUT (option).

Toggles screens: STATUS, PROGRAM LIST, MONITOR, and CURRENT

POSITION, PAINTING STATUS.Repeat conditions can be selected in the STATUS screen.

Toggles screens among status, function selection, and keyboard entry.

STATUS, FUNCTION, INTERFACE PANEL SETTING (option),

KEYBOARD screens are equipped with auxiliary functions with which

various data can be displayed and set.

As for the multifunction panel with specification 2 (pull-down menu type), pushing

STATUS and MENU keys drops menu selection keys below each key.

1

pg1

STEP

PC

pg1 1

PCPROGRAM STEP


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1-7

1.2.4 KEYBOARD

The keyboard screen can be selected when the

MENU

key on the multifunction panel is pressed.

Robot language programming and operation control of the robot are possible using AS

Language in this screen.

Switch Function

The BACK SPACE key is used to delete the entered

characters one by one.

NEXTMENU

The NEXT MENU key switches the multifunction panel

display from the keyboard screen to the status screen.

The ENTER key is used for setting the AS Language

commands, executing, and entering data.

SHIFT

The SHIFT key is used to enter the special symbols

indicated on the top of the character keys by pressing with

the other character keys. For example, when is

pressed with the shift key, the symbol ! can be entered.

NEXT PG Goes to the next page.

Displays the previously entered character strings (can go

back a maximum of 10 previous entries). When theSHIFT key is pressed, this key turns into CTL+N key.

CTL+N key displays the next character string to the present

string.

SPACE key Used to enter a space.

CTL+L key NEXT MENU key

Backspace key

SPACE key SHIFT key ENTER key


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1-8

1.3 EXPLOSION-PROOF TEACH PENDANT

1.3.1 KEYS AND SWITCHES

The explosion-proof teach pendant is equipped with the keys for robot manual operation,

teaching programs, entering and editing various data.

Liquid crystaldisplay

Backside of the explosion-proof teach pendant

Emergency stop

switch

Trigger

switch


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1-9

Key Function

For entering the numeric value of 1.

Decimal point can be entered when pressed with the shift key.


Numeric value A (hexadecimal) can be entered when pressed with theshift key.


Numeric value B (hexadecimal) can be entered when pressed with the

shift key.


Numeric value C (hexadecimal) can be entered when pressed with the

shift key.


For entering the numeric value of 6.The minus can be entered when pressed with the shift key.


Numeric value D (hexadecimal) can be entered when pressed with the

shift key.


Numeric value E (hexadecimal) can be entered when pressed with the

shift key.


Numeric value F (hexadecimal) can be entered when pressed with the

shift key.


SHIFTUsed with the other keys. The additional values such as A F can be

entered when pressed with the other keys.

Moves the cursor up the screen (to smaller numbers).

SHIFT Goes back to the previous screen.

Moves the cursor down the screen (to larger numbers).

SHIFT Goes to the next screen.

Cancels the numeric entry and clears all.CLR

SPEED

CONVR

JUMP

CALL

TIMER

X-OUT

GUN

X-IN

SMOTH

SPRAY

DATA


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1-10

Key Function

Returns to the main menu.

SHIFT Cancel the selection of program.

The repeat operation ends when pushed during the repeat operation.

Holds the present mode and moves to the other mode.

The original mode appears when this key is pressed again.

Returns to the upper screen.

Moves to the next screen when pressed for confirmation of menu

selection or numeric value entry.

Moves the robot in the right direction in the Cartesean coordinates or

swivels the 1st axis to the right.

The table axis rotates in normal (+) direction.

Moves the robot in the left direction in the Cartesean coordinates or

swivels the 1st

axis to the left.

The table axis rotates in reverse (-) direction.

Moves the robot forward in the Cartesean coordinates or rotates the

2ndaxis forward.

SHIFT Moves in the forward direction of the gun (only for the frame

coordinates).

Moves the robot backward in the Cartesean coordinates or rotates the

2nd

axis backward.

SHIFT Moves in the backward direction of the gun (only for the frame

coordinates).

Moves the robot upward in the Cartesean coordinates or rotates the 3rd

axis upward.

Moves the robot downward in the Cartesean coordinates or rotates the

3rd

axis downward.

Turns the gun to the right in the Cartesean coordinates or rotates the

4th

axis to the right.

Turns the gun to the left in the Cartesean coordinates or rotates the 4th

axis to the left.

Rotates the gun upward in the Cartesean coordinates or rotates the 5th

axis to the right.

Rotates the gun downward in the Cartesean coordinates or rotates the

5th

axis to the left.

LFT

RT

BCK

FRNT

DWN

UP

SWING

RT

SWING

LFT

BEND

FRNT

BEND

BCK

FRNT

BCK

SET

END

END

END

SUSPEND


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1-11

Key Function

Rotates the gun to the right in the Cartesean coordinates or rotates the

6th

axis to the right.

Rotates the gun to the left in the Cartesean coordinates or rotates the

6th axis to the left.

FRAME

Toggles the coordinate system at manual operation:

Easy Gun Joint

SHIFT

FRAME

Selects the coordinate system to be switched with the coordinate

selection key:

Easy XYZ1 XYZ2

Selects an axis to be operated with the axis key: robot or other axes.

LED toggles by pressing the device selection key as:

Robot

Traverse

Table

Note: The detail of the device selection key may be different

depending on the robot system structure.

SPEED

H

M

L

Toggles the manual speed of the robot and the peripheral devices

among three levels:

High Medium Low

MOTION

L

C

J

Selects interpolation when recording positions. LED toggles by

pressing the interpolation key as:

Linear Circular (middle end) Joint

The circular LED is lit up in the middle of the circular arc and blinks

at the end.

SHIFT During linear/circular interpolation toggles among: Retaining gun

posture/wrist axis angle.

Note: When retaining wrist axis angle, linear and circular interpolation

LEDs are lit up and joint interpolation LED blinks.

STORE

POSRecords the present location as a teaching point.

CRCTIn teaching and edit modes, selects a type for correcting command

codes from among Prohibit/Add/Modify/Delete/ Search.

SHIFT

CRCT

Changes the default correction mode to Prohibit/Add/Modify when

correcting command codes on the command display screen for

teaching and editing.

RESET Resets all the errors.

TURN

UP

TURN

DWN

EQPMT

MOTION

TBL

ROB TRV


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1-12

Key Function

SHIFT

RESETResets errors one by one when more than one errors occur at the same

time.

Selects whether or not to spray paint.

When spraying (ON), the LED is lit up.

Turns on the Spray 1 signal (outputs while key is pressed).

SHIFT Turns on the Spray 2 signal (outputs while key is pressed).

TEACH

LOCK

Switch is designed to avoid repeat operation from being conducted

accidentally during teaching. This switch needs to be ON after

stopping repeat operation before entering into the safety fence.

Cycle start cannot be conducted while Teach Lock is ON (LED is on).

STEP

Toggles the way to move through steps, backwards or forwards, whenin check mode (confirming the trajectory). Every time the key is

pressed, the way to move from the first move in the screen toggles as:

Move Command Continuous Jump

STEPNEXT

Shifts the program forward when in check mode (confirming the

trajectory).

STEPBACK

Shifts the program backward when in check mode (confirming the

trajectory).

The keys below are the LED indication only:

Key Function

Indicates that the servo of the robot (manipulator) is ON

when this LED is lit.

Indicates that the servo of the table is ON when this LED is

lit.

Note: LED names may be different depending on the robot system structure.

(The above is for standard specification.)

Switch and push-button switch on the explosion-proof teach pendant:

Key Function

Emergency stop

switchTurns OFF the servo power and stops the robot.

Trigger switch Enables/disables the robots motion (enabled only while pressed.)

These switches can be engaged only in teach mode.

SPRAY

ON/OFF

SPRAY

1/2

SPRAY

1/2

SERVO

SERVO

ROB

ROB

TBL

TBL


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1-13

1.3.2 DISPLAY DURING TEACHING

The display during teaching appears as follows:

1

Correction mode (Prohibit/Add/Modify/Delete/Search), which is a sub-mode, is

displayed. Use CRCT key to change the mode.

2

Displays coordinate system (Easy (XYZ1)(XYZ2)/Gun/Joint) at manual operation.

Use FRAME key to change the system.

3

Displays how the program is shifted (per move/command/continuous/jump) when

pressingSTEPNEXT and

STEPBACK keys in check mode. Use STEP key to change

the shifting method.

4 Displays program number that is presently taught.

5Displays present point number.Counts MOVE commands in the program from the top and displays as a point

number.

6 Displays operation guidance.

7

Displays commands taught in each step below the 3rdline.

The sequential number on the left indicates in command unit.

The highlighted number indicates that the the command execution is complete.

The above example means that the commands up to the command unit 3, turning on

the spray No.1, are executed.

1 2 3 4 5

7

6


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1-14

Memo


40/514

2-1

PROCEDURES FOR POWER

ON/OFF AND STOPPING THE

ROBOT MOTION

This chapter describes the procedures for power on/off of the controller and for stopping the robot

motion.

2.1 TURNING THE POWER ON ............................................................................................................2-2

2.2 TURNING THE POWER OFF ............................................................................................................2-5

2.3 STOPPING THE ROBOT ................................................................................................................2-6

2


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C Series Controller, Explosion-Proof Type 2. Procedures for Power ON/OFF and

Kawasaki Robot Operation Manual Stopping the Robot Motion

2-2

2.1 TURNING THE POWER ON

The procedure for starting the robot operation is as follows:

Turn the Control Power on.

The version information is displayed on the teach pendant screen.

Note: The version displayed depends on the software.

Air purging process is automatically started.Note: This process is executed in pressurized explosion-proof type of

robots such as KE and KF series. Steps 3-5 are skipped in the

flame-proof type of robots.

After confirming that the the purge air is

supplied, step 4 is automatically started.

WARNING

When turning the Control and Motor Power of the robot controller on, thorough

attention should be taken to prevent personnel from entering the motion range o

the robot and the peripheral equipment controlled by the robot controller. The

robot may move or operate accidentally when turning on the motor power, if the

robot servo system is damaged.


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2-3

The purging time starts to be counted down.

Note: Purging time depends on the manipulator type.

After purging, the robot waits for the pressure to rise in the pressurized

enclosure.

The main menu appears.

Turn the TEACH/REPEAT Switch to TEACH.

Turn the MOTOR POWER on.

The lamp is lit up.

When purging is complete, the next screen

automatically appears.

When the pressure rises, the next screen

automatically appears.


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2-4

In teach mode, turning the motor power ON will not bring actual motor power to the robot

immediately. The motor brake holds the robot at the current posture. After the motor power is

on, the motor current is activated by pressing the trigger switch located on the backside of the

explosion-proof teach pendant. Then, after 0.5 second, the motor brake is released and the robot

becomes servo-locked.


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2-5

2.2 TURNING THE POWER OFF

The procedure for turning the power off when finishing the robot operation is as follows.

In this example external signals are not used. See the External I/O Manual, a separate volume,

for using external signals.

Press the EMERGENCY STOP switch and

Turn the MOTOR POWER off. (The light goes off.)

Turn the CONTROL POWER switch off.

Turning off the motor and control power is complete.

WARNING

When shutting off the control power (breaker) of the robot, be sure to turn off the

motor power by pressing the EMERGENCY STOP Switch located on the

controller before turning off the control power switch (breaker).


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2-6

2.3 STOPPING THE ROBOT MOTION

The following emergency stop procedures are provided for stopping the robot motion

immediately. These procedures can be executed regardless of the robot mode, repeat or teach.

The robot motor power is shut off and the arm comes to a complete stop when executed.

When stopping the robot motion using the above procedures, the ERROR light on the controller

may turn on or an error message may appear on the display. For restarting the robot from the

stopped condition, press the ERROR RESET switch and then the MOTOR POWER or CYCLE

START switch.

Controller

Explosion-proof teach pendant

External equipment such as interlock board

Press the EMERGENCY STOP switch located on

the controller.

The MOTOR POWER and CYCLE START

lights on the controller turn off.

Press the EMERGENCY STOP switch located on

the explosion-proof teach pendant.The MOTOR POWER and CYCLE START lights

on the controller turn off.

Press the EMERGENCY STOP switch.

The MOTOR POWER and CYCLE START lightson the controller turn off.

See the External I/O Manual (Interlock Signals),

a separate volume.

The EMERGENCY STOP switch should be used only for urgency

during the robot operation.

An emergency stop gives a sudden brake on the motor that drives the

robot arm. This means that the robot is forced to stop by excessive

power, and this may give a damage to the robot components.

[ NOTE ]

EMERGENCY STOP


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2-7

The following three procedures are provided for stopping the robot motion during repeat

operation.

Switches used for sto in the robot motion

E-STOP

E-STOP

E-STOP

Press

Press

TOGGLE SWITCH SWITCHTOGGLE SWITCH

E-STOP SWITCH onthe teach pendant

To REPEAT

To TEACH

E-STOP

HOLD

RUN

Arm

inmotion

Arm

inhold

Armina

completestop

CYCLESTART

ON

CYCLESTAR

T

OFF

MOTORPOWER

OFF

MOTORPOWER

ON


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2-8

Memo


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3-1

BASIC OPERATION

OF MULTIFUNCTION PANEL

This chapter describes the basic operation

procedures for using the multifunction panel.

3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL..............................3-2

3.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL........................3-43.1.2 STATUS SCREEN.........................................................................................................3-53.1.3 OTHERS ........................................................................................................................3-63.1.4 STATUS SCREEN.........................................................................................................3-83.1.5 SPRAY STATUS SCREEN...........................................................................................3-93.1.6 PROGRAM LIST SCREEN........................................................................................ 3-133.1.7 MONITOR SCREEN................................................................................................... 3-143.1.8 CURRENT POSITION SCREEN ............................................................................... 3-17

3.2 MOVING CURSORS.................................................................................................. 3-18

3.3 SELECTION BY ENTERING NUMERIC VALUES OR CURSOR OPERATION .... 3-19

3.4 ENTERING CHARACTERS....................................................................................... 3-20

3.5 SELECTING PROGRAMS......................................................................................... 3-21

3.6 SELECTING STEPS................................................................................................... 3-23

3


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C Series Controller, Explosion-Proof Type 3. Basic Operation of

Kawasaki Robot Operation Multifunction Panel

3-2

3.1 SWITCHING THE SCREEN OF THE MULTIFUNCTION PANEL

PressSTATUS

orMENU

keys to display pull-down menu.

Select the desired key to switch screens.

Status Display screen

STATUS

Status screen See 4 Status screen.

Program List screen See 3.1.6 Program List screen.

Monitor screen See 3.1.7 Monitor screen.

Current Position screen See 3.1.8 Current Position screen.

Spray Status screen See 3.1.5 Spray Status screen.


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3-3

Menu screen

Status screen

See 3.1.4 Status screen, 3.1.5 Spray Status screen,

3.1.6 Program List screen, 3.1.7 Monitor screen (Output signal),

and 3.1.8 Current Position screen

Aux function screen

See 9. Auxiliary Functions

Setting screen for interface panel (option)

See 13. Interface Panel Setting

Keyboard screen (Option)

See 1.2.4 Keyboard


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3-4

3.1.1 BASIC SCREEN STRUCTURE ON THE MULTIFUNCTION PANEL

(1) Keys for switching screens

Note: The left and right menu keys can be switched by pressing the keys indicated by (A) and

(B) above. The selected menu key is darkened.

(D): Returns to the STATUS screen by pressing the EXIT key on the function list screen of

the Aux screen.

(2) Keys for program and step selection

(3) Others

Program List screen contains two pages which can be switched by the PRE PG and

NEXT PG keys.

Monitor screen contains Input, Output, and Internal Signal screens which can be switched by

each key located on the downside.

(A): Left menu key for teaching

(B): Right menu key for status display

(C): Menu key

Status

Program List

Monitor

Current Position

Status Display

Aux. Function

Interface Panel

Keyboard

(A) (B) (C)

Spray Status

Program List

(2/2)

Program List

(1/2)

NEXT

PRE PG

(A): Program selection and display key(B): Step selection and display key

(C : PC ro ram dis la ke

A small screen for step selection appears.

Switches to the program selection screen.

(A) (B) (C)

Monitor(Output signal)

Monitor(Internal Signal)

Monitor(Input Signal)

Out ut

In ut

Internal Out ut

InternalInput

PROGRAM STEP


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3.1.2 STATUS SCREEN

(1) Status

(2) Program List

(3) Monitor


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(4) Current Position

(5) Spray status

3.1.3 OTHERS

(1) Auxiliary Function


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(2) Key board

(3) Program selection

(4) Step selection

(When the status screen is displayed.)


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3-8

3.1.4 STATUS SCREEN

Shows the current status and repeat conditions.

Set Items Descriptions

Repeat 10% The repeat speed is indicated in percentage.

Repeat

conditionSee 8.5 Repeat Condition Selection

Display Items Descriptions

E-STOP Turns on when the EMERGENCY STOP switch is pressed.

Motor power Turns on when the MOTOR POWER switch is pressed.

Cycle start Turns on when the CYCLE START switch is engaged.Teach/Repeat Indicates robot mode; Teach or Repeat.

Hold/Run Indicates the robot condition; Hold or Run

Error Turns on when errors occur.

Normal Turns on when the robot is operating normally without any errors.

Release ext.

holdTurns on when the stop release is engaged.

Record accept The color changes when teaching becomes effective.

Step forward Appears when STEP ONCE is selected.

Repeat

Cont/Once

Indicates the status of the repeat operation programmed, one cycle only

(Repeat Once) or continuous cycle (Repeat Cont).Step

Cont/Once

Indicates the program execution status, step by step (Step Once) or

continuously (Step Cont).

RPS

Enable/Disable

Indicates that RPS (Random Program Selection) function is enabled or

disabled. RPS is a function for selecting programs by external input

signal to the robot.

Dryrun

ON/OFFIndicates that the Dryrun mode is effective (ON) or not effective (OFF).

Shows year, date, and time.

Shows the location data of

the step in progress.

Shows the step numberand data. The secondline is highlighted andshows the step in progress.

Displayed only whenSTEP ONCE is selected.

Shows the current mode.The displayed color changeswhen turned ON and OFF.

Shows the repeat condition.

Shows the monitor speed.


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3.1.5 SPRAY STATUS SCREEN

Set items DescriptionsSpray output Switches to the Spray output screen.

All ratio set Switches to the All ratio set screen.

Signal output Switches to the Signal output screen.

Display items Descriptions

Production speed ratio Indicates the production speed ratio data.

Conveyor speedIndicates the conveyor speed.

(when the conveyor synchronization function is enabled.)

Conveyor positionIndicates the conveyor position.

(when the conveyor synchronization function is enabled.)

Production number Indicates the production number.

Repeat time Indicates the repeat time.


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(1) Spray output

Changes the manual spray output signal.

Verify that the mode is in TEACH and the Teach lock keys on the explosion-proof teach

pendant is OFF before changing.

The screens for entering numeric values appear when the FLOWRATE , SHAPING AIR ,

AIRMOTOR , HIGH VOLT keys are pressed.


Spray 1 Indicates the ON/OFF condition of the spray 1.

Spray 2 Indicates the ON/OFF condition of the spray 2.

Flow rate

Indicates the dedicated signal condition of the flow rate in numeric

values for the corresponding signal. The numeric value screen

appears for entering.

Shaping air

/ Pattern air

Indicates the dedicated signal conditions of the shaping or pattern air

in numeric values for the corresponding signal. The numeric value

screen appears for entering.

Air motor

/ Atomize air

Indicates the dedicated signal conditions of the air motor or atomizing

air in numeric values of the signal. The numeric value screen


High voltage

Indicates the dedicated signal condition of the high voltage in numeric

values for the corresponding signal. The numeric value screen


Flushing Indicates the ON/OFF condition of the dedicated signal for flushing.

Push thinnerIndicates the ON/OFF condition of the dedicated signal for push

thinner.

Flow rate upperIndicates the upper limit setting of the flow rate in numeric values for

the signal. The numeric value screen appears for entering.

Shaping air upper

/ Pattern air upper

Indicates the upper limit setting of the shaping or pattern air in

numeric values for the signal. The numeric value screen appears for

entering.

Air motor upper

/ Atomize air upper

Indicates the upper limit setting of the air motor or atomizing air in

numeric values for the signal. The numeric value screen appears for

entering.

High volt upperIndicates the upper limit setting of the high voltage in numeric values

for the signal. The numeric value screen appears for entering.


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(2) All ratio set

Ratios for all the manual spray output signals can be set.


Flow rate

Ratio for all the spray signals of the flow rate is indicated in

percentage.The numeric entry screen appears when entering with keys.

Shaping air

/ Pattern air

Ratios for all the spray signals of the shaping or pattern air are

indicated in percentage.

The numeric entry screen appears when entering with keys.

Air motor air

/ Atomize air

Ratios for all the spray signals of the air motor or atomizing air are

indicated in percentage.


High volt

Ratios for all the spray signals of the high voltage are indicated in

percentage.


(3) Signal output

Sets ON/OFF for the general output signals.

The ON/OFF status of the signal is indicated by the LED on each key.

Red : ON

Blue: OFF

Switched ON and OFF by pr

manual robo kawasaki.pdf

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