spi interface

FANUC Robotics R-J3iB Controller SPI Interface Setup and Operations Manual

MARO2SPIS11801E REV. C

This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics North America, Inc. FANUC Robotics North America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 483093253

The descriptions and specifications contained in this manual were ineffect at the time this manual was approved for printing. FANUCRobotics North America, Inc, hereinafter referred to as FANUCRobotics, reserves the right to discontinue models at any time or tochange specifications or design without notice and without incurringobligations.FANUC Robotics manuals present descriptions, specifications,drawings, schematics, bills of material, parts, connections and/orprocedures for installing, disassembling, connecting, operating andprogramming FANUC Robotics products and/or systems. Suchsystems consist of robots, extended axes, robot controllers,application software, the KAREL programming language,INSIGHT vision equipment, and special tools.FANUC Robotics recommends that only persons who have beentrained in one or more approved FANUC Robotics TrainingCourse(s) be permitted to install, operate, use, perform procedureson, repair, and/or maintain FANUC Robotics products and/orsystems and their respective components. Approved trainingnecessitates that the courses selected be relevant to the type ofsystem installed and application performed at the customer site.

WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordancewith the instruction manual, may cause interference to radiocommunications. As temporarily permitted by regulation, ithas not been tested for compliance with the limits for Class Acomputing devices pursuant to subpart J of Part 15 of FCCRules, which are designed to provide reasonable protectionagainst such interference. Operation of the equipment in aresidential area is likely to cause interference, in which casethe user, at his own expense, will be required to takewhatever measure may be required to correct theinterference.

FANUC Robotics conducts courses on its systems and products ona regularly scheduled basis at its headquarters in Rochester Hills,Michigan. For additional information contact

FANUC Robotics North America, Inc.Training Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253www.fanucrobotics.com

Send your comments and suggestions about this manual to:[email protected]

Copyright 2002 by FANUC Robotics North America, Inc.All Rights ReservedThe information illustrated or contained herein is not to bereproduced, copied, translated into another language, or transmittedin whole or in part in any way without the prior written consent ofFANUC Robotics North America, Inc.AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,PalletTool, SOCKETS, SOFT PARTS SpotTool,TorchMate, and YagTool are Registered Trademarks of FANUCRobotics.FANUC Robotics reserves all proprietary rights, including but notlimited to trademark and trade name rights, in the following names:AccuAir AccuCal AccuChop AccuFlow AccuPathAccuSeal ARC Mate ARC Mate Sr. ARC Mate System 1ARC Mate System 2 ARC Mate System 3 ARC Mate System4 ARC Mate System 5 ARCWorks Pro AssistToolAutoNormal AutoTCP BellTool BODYWorks Cal Mate CellFinder Center Finder Clean Wall CollisionGuardDispenseTool F-100 F-200i FabTool FANUC LASERDRILL Flexibell FlexTool HandlingTool HandlingWorksINSIGHT INSIGHT II IntelliTrak Integrated Process SolutionIntelligent Assist Device IPC -Integrated Pump Control IPDIntegral Pneumatic Dispenser ISA Integral Servo Applicator ISDIntegral Servo Dispenser Laser Mate System 3 Laser MateSystem 4 LaserPro LaserTool LR Tool MIG EyeMotionParts NoBots Paint Stick PaintPro PaintTool 100PAINTWorks PAINTWorks II PAINTWorks III PalletMatePalletMate PC PalletTool PC PayloadID RecipToolRemovalTool Robo Chop Robo Spray S-420i S-430iShapeGen SoftFloat SOF PARTS SpotTool+ SR MateSR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R-J3 Controller SYSTEM R-J3iB Controller TCP MateTurboMove TorchMate visLOC visPRO-3D visTRACWebServer WebTP YagTool

This manual includes information essential to the safety ofpersonnel, equipment, software, and data. This information isindicated by headings and boxes in the text.

WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to set itapart from other text.

Conventions

CAUTIONInformation appearing under CAUTION concerns the protection ofequipment, software, and data. It is boxed to set it apart fromother text.

NOTE Information appearing next to NOTE concerns relatedinformation or useful hints.

Safety-1

FANUC Robotics is not and does not represent itself as an expert insafety systems, safety equipment, or the specific safety aspects ofyour company and/or its work force. It is the responsibility of theowner, employer, or user to take all necessary steps to guaranteethe safety of all personnel in the workplace.The appropriate level of safety for your application and installationcan best be determined by safety system professionals. FANUCRobotics therefore, recommends that each customer consult withsuch professionals in order to provide a workplace that allows forthe safe application, use, and operation of FANUC Robotic systems.According to the industry standard ANSI/RIA R15.06, the owner oruser is advised to consult the standards to ensure compliance withits requests for Robotics System design, usability, operation,maintenance, and service. Additionally, as the owner, employer, oruser of a robotic system, it is your responsibility to arrange for thetraining of the operator of a robot system to recognize and respondto known hazards associated with your robotic system and to beaware of the recommended operating procedures for your particularapplication and robot installation.FANUC Robotics therefore, recommends that all personnel whointend to operate, program, repair, or otherwise use the roboticssystem be trained in an approved FANUC Robotics training courseand become familiar with the proper operation of the system.Persons responsible for programming the systemincluding thedesign, implementation, and debugging of application programsmust be familiar with the recommended programming proceduresfor your application and robot installation.The following guidelines are provided to emphasize the importanceof safety in the workplace.

Safety-2

Safety is essential whenever robots are used. Keep in mind thefollowing factors with regard to safety:

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the

robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

The safety of people is always of primary importance in anysituation. However, equipment must be kept safe, too. Whenprioritizing how to apply safety to your robotic system, consider thefollowing: People External devices Robot(s) Tooling Workpiece

Always give appropriate attention to the work area that surroundsthe robot. The safety of the work area can be enhanced by theinstallation of some or all of the following devices: Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

A safe workcell is essential to protect people and equipment.Observe the following guidelines to ensure that the workcell is setup safely. These suggestions are intended to supplement and notreplace existing federal, state, and local laws, regulations, andguidelines that pertain to safety.

Sponsor your personnel for training in approved FANUCRobotics training course(s) related to your application. Neverpermit untrained personnel to operate the robots.

CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION

Keeping People andEquipment Safe

Using SafetyEnhancing Devices

Setting Up a SafeWorkcell

Safety-3

Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.

Use antitiedown logic to prevent the operator from bypassingsafety measures.

Arrange the workcell so the operator faces the workcell and cansee what is going on inside the cell.

Clearly identify the work envelope of each robot in the systemwith floor markings, signs, and special barriers. The workenvelope is the area defined by the maximum motion range ofthe robot, including any tooling attached to the wrist flange thatextend this range.

Position all controllers outside the robot work envelope.

Never rely on software as the primary safety element.

Mount an adequate number of EMERGENCY STOP buttons orswitches within easy reach of the operator and at critical pointsinside and around the outside of the workcell.

Install flashing lights and/or audible warning devices thatactivate whenever the robot is operating, that is, wheneverpower is applied to the servo drive system. Audible warningdevices shall exceed the ambient noise level at the enduseapplication.

Wherever possible, install safety fences to protect againstunauthorized entry by personnel into the work envelope.

Install special guarding that prevents the operator from reachinginto restricted areas of the work envelope.

Use interlocks.

Use presence or proximity sensing devices such as lightcurtains, mats, and capacitance and vision systems to enhancesafety.

Periodically check the safety joints or safety clutches that can beoptionally installed between the robot wrist flange and tooling. Ifthe tooling strikes an object, these devices dislodge, removepower from the system, and help to minimize damage to thetooling and robot.

Safety-4

Make sure all external devices are properly filtered, grounded,shielded, and suppressed to prevent hazardous motion due tothe effects of electromagnetic interference (EMI), radiofrequency interference (RFI), and electrostatic discharge(ESD).

Make provisions for power lockout/tagout at the controller.

Eliminate pinch points. Pinch points are areas where personnelcould get trapped between a moving robot and other equipment.

Provide enough room inside the workcell to permit personnel toteach the robot and perform maintenance safely.

Program the robot to load and unload material safely.

If high voltage electrostatics are present, be sure to provideappropriate interlocks, warning, and beacons.

If materials are being applied at dangerously high pressure,provide electrical interlocks for lockout of material flow andpressure.

Advise all personnel who must teach the robot or otherwisemanually operate the robot to observe the following rules:

Never wear watches, rings, neckties, scarves, or loose clothingthat could get caught in moving machinery.

Know whether or not you are using an intrinsically safe teachpendant if you are working in a hazardous environment.

Before teaching, visually inspect the robot and work envelope tomake sure that no potentially hazardous conditions exist. Thework envelope is the area defined by the maximum motionrange of the robot. These include tooling attached to the wristflange that extends this range.

The area near the robot must be clean and free of oil, water, ordebris. Immediately report unsafe working conditions to thesupervisor or safety department.

FANUC Robotics recommends that no one enter the workenvelope of a robot that is on, except for robot teachingoperations. However, if you must enter the work envelope, besure all safeguards are in place, check the teach pendantDEADMAN switch for proper operation, and place the robot inteach mode. Take the teach pendant with you, turn it on, and beprepared to release the DEADMAN switch. Only the personwith the teach pendant should be in the work envelope.

Staying Safe WhileTeaching or ManuallyOperating the Robot

Safety-5

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

Know the path that can be used to escape from a moving robot;make sure the escape path is never blocked.

Isolate the robot from all remote control signals that can causemotion while data is being taught.

Test any program being run for the first time in the followingmanner:

WARNINGStay outside the robot work envelope whenever a program isbeing run. Failure to do so can result in injury.

- Using a low motion speed, single step the program for atleast one full cycle.

- Using a low motion speed, test run the program continuouslyfor at least one full cycle.

- Using the programmed speed, test run the programcontinuously for at least one full cycle.

Make sure all personnel are outside the work envelope beforerunning production.

Advise all personnel who operate the robot during production toobserve the following rules:

Make sure all safety provisions are present and active.

Know the entire workcell area. The workcell includes the robotand its work envelope, plus the area occupied by all externaldevices and other equipment with which the robot interacts.

Understand the complete task the robot is programmed toperform before initiating automatic operation.

Make sure all personnel are outside the work envelope beforeoperating the robot.

Staying Safe DuringAutomatic Operation

Safety-6

Never enter or allow others to enter the work envelope duringautomatic operation of the robot.

Know the location and status of all switches, sensors, andcontrol signals that could cause the robot to move.

Know where the EMERGENCY STOP buttons are located onboth the robot control and external control devices. Be preparedto press these buttons in an emergency.

Never assume that a program is complete if the robot is notmoving. The robot could be waiting for an input signal that willpermit it to continue activity.

If the robot is running in a pattern, do not assume it will continueto run in the same pattern.

Never try to stop the robot, or break its motion, with your body.The only way to stop robot motion immediately is to press anEMERGENCY STOP button located on the controller panel,teach pendant, or emergency stop stations around the workcell.

When inspecting the robot, be sure to

Turn off power at the controller.

Lock out and tag out the power source at the controlleraccording to the policies of your plant.

Turn off the compressed air source and relieve the air pressure.

If robot motion is not needed for inspecting the electrical circuits,press the EMERGENCY STOP button on the operator panel.


If power is needed to check the robot motion or electricalcircuits, be prepared to press the EMERGENCY STOP button,in an emergency.

Be aware that when you remove a servomotor or brake, theassociated robot arm will fall if it is not supported or resting on ahard stop. Support the arm on a solid support before yourelease the brake.

When performing maintenance on your robot system, observe thefollowing rules:

Staying Safe DuringInspection

Staying Safe DuringMaintenance

Safety-7

Never enter the work envelope while the robot or a program is inoperation.

Before entering the work envelope, visually inspect the workcellto make sure no potentially hazardous conditions exist.


Consider all or any overlapping work envelopes of adjoiningrobots when standing in a work envelope.

Test the teach pendant for proper operation before entering thework envelope.

If it is necessary for you to enter the robot work envelope whilepower is turned on, you must be sure that you are in control ofthe robot. Be sure to take the teach pendant with you, press theDEADMAN switch, and turn the teach pendant on. Be preparedto release the DEADMAN switch to turn off servo power to therobot immediately.

Whenever possible, perform maintenance with the power turnedoff. Before you open the controller front panel or enter the workenvelope, turn off and lock out the 3phase power source at thecontroller.


WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.

HIGH VOLTAGE IS PRESENT at the input side whenever thecontroller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removespower from the output side of the device only.

Release or block all stored energy. Before working on thepneumatic system, shut off the system air supply and purge theair lines.

Safety-8

Isolate the robot from all remote control signals. If maintenancemust be done when the power is on, make sure the personinside the work envelope has sole control of the robot. Theteach pendant must be held by this person.

Make sure personnel cannot get trapped between the movingrobot and other equipment. Know the path that can be used toescape from a moving robot. Make sure the escape route isnever blocked.

Use blocks, mechanical stops, and pins to prevent hazardousmovement by the robot. Make sure that such devices do notcreate pinch points that could trap personnel.

WARNINGDo not try to remove any mechanical component from therobot before thoroughly reading and understanding theprocedures in the appropriate manual. Doing so can result inserious personal injury and component destruction.


When replacing or installing components, make sure dirt anddebris do not enter the system.

Use only specified parts for replacement. To avoid fires anddamage to parts in the controller, never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the workenvelope; be sure that the robot and all external devices areoperating normally.

Certain programming and mechanical measures are useful inkeeping the machine tools and other external devices safe. Someof these measures are outlined below. Make sure you know allassociated measures for safe use of such devices.

Implement the following programming safety measures to preventdamage to machine tools and other external devices.

KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE

Programming SafetyPrecautions

Safety-9

Backcheck limit switches in the workcell to make sure they donot fail.

Implement failure routines in programs that will provideappropriate robot actions if an external device or another robotin the workcell fails.

Use handshaking protocol to synchronize robot and externaldevice operations.

Program the robot to check the condition of all external devicesduring an operating cycle.

Implement the following mechanical safety measures to preventdamage to machine tools and other external devices.

Make sure the workcell is clean and free of oil, water, anddebris.

Use software limits, limit switches, and mechanical hardstops toprevent undesired movement of the robot into the work area ofmachine tools and external devices.

Observe the following operating and programming guidelines toprevent damage to the robot.

The following measures are designed to prevent damage to therobot during operation.

Use a low override speed to increase your control over the robotwhen jogging the robot.

Visualize the movement the robot will make before you pressthe jog keys on the teach pendant.

Make sure the work envelope is clean and free of oil, water, ordebris.

Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage tothe robot during programming:

Establish interference zones to prevent collisions when two ormore robots share a work area.

Mechanical SafetyPrecautions

KEEPING THEROBOT SAFE

Operating SafetyPrecautions

Programming SafetyPrecautions

Safety-10

Make sure that the program ends with the robot near or at thehome position.

Be aware of signals or other operations that could triggeroperation of tooling resulting in personal injury or equipmentdamage.

In dispensing applications, be aware of all safety guidelines withrespect to the dispensing materials.

NOTE Any deviation from the methods and safety practicesdescribed in this manual must conform to the approved standards ofyour company. If you have questions, see your supervisor.

Process technicians are sometimes required to enter the paintbooth, for example, during daily or routine calibration or whileteaching new paths to a robot. Maintenance personal also mustwork inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilationequipment must be used. Instruction on the proper use ofventilating equipment usually is provided by the paint shopsupervisor.Although paint booth hazards have been minimized, potentialdangers still exist. Therefore, todays highly automated paint boothrequires that process and maintenance personnel have fullawareness of the system and its capabilities. They mustunderstand the interaction that occurs between the vehicle movingalong the conveyor and the robot(s), hood/deck and door openingdevices, and highvoltage electrostatic tools.Paint robots are operated in three modes: Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic modeDuring both teach and automatic modes, the robots in the paintbooth will follow a predetermined pattern of movements. In teachmode, the process technician teaches (programs) paint paths usingthe teach pendant.In automatic mode, robot operation is initiated at the SystemOperator Console (SOC) or Manual Control Panel (MCP), ifavailable, and can be monitored from outside the paint booth. Allpersonnel must remain outside of the booth or in a designated safe

ADDITIONALSAFETYCONSIDERATIONSFOR PAINT ROBOTINSTALLATIONS

Safety-11

area within the booth whenever automatic mode is initiated at theSOC or MCP.In automatic mode, the robots will execute the path movements theywere taught during teach mode, but generally at production speeds.When process and maintenance personnel run diagnostic routinesthat require them to remain in the paint booth, they must stay in adesignated safe area.

Process technicians and maintenance personnel must becometotally familiar with the equipment and its capabilities. To minimizethe risk of injury when working near robots and related equipment,personnel must comply strictly with the procedures in the manuals.

This section provides information about the safety features that areincluded in the paint system and also explains the way the robotinteracts with other equipment in the system.The paint system includes the following safety features:

Most paint booths have red warning beacons that illuminatewhen the robots are armed and ready to paint. Your boothmight have other kinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated,indicates that the electrostatic devices are enabled. Your boothmight have other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controllerand teach pendant. Become familiar with the locations of all ESTOP buttons.

An intrinsically safe teach pendant is used when teaching inhazardous paint atmospheres.

A DEADMAN switch is located on each teach pendant. When thisswitch is held in, and the teach pendant is on, power is applied to therobot servo system. If the engaged DEADMAN switch is releasedduring robot operation, power is removed from the servo system, allaxis brakes are applied, and the robot comes to an EMERGENCYSTOP. Safety interlocks within the system might also ESTOP otherrobots.

WARNINGAn EMERGENCY STOP will occur if the DEADMAN switch isreleased on a bypassed robot.

Paint System SafetyFeatures

Safety-12

Overtravel by robot axes is prevented by software limits. All ofthe major and minor axes are governed by software limits. Limitswitches and hardstops also limit travel by the major axes.

EMERGENCY STOP limit switches and photoelectric eyesmight be part of your system. Limit switches, located on theentrance/exit doors of each booth, will EMERGENCY STOP allequipment in the booth if a door is opened while the system isoperating in automatic or manual mode. For some systems,signals to these switches are inactive when the switch on theSCC is in teach mode.

When present, photoelectric eyes are sometimes used tomonitor unauthorized intrusion through the entrance/exitsilhouette openings.

System status is monitored by computer. Severe conditionsresult in automatic system shutdown.

When you work in or near the paint booth, observe the followingrules, in addition to all rules for safe operation that apply to all robotsystems.

WARNINGObserve all safety rules and guidelines to avoid injury.

WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.

Know the work area of the entire paint station (workcell).

Know the work envelope of the robot and hood/deck and dooropening devices.

Be aware of overlapping work envelopes of adjacent robots.

Know where all red, mushroomshaped EMERGENCY STOPbuttons are located.

Staying Safe WhileOperating the PaintRobot

Safety-13

Know the location and status of all switches, sensors, and/orcontrol signals that might cause the robot, conveyor, andopening devices to move.

Make sure that the work area near the robot is clean and free ofwater, oil, and debris. Report unsafe conditions to yoursupervisor.

Become familiar with the complete task the robot will performBEFORE starting automatic mode.

Make sure all personnel are outside the paint booth before youturn on power to the robot servo system.

Never enter the work envelope or paint booth before you turn offpower to the robot servo system.

Never enter the work envelope during automatic operationunless a safe area has been designated.


Remove all metallic objects, such as rings, watches, and belts,before entering a booth when the electrostatic devices areenabled.

Stay out of areas where you might get trapped between amoving robot, conveyor, or opening device and another object.

Be aware of signals and/or operations that could result in thetriggering of guns or bells.

Be aware of all safety precautions when dispensing of paint isrequired.

Follow the procedures described in this manual.

When you work with paint application equipment, observe thefollowing rules, in addition to all rules for safe operation that apply toall robot systems.

WARNINGWhen working with electrostatic paint equipment, follow allnational and local codes as well as all safety guidelineswithin your organization. Also reference the followingstandards: NFPA 33 Standards for Spray Application UsingFlammable or Combustible Materials, and NFPA 70 NationalElectrical Code.

Staying Safe WhileOperating PaintApplication Equipment

Safety-14

Grounding: All electrically conductive objects in the spray areamust be grounded. This includes the spray booth, robots,conveyors, workstations, part carriers, hooks, paint pressurepots, as well as solvent containers. Grounding is defined as theobject or objects shall be electrically connected to ground with aresistance of not more than 1 megohms.

High Voltage: High voltage should only be on during actualspray operations. Voltage should be off when the paintingprocess is completed. Never leave high voltage on during a capcleaning process.

Avoid any accumulation of combustible vapors or coatingmatter.

Follow all manufacturer recommended cleaning procedures.

Make sure all interlocks are operational.

No smoking.

Post all warning signs regarding the electrostatic equipment andoperation of electrostatic equipment according to NFPA 33Standard for Spray Application Using Flammable orCombustible Material.

Disable all air and paint pressure to bell.

Verify that the lines are not under pressure.

When you perform maintenance on the painter system, observe thefollowing rules, and all other maintenance safety rules that apply toall robot installations. Only qualified, trained service or maintenancepersonnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Usecaution when working with electric tools.

When a maintenance technician is repairing or adjusting a robot,the work area is under the control of that technician. Allpersonnel not participating in the maintenance must stay out ofthe area.

For some maintenance procedures, station a second person atthe control panel within reach of the EMERGENCY STOPbutton. This person must understand the robot and associatedpotential hazards.

Staying Safe DuringMaintenance

Safety-15

Be sure all covers and inspection plates are in good repair andin place.

Always return the robot to the home position before youdisarm it.

Never use machine power to aid in removing any componentfrom the robot.

During robot operations, be aware of the robots movements.Excess vibration, unusual sounds, and so forth, can alert you topotential problems.

Whenever possible, turn off the main electrical disconnectbefore you clean the robot.

When using vinyl resin observe the following:

- Wear eye protection and protective gloves during applicationand removal

- Adequate ventilation is required. Overexposure could causedrowsiness or skin and eye irritation.

- If there is contact with the skin, wash with water. When using paint remover observe the following:

- Eye protection, protective rubber gloves, boots, and apronare required during booth cleaning.

- Adequate ventilation is required. Overexposure could causedrowsiness.

- If there is contact with the skin or eyes, rinse with water forat least 15 minutes.

3Table of Contents

1. INTRODUCTION 5

1.1. MANUAL PLAN 51.2. WORKERS 51.3. GENERAL SAFETY PRECAUTIONS 51.4. SAFETY PRECAUTIONS 51.5. SPI SAFETY PRECAUTIONS 6

2. OVERVIEW 9

2.1. FANUC ROBOTICS SPI INTERFACE 92.2. SPI INTERFACE SOFTWARE (R-J2, R-J3, R-J3IB MATE AND R-J3IB CONTROLLERS) 92.3. SPI INTERFACE SOFTWARE (R-J2 MATE CONTROLLERS) 102.4. SPI STANDARD INDUSTRIAL INTERFACE 11

3. SETTING THE SPI SYSTEM 13

3.1. SPI INTERFACE (R-J2, R-J3 AND R-J3IB CONTROLLERS) 133.1.1. CONNECTING (R-J2, R-J3 AND R-J3IB CONTROLLERS) 133.1.2. CONFIGURING (R-J2, R-J3 AND R-J3IB CONTROLLERS) 153.1.3. SETTING SYSTEM CONFIG MENU (R-J2, R-J3 AND R-J3IB CONTROLLERS) 153.1.4. LOADING SPI SOFTWARE 15A. R-J2 controller 15B. R-J3 or R-J3iB controller 163.1.5. CONFIGURING ROBOT I/O (R-J2, R-J3 AND R-J3IB CONTROLLERS) 183.2. SPI INTERFACE (R-J2 MATE AND R-J3IB MATE CONTROLLERS) 193.2.1. CONNECTING (R-J2 MATE AND R-J3IB MATE CONTROLLERS) 193.2.2. CONFIGURING (R-J2 MATE AND R-J3IB MATE CONTROLLERS) 203.2.3. SETTING ROBOT SYSTEM VARIABLES (R-J2 MATE AND R-J3IB MATE CONTROLLERS)213.2.4. SETTING SYSTEM CONFIG MENU (R-J2 AND R-J3IB MATE CONTROLLERS) 213.2.5. LOADING SPI SOFTWARE 21A. R-J2 Mate controller 21B. R-J3iB Mate controller 233.2.6. CONFIGURING ROBOT I/O (R-J2 MATE AND R-J3IB MATE CONTROLLERS) 233.2.7. SETTING PNS (R-J2 MATE AND R-J3IB MATE CONTROLLERS) 243.3. SETTING REFERENCE POSITIONS 243.4. TEACHING THE POSITIONS 25

4. TESTING THE SPI SOFTWARE & RUNNING PRODUCTION 27

5. TROUBLESHOOTING THE SPI SOFTWARE 29

46. SPI SOFTWARE PROGRAMS 31

6.1. CLAMP.TP 316.2. CLS.TP 326.3. DPRT_IMM.TP 336.4. EXIT_IMM.TP 336.5. GETINSRT.TP 346.6. GRIP_PRT.TP 346.7. HOME.TP 346.8. INISHLZE.TP 356.9. INTLK_ON.TP 366.10. INTLKOFF.TP 376.11. M_EJCTFW.TP 396.12. M_EJCTRT.TP 396.13. M_GETPRT.TP 396.14. M_HOLD.TP 406.15. M_HOME.TP 406.16. M_IN_IMM.TP 406.17. M_MOLDOP.TP 416.18. M_NOTDRP.TP 416.19. M_PLCING.TP 416.20. M_PRTDRP.TP 426.21. M_RJCTNG.TP 426.22. MAIN.TP 436.23. PIK_PRT.TP 456.24. POLLCLAMP 466.25. PUT_PART.TP 476.26. PUTINSRT.TP 486.27. RJCT_PRT.TP 486.28. RLSE_PRT.TP 496.29. TO_IMM.TP 49

7. SPI DATA 50

7.1. POSITION REGISTER ASSIGNMENTS 507.2. REGISTER ASSIGNMENTS 517.3. I/O ASSIGNMENTS 52

8. APPENDIX A - SPI STANDARD INDUSTRIAL INTERFACE E-STOPCONNECTIONS FOR R-J2, R-J3 (NON-RIA) AND R-J3IB MATE CONTROLLERS. 54

9. APPENDIX B - SPI STANDARD INDUSTRIAL INTERFACE E-STOPCONNECTIONS FOR R-J2 MATE CONTROLLERS 57

51. INTRODUCTION

WARNINGThis chapter explains the manual plan and the safety precautionsthat must be observed in working with the FANUC Robot. Pleasenote the safety precautions for the injection molding machine areNOT addressed in this manual - refer to the documentation suppliedwith the injection molding machine.

1.1. Manual Plan

FANUC Robotics SPI Interface Setup and Operations Manual.

This manual describes how to setup and use the FANUC Robotics SPIInterface with a FANUC Robotics robot (R-J2, R-J2 Mate, R-J3, R-J3iBMate or R-J3iB controller) and an injection molding machine equippedwith an SPI connector.

1.2. Workers

Refer to the Setup and Operations manual supplied with the FANUC robotfor an explanation of Workers.

1.3. General Safety Precautions

Refer to the Setup and Operations manual supplied with the FANUC robotfor an explanation of General Safety Precautions.

Note the explanation listed in the Setup and Operations manual is for aFANUC robot only. Please refer to the manual supplied with the injectionmolding machine for safety concerns associated with operating theinjection molding machine.

1.4. Safety Precautions

Refer Setup and Operations manual supplied with the FANUC robot for anexplanation of Safety Precautions.

Note the explanation listed in the Setup and Operations manual is for aFANUC robot. Please refer to the manual supplied with the injection

6molding machine for safety precautions associated with operating theinjection molding machine.

1.5. SPI Safety Precautions

The FANUC Robotics SPI Interface provides an electricalcommunications connection between a FANUC robot controller and aninjection molding machine. Digital signals are sent between the robot andthe injection molding machine as a result of software programs operatingon both machines. With these programs operating the robot and/or theinjection molding machine can move with no apparent input from the user.

WARNINGUSERS MUST TAKE EXTENSIVE SAFETY PRECAUTIONS BEFOREWORKING ON OR WITH THE SPI INTERFACE, THE FANUC ROBOTOR THE INJECTION MOLDING MACHINE.

NOTE: The SPI Recommended Guideline for Robot/Injection MoldingMachine Electrical Interface, Version 3.0 states the emergency stopcircuit of the robot and the injection molding machine are to be hardwiredin series. The FANUC Robotics SPI Standard Industrial Interface followsthis recommendation - if the injection molding machine also follows theSPI Recommended Guideline both the robot and the injection moldingmachine will come to an immediate stop if an emergency stop signal isinitiated on either machine.

FANUC ROBOTS MANUFACTURED AFTER JUNE 21ST, 2001 AREDELIVERED WITH RIA-COMPLIANT CONTROLLERS. ADDITIONALLYIT IS POSSIBLE TO CONVERT AN NON-RIA R-J3 CONTROLLER TOBE RIA-COMPLIANT. MOST RIA-COMPLIANT CONTROLLERS USE ADUAL-CHANNEL E-STOP CHAIN THAT WILL NOT FUNCTIONCORRECTLY IF IT IS CONNECTED DIRECTLY TO THE SINGLE-CHANNEL E-STOP CHAIN FOUND ON MOST INJECTION MOLDMACHINES. REFER TO SECTION 2.4 FOR AN EXPLANATION ONCONNECTING THE DUAL-CHANNEL E-STOP OF AN RIA-COMPLIANTCONTROLLER TO THE SINGLE-CHANNEL E-STOP OF THEINJECTION MOLDING MACHINE.

7SPI Safety Precautions related to installation and layout.

Use warning lamps and other provisions to indicate the robot or theinjection molding machine is operating.

Use a protective fence so the motion range of the robot is surroundedcompletely.

Install additional emergency stop buttons where they will be readilyaccessible to the operator.

92. OVERVIEW

This manual explains the injection molding machine load/unload systemthat consists of the FANUC Robotics SPI Interface and the FANUC robot.

2.1. FANUC Robotics SPI Interface

The FANUC robot is connected to the injection molding machine throughthe FANUC Robotics SPI Interface. This interface uses the protocolestablished by the Society of Plastics Industry, Machinery Division -Recommended Guideline for Robot/Injection Molding Machine ElectricalInterface, Version 3.0

The FANUC Robotics SPI Interface consists of the FANUC Robotics SPIInterface Software (for R-J2, R-J3, R-J3iB Mate and R-J3iB Controllers orfor R-J2 Mate Controllers) and the FANUC Robotics SPI StandardIndustrial Interface.

2.2. SPI Interface Software (R-J2, R-J3, R-J3iB Mate and R-J3iB controllers)

The SPI Interface Software for R-J2, R-J3, R-J3iB Mate and R-J3iBcontrollers is an application software package that uses modular pre-written teach pendant programs to control a FANUC robot when it isattached to an injection molding machine using the FANUC Robotics SPIStandard Industrial Interface. The teach pendant programs are based onthe HandlingTool software provided as an option with most FANUCmaterial handling robots. (refer to the FANUC Robotics SYSTEMHandlingTool Setup and Operations Manual for details on HandlingTool).

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The SR Mate 200i can also use SHOT Tool Software if it is attached to aFANUC ROBOSHOT injection molding machine. SHOT Tool softwareuses a different, non-SPI, interface architecture.

The SPI Interface Software consists of a collection of modular, pre-writtenTeach Pendant (TP) programs that the user must modify for use on aparticular injection molding machine. In most cases the modifications willbe limited to teaching of robot positions. In some cases the user mayhave to add new instructions to control peripheral devices, modify robotlogic, etc. Section 6.0 provides program listings of all the SPI programs.

R-J2, R-J3, R-J3iB Mate and R-J3iB controllers are capable of multi-tasking and the SPI Interface Software for R-J2, R-J3, R-J3iB Mate andR-J3iB controllers is written to make use of this function.

WARNINGThe SPI Interface Software contains TP programs that protect therobot, the injection molding machine and the operator byinterlocking critical SPI signals. Modifying these programs withoutunderstanding their function could result in damage or severe injury.The programs that should not be modified without a clearunderstanding of their function are indicated in this manual and bytext instructions within each respective program - contact FANUCRobotics for assistance

2.3. SPI Interface Software (R-J2 Mate controllers)

The SPI Interface Software for R-J2 Mate Controllers is an applicationsoftware package that uses modular pre-written teach pendant programsto control an FANUC robot controlled by an R-J2 Mate controller when it isattached to an injection molding machine using the FANUC Robotics SPIStandard Industrial Interface. The teach pendant programs are based onLR Tool software provided with every LR Mate 100i and LR Mate 200irobot (refer to the FANUC Robotics SYSTEM R-J2 Controller LR TOOLSetup and Operations Manual (MARO2LRTL05701E) for details of LRTool. Since the SR Mate 100i uses the R-J2 Mate controller it can alsouse the FANUC Robotics SPI Interface if LR Tool software is loaded intothe controller.

The SR Mate 100i can also use SHOT Tool Software if it is attached to aFANUC ROBOSHOT injection molding machine. SHOT Tool softwareuses a different non-SPI interface architecture.

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The SPI Interface Software consists of a collection of modular, pre-writtenTeach Pendant (TP) programs that the user must modify for use on aparticular injection molding machine. In most cases the modifications willbe limited to teaching of robot positions. In some cases the user mayhave to add new instructions to control peripheral devices, modify robotlogic, etc. Section 6.0 provides program listings and flow charts of all theSPI programs.

In order to use the FANUC Robotics SPI Interface Software for R-J2 Matecontrollers, which requires multi-tasking, a software option calledCondition Monitor must be loaded into the R-J2 Mate controller. Since allsoftware must be loaded into the R-J2 Mate controller at the same time itmay be necessary for the user to send the robot FROM chip to FANUCRobotics for software reloading.

WARNINGThe SPI Interface Software contains TP programs that protect therobot, the injection molding machine and the operator byinterlocking critical SPI signals. Modifying these programs withoutunderstanding their function could result in damage or severe injuryThe programs that should not be modified without a clearunderstanding of their function are indicated in this manual and bytext instructions within each respective program - contact FANUCRobotics for assistance

2.4. SPI Standard Industrial Interface

The SPI Standard Industrial Interface is an electrical hardware packageconsisting of an enclosure, I/O rack, I/O modules and relays. It allows therobot to communicate with an injection molding machine through digitalsignals.

On the R-J2, R-J3 or R-J3iB controller the SPI Standard IndustrialInterface is connected in series with a standard Model A I/O Interfacebackplane (supplied with most R-J2, R-J3 and R-J3iB controllers).

On the R-J3iB Mate controller the SPI Standard Industrial Interface isconnected directly to the FANUC I/O Link connector on the R-J3iB MateCPU. Refer to the FANUC Robotics System R-J3iB Mate LR HandlingTool Operators Manual (MAROIBLRH02021E, Chapter 3, Section 3.5) formore information on the FANUC I/O Link.

On the R-J2 Mate controller the SPI Standard Industrial Interface isconnected through the FANUC I/O Link. Refer to the FANUC RoboticsSystem R-J2 Mate Controller LR TOOL Setup and Operations Manual

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(MARO2LRTO05701E, Chapter 3) for more information on the FANUCI/O Link.

Elements of the SPI Standard Industrial Interface:

16 x 16 x 10 enclosure 1 FANUC Model A I/O rack & backplane 3 FANUC Model A 16 point digital I/O modules 7 A-B relays I/O Link cable SPI Standard Industrial Interface Cable SPI power and E-Stop connections (cable supplied by end-

user/customer)

Most RIA-compliant controllers (some R-J3 and all R-J3iB Mate and R-J3iB controllers are RIA-compliant) use dual-channel E-stop chains whilemost injection molding machines use single-channel E-stop chains.

To connect an RIA-compliant R-J3 controller to the single-channel E-stop chain of an injection molding machine you can order EE-4062-620, R-J3 Dual to Single E-Stp Assy. The assembly includescomplete connection instructions.

To connect an RIA-compliant R-J3iB controller to the single-channel E-stop chain of an injection molding machine can order EE-4062-625, R-J3i Dual to Single E-Stp Assy. The assembly includes completeconnection instructions.

It is possible to use other methods to connect a dual-channel E-stopchain to a single-channel E-stop chain. You must ensure that use of adifferent method does not compromise the E-stop circuit of either theFANUC robot or the IMM.

The R-J3iB Mate controller is also RIA-compliant but uses a single-channel E-Stop chain you do not need to use an adapter assembly withthe R-J3iB Mate controller.

Additional I/O can be added by purchasing standard FANUC Model Adigital I/O modules (up to a maximum of 5 I/O modules on the Model A I/Orack located inside the enclosure).

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3. SETTING THE SPI SYSTEM

To use the FANUC Robotics SPI Interface the hardware and softwaremust be set up.

3.1. SPI Interface (R-J2, R-J3 and R-J3iB controllers)

3.1.1. Connecting (R-J2, R-J3 and R-J3iB controllers)

Connections to the R-J2, R-J3 or R-J3iB controller consist of the following:

a Model A I/O Link cable between the Model A I/O Interface Moduleand the Model A I/O rack inside SPI Standard Industrial InterfaceModule.

a ground cable between the controller and the Model A I/O rack insidethe SPI Standard Industrial Interface

the SPI Cable from the SPI Standard Industrial Interface to the SPIconnection on the injection molding machine

The following must be provided by the end-user/customer since the lengthof cable varies. FANUC Robotics recommends 16AWG-Blue conductor.

SPI power and E-Stop connections (cable supplied by end-user/customer) Refer to Section 2.4 for an explanation on connecting the RIA-

complaint dual-channel E-Stop of a robot controller to the single-channel E-Stop of the injection molding machine.

UOP signals (user inputs/output connections - cable supplied by end-user/customer)

WARNINGRemove power from the robot controller and the injection moldingmachine when the following connections are made.

Model A I/O Link Cable:Open the operator box or controller door and locate the Model A I/OInterface unit. Route the Model A I/O Link cable from the SPI StandardIndustrial Interface enclosure through the existing cable slot on the rightside of the operator box or controller and attach the connector labeledJD4 to the JD1A terminal on the Model A I/O Interface unit.

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Ground Cable:Locate a convenient place to attach a ground wire inside the robotcontroller or operator box and attach the ground wire from the SPI ModelA I/O rack.

SPI Cable:Locate the SPI terminal on the injection molding machine and attach theSPI Cable from the SPI Standard Industrial Interface to the SPIconnection on the injection molding machine.

SPI Power and E-Stop Connections:Complete the SPI power and E-Stop connections - refer to Appendix A forelectrical schematics. The user must supply their own cable(s) to makethese connections. FANUC Robotics recommends minimum 16 AWG Blue wiring.

Refer to Section 2.4 for an explanation on connecting the RIA-complaint dual-channel E-Stop of the robot to the single-channel E-Stop of the injection molding machine.

WARNINGThe Emergency Stop signal from the injection molding machine tothe R-J2 or R-J3 controller must be connected across the EMGOUT1and EMGOUTC terminals on the robot E-Stop board (located insidethe operator box or the controller cabinet). The EMGOUT1 andEMGOUTC dry contacts are rated at 250VAC, 5-A resistor load.

The Emergency Stop signal to the injection molding machine fromthe R-J2 or R-J3 controller must be connected across the EMGIN1and EMGIN2 terminals on the robot E-Stop board (located inside theoperator box or the controller cabinet). When using contacts of arelay or contactor instead of the switch, connect a spark killer to thecoil of the relay or contactor, to suppress noise. The EMGIN1 andEMGIN2 contact open and close with 24VDC 0.1A.

UOP signals:Complete the UOP (User Operation) connections. The UOP connectionsare a series of hard-wired connections between the injection moldingmachine and the first eight connections on the Model A I/O modulelocated in slot 3 of the SPI Interface unit (refer to Section 3.1.2, VerifyingI/O configuration). The user must supply their own cable(s) to make theseconnections. FANUC Robotics recommends minimum 16 AWG Bluewiring.

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3.1.2. Configuring (R-J2, R-J3 and R-J3iB controllers)

Configuring the R-J2, R-J3 or R-J3iB controller for the SPI Interfaceconsists of the following:

Setting System Config Menu Loading files from the software disk into the controller. HandlingTool

software versions V5.30-3, V6.20 and later include all the necessaryfiles on the memory card shipped with the robot.

Configuring robot I/O Setting Reference Positions (optional)

To configure these settings the robot power must be on. During initialpower up, with the SPI Interface connected to the robot, the TeachPendant may display several errors while the robot is powering up. Oncethe following procedures have been completed turn the robot controller offand then on and the errors, if any, will be cleared.

3.1.3. Setting System Config Menu (R-J2, R-J3 and R-J3iB controllers)

For remote operation the robot uses peripheral I/O (UI/UO). If you want touse remote operation the UI (User Input) signals must be enabled. PressMENUS, SYSTEM, F1 TYPE, and CONFIG. The system configurationscreen is displayed. Move the cursor to Enable UI signals and set thevalue to TRUE. You need to ensure the User Input signals are connectedand configured correctly (refer to Section 3.1.6 Configuring robot I/O). Ifthe User Input signals are not functioning correctly you may see the redfault light for Hold illuminate.

3.1.4. Loading SPI software

A. R-J2 controller

Contact FANUC Robotics North America to receive a copy of the SPIsoftware needed for an R-J2 controller.

1. Perform a controlled start. To do this; start with the robot off,simultaneously press and hold the PREV and NXT key on the teachpendant and press the ON button on the controller. Continue pressingPREV and NXT until you see the BMON> prompt on the teachpendant screen.

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2. Choose F2 CTRL, press ENTER, choose F5 START, press ENTERand wait until the Controlled Start Initialization screen appears.Press 4, EXIT.

3. Locate the disk containing the FANUC Robotics SPI software. Placethe floppy disk into a PS100/PS110 floppy drive or load all files fromthe disk into the desired directory in the PC. Use the floppy drive or aPC with FANUC Robotics floppy emulator software and connect to theR-J2/R-J3 controller RS-232C connector.

4. If you are loading software using a PCMCIA card press MENUS, selectFILE, select F5 UTIL, select 1 SET DEVICE and choose MC:(Memory card).

5. Press MENUS, select FILE, scroll down the list, select and LoadDIOCFGSV.IO, SYSMACRO.SV, NUMREG.VR and POSREG.VR. Atthe prompt, CONVERT, Y/N answer Y for Yes. Perform a cold start -press FCTN and select START(COLD).

CAUTIONNever turn off the robot after a START (COLD) or START (CTRL2) hasbeen selected (i.e. when the message, System save in progress isdisplayed on the teach pendant). Otherwise, you will corrupt thecontroller and all software will have to be reloaded.

6. Press MENUS, FILE, F3 DIR on the teach pendant to get a directoryof files. Load all of the program files (*.TP) into the controller.

B. R-J3 or R-J3iB controller

Contact FANUC Robotics North America to receive a copy of the SPIsoftware needed for an R-J3 controller operating on HandlingToolsoftware versions prior to V5.30-3. To load the software use theprocedure listed in Section 3.1.4 Loading files (R-J2 controller).

NOTE: HandlingTool software versions V5.30-3, -3A, V6.20 and laterinclude all the SPI software files on the HandlingTool backup memorycard shipped with the robot. The following procedure details how toretrieve the files from the backup memory card.

The next 7 steps contain instructions which will overwrite the existingMacro setup file (SYSMACRO.SV) if you want to keep a previous Macroassignment you will need to record the previous Macro names andassociated Macro files and manually enter them later.

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1. Locate the memory card containing the HandlingTool software. Placethe memory card into the PCMCIA slot on the operator box orcontroller.

2. Turn the controller on and press MENUS, select FILE, select F5UTIL, select 1 SET DEVICE and choose MC: (memory card).

3. Perform a controlled start. To do this; start with the robot off,simultaneously press and hold the PREV and NXT key on the teachpendant and press the ON button on the controller.

4. At the CONFIGURATION MENU select 3, CONTROLLED START and

press ENTER.

5. Once the controlled start completes press MENUS, choose S/WINSTALL and press ENTER.

6. At the APPLICATION : HANDLINGTOOL (N.A.) screen choose 3,OPTION and press ENTER. Scroll down the alphabetical list to SPII :SPI INTERFACE and press F1 INSTALL. With the exception of theI/O configuration file all the necessary files (teach pending programsand system variable files) will be loaded onto the robot controller.

7. Press FCTN and choose START (COLD).

CAUTIONNever turn the robot off after a START (COLD) or START (CTRL2) hasbeen selected (i.e. when the message, System save in progress isdisplayed on the teach pendant). Otherwise, you will corrupt thecontroller and all software will have to be reloaded.

You can either manually configure the I/O (refer to Section 3.1.7) or loadthe I/O configuration file from the robot controller Flash ROM System(FRS). Steps 8 through 11 will overwrite your existing I/O configuration - ifyou want to keep a previous I/O configuration you will need to record itand manually enter it later:

8. Press MENUS, press 0 NEXT and select SYSTEM.

9. Press F1 TYPE and choose Variables. Cursor down to $DEVICE,press ENTER and manually erase the current setting (i.e. MC:, FS:,etc) and replace with FRS: You must include the colon.

10. Press MENUS, select FILE, select F3 DIR, *.*, press ENTER andscroll to the file DIOCFGSV.IO.

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11. Select LOAD. The base SPI I/O configuration will be setup on therobot controller depending on your unique I/O configuration you mayhave to configure your non-SPI I/O configuration manually. Refer toSection 3.1.7 in this manual and the INPUT/OUTPUT (I/O) SETUPsection in the FANUC Robotics SYSTEM R-J3iB ControllerHandlingTool Setup and Operations Manual.

3.1.5. Configuring robot I/O (R-J2, R-J3 and R-J3iB controllers)

1. Press MENUS, 0, SYSTEM, F1 TYPE and select VARIABLES.

2. Change the system variable $IO_AUTO_CFG to FALSE.

3. Cycle power on the robot controller.

4. Press MENUS, I/O, F1 TYPE and select DIGITAL. To switchbetween the outputs and inputs press F3 IN/OUT. PressCONFIGURATION to verify or change the I/O configuration.

To use the SPI Interface with the R-J2, R-J3 or R-J3iB controller the robotI/O should be configured similar to the following (your configuration maydiffer depending on other I/O on your robot):

RANGE RACK SLOT START PT1 DO [ 1- 8] 2 1 12 DO [ 9-16] 2 1 9

RANGE RACK SLOT START PT1 DI [ 1- 8] 2 2 12 DI [ 9-16] 2 2 93 DI [17-24] 2 3 9Note: the SPI software does not use DI [17-24] - these are spare inputsignals.

5. Press MENUS, I/O, F1 TYPE and select UOP. To switch betweenthe outputs and inputs press F3, IN/OUT.

RANGE RACK SLOT START PT1 UI [ 1- 8] 2 3 1

The UI signals are used by SPI Interface and are dedicated signals fromthe injection molding machine to the robot. On the R-J2, R-J3 and R-J3iBcontrollers these signals include *IMSTP, *HOLD, *SFSPD, Cycle stop,Fault Reset, Start, Home and Enable.

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It is also possible to make use of the UO (User Output) signals from therobot. These output signals include; CMDENBL, FAULT, BATALM andBUSY. These signals are not part of the SPI protocol. If these signals areneeded another Model A digital I/O module (A03B-0807-C104) must beadded to slot 4 on the Model A rack in the SPI Standard IndustrialInterface enclosure and the following configuration made. Additionalwiring will be needed for UOP signals - FANUC Robotics recommendsminimum 16 AWG Blue wiring.

RANGE RACK SLOT START PT1 UO [ 1- 8] 2 4 12 UO [9-16] 2 4 9

NOTE: All other I/O should be configured to zero 0 (Rack, Slot and StartPt) unless you have added I/O.

3.2. SPI Interface (R-J2 Mate and R-J3iB Mate controllers)

3.2.1. Connecting (R-J2 Mate and R-J3iB Mate controllers)

Connections to the R-J2 Mate or R-J3iB Mate controllers consist of thefollowing:

a FANUC I/O Link cable between the controller and the Model A I/Orack inside SPI Standard Industrial Interface

a ground cable between the controller and the Model A I/O rack insidethe SPI Standard Industrial Interface

the SPI Cable from the SPI Standard Industrial Interface to theinjection molding machine

The following must be provided by the end-user/customer since the lengthof cable varies. FANUC Robotics recommends 16AWG-Blue conductor.

SPI power and E-Stop connections (cable supplied by end-user/customer)

WARNINGRemove power from the robot controller and the injection moldingmachine when the following connections are made.

FANUC I/O Link Cable:Open the robot controller door and locate the terminal labeled I/O-LK,JD4 (JD1B) on the robot CPU. Route the cable through the cable slot

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(lower right side of controller) and attach the connector labeled JD1Bfrom the Model A I/O Interface Module inside the SPI Standard IndustrialInterface to the I/O-LK, JD4 (JD1B) terminal on the robot CPU.

Ground Cable:Locate a convenient place to attach a ground wire inside the robotcontroller (there are several grounding screws on the inside of thecontroller door). Route the ground cable through the cable slot (lowerright side of controller) and attach the ground wire from the SPI Model AI/O rack.

SPI Cable:Locate the SPI terminal on the injection molding machine and attach theSPI Standard Industrial Interface Cable from the SPI Standard IndustrialInterface.

SPI power and E-Stop connections:Complete the SPI power and E-Stop connections refer to Appendix B forwiring schematics. The end-user/customer must supply the cable(s).FANUC Robotics recommends minimum 16 AWG Blue wiring.

CAUTIONThe Emergency Stop signal from the injection molding machine tothe R-J2 Mate controller must be connected across the EMGOUT1and EMGOUT2 terminals on the robot E-Stop board (located insidethe controller cabinet).

The Emergency Stop signal to the injection molding machine fromthe R-J2 Mate controller must be connected across the EMGIN1 andEMGINC terminals on the robot E-Stop board (located inside thecontroller cabinet). Do not use EMGIN2 since external emergencystop input #2 is NOT reflected in the external emergency stop output.

3.2.2. Configuring (R-J2 Mate and R-J3iB Mate controllers)

Configuring the R-J2 Mate or R-J3iB Mate controller for the SPI Interfaceconsists of the following:

Setting robot system variables Setting System Config Menu Loading files Configuring robot I/O Setting PNS Setting Reference Positions (optional)

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To configure these settings the robot power must be on. During initialpower up with the SPI Interface connected to the robot the TeachPendant may display several errors while the robot is powering up. Oncethe following settings have been configured turn the robot controller offand then on and the errors, if any, will be cleared.

3.2.3. Setting robot system variables (R-J2 Mate and R-J3iB Mate controllers)

The R-J2 Mate and R-J3iB Mate controllers use the FANUC I/O Link tocommunicate with the SPI Interface. To do this the controller must be setas the master of the I/O link. Press MENUS, 0 NEXT, SYSTEM, F1TYPE, select VARIABLES and cursor down to $IOMASTER. Confirmthat $IOMASTER=TRUE. Cursor down to $RMT_MASTER and confirm itis set equal to 0.

3.2.4. Setting System Config Menu (R-J2 and R-J3iB Mate controllers)

For remote operation the R-J2 Mate and R-J3iB Mate controllers useperipheral I/O (UI/UO). The UI (User Input) signals must be enabled.Press MENUS, SYSTEM, F1 TYPE, CONFIG. The system configurationscreen is displayed. Move the cursor to Enable UI signals and set thevalue to TRUE.

R-J2 MateFor a more detailed explanation on how to set the System Config Menurefer to the FANUC Robotics SYSTEM R-J2 Controller LR TOOL Setupand Operations Manual (MARO2LRTL05701E) Section 3.3.

R-J3iB MateFor a more detailed explanation on how to set the System Config Menurefer to the FANUC Robotics System R-J3iB Mate LR Handling ToolOperators Manual (MAROIBLRH02021E), Section 3.14.

3.2.5. Loading SPI software

A. R-J2 Mate controller

1. Perform a controlled start.

2. Start with the robot off, simultaneously press and hold the PREV andNXT key on the teach pendant and press the ON button on thecontroller. Continue pressing PREV and NXT until you see theBMON> prompt on the teach pendant screen.

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3. Choose F2 CTRL, press ENTER, choose F5 START, pressENTER and wait until the Controlled Start Initialization screenappears. Press 4 EXIT.

4. Locate the disk containing the FANUC Robotics SPI software. Placethe floppy disk into a PS100/PS110 floppy drive or load all files fromthe disk into the desired directory in the PC.

NOTE:To use the RS-232 port on the R-J2 Mate controller you must first setthe port to read/write to a PS100/PS110/PC. To set the port, pressMENUS, 6 SETUP, F1 TYPE and select Port Init. Move the cursorto the RS-232-C port field and press F3 DETAIL. Move the cursorto the Device field and press F4 CHOICE. Select PS-100/200 Disk.It is not necessary to set the device details since the default valuesare correct (Speed Baud rate = 9600, Parity bit = None, Stop bit =2bits, Time out value sec = 0).

5. Use the floppy drive or a PC with FANUC Robotics floppy emulatorsoftware and connect to the R-J2 Mate controller RS-232C connector.

6. If you have a memory card adapter (for a PCMCIA card) remove the slot blank faceplate (next to the CPU) and insert the adapter into theslot located at the bottom of the slot.

7. If you are loading from a PCMCIA card press MENUS, select FILE,select F5 UTIL, 1 SET DEVICE and choose MC: (memory card).

8. Press MENUS, select FILE, F3 DIR, scroll down, select and LoadDIOCFGSV.IO, SYSMACRO.SV, NUMREG.VR and POSREG.VR. Atthe prompt, CONVERT, Y/N answer N for No. Perform a cold start -press FCTN and select START(COLD).

CAUTIONNever turn the robot OFF after a START (COLD) or START (CTRL2)has been selected (when the message, System save in progress isdisplayed on the teach pendant). Otherwise, you will corrupt thecontroller and all software will have to be reloaded.

9. Press MENUS, FILE, F3 DIR on the teach pendant to get a directoryof files. Load all of the program files (*.TP) into the controller.

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B. R-J3iB Mate controller

Contact FANUC Robotics North America to receive a copy of the SPIsoftware needed for an R-J3iB Mate controller. To load the software usethe procedure listed in Section 3.1.4 Loading files (R-J2 controller).

3.2.6. Configuring robot I/O (R-J2 Mate and R-J3iB Mate controllers)

To use the SPI Interface Software the R-J2 Mate or R-J3iB Matecontroller I/O should be configured similar to the following (yourconfiguration may differ depending on other I/O on your robot):

1. Press MENUS, I/O, F1 TYPE and select DIGITAL. To switchbetween the outputs and inputs press F3, IN/OUT.

RANGE RACK SLOT START PT1 DO [ 1- 8] 1 1 12 DO [ 9-16] 1 1 9

RANGE RACK SLOT START PT1 DI [ 1- 8] 1 2 12 DI [ 9-16] 1 2 9

2. Press MENUS, I/O, F1 TYPE and select UOP. To switch betweenthe outputs and inputs press F3 IN/OUT.

RANGE RACK SLOT START PT1 UI [ 1- 8] 1 3 1

The UI signals are required for the SPI Interface Software and are signalsfrom the injection molding machine to the R-J2 Mate or R-J3iB Matecontroller. These signals include HOLD, RESET, START, ENBL, PNS1,PNS2, PNS3 and PNS4.

It is also possible to make use of the UO (User Output) signals from therobot. These output signals include; CMDENBL, FAULT, BATALM andBUSY. These signals are not part of the SPI protocol - the user mustdecide where to send the signal. If these signals are needed anotherModel A digital I/O module (A03B-0807-C104) must be added to slot 4 onthe Model A rack in the SPI Standard Industrial Interface enclosure andthe following configuration made. Additional wiring will be needed for UPsignals - FANUC Robotics recommends minimum 16 AWG Blue wiring.

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RANGE RACK SLOT START PT1 UO [ 1- 8] 1 4 12 UO [9-16] 1 4 9

R-J2 MateFor a more detailed explanation of setting I/O refer to the FANUCRobotics SYSTEM R-J2 Controller LR TOOL Setup and OperationsManual (MARO2LRTL05701E).

R-J3iB MateFor a more detailed explanation of setting I/O refer to the FANUCRobotics System R-J3iB Mate LR Handling Tool Operators Manual(MAROIBLRH02021E), Section 3.1.

3.2.7. Setting PNS (R-J2 Mate and R-J3iB Mate controllers)

PNS (Program Number Select) signals are a group of user input (UI)signals that allow an injection molding machine to tell the robot whichprogram to run without any operator input. PNS is automatically enabledwhen Enable UI signals = TRUE is set in the System Config menu.Refer to the previous page for details on setting the UI signals.

R-J2 MateFor a more detailed explanation of setting PNS refer to the FANUCRobotics SYSTEM R-J2 Controller LR TOOL Setup and OperationsManual (MARO2LRTL05701E) Section 3.3, 3.4 and 3.4.1.

R-J3iB Mate For a more detailed explanation of setting PNS refer to the FANUCRobotics System R-J3iB Mate LR Handling Tool Operators Manual(MAROIBLRH02021E), Section 3.7.

3.3. Setting Reference Positions (optional for R-J2, R-J2 Mate, R-J3, R-J3iB Mate and R-J3iB)

A reference position is a fixed (predetermined) position that is associatedwith a digital output signal from the robot. The user defines a position bythe positions joint angles, sets a joint angle tolerance for each joint andthen defines a signal to specify which signal will be output when the robotis within the joint angle tolerance of the predetermined position.

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For an explanation of setting a reference position refer to the FANUCRobotics SYSTEM R-J2 Controller HandlingTool Setup and OperationsManual, the FANUC Robotics SYSTEM R-J3 Controller HandlingToolSetup and Operations Manual or the FANUC Robotics SYSTEM R-J2Controller LR TOOL Setup and Operations Manual.

3.4. Teaching the positions (R-J2, R-J2 Mate, R-J3, R-J3iB Mate and R-J3iB)

All the positions and offset values used by the SPI software are initially setto the exact same location - all joint angles = 0. The user must manuallyteach each position so the robot moves as required.

All the Position Registers are uninitialized. The user must manually teacheach position register so the robot moves as required.

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4. TESTING THE SPI SOFTWARE & RUNNING PRODUCTION

Use the HandlingTool manual (R-J2, R-J3, R-J3iB Mate, R-J3iB) or LR-Tool manual (R-J2 Mate) as a guide.

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5. TROUBLESHOOTING THE SPI SOFTWARE

Use the HandlingTool manual (R-J2, R-J3, R-J3iB Mate, R-J3iB) or LR-Tool manual (R-J2 Mate) as a guide.

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6. SPI SOFTWARE PROGRAMS

NOTE: The SPI Software used on R-J2, R-J3, R-J3iB Mate, R-J3iB andR-J2 Mate controllers is similar. The following listing of teach pendantprograms is for the R-J2, R-J3, R-J3iB Mate, R-J3iB and R-J2 Matecontroller platforms - where differences exist they are noted in theprogram description.

NOTEAll position registers, PR[n], are global positions and are the sameposition in space for all teach pendant programs - you need onlyteach a position register once for it to be valid in all other teachpendant programs.

All positions, P[n], are local positions and are only valid for the teachpendant program in which they reside.

6.1. CLAMP.TP

CLAMP.TP in a non-motion, condition handler program. It uses the multi-tasking capabilities of the R-J2, R-J3, R-J3iB Mate and R-J3iB controllersto monitor DI[11]. When using the R-J2 Mate controller the softwareoption Condition Monitor must be loaded. Before CLAMP.TP is executedthe robot permits clamp motion allowing the injection molding machine toclose and create another part. CLAMP.TP is then executed. CLAMP.TPmonitors the state of DI[11: MLD FULL CLS] (which indicates when themold is fully closed). When DI[11: MLD FULL CLS] turns ONPOLLCLMP.TP is called. POLLCLMP.TP prevents the mold from closingagain until the robot returns and removes the molded part. This preventsdouble-stamping of a part.

CAUTIONDo not add any motion statements to this program.

PROGRAM CLAMP Cond1: WHEN DI[11:Mold fullcls]=ON,CALL POLLCLMP ;END

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6.2. CLS.TP

CLS.TP in a non-motion program. It writes blank lines to the TP userscreen to erase a previously posted message if R10: Suppress messags]does not equal 1. If R[10: Suppress messags]=1 messages are notposted to the user screen this allows the user to watch the teachpendant programs beings executed.


PROGRAM CLS Macro 1: !This program clears ; 2: !the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[ ] ; 8: MESSAGE[ ] ; 9: MESSAGE[ ] ; 10: MESSAGE[ ] ; 11: MESSAGE[ ] ; 12: MESSAGE[ ] ; 13: MESSAGE[ ] ; 14: MESSAGE[ ] ; 15: MESSAGE[ ] ; 16: MESSAGE[ ] ; 17: MESSAGE[ ] ; 18: LBL[10] ;END

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6.3. DPRT_IMM.TP

DPRT_IMM.TP contains motion statements instructing the robot to take apredetermined path to depart or move away from the injection moldingmachine. Register 1, R[1: CONTINUE CYCLE], sets the cycle continueflag equal to 1.

PR[2: IMM approach 1, PR[3: IMM approach 2] and PR[4: IMM approach3] are position registers that define positions along a path that ensures therobot avoids obstacles as it approaches or departs from the injectionmolding machine. PR[2: IMM approach 1] must be taught by the usersince it defines the first approach/depart position. PR[3: IMM approach 2]defines an intermediate position - if it is not used when departing theinjection molding machine it must be either taught in the same location asPR[2: IMM approach 1] or deleted from DPRT_IMM.TP. PR[4 IMMapproach 3] must be taught by the user since it defines the lastapproach/depart position.

PROGRAM DPRT_IMM Job 1: !This program moves the robot ; 2: !away from the IMM. ; 3: ; 4:J PR[4:IMM approach 3] 100% CNT100 ; 5:J PR[3:IMM approach 2] 100% CNT100 ; 6:J PR[2:IMM approach 1] 100% CNT100 ; 7: R[1:CONTINUE CYCLE]=1 ;END

6.4. EXIT_IMM.TP

EXIT_IMM contains a single motion statement to move the robot out ofthe injection mold machine after it has picked up the molded part.Register 4, R[4: INSIDE IMM], sets a flag equal to 0 to indicate the robotis no longer inside the injection mold machine.

WARNINGRegister 4 is used to protect the robot and the IMM in the event of aloss of power - do not delete this instruction from this program.

PROGRAM EXIT_IMM Job 1: !This program moves the robot ; 2: !to exit the IMM. ; 3: ; 4:J PR[4:IMM approach 3] 100% CNT100 ; 5: R[4:INSIDE IMM]=0 ;END

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6.5. GETINSRT.TP

GETINSRT.TP is a motion program that requires the user enter the logicand motion instructions to move the robot to pick up an insert for insertmolding.

PROGRAM GETINSRT Job 1: !Use this program to instruct ; 2: !the robot to get an insert. ;END

6.6. GRIP_PRT.TP

GRIP_PRT.TP is a non-motion program that activates the gripper to pickup the molded part inside the IMM. This program is called in thePIK_PRT.TP program.

Modify this program to turn on the required digital and/or robot outputsignals on your gripper to pick the molded part.


PROGRAM GRIP_PRT Job 1: !This program turns an output ; 2: !ON to grip the part. ; 3: ; 4: RO[...]=ON ;END

6.7. HOME.TP HOME.TP is a motion program that sends the robot to the home positionunder two conditions - register 1 has been set to zero in the signalinterlock program (INTLK_ON.TP) or the automatic operation signal fromthe IMM has been lost. Register 4, R[4: INSIDE IMM], sets a flag equal to0 to indicate the robot is no longer inside the injection mold machine

PROGRAM HOME Job 1: !This program sends the robot ; 2: !to the Home position. ; 3: ; 4:J PR[1:Robot HOME pos] 100% FINE ; 5: R[4:INSIDE IMM]=0 ;END

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6.8. INISHLZE.TP

INISHLZE.TP initializes communications with the IMM by setting the SPIsignals to prepare for automatic operation and then moves the robot tothe start position. If register 4, R[4:INSIDE IMM], is set to 1, indicating therobot is inside the IMM, the robot will not move to the home position.

PROGRAM INISHLZE Job 1: !This program initializes the ; 2: !robot position; sets digital ; 3: !output ON_OFF conditions and ; 4: !sets register values. ; 5: ; 6: Clear screen ; 7: IF R[4:INSIDE IMM]=1,JMP LBL[10] ; 8: Moving to Home ; 9:J PR[1: Robot HOME pos] 10% FINE ; 10: ; 11: DO[1:Prmt clmpcls]=ON ; 12: DO[2:Prmt clmpmtn]=ON ; 13: DO[4:Prmt ejctrtt]=PULSE,2.0sec ; 14: DO[5:Prmt ejctfwd]=PULSE,2.0sec ; 15: DO[6:Prmt corepul]=OFF ; 16: DO[7:Prmt coreset]=ON ; 17: R[1:CONTINUE CYCLE]=1 ; 18: R[3:Dropped parts]=0 ; 19: R[6:REJECT COUNTER]=0 ; 20: ; 21: LBL[10] ;END

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6.9. INTLK_ON.TP

INTLK_ON.TP is called before the robot enters the IMM. It checks theMold Fully Open or Mold Intermediate Open signals from the IMM. Ifthese signals are ON the robot outputs a signal to prevent the clamp fromclosing, allows the cores to be pulled, waits for the cores to be pulled (ifR[7: Check cores]=1) and then signals to prevent core or clamp motion. Ifthe Mold Fully Open or Mold Intermediate Open signal has not beenreceived by the robot it will check that the Fully Automatic signal is stillbeing sent by the IMM. If the Fully Automatic is no longer being sentregister 1 is set to 0, and the current cycle will be aborted whenINTLK_ON.TP is finished and control returns to MAIN.TP.

WARNINGDO NOT MODIFY THE I/O LOGIC IN THIS PROGRAM WITHOUT ATHOROUGH UNDERSTANDING OF ITS PURPOSE - SEVEREDAMAGE TO THE IMM OR ROBOT WILL OCCUR. Do not add anymotion statements to this program.

PROGRAM INTLK_ON Job 1: !This program prevents the IMM ; 2: !from closing the platen. DO NOT ; 3: !MODIFY UNLESS YOU HAVE A ; 4: !THOROUGH UNDERSTANDING OF THE ; 5: !LOGIC. ; 6: ; 7: LBL[10] ; 8: Wait mold open ; 9: WAIT DI[1:Mold fullopn]=ON OR DI[2:Int moldopen]=ON TIMEOUT,LBL[20] ; 10: ; 11: Clear screen ; 12: DO[1:Prmt clmpcls]=OFF ; 13: ; 14: IF R[7:Check cores]=0,JMP LBL[30] ; 15: DO[6:Prmt corepul]=ON ; 16: WAIT DI[6:Core fullpul]=ON ; 17: DO[6:Prmt corepul]=OFF ; 18: ; 19: LBL[30] ; 20: DO[2:Prmt clmpmtn]=OFF ; 21: R[1:CONTINUE CYCLE]=1 ; 22: JMP LBL[40] ; 23: ; 24: LBL[20] ; 25: R[1:CONTINUE CYCLE]=0 ; 26: IF DI[8:Full auto]=ON,JMP LBL[10] ; 27: ; 28: LBL[40] ; 29: Clear screen ;

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END

6.10. INTLKOFF.TP

INTLKOFF.TP is called after the robot has exited the IMM. It allows theIMM to operate normally.

When using the R-J2 Mate controller the software option ConditionMonitor must be loaded. INTLKOFF.TP makes use of multi-tasking bymonitoring another teach pendant program called CLAMP.TP in thebackground while continuing with robot motion. CLAMP.TP in a non-motion, condition handler program. It uses the multi-tasking capabilities ofthe R-J2, R-J3, R-J3iB Mate and R-J3iB controllers to monitor DI[11:Moldfullcls]. Before CLAMP.TP is executed the robot permits clamp motionallowing the injection molding machine to close and create another part.CLAMP.TP is then executed. CLAMP.TP monitors the state of DI[11:Mold fullcls]. When DI[11: Mold fullcls] turns to ON POLLCLMP.TP iscalled. POLLCLMP.TP prevents the mold from closing again until therobot returns and removes the part. This prevents double-stamping of apart.

WARNINGDO NOT MODIFY THE I/O LOGIC IN THIS PROGRAM WITHOUT ATHOROUGH UNDERSTANDING OF ITS PURPOSE - SEVEREDAMAGE TO THE IMM OR ROBOT WILL OCCUR. Do not add anymotion statements to this program.

PROGRAM INTLKOFF Job 1: !This program allows the IMM ; 2: !to close the platen. DO NOT ; 3: !MODIFY UNLESS YOU HAVE A ; 4: !THOROUGH UNDERSTANDING OF THE ; 5: !LOGIC. ; 6: ; 7: DO[4:Prmt ejctrtt]=OFF ; 8: DO[5:Prmt ejctfwd]=OFF ; 9: DO[2:Prmt clmpmtn]=ON ; 10: IF R[7:Check cores]=0,JMP LBL[10] ; 11: ; 12: DO[6:Prmt corepul]=OFF ; 13: DO[7:Prmt coreset]=ON ; 14: WAIT DI[5:Core fullset]=ON ; 15: DO[7:Prmt coreset]=OFF ; 16: ; 17: LBL[10] ; 18: DO[1:Prmt clmpcls]=ON ; 19: MONITOR CLAMP ;

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END

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M_*.*All programs beginning with M_ write messages to the TP user screen. IfR[10: Suppress messags]=1 messages are not posted to the user screen this allows the user to watch the teach pendant programs beingsexecuted.


6.11. M_EJCTFW.TP

PROGRAM M_EJCTFW Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Waiting for ejectors] ; 8: MESSAGE[forward] ; 9: LBL[10] ;END

6.12. M_EJCTRT.TP

PROGRAM M_EJCTRT Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Waiting for ejectors] ; 8: MESSAGE[to retract] ; 9: LBL[10] ;END

6.13. M_GETPRT.TP

PROGRAM M_GETPRT Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Picking molded part] ; 8: LBL[10] ;END

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6.14. M_HOLD.TP

PROGRAM M_HOLD Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[R[4:INSIDE IMM] does not] ; 8: MESSAGE[equal 0. The robot MAY ] ; 9: MESSAGE[be inside the IMM or a] ; 10: MESSAGE[part MAY be left in the] ; 11: MESSAGE[mold.] ; 12: MESSAGE[...] ; 13: MESSAGE[When it is safe to ] ; 14: MESSAGE[resume operation press] ; 15: MESSAGE[CYCLE START.] ; 16: LBL[10] ;END

6.15. M_HOME.TP

PROGRAM M_HOME Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Robot is at or is] ; 8: MESSAGE[moving to Home position] ; 9: LBL[10] ;END

6.16. M_IN_IMM.TP

PROGRAM M_IN_IMM Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[The robot is inside the] ; 8: MESSAGE[Injection Mold Machine] ; 9: MESSAGE[ ] ; 10: LBL[10] ;END

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6.17. M_MOLDOP.TP

PROGRAM M_MOLDOP Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Waiting for mold open] ; 8: LBL[10] ;END

6.18. M_NOTDRP.TP

PROGRAM M_NOTDRP Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[The robot sensor shows] ; 8: MESSAGE[the part has not been] ; 9: MESSAGE[released. ] ; 10: ; 11: MESSAGE[...] ; 12: ; 13: MESSAGE[Check the gripper] ; 14: ; 15: MESSAGE[Correct the problem and] ; 16: MESSAGE[restart the robot] ; 17: LBL[10] ;END

6.19. M_PLCING.TP

PROGRAM M_PLCING Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Placing molded part] ; 8: LBL[10] ;END

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6.20. M_PRTDRP.TP

PROGRAM M_PRTDRP Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[The robot sensor shows] ; 8: MESSAGE[a part has been dropped] ; 9: MESSAGE[ ] ; 10: MESSAGE[Check the gripper and] ; 11: MESSAGE[Injection Mold Machine] ; 12: ; 13: MESSAGE[Correct the problem and] ; 14: MESSAGE[press CYCLE START] ; 15: LBL[10] ;END

6.21. M_RJCTNG.TP

PROGRAM M_RJCTNG Macro 1: !This program posts a message ; 2: !to the user screen if R[10] ; 3: !is set equal to 1. ; 4: ; 5: IF R[10:Suppress messags]1,JMP LBL[10] ; 6: ; 7: MESSAGE[Injection Mold Machine] ; 8: MESSAGE[signaled the robot to] ; 9: MESSAGE[reject this part] ; 10: LBL[10] ;END

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6.22. MAIN.TP

MAIN.TP is the main controlling program. If you use the Program NumberSelect (PNS) feature you must copy this program as O001.TP. MAIN.TPcalls all the motion and non-motion programs used to move the robot,checks registers and processes input/output signals.

The MONITOR instructions are condition handlers that prevent the IMMclamp from closing unless the robot has removed a part from the mold.

NOTEMAIN.TP contains logic to support insert molding. To allow insertmolding use the programs called GETINSRT.TP and PUTINSRT.TPand set R[2: Insert molding]=1. Note that you must create the logicand motion instructions within GETINSRT.TP and PUTINSRT.TP andset R[2: Insert molding]=1 to instruct the robot to pick and place aninsert. PROGRAM MAIN Job 1: !This program controls the robot ; 2: !and IMM motion when the FULL ; 3: !AUTO signal is ON. ; 4: ; 5: LBL[10] ; 6: MONITOR CLAMP; 7: CALL INISHLZE ; 8: Clear screen ; 9: IF R[4:INSIDE IMM]0,JMP LBL[100] ; 10: ; 11: LBL[20] ; 12: IF DI[8:Full auto]=ON,JMP LBL[30] ; 13: Waiting FULLAUTO ; 14: WAIT DI[8:Full auto]=ON TIMEOUT,LBL[10] ; 15: ; 16: LBL[30] ; 17: IF R[4:INSIDE IMM]0,JMP LBL[90] ; 18: IF R[2:Insert molding]=0,JMP LBL[40] ; 19: CALL GETINSRT ; 20: IF R[1:CONTINUE CYCLE]1,JMP LBL[70] ; 21: ; 22: LBL[40] ; 23: CALL TO_IMM ; 24: CALL INTLK_ON ; 25: IF R[1:CONTINUE CYCLE]=0,JMP LBL[80] ; 26: ; 27: CALL PIK_PRT ; 28: IF R[4:INSIDE IMM]=2,JMP LBL[90] ; 29: IF R[1:CONTINUE CYCLE]=0,JMP LBL[70] ; 30: IF R[2:Insert molding]=0,JMP LBL[50] ; 31: CALL PUTINSRT ;

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32: ; 33: LBL[50] ; 34: CALL EXIT_IMM ; 35: CALL INTLKOFF ; 36: MONITOR CLAMP ; 37: CALL DPRT_IMM ; 38: IF R[8:REJECT PART]=0,JMP LBL[60] ; 39: CALL RJCT_PRT ; 40: IF R[1:CONTINUE CYCLE]=1,JMP LBL[20] ; 41: ; 42: LBL[60] ; 43: CALL PUT_PART ; 44: IF R[1:CONTINUE CYCLE]=1,JMP LBL[20] ; 45: ; 46: LBL[70] ; 47: Clear screen ; 48: CALL HOME ; 49: JMP LBL[20] ; 50: ; 51: LBL[80] ; 52: Clear screen ; 53: CALL DPRT_IMM ; 54: IF R[1:CONTINUE CYCLE]=1,JMP LBL[20] ; 55: CALL HOME ; 56: JMP LBL[20] ; 57: ; 58: LBL[90] ; 59: CALL EXIT_IMM ; 60: CALL INTLKOFF ; 61: CALL DPRT_IMM ; 62: R[4:INSIDE IMM]=0 ; 63: JMP LBL[20] ; 64: ; 65: LBL[100] ; 66: Robot in HOLD ; 67: PAUSE ; 68: JMP LBL[20] ;END

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6.23. PIK_PRT.TP

PIK_PRT.TP moves the robot into position to pick up a completed partinside the IMM. Register 4 is set to 1 to indicate the robot is in the IMM.

PR[5: Prt approach] and PR[6: Prt pick] are position registers that definethe positions along the path that ensures the robot avoids obstacles asmoves in the IMM. PR[5: Prt approach] must be taught by the user sinceit defines the first approach/depart position. PR[6: Prt pick] must betaught by the user since it defines the last approach/depart position.PR[7: Prt pick offset] is an offset value that is added to PR[6: Prt pick] -you will normally set only the Z-value of PR[7:Prt pick offset] (i.e.X,Y,Z,W,P,R often referred to as the configuration string) to some smallvalue. FANUC Robotics recommends teaching the final pick position,PR[6: Prt pick] before determining the value(s) of the configuration stringin PR[7:Prt pick offset]. Once PR[6: Prt pick] has been taught the usercan then fine-tune the value of PR[7:Prt pick offset] to realize the optimalfinal approach position and orientation the configuration string valueswithin a position register can be adjusted during automatic operation,allowing the user can continue to fine-tune these value(s).

PROGRAM PIK_PRT Job 1: !This program moves the robot ; 2: !to extract a part from the IMM. ; 3: ; 4: Robot in IMM ; 5: R[4:INSIDE IMM]=1 ; 6:J PR[5:Prt approach pos] 100% CNT100 ; 7:J PR[6:Prt pick pos] 100% CNT10 Offset,PR[7:Prt pick offset] ; 8:L PR[6:Prt pick pos] 500mmsec FINE ; 9: ; 10: DO[5:Prmt ejctfwd]=ON ; 11: Wait ejectr fwd ; 12: WAIT DI[4:Ejt fullfwrd]=ON ; 13: Clear screen ; 14: Grip part in IMM ; 15: CALL GRIP_PRT ; 16: DO[4:Prmt ejctrtt]=ON ; 17: Wait ejectr rtrc ; 18: WAIT DI[3:Ejt fullrtrt]=ON ; 19: Clear screen ; 20:L PR[6:Prt pick pos] 500mmsec CNT10 Offset,PR[7:Prt pick offset] ; 21: IF DI[7:Reject part]=OFF,JMP LBL[10] ; 22: R[8:REJECT PART]=1 ; 23: ; 24: LBL[10] ; 25: IF R[5:Check prt sensor]=1,JMP LBL[20] ; 26: Clear screen ; 27: JMP LBL[30] ; 28: ;

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29: LBL[20] ; 30: IF RI[1]=ON,JMP LBL[30] ; 31: R[3:Dropped parts

spi interface

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